Wa470 7

SEN06006-02
WHEEL LOADER
WA470 -7
SERIAL NUMBERS
10001
and up
SHOP MANUAL
WHEEL LOADER
WA470-7
Model
Serial Number
WA470-7
10001 and up
00 Index and foreword

1 00 Index and foreword
WA470-7
00-1

Index
Index
(ALL-0310-001-A-00-A)
00 Index and foreword ....................................................................................................................... 00-1

Index ......................................................................................................................................... 00-2
Foreword, safety and general information ................................................................................... 00-18
Important safety notice ....................................................................................................... 00-18
How to read the shop manual.............................................................................................. 00-25
Explanation of terms for maintenance standard .................................................................... 00-27
Handling equipment of fuel system devices .......................................................................... 00-29
Handling of intake system parts........................................................................................... 00-30
Handling of hydraulic equipment.......................................................................................... 00-31
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-33
Handling of electrical equipment.......................................................................................... 00-36
How to read electric wire code............................................................................................. 00-44
Precautions when performing operation ............................................................................... 00-47
Practical use of KOMTRAX ................................................................................................. 00-51
Standard tightening torque table.......................................................................................... 00-52
List of abbreviation ............................................................................................................. 00-56
Conversion table ................................................................................................................ 00-61
01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Specifications ...................................................................................................................... 01-5
Weight table ...................................................................................................................... 01-11
Table of fuel, coolant, and lubricants .................................................................................... 01-13
10 Structure and function ................................................................................................................... 10-1
Engine and cooling system .......................................................................................................... 10-4
Engine related parts ............................................................................................................. 10-4
KVGT.................................................................................................................................. 10-6
EGR system piping drawing ................................................................................................ 10-12
EGR system circuit diagram ................................................................................................ 10-14
EGR valve......................................................................................................................... 10-15
EGR cooler........................................................................................................................ 10-17
KCCV layout drawing ......................................................................................................... 10-19
KCCV ventilator ................................................................................................................. 10-21
KDPF................................................................................................................................ 10-23
Cooling system .................................................................................................................. 10-27
Cooling fan pump ............................................................................................................... 10-30
Cooling fan motor............................................................................................................... 10-39
Power train............................................................................................................................... 10-46
Power train system............................................................................................................. 10-46
Drive shaft ......................................................................................................................... 10-49
Power train piping drawing .................................................................................................. 10-50
Transmission control .......................................................................................................... 10-51
Torque converter ................................................................................................................ 10-54
Transmission ..................................................................................................................... 10-59
Transmission control valve.................................................................................................. 10-78
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV .......................................... 10-81
3rd, 4th clutch ECMV.......................................................................................................... 10-88
Lockup clutch ECMV .......................................................................................................... 10-95
Main relief and torque converter relief valve.......................................................................... 10-99
Axle ................................................................................................................................ 10-101
Differential ....................................................................................................................... 10-103
Final drive ....................................................................................................................... 10-113
Steering system...................................................................................................................... 10-115
Layout of steering parts .................................................................................................... 10-115
Steering column............................................................................................................... 10-116
00-2
WA470-7

Index
Steering pump ................................................................................................................. 10-117

Steering valve.................................................................................................................. 10-129
Orbit-roll valve ................................................................................................................. 10-143
Stop valve ....................................................................................................................... 10-149
Emergency steering motor ................................................................................................ 10-150
Emergency steering pump ................................................................................................ 10-151
Brake system ......................................................................................................................... 10-152
Layout of brake parts........................................................................................................ 10-152
Charge valve ................................................................................................................... 10-154
Brake valve ..................................................................................................................... 10-160
Slack adjuster .................................................................................................................. 10-164
Accumulator (for brake) .................................................................................................... 10-167
Brake .............................................................................................................................. 10-168
Parking brake control ....................................................................................................... 10-171
Parking brake .................................................................................................................. 10-172
Parking brake solenoid valve ............................................................................................ 10-173
Parking brake emergency release valve............................................................................. 10-176
Undercarriage and frame......................................................................................................... 10-177
Axle mount and center hinge pin........................................................................................ 10-177
Tire ................................................................................................................................. 10-178
Hydraulic system .................................................................................................................... 10-180
Hydraulic component layout .............................................................................................. 10-180
Work equipment control .................................................................................................... 10-182
Hydraulic tank.................................................................................................................. 10-183
Double type gear pump .................................................................................................... 10-186
Work equipment pump...................................................................................................... 10-187
Control valve ................................................................................................................... 10-208
CLSS .............................................................................................................................. 10-217
Hydraulic circuit diagram and names of valves.................................................................... 10-221
Accumulator charge valve................................................................................................. 10-232
Work equipment lock solenoid valve .................................................................................. 10-236
Accumulator (for PPC circuit) ............................................................................................ 10-237
Accumulator (for ECSS) ................................................................................................... 10-238
Work equipment ..................................................................................................................... 10-239
Work equipment linkage ................................................................................................... 10-239
Bucket ............................................................................................................................ 10-240
Bucket positioner and boom positioner............................................................................... 10-241
Cab and its attachments .......................................................................................................... 10-242
ROPS cab ....................................................................................................................... 10-242
Electrical system .................................................................................................................... 10-243
Engine control system ...................................................................................................... 10-243
Preheating system ........................................................................................................... 10-245
Engine power mode selector circuit ................................................................................... 10-247
Engine output limit function ............................................................................................... 10-248
Automatic warm-up function.............................................................................................. 10-249
Parking brake control system ............................................................................................ 10-250
System operating lamp function......................................................................................... 10-252
Battery disconnect switch function ..................................................................................... 10-254
Transmission controller system ......................................................................................... 10-256
Work equipment control system......................................................................................... 10-277
Machine monitor system ................................................................................................... 10-293
Rear view monitor system................................................................................................. 10-317
KOMTRAX system ........................................................................................................... 10-320
System component parts .................................................................................................. 10-323
Sensor ............................................................................................................................ 10-350
20 Standard value tables.................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
WA470-7
00-3

Index
Standard value table for machine .......................................................................................... 20-5

Standard value table for electrical system............................................................................. 20-18
30 Testing and adjusting .................................................................................................................... 30-1
General information on testing and adjusting................................................................................. 30-4
Tools for testing and adjusting ............................................................................................... 30-4
Sketch of tools for testing and adjusting ................................................................................. 30-8
Engine and cooling system ........................................................................................................ 30-10
Testing engine speed ......................................................................................................... 30-10
Testing boost pressure ....................................................................................................... 30-12
Testing exhaust gas color ................................................................................................... 30-14
Testing and adjusting valve clearance .................................................................................. 30-16
Testing compression pressure............................................................................................. 30-18
Testing blowby pressure ..................................................................................................... 30-22
Testing engine oil pressure ................................................................................................. 30-24
Testing EGR valve and KVGT oil pressures .......................................................................... 30-25
Testing fuel pressure .......................................................................................................... 30-26
Testing fuel return rate and leakage ..................................................................................... 30-27
Bleeding air from fuel system .............................................................................................. 30-31
Testing fuel circuit for leakage ............................................................................................. 30-33
Handling cylinder cutout mode operation.............................................................................. 30-34
Handling no injection cranking operation .............................................................................. 30-35
Testing of KDPF and muffler stack for looseness and damage ............................................... 30-36
Testing of installed condition of cylinder head and manifolds .................................................. 30-37
Testing engine piping for damage and looseness .................................................................. 30-38
Testing and adjusting air conditioner compressor belt tension ................................................ 30-39
Testing and adjusting alternator belt tension ......................................................................... 30-41
Procedures for cleaning fuel doser....................................................................................... 30-43
Writing compensation values at replacement of injector and engine controller ......................... 30-46
Power train............................................................................................................................... 30-50
Adjusting transmission output speed sensor ......................................................................... 30-50
Adjusting transmission input speed sensor ........................................................................... 30-51
Flushing procedure for torque converter and transmission hydraulic circuit.............................. 30-52
Retrieval of disabled machine due to transmission valve failure.............................................. 30-54
Testing oil leakage from axle final drive ................................................................................ 30-56
Testing drive shaft for looseness, backlash, and damage....................................................... 30-57
Testing and adjusting power train oil pressure....................................................................... 30-58
Steering system........................................................................................................................ 30-73
Testing directional lever ...................................................................................................... 30-73
Testing steering wheel ........................................................................................................ 30-74
Testing work equipment control lever ................................................................................... 30-76
Testing and adjusting steering circuit oil pressure.................................................................. 30-78
Bleeding air from steering cylinder circuit.............................................................................. 30-81
Testing and adjusting steering stopper valve......................................................................... 30-82
Brake system ........................................................................................................................... 30-83
Testing brake pedal ............................................................................................................ 30-83
Testing and adjusting brake pedal linkage ............................................................................ 30-84
Testing braking performance ............................................................................................... 30-85
Testing and adjusting of accumulator charge pressure........................................................... 30-86
Testing of brake accumulator nitrogen gas pressure and procedure for charging brake
accumulator with nitrogen gas................................................................................ 30-88
Testing wheel brake oil pressure.......................................................................................... 30-92
Testing lowering of wheel brake pressure ............................................................................. 30-94
Testing wear of wheel brake disc ......................................................................................... 30-96
Bleeding air from wheel brake circuit.................................................................................... 30-97
Releasing remaining pressure in brake accumulator circuit .................................................... 30-99
Testing parking brake performance .................................................................................... 30-100
Testing parking brake oil pressure ..................................................................................... 30-101
Testing wear of parking brake disc ..................................................................................... 30-102
00-4
WA470-7

Index
Method of releasing parking brake manually ....................................................................... 30-103

Testing fan speed............................................................................................................. 30-105
Testing fan pump circuit oil pressure .................................................................................. 30-106
Bleeding air from hydraulic fan circuit ................................................................................. 30-108
Testing and adjusting work equipment EPC oil pressure ...................................................... 30-110
Testing and adjusting work equipment oil pressure.............................................................. 30-113
Bleeding air from work equipment circuit ............................................................................ 30-117
Releasing remaining pressure from work equipment circuit .................................................. 30-118
Testing of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator
with nitrogen gas ................................................................................................ 30-119
Work equipment ..................................................................................................................... 30-123
Testing and adjusting bucket position detection lever........................................................... 30-123
Testing and adjusting boom position detection lever ............................................................ 30-124
Adjusting replaced, reassembled or added sensor, controller, etc. with machine
monitor .............................................................................................................. 30-125
Special functions of machine monitor ................................................................................. 30-127
Adjusting rearview camera angle ....................................................................................... 30-216
Handling voltage circuit of engine controller........................................................................ 30-217
Handling battery disconnect switch .................................................................................... 30-218
Testing diodes ................................................................................................................. 30-219
Pm clinic ................................................................................................................................ 30-220
Pm Clinic service ............................................................................................................. 30-220
Check sheet .................................................................................................................... 30-221
40 Troubleshooting............................................................................................................................ 40-1
General information on troubleshooting ...................................................................................... 40-11
Troubleshooting points ....................................................................................................... 40-11
Sequence of events in troubleshooting................................................................................. 40-13
Check before troubleshooting.............................................................................................. 40-15
Inspection procedure before troubleshooting ........................................................................ 40-17
Preparation work for troubleshooting of electrical system....................................................... 40-34
Classification and procedures for troubleshooting ................................................................. 40-40
Symptom and troubleshooting numbers ............................................................................... 40-43
Information in troubleshooting table ..................................................................................... 40-46
Connector list and layout .................................................................................................... 40-48
Connector contact identification........................................................................................... 40-62
T-branch box and T-branch adapter table ............................................................................. 40-98
Fuse location table ........................................................................................................... 40-104
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-107
Precautions on troubleshooting of machine monitor ............................................................ 40-110
Processing procedure of harness checker for troubleshooting of machine monitor LCD
unit .................................................................................................................... 40-112
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature
sensors)............................................................................................................. 40-117
Fabrication of short-circuit connector (for CA1883 and CA3135)........................................... 40-118
Failure codes table........................................................................................................... 40-119
Troubleshooting by failure code (Display of code) ...................................................................... 40-133
Failure code [1500L0] Double Engagement of T/M Clutches ................................................ 40-133
Failure code [15SAL1] Release Trouble of ECMV (Forward) ................................................ 40-134
Failure code [15SALH] Malfunction of ECMV (Forward)....................................................... 40-136
Failure code [15SBL1] Release Trouble of ECMV (Reverse)................................................ 40-138
Failure code [15SBLH] Malfunction of ECMV (Reverse) ...................................................... 40-140
Failure code [15SEL1] Release Trouble of ECMV (1st)........................................................ 40-142
Failure code [15SELH] Malfunction of ECMV (1st) .............................................................. 40-144
Failure code [15SFL1] Release Trouble of ECMV (2nd)....................................................... 40-146
Failure code [15SFLH] Malfunction of ECMV (2nd) ............................................................. 40-148
Failure code [15SGL1] Release Trouble of ECMV (3rd) ....................................................... 40-150
WA470-7
00-5

Index
Failure code [15SGLH] Malfunction of ECMV (3rd).............................................................. 40-152

Failure code [15SHL1] Release Trouble of ECMV (4th) ....................................................... 40-154
Failure code [15SHLH] Malfunction of ECMV (4th) .............................................................. 40-156
Failure code [2F00MA] Failure of Parking Brake Circuit ....................................................... 40-158
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................. 40-162
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) .............................................. 40-164
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-166
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-167
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-168
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-169
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-170
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-171
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-172
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-173
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-174
Failure code [989A00] Engine Overrun Prevention Activated ............................................... 40-175
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-176
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-177
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-178
Failure code [A1U0N3] HC Desorb Request 1 .................................................................... 40-179
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-183
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-185
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-186
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-188
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-189
Failure code [B@CENS] T/C Oil Temp. Overheat................................................................ 40-191
Failure code [B@HANS] HYD Oil Temp. Overheat .............................................................. 40-192
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-193
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-194
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-196
Failure code [CA131] Throttle Sensor High Error................................................................. 40-198
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-200
Failure code [CA135] Eng Oil Press Sensor High Error........................................................ 40-202
Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................ 40-204
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-206
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-208
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-210
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-212
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-214
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-216
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-218
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-220
Failure code [CA234] Eng Overspeed ................................................................................ 40-221
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-222
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-223
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-224
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-225
Failure code [CA273] PCV2 Short Error ............................................................................. 40-226
Failure code [CA274] PCV2 Open Error ............................................................................. 40-227
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-228
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-240
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-241
00-6
WA470-7

Index
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-244
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-246
Failure code [CA431] Idle Validation Sw Error..................................................................... 40-249
Failure code [CA432] Idle Validation Process Error ............................................................. 40-252
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-255
Failure code [CA442] Battery Voltage High Error................................................................. 40-257
Failure code [CA449] Rail Press Very High Error................................................................. 40-258
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-259
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-261
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-263
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-265
Failure code [CA553] Rail Press High Error ........................................................................ 40-267
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-268
Failure code [CA559] Rail Press Low Error......................................................................... 40-270
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-274
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-275
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-277
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-279
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-281
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-283
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-284
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-285
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-286
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-288
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-289
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-292
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-295
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-296
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-298
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-300
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-302
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-304
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-306
Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-309
Failure code [CA1923] Dosing Fuel Valve 1 High Error ........................................................ 40-317
Failure code [CA1924] Dosing Fuel Valve 1 Low Error......................................................... 40-319
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ................................................. 40-322
Failure code [CA1927] Dosing Fuel Press Sens High Error .................................................. 40-324
Failure code [CA1928] Dosing Fuel Press Sens Low Error................................................... 40-326
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-328
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ...................................................... 40-329
Failure code [CA1977] Fuel Doser Open/Short Error ........................................................... 40-331
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-333
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-335
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-337
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-339
Failure code [CA2265] Fuel Feed Pump Open Error............................................................ 40-340
Failure code [CA2266] Fuel Feed Pump Short Error ............................................................ 40-342
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-344
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-346
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-348
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-350
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-352
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-353
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-355
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-357
WA470-7
00-7

Index
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-359

Failure code [CA2387] KVGT Servo Error .......................................................................... 40-361
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-362
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-364
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-366
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-368
Failure code [CA2741] Dosing Fuel Valve Swap Error ......................................................... 40-375
Failure code [CA2765] Inj Trim Data Error .......................................................................... 40-377
Failure code [CA2881] Dosing Fuel Pressure Low Error 1.................................................... 40-381
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-386
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-388
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-390
Failure code [CA3167] Fuel Doser Degradation .................................................................. 40-393
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-396
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-399
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-402
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-405
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-409
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-412
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-418
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-421
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-425
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-430
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-433
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-437
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-442
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-446
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-449
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-454
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-456
Failure code [D150KA] Disconnection of Emerg. Steering Relay .......................................... 40-458
Failure code [D150KB] Ground Fault of Emerg. Steering Relay ............................................ 40-460
Failure code [D150KY] Hot Short of Emergency Steering Relay ........................................... 40-462
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ................................... 40-464
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output..................................... 40-466
Failure code [D160KY] Hot Short of Backup Lamp Relay Output .......................................... 40-468
Failure code [D191KA] Disconnection of Neutral Output Relay............................................. 40-470
Failure code [D191KB] Ground Fault of Neutral Output Relay .............................................. 40-472
Failure code [D191KY] Hot Short of Neutral Output Relay.................................................... 40-474
Failure code [D192KA] Disconnection of ECSS Solenoid..................................................... 40-476
Failure code [D192KB] Ground Fault of ECSS Solenoid ...................................................... 40-478
Failure code [D192KY] Hot Short of ECSS Solenoid ........................................................... 40-479
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-480
Failure code [D1E6KA] Disconnection of Parking Brake Relay ............................................. 40-482
Failure code [D1E6KB] Ground Fault of Parking Brake Relay............................................... 40-484
Failure code [D1E6KY] Hot Short of Parking Brake Relay .................................................... 40-486
Failure code [D5ZHKA] Failure of Key SW C Signal ............................................................ 40-488
Failure code [D5ZHKB] Key SW C Signal Short Circuit........................................................ 40-490
Failure code [D5ZHKZ] Failure of Key SW C Signal ............................................................ 40-492
Failure code [D5ZHL6] Disconnection of Key SW C ............................................................ 40-494
Failure code [D811MC] KOMTRAX Error............................................................................ 40-496
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-497
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-498
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-500
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 .......................................................... 40-502
00-8
WA470-7

Index
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-503

Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................... 40-505
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-506
Failure code [DAF0MC] Monitor Error ................................................................................ 40-507
Failure code [DAF3KK] Controller Power Source Low (MON)............................................... 40-508
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-510
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .......................................... 40-511
Failure code [DAFGMC] GPS Module Error........................................................................ 40-513
Failure code [DAFLKA] Operating Lamp Open Circuit (MON)............................................... 40-514
Failure code [DAFLKB] Operating Lamp Short Circuit (MON)............................................... 40-516
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-518
Failure code [DAQ0KK] Controller Power Source Low (T/M) ................................................ 40-519
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ....................................... 40-522
Failure code [DAQ0MC] T/M Con Error .............................................................................. 40-523
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .............................................. 40-524
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ................................................. 40-526
Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay .......................................... 40-529
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) .......................................... 40-531
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ................................................ 40-532
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ................................................ 40-534
Failure code [DAQQKR] CAN2 Discon (Transmission Con) ................................................. 40-536
Failure code [DAQRKR] CAN1 Discon (Transmission Con) ................................................. 40-537
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ......................................... 40-538
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-539
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-540
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-541
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-546
Failure code [DB90KK] Drop in BBC Controller Main Power Source ..................................... 40-551
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ...................................... 40-553
Failure code [DB90MC] BBC Error..................................................................................... 40-554
Failure code [DB91KA] Disconnection of Key SW ACC (BBC) ............................................. 40-555
Failure code [DB92KK] Solenoid Power Source Low (BBC) ................................................. 40-557
Failure code [DB95KX] Failure of 5 V Power Source 1......................................................... 40-559
Failure code [DB99KQ] Inconsistency of Model Selection (BBC) .......................................... 40-563
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC)................................................ 40-564
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ................................................ 40-566
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) .................................................. 40-568
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) .................................................. 40-569
Failure code [DB9RMA] Inconsistency of Option Selection (BBC)......................................... 40-570
Failure code [DBE5KX] Failure of 5V Power Source............................................................ 40-571
Failure code [DBE6KX] Failure of 24 V Power Source ......................................................... 40-573
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ..................................... 40-575
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................................ 40-577
Failure code [DDB6L4] Neutral Signal Malfunction .............................................................. 40-579
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ........................................... 40-582
Failure code [DDK3KA] FNR SW Input Signal Disconnection............................................... 40-584
Failure code [DDK3KB] FNR SW Input Signal Short Circuit.................................................. 40-587
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ............................................ 40-589
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit............................................... 40-592
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW .......................................... 40-594
Failure code [DDT0L4] Failure of Shift Mode Select SW ...................................................... 40-596
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal...................................... 40-598
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal ........................................... 40-600
Failure code [DDW9LD] Ground Fault of Kickdown Switch................................................... 40-602
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW ................................................ 40-604
Failure code [DF10KA] Disconnection of Shift Lever Input ................................................... 40-606
Failure code [DF10KB] Ground Fault of Shift Lever Input ..................................................... 40-608
Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor........................................... 40-611
WA470-7
00-9

Index
Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ............................................ 40-613
Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor .......................................... 40-615
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ......................................... 40-617
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor .................................................. 40-618
Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor ........................................... 40-620
Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor............................................. 40-623
Failure code [DH21KA] Failure of Loader Pump Press. Sensor ............................................ 40-625
Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit........................................ 40-627
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ............................................... 40-629
Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor.................................. 40-631
Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor .................................... 40-633
Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor...................................... 40-635
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ..................................... 40-637
Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor .................................. 40-639
Failure code [DHT8KA] Failure of Steering Pump Press. Sensor .......................................... 40-641
Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit...................................... 40-643
Failure code [DHT8ZG] Steering Oil Pressure Low.............................................................. 40-645
Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor ......................................... 40-646
Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit ............................................ 40-648
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ................................................. 40-650
Failure code [DK55KA] Failure of FNR Lever Potentio ......................................................... 40-652
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ........................................... 40-655
Failure code [DK55L5] Failure of FNR Lever Potentio.......................................................... 40-657
Failure code [DK59KA] Failure of Boom Lever Potentio (Main) ............................................. 40-658
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ......................................... 40-661
Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree .................................... 40-664
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub).............................................. 40-668
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) .......................................... 40-671
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ........................................... 40-674
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) ....................................... 40-677
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree .................................... 40-680
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ............................................ 40-684
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ........................................ 40-687
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ................................................ 40-690
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ............................................ 40-693
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree........................................ 40-695
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub).................................................. 40-698
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub).............................................. 40-701
Failure code [DKA0KA] Failure of Boom Angle Sensor ........................................................ 40-703
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit .......................................... 40-705
Failure code [DKA0L0] Boom Angle Sensor Dislocation ...................................................... 40-707
Failure code [DKA1KA] Failure of Bucket Angle Sensor....................................................... 40-709
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit......................................... 40-711
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor........................................ 40-713
Failure code [DLF1LC] Failure of T/M Input Speed Sensor................................................... 40-715
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor.................................. 40-717
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor............................................. 40-719
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main).................................... 40-721
Failure code [DLT3LC] Failure of Output Speed Sensor (Main)............................................. 40-723
Failure code [DPQ1KR] LIN Discon (Switch Panel) ............................................................. 40-725
Failure code [DPQ2KR] LIN Discon (LED Unit) ................................................................... 40-728
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ..................................................... 40-731
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) .............................................................. 40-734
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator .............................................. 40-736
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. .......................................... 40-738
Failure code [DV00KB] Ground Fault of Buzzer Output........................................................ 40-740
Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ................................ 40-742
Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise).................................. 40-744
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ....................................... 40-746
00-10
WA470-7

Index
Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ............................... 40-748
Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) ................................. 40-750
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ...................................... 40-752
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) .......................................... 40-754
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) .................................... 40-756
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt).......................................... 40-758
Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ..................................... 40-760
Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ................................ 40-762
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ..................................... 40-764
Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid ......................................... 40-766
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. .......................................... 40-768
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol................................................. 40-770
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ......................................... 40-771
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid........................................... 40-773
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ................................................ 40-775
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...................................... 40-777
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ........................................ 40-779
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ............................................. 40-781
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ..................................... 40-783
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket)....................................... 40-785
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ............................................ 40-787
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol....................................... 40-789
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....................................... 40-791
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ....................................... 40-793
Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid ................................. 40-795
Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ................................... 40-797
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid ........................................ 40-799
Failure code [DXANKA] Disconnection of Steering Pump EPC Sol. ...................................... 40-801
Failure code [DXANKB] Ground Fault of Steering Pump EPC Solenoid ................................ 40-803
Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid...................................... 40-805
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ..................................... 40-806
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....................................... 40-808
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ............................................ 40-810
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)............................................ 40-812
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ............................................. 40-814
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)................................................... 40-816
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)........................................... 40-818
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ............................................ 40-820
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd).................................................. 40-822
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ........................................... 40-824
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ............................................. 40-826
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) .................................................. 40-828
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse).................................... 40-830
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ..................................... 40-832
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)........................................... 40-834
Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) .................................... 40-836
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward)...................................... 40-838
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ........................................... 40-840
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ........................................... 40-842
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)............................................. 40-844
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) .................................................. 40-846
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ....................................... 40-848
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)......................................... 40-850
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) .............................................. 40-852
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...................................... 40-854
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ........................................ 40-856
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ............................................. 40-858
Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor........................................... 40-860
Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor .......................................... 40-863
WA470-7
00-11

Index
Failure code [DY30ME] Emerg. Steering Long-Time Activated ............................................. 40-867

Failure code [LA00L3] Failure of Fan Reverse .................................................................... 40-869
Troubleshooting of electrical system (E-mode) .......................................................................... 40-870
E-1 Engine does not start.................................................................................................. 40-870
E-2 Manual preheating system does not work..................................................................... 40-876
E-3 Automatic preheating system does not work................................................................. 40-879
E-4 While preheating is working, preheating monitor does not light up .................................. 40-881
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing .................. 40-883
E-6 LCD unit on machine monitor displays nothing.............................................................. 40-886
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or
flickers) .............................................................................................................. 40-888
E-8 LCD on machine monitor does not display properly ....................................................... 40-890
E-9 Meter unit display on machine monitor is abnormal ....................................................... 40-892
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ................................. 40-895
E-11 Caution LED on machine monitor is abnormal............................................................. 40-898
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate
properly ............................................................................................................. 40-900
E-13 Two switches operation of switch panel on machine monitor does not function .............. 40-902
E-14 Switch panel buzzer of machine monitor is abnormal................................................... 40-905
E-15 Rear view monitor does not light up or backlight flickers............................................... 40-907
E-16 Rear view monitor images are not displayed clearly..................................................... 40-910
E-17 Rear view monitor brightness cannot be adjusted........................................................ 40-913
E-18 Night lighting lamp of rear view monitor is abnormal .................................................... 40-916
E-19 Some items of gauges and caution lamps on machine monitor are not displayed
properly ............................................................................................................. 40-918
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking)
position .............................................................................................................. 40-919
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not
light ................................................................................................................... 40-923
E-22 Air cleaner clogging indicator lamp does not light ........................................................ 40-925
E-23 Radiator coolant level caution lamp does not light ....................................................... 40-926
E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil
temperature caution lamp does not light................................................................ 40-928
E-25 Indication of torque converter oil temperature gauge does not increase, or torque
converter oil temperature caution lamp does not light ............................................. 40-930
E-26 Fuel level gauge does not indicate correct level .......................................................... 40-931
E-27 Seat belt caution lamp indication is abnormal.............................................................. 40-933
E-28 Horn does not sound ................................................................................................ 40-934
E-29 Horn does not stop sounding..................................................................................... 40-937
E-30 Alarm buzzer does not sound .................................................................................... 40-939
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ................ 40-940
E-32 Kickdown does not work when kickdown switch is turned ON....................................... 40-941
E-33 The hold switch does not work when it is pressed........................................................ 40-943
E-34 Parking brake does not work even if it is applied, or the brake drags when parking brake
is released and FR drive is operated..................................................................... 40-945
E-35 Transmission cut-off mode is not selected or not released............................................ 40-948
E-36 Transmission cut-off setting cannot be released .......................................................... 40-950
E-37 Directional selector (FNR) switch mode is not selected or not released ......................... 40-952
E-38 When operating engine power selection switch, engine power selection function does not
operate properly ................................................................................................. 40-954
E-39 Flow of loader pump does not increase from the minimum rate..................................... 40-956
E-40 ECSS function cannot be selected or cannot be released ............................................ 40-957
E-41 None of headlamp, clearance lamp, and tail lamp lights ............................................... 40-959
E-42 Clearance lamp and tail lamp do not light up or go out ................................................. 40-961
E-43 Both High and Low beams of headlamp do not light up or go out .................................. 40-964
E-44 Low beam of headlamp does not light up or go out ...................................................... 40-968
E-45 High beam of headlamp does not light up or go out ..................................................... 40-970
E-46 Front working lamp does not light up or go out ............................................................ 40-972
E-47 Rear working lamp does not light up or go out............................................................. 40-975
00-12
WA470-7

Index
E-48 All of turn signal lamps and hazard lamps do not light up or go out................................ 40-978
E-49 Turn signal lamps do not light up or go out .................................................................. 40-981
E-50 Hazard lamp does not light up or go out...................................................................... 40-984
E-51 Brake lamp does not light or stays lighted ................................................................... 40-987
E-52 Backup lamp does not light up or does not go out........................................................ 40-990
E-53 Backup buzzer does not sound or continues to sound ................................................. 40-993
E-54 Front wiper does not operate ..................................................................................... 40-995
E-55 Rear wiper does not operate ..................................................................................... 40-998
E-56 Window washer does not operate ............................................................................ 40-1000
E-57 Fuel feed pump does not operate or stop automatically ............................................. 40-1003
E-58 KOMTRAX system does not operate properly........................................................... 40-1005
Troubleshooting of hydraulic and mechanical system (H-mode) ................................................ 40-1007
Information described in troubleshooting table (H-mode) ................................................... 40-1007
System chart of hydraulic and mechanical systems........................................................... 40-1008
Failure mode and cause table ..........................................................................................40-1011
H-1 Machine does not move off ....................................................................................... 40-1019
H-2 Torque converter lockup clutch is not disengaged (engine stalls).................................. 40-1022
H-3 Torque converter lockup clutch is not engaged ........................................................... 40-1023
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not
shift ................................................................................................................. 40-1024
H-5 Large shock is made when machine starts or gear is shifted ........................................ 40-1027
H-6 Machine starts or gear speed shifts with long time lag ................................................. 40-1029
H-7 Torque converter oil temperature is high..................................................................... 40-1031
H-8 Machine does not turn .............................................................................................. 40-1033
H-9 Turning response is poor .......................................................................................... 40-1035
H-10 Steering wheel is heavy to turn................................................................................ 40-1037
H-11 Machine sways or large shocks are made while machine turns .................................. 40-1038
H-12 Turning radius differs between right and left turns...................................................... 40-1040
H-13 Wheel brakes do not work or are weak..................................................................... 40-1041
H-14 Wheel brakes are not released or drag..................................................................... 40-1043
H-15 Parking brake does not work or it is weak ................................................................. 40-1044
H-16 Parking brake is not released or drags (including emergency release system) ............. 40-1045
H-17 Boom does not rise ................................................................................................ 40-1046
H-18 Boom moves slow or boom lacks lifting force ............................................................ 40-1048
H-19 Rising boom slows down at certain height ................................................................ 40-1050
H-20 Lift cylinders do not serve to hold bucket on ground .................................................. 40-1051
H-21 Hydraulic drift of boom is large ................................................................................ 40-1052
H-22 Boom moves up and down during operation ............................................................. 40-1053
H-23 Bucket does not tilt back ......................................................................................... 40-1054
H-24 Bucket moves slow or lacks tilt-back force................................................................ 40-1056
H-25 Bucket decelerates during tilt-back operation............................................................ 40-1058
H-26 Bucket cylinder does not hold bucket on ground ....................................................... 40-1059
H-27 Hydraulic drift of bucket is large ............................................................................... 40-1060
H-28 Bucket tilts back and forth during carrying load (work equipment valve in
HOLD) ............................................................................................................. 40-1061
H-29 Boom and bucket control levers do not move smoothly and are heavy to move ........... 40-1062
H-30 Operating work equipment causes engine speed to lower significantly or engine to
stall ................................................................................................................. 40-1063
H-31 Large shocks are made when work equipment starts to move and stops ..................... 40-1064
H-32 When certain work equipment stalls hydraulically, other work equipment
moves ............................................................................................................. 40-1066
H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces................. 40-1067
H-34 Bucket does not stop at the position which is set with remote bucket positioner ........... 40-1068
H-35 Fan speed is abnormal (too high or low, or fan does not rotate) .................................. 40-1069
H-36 Unusual noise is heard from around fan ................................................................... 40-1070
Troubleshooting of engine (S-mode)....................................................................................... 40-1071
Information mentioned in troubleshooting table (S mode)................................................... 40-1071
S-1 When starting switch is turned to START position, engine is not cranked....................... 40-1072
S-2 The engine cranks but exhaust smoke does not come out ........................................... 40-1073
WA470-7
00-13

Index
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start
but does not) .................................................................................................... 40-1074
S-4 Engine startability is poor .......................................................................................... 40-1075
S-5 Engine does not pick-up smoothly ............................................................................. 40-1077
S-6 Engine stops during operation ................................................................................... 40-1079
S-7 Engine runs rough or is unstable ............................................................................... 40-1081
S-8 Engine lacks power .................................................................................................. 40-1082
S-9 KDPF gets clogged in a short time ............................................................................. 40-1084
S-10 Engine oil consumption is excessive ........................................................................ 40-1086
S-11 Engine oil becomes contaminated early.................................................................... 40-1087
S-12 Fuel consumption is excessive ................................................................................ 40-1088
S-13 Oil is in coolant (or coolant spurts or coolant level goes down).................................... 40-1089
S-14 Oil pressure drops .................................................................................................. 40-1090
S-15 Fuel mixes into engine oil........................................................................................ 40-1091
S-16 Water mixes into engine oil (milky) ........................................................................... 40-1092
S-17 Coolant temperature rises too high (overheating) ...................................................... 40-1093
S-18 Unusual noise is heard ........................................................................................... 40-1094
S-19 Vibration is excessive ............................................................................................. 40-1095
S-20 Air cannot be bled from fuel circuit ........................................................................... 40-1096
S-21 Active regeneration is executed frequently ............................................................... 40-1097
S-22 Active regeneration takes a long time....................................................................... 40-1098
S-23 White smoke is exhausted during active regeneration ............................................... 40-1099
50 Disassembly and assembly ........................................................................................................... 50-1
General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-17
Removal and installation of supply pump assembly............................................................... 50-47
Removal and installation of injector assembly....................................................................... 50-53
Removal and installation of fuel doser assembly ................................................................... 50-61
Removal and installation of cylinder head assembly.............................................................. 50-63
Removal and installation of engine hood assembly ............................................................... 50-77
Removal and installation of grille assembly .......................................................................... 50-79
Removal and installation of cooling system assembly............................................................ 50-82
Removal and installation of radiator core assembly ............................................................... 50-85
Removal and installation of aftercooler................................................................................. 50-87
Removal and installation of hydraulic oil cooler ..................................................................... 50-90
Removal and installation of power train oil cooler assembly ................................................... 50-92
Removal and installation of engine assembly ....................................................................... 50-96
Removal and installation of engine front oil seal .................................................................. 50-102
Removal and installation of engine rear oil seal................................................................... 50-105
Removal and installation of cooling fan and cooling fan motor assembly ............................... 50-110
Removal and installation of KDPF assembly....................................................................... 50-112
Disassembly and assembly of KDPF assembly .................................................................. 50-117
Removal and installation of KCCV assembly ...................................................................... 50-126
Removal and installation of KVGT assembly....................................................................... 50-128
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly...................... 50-133
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly..................... 50-134
Removal and installation of air cleaner assembly ................................................................ 50-136
Removal and installation of air conditioner compressor belt ................................................. 50-138
Removal and installation of alternator belt .......................................................................... 50-139
Removal and installation of fuel tank assembly ................................................................... 50-140
Power train............................................................................................................................. 50-143
Removal and installation of torque converter and transmission assembly.............................. 50-143
Disassembly and assembly of transmission assembly......................................................... 50-148
Disassembly and assembly of torque converter assembly ................................................... 50-178
00-14
WA470-7

Index
Disassembly and assembly of transmission clutch pack assembly ....................................... 50-185

Removal and installation of front axle assembly .................................................................. 50-208
Removal and installation of rear axle assembly................................................................... 50-210
Disassembly and assembly of axle housing assembly......................................................... 50-215
Disassembly and assembly of differential assembly ............................................................ 50-225
Steering system...................................................................................................................... 50-244
Removal and installation of steering valve assembly ........................................................... 50-244
Brake system ......................................................................................................................... 50-246
Removal and installation of brake charge valve assembly.................................................... 50-246
Removal and installation of parking brake disc and plate ..................................................... 50-247
Removal and installation of center hinge pin ....................................................................... 50-250
Removal and installation of counterweight assembly ........................................................... 50-258
Removal and installation of full-length fender assembly ....................................................... 50-260
Removal and installation of hydraulic tank assembly ........................................................... 50-261
Removal and installation of control valve assembly ............................................................. 50-264
Removal and installation of steering pump and power train pump assembly .......................... 50-267
Removal and installation of work equipment pump and cooling fan pump assembly............... 50-269
Disassembly and assembly of hydraulic cylinder assembly.................................................. 50-271
Work equipment ..................................................................................................................... 50-278
Removal and installation of work equipment assembly ........................................................ 50-278
Removal and installation of operator's cab and floor frame assembly.................................... 50-283
Removal and installation of operator's cab glass (stuck window glass).................................. 50-287
Removal and installation of operator's seat assembly.......................................................... 50-295
Removal and installation of seat belt .................................................................................. 50-297
Removal and installation of air conditioner unit assembly..................................................... 50-298
Removal and installation of air conditioner compressor assembly......................................... 50-303
Removal and installation of air conditioner condenser assembly .......................................... 50-305
Removal and installation of machine monitor assembly ....................................................... 50-307
Removal and installation of engine controller assembly ....................................................... 50-308
Removal and installation of work equipment controller assembly.......................................... 50-309
Removal and installation of transmission controller assembly .............................................. 50-311
Removal and installation of monitor controller assembly ...................................................... 50-312
Removal and installation of mass air flow and temperature sensor ....................................... 50-314
Removal and installation of KOMTRAX terminal assembly .................................................. 50-315
60 Maintenance standard................................................................................................................... 60-1
Cooling fan pump ................................................................................................................. 60-4
Cooling fan motor................................................................................................................. 60-7
Power train................................................................................................................................. 60-9
Drive shaft ........................................................................................................................... 60-9
Transmission ..................................................................................................................... 60-12
3rd, 4th clutch ECMV.......................................................................................................... 60-24
Axle .................................................................................................................................. 60-27
Differential ......................................................................................................................... 60-29
Final drive ......................................................................................................................... 60-39
Steering system........................................................................................................................ 60-41
Steering column................................................................................................................. 60-41
Steering pump ................................................................................................................... 60-42
WA470-7
00-15

Index
Steering valve.................................................................................................................... 60-46

Steering cylinder ................................................................................................................ 60-48
Emergency steering pump .................................................................................................. 60-51
Brake system ........................................................................................................................... 60-52
Charge valve ..................................................................................................................... 60-52
Slack adjuster .................................................................................................................... 60-54
Brake ................................................................................................................................ 60-55
Parking brake .................................................................................................................... 60-57
Parking brake solenoid valve .............................................................................................. 60-58
Undercarriage and frame........................................................................................................... 60-59
Axle mount and center hinge pin.......................................................................................... 60-59
Hydraulic system ...................................................................................................................... 60-63
Hydraulic tank.................................................................................................................... 60-63
Double type gear pump ...................................................................................................... 60-64
Work equipment pump........................................................................................................ 60-65
Control valve ..................................................................................................................... 60-67
Work equipment ....................................................................................................................... 60-76
Work equipment linkage ..................................................................................................... 60-76
Bucket .............................................................................................................................. 60-80
Work equipment cylinder .................................................................................................... 60-81
80 Appendix...................................................................................................................................... 80-1
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-6
Outline of refrigeration cycle.................................................................................................. 80-7
Air conditioner unit ............................................................................................................... 80-9
Dual pressure switch .......................................................................................................... 80-14
Air conditioner controller ..................................................................................................... 80-15
Compressor....................................................................................................................... 80-16
Condenser ........................................................................................................................ 80-17
Receiver drier .................................................................................................................... 80-18
Sunlight sensor .................................................................................................................. 80-20
Outer temperature sensor (outside air temperature sensor) ................................................... 80-21
Procedure for testing and troubleshooting ............................................................................ 80-22
Circuit diagram and arrangement of connector pins............................................................... 80-24
System diagram................................................................................................................. 80-27
Parts and connectors layout................................................................................................ 80-30
Testing with self-diagnosis function ...................................................................................... 80-35
How to open the electrical system abnormality record screen in service mode of the machine
monitor ................................................................................................................ 80-36
Testing temperature control system ..................................................................................... 80-38
Testing vent (mode) changeover.......................................................................................... 80-40
Testing FRESH/RECIRC air changeover.............................................................................. 80-42
Check evaporator temperature sensor ................................................................................. 80-44
Testing relays .................................................................................................................... 80-46
Troubleshooting chart 1 ...................................................................................................... 80-48
Failure code list related to air conditioner.............................................................................. 80-52
Failure code [879AKA] A/C Inner Sensor Open Circuit .......................................................... 80-53
Failure code [879AKB] A/C Inner Sensor Short Circuit........................................................... 80-55
Failure code [879BKA] A/C Outer Sensor Open Circuit.......................................................... 80-57
Failure code [879BKB] A/C Outer Sensor Short Circuit .......................................................... 80-59
Failure code [879CKA] Ventilating Sensor Open Circuit ......................................................... 80-61
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-63
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................................................ 80-65
Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-67
00-16
WA470-7

Index
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-70

A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does
not operate).......................................................................................................... 80-73
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-76
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-79
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-82
Troubleshooting with gauge pressure................................................................................... 80-84
Connection of service tool................................................................................................... 80-87
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit................................................................................................................... 80-89
Handling of compressor oil.................................................................................................. 80-91
90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram of power train .................................................................................. 90-7
Hydraulic circuit diagram....................................................................................................... 90-9
Electric circuit diagram .............................................................................................................. 90-11
Symbols in electric circuit diagram ....................................................................................... 90-11
Electrical circuit diagram of machine body ............................................................................ 90-15
Electrical circuit diagram of floor .......................................................................................... 90-25
Index.................................................................................................................................................................... 1
WA470-7
00-17

Foreword, safety and general information

Important safety notice
(ALL-0370-001-A-00-A)
(ALL-1120-012-A-01-A)
(Rev. 2012/01)
Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
The symbol mark k is used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
General precautions
k Inappropriate
handling causes an extreme

danger. Read and understand what is
described in the operation and maintenance
manual before operating the machine. Read
and understand what is described in this
manual before starting the work.
Before performing any greasing or repairs, read

all the safety labels stuck to the machine. For
the locations of the safety labels and detailed
explanation of precautions, see the operation
and maintenance manual.
Locate a place in the repair workshop to keep
the 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, water or oil on the floor. Smoke
only in the areas provided for smoking. Never
smoke while working.
When performing any work, always wear the
safety shoes and helmet. Do not wear loose
work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when

hitting parts with a hammer.
2. Always wear the protective eyeglasses when
grinding parts with a grinder, etc.
When performing any work with two or more
workers, always agree on the working procedure
before starting. While working, always keep
conversations of the work between your fellow
workers and your self on any step of the work.
During the work, hang the warning tag of
"UNDER WORKING" in the operator's
compartment.
Only qualified workers must perform the work
and operation which require license or
qualification.
Keep the tools in good condition. And learn the
correct way to use the tools, and use the proper
ones among them. Before starting the work,
thoroughly check the tools, forklift truck, service
car, etc.
If welding repairs is required, always have a
trained and experienced welder with good
00-18
knowledge of welding perform the work. When

performing welding work, always wear welding
gloves, apron, shielding goggles, cap, etc.
Before starting work, warm up your body
thoroughly to start work under good condition.
Avoid continuing work for long hours and take
rests with proper intervals to keep your body in
good condition. Take a rest in a specified safe
place.
Safety points
1
2
3
4
5
6
7
8
9
10
Good arrangement
Correct work clothes
Observance of work standard
Practice of making and checking signals
Prohibition of operation and handling by
unlicensed workers
Safety check before starting work
Wearing protective goggles (for cleaning or
grinding work)
Wearing shielding goggles and protectors (for
welding work)
Good physical condition and preparation
Precautions against work which you are not
used to or you are used to too much
Preparation
Before adding oil or making any repairs, place
the machine on a firm and level ground, and
apply the parking brake and chock the wheels or
tracks to prevent the machine from moving.
Before starting work, lower the work equipment
(blade, ripper, bucket, etc.) to the ground. If it is
not possible to lower the equipment to the
ground, insert the lock pin or use blocks to
prevent the work equipment from falling. And be
sure to lock all the work equipment control levers
and hang a warning tag on them.
When performing the disassembling or
assembling work, support the machine securely
with blocks, jacks, or stands before starting the
work.
Remove all of mud and oil from the steps or
other places used to get on and off the machine
completely. Always use the handrails, ladders of
WA470-7

steps when getting on or off the machine. Never

jump on or off the machine. When the scaffold is
not provided, use steps or stepladder to secure
your footing.
Precautions during work
For the machine equipped with the battery
disconnect switch, check that the system
operating lamp is turned off before starting the
work. Then, turn the battery disconnect switch to
the OFF (Q) position and remove the switch key.
For the machine not equipped with the battery
disconnect switch, remove the cable from the
battery before starting the work. Be sure to
remove the negative end (-) of the battery cable
first.
Release the remaining pressure in the circuits
completely before the work when the parts in the
circuits of oil, fuel, coolant and air are
disconnected or removed. When the cap of the
oil filter, drain plug or oil pressure pickup plug is
removed, loose them slowly to prevent the oil
from spurting out.
When removing or installing the checking plug or
the piping in the fuel circuit, wait 30 seconds or
longer after the engine is shut down and start
the work after the remaining pressure is
released from the fuel circuit.
Immediately after the engine is shut down, the
coolant and oil in the circuits are hot. Be careful
not to get scalded by the hot coolant and oil.
Start the work after checking that the coolant
and oil are cooled down sufficiently.
Start the work after the engine is shut down. Be
sure to shut down the engine when working on
or around the rotating parts in particular. When
checking the machine without shutting down the
engine (measuring oil pressure, engine speed,
oil or coolant temperature), take extreme care
not to get caught in the rotating parts or the
working equipment.
The hoist or crane must be used to sling the
components weighing 25 kg or heavier. Check
the slings (wire rope, nylon sling, chain and
hook) for damage before the work. Use the
slings with ample capacity and install them to
the proper places. Operate the hoist or crane
slowly to prevent the component from hitting any
other part. Do not work with any part still raised
by the hoist or crane.
When removing the part which is under internal
pressure or reaction force of the spring, always
leave two bolts in diagonal positions. Loosen
those two bolts gradually and alternately and
release the pressure, then, remove the part.
When removing the part, be careful not to break
or damage the electrical wiring. The damaged
wiring may cause electrical fires.
WA470-7
When removing piping, prevent the fuel or oil

from spilling out. If any fuel or oil drips onto the
floor, wipe it off immediately. Fuel or oil on the
floor can cause you to slip and can even cause
fires.
As a general rule, do not use gasoline to wash
parts. Do not use gasoline to clean the electrical
parts, in particular.
Reinstall the parts removed to their original
places. Replace the damaged parts and the
parts which must not be used with new ones.
When installing the hoses and wiring harnesses,
be careful that they are not damaged by
contacting with other parts when the machine is
operated.
When connecting the high pressure hoses and
tubes, make sure that they are not twisted. The
damaged high pressure hoses and tubes are
very dangerous when they are installed. So, be
extremely careful when connecting the high
pressure pipings. In addition, check that their
connections are correct.
When assembling or installing the parts, be sure
to tighten the bolts to the specified torque. When
installing the protective parts such as guards, or
the parts which vibrate violently or rotate at high
speeds, be sure to check that they are installed
correctly.
When aligning two holes, never insert your
fingers or hand into the holes. Align the holes
with care so that your fingers are not caught in
the hole.
When measuring hydraulic pressure, check that
the measuring tools are correctly installed.
Pay attention to safety when removing and
installing the tracks of the track type machines.
When removing the track, it separates suddenly.
The workers should not stand at either end of
the track.
If the engine is operated for a long time in a
closed place which is not ventilated well, you
may suffer from gas poisoning. Accordingly,
open the windows and doors to ventilate the
place well.
Precautions for slinging work and making
signals
Only one appointed worker must make signals
and co-worker must communicate with each
other frequently. The appointed signaler must
make specified signals clearly at the place
where the signaler is well seen from the
operator's seat and where the signaler can see
the working condition easily. The signaler must
always stand in front of the load and guide the
operator safely.
1. Do not stand under the load.
2. Do not step on the load.
Check the slings before starting sling work.
00-19

Keep putting on the gloves during sling work.

(Put on the leather gloves, if available.)
Measure the weight of the load by the eye and
check its center of gravity.
Use the proper sling according to the weight of
the load and method of slinging. If too thick wire
ropes are used to sling a light load, the load may
slip and fall.
Do not sling a load with one wire rope only. If do
so, the load may rotate or the sling gets loose
and the sling may slip off. Install two or more
wire ropes symmetrically.
Use the specified eye bolts and fix wire ropes,

chains, etc. to them with shackles, etc.
Apply wire ropes to the middle portion of the
hook.
a Slinging near the tip of the hook may cause
the rope to slip off the hook during hoisting.
The hook has the maximum strength at the
middle part.
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 slinging position on the load,
which can result in a dangerous accident.
Hanging angle must be 60 degrees or smaller as

a rule.
When hanging a heavy load (25kg or heavier),
the hanging angle of the rope must be narrower
than that of the hook.
a When slinging a load with two ropes or more,
the larger the hanging angle is, the larger the
tension of each rope. The figure bellow
shows the variation of allowable load in kN
{kg} when hoisting is made with two ropes,
each of which is allowed to sling up to 9.8 kN
{1000kg} a load vertically, at various hanging
angles. When the two ropes sling a load
vertically, up to19.6 kN {2000 kg} of total
weight can be suspended. This weight is
reduced to 9.8 kN {1000 kg} when the two
ropes make a hanging angle of 120 degrees.
If the two ropes sling a 19.6 kN {2000 kg}
load at a hanging angle of 150 degrees, each
rope is subjected to a force as large as 39.2
kN {4000 kg}.
Do not use twisted or kinked wire ropes.

When slinging up a load, observe the following.
1. Wind up the rope slowly until the wire rope
tensions. When putting your hands on the
wire ropes, do not grasp them but press them
down from above. If you grasp them, your
fingers may be caught.
2. After the wire ropes are stretched, stop the
crane and check the condition of the slung
load, wire ropes, and pads.
3. If the load is unstable or the wire rope or
chains are twisted, lower the load and lift it
up again.
4. Do not lift up the load at an angle.
When lowering a load, pay attention to the
following.
1. When lifting down a load, stop it temporarily
at 30 cm above the floor, and then lower it
slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
Precautions for using mobile crane
a Read the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.
When installing wire ropes to an angular load,

apply pads to protect the wire ropes. If the load
is slippery, apply proper material to prevent the
wire rope from slipping.
00-20
WA470-7

Precautions for using overhead traveling crane

k The
hoist or crane must be used to sling the

components weighing 25 kg or heavier. A
part weighing 25 kg or heavier in
"disassembly and assembly" section is
indicated with the symbol of 4 .
Before starting work, check the wire ropes,

brake, clutch, controller, rails, over winding
prevention device, ground fault circuit interrupter
for electric shock prevention, crane collision
prevention device, and energizing warning lamp,
and check the following safety items.
Observe the signals for sling work.
Operate the hoist at a safe place.
Be sure to check the directions of the direction
indication plate (north, south, east and west) and
the operating button.
Do not sling a load at an angle. Do not move the
crane while the slung load is swinging.
Do not raise or lower a load while the crane is
moving longitudinally or laterally.
Do not drag a sling.
When lifting up a load, stop it just after it leaves
the ground and check safety, and then lift it up.
Consider the travel route in advance and lift up a
load to a safe height.
Place the control switch in a position where it will
not be an obstacle to work and passage.
After operating the hoist, do not swing the
control switch.
Remember the position of the main switch so
that you can turn off the power immediately in an
emergency.
Shut down the main switch when the hoist stops
because of a blackout. When turning on a switch
which is turned OFF by the ground fault circuit
interrupter for electric shock prevention, check
that the devices related to that switch are not in
operating condition.
If you find an obstacle around the hoist, stop the
operation.
After finishing the work, stop the hoist at the
specified position and raise the hook to at least
two meters above the floor. Do not leave the
sling attached to the hook.
Selecting wire ropes
Select adequate ropes depending on the weight
of the parts to be hoisted, referring to the table
below
Wire ropes (standard "Z" twist ropes without
galvanizing) (JIS G3525, Type 6x37-A)
Nominal
diameter of rope
mm
10
WA470-7
Allowable load
kN
8.8
ton
0.9
Nominal
diameter of rope
mm
12
14
16
18
20
25
30
40
50
60
Allowable load
kN
12.7
17.3
22.6
28.6
35.3
55.3
79.6
141.6
221.6
318.3
ton
1.3
1.7
2.3
2.9
3.6
5.6
8.1
14.4
22.6
32.4
a The allowable load is calculated as one sixth of

the breaking load of the rope to be used (safety
coefficient: 6).
Precautions for disconnecting and connecting
hoses and tubes in air conditioner circuit
Disconnection
k When
replacing the air conditioner unit, air

conditioner compressor, condenser or
receiver drier, etc., collect the refrigerant (air
conditioner gas: R134a) from the air
conditioner circuit before disconnecting the
air conditioner hoses.
a Ask a qualified person for collecting, adding and

filling operations of the refrigerant (air
conditioner gas: R134a).
a Never release the refrigerant (air conditioner
gas: R134a) to the atmosphere.
k If
refrigerant gas (air conditioner gas: R134a)

gets in your eyes, you may lose your sight.
And if it touches your skin, you may suffer
from frostbite. Put on protective eyeglasses,
gloves and working cloth with long sleeves
while collecting the refrigerant or filling the
air conditioner circuit with the refrigerant.
When loosening the nuts fixing air conditioner

hoses and tubes, be sure to use two wrenches;
use one wrench to fix and use the other one to
loosen the nut.
Connection
When installing the hose for the air conditioner
circuit, take care not to allow invasion of dirt,
dusts and water into the hose.
Check that the O-rings are fitted to the joints
when connecting the air conditioner piping.
Once an O-ring is used, it is deformed and
deteriorated. Accordingly, do not reuse it.
When removing the O-rings, use a soft tool so
that the piping is not damaged.
00-21

Check that the O-ring is not damaged or

deteriorated.
Apply compressor oil for refrigerant (R134a) to
the O-ring.
a However, do not apply oil to the threaded
portion of a bolt, nut or union.
Manufacturer
DENSO
VALEO THERMAL
SYSTEMS
SANDEN
Part name
ND-OIL8
ZXL100PG (equivalent to
PAG46)
SP-10
When tightening nuts of the air conditioner

hoses and tubes, be sure to use two wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
a Example of fitting of O-ring
An O-ring is fitted to every joint of the air
conditioner piping.
For tightening torques, see "Others",

"Precautions for disconnection and connection
of air conditioner piping".
00-22
WA470-7

Fire prevention
Action if fire occurs
(ALL-0000-001-K-27-A)
(ALL-0000-17A-K-01-A)
Turn the starting switch to the OFF position to

shutdown the engine.
Use the handrails and steps to get off the
machine.
Do not jump off the machine. You may fall or
suffer serious injury.
The fume generated by a fire contains harmful
materials which have a bad influence on a
human body when they are sucked.
Don't breathe a fume.
After a fire, there may be harmful compounds
left. If it touches your skin it may have a bad
influence on your body.
Be sure to wear rubber gloves when handle the
materials left after the fire.
The material of the gloves, which is
recommended is polychloroprene (Neoprene) or
polyvinyl chloride (in the lower temperature
environment).
When wearing cotton-work-gloves, wear rubber
gloves under them.
Prevent fire
(ALL-0000-17B-K-03-A)
Fire caused by fuel, oil, coolant or window

washer fluid
Do not bring any flame or fire close to flammable
substances such as fuel, oil, coolant or window
washer fluid.There is danger that they may catch
fire. Always observe the following.
Do not smoke or use any flame near fuel or
other flammable substances.
Shut down the engine before adding fuel.
Do not leave the machine when adding fuel
or oil.
Tighten all the fuel and oil caps securely.
Be careful not to spill fuel on overheated
surfaces or on parts of the electrical system.
After adding fuel or oil, wipe up any spilled
fuel or oil.
Put greasy rags and other flammable
materials into a safe container to maintain
safety at the workplace.
When washing parts with oil, use a nonflammable oil. Do not use diesel oil or
gasoline.There is danger that they may catch
fire.
Do not weld or use a cutting torch to cut any
pipes or tubes that contain flammable liquids.
Determine well-ventilated areas for storing oil
and fuel. Keep the oil and fuel in the
specified place and do not allow
unauthorized persons to enter.
When performing grinding or welding work
on the machine, move any flammable
materials to a safe place before starting.
WA470-7
9 J D 0 1 7 2 0
9 J D 0 1 7 2 1
Fire caused by accumulation or attachment

of flammable material
Remove any dry leaves, chips, pieces of
paper, coal dust, or any other flammable
materials accumulated or attached to or
around the engine exhaust manifold, muffler,
or battery, or on the undercovers.
To prevent fires from being caught, remove
any flammable materials such as dry leaves,
chips, pieces of paper, coal dust, or any
other flammable materials accumulated
around the cooling system (radiator, oil
cooler) or on the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause
fire. Always observe the following.
Keep all the electric wiring connections clean
and securely tightened.
Check the wiring every day for looseness or
damage. Reconnect any loose connectors or
refasten wiring clamps. Repair or replace any
damaged wiring.
Fire caused by piping
Check that all the clamps for the hoses and
tubes, guards, and cushions are securely fixed
in position.
If they are loose, they may vibrate during
operation and rub against other parts. There is
danger that this may lead to damage to the
hoses and cause high-pressure oil to spurt out,
leading to fire and serious personal injury or
death.
Fire around the machine due to highly heated
exhaust gas
This machine is equipped with KDPF (Komatsu
Diesel Particulate Filter).
00-23

KDPF is a system for purifying soot in exhaust

gas. The exhaust gas discharged during the
purification process (regeneration) can be higher
temperature than that of existing models. Do not
bring any flammable material close to the outlet
of the exhaust pipe.
If there are thatched houses, dry leaves or
pieces of paper around the job site, set the
system to the "Regeneration Disable" before
starting operation to prevent fire hazard of
highly heated exhaust gas caused by KDPF
regeneration.
See the operation and maintenance manual
for the setting procedure.
Explosion caused by lighting equipment
When checking fuel, oil, battery electrolyte,
or coolant, always use lighting equipment
with anti-explosion specifications.
When taking the electrical power for the
lighting equipment from the machine itself,
follow the instructions in the operation and
maintenance manual.
Dispose of waste materials
(ALL-0000-99A-K-02-A)
To prevent pollution, pay full attention to the way to

dispose of waste materials.
Always put the oil and coolant drained from the
machine in containers. Never drain the oil and
coolant directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
Observe the related laws and regulations when
disposing of harmful objects such as oil, fuel,
coolant, solvent, filters, and batteries.
Some kinds of rubber and plastics may produce

poisonous gas harmful to human body when they
are burned.
As for rubber, plastics, or parts (hoses, cables,
and wiring harnesses, etc.) which contain those
materials, ask the industrial waste treatment
firms for their disposals in accordance with the
local regulations.
00-24
WA470-7

How to read the shop manual
(ALL-0320-010-A-01-A)
(Rev. 2012/01)
Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
Materials and specifications are subject to change without notice.
The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual
This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
This section includes the index, foreword, safety and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure and function
This section explains the structure and function of the machine. The section of "Structure and function"
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
The standard values for a new machine and trouble shooting are described. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual is used
practically.
Symbol
Item
Safety
Caution
Weight
Tightening
torque
WA470-7
Remarks
The special safety precautions required for performing work are
described.
The special technical precautions or other precautions for preserving
standards required when performing work are described
The weight of part or component and the cautions required when
selecting hoisting wire or when working posture is important are
described.
The tightening torques that require special attention during assembly
work are described.
00-25

Symbol
Item
Coat
Oil, coolant
Drain
Remarks
The places to be coated with adhesives, etc. during assembling are
indicated.
The places to which oil is supplied and the quantity of the oil are
indicated.
The places from which oil is drained and quantity of the oil are indicated.
Unit
In this shop manual, the units are indicated with International System of units (SI).
For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.
00-26
WA470-7

Explanation of terms for maintenance standard
(ALL-0330-006-A-01-A)
(Rev. 2012/01)
The chapter of maintenance standard shows judgement criteria to determine the products to be replaced
or to be reused. The judgement criteria are described by using the following terms.
Standard dimension and tolerance
To be accurate, the finished dimension of a part
is slightly different from one to another.
To specify the finished dimension of a part, a
certain dimension is set for the part and an
allowable difference from that dimension is
indicated.
The above dimension set is called the "standard
dimension" and the range of difference from the
standard dimension is called the "tolerance".
The standard dimension and tolerance are
indicated by attaching the symbols of + or - and
a number on the right side of the standard
dimension.
Example:
Standard dimension
Tolerance
-0.022
-0.126
120
The tolerance may be indicated in the text and a

table as "standard dimension (upper limit of
tolerance/lower limit of tolerance)."
Example: 120(-0.022/-0.126)
Usually, the dimension of a hole and the
dimension of a shaft to be inserted into the hole
are indicated by the same standard dimension
and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of dimension of rotating shaft and hole
and their related drawing.
Example:
Standard
dimension
60
Tolerance
Shaft
-0.030
-0.076
Hole
+0.046
0
Standard clearance and standard value

The clearance made when new parts are
assembled is called the standard clearance,
which is indicated by the range from the
minimum clearance to the maximum clearance.
When some parts are repaired, the clearance is
generally adjusted to the standard clearance.
The values indicating performance and function
of new products or equivalent are called the
"standard value", which is indicated by a range
or a target value.
When some parts are repaired, the value of
performance/function is set to the standard
value.
WA470-7
Standard interference
When the diameter of a hole of a part shown in
the given standard dimension and tolerance
table is smaller than that of the shaft to be
inserted, the difference between those
diameters is called the "interference".
Subtract the maximum dimension of the hole
from the minimum dimension of the shaft and
call it (A). Subtract the minimum dimension of
the hole from the maximum dimension of the
shaft and call it (B). The range between (A) and
(B) is the "standard interference".
After repairing or replacing some parts, measure
the dimension of their hole and shaft and check
that the interference is in the standard range.
Repair limit and allowable value or allowable
dimension
The dimensions of parts change because of the
wear or deformation while they are used. When
the dimension changes exceeding certain value,
the parts can not be used any longer. This value
is called "repair limit".
If a part is worn to the repair limit, it must be
replaced or repaired.
00-27

The performance and function of the products

lower while they are used. When the value of the
performance and function lowers exceeding a
certain limit and it influences the operation etc.,
this value is called the allowable value or
allowable dimension.
A product whose dimension is out of the
allowable value, must be repaired. However,
since the allowable values are generally
estimated through various tests or experiences
in most cases, the judgement must be made in
consideration of the operating condition and
customer's requirement.
Allowable clearance
Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.
Allowable interference
The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "allowable
interference".
The allowable interference shows the repair limit
of the part of smaller tolerance.
The parts whose interferences are out of the
allowable interference must be replaced or
repaired.
00-28
WA470-7

Handling equipment of fuel system devices
(PC-AD00-2A4-K-00-A)
(Rev. 2012/01)
The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. If foreign material enters this system, it
may cause a failure. Use special care to prevent
entry of the foreign material when servicing the
fuel system.
Use care for working environment
Avoid filter change or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left as they
are or plugged with cloths as foreign material
may enter or environment may be polluted by
the oil leaked. Do not discard the waste oil
somewhere or other. Hand it over to your
customer for disposal, or dispose it by yourself.
How to clean parts when dirt is stuck
If any dirt or dust sticks the parts of the fuel
system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter
cartridge.
The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. In order to prevent foreign material from
entering this system, the filter employs a
specially high performance of filter element. If a
filter element other than the genuine one is used,
the fuel system may have a failure. Accordingly,
never use such a filter element.
WA470-7
00-29

Handling of intake system parts
(PC220-A900-2A4-K-00-A)
(Rev.2012/01)
The Komatsu Variable Geometry Turbocharger
(KVGT) consists of more precise parts (variable
mechanism) than the parts used in the
conventional turbocharger. If foreign material
enters this system, it may cause a failure. Use
special care to prevent entry of the foreign
material when servicing the air intake system.
Be careful of working environment
Avoid the repair work of the machine in rain or
strong wind or at the places where there is a lot
of dust.
Sealing openings
components which are removed, with the caps,
from entering. Never perform repair works under
the condition that the openings are left open or
plugged with rag since foreign material may
enter.
00-30
WA470-7

Handling of hydraulic equipment
(ALL-C000-2A4-P-01-A)
(Rev. 2012/01)
With the increase in pressure and precision of the hydraulic components, the most common cause of a
failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when
adding hydraulic oil,or when disassembling or assembling the hydraulic components.
Be careful of working environment
Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.
Disassembly and maintenance work in the field
When disassembly or maintenance work of the
hydraulic is performed in the field, there is
danger of dust entering the components. It is
also difficult to check the performance of the
components after repairs, so it is desirable to
use the component exchange service. The
disassembly and assembly of the hydraulic
components must be performed in the specially
arranged dustproof workshop and the
performance test of the components must be
performed with the special testing equipment.
Sealing openings
components which are removed with the caps,
from entering. Never leave the openings of the
pipes and hoses without being covered or
plugged with cloth as foreign material may enter
them or environment may be polluted by the oil
leaked. Do not discard the waste oil somewhere
or other. Hand it over to your customer for
disposal, or dispose it by yourself.
WA470-7
Preventing intrusion of foreign materials during

refilling operations.
Care must be taken when adding hydraulic oil so
that foreign material does not enter. Keep the oil
filler port and the area around it, oil supply pump
and oil container clean. If an oil cleaning device
is used, it is possible to remove the dirt that is
collected during storage. It is a surer means.
Replacing hydraulic oil while its temperature is

high
When the hydraulic oil is warm, it flows easily. In
addition, sludge can also be drained from the
circuit together with the oil. So, it is better to
change the hydraulic oil while it is warm. When
changing the hydraulic oil, the old oil must be
drained as much as possible. (Drain the oil not
only from the hydraulic tank, but also from the
filter housing and the drain plug hole in the
circuit.) If the old oil is left in the system, the
contaminant and sludge in the oil mix with the
new oil and shorten the life of the new hydraulic
oil.
00-31

Flushing operations
After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil circuit.
The oil cleaning equipment can remove the ultra
fine (approximately 3 m) particles that the filter
built in the hydraulic equipment can not remove.
So, it is an extremely effective device.
00-32
WA470-7

Method of disconnecting and connecting of push-pull type coupler
(ALL-
C930-001-P-00-A)
(Rev. 2012/01)
k Loosen
the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the
hydraulic tank.
k Even
if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1
(ALL-C930-925-P-01-A)
Disconnection
1. Hold adapter (1) and push hose joint (2) into
mating adapter (3). (Fig. 1)
a It can be pushed in by approximately 3.5mm.
a Do not hold rubber cap portion (4).
2. While pushing hose joint (2) into adapter (3),
push rubber cap (4) against adapter (3) until
"click" is heard. (Fig. 2)
3. Hold hose adapter (1) or hose (5) and pull it out.
(Fig. 3)
a Since some hydraulic oil flows out, prepare
an oil container.
WA470-7
Connection
1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3) aligning them with each other.
(Fig. 4)
a Do not hold rubber cap part (4).
2. After inserting the hose fitting in the adapter on
the other side perfectly, pull it back to check the
connecting condition. (Fig. 4)
a When the hose fitting is pulled back, the
rubber cap will move toward the hose,
however, it is not a problem.
00-33

Type 2
(ALL-C930-925-P-02-A)
Disconnection
1. While holding the fitting, push body (7) in straight
until sliding prevention ring (6) hits contact
surface (a) at the hexagonal part on the male
side. (Fig. 6)
2. While keeping the condition of Step 1, turn lever
(8) to the right (clockwise). (Fig. 7)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (7) to disconnect it. (Fig. 8)
00-34
Connection
surface (a) at the hexagonal part on the male
side to connect it. (Fig. 9)
WA470-7

Type 3
(ALL-C930-925-P-03-A)
Disconnection
surface (b) at the hexagonal portion on the male
side. (Fig. 10)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface (b)
of the hexagonal portion on the male side. (Fig.
11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig. 12)
WA470-7
Connection
surface (a) at the hexagonal portion on the male
side to connect them. (Fig. 13)
00-35

Handling of electrical equipment
(ALL-E000-2A4-P-01-A)
(Rev. 2012/01)
To maintain the performance of the machine over a long period, and to prevent failures or troubles before
they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics components
and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in
"Handling of electrical equipment".
Precautions for handling electric equipment
Handling wiring harnesses and connectors
Wiring harnesses consist of wires 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 wires.
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 the wiring harnesses.
Main failures occurring in wiring harness

Defective contact of connectors (defective
contact between male and female connectors)
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 connectors are
deformed or the position is not correctly aligned,
or because there is corrosion or oxidization of
the contact surfaces. The corroded or oxidized
contact surfaces may become shiny again (and
contact may become normal) by connecting and
disconnecting the connectors approximately ten
times.
00-36
Defective crimping or soldering of connectors

The pins of the male and female connectors are
attached to wires by crimping or soldering. If
excessive force is applied to the wire, the joining
area may become loose, which may result in a
defective connection or breakage.
Disconnections in wiring
If the wiring harness is pulled to disconnect the
connector, or the components are lifted with a
crane while the wiring harness is still connected,
or a heavy object hits the wiring harness, the
crimping of the connector may separate, or the
soldering may be damaged, or the wiring
harness may be broken.
WA470-7

blow it with compressed air and spray it with

electrical contact restorer.
a When wiping the joint portion of the
connector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed air, it
causes the contacts to become dirtier. So,
remove the oil and water from the
compressed air completely before cleaning
the connector with the compressed air.
High-pressure water entering connector

The connector is designed to make it difficult for
water to enter (drip-proof structure), but if highpressure water is sprayed directly on the
connector, water may enter the connector,
depending on the direction of the water jet.
Accordingly, take care not to spray water over
the connector.
The connector is designed to prevent water from
entering, but once water does enter, it is difficult
to drain it. If water should get into the connector,
the pins will be short-circuited by the water. So if
any water gets in, immediately dry the connector
or take other appropriate action before passing
electricity through it.
Removing, installing, and drying connectors

and wiring harnesses
Disconnecting connectors
1. Hold the connectors when disconnecting.
Disconnect connectors by holding the
connector bodies. For the connectors held by
a screw, loosen the screw fully, then hold the
male and female connectors with each hand
respectively and pull them apart horizontally.
For the connectors with lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull the connector with one hand.
Entry of water, mud or dirt when disconnecting a

connector
If any water, mud or dirt is stuck to the outside
surface of a connector, it can enter inside the
connector when the connector is disconnected.
Before disconnecting the connector, wipe off any
stuck water or dirt by using a piece of dry cloth
or blow it with compressed air.
Oil, mud or dirt stuck to connector
If any oil or grease is stuck to the connector and
an oil film is formed on the mating surface of the
male and female pins, the oil prevents electricity
from passing through, resulting in defective
contact. If any oil or grease, mud or dirt is stuck
to the connector, wipe it off with a dry cloth or
WA470-7
2. When removing from clips

Both of the connector and clip have stoppers,
which are engaged with each other when the
connector is connected.
00-37

Check that there is no oil, dirt or water stick

to the connector pins (joint portion).
Check that the connector pins are free from
deformation, defective contact, corrosion, or
damage.
Check that external surfaces of the
connectors are free from damage or
breakage.
When removing a connector from a clip, pull

the connector in a parallel direction to the clip
for removing stoppers.
a If the connector is pried up and down or
to the right and left, the housing may
break.
a If any oil, water or dirt is stuck to the

connector, wipe it off with a dry cloth. If any
water is inside the connector, warm the
connector and the inside of the wiring
harness with a dryer. But be careful not to
make it too hot as it causes short circuit.
a If there is any damage or breakage, replace
the connector.
2. Fix the connector securely.
Align the connectors correctly, and fit them
securely. For the connectors with the lock
stopper, push in the connectors until "click" is
heard.
3. Action to take after removing connectors

After removing the connector, cover it with
the vinyl bag to prevent entry of dust, dirt,oil
or water in the contact portion.
a If the machine is left disassembled for a
long time, it is particularly easy for
improper contact to occur, so always
cover the connector.
3. Correct the protrusion of the boot and

misalignment of the wiring harness
For connectors fitted with the boot, correct
any extrusion of the boot. In addition, if the
wiring harness or the clamp is out of the
position, put it in its original position.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
Connecting connectors
1. Check the connector visually.
00-38
WA470-7

If the connector clamp is removed, be sure to

return it to its original position. And check
that it is securely installed.
If there is any oil or dirt on the wiring harness,

wipe it off with a dry cloth. Avoid washing by
using steam. If the wire harness must be
washed in water, do not apply high pressure
water or steam directly to the wiring harness. If
water gets directly on the connector, do as
follows.
1. Disconnect the connector and wipe off the water
with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is a risk that oil in the
air may cause defective contact of the
conditioner, remove oil and water in the air
before starting air blow.
Deutsch connector (DT8-pin, DT12-pin)

Disconnection
1. While pressing locks (a) and (b) from each side
respectively, pull out female connector (2).
2. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to
dry the connector.
Connection
1. Push in female connector (2) horizontally until
the lock clicks. (Arrow: x)
2. Since locks (a) and (b) may not be set
completely, push in female connector (2) with
curving movement until the locks are set
normally. (Arrow: x, y, and z)
a Hot air from the dryer can be used, but

regulate the time to use hot air in order to
prevent the connector or related parts from
becoming too hot, as it causes deformation
or damage to the connector.
a Lock (a) in the figure is pulled down (not set

completely), and lock (b) is set completely.
3. Perform a continuity test on the connector.

After drying, leave the wiring harness
disconnected and perform a continuity test to
check for any short circuits between pins caused
by water.
a After the connector is completely dried, blow
the contact restorer and reassemble them.
Drying wiring harness
WA470-7
00-39

Handling of connectors used on engine
2. While pressing lock (L2), pull out connector (1).
Slide, lock type (Type 1) (FRAMATOME-3,

FRAMATOME-2)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a In the case that even if lock (L2) is pressed,
connector (1) cannot be pulled out toward
you unless part A floats, float part A with a
small flat-head screwdriver while pressing
lock (L2), and then pull out connector (1)
toward you.
a Lock (L2) is located in the back of connector
(1).
Connection
1. Insert the connector securely until a click is
heard.
Slide, lock type (Type 2) (FRAMATOME-24)
Disconnection
1. Slide down lock (red) (L1).
00-40
Connection
heard.
Pull lock type (PACKARD-2)
Disconnection
1. Disconnect the connector (2) by pulling lock (B)
(on the wiring harness side) of connector (2)
outward.
WA470-7

Connection
heard.
Connection
heard.
Push lock type (1) (BOSCH-3)

Disconnection
Push lock type (2) (SUMITOMO-4)

Disconnection
1. While pressing lock (C), pull out connector (3) in

the direction of the arrow.
114 series
1. While pressing lock (C), pull out connector (4) in

Connection
heard.
107 series
Push lock type (3) (AMP-3)
Disconnection
1. While pressing lock (E), pull out connector (5) in
Example) Fuel pressure sensor in common rail:
PFUEL etc (AMP-3)
a If the lock is located on the underside, use

flat-head screwdriver [1] since you cannot
insert your fingers.
While pushing up lock (C) of the connector
with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
WA470-7
00-41

Example) Injection pressure control valve of

supply pump: PCV (SUMITOMO-2)
Example) Speed sensor of supply pump: G

(SUMITOMO-3)
a Pull the connector straight up.
Connection
heard.
Turn-housing type (Round green connector)
(CANNON-4)
Disconnection
Connection
1. Insert the connector to the end while aligning its
grove to the other.
2. Turn housing (H1) in the direction of the arrow
until it "clicks".
Handling controller
The electronic circuits for control including the
microcomputers are assembled in the controller.
These electronic circuits in the controller must
be handled with care as they control the
machine.
Do not place objects on top of the controller.
1. Turn housing (H1) in the direction of the arrow.

a Unlock the connector by turning housing (H1).
When the lock is release the housing is felt
tight to turn.
2. Pull out housing (H1) in the direction of the
arrow.
a Housing (H1) is left on the wiring harness
side.
Cover the control connectors with tape or a vinyl

bag. Never touch the connector contacts.
During rainy weather, do not leave the controller
in a place where it is exposed to rain.
Do not place the controller on oil, water, or soil,
or in a place that can be heated to a high
00-42
WA470-7

temperature even for a short period of time.

(Place it on a suitable dry stand.)
Precautions when performing arc welding

When performing arc welding on the machine
body, disconnect all the wiring harness
connectors connected to the controller. Put the
arc welding ground to the place close to the
welding point.
Precautions for troubleshooting electrical
circuits
Be sure to turn the starting switch to the "OFF"
position before disconnecting or connecting the
connectors.
Before performing troubleshooting, check all the
related connectors for loose connection.
a Check the related connectors for their
performance by disconnecting and
connecting them several times.
Be sure to connect all the disconnected
connectors before proceeding to the next step.
a If the starting switch is turned to the "ON"
position with the connectors disconnected,
the failure which is not related to the part
which is actually failed.
When performing the troubleshooting for the
circuit (measurement of voltage, resistance,
continuity, current, etc.), shake the related wiring
harnesses and connectors several times and
check that the multimeter reading does not
change.
a If there is any value change on the
multimeter, there may be a defective contact
in the circuit.
WA470-7
00-43

How to read electric wire code
(ALL-E500-030-P-00-A)
(Rev. 2012/01)
In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by
symbols. The wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not
indicated on the diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.
Type, symbol, and material
AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular
compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of
the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV
and AVS in material of the coating.
(Table 1)
Type
Symbol
Low-voltage
wire for
AV
automobile
Thin-cover
low-voltage
wire for
AVS
automobile
(Type 1)
Thin-cover
low-voltage
wire for
CAVS
automobile
Type 2
Heatresistant lowvoltage wire AEX
for
automobile
00-44
Conductor
material
Insulator material
Temperature
range (C) in
use
Example of use
For large current wiring
(nominal No. 5 and above)
Soft polyvinyl chloride
-30 to +60
Annealed
copper for
electric
appliance
General wiring
(nominal No. 3 and lower)
For mid- to small-size

excavators
(nominal No. 1.25 and lower)
Heat-resistant cross
linked polyethylene
-50 to +110
(Safety factor:
Wiring at high-temperature
place
WA470-7

Dimension
(Table 2)
Coating D
(0.5) 0.75f (0.85) 1.25f (1.25)

Nominal No.
0.5f
Number of
strands/
20/
30/
11/
50/
16/
7/0.32
Diameter of 0.18
0.18 0.32 0.18 0.32
strand
Conductor
Crosssectional
0.51 0.56 0.76 0.88 1.27 1.29
area (mm2)
d (approx.)
1.0
1.2
1.5
AVS Standard
2.0
2.2
2.5
AV
Standard
AEX
Standard
2.0
2.2
2.7
2f
3f
37/
0.26
26/
0.32
58/
0.26
41/
0.32
65/
0.32
1.96
2.09
3.08
3.30
5.23
1.9
2.9
1.9
2.9
2.3
3.5
2.4
3.6
3.0
4.6
3.0
3.1
3.8
4.6
Coating D
Nominal No.
8
15
20
30
40
Number of
strands/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of
strand
Conductor
Crosssectional
7.95
13.36
20.61
35.19
42.73
area (mm2)
d (approx.)
3.7
4.8
6.0
8.0
8.6
AVS Standard
AV
Standard
5.5
7.0
8.2
10.8
11.4
AEX
Standard
Coating D
Nominal No.
Number of
strands/
Diameter of
strand
Conductor
Crosssectional
area (mm2)
d (approx.)
CAVS
Standard
5.3
7.0
8.2
10.8
50
60
85
100
108/
0.80
127/
0.80
169/
0.80
217/
0.80
54.29
63.84
84.96
109.1
9.8
13.0
10.4
13.6
12.0
16.0
13.6
17.6
13.0
13.6
16.0
17.6
11.4
0.5f
0.5
0.75f
0.85
1.25f
1.25
7/round
compression
11/round
compression
16/round
compression
0.56
0.88
1.29
0.9
1.1
1.4
1.6
1.8
2.1
a "f" of nominal No. denotes "flexible".
WA470-7
00-45

Color codes table

(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow & Green
Yellow & Blue
Yellow & Red
Yellow & White
a Remarks: In a color code consisting of two colors, the first color is the color of the background and the
second color is the color of the marking.
Examples)
GW means that the background is "Green" and marking is "White".
Types of circuits and color codes
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Appendix
00-46
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
WG
RB
YR
GW
LW
BrW
LgR
AVS, AV, CAVS
RY
RG
YB
YG
GR
GY
LR
LY
BrR
BrY
LgY
LgB
AEX
RL
YL
GB
LB
BrB
LgW
YW
GL
R
B
R
D
Y
G
L
Gr
Br
WA470-7

Precautions when performing operation
(ALL-1160-927-A-00-A)
(Rev. 2012/01)
When performing "removal or installation" and "disassembly or assembly" of the components, observe the
following general cautions.
Precautions for removal work
If the coolant contains antifreeze, dispose of it correctly as chemicals. Do not drain the coolant to the
sewage rashly.
After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
When draining oil, prepare a container with sufficient capacity.
Check the match marks which indicate the installing position, and put match marks on the places where
they seem necessary before removal of the components 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.
Attach the tags to wires and hoses to show their installing positions to prevent any mistake when
installing.
Check the number and thickness of the shims, and keep them in a safe place.
When hoisting the components, prepare the slings with sufficient strength.
When using forcing screws to remove any component, tighten the forcing screws uniformly and
alternately.
Before removing any component, clean the surrounding area and cover the component to prevent any
foreign material from entering after removal.
a Precautions when handling piping during disassembly
Use the plugs indicated below for the pipes disconnected at the disassembly.
Face seal type hoses and tubes
Nominal No.
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
Split flange type hoses and tubes

Nominal No.
04
05
WA470-7
Flange (hose end)

07379-00400
07379-00500
Sleeve head (tube end)

07378-10400
07378-10500
Split flange
07371-30400
07371-30500
00-47

If the part is not under hydraulic pressure, the following corks can be used.
Nominal No.
Part No.
06
08
10
12
14
16
18
20
22
24
27
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
07049-02734
D
6
8
10
12
14
16
18
20
22
24
27
Dimensions
d
5
6.5
8.5
10
11.5
13.5
15
17
18.5
20
22.5
L
8
11
12
15
18
20
22
25
28
30
34
Precautions for installation work

Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES).
Install the hoses without twist and interference, and securely fasten the clamps located in-between if they
are.
Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When applying adhesive, clean and degrease the part, and apply two to three drops of adhesive to the
threaded portion.
When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dirt or damage.
Clean all of the parts, and correct any damage, dents, burrs, or rust found on them.
Coat the rotating parts and sliding parts with engine oil.
Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
After installing the snap ring, check that the snap ring is settled in the ring groove completely.
When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then
connect them securely.
Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on
one side.
a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as
the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding
of the hydraulic circuit according to the following procedure.
1. Start and run the engine at low idle.
2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100
mm before the stroke end four to five times.
3. Operate the hydraulic cylinder three to four times to the end of its stroke.
00-48
WA470-7

a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.
WA470-7
00-49

Precautions at the time of completing work

Refilling of coolant, oil and grease
When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the
coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping,
and add the coolant to the specified level again.
When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu
recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the
specified level again.
If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after
rebuilding the parts, by referring to "Testing and adjusting".
Supply the specified amount of grease to the work equipment parts.
Check of installed condition of cylinder heads and manifolds
Check the cylinder head and intake and exhaust manifold mountings for looseness.
If any bolt is loose, retighten it.
a For the tightening torques, see the "Disassembly and assembly".
Check of engine piping for damage and looseness
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Intake and exhaust for air suction and exhaust gas leakage.
system
If any part is loosely installed or damaged, retighten the bolts or repair the part.
for water leakage.
Cooling system
If any part is loosely installed or damaged, retighten the bolts or repair the part.
for fuel leakage.
Fuel system
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check of KDPF or muffler and exhaust pipe for damage and looseness
Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any
part is damaged, replace it.
Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts
for looseness.
If any part is loosely installed, retighten the bolts.
Check of KDPF or muffler function
Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.
If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
00-50
WA470-7

Practical use of KOMTRAX
(ALL-Q210-13V-K-00-A)
(Rev. 2012/01)
KOMTRAX system transmits various machine information by use of the radio communication and KOMTRAX
operator can refer this information in the office and provide various services to the customers.
When KOMTRAX is installed on the machine, the machine information can be checked through the
KOMTRAX system and the testing and troubleshooting can be performed efficiently.
(KOMTRAX may not be installed on the machine in some countries or areas.)
Merit of using KOMTRAX
The working place of the machine can be checked in the map on PC.
Operation information such as service meter reading, operating hours, fuel consumption, occurred caution
and failure code can be checked.
The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic oil
filter, hydraulic oil and engine oil can be checked.
The information of machine working condition (idling time, traveling time, digging time, relieving time, etc.)
can be checked and the machine operating condition can be presumed with these information.
Various reports such as "Fuel saving operation support", "Summary of operation", etc. can be generated
and utilized as an advice tool for the user and operator.
How to use KOMTRAX practically
With KOMTRAX, following support activities will be available.
1. Quick response to sudden request of repair
1) When receiving a repair request from a user, check the displayed caution and failure code, etc. through
KOMTRAX.
2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed
failure code.
3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there.
2. Proactive maintenance
1) Check the service summary screen of KOMTRAX, and find the machine which has high priority failure
code indicated by a red or yellow flag.
2) Check the condition of the machine with the customer and make a plan to visit.
3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure
code.
3. Practice of periodic maintenance and periodic inspection service
1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for
the consumable parts indicated by red flags are over.
2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the
replacement work to the customer.
3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading.
How to operate KOMTRAX
For the operating method of each screen of KOMTRAX, see "KOMTRAX basic operation manual".
WA470-7
00-51

Standard tightening torque table
(ALL-M140-03B-P-01-A)
(Rev. 2012/01)
Table of tightening torque for bolts and nuts
Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.
1. The following table applies to the bolts in Fig. A.
Thread
diameter
(mm)
6
8
10
12
14
16
18
Width
across flats
(mm)
10 (10)
13 (12)
17 (14)
19 (17)
22
24
27
(Nm)
11.8 to 14.7
27 to 34
59 to 74
98 to 123
157 to 196
245 to 309
343 to 427
(kgm)
1.2 to 1.5
2.8 to 3.5
6.0 to 7.5
10.0 to 12.5
16 to 20
25 to 31.5
35 to 43.5
20
30
490 to 608
50 to 62
22
24
27
30
33
36
39
32
36
41
46
50
55
60
662 to 829
824 to 1,030
1,180 to 1,470
1,520 to 1,910
1,960 to 2,450
2,450 to 3,040
2,890 to 3,630
67.5 to 84.5
84 to 105
120 to 150
155 to 195
200 to 250
250 to 310
295 to 370
Tightening torque
a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.
2. The following table applies to the bolts in Fig. B.
Thread
diameter
(mm)
6
8
10
12
Fig. A
Width
across flats
(mm)
10
12
14
17
Tightening torque
(Nm)
5.9 to 9.8
13.7 to 23.5
34.3 to 46.1
74.5 to 90.2
(kgm)
0.6 to 1.0
1.4 to 2.4
3.5 to 4.7
7.6 to 9.2
Fig. B
a Values with parentheses are applied to the width across flats of (*) marked bolts (flanged bolts)
00-52
WA470-7

Table of tightening torque for split flanged bolts

a Unless otherwise specified, tighten the split flange bolt to the torque shown in the table below.
Thread
diameter
(mm)
10
12
16
Width
across flats
(mm)
14
17
22
Tightening torque
(Nm)
59 to 74
98 to 123
245 to 309
(kgm)
6.0 to 7.5
10.0 to 12.5
25 to 31.5
Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.
Nominal No.
02
03, 04
05, 06
10, 12
14
Thread
diameter
(mm)
14
18
20
24
33
42
Width
across flats
mm
Varies
depending
on type of
connector.
Tightening torque (Nm {kgm})

Range
35 to 63 {3.5 to 6.5}
59 to 98 {6.0 to 10.0}
84 to 132 {8.5 to 13.5}
128 to 186 {13.0 to 19.0}
363 to 480 {37.0 to 49.0}
746 to 1,010 {76.0 to 103}
Target
44 {4.5}
78 {8.0}
103 {10.5}
157 {16.0}
422 {43.0}
883 {90.0}
Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.
Nominal No.
08
10
12
14
16
18
20
24
30
33
36
42
52
WA470-7
Thread
diameter
(mm)
8
10
12
14
16
18
20
24
30
33
36
42
52
Width
across flats
mm
14
17
19
22
24
27
30
32
32
36

Range
5.88 to 8.82 {0.6 to 0.9}
9.8 to 12.74 {1.0 to 1.3}
14.7 to 19.6 {1.5 to 2.0}
19.6 to 24.5 {2.0 to 2.5}
24.5 to 34.3 {2.5 to 3.5}
34.3 to 44.1 {3.5 to 4.5}
44.1 to 53.9 {4.5 to 5.5}
58.8 to 78.4 {6.0 to 8.0}
93.1 to 122.5 {9.5 to 12.5}
107.8 to 147.0 {11.0 to 15.0}
127.4 to 176.4 {13.0 to 18.0}
181.3 to 240.1 {18.5 to 24.5}
274.4 to 367.5 {28.0 to 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}
127.4 {13.0}
151.9 {15.5}
210.7 {21.5}
323.4 {33.0}
00-53

Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a The table is applied to the threads coated with engine oil (wet threads)
Nominal
No. of
hose
Width
across
flats
(mm)
02
19
03
04
05
06
(10)
(12)
(14)
22
24
27
32
36
41
46
55
Taper seal
Range
Target
34 to 54 {3.5 to 5.5}
34 to 63 {3.5 to 6.5}
54 to 93 {5.5 to 9.5}
59 to 98 {6.0 to 10.0}
84 to 132 {8.5 to 13.5}
128 to 186 {13.0 to 19.0}
177 to 245 {18.0 to 25.0}
177 to 245 {18.0 to 25.0}
197 to 294 {20.0 to 30.0}
246 to 343 {25.0 to 35.0}
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}
Face seal
Nominal No. - Thread root
Thread size threads per
diameter
inch, type of (reference)
(mm)
thread
9/16 -18UN
14.3
14
11/16 -16UN
17.5
18
22
13/16 -16UN
20.6
24
1 -14UNS
25.4
30
1-3/16 -12UN
30.2
33
36
42
Table of tightening torque for face seal joints

a The tightening torque table below applies to the seal joint (sleeve nut type)
a The table is applied to the threads coated with engine oil (wet threads).
Outer
Width
diameter of
across flats
pipe
(mm)
(mm)
8
10
12
15 {16}
22 {20}
19
22
24 {27}
30 {32}
36

Range
Target
14 to 16 {1.4 to 1.6}
24 to 27 {2.4 to 2.7}
43 to 47 {4.4 to 4.8}
60 to 68 {6.1 to 6.8}
90 to 95 {9.2 to 9.7}
15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}
Face seal
Thread root
Nominal No. diameter
threads per inch,
type of thread
(Reference)
9/16 -18UN
11/16 -16UN
13/16 -16UN
1 -14UNS
1-3/16 -12UN
14.3
17.5
20.6
25.4
30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.
00-54
WA470-7

Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Thread diameter
(mm)
6
8
10
12
14
Tightening torque
(Nm)
10 2
24 4
43 6
77 12
(kgm)
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
Tightening torque table for I-joints on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric I-joints used on the 102, 107 and 114 series engines to the
torque shown in the following table.
Thread diameter
(mm)
6
8
10
12
14
Tightening torque
(Nm)
82
10 2
12 2
24 4
36 5
(kgm)
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
Tightening torque table for tapered screws on 102,107 and 114 series engines
a Unless otherwise specified, tighten the tapered inch thread screws used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Material
Thread diameter (inch)
1/16
1/8
1/4
3/8
1/2
3/4
WA470-7
In cast iron or steel

Tightening torque
(Nm)
(kgm)
15 2
1.53 0.20
20 2
2.04 0.20
25 3
2.55 0.31
35 4
3.57 0.41
55 6
5.61 0.61
75 8
7.65 0.82
In aluminum
Tightening torque
(Nm)
(kgm)
51
0.51 0.10
15 2
1.53 0.20
20 2
2.04 0.20
25 3
2.55 0.31
35 4
3.57 0.41
45 5
4.59 0.51
00-55

List of abbreviation
(ALL-0360-005-A-00-A)
(Rev. 2012/09)
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts,
components, and functions whose meaning is not immediately clear. The spelling is given in full with an
outline of the meaning.
Abbreviations that are used in general society may not be included.
Special abbreviations which appear infrequently are noted in the text(marked witha).
This list of abbreviations consists of 2 parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the shop manual
Abbreviation
Actual word spelled

out
Purpose of use (major

applicable machine (*), or
equipment/device)
Explanation
ABS
Anti-skid Brake
System
Travel and brake

(HD, HM)
Function with which when the tires skid

(wheels stop rotating), the brakes are
released, and when the wheels start to rotate,
the brakes are applied again.
AISS
Automatic Idling
Setting System
Engine
Automatic setting function of at idle speed
AJSS
ARAC
ARSC
ASR
ATT
BCV
CAN
CDR
CLSS
CRI
ECM
00-56
Function that a lever can perform the steering

operations, shifting gear speed operation and
changing direction operation instead of a
steering wheel.
Function that the retarder works automatically
Travel and brake
with a certain braking force when the
Automatic Retarder
accelerator pedal is released while the
Accelerator Control
(HD, HM)
machine travels downhill.
Function that the retarder works automatically
with a certain braking force so that the
Travel and brake
Automatic Retarder
machine travels with the speed not exceeding
Speed Control
the speed set by the operator when the
(HD, HM)
accelerator pedal is released while the
machine travels downhill.
Function with which, when the rear wheels
Travel and brake
Automatic Spin
spin on soft ground surfaces, this function
Regulator
automatically uses the optimum braking force
(HD, HM)
to drive both wheels.
A device that can be fixed onto a machine in
Work equipment
Attachment
order to enable it to do different jobs.
Valve that bypasses part of the brake cooling
Brake
Brake cooling oil
oil to reduce the load on the hydraulic pump
control valve
(HD)
when the retarder is not being used.
Controller Area
Communication and
One of communication standards that is used
Network
electronic control
in the network on the machine
Regulator
valve that is installed to the KCCV
Crankcase Depression
Engine
ventilator
It
is not used independently and
Regulator
described CDR valve.
System that can simultaneously actuate
Closed-center Load
multiple actuators regardless of the load
Oil pressure
Sensing System
(provides better combined operation
comparing to OLSS).
Function to maintain optimum fuel injection
amount and fuel injection timing by using
Common Rail Injection Engine
engine controller to perform electronic control
of supply pump, common rail, and injector.
Electronic control device that uses the signals
from the sensors on the machine to indicate
Electronic Control
Electronic control system
the optimum actuation to the actuators .
Module
(Same as ECU)
Advanced Joystick
Steering System
Steering
(WA)
WA470-7

Abbreviation
ECMV
ECSS
ECU
EGR
EMMS
EPC
FOPS
F-N-R
GPS
HSS
Actual word spelled

out

equipment/device)
Proportional electromagnetic valve that

gradually increases oil pressure to engage
clutch and reduces transmission shock.
System that ensures smooth high-speed
Electronically
Travel
travel by using hydraulic spring effect of
Controlled Suspension
accumulator to absorb vibration of machine
(WA)
System
during travel
Electronic control device that uses the signals
from the sensors on the machine to indicate
Electronic Control Unit Electronic control system the optimum actuation to the actuators .
(Same as ECM)
Function to recirculate part of exhaust gas to
Exhaust Gas
combustion chamber in order to reduce
Engine
Recirculation
combustion temperature and to control
emission of NOx.
System
that allows data (filter, oil replacement
Equipment
interval,
malfunctions on machine, failure
Management
Machine monitor
code,
and
failure history) from each sensor on
Monitoring System
the machine to be checked on monitor.
Electromagnetic proportional control
Electromagnetic
Oil pressure
Mechanism that actuator works in proportion
Proportional Control
to current
Structure that protects operator's head from
Falling Object
falling objects. (Structure to protect operator)
Cab and canopy
Protective Structure
Performance standardized in ISO 3449
Forward-NeutralOperation
Forward - NEUTRAL - REVERSE
Reverse
Communication
Global Positioning System Satellite
Global Positioning
positioning system that is used to determine
(KOMTRAX
KOMTRAX
System
the current location on the earth
Plus)
Steering function that uses a combination of
hydraulic motor and bevel shaft to control
Steering
Hydrostatic Steering
difference in travel speed of right and left
System
(D)
tracks to turn machine without using steering
Electronic Control
Modulation Valve
Transmission
(D, HD, WA, etc.)
Transmission
(D, WA)
HST
Hydro Static
Transmission
IMA
Inlet Metering Actuator Engine
IMV
Inlet Metering Valve
Engine
KCCV
Komatsu Closed
Engine
Crankcase Ventilation
KCSF
Komatsu Catalyzed
Soot Filter
Engine
KDOC
Komatsu Diesel
Oxidation Catalyst
Engine
KDPF
Komatsu Diesel
Particulate Filter
Engine
WA470-7
Explanation
clutch.
Hydraulic transmission system that uses a
combination of hydraulic pump and hydraulic
motor to shift gear steplessly without using
gears.
Valve that adjusts fuel intake amount at inlet
port of pump in order to control fuel discharge
amount of supply pump. Same meaning as
IMV
Valve adjusting fuel intake amount at inlet port
of pump in order to control fuel discharge
amount of supply pump. Described IMV (IMA)
This mechanism separates oil in blowby gas
and returns it to the intake side to afterburn it
there. It primarily consists of filters.
This filter is used to capture soot in exhaust
gas.
It is built in to KDPF.
The catalyst used for purifying exhaust gas.
This is built in KDPF or assembled with the
muffler.
This component with built-in KDOC (catalyst)
and KCSF (soot-capturing filter)
purifies exhaust gas.
00-57

Abbreviation
Actual word spelled

out

equipment/device)
KTCS
Komatsu Traction
Control System
Travel and brake

(HM system)
KVGT
Komatsu Variable
Geometry
Turbocharger
Engine
LCD
Liquid Crystal Display
Machine monitor
LED
Light Emitting Diode
Electronic parts
LIN
Local Interconnect
Network
Communication and
electronic control
LS
Load Sensing
Oil pressure
LVDS
Low Voltage
Differential Signaling
Communication and
electronic control
MAF
Mass Air Flow
Engine
MMS
Multimedia Messaging
Communication
Service
NC
Normally Closed
Electric and hydraulic
NO
Normally Open
Electric and hydraulic
Open-center Load
Sensing System
Oil pressure
Pressure
Compensation
Oil pressure
OLSS
PC
PCCS
Palm command control Steering

system
(D)
PCV
Pre-stroke Control
Valve
PPC
Proportional Pressure Oil pressure

Control
PPM
PTO
PTP
00-58
Piston Pump and

Motor
Power Take Off
Power Tilt and power
Pitch dozer
Engine
Oil pressure
(D, PC, etc.)
Power transmission
Work equipment
(D)
Explanation
It is installed in place of the currently used
muffler.
Function that recovers the drive force of the
wheels by braking automatically with the
optimum force and at the same time activates
the inter-axle differential lock when the wheels
idle while the machine travels on the soft
ground road.
The turbocharger on which the cross-section
area of the exhaust passage is made variable.
Liquid Display Image display equipment such
as the monitor which assembles in the liquid
crystal element.
Light Emitting Diode Semi-conductor element
that emits light when the voltage is applied in
the normal direction.
Function that detects differential pressure of
pump and controls discharge amount
according to load.
It means the intake air flow of the engine. It is
not used independently but used together with
the sensor. The mass air flow sensor may be
called MAF sensor.
Service that allows transmission and
reception of short messages consisting of
characters or voice or images between cell
phones.
Device actuated to open electric or hydraulic
circuits that are normally closed if not
actuated.
Device actuated to close electric or hydraulic
circuits that are normally open if not actuated.
Hydraulic system that can operate multiple
actuators at the same time, regardless of the
load.
A function used to correct oil pressure.
System in which a controller instantly
analyses data from each lever, pedal, and
dial, and performs optimum electronic control
of the engine and transmission.
Valve installed at inlet port of pump to adjust
fuel intake amount in order to control fuel
discharge amount of supply pump.
Proportional pressure control Mechanism that
actuator works in proportion to hydraulic
pressure
Piston pump and motor.
Power take-off mechanism
Function that performs hydraulic control of the
tilt and pitch of the bulldozer blade.
WA470-7

Abbreviation
Actual word spelled

out

equipment/device)
Roll-Over Protective
Structure
Cab and canopy
International unit
system
Unit
SOL
Solenoid
Electric
TWV
Two Way Valve
Hydraulic and electric
VFT
Variable Flow
Turbocharger
Engine
ROPS:
SI
Explanation
Structure that protects operator fastening seat
belt from being crushed when machine tips
over (Structure to protect operator when
machine tips over)
Performance standardized in ISO 3471
Abbreviation for "International system of units"
Unit system that is employed worldwide, and
"one unit against one factor"
Actuator that moves a part with a movable iron
core in the coil (solenoid), which is moved by
energizing the coil.
Solenoid valve that switches the direction of
flow.
Turbocharger variable in route of exhaust
passage.
*1: Code for applicable machine family

D: Bulldozer
HD: Dump truck
HM: Articulated dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation
A/C
A/D
A/M
ACC
ADD
AUX
BR
CW
CCW
ECU
ECM
ENG
EXGND
F.G.
GND
IMA
NC
S/T
STRG
SIG
SOL
STD
OPT
OP
PRESS
SPEC
SW
TEMP
WA470-7
Actual word spelled out

Air Conditioner
Analogue-to-Digital
Air Mix Damper
Accessory
Additional
Auxiliary
Battery Relay
Clockwise
Counter Clockwise
Electronic Control Unit
Electronic Control Module
Engine
External Ground
Frame Ground
Ground
Inlet Metering Actuator
No Connection
Steering
Signal
Solenoid
Standard
Option
Pressure
Specification
Switch
Temperature
00-59

Abbreviation
T/C
T/M
00-60
Actual word spelled out

Torque Converter
Transmission
WA470-7

Conversion table
(ALL-2150-931-A-00-A)
(Rev. 2012/01)
Method of using the conversion table
The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 55 mm into inches
1. Locate the number 50 in the vertical column at the left side, take this as (A), and 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 vertical line down from (B).
3. Take the point where the two lines cross as (C). This point (C) gives the value when converting the unit
from millimeters to inches. Therefore, 55 mm = 2.165 in.
Conversion of 550 mm into inches
1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the
left) to get 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
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 get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65
in.
Millimeters to inches
(B)
(A)
WA470-7
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.017
2.441
2.835
3.228
3.622
2.087
2.480
2.847
3.268
3.661
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
1 mm 0.03937 in
7
8
9
0.276 0.315 0.354
0.669 0.709 0.748
1.063 1.102 1.142
1.457 1.496 1.536
1.850 1.890 1.929
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
00-61

Millimeters to inches
0
10
20
30
40
50
60
70
80
90
0
0
0.394
0.787
1.181
1.575
1.969
2.362
2.756
3.150
3.543
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
2.847
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
1 mm 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.323
2.677
2.717
3.071
3.110
3.465
3.504
3.858
3.898
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
1 kg 2.2046 lb
8
9
17.64
19.84
39.68
41.89
61.73
63.93
83.78
85.98
105.82 108.03
127.87 130.07
149.91 152.12
171.96 174.17
194.01 196.21
216.05 218.26
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
1 l 0.2642 U.S.Gal
7
8
9
1.849
2.113
2.378
4.491
4.755
5.019
7.133
7.397
7.661
9.774
10.039 10.303
12.416 12.680 12.944
15.058 15.322 15.586
17.700 17.964 18.228
20.341 20.605 20.870
22.983 23.247 23.511
25.625 25.889 26.153
1
0.039
0.433
0.827
1.220
1.614
2.008
2.402
2.795
3.189
3.583
Kilograms to pounds
0
10
20
30
40
50
60
70
80
90
0
0
22.05
44.09
66.14
88.18
110.23
132.28
154.32
176.37
198.42
l to U.S. Gallons
0
10
20
30
40
50
60
70
80
90
00-62
0
0
2.642
5.283
7.925
10.567
13.209
15.850
18.492
21.134
23.775
WA470-7

l to U.K. Gallons
0
10
20
30
40
50
60
70
80
90
0
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
7.699
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
1 l 0.21997 U.S.Gal
7
8
9
1.540
1.760
1.980
3.740
3.950
4.179
5.939
6.159
6.379
8.139
8.359
8.579
10.339 10.559 10.778
12.528 12.758 12.978
14.738 14.958 15.178
16.938 17.158 17.378
19.137 19.357 19.577
21.337 21.557 21.777
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
kgm to ft.lb
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
WA470-7
0
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 kgm 7.233 ft.lb

8
9
57.9
65.1
130.2
137.4
202.5
209.8
274.9
282.1
347.2
354.4
419.5
426.8
491.8
499.1
564.2
571.4
636.5
643.7
708.8
716.1
781.2
788.4
853.5
860.7
925.8
933.1
998.2
1005.4
1070.5 1077.7
1142.8 1150.0
1215.1 1222.4
1287.5 1294.7
1359.8 1367.0
1432.1 1439.4
00-63

kg/cm2 to lb/in2
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
00-64
0
0
142.2
284.5
426.7
568.9
711.2
853.4
995.6
1,138
1,280
1,422
1,565
1,707
1,849
1,991
2,134
2,276
2,418
2,560
2,702
2,845
2,987
3,129
3,271
3,414
1
14.2
156.5
298.7
440.9
583.2
725.4
867.6
1,010
1,152
1,294
1,437
1,579
1,721
1,863
2,005
2,148
2,290
2,432
2,574
2,717
2,859
3,001
3,143
3,286
3,428
2
28.4
170.7
312.9
455.1
597.4
739.6
881.8
1,024
1,166
1,309
1,451
1,593
1,735
1,877
2,020
2,162
2,304
2,446
2,589
2,731
2,873
3,015
3,158
3,300
3,442
3
42.7
184.9
327.1
469.4
611.6
753.8
896.1
1,038
1,181
1,323
1,465
1,607
1,749
1,892
2,034
2,176
2,318
2,460
2,603
2,745
2,887
3,030
3,172
3,314
3,456
4
56.9
199.1
341.4
483.6
625.8
768.1
910.3
1,053
1,195
1,337
1,479
1,621
1,764
1,906
2,048
2,190
2,333
2,475
2,617
2,759
2,901
3,044
3,186
3,328
3,470
5
71.1
213.4
355.6
497.8
640.1
782.3
924.5
1,067
1,209
1,351
1,493
1,636
1,778
1,920
2,062
2,205
2,347
2,489
2,631
2,773
2,916
3,058
3,200
3,343
3,485
6
85.3
227.6
369.8
512.0
654.3
796.5
938.7
1,081
1,223
1,365
1,508
1,650
1,792
1,934
2,077
2,219
2,361
2,503
2,646
2,788
2,930
3,072
3,214
3,357
3,499
1 kg/cm2 14.2233 lb/in2

7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9
810.7
825.0
839.2
953.0
967.2
981.4
1,095
1,109
1,124
1,237
1,252
1,266
1,380
1,394
1,408
1,522
1,536
1,550
1,664
1,678
1,693
1,806
1,821
1,835
1,949
1,963
1,977
2,091
2,105
2,119
2,233
2,247
2,262
2,375
2,389
2,404
2,518
2,532
2,546
2,660
2,674
2,688
2,802
2,816
2,830
2,944
2,958
2,973
3,086
3,101
3,115
3,229
3,243
3,257
3,371
3,385
3,399
3,513
3,527
3,542
WA470-7

Temperature
Conversion of Fahrenheit to Celsius
A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice
versa is to see the number in the center column of the following table. The figures on the following table
show the temperatures in both Fahrenheit and Celsius.
When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
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
WA470-7
-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
60
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
1C 33.8F
F
81
177.8
82
179.6
83
181.4
84
183.2
85
185.0
86
186.8
87
188.6
88
190.4
89
192.2
90
194.0
91
195.8
92
197.6
93
199.4
94
201.2
95
203.0
96
204.8
97
206.6
98
208.4
99
210.2
100
212.0
105
221.0
110
230.0
115
239.0
120
248.0
125
257.0
130
266.0
135
275.0
140
284.0
145
293.0
150
302.0
155
311.0
160
320.0
165
329.0
170
338.0
175
347.0
00-65

00-66
WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model
Serial Number
WA470-7
10001 and up
01 Specification
2 01 Specification
WA470-7
01-1
01 Specification
Table of contents
Table of contents
(ALL-0310-002-A-00-A)
01 Specification................................................................................................................................. 01-1
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Specifications ...................................................................................................................... 01-5
Weight table ...................................................................................................................... 01-11
Table of fuel, coolant, and lubricants .................................................................................... 01-13
01-2
WA470-7
01 Specification
Specification drawing
Specifications
(ALL-2111-001-A-00-A)
(WA470_7-2110-931-A-00-A)
Item
A
B
C
D
E
F
G
H
I
Machine weight (with BOC)

Operating load
Bucket capacity (heaped, with BOC)
Engine model
Rated horsepower
SAE J1995 [Gross] (*1)
ISO 14396
ISO 9249/ SAE J1349 [Net] (*2)
Overall length (with BOC, additional weight)
Overall height
Overall height with bucket at max. height
Overall width
Min. ground clearance
Bucket width
Dumping clearance (*3) Bucket tip / BOC tip
Dumping reach (*3)
Bucket tip / BOC tip
Dumping angle
Bucket tip / BOC tip
Min. turning radius
Center of outside tire
Allowable towing load
1st (forward/reverse)
2nd (forward/reverse)
locked up travel speed
(P mode)
3rd (forward/reverse)
4th (forward/reverse)
Unit
kg
kg
m3
WA470-7
(in P mode)
23,510
6,720
4.2
Komatsu SAA6D125E-6 diesel engine
kW {HP} /
min-1 {rpm}
mm
mm
mm
mm
mm
mm
mm
mm
deg.
mm
mm
kN {kg}
km/h
204 {273}/ 2,000 {2,000}

204 {273}/ 2,000 {2,000}
203 {272}/ 2,000 {2,000}
8,825
3,500
5,960
3,010
525
3,170
3,270/3,185
1,190/1,235
45
7,615/7,650
6,630
171 {17,400}
7.6/7.9
13.2/13.7
23.6/24.3
38.3/39.0
*1: Indicates the value of the basic engine (without cooling fan).
*2: Indicates the value at the minimum cooling fan speed.
*3: Indicates the value when the tilt down angle of bucket is 45 degrees.
WA470-7
01-3
01 Specification
a The engine rated horsepower is indicated in the net value and gross value. The gross denotes the
flywheel horsepower measured on the basic engine unit, while the net denotes the value measured of an
engine under the condition essentially the same as that when it is installed on a machine.
a Following shows the rated horsepower (net) at the maximum cooling fan speed.
194 kW {260 HP}/ 2,000 min-1 {2,000 rpm}
a BOC: Abbreviation for Bolt On Cutting edge
01-4
WA470-7
01 Specification
Specifications
Specifications
(WA470_7-2111-931-A-00-A)
Machine model
Serial No.
Machine weight
Machine weight (front wheel) in SAE
travel posture
Machine weight (rear wheel) in SAE
travel posture
kg
WA470-7
10001 and up
23,510
kg
10,600
kg
12,910
m3
kg
WA470-7
10001 and up
4.2
6,720
Performance
When traveling in torque converter drive mode

When traveling with torque converter locked up
Travel speed
Machine model
Serial No.
Bucket capacity (heaped)
Operating load
E mode
6.6
11.4
19.6
30.8
6.8
11.7
20.2
P mode
7.6
13.1
22.9
36.2
7.9
13.5
23.6
Reverse 4th
31.7
37.3
Forward 1st
Forward 2nd
Forward 3rd
Forward 4th
Reverse 1st
Reverse 2nd
Reverse 3rd
Reverse 4th
6.6
11.5
20.4
33.1
6.8
11.8
21.1
7.6
13.2
23.6
38.3
7.9
13.7
24.3
34.2
39.0
170 {17,300}
160 {16,300}
192 {19,600}
181 {18,500}
Forward 1st
Forward 2nd
Forward 3rd
Forward 4th
Reverse 1st
Reverse 2nd
Reverse 3rd
km/h
Maximum rim pull

Forward
Reverse
Gradeability
WA470-7
km/h
km/h
km/h
kN {kg}
deg.
25
01-5
01 Specification
Specifications
Machine model
Serial No.
Minimum turning radius (center of
outside tire)
Turning radius (cutting edge tip/BOC tip)
in SAE travel posture
WA470-7
10001 and up
mm
6,630
mm
7,615/7,650
01-6
WA470-7
01 Specification
Specifications
Dimension
Machine model
Serial No.
Overall length (with BOC)
Overall width (machine body)
Bucket width (with BOC)
Overall height (top of cab)
Overall height with bucket at max.
height
Wheelbase
Tread
Min. ground clearance
Max. hinge pin height
Dumping clearance (*1)
(cutting edge tip/BOC tip)
Dumping reach (*1)
(cutting edge tip/BOC tip)
Steering angle
Tilt back angle of bucket (travel posture/
max. height)
Tilt down angle of bucket (max. height)
Digging depth, 10 deg. (cutting edge tip/
BOC end)
mm
mm
mm
mm
WA470-7
10001 and up
8,825
3,010
3,170
3,500
mm
5,960
mm
mm
mm
mm
3,450
2,300
525
4,360
mm
3,270/3,185
mm
1,190/1,235
deg.
35
deg.
50/65
deg.
45
mm
265/315
*1: Indicates the value when the tilt down angle of bucket is 45 degrees.
WA470-7
01-7
01 Specification
Specifications
Engine
Machine model
Serial No.
Model
Type
Performance (In P mode)
mm
No. of cylinders bore x stroke
Total piston displacement
l {cc}
Rated horsepower
SAE J1995 [Gross] (*1)
kW {HP}/min1 {rpm}
ISO 14396
ISO 9249/ SAE J1349 [Net] (*2)
Nm {kgm}/
Max. torque (*1)
min-1 {rpm}
g/kWh
Fuel consumption rate at rated
horsepower
{g/HPh}
Max. speed with no load
min-1 {rpm}
min-1 {rpm}
Min. speed with no load
WA470-7
10001 and up
SAA6D125E-6
4-cycle, water-cooled, in-line vertical, direct injection,
with turbocharger, air-cooled aftercooler, and watercooled EGR
6 - 125 x 150
11.04 {11,040}
204 {273}/ 2,000 {2,000}
204 {273}/2,000 {2,000}
203 {272}/ 2,000 {2,000}
1,307 {133}/ 1,450 {1,450}
224 {165}
2,170 50
800 (+ 50/0)
Starting motor
Alternator
Battery (*3)
24 V, 7.5 kW
24 V, 50 A
12 V, 140 Ah, 2 pieces
*1: Indicates the value of the basic engine (without cooling fan).
*2: Indicates the value at the minimum cooling fan speed.
*3: The battery capacity (Ah) is indicated in the 5-hour rate.
a The engine rated horsepower is indicated in the net value and gross value. The gross denotes the
flywheel horsepower measured on the basic engine unit, while the net denotes the value measured of an
engine under the condition essentially the same as that when it is installed on a machine.
a Following shows the rated horsepower (net) at the maximum cooling fan speed.
194 kW {260 HP}/ 2,000 min-1 {2,000 rpm}
Power train
Machine model
Serial No.
Torque converter
Transmission
Reduction gear system
Differential
Final drive
WA470-7
10001 and up
3-element, 1-stage, 2-phase
Counter-shaft, power shift, helical and spur gear,
constant mesh type
Multiple disc, hydraulically actuated, modulation
Spiral bevel gear, oil bath lubrication type
Straight bevel gear type
Planetary gear single reduction type, oil bath
lubrication type
Axle
Machine model
Serial No.
Drive wheel
Front axle
Rear axle
01-8
WA470-7
10001 and up
Front and rear wheel drive
Fixed to frame, semi-float type
Center pin support, semi-float type
WA470-7
01 Specification
Specifications
Tire
Machine model
Serial No.
Size
Rim size
Inflation pressure
Front wheel
Rear wheel
WA470-7
10001 and up
26.5R25 AA L - 3
22.00 - 25WTB
kPa
{kg/cm2}
450 {4.5}
350 {3.5}
Brake
Machine model
Serial No.
WA470-7
10001 and up
4-wheel braking, braking with independent front and
rear wheel systems
Sealed, wet disc type
Hydraulically operated type
With hydraulic booster
Transmission output shaft braking
Wet disc type
Actuation with spring, hydraulic release
Parking
Main
Braking method
Brake type
Operation type
Operating method
Braking method
Brake type
Actuating method
Steering
Machine model
Serial No.
WA470-7
10001 and up
Articulation type
Hydraulic operation type
Steering method
Actuating method
Hydraulic pump
Hydraulic system
Machine model
Serial No.
Power train pump
Type
Discharge
Steering pump
Type
Discharge
Work equipment pump
Type
Discharge
Cooling fan pump
Type
Discharge
Emergency steering pump
Type
Discharge
WA470-7
WA470-7
10001 and up
cm3/rev
Gear type
80+32
cm3/rev
Variable displacement swash plate piston type

90
cm3/rev

120
cm3/rev

30
cm3/rev
Gear type
21
01-9
01 Specification
Specifications
Hydraulic system
Type
Cylinder bore
Piston rod outside diameter
Stroke
Max. distance between pins
mm
mm
mm
mm
WA470-7
10001 and up
Double-acting piston type
90
50
441
1,296
Min. distance between pins
mm
855
Lift cylinder
Type
Cylinder bore
Stroke
Type
Cylinder bore
Stroke
Work equipment control valve
Type
Control valve
Bucket cylinder
Cylinder
Steering cylinder
Machine model
Serial No.
Set pressure
mm
mm
mm
mm
mm
2-spool type
MPa {kg/
cm2}
Steering valve
Type
34.3 {350}
Spool type
Set pressure
Motor
mm
mm
mm
mm
mm

140
95
764
2,167
1,403
160
100
575
1,795
1,220
Cooling fan motor

Type
Motor capacity
MPa {kg/
cm2}
cm3/rev
24.5 {250}
Fixed displacement, swash plate, piston type
28
Work equipment
Machine model
Serial No.
Link type
Shape of bucket cutting edge
WA470-7
10001 and up
Z-bar link
Straight cutting edge with BOC
01-10
WA470-7
01 Specification
Weight table
Weight table
k This
(WA470_7-2120-931-A-00-A)
weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model
Serial No.
Engine (excluding coolant and oil)
Cooling assembly (including fan, frame, and air conditioner condenser)
(excluding coolant and oil)
Cooling sub assembly (excluding fan, cooling fan motor, frame, coolant,
and oil)
Radiator (1 piece)
Aftercooler
Oil cooler
Air conditioner condenser
Cooling fan motor
Torque converter oil cooler
Cooling fan pump
Transmission (including torque converter)
Without lockup clutch
With lockup clutch
Front drive shaft
Center drive shaft
Rear drive shaft
Front axle
With conventional differential
With limited slip differential
Rear axle
with conventional differential
With limited slip differential
Axle pivot (rear axle)
Tire and rim assembly (26.5 - R25 AA L - 3) (1 piece)
Tire (26.5R25 AA L - 3) (1 piece)
Rim (22.00-25WTB) (1 piece)
Power train pump
Work equipment pump
Steering pump
Work equipment EPC valve
Brake valve
Steering valve
Emergency steering motor
Steering cylinder assembly (1 piece)
Lift cylinder assembly (1 piece)
Bucket cylinder assembly
Front frame
Rear frame
Counterweight
Additional weight
WA470-7
WA470-7
10001 and up
1,486
369
204
33
25
7
3
14
25
25
1,148
1,193
33
40
20
1,238
1,250
1,168
1,180
144
655
415
240
20
103
40
108
4
7
24
13
3
37
185
206
1,852
1,735
1,595
385
01-11
01 Specification
Weight table
Unit: kg
Machine model
Serial No.
Engine hood assembly (including hydraulic tank, hydraulic tank mounting
bracket, hood, grille assembly, and upper portion of bulkhead)
Food body (excluding hydraulic tank hydraulic tank mounting bracket)
Hood
Side door (1 piece)
Grille
Mask
Hydraulic tank (excluding hydraulic oil)
Hydraulic tank mounting bracket
Fuel tank (excluding fuel)
Boom (including bushings)
Bucket link
Bell crank
Bucket (3,170 mm wide, including BOC side guard)
Operator's cab (including floor assembly)
Operator's seat
Air conditioner unit
Battery (1 piece)
WA470-7
10001 and up
690
428
38
47
87
25
168
68
194
1,470
89
390
2,023
1,078
50
5
45
01-12
WA470-7
01 Specification
Table of fuel, coolant, and lubricants
(WA470_7-RA19-05A-K-00-A)
a For details of notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.
WA470-7
01-13
01 Specification
Unit: l
Refill point
Engine oil pan
Transmission case
Hydraulic oil system
Axle (front / rear)
Cooling system
Fuel tank
01-14
Specified capacity
47
76
270
57/56
80
380
Refill capacity
38
65
173
57/56
WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model
Serial Number
WA470-7
10001 and up
10 Structure and function

3 10 Structure and function
WA470-7
10-1

Table of contents
Table of contents
(ALL-0310-002-A-00-A)
10 Structure and function ................................................................................................................... 10-1

KVGT.................................................................................................................................. 10-6
EGR system piping drawing ................................................................................................ 10-12
EGR system circuit diagram ................................................................................................ 10-14
EGR valve......................................................................................................................... 10-15
EGR cooler........................................................................................................................ 10-17
KCCV layout drawing ......................................................................................................... 10-19
KCCV ventilator ................................................................................................................. 10-21
KDPF................................................................................................................................ 10-23
Cooling system .................................................................................................................. 10-27
Cooling fan pump ............................................................................................................... 10-30
Cooling fan motor............................................................................................................... 10-39
Power train............................................................................................................................... 10-46
Power train system............................................................................................................. 10-46
Drive shaft ......................................................................................................................... 10-49
Power train piping drawing .................................................................................................. 10-50
Transmission control .......................................................................................................... 10-51
Transmission ..................................................................................................................... 10-59
3rd, 4th clutch ECMV.......................................................................................................... 10-88
Axle ................................................................................................................................ 10-101
Differential ....................................................................................................................... 10-103
Final drive ....................................................................................................................... 10-113
Steering system...................................................................................................................... 10-115
Layout of steering parts .................................................................................................... 10-115
Steering column............................................................................................................... 10-116
Steering pump ................................................................................................................. 10-117
Steering valve.................................................................................................................. 10-129
Orbit-roll valve ................................................................................................................. 10-143
Stop valve ....................................................................................................................... 10-149
Emergency steering motor ................................................................................................ 10-150
Emergency steering pump ................................................................................................ 10-151
Brake system ......................................................................................................................... 10-152
Layout of brake parts........................................................................................................ 10-152
Charge valve ................................................................................................................... 10-154
Brake valve ..................................................................................................................... 10-160
Slack adjuster .................................................................................................................. 10-164
Accumulator (for brake) .................................................................................................... 10-167
Brake .............................................................................................................................. 10-168
Parking brake control ....................................................................................................... 10-171
Parking brake .................................................................................................................. 10-172
Parking brake solenoid valve ............................................................................................ 10-173
Parking brake emergency release valve............................................................................. 10-176
Axle mount and center hinge pin........................................................................................ 10-177
Tire ................................................................................................................................. 10-178
Hydraulic component layout .............................................................................................. 10-180
Work equipment control .................................................................................................... 10-182
Hydraulic tank.................................................................................................................. 10-183
10-2
WA470-7

Table of contents
Double type gear pump .................................................................................................... 10-186

Work equipment pump...................................................................................................... 10-187
Control valve ................................................................................................................... 10-208
CLSS .............................................................................................................................. 10-217
Hydraulic circuit diagram and names of valves.................................................................... 10-221
Accumulator charge valve................................................................................................. 10-232
Work equipment lock solenoid valve .................................................................................. 10-236
Accumulator (for PPC circuit) ............................................................................................ 10-237
Accumulator (for ECSS) ................................................................................................... 10-238
Work equipment ..................................................................................................................... 10-239
Work equipment linkage ................................................................................................... 10-239
Bucket ............................................................................................................................ 10-240
Bucket positioner and boom positioner............................................................................... 10-241
ROPS cab ....................................................................................................................... 10-242
Engine control system ...................................................................................................... 10-243
Preheating system ........................................................................................................... 10-245
Engine power mode selector circuit ................................................................................... 10-247
Engine output limit function ............................................................................................... 10-248
Automatic warm-up function.............................................................................................. 10-249
Parking brake control system ............................................................................................ 10-250
System operating lamp function......................................................................................... 10-252
Battery disconnect switch function ..................................................................................... 10-254
Transmission controller system ......................................................................................... 10-256
Work equipment control system......................................................................................... 10-277
Machine monitor system ................................................................................................... 10-293
Rear view monitor system................................................................................................. 10-317
KOMTRAX system ........................................................................................................... 10-320
System component parts .................................................................................................. 10-323
Sensor ............................................................................................................................ 10-350
WA470-7
10-3

Engine related parts
Engine and cooling system

(ALL-R401-001-K-00-A)
(WA470-A001-041-K-00-A)
1. Air cleaner
10-4
WA470-7

2. KDPF (*1)
3. KVGT (*2)
4. Alternator
5. Engine mount
6. EGR cooler (*3)
7. Starting motor
8. Engine oil filter
9. Engine controller
10. KCCV ventilator (*4)
11. Vibration damper
*1: For KDPF, see "KDPF".
*2: For KVGT, see "KVGT".
*3: For the EGR cooler, see "EGR cooler".
*4: For the KCCV ventilator, see "KCCV ventilator".
WA470-7
10-5

KVGT
KVGT
(ENG125-AA10-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger and denotes the variable displacement
turbocharger.
a The shape is subject to machine models.
10-6
WA470-7

KVGT
1. Blower housing
2. KVGT speed sensor
3. Hydraulic actuator
4. Turbine housing
5. Plate
6. Vane
7. Nozzle ring
8. Push rod
9. Shaft
10. Blower impeller
11. Turbine impeller
12. Piston
A: Air intake inlet
B: Air intake outlet
C: Exhaust inlet
D: Exhaust outlet
Operation
(ENG125-AA10-044-K-00-A)
1. Air cleaner
2. KVGT
3. KDPF
4. EGR cooler
5. EGR valve
C: Blower impeller
T: Turbine impeller
The new exhaust gas regulation not only requires to control emissions at high engine speed but also at
low engine speed. To meet the requirements, the EGR ratio is increased. (EGR ratio = volume of EGR/
intake air flow)
To obtain a high EGR ratio especially at low engine speed, the turbine inlet pressure (P3) must be higher
than the boost pressure (P2). A variable displacement turbocharger (KVGT), in which the exhaust gas
pressure hitting the turbine impeller (T) can be adjusted, is introduced.
The charged pressure rises faster, also contributing to suppress the generation of PM (particles) due to
insufficient oxygen at low engine speed.
The turbine impeller (T) drives the blower impeller (C) via a shaft to send a large amount of air to the
cylinders for combustion. When the air flow from KVGT (2) increases, more fuel can be injected, and the
engine output increases.
Since the density of the air and the amount of oxygen increases when the air is cooled, more fuel can be
injected, and the engine output increases.
WA470-7
10-7

KVGT
a Adequate amount of clean high quality oil is required to maintain the KVGT performance. Be sure to use
Komatsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when
replacing oil or oil filter.
Exhaust gas enters from (C) of turbine housing (4), and flows out from (D) through section (P). Section (P)
is surrounded by plate (5) and nozzle ring (7) fixed on turbine housing (4), and vane (6).
The passage area varies when push rod (8) slides right or left.
The hydraulic actuator (3) moves piston (12) in the actuator up/down by using the oil pressure controlled
at the EPC valve installed to the front cover, and also controls the right/left slide of push rod (8).
Exhaust gas flows through vanes (6) and rotates turbine impeller (11), the torque of which rotates blower
impeller (10) via shaft (9). This works as a compressor and the air entered from (A) is compressed and
sent out from (B).
When the exhaust gas pressure at the inlet (C) of turbine housing (4) is low (at low engine speed), push
rod (8) slides to the right to narrow section (P).
Then the exhaust gas pressure to turbine impeller (11) increases, the turbocharger speed also increases,
and more air (oxygen) is inhaled.
The turbocharger speed is sensed by KVGT speed sensor (2).
When nozzle ring is closed
At low engine speed, exhaust gas inlet passage (P) is narrowed (L1). (Not completely closed.)
When the turbine inlet pressure increases while the nozzle ring is closed, the flow speed to the turbine
increases and the turbocharger speed increases.
10-8
WA470-7

KVGT
When nozzle ring is open

At high engine speed, exhaust gas inlet passage (P) is widened (L2).
As the engine speed and the turbine inlet pressure (exhaust gas pressure) increases, exhaust gas inlet
passage (P) widens (L2) to effectively apply the exhaust gas pressure to turbine impeller (11).
a Nozzle ring (7), vane (6) and rod (8) are integrated and slide together but do not rotate.
a KVGT position sensor is installed to hydraulic actuator (3). The KVGT position sensor is calibrated
together with the variable mechanism in the KVGT, and values are stored in the memory inside the KVGT
position sensor. If any of the hydraulic actuator (3), KVGT position sensor, or KVGT body fails, replace the
whole KVGT.
Hydraulic actuator operation
Hydraulic actuator (6) is moved by the oil pressure controlled by EPC valve (8) installed to the front cover.
The force for the movement is the oil pressure supplied from boost pump (12).
WA470-7
10-9

KVGT
Position of hydraulic actuator (6) is sensed by KVGT position sensor (5) and the signals are fed back to
engine controller (7).
1. Air cleaner
2. Mass air flow and temperature sensor
10-10
WA470-7

KVGT
3. KVGT
4. KVGT speed sensor
5. KVGT position sensor
6. Hydraulic actuator
8. EPC valve (for KVGT)
9. KDPF
10. EGR system (EGR cooler and EGR valve)
11. EGR valve lift sensor
C. Blower impeller
T. Turbine impeller
KVGT control system
Based on information from KVGT position sensor (5), mass air flow and temperature sensor (2), and
KVGT speed sensor (4), etc., the engine controller (7) moves hydraulic actuator (6) by using the oil
pressure controlled by EPC valve (8), and then move the piston.
A good response at high altitudes is maintained by sensing high elevations with the ambient pressure
sensor, and automatically controlling the fuel injection and the KVGT.
The KVGT is protected by controlling its speed to prevent overspeed.
Lubrication
Cooled oil from the engine oil cooler is sent through the supply pipe to the KVGT for lubrication
Oil is sent to the bearing housing to lubricate the shaft bearing and thrust bearing.
Return oil is drained from the return pipe connected to the bottom of the bearing housing and falls to the oil
pan.
Cooling
Coolant from the cylinder block enters the center housing to cool the KVGT.
Returning coolant flows from the center housing to the radiator.
WA470-7
10-11

EGR system piping drawing
(ENG125-A9J0-04D-K-00-A)
EGR: Abbreviation for Exhaust Gas Recirculation

1. KVGT
2. EGR valve
3. Air intake connector
4. Intake manifold
5. Exhaust manifold
6. EGR cooler
7. Mixing connector
Function
(ENG107-A9J0-042-K-00-A)
EGR valve (driven hydraulically)

Controls the gas flow from the exhaust system to the air intake system. Since the exhaust pressure is
higher than the boost pressure, the exhaust gas flows to the air intake side.
10-12
WA470-7

EGR cooler
Cools the exhaust gas.
Engine coolant is used for cooling.
Air intake connector
Returns the air from the air-cooled aftercooler and exhaust gas from the EGR valve to the air intake side.
Each sensor
Controls the EGR according to the operating condition.
Troubleshoots the system.
Controls each part of the EGR circuit and controls the EGR rate according to the operating condition to
ensure clean exhaust at all times.
Since the EGR circuit is monitored and troubleshooted, a serious trouble is prevented.
WA470-7
10-13

EGR system circuit diagram
EGR system circuit diagram
(ENG125-A9J0-052-K-00-A)
1. Air cleaner
2. KDPF
3. Ambient pressure sensor
4. Aftercooler
5. EGR cooler
6. EGR valve
7. Hydraulic actuator (power piston)
8. EPC valve (for EGR valve)
10. Exhaust manifold
11. Boost pump
12. Intake manifold
13. Charge (boost) pressure and temperature sensors
15. Mixing connector
C: Blower impeller
T: Turbine impeller
Operation
(ENG125-A9J0-044-K-00-A)
The engine controller outputs signals for opening EGR valve (6) most properly according to the load on
the engine to attain both clean exhaust gas and low fuel consumption.
When EGR valve (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (10)
through EGR piping to EGR cooler (5).
The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6) and mixes with the intake air in
mixing connector (15), and then flows into intake manifold (12).
10-14
WA470-7

EGR valve
EGR valve
(ENG125-A9K1-041-K-00-A)
1. Valve
2. Spring
3. Power piston
4. Spool
5. Spring
7. EPC valve (for EGR)
A: EGR gas inlet (from EGR cooler)
B: EGR gas outlet (to intake manifold)
C: Servo drive oil inlet
D: Servo drive oil outlet
Structure
The EGR valve consists of the EGR gas flow control mechanism and the EPC valve .
An EPC valve is provided for EGR valve control, and an EPC valve for KVGT control is installed to front
cover.
WA470-7
10-15

EGR valve
Operation
(ENG107-A9K1-044-K-00-A)
Oil from the boost oil pump flows into the EGR valve from port (C). Control pressure from the EPC valve
flows into port (E).
Spool (4) is pressed to the right by the force of spring (5), and EGR valve (1) is closed by the force of
spring (2) Therefore, exhaust gas from the EGR cooler does not flow to the intake side.
To open EGR valve (1), first the control pressure from the EPC valve enters port (E). Spool (4) moves to a
position whereat this control pressure and the force of spring (5) are balanced.
The hydraulic circuit in power piston (3) opens, and then the oil from the boost oil pump entering from port
(C) pushes power piston (3) to the left.
Oil from the boost oil pump acts on power piston (3) and generates force (Fp).
When force (Fp) becomes larger than force (Fs) of spring (2), EGR valve (1) opens and then exhaust gas
will flow to the intake side.
Since the hydraulic circuit to spool (4) is closed by movement of power piston (3), power piston (3) stops at
a position determined by spool (4).
The valve position is controlled by the engine controller by controlling the spool position with the control
pressure of the EPC valve.
A servo mechanism prevents external force applied to valve (1) from acting on spool (4), which is in
contact with power piston (3).
Position of spool (4) is sensed by the EGR valve lift sensor.
10-16
WA470-7

EGR cooler
EGR cooler
(ENG125-A9L0-041-K-00-A)
1. Header plate
4. Shell
A: EGR gas inlet
B: EGR gas outlet (to EGR valve)
C: Coolant inlet
D: Coolant outlet
E: Air vent
F: Air vent
2. Flat tube
3. Inner fin
Operation
(ENG125-A9L0-044-K-00-A)
The EGR gas enters from (A) and flows through 9 flat tubes (2).
WA470-7
10-17

EGR cooler
Coolant enters from (C) and flows around flat tube (2) in shell (4) and then goes out from (D).
The EGR gas is effectively cooled by flat tubes (2) with inner fins (3) and flows out from EGR gas outlet
(B).
10-18
WA470-7

KCCV layout drawing
KCCV layout drawing
(ENG125-A180-04D-K-00-A)
KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation

1. KCCV ventilator
2. KVGT
3. Check valve
4. CDR valve
A: Blowby gas
B: Engine oil-free blowby gas (to KVGT)
C: Engineoil that C is separated (to oilpan)
Formerly blowby gas (A) was discharged to the atmosphere as is. However, the tightened exhaust gas
regulation no longer permits releasing blowby gas to the atmosphere.
Since blowby gas (A) contains engine oil components, which may cause the following problems when
recirculated to KVGT (2), a filter is provided at KCCV ventilator (1) to remove the oil.
1. Degraded performance of turbocharger and aftercooler due to adherence of engine oil
2. Abnormal engine combustion
3. Malfunction of sensors due to adherence of engine oil
WA470-7
10-19

KCCV layout drawing
Operation
(ENG125-A180-044-K-00-A)
a The figure on the left shows the traditional flow of blowby gas that has been discharged to the atmosphere.
The figure on the right shows the flow of blowby gas recirculated to the intake system by the KCCV
ventilator.
1. Air cleaner
2. KVGT
3. Aftercooler
4. Cylinder block (crankcase)
5. Breather
6. KCCV ventilator
7. Oil pan
Engine oil is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and
then the cleaned gas (B) is recirculated to the intake side of the KVGT.
Separated engine oil (C) flows through a check valve and falls to the oil pan.
10-20
WA470-7

KCCV ventilator
KCCV ventilator
(ENG125-A18H-041-K-00-A)
1. Case
2. CDR valve
3. Crankcase pressure sensor
4. Relief valve
5. Impactor
6. Filter
7. Heater tube
A: Blowby gas inlet (engine breather)
B: Blowby gas outlet (to KVGT intake side)
C: Oil drain port (to oil pan)
D: Coolant inlet
E: Coolant outlets
Function
(ENG125-A18H-042-K-00-A)
When blowby gas is recirculated to the intake side of the KVGT, the pressure inside the crankcase
becomes negative, and dust may be sucked in through the crankshaft seals. Therefore, CDR valve
(regulator valve) controls the pressure inside the crankcase.
If the filter in the KCCV ventilator clogs, pressure inside the crankcase increases and oil may leak, so clog
of filter is detected by crankcase pressure sensor.
There are two types of filters that differ by the filter replacement method; the top load type (removed
upward) and the bottom load type (removed downward).
Warmed engine coolant is conducted to the locations that pose potential problem of freezing to prevent it
from happening.
WA470-7
10-21

KCCV ventilator
Operation
(ENG107-A18H-044-K-00-A)
Blowby gas enters from (A). The larger drops of oil mist are removed from the blowby gas when it flows
through the impactor (5) holes in filter (6).
Smaller drops of oil mist are removed by filter (6).
Removed oil flows down along the case wall to oil drain port (C) and then flows to the oil pan.
The CDR valve operates when the pressure inside the crankcase becomes negative, to prevent excessive
negative pressure in the crankcase.
Crankcase pressure sensor (3) senses the blowby gas pressure (crankcase pressure).
When the engine controller determines that the filter is clogged from crankcase pressure sensor (3)
signals, failure code CA555 is issued. If the pressure increases further, failure code CA556 is issued.
Relief valve (4) is installed in case (1). It operates to protect the KCCV ventilator and engine when filter (6)
is blocked.
CDR valve
(ENG107-A18A-041-K-00-A)
CDR: Abbreviation for Crankcase Depression Regulator
1. Diaphragm
2. Spring
A: Crankcase side
B: KVGT side (intake side)
The CDR valve is a regulator valve which prevents excessive negative crankcase pressure (P1).
Normally, diaphragm (1) is pushed up by spring (2) and blowby gas flows from crankcase side (A) to
KVGT side (intake side) (B).
When intake air flow at KVGT side (intake side) (B) increases and crankcase pressure (P1) decreases,
force of spring (2) yields to ambient pressure (P2). The diaphragm shuts the passage and temporarily
blocks the flow.
Then, when blowby gas accumulates in the crankcase and pressure (P1) recovers, the diaphragm is
pushed up again and blowby gas starts to flow again.
10-22
WA470-7

KDPF
KDPF
(ENG125-A9H0-041-K-00-A)
KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

1. Inlet unit
2. KDOC inlet temperature sensor
3. KDOC outlet temperature sensor
4. KCSF unit
5. Aggregate connector box
6. KDPF outlet temperature sensor
7. Outlet unit
8. KDPF differencial pressure sensor port
9. KDPF differencial pressure sensor
10. KDPF differential pressure sensor port
11. KDOC unit
12. Hanger bracket
13. Sensor bracket
14. Sensor bracket band
15. Water drain port
A: From KVGT
B: Exhaust
C: Water drain
The KDPF consists of the following components: inlet unit (1) to introduce exhaust gas, KDOC unit (11)
that houses an oxidation catalyst, KCSF unit (4) that houses a soot collecting filter with a catalyzer, and
outlet unit (7) that sends out exhaust gas and has a "dam" to prevent rain water from entering KCSF unit
(4).
WA470-7
10-23

KDPF
KDOC unit (11) consists of a ceramic honeycomb coated with oxidation catalyst material. By using this
ceramic honeycomb, it regenerates (*1) NO (nitrogen monoxide) to NO2 (nitrogen dioxide) in exhaust gas.
The ceramic honeycomb is guarded by a mat made of special fiber to prevent damage caused by engine
and machine vibrations.
The mat also prevents overheating of the KDPF outer periphery by insulating the heat generated at the
ceramic honeycomb during operation.
The KCSF unit (4) also consists of a ceramic honeycomb coated with oxidation catalyst material, like the
KDOC unit (11). This ceramic honeycomb collects soot.
Three temperature sensors and one differential pressure sensor (an integrated KDPF differential pressure
and KDPF outlet pressure sensor) are installed to the KDPF.
Temperature signals from these three temperature sensors are used in combination to monitor the KDOC
and KCSF operations and to perform various troubleshootings.
The differential pressure sensor detects the amount of soot deposited in the KCSF by sensing the
pressure difference across the KCSF. Like the temperature sensors, this sensor is also used for various
troubleshootings.
*1: Denotes to purification (oxidation) processing of soot.
k While
engine is running and for some time after engine is stopped, the surface of KDPF and
nearby piping are extremely hot. Be careful not to get burned when working near the KDPF.
Function
(ENG125-A9H0-042-K-00-A)
A: Flow of exhaust gas

1. KDOC(oxidation catalyzer)
2. KCSF
3. Sealing (made of ceramics)
4. Cell
5. Ceramics honeycomb
The KDPF purifies the exhaust gas by catching most of the granulous or chain-like soot formed by the PM
(particulates in air such as soot) included in the exhaust from the engine.
KCSF (2) is made of ceramic.
10-24
WA470-7

KDPF
Inside the KCSF (2), there are many cells partitioned by ceramic walls. Cells plugged at the inlet side and
cells plugged at the outlet side are alternately arranged.
The soot deposited in KCSF (2) are naturally oxidized and burned away by the effect of KDOC (1)
(oxidation catalyzer), in operating conditions with relatively high exhaust gas temperatures. (This is
referred to as "passive regeneration".)
On the other hand, when the exhaust temperature is relatively low, in conditions such as continued low
load operations, the deposit of soot in KCSF (2) increases.
The engine controller continuously monitors the amount of deposited soot by estimating from the
operating conditions and calculating based on the KCSF (2) differential pressure sensor signals.
When the soot deposit exceeds a certain level, and the engine is operated with the exhaust gas
temperature exceeding a certain level, the engine controller executes "automatic regeneration" to burn
(oxidize) the soot.
During automatic regeneration, the engine controller automatically controls the fuel injection timing and
the KVGT to raise the exhaust temperature. (This operation is called "exhaust temperature-raising
control")
As the exhaust temperature increases, the engine controller automatically performs calculations based on
the exhaust temperature at the KDOC inlet and flow of the exhaust gas, so that KCSF (2) can efficiently
burn (oxidize) the soot.
Fuel is injected from (fuel doser) installed to the outlet portion of turbocharger. (Fuel dosing) Fuel that is
injected into this piping mixes with exhaust gas and combusts (oxidizes) soot by the action of KDOC (1).
Automatic regeneration is not performed when regeneration is executed from the machine monitor, or
when the outside air temperature is extremely low, and when the exhaust gas temperature is not high
enough to burn soot because the engine has been operated at low loads for a while. Thus, soot deposit in
the KCSF (2) will increase.
If the soot deposit in the KCSF (2) exceeds a certain level, it will be necessary to perform "manual
stationary regeneration" to burn away (oxidize) the soot in the KCSF (2).
If the soot deposit exceeds the acceptable level, the exhaust gas flow will be restricted. This can increase
fuel consumption, degrade engine combustion, or cause other problems.
If the soot deposit exceeds the limit to safely perform "manual stationary regeneration", the KDPF fails and
replacement becomes unavoidable. Make sure to follow the procedures in the Operation and
Maintenance Manual when performing "manual stationary regeneration"
Displaying KDPF regeneration
(HM400-A9H0-042-K-00-A)
a Regeneration refers to a new function used for purifying (oxidizing) soot accumulated in the soot collection
filter (KCSF) inside the KDPF.
1. Passive regeneration
When the engine exhaust temperature is relatively high, the catalyst effect of the KDOC to oxidize soot will
be stronger and the soot deposit in the KCSF will be naturally burned away.
2. Active regeneration (increase of engine exhaust temperature + fuel dosing)
1) Automatic regeneration
This is the regeneration process started automatically when the soot deposit exceeds a certain level.
At this time, the engine controller performs the exhaust temperature-raising control mode (*1) and fuel
dosing (*2). Another type of automatic regeneration is performed by the engine controller at certain
intervals, regardless of the amount of soot deposited in the KCSF.
*1: The fuel injection timing and the KVGTare controlled to raise the exhaust temperature.
*2: Fuel is injected to increase the exhaust temperature and accelerate the regeneration process.
2) Manual stationary regeneration
When the exhaust temperature does not reach a certain level due to the machine operating condition,
or when regeneration is disabled by the operator, automatic regeneration will not be performed and the
soot deposit in the KCSF may increase. In such conditions, the machine monitor displays a manual
stationary regeneration request, on the screen. The operator must perform regeneration by operating
the machine monitor on its screen. A regeneration feature is also provided for the technician who
should use this feature from the machine monitor menu after engine controller replacement, KDPF
replacement, and KCSF ash cleaning. (= Regeneration for service)
A KDPF drying feature is provided to prevent excessive accumulation of unburned fuel in the KDPF
when the machine is operated for a long time with low exhaust temperature.
WA470-7
10-25

KDPF
When certain conditions are met, the engine controller automatically switches control to increase
the exhaust temperature to dry the KDOC. If some of the conditions for automatic drying are not
met, manual stationary regeneration may be requested.
a Follow the procedures in the Operation and Maintenance Manual when starting and stopping KDPF
regeneration.
a Be sure to use ultra-low-sulfur diesel fuel. Non-specified fuels may cause KDPF failure.
a Be sure to use the specified Komatsu genuine oil for the KDPF. Non-specified oils may cause
KDPF clogging in a short time, resulting in increased fuel consumption or KDPF failure.
a Do not modify the KDPF itself or exhaust pipes. Modifications disturb normal operation of the KDPF,
leading to a failure.
a Do not apply impacts to the KDPF by stepping on, dropping, or striking it. The KDPF contains a
ceramic honeycomb, which can be damaged by strong impacts.
a The engine controller performs automatic regeneration even when the amount of soot deposit is low.
Since this is programmed to maintain the KDPF performance, this is normal.
a During automatic regeneration and manual stationary regeneration, the KVGTautomatically
operates and the engine sound changes. The flow of exhaust gas through the KDPF changes and
the exhaust sound changes, but this is normal.
a During automatic regeneration and manual stationary regeneration, especially at low temperatures,
white smoke may come out from the exhaust pipe for a short time, but this is normal. Be sure to
perform regeneration at a well ventilated place since carbon monoxide can be produced.
a During automatic regeneration and manual stationary regeneration, a strange odor may be smelled
from the exhaust pipe, but this is normal.
a During automatic regeneration and manual stationary regeneration, the exhaust temperature at the
exhaust pipe can exceed 650C. Make sure that there is no flammable material near the exhaust
system to prevent fire. Make sure that nobody is standing in front of the exhaust pipe, and pay
sufficient attention to safety of the environment.
a KDPF temperature values are shown below for reference.
KDOC_In
(KDOC inlet temperature
sensor)
Not regenerating (idling)
Regenerating (under
exhaust temperature-raising
control: 1,000 rpm)
10-26
100 to 250C
KDOC_Out
(KDOC outlet
temperature sensor)
100 to 250C
KDPF_Out
(KDPF outlet
temperature sensor)
400 to 550C
WA470-7

Cooling system
Cooling system
(WA470-B000-041-K-00-A)
1. Accumulator charge valve

2. Reservoir tank
3. Cooling fan, brake pump
WA470-7
10-27

Cooling system
4. Aftercooler outlet hose

5. Radiator cap
6. Radiator inlet hose
7. Aftercooler inlet hose
8. Power train oil cooler inlet
9. Coolant drain valve
10. Cooling fan motor
11. Fan guard
12. Radiator
13. Cooling fan
14. Hydraulic oil cooler inlet hose
15. Aftercooler
16. Condenser
17. Power train oil cooler
18. Power train oil cooler outlet
19: Hydraulic oil cooler outlet hose
20. Radiator outlet hose
21. Hydraulic oil cooler
10-28
WA470-7

Cooling system
Specifications
(WA470-B000-030-K-00-A)
Core type
Fin pitch (mm)
Total heat dissipation
area (m2)
Pressure valve cracking
pressure
(kPa {kg/cm2})
Vacuum valve cracking
pressure
(kPa {kg/cm2})
Power train oil

cooler
PTO-OL
100 x 558 x 20
layers
(*1)
Radiator
Oil cooler
Aftercooler
AL WAVE-5
AL WAVE
AL WAVE
6.0/2
6.0/2
6.0/2
84.28 x 2
8.16
25.24
2.152
88.3 14.7
{0.9 0.15}
0 to 4.9
{0 to 0.05}
1: Indicates the element size.
WA470-7
10-29

Cooling fan pump
Cooling fan pump
(WA500-B450-041-K-00-A)
P1: Pump discharge port

PAEPC: EPC output pressure pickup plug
PE: Control piston pressure input port
PEPC: EPC valve source pressure input port
PH: Pump discharge pressure output port
PS: Pump suction port
T0: Drain port
1. Servo valve
2. Air bleeder
3. EPC valve
4. Control current input connector
10-30
WA470-7

Cooling fan pump
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
11. Ball retainer
WA470-7
10-31

Cooling fan pump
Structure
Cylinder block (7) is supported on shaft (1) by spline (a).
Shaft (1) is supported by each bearing at the front and rear.
The tip of piston (6) is shaped as a concave sphere and crimped together with shoe (5).
Piston (6) and shoe (5) form a spherical bearing.
Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
Rocker cam (4) pivot on ball retainer (11).
Piston (6) moves relatively in the axial direction in each cylinder chamber of cylinder block (7).
Cylinder block (7) rotates relatively to valve plate (8) while blocking the pressurized oil.
This plane is designed so that the oil pressure is balanced correctly.
The pressurized oil can be sucked in and discharged from each cylinder chamber in cylinder block (7)
through valve plate (8).
Specifications
(WA470-B450-030-K-00-A)
Model
Type
Theoretical discharge (cm3/rev)
Fan drive pressure (MPa {kg/cm2})
Rated speed (rpm)
Function
LPV30
Variable displacement swash plate type piston pump
30
10.9 {111}
2,282
(WA380-B450-042-K-00-A)
The engine rotation and torque transmitted to the pump shaft is converted into the hydraulic energy and
the pressurized oil corresponding to the load is discharged.
It is possible to change the delivery by changing the swash plate angle.
10-32
WA470-7

Cooling fan pump
Operation
(WA380-B450-044-K-00-A)
Operation of pump
Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
Rocker cam (4) pivots on ball retainer (11), and accordingly angle (a) between center line (X) of rocker
cam (4) and the axial direction of cylinder block (7) changes.
Angle (a) is called the swash plate angle.
While angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane
(A) works as a cam for shoe (5).
Pistons (6) slides inside cylinder block (7) and a difference is made between volumes (E) and (F) in
cylinder block (7).
Oil in amount of (F) minus (E) goes in and out of each cylinder.
Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
Oil is sucked in when the volume of chamber (F) increases.
In the figure, chamber (F) is at the end of the suction stroke and chamber (E) is at the end of the discharge
stroke.
WA470-7
10-33

Cooling fan pump
When center line (X) of rocker cam (4) matches the axis of cylinder block (7) (the swash plate angle is
zero), the difference between volumes (E) and (F) inside cylinder block (7) is zero.
Pressurized oil is not sucked or discharged, namely pumping action is not performed. (Actually, however,
the swash plate angle does not become 0 deg.)
The pump delivery is in proportion to swash plate angle (a).
10-34
WA470-7

Cooling fan pump
Control of delivery
When swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, then
delivery (Q) is increased.
Swash plate angle (a) is changed by servo piston (10).
Servo piston (10) reciprocates linearly according to the signal pressure of the servo valve.
This straight line movement is transmitted to rocker cam (4).
Rocker cam (4) supported with ball retainer (11) pivots on ball retainer (11).
WA470-7
10-35

Cooling fan pump
Servo valve
(WA470-B4H0-041-K-00-A)
P: EPC valve source pressure port

PE: Control piston pressure port
PH: Pump discharge pressure port
T: Drain port
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
8. Spring
9. Pilot valve
10-36
WA470-7

Cooling fan pump
Function
(PC400-B4H0-042-K-00-A)
The servo valve controls the pump so that the input current (i) to the EPC valve relates to pump delivery
(Q) as shown in the figure below.
Operation
(PC400-B4H0-044-K-00-A)
The output pressure of the EPC valve enters piston chamber (C) and pushes piston (6).
Piston (6) pushes spool (5) and moves to a position where it is balanced with the spring.
Land (PE) of the servo piston pressure passage is connected to pump delivery pressure passage (PH)
through the notch of spool (5), so the pump delivery pressure is transmitted to servo piston (10).
Rocker cam (9) is pushed up by servo piston (10), and then its position is fed back and lever (2) moves to
compress spring (8).
WA470-7
10-37

Cooling fan pump
If spool (5) is pushed back, the pump delivery circuit and servo piston circuit are disconnected.
The pressure in the servo piston chamber decreases and rocker cam (9) moves toward the maximum
swash plate angle.
These processes are repeated until the swash plate stabilizes at an angle where the EPC output pressure
is balanced with the force of spring (8).
As the EPC output pressure increases, the swash plate angle decreases. As the EPC output pressure
decreases, the swash plate angle increases.
10-38
WA470-7

Cooling fan motor
Cooling fan motor
(WA380-B5L0-041-K-00-A)
P: From fan pump

T: To oil cooler
TC: To hydraulic tank
WA470-7
10-39

Cooling fan motor
1. Output shaft
2. Case
3. Thrust plate
4. Piston assembly
5. Cylinder block
6. Valve plate
7. End cover
8. Center spring
9. Check valve
10. Pilot valve
11. Reversible valve spool
12. Safety valve
13. Cooling fan speed sensor
Specifications
(WA470-B5L0-030-K-00-A)
Model
Capacity (cc/rev)
Rated speed (rpm)
Rated flow rate (l/min)
Check valve cracking pressure (MPa {kg/
cm2})
10-40
LMF28
28.0
1,300
36.4
0.044 {0.45}
WA470-7

Cooling fan motor
Hydraulic motor
(WA380-B5N0-042-K-00-A)
This hydraulic motor is called a swash plate axial piston motor. It converts the energy of the pressurized oil
sent from the hydraulic pump into rotary motion.
This fan motor is installed within the blade width as shown in the figure.
Principle of operation
(HM300-B5N0-04B-K-00-A)
The pressurized oil sent from the pump flows through valve plate (3) into cylinder block (5).
This oil can flow to only one side of the (Y - Y) line connecting the top dead center and bottom dead center
of the stroke of piston (4).
The pressurized oil sent to one side of cylinder block (5) pushes each piston (4) (two or three pistons).
A single piston generates force F1 [F1 (kg) = P (kg/cm2) x xD2 / 4 (cm2)].
This force acts on thrust plate (2).
Since thrust plate (2) is fixed at specific angle (a) to output shaft (1), the force is divided into components
(F2) and (F3).
Of those components, radial component (F3) generates torque (T = F3 x ri) against the (Y - Y) line
connecting the top dead center and bottom dead center.
The total of these torque [T = s (F3 x ri)] rotates cylinder block (5) through piston (4).
Cylinder block (5) is connected to output shaft (1) with spline.
Output shaft (1) rotates to transmit the torque.
WA470-7
10-41

Cooling fan motor
10-42
WA470-7

Cooling fan motor
Suction valve
Function
(HM300-B6D0-001-K-00-A)
(HM300-B6D0-042-K-00-A)
When the pump stops, the pressurized oil does not flow into the motor any more.
Since the motor continues to rotate with the force of inertia, the pressure on the outlet side of the motor
increases.
When the oil stops flowing in from inlet port (P), suction valve (1) sucks in the oil on the outlet side and
supplies it to port (MA), compensating for the lack of oil on that side to prevent cavitation.
Operation
(WA500-B6D0-044-K-00-A)
When pump is started
The pressurized oil from the pump is supplied to port (P), increasing the (MA) side pressure.
The starting torque is generated in the motor, and the motor starts rotating.
The pressurized oil on the motor outlet (MB) side returns to the tank through port (T).
WA470-7
10-43

Cooling fan motor
When pump is stopped
When the engine stops, the pump input speed becomes 0 rpm.
The pressurized oil from the pump is not supplied to port (P).
As the pressurized oil is not supplied to (MA) side of the motor, the motor speed decreases gradually to
stop.
When the motor shaft is rotated by the force of inertia while the oil flow in port (P) is decreasing, the oil in
port (T) on the outlet side is sent by suction safety valve (1) to the (MA) side to prevent cavitation.
Reversible valve
(WA500-B6E0-041-K-00-A)
The rotating direction of the fan motor changes from the normal rotation to the reverse rotation, or from the
reverse rotation to the normal rotation corresponding to the current data which controls the pilot valve.
When changing from the normal rotation to the reverse rotation:
The solenoid valve controls the spool position according to the command current which is output from
controller in proportion to the set rate. While the command current passes the neutral range area, the fan
becomes neutral and the fan speed decreases sufficiently. As a result, the direction of the fan changes to
reverse rotation smoothly.
The fan rotation changes similarly from reverse to normal.
10-44
WA470-7

Cooling fan motor
Safety valve
Function
(ALL-B6G0-001-K-00-A)
(PC400-B6G0-042-K-00-A)
When the engine is started, the pressure in port (P) of the fan motor is increased in some cases.
Safety valve (1) is provided in order to protect the fan system circuit.
Operation
(WA500-B6G0-044-K-00-A)
If the pressure in port (P) rises above the cracking pressure of safety valve (1), valve (2) of safety valve (1)
opens to release the pressurized oil into port (T).
This operation prevents the generation of the abnormally high pressure in port (P).
WA470-7
10-45

Power train system
Power train
(ALL-C100-001-K-00-A)
Power train system
(WA470-C100-041-K-00-A)
1. Transmission
2. Torque converter
3. Engine
4. Rear axle
5. Rear drive shaft
6. Center drive shaft
7. Front drive shaft
8. Front axle
10-46
WA470-7

Power train system
Power train system
1. Front axle
2. Differential
3. Wet-type multiple-disc brake
WA470-7
10-47

Power train system
4. Final drive
7. Parking brake (wet-type multiple-disc)
8. Transmission (counter-shaft type)
9. Rear drive shaft
10. Rear tire
11. Final drive
13. Differential
14. Rear axle
15. Engine
16. Torque converter
17. Steering pump
18. Power train pump
19. Work equipment pump
20. Cooling fan pump
21. Flange bearing
22. Front tire
Function
(WA470-C100-042-K-00-A)
The power of engine (15) is transmitted to torque converter (16) through the flywheel.
The torque converter converts the received torque to the torque corresponding to the fluctuation of the
load by using oil as a medium, and transmits it to the input shaft of transmission (8). The engine power is
also transmitted through the pump drive gear of the torque converter to work equipment pump (19),
cooling fan pump (20), steering pump (17), and power train pump (18) to drive those pumps.
Transmission (8) selects one from the four gear speeds each in the forward and reverse directions by
operating the six hydraulic clutches with the directional and gear shift valves among the transmission
valves.
Parking brake (7) is a wet-type multiple-disc brake to stop the machine. It is installed on the front side of
the output shaft and actuated by the solenoid valve which is operated with the parking brake switch.
The power of transmission (8) is transmitted to the front and rear axles.
The power for the front side is transmitted through center drive shaft (6), flange bearing (21), and front
drive shaft (5) to front axle (1).
The power for the rear side is transmitted through rear drive shaft (9) to rear axle (14).
The powers transmitted to front axle (1) and rear axle (14) is reduced in speed by the pinions of
differentials (2) and (13), and then transmitted to the respective sun gear shafts through the differentials.
The power of each sun gear is further reduced in speed by final drives (4) and (11), and then transmitted
through the axle shafts to tires (10) and (22).
10-48
WA470-7

Drive shaft
Drive shaft
(WA470-D510-041-K-00-A)

2. Flange bearing
4. Rear drive shaft
Function
(WA380-D510-042-K-00-A)
The power from the transmission output shaft is transmitted through center drive shaft (3), front drive shaft
(1), and rear drive shaft (4) to the front and rear axles.
The relative positions of the transmission and front and rear axles change due to articulation of the
machine body, or impacts received from the road surface during traveling, or impacts during operations,
etc. The drive shafts absorb the fluctuation of their angle and length by the universal joints and flange
bearings (2) so that the power is transmitted even when the machine receives the above impacts and
when the positions of the components change.
WA470-7
10-49

Power train piping drawing
Power train piping drawing
(WA470-C150-041-K-00-A)
1. Power train pump

2. Hydraulic tank
4. Last chance filter
5. Transmission ECMV
6. Power train mount
7. Oil filler pipe
8. Oil filter
9. Transmission assembly
10-50
WA470-7

Transmission control
WA470-7
(WA470-CN20-041-K-00-A)
10-51

1. Machine monitor
2. Parking brake switch
3. Kickdown switch
4. Hold switch
5. Transmission cut-off and transmission cut-off set switch
6. Monitor controller
7. Transmission controller
8. Relay
9. Fuse box
10. Transmission cut oil pressure sensor
11. Brake valve
12. Directional lever and gear speed switch
14. Transmission output speed sensor
Function
No.
(WA380-CN20-042-K-00-A)
Function
Selection of FORWARD,
REVERSE or NEUTRAL
Selection of gear speed
Kickdown
Hold
10-52
Operation
The travel direction can be selected with the directional lever.
The gear speed can be selected with the gear speed switch.
The gear speed can be shifted down by pushing the kickdown switch
without operating the gear shift lever. In the manual shift mode, only the
forward 2nd is shifted down. In the automatic shift mode, the gear speed is
shifted down according to the gear speed and travel speed before the
switch is operated.
If the hold switch is pushed in the automatic shift mode, the current gear
speed is maintained and is not shifted up even if the travel speed
increases. Even if the travel speed decreases, the gear speed is not
shifted down.
WA470-7

When the transmission cut-off switch is turned "ON", the transmission is

set in neutral with the adjusted pressing distance of the L.H. brake pedal.
Transmission cut-off function is used to adjust the pressing distance of the
6 Transmission cut-off setting L.H. brake pedal to set the transmission in neutral.
The transmission cut-off function can be turned ON/OFF. While this
Transmission cut-off
function is turned "OFF", the L.H. brake pedal works as a normal brake
7
selection
pedal.
The transmission is kept in neutral while the parking brake is applied.
Seizure of the parking brake is prevented with this function when the
8 Neutralizer
operator starts the machine by mistake while the parking brake is applied.
Even if the starting switch is operated, the engine does not start, that is,
the machine does not start, while the directional lever is not in the "N
9 Neutral safety
(NEUTRAL)" position.
While the machine is traveling in reverse, the backup lamp and backup
10 Alarm
buzzer are turned on to give a warn around the machine.
5
WA470-7
10-53

Torque converter
Torque converter
(WA470-CD00-041-K-00-A)
1. Pilot
2. Flywheel
3. Lockup clutch housing
4. Boss
5. Turbine
6. Drive case
7. Stator
8. Pump
9. PTO gear
10. PTO drive gear (number of teeth: 97)
11. Stator shaft
12. Guide
13. Input shaft
10-54
WA470-7

Torque converter
14. Free wheel

15. Race
16. Lockup clutch disc
17. Lockup clutch piston
Specifications
Type
Stall torque ratio
WA470-7
(WA470-CD00-030-K-00-A)
3-element, 1-stage, 2-phase

2.14
10-55

Torque converter
Power transmitting route
(WA470-CD00-052-K-00-A)
When lockup clutch is "disengaged"
Drive case (3), boss (9) and turbine (8) are separated and the torque converter works as an ordinary torque
converter.
Power from engine
O
Flywheel (1)
O
Clutch housing (2)
O
Drive case (3), pump (5), and PTO drive gear (6) rotate as one unit
O
Oil is used as a medium
O
Turbine (8) and boss (9)
O
Transmission input shaft (10)
The power transmitted to PTO drive gear (6) is then transmitted through PTO gear (7) to drive the pump.
10-56
WA470-7

Torque converter
When lockup clutch is "engaged"
Drive case (3), boss (9), and turbine (8) are connected and the torque converter is locked up.
Power from engine
O
Flywheel (1)
O
Clutch housing (2)
O
Drive case (3), pump (5), and PTO drive gear (6) rotate as one unit
O
Lockup clutch (4)
O
Boss (9)
O
Transmission input shaft (10)
The power transmitted to PTO drive gear (6) is then transmitted through PTO gear (7) to drive the pump.
WA470-7
10-57

Torque converter
Oil flow
(WA470-CD00-044-K-00-A)
The oil flows through the main relief valve and its pressure is regulated to the set pressure or below by the
torque converter relief valve. It then flows in inlet port (A), goes through the oil passages of stator shaft (1)
and guide (2), and flows into pump (3).
The oil is given centrifugal force by pump (3) and flows in turbine (4) to transfer its energy to turbine (4).
The oil from turbine (4) is sent to stator (5) and flows into pump (3) again. However, a part of the oil flows
between turbine (4) and stator (5), and through outlet port (B) to the oil cooler to be cooled, and then
lubricates the transmission.
10-58
WA470-7

Transmission
Transmission
WA470-7
(WA470-CF00-041-K-00-A)
10-59

Transmission
A: From power train pump (for torque converter)

B: From torque converter oil cooler
C: Torque converter outlet oil pressure pickup port
D: To power train oil cooler
E: To power train pump
F: From power train pump (for lubricating oil)
1. Work equipment hydraulic pump and cooling fan pump mounting port
2. Steering and power train pump mounting port
3. Oil filler pipe mounting port
4. Front coupling
5. Torque converter
6. Transmission control valve (left valve assembly)
7. Transmission input speed sensor
8. Parking brake indicator switch
9. Rear coupling
10. Oil level gauge
11. Transmission oil filter
12. Transmission case (front)
13. Main relief valve and torque converter relief valve
14. Transmission case (rear)
15. Drain plug
17. Transmission lubricating oil temperature sensor
18. Breather
19. Torque converter outlet port oil temperature sensor
20. Transmission cntrol valve (right valve assembly)
21. Torque converter in let pressure sensor
22. Torque converter out let pressure sensor
10-60
WA470-7

Transmission
1. Input shaft
2. Torque converter
3. F clutch
4. R clutch
5. 4th clutch
6. Rear coupling
7. Output shaft
8. Output gear (number of teeth: 52)
9. Parking brake
10. Front coupling
11. Transfer gear 2
12. Lower shaft
13. Transfer shaft 2
14. 3rd clutch
15. middle shaft
WA470-7
10-61

Transmission
16. Transfer gear 1

17. 2nd clutch
18. Upper shaft
19. 1st clutch
1. PTO gear A(number of teeth: 85)

2. PTO gear B(number of teeth: 85)
3. Strainer
10-62
WA470-7

Transmission
F, 1st clutch
(WA470-CF82-041-K-00-A)
A: F clutch oil port

B: 1st clutch oil port
C: Lubricating oil port
1. Upper shaft
2. 1st clutch gear (number of teeth: 35)
3. 1st clutch
4. F and 1st cylinders
5. F clutch
6. F clutch gear (number of teeth: 51)
WA470-7
10-63

Transmission
R, 2nd clutch
(WA470-CFJ1-041-K-00-A)
A: R clutch oil port

B: 2nd clutch oil port
1. Middle shaft
2. Transfer shaft 1 (number of teeth: 64)
3. 2nd hub
4. 2nd clutch
5. R and 2nd cylinders (number of teeth: 50,62)
6. R clutch
7. R gear (number of teeth: 51)
10-64
WA470-7

Transmission
3rd, 4th clutch
(WA470-CFK1-041-K-00-A)
A: 3rd clutch oil port

B: 4th clutch oil port
1. Lower shaft
2. 3rd cylinder
3. 3rd clutch
4. 3rd gear (number of teeth: 48)
5. 4th gear (number of teeth: 36)
6. 4th clutch
7. 4th cylinder
Structure
(WA470-CF60-041-K-00-A)
The transmission employs the counter-shaft, constant mesh type gear mechanism and the disc clutches
and has "forward 4-speeds and reverse 4-speeds".
The transmission selects one rotating direction and one gear speed by fixing two of the six disc clutches
hydraulically by the operation of the ECMV in the counter-shaft type constant mesh gear mechanism.
The transmission transmits the power received by the transmission input shaft to the output shaft by
changing the gear speed (forward 1st to 4th or reverse 1st to 4th) with any combination of the forward or
reverse clutch, and one of four speed clutches.
Number of plates and discs used
Clutch name
F clutch
R clutch
1st clutch
2nd clutch
3rd clutch
4th clutch
Number of plates
15
15
13
13
10
13
Number of discs
14
14
12
12
9
12
Combinations of clutches for each gear speed and reduction ratios

Gear speed
Forward 1st
Forward 2nd
Forward 3rd
WA470-7
Clutches to be used
F x 1st
F x 2nd
F x 3rd
Reduction ratio
3.886
2.196
1.218
10-65

Transmission
Gear speed
Forward 4th
Neutral
Reverse 1st
Reverse 2nd
Reverse 3rd
Reverse 4th
10-66
Clutches to be used
F x 4th
R x 1st
R x 2nd
R x 3rd
R x 4th
Reduction ratio
0.737
3.760
2.125
1.179
0.713
WA470-7

Transmission
Disc clutch
Operation
(HM300-CF60-001-K-00-A)
(WA470-CF60-044-K-00-A)
When clutch is "engaged" (locked)
The oil sent from the ECMV is supplied with pressure through the oil passage of shaft (1) to the back of
piston (2), and pushes piston (2) to the right.
Piston (2) presses plates (3) against discs (4) to stop rotation of discs (4) with the friction force between
them.
As the internal teeth of discs (4) are meshed with clutch gear (5), shaft (1) and clutch gear (5) transmit the
power in one piece.
The oil is drained through oil drain hole (6), but it does not affect the operation of the clutch since its
quantity is far less than the quantity of the supplied oil.
When clutch is "disengaged" (released)
When the oil sent from the ECMV is shut off, the oil pressure applied to the back of piston (2) decreases.
Piston (2) is pushed back to the left by the reactive force of wave spring (7).
The friction force between plates (3) and discs (4) is lost and shaft (1) and clutch gear (5) are released.
When the clutch is disengaged, the oil on the back of the piston is drained by the centrifugal force through
oil drain hole (6) to prevent partial engagement of the clutch.
a Oil drain hole (6) is provided only in the 3rd and 4th clutches.
WA470-7
10-67

Transmission
Power transmitting route

Forward 1st
10-68
(HM300-CF60-001-K-01-A)
(WA470-CF60-044-K-01-A)
WA470-7

Transmission
F clutch (5) and 1st clutch (9) are fixed hydraulically.

Power from torque converter
O
Input shaft (1)
O
Input shaft gear (2)
O
F gear (3)
O
F clutch (5)
O
F/1st cylinder (7)
O
(to top center)o
WA470-7
o (from bottom left)

O
1st clutch (9)
O
1st clutch gear (10)
O
Transfer shaft 1 (13)
O
Transfer gear 1 (14)
O
O
(to top right) o
o (from bottom center)

O
Output gear (24)
O
Output shaft (25)
10-69

Transmission
Forward 2nd
10-70
(WA470-CF60-044-K-02-A)
WA470-7

Transmission
F clutch (5) and 2nd clutch (11) are fixed hydraulically.

O
Input shaft (1)
O
Input gear (2)
O
F gear (3)
O
F clutch (5)
O
F/1st cylinder (7)
O
R/2nd cylinder (8)
O
(to top center)o
WA470-7

O
2nd clutch (11)
O
2nd hub (12)
O
O
O
O
Output gear (24)
O
(to top right) o

O
Output shaft (25)
10-71

Transmission
Forward 3rd
10-72
(WA470-CF60-044-K-03-A)
WA470-7

Transmission
F clutch (5) and 3rd clutch (16) are fixed hydraulically.

O
Input shaft (1)
O
Input gear (2)
O
F gear (3)
O
F clutch (5)
O
F/1st cylinder (7)
O
R/2nd cylinder (8)
O
(to top right) o
O
3rd gear (15)
O
3rd clutch (16)
O
3rd cylinder (17)
O
Lower shaft (21)
O
O
O
(to top right) o
O
Output gear (24)
O
Output shaft (25)
WA470-7
10-73

Transmission
Forward 4th
10-74
(WA470-CF60-044-K-04-A)
WA470-7

Transmission
F clutch (5) and 4th clutch (19) are fixed hydraulically.

O
Input shaft (1)
O
Input gear (2)
O
F gear (3)
O
F clutch (5)
O
F/1st cylinder (7)
O
R/2nd cylinder (8)
O
(to top right) o
O
4th gear (18)
O
4th clutch (19)
O
4th cylinder (20)
O
Lower shaft (21)
O
O
O
(to top right) o
O
Output gear (24)
O
Output shaft (25)
WA470-7
10-75

Transmission
Reverse 1st
10-76
(WA470-CF60-044-K-05-A)
WA470-7

Transmission
R clutch (6) and 1st clutch (9) are fixed hydraulically.

O
Input shaft (1)
O
Input gear (2)
O
R gear (4)
O
R clutch (6)
(The output rotation is reversed by
transmitting the power of input gear
(2) without through the upper shaft)
O
(to top center)o
WA470-7

O
R/2nd cylinder (8)
O
F/1st cylinder (7)
O
1st clutch (9)
O
1st gear (10)
O
O
O
(to top right) o

O
O
Output gear (24)
O
Output shaft (25)
10-77

Transmission control valve
(WA470-CJA0-041-K-00-A)
Left valve assembly
A: R clutch oil pressure pickup port

B: 2nd clutch oil pressure pickup port
C: 3rd clutch oil pressure pickup port
D: From parking brake emergency release valve
E: To parking brake
F: Parking brake indicator switch mounting location
G: Parking brake oil pressure pickup port
H: Transmission lubricating oil pressure pickup port
1. R clutch ECMV
2. 2nd clutch ECMV
3. 3rd clutch ECMV
4. Parking brake solenoid valve
5. Last chance filter
10-78
WA470-7

Right valve assembly
A: Lockup clutch oil pressure pickup port

B: F clutch oil pressure pickup port
C: 1st clutch oil pressure pickup port
D: 4th clutch oil pressure pickup port
1. Lockup clutch ECMV
2. F clutch ECMV
3. 1st clutch ECMV
4. 4th clutch ECMV
WA470-7
10-79

Function
(WA470-CJA0-042-K-00-A)
The oil from the pump flows through the oil filter into the transmission control valve assembly and then is
divided into the main relief circuit and clutch actuation circuit.
The oil regulated its pressure by the main relief valve and flowed into the clutch operating circuit goes
through the last chance filter, then operates the clutch and parking brake. The oil relieved from the main
relief valve is supplied to the torque converter.
When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according to
the command current from the transmission controller to reduce the gear shifting shocks. The ECMV also
keeps the clutch pressure constant during travel.
If the F or R, and one of the 1st to 4th clutch ECMVs are selected, the regulated oil pressure is supplied to
the selected clutches and the desired gear speed is obtained.
The lockup ECMV is actuated when the machine travels in the 2nd, 3rd, or 4th gear speed and its travel
speed exceeds the travel speed set by the transmission controller.
This machine uses three types of the ECMVs, which have the following identifications and differences.
Stamp on name plate
(A)
Identification
color
(B)
Mark
(C)
Flow detection valve
L*******
Not installed
Q*******
Pink
Installed
K*******
L/U: Indicates lockup clutch ECMV.
Fill switch
(operating pressure:
MPa {kg/cm2})
Installed
(0.20 {2.0})
Installed
(0.24 {2.45})
Not installed
Not installed
Clutches to
be used
F, R, 1st,
2nd
3rd, 4th
L/U
Table of ECMV
operation
ECMV
Gear speed
F
F1
F2
F3
F4
1st
2nd
3rd
4th
L/U
Q
Q
Q
Q
Q
Q
R1
R2
R3
R4
Q
Q
Q
Q
Q
Q
L/U: Indicates lockup clutch ECMV.
10-80
WA470-7

Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV
(WA470-CJJ0-
041-K-00-A)
a ECMV: Abbreviation for Electronic Control Modulation Valve

a Do not disassemble this since it needs to be adjusted for maintaining the performance after reassembly.
A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
1. Fill switch connector
2. Proportional solenoid connector
3. Oil pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate
Function
(HM300-CJJ0-042-K-00-A)
The ECMV consists of a pressure control valve and a fill switch.

Pressure control valve
WA470-7
10-81

clutch ECMV
The proportional solenoid receives the current from the transmission controller, and this valve converts it
into oil pressure.
Fill switch
This switch detects that the clutch is filled with oil and has the following functions.
1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with
oil.
2. Keeps outputting the signals (fill signals) to the controller to notify that the oil pressure is applied while oil
pressure is applied to the clutch.
Range A: Before shifting gear (oil is drained)

Range B: Clutch is being filled
Range C: Pressure is being adjusted
Range D: Clutch is being filled (triggering period)
Point E: Filling is started
Point F: Filling is finished
a The logic is designed so that the controller does not recognize completion of filling even if the fill switch is
turned "ON" during the triggering period (Range D).
ECMV and proportional solenoid
Each ECMV is equipped with one proportional solenoid.
The proportional solenoid generates thrust shown below according to the command current from the
controller.
Oil pressure is generated as shown below by applying the thrust generated by the proportional solenoid to
the pressure control valve spool.
Accordingly, the thrust is changed by controlling the command current to operate the pressure control
valve and control the flow and pressure of the oil.
10-82
WA470-7

clutch ECMV
Proportional solenoid current - thrust characteristics
Proportional solenoid thrust - oil pressure characteristics
ECMV and fill switch

Each ECMV is equipped with one fill switch.
When the clutch is filled with oil, the fill switch is turned "ON" by the pressure of the clutch. This signal
allows the oil pressure to build up.
WA470-7
10-83

clutch ECMV
Operation of ECMV
(HM300-CJJ0-044-K-00-A)
ECMV is controlled by 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 for ECMV, clutch input pressure, and
fill switch output signal is shown below.

10-84
WA470-7

clutch ECMV
Before shifting gear [when oil is drained] (range A in chart)
While no current is flowing to the proportional solenoid (1), pressure control valve (3) drains the oil from
clutch port (A) through drain port (T).
Fill switch (5) is turned OFF at this time since the oil pressure is not applied to pressure sensing valve (4).
WA470-7
10-85

clutch ECMV
Filling phase (range B in chart)
When the current flows to proportional solenoid (1) while there is no oil in the clutch, the hydraulic force
balanced with the solenoid force is applied to chamber (B) to push pressure control valve (3) to the left. As
a result, pump port (P) is connected with clutch port (A) and the oil starts filling the clutch. When the clutch
is filled with the oil, oil pressure sensing valve (4) operates and fill switch (5) is turned "ON".
10-86
WA470-7

clutch ECMV
Pressure build-up (range C in chart)
When a current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current.
The pressure builds up until the thrust of the solenoid is balanced with the sum of the thrust generated by
the oil pressure in clutch port and the reaction force of pressure control valve spring (2).
WA470-7
10-87

3rd, 4th clutch ECMV
(WA470-CJJ0-041-K-01-A)
A: To clutch
P: From pump
T: Drain
DR: Drain
1. Fill switch connector
2. Proportional solenoid connector
3. Flow detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate
Function
(WA470-CJJ0-042-K-00-A)
The ECMV consists of a pressure control valve and a fill switch.

The proportional solenoid receives the current from the transmission controller, and this valve converts it
into oil pressure.
Fill switch
10-88
WA470-7

This switch detects that the clutch is filled with oil and has the functions explained later.
1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with
oil.
2. Keeps outputting the signals (fill signals) to the controller to notify that the oil pressure is applied while oil
pressure is applied to the clutch.

ECMV and proportional solenoid
Each ECMV is equipped with one proportional solenoid.
The proportional solenoid generates thrust shown below according to the command current from the
controller.
Oil pressure is generated as shown below by applying the thrust generated by the proportional solenoid to
the pressure control valve spool.
Accordingly, the thrust is changed by controlling the command current to operate the pressure control
valve and control the flow and pressure of the oil.
WA470-7
10-89

Proportional solenoid current thrust characteristics
Proportional solenoid thrust hydraulic pressure characteristics
ECMV and fill switch

Each ECMV is equipped with one fill switch.
When the clutch is filled with oil, the fill switch is turned "ON" by the pressure of the clutch. This signal
allows the oil pressure to build up.
Operation of ECMV
(WA470-CJJ0-044-K-00-A)
ECMV is controlled by the command current sent from the controller to the proportional solenoid and the
fill switch output signal.
The relation between the proportional solenoid command current for ECMV, clutch input pressure, and fill
switch output signal is shown below.
10-90
WA470-7


WA470-7
10-91

Before shifting gear [when oil is drained] (range A in chart)
Fill switch (5) is turned OFF at this time since the oil pressure is not applied to pressure sensing valve (4).
10-92
WA470-7

Filling phase (range B in chart)
When a current flows in proportional solenoid (1) while the clutch piston is not pressurized, the thrust of
the solenoid pushes ball (6) to the left to throttle the drain circuit.
Oil pressure balanced with the thrust of the solenoid is applied to chamber (B) to move pressure control
valve (3) to the left.
The oil flows into the clutch chamber through pump port (P) and orifice (a) of flow detection valve (4).
Differential pressure is generated between the upstream and downstream over orifice (a) of flow detection
valve (4), and then flow detection valve (4) moves to the left.
When the clutch chamber is filled with the oil and the oil does not flow from pump port (P) to clutch port (A)
any more, the differential pressure over orifice (a) of flow detection valve (4) is lost.
Flow detection valve (4) is pushed back to the right by the oil pressure generated by the area difference
between clutch port (A) side and drain port side of flow detection valve (4) to turn ON fill switch (5).
WA470-7
10-93

Pressure build-up (range C in chart)
When a current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current.
The pressure builds up until the thrust of the solenoid is balanced with the sum of the thrust generated by
the oil pressure in clutch port and the reaction force of pressure control valve spring (2).
10-94
WA470-7

Lockup clutch ECMV
Lockup clutch ECMV
(HM300-CDT8-041-K-00-A)

a Do not disassemble this ECMV since it needs to be adjusted for maintaining the performance after
assembly.
A: To clutch
P: From pump
T: Drain
Dr: Drain
1.
2.
3.
4.
5.
Proportional solenoid connector

Sleeve
Proportional solenoid
Name plate
Function
(WA470-CDT8-042-K-00-A)
This valve is used for adjusting the clutch oil pressure to the set pressure and selecting a clutch.
Since the modulation waveform is used for the pressure application characteristics to the clutch, the
lockup clutch is engaged smoothly and the gear shift shocks are reduced. In addition, generation of a
peak torque in the power train is prevented. As a result, the operator comfort improves and the power train
durability increases.
WA470-7
10-95

Lockup clutch ECMV
When torque converter drive mode changes to direct drive mode
When gear is shifted (traveling in direct drive mode)
10-96
WA470-7

Lockup clutch ECMV
Operation
(WA380-CDT8-044-K-00-A)
When clutch is "disengaged" (released)
WA470-7
10-97

Lockup clutch ECMV
When clutch is "engaged" (locked)
When the current flows to proportional solenoid (1), the hydraulic force balanced with the solenoid force is
applied to chamber (B) to push pressure control valve (3) to the left. As a result, pump port (P) is
connected to clutch port (A) and the oil starts filling the clutch.
When the clutch is filled with oil, the thrust of the solenoid is balanced with the sum of the thrust generated
by the oil pressure in clutch port and the reaction force of pressure control valve spring (2), thus the
pressure is adjusted.
10-98
WA470-7

Main relief and torque converter relief valve
(WA380-C156-041-K-00-A)
1. Body
2. Piston
3. Torque converter relief valve
4. Piston
5. Main relief valve
A: Drain (torque converter relief)
B: Drain
C: From pump
D: Drain
E: To torque converter
P1: Main relief oil pressure pickup port
P2: Torque converter relief oil pressure pickup port
Function
(WA470-CJ10-042-K-00-A)
Main relief valve

The main relief valve regulates the oil pressure in the transmission and parking brake oil circuits to the set
pressure.
Set pressure: 2.55 MPa {26.0 kg/cm2} (at engine rated speed)
Torque converter relief valve
The torque converter relief valve maintains the torque converter inlet pressure below the set pressure to
protect the torque converter from abnormally high pressure.
Set pressure: 0.91 MPa {9.31 kg/cm2} (cracking pressure)
WA470-7
10-99

Operation
(WA380-CJ10-044-K-00-A)
Operation of main relief valve
The oil from the hydraulic pump flows to port (C) through the filter. Then it flows to chamber (F) through
orifice (a) in main relief valve (1).
When the oil pressure in the circuit exceeds the set pressure, the oil in chamber (F) pushes piston (2) and
the reaction force pushes main relief valve (1) leftward. This connects ports (C) and (E).
Then, the oil from the pump flows through port (E) into the torque converter.
Operation of torque converter relief valve
The oil relieved through the main relief valve flows through port (E) into the torque converter. It also flows
through orifice (b) in torque converter relief valve (3) into chamber (G).
When the oil pressure to the torque converter exceeds the set pressure, the oil in chamber (G) pushes
piston (4) and the reaction force of the piston pushes torque converter relief valve (3) rightward to connect
ports (E) and (A).
Then, the oil in port (E) is drained through port (A).
10-100
WA470-7

Axle
Axle
(HM300-DA00-001-K-00-A)
Front axle
(WA470-DA20-041-K-00-A)
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
6. Coupling
7. Oil filler pipe and level plug
8. Brake oil port
9. breather
10. Brake wear gauge
11. Drain plug
12. Air bleeder
WA470-7
10-101

Axle
Rear axle
(WA470-DAC0-041-K-00-A)
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
6. Coupling
7. Oil filler port/ level plug
8. Brake oil port
9. breather
10. Brake wear gauge
11. Drain plug
12. Air bleeder
10-102
WA470-7

Differential
Differential
(HM300-DC10-001-K-00-A)
Front conventional differential
(WA470-DC70-041-K-00-A)
1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear
WA470-7
10-103

Differential
Rear conventional differential
(WA470-DCD0-041-K-00-A)
1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear
10-104
WA470-7

Differential
Operation
(WA380-DC10-044-K-00-A)
The power from the engine is transmitted to the front and rear axles through the torque converter,
transmission, and drive shafts.
The power to be transmitted is changed in direction 90 degrees and in transmitting speed by bevel pinion
(1) and bevel gear (5) in the axle housing, and then transmitted to sun gear shaft (2) through pinion (4).
The power of the sun gear is further reduced in transmitting speed by the planetary gear type final drives,
and then transmitted to the axle shaft and wheels.
When machine is traveling straight
When the machine is traveling straight, the right and left wheels rotate at the same speed. Accordingly,
pinions (4) in the differential assembly do not rotate and the power of carrier (6) is transmitted through
pinions (4) and side gears (3) to the right and left sun gear shafts (2) evenly.
WA470-7
10-105

Differential
When machine is turning
When the machine is turning, the right and left wheels rotate at different speeds. Accordingly, pinions (4)
and side gears (3) in the differential rotate and transmit the power of carrier (6) to right and left sun gear
shafts (2), depending on the difference in rotation speed between the right and left wheels.
10-106
WA470-7

Differential
Front limited slip differential
(WA470-DCH3-041-K-00-A)
(if equipped)
1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear
WA470-7
10-107

Differential
Rear limited slip differential
(WA470-DCH4-041-K-00-A)
(if equipped)
1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear
10-108
WA470-7

Differential
Operation
(WA470-DCH2-042-K-00-A)
1. Washer
2. Disc
3. Plate
4. Pressure ring
5. Cover
6. Side gear
7. Shaft
8. Pinion
9. Bevel gear
10. Case
The power from the transmission is transmitted through bevel gear (9) to case (10), pressure ring (4), shaft (7),
pinion (8), and side gears (6), and then distributed to the right and left shafts. On the back of each side gear
(6), the brake mechanism consisting of discs (2) and plates (3) is installed. It generates braking torque in
proportion to the torque transmitted from pressure rings (4) to shaft (7).
Since the braking torque restricts the rotation of side gears (6) and case (10), side gears (6) on the right and
left sides do not rotate freely and the operation of the differential is restricted.
WA470-7
10-109

Differential
<Mechanism of generating braking torque to right and left side gears (6)>
Shaft (7) is supported on the cam surfaces made on the surfaces of pressure rings (4) that are facing each
other. The power (= torque) from pressure rings (4) is transmitted to shaft (7) through the cam surfaces. Force
Fa to separate right and left pressure rings (4) is generated by inclination of the cam surfaces in proportion to
the transmitted torque.
This separating force (Fa) acts on the brakes on the back of right and left side gears (6) to generate braking
torque.
<When machine is traveling straight>
When the driving forces of the right and left wheels are balanced
[When road conditions (friction coefficient) under the right and left wheels and the loads on wheels are even
and the center of load on the bucket is not shifted]
The power from the transmission is distributed evenly by the differential gear to the right and left. Since the
tire slip limits on the right and left sides are the same under this condition, both tires slip and the differential
does not operate even if the power from the transmission exceeds the tire slip limit.
No load is applied to the brake on the back of each side gear.
10-110
WA470-7

Differential
When the driving forces of the right and left wheels are unbalanced
[When the road conditions (friction coefficient) under the right and left wheels and the loads on wheels are
uneven and either of the wheels slips more easily than the other]
Example 1. Either wheel is on soft ground during digging work
Example 2. Either wheel is on snow and the other is on asphalt during snow plowing work
Example 3. The loads on the right and left wheels are unbalanced during travel on a slope
The power from the transmission is distributed evenly by the differential gear to the right and left. If the driving
force exceeds the tire slip limit on the more slippery side, the excessive driving force is transmitted to the
brake on the opposite side (locked side) and given to the tire on the locked side through the brake on the back
of the side gear and the case.
Only when this excessive driving force exceeds the braking force, the differential operates.
Difference of wheel driving force by type of differential when either wheel slips
Limited Slip Differential

Conventional differential
Wheel driving force (slipping wheel is set as 1)

Slipping wheel
Total (ratio)
Locked wheel
3.64 (1.82)
1
2.64
1
2 (1)
On a road surface where either wheel slips easily, the Limited Slip Differential increases the driving force by
1.82 times compared to the conventional differential.
WA470-7
10-111

Differential
Since the differential gear in the Limited Slip Differential is the same as the one used in the conventional
differential, it can smoothly generate the rotational difference between the inside and outside wheels that is
caused by turning.
10-112
WA470-7

Final drive
Final drive
(WA470-DF10-041-K-00-A)
a The figure shows the front axle.
1. Planetary gear
2. Planetary carrier
3. Axle shaft
4. Ring gear
5. Sun gear shaft
WA470-7
10-113

Final drive
Operation
(WA380-DF10-044-K-00-A)
The final drive finally reduces the speed to transmit the power from the engine and increases in drive
power.
Ring gear (4) is press-fitted to the axle housing and fixed with the pin.
The power transmitted from the differential through sun gear shaft (5) is reduced in speed and increased
in drive power by the planetary gear mechanism.
The increased drive power is transmitted through planetary carrier (2) and axle shaft (3) to the wheels.
10-114
WA470-7

Layout of steering parts
Steering system
(ALL-F000-001-K-00-A)
Layout of steering parts
(WA470-DT00-04D-K-00-A)
1. Steering cylinder (R.H.)

2. Steering valve
3. Orbitrol valve
4. Stop valve (R.H.)
5. Steering pump
6. Hydraulic tank
7. Emergency steering motor (if equipped)
8. Emergency steering pump (if equipped)
9. Stop valve (L.H.)
10. Steering cylinder (L.H.)
WA470-7
10-115

Steering column
Steering column
(WA380-F171-041-K-00-A)
1. Steering wheel
2. Steering column
3. Steering tilt lock lever
4. Short column
5. Orbit-roll valve
10-116
WA470-7

Steering pump
Steering pump
(WA470-F220-041-K-00-A)
P1: Pump discharge port

PD: Drain port
P1L: Pump pressure input port
PD2: Drain plug
PEN: Control pressure pickup plug
PLS: Load pressure input port
POP: External pilot pressure input port
WA470-7
10-117

Steering pump
PEPC: EPC source pressure input port

1. Pump body
2. Servo valve
3. Air bleeder
Pump body
PA: Control source pressure output port

PD4: Drain port
PD5: Drain port
PE: Control pressure input port
10-118
WA470-7

Steering pump
1. Bearing
2. Shaft
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
WA470-7
10-119

Steering pump
10. Shoe retainer

11. Servo piston
12. Spring
13. Oil seal
14. Ball retainer
Structure
Cylinder block (6) is supported by spline (a) on shaft (1).
Shaft (1) is supported by each bearing at the front and rear.
The tip of piston (5) shapes a spherical concave and integrates with shoe (4) by gripping it.
Rocker cam (3) is supported by case (2) and ball retainer (9) and has flat surface (A), and shoe (4) is
always pressed against this surface while sliding in a circular pattern.
Shoe (4) leads high-pressure oil to form a static pressure bearing for its sliding.
Cylinder block (6) rotates relatively to valve plate (7) while sealing the pressurized oil.
This plane is designed so that the oil pressure is balanced correctly.
The pressurized oil can be sucked in and discharged from each cylinder chamber in cylinder block (6)
through valve plate (7).
Specifications
(WA470-F220-030-K-00-A)
Model
Type
Theoretical delivery (cm3/rev)
Rated delivery pressure: (MPa {kg/
cm2})
Rated speed (rpm)
Function
LPV90
90
24.5 {250}
2,280
(WA380-F220-042-K-00-A)
The engine rotation and torque transmitted to the pump shaft is converted into the hydraulic energy and
the pressurized oil corresponding to the load is discharged.
10-120
WA470-7

Steering pump
It is possible to change the delivery by changing the swash plate angle.
Operation
(WA470-F220-044-K-00-A)
Operation of pump
Rocker cam (3) pivots on ball retainer (9), and accordingly angle (a) between center line (X) of rocker cam
(3) and the axis of cylinder block (6) changes.
Piston (5) reciprocates inside cylinder block (6) and a difference is made between volumes (E) and (F) of
the cylinder chamber in cylinder block (6).
Oil in amount of (F) minus (E) is sucked in and discharged from piston (5).
In the figure, chamber (F) is at the end of the suction stroke and chamber (E) is at the end of the discharge
stroke.
WA470-7
10-121

Steering pump
Suction and discharge of pressurized oil is not performed in this stage. Namely pumping action is not
performed. (Actually, however, a zero swash plate angle never occurs.)
The pump delivery is in proportion to swash plate angle (a).
Control of delivery
When swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, then
delivery (Q) is increased.
Servo piston (11) reciprocates linearly according to the signal pressure from the PC valve and LS valve.
This linear motion is transmitted to rocker cam (3).
Being supported by ball retainer (9) on case (2), rocker cam (3) slides in the direction of rotary movement.
10-122
WA470-7

Steering pump
Servo valve
(WA380-F2J0-041-K-00-A)
P1: Pump delivery pressure port

PE: Control pressure output port
T: Drain port
WA470-7
10-123

Steering pump
PC valve
T: Drain
PA: Pump pressure input
PPL: PC valve output pressure
PM: PC mode selector pressure
1. Lever
2. Spring
3. Retainer
4. Seat
5. Spool
6. Sleeve
7. Piston
8. Seal
9. Piston
LS valve
10-124
WA470-7

Steering pump
PA: Pump pressure input

PE: Control piston pressure
PLS: LS pressure input
PPL: PC valve output pressure
PPLS: LS pump pressure input
10. Nut
11. Plate
12. Plug
13. Spring
14. Seat
15. Spool
16. Plug
LS valve
(WA380-F2R0-001-K-00-A)
Function (WA380-F2R0-042-K-00-A)
The LS valve controls the pump delivery according to the travel of the control lever, or the flow demanded
by the actuator.
The LS valve detects the flow rate demanded by the actuator from differential pressure (dPLS) between
inlet pressure (PPLS) and outlet pressure (PLS) of the control valve and controls pump delivery (Q) of the
main pump. [(PPLS) is called the LS pump pressure, (PLS) the LS pressure, and (dPLS) the LS
differential pressure.]
In other words, pressure loss [= LS differential pressure (dPLS)], which occurs when oil flows through the
passage in control valve spool, is detected, and pump delivery (Q) is controlled to maintain the pressure
loss at a constant level. Through this operation, pump can deliver the proper volume of oil as demanded
by the actuator.
Main pump delivery pressure (PP), LS pump pressure (PPLS) and LS pressure (PLS) are transmitted into
the LS valve. Pump delivery (Q) changes as shown in the following figure according to the LS differential
pressure (dPLS).
WA470-7
10-125

Steering pump
PC valve
(WA380-F2S0-001-K-00-A)
Function (WA380-F2S0-042-K-00-A)
The PC valve limits the oil flow to a certain level (depending on the delivery pressure) even if the travel of
the control valve is increased extremely so that the horsepower absorbed by the pump does not exceed
the engine horsepower, when pump delivery pressure (PA) is high.
In other words, the PC valve decreases the pump delivery when the actuator load is increased and the
pump delivery pressure rises, and increases it when the pump delivery pressure lowers.
If command current (X) sent to EPC valve increases further, the relationship between pump pressure (PP)
and pump delivery (Q) is shifted parallel in proportion to the thrust of EPC valve solenoid.
That is, since the thrust of the EPC valve solenoid is added to the left-hand thrust caused by the pump
pressure applied to spool (6), the relationship between pump pressure (PA) and (Q) is shifted from [1] to
[2] as (X) increases.
Operation
(WA380-F2S0-044-K-00-A)
Action of spring
The spring force of spring (3) in the PC valve is determined by the angle of the swash plate.
When servo piston (9) moves to the right, spring (3) is compressed through lever (2) and the spring force
changes.
When pump pressure (PA) is low
The pressing force of piston (10) is decreased and spool (6) is a little closer to the right (Fig. 1). At this time,
port (C) is connected to port (D) and the pressure transmitted to the LS valve becomes drain pressure
(PT).
When port (F) is connected to port (G) of the LS valve, the pressure in port (J) becomes drain pressure
(PT) and servo piston (9) moves to the left.
Consequently, the pump delivery is increased.
As servo piston (9) moves, lever (2) moves to the left and spring (3) expands and the spring force is
decreased. Consequently, spool (6) moves to the left and port (C) is disconnected from port (D) and
connected to pump discharge port (B).
As a result, the pressure in port (C) rises and the piston pressure is increased and servo piston (9) stops
moving to the left.
When pump pressure (PA) is high
The pressing force of piston (10) is increased and spool (6) is a little closer to the left (Fig. 2). At this time,
port (C) is connected to port (B) and the pressure transmitted to the LS valve becomes pump pressure
(PA).
When port (F) is connected to port (G) of the LS valve, the pressure in port (J) becomes pump pressure
(PA) and servo piston (9) moves to the right.
Consequently, the pump delivery is decreased.
As servo piston (9) moves, lever (2) moves to the right and spring (3) is compressed and spring force is
increased. Consequently, spool (6) moves to the right and port (C) is disconnected from port (B) and
connected to drain pressure port (D).
As a result, the pressure in port (C) lowers and the piston pressure is decreased and servo piston (9)
stops moving to the right.
10-126
WA470-7

Steering pump
Accordingly, the stop position (= pump delivery) of servo piston (9) is determined by the position where the
thrust caused by pressure (PA) applied to piston (10) is balanced with the spring force of spring (3) acting
through spool (6). (Fig. 3)
When PC mode selector pressure increases or decreases
PC-EPC changes output pressure (PM) according to the input current from the controller to change the
pressing force of piston (8). As a result, the PC valve moves similarly to when (PA) increases or
decreases.
When load is light
(Fig. 1)
When load is heavy

(Fig. 2)
WA470-7
10-127

Steering pump
When servo valve is balanced

(Fig. 3)
10-128
WA470-7

Steering valve
Steering valve
(WA380-F570-041-K-00-A)
P: From steering pump

Pr: To steering pump port P1L
Pa: From stop valve (left)
Pb: From stop valve (right)
A: To steering cylinder
B: To steering cylinder
T1: Drain
T2: Drain
WA470-7
10-129

Steering valve
1. Relief valve
2. Flow control spool
3. Steering relief valve
4. Steering spool
5. Overload relief valve
10-130
WA470-7

Steering valve
Operation
(WA380-F570-044-K-00-A)
Operation of flow amplifier

When spool is in neutral (When orbit-roll valve is not operating)
Since ports (Pa) and (Pb) are connected to the drain circuit through the orbit-roll valve, steering spool (1)
is held in the neutral position by right and left return springs (2).
When spool operates (When oil flows in port (Pa))
The pressure in port (Pa) increases and steering spool (1) compresses left return spring (2) and moves to
the left.
The oil in port (Pa) flows through the hole of spring seat (3) and orifice (a) of steering spool (1) to port (Pb).
Since port (Pb) is connected to the drain circuit through the orbit-roll valve, the oil in port (Pb) is drained.
Since the pressure generated in port (Pa) is in proportion to the oil flow, steering spool (1) moves to a
position in which the oil pressure reduced by orifice (a) is balanced with the reaction force of return spring
(2).
When spool returns (When steering wheel operation is stopped)
WA470-7
10-131

Steering valve
Since ports (Pa) and (Pb) are connected to the drain circuit through the orbit-roll valve, steering spool (1)
is returned to the neutral position by left return springs (2).
Operation of flow control spool
When steering spool is in neutral
The oil from the steering pump flows in port (P).

Since notch (e) is closed, the oil pressure in port (P) increases and flows through orifice (a) to pressure
receiving chamber (X), and moves flow control spool (1) to the left.
The oil in pressure receiving chamber (Y) is drained through orifice (b), notch (f) and port (T1).
If the oil pressure in pressure receiving chamber (X) exceeds the set pressure, flow control spool (1)
moves to the left, and notch (c) opens.
The oil in port (P) flows through notch (c) and port (Pr) to the LS valve of the steering pump. Port (Pr) is
connected to port (T2) through orifice (j).
The oil pressure in port (Pr) becomes the middle between the pump pressure and the drain pressure of
port (T2) by the passing resistance through notch (c) and orifice (j).
When the oil pressure in port (Pr) exceeds the set pressure, the swash plate angle of the steering pump is
decreased to reduce the delivery.
If the oil pressure in port (P) increases further even after the pump delivery becomes the minimum, flow
control spool (1) moves to the left further.
When the oil pressure in pressure receiving chamber (X) exceeds the set pressure, notch (d) opens and
the oil in port (P) is drained through notch (d) and port (T1).
10-132
WA470-7

Steering valve
When steering spool operates
When steering spool (2) operates, notch (f) closes to disconnect pressure receiving chamber (Y) and port
(T1), and notch (e) opens.
The oil pressure in pressure receiving chamber (Y) increases, flow control spool (1) moves to the right,
and the open area of notch (d) decreases.
The oil before passing through notch (e) is led to pressure receiving chamber (X) and the oil after passing
through notch (e) is led to pressure receiving chamber (Y).
When the oil pressure in pressure receiving chamber (Y) exceeds that in port (A), the oil flowing in through
orifice (h) pushes load check valve (3) open to the left.
Since the oil from notch (e) flows through port (A) to the steering cylinder, pressure difference is made
before and after notch (e).
Since flow control spool (1) operates to maintain the differential pressure generated over notch (e) to the
set pressure, oil is delivered to the steering cylinder according to the open area of notch (e).
The excessive oil from the steering pump is drained through orifice (d) and port (T1).
The return oil from the steering cylinder is drained through orifice (g) and port (T1).
Even if flow control spool (1) moves to the right until notch (d) is closed, it moves further to the right if the
pressure before notch (e) is below the set pressure.
Since the open area of notch (c) is narrowed and the oil flow to port (Pr) is reduced, the oil pressure in port
(Pr) decreases.
When the oil pressure in port (Pr) decreases, the LS valve of the steering pump increases its delivery to
maintain the oil pressure in port (Pr) at the set pressure.
Flow control spool (1) is held in a position where the pressure in port (P) is balanced with the pressure in
port (Pr), and the pump delivery is kept constant.
WA470-7
10-133

Steering valve
If the open area of notch (e) changes, the steering pump delivers oil according to the open area of notch
(e) to keep the oil pressure in port (Pr) constant.
Operation of steering valve
When in neutral
Since the steering wheel is not operated, steering spool (1) does not move.
The oil from the steering pump flows in port (P).
When the oil pressure in port (P) increases, flow control spool (2) moves to the left to drain the oil from the
steering pump through notch (a) and port (T1).
10-134
WA470-7

Steering valve
When machine turns to left
When the steering wheel is turned to the left, the output pressure from the orbit-roll valve enters port (Pa)
and steering spool (1) is pushed to the right.
The oil from the steering pump enters port (P) and flows through flow control spool (2) to steering spool
(1).
Load check valve (3) is pushed open to the left and the oil flows to the head side of the left steering
cylinder and to the bottom side of the right steering cylinder to turn the machine to the left.
The return oil from the right and left steering cylinders is drained through load check valve (4) and port
(T1).
WA470-7
10-135

Steering valve
When machine turns to right
When the steering wheel is turned to the right, the output pressure from the orbit-roll valve enters port (Pb)
and steering spool (1) is pushed to the left.
The oil from the steering pump enters port (P) and flows through flow control spool (2) to steering spool
(1).
Load check valve (4) is pushed open to the right and the oil flows to the head side of the right steering
cylinder and to the bottom side of the left steering cylinder to turn the machine to the right.
The return oil from the right and left steering cylinders is drained through load check valve (3) and port
(T1).
10-136
WA470-7

Steering valve
Steering relief valve
(WA380-F590-041-K-00-A)
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
(WA380-F590-042-K-00-A)
The steering relief valve is installed to the steering valve and maintains the oil pressure in the steering
circuit at the set pressure during steering operation.
WA470-7
10-137

Steering valve
Operation
(WA380-F590-044-K-00-A)
If the oil pressure in the steering circuit increases to the pressure set with adjustment screw (1) and spring
(2), pilot poppet (3) opens to drain the oil through port (T1).
Pressure receiving chambers (X) and (Y) are unbalanced in pressure and flow control spool (4) moves to
the left.
Flow control spool (4) operates to drain the oil from the steering pump and maintain the steering circuit
pressure below the set value.
10-138
WA470-7

Steering valve
Overload relief valve
(WA380-F5B0-041-K-00-A)
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
Function
(WA380-F5B0-042-K-00-A)
The overload relief valve is installed to the steering valve and protects the cylinder circuit from abnormally
high pressure generated by impacts applied to the cylinder for some reason while the steering valve is in
neutral.
If abnormally high pressure is generated on the cylinder side, this valve works as a safety valve to prevent
breakage of the cylinder and hydraulic piping.
If negative pressure is generated on the cylinder side, this valve works as a suction valve to prevent a
vacuum in the circuit.
WA470-7
10-139

Steering valve
Operation
(WA380-F5B0-044-K-00-A)
Operation as relief valve
Port (A) is connected to the cylinder circuit and port (B) is connected to the drain circuit.
The oil flows through the hole of poppet (1) to the inside of relief valve poppet (2).
Check valve poppet (3) and relief valve poppet (2) are securely seated because of the area difference
between diameters (d1) and (d2).
If the oil pressure in port (A) exceeds the set pressure of the relief valve, pilot poppet (4) is moved open to
the right.
The oil flows through pilot poppet (4) and drill hole to port (B).
Since pilot poppet (4) opens, the oil pressure inside poppet (1) lowers.
Poppet (1) moves to the right to seat pilot poppet (4).
10-140
WA470-7

Steering valve
The oil pressure inside relief valve poppet (2) is lower than the oil pressure in port (A).
Since the oil pushes open relief valve poppet (2) to the right and flows from port (A) to port (B), the circuit
is protected from abnormally high pressure.
Operation as suction valve
If negative pressure is generated in port (A), it acts on the area difference between diameters (d3) and
(d4) and pushes check valve poppet (3) to the right.
The oil flows from port (B) to port (A) to prevent a vacuum.
WA470-7
10-141

Steering valve
Relief valve
(WA380-F530-041-K-00-A)
1. Plug
2. Spring
3. Valve
4. Valve seat
Function
(WA380-F530-042-K-00-A)
The relief valve is installed to the steering valve and relieves the oil when the oil pressure in port (Pr)
exceeds the set pressure to protect the LS circuit of the steering pump from abnormally high pressure.
10-142
WA470-7

Orbit-roll valve
Orbit-roll valve
(WA380-F550-041-K-00-A)
P: From charge valve

T: Drain
L: To left stop valve
R: To right stop valve
1. Gerotor
2. Valve body
3. Drive shaft
4. Centering spring
5. Needle bearing
6. Bushing
7. Center pin
8. Sleeve
9. Spool
WA470-7
10-143

Orbit-roll valve
10. Spacer
11. End cap
Outline
The orbit-roll valve is connected directly to the drive shaft of the steering column, and sends the oil from
the steering pump to the right or left steering cylinder to change the travel direction of the machine.
The orbit-roll valve roughly consists of two sections; One is the section of spool (9) and sleeve (8) which
has rotary-type direction selection function, and the other is gerotor (5) (combination of rotor (5a) and
stator (5b)) which works as a hydraulic motor during the normal steering operation but works as a hand
pump when no oil is supplied because of a steering pump failure or an engine failure (however, it cannot
be operated actually since its operating effort is too high).
10-144
WA470-7

Orbit-roll valve
Structure
Top (A) of spool (9) is connected to the drive shaft of the steering column and further connected to sleeve
(8) by center pin (7) (which does not touch spool (9) when the steering wheel is in "neutral") and centering
spring (2).
Drive shaft (3) is meshed at top (B) with center pin (7) and forms one unit with sleeve (8). Its bottom is
meshed with the spline of rotor (5a) of gerotor (5).
Valve body (4) has four ports, which are connected respectively to the pump circuit, tank circuit, left
steering circuit, and right steering circuit. The ports on the pump and tank are connected through the
check valve inside the body. If the pump or the engine is failed, the oil can be sucked in directly from the
tank through this check valve.
WA470-7
10-145

Orbit-roll valve
Connection of hand pump and sleeve
The above figure shows the connections of suction and discharge ports (P) of the gerotor and the sleeve
ports.
When the steering wheel is turned to the right, ports (a), (c), (e), (g), (i) and (k) are connected by the
vertical grooves in the spool to the pump. At the same time, ports (b), (d), (f), (h), (j) and (l) are connected
to the head side of the right steering cylinder in the same way.
In the condition shown in Fig. 1, ports (1), (2) and (3) are the discharge ports of the gerotor and connected
to ports (l), (b) and (d) to send the oil to the steering cylinder.
Ports (5), (6) and (7) are also connected to each other and the oil flows in from the pump.
Fig. 2 shows the condition after the steering wheel is turned 90 from the above condition. Under this state,
ports (2), (3) and (4) are in the suction condition and connected to ports (k), (a) and (c). Ports (5), (6) and
(7) are in the discharge condition and connected to ports (d), (f) and (h).
In this way, the ports of the gerotor in the discharge condition are connected to the ports connected to the
steering cylinder. The ports in the suction condition are connected to the pump circuit.
For every 1/7 turn of the steering wheel, the inner teeth of the gerotor gear advance one position to deliver
oil from the pump by the quantity for this operation.
Accordingly, the quantity of the oil delivered from the pump is directly proportional to the turning angle of
the steering wheel.
10-146
WA470-7

Orbit-roll valve
Role of centering spring
Centering spring (2) is composed of layers of two flat leaf springs and four X-shaped leaf springs and
installed between spool (9) and sleeve (8) as shown in the figure.
WA470-7
10-147

Orbit-roll valve
When the steering wheel is turned, spool (9) compresses the centering spring and angular displacement
(a) is generated between spool (9) and sleeve (8).
As a result, the ports in spool (9) and sleeve (8) are connected and the oil is sent to the steering cylinder.
When the steering wheel is stopped turning, the gerotor also stops turning, and accordingly no more oil is
sent to the steering cylinder and the oil pressure rises.
To prevent this, when the steering wheel is stopped turning, centering spring (2) rotates spool (9) by the
turning angular displacement (a) from sleeve (8) to return the steering wheel to the neutral condition.
10-148
WA470-7

Stop valve
Stop valve
(WA380-F5U0-041-K-00-A)
A: From orbit-roll valve

B: To steering valve
DR: Drain
1. Boot
2. Wiper
3. Seal
4. Poppet
5. Spring
6. Spool
7. Spring
WA470-7
10-149

(WA380-F9R0-041-K-00-A)
(if equipped)
1. Terminal E
2. Terminal M
Function
(WA380-F9R0-042-K-00-A)
The emergency steering motor drives the emergency steering pump according to the signals from the
transmission controller when the steering circuit pressure decreases abnormally.
Specification
Name
Rated voltage (V)
Rated output (KW)
10-150
(WA380-F9R0-030-K-00-A)
DC motor
24
0.9
WA470-7

(WA380-F940-041-K-00-A)
(if equipped)
Specification
(WA380-F940-030-K-00-A)
Model
Rotating speed (rpm)
Delivery pressure (MPa {kg/cm2})
Standard delivery (l/min)
Allowable delivery (l/min)
Function
SBL (1) 21
3,500
20.6 {210}
67.6
62.4
(WA380-F940-042-K-00-A)
The emergency steering pump is installed together with the emergency steering motor to the right side of
the transmission. It supplies oil to the steering circuit if the engine stops or the steering circuit pressure
decreases below the specified value.
WA470-7
10-151

Layout of brake parts
Brake system
(ALL-G000-001-K-00-A)
(WA470-G000-04D-K-00-A)
1. Slack adjuster (front)

2. Cooling fan and brake pump
3. Hydraulic tank
4. Rear brake
5. Slack adjuster (rear)
6. Parking brake
7. Front brake
8. Transmission cut-off oil pressure sensor
9. Brake valve
10. Stop lamp oil pressure switch
11. Brake pedal
12. Brake accumulator (for front)
10-152
WA470-7


14. Brake accumulator (for rear)
15. Parking brake emergency release valve
16. Rear brake oil pressure switch
17. Front brake oil pressure switch
19. Parking brake oil pressure switch
WA470-7
10-153

Charge valve
Charge valve
(WA470-G2H0-041-K-00-A)
P: From pump
A: To cooling fan motor
PPC: To Orbitrol valve or work equipment valve or EPC valve of each pump
ACC1: To brake valve port PA
ACC2: To brake valve port PB
T: Drain
G: Accumulator charge pressure pickup port
10-154
WA470-7

Charge valve
1. Valve body
2. Sequence valve (H1)
3. Relief valve (R2)
4. Shuttle valve (S1)
5. Priority valve
6. PPC relief valve (R3)
7. Main relief valve (R1)
Function
(WA380-G2H0-042-K-00-A)
The charge valve maintains the oil pressure from the pump at the set pressure and saves the pressure in
the accumulator.
When the pressure is saved in the accumulator, the circuit to the cooling fan motor opens to output the
pressurized oil from the pump to drive the cooling fan motor.
When the oil pressure rises above the specified pressure, the oil from the pump is led to the drain circuit to
reduce the load on the pump.
The charge valve reduces the oil from the pump in pressure and outputs the source pressure for the pilot
circuit.
WA470-7
10-155

Charge valve
Operation
(WA380-G2H0-044-K-00-A)
When oil is not supplied to accumulator (cut-out condition)
Since the pressure in oil passage (B) is higher than the set pressure of relief valve (1), piston (2) is pushed
forcibly to the right by the pressurized oil from oil passage (B).
Relief valve (1) opens, and oil passage (C) and port (T) are interconnected.
The pressurized oil from the pump flows through orifices (a) and (b) and oil passage (C) to port (T).
Since the pressure drops when it passes orifice (a), pressure difference is generated between pressure
receiving chambers (D) and (E).
When the pressure in pressure receiving chamber (D) exceeds the set pressure of priority valve (5),
priority valve (5) compresses spring (6) and moves to the right.
The open areas of port (P) and orifice (c) are narrowed and port (P) starts to be interconnected to port (A).
The pressurized oil from the pump flows through port (P), sequence valve (7), and port (A) to the cooling
fan motor.
When oil is supplied to accumulator (Cut-in condition)
When the pressure in oil passage (B) decreases below the set pressure of relief valve (1), relief valve (1)
is returned to the left by the reaction forces of springs (3) and (4).
10-156
WA470-7

Charge valve
Relief valve (1) closes, and oil passage (C) and port (T) are disconnected.
Since oil passage (C) and port (T) are disconnected, the pressure drops less when it passes orifice (a)
and the pressure difference between pressure receiving chambers (D) and (E) decreases.
Priority valve (5) is moved to the left by the reaction force of spring (6).
The open areas of port (P) and orifice (c) are increased and port (P) starts to be disconnected from port
(A).
When the oil pressure from the pump exceeds the pressure of ports (ACC1) and (ACC2), it pushes up
check valve (8) and pressure starts being saved in the accumulator through ports (ACC1) and (ACC2).
A certain quantity of oil decided by the size (area) of orifice (c) and the pressure difference over orifice (c)
(equivalent to force of spring (6)) is supplied through ports (ACC1) and (ACC2) to the accumulator. The
excess oil flows to ports (A) and (PPC).
When pressure reaches cut-off pressure
When the pressure in oil passage (C) reaches the set pressure of relief valve (1), relief valve (1) is pushed
to the right by the oil pressure from oil passage (C).
Relief valve (1) opens, and oil passage (C) and port (T) are interconnected.
Pressure difference is generated between the right and left sides of piston (2), and then piston (2) moves
to the right to open relief valve (1) forcibly.
Since pressure receiving chamber (E) of priority valve (5) is also connected to oil passage (C), the
pressure in pressure receiving chamber (E) becomes the drain pressure.
Since the pressure in pressure receiving chamber (D) decreases to the level for the force of spring (6), oil
supply to oil passage (B) stops.
Main relief valve (R1)
When the pressure in port (P) (pump pressure) exceeds the set pressure, it compresses spring (1) and
moves ball (2) to the left.
WA470-7
10-157

Charge valve
The pressurized oil from the pump reduces in pressure when it passes through orifice (a). As a result, the
pressure difference compresses spring (3) and moves valve (4) to the left largely.
Since ports (P) and (T) are connected to drain the pump pressure, the maximum pressure of the charge
circuit is limited to protect the circuit.
PPC relief valve (R3)
When the pressure in port (PPC) (pilot pressure) exceeds the set pressure, the pressurized oil from the
pump compresses spring (1) and moves ball (2) to the left.
The pressurized oil from the pump reduces in pressure when it passes through orifice (a). As a result, the
pressure difference compresses spring (3) and moves valve (4) to the left.
The open area between ports (PPC) and (P) decreases and causes pressure drop. As a result, the
pressure in port (P) does not decrease to the set pressure of the PPC relief valve but is maintained.
The pressure in port (PPC) is maintained at a certain value of pressure by adjusting the open area
between ports (PPC) and (P) and supplied as the source pressure of the pilot pressure.
When the pressure in port (PPC) becomes abnormal, port (PPC) and port (T) are interconnected to
release the abnormal pressure and protect the pilot circuit.
Sequence valve (H1)
The pressure of port (P) (pump pressure) is applied to the left end of sequence valve (1) and the drain
pressure is applied to the right end.
When the pump pressure exceeds the set pressure of spring (2), sequence valve (1) moves to the right to
interconnect ports (P) and (A).
The pressurized oil from the pump flows through priority valve (3) and port (A) to the cooling fan motor to
drive the motor.
Even when the driving pressure of the cooling fan motor is low, the sequence valve maintains the pump
pressure above the set pressure of spring (2) and prevents the accumulator charge pressure and the
source pressure of the pilot circuit from decreasing.
10-158
WA470-7

Charge valve
Shuttle valve (S1)
When the pressure in port (ACC1) is higher than the pressure in port (ACC2), shuttle valve (1) moves to
the left to disconnect port (ACC1) and oil passage (B).
The open area between port (ACC2) and oil passage (B) increases and the oil is supplied to the
accumulator on the port (ACC2) side.
When the pressure in port (ACC2) is higher than port (ACC1), the oil is supplied to the accumulator on the
port (ACC1) side.
The pressurized oil from the pump is supplied first to the lower pressure circuit of the two systems.
WA470-7
10-159

Brake valve
Brake valve
(WA380-G2B0-041-K-00-A)
PA: From charge valve ACC1 port

PB: From charge valve ACC2 port
A: To rear brake
B: To front brake
TA: Plug
TB: Drain
SA: Stop lamp oil pressure switch
SB: Plug
1. Piston
2. Spool (for rear)
3. Cylinder (for rear)
4. Spool (for front)
5. Cylinder (for front)
Function
(WA380-G2B0-042-K-00-A)
The brake valve is installed to the front lower part of the operator's seat. When the brake pedal is
depressed, the oil flows to the brake piston to operate the brake.
The right and left brake pedals are connected mechanically. When either of them is depressed, the other
one is operated, as well.
If the brake pedal is depressed, the transmission cut-off oil pressure sensor operates and supplies signals
to the transmission controller to set the transmission in neutral electrically.
10-160
WA470-7

Brake valve
Operation
(WA380-G2B0-044-K-00-A)
When brake pedal is depressed
When brake pedal (1) is depressed, the depressing force is transmitted to spool (5) through rod (2), piston
(3), and spring (4).
When spool (5) is pushed to the right, port (TA) is closed and the oil from the pump flows through the
accumulator to port (PA) and further flows through port (A) to the rear brake piston to operate the rear
brake.
At the same time when spool (5) is moved to the right, spool (6) is also moved to the right to close port
(TB). Then, the oil from the pump flows through the accumulator to port (PB) and further flows through port
(B) to the front brake piston to operate the front brake.
When only either brake operates
(When either brake has trouble)
Even if the front or rear brake system has trouble such as oil leakage and only either of them operates, the
depressing force of brake pedal (1) moves spools (5) and (6) to the right mechanically.
Accordingly, the oil from the pump flows to the normal brake piston to apply the brake as usual, thus the
machine can be stopped and the safety is kept high.
WA470-7
10-161

Brake valve
Balancing operation
When the oil fills the rear brake piston and the pressure between ports (PA) and (A) increases, the oil
flowing in chamber (E) through orifice (c) of spool (5) pushes spool (5) back to the left against the reaction
force of spring (4) to disconnect port (PA) from port (A).
At this time, port (TA) is kept closed to maintain the oil in the brake piston and leave the brake applied.
At the same time when spool (5) moves to the left, the oil also fills the front brake piston and the pressure
between ports (PB) and (B) increases, and the oil flowing in chamber (F) through orifice (d) of spool (6)
pushes back spool (6) to the left by the distance of movement of spool (5) to disconnect port (PB) from
port (B).
Port (TB) is kept closed to maintain the oil in the brake piston and leave the brake applied.
The oil pressure in the rear brake circuit [on port (A) side] is balanced with the depressing force of the
brake pedal, and the oil pressure in the front brake circuit [on port (B) side] is balanced with the oil
pressure in the rear brake circuit [on port (A) side].
When spools (5) and (6) are moved to the right stroke end, the line between port (PA) and (A) and that
between port (PB) and (B) are open fully, and the oil pressures in the rear and front brake circuits are
equal to the oil pressure from the pump.
Accordingly, the braking force can be adjusted by adjusting the depressing force of the brake pedal until
spools (5) and (6) move to the right stroke end.
10-162
WA470-7

Brake valve
When brake pedal is released
If brake pedal (1) is released, the depressing force of the pedal applied to spool (5) is released.
When spool (5) is pushed back to the left by the back pressure on the rear brake piston and the reaction
force of spring (7), port (PA) is closed and the oil in the rear brake piston flows through port (A) to port (TA),
and then is drained into the hydraulic tank through port (TB), and the rear brake is released.
At the same time when spool (5) is moved to the left, spool (6) is also pushed back to the left by the back
pressure on the front brake piston and the reaction force of spring (7), and port (PB) is closed and the oil in
the front brake piston flows through port (B) to port (TB), and then is drained into the hydraulic tank, and
the front brake is released.
WA470-7
10-163

Slack adjuster
Slack adjuster
(WA500-G310-041-K-00-A)
A: Inlet port
B: Outlet port
1. Cylinder
2. Check valve
3. Piston
4. Spring
5. Bleeder
Specifications
(WA470-G310-030-K-00-A)
Piston operating pressure (MPa {kg/cm2})

Cracking pressure of check valve (MPa {kg/cm2})
Closing pressure of check valve (MPa {kg/cm2})
Function
0.01 to 0.02 {0.1 to 0.2}

0.93 0.05 {9.5 0.5}
0.60 0.05 {6.0 0.5}
(WA470-G310-042-K-00-A)
The slack adjuster is installed in the brake oil line going to the brake piston from the brake valve, and
keeps the time lag in braking operation at a constant value.
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WA470-7

Slack adjuster
Operation
(WA470-G310-044-K-00-A)
1. When brake pedal is depressed
Before the brake pedal is depressed, pistons (4) are returned by stroke (S) (full stroke). When the brake
pedal is depressed, the oil from the brake valve is divided at slack adjuster port (P) and flows to the right
and left cylinders (2) to move pistons (4) rightward and leftward by stroke (S).
As a result, brake piston (6) moves by stroke (S). At this time, the clearance between brake piston (6) and
disc becomes zero, but no braking force is generated.
When the brake pedal is depressed further and the oil pressure from the brake valve exceeds the
specified pressure, check valve (3) opens and pressure is applied to port (C) to generate braking force.
Thus, the time lag when the brake is applied is maintained constant.
WA470-7
10-165

Slack adjuster
2. When brake pedal is released
When the brake pedal is released, piston (4) is returned by return spring (7) of brake piston (6) for the oil
amount equivalent to stroke (S) and the brake is released. That is, return stroke (T) of brake piston (6) is
decided by the oil amount for piston stroke (S) of the slack adjuster and the time lag in braking is kept
constant, regardless of wear of the brake disc.
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WA470-7

Accumulator (for brake)
Accumulator (for brake)
(WA380-G2G0-041-K-00-A)
1. Plug
2. Gas valve
3. Top cover
4. Cylinder
5. Free piston
6. End cover
Specifications
(WA380-G2G0-030-K-00-A)
Gas to be used
Gas capacity (cc)
Charged pressure
(MPa {kg/cm2})
Max. pressure used
(MPa {kg/cm2})
Function
Nitrogen gas
2,850
3.43 0.1 {35 1.0}
(At 20C)
20.6 {210}
(WA380-G2G0-042-K-00-A)
The accumulator is installed between the charge valve and brake valve. The space between cylinder (4)
and free piston (5) is filled with nitrogen gas. The nitrogen gas absorbs the hydraulic pulsation generated
by the hydraulic pump by utilizing its compressibility, and secures the braking force and operability when
the engine is stopped.
WA470-7
10-167

Brake
Brake
Front
(HM300-G160-001-K-00-A)
(WA470-G16H-041-K-00-A)
1. Differential housing
2. Carrier
3. Piston
4. Spring
5. Plate
6. Sun gear shaft
7. Axle housing
8. End plate
9. Disc
Structure
The front brake is a wet-type multiple-disc brake, which consists of piston (3), plate (5), disc (9), end plate
The brake cylinder consists of differential housing (1) and carrier (2), and piston (3) is installed in it.
Plate (5) and end plate (8) are engaged with the spline of differential housing (1).
Disc (9) has linings stuck to its both sides and is installed between plate (5) and end plate (8), and
engaged with the spline of sun gear shaft (6).
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WA470-7

Brake
Rear
(WA470-G16K-041-K-00-A)
1. Differential housing
2. Carrier
3. Piston
4. Spring
5. Plate
6. Sun gear shaft
7. Axle housing
8. End plate
9. Disc
Structure
The rear brake is a wet-type multiple-disc brake, which consists of piston (3), plate (5), disc (9), end plate
The brake cylinder consists of differential housing (1) and carrier (2), and piston (3) is installed in it.
Plate (5) and end plate (8) are engaged with the spline of differential housing (1).
Disc (9) has linings stuck to its both sides and is installed between plate (5) and end plate (8), and
engaged with the spline of sun gear shaft.
WA470-7
10-169

Brake
Operation
(WA380-G160-044-K-00-A)
When brake is applied
When the brake pedal is depressed, pressurized oil (P) supplied from the hydraulic tank through the pump
and brake charge valve flows through the oil passage in the brake cylinder to pushes piston (2) to the left.
Accordingly, discs (4) held between piston (2), plates (3), and end plate (5) are locked and the machine is
braked.
When brake is released
When the oil pressure is released, piston (2) is returned by the reaction force of spring (8). As a result,
clearance is made between plate (3) and end plate (5), and the brake is released.
The linings stuck to discs (4) are grooved in a check pattern, and oil flows in the grooves to cool the linings
while discs (4) are turning.
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WA470-7

Parking brake control
Parking brake control
(WA470-GJ00-041-K-00-A)

2. Parking brake emergency release valve
4. Parking brake oil pressure switch
5. Parking brake
Outline
Parking brake (4) is a wet-type multiple-disc brake built in the transmission, which is installed in the output
shaft bearing area, operated mechanically with the pressing force of the spring, and released hydraulically.
When parking brake switch (1) installed in the operator's compartment is turned "ON", parking brake
solenoid valve (3) installed to the valve assembly blocks the hydraulic oil, and consequently parking brake
(5) operates.
When parking brake switch is turned "OFF", the hydraulic pressure of the cylinder releases parking brake
(5).
While the parking brake is applied (the solenoid valve is in "OFF"), the neutralizer signal blocks the signals
from the transmission controller to the transmission solenoid valve to keep the transmission in neutral.
Parking brake emergency release valve (2) is installed to move the machine when it stops because of a
trouble in the engine or drive system (the parking brake is applied).
WA470-7
10-171

Parking brake
Parking brake
(WA470-GJ20-041-K-00-A)
1. Output shaft
2. Spring (outside)
3. Spring (inside)
4. Parking brake oil port
5. Piston
6. Plate
7. Disc
8. Wave spring
Structure
The parking brake is a wet-type multiple-disc brake, which is operated mechanically by springs (2) and (3)
to brake output shaft (1).
Operation
(WA380-GJ20-044-K-00-A)
When the brake is applied, piston (5) presses plates (6) and discs (7) against each other with the tension
of springs (2) and (3) to lock output shaft (1).
When the brake is released, the oil pressure from parking brake oil port (4) moves piston (5) to release the
pressing force on discs (7) and plates (6).
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WA470-7

Parking brake solenoid valve
(WA470-GJD0-041-K-00-A)
1. Transmission control valve assembly (L.H. valve assembly)

2. Coil (ON/OFF type)
3. Push pin
4. Spring
5. Spool
6. Valve block
7. Check valve
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10-173

Operation
(WA380-GJD0-044-K-00-A)
When parking brake is applied (solenoid is de-energized)
When the parking brake switch is turned "ON", coil (1) is "de-energized" and spool (2) is moved down by
the reaction force of spring (3).
Pump port (P) and parking brake port (A) are closed and the pressurized oil from the pump does not flow
to the parking brake. At this time, the oil that is operating the parking brake flows through port (A) to port
(T) and is drained.
Since the oil that is operating the piston is drained, the piston pushed back by the spring presses the
plates and discs to apply the brake.
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WA470-7

When parking brake is released (solenoid is energized)
When the parking brake switch is turned "OFF", coil (1) is "energized" and spool (2) moves up.
The pressurized oil from the pump enters port (P) and flows around spool (2) and through port (A) to the
parking brake. At the same time, port (T) closes and the oil is not drained.
Since the oil pressure is applied to the piston, the piston compresses the spring and separates the plates
and discs to release the parking brake.
WA470-7
10-175

Parking brake emergency release valve
(WA470-GJG0-041-K-00-A)
A: From accumulator
B: To parking brake solenoid valve
1. Grip
2. Valve
Function
(WA380-GJG0-042-K-00-A)
The parking brake emergency relief valve is installed between the accumulator of the brake circuit and
parking brake solenoid. When the oil pressure from the power train pump cannot be supplied because of
an engine trouble etc., the accumulator charge pressure of the brake circuit can be supplied to the parking
brake cylinder by opening this valve manually.
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WA470-7

Axle mount and center hinge pin
Undercarriage and frame
(ALL-DT00-001-K-00-A)
(WA470-H1K0-041-K-00-A)
1. Front axle
2. Front frame
3. Rear axle
4. Rear frame
Function
(WA380-H1K0-042-K-00-A)
Front frame (2) and rear frame (4) are connected by the center hinge pin with the bearing between them.
The right and left steering cylinders connecting front frame (2) and rear frame (4) adjust the articulate
angle of the frames, or the turning radius, by extending and retracting their piston rods.
WA470-7
10-177

Tire
Tire
(WA470-DW60-041-K-00-A)
This machine has the following features by employing radial tires.
High grip
High operator comfort
Low puncture rate
Less uneven wear
Less fuel consumption
Long life
Less damage on machine
Less heat generation
Comparison of structures and characteristics of tires

Radial tire
Structure
The cords composing carcass (1) are arranged at right angles (radially) to the center line of tread (T).
Tread (T) is stabilized and protected by several strong belts (2).
Side wall (W) and tread (T) are independent structurally from each other.
Gripping characteristics
Even when the tire is deflected by the load, it makes little unnecessary movement and grips the ground
stably and securely.
Deflection characteristics
When the tire is loaded, only its side wall (W) is deflected and tread (T) composed of strong belts (2)
maintains independent stability.
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WA470-7

Tire
Bias tire
Structure
The cords composing carcass (1) are arranged diagonally (bias) to the center line of tread (T).
Side wall (W) and tread (T) are made integrally.
Gripping characteristics
When the tire is deflected by the load, its ground contact face is deflected and it makes unnecessary
movement. Accordingly, the ground contact face becomes unstable.
Deflection characteristics
When the tire is loaded, side wall (W) and tread (T) move as one piece.
WA470-7
10-179

Hydraulic component layout
Hydraulic system
(D65-PM10-001-K-00-A)
(WA470-PM10-04D-K-00-A)
1. Lift cylinder (R.H.)
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WA470-7

2. Bucket cylinder
3. Control valve
4. Work equipment lock solenoid valve
5. Steering valve
6. Orbitrol valve
7. Stop valve (R.H.)
8. Brake valve
9. Cooling fan and brake pump
10. Work equipment pump
11. Hydraulic tank
13. Hydraulic oil cooler
15. Slack adjuster (rear)
16. Steering pump
17. Double type gear pump (power train charge pump and power train lubrication pump)
18. Emergency steering motor (if equipped)
19. Emergency steering pump (if equipped)
20. Stop valve (L.H.)
21. ECSS accumulator
22. Steering cylinder (L.H.)
23. Steering cylinder (R.H.)
24. Lift cylinder (L.H.)
25. Slack adjuster (front)
26. Brake accumulator (for front)
28. PPC accumulator
29. Brake accumulator (for rear)
30. Brake emergency release valve
31. Breather
Outline
The hydraulic system consists of the work equipment circuit and steering circuit. The work equipment
circuit controls the operation of the bucket and attachment.
The oil in hydraulic tank (11) is sent to control valve (3) by work equipment pump (10). While the spools of
control valve (3) for the bucket and boom are in the hold position, the oil flows through the drain circuit of
control valve (3) and is filtrated by the filter in hydraulic tank (11) and returned to the tank.
When the work equipment control lever is operated, the work equipment controller sends a command
current to EPC valve.
EPC valve operates each spool of control valve (3) hydraulically in accordance with the command current.
The oil flows from control valve (3) to lift cylinders (1) and (24) or bucket cylinder (2) to move the boom or
bucket.
The maximum pressure in the hydraulic circuit is controlled with the relief valve in control valve (3). The
bucket cylinder circuit is equipped with a safety valve (with suction valve) to protect itself.
Hydraulic tank (11) is of pressurized and sealed type, and equipped with an oil filler cap/breather having a
relief valve, which pressurizes the tank, prevents generation of negative pressure in the tank, and
prevents cavitation in the pump. Air is taken in through the breather (31).
When the machine cannot be steered normally during travel because of an engine stall, steering pump
trouble, oil leakage from the piping, etc., electric emergency steering motor (18) is operated to drive
emergency steering pump (19) and enables steering (if equipped).
Fan motor (14) installed to the radiator is driven with variable hydraulic pressure by cooling fan/ brake
pump (9).
WA470-7
10-181

Work equipment control

3-lever type
(WA380-PK00-001-K-00-A)
(WA380-PK3A-041-K-00-A)
a The figure shows the machine with the auxiliary control lever.
1. Work equipment lock switch

2. Boom control lever
3. Bucket control lever
4. Auxiliary control lever (if equipped)
5. Armrest
6. Armrest height and angle adjustment grip
7. R.H. console fore-and-aft lever
8. Electric service lever (if equipped)
9. Electric bucket lever
10. Electric boom lever
10-182
WA470-7

Hydraulic tank
Hydraulic tank
(WA470-PM30-041-K-00-A)
Oil filler cap with relief valve

2. Breather (for air intake)
3. Hydraulic tank
WA470-7
10-183

Hydraulic tank
4. Drain plug
5. Strainer
6. Filter element
7. Bypass valve
8. Suction strainer
9. Sight gauge
Specifications
(WA470-PM30-030-K-00-A)
Hydraulic tank capacity (l)

Hydraulic oil in tank (l)
Bypass valve set pressure (MPa {kg/cm2})
Oil filler cap with relief valve
255
173
0.15 0.03 {1.53 0.31}
(WA470-PM37-041-K-00-A)
1. Bottom plate
2. Gasket
Prevention of pressure rise in tank
While the hydraulic circuit is in operation, the pressure in the hydraulic tank increases as the oil level and
the temperature in the hydraulic tank rise according to the operation of the hydraulic cylinders.
If the pressure in the tank exceeds the set pressure, bottom plate (1) is pushed up to release the pressure
in the tank and prevent pressure rise.
(Set pressure of air bleeding valve: 75 15 kPa {0.76 0.15 kg/cm 2})
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WA470-7

Hydraulic tank
Breather
(WA500-PM38-041-K-00-A)
1. Body
2. Filter element
3. Poppet
4. Sleeve
Function
(WA470-PM38-042-K-00-A)
Prevention of negative pressure in tank

Since the tank is pressurized and sealed, the oil level in it decreases and negative pressure is generated
in it. At this time, poppet (3) is opened by the differential pressure from the ambient pressure. As a result,
the ambient pressure is let into the tank and generation of negative pressure is prevented.
(Set pressure of air bleeding valve: 0 2.9 kPa {0 0.03 kg/cm2})
Prevention of pressure rise in tank
If the circuit pressure increases above the specified pressure because of the oil level change caused by
the hydraulic cylinder and temperature rise during operation, sleeve (4) operates to release the pressure
in the hydraulic tank.
(Set pressure of air bleeding valve: 137 20 kPa {1.4 0.2 kg/cm2})
WA470-7
10-185

Double type gear pump
(WA470-RA1S-041-K-00-A)
Power train charge pump and power train lubrication pump
1. Power train charge pump (SAL (3) 80)

2. Power train lubrication pump (SAL (1) 32)
Specifications
(WA470-RA1S-030-K-00-A)
Model
Rotating speed (rpm)
Discharge pressure (MPa {kg/cm2})
Standard discharge (l/min)
Allowable discharge (l/min)
Function
SAL (3) 80
2,500
2.9 {30}
192
176
SAL (1) 32
2,500
2.9 {30}
78
70
(WA380-RA1S-042-K-00-A)
The double type gear pump consists of the power train charge pump and the power train lubrication pump.
It is installed to the PTO shaft of the torque converter and driven by the PTO shaft to supply oil pressure to
the torque converter and transmission circuits.
10-186
WA470-7

Work equipment pump
Work equipment pump
(WA470-C200-041-K-00-A)
IM: PC mode selector current

PA: Pump discharge port
PB: Pump pressure inlet port
WA470-7
10-187

Work equipment pump
PC: Cooling port

PD1: Case drain port
PD2: Air bleeder
PEN: Control pressure pickup port
PEPC: EPC source pressure port
PEPCC: EPC source pressure pickup port
PLS: Load pressure input port
PLSC: Load pressure pickup port
PM: PC mode selector pressure pickup port
1. Main pump
2. LS valve
3. PC valve
4. PC-EPC valve
10-188
WA470-7

Work equipment pump
1. Shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Servo piston
11. PC valve
Structure
Cylinder block (7) is supported to shaft (1) by spline (12).
Shaft (1) is supported by each bearing (13) at the front and rear.
The tip of piston (6) is shaped as a concave sphere and crimped together with shoe (5).
Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
Rocker cam (4) rocks on cylindrical surface (B) of cradle (2) fixed to the case. High-pressure oil is supplied
between them to form a static pressure bearing.
WA470-7
10-189

Work equipment pump
Cylinder block (7) rotates relatively to valve plate (8) while sealing the pressurized oil.
The oil pressure is balanced properly on the sealing surface of cylinder block (7) and valve plate (8).
The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).
Specifications
(WA470-C200-030-K-00-A)
Model
Type
Theoretical delivery (cm3/rev)
Rated delivery pressure: (MPa {kg/
cm2})
Rated speed (rpm) (*1)
HPV140
120 1
34.3 {350}
2,282
*1: It shows the value when engine speed is at rated speed of 2,000 rpm.
Function
(WA500-C200-042-K-00-A)
This pump converts the rotation and torque of the engine transmitted to its shaft into hydraulic pressure
and discharges pressurized oil according to the load.
It is possible to change the discharge by changing the swash plate angle.
Operation
(WA470-C200-044-K-00-A)
Operation of pump
Rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (7) changes.
Piston (6) slides inside cylinder block (7) and a difference is made between volumes (E) and (F) in cylinder
block (7).
Oil in amount of (F) minus (E) is sucked in and discharged from each piston (6).
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WA470-7

Work equipment pump
Pressurized oil is not sucked or discharged, namely pumping action is not performed. (Actually, however,
the swash plate angle does not become 0 deg.)
The pump discharge is in proportion to swash plate angle (a).
Control of discharge
WA470-7
10-191

Work equipment pump
When the swash plate angle (a) increases, the difference between volumes (E) and (F) increases and also
pump discharge (Q) increases.
Servo piston (10) moves in a linear reciprocating movement according to the signal pressure from the PC
valve and LS valve.
The linear reciprocating movement of servo piston (10) is transmitted to rocker cam (4) through slider (14).
Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while
continuing revolving movement.
The area of servo piston (10) for receiving the pressure are not identical on the left side and right side.
Main pump discharge pressure (self pressure) (PP) is always brought to the pressure chamber of the
small diameter piston side.
Output pressure (PEN) of LS valve is supplied to the chamber receiving the pressure at the large diameter
piston end.
The movement of servo piston (10) is controlled by the relationship of pressure between small diameter
piston side (PP) and large diameter side (PEN) and by the ratio of the area receiving the pressure
between small diameter piston and large diameter piston.
LS valve
10-192
(WA470-C2J0-041-K-00-A)
WA470-7

Work equipment pump
PA: Pump port

PDP: Drain port
PLP: LS control pressure output port
PLS: LS pressure input port
PP: Pump port
PPL: Control pressure input port
PSIG: Drain port
1. Sleeve
2. Piston
3. Spool
4. Spring
5. Seat
6. Sleeve
7. Plug
8. Lock nut
Function
(WA470-C2J0-042-K-00-A)
The LS (load sensing) valve detects the load of the actuator and controls the pump discharge.
The LS valve controls pump discharge (Q) according to differential pressure (dPLS) [ = (PP - PLS)] (called
LS differential pressure) between pump discharge pressure (PP) and control valve outlet port pressure
(PLS).
The LS valve receives main pump pressure (PP) and pressure (PLS) (called the LS pressure) coming
from the control valve output.
WA470-7
10-193

Work equipment pump
Operation
(WA500-C2J0-044-K-00-A)
When control valve is in neutral
The LS valve is a 3-way selector valve, and LS pressure (PLS) on the inlet of the control valve is
transmitted to spring chamber (B), and pump discharge pressure (PP) is transmitted to port (H) of sleeve
(8).
Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump discharge
pressure (PP) determine the position of spool (6).
Before the engine is started, servo piston (12) is pushed to the left. (See the figure below)
When the control lever is in the NEUTRAL position when the engine is started, LS pressure (PLS) is set to
0 MPa {0 kg/cm2}. (It is connected to the drain circuit through the control valve spool)
Spool (6) is pushed to the right, and port (C) and port (D) are connected.
Shuttle valve output pressure (PPH) is transmitted to the large end of the piston through port (K).
Pump pressure (PP) is transmitted to port (J) on small end side.
According to the area difference of servo piston (12), the servo piston is moved in the direction which
makes the swash plate angle minimum.
10-194
WA470-7

Work equipment pump
Operation in direction to increase pump discharge
When the difference between pump discharge pressure (PP) and LS pressure (PLS), in other words, LS
differential pressure (dPLS) becomes smaller [for example, when the area of opening of the control valve
becomes larger and pump discharge pressure (PP) drops], spool (6) is pushed to the left by the combined
force of LS pressure (PLS) and the force of spring (4).
As spool (6) moves, ports (D) and (E) are interconnected and also connected to the PC valve.
Since the PC valve is connected to the drain port, the pressure between circuits (D) and (K) becomes
drain pressure (PT). (The operation of the PC valve is described later.)
WA470-7
10-195

Work equipment pump
The pressure at the large end of servo piston (12) becomes drain pressure (PT) and pump pressure (PP)
is constantly transmitted to port (J) at the small end. Accordingly, servo piston (12) is pushed to the left
and moves the swash plate in the direction to increase the discharge.
Operation in direction to increase pump discharge
When LS differential pressure (dPLS) becomes larger (for example, when the area of opening of the
control valve becomes smaller and pump pressure (PP) rises), pump pressure (PP) pushes spool (6) to
the right.
When spool (6) moves, shuttle valve output pressure (PPH) is transmitted to port (D) through port (C), and
then to the large end of the piston through port (K).
Main pump pressure (PP) is transmitted to port (J) of the small end of the piston, but servo piston (12) is
pushed to the right because of the difference in area between the large and the small ends of servo piston
(12). As a result, the swash plate angle is decreased.
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WA470-7

Work equipment pump
When servo piston is balanced
The symbols (A1), (A0) and (PEN) respectively represent the area receiving the pressure at the large end
of the piston, the area receiving the pressure at the small end and the pressure transmitted to the large
diameter end of the piston.
When main pump pressure (PP) of the LS valve is balanced with the combined force of LS pressure (PLS)
and spring (4) and (A0) x (PP) = (A1) x (PEN), servo piston (12) stops at the current position.
The pump swash plate is held at an intermediate position. [The swash plate stops at a position where the
opening between ports (D) and (E) of spool (6) and that between ports (C) and (D) are approximately
equal]
The relation between the area receiving the pressure at both ends of servo piston (12) is (A0):(A1) = 3:5,
so the pressure applied to both ends of the piston when it is balanced becomes (PP):(PEN) C 5 : 3.
The position where spool (6) is balanced and stopped is the standard center, and the force of spring (4) is
adjusted so that it is determined when (PP) - (PLS) = 1.4 MPa {14 kg/cm 2}.
WA470-7
10-197

Work equipment pump
PC valve
(WA470-C2K0-041-K-00-A)
PA: Pump port

PDP: Drain port
PM: Mode selector pressure pilot port
PPL: Control pressure output port (to LS valve)
1. Plug
2. Servo piston assembly
3. Pin
4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring
Function
(WA470-C2K0-042-K-00-A)
The PC valve limits the oil flow to a certain level (depends on the discharge pressure) even if the stroke of
the control valve is increased extremely when pump discharge pressure (PP) is high.
If the pump discharge pressure increases due to increased load during operation, this valve decreases the
pump discharge.
If the pump discharge pressure decreases, this valve increases the pump discharge.
The relation between the pump discharge pressure (PP) and pump discharge (Q) is as shown in the
following figure, as a parameter for each current (X) value applied to the PC-EPC valve solenoid.
The controller continues counting the actual engine speed.
During low speed, command current (X) flows from the controller to PC-EPC valve solenoid according to
the engine speed to reduce the pump discharge.
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WA470-7

Work equipment pump
Operation
(WA470-C2K0-044-K-00-A)
When actuator load is small and pump discharge pressure (PP) is low
Action of PC-EPC valve solenoid (1)

Command current (X) from the work equipment controller flows to the PC-EPC valve solenoid (1).
This command current (X) acts on the PC-EPC valve to generate signal pressure to vary the force pushing
piston (2).
Spool (3) stops at a position where the combined force exerted by spring (4) is equalized to the force
exerted by pump pressure (PP) acting on spool (3).
WA470-7
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Work equipment pump
Depending on the position where spool stops, the pressure output from the PC valve [port (C) pressure]
varies.
The amperage of the command current (X) depends on the type of work (lever operation), working mode
selection, engine speed setting, and the actual engine speed.
Action of spring
The spring force of spring (4) in the PC valve depends on the position of the swash plate.
When servo piston (9) compresses or decompresses spring (4), the spring force varies.
When the command current (X) input to PC-EPC valve solenoid (1) varies, the thrust pushing piston (2)
varies.
The spring force of spring (4) is also varied by the PC-EPC valve solenoid command current (X).
Port (C) on the PC valve is connected to port (E) on the LS valve.
Pump pressure (PP) is transmitted to the small diameter end of servo piston (9), port (A), and port (B).
When pressures (PP) is low, spool (3) is at the left.
Port (C) and port (D) are connected, and the pressure entering the LS valve will be drain pressure (PT).
When port (E) of the LS valve is connected to port (G), the pressure from port (J) entering the large
diameter side of the piston becomes drain pressure (PT), and servo piston (9) moves to the left.
The pump discharge goes to increase.
The movement of servo piston (9) lets spring (4) to expand, and the spring force decreases.
When the spring force decreases, spool (3) moves to the right. Ports (C) and (D) are blocked, while pump
discharge pressure port (B) is connected to port (C).
Since the pressure in port (C) and the pressure at the large diameter side of the piston increase, servo
piston (9) stops moving to the left.
10-200
WA470-7

Work equipment pump
Stop position of servo piston (9) (= pump discharge) is determined by a position where the press force
generated by pressure (PP) on spool (3) and the thrust by PC-EPC valve solenoid and the force of spring
(4) are balanced.
When actuator load is large and pump discharge pressure is high
When the load is large and the pump discharge pressure (PP) is high, the thrust moving spool (3) to the
right increases, and spool (3) comes to a position as shown above.
The pressure from port (C) to the LS valve becomes approximately half of pump pressure (PP), because a
part of the pressure from port (B) is transmitted to port (D) through the LS valve and port (C), as shown
above.
When ports (E) and (G) of the LS valve are connected, the pressure is transmitted from port (J) to the
large diameter end of servo piston (9), and servo piston (9) stops moving.
When pump pressure (PP) increases more and spool (3) moves further to the right, pump pressure (PP)
flows to port (C) to minimize the pump discharge.
When servo piston (9) moves to the right, springs (4) and (6) are compressed, and push back spool (3).
When spool (3) moves to the left, the openings of ports (C) and (D) widen.
The pressure in port (C) (=J) decreases, and the movement of servo piston (9) to the right stops.
At this time, servo piston (9) stops at a position further to the right than the position when pump pressure
(PP) is low.
The relationship between pump pressure (PP) and pump average discharge (Q) becomes as shown in the
following figure.
WA470-7
10-201

Work equipment pump
If command current (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between
pump pressure (PP) and pump discharge (Q) is shifted parallel in proportion to the thrust of PC-EPC valve
solenoid.
The thrust of PC-EPC valve solenoid (1) is added to the rightward thrust caused by the pump pressure
applied to spool (3), so the relationship between pump pressure (PP) and pump discharge (Q) moves from
(A) to (B) as the command current (X) is increased.
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WA470-7

Work equipment pump
PC-EPC valve
(WA500-C2N0-041-K-00-A)
C: To PC valve
P: From pilot lamp
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
Function
(WA500-C2N0-042-K-00-A)
The EPC valve consists of the proportional solenoid and the hydraulic valve.
WA470-7
10-203

Work equipment pump
When signal current (i) from the controller is received, an EPC output pressure proportional to the
amperage of current is generated and output to the PC valve.
Operation
(WA500-C2N0-044-K-00-A)
When signal current is zero (coil de-energized)

When the signal current from the controller is not flowing through coil (2), coil (2) is de-energized.
Spool (5) is pushed to the left side by spring (4).
Port (P) is closed, and the pressurized oil from the pilot pump does not flow to the PC valve.
The pressurized oil from the PC valve is drained to the tank through port (C) and port (T).
10-204
WA470-7

Work equipment pump
WA470-7
10-205

Work equipment pump
When signal current is minute (coil is energized)

When a small signal current flows through coil (2), coil (2) is energized and a thrust pushing plunger (7) to
the right is generated.
Rod (6) pushes spool (5) to the right, and the pressurized oil flows from port (P) to port (C).
The pressure at port (C) increases and the total of the force applied to the surface of spool (5) and the
force of spring (4) becomes larger than the thrust of plunger (7).
Spool (5) is pushed to the left, and ports (P) and (C) are blocked.
Port (C) connects to port (T).
Spool (5) moves to a position where the thrust of plunger (7) becomes equal to the total of the pressure at
port (C) and the force of spring (4).
The circuit pressure between the EPC valve and the PC valve is controlled in proportion to the amperage
of the signal current.
10-206
WA470-7

Work equipment pump
When signal current is maximum (coil is energized)

Coil (2) is energized when signal current is supplied to coil (2).
As the amperage of energized signal current is maximum, the thrust of plunger (7) is also maximized.
Spool (5) is pushed to the right by rod (6).
The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and PC valve is maximized.
Port (T) closes, and no pressurized oil flows to the tank.
WA470-7
10-207

Control valve
Control valve
(WA470-R404-041-K-00-A)
a In this section, the 4-spool valve (with ECSS control valve) is described.
A1: To bucket cylinder bottom

A2: To lift cylinder bottom
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WA470-7

Control valve
A3: To attachment port

ACC: To accumulator for ECSS
B1: To bucket cylinder head
B2: To lift cylinder head
B3: To attachment port
CAC: Accumulator pressure pickup port
CLS: LS pressure pickup port
CP1: Pump discharge pressure pickup port
CP2: Pressure sensor mounting port
CR: Accumulator charge pressure pickup port
P1: From work equipment hydraulic pump
PA1: From bucket tilt controller
PA2: From boom raise controller
PA3: From attachment control
PACC: From ECSS controller
PB1: From bucket dump controller
PB2: From boom lower controller
PB3: From attachment control
PLS: To work equipment hydraulic pump LS port
PP: From pilot pump
PPS: To work equipment hydraulic pump
T: To tank
TS: To tank
1. Bucket valve
2. Boom valve
3. ECSS valve
4. Attachment valve
5. Cover (A)
6. Cover (B)
7. Boom suction valve
WA470-7
10-209

Control valve
1. Load check valve (bucket bottom)

2. Load check valve (boom bottom)
3. Pressure compensation valve (boom head)
4. Pressure compensation valve (bucket head)
5. Pressure compensation valve (attachment)
6. Pressure compensation valve (attachment)
10-210
WA470-7

Control valve
1. Spool (ECSS control)

2. Spool (boom)
3. Spool (bucket)
4. Spool (attachment)
WA470-7
10-211

Control valve
1. Suction safety valve (bucket bottom)

2. Suction safety valve (bucket head)
3. Suction safety valve (boom bottom)
4. Suction safety valve (boom head)
5. Suction safety valve (attachment)
6. Suction safety valve (attachment)
10-212
WA470-7

Control valve
1. Unload valve
Bucket valve
2. EPC valve (dump)
3. Load check valve (tilt)
4. Pressure compensation valve (dump)
5. EPC valve (tilt)
6. Suction safety valve (dump)
7. Bucket spool
8. Suction safety valve (tilt)
WA470-7
10-213

Control valve
Boom valve
1. EPC valve (lower and float)
2. Load check valve (raise)
3. LS shuttle valve
4. Pressure compensation valve (lower)
5. EPC valve (raise)
6. Suction safety valve (lower and float)
7. Suction safety valve (lower and float)
8. Boom spool
10-214
WA470-7

Control valve
9. Suction safety valve (raise)

ECSS valve
10. ECSS spool
11. EPC valve (ECSS ON - OFF)
Attachment valve
1. EPC valve
2. Load check valve
3. LS shuttle valve
WA470-7
10-215

Control valve
4. Load check valve

5. EPC valve
6. Suction safety valve
7. Attachment spool
9. Unload valve
11. LS bypass valve
10-216
WA470-7

CLSS
CLSS
(ALL-PNJ1-001-K-00-A)
CLSS: Abbreviation for Closed center Load Sensing System
Structure of CLSS
(WA470-PNJ1-041-K-00-A)
Features
CLSS is an abbreviation for Closed center Load Sensing System, which has the following features.
Fine control not influenced by load
Control performance that allows digging even under fine control operation condition
Ease of combined operation ensured by the flow dividing performance that is determined by the opening
areas of spools during combined operations
Energy saving by variable discharge pump control
Configuration
CLSS consists of variable capacity piston pump, control valves, and respective actuators.
The variable capacity piston pump consists of a pump body, LS valve, and PC valve.
Basic principle
Pump swash plate angle control
The pump swash plate angle (pump discharge) is so controlled that LS differential pressure (dPLS), which
is the differential pressure between pump discharge pressure (PP) and control valve outlet LS pressure
(PLS) (actuator load pressure), is kept constant.
[LS differential pressure (dPLS) = Pump discharge pressure (PP) - LS pressure (PLS)]
WA470-7
10-217

CLSS
The pump swash plate shifts toward the maximum angle position if LS differential pressure (dPLS) is
lower than the set pressure of the LS valve.
The pump swash plate shifts toward the minimum angle position if LS differential pressure is higher than
the set pressure.
10-218
WA470-7

CLSS
LS differential pressure (d
d PLS) and pump swash plate angle
a For details of the operation, see "Work equipment pump".

Pressure compensation control
WA470-7
10-219

CLSS
A valve to balance the load (pressure compensation valve) is installed on the lift cylinder head outlet side
of the control valve.
When actuators are operated in combined operations, the pressure difference (dP) between the upstream
(inlet port) and downstream (outlet port) of the spool of each valve is kept the same among them,
regardless the level of the load (pressure).
The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and
(S2) of each valve.
If the pressurized oil flows into the lift cylinder head too much because of the hydraulic drift of the boom
and combined operation of the bucket, the bucket does not move. This is prevented by the above control.
10-220
WA470-7

Hydraulic circuit diagram and names of valves
(WA470-PM10-054-K-00-A)
1. Bucket valve
2. Boom valve
3. ECSS valve
4. Attachment valve
5. Bucket spool
6. Boom spool
7. ECSS spool
8. Attachment spool
WA470-7
10-221

9. Pressure compensation valve

10. Suction valve
11. Load check valve
Relief pressure: 34.3 MPa {350 kg/cm2}
14. Unload valve
Cracking pressure: 1.9 MPa {19.5 kg/cm2}
Cracking pressure: 32.4 MPa {330 kg/cm2}
16. Safety valve
17. Safety valve
18. Safety valve
Unload valve
(WA470-PQD0-040-K-00-A)
When the unload valve is actuating
a: Orifice
b: Port
c: Port
P: Pump circuit
PLS: LS circuit
T: Tank circuit
1. Spring
10-222
WA470-7

2. Valve
Function
Drains an oil discharge for the portion of the minimum pump swash plate angle while all control valves are
in the holding.
The pump pressure will correspond to a set load of spring (5) inside the valve (this pressure will be P1).
Since LS pressure is drained from the LS bypass valve, LS pressure C tank pressure C 0 MPa {0 kg/cm2}
Operation
Pressure of pump circuit (P) is received by the end of valve (2).

Since the control valve is in neutral position, pressure of LS circuit (PLS) is 0 MPa {0 kg/cm2}.
Pressurized oil of pump circuit (P) stops at valve (2), and the pressure rises as no relief is available.
When this pressure becomes larger than the force of spring (1), valve (2) moves to the right.
Ports (b) and (c) are interconnected and the pump pressure flows to tank circuit (T).
Since the pump discharge pressure - LS circuit pressure during unloading is larger than the pump LS
control pressure, the signal is output to minimize the pump swash plate angle.
During operation (a work within a scope of discharge by a minimum swash plate angle), the discharge
pressure for the portion of minimum pump swash plate angle is set to LS pressure + P1 pressure.
LS control differential pressure (dPLS) of discharge for the portion of minimum swash plate angle will be
equal to P1 pressure.
Operation of relief valve
When cylinder reaches its stroke end, main relief valve opens.
Pump delivery (Q) is relieved to the tank.
Since the pump delivery pressure (PP) and LS pressure (PLS) do not flow neither to the upstream nor
downstream, they become approximately the same and LS differential pressure (dPLS) becomes 0 MPa
{0 kg/cm2}.
As LS differential pressure (dPLS) is lower than the LS set pressure of LS valve, LS valve operates to
make the pump swash plate angle maximum.
Mechanically, operation of PC valve has priority over that of LS valve.
The pump is maintained at the minimum swash plate angle due to PC valve cut-off function.
WA470-7
10-223

Pressure compensation valve
(WA470-C790-040-P-00-A)
(installed to cylinder head side of boom valve)

When high load is applied to the boom.
1. Main pump
Pressure compensation valve
2. Load check valve
3. Shuttle valve
4. Piston
5. Spring
6. LS shuttle valve
Function
High load pressure is generated during independent operation of the boom and combined operation with
the bucket.
When the load pressure of the boom is higher than the pump pressure, this valve functions as a load
check valve to prevent reverse oil flow in the circuit.
Operation
Actuator circuit pressure (B) increases higher than pump discharge pressure (PPS) and LS pressure
(PLS).
Shuttle valve (3) of the pressure compensation valve moves to the right.
10-224
WA470-7

Actuator circuit pressure (B) is interconnected with spring chamber (C).

Piston (4) is pushed to the left by spring (5).
Valve (2) is also pushed to the left by piston (4) to close pump outlet circuit (A) and prevent reverse flow
from actuator circuit (B) to pump outlet circuit (A).
During combined operation (lowering boom and tilting bucket)
Function
When the flow rate of the boom starts to increase because the load pressure of the boom becomes lower
than that of the bucket during combined operation, this valve compensates the pressure on the boom side.
On the bucket side, the load pressure is higher and the flow rate starts to decrease.
Operation
When the load pressure on the boom side increases during combined operation, the flow to the actuator
circuit (B) starts to increase.
Since the LS pressure (PLS) on the bucket side increases, it pushes shuttle valve (3) of the pressure
compensation valve on the boom side to the left.
The pressurized oil flows through the internal passage of piston (4) to spring chamber (C).
Piston (4) and valve (2) are pushed to the left to close the outlet side of pump circuit (PPS).
Outlet pressure (A) (spool meter-in downstream pressure) becomes equal to the output pressure of the
bucket.
Pump pressure (PPS) (spool meter-in upstream pressure) becomes the same in all the actuators.
Pump pressure (PPS) and outlet pressure (A) become the same in all the operated spools.
The pump discharge flow is divided in proportion to the opening area of each spool.
WA470-7
10-225

Shuttle valve in pressure compensation valve
(WA470-C7C0-041-P-00-A)
When holding pressure in port (B) LS pressure in spring chamber (C)
1. Hydraulic pump
2. Load check valve
3. Shuttle valve
4. Piston
Function
(WA500-C7C0-042-P-00-A)
Shuttle valve (3) is pushed to the right by the port (B) pressure to disconnect the port (B) from port (D).
The holding pressure of port (B) is transmitted to spring chamber (C) to push piston (4) to the left so that
piston (4) and load check valve (2) do not separate from each other.
10-226
WA470-7

Surface area ratio of pressure compensation valve
(WA470-C790-042-P-00-A)
The flow division ratio varies with the surface area ratio of portions (A1) and (A2) of the pressure
compensation valve. Surface area ratio = (A2)/(A1)
When the surface area ratio is 1: The spool meter-in downstream pressure is equal to the maximum load
pressure and oil flows in accordance with the opening area ratio of spool meter-in.
When the surface area ratio is 1 or more: The spool meter-in downstream pressure is more than the
maximum load pressure and oil flows less than the opening area ratio of spool meter-in into the lower
pressure side.
When the surface area ratio is 1 or less: The spool meter-in downstream pressure is less than the
maximum load pressure and oil flows more than the opening area ratio of spool meter-in into the lower
pressure side.
WA470-7
10-227

Introduction of LS pressure
LS shuttle valve
(ALL-C2A4-001-K-01-A)
(WA470-L1P0-041-K-00-A)
1. Hydraulic pump
2. Main spool
4. Load check valve
5. Check valve
6. LS circuit
7. LS shuttle valve
Function (WA500-L1P0-042-K-00-A)
LS pressure (PLS) is the actuator load pressure on the outlet side of the control valve.
The upstream pressure (spool meter-in downstream pressure) of pressure compensation valve (3) is
transmitted through main spool (2) to LS shuttle valve (7).
The LS pressure is connected through valve (5) to port (B) of the actuator, and then it the actuator load
pressure.
Inlet hole (a) in main spool (2) is small in diameter and has a throttling function.
Operation (WA500-L1P0-044-K-00-A)
When main spool (2) is operated, the discharged oil from pump flows into actuator circuit (B).
Pump discharge pressure (PPS) is transmitted through inlet hole (a) of main spool (2) to LS circuit (PLS).
Pump discharge pressure (PPS) increases to the necessary pressure for actuator circuit (B).
10-228
WA470-7

Check valve (5) in main spool (2) opens and the high pressure oil of LS circuit (PLS) flows into actuator
circuit (B).
The pressure in LS circuit (PLS) becomes almost the same as that in actuator circuit (B).
LS bypass plug
(WA470-PNSH-041-K-00-A)
1. Hydraulic pump
2. Main spool
4. LS shuttle valve
5. LS bypass plug
6. LS circuit
Function
(WA500-PQH2-042-K-00-A)
This valve releases the remaining pressure in LS pressure circuit (6) through orifices (a) and (b).
This valve decreases the rising speed of the LS pressure to prevent a sudden change of the oil pressure.
Since the oil flows through LS valve (5), pressure loss is made by the circuit resistance between throttle
(c) of main spool (2) and LS shuttle valve (4).
The effective LS differential pressure decreases to improve the dynamic stability of the actuator.
WA470-7
10-229

ECSS control valve
(WA500-L320-041-K-00-A)
1. Spool
2. Solenoid valve
3. Plug
4. Nut
5. Check valve
Function
(WA500-L320-042-K-00-A)
The controller automatically turns ON/OFF the accumulator charged with the high-pressure gas according
to the travel condition of the machine.
This valve gives elasticity to the vertical movement of the work equipment to restrict the machine body
from rocking, improve the operator comfort, and prevent the load from spilling during high-speed travel.
Operation
(WA500-L320-044-K-00-A)
When the travel speed exceeds 5 km/h, the signal enters solenoid valve (2) and the pressure is
transmitted to (a).
Spool (1) moves to the left.
When spool (1) moves, the passage of (PR) accumulator (ACC) closes and the passage of (A2)
accumulator (ACC), (B2) (T) opens, and ECSS is turned ON.
When the travel speed is 4 km/h or below, no signal enters solenoid valve (2) and spool (1) is kept in
neutral position. At this time, the passage of (PR) accumulator (ACC) opens and accumulator (ACC) is
charged.
10-230
WA470-7

When accumulator (ACC) is charged up to the set pressure, check valve (5) closes and the pressure in
the accumulator (ACC) does not increase any more.
Pressure release valve of accumulator
To release the pressure in accumulator (ACC), loosen nut (4) and plug (3) to open the circuits of (PR) and
(TS).
WA470-7
10-231

Accumulator charge valve
(WA500-G2H0-040-K-00-A)
CR: Accumulator charge pressure pickup port

P: From main pump
PR: To accumulator via ECSS spool
TS1: To tank
TS2: To tank
TS3: To tank
1. Screw
2. Poppet (relief valve)
3. Spring (relief valve)
4. Spring (main pressure reducing valve)
5. Pressure reducing valve spool
6. Check valve
7. Spring (check valve)
10-232
WA470-7

WA470-7
10-233

When in neutral and (P) is low
Function
The discharge pressure (P) of the hydraulic pump is reduced and the pressurized oil is supplied to the
accumulator for ECSS.
Operation
Spring (3) presses poppet (2) against the seat and the line between ports (P1) and (T) is closed.
Check valve (6) is pushed to the left and the line between ports (P1) and (PR) is closed.
Check valve (6) is moved to the right by the pressure of (P1) and the line between (P1) and (PR) is
opened. When (P1) < (PR), spring (7) pushes check valve (6) to the left and the line between ports (P1)
and (PR) is closed.
10-234
WA470-7

When load pressure (P) is high
Operation
When the pressure increases to the set pressure or above, poppet (3) opens and the pressurized oil flows
from port (P1) through hole (a) in spool (5) and the opening of poppet (2) to tank port (T). As a result,
pressure P2 is kept constant.
When pressure P1 is larger than pressure P2, spool (5) moves to the left and closes the opening of the P
o (P1) part. When pressure P1 becomes smaller than pressure P2, the opening of the P o (P1) part
opens. The pressure (P) is reduced to equalize pressure P2 and pressure P1 when this movement is
repeated.
WA470-7
10-235

Work equipment lock solenoid valve
Work equipment lock solenoid valve
(WA380-PK1K-041-K-00-A)
P: From charge valve

A: To work equipment EPC valve port P
T: Drain
Function
(WA380-PK1K-042-K-00-A)
This valve is installed between the charge valve and work equipment EPC valve. Upon receiving the
operation signal from the work equipment controller, the solenoid is "energized" to block the oil to the work
equipment EPC valve and disables the operation of the work equipment.
10-236
WA470-7

Accumulator (for PPC circuit)
Accumulator (for PPC circuit)
(WA380-PL40-041-K-00-A)
1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port
Specification
(WA380-PL40-030-K-00-A)
Gas to be used
Gas capacity (cc)
Charged pressure (MPa {kg/cm2
})
Max. allowable working pressure
(MPa {kg/cm2 })
Function
Nitrogen gas
500
1.18 {12} (at 80C)
3.92 {40}
(WA380-PL40-042-K-00-A)
This accumulator is installed between the charge valve and work equipment PPC valve. Even if the
engine is stopped while the work equipment is raised, pilot oil pressure can be supplied to the work
equipment control valve with the pressure of the compressed nitrogen gas in the accumulator to lower the
work equipment by its own weight.
WA470-7
10-237

Accumulator (for ECSS)
Accumulator (for ECSS)
(WA470-L370-041-K-00-A)
1. Valve
2. Top cover
3. Cylinder
4. Free piston
Specifications
(WA470-L370-030-K-00-A)
Gas to be used
Gas capacity (cc)
Charged pressure (MPa {kg/cm2
})
Max. operating pressure (MPa
{kg/cm2 })
Function
Nitrogen gas
4,000
2.94 {30} (at 20C)
40 {408}
(WA380-L370-042-K-00-A)
This accumulator is installed in the lift cylinder bottom circuit. The space between cylinder (3) and free
piston (4) is filled with nitrogen gas. The nitrogen gas absorbs the hydraulic pulsation generated on the lift
cylinder bottom side to improve the travel performance and workability during travel by utilizing its
compressibility.
10-238
WA470-7

Work equipment linkage
Work equipment
(ALL-L000-001-K-00-A)
(WA470-LB31-041-K-00-A)
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Boom
6. Bucket link
WA470-7
10-239

Bucket
Bucket
(WA470-LB00-041-K-00-A)
1. Bucket
2. Wear plate
3. Bolt-on cutting edge
4. Bucket tooth (if equipped)
10-240
WA470-7

Bucket positioner and boom positioner
Bucket positioner and boom positioner
(WA470-LEE0-041-K-00-A)
1. Bell crank
2. Boom
3. Bucket potentiometer
4. Bucket potentiometer lever
5. Boom potentiometer
6. Front frame
7. Boom potentiometer lever
WA470-7
10-241

ROPS cab
Cab and its attachments

ROPS cab
(ALL-K000-001-K-00-A)
(WA380-K211-041-K-00-A)
The appearance differs corresponding to the destination.

1. Front working lamp
2. Radio antenna
3. Door (left)
4. Air conditioner fresh air filter
5. Front glass
6. Front wiper
7. KOMTRAX communication antenna
8. KOMTRAX GPS antenna
9. Emergency escape door
10. Rear wiper
10-242
WA470-7

Engine control system
Electrical system
(ALL-RA1D-001-K-00-A)
(WA470-AK60-042-K-00-A)
1. Battery disconnect switch

2. Battery
3. Battery relay
4. Slow-blow fuse
5. Fuse box 1
6. Fuse box 2
7. Engine shutdown secondary switch
8. Starting switch
9. KOMTRAX terminal
13. Work equipment controller
14. Service connector
15. Machine monitor
16. Rear view monitor
17. Neutral holding relay
WA470-7
10-243

18. Neutral safety relay

19. Personal code relay
20. Cooling fan pump relay
21. Alternator
22. Starting motor
23. Accelerator pedal
Function
The neutral safety circuit is employed to secure safety when the engine is started.
The engine does not start while the directional lever is not in the "N" position.
When you cannot stop the engine due to stuck starting switch, engine shutdown secondary switch is
usable for stopping the engine.
Operation
When starting switch is in "ON" position
When the starting switch is turned to the "ON" position, starting switch terminals B and BR are closed and
a current flows from the battery to the ground through the starting switch and battery relay, and the battery
relay contacts are closed. As a result, power is supplied to each circuit of the machine. At this time, the
ACC signal flows from starting switch terminal ACC to the engine controller, and the engine is ready to
start.
Neutral safety circuit
When the directional lever is set to the "N (Neutral)" position, a current flows from contact N of the
directional lever to the neutral safety relay coil.
When starting switch is in "START" position
When the starting switch is turned to the "START" position, a current flows from starting switch terminal C
to the starting motor safety relay through the neutral safety relay and personal code relay, and then the
engine starts.
When the directional lever is not in the "N (Neutral)" position, the neutral safety relay does not operate and
the engine does not start.
When starting switch is in "OFF" position
When the starting switch is turned to the "OFF" position, the ACC signal from starting switch terminal ACC
to the engine controller is cut off.
When the ACC signal is cut off, the engine decreases its speed and stops. At the same time, the alternator
stops generating power and the voltage from alternator terminal R is cut off. The current from starting
switch terminal BR is also cut off and the battery relay contacts open to cut off the power supplied to each
circuit of the machine.
Stopping engine with engine shutdown secondary switch
If the engine shutdown secondary switch is turned to the "Stop Engine" position, the current from starting
switch terminal ACC to the engine controller is forcibly cut off.
The above induces the same condition as when starting switch is turned to "OFF" position and the engine
stops.
10-244
WA470-7

Preheating system
Preheating system
(WA500-AM40-051-K-00-A)

2. Battery
3. Battery relay
4. Slow-blow fuse
5. Starting switch
7. Machine monitor
8. Fuse box 2
9. Electric heater
10. Preheater relay
11. Electric heater relay
Automatic preheating system
(WA470-AM40-042-K-00-A)
Function
The automatic preheating system is installed to improve the engine startability in a cold district.
When the starting switch is turned to the "ON" position, the automatic preheating system shortens the
preheating time and sets the preheating time automatically according to the intake air temperature.
When the starting switch is turned to the "ON" position, the preheater pilot lamp on the machine monitor
lights up and the electric heater preheats the intake air
The engine controller sets the preheating time according to the engine coolant temperature sensed.
Keep the starting switch in the "ON" position while the pilot lamp is lit since the engine is being preheated
during this period. In this period, if the starting switch is turned to the "START" position, preheating is
canceled.
Operation
(WA470-AM40-044-K-00-A)
When the starting switch is turned to the "ON" position, the engine controller starts.
When the intake air temperature is -5C or below, the engine controller drives the preheater relay just after
the starting switch is turned to the "ON" position, and then the electric heater relay operates and the
electric heater start preheating the engine.
The operating time of the preheater is shown below.
WA470-7
10-245

Preheating system
Manual preheating system
(WA380-AM40-042-K-01-A)
Function
When the engine is started in the cold season, the preheating time can be lengthened more than the time
with the auto preheating by turning the starting switch to the "Manual preheat" position.
If the starting switch is turned to the "Manual preheat" position, the preheater pilot lamp on the machine
monitor lights up and the electric heater preheats the intake air.
When the starting switch is turned to the "OFF" position, the pilot lamp goes off and the manual preheating
function is canceled.
Operation
(WA380-AM40-044-K-01-A)
If the starting switch is turned to the "Manual preheating" position, the electric heater relay operates and
the electric heater starts preheating.
10-246
WA470-7

Engine power mode selector circuit
Engine power mode selector circuit
(WA380-AP11-051-K-00-A)
1. Power mode selector switch

3. Machine monitor
Function
(WA380-AP11-042-K-00-A)
The engine output can be maximized by turning the power mode selector switch to the "P mode" position.
The fuel consumption during work can be reduced by setting the power mode selector switch to the "E
mode".
The switch signal is input to the work equipment controller. The work equipment controller sends the
signal to the transmission controller, which selects a proper gear speed and travel speed matched to the
power mode in the auto-shift mode.
Operation
(WA380-AP11-044-K-00-A)
When the power mode selector switch is turned to the "P mode" position, the switch signal is input to the
work equipment controller and the CAN signal is sent to the transmission controller.
The transmission controller determines the final engine mode and sends the CAN signal to the engine
controller, and the engine torque performance curve changes to the "P-mode".
When the engine mode is set to the "P mode" with the one-touch power maximizing function, the
transmission controller also sends the CAN signal to the engine controller, and the engine torque
performance curve changes to the "P-mode".
The transmission controller sends the engine output mode pilot lamp lighting signal to the machine
monitor with the CAN signal .
WA470-7
10-247

Engine output limit function
Engine output limit function
(WA380-AP12-042-K-00-A)
If the engine controller recognizes a failure, it limits the engine torque or engine speed to protect the
engine.
The engine torque performance when the torque is limited is shown in the following figure.
A: 30% cut of maximum torque point

B: Approximately 50% of rated output point
The engine torque performance when the engine speed is limited is shown in the following figure.
A: Cut up to about engine speed at maximum torque point
10-248
WA470-7

Automatic warm-up function
Automatic warm-up function
(WA470-AP13-042-K-00-A)
When the engine is started in a cold district, the low idle speed of the engine is increased automatically to
warm up the engine.
If the coolant temperature is 30C or below when the engine is started, the low idle speed increases to
1,020 rpm. The condition for the low idle speed to increase is determined according to the coolant
temperature as shown in the following figure.
If the coolant temperature reaches 60C or higher or the accelerator pedal position is kept at 70% or
above for 3 seconds or longer during the warm-up operation, the automatic warm-up function is canceled
and the engine speed returns to 800 rpm.
WA470-7
10-249

Parking brake control system
(WA380-GP10-051-K-00-A)
1. Parking brake relay

5. Auto idle stop parking brake relay
Operation
(WA470-GP10-044-K-00-A)
When starting switch is in "OFF" position

When the starting switch is turned to the "OFF" position, the contacts of parking brake relay (1) open, thus
no current flows in the parking brake circuit and the parking brake is applied.
While starting switch is in the "OFF" position, no current flows in parking brake solenoid valve (3) and the
parking brake keeps applied, regardless of the operating condition of parking brake switch (2).
When starting switch is in "ON" position
When parking brake switch is turned "ON" (operating) before starting switch is turned "ON"
When parking brake switch (2) is turned "ON" (operating), the current from the battery relay flows through
parking brake switch (2) to the coil of parking brake relay (1) and the contacts close.
If the contacts of parking brake relay (1) are closed, the current from the battery relay continues to flow
into the coil, and the relay contacts are held until the current from the battery relay is cut out.
No current flows in parking brake solenoid valve (3), and the parking brake keeps applied.
Transmission controller (4) recognizes the operation signal of parking brake switch (2) and keeps the
transmission in neutral while the parking brake is in operation to prevent dragging of the parking brake.
If parking brake switch (2) is turned "OFF" (release), the current from the battery relay flows through
parking brake relay (1), parking brake switch (2), and auto idle stop parking brake relay (5) to parking
brake solenoid valve (3), and then release the parking brake.
When parking brake switch is turned "OFF" (releasing) before starting switch is turned "ON"
10-250
WA470-7

When parking brake switch (2) is turned "OFF" (release), no current flows in parking brake relay (1) and
the relay contacts are open.
Even if starting switch is turned "ON", no current flows to parking brake solenoid valve (3). Accordingly, the
parking brake is not released automatically.
When auto-idle stop operates
If parking brake switch (2) is turned "OFF" (release) while the starting switch is turned "ON", the current
from the battery relay flows through parking brake relay (1), parking brake switch (2), and auto idle stop
parking brake relay (5) to parking brake solenoid valve (3), thus the parking brake is kept released.
When the auto idle stop operates, transmission controller (4) outputs a current to auto idle stop parking
brake relay (5).
The current flows in the coil of auto idle stop parking brake relay (5) and the contacts open.
No current flows in parking brake solenoid valve (3), and the parking brake is applied.
When the auto-idle stop operates, the parking brake also operates automatically and keeps operating
during restarting operation.
WA470-7
10-251

System operating lamp function
(WA380-AW1Q-051-K-00-A)

2. Battery
3. Fusible link
4. Fuse box
5. System operating lamp
10. KOMTRAX terminal
Function
The operating condition of each controller can be checked with the system operating lamp to prevent the
abnormal end of the disconnection of the battery power supply circuit while the controllers are in
operation.
a Before cutting off the battery power supply circuit, turn the starting switch to the "OFF" position, and check
that the system operating lamp goes out, then turn the battery disconnect switch to the "OFF" position.
a If you turn the battery disconnect switch to the "OFF" position (battery power supply circuit is cut off) while
the system operating lamp lights up, Controller Data Lost Error can occur. Do not operate the battery
disconnect switch as long as the system operating lamp lights up.
a The system operating lamp goes out in two minutes longest after the starting switch is turned to the "OFF"
position.
a Even if the starting switch is in the OFF position, the system operating lamp may light up since the
KOMTRAX terminal may perform communication.
Lighting up and going off of system operating lamp
Voltage of 24 V is always applied to the one end of the system operating lamp (LED).
When any controller is in operation, the output from the controller to the system operating lamp becomes
Low (0 V). This allows electric current to flow through the diode, lighting up the system operating lamp.
When all controllers are resting, the output from each controller to the system operating lamp becomes Hi
(24 V). The electric current does not flow through the diode, and the system operating lamp goes out.
a The system operating lamp may look slightly luminous in the dark after it is turned off. It is due to the
minute leakage of current and not an abnormal phenomenon.
The KOMTRAX terminal performs communication periodically even if the starting switch is kept in the OFF
position, thus it starts and stops repeatedly.
The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including the
communication status and machine stop time. So the lamp can light up as long as approximately an hour.
10-252
WA470-7

a When you want to cut off the battery circuit for maintenance but the system operating lamp keeps on
lighting up, turn the starting switch to the "ON" position once, then turn it to the "OFF" position. The lamp
will go out in two minutes maximum.
After the system operating lamp goes out, turn the battery disconnect switch to the OFF position
immediately.
WA470-7
10-253

Battery disconnect switch function
(WA470-AW1P-041-K-00-A)
1. System operating lamp

O: OFF
I: ON
Function
(WA380-AW1P-042-K-00-A)
Usually, the battery disconnect switch is used instead of disconnecting the cable from the negative
terminal of the battery in the following cases.
1. When storing the machine for a long period (more than one month)
2. When servicing or repairing the electrical system
3. When performing electric welding
When the battery disconnect switch is turned OFF (the contact is opened), all the continuous power
supplies for the components, including the starting switch B terminal and controllers, are all cut out, and
the condition is the same as the condition when the battery is not connected. Accordingly, all the electric
system of the machine is disabled.
Precautions for using battery disconnect switch
The system operating lamp lights up when the controller is turned ON. Even if the starting switch is in the
OFF position, the lamp lights up while the KOMTRAX is performing communication.
Do not turn OFF the battery disconnect switch while the system operating lamp is lighting up.
If the battery disconnect switch is turned OFF while the lamp is lighting up, the data in the controller may
be lost and the controller may be damaged seriously.
Do not turn OFF the battery disconnect switch while the engine is running or immediately after the engine
is stopped.
10-254
WA470-7

If the battery disconnect switch is turned OFF while the alternator is generating power, the generated
current has nowhere to go, leading to overvoltage in the electrical system of the machine, which may
cause serious damage to the electrical system, including the electric devices and controllers.
If the battery disconnect switch is turned OFF for a long period, the machine monitor and the clock of the
radio may be initialized. In this case, re-setting is required.
WA470-7
10-255

Transmission controller system
(WA380-CN20-001-K-00-A)
a The display of the travel speed explained in this section is for the tires of size 26.5-25, unless otherwise
specified.
Transmission controller system diagram
10-256
(WA470-CN20-051-K-00-A)
WA470-7

WA470-7
10-257

Transmission gear shift control function

Electronic modulation function
(WA380-CN11-042-K-00-A)
(WA380-CN12-042-K-00-A)
1. Engine
2. Torque converter
3. Transmission
4. Axle
6. Combination switch
9. Engine speed sensor
10. Transmission input speed sensor
10-258
WA470-7

Input/output signal
a. Directional signals
b. Shift range signal
c. Accelerator signal
d. Transmission output speed signal
e. ECMV operation signal
f. Fill switch signal
g. Transmission input speed signal
h. Engine speed signal
The modulation control system controls the clutch pressure so that the transmission is shifted properly to
all the gear speeds (including the lockup clutch) and less shocks are generated at gear shifting
(engagement of the clutch) according to the engine speed, transmission oil temperature, transmission
input and output speeds, and gear shift pattern.
The clutch pressure is so controlled that the difference between the input and output speeds will follow the
target value corresponding to the engine speed and accelerator pedal position to prevent sharp
engagement.
After the clutch is disengaged, the disengagement pressure is kept low to prevent loss of torque until
engagement of the clutch starts.
If abnormal gear shift time lag occurs, the learning function corrects the modulation automatically.
Gear shift display function
(WA380-CN13-042-K-00-A)
The transmission controller sends the input signal condition related to gear shift via the network to the
machine monitor to display it.
1. Travel direction indicator
The shift lever position pilot lamps of the machine monitor indicate the directional lever condition input
from the transmission controller.
If the directional lever is in neutral and no signal is input to the transmission controller, all the shift lever
position pilot lamps of the machine monitor go off.
If two signals are input to the transmission controller because of a failure, two shift lever position pilot
lamps of the machine monitor may light up simultaneously.
While the directional lever is in the "R (Reverse)" position, the controller operates the backup lamp relay to
turn on the backup lamp and backup alarm buzzer.
2. Gear speed indicator
The shift lever position pilot lamps of the machine monitor indicate the gear shift lever condition input from
the transmission controller.
If the gear shift lever is in neutral and no signal is input to the transmission controller, all the shift lever
position pilot lamps of the machine monitor go off.
If two signals are input to the transmission controller because of a failure, a shift lever position pilot lamp
which is different from the gear shift lever position may light up since the higher gear speed is given priority.
3. Display of actual gear speed
The shift indicator of the machine monitor indicates the travel direction and gear speed output by the
transmission controller.
If the directional lever is in the "N (Neutral)" position, "N" is displayed. If the directional lever is in the "F
(Forward)" or "R (Reverse)" position, "F" or "R" and the gear speed are displayed simultaneously.
While the parking brake is in operation, "N" is always displayed since no gear speed signal is output.
While the transmission cut-off function is in operation and the transmission is in neutral, "N" is always
displayed as well.
Automatic gear shift function
(WA380-CN14-042-K-00-A)
The transmission gear is shifted in the automatic shift mode where the gear speed is selected
automatically according to the travel speed or is shifted in the manual shift mode where the gear speed is
selected with the gear shift lever.
The shift mode is changed with the transmission shift mode selector switch. If the auto-shift is selected,
the auto shift pilot lamp on the machine monitor lights up.
In the auto-shift mode, upshift/downshift operations and ON/OFF of the lockup clutch are controlled
according to the condition of the power mode.
WA470-7
10-259

There are two modes of "H" and "L" in the auto-shift mode, which are selected as shown in the following
table according to the condition of the transmission mode selector switch and power mode selector switch.
Power mode
selector switch
P mode
E mode
Transmission shift mode selector switch

H
L
Auto-shift H mode
Auto-shift L mode
Auto-shift L mode
Auto-shift L mode
MANUAL
Manual shift mode
Manual shift mode
In the auto-shift mode, the upshift/downshift operations are controlled, corresponding to the directional
lever, gear shift lever, travel speed, accelerator pedal position, and engine speed.
a1: Upshift (Other than hunting prevention)

a2: Upshift (Hunting prevention)
b: Upshift
c: Downshift
d: Downshift
1. When gear shift lever is in either position of "1st" to "4th"
The maximum gear speed of auto-shift operation (gear shift range) is limited.
Since the machine is usually started in the 2nd gear in the auto-shift mode, the gear is upshifted/
downshifted between the 2nd and 4th. If the kickdown function is used, the gear can be downshifted to the
1st under a certain condition.
2. When directional lever is in N (Neutral) position
When the directional lever is in the "N (Neutral)" position, the actual transmission gear speed is fixed to
the gear speed before the directional lever is set in the "N (Neutral)" position.
Even if the gear shift lever is operated while the directional lever is in the "N (Neutral)" position, the gear
speed before the operation is held. The gear speed changes when the directional lever is operated to the
"F (Forward)" or "R (Reverse)" position.
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WA470-7

Shift hold function
(WA380-CP11-042-K-00-A)
If the auto-shift is selected and the hold switch is pushed, the shift hold function maintains the current gear
speed and does not upshift the gear even when the travel speed increases. When the travel speed
decreases, this function does not downshift the gear.
The shift hold pilot lamp on the machine monitor keeps lighting while the shift hold function is in operation.
The shift hold function is canceled and the pilot lamp is turned OFF by pressing the hold switch again.
When the directional lever, gear shift lever, or kickdown switch is operated, the shift hold function is
canceled automatically. The operating condition of the torque converter lockup is not maintained.
Kickdown function
(WA470-CP12-042-K-00-A)
1. In manual shift mode

While the directional lever is not in "N (Neutral)" and the gear shift lever is in the "2nd", if the kickdown
switch is pressed, the gear is shifted to the "1st".
While the directional lever is not in "N (Neutral)" or the gear shift lever is not in the 2nd, the operation of the
kickdown switch is ignored.
If the directional lever is operated or the gear shift lever is operated to a position other than the "2nd" after
the actual gear speed is changed to the "1st", the kickdown function is canceled. After the kickdown
function is canceled, the gear speed is changed to the gear speed selected with the gear shift lever.
2. In auto-shift mode
The kickdown function works when the directional lever is not in "N (Neutral)" and the gear shift lever is not
in the "1st".
The gear speed is changed as shown in the following table by the operation of the kickdown switch.
When the directional lever is operated or the disapproved time for shift for preventing shift hunting passes,
the kickdown function is canceled. After it is canceled, the gear shifting becomes normal as an automatic
gearshift.
Gear speed before
kickdown
2nd T/C
3rd T/C
4th T/C
2nd L/U
3rd L/U
4th L/U
Transmission output speed when kickdown switch is pressed

[rpm]
(Reference: Actual travel speed [km/h])
Whole range
Below 775 (10.5)
775 (10.5) or above
Below 775 (10.5)
775 (10.5) or above
Whole range
Below 775 (10.5)
775 (10.5) or above
Below 775 (10.5)
775 (10.5) or above
Gear speed after

kickdown
1st T/C
1st T/C
2nd T/C
1st T/C
3rd T/C
1st T/C
1st T/C
3rd T/C (*1)
1st T/C
4th T/C (*1)
T/C: Indicates travel through torque converter

L/U: Indicates travel through direct drive (lockup operation)
*1: When the lockup function is canceled by pressing the kickdown switch, it is not turned on again until
the following conditions are met.
After the torque converter lockup switch is returned to the "OFF" position, it is turned to the "ON"
position again.
The travel speed becomes the faster speed at which the lockup operates.
3. In forward 1st
If the kickdown switch is pressed while the power mode is in "E mode" and the transmission is in the
forward 1st, the power mode changes to "P mode" temporarily. (One-push power max. function)
The change of the power mode occurs only when the transmission is in the forward 1st, regardless of the
auto-shift / manual shift, and canceled when the actual gear speed is changed to another position from the
1st or the directional lever is changed to another position from the forward.
Auto-kickdown function
(WA380-CP13-042-K-00-A)
When the machine is set in the digging condition in the auto-shift mode, if the travel speed reaches the
specified speed, the gear speed is changed to the 1st gear automatically.
The digging condition means the condition in which the travel speed decreases, the boom is near the
ground, the bucket is not tilted, and the brake pedal is not depressed.
WA470-7
10-261

Torque converter lockup function
(WA500-CDR8-042-K-00-A)
The torque converter lockup function automatically controls the lockup operation while the torque
converter lockup switch is turned "ON", regardless of the shift mode.
The torque converter lockup pilot lamp on the machine monitor keeps lighting while the lockup is in
operation.
The lockup operates in the gear speeds shown in the following table.
Transmission shift
mode selector
switch
H
L
MANUAL
Gear speed for lockup operation (Lockup operates: Q)

F1
F2
F3
F4
Q
Q
Q
Q
Q
Q
Q
Q
Q
R1
R2
R3
R4
Q
Q
Q
Q
Q
Q
Q
Q
Q
1. Travel speed for lock up operation

The travel speed at which the lockup operates is determined by the directional lever, the gear shift lever,
the travel speed, and the accelerator pedal position. When the manual shift is selected, the lockup
operates at the same travel speed as in the auto-shift H mode.
2. Lockup protection function
The lockup operates only when the machine travel direction matches to the directional lever position.
3. Condition for disabling lockup
The lockup does not operate in the following cases.
Machine is digging (lockup protection)
Boom is being raised (boom raise operation priority)
When the accelerator is operated and the engine speed is low.
Hunting prevention function
(WA500-CN15-042-K-00-A)
The transmission controller detects and prevents hunting that occurs when the gear speed is shifted from
the 2nd to the 3rd and from the 3rd to the 2nd in the auto-shift mode.
If the gear is shifted continuously in the order of the 2nd o 3rd o 2nd o 3rd (3rd o 2nd o 3rd o 2nd), the
transmission controller judges that hunting occurs and changes the upshift point temporarily.
The hunting prevention function is canceled at the next gear shift operation (including the directional
change operation and kickdown operation). After the hunting prevention function is canceled, the normal
auto-shift point is applied.
When the 2nd lockup is turned ON/OFF continuously, the lockup is canceled. (This is also applied to the
3rd lockup.) Then the travel speed at which the lockup operates is changed temporarily.
The hunting prevention function related to the lockup operates when the controller recognizes hunting
even in the manual shift mode.
Adjustment of transmission initial learning and ECMV current
(WA380-CN16-042-K-00-A)
Dispersion of the transmission itself and ECMV can be corrected by adjusting the items of "ECMV
automatic correction" and "T/M initial learning" with the adjustment function of the machine monitor.
If the above items are not adjusted, gear shift shocks or time lag may occur.
a For the adjustment procedure, see Testing and adjusting, "Special functions of machine monitor".
Change of shift point
(WA380-CN17-042-K-00-A)
The transmission controller has the function to adjust gear shift point of forward travel in the auto-shift "L
mode".
Hunting occurs under a certain condition of jobsite, the travel speed at which the gear speed is
downshifted/upshifted can be adjusted by adjusting the items of "T/M gear shift point" with the adjustment
function of the machine monitor.
a For the adjustment procedure, see Testing and adjusting, "Special functions of machine monitor".
4th gear speed limit function
(WA380-CN18-042-K-00-A)
Operation in the 4th gear can be limited by setting "4th Gear Prohibition" to "ADD" with the "Option Select
function" of the machine monitor.
a For the setting procedure, see Testing and adjusting, "Special functions of machine monitor".
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WA470-7

Transmission protection function
(WA380-CV31-001-K-00-A)
Protection function when travel direction is changed
(WA470-CV32-042-K-00-A)
When the directional lever is operated during high-speed (3rd/4th gear) travel, gear shifting is limited to
protect the transmission.
1. In manual shift mode
Range X: Travel direction is changed. (Normal range)
Range Y: Travel direction is changed and alarm buzzer sounds.
Range Z: Travel direction is changed and alarm buzzer sounds. The gear speed is shifted to the 3rd or 4th
gear, depending on the travel speed. Then, the gear speed is downshifted to the current speed position as
the travel speed decreases.
2. In auto-shift mode
Range X: Travel direction is changed and transmission is shifted to the 2nd. (Normal range)
Range Y: Travel direction is changed and transmission is shifted to the 2nd and alarm buzzer sounds.
Range Z: Travel direction is changed and alarm buzzer sounds. The gear speed is shifted to the 3rd or 4th
gear, in accordance with the travel speed. Then, the gear speed is downshifted to the 2nd if the travel
speed decreases further.
a The upshift/downshift and kickdown operations are not accepted for 2 seconds just after the travel
direction changing operation. If the upshift/downshift operation is performed with the gear shift lever, the
gear speed is shifted after 2 seconds.
In the auto shift mode, the gear is not upshifted until it is downshifted to the 2nd.
Transmission output shaft speed [rpm]

Engine speed [rpm]
960 {13}
1,700
1,034 {14}
1,900
1,181 {16}
Downshift protection function
(WA470-CV33-042-K-00-A)
If the travel speed is above the set speed in downshift operation, downshift is not accepted for protection
of the engine and pump.
The alarm buzzer sounds while the downshift protection function is in operation.
The alarm buzzer keeps sounding until the gear speed position of the gear shift lever matches with the
actual gear speed. Accordingly, the alarm buzzer stops sounding if the gear is upshifted even if the travel
speed does not decrease.
The downshift protection is effective even in the kickdown operation. If the kickdown switch is pressed
when the travel speed is higher than the protection condition, it is not accepted but the alarm buzzer
sounds for 3 seconds.
The downshift protection is effective even when the auto kickdown is applied, but the alarm buzzer does
not sound in this case.
The downshift protection operates under the following condition.
WA470-7
10-263

Transmission output shaft speed [rpm]

Protection cancelation condition
Protection condition
Min. 2,227 (30.2)
Below 2,005 (27.2)
Min. 1,470 (19.9)
Below 1,322 (17.9)
Min. 1,061 (14.4)
Below 951 (12.9)
Downshift
target gear
speed
To 3rd speed
To 2nd speed
To 1st speed
Engine overrun prevention function
(WA380-CV34-042-K-00-A)
If the engine speed rises above 2,425 rpm, the alarm buzzer sounds for notice of operation of engine
overrun prevention function. The alarm buzzer stops when the engine speed lowers below 2,325 rpm.
If the engine speed rises above 2,500 rpm, the lockup is cancelled automatically to prevent overrun of the
engine.
The alarm buzzer sounds while the engine overrun prevention function is in operation.
Once the lockup is cancelled, the lockup condition is maintained for 5 seconds. When the transmission
output shaft speed decreases to a level corresponding to below 2,350 rpm of the engine speed after 5 or
more seconds, the lockup is applied again.
While the lockup is not in operation, the buzzer sounds for notice or warning at the above engine speeds,
but no special remedy is performed.
Speed limiting function
(WA470-CV35-042-K-00-A)
If the travel speed exceeds the specified maximum travel speed, the alarm buzzer sounds.
Unit: km/h
Model
Alarm activation specified value (actual travel speed)
Alarm cancellation specified value (actual travel speed)
WA470-7
40.0
39.5
If the travel speed exceeds the threshold value in the 4th lockup mode, the upper limit of the accelerator
pedal position is restricted to limit the maximum travel speed.
Unit: km/h
Model
Shift range
Actual travel speed (B)
Actual travel speed (C)
Neutralizer function
WA470-7
F4
R4
37.0
38.0
(WA380-CV36-042-K-00-A)
While the parking brake switch is turned "ON", the transmission is kept in neutral to prevent dragging of
the parking brake, regardless of the positions of the directional lever and gear shift lever.
Since the parking brake circuit employs the safety mechanism, the parking brake is kept applied even if
the starting switch is turned from the "OFF" position to the "ON" position. Accordingly, when the starting
switch is turned to the "ON" position, the transmission is always set in neutral, regardless of the positions
of the directional lever and gear shift lever.
10-264
WA470-7

Engine control function
(WA380-CN19-001-K-00-A)
Power mode selection control
(WA380-CN1A-042-K-00-A)
When the power mode selector switch is set to the "P mode" position, the torque curve information in the P
mode is sent to the engine controller. At the same time, the information of the power mode is sent to the
machine monitor to change the output mode pilot lamp.
The output mode pilot lamp also changes when the "P mode" is selected with the one-touch power
maximizing function.
Engine stop prevention function
(WA500-CN1B-042-K-00-A)
When the travel direction is changed during high-speed travel, if the engine speed is low, the engine
receives counter-torque from the tires and may stall.
To prevent the engine from stalling, the throttle (accelerator pedal) position lower limit value is sent to the
engine controller when the travel direction is changed.
Overheat prevention function of transmission controller
(WA500-CV3C-042-K-00-A)
When the torque converter oil temperature exceeds 120C, the accelerator pedal position is controlled to
prevent overheat.
When the coolant temperature exceeds 100C, the engine output torque is limited to prevent overheat.
Brake load reduction control
(WA500-CV3D-042-K-00-A)
When the 2nd gear is selected in P mode, the upper limit of the accelerator pedal position is restricted to
limit the rim pull and reduce the load when the brake is dragged, according to the transmission output
shaft speed and the brake oil pressure.
a The larger one between the accelerator pedal position judged by the transmission output speed and that
judged by the brake oil pressure is selected.
Judgment by transmission output speed
A: Upper limit of accelerator pedal position

Judgment by brake oil pressure
B: Upper limit of accelerator pedal position

WA470-7
10-265

Driving force cut control
(WA470-CV3E-042-K-00-A)
In the digging work, the upper limit of the accelerator pedal position is restricted to reduce the driving force
and priority is given to the "raising" operation of the boom, according to the load on the work equipment.
When conditions 1 to 4 are satisfied, the rim pull is judged too large and the upper limit of the accelerator
pedal position matched to the target rim pull is sent to the engine controller.
This function becomes effective when Lift up mode in Option select function of the machine monitor is
set to ADD.
a For the setting procedure of the Lift up mode, see Testing and adjusting, Special functions of machine
monitor.
Operating condition
Condition 1
Condition 2
Condition 3
Condition 4
Machine is digging
Machine is not scraping up
The traction force is high comparing to the lifting force. Or, boom stalls in boom RAISE
operation.
"Lift up mode" is set to ADD in Option Select
Engine torque control function (WA380-CV3H-042-K-00-A)

Engine torque control by phase of work
The engine output torque is controlled so that it is sufficient for each phase of the work by judging each phase
from the engine speed, travel speed, pump discharge pressure, travel direction, work equipment condition,
etc.
Cooling fan control function
(WA470-B711-042-K-00-A)
The hydraulic cooling fan is employed and the swash plate angle of the hydraulic pump is controlled to
reduce the horsepower loss and noise at low temperature.
The transmission controller receives the engine speed and coolant temperature received by the engine
controller via the network. The transmission controller also directly receives the information on the
hydraulic oil temperature and torque converter oil temperature.
The transmission controller sends the signal current to the swash plate angle control EPC valve of the
cooling fan pump on the basis of the received information and sets the fan speed corresponding to each
temperature and engine speed by controlling the swash plate angle.
10-266
WA470-7

1. Radiator
2a. Cooling fan reverse rotation solenoid valve
3. Cooling fan pump
3a. Swash plate angle control EPC valve
4. Cooling fan speed sensor
6. Engine
7. Coolant temperature sensor
8. Engine speed sensor
11. Hydraulic oil temperature sensor
12. Hydraulic tank
13. Torque converter oil temperature sensor
14. Torque converter
16. Front brake accumulator pressure drop sensor switch
17. Rear brake accumulator pressure drop sensor switch
Input/output signal
a. Accelerator position signal
b. Coolant temperature signal
c. Engine speed signal
d. CAN signal
e. Cooling fan speed signal
WA470-7
10-267

f. Hydraulic oil temperature signal

g. Torque converter oil temperature signal
h. Cooling fan reverse signal
j. Cooling fan pump swash plate angle control signal
k. Cooling fan reverse pilot lamp signal
l. Front brake accumulator pressure drop signal
m. Rear brake accumulator pressure drop signal
Fan speed and temperature
*1: The target fan speed is decided by the highest temperature information among the coolant temperature,
hydraulic oil temperature, and torque converter oil temperature. However, when the coolant temperature is
low, the torque converter oil temperature is not used.
*2: In this range, the fan speed corresponds to the coolant temperature, hydraulic oil temperature, and torque
converter oil temperature.
*3: When the air conditioner is in operation, the minimum speed becomes 600 rpm.
Control function when engine is started
(WA470-B714-042-K-00-A)
When the engine is started, control different from the ordinary control by temperature is performed.
Range A: Engine speed Z 500 rpm (Engine "stopped" to "being cranked")

The target fan speed is set to 0 rpm to reduce the torque required to start the engine and for higher engine
startability. After the engine speed reaches 500 rpm, the target fan speed is kept at 100 rpm for 2 seconds.
Range B: Basic control (500 rpm < Engine speed)
10-268
WA470-7

The ordinary fan control based on "Fan speed set by temperature" is performed.
Control function when brake accumulator is charged
(WA380-B71B-042-K-00-A)
The fan pump is used for charging the brake accumulator as well.
While the brake accumulator is being charged, the charge time is shortened and the control is performed
differently from the normal control by temperature to prevent the fan from stopping during the charge.
For 10 seconds after the brake accumulator pressure drop signal is turned OFF, the minimum fan speed is
set to 750 rpm.
If the brake accumulator pressure is turned OFF, the minimum fan speed is 750 rpm for 10 seconds after
the control at the start of the engine is finished.
Fan reverse function
(WA470-B715-042-K-00-A)
When the manual fan reverse mode is operated through the machine monitor to clean the radiator core,
the cooling fan reverse rotation solenoid valve of the cooling fan motor operates to reverse the fan
rotation.
Fan rotation auto reverse function
1. Fan rotation manual reverse function
The operator can change the fan rotation direction freely by setting the manual fan reverse mode to the
Reverse or Default position.
While the fan rotation direction is being changed, the pilot lamp indicating the change is displayed on
the standard screen to notify the operator of the operating condition. If the changing condition is not
satisfied because of high temperature of the coolant or oil, changeover condition waiting pilot lamp
lights up.
On the standard screen, the cooling fan reverse pilot lamp indicates the fan reverse rotation condition.
When all the conditions are satisfied, the fan rotation direction is changed from Default to Reverse.
Condition 1 The manual fan reverse rotation mode is set to "Reverse".
The coolant temperature is below 102C.
Condition 2
[for prevention of overheat]
The hydraulic oil temperature is below 97C.
Condition 3
The torque converter oil temperature is below 120C.
Condition 4
At least 10 seconds elapse after the brake accumulator pressure drop signal is turned OFF.
Even if the accumulator pressure drop signal turns OFF, at least 10 seconds elapse after the
Condition 5 engine is started.
[For securing oil quantity to be added to the brake accumulator]
Condition 6 There is no error in the fan speed sensor or engine speed sensor.
When any of the conditions is satisfied, the fan rotation direction is changed from Reverse to Default.
The manual fan reverse rotation mode is set to the "Default" position while the fan is rotating in
reverse.
Condition 2 10 minutes elapse with the fan rotating in reverse.
Condition 3 An error is detected in the fan reverse solenoid or fan pump EPC solenoid.
Condition 4 The engine stops.
Condition 1
2. Fan rotation auto reverse function

The fan rotation reverse cycle and fan reverse rotation duration can be set at a certain interval by
setting the auto-fan rotation reverse mode through the machine monitor.
While the fan rotation direction is being changed, the pilot lamp indicating the change is displayed on
the standard screen to notify the operator of the operating condition. If the changing condition is not
satisfied because of high temperature of the coolant or oil, changeover condition waiting pilot lamp
lights up.
On the standard screen, the cooling fan reverse pilot lamp indicates the fan reverse rotation condition.
When all the conditions are satisfied, the fan rotation direction is changed from Default to Reverse.
WA470-7
10-269

Condition 1
Condition 2
Condition 3
Condition 4
Condition 5
Condition 6
Condition 7
The fan reverse rotation switch is set to AUTO.

The auto-fan reverse rotation mode is set to any position of A to D.
The coolant temperature is below 102C.
The hydraulic oil temperature is below 97C.
The torque converter oil temperature is below 120C.
At least 10 seconds elapse after the brake accumulator pressure drop signal is turned OFF.
Even if the accumulator pressure drop signal turns OFF, at least 10 seconds elapse after the
engine is started.
[For securing oil quantity to be added to the brake accumulator]
The fan rotation direction change cycle has passed.
There is no error in the fan speed sensor or engine speed sensor.
When any of the conditions is satisfied, the fan rotation direction is changed from Reverse to Default.
The auto-fan reverse rotation mode is turned OFF while the fan is rotating in reverse.
Condition 1 Or, it is set to a mode of fan reverse rotation time which is shorter than the fan reverse rotation
elapsed time.
Condition 2 The fan reverse rotation time has passed.
Condition 3 An error is detected in the fan reverse solenoid or fan pump EPC solenoid.
Condition 4 The engine stops.
3. Adjustment of fan reverse rotation changing cycle and duration
Three defaults, A to C, for fan reverse rotation cycle and duration are prepared. The fan reverse rotation
cycle and duration can be adjusted freely by adjusting the "Fan reverse rotation cycle" and "Fan reverse
rotation duration" with the adjustment function of the machine monitor. The set value is displayed as mode
D.
a For the adjustment procedure, see Testing and Adjusting, "Special functions of machine monitor".
4. Overheat prevention function
When the coolant, hydraulic oil, or torque converter oil overheats (the thermometer caution lamp on the
machine monitor lights up) while the fan is rotating in reverse, the reverse rotation is stopped and changed
to the forward rotation forcibly to increase the air flow to the radiator.
5. Fan speed in reverse rotation mode
The fan speed in the reverse rotation mode depends on the engine speed.
Engine speed [rpm]
Fan target speed [rpm]
850
900
Fan 100% setting function
1,750
1,300
2,050
1,300
(WA380-B71D-042-K-00-A)
The cooling fan speed can be set to 100% forcibly, independent from the hydraulic oil temperature or
coolant temperature.
The cooling fan speed can be set to 100% by setting the "Fan 100% adjustment" with the adjustment
function of the machine monitor.
The fan speed becomes the lower one of 1) or 2) below.
1) Max. target fan speed
2) Target fan speed decided by engine speed
a For the setting procedure, see Testing and Adjusting, "Special functions of machine monitor".
Protection function
(WA470-B713-042-K-00-A)
If the engine speed increases to 2,300 rpm or above, the swash plate angle of the cooling fan pump is
minimized to prevent overrun of the cooling fan motor.
If the transmission controller cannot recognize the engine speed or each temperature data because of a
network communication trouble etc., it sets those items as follows.
1) Engine speed: Assumes as 2,170 rpm.
10-270
WA470-7

2) Engine coolant temperature: Ignored. The value obtained from the remaining normal sensors are used.
However, if neither of the hydraulic oil temperature and torque converter oil temperature is recognized, the
engine coolant temperature is assumed to be 90 C.
3) Hydraulic oil temperature: Ignored. The value obtained from the remaining normal sensors are used.
4) Torque converter oil temperature: Ignored. The value obtained from the remaining normal sensors are
used.
Transmission cut-off function
(WA380-CP30-042-K-00-A)
The transmission cut-off oil pressure sensor detects the brake pilot pressure when the right and left brake
pedals are depressed and the transmission is set in neutral.
The transmission can be cut off at any position by saving the brake pilot pressure at the brake pedal
position where the transmission comes in neutral.
1. Contents of control
If the transmission cut-off operating condition is met, the transmission is set in
neutral.
Outline
If the transmission cut-off cancellation condition is met, the cut-off is canceled
and the transmission gear is shifted by modulation.
<Operating condition in 1st or 2nd gear>
The transmission cut-off pilot lamp is turned "ON" and the brake pilot pressure
Transmisexceeds the cut-off-IN pressure.
sion cut- Operating <Operating condition in 3rd or 4th gear>
off control condition The transmission cut-off pilot lamp is turned "ON" and the accelerator pedal
depression is larger than 30% and the brake pilot pressure exceeds the IN
pressure of the cut-off circuit.
Condition The cut-off is canceled when any of the following conditions is met.
for
cancella- The transmission cut-off pilot lamp is turned "OFF".
The brake pilot pressure is below the OUT pressure of the cut-off circuit.
tion
Condition
possible to The transmission cut-off pilot lamp is turned "ON".
be set
1) The brake pedal is depressed to a set position. (Setting is possible even if the
brake pedal is not depressed)
2) The transmission cut-off set switch is pressed.
3) The brake pilot pressure when the switch is pressed is recognized.
<In case of within settable range>
The brake pilot pressure when the switch is pressed is saved temporarily.
<In case of out of settable range>
Setting
method
The upper or lower limit of the brake pilot pressure in the settable range is saved
Setting of
temporarily.
transmisThe setting completion buzzer (pip, pip) sounds.
sion cut4) The transmission cut-off switch built-in pilot lamp flashes for 2.5 seconds.
off point
5) The set value is saved. (Setting mode is finished)
Resetting
method
a The set condition is maintained even after the starting switch is turned to the
"OFF" position.
1) Under the condition of setting method Step 4) (the pilot lamp built in the
transmission cut-off switch flashes for 2.5 seconds), press the transmission cut-off
set switch again.
2) The pilot lamp stops flashing and the cut-off point is set to the brake pilot pressure
in default. The setting cancel buzzer (peep) sounds.
3) The set (default) value is saved. (Setting mode is finished)
a The set condition is maintained even after the starting switch is turned to the
"OFF" position.
2. Outputting condition
WA470-7
10-271

Pilot lamp built-in

transmission cut-off
switch
Outputting condition
Transmission cut-off pilot lamp is turned "ON". Lights up

Transmission cut-off pilot lamp is turned "ON"
and transmission cut-off set switch is turned
"ON".
For 2.5 seconds or until resetting (sensor is
normal)
Setting method Steps 2) to 5)
Flashes
(For 2.5 seconds or
until resetting)
Transmission cut-off pilot lamp lamp is turned

"ON" and transmission cut-off pressure sensor Keeps turned OFF
is abnormal.
Transmission cut-off pilot lamp is turned "ON" Lights up

and transmission cut-off set switch is abnormal
Transmission cut-off pilot lamp is turned "ON"

and transmission cut-off set switch is turned
"ON".
Reset during 2.5 seconds
Lights up
Transmission cut-off pilot lamp is turned "OFF" Goes out
Buzzer
command
Cut-off point
(Communication
output)
Controlled by
None
previously saved
value
When set switch
is pressed,
Brake pilot pressure
setting
when set switch is
completion
pressed is saved.
buzzer sounds
(pip, pip).
None
(Error is
displayed on
machine
monitor)
None
(Error is
displayed on
machine
monitor)
When set switch
is pressed,
setting
cancelltion
buzzer sounds
(peep).
None
Control is not made.

Saved value is not
changed.
Controlled by
position where error
occurred. Saved
value is not
changed.
Default value for
brake pilot oil
pressure is saved.
Control is not made.
a While the transmission is cut off, "N" is displayed on the shift indicator of the machine monitor. (Travel
direction output signal "N")
a If the transmission is cut off after the kickdown switch is pressed to set the gear speed to the 1st, it is
reset to the 1st, regardless of the shift mode.
a When the lockup is in operation, the cut-off operates after the lockup is released.
3. Settable range of transmission cut-off point
Settable range
0.49 to 4.41 MPa {5 to 45 kg/cm2}
Note 1: When the cut-off point is set 0.49 MPa {5 kg/cm2} or less, it is actually set to 0.49 MPa {5 kg/cm2}.
Note 2: When the cut-off point is set 4.41 MPa {45 kg/cm2} or more, it is actually set to 4.41 MPa {45 kg/
cm2}. The default value is 1.47 MPa {15 kg/cm2}.
Set a hysteresis of 0.20 MPa {2 kg/cm2} between cut-off-IN (neutralizing) pressure and cut-off-OUT
(restoration) pressure.
Example) When pressure sensor is set to a position of 0.98 MPa {10 kg/cm2}
Cut-off-IN pressure = 0.98 MPa {10 kg/cm2}
Cut-off-OUT pressure = 0.78 MPa {8 kg/cm2}
10-272
WA470-7

E.C.S.S. function
(WA500-L3B0-051-K-00-A)
E.C.S.S.: Electronically Controlled Suspension System
2. Gear shift lever
3. Speed sensor
4. E.C.S.S. switch
5. 1st clutch ECMV
6. 2nd clutch ECMV
7. 3rd clutch ECMV
8. 4th clutch ECMV
9. E.C.S.S. solenoid valve
Input/output signal
a. Gear shift lever "1st" signal
b. Gear shift lever "2nd" signal
c. Gear shift lever "3rd" signal
d. Gear shift lever "4th" signal
e. Travel speed signal
f. Pulse GND
g. E.C.S.S. switch "ON" signal
h. 1st clutch ECMV operation signal
i. 2nd clutch ECMV operation signal
j. 3rd clutch ECMV operation signal
k. 4th clutch ECMV operation signal
l. ECMV GND
m. ECMV GND
n. E.C.S.S. operation signal
Function
(WA380-L3B0-042-K-00-A)
The ECSS gives elasticity to the vertical movement of the work equipment to restrict rocking of the
machine body, improve the operator comfort, prevents the load from spilling, and improves the working
efficiency during high-speed travel by using the buffering effect of the accumulator charged with highpressure gas and automatically controlling the relief pressure of the lift cylinder for the traveling condition.
Setting method
The ECSS does not function unless ECSS Operating Speed is set to "ADD" with the "Option selection
function" of the machine monitor.
a For the setting procedure, see Testing and adjusting, "Special functions of machine monitor".
WA470-7
10-273

Operation
(WA500-L3B0-044-K-00-A)
The operating condition of the ECSS is as per the following table.

ECSS switch
Gear speed
Travel speed [km/h]
OFF
All gear speeds

All gear speeds
1st
0 to Max.
0 to Max.
0 to Max.
(*3) Max. 4
(*2) Min. 5
ON
2nd to 4th
Boom lever
condition (*1)
ON/OFF
OFF
ON/OFF
ON/OFF
ON
E.C.S.S. operation
signal
OFF
OFF
OFF
OFF
ON
*1. Boom lever condition ON: Boom lever stroke > -80%
E.C.S.S. selection point

Travel speed [km/h]
A
(*3)
4
B
(*2)
5
*2: ECSS selection point (A) is the value obtained by subtracting 1 km/h from ECSS selection point (B) (4 to
15 km/h).
*3: The travel speed of ECSS selection point (B) can be set freely in the range from 5 to 15 km/h by adjusting
ECSS Operating Speed in the adjustment function of the machine monitor.
a For the adjustment procedure, see Testing and Adjusting, "Special functions of machine monitor".
Directional switch control function
(WA380-CV3F-042-K-00-A)
The switch to select the travel direction is installed on the side of the work equipment control lever
independently from the standard directional lever so that the operator can select the travel direction with
his/her right hand.
1. Selection of directional selector switch
When only the directional lever is used, the directional lever input signal leads to recognition of
travel direction. Since the switch to select the travel direction is added, a selector switch is installed
to select the additional switch or the directional lever.
a The operation with the directional selector switch is selected only when the directional selector
switch actuation switch is turned ON. However, the directional lever (standard directional lever) is
given the priority for the operation.
The condition for operating with the directional selector switch is that the standard directional lever
is in N (Neutral), the directional selector switch is in N (Neutral), and the directional selector switch
actuation switch is turned ON.
a When travel direction can be changed with the directional selector switch, the directional selector
pilot lamp of the machine monitor lights up in green.
a If the directional selector switch actuation switch is turned ON/OFF while either is not in N (Neutral),
the directional selector pilot lamp of the machine monitor lights up in yellow and the caution lamp
lights up.
Even if the directional selector switch is effective, if the standard directional lever is set in a position
other than N (F or R), the travel direction is set according to the operation of the directional lever.
10-274
WA470-7

Since the directional operation is not selected normally, the directional selector pilot lamp of the
machine monitor lights up in yellow and the caution lamp lights up.
a If the alarm operates and the directional selector pilot lamp lights up in yellow, the alarm is not
turned OFF and the directional selector switch does not work until both of the standard directional
lever and the directional selector switch are set in N (Neutral).
The above description is shown in the table below.
Mode
Condition
Directional lever: [F or N or R]
Directional selector switch: [N]
Directional selector switch
actuation switch: [OFF]
Directional lever: [N]
Directional selector
Directional selector switch: [F
switch enable switch
or N or R]
(normal [directional
selector switch])
actuation switch: [ON]
Directional lever: [F or R]
Directional lever priority Directional selector switch: [F
or N or R]
(emergency operation)
actuation switch: [ON]
Directional lever: [F or N or R]
Directional lever,
Directional selector switch: [F
directional switch error or R]
(wrong operation)
actuation switch: [OFF]
Directional lever: [other than
N]
<e> Selection error
Directional selector switch:
[other than N]
(wrong operation)
actuation switch: [OFFio
Directional lever
(normal)
FNR recognition
Right
FNR
enabled/
disabled
Monitoring
operation
(Reference)
Subject to directional
lever
OFF
(disabled)
Pilot lamp
Goes out
Buzzer stops
selector switch
ON
(enabled)
Pilot lamp
Lights up in
green
Buzzer stops
lever
OFF
(disabled)
Pilot lamp
Lights up in
yellow
Buzzer stops
lever
(Directional selector
switch is ignored)
OFF
(disabled)
Pilot lamp
Lights up in
yellow
Buzzer stops
lever
OFF
(disabled)
Pilot lamp
Lights up in
yellow
Buzzer stops
2. Interlock when engine is started (Prohibition of starting of engine)

When the directional selector switch actuation switch is in the ON position and the directional selector
switch is not in the N (Neutral) position, the transmission controller operates the neutral safety function
to cut the starting motor C terminal signal to prevent the machine from moving just after the engine is
started.
3. Setting of directional selector switch
The directional selector switch does not perform control, unless the option setting of the directional
selector switch is set effective by the option setting of the machine monitor. This switch cannot be
installed together with joystick steering.
a For the method of setting the option, see Testing and Adjusting, "Special functions of machine
monitor".
Auto idle stop function
(WA380-AF87-042-K-00-A)
When the operating condition is satisfied, the engine is stopped after a set period.
After the engine is stopped, if the parking brake switch is in OFF position, the parking brake is applied.
After the engine is stopped, if the work equipment lever lock is released, the work equipment lever lock is
operated.
This function works when conditions 1 to 4 are satisfied at the same time.
a For the adjustment procedure of the set time, see Testing and Adjusting, "Special functions of machine
monitor".
WA470-7
10-275

Operating condition
Condition 1
Condition 2
Condition 3
Condition 4
Accelerator pedal is released

Directional lever is in neutral
Machine is stopped
KDPF is not in regeneration
Action for restarting engine

To restart the engine, turn the starting switch from the ON position to the START position.
Real-time monitoring function of transmission controller
(WA380-CV3G-042-K-00-A)
The conditions of the input and output signals of the controller can be checked with the monitoring function of
the machine monitor.
a For the monitoring procedure, see Testing and adjusting, "Special functions of machine monitor".
Transmission controller self-diagnosis function
(WA380-CN1G-042-K-00-A)
The transmission controller constantly monitors the input and output conditions and performs selfdiagnosis of the system.
If any failure is detected by the self-diagnosis, its information is sent to the machine monitor through the
network.
If any failure occurs, it can be checked with the machine monitor / KOMTRAX.
10-276
WA470-7

Work equipment control system
(WA380-PK01-001-K-00-A)
Work equipment control system diagram
WA470-7
(WA470-PK01-051-K-00-A)
10-277

10-278
WA470-7

Work equipment control function
(WA380-PK01-042-K-00-A)
Neutral position and work equipment speed
(WA500-PK11-042-K-00-A)
Function
The work equipment control lever has a play of 5% of the lever travel in the neutral position. The work
equipment starts moving when the lever moves over the play.
The work equipment speed for the lever travel can be changed by the setting of the controller.
The boom has five changeable tables and the bucket has three.
a For the adjustment method and the features of each table, see Testing and adjusting "Changing boom
lever pattern" and "Changing bucket lever pattern".
Boom lever stroke vs. speed table
Bucket lever stroke vs. speed table
WA470-7
10-279

Work equipment neutral lock function
(WA380-PTLD-051-K-00-A)
2. Work equipment lock switch
5. Machine monitor
6. Work equipment neutral lock valve
Function (WA380-PTLD-042-K-00-A)
When the work equipment lock switch is operated, the controller turns OFF the output of the work
equipment EPC to stop the operation of the work equipment.
When the ECSS switch is turned OFF, the work equipment neutral lock valve is turned ON. Then, the EPC
pilot source pressure is cut and the operation of the work equipment is stopped.
When the lever is operated while the work equipment is locked even if the operator tries to unlock the work
equipment, the work equipment is not unlocked but kept locked for safety.
Work
Controller
equipment
control
lever
condiOperator's
tion
intention in
when
operation of work
work
Recogniequipment lock
equipzes
switch
ment
lock
switch
is
operated
In locking (no
switch operation)
10-280
In locking
Operation
of ECSS
Movement
of machine
Controller output
Work equipment
lock
indicator
ECSS
switch
Work
signal
equip(Transmis- ment lock
sion
solenoid
controller
valve
input)
ECSS
switch =
OFF
ON
(24 V)
ECSS SW
= ON
OFF
(OPEN)
Switch
ON
(Lights
up)
Monitor
ON
(Lights
up)
Work
equipment
EPC,
work
equipment
detent
Hydraulic
Cut (Work
equipment
OFF (No and ECSS
stop)
output)
Only ECSS
operates
WA470-7

Lock o Unlock
(Switch
operation)
Lock o Unlock
(Switch
operation)
In unlocking (no
switch operation)
Unlock o Lock
(Switch
operation)
Work
equipment
control In locking
lever is
not in
neutral
Work
equipment
In
control
unlocked
lever is
in
neutral
In
unlocked
In locking
ECSS
switch =
OFF
ON
(24 V)
ECSS SW
= ON
OFF
(OPEN)
Cut (Work
equipment
and ECSS
stop)
ON
(Lights
up)
ON
(Lights
up)
OFF (No
output)
OFF
(OPEN)
OFF
(Lights
out)
OFF
(Lights
out)
Outputs
according
to lever
operation
Operates
OFF
(OPEN)
OFF
(Lights
out)
OFF
(Lights
out)
Outputs
according
to lever
operation
Operates
ECSS
switch =
OFF
ON
(24 V)
ECSS SW
= ON
OFF
(OPEN)
ON
(Lights
up)
ON
(Lights
up)
* Popup
Cut (Work
equipment
OFF (No and ECSS
stop)
output)
Only ECSS
operates
Only ECSS
operates
* If the work equipment is locked with the switch operation by the operator, popup display appears on the
machine monitor.
Operation of work equipment control lever
(WA500-PK11-042-K-01-A)
Function
The work equipment controller detects the quantity of RAISE/LOWER and TILT/DUMP operations through
the signals of the work equipment control lever potentiometers, controls the operation of each EPC valve
with current, and operates the main spool with the EPC pressure to operate the work equipment.
WA470-7
10-281

The work equipment control lever has detent notches and the system is adjusted so that the work
equipment operates at the maximum speed just before each detent.
The range beyond the LOWER detent is the "Boom float" position, where the boom is moved by external
forces.
Bucket priority control
(WA500-PTL3-042-K-00-A)
Function
Since this machine employs the CLSS, it can operate the bucket and boom simultaneously. However, it
can prevent the boom from rising to improve the digging work efficiency when the bucket operation
frequency is large.
This is realized by limiting the maximum boom rising speed for the bucket speed (Table below).
Boom stop modulation
(WA500-PTL4-042-K-00-A)
Function
When the operator performs boom stop operation faster than a certain speed, the work equipment
controller operates the modulation to reduce the stopping shocks of the boom raise/lower operation.
The operation of this stop modulation function can be changed by the setting of the controller.
10-282
WA470-7

a For the changing method and precautions, see Testing and adjusting, "Boom stop modulation".
Case A: Modulation 0
When lever command flow > modulation command flow
Output matched to lever command flow
Case B: Modulation 20
When lever command flow < modulation command flow
Output matched to modulation command flow
a: Modulation 10 (when shipped)
b: Modulation starting position
Adjustment of lever detent position and work equipment starting current
(WA380-PLT5-042-K-00-A)
Function
The work equipment controller has the adjustment function of correcting dispersion.
The controller saves the lever potentiometer voltage in the detent position and adjusts the detent position
to perform the control before and after the detent securely. If the adjustment is not performed, "the
positioner may not operate normally before and after the detent" or "the lever position for floating the boom
may be abnormal".
If the work equipment starting current is not adjusted, "the dead zone of neutral may be wide" or "the work
equipment may generate large shocks when it starts/stops".
a For the adjustment procedure, see Testing and adjusting, "Boom raise adjustment", "Bucket tilt
adjustment", or "Bucket dump adjustment".
Swash plate control function of work equipment pump and steering

pump (WA470-PLT6-042-K-00-A)
The control function of the swash plate of the work equipment pump and steering pump includes "Pickup
assistance control when engine speed is low" and "Overheat prevention control". The smaller pump
discharge (the command current to the swash plate angle control EPC valve is large) among the
calculation results of each control is selected.
Oil pressure - Flow characteristics when command current to swash plate angle control EPC valve of work
equipment pump is controlled
WA470-7
10-283

A: Small electric current

B: Large electric current
Oil pressure - Flow characteristics when command current to swash plate angle control EPC valve of steering
pump is controlled
A: Small electric current

B: Large electric current
Pickup assistance control function when engine speed is low
(WA500-PTL7-042-K-00-A)
When the work equipment and steering are operated simultaneously while the engine speed is low, the
pump absorption torque is larger for the torque generated by the engine and the engine does not pick up
well.
To help the engine picking up, when the accelerator pedal is depressed while the engine speed is low, a
command current matched to the work equipment pump pressure or travel speed is sent to the swash
plate angle control EPC valves of the work equipment pump to control the pump swash plate angles and
reduce the load is reduced.
Overheat prevention function of work equipment controller
(WA470-PLT8-042-K-00-A)
The work equipment controller controls the work equipment pump discharge in accordance with the
hydraulic oil temperature to prevent overheat.
It sends a command current to the swash plate angle control EPC valve of the work equipment pump to
control the pump swash plate angle.
10-284
WA470-7

Remote positioner function

Remote bucket positioner
(WA380-PTL9-001-K-00-A)
(WA470-PTL9-042-K-01-A)
Function
When the bucket is at the flat position or below, if the tilt lever is set in the detent position, the bucket stops
slowly at a set position.
1. Setting stop position
The bucket stop position when the positioner is operated is changed with the bucket positioner
position set switch.
Condition for
enabling
Bucket lever is in Neutral and bucket is within 5.5 degrees of setting angle.
(1)
Setting method
(2)
(1)
Cancellation
method
(2)
(3)
Set the bucket to a desired position and push the bucket positioner switch. (less than
1 second)
The current bucket cylinder length is saved for the saved set position, and the setting
completion buzzer sounds and the value is displayed on the monitor for 3 seconds.
(The set position is maintained even after the key is turned to the OFF position.)
To cancel the saved position (returned it to the default), hold down the bucket
positioner switch for 1 second or more.
If within the set range, the position is set temporarily. However, the setting
cancellation buzzer sounds 1 second after and the stop position is set to the default.
The monitor displays the saved value (default: 0) for 3 seconds.
a The value displayed on the monitor is indication of a level and does not match to the actual bucket
angle.
a The bucket-equivalent angle means a calculated bucket angle. It does not always match to the
actual angle because of the shape of the bucket.
2. Cancellation of tilt detent
When the bucket lever is in the tilt detent position, if the cylinder reaches the detent cancellation
position, the detent is canceled and the bucket stops slowly.
3. Stopping tilting (slowly)
Tilting (slow) stop function decreases the speed of tilting within the range of 100 to 7 mm before the
target stop position by feeding back the cylinder length, corresponding to the stopping angle.
After the tilt detent is canceled, if the bucket lever is held in the tilt detent position, tilting is not
stopped (slowly) but accelerated from the time when the lever is judged to be held, in the return
modulation at the target flow set with the lever.
WA470-7
10-285

Accordingly, if the detent is held with the bucket positioner operated and the bucket is operated
over the stop position, the bucket tilting is decelerated temporarily and then accelerated.
4. Detent operation while engine is stopped
While the engine is stopped, the detent is kept OFF, thus the lever is not held in the detent position
while the engine is stopped.
5. Adjustment of bucket angle
The work equipment controller has a function to correct the cylinder length when the bucket is in
the flat position.
As for the flat position of the bucket, one of the three positions A, B, and C can be saved according
to the attachment.
a For details of adjustment procedure, see "Bucket flat level adjustment" of "Explanation of components",
"Operation" in the Operation and maintenance manual.
Remote boom positioner
(WA500-PTL9-042-K-01-A)
Function
Raising kick-out (When pilot lamp lights up to indicate that only raising is effective or both raising and lowering
are effective)
If the boom lever is set in the "Raising detent" position, the boom starts deceleration before the set
position, cancels the raising detent, and controls stopping (slowly).
When the boom is not in the "Raising detent" position, it is raised by the operator's operation.
If raising is not selected, only the raising detent operates.
If the detent is turned ON, the remote positioner does not operated and only the kick-out function operates
(the boom stops at the top).
Stopping boom lowering (When pilot lamp lights up to indicate that only lowering is effective or both raising
and lowering are effective)
If the boom lever is set in the "Floating detent" position, the boom starts deceleration before the set
position, cancels the floating detent, and controls stopping (slowly).
If the boom lever is kept as it is, the boom starts lowering again.
If lowering is not selected, only the floating detent operates.
If the detent is turned ON when the boom angle is flat or below, the remote positioner does not operate
and only the floating detent function operates (the boom does not stop automatically).
a If the detent is turned ON when the boom is flat or below, the lowering remote positioner does not function
as the positioner and does not stop the boom, for distinction from the floating operation in the grading
work.
10-286
WA470-7

a The floating detent does not operate at around the setting stop position. However, the floating detent
operates when the boom angle is below -37 degrees for the grading work.
1. Setting stop position
The boom stop position when the positioner is operated is changed with the boom positioner switch.
Setting and cancelation of raising stop position
Condition for
enabling
Boom lever travel: Neutral and boom position is flat or above
(1) Raise the boom to a position to set.

(2) Press the remote positioner raising position set switch (less than 1 second).
(3) If the position in which the switch is pressed is within the set range, the boom angle
is saved, the setting completion buzzer (pip, pip) sounds, and the pilot lamp on the
monitor lights up.
Method of setting (4) If the position is out of the range (boom angle is below 0 degrees) or the sensor has
raising stop
an error, setting is not performed again.
(The buzzer does not sound and set position is not changed)
(5) If the setting switch is operated less than 1 second, the set position is always
changed.
(1) Press the remote positioner raising position set switch for 1 second or more.
(2) If the position is within the set range when the switch is pressed, it is set temporarily.
If the switch is held down for 1 second or more in (3) above, the setting cancel buzzer
sounds (peep) when 1 second elapses and the raising selection is canceled and the
Method of
canceling setting of pilot lamp of the monitor goes off.
raising stop
a The setting can be canceled when the boom is in the range above the flat position.
(3) Leave the remote positioner raising stop control unexecuted. Perform only the boom
kick-out control.
(4) In this operation, the lowering stop setting is not canceled.
Setting and cancelation of lowering stop position
Condition for
enabling
Method of setting
lowering stop
Boom lever stroke: Neutral and boom position is flat or below

(1) Lower the boom to a position to set.
(2) Press the remote positioner lowering position set switch. (less than 1 second)
(3) If the position in which the switch is pressed is within the set range, the boom angle
is saved, the setting completion buzzer (pip, pip) sounds, and the pilot lamp on the
monitor lights up.
(4) If the position is out of the range (boom angle is out of the range between -37
degrees and 0 degrees ) or the sensor has an error, setting is not performed again.
(The buzzer does not sound and set position is not changed)
(5) If the setting switch is operated less than 1 second, the set position is always
changed.
(1) Press the remote positioner lowering position set switch for 1 second or more.
(2) If the position is within the set range when the switch is pressed, it is set temporarily.
If the switch is held down for 1 second or more in (3) above, the setting cancel buzzer
sounds (peep) when 1 second elapses and the lowering selection is canceled and the
pilot lamp of the monitor goes off.
Method of
canceling setting of
lowering stop
a The setting can be canceled when the boom is in the range below the flat position.
(3) Leave the remote positioner lowering stop control unexecuted.
Perform only the float detent control.
(4) In this operation, the lowering stop setting is not canceled.
Remote positioner stop position settable range
[Raising/Lowering stop position settable range]
WA470-7
10-287

Stop position
Range
0 degrees: Boom horizontal position
"Raising"
Min. 0 degrees
"Lowering"
0 to -37 degrees
2. Cancelation of boom raising detent

When the remote positioner is operated, the detent is turned OFF if the boom reaches the detent
cancelation position.
Once the boom raising detent is turned OFF automatically by the operation of the stop (slow) function, the
boom raising/lowering detent is kept OFF for 1 second.
3. Raising stop (slow)
Boom raising (slow) stop function decreases boom speed according to the stopping angle by feeding back
the boom angle.
After the boom raising detent is canceled, if the boom lever is held in the raising detent position, boom
raising (slow) stop function does not work and the boom raising is accelerated again.
Accordingly, if the detent is held with the boom raising remote positioner operated and the boom is
operated over the target stop angle, the boom raising is decelerated temporarily o accelerated.
4. Boom kick-out function
When the stop position of the remote positioner is not set or the boom raising detent is turned ON above
the stop position, the boom performs the kick-out operation and stops slowly before the travel end to
reduce the stopping shocks at the travel end.
5. Cancelation of boom lowering detent
When the remote positioner is operated, the detent is turned OFF if the boom reaches the detent
cancelation position.
Once the boom lowering detent is turned OFF automatically by the operation of the stop (slow) function,
the boom raising/lowering detent is kept OFF for 1 second.
6. Boom lowering stop (slow)
Boom lowering (slow) stop function decreases boom speed according to the stopping angle by feeding
back the boom angle.
After the boom lowering detent is canceled, the system checks for 0.05 seconds if the boom is held in the
raising detent. If the boom is held in the detent, the system does not perform the stopping (slow) operation
but accelerates the boom lowering again.
Accordingly, if the detent is held with the boom lowering remote positioner operated and the boom is
operated over the target stop angle, the boom lowering is decelerated temporarily o accelerated.
When the boom angle reaches -37 degrees, the system stops acceleration and performs the floating
operation even if during acceleration.
7. Detent operation while engine is stopped
While the engine is stopped, the detent is kept OFF, thus the lever is not held in the detent position while
the engine is stopped.
8. Adjustment of boom angle
The work equipment controller has function to correct the installation error of the boom potentiometer.
The controller saves the boom potentiometer voltage at the boom top and operates the remote boom
positioner function.
If the adjustment is not performed, the kick-out position may be "too much near this side" or "the boom
may not kick out and shocks may be generated at travel end".
Semi auto-digging function
(WA380-PTLA-042-K-00-A)
The semi auto-digging function uses only the kickdown switch and boom raising operation for the ease of
digging work. With this function, even an unskilled operator can improve the working efficiency. This
function has two modes of LOOSE and ROCK, either of which is selected according to the properties of
the objective material.
10-288
WA470-7

A bucket automatic operation pattern matched to the working cycle and load is selected.
Mode selection
No.
1
2
Objective material
Gravel/Sand
Quarry/Blasted rocks
Mode
LOOSE mode
ROCK mode
1. Condition for starting semi auto-digging
Condition 1
Condition 2
WA470-7
The semi auto-digging is ready when following (1) to (4) are satisfied.
(1) Semi auto-digging is set in "ROCK" or "LOOSE" mode.
(2) Machine is traveling forward (There is F signal)
(3) Boom angle is less than -30 (almost on ground)
(4) Kickdown switch is operated
a Even during work in 1st gear speed, semi auto-digging does not start if kickdown
switch is not operated.
Semi auto-digging (auto tilt) starts when following (1) and (2) are satisfied.
(1) Boom is raised after condition 1 is satisfied.
10-289

(2) Low speed travel (km/h) < 3.5 x ENG rpm/1,800

2. Condition for finishing semi auto-digging
Condition
Semi auto-tilt finishes when one of the following conditions is satisfied.

(1) Forward travel is finished (There is F signal o There is no F signal.)
(2) Boom angle is above flat.
(3) Tilt end is detected (Full tilt condition)
(4) Boom is lowered.
(5) Bucket is dumped.
3. Tilt operation in digging mode

1) Operation in "LOOSE" mode
2) Operation in "ROCK" mode
10-290
WA470-7

Electric emergency steering function
(WA470-F910-042-K-00-A)
1. Emergency steering switch

4. Fuse box
5. Slow-blow fuse
6. Battery relay
7. Battery
9. Emergency steering switch relay
10. Emergency steering relay
11. Emergency steering pump oil pressure sensor
12. Steering pump
13. Steering pump oil pressure sensor
14. Steering valve
15. Emergency steering pump
16. Emergency steering motor
Input/output signal
a. CAN signal
b. Emergency steering manual operation signal
c. Steering pump oil pressure signal
d. Emergency steering relay signal
e. Emergency steering pump oil pressure signal
f. Sensor power supply
Function
The condition of the oil pressure sensors in the steering circuit is constantly monitored. When the steering
oil pressure decreases and the transmission output shaft speed (travel speed) increases above the
emergency steering "ON" value in the following figure, the emergency steering operation signal is output
to the emergency steering switch relay to operate the emergency steering.
The emergency steering motor can be operated by operating the emergency steering switch, regardless
of the steering oil pressure or transmission output shaft speed (travel speed).
WA470-7
10-291

a The continuous operation time with the emergency steering switch must be limited within 60 seconds.
a The travel speed must be kept 5 km/h or below while the emergency steering is operated.
Emergency steering selection point

Travel speed [km/h]
A
1.9
B
2.0
The emergency steering does not function if "Emergency steering" is not set to "ADD" with the "Option
select function" of the machine monitor.
a For the setting procedure, see Testing and Adjusting, "Special functions of machine monitor".
Self-check function for emergency steering
The emergency steering performs the self-check of its operation automatically 3 seconds after the starting
switch is turned to the "ON" position (after the self-check of the machine monitor is finished).
However, the self-check is not performed in the following cases.
1. The starting motor is started by turning the starting switch to the "START" position
2. The engine is running already.
(Engine speed of 500 rpm or higher is detected)
3. Steering pressure is detected
4. The automatic preheating function operates
5. An error related to the emergency steering is detected by the self-check of the machine monitor
6. The engine is not started for 10 seconds or more after the previous self-check
(Engine speed of 500 rpm is not detected for 10 seconds or more)
During the self-check of the emergency steering, the emergency steering operation signal is output for up
to 3 seconds.
When the machine monitor detects the emergency steering operating pressure within 3 seconds, the
emergency steering system receives the emergency steering operation sensing signal through the
network from the machine monitor and finishes its self-check.
If the machine monitor does not detect the emergency steering operating pressure in 3 seconds, the
emergency steering system does not receive the emergency steering operation signal from the machine
monitor, thus it gives an error alarm.
Real-time monitoring function of work equipment controller
(WA380-PTLB-042-K-00-A)
The conditions of the input and output signals of the controller can be checked with the monitoring function of
a For the monitoring procedure, see Testing and adjusting, Special functions of machine monitor.
Self-diagnosis function of work equipment controller
(WA380-PTLC-042-K-00-A)
The work equipment controller constantly monitors the input and output conditions and performs selfdiagnosis of the system.
If any failure is detected by the self-diagnosis, its information is sent to the machine monitor via the
network.
If any failure occurs, it can be checked with the machine monitor / KOMTRAX.
10-292
WA470-7

Machine monitor system
Function
(WA470-Q170-041-K-00-A)
(WA380-Q170-042-K-00-A)
The machine monitor system mainly consists of the machine monitor, monitor controller, and switch panel.
1. Machine monitor
WA470-7
10-293

Displays the machine condition to the operator.

a The machine monitor has two display modes; One is the operator mode and the other is the service
mode.
Obtains the condition data of various sections of the machine monitored with sensors and switches and
processes them. Communicates the network information with each controller.
a For details, see "Monitor controller".
3. Switch panel
Accepts operations of the operator.
a For details, see "Switch panel".
Details of monitor controller network signals
(WA470-Q180-03C-K-00-A)
Data sent
Updated every 10 msec (RTCDB/r)
No.
1
2
3
4
5
6
7
Item
Fan reverse set condition (reverse time)
Fan reverse set condition (interval time)
Fan manual selection (forward/reverse) enabled/disabled
Air conditioner Compressor Status
Attachment flow mode
Attachment flow level
Attachment set switch information

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Item
Service meter reading
Semi-auto digging mode setting
Auto-deceleration enabled/disabled setting
Parking brake operation
Adjustment ID
Adjustment switch information
Data for adjustment
Auto-kickdown enabled/disabled
Machine model data
Option data
Brake oil pressure (front)
Brake oil pressure (rear)
Idle stop set time
In-idle stop service mode flag
Idle stop set entry signal
Preheat condition
Engine speed fixing control command
Bucket flat level adjustment selection information
Bucket flat level adjustment initialization command
Recirculation air temperature
Set temperature
Air conditioner setting
Data received
No.
1
2
10-294
Item
Engine speed
Final injection rate
WA470-7

No.
3
4
5
6
7
8
9
10
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
46
47
48
49
50
51
52
53
54
WA470-7
Item
1st throttle position (accelerator pedal)
Engine condition
Key switch ACC terminal (engine controller)
Throttle correction value
Throttle upper limit value
Throttle lower limit value
Dynamic torque request
Torque curve selection
Droop type selection
Droop switch selection
ABS droop trim
Automatic warm-up cancel flag
Machine safety state 1
Machine safety state 2
Engine speed control flag
Travel speed (tire diameter and correction counted in)
Actual gear speed display (F)
Actual gear speed display (N)
Actual gear speed display (R)
Actual gear speed display (1st)
Actual gear speed display (2nd)
Actual gear speed display (3rd)
Actual gear speed display (4th)
Directional lever display (F)
Directional lever display (N)
Directional lever display (R)
Shift range display (1st)
Shift range display (2nd)
Shift range display (3rd)
Shift range display (4th)
Transmission controller recognition lever direction
Working situation discrimination status
ECSS switch condition
Rim pull
Engine output mode
Engine output mode (Engine output mode condition in transmission controller)
Engine output mode selection
Throttle lock (RPM set) lower limit command value
Engine start permission flag
Boom lever condition
Bucket lever condition
Working condition check
Target rim pull
Scrape-up flag
Digging flag
Loader pump neutral flag
Steering pump neutral flag
Boom angle
Boom bottom pressure
Boom head pressure
Bell crank angle
Key SIG condition (ACC)
10-295

No.
55
56
Item
Auto-kickdown work equipment posture sensing information
Depressing right brake pedal

No.
1
2
3
4
5
6
7
8
9
10
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
10-296
Item
Engine coolant temperature
Overrun condition
Grid heater control condition
Instantaneous fuel consumption
Soot accumulation level
KDPF regeneration mode
Manual regeneration permission condition
Thermal management auxiliary request
HC desorb flag
Hydraulic oil temperature
Torque converter oil temperature
AJSS indicator or FNR switch
Auto shift condition
Shift hold condition
Lockup operation condition
Fan reverse pilot lamp
Kickdown switch condition
Kickdown information
Transmission cut-off point setting buzzer operation
Lockup function switch
Left brake pressure
Idle stop remaining time
Idle stop condition
Cut-off switch built-in indicator condition
Semi-auto digging condition
Multicoulper operation condition
Throttle lock (RPM set) operation condition
Boom positioner operation condition
Positioner setting buzzer operation
Emergency steering motor operation condition
All work equipment lever neutral flag
Work equipment pump relief flag
AJSS warning
ATT (PCS) detent condition
ATT (PCS) mode (flow mode) condition
ATT (PCS) flow rate level
Bucket selection information
Work equipment lock indicator
WA470-7

Machine monitor
(HM300-Q180-042-K-00-A)
Precautions on the machine monitor display

If there is trouble in the machine monitor, monitor controller, another controller, or network wiring, the
machine monitor does not display normally.
One of the features of the liquid crystal unit is that there may be black spots (spots that do not light up) or
white spots (spots that stay lighting up) on the screen.
When there are fewer than 10 black or white spots, this is not a failure or a defect.
When the emergency steering self check is performed or the engine is started, the battery voltage may
drop suddenly, depending on the ambient temperature and the condition of the battery.
In this case, the machine monitor may go out for a moment or may be restarted. However, this
phenomenon is not a trouble.
Input and output signals of machine monitor
(WA380-Q180-03C-K-01-A)
JAE-8P [ CN-MDM1] (for LC unit)

Pin No.
1
2
3
4
5
6
WA470-7
Signal name
LC unit LVDS +
LC unit LVDS LC unit power supply return GND
LC unit backlight adjustment
LC unit power supply
LC unit ON/OFF control
Input/Output
Signal
Input
Input
Input
Input
Input
10-297

Signal name
Pin No.
7
8
LC unit backlight ON/OFF control

LC unit temperature sensor
Input/Output
Signal
Input
Input
AMP-6P [ CN-MDM2] (for LED unit)

Signal name
Pin No.
1
2
3
4
5
6
LED unit power supply (+12 V)

LED unit power supply return GND
LIN
LED unit power supply (+5 V)
(*1)
GND
Input/Output
Signal
Input
Input/Output
Input
AMP-8P [ CN-MDM3] (for meter unit)

Pin No.
1
2
3
4
5
6
7
8
Signal name
Meter unit power supply (battery direct 24 V)
Key switch ACC terminal
CAN (+)
Meter unit power supply return GND
Monitor brightness selector switch (night mode signal)
(*1)
CAN2 terminating resistor
CAN (-)
Input/Output
Signal
Input
Input
Input/Output
Input
Input
Input/Output
*1: Never connect these pins. Malfunctions or failures may occur.
10-298
WA470-7

Display
WA470-7
(WA470-Q1LA-042-K-00-A)
10-299

A: Standard screen
B: ECO guidance screen
C: Maintenance time warning screen
D: Warning screen
E. Bucket positioner pop-up screen
F: User menu screen
1. Speedometer
2. Engine tachometer
3. Centralized warning lamp
10-300
WA470-7

4. Parking brake pilot lamp

5. Turn signal pilot lamp (left)
6. Headlamp (high beam) pilot lamp
7. Turn signal pilot lamp (right)
8. Brake oil pressure caution lamp
9. Clearance lamp pilot lamp
10. Engine coolant temperature gauge
11. Engine coolant temperature caution lamp
12. Torque converter oil temperature gauge
13. Torque converter oil temperature gauge caution lamp
14. Hydraulic oil level gauge
15. Hydraulic oil temperature caution lamp
16. Fuel level gauge
17. Fuel level caution lamp
18. ECO gauge
19. Air conditioner display area
20. Clock
21. L.H. meter display area (select service meter, odometer, or clock)
22. R.H. meter display area (select service meter, odometer, clock, or average fuel consumption gauge)
23. Shift indicator
24. Shift lever position pilot lamp
25. Message pilot lamp
26. Semi-auto digging/ Multi-coupler lock release pilot lamp (if equipped)
27. Directional selector pilot lamp (if equipped)
28. ECSS (Electronically Controlled Suspension System) pilot lamp
29. Double low idle pilot lamp
30. Remote positioner/ work equipment lock pilot lamp
31. KDPF regeneration pilot lamp
32. Emergency steering pilot lamp (if equipped)
33. Power mode pilot lamp
34. Shift hold pilot lamp
35. Lockup pilot lamp
36. Auto shift pilot lamp
37. Fan reverse rotation pilot lamp
38. Engine preheater/ transmission cut-off pilot lamp
39. ECO guidance
40. Maintenance time caution lamp
41. Guidance icon
42. Seatbelt caution lamp
43. Caution display area
44. Action level
45. Bucket positioner pilot lamp
WA470-7
10-301

Meters and gauges

Monitor
display
Item
displayed
(WA470-Q1LB-043-K-00-A)
Display
color
CharacSpeedomters:
eter
black
Engine
tachometer
10-302
Display range: 0 to 99 km/h
Graduations:
green,
red
Pointer:
red
D1
D2
D3
D4
Coolant
temperature (C)
135
102
88
74
59
50
Oil
temperature (C)
135
120
97
73
50
Oil
temperature (C)
125
100
83
67
50
Fuel
level (l)
226
190
114
42
D5
41
Point
Display range:
50 to 135 C
(red zone: 102
C and above)
A1
A2
A3
A4
A5
A6
Point
Display range:
50 to 135 C
(red zone: 120
C and above)
B1
B2
B3
B4
B5
Point
GraduaHydraulic tions:
green,
oil
temperared
ture gauge Pointer:
red
Display range:
50 to 125 C
(red zone: 100
C and above)
Graduations:
green,
red
Pointer:
red
Display range:
EMPTY to
FULL (red
zone: 42l or
less)
Fuel level
gauge
Remarks
Characters:
white
Display range: 0 to 3,500 rpm (red
Gradua- zone: 2,500 rpm and above)
tions:
white, red
Graduations:
Engine
white,
coolant
green,
temperared
ture gauge
Pointer:
red
Torque
converter
oil
temperature gauge
Contents
C1
C2
C3
C4
C5
Point
If communication error
occurs between monitor
controller and transmission
controller, "0" is displayed.
occurs between monitor
controller and meter unit,
"00" is displayed.
If engine speed increases
above specified level,
engine overrun caution
lights up. (For details, see
engine overrun caution.)
occurs, gauge pointer reads
0.
If temperature exceeds 102
C, engine coolant overheat
caution lights up. (For
details, see engine overrun
caution.)
occurs, gauge pointer
disappears.

C, torque converter oil
overheat caution lights up.
disappears.

C, hydraulic oil caution
lights up.
disappears.
42 l or below, fuel level

caution lights up.
If sensor is abnormal, gauge
pointer disappears.
WA470-7

Monitor
display
Item
displayed
ECO
gauge
Display
color
Green,
orange
Air
Characconditioner
ters:
display
white
area
Clock
Characters:
white
CharacService
meter (*1) ters:
white
Travel
odometer
(*1)
Characters:
white
CharacClock (*1) ters:

white
Fuel
consump- Charaction gauge ters:
white
(*1)
Contents
Remarks
Display range: 0 to 48.75 l/h

(Orange zone: 39 l/h or above)
Indicates instantaneous fuel

consumption (average of
fuel consumption per 3
seconds) in 10 steps.
Display/Non display of ECO
gauge can be set by using
user menu as follows; "ECO
Guidance" o "Display
Setting" o "ECO Gauge
Display".
Display/Non display of ECO
gauge can be set by using
user menu as follows; "ECO
Guidance" o "Display
Setting" o "ECO Gauge
Display".
occurs, gauge reads 0.
Set temperature
Air blow rate
Vent
For details, see Operation &

Maintenance Manual.
Displays time.
12-hour/24-hour system
display can be switched by
12-hour system display (AM/PM)
using user menu as follows;
24-hour system display
"Monitor Setting" o "Clock
Adjustment".
Indicates accumulated
engine operating hours.
When engine operating

Display range: 0 to 999999.9 h
hours exceeds 999999.9 h,
meter reading stops at
999999.9 h.
Indicates accumulated travel
distance.
When travel distance
Display range: 0 to 3999999.9 km
exceeds 3,999,999.9 km,
meter reading stops at
3,999,999.9 km.
Displays time.
12-hour/24-hour system
display can be switched by
12-hour system display (AM/PM)
using user menu as follows;
24-hour system display
"Monitor Setting" o "Clock
Adjustment".
Indicates average fuel
consumption.
1 Day/Split can be switched
1 Day display
by using user menu as
Split display
follows; "ECO Guidance" o
"Display Setting" o "Fuel
Consumption Gauge
Display".
*1: These items indicated to R.H. and L. H. meter display can be selected with user menu "Monitor Setting" o
"Select Meter Display" as follows.
L.H. meter display: Service meter, odometer, clock
R.H. meter display: Service meter, odometer, clock, fuel consumption gauge
WA470-7
10-303

Alarm monitor
Monitor
display
(WA470-Q1LA-043-K-00-A)
Item
displayed
Action
level
Centralized
warning
lamp
Brake oil
pressure
caution
Engine
coolant
temperature
Action
level
Centralized
warning
lamp
L04
L03
L02
Yellow
L01
Red
(LED)
See
remarks.
Q
(intermittent)
L03
L02
Q
(intermittent)
L02
Q
(intermittent)
Display
color
Red
Red
(LED)
Red
Alarm
buzzer
Q
(continuous)
Q
(intermittent)
Q
(intermittent)
Q
(intermittent)
Q
(intermittent)
Appears when trouble is

detected in machine.
Lights up for 2 seconds, then

goes out.
Lights up when failure of
action level L02 or higher
occurs or alarm to warn
operator is made. Buzzer
sounds, as well.
Appears when brake oil
pressure drops while engine
is running.
Appears if brake oil pressure
does not increase after
engine is started.
Lights up if brake oil pressure
drops while engine is
stopped.
Appears when engine coolant
temperature is 105C or
above.
Lights up when engine
coolant temperature is 102C
or above.
Appears when torque
converter oil temperature is
130C or above.
Appears when torque
converter oil temperature is
120C or above.
Torque
converter
oil
temperature
Red
Hydraulic
oil
temperature
Red
L02
Q
(intermittent)
Appears when hydraulic oil

temperature is 100C or
above.
Fuel level
Red
Lights up when fuel level is

42 l or below.
Red
Yellow
Maintenance time
warning
10-304
Remarks
Lights up for 30 seconds after

starting switch is turned to the
ON position if maintenance
due time of any item is over.
Lights up for 30 seconds after
starting switch is turned to the
ON position if maintenance
reminder due time of any item
is over.
WA470-7

Monitor
display
Item
displayed
Display
color
Action
level
Centralized
warning
lamp
Alarm
buzzer
Remarks
Notice time can be changed
in service menu
"Mmaintenance Mode
Setting" o "Maintenance
ModeChange" o
"Maintenance Notice Time
Setting".
Seat belt
Engine
system
error
Red
KDPF soot
accumulation
caution
icon
Engine
overrun
Engine oil
pressure
Transmission
system
error
Fan
control
system
error
Radiator
coolant
level
WA470-7
L04
Red
Yellow
Defective
KDPF
system
L03
L01
L04
Red
L03
Yellow
L01
Red
L03
Yellow
L01
L02
L03
L04
Red
Red
Red
Q
(continuous)
Q
(intermittent)
Q
(continuous)
Q
(intermittent)
Q
(intermittent)
Q
(intermittent)
Q
(intermittent)
Q
(intermittent)
Q
(continuous)
Q
(intermittent)
Q
(intermittent)
L03
Yellow
L01
Red
L03
Yellow
L01
Yellow
L01
Lights up when seat belt is

not fastened.
Appears when error is

detected in engine system.

detected in KDPF system.
Appears when much soot is

accumulated in KDPF or
system error including
lowered purification function
is detected.
Appears when engine speed
is 2,525 rpm or above.
Appears when engine speed
is 2,425 rpm or above.
Appears when engine oil
pressure is below specified
value

detected in transmission
system.

detected in fan control
system.
Lights up when radiator

coolant level is low.
10-305

Monitor
display
Item
displayed
Display
color
Action
level
Centralized
warning
lamp
Alarm
buzzer
Engine oil
level
Yellow
L01
Lights up when engine oil

level is low.
Air cleaner
clogging
Yellow
L01
Lights up when air cleaner is

clogged.
Yellow
L01

detected in steering system.
L03
Q
(intermittent)
Steering
system
error
caution
icon
Emergency steering
system
error
caution
icon (if
equipped)
Directional
switch
Brake oil
temperature
Work
equipment
system
Steering
oil
pressure
Emergency steering
motor (if
equipped)
System
error
caution
icon
Air
conditioner
system
error
caution
icon
10-306
Red
Remarks

detected in emergency
steering system.
Yellow
L01
Red
Q
(intermittent)
Lights up when directional

switch or directional lever is
operated wrongly.
Lights up when brake oil
temperature is kept at 140C
or above for 900 seconds, or
at 150C or above for 20
seconds.
Yellow
Red
L03
Q
(continuous)
Yellow
L01
L03
L02
Red
L03
Q
(intermittent)
Yellow
L01
Yellow
L01
Red
Red
Q
(intermittent)
Q
(intermittent)
Q
(intermittent)
Appears when trouble is

detected in work equipment
system.
Appears when steering oil
pressure drops while engine
is running.
Lights up when steering oil
pressure does not increase
after engine is started.
Appears when emergency
steering motor is used for 60
seconds or more.
Lights up while emergency
steering motor is functioning
normally.
Appears when error related to
machine monitor or rear view
monitor or error in
communication between
controllers is detected.
detected in air conditioner
system.
WA470-7

a If three or more cautions are occurring, the icons displayed are changed two by two every 2 seconds.
WA470-7
10-307

Pilot lamp
Monitor
display
(WA470-C7K6-043-K-00-A)
Item
displayed
Contents
Parking
brake
Red
(LED)
Lights up when parking brake is

applied.
Turn signal
(left)
Green
(LED)
Lights up when left turn signal is

turned on.
Headlamp
(high
beam)
Blue
(LED)
Lights up when headlamp (high

beam) is turned on.
Turn signal
(right)
Green
(LED)
Lights up when right turn signal is

turned on.
Clearance
lamp
Green
(LED)
Lights up when clearance lamp is

turned on.
Shift
indicator
Remarks
Charac- Indicates actual gear speed (F1, F2,

ters:
F3, F4, N, R1, R2, R3, or R4).
White
Shift lever
position
Characters:
HighlighCurrent shift lever position (1, 2, 3,
ted in
4, N, R, N, or F) is highlighted.
white
(other
than N)
Message
(Unread)
Back- Lights up when there is unread

ground: message.
Green
Message
(read but
unreturned)
Back- Lights up when there is message

ground: read but not returned yet.
Black
Semi-auto
Digging
10-308
Display
color
Green
When starting switch is

turned to the ON position
while shift lever is not in N,
character of current shift
lever position flashes,
centralized warning lamp
lights up and alarm buzzer
sounds. (Neutral safety
alarm)
When all signals from shift
lever are OFF, character of
current shift lever position
flashes , centralized warning
lamp lights up and alarm
buzzer sounds.
Goes out when answer is

sent or validity of message
expires.
Lights up while machine is digging in

semi-auto mode.
WA470-7

Monitor
display
Item
displayed
Multicoupler
lock
release (if
equipped)
Directional
selection
Display
color
Contents
Red
Lights up when multi-coupler lock is

released.
Green
Yellow
Remarks
Lights up when directional switch is

effective.
Lights up when wrong operation is
made.
E.C.S.S.
Green
Lights up when ECSS is effective.
2-stage
low idle (if
equipped)
Green
Lights up when 2-stage low idle is

effective.
Lights up when raise stop is set.
Remote
positioner
Green
Lights up when lower stop is set.
Lights up when raise and lower

stops are set.
Work
equipment
lock
Red
Lights up when work equipment is

locked.
Auto-shift
Green
Lights up when auto-shift operates.
Green
Lights up when transmission cutoff operates.

Flashes when resetting is
acceptable.
Green
Pops up for only 3 seconds when

bucket positioner switch is
turned ON.
Displays set angle in range of 5
levels.
Bucket
positioner
Lights up during KDPF regeneration.

KDPF
regeneration
WA470-7
Yellow
Lights up when KDPF regeneration
is stopped.
KDPF soot accumulation

caution icon lights up when
manual stationary
regeneration is required.
10-309

Monitor
display
Item
displayed
Display
color
Contents
Emergency steering
(if
equipped)
Green
Lights up when emergency steering

operates.
Remarks
Lights up when P mode is selected

with power mode selector switch.
P mode
Green
Lights up when E mode is selected

with power mode selector switch.
E mode
Shift hold
Green
Lights up when shift hold operates.
Lockup
Green
Lights up when lockup is engaged.
Yellow
Lights up when fan rotates in

reverse.
Flashes while rotation direction
is being changed.
Red
Lights up while rotation direction

change condition is being waited to
meet.
Fan
reverse
rotation
Preheating
ECO
guidance
10-310
Yellow
Background:
Green
Characters:
White
Lights up when engine electric

preheater operates.
Guidance on excessive engine
idling
Guidance on deterrence of
hydraulic relief
Guidance on deterrence of brake
dragging
Guidance on deterrence of
accelerator pedal depressing
Guidance on recommendation of
4th gear
Guidance on recommend of
lockup
Guidance on deterrence of longperiod digging
WA470-7

Guidance icon
Monitor
display
(WA380-Q1L3-043-K-00-A)
Item
User menu
selection
Display of
occurred error list
Move between
items (upper)
Move between
items (lower)
Return
Enter
Move between
tabs (right)
WA470-7
Function (Action that starts when

corresponding switch is pressed)
<When KDPF soot accumulation
caution lights up>
Moves to user menu "KDPF
regeneration"
<When maintenance caution lights
up>
Moves to user menu "Maintenance"
Displays occurred error list
<In user menu or service menu>
Moves to upper item
<When value is input>
Increases value
Moves to upper item
<When value is input>
Decreases value
Returns to previous screen or
standard screen
<When Yes/No is selected>
Selects "No"
Moves to upper item
<When Yes/No is selected>
Selects "Yes"
Moves to right tab
<In service menu>
Selects monitoring item tab
Move between
pages (upper)
Moves to upper page

(Moves to bottom page from top
page)
Move between
pages (lower)
Moves to lower item

(Moves to top page from bottom
page)
Start split fuel

consumption
measurement
Starts measurement of split fuel

consumption
Display location
Standard screen (when KDPF
soot accumulation caution lights
up)
Standard screen (when
maintenance caution lights up)
Standard screen (when failure

occurs)
Overall user menu

Overall service menu
Overall user menu

Overall user menu

Overall user menu

User menu
Service menu "Monitoring"
Occurred error list
User menu "ECO guidance"
"Operation record", "ECO
guidance record"
Service menu "Monitoring / Predefined"
Service menu "Abnormality
record" "Mechanical system
abnormality record"
Occurred error list
guidance record"
record" "Mechanical system
abnormality record"
guidance record"
10-311

Monitor
display
Item
Stop split fuel

consumption
measurement
Stops measurement of split fuel

consumption
Display location
a Displayed when setting of
"Average fuel consumption
display" is split
guidance record"
a Displayed when setting of
"Average fuel consumption
display" is split
Clear average fuel Clears average fuel consumption

consumption logs logs

"Average fuel consumption logs"
Select average
fuel consumption
log
Selects 1-hour/1-day average fuel

consumption log

"Average fuel consumption logs"
Initialize screen
brightness
Returns to monitor screen brightness User menu "Monitor setting"

"Screen adjustment"
to initial level
Store monitoring
item
Stores monitoring item
Clear saved
monitoring item
Clears monitoring item
Hold monitoring
value
Holds value of monitoring item
Cancel held
monitoring value
Cancels held value of monitoring

item
Clear
<Electrical system abnormality

record>
Clears electrical system abnormality
record
<Phone number entry>
Clears phone number
<Adjusting>
Clears input value
Move between
items (right)
10-312

Moves to right item

Service menu "Testing"
"Cylinder cut-out operation"
Service menu "Adjusting"
record" "Electrical system
abnormality record"
a For method of clearing

abnormality record, see
Testing and adjusting
Service menu "Phone number
entry"
entry"
Other items (Adjusting screen)
WA470-7

Monitor
display
Item


entry"
Other items (Adjusting screen)
Move between
items (left)
Moves to left item
Change between
plus and minus
Changes plus or minus of input value Service menu "Adjusting"
Input decimal point Inputs decimal point
WA470-7
Display location
10-313

Operator mode functions
(WA470-Q193-042-K-00-A)
The functions which the operator can display or set by operating switches in normally displayed screen.
Display and setting of some functions require special operation of the switch.
Items available in the operator mode are as follows:
Category
(*1)
Item
Display of KOMATSU logo
Password input screen
Display of standard screen
Display of end screen
Display of the operation screen for engine shutdown secondary switch
Operation of air conditioner
Displaying and setting user menu
ECO Guidance
Machine Setting / Information
KDPF Regeneration
Maintenance
Monitor Setting
User Message (including KOMTRAX messages for user)
Display of ECO guidance
Display of warning (caution and action level)
Display of maintenance due time over
Display of KDPF regeneration
Checking function by LCD (Liquid Crystal Display)
Function of checking service meter and odometer
Function of setting usage limitation/ changing password
*1: The items available in the operator mode are categorized as shown below.
A: Displays that appear since starting switch is turned to ON position until the standard screen appears, and
the displays that appear after starting switch is turned to OFF position.
B: Displays that appear when the switch on the machine monitor is operated.
C: Displays when a certain condition is satisfied.
D: Displays that require special switch operations.
a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Operator
mode (Outline)" section in Testing and adjusting.
a For the operating method of the engine start lock function, see "Password setting and canceling manual".
a For how to operate the function of changing the ID key registration, see the Operation and Maintenance
Manual.
10-314
WA470-7

Service mode functions
(WA470-Q194-042-K-00-A)
These functions are not displayed normally. A technician can display and set them by performing special
operations.
This mode is used for special setting, testing, adjusting, or troubleshooting.
The main service mode functions are as follows.
Monitoring/Pre-defined
Monitoring/Custom
Mechanical Systems
Abnormality Record
Electrical Systems
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Machine Model Select
Option Select
Default
Unit
Auto Idle Stop Time Fixing
Cylinder Cut-out
Diagnostic Tests
Regeneration for Service
KDPF Memory Reset
ECMV Automatic Compensation
T/M Initial Learning
T/M Initial Learning Reset
T/M Shift Point
T/M Shift Point Data Clear
Boom Angle Sensor for EPC (Raise)
Boom Angle Sensor for EPC (Lower)
Boom Raise Adjustment
Boom Lower Adjustment
Bucket Tilt Adjustment
Bucket Dump Adjustment
3rd Ext Adjustment
3rd Ret Adjustment
Adjustment
PCS Adjustment (Push)
PCS Adjustment (Pull)
Change of Boom Lever Pattern
Change of Bucket Lever Pattern
Boom Stop Modulation
2-Stage Low Idle Throttle Position
Loader Pump Displacement
Steering Pump Displacement
Fan Reverse Cycle
Fan Reverse Duration
ECSS Operating Speed
Fan 100% Mode
No Injection
Terminal Status
KOMTRAX Settings
GPS & Communication Status
Modem Status
Service Message
a For operating method of the service mode functions, see "Service mode" section in Testing and adjusting.
WA470-7
10-315

Switch panel
(HM300-Q1C0-042-K-00-A)
Input/output signals of switch panel
(WA380-Q1A1-03C-K-00-A)
AMP-6P [ CN-MOM1]
Pin No.
1
2
3
4
5
6
10-316
Signal name
Switch panel power supply (+12 V)
GND (Switch panel power supply)
LIN
Switch panel continuous power supply (+5.6 V)
External starting signal (for switch panel)
Switch panel built-in buzzer
Input/output signal
Input
Input/Output
Input
Output
Input
WA470-7

Rear view monitor system
Function
(HM300-Q162-041-K-00-A)
(HM300-Q162-042-K-00-A)
The rear view monitor system mainly consists of the rear view monitor, rear view camera, and monitor
controller.
1. Rearview monitor
Displays the rear view camera image to the operator according to the setting of the rear view monitor
controller (guide lines, display of reverse-interlock, luminance, etc.)
2. Rear view camera
Transmits the taken images to the rear view monitor.
Sends the contents of change of the rear view monitor setting to the monitor.
WA470-7
10-317

Rear view monitor
(HM300-Q16D-042-K-00-A)
Precautions for using rear view monitor

The reference lines must be re-adjusted in the following cases.
1. When the machine dimensions are changed because of replacement of tires, installation of optional
attachment, etc.
2. When the rear view camera is removed or its direction is changed because of damage etc.
Rear view monitor input/output signals
(WA380-Q16D-03C-K-00-A)
AMP-12P [ CN-RVM1]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
Signal name
Continuous power supply (24 V)
GND (continuous power supply)
Service connector external start signal
(*1)
Rear view monitor brightness adjustment switch +
Rear view monitor brightness adjustment switch Shift lever R signal
Monitor brightness selector switch
(Night mode signal)
LIN
(*1)
(*1)
Key switch ACC signal
Input/output signal
Input
Input
Input
Input
Input
Input
Input/Output
Input

AMP-8P [ CN-RVM2]
Signal name
Pin No.
Rear view camera power supply output
1
10-318
Input/output signal
Output
WA470-7

2
3
4
5
6
7
8
Rear view camera NTSC signal

(*1)
(*1)
GND (rear view camera power supply)
(*1)
(*1)
GND (rear view camera shield)
Input
Rear view camera
(HM300-Q162-042-K-01-A)
Rear view camera input/output signals
(WA380-Q162-03C-K-00-A)
DT-T-8P [ CN-RVC_1]
Pin No.
1
2
3
4
Signal name
Rear view camera power supply
Rear view camera NTSC signal output
(*1)
GND (rear view camera power supply)
Input/output signal
Input
Output
WA470-7
10-319

KOMTRAX system
KOMTRAX system
(HM300-Q210-042-K-00-A)
The KOMTRAX system consists of the KOMTRAX terminal, communication antenna, and GPS antenna.
This system transmits various machine information by use of the radio communication. KOMTRAX
operator can refer this information and provide various services to the customers.
Following information can be transmitted from the KOMTRAX system.
1.
2.
3.
4.
5.
6.
Position information
Operation information (service meter, odometer, etc.)
Alarm and failure information
Fuel consumption information
Maintenance information
Machine working condition information
a To provide the services, you need to establish radio station for KOMTRAX separately.
KOMTRAX terminal
(HM300-Q220-042-K-00-A)
Model: TC330
1. LED lamp display

2. GPS antenna connection port
10-320
WA470-7

KOMTRAX system
3. Machine wiring harness connection port (CN1A)

4. Machine wiring harness connection port (CN1B)
5. Communication antenna connection port
Input and output signals of KOMTRAX terminal
(HM300-Q220-03C-K-00-A)
CN1A[CN-KOM1]
Signal name
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
CAN2_H
CAN2_L
(*1)
(*1)
External starting signal
System operating lamp
(*1)
(*1)
(*1)
Input/output
signal
Input/Output
Input/Output
Input/Output
Output

CN1B[CN-KOM2]
Signal name
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12

Starting switch ACC signal
Alternator R signal
(*1)
(*1)
(*1)
(*1)
Starting switch C signal
(*1)
Input/output
signal
Input
Input
Input
Input
Input
Function
(D65-Q220-042-K-01-A)
This terminal utilizes satellite communications technology.

The terminal is an equipment which transmits various machine information obtained through network
signals and input signals, as well as GPS positioning data. The terminal can transmit data via the
communication antenna.
The status of the terminal can be checked by using the menu of KOMTRAX setting in the service mode
of the machine monitor .
Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
WA470-7
10-321

KOMTRAX system
This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a When commencing operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice about the name of the country to Komatsu Ltd.
a When operating the system in Japan, install a terminal dedicated for use in Japan.
10-322
WA470-7

System component parts

Engine controller
(ALL-RA1C-001-K-00-A)
(PC220-AP70-041-K-00-A)
Engine controller input and output signals
(PC400-AP70-03C-K-00-A)
The following is the list of the symbols used for signal classification in the input/output signal table.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
DRC26-60P(1)[ECM J1(CN-CE01)]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
WA470-7
Signal name
(*1)
Engine oil pressure sensor
Crankcase pressure sensor
(*1)
Charge temperature sensor
Intake temperature MAF sensor
CAN_C(+)
CAN_B(+)(KOMNET/r)
Bkup (camshaft) speed sensor (+)
(*1)
(*1)
(*1)
GND
Coolant temperature sensor
Charge pressure sensor
Ambient pressure sensor
Signal category
B
B
B
B
E
E
B
C
B
B
B
10-323

Pin No.
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
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
Signal name
CAN_C(-)
CAN_B(-)(KOMNET/r)
(*1)
(*1)
Sensor power supply (12 V)
GND
Mass air flow sensor
(*1)
(*1)
Ne (crankshaft) speed sensor (+)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
NE (crankshaft) speed sensor (-)
(*1)
(*1)
(*1)
(*1)
(*1)
Injector #4 (+)
Injector #5 (+)
Injector #6 (+)
Injector #3 (+)
Injector #2 (+)
Injector #1 (+)
(*1)
(*1)
(*1)
(*1)
Injector #4 ()
Injector #5 ()
Injector #6 ()
Injector #3 ()
Injector #2 ()
Injector #1 ()
GND
Signal category
E
E
A
C
B
A
C
D
D
D
D
D
D
C
C
C
C
C
C
C
A

DRC26-60P(2)[ECM J2(CN-CE02)]
Pin No.
1
2
3
4
10-324
Signal name
Supply pump #2 ()
Supply pump #2 (+)
(*1)
Supply pump #1 ()
Input/output
C
D
C
WA470-7

Pin No.
5
6
7
8
9
10
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
46
47
48
49
50
51
52
53
54
55
56
WA470-7
Signal name
Supply pump #1 (+)
EGR actuator (+)
(*1)
Fuel dozer solenoid valve #2 (+)
Fuel dozer solenoid valve #1 (+)
KVGT actuator (+)
(*1)
(*1)
(*1)
(*1)
(*1)
EGR actuator (-)
(*1)
GND
(*1)
KVGT actuator (-)
GND
(*1)
(*1)
CAN_B(+)
CAN_B(-)
(*1)
(*1)
(*1)
(*1)
Power supply of dosing fuel pressure sensor (5 V)
Power supply of common rail pressure sensor (5 V)
KVGT speed sensor (+)
KVGT speed sensor (-)
(*1)
(*1)
Dosing fuel pressure sensor
(*1)
KVGT position sensor
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
Input/output
D
D
D
D
D
C
C
E
E
A
A
B
C
(*1)
(*1)
GND
(*1)
(*1)
HC dozing solenoid (+)
(*1)
(*1)
(*1)
(*1)
Common rail pressure sensor
(*1)
10-325

Pin No.
57
58
59
60
Signal name
(*1)
(*1)
EGR valve lift sensor
HC dozing solenoid (-)
Input/output
B
C

DRC26-60P(3)[CN-CE03]
Pin No.
1
2
3
4
5
6
7
8
9
10
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
10-326
Signal name
Electric power supply (24 V)
Electric power supply (24 V)
Electrical intake air heater relay (+)
(*1)
(*1)
(*1)
(*1)
System operating lamp (in-use signal)
(*1)
Unswitched power supply (24 V)
Unswitched power supply (24 V)
(*1)
Dozing pump relay drive
(*1)
(*1)
CAN_A(+)(KOMNET/c)
CAN_A(-)(KOMNET/c)
Sensor GND
(*1)
GND (return from power supply)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
Fuel control dial GND
Fuel control dial power supply (5 V)
KDPF pressure sensor GND
(*1)
Input/output
A
A
B
D
A
A
E
E
C
C
C
C
C
C
A
C
WA470-7

Pin No.
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
Signal name
KDOC inlet temperature sensor
(*1)
(*1)
KDOC outlet temperature sensor
(*1)
(*1)
Fuel control dial
KDPF pressure sensor power supply (5 V)
(*1)
KDPF outlet temperature sensor
KDPF differential pressure sensor
(*1)
(*1)
KDPF outlet pressure sensor
(*1)
(*1)
Input/output
B
B
A
B
B
Work equipment controller
(WA380-PT10-041-K-00-A)
Input and output signals of work equipment controller
(WA380-PT10-03C-K-00-A)
DEUTSCH-24P [CN-L71]
Pin No.
1
2
3
4
5
WA470-7
Signal name
Joystick lever position B
Boom lever B
Steering pump oil pressure sensor
Signal GND
(*1)
Input/output signal
Input
Input
Input
10-327

Pin No.
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Signal name
(*1)
Joystick lever potentiometer A
Boom lever A
Oil pressure sensor of work equipment pump
(*1)
(*1)
Emergency steering pump oil pressure sensor
(*1)
Bucket lever B
(*1)
(*1)
(*1)
(*1)
(*1)
Bucket lever A
(*1)
Potentiometer power supply (5 V)
(*1)
2-stage low idle switch
Input/output signal
Input
Input
Input
Input
Input
Input
Output
Input

DEUTSCH-40P (1) [CN-L72]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
10-328
Signal name
Potentiometer power supply (5 V)
(*1)
Remote positioner switch (boom)
(*1)
4th lever B
Lift cylinder bottom oil pressure sensor
(*1)
Emergency steering relay
Bucket tilt detent
(*1)
(*1)
Remote positioner switch (bucket)
(*1)
(*1)
4th lever A
Lift cylinder head oil pressure sensor
(*1)
Boom raise detent
Work equipment lock solenoid
(*1)
(*1)
CAN-L (KOMNET/c)
CAN-L (KOMNET/r)
3rd lever B
Boom potentiometer
Joystick steering HI/LO selector switch
Work equipment lock pilot monitor
(*1)
Input/output signal
Output
Input
Input
Input
Output
Output
Input
Input
Input
Output
Output
Input/Output
Input/Output
Input
Input
Input
Input
Output
WA470-7

Pin No.
30
31
32
33
34
35
36
37
38
39
40
Signal name
(*1)
(*1)
CAN-H (KOMNET/c)
CAN-H (KOMNET/r)
(*1)
3rd lever A
Bucket potentiometer
Power mode selector switch (E)
(*1)
(*1)
(*1)
Input/output signal
Input/Output
Input/Output
Input
Input
Input
WA470-7
10-329


Pin No.
1
2
3
4
5
6
7
8
9
10
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
Signal name
Power supply (24 V)
GND (solenoid)
(*1)
4th valve retraction EPC
Boom RAISE EPC
Joystick lever left EPC
(*1)
Multicoulper release
Power supply (24 V)
GND (solenoid)
4th valve extension EPC
Boom LOWER EPC
Joystick lever right EPC
(*1)
Battery relay
Work equipment lock switch
GND (controller)
Power supply (24 V)
GND (solenoid)
Steering pump EPC
3rd valve retraction EPC
Bucket DUMP EPC
Joystick EPC cut relay
(*1)
Emergency steering switch
GND (controller)
GND (controller)
GND (controller)
Work equipment pump EPC
3rd valve extension EPC
Bucket TILT EPC
(*1)
(*1)
Multicoupler release switch failure
Input/output signal
Input
Input
Output
Output
Output
Input
Input
Input
Input
Input
Output
Output
Output
Input
Input
Input
Input
Output
Output
Output
Output
Input
Input
Output
Output
Output
Input
10-330
WA470-7

Transmission controller
(WA380-CV10-041-K-00-A)
Transmission controller input and output signals
(WA380-CV10-03C-K-00-A)
DEUTSCH-24P [CN-L61]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
WA470-7
Signal name
Torque converter outlet pressure sensor
(*1)
Torque converter oil temperature sensor
Signal GND
Gear speed switch 4th
Joystick downshift switch
Torque converter inlet pressure sensor
Directional lever position (analogue)
Transmission oil temperature sensor
(*1)
Gear speed switch 3rd
Joystick upshift switch
Transmission cut-off oil pressure sensor
(*1)
(*1)
Gear speed switch 2nd
Shift mode manual
(*1)
Hydraulic oil temperature sensor
Analog GND
Directional lever power supply (5 V)
Input/output signal
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Output
Input
Input
Input
Output
10-331

Pin No.
23
24
Signal name
Gear speed switch 1st
Shift mode H
Input/output signal
Input
Input

Pin No.
1
2
3
4
5
6
7
8
9
10
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
Signal name
(*1)
ECMV fill switch R
ECMV fill switch 4th
(*1)
Directional selector switch (F)
Parking brake switch
ECMV fill switch 2nd
(*1)
(*1)
(*1)
(*1)
ECMV fill switch F
ECMV fill switch 3rd
(*1)
Directional lever (R)
ECMV fill switch 1st
(*1)
Backup lamp relay
Transmission output shaft speed sensor
(*1)
CAN-L (KOMNET/c)
CAN-L (KOMNET/r)
Directional lever (N)
Directional selector switch (R)
Directional selector switch enable switch
Transmission cut-off switch built-in indicator
Pulse GND
Cooling fan speed sensor
(*1)
CAN-H (KOMNET/c)
CAN-H (KOMNET/r)
(*1)
Directional lever (F)
Directional selector switch (N)
E.C.S.S. switch
Torque converter lockup switch
Pulse GND
Transmission input speed sensor
Input/output signal
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Output
Input
Input/Output
Input/Output
Input
Input
Input
Input
Input
Input
Input/Output
Input/Output
Input
Input
Input
Input
Input
10-332
WA470-7


Pin No.
1
2
3
4
5
6
7
8
9
10
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
Signal name
Power supply (24 V)
GND (solenoid)
Battery relay
ECMV R
ECMV 3rd
(*1)
Neutral safety relay
Kickdown switch
(*1)
Power supply (24 V)
GND (solenoid)
E.C.S.S. solenoid
ECMV 4th
(*1)
Parking brake relay
Shift hold switch
Transmission cut-off switch
GND (controller)
Power supply (24 V)
GND (solenoid)
Cooling fan EPC
ECMV F
ECMV 1st
(*1)
(*1)
Transmission cut-off set switch
GND (controller)
GND (controller)
GND (controller)
Cooling fan reverse rotation solenoid
ECMV L/U
ECMV 2nd
(*1)
(*1)
(*1)
Input/output signal
Input
Input
Output
Output
Output
Output
Input
Input
Input
Input
Output
Output
Output
Input
Input
Input
Input
Output
Output
Output
Input
Input
Output
Output
Output
WA470-7
10-333

Monitor controller
(HM300-Q180-041-K-00-A)
Monitor controller input and output signals
(WA380-Q180-03C-K-02-A)
AMP-81P [CN-MCM1 A]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
10-334
Signal name
GND (controller)
GND (controller)
(*1)
Alternator R signal
(*1)
Fuel level sensor
Signal GND
Auto grease A
Preheating
Signal GND
Right headlamp
Left turn signal lamp
Right turn signal lamp
Signal GND
Engine speed signal (pulse)
Personal lock relay
Alarm buzzer
(*1)
(*1)
(*1)
Input/output signal
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Output
Output
Output
WA470-7

Pin No.
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
WA470-7
Signal name
(*1)
(*1)
Brake oil temperature sensor
(*1)
Seat belt
Unit selection
Engine shutdown secondary switch
(*1)
Monitor brightness selector switch
Clearance lamp switch
Auto grease B
Signal GND
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
Battery electrolyte level sensor
(*1)
Coolant level sensor
Headlamp high beam
(*1)
(*1)
(*1)
Air cleaner clogging sensor
(*1)
(*1)
Travel speed signal (pulse)
Tachograph power supply
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
Load meter subtotal switch
Load meter sub cancel switch
Engine oil level sensor
(*1)
Parking brake oil pressure switch
Rear brake oil pressure switch
Front brake oil pressure switch
(*1)
(*1)
Input/output signal
Input
Output
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Output
Output
Output
Input
Input
Input
Input
Input
Input
Input
10-335

Pin No.
76
77
78
79
80
81
Signal name
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
Input/output signal

AMP-40P [CN-MCM1 B]
Pin No.
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
Signal name
Switch panel built-in buzzer
(*1)
(*1)
(*1)
Load meter printer BUSY
(*1)
(*1)
CAN-L (KOMNET/c)
(*1)
Caution LED power supply
(*1)
(*1)
Load meter printer GND
(*1)
(*1)
CAN-H (KOMNET/c)
Continuous power supply (5.6 V)
GND
(*1)
(*1)
Load meter printer TX
(*1)
(*1)
CAN-L (KOMNET/r)
Power supply (12 V)
LIN
(*1)
(*1)
(*1)
CAN-H (KOMNET/r)
CAN-H (KOMNET/r)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
Input/output signal
Output
Input
Input/Output
Output
Input/Output
Output
Output
Input/Output
Input
Output
Input/Output
Input/Output
Input/Output

JAE-8P [CN-MCM2]
10-336
WA470-7

Pin No.
1
2
3
4
5
6
7
8
Signal name
LC unit LVDS (+)
LC unit LVDS (-)
LC unit GND (power supply return)
LC unit backlight adjustment
LC unit power supply
LC unit ON/OFF control
LC unit backlight ON/OFF control
LC unit temperature sensor
Input/output signal
Output
Output
Output
Output
Output
Output
Output
Work equipment electric lever
(WA380-PK11-041-K-00-A)
a Do not disassemble this lever since it needs to be adjusted for maintaining the performance after
reassembly.
1. Boot
2. Sensor
WA470-7
10-337

3. Detent solenoid
4. Connector
Function
10-338
(WA380-PK11-042-K-02-A)
WA470-7

Operating effort characteristics

"Boom LOWER", "Boom RAISE", and "Bucket TILT" operations
The control lever is held at the three operation stroke ends of "Boom LOWER", "Boom RAISE", and
"Bucket TILT". (Electric detent)
"Bucket DUMP" operation
Free return
Output voltage characteristics
The operating angle (stroke) of the control lever is detected with the sensor and signal voltages are output
to the controller.
Each sensor outputs two signal voltages which are opposite to each other as shown in the figure.
WA470-7
10-339

10-340
WA470-7

Throttle position sensor
(WA380-AG22-041-K-00-A)
1. Pedal
2. Connector
3. Sensor
Function
(WA470-AG22-042-K-00-A)
This sensor, installed to the floor top, outputs accelerator signals and idle validation signals according to
the depressing angle of the accelerator pedal.
Accelerator signal
The potentiometer in the sensor detects displacement of the accelerator pedal and outputs the variable
voltage through pin No. 2.
Idle validation signal
The switch in the sensor detects the operating condition of the accelerator pedal. It outputs the signal input
to pin No. 5 from pin No. 4 while the accelerator pedal is released, and outputs the signal input to pin No. 6
from pin No. 4 while the accelerator pedal is depressed.
WA470-7
10-341

Output characteristics
10-342
WA470-7

Combination switch
(WA380-CX10-041-K-00-A)
Structure
The directional lever has three positions and the gear speed switch has four positions. The switch itself
does not have a detent mechanism, which is in the combination switch. Each switch is positioned with
pins at two places and fixed to the body with three screws. When each lever is operated to a desired
position, the switch connected with the shaft moves to supply the current to only its circuit.
Function
(WA380-CX10-042-K-00-A)
No.
Name
1 Gear speed switch
2 Directional lever
3
Self-cancel
4
5
6
Turn signal lever

Dimmer switch
Lamp switch
WA470-7
Operation
Selects gear speed.
Selects forward or reverse travels and neutral.
Returns turn signal lever to neutral position automatically when steering wheel
is returned after turning to right or left.
Operates turn signal lamps.
Selects high or low beams of headlamp.
Lights up headlamp, clearance lamp, tail lamp, and instrument panel lamp.
10-343

Operation
(WA380-CX10-044-K-00-A)
When directional lever (1) of the combination switch is operated, body (2) rotates.
Slider (4) moves on control switch (5) via arm (3) of body (2). Slider (4) has magnet (6) in it.
Control switch (5) has Hall elements (7), which are arranged on the circuit board and matched to each
position of forward and reverse travels.
If the combination switch senses that magnet (6) comes just above Hall element (7) at each position, it
outputs the "F (Forward)", "N (Neutral)", or "R (Reverse)" signal according to the operation of directional
lever (1).
At the same time, slider (9) moves on control switch (5) via arm (8) of body (2). Slider (9) has magnet (10)
in it.
Hall elements (11) built in control switch (5) are arranged respectively on the circuit boards at each
position of forward and reverse travels and at the intermediate position between them.
Hall elements (11) are in the voltage signal output circuit. When it is sensed that magnet (10) comes just
above each Hall element (11), the output signal voltage changes.
The combination switch changes the output voltage of the analogue backup signal according to the
position of directional lever (1).
If gear speed switch (13) is rotated around shaft (12) of the combination switch, slider (16) moves on
control switch (5) via shaft (14) and arm (15) connected to gear speed switch (13). Slider (16) has magnet
(17) in it.
Control switch (5) has Hall elements (18), which are arranged on the circuit board and matched to each
position of the gear speeds.
If the combination switch senses that magnet (17) comes just above Hall element (18) at each position, it
outputs the "1st", "2nd", "3rd", or "4th" signal according to the operation of gear speed switch (13).
10-344
WA470-7

Kickdown switch
2-lever type
1.
2.
3.
4.
(WA380-CP22-001-K-00-A)
(WA380-CP22-041-K-00-A)
Switch A (white harness)

Switch B (yellow harness)
Spring
Harness
Function (WA380-CP22-042-K-00-A)
Switch A (1) installed to the boom control lever knob operates as a kickdown switch to downshift the gear.
Switch A (1) is a momentary type switch, namely, its contacts are closed only while it is pressed.
Hold switch
2-lever type
1.
2.
3.
4.
(WA380-CP25-001-K-00-A)
(WA380-CP25-041-K-00-A)
Switch A (white harness)

Switch B (yellow harness)
Spring
Harness
WA470-7
10-345

Function (WA380-CP25-042-K-00-A)
Switch B (2) installed to the boom control lever knob operates as a hold switch to hold the gear speed in
the auto-shift mode.
Switch B (2) is a momentary type switch, namely, its contacts are closed only while it is pressed.
10-346
WA470-7

CAN terminating resistor
(PC220-Q2V1-041-K-00-A)
CAN: Abbreviation for Controller Area Network
1. Connector (with built-in resistor)
Specifications
(PC220-Q2V1-030-K-00-A)
Resistance: 120 z
Function
(PC220-Q2V1-042-K-00-A)
This resistance controls the reflection of the high-frequency signals at the end of CAN communication line
not to generate noise on the CAN communication signals sending and receiving between controllers.
a If this resistance is missing, an error occurs on CAN communication and the machine cannot be
operated.
Front brake oil pressure switch
(WA380-G41C-041-K-00-A)
1. Switch
2. Connector
Specification
(WA380-G41C-030-K-00-A)
Contact type: Normally open

Operating (ON) pressure: 5.39 0.49 MPa {55 5 kg/cm2}
Resetting (OFF) pressure: 4.41 0.49 MPa {45 5 kg/cm2}
Function
(WA380-G41C-042-K-00-A)
This sensor, installed to the inlet port of the front brake accumulator, senses the charge pressure in the
front brake circuit and turns the switch "ON" when the pressure exceeds the specified level.
WA470-7
10-347

Rear brake oil pressure switch
(WA380-G41E-041-K-00-A)
1. Switch
2. Connector
Specification
(WA380-G41E-030-K-00-A)

Operating (ON) pressure: 5.39 0.49 MPa {55 5 kg/cm2}
Resetting (OFF) pressure: 4.41 0.49 MPa {45 5 kg/cm2}
Function
(WA380-G41E-042-K-00-A)
This sensor, installed to the inlet port of the rear brake accumulator, senses the charge pressure in the
rear brake circuit and turns the switch "ON" when the pressure exceeds the specified level.
Stop lamp oil pressure switch
(WA380-G7B4-041-K-00-A)
1. Switch
2. Connector
Specification
(WA380-G7B4-030-K-00-A)

Operating (ON) pressure: 0.59 0.098 MPa {6 1.0kg/cm 2}
Resetting (OFF) pressure: 0.39 0.049 MPa {4 0.5 kg/cm2}
Function
(WA380-G7B4-042-K-00-A)
This sensor, installed to the brake valve, senses the actuating pressure in the brake circuit and turns the
switch "ON" when the pressure exceeds the specified level.
10-348
WA470-7

Parking brake oil pressure switch
(WA380-GP2F-041-K-00-A)
1. Switch
2. Connector
Specification
(WA380-GP2F-030-K-00-A)

Operating (ON) pressure: 0.59 0.049 MPa {6 0.5 kg/cm 2}
Resetting (OFF) pressure: 0.39 0.049 MPa {4 0.5 kg/cm2}
Function
(WA380-GP2F-042-K-00-A)
This sensor, installed to the parking solenoid valve of the transmission control valve, senses the actuating
pressure in the parking brake circuit and turns the switch "ON" when the pressure exceeds the specified
level.
WA470-7
10-349

Sensor
Sensor
(ALL-E700-001-P-00-A)
(ENG-AAP2-041-K-00-A)
1. Connector
2. Sensor
Function
(ENG-AAP2-042-K-00-A)
This sensor, installed to the air intake cover at the engine top side, detects the ambient pressure to output
the corresponding variable voltage.
10-350
WA470-7

Sensor
(PC400-ABK5-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function
(PC400-ABK5-042-K-00-A)
This oil pressure sensor, installed in the cylinder block, It detects engine oil pressure to output variable
voltage.
Charge (Boost) pressure sensor
(PC400-AAM3-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function
(PC400-AAM3-042-K-00-A)
This sensor is installed to the engine intake manifold. It detects the engine boost pressure to output
signals as a variable voltage.
a a "Chargepressure" is the turbocharged pressure of a turbocharged engine. It is also referred to as a
"boost pressure".
WA470-7
10-351

Sensor
Charge (Boost) temperature sensor
Function
(D155-AAM4-041-K-00-A)
(D155-AAM4-042-K-00-A)
The charge (boost) temperature sensor detects the intake air temperature (boost temperature) and sends
it to the engine controller.
The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine
controller applies voltage to the thermistor and detects the temperature by the voltage divided by the
resistance in the computer and the resistance of the thermistor.
(ENG-BA87-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function
(WA470-BA87-042-K-00-A)
This sensor, installed on the cylinder block of the engine, converts the temperature variation into the
resistance variation, and outputs the corresponding signals.
10-352
WA470-7

Sensor
Ne (crankshaft) speed sensor
(ENG-AG42-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function
(WA470-AG42-042-K-00-A)
This sensor, installed to the flywheel housing, outputs the pulse voltage according to the rotation of the
gear.
WA470-7
10-353

Sensor
Bkup (camshaft) speed sensor
Function
(ENG125-AG62-041-K-00-A)
(ENG125-AG62-042-K-00-A)
Like the NE speed sensor, it utilizes 0 to 5 V pulses that result from the change in the magnetic lines
passing through the sensor.
The disc gear installed to the central part of the camshaft of the high-pressure pump has teeth (cut parts)
around it at intervals of 120 deg.
In addition to the above teeth, one more tooth is installed. Accordingly, seven pulses are generated every
two revolutions of the engine.
The standard pulse of No. 1 cylinder is recognized by the combination of the NE speed sensor pulse and
Bkup speed sensor pulse.
(ENG-AE28-041-K-00-A)
1. Connector
2. Sensor
10-354
WA470-7

Sensor
Function
(ENG-AE28-042-K-00-A)
This sensor, installed to the common rail in the engine, detects the fuel pressure to output the
corresponding variable voltage.
(ENG125-A9S2-041-K-00-A)
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function
(ENG125-A9S2-042-K-00-A)
The sensor, installed to EGR valve on the engine, detects the EGR valve opening to output the
The relation between stroke and output voltage is as shown in the following graph.
WA470-7
10-355

Sensor
KVGT speed sensor
(ENG125-AAQ4-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger
1. Sensor
2. O-ring
3. Connector
Function
(ENG125-AAQ4-042-K-00-A)
This sensor, installed to KVGT in the engine, outputs the pulse voltage by means of the rotation of KVGT
turbine.
10-356
WA470-7

Sensor
(ENG-AAQ3-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function
(ENG-AAQ3-042-K-00-A)
This sensor, installed to KVGT in the engine, detects the location of the nozzle ring which is built in KVGT
to output the corresponding variable voltage.
The relation between stroke and output voltage is as shown in the following graph.
WA470-7
10-357

Sensor
Mass air flow and temperature sensor
(ENG-A96H-041-K-00-A)
1. Connector
2. O-ring
3. Sensor
Function
(ENG-A96H-042-K-00-A)
This sensor is installed to the outlet side of air cleaner, converts the variations of intake air flow and
temperature into the resistance variation, and outputs the corresponding signals.
a The MAF (Mass Air Flow) means the intake air flow.
10-358
WA470-7

Sensor
KDPF differential pressure and outlet pressure sensor
(ENG-A9HL-041-K-00-A)
1. High-pressure port
2. Low-pressure port
3. Connector
4. Sensor
Function
(ENG-A9HL-042-K-00-A)
This sensor, installed to KDPF, detects the inlet pressure and outlet pressure of KDPF to output the
The output pressure difference is the difference between the KDPF inlet pressure which is detected at
high-pressure port (1) and the KDPF outlet pressure which is detected at low-pressure port (2).
The KDPF outlet pressure is output as a pressure which is detected at low-pressure port (2).
WA470-7
10-359

Sensor
KDOC inlet temperature sensor
(ENG-A9HG-041-K-00-A)
KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst
1. Sensor
2. Connector
Function
(ENG-A9HG-042-K-00-A)
This sensor, installed to the inlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
KDOC outlet temperature sensor
(ENG-A9HH-041-K-00-A)
KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst
1. Sensor
2. Connector
Function
(ENG-A9HH-042-K-00-A)
This sensor, installed to the outlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
10-360
WA470-7

Sensor
KDPF outlet temperature sensor
(ENG-A9HJ-041-K-00-A)
1. Sensor
2. Connector
Function
(ENG-A9HJ-042-K-00-A)
This sensor, installed to the outlet side of KDPF, converts the temperature variation into the resistance
variation, and outputs the corresponding signals.
(ENG-A18C-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function
(ENG-A18C-042-K-00-A)
This sensor, installed to the inlet side of KCCV head portion, detects the crankcase pressure (blowby
pressure) to output the corresponding variable voltage.
WA470-7
10-361

Sensor
(ENG-AB45-041-K-00-A)
1. Connector
2. Bracket
3. Float
4. Switch
Function
(ENG-AB45-042-K-00-A)
This sensor, installed on the side face of the oil pan, turns OFF by the lowered float, if the oil level
becomes lower than specified.
(PC400-A9JC-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function
(PC400-A9JC-042-K-00-A)
This sensor, which is installed to the dosing fuel solenoid valve assembly, detects the pressure of the fuel
supplied to output the corresponding variable voltage.
10-362
WA470-7

Sensor
Transmission input speed sensor
1.
2.
3.
4.
(WA470-CNB1-041-K-00-A)
Wire
Magnet
Housing
Connector
Function
(WA470-CNB1-042-K-00-A)
This sensor, installed to the left side of the transmission rear case, outputs the pulse voltage according to
the rotation of the gear.
WA470-7
10-363

Sensor
1.
2.
3.
4.
5.
(WA380-CNA1-041-K-00-A)
Wire
Magnet
Terminal
Housing
Connector
Function
(WA470-CNA1-042-K-00-A)
This sensor, installed to the right side of the transmission front case, outputs the pulse voltage according
to the rotation of the gear.
Cooling fan speed sensor
(D65-B750-041-K-00-A)
1. Sensor
2. Connector
Function
(D65-B750-042-K-00-A)
This sensor is installed to the cooling fan motor.

This sensor detects the gear speed and outputs corresponding pulse signals.
10-364
WA470-7

Sensor
Torque converter oil temperature sensor
(WA380-CDK4-041-K-00-A)
1. Connector
2. Plug
3. Thermistor
Function
(WA380-CDK4-042-K-00-A)
This sensor is installed to the block on the right side of the transmission rear case. It outputs a resistance
change signal of the thermistor for the temperature change.
(WA380-CH18-041-K-00-A)
1. Connector
2. Plug
3. Thermistor
Function
(WA470-CH18-042-K-00-A)
This sensor, installed to the transmission rear case, outputs a resistance change signal of the thermistor
for the temperature change.
WA470-7
10-365

Sensor
(PC-PMT1-041-K-00-A)
1. Connector
2. Plug
3. Thermistor
Function
(WA380-PMT1-042-K-00-A)
This sensor is installed to the block of the hydraulic tank return line. It outputs a resistance change signal
of the thermistor for the temperature change.
(WA380-GGD1-041-K-00-A)
1. Connector
2. Plug
3. Thermistor
Function
(WA380-GGD1-042-K-00-A)
This sensor is installed to the rear axle. It outputs a resistance change signal of the thermistor for the
temperature change.
10-366
WA470-7

Sensor
(WA470-CDL5-041-K-00-A)
1. Sensor
2. Lead wire
3. Connector
Function
(WA470-CDL5-042-K-00-A)
This sensor, installed to the block on the left side of the transmission rear case, detects the torque
converter in let pressure and outputs it as a variable voltage.
WA470-7
10-367

Sensor
(WA470-CDL6-041-K-00-A)
1. Sensor
2. Lead wire
3. Connector
Function
(WA470-CDL6-042-K-00-A)
This sensor, installed to the block on the right side of the transmission rear case, detects the torque
converter outlet pressure and outputs it as a variable voltage.
10-368
WA470-7

Sensor
(WA380-PPD1-041-K-00-A)
1. Plug
2. Sensor
3. Connector
Function
(WA380-PPD1-042-K-00-A)
This sensor is installed to the work equipment control valve. It senses the pump delivery pressure and
outputs a variable voltage for it.
WA470-7
10-369

Sensor
(WA380-F7C1-041-K-00-A)
1. Plug
2. Sensor
3. Connector
Function
(WA380-F7C1-042-K-00-A)
This sensor is installed to the block of the steering pump delivery line. It senses the pump delivery
pressure and outputs a variable voltage for it.
10-370
WA470-7

Sensor
Emergency steering pump pressure sensor
(WA380-F9SA-041-K-00-A)
1. Plug
2. Sensor
3. Connector
Function
(WA380-F9SA-042-K-00-A)
This sensor, installed to the block of the emergency steering pump discharge port, detects the pump
discharge pressure and outputs a variable voltage for it.
WA470-7
10-371

Sensor
Lift cylinder bottom oil pressure sensor
(WA380-L261-041-K-00-A)
1. Plug
2. Sensor
3. Connector
Function
(WA380-L261-042-K-00-A)
This sensor is installed to the line piping of the lift cylinder bottom. It senses the oil pressure in the cylinder
bottom and outputs a variable voltage for it.
10-372
WA470-7

Sensor
Transmission cut-off oil pressure sensor
(WA380-CP61-041-K-00-A)
1. Sensor
2. Lead wire
3. Connector
Function
(WA380-CP61-042-K-00-A)
This sensor is installed to the front brake circuit tube under the floor. It senses the brake actuating
pressure and outputs a variable voltage.
WA470-7
10-373

Sensor
(WA380-B252-041-K-00-A)
1. Reservoir tank
2. Float
3. Sensor
4. Connector
Function
(WA380-B252-042-K-00-A)
This sensor is installed to the ladder on the right side of the machine. When the coolant level lowers below
the specified level, the float of this sensor lowers and turns the switch "OFF".
10-374
WA470-7

Sensor
Fuel level sensor
1.
2.
3.
4.
5.
6.
7.
(WA380-AD41-041-K-00-A)
Connector
Float
Arm
Body
Spring
Contact
Spacer
Function
(WA380-AD41-042-K-00-A)
This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level. The movement of the float moves the variable resistor through the arm and the resistance
change is converted into the change of the power supply voltage, which is output as a signal voltage.
WA470-7
10-375

Sensor
Air cleaner clogging sensor
(WA380-A968-041-K-00-A)
1. Boss
2. Switch
3. Conduit
4. Wire
5. Connector
Function
(PC-A968-042-K-00-A)
This sensor is installed on the air cleaner outlet side. The switch is turned to ON position, if the air
cleaner is clogged and the pressure level drops to the specified level (negative pressure).
10-376
WA470-7

Sensor
Boom potentiometer
(WA380-L6W6-041-K-00-A)
1. Shaft
2. Housing
3. Bearing
4. Brush
5. Variable resistor
6. Connector
Function
(WA380-L6W6-042-K-00-A)
This potentiometer is installed to the front frame. The movement of the boom moves the variable resistor
through the link installed to the boom and the resistance change is converted into the change of the power
supply voltage, which is output as a signal voltage.
WA470-7
10-377

Sensor
Bucket potentiometer sensor
(WA380-LENB-041-K-00-A)
1. Shaft
2. Housing
3. Bearing
4. Brush
5. Variable resistor
6. Connector
Function
(WA380-LENB-042-K-00-A)
This potentiometer is installed to the pin connecting bell crank and boom. The movement of the bucket
moves the variable resistor through the link installed to the bell crank and the resistance change is
converted into the change of the power supply voltage, which is output as a signal voltage.
10-378
WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model
Serial Number
WA470-7
10001 and up
20 Standard value tables

4 20 Standard value tables
WA470-7
20-1

Table of contents
Table of contents
(ALL-0310-002-A-00-A)
20 Standard value tables.................................................................................................................... 20-1

Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
Standard value table for electrical system............................................................................. 20-18
20-2
WA470-7

Standard value table for engine
Standard service value table

(ALL-A000-001-K-00-A)
(WA470_7-A000-033-K-00-A)
Engine
Classification
Machine model
Engine
Item
WA470-7
SAA6D125E-6
Measurement condition
Coolant temperature: 60 to High idle

Engine speed
102C
Low idle
Power mode
Rated speed
Coolant temperature: 60 to 102C
Boost
Torque converter oil temperature: 60 to 80
pressure
C
Torque converter stall
Engine
Coolant
At high idle
temperature: outlet
60 to 102C (between
After kept for turbochar- Torque
5 seconds at ger and
converter stall
Exhaust gas
normal
KDPF inlet)
color
condition
Torque
KDPF outlet At high idle
converter oil (exhaust
temperature: pipe outlet) Torque
converter stall
60 to 80C
Intake
valve
Valve
At cold
clearance
Exhaust valve
Engine oil temperature: 40
Compression
to 60C
Compression
Engine speed: 200 to 280 pressure
pressure
rpm
Torque converter oil temperature: 60 to 80
Blowby
C
pressure
With torque converter stalled
KCCV circuit disconnected
Coolant temperature: Min.
High idle
60C
Engine oil
EOS5W30-LA
pressure
EOS5W40-LA
Low idle
EO10W30-LA
EO15W40-LA
EGR valve oil
pressure and Coolant temperature: 60 to
KVGT oil
102C
pressure
Oil
temperature
High idle
Low idle
Whole speed range (inside oil pan)
Between crankshaft pulley and alternator

pulley
Alternator belt
Deflection when pressed with finger at 59
tension
N {6 kg}
WA470-7
Unit
Standard value
for new
machine
Repair limit
rpm
rpm
rpm
2,170 50
800 (+ 50/-0)
2,000
kPa
{mmHg}
Min. 153
{Min. 1,150}
127
{950}
Bosch
index
Max. 1.0
Bosch
index
Max. 1.5
Max. 0.5
Max. 0.5
0.33
0.71
MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
kPa
{mmH2O}
Max. 1.96
{Max. 200}
3.92
{400}
MPa
{kg/cm2}
0.29 to 0.69
{3.0 to 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
MPa
{kg/cm2}
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}
Min. 1.18
{Min. 12.0}
1.43
{14.6}
1.18
{12.0}
90 to 110
120
mm
13 to 16
13 to 16
Bosch
index
Bosch
index
mm
mm
20-3

Classification
Machine model
Engine
Item
Air
conditioner
compressor
belt tension
WA470-7
SAA6D125E-6
Unit
Standard value
for new
machine
Repair limit
Between compressor pulley and fan pulley

Deflection when pressed with finger at 98
N {10 kg}
mm
25 to 26
25 to 26
Others
Classification
Machine model
Engine
Item
Unit
MPa
Engine at high idle
{kg/cm2}
Engine speed:
1,600 rpm
Engine speed:
1,700 rpm
Fuel return
Coolant temperature: 60 to Engine speed:
rate from
cc/min
1,800 rpm
102C
injector
Engine speed:
1,900 rpm
Engine speed:
2,000 rpm
Leakage from Torque converter oil temperature: 60 to 80
cc/min
pressure
C
limitter
compression
pressure
Engine
WA470-7
SAA6D125E-6
20-4
Standard value
for new
machine
Repair limit
0.15 to 0.3
{1.5 to 3.0}
0.15 to 0.3
{1.5 to 3.0}
Max. 960
Max. 1,020
Max. 1,080
Max. 1,140
Max. 1,200
Max. 10
WA470-7

Standard value table for machine
(WA470_7-0000-033-K-00-A)
Directional lever
Machine model
Item
Operating
effort
Stroke
NEUTRAL o Engine stopped

FORWARD/ Measure at center of lever
REVERSE
knob stem.
Measure at 10 mm from lever
top.
NEUTRAL o
FORWARD/ Tilt angle of steering column:
Deepest position (monitor
REVERSE
side)
WA470-7
Standard value
Repair limit
Unit
for new machine
9.0 1.0
9.0 1.7
N {kg}
{0.92 0.1}
{0.92 0.17}
mm
39 6
39 12
Gear speed switch

Machine model
Item
1st o 2nd
Operating
effort
2nd o 3rd
3rd o 4th
Rotation
angle
WA470-7
1st io 2nd
2nd io 3rd
3rd io 4th
Engine stopped
WA470-7
Standard value
Repair limit
Unit
for new machine
0.39 0.03
0.36 0.12
{4 0.3}
{3.7 1.2}
0.39 0.03
0.36 0.12
N {kg}
{4 0.3}
{3.7 1.2}
0.39 0.03
0.36 0.12
{4 0.3}
{3.7 1.2}
20 2
20 4
deg
20 2
20 4
20 2
20 4
20-5

Work equipment control lever

Machine model
Item
Unit
HOLD o
RAISE (*1)
RAISE (*2) o
HOLD
HOLD o
LOWER (*1)
LOWER o
HOLD
LOWER o
FLOAT
Operating effort
Boom
Engine speed: Low idle
N {kg}
FLOAT (*2) o
HOLD
HOLD o
DUMP
HOLD o TILT
(*1)
Bucket
TILT (*2) o
HOLD
HOLD io
RAISE (*2)
HOLD io
LOWER (*1)
HOLD io Engine speed: Low idle
FLOAT
HOLD o
DUMP
HOLD o TILT
(*2)
Stroke
Boom
Bucket
WA470-7
Standard value
Repair limit
for new machine
6.5 to 11.4
Max. 17.1 {1.74}
{0.66 to 1.16}
9.8 to 20.6
4.9 to 30.5
{1.0 to 2.10}
{0.5 to 3.11}
6.5 to 11.4
Max. 17.1 {1.74}
{0.66 to 1.16}
mm
11.4 to 20.2
{1.16 to 2.06}
9.8 to 20.6
{1.0 to 2.0}
7.5 to 17.7
{0.76 to 1.80}
6.5 to 11.4
{0.66 to 1.16}
9.8 to 20.6
{1.0 to 2.10}
Max. 30.3 {3.09}

4.9 to 30.5
{0.5 to 3.11}
Max. 26.6 {2.7}
Max. 17.1 {1.74}
4.9 to 30.5
{0.5 to 3.11}
44.5 2.2
44.5 4.4
31.2 to 37.9
Min. 31.2
44.5 2.2
44.5 4.4
44.5 2.2
44.5 4.4
44.5 2.2
44.5 4.4
*1: Position before detent

*2: Position of detent
Steering wheel
Machine model
Item
Play
Operating effort
No. of turns (not including
play)
Low idle
Operating
High idle
time
20-6
Engine stopped
Machine facing straight to
front
Flat, level, straight, and dry
paved road
(bucket empty)
Engine speed: High idle
Left lock to right lock
Start engine.
Hydraulic oil temperature: 45
to 55C
Left lock to right lock
Unit
WA470-7
Standard value
Repair limit
for new machine
mm
Max. 20
Max. 40
N {kg}
9.4 to 15.6
{0.96 to 1.6}
9.4 to 15.6
{0.96 to 1.6}
times
3.5 0.4
3.5 0.4
4.1 0.4
4.1 0.4
3.5 0.4
3.5 0.4
sec.
WA470-7

Accelerator pedal
Machine model
Item
Start engine.
Measure at 150 mm away
from pedal fulcrum
Depressing effort
NEUTRAL
(a1)
Depressing
angle
Max. (a2)
a For details, see Fig. A at end

of this section
Start engine.
Unit
N {kg}
deg.
WA470-7
Standard value
Repair limit
for new machine
45.5 to 58.8
{4.64 to 6.00}
45 2
17 2
Brake pedal
Machine model
Item
Depressing effort
NEUTRAL
(a1)
Max. (a2)
Depressing
angle
Play
a For details, see Fig. B at the

end of this section
to 55C
WA470-7
Standard value
Repair limit
Unit
for new machine
323 30
Min. 264
N {kg}
{32.9 3.0}
{Min. 26.9}
deg.
53
15 (+1 / 0)
51
Tire
Machine model
Item
Fitting of wheel lock ring
Clearance of wheel lock
ring
A
a For details, see Fig. C at end
B
of this section.
C Tire inflation pressure:
Specified pressure
Unit
mm
WA470-7
Standard value
Repair limit
for new machine
Max. 2.5
Max. 4.0
2 to 10
Engine speed
Machine model
Item
Hydraulic stall
Bucket CURL relief
Torque converter stall and
hydraulic relief speed
Bucket CURL relief
WA470-7
Hydraulic oil
temperature: 60 to
102C
Torque converter
oil temperature: 60
to 80C
Hydraulic oil
temperature: 45 to
55C
E mode
P mode
E mode
P mode
E mode
P mode
Unit
rpm
WA470-7
Standard value
Repair limit
for new machine
1,710 50
1,710 100
1,785 50
1,785 100
1,825 100
1,825 200
2,110 100
2,110 200
1,555 100
1,555 200
1,645 100
1,645 200
20-7

Transmission and torque converter

Machine model
Item
Unit
Low idle
Main relief oil pressure
Torque converter relief (inlet)

pressure
Torque converter outlet
pressure
Torque
converter oil
temperature: 60
to 80C
Lubricating oil pressure
Engine
speed:
2,000 rpm
Engine
speed:
2,000 rpm
Engine
speed:
2,000 rpm
Engine
speed:
2,000 rpm
MPa
{kg/
cm2}
1st, 2nd
ECMV output
(clutch)
Oil pressure
3rd, 4th
Forward,
Reverse
Torque converter oil

temperature: 60 to 80C
Engine speed: 2,000 rpm
Manual switch: ON
Lockup
WA470-7
Standard value
Repair limit
for new machine
2.32 0.2
2.32 0.2
{23.5 2.0}
{23.5 2.0}
2.55 0.2
{26.0 2.0}
2.55 0.2
{26.0 2.0}
0.1 to 0.88
{1.0 to 9.0}
0.1 to 0.88
{1.0 to 9.0}
0.06 to 0.71
{0.6 to 7.1}
0.06 to 0.71
{0.6 to 7.1}
0.175 0.075
{1.75 0.75}
0.175 0.075
{1.75 0.75}
2.35 0.15
{24 1.5}
2.30 0.15
{23.5 1.5}
2.06 0.15
{21.0 1.5}
1.66 0.15
{17.0 1.5}
2.35 0.15
{24 1.5}
2.30 0.15
{23.5 1.5}
2.06 0.15
{21.0 1.5}
1.66 0.15
{17.0 1.5}
Steering
Machine model
Item
Steering relief pressure
Steering control pressure
20-8
to 55C
to 55C
Steering wheel: Free
Unit
MPa
{kg/
cm2}
WA470-7
Standard value
Repair limit
for new machine
24.5 (+1.23 /
24.5 1.23
-2.45)
{250 12.5}
{250 (+12.5 /
-25)}
1.25 to 1.45
{12.7 to 14.8}
1.15 to 1.55
{11.7 to 15.3}
WA470-7

Accumulator
Machine model
Item
Charge cut-in pressure
Charge cut-out pressure
WA470-7
Checking to
be
performed
when the
Engine
brake oil
speed: Low
pressure
idle
warning
Hydraulic
lamp goes
oil
off
tempera Measure
ture: 45 to
when brake
55C
oil pressure
starts
lowering
after rising.
Unit
WA470-7
Standard value
Repair limit
for new machine
5.9 (+0.5 / 0)
{60 (+5 / 0)}
5.9 (+0.98 /
-0.5)
{60 (+10 / -5)}
9.8 (+0.98 / 0)
{100 (+10 / 0)}
9.8 (+1.5 / -0.5)

{100 (+15 / -5)}
MPa
{kg/
cm2}
20-9

Power train
Machine model
Item
P mode
Forward
E mode
Travel speed
(bucket empty)
(Lockup clutch: OFF)
P mode
Reverse
E mode
P mode
Forward
E mode
Travel speed
(bucket empty)
(Lockup clutch: ON)
P mode
Reverse
E mode
20-10
1st speed
2nd
speed
3rd
speed
4th speed
1st speed
2nd
speed
3rd
speed
4th speed
1st speed
2nd
speed
3rd
speed
4th speed
1st speed
2nd
speed
3rd
speed
4th speed
1st speed
2nd
speed
3rd
speed
4th speed
1st speed
2nd
speed
3rd
speed
4th speed
1st speed
2nd
speed
3rd
speed
4th speed
1st speed
2nd
speed
3rd
speed
4th speed
Unit
km/h
km/h
WA470-7
Standard value
Repair limit
for new machine
7.6 0.4
7.6 0.5
13.1 0.7
13.1 0.9
22.9 1.1
22.9 1.6
36.2 1.8
6.6 0.3
36.2 2.5
6.6 0.5
11.4 0.6
11.4 0.8
19.6 1.0
19.6 1.4
30.8 1.5
7.9 0.4
30.8 2.2
7.9 0.6
13.5 0.7
13.5 0.9
23.6 1.2
23.6 1.7
37.3 1.9
6.8 0.3
37.3 2.6
6.8 0.5
11.7 0.6
11.7 0.8
20.2 1.0
20.2 1.4
31.7 1.6
7.6 0.4
31.7 2.2
7.6 0.5
13.2 0.7
13.2 0.9
23.6 1.2
23.6 1.7
38.3 1.9
6.6 0.3
38.3 2.7
6.6 0.5
11.5 0.6
11.5 0.9
20.4 1.0
20.4 1.5
33.1 1.7
7.9 0.4
33.1 2.4
7.9 0.6
13.7 0.7
13.7 0.9
24.3 1.2
24.3 1.7
39.0 2.0
6.8 0.3
39.0 2.8
6.8 0.5
11.8 0.6
11.8 0.9
21.1 1.1
21.1 1.6
34.2 1.7
34.2 2.4
WA470-7

Wheel brake
Machine model
Item
Brake oil pressure
Drop of brake oil pressure
Performance
to 55C
Engine stopped
Measure lowering of oil
pressure after depressing
brake pedal for 5 min with 4.9
MPa {50 kg/cm2}
Tire inflation pressure:
Specified pressure
Flat, level, straight, and dry
paved road
Travel speed at beginning of
brake application 20 km/h:
Delay in applying brakes
Max. 0.1sec.
Brake pedal depressing
force:
Specified depressing effort
323 30 N {32.9 3 kg}
Measure braking distance.
Oil pressure: 4.9 MPa {50 kg/
cm2}
Pedal depressed completely
Wear of disc
Unit
MPa
{kg/
cm2}
WA470-7
Standard value
Repair limit
for new machine
4.8 0.4
Min. 4.2
{48.9 4.1}
{Min. 42.7}
Max. 0.49
Max. {5.0}
Max. 0.49
Max. {5.0}
Max. 5
Max. 5
mm
Protrusion of
shaft
0
Shaft protrusion
reaches wear
limit position
[Max. 2.4 mm]
Parking brake
Machine model
Item
Parking brake oil pressure
basic pressure
Performance
Parking brake: OFF
Specified pressure
Flat paved road with a slope
of 1/5 (11 degrees 20') and
dry surface
Set machine in operating
condition.
Unit
MPa
{kg/
cm2}
WA470-7
Standard value
Repair limit
for new machine
Min. 2.32
Min. 2.32
{Min. 23.5}
{Min. 23.5}
Min. 2.32
Min. 2.32
{Min. 23.5}
{Min. 23.5}
Stopped
Stopped
mm
3.2 0.08
2.97
a For measuring posture, see

Figs. D and E at the end of
this section
Disc thickness
WA470-7
20-11

Work equipment EPC

Machine model
Item
Work equipment EPC valve
source pressure
Unit

to 55C
Boom RAISE
Work
equipment
EPC valve
output
pressure
Boom FLOAT

to 55C
Boom LOWER Engine speed: High idle
Work equipment control lever
full operation
Bucket DUMP
Bucket TILT
20-12
MPa
{kg/
cm2}
WA470-7
Standard value
Repair limit
for new machine
3.72 (+0.2 /
3.72 (+0.2 / 0)
-0.2)
{38 (+2 / 0)}
{38 (+2 / -2)}
2.94 0.16
2.94 0.16
{30.0 1.6}
{30.0 1.6}
3.37 0.17
3.37 0.17
{34.4 1.7}
{34.4 1.7}
1.99 0.14
1.99 0.14
{20.3 1.4}
{20.3 1.4}
2.75 0.14
2.75 0.14
{28.0 1.4}
{28.0 1.4}
3.1 0.17
3.1 0.17
{31.5 1.7}
{31.5 1.7}
WA470-7

Work equipment
Machine model
Item
Work equipment relief

pressure
Unload pressure
LS differential pressure
Work equipment speed
Boom RAISE
Boom LOWER
Bucket full
stroke
Bucket from
level position
Dump
Tilt back
Tilt back
Hydraulic drift
Retraction of lift cylinder

rod
Retraction of bucket
cylinder rod

to 55C
to 55C
lever: NEUTRAL
to 55C
Boom control lever: In
halfway
Hydraulic oil
E mode
temperature: 45 to P mode
55C
E mode
Engine speed:
High idle
Apply no load
a For measuring
posture, see Figs.
F and G at end of
this section
Hydraulic oil
temperature: 45 to
55C
Engine speed:
High idle
Apply no load
Unit
MPa
{kg/
cm2}
P mode
E mode
P mode
E mode
P mode
E mode
a For measuring
posture, see Figs. P mode
H and J at the end
of this section
to 55C
Stop the engine and leave it
for 5 minutes, then take
measurement for 15 minutes.
Apply no load to bucket and
set boom and bucket in level
position.
sec.
WA470-7
Standard value
Repair limit
for new machine
34.3 (+1.8 /
34.3 1.77
-4.4)
{350 18}
{350 (+18 / -45)}
1.72 to 3.43
{17.5 to 35}
1.72 to 3.43
{17.5 to 35}
1.37 0.1
{14 1}
1.37 0.2
{14 2}
6.3 0.5
5.9 0.5
3.1 0.5
Max. 8.4
Max. 7.7
Max. 4.4
3.1 0.5
Max. 4.0
1.8 0.3
1.6 0.3
2.6 0.3
2.4 0.3
1.6 0.3
Max. 2.4
Max. 2.1
Max. 3.5
Max. 3.2
Max. 2.1
1.5 0.3
Max. 2.0
Max. 30
Max. 36
Max. 20
Max. 24
mm
a For measuring posture, see

Fig. K at the end of this
section
WA470-7
20-13

Hydraulic fan
Machine model
Item
Cooling fan maximum speed
Cooling fan minimum speed
Cooling fan drive pressure
Cooling fan reverse solenoid

output pressure
Engine high idle
95C
Hydraulic oil temperature:
Min. 95C
temperature: Min. 105C
Engine low idle
Coolant temperature: Max.
70C
Max. 70C
temperature: Max. 80C
Air conditioner: OFF
Engine high idle
Fan 100% mode (*)
50C
When cooling fan is reversed
Engine high idle
50C
Unit
rpm
MPa
{kg/
cm2}
WA470-7
Standard value
Repair limit
for new machine
1,300 100
1,300 200
Air conditioner:
OFF
175 50
Air conditioner:
ON
727 50
Air conditioner:
OFF
175 100
Air conditioner:
ON
727 100
14.3 1.4
{146 15}
14.3 2.1
{146 22}
2.51 0.35
{25.6 3.6}
2.51 0.53
{25.6 5.4}
*: Fan speed becomes 100% when it is set to reverse mode.
20-14
WA470-7

Machine posture and procedure for measuring performance
(WA380_7-0000-321-K-00-A)
a Fig. A
a Fig. B
a Fig. C
WA470-7
20-15

a Fig. D
a Fig. E
a Fig. F
a Fig. G
20-16
WA470-7

a Fig. H
a Fig. J
a Fig. K
WA470-7
20-17

Standard value table for electrical system

Controller
(WA470-RA1E-033-K-00-A)
Equipment name
Engine
controller
Continuous
power
supply
voltage
Continuous
power
supply
voltage
Work
equipment
controller
Solenoid
power
supply
voltage
Continuous
power
supply
voltage
Transmission
controller
Solenoid
power
supply
voltage
Monitor
controller
(D155-E000-001-P-00-A)
Continuous
power
supply
voltage
Procedure, measuring location, criteria and remarks

1. Turn starting switch to the OFF position, and set battery disconnect switch to
the OFF position.
2. Insert T-adapter into EC3.
3. Set battery disconnect switch to ON position.
4. Measure voltage with starting switch at OFF position and when starting
engine.
Between EC3 (1) and (21)
20 to 30 V
20 to 30 V
Voltage
20 to 30 V
20 to 30 V
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
Turn starting switch to OFF position.

Turn the battery disconnect switch to OFF position.
Insert T-adapter into connector L73.
Turn battery disconnect switch to ON position.
Turn starting switch to ON position.
Between L73 (1) and each of (21), (31), (32),
Voltage
and (33), and between L73 (11) and each of
(21), (31), (32), and (33)
Between L73 (2) and (21)
Voltage
Between L73 (22) and (32), and between L73
(22) and (33)
Between L63 (1) and each of (21), (31), (32),
Voltage
and (33), and between L63 (11) and each of
(21), (31), (32), and (33)
Voltage
Between L63 (22) and (33), and between L63
(32) and (33)
20 to 30 V
20 to 30 V
20 to 30 V
20 to 30 V
20 to 30 V
20 to 30 V
20 to 30 V
20 to 30 V

Disconnect connector MCM1 A, and connect T-adapter to female side.
Between MCM1 A (female) (1) and (2)
20 to 30 V
Voltage
20 to 30 V
1. Check that system operating lamp does not light up, and then set battery
disconnect switch to OFF position.
20-18
WA470-7

Equipment name
2.
3.
4.
5.

Disconnect connector MCM1 A, and connect T-adapter to female side.
a Check that engine shutdown secondary switch is at lower (OFF) position.

20 to 30 V
Voltage
20 to 30 V
20 to 30 V
WA470-7
20-19

Engine control
(WA470-AG10-033-K-00-A)
Equipment name
EGR valve solenoid
1. Turn starting switch to OFF position.

2. Disconnect connector EGR-SOL and connect T-adapter to male side.
Resistance Between EGR-SOL (male) (1) and (2)
5 to 10 z
KVGT solenoid

2. Disconnect connector VGT-SOL and connect T-adapter to male side.
Resistance Between VGT-SOL (male) (1) and (2)
5 to 10 z
2. Disconnect connector TWTR, and connect to socket to male side.
Coolant temperature
sensor
a Regard coolant temperature sensor as normal if its resistance is 700 z to 37

kz when coolant temperature is min. 0C.
0C
30 to 37 kz
Between TWTR (male) (A) and
25C
9.3
to 10.7 kz
(B)
50C
3.2 to 3.8 kz
a Coolant temperature80C
1.0 to 1.3 kz
Resistance
Resistance characteristics
95C
700 to 800 z
Whole coolant
Between TWTR (male) (B) and
temperature
Min. 1 Mz
ground
range
2. Disconnect connector TIM and connect socket to male side.
Charge temperature
sensor
a Regard charge temperature sensor as normal if its resistance is 280 z to

382 kz.
-40C
291 to 382 kz
-20C
85 to 109 kz
Between TIM (male) (A) and (B)
0C
29 to 36 kz
Resistance a Charge temperature30C
7.3 to 8.8 kz
60C
2.3 to 2.7 kz
90C
860 to 970 z
130C
280 to 320 z
Intake air temperature

sensor

2. Disconnect connector E27 and connect T-adapter to male side.
-30C
25 to 28 kz
Between E27 (male) (3) and (4)
0C
5.5 to 6.1 kz
25C
1.9 to 2.1 kz
a Intake air temperatureResistance
40C
1.1 to 1.2 kz
100C
180 to 185 z
Between E27 (male) (3) and
Whole range
Min. 1 Mz
ground (sensor body)
KDOC inlet temperature

sensor

2. Disconnect connectors TEMP1 and connect T-adapter to female side.
-10C
33 to 65 kz
0C
25 to 47 kz
Between TEMP1 (female) (1)
and (2)
50C
7.8 to 12.2 kz
100C
3.2 to 4.5 kz
Resistance a Temperature-Resistance
400C
200 to 240 z
characteristics
700C
64 to 69 z
Between TEMP1 (female) (1) and ground
Min. 1 Mz
KDOC outlet temperature

sensor

2. Disconnect connectors TEMP2 and connect T-adapter to female side.
Between TEMP2 (female) (1)
-10C
33 to 65 kz
Resistance and (2)
0C
25 to 47 kz
20-20
WA470-7

Equipment name

50C
7.8 to 12.2 kz
100C
3.2 to 4.5 kz
a Temperature-Resistance
400C
200 to 240 z
characteristics
700C
64 to 69 z
Min. 1 Mz
KDPF outlet temperature

sensor

2. Disconnect connectors E38 and connect T-adapter to female side.
-10C
33 to 65 kz
0C
25 to 47 kz
Between E38 (female) (1) and
(2)
50C
7.8 to 12.2 kz
Resistance
100C
3.2 to 4.5 kz
a Temperature-Resistance
400C
200 to 240 z
characteristics
700C
64 to 69 z
Charge (Boost) pressure

sensor

2. Insert T-adapter into connector J1 or PIM.
3. Turn starting switch to ON position.
Between J1 (15) and (59), or
Voltage
between PIM (3) and (2)
Engine oil pressure

sensor
Common rail pressure

sensor
Crankcase pressure
sensor
KDPF differential
pressure sensor
Dosing fuel pressure

sensor
KDPF outlet pressure

sensor
Turbocharger speed
sensor
WA470-7
Sensor output
0.3 to 4.7 V
Sensor output
0.3 to 4.7 V
Sensor output
0.3 to 4.7 V

2. Insert T-adapter into connector PFUEL or J2.
Between PFUEL (2) and (3) or
Voltage
Sensor output
J2 (55) and (21)
0.2 to 4.6 V

2. Insert T-adapter into connector PCCV.
Voltage
Between PCCV (3) and (2)
0.3 to 4.7 V

2. Insert T-adapters into connector J1 or POIL.
Between J1 (2) and (59) or
Voltage
between POIL (3) and (2)
2. Insert T-adapter into connector J1 or PAMB.
Voltage
between PAMB (3) and (2)
Sensor output

2. Insert T-adapter into connector E25.
Voltage
Between E25 (2) and (1)
0.5 to 4.5 V

2. Insert T-adapter into connector PDOSER.
Voltage
Between PDOSER (3) and (2)
0.5 to 4.5 V

Voltage
Between E25 (3) and (1)
0.5 to 4.5 V

2. Disconnect connector VGT REV, and connect T-adapter to female side of
connector.
Resistance Between VGT REV (female) (1) and (2)
600 to 1600 z
20-21

Equipment name

Accelerator pedal (throttle 2. Insert T-adapter into connector PD.
sensor)
Voltage
Between PD (2) and (1)

2. Insert T-adapter into connector J2 or SEGR.
Between J2 (59) and (47), or between SEGR (3)
Voltage
and (2)
1.0 to 4.0 V

2. Insert T-adapter into connector J2 or SVGT.
Between J2 (38) and (47), or between SVGT (C)
Voltage
and (B)
1.0 to 4.0 V
1.
2.
3.
4.

pressure sensor
20-22
3.7 to 4.0 V

Insert T-adapter into connector R37.
Start engine.
Turn emergency steering ON and operate steering.
Continuous
When
emergency
steering is
stopped
Voltage
Between R37 (2) and (1)
When
emergency
steering is
turned ON and
steering is
operated
0.50 to 4.5 V
0.50 to 0.90 V
0.50 to 3.05 V
WA470-7

Machine control
(WA470-E000-033-P-00-A)
Equipment name
E.C.S.S. solenoid

2. Disconnect connector F20 and connect T-adapter to male side.
Between F20 (male) (1) and (2)
35 to 45 z
Resistance Between ground and each of F20 (male) (1) and
Min. 1 Mz
(2)
Boom RAISE EPC

solenoid

2. Disconnect connector F23, and connect T-adapter to male side.
5 to 15 z
Min. 1 Mz
(2)
Boom LOWER EPC

solenoid

5 to 15 z
Min. 1 Mz
(2)

Bucket TILT EPC solenoid
5 to 15 z
Min. 1 Mz
(2)
Bucket DUMP EPC
solenoid

5 to 15 z
Min. 1 Mz
(2)
Radiator fan reverse

solenoid

2. Disconnect connector R59 and connect T-adapter to male side.
Between R59 (male) (1) and (2)
5 to 15 z
Resistance Between ground and each of R59 (male) (1) and
Min. 1 Mz
(2)
Neutral lock solenoid

35 to 45 z
Min. 1 Mz
(2)
Boom detent solenoid

2. Disconnect connector L28B, and connect T-adapter to male side.
Between L28B (male) (1) and (2)
100 to 123 z
Resistance
Between L28B (male) (1) and ground
Min. 1 Mz
Bucket detent solenoid

100 to 123 z
Resistance
Min. 1 Mz
Fan pump EPC solenoid

2. Disconnect connector R29, and connect T-adapter to male side.
5 to 10 z
Resistance Between chassis ground and each of R29
Min. 1 Mz
(male) (1) and (2)
Loader pump EPC

solenoid

Resistance Between R71 (male) (1) and (2)
5 to 15 z
WA470-7
20-23

Equipment name
Lockup clutch ECMV

solenoid

Between ground and each of R71 (male) (1) and
Min. 1 Mz
(2)
2. Disconnect connector LC.PS, and connect T-adapter to male side.
Between LC.PS (male) (1) and (2)
5 to 15 z
Resistance
Between ground and LC.PS (male) (1) or (2)
Min. 1 Mz

2. Disconnect connector 1.PS, and connect T-adapter to male side.
1st clutch ECMV solenoid
Between 1.PS (male) (1) and (2)
5 to 15 z
Resistance
Between ground and 1.PS (male) (1) or (2)
Min. 1 Mz
2nd clutch ECMV
solenoid

5 to 15 z
Resistance
Min. 1 Mz

3rd clutch ECMV solenoid
5 to 15 z
Resistance
Min. 1 Mz
R clutch ECMV solenoid

2. Disconnect connector R.PS and connect T-adapter to male side.
Between R.PS (male) (1) and (2)
5 to 15 z
Resistance
Between ground and R.PS (male) (1) or (2)
Min. 1 Mz
F clutch ECMV solenoid

2. Disconnect connector F.PS, and connect T-adapter to male side.
Between F.PS (male) (1) and (2)
5 to 15 z
Resistance
Between ground and F.PS (male) (1) or (2)
Min. 1 Mz

4th clutch ECMV solenoid
5 to 15 z
Resistance
Min. 1 Mz
3rd valve (attachment)
EXTEND EPC solenoid

5 to 15 z
Min. 1 Mz
(2)
3rd valve (attachment)

RETRACT EPC solenoid

5 to 15 z
Min. 1 Mz
(2)
Transmission oil
temperature sensor

2. Disconnect connector TM.T and connect T-adapter to male side.
Oil temperature: 25C
35 to 50 kz
Between TM.T
(normal temperature)
Resistance (male) (1) and (2)
3.1 to 4.5 kz
Hydraulic oil temperature

sensor

35 to 50 kz
Between R47 (male) (normal temperature)
Resistance (1) and (2)
3.1 to 4.5 kz
Brake oil temperature

sensor (rear)

20-24
WA470-7

Equipment name

temperature sensor
Loader pump pressure

sensor
Boom cylinder bottom

pressure sensor
Boom cylinder head

pressure sensor
Pilot pressure sensor of

main flow selector
solenoid
pressure sensor
Torque converter input

pressure sensor
WA470-7

Rear brake oil
temperature: 25C
Rear brake oil
temperature: 30C
Between R60 (male) Rear brake oil
temperature: 80C
Rear brake oil
temperature: 90C
Rear brake oil
temperature: 100C
42.7 kz
35.13 kz
6.556 kz
4.925 kz
3.75 kz

2. Disconnect connector TC.T and connect T-adapter to male side.
temperature: 25C
35 to 50 kz
Between TC.T
3.1 to 4.5 kz
temperature: 100C
2. Insert T-adapter into connector F10.
3. Start engine.
Loader pump pressure:
0.50 to 4.4 V
Continuous
Between F10 (C)
Loader pump pressure: At
Voltage
0.50 to 0.90 V
and (A)
NEUTRAL
Loader pump pressure: At
2.97 to 3.39 V
bucket tilt relief
3. Start engine, and move lever to boom RAISE to perform troubleshooting.
Always
0.50 to 4.4 V
Between F12 (C)
Boom: At NEUTRAL
0.50 to 0.90 V
Voltage
and (A)
Boom cylinder bottom:
2.97 to 3.39 V
Hydraulic relief
3. Start engine, and troubleshoot by lowering boom.
Always
Between F13 (C)
Boom: At NEUTRAL
Voltage
and (A)
Boom cylinder head:
Hydraulic relief
0.50 to 4.4 V
0.50 to 0.90 V
2.97 to 3.39 V

2. Disconnect connector FLOW.P, and connect T-adapter to female side.
Voltage
Between FLOW.P (female) (2) and (1)
0.3 to 4.7 V
1.
2.
3.
4.

Start engine.
Turn transmission cut-off switch ON.
When brake is released
When brake pedal is
Between R73 (C)
depressed (both right and
Voltage
and (A)
left)
Always
0.9 to 1.1 V
1.1 to 5.1 V
0.9 to 5.1 V

2. Insert T-adapter into connector TCIN.P.
20-25

Equipment name

Sensor output
Between TCIN.P (C) and (A)
0.9 to 5.1 V
voltage

2. Insert T-adapter into connector R91.
Torque converter outlet oil
pressure sensor
Sensor output
Between R91 (C) and (A)
voltage
0.9 to 5.1 V
Steering pump pressure

sensor

3. Start engine and operate steering.
Always
Between R86 (2)
Voltage
Steering: At NEUTRAL
and (1)
Steering: At Relief
Transmission input shaft

speed sensor

2. Disconnect connector REV IN, and connect T-adapter to male side.
Between REV IN (male) (1) and (2)
500 to 1,000 z
Resistance Between ground and each of REV IN (male) (1)
Min. 1 Mz
and (2)
Radiator fan speed

sensor

1,000 to 4,000
z
Resistance Between ground and each of R89 (male) (1) and
Min. 1 Mz
(2)
0.50 to 4.5 V
0.50 to 0.90 V
3.02 to 3.42 V

2. Disconnect connector REV OUT, and connect T-adapter to male side.
Transmission output shaft
Between REV OUT (male) (1) and (2)
500 to 1,000 z
speed sensor
Resistance Between ground and each of REV OUT (male)
Min. 1 Mz
(1) and (2)
1.
2.
3.
4.
Analog signal system of
FNR lever
1.
2.
3.
4.
5.
Boom lever potentiometer
Bucket lever
potentiometer
20-26

Move FNR lever to perform troubleshooting.
FNR (directional) lever: F
(FORWARD)
FNR (directional) lever: N
Between L02 (11)
Voltage
(NEUTRAL)
and (12)
FNR (directional) lever: R
(REVERSE)
Insert T-adapter into connector L28A.
Set work equipment lock switch to LOCK position.
Operate boom lever to perform troubleshooting.
Boom lever: NEUTRAL
Boom lever: RAISE (to
short of detent position)
Boom lever: RAISE (at
Between L28A (3)
Voltage
detent position)
and (2)
Boom lever: RAISE (at
detent position)
Boom lever: FLOAT
1.2 to 1.8 V
1.7 to 3.3 V
3.2 to 3.8 V
2.38 to 2.62 V
3.38 to 4.04 V
3.90 to 4.40 V
0.96 to 1.62 V
0.60 to 1.10 V

2. Insert T-adapter into connector L29A.
3. Turn work equipment lock switch to LOCK position.
WA470-7

Equipment name

5. Operate bucket lever to perform troubleshooting.
Bucket lever: NEUTRAL
2.38 to 2.62 V
Bucket lever: TILT (to
3.38 to 4.04 V
short of detent position)
Between L29A (3)
Voltage
and (2)
Bucket lever: TILT (at
3.90 to 4.40 V
detent position)
Bucket lever: Full DUMP
0.60 to 1.10 V
1.
2.
3.
4.
5.
3rd (attachment) lever

potentiometer
Boom angle sensor
Bucket angle sensor
1.
2.
3.
4.
1.
2.
3.
4.

Turn work equipment lock switch to LOCK position.
Operate 3rd (attachment) lever to perform troubleshooting.
3rd (attachment) lever:
NEUTRAL
Between L30 (3) and Operated to extend
Voltage
cylinder fully
(2)
Operated to retract
cylinder fully
2.38 to 2.62 V
3.90 to 4.40 V
0.60 to 1.10 V

Insert T-adapter into connector F11.
Always
Between F11 (B)
Voltage
RAISE stroke end
and (A)
LOWER stroke end
1.13 to 4.02 V
3.52 to 4.02 V
1.13 to 1.63 V

Operate bucket lever to perform troubleshooting.
Always
Between F32 (B)
Voltage
Full TILT
and (A)
Full DUMP
2.15 to 4.45 V
3.95 to 4.45 V
2.15 to 2.65 V
Air cleaner clogging

sensor

2. Disconnect connector E45 and connect T-adapters to male side.
When air cleaner is
Max. 1 z
Between E45 (male) normal
When air cleaner is
Min. 1 Mz
clogged
Fuel level sensor

2. Disconnect connector R33, and connect T-adapters to male side.
Between R33 (male) Fuel level: Full
Max. 12 z
Fuel level: Empty
80 to 100 z
Starting switch

2. Disconnect connector S40 and connect T-adapter to male side.
3. Troubleshoot by turning starting switch to ON, OFF, START, and HEAT
positions.
Starting switch: START
Max. 1 z
Between S40 (male)
Starting switch: OFF and
(1) and (3)
Min. 1 Mz
Resistance
ON
Between terminal B Starting switch: HEAT
Max. 1 z
and terminal R1
switch
WA470-7
20-27

Equipment name
Remote positioner set

switch (boom)
Throttle lock set/

acceleration switch
Defective throttle lock

resume/deceleration
switch
Engine shutdown
secondary switch

2. Disconnect connector S_RH1 and connect T-adapter to male side.
Engine power mode
Max. 1 z
Between S_RH1
selection switch: ON
(male) (5) and (6)
Engine power mode
Min. 1 Mz
selection switch: OFF
Resistance
Between ground and
each of S_RH1
Always
Min. 1 Mz
(male) (5) and (6)
2. Disconnect connector S_RH6, and connect T-adapters to male side.
Max. 1 z
switch: Boom set ON
Between S_RH6
(male) (5) and (6)
switch: Other than boom
Min. 1 Mz
Resistance
set ON
Between ground and each of S_RH6 (male) (5)
Min. 1 Mz
and (6)
2. Disconnect connector S_RH7, and connect T-adapter to male side.
Throttle lock set/
acceleration switch: Other
Min. 1 Mz
Between S_RH7
than ON
Throttle lock set/
Max. 1 z
acceleration switch: ON
2. Disconnect connector S_RH7, and connect T-adapter to male side
Throttle Lock Resume/
Deceleration Switch:
Min. 1 Mz
Between S_RH7
Other than ON
Throttle Lock Resume/
Max. 1 z
Deceleration Switch: ON
2. Disconnect connector S_FS and connect T-adapter to male side.
Between S_FS
Min. 1 Mz
(male) (3) and (2)
Engine shutdown
secondary switch: ON
Between S_FS
Min. 1 Mz
(male) (6) and (5)
Resistance
Between S_FS
Max. 1 z
(male) (1) and (2)
Engine shutdown
secondary switch: OFF
Between S_FS
Max. 1 z
(male) (4) and (5)
Parking brake indicator

switch

2. Disconnect connector PB.SW, and connect T-adapter to male side.
Parking brake pressure:
When parking brake is
Max. 1 z
released, Min. 0.61 MPa
2
{Min. 6.2 kg/cm }
Between PB.SW
Min. 1 Mz
applied, Max. 0.34 MPa
{Min. 3.5 kg/cm2}

switch (bucket)

Between S_RH6
switch: Bucket angle set
Max. 1 z
ON
20-28
WA470-7

Equipment name
Right FNR (directional)

switch
Work equipment lock

switch
Transmission auto/
manual shift mode
selector switch

switch: Other than bucket
Min. 1 Mz
angle set ON
Min. 1 Mz
and (6)
2. Disconnect connector S_RHB, and connect T-adapter to male side.
Max. 1 z
switch: F (FORWARD)
Between S_RHB
(male) (1) and (2)
Min. 1 Mz
switch: Other than F
Max. 1 z
switch: N (NEUTRAL)
Between S_RHB
(male) (1) and (3)
Min. 1 Mz
switch: Other than N
Resistance
Max. 1 z
switch: R (REVERSE)
Between S_RHB
(male) (1) and (4)
Min. 1 Mz
switch: Other than R
Between S_RHB (1)
Always
or (2),(3),(4) and
Min. 1 Mz
ground
2. Disconnect connector S_RHC, and connect T-adapter to male side.
Work equipment lock
Min. 1 Mz
Between S_RHC
switch: OFF
Work equipment lock
Max. 1 z
switch: ON
Shift mode: Manual shift
Max. 1 z
Between S_RH3
Shift mode: Auto shift (L)
Min.
1 Mz
(male) (4) and (5)
Shift mode: Auto shift (H)
Min. 1 Mz
Resistance
Min. 1 Mz
Between S_RH3
Shift mode: Auto shift (L)
Min. 1 Mz
(male) (5) and (6)
Shift mode: Auto shift (H)
Max. 1 z
switch

Transmission cut-off set
Max. 1 z
Between S_RH1
switch: ON
(male) (5) and (6)
Min. 1 Mz
switch: OFF
Resistance
Between ground and
each of S_RH1
Always
Min. 1 Mz
(male) (5) and (6)
Kickdown switch

2. Disconnect connector L14 and connect T-adapter to male side.
Between L14 (male) Kickdown switch: ON
Max. 1 z
(1) and (2)
Kickdown switch: OFF
Min. 1 Mz
Resistance Between ground and
each of L14 (male) Always
Min. 1 Mz
(1) and (2)
Hold switch

Between L14 (male) Kickdown switch: ON
Max. 1 z
Min. 1 Mz
WA470-7
20-29

Equipment name
20-30

Between ground and
each of L14 (male) Always
Min. 1 Mz
(3) and (4)
WA470-7

Machine monitor
Equipment name
LCD unit of
machine
monitor
Continuous
power
supply
voltage
(WA470-Q170-033-K-00-A)

1. Check that system operating lamp does not light up, and then turn battery
3. Disconnect connector MCM2, and connect harness checker to female side.
4. Turn battery disconnect switch to ON position.
Between harness checker (1) and (3)
Min. 0.3 V
Min. 0.3 V
Voltage
Min. 0.3 V
6.2 to 9.1 V
6.2 to 9.1 V
a When using T-adapters for connector MDM3 (070-8)

3. Disconnect connector MDM3, and connect T-adapters to female side.
Continuous 4. Turn battery disconnect switch to ON position.
Meter unit of power
machine
6. Lighting up of clearance lamp
supply
monitor
voltage
Between MDM3 (female) (1) and (4)
20 to 30 V
20 to 30 V
Between
MDM3
Night lighting switch:
Voltage
Max. 0.2 V
(female) (5) and (4)
OFF
Between MDM3
20 to 30 V
ON
LED unit of
machine
monitor
a When using T-adapter for connector MDM2 (070-6)

Continuous 3. Disconnect connector MDM2, and connect T-adapters to female side.
power
supply
voltage
9.3 to 14.1 V
a 12 V power supply
Voltage
4 to 6.1 V
a 5 V power supply
Switch
panel of
machine
monitor
a When using T-adapter for connector MOM1 (070-6)

Continuous 3. Disconnect connector MOM1, and connect T-adapters to female side.
power
supply
voltage
Between MOM1 (female) (1) and (2)
9.3 to 14.1 V
a 12 V power supply
Voltage
4 to 6.1 V
a 5 V power supply
WA470-7
20-31

20-32
WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model
Serial Number
WA470-7
10001 and up
30 Testing and adjusting

5 30 Testing and adjusting
WA470-7
30-1

Table of contents
Table of contents
(ALL-0310-002-A-00-A)
30 Testing and adjusting .................................................................................................................... 30-1

General information on testing and adjusting................................................................................. 30-4
Tools for testing and adjusting ............................................................................................... 30-4
Sketch of tools for testing and adjusting ................................................................................. 30-8
Testing engine speed ......................................................................................................... 30-10
Testing boost pressure ....................................................................................................... 30-12
Testing exhaust gas color ................................................................................................... 30-14
Testing and adjusting valve clearance .................................................................................. 30-16
Testing compression pressure............................................................................................. 30-18
Testing blowby pressure ..................................................................................................... 30-22
Testing engine oil pressure ................................................................................................. 30-24
Testing EGR valve and KVGT oil pressures .......................................................................... 30-25
Testing fuel pressure .......................................................................................................... 30-26
Testing fuel return rate and leakage ..................................................................................... 30-27
Bleeding air from fuel system .............................................................................................. 30-31
Testing fuel circuit for leakage ............................................................................................. 30-33
Handling cylinder cutout mode operation.............................................................................. 30-34
Handling no injection cranking operation .............................................................................. 30-35
Testing of KDPF and muffler stack for looseness and damage ............................................... 30-36
Testing of installed condition of cylinder head and manifolds .................................................. 30-37
Testing engine piping for damage and looseness .................................................................. 30-38
Testing and adjusting air conditioner compressor belt tension ................................................ 30-39
Testing and adjusting alternator belt tension ......................................................................... 30-41
Procedures for cleaning fuel doser....................................................................................... 30-43
Writing compensation values at replacement of injector and engine controller ......................... 30-46
Power train............................................................................................................................... 30-50
Adjusting transmission output speed sensor ......................................................................... 30-50
Adjusting transmission input speed sensor ........................................................................... 30-51
Flushing procedure for torque converter and transmission hydraulic circuit.............................. 30-52
Retrieval of disabled machine due to transmission valve failure.............................................. 30-54
Testing oil leakage from axle final drive ................................................................................ 30-56
Testing drive shaft for looseness, backlash, and damage....................................................... 30-57
Testing and adjusting power train oil pressure....................................................................... 30-58
Steering system........................................................................................................................ 30-73
Testing directional lever ...................................................................................................... 30-73
Testing steering wheel ........................................................................................................ 30-74
Testing work equipment control lever ................................................................................... 30-76
Testing and adjusting steering circuit oil pressure.................................................................. 30-78
Bleeding air from steering cylinder circuit.............................................................................. 30-81
Testing and adjusting steering stopper valve......................................................................... 30-82
Brake system ........................................................................................................................... 30-83
Testing brake pedal ............................................................................................................ 30-83
Testing and adjusting brake pedal linkage ............................................................................ 30-84
Testing braking performance ............................................................................................... 30-85
Testing and adjusting of accumulator charge pressure........................................................... 30-86
Testing of brake accumulator nitrogen gas pressure and procedure for charging brake
accumulator with nitrogen gas................................................................................ 30-88
Testing wheel brake oil pressure.......................................................................................... 30-92
Testing lowering of wheel brake pressure ............................................................................. 30-94
Testing wear of wheel brake disc ......................................................................................... 30-96
Bleeding air from wheel brake circuit.................................................................................... 30-97
Releasing remaining pressure in brake accumulator circuit .................................................... 30-99
Testing parking brake performance .................................................................................... 30-100
Testing parking brake oil pressure ..................................................................................... 30-101
Testing wear of parking brake disc ..................................................................................... 30-102
30-2
WA470-7

Table of contents
Method of releasing parking brake manually ....................................................................... 30-103

Testing fan speed............................................................................................................. 30-105
Testing fan pump circuit oil pressure .................................................................................. 30-106
Bleeding air from hydraulic fan circuit ................................................................................. 30-108
Testing and adjusting work equipment EPC oil pressure ...................................................... 30-110
Testing and adjusting work equipment oil pressure.............................................................. 30-113
Bleeding air from work equipment circuit ............................................................................ 30-117
Releasing remaining pressure from work equipment circuit .................................................. 30-118
Testing of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator
with nitrogen gas ................................................................................................ 30-119
Work equipment ..................................................................................................................... 30-123
Testing and adjusting bucket position detection lever........................................................... 30-123
Testing and adjusting boom position detection lever ............................................................ 30-124
Adjusting replaced, reassembled or added sensor, controller, etc. with machine
monitor .............................................................................................................. 30-125
Special functions of machine monitor ................................................................................. 30-127
Adjusting rearview camera angle ....................................................................................... 30-216
Handling voltage circuit of engine controller........................................................................ 30-217
Handling battery disconnect switch .................................................................................... 30-218
Testing diodes ................................................................................................................. 30-219
Pm clinic ................................................................................................................................ 30-220
Pm Clinic service ............................................................................................................. 30-220
Check sheet .................................................................................................................... 30-221
WA470-7
30-3

General information on testing and adjusting

Testing and
adjusting item
Testing boost
pressure
Symbol
Part No.
Feeler gauge
1 795-502-1590
795-471-1420
2
6217-71-6112
Commercially
3
available
1 799-201-1504
2 799T-201-3210
3 799T-201-3220
Gauge assembly
Adapter
Gasket
1
1
1
1 799-101-5002
Hydraulic tester
2 790-261-1204
Digital hydraulic tester
3 799-401-2320
Gauge
1 799-201-9002
Commercially
2
available
Testing and
adjusting valve
clearance
Testing engine oil

pressure
Testing fuel
pressure
Testing fuel
discharge, return
and leakage
30-4
Commercially
available
Boost gauge kit

Handy smoke checker
2 799-101-5002
Hydraulic tester
3 790-261-1204
1 799-101-5002
Hydraulic tester
2 790-261-1204
795-790-5120
3 07005-01412
790-301-1530
4 799-401-2320
1 6151-51-8490
2 6206-71-1770
Commercially
3
available
Commercially
4
available
Commercially
5
available
Commercially
6
available
Screw
Gasket
Elbow
Gauge
Spacer
Joint
Inner diameter 14 mm, length

1 approx. 2 m
1 0 to 10 kPa {0 to 1,000 mmH2O}
1 Hose inside diameter: 24 mm
2 Pipe outside diameter: 25.4 mm
Pressure gauge: 2.5, 6.0, 40, 60
1 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
1 kg/cm2}
Pressure gauge: 1.0 MPa {10
1 kg/cm2}
1
1
1 MPa
{25, 60, 400, 600 kg/cm2}
1 kg/cm2}
1 MPa
{25, 60, 400, 600 kg/cm2}
1 kg/cm2}
1 M14 x 1.5 o Rc1/8
1
1 Rc1/8 x Rc1/8
1 1 MPa
1
1
Hose
1 Inside diameter: approx. 6 mm
Hose
1 Inside diameter: approx. 16 mm
Measuring cylinder
Stopwatch
1
Testing EGR valve
and KVGT oil
pressure
Remarks
Smoke meter
799-201-2202
Testing exhaust gas

color
Testing blowby
pressure
Part name
-101 to 200 kPa {-760 to 1,500

1 mmHg}
1
Bosch index: 0 to 9
1
Testing compression
E
pressure
(WA470-5320-304-A-00-A)
Q'ty
Tools for testing and adjusting
(ALL-3831-001-A-00-A)
Hose
Blowby checker
Plug
Cap
795T-401-1310 Plug
02896-21018 O-ring
WA470-7
Testing and
adjusting item
Symbol
Part name
Q'ty
Developer for dye

penetrant (color
checker)
Part No.
Testing fuel circuit

for leakage
Commercially
available
Testing directional
lever
79A-264-0021 Push-pull scale
Testing and
adjusting power
train oil pressure
Hydraulic tester
2 790-261-1204
3 799-401-2320
Gauge
799-101-5220
07002-11023
Nipple
O-ring
1
1
794-423-1190
Plug
4
Retrieval of disabled
machine due to
transmission valve
failure
Testing steering
wheel
Testing and
adjusting steering oil Q
pressure
Bleeding air from

hydraulic fan circuit
Testing and
adjusting of
accumulator charge
pressure
Testing lowering of
wheel brake
pressure
Testing wear of
wheel brake disc
Hydraulic tester
2 790-261-1204
1 799-101-5002
Hydraulic tester
2 790-261-1204
3 790-261-1130
Coupling
1 799-101-5002
Hydraulic tester
2 790-261-1204
1
2
3
4
5
6
7
Brake test kit

Coupler
Pump
Adapter
Nipple
Hose
Coupling
Vernier calipers
2 790-261-1204
WA470-7
799-101-5220
07002-11023
Nipple
O-ring
1 799-101-5002
1 799-101-5002

MPa
{25, 60, 400, 600 kg/cm2}
kg/cm2}
Pressure gauge: 1.0 MPa {10
kg/cm2}
10 x 1.25 mm

1 MPa
{25, 60, 400, 600 kg/cm2}
1 kg/cm2}
1 10 x 1.25 mm
1
1 MPa
{25, 60, 400, 600 kg/cm2}
1 kg/cm2}
1 MPa
{25, 60, 400, 600 kg/cm2}
1 kg/cm2}
1
1 MPa
{25, 60, 400, 600 kg/cm2}
1 kg/cm2}
1
1
1
1 10 x 1.25 mm o R1/8
1
1 Length: 5 m
1
Hydraulic tester
3
Testing oil pressure
in cooling fan pump
circuit
1 799-101-5002
Remarks
793-605-1001
790-101-1430
790-101-1102
790-301-1720
799-101-5160
799-401-2220
790-261-1130
Commercially
available
30-5
Testing and
adjusting item
Symbol
Part No.
Testing wear of
parking brake disc
Testing work
equipment control
lever
Ruler
Hydraulic tester
2 790-261-1204
ZA
799-101-5220
07002-11023
Nipple
O-ring
1 799-101-5002
Hydraulic tester
2 790-261-1204
799-101-5220
07002-11023
4 799-401-2701
1 401-799-2930
Nipple
O-ring
Differential pressure
gauge
Adapter

1 MPa
{25, 60, 400, 600 kg/cm2}
1 kg/cm2}
1 10 x 1.25 mm
1
1 MPa
{25, 60, 400, 600 kg/cm2}
1 kg/cm2}
1 10 x 1.25 mm
1
3 790-261-1204
Commercially
available
Cu3886388
795-799-5730
Commercially
available
or
795-799-5740
795-799-5720
799-601-4510
Commercially
available
Commercially
available
Lap top type personal

computer
INSITE ver. 7.4
INLINE 5 Kit

1 MPa
{25, 60, 400, 600 kg/cm2}
1 kg/cm2}
Windows XP SP2/VISTA/
1
Windows 7
1
1
Cable (USB)
Cable (RS232)
Cable (9P)
Cable (12P)
1
1
Gas charge tool
Pressure reducing valve
Commercially
available
Charging hose
Testing wheel brake

2 799-101-5002
ZB
oil pressure
1
2
3
ZC
4
5
6
30-6
Push-pull scale
1 799-101-5002
Testing ECSS
accumulator
nitrogen gas
pressure and
procedure for
charging
accumulator with
nitrogen gas.
793T-615-1820
07002-11023
Commercially
X
available
1 79A-264-0021
Y
Commercially
2
available
Writing
compensation
values at
replacement of
injector and engine
controller
Vernier calipers
790-261-1204
2
Testing and
adjusting work
equipment oil
pressure
Adapter
O-ring
799-101-5002
1
W
Remarks

1 MPa
{25, 60, 400, 600 kg/cm2}
1 kg/cm2}
1 10 x 1.25 mm
1
Hydraulic tester
Testing parking
brake oil pressure
Testing and
adjusting work
equipment EPC oil
pressure
Part name
Q'ty
1
2
ZD
3
Hydraulic tester
WA470-7
Testing and
adjusting item
SymPart No.
bol
1 792-610-1702
792-610-1310
Testing brake
accumulator
nitrogen gas
pressure and
procedure for
charging
accumulator with
nitrogen gas.
Removal and
installation of
coolant temperature
sensor
WA470-7
792-610-1320
ZE
792-610-1330
Part name
Gas charge tool
Nipple
(for Russia)
Nipple
(for US)
Nipple
(for US)
792-610-1350
Nipple
(for German)
792-610-1360
Nipple
(for UK)
795T-981-1010 Socket
Q'ty
Remarks
1
1 GOST
1 CGA No. 351
1 ASA B-571-1965
DIN 477-7963
1 NEN 3268-1966
SIS-SMS 2235/2238
BS 341
1
Part1-1962
1
30-7

Sketch of tools for testing and adjusting
(WA470-3531-061-A-00-A)
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
H1: Plug
-:Socket
30-8
WA470-7

W: Adapter
WA470-7
30-9


Testing engine speed
(ALL-R401-001-K-00-A)
(WA470-A000-360-K-01-A)
k Place
the machine on a level ground and

lower the work equipment to the ground.
a Measure the engine speed under the following

conditions.
Hydraulic oil temperature: 45 to 55C
Torque converter oil temperature: 60 to 80C
Testing
(WA470-A000-388-K-00-A)
a Check the engine speed with Monitoring/Predefined or Monitoring/Custom function of the

machine monitor.
Preparation
Operate machine monitor to display Fan 100%
Mode.
a For the machine monitor operating method, see
the section of "Adjustment (Fan 100% Mode)".
a Bucket does not move even when the bucket

lever is operated, since work equipment lock
switch is in ON (LOCK) position.
Measuring torque converter stall speed
1. Start the engine.
2. Set transmission cut-off switch to "OFF" position
and depress left brake pedal securely.
3. Set the torque converter lockup switch (if
equipped) to OFF position.
4. Set transmission shift mode selector switch to
the MANUAL position.
5. While keeping the directional lever or directional
selector switch in N (neutral) position, set the
gearshift lever to the 4th speed.
6. Release parking brake.
7. While depressing brake pedal, set directional
lever or directional selector switch to "F
(forward)" or "R (reverse)" position.
k Keep
brake pedal firmly depressed.
8. Depress the accelerator pedal gradually to run

the engine at full speed and stall the torque
converter to measure the engine speed.
a Measure the stall speed 2 to 3 times.
a Do not keep stalling torque converter for
more than 20 seconds. Take care that torque
converter oil temperature does not exceed
120C.
Measuring engine speed (low idle)

Start the engine, set it in the measuring condition,
and measure the engine speed.
Measuring engine speed (high idle)
2. Set the work equipment mode to P, and work
equipment lock switch to OFF (released)
position.
3. Set boom at the lowest position. (Boom angle:
Max. -35.5 degrees)
a Bottom of the bucket is approx. 100 mm off
the ground while the bucket is level, and the
boom angle is Max. -35.5 degrees.
4. Set work equipment lock switch to ON (LOCK)
position.
5. Depress the accelerator pedal gradually while
operating bucket lever tilting. Measure the
engine speed at high idle.
30-10
a Measure the torque converter stall speed

respectively when the power mode and
economy mode are selected.
Measuring hydraulic stall speed
1. Start the engine and run it at high idle.
2. Set the work equipment lock switch to OFF
(released) position.
3. Set boom at the lowest position. (Boom angle:
Max. -35.5 degrees)
4. Relieve the bucket cylinder on the extension
side (bucket digging relief), and measure the
engine speed.
a Measure the hydraulic stall speed
respectively when the power mode and
economy mode are selected.
Measuring engine speed at torque converter
stall and hydraulic stall (full stall)
2. Set transmission cut-off switch to "OFF" position
and depress left brake pedal securely.
3. Set the torque converter lockup switch (if
equipped) to OFF position.
WA470-7


5. While keeping the directional lever in N (neutral)
position, set the gear speed switch to the 4th
speed.
7. While depressing the brake pedal, set the
directional lever to the "F (forward)" or "R
(reverse)" position.
k Keep
8. Run the engine at high idle with the torque

converter stalled, and relieve the bucket cylinder
on the extension side (bucket digging relief), and
measure the engine speed at this time.
more than 20 seconds. Take care that torque
120C.
a Measure the full stall speed when the power
mode is selected.
WA470-7
30-11

Testing boost pressure
(WA470-A900-360-K-01-A)
a Testing tools
Symbol
A
Part No.
Part name
799-201-2202 Boost gauge kit
k Place
the machine on a level ground, lower

the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.
k When
installing and removing testing tools,

be careful not to touch a hot part of the
engine.
2. Install nipple [1] of boost gauge kit A, and

connect it to gauge [2].
a Testing of the boost pressure is to be performed

under the following conditions.
3 Nipple [1]:
15 2 Nm {1.53 0.2 kgm}

Testing with machine monitor
(WA380-
A900-362-K-00-A)
Check the boost pressure with Monitoring/Predefined or Monitoring/Custom of the machine

monitor.
the section of "Special functions of machine
monitor".
a Monitoring code: 36500 Charge Pressure-A
3. Start the engine and increase the coolant

temperature to the operating range.
4. Run the engine at medium or higher speed to
drain the oil in the hose.
a Repeat opening the self-sealing portion on
the hose by inserting approximately half of
the connection part of the gauge into the
hose to drain oil.
a When Pm kit (A) is available, you can use air
bleeding coupling (790-261-1130) in the kit.
Testing by use of testing tools
5.
(WA470-
A900-362-K-00-A)
1. Open side cover on the right of engine, and

remove boost pressure pickup port plug (1).
6.
7.
8.
9.
30-12
a If oil is left in the hose, the gauge does not

work. Accordingly, be sure to drain the oil.
Set the transmission cut-off switch to OFF
position and depress the left brake pedal
securely.
Set the torque converter lockup switch to OFF
position.
Set transmission shift mode selector switch to
While keeping the directional lever or directional
gearshift switch to the 4th speed.
Release parking brake.
WA470-7

10.While depressing the brake pedal, set the

directional lever to the "F (forward)" or "R
k Keep
11.Depress the accelerator pedal gradually to run

the engine at high idle and stall the torque
converter, then measure the boost pressure.
more than 20 seconds. Be careful that torque
120C.
3 Pickup port plug (1):
15 2 Nm {1.53 0.2 kgm}
Boost pressure
Min. 93 kPa {min. 700 mmHg}
12.After finishing test, remove the testing tools and

restore the machine.
WA470-7
30-13

Testing exhaust gas color
(WA470-A900-360-K-00-A)
a Testing tools
Symbol
1
C
2
Part No.
Part name
799-201-9002 Handy smoke checker

Commercially
Smoke meter
available
3 Plug:
42.1 to 70.6 Nm {4.3 to 7.2 kgm}
2 Plug:
Seizure prevention compound (LC-G)
k Place

k Be
careful not to touch any hot part when

installing or removing the testing tools.
k When
KDPF regeneration is started, the

high-temperature exhaust gas spurts from
the inspection port, that may cause burn
injury. Therefore, you must stop KDPF
regeneration through the machine monitor
before starting the inspection.
(For the stopping procedure for KDPF
regeneration, see the Operation and
Maintenance Manual.)
a Measure the exhaust gas color under the

following conditions.

Hold in stationary state for 5 seconds, then
collect the exhaust gas.
3. Measuring by using handy smoke checker C1

1) Fit a sheet of filter paper to handy smoke
checker C1.
2) Insert the exhaust gas intake pipe into plug
hole (6).
a Set the probe end so that it is in parallel
with the direction of the pipe at its center.
3) Start the engine, and operate the handle of
handy smoke checker C1 under the torque
converter stalled condition so that the filter
paper will absorb the exhaust gas.
a Suction time: 1.4 0.2 second
a If an air source and a electric power source are

not available in the field, use handy smoke
checker C1. When recording official data, etc.,
use smoke meter C2.
Testing
(WA470-A900-385-K-00-A)
1. Open the engine left side cover and remove

cover (4).
4) Remove the filter paper and compare it with

the attached scale for judgment.
5) After finishing the test, remove the testing
tools and restore the machine.
4. Testing with smoke meter C2
1) Connect the probe hose, accelerator switch
outlet and air hose to smoke meter C2.
2. Remove plug (5).
30-14
a The supplied air pressure must be 1.5

MPa {15 kg/cm2} or below.
2) Connect the power cable to an AC 100 V
receptacle.
WA470-7

a Before connecting the power cable, make

sure that the power switch of the smoke
meter is turned OFF.
3) Insert probe [1] of the smoke meter C2 into
port (6) for the removed plug.
a Set the probe end so that it is in parallel
with the direction of the pipe at its center.
4) Loosen the cap nut of the suction pump and

place the filter paper.
a Place the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch of smoke meter C2
ON.
6) Start the engine, put the torque converter in

the stalled condition, and then depress the
accelerator pedal of smoke meter C2 to
collect the exhaust gas impurities on the filter
paper.
7) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
8) After finishing the test, remove the testing
tools and restore the machine.
WA470-7
30-15

Testing and adjusting valve clearance

a Testing tools
Symbol
D
Part No.
Part name
Commercially Feeler gauge

available
k Place

(WA470-A700-360-K-00-A)
a The rocker arm of No.1 cylinder with the

piston at the compression top dead center
can be moved by hand by the distance
equivalent to the valve clearance. If the
rocker arm cannot be moved, the No.1
cylinder is not at its compression top dead
center. In that case, rotate the crankshaft one
more turn.
k Turn
the battery disconnect switch to OFF

position, and remove the key.
a Test and adjust the valve clearance under the

When engine is cold
Testing
(WA470-A700-361-K-00-A)
1. Remove cylinder head cover (1). For details, see

Disassembly and assembly, removal and
installation of cylinder head assembly.
2. Remove rubber cover (2) on the front side of

damper
3. Rotate the crankshaft in the normal direction to

set No.1 cylinder to the compression top dead
center by matching "1.6 TOP" stamping mark (a)
of the damper to pointer (4).
4. While No.1 cylinder is at the compression top

dead center, check the valve clearance of the
valves marked with q in the following figure.
5. Rotate the crankshaft in the normal direction by
one turn and check the valve clearance of the
remaining valves marked with Q.
a Stamp marks are "1.6 TOP", "2.5 TOP" and

"3.4 TOP".
30-16
WA470-7

a You may check the valve clearance of No.1

cylinder while No.1 cylinder is at the
compression top dead center and then turn
the crankshaft in the normal direction by 120
degrees and check the valve clearance of
each cylinder in the firing order.
4. After finishing the adjustment, remove the

adjusting tools and restore the machine.
3 Cylinder head cover (1) mounting
bolt:
9.8 1 Nm {1.0 0.1 kgm}
a Firing order: 1-5-3-6-2-4

a The valve clearance is normal if it is within
the range of the standard value. For standard
values, see "Standard value table",
"Standard value table related to engine".
6. After finishing the test, remove the testing tools
and restore the machine.
Adjusting
(WA470-A700-27D-K-00-A)
After testing, adjust the valve clearance according

to the following procedure if necessary.
a After setting the No.1 cylinder at the
compression top dead center, adjust valve
clearance of No.1 cylinder.
1. While fixing adjustment screw (6), loosen lock
nut (7).
2. Insert feeler gauge D into the clearance between
rocker arm (8) and crosshead (9), and adjust the
valve clearance with adjustment screw (6).
a With feeler gauge D inserted, turn the
adjustment screw (6) until the feeler gauge D
can move lightly.
a For standard values, see "Standard value
table", "Standard value table related to
engine".
3. With adjustment screw (6) fixed, tighten lock nut
(7).
3 Lock nut (7):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a After tightening lock nut (7), check the valve
clearance again.
a The following figure shows adjustment of air
intake side of No.4 cylinder.
WA470-7
30-17

Testing compression pressure
(WA470-A000-360-K-00-A)
a Testing tools
Symbol
1
2
E
3
Part No.
Part name
795-502-1590 Gauge assembly

795-471-1420 Adapter
6217-71-6112 Gasket
Hose (inside diameter 14
Commercially mm, length approximately
available
2 m)
k Place

k Turn

position and remove the key.
k When
testing the compression pressure, be

careful not to burn yourself by touching the
exhaust manifold or KDPF, or get caught in a
rotating part.
a Measure the compression pressure under the

Engine oil temperature: 40 to 60C
Testing
(WA470-A000-36B-K-00-A)
1. Remove engine hood, air cleaner assembly, and

KDPF assembly according to "Removal and
installation of cylinder head assembly" in
"Disassembly and assembly".
2. Remove tubes (1) and (2) of KCCB, and
harness (3).
3. Remove spill tube (8).

a This helps the sleep nut to be removed
easily.
a Remove all connectors and clamps of supply

pump (4), EGR Valve (5), air conditioner
compressor (6), and dosing valve (7) for
wiring harness (3) to be released.
4. Remove the cylinder head cover (9), and set the

cylinder to be tested to the compression top
dead center. For details, see "Testing and
adjusting valve clearance".
30-18
WA470-7

a Check that both the intake rocker arm and

exhaust rocker arm at the compression top
dead center are movable by hand by the
distance equivalent to the valve clearance.
5. Replace the filter cartridge (10).
8. Pull high-pressure tube (12), and remove the

injector (16).
9. Install adapter E2 to the injector mounting hole.

a Be sure to install the gasket to the top of the
adapter E2.
6. Remove cover (11) of the common rail, then
remove high-pressure fuel tube (12) to be
checked.
a Fix the adapter E2 with the injector holder

(17).
3 Holder mounting bolt (18):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
10.Install rocker arm assembly (13).
3 Rocker arm assembly mounting bolt
(19):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
11.Adjust the valve clearance.
See "Testing and adjusting valve clearance".
7. Remove rocker arm assembly (13), and

disconnect injector wiring harness (14).
a Disconnect the injector wiring harness (14)
from the terminals on the injector side, and
pull it to the outside of the rocker housing.
(Loosen 2 pieces of terminal nuts
alternately).
a QR code tab (15) is attached to the top of the
injector. Do not remove or damage it.
WA470-7
12.Install spill tube, filter cartridge, wiring harness,

and air cleaner assembly.
13.Connect compression gauge E1 to adapter E2.
30-19

a Apply a small amount of engine oil to the

connecting portion of the adapter E2 and
compression gauge to prevent air leakage.
14.Install a fuel drain hose (E3) at where the tube is

disconnected of the common rail, and let
injected fuel drain to a container.
16.Rotate the crankshaft by the starting motor and

measure the compression pressure.
17.After finishing the test, remove the testing tools
and restore the machine to its original condition.
a Install the injector, injector wiring harness
and high-pressure fuel tube according to the
following procedure.
1) Install 2 O-rings (20) and (21) and gasket
(22) to injector (16).
a Do not fit O-ring (20) into spill groove in
the center, but fit it into O-ring groove.
Insert injector into cylinder head after
applying engine oil to O-ring.
2) Assemble holder (17) and injector (16), then
install them to the cylinder head temporarily.
3) Set spherical washer (23) to mounting bolt
(18) and tighten the bolts to the cylinder
head.
15.Select the "No-Injection cranking" operation by

operating the machine monitor.
a Turn the battery disconnect switch to ON
position, then turn the starting switch to ON
position.
a For the "No-Injection cranking" setup
procedure, see the section of "Special
functions of machine monitor".
k If
the engine is not set to the "No-Injection

cranking", it may start during
measurement and cause personal injury.
Accordingly, be sure to set the engine in
this mode.
30-20
2 Spherical part of spherical washer

(23):
Engine oil (SAE30DH)
3 Mounting bolt (18):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
4) Tighten 2 nuts at the tip of wiring harness
(14) alternately to injector (16).
3 Nut:
2.0 to 2.4 Nm {0.2 to 0.24 kgm}
5) Tighten tube (12) to injector (16).
3 Sleeve nut:
39.2 to 44.1 Nm {4 to 4.5 kgm}
6) Tighten the clamp bolt for the fuel piping.
WA470-7

3 Clamp bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
3 Rocker arm assembly mounting

bolt (19):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a Adjust the valve clearance. For details of
the procedure, see "Adjusting valve
clearance".
3 Cylinder head cover mounting
bolt:
9.8 1 Nm {1.0 0.1 kgm}
WA470-7
30-21

Testing blowby pressure
(WA470-A000-360-K-02-A)
a Testing tools
Symbol
1
F
Part No.
Part name
799-201-1504 Blowby checker

Plug (hose inside
2 799T-201-3210 diameter: 24 mm)
Cap (pipe outside
3 799T-201-3220 diameter: 25.4 mm)
k Place

a Measure the blowby pressure under the

Perform when the regeneration is stopped.
Testing
(WA470-A000-36C-K-00-A)
1. Open the side cover on the right side of engine.

2. Disconnect KCCV gas outlet side hose (1) and
KCCV gas inlet side hose (2).
4. Start the engine to increase temperature of the

engine coolant to the operating range.
5. Set the transmission cut-off selector switch to
OFF position, and depress the left brake pedal
securely.
6. Set the torque converter lockup switch to OFF
position.
MANUAL position.
gearshift lever to 4th speed.
10.While depressing brake pedal, set directional
lever or directional selector switch to "F
(forward)" or "R (reverse)" position.
k Keep
11.Depress the accelerator pedal gradually to run

the engine at full speed and stall the torque
converter to measure the blowby pressure.
a Do not keep stalling the torque converter for
more than 20 seconds. Be careful that the
torque converter oil temperature will not
exceed 120C.
3 Clamp:
4.4 0.49 Nm {0.45 0.05 kgm}
3. Plug pipe (3) on KCCV gas outlet side with plug
F2, and install cap F3 to KCCV gas inlet pipe (4)
and outlet pipe (5). Install tool and adapter [1] of
blowby checker F1 to KCCV gas inlet hose (6),
and connect gauge [3].
30-22
a Normally, the blowby 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.
a Precaution for measuring blowby pressure
The blowby pressure may vary largely with
the engine condition. If the measured value
is judged unusual, make a check for increase
of oil consumption, bad exhaust gas color,
early deterioration or contamination of oil, etc.
which are related to the unusual blowby
pressure.
WA470-7

12.After finishing test, remove the testing tools and

WA470-7
30-23

Testing engine oil pressure
(WA470-AB00-360-K-00-A)
a Testing tools
Symbol
1
G 2
3
Part No.
Part name
799-101-5002 Hydraulic tester

790-261-1204 Digital hydraulic tester
799-401-2320 Gauge
k Place

a Measure the engine oil pressure under the

following condition.
Testing
(WA470-AB00-362-K-00-A)
a Check the engine oil pressure with Monitoring/

Pre-defined or Monitoring/Custom of the
machine monitor.
3. Start the engine to increase the cooling

temperature to the operating range.
4. Measure the oil pressure with the engine at low
idle and high idle.
a The engine oil pressure is normal if it is within
the range of the following standard values.
At high idle
At low idle
See standard value table

a Monitoring code: 37200 Engine Oil Pressure

1. Open side cover on the left of engine, and
remove oil pressure pickup port plug (1) from the
engine oil filter.

3 Oil pressure pickup plug:
2. Install nipple [1] and hose [2] of hydraulic tester
G1 and connect them to gauge G3.
20 2 Nm {2.04 to 0.2 kgm}
3 Nipple:
20 2 Nm {2.04 to 0.2 kgm}
a The nipple and hose for digital hydraulic
tester G2 can also be used.
30-24
WA470-7

Testing EGR valve and KVGT oil pressures

a Testing tools
Symbol
H
Part No.
795T-401-1310
1
02896-21015
2 799-101-5002
3 790-261-1204
Part name
Plug
O-ring
Hydraulic tester
(WA470-A9K1-360-K-00-A)
a The nipple and hose of digital hydraulic tester

H3 can also be used.
3 Plug H1:
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
k Place


a The standard values for the EGR valve drive oil
pressure and the KVGT drive oil pressure are
the same, because they share the same circuit.
Testing
(WA470-A9K1-362-K-00-A)
1. Open side cover (1) on the left of engine
5. Start the engine and measure the oil pressure at

low idle and high idle.
a When the EGR valve and KVGT driving oil
pressure is in the following standard range, it
is normal.
At low idle
At high idle

2. Remove clamp (2), and lower dosing fuel hose

(4).
3. Remove plug (3) (driving oil pressure).
3 When installing plug (3), install new Orings H1(2 pieces).
3 Joint plug (3):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
4. Install plug H1, and install nipple and hose of

hydraulic tester H2, and then connect them to
gauge [3].
a Be sure to fit the O-ring to plug H1.
a Use gauge [3] of 2.5 MPa {25 kg/cm2}.
WA470-7
30-25

Testing fuel pressure
(WA470-AE20-360-K-00-A)
a Testing tools
Symbol
1
2
J
3
4
Part No.
799-101-5002
790-261-1204
795-790-5120
07005-01412
790-301-1530
799-401-2320
Part name
Hydraulic tester
Screw
Gasket
Elbow
Gauge
k When
removing or installing testing tools for

the fuel system, stop the engine and wait for
at least 30 seconds until the remaining
pressure is released from the fuel circuit. (Do
not start the work immediately after the
engine is stopped since remaining pressure
is still in the circuit.)
k Place

5. Start the engine and measure the fuel pressure

at engine high idle.
a The fuel pressure is normal when it is within
the following standard value range.
Engine speed
High idle
Fuel pressure
k Since
the pressure in the high-pressure

circuit from the supply pump through the
common rail to the injector is very high and
dangerous, do not measure it.
Testing
(WA470-AE20-362-K-00-A)

2. Remove fuel tube mounting bolt (3) on the upper
side of fuel filter.

3 Fuel pressure pickup plug (3):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3. Install screw and elbow J3.

a Be sure to fit the gasket.
4. Install nipple and hose [2] of hydraulic tester J1
to screw and elbow J3, and then connect them
to gauge J4.
J2 can also be used.
30-26
WA470-7

Testing fuel return rate and leakage
(WA500-AE20-360-K-00-A)
a Testing tools
Symbol
1
2
3
K
4
5
6
Part No.
6151-51-8490
6206-71-1770
Commercially
available
Commercially
available
Commercially
available
Commercially
available
Part name
Spacer
Joint
Hose (inside diameter:
approximately 6 mm)
Hose (inside diameter:
approximately 16 mm)
Measuring cylinder
Stopwatch
k Place

lock switch in the LOCK position, stop the
a Since some fuel flows out during test, prepare a

container of approximately 20 l.
k When
removing or installing testing tools for

the fuel system, stop the engine and wait for
at least 30 seconds until the remaining
pressure is released from the fuel circuit. (Do
not start the work immediately after the
engine is stopped since remaining pressure
is still in the circuit.)
WA470-7
30-27

A: Measuring position of leakage from pressure limiter

B: Measuring position of return rate from injector
30-28
WA470-7

Testing
(WA470-AE20-363-K-00-A)
Testing leakage from pressure limiter

1. Open engine right side cover (1) and (2).
a Be sure to install the gasket to the both ends

of the joint.
5. Connect test hose K3 to the end of joint K2.
a Bind the connected part of the test hose with
a wire, etc. to prevent it from coming off.
a Arrange the route of the test hose so that it
does not sag, and put its end in a container.
2. Remove tube (5) between pressure limiter (3)

and return block (4).
6. Start the engine, and stall the torque converter.

a For the torque converter stalling procedure,
see "Testing engine speed".
7. After the engine speed is stabilized, measure
the leakage for 1 minute by using measuring
cylinder K5.
3. Insert spacer K1 into the return block (4) side,

and tighten the removed joint bolt again.
3 Joint bolt:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
a Be sure to install the gasket to the both ends
of the spacer.
4. Insert joint K2 into the common rail (6) side and

tighten the removed joint bolt again.
3 Joint bolt:
17.7 to 22.6 Nm {1.8 to 2.3 kgm}
WA470-7
a Measuring duration can be 20 seconds if the

leaked amount is multiplied by 3 after the
measurement.
a Leakage from the pressure limiter is normal
when it is within the following standard value
range.
Leakage
(cc/min)
With torque converter

stalled
8. Stop the engine after the measurement is over.

Testing fuel return rate from injector
30-29

a While measuring the fuel return rate from the

injector, keep the hose on the pressure limiter
side connected and insert the hose end in the
container.
1. Disconnect fuel return hose (7) of return block
(4).
a Plug the fuel hose by using a plug.
Plug part number: 07376-70315
a Return (spill) rate from the injector is normal

if it is within the following standard value
range.
Engine speed
(rpm)
Limit return (spill) rate

(cc/min)
1,600
1,700
1,800
1,900
2,000

2. Connect test hose K4 to the return block (4)

side.
a Bind the connected part of the test hose with
a wire, etc. to prevent it from coming off.
a Arrange the route of the test hose so that it
does not sag, and put its end in a container.
5. After finishing the test, stop the engine, remove

the testing tools and restore the machine.
3 Joint bolt on block side:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Joint bolt on common rail side:
17.7 to 22.6 Nm {1.8 to 2.3 kgm}
3. Start the engine, and stall the torque converter.

a For the torque converter stalling procedure,
see "Testing engine speed".
4. After the engine speed is stabilized, measure
the return rate for 1 minute by using measuring
cylinder K5.
a Measuring duration can be 20 seconds if the
leaked amount is multiplied by 3 after the
measurement.
a If the error of no-pressure feed occurs on the
supply pump, there is a case that the engine
speed does not increase. In such case,
record the engine speed during testing, as
well.
30-30
WA470-7

Bleeding air from fuel system
(PC400-AD00-001-K-00-A)
Low-pressure fuel circuit
1. Fuel tank
2. Fuel connector
3. Pre-filter
4. Fuel feed pump
5. Doser
6. Supply pump
7. Feed pump
a In the following cases, bleed air according to this

procedure.
When a fuel filter is replaced
When run out of fuel occurs
When starting the engine for the first time
after replacing fuel piping or supply pump
k Place
the machine on a level ground, and

8. Cooling plate
9. Main fuel filter
10. Common rail pressure
11. Injector
12. Pressure limiter valve
WA470-7
k While
the fuel feed pump is in operation,

pressure is applied to the fuel circuit. Do not
loosen the air bleeding plug at this time,
since the fuel may spout out.
30-31

Bleeding air
(WA470-AD00-231-K-00-A)
1. Supply fuel to the fuel tank.

a Continue the supply of fuel until the fuel
gauge monitor turns to blue.
(Check the fuel level with monitor after
turning the starting switch to ON position.)
2. Open side cover (1) on the right of engine.
4. After the specified time (approximately 6

minutes and 30 seconds), lamp (3) automatically
goes off and the fuel feed pump stops.
3. Tilt switch (2) for the fuel feed pump in the

engine room to ON position.
a The fuel feed pump operates and lamp (3)
flashes.
a When only the fuel filter is replaced, air

bleeding work is completed at this point.
5. When fuel in the fuel circuit is lost in the cases
as fuel is run out or the fuel piping or supply
pump is replaced, set switch (2) to ON position
again immediately after the fuel feed pump stops
automatically.
6. Air bleeding is complete when lamp (3) goes off.
k Make
sure that no person is found around

the engine before starting the engine.
a Do not turn the starting motor continuously

for more than 20 seconds.
a The air in the high-pressure circuit is bled
automatically by cranking the engine.
a After the engine is started, run it at low idle
for approximately 5 minutes to bleed air
completely from the fuel circuit.
a The timer built in this switch automatically
starts up and stops the fuel feed pump (see
the figure).
a Operation of the fuel feed pump stops while
the lamp is flashing. It is, however, not a
failure.
a If you set the switch to OFF position while the
lamp is lighted, the lamp goes out and the
fuel feed pump stops.
30-32
WA470-7

Testing fuel circuit for leakage
(WA380-AD00-001-K-01-A)
a Testing tools
Symbol
L
Part No.
Part name
Developer
Commercially for dye penetrant
available
check (color
checker)
k Very
high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it presents
a serious danger that could result in a fire.
After testing the fuel system and removing or
installing the tools for the test, test it for fuel
leakage according to the following procedure.
a To apply a load to the engine installed on the

machine, perform the torque converter stall
operation or hydraulic relief of the hydraulic
pump.
9. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
checker L is sprayed.
a If any fuel leakage is detected, repair it and
perform the checks from Step 1 again.
a If no fuel leakage is detected, check is
completed.
k Park

a Clean and degrease the engine and the parts

around it in advance so that you can check it
easily for fuel leakage.
Testing
(WA380-AD00-364-K-00-A)
1. Spray color checker (developer) L to the fuel

supply pump, common rail, fuel injectors, and
joints of the high-pressure fuel piping.
2. Start the engine, keep its speed at 1,000 rpm or
below, and stop it when its speed is stabilized.
leakage.
4. Start the engine and keep it running at low idle.
leakage.
6. Start the engine and keep it running at high idle.
leakage.
8. Start the engine and keep it running at high idle,
then apply a load to the engine.
WA470-7
30-33

Handling cylinder cutout mode operation
(PC-AD00-34F-K-00-A)
a The cylinder cut-out test mode operation means

to run the engine with the fuel injectors of one or
more cylinders disabled electrically to reduce the
number of active cylinders. The purposes and
effects of this operation are as follows.
1. This mode is used to find out a cylinder which
does not output power properly (or, combustion
in it is abnormal).
2. When a cylinder is selected for the Cylinder Cutout Mode operation, if the engine speed and
output do not change from the normal operation
(all-cylinder operation), that cylinder has one or
more defects.
The following problems can be considered:
Compression leak from cylinder head gasket
Defective injection from injector
Defective piston or piston ring
Defective valve mechanism (valve operating
system)
Defective electrical system
3. The injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, so the cylinder cut-out test can
be performed easily by the simple operations of
the switches compared with the mechanical fuel
injection system. This allows to find out a
defective cylinder easily.
30-34
WA470-7

Handling no injection cranking operation
(PC-A000-25L-K-00-A)
a No-injection cranking means to crank the engine

by using the starting motor while all the
injections are stopped electrically. The purpose
and effect of this operation are as follows.
Before the engine is started after it or the
machine has been stored for a long period, the
no-injection cranking is performed to lubricate
the engine parts and protect them from seizure.
WA470-7
30-35

Testing of KDPF and muffler stack for looseness and damage
(WA380-A9H0-280-K-
00-A)
1. Visually check KDPF and muffler stack for

cracking and damage. If any part is damaged,
replace it.
2. Check the mounting bolts of the KDPF and
muffler stack for looseness. If any part is
loosened, retighten it.
30-36
WA470-7

Testing of installed condition of cylinder head and manifolds
(WA380-A100-280-K-00-
A)
Check the cylinder head and intake and exhaust

manifold mountings for looseness. If any part is
loosened, retighten it.
a For the tightening torques, see the "Disassembly
and assembly".
WA470-7
30-37

Testing engine piping for damage and looseness
(WA380-A000-280-K-00-A)
Air intake and exhaust systems: Check the piping

for damage, the mounting bolts and nuts for
looseness, and the joints for air suction and exhaust
gas leakage. If any part is loosened or damaged,
retighten or repair it.
Cooling system: Check the piping for damage, the
mounting bolts and nuts for looseness, and the
joints for water leakage. If any part is loosened or
damaged, retighten or repair it.
Fuel system: Check the piping for damage, the
mounting bolts and nuts for looseness, and the
joints for fuel leakage. If any part is loosened or
damaged, retighten or repair it.
30-38
WA470-7

Testing and adjusting air conditioner compressor belt tension
(WA380-K5A0-001-K-
00-A)
k Place

Testing
(WA470-K5A0-285-K-00-A)

2. Before checking, insert the starting switch key
into lock (1) to release it, and open cover (2).
2. Loosen bolts (4) and (5).

3. Tighten bolt (9) after loosening nut (8) installed
to bracket (7), compressor (6) shifts in direction
A, and the compressor belt can be stretched.
3. Press the intermediate point of the belt between

air conditioner compressor pulley and crankshaft
pulley with a finger and measure deflection (a).
Belt pressing force: Approx. 98 N {Approx.
10 kg}
Deflection (a): 25 to 26 mm
4. After measurement, close cover (2), and lock it

with the starting switch key.
Adjusting
(WA470-K5A0-27C-K-00-A)
a If the belt deflection is abnormal, adjust it

according to the following procedure.
1. Before adjusting, insert the starting switch key
into lock (1) to release it, and open covers (2)
and (3).
4. After adjusting the belt tension properly, tighten

nut (8) until it touches boss (10) and tighten it
further in direction B so that it is not loosened.
3 Tightening torque:
157 to 196 Nm {16 to 20 kgm}
5. Tighten bolts (4) and (5) to fix bracket (7).
3 Tightening torque
Bolt (4): 157 to 196 Nm {16 to 20 kgm}
Bolt (5): 98 to 123 Nm {10 to 12.5 kgm}
WA470-7
30-39

6. After adjusting, close covers (2) and (3), and

lock it with the starting switch key.
a Check each pulley for damage, wear of the Vgroove, and the wear of the V-belt. In particular,
be sure to check that the V-belt does not touch
the bottom of the V-groove.
a Replace the belt with a new one if the belt is
stretched and has no allowance for adjustment,
or has slipping sound or squeak because of cuts
or cracks of the belt.
a If the V-belt is replaced, adjust its tension again
after one hour of operation.
30-40
WA470-7

Testing and adjusting alternator belt tension

Testing
(WA470-AKM4-923-K-00-A)
1. Open side cover on the left of engine.

2. Insert the starting switch key into lock (1) to
release it, and open cover (2).
3. Press the belt at the intermediate point between

the alternator pulley and crank pulley with your
finger and measure deflection (a).
Depressing force: Approximately 59 N {6 kg}
Deflection (a): Approximately 13 to 16 mm
(WA470-AKM4-360-K-00-A)
2. After loosening bolts (5) and (6), loosen locknut

(7).
3. Alternator (8) moves to the direction (A) by
rotating adjustment nut (9), and tension can be
applied to alternator drive belt.
4. When the belt tension becomes appropriate,
tighten locknut (7) until it comes to contact with
boss (10).
5. Tighten bolts (5) and (6) to fix alternator (8).
Bolt (5): 28.4 to 38.2 Nm {2.9 to 3.9 kgm}
Bolt (6): 107.8 to 147 Nm {11 to 15 kgm}
6. After adjusting, install cover (3) and handrail (4),
close cover (2), and lock it with the starting
switch key.
a Check each pulley for damage, wear of the Vgroove, and the wear of the V-belt. In particular,
be sure to check that the V-belt does not touch
the bottom of the V-groove.
a Replace the belt with a new one if the belt is
stretched and has no allowance for adjustment,
or has slipping sound or squeaks because of
cuts or cracks of the belt.
a If the V-belt is replaced, adjust its tension again
after one hour of operation.
4. After measurement, close cover (2), and lock it

with the starting switch key.
Adjusting
(WA470-AKM4-285-K-01-A)

release it, open cover (2), then remove cover (3)
and handrail (4).
WA470-7
30-41

30-42
WA470-7

Procedures for cleaning fuel doser
(WA500-A9H6-360-K-00-A)
a The procedure given below is applicable when

you perform the engine troubleshooting "S-22
Active regeneration is operated for long" due to
malfunctioning of KDPF device or clean the fuel
doser in 4,500-hour periodic maintenance.
k Place

k Install
and remove the fuel doser after

making sure that the temperature of the
exhaust manifold and exhaust piping has
lowered.
Removal
Cleaning
(HM300-A9H6-255-K-00-A)
1. Eliminate soot (14) adhered to fuel doser (8).
(WA470-A9H6-520-K-00-A)
1. Open full-length fender (1), and side cover (2).
2.
3.
4.
5.
6.
Disconnect connector DOSER (3).

Remove clamps (4) (3 pieces).
Disconnect fuel hose (5). [*1]
Disconnect coolant hose (6). [*2]
Remove bolts (7) (2 pieces) (8 mm of width
across flats), and remove fuel doser assembly
(8).
2. Soak cloth (15) with sufficient volume of diesel

fuel, and press it against the accumulated soot
in the tip of the fuel doser injection port for the
diesel oil to permeate into the soot.
3. After the diesel fuel permeates into the

accumulated soot, clean it with cloth (15).
WA470-7
30-43

4. Eliminate soot in the injection port by scrubbing

the tip of the port by using nylon brush (16).
Eliminate soot completely from the injection
port by using nylon brush (16) and cloth (15).
a Use a nylon brush for the cleaning since a
wire brush can damage the injection port.
a Use diesel fuel for the cleaning agent without
using other solvents.
Installation
(HM300-A9H6-720-K-00-A)
1. Install heat insulator (10) to fuel doser (8).

2. Insert bolt (11) into fuel doser (8), install gasket
(9) to the fuel doser, then install them to the
exhaust connector.
3 Bolt (11) (width across flats 8 mm):
8.5 to 9.5 Nm {0.87 to 0.97 kgm}
a Bolt (11), gasket (9) and heat insulator (10) to
be used must be new ones.
a Tip of injection port after cleaning

Cleaning complete (A: Tip of injection port is
free from remaining soot)
Cleaning incomplete (B: Tip of injection port
has remaining soot)
30-44
a Install gasket (9) so that its stepped portion

becomes convex against the exhaust
connector.
WA470-7

a When installing gasket (9) and heat insulator

(10), be careful for them not to fall.
3. Install the bracket, fuel hose clamp and wiring
harness clamp in the reverse order of removal.
4. After installing the fuel doser, run the engine at
low idle for approximately three minutes. Then
stop the engine and check the fuel doser for
water and fuel circuits for leakage.
WA470-7
30-45

Writing compensation values at replacement of injector and engine

controller (WA500-AP70-360-K-00-A)
a Equipment for writing compensation values
Symbol
Part No.
1
2
3
ZC
4
5
6
Part name
a Service connector (1) (CN-SV) is installed to

rear left of the operator's seat.
Notebook computer:
Commercially
Windows XP SP2/VISTA/
available
Windows 7
Cu3886388 INSITE ver 7.4
795-799-5730 INLINE 5 Kit
Commercially
Cable (USB)
available
Cable (RS232)
or
795-799-5740
795-799-5720 Cable (9P)
799-601-4510 Cable (12P)
a To install INSITE to a PC, insert DVD-ROM

software and operate the PC according to the
displayed menus.
a Use INSITE ver 7.4 Feature Pack 1 or later
version for the writing.
a Since a failure (shutdown or disconnection) on a
PC or cable can induce a serious error to the
engine controller, sufficient care must be taken
for the cable connection.
Start INSITE
1. Boot the PC.
2. Turn the starting switch to the ON position and
supply power from the battery to the engine
controller.
3. Double-click the icon on the PC shown below.
a When connecting INSITE to the engine

controller, make sure not to stop supply of power
from the battery to the engine controller.
Stopping the power supply loses the connection
with INSITE.
Adjusting
(WA500-AP70-270-K-00-A)
Connecting PC
1. Check that the starting switch is turned to the
OFF position.
k The
starting switch must be turned to the

OFF position when a PC is connected or
disconnected.
2. Install personal computer ZC1, data link adapter

ZC3, and cables ZC4, ZC5, and ZC6, and then
connect them to service connector (1) (CN-SV).
4. Establish communication with the engine

controller.
1) Select "Connect to ECM".
Section A: Make sure that "INLINE 5 USB
(J1939) Connection" is indicated.
2) Select "Connect".
Section B: Confirm that "None" is
displayed.
30-46
WA470-7

a C: Connection-in-process screen
D: Screen after the connection is
completed (illustration does not move)
E: Communication status is displayed
(illustration moves during communication)
3) Input the new data to "New Barcode"

column.
a Replacement of the injector and engine
controller is performed.
1] Replace injector.
When the injector is replaced, write
the injector compensation value
written on the new injector in the
engine controller.
If the compensation value is not
correctly written, an engine trouble
can result.
The character string on the injector
top face is read from left to right.
5. Execute the injector trim function and data

writing.
1) Select "Advanced ECM Data".
Section F: Make sure that "Advanced
ECM Data" is indicated.
2) Select "High Pressure Common Rail Injector

Setup".
Section G: Make sure that "High
Pressure Common Rail Injector Setup" is
indicated.
WA470-7
2] Replacing engine controller

When the engine controller is
replaced, write the injector
compensation value written on the old
30-47

engine controller to the new engine

controller.
If the compensation value is not
correctly written, an engine trouble
can result.
Compensation value information
provided on the back of engine
controller
a: String of characters
b: QR code
Section K: Select "OK."
Screen while data processing is

continued (wait for 30 seconds)
Section H: "New Barcode" column
6) After data processing is over, turn the

starting switch to the ON position and select
"OK".
Section L: Select "OK."
4) Execute writing to the engine controller.

After entering the injector data, select "Apply".
I: Entry of data of the target injector.
Examples)
Enter data of No.1 cylinder injector
corresponding to "Cylinder1".
Section J: Select "Apply."
7) Screen that indicates data writing is over.

Select "OK".
Section M: Select "OK."
5) After writing data, turn the starting switch to

the OFF position and select "OK".
30-48
WA470-7

8) Screen that appears when data writing ends

successfully. "Success" is displayed on the
screen.
Section N: Make sure that "success" is
indicated.
7. Turn the starting switch to the OFF position, then

boot the PC again (turn the starting switch to the
ON position) to make sure that an error is not
present on the monitor.
a Failure code:
CA2765: Inj Trim Data Error
8. When replacing the injector, clear the values on
the compensation values sheet on the back of
the engine controller.
a Clear the data of the replaced injector on the
compensation values sheet that is provided
on the back of the engine controller.
a Screen that appears for faulty data writing

Section P: Indicates that writing is
faulty.
If the following screen appears in
stead of the screen of item 8) after the
operation of Step 7), it is suspected
that the entered new data is
inappropriate.
(Check the data again and repeat its
entry.)
a Record the data of the replaced injector in

the maintenance register.
9. When the engine controller is replaced,
inconsistency may result between the data
recorded on the sheet on the back of the engine
controller and that recorded in the register when
replacement of an injector or engine controller
was done before. In such case, you must use
the compensation character strings contained in
the maintenance record information or import
the compensation value information described
on the top face of every injector installed on the
cylinders, in the same way as you did in the
above when you replaced the injector.
6. Disconnect and end the communication with the

engine controller.
Section Q: Select "Disconnect from ECM."
WA470-7
30-49

Power train
Power train
(ALL-C100-001-K-00-A)
Adjusting transmission output speed sensor

Adjusting
(WA380-CNA1-001-K-00-A)
(WA470-CNA1-270-K-00-A)
1. Remove cover on the right side of the rear

frame.
2. Disconnect connector REV OUT (1).
3. Loosen locknut (3), and screw in until tip of

sensor (4) touches a tooth tip of gear (5).
a Check that the sensor tip is free from iron
dust and flaws before installing.
a Apply the liquid gasket between the case and
threaded part of the sensor.
2 Thread portion: Liquid gasket (LG-5)
4. Unscrew sensor (4) from the current position by

a half to one turn.
a Adjust clearance (a) between the sensor tip
and gear (5) tooth tip to 0.75 to 1.5 mm.
5. Secure sensor (4) with lock nut (3).
3 Nut: 49.0 to 68.6 Nm (5.0 to 7.0 kgm)
30-50
WA470-7

Power train
Adjusting transmission input speed sensor

Adjusting
(WA380-CNB1-001-K-00-A)
(WA470-CNB1-270-K-00-A)
1. Remove cover (1) on the left side of the rear

frame.
2. Disconnect connector REV IN (2).

3. Loosen locknut (3), and screw in sensor (4) until
its tip hits a tooth tip of gear(5) lightly.
dust and flaws before installing.
a Apply the liquid gasket between the case and
threaded part of the sensor.
2 Thread portion: Liquid gasket (LG-5)
4. Secure sensor (4) with lock nut (3).

3 Nut: 24.5 to 34.3 Nm (2.5 to 3.5 kgm)
WA470-7
30-51

Power train
Flushing procedure for torque converter and transmission hydraulic

circuit (WA380-C151-001-K-00-A)
a Dust such as metal powder in the hydraulic
circuits of the torque converter and transmission
shortens the life of the torque converter and
transmission and causes internal breakage. To
remove dust in the hydraulic circuit, perform
flushing in the following cases.
1. When metal powder flows into the circuit
because of damage to the torque converter,
transmission and hydraulic components.
2. When the torque converter and transmission
are overhauled or modified.
Flushing procedures
(WA470-C151-256-K-00-A)
1. Install a new filter cartridge.

1) Remove inspection cover (1) on the left side
of the rear frame.
2. Supply oil to the transmission case.

Add oil through oil filler (4) to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Transmission case:
65 l (refill capacity)
2) Loosen drain plug (2) and drain the oil in the

filter piping.
3. Flush the hydraulic circuit according to the

1) Start the engine and run it at low idle without
operating the gear shift lever and directional
lever for approximately 20 minutes.
a Increase the engine speed to
approximately 1,500 rpm sometimes.
3) Remove transmission oil filter cartridge (3)

and install cartridge (714-07-28713).
a If the engine coolant temperature gauge

does not rise to the operating range
because of low ambient temperature,
continue the warm-up operation further.
2) Operate or travel for at least 20 minutes.
a Use all the gear speeds (Forward,
reverse, and 1st to 4th).
3) Run the engine at low idle for approximately
20 minutes in the similar procedure to the
one described in 3-1).
4. Replace the filter cartridge.
1) Replace cartridge (1) used for flushing with a
new cartridge (714-07-28713) following the
30-52
WA470-7

Power train
same procedure as the one described in the

step 1.
k Be
sure to replace the cartridge with a

new one because the cartridge used
for flushing for long hours causes
premature clogging.
a When installing the filter cartridge, tighten

it by 2/5 turns after the O-ring came in
touch with the filter head.
2) Add oil and check the oil level again.
WA470-7
30-53

Power train
Retrieval of disabled machine due to transmission valve failure
(WA470-CJA0-360-
K-00-A)
a Locations of ECMV units
Testing tools
Symbol
O
Part No.
k Place
Part name
794-423-1190 Plug
a If the machine cannot move due to failure of any

part of transmission valves (electrical system,
solenoid valve, spool, etc.), install plugs O. Then
the machine can move.

k Apply
the parking brake, and chock the

wheels.
k When
working while the oil temperature is

still high, be careful not to get burn injury.
k If
the machine cannot move in any gear

speed due to transmission control valve
failure, install the plugs L to ECMV. Then the
machine can move from a dangerous work
site to a safe place where repair can be
performed. Do not use this method for any
situations other than failure.
k When
moving the machine by this method,

observe the procedure and be careful for
safety.
30-54
WA470-7

Power train
How to move
(WA470-CJA0-14A-K-00-A)
1. Remove side covers on the right and left of rear

frame.
2. Remove mud and dirt from around the ECMV.
3. Disconnect all connectors (1) from each ECMV.
(13 places)
5. Depress the brake pedal securely.

6. Start the engine, release the parking brake, and
then release the brake pedal gradually to start
and move the machine.
4. Remove 2nd ECMV and F or R ECMV solenoids
(2) (2 pieces), and then install plugs O as
referring to preceding position of each ECMV
installed.
Forward travel: F solenoid and 2nd solenoid
Reverse travel: R solenoid and 2nd solenoid
a If a wrong solenoid is removed, the
transmission may be broken. Care must be
taken.
a Install the plug with its projection facing the
ECMV. Check that the O-ring is fitted to the
mating face.
a Be careful that mud or dirt will not enter the
removed solenoids and valves.
a If the parking brake cannot be released

because of a failure in the electrical system,
release the parking brake referring to
"Method of releasing parking brake
manually".
k Remove
the chocks.
k If
the engine is started, the transmission

is engaged and the machine starts
immediately. Accordingly, when starting
the engine, check the moving direction of
the machine and secure safety around the
machine thoroughly and keep depressing
the brake pedal.
k Stop
the engine after moving the machine,

apply the parking brake, and chock the
wheels.
7. After finishing work, remove the testing tools and

WA470-7
30-55

Power train
Testing oil leakage from axle final drive
(WA470-DF10-280-K-00-A)
Check axle final drive (1) for oil leakage.

If oil leakage is found, the seal or the bearing may
be damaged. Check and repair as necessary.
a See "Disassembly and assembly".
30-56
WA470-7

Power train
Testing drive shaft for looseness, backlash, and damage
(WA380-D510-280-K-00-A)
Check the drive shaft for damage, abnormal

backlash, and loosening of connecting bolts and
nuts. If any part is loosened or damaged, retighten
or repair it.
Move the cross member at the universal joint up
and down, right and left, and rotate in both
directions to check.
Push the sliding part of the front drive shaft upward
for several times, and rotate it both directions to
check.
a For the tightening torques, see the "Disassembly
and assembly".
WA470-7
30-57

Power train
Testing and adjusting power train oil pressure
(WA470-C100-360-K-00-A)
Pressure pickup plug for P1 (main relief pressure) and P2 (torque converter inlet pressure) is pressure
pickup port for torque converter valve itself. However, this machine is equipped with pressure pickup
nipple (No. 1 and 2) separately.
30-58
WA470-7

Power train
WA470-7
30-59

Power train
a Testing tools
Symbol
1
2
N 3
4
Part No.
799-101-5002
790-261-1204
799-401-2320
799-101-5220
07002-11023
Part name
Hydraulic tester
Gauge
Nipple
O-ring
Oil pressure measuring point and measuring gauge
No.
Oil pressure to be measured
Main relief pressure

Torque converter relief pressure
Torque converter outlet
3 pressure
4 Lockup clutch pressure
5 Transmission F clutch pressure
6 Transmission R clutch pressure
Transmission 1st clutch
7 pressure
Transmission 2nd clutch
8 pressure
Transmission 3rd clutch
9 pressure
Transmission 4th clutch
10 pressure
11 Lubricating pressure
1
2
Measuring
gauge
MPa {kg/
cm2}
6 {60}
2.5 {25}
1 {10}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
1 {10}
k Place

k If
the transmission gear speed must be

shifted while the tires are off ground or the
drive shaft is removed, be sure to lower the
engine speed 1,500 rpm or below, and then
operate the gear shift lever.
Also, be sure to shift only one speed at a
time and wait at least 5 seconds before
making the next shift. Never make multiple
shifts in short intervals or shift more than
one speed at once.
a Test the power train oil pressure under the

Set the transmission cut-off switch to OFF
position, and use the left brake.
1. Remove side covers on the right and left side of
the transmission.
30-60
WA470-7

Power train
Testing
(WA470-C100-362-K-00-A)
Testing transmission main relief pressure
3. While running the engine at low idle and at 2,000

rpm, measure the transmission main relief
pressure.
a Transmission main relief pressure pickup port

(1)
4. After finishing test, remove the testing tools and

Testing torque converter relief pressure (inlet
pressure)
a Torque converter relief pressure (inlet pressure)
pickup port (nipple) (2)
1. Install hose [1] of hydraulic tester N1 to

transmission main relief pressure pickup nipple
(1). Connect gauge [2] to the hose.
a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.
2. Start the engine with power mode, and keep the

directional lever or directional selector switch in
N (NEUTRAL).
WA470-7

1. Install hose [1] of the hydraulic tester N1 to
torque converter relief pressure (inlet pressure)
pickup nipple (2). Connect gauge [2] to the hose.
also be used.
30-61

Power train
a Use an oil pressure gauge of 2.5 MPa {25 kg/

cm2}.

N (NEUTRAL).
3. While running the engine at 2,000 rpm, measure
the torque converter relief pressure (inlet
pressure).
a Monitoring/Pre-defined (9/16) screen

N (NEUTRAL).
the torque converter relief pressure (inlet
pressure).
a When measuring torque converter inlet pressure
accurately for troubleshooting, etc, refer "testing
with testing tools".
Testing torque converter outlet pressure
a Torque converter outlet pressure pickup port (3)

Torque converter relief pressure (inlet pressure) can
be checked with Monitering/Pre-difined (9/16) or
Monitering (monitoring code: 32601) of the
machine monitor.
monitor".

1. Remove torque converter outlet pressure pickup
port plug (3). Install nipple N4 and hose [1] of
30-62
WA470-7

Power train
hydraulic tester N1 to it, and connect gauge N3

to the hose.
3 Joint:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The elbow, nipple, and hose of digital
hydraulic tester N2 can also be used.
cm2}.

N (NEUTRAL).
torque converter outlet pressure.

N (NEUTRAL).
torque converter outlet pressure.
a When measuring torque converter outlet

pressure accurately for troubleshooting, etc,
refer "testing with testing tools".

3 Torque converter outlet pressure
pickup port plug (5):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Torque converter outlet pressure can be measured
with Monitering/Pre-difined or Monitering
(monitoring code: 32603) of the machine monitor.
monitor".
WA470-7
30-63

Power train
Testing lockup clutch pressure

k This
measurement is done in the traveling

condition. Therefore, care must be taken to
safety of surrounding area.
a Lockup clutch pressure pickup port (4)
3. Set the transmission shift mode selector switch

to AUTO.
4. Set working mode to the power mode, start the
engine, and set the parking brake switch to OFF
position.
5. Move the gear speed switch to the 3rd position.
6. Set the directional lever or directional selector
switch to the F (FORWARD) or R (REVERSE),
and then start traveling.
7. While traveling with the engine speed at 2,000
rpm, measure the lockup clutch oil pressure
when the lockup pilot lamp lights up.

3 Lockup clutch pressure pickup port
plug (3):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
1. Remove lockup clutch pressure pickup port plug

(4). Install nipple N4 and hose [1] of hydraulic
tester N1, and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
also be used.
cm2}.
2. Set the torque converter lockup switch to ON.
30-64
WA470-7

Power train
Testing F (forward) clutch pressure

a F (forward) clutch pressure pickup port (5)

position.
selector switch in N (NEUTRAL), set the gear
speed switch to 4th (4th speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) position while depressing the
brake pedal.
k Keep
brake pedal firmly depressed. Take

extreme care for safety around the
machine since the machine may move.

the F (forward) clutch oil pressure.
1. Remove F (forward) clutch pressure pickup port

plug (4). Install nipple N4 and hose [1] of
hydraulic tester N1, and connect gauge [2] to the
hose.
3 Nipple:

3 F clutch pressure pickup port plug (4):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

also be used.
cm2}.

to MANUAL.
3. Depress the brake pedal.
WA470-7
30-65

Power train
Testing R (reverse) clutch pressure

a R (reverse) clutch pressure pickup port (6)

position.
the R (REVERSE) position while depressing the
brake pedal.
k Keep


the R (REVERSE) clutch oil pressure.
1. Remove R (reverse) clutch pressure pickup port

plug (5). Install nipple N4 and hose [1] of
hydraulic tester N1, and connect gauge [2] to the
hose.
3 Nipple:

3 R clutch pressure pickup port plug
(5):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

also be used.
cm2}.

to MANUAL.
30-66
WA470-7

Power train
Testing 1st clutch pressure

a 1st clutch pressure pickup port (7)

position.
5. While keeping the directional lever or right
directional selector switch in N (NEUTRAL), set
the gear speed switch to 1st (1st speed).
the F (FORWARD) or R (REVERSE) position
once while depressing the brake pedal, then
return it to the N (NEUTRAL) position.
k Keep

a When the directional lever or directional

selector switch is in N (NEUTRAL), the gear
speed is not changed even if the gear speed
switch is moved. To avoid this, perform the
above operation.
the 1st clutch oil pressure.
1. Remove 1st clutch pressure pickup port plug (7).

Install nipple N4 and hose [1] of hydraulic tester
N1, and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
also be used.
cm2}.

3 1st clutch pressure pickup port plug
(9):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

to MANUAL.
WA470-7
30-67

Power train
Testing 2nd clutch pressure

a 2nd clutch pressure pickup port (8)

position.
speed switch to 2nd (2nd speed).
k Keep


above operation.
the 2nd clutch oil pressure.
1. Remove 2nd clutch pressure pickup port plug (8).

Install nipple N4 and hose [1] of hydraulic tester
N1, and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
also be used.
cm2}.

3 2nd clutch pressure pickup port plug
(8):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

to MANUAL.
30-68
WA470-7

Power train
Testing 3rd clutch pressure

a 3rd clutch pressure pickup port (9)

position.
speed switch to 3rd (3rd speed).
k Keep


above operation.
the 3rd clutch oil pressure.
1. Remove 3rd clutch pressure pickup port plug (9).

Install nipple N4, elbow (male: 10 x 1.25 and
female: PT1/8) of hydraulic tester N1, and nipple
hose [1], and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
also be used.
cm2}.

3 3rd clutch pressure pickup port plug
(9):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

to MANUAL.
WA470-7
30-69

Power train
Testing 4th clutch pressure

a 4th clutch pressure pickup port (10)

position.
k Keep


above operation.
the 4th clutch oil pressure.
1. Remove 4th clutch pressure pickup port plug

(10). Install nipple N4 and hose [1] of hydraulic
tester N1, and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
also be used.
cm2}.

3 4th clutch pressure pickup port plug
(10):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

to MANUAL.
30-70
WA470-7

Power train
Testing lubrication pressure

a Lubrication pressure pickup port (11)

the lubricating oil pressure.

3 Lubrication pressure pickup port plug
(13):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
1. Remove lubrication pressure pickup port plug

(11). Install nipple N4, install elbow [1], and hose
[1] of hydraulic tester N1, and connect gauge N3
to the hose.
3 Joint:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The elbow, nipple, and hose of digital
hydraulic tester N2 can also be used.
cm2}.

N (NEUTRAL).
WA470-7
30-71

Power train
Adjusting
(WA470-C100-270-K-00-A)
Adjusting transmission main relief valve

k Stop
the engine before starting adjustment

of the transmission main relief valve.
a If the transmission main relief pressure is out of

the standard value, adjust it according to the
1. Remove plug (13) from transmission and torque
converter relief valve (12).
2. Remove outer spring (16) and inner spring (17).

3. Adjust by adding or removing shims (18).
a Standard shim thickness: 3.5 mm (0.5 x 7
pcs.)
a Amount of adjustment per shim:
0.04 MPa {0.4 kg/cm2}
30-72
WA470-7

Steering system
Steering system
(ALL-F000-001-K-00-A)
Testing directional lever
(WA380-CX31-001-K-00-A)
a Testing tools
Symbol
M
Part No.
Part name
k Place

Testing
(WA470-CX31-384-K-00-A)
Operating effort of directional lever

Set push-pull scale M or a spring scale at the
point 12 mm from the tip of the directional lever
(1). Pull the push-pull scale M or the spring scale
in the operative direction of the lever to measure
the operating effort.
Travel of directional lever

Put a mark (a) at the center of the knob of the
directional lever (1). Move the knob in the
operating direction and measure its travel.
WA470-7
30-73

Steering system
Testing steering wheel
(WA380-F151-001-K-00-A)
a Testing tools
Symbol
Part No.
Part name
P
Testing
(WA470-F151-384-K-00-A)
Measuring play of steering wheel

a Measure the play of the steering wheel under
the following conditions.
Engine speed: Stop
Posture of machine: Straight travel
Measuring method
1. Move the steering wheel lightly to the right and
left to find the neutral point in the steering
mechanism and put mark (A) on the outer frame
of the machine monitor.
2. Turn the steering wheel to the right until the
operating effort starts to become heavy. Put
mark (B) at the position right above mark (A).
Measuring operating effort of steering wheel

a Measure the operating effort of the steering
wheel under the following conditions.
Road surface: Flat, level, and dry paved
surface
Engine coolant temperature: 60 to 102C
Hydraulic oil temperature: 45 to 55 C
Tire inflation pressure: Specified pressure
(bucket empty)
Measuring method
1. Install push-pull scale P to the steering wheel
knob.
a Install the push-pull scale P to the center of
the knob.
a After starting the engine, raise the bucket
approximately 400 mm and remove the
frame lock bar.
3. Pull the push-pull scale N in the tangential
direction and read the value when the steering
wheel moves smoothly.
a Do not read the value indicated when the
steering wheel starts moving as the
operating effort.
3. Turn the steering wheel to the left (opposite to

step 2) until the operating effort starts to become
heavy. Put mark (C) at the position right above
mark (A), and measure the straight-line distance
between marks (B) and (C).
Measuring operating time of steering wheel

a Measure the operating time of the steering
wheel under the following conditions.
Road surface: Flat, level, dry paved surface

Engine coolant temperature: 60 to 102C
Hydraulic oil temperature: 45 to 55 C
Engine speed: at low idle and high idle
Measuring method
a After starting the engine, raise the bucket
approximately 400 mm and remove the
frame lock bar.
30-74
WA470-7

Steering system
2. Turn the steering wheel in order to bring the

machine posture to the right or left turn with the
steering wheel at its travel end.
3. Turn the steering wheel in the reverse direction
of it described above, and measure the time
taken by the steering wheel to come to the end
of the travel.
a Do not turn the steering wheel forcibly but
turn it at the speed of 60 turns per minute.
a Measurement should be taken when the
machine is turning both to the right and left
with the engine running at low idle and high
idle.
WA470-7
30-75

Steering system
Testing work equipment control lever

a Testing tools
Symbol
Part No.
Part name
1 79A-264-0021 Push-pull scale
Y
Commercially
Ruler
2
available
k Apply
(WA380-PK00-001-K-01-A)
Push the point, 42 mm (z) up the center (c) of

side screw (2), toward tangential direction of
lever movement (right and left direction).
the frame lock bar.
a Check the work equipment control lever under

the following condition.
Testing
(WA380-PK00-384-K-00-A)
1. Measuring operating effort of work equipment

control lever
Install and fix tool Y1 to the work equipment
control lever.
3-lever type
a Install tool Y1 to the position 12 mm down
from the top of the knob.
a Operate the control lever at the same speed
as that for the normal operation, with the
minimum value for the effort needed to
operate the knob.
2. Measuring travel of work equipment control lever

Check the travel of the work equipment control
lever at each point.
3-lever type
a Put a mark on the lever knob at 12 mm down
from the top and use scale Y2 for the
measurement.
Multi-function mono-lever type
a Install tool Y1 to the following position.
a If the travel is out of the standard range,

replace the lever.
a Operate the control lever at the same speed

as that for the normal operation, with the
minimum value for the effort needed to
operate the knob.
1) RAISE
Push the lower end of kickdown switch (8
mm from center (a) of switch) horizontally
toward tangential direction of lever
movement.
2) LOWER
Push the point, 21 mm (y) under the lower
end (b) of cap (1), toward tangential direction
of lever movement.
3) TILT, DUMP
30-76
WA470-7

Steering system
Multi-function mono-lever type

a Use scale Y2 for the measurement.
Mark and measure the positions as follows.
1) RAISE, LOWER
The position at 42 mm toward the lever top
end from the center (c) of side screw (2).
2) TILT, DUMP
The position at 21 mm down (y) from the
bottom (b) of cap (1).
a If the travel is out of the standard range,
replace the lever.
WA470-7
30-77

Steering system
Testing and adjusting steering circuit oil pressure

a Tools for testing and adjusting
Symbol
1
Q
2
Part No.
799-261-5002
790-261-1204
799-401-3200
07002-12024
(WA470-F210-360-K-00-A)

Part name
Hydraulic tester
Adapter
O-ring
a Test the steering circuit pressure under the

k Loosen
the oil filler cap of the hydraulic tank

to release the pressure inside the hydraulic
tank, then operate the steering wheel 2 or 3
turns to release the remaining pressure in
the piping.
k Set
frame lock bar (1) in position.
1. Start the engine, and run it at high idle, then turn

the steering wheel to the right or left. Measure
the oil pressure (maximum pressure at operating
steering) when the steering relief valve operates.
a When accurate measurement of steering circuit
oil pressure is required for the troubleshooting,
etc., refer "Testing by use of testing tools".
1. Remove steering circuit pressure pickup plug (2)
on the left steering cylinder head side.
Testing
(WA470-F210-362-K-00-A)
Testing steering relief pressure

Steering circuit oil pressure can be measured with
Monitering/Pre-difined (14/16) or Monitering
monitor".
2. Install nipple Q3 and hose [1] of hydraulic tester

Q1, and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.74 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester Q2 can
also be used.
a Use the oil pressure gauge of 40 MPa {400
kg/cm2}.
30-78
WA470-7

Steering system
2. Install adapter Q2, and connect hose (4) or (5)

(opposite side) to it.
3. Install hose [1] of hydraulic tester Q1and
connect gauge [2].
a Use the oil pressure gauge of 6 MPa {60 kg/
cm2}.
3. Start the engine, turn the steering wheel to the

left with engine running at high idle. Measure the
oil pressure (maximum pressure at operating
steering) when the steering relief valve operates.
a When the gauge is connected to the steering
circuit pressure pickup port plug on the right
side steering cylinder head, measure the
pressure by turning the steering wheel to the
right.
4. Start the engine, and measure the oil pressure

(maximum pressure at operating steering) when
turning the steering wheel with engine running at
high idle.
When measuring at hose (4): Turn the
steering wheel to the left.
When measuring at hose (5): Turn the
steering wheel to the right.

3 Steering circuit pressure pickup plug:
9.8 to 12.74 Nm {1.0 to 1.3 kgm}
Testing steering pilot circuit pressure
1. Remove steering control circuit hose (4) or (5)
(opposite side) of steering valve assembly (3)
through the clearance between the front side of
the operator's cab and front frame.
WA470-7
5. After finishing the measurement, remove the

measuring tools and restore the machine.
Testing steering control circuit pressure
1. Remove steering control circuit pressure pickup
port plug (6) of steering valve assembly (3)
through the clearance between the front side of
the operator's cab and front frame.
30-79

Steering system
assembly (3) according to the following

procedure.
2. Install nipple Q3 and hose [1] of hydraulic tester

Q1, and connect gauge [2] to the hose.
a The hose of digital hydraulic tester Q2 can
also be used.
cm2}.
2. Loosen lock nut (6) and turn adjustment screw

(7) to adjust the pressure.
a When the adjustment screw is:
turned clockwise, the pressure is
increased.
turned counterclockwise, the pressure is
decreased.
a Quantity of adjustment per turn of adjustment
screw:
Per turn: 17.8 MPa {181.5 kg/cm2}
3 Lock nut:
27 to 31 Nm {2.8 to 3.2 kgm}
3. Start the engine, keep the steering wheel in

neutral, then measure the oil pressure with
engine at low idle.
Adjusting steering control circuit pressure

a Adjusting steering control circuit pressure is not
available.

Adjusting
(WA470-F210-27B-K-00-A)
k When
adjusting the oil pressure, be sure to

stop the engine.
Adjusting steering relief pressure

1. If the steering relief pressure is incorrect, adjust
steering relief valve (8) of steering valve
30-80
WA470-7

Steering system
Bleeding air from steering cylinder circuit.

a Before bleeding air, check that the hydraulic oil
level is proper.
a If the steering valve or the steering cylinder is
removed and installed, bleed air from the
steering circuit according to the following
procedure.
Bleeding air
(WA470-F210-231-K-00-A)
Bleeding air from steering pump

1. Remove cover (1) located under the right side of
the hydraulic tank.
(WA380-F210-001-K-01-A)
3 Air bleeder:
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
4. Start the engine and run it at low idle for 5
minutes minimum.
Bleeding air from cylinder circuit.
1. Start engine, run engine at low idle for 5
minutes.
2. Run the engine at low idle, and turn the steering
wheel 4 to 5 times to the right and left.
a Stop the piston rod approximately 100 mm
before each stroke end and take care not to
relieve the circuit.
3. Run the engine at high idle and then, perform
the operation of Step 2.
4. Run the engine at low idle and operate the
piston rod to the end of its stroke to relieve the
circuit.
2. While the engine is stopped, loosen air bleeder

(2) of the steering pump and connect air bleeder
hose [1].
3. As oil containing no bubbles starts to flow out of

air bleeder(2), tighten air bleeder (2).
WA470-7
30-81

Steering system
Testing and adjusting steering stopper valve

Testing
(WA470-F5U0-365-K-00-A)
1. Align the front frame and rear frame.

2. Check that lock nut (2) on stopper bolt (1) is not
loose.
(WA380-F5U0-001-K-00-A)
3. Stop the engine and then loosen stopper bolt (1)

until it touches the contact surface of steering
stop valve (3).
a Use care not to loosen the stopper bolt
excessively. Excessive loosening can result
in pushing the spool at the tip of steering stop
valve (3) .
4. Start and run the engine at low idle, and then
return the steering wheel slowly to set the
machine to the straight travel condition. Then
stop the engine.
5. Turn stopper bolt (1) in the loosening direction
by 8.5 turns (approx. 15 mm), then fix it by lock
nut (2) .
a Adjust both the right and left sides by
following the procedure from steps 1 to 5.
3. Start the engine and turn the steering wheel to

the right and left. Check that a clearance is
maintained between the front frame stopper and
rear frame stopper.
k Measure
the clearance while engine is
stopped.
a If the check can not be made because of
missing frame stopper and so on, do
necessary repair and then make sure that
the clearance is provided on both sides.
Adjustment
(WA380-F5U0-270-K-00-A)
a When the clearance between the front frame

and rear frame is out of the specified range,
adjust it in the following procedure.
1. Loosen lock nut (2) and then tighten stopper bolt
(1) to set distance (a) to the minimum.
6. Start the engine, turn the machine and then

check that there is a clearance between the front
frame and rear frame when the turning is
stopped due to the contact of steering stop valve
(3) and stopper bolt (1).
2. Run the engine at low idle and then bring the

front frame and rear frame into contact by
turning the steering wheel slowly.
k Use
care in this operation so that your

body or arm are not caught between the
front and rear frames.
30-82
WA470-7

Brake system
Brake system
(ALL-G000-001-K-00-A)
Testing brake pedal
(WA470-G4A1-360-K-00-A)
a Test the brake pedal under the following

conditions.
Engine low idle
Testing
(WA380-G4A1-361-K-00-A)
1. Install push gauge [1] to the operator's foot.

a Set the push gauge at a point 150 mm from
the fulcrum of the pedal.
2. Start the engine and measure the pedal
depressing angle (a1) while running the engine
at low idle.
3. Apply angle gauge [2] to the brake pedal and
measure neutral angle a1 and maximum
depressing angle a2.
a2: Depressing angle at depressing effort of
32330 N {32.93.0 kg}
WA470-7
30-83

Brake system
Testing and adjusting brake pedal linkage

Testing
(WA380-G4C0-001-K-00-A)
(WA380-G4C0-361-K-00-A)
1. Check linkage mounting pin (5), pinhole of lever

(6), and lever bushing for play. Make
adjustments as necessary.
2. Measure the length of the link (a 213 mm),
and check that it is within the standard value.
a Measure the length between the center of pin
(5) and the center of ball joint (3).
3. Measure the distance of movement of rod (8)
and check that clearance (b) is within the
standard value.
a When doing this, check that the brake pedal
hits the stopper.
4. Check bolts and nuts at each part and retighten
them if loosened.
Adjustment
(WA380-G4C0-270-K-00-A)
1. Adjusting link length (a)

1) Remove pin (5) and ball joint (3), then
remove rod (1).
2) Loosen lock nut (4), then turn yoke (2) and
ball joint (3) to adjust the length.
3) After adjusting the length of link (a), connect
it to the brake pedal.
a Standard length (a): 213 mm
2. Adjusting play of rod (b)
1) Loosen locknut (7), turn rod (8) so that the tip
of the rod contacts the booster cylinder
piston, then turn rod (8) back 1/4 turn.
a Moving distance in 1/2 turn of rod: 0.75
mm
2) Turn back by 1/4 turn and tighten lock nut (7).
a Standard value (b): 0 to 0.3 mm
30-84
WA470-7

Brake system
Testing braking performance
(WA470-G000-360-K-00-A)
a Test the brake performance under the following

conditions.
Road surface: Flat, horizontal, dry paved
surface
Speed: Speed when applying brake: 20 km/h
Tire size: 26.5 to 25
Brake pedal depressing force: Specified
depressing force
323 30 N {32.9 3 kg}
Delay in applying brakes: 0.1 sec
Testing
(WA380-G000-38E-K-00-A)
1. Start the engine and drive the machine.

2. Move the gear speed switch to the 4th position and give the machine a run-up.
3. When the travel speed reaches 20 km/h, depress the left brake pedal with the specified depressing force.
a Before performing this test, fix the run-up path and the point for applying the brakes, then apply the
brakes when the machine reaches that point.
4. Measure the distance between the point where the brake is applied and the point where the machine
stops.
a Repeat the preceding measurement three times and take the average.
WA470-7
30-85

Brake system
Testing and adjusting of accumulator charge pressure
(WA470-G2H0-360-K-00-A)

Symbol
T
Part No.
Part name

k Place

k Stop
the engine, then depress the brake

pedal at least 100 times to release the
pressure inside the accumulator circuit.
a Measure the accumulator charge pressure

Testing
(WA470-G2H0-362-K-00-A)
1. Remove cover (1) and (2) on the right side of the

machine.
3. Measure the accumulator charge cut-in
pressure.
Start and run the engine at low idle, and then
measure the oil pressure when the brake
pressure caution lamp on the machine monitor
panel goes out.
4. Measure the accumulator charge cut-out
pressure.
After the accumulator charge cuts in, measure
the oil pressure when the rising indicator of the
gauge suddenly shifts to drop.
2. Install hose [1] of hydraulic tester T to
accumulator charge pressure pickup nipple (3)
of the accumulator charge valve, and connect
them to gauge [2].
a The hose for digital hydraulic tester T2 can
also be used.
a Use gauge of 40 MPa {400 kg/cm2}.

Adjusting
(WA470-G2H0-270-K-00-A)
a When the accumulator charge cut-out pressure

is adjusted, the cut-in pressure also changes in
proportion to the valve area ratio.
30-86
WA470-7

Brake system
1. Loosen lock nut (6) of unload relief valve

(accumulator charge cut-out valve) (5), then turn
adjustment screw (7) to adjust.
increased.
decreased.
a Quantity of pressure adjustment per turn of
adjustment screw:
1.45 MPa {14.8 kg/cm2}
3 Lock nut (4):
11.8 to 16.7 Nm {1.2 to 1.7 kgm}
a After finishing measuring, check the

accumulator charge cut-in and cut-out
pressures again according to the above
measuring procedure.
WA470-7
30-87

Brake system
Testing of brake accumulator nitrogen gas pressure and procedure for

charging brake accumulator with nitrogen gas (WA470-G2G0-001-K-00-A)
a Testing tools
Symbol
Part No.
Part name
Gas charge
tool
Nipple
792-610-1310
(for Russia)
Nipple
792-610-1320
(for US)
Nipple
792-610-1330
(for US)
1 792-610-1702
ZE
2
Nipple
792-610-1350 (for
Germany)
792-610-1360
Applicable
standard
Nipple
(for UK)
GOST
CGA No. 351
ASA B-5711965
DIN 477-1963
NEN 32681966
SIS-SMS
2235/2238
BS 341
Part1-1962
Testing nitrogen gas pressure in

accumulator (WA470-G2G0-280-K-00-A)
a The following testing procedure is applicable to
an independent accumulator as well.
Nitrogen gas cylinder (c) must be connected
even when the gas pressure only is measured.
1. Stop the engine and eliminate the pressure in
the brake circuit completely by depressing the
brake pedal until its reactive force disappears.
a Depressing the brake pedal roughly 30 times
eliminates its reactive force and no oil
pressure is left in the circuit.
2. Remove plug (2) and cap (3) from accumulator
(1).
k In
order to prevent leaked nitrogen gas from

contacting your skin and clothing, be sure to
wear the appropriate protective items (such
as goggles, leather gloves and protective
clothing) and do the work from the windward
side as much as possible.
k When
handling nitrogen in an ill-ventilated

location like in a room, you must improve
ventilation of the room and observe the local
regulation for labor safety and health to
prevent oxygen deficiency disease and other
hazards.
k The
accumulator is charged with highpressure nitrogen gas. Its inappropriate

handling can cause an explosion accident,
leading to serious personal injuries. The
following rules must be strictly observed
when handling the gas.
Do not bring any open flame near the
accumulator or expose it to fire.
Do not drill it, weld or fuse-cut it.
Do not give impacts to it by hitting or
rolling it.
Bleed the gas in it before disposing it.
Decrease the charged gas pressure to the
level of atmospheric pressure before
disassembling or removing it.
The gas to be charged must be nitrogen
gas.
Do not use explosive gases including
oxygen.
The accumulator must be handled strictly
following the procedure described in this
manual.
30-88
3. Connect gas charge tool ZE1 to valve (4) of

accumulator (1) according to the following
procedure.
1) Turn handle (a) of gas charge tool ZE1 fully
counterclockwise until it becomes
immovable.
2) Keep the valve and handle (b) of nitrogen
gas cylinder (c) closed.
3) After installing the attached extension of gas
charge tool ZE1 to gas valve (4) of
accumulator (1), connect the gas charge tool
to the accumulator.
4) Connect gas charge tool ZE1 and nitrogen
gas cylinder (c).
a Exercise care in the above operation
since the bending load applied to gas
valve (4) can damage it.
2 types of threads, w22-14 threads (male
thread A type) and w23-14 threads
(female thread B type), are available for
the nitrogen gas cylinder. When using a
cylinder with w23-14 threads (female
thread B type), connect the hose by using
the adapter.
WA470-7

Brake system
(The adapter comes with gas charge tool

ZE1.) [Inside of Japan]
Depending on the given specification of
the nitrogen gas cylinder, nipple ZE2 is
used for connecting the hose.
4. Turn handle (a) of gas charge tool ZE1

clockwise gradually and read the gauge value.
k In
order to prevent damage of gas valve

(4), it is prohibited to rotate handle (a) 1.5
turns or more after the pressure of the
charged gas is displayed.
Check that no gas leakage is recognized.
a Since the pressure indication varies

depending on the ambient temperature at the
time of measurement, you must refer to the
following table when measuring the gas
pressure.
Ambient
temperature
C
15
16
17
18
19
MPa
3.37
3.39
3.40
3.41
3.42
kg/cm2
34.4
34.5
34.6
34.8
34.9
20
3.43
35.0
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
3.44
3.46
3.47
3.48
3.49
3.50
3.52
3.53
3.54
3.55
3.56
3.57
3.58
3.60
3.61
3.63
3.64
3.65
3.67
3.68
3.69
3.70
3.71
3.72
3.73
35.1
35.2
35.4
35.5
35.6
35.7
35.8
36.0
36.1
36.2
36.4
36.6
36.7
36.8
36.9
37.0
37.2
37.3
37.4
37.5
37.6
37.7
37.8
37.9
38.0
Gas pressure
Remarks
Base gas
pressure
Displayed gas pressure = Base gas pressure

x ((273 + t) / (273 + 20))
(Every number in the formulas is represented
in C.)
5. If the indicated gas pressure is below or above
the targeted level, adjust it referring to "Charging
procedure of accumulator nitrogen gas".
a A certain amount of nitrogen gas is
discharged every time measurement is done
and the pressure decreases. Be sure to
replenish by the amount of the gas
discharged.
WA470-7
30-89

Brake system
6. Turn handle (a) of gas charge tool ZE1 fully

counterclockwise until it becomes immovable.
7. Remove gas charge tool ZE1 from accumulator
(1) and restore it. See "Charging procedure of
accumulator nitrogen gas".
Procedure for charging accumulator

with nitrogen gas (WA470-G2G0-219-K-00-A)
a The following charging procedure is applicable
to an independent accumulator as well.
1. Stop the engine and eliminate the pressure in
the brake circuit completely by depressing the
brake pedal until its reactive force disappears.
a Depressing the brake pedal roughly 30 times
eliminates its reactive force and no oil
pressure is left in the circuit.
2. Remove plug (2) and cap (3) from accumulator
(1).
3. Connect gas charge tool ZE1 and nitrogen gas

cylinder (c) to valve (4) of accumulator (1)
1) Turn handle (a) of gas charge tool ZE1 fully
counterclockwise until it becomes
immovable.
2) Turn handle (b) counterclockwise and leave
the valve open.
3) After installing the attached extension of gas
charge tool ZE1 to gas valve (4) of
accumulator (1), connect the gas charge tool
to the accumulator.
4) Connect gas charge tool ZE1 and nitrogen
gas cylinder (c).
2 types of threads, w22-14 threads (male
thread A type) and w23-14 threads
cylinder with w23-14 threads (female
the adapter.
(The adapter comes with gas charge tool
ZE1.) [Inside of Japan]
Depending on the given specification of
the nitrogen gas cylinder, nipple ZE2 is
used for connecting the hose.
30-90
4. Open the valve of nitrogen gas cylinder (c)

slightly to discharge the gas with the pressure of
approximately 0.19 to 0.29 MPa {2 to 3 kg/cm2}.
5. Turn handle (b) clockwise to close the valve
when nitrogen gas starts to come out of handle
(b).
6. Turn handle (a) clockwise slowly to gradually
open valve (4) of accumulator (1).
a Exercise care in operating handle (a) since
excessive turning of handle (a) can damage
the accumulator valve core, inducing gas
leakage.
7. Open the valve of nitrogen gas cylinder (c)
further to charge the nitrogen gas to the
accumulator.
8. Close the valve of nitrogen gas cylinder (c) from
time to time during this operation to check the
nitrogen gas pressure in the accumulator.
a For the nitrogen gas pressure testing
procedure, see Item 4 of "Testing of
accumulator nitrogen gas pressure".
9. After the gas is charged up to the standard value,
close the valve of nitrogen gas cylinder (c).
When the charged gas volume is excessive,
discharge excessive gas by turning handle
(b) slowly counterclockwise while keep the
valve of nitrogen gas cylinder (c) being
closed.
10.Remove gas charge tool ZE1 from valve (4) of
accumulator (1) according to the following
procedure.
WA470-7

Brake system
1) Turn handle (a) counterclockwise to close

the accumulator valve.
2) Turn handle (b) counterclockwise to open the
valve and discharge remaining nitrogen gas
in gas charge tool ZE1 and hose.
3) Remove gas charge tool ZE1 from valve (4)
of the accumulator.
11.Apply suds to valve (4) of the accumulator to
make sure there is not leakage of nitrogen gas.
12.Install plug (2) and cap (3) to accumulator (1).
3 Plug
73.5 to 98.0 Nm {7.5 to 10.0 kgm}
13.Within a week from charging nitrogen gas,

check the performance of the brake according to
the following procedure to check that no
pressure drop of nitrogen gas is found.
a Check the brake function within 5 minutes
from stop of the engine. (If more than 5
minutes elapse from stop of the engine,
correct measurement becomes unavailable
because oil pressure in the brake circuit
drops.)
1) Place the machine on a flat ground and turn
the parking brake switch to "PARKING"
position.
2) Start and run the engine at medium speed for
a minute, then stop the engine.
3) Turn the starting switch to ON position and
depress the brake pedal repeatedly to record
the depressing frequency required for the
brake oil pressure caution lamp to light up.
Depressing frequency is less than 5:
Accumulator gas pressure may be low
Depressing frequency is 5 or more:
Accumulator gas pressure is normal.
WA470-7
30-91

Brake system
Testing wheel brake oil pressure
(WA470-G210-360-K-01-A)
a Tools for testing

Symbol
1
ZB 2
3
Part No.
Part name
401-799-2930 Adapter
k High
pressurized oil in the accumulator may

spout out because of a trouble in the brakerelated equipment even when the brake
pedal is not depressed. To prevent this,
depress the brake pedal at least 100 times
with the engine stopped to release the
accumulator circuit pressure.
a When accurate measurement of brake oil

pressure is required for troubleshooting, etc.,
refer "Testing by use of testing tools".
1. Remove inspection cover (1) of the front frame
(front side).
Perform measurement at slack adjuster portion
on the left side of rear frame (rear side).
k When
removing the inspection cover with

the boom raised, place a stand under the
boom to support the boom securely.
k Place

a Perform measurement on both of front brake and

rear brake.
a Measure the wheel brake oil pressure under the
Coolant temperature: 60 to 102
Testing
(WA470-G210-362-K-00-A)

Brake oil pressure (front brake only) can be
measured with Monitering/Pre-difined (12/16) or
Monitering (monitoring code: 41201) of the
machine monitor.
2. Remove hose (2). Install adapter ZB1, install

nipple [1] and hose [2] of hydraulic tester ZB2,
and then connect gauge [3] to the hose.
ZB3 can also be used.
a Use gauge [3] of 6 MPa {60 kg/cm2}.
(Front side)

monitor".
(Rear side)
1. Bleed air from the brake circuit. For details, see

Testing and adjusting "Bleeding air from wheel
brake circuit".
2. Start the engine and measure the wheel brake
oil pressure as the left brake pedal is depressed.
30-92
WA470-7

Brake system
3. Bleed air from the brake circuit. For details, see

brake circuit".
4. Start the engine and measure the wheel brake
oil pressure as the left brake pedal is depressed.

WA470-7
30-93

Brake system
Testing lowering of wheel brake pressure
(WA470-G210-360-K-00-A)
a Testing tools
Symbol
1
2
3
U 4
5
6
7
Part No.
793-605-1001
790-101-1430
790-101-1102
790-301-1720
799-101-5160
799-401-2220
790-261-1130
Part name
Brake test kit
Coupler
Pump
Adapter
Nipple
Hose
Coupling
k High
pressurized oil in the accumulator may

spout out because of a trouble in the brakerelated equipment even when the brake
pedal is not depressed. To prevent this,
depress the brake pedal at least 100 times
with the engine stopped to release the
accumulator circuit pressure.
3. Remove union, and install adapter U4, nipple U5

and hoseU6, and then install brake test kit U1.
a Use the O-ring fitted to the union.
k Place

a Measure the oil pressure of the front brakes

(right and left) and rear brakes (right and left)
similarly.
a Measure the wheel brake pressure lowering
Testing
(WA470-G210-38F-K-00-A)
1. Remove inspection cover (1) of the front frame.

k When

2. Remove brake tube (2) on the testing side.

4. Loosen bleeder screw (4) to bleed air.
30-94
WA470-7

Brake system
a Bleed air by operating pump U3.
5. Tighten bleeder screw (4), operate pump U3 to

increase the pressure to 4.9 MPa {50 kg/cm2},
and close stop-valve [1].
6. Leave the brake circuit pressurized for 5 minutes

and check lowering of the pressure.
a If the hose is moved while the pressure is
measured, the pressure fluctuates.
Accordingly, do not move the hose.
a After testing the pressure, operate pump U3
to lower the pressure in brake test kit U1, and
then remove brake test kit U1.
a After finishing testing, install the brake tube
and bleed air from the brake circuit.
Brake test kit
WA470-7
30-95

Brake system
Testing wear of wheel brake disc

a Testing tools
Symbol
V
Part No.
Part name
Commercially Vernier calipers
available
k Place

a There are inspection plugs on the right and left

sides of the front and rear axles. Perform the
check at all of the four plugs similarly.
Testing
(WA380-G167-001-K-00-A)
2. Depress the brake pedal to the travel end.

3. Push in shaft (2) and measure its projection (x)
(distance of wear) from end face (a) of guide (3)
with vernier calipers V.
a Keep depressing the brake pedal while
measuring the wear.
a If shaft (2) is projected from the end of guide
(3) to the groove, replace the disc.
Projection x from (a): Amount of wear
Projection y from (a): Wear limit (2.4 mm)
a If face (b) of the shaft is seen, the disc is
worn to the repair limit.
(WA470-G167-389-K-00-A)
1. Remove cap (1).

3 Cap (1):
29.4 to 39.2 Nm {3.0 to 4.0 kgm}
30-96
WA470-7

Brake system
Bleeding air from wheel brake circuit
(WA470-G200-360-K-00-A)
k Place
the machine on a level ground, lower the work equipment to the ground, set the parking
brake switch and work equipment lock switch in LOCK position, stop the engine, and chock the
wheels.
a When brake circuit equipment is removed or installed, bleed air from the brake circuit according to the
a Take the similar procedure for the front brake circuit and rear brake circuit. (2 places each).
a Perform air bleeding in order of right side of rear axle o left side of rear axle o right side of front axle o
left side of front axle o slack adjuster.
Bleeding air
(WA470-G200-231-K-00-A)
1. Start the engine to accumulate pressure in the

accumulator, and then stop the engine.
k When

5. Connect hose [1] to bleeder screw (3) of wheel

brake, and place one end of hose [1] in the oil
container.
6. Depress the brake pedal and then loosen
bleeder screw (3) to bleed air.
a Release the brake pedal slowly after
tightening bleeder screw (3).
3. Connect hose [1] to bleeder screw (2) of slack
adjuster, and place one end of hose [1] in the oil
container.
4. Depress the brake pedal, and then loosen

bleeder screw (2) to bleed air.
a Release the brake pedal slowly after
tightening bleeder screw (2).
WA470-7
7. Repeat this operation until the oil flowing

through hose [1] becomes free from bubbles.
Then depress the pedal fully, and tighten
bleeder screw (2) and (3) while the oil is flowing.
8. Bleed air from other brake cylinders by using the
same procedure.
a When a complete bleeding is required, it is
advisable to start the operation from the
brake cylinder situated farthest from the
brake pedal.
30-97

Brake system
a If the pressure in the accumulator is

decreased, start the engine to charge the
accumulator. Then stop the engine and
perform air bleeding following the same
procedure as described above.
a After finishing bleeding air, run the engine at
low idle, and check the oil level in the
hydraulic tank. If the level is low, refill with oil
to the specified level.
Bleeding method after removal and installation
of cab
a Perform the following if removing cab for work.
1. Remove hoses (1) to (5) (5 pieces) from brake
valve.
2. Remove hoses of front brake (1), rear brake (2),
accumulator (4) and (5), and hydraulic tank (3).
3. Perform air blowing through inlet of hoses
removed from brake valve side. (Blow the air in)
4. Install hoses (1) to (5) removed.
5. Perform air bleeding according to procedure for
air bleeding.
30-98
WA470-7

Brake system
Releasing remaining pressure in brake accumulator circuit
(WA380-G2F0-001-K-00-A)
k Before
disconnecting any of the following

brake accumulator circuits, release
remaining pressure in the brake circuit.
Releasing remaining pressure
(WA380-
G2F0-22A-K-00-A)
Between accumulator charge valve and brake

accumulator
Between accumulator charge valve and parking
brake solenoid valve
Between brake accumulator and brake valve
1. Stop the engine.
2. Depress the brake pedal at least 100 times to
release the pressure in the brake accumulator
circuit.
WA470-7
30-99

Brake system
Testing parking brake performance
(WA380-GJ20-001-K-00-A)
a Testing conditions
Road surface: Flat, dry, paved road with (11
deg. 20') grade
Machine: Operating condition
Testing
(WA380-GJ20-38E-K-00-A)
1. Start the engine and set the machine in the

straight travel position, and then drive up a slope
of 1/5 gradient with no load in the bucket.
2. Depress the brake pedal to stop the machine,
set the directional lever in the" N (neutral)"
position, and stop the engine.
3. Turn the parking brake switch ON (to park), and
then release the brake pedal gradually. At this
time, the machine must not move.
a When the engine is stopped, the parking
brake is turned ON (to park) automatically.
a Test the parking brake performance on an
uphill and a downhill.
30-100
WA470-7

Brake system
Testing parking brake oil pressure

a Testing tools
Symbol
1
W
2
(WA470-GJB0-360-K-00-A)
Part No.
Part name

793T-615-1730 Adapter
07002-11023
O-ring
k Place

a Measure the parking brake oil pressure under

Testing
(WA470-GJB0-362-K-00-A)
1. Remove side cover (1) on left of rear frame.

2. Remove parking brake oil pressure pickup plug
(1).
4. Start the engine, and run it at low idle, and

measure the parking brake oil pressure.
k Keep
depressing the brake pedal for

safety.
a Measure the oil pressure at when the parking

brake switch is turned OFF.

3 Parking brake pressure pickup port
plug (1):
9.8 to 12.74 Nm {1.0 to 1.3 kgm}
3. Install adapter W2 and hose [1] of hydraulic

tester W1, and connect them to gauge [2].
3 Adapter:
9.8 to 12.74 Nm {1.0 to 1.3 kgm}
a The hose for digital hydraulic tester W2 can
also be used.
WA470-7
30-101

Brake system
Testing wear of parking brake disc

a Testing tools
Symbol
X
Part No.
Part name
Commercially Vernier calipers

available
(WA380-GJ72-001-K-00-A)
and assembly, "Removal of parking brake discs

and plates".
Judgement criteria of thickness(W): 2.97 mm
a If the parking brake disc thickness is below
the service limit, replace the disc.
k Place

a If the parking brake does not work effectively,

check the parking brake disc for wear according
to the following procedure.
Testing
(WA470-GJ72-389-K-00-A)
1. Drain the oil from the transmission case.

6 Transmission case: 65 l (refill
capacity)
2. Remove one of 2 bolts (1).
a Prepare an oil container to receive oil flew
from the bolt mounting holes.
Refilling of oil (transmission case)

Refill with oil to the specified level through
the oil filler port. Run the engine to circulate
the oil through the system. Then check the
oil level again.
3. Measure depth (a) from the end of cage (2) to

piston (3) by using vernier calipers X.
Clearance (a): Max. 38.3 mm
4. If depth (a) is above the standard, remove

parking brake disc (4), and measure its
thickness (W) of disc, referring to Disassembly
30-102
WA470-7

Brake system
Method of releasing parking brake manually
(WA380-GJ20-001-K-01-A)
k Releasing
the parking brake manually is a

means to move the machine from a
dangerous job site to a safe place. Apply this
means only in an emergency.
k Place

a The parking brake is controlled hydraulically. If

you cannot release the parking brake because
of a failure in the transmission, emergency
release solenoid valve, etc., you can move the
machine by releasing the parking brake
manually.
How to release
(WA470-GJ20-141-K-00-A)
Releasing method by using the parking brake

emergency release valve
1. Remove inspection cover (1) on the right side of
the machine.
3. Turn the starting switch to ON position, turn the

parking brake switch to ON position and then to
OFF position.
a The parking brake is released by the above
procedure.
Mechanical releasing method
1. Drain the oil from the transmission case.
2. Loosen lock nut (3) and grip (4) of parking brake
emergency release valve (2) and open the
release valve.
3 Lock nut (3):
19.6 4.9 Nm {2.0 0.5 kgm}
6 Transmission case: 65 l (refill

capacity)
2. Remove 2 bolts (1). (Right and left)
a Prepare an oil container to receive oil flew
from the plug mounting holes.
3 Grip (4):
19.6 4.9 Nm {2.0 0.5 kgm}
3. Remove mounting bolts (2) (2 pieces), and

tighten them alternately into mounting part of
bolt (1).
WA470-7
30-103

Brake system
a Remove bolts (2) (2 pieces) on the diagonal

positions.
a Piston (3) is pulled back by tightening bolts
(2), then the parking brake is released.
a Tighten the bolts (2 pieces) gradually and
evenly. (Tighten the bolts approximately 3
turns after it contacts the seat surface.)
4. After finishing the work, restore the machine.

Refilling of oil (transmission case)
After releasing the parking brake manually, refill
with oil to the specified level through the oil filler
port. Run the engine to circulate the oil through
the system. Then check the oil level again.
30-104
WA470-7

Hydraulic system
Hydraulic system
Testing fan speed
(D65-PM10-001-K-00-A)
(WA380-B400-001-K-00-A)
k Place

a Test the cooling fan motor speed under the

Cooling fan maximum speed
Engine at high idle
Coolant temperature: Min. 95C
Hydraulic oil temperature: Min. 95C
Torque converter oil temperature: Min. 105C
Cooling fan minimum speed
Engine at low idle

Coolant temperature: Max. 75C
Hydraulic oil temperature: Max. 75C
Torque converter oil temperature: Max. 85C
Testing
(WA470-B400-388-K-00-A)
1. Start the engine, and switch the machine

monitor to 01 Monitoring/Pre-defined display of
the service mode.
a For the operating method, see "Special
a Monitoring/Pre-defined (15/16)
2. While running the engine at low idle and high

idle, measure the cooling fan speed.
Cooling fan
speed
Engine speed
Standard value
Max. speed
High idle
See standard
value table
Min. speed
WA470-7
Low idle
Air
conditioner:
OFF
Air
conditioner:
ON
See standard
value table
See standard
value table
30-105

Hydraulic system
Testing fan pump circuit oil pressure
(WA380-B441-001-K-00-A)
a Testing tools
Symbol
1
R
2
Part No.
Part name

k Place

k Loosen
the cap of the hydraulic tank

gradually to release the pressure in the tank.
3. Remove cover (2).
a Measure the cooling fan pump circuit pressure

Engine high idle
Fan 100% mode
Hydraulic oil temperature: 50C
Testing
(WA470-B441-362-K-00-A)
Testing fan drive pressure

1. Start the engine, and switch machine monitor to
Fan 100% Mode display of "Adjustment"
function in the service mode.
a For the operating method, see "Special
a If this mode is displayed, the fan speed is
kept at 100% speed in accordance with the
engine speed, regardless of the condition of
the machine.
4. Connect oil pressure gauge [2] of hydraulic

tester R to oil pressure pickup nipple (3).
kg/cm2}.
5. Run the engine at high idle and measure the

cooling fan pump circuit oil pressure.
2. Open radiator grille (1).
30-106
Cooling fan pump circuit

oil pressure
WA470-7

Hydraulic system

Testing cooling fan reverse solenoid output
pressure
4. Select "Manual Fan Reverse Mode" by

operating the machine monitor.
a For the selection procedure, see the
Operation and Maintenance Manual.
5. Run the engine at high idle and measure the
cooling fan reverse solenoid output pressure.
a Measure the pressure in both fan reverse
mode and fan normal rotation mode and
confirm that the solenoid operates and the
specified oil pressure is generated in the fan
reverse mode.
Cooling fan reverse
solenoid output pressure See standard value table
6. After finishing the measurement, remove the

testing tools and restore the machine.
3 Pickup port plug (4):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3. Remove pickup port plug (4) and connect oil
pressure gauge [2] of hydraulic tester R to it.
cm2}.
WA470-7
30-107

Hydraulic system
Bleeding air from hydraulic fan circuit
(WA380-B441-001-K-01-A)
a Testing tools
Symbol
1
S 2
3
Part No.
Part name

790-261-1130 Coupling
k Place

a Before bleeding air, check that the hydraulic oil

level is proper.
Bleeding air
(WA470-B441-231-K-00-A)
Bleeding air from cooling fan pump

1. Remove cover (1) at the lower right of the
operator's cab.
3. Install hose [1] in hydraulic tester S1 to the fan

pump circuit pressure pickup port nipple (3), and
also connect air bleeder coupling S3 to the
outlet end of the hose.
a Put the outlet end of the hose in the oil
container.
2. Connect air bleeder hose [1], and loosen air
bleeder (2) of the cooling fan pump.
a The hose for digital hydraulic tester S2 can

also be used.
3. As oil containing no bubbles starts to flow out of

air bleeder(2), tighten air bleeder (2).
3 Air bleeder (2):
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
4. Start the engine, and run it at low idle for 5
minutes minimum.
Bleeding air from cooling fan motor circuit
30-108
WA470-7

Hydraulic system
4. Start the engine, then stop it when the oil flows

out of the outlet end of the hose.
5. After finishing bleeding the air, remove the
testing tools and restore the machine.
WA470-7
30-109

Hydraulic system
Testing and adjusting work equipment EPC oil pressure
(WA470-PL70-360-K-00-A)
a Testing tools
Symbol
1
2
Z
3
Part No.
799-101-5002
790-261-1204
799-101-5220
07002-11023
Part name
Hydraulic tester
Nipple
O-ring
k Loosen
the oil filler cap slowly to release the

pressure inside the hydraulic tank.
k Turn
the starting switch to ON position,

release the work equipment lock switch, and
then operate the work equipment control
lever 2 to 3 times to release the pressure in
the PPC accumulator circuit.
a Measure the work equipment PPC oil pressure

under the following condition.
4. Start and run the engine at high idle, and then

operate the work equipment control lever and
measure the EPC valve source pressure.
EPC valve source
pressure
3.72 (+0.2/-0.2) MPa

{38 (+2/-2) kg/cm2}
Testing
(WA470-PL70-362-K-00-A)
EPC valve source pressure

1. Remove side cover (1) on the right of rear frame.

Testing EPC oil pressure (shut off valve output
pressure)
2. Remove oil pressure pickup port plug (3).
k When

3. Install nipple Z3 and hose [1] of hydraulic tester

Z1 and connect them to gauge [2].
a The hose for digital hydraulic tester Z2 can
also be used.
30-110
WA470-7

Hydraulic system

Measuring EPC valve output pressure
k When

2. Disconnect EPC circuit hose (2) to be

measured.
2. Remove oil pressure pickup port plug (5) of EPC

valve output circuit to be measured.
a A: Attachment
3. Connect nipple and O-ring Z3.
B: Attachment
C: ECSS
D: Boom RAISE
E: Boom LOWER and boom FLOAT
F: Bucket TILT
G: Bucket DUMP
4. Install nipple and hose of hydraulic tester Z1,

and connect them to gauge G3.
6. Operate the work equipment lock switch to
release the lock of work equipment.
7. Run the engine at high idle, and measure EPC
valve source pressure (oil pressure) (shut off
valve output pressure).
k Do
not operate the work equipment

control lever.
Work equipment EPC
valve oil pressure
(Shut off valve outlet
pressure)
WA470-7
30-111

Hydraulic system
3. Install nipple Z3 and hose [1] of hydraulic tester

Z1 and connect them to gauge [2].
a The hose for digital hydraulic tester Z2 can
also be used.
4. Start the engine, run it at high idle, and move the

work equipment lever to measure the EPC valve
output pressure.

Adjusting
(WA470-PL70-270-K-00-A)
a The EPC relief valve is not adjustable.

1. Remove EPC relief valve cartridge assembly,
and replace it.
3 EPC relief valve cartridge assembly:
25 to 33.9 Nm {2.6 to 3.5 kgm}
3 Lock nut:
11.8 to 16.7 Nm {1.2 to 1.7 kgm}
a After the replacement, measure the EPC oil
pressure again.
30-112
WA470-7

Hydraulic system
Testing and adjusting work equipment oil pressure

Symbol
1
2
ZA 3
4
Part No.
(WA470-PM10-360-K-00-A)
k When
Part name

Hydraulic tester
Nipple
O-ring
Differential pressure
799-401-2701 gauge
799-101-5002
790-261-1204
799-101-5220
07002-11023
a Measure the work equipment oil pressure under

Preparation
(WA470-PM10-330-K-00-A)
Combination of actuator and valve

a Note that the valve which relieves the oil
pressure depends on the actuator.
a The number of each actuator in the following
table shows the order from the top, when the
control valve is seen from the front of the
machine. (As for the service actuator, an
example of a single attachment installation is
shown.)
No.
1
Actuator
Service
Tilt
DUMP
Boom
(Lift cylinder)
Bucket
Valve to be relieved
Safety valve
Safety valve
Main relief valve
Testing
(WA470-PM10-362-K-00-A)
Testing work equipment relief pressure

Work equipment oil pressure can be measured with
Monitering/Pre-difined (9/16) or Monitering
monitor".
Main relief valve
1. Lower section (b) to the ground keeping bucket

(a) 30 to 50 mm off the ground.
2. Stop the engine and operate the work
equipment control lever to check that both parts
(a) and (b) of the bucket touch the ground.
a After lowering the bucket to the ground,
operate the work equipment control lever 2 to
3 times to release the remaining pressure in
the piping.
1. Start the engine, and raise the boom, and keep it
level. Then, measure the oil pressure with the
bucket dumped while running the engine at high
idle.
a When accurate measurement of work equipment
relief pressure is required for troubleshooting,
etc., refer "Testing by use of testing tools".
1. Remove pump pressure pickup port plug (2)
from the work equipment control valve.
WA470-7
30-113

Hydraulic system

monitor".
2. Install nipple ZA3 and hose [1] of hydraulic tester

ZA1 and connect them to gauge [2].
a The hose for digital hydraulic tester ZA2 can
also be used.
kg/cm2}.
1. Start the engine and raise the boom

approximately 400 mm. Then, measure the oil
pressure when all the levers are in NEUTRAL
position with the engine running at high idle.
a When accurate measurement of unload oil
pressure is required for troubleshooting, etc.,
refer "Testing by use of testing tools".
1. Remove pump pressure pickup port plug (2)
from the work equipment control valve.
3. Start the engine, and raise the boom, and keep it

level. Then, measure the oil pressure with the
bucket dumped while running the engine at high
idle.

ZA1, and connect them to gauge [2].
a The hose for digital hydraulic tester ZA2 can
also be used.
cm2}.
Testing unload oil pressure
Unload oil pressure can be measured with
Monitering/Pre-difined or Monitering (monitoring
code: 94700) of the machine monitor.
30-114
WA470-7

Hydraulic system

ZA1 and connect them to gauge [2] or
differential pressure gauge ZA4.
a When using the differential pressure gauge,
connect its high-pressure side to the pump
pressure side, and connect its low-pressure
side to the LS pressure side. The differential
pressure gauge requires 12 V power supply.
Thus, connect a battery.
a Use the gauge of 40 MPa {400 kg/cm2}.
3. Start the engine, and raise the boom
approximately 400 mm. Then, measure the oil
pressure when all the levers are in neutral
position with the engine running at high idle.

Testing LS differential pressure
a Before measuring the LS control circuit oil
pressure, check that the work equipment relief
oil pressure and work equipment EPC oil
pressure are normal.
a To obtain the LS differential pressure, measure
the pump discharge pressure and LS pressure
(actuator load pressure) simultaneously and
calculate the difference.
1. Remove pump pressure pickup port plug (2) and
LS pressure pickup port plug (3) from the work
equipment control valve.
Since the differential pressure is 1.5 MPa {15

kg/cm2} at maximum, use the gauge whose
accuracy is the same throughout the
measurement.
3. Start the engine and raise the boom

approximately 400 mm.
4. Run the engine at high idle and then, under the
following condition, measure the pump
discharge pressure and LS pressure (actuator
load pressure) simultaneously.
When all of control levers are in NEUTRAL
and when boom lever is moved halfway
a While measuring, take care not to move the
lift cylinder to the stroke end.
a Calculation of LS differential pressure:
LS differential pressure = pump discharge
pressure - LS pressure
a When the LS differential pressure is as
follows, it is normal.
Operation of lever
All control levers in
NEUTRAL
Boom control lever in
halfway
WA470-7
LS differential pressure
Unload pressure (see
the standard values
table)
Specified LS differential
pressure (see the
standard values table)
30-115

Hydraulic system
a After finishing adjusting, measure the work

equipment relief valve pressure according to
the above measurement procedure.
Adjusting LS differential pressure
a LS differential pressure cannot be adjusted.

Adjusting work equipment relief pressure
1. Adjust main relief valve (5) of work equipment
control valve (4).
2. Loosen lock nut (6) and turn adjustment screw

(7) to adjust.
increased.
decreased.
a Quantity of adjustment per turn of adjusting
screw:
12.6 MPa {128 kg/cm2}
3 Lock nut:
29.4 to 39.2 Nm {3 to 4 kgm}
30-116
WA470-7

Hydraulic system
Bleeding air from work equipment circuit
(WA470-PM10-231-K-00-A)
Bleeding air from cylinder

1. Start the engine and run it at idle for
approximately 5 minutes.
2. Run the engine at low idle and then, raise and
lower the boom 4 to 5 times.
a Stop the piston rod approximately 100 mm
before each stroke end and take care not to
relieve the circuit.
3. Run the engine at high idle and then, perform
operation of Step 2. Then, retract the piston rod
to the stroke end at low speed to relieve the
circuit.
4. Perform the same operation as the one in Steps
2 and 3 for the bucket and steering cylinders as
well.
a When a cylinder is replaced, perform this
operation before connecting the piston rod.
WA470-7
30-117

Hydraulic system
Releasing remaining pressure from work equipment circuit
(WA470-PM10-22A-K-00-A)
Releasing remaining pressure between each

hydraulic cylinder and control valve
a If the piping between the hydraulic cylinder and
the control valve is to be disconnected, release
the remaining pressure in the circuit according to
the following procedure.
1. Stop the engine.
2. Loosen the oil filler cap slowly to release the
pressure inside the tank.
3. Turn the starting switch to ON position.
4. Set the work equipment lock switch to OFF
position.
5. Release the remaining pressure by operating
the work equipment control lever.
Releasing remaining pressure in ECSS circuit
k When
disconnecting the piping of ECSS

circuit (between the accumulator for ECSS
and work equipment control valve), release
the pressure of the accumulator for ECSS

k When

4. After releasing the remaining pressure, tighten

plug (5)and lock nut (4) securely in this order.
a Loosen lock nut (4) to the maximum before
tightening plug (5). After tightening plug (5),
tighten lock nut (4).
3 Plug (5):
19.6 to 27.5 Nm {2.0 to 2.8 kgm}
3 Lock nut (4):
19.6 to 27.5 Nm {2.0 to 2.8 kgm}
2. Loosen lock nut (2) of ECSS bleeder plug (5) on

work equipment control valve (4).
3. Loosen bleeder plug (5) 1/2 to 1 turn to release
the accumulator pressure.
a When the work equipment control valve is
seen from the front of the machine, plug (5)
is installed to the left side of the control valve.
30-118
WA470-7

Hydraulic system
Testing of ECSS accumulator nitrogen gas pressure and procedure for

charging accumulator with nitrogen gas (WA470-L370-360-K-00-A)
a Testing tools
Symbol
1
Z2
D
3
Part No.
k Place
Part name
Commercially Gas charge tool

available
Commercially Pressure reducing valve
available
Commercially Charging hose
available
a For testing and adjusting HYDAC accumulators,

commercially available tools are used. Please
contact one of distributors in your area.

the work equipment to the ground, and
chock the wheels.
a The following testing procedure is applicable to

an independent accumulator as well.
1. Remove cap (2) from the filling port of
accumulator (1).
2. Loosen hexagonal socket head bolt (3)
counterclockwise ( approximately 1/2 turn)
slightly by using hexagonal wrench with 6mm
(SW6)
Model and type (reference)

FPU-1 250 F4.0 G6 A3 K
k In
order to prevent leaked nitrogen gas from

contacting your skin and clothing, be sure to
wear the appropriate protective items (such
as goggles, leather gloves and protective
clothing) and do the work from the windward
side as much as possible.
k When
handling nitrogen gas in an illventilated location like in a room, you must

improve ventilation of the room and observe
the rules stipulated in the Industrial Safety
and Health Act to prevent oxygen deficiency
disease and other hazards.
k The
accumulator is charged with highpressure nitrogen gas. Its inappropriate

handling can cause an explosion accident,
leading to serious personal injury or death.
The following rules must be strictly observed
when handling the gas.
Do not bring any open flame near the
accumulator or expose it to fire.
Do not drill it, weld or fuse-cut it.
Do not give impacts to it by hitting or
rolling it.
Bleed the gas in it before disposing it.
3. Turn handle (4) of gas charge tool ZD1 fully

4. Close pressure relief valve (5).
5. Screw cap nut (6) into filling port of accumulator
(1) with hands. Adjust it so that a pressure
gauge (7) of gas charge tool ZD1 can be easily
seen.
6. Slowly turn handle (4) counterclockwise to
loosen the hexagonal socked head bolt (3), and
open it.
7. When pressure gauge (7) indicator reaches the
maximum value, turn handle (4) clockwise to the
fully closed position.
The pressure shown at this time is the
charge pressure of the accumulator.
Testing nitrogen gas pressure in

accumulator (WA470-L370-280-K-00-A)
k Loosen

k Cancel
the work equipment lock switch while

starting switch is ON.
k Operate
the work equipment control lever 2

to 3 times to release the pressure in the PPC
accumulator circuit.
WA470-7
30-119

Hydraulic system
a Since the indicated value varies with the ambient

temperature, refer to the following table and
check the gas pressure.
Ambient
temperature
C
15
16
17
18
19
MPa
4.43
4.35
4.37
4.38
4.4
kg/cm2
44.2
44.4
44.5
44.7
44.8
20
4.41
45
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
4.43
4.44
4.46
4.47
4.49
4.5
4.52
4.53
4.55
4.56
4.58
4.59
4.61
4.62
4.64
4.65
4.67
4.68
4.7
4.71
4.73
4.74
4.76
4.77
4.79
45.2
45.3
45.5
45.6
45.8
45.9
46.1
46.2
46.4
46.5
46.7
46.8
47
47.2
47.3
47.5
47.6
47.8
47.9
48.1
48.2
48.4
48.5
48.7
48.8
Gas pressure
Remarks
a The following charging procedure is applicable

to an independent accumulator as well.
1. Remove cap (2) from the filling port of
accumulator (1).
2. Loosen hexagonal socket head bolt (3)
counterclockwise ( approximately 1/2 turn)
slightly by using hexagonal wrench with 6 mm
(SW6).
Base gas
pressure
Procedure for charging accumulator

with nitrogen gas (WA470-L370-219-K-00-A)
k Loosen

3. Turn handle (4) of gas charge tool ZD1 fully

4. Close pressure relief valve (5).
5. Screw cap nut (6) into filling port of accumulator
(1) with hands. Adjust it so that a pressure
gauge (7) of gas charge tool ZD1 can be easily
seen.
6. Connect gas charge tool ZD1 and nitrogen gas

cylinder according to the following procedure.
1) Connect cap nut (7) of pressure reducing
valve ZD2 to the nitrogen gas cylinder.
k Cancel
the work equipment lock switch while

starting switch is ON.
k Operate
the work equipment control lever 2

to 3 times to release the pressure in the PPC
accumulator circuit.
k Place

the work equipment to the ground, and
chock the wheels.
30-120
WA470-7

Hydraulic system
5) Slowly turn handle (4) counterclockwise to

loosen the hexagonal socked head bolt (3),
and open it.
2 types of threads, W22-14 threads (male

thread A type) and W23-14 threads
cylinder with W23-14 threads (female
the adapter.
Connect cap nut (8) of charging hose
ZD3 to pressure reducing valve ZD2.
2) Connect cap nut (9) of charging hose ZD3 to
pressure relief valve (5) of gas charging tool
ZD1.
3) Slightly open shut off valve (11) of nitrogen

gas cylinder (10), and set the filling pressure
of pressure reducing valve ZD2 not to
damage the gas charging tool ZD1.
4) Close shut off valve (11) of nitrogen gas
cylinder (10), and check the pressure on the
gauge.
WA470-7
6) Open shut off valve (11) of nitrogen gas

cylinder (10) further, to charge the
accumulator with nitrogen gas.
7) Repeat the above operations until it reaches
to the filling pressure.
8) If the pressure in the accumulator is higher
than the set pressure, open the pressure
relief valve (5) of gas charge tool ZD1 to
reduce the pressure.
9) During this operation, close shut off valve
(11) of nitrogen gas cylinder (10) from time to
time to check the nitrogen gas pressure in
the accumulator.
a For the procedure of testing nitrogen gas
pressure, see "Testing of accumulator
nitrogen gas pressure".
10)After it is charged up to the standard value,
close shut off valve (11) of nitrogen gas
cylinder (10).
When it is charged excessively, open the
pressure relief valve (5) of gas charge
tool ZD1 to reduce the pressure with shut
off valve (11) of nitrogen gas cylinder (10)
closed.
a Since the indicated value varies with the
ambient temperature, refer to the following
table and check the gas pressure.
Ambient
temperature
C
15
16
17
18
19
MPa
2.89
2.90
2.91
2.92
2.93
kg/cm2
20
2.94
30.0
21
22
2.95
2.96
30.1
30.2
Gas pressure
Remarks
29.5
29.6
29.7
29.8
29.9
Base gas
pressure
30-121

Hydraulic system
Ambient
temperature
C
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
Gas pressure
MPa
2.97
2.98
2.99
3.00
3.01
3.03
3.04
3.05
3.06
3.07
3.08
3.09
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
Remarks
kg/cm2
30.3
30.4
30.5
30.6
30.7
30.8
31.0
31.1
31.2
31.3
31.4
31.5
31.6
31.7
31.8
31.9
32.0
32.1
32.2
32.3
32.4
32.5
32.6
7. Remove gas charge tool ZD1 from the

accumulator according to the following
procedure.
1) Slowly turn handle (4) clockwise, and tighten
the hexagonal socked head bolt (3).
2) Open pressure relief valve (5), and discharge
nitrogen gas remaining in gas charge tool
ZD1 and hose.
3) Remove gas charge tool ZD1 from the filling
port of the accumulator.
10.Within a week from charging nitrogen gas,

check that no pressure drop of nitrogen gas is
found.
a Check the brake function within 5 minutes
from stop of the engine. (If more than 5
minutes elapse from stop of the engine,
correct measurement becomes unavailable
because oil pressure in the brake circuit
drops.)
1) Place the machine on a level ground and
turn the parking brake switch to the ON
position.
2) Start and run the engine at medium speed for
a minute, then stop the engine.
3) Turn the starting switch to ON position and
depress the brake pedal repeatedly to record
how many times depressing are required for
the brake oil pressure caution lamp to light
up.
Number of times of depressing is less than 5:
Accumulator gas pressure may be low
Number of times of depressing is 5 or more:
Accumulator gas pressure is normal.
8. Apply suds to the filling port of the accumulator

to make sure there is no leakage of nitrogen
gas.
9. Install hexagonal socket head bolt (3) and cap
(2) to accumulator (1).
30-122
WA470-7

Work equipment
Work equipment
(ALL-L000-001-K-00-A)
Testing and adjusting bucket position detection lever
(WA380-LEE1-001-K-00-A)
k Place

Testing
(WA470-LEE1-365-K-00-A)
1. Remove bucket positioner covers (1) and (2).
2. Make sure that clearance (a) between bucket

angle sensor (3) and detection lever (4) is within
the standard value.
Clearance (a): 0.5 to 1 mm
Adjusting
(WA470-LEE1-270-K-00-A)
a If clearance (a) does not conform to the standard

value, adjust it according to the following
procedure.
1. Loosen bolt (5).
2. Adjust position of detection lever (4) so that
clearance (a) between bucket angle sensor (3)
and detection lever (4) becomes in the specified
range. Then tighten bolt (5).
WA470-7
30-123

Work equipment
Testing and adjusting boom position detection lever
(WA380-L6WR-001-K-00-A)
k Place

Testing
(WA470-L6WR-365-K-00-A)
1. Make sure that clearance (a) between boom

angle sensor (1) and detection lever (2) is within
the standard value.
Clearance (a): 0.5 to 1 mm
Adjusting
(WA470-L6WR-270-K-00-A)
a If clearance (a) does not conform to the standard

procedure.
1. Loosen bolt (3).
2. Adjust position of detection lever (2) so that
clearance (a) between boom angle sensor (1)
and detection lever (2) becomes in the specified
range. Then tighten bolt (3).
30-124
WA470-7

Electrical system
Electrical system
(ALL-RA1D-001-K-00-A)
Adjusting replaced, reassembled or added sensor, controller, etc. with

machine monitor (WA500-RA1D-270-K-00-A)
1. Items to be set when sensor or controller is
replaced, reassembled or added
a If any of the following components and parts
is replaced or reassembled, make an initial
adjustment of the sensors, solenoids, etc.
with the machine monitor.
a For details of adjustment items (A to O), see
"Adjustment items table".
Corresponding chart of device, parts and
adjustment item
Device/Optional items replaced,
disassembled, assembled or
added
Machine monitor
Transmission
Transmission ECMV solenoid
Boom angle sensor
Work equipment EPC solenoid
Work equipment electric lever
Work equipment bucket angle
sensor
Bucket
Boom
Addition or removal of optional
item
Rearview monitor
Rearview camera
Work equipment pump
Adjustment
Contents of work
item
Adjusting reference line
N
Adjusting work equipment pump swash
O
plate
*1 See "Bucket flat level adjustment"in the
Operation section of the Operation and
maintenance manual.
*2 For setting procedures, see "Service News".
Adjustment
item
(sequence)
A, L, B
D, C, E
A, B, D, C, E
D, C, E
F, I
H
H
G
A, B, F, G, H, I
F, I
I
F, I
B
M, N
N
O
Adjustment items table

Adjustment
Contents of work
item
A
Machine Model Select
Option Select
B
Adjusting transmission ECMV electric
C
current
T/M initial learning reset
D
T/M initial learning
E
Adjustment of work equipment controller
F
boom angle
Adjustment of work equipment EPC
G
lever detent position
Adjustment of work equipment EPC
H
starting current
Setting of bucket positioner (*1)
I
Setting of service meter and travel
L
odometer (*2)
Initializing rearview monitor
M
WA470-7
30-125

Electrical system
2. Adjustment based on user's report

If the user makes the following indications or
requests which may fall in the items below,
change or adjust the items with the machine
monitor.
a For details of adjustment items (P to X), see
"Adjustment items table".
Corresponding chart of indication or request
and adjustment item
Details of indication/ request
Wants to change the display unit of the
speedometer.
Wants to suppress hunting.
Wants to change the travel speed at a
shifting point in auto shift mode.
Fine control performance or response of
boom RAISE and LOWER operation is
poor.
Fine control is poor in the bucket tilt/
dump operation or the shock dump effort
is weak.
Large shocks result at stopping the
boom RAISE and LOWER operations or
substantial overrun occurs at stopping.
Interval change of automatic fan reverse
operation is desired.
Duration change of automatic fan
reverse operation is desired.
The value of travel speed indication is
too high or low.
Change of E.C.S.S. operating travel
speed is desired.
Adjustment
item
P
Q
Q
R
S
T
U
V
W
X
Adjustment items table

Adjustment
Contents of work
item
Default setting/ selection of unit
P
Adjustment, adjustment of transmission
Q
L mode shift point
Adjustment, changing of boom lever
R
pattern
Adjustment, changing of bucket lever
S
pattern
Adjustment, changing of boom stop
T
modulation
Adjustment, changing of fan reverse
U
cycle
Adjustment, changing of fan reverse
V
duration
Option setting/changing of tire size
W
Adjustment, setting of E.C.S.S.
X
operating speed
30-126
WA470-7

Electrical system
Special functions of machine monitor
(WA500-Q170-042-K-00-A)
Machine monitor
Switch panel
(a): LCD unit
(d): Menu switch
(b): Meter unit

(c): LED unit
(e): Enter switch

(f): Return switch
When the engine is started or the self-check of

the emergency steering is taking place, the
battery voltage may drop suddenly depending
on the ambient temperature and the condition of
the battery.
In this case, the display of the machine monitor
may go out transiently or restart but this
phenomenon is not a failure.
When the starting switch passes through OFF
position in the manual preheating, the meter unit
only may re-boot (the pointer of the tachometer
makes one round-swing and "88" are displayed
on the speedometer). This phenomenon is not a
failure.
(g): Up switch
(h): Down switch
WA470-7
a In the User/ Service Menu, the switches that are

not shown in the graphic display at the bottom of
LCD unit (a) does not function.
(i) Air conditioner switch / Numeral input switches
a Air conditioner switch / numeral input switches
have 2 functions. One is graphically indicated on
the switch, and the other is numeral input
function.
a The machine monitor automatically judges which
function of each switch is currently enabled
according to the screen display of LCD unit (a).
30-127

Electrical system
Ordinary functions and special functions of machine monitor
(WA470-Q170-042-K-00-A)
The machine monitor has the ordinary functions and special functions to display the various types of
information on the LCD unit (a).
Some items are displayed automatically according to the internal setting of the machine monitor and the
others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The functions in this mode are displayed ordinarily. Display and setting of these functions are available
from the operator's switch operations.
(Display and setting of some functions require special operation of the switch.)
Operator mode (outline)

A KOMATSU logo screen(PAGE 30-130)
A Password input screen(PAGE 30-130)
A Display of standard screen(PAGE 30-130)
A Display of end screen(PAGE 30-131)
Display of operation screen for engine
A shutdown secondary switch(PAGE 30-131)
B Operation of air conditioner(PAGE 30-131)
Displaying and setting user menu(PAGE 30B 132)
C Display of ECO guidance(PAGE 30-132)
C (PAGE 30-135)
Overdue replacement item screen(PAGE 30C 137)
Display of KDPF Regeneration(PAGE 30C 137)
O (Special operation)
LCD (Liquid Crystal Display) check function
D (PAGE 30-139)
Function of checking service meter and
D odometer(PAGE 30-139)
Function of usage limitation setting/ changing
D password(PAGE 30-140)
(Special operation)
a For details of the operator mode, see Operation and Maintenance Manual.
2. Special function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by
operating the switches specially. This function is used for special setting, testing, adjusting, or
troubleshooting.
Service mode
Monitoring/ Pre-defined(PAGE 30-145)
Monitoring(PAGE 30-150)
Abnormality record (mechanical systems)(PAGE 30160)
Abnormality record (electrical systems)(PAGE 30161)
Maintenance Record(PAGE 30-163)
"Maintenance Mode Setting"(PAGE 30-164)
o Phone number entry(PAGE 30-167)

Default (Machine Model Select)(PAGE 30-168)
Default (Option Select)(PAGE 30-169)
Default (Unit)(PAGE 30-171)
Default (Rear View Monitor Setting)(PAGE 30-172)
Default (Auto Idle Stop Timer Setting)(PAGE 30176)
Testing (Cylinder Cut-out operation)(PAGE 30-177)
Testing (Regeneration for Service)(PAGE 30-178)
Testing (KDPF Memory Reset)(PAGE 30-180)
Preparations for transmission ECMV current
adjustment(PAGE 30-181)
Adjustment (T/M Initial Learning)(PAGE 30-183)
Adjustment (T/M Initial Learning Reset)(PAGE 30185)
Adjustment (T/M Shift Point)(PAGE 30-185)
Adjustment (T/M Shift Point Data Clear)(PAGE 30187)
Adjustment (Boom Angle Sensor for EPC (Raise))
(PAGE 30-188)
Adjustment (Boom Angle Sensor for EPC (Lower))
(PAGE 30-189)
Adjustment (Boom Raise Adjustment)(PAGE 30190)
30-128
WA470-7

Electrical system
Adjustment (Boom Raise Adjustment)(PAGE 30192)

Adjustment (Bucket Tilt Adjustment)(PAGE 30-194)
Adjustment (Bucket Dump Adjustment)(PAGE 30196)
Adjustment (3rd Ext Adjustment)
Adjustment (3rd Ret Adjustment)
Adjustment (J/S Right Adjustment) *1
Adjustment (J/S Left Adjustment) *1
Adjustment (PCS Adjustment(Push) *1
Adjustment (PCS Adjustment(Pull) *1
Adjustment (Change of Boom Lever Pattern)(PAGE
30-198)
Adjustment (Change of Bucket Lever Pattern)
(PAGE 30-201)
Adjustment (Boom Stop Modulation)(PAGE 30-204)
Adjustment (2-Stage Low Idle Throttle Position)
(PAGE 30-205)
Adjustment "Steering Pump Displacement" *1
Adjustment (Fan Reverse Cycle)(PAGE 30-206)
Adjustment (Fan Reverse Duration)(PAGE 30-207)
Adjustment (ECSS Operating Speed)(PAGE 30209)
Adjustment (Fan 100% Mode)(PAGE 30-210)
No Injection(PAGE 30-211)
KOMTRAX Settings (terminal setting status)(PAGE
30-212)
KOMTRAX Settings (GPS & Communication
Status)(PAGE 30-213)
KOMTRAX Settings screen (Modem Status)(PAGE
30-213)
Service Message(PAGE 30-214)
(*1): These items are not used.
a Classification of operator mode
A: Display or function that is indicated or enabled from the time when the starting switch is turned to ON
position to the time when display changes to the standard screen, and display after starting switch is
turned to OFF position
B: Display/Function when machine monitor switch is operated
C: Display/Function when certain condition is satisfied
D: Display/Function that require special operations of switches
WA470-7
30-129

Electrical system
(WA470-Q193-042-K-01-A)
a Only outline of the operator mode is described in

this section.
For details of each function and display, and
their operation, see "Structure and function ", or
the "Operation and Maintenance Manual".
a In this section, the following displays or functions
of the operator mode are explained (including
some items which need special operations).
KOMATSU logo screen(PAGE 30-130)
Password input screen (WA380-Q180-044-K-06-A)

After KOMATSU logo mark is displayed, input
screen of engine start lock password appears.
a This screen is displayed only when the engine
start lock function is enabled.
a When a correct password is input, the display
changes to the standard screen.
a The machine monitor equips with several protect
functions by passwords other than the engine
start lock. Those functions are independent from
each other.
Password input screen(PAGE 30-130)

Display of standard screen(PAGE 30-130)
Display of end screen(PAGE 30-131)
Display of operation screen for engine shutdown
secondary switch(PAGE 30-131)
Operation of air conditioner(PAGE 30-131)
Displaying and setting user menu(PAGE 30-132)
Display of ECO guidance(PAGE 30-132)
Display of warning (caution and action level)(PAGE
30-135)
Overdue replacement item screen(PAGE 30-137)
Display of KDPF Regeneration(PAGE 30-137)
O (Special operation)
LCD (Liquid Crystal Display) check function(PAGE
30-139)
Function of checking service meter and odometer
(PAGE 30-139)
password(PAGE 30-140)
a The following screen may sometimes be

displayed instead of the above Password input
screen.
a If this screen is displayed, call the person
responsible for the operation of KOMTRAX in
your Komatsu distributor and ask for remedy.
KOMATSU logo screen (HM300-Q180-044-K-00-A)

When starting switch is turned to ON position,
KOMATSU logo is displayed for 2 seconds.
a After the 2-seconds display, the screen changes
to "Password Input (if password is set)" screen
or "standard screen".
Display of standard screen (WA380-Q180-044-K-07-A)

If the machine monitor starts normally, the standard
screen is displayed.
30-130
WA470-7

Electrical system
a For the displayed items, see "Structure and

function" or "Operation and Maintenance
Manual."
Display of end screen (HM300-Q180-044-K-08-A)

Turning the starting switch to the OFF position
closes the screen.
a If a KOMTRAX message or one point advice on
ECO guidance are prepared, they are displayed
on the end screen for 5 seconds.
a The engine shutdown secondary switch is

provided on the left wall of the front console.
This switch is used to stop the engine when it
does not stop after the starting switch is turned
to OFF position.
If you turn the engine shutdown secondary switch to

OFF position, the KOMATSU logo appears once
and then the display is switched to the standard
screen.
Operation of air conditioner (WA380-K500-100-K-00-A)

Operating the air conditioner switch on the standard
screen pops up the air conditioner display, allowing
you to adjust the air conditioner.
Operating the air conditioner switch in the user
menu pops up the air conditioner adjustment screen,
allowing you to adjust the air conditioner.
Display of operation screen for engine

shutdown secondary switch (WA380-AKHL-100-K-00A)
Turning on the engine shutdown secondary switch

displays the "Engine Shutdown Secondary Switch
Activated" screen on every screen except the end
screen after 3 seconds.
WA470-7
30-131

Electrical system
a If other display is popped up by the user menu,

the air conditioner adjustment screen does not
appear and operation of the air conditioner
becomes unavailable.
a There are following items in the user menu.

ECO Guidance
Machine setting/information
KDPF regeneration
Maintenance
Monitor setting
Check message
[KOMTRAX message]
There are 2 types of KOMTRAX message; one
is for the user and the other is for the technician.
For user:
This is a user-directed message received from
the KOMTRAX base station. When this is
received, message pilot lamp is displayed on the
standard screen. Operate "Check Message" in
the user menu to read the message.
For technician:
The standard screen does not display anything
when a message for the technician is received
from the KOMTRAX base station. Operate
Service Message in the service menu to read
the message.
a For the details of user menu, see the "Operation
and Maintenance Manusl".
Display of ECO guidance (WA380-Q1L3-100-K-00-A)

When the machine remains in a certain operating
condition, the ECO Guidance is displayed
automatically to urge the operator to perform
energy-saving operation.
Displaying and setting user menu
(HM300-Q1C3-
100-K-00-A)
Press the menu switch while the standard screen is

displayed and the "User Menu" screen will appear.
a While the machine is traveling, pressing the
menu switch does not display the user menu.
If you start the machine travel while the user
menu is displayed, the display returns to the
standard screen.
a ECO Guidance appears when its display

function is enabled in the user menu.
Excessive Idling guidance
If the engine runs idle for 5 minutes or longer,
the Excessive Idling guidance is displayed on
the monitor.
a The Excessive Idling guidance disappears if
you depress the accelerator pedal or start
traveling the machine.
a The guidance is not displayed while warm up
or KDPF regeneration is in progress.
30-132
WA470-7

Electrical system
Deterrence guidance on Hydraulic Relief

Pressure Event
If hydraulic relief of work equipment
continues for 8 seconds or longer, the
guidance on Hydraulic Relief Pressure
Event is displayed.
deterrence guidance on Excessive Stepping

on Accelerator Event is displayed.
a The deterrence guidance on Excessive
Stepping on Accelerator Event
disappears automatically in 10 seconds.
a The deterrence guidance on Hydraulic

Relief Pressure Event disappears
automatically in 10 seconds.
a Hydraulic Relief Pressure Event occurs
when a fully-extended hydraulic cylinder
is extended further or a fully-retracted
hydraulic cylinder is retracted further. For
example, it occurs when the bucket
control lever is set to the TILT position
even though the bucket is fully tilted.
Guidance on Recommendation of 4th Gear
If the upshifting is suppressed due to manual
shifting or use of the shift hold switch for 30
seconds or longer while traveling in 3rd gear
and the travel speed is increases, the
deterrence guidance on Recommendation
of 4th Gear is displayed on the monitor.
a Recommendation of 4th Gear
Deterrence guidance on Dragging of Brake

Event
If the accelerator pedal is kept depressed for
3 seconds or longer while the brake is
applied during travel, the deterrence
guidance on Dragging of Brake Event is
displayed.
a It also disappears by shifting up the gear

speed switch to the 4th position.
a The guidance does not appear for 2
hours after it appeared previously even if
its display condition is satisfied.
a The deterrence guidance on Dragging of

Brake Event disappears automatically in
10 seconds.
Deterrence guidance on Excessive

Stepping on Accelerator Event
If the accelerator pedal is depressed
excessively at directional changes, the
WA470-7
Guidance on Recommendation of Lockup

If lock up is suppressed for 20 seconds or
longer due to lock up switch placed in OFF
position after the travel speed increases
enough while traveling, the guidance on
Recommendation of Lockup is displayed on
the monitor.
a The Recommendation of Lockup
30-133

Electrical system
a It disappears if the lockup switch is set to

ON.
a The guidance does not appear for 2
hours after it appeared previously even if
its display condition is satisfied.
Deterrence guidance on Excessive Digging

Event
If the machine continues digging operation
for 8 seconds or longer, the guidance on
Excessive Digging Event is displayed on
the monitor.
a The deterrence guidance on Excessive
Digging Event disappears automatically
in 10 seconds.
30-134
WA470-7

Electrical system

If the controller detects a failure on the machine, a
warning is displayed on the standard screen.
(1): Caution lamp
Action level (L01: Goes out in 2 seconds, L02 to
L04: Remains lit until the failure is eliminated)
(3): Centralized warning lamp
(4): Guidance icon
If 3 or more failure codes occurred
simultaneously, all of corresponding caution
lamp (1) are displayed repeatedly in order.
If you press enter switch (D) while guidance icon (4)

is displayed, Error List appears.
(a): Caution lamp
(b): Action level (3 digits)
(c): Failure code (5 or 6 digits)
(WA500-Q1FC-044-K-00-A)
Remedies that displayed action levels requires

operator to do (The following table is an excerpt
from the Operation and Maintenance Manual)
(d): Failure code name

(e): Message
(f): Telephone No. (if registered)
This screen appears when trouble (failure code)
occurs only if its action level is set.
The telephone number is displayed only when
the telephone number is registered in the
service mode.
If 5 or more failure codes occurred
simultaneously, the display can be changed by
using Up switch (A) or Down switch (B)
As the information of the displayed failure code
is recorded in the Abnormality Record in the
service mode, check the details in the service
mode.
Error List is replaced with the standard screen
if the machine travel is started or a switch is left
untouched for 30 seconds.
WA470-7
30-135

Electrical system
List of action levels and corresponding remedies

Degree
of
urgency
Centralized
warning
lamp
Alarm
buzzer
L04
Lights up
Sounds
continuously
Red
L03
Lights up
Sounds
intermittently
Red
L02
Lights up
Sounds
intermittently
Red
L01
Goes out
Yellow
Action
level
Color of
caution
High
I
|
|
|
|
O
Low
30-136
Remedies
Stop the machine immediately, and perform
checking and maintenance.
Check the failure code and contact your Komatsu
distributor for inspection and maintenance.
Cease the work and after moving the machine to a
safe place stopping it there, perform checking and
maintenance.
Check the failure code and contact your Komatsu
distributor for inspection and maintenance.
When an overrun-related caution is displayed,
operate the machine reducing the engine speed
and machine travel speed.
When an overheat-related caution is displayed,
stop the machine at a safe place and run the
engine at medium speed with no load.
When an emergency steering-related caution is
displayed, refrain from using the emergency
steering for a long time.
If the condition is not improved, check the failure
code and contact your Komatsu distributor for
inspection and maintenance.
Some functions may be restricted for use, but the
machine can operate. Whenever finished working,
perform the inspection and maintenance.
As needed, ask your Komatsu distributor for
inspection and maintenance.
WA470-7

Electrical system
Overdue replacement item screen
(WA380-Q180-
044-K-08-A)
If a maintenance item that is near or exceeded the

set interval, the controller displays the maintenance
caution for 30 seconds after the starting switch is
turned to ON position to urge the operator to
perform maintenance.
a The yellow caution is displayed if the remaining
time of any item before the maintenance is 30
hours (default value) or less, and the red caution
is displayed if the remaining time of any item is 0
hour or less.
a You can check the maintenance information by
pressing the menu switch while guidance icon
(a) is displayed.
a To reset the remaining time left after finishing the
maintenance, further operations are required at
the User menu.
a Perform setting and changing of the
maintenance function at the service menu.
Display of KDPF Regeneration
(WA470-A9H0-251-K-
01-A)
1. KDPF Regeneration
k The
exhaust gas temperature of this

model during KDPF regeneration may
sometimes be higher than that of the
conventional models. High temperature
may continue even after finishing the
regeneration. Do not approach the
exhaust pipe to avoid getting burned. In
addition, to prevent a fire, do not bring
any combustibles near the exhaust pipe
outlet.
WA470-7
k If
there is a thatched roof, dead leaves,

paper, or other combustibles near the
machine, set "Regeneration Disable" to
prevent a fire caused by the hightemperature exhaust gas generated
during the KDPF regeneration. For the
setting procedure, see the Operation and
Maintenance Manual.
KDPF (Komatsu Diesel Particulate Filter) is the

device for capturing soot in the exhaust gas to
clean the gas. If a certain level of soot
accumulates on the filter, KDPF automatically
starts the purification treatment of burning the
trapped soot in order to maintain the
performance of its filter in good condition. This
purification treatment is called "regeneration."
If an operation that may lower the filtering
performance of the KDPF continues for a long
period of time, the regeneration may be
performed to protect the KDPF system,
regardless the amount of the accumulated soot.
During the KDPF regeneration, KDPF pilot lamp

(1) lights up on the standard screen and idling
speed becomes approximately 1,000 rpm.
a Even if KDPF regeneration pilot lamp (1)
lights up, you can continue your work without
stopping the machine unless the KDPF soot
accumulation caution lamp (2) lights up.
30-137

Electrical system
a Although KDPF Regeneration is normally

performed automatically, it may not be able
to burn soot as intended or improve the
purifying performance sufficiently depending
on the operating conditions. In such case,
the KDPF soot accumulation caution lamp
(2) lights up. If the lamp lights up, stop the
machine at a safe place and perform the
manual stationary regeneration. For details
of the procedure, see the Operation and
Maintenance Manual.
2. Manual stationary regeneration
There are 2 levels of monitor displays to require
the manual stationary regeneration, depending
on the degree of emergency.
you continue your work despite KDPF
soot accumulation caution lamp (2) lights
up in red, it may cause the damage of the
KDPF and engine.
If you stop the machine, KDPF Regeneration

screen appears once for every 2 hours after
the occurrence. If you do not perform KDPF
Regeneration, the display is replaced with
the standard screen in 30 seconds.
k If
Be sure to perform the manual stationary

regeneration whenever KDPF soot
accumulation caution lamp (2) lights up.
1) When degree of urgency is low
When KDPF soot accumulation caution lamp
(2) lights up in yellow (Action Level (3): L01),
the following screen is displayed first.
The action level caution lamp goes out in 2

seconds and the following standard screen
appears.
30-138
a If KDPF soot accumulation caution lamp

(2) lights up in yellow, stop the machine
on a safe place after the work and
perform the manual stationary
regeneration.
2) When level of urgency is high
If KDPF soot accumulation caution lamp (2)
lights up in red (Action Level (3): L03), the
following screen is displayed.
After the machine is stopped, the screen

changes to KDPF Regeneration screen in 3
seconds. Then KDPF Regeneration screen
and standard screen with the caution lamp lit
are alternately displayed until the manual
stationary regeneration is performed.
WA470-7

Electrical system
a The engine maximum output and

maximum speed are limited to protect the
engine and KDPF system.
a The manual stationary regeneration ends
when the soot accumulation is reduced to
2 g/l maximum and approximately 35
minutes (the time varies depending of the
soot accumulation reduced in the
regeneration) has elapsed from the start
of the regeneration.
k If
the work is continued without

performing the manual stationary
regeneration and the soot quantity
exceeds the allowable limit, action
level "L04" lights up and the repair of
the machine will be required.
a If KDPF soot accumulation caution lamp

(2) lights up in red, immediately stop the
machine on a safe place and perform the
manual stationary regeneration.
LCD (Liquid Crystal Display) check

function (HM300-Q1LE-100-K-00-A)
If you perform the following operation when the
ordinary screen is displayed, entire LCD (Liquid
Crystal Display) lights up in white.
Switch operation: Press Up switch (A) while
pressing Down switch (B) and release Up switch
(A) first.
WA470-7
a The entire LCD is not turned to white when the

engine is running.
a If there is a display error in the LCD, only that
part is indicated in black.
a If you press any of Up switch (A), Down switch
(B), Return switch (C), Enter switch (D) and
Menu switch (E), the display is returned to the
original screen.
Reference: On the LCD panel sometimes, there
may be black spots (spots not lit) and bright spots
(remaining constantly lit) as one of its
characteristics.
If the number of the bright spots and black spots
does not exceed 10, the LCD panel is not faulty or
defective.
Function of checking service meter and

odometer (HM300-Q1MB-100-K-00-A)
When the following operation is performed with the
stating switch being turned to OFF position, only the
service meter and odometer are displayed.
Switch operation: Press Down switch (B) and Up
switch (A) at the same time.
30-139

Electrical system
a This operation of the switches is not

accepted until 10 minutes elapse after the
starting switch is turned to ON position.
a There is some time lag in start of the LCD, so

hold down the switches until the LCD displays
normally.
a If you release one of the switches, the monitor
goes out.
Reference: If you use the machine monitor for a
long time, bright spots (spots that remain being lit)
may appear on the screen. If the number of the
bright spots is 10 or less; the LCD panel is not faulty
or defective.
2. After the "Usage Limitation Password" screen is

displayed, input the current password by using
the numeral input switches and validate it with
the function switch.
Return switch (C): Clears input numbers/
Returns the display to the standard screen
Enter switch (D): Validates the entered
password

password (WA380-Q19X-100-K-00-A)
As a result of "Usage Limitation Setting", the
password input screen is displayed when you
perform the maintenance resetting. Set the usage
limitation according to the following procedure.
1. While the standard screen is displayed, perform
the following operation.
Switch operation: Press "5" of numeral input
switches (E) 3 times while pressing Down
switch (B).
30-140
a Default password: [000000]

a When the input password is correct, the
screen changes to the next screen.
a When the input password is incorrect, the
message to request inputting the password
again is displayed.
WA470-7

Electrical system
3. After the "Usage Limitation Setting" screen is

displayed, select a desired setting by using the
function switch.
Up switch (A): Moves your selection to the
immediate above item
Down switch (B): Moves selection to the below
item
Return switch (C): Cancels selection and returns
the display to the previous screen
Enter switch (D): Validates the selection
password with the numeral input switches (E)

and validate it with the function switch.
Return switch (C): Deletes input numbers/
Returns the display to the previous screen
password
a Default password: [000000]
a When the input password is correct, the
screen changes to the next screen.
a When the input password is incorrect, the
message to request inputting the password
again is displayed.
a Set a new password of 4 to 6 digits (If it has
only 3 or less digits or has 7 or more digits, it
is not accepted).
4. Selecting "Usage Limitation ON/OFF"

After the "Usage Limitation ON/OFF" screen is
displayed, select a desired setting using the
function switch.
OFF: Password input screen is not displayed
ON: Displays the password input screen
when you perform maintenance resetting
Up switch (A): Moves selection to the above
item
item
Return switch (C): Cancels selection and returns
the display to the previous screen
When the "Usage Limitation New Password

Input" screen is displayed again for
confirmation, input a new password with the
numeral input switches (E) and validate it
with the function switch.
Returns the display to the standard screen
password
a The password for the Usage Limitation and

the engine start lock password are not
identical.
5. Changing a password
After the "Usage Limitation New Password
Input" screen is displayed, input a new
WA470-7
30-141

Electrical system
a If the input password is different from the one

input before, the message to request
inputting again is displayed.
If the usage limitation screen is displayed

after the screen to notify completion of
setting is displayed, the password is
changed successfully.
30-142
WA470-7

Electrical system
Service mode
(WA470-Q194-100-K-00-A)
To change the operator mode to the service mode,

perform the following operation.
This operation is always required when you use the
service mode.
1. Checking of display of screen, and switch
operation
While the standard screen is displayed, perform
the following switch operations.
Switch operation: While pressing Down switch
(B), press air conditioner/ numeral input
switches (E) "1" o "2" o "3" in order.
a This switch operation is accepted only while
the standard screen is displayed.
2. Selecting the service menu

When Service Menu screen is displayed, the
service mode is selected. Select a desired
service menu.
Up switch (A): Moves the selection up by one
item
Down switch (B): Moves the selection down by
one item
Return switch (C): Returns the display to the
standard screen (operator mode)
a If you enter a 2-digit item number with the
numeral input switches (E), the entered item
is directly selected.
WA470-7
a The following shows the items selectable on

Service Menu screen (including some items
which need special operations).
No.
Menu items
01 Monitoring/ Pre-defined(PAGE 30-145)
02 Monitoring(PAGE 30-150)
Abnormality record (mechanical systems)
(PAGE 30-160)
03 Abnormality record (electrical systems)(PAGE
30-161)
04 Maintenance Record(PAGE 30-163)
05 "Maintenance Mode Setting"(PAGE 30-164)
06 Phone number entry(PAGE 30-167)
Default (Machine Model Select)(PAGE 30168)
Default (Option Select)(PAGE 30-169)
Default (Unit)(PAGE 30-171)
07
Default (Rear View Monitor Setting)(PAGE
30-172)
Default (Auto Idle Stop Timer Setting)(PAGE
30-176)
Testing (Cylinder Cut-out operation)(PAGE
30-177)
08 Testing (Regeneration for Service)(PAGE 30178)
Testing (KDPF Memory Reset)(PAGE 30-180)
adjustment(PAGE 30-181)
Adjustment (T/M Initial Learning)(PAGE 30183)
Adjustment (T/M Initial Learning Reset)
(PAGE 30-185)
Adjustment (T/M Shift Point)(PAGE 30-185)
Adjustment (T/M Shift Point Data Clear)
(PAGE 30-187)
09 Adjustment (Boom Angle Sensor for EPC
(Raise))(PAGE 30-188)
Adjustment (Boom Angle Sensor for EPC
(Lower))(PAGE 30-189)
Adjustment (Boom Raise Adjustment)(PAGE
30-192)
Adjustment (Boom Raise Adjustment)(PAGE
30-192)
Adjustment (Bucket Tilt Adjustment)(PAGE
30-194)
30-143

Electrical system
No.
Menu items
Adjustment (Bucket Dump Adjustment)(PAGE
30-196)
Adjustment (3rd Ext Adjustment) *1
Adjustment (3rd Ret Adjustment) *1
Adjustment (J/S Right Adjustment) *1
Adjustment (J/S Left Adjustment) *1
Adjustment (PCS Adjustment(Push) *1
Adjustment (PCS Adjustment(Pull) *1
Adjustment (Change of Boom Lever Pattern)
(PAGE 30-198)
(PAGE 30-201)
Adjustment (Boom Stop Modulation)(PAGE
30-204)
Adjustment (2-Stage Low Idle Throttle
Position)(PAGE 30-205)
Adjustment "Steering Pump Displacement" *1
Adjustment (Fan Reverse Cycle)(PAGE 30206)
Adjustment (Fan Reverse Duration)(PAGE
30-207)
Adjustment (ECSS Operating Speed)(PAGE
30-209)
Adjustment (Fan 100% Mode)(PAGE 30-210)
10 No Injection(PAGE 30-211)
KOMTRAX Settings (terminal setting status)
(PAGE 30-212)
11 Status)(PAGE 30-213)
KOMTRAX Settings screen (Modem Status)
(PAGE 30-213)
12 Service Message(PAGE 30-214)
a The items written in ( ) are the menus on the
next hierarchy to Survice Menu screen.
30-144
WA470-7

Electrical system
Monitoring/ Pre-defined (WA500-Q1S1-100-K-00-A)

The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
various parts of the machine and the information
from the controllers which is controlling switches,
etc.
In the "Monitoring/ Pre-defined", frequently used
monitoring items in daily work are selected
beforehand.
1. Selecting menu
Select Monitoring/Pre-defined on Service
Menu screen.
a For the items not displayed in Monitoring/
Pre-defined, you can freely select and check
from Monitoring/Custom items.
2. Checking Monitoring/Pre-defined information

Monitoring/Pre-defined screen displays the
following information and allows switching
among the monitoring items.
(a): Monitoring information
(b): Power mode pilot lamp
(c): Shift indicator
(d): Engine coolant temperature
(e): Torque converter oil temperature
(f): Hydraulic oil temperature
(g): Fuel level
(h): Current number of pages / total number of
pages
Up switch (A): Moves selection to the previous
page (screen)
Down switch (B): Moves selection to the next
page (screen)
Return switch (C): Returns to the service menu
Enter switch (D): Validates your selection
Menu switch (E): Switches between the Hold
and the Releasing hold
(If the Hold is selected, a diagonal line appears
on the HOLD portion.)
WA470-7
30-145

Electrical system
List of Monitoring/ Pre-defined items

(SI unit is the default value)
Monitoring/ Pre-defined screen (1/16) Machine basics 1
No.
ID
1
2
3
4
5
6
01002
04107
37200
03203
30100
04401
Monitoring item
Engine Speed
Coolant Temperature
Engine Oil Pressure
Battery Power Supply
T/C Oil Temperature
Hydr. Oil Temperature
Unit (SI)
r/min
C
kPa
V
C
C
Applicable
component
ENG
ENG
ENG
T/M
T/M
T/M
Monitoring/ Pre-defined screen (2/16) Machine basics 2

No.
ID
1
2
3
4
5
6
01002
48400
47300
36500
18500
18400
Monitoring item
Engine Speed
Crankcase Pressure
KDOC 1 Inlet Temperature
Charge Pressure-A
Charge Temperature
Intake Temperature
Unit (SI)
r/min
kPa
C
kPa
C
C
Applicable
component
ENG
ENG
KDPF
ENG
ENG
ENG
Monitoring/ Pre-defined screen (3/16) Engine fuel injection system

No.
ID
1
2
3
4
5
01002
47300
36400
36200
17201
Monitoring item
Engine Speed
Rail Pressure
Rail Pressure Command
PCV Close Timing
Unit (SI)
r/min
C
MPa
MPa
CA
Applicable
component
ENG
KDPF
ENG
ENG
ENG
Monitoring/ Pre-defined screen (4/16) Engine, EGR, KVGT actuator

No.
ID
1
2
3
4
5
6
01002
48100
18100
48600
48700
48800
Monitoring item
Engine Speed
Turbo Speed
EGR Valve Position
EGR Solenoid Current
KVGT Position
KVGT Solenoid Current
Unit (SI)
r/min
r/min
mm
mA
mm
mA
Applicable
component
ENG
ENG
ENG
ENG
ENG
ENG
Monitoring / Pre-defined screen (5/16) Engine temperature system

No.
ID
1
2
3
4
5
01002
48100
04107
18400
18500
30-146
Monitoring item
Engine Speed
Turbo Speed
Coolant Temperature
Intake Temperature
Charge Temperature
Unit (SI)
r/min
r/min
C
C
C
Applicable
component
ENG
ENG
ENG
ENG
ENG
WA470-7

Electrical system
Monitoring/ Pre-defined screen (6/16) Engine intake and exhaust pressure system
No.
ID
1
2
3
4
5
01002
37400
36500
48100
48200
Monitoring item
Engine Speed
Ambient Pressure
Charge Pressure-A
Turbo Speed
Mass Air Flow
Unit (SI)
r/min
kPa
kPa
r/min
kg/min
Applicable
component
ENG
ENG
ENG
ENG
ENG
Monitoring/ Pre-defined screen (7/16) Engine post-treatment system

No.
ID
1
2
3
4
5
6
47000
47100
47200
47300
47400
47600
Monitoring item
KDPF Outlet Pressure
KDPF Delta Pressure
KDPF 1 Outlet Temperature
KDOC 1 Outlet Temperature
Dosing Fuel Pressure
Unit (SI)
kPa
kPa
C
C
C
kPa
Applicable
component
KDPF
KDPF
KDPF
KDPF
KDPF
KDPF
Monitoring/ Pre-defined screen (8/16) Engine

No.
ID
1
2
3
4
5
6
01002
37200
48400
47300
36500
48100
Monitoring item
Engine Speed
Engine Oil Pressure
Crankcase Pressure
Charge Pressure-A
Turbo Speed
Unit (SI)
r/min
kPa
kPa
C
kPa
r/min
Applicable
component
ENG
ENG
ENG
KDPF
ENG
ENG
Monitoring/ Pre-defined screen (9/16) Work equipment, power train hydraulic system
No.
ID
1
2
3
4
5
01002
32601
32603
95302
94700
Monitoring item
Engine Speed
T/C Input Oil Pressure
T/C Output Oil Pressure
Steering Pump Pressure
Loader Pump Pressure
Unit (SI)
r/min
MPa
MPa
MPa
MPa
Applicable
component
ENG
T/M
T/M
BBC
BBC
Monitoring/ Pre-defined screen (10/16) Transmission clutch operation system

No.
ID
1
2
3
4
5
6
41802
41803
41804
41805
41806
41808
WA470-7
Monitoring item
Fill Time (1st)
Fill Time (2nd)
Fill Time (3rd)
Fill Time (4th)
Fill Time (Reverse)
Fill Time (Forward)
Unit (SI)
msec
msec
msec
msec
msec
msec
Applicable
component
T/M
T/M
T/M
T/M
T/M
T/M
30-147

Electrical system
Monitoring / Pre-defined screen (11/16) Transmission clutch operation system

No.
ID
1
2
3
4
5
6
31602
31603
31604
31605
31606
31608
Monitoring item
ECMV Current (1st)
ECMV Current (2nd)
ECMV Current (3rd)
ECMV Current (4th)
ECMV Current (Reverse)
ECMV Current (Forward)
Unit (SI)
mA
mA
mA
mA
mA
mA
Applicable
component
T/M
T/M
T/M
T/M
T/M
T/M
Monitoring / Pre-defined screen (12/16) Transmission clutch operation system

No.
ID
1
2
3
4
5
6
01002
31609
32500
41201
41203
30202
Monitoring item
Engine Speed
ECMV Current (Lockup)
T/M Oil Temperature
Brake Oil Pressure
Brake Cut Off Pressure
Brake Oil Temperature
Unit (SI)
r/min
mA
C
MPa
MPa
C
Applicable
component
ENG
T/M
T/M
T/M
T/M
MON
Monitoring/ Pre-defined screen (13/16) EPC

No.
ID
1
2
3
4
5
41900
41901
41902
41903
04306
Monitoring item
Boom Raise EPC Current
Boom Lower EPC Current
Bucket Tilt EPC Current
Bucket Dump EPC Current
Battery Charge Volt (MON)
Unit (SI)
mA
mA
mA
mA
V
Applicable
component
BBC
BBC
BBC
BBC
MON
Monitoring/ Pre-defined screen (14/16) Steering

No.
ID
1
2
3
04401
95302
95600
Monitoring item
Steering Pump EPC Current
Unit (SI)
C
MPa
mA
Applicable
component
T/M
BBC
BBC
Monitoring/ Pre-defined screen (15/16) Hydraulic fan (1)

No.
ID
1
2
3
4
5
6
01002
04107
04401
30100
10007
10009
Monitoring item
Engine Speed
Coolant Temperature
T/C Oil Temperature
Radiator Fan Speed Command
Radiator Fan Speed
Unit (SI)
r/min
C
C
C
r/min
r/min
Applicable
component
ENG
ENG
T/M
T/M
T/M
T/M
Monitoring/ Pre-defined screen (16/16) Hydraulic fan (2)

No.
ID
1
2
3
4
5
01002
10007
10009
41400
31646
30-148
Monitoring item
Engine Speed
Radiator Fan Speed
Rad. Fan Pump EPC Sol. Current
Fan Reverse Solenoid Current
Unit (SI)
r/min
r/min
r/min
mA
mA
Applicable
component
ENG
T/M
T/M
T/M
T/M
WA470-7

Electrical system
a Applicable component
ENG: The engine controller is in charge of detecting the monitoring information.
KDPF: The engine controller is in charge of detecting the monitoring information.
T/M: The transmission controller is in charge of detecting the monitoring information.
BBC: The work equipment controller is in charge of detecting the monitoring information.
MON: The monitor controller is in charge of detecting the monitoring information.
WA470-7
30-149

Electrical system
Monitoring (WA380-Q19L-100-K-00-A)
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
various parts of the machine and the information
from the controllers which is controlling switches,
etc.
The monitoring function allows you to select a
desired monitoring item.
1. Selecting menu
Select Monitoring/Custom on Service Menu
screen.
a Selection with switch operation: Select the

component in charge with menu switch (E),
select the item with Up switch (A) or Down
switch (B) and validate your selection with
the enter switch (D).
a Selection through entry of a monitoring code:
If you input a monitoring code (5 digit) using
numeral input switches (F), the target item is
selected directly. So validate it with the enter
switch (D).
a If the color of the selected box changes from
yellow to red, the selection of the item of that
box is entered.
a Up to 6 monitoring items are selectable at a
time. However, all the six items may not be
selected depending on the condition of
display of the selected item.
2. Selecting monitoring item

When the Monitoring Selection Menu screen is
displayed, select the item to monitor.
UP switch (A): Moves the selection up by one
item.
DOWN switch (B): Moves the selection down by
one item
Returns the display to Service Menu screen
Menu switch (E): Moves your selection to the
immediate right item
3. Deciding monitoring items

After selecting monitoring items, execute the
monitoring according to the following operations.
Switch operation: Double-click the enter
switch (D).
Or hold down the enter switch (D) (for
approximately 2 seconds).
Or enter [99999] by using numeral input
switch (F) and press the enter switch.
a If monitoring items are selected up to the limit
number, monitoring is executed
automatically.
a In setting of the monitoring, each time menu

switch (E) is pressed, sequential switching
among "ENG"o"KDPF"o"T/
M"o"BBC"o"MON"o" ENG" takes place in
this order.
30-150
WA470-7

Electrical system
4. Performing monitoring
After the Monitoring screen is displayed,
perform the necessary operation of the machine
and check the monitoring information.
Monitoring screen displays the following
information.
(a): Monitoring information
(b): Power mode pilot lamp
(c): Shift indicator
(d): Engine coolant temperature
(e): Torque converter oil temperature
(f): Hydraulic oil temperature
(g): Fuel level
Up switch (A): MEMORY (saves the selected

item)
Down switch (B): CLEAR (clears the selected
item)
a Monitoring information is indicated by value,

ON/OFF, or special display.
a The unit to be displayed can be set to SI or
Non-SI with the Default function in the
service mode.
a When a monitoring item is saved, a

confirmation screen appears asking whether
the saved item should be displayed or not,
when Monitoring is selected again.
a When an item is saved, it can be displayed
as many times as required unless it is
cleared.
a If another item is saved while having the
previous item saved, the previously saved
item is overwritten by the latest one.
5. Holding monitoring information

In the monitoring information, Hold and Hold
releasing can be made.
(If the Hold is selected, a diagonal line is drawn
Monitoring Selection Menu screen
a The saved monitoring item can be cleared by

the Down switch, and by the following setting
change as well. Validating operation also
clears the selected item.
Default (Machine Model Select)
Default (Option Select)
6. Saving of monitoring item

A selected monitoring item can be saved or
cleared.
WA470-7
30-151

Electrical system
Table of Monitoring items
(WA470-Q19L-208-K-00-A)
Code
No.
Monitoring item (Display on screen)
00201
20216
20217
18900
20400
01002
36700
31701
03000
17500
36400
36401
36200
04107
04105
37200
37201
37400
37401
36500
36501
03203
37300
31706
18400
18401
18500
18501
18100
18101
18300
18301
18600
17201
18700
08402
48400
48401
48100
48200
48700
48701
48600
48800
48900
47000
47001
47100
47101
47200
Machine ID
ECM Build Version
Calibration Data Version
ECM Internal Temp
ECM S/N
Engine Speed
Engine Torque Ratio
Throttle Position
Throttle Position Sensor Volt
Engine Power Mode
Rail Pressure
Rail Pressure Sensor Volt
Rail Pressure Command
Coolant Temperature
Coolant Temp Sensor Volt
Engine Oil Pressure
Eng Oil Pressure Sensor Volt
Ambient Pressure
Ambient Pressure Sensor Volt
Charge Pressure-A
Charge Pressure Sensor Volt
Battery Power Supply
Fuel Rate
Final Throttle Position
Intake Temperature
Intake Temp Sensor Volt
Charge Temperature
Charge Temp Sensor Volt
EGR Valve Position
EGR Valve Pos Sensor Volt
Idle Validation Sw 1
Idle Validation Sw 2
Inject Fueling Command
PCV Close Timing
Engine Output Torque
Droop switch
Crankcase Pressure
Crankcase Pressure Sens Volt
Turbo Speed
Mass Air Flow
KVGT Position
KVGT Position Sensor Volt
EGR Solenoid Current
KVGT Solenoid Current
Engine Operation Mode
KDPF Outlet Pressure
KDPF Out Pressure Sensor Volt
KDPF Delta Pressure
KDPF Delta Press. Sensor Volt
KDPF 1 Outlet Temperature
30-152
Unit (Default: SI)

SI
C
r/min
%
%
V
MPa
V
MPa
C
V
kPa
V
kPa
V
kPa
V
V
l/h
%
C
V
C
V
mm
V
mg/st
CA
Nm
kPa
V
r/min
kg/min
mm
V
mA
mA
kPa
V
kPa
V
C
Applicable
compoNon-SI
nent
ENG
ENG
ENG
F
ENG
ENG
rpm
ENG
%
ENG
%
ENG
V
ENG
ENG
psi
ENG
V
ENG
psi
ENG
F
ENG
V
ENG
psi
ENG
V
ENG
psi
ENG
V
ENG
psi
ENG
V
ENG
V
ENG
gal/h
ENG
%
ENG
F
ENG
V
ENG
F
ENG
V
ENG
in
ENG
V
ENG
ENG
ENG
mg/st
ENG
CA
ENG
lbft
ENG
ENG
psi
ENG
V
ENG
rpm
ENG
lb/min
ENG
in
ENG
V
ENG
mA
ENG
mA
ENG
ENG
psi
KDPF
V
KDPF
psi
KDPF
V
KDPF
F
KDPF
Remarks
WA470-7

Electrical system
Code
No.
47201
47300
47301
47400
47401
47500
47600
47601
47700
41600
31200
31400
10009
10007
30100
30101
04401
04404
32500
32501
32601
32602
32603
32604
41201
41202
41203
93700
93501
91105
31602
31603
31604
31605
31606
31608
KDPF 1 Outlet Temp Sens Volt

KDOC 1 Inlet Temp Sens Volt
KDOC 1 Outlet Temperature
KDOC 1 Outlet Temp Sens Volt
Dosing Fuel Rate
Dosing Fuel Pressure
Dosing Fuel P Sens Volt
Soot Level Estimation
Engine Power Mode
T/M Input Shaft Speed
T/M Output Shaft Speed
Radiator Fan Speed
T/C Oil Temperature
T/C Oil Temp. Sensor Volt
Hydr. Temp. Sensor Volt
T/M Oil Temperature
T/M Oil Temp. Sensor Volt
T/C Input Oil Pressure
T/C In. Oil Press Sensor Volt
T/C Output Oil Pressure
T/C Out. Oil Press Sensor Volt
Brake Oil Pressure
Brake Oil Press Sensor Volt
Brake Cut Off Pressure
T/C Speed Ratio
T/C Output Shaft Torque
Shift Lever Volt
ECMV Current (1st)
ECMV Current (2nd)
ECMV Current (3rd)
ECMV Current (4th)
ECMV Current (Reverse)
ECMV Current (Forward)
Unit (Default: SI)

SI
V
C
V
C
V
l/h
kPa
V
g/l
r/min
r/min
r/min
r/min
C
V
C
V
C
V
kPa
V
kPa
V
kPa
V
kPa
%
Nm
V
mA
mA
mA
mA
mA
mA
Applicable
compoNon-SI
nent
V
KDPF
F
KDPF
V
KDPF
F
KDPF
V
KDPF
gal/h
KDPF
psi
KDPF
V
KDPF
g/gal
KDPF
T/M
rpm
T/M
rpm
T/M
rpm
T/M
rpm
T/M
F
T/M
V
T/M
F
T/M
V
T/M
F
T/M
V
T/M
psi
T/M
V
T/M
psi
T/M
V
T/M
psi
T/M
V
T/M
psi
T/M
%
T/M
lbft
T/M
V
T/M
mA
T/M
mA
T/M
mA
T/M
mA
T/M
mA
T/M
mA
T/M
31609 ECMV Current (Lockup)
mA
mA
T/M
93300 ECSS Current
mA
mA
T/M
mA
mA
msec
msec
msec
mA
mA
msec
msec
msec
T/M
T/M
T/M
T/M
T/M
T/M
T/M
T/M
T/M
T/M
T/M
41400
31646
38902
38903
38904
38905
38906
38907
41802
41803
41804
WA470-7
Rad. Fan Pump EPC Sol. Current

Fan Reverse Solenoid Current
Trigger Compensation (1st)
Trigger Compensation (2nd)
Trigger Compensation (3rd)
Trigger Compensation (4th)
Trigger Compensation (Reverse)
Trigger Compensation (Forward)
Fill Time (1st)
Fill Time (2nd)
Fill Time (3rd)
Remarks
Displays only when optional

setting is enabled.
setting is enabled.
30-153

Electrical system
Code
No.
Fill Time (4th)

Fill Time (Reverse)
Fill Time (Forward)
Throttle Lower Limit Command
Throttle Higher Limit Command
Throttle Adjustment Command
Dynamic Torque Command
T/M Initial Learning Status
F Clutch
R Clutch
94100 1st Clutch
2nd Clutch
3rd Clutch
4th Clutch
Clutch Fill SW Input
F Clutch
R Clutch
02216 1st Clutch
2nd Clutch
3rd Clutch
4th Clutch
T/M Con. SW Input 1
Main FNR Signal F
Main FNR Signal N
Main FNR Signal R
41805
41806
41808
44201
44200
36000
17302
02211
02214
30-154
Applicable
compoSI
Non-SI
nent
msec
msec
T/M
msec
msec
T/M
msec
msec
T/M
%
%
T/M
%
%
T/M
%
%
T/M
%
%
T/M
T/M
ON/OFF
T/M
ON/OFF
T/M
ON/OFF
T/M
ON/OFF
T/M
ON/OFF
T/M
ON/OFF
T/M
T/M
ON/OFF
T/M
ON/OFF
T/M
ON/OFF
T/M
ON/OFF
T/M
ON/OFF
T/M
ON/OFF
T/M
T/M
ON/OFF
T/M
ON/OFF
T/M
ON/OFF
T/M
Option FNR Signal F
ON/OFF
T/M
Option FNR Signal N
ON/OFF
T/M
Option FNR Signal R
ON/OFF
T/M
T/M Con. SW Input 2

Shift Lever 1
Shift Lever 2
02212 Shift Lever 3
Shift Lever 4
Kick Down Switch
Hold Switch
T/M Con. SW Input 3
02213
Unit (Default: SI)
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
T/M
Shift Down Switch N. O.
ON/OFF
T/M
Shift Mode Switch Manual

Shift Mode Switch H.
T/M Con. SW Input 4
Starter Status
ON/OFF
ON/OFF
ON/OFF
T/M
T/M
T/M
T/M
ECSS Switch
ON/OFF
T/M
Lock Up Switch
ON/OFF
T/M
T/M Cut Off Switch
ON/OFF
T/M

setting is enabled.
setting is enabled.
setting is enabled.
T/M
T/M
T/M
T/M
T/M
T/M
T/M
T/M
Shift Up Switch N. O.
Remarks

setting is enabled.
setting is enabled.

setting is enabled.
setting is enabled.
WA470-7

Electrical system
Code
No.

T/M Cut Off Set Switch
Unit (Default: SI)
Applicable
compoSI
Non-SI
nent
ON/OFF
T/M
Option FNR Switch

T/M Con. SW Input 5
Parking Brake Switch
T/M Con. Switch Output 1
Neutral Safety Relay
T/M Cut Off Indicator
Backup Lamp Relay
T/M Con. Switch Output 2
Parking Brake Relay
Assembly P/N (T/M Con.)
Serial No. (T/M Con.)
Software P/N (T/M Con.)
Application Version (T/M Con.)
Data Version (T/M Con.)
Boom Angle
Boom Angle Sensor Volt
Bucket Link Angle
Bucket Link Angle Sensor Volt
Bucket Tilt Set Angle
Tilt Cylinder Stroke
Steering Pump Pres. Sensor Volt
Emerg. Steering Pressure
Emerg. Steering Press S. Volt
Loader Pump Pressure
Loader Pump Pres. Sensor Volt
Loader Pump MAX. Flow
Boom Bottom Pressure
Boom Bottom Pres. Sensor Volt
ON/OFF
-
T/M
-
deg
V
deg
V
deg
mm
MPa
V
MPa
V
MPa
V
cc/rev
MPa
V
deg
V
deg
V
deg
in
psi
V
psi
V
psi
V
cc/rev
psi
V
T/M
T/M
T/M
T/M
T/M
T/M
T/M
T/M
T/M
T/M
T/M
T/M
T/M
BBC
BBC
BBC
BBC
BBC
BBC
BBC
BBC
BBC
BBC
BBC
BBC
BBC
BBC
BBC
MPa
psi
BBC
BBC
V
V
%
%
V
V
%
%
V
V
%
%
V
V
%
%
BBC
BBC
BBC
BBC
BBC
BBC
BBC
BBC
42006 3rd Lever Volt (Main)
BBC
42007 3rd Lever Volt (Sub)
BBC
02215
03705
03706
20414
20413
20201
20223
20224
06002
06005
55600
55601
55700
55800
95302
95303
07703
07705
94700
94701
94702
40400
40402
40500 Boom Head Pressure

40501 Boom Head Pres. Sensor Volt
42000
42001
42104
55900
42002
42003
42106
55901
WA470-7
Boom Lever Volt (Main)

Boom Lever Volt (Sub)
Boom Lever Stroke
Boom Speed Command
Bucket Lever Volt (Main)
Bucket Lever Volt (Sub)
Bucket Lever Stroke
Bucket Speed Command
ON/OFF
-
ON/OFF
ON/OFF
ON/OFF
ON/OFF
Remarks

setting is enabled.

setting of load meter is
enabled.
setting of load meter is
enabled.
Displays according to the

optional setting of work
equipment control
equipment control
30-155

Electrical system
Code
No.
Unit (Default: SI)

SI
Applicable
compoNon-SI
nent
42107 3rd Lever Stroke
BBC
55902 3rd EPC Speed Command
BBC
42004 Bucket Lever Volt (Main)
BBC
42005 Bucket Lever Volt (Sub)
BBC
42110
BBC
BBC
mA
mA
mA
mA
mA
mA
mA
mA
BBC
BBC
BBC
BBC
41906 3rd Extend EPC Current
mA
mA
BBC
41907 3rd Retract EPC Current
mA
mA
BBC
41904 J/S R. H. EPC Current
mA
mA
BBC
41905 J/S L. H. EPC Current
mA
mA
BBC
94500 Loader Pump EPC Current

95600 Steering Pump EPC Current
94900 Work Status
BBC Output 1
Work Equipment Lock Sol.
03707 Work Equipment Lock Ind.
Bucket Tilt Detent Sol.
Boom Detent Sol.
mA
mA
mA
mA
ON/OFF
ON/OFF
ON/OFF
ON/OFF
BBC
BBC
BBC
BBC
BBC
BBC
BBC
BBC
J/S Lever Stroke
55905 J/S Speed Command

41900
41901
41902
41903
Boom Raise EPC Current

Boom Lower EPC Current
Bucket Tilt EPC Current
Bucket Dump EPC Current
BBC Output 2
03708 Emergency S/T Press SW

J/S Solenoid Cut Relay
BBC Input 1
Key SW C
02217
Eng. Power Mode Switch
Work Equipment Lock SW
"BBC Input 2"
02218 Boom Positioner Set SW
Bucket Positioner Set SW
BBC Input 3
Emergency Steering SW
BBC
ON/OFF
BBC
ON/OFF
BBC
ON/OFF
BBC
BBC
BBC
BBC
BBC
BBC
BBC
BBC
BBC
02219 Quick Coupler Release SW
ON/OFF
BBC
Quick Coupl. Rel. SW OFF

BR Signal
ON/OFF
ON/OFF
BBC
BBC
30-156
ON/OFF
ON/OFF
ON/OFF
-
ON/OFF
ON/OFF
Remarks
equipment control
equipment control
setting is enabled.
setting is enabled.
setting is enabled.
setting is enabled.

equipment control
equipment control
setting is enabled.
setting is enabled.

setting is enabled.
setting is enabled.

setting is enabled.
WA470-7

Electrical system
Code
No.
20416
20415
20202
20225
20226
01001
40000
04200
04201
04202
30202
30205
40300
55400
55401
03220
04306
Assembly P/N (BBC)

Serial No. (BBC)
Software P/N (BBC)
Application Version (BBC)
Data Version (BBC)
Engine Speed (Tachometer)
Travel Speed (Speedometer)
Fuel Level Sensor Volt
Fuel Level Sensor Resistance
Fuel Level
Brake Oil Temperature
Brake Oil Temp. Sensor Volt
Battery Liquid Level Sensor
Tachograph Output Pulse
Speed Recorder Output Pulse
Controller Battery Volt (MON)
Battery Charge Volt (MON)
Monitor Input 1
Right Turn Signal
Left Turn Signal
Head Light SW
High Beam Status
Night Lighting SW
Daytime Lighting SW
Monitor Input 2
Seat Belt SW
Engine Starter
ENG Shutdown Secondary
Preheater Relay
Monitor Input 3
Air Cleaner Clog Sig
Coolant Level Sensor
Monitor Input 4
Front Brake Oil Press
Rear Brake Oil Press
Parking Brake Press SW
Eng Oil Pressure Sensor Volt
Monitor 1st & 2nd Row SW
SW1
SW2
SW3
SW4
SW5
SW6
Monitor 3rd & 4th Row SW
SW7
SW8
SW9
SW10
SW11
SW12
04507
04508
04509
04510
04504
04505
WA470-7
Unit (Default: SI)
Applicable
compoSI
Non-SI
nent
BBC
BBC
BBC
BBC
BBC
r/min
r/min
MON
km/h
MPH
MON
V
V
MON
MON
1z
1z
%
%
MON
C
F
MON
V
V
MON
V
V
MON
Hz
Hz
MON
Hz
Hz
MON
V
V
MON
V
V
MON
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
MON
ON/OFF
MON
ON/OFF
MON
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
Remarks
30-157

Electrical system
Code
No.
04506
04700
00205
20227
20402
20228
20221
20278
20279
55300
55000
55001
55100
55101
55200
55201
20266
20421
20267
20268

Monitor 5th Row SW
SW13
SW14
SW15
Monitor Output
Buzzer
Personal Code Relay
Selected Model (MON)
Assembly P/N (MON)
Serial No. (MON)
Software P/N (MON)
Application Version (MON)
Data Version 1 (MON)
Data Version 2 (MON)
Aircon Compressor Status
Aircon Outside Temp. Code
Aircon Outside Temp.
Aircon Inside Temp. Code
Aircon Inside Temp.
Aircon Mode Data (MON)
Aircon Mode Data (Aircon ECU)
Assembly P/N (Rearview Mon.)
Serial No. (Rearview Mon.)
Software P/N (Rearview Mon.)
Software Version(Rearview Mon.)
Unit (Default: SI)
Applicable
compoSI
Non-SI
nent
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
MON
ON/OFF
MON
ON/OFF
MON
MON
MON
MON
MON
MON
MON
MON
ON/OFF
MON
MON
C
F
MON
MON
C
F
MON
MON
MON
MON
MON
MON
MON
20260 Assembly P/N (KOMTRAX)
MON
20418 Serial No. (KOMTRAX)
MON
20261 Software P/N (KOMTRAX)
MON
20273 Program Version (KOMTRAX)
MON
20262 Assembly P/N (ID Key Con.)
MON
20419 Serial No. (ID Key Con.)
MON
20263 Software P/N (ID Key Con.)
MON
Remarks

setting of KOMTRAX
terminals is enabled.
setting of KOMTRAX
setting of KOMTRAX
setting of KOMTRAX
Displays only when ID Key
Con. is connected
Con. is connected
Con. is connected
a Listing order in the table of monitoring items

The monitoring items are listed in the order of the display on the monitoring item selection menu screen.
a Unit
SI or Non-SI is selectable for the unit displayed on the screen.
(Switch of the displayed unit is made by using Unit of Defoult of the service menu.)
"mg/st" in the unit indicates the mass per stroke (milligram/stroke).
30-158
WA470-7

Electrical system
a Applicable component
ENG: The engine controller is in charge of detecting the monitoring information.
KDPF: The engine controller is in charge of detecting the monitoring information.
T/M: The transmission controller is in charge of detecting the monitoring information.
BBC: The work equipment controller is in charge of detecting the monitoring information.
MON: The monitor controller is in charge of detecting the monitoring information.
Note 1: Fuel Rate (Code No.: 37300) is the theoretical fuel consumption ratio. (Since it is a theoretical value,
it is slightly different from the actual fuel consumption ratio).
WA470-7
30-159

Electrical system
Abnormality record (mechanical

systems) (WA380-Q1S2-100-K-00-A)
The machine monitor logs the past and currently
occurring failures classifying them into the
mechanical system abnormality and electrical
system abnormality.
To check the mechanical system abnormality record,
perform the following procedures.

a For the failure code list, see "40 Failure code list
for troubleshooting".
1. Selecting menu
Select "Abnormality Record" on the "Service
Menu" screen.
2. Selecting sub menu

When the "Abnormality Record" screen is
displayed, select "Mechanical Systems".
item
item
service menu screen
3. Information displayed on "Abnormality Record"

screen
On the "Mechanical Systems" abnormality
record screen, the following information is
displayed.
(a): Occurrence order of abnormalities from
latest one/ Total number of abnormalities in the
log
(b): Failure code
(c): Detail of failure
(d): Number of occurrences (displayable range:
0 to 65,535 times)
(e): Service meter reading at first occurrence
(f): Service meter reading at last occurrence
Up switch (A): Moves the display to the previous
page (screen)
(if abnormality record extends to multiple pages)
Down switch (B): Move the display to the next
page (screen)
(if abnormality record extends to multiple pages)
Return switch (C): Return to the "Abnormality
Record" screen
a If no abnormality is recorded, "No Error" is
displayed.
a In the mechanical systems abnormality
record screen, up to 50 cases currently
stored are displayed.
30-160
WA470-7

Electrical system
a If the number of occurrence is 1 (first

occurrence), the service meter reading at the
first occurrence and that at the last
occurrence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or correction
of it is not confirmed.
a An abnormality record of the mechanical
system cannot be deleted.

one item
Return switch (C): Returns to the Service Menu
screen
a If you enter a 2 digit item number with the
numeral input switches (F), the entered item
a For all of the failure codes that the machine

monitor can record, see the failure code list.
Abnormality record (electrical

systems) (WA380-Q1S3-100-K-00-A)
The machine monitor logs the past and currently
occurring failures classifying them into the
mechanical system abnormality and electrical
system abnormality.
To check Electrical Systems abnormality record,
perform the following procedures.
a For the failure code list, see "40 Failure code list
for troubleshooting".
1. Selecting menu
Select Abnormality Record on Service Menu
screen.

After Abnormality Record screen is displayed,
select Electrical Systems
item
WA470-7
3. Information displayed on "Abnormality Record"

screen
On Electrical Systems abnormality record
screen, the following information is displayed.
(a): Occurrence order of abnormalities from
latest one/ Total number of records
(b): Failure code
(c): Detail of failure
(d): Number of occurrences (displayable range:
0 to 65,535 times)
(e): Service meter reading at the first occurrence
(f): Service meter reading at the last occurrence
Up switch (A): Moves your selection to the item
right above the current one (when 2 or more
abnormalities are recorded)
Down switch (B): Moves your selection to the
item right below the current one (when 2 or more
abnormalities are recorded)
Return switch (C): Returns to Abnormality
Record screen
a If no abnormality is recorded, No Error is
displayed.
30-161

Electrical system
a On the electrical systems abnormality record

screen, up to 20 cases currently stored are
displayed.
If the number of abnormality records
increases to 21 or beyond, the latest
occurrence code is displayed and the oldest
one is deleted.
a If the number of occurrence is 1 (first
occurrence), the time of the first occurrence
is identical with the time being read on the
service meter at the first occurrence.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or correction
of it is not confirmed.
a For all of the failure codes that the machine
monitor can record, see the failure code list.
a The screen is in the clear mode if graphic

mark [CLEAR] is indicated at the bottom
of the screen.
Up switch (A): Moves your selection to
the item right above the current one
(when 2 or more abnormalities are
recorded)
Down switch (B): Moves your selection to
the item right below the current one
(when 2 or more abnormalities are
recorded)
Return
switch
(C):
Returns
Abnormality Record screen
to
Enter switch (D): Clears the information

one by one
Menu switch (E): Clears all information at
once
a When clearing the information one by
one: Select the item to be cleared by
using Up switch (A) or Down switch (B)
and press the enter switch (D) to clear it.
a When clearing all the information at once:
Press menu switch (E) to clear all the
items regardless of the selection of the
individual item.
a If [E] is displayed on the left of a failure
code, the clearing operation is accepted
but the item is not cleared.
4. Clearing abnormality record

1) While Electrical Systems screen is
displayed, perform the following operation.
Switch operation: While pressing Down
switch (B), press numeral input switches (F)
in the sequence of "1"o"2"o"3".
3) After the Electrical Sys. Error Reset screen

is displayed, operate the switches.
Return switch (C): Returns to Electrical Sys.
Error Reset screen
Enter switch (D): Clears the information.
2) Check that the display on the screen
becomes the clear mode, then clear the
individual information one by one or all
together.
30-162
WA470-7

Electrical system
a The following figure shows the screen

when an individual item is cleared (it is
slightly different from the screen when all
the item are cleared at once).
2. Selecting maintenance record item

After the Maintenance Record screen is
displayed, select the item to confirm.
item
one item
Service Menu screen
4) If the screen to notify completion of clearing

is displayed and then Electrical Sys. Error
Reset screen is displayed, the clearing of
the abnormality record is completed.

Maintenance Record (WA470-Q19Z-100-K-00-A)

The machine monitor records the maintenance
information of the filters, oils, etc., which are
displayed and checked by the following operations.
If you reset the data from the user menu after a
maintenance operation, the number of maintenance
performed is recorded in this section.
1. Selecting menu
Select Maintenance Record on Service Menu
screen.
WA470-7
a Setting for the following items is available in

Maintenance Record.
No.
49
41
01
02
13
03
12
15
10
04
05
47
Maintenance record items

Air Cleaner Cleaning/Change
Fuel Pre-Filter
Engine Oil
Engine Oil Filter
Transmission Oil Filter
Fuel Main Filter
Transmission Oil
Axle Oil
Hydraulic oil
Hydraulic Oil Filter
Hydraulic Oil Tank Breather
KCCV Filter
30-163

Electrical system
No.
Maintenance record items
48 KDPF Filter Cleaning
52 Fuel Doser Cleaning
3. Information displayed in Maintenance Record

screen
The following information is displayed.
(a): Maintenance items
(b): Number of replacements up to now
(c): Service meter reading (SMR) at the last
replacement

"Maintenance Mode Setting"
(WA380-Q1F1-100-K-00-
A)
The actuating condition of the maintenance

reminder function in the operator mode can be set
and changed by using this menu.
To enable or disable the function
Change set replacement interval (by item)
Initialize all of set change intervals
1. Selecting menu
Select "Maintenance Mode Setting" on the
"Service Menu" screen.

On the "Maintenance Mode setting" screen
displayed, select the item to change the setting.
item
item
"Service Menu" screen
30-164
WA470-7

Electrical system
a Setting for the following items is available in

"Maintenance Mode Setting".
No.
00
49
41
01
02
13
03
12
15
10
04
05
99
Maintenance Mode Setting item

Maintenance Mode
On/Off
"Maintenance Mode
Maintenance
Change"
Notice Time
Setting
"Air Cleaner
OFF/ON Set
Cleaning / Change
Set Value
Interval"
"Fuel Pre Filter
OFF/ON Set
Change Interval"
Set Value
"Engine Oil Change OFF/ON Set
Interval"
Set Value
"Engine Oil Filter
OFF/ON Set
Change Interval"
Set Value
"Transmission Oil
OFF/ON Set
Filter Change
Set Value
Interval"
"Fuel Main Filter
OFF/ON Set
Change Interval"
Set Value
"Transmission Oil
ON/OFF Set
Change Interval"
Set Value
OFF/ON Set
"Axle Oil Change
Interval"
Set Value
"Hydraulic Oil
OFF/ON Set
Change Interval"
Set Value
"Hydraulic Oil Filter OFF/ON Set
Change Interval"
Set Value
"Hydraulic Oil Tank OFF/ON Set
Breather Change
Set Value
Interval"
Returns all to Default Values
a KCCV filter, KDPF filter cleaning, and fuel

doser cleaning settings cannot be changed.
3. Description of maintenance mode change
procedure (Maintenance Mode On/Off)
Select "Maintenance Mode On/Off" of
"Maintenance Mode Change" and proceed to its
setting.
ON: Functions of all maintenance items
become enabled in operator mode.
OFF: Functions of all maintenance items
become disabled in operator mode.
item
Down switch (B): Moves selection to the
below item
Return switch (C): Cancels selection and
returns to the "Maintenance Mode Change"
screen
Enter switch (D): Validates selection and
screen
WA470-7
a Even if ON/OFF of each item has been set, if

the above setting is changed, it overrides the
individual setting.
a The maintenance function for cleaning KCCV
filter, KDPF filter and fuel doser remains
enabled even if "OFF" is selected.
4. Description of maintenance mode change

procedure (Maintenance Notice Time Setting)
Select "Maintenance Notice Time Setting" of
"Maintenance Mode Change" and proceed to its
setting.
Default value: "Maintenance Notice Time" set

in machine monitor (Recommended by the
manufacturer and not changeable).
Set value: Maintenance interval that can be
freely set. Maintenance reminder function
works according to this set time in operator
mode (which is set in increments of 10
hours).
Up switch (A): Increases the set value
Down switch (B): Decreases the set value
Return switch (C): Cancels setting before
validated and return to the "Maintenance
Mode Change" screen.
screen
30-165

Electrical system
5. Description of setting of individual maintenance

item (ON/OFF setting)
Select "ON/OFF setting" for individual
maintenance item and proceed to its setting.
ON: Function of each maintenance item
selected is enabled in the operator mode
OFF: Function of each maintenance item
selected is disabled in the operator mode
item
Down switch (B): Moves selection to the
below item
Return switch (C): Cancels selection and
returns to each maintenance item screen
return to each maintenance item screen
"Default": Maintenance notice time set in

machine monitor (recommended by the
manufacturer and not changeable).
"Set": Maintenance interval that can be freely
set. Maintenance reminder function works
according to this set time in operator mode
(which is set in increments of 25 hours).
Up switch (A): Increases the "Set"
Down switch (B): Decreases the "Set"
Return switch (C): Cancels selection before
validated and return to each maintenance
item screen
return to each maintenance item screen
a When your selection is validated with Enter
switch (D) and the display returns to the
"Maintenance Mode Setting" screen, your
setting is validated.
a If currently selected "ON" for an item is
changed to "OFF" after operation of an hour
or longer, such change is recognized as a
reset operation.
7. Function to return all of the values to Default

Values
After selecting "All Default Value", and the
screen is displayed, set it by using the switches.
6. Description of setting of individual maintenance
item (Set Value) Select "Set Value" for individual
maintenance item and proceed to its setting.
If the operation for this function is executed,

the set values of all the maintenance items
are initialized (returned to the default values).
30-166
WA470-7

Electrical system
Return switch (C): Returns the display to

"Maintenance Mode Setting" screen
Enter switch (D): Executes initialization
a The initialization work is completed if the
Initialization Completion screen appears
sometime after pressing Enter switch (D)
being followed by the Maintenance Mode
Setting screen.
Phone number entry (HM300-Q19A-110-K-00-A)

The telephone number, which is displayed together
with the Error List in the operator mode, can be
input and changed according to the following
procedure.
If a telephone number is not input with this function,
no telephone number is displayed in the operator
mode.
1. Selecting menu
Select Phone Number Entry on the Service
Menu screen.
Menu switch (E): Clears all the input phone

numbers.
Numeral input switch (F): Inputs the phone
number.
a Up to 14 digits can be input from the left.

Input nothing in the surplus places.
a When you entered a value that contains a
wrong number, move the input position (with
yellow background) to that digit and overwrite
it with the correct number.
a If you press Enter switch (D) without inputting
a digit, no phone number is displayed in the
operator mode since there is no phone
number information.
2. Registering and changing phone number

After the Phone Number Entry screen is
displayed, register or change the phone number
Up switch (A): Moves the input position to the
immediate left place (if not blank).
Down switch (B): Moves the input position to the
immediate right place (if not blank).
Return switch (C): Cancels the entry and returns
to the Service Menu screen.
Enter switch (D): Validates the entry.
WA470-7
30-167

Electrical system
Default (Machine Model Select)
(WA470-Q1GB-100-K-
00-A)
Use the menu of "Default" to check or change

various settings of the machine monitor and
machine.
When a controller is replaced with a new one, the
machine model selection function informs the new
control of the machine model to which it is now
installed.
1. Selecting menu
Select Default on Service Menu screen.
2) When the machine model selection is
enabled, select the model.
item
Down switch (B): Moves the selection down
by one item
Return switch (C): Cancels the selection and
returns the display to Default screen

After the Default screen is displayed, select
Machine Model Select.
3. Selecting machine model

1) When Machine Model Select screen is
displayed, perform the following operation.
Switch operation: While pressing DOWN
switch (B), press numeral input switches
(E) "1" o "2" o "3" in order.
a If you press the enter switch (D) to

validate Machine Model Select, the
followings are performed.
Monitoring/Custom: Currently stored
items are cleared
Maintenance Mode Setting:
Maintenance Mode On/Off and
Maintenance Notice Time Setting
are returned to the default values of
the model.
Default (Option Select): Default
value of the selected model are
restored
ECO Guidance: All of the fuel
consumption data are reset
a This screen is displayed when the service
menu is opened for the first time after the
monitor controller is replaced to the one
that has not been used for the machine
model selection before. Therefore, select
the model first (the screen display may be
somewhat different from the actual one).
30-168
WA470-7

Electrical system
Select Option Select on Default screen.
3) When the screen that urges you to turn the

starting switch to OFF position appears, turn
the starting switch to OFF position once and
turn it to ON position again. Then perform the
following "Default (Option Select)."
3. Selecting optional equipment

1) After Option Select screen is displayed,
check the optional equipment installed to the
machine concerned and set each item.
a When the current settings are acceptable,
select either one of the items and press
the enter switch (D) without making any
modification, and your settings will be
reflected on the machine.
Default (Option Select) (WA470-Q1GC-100-K-00-A)

machine.
When all the settings relevant to the current optional
equipment are reset due to the machine model
selection or when an option equipment is added
later, the optional equipment selection function is
used to select the said optional equipment and
enable its function.
1. Selecting menu
a Optional device installation setting table

Item name
Work
Equipment
Control
Quick
Coupler
Semi-auto
digging
Load Meter
Lift Arm
Model
Default
setting
Remarks
See "(2) Setting Work

TYPE A Equipment Control"
Select "JAPAN SPEC" or
NO ADD "OTHERS" when optional
equipment is installed.
Select "ADD" and do not
ADD change it.
Select "ADD" when
NO ADD optional equipment is
installed.
Set the following items
according to the boom
specification.
Standard
If standard boom is
used, select
"Standard".

WA470-7
30-169

Electrical system
Item name
Default
setting
Remarks
If high lift boom

(optional) is used ,
select "High Lift".
Select "ADD" when
Auto Grease NO ADD optional equipment is
installed.
Battery
Select "NO ADD" and do
Electrolyte
NO ADD not change it.
Level Sensor
If difference is recognized
in the travel speed display,
adjust it with this function.
Tire Size
0%
CompensaIncreasing the setting by
tion
1% increases the travel
speed by 1% against the
one at 0%.
Select
"B" when 26.5 tires
Tire Type
A
are installed.
Select "ADD" when
Emergency
ADD optional equipment is
Steering
installed.
When the multi-function
lever (joystick lever is not
installed) or directional
(FNR) switch (on the right)
J/S or FNR
NON
is installed, select "OPT
SW
FNR". When the joystick
steering is installed, select
"J/S FNR".
Lift Up Mode
ADD change it.
ECSS
ADD change it.
T/C Lockup NO ADD
change it.
Prohibition of
Select "NO ADD" and do
use of 4th
NO ADD not change it.
speed
Set as follows according to
installed optional
equipment and
destination.
Set to "HEATER" if
machine is equipped
with optional
equipment and used in
Tow Stage
NO ADD
Japan.
Low Idle
Set to "KOHAG" if
machine is equipped
with optional
equipment and used
outside Japan.
Select "NON" when
optional equipment is
not installed.
F1 PWR
ADD change it.
CUT
30-170
Item name
Default
setting
Komatsu
Smart
ADD
Loader Logic
Auto Idle
Stop Setting NO ADD
Remarks
change it.
Select "ADD" on machines
for North America.
2) Setting of work equipment control

Select Work Equipment Control and set
one of TYPE A to G.
item
by one item
returns the display to Option Select screen
Enter switch (D): Validates the setting and
TYPE A
Main Valve Type: 2 spool
Lever Type: 2 levers
TYPE B
Lever Type: MF lever
TYPE C
Lever Type: 3 levers
TYPE D
Lever Type: MF lever + PCS
TYPE E
Non Use
WA470-7

Electrical system
TYPE F
Non Use
TYPE G
Non Use
a Depending on the set type of the work
equipment control, the following optional
equipment selections will be fixed and
unchangeable.
Semi-auto Digging
Boom specification
3) Setting tire size compensation
Select and set Tire Size Compensation.
Up switch (A): Increases the set value by 1%
Down switch (B): Decreases the set value by
1%
Return switch (C): Cancels the setting
operation before validation and returns the
display to Option Select screen
4) Selection of optional item setting/ not setting

Among the items included in "List of installed
optional devices and their setting", the items
applied the option setting/ not setting
selection must select either one of them.
item
by one item
WA470-7
4. Reflecting setting
If you exit Option Select screen by using the
return switch after completing the setting of the
items, a screen appears to urge you to turn the
starting switch to OFF position. Turn the starting
switch to OFF position once and Option Select
is completed.
a When you do not press the enter switch (no
change is made) even once for any item,
even if you exit Option Select screen, this
screen does not appear.
Default (Unit) (WA470-Q1F3-100-K-00-A)

machine.
The unit selecting function is used to select the unit
of the data to be displayed in monitoring, etc.
1. Selecting menu
30-171

Electrical system
a Switching of the unit is not available inside

Japan.

Select Unit on Default screen.
Default (Rear View Monitor Setting)
(WA470-
Q1GD-100-K-00-A)

machine.
The rearview monitor setting function is used for the
setting required for the removal or installation of the
rearview monitor of camera.
1. Selecting menu
3. Selecting unit
After Unit screen is displayed, select the unit to
be set.
item
one item
Select Rear View Monitor Setting on Default
screen.
3. Setting rearview monitor (setting of camera 1)

ON/OFF setting of the rearview camera can be
set.
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WA470-7

Electrical system
1) Select Camera1 setting on Rear View

Monitor Setting screen.
2) Setting of camera 1.
"Unavailable": Camera is unavailable
"Available": Camera is available
item
by one item
returns the display to Rear View Monitor
Setting screen
returns the display to Rear View Monitor
Setting screen
a Reverse images (mirror images) are
displayed on the rearview monitor.
a Switching to the normal images (visual
images) is not available.
a The factory default is "Available".
4. Rear View Monitor Setting (Guide Line Position

Adjustment)
The position of the guide line displayed on the
rearview monitor can be adjusted.
a Be sure to readjust the guide line position
with this function whenever the rearview
camera position is changed due to its
removal or installation.
a If the above adjustment is not done at all, you
cannot select Monitor Setting o Rear View
Monitor Setting o Guide Line Display in
the user menu (guide line is not displayable).
1) After the Rear View Monitor Setting screen
is displayed, select Guide Line Position
Adjustment.
a Perform this adjustment with the rearview
monitor displayed.
(In the user menu, select and turn OFF
Monitor Setting o Rear View Monitor
Setting o Reverse-interlock enabled
mode.)
a When "Unavailable" is selected for
camera 1, this item is not selectable.
2) After Guide Line Position Adjustment

screen is displayed, adjust the horizontal and
vertical positions at each point of the guide
line displayed on the rearview monitor
1] Select point 1 from the "Guide Line
Position Adjustment" screen.
WA470-7
30-173

Electrical system
Up switch (A): Moves the selection up by

one item
Down switch (B): Moves your selection to
the item directly below the current one
Return switch (C): Cancels the selection
and returns the display to Rear View
Monitor Setting screen
Enter switch (D): Validates your selection
and returns the display to the Point
Position Adjustment screen
3] Validate the setting with the enter switch

(D).
4] Above operation allows you to adjust the
vertical position of "Point 1". So, by using
the brightness adjustment switch of the
rearview monitor, align (b) portion at 1.5
m from the rear edge of the machine.
Brightness adjustment switch + (E):
Moves the point upward.
Brightness adjustment switch - (F):
Moves the point downward.
2] This screen allows adjusting the

horizontal position of "Point 1". So, using
the brightness adjustment switch of the
rearview monitor, align (a) portion with the
outside width of the tire.
Brightness adjustment switch + (E):
Moves the point rightward.
Brightness adjustment switch - (F):
Moves the point leftward.
5] When the vertical position adjustment is

over, validate the setting with the enter
switch (D).
6] The display returns to the Point Selection
screen. On this screen, adjust the guide
line positions at points 2 to 4 by using the
same procedure.
30-174
WA470-7

Electrical system
5. Initializing rearview monitor

This function allows initializing the rearview
monitor setting.
a Whenever you have replaced the rearview
monitor, you must initialize the rearview
monitor with this function.
1) After the Rear View Monitor Setting screen
is displayed, selectRear View Monitor
Initialize.
3) Check that the positional relationship

between the guide line and machine is as
shown in the following figure.
(c): Outer face of tire (green line)
(d): 1.5 m from machine rear edge (yellow
line)
(e): Outer face of tire (green line)
2) The screen to confirm that want to perform

the initialization appears. Answer
affirmatively to it and start your operation.
Rear View Monitor Setting screen
Enter switch (D): Executes the initialization
4) When the setting of Reverse-interlock

enabled mode of the user menu was
changed at the first, return it to the original
condition and the guide line position
adjustment is completed.
WA470-7
a If the enter switch (D) is pressed to

execute the initialization, the following
Rear View Monitor Setting is returned to
the default values.
Reference Line: Not displayed
Reverse-interlock enabled mode:
ON
Camera1 Setting: Used
Guide Line Position Adjustment: Not
set
30-175

Electrical system
Select Auto Idle Stop Time Fixing on Default

screen.
a When the Initialization Completion screen

appears sometime after pressing the
enter switch (D), display Rear View
Monitor Setting and the initialization is
completed.
Default (Auto Idle Stop Timer Setting)
(WA470-
Q1GE-100-K-00-A)
Checking and change of auto idle stop setting range

are performed in "Default".
This is to select the range of auto idle stop time
setting that can be selected in the user mode.
a This item is displayed only when "Auto Idle Stop
Setting" is set to "ADD".
3. Setting auto idle stop time

Select a time on Auto Idle Stop Time Fixing
screen.
a The value selected here will become the

maximum value of auto idle stop time that
can be selected in the user menu.
a The maximum value of the auto idle stop
time must be set after checking compliance
with the applicable law, which differs by
region.
1. Selecting menu
30-176
WA470-7

Electrical system
Testing (Cylinder Cut-out operation)
(HM300-
AD00-34F-K-00-A)
In the machine monitor, the cylinder cut-out mode

operation and the KDPF regeneration operation can
be executed as well as their cancellation.
Cylinder Cut-out mode operation means to run the
engine with one or more fuel injectors disabled
electrically to reduce the number of effective
cylinders. This operation is used to identify a
cylinder that does not output power normally
(combustion in it is abnormal).
1. Selecting menu
Select Diagnostic Tests on Service Menu
screen.
a This operation may be performed while the

engine is running.
a If background (a) of the selected cylinder
number becomes white after you press Enter
switch (D), the cylinder is cut out.
a If the machine monitor cuts out a cylinder but
the engine controller cannot cut out that
cylinder, the background (a) of the cylinder
number becomes yellow.
a The number of cylinders cut out may be one
or more.

After Diagnostic Tests screen is displayed,
select Cylinder Cut-out.
4. Releasing cut-out cylinder

When changing a cylinder to be cut out or when
the cylinder cut-out operation is finished, select
the cut-out cylinder(s) to be released.
3. Selecting cylinder to be cut-out
After the Cylinder Cut-out screen is displayed,
select a cylinder to be cut out.
Up switch (A): Moves selection to the left
Down switch (B): Moves selection to the right
Diagnostic Test screen
(If the Hold is selected, a diagonal line appears
WA470-7
a This operation may be performed while the

engine is running.
a If background (a) of the selected cylinder
number changes to gray when you press
Enter switch (D), the cylinder is released the
cut-out.
a If the machine monitor releases a cut-out
cylinder but the engine controller cannot
release the cut-out cylinder, the background
(a) of the cylinder number becomes red.
30-177

Electrical system
a The cut-out cylinder mode operation is not

automatically released after the screen
returns to the operator mode. Accordingly, be
sure to perform the releasing operation after
the cylinder cut-out mode operation is
finished.
5. Holding displayed data
If you press menu switch (E) during the cylinder
cut-out operation, the displayed information is
held anew (b) (display of the real-time
information is maintained on the left side).
If you press menu switch (E) while the data is
held, the data holding function is canceled.
a The holding function is available for a
cylinder, regardless of whether it is cut out or
not.

After Diagnostic Tests screen is displayed,
select Regeneration for Service.
a While the manual stationary regeneration is
turned on or stopped from KDPF
Regeneration of the user menu, you cannot
select Regeneration for Service.
[Reference]
If a normally operating cylinder is cut out, the
following phenomena occur.
1) Decrease in engine speed
2) The quantity of final injection rate
command increases.
If the engine is running at around high idle,
however, the engine speed may not
decrease because for the reason of engine
control.
In this case, lower the engine speed by
adjusting the accelerator pedal depressing,
and make the judgment observing increase
of the final fuel injection volume command.
Testing (Regeneration for Service)
3. Setting regeneration for service

When Regeneration for Service screen is
displayed, the following informations are
displayed corresponding to the KDPF
regeneration condition. Set the KDPF
regeneration according to the given messages.
(a): Soot accumulation level
(b): Regenerating condition of KDPF
(c): Selectable items
(d): Message
(WA500-A9H0-
252-K-00-A)

Active regeneration for service refers to the method
of burning soot by performing the KDPF
regeneration, regardless of the soot accumulation.
It is used before cleaning of KDPF is performed or
after replacement of the engine controller.
1. Selecting menu
Select Diagnostic Tests on Service Menu
screen.
30-178
WA470-7

Electrical system
1) KDPF active regeneration (manual stationary

regeneration)
Select Manual Stationary Regeneration on
Regeneration for Service screen.
Diagnostic Tests screen
Enter switch (D): Executes Manual
Stationary Regeneration
a The screen displays Monitoring
Selection Menu screen by the following
switch operations while the regeneration
for service is in progress.
Switch operation: While pressing
Down switch (B), press numeral input
switches (E) "1" o "2" o "3" in order.
a The active regeneration for service

automatically stops in 40 minutes.
However, if the regeneration is started
with the soot accumulation of
approximately 4 g/liter and if the soot
accumulation still remains at above 2 g/
liter after 40 minutes from the start, the
regeneration is continued until the soot
accumulation decreases to 1.99 g/liter.
To return the regeneration for service

screen from monitoring screen, press
the return switch (C).
a For the monitoring operating, see
"Monitoring" of "Ordinary functions and
special functions of machine monitor".
2) Finishing regeneration
When Regeneration for Service
completed, Regeneration completed
displayed on the screen.
a Manual Stationary Regeneration can be

executed only when your foot is released
from the accelerator pedal, the gear shift
lever is set to the N (NEUTRAL) position
and the parking brake switch is turned to
the PARKING position.
a It can not be executed as well, when the
fuel level caution lamp is lit or a KDPFrelated error is detected.
a Before performing the manual stationary
regeneration, make sure the surrounding
environment is safe, no people and no
combustibles are in the area.
is
is
3) Stopping regeneration
Press the enter switch (D) during the manual
stationary regeneration, and Stop manual
stationary regeneration? is displayed on the
screen and you can stop the regeneration.
Return switch (C): Does not stop
regeneration
(manual
stationary
regeneration is continued)
Enter switch (D): Stops regeneration
When you have to move the machine

again for the sake of security, move it to a
safe place and repeat the operation from
the start.
a While the manual stationary regeneration
is taking place, idling speed reaches
approximately 1,000 rpm.
WA470-7
30-179

Electrical system
Testing (KDPF Memory Reset)
(HM300-A9H0-271-K-
00-A)

KDPF memory reset function is used for resetting
the KDPF information stored on the machine. This
function is used when a KDPF-related part is
cleaned or replaced.
The following items can be reset.
3. Selecting reset item

On the KDPF Memory Reset screen, select an
item to be reset.
item
item
Diagnostic Tests screen
Reset after KDPF change: It is done after the

KDPF is replaced with another one.
Reset after KDPF cleaning: It is done after the
KDPF is replaced or cleaned.
Reset after KDOC change: It is done after the
KDOC is replaced with another one.
Fuel doser reset: It is done after cleaning of the
fuel doser.
1. Selecting menu
Select Diagnostic Tests on the Service Menu
screen.

After the Diagnostic Tests screen is displayed,
select 03 KDPF Memory Reset.
30-180
The screen confirms if you want to execute the

resetting. Answer affirmatively to it and start your
operation.
previous screen
Enter switch (D): Executes the reset
WA470-7

Electrical system

adjustment (WA380-CN16-330-K-00-A)
a The adjustment work must be performed at the
specified oil temperature. So adjust the
transmission oil temperature according to the
following procedure while checking that nothing
abnormal is displayed on the machine monitor.
1. Select Monitoring/Custom on Service Menu
screen.
a When the reset is finished normally, Reset

Done is displayed on the screen. If the reset
is not finished properly, "Reset failed" is
displayed on the screen.
Adjusting (WA500-Q170-270-K-00-A)
The machine monitor implements the initial setting
after disassembly or replacement of the
transmission or hydraulic components, to
compensate installation errors or manufacturing
variations of individual parts.
2. Move to the tab of T/M by using menu switch (E)

and select T/M Oil Temperature.
a Adjusting function
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Adjustment item
ECMV Automatic Compensation
T/M Initial Learning
T/M Initial Learning Reset
T/M Shift Point
T/M Shift Point Data Clear
Boom Angle Sensor for EPC (Raise)
Boom Angle Sensor for EPC (Lower)
Boom Raise Adjustment
Boom Lower Adjustment
Bucket Tilt Adjustment
Bucket Dump Adjustment
3rd Ext Adjustment *1
3rd Ret Adjustment *1
J/S Right Adjustment *1
J/S Left adjustment *1
PCS Adjustment(Push) *1
PCS Adjustment(Pull) *1
Change of Boom Lever Pattern
Change of Bucket Lever Pattern
Boom Stop Modulation
2-Stage Low Idle Throttle Position
Steering Pump Displacement *1
Steering Pump Displacement *1
Fan Reverse Cycle
Fan Reverse Duration
ECSS Operating Speed
Fan 100% Mode
Checking transmission oil pressure control

1. Start the engine, depress the brake pedal fully
and then, release the parking brake.
2. Set the transmission shift mode to "Manual", and
move the directional lever to F (FORWARD),

WA470-7
30-181

Electrical system
and set the gear speed switch to 4th (4th

speed).
3. Referring to "Preparation for transmission ECMV
current adjustment", check that the transmission
oil temperature is within the range from 55 to 70
C. If the temperature is not within the range 55 to
70C, perform torque converter stall operation to
adjust the oil temperature to 55 to 70 C.
4. Return the directional lever to "N" (Neutral),
leave the machine for 3 minutes, and check that
the oil temperature remains within the range 55
to 70 C.
5. Operate the directional lever and gear speed
switch as shown in the following table to
circulate the oil around inside of the
transmission.
Order
Gear
speed
Holding
time
Order
Gear
speed
Holding
time
Order
Gear
speed
Holding
time
N2
F2
F1
F2
Min. 2
Min. 2
Min. 2
Min. 2
seconds seconds seconds seconds
5
F3
F4
F3
F2
Parking brake switch: ON

Directional lever: N position
Engine: Low idle
Accelerator pedal: Released
1. Selecting menu screen

Select Adjustment on Service Menu screen.

After the Adjustment screen is displayed,
select ECMV Automatic Compensation.
Min. 2
Min. 2
Min. 2
Min. 2
9
10
11
N2
R2
N2
Min. 2
seconds
Min. 2
seconds
Min. 2
seconds
a Perform these operations with the engine at low

speed, manual shift switch at ON position, and
torque converter lockup sitch at OFF position.
a Check that the machine is in normal condition
(no error indication is displayed on the machine
monitor).
3. When "START" is displayed, press Enter switch

(D) to start the adjustment.
a Be careful not to overheat the torque converter

during torque converter stall operation.
Adjustment (ECMV automatic

compensation) (WA380-CN16-270-K-00-A)
a Adjustment is performed 4 times automatically
against the F, R, 1st, 2nd, 3rd, and 4th valves
respectively.
Refer to "Preparation for adjusting transmission
ECMV electric current", and select the
monitoring code of transmission oil temperature.
Monitoring code: 32500 T/M Oil
Temperature
a Do not start the engine at this point in time.
Start the engine, set the machine to the following
condition, and check that the transmission oil
temperature is between 55 to 70C.
30-182
WA470-7

Electrical system
The codes displayed when it ends normally

or abnormally
Code
"0 : OK"
"1 : NG (Out of Condition)"
"2 : NG (No fill)"
"3 : NG (Over the Value)"
a The adjustment must be consecutively

performed 4 times on the target clutch and
the screen as shown in the table below is
displayed.
2nd
3rd time 4th time
time
1
F
F-1
F-2
F-3
F-4
2
R
R-1
R-2
R-3
R-4
3
1st
1-1
1-2
1-3
1-4
4
2nd
2-1
2-2
2-3
2-4
5
3rd
3-1
3-2
3-3
3-4
6
4TH
4-1
4-2
4-3
4-4
4. The screen indicates for each adjustment work
whether it ends normally or abnormally.
1) The screen when it ends normally
No.
Valve
1st time
Condition
Normal end
Abnormal end
When "0" (normal end) is displayed:

Adjustment work ends normally.
When "1" is displayed:
Adjust the transmission oil temperature
accurately and check the conditions set on
the machine again, then repeat the work
from step 1.
Perform the troubleshooting for failure codes
[15S*LH] and [DXH*KA] and when the
condition is checked to be normal, repeat the
work from step 1 (symbols indicated with *
vary depending on the target clutch of
adjustment).
Perform the troubleshooting for failure code
[15S*L1] and when the condition is checked
to be normal, repeat the work from step 1
(symbols indicated with * vary depending on
the target clutch of adjustment).
5. When the adjustment work ends normally, turn
the starting switch to OFF position and the
compensation value will be recorded on the
transmission controller in approximately 3
seconds.
a When you have to turn the starting to ON
position soon after the adjustment is finished,
hold the starting switch in OFF position for 10
seconds minimum just to be sure, then turn it
to ON position.
Adjustment (T/M Initial Learning)
(WA380-CN16-270-
K-01-A)
2) The screen when it ends abnormally
a Before performing this adjustment, be sure to

perform "Adjustment (ECMV Automatic
Compensation)".
a Before starting the learning work, check that the
transmission oil temperature is set to the
specified temperature referring to "Preparation
for transmission ECMV current adjustment". (An
adjustment performed at an unspecified
temperature may induce time lags and gearshift
shocks.)
a Implement the gearshift operation using actual
travel, bench travel or while pressing the wheel
brake.
WA470-7
30-183

Electrical system
k Be
sure to perform the learning work in a

place where an ample traveling area is
available while paying attention to safety in
the surrounding area.


select T/M Initial Learning.
4. Operate the directional (FNR) lever and gear

speed switch according to the following table to
perform the initial learning.
a When setting N2 for the first time, shift
directional lever to N position after setting
gearshift switch to F2 or R2.
(Since gear speed is not changed if gearshift
switch is set to 2 after shifting directional
lever to N position, set gearshift switch to 2
first, and then shift directional lever to N
position.
If directional lever is shifted to N position
while gearshift switch is set at other than 2,
operate directional lever to F position or R
position once. Then operate directional lever
to N position after setting gearshift switch to
F2 or R2.)
Order
Gear
speed
Holding
time
Order
Gear
speed
Holding
time
Order
Gear
speed
Holding
time
3. Start the engine, set the machine to the following

condition, and check that the transmission oil
temperature is between 55 to 70C.
Engine: Low idle
Transmission shift mode: Manual
Transmission cut-off: OFF
Lockup: OFF
30-184
N2
F2
F1
F2
Min. 5
Min. 5
Min. 5
Min. 3
5
F3
F4
F3
F2
Min. 3
Min. 3
Min. 3
Min. 3
9
10
11
N2
R2
N2
Min. 3
seconds
Min. 3
seconds
Min. 3
seconds
a Hold the gear shift lever in each gear speed

for more than the specified time.
5. When the display for each clutch becomes ON,
initial learning is complete. Exit by using the
return switch.
If any of the display is still OFF, initial learning is
not completed. Repeat step 4.
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Electrical system
Adjustment (T/M Initial Learning Reset)
(WA380-
CN16-271-K-00-A)
a This function is used to initialize the data

obtained by using T/M Initial Learning function.

select T/M Initial Learning Reset.
5. After the initialization, check that the initialization

condition is 1: Learning Not Done Yet.
3. Check the initialization condition shown in the

left display area. If 0: Learning Completed is
displayed there, proceed to the next step and
initialize the learned data.
Adjustment (T/M Shift Point)
(WA380-CN1X-270-K-00-
A)
a This function is used to set the offset value that

is added to the value of the shift point when the
shift mode is positioned at "L". However, the
correction amount to the shift point of auto kick
down to the 1st speed is also applied in the "H
mode".
a The factory default setting of the correction
amount is always 0.
4. While T/M Initial Learning Reset is displayed,
press Enter switch (D) to display the Initialization
Operation screen. When the screen appears,
press Enter switch (D) again to start the
initialization.
WA470-7
a While the shift points depend on the engine

mode, the same offset values set by this function
are applied to all engine modes.
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Electrical system
a The following shift patterns are not included in

shift points applicable to this shift point
adjustment function.
1. The shift point that is used when the hunting
prevention function is in operation
2. Downshift points below 1,000 rpm
a After the shift point adjustment is done, be sure
to check the result on the machine.
a This operation allows you to change the
threshold travel speed (shift point) when "L
mode" is selected for the auto shift mode. Shift
points for following gear shift patterns can be
changed.
F2T/CoF3T/C
a Shift Point adjustment screen is displayed.
F3T/CoF4T/C
F4T/CoF3T/C
F4T/CoF2T/C
F3T/CoF2T/C
F2L/UoF3T/C
F3L/UoF4T/C
F4T/CoF3L/U
F3T/CoF2L/U
F2L/U ON
F2L/U OFF
F3L/U ON
F3L/U OFF
F4L/U ON
F4L/U OFF
AUTO F1 K/D
Change the speed to change F2T/CoF3T/C
according to the following procedure. The other
shift patterns can be also adjusted similarly.
1. Select menu screen and press the enter switch
(D).
3. Press numeric keypad (E) on T/M Shift Point

adjustment screen (any of 0 to 9).
a The setting input screen is displayed.
Up switch (A): Switches sign between "+"
and "-"
Down switch (B): Enters decimal point
Adjustment screen
Enter switch (D): Validates the setting
a Input a set value with numeral input switches
(E) and accept the setting with the enter
switch (D).

select T/M Shift Point.
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Electrical system
4. The input value is displayed at the right part of

the screen. If this value is correct, press the
enter switch (D) again.

select T/M Shift Point Data Clear.
5. When the input numeric value is displayed in the

left display area, the setting is complete.
3. When T/M Shift Point Data Clear screen is

displayed, press enter switch (D).
a If the return switch is pressed while the

calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.
Adjustment (T/M Shift Point Data Clear)
(WA380-
CN1Y-270-K-00-A)
a This function is used to set all adjustments made

at "T/M Shift Point " back to zero.
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4. The confirmation screen is displayed. Validate

the setting by pressing enter switch (D) again.
3. Press Enter switch (D) after raising the boom to

the upper limit position (cylinder stroke end).
5. When "1" is displayed at the left part of the
screen, T/M Shift Point Data Clear is complete.
a When all of the memory is cleared, the set
values will become the default value (0).
a The data will not be cleared if the return
switch is pressed during the process.

(Raise)) (WA470-CN1Z-270-K-00-A)
4. If the display in the left window changes to "1",
adjustment is complete.

After Adjustment screen is displayed, select
Boom Angle Sensor for EPC (Raise).
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Electrical system
5. If the display in the left window changes to "2",

the boom angle voltage is out of the specified
value and the adjustment is not made.
not completed.
3. Press Enter switch (D) after lowering the boom

to the lower limit position (cylinder stroke end).
6. When the adjustment does not end successfully,

check the boom angle sensor voltage on
Monitoring/Custom screen.
7. Adjust the installed position of the boom angle
sensor so that the voltage displayed on
Monitoring/Custom screen is within the
following range, and then perform the sensor
adjustment again.
Boom
specification
STD
Hi Lift
Boom position
Voltage range
Top
3.77 0.3 V
3.88 0.3 V

(Lower)) (WA470-CN21-270-K-00-A)
4. When "1" is displayed in the display area, this


Boom Angle Sensor for EPC (Lower).
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Electrical system
5. If the display changes to "2", the boom angle

voltage is out of the specified value and the
adjustment is not made.
not completed.

select Boom Raise Adjustment.
6. When the adjustment does not end successfully,

check the boom angle sensor voltage on
Monitoring/Custom screen.
7. Adjust the installed position of the boom angle
sensor so that the voltage displayed on
Monitoring/Custom screen is within the
following range, and then perform the sensor
adjustment again.
Boom
specification
STD
Hi Lift
Boom position
Voltage range
Bottom
1.38 0.3 V
1.49 0.3 V
Adjustment (Boom Raise Adjustment)
3. Move the boom lever to RAISE, stop and hold

the lever just before the boom RAISE detent
position. While holding the lever at that position,
press Enter switch (D).
(WA380-
CN22-270-K-00-A)
a This function is used to perform calibration in

order to correct dispersion at just before the
boom lever RAISE detent and the starting
current.
Correcting the position just before the boom
lever RAISE detent
a Perform this adjustment with the engine stopped
after the bucket is lowered to the ground.
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Electrical system
a Do not move the lever to RAISE detent

position.

not completed.
Adjusting starting current of boom RAISE EPC

a Perform this adjustment with the engine running.


select Boom Raise Adjustment.
5. If "2" is displayed, the signal voltage of lever

angle is out of the standard voltage range. This
adjustment is not performed.
3. Set the bucket in DUMP posture and lower the

boom to lift the front wheels off the ground.
4. With the engine running at high speed, start to
lower the boom (to lower the machine) gradually.
5. Return the lever finely. When the boom stops
moving (front wheels are off ground), hold the
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lever at the current position. While holding the

lever at that position, press enter switch (D).
Correcting the position just before the boom

lever LOWER detent


select Boom Lower Adjustment.

If the return switch is pressed while the
calibration is continued, the calibration currently
taking place is stopped even if it is not
completed.
Adjustment (Boom Raise Adjustment)
3. Move the boom lever to FLOAT, stop and hold

the lever just before the boom FLOAT detent
position. While holding the lever at that position,
press Enter switch (D).
(WA380-
CN23-270-K-00-A)

order to correct dispersion at just before the
boom lever LOWER detent and the starting
current.
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Electrical system


not completed.

select Boom Lower Adjustment.
3. Set the boom almost horizontal with the bucket

empty.
lower the boom gradually.
moving, hold the lever at the current position.
While holding the lever at that position, press
enter switch (D).
Adjusting starting current of boom LOWER EPC

WA470-7

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Electrical system


On the Adjustment screen, select Bucket Tilt
Adjustment.

not completed.
3. Move the bucket lever to TILT, stop and hold the

lever at the near point just before the Bucket
TILT detent position. While holding the lever at
that position, press Enter switch (D).
Adjustment (Bucket Tilt Adjustment)
(WA380-
CN24-270-K-00-A)

order to correct dispersion of the near-point for
boom lever TILT detent and the starting current.
Correcting near-point for bucket lever TILT
detent
1. Selection of menu screen
Select Adjustment on the Service Menu
screen.
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Electrical system
a Do not set the lever to the bucket TILT detent

position.

not completed.
Adjusting starting current of bucket Tilt EPC

1. Selection of menu screen
Select Adjustment on the Service Menu
screen.


On the Adjustment screen, select Bucket Tilt
Adjustment.
5. When "2" is displayed, the signal voltage of lever

3. Set the bucket in DUMP posture and lower the

boom to lift the front wheels off the ground.
4. With the engine running at high speeds, start to
tilt the bucket (to lower the machine) gradually.
WA470-7
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Electrical system

moving (front wheels are off ground), hold the
lever at the current position. While holding the
lever at that position, press enter switch (D).
Adjustment (Bucket Dump

Adjustment) (WA380-CN25-270-K-00-A)
order to correct dispersion of the starting current
of the bucket DUMP lever.


select Bucket Dump Adjustment.

not completed.
30-196
3. Set the empty bucket almost horizontal.

dump the bucket gradually.
5. Return the lever finely. When the bucket stops
moving, hold the lever at the current position.
While holding the lever at that position, press
Enter switch (D).
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Electrical system


not completed.
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Electrical system
Adjustment (Change of Boom Lever Pattern)
(WA500-CN26-270-K-00-A)
a This function is used to modify the fine-controllability and response of the boom by changing the data on
EPC output current to the boom lever stroke.
a Characteristics of tables 0 to 4 are summarized as shown in the table below. (table when shipped: 2)
a Table No. and function

Table No.
0
1
2
3
Function
Fine control has
priority.
Fine control has
priority.
Outline
The controllability is enhanced further than the No. 1.
Speed change becomes more drastic as the stroke grows bigger.
Improved controllability when lever is operated with short travel.
This table allows compatibility between controllability and response

ability in both RAISE and LOWER operations.
Response priority Shorter lever travel and faster lever movement enhance response.
Response is further improved because of the faster speed by the fewer
lever travel than that of No. 3.
Response priority If this table is used, boom speed changes sharply when control lever is
moved in short distances. Accordingly, improper lever operation can
cause substantial shocks when stopping boom.
Standard
a Normally, change is made to tables No. 1 to No. 3. When selecting No. 0 or No. 4 table, thorough
preliminary performance check and operator evaluation are required.
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Electrical system

Change of Boom Lever Pattern.
a The adjustment screen for Change of Boom

Lever Pattern is displayed.

3. Press numeral input switch (E) on Change of

Boom Lever Pattern adjustment screen. (Any
switch of "0" to "9" is accepted.)
and "-"
Adjustment screen
switch (D).
WA470-7

30-199

Electrical system

not completed.
30-200
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Electrical system
(WA500-CN27-270-K-00-A)
a This function is used to modify the fine-controllability, response and shock dump of the bucket by changing
the data on EPC output current to the bucket lever stroke.
a Characteristics of tables 0 to 2 are summarized as shown in the table below. (table when shipped: 1)
a Table No. and function

Table No.
0
Function
Fine control has
priority.
Standard
Response priority
Outline
Both in bucket dump and tilt operations, this table improves controllability
when lever is operated with short travel.
This table satisfies both of controllability and response in bucket dump
operation as well as bucket tilt operation.
Shorter lever travel and faster lever movement enhance response.
It makes it easier to dump load by swinging the bucket as well as shock
dump and leveling of load with the tilted end of the bucket.

WA470-7
30-201

Electrical system

Change of Bucket Lever Pattern.
a The adjustment screen for Change of

Bucket Lever Pattern is displayed.

3. Press numeral input switch (E) on the Change

of Bucket Lever Pattern adjustment screen.
(Any switch of "0" to "9" is accepted.)
and "-"
Adjustment screen
switch (D).
30-202

WA470-7

Electrical system

not completed.
WA470-7
30-203

Electrical system
Adjustment (Boom Stop Modulation)
(WA380-
CN28-270-K-00-A)
a When the boom lever is operated for sudden

stop, this function modifies the speed reduction
rate of the stop modulation, which is prepared
for reducing shocks resulting from stopping, by
applying the stop modulation to EPC output
current.
a This data change does not affect the stop
modulation of the boom when it is stopped
automatically by the remote positioner or kickout
function.
a Before starting a modification of the modulation
by using this function, Change of Boom Lever
Pattern and operator's evaluation must be done
first.

select Boom Stop Modulation.
a The stop modulation function acts in the same

way in both the raise and lower directions.
a The data when shipped out is "10".
Modulation
quantity
10
20
Condition
The stop
modulation is not
activated. Boom
stops without
delaying to the
boom lever stroke.
It allows
compatibility
between delay in
response at stop
and stopping
shocks
Remarks
Stopping shocks
can result if the
operator does not
take reasonable
care.
a Adjustment screen of Boom Stop
Modulation is displayed.
-
When the lever is

returned to
It reduces stopping
NEUTRAL, the
shocks against
boom delays
sudden stop
stopping and
operation by
exceeds the
operator.
target stop
position.

3. Press numeric keypad (E) on the Boom Stop

Modulation adjustment screen (any of o to 9).
and "-"
Adjustment screen
30-204
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Electrical system

switch (D).
Adjustment (2-Stage Low Idle Throttle

Position) (WA380-AF71-270-K-00-A)
Adjust 2-Stage Low Idle Throttle Position
a The throttle position adjusted at this stage is
reflected on low idle throttle position when
directional lever is shifted to FORWARD or
REVERSE position.


After Adjustment screen is displayed, select 2stage Low Idle Throttle Position.

not completed.
WA470-7
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Electrical system
a 2-stage Low Idle Throttle Position adjusting

screen is displayed after selecting.
7. Press the return switch to exit the adjustment

mode.
3. Press a numeric keypad (any of 0 to 9) on
adjustment screen of 2-stage Low Idle Throttle
Position.
a The numeral input screen is displayed.

not completed.
a When setting a higher value than the default
value (12.0%), thoroughly check the
operation of the machine and receive
operator's feedback.
Adjustment (Fan Reverse Cycle)
(WA380-B71E-270-
K-00-A)
a The adjusted value with this function is applied

to Machine Setting/Information in user mode,
and to Mode D of Automatic Fan Reverse
Mode.
a Adjust Fan Reverse Duration too, also applied
to Mode D.
4. Input desired value with numeral input switches
and press the Enter switch.
Up switch: Switches + and Down switch: Enters decimal point
5. The value input with numeral input switches is
displayed in the display area at the right part of
Enter switch again.


select Fan Reverse Cycle.

30-206
a While Mode D is selected in user mode, this

adjustment function is not able to select. So
select other item than Mode D when
perform adjustment.
WA470-7

Electrical system
a Fan Reverse Cycle adjustment screen is

displayed.
3. Press numeral input switch (E) on the Fan

Reverse Cycle adjustment screen. (Any switch
of "0" to "9" is accepted.)
and "-"


not completed.

Adjustment screen
switch (D).
Adjustment (Fan Reverse Duration)
(WA380-B71F-
270-K-00-A)
a The adjusted value with this function is applied

to Machine Setting/Information in user mode,
and to Mode D of Automatic Fan Reverse
Mode.
a Adjust it in Fan Reverse Cycle too, since it is
applied to Mode D as well.
WA470-7
30-207

Electrical system


and "-"
Adjustment screen
switch (D).

select Fan Reverse Duration.
a While Mode D is selected in user mode, this
adjustment function is not able to select. So
select other item than Mode D when
perform adjustment.
a Fan Reverse Duration adjustment screen is

displayed.
3. Press numeral input switch (E) on the Fan

Reverse Duration adjustment screen. (Any
30-208


WA470-7

Electrical system

not completed.
3. Press numeral input switch (E) on the ECSS

Operating Speed adjustment screen. (Any
Adjustment (ECSS Operating Speed)
(WA380-
L3B1-270-K-00-A)


and "-"
Adjustment screen
switch (D).

select ECSS Operating Speed.
a ECSS Operating Speed screen is

displayed.
WA470-7
30-209

Electrical system

not completed.

select Fan 100% Mode.
3. When the enter switch (D) is pressed, "1" is

displayed at the left part of the screen, and the
fan 100% mode is set.
Adjustment (Fan 100% Mode)
(WA380-B71G-270-K-00-
A)
This adjustment code is used to forcibly set the

cooling fan speed to approximately 100%
regardless of the actual oil and coolant
temperatures.
a Use this adjustment code for testing, adjusting,
or troubleshooting as needed.
a Since the cooling fan speed still depends on the
throttle position in this mode, depress the
accelerator pedal to check the maximum speed.
30-210
WA470-7

Electrical system
4. When the enter switch (D) is pressed again, "0"

is displayed at the left part of the screen, and the
fan mode returns to the normal mode.
a If the return switch (C) pressed to exit from
the Adjustment screen, the fan mode
returns to the normal mode even if it is set to
the 100% mode.
No Injection (HM300-AD00-25L-K-00-A)
If the engine is operated after long storage of the
machine, it may be worn or damaged because of
insufficient lubrication with oil. To prevent this, the
machine monitor has a function to crank the engine
without injecting fuel to lubricate the engine before
starting it.
Set the no-injection cranking while the engine is
stopped.
1. Selecting menu
Select No Injection on Service Menu screen.
3. Starting no-injection cranking

If No Injection cranking (no fuel injection to every
cylinder) is enabled, a message to notify that is
displayed on the screen. Under this condition,
turn the starting switch to the START position
and crank the engine.
a While the screen is changing to the following
screen, the screen of Getting Ready. is
displayed.
a Do not crank the engine for 20 seconds or
longer to protect the starting motor.
2. Displaying confirmation screen

When No Injection screen is displayed, a
message "Begin Injectionless Cranking?" is
displayed. Perform the operation as follows.
Return switch (C): Does not execute No
Injection (returns the display to the Service
Menu screen)
Enter switch (D): Executes No Injection.
4. Finishing no-injection cranking

After the cranking is over, turn the starting switch
to OFF position.
a You cannot change the screen described
above to another screen.
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Electrical system
a When you want to turn the starting switch to

ON position again, set a sufficient time (1
minute minimum) before doing so.
5. Prohibiting no-injection cranking
Even if the operator tries to perform the No
Injection cranking while the engine is running,
the message "The engine is operating" is
displayed and the no-injection cranking does not
become effective.
Select KOMTRAX Settings on Service Menu

screen.
a This function can be selected even when the

engine is running. However, if you execute
the no-injection cranking, a message Please
turn the key off once. appears on the
screen.
Select Terminal Status
Settings screen.
Also, if the no-injection cranking is operated

while "Check" screen appears, the function does
not become effective in the following case.
The communication between the monitor and
engine controller is not normal.
Perform an engine start operation before the
message No injection is possible appears.
on
KOMTRAX
3. Contents displayed on Terminal Status screen

On the Terminal Status screen, the following
items of information are displayed.
Terminal Type: Model name of the
KOMTRAX communication modem
KOMTRAX Communication: Status of radio
station establishment underway
GMT Time: Greenwich Mean Time (add 9
hours to it for Japan time)
KOMTRAX Settings screen
KOMTRAX Settings (terminal setting

status) (HM300-Q210-110-K-00-A)
The setting and operating conditions of KOMTRAX
can be checked on the display of KOMTRAX
Settings.
Terminal setting status is used to check the setting
condition of the KOMTRAX terminal.
1. Selecting menu
30-212
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Electrical system
On the GPS & Communication Status screen,

the following items of information are displayed.
Positioning: GPS positioning status
Communication: Communication
environment and connecting condition of the
communication modem
Number of message(s) not yet sent: Number
of mails that are saved in the machine
monitor and have not yet been transmitted
KOMTRAX Settings screen.

Status) (HM300-Q210-110-K-01-A)
The setting and operating conditions of KOMTRAX
can be checked through the display of KOMTRAX
Settings.
GPS & Communication Status is used to check the
positioning and communication condition of the
KOMTRAX terminal.
1. Selecting menu
Select KOMTRAX Settings on the Service
Menu screen.

After the KOMTRAX Settings screen is
displayed, select GPS & Communication
Status.
KOMTRAX Settings screen (Modem

Status) (HM300-Q210-110-K-02-A)
Settings and operating status of KOMTRAX can be
checked on the "KOMTRAX Settings" screen.
Modem information is used to check the IP address
of the KOMTRAX communication modem.
1. Selecting menu
Select KOMTRAX Settings on the Service
Menu screen.
3. Contents of display of GPS & Communication

Status
WA470-7
30-213

Electrical system

After the KOMTRAX Settings
displayed, select Modem Status.
screen is
Service Message (HM300-Q210-100-K-00-A)

Special messages for the technician sent from the
KOMTRAX base station (a distributor, etc.) can be
checked with this function.
If a received message includes a setting operation,
a return mail can be sent by using the numeral input
switches as well.
1. Selecting menu
Select Service Messageon Service Menu
screen.
3. Details displayed on Modem Status screen

IP addresses (2 systems) of the modem are
displayed.
Return switch (C): The display is returned to
KOMTRAX settings screen
a An IP address is a unique number assigned
to each modem that is used when
communication between the modem and
server is established.
2. Displaying message (read only)

If a message is received, the description in the
message is displayed. If there is no
message,No message. is displayed.
Return switch (C): Returns to the Service Menu
screen
a This message is different from that sent to
the operator with the machine monitor in the
operator mode.
a Since this message is special for the
technician, the message pilot lamp does not
light up when it is received unlike the
operator mode.
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Electrical system
3. Display of message (with return mail function)

If the Numeric Input is displayed at the bottom
of the text, enter the number by using numeral
input switches (F) and validate it by using the
enter switch (D). Then, the information is
returned to the KOMTRAX base station.
KOMTRAX Settings screen
Enter switch (D): Validates the input value and
returns it
a This message is different from that sent to
the operator with the machine monitor in the
operator mode.
a Since this message is special for the
technician, the message pilot lamp does not
light up when it is received unlike the
operator mode.
WA470-7
30-215

Electrical system
Adjusting rearview camera angle
(WA470-Q162-360-K-00-A)
a Adjust the camera so that persons in the area

(w) of 1 meter around the machine is displayed
on the monitor in the operator's cab.
a Machine is displayed partially on the

machine monitor screen.
a If the image displayed on the monitor is out of
position, adjust the installation angle (A) of the
rear view camera.
a Angle (A) can be adjusted in the range of 34.0 to
49.0 degrees.
2. After adjusting, tighten mounting bolts (1).
Adjusting
(WA380-Q162-270-K-01-A)
1. Loosen mounting bolts (1) (3 places) and adjust

them within the range of angle (A).
30-216
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Electrical system
Handling voltage circuit of engine controller
(PC220-AP40-2A4-K-00-A)
1. Disconnecting or connecting work of the

connector between the engine controller and the
engine must be performed only when the
starting switch and disconnect switch are in the
OFF position and the system operating lamp
goes out.
k Before
connecting the wiring harness

connector, be sure to completely remove
sand, dust, water, etc., inside the
connector on the controller side.
2. Perform the measuring operation with the Tadapter inserted or connected to the connector
between the engine controller and engine when
you perform the troubleshooting.
a You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.
WA470-7
30-217

Electrical system
Handling battery disconnect switch
(WA470-AW1P-100-K-00-A)
1. When the battery disconnect switch is turned to

OFF position, be sure to remove switch key (1).
kA
hazard can result if an unauthorized

person turns switch key (1) ON carelessly.
2. You can prevent an abnormal end of the

operation due to cut-off of the battery power
supply circuit while the controllers are in
operation by checking the operating status of
each controller with system operating lamp (2).
1) Before cutting off the battery power supply
circuit, turn the starting switch to OFF
position, and check that system operating
lamp (2) goes out, then turn the battery
2) If you turn the battery disconnect switch to
OFF position (battery power supply circuit is
cut off) while system operating lamp (2) lights
up, Controller data lost error can occur. Do
not operate the battery disconnect switch as
long as system operating lamp (2) lights up.
3) System operating lamp (2) goes out in 2
minutes longest after the starting switch is
turned to OFF position.
4) System operating lamp (2) may sometimes
light up while the starting switch is turned to
OFF position because KOMTRAX terminal
may maintain its communication under this
condition.
5) The system operating lamp (2) may look
slightly luminous in the dark after it is turned
off. It is due to the minute leakage of current
and not an abnormal phenomenon.
After the starting switch is turned to OFF
position, KOMTRAX terminal repeats the
start and stop to maintain the periodic
communication.
The start and stop cycle (sleep cycle) of
KOMTRAX terminal varies depending on
the factors including the communication
status and machine stop time. So the
lamp can be lighting as long as
approximately an hour.
6) When you want to cut off the battery circuit
for maintenance but system operating lamp
(2) keeps on lighting up, turn the starting
switch to ON position once, then turn it to
OFF position. The lamp will go out in 2
minutes maximum.
After the system operating lamp (2) goes out,
turn the battery disconnect switch to OFF
position immediately.
30-218
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Electrical system
Testing diodes
(ALL-E300-001-P-00-A)
a Test the diode array (8-pin) and the single diode

(2-pin) according to the following procedure.
a The continuity directions of the diode array are
as follows.
a The continuity direction of the single diode is

indicated on the surface of the diode.
Testing
(PC220-E300-36J-P-00-A)
1. When using a digital tester

1) Select the diode range screen to check the
displayed values.
a When an ordinary circuit tester is used,
the voltage of the internal battery is
indicated.
2) Apply the red (+) lead of the multimeter to the
anode (P) side of the diode and apply the
black (-) lead to the cathode (N) side and
check the indicated value.
3) Evaluate the condition of the diode by the
indicated value.
Indicated value does not change: No
continuity (defective)
Indicated value changes: Continuity
(normal) (note)
Note: In the case of a silicon diode, a value in
the range from 460 to 600 mV is indicated.
The indicated value is 0 or approximate
0:
The diode has internal short circuit
(defective).
WA470-7
2. When using analog tester

1) Selects the resistance range screen.
2) Check the movement of the pointer when
performing the following connection.
1] Apply the red (+) lead of the multimeter to
the anode (P) side of the diode and apply
the black (-) lead to the cathode (N) side.
2] Apply the red (+) lead of the multimeter to
the cathode (N) side of the diode and
apply the black (-) lead to the anode (P)
side.
3) Evaluate the condition of the diode by the
movement of the pointer.
The pointer does not move by the above
1] connection, but it does by the 2]
connection: Normal (however, the
movement of the pointer (resistance)
varies by type of tester, or selection of
measuring range).
The pointer moves by either connection
of the above 1], and 2]:
Defective (internal short circuit)
The pointer moves by neither connection
the above 1], nor 2]: Defective (internal
open circuit)
30-219

Pm clinic
Pm clinic
(ALL-2160-001-A-00-A)
Pm Clinic service
(WA470-2160-209-A-00-A)
WA470-7 #10001 and up

Time check
Work order No.
Date of inspection
Year
Month
Day
Machine serial
#
number
Engine serial
No.
SAA6D125E-6
Service meter reading
Inspector
Hours
Questions asked to operator, walk around inspection

Was there any abnormality before inspection started?
Maximum coolant temperature

(overheated)?
(during operation)
Ambient temperature
Max.
C
Min.
C
m
Altitude
Do lighted segments of torque converter

oil temperature gauge reach HIGH
(overheating)? (during operation)
a If the machine is cold, warm it up fully

a Standard values at working mode P are shown.
30-220
WA470-7

Pm clinic
Check sheet
(WA470_7-2160-033-A-00-A)
WA470-7 #10001 and up

1. Engine
Item
Condition
Power mode
Low idle
1) Set working mode to power
mode, and start engine.
2) Set the work equipment
lock switch to OFF position
(release).
3) Set the boom at the lowest
position.
(Boom angle: Max. -35.5
degrees)
(Bucket is level and
approximately 100 mm off
the ground)
4) Set work equipment lock
Engine
switch to LOCK position.
speed (*1) 5) Depress the accelerator
pedal gradually while
operating bucket lever
tilting. Measure the engine
speed at high idle.
Power mode
Torque converter stall (gear
speed: F4)
Power mode
Hydraulic stall (Bucket
CURL relief)
Power mode
speed: F4) and hydraulic
stall (Bucket CURL relief)
Blowby
pressure

speed: F4)
Unit
Standard
value for new
machine
Repair limit
800 to 850
800 to 850
Test
results
UnAcaccepceptable
table
2,120 to 2,220 2,120 to 2,220
rpm
1,735 to 1,835 1,685 to 1,885
2,010 to 2,210 1,910 to 2,310
1,545 to 1,745 1,445 to 1,845

kPa
{mmH2O}
Max. 1.96
{Max. 200}
3.92
{400}
High idle
Engine oil
290 to 690
180
tempera{3.0
to
7.0}
{18}
SAW5W-30LA
ture: Min.
Engine oil
kPa
SAW5W-40LA
80C
pressure
2}
Low
idle
{kg/cm
SAE10W-30LA
(*1)
Engine
oil
Min. 80
50
SAE15W-40LA
tempera{Min.
1.0}
{0.5}
ture: Min.
80C
Boost
kPa
Min. 127
100
pressure
speed: F4)
{mmHg}
{Min.
950}
{750}
(*1)
Exhaust
tempera- Whole speed range (20C)
C
Max. 650
650
ture
*1: Items which can be inspected in special functions of machine monitor
WA470-7
30-221

Pm clinic
2. Transmission valve
a When shifting transmission gear to forward or reverse, apply brake securely.
Item
Condition
Unit
Low idle
Main relief
Engine
pressure
speed:
2,000 rpm
Torque
converter Engine
inlet
speed:
pressure
2,000 rpm
(*1)
Torque
converter Engine
outlet
speed:
pressure
2,000 rpm
(*1)
Torque
converter oil
temperature: 60 to
80C
Transmission:
Neutral
MPa
{kg/cm2}
1st
2nd
ECMV
output
(clutch)
pressure
3rd
4th
F (forward)
R (reverse)
Torque
converter oil
temperature: 60 to
80C
Engine
speed:
2,000 rpm
Manual
switch
at
ON
L/C
(lockup)
Standard
value for new
machine
Repair limit
2.12 to 2.52
{21.5 to 25.5}
2.12 to 2.52
{21.5 to 25.5}
2.35 to 2.75
{24.0 to 28.0}
2.35 to 2.75
{24.0 to 28.0}
0.1 to 0.88
{1.0 to 9.0}
0.1 to 0.88
{1.0 to 9.0}
0.06 to 0.71
{0.6 to 0.7}
0.06 to 0.71
{0.6 to 0.7}
2.2 to 2.5
{22.5 to 25.5}
2.2 to 2.5
{22.5 to 25.5}
2.15 to 2.45
{22 to 25}
2.15 to 2.45
{22 to 25}
1.91 to 2.21
{19.5 to 22.5}
1.91 to 2.21
{19.5 to 22.5}
1.51 to 1.81
{15.5 to 18.5}
2.2 to 2.5
{22.5 to 25.5}
2.2 to 2.5
{22.5 to 25.5}
2.15 to 2.45
{22 to 55}
2.15 to 2.45
{22 to 25}
1.91 to 2.21
{19.5 to 22.5}
1.91 to 2.21
{19.5 to 22.5}
1.51 to 1.81
{15.5 to 18.5}
Test
results
UnAcaccepceptable
table
Test
results
UnAcaccepceptable
table

3. Steering
Item
Condition
Secure frame with frame lock bar.

Steering
45 to 55C
relief
pressure
Maximum pressure at
(*1)
operation
Unit
Standard
value for new
machine
Repair limit
MPa
{kg/cm2}
23.3 to 25.7
{237.5 to
262.5}
22.0 to 25.7
{225 to 262.5}
30-222
WA470-7

Pm clinic
4. Brake
Item
Condition
Unit
Standard
value for new
machine

Parking
MPa
Min. 2.32
brake inlet
2
{kg/cm } {Min. 23.5}
pressure
As parking brake is released
Specified pressure
Parking
Flat paved road with a slope of
brake
Stopped
1/5 (11 degrees 20 minutes)
perforand dry surface
mance
Set machine in operating
condition.
Parking
mm
brake disc
3.12 to 3.28
thickness
Charge
5.9 to 6.4
cut-in
(60 to 65)
pressure
to 55C
Charge
9.8 to 10.78
cut-out
{100 to 110}
pressure
MPa
4.4 to 5.2
Brake oil to 55C
2}
{kg/cm
pressure
{44.8 to 53}
Engine stopped
Drop of
Measure lowering of oil
Max. 0.49
brake oil
pressure from 4.9 MPa {50 kg/
{Max. 5}
pressure cm2} after depressing brake
pedal for 5 min.
Specified pressure
Test on flat, level, straight, and
dry paved road.
Travel speed at beginning of
Wheel
brake application 20 km/h:
brake
m
Max. 5
Delay in applying brakes Max.
perfor0.1sec.
mance
Brake pedal depressing force:
Specified depressing effort 293
to 353Nm {29.9 to 35.9 kg}
Measure braking distance.
Use disc wear indicator for
measurement.
Protrusion of
Wear of
shaft
Oil pressure: 4.9 MPa {50 kg/
mm
wheel
2
brake disc cm }
0
Pedal depressed completely
WA470-7
Repair limit
Test
results
UnAcaccepceptable
table
Min. 2.32
{Min. 23.5}
Stopped
2.97
5.4 to 6.88
{55 to 70}
9.4 to 11.3
{95 to 115}
Min. 4.2
{Min. 42.7}
Max. 0.49
{Max. 5}
Max. 5
Shaft
protrusion
reaches wear
limit position
[Max. 2.4]
30-223

Pm clinic
5. Work equipment
Item
Work
equipment
relief
pressure
(*1)
Work
equipment
valve LS
differential
pressure
Boom
speed
Bucket tilt
back
speed
Condition
Unit
Bucket relief
Power mode
Hydraulic oil
temperature:
45 to 55C
Engine speed:
High idle
Standard
value for new
machine
Repair limit
32.5 to 36.1
{332 to 368}
29.9 to 36.1
{305 to 368}
1.27 to 1.47
{13 to 15}
1.17 to 1.57
{12 to 16}
5.4 to 6.4
2.6 to 3.6
Max. 7.7
Max. 4.4
2.1 to 2.7
Max. 3.2
1.2 to 1.8
Max. 2.0
Test
results
UnAcaccepceptable
table
Test
results
UnAcaccepceptable
table
MPa
{kg/cm2}
Boom control
lever: Half
stroke
Raising time
Lowering time
Bucket full
sec
stroke time
Level o apply
a load
afterward
Retraction of
lift cylinder rod
mm/15
Retraction of
min.
bucket
cylinder rod
Hydraulic oil
Max. 30
Max. 36
Hydraulic temperature:
drift in
45 to 55C
work
Max. 20
Max. 24
equipment Engine
stopped
6. Hydraulic fan
Item
Condition
Unit
Standard
value for new
machine
Repair limit

95C
Cooling
fan
1,200 to 1,400 1,100 to 1,500
Min. 50C
maximum
Torque
converter
oil
speed (*1)
temperature: Min. 105C
Can be substituted with fan
rpm
100% mode
Engine low idle
Coolant temperature: Max.
Cooling
70C
fan
125 to 225
75 to 275
minimum
Max. 70C
speed (*1) Torque converter oil
Cooling
12.9 to 15.7
12.2 to 16.4
fan drive
50C
{131 to 161} {124 to 168}
pressure
Fan 100% mode (*2)
MPa
Cooling
Fan rotating in reverse
fan
{kg/cm2}
Engine: High idle
2.16 to 2.86
1.98 to 3.04
reverse
solenoid
{22.0
to
29.2}
{20.2
to 31.0}
50C
output
Fan 100% mode (*2)
pressure
*2: For the fan 100% mode, see "Testing and adjusting", "Special functions of machine monitor".
30-224
WA470-7

Pm clinic
7. Axle
Item
Draining of Front axle
differential
Visual
Rear axle
check of
plug
Condition
Unit
Standard
value for new
machine
Repair limit
Test
results
UnAcaccepceptable
table
Must be no excessive metal

particles
MEMO
WA470-7
30-225

Pm clinic
30-226
WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model
Serial Number
WA470-7
10001 and up
40 Troubleshooting
6 40 Troubleshooting
WA470-7
40-1
40 Troubleshooting
Table of contents
Table of contents
(ALL-0310-002-A-00-A)
40 Troubleshooting............................................................................................................................ 40-1
General information on troubleshooting ...................................................................................... 40-11
Troubleshooting points ....................................................................................................... 40-11
Sequence of events in troubleshooting................................................................................. 40-13
Check before troubleshooting.............................................................................................. 40-15
Inspection procedure before troubleshooting ........................................................................ 40-17
Preparation work for troubleshooting of electrical system....................................................... 40-34
Classification and procedures for troubleshooting ................................................................. 40-40
Symptom and troubleshooting numbers ............................................................................... 40-43
Connector list and layout .................................................................................................... 40-48
Connector contact identification........................................................................................... 40-62
T-branch box and T-branch adapter table ............................................................................. 40-98
Fuse location table ........................................................................................................... 40-104
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-107
Precautions on troubleshooting of machine monitor ............................................................ 40-110
Processing procedure of harness checker for troubleshooting of machine monitor LCD
unit .................................................................................................................... 40-112
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature
sensors)............................................................................................................. 40-117
Fabrication of short-circuit connector (for CA1883 and CA3135)........................................... 40-118
Failure codes table........................................................................................................... 40-119
Troubleshooting by failure code (Display of code) ...................................................................... 40-133
Failure code [1500L0] Double Engagement of T/M Clutches ................................................ 40-133
Failure code [15SAL1] Release Trouble of ECMV (Forward) ................................................ 40-134
Failure code [15SALH] Malfunction of ECMV (Forward)....................................................... 40-136
Failure code [15SBL1] Release Trouble of ECMV (Reverse)................................................ 40-138
Failure code [15SBLH] Malfunction of ECMV (Reverse) ...................................................... 40-140
Failure code [15SEL1] Release Trouble of ECMV (1st)........................................................ 40-142
Failure code [15SELH] Malfunction of ECMV (1st) .............................................................. 40-144
Failure code [15SFL1] Release Trouble of ECMV (2nd)....................................................... 40-146
Failure code [15SFLH] Malfunction of ECMV (2nd) ............................................................. 40-148
Failure code [15SGL1] Release Trouble of ECMV (3rd) ....................................................... 40-150
Failure code [15SGLH] Malfunction of ECMV (3rd).............................................................. 40-152
Failure code [15SHL1] Release Trouble of ECMV (4th) ....................................................... 40-154
Failure code [15SHLH] Malfunction of ECMV (4th) .............................................................. 40-156
Failure code [2F00MA] Failure of Parking Brake Circuit ....................................................... 40-158
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................. 40-162
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) .............................................. 40-164
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-166
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-167
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-168
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-169
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-170
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-171
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-172
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-173
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-174
Failure code [989A00] Engine Overrun Prevention Activated ............................................... 40-175
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-176
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-177
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-178
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-183
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-185
40-2
WA470-7
40 Troubleshooting
Table of contents
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-186

Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-188
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-189
Failure code [B@CENS] T/C Oil Temp. Overheat................................................................ 40-191
Failure code [B@HANS] HYD Oil Temp. Overheat .............................................................. 40-192
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-193
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-194
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-196
Failure code [CA131] Throttle Sensor High Error................................................................. 40-198
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-200
Failure code [CA135] Eng Oil Press Sensor High Error........................................................ 40-202
Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................ 40-204
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-206
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-208
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-210
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-212
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-216
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-218
Failure code [CA234] Eng Overspeed ................................................................................ 40-221
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-222
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-223
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-224
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-225
Failure code [CA273] PCV2 Short Error ............................................................................. 40-226
Failure code [CA274] PCV2 Open Error ............................................................................. 40-227
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-240
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-241
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-244
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-246
Failure code [CA431] Idle Validation Sw Error..................................................................... 40-249
Failure code [CA432] Idle Validation Process Error ............................................................. 40-252
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-255
Failure code [CA442] Battery Voltage High Error................................................................. 40-257
Failure code [CA449] Rail Press Very High Error................................................................. 40-258
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-259
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-261
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-263
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-265
Failure code [CA553] Rail Press High Error ........................................................................ 40-267
Failure code [CA559] Rail Press Low Error......................................................................... 40-270
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-274
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-275
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-277
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-279
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-281
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-283
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-284
WA470-7
40-3
40 Troubleshooting
Table of contents
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-285
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-286
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-288
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-289
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-292
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-295
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-296
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-298
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-300
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-302
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-304
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-306
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ................................................. 40-322
Failure code [CA1927] Dosing Fuel Press Sens High Error .................................................. 40-324
Failure code [CA1928] Dosing Fuel Press Sens Low Error................................................... 40-326
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-328
Failure code [CA1977] Fuel Doser Open/Short Error ........................................................... 40-331
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-333
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-335
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-337
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-339
Failure code [CA2265] Fuel Feed Pump Open Error............................................................ 40-340
Failure code [CA2266] Fuel Feed Pump Short Error ............................................................ 40-342
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-344
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-346
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-348
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-350
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-352
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-353
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-355
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-357
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-359
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-361
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-362
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-364
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-366
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-368
Failure code [CA2741] Dosing Fuel Valve Swap Error ......................................................... 40-375
Failure code [CA2765] Inj Trim Data Error .......................................................................... 40-377
Failure code [CA2881] Dosing Fuel Pressure Low Error 1.................................................... 40-381
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-386
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-388
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-390
Failure code [CA3167] Fuel Doser Degradation .................................................................. 40-393
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-396
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-399
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-402
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-405
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-412
40-4
WA470-7
40 Troubleshooting
Table of contents
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-418
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-421
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-425
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-430
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-433
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-437
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-442
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-446
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-449
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-454
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-456
Failure code [D150KA] Disconnection of Emerg. Steering Relay .......................................... 40-458
Failure code [D150KB] Ground Fault of Emerg. Steering Relay ............................................ 40-460
Failure code [D150KY] Hot Short of Emergency Steering Relay ........................................... 40-462
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ................................... 40-464
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output..................................... 40-466
Failure code [D160KY] Hot Short of Backup Lamp Relay Output .......................................... 40-468
Failure code [D191KA] Disconnection of Neutral Output Relay............................................. 40-470
Failure code [D191KB] Ground Fault of Neutral Output Relay .............................................. 40-472
Failure code [D191KY] Hot Short of Neutral Output Relay.................................................... 40-474
Failure code [D192KA] Disconnection of ECSS Solenoid..................................................... 40-476
Failure code [D192KB] Ground Fault of ECSS Solenoid ...................................................... 40-478
Failure code [D192KY] Hot Short of ECSS Solenoid ........................................................... 40-479
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-480
Failure code [D1E6KA] Disconnection of Parking Brake Relay ............................................. 40-482
Failure code [D1E6KB] Ground Fault of Parking Brake Relay............................................... 40-484
Failure code [D1E6KY] Hot Short of Parking Brake Relay .................................................... 40-486
Failure code [D5ZHKA] Failure of Key SW C Signal ............................................................ 40-488
Failure code [D5ZHKB] Key SW C Signal Short Circuit........................................................ 40-490
Failure code [D5ZHKZ] Failure of Key SW C Signal ............................................................ 40-492
Failure code [D5ZHL6] Disconnection of Key SW C ............................................................ 40-494
Failure code [D811MC] KOMTRAX Error............................................................................ 40-496
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-497
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-498
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-500
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 .......................................................... 40-502
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-503
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................... 40-505
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-506
Failure code [DAF0MC] Monitor Error ................................................................................ 40-507
Failure code [DAF3KK] Controller Power Source Low (MON)............................................... 40-508
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-510
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .......................................... 40-511
Failure code [DAFGMC] GPS Module Error........................................................................ 40-513
Failure code [DAFLKA] Operating Lamp Open Circuit (MON)............................................... 40-514
Failure code [DAFLKB] Operating Lamp Short Circuit (MON)............................................... 40-516
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-518
Failure code [DAQ0KK] Controller Power Source Low (T/M) ................................................ 40-519
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ....................................... 40-522
Failure code [DAQ0MC] T/M Con Error .............................................................................. 40-523
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .............................................. 40-524
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ................................................. 40-526
Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay .......................................... 40-529
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) .......................................... 40-531
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ................................................ 40-532
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ................................................ 40-534
Failure code [DAQQKR] CAN2 Discon (Transmission Con) ................................................. 40-536
Failure code [DAQRKR] CAN1 Discon (Transmission Con) ................................................. 40-537
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ......................................... 40-538
WA470-7
40-5
40 Troubleshooting
Table of contents
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-539

Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-540
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-541
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-546
Failure code [DB90KK] Drop in BBC Controller Main Power Source ..................................... 40-551
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ...................................... 40-553
Failure code [DB90MC] BBC Error..................................................................................... 40-554
Failure code [DB91KA] Disconnection of Key SW ACC (BBC) ............................................. 40-555
Failure code [DB92KK] Solenoid Power Source Low (BBC) ................................................. 40-557
Failure code [DB99KQ] Inconsistency of Model Selection (BBC) .......................................... 40-563
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC)................................................ 40-564
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ................................................ 40-566
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) .................................................. 40-568
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) .................................................. 40-569
Failure code [DB9RMA] Inconsistency of Option Selection (BBC)......................................... 40-570
Failure code [DBE5KX] Failure of 5V Power Source............................................................ 40-571
Failure code [DBE6KX] Failure of 24 V Power Source ......................................................... 40-573
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ..................................... 40-575
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................................ 40-577
Failure code [DDB6L4] Neutral Signal Malfunction .............................................................. 40-579
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ........................................... 40-582
Failure code [DDK3KA] FNR SW Input Signal Disconnection............................................... 40-584
Failure code [DDK3KB] FNR SW Input Signal Short Circuit.................................................. 40-587
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ............................................ 40-589
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit............................................... 40-592
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW .......................................... 40-594
Failure code [DDT0L4] Failure of Shift Mode Select SW ...................................................... 40-596
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal...................................... 40-598
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal ........................................... 40-600
Failure code [DDW9LD] Ground Fault of Kickdown Switch................................................... 40-602
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW ................................................ 40-604
Failure code [DF10KA] Disconnection of Shift Lever Input ................................................... 40-606
Failure code [DF10KB] Ground Fault of Shift Lever Input ..................................................... 40-608
Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor........................................... 40-611
Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ............................................ 40-613
Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor .......................................... 40-615
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ......................................... 40-617
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor .................................................. 40-618
Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor ........................................... 40-620
Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor............................................. 40-623
Failure code [DH21KA] Failure of Loader Pump Press. Sensor ............................................ 40-625
Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit........................................ 40-627
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ............................................... 40-629
Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor.................................. 40-631
Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor .................................... 40-633
Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor...................................... 40-635
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ..................................... 40-637
Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor .................................. 40-639
Failure code [DHT8KA] Failure of Steering Pump Press. Sensor .......................................... 40-641
Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit...................................... 40-643
Failure code [DHT8ZG] Steering Oil Pressure Low.............................................................. 40-645
Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor ......................................... 40-646
Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit ............................................ 40-648
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ................................................. 40-650
Failure code [DK55KA] Failure of FNR Lever Potentio ......................................................... 40-652
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ........................................... 40-655
Failure code [DK55L5] Failure of FNR Lever Potentio.......................................................... 40-657
40-6
WA470-7
40 Troubleshooting
Table of contents
Failure code [DK59KA] Failure of Boom Lever Potentio (Main) ............................................. 40-658
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ......................................... 40-661
Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree .................................... 40-664
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub).............................................. 40-668
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) .......................................... 40-671
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ........................................... 40-674
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) ....................................... 40-677
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree .................................... 40-680
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ............................................ 40-684
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ........................................ 40-687
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ................................................ 40-690
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ............................................ 40-693
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree........................................ 40-695
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub).................................................. 40-698
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub).............................................. 40-701
Failure code [DKA0KA] Failure of Boom Angle Sensor ........................................................ 40-703
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit .......................................... 40-705
Failure code [DKA0L0] Boom Angle Sensor Dislocation ...................................................... 40-707
Failure code [DKA1KA] Failure of Bucket Angle Sensor....................................................... 40-709
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit......................................... 40-711
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor........................................ 40-713
Failure code [DLF1LC] Failure of T/M Input Speed Sensor................................................... 40-715
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor.................................. 40-717
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor............................................. 40-719
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main).................................... 40-721
Failure code [DLT3LC] Failure of Output Speed Sensor (Main)............................................. 40-723
Failure code [DPQ1KR] LIN Discon (Switch Panel) ............................................................. 40-725
Failure code [DPQ2KR] LIN Discon (LED Unit) ................................................................... 40-728
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ..................................................... 40-731
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) .............................................................. 40-734
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator .............................................. 40-736
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. .......................................... 40-738
Failure code [DV00KB] Ground Fault of Buzzer Output........................................................ 40-740
Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ................................ 40-742
Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise).................................. 40-744
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ....................................... 40-746
Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ............................... 40-748
Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) ................................. 40-750
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ...................................... 40-752
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) .......................................... 40-754
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) .................................... 40-756
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt).......................................... 40-758
Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ..................................... 40-760
Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ................................ 40-762
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ..................................... 40-764
Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid ......................................... 40-766
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. .......................................... 40-768
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol................................................. 40-770
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ......................................... 40-771
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid........................................... 40-773
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ................................................ 40-775
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...................................... 40-777
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ........................................ 40-779
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ............................................. 40-781
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ..................................... 40-783
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket)....................................... 40-785
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ............................................ 40-787
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol....................................... 40-789
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....................................... 40-791
WA470-7
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40 Troubleshooting
Table of contents
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ....................................... 40-793
Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid ................................. 40-795
Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ................................... 40-797
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid ........................................ 40-799
Failure code [DXANKA] Disconnection of Steering Pump EPC Sol. ...................................... 40-801
Failure code [DXANKB] Ground Fault of Steering Pump EPC Solenoid ................................ 40-803
Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid...................................... 40-805
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ..................................... 40-806
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....................................... 40-808
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ............................................ 40-810
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)............................................ 40-812
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ............................................. 40-814
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)................................................... 40-816
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)........................................... 40-818
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ............................................ 40-820
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd).................................................. 40-822
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ........................................... 40-824
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ............................................. 40-826
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) .................................................. 40-828
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse).................................... 40-830
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ..................................... 40-832
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)........................................... 40-834
Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) .................................... 40-836
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward)...................................... 40-838
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ........................................... 40-840
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ........................................... 40-842
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)............................................. 40-844
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) .................................................. 40-846
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ....................................... 40-848
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)......................................... 40-850
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) .............................................. 40-852
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...................................... 40-854
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ........................................ 40-856
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ............................................. 40-858
Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor........................................... 40-860
Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor .......................................... 40-863
Failure code [DY30ME] Emerg. Steering Long-Time Activated ............................................. 40-867
Failure code [LA00L3] Failure of Fan Reverse .................................................................... 40-869
Troubleshooting of electrical system (E-mode) .......................................................................... 40-870
E-1 Engine does not start.................................................................................................. 40-870
E-2 Manual preheating system does not work..................................................................... 40-876
E-3 Automatic preheating system does not work................................................................. 40-879
E-4 While preheating is working, preheating monitor does not light up .................................. 40-881
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing .................. 40-883
E-6 LCD unit on machine monitor displays nothing.............................................................. 40-886
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or
flickers) .............................................................................................................. 40-888
E-8 LCD on machine monitor does not display properly ....................................................... 40-890
E-9 Meter unit display on machine monitor is abnormal ....................................................... 40-892
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ................................. 40-895
E-11 Caution LED on machine monitor is abnormal............................................................. 40-898
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate
properly ............................................................................................................. 40-900
E-13 Two switches operation of switch panel on machine monitor does not function .............. 40-902
E-14 Switch panel buzzer of machine monitor is abnormal................................................... 40-905
E-15 Rear view monitor does not light up or backlight flickers............................................... 40-907
E-16 Rear view monitor images are not displayed clearly..................................................... 40-910
E-17 Rear view monitor brightness cannot be adjusted........................................................ 40-913
E-18 Night lighting lamp of rear view monitor is abnormal .................................................... 40-916
40-8
WA470-7
40 Troubleshooting
Table of contents
E-19 Some items of gauges and caution lamps on machine monitor are not displayed
properly ............................................................................................................. 40-918
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking)
position .............................................................................................................. 40-919
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not
light ................................................................................................................... 40-923
E-22 Air cleaner clogging indicator lamp does not light ........................................................ 40-925
E-23 Radiator coolant level caution lamp does not light ....................................................... 40-926
E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil
temperature caution lamp does not light................................................................ 40-928
E-25 Indication of torque converter oil temperature gauge does not increase, or torque
converter oil temperature caution lamp does not light ............................................. 40-930
E-26 Fuel level gauge does not indicate correct level .......................................................... 40-931
E-27 Seat belt caution lamp indication is abnormal.............................................................. 40-933
E-28 Horn does not sound ................................................................................................ 40-934
E-29 Horn does not stop sounding..................................................................................... 40-937
E-30 Alarm buzzer does not sound .................................................................................... 40-939
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ................ 40-940
E-32 Kickdown does not work when kickdown switch is turned ON....................................... 40-941
E-33 The hold switch does not work when it is pressed........................................................ 40-943
E-34 Parking brake does not work even if it is applied, or the brake drags when parking brake
is released and FR drive is operated..................................................................... 40-945
E-35 Transmission cut-off mode is not selected or not released............................................ 40-948
E-36 Transmission cut-off setting cannot be released .......................................................... 40-950
E-37 Directional selector (FNR) switch mode is not selected or not released ......................... 40-952
E-38 When operating engine power selection switch, engine power selection function does not
operate properly ................................................................................................. 40-954
E-39 Flow of loader pump does not increase from the minimum rate..................................... 40-956
E-40 ECSS function cannot be selected or cannot be released ............................................ 40-957
E-41 None of headlamp, clearance lamp, and tail lamp lights ............................................... 40-959
E-42 Clearance lamp and tail lamp do not light up or go out ................................................. 40-961
E-43 Both High and Low beams of headlamp do not light up or go out .................................. 40-964
E-44 Low beam of headlamp does not light up or go out ...................................................... 40-968
E-45 High beam of headlamp does not light up or go out ..................................................... 40-970
E-46 Front working lamp does not light up or go out ............................................................ 40-972
E-47 Rear working lamp does not light up or go out............................................................. 40-975
E-48 All of turn signal lamps and hazard lamps do not light up or go out................................ 40-978
E-49 Turn signal lamps do not light up or go out .................................................................. 40-981
E-50 Hazard lamp does not light up or go out...................................................................... 40-984
E-51 Brake lamp does not light or stays lighted ................................................................... 40-987
E-52 Backup lamp does not light up or does not go out........................................................ 40-990
E-53 Backup buzzer does not sound or continues to sound ................................................. 40-993
E-54 Front wiper does not operate ..................................................................................... 40-995
E-55 Rear wiper does not operate ..................................................................................... 40-998
E-56 Window washer does not operate ............................................................................ 40-1000
E-57 Fuel feed pump does not operate or stop automatically ............................................. 40-1003
E-58 KOMTRAX system does not operate properly........................................................... 40-1005
Troubleshooting of hydraulic and mechanical system (H-mode) ................................................ 40-1007
Information described in troubleshooting table (H-mode) ................................................... 40-1007
System chart of hydraulic and mechanical systems........................................................... 40-1008
Failure mode and cause table ..........................................................................................40-1011
H-1 Machine does not move off ....................................................................................... 40-1019
H-2 Torque converter lockup clutch is not disengaged (engine stalls).................................. 40-1022
H-3 Torque converter lockup clutch is not engaged ........................................................... 40-1023
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not
shift ................................................................................................................. 40-1024
H-5 Large shock is made when machine starts or gear is shifted ........................................ 40-1027
H-6 Machine starts or gear speed shifts with long time lag ................................................. 40-1029
H-7 Torque converter oil temperature is high..................................................................... 40-1031
WA470-7
40-9
40 Troubleshooting
Table of contents
H-8 Machine does not turn .............................................................................................. 40-1033

H-9 Turning response is poor .......................................................................................... 40-1035
H-10 Steering wheel is heavy to turn................................................................................ 40-1037
H-11 Machine sways or large shocks are made while machine turns .................................. 40-1038
H-12 Turning radius differs between right and left turns...................................................... 40-1040
H-13 Wheel brakes do not work or are weak..................................................................... 40-1041
H-14 Wheel brakes are not released or drag..................................................................... 40-1043
H-15 Parking brake does not work or it is weak ................................................................. 40-1044
H-16 Parking brake is not released or drags (including emergency release system) ............. 40-1045
H-17 Boom does not rise ................................................................................................ 40-1046
H-18 Boom moves slow or boom lacks lifting force ............................................................ 40-1048
H-19 Rising boom slows down at certain height ................................................................ 40-1050
H-20 Lift cylinders do not serve to hold bucket on ground .................................................. 40-1051
H-21 Hydraulic drift of boom is large ................................................................................ 40-1052
H-22 Boom moves up and down during operation ............................................................. 40-1053
H-23 Bucket does not tilt back ......................................................................................... 40-1054
H-24 Bucket moves slow or lacks tilt-back force................................................................ 40-1056
H-25 Bucket decelerates during tilt-back operation............................................................ 40-1058
H-26 Bucket cylinder does not hold bucket on ground ....................................................... 40-1059
H-27 Hydraulic drift of bucket is large ............................................................................... 40-1060
H-28 Bucket tilts back and forth during carrying load (work equipment valve in
HOLD) ............................................................................................................. 40-1061
H-29 Boom and bucket control levers do not move smoothly and are heavy to move ........... 40-1062
H-30 Operating work equipment causes engine speed to lower significantly or engine to
stall ................................................................................................................. 40-1063
H-31 Large shocks are made when work equipment starts to move and stops ..................... 40-1064
H-32 When certain work equipment stalls hydraulically, other work equipment
moves ............................................................................................................. 40-1066
H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces................. 40-1067
H-34 Bucket does not stop at the position which is set with remote bucket positioner ........... 40-1068
H-35 Fan speed is abnormal (too high or low, or fan does not rotate) .................................. 40-1069
H-36 Unusual noise is heard from around fan ................................................................... 40-1070
Troubleshooting of engine (S-mode)....................................................................................... 40-1071
Information mentioned in troubleshooting table (S mode)................................................... 40-1071
S-1 When starting switch is turned to START position, engine is not cranked....................... 40-1072
S-2 The engine cranks but exhaust smoke does not come out ........................................... 40-1073
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start
but does not) .................................................................................................... 40-1074
S-4 Engine startability is poor .......................................................................................... 40-1075
S-5 Engine does not pick-up smoothly ............................................................................. 40-1077
S-6 Engine stops during operation ................................................................................... 40-1079
S-7 Engine runs rough or is unstable ............................................................................... 40-1081
S-8 Engine lacks power .................................................................................................. 40-1082
S-9 KDPF gets clogged in a short time ............................................................................. 40-1084
S-10 Engine oil consumption is excessive ........................................................................ 40-1086
S-11 Engine oil becomes contaminated early.................................................................... 40-1087
S-12 Fuel consumption is excessive ................................................................................ 40-1088
S-13 Oil is in coolant (or coolant spurts or coolant level goes down).................................... 40-1089
S-14 Oil pressure drops .................................................................................................. 40-1090
S-15 Fuel mixes into engine oil........................................................................................ 40-1091
S-16 Water mixes into engine oil (milky) ........................................................................... 40-1092
S-17 Coolant temperature rises too high (overheating) ...................................................... 40-1093
S-18 Unusual noise is heard ........................................................................................... 40-1094
S-19 Vibration is excessive ............................................................................................. 40-1095
S-20 Air cannot be bled from fuel circuit ........................................................................... 40-1096
S-21 Active regeneration is executed frequently ............................................................... 40-1097
S-22 Active regeneration takes a long time....................................................................... 40-1098
S-23 White smoke is exhausted during active regeneration ............................................... 40-1099
40-10
WA470-7
40 Troubleshooting
General information on troubleshooting

Troubleshooting points
(ALL-5100-001-A-00-A)
(ALL-5130-42A-A-00-A)
(Rev. 2011/09)
k Place
the machine on a level ground, and make sure that the frame lock bar, chocks, and parking
brake are applied.
k When
performing the operation with two or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k If
the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be
extremely careful not to touch any hot parts or to get caught in any rotating parts.
k Before
disconnecting wiring, remove the key and turn the battery disconnect switch to OFF
position.
k When
removing the plug or cap from a component which is under pressure of oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.
Troubleshooting denotes to locate the primary cause, fix the trouble without delay and prevent its recurrence.
Despite the importance of understanding the structure and operation of the target system in troubleshooting,
you should be aware how interviewing with the operator concerned can facilitate in roughly identifying the
cause of the given undesirable symptom.
1. When performing troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately after 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 performing troubleshooting, it is necessary to perform thorough prior investigation
and to perform troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) 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 the failure?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1)
2)
3)
4)
Is there any sign of irregularities of the machine?

Make checks before starting day's work.
Make checks of other items.
Check other maintenance matters which can be checked externally and are considered to be
necessary.
4. Checking failure
Check the extent of the failure by yourself, and judge whether it is a real failure or a problem with the
method of operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not perform any inspection
or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the probable causes of
the failure, then use the troubleshooting flowchart to locate the failure exactly.
WA470-7
40-11
40 Troubleshooting
a 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.
6. Measures to remove root cause of failure
Fixing a trouble in hand does not necessarily prevents its recurrence unless the primary cause is
eliminated. To that end, you must locate and eliminate the primary cause behind the given failure.
40-12
WA470-7
40 Troubleshooting
Sequence of events in troubleshooting
(ALL-5140-42A-A-00-A)
(Rev. 2011. 7)
WA470-7
40-13
40 Troubleshooting
40-14
WA470-7
40 Troubleshooting
c: Electrical equipment
b: Hydraulic and mechanical equipment
a: Engine, lubricating oil, and coolant
Check before troubleshooting

No.
1
2
3
4
5
6
7
8
9
10
11
(WA500-5150-208-A-00-A)
Item
Check of unusual noise and smell
Check of engine for dirt
Check of engine for water leakage
Check of engine for oil leakage
Check of fuel line for leakage
Check of radiator for clogging
Check of fuel level and type
Check of foreign material in fuel
Check of fuel pre-filter
Check of fuel main filter
Check of engine oil level (in oil pan) and type
12 Check of coolant level (in sub tank)

13 Check of air cleaner for clogging
Criteria
Between H and L
Between H and L

monitor does not Clean or replace
light up on the
machine monitor.
Repair
Repair
Refilling of oil
Between H and L
Clean or replace
Replace
Refilling of oil
Between H and L
Refilling of oil
Between H and L
1
2
3
4
5
6
7
Check of unusual noise and smell

Check for oil leakage
Check of hydraulic oil level
Check of hydraulic oil strainer
Check of hydraulic oil filter
Check of transmission case oil level
Check of axle case oil level (front and rear)
Perform air bleeding.
Check of battery terminal for looseness and corrosion
Check of alternator terminal for looseness and corrosion
Check of starting motor terminal for looseness and

corrosion
Check of battery voltage (with engine stopped)
Check of battery electrolyte level

Check of wiring harness for discoloration, burnt areas and
6 cover peeling
Check for coming off of wiring harness clamp and sagging
7 of wiring harness
8 Check of grounding
9 Check for loose connector and damaged lock
Check of connector pin for corrosion, bends and
10
deformation
5
11 Check of connector for water and foreign material
WA470-7
Remedy
Repair
Remove
Repair
Repair
Repair
Remove
Refilling of oil
Clean and drain
Replace
Replace
Refilling of oil
Refilling with
coolant
Bleeding air
Between H and L
Retighten or
replace
Retighten or
replace
Retighten or
replace
Charge or
replace
Add or replace
Repair or replace
Repair
Repair
Repair or replace
Repair or replace
Dry, clean or
replace
20 to 30 V
40-15
40 Troubleshooting
e: Interior parts
d: Exterior parts
c: Electrical equipment
40-16
Criteria
Remedy
Repair or replace
Replace
27.5 to 29.5 V after

few minutes
operation
Replace
Check of battery relay operation sound (when starting

15 switch is turned to ON or OFF position)
Replace
16 Check, clean rear view camera
Clean or repair
No.
Item
12 Check of wiring harness for open or short circuit
Check of fuse and slow-blow fuse for blowout and
13
corrosion
Check of alternator voltage (when engine speed is
14 medium or higher)
1
2
Check of undercarriage
Check of handrails and steps
Repair
Repair
Check of mirrors
Clean or repair
Check of gauges and monitors
Clean or replace
Check of seat belt
Repair
WA470-7
40 Troubleshooting
Inspection procedure before troubleshooting

Walk-around check
(ALL-5150-001-A-00-A)
(WA500-5150-289-A-00-A)
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.
k Accumulated
combustibles around hot engine parts such as the engine, KDPF, and turbocharger,
etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and repair any
failures.
a a1 and a2, , b1, b2, refer to the symbols in the table on the previous page.
a1. and b1. Check for unusual noise and smell
Check for unusual noise and smell.
Some causes of unusual noise and smell can
damage the machine if they are left as they are.
Therefore, stop the machine immediately when you
find any abnormality.
a2. Check around engine and dirt removal
Check and remove any accumulated dirt around the
engine and any combustibles (dead leaves, twigs,
etc.) on hot engine parts such as the engine, KDPF,
turbocharger, etc.
a3. Check for water leakage around engine
a4. Check for oil leakage around engine
Check any oil leaks from the engine and any water
leaks from the cooling system. If any of them is
abnormal, carry out a repair.
a5. Check for leakage from fuel line
Check any fuel leaks and damaged hoses and
tubes. If any of them is abnormal, carry out a repair.
a6. Check of radiator and dirt removal
Check and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around the
radiator.
a14. Check around KDPF and dirt removal
combustibles (dead leaves, twigs, etc.) around
KDPF.
a15. Check around KDPF for gas leakage

combustibles (dead leaves, twigs, etc.) around the
battery.
c16. Check and cleaning of rear view camera
Check the rear view camera for any defect, and
repair any failures.
d1. Check of undercarriage (track, sprocket,
idler and guard) for abnormalities, wear, loose
bolts and oil leakage from roller
Repair any abnormalities.
d2. Check of handrails and steps for
abnormalities and loose bolts
Repair any abnormalities and retighten any loose
bolts.
d3. Check and cleaning of rear view mirrors
Check and repair any abnormalities and breakage
of the rear view mirrors.
Clean the mirror surfaces and adjust their angles so
that the operator can see the area behind machine
at the operator's seat.
e1. Check of gauges and monitors for
abnormalities
Check the gauges and monitors inside the operator
cab. If any of them is abnormal, replace it.
Clean up the surfaces.
e2. Check of seat belt and mounting hardware
Check the hooks, locks and hook fittings for
damage. If any of them has a problem, replace.
Check piping between the turbocharger and KDPF

and joints of KDPF for gas leakage (sticking soot,
etc.) If any abnormality is found, repair.
b2. Check of work equipment, cylinders, linkage
and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage and
hoses for cracks and excessive wear, check that the
clearance between them is within the normal range,
and then repair any abnormalities.
b3. Check of hydraulic equipment, hydraulic
tank, hoses and joints for oil leakage
Check and repair any oil leaks.
c1. Check around battery and dirt removal
WA470-7
40-17
40 Troubleshooting
Testing in accordance with testing procedure
(WA470-5150-280-A-00-A)
a: Engine, lubricating oil, and coolant

a7. Check of fuel level and type
k Fuel
is highly flammable and dangerous.

Never bring flames near fuel.
k When
adding fuel, never spill it or let it

overflow.
k Wipe
off any spilled fuel. If fuel spills over

soil or sand, remove all the fuel and soil or
sand together.
1. Turn the engine starting switch to ON position

and check the fuel level with fuel gauge (G) on
monitor panel.
After checking, turn the switch back to OFF
position.
a9. Check of fuel pre-filter

k Immediately
after the engine is stopped, its

parts and oil are still very hot, and may cause
burn injury. Accordingly, wait until all parts
have cooled down before starting the work.
k High
pressure is generated inside the engine

fuel piping system when the engine is
running. Stop the engine and wait at least 30
seconds until the inner pressure is released
and then replace the filter .
k Never
2. If fuel level is low, open fuel filler cap (F) at the

rear right of machine, and add fuel through filler
port to the level enough to perform the check.
bring flames near fuel.
a A special filter with high-efficiency filtering

properties is adopted for Komatsu genuine fuel
pre-filter cartridges. Be sure to use Komatsu
genuine parts when replacing.
a The common rail fuel injection system used on
this machine consists of more precise parts than
those in the conventional injection pump and
nozzles. If any cartridge other than a Komatsu
genuine fuel pre-filter cartridge is used, foreign
material may enter and it may cause problems in
the injection system. Do no use substitute parts.
a During testing or maintenance of the fuel system,
take extreme care not to allow any foreign
material to enter the fuel system. If any dust or
other material sticks to any part, wash the part
thoroughly with clean fuel.
Prepare a container to receive drained oil.
Prepare a filter wrench.
a8. Check of foreign material in fuel

1. Prepare a container to receive drained fuel.
Place it under the fuel tank.
2. Open drain valve (1) on the right side of the fuel
tank, and drain the water mixed in the fuel and
sediments at the bottom of the tank.
3. Close drain valve (1) when all of mixed water
and deposits are drained.
40-18
1. Stop the engine and wait until the temperature of

each part to drop.
2. Open the engine side cover on the right side of
the machine.
3. Place a container to receive fuel under fuel prefilter cartridge (1).
4. Loosen drain valve (2) to drain water and
sediments from transparent cup (3), and also
drain all the fuel from filter cartridge (1).
WA470-7
40 Troubleshooting
5. Remove drain hose (4). Reuse the drain hose

and clip.
6. By using the filter wrench, turn filter cartridge (1)
counterclockwise to remove it. The filter
cartridge (1) is one with transparent cup (3).
7. Make sure that drain valve (2) which is provided
in the lower part of transparent cup (3) of the
new filter cartridge is firmly tightened.
3 Tightening torque of drain valve:
2.5 to 3.4 Nm {0.25 to 0.35 kgm}
leads to leakage of fuel. If the filter cartridge is

too loose, fuel will also leak from the packing.
Therefore, be sure to observe the fastening
angle.
10.Fasten it by using filter wrench 1/2 to 3/4 turns.
At that time, take care not to damage or deform
the filter cartridge.
11.Install drain hose (4).
12.After replacing the filter cartridge, start the
engine and run it at low idle for 10 minutes.
Check for fuel leakage from the filter seal
surface and transparent cup mounting face. If
there is any leakage of fuel, check the fastening
condition of the filter cartridge.
If the fuel still leaks, follow Step 1 to 6 to remove
the filter cartridge, then check the packing
surface for damage or foreign material. If any
damage or foreign material is found in the
packing, replace the cartridge with a new one,
then repeat Steps 7 to 10.
a10. Check of fuel main filter
k Immediately
8. Clean the filter holder, fill the new filter cartridge

with clean fuel, apply thin film of oil to the
packing surface, then install it to the filter holder.
k When
adding fuel, do not remove cap (A)

at the center. Always fill fuel from dirty
side of eight small holes (B).
k After
adding fuel, remove cap (A) at the

center and install fuel filter.

k High
pressure is generated inside the engine

fuel piping system when the engine is
running. Stop the engine and wait at least 30
seconds until the inner pressure is released
and then replace the filter .
k Never
bring flames near fuel.
k When
k Always
fill with clean fuel. Be careful not

to let any dirt or dust get into the fuel. In
particular, since center portion is the
clean side, do not remove cap (A) when
adding fuel. Be careful not to let dirt or
dust get into the center clean side.
using fuel feed pump, be sure not to

loosen air bleeding plug in fuel circuit. While
the fuel feed pump is in operation, pressure
is applied to the fuel circuit. Do not loosen
the air bleeding plug at this time, since the
fuel may spout out.
a A special filter with high-efficiency filtering

properties is adopted for Komatsu genuine fuel
filter cartridges. Be sure to use Komatsu
genuine parts when replacing.
a The common rail fuel injection system used on
this machine consists of more precise parts than
those in the conventional injection pump and
nozzles. If any cartridge other than a Komatsu
genuine fuel filter cartridge is used, foreign
material may enter and it may cause problems in
the injection system. Do no use substitute parts.
9. When installing, fasten it by finger until the

packing surface contacts the seal surface of the
filter holder. If the filter cartridge is fastened too
much, the packing will be damaged and this
WA470-7
a During testing or maintenance of the fuel system,

take extreme care not to allow any foreign
material to enter the fuel system. If any dust or
other material sticks to any part, wash the part
thoroughly with clean fuel.
40-19
40 Troubleshooting
Prepare a container to receive drained oil.

Prepare a filter wrench.
each part to drop.
2. Open the engine side cover on the right side of
the machine.
3. Place a container to receive drained oil under
filter cartridge (1).
4. By using the filter wrench, turn filter cartridge (1)

counterclockwise to remove it.
5. Clean the filter holder, apply the thin film of oil to
the packing surface of the new filter cartridge,
then install the filter cartridge to the filter holder.
a Continue the supply of fuel until the fuel

gauge monitor turns to blue.
(Check the fuel level with monitor after
turning the starting switch to ON position.)
9. Tilt switch (2) for the fuel feed pump in the
engine room to ON position.
a The fuel feed pump operates and lamp (3)
flashes.
a The timer built in this switch automatically

starts up and stops the fuel feed pump (see
the figure).
k Do
a Operation of the fuel feed pump stops while

the lamp is flashing. It is, however, not a
failure.
k Remove
a If you set the switch to OFF position while the

lamp is lighted, the lamp goes out and the
fuel feed pump stops.
not fill the new filter cartridge with

fuel.
cap (A) at the center, and then
install the filter cartridge.
6. When installing, fasten it by finger until the

packing surface contacts the seal surface of the
filter holder. Then fasten filter cartridge 1/2 to 3/4
turns. If the filter cartridge is fastened too much,
the packing will be damaged and this leads to
leakage of fuel. If the filter cartridge is too loose,
fuel will also leak from the packing. Therefore,
be sure to observe the fastening angle.
7. Supply fuel to the fuel tank.
40-20
10.After the specified time (approximately 6

minutes and 30 seconds), lamp (3) goes out
automatically and the fuel feed pump stops.
a11. Check of engine oil level (in oil pan) and
type
k Immediately

WA470-7
40 Troubleshooting
a When checking the oil level after the engine has

been operated, wait for at least 15 minutes after
stopping the engine.
a If the machine is at an angle, make it level
before checking.
a If the coolant level is low, add coolant.
6 Engine oil: Approximately 38 l
each part to drop.
2. Open the engine side cover at the rear right side
of the machine.
3. Pull out dipstick (G) and wipe the oil off with a
cloth.
4. Fully insert dipstick (G) into the dipstick pipe,
then remove it.
a When the ambient temperature is low, water

or emulsified matter may stick to the dipstick,
oil filler cap, etc. or the drained oil may be
milky white because of water vapor in the
blowby gas. However, if the coolant level is
normal, it is not a problem.
a If the coolant level is low, add coolant.
a12. Check of coolant level (in sub tank)
k The
radiator cap does not need to be opened

for standard checks. When checking the
coolant level, check the sub-tank when the
engine is cooled down.
k Immediately
5. The oil level should be between the H and L

marks on dipstick (G). If the oil level is below the
L mark, add oil through oil filler port (F).
a The labels ENGINE STOPPED and ENGINE

IDLING are stamped on respective sides of
the dipstick.
a When checking the oil level after stopping
the engine, use the side with the stamped
mark ENGINE STOPPED .
6. If the oil level is above the H line, drain the
excess oil from drain plug (P), then check the oil
level again.
7. If the oil level is correct, tighten oil filler cap (F)
securely and close the engine side cover.
WA470-7
after the engine is stopped, the

coolant is still very hot and the pressure is
accumulated in the radiator. If the cap is
opened under these conditions, you may be
scalded. If you need to remove the radiator
cap, wait until the temperature drops before
you do. Then turn the cap slowly to release
the pressure and remove it with care.
1. Open platform cover (1) on the right side of

machine.
2. Check that the coolant level is between the
FULL and LOW marks of the sub-tank. If the
coolant level is low, open the cover on top of the
platform and refill both sub-tanks with coolant
through the coolant filler ports (2) to the FULL
level.
3. After refilling with coolant, tighten the cap
securely.
4. If the sub-tank is empty, leakage of coolant is
suspected. If any abnormality is found in the
check for leakage, repair it immediately. If no
abnormality is found, check the level of the
coolant in the radiator. If it is low, add coolant to
the radiator and then to the sub-tank. If the
amount of added coolant is larger than usual,
check for leakage of coolant. Check the coolant
for any abnormality such as mixing of oil, etc.
40-21
40 Troubleshooting
If air cleaner clogging caution lamp (1) lights up on

the machine monitor, clean the air cleaner element.
a Do not clean the air cleaner element until the air
cleaner clogging caution lamp lights up.
If you clean the element frequently before the air
cleaner clogging caution lamp lights up, the air
cleaner will not deliver optimum performance
and the cleaning efficiency will be reduced. In
addition, dust attached to the element can drop
into the inner element more frequently during the
cleaning process.
a Dust indicator (2) for indicating seriousness of
clogging of air cleaner (indicates clogging in five
steps) is installed in the engine hood on the left
side of machine. It helps to check cleanliness of
the air cleaner and its replacement timing.
a.13 Check of air cleaner for clogging

k When
using compressed air for cleaning, put

on personal protective items such as
protective eyeglasses, gloves, dust mask,
etc. to protect yourself from dirt that will fly
out.
k When
removing the outer element from the

air cleaner body, do not forcibly pull it out,
otherwise it can be dangerous. Be careful not
to fall from a high location on unsafe
scaffolding as a reaction when pulling out
the outer element.
Cleaning and replacement of outer element

1. Fully open air engine side cover on the right side
of engine hood.
2. Remove clips (4) (3 places) of cover (3) and
remove the cover (3).
k If
performing testing, cleaning, or

maintenance while the engine running, dust
may enter into the engine and engine may be
damaged. Be sure to stop the engine before
performing these works.
40-22
WA470-7
40 Troubleshooting
3. Remove the outer element (6).

a Never remove inner element (7). If it is
removed, dirt will enter and can cause an
engine trouble.
4. Hold inner element (7) so that it does not come
out, and clean the inside of the air cleaner body
and the cover.
5. Use a dry cloth or compressed air to clean off
the dirt stuck to the cover (2) and vacuator valve
(5).
6. Check that there are no cracks in the lip of the
vacuator valve (5). If any cracks are found,
replace it with a new one.
7. Blow dry compressed air (less than 0.2 MPa

{2.1kg/cm2}) from the inside of the outer element
along the folds. Then blow it from outside along
the folds, and finally blow it from the inside
again.
8. Install cleaned outer element to the air cleaner

body.
9. Check that O-ring (8) is fitted to cover (2).
10.Set so that vacuator valve (5) of cover (2) is at
the bottom, and insert it into the air cleaner body.
11.Fit clips (4) (3 places) of cover (2) to the
protruding portion of the air cleaner body to lock
in position.
12.After cleaning or replacing the element, press
the button of dust indicator to restore the red
indication to normal indication.
a If the dust indicator still indicates the 5th level
even when the button is pressed after
cleaning the element, replace the element.
a Even when the element is cleaned or
replaced with a new one, the dust indicator
may go to the 3rd position.
a After clearing the element, throw light on its

inside using a light bulb to check it. If it has a
small hole or thin part, replace it.
a Do not tap or hit the element against any
other object when cleaning it.
a Do not use the element if its folds or gasket
or seal are damaged.
WA470-7
40-23
40 Troubleshooting
9. After replacing the element, restore the red

indication of the indicator to normal indication.
b. Hydraulic and mechanical equipment
b3. Check of hydraulic oil level
k Immediately

k When
removing the oil filler cap, the oil may

spout out. Turn it slowly to release the
internal pressure, then remove it.
Replacement of inner element

a Do not clean and reuse the inner element.
Replace the inner element with a new one at the
same time as you replace the outer element.
1. Fully open air engine side cover on the right side
of engine hood.
2. Remove clips (4) (3 places) of cover (3) and
remove the cover (3).
1. Lower the bucket to the ground, wait for at least

5 minutes after stopping the engine before
checking.
2. Check the oil level with sight gauge (G) of
hydraulic tank. The oil level is appropriate when
it is nearby the top of the sight gauge (G).
a Since it may damage the oil circuit and cause
the oil to spurt out, when the refilled oil
exceeds the top level of the sight gauge (G),
stop the engine and wait for the hydraulic oil
to cool down.Then drain excess oil through
the drain plug.
3. Loosen bolt, and turn and open cover (1).
3. Remove the outer element (6).

4. Remove the inner element (7).
4. If the oil level is not nearby the top of the sight

gauge (G), add oil through oil filler port (F) at the
top of the hydraulic tank.
5. Cover air connector side (outlet side) with a

clean cloth or tape.
6. Clean up the inside of air cleaner body, and
remove the cover installed at step 5.
7. Install a new inner element to connector and
tighten nut.
8. Install the outer element.
40-24
b4. Check of hydraulic oil strainer
WA470-7
40 Troubleshooting
k Immediately

k When
you remove the oil filler cap, oil may

spurt out. Be careful to rotate it slowly, and
release inner pressure gradually.
1. Lower bucket to the ground with its bottom level,

apply parking brake, and stop engine.
2. Loosen bolts and remove cover (1).
8. Remove bolts (4) (6 pieces) and remove cover
(5).
9. Hold the top of rod (6) and pull it up to remove
strainer (7).
10.Remove any dirt stuck to strainer (7), then wash
it in flushing oil. If strainer (7) is damaged,
replace it with a new one.
3. Remove the cap of oil filler port (F).
11.Refill with the specified quantity of hydraulic oil

through oil filler port (F), then install the cap.
b.5 Check of hydraulic oil filter
k Immediately
4. Place a container under drain plug (2) to catch

drained oil.
6 Hydraulic oil: approximately. 173 l
5. Remove drain plug (2).
6. Open drain valve (3) gradually to drain oil.
7. After draining the oil, close drain valve (3) and
tighten drain plug (2).
Tightening torque
Drain plug (2): 68.6 9.8 Nm {7.0 1.0 kgm}
Drain valve (3): 63.7 14.7 Nm {6.5 1.5 kgm}
WA470-7

k When
you remove the oil filler cap, oil may

spurt out. Be careful to rotate it slowly, and
release inner pressure gradually.
1. Lower the bucket to the ground with its bottom

level, turn the parking brake switch to ON
position, and apply the parking brake.
2. Stop the engine and wait for the temperature of
each part to drop.
3. Loosen bolt and remove cover (1).
40-25
40 Troubleshooting
Be sure to bleed air while running the engine at

low idle.
4. Remove mounting bolts (3) of filter cover (2) on

the top of the tank, then remove cover.
When doing this work, cover may jump out
under the force of spring (4), so hold cover down
when removing bolts.
5. Remove spring (4) and bypass valve (5), then
pull out element (6).
6. Check inside of the tank for foreign material,
then remove foreign material if any.
7. Install new element (6), then set bypass valve
(5), spring (4), and cover (2) to tank.
When doing this, if O-ring of cover is damaged
or deteriorated, replace it with a new one.
12.Make sure that hydraulic oil is added to the

specified level.
13.Next, increase the engine speed, and repeat air
bleed according to procedures of 10 above until
no air comes out from plug (7).
14.After completing air bleeding, tighten plug (7).
3 Tightening torque: 11.3 1.5 Nm {1.15
0.15 kgm}
15.Be sure that hydraulic oil is added to the
specified level.
16.Check the filter cover mount for oil leakage.
17.Install cover (1).
b6. Check of transmission case oil level
k Immediately

burn injury. Accordingly, wait until they have
cooled down before starting the work.
8. While pressing down cover, tighten mounting

bolts evenly.
9. Make sure that hydraulic oil is added to the
specified level.
10.Run the engine at low idle, and extend and
retract each of the steering, bucket, and boom
cylinders 4 to 5 times, and be careful not to
move them to the stroke end (stop
approximately 100 mm before the stroke end).
Perform this operation when ooze of oil on the

transmission case is recognized or when oil in
the coolant is recognized.
1. Stop the engine.
You cannot measure the exact oil level until
12 hours elapses after the engine is stopped
because of the oil remaining in various parts.
2. Remove oil filler cap (F).
3. Pull out dipstick (G) and wipe the oil off with a
cloth.
4. Fully insert dipstick (G) into the dipstick pipe,
then remove it.
Whenever inserting the dipstick, be sure to
insert it into the dipstick pipe in the filler pipe.
a If the engine is run at a high speed

immediately after startup or a cylinder is
moved up to its stroke end, air taken inside
the cylinder may cause damage to the piston
packing.
11.Next, move each of the steering, bucket, and
boom cylinders to the stroke end 3 or 4 times.
Stop the engine and loosen air bleeding plug (7)
to bleed air from the hydraulic tank, and then
tighten plug (7).
40-26
WA470-7
40 Troubleshooting
When checking the oil level after leaving the

engine to running at idle.
(when the entire transmission is in heat balance
like immediately after the actual operation)
(1) Run the engine at low idle and wait at least
15 minutes.
(2) Check the level when the indication of the
torque converter oil temperature gauge is at the
mid of the lowest range.
5. The oil level should be between the H and L

marks on dipstick (G). If the oil level is below the
L mark, add oil through oil filler port (F).
The following levels are marked on the dipstick.
(A): ENG STOP (Engine is stopped)
(B): ENG LOW IDLE (Engine is running at low
idle)
When check it after the temperature is increased

with the torque converter stall.
(1) Wait until the indication of the torque
converter oil temperature gauge moves in
between the lowest and the 2nd lowest by
increasing temperature with the torque converter
stall.
(2) Run the engine at low idle for approximately
5 minutes and check the oil level.
6. If the oil level is above the H line, drain the
excess oil from drain valve (P), then check the
oil level again.
b7 Check of axle case oil level (front and rear)

k Immediately
7. If the oil level is at the correct level, insert

dipstick (G) in the dipstick pipe and close the
cap.
Checking of the oil level must be done at "ENG
STOP" position after 12 hours or more elapsed after
the engine is stopped. The oil level check can be
performed when the engine is running at low idle as
well. In this case, observe the following.
WA470-7

burn injury. Accordingly, wait until they have
cooled down before starting the work.
This check is required if ooze of oil is recognized on

the axle case.
Place the machine on a level ground before starting
the check.
(If the machine is at an angle, exact measurement
of oil level is impossible.)
40-27
40 Troubleshooting
1. Stop the engine and remove plug (1).

a Remove mud and dirt from around plug (1),
then remove plug.
2. Wipe off oil on dipstick (G) attached to plug (1)
by using a piece of cloth.
A: Front
a Since lubricating oil of a different brand is

used for the axle with ASD (Anti-Slip
Differential), be sure to use the specified
lubricating oil.
5. If the oil level is above the top groove (H), drain
the excess oil from drain plug (P), then check
the oil level again.
6. If the oil level is appropriate, install plug (1).
3 Tightening torque: 127 to 177 Nm {13
to 18 kgm}
b8. Bleeding air
For the bleeding air from the fuel system, see
Testing and adjusting, "Bleeding air from fuel
circuit".
For the bleeding air from the hydraulic system,
see Testing and adjusting, "Bleeding air from
each part".)
c. Electric equipment
B: Rear
c1. Check of battery terminal for looseness and

corrosion
Check battery terminals for looseness and
corrosion.
combustibles (dead leaves, twigs, etc.) around
the batteries.
3. Set oil level gauge (G) as shown in the figure to

the right.
(2): Axle
(3): Spot-faced surface
4. Oil level is appropriate if it is between two
grooves (H) and (L) of oil level gauge.
If the oil does not reach the lower groove (L),
supply axle oil from oil filler port (F).
c2. Check of alternator terminal for looseness

and corrosion
Remove the engine undercover.
Check alternator terminals B, R and E for open
circuit, loosening and corrosion.
c3. Check of starting motor terminal for
looseness and corrosion
Check starting motor terminals B, C and R for
open circuit, loosening and corrosion.
c4. Check of battery voltage (with engine
stopped)
Check the battery voltage by using the battery
tester while the engine is stopped.
c5. Check of battery electrolyte level
Check before operating the machine.
k Do
not use the battery if the battery

electrolyte level is below the LOWER LEVEL
line. This will accelerate deterioration of the
inside of the battery and reduce the service
life of the battery. In addition, it may cause an
explosion.
k Since
the battery produces combustible gas

that can explode, do not bring any open
flame near it.
k Battery
electrolyte is dangerous. Take care

that it does not come in contact with your
eyes or skin. If it does, wash it away with
water and contact your doctor.
40-28
WA470-7
40 Troubleshooting
a Do not add the battery fluid above the UPPER

LEVEL line. If done, the fluid may leak and the
coating surface may be damaged or the parts
may be corroded.
(B) Low: Since the electrolyte level does not

reach the sleeve bottom, the shape of the
electrode plates will appear straight.
3. After adding the refined water, tighten the cap.
a To avoid freezing, add the purified water (such

as a commercial battery fluid) before starting the
work in the next day.
When checking the electrolyte level through the
side face of the battery
1. Wipe and clean the battery surface, especially
around the battery level lines with a wet cloth,
and check to see that the battery fluid is
between the UPPER LEVEL and LOWER
LEVEL lines.
a Do not clean the battery with a dry cloth
since static electricity may cause an
explosion.
a If the fluid exceeds the UPPER LEVEL,

remove the fluid using a dropping pipette or
others until the fluid drops to the UPPER
LEVEL. When you have removed the fluid
from the battery, neutralize it with the baking
soda (sodium bicarbonate) and wash it away
with a large quantity of water.
c6. Check of wiring harness for discoloration,
burn and cover peeling
Check the wiring harness and cables for
discoloration and burn.
2. If the battery fluid drops below the center

position between the UPPER LEVEL and
LOWER LEVEL lines, remove the cap and add
the fluid (such as a commercial battery fluid)
immediately until the fluid reaches the UPPER
LEVEL.
a If discolored or burnt, the circuit may be shorted

or grounded.
a After adding the refined water, tighten the

cap securely.
c7. Check for coming off of wiring harness

clamp and sagging of wiring harness
Check wiring harness for sagging and looseness
due to coming off of harness clamp
a If the fluid exceeds the UPPER LEVEL,

remove the fluid using a dropping pipette or
others until the fluid drops to the UPPER
LEVEL. When you have removed the fluid
from the battery, neutralize it with the baking
soda (sodium bicarbonate) and wash it away
with a large quantity of water.
When electrolyte level cannot be checked
through the side face of the battery
1. Remove the cap from the top of battery.
2. Observe fluid level port (3), and check the fluid
level. If the fluid level is below sleeve (4), always
add the fluid (such as a commercial battery fluid)
until it reaches the bottom of sleeve (4) (the
UPPER LEVEL).
Check the wiring harnesses and cables for

damage and peeling of the covers.
If any abnormality is found, repair or replace the
wiring harness or cables.
a In particular, carefully check the wiring harness

around the hot and movable parts.
If removed from the clamp, secure it with the
clamp.
(A) Correct level: Since the electrolyte level

reaches to the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.
WA470-7
40-29
40 Troubleshooting
c8. Check of grounding

a Take special care not to cause a loose cable
connection and corrosion.
Check connection of ground terminal (F40) in
the left side of front frame.
Remove cover (1) under the left of the operator's

cab.
Check connection of ground cables (E14A),

(E14B) and (E14C) of engine controller.
a The engine ground terminal locates under the
hydraulic oil tank.
Check the connection of engine ground
terminals (3) and (4).
Check the connection of ground terminal (L100).
Check the connection of cab ground (2).
Open the both right and left engine side covers.

Check the connection of ground terminals (R50)
and (R22).
40-30
WA470-7
40 Troubleshooting
Open the engine left side cover.

Check connection of ground terminal (E15).
a Transmission ground terminal is located on the

left side of transmission.
Check the connection of transmission ground
(TGN).
c9. Check for loose connector and damaged

lock.
Check the connection of male and female
connectors by pulling them by hand.
If the connection is loose, secure it.
WA470-7
Check the connectors for unlocking, and check

the lock and connector housing for cracking.
Remove cover (1) and fuel feed pump switch (2).
Check lock screws (4) to (6) of engine controller

(3) for looseness.
a Use a hexagonal wrench with 4 mm width
across flats.
Check lock screws (8) to (10) of transmission

controller (7) for looseness.
a Use a hexagonal wrench with 4 mm width
across flats.
Check the lock screws of work equipment
controller (11) in the similar way.
40-31
40 Troubleshooting
c10. Check the connector pins for corrosion,

bending and deformation.
Disconnect the connectors, and check their pins
for corrosion, bending, sinking than other pins,
and extension of female pins.
If pins are defective, repair or replace them.
Wipe and remove any foreign material with a

cloth or others, and blow the air to clean the
connector.
a If the pins are not shiny, apply contact restorer to

them and connect and disconnect the
connectors several times to shine them. (If the
pins do not become shiny, connect and
disconnect the connectors 10 times)
c11. Check of connector for water and foreign
material insertion.
Disconnect connectors, and check them for
insertion of water or foreign materials.
c12. Check of wiring harness for open or short
circuit
Check the connection (crimped part) between
connector pins and wiring harness.
If the line is open as shown as (A), repair or
replace the wiring harness or cables.
a If found, the seals may be damaged. Check the

seals for damage.
If the seal is defective, repair or replace it.
Dry the inside of the connector with a dryer.
Visually check wiring harnesses for peeling of
harness covers and the pins for contact with
adjacent pins due to defective crimping.
c13. Check of slow-blow fuse for blowout and
corrosion
a When replacing a fuse, be sure to turn off the
power (turn the starting switch to OFF position)
and turn the battery disconnect switch to OFF
position.
40-32
WA470-7
40 Troubleshooting
A fusible link is a large-capacity fuse.

If a fuse is corroded and coated with white
powder, or there is any play between the fuse
and fuse holder, replace the fuse.
Replace each fuse with the one of the same
capacity.
3. Start and warm up the engine and measure the

voltage while running the engine at a medium or
a higher speed.
If the voltage is abnormal, repair or replace
the alternator.
Open the engine left side cover and remove cover

(1).
c 15. Check of battery relay operation sound

(when starting switch is turned to ON or OFF
position)
There are slow-blow fuses (2) to (4): 50 A, and (5):
120 A.
1. Open the engine left side cover.

2. Turn the starting switch to the ON and OFF
positions, and check whether the battery relay
operation sound is heard or not.
If the operation sound is not heard, check the
related circuits, referring to troubleshooting
for E-1 described in the E mode
troubleshooting.
If the relating circuit is normal, replace the
battery relay.
Remove the cover from the rear of operator cab,

and you can access to fuse box 1 and fuse box 2.
c14. Check of alternator voltage (when engine

speed is medium or higher)
1. Open upper right of the engine side cover.
2. Connect the positive (+) lead of the multimeter to
alternator terminal (B) and connect the negative
(-) lead to the chassis ground.
WA470-7
40-33
40 Troubleshooting
Preparation work for troubleshooting of electrical system

a When carrying out troubleshooting of an electric
circuit related to the transmission controller,
monitor controller, engine controller, work
equipment controller , or KOMTRAX
communication MODEM, expose the related
connectors according to the following procedure.
(WA380-C050-42C-K-01-A)
5) Disconnect connectors M01B (7), L18A (8),

and L18B (9).
6) Remove cover (10).
a Disconnect and connect the connectors, which

have a special locking device, according to the
Preparation
(WA470-C050-42C-K-00-A)

1) Fold operator's seat (1) forward.
2) Remove box mounting bolts (2) (4 pieces)
and remove the box.
7) Disconnect connectors L71 (12), L72 (13),
and L73 (14) of work equipment controller
(11), and insert or connect T-adapters for
troubleshooting.
3) Remove top cover mounting bolts (3) (4

pieces), and remove top cover (4). [*1]
a Install top cover (4) so that the whole

circumference of clearance (a) becomes
Min. 2 mm.
4) Remove bolts (5) and (6) (2 pieces each).
1) Open the right engine side cover.
a The engine controller is mounted on the
engine (front of the machine).
2) Remove cover (1) and fuel feed pump switch
(2).
40-34
WA470-7
40 Troubleshooting
3) Insert or connect T-adapters for

troubleshooting to connectors J1 (3), J2 (4),
and EC3 (5) of engine controller.
a Since the connectors is secured with

screws, loosen them before
disconnecting the connector.
a When restore them, tighten the screws to
the specified torque.
3 Screw:
3 1 Nm {0.3 0.1 kgm}

and L18B (9).
and remove the box.
7) Disconnect connectors L61 (12), L62 (13),
and L63 (14) of transmission controller (11),
and insert or connect T-adapters for
troubleshooting.

pieces), and remove top cover (4). [*1]
WA470-7
40-35
40 Troubleshooting

and L18B (9).
and remove the box.
7) Unlock connectors (11) and (12).

a Shift lever (c) inward while pressing tab
(b). (as shown in the right of the following
figure)

pieces) and remove top cover (4). [*1]
8) Disconnect connectors MCM2 (11), MCM1B

(12), and MCM1A (13) of monitor controller
(14), and insert or connect T-adapters for
troubleshooting.

circumference of clearance (a) becomes
Min. 2 mm.
40-36
WA470-7
40 Troubleshooting
5. KOMTRAX communication module

and remove cover (3).
6. Ambient pressure sensor (PAMB)

Engine Ne speed sensor (NE)
Crankcase pressure sensor (PCCV)
Engine oil pressure sensor (POIL)
Charge (Boost) pressure sensor (PIM)
Fuel dosing pressure sensor (PDOSER)
Mass air flow and temperature sensor (R93)
Shut off valve solenoid #1 (SOV1)
Shut off valve solenoid #2 (SOV2)
Fuel dosing solenoid (DOSER)
KDPF differential pressure and outlet pressure
sensor (E25)
a Disconnection and connection of connectors
3) Remove bolts (4) (5 pieces) and remove

cover (5).
Since the connectors of ambient pressure

sensor and engine Ne speed sensor have a
special lock mechanism, disconnect them in
the order of (a) to (c), and connect them in
the order of (d) to (f) as shown in the
following figure.
Disconnection: (a) Slide the lever, (b) unlock,
and (c) disconnect the connectors.
Connection: (d) Connect the connectors, (e)
engage the lock, and (f) slide the lever.
4) Disconnect connectors L80A (7), L80B (8) of

KOMTRAX communication module (6), and
insert or connect T-adapters for
troubleshooting.
7. Bkup (camshaft) speed sensor (G)
Supply pump PCV1 (PCV1)
Supply pump PCV2 (PCV2)
WA470-7
40-37
40 Troubleshooting

Since the connectors of Bkup speed sensor
and supply pump PCV have a special lock
mechanism, disconnect them in the order of
(a) to (b), and connect them in the order of
(c) to (d) as shown in the following figure.
Disconnection: (a) Unlock and (b) disconnect
the connectors.
Connection: (c) Connect the connectors and
(d) engage the lock.
a Precautions for disconnection of connectors

The direction of the lock for connector may
be changed toward the difficult direction
(facing to the bottom or to the engine side)
for unlocking depending on the position
where the sensor is screwed in.
In such a case, turn the lock to the direction
(a) by using the needle nose pliers with
curved tip (commercially available) [1], then
the lock can be canceled easily.
Since the lock is canceled with "click" sound,
listen the sound and disconnect the
connectors.
8. Common rail pressure sensor (FUEL RAIL

PRESS)
Since the connectors of common rail
pressure sensor have a special lock
the connectors.
a Precautions for connecting connectors

When connecting connectors, pay attention
not to connect the connectors reverse.
Engage lock portion (e) on the harness side
to triangle notch portion (f). (Pay attention not
to take square guide portion (g) on the
opposite side of triangle notch portion (f) by
mistake.)
9. Engine coolant temperature sensor (TWTR)

Charge (Boost) temperature sensor (TIM)
40-38
WA470-7
40 Troubleshooting

Since the connectors of engine coolant
temperature sensor have a special lock
the connectors.
a Removal and installation of sensor body

Since a deep socket is necessary when
removing and installing the engine coolant
temperature sensor, see "Tools for testing,
adjusting, and troubleshooting".
WA470-7
40-39
40 Troubleshooting
Classification and procedures for troubleshooting
(HM300-5160-40D-A-00-A)
Classification of troubleshooting codes

Mode
Display of code
E mode
H-mode
S-mode
Content
Troubleshooting by failure code
Troubleshooting of electrical system
Troubleshooting of hydraulic and mechanical systems
Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon which appears a source of a trouble occurs on the machine, go to the corresponding
troubleshooting section according to the following procedure.
1. Procedure for troubleshooting when user code and failure code are displayed on machine monitor:
If a user code and a failure code are displayed on the standard screen of the machine monitor, perform the
troubleshooting for the corresponding "Display of code" according to the displayed failure code.
a If multiple failures occur simultaneously, all failure codes are displayed repeatedly in order. Record all
failure codes on a paper.
2. Procedure for troubleshooting when user code and failure code are not displayed on machine monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor. (See [*1].)
1) If a failure code is displayed, perform troubleshooting for the corresponding "Display of code"
according to the failure code.
a If an electrical system failure code is displayed delete all the codes once and reproduce them, and
then see if the failure is still detected. (See [*2].)
a A failure code of the mechanical system cannot be deleted.
2) If no failure code is found in the abnormality record, a failure that the machine cannot find out by itself
may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon which is assumed to show the failure again and select the same
phenomenon from the table of "Phenomenon to be assumed a failure and troubleshooting number",
and then perform troubleshooting corresponding to that phenomenon in the "E-mode", "H-mode", or
"S-mode".
3. Action to take after failure is eliminated
Clear all the failure codes in the electrical system abnormality record, referring to the next page.
[*1], [*2]
1. On the normal operation screen, hold down inverted triangle key [] (6), and press numeric keys [1], [2]
and [3] in this order.
(4) is the Enter switch (check mark).
(5) is the Return switch.
(7) is the Menu switch (to clear all).
2. Press the inverted triangle key [] twice on the Service Menu screen to select "03 Abnormality Record".
3. Press the Enter key (check mark) to validate it, and go to the "Abnormality Record" screen.
40-40
WA470-7
40 Troubleshooting
4. Press the Enter key (check mark) on the "Abnormality Record" screen, and go to the "Mechanical
Systems" screen.
5. Press the inverted triangle key [] and make sure that the following failure codes are not generated.
Record all failure codes on a paper.
a A failure code of the mechanical system cannot be deleted.
6. Return to the "Abnormality Record" screen by pressing the Return key (explained above).
7. Go to the "Electrical system abnormality record" similarly to steps 2 and 3.
8. Press the inverted triangle key [] and make sure that the following failure codes are not generated.
Record all failure codes on a paper.
WA470-7
40-41
40 Troubleshooting
a If "E" is displayed at the left to the failure code, this code is "active" (that is, this failure still continues or
its recovery is not verified yet). If "E" is not displayed, the failure code is "inactive" and the code will be
cleared in the subsequent clearing step. Be sure to record this failure code on a paper.
9. Hold down the inverted triangle key [], and press numeric keys [1], [2] and [3] in this order to go to the
"Clear mode". (Same as 1)
10.Press the Menu switch of the switch panel (as explained above).
11.Press the Enter key (check mark) to clear all failure codes.
12.Return to the "Electrical Systems" screen by pressing the Return key (explained above). Check if a failure
code is still displayed or not, and record it on a paper.
13.Return to the "Abnormality Record" screen by pressing the Return key (explained above).
40-42
WA470-7
40 Troubleshooting
Symptom and troubleshooting numbers

Symptom of failure
No.
1
2
3
4
5
6
7
8
9
10
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
(WA470-5540-441-A-00-A)
Action level and failure code

Action level is displayed on machine monitor. Press Enter switch (check
mark) to display "Occurred error list".
Failure code is displayed on mechanical system abnormality record.
Failure code is displayed on electrical system abnormality record.
Symptom related to engine
Engine does not start
Engine does not crank when starting switch is turned to "START" position.
Engine cranks but no exhaust smoke comes out.
Fuel is being injected but engine does not start.
Engine startability is poor.
Engine does not pick up smoothly.
Engine stops during operation.
Engine runs rough or is unstable.
Engine lacks power.
KDPF gets clogged in a short time
Engine oil consumption is excessive.
Oil becomes contaminated quickly.
Fuel consumption is excessive.
Oil is in coolant (or coolant spurts back or coolant level goes down).
Engine oil pressure drops.
Fuel mixes into engine oil.
Water mixes into engine oil (milky).
Coolant temperature rises too high (overheating).
Unusual noise is heard.
Vibration is excessive.
Air cannot be bled from fuel circuit.
Active regeneration of KDPF is performed frequently.
Active regeneration takes time.
White smoke is exhausted during active regeneration.
Manual preheating system does not work.
Automatic preheating system does not work.
While preheating is working, preheating monitor does not light up.
When operating engine power mode selector switch, engine mode selector
function does not operate properly.
Fuel feed pump does not operate properly.
Symptom related to travel
Machine does not move off.
Torque converter lockup clutch is not disengaged (engine stalls).
Torque converter lockup clutch is not engaged.
Travel speed is slow, bucket thrust force is weak, gradability is low, or gear
speed does not shift.
Large shocks are made when machine starts or gear is shifted.
Machine starts or gear speed shifts with long time lag.
Torque converter oil temperature is high.
Steering component
Machine does not turn.
Turning response is poor.
Steering wheel is heavy to turn.
Machine sways or large shocks are made while machine turns.
Turning radius differs between right and left turns.
WA470-7
Troubleshooting
Index
Perform
troubleshooting for
failure code.
E-1, S-1
E-1, S-1
S-2
S-3
S-4
S-5
S-6
S-7
S-8
S-9
S-10
S-11
S-12
S-13
S-14
S-15
S-16
S-17
S-18
S-19
S-20
S-21
S-22
S-23
E-2
E-3
E-4
E-38
E-57
H-1
H-2
H-3
H-4
H-5
H-6
H-7
H-8
H-9
H-10
H-11
H-12
40-43
40 Troubleshooting
No.
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
40-44
Symptom of failure
Brake component
Wheel brakes do not work or they are weak.
Wheel brakes are not released or drag.
Parking brake does not work or it is weak.
Parking brake is not released or it drags (including emergency release
system)
Symptom related to work equipment
Boom does not rise.
Boom moves slow or boom lacks lifting force.
Rising boom slows down at certain height.
Lift cylinders do not serve to hold bucket on ground
Hydraulic drift of boom is large.
Boom moves up and down during operation.
Bucket does not tilt back.
Bucket moves slow or bucket lacks tilt back force.
Bucket decelerates during tilt-back operation.
Bucket cylinder does not hold bucket on ground.
Hydraulic drift of bucket is large.
Bucket tilts back and forth during carrying load (work equipment valve in
HOLD).
Boom and bucket control levers do not move smoothly and heavy to move.
Operating work equipment causes engine speed to lower significantly or
engine to stall.
Large shocks are made when work equipment starts and stops working.
When single work equipment is relieved hydraulically, other work equipment
moves.
E.C.S.S. (travel damper) does not work and machine pitches and bounces.
Bucket does not stop at the position which is set with remote bucket
positioner
Symptom related to fan
Fan speed is abnormal (too high or low, or fan does not rotate)
Unusual noise is heard from around fan.
Symptom related to machine monitor
All of LCD unit, LED unit, and meter unit on machine monitor displays
nothing.
LCD unit on machine monitor displays nothing.
Backlight of LCD unit on machine monitor is abnormal (backlight goes out or
flickers).
LCD on machine monitor does not display properly.
Meter unit display on machine monitor is abnormal
Night lighting lamp of meter unit on machine monitor is abnormal.
Caution LED on machine monitor is abnormal
LED of switch panel on machine monitor is abnormal or switches does not
operate properly.
2 switches operation of switch panel on machine monitor does not function.
Switch panel buzzer of machine monitor is abnormal.
Rearview monitor does not light up or backlight flickers.
Rearview monitor images are not displayed clearly.
Rearview monitor brightness cannot be adjusted.
Night lighting lamp of rearview monitor is abnormal.
Some items of gauges and caution lamps on machine monitor are not
displayed properly.
Troubleshooting
Index
H-13
H-14
H-15
H-16
H-17
H-18
H-19
H-20
H-21
H-22
H-23
H-24
H-25
H-26
H-27
H-28
H-29
H-30
H-31
H-32
H-33
H-34
H-35
H-36
E-5
E-6
E-7
E-8
E-9
E-10
E-11
E-12
E-13
E-14
E-15
E-16
E-17
E-18
E-19
WA470-7
40 Troubleshooting
Symptom of failure
No.
90
91
92
93
Parking brake indicator lamp does not light when the parking brake is set to
ON (Parking) position (stays in NEUTRAL).
When brake accumulator oil pressure drops, the brake oil pressure caution
lamp does not light.
Air cleaner clogging indicator lamp does not light.
Radiator coolant level caution lamp does not light.
Indication of hydraulic oil temperature gauge does not increase, or hydraulic
oil temperature caution lamp does not light.
Indication of torque converter oil temperature gauge does not increase, or
torque converter oil temperature caution lamp does not light.
Fuel level gauge does not indicate correct level.
Seat belt caution lamp indication is abnormal.
Alarm buzzer does not sound.
When starting switch is in ON position, alarm buzzer does not stop sounding.
94
Air conditioner does not operate normally (including failure codes related to
air conditioner).
84
85
86
87
88
89
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
Others
Horn does not sound.
Horn does not stop sounding.
Kickdown does not work when kickdown switch is turned ON.
The hold switch does not work when it is pressed.
Parking brake does not work even if it is applied, or the brake drags when
traveling in forward or reverse while parking brake is released.
Transmission cut-off mode is not selected or not released.
Transmission cut-off position cannot be released.
Direction selector (FNR) switch mode is not selected or not released.
Flow of loader pump does not increase from the minimum rate.
ECSS function cannot be selected or cannot be released.
None of headlamp, clearance lamp, and tail lamp lights.
Clearance lamp and tail lamp does not light up.
Both "High and Low beams" of headlamp do not light up or go out.
The headlamp "Low beam" does not light up or go out.
The headlamp "High beam" does not light up or go out.
Front working lamp does not light up or go out.
Rear working lamp does not light up or go out.
All of turn signal lamps and hazard lamps do not light up or go out.
Turn signal lamps do not light up or go out.
Hazard lamp does not light up or go out.
Brake lamp does not light up or stays lighted.
Backup lamp does not light or continues to light.
Backup buzzer does not sound or continues to sound.
Front wiper does not operate.
Rear wiper does not operate.
Window washer does not operate.
KOMTRAX system does not operate normally.
WA470-7
Troubleshooting
Index
E-20
E-21
E-22
E-23
E-24
E-25
E-26
E-27
E-30
E-31
"Procedure for testing
and troubleshooting" in
Chapter 80
E-28
E-29
E-32
E-33
E-34
E-35
E-36
E-37
E-39
E-40
E-41
E-42
E-43
E-44
E-45
E-46
E-47
E-48
E-49
E-50
E-51
E-52
E-53
E-54
E-55
E-56
E-58
40-45
40 Troubleshooting
Information in troubleshooting table
(ALL-5170-421-A-01-A)
(Rev. 2011/12)
a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Action level
Display on
machine
monitor
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Failure code
Display on
machine monitor
Failure
Failure name displayed on the Abnormality Record screen

of the machine monitor
Description of the failure detected by the machine monitor or controller

An action that is performed to protect the system and devices when a failure is detected by
the machine monitor or controller
A problem that appears as a failure on the machine as a result of an action (above) that is
performed by the machine monitor or controller.
Information on occurred failure or troubleshooting

No.
Cause
<Contents
of description>
1 Defective
Open or short circuit in wiring Procedure
2
harness
Measuring location
Open circuit in wiring harness
a "Between A and B" denotes measuring values such as voltage
3 (wire breakage or defective
and resistance between A and B.
contact of connector)
a "Between A and ground" means the measurement of voltage,
Ground fault in wiring harness
resistance or others between terminal A and the place which has
4
(contact with ground circuit)
a continuity with chassis frame such as unpainted hexagonal
5 Hot short circuit
head bolt or bolt hole which has no rust, etc.
Criteria to judge probable causes (standard value), remarks
<How to use troubleshooting sheet>
Perform troubleshooting procedures in numerical order.
If the check result does not meet the criteria, the probable cause
described on the left column is the actual cause of the failure.
If the check result meet the criteria and there is no specific
instruction, proceed to the next step (cause).
If a defect is found and repaired, check that the defect has been
corrected.
<Failures in wiring harness>
Short circuit in wiring harness
Open circuit
6
Connection of connector is defective or wiring harness is broken.
Ground fault
A harness not to be connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit or chassis accidentally.
Hot short circuit
A harness not to be connected to the power circuit comes into
contact with the power circuit accidentally.
Short circuit
An independent wire in the harness erroneously comes into contact
with another independent wire.
(poor insulation at connector and others)
40-46
WA470-7
40 Troubleshooting
No.
Cause
Defective controller

<Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapters as follows unless
otherwise specified.
When "male" or "female" is not indicated with a connector number,
disconnect the connector, and insert T-adapter between the male
and female connectors.
When "male" or "female" is indicated with a connector number,
disconnect the connector, and connect T-adapter to the male or
female connector.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads as
shown below unless otherwise specified.
Connect the positive (+) lead to pin or wire indicated first.
Connect the negative (-) lead to a pin or wire indicated second.
Related circuit diagram

This is the excerpted circuit diagram related to
troubleshooting
The circuit diagram contains the connector Nos.,
pin Nos., and connector colors related to the
failure.
The / in a connector number is either:
1) An abbreviation (of more than three letters)
Example: T/C (Torque Converter)
2) Different connector number at male and female
sides
Example: BREAK OUT/E24
The circuit diagram contains the destination or
source of the branch line in a wiring harness.
The arrow (io) indicates a rough installation
position on the given machine.
NO: Normally Open
NC: Normally Closed
Signal names such as GND and 24 V are included
in addition to connector numbers at junctions, etc.
in circuit diagrams.
Except for GND and 24 V, a signal name indicated
at a junction, etc. shows that the wire is connected
to another junction or controller at where the same
signal name is indicated.
WA470-7
40-47
40 Troubleshooting
Connector list and layout

DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
Number
of pins
2
2
2
2
2
2
2
2
8
6
1st solenoid
1st fill switch
2nd solenoid
2nd fill switch
3rd solenoid
3rd fill switch
4th solenoid
4th fill switch
Intermediate connector
AE-9
AE-8
AJ-4
AJ-4
AJ-4
AJ-3
AE-8
AE-8
O-3
H-2
FRAMATOME
24
AO-6
DT
PA
M
M
DT
DT
KES 1
M
M
3
9
2
2
2
2
2
1
1
2
6
4
2
1
3
4
1
1
1
1
1
1
4
6
8
12
6
2
6
2
2
2
2
2
2
3
3
2
Terminating resistor (120 z)

Radio
Speaker (R.H.)
Speaker (L.H.)
Front working lamp (R.H.)
Front working lamp (L.H.)
Room lamp
Door switch (R.H.)
Door switch (L.H.)
Cigarette lighter
Front wiper motor
Rear wiper motor
Warning lamp
Revolving warning lamp
Revolving warning lamp
Rear glass heater
Rear glass heater
Rear glass heater
Ground (radio body)
Ground
Intermediate connector (warning lamp)
Side wiper
Injector #1
Injector #2
Injector #3
Injector #4
Injector #5
Injector #6
Front right combination lamp
Front left combination lamp
Diode
AL-3
Z-9
AC-9
AD-8
Y-8
AD-5
AD-7
Y-8
AD-6
O-2
M-3
AD-5
AA-9
AB-9
AA-9
Y-8
Y-6
AD-7
AB-9
Z-8
AC-8
Y-6
W-9
W-9
Y-4
Y-5
V-9
Q-7
Y-4
AK-8
AK-8
AK-9
AL-9
AM-9
AN-9
C-6
F-1
X-4
Connector No. Connector type

1.PS
1.SW
2.PS
2.SW
3.PS
3.SW
4.PS
4.SW
AL1
AR1
BREAKOUT
(E24)
B-RES
C01
C02
C03
C04
C05
C07
C08
C09
C10
C12
C15
C18
C18A
C22
C25
C29
C33
C35
C39
C40
C91
C140
C141
CL1
CL2
CL21
CL24
CL27
CN1
CN2
CN3
CN4
CN5
CN6
COMBI
COMBI
D04
40-48
(WA470-C050-055-K-00-A)
M
M
DT
M
DT
DT
M
Terminal
Terminal
M
DT
DT
SWP
SWP
SWP
X
SWP
DT
DT
DT
DT
DT
DT
DT
DT
YAZAKI
Equipment name
Address
WA470-7
40 Troubleshooting

D05
D06
D07
D08
D09
D11
D12
DIODE
DOSER
E01
E02
E04
E05
E06
E06A
E07A
E07B
E10
E14A
E14B
E14C
E15
E25
E26
E27
E28
E29
E33
E45
EC3
EGR-SOL
ER1
ER2
ER3
ER4
F.PS
F.SW
F01
F02
F03
F04
F10
F11
F12
F13
F20
F21
F22
F23
F24
F25
F26
WA470-7
YAZAKI
YAZAKI
YAZAKI
YAZAKI
YAZAKI
YAZAKI
YAZAKI
DT
FRAMATOME
DT
Terminal
Terminal
Terminal
Terminal
DT
Terminal
Terminal
DT
Terminal
Terminal
Terminal
Terminal
FRAMATOME
DT
DT
DT
DT
DT
DT
DRC
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
Number
of pins
2
2
2
2
2
2
2
2
2
2
1
1
1
1
2
1
1
2
1
1
1
1
4
4
2
12
2
6
2
60
2
12
12
2
6
2
2
6
6
2
2
3
3
3
3
2
2
2
2
2
2
2
Equipment name
Diode
Diode
Diode
Diode
Diode
Diode
Diode
Diode
HC dosing solenoid
Alternator terminal E
Alternator terminal R
Heater relay
Heater relay
Diode
Heater relay
Electrical intake air heater (ribbon heater)
Freon compressor magnet clutch
Ground
Ground
Ground
Ground
KDPF pressure sensor
KDPF temperature sensor
Pump timer switch
Fuel feed pump
Dust indicator
Engine controller
EGR valve solenoid
F solenoid
F fill switch
Horn
Horn
Ladder pump pressure sensor
Boom potentiometer sensor
Boom bottom pressure sensor
Boom head pressure sensor
E.C.S.S. solenoid
Bucket TILT EPC
Bucket DUMP EPC
Boom RAISE EPC
Boom LOWER EPC
3rd ATT EXT EPC
3rd ATT RET EPC
Address
W-4
W-6
W-4
W-4
W-4
W-6
W-6
AH-1
AM-4
I-2
L-6
L-5
K-1
L-3
K-4
L-2
I-9
I-9
AL-1
AL-2
AN-6
J-3
AO-6
AN-6
L-3
AO-6
AM-1
I-1
H-9
AN-6
AL-5
I-3
I-3
I-2
L-2
AE-9
AE-9
C-7
E-8
A-2
B-4
C-1
C-7
D-1
E-1
A-3
A-3
A-1
A-3
A-1
A-2
B-4
40-49
40 Troubleshooting

F29
F30
F31
F32
F40
FR1
FR2
FR3
FR4
FS6
FS7
FS8
FS9
G
G04
G05
G06
GR1
G-RES
HEAD
HEAD
INJ
J01
J02
J03
J04
J05
J06
J07
J08
J09
J1(EC1)
J1939
J10
J11
J12
J13
J14
J15
J16
J17
J18
J19
J2(EC2)
J20
J21
J22
J41
J42
J43
J44
JC01
40-50
DT
DT
DT
DT
Terminal
DT
DT
DT
DT
X
X
Terminal
Terminal
SUMITOMO
DT
DT
DT
DT
DT
DT
DT
DTA
DRC
DRC
Number
of pins
2
3
2
3
1
12
8
12
6
1
1
15
15
3
2
2
4
12
2
3
3
12
20
20
20
20
20
20
20
20
20
60
3
20
20
20
20
20
20
20
20
20
20
60
20
20
20
20
20
20
20
8
Equipment name
Diode
Boom EPC cut-off solenoid
Bucket angle signal
Ground (front frame)
Fuse box
Fuse box
G sensor
Rear working lamp (L.H.)
Rear working lamp (R.H.)
Rearview camera
Fuel supply pump pull-up resistor
Right headlamp
Left headlamp
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Engine controller
CAN_C
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Engine controller
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Address
A-4
D-8
A-4
B-1
F-1
E-1
E-1
E-1
F-1
W-2
W-2
X-7
X-8
AM-5
L-7
J-9
K-9
L-6
AL-2
C-5
F-1
AN-9
X-2
T-2
X-2
X-2
X-2
T-2
T-2
T-2
V-5
AO-6
AN-9
X-2
X-2
T-2
T-2
T-2
T-2
O-4
O-4
R-2
O-4
AN-6
X-2
X-2
V-5
V-4
V-4
V-4
V-4
AO-7
WA470-7
40 Troubleshooting
DT
KES 1
DT
DT
DT
DT
DT
DT
VCH
Number
of pins
8
8
12
6
8
6
12
12
2
2
2
4
4
6
2
2
4
2
10
4
4
2
4
2
4
6
12
12
12
12
4
3
10
L44
L50
L51
L52
L61
L62
L63
L71
L72
L73
L80A
L80B
L100
L111
L112
L113
L114
L115
Terminal
Terminal
Terminal
DRC
DRC
DRC
DRC
DRC
DRC
070
070
Terminal
Relay
Relay
Relay
Relay
Relay
1
1
1
24
40
40
24
40
40
18
12
1
5
5
5
5
5

JC02
JL1
JL2
JL3
JT1
JT2
L02
L04
L05
L09
L11
L14
L15
L17
L18A
L18B
L19
L20
L21
L23
L28A
L28B
L29A
L29B
L30
L31
L32
L33
L34
L35
L36A
L40
L41
WA470-7
DT
Relay
DT
DT
DT
SWP
DT
DT
DT
DT
DT
YAZAKI
YAZAKI
M
M
S
DT
DT
DT
Equipment name
Junction connector
Joystick lever switch
Joystick safety relay
Junction connector
Junction connector
Gear speed switch
Lighting switch
Horn switch
Brake lamp switch
Air suspension seat
Boom lever
Bucket lever
DC/DC converter
12 V socket
12 V socket
Flasher unit
Alarm buzzer
Wiper switch
4th EPC lever
Boom EPC lever
Boom EPC lever
Bucket EPC lever
Bucket EPC lever
3rd EPC lever
Wiper timer
Multi-coupler switch
Intermediate connector (load meter printer wiring
harness)
Ground
Ground
Ground
Transmission and fan pump controller
KOMTRAX terminal
KOMTRAX terminal
Ground (floor)
Relay No. 13 (turn signal lamp and hazard lamp 1)
Relay No. 12 (fan pump)
Relay No. 11 (personal lock)
Relay No. 5 (beacon lamp)
Relay No. 5 (yellow working lamp)
Address
AO-7
U-8
U-8
V-7
AG-1
AI-2
O-2
O-1
N-1
T-2
S-2
M-8
M-8
U-8
R-8
Q-8
U-2
X-8
O-1
O-7
N-6
M-8
O-7
M-8
O-7
V-4
P-8
O-7
P-7
P-7
V-2
M-1
M-1
R-8
O-5
O-6
V-3
S-9
S-9
S-9
S-9
T-9
T-9
V-6
V-5
V-3
X-8
V-6
V-7
X-7
V-7
40-51
40 Troubleshooting

L116
L117
L118
L119
L120
L121
L122
L125
L126
L127
L128
L129
L131
L132
L133
L180
L/C.PS
LDR_L
LDR_R
LDW_L
LDW_R
LDY_L
LDY_R
LR1
LR2
LR3
LR4
LR5
LR6
LR7
LR8
LR9
LR11
LR12
LT1
M01A
M01B
MCM1_A
MCM1_B
MCM2
MDM1
MDM2
MDM3
MOM1
NE
PAMB
PB.PS
PB.SW
PCCV
PCV1
PCV2
PD
40-52
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
Relay
DT
Relay
DT
DT
DT
DT
DT
DT
DT
DT
DRC
DT
DT
DT
X
#8
#8
#8
#8
DT-P
#8
24-31
M
M
AMP
AMP
AMP
AMP
AMP
FRAMATOME
FRAMATOME
DT
DT
FRAMATOME
SUMITOMO
SUMITOMO
DT
Number
of pins
5
5
5
5
5
5
6
5
5
5
5
5
5
6
5
2
2
3
3
2
2
2
2
70
12
12
12
1
1
1
1
1
2
1
31
3
3
80
40
8
8
6
8
6
3
3
2
2
3
2
2
6
Equipment name
Relay No. 21 (neutral safety)
Relay No. 20 (backup lamp)
Relay No. 19 (stop lamp)
Relay No. 18 (horn)
Relay No. 17 (parking brake)
Relay No. 14 (neutral hold)
Relay No. 3 (turn signal lamp and hazard lamp 2)
Relay No. 6 (preheat)
Relay No. 6 (emergency steering)
Relay No. 15 (front working lamp)
Relay No. 9 (rear working lamp)
Relay No. 4 (rear heated wire glass)
Relay No. 7 (headlamp)
Relay No. 8 (automatic idle stop parking brake)
Torque converter lockup solenoid
Left LED tail and step lamp
Right LED tail and step lamp
Left LED backup lamp
Right LED backup lamp
Left turn signal lamp
Right turn signal lamp
AUX jack
AUX jack
Monitor controller
Monitor controller
Monitor controller
Machine monitor
Machine monitor
Machine monitor
Switch panel
Ne speed sensor
Parking brake solenoid
Parking brake indicator switch
Supply pump PCV1
Supply pump PCV2
Accelerator pedal
Address
X-9
W-9
W-9
W-9
V-9
V-8
V-7
V-8
V-9
V-9
V-8
X-6
V-8
U-2
V-8
S-2
AE-9
L-7
K-9
L-6
K-9
L-6
K-9
C-9
A-8
C-9
C-9
U-2
A-8
B-9
B-9
B-9
C-8
A-8
U-2
Z-9
Y-5
Q-8
Q-8
R-8
N-3
N-3
N-3
O-2
AM-1
AM-5
AJ-2
AH-1
AK-9
AM-5
AN-5
O-2
WA470-7
40 Troubleshooting

PDOSER
PDV
PFUEL
PIM
POIL
R.PS
R.SW
R01
R02
R03
R04
R05
R06A
R06B
R07
R08
R10
R11
R13
R14
R15
R16
R20
R21
R22
R29
R32
R33
R37
R43
R45
R47
R50
R52
R54
R58
R59
R60
R61
R71
R73
R86
R87
R89
R90
R91
R93
R96
R100A
REV IN
REV OUT
RVC_1
WA470-7
FRAMATOME
DT
AMP
FRAMATOME
FRAMATOME
DT
DT
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
DT
DT
Terminal
DT
DT2
DT
DT
KES_1
KES_1
DT
Terminal
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
FRAMATOME
Terminal
DT
DT
DT
DT
Number
of pins
3
2
3
3
3
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
6
1
2
2
2
2
2
2
2
1
2
2
2
2
2
2
2
3
3
2
2
2
3
4
1
8
2
2
4
Equipment name
Shut off valve pressure sensor
Accelerator pedal
Boost pressure sensor
R clutch solenoid
R clutch fill switch
Battery relay
Slow blow fuse
Slow blow fuse
Slow blow fuse
Slow blow fuse
Slow blow fuse
Slow blow fuse
Battery relay
Slow blow fuse
Slow blow fuse
Battery relay
Battery relay
Ground
Fan pump EPC
Fuel level sensor
Emergency steering pressure sensor
Front windshield washer
Rear windshield washer
Ground (rear frame)
Front brake pressure switch
Rear brake pressure switch
Backup alarm buzzer
Fan solenoid
Operating lamp
Loader pump EPC
Steering pump pressure sensor
Service connector
Fan speed sensor
Steering pump EPC
Mass air flow sensor
Heater relay
Transmission input shaft speed sensor
Address
AP-5
O-3
AO-7
AO-9
AL-5
AJ-5
AJ-5
L-2
K-3
L-3
K-1
J-3
J-3
K-3
I-2
I-2
K-3
J-3
I-1
J-1
K-1
K-1
K-4
B-5
A-5
G-9
F-9
L-1
G-1
H-2
H-2
E-9
K-4
D-8
E-8
J-9
L-8
H-2
B-7
G-9
G-1
F-9
C-8
L-8
H-2
G-1
I-9
L-1
F-1
AI-8
AE-6
A-9
40-53
40 Troubleshooting

RVM1
RVM2
S_F1
S_F2
S_F3
S_F3A
S_F4
S_F6
S_F7
S_FA
S_FB
S_FS
S_OH1
S_OH2A
S_OHA
S_RH1
S_RH2
S_RH3
S_RH4
S_RH5
S_RH6
S_RH7
S_RH8
S_RHA
S_RHB
S_RHC
S_RV
S40
SBS
SEGR
SI_CH
SOV1
SOV2
SV
SVGT
TC.T
TCIN.P
TEL
TGN
TIM
TM.T
TWTR
VGT-REV
VGT-SOL
40-54
AMP
AMP
SWP
SWP
SWP
SWP
SWP
SWP
SWP
SWP
SWP
SWP
SWP
DT
SWP
SWP
SWP
SWP
SWP
SWP
SWP
SWP
SWP
DT
DT
SWP
SWP
DT
DT2
DT
DT
FRAMATOME
FRAMATOME
DT
DT
DT
DT2
DT
Terminal
PKD
DT
PKD
DT
DT
Number
of pins
12
8
6
6
6
6
6
6
6
6
6
6
6
3
6
6
6
6
6
6
6
6
6
2
4
6
6
6
2
4
2
2
2
12
3
2
3
12
1
2
2
2
2
2
Equipment name
Rearview monitor
Rearview monitor
Front working lamp switch
Rear working lamp switch
Beacon lamp switch
Revolving warning lamp switch
ECCS on-off switch
Auto greasing switch
Daytime light switch
Parking brake switch
Hazard lamp
Engine shutdown secondary switch
Yellow working lamp
Intermediate connector (for Japan)
Rear window glass
Transmission cut-off/cut-off set switch
Power mode selector switch
Transmission shift mode selector switch
Torque converter lockup switch
Directional selector switch actuation switch
Remote positioner switch
2-stage low idle switch
Emergency steering operation check
Horn
Right FNR switch
Boom lock switch
Camera brightness adjustment switch
Starting switch
Seat belt switch
EGR valve position sensor
SI unit selection switch
Shut off valve solenoid #1
Shut off valve solenoid #2
KOMNET SV connector
VGT valve position sensor
Torque converter outlet oil temperature sensor
Ground (transmission)
Boost temperature sensor
Transmission lubricating oil sensor
KVGT speed sensor
KVGT solenoid
Address
O-5
O-6
M-1
M-2
M-2
Q-2
M-1
M-1
N-1
N-3
M-2
M-2
AA-9
AB-9
Z-9
M-9
N-9
N-9
N-9
N-9
O-9
O-9
O-9
N-6
N-6
M-8
O-5
N-3
T-2
AK-5
S-2
AO-6
AM-5
X-8
AM-5
G-9
AI-8
S-2
AJ-2
AO-8
AG-8
AN-1
AP-5
AK-6
WA470-7
40 Troubleshooting
Layout of connectors (1/7)
WA470-7
40-55
40 Troubleshooting
40-56
WA470-7
40 Troubleshooting
WA470-7
40-57
40 Troubleshooting
40-58
WA470-7
40 Troubleshooting
WA470-7
40-59
40 Troubleshooting
40-60
WA470-7
40 Troubleshooting
WA470-7
40-61
40 Troubleshooting
Connector contact identification
(ALL-5310-030-A-00-A)
(Rev. 2009. 04)

a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
40-62
WA470-7
40 Troubleshooting
WA470-7
40-63
40 Troubleshooting
40-64
WA470-7
40 Troubleshooting
WA470-7
40-65
40 Troubleshooting
40-66
WA470-7
40 Troubleshooting
WA470-7
40-67
40 Troubleshooting
40-68
WA470-7
40 Troubleshooting
WA470-7
40-69
40 Troubleshooting
40-70
WA470-7
40 Troubleshooting
WA470-7
40-71
40 Troubleshooting
40-72
WA470-7
40 Troubleshooting
WA470-7
40-73
40 Troubleshooting
40-74
WA470-7
40 Troubleshooting
WA470-7
40-75
40 Troubleshooting
40-76
WA470-7
40 Troubleshooting
WA470-7
40-77
40 Troubleshooting
40-78
WA470-7
40 Troubleshooting
WA470-7
40-79
40 Troubleshooting
40-80
WA470-7
40 Troubleshooting
WA470-7
40-81
40 Troubleshooting
40-82
WA470-7
40 Troubleshooting
WA470-7
40-83
40 Troubleshooting
40-84
WA470-7
40 Troubleshooting
WA470-7
40-85
40 Troubleshooting
40-86
WA470-7
40 Troubleshooting
WA470-7
40-87
40 Troubleshooting
40-88
WA470-7
40 Troubleshooting
WA470-7
40-89
40 Troubleshooting
40-90
WA470-7
40 Troubleshooting
WA470-7
40-91
40 Troubleshooting
40-92
WA470-7
40 Troubleshooting
WA470-7
40-93
40 Troubleshooting
40-94
WA470-7
40 Troubleshooting
WA470-7
40-95
40 Troubleshooting
40-96
WA470-7
40 Troubleshooting
WA470-7
40-97
40 Troubleshooting
T-branch box and T-branch adapter table
(ALL-5330-305-A-00-A)
(Rev. 2009. 03)

a The vertical column indicates a part number of T-branch box or T-branch adapter, while the horizontal
column indicates a part number of harness checker assembly.
799-6012600
799-6013100
799-6013200
799-6013380
799-6013410
799-6013420
799-6013430
799-6013440
799-6013450
799-6013460
799-6013510
799-6013520
799-6013530
799-6012910
799-6013470
799-6012710
799-6012720
799-6012730
799-6012740
799-6012950
799-6012750
799-6012760
799-6012770
40-98
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
799-601-2700
799-601-2500
Part name
Identification symbol
Part number
Number of pins
T-adapter kit
T-box (for ECONO)
21
T-box (for MS)
37
T-box (for MS)
37
q q
Plate for MS (14-pin)
Adapter for BENDIX (MS)
24 MS-24P
24 MS-24P
17 MS-17P
17 MS-17P
MS-5P
10 MS-10P
MS-5P
17 MS-17P
19 MS-19P
14 MS-14P
q
q
Case
Adapter for MIC
Adapter for MIC
13
Adapter for MIC
17
Adapter for MIC
21
Adapter for MIC
Adapter for ECONO
Adapter for ECONO

Adapter for ECONO
MIC-5P q q
MIC13P
MIC17P
MIC21P
q q
q
q
q q q
q q
q q q
q q
q q q
MIC-9P
ECONO
q q
2P
ECONO
q q
3
3P
ECONO
q q
4
4P
WA470-7
40 Troubleshooting
799-6012780
799-6012790
799-6012810
799-6012820
799-6012830
799-6012840
799-6012850
799-6014350
799-6014360
799-6017010
799-6017020
799-6017030
799-6017040
799-6017050
799-6017060
799-6017310
799-6017070
799-6017320
799-6017080
799-6017090
799-6017110
799-6017120
799-6017130
799-6017340
799-6017140
799-6017150
WA470-7
Adapter for ECONO

Adapter for ECONO
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
ECONO
q q
8P
ECONO
q q
12
12P
8
Adapter for DLI
Adapter for DLI
12 DLI-12P q q
Adapter for DLI
16 DLI-16P q q
Extension cable (ECONO type)
12
DLI-8P q q
ECONO
q q
12P
Case
T-box (for DRC60, ECONO)
799-601-2800
799-601-2700
799-601-2500
Part name
Part number
Number of pins
T-adapter kit
60
Case
Adapter for X (T-adapter)
Adapter for X
Adapter for X
X2P
q q q
X3P
q q q
Adapter for X
X4P
q q q
Adapter for SWP
SW6P
q q q
Adapter for SWP
SW8P
q q q
Adapter for SWP
12 SW12P
Adapter for SWP
14 SW14P
Adapter for SWP
16 SW16P
Adapter for M (T-adapter)
Adapter for M
Adapter for M
q
q
q
q
M2P
q q q
M3P
q q q
Adapter for M
M4P
q q q
Adapter for M
M6P
q q q
Adapter for M
M8P
Adapter for S
S8P
q q q
Adapter for S (White)
10
S10P
q q q
40-99
40 Troubleshooting
799-6017160
799-6017170
799-6017330
799-6017350
799-6017180
799-6017190
799-6017210
799-6017220
799-6017230
799-6017240
799-6017270
799-6017510
799-6017520
799-6017530
799-6017540
799-6017550
799-6017360
799-6017370
799-6017380
799-6019010
799-6019020
799-6019030
799-6019040
799-6019050
799-6019060
799-6019070
A8P
Adapter for AMP040
12
A12P
Adapter for AMP040
16
A16P
q q q
Adapter for AMP040
20
A20P
q q q
Short connector for X
q q q
40-100
Out of kit
799-601-4201
Adapter for AMP040
799-601-4101
12 S12PW
799-601-9300
799-601-9200
16 S16PW
799-601-9100
799-601-9000
q q q
799-601-8000
S16P
799-601-7500
16
799-601-7400
Adapter for S (Blue)
799-601-7100
q q q
799-601-7000
S12P
799-601-2800
12
Part name
799-601-2700
Adapter for S (Blue)
Part number
799-601-2500
Number of pins
T-adapter kit
q
q
q
q q
Case
Case
Adapter for 070
10
07-10
Adapter for 070
12
07-12
Adapter for 070
14
07-14
Adapter for 070
18
07-18
Adapter for 070
20
07-20
Adapter for relay
5 REL-5P
Adapter for relay
6 REL-6P
Adapter for JFC
Adapter for DTM
DTM2
Adapter for DT
DT2
Adapter for DT
DT3
Adapter for DT
DT4
Adapter for DT
DT6
Adapter for DT (gray)
DT8GR
Adapter for DT (black)
DT8B
q
q
q q
q
q
q q
q
q
q
WA470-7
40 Troubleshooting
799-6019080
799-6019090
799-6019110
799-6019120
799-6019130
799-6019140
799-6019210
799-6019220
799-6019230
799-6019240
799-6019250
799-6019260
799-6019270
799-6019280
799-6019290
799-6019310
799-6019320
799-6019330
799-6019340
799-6019350
799-6019360
799-6019410*
Adapter for DT (green)
12 DT12G
Adapter for DT (Brown)
12 DT12BR
Adapter for HD30-18
D18-8
q q
Adapter for HD30-18
14 D18-14
q q
Adapter for HD30-18
20 D18-20
q q
Adapter for HD30-18
21 D18-21
q q
Adapter for HD30-24
D24-9
q q
Adapter for HD30-24
16 D24-16
q q
Adapter for HD30-24
21 D24-21
q q
Adapter for HD30-24
23 D24-23
q q
Adapter for HD30-24
31 D24-31
q q
799-6019420
799-6019430*
799-6019440*
WA470-7
Plate for HD30 (24-pin)

T-box (for ECONO)
q
q
q
q
q
q
q
q
Case
Adapter for DRC
40 DRC-40
Adapter for DRC
24 DRC-24
Socket for engine (CRI-T2)
q q
Case
Adapter for engine (CRI-T2)

PFUEL
Oil pressure sensor
Socket for engine(CRI-T3) PCV
q q
24
Out of kit
12 DT12B
799-601-4201
Adapter for DT (black)
799-601-4101
799-601-9300
DT12GR
799-601-9200
12
799-601-9100
Adapter for DT (gray)
799-601-9000
799-601-8000
DT8BR
799-601-7500
799-601-7400
Adapter for DT (Brown)
799-601-7100
799-601-7000
DT8G
799-601-2800
Part name
799-601-2700
Adapter for DT (green)
Part number
799-601-2500
Number of pins
T-adapter kit
q
q
q
G
q q
A3
1, 2, 3
q q
q
40-101
40 Troubleshooting
795-7995520*
795-7995530*
795-7995540*
795-7995460
795-7995470
795-7995480
799-6014110
799-6014130
799-6014140
799-6014150
799-6014160
799-6014180
799-6014190*
799-6014230*
799-6014240*
799-6014250*
799-6014330*
799-6014340*
799-6014380*
799-6014260
799-6014211
799-6014220
799-6014390*
799-6014280*
40-102
Socket for engine (HPI-T2)

Temperature sensor
Socket for engine(CRI-T3) TIM
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
799-601-2700
799-601-2500
Part name
Part number
Number of pins
T-adapter kit
q
q q
q q
Cable for engine (HPI-T2)
Adapter for engine (140-T3) PIM 4

Adapter for engine (CRI-T3) NE,
CAM
Ambient pressure
POIL
Oil pressure switch
PEVA
Rail pressure
Air intake pressure/temperature
PAMB
ITT3N
q q
q q
FCIN
FCIG
FCIB
4160
4180
1, 2, 3L
1, 2, 3,
4C
1, 2, 3A
Socket for engine (CRI-T3) PIM
1, 2, 3B
Socket for engine (CRI-T3) G
1, 2, 3,
G
2, PA
1, 2, 3,
4T
Adapter for controller (ENG)
DTP4
50 DRC50
60 DRC60
Socket for controller (95 ENG)
60
Box for controller (PUMP)
121

Pump actuator
Socket for engine (CRI-T3)(95)
Air intake pressure/temperature
q q
q q
q q
q q
q q
q q
q q
q q
q q
q q
q
q q
q
q
WA470-7
40 Troubleshooting
799-6019720
799-6019710
799-6019730
799-6019890
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
799-601-2700
799-601-2500
Part name
Part number
Number of pins
T-adapter kit
Adapter for controller (HST)
16 HST16A
16 HST16B
26 HST26A
Multi-adapter for pins DT2 to 4

and DTM2
2,
3,
4
*: Shows not T-adapter but socket.
WA470-7
40-103
40 Troubleshooting
Fuse location table
(WA470-5530-04D-A-00-A)
Connection table of fusible links and fuse boxes

a This connection table shows the devices to which each power supply of the fusible links and fuse boxes
supplies power.
a The switched power supply is the power (battery relay output) which is supplied while the stating switch is
in ON position and the continuous power supply is the power (battery direct output) which is supplied while
the starting switch is in the OFF or ON position.
a When performing the troubleshooting related to the electrical system, check the fusible links and fuses to
see if the power is supplied properly.
Fuse box 1
Type of power
supply
Switched power
supply
Slow-blow fuse (50
A)
Switched power
supply
Lamp switch
Switched power
supply
Headlamp relay
Fuse box 2
Type of power
supply
Continuous power
supply
Slow-blow fuse (50
A)
Switched power
supply
Slow-blow fuse (50
A)
Switched power
supply
Starting switch
ACC
40-104
1
2
3
4
Fuse
capacity
15 A
20 A
5A
5A
15 A
6
7
8
9
10
11
12
10 A
30 A
20 A
5A
10 A
30 A
10 A
Horn circuit
Transmission controller (A) circuit
Parking brake circuit
Emergency steering circuit
Work equipment positioner circuit
Work equipment controller (A) circuit
Backup lamp and brake lamp circuit
Wiper and washer circuit
Air conditioner circuit (blower)
Air conditioner compressor
Monitor controller circuit
Main lamp circuit
Clearance lamp (right) circuit
13
10 A
Clearance lamp (left) circuit
14
15 A
Headlamp (right) circuit
15
15 A
Headlamp (left) circuit
Fuse No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Fuse
capacity
20 A
10 A
10 A
10 A
15 A
30 A
10 A
10 A
10 A
30 A
10 A
20 A
20 A
30 A
15
5A
Fuse No.
Destination of power
Starting switch B-terminal circuit
Hazard lamp circuit
Monitor controller circuit (UNSW)
Room lamp circuit and system operating circuit
Transmission controller circuit
Engine controller circuit (UNSW)
Spare 1
Front working lamp circuit
Rear working lamp circuit
Radio circuit and 12 V converter circuit
Turn signal lamp circuit
Yellow revolving warning lamp circuit
Air suspension system
Rear heated wire glass circuit
ACC input of engine controller and monitor controller
WA470-7
40 Troubleshooting
Slow-blow fuse
Type of power
supply
Continuous power
supply
Fuse No.
Fuse
capacity
50 A
50 A
50 A
120 A
Switched power
supply
Spare 1, engine controller circuit, transmission controller
circuit, work equipment controller circuit, room lamp circuit,
machine monitor circuit, KOMTRAX circuit, hazard lamp
circuit, starting switch B-terminal circuit
Main lamp circuit, machine monitor circuit, air conditioner
circuit, wiper and washer circuit, backup lamp and brake
lamp circuit, work equipment positioner circuit, work
equipment controller circuit, emergency steering circuit,
parking brake circuit, transmission controller circuit, horn
circuit
Rear heated wire glass circuit, air suspension seat and
yellow revolving warning lamp circuit, turn signal lamp
circuit, radio circuit, 12V converter circuit, rear working
lamp circuit, front working lamp circuit
Heater relay circuit
Fuse box position and No.

a The fuse box is located at the rear of operator's seat.
Slow-blow fuse mounting position
WA470-7
40-105
40 Troubleshooting
a Open the left engine hood, remove cover (1), and then you'll see 50 A slow-blow fuses (2) to (4), and 120
A fuse (5).
40-106
WA470-7
40 Troubleshooting
Precautions for KDPF (KCSF and KDOC) Cleaning and

Replacement (PC220-A9H0-2A4-K-00-A)
1. Related information
k Since
KDPF and KDOC are heated to 500

C or above, take care not to get burn
injury.
Soot accumulation at KCSF inside the KDPF

is classified into 8 levels. The current soot
level can be checked on the machine
monitor by selecting the "Diagnostic Test"
screen from the service menu, and then
selecting the "Regeneration for Service"
screen.
a If the soot accumulation reaches level 4 or 5,
failure code [CA2639] is displayed.
a If the soot accumulation reaches level 6 or 7,
a If the soot accumulation reaches level 8,
If the soot accumulation reaches level 8, the
KDPF is completely clogged with soot, and
inspection, cleaning, or replacement is
required.
Manual stationary regeneration can be
performed to burn away soot in the KCSF
when the soot accumulation is up to level 7.
a At soot accumulation levels 4 to 7, manual
stationary regeneration can also be
performed from the user mode.
Procedure of performing manual stationary
regeneration from Regeneration for Service
a When soot accumulation is at level 3 or lower,
the manual stationary regeneration can be
performed only from "Regeneration for
Service".
1) Start the engine.
2) Make sure that machine is in safe condition.
3) From the service menu of the machine
monitor, display the "Diagnostic Tests"
screen, open "Regeneration for service", and
then perform the "Manual Stationary
Regeneration".
a Time required for manual stationary
regeneration depends on the accumulated
soot in KCSF, however, it is estimated as
follows.
If soot accumulation is level 4: Approx. 40
minutes to 1 hour
If soot accumulation is level 5: Approx. 1 to 2
hours
Resetting after KDPF (KCSF) cleaning
WA470-7
From service menu of machine monitor,

display the "Diagnostic Tests" screen, open
"KDPF Memory Reset", and then perform
"KDOC Cleaning" (reset after KDOC
cleaning).
Resetting after KDPF (KCSF) change
"KDPF Change" (resetting after KDPF
change).
a When KCSF in KDPF is replaced, always
perform resetting procedures for KDPF
cleaning and KDPF change, and then
perform manual stationary regeneration from
"Regeneration for Service" to eliminate
moisture from KCSF.
Resetting after KDOC change
"KDOC Change" (reset after KDOC change).
a When KDOC in KDPF is changed, resetting
procedure for KDOC change must be
performed though manual stationary
regeneration is not necessary.
2. When cleaning and replacing KCSF
1) Regular cleaning at 4500H
1] Check the soot accumulation level. If the
level is not zero, repeat "Regeneration for
Service" until the level returns to zero.
2] Stop the engine and wait until the
temperature of piping around the engine
cools down. Remove the KDPF, and then
remove the KCSF.
3] Clean the KCSF by using an ash cleaner,
which is equipped at certain workshops.
(when the removed KCSF is cleaned and
reused)
4] Install the cleaned KCSF to the machine.
(when the removed KCSF is cleaned and
reused)
5] Install the replacement KCSF to the
machine (when the KCSF is replaced
with a new one).
6] Turn the starting switch to the ON
position. From the KDPF reset screen,
perform resetting after KDPF cleaning.
7] Start the engine and run at low idle to
warm up.
8] Perform regeneration for service.
2) If cracks or damages are found during
inspection
40-107
40 Troubleshooting

cools down. Remove the KDPF, and then
remove the KCSF.
2] Install the replacement KCSF (new or
reused) to the machine.
3] Turn the starting switch to the ON
position. From the KDPF reset screen,
perform resetting after KDPF cleaning.
4] From the KDPF reset screen, perform
resetting after KDPF change.
5] Start the engine and run at low idle to
warm up.
6] Perform regeneration for service.
3) If Soot Level High Error 2 (CA1922) is
displayed
1] Stop the machine and check that failure
code (CA1922) is displayed on the
machine monitor.
2] Check the abnormality record for failure
codes "CA2639: Manual Stationary
Regeneration Request", "CA1921: KDPF
Soot Level High Error 1", and "CA1922:
KDPF Soot Level High Error 2"on the
machine monitor.
<Case 1> When KDPF is removed and KCSF is
replaced
a If the following conditions are met, soot
accumulation is beyond the limit to burn
away by regeneration. The KDPF must be
removed to change the KCSF.
Time between activation of "CA2639: Manual
Stationary Regeneration Request (L01)" and
"CA1921: KDPF Soot Level High Error 1
(L03)" X 360 sec. (KOMTRAX history) or X
0.1 h (Abnormality record screen on monitor)
and
Time between activation of "CA1921: KDPF
Soot Level High Error 1 (L03)" and "CA1922:
KDPF Soot Level High Error 2 (L04)" X360
sec. (KOMTRAX history) or X 0.1 h
(Abnormality record screen on monitor)
[Contents of work]
Case 1-1] Stop the engine and wait until the
temperature of piping around the engine cools
down, then remove KCSF.
Case 1-2] Install the replacement KCSF (new or
reused).
Case 1-3] Turn the starting switch to the ON
position. From the KDPF reset screen, perform
resetting after KDPF cleaning.
a When resetting after KDPF cleaning is
performed, changes in ( ) are reflected.
(Soot accumulation amount: 9 g/lo8.1 g/l;
Action
level:
L04oL03;
Failure
code:
CA1922oCA1921)
40-108
Case 1-4] From the KDPF reset screen, perform

resetting after KDPF change.
Case 1-5] Start the engine and run at low idle to
warm up.
Case 1-6] Perform Regeneration for Service.
(In this case, Regeneration for Service may
continue for about 2 hours, since it is set to
terminate when the soot accumulation drops to 2
g/l.)
Case 1-7] When Regeneration for Service is
completed, check that failure codes (CA1922,
CA1921, and CA2639) are not displayed.
<Case 2> When Regeneration for Service is
performed (KDPF removal unnecessary)
a If the following conditions are met, the total
soot sediment is not beyond the limit (9 g/l),
but the differential pressure has increased
due to clogging caused by uneven
accumulation of soot. In this case, actual
regeneration will not result in abnormal
burning. Regeneration for Service can be
performed safely without replacing the KCSF,
and the KCSF can be continuously used
after the regeneration.
After checking that no sensor related failures
are present, perform this work if any of the
following is met.
Time between activation of "CA2639: Manual
Stationary Regeneration Request (L01)" and
"CA1921: KDPF Soot Level High Error 1
(L03)" < 360 sec. (KOMTRAX history) or <
0.1 h (Abnormality record screen on monitor)
"Time between activation of "CA1921: KDPF
Soot Level High Error 1 (L03)" and "CA1922:
KDPF Soot Level High Error 2 (L04)" <
360sec. (KOMTRAX history) or < 0.1 h
(Abnormality record screen on monitor)
[Contents of work]
Case 2-1] Start the engine and run at low idle to
warm up. From the KDPF reset screen, perform
resetting after KDPF cleaning.
Case 2-2] Perform Regeneration for Service.
(In this case, Regeneration for Service may
continue for about 2 hours, since it is set to
terminate when the soot accumulation drops to 2
g/l.)
Case 2-3] When Regeneration for Service is
completed, check that failure codes (CA1922,
CA1921, and CA2639) are not displayed.
3. When cleaning and replacing KDOC
1) If cracks or damages are found during
inspection
1] If cracks or damages are found in the
KDOC, replace it with a new one.
2] From the KDPF reset screen, perform
resetting after KDOC change.
WA470-7
40 Troubleshooting
2) When Regeneration Ineffective (CA1691) is

displayed
1] Stop the machine and check that failure
code (CA1691) is displayed on the
machine monitor.
(CA2637 may be displayed at the same
time.)
2] Check the exhaust gas color.
3] With CA1691 displayed, perform
Regeneration for Service for 40 minutes.
(Since this is done for drying the KDOC,
fuel is not injected during the
regeneration)
cools down. Remove the KDOC and
check it for cracks or damages.
<Case 1> If cracks or damages are found in
KDOC
Case 1-1] Replace KDOC with a new one.
Case 1-2] From the KDPF reset screen,
perform resetting after KDOC change.
<Case 2> If cracks or damages are not found
in KDOC
Case 2-1] Clean KDOC and reinstall it.
Case 2-2] From the KDPF reset screen,
perform resetting after KDOC cleaning.
Case 2-3] Perform Regeneration for Service
twice for 40 minutes each. (Fuel is injected
during regeneration)
*When performing Regeneration for Service
several times, stop the engine each time
before repeating the regeneration.
Case 2-4] If failure code "CA2637: KDOC
Face
Plugging"
is
displayed
after
Regeneration for Service is completed, the
catalyst
performance
of
KDOC
is
deteriorated. Replace KDOC with a new one.
WA470-7
40-109
40 Troubleshooting
Precautions on troubleshooting of machine monitor
(WA500-Q180-2A4-K-00-A)
The machine monitor consists of various independent units that send and receive data to/from the monitor
controller through LIN communication (see the next page).
As the result, troubleshooting of the machine monitor and related units involves complicated procedures
(see E-5 to E-20 of E-mode troubleshooting).
Each unit related to the machine monitor has many new type of connectors (see Table 1).
When performing the troubleshooting of the machine monitor LCD unit (see E-6 to E-8 of E-mode
troubleshooting), refer to "Processing procedure of harness checker for troubleshooting of machine
monitor LCD unit".
Table 1. Detail of connectors related to machine monitor
Manu- Connector
Con- NumTool New
Remarks
Name of unit
nector ber of Type code factur- type, etc.
er
name pins
MX40008U
q
JAE
LCD unit
MDM1
8
Q1
MaT070
chine
q
LED unit
MDM2
6
175954-1
AMP
connector adapter
monitor
T070
q
Meter unit
MDM3
8
175955-1
AMP
connector adapter
Measuring
MCM1
Same as
81
tool is not a TA
those used
adapter, so
in pump Box-type
TYCOoperating
AMP
controller of socket
1241434
MCM
voltage
40
hydraulic
B
cannot be
excavators
measured.
See
Monitor controller
"Processing
procedure of
harness
MX40008NHarness
checker
for
q
JAE
MCM2
8
Q1
checker
troubleshooting of
machine
monitor LCD
unit".
T070
Switch panel
q
MOM1
6
175954-1
AMP
connector adapter
T070
RVM1 12
175957-1
AMP
connector adapter
Rear view monitor
T070
q
RVM2
8
175955-1
AMP
connector adapter
40-110
WA470-7
40 Troubleshooting
Configuration drawing of machine monitor and related units
WA470-7
40-111
40 Troubleshooting
Processing procedure of harness checker for troubleshooting of

machine monitor LCD unit (HM300-Q000-330-K-00-A)
1. Purpose
This section describes the processing procedure of the monitor harness checker (jig) by using a massproduced harness between machine monitor LCD unit and monitor controller.
The machine monitor receives data from the monitor controller and displays the information on its LCD
unit.
The monitor harness checker allows you to measure the output voltage from the monitor controller and
determine whether cause of failure is in the monitor controller or not.
Use the monitor harness checker for troubleshooting of the machine monitor LCD unit. (See E-6 to E-8
of E-mode troubleshooting.)
2. Outline
Mass-produced harness between machine monitor LCD unit and monitor controller: 7831-47-8710
Before being modified
O
After being modified
Part to be modified is portion P.
40-112
WA470-7
40 Troubleshooting
Cut off the wiring harness at the connector (having no crimped portion), install a heat shrink tube to
each cable to prevent short circuit, and then install a check pin to each cable.
Finished harness checker
Fig. 1 Mass-produced harness between machine monitor LCD unit and monitor controller: 7831-47-8710
a Determine the pin number of each check pin by checking the cable color indicated at portion Q in the
figure or by checking the number of pin on the opposite side to which the cable is connected.
WA470-7
40-113
40 Troubleshooting
3. Preparation
Materials to be prepared
No.
1
Part name
Wiring harness
Check pin
Heat shrink tube f5 (Min. 35 mm in
3
length)
Heat shrink tube f5 (Min. 140 mm in
4
length)
Labels (with numbers <1> to <8>
5 printed on them) *2
6 Vinyl tape
7 Nipper
8 Wire stripper (for AWG 20-34)
9 Cutter
10 Soldering iron
11 Solder
12 Dryer *3
2
Type
Manufacturer
Japan Aviation
7831-47-8710
Electronics Industry
TJ-1-W *1
SATO PARTS
Sumitomo Electric
SUMI-F2Z-5x0.25 *1
Industries
Sumitomo Electric
SUMI-F2Z-3.5x0.25 *1
Industries
Quantity
1
8
1
1
1 label each (8
labels in total)
1
1
1
1
1
1
1
*1 Can be substituted with an equivalent

*2 They are attached for easy understanding of harness pin number. You may mark numbers on labels.
*3 Can be substituted with a heat gun.
4. Work procedure
Modification of cables with pin Nos. 3 to 8
1) Use a nipper to cut off the wiring harness at the root of the connector that does not have crimped
portion ((07) in the Fig. 1).
2) Use a wire stripper to remove covers of cables with pin Nos. 3 to 8, 5 mm from the cut end.
a take care not to cut the wire inside the cover.
3) Make six 15-mm heat shrink tubes f3.5 (A).
4) Pass a heat shrink tube (A) over any one of the cut cables, and solder a check pin to the cable.
40-114
WA470-7
40 Troubleshooting
5) Slide heat shrink tube (A) of the cable to which the check pin is soldered in step 4) to a position where
the check pin conductor is covered, and use a dryer to contract heat shrink tube (A).
6) Attach the label so that the pin number of the cable is easily read.
a Determine the pin number of each check pin by checking the cable color indicated at portion Q of
Fig. 1 or by checking the number of pin on the opposite side to which the pin is connected.
7) Repeat steps 4 to 6 for other cables with pin Nos. 3 to 8.

8) Remove tape (B) winding around the conduit to an appropriate position because it is an obstacle for
the work.
Modification of cables with pin Nos. 1 and 2

1. Strip the cover of shield cable 35 mm in length with your nail.
a take care not to cut the wire inside the cover.
2. Tear off shield cable (C) with your fingers and wind it around the cover.
3. Strip aluminum leaf and yellow thin paper (D) with your nail, and wind it around the cover.
4. Strip the covers of cables with pin Nos. 1 and 2, 5 mm in length by using a wire stripper.
5. Make one 35-mm heat shrink tube f5 (E).
6. Pass the cut heat shrink tube (E) over the cables with pin Nos. 1 and 2.
WA470-7
40-115
40 Troubleshooting
7. Make two 25-mm heat shrink tubes f3.5 (F).

8. Pass the cut heat shrink tube (F) over each of the cables with pin Nos. 1 and 2.
9. Solder the check pin to each of the cables with pin Nos. 1 and 2.
10.Slide heat shrink tube (F) to a position where the check pin conductor is covered, and use a dryer to
contract the heat shrink tube.
11.Attach the label so that the pin number of the cable is easily read.
a Determine the pin number of each check pin by checking the cable color indicated at portion Q of Fig. 1
or by checking the number of pin on the opposite side to which the cable is connected.
12.Slide heat shrink tube f5 (E) to a position where it overlaps heat shrink tube f3.5 (F) for cables with pin
Nos. 1 and 2, and then use a dryer to contract heat shrink tube (E).
13.Cut off tape (B) that was stripped from the conduit at an appropriate position, From that position, Wrap
vinyl tape around the cables with pin Nos. 3 to 8 to bind them. This completes the work.
40-116
WA470-7
40 Troubleshooting
Fabrication of dummy temperature sensor (for KDOC and KDPF

temperature sensors) (HM300-A9J2-304-K-00-A)
Use this dummy temperature sensor in troubleshooting for KDPF-related failure codes.
To fabricate dummy temperature sensor, purchase KDPF temperature sensor consolidating box that are
installed on KDPF, and modify it (break up KDPF temperature sensor consolidating box and take out 4-pin
connector section).
Dummy temperature sensor
WA470-7
40-117
40 Troubleshooting
Fabrication of short-circuit connector (for CA1883 and CA3135)
(HM300-A9J2-
304-K-01-A)
a KDPF differential pressure sensor is the same as KDPF outlet pressure sensor.
CA1883 Short-circuit connector for KDPF delta pressure sensor
CA3135 Short-circuit connector for KDPF outlet pressure sensor
40-118
WA470-7
40 Troubleshooting
Failure codes table

Failure
code
(WA470-5520-441-A-00-A)
Category
history
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Mechanical
system
Mechanical
system
Controller
Action
level
TM
L04
TM
L03
TM
L01
TM
L03
TM
L01
TM
L03
TM
L01
TM
L03
TM
L01
TM
L03
TM
L01
TM
L03
TM
L01
MON
L03
MON
L03
MON
L03
Failure code [879AKA] A/C Inner Sensor

879AKA Open Circuit(PAGE 40-166)
MON
Electrical
system
Failure code [879AKB] A/C Inner Sensor Short

879AKB Circuit(PAGE 40-167)
MON
Electrical
system
Failure code [879BKA] A/C Outer Sensor

879BKA Open Circuit(PAGE 40-168)
MON
Electrical
system
Failure code [879BKB] A/C Outer Sensor

879BKB Short Circuit(PAGE 40-169)
MON
Electrical
system
Failure code [879CKA] Ventilating Sensor

879CKA Open Circuit(PAGE 40-170)
MON
Electrical
system
Failure code [879CKB] Ventilating Sensor

879CKB Short Circuit(PAGE 40-171)
MON
Electrical
system
Failure code [879DKZ] Sunlight Sensor Open

879DKZ or Short Circuit(PAGE 40-172)
MON
Electrical
system
Failure code [879EMC] Ventilation Damper

879EMC Abnormality(PAGE 40-173)
MON
L01
Electrical
system
1500L0
15SAL1
15SALH
15SBL1
15SBLH
15SEL1
15SELH
15SFL1
15SFLH
15SGL1
15SGLH
15SHL1
15SHLH
2F00MA
2G42ZG
2G43ZG
WA470-7
Failure (Displayed on screen)

Failure code [1500L0] Double Engagement of
T/M Clutches(PAGE 40-133)
Failure code [15SAL1] Release Trouble of
ECMV (Forward)(PAGE 40-134)
Failure code [15SALH] Malfunction of ECMV
(Forward)(PAGE 40-136)
Failure code [15SBL1] Release Trouble of
ECMV (Reverse)(PAGE 40-138)
Failure code [15SBLH] Malfunction of ECMV
(Reverse)(PAGE 40-140)
Failure code [15SEL1] Release Trouble of
ECMV (1st)(PAGE 40-142)
Failure code [15SELH] Malfunction of ECMV
(1st)(PAGE 40-144)
Failure code [15SFL1] Release Trouble of
ECMV (2nd)(PAGE 40-146)
Failure code [15SFLH] Malfunction of ECMV
(2nd)(PAGE 40-148)
Failure code [15SGL1] Release Trouble of
ECMV (3rd)(PAGE 40-150)
Failure code [15SGLH] Malfunction of ECMV
(3rd)(PAGE 40-152)
Failure code [15SHL1] Release Trouble of
ECMV (4th)(PAGE 40-154)
Failure code [15SHLH] Malfunction of ECMV
(4th)(PAGE 40-156)
Failure code [2F00MA] Failure of Parking
Brake Circuit(PAGE 40-158)
Failure code [2G42ZG] Accumulator Oil
Pressure Low (Front)(PAGE 40-162)
Pressure Low (Rear)(PAGE 40-164)
Remarks
See Chapter
80, Other
items
See Chapter
80, Other
items
See Chapter
80, Other
items
See Chapter
80, Other
items
See Chapter
80, Other
items
See Chapter
80, Other
items
See Chapter
80, Other
items
See Chapter
80, Other
items
40-119
40 Troubleshooting
Failure
code
Failure code [879FMC] Air Mix Damper

879FMC Abnormality(PAGE 40-174)
989A00
989L00
989M00
989N00
A1U0N3
A1U0N4
AA10NX
B@BAZG
B@BAZK
B@BCNS
B@BCZK
B@CENS
B@HANS
CA115
CA122
CA123
CA131
CA132
CA135
CA141
CA144
CA145
CA153
CA154
CA187
CA221
40-120
Failure code [989A00] Engine Overrun

Prevention Activated(PAGE 40-175)
Failure code [989L00] Engine Controller Lock
Caution 1(PAGE 40-176)
Failure code [989M00] Engine Controller Lock
Failure code [989N00] Engine Controller Lock
Failure code [A1U0N3] HC Desorb Request 1
(PAGE 40-179)
(PAGE 40-181)
Failure code [AA10NX] Air Cleaner Clogging
(PAGE 40-183)
Failure code [B@BAZG] Eng Oil Press Low
(PAGE 40-185)
Failure code [B@BAZK] Eng Oil Level Low
(PAGE 40-186)
Failure code [B@BCNS] Eng Water Overheat
(PAGE 40-188)
Failure code [B@BCZK] Eng Water Level Low
(PAGE 40-189)
Failure code [B@CENS] T/C Oil Temp.
Overheat(PAGE 40-191)
Failure code [B@HANS] HYD Oil Temp.
Overheat(PAGE 40-192)
Failure code [CA115] Eng Ne and Bkup Speed
Sens Error(PAGE 40-193)
Failure code [CA122] Chg Air Press Sensor
High Error(PAGE 40-194)
Low Error(PAGE 40-196)
Failure code [CA131] Throttle Sensor High
Error(PAGE 40-198)
Failure code [CA132] Throttle Sensor Low
Error(PAGE 40-200)
Failure code [CA135] Eng Oil Press Sensor
Failure code [CA144] Coolant Temp Sens
Failure code [CA145] Coolant Temp Sens Low
Error(PAGE 40-208)
Failure code [CA153] Chg Air Temp Sensor
Failure code [CA187] Sensor 2 Supply Volt
Failure code [CA221] Ambient Press Sensor
Controller
Action
level
Category
history
Remarks
MON
L01
Electrical
system
See Chapter
80, Other
items
TM
L02
MON
MON
MON
ENG
L01
ENG
L03
MON
L01
ENG
L03
MON
L01
ENG
L02
MON
L01
MON
L02
MON
L02
ENG
L04
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L01
ENG
L01
ENG
L01
ENG
L01
ENG
L03
ENG
L03
ENG
L03
ENG
L03
Mechanical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Mechanical
system
Electrical
system
Mechanical
system
Electrical
system
Mechanical
system
Mechanical
system
Mechanical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
WA470-7
40 Troubleshooting
Failure
code
CA222
CA227
CA234
CA238
CA239
CA271
CA272
CA273
CA274
CA322
CA323
CA324
CA325
CA331
CA332
CA343
CA351
CA352
CA356
CA357
CA386
CA431
CA432
CA441
CA442
CA449
CA451
CA452
WA470-7

Failure code [CA222] Ambient Press Sensor
Failure code [CA234] Eng Overspeed(PAGE
40-221)
Failure code [CA238] Ne Speed Sensor
Supply Volt Error(PAGE 40-222)
Failure code [CA239] Ne Speed Sens Supply
Volt High Error(PAGE 40-223)
Failure code [CA271] IMV/PCV1 Short Error
(PAGE 40-224)
Failure code [CA272] IMV/PCV1 Open Error
(PAGE 40-225)
Failure code [CA273] PCV2 Short Error(PAGE
40-226)
Failure code [CA274] PCV2 Open Error(PAGE
40-227)
Failure code [CA322] Inj #1(L#1) Open/Short
Error(PAGE 40-228)
Error(PAGE 40-230)
Error(PAGE 40-232)
Error(PAGE 40-234)
Error(PAGE 40-236)
Error(PAGE 40-238)
Failure code [CA343] ECM Critical Internal
Failure(PAGE 40-240)
Failure code [CA351] Injectors Drive Circuit
Error(PAGE 40-241)
Failure code [CA356] Mass Air Flow Sensor
Failure code [CA431] Idle Validation Sw Error
(PAGE 40-249)
Failure code [CA432] Idle Validation Process
Error(PAGE 40-252)
Failure code [CA441] Battery Voltage Low
Error(PAGE 40-255)
Failure code [CA442] Battery Voltage High
Error(PAGE 40-257)
Failure code [CA449] Rail Press Very High
Error(PAGE 40-258)
Failure code [CA451] Rail Press Sensor High
Error(PAGE 40-259)
Failure code [CA452] Rail Press Sensor Low
Error(PAGE 40-261)
Controller
Action
level
ENG
L03
ENG
L03
ENG
L02
ENG
L01
ENG
L01
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L04
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L01
ENG
L03
ENG
L04
ENG
L04
ENG
L03
ENG
L03
ENG
L03
Category
history
Electrical
system
Electrical
system
Mechanical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Remarks
40-121
40 Troubleshooting
Failure
code
CA515
CA516
CA553
CA555
CA556
CA559
CA595
CA687
CA689
CA691
CA692
CA697
CA698
CA731
CA778
CA1117
CA1664
CA1691
CA1695
CA1696
CA1843
CA1844
CA1879
CA1881
CA1883
CA1921
CA1922
CA1923
40-122

Failure code [CA515] Rail Press Sens Sup
Volt High Error(PAGE 40-263)
Failure code [CA516] Rail Press Sens Sup
Volt Low Error(PAGE 40-265)
Failure code [CA553] Rail Press High Error
(PAGE 40-267)
Failure code [CA555] Crankcase Press High
Error 1(PAGE 40-268)
Failure code [CA559] Rail Press Low Error
(PAGE 40-270)
Failure code [CA595] Turbo Speed High Error
2(PAGE 40-274)
Failure code [CA687] Turbo Speed Low Error
(PAGE 40-275)
Failure code [CA689] Eng Ne Speed Sensor
Error(PAGE 40-277)
Failure code [CA691] Intake Air Temp Sens
Failure code [CA692] Intake Air Temp Sens
Failure code [CA697] ECM Internal Temp
Sensor High Error(PAGE 40-283)
Failure code [CA698] ECM Int Temp Sensor
Failure code [CA731] Eng Bkup Speed Sens
Phase Error(PAGE 40-285)
Failure code [CA778] Eng Bkup Speed
Sensor Error(PAGE 40-286)
Failure code [CA1117] Persistent Data Lost
Error(PAGE 40-288)
Failure code [CA1664] KDOC Malfunction
(PAGE 40-289)
Failure code [CA1691] Regeneration
Ineffective(PAGE 40-292)
Failure code [CA1843] Crankcase Press Sens
Failure code [CA1879] KDPF Delta P Sensor
Failure code [CA1883] KDPF Delta P Sens In
Range Error(PAGE 40-306)
Failure code [CA1921] KDPF Soot Load High
Failure code [CA1923] Dosing Fuel Valve 1
Controller
Action
level
ENG
L03
ENG
L03
ENG
L01
ENG
L01
ENG
L03
ENG
L01
ENG
L01
ENG
L01
ENG
L01
ENG
L01
ENG
L01
ENG
L01
ENG
L01
ENG
L01
ENG
L01
ENG
L04
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L01
ENG
L01
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L04
ENG
L03
Category
history
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Remarks
WA470-7
40 Troubleshooting
Failure
code

CA1924 Low Error(PAGE 40-319)
Failure code [CA1925] Dosing Fuel Valve 1 In
CA1925 Range Error(PAGE 40-322)
Failure code [CA1927] Dosing Fuel Press
CA1927 Sens High Error(PAGE 40-324)
CA1928 Sens Low Error(PAGE 40-326)
CA1942 In Range Error(PAGE 40-328)
CA1963 Servo Error(PAGE 40-329)
Failure code [CA1977] Fuel Doser Open/Short
CA1977 Error(PAGE 40-331)
Failure code [CA1993] KDPF Delta Pressure
Failure code [CA2185] Throt Sensor Sup Volt
CA2185 High Error(PAGE 40-335)
Failure code [CA2249] Rail Press Very Low
Failure code [CA2265] Fuel Feed Pump Open
Failure code [CA2266] Fuel Feed Pump Short
Failure code [CA2271] EGR Valve Pos Sens
Failure code [CA2349] EGR Valve Solenoid
CA2349 Open Error(PAGE 40-348)
CA2353 Short Error(PAGE 40-350)
Failure code [CA2357] EGR Valve Servo Error
CA2357 (PAGE 40-352)
Failure code [CA2381] KVGT Pos Sens High
Failure code [CA2382] KVGT Pos Sens Low
Failure code [CA2383] KVGT Solenoid Open
Failure code [CA2386] KVGT Solenoid Short
Failure code [CA2387] KVGT Servo Error
CA2387 (PAGE 40-361)
Failure code [CA2555] Grid Htr Relay Volt Low
Failure code [CA2556] Grid Htr Relay Volt
Failure code [CA2637] KDOC Face Plugging
CA2637 (PAGE 40-366)
Failure code [CA2639] Manual Stationary
CA2639 Regeneration Request(PAGE 40-368)
WA470-7
Controller
Action
level
ENG
L03
ENG
L03
ENG
L01
ENG
L01
ENG
L01
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L01
ENG
L01
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L01
ENG
L01
ENG
L01
ENG
L01
ENG
L03
Category
history
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Remarks
40-123
40 Troubleshooting
Failure
code

Failure code [CA2741] Dosing Fuel Valve
CA2741 Swap Error(PAGE 40-375)
Failure code [CA2765] Inj Trim Data Error
CA2765 (PAGE 40-377)
CA2878 Servo Error(PAGE 40-378)
Failure code [CA2881] Dosing Fuel Pressure
CA2881 Low Error 1(PAGE 40-381)
Failure code [CA3133] KDPF Outlet Press
CA3135 Sens In Range Error(PAGE 40-390)
Failure code [CA3167] Fuel Doser
CA3167 Degradation(PAGE 40-393)
Failure code [CA3251] KDOC Inlet Temp High
Failure code [CA3253] KDOC Temp Error CA3253 Non Regeneration(PAGE 40-399)
Failure code [CA3254] KDOC Outlet Temp
CA3254 High Error 1(PAGE 40-402)
Failure code [CA3255] KDPF Temp Error CA3255 Non Regeneration(PAGE 40-405)
Failure code [CA3256] KDPF Outlet Temp
Failure code [CA3313] KDOC Inlet Temp
CA3313 Sensor Low Error(PAGE 40-418)
Failure code [CA3314] KDOC Inlet Temp Sens
CA3315 In Range Error(PAGE 40-425)
CA3419 Sup Volt High Error(PAGE 40-454)
CA3421 Sup Volt Low Error(PAGE 40-456)
Failure code [D150KA] Disconnection of
D150KA Emerg. Steering Relay(PAGE 40-458)
40-124
Controller
Action
level
ENG
L03
ENG
L03
ENG
L01
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
ENG
L03
ENG
L03
ENG
L01
ENG
L03
ENG
L01
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
ENG
L03
WRK
L03
Category
history
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Remarks
WA470-7
40 Troubleshooting
Failure
code
Failure code [D150KB] Ground Fault of

D150KB Emerg. Steering Relay(PAGE 40-460)
Failure code [D150KY] Hot Short of
D150KY Emergency Steering Relay(PAGE 40-462)
D160KA Backup Lamp Relay Output(PAGE 40-464)
D160KB Backup Lamp Relay Output(PAGE 40-466)
Failure code [D160KY] Hot Short of Backup
D160KY Lamp Relay Output(PAGE 40-468)
D191KA Neutral Output Relay(PAGE 40-470)
D191KB Neutral Output Relay(PAGE 40-472)
Failure code [D191KY] Hot Short of Neutral
D191KY Output Relay(PAGE 40-474)
D192KA ECSS Solenoid(PAGE 40-476)
Failure code [D192KB] Ground Fault of ECSS
D192KB Solenoid(PAGE 40-478)
Failure code [D192KY] Hot Short of ECSS
D192KY Solenoid(PAGE 40-479)
Failure code [D19JKZ] Personal Code Relay
D19JKZ Abnormality(PAGE 40-480)
Failure code [D1E6KA] Disconnection of
D1E6KA Parking Brake Relay(PAGE 40-482)
Failure code [D1E6KB] Ground Fault of
D1E6KB Parking Brake Relay(PAGE 40-484)
Failure code [D1E6KY] Hot Short of Parking
D1E6KY Brake Relay(PAGE 40-486)
Failure code [D5ZHKA] Failure of Key SW C
D5ZHKA Signal(PAGE 40-488)
Failure code [D5ZHKB] Key SW C Signal
D5ZHKB Short Circuit(PAGE 40-490)
Failure code [D5ZHKZ] Failure of Key SW C
D5ZHKZ Signal(PAGE 40-492)
Failure code [D5ZHL6] Disconnection of Key
D5ZHL6 SW C(PAGE 40-494)
Failure code [D811MC] KOMTRAX Error
D811MC (PAGE 40-496)
Failure code [D862KA] GPS Antenna Open
D862KA Circuit(PAGE 40-497)
Failure code [D8ALKA] Operating Lamp Open
D8ALKA Circuit (KOMTRAX)(PAGE 40-498)
Failure code [D8ALKB] Operating Lamp Short
D8ALKB Circuit (KOMTRAX)(PAGE 40-500)
Failure code [D8AQK4] CAN2 Discon
D8AQK4 (KOMTRAX) 2(PAGE 40-502)
Failure code [D8AQKR] CAN2 Discon
D8AQKR (KOMTRAX)(PAGE 40-503)
Failure code [DAF0KT] Abnormality of NonDAF0KT volatile Memory (MON)(PAGE 40-505)
Failure code [DAF0MB] Monitor ROM
DAF0MB Abnormality(PAGE 40-506)
Failure code [DAF0MC] Monitor Error(PAGE
DAF0MC 40-507)
WA470-7
Controller
Action
level
WRK
L03
WRK
L03
TM
L01
TM
L01
TM
L01
TM
L03
TM
L03
TM
L03
TM
L01
TM
L01
TM
L01
MON
L03
TM
L03
TM
L03
TM
L03
TM
L01
TM
L01
WRK
L01
MON
L01
KOMTRAX
KOMTRAX
KOMTRAX
KOMTRAX
MON
L03
MON
MON
L03
MON
MON
Category
history
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Remarks
40-125
40 Troubleshooting
Failure
code
Controller
Failure code [DAF3KK] Controller Power

MON
DAF3KK Source Low (MON)(PAGE 40-508)
Failure code [DAF8KB] Camera Power Supply
DAF8KB Short Circuit(PAGE 40-510)
MON
Failure code [DAFDKB] Monitor 12V Power
MON
DAFDKB Output Short Circuit(PAGE 40-511)
Failure code [DAFGMC] GPS Module Error
DAFGMC (PAGE 40-513)
KOMTRAX
Failure code [DAFLKA] Operating Lamp Open
MON
DAFLKA Circuit (MON)(PAGE 40-514)
Failure code [DAFLKB] Operating Lamp Short
DAFLKB Circuit (MON)(PAGE 40-516)
MON
Failure code [DAFQKR] CAN2 Discon
DAFQKR (Monitor)(PAGE 40-518)
KOMTRAX
Failure code [DAQ0KK] Controller Power
DAQ0KK Source Low (T/M)(PAGE 40-519)
TM
Failure code [DAQ0KT] Abnormality of NonDAQ0KT volatile Memory (T/M)(PAGE 40-522)
TM
Failure code [DAQ0MC] T/M Con Error(PAGE
DAQ0MC 40-523)
TM
Failure code [DAQ1KA] Disconnection of Key
DAQ1KA SW ACC (T/M)(PAGE 40-524)
TM
Failure code [DAQ2KK] Solenoid Power
DAQ2KK Source Low (T/M)(PAGE 40-526)
TM
Failure code [DAQ4KB] Ground Fault of Sol.
DAQ4KB Self-Holding Relay(PAGE 40-529)
TM
Failure code [DAQ9KQ] Inconsistency of
DAQ9KQ Model Selection (T/M)(PAGE 40-531)
TM
Failure code [DAQLKA] Operating Lamp Open
DAQLKA Circuit (T/M)(PAGE 40-532)
TM
Failure code [DAQLKB] Operating Lamp Short
DAQLKB Circuit (T/M)(PAGE 40-534)
TM
Failure code [DAQQKR] CAN2 Discon
DAQQKR (Transmission Con)(PAGE 40-536)
MON
Failure code [DAQRKR] CAN1 Discon
DAQRKR (Transmission Con)(PAGE 40-537)
MON
Failure code [DAQRMA] Inconsistency of
DAQRMA Option Selection (T/M)(PAGE 40-538)
TM
Failure code [DAZ9KQ] A/C Model Selection
DAZ9KQ Abnormality(PAGE 40-539)
MON
Failure code [DAZQKR] CAN2 Discon (Aircon
DAZQKR ECU)(PAGE 40-540)
MON
Failure code [DB2QKR] CAN2 Discon (Engine
DB2QKR Con)(PAGE 40-541)
MON
Failure code [DB2RKR] CAN1 Discon (Engine
MON
DB2RKR Con)(PAGE 40-546)
Failure code [DB90KK] Drop in BBC Controller
WRK
DB90KK Main Power Source(PAGE 40-551)
Failure code [DB90KT] Abnormality of NonWRK
DB90KT volatile Memory (BBC)(PAGE 40-553)
Failure code [DB90MC] BBC Error(PAGE 40WRK
DB90MC 554)
Failure code [DB91KA] Disconnection of Key
WRK
DB91KA SW ACC (BBC)(PAGE 40-555)
Failure code [DB92KK] Solenoid Power
DB92KK Source Low (BBC)(PAGE 40-557)
WRK
40-126
Action
level
L03
L01
L03
L01
L03
L03
L01
L03
L03
L03
L03
L01
L03
L03
L03
L01
L03
L03
Category
history
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Remarks
WA470-7
40 Troubleshooting
Failure
code
Failure code [DB95KX] Failure of 5 V Power

DB95KX Source 1(PAGE 40-559)
DB96KX Source 2(PAGE 40-561)
Failure code [DB99KQ] Inconsistency of
DB99KQ Model Selection (BBC)(PAGE 40-563)
Failure code [DB9LKA] Operating Lamp Open
DB9LKA Circuit (BBC)(PAGE 40-564)
Failure code [DB9LKB] Operating Lamp Short
DB9LKB Circuit (BBC)(PAGE 40-566)
Failure code [DB9QKR] CAN2 Discon (Bucket
DB9QKR Boom Con)(PAGE 40-568)
Failure code [DB9RKR] CAN1 Discon (Bucket
DB9RKR Boom Con)(PAGE 40-569)
Failure code [DB9RMA] Inconsistency of
DB9RMA Option Selection (BBC)(PAGE 40-570)
Failure code [DBE5KX] Failure of 5V Power
DBE5KX Source(PAGE 40-571)
Failure code [DBE6KX] Failure of 24 V Power
DBE6KX Source(PAGE 40-573)
Failure code [DD1ALD] Ground Fault of
DD1ALD Remote Positioner Set SW(PAGE 40-575)
Failure code [DDAAL6] Discon of Engine
DDAAL6 Shutdown Secondary Switch(PAGE 40-577)
Failure code [DDB6L4] Neutral Signal
DDB6L4 Malfunction(PAGE 40-579)
Failure code [DDD1LD] Failure of Bucket
DDD1LD Positioner Set Switch(PAGE 40-582)
Failure code [DDK3KA] FNR SW Input Signal
DDK3KA Disconnection(PAGE 40-584)
Failure code [DDK3KB] FNR SW Input Signal
DDK3KB Short Circuit(PAGE 40-587)
Failure code [DDK6KA] FNR Lever Input
DDK6KA Signal Disconnection(PAGE 40-589)
Failure code [DDK6KB] FNR Lever Input
DDK6KB Signal Short Circuit(PAGE 40-592)
Failure code [DDNRKY] Hot Short of Work
DDNRKY Equipment Lock SW(PAGE 40-594)
Failure code [DDT0L4] Failure of Shift Mode
DDT0L4 Select SW(PAGE 40-596)
Failure code [DDT4LD] Ground Fault of T/M
DDT4LD Cut Off Set SW Signal(PAGE 40-598)
DDT9LD Cut Off SW Signal(PAGE 40-600)
Failure code [DDW9LD] Ground Fault of
DDW9LD Kickdown Switch(PAGE 40-602)
Failure code [DDWLLD] Ground Fault of T/M
DDWLLD Shift Hold SW(PAGE 40-604)
Failure code [DF10KA] Disconnection of Shift
DF10KA Lever Input(PAGE 40-606)
Failure code [DF10KB] Ground Fault of Shift
DF10KB Lever Input(PAGE 40-608)
Failure code [DGF1KA] Disconnection of T/M
DGF1KA Oil Temp. Sensor(PAGE 40-611)
Failure code [DGF1KB] Ground Fault of T/M
DGF1KB Oil Temp. Sensor(PAGE 40-613)
WA470-7
Controller
Action
level
WRK
L03
WRK
L03
WRK
L03
WRK
WRK
MON
L03
MON
L03
WRK
L03
TM
L01
TM
L01
WRK
L01
MON
L03
TM
L03
WRK
L01
TM
L03
TM
L03
TM
L03
TM
L03
WRK
L01
TM
L01
TM
L01
TM
L01
TM
L01
TM
L01
TM
L03
TM
L03
TM
L01
TM
L01
Category
history
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Remarks
40-127
40 Troubleshooting
Failure
code
Failure code [DGH2KX] Out of Range of HYD

DGH2KX Oil Temp. Sensor(PAGE 40-615)
Failure code [DGR2KB] Ground Fault of Brake
DGR2KB Oil Temp. Sensor(PAGE 40-617)
Failure code [DGR2KZ] Failure of Brake Oil
DGR2KZ Temp. Sensor(PAGE 40-618)
Failure code [DGT1KA] Disconnection of T/C
DGT1KA Oil Temp. Sensor(PAGE 40-620)
Failure code [DGT1KB] Ground Fault of T/C
DGT1KB Oil Temp. Sensor(PAGE 40-623)
Failure code [DH21KA] Failure of Loader
DH21KA Pump Press. Sensor(PAGE 40-625)
Failure code [DH21KB] Loader Pump Press.
DH21KB Sensor Short Circuit(PAGE 40-627)
Failure code [DHA4KA] Failure of Air Cleaner
DHA4KA Sensor Circuit(PAGE 40-629)
Failure code [DHPCKX] Out of Range of
DHPCKX Boom Bottom Press. Sensor(PAGE 40-631)
Failure code [DHPDKX] Out of Range of
DHPDKX Boom Head Press. Sensor(PAGE 40-633)
Failure code [DHT1KX] Out of Range of T/M
DHT1KX Cut Off Press. Sensor(PAGE 40-635)
Failure code [DHT5KX] Out of Range of T/C
DHT5KX Input Pressure Sensor(PAGE 40-637)
DHT7KX Output Pressure Sensor(PAGE 40-639)
Failure code [DHT8KA] Failure of Steering
DHT8KA Pump Press. Sensor(PAGE 40-641)
Failure code [DHT8KB] Steering Pump Press.
DHT8KB Sensor Short Circuit(PAGE 40-643)
Failure code [DHT8ZG] Steering Oil Pressure
DHT8ZG Low(PAGE 40-645)
Failure code [DHUDKA] Failure of Emrg.
DHUDKA Steering Press. Sensor(PAGE 40-646)
Failure code [DHUDKB] Emrg. Steering Press.
DHUDKB S. Short Circuit(PAGE 40-648)
Failure code [DJF1KA] Disconnection of Fuel
DJF1KA Level Sensor(PAGE 40-650)
Failure code [DK55KA] Failure of FNR Lever
DK55KA Potentio(PAGE 40-652)
Failure code [DK55KY] Hot Short of FNR
DK55KY Lever Potentio Circuit(PAGE 40-655)
Failure code [DK55L5] Failure of FNR Lever
DK55L5 Potentio(PAGE 40-657)
Failure code [DK59KA] Failure of Boom Lever
DK59KA Potentio (Main)(PAGE 40-658)
Failure code [DK59KY] Hot Short of Boom
DK59KY Lever Potentio (Main)(PAGE 40-661)
Failure code [DK59L8] Boom Lever Potentio
DK59L8 (Main & Sub) Disagree(PAGE 40-664)
Failure code [DK5AKA] Failure of Boom Lever
DK5AKA Potentio (Sub)(PAGE 40-668)
Failure code [DK5AKY] Hot Short of Boom
DK5AKY Lever Potentio (Sub)(PAGE 40-671)
Failure code [DK5BKA] Failure of Bucket
DK5BKA Lever Potentio (Main)(PAGE 40-674)
40-128
Controller
Action
level
TM
L01
MON
L01
MON
L01
TM
L01
TM
L01
WRK
L01
WRK
L01
MON
L01
WRK
L01
WRK
L01
TM
L01
TM
L01
TM
L01
WRK
L01
WRK
L01
WRK
L03
WRK
L01
WRK
L01
MON
L01
TM
L01
TM
L01
TM
L01
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L03
Category
history
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Mechanical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Remarks
WA470-7
40 Troubleshooting
Failure
code
Failure code [DK5BKY] Hot Short of Bucket

DK5BKY Lever Potentio (Main)(PAGE 40-677)
Failure code [DK5BL8] Bucket Lever Potentio
DK5BL8 (Main&Sub) Disagree(PAGE 40-680)
Failure code [DK5CKA] Failure of Bucket
DK5CKA Lever Potentio (Sub)(PAGE 40-684)
Failure code [DK5CKY] Hot Short of Bucket
DK5CKY Lever Potentio (Sub)(PAGE 40-687)
Failure code [DK5DKA] Failure of 3rd Lever
DK5DKA Potentio (Main)(PAGE 40-690)
Failure code [DK5DKY] Hot Short of 3rd Lever
DK5DKY Potentio (Main)(PAGE 40-693)
Failure code [DK5DL8] 3rd Lever Potentio
DK5DL8 (Main & Sub) Disagree(PAGE 40-695)
Failure code [DK5EKA] Failure of 3rd Lever
DK5EKA Potentio (Sub)(PAGE 40-698)
Failure code [DK5EKY] Hot Short of 3rd Lever
DK5EKY Potentio (Sub)(PAGE 40-701)
Failure code [DKA0KA] Failure of Boom Angle
DKA0KA Sensor(PAGE 40-703)
Failure code [DKA0KY] Hot Short of Boom
DKA0KY Angle Sensor Circuit(PAGE 40-705)
Failure code [DKA0L0] Boom Angle Sensor
DKA0L0 Dislocation(PAGE 40-707)
Failure code [DKA1KA] Failure of Bucket
DKA1KA Angle Sensor(PAGE 40-709)
Failure code [DKA1KY] Hot Short of Bucket
DKA1KY Angle Sensor Circuit(PAGE 40-711)
Failure code [DLF1KA] Disconnection of T/M
DLF1KA Input Speed Sensor(PAGE 40-713)
Failure code [DLF1LC] Failure of T/M Input
DLF1LC Speed Sensor(PAGE 40-715)
Failure code [DLM3KA] Disconnection of
DLM3KA Radiator Fan Speed Sensor(PAGE 40-717)
Failure code [DLM3LC] Failure of Radiator
DLM3LC Fan Speed Sensor(PAGE 40-719)
Failure code [DLT3KA] Disconnection of
DLT3KA Output Speed Sens. (Main)(PAGE 40-721)
Failure code [DLT3LC] Failure of Output
DLT3LC Speed Sensor (Main)(PAGE 40-723)
Failure code [DPQ1KR] LIN Discon (Switch
DPQ1KR Panel)(PAGE 40-725)
Failure code [DPQ2KR] LIN Discon (LED Unit)
DPQ2KR (PAGE 40-728)
Failure code [DPQ3KR] LIN Discon (Rear
DPQ3KR View Monitor)(PAGE 40-731)
Failure code [DSJ0KR] CAN2 Discon (Meter
DSJ0KR Unit)(PAGE 40-734)
Failure code [DT20KB] Ground Fault of T/M
DT20KB Cut Off Indicator(PAGE 40-736)
Failure code [DT22KB] Ground Fault of Work
DT22KB Equip. Lock Indic.(PAGE 40-738)
Failure code [DV00KB] Ground Fault of
DV00KB Buzzer Output(PAGE 40-740)
Failure code [DW4PKA] Disconnection of
DW4PKA Boom EPC Solenoid (Raise)(PAGE 40-742)
WA470-7
Controller
Action
level
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L01
WRK
L01
WRK
L01
WRK
L01
WRK
L01
TM
L03
TM
L03
TM
L01
TM
L01
TM
L03
TM
L03
MON
L01
MON
L01
MON
L01
MON
L01
TM
L01
WRK
L01
MON
L01
WRK
L03
Category
history
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Remarks
40-129
40 Troubleshooting
Failure
code
Failure code [DW4PKB] Ground Fault of

DW4PKB Boom EPC Solenoid (Raise)(PAGE 40-744)
Failure code [DW4PKY] Hot Short of Boom
DW4PKY EPC Solenoid (Raise)(PAGE 40-746)
Failure code [DW4QKA] Disconnection of
DW4QKA Boom EPC Solenoid (Lower)(PAGE 40-748)
Failure code [DW4QKB] Ground Fault of
DW4QKB Boom EPC Solenoid (Lower)(PAGE 40-750)
Failure code [DW4QKY] Hot Short of Boom
DW4QKY EPC Solenoid (Lower)(PAGE 40-752)
Failure code [DW4RKA] Disconnection of
DW4RKA Bucket EPC Sol. (Tilt)(PAGE 40-754)
Failure code [DW4RKB] Ground Fault of
DW4RKB Bucket EPC Solenoid (Tilt)(PAGE 40-756)
Failure code [DW4RKY] Hot Short of Bucket
DW4RKY EPC Solenoid (Tilt)(PAGE 40-758)
Failure code [DW4SKA] Disconnection of
DW4SKA Bucket EPC Sol. (Dump)(PAGE 40-760)
Failure code [DW4SKB] Ground Fault of
DW4SKB Bucket EPC Solenoid (Dump)(PAGE 40-762)
Failure code [DW4SKY] Hot Short of Bucket
DW4SKY EPC Solenoid (Dump)(PAGE 40-764)
Failure code [DW7BKA] Disconnection of Fan
DW7BKA Reverse Solenoid(PAGE 40-766)
Failure code [DW7BKB] Ground Fault of
DW7BKB Radiator Fan Rev. Sol.(PAGE 40-768)
Failure code [DW7BKY] Hot Short of Radiator
DW7BKY Fan Rev. Sol.(PAGE 40-770)
Failure code [DWM1KA] Disconnection of
DWM1KA Neutral Lock Solenoid(PAGE 40-771)
Failure code [DWM1KB] Ground Fault of
DWM1KB Neutral Lock Solenoid(PAGE 40-773)
Failure code [DWM1KY] Hot Short of Neutral
DWM1KY Lock Solenoid(PAGE 40-775)
Failure code [DWN6KA] Disconnection of
DWN6KA Detent Solenoid (Boom)(PAGE 40-777)
Failure code [DWN6KB] Ground Fault of
DWN6KB Detent Solenoid (Boom)(PAGE 40-779)
Failure code [DWN6KY] Hot Short of Detent
DWN6KY Solenoid (Boom)(PAGE 40-781)
DWN8KA Detent Solenoid (Bucket)(PAGE 40-783)
DWN8KB Detent Solenoid (Bucket)(PAGE 40-785)
DWN8KY Solenoid (Bucket)(PAGE 40-787)
Failure code [DX16KA] Disconnection of Rad.
DX16KA Fan Pump EPC Sol.(PAGE 40-789)
Failure code [DX16KB] Ground Fault of Rad.
DX16KB Fan Pump EPC Sol.(PAGE 40-791)
Failure code [DX16KY] Hot Short of Radiator
DX16KY Fan Pump EPC Sol.(PAGE 40-793)
Failure code [DXA1KA] Disconnection of
DXA1KA Loader Pump EPC Solenoid(PAGE 40-795)
Failure code [DXA1KB] Ground Fault of
DXA1KB Loader Pump EPC Solenoid(PAGE 40-797)
40-130
Controller
Action
level
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L03
WRK
L03
TM
L01
TM
L01
TM
L01
WRK
L01
WRK
L01
WRK
L01
WRK
L01
WRK
L01
WRK
L01
WRK
L01
WRK
L01
WRK
L01
TM
L03
TM
L03
TM
L01
WRK
L01
WRK
L01
Category
history
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Remarks
WA470-7
40 Troubleshooting
Failure
code
Failure code [DXA1KY] Hot Short of Loader

DXA1KY Pump EPC Solenoid(PAGE 40-799)
Failure code [DXANKA] Disconnection of
DXANKA Steering Pump EPC Sol.(PAGE 40-801)
Failure code [DXANKB] Ground Fault of
DXANKB Steering Pump EPC Solenoid(PAGE 40-803)
Failure code [DXANKY] Hot Short of Steering
DXANKY Pump EPC Solenoid(PAGE 40-805)
Failure code [DXH1KA] Disconnection of
DXH1KA ECMV Solenoid (Lockup)(PAGE 40-806)
Failure code [DXH1KB] Ground Fault of
DXH1KB ECMV Solenoid (Lockup)(PAGE 40-808)
Failure code [DXH1KY] Hot Short of ECMV
DXH1KY Solenoid (Lockup)(PAGE 40-810)
DXH4KA ECMV Solenoid (1st)(PAGE 40-812)
DXH4KB ECMV Solenoid (1st)(PAGE 40-814)
DXH4KY Solenoid (1st)(PAGE 40-816)
DXH5KA ECMV Solenoid (2nd)(PAGE 40-818)
DXH5KB ECMV Solenoid (2nd)(PAGE 40-820)
DXH5KY Solenoid (2nd)(PAGE 40-822)
DXH6KA ECMV Solenoid (3rd)(PAGE 40-824)
DXH6KB ECMV Solenoid (3rd)(PAGE 40-826)
DXH6KY Solenoid (3rd)(PAGE 40-828)
DXH7KA ECMV Solenoid (Reverse)(PAGE 40-830)
DXH7KB ECMV Solenoid (Reverse)(PAGE 40-832)
DXH7KY Solenoid (Reverse)(PAGE 40-834)
DXH8KA ECMV Solenoid (Forward)(PAGE 40-836)
DXH8KB ECMV Solenoid (Forward)(PAGE 40-838)
DXH8KY Solenoid (Forward)(PAGE 40-840)
Failure code [DXHHKA] Disconnection of
DXHHKA ECMV Solenoid (4th)(PAGE 40-842)
Failure code [DXHHKB] Ground Fault of
DXHHKB ECMV Solenoid (4th)(PAGE 40-844)
Failure code [DXHHKY] Hot Short of ECMV
DXHHKY Solenoid (4th)(PAGE 40-846)
Failure code [DXHJKA] Disconnection of 3rd
DXHJKA EPC Solenoid (EXT)(PAGE 40-848)
Failure code [DXHJKB] Ground Fault of 3rd
DXHJKB EPC Solenoid (EXT)(PAGE 40-850)
Failure code [DXHJKY] Hot Short of 3rd EPC
DXHJKY Solenoid (EXT)(PAGE 40-852)
WA470-7
Controller
Action
level
WRK
L01
WRK
L01
WRK
L01
WRK
L01
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
TM
L03
WRK
L03
WRK
L03
WRK
L03
Category
history
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Remarks
40-131
40 Troubleshooting
Failure
code
Failure code [DXHKKA] Disconnection of 3rd

DXHKKA EPC Solenoid (RET)(PAGE 40-854)
Failure code [DXHKKB] Ground Fault of 3rd
DXHKKB EPC Solenoid (RET)(PAGE 40-856)
Failure code [DXHKKY] Hot Short of 3rd EPC
DXHKKY Solenoid (RET)(PAGE 40-858)
Failure code [DY30MA] Malfunction 1 of
DY30MA Emerg. Steering Motor(PAGE 40-860)
Failure code [DY30MC] Malfunction 2 of
DY30MC Emerg. Steering Motor(PAGE 40-863)
Failure code [DY30ME] Emerg. Steering
DY30ME Long-Time Activated(PAGE 40-867)
Failure code [LA00L3] Failure of Fan Reverse
LA00L3 (PAGE 40-869)
Controller
Action
level
WRK
L03
WRK
L03
WRK
L03
WRK
L01
WRK
L03
WRK
L02
TM
L01
Category
history
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Mechanical
system
Mechanical
system
Remarks
a In this table, failure codes are arranged in the order of characters from numeric to alphabetic character.
a A component in charge is a controller or the machine monitor in charge of the system check.
MON: Machine monitor
ENG: Engine controller
PT: power train controller
WE: Work equipment controller
KOMTRAX: KOMTRAX terminal
a The failure codes that do not have numbers in the action level columns are not displayed on the standard
screen even when a failure related to them occurs. They are simply recorded in the abnormality record
(electrical system or mechanical system) of the service menu.
a The history classification column shows in which system each failure is classified, the electrical system or
mechanical system, when it is recorded in the abnormality record.
For details, see "Troubleshooting by failure code (Display of code)".
40-132
WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
(ALL-3840-001-A-00-A)
Failure code [1500L0] Double Engagement of T/M Clutches
(WA380_7-1500L0-400-A-
Z0-A)
Action level
L04
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
Failure code
1500L0
Double Engagement of T/M Clutches

(Transmission controller system)
Fill switch ON signals from impossible combination of two or more clutches are input.
Lights up centralized warning lamp and sounds alarm buzzer.
Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position once.
Shifts gear speed to NEUTRAL.
Transmission can be damaged.
Machine cannot travel.
Other failure code (failure code related to clutch pressure control valve system: 15S*L1) is
generated together.
Method of reproducing failure code: Start engine and drive machine.
Cause
Generation of failure code
(15S*L1) related to clutch
pressure control valve
Defective hydraulic or
mechanical system of clutch
ECMV
WA470-7
Failure

Perform troubleshooting for generated failure code.
Clutch ECMV may malfunction. Perform troubleshooting of hydraulic
and mechanical systems.
40-133
40 Troubleshooting
Failure code [15SAL1] Release Trouble of ECMV (Forward)
(WA380_7-15SAL1-400-A-
Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Release Trouble of ECMV (Forward)

Failure code
Failure
15SAL1
When controller does not drive F (forward) ECMV solenoid, ON signal is input from F
(forward) ECMV fill switch and F clutch is not disengaged.
Determines that F (forward) ECMV fill switch signal is ON.
Even if cause of failure disappears, machine does not become normal until directional
(FNR) lever or R.H. directional selector (FNR) switch is set to N (NEUTRAL) position.
Problem on
machine
Machine can travel forward but cannot travel in reverse.
Related
information
Output current value to F (forward) clutch ECMV solenoid can be checked with monitoring
function. (Code: 31608 "ECMV Current (Forward)")
Input signal (ON/OFF) from F (Forward) clutch fill switch can be checked with monitoring
function (0: OFF, 1: ON) (Code: 02216 "F clutch").
First, check for mechanical trouble such as clogged oil filter of F clutch or pressure control
valve.
Method of reproducing failure code: Start engine.
No.
1
Cause
Abnormal F (forward)
clutch pressure

This failure code appears if clutches other than F (forward) clutch do not have
remaining pressure and only F (forward) clutch has remaining pressure.
(See troubleshooting for hydraulic and mechanical systems (H mode).)
2. Disconnect connector F.SW.
If failure code [15SAL1] disappears, F clutch fill switch is defective.
Defective F (forward)
clutch fill switch
a If failure code [15SAL1] is still displayed, wiring harness has ground fault
or transmission controller is defective.
2. Disconnect connector F.SW, and connect T-adapter to male side.
Between F.SW (male) (1) and ground
Resistance
Min. 1 Mz
(Fill switch turned OFF)
Ground fault in wiring

harness
(contact with ground
circuit)
Defective transmission
controller

2. Disconnect connectors L62 and F.SW, and connect T-adapter to either
female side.
Between ground and L62 (female) (12) or F.SW
Resistance (female) (1)
Min. 1 Mz
If no failure is found by above checks, transmission controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
Reference
2. Insert T-adapter into connector L62.
3. Start engine.
4. Set transmission cut-off switch to OFF position.
5. Set parking brake switch to OFF position.
6. Depress brake pedal to prevent machine from starting.
Directional (FNR) lever
or directional selector
Max. 1 V
(FNR) switch: F (forward)
Between L62 (12) and
Voltage
ground
7 to 9 V
40-134
WA470-7
40 Troubleshooting
Circuit diagram related to F clutch ECMV
WA470-7
40-135
40 Troubleshooting
Failure code [15SALH] Malfunction of ECMV (Forward)

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA380_7-15SALH-400-A-Z0-A)
Malfunction of ECMV (Forward)

Failure code
Failure
15SALH
When controller drives F (forward) ECMV solenoid, ON signal is not input from F (forward)
ECMV fill switch.
Determines that F (forward) ECMV fill switch signal is OFF.
If cause of failure disappears, machine becomes normal by itself.
Directional selection may cause shifting shocks or have time lag.
This failure code may appear immediately after replacement of transmission oil.
function. (Code: 31608 "ECMV Current (Forward)")
Input signal (ON/OFF) from F (Forward) clutch fill switch can be checked with monitoring
function (0: OFF, 1: ON) (Code: 02216 "F clutch").
First, check for mechanical trouble such as clogged oil filter of F clutch or pressure control
valve.
Method of reproducing failure code: Start engine and set directional (FNR) lever or R.H.
directional selector (FNR) switch to F (forward).
Cause
Abnormal F (forward)
clutch pressure
clutch fill switch
(internal open circuit)

This failure code appears if F (forward) clutch pressure is not detected when
the F (forward) ECMV solenoid is energized.
1. Start engine.
2. While depressing brake pedal, move shift lever to gear speed R2 (R: 2nd)
and check that failure code [15SBLH] does not appear.
4. Interchange connections of connectors of R clutch and F clutch.
R.PS io F.PS
R.SW io F.SW
5. Start engine.
6. While depressing brake pedal, move shift lever to gear speed R2 (R: 2nd).
a If failure code [15SBLH] appears, check clutch pressure. If clutch pressure
is normal, F clutch fill switch is defective.
a If failure code [15SBLH] does not appear, wiring harness has open circuit
a After check, return connectors to their original positions.

2. Disconnect connector F.SW and connect T-adapter to female side.
Open circuit, short
circuit, ground fault, hot 3. Turn starting switch to ON position.
short circuit of wiring
a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective
voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller
this point.
Voltage Between F.SW (female) (1) and ground
7 to 9 V
Open circuit in wiring

harness
(wire breakage or
defective contact of
connector)
40-136
a If no failure is found by check on cause 3, this check is not required.

2. Disconnect connectors L62 and F.SW, and connect T-adapters to each
female side.
Max. 1z
Resistance Between L62 (female) (12) and F.SW (female) (1)
WA470-7
40 Troubleshooting
No.
Cause
controller

Reference
3. Start engine.
4. Set transmission cut-off switch to the OFF position.
5. Set parking brake switch to the OFF position.
Max. 1 V
Voltage
ground
7 to 9 V
(FNR) switch: Other than
F (forward)
Circuit diagram related to F clutch ECMV
WA470-7
40-137
40 Troubleshooting
Failure code [15SBL1] Release Trouble of ECMV (Reverse)
(WA380_7-15SBL1-400-A-Z0-
A)
Action level
L03
Detail of
failure
Action of
controller
Release Trouble of ECMV (Reverse)

Failure code
Failure
15SBL1
When controller does not drive R (reverse) clutch ECMV solenoid, ON signal is input from
R (reverse) ECMV fill switch and R clutch is not disengaged.
Determines that R (reverse) clutch fill switch signal is ON.
Problem on
machine
Machine can travel in reverse but cannot travel forward.
Related
information
Output current value to R (reverse) clutch ECMV solenoid can be checked with monitoring
function. (Code: 31606 "ECMV Current (Reverse)")
Input signal (ON/OFF) from R (reverse) clutch fill switch can be checked with monitoring
function (0: OFF, 1: ON) (Code: 02216 "R Clutch").
First, check for mechanical trouble such as clogged oil filter of R clutch or pressure control
valve.
No.
1
Cause
Abnormal R (reverse)
clutch pressure

This failure code appears if clutches other than R (reverse) clutch do not have
remaining pressure and only R (reverse) clutch has remaining pressure.
2. Disconnect connector R.SW.
If failure code [15SBL1] is not displayed, R clutch fill switch is defective.
Defective R (reverse)
clutch fill switch
a If failure code [15SBL1] is still displayed, wiring harness has ground fault
2. Disconnect connector R.SW and connect T-adapter to male side.
Between R.SW (male) (1) and ground
Resistance
Min. 1 Mz

harness
circuit)
controller

2. Disconnect connectors R.SW and L62, and connect T-adapter to either
female side.
Between ground and L62 (female) (2) or R.SW
Min. 1 Mz
Reference
3. Start engine.
Max. 1 V
(FNR) switch: R
(reverse)
Between L62 (female)
Voltage
(2) and ground
7 to 9 V
R (reverse)
40-138
WA470-7
40 Troubleshooting
Circuit diagram related to R clutch ECMV solenoid
WA470-7
40-139
40 Troubleshooting
Failure code [15SBLH] Malfunction of ECMV (Reverse)

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA380_7-15SBLH-400-A-Z0-A)
Malfunction of ECMV (Reverse)

Failure code
Failure
15SBLH
When controller drives R (reverse) ECMV solenoid, ON signal is not input from R
(reverse) ECMV fill switch.
Determines that R (reverse) ECMV fill switch signal is OFF.
Directional selection may cause shifting shocks or have time lag.
function. (Code: 31606 "ECMV Current (Reverse)")
Input signal (ON/OFF) from R (reverse) clutch fill switch can be checked with monitoring
function (0: OFF, 1: ON) (Code: 02216 "R Clutch").
First, check for mechanical trouble such as clogged oil filter of R clutch or pressure control
valve.
Method of reproducing failure code: Start engine and set directional (FNR) lever or R.H.
directional selector (FNR) switch to R (reverse).
Cause
Abnormal R (reverse)
clutch pressure
clutch fill switch

This failure code appears if R (reverse) clutch pressure is not detected when
the R (reverse) ECMV solenoid is turned ON.
1. Start engine.
2. While depressing brake pedal, move the shift lever to gear speed F2 (F:
2nd) and check that failure code [15SALH] does no appear.
4. Interchange connections of connectors of R clutch and F clutch.
R.PS io F.PS
R.SW io F.SW
5. Start engine.
6. While depressing brake pedal, move shift lever to gear speed F2 (F: 2nd).
a If failure code [15SALH] appears, check clutch pressure. If clutch pressure
is normal, R clutch fill switch is defective.
a If failure code [15SALH] does not appear, wiring harness has open circuit

2. Disconnect connector R.SW and connect T-adapter to female side.
Open circuit, short
this point.
Voltage Between R.SW (female) (1) and ground
7 to 9 V

harness
(wire breakage or
connector)
40-140

2. Disconnect connectors L62 and R.SW, and connect T-adapters to each
female side.
Max. 1z
Resistance Between L62 (female) (2) and R.SW (female) (1)
WA470-7
40 Troubleshooting
No.
Cause
controller

Reference
3. Start engine.
Max. 1 V
(FNR) switch: R
(reverse)
Voltage
(2) and ground
7 to 9 V
R (reverse)
WA470-7
40-141
40 Troubleshooting
Failure code [15SEL1] Release Trouble of ECMV (1st)

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA380_7-15SEL1-400-A-Z0-A)
Release Trouble of ECMV (1st)

Failure code
Failure
15SEL1
When controller does not drive 1st ECMV solenoid, ON signal is input from 1st clutch fill
switch and 1st clutch is not disengaged.
Determines that 1st ECMV fill switch signal is ON.
Continues to stop driving 2nd, 3rd and 4th clutch proportional solenoids.
Machine may be able to travel in 1st gear speed but cannot travel in 2nd, 3rd, nor 4th gear
speed.
Output current value to 1st clutch ECMV solenoid can be checked with monitoring
function. (Code: 31602 "ECMV Current (1st)")
Input signal (ON/OFF) from 1st clutch fill switch can be checked with monitoring function.
(0: OFF, 1: ON) (Code: 02216 "1st clutch")
First, check for mechanical failures such as problem in 1st clutch, clogged oil filter of
pressure control valve, etc.
Cause
Abnormal 1st clutch

pressure

This failure code appears if clutches other than 1st clutch do not have
remaining pressure and only 1st clutch has remaining pressure.
2. Disconnect connector 1.SW.
If failure code [15SEL1] disappears, 1st clutch fill switch is defective.
Defective 1st clutch fill

switch
a If failure code [15SEL1] is still displayed, wiring harness has ground fault
2. Disconnect connector 1.SW, and connect T-adapter to male side.
Between 1.SW (male) (1) and ground
Resistance
Min. 1 Mz

harness
circuit)
controller

2. Disconnect connectors 1.SW and L62, and connect T-adapter to either
female side.
Between ground and L62 (female) (17) or 1.SW
Min. 1 Mz
Reference
3. Start engine.
7. Set manual/auto shift selector switch to MANUAL.
8. Set directional (FNR) lever or R.H. directional selector (FNR) switch to F
(forward) or R (reverse) position.
Gear shift lever: 1st
Max. 1 V
Voltage
Gear
shift
lever:
Other
ground
7 to 9 V
than 1st
40-142
WA470-7
40 Troubleshooting
Circuit diagram related to 1st clutch
WA470-7
40-143
40 Troubleshooting
Failure code [15SELH] Malfunction of ECMV (1st)

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA380_7-15SELH-400-A-Z0-A)
Malfunction of ECMV (1st)

Failure code
Failure
15SELH
When controller drives 1st clutch ECMV solenoid, ON signal is not input from 1st clutch
ECMV fill switch.
Determines that 1st ECMV fill switch signal is ON.
Machine may not be able to travel in 1st gear speed.
Shifting to 1st gear speed may cause shifting shocks or time lag.
function. (Code: 31602 "ECMV Current (1st)")
Input signal (ON/OFF) from 1st clutch fill switch can be checked with monitoring function.
(0: OFF, 1: ON) (Code: 02216 "1st clutch")
First, check for mechanical failures such as problem in 1st clutch, clogged oil filter of
Method of reproducing failure code: Start engine, turn manual/auto shift selector switch to
"MANUAL", move directional (FNR) lever or set R.H. directional selector (FNR) switch to
F (forward) or R (reverse) position, and set shift lever to 1st speed.
Cause
Abnormal 1st clutch

pressure

switch (internal open
circuit)

This failure code appears if 1st clutch pressure is not detected when the 1st
clutch ECMV solenoid is energized.
1. Start engine.
2. While depressing brake pedal, move shift lever to gear speed F4 (F: 4th),
and check that failure code [15SHLH] does not appear.
4. Interchange connections of connectors of 1st clutch and 4th clutch.
1.PS io 4.PS
1.SW io 4.SW
5. Start engine.
6. While depressing brake pedal, set manual/auto shift selector switch to
"MANUAL", and move shift lever to gear speed F4 (F: 4th).
a If failure code [15SHLH] appears, check clutch pressure. If clutch pressure
is normal, 1st clutch fill switch is defective.
a If failure code [15SHLH] does not appear, wiring harness has open circuit

2. Disconnect connector 1.SW, and connect T-adapter to female side.
Open circuit, short
this point.
Voltage Between 1.SW (female) (1) and ground
7 to 9 V

harness
(wire breakage or
connector)
40-144

2. Disconnect connectors L62 and 1.SW, and connect T-adapters to each
female side.
Max. 1z
Resistance Between L62 (female) (17) and 1.SW (female) (1)
WA470-7
40 Troubleshooting
No.
Cause
controller

Reference
3. Start engine.
Gear shift lever: 1st
Max. 1 V
Voltage
Gear
shift
lever:
Other
ground
7 to 9 V
than 1st
Circuit diagram related to 1st clutch ECMV
WA470-7
40-145
40 Troubleshooting
Failure code [15SFL1] Release Trouble of ECMV (2nd)

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA380_7-15SFL1-400-A-Z0-A)
Release Trouble of ECMV (2nd)

Failure code
Failure
15SFL1
When controller does not drive 2nd clutch ECMV solenoid, ON signal is input from 2nd
clutch fill switch and 2nd clutch is not disengaged.
Determines that 2nd clutch fill switch signal is ON.
Continues to stop driving 2nd, 3rd and 4th clutch proportional solenoids.
(FNR) lever or R.H. directional selector (FNR) switch is set to N (neutral) position.
Machine may be able to travel in 2nd gear speed but cannot travel in 1st, 3rd or 4th gear
speed.
Output current value to 2nd clutch ECMV solenoid can be checked with monitoring
function. (Code: 31603 ECMV solenoid current (2nd))
Input signal (ON/OFF) from 2nd clutch fill switch can be checked with monitoring function.
(Code: 02216 2nd clutch) (0: OFF, 2: ON)
First, check for mechanical trouble such as clogged oil filter of 2nd clutch or pressure
control valve.
Cause
Abnormal 2nd clutch

pressure

This failure code appears if clutches other than 2nd clutch do not have
remaining oil pressure and only 2nd clutch has remaining pressure.
If failure code [15SFL1] disappears, 2nd clutch fill switch is defective.
Defective 2nd clutch fill a If failure code [15SFL1] is still displayed, wiring harness has ground fault
switch
2. Disconnect connector 2.SW, and connect T-adapters to male side.
Resistance
Min. 1 Mz
(Fill switch turned: OFF)

harness
circuit)
controller
40-146

2. Disconnect connectors 2.SW and L62, and connect T-adapters to either
female side.
Min. 1 Mz
Reference
2. Insert T-adapters to connector L62.
3. Start engine.
4. Set transmission cut-off switch to OFF.
5. Set parking brake switch to OFF.
6. Depress brake to prevent machine from starting.
(FORWARD) or R (REVERSE) position.
Shift lever: 2nd
Max. 1 V
Voltage
Shift
lever:
Other
than
(7) and ground
7 to 9 V
2nd
WA470-7
40 Troubleshooting
Circuit diagram related to 2nd clutch ECMV
WA470-7
40-147
40 Troubleshooting
Failure code [15SFLH] Malfunction of ECMV (2nd)

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA380_7-15SFLH-400-A-Z0-A)
Malfunction of ECMV (2nd)

Failure code
Failure
15SFLH
When controller drives 2nd clutch ECMV solenoid, ON signal is not input from 2nd ECMV
fill switch.
Determines that 2nd clutch fill switch signal is OFF.
Machine may not be able to travel in 2nd gear speed.
Shifting to 2nd gear speed may cause shifting shocks or time lag.
function. (Code: 31603 "ECMV Current (2nd)")
Input signal (ON/OFF) from 2nd clutch fill switch can be checked with monitoring function.
(0: OFF, 2: ON) (Code: 02216 "2nd clutch")
First, check for mechanical failures such as problem in 2nd clutch, clogged oil filter of
F (forward) or R (reverse) position, and set shift lever to 2nd speed.
Cause
Abnormal 2nd clutch

pressure
Defective 2nd clutch fill

circuit)

If 2nd clutch pressure is not detected when 2nd ECMV solenoid is energized,
this failure code appears.
1. Start engine.
2. While depressing brake pedal, move shift lever to gear speed F3 (F: 3rd)
and check that failure code [15SGLH] does no appear.
4. Interchange connections of connectors of 2nd clutch and 3rd clutch.
2.PS io 3.PS
2.SW io 3.SW
5. Start engine.
"MANUAL", and move shift lever to gear speed F3 (F: 3rd).
a If failure code [15SGLH] appears, check clutch pressure. If clutch pressure
is normal, 2nd clutch fill switch is defective.
a If failure code [15SGLH] does not appear, wiring harness has open circuit

Open circuit, short
this point.
7 to 9 V

harness
(wire breakage or
connector)
40-148

female side.
Max. 1z
WA470-7
40 Troubleshooting
No.
Cause
controller

Reference
3. Start engine.
Gear shift lever: 2nd
Max. 1 V
Voltage
Gear
shift
lever:
Other
(7) and ground
7 to 9 V
than 2nd
Circuit diagram related to 2nd clutch ECMV
WA470-7
40-149
40 Troubleshooting
Failure code [15SGL1] Release Trouble of ECMV (3rd)

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA380_7-15SGL1-400-A-Z0-A)
Release Trouble of ECMV (3rd)

Failure code
Failure
15SGL1
When controller does not drive 3rd clutch ECMV solenoid, ON signal is input from 3rd
ECMV fill switch and 3rd clutch is not disengaged.
Determines that 3rd ECMV fill switch signal is ON.
Continues to stop driving 1st, 2nd, and 4th clutch proportional solenoids.
Machine may be able to travel in 3rd gear speed but cannot travel in 1st, 2nd, nor 4th gear
speed.
Output current value to 3rd clutch ECMV solenoid can be checked with monitoring
function. (Code: 31604 "ECMV Current (3rd)")
Input signal (ON/OFF) from 3rd clutch fill switch can be checked with monitoring function.
(0: OFF, 1: ON) (Code: 02216 "3rd clutch")
First, check for mechanical failures such as problem in 3rd clutch, clogged oil filter of
Cause
Abnormal 3rd clutch

pressure

This failure code appears if clutches other than 3rd clutch do not have
remaining pressure and only 3rd clutch has remaining pressure.
If failure code [15SGL1] disappears, 3rd clutch fill switch is defective.

switch
a If failure code [15SGL1] is still displayed, wiring harness has ground fault
Resistance
Min. 1 Mz

harness
circuit)
controller

2. Disconnect connectors 3.SW and L62, and connect T-adapter to either
female side.
Min. 1 Mz
Reference
3. Start engine.
Gear shift lever: 3rd
Max. 1 V
Voltage
Gear
shift
lever:
Other
(13) and ground
7 to 9 V
than 3rd
40-150
WA470-7
40 Troubleshooting
Circuit diagram related to 3rd clutch ECMV solenoid
WA470-7
40-151
40 Troubleshooting
Failure code [15SGLH] Malfunction of ECMV (3rd)

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA380_7-15SGLH-400-A-Z0-A)
Malfunction of ECMV (3rd)

Failure code
Failure
15SGLH
When controller drives 3rd clutch ECMV solenoid, ON signal is not input from 3rd clutch
fill switch.
Determines that 3rd clutch fill switch signal is OFF.
Machine may not be able to travel in 3rd gear speed.
Shifting to 3rd gear speed may cause shifting shocks or time lag.
function. (Code: 31604 "ECMV Current (3rd)")
Input signal (ON/OFF) from 3rd clutch fill switch can be checked with monitoring function.
(0: OFF, 1: ON) (Code: 02216 "3rd clutch")
First, check for mechanical failures such as problem in 3rd clutch, clogged oil filter of
F (forward) or R (reverse) position, and set shift lever to 3rd speed.
Cause
Abnormal 3rd clutch

pressure
Defective 3rd clutch fill

circuit)

If 3rd clutch pressure is not detected when 3rd ECMV solenoid is energized,
1. Start engine.
2. While depressing brake pedal, move shift lever to gear speed F2 (F: 2nd)
and check that failure code [15SFLH] does no appear.
4. Interchange connections of connectors of 2nd clutch and 3rd clutch.
2.PS io 3.PS
2.SW io 3.SW
5. Start engine.
"MANUAL", and move shift lever to gear speed F2 (F: 2nd).
a If failure code [15SFLH] appears, check clutch pressure. If clutch pressure
is normal, 3rd clutch fill switch is defective.
a If failure code [15SFLH] does not appear, wiring harness has open circuit

Open circuit, short
this point.
7 to 9 V

harness
(wire breakage or
connector)
40-152

female side.
Max. 1z
WA470-7
40 Troubleshooting
No.
Cause
controller

Reference
3. Start engine.
Gear shift lever: 3rd
Max. 1 V
Voltage
Gear
shift
lever:
Other
ground
7 to 9 V
than 3rd
Circuit diagram related to 3rd clutch ECMV
WA470-7
40-153
40 Troubleshooting
Failure code [15SHL1] Release Trouble of ECMV (4th)

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA380_7-15SHL1-400-A-Z0-A)
Release Trouble of ECMV (4th)

Failure code
Failure
15SHL1
When controller does not drive 4th clutch ECMV solenoid, ON signal is input from 4th
ECMV fill switch and 4th clutch is not disengaged.
Determines that 4th ECMV fill switch signal is ON.
Continues to stop driving 1st, 2nd, and 3rd clutch proportional solenoids.
Machine may be able to travel in 4th gear speed but cannot travel in 1st, 2nd, nor 3rd gear
speed.
Output current value to 4th clutch ECMV solenoid can be checked with monitoring
function. (Code: 31605 "ECMV Current (4th)")
Input signal (ON/OFF) from 4th clutch fill switch can be checked with monitoring function.
(0: OFF, 1: ON) (Code: 02216 "4th clutch")
First, check for mechanical trouble such as clogged oil filter of 4th clutch or pressure
control valve.
Cause
Abnormal 4th clutch

pressure

This failure code appears if clutches other than 4th clutch do not have
remaining pressure and only 4th clutch has remaining pressure.
If failure code [15SHL1] disappears, 4th clutch fill switch is defective.
Defective 4th clutch fill

circuit)

harness
circuit)
controller
40-154
a If failure code [15SHL1] is still displayed, wiring harness has ground fault
Resistance
Min. 1 Mz
2. Disconnect connectors L62 and 4.SW, and connect T-adapter to either
female side.
Min. 1 Mz
Reference
3. Start engine.
Gear shift lever: 4th
Max. 1 V
Between L62 (3) and
Voltage
Gear
shift
lever:
Other
ground
7 to 9 V
than 4th
WA470-7
40 Troubleshooting
Circuit diagram related to 4th clutch ECMV
WA470-7
40-155
40 Troubleshooting
Failure code [15SHLH] Malfunction of ECMV (4th)

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA380_7-15SHLH-400-A-Z0-A)
Malfunction of ECMV (4th)

Failure code
Failure
15SHLH
When controller drives 4th clutch ECMV solenoid, ON signal is not input from 4th ECMV
fill switch.
Determines that 4th ECMV fill switch signal is OFF.
Machine may not be able to travel in 4th gear speed.
Shifting to 4th gear speed may cause shifting shocks or time lag.
function. (Code: 31605 "ECMV Current (4th)")
Input signal (ON/OFF) from 4th clutch fill switch can be checked with monitoring function.
(0: OFF, 1: ON) (Code: 02216 "4th clutch")
First, check for mechanical trouble such as clogged oil filter of 4th clutch or pressure
control valve.
F (forward) or R (reverse) position, and set shift lever to 4th speed.
Cause
Abnormal 4th clutch

pressure
Defective 4th clutch fill

circuit)

If 4th clutch pressure is not detected when 4th ECMV solenoid is energized,
1. Start engine.
2. While depressing brake pedal, move shift lever to gear speed F1 (F: 1st),
and check that failure code [15SELH] does not appear.
4. Interchange connections of connectors of 1st clutch and 4th clutch.
1.PS io 4.PS
1.SW io 4.SW
5. Start engine.
"MANUAL", and move shift lever to gear speed F1 (F: 1st).
a If failure code [15SELH] appears, check clutch pressure. If clutch pressure
is normal, 4th clutch fill switch is defective.
a If failure code [15SELH] does not appear, wiring harness has open circuit

Open circuit, short
this point.
7 to 9 V

harness
(wire breakage or
connector)
40-156

female side.
Max. 1z
WA470-7
40 Troubleshooting
No.
Cause
controller

Reference
3. Start engine.
Gear shift lever: 4th
Max. 1 V
Voltage
Gear
shift
lever:
Other
(3) and ground
7 to 9 V
than 4th
Circuit diagram related to 4th clutch ECMV
WA470-7
40-157
40 Troubleshooting
Failure code [2F00MA] Failure of Parking Brake Circuit
(WA470_7-2F00MA-400-A-Z0-A)
k Be
sure to chock wheels. If you perform troubleshooting with parking brake released, depress foot
brake (two persons required for this work).
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure of Parking Brake Circuit

Failure code
Failure
(Machine monitor system)
2F00MA
Parking brake pressure switch remains off for 20 seconds during travel (parking brake is
applied).
(Monitor controller does not correctly recognize that parking brake pressure switch is ON
(parking brake is released)).
If machine is used as is, parking brake may be damaged.
When 24 V is applied to parking brake solenoid, parking brake is released.
Method of reproducing failure code: Start engine and actual gear speed is other than
NEUTRAL.
Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
Parking brake relay (L120) works as self-holding relay.
1. When parking brake switch is operated, pin 5 and pin 6 of parking brake switch are
connected with each other.
2. Parking brake relay is engaged and L120 works as self-holding relay.
3. When parking brake switch is set to Release position, pin 3 and pin 4 of parking brake
are connected with each other. Since L120 remains engaged, power is supplied to pin
4 of parking brake switch and then flows to L62 (6) pin of transmission controller.
4. If voltage of L62 (6) pin goes to 20 V or above, transmission controller drives parking
brake solenoid from L63 (18) pin (parking brake is released).

Cause
Inappropriate operation Check that parking brake switch is set to "Release" position.
of parking brake switch Do not use parking brake while machine is travelling.
2. Interchange relay L120 with horn relay L119.
3. Start engine and drive machine.
Defective parking brake Does machine become Machine becomes
Original relay L120 is
relay (L120)
normal after parking
normal.
defective.
brake relay (L120) is
Machine does not
interchanged with relay
become normal.
normal.
L119?
When failure code [D1E6KA], [D1E6KB] or [D1E6KY] is displayed,
perform troubleshooting for it first.
Defective auto-idle stop 3. Start engine and drive machine.
parking brake relay
Does machine become Machine becomes
L133
normal.
normal after parking
defective.
brake relay (L133) is
Machine does not
interchanged with relay
normal.
become normal.
L119?
40-158
WA470-7
40 Troubleshooting
No.
Cause

2. Connect T-adapters to connector S_FA (male).
3. Start engine.
Parking brake switch:
Between S_FA (male) (3) Release
Defective parking brake
and (4)
switch
Parking
Resistance
and (6)
Parking
Max. 1 z
Min. 1 Mz
Min. 1 Mz
Max. 1 z

2. Disconnect connector PB.SW and connect T-adapters to female side.
3. Start engine.
pressure switch
Max. 1 z
Between PB.SW (male) Release
Min. 1 Mz
Parking
Parking brake switch operation line
Open circuit, short
2. Disconnect connector PB.SW, and connect T-adapter to female side.
this point.
Voltage Between PB.SW (female) (1) and (2)
Min. 10 V
2. Disconnect connectors L62 and L63, and insert T-adapters into them.
Parking
brake
20 to 30 V
switch:
Release
Voltage Between L62 (6) and L63 (18)
Parking
brake
Max. 3 V
switch:
Parking
Parking brake pressure switch line
harness
(wire breakage or
2. Disconnect connectors MCM1 A and PB.SW, and connect T-adapters to
connector)
each female side.
Between MCM1 A (female) (71) and PB.SW
Max. 1 z
Between PB.SW (female) (2) and ground
Max. 1 z
Parking brake solenoid line
2. Disconnect connector PB.PS and connect T-adapters to female side.
20 to 30 V
Between PB.PS (female) Release
Voltage
(1) and (2)
Max. 3 V
Parking
WA470-7
40-159
40 Troubleshooting
No.
8
Cause

Defective parking brake 2. Disconnect connector PB.PS and connect T-adapters to male side.
solenoid
Between PB.PS (male) (1) and (2)
10 to 100 z
Resistance
Between PB.PS (male) (1) and ground
Min. 1 Mz
controller

10 hydraulic circuit or
parking brake valve
Defective monitor
11
controller
40-160

2. Insert T-adapters to connector L63.
Voltage
(31)
Release
20 to 30 V
Perform testing and troubleshooting of parking brake hydraulic piping or

parking brake valve.
If no failure is found by above checks, monitor controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
WA470-7
40 Troubleshooting
Circuit diagram related to parking brake
WA470-7
40-161
40 Troubleshooting
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)
(WA470_7-2G42ZG-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Accumulator Oil Pressure Low (Front)

Failure code
Failure
2G42ZG
After engine is started, front brake accumulator pressure sensor indicates specified
pressure once, but then pressure switch becomes open.
Front brake accumulator pressure drops.
Brakes may not work.
Input signal (ON/OFF) from brake pressure sensor can be checked with monitoring
function.
(Code: 04510 Front brake oil pressure switch signal)
Method of reproducing failure code: Turn starting switch to ON position.
Cause
Pressure drop of front
brake accumulator

Check oil pressure of front brake accumulator.
(See Testing and adjusting.)
Defective front brake

pressure sensor

2. Disconnect connector R52 and connect T-adapters to male side.
Front brake accumulator
pressure: Normal
Max. 1 z
Min. 5.88 MPa
Between R52 (male) (1) Min. {60 kg/cm2}
Resistance and (2)
pressure: Dropped
Min. 1 Mz
Max. 3.92 MPa
Max. {40 kg/cm2}

2. Disconnect connector R52, and connect T-adapter to female side.
Open circuit, short
this point.
Voltage Between R52 (female) (1) and (2)
Min. 10 V

2. Disconnect connector MCM1 A, and connect T-adapters to female side.
pressure: Normal
Max. 1 z
Min. 5.88 MPa
Between MCM1 A
Min. {60 kg/cm2}
Resistance (female) (73) and (13) or
(17)
pressure: Dropped
Min. 1 Mz
Max. 3.92 MPa
Max. {40 kg/cm2}
No.
1
Open circuit or ground

fault in wiring harness
40-162
WA470-7
40 Troubleshooting
No.
Cause

harness
(wire breakage or
connector)
Defective monitor
controller

2. Disconnect connectors MCM1 A and R52, and connect T-adapters to each
female side.
Between MCM1 A (female) (73) and R52 (female)
Max. 1 z
(1)
Between R52 (female) (2) and MCM1 A (female)
Resistance (13)
Max. 1 z
Max. 1 z
(17)
Circuit diagram related to brake accumulator
WA470-7
40-163
40 Troubleshooting
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)
(WA470_7-2G43ZG-400-
A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Accumulator Oil Pressure Low (Rear)

Failure code
Failure
2G43ZG
After engine is started, rear brake accumulator pressure sensor indicates specified
pressure once, but then pressure switch becomes open.
Rear brake accumulator pressure drops.
Brakes may not work.
Input signal (ON/OFF) from brake pressure sensor can be checked with monitoring
function.
(Code: 04510 Rear brake oil pressure switch signal)
Cause
Pressure drop of rear
brake accumulator

Check oil pressure of rear brake accumulator.
(See Testing and adjusting.)
Defective rear brake

pressure sensor

Rear brake accumulator
pressure: Normal
Max. 1 z
Min. 5.88 MPa
Between R54 (male) (1) Min. {60 kg/cm2}
Resistance and (2)
pressure: Dropped
Min. 1 Mz
Max. 3.92 MPa
Max. {40 kg/cm2}

Open circuit, short
this point.
Min. 10 V

pressure: Normal
Max. 1 z
Min. 5.88 MPa
Between MCM1 A
Min. {60 kg/cm2}
Resistance (female) (72) and (13) or
(17)
pressure: Dropped
Min. 1 Mz
Max. 3.92 MPa
Max. {40 kg/cm2}
No.
1

40-164
WA470-7
40 Troubleshooting
No.
Cause

harness
(wire breakage or
connector)
Defective monitor
controller

female side.
Max. 1 z
(2)
Resistance (13)
Max. 1 z
Max. 1 z
(17)
WA470-7
40-165
40 Troubleshooting
Failure code [879AKA] A/C Inner Sensor Open Circuit
(WA380_7-879AKA-441-A-Z0-A)
See "Failure code [879AKA] A/C Inner Sensor Open Circuit" in chapter 80 of "Others".
40-166
WA470-7
40 Troubleshooting
Failure code [879AKB] A/C Inner Sensor Short Circuit
(WA380_7-879AKB-441-A-Z0-A)
See "Failure code [879AKB] A/C Inner Sensor Short Circuit" in chapter 80 of "Others".
WA470-7
40-167
40 Troubleshooting
Failure code [879BKA] A/C Outer Sensor Open Circuit
(WA380_7-879BKA-441-A-Z0-A)
See "Failure code [879BKA] A/C Outer Sensor Open Circuit" in chapter 80 of "Others".
40-168
WA470-7
40 Troubleshooting
Failure code [879BKB] A/C Outer Sensor Short Circuit
(WA380_7-879BKB-441-A-Z0-A)
See "Failure code [879BKB] A/C Outer Sensor Short Circuit" in chapter 80 of "Others".
WA470-7
40-169
40 Troubleshooting
Failure code [879CKA] Ventilating Sensor Open Circuit
(WA380_7-879CKA-441-A-Z0-A)
See "Failure code [879CKB] Ventilating Sensor Short Circuit" in chapter 80 of "Others".
a The ventilating sensor means the evaporator temperature sensor.
40-170
WA470-7
40 Troubleshooting
Failure code [879CKB] Ventilating Sensor Short Circuit
(WA380_7-879CKB-441-A-Z0-A)
See "Failure code [879CKB] Ventilating Sensor Short Circuit" in chapter 80 of "Others".
a The ventilating sensor means the evaporator temperature sensor.
WA470-7
40-171
40 Troubleshooting
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
(WA380_7-879DKZ-
441-A-Z0-A)
See "Failure code [879DKZ] Sunlight Sensor Open or Short Circuit" in chapter 80 of "Others".
40-172
WA470-7
40 Troubleshooting
Failure code [879EMC] Ventilation Damper Abnormality
(WA380_7-879EMC-441-A-Z0-A)
See "Failure code [879EMC] Ventilation Damper Abnormality" in chapter 80 of "Others".
WA470-7
40-173
40 Troubleshooting
Failure code [879FMC] Air Mix Damper Abnormality
(WA380_7-879FMC-441-A-Z0-A)
See "Failure code [879FMC] Air Mix Damper Abnormality" in chapter 80 of "Others".
40-174
WA470-7
40 Troubleshooting
Failure code [989A00] Engine Overrun Prevention Activated
(WA380_7-989A00-400-A-
Z0-A)
Action level
L02
Detail of
failure
Action of
machine
monitor
Problem on
machine
Related
information
No.
Failure code
989A00
Engine Overrun Prevention Activated

Engine speed exceeds upper control limit.

Disengages lockup clutch.
Lockup clutch does not work.
Engine speed can be checked with monitoring function.(Code 01002: Engine speed)
Cause
Defective relevant system
Improper method of using

machine
Defective engine controller
WA470-7
Failure

If other failure codes are also displayed, perform troubleshooting for
them.
Method of using machine may be improper, so instruct operator on
how to use machine properly.
If no failure is found by checks on causes 1 and 2, power train
controller may be defective. (Since this is an internal defect,
troubleshooting cannot be performed.)
40-175
40 Troubleshooting
Failure code [989L00] Engine Controller Lock Caution 1

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
989L00
Engine Controller Lock Caution 1

Machine monitor detects engine controller lock (cause 1).

None in particular.
Engine does not start.
When this failure code appears after replacement of monitor controller, user password
must be replaced with one before replacement of controller.
Cause
Replacement of monitor
controller
40-176
Failure
(WA380_7-989L00-400-A-Z0-A)

This trouble may result from replacement of monitor controller.
WA470-7
40 Troubleshooting
Failure code [989M00] Engine Controller Lock Caution 2

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
Failure code
989M00


None in particular.
When this failure code appears after replacement of monitor controller, user password
must be replaced with one before replacement of controller.
Cause
Replacement of monitor
controller
Defective monitor controller
WA470-7
Failure
(WA380_7-989M00-400-A-Z0-A)

This trouble may result from replacement of monitor controller.
If this failure code appears when monitor controller is not replaced,
monitor controller may be defective. (Since this is an internal defect,
40-177
40 Troubleshooting
Failure code [989N00] Engine Controller Lock Caution 3

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
989N00


Tries automatic restoration.
Method of reproducing failure code: Failure code is not reproduced because of automatic
restoration.
Cause
40-178
Failure
(WA380_7-989N00-400-A-Z0-A)

If this failure code appears repeatedly, engine controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
WA470-7
40 Troubleshooting

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
(HM300_3-A1U0N3-400-A-Z0-A)
HC Desorb Request 1
Failure code
Failure
(Engine controller system)
A1U0N3
Unburned fuel remains in KDPF because engine has been run at low idle or low load for a
long time.
Requests manual stationary regeneration (fuel drying) to operator.
Or, informs that manual stationary regeneration (fuel drying) is in progress.
Machine comes into same state as that of automatic regeneration.
(When machine is in safe condition, engine speed is limited to approximately 1,000 rpm.)
k Since
temperature of KDPF and KDOC becomes 500 C or higher, take care not to
get burn injury.
Related
information
WA470-7
Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (C))
Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approx. 100 to 250C, and
difference between these temperatures is approx. 10 C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
When active regeneration (manual stationery regeneration) is performed due to the
guidance of monitor displaying failure code A1U0N3 or A1U0N4, fuel dosing is disabled.
Accordingly, each temperature of KDOC inlet, KDOC outlet, and KDPF outlet reaches to
approx. 250 to 400 C.
When active regeneration (manual stationary regeneration) except above is in progress,
KDOC inlet temperature is approx. 250 to 400 C, and KDOC outlet temperature and
KDPF outlet temperature are approx. 450 to 550 C.
If there is a significant difference between the KDOC inlet temperature and KDOC outlet
temperature when the KDPF is completely cool or engine running at idle (not
regenerating), replace the KDOC inlet temperature sensor or the KDOC outlet
temperature sensor, whichever is suspected to be abnormal, judging by the KDPF outlet
temperature reading.
KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet sensor connector label "TEMP3" are
shown similarly to "TEMP1").
40-179
40 Troubleshooting
No.
1
Cause
Performing manual stationery 1. Perform manual stationary regeneration by following the instructions
on the monitor.
regeneration
If this failure code is cleared after regeneration is performed, repair is
regeneration (to dry KDPF)
complete.
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
Defective KDOC inlet
temperature sensor
a If this failure code appears, perform following checks.

If failure code [CA3313], [CA3314] or [CA3315] is also displayed,
perform troubleshooting for [CA3313], [CA3314] or [CA3315] first.
If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
a Turn the starting switch ON and make sure that this failure code is not displayed.
40-180
WA470-7
40 Troubleshooting

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
(HM300_3-A1U0N4-400-A-Z0-A)
HC Desorb Request 2
Failure code
Failure
A1U0N4
Unburned fuel remains in KDPF because engine has been run at low idle or low load for a
long time.
Requests manual stationary regeneration (fuel drying) to operator.
Or, informs that manual stationary regeneration (fuel drying) is in progress.
Machine comes into same state as that of automatic regeneration.
(When machine is in safe condition, engine speed is limited to approximately 1,000 rpm.)
k Since
the temperature of the KDPF and KDOC will become higher than 500 C , take
care not to get burn injury.
Related
information
No.
function. (Code: 47301(V))
function. (Code: 47300 ( C ))
KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature with
engine running at idle (without regenerating KDPF) are all approx. 100 to 250 C and
temperature differences among them are approx. 10 C (KDOC inlet temperature >
KDOC outlet temperature> KDPF outlet temperature).
When manual stationary regeneration is performed as an action taken for A1U0N3 or
A1U0N4, dosing fuel is not injected. Therefore, KDOC inlet, KDOC outlet, and KDPF
outlet temperatures will be around 250 to 400 C .
In other cases than the above, when active regeneration (manual stationary regeneration)
is in progress, the KDOC inlet temperature will be approx. 250 to 400 C , and the KDOC
outlet temperature and KDPF outlet temperature will both be approx. 450 to 550 C .
If there is a significant difference between the KDOC inlet temperature and KDOC outlet
temperature when the KDPF is completely cool or engine running at idle (not
regenerating), replace the KDOC inlet temperature sensor or the KDOC outlet
temperature sensor, whichever is suspected to be abnormal, judging by the KDPF outlet
temperature reading.
KDOC inlet temperature sensor connecter label "TEMP1" is indicated on KDPF
temperature sensor consolidating box in black embossed letters (same for KDOC outlet
temperature sensor connector label "TEMP2" and KDPF outlet sensor connector label
"TEMP3").
Cause
Performing manual stationary

1
regeneration (to dry KDPF)
Defective wiring harness

connector

3 temperature sensor
WA470-7

1. Perform manual stationary regeneration by following the instructions
on the monitor.
If this failure code is cleared after regeneration is performed, repair is
complete.
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
If failure code [CA3313], [CA3314], or [CA3315] is displayed, perform
troubleshooting for it.
40-181
40 Troubleshooting
No.
Cause
4 Defective engine controller

a Turn the starting switch ON and make sure that this failure code and code [A1U0N3] are not displayed.
40-182
WA470-7
40 Troubleshooting
Failure code [AA10NX] Air Cleaner Clogging

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
General
information
No.
1
Air Cleaner Clogging

Failure code
Failure
AA10NX
When engine is started, air cleaner clogging signal circuit is "open" (disconnected from
GND).
Lights up air cleaner clogging caution lamp.
Engine does not start smoothly, does not pick-up smoothly, lacks power or exhaust gas is
black.
If machine is used as it is, engine may be damaged.
Voltage at MCM1 A (53) is GND level when air cleaner is normal and Min. 10 V when air
cleaner is clogged (circuit is open).
Input signal (ON/OFF) from air cleaner clogging sensor can be checked with monitoring
function.
(Code: 04509 "Air cleaner clogging sensor")
Cause
Defective air cleaner

clogging sensor
Open circuit, short

circuit, hot short circuit
of wiring harness, or
defective monitor
controller
(WA470_7-AA10NX-400-A-Z0-A)

Dust indicator does not indicate red
When air cleaner is normal
zone.
Dust indicator indicates red zone.
3. Turn starting switch to ON position or start engine to perform
troubleshooting.
Max. 1z
Between E45 (male) (1) Air cleaner is normal.
Resistance and (2)
Air cleaner is clogged.
Min. 1 Mz
2. Disconnect connector E45, and connect T-adapter to female side.
this point.
Voltage Between E45 (female) (1) and (2)
16 to 24 V

harness
(wire breakage or
connector)

2. Disconnect connectors MCM1 A and E45, and connect T-adapters to each
female side.
Between MCM1 A (female) (53) and E45 (female)
Max. 1z
(1)
Resistance
Between E45 (female) (2) and each of MCM1 A
Max. 1z
Defective monitor
controller

3. Turn starting switch to ON position or start engine to perform
troubleshooting.
Air cleaner is normal.
Voltage Between E45 (1) and (2)
WA470-7
Max. 1 V
16 to 24 V
40-183
40 Troubleshooting
Circuit diagram related to air cleaner clogging sensor
40-184
WA470-7
40 Troubleshooting
Failure code [B@BAZG] Eng Oil Press Low

Action level
L03
Detail of
failure
Action of
machine
monitor
Problem on
machine
Related
information
No.
1
2
(WA500_7-BaBAZG-400-A-Z0-A)
Engine Oil Pressure Low

Failure code
Failure
B@BAZG
Engine controller determines that engine oil pressure drops abnormally because signal
voltage from engine oil pressure switch drops to ground level while engine is running.
Lights up engine oil pressure caution lamp in red on machine monitor.
If machine is operated as it is, engine may seize up.

Engine oil pressure switch signal is input to engine controller that transmits information to
machine monitor through CAN communication system.
Engine oil pressure can be checked with monitoring function (Code: 37200 Engine oil
pressure)

Engine oil pressure may drops. Check it and remove cause of failure if
oil pressure is low.
If no failure is found by check on cause 1, engine oil pressure sensor
Defective engine oil pressure
system may be defective. Perform troubleshooting for failure code
sensor system
[CA135], [CA141]
Cause
Drop of engine oil pressure
(When system is normal)
WA470-7
40-185
40 Troubleshooting
Failure code [B@BAZK] Eng Oil Level Low

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA470_7-BaBAZK-400-A-Z0-A)
Engine Oil Level Low

Failure code
Failure
B@BAZK
When engine is stopped, engine oil level sensor circuit is open (disconnected from
ground) for 2 seconds or more.
(This error, however, is not detected for 5 minutes after the engine stops.)
The failure code generated while the engine is not running remains active even after the
engine is started until the problem is solved.
Lights up the engine oil level caution lamp.
If machine is used as it is, engine may be seized.
Input signal (ON/OFF) from engine oil level sensor can be checked with monitoring
function.
(Code: 04510 Engine oil level sensor)
Cause
Engine oil level is low.
Defective engine oil

level switch

Engine oil level is normal.
a If engine oil level is low, check for oil leakage from engine before adding
oil.
Engine oil level is
Max. 1 z
Between E27 (male) (1)
normal.
Resistance and ground
Min. 1 Mz
Open circuit, short

defective monitor
controller

harness
(wire breakage or
connector)

female side.
Resistance (1)
Max. 1 z
Defective monitor
controller

Engine oil level is
Between E27 (2) and
normal.
Voltage
ground
40-186
this point.
Voltage Between E27 (female) (1) and ground
16 to 24 V
Max. 1 V
16 to 24 V
WA470-7
40 Troubleshooting
Circuit diagram related to engine oil level sensor
WA470-7
40-187
40 Troubleshooting
Failure code [B@BCNS] Eng Water Overheat

Action level
L02
Detail of
failure
Action of
controller
(WA380_7-BaBCNS-400-A-Z0-A)
Engine Water Overheat

Failure code
Failure
B@BCNS
Engine controller determines that engine coolant overheats because signal voltage from
engine coolant temperature sensor drops while engine is running.
Lights up engine coolant temperature overheat caution lamp in red on machine monitor.
Problem on
machine
If machine is operated as it is, engine may seize up.
Related
information
Signal voltage of engine coolant temperature sensor is input to engine controller that
transmits information to machine monitor through CAN communication system.
Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)
No.
1
Cause
Overheating of engine
coolant
Defective engine coolant
temperature sensor system
40-188

Engine coolant may overheat. Check coolant temperature and remove
cause of failure if coolant overheats.
If no failure is found by check on cause 1, engine coolant temperature
sensor system may be defective. Perform troubleshooting for failure
codes [CA144] and [CA145].
WA470-7
40 Troubleshooting
Failure code [B@BCZK] Eng Water Level Low

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA470_7-BaBCZK-400-A-Z0-A)
Engine Water Level Low

Failure code
Failure
B@BCZK
(Monitor controller system)
Radiator coolant level switch signal circuit is "open" (disconnected from ground).
(detected time 30 sec)
Lights up radiator coolant level caution lamp.
If the machine continues to be used with a low coolant level, the engine may overheat.
Input signal (ON/OFF) from coolant level sensor can be checked by using monitoring
function.
(Code: 04509 Engine coolant level sensor)
Cause
Low radiator coolant

level

Check if radiator coolant level is normal.
a If radiator coolant level is low, check for coolant leakage from engine and
radiator components before adding coolant.
Radiator coolant level is
Max. 1 z
Between R32 (male) (1) normal.
Resistance and ground
Min. 1 Mz
low.
Defective radiator
coolant level switch
Open circuit, short

defective monitor
controller

harness
(wire breakage or
connector)

2. Disconnect connectors and connect T-adapters to each female side.
Max. 1 z
Resistance (1)
Between R32 (female) (2) and ground
Max. 1 z
Defective monitor
controller

Voltage Between R32 (1) and (2) normal.
low.
WA470-7
this point.
16 to 24 V
Max. 1 V
16 to 24V
40-189
40 Troubleshooting
Circuit diagram related to coolant level sensor
40-190
WA470-7
40 Troubleshooting
Failure code [B@CENS] T/C Oil Temp. Overheat

Action level
L02
Detail of
failure
Action of
controller
Failure code
B@CENS
Failure
(WA380_7-BaCENS-400-A-Z0-A)
Torque Converter Oil Temperature Overheat

Overheating of the torque converter oil temperature is detected (130C or above).

Lights up torque converter oil overheat caution lamp.
(If oil temperature remains below 130 C for continuous one second.)
Problem on
machine
If machine is used as is, torque converter may be damaged.
Related
information
Information from torque converter oil temperature sensor is obtained from transmission
controller through CAN communication.
Torque converter oil temperature can be checked with monitoring function.
(Monitoring code: 30100 (C), 30101 (V))
No.
1
2
3
4

Cause
Overheating of torque
converter oil (when system is Torque converter oil may overheat. Check and remove cause of failure.
normal)
Defective torque converter oil
Perform troubleshooting for failure codes [DGT1KA] and [DGT1KB].
If no failure is found by check on cause 2 but substantial difference is
observe between torque converter oil temperature sensed by using
monitoring function (code: 30100) and actual oil temperature,
controller
transmission controller may be defective.
Defective monitor controller If no failure is found by above checks, monitor controller is defective.
WA470-7
40-191
40 Troubleshooting
Failure code [B@HANS] HYD Oil Temp. Overheat

Action level
L02
Detail of
failure
Action of
controller
(WA380_7-BaHANS-400-A-Z0-A)
Hydraulic Oil Temperature Overheat

Failure code
Failure
B@HANS
Monitor controller determines that hydraulic oil overheats (100C or higher for more than
10 second).
Lights up hydraulic oil temperature caution lamp.
(If hydraulic oil temperature remains below 100 C for continuous 10 second.)
Problem on
machine
If machine is operated as it is, pump and cylinder seal may be damaged.
Related
information
Information of hydraulic oil temperature sensor is obtained from transmission controller

through CAN communication system.
Hydraulic oil temperature can be checked with monitoring function.
(Monitoring code: 04401 Hydraulic oil temperature (C), 04404 Sensor voltage (V))
No.
1
2
Cause
Overheating of hydraulic oil
(when system is normal)
Defective hydraulic oil
controller
40-192

Hydraulic oil may overheat. Check and remove cause of failure.
Perform troubleshooting for failure code [DGH2KX].
If no failure is found by check on cause 2 but substantial difference is
observed between hydraulic oil temperature sensed by using monitoring
function (code: 04401) and actual oil temperature, transmission
controller may be defective.
If no failure is found by above checks, monitor controller is defective.
WA470-7
40 Troubleshooting
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

Action level
L04
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
3
Failure code
CA115
Failure
(PC400-CA115-400-A-Z0-A)
Engine Ne and Bkup Speed Sensor Error

Abnormality is detected in signal circuits of Ne and Bkup speed sensors at the same time.
Stops engine.
Engine does not start (if engine is stopped).
Engine stops (if engine is running).

Cause
Defective Ne speed sensor
Perform troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
system
If no failure is found by above checks, engine controller is defective.
WA470-7
40-193
40 Troubleshooting
Failure code [CA122] Chg Air Press Sensor High Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA122
Failure
(PC400-CA122-400-A-Z0-A)
Charge Air Pressure Sensor High Error

High voltage occurs in charge (boost) pressure sensor signal circuit.
Sets charge (boost) pressure to fixed value (400 kPa {4.1 kg/cm2}) and runs engine.
Closes EGR valve and opens KVGT fully.
Limits engine output and allows engine to run.
Stops KDPF regeneration control.
Acceleration performance of engine drops.
Engine output reduces.
Signal voltage from charge (boost) pressure sensor can be checked with monitoring
Boost pressure sensed by charge (boost) pressure sensor can be checked with
monitoring function. (Code: 36500 (kPa))
If sensor connector is disconnected, failure code [CA123] for "Low Error" is displayed
even in normal condition.
Cause
Defective wiring
harness connector

equipment" in "Checks before troubleshooting" of "General information on
troubleshooting", and check it.
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.

Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
supply system
for it first.

2. Disconnect connector PIM.
If failure code changes from [CA122] to [CA123], charge (boost) pressure
sensor is defective.
Defective charge
(boost) pressure sensor Reference
Between J1 (15) and (59), or between
Sensor
Voltage
0.3 to 4.7 V
PIM (3) and (2)
output

harness
(wire breakage or
connector)
Short circuit in wiring

harness
Hot short circuit in

wiring harness
Defective engine
controller
40-194

2. Disconnect connectors J1 and PIM, and connect T-adapters to each
female side.
a To check open circuit in GND line
Resistance Between J1 (female) (59) and PIM (female) (2)
Max. 1 z
1. Turn starting switch to OFF position, then perform troubleshooting.

2. Disconnect connectors J1 and PIM, and connect T-adapter to either
female side.
Between J1 (female) (15) and (60), or between PIM
Resistance (female) (3) and (1)
Min. 1 Mz
2. Disconnect connector PIM, and connect T-adapter to female side or insert
T-adapters into connector J1.
3. Turn starting switch to ON position (with connector PIM disconnected).
Between PIM (female) (3) and (2), or between J1
Voltage
Max. 1 V
(15) and (59)
WA470-7
40 Troubleshooting
Circuit diagram related to charge pressure sensor
WA470-7
40-195
40 Troubleshooting
Failure code [CA123] Chg Air Press Sensor Low Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA123
Failure
(PC400-CA123-400-A-Z0-A)
Charge Air Pressure Sensor Low Error

Low voltage appears in boost pressure sensor signal circuit.

Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to
run.
Acceleration performance of engine drops.
Engine output lowers.
Signal voltage from charge pressure sensor (boost pressure sensor) can be checked by
using monitoring function (Code: 36501 (V)).
Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor)
can be checked by using monitoring function (Code: 36500 (kPa)).
If sensor connector is disconnected, this failure code is displayed.
Cause
Defective wiring
harness connector


If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it
first.
Defective power supply 1. Turn starting switch to OFF position.
system of boost
2. Disconnect connectors PIM and connect T-adapter to female side.
pressure sensor
3. Switch: ON
Voltage Between PIM (female) (1) and (2)
Power input 4.75 to 5.25
V
2. Disconnect connectors J1 and PIM and connect T-adapters to each
harness
female side.
(wire breakage or
Between J1 (female) (60) and PIM (female) (1)
Max. 1 z
Resistance Between J1 (female) (15) and PIM (female) (3)
Max. 1 z
connector)
Between J1 (female) (59) and PIM (female) (2)
Max. 1 z

harness

2. Disconnect connectors J1 and PIM and connect T-adapters to either
female side.
3.
Between J1 (female) (15) and (59) or between PIM
Min. 1 Mz

harness
circuit)

2. Disconnect connectors J1 and PIM and connect T-adapter to either female
side.
Between J1 (female) (15) or PIM (female) (3) and
Resistance ground
Min. 1 Mz
Defective charge
pressure (boost
pressure) sensor
a If no failure is found by checks on causes 1 to 5 and check result on cause

6 is abnormal, sensor is defective.
Sensor
0.3 to 4.7 V
Voltage
PIM (3) and (2)
output
40-196
WA470-7
40 Troubleshooting
No.
7
Cause
Defective engine
controller

Circuit diagram related to boost pressure sensor
WA470-7
40-197
40 Troubleshooting
Failure code [CA131] Throttle Sensor High Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
Failure code
CA131
Failure
(WA380_7-CA131-400-A-Z0-A)
Throttle Sensor High Error

High voltage appears in throttle sensor signal circuit.

Sets throttle position at 0% with accelerator pedal released and at 50% with accelerator
pedal depressed, and allows engine to run.
Engine does not run at full throttle.
Input voltage from throttle sensor can be checked with monitoring function. (Code:
03000).
Accelerator pedal position sensed by throttle sensor can be checked with monitoring
function. (Code: 31701)

See descriptions of wiring harness and connectors in "c: Electrical
Defective harness connector equipment" in "Checks before troubleshooting" of "General information
on troubleshooting", and check it.
Defective throttle sensor
If failure code [CA2185] is also displayed, perform troubleshooting for it
power supply system
first.
Cause

harness

2. Disconnect connectors EC3 and PD, and connect T-adapters to
either female side.
Resis- Between EC3 (female) (51) and (42), or
Min. 1 Mz
between PD (female) (1) and (2)
tance
Hot short circuit in wiring

harness
(contact with 24 V circuit)

2. Disconnect connector PD and connect T-adapters to female side.
Voltage Between PD (female) (2) and ground
Max. 1 V
Defective accelerator pedal

(throttle sensor)
40-198

2. Insert T-adapters into connector PD.
When accelerator
3.7 to 4.0 V
pedal is depressed
Between PD (2) and
Voltage
(3)
When accelerator
0.5 to 0.8 V
pedal is released
Reference
2. Insert T-adapters into EC3.
4. Operate accelerator pedal to perform troubleshooting.
Between EC3 (42) and
4.75 to 5.25
Power supply
(41)
V
When accelerator
Voltage
3.7 to 4.0 V
Between EC3 (51) and pedal is depressed
(41)
When accelerator
0.5 to 0.8 V
pedal is released
WA470-7
40 Troubleshooting
Circuit diagram related to throttle sensor
WA470-7
40-199
40 Troubleshooting
Failure code [CA132] Throttle Sensor Low Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
CA132
Failure
(WA380_7-CA132-400-A-Z0-A)
Throttle Sensor Low Error

Low voltage appears in throttle sensor signal circuit.

Sets throttle position at 0% with accelerator pedal released and at 50% with accelerator
Input voltage from throttle sensor can be checked with monitoring function. (Code:
03000).

first.
1. Turn starting switch to OFF position, and set battery disconnect
switch to OFF position.
2. Disconnect connectors PD and PDV, and connect T-adapters to
power supply system
each female side.
Between PD (female) (1) and (3)
4.75 to 5.25 V
Voltage
Between PDV (female) (1) and (2)
4.75 to 5.25 V
Cause

2. Disconnect connectors EC3, PD, and PDV, and connect T-adapters
to each female side.

(wire breakage or defective
a If no failure is found by check on cause 2,

this check is not required.
Between EC3 (female) (42) and PD (female)
(1)
Resistance

(3)
(2)
Between EC3 (43) and PDV (female) (2)
Between EC3 (52) and PDV (female) (1)
Max. 1 Mz
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z

Short circuit in wiring harness 2. Disconnect connectors EC3 and PD, and connect T-adapters to
either female side.
Resis- Between EC3 (female) (51) and (41), or
Min. 1 Mz
tance between PD (female) (2) and (3)

Ground fault in wiring harness 2. Disconnect connectors EC3 and PD, and connect T-adapters to
either female side.
Resis- Between ground and EC3 (female) (51) or
Min. 1 Mz
tance PD (female) (2)
40-200
WA470-7
40 Troubleshooting
No.
Cause

(throttle sensor)

When accelerator
3.7 to 4.0 V
Between PD (2) and pedal is depressed
Voltage
(3)
When accelerator
0.5 to 0.8 V
pedal is released
Reference
2. Insert T-adapter to EC3.
4. Operate accelerator pedal to perform troubleshooting.
Between EC3 (42)
Power supply
4.75 to 5.25 V
and (43)
When accelerator
Voltage
3.7 to 4.0 V
pedal is depressed
Between EC3 (51)
and (43)
When accelerator
0.5 to 0.8 V
pedal is released
WA470-7
40-201
40 Troubleshooting
Failure code [CA135] Eng Oil Press Sensor High Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA135
Engine Oil Pressure Sensor High Error

High voltage occurs in engine oil pressure sensor signal circuit.

Sets engine oil pressure to fixed value (250 kPa {2.5 kg/cm2}) and runs engine.
Signal voltage from engine oil pressure sensor can be checked with monitoring function.
(Code: 37201 (V))
Engine oil pressure sensed by engine oil pressure sensor can be checked with monitoring
function. (Code: 37200 (kPa))
Cause
Defective wiring
harness connector


Defective power supply
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
system of engine oil
for it first.
pressure sensor
Defective engine oil

pressure sensor

harness
(wire breakage or
connector)
Failure
(PC400-CA135-400-A-Z0-A)

harness

wiring harness
Defective engine
controller
40-202

2. Disconnect connector POIL.
If failure code changes from [CA135] to [CA141] , engine oil pressure sensor
is defective.
Reference
2. Insert T-adapters into connector J1 or POIL.
Between J1 (2) and (59) or between
Sensor
Voltage
0.3 to 4.7 V
POIL (3) and (2)
output
2. Disconnect connectors J1 and POIL, and connect T-adapters to each
female side.
Resistance Between J1 (female) (59) and POIL (female) (2)
Max. 1 z

2. Disconnect connectors J1 and POIL, and connect T-adapter to either
female side.
Between J1 (female) (2) and (60), or between POIL
Min. 1 Mz
2. Disconnect connector POIL.
3. Connect T-adapter to female side of connector POIL, or insert T-adapter
into connector J1.
4. Turn starting switch to ON position (with connector POIL disconnected).
Between J1 (2) and (59) or between POIL (female)
Voltage
Max. 1 V
(3) and (2)
WA470-7
40 Troubleshooting
Circuit diagram related to engine oil pressure sensor
WA470-7
40-203
40 Troubleshooting
Failure code [CA141] Eng Oil Press Sensor Low Error

Action level
Failure code
L01
Detail of
failure
Action of
controller
Problem on
machine
CA141
Related
information
No.
Failure
(PC400-CA141-400-A-Z0-A)
Engine Oil Pressure Sensor Low Error

Low voltage appears in engine oil pressure sensor signal circuit.

Sets engine oil pressure to fixed value (250 kPa {2.5 kg/cm2}), and allows engine to run.
Signal voltage from engine oil pressure sensor can be checked by using monitoring
Engine oil pressure sensed by engine oil pressure sensor can be checked by using
Cause

connector


If failure code [CA187] or [CA227] is displayed, perform troubleshooting
for it first.
system of engine oil pressure 2. Disconnect connector POIL and connect T-adapter to female side.
sensor
Power
4.75 to 5.25
Voltage Between POIL (female) (1) and (2)
input
V
2. Disconnect connectors J1 and POIL and connect T-adapters to each
female side.

a If power supply input in checks on cause 2

is normal, this check is not required.
Between J1 (female) (60) and POIL
(female) (1)
Resistance
a If power supply input in checks on cause 2

is normal, this check is not required.
Between J1 (female) (59) and POIL
(female) (2)
Between J1 (female) (2) and POIL (female) (3)
(Sensor output)
Max. 1 z
Max. 1 z
Max. 1 z

female side.
Resis- Between J1 (female) (2) and ground, or
Min. 1 Mz
between POIL (female) (3) and ground
tance

harness

female side.
Resis- Between J1 (female) (2) and (59), or between
Min. 1 Mz
POIL (female) (2) and (3)
tance
40-204
WA470-7
40 Troubleshooting
No.
Cause
a If no failure is found by checks on causes 1 to 5 and check result of

cause 6 is abnormal, sensor is defective.
sensor
2. Insert T-adapter into connector J1 or POIL.
(improper input voltage to
engine controller)
Sensor
Voltage
0.3 to 4.7 V
between POIL (3) and (2)
output
Circuit diagram related to engine oil pressure sensor
WA470-7
40-205
40 Troubleshooting
Failure code [CA144] Coolant Temp Sens High Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA144
Failure
(PC400-CA144-400-A-Z0-A)
Coolant Temperature Sensor High Error

High voltage appears in engine coolant temperature sensor signal circuit.

Takes it that coolant temperature is at fixed value (90C) and allows engine to run.
Engine startability is poor at low temperatures.
Overheat prevention function does not work.
Signal voltage from engine coolant temperature sensor can be checked with monitoring
Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (C))
This failure code appears if sensor connector is disconnected.
Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not connectable to female connector on sensor wiring harness side and thus
not usable for check of open circuit (not designed as T-adapter).
Cause

Defective coolant
temperature sensor
a Regard coolant temperature sensor as normal if its resistance is 700

z to 37 kz when coolant temperature is min. 0 C.
0C
30 to 37 kz
9.3 to 10.7
Between TWTR (male) (A) and (B)
25C
kz
Resisa Coolant temperature50C
3.2 to 3.8 kz
tance
80C
1.0 to 1.3 kz
95C
700 to 800 z

2. Disconnect connector J1 and connect T-adapters to female side.
Between J1 (female) (14) and (13) (Coolant
Open or short circuit in wiring
temperature: Min. 0 C)
harness
Resis700 z to 37
a Use Coolant temperature-Resistance
tance
kz
characteristics table for check on cause 2
as resistance criteria.
40-206
WA470-7
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
WA470-7
40-207
40 Troubleshooting
Failure code [CA145] Coolant Temp Sens Low Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA145
Failure
(PC400-CA145-400-A-Z0-A)
Coolant Temperature Sensor Low Error

Low voltage appears in engine coolant temperature sensor signal circuit.

Takes it that coolant temperature is at fixed value (90C) and allows engine to run.
Engine startability is poor at low temperatures.
Overheat prevention function does not work.
Signal voltage from engine coolant temperature sensor can be checked with monitoring
If temperature sensor connector is disconnected, failure code [CA144] for high error is
displayed in place of this failure code.
Cause

Defective coolant
temperature sensor

harness

harness
40-208
a Regard coolant temperature sensor as normal if its resistance is 700

z to 37 kz when coolant temperature is min. 0 C.
0C
30 to 37 kz
9.3 to 10.7
Between TWTR (male) (A) and (B)
25C
kz
a Coolant temperature50C
3.2 to 3.8 kz
Resis80C
1.0 to 1.3 kz
tance
95C
700 to 800z
Whole
coolant
Between TWTR (male) (B) and
tempera- Min. 1 Mz
ground
ture range
Between J1 (female) (14) and (13) (Coolant
temperature: Min. 0C)
Resis700 z to 37
a Use Coolant temperature-Resistance
tance
kz
characteristics table for check on cause 2
as resistance criteria.
2. Disconnect connectors J1 and TWTR, and connect T-adapters to
female side of connector J1.
Resis- Between J1 (female) (14) and ground
Min. 1 Mz
tance
WA470-7
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
WA470-7
40-209
40 Troubleshooting
Failure code [CA153] Chg Air Temp Sensor High Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA153
Failure
(PC400-CA153-400-A-Z0-A)
Charge Air Temperature Sensor High Error

High voltage appears in boost temperature sensor signal circuit.

Takes it that boost temperature is at fixed temperature (70 C ) and allows engine to run.
Engine does not start easily at low temperatures.
Signal voltage from boost temperature sensor can be checked with monitoring function.
(Code: 18501 (V))
Temperature sensed by boost temperature sensor can be checked with monitoring
Because troubleshooting "socket" for this sensor features female connector alone, it is not
connectable to female connector of sensor wiring harness, and thus not usable for
checking open circuit (not designed as a T-adapter).
This failure code is displayed if temperature sensor connector is disconnected.
Cause

connector

a If temperature sensor has resistance of 280 z to 382 kz, regard

boost temperature sensor as normal.
291 to 382
-40 C
kz
Defective boost temperature
sensor
-20 C 85 to 109 kz
0 C
29 to 36 kz
Resisa Boost temperature-Resistance
30 C
7.3 to 8.8 kz
tance
chariacteristic
60 C
2.3 to 2.7 kz
90 C
860 to 970 z
130 C 280 to 320 z
Between J1 (female) (5) and (59)
harness
Resis- a Use Temperature-Resistance
280 z to 382
tance
kz
characteristics table for troubleshooting on
cause 2.
40-210
WA470-7
40 Troubleshooting
Circuit diagram related to boost temperature sensor
WA470-7
40-211
40 Troubleshooting
Failure code [CA154] Chg Air Temp Sensor Low Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA154
Failure
(PC400-CA154-400-A-Z0-A)
Charge Air Temperature Sensor Low Error

Low voltage appears in boost temperature sensor signal circuit.
Takes it that boost temperature is at fixed temperature (70 C ) and allows engine to run.
Engine does not start easily at low temperatures.
Signal voltage from boost temperature sensor can be checked with monitoring function.
(Code: 18501 (V))
Temperature sensed by boost temperature sensor can be checked with monitoring
If temperature sensor connector is disconnected, this failure code is not displayed but
failure code [CA153] for "High Error" is displayed.
Cause

connector

a If temperature sensor has resistance of 280 z to 382 kz, regard

boost temperature sensor as normal.
291 to 382
-40 C
kz
-20 C 85 to 109 kz
Defective boost temperature
sensor
0 C
29 to 36 kz
a
Boost
temperature-Resistance
30
C
7.3
to 8.8 kz
Resischariacteristic
60 C
2.3 to 2.7 kz
tance
90 C
860 to 970 z
130 C 280 to 320 z
Whole
Between TIM (male) (B) and
Min. 1 Mz
range
ground

harness

harness
40-212

Resis- a Use Temperature-Resistance
280 z to 382
tance
kz
characteristics table for troubleshooting on
cause 2.
2. Disconnect connectors J1 and TIM, and connect T-adapter to the
Min. 1 Mz
tance
WA470-7
40 Troubleshooting
Circuit diagram related to boost temperature sensor
WA470-7
40-213
40 Troubleshooting
Failure code [CA187] Sensor 2 Supply Volt Low Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA187
Failure
(HM300_3-CA187-400-A-Z0-A)
Sensor 2 Supply Voltage Low Error

Low voltage appears in sensor power supply 2 (5 V) circuit.

Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
Ignores signals from engine oil pressure sensor, takes it that engine oil pressure is at fixed
value (250 kPa {2.5 kg/cm2}), and allows engine to run.
Ignores signals from ambient pressure sensor, takes it that ambient pressure is at fixed
value (52.44 kPa {0.53 kg/cm2}), and allows engine to run.
Ignores signals from boost pressure sensor, takes it that boost pressure is at fixed value
(400 kPa {4.1 kg/cm2}), and allows engine to run.
Ignores signals from crankcase pressure sensor, takes it that crankcase pressure is at
fixed value (0 kPa), and allows engine to run.
Engine output decreases.
Cause
Defective harness
connector

2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine harness is
defective.
a Other failure codes (many codes) are also displayed. They are generated
because of disconnection of connector. Ignore failure codes other than
[CA187].
Bkup speed sensor
G
Engine oil pressure
POIL
sensor
Boost pressure sensor
PIM
Connector
PAMB
Crankcase pressure
PCCV
sensor
Engine harness
J1
Defective sensor or
wiring harness
Defective relevant
system
If other failure codes are also displayed, perform troubleshooting for them.
Defective engine
controller

2. Disconnect connector J1 and connect T-adapters to male side.
3. Turn starting switch to ON position with connector J1 disconnected.
4.75 to 5.25
Voltage Between J1 (male) (60) and (59)
V
40-214
WA470-7
40 Troubleshooting
Circuit diagram related to sensor power supply 2 (5 V) circuit
WA470-7
40-215
40 Troubleshooting
Failure code [CA221] Ambient Press Sensor High Error

Action level
L03
Detail of
failure
Action of
controller
Failure code
CA221
Failure
(PC400-CA221-400-A-Z0-A)
Ambient Pressure Sensor High Error

High voltage occurs in signal circuit of ambient pressure sensor.
Sets ambient pressure to fixed value (52.44 kPa {0.53 kg/cm2}) and runs engine.
Problem on
machine
Related
information
Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
No.
Cause
Defective wiring
harness connector


Defective ambient
pressure sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
for it first.
supply system
Defective ambient
pressure sensor

harness
(wire breakage or
connector)

harness

wiring harness
Defective engine
controller
40-216

2. Disconnect connector PAMB.
If failure code changes from [CA221] to [CA222], sensor is defective.
Reference
2. Insert T-adapters into connector J1 or PAMB.
Sensor
Voltage
0.3 to 4.7 V
PAMB (3) and (2)
output
2. Disconnect connectors J1 and PAMB, and connect T-adapters to each
female side.
Resistance Between J1 (female) (59) and PAMB (female) (2)
Max. 1 z

2. Disconnect connectors J1 and PAMB, and connect T-adapter to either
female side.
Between J1 (female) (60) and (16), or between
Resistance PAMB (female) (1) and (3)
Min. 1 Mz
2. Disconnect connector PAMB, and connect T-adapter to female side.
Voltage Between PAMB (female) (3) and (2)
Max. 1 V
WA470-7
40 Troubleshooting
Circuit diagram related to ambient pressure sensor
WA470-7
40-217
40 Troubleshooting
Failure code [CA222] Ambient Press Sensor Low Error

Action level
L03
Detail of
failure
Action of
controller
Failure code
CA222
Failure
(PC400-CA222-400-A-Z0-A)
Ambient Pressure Sensor Low Error

Low voltage occurs in signal circuit of ambient pressure sensor.
Sets ambient pressure to fixed value (52.44 kPa {0.53 kg/cm2}) and runs engine.
Problem on
machine
Related
information
Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not usable for check of open circuit in wiring harness and voltage at sensor
connector (not designed as T-adapter).
No.
Cause
Defective wiring
harness connector


If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
for it first.
Defective ambient
pressure sensor power 2. Disconnect connector PAMB, and connect T-adapter to female side.
supply system
Power
4.75 to 5.25
Voltage Between PAMB (female) (1) and (2)
supply input
V

harness

2. Disconnect connectors PAMB and J1, and connect T-adapter to either
female side.
Resistance PAMB (female) (3) and (2)
Min. 1 Mz

harness
circuit)

2. Disconnect connectors PAMB and J1, and connect T-adapter to either
female side.
Between ground and J1 (female) (16) or PAMB
Min. 1 Mz

harness

2. Disconnect connectors PAMB and J1, and connect T-adapter to female
side of connector J1.
Between J1 (female) (16) and PAMB (female) (3)
Max. 1 z
Resistance Between J1 (female) (59) and PAMB (female) (2)
Max. 1 z
Between J1 (female) (60) and PAMB (female) (1)
Max. 1 z
40-218
WA470-7
40 Troubleshooting
No.
Cause
Defective ambient
pressure sensor
Defective engine
controller

a If no failure is found by checks on causes 1 to 5 and failure is found by
check on cause 6, sensor is defective.
2. Insert T-adapters into connector J1 or PAMB.
Between J1 (16) and (59), or between Sensor
Voltage
0.3 to 4.7 V
PAMB (3) and (2)
output
Circuit diagram related to ambient pressure sensor
WA470-7
40-219
40 Troubleshooting
Failure code [CA227] Sensor 2 Supply Volt High Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
CA227
Sensor 2 Supply Voltage High Error

High voltage appears in sensor power supply 2 (5V) circuit.

Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
Ignores signals from engine oil pressure sensor, takes it that engine oil pressure is at
fixed value (250 kPa {2.5 kg/cm2}), and allows engine to run.
Ignores signals from ambient pressure sensor, takes it that ambient pressure is at fixed
value (52.44 kPa {0.53 kg/cm2}), and allows engine to run.
Ignores signals from boost pressure sensor, takes it that boost pressure is at fixed value
(400 kPa {4.1 kg/cm2}), and allows engine to run.
Ignores signals from crankcase pressure sensor, takes it that crankcase pressure is at
fixed value (0 kPa), and allows engine to run.
Cause
Defective sensor power
supply 2 circuit
40-220
Failure
(PC400-CA227-400-A-Z0-A)

WA470-7
40 Troubleshooting
Failure code [CA234] Eng Overspeed

Action level
L02
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Failure code
CA234
Engine Overspeed
Engine speed is above operating range.

Limits fuel injection rate until engine speed lowers to operating range.
Engine speed fluctuates.
Engine speed can be checked by using monitoring function. (Code: 01002 (rpm))
Method of reproducing failure code: Run engine at full speed.
No.
Cause
1 Use of improper fuel
2 Defect in related system
3
Improper use
WA470-7
Failure
(PC400-CA234-400-A-Z0-A)

Fuel used may be improper. Check it.
If another failure code is displayed, perform troubleshooting for it.
Usage of machine may be improper. Instruct operator on proper use of
machine.
If no problem is found by checks on causes 1 and 2, engine controller is
defective.
40-221
40 Troubleshooting
Failure code [CA238] Ne Speed Sensor Supply Volt Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA238
Failure
(PC400-CA238-400-A-Z0-A)
Ne speed sensor supply voltage error

Ne speed sensor power supply (5 V) circuit is defective.

Controls engine by using signals of Bkup speed sensor.
Running engine stops (when Bkup (G) speed sensor is also abnormal).
Stopped engine cannot be started (when Bkup(G) speed sensor is also abnormal).
Cause

connector

Defective sensor or wiring

harness

2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
3. After each troubleshooting, turn starting switch to OFF position.
If this failure code is not displayed when a sensor is disconnected,
sensor or engine wiring harness is defective.
a Other failure codes are displayed, too. This is because connector is
disconnected. Ignore failure codes other than [CA238].
Sensor or harness
Connector
Ne speed sensor
NE
Engine wiring harness
J1
2. Disconnect connector J1 and connect T-adapter to male side.
3. Turn starting switch to ON position with engine wiring harness
disconnected.
4.75 to 5.25
Voltage
Between J1 (male) (36) and (37)
V
Circuit diagram related to Ne speed sensor
40-222
WA470-7
40 Troubleshooting
Failure code [CA239] Ne Speed Sens Supply Volt High Error
(PC400-CA239-400-A-Z0-
A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA239
Failure
Ne Speed Sensor Supply Voltage High Error

High voltage appears in Ne speed sensor power supply (5 V) circuit.

Controls engine by using signals from engine Bkup speed sensor.
Running engine stops (when Bkup (G) speed sensor is also defective).
Stopped engine cannot be started (when Bkup (G) speed sensor is also defective).
Cause


2. Disconnect connector NE.
If this failure code is not displayed, disconnected sensor or engine wiring
harness is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than [CA239].

2. Disconnect connector J1.
If this failure code disappears, wiring harness is defective.

3. Turn starting switch to ON position with engine wiring harness
disconnected.
4.75 to 5.25
V
Circuit diagram related to Ne speed sensor
WA470-7
40-223
40 Troubleshooting
Failure code [CA271] IMV/PCV1 Short Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA271
Failure
(PC400-CA271-400-A-Z0-A)
IMV/PCV1 Short Error

Short circuit is detected in supply pump PCV1 circuit.

Under normal conditions, pulse voltage of approx. 24 V is applied to PCV1 (1) while
engine is running. However, it cannnot be measured by using multimeter since it is pulse
voltage.
Cause

connector


2. Disconnect connectors PCV1 and connect socket to male side.
Defective supply pump PCV1 3. Turn starting switch to ON position.
Resis- Between PCV1 (male) (1) and (2)
2.3 to 5.3
(internal short circuit)
tance
z
Resis- Between PCV1 (male) (1) and ground
Min. 1 Mz
tance
Resis- Between J2 (female) (4) and (5) (PCV1
2.3 to 5.3
resistance)
tance
z
Ground fault in wiring harness 2. Disconnect connectors J2 and PCV1 and connect T-adapter to
Min. 1 Mz
tance
If no abnormality is found by above diagnosis, engine controller is
defective.
Circuit diagram related to PCV1
40-224
WA470-7
40 Troubleshooting
Failure code [CA272] IMV/PCV1 Open Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA272
Failure
(PC400-CA272-400-A-Z0-A)
IMV/PCV1 Open Error

Open circuit is detected in supply pump PCV1 circuit.

Under normal conditions, pulse voltage of approximately 24 V is applied to PCV1 (1) while
engine is runing. However, it cannot be measured by using multimeter since it is pulse
voltage.
Because troubleshooting "socket" for this sensor features female connector alone, it is not
connectable to female connector of sensor wiring harness, and thus not usable for
Cause

connector


Defective supply pump PCV1 2. Disconnect connectors PCV1 and connect socket to male side.
2.3 to 5.3 z
tance
Open or short circuit in wiring 2. Disconnect connector J2 and connect T-adapters to female side.
harness
2.3 to 5.3 z
resistance)
tance

harness

2. Disconnect connectors J2 and PCV1.
3. Connect T-adapter to female side of connector J2.
Min. 1 Mz
tance
WA470-7
40-225
40 Troubleshooting
Failure code [CA273] PCV2 Short Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA273
Failure
(PC400-CA273-400-A-Z0-A)
PCV2 Short Error

Short circuit is detected in supply pump PCV2 circuit.

Under normal conditions, pulse voltage of approx. 24 V is applied to PCV2 (1) while
engine is running. However, it cannot be measured by using multimeter since it is pulse
voltage.
Cause

connector


2. Disconnect connector PCV2 and connect socket to male side.
Defective supply pump PCV2
2.3 to 5.3
tance
z
Resis- Between PCV2 (male) (1) and ground
Min. 1 Mz
tance
2.3 to 5.3
resistance)
tance
z
Ground fault in wiring harness 2. Disconnect connectors J2 and PCV2 and connect T-adapter to
Min. 1 Mz
tance
40-226
WA470-7
40 Troubleshooting
Failure code [CA274] PCV2 Open Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA274
Failure
(PC400-CA274-400-A-Z0-A)
PCV2 Open Error

Open circuit is detected in supply pump PCV2 circuit.

Under normal conditions, pulse voltage of approximately 24 V is applied to PCV2 (1)
while engine is running. However, it cannot be measured by using multimeter since it is
pulse voltage.
Because troubleshooting "socket" for this sensor features female connector alone, it is
not connectable to female connector of sensor wiring harness, and thus not usable for
Cause

connector


Defective supply pump PCV2 2. Disconnect connector PCV2 and connect socket to male side.
2.3 to 5.3
tance
z
harness
2.3 to 5.3
resistance)
tance
z
Ground fault in wiring harness 2. Disconnect connectors J2 and PCV2.
3. Connect T-adapter to female side of connector J2.
Min. 1 Mz
tance
WA470-7
40-227
40 Troubleshooting
Failure code [CA322] Inj #1(L#1) Open/Short Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA322
Failure
(PC400-CA322-400-A-Z0-A)
Injector #1(L#1) Open/Short Error

Open circuit or short circuit is detected in injector #1 circuit.

Engine speed does not stabilize.
While engine is running normally, approximately 65 V of pulse voltage is applied to
injector (positive) side. But it is pulse voltage and cannot be measured by using
multimeter.
Cause

connector


2. Disconnect connector CN1 and connect T-adapter to male side.
Resis- Between CN1 (male) (1) and (2)
Defective injector #1
0.4 to 1.1 z
tance
Resis- Between CN1 (male) (1) and ground
Min. 1 Mz
tance
Open circuit or ground fault in
Resis- Between J1 (female) (48) and (58)
0.4 to 1.1 z
wiring harness
tance
Min. 1 Mz
tance

Open circuit in wiring harness 2. Disconnect connectors J1 and CN1, and connect T-adapters to each
female side.
Resis- Between J1 (female) (48) and CN1 (female)
Max. 1 z
(1)
tance
Resis- Between J1 (female) (58) and CN1 (female)
Max. 1 z
(2)
tance

2. Disconnect connectors J1 and CN1, and connect T-adapters to
either female side.
Resis- Between J1 (female) (48) or CN1 (female) (1)
Min. 1 Mz
and ground
tance
40-228
WA470-7
40 Troubleshooting
No.
Cause

2. Disconnect connectors J1 and CN1, and connect T-adapters to
a Check by using multimeter in continuity mode.
6
Defective other cylinder

injectors or wiring harness
No
Between J1 (female) (48) and and each other continuity
pin
(No sound
is heard)
Continuity
No
continuity
Between J1 (female) (58) and each other pin
(No sound
is heard)
If failure codes for other injectors are displayed, perform troubleshooting
for them, too.
Circuit diagram related to injector #1
WA470-7
40-229
40 Troubleshooting

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA323
(PC400-CA323-400-A-Z0-A)

Failure

multimeter.
Cause

connector

0.4 to 1.1 z
tance
Between CN5 (male) (1) and ground
Min. 1 Mz

Open circuit or ground fault in 2. Disconnect connector J1 and connect T-adapters to female side.
wiring harness
0.4 to 1.1 z
tance
Between J1 (female) (44) and ground
Min. 1 Mz

Open circuit in wiring harness 2. Disconnect connectors J1 and CN5, and connect T-adapter to each
female side.
Between J1 (female) (44) and CN5 (female)
Max. 1 z
Resis- (1)
tance
Max. 1 z
(2)

2. Disconnect connectors J1 and CN5, and connect T-adapter to either
female side.
Min. 1 Mz
and ground
tance
2. Disconnect connectors J1 and CN5, and connect T-adapter to the

Continuity
40-230
No
continuity
(No sound
is heard)
No
continuity
(No sound
is heard)
WA470-7
40 Troubleshooting
No.
7
Cause

for them, too.
WA470-7
40-231
40 Troubleshooting

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA324
(PC400-CA324-400-A-Z0-A)

Failure

multimeter.
Cause

connector

0.4 to 1.1 z
tance
Min. 1 Mz

wiring harness
0.4 to 1.1 z
tance
Min. 1 Mz

female side.
Max. 1 z
Resis- (1)
tance
Max. 1 z
(2)

female side.
Min. 1 Mz
and ground
tance

Continuity
40-232
No
continuity
(No sound
is heard)
No
continuity
(No sound
is heard)
WA470-7
40 Troubleshooting
No.
7
Cause

for them, too.
WA470-7
40-233
40 Troubleshooting

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA325
(PC400-CA325-400-A-Z0-A)

Failure

multimeter.
Cause

connector

0.4 to 1.1 z
tance
Min. 1 Mz

wiring harness
0.4 to 1.1 z
tance
Min. 1 Mz

female side.
Max. 1 z
Resis- (1)
tance
Max. 1 z
(2)

female side.
Min. 1 Mz
and ground
tance

Continuity
40-234
No
continuity
(No sound
is heard)
No
continuity
(No sound
is heard)
WA470-7
40 Troubleshooting
Cause

for them, too.

No.
WA470-7
40-235
40 Troubleshooting

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA331
(PC400-CA331-400-A-Z0-A)

Failure

multimeter.
Cause

connector

0.4 to 1.1 z
tance
Min. 1 Mz

wiring harness
0.4 to 1.1 z
tance
Min. 1 Mz

female side.
Max. 1 z
Resis- (1)
tance
Max. 1 z
(2)

female side.
Min. 1 Mz
and ground
tance

Continuity
40-236
No
continuity
(No sound
is heard)
No
continuity
(No sound
is heard)
WA470-7
40 Troubleshooting
No.
7
Cause

for them, too.
WA470-7
40-237
40 Troubleshooting

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA332
(PC400-CA332-400-A-Z0-A)

Failure

multimeter.
Cause

connector

0.4 to 1.1 z
tance
Min. 1 Mz

wiring harness
0.4 to 1.1 z
tance
Min. 1 Mz

female side.
Max. 1 z
Resis- (1)
tance
Max. 1 z
(2)

female side.
Min. 1 Mz
and ground
tance

Continuity
40-238
No
continuity
(No sound
is heard)
No
continuity
(No sound
is heard)
WA470-7
40 Troubleshooting
No.
7
Cause

for them, too.
WA470-7
40-239
40 Troubleshooting
Failure code [CA343] ECM Critical Internal Failure

Action level
L04
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
CA343
ECM Critical Internal Failure

Engine controller has internal defect.

None in particular
Engine continues to run normally, but it may stop during running or may not be able to
start if it is stopped.
Power supply voltage of engine controller can be checked with moniitoring funtion.
(Code: 03203 Battery voltage)
Method of reproducing failure code: Turn starting switch to ON position
Cause
system
40-240
Failure
(PC400-CA343-400-A-Z0-A)

WA470-7
40 Troubleshooting
Failure code [CA351] Injectors Drive Circuit Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA351
Injectors Drive Circuit Error

Injector drive circuit is defective.

Limits engine output (limits common rail pressure) and allows engine to run.
Cause
Defect in related system

system
WA470-7
Failure
(PC400-CA351-400-A-Z0-A)

Check failure code (injector system failure code) that is displayed at the
same time. If another code is displayed, perform troubleshooting for it.
40-241
40 Troubleshooting

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA352
Failure
(PC400-CA352-400-A-Z0-A)

Low voltage appears in sensor power supply 1 (5 V) circuit.

Ignores signals from dosing (post-treatment injector) fuel pressure sensor, and stops
KDPF regeneration control.
Ignores signals from EGR valve lift sensor and KVGT position sensor, takes it that they
remain at values before failure detection, and allows engine to run.
Cause

2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
If this failure code is not displayed, disconnected sensor or engine
harness is defective.
Defective sensor or wiring

harness
40-242
PDOSER connector
SEGR connector
Connector
SVGT connector
Engine harness
J2
them.
3. Turn starting switch to ON position with connector J2 disconnected.
4.75 to 5.25
V
WA470-7
40 Troubleshooting
Circuit diagram related to sensor power supply 1 (5 V)
WA470-7
40-243
40 Troubleshooting
Failure code [CA356] Mass Air Flow Sensor High Error

Action level
L03
Detail of
failure
Action of
controller
Failure code
CA356
Failure
(WA500_7-CA356-400-A-Z0-A)
Mass Air Flow Sensor High Error

High frequency appears in signal circuit of mass air flow sensor.
Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
Problem on
machine
Related
information
Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.

Mass air flow sensor and intake air temperature sensor are integrated.
No.
Cause


supply system
Defective mass air flow

sensor
(internal defect)

supply system

If failure code [CA3419] or [CA3421] is also displayed, perform
troubleshooting for it first.
2. Disconnect connector E27.
If this failure code changes to [CA357], mass air flow sensor is
defective.
1. Be ready with starting switch at OFF position.
2. Disconnect connector E27 and connect T-adapters to female side.
Power
Approx. 12
supply
V

Open circuit in wiring harness 2. Disconnect connectors J1 and E27, and connect T-adapters to each
female side.
Resis- Between J1 (female) (22) and E27 (female) (3)
Max. 1 z
tance
2. Disconnect connectors J1 and E27, and connect T-adapters to
female side of J1.
Resis- Between J1 (female) (23) and each pin other
Min. 1 Mz
than pin (23)
tance
40-244
WA470-7
40 Troubleshooting
Circuit diagram related to mass air flow sensor
WA470-7
40-245
40 Troubleshooting
Failure code [CA357] Mass Air Flow Sensor Low Error

Action level
L03
Detail of
failure
Action of
controller
Failure code
CA357
Failure
(WA500_7-CA357-400-A-Z0-A)
Mass Air Flow Sensor Low Error

Low frequency appears in signal circuit of mass air flow sensor.
Problem on
machine
Related
information
Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.

If sensor connector is disconnected, both this failure code and failure code [CA691] are
displayed.
No.
Cause


supply system

sensor
(internal defect)

supply system

2. Replace mass air flow sensor.
If this failure code does not appear, original mass air flow sensor is
defective.
2. Disconnect connectorE27, and connect T-adapters to female side.
Power
Approx. 12
supply
V
2. Disconnect connectors J1 and E27, and connect T-adapters to each
female side.

Resistance

Between J1 (female) (21) and E27 (female) (2)
Max. 1 z
Max. 1 z
Max. 1 z

Ground fault in wiring harness 2. Disconnect connectors J1 and E27, and connect T-adapters to
either female side.
Resis- Between ground and J1 (female) (23) or E27
Min. 1 Mz
(female) (1)
tance
40-246

than pin (23)
tance
Min. 1 Mz
WA470-7
40 Troubleshooting
No.
Cause
harness

2. Disconnect connector E27, and connect T-adapters to female side.
a Ignore displayed failure codes.
Max. 1 V
WA470-7
40-247
40 Troubleshooting

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
CA386

High voltage appears in sensor power supply 1 (5 V) circuit.

Ignores signals from dosing (post-treatment injector) fuel pressure sensor, and stops
KDPF regeneration control.
Ignores signals from EGR valve lift sensor and KVGT position sensor, takes it that they
remain at values before failure detection, and allows engine to run.
Cause
supply 1 circuit
40-248
Failure
(PC400-CA386-400-A-Z0-A)

WA470-7
40 Troubleshooting
Failure code [CA431] Idle Validation Sw Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA431
Failure
(WA380_7-CA431-400-A-Z0-A)
Idle Validation Switch Error

Idle validation switch signals 1 and 2 (IVS1 and IVS2) are abnormal.
Uses throttle position from throttle sensor to run engine.
Input (ON/OFF) of idle validation signal 1 can be checked with monitoring function. (Code:
18300)
18301)
Cause
Defective harness connector

system

equipment" in "Checks before troubleshooting" of "General information
2. Insert T-adapters into connector PDV.
a If check result is unusual, go to check on cause 4.
Voltage
Between PDV (1) and (2)
4.75 to 5.25
V

3

(internal defect)
a If check result is unusual, perform checks on causes 4 and 5 to

check wiring harness. If wiring harness is normal, regard accelerator
pedal as defective.
See IVS1 in Fig. 1
See IVS2 in Fig. 1
2. Disconnect connectors PD, PDV and EC3, and connect T-adapters
Max. 1 z
(4)
Max. 1 z
(5)
Resis- Between EC3 (female) (50) and PD (female)
Max. 1 z
(6)
tance
Between EC3 (female) (52) and PDV
Max. 1 z
(female) (1)
Between EC3 (female) (43) and PDV
Max. 1 z
(female) (2)
2. Disconnect connectors PD and EC3, and connect T-adapters to
female side of EC3.
Between EC3 (female) (49) and each pin
Min. 1 Mz
Resis- other than pin (49)
tance
Min. 1 Mz
other than pin (50)
WA470-7
40-249
40 Troubleshooting
No.
Cause
controller (internal defect)

(internal defect)

2. Insert T-adapters into connector EC3.
4.75 to 5.25
V
Voltage
4.75
to
5.25
V
Reference
See IVS1 in Fig. 1
See IVS2 in Fig. 1
Circuit diagram related to idle validation
40-250
WA470-7
40 Troubleshooting
Fig. 1
Pedal stroke: Stroke of accelerator pedal
Output voltage : Output voltage: (pin 2 of connector PD and pin 51 of connector EC3)
IVS1: Signal voltage of idle validation switch 1
Switch gap: Zone where both signals of IVS1 and IVS2 are OFF
WA470-7
40-251
40 Troubleshooting
Failure code [CA432] Idle Validation Process Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
CA432
Failure
(WA380_7-CA432-400-A-Z0-A)
Idle Validation Process Error

Idle validation switch signal does not match with (but contradicts) signal of throttle sensor.
1. When idle validation switch signal indicates that accelerator pedal is OFF but throttle
sensor signal indicates that accelerator pedal is ON: Controls throttle position to 0 %
while idle validation signal is indicating that accelerator pedal is OFF, and to 50 % while
idle validation signal is indicating that accelerator pedal is ON.
2. When idle validation switch signal indicates that accelerator pedal is ON but throttle
sensor signal indicates that accelerator pedal is OFF: Controls throttle position to 0 %.
(Fix engine speed to low idle.)
Engine speed does not increase from low idle speed.
Centralized warning lamp lights up and alarm buzzer sounds (according to command
from machine monitor).
18300)
18301)
Input voltage from throttle sensor can be checked with monitoring function. (Code: 03000)

Cause
For idle validation switch signal error, perform troubleshooting for failure code [CA431].
(For throttle sensor error, perform checks on causes 2 and after)
system
4.75 to 5.25
Voltage Between PD (1) and (3)
V
a If check result is unusual, perform checks on causes 4 and 5 to
(internal defect)
check wiring harness. If wiring harness is normal, regard accelerator
pedal as defective.
See output voltage in Fig. 1
2. Disconnect connectors PD and EC3, and connect T-adapters to each
female side.
Max. 1 z
(1)
Resis- Between EC3 (female) (51) and PD (female)
Max. 1 z
(2)
tance
Max. 1 z
(3)
2. Disconnect connectors PD and EC3, and connect T-adapters to
Short circuit in wiring harness female side of EC3.
Resis- Between EC3 (female) (9) and each pin other
Min. 1 Mz
than pin (9)
tance
40-252
WA470-7
40 Troubleshooting
No.
Cause

(internal defect)

Reference
See output voltage in Fig. 1 on next
page.
Circuit diagram related to idle validation
WA470-7
40-253
40 Troubleshooting
Fig. 1
Pedal stroke: Stroke of accelerator pedal
Output voltage : Output voltage: (pin 2 of connector PD and pin 51 of connector EC3)
Switch gap: Zone where both signals of IVS1 and IVS2 are OFF
40-254
WA470-7
40 Troubleshooting
Failure code [CA441] Battery Voltage Low Error

Action level
L04
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
Failure code
CA441
Failure
(WA470_7-CA441-400-A-Z0-A)
Battery Voltage Low Error

Low voltage appears in engine controller power supply circuit.

Takes it that power supply voltage is at fixed value (24 V) and allows engine to run.
restart if it is stopped.
Power supply voltage of engine controller can be checked with monitoring function.
Since T-adapter is not provided for alternator connector, operating voltage cannot be
measured.
Cause
Loose or corroded
battery terminal

Battery terminal may be loose or corroded. Check it directly.

Loose terminal or partial
open circuit at terminal Check terminals of alternator, battery relay, ground terminals (R50, E14A,
E14B, and E09), etc.
Defective harness
connector


Lowered battery voltage 2. Measure voltage while cranking engine.
Voltage Between battery terminals (+) and (-).
20 to 30 V
Defective alternator
Defective engine
controller
WA470-7

2. Start engine. (Engine speed: Middle or faster)
Voltage Between terminal E02 and ground
26 to 30.5 V
If no failure is found by above checks, engine controller is defective. (Since
Reference
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
4. Measure voltage with starting switch at OFF position and when starting
engine.
20 to 30 V
20 to 30 V
Voltage
20 to 30 V
20 to 30 V
40-255
40 Troubleshooting
Circuit diagram related to engine controller power supply
40-256
WA470-7
40 Troubleshooting
Failure code [CA442] Battery Voltage High Error

Action level
L04
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
CA442
Battery Voltage High Error

High voltage (approx. 36 V or higher) appears in controller power supply circuit.

Takes it that power supply voltage is at fixed value (24 V) and allows engine to run.
restart if it is stopped.
Power supply voltage of engine controller can be checked with monitoring function.
Cause
system of engine controller
WA470-7
Failure
(WA500_7-CA442-400-A-Z0-A)

40-257
40 Troubleshooting
Failure code [CA449] Rail Press Very High Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
CA449
Rail Pressure Very High Error

High voltage (exceeding the preset limit) occurs in common rail pressure sensor circuit.
Limits engine output and allows engine to run (limits common rail pressure).
Signal voltage from common rail pressure sensor can be checked with monitoring
Common rail pressure sensed by common rail pressure sensor can be checked with
monitoring function. (Code: 36400 (MPa))
Cause
Defective common rail
pressure sensor system
40-258
Failure
(PC400-CA449-400-A-Z0-A)

WA470-7
40 Troubleshooting
Failure code [CA451] Rail Press Sensor High Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA451
Failure
(PC400-CA451-400-A-Z0-A)
Rail Pressure Sensor High Error

High voltage appears in signal circuit of common rail pressure sensor.

This failure code appears if common rail pressure sensor connector is disconnected.
Cause

a If failure code [CA515] or [CA516] is also displayed, perform

2. Disconnect connector PFUEL, and connect T-adapter to female side
pressure sensor power supply
of connector.
system
Power
Between PFUEL (female) (1) and
Voltage
supply 4.75 to 5.25
(3)
V
input
2. Disconnect connectors PFUEL and J2, and connect T-adapters to
each female side of connectors.

a If power supply input is normal in check on

cause 2, this check is not required.
Between J2 (female) (31) and PFUEL
(female) (1)
Resistance a If power supply input is normal in check on
cause 2, this check is not required.
(female) (3)
(female) (2) (sensor output)
Max. 1 z
Max. 1 z

2. Disconnect connectors PFUEL and J2.
3. Connect T-adapter to female side of J2.
Resistance Between J2 (female) (55) and (31)
WA470-7
Max. 1 z
Min. 1 Mz
40-259
40 Troubleshooting
No.
Cause

harness

pressure sensor
(improper input voltage to
engine controller)

2. Disconnect connector PFUEL, and insert T-adapter to connector J2.
3. Turn starting switch to ON position (with connector PFUEL
disconnected).
a Pin (55) of connector J2 is connected to 5 V circuit via resistor inside
engine controller.
Voltage Between J2 (55) and (21)
Approx. 5 V
a If no failure is found by checks on causes 1 to 5 and if failure is
found by check on cause 6, sensor is defective.
2. Insert T-adapters into connector J2.
Sensor
output 0.2 to 4.6 V
Circuit diagram related to common rail pressure sensor
40-260
WA470-7
40 Troubleshooting
Failure code [CA452] Rail Press Sensor Low Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA452
Failure
(PC400-CA452-400-A-Z0-A)
Rail Pressure Sensor Low Error

Low voltage occurs in signal circuit of common rail pressure sensor.

If sensor connector is disconnected even in normal condition, failure code [CA451] for
"High Error" is generated instead of this code.
Cause

connector

If this failure code is not displayed, wiring harness connector is
defective.
a If failure code [CA515] or [CA516] is also displayed, perform

pressure sensor power supply
of connector.
system
Power
Between PFUEL (female) (1)
Voltage
supply 4.75 to 5.25 V
and (3)
input
2. Disconnect connector PFUEL.
If failure code [CA452] changes to [CA451], sensor is defective.
Reference
2. Insert T-adapter into connector PFUEL or J2.
Between PFUEL (2) and (3), or
Sensor
Voltage
0.2 to 4.6 V
between J2 (55) and (21)
output

pressure sensor

2. Disconnect connectors J2 and PAMB, and connect T-adapters to
each female side of connectors.
a Open circuit of 5 V circuit
Max. 1 z

Ground fault in wiring harness 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
either female side.
Between ground and PFUEL (female) (2) or Min. 1 Mz
Resistance J2 (female) (55)
WA470-7
40-261
40 Troubleshooting
No.
Cause

2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
either female side.
Between PFUEL (female) (2) and (3) or
Resistance between J2 (female) (55) and (21)
Min. 1 Mz
40-262
WA470-7
40 Troubleshooting
Failure code [CA515] Rail Press Sens Sup Volt High Error
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA515
Failure
(PC400-CA515-400-A-Z0-A)
Rail Pressure Sensor Supply Voltage High Error

High voltage appears in common rail pressure sensor power supply (5 V) circuit.
Limits the common rail pressure.
Cause


pressure sensor
(internal defect)

If this failure code disappears, sensor is defective.
codes other than this code.
If this failure code does not appear, wiring harness may be defective.
Perform following troubleshooting.

harness
WA470-7

of connector.
4.75 to 5.25
Voltage Between PFUEL (female) (1) and (3)
V
2. Disconnect connector J2, and connect T-adapter to male side.
4.7 to 5.25
V
40-263
40 Troubleshooting
40-264
WA470-7
40 Troubleshooting
Failure code [CA516] Rail Press Sens Sup Volt Low Error
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA516
Failure
(PC400-CA516-400-A-Z0-A)
Rail Pressure Sensor Supply Voltage Low Error

Low voltage appears in common rail pressure sensor power supply (5 V) circuit.
Limits the common rail pressure.
Cause


pressure sensor
(internal defect)

If this failure code disappears, sensor is defective.
If this failure code does not appear, wiring harness may be defective.
Perform following troubleshooting.

2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
female side of either connector.
Resis- Between ground and J2 (female) (31) or
Min. 1 Mz
PFUEL (female) (1)
tance

Short circuit in wiring harness 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
Resis- Between J2 (female) (21) and (31), or
Min. 1 Mz
between PFUEL (female) (1) and (2)
tance

2. Disconnect connector J2, and connect T-adapter to male side.
4.7 to 5.25
V
WA470-7
40-265
40 Troubleshooting
40-266
WA470-7
40 Troubleshooting
Failure code [CA553] Rail Press High Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
3
4
5
6
7
(PC400-CA553-400-A-Z0-A)
Rail Pressure High Error

Failure code
Failure
CA553
High voltage (above the limit) appears and continued 15 or more seconds in signal circuit
of common rail pressure sensor.
None in particular

them.
Improper fuel
Fuel used may be improper. Check it (the viscosity is high).
Electrical system of common rail pressure sensor may be defective.
Defective electric system of
common rail pressure sensor Perform troubleshooting for failure codes [CA451] and [CA452].
Defective mechanical system
Common rail pressure sensor may have mechanical failure. Check it.
of common rail pressure
sensor
The overflow valve may has a damaged spring, worn seat, or ball
Defective overflow valve
clogging trouble. Check it.
Clogging of overflow piping
Check overflow piping for clogging.
Defective pressure limiter
The pressure limiter may have a mechanical failure. Check it.
WA470-7
Cause
40-267
40 Troubleshooting
Failure code [CA555] Crankcase Press High Error 1

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Failure code
CA555
Crankcase Press High Error 1

High pressure error of crankcase pressure is detected.

None in particular.
Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401(V))
Pressure sensed by crankcase pressure sensor can be checked with monitoring function.
(Code: 48400 (MPa))
No.
Cause
Clogged
KCCV
filter
1
2
Blocked KCCV gas piping

defective
40-268
Failure
(PC400-CA555-400-A-Z0-A)

Replace KCCV filter with a new one.
When this failure code is not cleared after KCCV filter is replaced and
emulsion is found inside KCCV, KCCV blowby gas piping may be
blocked with emulsified matter. Perform troubleshooting for coolant
leaks.
Crankcase pressure sensor system may be defective. Perform
troubleshooting for failure codes [CA1843] and [CA1844].
WA470-7
40 Troubleshooting
Failure code [CA556] Crankcase Press High Error 2

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Failure code
CA556
Crankcase Pressure High Error 2

Crankcase pressure high error (level 2) has occurred.

(Code: 48401(V))
The pressure sensed by the crankcase pressure sensor can be checked by using
No.
Cause
Clogged
KCCV
filter
1
2

defective
Blow-by gas increases
WA470-7
Failure
(PC400-CA556-400-A-Z0-A)

Replace KCCV filter with a new one.
When this failure code is not cleared after KCCV filter is replaced and
emulsion is found inside KCCV, KCCV blowby gas piping may be
blocked with emulsified matter. Perform troubleshooting for coolant
leaks.
Crankcase pressure sensor system may be defective. Perform
When the error is not cleared after the KCCV filter is replaced and
crankcase pressure high error 2 occurs in a short time, the engine may
be seized or the turbocharger may be defective. Carry out
troubleshooting for the mechanical system.
40-269
40 Troubleshooting
Failure code [CA559] Rail Press Low Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
General
information
No.
1
2
Failure code
CA559
Failure
(WA470_7-CA559-400-A-Z0-A)
Rail Pressure Low Error

Supply pump pressure is very low (level 1).

Cause
Defective relevant
system
Improper fuel

If another failure code is displayed, perform troubleshooting for it first.
Improper fuel may be used, so check fuel.
a For details of troubleshooting, see Note 1.
4
5
6
a For check of fuel pressure in low-pressure circuit, see Testing and

Defective low-pressure
adjusting, "Testing fuel pressure".
circuit devices
Fuel pressure in low-pressure circuit
0.15 to 0.3 MPa
(with engine running at high idle or under load
{1.5 to 3.0 kg/cm2}
equivalent to rated load)
Clogged fuel filter or
a For details of troubleshooting, see Note 2.
strainer
Defective electrical
Electrical system of supply pump PCV may be defective. Perform
system of supply pump troubleshooting for failure codes [CA271], [CA272], [CA273], and [CA274].
PCV
Defective common rail Common rail pressure sensor may be defective. Check wiring harness for
damage.
pressure sensor
Defective pressure
limiter
a For check of leakage from pressure limiter, see Testing and adjusting,
"Testing fuel return rate and leakage".
Leakage from pressure limiter
Max. 10 cc/min
(Engine operation equivalent to rated operation
(with load by torque converter stall))
a For check of limit return rate (spill) from injector, see Testing and adjusting,
"Testing fuel return rate and leakage".
Engine speed at rated operation (with
Limit return rate (spill) from injector
load by torque converter stall)
Defective injector
1,600 rpm
960 cc/min
1,700 rpm
1,020 cc/min
1,800 rpm
1,080 cc/min
1,900 rpm
1,140 cc/min
2,000 rpm
1,200 cc/min
If
no
failure
is
found
by
checks
on
causes
1
to
8,
supply
pump may be
Defective supply pump
defective.
<How to use check sheet>

Perform above troubleshooting and fill in check results on attached "Check sheet for fuel pressure low error".
Note 1: Check low-pressure fuel circuit parts for following items.
1. Remaining quantity of fuel
2. Clogging of fuel tank breather
3. Looking and wear of fuel feed pump and clogging of filter
4. Leakage from or clogging of low-pressure fuel piping
5. Malfunction of bypass valve and installation of wrong part (See Fig. 1)
6. Clogging of fuel filter
40-270
WA470-7
40 Troubleshooting
7. Fuel in oil pan (fuel leakage inside cylinder head cover)

Figure 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
Overflow valve (1): Spring is seen through both holes.
Bypass valve (2): Spring is seen through the nut hole.
Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace filters and strainers according to following procedure.
1. Gauze filter: Disassemble and check gauze filter. If clogged, clean it.
2. Upstream filter of gauze filter: If gauze filter is clogged, clean upstream filter, as well.
3. Fuel filter: If trouble is not solved by performing above steps 1) and 2), replace fuel filter.
Check sheet for fuel pressure low error
SAA6D125E-6
#
A. Visual check
/
h
No good
Work No.
Date of check
Service meter
Worker's name
Good
Model
Machine serial No.
Engine
Engine serial No.
1 Fuel leakage to outside

2 Clogging of fuel tank breather
WA470-7
40-271
40 Troubleshooting
Good
No good
Good
No good
CA
CA
B. Inspection with machine monitor

(02 = Abnormality record; 01 = Monitoring; 09 = Cylinder cutout mode operation)
3 Check of failure code
Check of monitoring information

Code
01002
31701
4
18600
36200
36400
Item displayed
Engine speed
Throttle opening
ISO unit
Standard
value
(Reference
value)
Low idle
r/min
800 (+50 / -0)
High idle
r/min
2,170 ( 50)
r/min
1,710 ( 50)
r/min
1,785 ( 50)
Low idle
High idle
100
mg/st
MPa
MPa
CA
Testing conditions

(E-mode)
(P-mode)
Last fuel injection

quantity command Torque converter stall
(in weight)
Last common rail
pressure command
Common rail
pressure
Low idle
36300
Last injection timing High idle

command
36500
Charge pressure
kPa
04107
Engine coolant
temperature
Low idle
Low idle
C
14200 Fuel temperature
Check result of cylinder cutout mode operation (engine speed)
40-272
No good
Set
cylinder
to be cut
out by
cylinder.
ISO unit
Standard
value
(Reference
value)
Good
Function
Measured
value
No. 1 cylinder
Low idle
r/min
No. 2 cylinder
Low idle
r/min
No. 3 cylinder
Low idle
r/min
No. 4 cylinder
Low idle
r/min
No. 5 cylinder
Low idle
r/min
No. 6 cylinder
Low idle
r/min
Cutout cylinder
Testing conditions
Measured
value
WA470-7
40 Troubleshooting
Unit
Standard
value
(Reference
value)
cc/min
Max. 10
cc/min
960
cc/min
1,020
cc/min
1,080
cc/min
1,140
cc/min
1,200
D. Check of strainers and filters
No good
0.15 to 0.3
{1.5 to 3.0}
No good
MPa {kg/
cm2}
Measured
value
No good
High idle or under load

equivalent to rated
operation (load by torque
converter stall)
Unit
Good
Fuel pressure in low6 pressure circuit
Testing conditions
Standard
value
(Reference
value)
Good
C. Check of fuel circuit

pressure
Good
7 Visual check of strainer

8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
E. Check of leakage and

return rate
Testing conditions
Engine operation
equivalent to rated
operation (with load by
torque converter stall)
Torque converter stall at
1,600 rpm
1,700 rpm
12 Return rate from injector 1,800 rpm
1,900 rpm
2,000 rpm
Leakage from pressure
11
limiter
WA470-7
Measured
value
Speed:
Return rate:
40-273
40 Troubleshooting
Failure code [CA595] Turbo Speed High Error 2

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
3
Failure code
CA595
Failure
(PC400-CA595-400-A-Z0-A)
Turbocharger Speed High Error 2

Turbocharger runs at abnormally high speed.

Takes it that turbocharger is at fixed value of 130,000 (rpm), and allows engine to run.
Turbocharger speed sensed by turbocharger speed sensor can be checked with

monitoring function. (Code: 48100 (rpm))
Cause
Increased turbocharger
speed
Defective turbocharger

Turbocharger speed may increase abnormally high. Check it.
Turbocharger may be defective. Check it.

If no failure is found by check on cause 1, turbocharger speed sensor
Defective turbocharger speed system may be defective. Perform troubleshooting for failure code
sensor
[CA687].
40-274
WA470-7
40 Troubleshooting
Failure code [CA687] Turbo Speed Low Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Failure code
CA687
8
9
Turbocharger Speed Low Error

Turbocharger rotates at abnormally low speed.

Takes it that turbocharger is at fixed value of 130,000 (rpm), and allows engine to run.
Turbocharger speed sensed by turbocharger speed sensor can be checked with

monitoring function. (Code: 48100 (rpm))
No.
Cause
1 Defective turbocharger
Failure
(PC400-CA687-400-A-Z0-A)

Turbocharger may be defective. Check it.

supply system

first.

Defective turbocharger speed 2. Disconnect connector VGT REV. and connect T-adapter to female
sensor
side of connector.
(internal defect)
Resis- Between VGT REV. (female) (1) and (2)
600 to 1600
tance
z
Open or short circuit in wiring 1. Turn starting switch to OFF position.
harness
(short circuit, wire breakage
600 to 1600
or defective contact of
tance
z
connector)
2. Disconnect connectors J2 and VGT REV. and connect T-adapter to
either female side.
Resis- Between ground and J2 (female) (32) or VGT
Min. 1 Mz
REV. (female) (1)
tance
Resis- Between ground and J2 (female) (33) or VGT
Min. 1 Mz
REV. (female) (2)
tance
Short circuit in wiring harness 2. Disconnect connectors J2 and VGT REV. and connect T-adapter to
either female side.
Resis- Between J2 (female) (32) and (33), or
Min. 1 Mz
between VGT REV. (female) (1) and (2)
tance
Defective installation of
Turbocharger speed sensor may be installed incorrectly (loose fitting) or
sensor or defective speed
speed sensor parts (internal parts of KVGT) may be defective (due to
sensing part
thermal deformation). Check them.
WA470-7
40-275
40 Troubleshooting
Circuit diagram related to turbocharger speed sensor
40-276
WA470-7
40 Troubleshooting
Failure code [CA689] Eng Ne Speed Sensor Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
2
3
Failure code
CA689
Failure
(PC400-CA689-400-A-Z0-A)
Engine Ne Speed Sensor Error

Engine Ne speed sensor signal is abnormal.

Controls engine by using signals from engine Bkup speed sensor.
Running engine stops (when Bkup speed sensor is also defective).

Stopped engine cannot be restarted (when Bkup speed sensor is also defective).
Since interior portion of speed sensor is configured with hall sensor and electronic circuit
rather than coil, measurements of speed sensor resistance by using mulitimeter cannot
be used to determine whether sensor is normal or not.
Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable
for measurement.
The speed sensor detects holes drilled through the flywheel and calculates the engine
speed.
Cause

power supply system
Breakage or improper
installation (loosened) of
engine Ne speed sensor

first.
Engine Ne speed sensor may be broken or installed improperly
(loosened). Check it.
2. Disconnect connector NE, and connect T-adapter to female side.
Power
Voltage Between NE (female) (1) and (2)
supply 4.75 to 5.25
V
input

power supply input

2. Disconnect connectors J1 and NE, and connect T-adapter to each
female side.
If no failure is found by check on cause 4, this
check is not required.
Max. 1 z
Between J1 (female) (36) and NE (female) (1)
Resis- If no failure is found by check on cause 4, this
tance
Max. 1 z
Max. 1 z

2. Disconnect connectors J1 and NE, and connect T-adapter to either
female side.
Between J1 (female) (36) and (26), or
Min. 1 Mz
Resis- between NE (female) (1) and (3)
tance
Between J1 (female) (37) and (26), or
Min. 1 Mz
between NE (female) (2) and (3)

harness
WA470-7

2. Disconnect connectors J1 and NE, and connect T-adapter to either
female side.
Resis- Between ground and J1 (female) (26) or NE
Min. 1 Mz
(female) (3)
tance
40-277
40 Troubleshooting
No.
Cause

harness
Defective engine Ne speed

sensor

2. Disconnect connector NE, and connect T-adapter to female side.
Voltage Between NE (female) (3) and ground
Max. 1 V
If no failure is found by above checks, engine Ne speed sensor may be
performed.)
Circuit diagram related to engine Ne speed sensor
The Ne speed sensor detects area (A) where holes (H) are not drilled through flywheel (1), and the engine
controller calculates the engine speed and signal phase.
40-278
WA470-7
40 Troubleshooting
Failure code [CA691] Intake Air Temp Sens High Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA691
Failure
(WA500_7-CA691-400-A-Z0-A)
Intake Air Temperature Sensor High Error

High voltage appears in signal circuit of intake air temperature sensor.

Takes it that intake air temperature is at fixed value (25 C) and allows engine to run.
Signal voltage from intake air temperature sensor can be checked with monitoring
Temperature sensed by intake air temperature sensor can be checked with monitoring
If sensor connector is disconnected, this failure code is displayed together with failure
code [CA357].
Cause

Defective intake air

temperature sensor
(internal defect)

-30C
25 to 28 kz
0C
5.5 to 6.1 kz
25C
1.9
to 2.1 kz
Resis- a Intake air temperature40C
1.1
to 1.2 kz
Resistance
characteristics
tance
100C 180 to 185 z
Whole
Min. 1 Mz
range

harness
180 z to 28
tance
kz
a Use Intake air temperature-Resistance characteristics table for
connector)
check on cause 2 as resistance criteria.
3. Insert T-adapters into connector J1, or connect T-adapters to female
harness
side of connector E27.
Between J1 (6) and (22) or between E27
Voltage
Max. 5.25 V
WA470-7

Min. 1 Mz
than pin (6)
tance
40-279
40 Troubleshooting
Circuit diagram related to intake air temperature sensor
40-280
WA470-7
40 Troubleshooting
Failure code [CA692] Intake Air Temp Sens Low Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA692
Failure
(WA500_7-CA692-400-A-Z0-A)
Intake Air Temperature Sensor Low Error

Low voltage appears in signal circuit of intake air temperature sensor.

Takes it that intake air temperature is at fixed value (25 C) and allows engine to run.
Signal voltage from intake air temperature sensor can be checked with monitoring
Temperature sensed by intake air temperature sensor can be checked with monitoring
Cause

Defective intake air

temperature sensor
(internal defect)

If this failure code changes to failure code [CA691], intake air
temperature sensor is defective.
Reference
-30C
25 to 28 kz
0C
5.5 to 6.1 kz
25C
1.9
to 2.1 kz
Resis- a Intake air temperature40C
1.1
to 1.2 kz
Resistance
characteristics
tance
100C 180 to 185 z
Whole
Min. 1 Mz
range

harness
180 z to 28
tance
kz
a Use Intake air temperature-Resistance characteristics table for
connector)
check on cause 2 as resistance criteria.
either female side.
Min. 1 Mz
(female) (4)
tance
WA470-7

Min. 1 Mz
than pin (6)
tance
40-281
40 Troubleshooting
Circuit diagram related to intake air temperature sensor
40-282
WA470-7
40 Troubleshooting
Failure code [CA697] ECM Internal Temp Sensor High Error
(PC400-CA697-400-A-Z0-
A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Failure code
CA697
None in particular.
Temperature sensed by engine controller internal temperature sensor can be checked by

using monitoring function (Code: 18900(C)).
WA470-7
ECM Internal Temperature Sensor High Error

High voltage appears in engine controller internal temperature sensor signal circuit.
No.
Cause
Improper
usage
of controller
1
2
Failure

Check if the controller has been used in high temperature environments.
40-283
40 Troubleshooting
Failure code [CA698] ECM Int Temp Sensor Low Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Failure code
CA698
None in particular.
Temperature sensed by engine controller internal temperature sensor can be checked by

using monitoring function (Code: 18900(C)).
40-284
ECM Internal Temperature Sensor Low Error

Low voltage appears in engine controller internal temperature sensor signal circuit.
No.
Cause
1 Improper usage of controller
2
Failure
(PC400-CA698-400-A-Z0-A)

Check if the controller has been used in low temperature environments.
WA470-7
40 Troubleshooting
Failure code [CA731] Eng Bkup Speed Sens Phase Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
Engine Bkup Speed Sensor Phase Error

Failure code
Failure
CA731
Engine controller receives signals from engine Bkup sensor, and detects a signal phase
error.
(The signal is out of phase when compared with signals sent from Ne speed sensor.)
Controls engine by using signals from engine Ne speed sensor.
Running engine stops (when Ne speed sensor is also defective).
Stopped engine cannot be restarted (when Ne speed sensor is also defective).
a The fuel supply pump must also be replaced during replacement of Bkup speed sensor.
(See Disassembly and assembly, "Removal and installation of fuel supply pump".)
Cause
Defective engine Ne speed
sensor circuit
Defective engine Bkup speed
sensor circuit
WA470-7
(PC400-CA731-400-A-Z0-A)

Engine Ne speed sensor may be defective. Perform troubleshooting for
failure code [CA689].
Engine Bkup speed sensor may be defective. Perform troubleshooting
for failure code [CA778].
40-285
40 Troubleshooting
Failure code [CA778] Eng Bkup Speed Sensor Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
2
3
Failure code
CA778
Failure
(PC400-CA778-400-A-Z0-A)
Engine Bkup Speed Sensor Error

Abnormality occurred in engine Bkup speed sensor circuit.

Controls engine by using signals of Ne speed sensor.
Running engine stops (when Ne speed sensor is also defective).
Stopped engine cannot be started (when Ne speed sensor is also defective).
a If engine Bkup speed sensor needs to be replaced, fuel supply pump must be
replaced as a unit.
(See "Disassembly and assembly", "Removal and installation of fuel supply pump".)
Since inside of speed sensor is not composed of coil but electronic circuit, speed sensor
cannot be determined to be normal by measuring its resistance by using multimeter .
Since speed sensor output is 5 V pulse voltage during normal operation, it cannot be
measured by using multimeter.
Cause

connector

supply system
Damage or improper
installation (loose) of engine
Bkup speed (G) sensor

Engine Bkup speed (G) sensor may be damaged or improperly installed
(loose). Check it.

2. Disconnect connector G-RES and connect T-adapter to male side.
Defective resistor (G-RES)
Resis- Between G-RES (male) (1) and (2)
620 z
tance
2. Disconnect connector G and connect T-adapter to female side.
Defective engine Bkup speed
sensor power supply input
Power 4.75 to 5.25
Voltage Between G (female) (1) and (2)
supply
V
harness (resistor RES line)

40-286

2. Disconnect connectors J1 and G, and connect T-adapter to the
620 z
tance
2. Disconnect connectors J1, G, and G-RES, and connect T-adapters
Resistance
a If power supply voltage in checks on

cause 5 is normal, this check is not
required.
Between J1 (female) (60) and G (female) (1)
a If power supply voltage in checks on
cause 5 is normal, this check is not
required.
Max. 1 z
Max. 1 z
Max. 1 z
WA470-7
40 Troubleshooting
No.
Cause

2. Disconnect connectors J1, G, and G-RES, and connect T-adapter to
female side of J1 or G.
Min. 1 Mz
Resis- G (female) (1) and (3)
tance
Min. 1 Mz
G (female) (2) and (3)

Ground fault in wiring harness 2. Disconnect connectors J1 and G and connect T-adapter to either
female side.
Resis- Between J1 (female) (9) or G (female) (3) and
Min. 1 Mz
ground
tance

2. Disconnect connectors G and G-RES, and connect T-adapter to
female side of G.
10
harness
Voltage Between G (female) (3) and ground
Max. 1 V
If no problem is found by above checks, engine Bkup speed sensor may
Defective engine Bkup speed be defective.
11
sensor
defective.
Defective
engine
controller
12
Circuit diagram related to engine Bkup speed sensor
WA470-7
40-287
40 Troubleshooting
Failure code [CA1117] Persistent Data Lost Error

Action level
L04
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
Failure code
CA1117
Failure
(PC400-CA1117-400-A-Z0-A)
Persistent Data Lost Error

Internal defect occurred in controller.

None in particular.
start if it is stopped.
Engine controller cannot store internal data correctly.
Since the engine controller internal data (KDPF related, etc.) may be lost, appropriate
actions must be taken after the system recovers from the error.

Since the power supply circuit may be defective, carry out
Defective power supply circuit
troubleshooting for failure code [CA441].
Improper operation of battery Battery disconnect switch may have been operated improperly.
disconnect switch
Cause
Actions to be
taken after See "How to perform regeneration for service" section.
recovery from
error
40-288
WA470-7
40 Troubleshooting
Failure code [CA1664] KDOC Malfunction

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
(WA470_7-CA1664-400-A-Z0-A)
KDOC Malfunction
Failure code
Failure
CA1664
During KDPF regeneration, KDOC inlet temperature sensor and KDOC outlet
temperature sensor indicate similar values (temperature difference is approximately within
10C).
a You can cancel above measures by "turning starting switch to OFF position once, then
turning starting switch to ON position" after failure code is generated.
Reduced engine output.
k Since
KDPF and KDOC are heated to 500C or above, take care not to get burn
injury.
General
information
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250C,
and difference between these temperatures is approximately 10C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
When active regeneration (manual stationary regeneration) is in progress, KDOC inlet
temperature is approximately 250 to 400C, and KDOC outlet temperature and KDPF
outlet temperature are approximately 450 to 550C.
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
B. Machine operation for clearing failure code
clearing
failure code
a This failure code is not cleared by simply turning starting switch to ON position from OFF
position after repair. You must perform machine operation for clearing failure code after
repair.
WA470-7
40-289
40 Troubleshooting

Cause
temperature sensor
Defective KDOC outlet
temperature sensor

troubleshooting for [CA3313], [CA3314], or [CA3315].
Defective wiring
harness connector

troubleshooting", and check it and repair as needed.

harness

2. Monitor signal voltages from KDOC inlet temperature sensor and KDOC
outlet temperature sensor, and note signal voltages from respective
temperature sensors in initial condition (see Related information).
4. Disconnect either connector TEMP1 or TEMP2.
6. Monitor signal voltages from KDOC inlet temperature sensor and KDOC
outlet temperature sensor, and note second signal voltages from
respective temperature sensors (see Related information).
If second signal voltages sensed by KDOC inlet temperature sensor and
KDOC outlet temperature sensor do not change notably (almost same as first
signal voltages), check wiring harness for short circuit (troubleshooting for
failure codes [CA3313] and [CA3316]).
Defective KDOC
1. Check that KDPF is installed to exhaust system.

2. Check that KDOC is installed to KDPF.
No.
1
2
3

No.
Cause
1.
2.
3.
4.
Turn starting switch from OFF position to ON position.

Start engine and run it at low idle for approximately 1 minute.
Use monitoring function to display KDOC inlet temperature.
Run engine at high idle (approximately 2,170 rpm with no load) for 15 minutes.
(KDOC inlet temperature must be higher than 250C.)
If failure code is cleared after steps 1 to 4 are implemented, repair work is complete.
a To make the engine speed approximately 2,200 rpm, release the parking brake while running the engine
at high idle.
a When service tool "INSITE" is available, you can clear every failure code by executing Reset All Faults
command.
For how to use "INSITE", see "INSITE" operation manual.
If this failure code appears again after above procedures are implemented,
Defective engine
6
engine controller is defective.
controller
40-290
WA470-7
40 Troubleshooting
Circuit diagram related to KDOC temperature sensor
WA470-7
40-291
40 Troubleshooting
Failure code [CA1691] Regeneration Ineffective

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
(PC400-CA1691-400-A-Z0-A)
Regeneration Ineffective
Failure code
Failure
CA1691
KDOC efficiency (catalyst action) is degraded. (Soot trapped in KCSF does not burn
sufficiently because the KDOC outlet temperature does not rise enough. During
regeneration, KDOC inlet temperature is normally approximately 250 to 400C, and
KDOC outlet temperature is normally approximately 450 to 550C.)
Closes EGR valve and open KVGT fully.

k Since
injury.
Related
information
function. (Code: 47400 (C)
When manual stationary regeneration (normal) is in progress, KDOC inlet temperature is
approximately 250 to 400C, and KDOC outlet temperature and KDPF outlet temperature
are approximately 450 to 550C.
When manual stationary regeneration without injecting dosing fuel (KDOC drying) is in
progress, KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet
temperature are all approximately 250 to 400C.
a When KDOC in KDPF is changed, perform reset procedure for KDOC change and then
finish repair.
Procedure of performing manual stationary regeneration from Regeneration for Service.
a When soot accumulation is at level 3 or lower, the manual stationary regeneration can be
performed only from "Regeneration for Service".
2. Make sure that machine is in safe condition.
3. From service menu of machine monitor, select "Diagnostic Tests", open "02 Regeneration
for Service", and then perform "Manual Stationary Regeneration (manual stationary
regeneration will be completed in approximately 40 minutes).
a Failure code [CA2637] may be displayed at the same time, however, perform
troubleshooting for this failure code [CA1691].
Method of reproducing failure code:
When KDOC is changed, there is no need to check completion of repair.
When KDOC is not changed, start engine and turn manual stationary regeneration switch
ON. (See cause 6.)
40-292
WA470-7
40 Troubleshooting
No.
1
Cause
temperature sensor
Unusual exhaust gas color

If there is a significant difference between KDOC outlet temperature
and KDOC inlet temperature and KDPF outlet temperature when
KDPF is completely cool or engine running at idle (not regenerating),
replace KDOC outlet temperature sensor.
1. Rapidly accelerate engine from low idle to high idle 2 times, and then
keep engine running at high idle for 5 seconds.
If excessive black smoke is exhausted when accelerating engine or
running it at high idle, perform troubleshooting for "S-9 KDPF gets
clogged in a short time".
a It does not matter that black smoke particles are exhausted during
engine acceleration but are not exhausted during running at high
idle.
Defective KDOC
(KDOC drying)
a Dry KDOC.
2. Monitor signal voltages from KDOC inlet temperature sensor and
KDPF outlet temperature sensor, note temperature values from each
sensor with KDPF under initial condition and during manual
stationary regeneration, and check that KDOC outlet temperature
sensor is normal. (See "Related information".)
3. Perform manual stationary regeneration. (See "Related
information".)
a Since this is for drying KDOC, dosing fuel is not injected during
regeneration.
k Perform
Defective KDOC
(dirty or cracked or damaged
KDOC surface)
after KDPF and KDOC are sufficiently cooled.
1. Remove KDPF.
2. Remove KDOC.
3. Blow air from KDOC outlet side to clean ceramic surfaces inside
KDOC.
4. Check ceramic inside KDOC for cracks.
If cracks are found in KDOC, KDOC is defective (replace KDOC).
a Perform the following regardless whether KDOC is replaced or not.
1. Install KDOC and KDPF.
3. From service menu of machine monitor, display the "Diagnostic
Tests" screen, open "03 KDPF Memory Reset", and then perform "03
KDOC Change" (reset after KDOC change).
Reset after KDOC change
a When reset after KDOC change is performed, failure codes

[CA1691] and [CA2637] will not be displayed. At that time, remedy of
not injecting dosing fuel when the failure code is displayed is
released.
a Check that reset after KDOC change is completed successfully (by
reset count). If not, perform troubleshooting again.
a When KDOC is replaced, finish troubleshooting without performing
WA470-7
40-293
40 Troubleshooting
No.
Cause
Defective KDOC
(degraded KDOC catalyst
action)

a Perform this troubleshooting when KDOC is not changed.
2. Monitor signal voltages from KDOC inlet temperature sensor and
KDPF outlet temperature sensor, note temperature values from each
sensor with KDPF under initial condition and during manual
stationary regeneration, and check that KDOC outlet temperature
sensor is normal. (See "Related information".)
3. Perform manual stationary regeneration. (See "Related
information".)
5. Start engine and perform manual stationary regeneration again.
(Check whether failure code [CA2637] is displayed or not.)
a Check that failure code is not displayed and finish troubleshooting.
a If failure code [CA2637] is displayed after manual stationary
regeneration is completed, KDOC is defective (catalyst action of
KDOC is degraded. Change KDOC).
a When KDOC is changed, perform troubleshooting for cause 5 again.
40-294
WA470-7
40 Troubleshooting

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA500_7-CA1695-400-A-Z0-A)

Failure code
Failure
CA1695
High voltage appears in 5 V power supply for KDPF delta pressure sensor and KDPF
outlet pressure sensor.
Takes it that KDPF outlet pressure sensor is at fixed value (0 kPa {0 kg/cm 2 }) and allows
engine to run.
Takes it that KDPF delta pressure value is at estimated value and allows engine to run
(uses delta pressure of 0 kPa in some cases).

KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
Cause

Defective KDPF delta

pressure (outlet pressure)
sensor
(internal defect)

a Ignore displayed failure codes other than this code.
If this failure code is not displayed, KDPF delta pressure (outlet
pressure) sensor is defective.

harness

2. Disconnect connectors EC3 and E25, and connect T-adapters to
female side of EC3.
Resis- Between EC3 (female) (52) and each pin
Min. 1 Mz
other than pin (52)
tance

3. Insert T-adapters into connector EC3, or connect T-adapters to
female side of connector E25.
Between EC3 (52) and (43) or between E25
Voltage
4.75 to 5.25 V
Circuit diagram related to sensor power supply 5 circuit
WA470-7
40-295
40 Troubleshooting

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA500_7-CA1696-400-A-Z0-A)

Failure code
Failure
CA1696
Low voltage appears in 5 V power supply circuit for KDPF delta pressure sensor and
KDPF outlet pressure sensor.
Takes it that KDPF outlet pressure sensor value is at fixed value (0 kPa{0 kg/cm 2 }) and
allows engine to run.
Takes it that KDPF delta pressure sensor value is at estimated value and allows engine to
run (uses delta pressure of 0 kPa in some cases).

Cause


pressure (outlet pressure)
sensor
(internal defect)

harness

either female side.
Min. 1 Mz
E25 (female) (4)
tance

harness

female side of EC3.
Min. 1 Mz
other than pin (52)
tance

3. Insert T-adapters into connector EC3, or connect T-adapters to
female side of connector E25.
Between EC3 (52) and (43) or between E25
Voltage
4.75 to 5.25 V
40-296
a Ignore displayed failure codes other than this code.

If this failure code is not displayed, KDPF delta pressure (outlet
pressure) sensor is defective.
WA470-7
40 Troubleshooting
Circuit diagram related to sensor power supply 5 circuit
WA470-7
40-297
40 Troubleshooting
Failure code [CA1843] Crankcase Press Sens High Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA1843
Failure
(HM300_3-CA1843-400-A-Z0-A)
Crankcase Pressure Sensor High Error

High voltage occurs in signal circuit of crankcase pressure sensor.

Sets crankcase pressure to fixed value (approximately 0 kPa) and runs engine.
(Code: 48401(V))
(Code: 48400 (MPa))
Cause

connector

supply system

defective.
troubleshooting for [CA187] or [CA227] first.
2. Disconnect connector PCCV.
If failure code [CA1843] changes to [CA1844], crankcase pressure
Reference
2. Insert T-adapter into connector PCCV.
Between PCCV (female) (3) and
Sensor
Voltage
0.3 to 4.7 V
(2)
output
Defective crankcase
pressure sensor
(internal defect)

2. Disconnect connectors J1 and PCCV, and connect T-adapters to
each female side.
Resis- Between J1 (female) (59) and PCCV (female)
Max. 1 z
(2)
tance

2. Disconnect connectors J1 and PCCV, and connect T-adapter to
either female side.
Min. 1 Mz
PCCV (female) (1) and (3)
tance

harness
40-298

2. Disconnect connector PCCV and connect T-adapter to female side.
Max. 1 V
Voltage Between PCCV (female) (3) and (2)
WA470-7
40 Troubleshooting
No.
Cause

Reference
2. Insert T-adapter into connector J1.
Sensor
0.3 to 4.7 V
output
Circuit diagram related to crankcase pressure sensor
WA470-7
40-299
40 Troubleshooting
Failure code [CA1844] Crankcase Press Sens Low Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA1844
Failure
(HM300_3-CA1844-400-A-Z0-A)
Crankcase Pressure Sensor Low Error

Low voltage appears in signal circuit of crankcase pressure sensor.

Takes it that crankcase pressure is at fixed value (approximately 0 kPa), and allows
engine to run.
(Code: 48401(V))
(Code: 48400 (MPa))
Cause

for [CA187] or [CA227] first.

supply system

2. Disconnect connector PCCV and connect T-adapters to female
side.
Between PCCV (female) (1) and Power
4.75 to 5.25
Voltage
supply
(2)
V
2. Disconnect connectors J1 and PCCV and connect T-adapters to
each female side.
a If any failure is found in wiring harness, disconnect connector
BREAK OUT and check further to determine which is defective,
engine harness or chassis harness.

Resis(wire breakage or defective
tance
Resistance
Resistance

Between J1 (female) (60) and PCCV
(female) (1)
Between J1 (female) (59) and PCCV
(female) (2)
Between J1 (female) (3) and PCCV (female)
(3)
Max. 1 z
Max. 1 z
Max. 1 z

either female side.
4
Ground fault in wiring harness a If any failure is found in wiring harness, disconnect connector
BREAK OUT and check further to determine which is defective,
engine harness or chassis harness.
Between ground and J1 (female) (3) or PCCV Min. 1 Mz
Resis(female) (3)
tance
40-300
WA470-7
40 Troubleshooting
No.
Cause

either female side.
ResisMin. 1 Mz
PCCV (female) (2) and (3)
tance

Defective crankcase pressure 2. Insert T-adapters into connector PCCV.
sensor
(internal defect)
Voltage
Between PCCV (3) and (2)
Sensor
0.3 to 4.7 V
output
Reference
Sensor
Voltage
Between J1 (3) and (59)
0.3 to 4.7 V
output
Circuit diagram related to crankcase pressure sensor
WA470-7
40-301
40 Troubleshooting
Failure code [CA1879] KDPF Delta P Sensor High Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA1879
No.
KDPF Delta Pressure Sensor High Error

High voltage appears in signal circuit of KDPF delta pressure sensor.

Takes it that KDPF delta pressure is at estimated value and allows engine to run.
(If another failure code is also generated, controller may use delta pressure of 0 kPa to
run engine.)
Closes EGR valve and KVGT fully.
k Since
Related
information
Failure
(WA500_7-CA1879-400-A-Z0-A)
KDPF is heated to 500C or above, take care not to get burn injury.
If failure code [CA1695] is not displayed but failure code [CA3133] is on screen, GND
circuit probably has open circuit (defective contact of connector).
Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101 (V))
Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
Cause


supply system

pressure sensor

4.75 to 5.25 V
If failure code changes to [CA1881], KDPF delta pressure sensor is
defective.
a If this failure code remains displayed, wiring harness or engine
controller is defective.
a Ignore other displayed failure codes.

harness
40-302

each female side.
Resis- Between EC3 (female) (43) and E25 (female)
(1)
tance
Max. 1 z
WA470-7
40 Troubleshooting
No.
Cause

female side of EC3.

harness

Continuity

other than pin (55)
No continuity
(No sound is
heard)

Circuit diagram related to KDPF delta pressure sensor
WA470-7
40-303
40 Troubleshooting
Failure code [CA1881] KDPF Delta P Sensor Low Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA1881
No.
KDPF Delta Pressure Sensor Low Error

Low voltage appears in signal circuit of KDPF delta pressure sensor.

run engine.)
k Since
Related
information
Failure
(WA500_7-CA1881-400-A-Z0-A)
If failure code [CA1696] is not displayed but failure code [CA3134] is on screen, sensor
connector is probably disconnected or 5 V circuit probably has open circuit (defective
contact of connector).
(Code: 47101 (V))
Cause


supply system


harness
40-304

4.75 to 5.25
V
each female side.
Between EC3 (female) (43) and E25 (female)
(1)
Resistance

(4)
(2)
Max. 1 z
Max. 1 z
Max. 1 z

either female side.
Min. 1 Mz
E25 (female) (2)
tance
WA470-7
40 Troubleshooting
No.
Cause

female side of EC3.
Short circuit in wiring harness a Check by using multimeter in continuity mode.

Continuity

pressure sensor

other than pin (55)

2. Insert T-adapters into connector E25.
No continuity
(No sound is
heard)
0.5 to 4.5 V

WA470-7
40-305
40 Troubleshooting
Failure code [CA1883] KDPF Delta P Sens In Range Error

Action level
L03
Detail of
failure
Action of
controller
(WA500_7-CA1883-400-A-Z0-A)
KDPF Delta Pressure Sensor In Range Error

Failure code
Failure
CA1883
Signal voltage from KDPF delta pressure sensor is out of range. (Signal voltage from
sensor is within operating range.)
run engine.)
a You can cancel above measures by "turning starting switch to OFF position and then to
ON position" after failure code is generated.
Problem on
machine

k Since
Related
information
(Code: 47101 (V))
Oil temperature sensed by torque converter oil temperature sensor can be checked with
monitoring function. (Code: 30100 T/C oil temperature)
a Use "Short-circuit connector: 799T-601-4611".

As to procedure for accessing KDPF delta pressure sensor, wiring harness, and tube, see
50 Disassembly and assembly, "Removal and installation of KDPF assembly" and
"Disassembly and assembly of KDPF assembly".
position. So when you restart engine, wait 1 minute minimum before turning starting
When this failure code appears, perform troubleshooting according to following work flow.
A. Identification of cause and fixing
Machine
O
operation for B. Machine operation for clearing failure code
clearing
failure code a This failure code does not disappear by simply turning starting switch to ON position from
OFF position after repair. You must perform machine operation for clearing failure code
after fixing trouble.
A. Identification of cause and fixing
No.
Cause

Defective sensor power supply 1. Turn starting switch to OFF position.

system
4.75 to 5.25 V
40-306

information on troubleshooting", and check it and fix trouble as
needed.
WA470-7
40 Troubleshooting
No.
Cause

If failure code [CA1881] is not displayed, wiring harness or engine
a Perform check on cause 2 again.
Defective wiring harness or

engine controller

2. Disconnect connector E25 and connect short-circuit connector to
female side.
a To connect 5 V line to signal line (to short pin (4) to pin (2) of
connector E25).

pressure sensor
a If failure codes [CA1881] and [CA1879] are displayed in check on

cause 3, KDPF delta pressure sensor is defective.
each female side.



Between EC3 (female) (43) and E25
(female) (1)
Resisa If no failure is found by check on cause 1,
tance
(female) (4)
(female) (2)
Max. 1 z
Max. 1 z
Max. 1 z

either female side.
Min. 1 Mz
tance E25 (female) (2)
female side of EC3.

Continu- Between EC3 (female) (55) and each pin
ity
other than pin (55)
WA470-7
No continuity
(No sound is
heard)
40-307
40 Troubleshooting
No.
Cause
1.
2.
3.
4.

pressure sensor tube
Remove KDPF delta pressure sensor tube.

Clean KDPF delta pressure sensor tube to clear clogging.
Check KDPF delta pressure sensor tube for cracks and damage.
Install KDPF delta pressure sensor tube with both tube ends
connected securely.
Reference
How to check KDPF delta pressure sensor tube for clogging
2. Monitor delta pressure sensed by KDPF delta pressure sensor on
monitoring screen of machine monitor.
47100 (kPa)
0 3 (kPa)
Code

k Place
machine on a flat ground, turn parking brake switch to ON position, and chock wheels.
1. Turn starting switch to ON position and leave it in that position for 1 minute. (In order to allow engine
controller to determine drift of voltage when starting switch is turned to ON position.)
2. Turn starting switch from OFF position to ON position.
3. Start engine and run it at low idle for approximately 1 minute.
4. After warm-up operation, perform <torque converter stall operation> as described below.
<Torque converter stall operation>
5. Set transmission cut-off switch to "OFF" position and depress left brake pedal securely.
6. Set torque converter lockup switch (if equipped) to "OFF" position.
7. Set transmission shift mode selector switch to "MANUAL".
8. While keeping directional lever or directional selector switch in "N" (NEUTRAL) position, set gear shift
lever or gear shift switch to "4th" gear speed.
10.While depressing brake pedal, set directional lever or directional selector switch to "F (forward)" or "R
k Keep
11.Depress accelerator pedal gradually to stall torque converter with engine running at high idle.
a Take care that torque converter oil temperature does not exceed 120C.
a If failure code still remains displayed, repeat above steps 2 to 11 three times.
If failure code disappears, repair is complete.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
No.
Cause
If this failure code appears again after above procedures are
implemented, engine controller is defective.
40-308
WA470-7
40 Troubleshooting
Failure code [CA1921] KDPF Soot Load High Error 1

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
(PC400-CA1921-400-A-Z0-A)
KDPF Soot Load High Error 1

Failure code
Failure
CA1921
Soot accumulation of KDPF reaches level 6 or 7. As much soot is accumulated in KCSF,
the user is requested to perform "Manual Stationary Regeneration" immediately.
(If soot accumulation reaches level 8, KDPF must be replaced.)
Disables automatic regeneration but allows manual stationary regeneration.

k Since
KDOC and KDPF are heated to 500C or above, take care not to get burn
injury.
Related
information
WA470-7
(Code: 47101 (V))
When the active regeneration (the manual stationary regeneration) is in progress, KDOC
inlet temperature is approximately 250 to 400C, and KDOC outlet temperature and KDPF
Soot accumulation in KDPF is classified into 8 levels. Current soot accumulation level can
be checked on machine monitor by selecting the "02 Regeneration for Service" screen.
The manual stationary regeneration can be performed for removing soot when soot
accumulation is up to level 7.
If soot accumulation reaches level 8, failure code [CA1922] is displayed. At this level, the
KDPF is completely clogged with soot, and inspection, cleaning, or replacement is
required.
40-309
40 Troubleshooting
a Time required for the manual stationary regeneration depends on the accumulated soot in
KCSF, however, it is estimated as follows.
If soot accumulation is level 4: approximately 40 minutes to 1 hour
If soot accumulation is level 5: approximately 1 to 2 hours
If soot accumulation is level 6 or 7: approximately 1 to 3 hours
If soot accumulation is level 8: The manual stationary regeneration can not be performed.
Factors for excessive soot accumulation
1. Engine runs with light loads and cannot keep exhaust gas temperature high enough to
burn soot in KDPF.
If temperature of the gas entered into after-treatment system (KDPF) is low, a large
amount of soot may accumulate.
To avoid the soot accumulation in KDPF, the engine must run under high load.
2. Engine has failure that leads to excessive black smoke.
3. "Regeneration Disable" is set from the screen monitor.
Even if the soot is accumulated, regeneration does not start automatically.
You must move the machine to a safe place to release the "Regeneration Disable",
and perform the regeneration.
a Releasing method of "Regeneration Disable"
Select the "Cancel of Regeneration Disable" from the KDPF Regeneration screen and
execute.
(For details, see Operation and Maintenance Manual, "Operation", "Handling KDPF",
"Operation procedure of KDPF Regeneration Disable".)
a If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for it first.
a If failure code [CA1922] has been displayed originally, it changes to [CA1921] during
troubleshooting process of [CA1922]. In such case, refer to failure code [CA1922].
Method of reproducing failure code: Turn starting switch to the ON position.
No.
Cause

1. Check if the regeneration stop button is pressed down from the
machine monitor.
a If the regeneration stop button is pressed down, release it.
4. Perform manual stationary regeneration from user mode.
Excessive KDPF (KCSF)

soot accumulation level
a When the manual stationary regeneration is finished correctly, the

repair is completed.
a If the regeneration does not complete within 3 hours, perform the
troubleshooting of [CA2639].
a Check that failure code is not displayed after manual stationary
regeneration is completed.
a If failure code [CA1922] or [CA2639] is displayed after manual
stationary regeneration is completed, proceed to checks on
cause 2.
a If failure code [CA1921], or [CA2639] is displayed after manual
stationary regeneration is completed, perform following.
a For check of the exhaust gas color, see "30 Testing and adjusting",
"Testing exhaust gas color".
40-310
a When checking the exhaust gas color, perform the "Regeneration

Disable" from the machine monitor.
WA470-7
40 Troubleshooting
No.
Cause

idle.
a Check that no failure code appears.
a When you finish the check of the exhaust gas color, release
"Regeneration Disable".
WA470-7
40-311
40 Troubleshooting
Failure code [CA1922] KDPF Soot Load High Error 2

Action level
L04
Detail of
failure
Action of
controller
Problem on
machine
(PC400-CA1922-400-A-Z0-A)
KDPF Soot Load High Error 2

Failure code
Failure
CA1922
Soot accumulation in KDPF is very high, and machine must be stopped and performed
maintenance immediately.
Soot accumulation reaches level 8 (KDPF is completely clogged with soot).
Disables the automatic regeneration and the manual stationary regeneration.

k Since
injury.
Related
information
40-312
(Code: 47101 (V))
When the active regeneration (the manual stationary regeneration) is in progress, KDOC
inlet temperature is approximately 250 to 400C, and KDOC outlet temperature and KDPF
Soot accumulation in KDPF is classified into 8 levels. Current soot accumulation level can
be checked on machine monitor by selecting the "02 Regeneration for Service" screen.
The manual stationary regeneration can be performed for removing soot when soot
accumulation is up to level 7.
If soot accumulation reaches level 8, failure code [CA1922] is displayed. At this level, the
KDPF is completely clogged with soot, and inspection, cleaning, or replacement is
required.
WA470-7
40 Troubleshooting
a Time required for the manual stationary regeneration depends on the accumulated soot in
If soot accumulation is level 4: approximately 40 minutes to 1 hour
If soot accumulation is level 5: approximately 1 to 2 hours
If soot accumulation is level 6 or 7: approximately 1 to 3 hours
Factors for excessive soot accumulation
1. Engine runs with light loads and cannot keep exhaust gas temperature high enough to
burn soot in KDPF.
If temperature of the gas entered into after-treatment system (KDPF) is low, a large
amount of soot may accumulate.
To avoid the soot accumulation in KDPF, the engine must run under high load.
2. Engine has failure that lead to excessive black smoke.
3. "Regeneration Disable" is set from the screen monitor.
Even if the soot is accumulated, regeneration does not start automatically.
You must move the machine to a safe place to release the "Regeneration Disable",
and perform the regeneration.
a Releasing method of "Regeneration Disable"
Select the "Cancel of Regeneration Disable" from the KDPF Regeneration screen and
execute.
(For details, see Operation and Maintenance Manual, "Operation", "Handling KDPF",
"Operation procedure of KDPF Regeneration Disable".)
Procedure of performing the manual stationary regeneration from the "Regeneration for
Service".
performed only from the "Regeneration for Service".
3. From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"Regeneration for Service", and then perform the "Manual Stationary Regeneration".
a Resetting after KDPF cleaning
From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"KDPF Memory Reset", and then perform "KDPF Cleaning" (reset after KDPF cleaning).
a Resetting after KDPF change
From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"KDPF Memory Reset", and then perform "KDPF Change" (resetting after KDPF change).
a When KCSF in KDPF is changed, always perform resetting procedures for KDPF cleaning
and KDPF change, and then perform the "Manual Stationary Regeneration" from the
"Regeneration for Service" to eliminate moisture from KCSF.
Method of reproducing failure code: Turn starting switch to the ON position.
WA470-7
40-313
40 Troubleshooting
No.
Cause
Increase of soot
accumulation due to
"Regeneration Disable"

machine monitor.
a If the regeneration stop button is pressed down, release it.
a After releasing the "Regeneration Disable", proceed to checks on
causes 2 and after.
Check the abnormality record.
1. Turn starting switch to the ON position.
2. From the machine monitor, displays the abnormality record screen
and check the history of failure codes CA2639, CA1921 and
CA1922.
Interval between failure code CA2639 and CA1921
X360 sec (KOMTRAX history) or X0.1 h (Monitor history screen)
and
Interval between failure code CA1921 and CA1922
X360 sec (KOMTRAX history) or X0.1 h (Monitor history screen)
[When above conditions are satisfied]
a As much soot is accumulated, KDPF regeneration can not be
performed.
1. Replace the KCSF or the KDPF.
2. Turn the starting switch to the ON position, and perform the reset
after KDPF cleaning (see "Related information").
a Check that failure code [CA1922] is changed to [CA1921].
Defective KDPF (KCSF)

(change KCSF)
3.
4.
5.
6.
7.
a If the failure code [CA1922] continues, check the resetting

procedure after KDPF cleaning, and perform the reset after KDPF
cleaning again.
Reset the KDPF after its change (see "Related information").
Perform checks on causes 4 to 7 (When KDPF is changed, this is not
needed.)
Start the engine.
Make sure that machine is in safe condition.
Perform regeneration for service.
a If failure code [CA1922], [CA1921] or [CA2639] is displayed after

manual stationary regeneration is completed, perform checks on
cause 8.
[When above conditions are not satisfied]
(When the actual soot accumulation is less than the displayed value)
Proceed to checks on cause 3 and after.
40-314
WA470-7
40 Troubleshooting
No.
Cause

a When the actual soot accumulation is less than the displayed value
on the machine monitor
1. Proceed to checks on cause 4 to 7.
2. Turn the starting switch to the ON position, and perform the reset
after KDPF cleaning (see "Related information").
a Check that failure code [CA1922] is changed to [CA1921].
Defective KDPF (KCSF)

(abnormal condition of soot
accumulation)
a If the failure code [CA1922] continues, check the resetting

procedure after KDPF cleaning, and perform the reset after KDPF
cleaning again.
5. Perform manual stationary regeneration from user mode.
a If failure code [CA1922] is displayed again within 1 hour after
starting the manual stationary regeneration, perform Step 2 and 3
again.
4
5
6

temperature sensor
temperature sensor
Defective KDPF outlet
temperature sensor
a If failure code [CA1922], [CA1921] or [CA2639] is displayed after

manual stationary regeneration is completed, perform checks on
cause 8.
If failure code [CA3319], [CA3321] or [CA3322] is displayed, perform
troubleshooting for [CA3316], [CA3321] or [CA3322].
2. Monitor differential pressure sensed by KDPF differential pressure
sensor on monitoring screen of machine monitor.
47,100 (kPa)
0 3 (kPa)
Code
Defective KDPF differential

pressure sensor
(including sensor tubes)
a If the differential pressure is outside of the above range, perform the

following.
1. Remove KDPF differential pressure sensor tube.
2. Clean KDPF differential pressure sensor tube to clear clogging.
a If the KDPF differential pressure sensor tube is not clogged,
perform the following.
3. Perform for "Short circuit in wiring harness" of failure code [CA1881]
or [CA1883]. (If no short circuit occurs, replace the KDPF differential
pressure sensor.)
WA470-7
40-315
40 Troubleshooting
No.
Cause
a If failure code [CA1921], or [CA2639] is displayed after manual

stationary regeneration is completed, perform following.

a When black smoke particles are exhausted during engine
acceleration, if it disappears with engine at high idle, the exhaust gas
color is judged as normal.
40-316
WA470-7
40 Troubleshooting
Failure code [CA1923] Dosing Fuel Valve 1 High Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
(PC400-CA1923-400-A-Z0-A)
Dosing Fuel Valve 1 High Error

Failure code
Failure
CA1923
Abnormal low voltage (or high circuit resistance) has occurred in dosing fuel solenoid valve 1
(shut-off valve).
Automatic regeneration is disabled.
Manual stationary regeneration is disabled.
k Since
exhaust connector and KDPF are heated to 500C or above, take care not to
get burn injury.
Related
information
No.
If failure code [CA2732] is also displayed, the ground (GND) leads may be open.
See failure code [CA1925].
Cause


2. Disconnect connector SOV1, and connect T-adapter to male side of
connector.
Resis- Between SOV1 (male) (2) and (1)
4 to 6 z
tance
harness
4 to 6 z
tance
a The resistance is the same as above.
Defective dosing fuel
solenoid valve 1 (shut-off
valve)

2. Disconnect connectors J2 and SOV1, and connect T-adapter to each
female side of connectors.
Between J2 (female) (9) and SOV1 (female)
Max. 1 z
Resis- (1)
tance
Max. 1 z
(2)
2. Disconnect connectors J2 and SOV1, and connect T-adapter to

Between J2 (female) (9) and each pin other
Continuity
than pin (9)
No
continuity
(No sound
is heard)
1. Start engine and run it at low idle for 1 minute.

6
WA470-7
a If another failure code is displayed, perform troubleshooting for it.

40-317
40 Troubleshooting
Circuit diagram related to dosing fuel solenoid valve
40-318
WA470-7
40 Troubleshooting
Failure code [CA1924] Dosing Fuel Valve 1 Low Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
(PC400-CA1924-400-A-Z0-A)
Dosing Fuel Valve 1 Low Error

Failure code
Failure
CA1924
Abnormal high voltage (or low circuit resistance) has occurred in dosing fuel solenoid valve 1
(shut-off valve).
k Since
Related
information
No.
get burn injury.
If sensor connector is disconnected, failure code [CA1923] appears.

Cause


Defective fuel doser solenoid 2. Disconnect connector SOV1, and connect T-adapter to male side of
connector.
valve 1
Between SOV1 (male) (2) and (1)
4 to 6 z
(shut-off valve)
ResisBetween SOV1 (male) (1) and ground (SOV
tance
Min. 1 Mz
body)

harness
Resis4 to 6 z
a The resistance is the same as that of shuttance
off valve.

harness

Resis- Between ground and J2 (female) (9) or SOV1
Min. 1 Mz
(female) (1)
tance
Continuity
WA470-7

than pin (9)
No
continuity
(No sound
is heard)
40-319
40 Troubleshooting
No.
Cause
Defective electric fuel feed

pump

valve)

2. Loosen the joint bolt (JB) of fuel tube.
3. Tilt the switch for the fuel feed pump to ON position while starting
switch is in OFF position.
(Be careful since fuel may spurt out.)
When completing the check, turn the starting switch to ON position or
tilt the switch for the fuel feed pump to OFF position.
If fuel is not fed from the joint bolt (JB), the electric fuel feed pump is
defective.
Replace dosing fuel solenoid valve 1 (shut-off valve).

40-320
WA470-7
40 Troubleshooting
Circuit diagram related to fuel doser
A: From electric fuel pump

B: Fuel return
C: To fuel supply pump
D: From cooling plate of engine controller
JB: Fuel tube joint bolt
PDOSER: Dosing fuel pressure sensor connector
SOV1: Dosing fuel solenoid valve 1 (shut-off valve) connector
SOV2: Dosing fuel solenoid valve 2 (drain valve) connector
1. Fuel doser
2. Fuel supply line
3. Dosing fuel solenoid valve 1 (shut-off valve)
4. Dosing fuel solenoid valve 2 (drain valve)
5. Dosing fuel pressure sensor
WA470-7
40-321
40 Troubleshooting
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
(PC400-CA1925-400-A-Z0-A)
Dosing Fuel Valve 1 In Range Error

Failure code
Failure
CA1925
Dosing fuel solenoid valve 1 does not operate normally. (The valve at fuel inlet is half open
although it must be fully closed. Therefore, the dosing fuel pressure does not drop
sufficiently.)
k Since
get burn injury.
Related
information
No.
In this failure code, the dosing fuel valve 1 (shut-off valve) is determined defective from
the fuel pressure change caused by the operation of solenoid valve.
Therefore, the pressure check by fuel pressure sensor is required.
When the starting switch is turned to ON position, the fuel pressure is checked by the
engine controller.
Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
(Code: 47600 (V))
Pressure detected by dosing fuel pressure sensor can be checked with monitoring
Method of reproducing failure code: Start the engine (and observe for 3 minutes).
<How to clear failure code>
Turn starting switch ON from OFF position to start engine. If failure code is disappeared after
running engine at low idol for approx. 3 minutes, repair is completed.
Cause


pressure sensor

2. Disconnect fuel supply line (2) from fuel doser (1).
If the dosing fuel pressure is clearly different from ambient pressure, the
dosing fuel pressure sensor is defective (see "Related information").
a The dosing fuel pressure must be equal to the ambient pressure.
1.
2.
3.
4.
Defective dosing fuel shut-off

valve
40-322

Disconnect fuel supply line (2) from fuel doser (1).
Disconnect connector SOV1.
Connect the disconnected SOV1 connector to a new SOV connector
socket.
a If connector SOV1 is open, failure code [CA1923] is displayed

and the pressure test (which checks the fuel dosing system) is
not carried out. Also, the electric fuel pump is not driven.
6. Start engine.
If fuel leaks from the fuel connector of fuel supply line (2), dosing fuel
solenoid valve 1 (shut-off valve) (3) is defective.
WA470-7
40 Troubleshooting
No.
Cause
1. Start engine and run it for 3 minute.

2. If this failure code appears, perform procedure for <How to clear
failure code> in "Related information".
If this failure code is still displayed and no failure is found by above
checks, engine controller is defective. (Since this is an internal defect,

B: Fuel return
SOV1: Dosing fuel valve 1 (shut-off valve) connector
SOV2: Dosing fuel valve 2 (drain valve) connector
1. Fuel doser
2. Fuel supply line
WA470-7
40-323
40 Troubleshooting
Failure code [CA1927] Dosing Fuel Press Sens High Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
(PC400-CA1927-400-A-Z0-A)
Dosing Fuel Pressure Sensor High Error

Failure code
Failure
CA1927
Signal voltage from doser fuel pressure sensor indicates a value higher than the
threshold.
k Since
the temperature of the exhaust connector and KDPF will become higher than
500 C , take care not to get burn injury.
Related
information
No.
Signal voltage from the doser fuel pressure sensor can be checked by using monitoring
The pressure sensed by the doser fuel pressure sensor can be checked by using
Method of reproducing failure code: Turn starting switch to ON position (observe for one
minute) (since this is L01, check on the abnormality record screen).
Cause

connector
1. Perform checks referring to harness and connecter related

descriptions in "c: Electrical equipment" of "Checks before
troubleshooting" in "General information on troubleshooting".
for it first.
2. Disconnect connector PDOSER and connect T-adapter to female
side.
Voltage Between PDOSER (female) (1) and (2)
4.75 to 5.25 V
Doser fuel pressure sensor

power supply error

2. Disconnect connector PDOSER.
Defective doser fuel pressure If failure code changes from [CA1927] to [CA1928], doser fuel pressure
sensor
Carry out troubleshooting for cause 1 again.
If failure code [CA1927] does not changes to [CA1928], the wiring
harness or engine controller is defective.

harness
40-324

2. Disconnect connectors J2 and PDOSER, and connect T-adapters to
each female side.
a To check for open circuit in GND line
Resistance

Between J2 (female) (47) and PDOSER
(female) (2)
Max. 1 z
WA470-7
40 Troubleshooting
No.
Cause

2. Disconnect connectors J2 and PDOSER and connect T-adapter to

harness

Continuity Between J2 (female) (36) and each other pin
No continuity
(No sound is
heard)
1. Start the engine and run at low idle for one minute.
Circuit diagram related to doser fuel pressure sensor
WA470-7
40-325
40 Troubleshooting
Failure code [CA1928] Dosing Fuel Press Sens Low Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA1928
Failure
(PC400-CA1928-400-A-Z0-A)
Dosing Fuel Pressure Sensor Low Error

Signal voltage from doser fuel pressure sensor indicates a value lower than the threshold.
k Since
the temperature of the exhaust connector and KDPF will become higher than
500 C , take care not to get burn injury.
Related
information
No.
Signal voltage from the doser fuel pressure sensor can be checked by using monitoring
The pressure sensed by the doser fuel pressure sensor can be checked by using
This failure code is displayed if the sensor connector is disconnected.
Method of reproducing failure code: Turn starting switch to ON position (observe for one
minute) (since this is L01, check on the abnormality record screen).
Cause

connector

for it first.
2. Disconnect connector PDOSER and connect T-adapter to female
side.
Voltage Between PDOSER (female) (1) and (2)
4.75 to 5.25 V
Doser fuel pressure sensor

power supply error

Defective doser fuel pressure 2. Disconnect connector PDOSER.
sensor
Voltage Between PDOSER (3) and (2)
0.5 to 4.5 V

2. Disconnect connectors J2 and PDOSER, and connect T-adapters to
each female side.

harness
40-326

(female) (1)
Resistance

(female) (2)
(female) (3)
Max. 1 z
Max. 1 z
Max. 1 z
WA470-7
40 Troubleshooting
No.
Cause

2. Disconnect connectors J2 and PDOSER and connect T-adapter to

harness

Continuity Between J2 (female) (36) and each other pin
No continuity
(No sound is
heard)
1. Start the engine and run at low idle for one minute.
Circuit diagram related to doser fuel pressure sensor
WA470-7
40-327
40 Troubleshooting
Failure code [CA1942] Crankcase Press Sens In Range Error
(PC400-CA1942-400-A-
Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
3
Failure code
CA1942
Failure
Crankcase Pressure Sensor In Range Error

Output value from crankcase pressure sensor is out of normal range.

None in particular
(Code: 48401 (V))
(Code: 48400 (MPa))

Cause
Defective crankcase pressure Crankcase pressure sensor system may be defective. Perform
sensor
Clogged KCCV filter
Replace KCCV filter.
If error condition is not cleared after KCCV filter is replaced and
emulsion is found inside KCCV, emulsion may block KCCV blowby gas
piping. Perform troubleshooting for leakage of coolant.
If error condition is not cleared after KCCV filter is replaced and failure
code of crankcase pressure high error 2 is generated in short times,
Increase of blowby gas
engine may be seized or turbocharger may be defective. Perform
troubleshooting for mechanical system.
40-328
WA470-7
40 Troubleshooting
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
(PC400-CA1963-400-A-Z0-A)
Dosing Fuel Valve 1 Servo Error

Failure code
Failure
CA1963
Although dosing fuel solenoid valve 1 (shut-off valve) is ON, the pressure detected by
dosing fuel pressure sensor is below the threshold.
k Since
get burn injury.
Related
information
No.
(Code: 47600 (V))
Method of reproducing failure code: Start the engine (and observe for 3 minutes).
Cause


valve)
solenoid valve 2 (drain valve)
pressure sensor
Defective fuel supply pump
2
3
Defective electric fuel feed

pump
Clogging of fuel filter
WA470-7

If failure code [CA559] is also displayed, perform troubleshooting for
[CA559] first.
3. Tilt the switch for the fuel feed pump to ON position while starting
switch is in OFF position.
When completing the check, turn the starting switch to ON position or
tilt the switch for the fuel feed pump to OFF position.
If fuel is not fed from the joint bolt (JB), the electric fuel feed pump is
defective.
Check fuel filter for clogging.
40-329
40 Troubleshooting
No.
Cause

pressure sensor


valve)
Replace dosing fuel solenoid valve 1 (shut-off valve).

B: Fuel return
1. Fuel doser
2. Fuel supply line
40-330
WA470-7
40 Troubleshooting
Failure code [CA1977] Fuel Doser Open/Short Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA1977
Failure
(PC400-CA1977-400-A-Z0-A)
Fuel Doser Open/Short Error

The fuel doser circuit is short-circuited or opened.

k Since
exhaust connector and KDPF are heated to 500 C or above, take care not to
get burn injury.
Related
information
No.
(Code: 47600 (V))
Method of reproducing failure code: Turn starting switch to ON position (observe for 1
minute).
Cause


2. Disconnect connector DOSER, and connect T-adapter to male side
of connector.
Defective fuel doser (injector)
Between DOSER (male) (1) and (2)
0.5 to 2 z
ResisBetween DOSER (male) (1) and ground (fuel
tance
Min. 1 Mz
doser body)

harness
Resis0.5 to 2 z
a The resistance is the same as fuel doser
tance
(injector).

Open circuit in wiring harness 2. Disconnect connectors J2 and DOSER, and connect T-adapters to
each female side.
Between J2 (female) (50) and DOSER (female)
Max. 1 z
Resis- (1)
tance
Between J2 (female) (60) and DOSER (female)
Max. 1 z
(2)

harness
WA470-7

2. Disconnect connectors J2 and DOSER, and connect T-adapters to
either female side.
Resis- Between J2 (female) (50) or DOSER (female)
Min. 1 Mz
(1) and ground (frame)
tance
40-331
40 Troubleshooting
No.
Cause

2. Disconnect connectors J2 and DOSER, and connect T-adapter to
Between J2 (female) (50) and each No continuity (no sound
Continuity
pin other than pin (50)
is heard)
Circuit diagram related to fuel doser (injector)
40-332
WA470-7
40 Troubleshooting
Failure code [CA1993] KDPF Delta Pressure Low Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA1993
Failure
(WA500_7-CA1993-400-A-Z0-A)
KDPF Delta Pressure Low Error

Signal voltage from KDPF delta pressure sensor is lower than threshold value.
a You can cancel above measure by "turning starting switch to OFF position once, then
k Since
(Code: 47101 (V))
Related
information Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
"Disassembly and assembly of KDPF".
Machine
O
clearing
after repair trouble.
No.
Cause
1 pressure sensor
troubleshooting for [CA1879], [CA1881], or [CA1883] first.
KCSF abnormality 1
1. Turn starting switch to OFF position once, and then turn it to ON

position.
2. Check whether failure codes other than [CA1993] are generated.
3. Start engine and accelerate it suddenly from low idle to full speed 2
times, then run it at high idle for 5 seconds. During above operation,
check exhaust gas color at exhaust pipe when engine accelerates
suddenly and runs at high idle.
4. If black smoke is exhausted from exhaust pipe in above step 3,
KCSF is abnormal. Check whether KCSF is installed. If yes, check
KCSF for damage and contamination by foreign substances, and fix
trouble as needed.
a If black smoke is not exhausted, proceed to checks on causes 3 and
after.
WA470-7
40-333
40 Troubleshooting

Perform following checks.

1. Check whether KDPF delta pressure sensor tube is installed.
2. Check whether KDPF delta pressure sensor tube is connected
correctly.
3. Remove KDPF delta pressure sensor tube and check it for clogging,
cracks, and damage.
4. Check both ends of KDPF delta pressure sensor tube for loose
connection.

k Place
machine on a level ground and set parking brake lever to LOCK position.
1.
2.
3.
4.

Start engine and run it at low idle (with no load) for approximately 1 minute.
Run engine at high idle and perform hydraulic relief of work equipment for continuous 1 minute.
If failure code disappears after implementing steps 1 to 4, repair work is complete.
If failure code still remains displayed, repeat above steps 5 and after.
6. Start engine and run it at low idle (with no load) for approximately 1 minute.
7. Perform torque converter stall operation for approximately continuous 40 seconds with throttle position at
100% (see troubleshooting for failure code [CA1883]).
a Take care not to overheat torque converter oil.
command.
No.
Cause
If this failure code is still displayed after above procedures are
implemented, remove KDPF and remove KCSF, and check filter for
4 KCSF abnormality 2
damage or foreign material in it. After fixing trouble, implement above "B.
Machine operation for clearing failure code".
40-334
WA470-7
40 Troubleshooting
Failure code [CA2185] Throt Sensor Sup Volt High Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
CA2185
Failure
(WA380_7-CA2185-400-A-Z0-A)
Throttle Sensor Supply Voltage High Error

High voltage (5.25 V or higher) appears in throttle sensor power supply circuit.
Sets throttle position at 0% with accelerator pedal released and at 50 % with accelerator

Cause

(accelerator pedal)

2. Disconnect connector PD and turn starting switch to ON position.
If this failure code disappears, throttle sensor is defective.
a Other failure codes are also displayed. They are generated because
of disconnection of connector. Ignore failure codes other than
[CA2185].

female side of EC3.
Min. 1 Mz
Resis- other than pin (42)
tance
Between EC3 (female) (42) and EC3
Min. 1 Mz
(female) (1)

harness
WA470-7

2. Disconnect connector PD and connect T-adapters to female side.
4.75 to 5.25
Voltage Between PD (female) (1) and ground
V
2. Disconnect connectors EC3 and connect T-adapters to female side.
4.75 to 5.25
Voltage Between EC3 (42) and (41)
V
40-335
40 Troubleshooting
40-336
WA470-7
40 Troubleshooting
Failure code [CA2186] Throt Sensor Sup Volt Low Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
CA2186
Failure
(WA380_7-CA2186-400-A-Z0-A)
Throttle Sensor Supply Voltage Low Error

Low voltage appears in throttle sensor power supply circuit.

Sets throttle position at 0% with accelerator pedal released and at 50 % with accelerator

Cause

(accelerator pedal)

2. Disconnect connector PD and turn starting switch to ON position.
If this failure code disappears, throttle sensor is defective.
a Other failure codes are also displayed. They are generated because
of disconnection of connector. Ignore failure codes other than
[CA2186].
either female side.
Min. 1 Mz
PD (female) (1)
tance

harness

female side of EC3.
Min. 1 Mz
other than pin (42)
tance
WA470-7

2. Disconnect connectors EC3 and connect T-adapters to male side.
3. Turn starting switch to ON position with wiring harness
disconnected.
Voltage Between EC3 (42) and (41)
4.75 to 5.25 V
40-337
40 Troubleshooting
40-338
WA470-7
40 Troubleshooting
Failure code [CA2249] Rail Press Very Low Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
CA2249
Rail Pressure Very Low Error

Supply pump does not feed fuel (level 2).

Limits engine output (limits common rail pressure) and allows engine to run.
Signal voltage from common rail pressure sensor can be checked by using monitoring
Cause
Supply pump pressure low
error
WA470-7
Failure
(PC400-CA2249-400-A-Z0-A)

40-339
40 Troubleshooting
Failure code [CA2265] Fuel Feed Pump Open Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
General
information
No.
Failure code
CA2265
Failure
(WA470_7-CA2265-400-A-Z0-A)
Fuel Feed Pump Open Error

Fuel feed pump drive signal circuit is open (when controller drives pump time switch).
None in particular
KDPF regeneration does not work.
a Since this failure code has action level of L01, check whether this failure code is currently
active on abnormality record screen.
Cause
Defective wiring
harness connector

harness
(wire breakage or
connector)
Defective engine
controller or defective
time switch

a If this failure code is displayed, perform following troubleshooting.
40-340

2. Disconnect connectors EC3 and E28, and connect T-adapters to each
female side.
Between EC3 (female) (14) and E28 (female) (5)
Max. 1 z
Resistance
Between E28 (female) (10) and ground
Max. 1 z
If no failure is found by above checks, engine controller or time switch is
defective.
Reference
When time switch
Max. 1 V
(21)
operates
Voltage
When time switch stops 20 to 30 V
(21)
WA470-7
40 Troubleshooting
Circuit diagram related to fuel feed pump
WA470-7
40-341
40 Troubleshooting
Failure code [CA2266] Fuel Feed Pump Short Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
General
information
No.
Failure code
CA2266
Failure
(WA470_7-CA2266-400-A-Z0-A)
Fuel Feed Pump Short Error

Fuel feed pump drive signal circuit shorts (when controller drives pump time switch).
None in particular
KDPF regeneration does not work.
a Since this failure code has action level of L01, check whether this failure code is currently
active on abnormality record screen.
Cause
Defective wiring
harness connector

Defective electric fuel

feed pump

If this failure code [CA2266] disappears, electric fuel feed pump is defective.
Defective pump time

switch
a Ignore failure codes other than this code, which are generated due to
disconnection of connector.
If this failure code [CA2266] disappears, pump time switch is defective.

harness
circuit)

harness
Defective engine
controller or defective
time switch
40-342
a Ignore failure codes other than this code, which are generated due to
disconnection of connector.
2. Disconnect connectors EC3 and E28, and connect T-adapter to either
female side.
Between ground and EC3 (female) (14) or E28
Min. 1 Mz
2. Disconnect connectors EGC3, EPP, and EFP, and connect T-adapters to
female side of EC3 and E29.
Between EC3 (female) (14) and each of (21), (22),
Min. 1 Mz
Resistance (31), and (32)
Between E29 (female) (1) and (2)
Min. 1 Mz
If no failure is found by above checks, engine controller or time switch is
defective.
Reference
When time switch
Max. 1 V
(21)
operates
Voltage
When time switch stops 20 to 30 V
(21)
WA470-7
40 Troubleshooting
WA470-7
40-343
40 Troubleshooting
Failure code [CA2271] EGR Valve Pos Sens High Error

Action level
L03
Detail of
failure
Action of
controller
Failure code
CA2271
Failure
(PC400-CA2271-400-A-Z0-A)
EGR Valve Position Sensor High Error

High voltage appears in EGR valve lift sensor signal circuit.

Problem on
machine
Related
information
Signal voltage from EGR valve lift sensor can be checked by using monitoring function.
(Code: 18100 (mm))
EGR valve position (mm) sensed by EGR valve lift sensor can be checked by using
monitoring function. (Code: 18101 (V))
No.
Cause


connector

supply system
Defective EGR valve lift

sensor
(internal defect)

2. Disconnect connectors J2 and SEGR, and connect T-adapters to
each female side.
a To check for open circuit in GND line
Resis- Between J2 (female) (47) and SEGR (female)
Max. 1 z
(2)
tance

2. Disconnect connectors J2 and SEGR, and connect T-adapter to
either female side.
Between J2 (female) (30) and (59), between
Resis- SEGR (female) (1) and (3), or between SEGR
Min. 1 Mz
tance
Hot short circuit in harness

40-344

2. Disconnect connector SEGR.
3. Turn starting switch to ON position (with connector SEGR
disconnected).

2. Disconnect connector SEGR and connect T-adapter to female side.
3. Turn starting switch to ON position (with connector SEGR
disconnected).
Voltage Between SEGR (female) (3) or (4) and (2)
Max. 1 V
Reference
1.0 to 4.0
V
WA470-7
40 Troubleshooting
Circuit diagram related to EGR valve lift sensor
WA470-7
40-345
40 Troubleshooting
Failure code [CA2272] EGR Valve Pos Sens Low Error

Action level
L03
Detail of
failure
Action of
controller
Failure code
CA2272
Failure
(PC400-CA2272-400-A-Z0-A)
EGR Valve Position Sensor Low Error

Low voltage appears in EGR valve lift sensor signal circuit.

Problem on
machine
Related
information
Signal voltage from EGR valve lift sensor can be checked by using monitoring function.
(Code: 18101 (V))
EGR valve position (mm) sensed by EGR valve lift sensor can be checked by using
monitoring function. (Code: 18100 (mm))
No.
Cause

connector


supply system

2. Disconnect connector SEGR and connect T-adapter to female side.
Between SEGR (female) (1) and
Power
4.75 to 5.25
Voltage
supply
(2)
V
2. Disconnect connectors SEGR and J2, and connect T-adapters to
each female side.

harness
a If power supply voltage in check on cause

2 is normal, this check is not required.
Between J2 (female) (30) and SEGR
(female) (1)
Resistance

Between J2 (female) (47) and SEGR
(female) (2)
Between J2 (female) (59) and SEGR (female)
(3), (4) (sensor output)
Max. 1 z
Max. 1 z
Max. 1 z

harness

either female side.
Min. 1 Mz
between SEGR (female) (3) and ground
tance

harness

either female side.
Min. 1 Mz
SEGR (female) (2) and (3)
tance
40-346
WA470-7
40 Troubleshooting
No.
Cause

sensor

2. Insert T-adapter into connector J2 or SEGR.
Between J2 (59) and (47), or between SEGR
Voltage
1.0 to 4.0 V
(3) and (2)
Circuit diagram related to EGR valve lift sensor
WA470-7
40-347
40 Troubleshooting
Failure code [CA2349] EGR Valve Solenoid Open Error

Action level
L03
Detail of
failure
Action of
controller
Failure code
CA2349
Failure
(PC400-CA2349-400-A-Z0-A)
EGR Valve Solenoid Open Error

Open circuit is in EGR valve solenoid drive circuit .

Problem on
machine
Related
information
Signal current to the EGR valve solenoid can be checked with monitoring function. (Code:
48600 (mA))
No.
Cause

connector


Defective EGR valve solenoid 2. Disconnect connector EGR-SOL and connect T-adapter to male
side.
Resis- Between EGR-SOL (male) (1) and (2)
5 to 10 z
tance
Open or short circuit in wiring a If resistance is above 1 Mz, wiring harness has open circuit. If
harness
resistance is below 1z, wiring harness has short circuit.
5 to 10 z
tance
Open circuit in wiring harness 2. Disconnect connectors J2 and EGR-SOL, and connect T-adapters to
each female side.
Between J2 (female) (6) and EGR-SOL
Max. 1 z
Resis- (female) (1)
tance
Between J2 (female) (16) and EGR-SOL
Max. 1 z
(female) (2)

40-348

2. Disconnect connector EGR-SOL and connect T-adapter to male
side.
3. Turn starting switch to ON position (with connector EGR-SOL
disconnected).
Voltage
Between EGR-SOL (female) (1) and (2)
Max. 3 V
defective.
WA470-7
40 Troubleshooting
Circuit diagram related to EGR valve solenoid
WA470-7
40-349
40 Troubleshooting
Failure code [CA2353] EGR Valve Solenoid Short Error

Action level
L03
Detail of
failure
Action of
controller
Failure code
CA2353
Failure
(PC400-CA2353-400-A-Z0-A)
EGR Valve Solenoid Short Error

Short circuit is in EGR valve solenoid drive circuit.

Problem on
machine
Related
information
Signal current to the EGR valve solenoid can be checked with monitoring function. (Code:
48600 (mA))
No.
Cause

connector


Defective EGR valve solenoid 2. Disconnect connector EGR-SOL and connect T-adapter to male
side.
5 to 10 z
Resis- Between EGR-SOL (male) (1) and (2)
tance
Between EGR-SOL (male) (1) and ground
Min. 1 Mz
2. Disconnect connector J2 and connect T-adapter to male side.
harness
5 to 10 z
tance
2. Disconnect connectors J2 and EGR-SOL, and connect T-adapter to
either female side.
Min. 1 Mz
EGR-SOL (female) (1) and (2)
tance
Ground fault in wiring harness 2. Disconnect connectors J2 and EGR-SOL.
Resis- Between J2 (female) (6) or EGR-SOL (female)
(1) and ground
tance

40-350
Min. 1 Mz

2. Disconnect connector EGR-SOL and connect T-adapter to male
side.
3. Turn starting switch to ON position (with connector EGR-SOL
disconnected).
Voltage Between EGR-SOL (female) (1) and (2)
Max. 3 V
If no abnormality is found in the above, engine controller is defective.
WA470-7
40 Troubleshooting
Circuit diagram related to EGR valve solenoid
WA470-7
40-351
40 Troubleshooting
Failure code [CA2357] EGR Valve Servo Error

Action level
L03
Detail of
failure
Action of
controller
(PC400-CA2357-400-A-Z0-A)
EGR Valve Servo Error

Failure code
Failure
CA2357
EGR valve servo error occurs.
(EGR lift sensor sends back EGR valve position value that differs from command value.)
Does not supply current to EGR valve (closes EGR valve).
Fully open KVGT.
Problem on
machine
Related
information
Position of EGR valve can be checked with monitoring function. (Code: 18100 EGR Valve
Position (mm))
No.
Cause
Insufficient EGR valve drive

pressure
4
5
6
7
8
9

them.
a For testing of EGR valve drive pressure, see .Testing and adjusting,
"Testing EGR valve and KVGT drive oil pressure".
If EGR valve drive pressure is abnormal, perform checks on causes 3
and 4.
a For check of engine oil pressure, see Testing and adjusting, "Testing
engine oil pressure".
system (main circuit)
If engine oil pressure is abnormal, perform troubleshooting (S mode) for
mechanical system. (S-12 Oil pressure lowers.)
Defective oil pump for EGR Oil pump or relief valve for EGR valve circuit may be defective. Check
valve
them.
Defective hydraulic piping for Hydraulic piping of EGR valve circuit may be defective. Check it.
EGR valve
Defective return hydraulic
Return hydraulic piping for EGR valve circuit may be defective. Check it.
piping for EGR valve
EGR valve may have mechanical trouble. Check it.
Defective EGR valve
Perform troubleshooting for failure codes [CA2271] and [CA2272].
sensor
If no failure is found by checks on causes 1 to 8, engine controller is
defective.
40-352
WA470-7
40 Troubleshooting
Failure code [CA2381] KVGT Pos Sens High Error

Action level
L03
Detail of
failure
Action of
controller
Failure code
CA2381
Failure
(PC400-CA2381-400-A-Z0-A)
KVGT Position Sensor High Error

High voltage appears in KVGT position sensor signal circuit.

Problem on
machine
Related
information
Signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
Position (mm) sensed by KVGT position sensor can be checked with monitoring function.
(Code: 48700 (mm))
No.
Cause


connector

supply system
Defective KVGT position

sensor
(internal defect)

2. Disconnect connectors J2 and SVGT, and connect T-adapters to
each female side.
Resis- Between J2 (female) (47) and SVGT (female)
Max. 1 z
(B)
tance

2. Disconnect connectors J2 and SVGT, and connect T-adapters to
either female side.
Min. 1 Mz
SVGT (female) (A) and (C)
tance

WA470-7

If failure code [CA1695] or [CA1696] is displayed, perform
2. Disconnect connector SVGT.
3. Turn starting switch to ON position (with connector SVGT
disconnected).

2. Disconnect connector SVGT and connect T-adapters to female side.
3. Turn starting switch to ON position (with connector SVGT
disconnected).
Voltage Between SVGT (female) (C) and (B)
Max. 1 V
Reference
1.0 to 4.0
V
40-353
40 Troubleshooting
Circuit diagram related to KVGT position sensor
40-354
WA470-7
40 Troubleshooting
Failure code [CA2382] KVGT Pos Sens Low Error

Action level
L03
Detail of
failure
Action of
controller
Failure code
CA2382
Failure
(PC400-CA2382-400-A-Z0-A)
KVGT Position Sensor Low Error

Low voltage appears in KVGT position sensor signal circuit.

Problem on
machine
Related
information
Signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
Position (mm) sensed by KVGT position sensor can be checked with monitoring function.
(Code: 48700 (mm))
No.
Cause

connector


supply system

2. Disconnect connector SVGT and connect T-adapters to female side.
Between SVGT (female) (A) and
Power
4.75 to 5.25
Voltage
supply
(B)
V
2. Disconnect connectors SVGT2 and J, and connect T-adapters to
each female side.


Between J2 (female) (30) and SVGT
(female) (A)
Resistance

Between J2 (female) (47) and SVGT
(female) (B)
Between J2 (female) (38) and SVGT (female)
(C) (Sensor output)
Max. 1 z
Max. 1 z
Max. 1 z

2. Disconnect connectors J2 and SVGT, and connect T-adapter to
either female side.
Min. 1 Mz
between SVGT (female) (C) and ground
tance

harness

2. Disconnect connectors J2 and SVGT, and connect T-adapter to
either female side.
Resis- Between ENG (female) (38) and (47), or
Min. 1 Mz
between SVGT (female) (B) and (C)
tance
WA470-7
40-355
40 Troubleshooting
No.
Cause

sensor

2. Insert T-adapter into connector J2 or SVGT.
Between J2 (38) and (47), or between SVGT
Voltage
1.0 to 4.0 V
(C) and (B)
Circuit diagram related to KVGT solenoid
40-356
WA470-7
40 Troubleshooting
Failure code [CA2383] KVGT Solenoid Open Error

Action level
L03
Detail of
failure
Action of
controller
Failure code
CA2383
Failure
(PC400-CA2383-400-A-Z0-A)
KVGT Solenoid Open Error

Open circuit occurs in KVGT solenoid drive circuit.

Problem on
machine
Related
information
Signal current to KVGT solenoid can be checked with monitoring function. (Code: 48600
(mA))
No.
Cause

connector

defective.
2. Disconnect connector VGT-SOL and connect T-adapter to male
side.
Resis- Between VGT-SOL (male) (1) and (2)
5 to 10 z
tance
2. Disconnect connector J2 and connect T-adapter to female side.
Defective KVGT solenoid


harness

Open circuit in wiring harness 2. Disconnect connectors J2 and VGT-SOL, and connect T-adapters to
each female side.
Between J2 (female) (10) and VGT-SOL
Max. 1 z
Resis- (female) (1)
tance
Between J2 (female) (20) and VGT-SOL
Max. 1 z
(female) (2)

harness
WA470-7
a If resistance is 1 Mz or higher, harness has open circuit. If it is 1 z

or below, harness has short circuit.
5 to 10 z
tance

2. Disconnect connector VGT-SOL and connect T-adapter to female
side.
3. Turn starting switch to ON position (with connector VGT-SOL
disconnected).
Voltage Between VGT-SOL (female) (1) and (2)
Max. 3 V
40-357
40 Troubleshooting
40-358
WA470-7
40 Troubleshooting
Failure code [CA2386] KVGT Solenoid Short Error

Action level
L03
Detail of
failure
Action of
controller
Failure code
CA2386
Failure
(PC400-CA2386-400-A-Z0-A)
KVGT Solenoid Short Error

Short circuit is detected in KVGT solenoid drive circuit.

Problem on
machine
Related
information
Signal current to KVGT solenoid can be checked with monitoring function. (Code: 48600
(mA))
No.
Cause

connector

KVGT solenoid defective


2. Disconnect connector VGT-SOL and connect T-adapters to male
side.
5 to 10 z
Resis- Between VGT-SOL (male) (1) and (2)
tance
Between VGT-SOL (male) (1) and ground
Min. 1 Mz
harness
5 to 10 z
tance
2. Disconnect connectors J2 and VGT-SOL, and connect T-adapter to
either female side.
Min. 1 Mz
VGT-SOL (female) (1) and (2)
tance
Ground fault in wiring harness 2. Disconnect connectors J2 and VGT-SOL, and connect T-adapters to
each female side.
Resis- Between J2 (female) (10) or VGT-SOL (female)
Min. 1 Mz
(1) and ground
tance

WA470-7

2. Disconnect connector VGT-SOL and connect T-adapter to female
side.
3. Turn starting switch to ON position (with connector VGT-SOL
disconnected).
Voltage Between VGT-SOL (female) (1) and (2)
Max. 1 V
If no abnormality is found in the above, engine controller is defective.
40-359
40 Troubleshooting
40-360
WA470-7
40 Troubleshooting
Failure code [CA2387] KVGT Servo Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
KVGT servo error

Failure code
Failure
CA2387
KVGT servo error has occurred.
(Response from KVGT position sensor differs from KVGT opening command.)

No.
Cause
Defect
in
related
system
1
2
3
4
5
6
8
9
(PC400-CA2387-400-A-Z0-A)
KVGT drive oil pressure

abnormal

If another failure code is indicated, carry out troubleshooting for it.
For testing of KVGT drive pressure, see Testing and adjusting, "Testing
EGR valve and KVGT oil pressure".
a If the KVGT drive pressure is abnormal, check causes 3 and 4.

For check of engine oil pressure, see Testing and adjusting, "Testing
Defective engine oil pressure engine oil pressure".
system
a If engine oil pressure is not normal, perform troubleshooting (S
(main circuit)
mode) for mechanical system. (S-12 Oil pressure lowers.)
Defective oil pump for KVGT Oil pump or relief valve for KVGT circuit may be defective. Check them.
Defective oil supply pipe for Oil supply pipe for the KVGT circuit may be defective. Check it.
KVGT
Defective oil return pipe for
Oil return pipe for KVGT circuit may be defective. Check it.
KVGT
KVGT may have mechanical failure. Check it.
If values of KDOC inlet temperature: approximately 250C or below and
KVGT solenoid current: approximately 1000 mA remain unchanged
Defective KVGT
after performing regeneration for service, KVGT is defective.
(Since the time required for manual stationary regeneration depends on
the accumulated soot level, see failure code CA2639. )
Perform troubleshooting for failure codes [CA2381] and [CA2382].
sensor
WA470-7
40-361
40 Troubleshooting
Failure code [CA2555] Grid Htr Relay Volt Low Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
General
information
No.
Failure code
CA2555
Failure
(WA470_7-CA2555-400-A-Z0-A)
Grid Heater Relay Voltage Low Error

Open circuit is in preheat relay drive circuit (primary circuit).

None in particular
Intake air heater does not work in auto preheating mode (resulting in degraded startability
and emission of white smoke at low temperatures).
Method of reproducing failure code: Turn starting switch to the ON position (Engine
coolant temperature: Max. -5 C).
Troubleshooting of this failure code covers circuits from engine controller to primary circuit
(coil) of preheat relay L125.
For troubleshooting of secondary circuit of heater relay and preheat relay L125, see E-2 in
E-mode troubleshooting.
Cause
Defective wiring
harness connector

Defective preheat
relay L125

2. Disconnect relay L125 and connect T-adapter to male side.
Resistance Between L125 (male) (1) and (2)
200 to 400 z

Open or short circuit in 2. Disconnect connectors EC3 and connect T-adapter to female side.
Between EC3 (female) (4) and ground
wiring harness
Resistance
200 to 400 z
a To measure coil resistance of relay L125

harness
Defective engine
controller
40-362

2. Disconnect connector EC3 and relay L125, and connect T-adapters to each
female side.
Between EC3 (female) (4) and L125 (female) (1)
Max. 1 z
Resistance
Between L125 (female) (2) and ground
Max. 1 z
WA470-7
40 Troubleshooting
Circuit diagram related to intake air heater relay
WA470-7
40-363
40 Troubleshooting
Failure code [CA2556] Grid Htr Relay Volt High Error
(WA470_7-CA2556-400-A-Z0-A)
Grid Heater Relay Voltage High Error

Action level Failure code
Failure
L01
CA2556
Detail of
Short circuit is in preheat relay drive circuit (primary circuit).
failure
Action of
None in particular
controller
Problem on Intake air heater does not work in auto preheating mode (resulting in degraded startability
and emission of white smoke at low temperatures).
machine
Method of reproducing failure code: Turn starting switch to the ON position (Engine coolant
temperature: Max. -5 C).
General
information Troubleshooting of this failure code covers circuits from engine controller to primary circuit
(coil) of preheat relay L125.
For troubleshooting of secondary circuit of heater relay and preheat relay L125, see E-2 in
E-mode troubleshooting.
No.
Cause
Defective wiring
harness connector

Defective preheat
relay L125

2. Disconnect relay L125 and connect T-adapter to male side.

harness

2. Disconnect connector EC3 and relay L125, and connect T-adapter to either
female side.
Between ground and EC3 (female) (4) or L125
Min. 1 Mz

harness
Defective engine
controller
40-364
200 to 400 z

2. Disconnect connector EC3 and relay L125, and connect T-adapter to
female side of EC3.
No continuity
Between EC3 (female) (4) and each
Continuity
(No sound is heard)
WA470-7
40 Troubleshooting
Circuit diagram related to intake air heater relay
WA470-7
40-365
40 Troubleshooting
Failure code [CA2637] KDOC Face Plugging

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
(PC400-CA2637-400-A-Z0-A)
KDOC Face Plugging

Failure code
Failure
CA2637
KDOC face is plugged.
1. The KDOC surface is contaminated due to the operating conditions, and the catalytic
efficiency has dropped (clean the DOC).
2. Deteriorated KDOC due to high temperature, dropped efficiency due to deposit, or
dropped efficiency due to damage (Replace KDOC with a new or used one.)
Stops fuel dosing.
None in particular
k Since
temperature of the turbocharger exhaust connector, KDOC and KDPF

exceeds 500 C, take care not to get burn injury.
a When KDOC in KDPF is changed, perform reset procedure for KDOC change and then
finish repair.
Procedure of performing manual stationary regeneration from Regeneration for Service.
Related
information
performed only from "Regeneration for Service".
3. From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"02 Regeneration for service", and then perform the "Manual Stationary
Regeneration".
If the KDOC efficiency is still low, this failure code [CA2637] may be displayed repeatedly
and failure code [CA1691] indicating the poor regeneration may be displayed.
Start the engine and perform the warm-up operation, then operate the machine under
normal conditions for approximately 3 hours.
(If the exhaust gas temperature is high, this operation time can be reduced.)
No.
Cause
1 Defective KVGT
2
Defective EGR valve
Defective turbocharger
exhaust connector

If failure code [CA238*] is displayed, troubleshoot for it first.
If failure code [CA227*], [CA23**] or others is displayed, troubleshoot for
it first.
1. Remove turbocharger exhaust connector.
2. Check for oil or fuel inside turbocharger exhaust connector.
If contaminated, troubleshoot for failure codes [CA227*], [CA23**],
etc., relating to the EGR valve and KVGT.
Defective exhaust connector Check exhaust system between turbocharger and KDPF for damage of
and ducts connected to the
connector and ducts, and for loose connection.
KDPF
1. Rapidly accelerate engine from low idle to high idle two times, and
then keep engine running at high idle for 5 seconds.
If excessive black smoke is exhausted when running the engine at
high idle, troubleshoot for "S-9 KDPF gets clogged in a short time".
idle.
40-366
WA470-7
40 Troubleshooting
No.
Cause
Defective KDOC
1.
2.
Remove KDPF.
Remove KDOC.
Check KDOC for cracks (replace KDOC if cracks are found).
Check whether more than 50% of KDOC inlet surface is plugged with
soot or not.
(KDOC cleaning)
a When KDOC is replaced, perform check on cause 7. And when

cleaning of KDOC is done, perform checks on causes 7 and 8.
Reset after KDOC change
1. Install KDOC and KDPF.

3. From service menu of machine monitor, display the "Diagnostic
Tests" screen, open "03 KDPF Memory Reset", and then perform "03
KDOC Change" (reset after KDOC change).
a Check that reset after KDOC change is completed successfully (by
reset count). If not, perform troubleshooting again.
a When KDOC is replaced, finish troubleshooting without performing
1. Perform manual stationary regeneration from Regeneration for

Service.
3. Repeat the "Regeneration for service" (to check the repair
Performing manual stationery
completion).
regeneration
a If failure code [CA2637] is displayed after you have completed the
"Regeneration for Service", the KDOC efficiency has dropped.
Replace the KDOC and perform reset after KDOC change (see
Cause 7).
a Operate the machine approximately 3 hours and check that this failure code is not displayed.
WA470-7
40-367
40 Troubleshooting
Failure code [CA2639] Manual Stationary Regeneration Request
(HM300_3-
CA2639-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Manual Stationary Regeneration Request

Failure code
Failure
CA2639
Manual stationary regeneration request prompts operator to "forcibly" perform stationary
regeneration, which is more effective to remove soot, because soot accumulation in the
KCSF of KDPF has exceeded level for automatic regeneration.
Soot accumulation reaches level 4 or 5.
Normal control
None in particular
k Since
injury.
Related
information
a If manual stationary regeneration is started when KDOC inlet temperature is below

approximately 250C, fuel dosing will be disabled, so actually regeneration will not start.
KVGT solenoid current can be checked with monitoring function. (Code: 48800 (mA))
engine is at idle (KDPF regeneration is not executed) are approx. 100 to 250C, and
difference between these temperatures is approx. 10C. (KDOC inlet temperature >
When active regeneration (manual stationary regeneration) is in progress, KDOC inlet
temperature is approx. 250 to 400C, and KDOC outlet temperature and KDPF outlet
temperature are approx. 450 to 550C.
How to perform stationary manual regeneration
3. From the service menu of the machine monitor, display the "Diagnostic Tests" screen,
open "Regeneration for service", and perform the "Manual Stationary Regeneration".
a While the regeneration for service is in progress, the monitoring screen is displayed by
performing the switch operation: keep pressing r on the left bottom of the switch panel
and sequentially press numeral input switch [1], [2] and [3] in order.
(For detail, see Testing and adjusting Regeneration for service . )
40-368
WA470-7
40 Troubleshooting
Related
information
a Time required for manual stationary regeneration depends on the accumulated soot in
If soot accumulation is level 4: Approx. 40 minutes to 1 hour
If soot accumulation is level 5: Approx. 1 to 2 hours
If soot accumulation is level 6 or 7: Approx. 1 to 3 hours
a If this failure code is still displayed after several hours have passed after manual
stationary regeneration, perform following troubleshooting procedures.
a If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for it first.
No.
Cause
Increase of soot
accumulation due to
"Regeneration Disable"

machine monitor.
If the regeneration stop button is pressed down, release it.
4. Start the engine, and perform the manual stationary regeneration
from user mode.

temperature sensor
Defective KVGT
Defective KDPF (KDOC,

KCSF)
a If the regeneration does not complete within 3 hours, proceed to

checks on cause 2 and after.
If there is a significant difference between KDOC inlet temperature
and KDOC outlet temperature when KDPF is completely cool or
engine running at idle (not regenerating), replace KDOC inlet
temperature sensor.
If values of KDOC inlet temperature: approximately 250C or below and
KVGT solenoid current: approximately 1000 mA remain unchanged after
performing regeneration for service, KVGT is defective.
(The time required for manual stationary regeneration depends on the
accumulated soot level. See related information.)
1. Perform the troubleshooting "S-22 Active regeneration takes time" of
S mode.
a If failure code [CA2639] is displayed after the manual stationary
regeneration is completed, perform the following.

1. Rapidly accelerate engine from low idle to high idle two times, and
then keep engine running at high idle for 5 seconds.
running it at high idle, troubleshoot for "S-9 KDPF gets clogged in a
short time".
a When black smoke particles are exhausted during engine
acceleration, if it disappears with engine at high idle, the exhaust gas
color is judged as normal.
WA470-7
40-369
40 Troubleshooting
No.
6
Cause
40-370

WA470-7
40 Troubleshooting
Failure code [CA2732] Dosing Fuel Valve 2 High Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
(PC400-CA2732-400-A-Z0-A)
Dosing Fuel Valve 2 High Error

Failure code
Failure
CA2732
Abnormal low voltage (or high circuit resistance) has occurred in dosing fuel solenoid valve 2
(drain valve).
k Since
get burn injury.
Related
information
No.
If failure code [CA1923] is also displayed, the ground (GND) leads may be open.
Cause


connector.
Resis- Between SOV2 (male) (2) and (1)
4 to 6 z
tance
harness
Resis4 to 6 z
a The resistance is the same as that of
tance
dosing fuel solenoid valve 2.
2. Disconnect connectors J2 and SOV2, and connect T-adapter to each
female side of connectors.
Max. 1 z
Resis- (1)
tance
Max. 1 z
(2)
Continuity
WA470-7

than pin (8)
No
continuity
(No sound
is heard)
40-371
40 Troubleshooting
No.
Cause


40-372
WA470-7
40 Troubleshooting
Failure code [CA2733] Dosing Fuel Valve 2 Low Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
(PC400-CA2733-400-A-Z0-A)
Dosing Fuel Valve 2 Low Error

Failure code
Failure
CA2733
Abnormal high voltage (or low circuit resistance) has occurred in dosing fuel solenoid valve 2
(drain valve).
k Since
Related
information
No.
get burn injury.
If sensor connector is disconnected, failure code [CA2732] is displayed.

Cause


connector.
Between SOV2 (male) (2) and (1)
4 to 6 z
ResisBetween SOV2 (male) (1) and ground (dosing
tance
Min. 1 Mz
fuel valve 2 body)

harness
Resis4 to 6 z
a The resistance is the same as that of
tance
dosing fuel solenoid valve 2.

harness

Resis- Between ground (frame) and J2 (female) (8) or
Min. 1 Mz
SOV2 (female) (1)
tance

Continuity
than pin (8)
No
continuity
(No sound
is heard)

6
WA470-7

40-373
40 Troubleshooting
40-374
WA470-7
40 Troubleshooting
Failure code [CA2741] Dosing Fuel Valve Swap Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
(PC400-CA2741-400-A-Z0-A)
Dosing Fuel Valve Swap Error

Failure code
Failure
CA2741
Dosing fuel solenoid valve 1 (shut-off valve) and dosing fuel solenoid valve 2 (drain valve)
are connected reversely.
k Since
get burn injury.
Related
information
No.
1


Cause
Reverse connection of wiring
1. Check connectors SOV1 and SOV2.
harness

B: Fuel return
WA470-7
40-375
40 Troubleshooting
1. Fuel doser
2. Fuel supply line
40-376
WA470-7
40 Troubleshooting
Failure code [CA2765] Inj Trim Data Error

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
CA2765
Injector Trim Data Error

Injector trim data input to to the engine controller is not correct.
Since the engine controller can not know the production variance of each injector, the
exhaust gas purification will be degraded.
Cause
Injector trim data mismatch
WA470-7
Failure
(PC400-CA2765-400-A-Z0-A)

a When replacing injectors, see chapter 30 Testing and adjusting,
"Injector trim".
40-377
40 Troubleshooting
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
(PC400-CA2878-400-A-Z0-A)
Dosing Fuel Valve 2 Servo Error

Failure code
Failure
CA2878
When fuel pressure is checked immediately after engine startup, the ON/OFF command
of dosing fuel solenoid valve 2 (SOV2 drain valve) does not match with the expected
value of fuel pressure detected by dosing fuel pressure sensor.
1. When Open SOV1 Valve and Close SOV2 Valve commands are given, the dosing fuel
pressure detected by dosing fuel pressure sensor does not increase sufficiently.
2. When Close SOV1 Valve and Open SOV2 Valve commands are given, the dosing fuel
pressure detected by dosing fuel pressure sensor does not decrease sufficiently.
k Since
get burn injury.
Related
information
No.
2
3
4
5
(Code: 47600 (V))
Method of reproducing failure code: Start the engine (observe for 3 minutes).
Cause

Defective fuel system
valve)
pressure sensor
harness
40-378

For above check, see Testing and adjusting, "Measuring fuel pressure".
2. Disconnect connector SOV2, and connect T-adapter to female side
of connector.
Voltage Between SOV2 (female) (1) and (2)
Max. 4.7 V
WA470-7
40 Troubleshooting
No.
Cause

2. Disconnect connectors SOV1 and SOV2.
3. Replace dosing fuel solenoid valve 1 with dosing fuel solenoid valve
2.
8
9
Defective dosing fuel solenoid

valve 2 (drain valve)
Clogging of fuel return tube

Defective fuel shut-off valve
manifold
a Do not replace the SOV1 and SOV2 connectors.

If this failure code changes to [CA1963], the previous dosing fuel
solenoid valve 2 (drain valve) is defective.
Disconnect the fuel return tube and check it for clogging.
Disconnect the fuel system tube and check the fuel connector of fuel
shut-off valve manifold for clogging.

Defective dosing fuel pressure 4. See "Related information",and display dosing fuel pressure and
10
ambient pressure at the same time.
sensor
If the dosing fuel pressure is clearly different from ambient pressure,
the dosing fuel pressure sensor is defective.
WA470-7
40-379
40 Troubleshooting

B: Fuel return
1. Fuel doser
2. Fuel supply line
40-380
WA470-7
40 Troubleshooting
Failure code [CA2881] Dosing Fuel Pressure Low Error 1

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
(WA470_7-CA2881-400-A-Z0-A)
Dosing fuel pressure low error 1

Failure code
Failure
CA2881
Pressure detected by dosing fuel pressure sensor during dosing is below the threshold value
(the fuel pressure is low).
You can cancel above measure by "turning starting switch to OFF position once, then
k Since
get burn injury.
(Code: 47600 (V))
General
Pressure sensed by dosing fuel pressure sensor can be checked with monitoring function.
information
(Code: 47601 (kPa))
flow.
Machine
operation for O
clearing
failure code
completing repair.
No.
Cause
Defective wiring
harness connector


solenoid valve 1 (shutoff valve)
solenoid valve 2 (drain
valve)
pressure sensor
Defective fuel supply

pump
WA470-7
If failure code [CA1923] or [CA1924] or [CA1925] is also displayed, perform

troubleshooting for [CA1923] or [CA1924] or [CA1925] first.
If failure code [CA2732] is also displayed, perform troubleshooting for
[CA2732] first.
If failure code [CA559] is also displayed, perform troubleshooting for [CA559]
first.
40-381
40 Troubleshooting
No.
Cause
Defective electric fuel

feed pump

wiring harness
Clogging of fuel filter

Defective fuel system
Clogging of fuel supply
10 tube or leakage from
connector
Defective fuel shut-off
11
valve manifold
8
9

12 pressure sensor

3. Tilt the switch for the fuel feed pump to ON position while starting switch is
in OFF position.
When completing the check, turn the starting switch to ON position or tilt
the switch for the fuel feed pump to OFF position.
If fuel is not fed from the joint bolt (JB) of fuel tube, fuel feed pump is
defective.
2. Disconnect connector SOV2, and connect T-adapter to female side of
connector.
Voltage Between SOV2 (female) (1) and (2)
Max. 4.7 V
Check fuel filter for clogging.
For above check, see Testing and adjusting, "Testing fuel pressure".
Check the fuel supply tube and its joint bolt (JB).
Disconnect the fuel system tube and check the fuel connector of fuel shut-off
valve manifold for clogging.

13 solenoid valve 2 (drain
valve)
Replace dosing fuel solenoid valve 2 (drain valve).

2. Start engine and increase the engine speed from low idle (with no load) to high idle (with no load). After
engine speed reaches to high idle speed (approximately 2,170 rpm with no load), decrease it to low idle
speed.
a Automatic regeneration is started after performing the preceding procedure, then engine speed is
maintained at low idle speed (approximately 1,000 rpm).
a If automatic regeneration is started and fuel pressure of fuel doser increases properly, the failure code
is cleared.
a If automatic regeneration is not started(*), perform following steps.
4. Disconnect either connector R93 from mass air flow sensor or TEMP1, TEMP2, or TEMP3 from
temperature sensor consolidating box. (You may disconnect all of them.)
5. Turn starting switch to ON position and wait until soot accumulation level becomes "3" on machine
monitor (approximately 7 minutes).
a At this time, the next failure codes appear, however, ignore them because they are open circuit errors
caused by disconnecting the connectors.
When disconnecting connector R93 from mass air flow sensor: [CA357], [CA691]
When disconnecting connector TEMP1 from temperature sensor: [CA3314]
When disconnecting all the connectors: [CA3314], [CA3317], [CA3319]
40-382
WA470-7
40 Troubleshooting
a Failure codes [CA3313], [CA3316], and [CA3321] may remain in the abnormality record on rare
occasions.
7. Connect the disconnected sensor connectors.
8. If automatic regeneration is started and fuel pressure of fuel doser increases properly by performing the
preceding operations 1 and 2, the failure code is cleared.
*: When automatic regeneration is not started
In the following cases, automatic regeneration may not be started after performing the preceding operations
1 and 2. At that time, perform the operations 3 to 8.
When "Regeneration Disable" is set from machine monitor.
When failure code [CA2881] appears during regeneration for service.
When failure code [CA2881] appears during automatic regeneration or manual stationary regeneration of
user mode, and also machine is operated for long period at heavy load (under high exhaust temperature)
after the regeneration.
WA470-7
40-383
40 Troubleshooting
A: From fuel feed pump

B: Fuel return
SOV1: Dosing fuel solenoid valve 1 (shut-off valve)
connector
SOV2: Dosing fuel solenoid valve 2 (drain valve)
connector
1. Fuel doser
2. Fuel supply line
40-384
WA470-7
40 Troubleshooting
Circuit diagram related to KDOC and KDPF temperature sensors
WA470-7
40-385
40 Troubleshooting
Failure code [CA3133] KDPF Outlet Press Sens High Error
(WA500_7-CA3133-400-A-Z0-
A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA3133
No.
KDPF Outlet Pressure Sensor High Error

High voltage appears in signal circuit of KDPF outlet pressure sensor.

Takes it that KDPF delta pressure is at estimated value (gauge pressure) and allows
engine to run.
(Controller may use 0 kPa (gauge pressure) to run engine if another failure code is also
displayed.)
None in particular
k Since
Related
information
Failure
If failure code [CA1695] is not displayed but failure code [CA1879] is on screen, GND
circuit probably has open circuit (defective contact of connector).
Signal voltage from KDPF outlet pressure sensor can be checked with monitoring
Delta pressure sensed by KDPF outlet pressure sensor can be checked with monitoring
Cause


supply system

pressure sensor

4.75 to 5.25 V
If this failure code changes to [CA3134], KDPF outlet pressure sensor is
defective.
a If this failure code remains displayed, wiring harness or engine

harness
40-386

each female side.
Resis- Between EC3 (female) (43) and E25 (female)
(1)
tance
Max. 1 z
WA470-7
40 Troubleshooting
No.
Cause

female side of EC3.

harness

Continuity

other than pin (58)
No continuity
(No sound is
heard)

Circuit diagram related to KDPF outlet pressure sensor
WA470-7
40-387
40 Troubleshooting
Failure code [CA3134] KDPF Outlet Press Sens Low Error
(WA500_7-CA3134-400-A-Z0-
A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA3134
No.
KDPF Outlet Pressure Sensor Low Error

Low voltage appears in signal circuit of KDPF outlet pressure sensor.

Takes it that KDPF outlet pressure is at estimated value (gauge pressure) and allows
engine to run
displayed.)
None in particular
k Since
Related
information
Failure
If failure code [CA1696] is not displayed but failure code [CA1881] is on screen, sensor
connector is probably disconnected or 5 V circuit probably has open circuit (defective
contact of connector).
Cause


supply system

4.75 to 5.25 V
each female side.

harness

harness
40-388

(female) (1)
Resistance

(female) (4)
(female) (3)
Max. 1 z
Max. 1 z
Max. 1 z

2. Disconnect connectors EC3 and E25, and connect T-adapter to
either female side.
Min. 1 Mz
E25 (female) (3)
tance
WA470-7
40 Troubleshooting
No.
Cause

female side of EC3.

Continuity

pressure sensor

other than pin (58)

No continuity
(No sound is
heard)
0.5 to 4.5 V

WA470-7
40-389
40 Troubleshooting
Failure code [CA3135] KDPF Outlet Press Sens In Range Error
(WA500_7-CA3135-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
KDPF Outlet Pressure Sensor In Range Error

Failure code
Failure
CA3135
Pressure value sensed by KDPF outlet pressure sensor is higher than normal value.
(Signal voltage is within operating range.)
Takes it that KDPF outlet pressure is at estimated value (gauge pressure) and allows
engine to run
displayed.)
None in particular
k Since
Related
information
a Use "Short-circuit connector: 799T-601-4670" (its wiring is not identical with that of "Shortcircuit connector: 799T-601-4611).
"Disassembly and assembly of KDPF".
Machine
O
clearing
after repair trouble.
No.
Cause

Defective sensor power supply 1. Turn starting switch to OFF position.

system
4.75 to 5.25 V
40-390

needed.
WA470-7
40 Troubleshooting
No.
Cause


engine controller

2. Disconnect connector E25 and connect short-circuit connector to
female side.
a To connect 5 V line to signal line (to short pin (4) to pin (3) of
connector E25).

pressure sensor
a If failure codes [CA3134] and [CA3133] are displayed in check on

cause 3, KDPF outlet pressure sensor is defective.
each female side.



(female) (1)
Resisa If no failure is found by check on cause 1,
tance
(female) (4)
(female) (3)
Max. 1 z
Max. 1 z
Max. 1 z

either female side.
Min. 1 Mz
tance E25 (female) (3)
female side of EC3.

Continu- Between EC3 (female) (58) and each pin
ity
other than pin (58)
WA470-7
No continuity
(No sound is
heard)
40-391
40 Troubleshooting
No.
Cause
1.
2.
3.
4.

Remove KDPF delta pressure sensor tube.

Clean KDPF delta pressure sensor tube to clear clogging.
Check KDPF delta pressure sensor tube for cracks and damage.
Install KDPF delta pressure sensor tube with both tube ends
connected securely.
Reference
How to check KDPF delta pressure sensor tube for clogging
2. Monitor outlet pressure sensed by KDPF outlet pressure sensor on
monitoring screen of machine monitor.
47000 (kPa)
0 3 (kPa)
Code

k Place
machine on a level ground and set parking brake lever to LOCK position.
1.
2.
3.
4.

Run engine at high idle and perform hydraulic relief of work equipment for continuous 1 minute.
If failure code disappears after implementing steps 1 to 4, repair work is complete.
If failure code still remains displayed, repeat above steps 5 and after.
7. Perform torque converter stall operation for approximately continuous 40 seconds with throttle position at
100% (see troubleshooting for failure code [CA1883]).
a Take care not to overheat torque converter oil.
command.
No.
Cause
40-392
WA470-7
40 Troubleshooting
Failure code [CA3167] Fuel Doser Degradation
(D155-CA3167-400-A-Z0-A)
Fuel Doser Degradation

Action level
Failure code
Failure

CA3167
Fuel doser is deteriorated.
Detail of
The injection port of fuel doser is clogged.
failure
Action of
None in particular
controller
Problem on It takes time to perform automatic regeneration. (KDOC outlet temperature does not rise
easily and it takes much time to burn the soot.)
machine
k Since
exhaust connector and KDPF are heated to 500 C or above, take care not to
get burn injury.
Related
information
(Code: 47600 (V))
Pressure sensed by dosing fuel pressure sensor can be checked with monitoring function.
(Code: 47601 (kPa))
For the cleaning method of the fuel doser, see Chapter 30 Testing and adjusting
"Procedures for cleaning fuel doser".
Since this failure code has no action level, it is not displayed in the user screen of the
machine monitor. It is displayed in the service screen of the machine monitor and
KOMTRAX.
A: Identification of cause
O
B: Fuel doser memory reset
a When this failure code is displayed, the fuel doser injection amount is corrected. After
repair trouble, it is necessary to reset the corrected information of fuel doser injection
amount. Be sure to perform the fuel doser memory reset after repair.
a If it is not performed, there is a danger that KCSF may be damaged.
You can cancel above measure by "turning starting switch to the OFF position" once, then
"turning starting switch to the ON position" after failure code is generated.
Machine
operation for
a In the following cases, this failure code does not disappear by simply "turning starting
clearing
switch to ON position from OFF position". It disappears after performing the next
failure code
automatic regeneration.
1. After this failure code is displayed, any other failure code related to fuel doser is displayed
before "turning starting switch to the OFF position" is performed.
2. After this failure code is displayed, "B. Fuel doser memory reset" is performed before
"turning starting switch to the OFF position" is performed.
3. After this failure code is displayed, the automatic regeneration is performed before
"turning starting switch to the OFF position" is performed.
a When service tool "INSITE" is available, you can clear every failure code by executing
"Reset All Faults" command.
No.
1
2
3
Cause

needed.
pressure sensor
valve)
WA470-7
40-393
40 Troubleshooting
No.
4
5
6

Cause
solenoid valve 2 (drain valve) troubleshooting for [CA2732] or [CA2733] first.
If failure code [CA1977] is displayed, perform troubleshooting for
Defective fuel doser system
[CA1977] first.
Defective fuel doser solenoid If failure code [CA1963], [CA2878] or [CA2881] is also displayed,
valve
Clogged fuel doser injection
port

2. Remove fuel doser (1) from exhaust connector.
3. Clean fuel doser.
a For the cleaning method of the fuel doser, see "Related information".
1. Turn starting switch to the OFF position.
2. Remove fuel doser (1) from exhaust connector.
3. Install replacement fuel doser to exhaust connector.
Defective fuel doser
Defective fuel doser system
a This is for prevention of exhaust gas leakage from fuel doser

mounting hole.
5. Perform the "Regeneration Disable".
6. Start engine.
7. Run engine at low idle and wait 2 minutes.
If fuel leaks from the tip end of fuel doser (1), fuel doser is defective.
If this failure code appears again after above procedures are performed,
doser fuel block is clogged with some foreign materials, etc. In this case,
replace the doser fuel block itself.
After replacing, perform "B: Fuel doser memory reset (as follows)".
If this failure code appears again after above procedures are performed,
B: Fuel doser memory reset

How to perform "Fuel doser memory reset"
1. Turn starting switch to the ON position. (Do not start the engine.)
2. From the service menu of the machine monitor, display the "KDPF Memory Reset" and perform "04 Fuel
Doser Cleaning".
40-394
WA470-7
40 Troubleshooting
A: From fuel feed pump

B: Fuel return
SOV1: Dosing fuel solenoid valve 1 (shut-off valve)
connector
SOV2: Dosing fuel solenoid valve 2 (drain valve)
connector
1. Fuel doser
2. Fuel supply line
WA470-7
40-395
40 Troubleshooting
Failure code [CA3251] KDOC Inlet Temp High Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA3251
Failure
(WA470_7-CA3251-400-A-Z0-A)
KDOC Inlet Temperature High Error

KDOC inlet temperature remains at high level.

You can cancel above measure by "turning starting switch to the OFF position once, then
turning starting switch to the ON position" after failure code is generated.
k Since
injury.
General
information
Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
compensate for torque drop, causing high exhaust temperature.
of KDPF assembly".
flow.
Machine
operation for O
clearing
failure code
completing repair.
No.
1
2
Cause
temperature sensor
solenoid valve 1

If failure code [CA3313], [CA3314] or [CA3315] is also displayed, perform
troubleshooting for [CA3313], [CA3314] or [CA3315] first.
Defective wiring
harness connector

40-396
WA470-7
40 Troubleshooting
No.
Cause

harness

temperature sensor

2. Disconnect connectors EC3 and TEMP1 (KDOC inlet temperature
sensor), and connect T-adapter to female side of EC3.
Continuity
No continuity
(No sound is heard)

2. Use monitoring function to display signal voltages and temperatures from
KDOC inlet temperature sensor, KDOC outlet temperature sensor, and
KDPF outlet temperature sensor on screen.
3. Run engine at idle for 10 minutes.
4. Note temperature values (after checking that they are stabilized).
5. Monitor temperature from each sensor.
If temperature of any temperature sensor fluctuates 24C or greater, regard
that temperature sensor as defective.
a If none of temperature sensor values changes more than 24C, problem is
not in sensor system. Perform checks on causes 6 and after.
Malfunction of intake
system
Defective injector
Oil leak into

turbocharger exhaust
connector
Oil leak into exhaust

connector and ducts
leading to KDPF
a If another failure code appears with engine running at idle, perform

Check intake system hoses, clamps, and tubes for damage and loosening.
Repair as necessary. (Repair intake air leaks.)
Perform cylinder cutout mode operation to identify disabled cylinder (see
Testing and adjusting, Handling cylinder cutout mode operation).
2. Check inside of turbocharger exhaust connector for adhesion of oil and
fuel.
If oil or fuel is found, visually check for oil leaks from EGR valve and
turbocharger. Repair if any failure is found.
a Wipe off oil and fuel from piping.
Check exhaust system between turbocharger and KDPF for oil or fuel leaking
in.
Wipe off oil or fuel if found.
a If trace of oil or fuel leakage into KDPF is found, check KDPF, and clean or
replace it as necessary.

No.
Cause

If failure code is cleared, repair is complete.
command.
Defective engine
10
controller
WA470-7
40-397
40 Troubleshooting
40-398
WA470-7
40 Troubleshooting
Failure code [CA3253] KDOC Temp Error - Non Regeneration
(WA470_7-CA3253-400-
A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
KDOC Temperature Error - Non Regeneration

Failure code
Failure
CA3253
KDOC outlet temperature remains at high level when active regeneration is not
performed.
a You can cancel above measure by "turning starting switch to the OFF position once, then
k Since
injury.
General
information Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
2. Since cylinders other than disabled cylinder increase their fuel injection to compensate
for torque drop, exhaust temperature may rise and KDOC inlet temperature high error
may be generated.
of KDPF assembly".
position. So when you restart engine, wait 1 minute or more before turning starting switch
to ON position again.
flow.
O
Machine
clearing
failure code
completing repair.
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-6014680" is used.
WA470-7
40-399
40 Troubleshooting

No.
1
2
Cause
temperature sensor
temperature sensor

Perform checks on causes 1 and 3 to 5 of troubleshooting for failure code
[CA3251] (causes related to sensor and wiring harness).
Perform checks on causes 1 and 3 to 5 of troubleshooting for failure code
[CA3254] (causes related to sensor and wiring harness).
1. Remove KDPF.
2. Remove KDOC.
Defective KDOC
a When KDOC of KDPF is replaced, perform reset procedure for KDOC

change and then finish troubleshooting without performing manual
stationary regeneration (see check on cause 7 of failure code [CA2637]).
Check whether more than 50% of KDOC inlet surface is plugged with soot
or not.
(KDOC cleaning)

No.
Cause

If failure code is not cleared, perform following steps.
a If failure code is not cleared after above steps 1 and 2 are implemented, following temperature
requirements are included in clearing condition. Steps 4 and 5 are required to satisfy temperature
requirements.
KDOC inlet temperature X 200C
KDOC outlet temperature X 200C
3. Use monitoring function to display KDOC inlet and outlet temperatures.
4. Run engine at high idle (approximately 2,170 rpm with no load) for 3 minutes.
5. Run engine at full speed and perform hydraulic relief of work equipment for 1 minute.
If failure code is not cleared because of low ambient temperature (at -20C level), perform step 6 and
after.
7. Disconnect connector E26 and install dummy temperature sensor to wiring harness side.
8. Turn starting switch from OFF position to ON position and leave it there for 1 minute.
9. Monitor KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature, and check
that each temperature ranges from approximately 560 to 590C. For details, see Related information.
10.Turn starting switch to OFF position.
11.Remove dummy temperature sensor to restore connector connection.
command.
Defective engine
4
controller
40-400
WA470-7
40 Troubleshooting
WA470-7
40-401
40 Troubleshooting
Failure code [CA3254] KDOC Outlet Temp High Error 1

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA3254
Failure
(WA470_7-CA3254-400-A-Z0-A)
KDOC Outlet Temperature High Error 1

KDOC outlet temperature remains at high level.

None in particular
None in particular
k Since
injury.
General
information
of KDPF assembly".
flow.
Machine
operation for O
clearing
failure code
completing repair.
No.
1
2
Cause
temperature sensor
solenoid valve 1

If failure code [CA3316], [CA3317], or [CA3318] appears, perform
Defective wiring
harness connector

40-402
WA470-7
40 Troubleshooting
No.
Cause

harness

temperature sensor

2. Disconnect connectors EC3 and TEMP2 (KDOC outlet temperature
Continuity
No continuity
(No sound is heard)

a If none of temperature sensor values changes more than 24C, problem is
system
Defective injector
Oil leak into

connector

connector and ducts
leading to KDPF

Testing and adjusting, "Handling of cylinder cutout mode operation).
fuel.
in.
1. Remove KDPF.
2. Remove KDOC.
10 Defective KDOC
WA470-7
a When KDOC of KDPF is replaced, perform reset procedure for KDOC

change and then finish troubleshooting without performing manual
stationary regeneration (see check on cause 7 of failure code [CA2637]).
Check whether more than 50% of KDOC inlet surface is plugged with soot
or not.
(KDOC cleaning)
40-403
40 Troubleshooting

No.
Cause

3. Perform regeneration for service.
4. End regeneration for service.
(Perform regeneration for service for 15 minutes minimum from its start.)
If failure code is cleared when regeneration for service is ended, repair is complete.
command.
Defective engine
11
controller
40-404
WA470-7
40 Troubleshooting
Failure code [CA3255] KDPF Temp Error - Non Regeneration
(WA470_7-CA3255-400-
A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA3255
Failure
KDPF Temperature Error - Non Regeneration

KDPF outlet temperature remains at high level when active regeneration is not performed.
k Since
injury.
General
information Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
of KDPF assembly".
position. So when you restart engine, wait 1 minute or more before turning starting switch
to ON position again.
flow.
O
Machine
clearing
failure code
completing repair.
WA470-7
40-405
40 Troubleshooting

No.
1
2
Cause
temperature sensor

Defective wiring
harness connector


harness

temperature sensor
system
Defective injector
Oil leak into

connector

connector and ducts
leading to KDPF
40-406

2. Disconnect connectors EC3 and TEMP3 (KDPF outlet temperature
Between EC3 (female) (54) and each No continuity (no sound
Continuity
is heard)
If none of temperature sensor values changes more than 24C, problem is
If another failure code appears with engine running at idle, perform
fuel.
in.
WA470-7
40 Troubleshooting

No.
Cause
1. Turn starting switch from OFF position to ON position and hold it there for 1 minute.
a If failure code is not cleared after above steps 1 and 2 are implemented, following temperature
requirements are included in clearing condition. Steps 3 and 4 are required to satisfy temperature
requirements.
KDOC outlet temperature X 200C
KDPF outlet temperature X 200C
3. Use monitoring function to display KDOC outlet and KDPF outlet temperatures.
If failure code is not cleared because of low ambient temperature (at -20C level), perform step 5 and
after.
7. Turn starting switch from OFF position to ON position and leave it there for 1 minute.
command.
Defective engine
9
controller
WA470-7
40-407
40 Troubleshooting
40-408
WA470-7
40 Troubleshooting
Failure code [CA3256] KDPF Outlet Temp High Error 1

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA3256
Failure
(WA470_7-CA3256-400-A-Z0-A)
KDPF Outlet Temperature High Error 1

KDPF outlet temperature remains at high level.

None in particular
None in particular
k Since
injury.
General
information
engine is at idle (KDPF regeneration is not executed) are approximately100 to 250C, and
difference between these temperatures is approximately 10C. (KDOC inlet temperature >
of KDPF assembly".
flow.
Machine
operation for O
clearing
failure code
completing repair.
No.
1
Cause
temperature sensor

Defective wiring
harness connector

WA470-7
40-409
40 Troubleshooting
No.
Cause

harness

temperature sensor
system
Defective injector
Oil leak into

connector

connector and ducts
leading to KDPF

Between EC3 (female) (54) and each pin other than
pin (54)
No continuity
(No sound is heard)

fuel.
in.

No.
Cause
1.
2.
3.
4.

Perform regeneration for service.
End regeneration for service.
(Perform regeneration for service for 15 minutes minimum from its start.)
If failure code is cleared when regeneration for service is ended, repair is complete.
command.
Defective engine
9
controller
40-410
WA470-7
40 Troubleshooting
WA470-7
40-411
40 Troubleshooting
Failure code [CA3311] KDOC Outlet Temp High Error 2

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA3311
Failure
(WA470_7-CA3311-400-A-Z0-A)
KDOC Outlet Temperature High Error 2

KDOC outlet temperature remains extremely high relative to KDOC inlet temperature.
k Since
injury.
General
information
of KDPF assembly".
flow.
Machine
operation for O
C. Machine operation for confirming completion of repair
clearing
failure code
a This failure code is cleared when starting switch is turned from OFF position to ON
position after repair. However, following machine operation must be done to confirm
completion of repair.
No.
1
2
Cause
temperature sensor

If failure code [CA3316], [CA3317], or [CA3318] appears, perform
Defective wiring
harness connector


harness

2. Disconnect connectors EC3 and TEMP2 (KDOC outlet temperature
Continuity
40-412

No continuity
(No sound is heard)
WA470-7
40 Troubleshooting
No.
Cause

temperature sensor
system
Defective injector
Oil leak into

connector

connector and ducts
leading to KDPF

fuel.
in.

No.
Cause

a Failure code is cleared once when starting switch is turned from OFF position to ON position. Check
that cleared failure code is not generated again when engine runs at low idle.
a If this failure code appears when starting switch is turned to ON position but engine is not started, perform
troubleshooting for following failure codes, too, after finishing troubleshooting and repair for this code.
[CA3316] KDOC Outlet Temp Sens Low Error
[CA3317] KDOC Outlet Temp Sens High Error
Defective engine
9
controller
WA470-7
40-413
40 Troubleshooting
40-414
WA470-7
40 Troubleshooting
Failure code [CA3312] KDPF Outlet Temp High Error 2

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA3312
Failure
(WA470_7-CA3312-400-A-Z0-A)
KDPF Outlet Temperature High Error 2

KDPF outlet temperature remains at very high level.

k Since
injury.
General
information
of KDPF assembly".
flow.
Machine
operation for O
clearing
failure code
a This failure code is cleared when starting switch is turned from OFF position to ON
position after repair. However, following machine operation must be done to confirm
completion of repair.
No.
1
2
3
Cause
temperature sensor
solenoid valve 1
Defective wiring
harness connector
WA470-7

See descriptions of wiring harness and connectors in "c: Electrical equipment"
in "Checks before troubleshooting" of "General information on
40-415
40 Troubleshooting
No.
Cause

harness

temperature sensor

Continuity
No continuity
(No sound is heard)

a If none of temperature sensor values fluctuates more than 24C, problem
is not in sensor system. Perform checks on causes 5 and after.
system
Defective injector
Oil leak into

connector

connector and ducts
leading to KDPF

fuel.
in.

No.
Cause

a Failure code is cleared once when starting switch is turned from OFF position to ON position. Check
that cleared failure code is not generated again when engine runs at low idle.
a If this failure code appears when starting switch is turned to ON position but engine is not started, perform
troubleshooting for following failure codes, too, after finishing troubleshooting and repair for this code.
[CA3319] KDPF Outlet Temp Sens Low Error
CA3321] KDPF Outlet Temp Sens High Error
Defective engine
10
controller
40-416
WA470-7
40 Troubleshooting
WA470-7
40-417
40 Troubleshooting
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error
(WA470_7-CA3313-400-A-Z0-
A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA3313
Failure
KDOC Inlet Temperature Sensor Low Error

Low voltage appears in KDOC inlet temperature sensor circuit.

Uses KDOC outlet temperature for KDOC inlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor as well, controller sets KDOC
inlet temperature to default value (250C) and runs engine.)
k Since
injury.
General
information
If sensor connector is disconnected or open circuit occurs, this failure code does not
appear but failure code [CA3314] for "High Error" appears.
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may
cause automatic regeneration to be started after this failure code is cleared. Controller
takes this measure intentionally to reduce soot accumulation and it is not failure.
No.
Cause
Defective wiring
harness connector

40-418
WA470-7
40 Troubleshooting
No.
Cause

2. Disconnect TEMP1 (KDOC inlet temperature sensor).
If this failure code changes to [CA3314], KDOC inlet temperature sensor is
defective.
a If this failure code still remains displayed, wiring harness or engine
Reference
2. Disconnect connector TEMP1, and connect T-adapter to female side.
-10C
33 to 65 kz
0C
25 to 47 kz
7.8 to 12.2
50C
Between TEMP1 (female) (1) and (2)
kz
3.2 to 4.5
a
Temperature-Resistance
100C
Resistance
kz
characteristics
200 to 240
400C
z
700C
64 to 69 z
Min. 1 Mz

temperature sensor

2. Disconnect connectors EC3 and TEMP1, and connect T-adapter to female
side of EC3 or male side of TEMP1.

harness
circuit)
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
(including wiring
harness in KDPF
temperature sensor
consolidating box)

side of EC3.
Defective KDPF
temperature sensor
consolidating box
Between ground and EC3 (female) (45) or TEMP1

Resistance (male) (1)

Continuity
WA470-7
No continuity
(No sound is heard)
a If no failure is found by checks on causes 3 and 4, this check is not

required.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3.
Resistance

harness
circuit)
Min. 1 Mz
a If no failure is found by check on cause 3, this

Between E26 (male) (3) and ground
Min. 1 Mz

Between E26 (male) (3) and each pin other than
pin (3)
Min. 1 Mz

female side.
Min. 1 Mz
40-419
40 Troubleshooting
No.
Cause

harness
Defective engine
controller

2. Disconnect connectors EC3 and E26, and connect T-adapter to female
side of EC3.
Continuity
No continuity
(No sound is heard)

2. If this failure code appears, perform procedure for <How to clear failure
code> in "Related information".
If this failure code is still displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect, troubleshooting
cannot be performed.)
40-420
WA470-7
40 Troubleshooting
Failure code [CA3314] KDOC Inlet Temp Sens High Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA3314
Failure
(WA470_7-CA3314-400-A-Z0-A)
KDOC Inlet Temperature Sensor High Error

High voltage appears in KDOC inlet temperature sensor circuit.

k Since
injury.
General
information
If failure codes [CA3317] and [CA3319] are also displayed, connector in KDPF
temperature sensor consolidating box may be disconnected or probably has open circuit
(defective contact of connector) in ground line.
No.
Cause
Defective wiring
harness connector

WA470-7
40-421
40 Troubleshooting
No.
Cause

2. Disconnect connector TEMP1 (KDOC inlet temperature sensor) and
connect T-adapter to male side.
3. Connect T-box to T-adapter and connect pins (1) and (2) of T-box by using
jumper cable.
a Connect ground line to signal line
If this failure code changes to [CA3313] , KDOC inlet temperature sensor is
defective.

temperature sensor
Open or short circuit in

wiring harness
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
(wire breakage or
connector)
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
(including wiring
harness in KDPF
temperature sensor
consolidating box)
40-422
a If this failure code remains displayed, wiring harness or engine controller is

defective.
Reference
-10C
33 to 65 kz
0C
25 to 47 kz
7.8 to 12.2
50C
kz
3.2 to 4.5
100C
kz
characteristics
200 to 240
400C
z
700C
64 to 69 z
2. Disconnect connectors EC3 and connect T-adapter to female side.
64 z to 65
kz
Resistance a Use above Temperature-Resistance

characteristics as resistance criteria.

2. Disconnect connectors EC3 and TEMP1, and connect T-adapters to
female side of EC3 and male side of TEMP1.
Between EC3 (female) (45) and TEMP1 (male) (1)
Max. 1 z
Resistance
Max. 1 z

side of J3.
Continuity
Between J3 (female) (45) and each

No continuity
(No sound is heard)
WA470-7
40 Troubleshooting
No.
Cause
a
1.
2.
3.
Defective KDPF
temperature sensor
consolidating box

harness
(wire breakage or
connector)

harness
Defective engine
controller
WA470-7
If no failure is found by checks on causes 3 to 5, this check is not required.

Disconnect connector E26 and connect T-adapter to male side.
Disconnect connectors TEMP1, TEMP2, and TEMP3, and connect Tadapter to male side of TEMP1.
a If no failure is found by check on cause 3 or 4,
Between E26 (male) (2) and TEMP1 (male) (2)
Max. 1 z

Resistance
Max. 1 z

pin (3)
Min. 1 Mz
a If no failure is found by check on cause 3 or 4, this check is not required.

female side.
Max. 1 z
Resistance
Max. 1 z
side of EC3.
Continuity
No continuity
(No sound is heard)

40-423
40 Troubleshooting
40-424
WA470-7
40 Troubleshooting
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error
(WA470_7-CA3315-400-
A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
KDOC Inlet Temperature Sensor In Range Error

Failure code
Failure
CA3315
Difference between temperature sensed by KDOC inlet temperature sensor and that by
KDOC outlet temperature sensor differs from expected value.
(Signal voltage is within input range.)
k Since
injury.
General
information
of KDPF assembly".
position. So when you restart engine, wait one minute and more before turning starting
flow.
O
Machine
clearing
failure code
completing repair.
No.
1
Cause
temperature sensor

If failure code [CA3313] or [CA3314] is displayed, perform troubleshooting for
it first.
Defective wiring
harness connector

WA470-7
40-425
40 Troubleshooting
No.
Cause

2. Disconnect TEMP1 (KDOC inlet temperature sensor).
If failure code [CA3314] is not displayed, wiring harness or engine controller is
defective.
3
Defective wiring
harness or engine
controller

2. Disconnect connector TEMP1 and connect T-adapter to male side.
jumper cable.
defective.

harness
(wire breakage or
connector)
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
circuit)
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
(including wiring
harness in KDPF
temperature sensor
consolidating box)
40-426

Max. 1 z
Resistance
Max. 1 z

Min. 1 Mz

side of EC3.
Continuity

No continuity
(No sound is heard)
WA470-7
40 Troubleshooting
No.
Cause

3. Disconnect connectors TEMP1, TEMP2, and TEMP3, and connect Tadapter to male side of TEMP1.
Defective KDPF
temperature sensor
consolidating box
Resistance

Max. 1 z

Max. 1 z

Min. 1 Mz

pin (3)
Min. 1 Mz

harness
(wire breakage or
connector)

female side.
Max. 1 z
Resistance
Max. 1 z

harness
circuit)

female side.
Min. 1 Mz
10

harness

wiring harness
(including wiring
11
harness in KDPF
temperature sensor
consolidating box)
WA470-7

side of EC3.
Continuity
No continuity
(No sound is heard)

Resistance a Use Temperature-Resistance characteristics
shown below as resistance criteria.
64 z to 65
kz
40-427
40 Troubleshooting
No.
Cause


a When failure codes [CA3314] and [CA3313] are displayed in check on
cause 3 and no failure is found by checks on causes 2 and 4 to 10, and if
failure is found by check on cause 11, KDOC inlet temperature sensor is
defective.
Reference
-10C
33 to 65 kz
0C
25 to 47 kz
7.8 to 12.2
50C
kz
3.2 to 4.5
100C
kz
characteristics
200 to 240
400C
z
700C
64 to 69 z

No.
Cause

If the ambient temperature is below 0C, repeat above steps 4 and after.
If failure code is cleared after implementing steps 1 to 9, repair work is complete.
a Soot accumulation reaches level 3 when this failure code is being displayed. Controller takes this
measure intentionally to reduce soot accumulation and it is not failure.
command.
Defective engine
13
controller
40-428
WA470-7
40 Troubleshooting
WA470-7
40-429
40 Troubleshooting
Failure code [CA3316] KDOC Outlet Temp Sens Low Error
(WA470_7-CA3316-400-A-Z0-
A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA3316
Failure
KDOC Outlet Temperature Sensor Low Error

Low voltage appears in KDOC outlet temperature sensor circuit.

Uses KDOC inlet temperature for KDOC outlet temperature to run engine.
(If failure is detected in KDOC inlet temperature sensor as well, controller sets KDOC
outlet temperature to default value (250C) and runs engine.)
k Since
injury.
General
information
No.
Cause
Defective wiring
harness connector

40-430
WA470-7
40 Troubleshooting
No.
Cause

2. Disconnect TEMP2 (KDOC outlet temperature sensor).
If this failure code changes to [CA3317] , KDOC outlet temperature sensor is
defective.
defective.
Reference
2. Disconnect connector TEMP2 and connect T-adapter to female side.
-10C
33 to 65 kz
0C
25 to 47 kz
7.8 to 12.2
50C
kz
3.2 to 4.5
a
100C
Resistance
kz
characteristics
200 to 240
400C
z
700C
64 to 69 z
Min. 1 Mz

temperature sensor


harness
circuit)
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
(including wiring
harness in KDPF
temperature sensor
consolidating box)

side of EC3.
Defective KDPF
temperature sensor
consolidating box


Continuity
WA470-7
No continuity
(No sound is heard)

required.
Resistance

harness
circuit)
Min. 1 Mz

Min. 1 Mz

pin (1)
Min. 1 Mz

female side.
Min. 1 Mz
40-431
40 Troubleshooting
No.
Cause

harness
Defective engine
controller

side of EC3.
Continuity
No continuity
(No sound is heard)

If this failure code appears, perform procedure for <How to clear failure
40-432
WA470-7
40 Troubleshooting
Failure code [CA3317] KDOC Outlet Temp Sens High Error
(WA470_7-CA3317-400-A-Z0-
A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA3317
Failure
KDOC Outlet Temperature Sensor High Error

High voltage appears in KDOC outlet temperature sensor circuit.

k Since
injury.
General
information
No.
Cause
Defective wiring
harness connector

WA470-7
40-433
40 Troubleshooting
No.
Cause

2. Disconnect KDOC outlet temperature sensor (connector TEMP2) and
connect T-adapter to female side.
jumper cable.
If this failure code changes to [CA3316], KDOC outlet temperature sensor is
defective.
2

temperature sensor

wiring harness
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
(wire breakage or
connector)
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
(including wiring
harness in KDPF
temperature sensor
consolidating box)
40-434

defective.
Reference
-10C
33 to 65 kz
0C
25 to 47 kz
7.8 to 12.2
50C
kz
3.2 to 4.5
100C
kz
characteristics
200 to 240
400C
z
700C
64 to 69 z
64 z to 65
kz

Max. 1 z
Resistance
Max. 1 z

side of EC3.
Continuity

No continuity
(No sound is heard)
WA470-7
40 Troubleshooting
No.
Cause
a
1.
2.
3.
Defective KDPF
temperature sensor
consolidating box

harness
(wire breakage or
connector)

harness
Defective engine
controller
WA470-7

Max. 1 z

Resistance
Max. 1 z

pin (1)
Min. 1 Mz

female side.
Max. 1 z
Resistance
Max. 1 z
side of EC3.
Continuity
No continuity
(No sound is heard)

40-435
40 Troubleshooting
40-436
WA470-7
40 Troubleshooting
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error
(WA470_7-CA3318-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
KDOC Outlet Temperature Sensor In Range Error

Failure code
Failure
CA3318
Difference between temperature sensed by KDOC outlet temperature sensor and that by
KDOC inlet temperature sensor differs from expected value.
k Since
injury.
General
information
of KDPF assembly".
flow.
O
Machine
clearing
failure code
completing repair.
No.
1
2
Cause
temperature sensor

If failure code [CA3316] or [CA3317] is displayed, perform troubleshooting for
it first.
Defective wiring
harness connector

WA470-7
40-437
40 Troubleshooting
No.
Cause

2. Disconnect TEMP2 (KDOC outlet temperature sensor).
defective.
3
Defective wiring
harness or engine
controller

2. Disconnect connector TEMP2 and connect T-adapter to male side.
jumper cable.
defective.

harness
(wire breakage or
connector)
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
circuit)
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
(including wiring
harness in KDPF
temperature sensor
consolidating box)
40-438

Max. 1 z
Resistance
Max. 1 z

Min. 1 Mz

side of EC3.
Continuity

No continuity
(No sound is heard)
WA470-7
40 Troubleshooting
No.
Cause

Defective KDPF
temperature sensor
consolidating box
Resistance

Max. 1 z

Max. 1 z

Min. 1 Mz

pin (1)
Min. 1 Mz

harness
(wire breakage or
connector)

female side.
Max. 1 z
Resistance
Max. 1 z

harness
circuit)

female side.
Min. 1 Mz
10

harness

wiring harness
(including wiring
11
harness in KDPF
temperature sensor
consolidating box)
WA470-7

side of EC3.
Continuity
No continuity
(No sound is heard)

64 z to 65
kz
shown in the following resistance criteria.
40-439
40 Troubleshooting
No.
Cause


cause 3 and no failure is found by checks on causes 2 and 4 to 10, and if
failure is found by check on cause 11, KDOC outlet temperature sensor is
defective.
Reference
-10C
33 to 65 kz
0C
25 to 47 kz
7.8 to 12.2
50C
kz
3.2 to 4.5
100C
kz
characteristics
200 to 240
400C
z
700C
64 to 69 z

No.
Cause

If failure code is cleared after implementing steps 1 to 9, repair is complete.
command.
Defective engine
13
controller
40-440
WA470-7
40 Troubleshooting
WA470-7
40-441
40 Troubleshooting
Failure code [CA3319] KDPF Outlet Temp Sens High Error
(WA470_7-CA3319-400-A-Z0-
A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA3319
Failure
KDPF Outlet Temperature Sensor High Error

High voltage appears in KDPF outlet temperature sensor circuit.

Uses KDOC outlet temperature for KDPF outlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor as well, controller sets KDPF
k Since
injury.
General
information
No.
Cause
Defective wiring
harness connector

40-442
WA470-7
40 Troubleshooting
No.
Cause

2. Disconnect KDPF outlet temperature sensor (connector TEMP3) and
connect T-adapter to female side.
jumper cable.
If this failure code changes to [CA3321], KDPF outlet temperature sensor is
defective.

temperature sensor

wiring harness
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
(wire breakage or
connector)
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
(including wiring
harness in KDPF
temperature sensor
consolidating box)
WA470-7

defective.
Reference
-10C
33 to 65 kz
0C
25 to 47 kz
7.8 to 12.2
50C
kz
3.2 to 4.5
100C
kz
characteristics
200 to 240
400C
z
700C
64 to 69 z
64 z to 65
kz


Max. 1 z
Resistance
Max. 1 z

side of EC3.
Continuity

No continuity
(No sound is heard)
40-443
40 Troubleshooting
No.
Cause
a
1.
2.
3.
Defective KDPF
temperature sensor
consolidating box

harness
(wire breakage or
connector)

harness
Defective engine
controller
40-444

Max. 1 z

Resistance
Max. 1 z

pin (4)
Min. 1 Mz

female side.
Max. 1 z
Resistance
Max. 1 z
side of EC3.
Continuity
No continuity
(No sound is heard)

WA470-7
40 Troubleshooting
WA470-7
40-445
40 Troubleshooting
Failure code [CA3321] KDPF Outlet Temp Sens Low Error

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Failure code
CA3321
Failure
(WA470_7-CA3321-400-A-Z0-A)
KDPF Outlet Temperature Sensor Low Error

Low voltage appears in KDPF outlet temperature sensor circuit.

k Since
injury.
General
information
No.
Cause
Defective wiring
harness connector

40-446
WA470-7
40 Troubleshooting
No.
Cause

2. Disconnect TEMP3 (KDPF outlet temperature sensor).
If this failure code changes to [CA3319], KDPF outlet temperature sensor is
defective.
defective.
Reference
-10C
33 to 65 kz
0C
25 to 47 kz
7.8 to 12.2
50C
kz
3.2 to 4.5
a
100C
Resistance
kz
characteristics
200 to 240
400C
z
700C
64 to 69 z
Min. 1 Mz

temperature sensor


harness
circuit)
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
(including wiring
harness in KDPF
temperature sensor
consolidating box)

side of EC3.
Defective KDPF
temperature sensor
consolidating box


Continuity
WA470-7
No continuity
(No sound is heard)

required.
Resistance

harness
circuit)
Min. 1 Mz

Min. 1 Mz

pin (4)
Min. 1 Mz

female side.
Min. 1 Mz
40-447
40 Troubleshooting
No.
Cause

harness
Defective engine
controller

side of EC3.
Continuity
No continuity
(No sound is heard)

40-448
WA470-7
40 Troubleshooting
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error
(WA470_7-CA3322-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
KDPF Outlet Temperature Sensor In Range Error

Failure code
Failure
CA3322
Temperature sensed by KDPF outlet temperature sensor differs from expected value.
k Since
injury.
General
information
of KDPF assembly".
position. So when you restart engine, wait one minute and more before turning starting
flow.
O
Machine
clearing
failure code
completing repair.
No.
1

Cause
Defective KDPF outlet If failure code [CA3313] or [CA3314] is displayed, perform troubleshooting for it
temperature sensor
first.
Defective wiring
harness connector
WA470-7

40-449
40 Troubleshooting
No.
Cause

2. Disconnect TEMP3 (KDPF outlet temperature sensor).
defective.
3
Defective wiring
harness or engine
controller

2. Disconnect TEMP3 and connect T-adapter to female side.
jumper cable.
defective.

harness
(wire breakage or
connector)
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
circuit)
(including wiring
harness in KDPF
temperature sensor
consolidating box)
harness
(including wiring
harness in KDPF
temperature sensor
consolidating box)
40-450

2. Disconnect connectors EC3 and TEMP3, and connect T-adapters to female
side of EC3 and male side of TEMP3.
Max. 1 z
Resistance
Max. 1 z

Min. 1 Mz

side of EC3.
Continuity

No continuity
(No sound is heard)
WA470-7
40 Troubleshooting
No.
Cause

Defective KDPF
temperature sensor
consolidating box
Resistance

Max. 1 z

Max. 1 z

Min. 1 Mz

Between E26 (male) (4) and each pin other than pin
(4)
Min. 1 Mz

harness
(wire breakage or
connector)

female side.
Max. 1 z
Resistance
Max. 1 z

harness
circuit)

female side.
Min. 1 Mz
10

harness
Open or short circuit

in wiring harness
(including wiring
11
harness in KDPF
temperature sensor
consolidating box)
WA470-7

2. Disconnect connectors EC3 and E26, and connect T-adapter to female side
of EC3.
Continuity
No continuity
(No sound is heard)

64 z to 65
kz
shown in the following resistance criteria.
40-451
40 Troubleshooting
No.
Cause

cause 3 and no failure is found by checks on causes 2 and 4 to 10, if failure
is found by check on cause 11, KDOC inlet temperature sensor is defective.
Reference
-10C
33 to 65 kz
0C
25 to 47 kz
7.8 to 12.2
50C
kz
3.2 to 4.5
100C
kz
characteristics
200 to 240
400C
z
700C
64 to 69 z
No.
Cause

If failure code is cleared after implementing steps 1 to 9, repair is complete.
command.
Defective engine
13
controller
40-452
WA470-7
40 Troubleshooting
WA470-7
40-453
40 Troubleshooting
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
(WA500_7-
CA3419-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA3419
Failure
Mass Air Flow Sensor Supply Voltage High Error

High voltage appears in mass air flow sensor power supply (12 V) circuit.
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures for failure codes [CA356] and [CA357].
Cause


sensor (internal defect)

If this failure code does not appear, mass air flow sensor is defective.
If this failure code does not appear, wiring harness is defective.
40-454
Approx. 12
V
WA470-7
40 Troubleshooting
WA470-7
40-455
40 Troubleshooting
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
(WA500_7-
CA3421-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
CA3421
Failure
Mass Air Flow Sensor Supply Voltage Low Error

Low voltage appears in mass air flow sensor power supply (12 V) circuit.
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures for failure codes [CA356] and [CA357].
Cause


sensor (internal defect)

connector

If this failure code does not appear, mass air flow sensor is defective.
If this failure code does not appear, wiring harness is defective.
either female side.
Min. 1 Mz
(female) (2)
tance

either female side.
Min. 1 Mz
E27 (female) (2) and (3)
tance

Approx. 12
V
40-456
WA470-7
40 Troubleshooting
WA470-7
40-457
40 Troubleshooting
Failure code [D150KA] Disconnection of Emerg. Steering Relay
(WA470_7-
D150KA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Disconnection of Emergency Steering Relay

Failure code
Failure
(Work equipment controller system)
D150KA
When controller drives primary circuit (coil) of emergency steering relay (L126), no current
flows through circuit.
is turned to OFF position.
Automatic emergency steering does not work.
Emergency steering self-check ends abnormally.
When starting switch is turned to ON position, controller drives emergency steering relay
to diagnose emergency steering motor.
This failure code indicates failure on primary side (coil side) of emergency steering relay,
but not on secondary side (contact side).
Output condition (ON/OFF) to emergency steering relay can be checked with monitoring
function. (Code: 03708 BBC Output 2, Emerg. Steering Relay)
Cause
Defective emergency
steering relay L126
harness
(wire breakage or
connector)
Defective work
equipment controller
40-458

200 to 400
z
2. Disconnect connectors L72 and L126, and connect T-adapters to each
female side.
Between L72 (female) (8) and L126 (female) (1)
Max. 1 z
Resistance
Max. 1 z
If no failure is found by above checks, work equipment controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed).
WA470-7
40 Troubleshooting
Circuit diagram related to emergency steering relay
WA470-7
40-459
40 Troubleshooting
Failure code [D150KB] Ground Fault of Emerg. Steering Relay
(WA470_7-D150KB-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of Emergency Steering Relay

Failure code
Failure
D150KB
When controller drives primary circuit (coil) of emergency steering relay (L126), large
current flows.
Stops driving emergency steering relay (L126).
Automatic emergency steering does not work.
Cause
Defective emergency
steering relay (L126)

200 to 400
Between L126 (male) (1) and (2)
z
Resistance
Between L126 (male) (1) and ground
Min. 1 Mz

harness
circuit)

2. Disconnect connectors L72 and L126, and connect T-adapter to either
female side.
Between ground and L72 (female) (8) or L126
Min. 1 Mz

harness
Defective work
40-460

2. Disconnect connectors L72 and L126, and connect T-adapter to female
side of L126.
Resistance Between L126 (female) (1) and (2)
Min. 1 Mz
WA470-7
40 Troubleshooting
WA470-7
40-461
40 Troubleshooting
Failure code [D150KY] Hot Short of Emergency Steering Relay
(WA470_7-D150KY-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Hot Short of Emergency Steering Relay

Failure code
Failure
D150KY
When controller does not drive primary circuit (coil) of emergency steering relay (L126),
current flows through circuit.
Problem on
machine
Emergency steering continues on working.
Related
information

No.
Cause
Defective emergency
steering relay L126

wiring harness
Defective work
40-462

200 to 400
z
2. Insert T-adapters into connector L126.
3. Turn starting switch to ON position and check after 1 minute.
Voltage Between L126 (1) and (2)
Max 4.5 V
WA470-7
40 Troubleshooting
WA470-7
40-463
40 Troubleshooting
Failure code [D160KA] Disconnection of Backup Lamp Relay

Output (WA470_7-D160KA-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Disconnection of Backup Lamp Relay Output

Failure code
Failure
D160KA
When controller drives primary circuit (coil side) of backup lamp relay, no current flows
through circuit.
Stops driving primary circuit (coil side) of backup lamp relay.
Backup lamp does not light up.
Backup buzzer does not sound.
Output signal (ON/OFF) to backup lamp relay can be checked with monitoring function.
(Code: 03705 Backup Lamp Relay)
This failure code indicates failure on primary circuit (coil side) of backup lamp relay, but
not on secondary circuit (contact side).
Method of reproducing failure code:Turn starting switch to ON position and operate
directional (FNR) lever to R (reverse).
No.
Cause
Defective backup lamp

relay (L117) (internal
short circuit)

harness
(wire breakage or
connector)

200 to 400
z
female side.
Max. 1 z
Resistance
Max. 1 z
controller

Voltage
40-464

(19) and ground
Directional (FNR) lever:

R (reverse)
Other than R (reverse)
20 to 30 V
Max 4.5 V
WA470-7
40 Troubleshooting
Circuit diagram related to backup lamp relay
WA470-7
40-465
40 Troubleshooting
Failure code [D160KB] Ground Fault of Backup Lamp Relay

Output (WA470_7-D160KB-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Ground Fault of Backup Lamp Relay Output

Failure code
Failure
D160KB
When controller drives primary circuit (coil side) of backup lamp relay, no abnormal
Backup lamp does not light up.
Backup buzzer does not sound.
Method of reproducing failure code: Turn starting switch to ON position and operate
directional (FNR) lever to R (reverse).
No.
Cause

short circuit)

harness
circuit)

200 to 400
z
female side.
Min. 1 Mz
controller
40-466

Directional (FNR) lever:R
20 to 30 V
(reverse)
Voltage
(19) and ground
Max 4.5 V
WA470-7
40 Troubleshooting
WA470-7
40-467
40 Troubleshooting
Failure code [D160KY] Hot Short of Backup Lamp Relay Output
(WA470_7-
D160KY-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Hot Short of Backup Lamp Relay Output

Failure code
Failure
D160KY
When controller does not drive primary circuit (coil side) of backup lamp relay, current
Backup lamp continues to light up.
Backup alarm buzzer continues to sound.
No.
Cause

short circuit)

wiring harness

2. Disconnect connector L117, and connect T-adapters to female side.
200 to 400
z
Voltage Between L117 (female) (1) and ground
Max 4.5 V
controller

Voltage
40-468

(19) and ground
Directional (R) lever: R

(reverse)
Directional (R) lever:
20 to 30 V
Max 4.5 V
WA470-7
40 Troubleshooting
WA470-7
40-469
40 Troubleshooting
Failure code [D191KA] Disconnection of Neutral Output Relay
(WA470_7-D191KA-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of Neutral Output Relay

Failure code
Failure
D191KA
When controller drives primary circuit (coil side) of neutral safety relay, no current flows
through circuit.
Stops driving primary circuit (coil side) of neutral safety relay.
Problem on
machine
Related
information
Output signal to primary circuit (coil side) of neutral safety relay can be checked with
monitoring function. (Code: 03705 Neutral Safety Relay)
Method of reproducing failure code:Turn starting switch to ON position and operate
directional lever to N (neutral).
This failure code indicates failure on primary circuit (coil side) of neutral safety relay, but
No.
1
Cause
Defective neutral safety 1. Turn starting switch to OFF position.

relay (internal open or
200 to 400
short circuit)
z
2. Disconnect connectors D11 and D12, and connect T-adapters to diode.
Defective diode
(internal open or short
circuit)
a Measure it with diode range of multimeter.

Between D11 (male) (1) (+) and (2) (-)
Continuity
No continuity
Continuity
No continuity
Continuity

2. Disconnect connectors L63 and D12, and connect T-adapters to each
female side.
3

wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit.

Between L63 (female) (8) and D12 (female) (2)
Max. 1 z
Resistance a Coil resistance of relay
Between D12 (female) (1) and ground

harness
(wire breakage or
connector)
controller
40-470
200 to 400
z

2. Disconnect connectors D11 and L116, and connect T-adapters to each
female side.
Max. 1 z
Resistance
Max. 1 z
Reference
4. Move directional lever to perform troubleshooting.
Directional lever: N
20 to 30 V
(neutral)
Voltage
(8) and ground
Directional lever: Other
Max. 4.5 V
than N (neutral)
WA470-7
40 Troubleshooting
Circuit diagram related to neutral safety relay
WA470-7
40-471
40 Troubleshooting
Failure code [D191KB] Ground Fault of Neutral Output Relay
(WA470_7-D191KB-400-
A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Ground Fault of Neutral Output Relay

Failure code
Failure
D191KB
When controller drives primary circuit (coil side) of neutral safety relay, abnormal current
Stops driving primary circuit (coil side) of neutral safety relay.
Problem on
machine
Related
information
Method of reproducing failure code: Turn starting switch to ON position and operate
No.
1
Cause
Defective neutral safety 1. Turn starting switch to OFF position.

relay (internal open or
200 to 400
short circuit)
z
2. Disconnect connectors D11 and D12, and connect T-adapters to diode.
Defective diode
circuit)

Continuity
No continuity
Continuity
No continuity
Continuity

2. Disconnect connectors L63 and D12, and connect T-adapters to each
female side.
3

wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit.

Max. 1 z
Resistance a Coil resistance of relay

harness
circuit)
controller
40-472
200 to 400
z

2. Disconnect connectors D11, L116, D11, and D12, and connect T-adapters
Between ground and L116 (female) (1) or D12
Min. 1 Mz
(female) (1)
Resistance
Between ground and D12 (female) (2) or L63
Min. 1 Mz
(female) (8)
Reference
20 to 30 V
(neutral)
Voltage
(8) and ground
Max. 4.5 V
than N (neutral)
WA470-7
40 Troubleshooting
WA470-7
40-473
40 Troubleshooting
Failure code [D191KY] Hot Short of Neutral Output Relay

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA470_7-D191KY-400-A-Z0-A)
Hot Short of Neutral Output Relay

Failure code
Failure
D191KY
When controller does not drive primary circuit (coil) of neutral safety relay, current flows
through circuit.
None in particular
Engine is allowed to start even when gear shift lever or directional selector (FNR) switch
is in a position other that N (neutral).
Method of reproducing failure code: Turn starting switch to ON position and move
Cause

Defective neutral safety 2. Disconnect connector L116 and connect T-adapter to male side.
relay
200 to 400
Resistance Between connector L116 (male) (1) and (2)
z
2. Disconnect connector D12 and connect T-adapter to female side.
4. Move directional lever to position other than N (neutral).
wiring harness
Max. 4.5 V
Voltage
Max. 4.5 V
If no failure is found by above checks, power train controller is defective.
Reference
Defective transmission 3. Turn starting switch to ON position.
controller
20 to 30 V
(neutral)
Voltage
(8) and ground
Max. 4.5 V
than N (neutral)
40-474
WA470-7
40 Troubleshooting
WA470-7
40-475
40 Troubleshooting
Failure code [D192KA] Disconnection of ECSS Solenoid

Action level
L01
Detail of
failure
Action of
controller
(WA470_7-D192KA-400-A-Z0-A)
Disconnection of ECSS Solenoid

Failure code
Failure
D192KA
When controller drives electronically controlled suspension system (ECCS) solenoid, no
None in particular
Problem on
machine
ECCS (electronically controlled suspension system) does not work.
Related
information
Output signal (ON/OFF) to ECCS (electronically controlled suspension system) solenoid

can be checked with monitoring function.
(Code: 03705 E.C.C.S. Solenoid)
This troubleshooting is applicable only to machines with ECCS (electronically controlled
suspension system) specification.
Method of reproducing failure code: Turn starting switch to ON position, set ECCS switch
to ON, and drive machine at gear speed other than "1st".
No.
Cause
Defective ECCS solenoid

35 to 45 z
ResisBetween ground and each of F20 (male) (1)
tance
Min. 1 Mz
and (2)
2. Disconnect connector F20, and connect T-adapter to female side.
Open circuit, short circuit,

ground fault, hot short circuit
of wiring harness, or defective a Shake the wiring harness by hand while measuring the voltage. If
the voltage drops to approximately 0 V during shaking, circuit is
open around this point.
Voltage Between F20 (female) (1) and (2)
1 to 4.5 V

harness

2. Disconnect connector L63, and connect T-adapter to female side.
a Coil resistance of solenoid
Resis- Between L63 (female) (15) and (13)
tance
35 to 45 z

Open circuit in wiring harness 2. Disconnect connectors L63 and F20, and connect T-adapters to
each female side.
Between L63 (female) (15) and F20 (female)
Max. 1 z
Resis- (1)
tance
Between L63 (female) (13) and F20 (female)
Max. 1 z
(2)
If no failure is found by above checks, transmission controller may be
controller
performed).
40-476
WA470-7
40 Troubleshooting
Circuit diagram related to electronically controlled suspension system (ECCS) solenoid
WA470-7
40-477
40 Troubleshooting
Failure code [D192KB] Ground Fault of ECSS Solenoid

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA470_7-D192KB-400-A-Z0-A)
Ground Fault of ECSS Solenoid

Failure code
Failure
D192KB
When controller drives electronically controlled suspension system (ECCS) solenoid,
abnormal current flows through circuit.
Stops driving ECCS (electronically controlled suspension system) solenoid.
ECCS (electronically controlled suspension system) does not work.
Wiring harness or controller may be burnt out.
Method of reproducing failure code: Turn starting switch to ON position, set ECCS switch
to ON, and drive machine at gear speed other than "1st".
Cause
Defective ECCS
solenoid

wiring harness

harness
circuit)
controller

35 to 45 z
Resistance
Between ground and each of F20 (male) (1) and (2) Min. 1 Mz
Resistance Between L63 (female) (15) and ground
35 to 45 z

2. Disconnect connectors L63 and F20, and connect T-adapter to either
female side.
Between L63 (female) (15) and F20 (female) (1), or
Resistance ground and L63 (female) (15) or F20 (female) (1)
Min. 1 Mz
performed).
40-478
WA470-7
40 Troubleshooting
Failure code [D192KY] Hot Short of ECSS Solenoid

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
(WA470_7-D192KY-400-A-Z0-A)
Hot Short of ECSS Solenoid

Failure code
Failure
D192KY
When controller drives electronically controlled suspension system (ECCS) solenoid,
abnormal voltage appears at circuit.
ECCS (electronically controlled suspension system) remains actuated.
No. Cause
1
Defective ECCS
solenoid

wiring harness

wiring harness
controller

35 to 45 z
Resistance
35 to 45 z

Max 1 V
performed).
WA470-7
40-479
40 Troubleshooting
Failure code [D19JKZ] Personal Code Relay Abnormality

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA470_7-D19JKZ-400-A-Z0-A)
Personal Code Relay Abnormality

Failure code
Failure
D19JKZ
When driving primary circuit (coil) of personal code relay, no current flows or excessive
When controller does not drive primary circuit (coil) of personal code relay, current flows
through circuit.
When cause of failure is open circuit, engine is allowed to start even if engine start lock is
activated.
When cause of failure is ground fault, engine does not start.
Output signal (ON/OFF) to personal code relay can be checked with monitoring function.
(Code: 04700)

Cause
Defective fuse-5 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on cause 4.)
box 2
Defective personal
code relay L113
250 to 350
z
2. Disconnect connectors MCM1 A , L113, and L112, and connect TOpen circuit in wiring
adapters to each female side.
harness
3. Remove fuse-5 in fuse box 2.
(wire breakage or
Between MCM1 A (female) (19) and L113 (female)
Max. 1 z
(2)
connector)
Resistance L113 (female) (1) and L112 (female) (3)
Max. 1 z
Between fuse-5 in fuse box 2 and L112 (female) (5) Max. 1 z

harness
circuit)

2. Disconnect connectors MCM1 A, L113, and L63, and connect T-adapter to
female side of MCM1 A or L113.
Between ground and MCM1 A (female) (19) or
Min. 1 Mz
L113 (female) (2)
Resistance
Between ground and fuse-5 in fuse box 2 or L112
Min. 1 Mz
(female) (5)
Defective monitor
controller

this is an internal defect, troubleshooting cannot be performed).
40-480
WA470-7
40 Troubleshooting
Circuit diagram related to personal code relay
WA470-7
40-481
40 Troubleshooting
Failure code [D1E6KA] Disconnection of Parking Brake Relay
(WA470_7-D1E6KA-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of Parking Brake Relay

Failure code
Failure
D1E6KA
When controller drives primary circuit (coil) of auto idle stop parking brake relay, no
Stops driving auto idle stop parking brake relay.
Problem on
machine
When auto idle stop function is actuated, parking brake is not applied automatically.
Related
information
This failure code indicates failure on primary circuit (coil side) of auto idle stop parking
brake relay, but not on secondary circuit (contact side).
Output signal (ON/OFF) to auto idle stop parking brake relay can be checked with
monitoring function. (Code: 03706 Parking Brake Relay)
Method of reproducing failure code: Actuate auto idle stop function.
No.
1
Cause
Defective auto idle stop 1. Turn starting switch to OFF position.

parking brake relay
200 to 400
(L133)
z
a Relay coil resistance
wiring harness
200 to 400
z

harness
a If no failure is found by above checks, this check is not required.

female side.
Max. 1 z
Resistance
Max. 1 z
controller

2. Connect T-adapter to connector L63.
Between Auto idle stop: After engine is stopped 20 to 30 V
L63
(female)
Voltage
Auto idle stop: Before engine is
Max 4.5 V
(18) and
stopped
ground
40-482
WA470-7
40 Troubleshooting
Circuit diagram related to parking brake relay
WA470-7
40-483
40 Troubleshooting
Failure code [D1E6KB] Ground Fault of Parking Brake Relay
(WA470_7-D1E6KB-400-
A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Ground Fault of Parking Brake Relay

Failure code
Failure
D1E6KB
When controller drives primary circuit (coil) of auto idle stop parking brake relay, abnormal
Problem on
machine
When auto idle stop function is actuated, parking brake is not applied automatically.
Related
information
This failure code indicates failure on primary circuit (coil side) of auto idle stop parking
brake relay, but not on secondary circuit (contact side).
Output signal (ON/OFF) to auto idle stop parking brake relay can be checked with
monitoring function. (Code: 03706 Parking Brake Relay)
No.
Cause

Defective auto idle stop 2. Disconnect connector L133 and connect T-adapter to male side.
parking brake relay
200 to 400
(L133)
z
Resistance
Min. 1 Mz

harness
circuit)

female side.
Min. 1 Mz

harness

female side.
Between L63 (female) (18) and (31), or between
Resistance L133 (female) (1) and (2)
Min. 1 Mz
controller

L63
(female)
Voltage
Max 4.5 V
(18) and
stopped
ground
40-484
WA470-7
40 Troubleshooting
WA470-7
40-485
40 Troubleshooting
Failure code [D1E6KY] Hot Short of Parking Brake Relay

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA470_7-D1E6KY-400-A-Z0-A)
Hot Short of Parking Brake Relay

Failure code
Failure
D1E6KY
When controller does not drive primary circuit (coil) of auto idle stop parking brake relay,
Parking brake remains applied.
Cause

Defective auto idle stop 2. Disconnect connector L133 and connect T-adapter to male side.
parking brake relay
200 to 400
(L133)
z
Resistance
Min. 1 Mz

wiring harness

Max. 4.5 V
controller

L63
Voltage
(female)
Max 4.5 V
(18) and
stopped
ground
40-486
WA470-7
40 Troubleshooting
WA470-7
40-487
40 Troubleshooting
Failure code [D5ZHKA] Failure of Key SW C Signal

Action level
L01
Detail of
failure
Action of
controller
(WA470_7-D5ZHKA-400-A-Z0-A)
Failure of Key Switch C Signal

Failure code
Failure
D5ZHKA
An open circuit or ground fault of terminal-C line (The engine speed is 500 rpm or higher,
and the starting switch terminal-C signal is not entered.)
None in particular
Problem on
machine
Related
information
Input condition (ON/OFF) to the transmission controller from terminal C of starting switch
can be checked with monitoring function (Code: 02214 Starter Status).
When the engine is rotating, the terminal-C signal line may not be grounded.
When the engine is rotating, terminal C of starting switch may be turned ON (the starting
switch is normal).
If fuse No. 1 in fuse box 2 is blown, the machine monitor does not light up.
Method of reproducing failure code: Turn the starting switch to the START position.
No.
Cause
harness
(wire breakage or
connector)
harness
circuit)
controller
40-488

2. Disconnect connectors S40, L116, and L62, and connect T-adapters to
each female side.
Between S40 (female) (3) and L116 (female) (3)
Max. 1 z
Resistance
Max. 1 z
2. Connect T-adapters to connectors L62 and L116.
Resistance Between L116 (5) or L62 (16) and ground
Min. 1 Mz

3. Be ready with starting switch OFF, then troubleshoot by switching to ON,
OFF and START positions.
20 to 30 V
Voltage
Starting
switch:
OFF
and
ground
Max 1 V
ON
WA470-7
40 Troubleshooting
Circuit diagram related to terminal-C signal circuit
WA470-7
40-489
40 Troubleshooting
Failure code [D5ZHKB] Key SW C Signal Short Circuit

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Key Switch C Signal Short Circuit

Failure code
Failure
D5ZHKB
A hot short in terminal-C line (The engine speed is 500 rpm or higher, and the starting
switch terminal-C signal is entered.)
Engine start-up assistance control function has stopped.
Input condition (ON/OFF) to the transmission controller from terminal C of starting switch
can be checked with monitoring function (Code: 02214 Starter Status).
Cause
Defective starting
switch

wiring harness
(contact with 24V
circuit)
controller
40-490
(WA470_7-D5ZHKB-400-A-Z0-A)

2. Disconnect connector S40 and connect T-adapter to male side.
3. Troubleshoot by turning starting switch to ON, OFF and START positions.
Max. 1 z
Between S40 (male) (1)
Resistance and (3)
Min. 1 Mz
ON
2. Insert T-adapters into connectors L116 and L62.
3. Start the engine and troubleshoot during engine running.
Between L116 (3) and ground
Max 1 V
Voltage
Between L116 (5) or L62 (16) and ground
Max 1 V
3. Be ready with starting switch OFF, then troubleshoot by switching to ON,
OFF and START positions.
20 to 30 V
Voltage
Starting
switch:
OFF
and
ground
Max 1 V
ON
WA470-7
40 Troubleshooting
WA470-7
40-491
40 Troubleshooting
Failure code [D5ZHKZ] Failure of Key SW C Signal

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure of Key Switch C Signal

Failure code
Failure
D5ZHKZ
An open circuit of terminal-C line (The engine speed is 500 rpm or higher, and the starting
switch terminal-C signal is not entered.)
A short circuit of power supply line of terminal C-line (The engine speed is 500 rpm or
higher, and the starting switch terminal-C signal is continued for 30 seconds or longer.)
None in particular
The engine starts rotating immediately when the starting key is turned to ON position (due
to short circuit to the power supply line).
Input condition (ON/OFF) to the work equipment controller from terminal C of starting
switch can be checked with monitoring function (Code: 02217).
When the engine is rotating, the terminal-C signal line may not be grounded.
When the engine is rotating, terminal C of starting switch may be turned ON.
If fuse No. 1 in fuse box 2 is blown, the machine monitor does not light up.
Method of reproducing failure code: Turn the starting switch to the START position.
Cause
Defective starting
switch

harness
(wire breakage or
connector)

wiring harness
Defective work
40-492
(WA470_7-D5ZHKZ-400-A-Z0-A)

2. Disconnect connector S40.
Max. 1 z
Resistance and (3)
Min. 1 Mz
ON
2. Disconnect connectors L116, L73 and S40, and insert T-adapters into
each female side.
Max. 1 z
Resistance
Max. 1 z
3. Start the engine and troubleshoot during engine running.
Max 1 V
Voltage
Between L116 (5) or L73 (10) and ground
Max 1 V
Reference
START
20 to 30 V
Between L73 (female) (10) and
Voltage
ground
OFF, ON
Max 1 V
WA470-7
40 Troubleshooting
WA470-7
40-493
40 Troubleshooting
Failure code [D5ZHL6] Disconnection of Key SW C

Action level
L01
Detail of
failure
Action of
controller
(WA470_7-D5ZHL6-400-A-Z0-A)
Disconnection of Key Switch C

Failure code
Failure
D5ZHL6
While engine speed is 500 rpm or higher and R signal voltage of alternator exceeds 8 V,
key switch C terminal signal received by monitor controller remains "OFF".
None in particular
Problem on
machine
None in particular
Related
information

Input condition (ON/OFF) to machine monitor from starting switch terminal C can be
checked with monitoring function (Code: 04508 Engine Starter).
No.
Cause
harness
(wire breakage or
connector)
Defective monitor
controller
40-494

2. Disconnect connectors MCM1 A and S40, and insert T-adapters into each
female side.
Between S40 (female) (3) and MCM1 A (female)
Resistance (11)
Max. 1 z
Reference
2. Disconnect connector MCM1 A, and connect T-adapter to female side.
3. Turn starting switch to START position.
Voltage Between MCM1 A (female) (11) and ground
20 to 30 V
WA470-7
40 Troubleshooting
Circuit diagram related to key switch C terminal
WA470-7
40-495
40 Troubleshooting
Failure code [D811MC] KOMTRAX Error

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Failure code
D811MC
Failure
(WA380_7-D811MC-400-A-Z0-A)
KOMTRAX Error
(KOMTRAX system)
KOMTRAX terminal does not operate properly.

KOMTRAX terminal resets CPU of KOMTRAX and restarts.
KOMTRAX system does not work properly.

KOMTRAX terminal is defective.
1 Defective KOMTRAX terminal
No.
40-496
Cause
WA470-7
40 Troubleshooting
Failure code [D862KA] GPS Antenna Open Circuit

Action level
Detail of
failure
Action of
machine
monitor
Problem on
machine
Related
information
Failure code
D862KA
Failure
(WA380_7-D862KA-400-A-Z0-A)
GPS Antenna Open Circuit

(KOMTRAX system)
GPS module detects open circuit in GPS antenna circuit.

None in particular.
GPS positioning system does not work.
No.
Cause
Defective GPS antenna or
1
antenna cable

GPS antenna may be defective, or antenna cable may have open or
short circuit, or poor contact at terminal area (A).
Figure of structure
WA470-7
40-497
40 Troubleshooting
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
(WA470_7-
D8ALKA-400-A-Z0-A)
Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Operating Lamp Open Circuit (KOMTRAX)

Failure code
Failure
(KOMTRAX system)
D8ALKA
KOMTRAX terminal determines that output circuit to system operating lamp is open
because voltage of output circuit remains at approximately 5 V or below for approx. 3
seconds after starting switch is turned to ON position, during which KOMTRAX terminal
does not drive system operating lamp.
It does not output for system operating lamp.
While system operating lamp is lit, battery disconnect switch must not be turned to OFF
position. Setting battery disconnect switch to OFF position may destroy data stored in
KOMTRAX terminal memory.
Although KOMTRAX terminal is not able to light up system operating lamp, no trouble will
result unless battery disconnect switch is turned to OFF position.
When controller lights up system operating lamp, output circuit voltage is at low level.
Since no controller drives system operating lamp for approximately 3 seconds after
starting switch is turned to ON position, open circuit can be detected.

Cause
Defective fuse-4 in fuse If fuse is blown, circuit probably has ground fault.
box 2
2. Turn the battery disconnect switch to OFF position.
harness
3. Disconnect connectors L80A and R61, and connect T-adapters to each
female side.
(wire breakage or
Between L80A (female) (15) and R61 (female) (2)
Max. 1 z
connector)
Resistance Between R61 (female) (1) and battery relay
Max. 1 z
terminal (R01)
If no failure is found by above checks, KOMTRAX terminal is defective.
Defective KOMTRAX
terminal
40-498
WA470-7
40 Troubleshooting
Circuit diagram related to system operating lamp
WA470-7
40-499
40 Troubleshooting
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
(WA470_7-
D8ALKB-400-A-Z0-A)
Action level
Detail of
failure
Problem on
machine
Action of
controller
Related
information
No.
Operating Lamp Short Circuit (KOMTRAX)

Failure code
Failure
(KOMTRAX system)
D8ALKB
KOMTRAX terminal determines that output circuit to system operating lamp shorts
because voltage of output circuit does not become Low level while KOMTRAX terminal
drives system operating lamp.
KOMTRAX terminal memory.
Stops driving system operating lamp.
Although KOMTRAX terminal is not able to light up system operating lamp, no trouble will
Cause

harness

wiring harness
Defective KOMTRAX
terminal
40-500
1.
2.
3.
4.

Remove fuse-4 in fuse box 2.
Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
connect T-adapter to female side of R61.
Resistance Between R61 (female) (1) and (2)
Min. 1 Mz
1.
2.
3.
4.

Voltage Between R61 (female) (2) and ground
Max 1 V
WA470-7
40 Troubleshooting
WA470-7
40-501
40 Troubleshooting
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
(WA380_7-D8AQK4-400-A-Z0-A)
CAN2 Disconnection (KOMTRAX) 2

Failure code
Failure
(Detected by monitor controller) (Machine monitor system)
D8AQK4
Monitor controller does not recognize KOMTRAX terminal over CAN communication-2
line (KOMNET/c).
Does not update communication information.
Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
For CAN communication error over CAN communication-2 line, monitor controller can
generate six failure codes; [D8AQKR], [DAQQKR], [DAZQKR], [DB2QKR], [DB9QKR],
and [DSJ0KR]. When all of these six failure codes are displayed simultaneously on
screen, ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN
communication line). In this case, check whether air conditioner is operated (ON/OFF and
air flow adjustment) from air conditioner operation screen since air conditioner is also
controlled over CAN communication line.
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No.
Cause
Defective CAN-2
1
communication line
40-502

Perform troubleshooting for [D8AQKR].
WA470-7
40 Troubleshooting
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)

Action level
Detail of
failure
Action of
machine
monitor
Problem on
machine
General
information
(WA470_7-D8AQKR-400-A-Z0-A)
Failure code
CAN2 Disconnection (KOMTRAX)
Failure
D8AQKR
Monitor controller does not recognize KOMTRAX terminal over CAN communication-2
line (KOMNET/c).
None
None in particular
switch is received.
generate six failure codes; [D8AQK4], [DAQQKR], [DAZQKR], [DB2QKR], [DB9QKR],
using multimeter.
No.
1
2
3
4
5
Cause

Defective fuse-3 in fuse
box 2
If fuse is blown, circuit probably has ground fault.
Defective power supply Perform troubleshooting for E-58 of E-mode troubleshooting.
to KOMTRAX terminal
Defective CAN2
Perform checks on causes 4 to 9 in troubleshooting for failure code
communication system [DB2QKR].
Defective KOMTRAX
terminal
Defective monitor
controller
WA470-7
40-503
40 Troubleshooting
Circuit diagram related to power supply system
40-504
WA470-7
40 Troubleshooting
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON)
(WA380_7-
DAF0KT-400-A-Z0-A)
Action level
Failure code
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
DAF0KT
No.
Abnormality of Non-volatile Memory (Monitor)

Data is not written to or read from non-volatile memory of monitor controller.
Reading of service meter and odometer and other set values are changed.
Cause
1 Defective monitor controller
WA470-7
Failure

Monitor controller is defective.
40-505
40 Troubleshooting
Failure code [DAF0MB] Monitor ROM Abnormality

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
DAF0MB
Monitor ROM Abnormality

Program of monitor controller is rewritten (program error).
Data displayed on machine monitor are unreliable.

Machine monitor cannot exchange data with controllers normally.
Cause
Defective monitor
controller
40-506
Failure
(WA380_7-DAF0MB-400-A-Z0-A)

WA470-7
40 Troubleshooting
Failure code [DAF0MC] Monitor Error

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
DAF0MC
Monitor Error
Monitor controller malfunctions.
Data displayed on machine monitor are unreliable.

Machine monitor cannot exchange data with controllers normally.
Cause
WA470-7
Failure
(WA380_7-DAF0MC-400-A-Z0-A)

40-507
40 Troubleshooting
Failure code [DAF3KK] Controller Power Source Low (MON)
(WA470_7-DAF3KK-400-
A-Z0-A)
Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
Failure code
DAF3KK
Failure
Controller Power Source Low (Monitor)

Continuous power supply voltage of monitor controller is below 18 V.
Inhibits writing to memory.

In some cases, monitor screen displays nothing.
Since writing to non-volatile memory is inhibited, reliability of data displayed on screen
lowers.
Machine monitor does not display this failure code.
As T-adapter for monitor controller connector is "socket-type box", operating voltage

Cause
Defective slow-blow
If slow-blow fuse is blown, circuit may have ground fault. (See check on cause
fuses (R02) and (R03) 4.)
Defective fuse-3 in fuse If fuse is blown, circuit may have ground fault. (See check on cause 4.)
box 2
2. Set battery disconnect switch to OFF position.
20 to 30 V
Voltage
20 to 30 V
harness
(wire breakage or
connector)

a If fuse-3 in fuse box 2 or slow-blow fuse (R02) is blown, replace it.
Between battery relay terminal R01 and each of
Max. 1 z
MCM1 A (female) (1) and (4)
Resistance a Loosened or rusted ground terminal ground
terminal R22
Between ground and each of MCM1 A (female) (2)
and (3)

harness
circuit)
Defective monitor
controller
40-508
Max. 1 z

2. Disconnect fuse-3 in fuse box 2 and connector MCM1 A, and connect Tadapters to female side.
Between ground and fuse-3 in fuse box 2, or
Resistance between ground and each of MCM1 A (female) (1) Min. 1 Mz
and (4)
If no failure is found in above checks, monitor controller is defective. (Since
WA470-7
40 Troubleshooting
Circuit diagram related to monitor controller power supply
WA470-7
40-509
40 Troubleshooting
Failure code [DAF8KB] Camera Power Supply Short Circuit
(WA380_7-DAF8KB-400-A-
Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Camera Power Supply Short Circuit

Failure code
Failure
DAF8KB
When rear view monitor does not supply power for camera, supply voltage (rated voltage:
8 V) is 10 V or more.
Stops supplying power for rearview camera.
Camera image is not displayed on rear view monitor screen.
Cause
Defective rearview camera

1

2. Disconnect rearview camera connector G06, and turn starting switch
to ON position.
Perform procedure for reproducing failure code. If this failure code
disappear, rearview camera has internal defect.
2 Defective rear view monitor

2. Disconnect connector RVM2 and connect T-adapters to male side.
Voltage Between RVM2 (male) (1) and ground
6 to 10 V

harness

2. Disconnect camera connector G06 and connect T-adapters to
female side.
(Disconnect rearview camera and check that rearview camera is normal
in advance.)
Voltage Between G06 (female) (1) and (2)
Max. 10 V
Circuit diagram related to camera power supply
40-510
WA470-7
40 Troubleshooting
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit
(WA380_7-
DAFDKB-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Monitor 12V Power Output Short Circuit

Failure code
Failure
DAFDKB
When starting switch is turned to ON position, 12 V power supply voltage is 8 V or below,
or 14 V or above.
Stops supplying 12 V power (stops until starting switch is turned to OFF position).
Switch panel cannot be operated.
LED unit does not light up or lights up incorrectly.
If engine start lock is enabled, engine cannot be started because password cannot be
entered.
If failure code [DAF3KK] (Controller Power Source Low (MON)) is generated, perform
Method of reproducing failure code: Turn starting switch to OFF position, and then to ON
position.
Cause

Ground fault in wiring harness 2. Disconnect connectors MCM1 B, MDM2, and MOM1, and connect
T-adapters to either female side.
1
Resis- Between ground and MCM1 B (female) (107),
Min. 1 Mz
MDM2 (female) (1), or MOM1 (female) (1)
tance
2 harness

2. Disconnect connector MCM1 B, and connect T-adapters to female
side.
Voltage Between MCM1 B (female) (107) and (99)
Max. 1 V

2. Disconnect connector MCM1 B, and connect T-adapters to male
side.
9.3 to 14.1
Voltage Between MCM1 B (male) (107) and (99)
V
WA470-7
40-511
40 Troubleshooting
Circuit diagram related to monitor controller 12 V power supply
40-512
WA470-7
40 Troubleshooting
Failure code [DAFGMC] GPS Module Error

Action level
Detail of
failure
Action of
machine
monitor
Problem on
machine
Related
information
No.
1
Failure code
DAFGMC
Failure
(WA380_7-DAFGMC-400-A-Z0-A)
GPS Module Error

(KOMTRAX system)
KOMTRAX terminal can not communicate with GPS module in serial communication..
None in particular.
Method of reproducing failure code: Turn starting switch to ON position (at least 50
seconds after starting switch is turned to ON position).

GPS module in KOMTRAX terminal may be defective.
Defective KOMTRAX terminal
WA470-7
Cause
40-513
40 Troubleshooting
Failure code [DAFLKA] Operating Lamp Open Circuit (MON)
(WA470_7-DAFLKA-400-
A-Z0-A)
Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Operating Lamp Open Circuit (Monitor)

Failure code
Failure
DAFLKA
Monitor controller determines that output circuit to system operating lamp is open
because voltage of output circuit remains at approximately 5 V or below for approx. 3
seconds after starting switch is turned to ON position, during which monitor controller
does not drive system operating lamp.
Do not turn system operating lamp output ON.
While system operating lamp lights up, battery disconnect switch must not be set to OFF
monitor controller memory.
Although monitor controller is not able to light up system operating lamp, no trouble will
result unless battery disconnect switch is set to OFF position.
When controller lights up system operating lamp, output circuit voltage is at Low level.
Since no controller drives system operating lamp for approx. 3 seconds after starting
switch is turned to ON position, open circuit can be detected.

Cause
box 2
harness
female side.
(wire breakage or
Max. 1 z
(2)
connector)
Resistance
Between R61 (female) (1) and battery relay
Max. 1 z
terminal (R01)

harness
circuit)
Defective monitor
controller
40-514
1.
2.
3.
4.

Set battery disconnect switch to OFF position.
connect T-adapters to female side of MCM1 A.
Between MCM1 A (female) (57) and ground
Min. 1 Mz
Resistance
Min. 1 Mz
WA470-7
40 Troubleshooting
WA470-7
40-515
40 Troubleshooting
Failure code [DAFLKB] Operating Lamp Short Circuit (MON)
(WA470_7-DAFLKB-400-
A-Z0-A)
Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Operating Lamp Short Circuit (Monitor)

Failure code
Failure
DAFLKB
Monitor controller determines that output circuit to system operating lamp shorts because
voltage of output circuit does not become Low level while monitor controller drives system
operating lamp.
While system operating lamp lights up, battery disconnect switch must not be set to OFF
monitor controller memory.
Although monitor controller is not able to light up system operating lamp, no trouble will
result unless battery disconnect switch is set to OFF position.
When controller lights up system operating lamp, output circuit voltage is at Low level.
Cause

harness

wiring harness
Defective monitor
controller
40-516
1.
2.
3.
4.

connect T-adapters to female side of R61.
Min. 1 Mz
1.
2.
3.
4.

connect T-adapters to female side of R61.
Max. 1 V
WA470-7
40 Troubleshooting
WA470-7
40-517
40 Troubleshooting
Failure code [DAFQKR] CAN2 Discon (Monitor)

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA380_7-DAFQKR-400-A-Z0-A)
CAN2 Disconnection (Monitor)

Failure code
Failure
(KOMTRAX system)
DAFQKR
KOMTRAX terminal does not recognize monitor controller over CAN communication-2
line (KOMNET/c).
None in particular.
KOMTRAX system may not function normally.
switch is received.
Failure code is transmitted to and displayed on machine monitor over CAN
communication line. Accordingly, if CAN communication with machine monitor fails,
failure code [DAFQKR] is not displayed on machine monitor and it can be observed only
through KOMTRAX system.
Since each controller and monitor controller are connected directly to battery, they are
using multimeter.
Cause
Defective power supply to
1
monitor controller

Perform troubleshooting for failure code [DAF3KK].
Perform checks on causes 4 and after in troubleshooting for failure

2 Defective CAN communication code [DB2QKR]
40-518
WA470-7
40 Troubleshooting
Failure code [DAQ0KK] Controller Power Source Low (T/M)
(WA470_7-DAQ0KK-400-A-
Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
3
Controller Power Source Low (Transmission)

Failure code
Failure
DAQ0KK
Continuous power supply voltage (power supply directly connected to battery) of
transmission controller drops.
Continuous power supply voltage (power supply directly connected to battery) is 18 V or
below while engine speed is 500 rpm or above.
Cannot detect input signals properly.
Stops driving all devices other than fan pump relay (comes into neutral state).
(reverse) lever or directional selector (reverse) switch is set to N (neutral) position.
Machine cannot travel (transmission is left in NEUTRAL).
Fan runs at its maximum speed and may be damaged.
Fan rotating in reverse changes its direction to normal.
If fuse-5 in fuse box 2 is blown, failure codes [DAQQKR] and [DAQRKR] are displayed.
Cause
Defective battery
a Check battery voltage and specific gravity of battery electrolyte.

Voltage Battery voltage
Min. 24 V
Specific
Specific gravity of battery electrolyte
Min. 1.26
gravity
If slow-blow fuse (R02) is blown, circuit may have ground fault, etc. (See
check on cause 4.)
Defective slow-blow
fuse (R02)
box 2

harness
(wire breakage or
connector)
WA470-7
a If voltage appears between battery (+) terminal and ground but not
between ground and each of L63 (female) (1) and (11), wiring harness or
fuse has open circuit.
Between battery (-) terminal and ground
20 to 30 V
Voltage Between ground and each of L63 (female) (1) and
20 to 30 V
(11)
a
1.
2.
3.
If no failure is found by above checks, this check is not required.

Disconnect connector L63, and connect T-adapter to female side.
Between ground and each of L63 (female) (21),
Max. 1 z
(31), (32), and (33)
Resistance
Between battery (+) terminal and each of L63
Max. 1 z
40-519
40 Troubleshooting
No.
Cause
harness
circuit)
a
1.
2.
3.
4.
controller
1.
2.
3.
4.
5.
40-520
If slow-blow fuse is blown, replace it in advance.

Remove all fuses in fuse box 2.
Min. 1 Mz
Resistance
Between ground and L63 (female) (1) or (11)
Min. 1 Mz
Between L63 (1) and each of (21), (31), (32), and
Voltage (33), and between L63 (11) and each of (21), (31),
(32), and (33)
20 to 30 V
WA470-7
40 Troubleshooting
Circuit diagram related to power supply of transmission controller
WA470-7
40-521
40 Troubleshooting
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M)
(WA380_7-
DAQ0KT-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Abnormality of Non-volatile Memory (Transmission)

Failure code
Failure
DAQ0KT
Non-volatile memory (ROM) in transmission controller is abnormal.
When starting switch is turned to OFF position, end processing is not completed
successfully.
Reset internal adjustment values and option setting to default values.
Machine control parameters change and transmission shifting shock increases in some
cases.
Perform initial setting and initial adjustment similar to those required when transmission is
replaced.
(See Testing and adjusting, "Setting and adjustment of devices".)
Cause
controller
40-522

Since this is an internal defect, troubleshooting cannot be performed.
(If noticeable failure symptom does not appear, you may use that
transmission controller.)
WA470-7
40 Troubleshooting
Failure code [DAQ0MC] T/M Con Error

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
DAQ0MC
Transmission Controller Error

Controller exhibits unusual behavior (unexpected behavior).

Resets controller CPU and restarts it.
Machine returns to same initial condition as that when starting switch is turned to ON
position.
None in particular.
Cause
controller
WA470-7
Failure
(WA380_7-DAQ0MC-400-A-Z0-A)

40-523
40 Troubleshooting
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M)
(WA470_7-DAQ1KA-400-
A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
DAQ1KA
Failure
Disconnection of Key Switch ACC (Transmission)

While engine is running, key switch ACC signal is not entered in transmission controller.
None in particular
Machine travels normally although lockup clutch is not engaged until engine is stopped.
If ACC signal lines of both work equipment controller and engine controller have open
circuit, machine comes into the same state as when engine shutdown secondary switch is
operated.
If fuse No. 1 or No. 15 in fuse box 2 is blown, nothing is displayed on machine monitor.
When the engine is rotating, power is supplied other than the line between terminal ACC
of starting switch and transmission controller.
Cause
1.
2.
3.
4.
5.

harness
(wire breakage or
connector)
controller
40-524

Between L63 (female) (14) and (21)
20 to 30 V
Voltage
20 to 30 V
a
1.
2.
3.

Disconnect connectors L63 and S40, and connect T-adapters to each
female side.
Between L63 (female) (14) and S40 (female) (4)
Max. 1 z
Resistance
Max. 1 z
1.
2.
3.
4.
5.

Voltage
20 to 30 V
20 to 30 V
WA470-7
40 Troubleshooting
Circuit diagram related to ACC signal
WA470-7
40-525
40 Troubleshooting
Failure code [DAQ2KK] Solenoid Power Source Low (T/M)
(WA470_7-DAQ2KK-400-A-Z0-
A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
Solenoid Power Source Low (Transmission)

Failure code
Failure
DAQ2KK
24 V solenoid power supply voltage (appears at transmission controller pins 2, 12, and
22) is 18 V or lower, while controller power supply (continuous power supply voltage from
battery) is normal.
Detection conditions: Continuous power supply (battery direct power supply) is 20 V or
above and solenoid power supply is 18 V or below. Terminal-C input is OFF.
Does not generate failure codes that can be falsely generated due to drop in 24 V
solenoid power supply voltage.
lever or directional selector switch is set to N (neutral) position.
Machine cannot travel (transmission is left in NEUTRAL).
Fan rotating in reverse changes its direction to normal.
If failure code [DAQ4KB] (Ground Fault of Sol. Self-Holding Relay) is also displayed,
If fuse No. 2 in fuse box 1 is blown, failure codes [DF10KA] and [DDK6A] are displayed.

Cause
Defective slow-blow
fuse FL (R05 and
If slow blow fuse is blown, circuit probably has ground fault.
R06A)
Defective fuse 2 in fuse If fuse is blown, circuit probably has ground fault.
box 1
290 30 z
Resistance
Max. 1 z
Defective fan pump
(power supply holding)
2. Replace fan pump relay L112 with other normal relay.
relay
Machine becomes
Check if machine
Original relay (L112) is
becomes normal when normal.
defective.
fan pump (power supply
Original relay (L112) is
holding) relay (L112) is Machine does not
become
normal.
normal.
replaced.

harness
(wire breakage or
connector)

harness
circuit)
40-526

3. Disconnect connectors L112 and L63, and insert T-adapters into each
female side.
Between battery relay terminal R07 and L63
Max. 1 z
(female) (2), (12) and (22)
Resistance a Coil resistance of fan pump (self-holding) relay
Between ground and each of L63 (21) and (31)
290 30 z
Max. 1 z
a
1.
2.
3.
4.
5.

Remove slow blow fuse R04.
Between battery relay terminal (R07) and ground
Min. 1 Mz
Resistance
Between ground and L63 (female) (2), (12), or (22) Min. 1 Mz
WA470-7
40 Troubleshooting
No.
Cause
controller
WA470-7
1.
2.
3.
4.
5.

Voltage
Between L63 (22) and (33), and between L63 (32)
and (33)
20 to 30 V
20 to 30 V
20 to 30 V
40-527
40 Troubleshooting
Circuit diagram related to power supply of transmission controller
40-528
WA470-7
40 Troubleshooting
Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay
(WA470_7-
DAQ4KB-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Ground Fault of Solenoid Self-Holding Relay (TM)

Failure code
Failure
DAQ4KB
Excessive current flows when the output to primary circuit (coil) of fan pump (solenoid
self-holding) relay is turned ON. When controller drives primary circuit (coil) of fan pump
(solenoid self-holding) relay, large current flows.
Stops driving fan pump (solenoid self-holding) relay circuit.
The radiator fan cannot be rotated reversely.
(If rotating reversely, it is changed to the normal rotation.)
Output signal of fan pump (solenoid self-holding) relay can be checked with monitoring
function (Code: 03900).
This failure code detects failure in primary (coil) circuit of fan pump (solenoid self-holding)
relay. It does not detect failure in secondary (contact) circuit.
Cause
Defective fan pump
(solenoid self-holding)
relay (L112)

290 30 z

harness
circuit)

female side.
Min. 1 Mz

harness

female side.
Resistance L112 (female) (1) and (2)
Min. 1 Mz
controller

WA470-7
20 to 30 V
40-529
40 Troubleshooting
Circuit diagram related to fan pump (transmission solenoid self-holding) relay
40-530
WA470-7
40 Troubleshooting
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M)
(WA380_7-
DAQ9KQ-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Inconsistency of Model Selection (Transmission)

Failure code
Failure
DAQ9KQ
Model selection information sent from machine monitor differs from that stored in
transmission controller.
Continues to operate taking it that machine model is same as that before generation of
this failure code.
Does not generates failure codes that can be falsely detected due to this error.
Problem on
machine
Driving machine may damage transmission.
Related
information
Part number of transmission controller can be checked with monitoring function.

(Code: 20414)
Model selection of machine monitor can be checked with monitoring function.
(Code: 00205)
No.
1
2
3

False model may be selected in machine monitor. When replacing
machine monitor, be sure to perform setting of model selection by
False model selection of
using adjustment function in service mode of machine monitor.
machine monitor
(See, Testing and adjustment, "Special functions of machine monitor".)
Transmission controller of
Check part number of transmission controller. If it is wrong, install
false part number
proper transmission controller.
If no failure is found by above checks, machine monitor or transmission
Defective machine monitor or controller is defective. (Since this is an internal defect, troubleshooting
cannot be performed).
WA470-7
Cause
40-531
40 Troubleshooting
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M)
(WA470_7-DAQLKA-400-A-
Z0-A)
Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Operating Lamp Open Circuit (Transmission)

Failure code
Failure
DAQLKA
Transmission controller determines that output circuit to system operating lamp is open
because voltage of output circuit remains at approximately 5V or below for approx 3 seconds
after starting switch is turned to ON position, during which transmission controller does not
drive system operating lamp.
position.
System operating lamp may not light up while controller is performing end processing
a While controller is performing end processing, if battery disconnect switch is set to "OFF"
position, fan stops suddenly and may be damaged. In addition, initial learning data are not
saved resulting in increased shifting shocks.
Although transmission controller is not able to light system operating lamp, no trouble will
When system operating lamp is lit up, output circuit voltage is at low level.

Cause
box 2
harness
female side.
(wire breakage or
Between battery relay terminal (R01) and R61
Max. 1 z
connector)
Max. 1 z

harness
circuit)
controller
40-532
1.
2.
3.
4.

connect T-adapter to female side of L63.
Min. 1 Mz
Resistance
Min. 1 Mz
WA470-7
40 Troubleshooting
WA470-7
40-533
40 Troubleshooting
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M)
(WA470_7-DAQLKB-400-A-
Z0-A)
Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Operating Lamp Short Circuit (Transmission)

Failure code
Failure
DAQLKB
Transmission controller determines that output circuit to system operating lamp shorts
because voltage of output circuit does not become Low level while transmission controller
drives system operating lamp.
When controller drives system operating lamp, large current may flow through circuit
causing burnout of controller.
System operating lamp may not light up while controller is performing end processing
a While controller is performing end processing, if battery disconnect switch is set to OFF
position, fan stops suddenly and may be damaged. In addition, initial learning data are not
saved resulting in increased shifting shocks.
Although transmission controller is not able to light system operating lamp, no trouble will
When system operating lamp is lit up, output circuit voltage is at low level.
Cause

harness

wiring harness
controller
40-534
1.
2.
3.
4.

Min. 1 Mz

3. Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
Max 1 V
WA470-7
40 Troubleshooting
WA470-7
40-535
40 Troubleshooting
Failure code [DAQQKR] CAN2 Discon (Transmission Con)
(WA380_7-DAQQKR-400-A-
Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
CAN2 Disconnection (Transmission Controller)

Failure code
Failure
DAQQKR
Monitor controller does not recognize transmission controller over CAN communication-2
line (KOMNET/c).
Failure codes to be generated by transmission controller are not displayed.
Fan rotation direction cannot be reverse.
Adjustment function is unavailable.
Monitoring data for which transmission controller is responsible are not updated.
switch is received.
generate six failure codes; [D8AQKR], [DAQQKR], , [DAZQKR], [DB2QKR], [DB9QKR],
using multimeter.
No.
1
2
Cause
Defective CAN-2
communication line
controller
40-536

Perform troubleshooting for failure code [DAQ0KK].
[DB2QKR].
If no failure is found by above checks, transmission controller is
defective.
WA470-7
40 Troubleshooting
Failure code [DAQRKR] CAN1 Discon (Transmission Con)
(WA500_7-DAQRKR-400-A-
Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
3
4
CAN1 Disconnection (Transmission Controller)

Failure code
Failure
DAQRKR
Monitor controller does not recognize transmission controller over CAN communication-1
line (KOMNET/r).
Hides pointer of torque converter oil temperature gauge and hydraulic oil temperature
gauge from screen.
Changes display of speedometer to "00".
Machine monitor leaves data of CAN communication from transmission controller as the
value just before this failure occurs.
Information to be obtained from transmission controller is not displayed and special
functions that need information do not work. Or received data are not updated.
Pointer of torque converter oil temperature gauge and hydraulic oil temperature gauge
disappears from screen.
switch is received.
generate two other failure codes; [DB2RKR] and [DB9RKR]. When these two failure
codes are also displayed on screen, ground fault, short circuit, or hot short circuit may
occur in wiring harness (CAN communication line).
CAN1 terminating resistor on operator's cab side is located in machine monitor and that
on engine side is connector "B_RES" (connector B_RES is not located on CAN
communication-1 line (KOMNET/r) but is connected to it via connector "J2").
using multimeter.
Cause
to transmission
controller
Defective CAN-1
communication line
controller
Defective monitor
controller
WA470-7

Perform troubleshooting for [DAQ0KK].
[DB2RKR].
40-537
40 Troubleshooting
Failure code [DAQRMA] Inconsistency of Option Selection (T/M)
(WA380_7-
DAQRMA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Inconsistency of Option Selection (Transmission)

Failure code
Failure
DAQRMA
When starting switch is turned to ON position, option setting information sent from monitor
controller differs from that stored in transmission controller.
Uses option setting stored in it to control machine.
Machine does not operates according to option setting.
Perform initial setting and initial adjustment similar to those required when transmission is
replaced.
Cause
Improper option setting of

machine monitor
controller
40-538

Option setting of machine monitor is probably incorrect. Perform
correct setting referring to Testing and adjustment, "Special functions of
machine monitor".
Monitor controller may be defective. (Since this is an internal defect,
If no failures is found by above checks, transmission controller may be
performed.)
WA470-7
40 Troubleshooting
Failure code [DAZ9KQ] A/C Model Selection Abnormality

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
(WA380_7-DAZ9KQ-400-A-Z0-A)
Air Conditioner Model Selection Abnormality

Failure code
Failure
DAZ9KQ
Machine model in machine monitor program differs from that in air conditioner controller
program.
(Replaced machine monitor or air conditioner controller has wrong part number.)
Air conditioner does not work normally.

Model code in machine monitor program can be checked with monitoring function.
(Code: 00205 Model selection (MON))
Air conditioner controller data (machine model and series) can be checked with
monitoring function. (Code: 55201) (Air conditioner control data must be 30 (indicating
wheel loader.)
Air conditioner control data (machine model and series) of machine monitor can be
checked with monitoring function. (Code: 55200) (Air conditioner control data must be 30
(indicating wheel loader.)

Defective machine monitor
(Wrong machine model is programmed.)
Defective air conditioner Defective air conditioner controller
controller
(Wrong machine model is programmed.)
Cause
Defective machine
monitor
WA470-7
40-539
40 Troubleshooting
Failure code [DAZQKR] CAN2 Discon (Aircon ECU)

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
(WA380_7-DAZQKR-400-A-Z0-A)
CAN2 Disconnection (Air Conditioner ECU)

Failure code
Failure
DAZQKR
Monitor controller does not recognize air conditioner controller over CAN communication2 line (KOMNET/c).
Holds information at time of occurrence of failure.
Failure codes to be generate by air conditioner controller are not displayed.
Monitoring data for which air conditioner controller is responsible are not updated.
Air conditioner cannot be operated (air does not blow out).
Display of air conditioner operation screen of machine monitor is not correct.
switch is received.
communication line).
using multimeter.
a If fuse-15 in fuse box2 is blown, machine monitor displays nothing..

No.
Cause
Defective power supply to air

conditioner controller
Defective CAN-2
communication line
Defective air conditioner

controller
40-540

a Perform troubleshooting shown in Chapter 80 "Troubleshooting of
power supply system".
[DB2QKR].
If no failure is found by above checks, air conditioner controller is
defective.
WA470-7
40 Troubleshooting
Failure code [DB2QKR] CAN2 Discon (Engine Con)

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
(WA470_7-DB2QKR-400-A-Z0-A)
CAN2 Disconnection (Engine Controller)

Failure code
Failure
DB2QKR
Monitor controller does not recognize engine controller over CAN communication-2 line
(KOMNET/c).
Failure codes to be generate by engine controller are not displayed.
Monitoring data for which engine controller is responsible are not updated.
Manual regeneration of KDPF cannot be performed.
Cylinder cutout mode operation and no-injection cranking cannot be performed.
switch is received.
If failure code [DB2RKR] is also displayed, engine controller may be defective (cause 2).
using multimeter.
a If fuse-15 in fuse box2 is blown, machine monitor displays nothing..
No.
1
Cause

box 2
When fuse is blown, engine controller may have internal short circuit.
Defective engine
controller
a If fuse is not blown, this check is not required.

2. Disconnect connectors EC3 and connect T-adapters to male side.
Between EC3 (male) (1) and (21)
Min. 10 z
Resistance
Between EC3 (male) (11) and (31)
Min. 10 z
a Check ground terminals E14A and E14B for looseness and corrosion in
advance.
Defective power supply 2. Disconnect connectors EC3 and connect T-adapters to female side.
to engine controller
a If check result is abnormal, perform troubleshooting for [CA441].
Between EC3 (female) (1) and (2)
20 to 30 V
Voltage
20 to 30 V
CAN terminating
resistor
circuit)
WA470-7

2. Disconnect connector MDM 3 and CAN1, and connect T-adapters to male
side.
Between CAN1 (male) (A) and (B)
120 12 z
Resistance
120 12 z
Between MDM3 (male) (3) and (8)
40-541
40 Troubleshooting
No.
Cause

CAN communication line
a CAN terminating resistor of 120 z is also located in machine monitor. That
is, two CAN terminating resistors of 120 z are connected in parallel. When
circuit resistance is measured at connector of controller other than
machine monitor, if combined resistance is 60 z, wiring harness does not
have open circuit.
OFF position.
2. Disconnect related connectors and connect T-adapters to connector at
which measurement is performed.

wiring harness

harness
(wire breakage or
connector)
40-542
a If open circuit is found (resistance between two terminals is 1 z or below),

disconnect all CAN communication connectors of every controller and
check whether open circuit occurs in wiring harness or inside controller.
Approx. 120
z
Approx. 60
z
Approx.
60
Between MCM1 B (female) (97) and (89)
z
Approx. 60
z
Resistance
Approx.
60
z
Approx. 60
Between AL1 (female) (4) and (6)
z
Approx.
60
Between L80A (female) (10) and (11)
z
Approx. 120
Between CAN1 (male) (A) and (B)
z
ACC signal of starting switch (start of CAN communication is not
recognized)
OFF position.
2. Disconnect connector at which measurement is performed and insert Tadapters into it.
3. Set battery disconnect switch to ON position, and turn starting switch to
ON position.
20 to 30 V
20 to 30 V
Between L73 (female) (21) and each of (14) and
20 to 30 V
(24)
Voltage
20 to 30 V
(24)
Between AL1 (1) and (5)
20 to 30 V
Between L80B (3) and (1)
20 to 30 V
OFF position.
2. Disconnect related connectors and connect T-adapters to female side of
connector at which measurement is performed.
Between MDM3 (female) (3) and MCM1 B (female)
Max. 1 z
(97)
Between MDM3 (female) (8) and MCM1 B (female)
Max. 1 z
(89)
Resistance
Between MCM1 B (female) (97) and L62 (female)
Max. 1 z
(32)
Max. 1 z
(22)
WA470-7
40 Troubleshooting
No.
Cause

Between MCM1 B (female) (97) and EC3 (female)
(17)
Between MCM1 B (female) (89) and EC3 (female)
(18)
(32)
(22)
Between MCM1 B (female) (97) and AL1 (female)
(4)
Between MCM1 B (female) (89) and AL1 (female)
(6)
Between MCM1 B (female) (97) and L80A (female)
(10)
Between MCM1 B (female) (89) and L80A (female)
(11)
Between EC3 (female) (17) and CAN1 (female) (A)
Between EC3 (female) (18) and CAN1 (female) (B)
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
a If no failure (open circuit) is found by check on cause 5, measure

resistance at any one place in each case.
OFF position.
2. Disconnect related connectors and connect T-adapters to female side of
connector at which measurement is performed.
Between ground and any of MDM3 (female) (3),
L62 (female) (32), L80A (female) (10), AL1 (female) Min. 1 Mz
(4), EC3 (female) (17), or L72 (female) (32)
Resistance
L62 (female) (22), L80A (female) (11), AL1 (female) Min. 1 Mz

harness
a If no failure (open circuit) is found by check on cause 5, measure voltage

at any one place in each case.
OFF position.
2. Disconnect connector at which measurement is performed and insert Tadapters into connector.
Open circuit or hot short 3. Set battery disconnect switch to ON position.
circuit in wiring harness 4. Turn starting switch to ON position.
(contact with 24 V
a Voltage of CAN H and CAN L is 2.5 1 V including during communication,
circuit)
so regard wiring harness as normal if measure voltage is 1 to 4 V.
L62 (female) (32), L80A (female) (10), AL1 (female)
1 to 4 V
Voltage
1 to 4 V
L62 (female) (22), L80A (female) (11), AL1 (female)
WA470-7
40-543
40 Troubleshooting
No.
Cause

When all of six failure codes [D8AQKR], [DAQQKR], [DAZQKR],
[DB2QKR], [DB9QKR], and [DSJ0KR] are displayed simultaneously
a To identify defective controller, repeat following steps 1. to 3. to disconnect

controllers one by one from CAN communication line .
Defective engine
controller, work
OFF position.
equipment controller,
2. Disconnect each CAN communication connector one by one in order
transmission controller,
engine controller connector EC3, work equipment controller connector
9
air conditioner
L72, transmission controller connector L62, air conditioner controller
controller, machine
connector AL1, KOMTRAX terminal connector L80A, and machine
monitor (meter unit), or
monitor (meter unit) connector MDM3.
KOMTRAX terminal
3. Set battery disconnect switch to ON position, turn starting switch to ON
position, then perform troubleshooting.
4. Return to step 1 to check next connector.
Has the number of displayed failure codes
If YES, disconnected
decreased from six?
Defective engine
10
controller
If
no failure is found by above checks, monitor controller is defective.
Defective monitor
11
controller
40-544
WA470-7
40 Troubleshooting
Circuit diagram related to CAN communication-2 line
WA470-7
40-545
40 Troubleshooting
Failure code [DB2RKR] CAN1 Discon (Engine Con)

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA470_7-DB2RKR-400-A-Z0-A)
CAN1 Disconnection (Engine Controller)

Failure code
Failure
DB2RKR
Monitor controller does not recognize engine controller over CAN communication-1 line
(KOMNET/r).
Hides pointer of engine coolant temperature gauge from screen.
Moves pointer of engine speed meter to zero point.
Machine monitor leaves CAN communication data from engine controller as the value just
before this failure occurs.
Information to be obtained from engine controller is not displayed and special functions
that need information do not work. Or received data are not updated.
Engine cannot be controlled.
Engine speed and coolant temperature cannot be detected.
Pointer of engine coolant temperature gauge disappears.
switch is received.
If failure code [DB2QKR] is also displayed, engine controller may be defective (cause 1).
generate failure codes [DAQRKR], [DB2RKR], and [DB9RKR].
on engine side is connector B_RES (connector B_RES is not located on CAN
communication-1 line (KOMNET/r) but is connected to it via connector "ECM J2").
using multimeter.
Cause
Defective engine
controller system

[DB2QKR].
Defective CAN
terminating resistor
circuit)

2. Disconnect connector MCM1 B and C23, and connect T-adapters to male
side.
Between C23 (male) (A) and (B)
120 12 z
Resistance
120 12 z
Between MCM1 B (male) (105) and (112)
40-546
WA470-7
40 Troubleshooting
No.
Cause

CAN communication line
a CAN terminating resistor of 120 z is also located in monitor controller.
That is, two CAN terminating resistors of 120 z are connected in parallel.
When circuit resistance is measured at connector of controller other than
monitor controller, if combined resistance is 60 z, wiring harness does not
have open circuit.
OFF position.
2. Disconnect connectors MCM1 B, L62, L72, ECM J1, ECM J2, and B_RES
one by one, and connect T-adapters to each female side.

wiring harness
WA470-7
a If open circuit is found (resistance between two terminals is 1 z or below),

disconnect all CAN communication connectors of every controller and
check whether open circuit occurs in wiring harness or inside controller.
Approx. 120
Between MCM1 B (female) (113) and (105)
z
Approx.
60
z
Approx. 60
z
Resistance Between B_RES (male) (A) and (B)
Approx. 120
z
Approx.
120
Between ECM J1 (female) (8) and (18)
z
Approx. 120
Between ECM J2 (female) (24) and (25)
z
40-547
40 Troubleshooting
No.
Cause

harness
(wire breakage or
connector)

harness
circuit)
40-548

ACC signal of starting switch (start of CAN communication is not
recognized)
1. Turn starting switch to OFF position, and disconnect battery ground cable.
2. Disconnect connectors MCM1 A, L63, and EC3, and insert T-adapters.
ON position.
Between MCM1 A (female) (4) and each of (24)
20 to 30 V
and (43)
20 to 30 V
Voltage Between L73 (female) (21) and each of (14) and
20 to 30 V
(24)
20 to 30 V
(24)
OFF position.
2. Disconnect connectors MCM1 B, L62, ECM J1, ECM J2, and B_RES, and
connect T-adapters to each female side.
Max. 1 z
(33)
Max. 1 z
(23)
Max. 1 z
(33)
Max. 1 z
(23)
Resistance
Between MCM1 B (female) (113) and ECM J1
Max. 1 z
(female) (8)
Between MCM1 B (female) (105) and ECM J1
Max. 1 z
(female) (18)
Between ECM J2 (female) (24) and B_RES
Max. 1 z
(female) (A)
Between ECM J2 (female) (25) and B_RES
Max. 1 z
(female) (B)
OFF position.
2. Disconnect connectors MCM1 B, L72, L62, ECM J1, ECM J2, and C23,
and connect T-adapters to each female side.
Between ground and any of L72 (female) (33), L62
(female) (33), MCM1 B (female) (113), MCM1 B
Min. 1 Mz
(female) (112), and ECM J1 (female) (8)
Between ground and ECM J2 (female) (24) or C23
Min. 1 Mz
(female) (A)
Resistance
(female) (23), MCM1 B (female) (105), and ECM J1 Min. 1 Mz
(female) (18)
Between ground and either of ECM J2 (female)
Min. 1 Mz
(25) and B_RES (female) (B)
WA470-7
40 Troubleshooting
No.
Cause
a If no failure (open circuit) is found by check on cause 3, measure voltage

at any one place in each case.
OFF position.
2. Disconnect any of connectors MCM1 B, L72, L62, and B_RES, and
connect T-adapters to female side.
Open circuit or hot short 4. Turn starting switch to ON position.
circuit in wiring harness a Measurement is not performed at connector ECM J1, ECM J2, or MCM1
B.
a Voltage of CAN H and CAN L is 2.5 1 V including during communication,
so regard wiring harness as normal if measured voltage is 1 to 4 V.
1 to 4 V
(female) (33) and B_RES (female) (A)
Voltage
1 to 4 V
(female) (22) and B_RES (female) (B)
If failure code [DAQRKR] is also displayed
controller
Defective work
Defective engine
controller
10
Defective engine
controller
11
Defective monitor
controller
WA470-7
a Disconnect transmission controller and engine controller one by one from

CAM communication line to determine which controller is defective.
OFF position.
2. Disconnect transmission controller connector L62.
ON position.
Does either of failure codes [DAQRKR] and
If YES, transmission
[DB2RKR] for CAN1 communication error
disappear?
When failure code [DB9RKR] is also displayed
a Disconnect work equipment controller and engine controller one by one
from CAM communication line to determine which controller is defective.
OFF position.
2. Disconnect work equipment controller connector L72.
ON position.
Does either of failure codes [DB2RKR] and
If YES, work equipment
[DB9RKR] for CAN1 communication error
disappear?
When failure codes[DAQRKR] and [DB9RKR] are also displayed
a Disconnect work equipment controller, transmission controller, and engine
controller one by one from CAM communication line to determine which
OFF position.
2. Disconnect engine controller connector ECM J1.
ON position.
Does any of failure codes [DAQRKR], [DB2RKR], If YES, engine controller
and [DB9RKR] for CAN1 communication error
is defective.
disappear?
40-549
40 Troubleshooting
Circuit diagram related to CAN communication-1 line
40-550
WA470-7
40 Troubleshooting
Failure code [DB90KK] Drop in BBC Controller Main Power Source
(WA470_7-
DB90KK-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
2
3
Drop in Bucket Boom Controller Controller Main Power Source

Failure code
Failure
DB90KK
Continuous power supply (power supply directly connected to battery) voltage of work
equipment controller drops.
Continuous power supply (battery direct power supply) voltage is 18 V or less.
Cannot detect input signals properly.
Correct the settings so that any failure code, other than this failure code, is not displayed
when the continuous power supply (power supply directly connected to battery) voltage is
18 V or less for 0.02 second.
Even if cause of failure disappears, machine does not become normal until work
equipment lever is set to NEUTRAL position.
Since an input signal cannot be detected correctly, normal operation cannot be
performed.
If fuse-5 in fuse box 2 is blown, failure codes [DAQQKR] and [DAQRKR] are displayed.
Cause
Defective battery
a Check battery voltage and specific gravity of battery electrolyte.

Voltage Battery voltage
Min. 24 V
Specific
Specific gravity of battery electrolyte
Min. 1.26
gravity
If slow-blow fuse (R02) is blown, circuit may have ground fault, etc. (See
check on cause 5.)
Defective slow-blow
fuse (R02)
Defective fuse 3 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on cause 5.)
box 2

harness
(wire breakage or
connector)

harness
circuit)
WA470-7
a If voltage appears between battery (+) terminal and ground but not
between ground and each of L73 (1) and (11), wiring harness or fuse has
open circuit.
20 to 30 V
Voltage Between ground and each of L73 (female) (1) and
20 to 30 V
(11)
a
1.
2.
3.

Max. 1 z
(31), (32), and (33)
Resistance
Between battery (+) terminal and each of L73 (1)
Max. 1 z
and (11)
a
1.
2.
3.
4.
If slow-blow fuse or fuse is blown, replace it in advance.

Disconnect connector L73, and connect T-adapter to female side of L73.
Min. 1 Mz
Resistance
Between ground and L73 (female) (1) or (11)
Min. 1 Mz
40-551
40 Troubleshooting
No.
Cause
Defective work
1.
2.
3.
4.
5.

Between L73 (1) and each of (21), (31), (32), and
Voltage (33), and between L73 (11) and each of (21), (31),
(32), and (33)
20 to 30 V
Circuit diagram related to work equipment controller power supply
40-552
WA470-7
40 Troubleshooting
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC)
(WA380_7-
DB90KT-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
DB90KT
Abnormality of Non-volatile Memory (Bucket Boom

Controller)
The non-volatile memory in the controller has failed.

Controls option settings and internal adjustment values with the default value.
An incorrect error detection may occur.
The machine performance drops as abnormal data is used for control.
Cause
Defective work equipment
controller
WA470-7
Failure

Replace the work equipment controller.
40-553
40 Troubleshooting
Failure code [DB90MC] BBC Error

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
DB90MC
Bucket Boom Controller Error

Malfunction of work equipment controller (unexpected behavior).

Resets the CPU of work equipment controller, and restarts it.
The system does not operate normally.
Machine returns to the initial status as when the starting switch is turned ON.
Method of reproducing failure code: Turn starting switch ON.
Cause
controller
40-554
Failure
(WA380_7-DB90MC-400-A-Z0-A)

The work equipment controller is defective.
WA470-7
40 Troubleshooting
Failure code [DB91KA] Disconnection of Key SW ACC (BBC)
(WA470_7-DB91KA-400-
A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Disconnection of Key Switch ACC (Bucket Boom Controller)

Failure code
Failure
DB91KA
While engine is running, key switch ACC signal is not entered in work equipment
controller.
None in particular
Work equipment does not operate.
If ACC signal lines of both transmission controller and engine controller have open circuit,
machine comes into the same state as when engine shutdown secondary switch is
operated.
If fuse No. 1 or No. 15 in fuse box 2 is blown, nothing is displayed on machine monitor.
When the engine is rotating, power is supplied other than the line between terminal ACC
of starting switch and work equipment controller.
Cause
1.
2.
3.
4.
5.

harness
(wire breakage or
connector)
Defective work
WA470-7

20 to 30 V
Voltage
20 to 30 V
a
1.
2.
3.

Disconnect connectors L73 and S40, and connect T-adapters to each
female side.
Max. 1 z
Resistance
Max. 1 z
1.
2.
3.
4.
5.

Voltage
20 to 30 V
20 to 30 V
40-555
40 Troubleshooting
Circuit diagram related to ACC signal
40-556
WA470-7
40 Troubleshooting
Failure code [DB92KK] Solenoid Power Source Low (BBC)
(WA470_7-DB92KK-400-A-
Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
Solenoid Power Source Low (Bucket Boom Controller)

Failure code
Failure
DB92KK
24V solenoid power supply voltage (appears at work equipment controller pins 2, 12, and
22) is 18 V or lower, while controller power supply (continuous power supply voltage from
battery) is normal.
Detection conditions: Continuous power supply voltage (continuous power supply voltage
from battery) is Min. 20 V and solenoid power supply is Max. 18 V.
Stops driving solenoids (stops driving all solenoids if solenoid power supply voltage drops
below 18 V).
Does not allow failure codes to be displayed, that can be falsely generated due to drop in
24 V solenoid power supply voltage.
Even if cause of failure disappears, machine does not become normal until work
equipment lever is set to NEUTRAL position.
Work equipment does not operate.

Cause
Defective slow-blow
fuse FL (R05 and
If slow blow fuse is blown, circuit probably has ground fault.
R06A)
box 1

harness
(wire breakage or
connector)

harness
circuit)
WA470-7
a If voltage appears between terminal R07 of battery relay and the ground,
but not between ground and each of L73 (2), (12) and (22), the wiring
harness may be broken or the fuse may be blown.
Between battery relay terminal R07 and ground
20 to 30 V
Voltage Between ground and each of L73 (female) (2), (12)
20 to 30 V
and (22)
a
1.
2.
3.

Max. 1 z
(31), (32), and (33)
Resistance
Between battery (+) terminal and each of L73
Max. 1 z
(female) (2), (12), and (22)
a
1.
2.
3.
4.
5.

Remove slow blow fuse R05.
Disconnect connector L73, and connect T-adapter to female side of L73.
Between battery relay terminal (R07) and ground
Min. 1 Mz
Resistance
Between ground and L73 (female) (2), (12), or (22) Min. 1 Mz
40-557
40 Troubleshooting
No.
Cause
Defective work
1.
2.
3.
4.
5.

Voltage
Between L73 (22) and (32), and between L73(22)
and (33)
20 to 30 V
20 to 30 V
20 to 30 V
Circuit diagram related to work equipment controller power supply
40-558
WA470-7
40 Troubleshooting
Failure code [DB95KX] Failure of 5 V Power Source 1

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA470_7-DB95KX-400-A-Z0-A)
Failure of 5 V Power Source 1

Failure code
Failure
DB95KX
Voltage of 5 V sensor power output circuit 1 is outside of normal output range of 4.7 to 5.3
V.
Does not detect input signal normally because erroneous signal is input from
potentiometer.
Pressure sensor and potentiometer signals are not input normally.
The boom operation stops.
Bucket leveler does not work.
Komatsu SmartLoader Logic function stops.
Cause

2. Disconnect connectors of the following sensors one by one and turn
starting switch ON each time.
a If this failure code goes out, disconnected sensor is defective.
a Since connector is disconnected, other failure codes appear. Ignore all

of displayed failure codes other than this one.
Defective
3rd (attachment) EPC lever potentiometer
potentiometer, pressure
L30
sensor, or angle sensor
Boom EPC lever potentiometer
L28A
F10
R86
Connector Emergency steering pump oil pressure sensor
R37
Boom bottom pressure sensor
F12
Boom head pressure sensor
F13
Boom angle sensor
F11
Bucket angle sensor
F32

harness (contact with
ground circuit)

2. Disconnect connectors F10 to F13, F32, L28A, L29A, L30, and L71.
3. Connect T-adapter to female side of connector L71.
Min. 1 Mz
Defective work

Voltage Between L71 (male) (22) and (4)
5.0 to 5.2 V

wiring harness

2. Disconnect connectors F10 to F13, F32, L28A, L29A, and L30.
4. Turn starting switch ON (with connector disconnected).
Voltage Between L71 (22) and ground
5.0 to 5.2 V
WA470-7
40-559
40 Troubleshooting
Circuit diagram related to 5V sensor power source (2 levers specification or 3 levers specification)
40-560
WA470-7
40 Troubleshooting
Failure code [DB96KX] Failure of 5 V Power Source 2

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA470_7-DB96KX-400-A-Z0-A)
Failure of 5 V power source 2

Failure code
Failure
DB96KX
Voltage of 5 V sensor power output circuit 2 is outside of normal output range of 4.7 to 5.3
V.
potentiometer.
Potentiometer signals are not input normally.
Bucket stops operation.
Potentiometer error shown in Cause 1 occurs.
Cause

Defective potentiometer

Connector Bucket lever potentiometer
L29A

harness
circuit)

2. Disconnect connectors L29A, L23, and L72.
Defective work

2. Disconnect connector L72, and connect T-adapter to male side.
Voltage Between L72 (male) (1) and ground
5.0 to 5.2 V

wiring harness

2. Disconnect connectors L29A and L23.
WA470-7
Min. 1 Mz
5.0 to 5.2 V
40-561
40 Troubleshooting
Circuit diagram related to 5 V sensor power supply
40-562
WA470-7
40 Troubleshooting
Failure code [DB99KQ] Inconsistency of Model Selection (BBC)
(WA380_7-
DB99KQ-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Inconsistency of Model Selection (Bucket Boom Controller)

Failure code
Failure
DB99KQ
Model selection signal sent from monitor controller when starting switch is turned ON
differs from the model setting stored in work equipment controller.
Continues to operate taking it that machine model is same as that before generation of
this failure code.
Problem on
machine
Work equipment may not operate normally.
Related
information
Perform initial setting and initial adjustment similar to those required when the work
equipment controller is replaced.
No.
Cause
Defective model setting by

monitor controller
Installation of wrong work


controller
WA470-7

a Model setting of monitor controller is probably incorrect. After
replacing the monitor controller or work equipment controller, set the
model correctly. For details, see Testing and Adjusting, "Special
Wrong work equipment controller may be installed. Check part No. and
install correct work equipment controller.
If no failure is found by above checks, work equipment controller is
performed.)
40-563
40 Troubleshooting
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC)
(WA470_7-DB9LKA-400-A-
Z0-A)
Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Operating Lamp Open Circuit (Bucket Boom Controller)

Failure code
Failure
DB9LKA
The work equipment controller has detected an open circuit because the output line
voltage of system operating lamp is approximately 5 V or less when the work equipment
controller does not output the voltage for approximately 3 seconds after the starting switch
has turned ON.
It does not output for system operating lamp.
work equipment controller memory.
Although work equipment controller is not able to light up system operating lamp, no
trouble will result unless battery disconnect switch is turned to OFF position.

Cause
box 2
harness
3. Disconnect connectors L73 and R61, and connect T-adapters to each
female side.
(wire breakage or
Between L73 (female) (34) and R61 (female) (2)
Max. 1 z
connector)
Resistance Between R61 (female) (1) and battery relay
Max. 1 z
terminal (R01)

harness
circuit)
Defective work
40-564
1.
2.
3.
4.

Min. 1 Mz
Resistance
Min. 1 Mz
WA470-7
40 Troubleshooting
WA470-7
40-565
40 Troubleshooting
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC)
(WA470_7-DB9LKB-400-A-
Z0-A)
Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Operating Lamp Short Circuit (Bucket Boom Controller)

Failure code
Failure
DB9LKB
Work equipment controller determines that output circuit to system operating lamp shorts
because voltage of output circuit does not become Low level while work equipment
controller drives system operating lamp.
work equipment controller memory.
Although work equipment controller is not able to light up system operating lamp, no
trouble will result unless battery disconnect switch is turned to OFF position.
Cause

harness

wiring harness
Defective work
40-566
1.
2.
3.
4.

Min. 1 Mz
1.
2.
3.
4.

Max 1 V
WA470-7
40 Troubleshooting
WA470-7
40-567
40 Troubleshooting
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con)
(WA380_7-DB9QKR-400-A-Z0-
A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
CAN2 Disconnection (Bucket Boom Controller)

Failure code
Failure
DB9QKR
Monitor controller does not recognize work equipment controller over CAN
communication-2 line (KOMNET/c).
Do not update CAN communication date.
Failure codes related to work equipment controller are not displayed
Monitoring code data are not updated.
Adjustment function cannot be used.
switch is received.
using multimeter.
No.
1
2
Cause
work equipment controller
Defective CAN2
communication system

controller
40-568

Perform troubleshooting for failure codes [DB90KK] and [DB91KA].
[DB2QKR].
defective.
WA470-7
40 Troubleshooting
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con)
(WA500_7-DB9RKR-400-A-Z0-
A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
2
CAN1 Disconnection (Bucket Boom Controller)

Failure code
Failure
DB9RKR
Monitor controller does not recognize work equipment controller over CAN
communication-1 line (KOMNET/r).
Information and failure code to be obtained from work equipment controller is not
displayed. Or received data are not updated.
Adjustment function does not work.
switch is received.
Monitor controller uses two other failure codes, [DAQRKR] and [DB2RKR], to indicate
failure in CAN communication through CAN 1 line. When failure code [DAQRKR] or
[DB2RKR] is displayed simultaneously on screen, ground fault, short circuit, or hot short
circuit may occur in wiring harness (CAN communication line).
on engine side is connector "B_RES" (connector B_RES is not located on CAN
communication-1 line (KOMNET/r) but is connected to it via connector "J2").
Since each controller is connected directly to battery, it is supplied with power even after
starting switch is turned to OFF position.
using multimeter.
Cause
system to work equipment
controller
Defective CAN-1
communication line

controller
WA470-7

Perform troubleshooting for failure codes [DB90KK] and [DB91KA].
[DB2RKR].
defective.
40-569
40 Troubleshooting
Failure code [DB9RMA] Inconsistency of Option Selection (BBC)
(WA380_7-
DB9RMA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Inconsistency of Option Selection (Bucket Boom Controller)

Failure code
Failure
DB9RMA
When starting switch is turned to the ON position, the option setting information sent from
machine monitor differs from that stored in the work equipment controller.
Controls with the option settings stored in the controller.
The option installed does not work normally.
Perform initial setting and initial adjustment similar to those required when the work
equipment controller is replaced.
Cause
Defective option setting of

monitor controller

controller
40-570

The option setting of monitor controller is probably incorrect. After
replacing the monitor controller or work equipment controller, set the
options correctly. For details, see Testing and Adjusting.
If no failure is found by check on cause 1, the work equipment controller
may be defective. (Since this is an internal defect, troubleshooting
WA470-7
40 Troubleshooting
Failure code [DBE5KX] Failure of 5V Power Source

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA380_7-DBE5KX-400-A-Z0-A)
Failure of 5V Power Source

Failure code
Failure
DBE5KX
Voltage of 5 V sensor power supply system is outside of normal voltage output range of
4.7 to 5.3 V.
potentiometer.
Sensor failure codes [DK55KA], [DK555Y], and [DK55L5] are displayed.
No particular problem occurs, as long as directional (FNR) lever switch is normal.
Cause
Defective directional
(FNR) lever
potentiometer

2. Disconnect connector L02.
If failure code [DBE5KX] disappears, directional (FNR) lever potentiometer is
defective.
a Other failure codes also appear due to disconnection of connector. Ignore
displayed failure codes other than this failure code.

harness

female side.
Min. 1 Mz
controller

4.7 to 5.3 V

wiring harness

Voltage Between L02 (female) (10) and (12)
4.7 to 5.3 V
WA470-7
40-571
40 Troubleshooting
Circuit diagram related to 5 V sensor power supply
40-572
WA470-7
40 Troubleshooting
Failure code [DBE6KX] Failure of 24 V Power Source

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
DBE6KX
Failure
(WA470_7-DBE6KX-400-A-Z0-A)
Failure of 24 V Power Source

24 V sensor power supply system is shorted to ground.

Cannot normally sense input signals of sensors that uses this power supply since sensor
signal is error.
Sensor failure codes [DHT1KX], [DHT5KX], and [DHT7KX] are displayed.
Voltage of each sensor is indicated as 0 V.
(Codes: 41202 Brake Oil Press Sensor Volt, 32602 T/C In. Oil Press Sensor Volt, 32604
T/C Out. Oil Press Sensor Volt)
Cause

Defective pressure
sensor

harness
circuit)

2. Disconnect connectors R73, R91, TCIN.P, and L61.
controller

20 to 30 V
WA470-7

Brake oil pressure sensor
R73
Connector Torque converter input pressure sensor
TCIN.P
R91
Min. 1 Mz
40-573
40 Troubleshooting
Circuit diagram related to 24 V sensor power supply output
40-574
WA470-7
40 Troubleshooting
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW
(WA470_7-
DD1ALD-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of Remote Positioner Set Switch

Failure code
Failure
DD1ALD
Due to ground fault in remote positioner set switch (boom) circuit, remote positioner
cannot be set for boom RAISE and LOWER.
Continuous operation for 30 seconds is detected on remote positioner set switch (boom).
Cancels boom RAISE set position if boom is positioned above horizontal.
Cancels boom LOWER set position if boom is positioned below horizontal.
Does not perform remote stop for canceled side.
Turns off remote positioner set indicator for canceled side.
Both boom RAISE and LOWER set positions cannot be set.
Remote positioner does not perform stop for canceled side.
Input signal (ON/OFF) from remote positioner set switch can be checked with monitoring
function. (Code: 02218 BBC Input 2, Boom Positioner Set SW)
Cause
Defective remote
positioner set switch
(boom)

Max. 1 z
Between S_RH6 (male) switch: Boom set ON
(5) and (6)
switch: Other than boom Min. 1 Mz
Resistance
set ON
Between ground and each of S_RH6 (male) (5) and
Min. 1 Mz
(6)

harness
circuit)

2. Disconnect connectors L72 and S_RH6, and connect T-adapter to either
female side.
Between ground and L72 (female) (3) or S_RH6
Min. 1 Mz
(female) (6)
Resistance
Min. 1 Mz
(female) (4)
Defective work

switch: Boom set ON
Between L72 (3) and
Voltage
ground
switch: Other than boom
set ON
WA470-7
Max. 1 V
7 to 10 V
40-575
40 Troubleshooting
Circuit diagram related to remote positioner set switch
40-576
WA470-7
40 Troubleshooting
Failure code [DDAAL6] Discon of Engine Shutdown Secondary

Switch (WA470_7-DDAAL6-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Discon of Engine Shutdown Secondary Switch

Failure code
Failure
DDAAL6
Monitor controller determines that engine shutdown secondary switch circuit has open
circuit.
None in particular.
Cause
Incorrect operation of
engine shutdown
secondary switch
Defective engine
shutdown secondary
switch

Check that engine shutdown secondary switch is in OFF position.
2. Disconnect connector S-FS and connect T-adapters to male side.
a Engine shutdown secondary switch at OFF
Between S-FS (male) (1) and (2)
Resistance
Between S-FS (male) (4) and (5)
Max. 1 z
Max. 1 z


harness
(wire breakage or
connector)
Defective monitor
controller
WA470-7
a Engine shutdown secondary switch at OFF

Resistance Between MCM1 A (female) (24) and (31)
Max. 1 z
a
1.
2.
3.

Disconnect connectors MCM1 A and S-FS, and connect T-adapters to
each female side.
Between MCM1 A (female) (31) and each of S-FS
Max. 1 z
40-577
40 Troubleshooting
Circuit diagram related to engine shutdown secondary switch
40-578
WA470-7
40 Troubleshooting
Failure code [DDB6L4] Neutral Signal Malfunction

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA470_7-DDB6L4-400-A-Z0-A)
Neutral Signal Malfunction

Failure code
Failure
DDB6L4
Controller indicates this failure code when all of following conditions are satisfied.
1. Parking brake switch signal is ON. (Neutralizer input signal (pin 6 of L62) is OPEN.)
2. Parking brake is released (judged from signals from monitor controller through CAN
communication).
3. Transmission oil temperature is 25C or higher.
Machine cannot travel forward and in reverse, or parking brake indicator is kept off.
Input signal (ON/OFF) to machine monitor from parking brake indicator switch can be
checked with monitoring function. (Code: 04510 Parking Brake Press SW)
Input signal (ON/OFF) from parking brake switch can be checked with monitoring
function.
(Code: 02215 Parking Brake Switch)
If failure code [DGF1KA] "Disconnection of T/M Oil Temp. Sensor" or failure code
[DGF1KB] "Ground Fault of T/M Oil Temp. Sensor" is also displayed, perform
If failure code [DAQRKR] "CAN1 Discon (Transmission Con)" or failure code [DAQQKR]
"CAN2 Discon (Transmission Con)" is also displayed, perform troubleshooting for it first.
Method of reproducing failure code: Turn starting switch to ON position and turn parking
brake switch to ON position.
Cause

2. Disconnect connector PB.SW, and connect T-adapter to male side.
Max. 1 z
released, Min. 0.61 MPa
indicator switch (internal
2
{Min.
6.2
kg/cm
}
Between PB.SW (male)
open circuit)
Min. 1 Mz
applied, Max. 0.34 MPa
2
{Min. 3.5 kg/cm }

2. Disconnect connector S_FA and connect T-adapter to male side.
Min. 1 Mz
Between S_FA (3) and
ON.
(4)
Max. 1 z
OFF
circuit)
Max. 1 z
Resistance Between S_FA (5) and
ON.
(6)
Min. 1 Mz
OFF
Between S_FA (3) and
Min. 1 Mz
(6)
ON
WA470-7
40-579
40 Troubleshooting
No.
Cause

harness
(wire breakage or
connector)

2. Disconnect connectors MCM1 A, PB.SW, and S_FA, and connect Tadapters to each female side.
Between MCM1 A (female) (71) and PB.SW
Max. 1 z
(female) (1)
Resistance Between PB.SW (female) (2) and ground
Max. 1 z
Between S_FA (female) (3) and L62 (female) (6)
Max. 1 z
controller

ON.
After turn starting switch
Voltage
(6) and ground
to ON position, turn
parking brake switch to
ON and then OFF.
40-580
Max. 1 V
20 to 30 V
WA470-7
40 Troubleshooting
WA470-7
40-581
40 Troubleshooting
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch
(WA470_7-
DDD1LD-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure of Bucket Positioner Set Switch

Failure code
Failure
DDD1LD
Due to ground fault in remote positioner set switch (bucket) circuit, bucket stop angle
cannot be set to desired angle.
Continuous operation for 30 seconds is detected on remote positioner bucket angle set
switch.
Judges that remote positioner bucket angle set switch is ON.
Changes setting to default (stopping at level position) 1 second after this failure code is
generated.
Remote positioner (bucket) set is turned to default (level position).
Setting cannot be changed upward or downward direction.
Input signal (ON/OFF) from remote positioner set switch can be checked with monitoring
function. (Code: 02218 BBC Input 2, Bucket Positioner Set SW)
Cause
Defective remote
positioner set switch
(bucket)

switch: Bucket angle set Max. 1 z
ON
Between S_RH6 (male)
(4) and (5)
Resistance
switch: Other than
Min. 1 Mz
bucket angle set ON
Min. 1 Mz
(5)

harness
circuit)

female side.
Min. 1 Mz
(female) (6)
Resistance
Min. 1 Mz
(female) (4)
Defective work
Voltage
40-582

(12) and ground

switch: Bucket angle set
ON
switch: Other than
bucket angle set ON
Max. 1 V
7 to 10 V
WA470-7
40 Troubleshooting
Circuit diagram related to remote positioner set switch
WA470-7
40-583
40 Troubleshooting
Failure code [DDK3KA] FNR SW Input Signal Disconnection
(WA470_7-DDK3KA-400-
A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
FNR Switch Input Signal Disconnection

Failure code
Failure
DDK3KA
Due to open circuit or ground fault in input signal circuit from R.H. directional selector
(FNR) switch, controller does not recognize R.H. directional selector (FNR) switch
signals.
Takes an input signal from R.H. directional selector (FNR) switch as neutral.
Even if cause of failure disappears, machine does not become normal until R.H.
directional selector (FNR) switch is set to N (neutral) position.
Machine does not travel with R.H. directional selector (FNR) switch.
Machine can travel by operating directional (FNR) lever.
Shift lever position pilot lamp goes out.
Input signal (ON/OFF) from R.H. directional selector (FNR) switch can be checked with
monitoring function.
(Code: 02211 Option FNR Signal F, Option FNR signal N, or Option FNR signal R)
Only for the machine equipped with R.H. directional selector (FNR) switch (if equipped).
Method of reproducing failure code:Turn starting switch to ON position, set directional
selector switch actuation switch to ON position, and operate R.H. directional selector
(FNR) switch.
Cause
Defective fuse No. 2 in
fuse box 1

If fuse is blown, circuit probably has ground fault, etc. (See check on cause 4.)
2. Disconnect connector S_RHB, and connect T-adapter to male side.
R.H. directional selector
(FNR) switch: F (forward) Max. 1 z
Between S_RHB (male)
(1) and (2)
(FNR) switch: Other than Min. 1 Mz
F
(FNR) switch: N (neutral) Max. 1 z
(1) and (3)
N
Resistance
(FNR) switch: R
Max. 1 z
(reverse)
(1) and (4)
R (reverse)
Between ground and
each of S_RHB (male)
Continuous
Min. 1 Mz
(1), (2), (3), and (4)
Defective R.H.
directional selector
(FNR) switch (internal
open or short circuit)

2. Remove fuse No. 2 in fuse box 1.
3. Disconnect connectors L62 and S_RHB, and connect T-adapters to each
female side.
Between fuse No. 2 in fuse box 1 and S_RHB
harness (wire breakage
Max. 1 z
(female) (1)
connector)
Between L62 (female) (26) and S_RHB (female) (4) Max. 1 z
Resistance
Between L62 (female) (36) and S_RHB (female) (3) Max. 1 z
Max. 1 z
Between L62 (female) (5) and S_RHB (female) (2)
40-584
WA470-7
40 Troubleshooting
No.
Cause

ground circuit)

3. Disconnect connectors L62 and S_RHB, and connect T-adapter to either
female side.
Between ground and fuse No. 2 in fuse box 1 or
Min. 1 Mz
S_RHB (female) (1)
Between ground and L62 (female) (26) or S_RHB
Min. 1 Mz
(female) (4)
Resistance
Min. 1 Mz
(female) (3)
Min. 1 Mz
(female) (2)
1.
2.
3.
4.
controller
WA470-7

Operate R.H. directional selector (FNR) switch.
(FNR) switch: F (forward) 20 to 30 V
Between L62 (5) and
ground
(FNR) switch: Other than Max 1 V
F
(FNR) switch: N (neutral) 20 to 30 V
ground
Voltage
N
(FNR) switch: R
20 to 30 V
(reverse)
ground
R (reverse)
40-585
40 Troubleshooting
Circuit diagram related to R.H. directional selector (FNR) switch
40-586
WA470-7
40 Troubleshooting
Failure code [DDK3KB] FNR SW Input Signal Short Circuit
(WA470_7-DDK3KB-400-A-
Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
FNR Switch Input Signal Short Circuit

Failure code
Failure
DDK3KB
Due to hot short circuit of R.H. directional selector (FNR) switch input signal system,
multiple signals of R.H. directional selector (FNR) switch are inputted.
Takes an input signal from R.H. directional selector (FNR) switch as neutral.
Even if cause of failure disappears, machine does not become normal until R.H.
directional selector (FNR) switch is set in N (neutral) position.
Machine does not travel with R.H. directional selector (FNR) switch.
Machine can travel by operating directional (FNR) lever.
Multiple pilot lamps of shift lever position light up.
Input signal (ON/OFF) from R.H. directional selector (FNR) switch can be checked with
(Code: 02211 Option FNR Signal F, Option FNR signal N, or Option FNR signal R)
Only for machines equipped with R.H. directional selector (FNR) switch (if equipped).
Method of reproducing failure code:Turn starting switch to ON position, set directional
selector switch actuation switch to ON position, and operate R.H. directional selector
(FNR) switch.
Cause
Defective R.H.
directional selector
(FNR) switch (internal
short circuit)

wiring harness (contact
with 24 V circuit)
WA470-7

2. Insert T-adapter into connector S_RHB.
Between S_RHB (2) and
ground
F
(FNR) switch: N (neutral)
ground
Voltage
N
(FNR) switch: R
(reverse)
ground
R (reverse)
Continuous
ground
20 to 30 V
Max 1 V
20 to 30 V
Max 1 V
20 to 30 V
Max 1 V
20 to 30 V

2. Disconnect connector S_RHB, and connect T-adapter to female side.
Max. 1 V
Between
L62
(female)
(26)
and
ground
Max. 1 V
Voltage
Max. 1 V
40-587
40 Troubleshooting
No.
Cause
1.
2.
3.
4.
controller

Operate R.H. directional selector (FNR) switch.
(FNR) switch: F (forward) 20 to 30 V
Between L62 (5) and
ground
F
(FNR) switch: N (neutral) 20 to 30 V
ground
Voltage
N
(FNR) switch: R
20 to 30 V
(reverse)
ground
R (reverse)
Circuit diagram related to R.H. directional selector (FNR) switch
40-588
WA470-7
40 Troubleshooting
Failure code [DDK6KA] FNR Lever Input Signal Disconnection
(WA380_7-DDK6KA-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
FNR Lever Input Signal Disconnection

Failure code
Failure
DDK6KA
No signal of directional (FNR) lever switch is input and analog signal recognizes F
because of open circuit or ground fault in directional (FNR) lever switch signal system.
Follows signal before abnormality for 2 seconds after detection.
Sounds alarm buzzer after continuous detection for 2 seconds and follows analog signal.
Lights up centralized warning lamp and sounds alarm buzzer after continuous detection
for 20 seconds.
Keeps following analog signal until directional (FNR) lever signal matches with analog
signal, even if cause of failure disappears.
Problem on
machine
Shift lever position pilot lamp goes out.
Related
information
Input signal (ON/OFF) from directional (FNR) lever switch can be checked with monitoring
function (Code: 02211, Main FNR Signal F, Main FNR Signal N, or Main FNR Signal R).
Method of reproducing failure code: Turn starting switch ON and operate directional
(FNR) lever
No.
1
Cause
Defective fuse No. 2 in fuse
box 1

If fuse is blown, circuit may have ground fault, etc. (See check on cause
4.)
1. Turn starting switch OFF.

3. Turn starting switch ON.
Between L02 (1) and
Constant
20 to 30 V
(9)
Directional (FNR)
20 to 30 V
Between L02 (3) and lever: N (NEUTRAL)
Defective directional (FNR)
(9)
Directional (FNR)
Max. 1 V
lever switch (internal short
lever: Other than N
circuit)
Directional (FNR)
Voltage
20 to 30 V
Between L02 (2) and lever: F (FORWARD)
(9)
Directional (FNR)
Max. 1 V
lever: Other than F
Directional (FNR)
20 to 30 V
Between L02 (4) and lever: R (REVERSE)
(9)
Directional (FNR)
Max. 1 V
lever: Other than R
2. Disconnect connectors L62 and L02, and connect T-adapters to
each female side.
Between fuse No. 2 in fuse box 1 and L02
Max. 1 z
(female) (1)
Between L62 (female) (15) and L02 (female)
Max. 1 z
(4)
Resis- Between L62 (female) (25) and L02 (female)
tance
Max. 1 z
(3)
Between L62 (female) (35) and L02 (female)
Max. 1 z
(2)
Max. 1 z
WA470-7
40-589
40 Troubleshooting
No.
Cause

harness

each female side.
Between ground and fuse No. 2 of fuse box 1
Min. 1 Mz
or L02 (female) (1)
Min. 1 Mz
Resis- (female) (4)
tance
Min. 1 Mz
(female) (3)
Min. 1 Mz
(female) (2)
controller

Right directional (FNR)
20 to 30 V
ground
Max. 1 V
lever: Other than N
20 to 30 V
Voltage
ground
Max. 1 V
lever: Other than F
20 to 30 V
ground
Max. 1 V
lever: Other than R
40-590
WA470-7
40 Troubleshooting
Circuit diagram related to directional (FNR) lever
WA470-7
40-591
40 Troubleshooting
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit
(WA380_7-DDK6KB-400-
A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
FNR Lever Input Signal Short Circuit

Failure code
Failure
DDK6KB
Multiple signals of directional (FNR) lever switch are input due to hot short in directional
(FNR) lever switch signal system.
Follows lever position recognition by analog input.
Problem on
machine
Multiple pilot lamps of shift lever position light up.
Related
information
function (Code: 02211, Main FNR Signal F, Main FNR Signal N, or Main FNR Signal R).
Method of reproducing failure code: Turn starting switch ON and operate directional
(FNR) lever
No.
Cause

lever switch (internal short
circuit)

harness (contact with 24 V
circuit)
40-592

Between L02 (1) and
Constant
20 to 30 V
(9)
Directional (FNR)
20 to 30 V
(9)
Directional (FNR)
Max. 1 V
lever: Other than N
Directional (FNR)
Voltage
20 to 30 V
(9)
Directional (FNR)
Max. 1 V
lever: Other than F
Directional (FNR)
20 to 30 V
(9)
Directional (FNR)
Max. 1 V
lever: Other than R
2. Disconnect connector L02 and connect T-adapter to female side.
Max. 1 V
Max. 1 V
Max. 1 V
WA470-7
40 Troubleshooting
No.
Cause
controller

Directional (FNR)
ground
Directional (FNR)
lever: Other than N
Directional (FNR)
Voltage
ground
Directional (FNR)
lever: Other than F
Directional (FNR)
ground
Directional (FNR)
lever: Other than R
20 to 30 V
Max. 1 V
20 to 30 V
Max. 1 V
20 to 30 V
Max. 1 V
Circuit diagram related to directional (FNR) lever
WA470-7
40-593
40 Troubleshooting
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW
(WA470_7-
DDNRKY-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Hot Short of Work Equipment Lock Switch

Failure code
Failure
DDNRKY
Due to hot short circuit in work equipment lock switch circuit, work equipment lock remains
released or applied.
None in particular
Condition of work equipment lock switches (work equipment lock is released if it has been
applied, or it is applied if it has been released).
Once condition of work equipment lock is changed, it is fixed and cannot be changed.
Output signal (ON/OFF) from work equipment lock switch can be checked with monitoring
function. (Code: 02217BBC Input 1, Work Equipment Lock SW)
Cause
Defective work
equipment lock switch

wiring harness
Defective work
40-594

2. Disconnect connector S_RHC and replace switch with another one of
same type.
If failure code [DDNRKY] disappears, original work equipment lock switch is
defective.
5. Disconnect connector S_RHC and connect T-adapter to male side.
Work equipment lock
Min. 1 Mz
Between S_RHC (male)
switch: OFF
Work equipment lock
Max. 1 z
switch: ON
2. Disconnect connector S_RHC and connect T-adapter to female side.
Voltage Between S_RHC (female) (6) and ground
Max. 1 V
WA470-7
40 Troubleshooting
Circuit diagram related to work equipment lock switch
WA470-7
40-595
40 Troubleshooting
Failure code [DDT0L4] Failure of Shift Mode Select SW

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA470_7-DDT0L4-400-A-Z0-A)
Failure of Shift Mode Select Switch

Failure code
Failure
DDT0L4
Impossible combination of signals is inputted from transmission shift mode selector
switch.
Sets transmission to manual shift mode.
Position of transmission shift mode selector switch does not match with shift mode in
auto-shift mode.
Input signal to machine monitor from transmission shift mode selector switch can be
checked with monitoring function.
(Code: 02213 Shift Mode Switch Manual and Shift Mode Switch H)
Current selection of shift mode can be checked by auto-shift pilot lamp.
Cause

Shift mode: Manual shift Max. 1 z
Shift mode: Auto shift (L) Min. 1 Mz
auto/manual shift mode
(4) and (5)
selector switch (internal
Shift mode: Auto shift (H) Min. 1 Mz
Resistance
defect)
Shift mode: Manual shift Min. 1 Mz
Shift mode: Auto shift (L) Min. 1 Mz
(5) and (6)
Shift mode: Auto shift (H) Max. 1 z

wiring harness (contact
with 24 V wiring
harness)

2. Disconnect connector S_RH3 and connect T-adapter to female side.
Between S_RH3 (female) (6) and ground
Max 1 V
Voltage
Max 1 V

(18) and ground
controller
Voltage

(24) and ground
40-596
Shift mode: Manual shift 20 to 30 V

Shift mode: Auto shift (L) Max 1 V
Shift mode: Auto shift (H) Max 1 V
Max 1 V
Shift mode: Auto shift (L) Max 1 V
Shift mode: Auto shift (H) 20 to 30 V
WA470-7
40 Troubleshooting
Circuit diagram related to shift mode switch
WA470-7
40-597
40 Troubleshooting
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal
(WA470_7-
DDT4LD-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of Transmission Cut Off Set Switch Signal

Failure code
Failure
DDT4LD
Transmission cut-off is not performed normally due to ground fault in transmission cut-off/
set switch circuit.
Transmission cut-off is performed at unintended timing.
Input signal (ON/OFF) from transmission cut-off switch can be checked with monitoring
function. (Code: 02214 T/M Cut Off Switch)
Cause
cut-off switch (internal
short circuit)

Max. 1 z
switch: ON
(4) and (5)
Min. 1 Mz
switch: OFF
Resistance
Between ground and
each of S_RH1 (male)
Continuous
Min. 1 Mz
(4) and (5)

harness
circuit)

female side.
Min. 1 Mz
controller

switch: ON
Voltage
ground
switch: OFF
40-598
Max. 1 V
7 to 9 V
WA470-7
40 Troubleshooting
Circuit diagram related to transmission cut-off/set switch
WA470-7
40-599
40 Troubleshooting
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal
(WA470_7-DDT9LD-
400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Ground Fault of Transmission Cut Off Switch Signal

Failure code
Failure
DDT9LD
Transmission cut-off is not normally performed due to ground fault in transmission cut-off
set switch system.
Recognizes input of transmission cut-off once when ground fault occurs, and then does
not control transmission cut-off any more.
Problem on
machine
Transmission cut-off is performed at unintended timing.
Related
information
Input signal (ON/OFF) from transmission cut-off switch can be checked with monitoring
function. (Code: 02214 T/M Cut Off Switch)
No.
Cause
short circuit)

Max. 1 z
switch:ON
(5) and (6)
Min. 1 Mz
switch:OFF
Resistance
Between ground and
each of S_RH1 (male)
Continuous
Min. 1 Mz
(5) and (6)

harness
circuit)

female side.
Min. 1 Mz
controller

Voltage
40-600

ground
switch:ON
switch:OFF
Max 1 V
7 to 9 V
WA470-7
40 Troubleshooting
Circuit diagram related to transmission cut-off switch
WA470-7
40-601
40 Troubleshooting
Failure code [DDW9LD] Ground Fault of Kickdown Switch
(WA470_7-DDW9LD-400-A-Z0-
A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
DDW9LD
Failure
Ground Fault of Kickdown Switch

Kickdown cannot be performed due to ground fault in kickdown switch system.

Performs kickdown once when ground fault occurs, and then does not control kickdown
any more.
Transmission is kicked down once when ground fault occurs.
Transmission is not kicked down any more after that.
Input condition (ON/OFF) from the kickdown switch can be checked with monitoring
function
(Code: 02212 Kick Down Switch)
Cause
Defective kickdown
switch

Between L14 (male) (1)
Kickdown switch: ON
Max. 1 z
and (2)
Kickdown switch: OFF Min. 1 Mz
Resistance
Between ground and
each of L14 (male) (1)
Continuous
Min. 1 Mz
and (2)

harness
circuit)

female side.
Min. 1 Mz
controller

Between L63 (9) and
Kickdown switch: ON
Voltage
ground
40-602
Max. 1 V
7 to 9 V
WA470-7
40 Troubleshooting
Circuit diagram related to kick-down switch and hold switch
WA470-7
40-603
40 Troubleshooting
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW
(WA470_7-DDWLLD-400-A-
Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Failure code
DDWLLD
Failure
Ground Fault of Transmission Shift Hold SWITCH

Holding operation cannot be performed because of ground fault in hold switch system.
Performs holding operation once when ground fault occurs, and then does not control
holding operation any more.
Problem on
machine
Transmission is held once when ground fault occurs.
Related
information
function
(Code: 02212 Hold Switch)
No.
Cause
Defective hold switch


Hold switch:ON
Max. 1 z
and (4)
Hold switch:OFF
Min. 1 Mz
Resistance
Between ground and
each of L14 (male) (3)
Continuous
Min. 1 Mz
and (4)

harness
circuit)

female side.
Min. 1 Mz
controller

Voltage
ground
40-604
Hold switch:ON
Hold switch:OFF
Max 1 V
7 to 9 V
WA470-7
40 Troubleshooting
WA470-7
40-605
40 Troubleshooting
Failure code [DF10KA] Disconnection of Shift Lever Input
(WA380_7-DF10KA-400-A-Z0-
A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Disconnection of Shift Lever Input

Failure code
Failure
DF10KA
No transmission shift lever switch signal is input due to open circuit or ground fault in
transmission shift lever switch signal input circuit.
Fixes shift range to that before occurrence of failure.
Transmission is not set to selected gear speed.
Shift indicator indicates shift range before occurrence of failure.
Input condition (ON/OFF) from each shift switch can be checked with monitoring function
(Code: 02212 Shift Lever 1, Shift Lever 2, Shift Lever 3, Shift Lever 4).
Method of reproducing failure code: Turn starting switch ON and operate shift lever.
No.
Cause
Defective operation of shift

lever

box 1

Force may be applied to depress lever while shift lever is not
operated.
Shift lever is stopped intermediate point between two positions.
5.)
1.
2.
3.
4.
Turn starting switch OFF.

Turn starting switch ON.
Operate shift lever to troubleshoot.
Between L02 (1) and
Constant
20 to 30 V
(9)
Shift range: 1st
20 to 30 V
Between L02 (5) and
Shift range: Other than
(9)
Max. 1 V
1st
Shift range: 2nd
20 to 30 V
Between L02 (6) and
Shift range: Other than
Voltage (9)
Max. 1 V
2nd
Shift range: 3rd
20 to 30 V
Between L02 (7) and
Shift
range:
Other
than
(9)
Max. 1 V
3rd
Shift range: 4th
20 to 30 V
Between L02 (8) and
Shift
range:
Other
than
(9)
Max. 1 V
4th
If harness is normal and voltage in each selected range is below
standard value, shift lever power supply or ground circuit is defective.
Defective shift lever

2. Remove No. 2 in fuse box 1.
each female side.
Between fuse No. 2 in fuse box 1 and L02
Max. 1 z
(female) (1)
Between L61 (female) (23) and L02 (female) (5) Max. 1 z
Resis- Between L61 (female) (17) and L02 (female) (6) Max. 1 z
tance
Max. 1 z
40-606
WA470-7
40 Troubleshooting
No.
Cause

required.
3. Disconnect connectors L61 and L02, and connect T-adapter to
either female side.
Between ground and fuse No. 2 in fuse box 1 or
Min. 1 Mz
L02 (female) (1)
Min. 1 Mz
(female) (5)
Resis- Between ground and L61 (female) (17) or L02
Min. 1 Mz
(female) (6)
tance
Min. 1 Mz
(female) (7)
Min. 1 Mz
(female) (8)
performed.)
controller
a For voltage between any pins of controller, see following codes.
Circuit diagram related to shift lever
WA470-7
40-607
40 Troubleshooting
Failure code [DF10KB] Ground Fault of Shift Lever Input

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA380_7-DF10KB-400-A-Z0-A)
Ground Fault of Shift Lever Input

Failure code
Failure
DF10KB
Multiple signals of transmission shift lever switch are input due to hot short in transmission
shift lever switch input signal system.
Uses shift range input of higher gear speed.
Transmission is not set to selected gear speed. (Transmission is not set to 1st or 2nd
even if transmission shift lever is operated.)
Shift indicator indicates shift range input of higher gear speed.
Input condition (ON/OFF) from each shift switch can be checked with monitoring function
(Code: 02212 Shift Lever 1, Shift Lever 2, Shift Lever 3, Shift Lever 4).
Method of reproducing failure code: Turn starting switch ON and operate shift lever.
Cause

harness (contact with 24 V
circuit)

Max. 1 V
Max. 1 V
Voltage
Max. 1 V
Max. 1 V
2. Disconnect connectors L61 and L02, and connect T-adapter to
female side of L61.
a Check by using multimeter in continuity range.

No continuity
each pin other than pin (23)
(No sound is heard)
(Short circuit between wiring
No continuity
harnesses)
(No sound is heard)
Continuity
No continuity
(No sound is heard)
No continuity
Between AL61 (female) (5) and
(No sound is heard)
1.
2.
3.
4.
Defective shift lever
40-608

Between L02 (1) and
Constant
20 to 30 V
(9)
Shift range: 1st
20 to 30 V
Between L02 (5) and
Shift
range:
Other
than
(9)
Max. 1 V
1st
Shift range: 2nd
20 to 30 V
Between L02 (6) and
Shift
range:
Other
than
Voltage (9)
Max. 1 V
2nd
Shift range: 3rd
20 to 30 V
Between L02 (7) and
Shift
range:
Other
than
(9)
Max. 1 V
3rd
Shift range: 4th
20 to 30 V
Between L02 (8) and
Shift
range:
Other
than
(9)
Max. 1 V
4th
If harness is normal and voltage in each selected range is below
standard value, shift lever power supply or ground circuit is defective.
WA470-7
40 Troubleshooting
No.
Cause

If no failure is found in above checks, transmission controller is
defective.
a
1.
2.
3.
4.
controller
WA470-7
Reference
Shift range:
Between L61 (23) and 1st
ground
Shift range:
Other than 1st
Shift range:
Between L61 (17) and 2nd
ground
Shift range:
Other than 2nd
Voltage
Shift range:
Between L61 (11) and 3rd
ground
Shift range:
Other than 3rd
Shift range:
Between L61 (5) and 4th
ground
Shift range:
Other than 4th
20 to 30 V
Max. 1 V
20 to 30 V
Max. 1 V
20 to 30 V
Max. 1 V
20 to 30 V
Max. 1 V
40-609
40 Troubleshooting
Circuit diagram related to shift lever
40-610
WA470-7
40 Troubleshooting
Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor
(WA380_7-
DGF1KA-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Disconnection of Transmission Oil Temperature Sensor

Failure code
Failure
DGF1KA
Due to open circuit in transmission oil temperature sensor signal system, transmission oil
temperature signal is higher than normal range (Transmission oil temperature sensor
signal voltage: Min. 4.56 V (Max. 15C)), and torque converter oil temperature sensor
signal voltage: Max. 3.7 V (Min. 55C).
Cannot determine transmission oil temperature correctly.
Gear shift shock may occur.
Input voltage from transmission oil temperature sensor can be checked with monitoring
function.
(Code: 32501 T/M Oil Temp. Sensor Volt)
Oil temperature sensed by transmission oil temperature sensor can be checked with
(Code: 32500 T/M Oil Temperature)
Input voltage from torque converter oil temperature sensor can be checked with
(Code: 30101 T/C Oil Temp. Sensor Volt)
(Code: 30100: T/C Oil Temperature)
Cause
oil temperature sensor

Transmission oil
Between
temperature: 25C
35 to 50 kz *
TM.T
Resistance (male) (1) (Normal temperature)
Transmission oil
and (2)
3.1 to 4.5 kz *
temperature: 100C
2. Disconnect connector TM.T and connect T-adapter to female side.
Open circuit, short

circuit, ground fault, hot a Voltage of approx. 5 V is applied to temperature sensor signal circuits
through resistor in transmission controller.
this point.
Voltage Between TM.T (female) (1) and (2)
Approx. 5 V

wiring harness
WA470-7
a Voltage of approx. 5 V is applied to temperature sensor signal circuits

Transmission oil
Between
temperature:25C
35 to 50 kz
L61
Resistance (female) (9) (Normal temperature)
Transmission oil
3.1 to 4.5 kz
and (4)
temperature:100C
40-611
40 Troubleshooting
No.
Cause

harness
(wire breakage or
connector)
controller
a
1.
2.
3.
If no failure is found by check on cause 3, this check is not required.

Disconnect connector L61, and connect T-adapters to female side.
Disconnect connector TM.T and connect T-adapter to female side.
Between L61 (female) (4) and TM.T (female) (2)
Max. 1 z
Resistance
Between L61 (female) (9) and TM.T (female) (1)
Max. 1 z
For average resistance of sensors at each temperature, see [DGR2KB].

Circuit diagram related to transmission oil temperature sensor
40-612
WA470-7
40 Troubleshooting
Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor
(WA380_7-DGF1KB-
400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of Transmission Oil Temperature Sensor

Failure code
Failure
DGF1KB
Due to ground fault of transmission oil temperature sensor signal system, transmission oil
temperature signal is lower than the normal range.
(Transmission oil temperature sensor signal voltage: Max. 0.97 V (Min. 150C))
Cannot determine transmission oil temperature correctly.
Gear shift shock may occur.
function.
(Code: 32500 T/C Oil Temperature)
Method of reproducing failure code: Turn starting switch ON.
Cause
Defective transmission oil

temperature sensor

Between Oil temperature: 25C
35 to 50 kz *
(Normal temperature)
Resis- TM.T
(male)
(1)
tance
3.1 to 4.5 kz *
and (2)

harness

Between Oil temperature: 25C
37 to 50 kz
(Normal temperature)
Resis- L61
(female)
tance
3.1 to 4.5 kz
(9) and (4) Oil temperature: 100C

2. Disconnect connectors L61 and TM.T, and connect T-adapters to
each female side.
Resis- Between ground and L61 (female) (9) or TM.T
Min. 1 Mz
(female) (1)
tance
controller
performed).
*: For average resistance of sensors at each temperature, see [DGR2KB].
WA470-7
40-613
40 Troubleshooting
Circuit diagram related to transmission oil temperature sensor
40-614
WA470-7
40 Troubleshooting
Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor
(WA470_7-DGH2KX-
400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Out of Range of Hydraulic Oil Temperature Sensor

Failure code
Failure
DGH2KX
Due to ground fault in signal circuit of hydraulic oil temperature sensor, hydraulic oil
temperature signal is lower than normal range.
(Signal voltage from hydraulic oil temperature sensor: 0.97 V or below (150C or above))
Cannot determine hydraulic oil temperature correctly.
Pointer of hydraulic oil temperature gauge is not displayed.
Input voltage from hydraulic oil temperature sensor can be checked with monitoring
function.
(Code: 04404 Hydr. Oil Temp. Sensor Volt)
Oil temperature sensed by hydraulic oil temperature sensor can be checked with
(Code: 04401 Hydr. Oil Temperature)
Cause

temperature sensor

Hydraulic oil
35 to 50 kz
temperature: 25C
Between R47 (male) (1) (normal temperature)
*
Resistance and (2)
Hydraulic oil
3.1 to 4.5
temperature: 100C
kz *
2. Disconnect connector R47 and connect T-adapters to female side.
Open circuit, short

this point.
Approx. 5 V

wiring harness

harness
controller

Hydraulic oil
temperature: 25C
35 to 50 kz
Hydraulic oil
3.1 to 4.5
temperature: 100C
kz
2. Disconnect connectors L61 and R47, and connect T-adapter to either
female side.
Between ground and L61 (female) (20) or R47
Min. 1 Mz
* For average resistance of sensors at each temperature, see [DGR2KB].
WA470-7
40-615
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature
40-616
WA470-7
40 Troubleshooting
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor
(WA380_7-
DGR2KB-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of Brake Oil Temperature Sensor

Failure code
Failure
DGR2KB
Voltage of signal circuit of brake oil temperature sensor (rear) drops below 0.97 V or
increases above 175 C.
Light up system caution lamp.
Oil temperature gauge is disabled due to failure code in sensor.
Signal from brake oil temperature sensor can be checked with monitoring function.
(Code: 30202 (C), 30205 (V))
Cause
Defective brake oil

temperature sensor (rear)

Rear brake oil
42.7 kz *
temperature: 25C
Rear brake oil
35.13 kz *
temperature: 30C
Rear brake oil
Resis- Between R60 (male)
6.556 kz *
(1) and (2)
temperature: 80C
tance
Rear brake oil
4.925 kz *
temperature: 90C
Rear brake oil
3.75 kz *
temperature: 100C

Ground fault in wiring harness 2. Disconnect connectors MCM1 A, R60 and connect T-adapter to
either female side.
Resis- Between ground and MCM1 A (female) (27) or
Min. 1 Mz
R20 (female) (1)
tance
*: Sensor resistance at various temperatures are only the average figures and they may vary.
Electrical circuit diagram related to brake oil temperature sensor (rear)
WA470-7
40-617
40 Troubleshooting
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor
(WA380_7-DGR2KZ-400-A-Z0-
A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure of Brake Oil Temperature Sensor

Failure code
Failure
DGR2KZ
Signal voltage of brake oil temperature sensor (rear) circuit is open circuit or not short
circuit.
None
Signal from brake oil temperature sensor can be checked with monitoring function.
(Code: 30202 (C), 30205 (V))
Cause

2. Disconnect connector R60, and connect T-adapters to female side.
1
Open circuit or short

a If voltage is 0 V, wiring harness has open-circuit, ground fault, or short
circuit or ground fault in
circuit.
wiring harness
a Voltage of approximately 5 V is applied to temperature sensor signal
circuits through resistor in monitor controller.
Approx. 5 V

harness

wiring harness
Defective brake oil

temperature sensor
(rear)
Defective monitor
controller

female side.
Max. 1 z
(1)
Resistance
Max. 1 z
(2)
a
1.
2.
3.

Insert T-adapter into connector MCM1 A or R60.
Between MCM1 A (27) and (9), or between R60
Voltage
Max. 4.5 V

Rear brake oil
42.7 kz *
temperature: 25C
Rear brake oil
35.13 kz *
temperature: 30C
Between R60 (male) (1) Rear brake oil
Resistance and (2)
6.556 kz *
temperature: 80C
Rear brake oil
4.925 kz *
temperature: 90C
Rear brake oil
3.75 kz *
temperature: 100C
*: Sensor resistance at various temperatures are only the average figures and they may vary.
40-618
WA470-7
40 Troubleshooting
Circuit diagram related to brake oil temperature sensor
WA470-7
40-619
40 Troubleshooting
Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor
(WA470_7-
DGT1KA-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Disconnection of Torque Converter Oil Temperature Sensor

Failure code
Failure
DGT1KA
Due to open circuit in torque converter oil temperature sensor signal system, torque
converter oil temperature signal is higher than normal range (torque converter oil
temperature sensor signal voltage: Min. 4.56 V (Max. 15C)), and transmission oil
temperature sensor signal voltage: Max. 3.7 V (Min. 55C).
Cannot determine torque converter oil temperature correctly.
Controls fan, ignoring torque converter oil temperature.
Fan speed may not be set properly, and that can cause overheat.
function.
(Code: 32500 T/M Oil Temperature)
a To access connector TC.T, see the illustration.
No.
Cause
Defective torque
converter oil
temperature sensor

temperature:
35 to 50 kz
*
25C (Normal
Between TC.T (male) (1)
temperature)
Resistance and (2)
3.1 to 4.5
temperature:
kz *
100C
2. Disconnect connector TC.T and connect T-adapter to female side.
Open circuit, short

this point.
Approx. 5 V
Voltage Between TC.T (female) (1) and (2)
40-620
WA470-7
40 Troubleshooting
No.
Cause


wiring harness

harness
(wire breakage or
connector)
controller
a Voltage of approx. 5 V is applied to temperature sensor signal circuits

temperature:
35 to 50 kz
25C (Normal
temperature)
3.1 to 4.5
temperature:
kz
100C
a
1.
2.
3.

Disconnect connector TC.T and connect T-adapter to female side.
Between L61 (female) (4) and TC.T (female) (2)
Max. 1 z
Resistance
Between L61 (female) (3) and TC.T (female) (1)
Max. 1 z

Circuit diagram related to torque converter oil temperature sensor
WA470-7
40-621
40 Troubleshooting
How to access to TC.T connector
Remove the right cover of the transmission.

Remove bolt (1) and clamp (2).
Connector TC.T is seen in upper section when hose (3) is moved.
40-622
WA470-7
40 Troubleshooting
Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor
(WA470_7-DGT1KB-
400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Ground Fault of Torque Converter Oil Temperature Sensor

Failure code
Failure
DGT1KB
Due to ground fault of torque converter oil temperature sensor signal system, torque
converter oil temperature signal is lower than the normal range.
(Torque converter oil temperature sensor signal voltage: Max. 0.97 V (Min. 150C))
Cannot determine torque converter oil temperature correctly.
Controls fan, ignoring torque converter oil temperature.
Problem on
machine
Fan speed may not be set properly, and that can cause over-cooling.
Related
information
No.
Cause
Defective torque
converter oil
temperature sensor

wiring harness

harness
controller

temperature:
35 to 50 kz
*
25C (Normal
Between TC.T (male) (1)
temperature)
Resistance and (2)
3.1 to 4.5
temperature:
kz *
100C
temperature:
35 to 50 kz
25C (Normal
temperature)
3.1 to 4.5
temperature:
kz
100C
2. Disconnect connector L61 and TC.T, connect T-adapter to either female
side.
Between ground and L61 (female) (3) or TC.T
Min. 1 Mz
WA470-7
40-623
40 Troubleshooting
Circuit diagram related to torque converter oil temperature sensor
How to access to TC.T connector
Remove the right cover of the transmission.

Remove bolt (1) and clamp (2).
Connector TC.T is seen in upper section when hose (3) is moved.
40-624
WA470-7
40 Troubleshooting
Failure code [DH21KA] Failure of Loader Pump Press. Sensor
(WA470_7-DH21KA-
400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure of Loader Pump Pressure Sensor

Failure code
Failure
DH21KA
Due to open circuit or ground fault in loader pump pressure sensor system, loader pump
pressure signal voltage is lower than the normal range.
(Work equipment pump pressure sensor signal voltage: Max. 0.3 V)
Operates, assuming loader pump pressure to be 0 MPa.
Cut-off operation is not performed when oil is relieved.
Accuracy of remote positioner decreases.
Engine does not pick up normally.
Komatsu SmartLoader Logic malfunctions.
Eco guidance function does not work normally.
Input voltage from loader pump pressure sensor can be checked with monitoring function.
(Code: 94701 Loader Pump Pres. Sensor Volt)
Oil pressure sensed by loader pump pressure sensor can be checked with monitoring
function.
(Code: 94700 Loader Pump Pressure)
Cause
a If failure code [DB95KX] is also displayed, perform troubleshooting for it

first.
system of loader pump 2. Disconnect connector F10 and connect T-adapter to female side.
pressure sensor
Power
5.00 to 5.20
Voltage Between F10 (female) (B) and (A)
supply input
V
a
1.
2.
3.
Defective loader pump

pressure sensor
circuit)

harness
(wire breakage or
connector)
WA470-7
Replace sensor and check whether failure code disappears.

Start engine.
Loader pump pressure: 0.50 to 4.40
Continuous
V
Loader
pump
pressure:
0.50
to
0.90
Voltage Between F10 (C) and (A)
At NEUTRAL
V
At bucket tilt relief
V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check harness for failure, and then determine whether
sensor is defective or not.
2. Disconnect connectors L71 and F10, and connect T-adapters to each
female side.
Between L71 (female) (9) and F10 (female) (C)
Max. 1 z
Resistance Between L71 (female) (22) and F10 (female) (B)
Max. 1 z

Between L71 (female) (4) and F10 (female) (A)
Max. 1 z
40-625
40 Troubleshooting
No.
Cause
harness
circuit)

harness
Defective work

female side.
Between ground and L71 (female) (9) or F10
Resistance (female) (C)
Min. 1 Mz
female side.
Between L71 (female) (9) and (4) or between F10
Resistance (female) (A) and (C)
Min. 1 Mz
Reference
3. Start engine and tilt bucket
Continuous
V
Between L71 (9) and
Loader
pump
pressure:
0.50
to
0.90
Voltage
ground
at Neutral
V
Bucket tilt
V
Circuit diagram related to loader pump pressure sensor
40-626
WA470-7
40 Troubleshooting
Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit
(WA470_7-
DH21KB-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Loader Pump Pressure Sensor Short Circuit

Failure code
Failure
DH21KB
Due to hot short in loader pump pressure sensor system, loader pump pressure sensor
signal voltage is higher than the normal range.
(Loader pump pressure sensor signal voltage: Min. 4.42 V)
Operates, assuming loader pump pressure to be 0 MPa.
Cut-off operation is not performed when oil is relieved.
Accuracy of remote positioner decreases.
Engine does not pick up normally.
Input voltage from loader pump pressure sensor can be checked with monitoring function.
(Code: 94701 Loader Pump Pres. Sensor Volt)
Oil pressure sensed by loader pump pressure sensor can be checked with monitoring
function.
(Code: 94700 Loader Pump Pressure)
Cause

first.
system of loader pump 2. Disconnect connector F10 and connect T-adapter to female side.
pressure sensor
Power
5.00 to 5.20
supply input
V
a
1.
2.
3.

pressure sensor
circuit)

wiring harness
(contact with 24V
circuit)
Defective work
WA470-7

Start engine.
Continuous
V
Loader
pump
pressure:
0.50
to
0.90
Voltage Between F10 (C) and (A)
At Neutral
V
At bucket tilt relief
V
2. Disconnect connector F10 and connect T-adapter to female side.
Voltage Between F10 (female) (C) and ground
Max 1 V
Reference
Continuous
V
Between L71 (9) and
Loader
pump
pressure:
0.50
to
0.90
Voltage
ground
at Neutral
V
Bucket tilt
V
40-627
40 Troubleshooting
Circuit diagram related to loader pump pressure sensor
40-628
WA470-7
40 Troubleshooting
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit
(WA470_7-DHA4KA-400-
A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure of Air Cleaner Sensor Circuit

Failure code
Failure
DHA4KA
Machine monitor determines that air cleaner clogging sensor circuit is open (open of
sensor contacts) because signal voltage from air cleaner clogging switch is not 1 V or
below when starting switch is turned to ON position.
Lights up air cleaner clogging caution lamp.
If machine continues to be used, clogging of air cleaner cannot be detected correctly,
inducing damage to engine.
Voltage at MCM1 A (53) is GND level when air cleaner is normal and Min. 10 V when air
function.
(Code: 04509 "Air cleaner clogging sensor")
Method of reproducing failure code: Turn starting switch to OFF position.
Cause

Dust indicator does not indicate red
When air cleaner is normal
zone.
Dust indicator indicates red zone.

clogging sensor

Open circuit, short
monitor controller
this point.
Min. 10 V

harness
(wire breakage or
connector)

female side.
Max. 1z
(1)
Resistance
Between E45 (female) (2) and each of MCM1 A
Max. 1z
Defective monitor
controller

WA470-7

Between E45 (male) (1) Air cleaner is normal.
Max. 1z
Resistance and (2)
Min. 1 Mz
Max. 1 V
Min. 10 V
40-629
40 Troubleshooting
40-630
WA470-7
40 Troubleshooting
Failure code [DHPCKX] Out of Range of Boom Bottom Press.

Sensor (WA470_7-DHPCKX-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Out of Range of Boom Bottom Pressure Sensor

Failure code
Failure
DHPCKX
Due to open circuit, ground fault, or hot short circuit in boom cylinder bottom pressure
sensor circuit, signal voltage of boom cylinder pressure is out of normal range.
(Signal voltage from boom cylinder bottom pressure sensor: Less than 0.3 V, or 4.42 V or
above)
Load is not displayed.

Komatsu SmartLoader Logic cannot be used.
Input voltage from boom cylinder bottom pressure sensor can be checked with monitoring
function.
(Code: 40402 Boom Bottom Pres. Sensor Volt)
Oil pressure sensed by boom cylinder bottom pressure sensor can be checked with
(Code: 40400 Boom Bottom Pressure)
Cause

system of boom cylinder
bottom pressure sensor
a If failure code [DB95KX] is also displayed, perform troubleshooting

for it first.
Power
Voltage Between F12 (female) (B) and (A) supply
5.0 to 5.2 V
input
a
1.
2.
3.

Start engine, and move lever to boom RAISE to perform
troubleshooting.
0.50 to 4.40
Defective boom cylinder
Continuous
V
bottom pressure sensor
Between F12 (C) and
(internal open or short circuit)
0.50 to 0.90
Boom: At NEUTRAL
Voltage
(A)
V
Boom cylinder bottom: 2.80 to 3.20
Hydraulic relief
V
Sensor voltage is measured with wiring harness connected. Accordingly,
if voltage is abnormal, check harness for failure, and then determine
whether sensor is defective or not.
2. Disconnect connectors L71, L72, and F12, and connect T-adapters
Between L72 (female) (6) and F12 (female) (C) Max. 1 z
Resis- Between L71 (female) (22) and F12 (female)
Max. 1 z
(B)
tance
Between L71 (female) (4) and F12 (female) (A) Max. 1 z
harness
WA470-7

female side.
Resis- Between ground and L72 (female) (6) or F12
Min 1 Mz
(female) (C)
tance
40-631
40 Troubleshooting
No.
Cause

2. Disconnect connectors L71, L72 and F12, and connect T-adapter to
either female side.
Resis- Between L72 (female) (6) and L71 (female) (4)
Min. 1 Mz
or between F12 (female) (A) and (C)
tance

harness

controller

Max. 1 V
defective.
Reference
3. Start engine and raise boom.
5.0 to 5.2 V
0.50 to 4.40
Continuous
V
Voltage Between L72 (6) and
0.50 to 0.90
Boom: At Neutral
ground
V
Boom cylinder bottom: 2.80 to 3.20
Hydraulic relief
V
Circuit diagram related to boom cylinder bottom pressure sensor
40-632
WA470-7
40 Troubleshooting
Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor
(WA470_7-
DHPDKX-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Out of Range of Boom Head Pressure Sensor

Failure code
Failure
DHPDKX
Due to open circuit, ground fault, or hot short circuit in boom cylinder head pressure
sensor circuit, signal voltage of boom cylinder pressure is out of normal range.
(Signal voltage from boom cylinder head pressure sensor: Less than 0.3 V, or 4.42 V or
above)
Load is not displayed.
Input voltage from boom cylinder head pressure sensor can be checked with monitoring
function.
(Code: 40501 Boom Head Pres. Sensor Volt)
Oil pressure sensed by boom cylinder head pressure sensor can be checked with
(Code: 40500 Boom Head Pressure)
Cause

first.
1.
Turn
starting switch to OFF position.
system of boom
2.
Disconnect
connector F13 and connect T-adapter to female side.
cylinder head pressure
sensor
Power
supply input 5.0 to 5.2 V
a
1.
2.
3.
Defective boom cylinder

head pressure sensor
circuit)

harness
(wire breakage or
connector)

harness
circuit)
WA470-7

Start engine, and troubleshoot by lowering boom.
0.50 to 4.40
V
0.50 to 0.90
Voltage Between F13 (C) and (A) Boom: At Neutral
V
Boom cylinder head:
2.80 to 3.22
Hydraulic relief
V
2. Disconnect connectors L71, L72, and F13, and connect T-adapters to
each female side.
Between L72 (female) (16) and F13 (female) (C)
Max. 1 z
Between
L71
(female)
(22)
and
F13
(female)
(B)
Resistance
Max. 1 z
Between L71 (female) (4) and F13 (female) (A)
Max. 1 z
Continuous

female side.
Min. 1 Mz
40-633
40 Troubleshooting
No.
Cause

2. Disconnect connectors L71, L72 and F13, and connect T-adapter to
either female side.
Min. 1 Mz
(4) or between F13 (female) (A) and (C)
tance

harness

controller

2. Disconnect connector F13 and connect T-adapter to female side.
Max 1 V
defective.
Reference
3. Start engine and lower boom
5.0 to 5.2 V
0.50 to 4.40
Continuous
V
Voltage Between L72 (16) and
0.50 to 0.90
Boom: At Neutral
ground
V
Boom cylinder head:
2.80 to 3.20
Hydraulic relief
V
Circuit diagram related to boom cylinder head pressure sensor
40-634
WA470-7
40 Troubleshooting
Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor
(WA470_7-
DHT1KX-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Out of Range of Transmission Cut Off Pressure Sensor

Failure code
Failure
DHT1KX
Due to open circuit or ground fault in transmission cut-off pressure sensor system,
transmission cut-off pressure signal voltage is lower than the normal range.
(Transmission cut-off pressure sensor signal voltage: Max. 0.3 V)
Turns off transmission cut-off function.
Disables change of transmission cut-off setting.
If cause of transmission cut-off failure disappears, machine becomes normal by itself.
Transmission cut-off indicator goes out.
Transmission cut-off function does not work.
Input voltage from transmission cut-off pressure sensor can be checked with monitoring
function.
(Code: 41202 Brake Oil Press Sensor Volt)
Oil pressure sensed by transmission cut-off pressure sensor can be checked with
(Code: 41201. Brake Oil Pressure)
Method of reproducing failure code:Turn starting switch ON and turn transmission cut-off
switch ON.
Cause
a If failure code [DBE6KX] is also displayed, perform troubleshooting for it

first.
system of transmission 2. Disconnect connector R73 and connect T-adapter to female side.
cut-off pressure sensor 3. Turn starting switch to ON position.
Power
Voltage Between R73 (female) (B) and (A)
supply input 20 to 30 V
a
1.
2.
3.
4.

Start engine.
Turn transmission cut-off switch ON.
When brake is released 0.9 to 1.1 V
cut-off pressure sensor
When brake pedal is
Voltage Between R73 (C) and (A) depressed (both right
1.1 to 5.1 V
circuit)
and left)
Continuous
0.9 to 5.1 V
female side.
harness
(wire breakage or
connector)
a Open circuit of 5 V circuit

Between L61 (female) (13) and R73 (female) (C)
Resistance Between L61 (female) (16) and R73 (female) (B)
Between L61 (female) (4) and R73 (female) (A)

harness
circuit)

female side.
Min. 1 Mz
WA470-7
Max. 1 z
Max. 1 z
Max. 1 z
40-635
40 Troubleshooting
No.
Cause

2. Disconnect connectors L61 and R73, and connect T-adapter to
either female side.
Resis- Between L61 (female) (13) and (4) or between
Min. 1 Mz
R73 (female) (A) and (C)
tance
defective.
Reference
controller
When brake is
0.9 to 1.1 V
released
Between L61 (13) and When brake pedal is
Voltage
depressed (both right 1.1 to 5.1 V
ground
and left)
Continuous
0.9 to 5.1 V
Circuit diagram related to transmission cut-off (left brake) pressure sensor
40-636
WA470-7
40 Troubleshooting
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor
(WA470_7-
DHT5KX-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Out of Range of Torque Converter Input Pressure Sensor

Failure code
Failure
DHT5KX
Voltage of signal circuit of torque converter input pressure sensor drops below 0.5 V or
increases above 4.5 V.
Controls it by fixing torque converter input pressure to set pressure stored in controller.
Large shocks are made when torque converter lockup clutch is engaged.
Input voltage from torque converter input pressure sensor can be checked with monitoring
function.
(Code: 32602 T/C In. Oil Press Sensor Volt)
Oil pressure sensed by torque converter input pressure sensor can be checked with
(Code: 32601 T/C Input Oil Pressure)
Cause

first.
Defective sensor power 2. Disconnect connector TCIN.P, and connect T-adapter to female side.
supply system
a If power supply voltage is abnormal, go to check on cause 5.
Power
Voltage Between TCIN.P (female) (B) and (A)

harness

2. Disconnect connectors L61 and TCIN.P, and connect T-adapter to either
female side.
3. Disconnect connector TCIN.P, and connect T-adapter to female side.
Between ground and L61 (female) (7) or TCIN.P
Min. 1 Mz

wiring harness

2. Disconnect connector TCIN.P, and connect T-adapter to female side.
Voltage Between TCIN.P (female) (C) and ground
Max 1 V
Defective torque
converter oil pressure
sensor
a
1.
2.
3.

Insert T-adapter into connector TCIN.P.
Voltage
WA470-7
Between TCIN.P (C) and (A)
0.9 to 5.1 V
40-637
40 Troubleshooting
No.
Cause

2. Disconnect connectors L61 and TCIN.P, and connect T-adapters to each
female side.

harness
(wire breakage or
connector)
controller
a If power supply voltage is normal, this check is

not required.
Between L61 (female) (16) and TCIN.P (female) (B)
Max. 1 z
Resistance

Max. 1 z
not required.
Between L61 (female) (4) and TCIN.P (female) (A)
Between L61 (female) (7) and TCIN.P (female) (C)
Max. 1 z
performed).
a
1.
2.
3.
Reference
Voltage
20 to 30 V
0.9 to 5.1 V
Circuit diagram related to torque converter oil pressure sensor
40-638
WA470-7
40 Troubleshooting
Failure code [DHT7KX] Out of Range of T/C Output Pressure

Sensor (WA470_7-DHT7KX-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Out of Range of Torque Converter Output Pressure Sensor

Failure code
Failure
DHT7KX
Voltage of signal circuit of torque converter output pressure sensor drops below 0.5 V or
increases above 4.5 V.
Fixes torque converter output pressure to set pressure in controller and continues control.
Large shocks are made when torque converter lockup clutch is engaged.
Input voltage from torque converter output pressure sensor can be checked with
(Code: 32604 T/C Out. Oil Press Sensor Volt)
Oil pressure sensed by torque converter output pressure sensor can be checked with
(Code: 32603 T/C Output Oil Pressure)
Cause

first.
Defective sensor power 2. Disconnect connector R91, and connect T-adapter to female side.
supply system
a If power supply voltage is abnormal, go to check on cause 5.
Power
Voltage Between R91 (female) (B) and (A)

harness

female side.
Min. 1 Mz

wiring harness

Voltage Between R91 (female) (C) and ground
Max. 1 V
Defective torque
converter oil pressure
sensor
a Replace sensor and check whether failure code disappears.

Voltage Between R91 (C) and (A)
WA470-7
0.9 to 5.1 V
40-639
40 Troubleshooting
No.
Cause

female side.

harness
(wire breakage or
connector)
controller

not required.
Between L61 (female) (16) and R91 (female) (B)
Max. 1 z
Resistance

Max. 1 z
not required.
Between L61 (female) (4) and R91 (female) (A)
Between L61 (female) (1) and R91 (female) (C)
Max. 1 z
performed).
a
1.
2.
3.
Reference
Voltage
20 to 30 V
0.9 to 5.1 V
Circuit diagram related to torque converter oil pressure sensor
40-640
WA470-7
40 Troubleshooting
Failure code [DHT8KA] Failure of Steering Pump Press. Sensor
(WA470_7-
DHT8KA-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure of Steering Pump Pressure Sensor

Failure code
Failure
DHT8KA
Due to open circuit or ground fault in steering pump pressure sensor system, steering
pump pressure signal voltage is lower than the normal range.
(Steering pump pressure sensor signal voltage: Max. 0.3 V)
Operates, assuming steering pump pressure to be 0 MPa.
Engine does not pick up normally at the low engine speed.
Input voltage from steering pump pressure sensor can be checked with monitoring
function.
(Code: 95303 Steering Pump Pres. Sensor Volt)
Oil pressure sensed by steering pump pressure sensor can be checked with monitoring
function.
(Code: 95302 Steering Pump Pressure)
Cause

first.
system of steering
2. Disconnect connector R86 and connect T-adapter to female side.
pump pressure sensor 3. Turn starting switch to ON position.
Power
5.00 to 5.20
supply input
V
a
1.
2.
3.
Defective steering
pump pressure sensor
circuit)

harness
(wire breakage or
connector)
WA470-7

Start engine and operate steering.
0.50 to 4.5
V
0.50
to
0.90
Voltage Between R86 (2) and (1) Steering: At NEUTRAL
V
3.02 to 3.42
Steering: At Relief
V
female side.
Continuous

Resistance

Max. 1 z
Max. 1 z
Max. 1 z
40-641
40 Troubleshooting
No.
Cause
harness
circuit)

harness
Defective work

female side.
Min. 1 Mz
female side.
Between L71 (female) (3) and (4), or between R86
Min. 1 Mz
Reference
0.50 to 4.5
Continuous
V
Between L71 (3) and
0.50
to
0.90
Voltage
Steering: At Neutral
ground
V
3.02 to 3.42
Steering: Relieved
V
Circuit diagram related to steering pump pressure sensor
40-642
WA470-7
40 Troubleshooting
Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit
(WA470_7-
DHT8KB-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Steering Pump Pressure Sensor Short Circuit

Failure code
Failure
DHT8KB
Due to hot short in steering pump pressure sensor system, steering pump pressure
sensor signal voltage is higher than the normal range.
(Steering pump pressure sensor signal voltage: Min. 4.7 V)
Operates, assuming steering pump pressure to be 0 MPa.
Engine does not pick up normally at the low engine speed.
function.
function.
Cause

first.
system of steering
pump pressure sensor 3. Turn starting switch to ON position.
Power
5.00 to 5.20
supply input
V
a
1.
2.
3.
Defective steering
pump pressure sensor
circuit)

wiring harness
(contact with 24V
circuit)
Defective work
WA470-7

Start engine and operate steering.
0.50 to 4.5
V
0.50
to
0.90
Voltage Between R86 (2) and (1) Steering: At Neutral
V
3.02 to 3.42
Steering: At Relief
V
Max 1 V
Reference
0.50 to 4.5
Continuous
V
Between L71 (3) and
0.50
to
0.90
Voltage
Steering: At Neutral
ground
V
3.02 to 3.42
Steering: At Relief
V
Continuous
40-643
40 Troubleshooting
Circuit diagram related to steering pump pressure sensor
40-644
WA470-7
40 Troubleshooting
Failure code [DHT8ZG] Steering Oil Pressure Low

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Failure code
DHT8ZG
Failure
(WA380_7-DHT8ZG-400-A-Z0-A)
Steering Oil Pressure Low

Steering pump pressure is lower than normal range.

When machine is steered, turning response is poor.
function.
function.
This failure code is displayed on only machines equipped with emergency steering
(optional).
Failure code [DHT8KA] of open circuit in steering pump pressure sensor is also displayed.

Cause
Perform troubleshooting according to [H-9] (Turning response is poor) in troubleshooting (H mode) for
hydraulic and mechanical system.
If no failure is found by above checks, troubleshoot for [DHT8KA] and [DHT8KB].
WA470-7
40-645
40 Troubleshooting
Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor
(WA470_7-
DHUDKA-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure of Emergency Steering Pressure Sensor

Failure code
Failure
DHUDKA
Due to open circuit or ground fault in emergency steering pump pressure sensor system,
emergency steering pump pressure signal voltage is lower than the normal range.
(Emergency steering pump pressure sensor signal voltage: Max. 0.3 V)
Judges that no emergency steering pump pressure is applied.
Emergency steering operation indicator does not light up while emergency steering is in
operation.
Only for the machine equipped with emergency steering (optional).
Input voltage from emergency steering pump pressure sensor can be checked with
(Code: 07705 Emrg. Steering Pres. S. Volt)
Oil pressure sensed by emergency steering pump pressure sensor can be checked with
(Code: 07703 Emrg. Steering Pressure)
Cause

first.
system of emergency
steering pump pressure 2. Disconnect connector R37 and connect T-adapter to female side.
sensor
Power
5.00 to 5.20
supply input
V
Defective emergency
steering pump pressure
sensor
circuit)

harness
(wire breakage or
connector)
40-646
a
1.
2.
3.
4.

Start engine.
Continuous
0.50 to 4.5
V
0.50 to 0.90
V
When emergency
Between R37 (2) and (1) steering is stopped
When emergency
0.50 to 3.05
steering is turned ON
V
and steering is operated
female side.
Voltage

Resistance

Max. 1 z
Max. 1 z
Max. 1 z
WA470-7
40 Troubleshooting
No.
Cause
harness
circuit)

harness
Defective work

female side.
Min. 1 Mz
female side.
Between L71 (female) (12) and (4) or between R37
Min. 1 Mz
Reference
3. Start engine.
4. Turn emergency steering ON and operate steering.
0.50 to 4.5
Continuous
V
When emergency
0.50 to 0.90
steering is stopped
Voltage
V
ground
When emergency
0.50 to 3.05
V
Circuit diagram related to emergency steering pump pressure sensor
WA470-7
40-647
40 Troubleshooting
Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit
(WA470_7-DHUDKB-
400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Emergency Steering Pressure Sensor Short Circuit

Failure code
Failure
DHUDKB
Due to hot short in emergency steering pump pressure sensor system, emergency
steering pump pressure sensor signal voltage is higher than the normal range.
(Emergency steering pump pressure sensor signal voltage: Min. 4.7 V)
Judges that no emergency steering pump pressure is applied.
Emergency steering operation indicator does not light up while emergency steering is in
operation.
Only for the machine equipped with emergency steering (optional).
(Code: 07705 Emrg. Steering Pres. S. Volt)
(Code: 07703 Emrg. Steering Pressure)
Cause

first.
system of emergency
steering pump pressure 2. Disconnect connector R37 and connect T-adapter to female side.
sensor
Power
5.00 to 5.20
supply input
V
Defective emergency
steering pump pressure
sensor
circuit)

wiring harness
(contact with 24V
circuit)
40-648
a
1.
2.
3.
4.

Start engine.
Continuous
0.50 to 4.5
V
0.50 to 0.90
V
When emergency
Between R37 (2) and (1) steering is stopped
When emergency
0.50 to 3.05
V
Max 1 V
Voltage
WA470-7
40 Troubleshooting
No.
Cause
Defective work

Reference
3. Start engine.
4. Turn emergency steering ON and operate steering.
0.50 to 4.5
Continuous
V
When emergency
0.50 to 0.90
steering is stopped
Voltage
V
ground
When emergency
0.50 to 3.05
V
Circuit diagram related to emergency steering pump pressure sensor
WA470-7
40-649
40 Troubleshooting
Failure code [DJF1KA] Disconnection of Fuel Level Sensor
(WA470_7-DJF1KA-400-A-
Z0-A)
Voltage of signal circuit of fuel level sensor is 2.0 V or above.
Problem on
machine
Fuel level gauge pointer disappears.
Related
information
Signal from fuel level sensor can be checked with monitoring function. (code: 04200 (V),
04201 (z))
No.
Failure code
DJF1KA
Disconnection of Fuel Level Sensor

Action level
L01
Detail of
failure
Action of
controller
Failure

Cause
Defective fuel level
sensor

Between
Fuel level: Full
Max. 12 z
Resistance R33 (male)
80 to 100 z
(1) and (2) Fuel level: Empty
Open circuit, short

circuit, ground fault, hot
this point.
monitor controller
Approx. 3.3
V

wiring harness

harness
(wire breakage or
connector)
Defective monitor
controller
40-650

Between
Fuel level: Full
Max. 12 z
MCM1 A
Fuel level: Empty
80 to 100 z
and (9)
female side.
Max. 1 z
(1)
Resistance
Max. 1 z
(2)
If no failure is found by above checks, monitor controller may be defective.
WA470-7
40 Troubleshooting
Circuit diagram related to fuel level sensor
WA470-7
40-651
40 Troubleshooting
Failure code [DK55KA] Failure of FNR Lever Potentio

Action level
L01
Detail of
failure
Action of
controller
(WA380_7-DK55KA-400-A-Z0-A)
Failure of FNR Lever Potentiometer

Failure code
Failure
DK55KA
Due to open circuit or ground fault in directional (FNR) lever analog signal system, analog
signal voltage from directional (FNR) lever is lower than normal range. (Analog signal
voltage from directional (FNR) lever: Below 1.2 V).
Judges that the lever position to be determined from analog signal is N (Neutral).
Continues to take it that lever position to be determined from analog signal is N (Neutral)
until it receives analog signal showing lever position of N (Neutral), even if cause of failure
disappears.
Problem on
machine
Related
information
Analog signal input voltage from lever can be checked with monitoring function. (Code:
91105 Shift lever Volt)
No.
Cause
Defective 5 V sensor
power supply system

If failure code [DBE5KX] is also displayed, perform troubleshooting for it first.
a If power supply voltage is abnormal, go to check on cause 3 and after.
5.0 to 5.2 V
1.
2.
3.
4.

Move directional (FNR) lever to perform troubleshooting.
a If power supply voltage is normal and sensor output voltage is abnormal

(0.5 V or lower), it cannot be determined whether ground fault or defective
sensor is the cause. In this case, go to check on cause 4.
Defective analog signal
system of directional
a If no failure is found in check on cause 4, analog signal system of
(FNR) lever
directional (FNR) lever is defective.
(internal open circuit or
ground fault)
position:
1.2 to 1.8 V
F (forward)
Voltage
1.7 to 3.3 V
(12)
position: N (neutral)
position:
3.2 to 3.8 V
R (reverse)
female side.

harness
(wire breakage or
connector)

Resistance Between L61 (female) (8) and L02 (female) (11)
40-652
Max. 1 z
Max. 1 z
Max. 1 z
WA470-7
40 Troubleshooting
No.
Cause

harness
circuit)
controller
WA470-7

female side.
Min. 1 Mz
Reference
4. Move directional (FNR) lever to perform troubleshooting.
Continuous
5.0 to 5.2 V
ground
position:
1.2 to 1.8 V
F (forward)
Voltage
Between L61 (8) and
1.7 to 3.3 V
ground
position:
3.2 to 3.8 V
R (reverse)
40-653
40 Troubleshooting
Circuit diagram related to directional (FNR) lever potentiometer
40-654
WA470-7
40 Troubleshooting
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit
(WA380_7-
DK55KY-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Hot Short of FNR Lever Potentiometer Circuit

Failure code
Failure
DK55KY
Due to hot short circuit in directional (FNR) lever analog signal system, analog signal
voltage from directional (FNR) lever is higher than normal range. (Signal voltage from
FNR lever potentiometer: Above 3.8 V)
Judges that the lever position to be determined from analog signal is N (Neutral).
Continues to take it that lever position to be determined from analog signal is N (Neutral)
until it receives analog signal showing lever position of N (Neutral), even if cause of failure
disappears.
Problem on
machine
Related
information
Analog signal input voltage from directional (FNR) lever can be checked with monitoring
function. (Code: 91105 Shift lever Volt)
No.
Cause
power supply system

If failure code [DBE5KX] is also displayed, perform troubleshooting for it first.
5.0 to 5.2 V

Defective analog signal 3. Turn starting switch to ON position.
system of directional
If this failure code [DK55KY] is not displayed, analog signal system of
(FNR) lever
directional (FNR) lever is defective. (If this failure code is still displayed, wiring
harness or transmission controller is defective.)
a Since connector L02 is disconnected, many failure codes appear. Ignore
all of displayed failure codes other than this failure code [DK55KY].

wiring harness
(contact with 24 V
circuit)
controller
WA470-7

Max. 1 V
Reference
4. Move directional (FNR) lever to perform troubleshooting.
Continuous
5.0 to 5.2 V
ground
position:
1.2 to 1.8 V
F (forward)
Voltage
Between L61 (8) and
1.7 to 3.3 V
ground
position:
3.2 to 3.8 V
R (reverse)
40-655
40 Troubleshooting
Circuit diagram related to directional (FNR) lever potentiometer
40-656
WA470-7
40 Troubleshooting
Failure code [DK55L5] Failure of FNR Lever Potentio

Action level
L01
Detail of
failure
Action of
controller
(WA380_7-DK55L5-400-A-Z0-A)
Failure of FNR Lever Potentiometer

Failure code
Failure
DK55L5
Input analog signal from directional (FNR) lever is impossible relative to input signal (ON/
OFF) from directional (FNR) lever switch where devices are normal.
This failure code is displayed under following conditions when short circuit to power
supply line not detected for directional (FNR) lever switch.
(In any case of [A], [B], and [C])
[A]
1. directional (FNR) lever switch recognizes that directional (FNR) lever is in F (Forward)
position.
2. directional (FNR) lever analog signal voltage is equal to or higher than 2.2 V.
3. Neither of open circuit and ground fault is detected in analog signal system of
directional (FNR) lever.
[B]
1. directional (FNR) lever switch recognizes that directional (FNR) lever is in R (Reverse)
position.
2. directional (FNR) lever analog signal voltage is higher than 2.8 V.
3. Short circuit to power supply line is not detected for directional (FNR) lever analog
signal system.
[C]
1. directional (FNR) lever switch recognizes that directional (FNR) lever is in N (Neutral)
position.
2. Analog signal system of directional (FNR) lever recognizes that directional (FNR) lever
is in F (Forward) or R (Reverse) position.
Takes it that lever position to be determined from analog signal is N (Neutral).
Problem on
machine
Related
information
Analog signal input voltage from lever can be checked with monitoring function. (Code:
91105 Shift lever Volt)
function. (Code: 02211 Main directional (FNR) Signal F, Main directional (FNR) Signal N,
Main directional (FNR) Signal R).
No.
1
Cause
lever
WA470-7

directional (FNR) lever may be defective.
40-657
40 Troubleshooting
Failure code [DK59KA] Failure of Boom Lever Potentio (Main)
(WA470_7-DK59KA-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure of Boom Lever Potentiometer (Main)

Failure code
Failure
DK59KA
Controller determines that boom lever potentiometer (main: A line) circuit has open circuit
or ground fault because signal voltage from boom lever potentiometer (main: A line) is
lower than normal range.
(Signal voltage from boom lever potentiometer (main: A line): Max. 0.3 V)
Controls boom by using signal voltage from boom lever potentiometer (sub: B line) if it is
normal.
However, in this case, bucket detent control does not work, and work equipment speed
decreases to 30 % of normal speed.
Even if cause of failure disappears, machine does not become normal until boom lever is
set in NEUTRAL.
Boom lowers momentarily, then it can be controlled by using signals from sub
potentiometer.
decreases to 30 % of normal speed.
Input voltage from boom lever potentiometer (main: A line) can be checked with
(Code: 42000 Boom Lever Volt(Main))
Input voltage from boom lever potentiometer (sub: B line) can be checked with monitoring
function.
(Code: 42001 Boom Lever Volt(Sub))
Cause
power supply system

If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
2. Disconnect connector L28A, and connect T-adapter to female side.
Voltage Between L28A (female) (1) and (2)
5.0 to 5.2 V
2. Disconnect connector L28A, and connect T-adapter to male side.
Between L28A (male) (1) and ground
Resistance Between L28A (male) (3) and ground
Min. 1 Mz
Defective boom lever

potentiometer (internal

5. Set work equipment lock switch to LOCK position.
7. Operate boom lever to perform troubleshooting.
Boom lever: NEUTRAL
Voltage
40-658
Between L28A (3) and

(2)
2.38 to 2.62
V
Boom lever: RAISE (just

3.38 to 4.04
before the detent
V
position)
Boom lever: RAISE (at 3.90 to 4.40
detent position)
V
Boom lever: LOWER
(just before the detent 0.96 to 1.62
V
position)
0.60 to 1.10
Boom lever: FLOAT
V
WA470-7
40 Troubleshooting
No.
Cause

2. Disconnect connectors L71 and L28A, and connect T-adapters to each
female side.

harness
(wire breakage or
connector)

harness
circuit)
Defective work
WA470-7
a If power supply voltage in check on cause 1 is

normal, this check is not required.
Between L71 (female) (22) and L28A (female) (1)
Resistance

Max. 1 z
Max. 1 z
Max. 1 z

2. Disconnect connectors L71 and L28A, and connect T-adapter to either
female side.
Between ground and L71 (female) (8) or L28A
Min. 1 Mz
Reference
Boom lever: Continuous 5.0 to 5.2 V
(4)
2.38 to 2.62
Boom lever: NEUTRAL
V
3.38 to 4.04
before the detent
V
position)
Voltage
detent position)
V
Boom lever: LOWER
V
position)
0.60 to 1.10
Boom lever: FLOAT
V
40-659
40 Troubleshooting
Circuit diagram related to boom lever potentiometer
40-660
WA470-7
40 Troubleshooting
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main)
(WA470_7-
DK59KY-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Hot Short of Boom Lever Potentiometer (Main)

Failure code
Failure
DK59KY
Controller determines that boom lever potentiometer (main: A line) circuit has hot short
because signal voltage from boom lever potentiometer (main: A line) is higher than normal
range.
(Signal voltage from boom lever potentiometer (main: A line): Min. 4.7 V)
Controls boom by using signal voltage from boom lever potentiometer (sub: B line) if it is
normal.
decreases 30%.
set in NEUTRAL.
Boom rises momentarily, then it is controlled normally by using signals from sub
potentiometer.
decreases 30%.
function.
Cause
power supply system

5.0 to 5.2 V

short circuit)
WA470-7

Resistance
Min. 1 Mz
40-661
40 Troubleshooting
No.
Cause
Boom lever: NEUTRAL

short circuit)

wiring harness

harness
Defective work
40-662
Voltage

(2)
2.38 to 2.62
V

3.38 to 4.04
before the detent
V
position)
detent position)
V
Boom lever: LOWER
V
position)
0.60 to 1.10
Boom lever: FLOAT
V

Voltage Between L28A (female) (3) and (2) or ground
Max. 1 V
2. Disconnect connectors L71 and L28A, and connect T-adapters to female
side of L71.
No continuity
Between L71 (female) (8) and each
Continuity
pin other than L71 (female) (8)
(No sound is heard)
Reference
(4)
2.38 to 2.62
Boom lever: NEUTRAL
V
3.38 to 4.04
before the detent
V
position)
Voltage
detent position)
V
Boom lever: LOWER
V
position)
0.60 to 1.10
Boom lever: FLOAT
V
WA470-7
40 Troubleshooting
WA470-7
40-663
40 Troubleshooting
Failure code [DK59L8] Boom Lever Potentio (Main & Sub)

Disagree (WA470_7-DK59L8-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Boom Lever Potentiometer (Main & Sub) Disagree

Failure code
Failure
DK59L8
Input signals from boom lever potentiometers (main: A line and sub: B line) disagree with
each other.
(Signal voltages from boom lever potentiometers (Total of signal voltages from main: A
line and sub: B line): Min. 4.65 V) or
(Signal voltages from boom lever potentiometers (Total of signal voltages from main: A
line and sub: B line): Min. 5.35 V)
Operates by using potentiometer sensor signal from either main: A line or sub: B line
which shows the standard voltage when lever is in NEUTRAL position.
In this case work equipment speed decreases 30% and stops boom detent output.
Stops output to boom detent solenoid, boom tilt EPC solenoid and boom dump EPC
solenoid if signal voltages from both main: A line and sub: B line potentiometers show out
of the standard value voltage when lever is in NEUTRAL position.
set in NEUTRAL.
If either main: A line or sub: B line potentiometer malfunctions, machine operates normally
with no boom detent output and decreasing work equipment speed 30% after lever is
once set to NEUTRAL.
If both main: A line and sub: B line potentiometers malfunction, boom does not move.
function.
Cause
power supply system

5.0 to 5.2 V

40-664

Min. 1 Mz
WA470-7
40 Troubleshooting
No.
Cause

Boom lever: NEUTRAL

(2)
2

Voltage

(2)
2.38 to 2.62
V

3.38 to 4.04
before the detent
V
position)
detent position)
V
Boom lever: LOWER
V
position)
0.60 to 1.10
Boom lever: FLOAT
V
2.38 to 2.62
Boom lever: NEUTRAL
V
0.96 to 1.62
before the detent
V
position)
detent position)
V
Boom lever: LOWER
V
position)
3.90 to 4.40
Boom lever: FLOAT
V

female side.

harness
(wire breakage or
connector)

harness
circuit)
WA470-7

Resistance a If power supply voltage in check on cause 1 is
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z

female side.
Min. 1 Mz
(female) (3)
Between L71 (female) (8) and (4) or between L28A
Min. 1 Mz
Resistance
Min. 1 Mz
(female) (4)
Between L71 (female) (2) and (4) or between L28A Min. 1 Mz
40-665
40 Troubleshooting
No.
Cause

wiring harness
Defective work
40-666

Between L28A (female) (3) and (2) or ground
Max. 1 V
Voltage
Between L28A (female) (4) and (2) or ground
Max. 1 V
Reference
(4)
2.38 to 2.62
Boom lever: NEUTRAL
V
3.38 to 4.04
before the detent
V
position)
detent position)
V
Boom lever: LOWER
V
position)
0.60 to 1.10
Voltage
Boom lever: FLOAT
V
2.38 to 2.62
Boom lever: NEUTRAL
V
0.96 to 1.62
before the detent
V
position)
detent position)
V
Boom lever: LOWER
V
position)
3.90 to 4.40
Boom lever: FLOAT
V
WA470-7
40 Troubleshooting
WA470-7
40-667
40 Troubleshooting
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub)
(WA470_7-DK5AKA-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure of Boom Lever Potentiometer (Sub)

Failure code
Failure
DK5AKA
Due to open circuit or ground fault in boom lever potentiometer (Sub: B line) system,
boom lever potentiometer (Sub: B line) signal voltage is lower than the normal range
(Boom lever potentiometer (Sub: B line) signal voltage: Max. 0.3 V).
Controls boom by using signal voltage from boom lever potentiometer (main: A line) if it is
normal.
In this case, however, boom detent control does not work, and work equipment speed
decreases to 30% of normal speed.
Boom detent control does not work.
Work equipment speed decreases 30%.
function.
Cause
power supply system

5.0 to 5.2 V

40-668

Resistance
Min. 1 Mz
2.38 to 2.62
Boom lever: NEUTRAL
V
0.96 to 1.62
before the detent
V
position)
Voltage
detent position)
V
(2)
Boom lever: LOWER
V
position)
3.90 to 4.40
Boom lever: FLOAT
V
WA470-7
40 Troubleshooting
No.
Cause

female side.

harness
(wire breakage or
connector)

harness
circuit)
Defective work
WA470-7

Resistance

Max. 1 z
Max. 1 z
Max. 1 z

female side.
Min. 1 Mz
Reference
(4)
2.38 to 2.62
Boom lever: NEUTRAL
V
0.96 to 1.62
before the detent
V
position)
Voltage
detent position)
V
Boom lever: LOWER
V
position)
3.90 to 4.40
Boom lever: FLOAT
V
40-669
40 Troubleshooting
40-670
WA470-7
40 Troubleshooting
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub)
(WA470_7-
DK5AKY-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Hot Short of Boom Lever Potentiometer (Sub)

Failure code
Failure
DK5AKY
Due to hot short in boom lever potentiometer (Sub: B line) system, boom lever
potentiometer (Sub: B line) signal voltage is higher than the normal range (Boom lever
potentiometer (Sub: B line) signal voltage: Min. 4.7 V).
Controls boom by using signal voltage from boom lever potentiometer (main: A line) if it is
normal.
decreases 30%.
set in NEUTRAL.
Boom detent control does not work.
monitoring function. (Code: 42000 Boom Lever Volt(Main))
function. (Code: 42001 Boom Lever Volt(Sub))
Cause
power supply system

5.0 to 5.2 V

short circuit)
WA470-7

Resistance
Min. 1 Mz
2.38 to 2.62
Boom lever: NEUTRAL
V
0.96 to 1.62
before the detent
V
position)
Voltage
detent position)
V
(2)
Boom lever: LOWER
V
position)
3.90 to 4.40
Boom lever: FLOAT
V
40-671
40 Troubleshooting
No.
3
Cause
wiring harness

harness
Defective work
40-672

Voltage Between L29A (female) (4) and ground
Max. 1 V
2. Disconnect connector L28A.
No continuity
Continuity
(No sound is heard)
Reference
(4)
2.38 to 2.62
Boom lever: NEUTRAL
V
0.96 to 1.62
before the detent
V
position)
Voltage
detent position)
V
Boom lever: LOWER
V
position)
3.90 to 4.40
Boom lever: FLOAT
V
WA470-7
40 Troubleshooting
WA470-7
40-673
40 Troubleshooting
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main)
(WA470_7-
DK5BKA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure of Bucket Lever Potentiometer (Main)

Failure code
Failure
DK5BKA
Controller determines that bucket lever potentiometer (main: A line) circuit has open
circuit or ground fault because signal voltage from bucket lever potentiometer (main: A
line) is lower than normal range. (Signal voltage from bucket lever potentiometer (main: A
line): Max. 0.3 V)
Controls bucket by using signal voltage from bucket lever potentiometer (sub: B line) if it is
normal.
In this case, however, bucket detent control does not work, and work equipment speed
Even if cause of failure disappears, machine does not become normal until bucket lever is
set in NEUTRAL.
Bucket makes dump movement momentarily, then it is controlled normally by using
signals from sub potentiometer.
Input voltage from bucket lever potentiometer (main: A line) can be checked with
monitoring function. (Code: 42002 Bucket Lever Volt(Main))
Input voltage from bucket lever potentiometer (sub: B line) can be checked with
monitoring function. (Code: 42003 Bucket Lever Volt(Sub))
Cause
power supply system

When failure code [DB96KX] is also displayed, perform troubleshooting for it
first.
5.0 to 5.2 V
Defective bucket lever

40-674

Resistance
Min. 1 Mz
2.38 to 2.62
V
Bucket lever: TILT (just
3.38 to 4.04
before the detent
V
position)
Voltage
(2)
Bucket lever: TILT (at 3.90 to 4.40
detent position)
V
0.60 to 1.10
V
WA470-7
40 Troubleshooting
No.
Cause

2. Disconnect connectors L71, L72, and L29A, and connect T-adapters to
each female side.

harness
(wire breakage or
connector)

harness
circuit)
Defective work
WA470-7

Resistance

Max. 1 z
Max. 1 z
Max. 1 z

female side.
Min. 1 Mz
Reference
Between L72 (1) and L71
Bucket lever: Continuous 5.0 to 5.2 V
(4)
2.38 to 2.62
V
3.38 to 4.04
Voltage
before the detent
V
position)
(4)
detent position)
V
0.60 to 1.10
V
40-675
40 Troubleshooting
Circuit diagram related to bucket lever potentiometer
40-676
WA470-7
40 Troubleshooting
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main)
(WA470_7-
DK5BKY-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Hot Short of Bucket Lever Potentiometer (Main)

Failure code
Failure
DK5BKY
Due to hot short circuit of bucket lever potentiometer (main: A line) system, signal voltage
from bucket lever potentiometer (main: A line) is higher than normal range.
(Signal voltage from bucket lever potentiometer (main: A line): Min. 4.7 V)
Controls bucket by using signal voltage from bucket lever potentiometer (sub: B line) if it is
normal.
set in NEUTRAL.
Bucket tilts momentarily, then it is controlled normally by using signals from sub
potentiometer.
Cause
power supply system

first.
5.0 to 5.2 V

short circuit)
WA470-7

Resistance
Min. 1 Mz
2.38 to 2.62
V
3.38 to 4.04
before the detent
V
position)
Voltage
(2)
detent position)
V
0.60 to 1.10
V
40-677
40 Troubleshooting
No.
3
Cause
wiring harness

harness
Defective work
40-678

each female side.
Max. 1 V
2. Disconnect connectors L71 and L29A, and connect T-adapter to female
side of L71.
No continuity
Continuity
(No sound is heard)
Reference
(4)
2.38 to 2.62
V
3.38 to 4.04
Voltage
before the detent
V
position)
(4)
detent position)
V
0.60 to 1.10
V
WA470-7
40 Troubleshooting
WA470-7
40-679
40 Troubleshooting
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub)

Disagree (WA470_7-DK5BL8-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Bucket Lever Potentiometer (Main & Sub) Disagree

Failure code
Failure
DK5BL8
Input signals from bucket EPC lever potentiometers (main: A line and sub: B line)
disagree with each other.
(Signal voltage from bucket EPC lever potentiometer (total of main: A line and sub: B
line): Max. 4.65 V) or (signal voltage from bucket EPC lever potentiometer (total of main:
A line and sub: B line): Min. 5.35 V)
which detects the standard voltage when lever is in NEUTRAL position.
In this case work equipment speed decreases to 30% of normal speed and stops bucket
detent solenoid output.
Stops output to bucket detent solenoid, bucket tilt EPC solenoid and bucket dump EPC
solenoid if signal voltages from both main: A line and sub: B line potentiometers show out
of the standard voltage when lever is in NEUTRAL position.
set in NEUTRAL.
with no bucket detent solenoid output and decreasing work equipment speed to 30% of
normal speed after lever is once set to NEUTRAL.
If both main: A line and sub: B line potentiometers malfunction, bucket does not move.
Cause
power supply system

first.
5.0 to 5.2 V
Defective bucket EPC

lever potentiometer
circuit)
40-680

Min. 1 Mz
WA470-7
40 Troubleshooting
No.
Cause
1.
2.
3.
4.
5.

Insert T-adapter into connector L29A.
Turn work equipment lock switch to LOCK position.
Move bucket EPC lever to perform troubleshooting.
Bucket EPC lever:
2.38 to 2.62
NEUTRAL
V
Bucket EPC lever: TILT
V
position)
(2)
Bucket EPC lever: TILT 3.90 to 4.40
(Detent position)
V
Bucket EPC lever: Full 0.60 to 1.10
DUMP
V
Voltage
Bucket EPC lever:
2.38 to 2.62
NEUTRAL
V
V
position)
(2)
(Detent position)
V
DUMP
V
female side.
Max. 1 z
Max. 1 z
Resistance
Max. 1 z
Max. 1 z
Defective bucket EPC

lever potentiometer
circuit)

harness
(wire breakage or
connector)

harness
circuit)

female side.
Min. 1 Mz
(female) (4)
Resistance
Min. 1 Mz
(female) (3)

wiring harness

Between L29A (female) (4) and ground
Max. 1 V
Voltage
Max. 1 V
Between L29A (female) (3) and ground
WA470-7
40-681
40 Troubleshooting
No.
Cause
Defective work
40-682

Reference
3. Set work equipment lock lever in LOCK position.
5. Move bucket EPC lever to perform troubleshooting.
Continuous
5.0 to 5.2 V
(4)
Bucket EPC lever:
2.38 to 2.62
NEUTRAL
V
V
position)
L71 (4)
(Detent position)
V
Bucket
EPC
lever:
Full
0.60
to
1.10
Voltage
DUMP
V
Bucket EPC lever:
2.38 to 2.62
NEUTRAL
V
V
position)
L71 (4)
(Detent position)
V
DUMP
V
WA470-7
40 Troubleshooting
WA470-7
40-683
40 Troubleshooting
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub)
(WA470_7-DK5CKA-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure of Bucket Lever Potentiometer (Sub)

Failure code
Failure
DK5CKA
Controller determines that bucket lever potentiometer (sub: B line) circuit has open circuit
or ground fault because signal voltage from bucket lever potentiometer (sub: B line) is
lower than normal range. (Signal voltage from bucket lever potentiometer (sub: B line):
Max. 0.3 V)
Controls bucket by using signal voltage from bucket lever potentiometer (main: A line) if it
is normal.
decreases 30%.
Bucket detent control does not work.
Work equipment speed decreases 30 %.
Cause
power supply system

first.
5.0 to 5.2 V

40-684

Resistance
Min. 1 Mz
2.38 to 2.62
V
0.96 to 1.62
before the detent
V
position)
Voltage
(2)
detent position)
V
3.90 to 4.40
V
WA470-7
40 Troubleshooting
No.
Cause

each female side.

harness
(wire breakage or
connector)

harness
circuit)
Defective work
WA470-7

Resistance

Max. 1 z
Max. 1 z
Max. 1 z

female side.
Min. 1 Mz
Reference
(4)
2.38 to 2.62
V
0.96 to 1.62
Voltage
before the detent
V
position)
(4)
detent position)
V
3.90 to 4.40
V
40-685
40 Troubleshooting
40-686
WA470-7
40 Troubleshooting
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub)
(WA470_7-
DK5CKY-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Hot Short of Bucket Lever Potentiometer (Sub)

Failure code
Failure
DK5CKY
Controller determines that bucket lever potentiometer (sub: B line) circuit has hot short
because signal voltage from bucket lever potentiometer (sub: B line) is higher than normal
range. (Signal voltage from bucket lever potentiometer (sub: B line): Min. 4.7 V)
Controls bucket by using signal voltage from bucket lever potentiometer (main: A line) if it
is normal.
decreases 30 %.
set in NEUTRAL.
Bucket detent control does not work.
Cause
power supply system

first.
5.0 to 5.2 V

short circuit)
WA470-7

Resistance
Min. 1 Mz
2.38 to 2.62
V
0.96 to 1.62
before the detent
V
position)
Voltage
(2)
detent position)
V
3.90 to 4.40
V
40-687
40 Troubleshooting
No.
Cause

wiring harness

harness
Defective work
40-688

Voltage Between ground and L71 (female) (14) or L29A (4)
Max 1 V
No continuity
Continuity
(No sound is heard)
Reference
(4)
2.38 to 2.62
V
0.96 to 1.62
Voltage
before the detent
V
position)
(4)
detent position)
V
3.90 to 4.40
V
WA470-7
40 Troubleshooting
WA470-7
40-689
40 Troubleshooting
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main)
(WA470_7-DK5DKA-400-A-
Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure of 3rd Lever Potentiometer (Main)

Failure code
Failure
DK5DKA
Controller determines that 3rd (attachment) lever potentiometer (main: A line) circuit has
open circuit or ground fault because signal voltage from 3rd (attachment) lever
potentiometer (main: A line) is lower than normal range.
(Signal voltage from 3rd (attachment) lever potentiometer (main: A line): Max. 0.3 V)
Controls attachment by using signals from 3rd (attachment) lever potentiometer (sub: B
line) if 3rd (attachment) lever potentiometer (sub: B line) is normal.
However, in this case, decreases work equipment speed 30 %.
Even if cause of failure disappears, machine does not become normal until 3rd
(attachment) lever is set in NEUTRAL.
Attachment cylinder retracts momentarily, then attachment is controlled normally by using
However, work equipment speed decreases 30 %.
This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment). (If this failure code is displayed on the machine, select "None" for 3rd valve
(attachment) setting on option setting screen of machine monitor.)
Input voltage from 3rd (attachment) lever potentiometer (main: A line) can be checked
with monitoring function. (Code: 42006 3rd Lever Volt(Main))
Input voltage from 3rd (attachment) lever potentiometer (sub: B line) can be checked with
monitoring function. (Code: 42007 3rd Lever Volt(Sub))
Cause
power supply system

5.0 to 5.2 V
Defective 3rd
(attachment) lever
potentiometer
40-690

2. Disconnect connector L30, and connect T-adapters to male side.
Resistance
Min. 1 Mz
7. Operated 3rd (attachment) lever to perform troubleshooting.
3rd (attachment) lever: 2.38 to 2.62
NEUTRAL
V
3.90 to 4.40
Operated to extend
V
cylinder fully
Operated to retract
V
cylinder fully
WA470-7
40 Troubleshooting
No.
Cause

2. Disconnect connectors L71, L72, and L30, and connect T-adapters to
each female side.

L71 (female) (22) and L30 (female) (1)
connector)
Resistance

ground circuit)
Defective work
WA470-7
Max. 1 z
Max. 1 z
Max. 1 z

female side.
Min. 1 Mz
Reference
5. Operate 3rd (attachment) lever to perform troubleshooting.
5.0 to 5.2 V
L71 (4)
Continuous
NEUTRAL
V
Voltage
3.90 to 4.40
Operated to extend
V
cylinder fully
L71 (4)
0.60 to 1.10
Operated to retract
V
cylinder fully
40-691
40 Troubleshooting
Circuit diagram related to 3rd (attachment) lever potentiometer
40-692
WA470-7
40 Troubleshooting
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main)
(WA470_7-DK5DKY-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Hot Short of 3rd Lever Potentiometer (Main)

Failure code
Failure
DK5DKY
Controller determines that 3rd (attachment) lever potentiometer (main: A line) circuit has
hot short because signal voltage from 3rd (attachment) lever potentiometer (main: A line)
is higher than normal range.
(Signal voltage from 3rd (attachment) lever potentiometer (main: A line): Max. 4.7 V)
Controls attachment by using signals from 3rd (attachment) lever potentiometer (sub: B
line) if 3rd (attachment) lever potentiometer (sub: B line) is normal.
Attachment cylinder extends momentarily, then attachment is controlled normally by using
However, work equipment speed decreases 30 %.
Cause
power supply system

5.0 to 5.2 V
Defective 3rd
(attachment) lever
potentiometer
WA470-7

Resistance
Min. 1 Mz
NEUTRAL
V
3.90 to 4.40
Operated to extend
V
cylinder fully
Operated to retract
V
cylinder fully
40-693
40 Troubleshooting
No.
3
Cause
wiring harness

harness

Max. 1 V
side of L72.
No continuity
(No sound is heard)
Reference
5.0 to 5.2 V
(4)
Continuous
NEUTRAL
V
Voltage
3.90 to 4.40
Operated to extend
V
cylinder fully
L71 (4)
0.60 to 1.10
Operated to retract
V
cylinder fully
Continuity
Defective work

40-694
WA470-7
40 Troubleshooting
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree
(WA470_7-
DK5DL8-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
3rd Lever Potentiometer (Main & Sub) Disagree

Failure code
Failure
DK5DL8
Input signals from 3rd (attachment) lever potentiometers (main: A line and sub: B line)
disagree with each other.
(Signal voltage from 3rd (attachment) lever potentiometers (total of main: A line and sub:
B line): Max. 4.65 V) or
(signals voltage from 3rd (attachment) lever potentiometers (total of main: A line and sub:
B line): Min. 5.35 V)
For PCS (type D and G),
(Total of signal voltages from main: A line and sub: B line is 4.58 V or less) or
(Total of signal voltages from main: A line and sub: B line is 5.42 V or above)
which shows the standard voltage when lever is in NEUTRAL position.
Stops output to 3rd EPC solenoid (extension) and 3rd EPC solenoid (retract) if signal
voltages from both main: A line and sub: B line potentiometers show out of the standard
voltage when lever is in NEUTRAL position.
with work equipment speed decreases 30% after lever is once set to NEUTRAL.
If both of main: A line and sub: B line potentiometers malfunction, cylinder that is
controlled by 3rd valve (attachment) does not move.
Cause
power supply system

5.0 to 5.2 V
Defective 3rd
(attachment) lever
potentiometer
WA470-7

Resistance
Min. 1 Mz
40-695
40 Troubleshooting
No.
Cause
Defective 3rd
(attachment) lever
potentiometer
Voltage

NEUTRAL
Operated to extend
cylinder fully
Operated to retract
cylinder fully
NEUTRAL
Operated to extend
cylinder fully
Operated to retract
cylinder fully
2.38 to 2.62
V
3.90 to 4.40
V
0.60 to 1.10
V
2.38 to 2.62
V
0.60 to 1.10
V
3.90 to 4.40
V

each female side.

connector)
Resistance a If power supply voltage in check on cause 1 is

ground circuit)

wiring harness
Defective work
40-696
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z

female side.
Min. 1 Mz
(female) (3)
Resistance
Min. 1 Mz
(female) (4)
Max. 1 V
Voltage
Max. 1 V
Reference
WA470-7
40 Troubleshooting
No.
Cause
Defective work
Voltage

(4)
Continuous
NEUTRAL
Operated to extend
cylinder fully
L71 (4)
Operated to retract
cylinder fully
NEUTRAL
Operated to extend
cylinder fully
L71 (4)
Operated to retract
cylinder fully
5.0 to 5.2 V
2.38 to 2.62
V
3.90 to 4.40
V
0.60 to 1.10
V
2.38 to 2.62
V
3.90 to 4.40
V
0.60 to 1.10
V
WA470-7
40-697
40 Troubleshooting
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub)
(WA470_7-DK5EKA-400-A-
Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Failure of 3rd Lever Potentiometer (Sub)

Failure code
Failure
DK5EKA
Controller determines that 3rd (attachment) lever potentiometer (sub: B line) circuit has
open circuit or ground fault because signal voltage from 3rd (attachment) lever
potentiometer (sub: B line) is lower than normal range. (Signal voltage from 3rd
(attachment) lever potentiometer (sub: B line): Max. 0.3 V)
Controls attachment by using signals from 3rd (attachment) lever potentiometer (main: A
line) if it is normal.
Problem on
machine
Related
information
No.
Cause
power supply system

5.0 to 5.2 V
Defective 3rd
(attachment) lever
potentiometer
40-698

Resistance
Min. 1 Mz
NEUTRAL
V
0.60 to 1.10
Operated to extend
V
cylinder fully
Operated to retract
V
cylinder fully
WA470-7
40 Troubleshooting
No.
Cause

each female side.

connector)
Resistance

ground circuit)
Defective work
WA470-7
Max. 1 z
Max. 1 z
Max. 1 z

female side.
Min. 1 Mz
Reference
5.0 to 5.2 V
L71 (4)
Continuous
NEUTRAL
V
Voltage
3.90 to 4.40
Operated to extend
V
cylinder fully
L71 (4)
0.60 to 1.10
Operated to retract
V
cylinder fully
40-699
40 Troubleshooting
40-700
WA470-7
40 Troubleshooting
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub)
(WA470_7-DK5EKY-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Hot Short of 3rd Lever Potentiometer (Sub)

Failure code
Failure
DK5EKY
Controller determines that 3rd (attachment) lever potentiometer (sub: B line) circuit has
hot short because signal voltage from 3rd (attachment) lever potentiometer (sub: B line) is
higher than normal range.
(Signal voltage from 3rd (attachment) lever potentiometer (sub: B line): Min. 4.7 V)
Controls attachment by using signals from 3rd (attachment) lever potentiometer (main: A
line) if it is normal.
Problem on
machine
Related
information
No.
Cause
power supply system

5.0 to 5.2 V
Defective 3rd
(attachment) lever
potentiometer
WA470-7

Resistance
Min. 1 Mz
NEUTRAL
V
0.60 to 1.10
Operated to extend
V
cylinder fully
Operated to retract
V
cylinder fully
40-701
40 Troubleshooting
No.
3
Cause
wiring harness

harness
Defective work

Max. 1 V
side of L72.
No continuity
Continuity
(No sound is heard)
Reference
5.0 to 5.2 V
(4)
Continuous
NEUTRAL
V
Voltage
3.90 to 4.40
Operated to extend
V
cylinder fully
L71 (4)
0.60 to 1.10
Operated to retract
V
cylinder fully
40-702
WA470-7
40 Troubleshooting
Failure code [DKA0KA] Failure of Boom Angle Sensor

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA470_7-DKA0KA-400-A-Z0-A)
Failure of Boom Angle Sensor

Failure code
Failure
DKA0KA
Due to open circuit or ground fault in boom angle sensor system, signal voltage from
boom angle sensor is lower than normal range. (Signal voltage from boom angle sensor:
Max. 0.3 V)
Determines that boom is at lowest position.
Disables remote positioner function.
Disables semi-auto digging.
Disables boom FLOAT detent function when remote positioner LOWER stop function is
ON, and allows boom FLOAT detent function to work normally when remote positioner
LOWER stop function is OFF.
Disables boom RAISE detent function.
Remote positioner malfunctions (boom does not stop).
Semi-auto digging system malfunctions (does not work).
Input voltage from boom angle sensor can be checked with monitoring function.
(Code: 06005 Boom Angle Sensor Volt)
Angle sensed by boom angle sensor can be checked with monitoring function.
(Code: 06002 Boom Angle)
Cause
power supply system

Voltage Between F11 (female) (C) and (A)
5.0 to 5.2 V
Defective boom angle

sensor
circuit)

Between F11 (male) (A) and (C)
4 to 6 kz
Between F11 (male) (A) and ground
Min. 1 Mz
Resistance
Between F11 (male) (B) and ground
Min. 1 Mz
Between F11 (male) (C) and ground
Min. 1 Mz
1.
2.
3.
4.

Continuous
Voltage
Between F11 (B) and (A) RAISE stroke end

LOWER stroke end

harness
(wire breakage or
connector)
WA470-7
1.13 to 4.02
V
3.52 to 4.02
V
1.13 to 1.63
V

each female side.
Between F11 (female) (A) and L71 (female) (4)
Max. 1 z
Between F11 (female) (B) and L72 (female) (26)
Max. 1 z
Resistance
Max. 1 z
Between F11 (female) (C) and L71 (female) (22)
40-703
40 Troubleshooting
No.
Cause

harness
circuit)
Defective work

2. Disconnect connectors L71, L72, and F11, and connect T-adapter to any
female side.
Between ground and F11 (female) (B) or L72
Min. 1 Mz
Reference
1.13 to 4.02
Continuous
V
3.52
to
4.02
Voltage
RAISE stroke end
ground
V
1.13 to 1.63
LOWER stroke end
V
Circuit diagram related to boom angle sensor
40-704
WA470-7
40 Troubleshooting
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit
(WA470_7-
DKA0KY-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Hot Short of Boom Angle Sensor Circuit

Failure code
Failure
DKA0KY
Due to hot short circuit in boom angle sensor system, signal voltage from boom angle
sensor is higher than normal range. (Signal voltage from boom angle sensor: Min. 4.7 V)
Determines that boom is at lowest position.
set in NEUTRAL.
Remote positioner malfunctions.
Semi-auto digging system malfunctions.
Cause
power supply system

5.0 to 5.2 V

sensor

Resistance
1.
2.
3.
4.

Continuous
Voltage

LOWER stroke end

wiring harness
WA470-7
4 to 6 kz
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
1.13 to 4.02
V
3.52 to 4.02
V
1.13 to 1.63
V

Max. 1 V
Voltage Between F11 (female) (B) and ground
40-705
40 Troubleshooting
No.
Cause
Defective work

Reference
1.13 to 4.02
Continuous
V
3.52
to
4.02
Voltage
RAISE stroke end
ground
V
1.13 to 1.63
LOWER stroke end
V
40-706
WA470-7
40 Troubleshooting
Failure code [DKA0L0] Boom Angle Sensor Dislocation

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA470_7-DKA0L0-400-A-Z0-A)
Boom Angle Sensor Dislocation

Failure code
Failure
DKA0L0
Due to boom angle sensor dislocation, boom angle is not sensed correctly.
(Boom angle: higher than upper limit by +5 degrees or lower than lower limit by -5
degrees)
If cause of failure disappears, machine becomes normal by itself (when cause is defective
adjustment of angle sensor).
is turned to OFF position (when cause is not defective adjustment of angle sensor).
Remote positioner malfunctions (boom does not stop).
This failure code may be displayed when initial setting of boom angle sensor fails.
In this case, reset boom angle sensor, see Testing and adjusting.
Method of reproducing failure code: Start engine and raise or lower boom to stroke end.
Cause
power supply system

5.0 to 5.2 V
4 to 6 kz
Min. 1 Mz
Resistance
Min. 1 Mz
Min. 1 Mz

sensor
circuit)
1.
2.
3.
4.

Continuous
Voltage

LOWER stroke end
WA470-7
1.13 to 4.02
V
3.52 to 4.02
V
1.13 to 1.63
V
40-707
40 Troubleshooting
No.
Cause
Defective work

Reference
1.13 to 4.02
Continuous
V
3.52
to
4.02
Voltage
RAISE stroke end
ground
V
1.13 to 1.63
LOWER stroke end
V
40-708
WA470-7
40 Troubleshooting
Failure code [DKA1KA] Failure of Bucket Angle Sensor

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA470_7-DKA1KA-400-A-Z0-A)
Failure of Bucket Angle Sensor

Failure code
Failure
DKA1KA
Due to open circuit or ground fault in bucket angle sensor system, signal voltage from
bucket angle sensor is lower than normal range. (Signal voltage from bucket angle
sensor: Max. 0.3 V)
Determines that bell crank angle is at its minimum.
Disables bucket positioner function.
Disables bucket detent function.
Bucket positioner malfunctions (does not work).
Input voltage from bucket angle sensor can be checked with monitoring function.
(Code: 55601 Bucket Link Angle Sensor Volt)
Angle sensed by bucket angle sensor can be checked with monitoring function.
(Code: 55600 Bucket Link Angle)
Cause
power supply system

5.0 to 5.2 V
Defective bucket angle

sensor
circuit)

4 to 6 kz
Min. 1 Mz
Resistance
Min. 1 Mz
Min. 1 Mz
1.
2.
3.
4.

Continuous
Voltage
Between F32 (B) and (A) Full TILT

Full DUMP
2.15 to 4.45
V
3.95 to 4.45
V
2.15 to 2.65
V

harness
(wire breakage or
connector)

each female side.
Between F32 (female) (A) and L71 (female) (4)
Max. 1 z
Resistance Between F32 (female) (B) and L72 (female) (36)
Max. 1 z
Between F32 (female) (C) and L71 (female) (22)
Max. 1 z

harness
circuit)

2. Disconnect connectors L71, L72, and F32, and connect T-adapter to any
female side.
Between ground and F32 (female) (B) or L72
Min. 1 Mz
WA470-7
40-709
40 Troubleshooting
No.
Cause
Defective work

Reference
2.15 to 4.45
Continuous
V
3.95
to
4.45
Voltage
Full TILT
ground
V
2.15 to 2.65
Full DUMP
V
Circuit diagram related to bucket angle sensor
40-710
WA470-7
40 Troubleshooting
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit
(WA470_7-
DKA1KY-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Hot Short of Bucket Angle Sensor Circuit

Failure code
Failure
DKA1KY
Due to hot short circuit in bucket angle sensor system, signal voltage from bucket angle
sensor is higher than normal range. (Signal voltage from bucket angle sensor: Min. 4.8 V)
Determines that bell crank angle is at its minimum.
Disables bucket positioner function.
Disables bucket detent function.
Bucket positioner malfunctions (does not work).
Input voltage from bucket angle sensor can be checked with monitoring function.
(Code: 55601 Bucket Link Angle Sensor Volt)
Angle sensed by bucket angle sensor can be checked with monitoring function.
(Code: 55600 Bucket Link Angle)
Cause
Defective 5 V sensor power

supply system

If failure code [DB95KX] is also displayed, perform troubleshooting for it
first.
a If power supply voltage is abnormal, go to check on cause 3 and
after.
5.0 to 5.2 V
Defective bucket angle

sensor

harness

controller
WA470-7

4 to 6 kz
Between
F32
(male)
(A)
and
ground
Min. 1 Mz
Resistance
Min. 1 Mz
Min. 1 Mz
1.
2.
3.
4.

Continuous
Between F32 (B) and
Voltage
Full TILT
(A)
Full DUMP
2.5 to 4.7 V
4.2 to 4.7 V
2.5 to 3.0 V

Voltage Between F32 (female) (B) and ground
Max. 1 V
defective.
Reference
Continuous
2.5 to 4.7 V
Voltage
Full
TILT
4.2
to 4.7 V
ground
Full DUMP
2.5 to 3.0 V
40-711
40 Troubleshooting
Circuit diagram related to bucket angle sensor
40-712
WA470-7
40 Troubleshooting
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor
(WA380_7-
DLF1KA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Disconnection of transmission input speed sensor

Failure code
Failure
DLF1KA
Due to open circuit or hot short circuit in transmission input shaft speed sensor circuit,
signal voltage from transmission input shaft speed sensor is higher than normal range.
This failure code appears if following conditions are met.
1) Input voltage is 3 V or above.
2) Pulse voltage input is not recorded.
Sets shift mode to manual mode.
Maintains rotation speed before failure.
Auto-shift mode is unavailable (manual shift mode is selected).
Lockup clutch is not engaged.
Gear shifting shocks result.
Input shaft speed input from transmission input shaft speed sensor can be checked with
monitoring function. (Code: 31200 T/M Input Shaft Speed)
Cause
Defective adjustment of
transmission input shaft
speed sensor

For adjustment, screw in speed sensor until it contacts with gear for
speed sensing, then return sensor half turn to one turn.
a For details, see Testing and adjusting, "Adjusting transmission input
shaft speed sensor".
2. Disconnect connector REV IN, and connect T-adapters to male side.
500 to 1,000
z
Resistance Between ground and each of REV IN (male)
Min. 1 Mz
(1) and (2)
Defective transmission input

shaft speed sensor

Open or short circuit in wiring 2. Disconnect connector L62, and connect T-adapters to female side.
harness
500 to 1,000
tance
z

harness
controller
WA470-7
a
1.
2.
3.

Disconnect connector REV IN, and connect T-adapter to female side.
Between L62 (female) (40) and REV IN
Max. 1 z
Resis- (female) (1)
tance Between L62 (female) (39) and REV IN
Max. 1 z
(female) (2)
performed.)
40-713
40 Troubleshooting
Circuit diagram related to transmission input shaft speed sensor
40-714
WA470-7
40 Troubleshooting
Failure code [DLF1LC] Failure of T/M Input Speed Sensor

Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA380_7-DLF1LC-400-A-Z0-A)
Failure of Transmission Input Speed Sensor

Failure code
Failure
DLF1LC
Due to ground fault in transmission input shaft speed sensor circuit, signal voltage from
transmission input shaft speed sensor is lower than normal range.
This failure code appears if following conditions are met when engine is running at min.
500 rpm after clutch pressure builds up.
(In any case of [A] and [B])
[A]
1) Input shaft speed calculated from output shaft speed sensor value and reduction ratio
is 200 rpm or above.
2) No pulse voltage is input from input shaft speed sensor.
3) Open circuit in input shaft speed sensor circuit is not detected.
[B]
1) Output shaft speed sensor value differs from output shaft speed calculated from input
shaft speed sensor value and reduction ratio by 200 rpm or above.
2) Pulse voltage is input from input shaft speed sensor.
3) Pulse voltage is input from output shaft speed sensor.
Sets shift mode to manual mode.
Maintains engine speed obtained before this failure is detected.
Input shaft speed from transmission input shaft speed sensor can be checked with
monitoring function. (Code: 31200, T/M Input Shaft Speed)
Cause
Defective transmission input

shaft speed sensor

2. Disconnect connector REV IN, and connect T-adapter to male side.
500 to 1,000
z
Resistance Between ground and each of REV IN (male)
Min. 1 Mz
(1) and (2)

harness

3. Disconnect connector REV IN, and connect T-adapter to female
side.
Resis- Between ground and L62 (female) (40) or REV
Min. 1 Mz
tance IN (female) (1)

harness

2. Disconnect connector REV IN, and connect T-adapter to female
side.
Voltage Between REV IN (female) (1) and ground
Max. 1 V

2. Disconnect connector REV IN.
Short circuit in wiring harness 3. Disconnect connector L62, and connect T-adapter to female side.
Resis- Between L62 (female) (40) and each pin other
Min. 1 Mz
tance than pin (40)
controller
performed.)
WA470-7
40-715
40 Troubleshooting
Circuit diagram related to transmission input shaft speed sensor
40-716
WA470-7
40 Troubleshooting
Failure code [DLM3KA] Disconnection of Radiator Fan Speed

Sensor (WA470_7-DLM3KA-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Disconnection of Radiator Fan Speed Sensor

Failure code
Failure
DLM3KA
Due to open circuit or hot short in fan speed sensor system, signal voltage from fan speed
sensor is higher than normal range.
1) Input voltage is 3 V or above.
2) Pulse voltage input is not recorded.
Stops feedback control of fan speed and switches fan speed control to open control.
Fan fails to accurately meet required fan speed.
Fan speed input by fan speed sensor can be checked with monitoring function. (Code:
10009 Radiator Fan Speed)
Cause
Defective radiator fan
speed sensor

Resistance
1.0 to 4.0
kz
Between ground and each of R89 (male) (1) and (2) Min. 1 Mz

Open circuit, short
this point.
3.0 to 4.0 V

wiring harness

a Coil resistance of radiator fan speed sensor

harness
(wire breakage or
connector)

wiring harness
(contact with 24 V
circuit)
controller
WA470-7
1.0 to 4.0
kz

female side.
Max. 1 z
Resistance
Max. 1 z

2. Disconnect connector R89.
3. Insert T-adapters into connector L62, or connect T-adapter to female side
of R89.
Voltage
Max. 4.5 V
(female) (1)
performed.)
40-717
40 Troubleshooting
Circuit diagram related to radiator fan speed sensor
40-718
WA470-7
40 Troubleshooting
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor
(WA470_7-DLM3LC-
400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure of Radiator Fan Speed Sensor

Failure code
Failure
DLM3LC
Due to ground fault in fan speed sensor system, no pulse signal is input fan speed sensor.
This failure code appears if the following conditions are met.
1) Open circuit in fan speed sensor is not detected.
2) Engine speed is 500 rpm or higher.
3) Fan is not in reverse rotation mode.
4) At least 10 seconds have passed after front and rear brake pressure is applied.
Stops feedback control of fan speed and switches fan speed control to open control.
Fan fails to accurately meet required fan speed.
Fan speed input by fan speed sensor can be checked with monitoring function. (Code:
10009 Radiator Fan Speed)
Cause
Defective radiator fan
speed sensor

wiring harness

Resistance
1.0 to 4.0
kz

a Coil resistance of radiator fan speed sensor
1.0 to 4.0
kz

harness
(wire breakage or
connector)

female side.
Max. 1 z
Resistance
Max. 1 z

harness
circuit)

female side.
Min. 1 Mz

harness

2. Disconnect connector L62 and R89.
3. Connect T-adapter to female side of L62.
Between L62 (female) (30) and each pin other than
Resistance pin (30)

wiring harness
(contact with 24 V
circuit)
controller
WA470-7
Min. 1 Mz

3. Insert T-adapters into connector L62, or connect T-adapter to female side
of R89.
Voltage
Max. 4.5 V
(female) (1)
performed.)
40-719
40 Troubleshooting
Circuit diagram related to radiator fan speed sensor
40-720
WA470-7
40 Troubleshooting
Failure code [DLT3KA] Disconnection of Output Speed Sens.

(Main) (WA380_7-DLT3KA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Disconnection of Output Speed Sensor (Main)

Failure code
Failure
DLT3KA
Due to open circuit in transmission output shaft speed sensor system, signal voltage from
transmission output shaft speed sensor is lower than normal range.
1. Input voltage is 3 V or above.
2. No pulse voltage is input.
Switches shift mode to manual mode when auto-shift mode is selected.
Selects manual mode for mode transmission signal to machine monitor, too, when autoshift mode is selected.
Performs normal control as long as manual shift mode is selected.
Calculates output shaft speed from input shaft speed sensor value and reduction ratio,
and uses it for machine control when input shaft speed sensor is normal.
Transmits input value from sensor, without modifying it, to machine monitor as speed of
output shaft.
Auto-shift pilot lamp goes out.
Output shaft speed input from transmission output shaft speed sensor can be checked
with monitoring function. (Code: 31400 T/M Output Shaft Speed)
Cause
Defective adjustment of
transmission output shaft
speed sensor

For adjustment, screw in speed sensor until sensor contacts with
gear for speed sensing, then return sensor by half turn to one turn.
a For details, see Testing and adjusting, "Adjusting transmission output
shaft speed sensor".
2. Disconnect connector REV OUT, and connect T-adapter to male
side.
500 to 1,000
z
Min. 1 Mz
(1) and (2)
output shaft speed sensor

Open or short circuit in wiring 2. Disconnect connector L62, and connect T-adapter to female side.
harness
500 to 1,000
tance
z

harness
controller
WA470-7
a
1.
2.
3.

Disconnect connector REV OUT, and connect T-adapter to female
side.
Between L62 (female) (20) and REV OUT
Max. 1 z
Resis- (female) (1)
tance Between L62 (female) (29) and REV OUT
Max. 1 z
(female) (2)
performed.)
40-721
40 Troubleshooting
Circuit diagram related to transmission output shaft speed sensor
40-722
WA470-7
40 Troubleshooting
Failure code [DLT3LC] Failure of Output Speed Sensor (Main)
(WA380_7-DLT3LC-
400-A-Z0-A)
Action level
L03
1.
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure of Output Speed Sensor (Main)

Failure code
Failure
DLT3LC
Due to ground fault in transmission output shaft speed sensor circuit, signal voltage from
transmission output shaft speed sensor is lower than normal range.
Conditions for failure detection
This failure code appears if the following conditions are met when engine is running at
500 rpm or higher after clutch pressure builds up. (In any of case [A] and [B])
[A]
1) Output shaft speed calculated from input shaft speed sensor value and reduction ratio
is 200 rpm or above.
2) No pulse voltage is input from output shaft speed sensor.
3) And open output shaft speed sensor is not open.
[B]
1) Output shaft speed sensor value differs from output shaft speed calculated from input
shaft speed sensor value and reduction ratio by 200 rpm or above.
2) Pulse voltage is input from input shaft speed sensor.
3) Pulse voltage is input from output shaft speed sensor.
Switches shift mode to manual mode when auto-shift mode is selected.
Selects manual mode for mode transmission signal to machine monitor, too, when autoshift mode is selected.
Performs normal control as long as manual shift mode is selected.
Calculates output shaft speed from input shaft speed sensor value and reduction ratio,
and uses it for machine control when input shaft speed sensor is normal.
Transmits input value from sensor, without modifying it, to machine monitor as speed of
output shaft.
Disengages lockup clutch of torque converter.
Lockup clutch of toque converter is not engaged.
Input shaft speed from transmission output shaft speed sensor can be checked with
monitoring function. (Code: 31400 T/M Output Shaft Speed)
Cause

2. Disconnect connector REV OUT, and connect T-adapter to male
side.
Defective transmission output
500 to 1,000
shaft speed sensor
z
Min. 1 Mz
(1) and (2)

harness

3. Disconnect connector REV OUT, and connect T-adapter to female
side.
Resis- Between ground and L62 (female) (20) or REV
Min. 1 Mz
tance OUT (female) (1)

harness

2. Disconnect connector REV OUT, and connect T-adapter to female
side.
Voltage Between REV OUT (female) (1) and ground
Max. 1 V
WA470-7
40-723
40 Troubleshooting
No.
Cause

2. Disconnect connector REV OUT.
Short circuit in wiring harness 3. Disconnect connector L62, and connect T-adapter to female side.
Resis- Between L62 (female) (20) and each pin other
Min. 1 Mz
tance than pin (20)
controller
performed.)
Circuit diagram related to transmission output shaft speed sensor
40-724
WA470-7
40 Troubleshooting
Failure code [DPQ1KR] LIN Discon (Switch Panel)

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA470_7-DPQ1KR-400-A-Z0-A)
LIN Disconnection (Switch Panel)

Failure code
Failure
DPQ1KR
Update of data received from switch panel (operation switches of machine monitor)
through LIN communication line is stopped.
Display operations in user menu and service menu are unavailable and setting operation
by using those menus is also unavailable.
Operation of air conditioner is unavailable.
Display of SMR is unavailable while starting switch is in OFF position.
If engine start lock is enabled, engine cannot be started because you cannot enter
password.
Since signal of active LIN communication line is pulse voltage, it cannot be measured by
using multimeter.
If failure codes [DPQ2KR] and [DPQ3KR] are also displayed, LIN communication line
probably has ground fault or hot short circuit.

Cause
Ground fault or hot short circuit
If failure code [DAFDKB] is also displayed, perform troubleshooting for
in 12 V power supply line of
[DAFDKB] first.
switch panel
Open circuit in 12 V power
supply line of switch panel

2. Disconnect connector MOM1, and connect T-adapters to female
side.
Voltage Between MOM1 (female) (1) and (2)
9 to 14 V
Defective 5 V power supply

line of switch panel

side.
4 to 6 V

harness (LIN communication
line)
a If failure codes [DPQ2KR] and [DPQ3KR] are not displayed

together with this failure code, this check is not required.
side.
Approx. 9 V


Defective switch panel

(operation switches of
machine monitor)
WA470-7

2. Disconnect connectors MCM1 B, MDM2, MOM1, and RVM1, and
connect T-adapters to any female side.
Between ground and MCM1 B (female)
Resis- (108), MDM2 (female) (3), MOM1 (female)
Min. 1 Mz
tance
(3) or RVM1 (female) (9)
Perform this check when failure codes [DPQ2KR] and [DPQ3KR]
are also displayed.
2. Disconnect connector MOM1.
If failure codes [DPQ2KR] and [DPQ3KR] disappear, switch panel is
defective.
40-725
40 Troubleshooting
No.
Cause
Defective LED unit (display

unit of machine monitor)
Defective rear view monitor
40-726

are also displayed.
2. Disconnect connector MDM2.
If failure codes [DPQ1KR] and [DPQ3KR] disappear, LED unit is
defective.
are also displayed.
2. Disconnect connector RVM1.
If failure codes [[DPQ1KR] and [DPQ2KR] disappear, rear view monitor
is defective.
If no failure is found by above checks, monitor controller may be
performed).
WA470-7
40 Troubleshooting
Circuit diagram related to LIN communication line
WA470-7
40-727
40 Troubleshooting
Failure code [DPQ2KR] LIN Discon (LED Unit)

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
(WA470_7-DPQ2KR-400-A-Z0-A)
LIN Disconnection (LED Unit)

Failure code
Failure
DPQ2KR
Update of data received from LED unit (display unit of machine monitor) through LIN
communication line is stopped.
Indications of following items on LED unit differ from actual conditions.
Turn signal (hazard) lamp
High-beam
Parking brake
Accumulator pressure drop caution lamp
Pilot lamp for clearance lamp
Centralized warning lamp
using multimeter.

Cause
Ground fault or hot short circuit If failure code [DAFDKB] is also displayed, perform troubleshooting for
in 12 V power supply line of
[DAFDKB] first.
LED unit
2. Disconnect connector MDM2, and connect T-adapters to female
side.
supply line of LED unit
Voltage Between MDM2 (female) (1) and (2)
9 to 14 V

supply line of LED unit

side.
4 to 6 V

line)

side.
Approx. 9 V

40-728

Between ground and MCM1 B (female)
Resistance (108), MDM2 (female) (3), MOM1 (female)
Min. 1 Mz
(3) or RVM1 (female) (9)
WA470-7
40 Troubleshooting
No.
Cause

machine monitor)

WA470-7

are also displayed.
2. Disconnect connector MOM1.
defective.
are also displayed.
defective.
are also displayed.
If failure codes [DPQ1KR] and [DPQ2KR] disappear, rear view monitor
is defective.
performed).
40-729
40 Troubleshooting
40-730
WA470-7
40 Troubleshooting
Failure code [DPQ3KR] LIN Discon (Rear View Monitor)

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
(WA470_7-DPQ3KR-400-A-Z0-A)
LIN Disconnection (Rear View Monitor)

Failure code
Failure
DPQ3KR
Update of data received from rear view monitor through LIN communication line is
stopped.
Various setting functions relevant to display of images from rear view camera (guide line
display, reverse-interlock mode selection, guide line position adjustment, and initialization
of rear view monitor) are unavailable.
using multimeter.

No.
Cause
1 Defective fuse-3 in fuse box 2 If fuse is blown, circuit may have ground fault. (See check on cause 5.)
Defective engine shutdown
If failure code [DDAAL6] is also displayed, perform troubleshooting for
2 secondary switch system
[DDAAL6] first.
Defective power supply line

2. Disconnect connector RVM1, and connect T-adapters to female
side.
Between RVM1 (female) (1) and (2)
20 to 30 V
Voltage
20 to 30 V

line)
a If failure codes [DPQ1KR] and [DPQ2KR] are not displayed together

with this failure code, this check is not required.
side.
Voltage Between RVM1 (female) (9) and (2)
Approx. 9 V
a If failure codes [DPQ1KR] and [DPQ2KR] are not displayed together
with this failure code, this check is not required.

Ground fault in wiring harness 1. Turn starting switch to OFF position.
Between ground and MCM1 B (female) (108),
Resis- MDM2 (female) (3), MOM1 (female) (3) or
Min. 1 Mz
tance
RVM1 (female) (9)
are also displayed.
machine monitor)
defective.
WA470-7
40-731
40 Troubleshooting
No.
Cause

40-732

are also displayed.
defective.
are also displayed.
If failure codes [[DPQ1KR] and [DPQ2KR] disappear, rear view monitor
is defective.
performed).
WA470-7
40 Troubleshooting
WA470-7
40-733
40 Troubleshooting
Failure code [DSJ0KR] CAN2 Discon (Meter Unit)

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
(WA500_7-DSJ0KR-400-A-Z0-A)
CAN2 Disconnection (Meter Unit)

Failure code
Failure
DSJ0KR
Monitor controller does not recognize meter unit (connector DPC3) of machine monitor
over CAN communication-2 line (KOMNET/c).
Pointer of engine speed meter returns to zero point.
Speedometer indicates "00".
switch is received.
Monitor controller uses six failure codes, [D8AQKR], [DAQQKR], [DAZQKR], [DB1QKR],
[DB2QKR], and [DSJ0KR] to indicate failure in CAN communication through CAN 2 line.
When all of these six failure codes are displayed simultaneously on screen, ground fault,
short circuit, or hot short circuit may occur in wiring harness (CAN communication line). In
this case, check whether air conditioner is operated (ON/OFF and air flow adjustment)
from air conditioner operation screen since air conditioner is also controlled over CAN
communication line.
using multimeter.
No.
1

Cause
Defective fuse-3 and fuse-15 If fuse is blown, circuit probably has grounding fault.
in fuse box 2
2. Turn battery disconnect switch to OFF position.
side.
meter unit of machine monitor 4. Turn battery disconnect switch to ON position.
Between MDM3 (1) and (4)
20 to 30 V
Voltage
Between MDM3 (2) and (4)
20 to 30 V
a
1.
2.
Ground fault in wiring harness 3.
4.
Defective CAN2
Defective meter unit of

machine monitor
40-734

Turn battery disconnect switch to OFF position.
Remove fuse-3 and fuse-15 in fuse box 2.
Disconnect connectors AL1, MCM1 A, S_FS, MDM3, TEL, L73, and
RVM1, and connect T-adapter to female side of S_FS or MDM3.
Between ground and S_FS (female) (2), (5) or
Min. 1 Mz
Resis- MDM3 (female) (2)
tance
Between MDM3 (female) (1) and ground
Min. 1 Mz
[DB2QKR].
If no failure is found by above checks, meter unit of machine monitor is
defective.
WA470-7
40 Troubleshooting
Circuit diagram related to machine monitor power supply
WA470-7
40-735
40 Troubleshooting
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator
(WA470_7-DT20KB-400-
A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of Transmission Cut Off Indicator

Failure code
Failure
DT20KB
Controller determines that transmission cut-off indicator lamp circuit has ground fault
because output signal is not entered to indicator lamp.
Stops driving transmission cut-off indicator lamp.
Transmission cut-off indicator lamp does not light up.
Method of reproducing failure code: Start engine and turn transmission cut-off switch to
ON position.
Cause
cut-off indicator lamp
(LED) (internal short
circuit)

Between S_RH1 (male) (1) and (2)
Min. 1 Mz
Resistance Between ground and each of S_RH1 (male) (1) and
Min. 1 Mz
(2)

harness

2. Disconnect connectors L62 and S_RH1, and connect T-adapter to female
side of S_RH1.
Resistance Between S_RH1 (female) (1) and (2)
Min. 1 Mz

harness
circuit)

2. Disconnect connectors S_RH1 and E26, and connect T-adapter to either
female side.
Min. 1 Mz
1.
2.
3.
4.
controller
40-736

Set transmission cut-off switch to ON and OFF positions to perform
troubleshooting.
Starting
switch: ON 20 to 30 V
position
Starting
switch: OFF Max. 1 V
position
WA470-7
40 Troubleshooting
Circuit diagram related to transmission cut-off indicator lamp
WA470-7
40-737
40 Troubleshooting
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic.
(WA470_7-
DT22KB-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Ground Fault of Work Equipment Lock Indicator

Failure code
Failure
DT22KB
Controller determines that output circuit to lamp built in work equipment lock switch has
ground fault because lamp built in work equipment lock switch is not driven.
None in particular
Problem on
machine
Lamp built in work equipment lock switch does not light up.
Related
information
Output signal (ON/OFF) to lamp built in work equipment lock switch can be checked with
monitoring function. (Code: 03707 BBC Output 1, Work Equipment Lock Ind.)
No.
Cause

Defective indicator lamp 2. Disconnect connector S_RHC, and connect T-adapter to male side.
(LED) of work
Between S_RHC (male) (1) and (2)
Min. 1 Mz
equipment lock switch
Resistance
Between
ground
and
each
of
S_RHC
(male)
(1)
Min. 1 Mz
and (2)

harness

2. Disconnect connectors L72 and S_RHC, and connect T-adapter to female
side of S_RHC.
Resistance Between S_RHC (female) (1) and (2)
Min. 1 Mz

harness
circuit)

2. Disconnect connectors S_RHC and E26, and connect T-adapter to either
female side.
Between ground and L72 (female) (28) or S_RHC
Min. 1 Mz
Defective work
40-738
1.
2.
3.
4.

Turn on and off work equipment lock switch, and perform troubleshooting.
LOCK
20 to 30 V
Voltage
ground
Release
Max 1 V
WA470-7
40 Troubleshooting
Circuit diagram related to work equipment lock switch indicator lamp
WA470-7
40-739
40 Troubleshooting
Failure code [DV00KB] Ground Fault of Buzzer Output

Action level
L01
Detail of
failure
Action of
controller
Failure code
DV00KB
Failure
(WA380_7-DV00KB-400-A-Z0-A)
Ground Fault of Buzzer Output

When controller drives caution buzzer, abnormal current flows through circuit.
Stops driving alarm buzzer.
is set to OFF position.
Problem on
machine
Related
information
Signal (ON/OFF) to alarm buzzer can be checked with monitoring function.

(Code: 04700 "Buzzer")
Method of reproducing failure code: Turn starting switch to ON position to drive alarm
buzzer.
No.
Cause

1
Defective alarm buzzer

(internal defect)
a If following voltages are normal and alarm buzzer does not sound, alarm
buzzer is defective.
When no driving alarm
Max. 1 V
buzzer
Voltage
When driving alarm
(1) and (2)
buzzer (when starting
20 to 30 V
engine)

harness

2. Disconnect connectors MCM1 A and L20, and connect T-adapters to each
female side.
Resistance (1)
Max. 1z

harness
circuit)

2. Disconnect connectors MCM1 A and L20, and connect T-adapter to either
female side.
Between ground and MCM1 A (female) (20) or L20
Min. 1 Mz
Defective monitor
controller
Voltage
40-740

(1) and (2)
When no driving alarm

buzzer
When driving alarm
engine)
Max. 1 V
20 to 30 V
WA470-7
40 Troubleshooting
Circuit diagram related to buzzer
WA470-7
40-741
40 Troubleshooting
Failure code [DW4PKA] Disconnection of Boom EPC Solenoid

(Raise) (WA470_7-DW4PKA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of Boom EPC Solenoid (Raise)

Failure code
Failure
DW4PKA
Due to open circuit in output signal circuit to boom RAISE EPC solenoid, no current flows
when controller drives boom RAISE EPC solenoid.
Problem on
machine
Boom does not rise.
Related
information
Output current value to boom RAISE EPC solenoid can be checked with monitoring
function. (Code: 41900 Boom Raise EPC Current)
Method of reproducing failure code: Start engine and move boom lever to RAISE position.
No.
1
Cause
Defective boom RAISE
EPC solenoid (internal
open circuit)

Resistance Between F23 (male) (1) and (2)
5 to 15 z

2. Disconnect connector F23 and connect T-adapters to female side.
Open circuit, short
this point.
1 to 4.5 V

wiring harness

harness
(wire breakage or
connector)
Defective work
40-742

a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
5 to 15 z
female side.
Between L73 (female) (6) and F23 (female) (1)
Max. 1 z
Resistance
Max. 1 z
If no failure is found by above checks, work equipment controller may be
performed.)
WA470-7
40 Troubleshooting
Circuit diagram related to boom RAISE EPC solenoid
WA470-7
40-743
40 Troubleshooting
Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid

(Raise) (WA470_7-DW4PKB-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Ground Fault of Boom EPC Solenoid (Raise)

Failure code
Failure
DW4PKB
Due to ground fault in signal output circuit to boom raise EPC solenoid, abnormal current
flows when controller drives boom RAISE EPC solenoid.
Stops driving boom RAISE EPC solenoid.
Stops driving boom RAISE detent.
Problem on
machine
Boom does not rise.
Related
information
Method of reproducing failure code: Start engine and move boom lever to RAISE position.
No.
Cause

short circuit)

5 to 15 z
Resistance

wiring harness

5 to 15 z

harness
circuit)

female side.
Min. 1 Mz

harness
Defective work
40-744

female side.
Between L73 (female) (6) and (3) or between F23
Min. 1 Mz
performed.)
WA470-7
40 Troubleshooting
WA470-7
40-745
40 Troubleshooting
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise)
(WA470_7-
DW4PKY-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Hot Short of Boom EPC Solenoid (Raise)

Failure code
Failure
DW4PKY
Due to hot short circuit in signal output circuit to boom RAISE EPC solenoid, abnormal
voltage appears when controller does not drive boom RAISE EPC solenoid.
Drives work equipment neutral lock solenoid.
Stops driving boom RAISE and LOWER, bucket TILT and DUMP, and 3rd (attachment)
EXTEND and RETRACT.
Stops driving every work equipment detent.
All work equipment do not move because work equipment neutral lock solenoid is
energized.
Boom RAISE EPC solenoid may be burnt out.
Output current value to boom LOWER EPC solenoid can be checked with monitoring
function. (Code: 41901 Boom Lower EPC Current)
Output current value to bucket TILT EPC solenoid can be checked with monitoring
function. (Code: 41902 Bucket Tilt EPC Current)
Output current value to bucket DUMP EPC solenoid can be checked with monitoring
function. (Code: 41903 Bucket Dump EPC Current)
Output current value to 3rd valve (attachment) EXTEND EPC solenoid can be checked
with monitoring function. (Code: 41906 3rd Extend EPC Current)
Output current value to 3rd valve (attachment) RETRACT EPC solenoid can be checked
with monitoring function. (Code: 41907 3rd Retract EPC Current)
Cause
short circuit)
wiring harness

harness
Defective work
40-746

5 to 15 z
Max. 4.5 V
2. Disconnect connectors L73 and F23, and connect T-adapter to female
side of L73.
No continuity
Continuity
(No sound is heard)
performed.)
WA470-7
40 Troubleshooting
WA470-7
40-747
40 Troubleshooting
Failure code [DW4QKA] Disconnection of Boom EPC Solenoid

(Lower) (WA380_7-DW4QKA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of Boom EPC Solenoid (Lower)

Failure code
Failure
DW4QKA
Due to open circuit in signal output circuit to boom LOWER EPC solenoid, no current
flows when controller drives boom LOWER EPC solenoid.
Problem on
machine
Boom does not lower.
Related
information
Method of reproducing failure code: Start engine and move boom lever to LOWER
position.
No.
1
Cause
Defective boom
LOWER EPC solenoid

5 to 15 z

Open circuit, short
this point.
1 to 4.5 V

wiring harness

harness
(wire breakage or
connector)
Defective work
40-748

5 to 15 z
female side.
Max. 1 z
Resistance
Max. 1 z
performed.)
WA470-7
40 Troubleshooting
Circuit diagram related to boom LOWER EPC solenoid
WA470-7
40-749
40 Troubleshooting
Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid

(Lower) (WA380_7-DW4QKB-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Ground Fault of Boom EPC Solenoid (Lower)

Failure code
Failure
DW4QKB
Due to ground fault in signal output circuit to boom LOWER EPC solenoid, abnormal
current flows when controller drives boom LOWER EPC solenoid.
Stops driving boom LOWER EPC solenoid.
Stops driving boom FLOAT detent.
Problem on
machine
Boom does not lower.
Related
information
Method of reproducing failure code: Start engine and move boom lever to LOWER
position.
No.
Cause

Defective boom LOWER EPC
5 to 15 z
solenoid (internal short circuit) Resis- Between F24 (male) (1) and (2)
Between ground and each of F24 (male) (1) and
tance
Min. 1 Mz
(2)

harness

5 to 15 z
tance
Ground fault in wiring harness 2. Disconnect connectors L73 and F24, and connect T-adapter to
either female side.
Min. 1 Mz
tance (female) (1)
Short circuit in wiring harness 2. Disconnect connectors L73 and F24, and connect T-adapter to
either female side.
Resis- Between L73 (female) (16) and (3), or between
Min. 1 Mz
tance F24 (female) (1) and (2)
If no failure is found by above checks, work equipment controller may
be defective. (Since this is an internal defect, troubleshooting cannot be
controller
performed.)
40-750
WA470-7
40 Troubleshooting
WA470-7
40-751
40 Troubleshooting
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower)
(WA470_7-
DW4QKY-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Hot Short of Boom EPC Solenoid (Lower)

Failure code
Failure
DW4QKY
Due to hot short circuit in signal output circuit to boom LOWER EPC solenoid, abnormal
voltage appears when controller does not drive boom LOWER EPC solenoid.
Stops driving boom RAISE and LOWER, bucket TILT and DUMP, and 3rd valve
(attachment) EXTEND and RETRACT.
energized.
Boom LOWER EPC solenoid may be burnt out.
Cause
Defective boom
LOWER EPC solenoid
wiring harness

harness
Defective work
40-752

5 to 15 z
Max. 4.5 V
side of L73.
No continuity
Continuity
(No sound is heard)
performed.)
WA470-7
40 Troubleshooting
WA470-7
40-753
40 Troubleshooting
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt)
(WA380_7-
DW4RKA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of Bucket EPC Solenoid (Tilt)

Failure code
Failure
DW4RKA
Due to open circuit in signal output circuit to bucket TILT EPC solenoid, no current flows
when controller drives bucket TILT EPC solenoid.
Problem on
machine
Bucket does not tilt.
Related
information
Method of reproducing failure code: Start engine and perform bucket TILT operation.
No.
1
Cause
Defective bucket TILT
open circuit)

5 to 15 z

Open circuit, short
this point.
1 to 4.5 V

wiring harness

harness
(wire breakage or
connector)
Defective work
40-754

5 to 15 z
female side.
Max. 1 z
Resistance
Max. 1 z
performed.)
WA470-7
40 Troubleshooting
Circuit diagram related to bucket TILT EPC solenoid
WA470-7
40-755
40 Troubleshooting
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid

(Tilt) (WA380_7-DW4RKB-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Ground Fault of Bucket EPC Solenoid (Tilt)

Failure code
Failure
DW4RKB
Due to ground fault in signal output circuit to bucket TILT EPC solenoid, abnormal current
flows when controller drives bucket TILT EPC solenoid.
Stops driving bucket TILT EPC solenoid.
Stops driving bucket TILT detent.
Problem on
machine
Bucket does not tilt.
Related
information
Method of reproducing failure code: Start engine and perform bucket TILT operation.
No.
Cause

Defective bucket TILT EPC
5 to 15 z
solenoid (internal short circuit) Resis- Between F21 (male) (1) and (2)
Between ground and each of F21 (male) (1) and
tance
Min. 1 Mz
(2)

harness

5 to 15 z
tance
either female side.
Min. 1 Mz
tance (female) (1)
either female side.
Min. 1 Mz
controller
performed.)
40-756
WA470-7
40 Troubleshooting
WA470-7
40-757
40 Troubleshooting
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt)
(WA470_7-
DW4RKY-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Hot Short of Bucket EPC Solenoid (Tilt)

Failure code
Failure
DW4RKY
Due to hot short circuit in signal output circuit to bucket TILT EPC solenoid, abnormal
voltage appears when controller does not drive bucket TILT EPC solenoid.
energized.
Bucket TILT EPC solenoid may be burnt out.
Cause
Defective bucket TILT
short circuit)
wiring harness

harness
Defective work
40-758

5 to 15 z
Max. 4.5 V
side of L73.
No continuity
Continuity
(No sound is heard)
performed.)
WA470-7
40 Troubleshooting
WA470-7
40-759
40 Troubleshooting
Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump)
(WA470_7-
DW4SKA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of Bucket EPC Solenoid (Dump)

Failure code
Failure
DW4SKA
Due to open circuit in signal output circuit to bucket DUMP EPC solenoid, no current flows
when controller drives bucket DUMP EPC solenoid.
Problem on
machine
Bucket does not move to dump position.
Related
information
Method of reproducing failure code: Start engine and perform bucket DUMP operation.
No.
1

Cause
Defective bucket DUMP 1. Turn starting switch to OFF position.
EPC solenoid (internal 2. Disconnect connector F22, and connect T-adapter to male side.
open circuit)
5 to 15 z
2. Disconnect connectors F22, and connect T-adapter to female side.
Open circuit, short
this point.
1 to 4.5 V

wiring harness

harness
(wire breakage or
connector)
Defective work
40-760

5 to 15 z
female side.
Max. 1 z
Resistance
Max. 1 z
performed.)
WA470-7
40 Troubleshooting
Circuit diagram related to bucket DUMP EPC solenoid
WA470-7
40-761
40 Troubleshooting
Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid

(Dump) (WA470_7-DW4SKB-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of Bucket EPC Solenoid (Dump)

Failure code
Failure
DW4SKB
Due to ground fault in signal output circuit to bucket DUMP EPC solenoid, abnormal
current flows when controller drives bucket DUMP EPC solenoid.
Stops driving bucket DUMP EPC solenoid.
Bucket does not move to dump position.
Method of reproducing failure code: Start engine and perform bucket DUMP operation.
Cause

Defective bucket DUMP 2. Disconnect connector F22, and connect T-adapter to male side.
EPC solenoid
5 to 15 z
Resistance

wiring harness

5 to 15 z

harness
circuit)

female side.
Min. 1 Mz

harness
Defective work
40-762

female side.
Between L73 (female) (27) and (3), or between F22
Min. 1 Mz
performed.)
WA470-7
40 Troubleshooting
WA470-7
40-763
40 Troubleshooting
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump)
(WA470_7-
DW4SKY-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Hot Short of Bucket EPC Solenoid (Dump)

Failure code
Failure
DW4SKY
Due to hot short circuit in output signal circuit to bucket DUMP EPC solenoid, abnormal
voltage appears when controller does not drive bucket DUMP EPC solenoid.
energized.
Bucket DUMP EPC solenoid may be burnt out.

Cause
Defective bucket DUMP 1. Turn starting switch to OFF position.
EPC solenoid (internal 2. Disconnect connector F22, and connect T-adapter to male side.
short circuit)
5 to 15 z
wiring harness

harness
Defective work
40-764

2. Disconnect connectors F22, and connect T-adapter to female side.
Max. 4.5 V
side of L73.
No continuity
Continuity
(No sound is heard)
performed.)
WA470-7
40 Troubleshooting
WA470-7
40-765
40 Troubleshooting
Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid
(WA470_7-
DW7BKA-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Disconnection of Fan Reverse Solenoid

Failure code
Failure
DW7BKA
Due to open circuit in fan reverse solenoid system, no current flows when controller drives
fan reverse solenoid.
Disables reverse rotation of fan.
Fan cannot rotate in reverse direction.
When this failure occurs with fan rotating in reverse direction, fan rotation direction
switches to normal direction.
Output current value to fan reverse solenoid can be checked with monitoring function.
(Code: 31646 Fan Reverse solenoid Current)
Cause
Defective fan reverse
solenoid

5 to 10 z

Open circuit, short
this point.
1 to 4.5 V

wiring harness

harness
(wire breakage or
connector)
controller
40-766

5 to 10 z
female side.
Max. 1 z
Resistance
Max. 1 z
performed.)
WA470-7
40 Troubleshooting
Circuit diagram related to fan reverse solenoid
WA470-7
40-767
40 Troubleshooting
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol.
(WA470_7-
DW7BKB-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of Radiator Fan Reverse Solenoid

Failure code
Failure
DW7BKB
Due to ground fault in fan reverse solenoid system, no current flows when controller
drives fan reverse solenoid.
Stops driving fan reverse solenoid.
Cause

solenoid

5 to 15 z
Resistance

wiring harness

5 to 15 z

harness
circuit)

female side.
Min. 1 Mz

harness
controller
40-768

female side.
Resistance R59 (female) (1) and (2)
Min. 1 Mz
performed.)
WA470-7
40 Troubleshooting
WA470-7
40-769
40 Troubleshooting
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol.
(WA470_7-DW7BKY-400-A-
Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Hot Short of Radiator Fan Reverse Solenoid

Failure code
Failure
DW7BKY
Due to hot short circuit in fan reverse solenoid system, abnormal voltage appears when
controller does not drive fan reverse solenoid.
Fan does not rotate in normal direction.
Radiator may overheat.
Cause
solenoid
wiring harness

harness
controller

5 to 15 z
Max. 4.5 V
2. Disconnect connectors L63 and R59, and connect T-adapter to female
side of L63.
No continuity
Continuity
(No sound is heard)
performed.)
40-770
WA470-7
40 Troubleshooting
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid
(WA470_7-
DWM1KA-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Disconnection of Neutral Lock Solenoid

Failure code
Failure
DWM1KA
Due to open circuit in work equipment neutral lock solenoid circuit, no current flows when
controller drives work equipment neutral lock solenoid.
Stops driving respective solenoids of work equipment according to input signal from work
equipment lock switch.
Respective work equipment solenoids are locked normally according to signal from work
Output signal (ON/OFF) to work equipment neutral lock solenoid can be checked with
monitoring function. (Code: 41903 Bucket Dump EPC Current)
Method of reproducing failure code: Turn starting switch to ON position and set work
equipment lock switch to LOCK.
Cause
Defective work
equipment neutral lock
solenoid (internal open
circuit)

35 to 45 z

Open circuit, short
this point.
1 to 4.5 V

wiring harness

side of L72.
35 to 45 z

harness
(wire breakage or
connector)
Defective work
WA470-7

female side.
Between F31 (female) (2) and ground
Max. 1 z
Resistance
L72 (female) (19) and F31 (female) (1)
Max. 1 z
performed.)
40-771
40 Troubleshooting
Circuit diagram related to work equipment neutral lock solenoid
40-772
WA470-7
40 Troubleshooting
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid
(WA470_7-
DWM1KB-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of Neutral Lock Solenoid

Failure code
Failure
DWM1KB
Due to ground fault in work equipment neutral lock solenoid circuit, abnormal current
flows when controller drives work equipment neutral lock solenoid.
Stops driving work equipment neutral lock solenoid.
Respective work equipment solenoids are locked normally according to signal from work
Method of reproducing failure code: Turn starting switch to ON position and set work
equipment lock switch to LOCK.
Cause
Defective work
equipment neutral lock
solenoid (internal short
circuit)
Defective diode F29

circuit)

35 to 45 z
Resistance
2. Disconnect connector F29 and connect T-adapter to the diode.
Between F29 (male) (1) (+) and (2) (-)
Continuity
No continuity
Continuity

wiring harness

side of L72.
35 to 45 z

harness
circuit)

2. Disconnect connectors L72, F31, and F29, and connect T-adapter to
either female side.
Min. 1 Mz

harness
Defective work
WA470-7

2. Disconnect connectors L72, F31, and F29, and connect T-adapter to
either female side.
Between ground and L72 (female) (19) or between
Resistance F31 (female) (1) and (2)
Min. 1 Mz
performed.)
40-773
40 Troubleshooting
40-774
WA470-7
40 Troubleshooting
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid
(WA470_7-DWM1KY-400-
A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Hot Short of Neutral Lock Solenoid

Failure code
Failure
DWM1KY
Due to hot short circuit in work equipment neutral lock solenoid circuit, abnormal voltage
appears when controller does not drive work equipment neutral lock solenoid.
Stops driving work equipment neutral lock solenoid.
Problem on
machine
All work equipment do not move.
Related
information
Disconnecting connector of work equipment neutral lock solenoid (open circuit state)
enables operating work equipment.
No.
1

Cause
Defective blade
LOWERL EPC solenoid 2. Disconnect connector F31 and connect T-adapter to male side.
35 to 45 z
Defective diode F29
circuit)

wiring harness

harness
Defective work
WA470-7

2. Disconnect connector F29 and connect T-adapter to the diode.
Continuity
No continuity
Continuity

Max. 4.5 V
2. Disconnect connectors L72, F31, and F29 and connect T-adapter to
female side of L72.
No continuity
Continuity
(No sound is heard)
performed.)
40-775
40 Troubleshooting
40-776
WA470-7
40 Troubleshooting
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom)
(WA470_7-
DWN6KA-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Disconnection of Detent Solenoid (Boom)

Failure code
Failure
DWN6KA
Controller determines that power supply circuit of boom magnet detent solenoid has open
circuit because no current flows when controller drives boom magnet detent solenoid.
Continues to drive boom magnet detent solenoid normally.
Stops driving remote positioner stop lamp.
Remote positioner for boom RAISE does not work.
Remote positioner for boom LOWER does not work.
Boom kick-out does not work.
Lever is not held in boom FLOAT detent position.
Lever is not held in boom RAISE detent position.
Output signal (ON/OFF) to boom magnet detent solenoid can be checked with monitoring
function. (Code: 03707 BBC Output 1, Boom Detent Sol.)
Method of reproducing failure code: Start engine and perform boom detent operation.
Cause
Defective boom
magnet detent
solenoid (internal
open circuit)
Open or short circuit

in wiring harness

harness
Defective work
WA470-7

100 to 123
Resistance Between L28B (male) (1) and (2)
z
a If resistance is 1 Mz or higher, wiring harness has open circuit. If resistance
is 1 z or below, wiring harness has short circuit.
100 to 123
z
female side.
L72 (female) (18) and L28B (female) (1)
Max. 1 z
Resistance
Between L28B (female) (2) and ground
Max. 1 z
1.
2.
3.
4.
5.

Start engine.
Boom lever: NEUTRAL
Voltage
Boom lever: Moved to
ground
RAISE detent position
Max. 4.5 V
20 to 30 V
40-777
40 Troubleshooting
Circuit diagram related to magnet detent solenoid
40-778
WA470-7
40 Troubleshooting
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom)
(WA470_7-
DWN6KB-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of Detent Solenoid (Boom)

Failure code
Failure
DWN6KB
Controller determines that power supply circuit of boom magnet detent solenoid has
ground fault because abnormal current flows when controller drives boom magnet detent
solenoid.
Stops driving boom magnet detent solenoid.
Stops driving remote positioner stop lamp, and stops boom stop control.
Remote boom positioner RAISE does not work.
Lever is not held in boom RAISE detent position.
Method of reproducing failure code: Start engine and perform boom RAISE detent
operation.
Cause
Defective boom
magnet detent
solenoid (internal
open circuit)

100 to 123
z
Resistance
Min. 1 Mz

harness
circuit)

2. Disconnect connectors L71 and L28B, and connect T-adapter to either
female side.
Between ground and L72 (female) (18) or L28B
Min. 1 Mz

harness

2. Disconnect connectors L72 and L28B.
3. Connect T-adapter to female side of L28B.
Resistance Between L28B (female) (1) and (2)
Defective work
WA470-7
1.
2.
3.
4.
5.

Start engine.
Boom lever: NEUTRAL
Voltage
ground
Min. 1 Mz
Max. 4.5 V
20 to 30 V
40-779
40 Troubleshooting
40-780
WA470-7
40 Troubleshooting
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom)
(WA470_7-DWN6KY-
400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Hot Short of Detent Solenoid (Boom)

Failure code
Failure
DWN6KY
Controller determines that power supply circuit of boom magnet detent solenoid has hot
short circuit because abnormal voltage appears when controller does not drive boom
magnet detent solenoid.
Stops driving boom magnet detent solenoid.
Stops driving remote positioner stop lamp, and stops boom stop control.
When boom is put in detent condition, boom is not automatically released from detent
condition (it can be released manually).
When boom is out of detent condition, boom lever does not return to NEUTRAL position
smoothly due to attraction of magnet (lever operability is degraded).
Cause
Defective boom magnet 1. Turn starting switch to OFF position.

detent solenoid (internal 2. Disconnect connector L28B, and connect T-adapter to male side.
100 to 123
open circuit)
z
2. Disconnect connector L28B, and connect T-adapter to female side.
wiring harness
Voltage Between L28B (female) (1) and (2)
Max. 4.5 V
2. Disconnect connectors L72 and L28B, and connect T-adapter to female
side of L72.
Continuity
pin other than (18)

harness

2. Disconnect connectors L72, L33 and L28B.
3. Connect T-adapter to either male or female side of connector L33.
Between L33 (male) (2) and each pin
Continuity
other than pin (2)
Continuity
WA470-7
No continuity (no sound

is heard)

pin other than (2)

is heard)
is heard)
40-781
40 Troubleshooting
No.
Cause
Defective work
1.
2.
3.
4.
5.

Start engine.
Boom lever: NEUTRAL
Voltage
(18) and ground
Max. 4.5 V
20 to 30 V
40-782
WA470-7
40 Troubleshooting
Failure code [DWN8KA] Disconnection of Detent Solenoid

(Bucket) (WA470_7-DWN8KA-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Disconnection of Detent Solenoid (Bucket)

Failure code
Failure
DWN8KA
Controller determines that power supply system of bucket TILT magnet detent solenoid
has open circuit because no current flows when controller drives bucket TILT magnet
detent solenoid.
Continues to drive bucket TILT magnet detent solenoid normally.
Lever is not held in bucket TILT detent position.
Output signal (ON/OFF) to bucket TILT magnet detent solenoid can be checked with
monitoring function. (Code: 03707 BBC Output 1, Bucket Tilt Detent Sol.)
Method of reproducing failure code: Start engine and perform bucket TILT detent
operation.
Cause

Defective bucket
magnet detent solenoid 2. Disconnect connector L29B, and connect T-adapter to male side.
100 to 123
z
Open or short circuit in a If resistance is 1 Mz or higher, wiring harness has open circuit. If
wiring harness

harness
Defective work
WA470-7
100 to 123
z

2. Disconnect connectors L72 and L29B, and connect T-adapters to each
female side.
L72 (female) (9) and L29B (female) (1)
Max. 1 z
Resistance
Between L29B (female) (2) and ground
Max. 1 z
1.
2.
3.
4.
5.

Start engine.
Between L72 (9) and
Voltage
Bucket lever: Bucket
ground
TILT detent position
Max 4.5 V
20 to 30 V
40-783
40 Troubleshooting
Circuit diagram related to bucket magnet detent solenoid
40-784
WA470-7
40 Troubleshooting
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket)
(WA470_7-
DWN8KB-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of Detent Solenoid (Bucket)

Failure code
Failure
DWN8KB
Controller determines that power supply circuit of bucket TILT magnet detent solenoid has
ground fault because abnormal current flows to bucket TILT magnet detent solenoid.
Stops driving bucket TILT magnet detent solenoid.
Lever is not held in bucket TILT detent position.
Method of reproducing failure code: Start engine and perform bucket TILT detent
operation.
Cause

Defective bucket
magnet detent solenoid
100 to 123
z
Resistance
Min. 1 Mz

harness
circuit)

2. Disconnect connectors L71 and L29B, and connect T-adapter to either
female side.
Between ground and L72 (female) (9) or L29B
Min. 1 Mz

harness

2. Disconnect connectors L72 and L29B.
3. Connect T-adapter to female side of L29B.
Resistance Between L29B (female) (1) and (2)
Defective work
WA470-7
Min. 1 Mz
1.
2.
3.
4.
5.

Start engine.
Bucket lever: NEUTRAL Max 4.5 V
Between L72 (9) and
Voltage
Bucket
lever: TILT detent
ground
20 to 30 V
operation
40-785
40 Troubleshooting
40-786
WA470-7
40 Troubleshooting
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket)
(WA470_7-DWN8KY-
400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Hot Short of Detent Solenoid (Bucket)

Failure code
Failure
DWN8KY
Controller determines that power supply circuit of bucket TILT magnet detent solenoid has
hot short circuit because abnormal voltage appears when controller does not drive bucket
TILT magnet detent solenoid.
Stops driving bucket TILT magnet detent solenoid.
When bucket is put in TILT detent condition, bucket is not automatically released from
detent condition (it can be released manually).
When bucket is out of detent condition, bucket lever does not return to NEUTRAL position
smoothly due to attraction of magnet (lever operability is degraded).
Cause

Defective bucket
magnet detent solenoid 2. Disconnect connector L29B, and connect T-adapter to male side.
100 to 123
z
2. Disconnect connector L29B, and connect T-adapter to female side.
wiring harness
Voltage Between L29B (female) (1) and (2)
Max 4.5 V
2. Disconnect connectors L72 and L29B, and connect T-adapter to female
side of L72.
Continuity
pin other than (9)

harness

2. Disconnect connectors L72, L33 and L29B.
3. Connect T-adapter to either male or female side of connector L33.
Between L33 (male) (4) and each pin
Continuity
other than pin (4)
Continuity
pin other than (4)
Defective work
WA470-7

is heard)

is heard)
is heard)
1.
2.
3.
4.
5.

Start engine.
Between L72 (9) and
Voltage
Bucket lever: Bucket
ground
TILT detent position
Max 4.5 V
20 to 30 V
40-787
40 Troubleshooting
40-788
WA470-7
40 Troubleshooting
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol.
(WA470_7-
DX16KA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Disconnection of Radiator Fan Pump EPC Solenoid

Failure code
Failure
DX16KA
Due to open circuit in fan pump EPC solenoid circuit, no current flows when controller
drives fan pump EPC solenoid.
Disables fan to rotate in reverse direction.
Fan rotates at its maximum speed.
Output current value to fan pump EPC solenoid can be checked with monitoring function.
(Code: 41400 Rad. Fan Pump EPC Sol. Current)
Cause
Defective fan pump
open circuit)

5 to 10 z

Open circuit, short
this point.
Min. 20 V
5 to 10 z

wiring harness

2. Disconnect connectors L61, L62, L63, and R29, and connect T-adapters
to each female side of L61, L62, and L63.
pin of L61 (female)
Continuity
pin of L62 (female)

harness
(wire breakage or
connector)
controller
WA470-7
No continuity
(No sound is heard)
No continuity
(No sound is heard)

female side.
Max. 1 z
Resistance
Max. 1 z
performed.)
40-789
40 Troubleshooting
Circuit diagram related to fan pump EPC solenoid
40-790
WA470-7
40 Troubleshooting
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol.
(WA470_7-
DX16KB-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of Radiator Fan Pump EPC Solenoid

Failure code
Failure
DX16KB
Due to ground fault in fan pump EPC solenoid circuit, abnormal current flows when
controller drives fan pump EPC solenoid.
Stops driving fan pump EPC solenoid.
Fan rotates at its maximum speed.
Cause
Defective fan pump

short circuit)

5 to 10 z
Resistance

wiring harness

5 to 10 z

harness
circuit)

female side.
Min. 1 Mz

harness
controller
WA470-7

female side.
Min. 1 Mz
performed.)
40-791
40 Troubleshooting
40-792
WA470-7
40 Troubleshooting
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol.
(WA470_7-
DX16KY-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Hot Short of Radiator Fan Pump EPC Solenoid

Failure code
Failure
DX16KY
Due to hot short circuit in fan pump EPC solenoid circuit, abnormal voltage appears when
controller does not drive fan pump EPC solenoid.
Stops driving fan pump EPC solenoid.
Fan rotates at its minimum speed.
Since female side voltage is 20 V or above when pump EPC solenoid connector is
disconnected and starting switch is turned to ON position, check of hot short circuit in
wiring harness is not available.
Cause
Defective fan pump
short circuit)

5 to 10 z
2. Disconnect connectors L63 and R29, and connect T-adapter to female
side of L63.
Continuity

harness
controller
WA470-7
No continuity
(No sound is heard)

No continuity
pin of L61 (female)
(No sound is heard)
Continuity
No continuity
pin of L62 (female)
(No sound is heard)
performed.)
40-793
40 Troubleshooting
40-794
WA470-7
40 Troubleshooting
Failure code [DXA1KA] Disconnection of Loader Pump EPC

Solenoid (WA380_7-DXA1KA-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Disconnection of Loader Pump EPC Solenoid

Failure code
Failure
DXA1KA
Due to open circuit in loader pump EPC solenoid system, current does not flow when
controller drives loader pump EPC solenoid.
Continues to drive loader pump EPC solenoid normally.
Fuel consumption may degrade at low engine speed.
Engine may stall.
Cut-off of pump becomes unavailable during hydraulic relief.
Engine acceleration may degrade.
Boom may accelerate suddenly.
Output current value to loader pump EPC solenoid can be checked with monitoring
function. (Code: 94500 Loader Pump EPC Current)
Using "2-stage low idle" function allows increasing engine speed at low idle, thereby
avoiding decrease in machine performance.
Cause
open circuit)

5 to 15 z

Open circuit, short
this point.
Min. 20 V

wiring harness

harness
(wire breakage or
connector)
Defective work
WA470-7

5 to 15 z
female side.
Max. 1 z
Resistance
Max. 1 z
performed.)
40-795
40 Troubleshooting
Circuit diagram related to loader pump EPC solenoid
40-796
WA470-7
40 Troubleshooting
Failure code [DXA1KB] Ground Fault of Loader Pump EPC

Solenoid (WA380_7-DXA1KB-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of Loader Pump EPC Solenoid

Failure code
Failure
DXA1KB
Due to ground fault in loader pump EPC solenoid system, abnormal current flows when
controller drives loader pump EPC solenoid.
Stops driving loader pump EPC solenoid.
Cut-off of pump becomes unavailable during hydraulic relief.
Boom may accelerate suddenly.
Cause

short circuit)

5 to 15 z
Resistance

wiring harness

5 to 15 z

harness
circuit)

female side.
Min. 1 Mz

harness
Defective work
WA470-7

female side.
Min. 1 Mz
performed.)
40-797
40 Troubleshooting
40-798
WA470-7
40 Troubleshooting
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid
(WA380_7-
DXA1KY-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Hot Short of Loader Pump EPC Solenoid

Failure code
Failure
DXA1KY
Due to hot short circuit in loader pump EPC solenoid power supply system, abnormal
voltage appears when controller does not drive loader pump EPC solenoid.
Stops driving loader pump EPC solenoid.
Problem on
machine
Flow rate of loader pump reaches minimum level, decreasing work equipment speed.
Related
information
No.
1
Cause

Defective loader pump EPC
solenoid (internal short circuit) ResisBetween R71 (male) (1) and (2)
5 to 15 z
tance
2. Disconnect connectors L73 and R71, and connect T-adapter to
female side of L73.
No continuity
Continuity
(No sound is heard)

controller
WA470-7

2. Disconnect connectors L71, L72, L73, and R71, and connect Tadapters to each female side of L71, L72, and L73.
No continuity
each pin of L71 (female)
(No sound is heard)
Continuity
No continuity
each pin of L72 (female)
(No sound is heard)
performed.)
40-799
40 Troubleshooting
40-800
WA470-7
40 Troubleshooting
Failure code [DXANKA] Disconnection of Steering Pump EPC Sol.
(WA470_7-
DXANKA-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Disconnection of Steering Pump EPC Solenoid

Failure code
Failure
DXANKA
Due to open circuit in steering pump EPC solenoid system, no current flows when
controller drives steering pump EPC solenoid.
Continues to drive steering pump EPC solenoid normally.
Engine may stall.
Turning speed may accelerate suddenly.
Output current value to steering pump EPC solenoid can be checked with monitoring
function. (Code: 94600 Steering Pump EPC Current)
Cause
Defective steering
pump EPC solenoid

5 to 15 z

Open circuit, short
this point.
Min. 20 V

wiring harness

Between L73 (female) (25) and each of (21), (31),
5 to 15 z

harness
(wire breakage or
connector)
Defective work
WA470-7

female side.
Between R90 (female) (1) and each of L73 (female)
Max. 1 z
Resistance (21), (31), (32), and (33)
Max. 1 z
40-801
40 Troubleshooting
Circuit diagram related to steering pump EPC solenoid
40-802
WA470-7
40 Troubleshooting
Failure code [DXANKB] Ground Fault of Steering Pump EPC

Solenoid (WA470_7-DXANKB-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of Steering Pump EPC Solenoid

Failure code
Failure
DXANKB
Due to ground fault in steering pump EPC solenoid system, abnormal current flows when
controller drives steering pump EPC solenoid.
Stops driving steering pump EPC solenoid.
Turning speed may accelerate suddenly.
Cause
Defective steering
pump EPC solenoid

5 to 15 z
Resistance
Between ground and R90 (male) (1) or (2)
Min. 1 Mz

wiring harness

5 to 15 z

harness
circuit)

female side.
Min. 1 Mz

harness
Defective work
WA470-7

female side.
Resistance (32), and (33), or between R90 (female) (1) and (2) Min. 1 Mz
40-803
40 Troubleshooting
40-804
WA470-7
40 Troubleshooting
Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid
(WA470_7-
DXANKY-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Hot Short of Steering Pump EPC Solenoid

Failure code
Failure
DXANKY
Due to hot short circuit in steering pump EPC solenoid power supply system, abnormal
voltage appears when controller does not drive steering pump EPC solenoid.
Stops driving steering pump EPC solenoid.
Problem on
machine
Flow rate of steering pump reaches minimum level, decreasing turning speed.
Related
information
No.
1
Cause
Defective steering
pump EPC solenoid

5 to 15 z

harness
Defective work

No continuity
pin of L71 (female)
(No sound is heard)
Resistance
No continuity
pin of L72 (female)
(No sound is heard)
WA470-7
40-805
40 Troubleshooting
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)
(WA380_7-
DXH1KA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of ECMV Solenoid (Lockup)

Failure code
Failure
DXH1KA
Due to open circuit in lockup clutch ECMV solenoid circuit, no current flows when
controller drives lockup clutch ECMV solenoid.
Stops driving lockup clutch ECMV solenoid.
Judges that lockup switch is at OFF and controls machine.
Problem on
machine
Torque converter lockup clutch does not engage.
Related
information
Output current value to lockup clutch ECMV solenoid can be checked with monitoring
function. (Code: 31609 ECMV Current (Lockup))
Method of reproducing failure code: Start engine, turn on lockup switch, and drive
machine.
No.
Cause
Defective lockup clutch

ECMV solenoid

Resistance Between LC.PS (male) (1) and (2)
5 to 15 z

2. Disconnect connector LC.PS, and connect T-adapter to female side.
Open circuit, short
this point.
Voltage Between LC.PS (female) (1) and (2)
1 to 4.5 V

wiring harness

harness
(wire breakage or
connector)
controller
40-806

5 to 15 z
2. Disconnect connectors L63 and LC.PS, and connect T-adapters to each
female side.
Between L63 (female) (36) and LC.PS (female) (1)
Max. 1 z
Resistance
Between L63 (female) (23) and LC.PS (female) (2)
Max. 1 z
WA470-7
40 Troubleshooting
Circuit diagram related to lockup clutch ECMV solenoid
WA470-7
40-807
40 Troubleshooting
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup)
(WA380_7-
DXH1KB-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Ground Fault of ECMV Solenoid (Lockup)

Failure code
Failure
DXH1KB
Due to ground fault in lockup clutch ECMV solenoid circuit, abnormally large current flows
when controller drives lockup clutch ECMV solenoid.
Stops driving lockup clutch ECMV solenoid.
Judges that lockup switch is at OFF and controls machine.
Problem on
machine
Torque converter lockup clutch does not engage.
Related
information
Method of reproducing failure code: Start engine, turn on lockup switch, and drive
machine.
No.
Cause

ECMV solenoid

Between LC.PS (male) (1) and (2)
5 to 15 z
Resistance
Between ground and LC.PS (male) (1) or (2)
Min. 1 Mz

wiring harness

5 to 15 z

harness

2. Disconnect connectors L63 and LC.PS, and connect T-adapter to either
female side.
Between ground and L63 (female) (36) or LC.PS
Min. 1 Mz

harness
controller
40-808

2. Disconnect connectors L63 and LC.PS, and connect T-adapter to either
female side.
Resistance LC.PS (female) (1) and (2)
Min. 1 Mz
WA470-7
40 Troubleshooting
WA470-7
40-809
40 Troubleshooting
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup)
(WA380_7-DXH1KY-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
Hot Short of ECMV Solenoid (Lockup)

Failure code
Failure
DXH1KY
Due to hot short circuit in lockup clutch ECMV solenoid circuit, abnormal voltage appears
when controller does not drive lockup clutch ECMV solenoid.
Maintains transmission in neutral position.
If directional (FNR) lever or R.H. directional (FNR) switch is set to N (neutral) position,
controller stops maintaining transmission in NEUTRAL position.
Transmission is maintained in NEUTRAL position until directional (FNR) lever or R.H.
directional (FNR) switch is set to N (meutral) position.
Lockup clutch remains engaged.
No.
Cause

ECMV solenoid

Resistance Between LC.PS (male) (1) and (2)
5 to 15 z

wiring harness

2. Disconnect connector LC.PS, and connect T-adapter to female side.
a If failure code [DXH1KA] for open circuit appears, wiring harness does not
have hot short circuit. (Lockup clutch ECMV solenoid is defective.)
Voltage Between LC.PS (female) (1) and (2)
Max 4.5 V
2. Disconnect connector LC.PS.
No continuity
Continuity
pin other than (36)
(No sound is heard)

harness
controller
40-810
1.
2.
3.
4.

Disconnect connector L63.
Disconnect connectors LT1 and LC.PS.
Connect T-adapter to either male or female side of connector LT1.
No continuity
Between LT1 (female) (13) and each
pin other than (13)
(No sound is heard)
Continuity
No continuity
Between LT1 (male) (13) and each pin
other than (13)
(No sound is heard)
WA470-7
40 Troubleshooting
WA470-7
40-811
40 Troubleshooting
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)
(WA380_7-DXH4KA-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of ECMV Solenoid (1st)

Failure code
Failure
DXH4KA
Due to open circuit in 1st clutch ECMV solenoid circuit, no current flows when controller
drives 1st clutch ECMV solenoid.
Stops driving 1st clutch ECMV solenoid.
Problem on
machine
1st clutch is not engaged (machine can travel with any gear speed other than 1st).
Related
information
function. (Code: 31602 ECMV Current (1st))
Method of reproducing failure code: Turn starting switch to ON position and set
transmission shift mode selector switch to AUTO shift mode, or set transmission shift
mode selector switch to MANUAL shift mode and select 1st gear speed by using shift
down switch or gear shift lever.
No.
Cause

Resistance Between 1.PS (male) (1) and (2)
5 to 15 z
Defective 1st clutch

ECMV solenoid

2. Disconnect connector 1.PS, and connect T-adapter to female side.
Open circuit, short
voltage drops to approximately 0 V during shaking, wiring harness is open
at this point.
Voltage Between 1.PS (female) (1) and (2)
1 to 4.5 V

wiring harness

harness
(wire breakage or
connector)
controller
40-812

5 to 15 z
2. Disconnect connectors L63 and 1.PS, and connect T-adapters to each
female side.
Between L63 (female) (27) and 1.PS (female) (1)
Max. 1 z
Resistance
Max. 1 z
WA470-7
40 Troubleshooting
Circuit diagram related to 1st clutch ECMV solenoid
WA470-7
40-813
40 Troubleshooting
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st)
(WA380_7-DXH4KB-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Ground Fault of ECMV Solenoid (1st)

Failure code
Failure
DXH4KB
Due to ground fault in 1st clutch ECMV solenoid circuit, abnormally large current flows
when controller drives 1st clutch ECMV solenoid.
Stops driving 1st clutch ECMV solenoid.
Problem on
machine
1st clutch is not engaged (machine can travel with any gear speed other than 1st).
Related
information
mode selector switch to MANUAL shift mode and select 1st gear speed by using shift
No.
Cause

ECMV solenoid

5 to 15 z
Resistance
Min. 1 Mz

wiring harness

5 to 15 z

harness

Between ground and L63 (female) (27) or 1.PS
Min. 1 Mz

harness
controller
40-814

2. Disconnect connectors L63 and 1.PS, and connect T-adapter to either
female side.
Between L63 (female) (27) and (13), or between 1.
Resistance PS (female) (1) and (2)
Min. 1 Mz
WA470-7
40 Troubleshooting
WA470-7
40-815
40 Troubleshooting
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)

Action level
L03
Detail of
failure
Action of
controller
(WA380_7-DXH4KY-400-A-Z0-A)
Hot Short of ECMV Solenoid (1st)

Failure code
Failure
DXH4KY
Due to hot short circuit in 1st clutch ECMV solenoid circuit, abnormal voltage appears
when controller does not drive 1st clutch ECMV solenoid.
Stops driving 2nd, 3rd and 4th clutch ECMV solenoids.
When not driving ECMV solenoids of speed clutches (other than 1st clutch), controller
also stops driving F (forward) and R (reverse) clutch ECMV solenoids.
Problem on
machine
2nd, 3rd, and 4th clutches are not engaged (machine can travel with 1st gear speed).
Related
information
No.
1
Cause
ECMV solenoid

wiring harness

5 to 15 z
have hot short circuit. (1st clutch ECMV solenoid is defective.)
Max. 4.5 V
2. Disconnect connector 1.PS.
No continuity
Continuity
pin other than (27)
(No sound is heard)

harness
controller
40-816
1.
2.
3.
4.

Disconnect connectors LT1 and 1.PS.
No continuity
pin other than (1)
(No sound is heard)
Continuity
No continuity
other than (1)
(No sound is heard)
WA470-7
40 Troubleshooting
WA470-7
40-817
40 Troubleshooting
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)
(WA380_7-
DXH5KA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of ECMV Solenoid (2nd)

Failure code
Failure
DXH5KA
Due to open circuit in 2nd clutch ECMV solenoid circuit, no current flows when controller
drives 2nd clutch ECMV solenoid.
Stops driving 2nd clutch ECMV solenoid.
Problem on
machine
2nd clutch is not engaged (machine can travel with any gear speed other than 2nd).
Related
information
function. (Code: 31603 ECMV Current (2nd))
mode selector switch to MANUAL shift mode and select 2nd gear speed by using shift
No.
Cause

5 to 15 z
Defective 2nd clutch

ECMV solenoid

Open circuit, short
this point.
1 to 4.5 V

wiring harness

harness
(wire breakage or
connector)
controller
40-818

5 to 15 z
female side.
Max. 1 z
Resistance
Max. 1 z
WA470-7
40 Troubleshooting
Circuit diagram related to 2nd clutch ECMV solenoid
WA470-7
40-819
40 Troubleshooting
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd)
(WA380_7-DXH5KB-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Ground Fault of ECMV Solenoid (2nd)

Failure code
Failure
DXH5KB
Due to ground fault in 2nd clutch ECMV solenoid circuit, abnormally large current flows
when controller drives 2nd clutch ECMV solenoid.
Stops driving 2nd clutch ECMV solenoid.
Problem on
machine
2nd clutch is not engaged (machine can travel with any gear speed other than 2nd).
Related
information
mode selector switch to MANUAL shift mode and select 2nd gear speed by using shift
No.
Cause

ECMV solenoid

5 to 15 z
Resistance
Min. 1 Mz

wiring harness

5 to 15 z

harness

female side.
Min. 1 Mz

harness
controller
40-820

female side.
Between L63 (female) (37) and (3), or between 2.
Min. 1 Mz
WA470-7
40 Troubleshooting
WA470-7
40-821
40 Troubleshooting
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd)
(WA380_7-DXH5KY-400-A-Z0-
A)
Action level
L03
Detail of
failure
Action of
controller
Hot Short of ECMV Solenoid (2nd)

Failure code
Failure
DXH5KY
Due to hot short circuit in 2nd clutch ECMV solenoid circuit, abnormal voltage appears
when controller does not drive 2nd clutch ECMV solenoid.
Stops driving 1st, 3rd, and 4th clutch ECMV solenoids.
When not driving ECMV solenoids of speed clutches (other than 2nd clutch), controller
Problem on
machine
1st, 3rd, and 4th clutches are not engaged (machine can travel with 2nd gear speed).
Related
information
No.
1
Cause
ECMV solenoid

wiring harness

5 to 15 z
a If failure code [DXH5KA] for open circuit appears,wiring harness does not
have hot short circuit. (2nd clutch ECMV solenoid is defective.)
Max. 4.5 V
No continuity
Continuity
pin other than (37)
(No sound is heard)

harness
controller
40-822
1.
2.
3.
4.

No continuity
pin other than (3)
(No sound is heard)
Continuity
No continuity
other than (3)
(No sound is heard)
WA470-7
40 Troubleshooting
WA470-7
40-823
40 Troubleshooting
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd)
(WA380_7-DXH6KA-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of ECMV Solenoid (3rd)

Failure code
Failure
DXH6KA
Due to open circuit in 3rd clutch ECMV solenoid circuit, no current flows when controller
drives 3rd clutch ECMV solenoid.
Stops driving 3rd clutch ECMV solenoid.
Problem on
machine
3rd clutch is not engaged (machine can travel with any gear speed other than 3rd).
Related
information
function. (Code: 31604 ECMV Current (3rd))
mode selector switch to MANUAL shift mode and select 3rd gear speed by using shift
No.
Cause

5 to 15 z
Defective 3rd clutch

ECMV solenoid

Open circuit, short
this point.
1 to 4.5 V

wiring harness

harness
(wire breakage or
connector)
controller
40-824

5 to 15 z
female side.
Max. 1 z
Resistance
Max. 1 z
WA470-7
40 Troubleshooting
WA470-7
40-825
40 Troubleshooting
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd)
(WA380_7-DXH6KB-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Ground Fault of ECMV Solenoid (3rd)

Failure code
Failure
DXH6KB
Due to ground fault in 3rd clutch ECMV solenoid circuit, abnormally large current flows
when controller drives 3rd clutch ECMV solenoid.
Stops driving 3rd clutch ECMV solenoid.
Problem on
machine
3rd clutch is not engaged (machine can travel with any gear speed other than 3rd).
Related
information
Method of reproducing failure code:Turn starting switch to ON position, set transmission
shift mode selector switch to AUTO and MANUAL repeatedly, and select 3rd gear speed
by using shift down switch or gear shift lever.
No.
Cause

ECMV solenoid

5 to 15 z
Resistance
Min. 1 Mz

wiring harness

5 to 15 z

harness

female side.
Min. 1 Mz

harness
controller
40-826

female side.
Between L63 (female) (6) and (3), or between 3.PS
Min. 1 Mz
WA470-7
40 Troubleshooting
WA470-7
40-827
40 Troubleshooting
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd)
(WA380_7-DXH6KY-400-A-Z0-
A)
Action level
L03
Detail of
failure
Action of
controller
Hot Short of ECMV Solenoid (3rd)

Failure code
Failure
DXH6KY
Due to hot short circuit in 3rd clutch ECMV solenoid circuit, abnormal voltage appears
when controller does not drive 3rd clutch ECMV solenoid.
Stops driving 1st, 2nd, and 4th clutch ECMV solenoids.
When not driving ECMV solenoids of speed clutches (other than 3rd clutch), controller
Problem on
machine
1st, 2nd and 4th clutches are not engaged (machine can travel with 3rd gear speed).
Related
information
No.
1
Cause
ECMV solenoid

wiring harness

5 to 15 z
have hot short circuit. (3rd clutch ECMV solenoid is defective.)
Max. 4.5 V
No continuity
Continuity
pin other than (6)
(No sound is heard)

harness
controller
40-828
1.
2.
3.
4.

No continuity
pin other than (5)
(No sound is heard)
Continuity
No continuity
other than (5)
(No sound is heard)
WA470-7
40 Troubleshooting
WA470-7
40-829
40 Troubleshooting
Failure code [DXH7KA] Disconnection of ECMV Solenoid

(Reverse) (WA380_7-DXH7KA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of ECMV Solenoid (Reverse)

Failure code
Failure
DXH7KA
Due to open circuit in R (reverse) clutch ECMV solenoid circuit, no current flows when
controller drives R (reverse) clutch ECMV solenoid.
Stops driving R (reverse) clutch ECMV solenoid.
Problem on
machine
R (reverse) clutch is not engaged (machine can travel with F (forward) clutch).
Related
information
function. (Code: 31606 ECMV Current (Reverse))
Method of reproducing failure code:Turn starting switch to ON position and set directional
(FNR) lever or R.H. directional selector (FNR) switch to R (reverse).
No.
Cause

Resistance Between R.PS (male) (1) and (2)
5 to 15 z
clutch ECMV solenoid

2. Disconnect connector R.PS, and connect T-adapter to female side.
Open circuit, short
this point.
Voltage Between R.PS (female) (1) and (2)
1 to 4.5 V

wiring harness

harness
(wire breakage or
connector)
controller
40-830

5 to 15 z
2. Disconnect connectors L63 and R.PS, and connect T-adapters to each
female side.
Between L63 (female) (5) and R.PS (female) (1)
Max. 1 z
Resistance
Between L63 (female) (13) and R.PS (female) (2)
Max. 1 z
WA470-7
40 Troubleshooting
WA470-7
40-831
40 Troubleshooting
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)
(WA380_7-
DXH7KB-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Ground Fault of ECMV Solenoid (Reverse)

Failure code
Failure
DXH7KB
Due to ground fault in R (reverse) clutch ECMV solenoid circuit, abnormally large current
flows when controller drives R (reverse) clutch ECMV solenoid.
Stops driving R (reverse) clutch ECMV solenoid.
Problem on
machine
R (reverse) clutch is not engaged (machine can travel with F (forward) clutch).
Related
information
(FNR) lever or R.H. directional selector (FNR) switch to R (reverse).
No.
Cause
Defective R clutch
ECMV solenoid

Between R.PS (male) (1) and (2)
5 to 15 z
Resistance
Between ground and R.PS (male) (1) or (2)
Min. 1 Mz

wiring harness

5 to 15 z

harness

2. Disconnect connectors L63 and R.PS, and connect T-adapter to either
female side.
Between ground and L63 (female) (5) or R.PS
Min. 1 Mz

harness
controller
40-832

2. Disconnect connectors L63 and R.PS, and connect T-adapter to either
female side.
Between L63 (female) (5) and (13), or between R.
Min. 1 Mz
WA470-7
40 Troubleshooting
WA470-7
40-833
40 Troubleshooting
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)
(WA380_7-DXH7KY-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Hot Short of ECMV Solenoid (Reverse)

Failure code
Failure
DXH7KY
Due to hot short circuit in R (reverse) clutch ECMV solenoid circuit, abnormal voltage
appears when controller does not drive R (reverse) clutch ECMV solenoid.
When directional (FNR) lever or directional selector (FNR) switch is set to R (reverse),
controller drives R (reverse) clutch ECMV solenoid as usual.
When shift lever is set to N (neutral) or F (forward), controller sets transmission to N
(neutral).
Problem on
machine
Machine can travel only in R (reverse) direction.
Related
information
No.
1
Cause

wiring harness

Resistance Between R.PS (male) (1) and (2)
5 to 15 z
2. Disconnect connector R.PS, and connect T-adapter to female side.
have hot short circuit. (R clutch ECMV solenoid is defective.)
Voltage Between R.PS (female) (1) and (2)
Max 4.5 V
2. Disconnect connector R.PS.
No continuity
Continuity
pin other than (5)
(No sound is heard)

harness
controller
40-834
1.
2.
3.
4.

Disconnect connector LT1 and R.PS.
No continuity
pin other than (9)
(No sound is heard)
Continuity
No continuity
other than (9)
(No sound is heard)
WA470-7
40 Troubleshooting
WA470-7
40-835
40 Troubleshooting
Failure code [DXH8KA] Disconnection of ECMV Solenoid

(Forward) (WA380_7-DXH8KA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of ECMV Solenoid (Forward)

Failure code
Failure
DXH8KA
Due to open circuit in F (forward) clutch ECMV solenoid circuit, no current flows when
controller drives F (forward) clutch ECMV solenoid.
Stops driving F (forward) clutch ECMV solenoid.
Problem on
machine
F (forward) clutch is not engaged (machine can travel with R (reverse) clutch).
Related
information
function. (Code: 31608 ECMV Current (Forward))
(FNR) lever or R.H. directional selector (FNR) switch to F (forward).
No.
Cause

Resistance Between F.PS (male) (1) and (2)
5 to 15 z

2. Disconnect connector FPS and connect T-adapter to female side of
Open circuit, short
connector.
this point.
Voltage Between F.PS (female) (1) and (2)
1 to 4.5 V

wiring harness

harness
(open circuit or
defective contact)
controller
40-836

5 to 15 z
2. Disconnect connectors L63 and F.PS, and connect T-adapters to each
female side.
Between L63 (female) (26) and F.PS (female) (1)
Max. 1 z
Resistance
Between L63 (female) (3) and F.PS (female) (2)
Max. 1 z
WA470-7
40 Troubleshooting
Circuit diagram related to F clutch ECMV solenoid
WA470-7
40-837
40 Troubleshooting
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward)
(WA380_7-
DXH8KB-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Ground Fault of ECMV Solenoid (Forward)

Failure code
Failure
DXH8KB
Due to ground fault in F (forward) clutch ECMV solenoid circuit, abnormally large current
flows when controller drives F (forward) clutch ECMV solenoid.
Stops driving F (forward) clutch ECMV solenoid.
Problem on
machine
F (forward) clutch is not engaged (machine can travel with R (reverse) clutch).
Related
information
(FNR) lever or R.H. directional selector (FNR) switch to F (forward).
No.
Cause

Between F.PS (male) (1) and (2)
5 to 15 z
Resistance
Between ground and F.PS (male) (1) or (2)
Min. 1 Mz

wiring harness

5 to 15 z

harness

2. Disconnect connectors L63 and F.PS, and connect T-adapter to either
female side.
Between ground and L63 (female) (26) or F.PS
Min. 1 Mz

harness
controller
40-838

2. Disconnect connectors L63 and F.PS, and connect T-adapter to either
female side.
Between L63 (female) (26) and (3), or between F.
Min. 1 Mz
WA470-7
40 Troubleshooting
WA470-7
40-839
40 Troubleshooting
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward)
(WA380_7-DXH8KY-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Hot Short of ECMV Solenoid (Forward)

Failure code
Failure
DXH8KY
Due to hot short circuit in F (forward) clutch ECMV solenoid circuit, abnormal voltage
appears when controller does not drive F (forward) clutch ECMV solenoid.
When directional (FNR) lever or R.H. directional selector (FNR) switch is set to F
(forward), controller drives F (forward) clutch ECMV solenoid as usual.
When shift lever is set to N (neutral) or R (reverse), controller sets transmission to N
(neutral).
Problem on
machine
Machine can travel only in F (forward) direction.
Related
information
No.
1
Cause

wiring harness

Resistance Between F.PS (male) (1) and (2)
5 to 15 z
2. Disconnect connector FPS and connect T-adapter to female side of
connector.
have no hot short circuit. (F clutch ECMV solenoid is defective.)
Voltage Between F.PS (female) (1) and (2)
Max. 4.5 V
2. Disconnect connector F.PS.
No continuity
Continuity
pin other than (26)
(No sound is heard)

harness
controller
40-840
1.
2.
3.
4.

Disconnect connector LT1 and F.PS.
No continuity
pin other than (11)
(No sound is heard)
Continuity
No continuity
other than (11)
(No sound is heard)
WA470-7
40 Troubleshooting
WA470-7
40-841
40 Troubleshooting
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th)
(WA380_7-
DXHHKA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of ECMV Solenoid (4th)

Failure code
Failure
DXHHKA
Due to open circuit in 4th clutch ECMV solenoid system, no current flows when controller
drives 4th clutch ECMV solenoid.
Stops driving 4th clutch ECMV solenoid.
Problem on
machine
4th clutch is not engaged (machine can travel with gear speed other than 4th).
Related
information
function. (Code: 31605 ECMV Current (4th))
transmission to auto shift, or set manual shift selector switch to MANUAL and select 4th
using shift down switch or set gear shift lever to 4th.
No.
1
Cause
Defective 4th clutch ECMV
solenoid

2. Disconnect connector 4.PS, and connect T-adapters to male side.
5 to 15 z
Resis- Between 4.PS (male) (1) and (2)
tance
Min. 1 Mz
Open circuit, short circuit, hot

short circuit of wiring harness, a Shake the wiring harness by hand while measuring the voltage. If
or defective monitor controller
1 to 4.5 V
Open or short circuit in wiring 1. Turn starting switch to OFF position.
2. Disconnect connector L63 and connect T-adapters to female side.
harness
5 to 15 z
tance
Open circuit in wiring harness 2. Disconnect connectors L63 and 4.PS, and connect T-adapters to
each female side.
Between L63 (female) (16) and 4.PS (female)
Max. 1 z
Resis- (1)
tance
Between L63 (female) (13) and 4.PS (female)
Max. 1 z
(2)
controller
performed.)
40-842
WA470-7
40 Troubleshooting
Circuit diagram related to 4th clutch ECMV solenoid
WA470-7
40-843
40 Troubleshooting
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)
(WA380_7-DXHHKB-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Ground Fault of ECMV Solenoid (4th)

Failure code
Failure
DXHHKB
Due to ground fault in 4th clutch ECMV solenoid system, abnormally large current flows
when controller drives 4th clutch ECMV solenoid.
Stops driving 4th clutch ECMV solenoid.
Problem on
machine
4th clutch is not engaged (machine can travel with gear speed other than 4th).
Related
information
transmission to auto shift, or set manual shift selector switch to MANUAL and select 4th
using shift down switch or set gear shift lever to 4th.
No.
Cause
Defective 4th clutch ECMV

solenoid

harness

2. Disconnect connector 4.PS, and connect T-adapters to male side.
5 to 15 z
Resis- Between 4.PS (male) (1) and (2)
tance
Min. 1 Mz

5 to 15 z
tance
2. Disconnect connectors L63 and 4.PS, and connect T-adapter to
either female side.
Resis- Between ground and L63 (female) (16) or 4.PS
Min. 1 Mz
(female) (1)
tance
Short circuit in wiring harness 2. Disconnect connectors L63 and 4.P3, and connect T-adapter to
either female side.
Resis- Between L63 (female) (16) and (13), or
Min. 1 Mz
between 4.PS (female) (1) and (2)
tance
controller
performed.)
40-844
WA470-7
40 Troubleshooting
WA470-7
40-845
40 Troubleshooting
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th)
(WA380_7-DXHHKY-400-A-Z0-
A)
Action level
L03
Detail of
failure
Action of
controller
Hot Short of ECMV Solenoid (4th)

Failure code
Failure
DXHHKY
Due to hot short circuit in 4th clutch ECMV solenoid circuit, abnormal voltage appears
when controller does not drive 4th clutch ECMV solenoid.
Stops driving 1st, 2nd and 3rd clutch ECMV solenoids.
When not driving ECMV solenoids of speed clutches (other than 4th clutch), controller
also stops driving F (forward) and R (reverse) clutch ECMV solenoid.
(FNR) lever or directional selector (FNR) switch is set to N (neutral) position.
Problem on
machine
1st, 2nd, and 3rd clutches are not engaged (machine can travel with 4th gear speed).
Related
information
No.
1
Cause
Defective 4th clutch
ECMV solenoid

wiring harness

5 to 15 z
a If failure code [DXHHKA] for open circuit appears, wiring harness does not
have hot short circuit. (4th clutch ECMV solenoid is defective.)
Max. 4.5 V
No continuity
Continuity
pin other than (16)
(No sound is heard)

harness
controller
40-846
1.
2.
3.
4.

No continuity
pin other than (7)
(No sound is heard)
Continuity
No continuity
other than (7)
(No sound is heard)
WA470-7
40 Troubleshooting
WA470-7
40-847
40 Troubleshooting
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)
(WA380_7-
DXHJKA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of 3rd EPC Solenoid (Extension)

Failure code
Failure
DXHJKA
Due to open circuit in signal output circuit to 3rd valve (attachment) EXTEND EPC
solenoid, no current flows when controller drives 3rd valve (attachment) EXTEND EPC
solenoid.
Continues driving solenoid.
Problem on
machine
Cylinder connected to 3rd valve (attachment) does not extend.
Related
information
(attachment).
If this failure code is displayed on the machine, select "None" for 3rd (attachment) lever
setting on option setting screen of machine monitor.
Only for machines equipped with 3rd valve (attachment)
Method of reproducing failure code: Start engine and move 3rd (attachment) lever to
EXTEND position.
No.
1
Cause

Defective 3rd valve
(attachment) EXTEND EPC
solenoid (internal open circuit) Resis- Between F25 (male) (1) and (2)
5 to 15 z
tance
1 to 4.5 V

harness
5 to 15 z
tance

Open circuit in wiring harness 1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and F25, and connect T-adapters to
each female side.
Max. 1 z
Resis- Between L73 (female) (3) and F25 (female) (2)
tance Between L73 (female) (26) and F25 (female) (1) Max. 1 z
controller
performed.)
40-848
WA470-7
40 Troubleshooting
Circuit diagram related to 3rd valve (attachment) EXTEND EPC solenoid
WA470-7
40-849
40 Troubleshooting
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)
(WA380_7-
DXHJKB-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of 3rd EPC Solenoid (Extension)

Failure code
Failure
DXHJKB
Due to ground fault in signal output circuit to 3rd valve (attachment) EXTEND EPC
solenoid, abnormal current flows when controller drives 3rd valve (attachment) EXTEND
EPC solenoid.
Stops driving 3rd valve (attachment) EXTEND EPC solenoid.
(attachment).
If this failure code is displayed on the machine that is not equipped with 3rd valve
(attachment), select "None" for 3rd (attachment) lever setting on option setting screen of
machine monitor.
Cause

Defective 3rd valve
(attachment) EXTEND EPC
5 to 15 z
solenoid (internal short circuit) Resis- Between ground and each of F25 (male) (1) and
tance
Min. 1 Mz
(2)

harness
5 to 15 z
tance
either female side.
Min. 1 Mz
tance (female) (1)
either female side.
Min. 1 Mz
controller
performed.)
40-850
WA470-7
40 Troubleshooting
WA470-7
40-851
40 Troubleshooting
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT)
(WA380_7-DXHJKY-400-
A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Hot Short of 3rd EPC Solenoid (Extension)

Failure code
Failure
DXHJKY
Due to hot short circuit in output signal circuit to 3rd valve (attachment) EXTEND EPC
solenoid, abnormal voltage appears when controller does not drive 3rd valve (attachment)
EXTEND EPC solenoid.
Stops driving boom RAISE and LOWER EPC solenoids, bucket TILT and DUMP EPC
solenoids, 3rd valve (attachment) EXTEND and RETRACT EPC solenoids, and 4th valve
(attachment) EXTEND and RETRACT EPC solenoids.
3rd valve (attachment) EXTEND EPC solenoid may be burnt.
(attachment).
Cause
Defective 3rd valve
(attachment) EXTEND
short circuit)


wiring harness

Max. 4.5 V

harness
Defective work
40-852
5 to 15 z

side of L73.
No continuity
Continuity
(No sound is heard)
performed.)
WA470-7
40 Troubleshooting
WA470-7
40-853
40 Troubleshooting
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET)
(WA380_7-
DXHKKA-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Disconnection of 3rd EPC Solenoid (Retract)

Failure code
Failure
DXHKKA
Due to open circuit in output signal circuit to 3rd valve (attachment) RETRACT EPC
solenoid, no current flows when controller drives 3rd valve (attachment) RETRACT EPC
solenoid.
Continues driving solenoid.
Problem on
machine
Cylinder connected to 3rd valve (attachment) does not retract.
Related
information
(attachment).
Output current value to 3rd valve (attachment) retract EPC solenoid can be checked with
monitoring function. (Code: 41907 3rd retract EPC current)
Method of reproducing failure code: Start engine and move 3rd (attachment) lever to
RETRACT position.
No.
1
Cause

Defective 3rd valve
(attachment) RETRACT EPC 2. Disconnect connector F26, and connect T-adapter to male side.
solenoid (internal open circuit) Resis- Between F26 (male) (1) and (2)
5 to 15 z
tance


1 to 4.5 V


harness
5 to 15 z
tance

Open circuit in wiring harness 1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and F26, and connect T-adapters to
each female side.
Max. 1 z
Resis- Between L73 (female) (3) and F26 (female) (2)
tance Between L73 (female) (36) and F26 (female) (1) Max. 1 z
controller
performed.)
40-854
WA470-7
40 Troubleshooting
Circuit diagram related to 3rd (attachment) valve RETRACT EPC solenoid
WA470-7
40-855
40 Troubleshooting
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)
(WA380_7-
DXHKKB-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Ground Fault of 3rd EPC Solenoid (Retract)

Failure code
Failure
DXHKKB
Due to ground fault in output signal circuit to 3rd valve (attachment) retract EPC solenoid,
abnormal current flows when controller drives 3rd valve (attachment) retract EPC
solenoid.
Stops driving 3rd valve (attachment) retract EPC solenoid.
Wiring harness or controller may be burnt.
(attachment).
If this failure code is displayed on the machine that is not equipped with 3rd valve
(attachment), select "None" for 3rd (attachment) lever setting on option setting screen of
machine monitor.
monitoring function. (Code: 41907 3rd retract EPC current)
Cause

Defective 3rd valve
(attachment) Rretract EPC
5 to 15 z
solenoid (internal short circuit) Resis- Between ground and each of F26 (male) (1) and
tance
Min. 1 Mz
(2)

harness

5 to 15 z
tance
either female side.
Min. 1 Mz
tance (female) (1)
either female side.
Min. 1 Mz
controller
performed.)
40-856
WA470-7
40 Troubleshooting
Circuit diagram related to 3rd valve (attachment) retract EPC solenoid
WA470-7
40-857
40 Troubleshooting
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET)
(WA380_7-DXHKKY-
400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Hot Short of 3rd EPC Solenoid (Retract)

Failure code
Failure
DXHKKY
Due to hot short circuit in output signal circuit to 3rd valve (attachment) retract EPC
solenoid, abnormal voltage appears when controller does not drive 3rd valve (attachment)
retract EPC solenoid.
Stops driving boom RAISE and LOWER EPC solenoids, bucket TILT and DUMP EPC
solenoids, 3rd valve (attachment) EXTEND and RETRACT EPC solenoids, and 4th valve
(attachment) EXTEND and RETRACT EPC solenoids.
3rd valve (attachment) retract EPC solenoid may be burnt out.
(attachment).
monitoring function. (Code: 41907 3rd Retract EPC Current)
Cause
Defective 3rd valve
(attachment) retract
short circuit)


wiring harness

Max. 4.5 V

harness
Defective work
40-858
5 to 15 z

side of L73.
No continuity
Continuity
(No sound is heard)
performed.)
WA470-7
40 Troubleshooting
Circuit diagram related to 3rd (attachment) valve RETRACT EPC solenoid
WA470-7
40-859
40 Troubleshooting
Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor
(WA470_7-
DY30MA-400-A-Z0-A)
Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Malfunction 1 of Emergency Steering Motor

Failure code
Failure
DY30MA
Emergency steering pump pressure is detected although work equipment controller does
not send emergency steering operation command.
Emergency steering pump pressure is 0.098 MPa or above.
Emergency steering motor (pump) operates although emergency steering switch is not
operated. Motor burns out due to prolonged operation.
Emergency steering operation indicator lights up.
monitoring function. (Code: 07705 Emrg. Steering Pres. S. Volt)
monitoring function. (Code: 07703 Emrg. Steering Pressure)
function. (Code: 95303 Steering Pump Pres. Sensor Volt)
function. (Code: 95302 Steering Pump Pressure)
Cause
Defective emergency
steering motor system
Defective emergency
steering motor,
emergency steering
relay, emergency
steering switch, work
equipment controller, or
wiring harness
Short circuit 1 in wiring

harness
40-860

1. Turn starting switch to ON position (wait for 30 seconds).
a If emergency steering motor starts to operate, perform check on causes 2
and after. If not, go to check on cause 11.
2. Disconnect emergency steering relay L126.
a If emergency steering motor starts to operate, perform check on causes 2
and after. If not, go to check on cause 11.
Emergency steering switch and work equipment controller
2. Disconnect switch S_RH8 and connector L72.
If emergency steering motor starts to operate, perform check on causes 6 and
7. If not, go to check on causes 8 and after.
Emergency steering relay (L126)
1Mz
WA470-7
40 Troubleshooting
No.
Cause
1.
2.
3.
Hot short circuit 1 in

wiring harness
(contact with 24V
circuit)
Defective emergency
steering pressure
sensor
Short circuit 2 in wiring

harness
Hot short circuit 2 in

wiring harness
(contact with 24V
circuit)
Defective emergency
steering relay (L126)
Defective emergency
steering switch
Defective work
10 equipment controller

Disconnect terminal R18 of emergency steering relay.
Turn starting switch to ON position (wait for 30 seconds).
a If emergency steering motor starts to operate, hot short circuit is in wiring

harness.
Max 1 V
2. Disconnect ground terminal of emergency steering motor.
a To prevent current from flowing through emergency steering motor
while it is being checked
Between terminals R13 and R14
Max 1 V
Voltage
Max 1 V
If measured voltage at terminal R13 is 1 V or below in check on cause 4 and
output from terminal R09 is unusual, emergency steering relay (motor side) is
defective.
Emergency steering switch
Resistance Between S_RH8 (male) (5) and (6)
Min. 1M z
2. Disconnect connectors S_RH8 and L72, and connect T-adapter to female
side.
Between ground and S_RH8 (female) (6) or L72
Voltage
Max 1 V
(female) (8)
2. Replace emergency steering relay L126 with horn relay L119.
If emergency steering motor does not start to operate, original emergency
steering relay (L126) is defective. If it starts to operate, go to check on next
cause.
When manual emergency steering
Between
Max. 1 z
switch is in "ON" position
S_RH8
When manual emergency steering
Min. 1M z
and (6)
switch is in "OFF" position
2. Disconnect connector S_RH8.
a If emergency steering motor starts to operate, work equipment controller is
defective.
Defective emergency
11 steering pressure
sensor system
WA470-7
Perform troubleshooting for failure code [DHUDKB].
40-861
40 Troubleshooting
Circuit diagram related to emergency steering motor
40-862
WA470-7
40 Troubleshooting
Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor
(WA470_7-
DY30MC-400-A-Z0-A)
Action level
L03
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Malfunction 2 of Emergency Steering Motor

Failure code
Failure
DY30MC
Emergency steering pump pressure is not detected although work equipment controller
sends emergency steering operation command.
Emergency steering pump pressure is 0.098 MPa or below.
Emergency steering motor (pump) does not operate although emergency steering switch
is operated.
Cause

Loose terminal or open Check ground terminal of emergency steering motor 100R, emergency
circuit
steering motor terminal 100B, and emergency steering relay terminal R18 for
looseness and breakage. If any terminal is loosened or broken, repair it.
Defective emergency
steering relay, or
defective emergency
steering relay L126,
emergency steering
switch, emergency
steering pressure
sensor, or wiring
harness

3. Open left engine cover.
a To check operation sound of emergency steering relay
5. Turn emergency steering switch on.
a If operation sound of emergency steering relay is not heard, go to check
on next cause.
a If operation sound is heard, go to check on cause 11.
3
4
5

box FS08
Defective 50 A slowblow fuse
Defective 120 A slowblow fuse
Defective emergency
steering relay L126
(internal open circuit or
connector)
WA470-7
If fuse-4 in fuse box FS08 is blown, perform check on cause 11 first.

If 50 A fuse on terminal R06A side of slow-blow fuse is blown, perform check
on cause 10 first.
If 120 A fuse on terminal R05A side of slow-blow fuse is blown, perform check
on cause 10 first.
2. Replace emergency steering relay L126 with horn relay L119.
If this failure code [DY30MC] does not appear, original relay (L126) is
defective.
40-863
40 Troubleshooting
No.
Cause

Resistance Between R14 and ground
Max. 1 z

a Check to where 24 V power is supplied to isolate cause.
a If no failure is found by this check, following check is not required.
Between terminal R17 and ground
20 to 30 V
Voltage Between terminals R13 and R14
20 to 30 V
20 to 30 V
Defective emergency
steering pressure
sensor
1.
2.
3.
4.

Insert T-adapters into connectors L126 and S_RH8.
Turn emergency steering switch on.
a If no failure is found by this check, following check is not required.

Between S_RH8 (5) and ground
20 to 30 V
Between S_RH8 (6) and ground
20 to 30 V
20 to 30 V
20 to 30 V
20 to 30 V
2. Disconnect connectors L126, L71, and R37, and connect T-adapter to
female side.
Max. 1 z
Between S_RH8 (female) (5) and FS084
Max. 1 z
Between FS084 and terminal R06A
Max. 1 z
Resistance Between terminals R10 and R05
Max. 1 z
Max. 1 z
Max. 1 z
40-864
WA470-7
40 Troubleshooting
Cause
Defective emergency
steering relay

In check on cause 7, if only measured voltage at terminal R18 is unusual in
emergency steering relay check, emergency steering relay is defective.
Defective emergency
steering switch

When emergency steering switch is in
Between
Max. 1 z
ON position
S_RH8
When emergency steering switch is in
Min. 1M z
and (6)
OFF position

10 harness (contact with
ground circuit)

2. Disconnect connectors S_RH8 and L126, and connect T-adapter to
female side.
Between ground and S_RH8 (female) (6) or L126
Max. 1 z
(female) (1)
Max. 1 z
Between
ground
and
terminal
FS084
or
R06A
Max. 1 z
Resistance
Between ground and terminal R10 or R05
Max. 1 z
Between ground and terminal R05 or R04
Max. 1 z
Between ground and terminal R18 or 100R
Max. 1 z
No.
8
Open circuit 2 in wiring 1. Turn starting switch to OFF position.

harness (wire breakage 2. Disconnect connector L72, and connect T-adapter to female side.
11 or defective contact of
200 to 400
Resistance
connector)
z
a Coil resistance of L126
Defective emergency
Perform troubleshooting for failure code [DHUDKA].
12 steering pressure
sensor system
Open circuit 3 in wiring Emergency steering motor system
harness (wire breakage 1. Turn starting switch to OFF position.
13 or defective contact of
Between terminals R18 and 100R
Max. 1 z
Resistance
connector)
Between terminal 100B and ground
Max. 1 z
Defective emergency
14 steering motor
Defective work
15 equipment controller
WA470-7

Between 100R (motor terminal) and ground
Voltage
20 to 30 V
(chassis ground)
1.
2.
3.
4.

Disconnect connector L71 and insert T-adapter into it.
Start engine.
a If measured voltage is normal in this check, controller is defective.

0.50 to 4.5
V
40-865
40 Troubleshooting
40-866
WA470-7
40 Troubleshooting
Failure code [DY30ME] Emerg. Steering Long-Time Activated
(WA470_7-DY30ME-
400-A-Z0-A)
Action level
L02
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
1
Emergency Steering Long-Time Activated

Failure code
Failure
Work equipment controller system
DY30ME
Emergency steering pump pressure is continuously detected for 1 minute or longer.
Emergency steering pump pressure is 0.098 MPa or above.
Warning is generated if emergency steering continues to operate for 1 minute or longer
(emergency steering motor may be malfunctioning or may be burnt out.).
Indicator lights up although emergency steering motor is not in operation.
Emergency steering remains activated.
Cause
Defective emergency
steering motor system
WA470-7

Perform troubleshooting for failure code [DY30MA].
40-867
40 Troubleshooting
40-868
WA470-7
40 Troubleshooting
Failure code [LA00L3] Failure of Fan Reverse

Action level
L01
Detail of
failure
Action of
controller
(WA380_7-LA00L3-400-A-Z0-A)
Failure code
Failure Failure of Fan Reverse
LA00L3
When controller drives fan REVERSE solenoid, fan speed does not decrease (does not
lower to 100 rpm or below). As a result, fan rotation direction is not switched.
Leaves fan rotating normal or in reverse and disables fan reverse function.
Problem on
machine
Fan cannot switch its rotation direction.
Related
information
(Code: 31646 Fan reverse solenoid current)
Fan speed can be checked with monitoring function. (Code: 10009 Radiator Fan speed)
Method of reproducing failure code: Start engine and switch fan rotation direction.
No.
1
2

Cause
Defective radiator fan reverse See troubleshooting for failure codes "DW7BKA", "DW7BKB", and
solenoid
"DW7BKY".
Fan motor may malfunction. Perform troubleshooting of hydraulic and
Internal failure of fan motor
mechanical systems.
WA470-7
40-869
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-1 Engine does not start
Failure
Related
information
No.
1
(ALL-3840-001-A-01-A)
(WA470_7-A20-400-A-Z0-A)
Engine does not start (engine does not crank).

Engine starting circuit has following two start lock mechanisms.
1. Start lock by password protection of machine monitor
2. Start lock by directional lever and R.H. directional selector (FNR) switch positions
(engine can start only when in NEUTRAL).
If failure symptom "Battery relay operation sound is not heard" appears when starting
switch is turned to ON position, perform troubleshooting for E-1 as well.
If failure symptom "Machine monitor does not light up" appears when turning starting
switch to ON position, main electric power supply system is supposed to be defective.
Perform the troubleshooting for E-5 (lines of slow-blow fuse, fuses-1 and -5 of fuse box 2).
Battery charge voltage sensed by transmission controller can be checked with monitoring
Cause

Loose terminal or open
Check
terminals of starting motor, alternator, battery relay, and ground
circuit at terminal
terminals R50, E14, etc.
Between battery relay terminal R16 and ground
Poor contact
(grounding) between
a Use machine frame as grounding point for
Max. 1 z
battery relay and frame Resistance
measurement.
a Loose or rusted terminal R50
a Be ready with starting switch at OFF position, then perform

troubleshooting without turning starting switch to ON position.
Battery voltage (two batteries)
Min. 24 V
Specific gravity of electrolyte (each battery)
Min. 1.26
Defects of engine controller power supply and ACC signal are indicated with
Defective engine
failure codes [DB2QKR] and [DB2RKR]. If these codes appear, perform
controller system
troubleshooting for causes 1 to 3 of [DB2QKR] first.
Defective transmission If failure code [DAQQKR] or [DAQRKR] is displayed, perform troubleshooting
controller system
for [DAQQKR] or [DAQRKR].
If failure code [DF10KA] or [DF10KB] is displayed, perform troubleshooting for
lever system
[DF10KA] or [DF10KB].
R.H. directional selector If failure code [DDK3KA] or [DDK3KB] is displayed, perform troubleshooting
(FNR) switch system
for [DDK3KA] or [DDK3KB].
Defective battery relay

system
4
5
6
Insufficient battery
capacity
1. Turn starting switch to ON position (to connect ACC).
a If battery relay operation sound is not heard, go to checks on causes 19

and after.
Defective starting
2. Remove fuse-6 (30 A) in fuse box 2. (To prevent engine from starting
switch, gear shift lever
during troubleshooting)
switch, neutral safety
9 relay L116, neutral keep 4. Turn starting switch to START position and hold it (two persons required
relay L121, personal
for this check).
code relay L113, battery
relay, or wiring harness a If voltage is abnormal, go to check on cause 13 and after.
Voltage Between E01 (1) and ground
20 to 30 V
Defective alternator
10
Between E01 (female)
Input from alternator
Max. 1 V
Voltage
(2) and ground
generation
40-870
WA470-7
40 Troubleshooting
No.
Cause

3. Turn starting switch to START position.
Between starting motor
Defective starting motor
Power supply
terminal B and ground
11
(internal defect)
Between E01 (1) and
Starting input to starting
Voltage
ground
motor
Between E01 (2) and
Input from alternator
ground
generation
20 to 30 V
20 to 30 V
Max. 1 V

Output inhibition to
12 transmission controller
is input
13
controller
a Check that directional lever and R.H. directional selector (FNR) switch are
in NEUTRAL position.
3. Turn starting switch to ON position (to connect ACC).
20 to 30 V
Voltage
20 to 30 V
2. Disconnect connector D12.
a Check that directional lever and R.H. directional selector (FNR) switch are
in NEUTRAL position.
a If check result on cause 12 is normal and the following voltages are

abnormal, transmission controller is defective.
20 to 30 V
Defective neutral safety 2. Replace neutral safety relay L116 with horn relay L119.
14 relay
3. Start engine.
If engine starts, original neutral safety relay is defective.
Defective neutral keep
15 relay

2. Replace neutral keep relay L121 with horn relay L119.
3. Start engine.
If engine starts, original neutral keep relay is defective.

Defective personal lock 2. Replace personal code relay L113 with horn relay L119.
16 relay
3. Start engine.
If engine starts, original personal code relay is defective.
2. Disconnect connectors D04, D05, D11, D12 and connect T-adapters to
diode.
Defective diode D04,

D05, D11, or D12
17 (internal open circuit or
short circuit)

Continuity

WA470-7
No
continuity
Continuity
No
continuity
Continuity
No
continuity
Continuity
No
continuity
Continuity
40-871
40 Troubleshooting
No.
Cause
Defective starting
18 switch
Open circuit 1 in wiring

harness
19 (wire breakage or
connector)
40-872

disconnect switch to the OFF position.
3. Disconnect connector S40.
4. Turn starting switch to the ON and START positions to perform
troubleshooting again.
Starting switch: OFF.
Min. 1 Mz
and (2) (terminal BR)
Starting switch: ON
Max. 1 z
Min. 1 Mz
Resistance and (4) (terminal ACC)
Starting switch: ON
Max. 1 z
Min. 1 Mz
and (3) (terminal C)
Max. 1 z
Battery relay
Resistance Between terminal R16 and ground
Max. 1 z
Battery relay
a Check where 24 V power is reached to, and locate open section.
20 to 30 V
Voltage Between terminals R15 and R16
20 to 30 V
20 to 30 V
Alternator and starting motor
3. Insert T-adapters into connectors S40, L116, L121, L113, and D05.
5. Turn starting switch to START position to perform troubleshooting.
a Check where 24 V power is reached to, and locate open section.
Between S40 (3) and ground
20 to 30 V
20 to 30 V
20 to 30 V
20 to 30 V
20 to 30 V
Between
D05
(2)
and
ground
20 to 30 V
Voltage
Between D05 (1) and ground
20 to 30 V
Between E01 (1) and ground
20 to 30 V
20 to 30 V
20 to 30 V
20 to 30 V
WA470-7
40 Troubleshooting
No.
Cause

harness
20 (wire breakage or
connector)
21
Defective battery relay

(does not turn ON)

harness
22
circuit)

23 wiring harness

a If no failure is found in "alternator, starting motor" by check on cause 19,
2. Disconnect connectors S40, L113, L116, L121, D04, D05, E01, and
Max. 1 z
Max. 1 z
Max. 1 z
Between D04 (female) (2) and D05 (female) (2)
Max. 1 z
Between D04 (female) (1) and D05 (female) (1)
Max. 1 z
Between D04 (female) (1) and E01 (female) (1)
Max. 1 z
Resistance
Max. 1 z
Max. 1 z
Between D11 (female) (1) and L116 (female) (1)
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
If voltage of terminal R04 only is unusual in battery relay checks on cause 19,
battery relay is defective.
2. Check that system operating lamp is not lit, and then turn battery
3. Disconnect connectors S40, L116, L121, L113, D05, D04, D11, E01, D12,
L62, L80B, L73, R15, and MCM1 A.
4. Connect T-adapters to female side of L116, D11, and D04.
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Resistance
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
2. Disconnect connector E01 and connect T-adapter to female side.
3. Disconnect terminal E02.
a If a hot short circuit occurs, the charging lamp lights up when the starting
switch is turned ON.
Voltage Between E01 (female) (2) and ground
Max. 1 V
WA470-7
40-873
40 Troubleshooting
Circuit diagram related to engine starting circuit
40-874
WA470-7
40 Troubleshooting
WA470-7
40-875
40 Troubleshooting
E-2 Manual preheating system does not work

Failure
Related
information
No.
1
2
3
4
(WA470_7-FEM-400-A-00-A)
Manual preheating system does not work.

a This troubleshooting describes procedures to be followed when manual preheating does
not function to heat electrical intake air heater mounting section.
This machine has "Automatic preheating" and "Manual preheating" functions. When either
preheating works, preheating monitor lights up. (When only preheating monitor does not
light up, perform troubleshooting for "E-4 While preheating is working, preheating monitor
does not light up").
If failure symptom "Machine monitor displays nothing" or "Battery relay does not make
operating sound" appears when starting switch is turned to ON position, main electric
power supply system may be defective. In these cases, perform troubleshooting for E-5
and E-1 respectively.
Before performing troubleshooting, check that no related failure code is displayed.

If fuse 6 in fuse box 2 is broken, circuit probably has ground fault. In this case,
perform check on cause 10 first.
If slow-blow fuse is blown out, circuit probably has ground fault. In this case,
Defective fuse (200 A) If fuse is blown out, circuit probably has ground fault. In this case, perform
check on cause 10 first.
Loose terminal or open 1. Turn starting switch to OFF position.
circuit at terminal
Check terminals of heater relay, battery relay, electrical intake air heater, etc.
Cause
Defective fuse 6 in fuse
box 2
Defective slow-blow
fuse

2. Turn the battery disconnect switch to the OFF position.
a Heater relay coil resistance
Resistance Between terminal R of starting switch and ground

a If slow-blow fuse or fuse is blown, replace it in advance.

2. Turn the battery disconnect switch to the ON position
Voltage Between heater relay terminal E05 and ground
Approx. 20
z
20 to 30 V

2. Disconnect heater relay terminal E07A.
a To prevent current from flowing through heater when starting switch is
turned to HEAT position
3. Turn starting switch to the HEAT position (connect R).
Voltage Between heater relay terminal E06 and ground
20 to 30 V
Continuity Between heater relay terminal E and ground
6
Defective heater relay

(does not engage)
(Terminal E07A)
Diode (E06A) is
defective.
circuit)
If no failure is found by check on cause 5 and heater relay operation sound is

not heard, heater relay is defective.
2. Disconnect connector E06A and connect T-adapters to diode.
a Check by using multimeter in diode range.
Continuity
Between E06A (male) (1) (+) and (2) (-)

Between E06A (male) (2) (+) and (1) (-)
Defective electrical
intake air heater
40-876
Continuity
No
continuity
Continuity

2. Disconnect terminal E07B.
Continuity Between terminal E07B and ground
Continuity
WA470-7
40 Troubleshooting
No.
Cause
Defective starting
switch

3. Turn starting switch to the OFF and the HEAT positions to perform
troubleshooting.
OFF
Min. 1 Mz
Resistance Between terminal B and terminal R
HEAT
Max. 1 z

harness
10
circuit)
WA470-7
a
1.
2.
3.
4.

Turn the battery disconnect switch to the OFF position.
Remove fuses 1 to 5 and 7 in fuse box 2 (FS9).
Disconnect connectors MCM1 A and E06A, and terminals E05, E06,
E07B, R03, R04, R05, and R12
Between heater relay terminal E05 (wiring harness
Min. 1 Mz
side) and ground
Between heater relay terminal E06 (wiring harness
Resistance side) and ground
Min. 1 Mz
Between heater terminal E07B (wiring harness
Min. 1 Mz
side) and ground
40-877
40 Troubleshooting
Circuit diagram related to engine preheating system
40-878
WA470-7
40 Troubleshooting
E-3 Automatic preheating system does not work

Failure
Related
information
No.
1
2
(WA470_7-FE1-400-A-Z0-A)
Automatic preheating system does not work.

Automatic preheating starts when coolant temperature is below -5C.
(Code: 04107 Engine coolant temperature)
If automatic preheating function does not work, check whether manual preheating
function works first.
Engine controller checks primary (coil) side of preheat relay (connector L125) and
generates failure code [CA2555] or [CA2556] if it is defective.
Engine controller checks engine coolant temperature sensor and generates failure code
[CA144] or [CA145] if it is defective.
Cause
Defective slow-blow
fuse
box 2

If fuse 6 in fuse box 2 is broken, circuit probably has ground fault. In this case,
Defective preheater
relay L125 (internal

2. Replace preheat relay (connector L125) with horn relay (connector L119).
If automatic preheating starts when coolant temperature is below -5C,
original auto preheat relay is defective.
2. Disconnect connectors MCM1 A and L125, and connect T-adapters to
female side of L125.

a If resistance is 1 Mz or higher, harness has open circuit. If it is 1 z or

below, harness has short circuit.
a Heater relay coil resistance

harness
(wire breakage or
connector)

harness
circuit)
WA470-7
a
1.
2.
3.
Approx. 20
z

Disconnect connectors L125 and MCM1 A, and connect T-adapters to
Between L125 (female) (3) and terminal R01 of
Max. 1 z
battery relay
Resistance a If no failure is found by check on cause 4, this

Max. 1 z
Between L125 (female) (5) and heater relay
terminal E06
If slow-blow fuse or fuse is not blown out, this check is not required.
a
1.
2.
3.

Remove fuses 1 to 7 in fuse box 2.
Disconnect connectors MCM1 A, L125, EC3, and connect T-adapter to
Min. 1 Mz
40-879
40 Troubleshooting
40-880
WA470-7
40 Troubleshooting
E-4 While preheating is working, preheating monitor does not light

up (WA470_7-FE2-400-A-Z0-A)
Failure
Related
information
No.
While preheating is working, preheating monitor does not light up.

This machine has "Automatic preheating" and "Manual preheating" functions. When either
preheating works, preheating monitor lights up.
Check whether manual preheating function works first.
"Socket-type box" is available for monitor controller connector.
Cause

harness
(wire breakage or
connector)

2. Disconnect connectors MCM1 A and L125, and connect T-adapters to
each female side.
Between terminal R of starting switch and MCM1 A
Max. 1 z
(female) (12)
Resistance
Between L125 (female) (5) and MCM1 A (female)
Max. 1 z
(12)
Defective machine
monitor
If no failure is found by above checks, machine monitor is defective.
WA470-7
40-881
40 Troubleshooting
40-882
WA470-7
40 Troubleshooting
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display
nothing (WA470_7-FH7-400-A-Z0-A)
Failure
Related
information
No.
1
2
3
4
5
6
All of LCD unit, LED unit, and meter unit on machine monitor display nothing.
Display of rearview monitor is normal.
Cause
battery disconnect
switch
engine shutdown
secondary switch
Defective slow-blow
fuse
box 2
Defective fuses 3 and
15 in fuse box 2
Defective continuous
power supply system

Check that battery disconnect switch is at ON position.
Check that engine shutdown secondary switch is at lower (OFF) position.
If fuse is blown, circuit may have ground fault, etc. (See check on cause 8.)
If fuse is blown, circuit may have ground fault. (See check on cause 8.)
Perform troubleshooting for failure code [DAF3KK].
a Check that engine shutdown secondary switch is at lower (OFF) position.
20 to 30 V
Voltage Between MCM1 A (female) (31) and (2)
20 to 30 V
20 to 30 V

harness
(wire breakage or
connector)
WA470-7

3. Disconnect connectors MCM1 A and S_FS, and connect T-adapters to
each female side.
Max. 1 z
Between MCM1 A (female) (24) and S_FS (female)
Max. 1 z
(2)
Between MCM1 A (female) (31) and S_FS (female)
Max. 1 z
Resistance (1)
Between S_FS (female) (1) and (4)
Max. 1 z
Between S_FS (female) (2) and (5)
Max. 1 z
Between S_FS (female) (2) and terminal ACC of
Max. 1 z
starting switch
40-883
40 Troubleshooting
No.
Cause

3. Remove fuses 1 to 7 in fuse box 2 (FS9).

harness
circuit)
Defective starting
switch (internal defect)
10
Defective monitor
controller
40-884
a For FS9, see circuit diagram for E-4.

Between ground and MCM1 A (female) (1), (4), or
FS9-3
Between ground and MCM1 A (female) (24), (43),
Resistance or FS9-15
Between MCM1 A (female) (31) and ground
Between FS9-1 (both terminals) and ground
Between FS9-15 (both terminals) and ground
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
3. Disconnect cable from terminal B of starting switch.
Between starting switch
Starting switch: OFF
Min. 1 Mz
terminals B and ACC
Resistance
Between starting switch
Starting switch: ON
Max. 1 z
terminals B and ACC
WA470-7
40 Troubleshooting
Circuit diagram related to monitor controller
WA470-7
40-885
40 Troubleshooting
E-6 LCD unit on machine monitor displays nothing
(WA380_7-FH8-400-A-Z0-A)
LCD unit on machine monitor displays nothing.

Display of LED unit, meter unit, and rearview monitor is normal.
Make harness checker. For details, see "Processing procedure of harness checker
for troubleshooting of machine monitor LCD unit" in General information on
Related information
troubleshooting.
Failure
a Harness checker for troubleshooting of machine monitor LCD unit is simply referred
to as "harness checker".
No.
Cause

3. Visually check connectors of wiring harness between LCD unit of
machine monitor and monitor controller, and repeat connection and
disconnection of connectors.
If normal conditions are restored, cause of failure is defective contact of
connector.
a When using harness checker

1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
Defective LCD unit of machine 3. Disconnect connector MCM2, and connect harness checker to
monitor
female side.
6.2 to 9.1 V
Voltage
6.2 to 9.1 V
a When performing troubleshooting by using new wiring harness

between machine monitor LCD unit and monitor controller
3. Replace wiring harness between LCD unit of machine monitor and
monitor controller with new one.
If normal conditions are restored, wiring harness between LCD unit of
machine monitor and monitor controller is defective.
Defective LCD unit of machine 2. Turn starting switch to ON position.
monitor
If display of LED unit and meter unit is normal, LCD unit is defective.
40-886

If display of LED unit and meter unit is unusual, monitor controller is
defective.
WA470-7
40 Troubleshooting
Wiring harness between monitor controller and LCD unit of machine monitor
Circuit diagram between monitor controller and LCD unit of machine monitor
WA470-7
40-887
40 Troubleshooting
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight

goes out or flickers) (WA500_7-FH9-400-A-Z0-A)
Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers).
Related information
troubleshooting.
Failure
No.
Cause

connector.

Defective LCD unit of machine 3. Disconnect connector MCM2, and connect harness checker for
monitor
troubleshooting of LCD unit of machine monitor to female side.
Min. 0.3 V
Voltage
6.2 to 9.1 V

monitor
40-888

defective.
WA470-7
40 Troubleshooting
WA470-7
40-889
40 Troubleshooting
E-8 LCD on machine monitor does not display properly
(WA500_7-FHA-400-A-Z0-A)
LCD on machine monitor does not display properly.

Related information
troubleshooting.
Failure
No.
Cause

connector.

Defective LCD unit of machine 3. Disconnect connector MCM2, and connect harness checker for
monitor
troubleshooting of LCD unit of machine monitor to female side.
Min. 0.3 V
Voltage
Min. 0.3 V

monitor
40-890

defective.
WA470-7
40 Troubleshooting
WA470-7
40-891
40 Troubleshooting
E-9 Meter unit display on machine monitor is abnormal

Failure
(WA380_7-FHB-400-A-Z0-A)
Meter unit on machine monitor displays nothing.

Pointer of meter on machine monitor does not swing.
Meter unit LCD display on machine monitor is abnormal.
Backlight of meter unit on machine monitor is unusual.
Display of LCD unit, LED unit, and rearview monitor is normal.
Related information a If fuse 3 or 15 in fuse box 2 (FS9) is blown, machine monitor displays nothing (see
troubleshooting E-5).
a Machine monitor connector DPC2 is a 070 type connector with 8 pins, and T-adapter
for this connector is newly developed.
No.
Cause
Defective CAN

3. Visually check connectors of wiring harness between meter unit of
connector.
Display abnormality record in the service mode of machine monitor. If
failure code [DSJ0KR] of action level L01 is logged, perform
troubleshooting for failure code [DSJ0KR].
a When using T-adapters for connector MDM3 (070-8)

side.
Open circuit in wiring harness 4. Turn battery disconnect switch to ON position.
20 to 30 V
20 to 30 V
Voltage
1 to 4 V
a CAN communication line
1 to 4 V
a CAN communication line
If no failure is found by check on cause 3, meter unit of machine monitor
is defective.

machine monitor
40-892
a When not using T-adapter for connector MDM3 (070-8)

If display of LCD unit and LED unit of machine monitor is normal, meter
unit of machine monitor is defective.
If display of LCD unit and LED unit of machine monitor is unusual,
monitor controller is defective.
WA470-7
40 Troubleshooting
Wiring harness between monitor controller and meter unit of machine monitor
WA470-7
40-893
40 Troubleshooting
Circuit diagram between monitor controller and meter unit of machine monitor
40-894
WA470-7
40 Troubleshooting
E-10 Night lighting lamp of meter unit on machine monitor is

abnormal (WA380_7-FHC-400-A-Z0-A)
Night lighting lamp of meter unit on machine monitor is abnormal.
Night lighting lamp of meter unit of machine monitor lights up only when clearance
lamp is turned on while monitor brightness selector switch is at the night mode.
Check whether night lighting lamp of rearview monitor is also abnormal or not.
Related information As T-adapter for monitor controller connector is "socket-type box", operating voltage
Failure
a Machine monitor connector MDM3 is a 070 type connector with 8 pins, and Tadapter for this connector is newly developed.
No.
Cause

3. Visually check connector of wiring harness connected to meter unit
of machine monitor and connector of night lighting switch, and
repeat connection and disconnection of connectors.
connector.
a If night lighting lamp of rearview monitor lights up, this check is not
required.
Defective monitor brightness 2. Disconnect connector S_F7 and connect T-adapter to male side.
selector (night lighting) switch
Between S_F7
Brightness selector
Min. 1 Mz
switch: OFF
Resis- (female) (5) and (4)
tance
Between S_F7
Brightness selector
Max. 1 z
switch: ON

side.
20 to 30 V
20 to 30 V
Voltage Between MDM3
Max. 0.2 V
OFF
Between MDM3
20 to 30 V
ON
3. Disconnect connectors MDM3, S_F7, S_RV, and connect Tadapters to each female side.
Between S_F7 (female) (4) and MDM3
Max. 1 z
Resis- (female) (5)
tance
Between S_RV (female) (3) and S_F7
Max. 1 z
(female) (5)
WA470-7
40-895
40 Troubleshooting
No.
Cause

machine monitor

If no failure is found by check on cause 3, meter unit of machine monitor
is defective.
a When not using T-adapter for connector MDM3 (070-8)
3. Turn on night lighting switch.
If night lighting of LCD unit , LED unit, switch panel, and rearview
monitor of machine monitor is normal, meter unit of machine monitor is
defective.
Wiring harness between monitor controller and meter unit of machine monitor
40-896
WA470-7
40 Troubleshooting
Circuit diagram between monitor controller and meter unit of machine monitor
WA470-7
40-897
40 Troubleshooting
E-11 Caution LED on machine monitor is abnormal

Failure
Related information
No.
(WA500_7-FHD-400-A-Z0-A)
LED unit lamp of machine monitor does not light up, or does not go out.
a Machine monitor connector MDM2 is a 070 type connector with 6 pins, and Tadapter for this connector is newly developed.
Cause
3. Visually check connector of wiring harness connected to LED unit of
machine monitor and connector of monitor controller, and repeat
connection and disconnection of connectors.
connector.
Defective LIN communication failure code [DPQ2KR] of action level L01 is logged, perform
line
troubleshooting for failure code [DPQ2KR].
failure code [DAFDKB] of action level L01 is logged, perform
system
troubleshooting for failure code [DAFDKB].
side.
9.3 to 14.1
V
a 12 V power supply
Voltage

a LIN communication line
Approx. 9 V
4 to 6.1 V
a 5 V power supply
If no failure is found by check on cause 4, LED unit of machine monitor
is defective.
6
7
Defective LED unit of machine

a When not using T-adapter for connector MDM2 (070-6), if no failure
monitor
is found by checks on causes 2 and 3, replace LED unit of machine
monitor to check whether LED unit is defective.
defective.
If you cannot perform check on cause 4 for some reason, take it that
wiring harness is defective.
40-898
WA470-7
40 Troubleshooting
Wiring harness between monitor controller and LED unit of machine monitor
Circuit diagram between monitor controller and LED unit of machine monitor
WA470-7
40-899
40 Troubleshooting
E-12 LED of switch panel on machine monitor is abnormal or switches

does not operate properly (WA500_7-FHE-400-A-Z0-A)
Failure
Related information
No.
Night lighting lamp of switch panel on machine monitor does not light up, or does not
go out.
Switch of switch panel of machine monitor does not work.
a Machine monitor connector MOM1 is a 070 type connector with 6 pins, and Tadapter for this connector is newly developed.
Cause
3. Visually check connector of wiring harness connected to switch
panel of machine monitor and connector of monitor controller, and
connector.
line
system
side.
9.3 to 14.1
V
a 12 V power supply
Voltage
Defective switch panel of

machine monitor
40-900

Approx. 9 V
4 to 6.1 V
a 5 V power supply
If no failure is found by check on cause 4, switch panel of machine
monitor is defective.
a When not using T-adapter for connector MOM1 (070-6), if no failure
is found by checks on causes 2 and 3, replace switch panel of
machine monitor to check whether switch panel is defective.
defective.
WA470-7
40 Troubleshooting
Wiring harness between monitor controller and switch panel of machine monitor
Circuit diagram between monitor controller and switch panel of machine monitor
WA470-7
40-901
40 Troubleshooting
E-13 Two switches operation of switch panel on machine monitor does

not function (WA500_7-FHF-400-A-Z0-A)
Failure
Related information
No.
Two switches operation of switch panel on machine monitor does not function
Cause
connector.
line
system
side.
a "Simultaneous operation of up and down switch" denotes turning on

Up switch (A) and Down switch (B) at the same time. (See
description of LCD check function in Testing and adjusting, "Special
functions of machine monitor".)
9.3 to 14.1
V
a 12 V power supply
Voltage
a 5 V power supply
Approx. 9 V
4 to 6.1 V
When Up and Down

switches are not
Max. 0.2 V
operated
simultaneously
When Up and Down
Between MOM1
switches are operated Min. 2.2 V
simultaneously
Between MOM1

machine monitor
40-902

WA470-7
40 Troubleshooting
No.
Cause

defective.
WA470-7
40-903
40 Troubleshooting
40-904
WA470-7
40 Troubleshooting
E-14 Switch panel buzzer of machine monitor is abnormal

Failure
Related information
No.
6
7
(WA500_7-FHG-400-A-Z0-A)
Switch panel buzzer of machine monitor does not sound or does not stop sounding.
Cause
connector.
line
system
side.
9.3 to 14.1
V
a 12 V power supply
Approx. 9 V
4 to 6.1 V
a 5 V power supply
Between MOM1
When turning on
Max. 0.2 V
buzzer
Between MOM1
When turning off
7 to 15 V
buzzer
machine monitor
defective.
WA470-7
40-905
40 Troubleshooting
40-906
WA470-7
40 Troubleshooting
E-15 Rear view monitor does not light up or backlight flickers
(WA380_7-FHH-400-A-
Z0-A)
Rearview monitor does not light up or backlight flickers.

Failure
Related information
No.
1
5
6

Defective fuse 3 in fuse box 2 4.)
Cause
3. Visually check connector (RVM1) of wiring harness connected to
rearview monitor, and repeat connection and disconnection of
connector.
connector.
side.
20 to 30 V
Voltage
Between
RVM1
(female)
(12)
and
(2)
20 to 30 V
3. Disconnect connectors RVM1 and S_FS, and connect T-adapters to
each female side.
4. Remove fuse 3 in fuse box 2 (FS9).
Between RVM1 (female) (1) and FS9-3
Max. 1 z
Resis- Between RVM1 (female) (2) and ground
Max. 1 z
tance
Between RVM1 (female) (12) and S_FS
Max. 1 z
(female) (4)
side.
Resis- Between ground and RVM1 (female) (1) or
Min. 1 Mz
tance
FS9-3
If no failure is found by above checks, rearview monitor may be
Defective rearview monitor
defective.
WA470-7
40-907
40 Troubleshooting
Circuit diagram related to rearview monitor power supply
40-908
WA470-7
40 Troubleshooting
Wiring harness of rearview monitor
WA470-7
40-909
40 Troubleshooting
E-16 Rear view monitor images are not displayed clearly

Failure
Related
information
No.
Rearview monitor images are not displayed clearly.

a Rearview monitor connector RVM2 is a 070 type connector with 8 pins, and T-adapter for
this connector is newly developed.
Cause
Defective harness
connector

harness
(wire breakage or
connector)
Defective rearview
monitor
40-910
(WA380_7-FHJ-400-A-Z0-A)

3. Visually check connectors (RVM1) and (RVM2) of wiring harness
connected to rearview monitor, and repeat connection and disconnection
of connectors.
connector.
3. Disconnect connector RVM1, and connect T-adapters to female side.
20 to 30 V
Voltage
20 to 30 V
3. Disconnect connectors RVM1 and S_FS, and connect T-adapters to each
female side.
Between RVM1 (female) (1) and FS9-3
Max. 1 z
Between RVM1 (female) (2) and ground
Max. 1 z
Resistance
Between RVM1 (female) (12) and S_FS (female)
Max. 1 z
(4)
3. Insert T-adapter into connector RVM1.
4. Disconnect connector RVM2 and connect T-adapters to male side.
Between RVM2 (male) (1) and RVM1 (2)
8 0.8 V
Between
RVM2
(male)
(5)
and
RVM1
(2)
Max. 0.2 V
Voltage
Max. 0.2 V
Between RVM2 (male) (8) and RVM1 (2)
WA470-7
40 Troubleshooting
No.
5
6
Cause

harness
(wire breakage or
connector)
Defective rearview
camera
Defective wiring
harness or rearview
monitor

2. Disconnect connector G06 and connect T-adapters to female side.
Voltage Between G06 (female) (1) and (4)
8 0.8 V
2. Disconnect connectors G06 and RVM2, and connect T-adapters to each
female side.
Between G06 (female) (1) and RVM2 (female) (1)
Max. 1 z
Between G06 (female) (2) and RVM2 (female) (2)
Max. 1 z
Resistance
Between G06 (female) (4) and RVM2 (female) (5),
Max. 1 z
(8)
If no failure is found by above checks, rearview camera may be defective.
If T-adapter is not available, take it that wiring harness or rearview monitor is
defective.
WA470-7
40-911
40 Troubleshooting
Circuit diagram related to rearview monitor power supply
40-912
WA470-7
40 Troubleshooting
E-17 Rear view monitor brightness cannot be adjusted
(WA380_7-FHK-400-A-Z0-A)
Rearview monitor brightness cannot be adjusted.

Failure
Related information
No.
1
Cause
Defective fuse 11 in fuse box
1 (FS8)

If fuse is blown, circuit may have ground fault. (See check on cause 5.)
rearview monitor, and repeat connection and disconnection of
connector.
connector.
3. Visually check connector (S_RV) of wiring harness connected to
brightness switch, and repeat connection and disconnection of
connector.
connector.
side.
Brightness adjustment
Between RVM1
Max. 0.2 V
switch (+): OFF
Between RVM1
20 to 30 V
switch (+): ON
Voltage
Between RVM1
Max. 0.2 V
switch (-): OFF
(female)
(6)
and
(2)
Between RVM1
20 to 30 V
switch (-): ON
(female)
(6)
and
(2)
3. Disconnect connectors RVM1 and S_RV, and connect T-adapters to
each female side.
4. Remove fuse No. 11 in fuse box 1 (FS8).
Between S_RV (female) (5) and FS8-11
Max. 1 z
Between S_RV (female) (4) and RVM1
Resis- (female) (5)
Max. 1 z
tance
Between S_RV (female) (6) and RVM1
Max. 1 z
(female) (6)
If no failure is found by above checks, rearview monitor is defective.
WA470-7
40-913
40 Troubleshooting
No.
Cause
3. Disconnect connectors RVM1 and S_RV, and connect T-adapters to
female side of S_RV.
4. Remove fuse No. 11 in fuse box 1 (FS8).
ResisBetween ground and S_RV (female) (5) or
Min. 1 Mz
tance
FS8-11
Between S_RV (female) (4) and ground
Min. 1 Mz
Between S_RV (female) (6) and ground
Min. 1 Mz
Defective brightness
adjustment switch

2. Remove brightness adjustment switch.
Between S_RV (male) Brightness adjustment
Min. 1 Mz
switch (+): OFF
(5) and (4)
Max. 1 z
switch (+): ON
Resis- (5) and (4)
tance
Min. 1 Mz
switch (-): OFF
(5) and (6)
Max. 1 z
switch (-): ON
(5) and (6)
Defective brightness
adjustment switch, wiring
harness, or rearview monitor
If T-adapter is not available, take it that brightness adjustment switch,

wiring harness, or rearview monitor is probably defective.
40-914
WA470-7
40 Troubleshooting
Circuit diagram related to brightness adjustment switch of rearview monitor
WA470-7
40-915
40 Troubleshooting
E-18 Night lighting lamp of rear view monitor is abnormal
(WA380_7-FHL-400-A-Z0-A)
Night lighting lamp of rearview monitor is abnormal.

Night lighting lamp of rearview monitor lights up only when clearance lamp is turned
on while monitor brightness selector switch is at the night mode.
Related information
Check whether night lighting lamp of meter unit of machine monitor is also unusual.
Failure
No.
Cause

rearview monitor and connector of night lighting switch, and repeat
connection and disconnection of connectors.
connector.
a If night lighting lamp of meter unit lights up, this check is not
required.
Defective monitor brightness 2. Disconnect connector S_F7 and connect T-adapter to male side.
selector (night lighting) switch
Between S_F7 (male)
Brightness selector
Min. 1 Mz
switch: OFF
Resis- (5) and (4)
tance
Between S_F7 (male)
Brightness selector
Max. 1 z
(5) and (4)
switch: ON

40-916
side.
Between RVM1
Max. 0.2 V
OFF
Voltage
Between RVM1
20 to 30 V
ON
3. Disconnect connectors RVM1, S_F7, S_RV, and connect Tadapters to each female side.
Between S_F7 (female) (4) and RVM1
Max. 1 z
Resis- (female) (8)
tance
Between L04 (female) (2) and S_F7 (female)
Max. 1 z
(5)
If no failure is found by check on cause 3, rearview monitor is defective.
a When not using T-adapter for connector RVM1 (070-12)
3. Turn on night lighting switch.
If night lighting of LCD unit , meter unit, LED unit, and switch panel of
machine monitor is normal, rearview monitor is defective.
WA470-7
40 Troubleshooting
Circuit diagram related to night lighting switch of rearview monitor
WA470-7
40-917
40 Troubleshooting
E-19 Some items of gauges and caution lamps on machine monitor are
not displayed properly (WA500_7-FHP-400-A-Z0-A)
Some gauges and caution lamps are not displayed normally.
If mechanical system failure code is displayed, perform troubleshooting for that code
Related information
first.
Failure
No.
1
2
3

Perform troubleshooting for failure code related to defective sensor or
Defective sensor or switch
switch.
Defective CAN communication Perform troubleshooting for failure code related to defective CAN
system
communication.
If no failure is found by above checks, machine monitor is defective.
Defective machine monitor
40-918
Cause
WA470-7
40 Troubleshooting
E-20 Parking brake indicator lamp does not light when the parking brake
is set to ON (Parking) position (WA500_7-HP6-400-A-Z0-A)
k Be
sure to chock the wheels. When performing troubleshooting with parking brake released, be
sure to depress foot brake pedal (two persons required for this work).
Failure
Related
information
No.
Parking brake indicator lamp does not light when the parking brake is set to ON (Parking)
position.
Short circuit or ground fault of parking brake indicator switch circuit
The parking brake detector circuit (MCM1 A (71 pin)) is at GND level even when the
parking brake switch is operated.
The parking brake does not apply.
If normal, the parking brake indicator (oil pressure) switch turns OFF when the parking
brake switch is set to ON (Parking) because oil pressure will not act on the switch.
For operation of parking brake relay (L120), see failure code [2F00MA].
Make sure that fuse No. 3 of fuse box 1 is not blown.
Input signal (ON/OFF) from the parking brake indicator switch can be checked with
monitoring function (Code: 04510 Parking Brake Press SW).
Input signal (ON/OFF) (neutralizer signal) from the parking brake switch can be checked
with monitoring function (Code: 02215 Parking Brake Switch).
See E-33.
Cause
Defective parking brake relay

(L120)
Defective auto-idle stop

parking brake relay L133

indicator switch
WA470-7
1.
2.
3.
4.
5.

Interchange relay L120 with horn relay L119.
Turn the parking brake switch to the Parking position.
Start engine.
If parking brake indicator lamp lights up, original relay L120 is
defective.
4. Turn the parking brake switch to the Parking position.
5. Start engine.
If parking brake indicator lamp lights up, original relay L133 is
defective.
2. Disconnect connector PB.SW and connect T-adapters to female
side.
Between PB.SW (male) (1) and (2)
Min. 1 Mz
ResisBetween ground and each of PB.SW
tance
Min. 1 Mz
(male) (1) and (2)
40-919
40 Troubleshooting
No.
Cause

2. Disconnect connectors L62 and L63, and insert T-adapters into
them.
Parking brake
20 to 30 V
switch: Release
Between L62 (6) and
Voltage
L63 (31)
Parking brake
Max. 3 V
switch: Parking
Parking brake oil pressure switch line
2. Disconnect connectors MCM1 A and PB.SW, and connect Tadapters to each female side.
Between MCM1 A (female) (71) and PB.
Max. 1 z
Resis- SW (female) (1)
tance
Between PB.SW (female) (2) and ground
Max. 1 z
Parking brake solenoid line
2. Disconnect connector PB.PS and connect T-adapters to female
side.
Parking brake
20 to 30 V
Between PB.PS (1) and switch: Release
Voltage
(2)
Parking brake
Max. 3 V
switch: Parking
Open circuit, short circuit, or

hot short circuit in wiring
harness

Ground fault in wiring harness 2. Disconnect connectors MCM1 A and PB.SW, and connect Tadapters to either female side.
Resis- Between ground and MCM1 A (female)
Min. 1 Mz
tance (71) or PB.SW (female) (1)

switch

solenoid

2. Connect T-adapters to connector S_FA (male).
3. Start engine.
Parking brake
switch: Release
Between S_FA (male)
(3) and (4)
Parking brake
switch: Parking
Resistance
Parking brake
switch: Release
Between S_FA (male)
(5) and (6)
Parking brake
switch: Parking
Max. 1 z
Min. 1 Mz
Min. 1 Mz
Max. 1 z

2. Disconnect connector PB.PS and connect T-adapters to male side.
20 to 60 z
Resis- Between PB.PS (male) (1) and (2)
tance Between PB.PS (male) (1) and ground
Min. 1 Mz
2. Disconnect connector DIODE, and connect T-adapters to diode.
Defective diode DIODE

(internal open or short circuit) a Check by using multimeter in diode range.
Continu- Between DIODE (male) (1) (+) and (2) (-)
ity
Between DIODE (male) (2) (+) and (1) (-)
40-920
No continuity
Continuity
WA470-7
40 Troubleshooting
No.
Cause
controller

10 hydraulic circuit
WA470-7

Parking brake
Voltage
Max. 4.5 V
switch: Parking
(31)
Check parking brake oil pressure. (See "Testing and adjusting".)
a Start engine and perform troubleshooting.
0.34 MPa {3.5
Parking brake
Parking brake pressure
kg/cm2 } Max
switch: ON.
40-921
40 Troubleshooting
40-922
WA470-7
40 Troubleshooting
E-21 When brake accumulator oil pressure drops, the brake oil pressure
caution lamp does not light (WA470_7-FP7-400-A-Z0-A)
Failure
Related
information
No.
When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not
light.
Short circuit or ground fault of front brake accumulator pressure switch
If normal, the brake accumulator pressure switch turns OFF when the brake oil pressure
drops.
When front brake accumulator oil pressure drops, the brake oil pressure caution lamp
does not light.
Input signal (ON/OFF) from the front brake accumulator pressure switch can be checked
with monitoring function (Code: 04510 "Front Brake Oil Press").
Cause
Defective front brake

accumulator pressure
switch (internal short
circuit)

2. Make sure that the brake oil pressure is 3.9 MPa {40 kg/cm2} or lower.
Min. 1 Mz
Resistance
Between R52 (male) (1) and ground
Min. 1 Mz

harness
circuit)

2. Disconnect connectors MCM1 A and R52, and connect T-adapters to
either female side.
Between ground and MCM1 A (female) (73) or R52
Min. 1 Mz

harness
Defective monitor
controller
WA470-7

either female side.
Between MCM1 A (female) (73) and (17), or
Resistance between R52 (female) (1) and (2)
Min. 1 Mz
40-923
40 Troubleshooting
Failure
Related
information
No.
When the rear brake accumulator oil pressure drops, the brake oil pressure caution lamp
does not light.
Short circuit or ground fault of rear brake accumulator pressure switch
If normal, the brake accumulator pressure switch turns OFF when the brake oil pressure
drops.
When the rear brake accumulator oil pressure drops, the brake oil pressure caution lamp
does not light.
Input signal (ON/OFF) from the rear brake accumulator pressure switch can be checked
with monitoring function (Code: 04510 "Rear Brake Oil Press").
Cause

accumulator pressure
switch (internal short
circuit)

2. Make sure that the brake oil pressure is 3.9 MPa {40 kg/cm2} or lower.
Min. 1 Mz
Resistance
Min. 1 Mz

harness
circuit)

2. Disconnect connectors MCM1 A and R54, and connect T-adapter to either
female side.
Min. 1 Mz

harness
Defective monitor
controller

either female side.
Resistance between R54 (female) (1) and (2)
Min. 1 Mz
40-924
WA470-7
40 Troubleshooting
E-22 Air cleaner clogging indicator lamp does not light

Failure
General
information
No.
(WA470_7-HP1-400-A-Z0-A)
When the air cleaner is clogged, air cleaner clogging indicator lamp does not light up.
Ground fault in dust indicator circuit
When the air cleaner is clogged, its sensor circuit is held to the "CLOSE" (not clogged)
state.
Voltage at MCM1 A (53) is GND level when air cleaner is normal, and 16 to 24 V when air
function. (Code: 04509 Air cleaner clogging sensor).
Cause

clogging sensor

2. Disconnect connector E45, and connect T-adapter to male side.
Max. 1 z
Resistance Between E45 (1) and (2)
Min. 1 Mz

harness
circuit)

2. Disconnect connectors MCM1 A and E45, and connect T-adapter to either
female side.
Between ground and MCM1 A (female) (53) or E45
Min. 1 Mz

harness

female side.
Resistance between E45 (female) (1) and (2)
Min. 1 Mz
Defective monitor
controller

Max. 1 V
16 to 24 V
WA470-7
40-925
40 Troubleshooting
E-23 Radiator coolant level caution lamp does not light

Failure
Related
information
No.
When the radiator coolant (or cooling water) is insufficient, the radiator coolant level caution
Short circuit or ground fault of coolant level sensor
When the radiator coolant (or cooling water) is insufficient, both radiator coolant level
sensor is closed (normal).
(The engine may be damaged.)
Input signal (ON/OFF) from coolant level sensor can be checked with monitoring function.
(Code: 04509 Engine coolant level sensor)
Defective radiator
coolant level switch

harness
circuit)
Cause

harness
Defective monitor
controller

2. Disconnect connector R32, and connect T-adapters to each male side.
Radiator coolant level
Max. 1 z
Between R32 (male) (1)
normal
Resistance and (2)
Min. 1 Mz
low
2. Disconnect connectors MCM1 A, R32, and connect T-adapter to either
female side.
Min. 1 Mz
Min. 1 Mz
Between
MCM1
A
(female)
(48)
and
(13)
Resistance
Min. 1 Mz
Min. 1 Mz
2. Insert T-adapters into connector R32.
Voltage
40-926
(WA380_7-HP2-400-A-Z0-A)
Between R32 (1) and (2)

normal
low
Max. 1 V
16 to 24 V
WA470-7
40 Troubleshooting
Circuit diagram related to radiator coolant level sensor
WA470-7
40-927
40 Troubleshooting
E-24 Indication of hydraulic oil temperature gauge does not increase, or

hydraulic oil temperature caution lamp does not light (WA470_7-BE4-400-A-Z0-A)
Failure
Related
information
No.
Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil
temperature caution lamp does not light.
Open circuit of hydraulic oil temperature sensor
When the hydraulic oil temperature increases, the indication of hydraulic oil temperature
gauge does not increase.
When the hydraulic oil temperature exceeds 110C, the hydraulic oil temperature caution
Input voltage from hydraulic oil temperature sensor can be checked with monitoring
function.
(Code: 04404 Hydraulic Oil Temperature Sensor Voltage)
Oil temperature sensed by hydraulic oil temperature sensor can be checked with
(Code: 04401 Hydraulic Oil Temperature)
Cause

temperature sensor

Hydraulic oil
Between
35 to 50 kz *
(room temperature)
Resistance R47 (male)
(1) and (2)
Hydraulic oil
3.1 to 4.5 kz *
temperature: 100C

wiring harness

Hydraulic oil
Between
35 to 50 kz
L61
(room temperature)
Resistance (female)
Hydraulic oil
(20) and (4)
3.1 to 4.5 kz
temperature: 100C

harness
(wire breakage or
connector)
controller

female side.
Max. 1 z
Resistance
Max. 1 z
*: For average resistance of sensors at each temperature, see [DGR2KB].
40-928
WA470-7
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
WA470-7
40-929
40 Troubleshooting
E-25 Indication of torque converter oil temperature gauge does not

increase, or torque converter oil temperature caution lamp does not
light (WA500_7-BE3-400-A-Z0-A)
Failure
Related
information
No.
1
Indication of torque converter oil temperature gauge does not increase, or torque converter
oil temperature caution lamp does not light.
Open circuit of torque converter oil temperature sensor
When the torque converter oil temperature increases, the indication of torque converter oil
temperature gauge does not increase.
When the torque converter oil temperature exceeds 120C, the torque converter oil
temperature caution lamp does not light.
Input status (oil temperature) from torque converter oil temperature sensor can be
checked with monitoring function.
(Code: 32100 T/C Oil Temperature)
Input status (voltage) from torque converter oil temperature sensor can be checked with
Cause
Defective torque converter oil
temperature gauge
40-930

Troubleshoot for failure code [DGT1KA].
WA470-7
40 Troubleshooting
E-26 Fuel level gauge does not indicate correct level

Failure
Related
information
No.
(WA470_7-FGB-400-A-Z0-A)
Fuel level gauge does not indicate correct level.

Input voltage from fuel level sensor can be checked with monitoring function.
(Code: 04200 Fuel Level Sensor [V])
Cause
Defective fuel level

sensor
circuit)

2. Disconnect connector R33, and connect T-adapters to male side.
FULL
Max. 12 z
EMPTY 80 to 100 z
Resistance a Fuel level sensor characteristics
Min. 1 Mz
Open circuit, short

a If voltage is 0 V, wiring harness has open circuit, ground fault, or short
circuit, or ground fault in
circuit, and if voltage is 24 V, wiring harness has hot short circuit.
wiring harness
a Voltage of approximately 3.3 V is applied to fuel level sensor signal line
through resistor inside monitor controller.
Approx. 3.3
V

wiring harness
a Use fuel level sensor characteristics table for check on cause 1 as

resistance criteria.
a If resistance is 1 Mz or higher, harness has open circuit. If it is 1 z or
below, harness has short circuit.
Approx. 4 to
Resistance Between MCM1 A (female) (8) and (9)
100 z

harness
(wire breakage or
connector)

female side.
Max. 1 z
(1)
Resistance
Max. 1 z
(2)

harness
circuit)

2. Disconnect connectors MCM1 A and R33, and connect T-adapter to either
female side.
Min. 1 Mz

harness
Defective monitor
controller
WA470-7

female side of MCM1 A.
Between MCM1 A (female) (8) and
Continuity
No continuity
(No sound is heard)
40-931
40 Troubleshooting
Circuit diagram related to fuel level sensor
40-932
WA470-7
40 Troubleshooting
E-27 Seat belt caution lamp indication is abnormal
(WA500_7-FHQ-400-A-Z0-A)
Seat belt caution lamp lights up even when seat belt is fastened, or caution lamp does
not light up when seat belt is not fastened.
Related information
first.
Failure
No.
Defective seat belt switch

Cause

2. Connect T-adapters to connector SBS (male).
3. Check switch itself.
When seat belt is
Max. 1 z
Between SBS (male) fastened
Resis(1)
and
(2)
tance
When seat belt is not
Min. 1 Mz
fastened
2. Disconnect connectors MCM1 A and SBS, and connect T-adapters
Between MCM1 A (female) (29) and SBS
Max. 1 z
Resis- (female) (1)
tance
Between MCM1 A (female) (13) and SBS
Max. 1 z
(female) (2)

Ground fault in wiring harness 2. Disconnect connectors MCM1 A and SBS.
3. Connect T-adapter to MCM1 A.
Resis- Between ground and MCM1 A (female) (29) or
Min. 1 Mz
SBS (female) (1)
tance
Reference
2. Insert T-adapters into connector SBS.
When seat belt is
Max. 1 V
Between SBS (1) and fastened
Voltage
(2)
When seat belt is not
7 to 9 V
fastened
Circuit diagram related to seat belt switch
WA470-7
40-933
40 Troubleshooting
E-28 Horn does not sound

Failure
Related
information
No.
1
(WA470_7-KA2-400-A-Z0-A)
Horn does not sound.

Cause
Defective fuse 1 in fuse If fuse 1 in fuse box 1 is blown, circuit probably has ground fault. In this case,
box 1
Defective horn relay

circuit)

2. Replace horn relay (connector: L119) with another relay.
4. Sound horn.
If horn sounds, original horn relay is defective.
Defective horn switch

circuit)

2. Disconnect connector S_RHA and connect T-adapters to each male side.
Between S_RHA (male)
Switch: OFF
Min. 1 Mz
Resistance
(1) and (2)
Switch: ON
Max. 1 z
Defective horn high

sound (F03) or horn low 2. Disconnect connectors F03 and F04.
sound (F04) (internal
Continuity Between F03 (male) (1) and (2)
Continuity Between F04 (male) (1) and (2)
Defective wiring
harness

harness
(wire breakage or
connector)
40-934
Continuity
Continuity
1.
2.
3.
4.

Press horn switch.
20 to 30 V
Voltage
20 to 30 V

2. Disconnect connectors L119, F03, F04, and connect T-adapters to each
female side.
3. Press horn switch.
Between F03 (female) (1) and ground
Continuity
Continuity Between F04 (female) (1) and ground
Continuity
Continuity
a
1.
2.
3.
If no failure is found in above checks, this check is not required.

Remove fuse 1 in fuse box 1.
Disconnect connectors L119 and S_RHA, and connect T-adapters to each
female side.
Between FS8-1 and L119 (female) (1)
Max. 1 z
Max. 1 z
Resistance Between S_RHA (female) (1) and L119 (female) (2) Max. 1 z
Max. 1 z
Between S_RHA (female) (2) and ground
WA470-7
40 Troubleshooting
No.
Cause

harness
circuit)
Defective horn
(internal defect)
WA470-7
a
1.
2.
3.
If fuse is not blown, this check is not required.

Remove fuse 1 in fuse box 1.
Disconnect connectors L119, F03, F04, and connect T-adapters to female
side of L119.
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
If no failure is found by above checks, horn may be defective.
40-935
40 Troubleshooting
Circuit diagram related to horn
40-936
WA470-7
40 Troubleshooting
E-29 Horn does not stop sounding

Failure
Related
information
No.
1
Horn does not stop sounding.
Cause
Defective horn relay
(L119)
circuit)

wiring harness
WA470-7
(WA470_7-KB2-400-A-Z0-A)

2. Remove horn relay (connector L119).
If horn stops sounding, original horn relay is defective.
2. Disconnect connectors F03 and F04, and connect T-adapters to each
female side.
Between F03 (female) (2) and (1)
Max. 1 V
Voltage
Between F04 (female) (2) and (1)
Max. 1 V
40-937
40 Troubleshooting
Circuit diagram related to horn
40-938
WA470-7
40 Troubleshooting
E-30 Alarm buzzer does not sound

Failure
Related
information
No.
(WA380_7-KA7-400-A-Z0-A)

Open circuit or ground fault of alarm buzzer output circuit
Output state (ON/OFF) from the alarm buzzer to the machine monitor can be checked
with monitoring function.
(Code: 04700 Buzzer)
If failure code [DV00KB] (alarm buzzer short circuit) is displayed, troubleshoot it first.
Cause

1
Defective alarm buzzer a If following voltages are normal and alarm buzzer does not sound, alarm
buzzer is defective.
Alarm buzzer: OFF
Max. 1 V
When
driving
alarm
Voltage
(1) and (2)
20 to 30 V
engine)

harness
(wire breakage or
connector)

2. Disconnect connectors MCM1 A and L20, and connect T-adapters to each
female side.
Max. 1 z
Resistance (1)
Max. 1 z

harness
circuit)

2. Disconnect connectors MCM1 A and L20, and connect T-adapter to either
female side.
Between ground and MCM1 A (female) (20) or L20
Min. 1 Mz
Defective monitor
controller
Circuit diagram related to alarm buzzer
WA470-7
40-939
40 Troubleshooting
E-31 When starting switch is in ON position, alarm buzzer does not stop
sounding (WA470_7-KB3-400-A-Z0-A)
Failure
Related
information
No.
When starting switch is in ON position, alarm buzzer does not stop sounding.
If any failure code is displayed, perform troubleshooting for that code first.
Signal (ON/OFF) to alarm buzzer can be checked with monitoring function.
(Code: 04700 Buzzer)
Cause

wiring harness

Under condition that
alarm buzzer does not
Max. 1 V
sound
Voltage
For approx. 1 second
after starting switch is
Min. 20 V
turned to ON position
Defective monitor
controller
Circuit diagram related to alarm buzzer
40-940
WA470-7
40 Troubleshooting
E-32 Kickdown does not work when kickdown switch is turned ON
(WA380_7-
F80-400-A-Z0-A)
Failure
Kickdown does not work when kickdown switch is turned ON.

Open circuit or hot short circuit kickdown system
function
Related information
(Code: 02212 Kick Down Switch)
If failure code [DDW9LD] is displayed, troubleshoot it first.
No.
Cause
Defective kickdown switch


Between L14 (male) Kickdown switch: ON Max. 1 z
(1) and (2)
Kickdown switch: OFF Min. 1 Mz
Resistance
Between ground and each of L14 (male) (1)
Min. 1 Mz
and (2)


each female side.
Resis- Between L63 (female) (9) and L14 (female) (1) Max. 1 z
tance
Max. 1 z

harness

7 to 9 V
controller

Between L63 (9) and Kickdown switch: ON
Voltage
ground
WA470-7
Max. 1 V
7 to 9 V
40-941
40 Troubleshooting
40-942
WA470-7
40 Troubleshooting
E-33 The hold switch does not work when it is pressed
(WA380_7-F90-400-A-Z0-A)
The hold switch does not work when it is pressed.

Open circuit or hot short of hold switch system
The hold switch cannot be switched.
Input condition (ON/OFF) from the hold switch can be checked with monitoring
Related information
function
(Code: 02212 Hold Switch)
If failure code [DDWLLD] is displayed, troubleshoot it first.
Failure
No.
Cause
Defective hold switch


Between L14 (male)
Hold switch: ON
Max. 1 z
(3) and (4)
Hold switch: OFF
ResisMin. 1 Mz
tance
Between ground and each of L14 (male) (3)
Min. 1 Mz
and (4)


each female side.
Max. 1 z
(3)
tance

harness

7 to 9 V
controller

Hold switch: ON
Voltage
ground
Hold switch: OFF
WA470-7
Max. 1 V
7 to 9 V
40-943
40 Troubleshooting
40-944
WA470-7
40 Troubleshooting
E-34 Parking brake does not work even if it is applied, or the brake drags
when parking brake is released and FR drive is operated (WA470_7-BHM-400-A-Z0-A)
k Be
sure to chock wheels. When performing troubleshooting with parking brake released, be sure
to depress the brake pedal (two persons required for this work).
Failure
Related
information
No.
1
Parking brake does not work even if it is applied, or the brake drags when parking brake is
released and FR drive is operated.
Input signal (ON/OFF status) from the neutralizer (parking brake) switch can be checked
with monitoring function (Code: 02215 Parking Brake Switch).
Parking brake relay L120 works as self-holding relay.
1. When parking brake switch is operated, pin 5 and pin 6 of parking brake switch are
connected with each other.
2. Parking brake relay is engaged and L120 works as self-holding relay.
3. When parking brake switch is set to Release position, pin 3 and pin 4 of parking brake
are connected with each other. Since L120 remains engaged, power is supplied to pin
4 of parking brake switch and then flows to L62 (6) pin of transmission controller.
4. If voltage of L62 (6) pin goes to 20 V or above, transmission controller drives parking
brake solenoid from L63 (18) pin (parking brake is released).
See E-20, failure code [2F00MA].

Cause
Defective fuse 3 in fuse If fuse is blown, the circuit may be opened or shorted. (See Cause 6.)
box 1
Defective parking brake 3. Turn starting switch to ON position.
relay (L120)
5. Start engine.
If parking brake indicator lamp lights up, original relay L120 is defective.
Defective auto-idle stop 2. Interchange relay L133 with horn relay L119.
parking brake relay
L133
5. Start engine.
If parking brake indicator lamp lights up, original relay L133 is defective.
Defective parking brake 2. Disconnect connector PB.PS and connect T-adapters to male side.
solenoid
Between PB.PS (male) (1) and (2)
20 to 60 z
Resistance
Between PB.PS (male) (1) and ground
Min. 1 Mz
2. Disconnect connector DIODE, and connect T-adapters to diode.
Defective diode DIODE a Check by using multimeter in diode range.

circuit)
Continuity
WA470-7
No
continuity
Continuity
40-945
40 Troubleshooting
No.
Cause

2. Disconnect connector S_FA and connect T-adapter to male side.
3. Start engine.
Max. 1 z
and (4)
switch
Min. 1 Mz
Parking
Resistance
Min. 1 Mz
and (6)
Max. 1 z
Parking
2. Disconnect connectors L62 and L63, and insert T-adapters into them.
20 to 30 V
Between L62 (6) and L63 Release
Voltage
(31)
Max. 3 V
Open circuit, short
Parking
circuit, or hot short
circuit in wiring harness Parking brake solenoid line
2. Disconnect connector PB.PS and connect T-adapters to female side.
20 to 30 V
Between PB.PS (female) Release
Voltage
(1) and (2)
Max. 3 V
Parking

harness
circuit)
controller

2. Disconnect connectors L62, L120, S_FA, and connect T-adapters to either
female side.
Between ground and L62 (female) (8) or S_FA
Min. 1 Mz
(female) (3)
Resistance Between S_FA (female) (4) and ground
Min. 1 Mz
Between S_FA (female) (6) and ground
Min. 1 Mz
Voltage
Parking
(31)
Check parking brake oil pressure. (See "Testing and adjusting".)
Defective parking brake a Start engine and perform troubleshooting.

10 hydraulic circuit
Parking brake pressure
Release
40-946
Max. 4.5 V
Max 2.5
MPa {25.5
kg/cm2 }
WA470-7
40 Troubleshooting
WA470-7
40-947
40 Troubleshooting
E-35 Transmission cut-off mode is not selected or not released
(WA380_7-FA2-
400-A-Z0-A)
Failure
Related
information
No.
Transmission cut-off mode is not selected or not released.

Defective transmission cut-off switch system
Input condition (ON/OFF) from transmission cut-off switch can be checked with monitoring
function (Code: 02214 T/M Cut Off Switch).
Cause
open circuit or short
circuit)

harness
(wire breakage or
connector)

Turn transmission cut-off
Max. 1 z
switch: ON
(5) and (6)
Min. 1 Mz
Resistance
switch: OFF
Min. 1 Mz
(6)
2. Disconnect connectors L63 and S_RH1, and connect T-adapters to each
female side.
Resistance Between L63 (female) (20) and S_RH1 (female) (6)
Max. 1 z

wiring harness

Voltage Between S_RH1 (female) (6) and ground
7 to 9 V

harness
circuit)

female side.
Min. 1 Mz
controller

Turn transmission cut-off
switch: ON
Voltage
ground
switch: OFF
40-948
Max. 1 V
7 to 9 V
WA470-7
40 Troubleshooting
WA470-7
40-949
40 Troubleshooting
E-36 Transmission cut-off setting cannot be released

Failure
Related
information
(WA380_7-E21-400-A-Z0-A)
Transmission cut-off setting cannot be released.

Open circuit or hot short circuit of transmission cut-off set switch
Input condition (ON/OFF) from transmission cut-off set switch can be checked with
monitoring function (Code: 02214 T/M Cut Off Switch).
If failure code [DDT4LD] is displayed, troubleshoot it first.
Cause
Defective transmission cut-off

set switch

2. Disconnect connector S_RH1, and connect T-adapters to male
side.
Max. 1 z
Between S_RH1
set switch: ON
(male) (4) and (5)
ResisMin. 1 Mz
set switch: OFF
tance
Min. 1 Mz
and (5)


2. Disconnect connectors L63 and S_RH1, and connect T-adapters to
each female side.
Resis- Between L63 (female) (30) and S_RH1
Max. 1 z
(female) (4)
tance

harness

2. Disconnect connector S_RH1 and connect T-adapter to female
side.
7 to 9 V


2. Disconnect connectors L63 and S_RH1, and connect T-adapter to
either female side.
Resis- Between ground and L63 (female) (30) or
Min. 1 Mz
S_RH1 (female) (4)
tance
controller

set switch: ON
Voltage
ground
set switch: OFF
No.
40-950
Max. 1 V
7 to 9 V
WA470-7
40 Troubleshooting
WA470-7
40-951
40 Troubleshooting
E-37 Directional selector (FNR) switch mode is not selected or not

released (WA380_7-FHS-400-A-Z0-A)
Failure
Related
information
No.
Directional selector (FNR) switch mode is not selected or not released.

Defective directional selector (FNR) switch mode is not selected (due to ground failure), or
the handle mode is not selected (due to open circuit.)
The ON/OFF status of directional selector switch actuation switch can be checked with
(Code: 02214 Option FNR Switch)
Also, you can check the mounting of right directional selector (FNR) switch in the Service
mode of the monitor.
Cause
selector switch
actuation switch
circuit)
harness
(wire breakage or
connector)

Min. 1 Mz
Between S_RH5 (male) Switch: OFF
Resistance
(5) and (6)
Switch: ON
Max. 1 z
2. Disconnect connectors L62 and S_RH5, and connect T-adapters to each
female side.
Between L62 (female) (27) and S_RH5 (female) (6) Max. 1 z
Resistance
Max. 1 z

harness
circuit)

female side.
Min. 1 Mz

wiring harness

7 to 9 V
controller

Switch: OFF
Voltage
ground
Switch: ON
40-952
7 to 9 V
Max. 1 V
WA470-7
40 Troubleshooting
Circuit diagram related to directional selector (FNR) switch
WA470-7
40-953
40 Troubleshooting
E-38 When operating engine power selection switch, engine power

selection function does not operate properly (WA380_7-E22-400-A-Z0-A)
When operating engine power selection switch, engine power selection function does
not operate properly.
Related information
first.
Failure
No.
Cause
Defective engine power

selection switch

2. Disconnect connector S_RH2 and connect T-adapters to male side.
Between S_RH2
Switch: OFF
Min. 1 Mz
Resis(male) (5) and (6)
tance
Switch: ON
Max. 1 z


2. Disconnect connectors L72 and S_RH2, and connect T-adapters to
each female side.
Between L72 (female) (37) and S_RH2
Max. 1 z
Resis- (female) (6)
tance
Max. 1 z

Ground fault in wiring harness 2. Disconnect connectors L72 and S_RH2, and connect T-adapter to
either female side.
Resis- Between ground and L72 (female) (37) or
Min. 1 Mz
S_RH2 (female) (6)
tance

harness

7 to 9 V

controller

Between L72 (female) Switch: OFF
Voltage
(37) and ground
Switch: ON
40-954
7 to 9 V
Max. 1 V
WA470-7
40 Troubleshooting
Circuit diagram related to engine power selection switch
WA470-7
40-955
40 Troubleshooting
E-39 Flow of loader pump does not increase from the minimum
rate (WA380_7-D51-400-A-Z0-A)
Failure
Related
information
No.
Flow of loader pump does not increase from the minimum rate.
The loader pump is set to the minimum flow rate due to the hot short in the loader pump
EPC solenoid circuit.
The current value of loader pump EPC solenoid can be checked with monitoring function.
(Code: 94500 Loader Pump EPC Current)
Cause

wiring harness

wiring harness
Defective work

Max. 4.5 V
5 to 10 z
40-956
WA470-7
40 Troubleshooting
E-40 ECSS function cannot be selected or cannot be released
(WA380_7-E50-400-A-
Z0-A)
Failure
Related
information
No.
ECSS function cannot be selected or cannot be released.

Defective ECSS (Electronically Controlled Suspension System) operating switch system
(The ECSS function cannot be selected due to hot short, or the ECSS function cannot be
released due to ground fault).
Input condition (ON/OFF) from the ECSS switch can be checked with monitoring function
monitoring function (Code: 02214 E.C.S.S. Switch).
Cause

Defective ECSS switch
2. Disconnect connector S_F4 and connect T-adapter to male side.
Between S_F4 (male) Switch: OFF
Min. 1 Mz
Resis(5) and (6)
tance
Switch: ON
Max. 1 z

Open circuit in wiring harness 2. Disconnect connectors L62 and S_F4, and connect T-adapters to
each female side.
Between L62 (female) (37) and S_F4 (female)
Max. 1 z
Resis- (5)
tance
Between S_F4 (female) (6) and ground
Max. 1 z

Ground fault in wiring harness 2. Disconnect connectors L62 and S_F4, and connect T-adapter to
either female side.
Resis- Between ground and L62 (female) (37) or S_F4
Min. 1 Mz
(female) (5)
tance

harness

2. Disconnect connector S_F4 and connect T-adapter to female side.
Voltage Between S_F4 (female) (5) and ground
7 to 9 V
controller

Between L62 (37) and Switch: OFF
Voltage
ground
Switch: ON
WA470-7
7 to 9 V
Max. 1 V
40-957
40 Troubleshooting
Circuit diagram related to ECSS switch
40-958
WA470-7
40 Troubleshooting
E-41 None of headlamp, clearance lamp, and tail lamp lights
(WA470_7-HQ1-400-A-Z0-
A)
Failure
Related
information
No.
1
None of headlamp, clearance lamp, and tail lamp lights.

All lamps do not light up due to an open circuit or ground fault of lamp system main circuit.
Headlamp switch at SMALL position: The clearance lamp, tail lamp, and night lighting
lamp of machine monitor switch panel light up.
Headlamp switch at HEAD position: The clearance lamp, tail lamp, night lighting lamp,
and headlamp light up.
Input condition (ON/OFF) to machine monitor from lamp switch (clearance lamp) can be
checked with monitoring function (Code: 04507 Night Lighting SW).
Input condition (ON/OFF) to machine monitor from lamp switch (headlamp) can be
checked with monitoring function (Code: 04507 Head Light SW).
Input condition (ON/OFF) to machine monitor from dimmer switch (high beam) can be
checked with monitoring function (Code: 04507 High Beam Status).
Cause
Defective fuse 11 in
fuse box 1

2. Disconnect connector L04 and connect T-adapters to male side.
3. Operate lamp switch and perform troubleshooting.
OFF
Min. 1 Mz
SMALL,
Max. 1 z
HEAD
OFF
Min. 1 Mz
SMALL
Min. 1 Mz
HEAD
Max. 1 z
Between ground and each of L04
Always
Min. 1 Mz
(male) (1), (2), and (3)
Defective lamp switch

circuit)

harness
(wire breakage or
connector)


harness
circuit)

Between ground and fuse FS8-11 or L04 (female)
Resistance (1)
Min. 1 Mz
WA470-7
Resistance Between FS8-11 and L04 (female) (1)
Max. 1 z
40-959
40 Troubleshooting
Circuit diagram related to headlamp, clearance lamp and tail lamp
40-960
WA470-7
40 Troubleshooting
E-42 Clearance lamp and tail lamp do not light up or go out

Failure
Related
information
No.
1
(WA470_7-HQ0-400-A-Z0-A)
Clearance lamp and tail lamp do not light up or go out.

Defective switch, lamps, or wiring harness of clearance lamp and tail lamp circuits
If the headlamp and turn signal lamp light up
The power is supplied through fuse 12 in fuse box 1 to the circuits of the R.H. clearance
lamp and R.H. tail lamp.
The power is supplied through fuse 13 in fuse box 1 to the circuits of the L.H. clearance
lamp and L.H. tail lamp.
Input condition (ON/OFF) to machine monitor from lamp switch (clearance lamp) can be
checked with monitoring function (Code: 04507 Night Lighting SW).
Cause
Blown lamp (bulb)

If only a certain lamp does not light up, inspect it directly as the lamp may be
blown or have poor contact.
a For the rear side, refer to cause 7.
Defective fuses 12 and If fuse is blown, circuit may have ground fault, etc. (See check on cause 5.)
13 in fuse box 1
OFF
Min. 1 Mz
SMALL,
Max. 1 z
HEAD
circuit)
OFF
Min. 1 Mz
SMALL
Min. 1 Mz
HEAD
Max. 1 z
Always
Min. 1 Mz
(male) (1), (2), and (3)
Ground line
2. Disconnect connectors L04, LDR_L, LDR_R, COMBI (R.H. and L.H.), and
Between R.H. COMBI (female) (B) and ground
Max. 1 z
Between L.H. COMBI (female) (B) and ground
Max. 1 z
Resistance
Between LDR_R (female) (C) and ground
Max. 1 z
Between LDR_L (female) (C) and ground
Max. 1 z
Power supply line (input side of fuse)
2. Remove fuses 12, and 13 in fuse box 1 (FS8).
harness
4. Lamp switch: SMALL
(wire breakage or
Between FS8-12 and ground
20 to 30 V
Voltage
Between
FS8-13
and
ground
20 to 30 V
connector)
Power supply line
4. Lamp switch: SMALL
Between R.H. COMBI (female) (A) and (B)
20 to 30 V
Between L.H. COMBI (female) (A) and (B)
20 to 30 V
Voltage Between LDR_R (female) (B) and (C)
20 to 30 V
20 to 30 V
Between LDR_L (female) (B) and (C)
WA470-7
40-961
40 Troubleshooting
No.
Cause

harness
circuit)

2. Remove fuses 12 and 13 in fuse box 1 (FS8).
Min. 1 Mz
Between ground and R.H. COMBI (female) (A) or
Min. 1 Mz
Resistance LDR_R (female) (B)
Between ground and L.H. COMBI (female) (A) or
Min. 1 Mz
LDR_L (female) (B)

wiring harness
Defective LED (rear

combination lamp)
40-962
a Headlamp switch OFF

Max. 1 V
Between ground and R.H. COMBI (female) (A) or
Max. 1 V
Voltage LDR_R (female) (B)
Between ground and L.H. COMBI (female) (A) or
Max. 1 V
LDR_L (female) (B)
If no failure is found by above checks, the LED (rear combination lamp) is
defective.
WA470-7
40 Troubleshooting
WA470-7
40-963
40 Troubleshooting
E-43 Both High and Low beams of headlamp do not light up or go

out (WA470_7-HQ9-400-A-Z0-A)
Failure
Related
information
No.
1
Both "High and Low beams" of headlamp do not light up or go out.

Defective switch, lamps, or wiring harness of headlamp (low and high beam) circuit
If clearance lamp, tail lamp, and license-plate lamp light up and go out:
If headlamp does not go out, remove headlamp relay. If headlamp then goes out,
headlamp relay is defective.

Cause
Defective fuses 14 and If fuse is blown, circuit may have ground fault, etc. (See check on cause 6.)
15 in fuse box 1
2. Replace headlamp relay L131 with another relay, for example, horn relay
Defective headlamp
L119.
relay L131
4. Turn the lamp switch to HEAD/OFF position.
If headlamp becomes normal, original headlamp relay (L131) is defective.

circuit)

OFF
Min. 1 Mz
SMALL,
Max. 1 z
HEAD
OFF
Min. 1 Mz
SMALL
Min. 1 Mz
HEAD
Max. 1 z
Always
Min. 1 Mz
(male) (1), (2), and (3)
Defective dimmer
switch
circuit)

3. Operate dimmer switch and perform troubleshooting.
Dimmer
switch:
Min. 1 Mz
LOW
Dimmer
switch:
Max. 1 z
HIGH
Dimmer
Resistance
switch:
Max. 1 z
LOW
Dimmer
switch:
Min. 1 Mz
HIGH
Min. 1 Mz
Always
(male) (5), (6), and (7)
40-964
WA470-7
40 Troubleshooting
No.
Cause

Primary circuit of headlamp relay L131
a Headlamp relay L131 coil resistance
200 to 400
z
Secondary circuit input of headlamp relay L131

20 to 30 V
R.H. headlamp line
4. Perform troubleshooting with dimmer switch in both high and low
positions.

harness
(wire breakage or
connector)
a Lamp resistance is approximately 8 z

Approx. 8 z
L.H. headlamp line
4. Perform troubleshooting with dimmer switch in both high and low
positions.
a Lamp resistance is approximately 8 z
Approx. 8 z
a
1.
2.
3.

Remove fuse 11, 14, and 15 in fuse box 1 (FS8).
Disconnect connectors L04 and L131, and connect T-adapters to each
female side.
Max. 1 z
Max. 1 z
Between fuse box FS8- 11 and L131 (female)(3)
Max. 1 z
Resistance Between L131 (female) (5) and FS8-15
Max. 1 z
Between L131 (female) (5) and FS8-14
Max. 1 z
Between FS8-15 and L.H. HEAD (female) (B)
Max. 1 z
Between FS8-14 and R.H. HEAD (female) (B)
Max. 1 z

harness
circuit)
WA470-7

3. Disconnect connectors L04, L131, HEAD (R.H. and L.H.) and connect Tadapters to either female side.
Min. 1 Mz
(female) (1)
Min. 1 Mz
Resistance
Between L.H. HEAD (female) (B) and ground
Min. 1 Mz
Min. 1 Mz
Between R.H. HEAD (female) (B) and ground
40-965
40 Troubleshooting
No.
Cause

3. Disconnect connectors L04, L131, HEAD (R.H. and L.H.) and connect Tadapters to either female side.

wiring harness
40-966
a Headlamp switch OFF

(female) (1)
Between L.H. HEAD (female) (B) and ground
Between R.H. HEAD (female) (B) and ground
Max. 1 V
Max. 1 V
Max. 1 V
Max. 1 V
WA470-7
40 Troubleshooting
Circuit diagram related to headlamp, clearance lamp, and tail lamp
WA470-7
40-967
40 Troubleshooting
E-44 Low beam of headlamp does not light up or go out

Failure
Related
information
No.
1
(WA470_7-HQA-400-A-Z0-A)
The headlamp "Low beam" does not light up or go out.

Open circuit or ground fault of switch, lamp, or wiring harness of headlamp (low beam)
circuit
If the high beam lights up (or goes out)
Cause
Blown lamp (bulb)

If only a certain headlamp does not light up, inspect it directly as the lamp may
be blown or have poor contact.
Defective dimmer
switch
circuit)

Dimmer
switch:
Min. 1 Mz
LOW
Dimmer
switch:
Max. 1 z
HIGH
Dimmer
Resistance
switch:
Max. 1 z
LOW
Dimmer
switch:
Min. 1 Mz
HIGH
Always
Min. 1 Mz
(male) (5), (6), and (7)

harness
(wire breakage or
connector)

2. Disconnect connectors L04, and HEAD (R.H. and L.H.), and connect Tadapters to each female side.
Between R.H. HEAD (female) (A) and L04 (female)
Max. 1 z
(7)
Resistance
Between L.H. HEAD (female) (A) and L04 (female)
Max. 1 z
(7)

harness
circuit)

2. Disconnect connectors L04 and HEAD (R.H. and L.H.), and connect Tadapters to either female side.
Between ground and R.H. HEAD (female) (A), L.H.
Resistance HEAD (female) (A) or L04 (female) (7)
Min. 1 Mz
40-968
WA470-7
40 Troubleshooting
WA470-7
40-969
40 Troubleshooting
E-45 High beam of headlamp does not light up or go out

Failure
Related
information
No.
1
(WA470_7-HQB-400-A-Z0-A)
The headlamp "High beam" does not light up or go out.

Open circuit or ground fault of switch, lamp, or wiring harness of headlamp (high beam)
circuit
If the low beam lights up (or goes out):
Cause
Blown lamp (bulb)

If only a certain headlamp does not light up, inspect it directly as the lamp may
be blown or have poor contact.
Defective dimmer
switch
circuit)

Dimmer
switch:
Min. 1 Mz
LOW
Dimmer
switch:
Max. 1 z
HIGH
Dimmer
Resistance
switch:
Max. 1 z
LOW
Dimmer
switch:
Min. 1 Mz
HIGH
Always
Min. 1 Mz
(male) (5), (6), and (7)

harness
(wire breakage or
connector)

2. Disconnect connectors L04, and HEAD (R.H. and L.H.), and connect Tadapters to each female side.
Between R.H. HEAD (female) (C) and L04 (female)
Max. 1 z
(6)
Resistance
Between L.H. HEAD (female) (C) and L04 (female)
Max. 1 z
(6)

harness
circuit)

2. Disconnect connectors L04 and HEAD (R.H. and L.H.), and connect Tadapters to either female side.
Between ground and R.H. HEAD (female) (C), L.H.
Resistance HEAD (female) (C) or L04 (female) (6)
Min. 1 Mz
40-970
WA470-7
40 Troubleshooting
WA470-7
40-971
40 Troubleshooting
E-46 Front working lamp does not light up or go out

Failure
Related
information
No.
1
2
(WA470_7-HR4-400-A-Z0-A)
Front working lamp does not light up or go out.

Defective switch, lamp, or wiring harness of front working lamp circuit
If the rear working lamp lights up (or goes out)
If the clearance lamp also does not light up, troubleshoot the clearance lamp first.
If front working lamp does not go out, remove front working lamp relay. If front working
lamp then goes out, front working lamp relay is defective.
Cause
Blown lamp (bulb)

If only a certain working lamp does not light up, inspect it directly as the lamp
may be blown or have poor contact.
box 2
2. Replace front working lamp relay (L127) with another relay, for example,
horn relay (L119).
Defective front working
3.
Turn
starting switch to ON position.
lamp relay (L127)
4. Turn front working lamp switch ON and OFF.
If front working lamp becomes normal, original front working lamp relay L127
is defective.
Defective front working 2. Turn front working lamp switch ON and OFF, and troubleshoot.
lamp switch
ON
Max. 1 z
Between S_F1 (male) (5) and (6)
OFF
Min. 1 Mz
Resistance
circuit)
Between ground and each of S_F1
Continuous Min. 1 Mz
(male) (5) and (6)
Primary circuit of front working lamp relay L127
2. Disconnect connector S_F1, and connect T-adapters to female side.
a Coil resistance of front working lamp relay L127
Resistance Between S_F1 (female) (5) and ground

harness
(wire breakage or
connector)
200 to 400
z
Secondary circuit input of front working lamp relay L127

20 to 30 V
Front working lamp line
a Since resistance of a working lamp is approx. 8 z and lamps are
connected in parallel, the standard value is approx. 4 z.
a If the reading is approx. 8 z one of the circuits is open. If the reading is
above 1 Mz, both circuits are open.
Approx. 4 z
Input line of the switch.
2. Disconnect connector S_F1 and connect T-adapters to female side.
20 to 30 V
Voltage Between S_F1 (female) (6) and (5)
40-972
WA470-7
40 Troubleshooting
No.
Cause

harness
(wire breakage or
connector)

harness
circuit)
a
1.
2.
3.

Remove fuse-8 in fuse box 2 (FS9).
Disconnect connectors S_F1, L127, C04, C05, and connect T-adapters to
each female side.
Between S_F1 (female) (5) and L127 (female) (1)
Max. 1 z
Max. 1 z
Max. 1 z
Resistance Between L127 (female) (5) and C04 (female) (1)
Max. 1 z
Between L127 (female) (5) and C05 (female) (1)
Max. 1 z
Between C04 (female) (2) and ground
Max. 1 z
Between C05 (female) (2) and ground
Max. 1 z

3. Disconnect connectors S_F1, L127, C04, C05, and connect T-adapter to
either female side.
Between ground and L127 (female) (3) or S_F1
Min. 1 Mz
(female) (6)
Between ground and S_F1 (female) (5) or L127
Min. 1 Mz
Between ground and L127 (female) (5), C04
Min. 1 Mz
(female) (1) or C05 (female) (1)
2. Remove fuse-8 in fuse box 2 (FS9).
3. Disconnect connectors S_F1, L127, C04, C05, and connect T-adapter to
either female side.

wiring harness
WA470-7
a Front working lamp switch is OFF.

(female) (6)
Voltage
(female) (1)
Between ground and L127 (female) (5), C04
(female) (1) or C05 (female) (1)
Max. 1 V
Max. 1 V
Max. 1 V
40-973
40 Troubleshooting
Circuit diagram related to working lamps
40-974
WA470-7
40 Troubleshooting
E-47 Rear working lamp does not light up or go out

Failure
Related
information
No.
1
2
(WA470_7-HR5-400-A-Z0-A)
Rear working lamp does not light up or go out.

Defective switch, lamp, or wiring harness of rear working lamp circuit
If the front working lamp and side working lamps (if equipped) light up (or go out)
If the clearance lamp also does not light up, troubleshoot the clearance lamp first.
If rear working lamp does not go out, remove rear working lamp relay. If rear working lamp
then goes out, rear working lamp relay is defective.
Cause
Blown lamp (bulb)

If only a certain working lamp does not light up, inspect it directly as the lamp
may be blown or have poor contact.
box 2
2. Replace rear working lamp relay L128 with another relay, for example,
horn relay L119.
Defective rear working
3.
Turn
lamp relay (L128)
4. Turn rear working lamp switch ON and OFF .
If rear working lamp becomes normal, original rear working lamp relay (L128)
is defective.
Defective rear working 2. Turn rear working lamp switch ON and OFF, and troubleshoot.
lamp switch
ON
Max. 1 z
Between S_F2 (male) (5) and (6)
OFF
Min. 1 Mz
Resistance
circuit)
Between ground and each of S_F2
Continuous Min. 1 Mz
(male) (5) and (6)
Primary side of rear working lamp relay L128
a Coil resistance of rear working lamp relay L128
Resistance Between S_F2 (female) (5) and ground

harness
(wire breakage or
connector)
200 to 400
z
Secondary side of rear working lamp relay L128

20 to 30 V
Front working lamp line
a Since resistance of a working lamp is approx. 8 z and lamps are
connected in parallel, the standard value is approx. 4 z.
a If the reading is approx. 8 z one of the circuits is open. If the reading is
above 1 Mz, both circuits are open.
Approx. 4 z
Input line of the switch.
20 to 30 V
Voltage Between S_F2 (female) (6) and (5)
WA470-7
40-975
40 Troubleshooting
No.
Cause

harness
(wire breakage or
connector)

harness
circuit)
a
1.
2.
3.

Remove fuse-9 in fuse box 2 (FS9).
Disconnect connectors S_F2, L128, G04, G05, and connect T-adapters to
each female side.
Between S_F2 (female) (5) and L128 (female) (1)
Max. 1 z
Max. 1 z
Max. 1 z
Resistance Between L128 (female) (5) and G04 (female) (2)
Max. 1 z
Between L128 (female) (5) and G05 (female) (2)
Max. 1 z
Between G04 (female) (1) and ground
Max. 1 z
Between G05 (female) (1) and ground
Max. 1 z

3. Disconnect connectors S_F2, L128, G04, G05, and connect T-adapter to
either female side.
Max. 1 z
(female) (6)
Max. 1 z
Between ground and L128 (female) (5), G04
Max. 1 z
(female) (2) or G05 (female) (2)
3. Disconnect connectors S_F2, L128, G04, G05, and connect T-adapter to
either female side.

wiring harness
40-976
a Turn rear working lamp switch to OFF position.

(female) (6)
Voltage
(female) (1)
Between ground and L128 (female) (5), G04
(female) (1) or G05 (female) (1)
Max. 1 V
Max. 1 V
Max. 1 V
WA470-7
40 Troubleshooting
Circuit diagram related to working lamps
WA470-7
40-977
40 Troubleshooting
E-48 All of turn signal lamps and hazard lamps do not light up or go
out (WA470_7-HS4-400-A-Z0-A)
Failure
Related
information
No.
1
All of turn signal lamps and hazard lamps do not light up or go out.
Defective switch, lamps or wiring harness of turn signal lamps and hazard lamp circuits
If turn signal lamps and hazard lamps do not go out, remove winker hazard lamp relay 2.
If turn signal lamps and hazard lamps then go out, winker hazard lamp relay 2 is
defective.
If all turn signal lamps and hazard lamps do not flash, try another flasher unit.
Input condition (ON/OFF) to machine monitor from turn signal lamp and hazard lamp
switches (right turn signal lamp) can be checked with monitoring function (Code: 04507
Right Turn Signal).
switches (left turn signal lamp) can be checked with monitoring function (Code: 04507 Let
Turn Signal).
Cause
Defective slow-blow
fuse

If a slow-blow fuse is blown, circuit may have ground fault, etc. (See check on
cause 8.)

2. Replace winker hazard lamp relay 1 L111 with another relay, for example,
horn relay L119.
Defective winker hazard 3. Turn starting switch to ON position.
lamp relay 1 L111
4. Turn ON and OFF hazard lamp switch
5. Operate turn signal lever to right and left
If turn signal lamps become normal, original winker hazard lamp relay 1 L111
is defective.
2. Replace winker hazard lamp relay 2 L122
lamp relay 2 L122
is defective.
Defective turn signal
switch (Internal open or 3. Turn starting switch to ON position.
short circuit)
If turn signal lamps become normal, turn signal switch is defective.
Defective hazard lamp

switch (internal open or
short circuit)

harness 1 (wire
breakage or defective

2. Disconnect connector S_FB.
If turn signal lamps become normal, hazard lamp switch is defective.
Flasher unit power supply
Voltage
40-978
20 to 30 V
WA470-7
40 Troubleshooting
No.
Cause

7
Defective flasher unit

Voltage
20 to 30
Vio0 V
are
repeated.

harness
(wire breakage or
connector)

female side.
Max. 1 z
Between
L19
(female)
(4)
and
L04
(female)
(9)
Resistance
Max. 1 z
Max. 1 z

ground circuit)

2. Disconnect connectors L111 and L19, and connect T-adapters to either
female side.
Min. 1 Mz
(female) (2)
Resistance
Min. 1 Mz
(female) (9)

10 wiring harness
WA470-7

female side.
Voltage
Max. 1 V
(female) (9)
40-979
40 Troubleshooting
Circuit diagram related to turn signal lamp and winker lamp (hazard lamp)
40-980
WA470-7
40 Troubleshooting
E-49 Turn signal lamps do not light up or go out

Failure
Related
information
No.
1
2
3
(WA470_7-HS6-400-A-Z0-A)
Turn signal lamps do not light up or go out.

Defective switch, lamps, or wiring harness of turn signal lamp circuit
If the hazard lamp flashes
If turn signal lamps do not go out, remove winker hazard lamp relay 2. If turn signal lamps
then go out, winker hazard lamp relay 2 is defective.
switches (right turn signal lamp) can be checked with monitoring function (Code: 04507
Right Turn Signal).
switches (left turn signal lamp) can be checked with monitoring function (Code: 04507 Let
Turn Signal).
Cause
Blown lamp (bulb)

Defective fuse 11 in
fuse box 2
Defective slow-blow
fuse

If only a certain turn signal lamp does not light up, inspect it directly as the
lamp may be blown or have poor contact.
If slow-blow fuse R06A is blown, circuit may have ground fault, etc. (See
check on cause 8.)

2. Replace winker hazard lamp relay 1 L111 with another relay, for example,
horn relay L119.
lamp relay 1 L111
is defective.
Turn signal
lamp lever: Min. 1 Mz
LEFT
Turn signal
NEUTRAL
Turn signal
Defective turn signal
lamp lever: Max. 1 z
switch (internal open or
RIGHT
short circuit)
Turn signal
Resistance
lamp lever: Max. 1 z
LEFT
Turn signal
NEUTRAL
Turn signal
RIGHT
Between ground and each of L04 (male) (9), (10),
Min. 1 Mz
and (11)
WA470-7
40-981
40 Troubleshooting
No.
Cause

harness
(wire breakage or
connector)

harness
circuit)

wiring harness
40-982

Turn signal lamp power supply
20 to 30 V
2. Disconnect connectors L04, LDY_R, LDY_L, COMBI (R.H. and L.H.), and
Between L04 (female) (10) and LDY_R (female) (1) Max. 1 z
Between L04 (female) (10) and R.H. COMBI
Max. 1 z
(female) (C)
Between L04 (female) (11) and LDY_L (female) (1)
Max. 1 z
Between L04 (female) (11) and L.H. COMBI
Max. 1 z
Between LDY_L (female) (2) and ground
Max. 1 z
Between LDY_R (female) (2) and ground
Max. 1 z
Between right COMBI (female) (B) and ground
Max. 1 z
Between left COMBI (female) (B) and ground
Max. 1 z
3. Disconnect connectors L04, L111, LDY_R, LDY_L, COMBI (R.H. and L.
H.), and connect T-adapters to each female side.
4. Remove slow blow fuse R06A.
5. Remove fuses 8 to 10 and 12 to 14 in fuse box 2 (FS9).
a If fuse 11 in fuse box 2 (FS9) is blown, replace it in advance.
Between ground and L111 (female) (6) or R06A
Between ground and L04 (female) (10), LDY_R
Resistance (female) (1) or R.H. COMBI (female) (C)
Between ground and L04 (female) (11), LDY_L
(female) (1) or L.H. COMBI (female) (C)
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz

2. Disconnect connectors L04, LDY_R, LDY_L, COMBI (R.H. and L.H.), and
connect T-adapters to either female side.
Max. 1 V
(female) (1) or R.H. COMBI (female) (C)
Voltage
Max. 1 V
(female) (1) or L.H. COMBI (female) (C)
WA470-7
40 Troubleshooting
Circuit diagram related to turn signal lamp and winker lamp (hazard lamp)
WA470-7
40-983
40 Troubleshooting
E-50 Hazard lamp does not light up or go out

Failure
Related
information
No.
1
2
(WA470_7-HS7-400-A-Z0-A)
Hazard lamp does not light up or go out.

Defective hazard lamp or its switch
If turn signal lamps flash normally
If hazard lamps do not go out, remove winker, hazard relay 2. If hazard lamps then go out,
winker, hazard lamp relay 2 is defective.

Cause
Defective fuse 2 in fuse If fuse is blown, circuit may have ground fault. (See check on cause 6.)
box 1
If the slow-blow fuse is blown, circuit may have ground fault. (See check on
Defective slow-blow
cause 7.)
fuse
2. Replace winker, hazard relay 1 L111 with another relay, for example, horn
relay L119.
Defective winker,
3.
Turn
hazard relay 1 L111
If hazard lamps become normal, original winker, hazard relay 1 L111 is
defective.
2. Replace winker, hazard relay 2 L122
Defective winker,
hazard relay 2 L122
If hazard lamps become normal, original winker, hazard relay 2 L122 is
defective.
2. Disconnect connector S_FB and connect T-adapter to male side.
3. Turn ON and OFF hazard switch
Defective hazard switch
Hazard lamp switch: ON
Max. 1 z
Between S_FB (male)
Hazard
lamp
switch:
(5) and (6)
Min. 1 Mz
circuit)
OFF
Resistance
Between ground and
Min. 1 Mz
each of S_FB (male) (5)
Always
and (6)
40-984
WA470-7
40 Troubleshooting
No.
Cause

harness
(wire breakage or
connector)

Primary side GND line of relay
female side.
3. Hazard lamp switch: ON
Max. 1 z
Resistance
Max. 1 z
Hazard lamp power supply input
female side.
20 to 30 V
20 to 30 V
20 to 30 V
2. Disconnect connectors L19, L122, LDY_R, LDY_L, COMBI (R.H. and L.
H.), and connect T-adapters to each female side.
Between L122 (female) (4) and LDY_L (female) (1) Max. 1 z
Between L122 (female) (4) and L.H. COMBI
Max. 1 z
(female) (C)
Resistance Between L122 (female) (2) and LDY_R (female) (1) Max. 1 z
Between L122 (female) (2) and R.H. COMBI
Max. 1 z
(female) (C)
Between L122 (female) (1), (3) and L19 (female) (4) Max. 1 z
2. Disconnect connectors S_FB, L111, L122, and connect T-adapters to each
female side.
Between L111 (female) (2) and S_FB (female) (5)
Max. 1 z
Resistance Between S_FB (female) (6) and ground
Max. 1 z
Between L122 (female) (6) and S_FB (female) (5)
Max. 1 z

harness
circuit)

wiring harness
WA470-7

3. Disconnect connectors S_FB, L111, L122, and connect T-adapters to
either female side.
4. Remove slow blow fuse R03.
5. Remove fuses 1, and 3 to 7 in fuse box 2 (FS9).
Between ground and L111 (female) (1), (5) or L122
(female) (5)
Resistance
Between ground and L111 (female) (2) or S_FB
(female) (5)
Min. 1 Mz
Min. 1 Mz

3. Disconnect connectors L122, LDY_R, LDY_L, COMBI (R.H. and L.H.),
and connect T-adapters to either female side.
Hot short circuit in wiring harness of the following two systems
Max. 1 V
(female) (1), or R.H. COMBI (female) (C)
Voltage
Max. 1 V
(female) (1), or L.H. COMBI (female) (C)
40-985
40 Troubleshooting
Circuit diagram related to hazard lamp
40-986
WA470-7
40 Troubleshooting
E-51 Brake lamp does not light or stays lighted

Failure
Related
information
No.
1
2
(WA470_7-HT1-400-A-Z0-A)
Brake lamp does not light up or stays lighted.

Defective brake lamp or its wiring harness
If brake lamp does not go out, remove brake lamp relay. If brake lamp then goes out,
brake lamp relay is defective.

Cause
If slow-blow fuse is blown, circuit may have ground fault, etc. (See check on
Defective slow-blow
cause 8.)
fuse
Defective fuse 6 in fuse If fuse is blown, circuit may have ground fault. (See check on cause 6.)
box 1
Defective brake lamp
2. Replace brake lamp relay L118 with another relay, for example, horn relay
relay (L118)
L119.
circuit)
If brake lamp becomes normal, original brake lamp relay L118 is defective.
Defective brake lamp
switch
circuit)

Max. 1 z
Between L09 (male) (1) Brake pedal: Depressed
and
(2)
Brake
pedal:
Released
Resistance
Min. 1 Mz
Between ground and each of L09 (male) (1) and (2) Min. 1 Mz
Brake lamp power supply
female side.
20 to 30 V
Voltage
20 to 30 V
Primary side of brake lamp relay L118
a Coil resistance of brake lamp relay L118

harness
(wire breakage or
connector)
200 to 400
z

2. Disconnect connectors L118, LDY_R, LDY_L, and connect T-adapters to
each female side.
Between L118 (female) (5) and LDR_R (female) (A) Max. 1 z
Between L118 (female) (5) and LDR_L (female) (A) Max. 1 z
Resistance
Between LDR_L (female) (C) and ground
Max. 1 z
Between LDR_R (female) (C) and ground
Max. 1 z
female side.
Max. 1 z
Resistance
Max. 1 z
WA470-7
40-987
40 Troubleshooting
No.
Cause

harness
circuit)

wiring harness
Defective LED (rear

combination lamp)
40-988

3. Disconnect connectors L09, L117, L118, LDY_R, LDY_L, and connect Tadapters to either female side.
4. Remove slow blow fuse R06A.
6. Remove fuses 1 to 5, 7, and 11 in fuse box 1 (FS8).
(female) (1) to L117 (female) (3)
Between ground and L118 (female) (5), LDR_R
(female) (A), or LDR_L (female) (A)
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz

2. Disconnect connectors L09, L118, LDY_R, LDY_L, and connect Tadapters to either female side.
Max. 1 V
(female) (1)
Voltage
Between ground and L118 (female) (5), LDR_R
Max. 1 V
(female) (A), or LDR_L (female) (A)
defective.
WA470-7
40 Troubleshooting
Circuit diagram related to brake lamp
WA470-7
40-989
40 Troubleshooting
E-52 Backup lamp does not light up or does not go out

Failure
Related
information
(WA470_7-HU1-400-A-Z0-A)
Backup lamp does not light or continues to light.

If brake lamps do not light up, perform troubleshooting for E-51 first.
If backup lamp does not go out, remove backup lamp relay. If backup lamp then goes out,
backup lamp relay is defective.
Cause
relay primary side
lever system
box 1

If failure code [D160KA], [D160KB], or [D160KY] is also displayed, perform
troubleshooting for [D160KA], [D160KB], or [D160KY] first.
If failure code [DF10KA] or [DF10KB] is displayed, perform troubleshooting for
[DF10KA] or [DF10KB] first.
If fuse is blown, circuit may have ground fault, etc. (E-51, see check on cause
7.)

relay L117 (internal
open circuit or short
circuit)

2. Replace backup lamp relay L117 with another relay, for example, horn
relay L119.
4. Set directional lever in the R position.
If backup lamp becomes normal, original backup lamp relay L117 is defective.

Defective backup alarm 3. Turn starting switch to ON position.
buzzer (internal defect) 4. Set directional lever in the R position.
If backup lamp becomes normal, the backup alarm buzzer is defective.
No.
1
2
3
40-990
WA470-7
40 Troubleshooting
No.
Cause

Backup lamp power supply
Set directional lever in the R position.
20 to 30 V
Voltage
20 to 30 V
Primary circuit of backup lamp relay L117
1.
2.
3.
4.
a Backup lamp relay L117 coil resistance


harness
(wire breakage or
connector)
200 to 400
z

2. Disconnect connectors L117, LDW_R, LDW_L, and connect T-adapters to
each female side.
Between L117 (female) (5) and LDW_L (female) (1) Max. 1 z
Between L117 (female) (5) and LDW_R (female)
Max. 1 z
Resistance (1)
Between LDW_L (female) (2) and ground
Max. 1 z
Between LDW_R (female) (2) and ground
Max. 1 z
female side.
Max. 1 z
If a failure occurs, failure code [D160KA] is
displayed.
Resistance
Max. 1 z
If a failure occurs, failure code [D160KA] is
displayed.

harness
circuit)

3. Disconnect connectors L117, L62, R58, LDW_R, LDW_L, RVMI, and
connect T-adapters to either female side.
Between ground and L117 (female) (5), LDW_L
(female) (1), LDW_R (female) (1), or R58 (female)
Min. 1 Mz
(1)
Resistance Between ground and L62 (female) (19) or L117
(female) (1)
Min. 1 Mz
If a failure occurs, failure code [D160KB] is
displayed.

wiring harness

2. Disconnect connectors L09, L117, LDW_R, LDW_L, RVMI, and connect Tadapters to either female side.
Between ground and L117 (female) (5), LDW_L
Voltage (female) (1), LDW_R (female) (1) or R58 (female)
Max. 1 V
(1)
controller

20 to 30 V
WA470-7
40-991
40 Troubleshooting
No.
Cause
Defective rearview
10 monitor (internal short
circuit)
Defective LED (rear
11 combination lamp)

If backup lamp becomes normal, the rearview monitor is defective.
defective.
Circuit diagram related to backup lamp
40-992
WA470-7
40 Troubleshooting
E-53 Backup buzzer does not sound or continues to sound

Failure
Related
information
No.
Backup buzzer does not sound or continues to sound.

If backup lamp is abnormal, perform troubleshooting for E-52 first.
Cause
Defective backup
buzzer
circuit)

harness
(wire breakage or
connector)
WA470-7
(WA470_7-KA5-400-A-Z0-A)
1.
2.
3.
4.

Disconnect connector R58 and connect T-adapters to female side.
Operate directional lever to troubleshoot.
a If following voltages are normal and backup alarm buzzer does not operate,
backup alarm buzzer may be defective.
directional lever: R
20 to 30 V
Voltage Between R58 (1) and (2) directional lever: other
Max. 1 V
than R
female side.
Max. 1 z
Resistance
Max. 1 z
40-993
40 Troubleshooting
Circuit diagram related to backup buzzer
40-994
WA470-7
40 Troubleshooting
E-54 Front wiper does not operate

Failure
Related
information
No.
1
(WA380_7-FG1-400-A-Z0-A)
Front wiper does not operate.

Front wiper does not operate due to the failure of front wiper motor, front wiper switch,
interval wiper timer, or wiring harness.
If the wiper does not work properly in INT only, try with another interval wiper timer.
T-adapter is not provided for connector L31.
Cause
box 1
harness 1 (wire
Defective front wiper

motor
(internal defect)

Ground line of front wiper motor
2. Disconnect connector C12, and connect T-adapters to female side.
Resistance Between C12 (female) (3) and ground
Max. 1z
Front wiper motor input voltage
2. Disconnect connector C12, and connect T-adapters to female side.
4. Operate the front wiper switch and perform troubleshooting.
a If the following voltage is normal but front wiper does not operate, front
wiper motor is defective.
Between C12 (female)
Power supply
20 to 30 V
(6) and ground
Front wiper switch: Lo
20 to 30 V
0
V o 20 to
Voltage
30
Vo0V
(2) and ground
Front wiper switch: INT
are
repeated*
Front wiper switch: Hi
20 to 30 V
(1) and ground
a If wiper switch is turned OFF while wiper is operating, voltage is applied
between C12 (5) and ground until the wiper motor stops.

switch (internal failure)
WA470-7

Front wiper switch: Lo
Max. 1z
Front
wiper
switch:
INT,
and (5)
Min. 1 Mz
Hi
Front wiper switch: Hi
Max. 1z
Front
wiper
switch:
INT,
and (4)
Min. 1 Mz
Lo
Resistance Between L21 (male) (7)
Max. 1z
and (2)
Front wiper switch: Lo, Hi Min. 1 Mz
Max. 1z
and (5)
Front wiper switch: Lo, Hi Min. 1 Mz
Min. 1 Mz
(4), (5), and (7)
40-995
40 Troubleshooting
No.
Cause

harness
(wire breakage or
connector)

Checks related to INT operation
a If no failure is found in INT operation, this check is not required.
side of L21.
Max. 1z
Between fuse box 1 (FS8) (7) and L31 (female)(3)
Max. 1z
Resistance
Max. 1z
Max. 1z
Front wiper motor related checks
a If each input voltage checked for cause 3 is normal, this check is not
required.
2. Disconnect connectors C12 and L21, and connect T-adapters to each
female side.
Between fuse box 1 (FS8) (7) and C12 (female) (6)
Max. 1z
Max. 1z
Resistance
Max. 1z
Between L21 (female) (7) and FS8-7
Max. 1z
2. Disconnect connectors C12, C15, L21, L31, CL27, and connect Tadapters to female side of either C12 or L21.
Min. 1 Mz
(female) (5)
Between ground and L21 (female) (5) or C12
Min. 1 Mz
(female) (2)
Min. 1 Mz
Min. 1 Mz
(female) (1)
Min. 1 Mz
(female) (4)

ground circuit)
Defective interval wiper

If no failure is found by above checks, interval wiper timer is defective.
timer (internal defect)
40-996
WA470-7
40 Troubleshooting
Circuit diagram related to wiper
WA470-7
40-997
40 Troubleshooting
E-55 Rear wiper does not operate

Failure
Related
information
No.
1
(WA470_7-FG2-400-A-Z0-A)
Rear wiper does not operate.

Rear wiper does not operate due to failure of rear wiper motor, rear wiper switch, or wiring
harness.
If front wiper does not operate, perform troubleshooting for E-54 first.
T-adapter is not prepared for connector L31.
Cause
harness 1 (wire

Ground line of rear wiper motor
2. Disconnect connector C15 and connect T-adapters to female side.
Resistance Between C15 (female) (4) and ground
Max. 1 z
Rear wiper motor input voltage
2. Disconnect connector C15 and connect T-adapters to female side.
4. Operate the rear wiper switch and perform troubleshooting.
Defective rear wiper

motor
(internal defect)
a If voltage measured below is normal but rear wiper does not operate, rear
wiper motor is defective.
Power supply
20 to 30 V
(1) and ground
Voltage
Rear wiper switch: ON
20 to 30 V
(2) and ground
a If wiper switch is turned OFF while wiper is operating, voltage is applied
between C15 (3) and ground until the wiper motor stops.

switch
(internal defect)

harness
(wire breakage or
connector)

harness
circuit)
40-998

Max. 1 z
Between L21 (male) (7) Rear wiper switch: ON
and (9)
Rear wiper switch: OFF
Min. 1 Mz
Max. 1 z
Resistance Between L21 (male) (8) Rear wiper switch: OFF
and (9)
Rear wiper switch: ON
Min. 1 Mz
Min. 1 Mz
and (9)
Front wiper motor related checks
a If each input voltage checked for cause 2 is normal, this check is not
required.
2. Disconnect connectors C15 and L21, and connect T-adapters to each
female side.
Between FS8-7 and C15 (female) (1)
Max. 1 z
Max. 1 z
Resistance
Max. 1 z
Max. 1 z
2. Disconnect connectors C12, C15, L21, L31, CL27, and connect Tadapters to female side of either L21 or C15.
Min. 1 Mz
(female) (3)
Resistance
Min. 1 Mz
(female) (2)
WA470-7
40 Troubleshooting
Circuit diagram related to wiper
WA470-7
40-999
40 Troubleshooting
E-56 Window washer does not operate

Failure
Related
information
No.
(WA470_7-FH0-400-A-Z0-A)
Window washer does not operate.

Window washer does not operate due to the failure of window washer motor, switch, timer
(front system only), or wiring harness.
Perform following troubleshooting when wiper operates normally. (If wiper does not
operate normally, perform troubleshooting for E-54 and E-55 first.)
Check that front wiper (Hi, Lo, INT) and rear wiper operate normally.
T-adapter is not prepared for connectors L31, R43, R45, D08, and D09.
Cause
Defective front washer

motor (internal failure)

3 to 10 z
Resistance
Min. 1 Mz
Defective rear washer

motor
(internal defect)

3 to 10 z
Resistance
Min. 1 Mz

switch (internal failure)

Front wiper washer
Max. 1 z
Between L21 (male) (7) switch: ON
and (6)
Front wiper washer
Min. 1 Mz
switch: OFF
Resistance
Front wiper switch: OFF
Max. 1 z
and (5)
Min. 1 Mz

switch
(internal defect)

Rear wiper washer
Max. 1 z
Between L21 (male) (7) switch: ON
Rear wiper washer
Resistance and (10)
Min. 1 Mz
switch: OFF
Min. 1 Mz

2. Disconnect connectors D08 and D09.
5
Defective diode
(internal defect)
Between D08 (male) (2) (-) and (1) (+)

Continuity Between D09 (male) (2) (+) and (1) (-)
Between D09 (male) (2) (-) and (1) (+)
40-1000
Continuity
No
continuity
Continuity
No
continuity
WA470-7
40 Troubleshooting
No.
Cause

harness
(wire breakage or
connector)

Window washer motor line
2. Disconnect connectors L21, R43, R45, and connect T-adapters to female
side of L21.
Max. 1 z
Max. 1 z
Resistance
Max. 1 z
Max. 1 z
Front wiper operation related checks
a If front wiper operates when front window washer is activated, this check is
not required.
side of L21.
Resistance Between L31 (female) (2) and L21 (female) (6)
Max. 1 z
2. Disconnect connectors L21, L31, R43, R45, D08, D09, and connect Tadapters to female side of L21.
Between ground and L21 (female) (6), R43
Min. 1 Mz
(female) (1) or L31 (female) (2)
Resistance
Min. 1 Mz
(female) (1)

harness
circuit)
Defective interval wiper a If no failure is found by above checks and the front wiper does not operate
when the front window washer is activated, the interval wiper timer is
timer (internal defect)
defective.
WA470-7
40-1001
40 Troubleshooting
Circuit diagram related to window washer system
40-1002
WA470-7
40 Troubleshooting
E-57 Fuel feed pump does not operate or stop automatically
(WA470_7-FHY-400-A-Z0-
A)
Failure
Related
information
No.
1
2
Fuel feed pump does not operate or stop automatically.
Cause
Insufficient battery
charge level
Defective fuses No. 1
and 15 in fuse box 2

harness
(drive power supply
system)
(wire breakage or
connector)

harness
circuit)
Defective fuel feed

pump timer switch
controller
Defective fuel feed

pump switch (pump
malfunctions or does
not stop automatically)
Overload of fuel feed

pump
Internal defect of fuel

feed pump
WA470-7

Battery charge level may be insufficient. Check the battery.
If fuse 1 or 15 in fuse box 2 is blown, circuit probably has ground fault.
(Perform troubleshooting for E-5.)
20 to 30 V
1. Turn battery disconnect switch to OFF position (to shut off continuous
power supply)
Resistance Between E28 (female) (10) and ground
Max. 1 z
1. Turn battery disconnect switch to OFF position (to shut off continuous
power supply)
Min. 1 Mz
Resistance
Min. 1 Mz
4. Fuel feed pump switch ON
20 to 30 V
If output voltage is inappropriate though lamp flashes or if lamp does not
flash though no failure is found in checks on causes 1 to 4, fuel feed pump
is defective.
If fuel feed pump does not stop automatically, fuel feed pump switch may be
defective.
(Turn toggle switch to OFF position to stop pump operation, then replace
switch.)
Lamp flashes but power supply to pump is stopped in approx. 5 seconds.
a * If pump is overloaded, power supply is automatically cut off for protection
of circuit (priming pump switch is automatically restored).
1 to 3 z
Resistance Between E29 (male) (1) and pump body
Min. 1 Mz
Between E29 (male) (2) and pump body
Min. 1 Mz
40-1003
40 Troubleshooting
40-1004
WA470-7
40 Troubleshooting
E-58 KOMTRAX system does not operate properly

Failure
Related
information
No.
1
(WA500_7-F50-400-A-Z0-A)
KOMTRAX system does not operate normally.

Perform following troubleshooting if administrator of KOMTRAX system requests to check
whether failure occurs in system on machine.
Even when KOMTRAX system is defective, no problem appears on machine.
Check all results of troubleshooting on service menu display of machine monitor.
Cause
Defective
communication 1

2. Display "Terminal status" screen.
Monitoring
Check item: Station set-up check
display
Complete

2. Display "GPS & Communication Status" screen.
2
N ###.##.## (Latitude)
E ###.##.## (Longitude)
Positioning in Progress
If latitude and longitude are not displayed within 5 minutes under the open
sky, contact KOMTRAX service hot line.
Defective positioning by Monitoring

GPS
display
Check item: Positioning
Defective
communication
environment

Monitoring
"Satellite in View" or "No
Check item: Communication
display
Satellite in View"
If Communication Status does not display "Satellite in view" within 15 minutes
under the open sky, check whether the connector of TC330 or the antenna on
top of cab is properly connected.
Defective
communication 2

Monitoring Check item: Number of message(s)
display
not yet sent
0 to 60 (normally 0)
a Select "Terminal Status" from "KOMTRAX settings" in service menu of machine monitor.
WA470-7
40-1005
40 Troubleshooting
a Select "GPS & Communication Status" from "KOMTRAX settings" in service menu of machine monitor.
40-1006
WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (Hmode)
Troubleshooting of hydraulic and mechanical system (H-mode)
(ALL-
3840-001-A-02-A)
Information described in troubleshooting table (H-mode)
(ALL-5170-010-A-00-A)
(Rev. 2011/03)
Failure
Related
information
No.
1
2
3
4
5
Failure symptom that appears on machine

Cause
Probable cause of failure

(Each number is serial
number, not priority
sequence.)
WA470-7

<Contents of description>
Criteria to determine probable causes
Remarks for determination of probable cause
40-1007
40 Troubleshooting
System chart of hydraulic and mechanical systems
40-1008
(WA470-PM10-054-K-01-A)
WA470-7
40 Troubleshooting
WA470-7
40-1009
40 Troubleshooting
Power train system chart
40-1010
WA470-7
40 Troubleshooting
(WA470-5340-40D-A-00-A)
Steering
system
Power train system

H-1
q
H-2
H-3
H-4
Travel speed is slow, bucket thrust force is weak, gradability is low,

or gear speed does not shift.
H-5
H-6
H-7
H-8
H-9
H-10

Brake
system
Troubleshooting No.
Pressure reducing valve of accumulator charge valve
Slack adjuster
Brake pedal linkage
Brake piston
Brake valve
Fan control pump
Lockup clutch
Transmission clutch (*)
Lockup clutch ECMV
Brake component
Last chance filter
Transmission breather
Transmission
Transmission valve (ECMV)
Torque converter
Transmission charge pump
Failure
Power train component
Component causing failure
Transmission charge pump main relief valve
Failure mode and cause table
H-11
H-12
H-13
H-14
H-15
Parking brake is not released or drags.
H-16
Boom does not rise.
H-17
H-18
H-19
Lift cylinders do not serve to hold bucket on ground (bucket rises off
Work equipment system and
hydraulic component
ground).
H-20
H-21
H-22
H-23
H-24
H-25
H-26
H-27
Bucket tilts back and forth during carrying load (work equipment
valve in "HOLD").
Boom and bucket control levers do not move smoothly and heavy to
H-28
H-29
move.
WA470-7
40-1011
40 Troubleshooting
Troubleshooting No.
Slack adjuster
Brake piston
Brake pedal linkage
H-30
H-31
H-32
Operating work equipment causes engine speed to lower

significantly or engine to stall.
Large shocks are made when work equipment starts to move and
stops.
When single work equipment is relieved hydraulically, other work
equipment moves.
E.C.S.S. (travel damper) does not work and machine pitches and
H-33
bounces.
H-34
positioner
Fan system
Brake valve
Fan control pump
Lockup clutch
Lockup clutch ECMV
Transmission clutch (*)
Last chance filter
Transmission breather
Transmission valve (ECMV)
Transmission
Torque converter
Transmission charge pump
Brake component
Pressure reducing valve of accumulator charge valve

hydraulic component
Failure
Transmission charge pump main relief valve
Power train component
Fan speed is abnormal (too high or low, or fan does not rotate).
40-1012
H-35
H-36
WA470-7
40 Troubleshooting
Power train system
H-1
H-2
H-3

q
H-4
H-5
H-6
Steering
system
H-7
Brake
system
Troubleshooting No.
Steering valve (unload valve)
Steering valve (main relief valve)
Steering valve (overload relief valve)
Steering valve (spool)
Flow control valve
Stop valve
Steering cylinder
Orbitrol
Brake accumulator
Steering pump
Steering component
parking brake solenoid)
Check valve (between last chance filter and
Parking brake
Brake disc and plate
Failure
Brake component
q
q
H-8
H-9
H-10
H-11
H-12
H-13
H-14
H-15
q
H-16
Boom does not rise.
H-17
H-18
H-19

hydraulic component
ground).
H-20
H-21
H-22
H-23
H-24
H-25
H-26
H-27
valve in "HOLD").
move.
stops.
equipment moves.
bounces.
H-28
H-29
H-30
H-31
H-32
H-33
H-34
positioner
WA470-7
40-1013
Fan
system
Failure
40-1014
Check valve (between last chance filter and
Troubleshooting No.
Steering valve (unload valve)
Steering valve (overload relief valve)
Steering valve (main relief valve)
Steering valve (spool)
Flow control valve
Brake component
Stop valve
Steering cylinder
Orbitrol
Steering pump
Brake accumulator
parking brake solenoid)
Parking brake
Brake disc and plate
40 Troubleshooting
Steering component
H-35

H-36
WA470-7
40 Troubleshooting
Power train system
H-1
H-2
H-3

q
q
q
q
H-4
H-5
H-6
H-7
H-8
H-9
H-10
H-11
H-12

Brake
system
Troubleshooting No.
Work equipment valve (unload valve)
Work equipment valve (main relief valve)
Bucket control valve (spool)
Boom control valve (load check valve)
Boom control valve (spool)
Pump suction piping
Work equipment pump
Hydraulic tank strainer

q
Steering
system
PT-
Engine
Failure
Radiator fan motor (relief valve)
Work equipment and hydraulic component
H-13
H-14
H-15
H-16
Boom does not rise.
H-17
H-18
H-19
H-20
ground).
H-21
H-22

hydraulic component
H-23
H-24
H-25
H-26
H-27
H-28
valve in "HOLD").
H-29
move.
stops.
q
equipment moves.
bounces.
Fan
system
WA470-7
H-31
H-32
H-33
H-34
positioner
H-30
H-35
H-36
40-1015
40 Troubleshooting
Power train system

Steering
system
Brake
system
Troubleshooting No.
Cooling component and exterior parts around fan
Air conditioner components
Bucket control lever
Boom control lever
LS-EPC valve (work equipment pump)
LS valve (work equipment pump)
PC-EPC valve (work equipment pump)
PC valve (work equipment pump)
LS valve (steering pump)
Radiator fan direction selector valve
PC valve (steering pump)
Accumulator selector valve for travel damper
Radiator fan valve (relief valve)
H-1
H-2
H-3

H-4

H-5
H-6
H-7
H-8

hydraulic component
Travel damper solenoid valve
Accumulator for travel damper
Travel damper charge valve
Shut off valve (for pilot circuit of work equipment valve)
Bucket EPC valve
Bucket cylinder
Boom EPC valve
Boom suction valve (cylinder head end)
Lift cylinder
Bucket overload relief valve
Failure
Pilot circuit (between EPC valve and work equipment control valve)
q q
H-9
H-10
H-11
H-12
H-13
H-14
H-15
H-16
Boom does not rise.
H-17
q
H-18
H-19
q
ground).
q

q

40-1016
H-20
H-22
H-21
q
q
H-23
H-24
H-25
q
q
H-26
WA470-7
40 Troubleshooting
Troubleshooting No.
Cooling component and exterior parts around fan
Bucket control lever
Boom control lever
LS-EPC valve (work equipment pump)
LS valve (work equipment pump)
PC-EPC valve (work equipment pump)
PC valve (work equipment pump)
LS valve (steering pump)
Radiator fan direction selector valve
PC valve (steering pump)
Accumulator selector valve for travel damper
Radiator fan valve (relief valve)
Travel damper solenoid valve
Accumulator for travel damper
Travel damper charge valve
Shut off valve (for pilot circuit of work equipment valve)
Bucket EPC valve
Bucket cylinder
Boom EPC valve
Boom suction valve (cylinder head end)
Lift cylinder
Bucket overload relief valve
Failure
Pilot circuit (between EPC valve and work equipment control valve)
H-27

hydraulic component
valve in "HOLD").
move.
H-28
q q
H-29
stops.
equipment moves.
bounces.
q q
Fan
system
WA470-7
H-31
H-32
q
q q q q
H-33
H-34
positioner
H-30
q q q q

q q
H-35
q H-36
40-1017
40 Troubleshooting
(*)
F
N
Gear
speed
40-1018
In auto shift
mode
In manual
shift mode
F1
F2
F3
F4
R1
R2
R3
R4
Clutches to be used
1st
2nd
3rd
4th
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
WA470-7
40 Troubleshooting
H-1 Machine does not move off

Failure
Related
information
No.
1
(WA470_7-BH0-400-A-Z0-A)
Machine does not move off at all gear speeds.

Check that transmission oil level is normal.
If any failure code is displayed, perform troubleshooting for that failure code first.
(15SAL1, 15SALH, 15SBL1, 15SBLH, 15SEL1, 15SELH, 15SFL1, 15SFLH, 15SGL1,
15SGLH, 15SHL1, or 15SHLH).
Check drive shaft, etc. for abnormalities.
Check that parking brake is surely released.
Torque converter oil pressure can be checked with monitoring function. (Monitoring code:
32601 (Input pressure), 32603 (Output pressure))
Engine speed can be checked with monitoring function. (Monitoring code: 01001)

Cause
Defective strainer of
Check strainer for clogging.
transmission charge
pump
Air sucked in on suction
side of transmission
Check suction piping for cracks, etc.
charge pump
Defective main relief

valve of transmission
charge pump
a Be ready with engine stopped, then perform troubleshooting with engine

running at low idle and 2,000 rpm.
2.32 0.2 MPa
Low idle
{23.5 2 kg/cm2}
Main relief pressure Engine speed
2.55 0.2 MPa
2,000 rpm
{26.0 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief valve for
malfunction (fatigue of spring) and internal defect (defective valve seat).
Improper torque
converter pressure
(relief valve)

running at 2,000 rpm.
0.1 to 0.88 MPa
Torque converter
Brake
OFF
input pressure
{1.0 to 9.0 kg/cm2}
0.06 to 0.71 MPa
Torque converter
Brake
OFF
output pressure
{0.6 to 7.1 kg/cm2}
When pressure cannot be adjusted to normal level, check relief valve for
If torque converter output pressure is below standard value, oil cooler may
be broken.
Defective torque
converter
a Be ready with engine stopped, then perform troubleshooting during torque

converter stall operation.
Economy mode
1,710 100 rpm
ON
Torque converter
switch
stall speed
Power mode
1,785 100 rpm
ON
switch
WA470-7
40-1019
40 Troubleshooting
No.
Cause
Defective gear speed

clutch ECMV

clutch
charge pump
Internal defect of
transmission
Clogged last chance
10
filter
Malfunction of check
11
valve
Malfunction of parking
12 brake emergency
release valve
9

2.06 0.15 MPa
Output pressure of F
F1
clutch ECMV
{21 1.5 kg/cm2}
2.06 0.15 MPa
Output pressure of R
R1
clutch ECMV
{21 1.5 kg/cm2}
2.35 0.15 MPa
Output pressure of
F1
1st clutch ECMV
{24 1.5 kg/cm2}
Gear speed
2.35 0.15 MPa
Output pressure of
F2
2nd clutch ECMV
{24 1.5 kg/cm2}
2.30 0.5 MPa
Output pressure of
F3
3rd clutch ECMV
{23.5 1.5 kg/cm2}
2.30 0.5 MPa
Output pressure of
F4
4th clutch ECMV
{23.5 1.5 kg/cm2}
* Combination of two gear speed clutches determines gear speed. Check
combination of two clutches to be used for selection of gear speed by
referring to Table 1.
If measured pressure is below standard value in check on cause (6), oil
may leak through clutch seal ring.
If measured pressure is normal in check on cause (6), clutch may slip.
If measured pressure is unusual in check on cause (3) and main relief
valve is normal, disconnect transmission charge pump outlet hose, crank
engine, and check that oil flows out.
Check line filter for foreign materials such as metal particles.
If no failure is found by checks on causes (1) to (8), transmission may
have internal defect.
If no failure is found by check on cause (3) but lockup clutch pressure is low or
0, check last chance filter for clogging.
Check check valve between last chance filter and parking brake solenoid for
sticking.
If turning release valve does not release parking brake, check release valve
spool for sticking.
a Be ready with engine stopped, then perform troubleshooting with engine at

low idle.
0 MPa
ON
Output
pressure
of
{0 kg/cm2}
Parking brake
13
parking
brake
switch
2.32 MPa
solenoid valve
OFF
{23.5 kg/cm2}
If oil pressure is not developed with parking brake switch at OFF position,
check solenoid valve spool for sticking.
If no failure is found by check on cause (13), parking brake may be
defective.
14 Defective parking brake
Check parking brake for worn disc, deformed spring, etc.
Thickness of parking brake disc
Min. 2.97 mm
40-1020
WA470-7
40 Troubleshooting
Table 1
F
Gear speed
In auto shift
mode
In manual
shift mode
F1
F2
F3
F4
R1
R2
R3
R4
Clutches to be used
1st
2nd
3rd
4th
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
a When manual shift mode is selected, speed clutch (marked with q) for current gear speed, to which gear
shift lever is set, remains engaged.
When transmission is at NATURAL, operating gear shift lever does not switch engaged clutches.
WA470-7
40-1021
40 Troubleshooting
H-2 Torque converter lockup clutch is not disengaged (engine

stalls) (WA470_7-AD1-400-A-Z0-A)
Failure
Related
information
No.

(DXH1KA, DXH1KB, or DXH1KY
Cause

When torque converter lockup
1.66 0.15 MPa
Malfunction of lockup
clutch is engaged
clutch ECMV
{17.0 1.5 kg/cm2}
Output pressure of (Manual lockup switch: ON)
lockup clutch ECMV
0 MPa
clutch is disengaged
{0 kg/cm2}
Defective lockup clutch If measured pressure is normal in check on cause (1), lockup clutch may be
seized.
40-1022
WA470-7
40 Troubleshooting
H-3 Torque converter lockup clutch is not engaged

Failure
Related
information
No.

(DXH1KA, DXH1KB, or DXH1KY
Cause

charge pump
Clogged last chance

filter
(WA470_7-F11-400-A-Z0-A)

2.32 0.2 MPa
Low idle
{23.5 2 kg/cm2}
2.55 0.2 MPa
2,000 rpm
{26.0 2.0 kg/cm2}
malfunction (setting of spring) and internal defect (defective valve seat).
"0", check last chance filter for clogging.

1.66 0.15 MPa
Malfunction of lockup
clutch is engaged
clutch ECMV
{17.0
1.5 kg/cm2}
Output pressure of (Manual switch: ON)
lockup clutch ECMV
0 MPa
clutch is disengaged
{0 kg/cm2}
If measured pressure is normal in check on cause (3), lockup clutch may have
worn.
If measured pressure is unusual but ECMV is normal, sealing of lockup clutch
piston may be defective.
WA470-7
40-1023
40 Troubleshooting
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low,
or gear speed does not shift (WA470_7-D20-400-A-Z0-A)
Failure
Related
information
No.
1
Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not
shift.
15SGLH, 15SHL1, or 15SHLH).
Check that wheel brake or parking brake is not dragged.

Cause
transmission charge
pump
charge pump

charge pump
Clogged last chance

filter

2.32 0.2 MPa
Low idle
{23.5 2 kg/cm2}
2.55 0.2 MPa
2,000 rpm
{26 2.0 kg/cm2}
"0", check last chance filter for clogging.
Improper torque
converter pressure
(relief valve)

0.1 to 0.88 MPa
Torque converter
Brake
OFF
input pressure
{1.0 to 9.0 kg/cm2}
0.06 to 0.71 MPa
Torque converter
Brake
OFF
output pressure
{0.6 to 7.1 kg/cm2}
If torque converter output pressure is below standard value, oil cooler may
be broken.
Defective torque
converter
a Be ready with engine stopped, then perform troubleshooting during torque

converter stall operation.
Economy mode
1,710 100 rpm
ON
Torque converter
switch
stall speed
Power mode
1,785 100 rpm
ON
switch
40-1024
WA470-7
40 Troubleshooting
No.
Cause

clutch ECMV

clutch
Lockup clutch
Malfunction of ECMV
10
Slippage of lockup
clutch
11 charge pump
Clogged transmission
breather
Internal defect of
13
transmission
12

2.06 0.15 MPa
F1
clutch ECMV
{21 1.5 kg/cm2}
2.06 0.15 MPa
R1
clutch ECMV
{21 1.5 kg/cm2}
2.35 0.15 MPa
Output pressure of
F1
1st clutch ECMV
{24 1.5 kg/cm2}
Gear speed
2.35 0.15 MPa
Output pressure of
F2
2nd clutch ECMV
{24 1.5 kg/cm2}
2.30 0.5 MPa
Output pressure of
F3
3rd clutch ECMV
{23.5 1.5 kg/cm2}
2.30 0.5 MPa
Output pressure of
F4
4th clutch ECMV
{23.5 1.5 kg/cm2}
If measured pressure is below standard value in check on cause (7), oil
may leak through clutch seal ring.
1.66 0.15 MPa
Output pressure of
Lockup switch
ON
lockup clutch ECMV
{17 1.5 kg/cm2}
If measured pressure is below standard value in check on cause (9),
clutch piston seal ring or ring groove may wear.
valve is normal, disconnect power train pump outlet hose, crank engine,
and check that oil flows out.
Check breather for clogging.
If no failure is found by checks on causes (1) to (12), transmission may have

internal defect.
If no failure is found by checks on causes (1) to (13) and torque converter
stall speed is below standard value (power mode: 1785 rpm), engine
14 Lowered engine output
performance may lower.
Table 1
F
Gear speed
WA470-7
In auto shift
mode
In manual
shift mode
F1
F2
F3
F4
R1
R2
R3
R4
Clutches to be used
1st
2nd
3rd
4th
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
40-1025
40 Troubleshooting
40-1026
WA470-7
40 Troubleshooting
H-5 Large shock is made when machine starts or gear is shifted
(WA470_7-C10-
400-A-Z0-A)
Failure
Related
information
No.
1
Large shock is made when machine starts or gear is shifted.

It is difficult to determine whether shock you feel is large or small. so, regard shocks as
large in following cases.
1. When you feel that shock increases significantly and suddenly
2. When you feel that shock is larger than that of other machines of same model
If any failure code is displayed, perform trouble shooting for that failure code first.
15SAL1, 15SALH, 15SBL1, 15SBLH, 15SEL1, 15SELH, 15SFL1, 15SFLH, 15SGL1,
15SGLH, 15SHL1, 15SHLH, DGF1KA, or DGF1KB)
Check that drive shaft, etc. are normal.
Clutch fill time can be checked with monitoring function. (Monitoring code: 41802 (1st),
41803 (2nd), 41804 (3rd), 41805 (4th), 41806R), 41808 (F))

Cause
transmission charge
pump
charge pump

charge pump
Clogged last chance

filter
WA470-7

2.32 0.2 MPa
Low idle
{23.5 2 kg/cm2}
2.55 0.2 MPa
2,000 rpm
{26 2.0 kg/cm2}
40-1027
40 Troubleshooting
No.
Cause

2.06 0.15 MPa
F1
clutch ECMV
{21 1.5 kg/cm2}
2.06 0.15 MPa
R1
clutch ECMV
{21 1.5 kg/cm2}
2.35 0.15 MPa
Output pressure of
F1
1st clutch ECMV
{24 1.5 kg/cm2}
Gear speed
2.35 0.15 MPa
Output pressure of
5
F2
clutch ECMV
2nd clutch ECMV
{24 1.5 kg/cm2}
2.30 0.5 MPa
Output pressure of
F3
3rd clutch ECMV
{23.5 1.5 kg/cm2}
2.30 0.5 MPa
Output pressure of
F4
4th clutch ECMV
{23.5 1.5 kg/cm2}
Pressure control valve spool may malfunction due to trapped dirt, or fill
switch or solenoid may malfunction.
If measured pressure is low in check on cause (5), oil may leak through
clutch seal ring.
6
clutch
If gear speed clutch is normal in check on cause (5), sealing of parking
7 Defective parking brake
brake piston may be defective.
8 charge pump
Internal defect of
If no failure is found by checks on causes 1 to 8, transmission may have
9
transmission
internal defect.
Defective transmission If no failure is found by checks on causes 1 to 9, transmission controller
10
may be defective.
controller
Table 1
F
Gear speed
In auto shift
mode
In manual
shift mode
F1
F2
F3
F4
R1
R2
R3
R4
Clutches to be used
1st
2nd
3rd
4th
q
Q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
40-1028
WA470-7
40 Troubleshooting
H-6 Machine starts or gear speed shifts with long time lag
Failure
Related
information
No.
1
(WA470_7-C60-400-A-Z0-A)

If any failure code is displayed, perform trouble shooting for that failure code first.
15SAL1, 15SALH, 15SBL1, 15SBLH, 15SEL1, 15SELH, 15SFL1, 15SFLH, 15SGL1,
15SGLH, 15SHL1, 15SHLH, DGF1KA, or DGF1KB)
Check that drive shaft, etc. are normal.

Cause
If unusual noise is heard from charge pump or transmission oil filter when
transmission charge
transmission oil temperature is low, check strainer for clogging.
pump
charge pump

charge pump
Clogged last chance

filter

2.32 0.2 MPa
Low idle
{23.5 2 kg/cm2}
2.55 0.2 MPa
2,000 rpm
{26 2.0 kg/cm2}
2.06 0.15 MPa
F1
clutch ECMV
{21 1.5 kg/cm2}
2.06 0.15 MPa
R1
clutch ECMV
{21 1.5 kg/cm2}
Output pressure of
1st clutch ECMV

clutch ECMV
brake
WA470-7
F1
Gear speed
2.35 0.15 MPa

{24 1.5 kg/cm2}
2.35 0.15 MPa

{24 1.5 kg/cm2}
2.30 0.5 MPa
Output pressure of
F3
3rd clutch ECMV
{23.5 1.5 kg/cm2}
2.30 0.5 MPa
Output pressure of
F4
4th clutch ECMV
{23.5 1.5 kg/cm2}
If no failure is found by check on cause (5) and any gear speed causes
long time lag, sealing of parking brake piston may be defective.
Output pressure of
2nd clutch ECMV
F2
40-1029
40 Troubleshooting
No.
Cause

clutch
charge pump
Internal defect of
transmission

clutch seal ring.
internal defect.
Table 1
F
Gear speed
In auto shift
mode
In manual
shift mode
F1
F2
F3
F4
R1
R2
R3
R4
Clutches to be used
1st
2nd
3rd
4th
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
a Clutch fill time can be checked with monitoring function.

Monitoring code: 41802 (1st)
41803 (2nd)
41804 (3rd)
41805 (4th)
41806 (R)
41808 (F)
40-1030
WA470-7
40 Troubleshooting
H-7 Torque converter oil temperature is high

Failure
Related
information
No.
1
2
3
(WA470_7-AM0-400-A-Z0-A)

15SGLH, 15SHL1, 15SHLH, DGT1KA, or DGT1KB)
Check that parking brake is surely released.
Measure torque converter oil temperature actually and compare it with that displayed by
using monitoring function to determine whether oil temperature sensor is normal.
(Monitoring code: 30100)

Cause
transmission charge
pump
charge pump
Clogged transmission Check breather for clogging.
breather

charge pump

2.32 0.2 MPa
Low idle
{23.5 2 kg/cm2}
2.55 0.2 MPa
2,000 rpm
{26 2.0 kg/cm2}
Improper torque
converter pressure
(relief valve)

0.1 to 0.88 MPa
Torque converter
Brake
OFF
input pressure
{1.0 to 9.0 kg/cm2}
0.06 to 0.71 MPa
Torque converter
Brake
OFF
output pressure
{0.6 to 7.1 kg/cm2}
If torque converter output pressure is low, oil cooler may be broken.
Defective torque
converter
a Be ready with engine stopped, then perform troubleshooting with torque

converter at stall.
Economy mode
1710 100 rpm
ON
Torque converter
switch
stall speed
Power mode
1785 100 rpm
ON
switch
WA470-7
40-1031
40 Troubleshooting
No.
Cause

2.06 0.15 MPa
F1
clutch ECMV
{21 1.5 kg/cm2}
2.06 0.15 MPa
R1
clutch ECMV
{21 1.5 kg/cm2}
Output pressure of
1st clutch ECMV
7

clutch ECMV

clutch
charge pump
10
Internal defect of
transmission
Defective engine
11 system
F1
Gear speed
2.35 0.15 MPa

{24 1.5 kg/cm2}
2.35 0.15 MPa

{24 1.5 kg/cm2}
2.30 0.5 MPa
Output pressure of
F3
3rd clutch ECMV
{23.5 1.5 kg/cm2}
2.30 0.5 MPa
Output pressure of
F4
4th clutch ECMV
{23.5 1.5 kg/cm2}
clutch seal ring.
If measured pressure is high in check on cause (7), clutch may slip.
Check whether hydraulic oil flows into transmission case due to broken
pump shaft seal.
internal defect.
If no failure is found by checks on causes 1 to 10, engine performance
may lower. Perform troubleshooting by referring to "S mode"
troubleshooting.
Output pressure of
2nd clutch ECMV
F2
Table 1
F
Gear speed
In auto shift
mode
In manual
shift mode
F1
F2
F3
F4
R1
R2
R3
R4
Clutches to be used
1st
2nd
3rd
4th
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
40-1032
WA470-7
40 Troubleshooting
H-8 Machine does not turn

Failure
Related
information
No.
1
2
3
(WA470_7-L10-400-A-Z0-A)

Check that oil level in hydraulic tank is normal.
Check that frame lock bar is removed.
Check that steering shaft is not damaged.
Check that steering stop valve is properly adjusted.
Steering pump pressure can be checked with monitoring function. (Monitoring code:
95302)
Fan speed can be checked with monitoring function. (Monitoring code: 10009)
Cause
Defective PTO

When machine does not turn to either side, if work equipment or cooling fan
also malfunctions, PTO may be defective.

side of steering pump
Check steering pump strainer for clogging.
steering pump

high idle.*
Defective charge valve Output pressure of
3.72 0.2 MPa
NEUTRAL
accumulator charge Steering wheel
of accumulator
{38 2.0 kg/cm2}
valve
Output pressure of accumulator charge valve is source pressure for
Orbitrol.

high idle.*
Pressure must be
applied while
Output pressure of
Steering wheel
Operation
steering wheel is
Orbitrol
operated.
Defective Orbitrol

Defective relief valve of
low idle.*
steering valve
1.15 to 1.55 MPa
Steering control
Steering wheel
NEUTRAL
pressure
{11.7 to 15.3 kg/cm2}
If measured pressure is abnormally high in check on cause (6), flow control
Defective flow control
spool may malfunction.
spool
Check spool for sticking.
When measured pressure is normal in check on cause (6), if oil pressure is
not applied to steering cylinder while steering wheel is operated, steering
Defective steering spool spool may malfunction.

high idle.*
24.5 (+1.23/-2.45)
Defective steering main
9
MPa
Steering
Steering
main
relief
relief valve
Relief
cylinder
pressure
{250 (+12.5/-25) kg/
cm2}
If measured relief pressure is unusual, adjust main relief valve.
If measured relief pressure of either side is low in check on cause (9),
Defective overload relief overload relief valve may be defective.
10
valve
Replace the assembly because it cannot be adjusted when it is installed to
actual machine.
When no failure is found by check on cause (10), if machine turn only to one
side or steering wheel is too heavy to turn to one side, stop valve may be
11 Defective stop valve
defective.
WA470-7
40-1033
40 Troubleshooting
No.
Cause
Defective steering
12 cylinder
Defective steering
13 pump
Defective cooling fan

14 pump

high idle.*
If measured relief pressure is below standard value in check on cause (9),
disconnect hydraulic hose from steering cylinder head end, set frame lock bar,
and extend that steering cylinder to relieve it hydraulically. If oil flows out of
cylinder, piston ring of steering cylinder is defective.
valve is normal, disconnect steering pump outlet hose, crank engine, and
check that oil flows out.
Check return filter and suction strainer for foreign materials such as metal
particles.
If measured output pressure of accumulator charge valve is below
standard value in check on cause (4), cooling fan pump may be defective.
a Perform troubleshooting with engine at high idle.
Torque converter oil temperature:
Fan speed
1,300 200 rpm
Min. 105C
Hydraulic oil temperature: Min.
95C
If fan speed is below standard value, perform troubleshooting for "H-35
Fan speed is abnormal".
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)
40-1034
WA470-7
40 Troubleshooting
H-9 Turning response is poor

Failure
General
information
No.
1
2
3
(WA470_7-L30-400-A-Z0-A)

95302)
Cause
Defective PTO

When machine does not turn to either side, if work equipment or cooling fan
also malfunctions, PTO may be defective.

side of steering pump
Check steering pump strainer for clogging.
steering pump

high idle.*
Defective charge valve Output pressure of
3.72 0.2 MPa
NEUTRAL
of accumulator
{38 2.0 kg/cm2}
valve
Orbitrol.

high idle.*
Pressure must be
developed while
Output pressure of
Steering wheel
Operation
steering wheel is
Orbitrol
operated.
Defective Orbitrol

low idle.
steering valve
1.15 to 1.55 MPa
Steering control
Steering wheel
NEUTRAL
pressure
{11.7 to 15.3 kg/cm2}
spool

relief valve
10
Defective overload relief

valve
11 Defective stop valve

12 Malfunction of PC valve
13 Malfunction of LS valve
WA470-7

high idle.*
24.5 (+1.23/-2.45)
MPa
Steering
Steering main relief
Relief
cylinder
pressure
{250 (+12.5/-25) kg/
cm2}
overload relief valve may be defective.
Replace the assembly because it cannot be adjusted when it is installed to
actual machine.
side or steering wheel is too heavy to turn to one side, stop valve may be
defective.
Check PC valve for sticking of spool and fatigue of spring. If any failure is
found, replace it.
Check LS valve for sticking of spool and fatigue of spring. If any failure is
found, replace it.
40-1035
40 Troubleshooting
No.
Cause
Defective steering
14 cylinder
Defective steering
15 pump

16 pump

high idle.*
If measured relief pressure is low, disconnect hydraulic hose from steering
cylinder head end, and relieve steering cylinder hydraulically at its stroke end.
If oil flows out from cylinder, cylinder piston ring is defective.
valve is normal, disconnect steering pump outlet hose, crank engine, and
check that oil flows out.
particles, etc.
Fan speed
1,300 200 rpm
Min. 105C
95C
40-1036
WA470-7
40 Troubleshooting
H-10 Steering wheel is heavy to turn

Failure
Related
information
No.
(WA470_7-LQ0-400-A-Z0-A)

Check that inflation pressure is normal.
If machine does not turn smoothly, perform troubleshooting for H-8 and H-9.
95302)
Cause

full speed.
Output
pressure of
Defective charge valve
3.72 0.2 MPa
NEUTRAL
of accumulator
{38 2.0 kg/cm2}
valve
Orbitrol.

high idle.*
Pressure must be
Output pressure of
developed while
Steering wheel
Operated
power steering
steering wheel is
control unit
operated.
4
5
Defective Orbitrol

high idle.*
24.5 (+1.23/-2.45)
MPa
Steering
Steering
main
relief
relief valve
Hydraulic relief
cylinder
pressure
{250 (+12.5/-25) kg/
cm2}
side or steering wheel is heavy and hard to turn only to one side, stop valve
Defective stop valve
may be defective.
Malfunction of steering
Check them after disconnecting steering shaft from Orbitrol.
wheel or steering shaft

pump

Fan speed
1,300 200 rpm
Min. 105C
95C
WA470-7
40-1037
40 Troubleshooting
H-11 Machine sways or large shocks are made while machine

turns (WA470_7-L54-400-A-Z0-A)
Failure
General
information
No.

Check that play of steering wheel is normal.
95302)
Cause

high idle.*
Output
pressure of
3.72 0.2 MPa
NEUTRAL
of accumulator
{38 2.0 kg/cm2}
valve
Orbitrol.

high idle.*
Pressure must be
developed while
Output pressure of
Steering wheel
Operation
steering wheel is
Orbitrol
operated.
Defective Orbitrol

low idle.*
steering valve
1.15 to 1.55 MPa
Steering control
Steering wheel
NEUTRAL
pressure
{11.7 to 15.3 kg/cm2}
spool
high idle.*
24.5 (+1.23/-2.45)
MPa
Steering
Steering main relief
relief valve
Relief
cylinder
pressure
{250 (+12.5/-25) kg/
cm2}
Defective overload relief overload relief valve may be defective.
valve
Replace valve assembly because valve cannot be adjusted when it is
installed to machine.
If machine sways to either side or large shock is made while machine turns,
stop valve may be defective.
Defective stop valve
If large shock is made when steering cylinder reaches its stroke end, stop
valve may be defective.
Defective steering
cylinder
40-1038

high idle.*
disconnect hydraulic hose from steering cylinder head end, set frame lock bar,
and extend that steering cylinder to relieve it hydraulically. If oil flows out of
cylinder, piston ring of cylinder is defective.
WA470-7
40 Troubleshooting
No.
Cause

10 pump

Fan speed
1,300 200 rpm
Min. 105C
95C
WA470-7
40-1039
40 Troubleshooting
H-12 Turning radius differs between right and left turns

Failure
Related
information
No.
1
(WA380_7-L90-400-A-Z0-A)

Check that stopper bolt for stop valve is not loosened.
Cause
Improper adjustment of
steering stop valve

a Adjust installed positions of stopper bolts for steering stop valves
(right and left).
a For adjustment procedure of stopper bolt, see

Testing and adjusting, "Testing and adjusting
stopper bolt".
(Reference) Adjustment procedure of stopper
bolt for stop valve
1. Set stopper bolt (1) to its minimum length.
k Take
care not to loosen stopper bolt

(1) excessively so that it does not
press spool.
4. Turn machine back more than 10 degrees

and stop engine.
5. Loosen stopper bolt (1) further 8.5 turns
(approx. 15 mm), and fix it with lock nut (3).
6. Adjust both right and left stopper bolts by
applying procedures of steps (1) to (5).
2. Run engine at low idle, and turn steering

wheel slowly so that stopper bolt contacts
frame end.
3. Under condition in step (2), loosen stopper
bolt (1) until its head contacts end face of
spool of stop valve (2).
40-1040
WA470-7
40 Troubleshooting
H-13 Wheel brakes do not work or are weak

Failure
Related
information
No.
1
2

Check that hydraulic oil level is normal.
Check that play of brake pedal is normal.
Brake pressure can be checked with monitoring function. (Monitoring code: 41201)
Brake cut-off operating pressure can be checked with monitoring function. (Monitoring
code: 41203)

Cause
side of cooling fan
pump
Air mixed in brake
Bleed air from brake circuit. For details, see Testing and adjusting "Bleeding
circuit
air from wheel brake circuit".
Defective accumulator
charge valve

high idle.*
Charge valve cut-in pressure
5.9 (+0.98/-0.5) MPa
(When brake pressure caution
{60 (+10/-5) kg/cm2}
lamp goes out)
Charge valve
operating pressure
Charge valve cut-out pressure
9.8 (+1.5/-0.5) MPa
(When brake pressure switches
{100 (+15/-5) kg/
from rising to lowering)
cm2}
Defective brake
accumulator

stopped.
Count number of times
Number of times
depressing brake pedal required
depressing brake
Min. 5 times
until brake pressure caution lamp
pedal
goes out.
If brakes went out immediately after engine is stopped, accumulator may be
short of charged gas or its sealing may be defective.
(Reference) Charged gas pressure: 3.4 0.10 MPa {35 1.0 kg/cm2 }
Defective brake valve
Defective wheel brake
(WA470_7-FL8-400-A-Z0-A)

high idle.*
Min. 4.2 MPa
Brake actuating
Brake pedal depressed
pressure
{Min. 42.7 kg/cm2}
If measured pressure is below standard value in check on cause (5), brake
piston seal ring or ring groove may be defective.
If measured pressure is normal in check on cause (5), brake disc may slip.
Protrusion of shaft
(See Testing and adjusting,
Max. 2.4 mm
Wear of disc
"Testing wear of wheel brake
disc".)

Coolant temperature: Min. 90 C
pump
Fan speed
1,300 200 rpm
Min. 100 C
Hydraulic oil temperature: Min. 90
C
If fan speed is below standard value, perform troubleshooting for H-34
Fan speed is abnormal.
If large depressing effort is required for brake pedal or brakes work with time
Defective slack adjuster
lag, slack adjuster may be defective.
WA470-7
40-1041
40 Troubleshooting
40-1042
WA470-7
40 Troubleshooting
H-14 Wheel brakes are not released or drag

Failure
Related
information
No.
2
3
(WA470_7-E63-400-A-Z0-A)

Check that brake pedal returns completely.
Check that parking brake is released completely.
Brake pressure can be checked with monitoring function. (Monitoring code: 41201)
Cause

high idle.*
0 MPa
When brake pedal is released
{0 kg/cm2}
Brake valve
operating pressure
Min. 4.2 MPa
Defective brake valve
When brake pedal is depressed
{Min. 42.7 kg/cm2}
If brake pressure is developed when brake pedal is released, brake valve
spool may be stuck.
Release brake pedal, remove oil from air bleeder, and check whether circuit
pressure lowers and brakes are released.
When air bleeder at wheel portion is loosened, if oil flows out and brake is
Defective slack adjuster
released, slack adjuster may be defective.
Jack up four wheels and put axles onto the stands. (Engine stopped)
Release parking brake and rotate the tires to check if there is any tire not
Defective wheel brake
rotate smoothly.
WA470-7
40-1043
40 Troubleshooting
H-15 Parking brake does not work or it is weak

Failure
Related
information
No.
(WA470_7-FPR-400-A-Z0-A)

(2F00MA or DDB6L4)
Check that parking brake has not been released mechanically.
Cause

low idle.
0 MPa
ON
{0 kg/cm2}
Defective parking brake Parking brake
Parking brake
solenoid valve
pressure
switch
Min. 2.32 MPa
OFF
{Min. 23.5 kg/cm2}
If oil pressure is developed with parking brake switch at ON position, check
solenoid valve spool for locking.
If no failure is found by check on cause (1), parking brake may be
defective.
Min. 2.97 mm
40-1044
WA470-7
40 Troubleshooting
H-16 Parking brake is not released or drags (including emergency

release system) (WA470_7-E73-400-A-Z0-A)
Failure
Related
information
No.

(DDB6L4)
Check that parking brake is automatically applied when engine is stopped.
Cause
brake emergency
release valve

accumulator

low idle.
0 MPa
ON
{0 kg/cm2}
Parking brake
Parking brake
pressure
switch
Min. 2.32 MPa
OFF
{Min. 23.5 kg/cm2}
If oil pressure is not developed with parking brake switch at OFF position,
check solenoid valve spool for locking.
If turning release valve does not release parking brake, release valve may
malfunction.
(For release procedure, see Testing and adjusting, "Release procedure of
parking brake".)
If parking brake becomes hard to release immediately after engine is stopped,
accumulator may be short of charged gas.
(Reference) Charged gas pressure: 3.4 0.10 MPa {35 1.0 kg/cm2 }

23.2 0.2 MPa
Low idle
{23.5 2.0 kg/cm2}
Main relief pressure Engine Speed
2.55 0.2 MPa
charge pump
1,900 rpm
{26 2.0 kg/cm2}
Check check valve between last chance filter and parking brake solenoid for
Malfunction of check
locking.
valve
If no failure is found by checks on causes (1) to (5), parking brake may be
defective.
Min. 2.97 mm
WA470-7
40-1045
40 Troubleshooting
H-17 Boom does not rise

Failure
Related
information
(WA470_7-M60-400-A-Z0-A)
Boom does not rise.

(DB90KK, DB92KK, DB95KX, DK59L8, DW4PKA, DW4PKB, DW4PKY, DW4QKY,
DW4RKY, DW4SKY, DWM1KY, DXA1KY, or DXHKKY)
Check that lever stroke of boom control lever is correct.
Check that engine high idle speed is normal with monitoring function. (Monitoring code:
01001)
(Engine high idle speed: 2,120 to 2,220 rpm)
For measuring procedure, see "Testing engine speed" in "Testing and adjusting".
Work equipment pump pressure can be checked with monitoring function. (Monitoring
code: 94700)

No.
Cause
If
bucket
does
not move and boom does not rise, PTO may be defective.
1 Defective PTO
2 work equipment pump Check strainer for clogging.
3 side of work equipment Check suction piping for cracks, etc.
pump

high idle.*
Output
pressure of All control levers
3.72 0.2 MPa
NEUTRAL
accumulator charge (including
of accumulator
{38
2.0 kg/cm2}
steering wheel)
valve
Output pressure of accumulator charge valve is source pressure of pilot
pressure for boom control valve (RAISE and LOWER).
high idle.*
2.94 0.2 MPa
Boom control
Output pressure of
RAISE
lever
EPC valve
{30.0 1.6 kg/cm2}
If output pressures of all EPC valves including boom (RAISE) control EPC
Malfunction of shut off valve are below standard value in check on cause (5), shut off valve may
valve (for pilot circuit of malfunction.
work equipment valve)
Check shut off valve spool for sticking.
Malfunction of boom
RAISE EPC valve
Defective unload valve

of work equipment
valve
Defective work
equipment main relief
valve
Malfunction of boom
control valve spool
Boom control valve

10 Malfunction of load
check valve
40-1046

high idle.*
1.72 to 3.43 MPa
Unload valve relief Work equipment
NEUTRAL
pressure
control lever
{17.5 to 35 kg/cm2}
full speed. (For measuring procedure, see Testing and adjusting, "Testing
work equipment oil pressure".)
34.3 (+1.8/-4.4) MPa
Work equipment
Lift cylinder
Relief
{350 (+18/-45) kg/
main relief pressure
cm2}
If relief pressure is not increased to normal level after main relief valve is
adjusted, unload valve may remain opened.
When no failure is found by checks on causes (4) and (7), if main circuit
pressure at boom RAISE operation does not rise above relief pressure of
unload valve, work equipment valve spool may malfunction.
When no failure is found by checks on cause (8), check load check valve for
sticking.
WA470-7
40 Troubleshooting
No.
11
12
13
14
Cause

high idle.*
If
measured
relief pressure is below standard value in check on cause (8),
Defective lift cylinder
disconnect hydraulic hose from lift cylinder head end and relieve it
hydraulically at its stroke end. If oil flows out of cylinder, piston ring of cylinder
is defective.
valve is normal, disconnect work equipment pump outlet hose, crank
Defective work
equipment pump
particles.
Malfunction of PC valve found, replace it.
Malfunction of LS valve found, replace it.

15 pump
Malfunction of suction
16 safety valve in lift
cylinder bottom circuit

Fan speed
1,300 200 rpm
Min. 105C
95C
While boom can be raised when it is unloaded, if it can not be raised in
digging or loading operation, or if hydraulic drift of boom is large, boom bottom
suction safety valve may malfunction.
WA470-7
40-1047
40 Troubleshooting
H-18 Boom moves slow or boom lacks lifting force

Failure
Related
information
No.
1
2
(WA470_7-D56-400-A-Z0-A)

(DK59KA, DK59KY, DK59L8, DK5AKA, DK5AKY, or DXA1KY)
Check that lever stroke of boom control lever is correct.
01001)
code: 94700)

Cause
Check work equipment pump strainer for clogging.
work equipment pump
side of work equipment Air may be sucked in. Check suction piping of work equipment pump.
pump
high idle.*
Output
3.72 0.2 MPa
NEUTRAL
accumulator
charge (including
of accumulator
{38 2.0 kg/cm2}
steering wheel)
valve
high idle.*
2.94 0.16 MPa
Boom control
Output pressure of
RAISE
lever
EPC valve
{30.0 1.6 kg/cm2}
If output pressures of all EPC valves including boom (RAISE) control EPC
Malfunction of boom
RAISE EPC valve

of work equipment
valve

high idle.*
Boom and
1.72 to 3.43 MPa
Unload valve relief
bucket
control
NEUTRAL
pressure
{17.5
to 35 kg/cm2}
levers

high idle. (For measuring procedure, see Testing and adjusting, "Testing
Defective work
34.3 (+1.8/-4.4) MPa
7 equipment main relief
Work equipment
Lift
cylinder
Relief
{350 (+18/-45) kg/
valve
cm2}
If relief pressure is not increased to normal level after main relief valve is
adjusted, unload valve may remain opened.
Defective charge valve If no failure is found by check on cause (7) but relief pressures of boom and
bucket are below standard value, travel damper charge valve may be
8 of travel damper
defective.
pressure at boom RAISE operation does not rise above relief pressure of
Malfunction of boom
9 control valve spool
unload valve, work equipment valve spool may malfunction.
Boom control valve
sticking.
check valve
40-1048
WA470-7
40 Troubleshooting

11 Malfunction of PC valve found, replace it.
12 Malfunction of LS valve found, replace it.
No.
Cause
13 Defective lift cylinder
Defective work
14 equipment pump

15 pump

high idle.*
If measured relief pressure is below standard value, disconnect hydraulic
hose from lift cylinder head end, and relieve lift cylinder hydraulically at its
stroke end. If oil flows out of cylinder, cylinder piston ring is defective.
particles.
Fan speed
1,300 200 rpm
Min. 105C
95C
WA470-7
40-1049
40 Troubleshooting
H-19 Rising boom slows down at certain height

Failure
Related
information
(WA470_7-D52-400-A-Z0-A)

Check booms and lift cylinders for visible deformation.
No.
Cause
Defective
lift cylinder
1

Lift cylinder tube may bulge or cylinder may have internal damage.
a When boom RAISE remote positioner is enabled, if boom control lever is held in detent position to allow
boom to exceed target stop angle, rising boom decelerates temporarily and then accelerates.
(Reference)
For other failure symptoms while boom is rising, see "H-18 Boom moves slow or boom lacks lifting force".
40-1050
WA470-7
40 Troubleshooting
H-20 Lift cylinders do not serve to hold bucket on ground

Failure
Related
information
No.
(WA470_7-A83-400-A-Z0-A)
Lift cylinders do not serve to hold bucket on ground (bucket rises off ground).
(DB90KK, DB92KK, DB95KX, DK59L8, DW4PKY, DW4QKA, DW4QKB, DW4QKY,
DW4RKY, DW4SKY, DWM1KY, DXA1KY, DXHJKY, or DXHKKY)
If failure symptom of "Boom moves slow" or "Boom lacks lifting power" also appears,
perform troubleshooting for "H-18" as well.
code: 94700)
Boom control lever stroke can be checked with monitoring function. (Monitoring code:
42104)
Cause

high idle.*
Defective charge valve Output pressure of All control levers
3.72 0.2 MPa
NEUTRAL
of accumulator
{38
2.0 kg/cm2}
steering wheel)
valve
high idle.*
34.3 (+1.8/-4.4) MPa
Boom LOWER
Defective suction-safety
Relief pressure
Lift cylinder
{350 (+18/-45) kg/
hydraulic relief
valve
cm2}
If only boom LOWER relief pressure is low, suction safety valve may
malfunction.
Replace suction safety valve assembly.
Stroke to
Lever strike of boom Boom control
LOWER
Min. -74%
Defective boom control control lever
lever
position
lever
a Stroke means lever travel to point just before detent position.
Malfunction of boom
LOWER EPC valve

high idle.*
1.91 0.15 MPa
Output pressure of
Boom control
LOWER
lever
EPC valve
{19.5 1.5 kg/cm2}

high idle.*
hose from lift cylinder head end, and relieve lift cylinder hydraulically at its
stroke end. If oil flows out of cylinder, cylinder piston ring is defective.
WA470-7
40-1051
40 Troubleshooting
H-21 Hydraulic drift of boom is large

Failure
Related
information
No.
(WA470_7-MS1-400-A-Z0-A)

(DK59KA, DK59L8, or DW4QKY)
code: 94700)
Cause

high idle.*
34.3 (+1.8/-4.4) MPa
Boom LOWER
Defective suction safety
Relief pressure
Lift cylinder
{350 (+18/-45) kg/
hydraulic relief
valve
cm2}
malfunction.
Replace suction safety valve assembly.
When boom is raised and hydraulic hose is disconnected from lift cylinder
Defective sealing of
head end, if oil does not flow out of cylinder and lift cylinder drifts hydraulically,
main spool of boom
sealing of spool may be defective.
control valve
Defective seating of
head end, if oil does not flow out of cylinder and lift cylinder drifts hydraulically,
check valve
load check valve at the lift cylinder bottom end may be seated defectively.
a Raise boom, stop engine, and then perform troubleshooting.

head end, if oil flows out of cylinder, piston ring of cylinder is defective.
40-1052
WA470-7
40 Troubleshooting
H-22 Boom moves up and down during operation

Failure
Related
information
No.
(WA470_7-M70-400-A-Z0-A)
Boom moves up and down during operation. (When machine is performing digging or leveling
work with boom control lever set in "HOLD" position, bucket and boom move up and down
along ground.
(DK59KA, DK59KY, DK59L8, DW4PKY, or DW4QKY)
code: 94700)
Check hydraulic drift of boom, and check that machine body is raised off ground by using
lift cylinders. If any failure is found, see troubleshooting for H-20 and H-21 respectively.
Cause

high idle.*
34.3 (+1.8/-4.4) MPa
Boom LOWER
Relief pressure
Lift cylinder
{350 (+18/-45) kg/
hydraulic relief
cm2}
valve at lift cylinder
head side
malfunction.
Move boom several times to allow lift cylinders to move over their whole
strokes. After that, if machine body is raised off ground by using lift cylinders,
cause of this failure is vacuum generated in cylinder. If this symptom occurs
repeatedly, valve seat of suction valve may be defective.

high idle.*
disconnect hydraulic hose from lift cylinder head end, and relieve lift cylinder
hydraulically at its stroke end. If oil flows out of cylinder, cylinder piston ring is
defective.
WA470-7
40-1053
40 Troubleshooting
H-23 Bucket does not tilt back

Failure
Related
information
(WA470_7-M80-400-A-Z0-A)

(DB90KK, DB92KK, DB95KX, DK5BL8, DW4PKY, DW4QKY, DW4RKA, DW4RKB,
DW4RKY, DW4SKY, DWM1KY, DXA1KY, DXHJKY, or DXHKKY)
Check that lever stroke of bucket control lever is correct.
code: 94700)
01001)

No.
Cause
If
boom
does
not move and bucket does not tilt back, PTO may be defective.
1 Defective PTO
2 work equipment pump Check strainer for clogging.
3 side of work equipment Check suction piping for cracks, etc.
pump

high idle.*
Output
3.72 0.2 MPa
NEUTRAL
of accumulator
{38
2.0 kg/cm2}
steering wheel)
valve
pressure for bucket control valve (TILT and DUMP).
high idle.*
3.1 0.17 MPa
Bucket control
Output pressure of
Tilt control
lever
EPC valve
{31.5 1.7 kg/cm2}
If output pressures of all EPC valves including bucket (TILT) control EPC
Malfunction of bucket
TILT BACK EPC valve

of work equipment
valve

high idle.*
1.72 to 3.43 MPa
NEUTRAL
pressure
control lever
{17.5 to 35 kg/cm2}

8 valve at bucket control
32.4 (+1.6/-4.3) MPa
valve on tilt side
Set pressure of
Bucket TILT
Bucket cylinder
{330 (+16/-43) kg/
safety valve
relief
cm2}
Bucket control valve
pressure at bucket TILT BACK operation does not rise above relief pressure
9
of unload valve, work equipment valve spool may malfunction.
Malfunction of spool
sticking.
check valve
40-1054
WA470-7
40 Troubleshooting
No.
11
12
13
14
Cause

high idle.*
Defective bucket
If
measured
relief pressure is below standard value, disconnect hydraulic
cylinder
hose from bucket cylinder head end, and relieve bucket cylinder hydraulically
at its stroke end. If oil flows out of cylinder, cylinder piston ring is defective.
Defective work
equipment pump
particles.

15 pump
16 safety valve in bucket
cylinder bottom circuit

Fan speed
1,300 200 rpm
Min. 105C
95C
While bucket can tilt back when it is unloaded, if bucket cannot tilt back in
digging or scooping operation, or if hydraulic drift of bucket is large, bucket
bottom suction safety valve may malfunction.
WA470-7
40-1055
40 Troubleshooting
H-24 Bucket moves slow or lacks tilt-back force

Failure
Related
information
No.
1
2
(WA470_7-D85-400-A-Z0-A)

(DK5BKA, DK5BKY, DK5BL8, DK5CKA, DK5CKY, or DXA1KY)
code: 94700)
01001)
For measuring procedure, see "Testing engine speed" in "Testing and adjusting"

Cause
work equipment pump
side of work equipment Check suction piping for cracks, etc.
pump
high idle.*
Defective charge valve Output pressure of All control levers
3.72 0.2 MPa
NEUTRAL
of accumulator
{38
2.0 kg/cm2}
steering wheel)
valve
high idle.*
3.1 0.17 MPa
Bucket
Output pressure of
TILT
EPC valve
{31.5 1.7 kg/cm2}
Control lever
If output pressures of all EPC valves including bucket (TILT) control EPC
Check shut off valve spool for locking.
TILT BACK EPC valve

of work equipment
valve

high idle.*
1.72 to 3.43 MPa
NEUTRAL
pressure
control lever
{17.5 to 35 kg/cm2}

7 valve at bucket control
32.4 (+1.8/-4.4) MPa
valve on tilt side
Set pressure of
Bucket TILT
Bucket cylinder
{330 (+18/-45) kg/
suction safety valve
relief
cm2}
Defective charge valve If no failure is found by check on cause (7) but relief pressures of boom and
8 of travel damper
bucket are below standard value, travel damper charge valve may be
defective.
If only bucket TILT back relief pressure is below standard value in check on
Malfunction of suction cause (7), suction safety valve in cylinder bottom circuit may be defective.
9 safety valve in bucket
Replace it with suction safety valve in bucket cylinder head circuit, and check
cylinder bottom circuit whether failure symptom changes (it cannot be adjusted when it is installed to
machine).
sticking.
check valve
40-1056
WA470-7
40 Troubleshooting

pressure at bucket TILT BACK operation does not rise above relief pressure
11
of unload valve, work equipment valve spool may malfunction.
Malfunction of spool
12 Malfunction of PC valve found, replace it.
13 Malfunction of LS valve found, replace it.
No.
Cause
Defective bucket
14 cylinder
Defective work
15 equipment pump

16 pump

high idle.*
hose from bucket cylinder head end, and relieve bucket cylinder hydraulically
at its stroke end. If oil flows out of cylinder, cylinder piston ring is defective.
particles, etc.
Fan speed
1,300 200 rpm
Min. 105C
95C
WA470-7
40-1057
40 Troubleshooting
H-25 Bucket decelerates during tilt-back operation

Failure
Related
information
(WA470_7-D82-400-A-Z0-A)

Check bucket and bucket cylinder for visible deformation.

Cause
Defective bucket
Bucket cylinder tube may bulge or cylinder may have internal damage.
1 cylinder
(Reference)
For other failure symptoms while operating bucket, see "H-24 Bucket moves slow or bucket lacks tilt-back
force".
No.
40-1058
WA470-7
40 Troubleshooting
H-26 Bucket cylinder does not hold bucket on ground

Failure
Related
information
No.
1
(WA470_7-A85-400-A-Z0-A)

(DB90KK, DB92KK, DB95KX, DK5BL8, DW4PKY, DW4QKY, DW4RKY, DW4SKA,
DW4SKB, DW4SKY, DWM1KY, DXA1KY, DXHJKY, or DXHKKY)
If failure symptom of "Bucket moves slow" or "Bucket lacks tilt-back force" also appears,
perform troubleshooting for "H-24" as well.
Bucket control lever stroke can be checked with monitoring function. (Monitoring code:
42106)
code: 94700)

Cause
Bucket control
Defective bucket control
Control lever stroke
HOLD o DUMP
Max. -95 %
lever
lever

high idle.*
Output
3.72 0.2 MPa
NEUTRAL
accumulator
charge (including
of accumulator
{38
2.0 kg/cm2}
steering wheel)
valve

34.3 (+1.8/-4.4) MPa
Bucket DUMP
Relief
pressure
Bucket
cylinder
{350 (+18/-45) kg/
valve at bucket control
relief
cm2}
valve on dump side
If only bucket DUMP relief pressure is below standard value, suction safety
valve in bucket DUMP circuit may malfunction.
DUMP EPC valve

high idle.*
2.75 0.14 MPa
Output pressure of Bucket control
DUMP
lever
EPC valve
{28 1.4 kg/cm2}
Defective bucket
cylinder

high idle.*
disconnect hydraulic hose from bucket cylinder head end, and relieve bucket
cylinder hydraulically at its stroke end. If oil flows out of cylinder, cylinder
piston ring is defective.
WA470-7
40-1059
40 Troubleshooting
H-27 Hydraulic drift of bucket is large

Failure
Related
information
No.
(WA470_7-MS2-400-A-Z0-A)

(DK5BKA, DK5BL8, or DW4SKY)
code: 94700)
Cause

full speed. (For measuring procedure, see Testing and adjusting, "Testing
32.4 (+1.8/-4.4) MPa
valve
Relief pressure
Bucket cylinder TILT back side {330 (+18/-45) kg/
relief
cm2}
If only relief pressure of bucket TILT back side is below standard value, valve
seat of suction safety valve in TILT back circuit may be defective.
When boom is raised and hydraulic hose is disconnected from bucket cylinder
Defective sealing of
head end, if oil does not flow out of cylinder and bucket cylinder drifts
main spool of bucket
hydraulically, sealing of spool may be defective.
control valve
Defective bucket
cylinder
40-1060
a Raise boom, stop engine, and then perform troubleshooting.

If oil flows out of cylinder when boom is raised, and hydraulic hose is
disconnected from bucket cylinder head side, piston ring of cylinder is
defective.
WA470-7
40 Troubleshooting
H-28 Bucket tilts back and forth during carrying load (work equipment
valve in HOLD) (WA470_7-M90-400-A-Z0-A)
Failure
Related
information
No.
Bucket tilts back and forth during carrying load (work equipment valve in HOLD).
(DK5BKA, DK5BKY, DK5BL8, DW4RKY, or DW4SKY)
Check pins and bushings of work equipment linkage for "play" (unusual noise).
code: 94700)
Cause

34.3 (+1.8/-4.4) MPa
Bucket
DUMP
safety valve in bucket
Bucket cylinder
Relief pressure
{350 (+18/-45) kg/
relief
cylinder circuit on head
cm2}
side.
If only relief pressure on bucket DUMP side is below standard value, suction
safety valve on bucket DUMP circuit may malfunction.

high idle.*
disconnect hydraulic hose from bucket cylinder head end, and relieve bucket
cylinder hydraulically at its stroke end. If oil flows out of cylinder, cylinder
piston ring is defective.
Defective bucket
cylinder
WA470-7
40-1061
40 Troubleshooting
H-29 Boom and bucket control levers do not move smoothly and are
heavy to move (WA470_7-LS1-400-A-Z1-A)
Failure
Related
information
No.
Boom and bucket control levers do not move smoothly and are heavy to move.

When lever
Max. 17.1 N {1.8
From HOLD to moves (to short
of detent
kgf}
RAISE
position)
When lever
4.9 to 30.5 N
From RAISE to passes through
HOLD
(0.5
to 3.1 kgf)
detent position
When lever
Defective boom control
Max. 17.1 N {1.8
Lever control effort From HOLD to moves (to short
lever
of detent
kgf}
LOWER
position)
When lever
Max. 30.3 N {3.1
From LOWER passes through
kgf}
to FLOAT
detent position
When lever
4.9 to 30.5 N
From FLOAT to passes through
HOLD
(0.5
to 3.1 kgf)
detent position
Max. 26.6 N {2.7
When lever
From HOLD to
kgf}
moves
DUMP
When lever
Max. 17.1 N {1.8
From HOLD to moves (to short
Defective bucket control
of detent
kgf}
Lever control effort
TILT
lever
position)
When lever
4.9 to 30.5 N
From TILT to passes through
HOLD
(0.5 to 3.1 kgf)
detent position
40-1062
Cause
WA470-7
40 Troubleshooting
H-30 Operating work equipment causes engine speed to lower

significantly or engine to stall (WA470_7-FT6-400-A-Z0-A)
Failure
Related
information
No.
Operating work equipment causes engine speed to lower significantly or engine to stall.
(AA10NX, B@BCNS, DXA1KA, or DXA1KB)
Check that engine speed is normal with monitoring function. (Monitoring code: 01001)
(Engine low idle speed: 825 25 rpm, engine high idle speed: 2,170 50 rpm) (For
measuring procedure, see "Testing engine speed" in "Testing and adjusting".)
code: 94700)
Cause

high idle.*
Output
3.72 0.2 MPa
NEUTRAL
accumulator
charge (including
of accumulator
{38 2.0 kg/cm2}
steering wheel)
valve
Output pressure of accumulator charge valve is source pressure for work
equipment pump EPC valve.
high idle.. (For measuring procedure, see Testing and adjusting, "Testing
Defective work
equipment main relief
34.3 (+1.8/-4.4) MPa
valve
Work equipment
Bucket TILT
Bucket cylinder
{350 (+18/-45) kg/
relief
cm2}
If measured oil pressure is unusual in check on cause (2) and main relief
Defective work
valve is normal, work equipment pump may be defective.
equipment pump
particles.
If no failure is found by checks on causes (1) to (5), engine performance
Defective engine
may lower. Perform troubleshooting by referring to "S mode"
system
troubleshooting.
WA470-7
40-1063
40 Troubleshooting
H-31 Large shocks are made when work equipment starts to move and
stops (WA470_7-FT3-400-A-Z0-A)
Failure
Related
information
No.
2
3
Large shocks are made when work equipment starts to move and stops.
Boom control lever stroke (expressed in percentage) can be checked with monitoring
function. (Monitoring code: 42104)
Input signal (voltage) from boom lever potentiometer (main) can be checked with
monitoring function. (Monitoring code: 42000)
Input signal (voltage) from bucket lever potentiometer (main) can be checked with
Bucket control lever stroke (expressed in percentage) can be checked with monitoring
function. (Monitoring code: 42106)
Cause

high idle.*
Output
3.72 0.2 MPa
NEUTRAL
of accumulator
{38
2.0 kg/cm2}
steering wheel)
valve
pressure for work equipment control valve (boom and bucket).
Pilot circuit between EPC valve and work equipment control valve may be
Clogged pilot circuit
clogged with dirt, etc.
Check pilot circuit of work equipment that causes large shock.
If abnormally large shock is made, main spool may not move smoothly.
Malfunction of main
After releasing remaining pressure, check main spool for jerky motion.
spool of control valve
RAISE
44.5 4.4 mm
Boom control
Boom control
lever
LOWER
Min. 31.2 mm
Check that lever is not caught or it does not become heavy to move while
Defective lever
operating it.
Be ready with starting switch at OFF position, and then turn starting switch to
ON position to perform troubleshooting.
Lever in
2.4 to 2.6 V
NEUTRAL
RAISE
3.38 to 4.04 V
(just before the
Boom lever
detent position)
Defective potentiometer Voltage from
Boom control
RAISE
3.90 to 4.40 V
potentiometer
lever
(Detent position)
LOWER
0.96 to 1.62 V
(just before the
detent position)
FLOAT
0.6 to 1.10 V
DUMP
44.5 4.4 mm
Bucket control
Bucket control
lever
Tilt control
44.5 4.4 mm
Check that lever is not caught or it does not become heavy to move while
Defective lever
operating it.
Be ready with starting switch at OFF position, and then turn starting switch to
ON position to perform troubleshooting.
Lever in
2.4 to 2.6 V
NEUTRAL
Tilt control
Bucket lever
3.38 to 4.04 V
(just
before the
Defective potentiometer Voltage from
Bucket control
detent
position)
potentiometer
lever
Tilt control
3.90 to 4.40 V
(Detent position)
Full DUMP
0.60 to 1.10 V
40-1064
WA470-7
40 Troubleshooting
No.
Cause
For boom RAISE

Malfunction of EPC
valve

high idle.*
2.94 0.16 MPa
Boom control
Output pressure of
RAISE
lever
EPC valve
{30.0 1.6 kg/cm2}
For boom LOWER

Malfunction of EPC
valve

high idle.*
1.99 0.14 MPa
Output pressure of
Boom control
LOWER
lever
EPC valve
{20.3 1.4 kg/cm2}
For bucket TILT

10 Malfunction of EPC
valve

high idle.*
3.1 0.17 MPa
Bucket control
Output pressure of
TILT
lever
EPC valve
{31.5 1.7 kg/cm2}
For bucket DUMP

11 Malfunction of EPC
valve

high idle.*
2.75 0.14 MPa
Output pressure of Bucket control
DUMP
lever
EPC valve
{28 1.4 kg/cm2}
WA470-7
40-1065
40 Troubleshooting
H-32 When certain work equipment stalls hydraulically, other work

equipment moves (WA380_7-FT4-400-A-Z0-A)
Failure
Related
information
No.
1
When single work equipment is relieved hydraulically, other work equipment moves.
Cause
Malfunction of main spool of

control valve
40-1066

After releasing remaining pressure from hydraulic tank and control
valve, check that pressure releasing port of main spool of work
equipment that moves by itself is not clogged with foreign materials.
WA470-7
40 Troubleshooting
H-33 E.C.S.S. (travel damper) does not work and machine pitches and
bounces (WA470_7-CG1-400-A-Z0-A)
Failure
Related
information
No.
E.C.S.S. (travel damper) does not work and machine pitches and bounces.
(D192KA, D192KB, D192KY, DLT3KA, or DLT3LC)
Transmission output shaft speed can be checked with monitoring function. (Monitoring
code: 31400)
Output command value (ON/OFF) to travel damper solenoid can be checked with
Cause

low idle.
Approx. 12.3 MPa
Defective ECSS
Charge relief
Boom control
accumulator charge
RAISE (*)
{Approx. 125 kg/
pressure
lever
relief valve
cm2}
(*) While raising boom slowly with engine running at low speed, measure
stabled charge pressure.
If no failure is found by check on cause (1) and travel damper does not work
Defective ECSS (travel at all, travel damper solenoid valve may be defective.
damper) solenoid valve
Check solenoid valve spool for seizure and locking.
If no failure is found by checks on causes (1) and (2), and travel damper does
Defective ECSS
not work at all, ECSS accumulator selector valve may be defective.
accumulator selector
valve
Check selector valve spool for seizure and locking.
Defective ECSS
accumulator
output shaft speed
sensor
controller
WA470-7

stopped.
Approx. 2.94 MPa
Nitrogen gas charged pressure
{Approx. 30.0 kg/
cm2}
If nitrogen gas charged pressure drops immediately, sealing of accumulator
may be defective.
Nitrogen gas charged pressure varies depending on outside air temperature.
Check charged pressure by referring to Testing and adjusting section.
While displaying monitoring screen of transmission output shaft speed on
machine monitor, drive machine on flat road at F1 or F2 gear speed with
engine at low speed. Increase engine speed gradually and check that
transmission output shaft speed indicated on monitoring screen increases as
engine speed increases (travel speed shall be 5 km/h and above).
If no failure is found by checks on causes (1) to (5), transmission controller
may be defective.
40-1067
40 Troubleshooting
H-34 Bucket does not stop at the position which is set with remote
bucket positioner (WA470_7-M91-400-A-Z0-A)
Failure
Related
information
No.
Bucket does not stop at the position which is set with remote bucket positioner
(DKA1KA, DKA1KY, DKA0KA, DKA0KY, or DKA0L0)
Check pins and bushings of work equipment linkage for "play" (unusual noise).
Cause
Defective ECSS
accumulator charge
relief valve
40-1068

stopped.
Lower the work equipment to the
ground, remove sensor cover (1)
Total clearance of
and (2), bolt (3), and washer (4),
Max. 1.5 mm
(a) and (b)
and measure the clearance
between lock boss (5) and the
hole.
Rotation lock may be worn by friction if clearances (a) and (b) of rotation lock
of bell crank pin are large. (As a result, bucket angle sensor becomes
inaccurate)
Perform repair of the actual machine according to 50. Disassembly and
assembly, "Repair of bell crank pin rotation lock".
WA470-7
40 Troubleshooting
H-35 Fan speed is abnormal (too high or low, or fan does not
rotate) (WA470_7-FTP-400-A-Z0-A)
Failure
Related
information
No.
When engine is started for first time after hydraulic oil replacement, fan may temporarily
rotates at higher speed but this is normal.
(DW7BKA, DW7BKB, DW7BKY, DLM3KA, DLM3LC, LA00L3, DX16KA, DX16KB,
DB16KY, DGT1KA, DGT1KB, or DGH2KX)
Radiator fan speed can be checked with monitoring function. (Monitoring code: 10009)
Cause
a For measuring procedure, see "Testing engine speed" in "Testing and

adjusting".
Engine low idle
825 25 rpm
Defective engine speed
Engine speed
Engine high idle
2,170 50 rpm
If engine speed is not increased to specification, perform troubleshooting for
"S-5 Engine runs rough or is unstable".
Defective fan speed

Fan speed
Min. 105C
95C
Defective PTO (fan

pump drive)
Fan pump drive of PTO may be defective.
Malfunction of
accumulator charge
valve (relief valve)
Defective fan pump
1,300 200 rpm

high idle.*
Fan adjustment mode: 100%
14.3 2.1 MPa
Fan motor drive
pressure
Hydraulic oil temperature: 50C
{146 22 kg/cm2}
If pressure does not reach specified value after relief valve is adjusted in
check on cause (4), fan pump may have internal defect.
Check strainer of self-pressure reducing valve inlet for metal particles.

full speed and fan in reverse rotation mode.
Fan reverse
Fan adjustment mode: 100%
1.98 to 3.04 MPa
solenoid output
Hydraulic oil temperature: 50C {20.2 to 31.0 kg/cm2}
Malfunction of fan motor pressure
(direction selector
a Release remaining pressure from hydraulic tank and piping, and then
valve)
perform troubleshooting with engine stopped.
Check direction selector valve spool in valve body for seizure or sticking.
(Spool shall move smoothly and shall not be caught.)
Take direction selector spool from valve body, and check it for defects and
dirt.
If no failure is found by checks on causes (1) to (6), fan motor may have
Defective fan motor
internal defect.
WA470-7
40-1069
40 Troubleshooting
H-36 Unusual noise is heard from around fan

Failure
Related
information
No.
1
2
3
Cause
Defective installation of
fan and fan motor
Interference with shroud
Internal defect of fan
motor
40-1070
(WA470_7-FTQ-400-A-Z0-A)

Check fan and fan motor for rattling due to loose installation.
Check fan for interference with shroud.
If no failure is found by checks on causes 1 and 2, fan motor may have
internal defect.
WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
(ALL-3840-001-A-03-A)
Information mentioned in troubleshooting table (S mode)
(PC400-5170-010-A-00-A)
(Rev. 2011/04 125T4)

a Troubleshooting Table collectively carries the following information. Carry out troubleshooting work after
fully grasping its contents.
Failure
Related
information
Problem on engine
Information related to the detected failure or troubleshooting
Probable cause
1
2
3
4
5
Contents of check and remarks

<Contents of description>
Probable causes for
Contents of check to judge
trouble (Each number is
probable causes
serial number, not priority
Remarks required for

sequence.)
judgment
Remedy
Actions to eliminate probable
causes of trouble
1. Gauze filter for feed pump

a This figure shows the location of gauze filter (1) for the feed pump explained in this manual.
WA470-7
40-1071
40 Troubleshooting
S-1 When starting switch is turned to START position, engine is not

cranked (PC400-A26-400-A-Z0-A)
When starting switch is turned to START position, engine is not cranked
See E mode (E-1) for troubleshooting the electrical system.
Related information If any failure code is displayed, carry out troubleshooting for it first.
Failure
No.
1
Cause
Defective starting circuit wiring
system
Defective starting motor

(safety relay section)
Broken flywheel ring gear
Detail of work, remarks

When starting switch is turned to START
position, starting motor pinion is not pushed
out
Grating noise is heard from starting motor
pinion
(When starting switch is turned to START
position, starting motor pinion is pushed
out)
Starting motor pinion disengages during
operation
out)
Ratting noise is heard and starting motor
does not turn.
out)
(Reference: Rattling noise is caused when
starting motor pinion is repeatedly pushed
out and pulled in.)
If grating noise is heard from starting motor
pinion and the starting motor does not
crank, visually check the flywheel ring gear.
Remove EGR cooler inlet and outlet gas
piping and check if coolant containing
antifreeze flows out
Cracked EGR cooler

(Reference: coolant in exhaust
a Water can normally be condensed in the
gas)
exhaust gas, so make sure the water is
coolant or not.
40-1072
Remedy
Diagnose and take
remedies for E-1
Diagnose and take

remedies for E-1
Replace if damaged
Replace EGR cooler

and drain water from
engine cylinders
WA470-7
40 Troubleshooting
S-2 The engine cranks but exhaust smoke does not come out
(PC400-A27-400-A-Z0-
A)
The engine cranks but exhaust smoke does not come out
Failure
No.
Cause
Insufficient fuel in tank
Air breather hole in fuel tank

cap is clogged
Clogged fuel filter element
Foreign material in fuel
Air in fuel piping system
Leakage from fuel piping

system

When fuel tank is inspected, it is found to
be empty
Remedy
Add fuel
Flush air breather hole

Air breather hole in fuel tank cap is clogged in fuel tank cap and
clean surrounding area
Check used hours of fuel filter. If used
beyond specified hours, fuel filter element Replace fuel filter
element
may be clogged
Rust and water are found when fuel tank is Replace fuel
drained
When air bleeding operation for fuel system Perform air bleeding
operation
is performed, air comes out
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system")
piping
Fuel is leaking from fuel piping
Correct or replace fuel
(Reference: See Testing and adjusting,
piping related parts
Check leakage from common rail pressure
limiter according to "Measuring fuel delivery,
return and leakage" in "Testing and adjusting".
Replace common rail
a Common rail is normal if the leakage from
common rail pressure limiter is Max.10
(CC/min)
a Check "Defective common rail" described
above first.
If the pressure doesn't rise during cranking
when checking common rail pressure on Replace supply pump
machine monitor, the supply pump is
defective.
a Common rail pressure can be checked with

When priming pump is operated, no
Replace priming pump
9 Defective priming pump
resistance is felt or it is heavy
Clean or replace
Clogging of feed pump gauze Gauze filter is clogged
10
gauze filter
filter
Common rail pressure does not go down
Loosen injection piping
when when pressure is checked with
and high pressure
Improper bleeding of common
monitoring function and then stopped
piping mounting nuts
11 rail or injection piping
(Code: 36400 Common rail pressure)
on common rail and
(pressure will not decrease if air is present) bleed air
WA470-7
40-1073
40 Troubleshooting
S-3 Fuel is injected but engine does not start (incomplete combustion,
engine seems to start but does not) (PC400-A28-400-A-Z0-A)
Fuel is injected but engine does not start (incomplete combustion, engine seems to start
but does not)
Failure
No.
Cause
Defective battery

cap is clogged

system
Defective priming pump
Clogging of feed pump gauze

filter
10 Clogged air cleaner element
11 Defective intake air heater
12 Worn valves or rocker arms
13 Defective piston ring

Defective injector
14 (clogged injector, defective
injection)
40-1074
Remedy
Specific gravity of electrolyte and voltage of Add electrolyte or
battery are low
charge battery
Add fuel
be empty
element
may be clogged
drained
operation
piping
Clean or replace
Gauze filter is clogged
gauze filter
Air cleaner dust indicator is at a caution
Test and adjust air
level
cleaner element
During pre-heating operation, intake air
heater mount is cold
Replace intake air
When engine is preheated or when
heater
temperature is low, preheating monitor
does not indicate properly
Check valve clearance
(Reference: For details, see Testing and
adjusting, "Testing and adjusting valve Replace valve or
clearance")
rocker arm
While engine is running, unusual noise is
heard around cylinder head
Testing compression pressure
Replace piston ring or
piston
"Testing compression pressure")
When a certain cylinder is cut out, engine
speed does not change
Replace Injector
(Note: see "Handling cylinder cutout mode
operation" section of Testing and adjusting)
Since this is an internal defect,
Replace engine
troubleshooting cannot be performed.
controller.
WA470-7
40 Troubleshooting
S-4 Engine startability is poor
(PC400-A10-400-A-Z0-A)

If any failure code is displayed, carry out troubleshooting for it first.
The common rail fuel injection system (CRI) controls the fuel injection timing
electrically. Accordingly, even if the engine is cranked properly, the engine may not
Related information
start until the crankshaft rotates two turns under the most disadvantageous
condition. This phenomenon does not mean a problem, however.
Failure
No.
Cause
Defective battery
Improper fuel used

cap is clogged

system
10 Defective supply pump

Specific gravity of electrolyte and voltage of
battery are low
be empty
Non-specified fuel is being used.
Fuel suitable for ambient temperature is not
used
(Reference: When engine starts in warm
temperatures but not in low temperatures)
Wax is found when clear bowl of fuel
prefilter is checked (milky)
Remedy
Add electrolyte or
charge battery
Add fuel
Use proper fuel

specified in Operation
and Maintenance
Manual

element
may be clogged
drained
operation
piping
Replace common rail
(CC/min)
above first.
defective.
11

filter
12 Clogged air cleaner element
13 Defective intake air heater
WA470-7

Air cleaner dust indicator is at a caution
level
During pre-heating operation, intake air
heater mount is cold
When engine is preheated or when
temperature is low, preheating monitor
does not indicate properly
Clean or replace
gauze filter
Check, clean air
cleaner element
Replace intake air
heater
40-1075
40 Troubleshooting
No.
Cause

Remove EGR cooler inlet and outlet gas
piping and check if coolant containing
antifreeze flows out
Cracks in EGR cooler

14 (Reference: coolant in exhaust
a Water can normally be condensed in the
gas)
exhaust gas, so make sure the water is
coolant or not.
When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
15 Defective injector
"Handling of cylinder cut-out operation".)
Measure the compression pressure (see
Defective contact of valve with
17
Test the valve clearances
valve seat
adjusting, "Testing and adjusting valve
clearance")
Open the exhaust gas color measuring hole
before the KDPF and check the color of the
exhaust gas.
"Testing exhaust gas color".)
Check piston rings and piston ring grooves
40-1076
Remedy
Replace EGR cooler
and drain water from
engine cylinders
Replace injector
Replace engine
controller.
Correct or replace
valve or valve seat

piston
WA470-7
40 Troubleshooting
S-5 Engine does not pick-up smoothly
(PC400-A30-400-A-Z0-A)
Engine does not pick up smoothly

Failure
No.
Cause

cap is clogged

system

be empty
Remedy
Add fuel

element
may be clogged
drained
operation
piping
Replace common rail
(CC/min)
above first.
defective.

filter
Abnormally high crankcase

10 pressure
12 Seized or broken KVGT
13 Incorrect valve clearance
WA470-7

If Crankcase Pressure High Error (failure
code: CA555) is still displayed after KCCV
filter element is replaced, blow-by pressure
may be high due to seizure or damage of
KVGT (see Testing and adjusting, "Testing
blow-by pressure")
Unusual noise is heard from KVGT
Check if KVGT shaft rotates
(Move KVGT vanes with hand in axial and
radial directions to judge)
When engine is cranked, Unusual noise is
generated around cylinder head
Clean or replace
gauze filter
Perform
troubleshooting for
cause 10 and after.
Replace injector
Replace KVGT
Adjust valve clearance
40-1077
40 Troubleshooting
No.
Cause
15
valve seat
40-1078

clearance")
clearance")
exhaust gas.
Remedy
Replace engine
controller.
Correct or replace
valve or valve seat

piston
WA470-7
40 Troubleshooting
S-6 Engine stops during operation
(WA500-AF0-400-A-Z0-A)
Engine stops during operation

Failure
No.
Cause

cap is clogged

system
Defective priming pump

filter

be empty
Remedy
Add fuel

element
may be clogged
drained
When air bleeding operation for fuel system Performing air
bleeding operation
piping
Clean or replace
gauze filter
See Testing and adjusting, "Checking fuel Replace supply pump
delivery, return rate and leakage"
and pressure limiter
Defective air intake hose

10 (from air cleaner to KVGT
inlet)
Visually check the air intake hose for

damage
Replace air intake

hose
11 Defective air intake manifold
Check the intake manifold for internal

damage
Replace air intake

manifold
Defective boost piping and

connections
Air flows out from boost piping
12
(from KVGT outlet to air intake
manifold)
Check exhaust pipes for damage and
Defective exhaust pipes
exhaust gas leakage
13 (from exhaust manifold to
(Check heat insulation cover and soot on
KDPF inlet)
heat shield plate)
Check valves and rocker arms
(Unusual noise is heard and engine
14 Damaged valve or rocker arm
stopped suddenly)
Metallic powders are found in oil drained
from oil pan
Remove oil pan and check pistons and
Broken or seized piston or
connecting rods
15 connecting rod
(Reference: Unusual noise is heard and
engine stopped suddenly, or stopped after
overheating)
Broken or seized crankshaft
from oil pan
16 main bearing
Remove oil pan and check crankshaft main
bearing
Check engine controller power supply
wiring
17 power supply wiring
(Reference: See Troubleshooting, Failure
Code [CA343].)
WA470-7
Correct or replace
boost piping
Replace exhaust pipes
Replace valve or
rocker arm
Replace piston or
connecting rod
Replace crankshaft
main bearing
Correct engine
controller power
supply wiring
40-1079
40 Troubleshooting
No.
Cause
Defective starting switch
18 wiring
Malfunction of hydraulic
19 system
40-1080
Remedy
Diagnose
and take
Check starting switch wiring
remedies for E-1
See H mode, "H-2 Torque converter lockup Diagnose and take
clutch is not disengaged (engine stalls)"
remedies for H-2
WA470-7
40 Troubleshooting
S-7 Engine runs rough or is unstable
(PC400-A40-400-A-Z0-A)
Engine runs rough or is unstable

Failure
No.
Cause

cap is clogged

system
Leakage in boost system

filter
Defective mass air flow and

temperature sensor
WA470-7

be empty
Remedy
Add fuel

element
may be clogged
drained
operation
piping
Check for leaks from boost system (KVGT Correct or replace
outlet to aftercooler, aftercooler to air intake parts around boost
manifold)
piping
Clean or replace
gauze filter
Replace sensor and check if problem is
Replace mass air flow
corrected
(Failure code may not be issued if the and temperature
sensor
sensor is covered with dust.)
40-1081
40 Troubleshooting
S-8 Engine lacks power
(PC400-A60-400-A-Z0-A)
Engine lacks power

Failure
No.
Cause

cap is clogged

system

filter
Clogged air cleaner element
10 Defective air cleaner

be empty
Remedy
Add fuel

element
may be clogged
drained
operation
piping
"Check fuel circuit for leaking")
See Testing and adjusting, "Checking fuel Replace supply pump
delivery, return rate and leakage"
and pressure limiter
Clean or replace
gauze filter
Check, clean air
Air cleaner dust indicator in caution level
cleaner element
Check air cleaner and airflow screen for
Correct or replace air
deformation
cleaner
Defective air intake hose

11 (from air cleaner to KVGT
inlet)
Visually check the air intake hose for

damage
Replace air intake

hose
12 Defective air intake manifold
Check the intake manifold for internal

damage
Replace air intake

manifold

connections
13
(from KVGT outlet to air intake
manifold)
Improperly installed boost
Air leaks from boost pressure sensor
14 pressure sensor
mounting
Check
exhaust pipes for damage and
exhaust gas leakage
15 (from exhaust manifold to
KDPF inlet)
heat shield plate)
16 Gas leakage from EGR piping Gas leaks from EGR piping
Check intake and exhaust
system
Measure boost pressure
17 (KVGT outlet to air intake
"Testing boost pressure")
manifold, exhaust manifold to
KDPF inlet)
40-1082
Correct or replace
boost piping
Correct mounting of
boost pressure sensor
Replace EGR piping
Correct or replace
defective parts
Replace KVGT
WA470-7
40 Troubleshooting
No.
19
20
21
22
23
24
25

Open the exhaust color inspection hole in
front of KDPF, check the exhaust gas (refer
Excessive soot accumulation
standard value table)
in KDPF
(Note: see "Measuring exhaust gas color"
section of Testing and adjusting
KDPF clogging - check exhaust pressure
Defective KDPF
before KDPF
Incorrect valve clearance
clearance")
Defective injector
valve seat
clearance")
exhaust gas.
Defective piston ring
WA470-7
Cause
Remedy
Clean or replace
KDPF
Clean or change
KDPF
Replace injector
Replace engine
controller.
Correct or replace
valve or valve seat

piston
40-1083
40 Troubleshooting
S-9 KDPF gets clogged in a short time
(PC400-AH5-400-A-Z0-A)
KDPF gets clogged in a short time

Failure
No.
Cause
Remedy
Use proper fuel
and Maintenance
Manual
Improper fuel used

(from exhaust manifold to
KDPF inlet)
Rust and water are found when fuel tank is

drained
Check air cleaner and airflow screen for
deformation
Check exhaust pipes for damage and
exhaust gas leakage
heat shield plate)
Defective mounting of charge

(boost) pressure sensor
Air leakage from mounting part of charge

(boost) pressure sensor
Correct charge (boost)

pressure sensor
mounting

connections
(From KVGT outlet to air
intake manifold)
Correct or replace
boost piping
7
8
9
10
11
12
13
KDPF clogging - check exhaust pressure

before KDPF
Gas leakage from EGR piping Gas leaks from EGR piping
KVGT seized or broken
Defective injector
Too much fuel is returned when flow is
checked
Defective fuel return piping
"Checking fuel delivery, return rate and
leakage")
Check fuel return piping for clogging
Replace sensor and check if problem is
corrected
Defective mass air flow and
temperature sensor
(Failure code may not be issued if the
sensor is covered with dust.)
Incorrect valve clearance
clearance".
Defective KDPF
40-1084
Replace fuel
Correct or replace air
cleaner
Clean or change
KDPF
Replace EGR piping
Replace KVGT
Replace Injector

return piping

and temperature
sensor
WA470-7
40 Troubleshooting

standard values table).
"Testing compression pressure".)
14
valve seat
clearance".
exhaust gas.
No.
WA470-7
Cause
Remedy
Correct or replace
valve or valve seat

piston
40-1085
40 Troubleshooting
S-10 Engine oil consumption is excessive
(PC400-B10-400-A-Z0-A)
Engine oil consumption is excessive

Failure
No.
Cause
Dust sucked in from intake

system
Broken or worn piston ring

When intake piping between air cleaner
and engine is removed, dust is found
inside.
Measured blowby pressure exceeds
standard value.
Blow-by pressure is still high after KCCV
filter element is replaced
Check for oil leaks from KCCV oil return
piping
Oil leakage from KCCV oil

return piping
External leakage of oil from
engine
Oil leakage from oil filter
Check for oil leaks from oil filter
Oil leakage from oil piping
Check for oil leaks from oil piping
Oil leakage from oil drain plug
Check for oil leaks from oil drain plug
Oil leakage from oil pan
Check for oil leaks from oil pan
Oil leakage from cylinder head Check for oil leaks from cylinder head
Check for oil leaks
Oil level in clutch chamber or damper

10 Worn or damaged rear oil seal
chamber on machine is low.
KVGT blower inlet and outlet, and turbine
outlet are dirty with oil.
11 Oil leakage from KVGT
Oil in coolant
Remove oil cooler and check for external oil
leaks
12 Oil leakage from oil cooler
Check for leaks by applying air pressure to
oil cooler
When EGR valve is removed, outlet port is
Oil leakage from EGR valve
13
found to be dirty with oil.
stem
Check valve guide and stem seal
Remove cylinder head. Check inside
Worn or damaged valve guide,
diameter of guide, and check stem seal for
14
stem seal
damages.
(Reference: See "Maintenance standard".)
40-1086
Remedy
Clean or replace
intake piping
Replace or correct
piston ring
Correct or replace oil

piping
Correct oil leaks
Reinstall or replace oil
filter
piping
Retighten oil drain plug
pan
Correct or replace
cylinder head
Correct or replace rear
oil seal
Replace KVGT
Replace oil cooler
Replace EGR valve
Replace valve guide

and stem seal
WA470-7
40 Troubleshooting
S-11 Engine oil becomes contaminated early

Failure
Related
information
No.
Engine oil becomes contaminated quickly.

Improper fuel used
Improper oil used
Black exhaust gas color

checked at location just
upstream of KDPF
Excessive blowby gas
Defective KVGT seal on

turbine side
Worn EGR valve guide
Excessive refilling of oil
Dirty oil cooler element
Broken or worn piston ring
Worn or damaged valve

10 guide or stem seal
WA470-7
Remedy
Use proper fuel
Fuel other than specified one is used.
and Maintenance
Manual.
Use proper oil
Oil other than specified one is used.
and Maintenance
Manual.
Check exhaust gas color at location just
Perform
upstream of KDPF.
troubleshooting for "S(Reference: See Testing and adjusting, 9 Exhaust gas is
"Testing exhaust color".)
black".
standard value.
Perform following
Blowby pressure is still high after KCCV
checks.
filter element is replaced.
Rotate KVGT shaft and check for play.
(Move KVGT vanes with hand in axial and Replace KVGT.
radial directions to make judgement.)
Remove EGR valve and check stem seal,
guide, and stem.
Replace EGR valve.
When EGR valve is remove, outlet port is
dirty with oil.
Check oil level for excessive refilling.
(If oil level is excessive, oil will reach high Refill with oil to correct
oil level.
temperatures and early deteriorates.)
Visually check oil cooler element for
contamination.
Clean or replace oil
(Contaminated oil cooler element can cooler element.
increased oil temperature.)
standard value.
Blowby pressure is still high after KCCV
filter element is replaced.
Measure compression pressure (see
correct its installation.
Standard value table).
Check valve guide and stem seal.
Remove cylinder head, and check inside
Replace valve guide
diameter of guide and stem seal for
and stem seal.
damage.
(Reference: See "Maintenance standards".)
Point to check, remarks
Cause
(PC400-B20-400-A-Z0-A)
40-1087
40 Troubleshooting
S-12 Fuel consumption is excessive
(PC400-B70-400-A-Z0-A)
Fuel consumption is excessive

Failure
No.
Too much fuel is spilled from

injector
Clogged fuel return piping
Defective injector
Fuel leakage from inside

cylinder head
Fuel leakage from feed pump

oil seal
6
7
Fuel leakage to outside

Fuel leakage from fuel doser
40-1088
Remedy
Replace injector
Test spill rate from injector
(Reference: See Testing and adjusting, There may be
"Checking fuel delivery, return rate and excessive dust in fuel.
Confirm quality control
leakage")
of fuel.
Check fuel return piping for clogging
(Injection rate increased due to clogged fuel
return piping
return piping)
Replace injector
Check for increased oil level
Correct defective parts
Check for smell of diesel fuel
Check for increased engine oil level and
Replace feed pump oil
smell of diesel fuel
seal
Check feed pump oil seal
Check for fuel leakage to outside of engine. Correct defective parts
Replace fuel doser
Check fuel doser for fuel leaks
Cause
WA470-7
40 Troubleshooting
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
(PC400-
B40-400-A-Z0-A)
Oil is in coolant (or coolant spurts or coolant level goes down)

Failure
No.
Cause
Milky engine oil
Engine oil level rises and oil is milky
Damaged oil cooler element
Check oil cooler element
Damaged cylinder head
Damaged cylinder head

gasket
Cracks or pitting in cylinder

block
WA470-7
Coolant in radiator has excessive air

bubbles and blows back.
Overhaul engine and perform a pressure
tightness test on cylinder head to check for
abnormalities
Coolant in radiator has excessive air
bubbles and blows back.
Overhaul engine and check cylinder head
gasket for abnormalities
Disassemble engine and check for cracks
or pitting in cylinder block
Remedy
Perform
troubleshooting for "S16 Water mixes into
engine oil (milky)".
Replace oil cooler
element
Replace cylinder head

gasket
Replace cylinder block
40-1089
40 Troubleshooting
S-14 Oil pressure drops
(PC400-10D-400-A-Z0-A)
Oil pressure drops

Related information Confirm if machine has been operated on a slope steeper than specified in the
Operation and Maintenance Manual.
Failure
No.
Cause

Oil level in oil pan is low
Oil pressure monitor indicates low oil
pressure when operating on slopes
Lack of oil in oil pan
Defective oil pressure sensor,

wiring harness
Check oil pressure sensor, wiring harness,

and connector
Fuel in oil
Water in oil
Clogged oil filter
6
7
Clogged oil strainer

Crushed or clogged hydraulic
piping
Defective oil pump
Defective regulator valve
10 Defective oil pump relief valve

Cracks in oil pump suction
11 piping
Defective seal between oil
12 pump and oil pump suction
piping
13 Defective boost oil pump
40-1090
Replace seal
Replace boost oil

pump
Check boost oil pump relief valve for fatigue Replace boost oil
or damage on valve and spring
pump relief valve
Replace EGR
Check EGR hydraulic piping
hydraulic piping
Check main journal bearing
Replace main journal
bearing
from oil pan
Check pin journal bearing
Replace pin journal
bearing
from oil pan
Replace idler bushing
Check idler bushing and idler gear
or idler gear
Replace piston cooling
Check piston cooling nozzle
nozzle
Check boost oil pump
Defective boost oil pump relief

valve
Oil leakage from EGR
15 hydraulic piping
16 Worn main journal bearing
Worn idler bushing, damaged

18 idler gear
Breakage or falling off of
19 piston cooling nozzle
Add oil
Replace oil pressure

sensor, wiring harness,
or connector
If oil is contaminated
with fuel, carry out
Perform oil analysis and check for fuel in oil
troubleshooting for "SEngine oil smells of diesel fuel
15 Fuel mixes into
engine oil"
If oil is contaminated
Perform oil analysis and check for water in with water, carry out
troubleshooting for "Soil
16 Water mixes into
Oil is milky
engine oil (milky)"
Check oil filter
(Reference: Oil filter has been used beyond
the
specified
period,
oil
heavily Replace oil filter
deteriorated, etc.)
Water in oil can cause oil filter blockage
Check oil strainer
Clean oil strainer
Replace hydraulic
Hydraulic piping is crushed or clogged
piping
Check oil pump
(worn or damaged gear)
Replace oil pump
Oil pump rotation is heavy or it has play
Replace regulator
Check valve spring for fatigue or damage
valve
Valve and spring of oil pump relief valve is Replace oil pump relief
fatigued, damaged.
valve
Replace oil pump
Check around oil pump suction piping
suction piping
(cracked piping)
Check seal
14
17 Worn pin journal bearing
Remedy
WA470-7
40 Troubleshooting
S-15 Fuel mixes into engine oil
(PC400-B31-400-A-Z0-A)
Fuel mixes into engine oil (smells of diluted diesel fuel)

Failure
No.
2
3
4
Cause
Defective injector
Fuel leakage from injector or

O-ring (spill circuit)
Defective seal between
injector and injection piping,
cracks in injection piping
Defects in supply pump
WA470-7
Remedy
Replace Injector
Check injector or O-ring
Replace injector O-ring
Check seal between injector and injection

Repair or replace
piping, and check injection piping for cracks
Confirm that fuel no longer mixes into oil
after supply pump is replaced
Replace supply pump
40-1091
40 Troubleshooting
S-16 Water mixes into engine oil (milky)
(PC400-B32-400-A-Z0-A)
Water mixes into engine oil (milky)

If oil mixes into the coolant, perform troubleshooting for "S-13 Oil mixes into coolant"
When engine starting and stopping is frequently repeated in low outside
temperatures, the KCCV may cause condensation of water vapor in the blow-by gas
Related information
leading to milky oil or emulsification inside the engine, but this is normal. This is not
a problem if coolant is not leaking.
If coolant leakage is suspected by such as drop of coolant level in a short time, carry
out the following troubleshooting procedures.
Failure
No.
2
3
4

Coolant containing antifreeze flows out
when EGR cooler inlet and outlet gas
piping are removed.
(Make sure the water is coolant or not. It
may be condensate water)
Cracks in EGR cooler
(Reference: If cracks are found in the EGR
cooler, this may be caused by low coolant
level in the cooling system. When replacing
the EGR cooler, check for leaks from
coolant system piping and radiator.)
Check oil cooler element and O-ring
Damaged oil cooler element or
Pressure-tightness test of oil cooler shows
O-ring
oil leakage
Leakage from water pump
Check for leaks from water pump
mechanical seal
mechanical seal
Clogged water pump drain
Check water pump drain hole
hole
Cause
Broken cylinder head or

cylinder head gasket
Disassemble engine and check cylinder

head and cylinder head gasket
Cracks or pitting in cylinder

block

Disassemble engine and check for cracks
or pitting in cylinder block
40-1092
Remedy
Replace EGR cooler
Replace oil cooler

element or O-ring
Replace water pump
mechanical seal
Clean water pump
drain hole
or cylinder head
gasket
Replace cylinder block
WA470-7
40 Troubleshooting
S-17 Coolant temperature rises too high (overheating)

Failure
Related
information
No.
(PC400-AL0-400-A-Z0-A)
Coolant temperature rises too high (overheating).

Cause
Clogged radiator core
Malfunction of thermostat
Remedy
Check radiator core for clogging, and check
Clean radiator core.
fin for crush.
Thermostat does not open at cracking
temperature.
a Thermostat cracking temperature: 76.5 2
C
(Full open temperature: 90 C)
Replace thermostat.
Defective coolant temperature

gauge
Error related to coolant temperature is

displayed, but measured value of radiator
coolant temperature is normal.
Increased fuel injection rate
Fuel injection rate is high.
Low coolant level
Check coolant level. for lowering.
Leakage of coolant
Check water leakage from coolant piping.
Replace coolant
temperature sensor,
monitor or wiring
harness.
Perform
troubleshooting for "S12 Fuel consumption is
excessive".
Refill with coolant.
Replace coolant
piping.
Breakage of water pump
Visually check water pump.

(Check shaft seal for water leakage,
Replace water pump.
impeller for damage, and shaft for
breakage.)
Overheating due to increased

EGR ratio (EGR amount
against fresh air amount)
caused by defective mass air
flow and temperature sensor
Overheating due to increased
EGR ratio (EGR amount
against fresh air amount)
caused by air cleaner
deformation
Check mass air flow and temperature

sensor.

and temperature
sensor.
Check air cleaner and rectifying wire net for Repair or replace air
cleaner.
deformation.
Perform
troubleshooting for "S13 Oil is in coolant".
Defective cylinder head or

10 cylinder head gasket
Check radiator coolant for excessive

bubbles and spurt back.
Open exhaust color inspection hole that is

just upstream of KDPF, and check exhaust
gas.
piston.
Check piston ring and piston ring groove.
WA470-7
40-1093
40 Troubleshooting
S-18 Unusual noise is heard

Failure
Related
information
No.
(PC400-BA1-400-A-Z0-A)
Unusual noise is heard.

Check whether noise source is in or outside engine before starting troubleshooting.
Engine runs in low-temperature mode while it is not warmed up sufficiently. Accordingly,
engine sound becomes slightly larger. This does not indicate abnormality, however.
When engine accelerates, it switches into acceleration mode and its sound becomes
slightly large further for up to approximately 3 to 5 seconds. This does not indicate
abnormality, however.
Cause
Exhaust gas leakage from

piping

Exhaust gas leaks from piping between
cylinder head and exhaust manifold,
between exhaust manifold and KVGT, or
between KVGT outlet and KDPF.
Exhaust gas leaks from EGR piping or air
intake piping.
Remedy
Repair or replace
defective parts.
Check and retighten

Vibration of exhaust piping or Visually check for vibration.
piping brackets.
exhaust bellows
Check whether KVGT shaft rotates.
(Move KVGT vanes with hand in axial and Replace KVGT.
radial directions to make judgement.)
Clean or replace
4 Internal damage of KDPF
Check inside of KDPF.
KDPF.
Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
When engine is run in cylinder cutout mode
Replace injector.
with some cylinder cut out, engine speed
does not change.
"Handling cylinder cutout mode operation".)
Check valve clearance.
(Reference: See Testing and adjusting, Adjust valve clearance.
6 Incorrect valve clearance
"Testing and adjusting valve clearance".)
Repair or replace
Seized pin bushing, front
Check for metal particles in oil pan.
7 bearing, or main bearing
damaged parts.
If metal particles is found in oil pan or oil
filter, overhaul engine and check piston ring
and cylinder liner.
Worn piston ring or cylinder
8
cylinder liner.
liner
Overhaul engine and check valves and
Replace valve or
9 Damaged valve or rocker arm
rocker arm parts.
rocker arm.
Overhaul engine and check idler gear parts. Replace idler gear.
10 Damaged idler gear
2
40-1094
WA470-7
40 Troubleshooting
S-19 Vibration is excessive

Failure
Related
information
Vibration is excessive.
If unusual noise is heard and vibration is excessive, perform troubleshooting for "S-18
Unusual noise is heard", too.
No.
Cause
Loose engine mounting bolts

or defective cushions
Damaged engine damper
6
7
8
(HM300_3-BC0-400-A-Z0-A)

Visually check engine mounting bolts for
looseness and cushions for cracks and
hardening.
Visually check viscous damper for
discoloration.
Check output shaft for damage and damper
for internal defect.
Defective output shaft or

internal defect of damper
Misalignment and facial
runout at connection between Measure misalignment and facial runout at
engine and hydraulic pump
connection from engine to output shaft.
are out of standard range.
Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
When engine is run in cylinder cutout mode
Defective injector
with some cylinder cut out, engine speed
does not change.
"Handling cylinder cutout mode operation".)
Worn main bearing or
If metal particles are found in oil pan or oil
connecting rod bearing
filter, overhaul engine.
Stuck valve or rocker arm
filter, open cylinder head cover and check
valves and rocker arms.
Worn camshaft bushing
filter, overhaul engine and check camshaft
bushings.
WA470-7
Remedy
Retighten bolts or
replace cushions.
Replace engine
damper.
Replace defective
parts.
Replace defective
parts.
Replace injector.
Repair or replace
damaged parts.
Repair or replace
damaged parts.
Replace camshaft
bushings.
40-1095
40 Troubleshooting
S-20 Air cannot be bled from fuel circuit
(PC400-A29-400-A-Z0-A)
Failure
Air cannot be bled from fuel circuit
Related information If any error code is displayed, carry out troubleshooting for it first.
No.
1
2
3

When fuel feed pump switch is turned ON,
pump operating sound is heard.
Even when fuel feed pump switch is turned
Low battery charge level
ON, pump operating sound is not heard.
Check drain valve of fuel prefilter for
Loose drain valve of fuel
loosening
prefilter
(Air leaking in due to loose drain valve)
beyond specified hours, fuel filter element
may be clogged
When air bleeding operation for fuel system
system
"Checking fuel system for leakage")
With fuel feed pump switch ON, voltage to
Malfunction of fuel feed pump
fuel feed pump is generated but pump does
not operate.
With fuel feed pump switch ON, voltage to
Malfunction of fuel feed pump
fuel feed pump is not generatedLamp does
switch
not light up.
Defective wiring harness of
fuel feed pump and fuel feed Check wiring harness
pump switch
40-1096
Cause
Remedy
Add fuel
Charge battery
Close drain valve
Replace fuel filter
element
piping
Replace fuel feed
pump
Replace fuel feed
pump switch
Replace wiring
harness
WA470-7
40 Troubleshooting
S-21 Active regeneration is executed frequently

Failure
Related
information
No.
1
(PC400-AQ0-400-A-Z0-A)
Active regeneration is executed frequently.


Cause
Long-term machine operation
with engine at low to medium Soot can accumulate if machine does not
speeds (exhaust temperature
perform heavy-duty work.
does not rise)
Open exhaust color inspection hole being
just upstream of KDPF, and check exhaust
gas (see Standard value table).
Defective exhaust gas color
If regeneration frequency does not return to
Plugged KDOC resulting from
normal after remedies for cause 2 are taken,
bad exhaust color
KDOC is plugged.
Improper oil used
Oil other than specified one is used.
Remedy
Perform Regeneration
for Service to burn
away soot completely.
Perform
troubleshooting for "S9 Exhaust gas is black
(KDPF gets clogged in
a short time)".
Clean KDOC.
Use proper oil
and Maintenance
Manual.
If regeneration frequency does not return to

normal after remedies for cause 4 are taken, Clean or replace
KCSF.
KCSF is plugged.
Perform
Coolant leaking into exhaust
troubleshooting for "S6 system
Check for low coolant level.
16 Water mixes into
Plugged KCSF due to coolant
Clean or replace
Check KCSF inlet for plugging.
7 leaking into exhaust system
KCSF.
Use proper fuel
8 Improper fuel used
and Maintenance
Manual.
KDOC is deteriorated by high sulfur content.
(If regeneration frequency does not return to
Deteriorated KDOC due to
Replace KDOC.
9 use of improper fuel
normal after remedies for causes 1 to 8 are
taken, KDOC is deteriorated.)
If regeneration frequency is not improved
after remedies on causes 1 to 9, KDOC is
Clean KDOC.
10 Plugged KDOC
blocked.
Check KDOC for damage.
Replace KDOC.
11 Damaged KDOC
5
Plugged KCSF due to use of

improper oil
WA470-7
40-1097
40 Troubleshooting
S-22 Active regeneration takes a long time
(PC400-AQ1-400-A-Z0-A)
Active regeneration takes a long time

Related information Since the time required for manual stationary regeneration depends on the
accumulated soot level, see failure code CA2639.
Failure
No.
Cause
Malfunction of KVGT
Exhaust gas color is bad

If values of KDOC inlet temperature:
approximately 250C or below and KVGT
solenoid current: approximately 1000 mA
remain unchanged after performing
regeneration for service, KVGT is defective.
(Since the time required for manual stationary
regeneration depends on the accumulated soot
level, see failure code CA2639. )
exhaust gas (see standard value table).
Defective regeneration due to

soot accumulation in fuel
Check fuel doser
doser
Bad exhaust color causing
If regeneration time is not improved after
KDOC face plugging
remedies on cause 2, KDOC is blocked.

system
KCSF plugged due to coolant

Check KCSF for plugging
leaking into exhaust system
Improper fuel used
KDOC deterioration due to

improper fuel used
Plugged KDOC
10 Damaged KDOC
40-1098
Check for low coolant level
Remedy
Replace the whole

KVGT (including
hydraulic actuator and
KVGT position sensor).
Carry out
troubleshooting for "S9 Exhaust gas is black
(KDPF gets clogged in
a short time)"
Clean fuel doser
Clean KDOC
Carry out
engine oil (milky)"
Clean KCSF
Use proper fuel
and Maintenance
Manual
KDOC deteriorated by high sulfur content

(If regeneration time is not improved after
Replace KDOC
remedies on causes 1 to 6, KDOC is
deteriorated.)
If regeneration duration does not return to
normal after remedies for causes 1 to 7 are Clean KDOC
taken, KDOC is plugged
Check KDOC for damage
Replace KDOC
WA470-7
40 Troubleshooting
S-23 White smoke is exhausted during active regeneration

Failure
Related
information
No.
White smoke is exhausted during active regeneration.

White smoke may be observed for a short time immediately after engine is started in cold
weather or during regeneration, but this is normal.
Cause

system
Plugged KDOC due to

coolant leaking into exhaust
system
Improper fuel used
Deteriorated KDOC due to

use of improper fuel
Plugged KDOC
6
7
Damaged KDOC
Damaged KCSF
WA470-7
(PC400-AQ2-400-A-Z0-A)

Check for low coolant level.
Remedy
Perform
If white smoke problem is not resolved after

Clean or replace
remedies for cause 1 are taken, KDOC is
KDOC.
plugged.
Use proper fuel
and Maintenance
Manual.
KDOC is deteriorated by high sulfur content.
(If white smoke problem is not resolved after
Replace KDOC.
remedies for causes 1 to 3 are taken, KDOC
is deteriorated.)
If white smoke problem is not resolved after
remedies for causes 1 to 4 are taken, KDOC Clean KDOC.
is plugged.
Check KDOC for damage.
Replace KDOC.
Check KCSF for damage.
Replace KCSF.
40-1099
40 Troubleshooting
40-1100
WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model
Serial Number
WA470-7
10001 and up
50 Disassembly and assembly

7 50 Disassembly and assembly
WA470-7
50-1

Table of contents
Table of contents
(ALL-0310-002-A-00-A)
50 Disassembly and assembly ........................................................................................................... 50-1

General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-17
Removal and installation of supply pump assembly............................................................... 50-47
Removal and installation of injector assembly....................................................................... 50-53
Removal and installation of fuel doser assembly ................................................................... 50-61
Removal and installation of cylinder head assembly.............................................................. 50-63
Removal and installation of engine hood assembly ............................................................... 50-77
Removal and installation of grille assembly .......................................................................... 50-79
Removal and installation of cooling system assembly............................................................ 50-82
Removal and installation of radiator core assembly ............................................................... 50-85
Removal and installation of aftercooler................................................................................. 50-87
Removal and installation of hydraulic oil cooler ..................................................................... 50-90
Removal and installation of power train oil cooler assembly ................................................... 50-92
Removal and installation of engine assembly ....................................................................... 50-96
Removal and installation of engine front oil seal .................................................................. 50-102
Removal and installation of engine rear oil seal................................................................... 50-105
Removal and installation of cooling fan and cooling fan motor assembly ............................... 50-110
Removal and installation of KDPF assembly....................................................................... 50-112
Disassembly and assembly of KDPF assembly .................................................................. 50-117
Removal and installation of KCCV assembly ...................................................................... 50-126
Removal and installation of KVGT assembly....................................................................... 50-128
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly...................... 50-133
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly..................... 50-134
Removal and installation of air cleaner assembly ................................................................ 50-136
Removal and installation of air conditioner compressor belt ................................................. 50-138
Removal and installation of alternator belt .......................................................................... 50-139
Removal and installation of fuel tank assembly ................................................................... 50-140
Power train............................................................................................................................. 50-143
Removal and installation of torque converter and transmission assembly.............................. 50-143
Disassembly and assembly of transmission assembly......................................................... 50-148
Disassembly and assembly of torque converter assembly ................................................... 50-178
Disassembly and assembly of transmission clutch pack assembly ....................................... 50-185
Removal and installation of front axle assembly .................................................................. 50-208
Removal and installation of rear axle assembly................................................................... 50-210
Disassembly and assembly of axle housing assembly......................................................... 50-215
Disassembly and assembly of differential assembly ............................................................ 50-225
Steering system...................................................................................................................... 50-244
Removal and installation of steering valve assembly ........................................................... 50-244
Brake system ......................................................................................................................... 50-246
Removal and installation of brake charge valve assembly.................................................... 50-246
Removal and installation of parking brake disc and plate ..................................................... 50-247
Removal and installation of center hinge pin ....................................................................... 50-250
Removal and installation of counterweight assembly ........................................................... 50-258
Removal and installation of full-length fender assembly ....................................................... 50-260
Removal and installation of hydraulic tank assembly ........................................................... 50-261
Removal and installation of control valve assembly ............................................................. 50-264
Removal and installation of steering pump and power train pump assembly .......................... 50-267
Removal and installation of work equipment pump and cooling fan pump assembly............... 50-269
Disassembly and assembly of hydraulic cylinder assembly.................................................. 50-271
50-2
WA470-7

Table of contents
Work equipment ..................................................................................................................... 50-278

Removal and installation of work equipment assembly ........................................................ 50-278
Removal and installation of operator's cab and floor frame assembly.................................... 50-283
Removal and installation of operator's cab glass (stuck window glass).................................. 50-287
Removal and installation of operator's seat assembly.......................................................... 50-295
Removal and installation of seat belt .................................................................................. 50-297
Removal and installation of air conditioner unit assembly..................................................... 50-298
Removal and installation of air conditioner compressor assembly......................................... 50-303
Removal and installation of air conditioner condenser assembly .......................................... 50-305
Removal and installation of machine monitor assembly ....................................................... 50-307
Removal and installation of engine controller assembly ....................................................... 50-308
Removal and installation of work equipment controller assembly.......................................... 50-309
Removal and installation of transmission controller assembly .............................................. 50-311
Removal and installation of monitor controller assembly ...................................................... 50-312
Removal and installation of mass air flow and temperature sensor ....................................... 50-314
Removal and installation of KOMTRAX terminal assembly .................................................. 50-315
WA470-7
50-3

General information on disassembly and assembly

How to read this manual
(ALL-3851-001-A-00-A)
(ALL-0320-011-A-00-A)
(Rev.2010.10)
Removal and installation of TTTT assembly
Special tools
Special tools which are necessary for removal or
installation of assemblies are described as
A1X1 etc. and their part numbers, part names,
necessities, and quantities are described in the
special tool list.
Marks used in the column of necessity are
explained below.
t: Tools are not substituted, must always be
equipped (used).
q: Tools extremely useful if available or tools
that can be substituted with commercially
available tool.
For details and the sketches of the special tools,
see "special tool list" and "sketches of special
tools".
Removal
In the removal section, the work procedures,
precautions and know-how to do the work and
the amount of oil and coolant to be drained are
described.
Common tools that are necessary for the
removal work are indicated as [1], [2] ... etc. and
their part numbers, part names and quantities
are not described.
Marks used in the removal section are explained
below.
k:
This mark indicates safety-related

precautions which must be followed when
performing the work.
a : This mark gives guidance or precautions when

[*1]: This mark indicates that instructions or
precautions for the assembly installation work are
given in the installation section.
6 : This mark shows the amount of oil or
coolant to be drained.
4 : This mark shows the weight of a part or
the assembled parts for a device.
Installation
Unless otherwise instructed the installation of
assemblies is to be made in the reverse order to
removal.
Instructions and precautions for assembly
installation are shown with [*1] mark in the
removal section, identifying which step the
instructions are intended for.
50-4
Common tools that are necessary for installation

are described as [1], [2] ... etc. and their part
numbers, part names and quantities are not
described.
Marks shown in the installation section are
explained below.
k:

a : This marks gives guidance or precautions

when performing the work.
2 : This mark indicates a specific coating
agent to be used.
3 : This mark indicates the specified
tightening torque.
5 : This mark indicates the amount of oil or
coolant to be added.
Disassembly and assembly of TTTT assembly
Special tools
Special tools which are necessary for
disassembly and assembly of assemblies are
described as A1X1 etc. and their part
numbers, part names, necessities, and
quantities are described in the special tool list.
Marks used in the column of necessity are
explained below.
t: Tools are not substituted, must always be
equipped (used).
q: Tools extremely useful if available or tools
that can be substituted with commercially
available tool.
For details and the sketches of the special tools,
see "special tool list" and "sketches of special
tools".
Disassembly
In the disassembly section, the work
procedures, precautions and know-how to do
the work, and the amount of oil and coolant to be
drained are described.
disassembly work are indicated as [1], [2] ... etc.
and their part numbers, part names, and
quantities are not described.
Marks used in the disassembly section are
explained below.
WA470-7

k:

a : This marks gives guidance or precautions

when performing the work.
6 : This mark shows the amount of oil or
coolant to be drained.
Assembly
In the assembly section, the work procedures,
precautions and the know-how to do the work,
and the amount of oil or coolant to be added are
described.
disassembly work are indicated as [1],[2] ... etc.
and their part numbers, part names, and
quantities are not described.
Marks used in the assembly section are
explained below.
k:

a : This mark gives guidance or precautions when

2 : This mark indicates a specific coating
agent to be used.
3 : This mark indicates the specified
tightening torque.
5 : This mark indicates the amount of oil or
coolant to be added.
WA470-7
50-5

Coating materials list
(ALL-3540-071-A-00-A)
(Rev.2012.08)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for
disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Komatsu code
Part No.
LT-1A
790-129-9030
LT-1B
790-129-9050
LT-2
790-129-9180
LT-3
790-129-9060
(Set of adhesive
and hardener)
LT-4
790-129-9040
Holtz MH705
790-129-9120
ThreeBond 1735
790-129-9140
Aron Alpha 201
790-129-9130
Loctite 499
428-99-80070
Loctite 648-50
79A-129-9110
50-6
Capacity
Main features and applications

Use to prevent rubber gaskets, rubber
150 g
Tube
cushions, and cork plugs from coming
out.
Use for plastic (except polyethylene,
20g
polypropylene, tetrafluoroethylene, and
Polyethylene
vinyl chloride), rubber, metal, and non(2 pcs.
container
metal parts which require immediate
contained)
and strong adhesion.
Features: Resistance to heat and
Polyethylene
chemicals
50 g
container
Use to fix and seal bolts and plugs.
Adhesive:
1 kg
Use to bond and seal metal, glass and
Can
plastics.
Hardener:
500 g
Polyethylene Use to seal plugs for blank holes.
250 g
container
Heat-resistant seal used to repair
75 g
Tube
engines
Instantaneous adhesive
Polyethylene Curing time: From 5 sec. to 3 min.
50 g
Use mainly to bond metals, rubbers,
container
plastics, and woods.
Instantaneous adhesive
Quick-curing type (max. strength is
Polyethylene
2g
obtained after 30 minutes)
container
Use mainly to bond rubbers, plastics,
and metals.
General-purpose instantaneous
adhesive with excellent resistance to
20 g
heat and impact
Tube
Use on the bushing mounting faces of
axle supports.
Features: Resistance to heat and
chemicals
Polyethylene
50 cc
Use for fitted portions used at high
container
temperatures.
Container
WA470-7

Liquid gasket
Komatsu code
LG-5
Part No.
790-129-9080
Capacity
1 kg
Container
Polyethylene
container
LG-6
790-129-9160
200 g
Tube
LG-7
790-129-9170
1 kg
Tube
LG-8
ThreeBond
1207B
419-15-18131
LG-9
ThreeBond
1206D
790-129-9310
LG-10
ThreeBond
1206E
790-129-9320
LG-11
ThreeBond 1121
790-129-9330
200 g
Tube
ThreeBond 1211
790-129-9090
100 g
Tube
Capacity
Container
100 g
Tube
200 g
Tube
200 g
Tube

Use to seal various thread portions,
pipe joints, and flanges.
Use to seal taper plugs, elbows, and
nipples for hydraulic piping.
Features: Silicon-based heat and
cold-resistant sealant
Use to seal thread portions and flange
surface.
Use to seal oil pan, final drive case,
etc.
Features: Silicon-based quick-curing
sealant
Use to seal flywheel housing, intake
manifold, oil pan, thermostat housing,
etc.
Features: Silicon-based, heat and
cold-resistant, vibration-resistant,
impact-resistant sealant
Use to seal transfer case, etc.
Use for rough surfaces such as the
circle gear top seal which is not
clamped by bolts, gaps in the weld
which must be caulked, etc.
Can be coated with paint.
Use as lubricant or sealant when the
radiator hoses are put on.
Can be coated with paint.
Feature: Can be used together with
solid gaskets.
Use for covers of the transmission
case and steering case etc.
Liquid gasket used to repair engine
Molybdenum disulfide lubricant

Komatsu code
Part No.
LM-P
09940-00040
200 g
Tube
LM-S
09995-00250
190 g
Can
WA470-7

Use to prevent galling and seizure of
press-fitted portions, shrinkage-fitted
portions, and thread portions.
Use to lubricate linkages, bearings,
etc.
Spray type
Thin molybdenum disulfide films are
made on metal surfaces to prevent the
metals from galling.
Use for the drive shaft splines, needle
bearings, pins and bolts of various
links, etc.
50-7

Seizure prevention compound

Komatsu code
Part No.
Capacity
Container
LC-G
NEVER-SEEZ
Can
Capacity
Container
Various
Various
Lithium grease with extreme pressure

lubrication performance, general
purpose type

Feature: Seizure and galling
prevention compound with metallic
super-fine-grain, etc.
Use for the mounting bolt in the high
temperature area of the exhaust
manifold and the turbocharger, etc.
Grease
Komatsu code
Part No.
SYG2-400LI-A
SYG2-16LI
G2-LI
G0-LI (*)
SYGA-16CNLI
*: For cold regions SYG0-400LI-A(*)
SYG0-16CNLI(*)
Molybdenum
disulfide grease
LM-G (G2-M)
Hyper White
Grease
G2-T
G0-T (*)
*: For cold regions
Bio grease
G2-B
G2-BT (*)
*: For use at high
temperature and
under high load
SYG2-400M
SYG2-400M-A
SYGA-16CNM
400 g x 10
400 g x 20
16 kg
Use for parts under heavy load.

Caution:
Do not use this grease for rolling
Bellows-type
bearings like swing circle bearings,
container
etc. and splines.
Use this grease for work
Can
equipment pins only when
installing them, but do not use it
afterward.
SYG2-400T
SYG2-16CNT
SYG0-400T(*)
SYG0-16CNT(*)
400 g
16 kg
Bellows-type
container
Can
SYG2-400B
SYGA-16CNB
SYG2-400BT(*)
SYGA-16CNBT(*)
400 g
16 kg
Bellows-type Since this grease is biodegradable in

container
short period, it has less impact on
microorganisms, animals, and plants.
Can
G2-S
ThreeBond 1855
200 g
Tube
G2-U-SENS
grease
427-12-11871
2 kg
Can
50-8
Higher seizure resistant, heat

resistant and water resistant than
molybdenum disulfide grease.
Not conspicuous on machine since
color is white.
Silicone grease with wide usable

temperature range, high resistance to
thermal-oxidative degradation and
performance to prevent deterioration
of rubber and plastic parts
Use for oil seals of the transmission,
etc.
Urea (organic system) grease with
heat resistance and long life.
Enclosed type.
Use for rubber, bearing and oil seal in
damper.
Caution: Do not mix it with lithium
grease.
WA470-7

Primer
Loctite 712
Part No.
Capacity
428-99-80080
100 ml
Sunstar Paint
Primer 580 Super
Container
Glass
container
20 ml
Glass
container
20 ml
Glass
container
417-926-3910
Sunstar Glass
Primer 580 Super
Sunstar Paint
Primer 435-95
22M-54-27230
20 ml
Glass
container
Sunstar Glass
Primer 435-41
22M-54-27240
150 ml
Steel can
Sunstar Sash
Primer GP-402
22M-54-27250
20 ml
Glass
container
Part No.
Capacity
Container
Sunstar Penguin
Seal 580 Super
"S" or "W"
417-926-3910
320 ml
Polyethylene
container
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
Sunstar Penguin
Super 560
22M-54-27210
320 ml
Ecocart
(Special
container)
Part No.
Capacity
Container
Sunstar Penguin
Seal No.2505
417-926-3920
320 ml
Polyethylene
container
Sekisui Silicone
Sealant
20Y-54-55130
333 ml
Polyethylene
container
GE Toshiba
Silicones
TOSSEAL 381
22M-54-27220
333 ml
Cartridge

Use to accelerate hardening of
instantaneous adhesive.
Use as primer for painted cab
sheet metal surface.
(Effective period: 4 months after
manufacture)
Use as primer for cab glass
surface.
manufacture)
Use as primer for painted cab
sheet metal surface.
manufacture)
Use as primer for black ceramiccoated glass surface and for hard
polycarbonate-coated surface.
manufacture)
Use as primer for sash (Almite)
manufacture)
For adhering cab glass
Komatsu code
Komatsu code
Adhesive
Use "S" in high temperature
season and "W" in low
temperature season as adhesive
for glass.
manufacture)
Use as adhesive for glass.
manufacture)
Use as adhesive for glass.
manufacture)
Komatsu code
WA470-7
Caulking material
Use to seal joints of glass parts.
manufacture)
Use to seal front window.
manufacture)
Use to seal glass-to-glass joint.
Translucent white seal.
manufacture)
50-9

Special tools list
(WA470-3530-061-A-00-A)
a Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
a Necessity
t: Tools are not substituted, must always be equipped (used).
q: Tools extremely useful if available or tools that can be substituted with commercially available tools.
a New/Redesign
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification.
Symbol
Part No.
Part name
Sketch
Work
Necessity
Q'ty
New/Redesign
a Tools marked with Q in the Sketch column have the sketches. (See "Sketches of special tools")
Details of work and

remarks
Removal and
installation of supply
pump assembly
1
2
3
795-630-5500 Standard puller

01010-81090 Bolt
01643-31032 Washer
t 1
t 2
t 2
Removal of gear and

shaft
Removal and
pump assembly
Removal and
pump assembly
6212-82-0110 Wrench
t 1
Removal and installation

of KCCV ventilator
790-331-1110 Wrench
q 1
Tightening of cylinder
head bolts
Removal and
installation of cylinder
head assembly
Removal and
installation of engine
front oil seal
Removal and
front oil seal
Removal and
front oil seal
Removal and
rear oil seal
Removal and
installation of KDPF
assembly
50-10
8
9
10
1
2
3
11
4
5
6
1
12
2
13
14
793T-601-1410
01011-81040
01643-31032
01580-01008
Bracket
Bolt
Washer
Nut
Seal puller
795-931-1100 assembly
795T-521-1140
01010-61650
01643-31645
795T-401-1310
795T-401-1320
795T-601-1310
795T-401-1330
795T-401-1340
795T-401-1350
01010-61660
01010-61640
01643-31645
Push tool
Bolt
Washer
Push tool
Guide bolt
Push tool
Push tool
Guide
Spacer
Bolt
Bolt
Washer
J4000-01650 Bolt
t
t
t
t
1 N Q
Installation of exhaust
2
tube between KVGT and
2
KDPF
2
q 1
Removal of engine front

seal and rear seal
t
t
t
t
t
t
t
t
t
t
t
t
Q
1
Installation of engine
3
front oil seal
9
Q
1
Q
3
1 N Q
1 N Q
Installation of engine
Q
1
rear oil seal
Q
1
1
1
1
Adjusting the installed
position of KDPF
q 1
assembly
WA470-7
Sketch
Work
Necessity
Q'ty
New/Redesign
15
795T-621-2820 Push tool
t 1
16
795T-621-2810 Installer
t 1
793T-607-1550 Bracket
01051-62240 Bolt
t 1 N Q
t 1
Symbol
Removal and
installation of KVGT
A
assembly
Disassembly and
assembly of
transmission
assembly
Removal and
installation of parking
brake disc and plate
01643-32260 Washer
3
4
5
9
10
WA470-7
Part name
793T-607-1260
01016-51645
01016-51690
01010-81245
793T-607-1570
790-102-1891
793T-607-1220
Plate
Bolt
Bolt
Bolt
Plate
Nut wrench
Lifting tool
793-607-1230 Pin
793T-607-1280
01016-31245
01580-11210
01017-30250
01643-32060
01580-12016
793T-607-1290
04530-11628
793T-607-1310
793T-607-1520
2989-01-1220
01643-33080
01017-31420
793T-607-1330
793T-607-1340
01010-80820
01643-30823
793T-607-1350
04530-11018
793T-607-1560
01017-51630
01643-31645
Lifting tool
Bolt
Nut
Bolt
Washer
Nut
Bar
Eyebolt
Plate
Push tool
Bolt
Washer
Bolt
Bracket
Plate
Bolt
Washer
Bolt
Eyebolt
Sleeve
Bolt
Washer
t 1
t
t
t
t
t
t
t
Q
1
1
4
1 N Q
1
Q
1
t 1
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
11
790-201-2660 Plate
12
792-135-3360 Plate
13
792-822-1430 Plate
14
790-201-2860 Spacer
Details of work and

remarks
Installation of exhaust
Q connector
Disassembly and
assembly of
transmission
assembly
Part No.

of ring
Removal of transfer
shaft 1 and inner race
of PTO gear nut
of F and 1st clutch pack
assembly
Q
2
4
4
of R and 2nd clutch pack
2
assembly and 3rd and
4
4th clutch pack
4
assembly
Q
1
1
Q
1
1 N Q Removal of transfer
1
shaft 2 and transfer gear
2
1
8
Q
1
Q
1
Layout of transfer gear 2
2
2
Q Installation of transfer
1
shaft 2
1
1 N Q
Installing spacer to
1
transfer gear 1
1
Press fit of outer races
into F and 1st clutch
1
shaft cage
Press fit of transfer shaft
1
1 bearing into case
1
for transfer gear 2 into
1
case
50-11
Disassembly and
assembly of
transmission
assembly
Disassembly and
assembly of torque
converter assembly
50-12
Symbol
Part No.
Part name
15
16
17
792T-227-1110 Push tool

792T-423-1230 Push tool
790-201-2680 Plate
18
794T-425-1110 Push tool
19
793T-615-1810 Push tool
20
791T-630-2410 Push tool
21
790-201-2220 Plate
22
790-201-2160 Plate
23
793T-607-1420 Push tool
24
793T-623-1170 Push tool
25
790-445-3810 Push tool
26
790-201-2860 Spacer
27
790-101-5401
790-101-5421
790-101-5441
01010-51240
28
790-434-1470 Push tool
29
793T-607-1430 Push tool

790-101-5421 Grip
01010-51240 Bolt
30
793T-607-1140 Spacer
31
793T-607-1440 Push tool

790-101-5421 Grip
01010-51240 Bolt
32
793T-607-1450 Spacer
33
790-501-5000 Unit repair stand

790-901-2110 Bracket
793T-613-1510 Plate
Push tool kit

Grip
Plate
Bolt
34
792-213-1110 Wrench
35
790-201-2650 Plate
36
790-201-2740 Spacer
Sketch
Work
Necessity
Q'ty
New/Redesign
Details of work and

remarks
t 1
t 1
q 1
Q Press fit of bearing into

Q transfer shaft 2
Press fit of outer race on
the rear side of output
t 1
Q shaft
Press fit of output shaft
t 1 N Q
bearing (small)
Press fit of output shaft
t 1
Q bearing (large)
Press fit of outer race on
q 1
the front side of output
shaft
Press fit of input shaft
q 1
bearing into case
t 1
Q
inner races
t 1
Q into PTO cage
Press fit of PTO bearing
t 1
q 1
cover
q 1
1
spacer
1
1
q 1
bearing (large)
t 1
Q Press fit of oil and dust
seals on the front side of
t 1
output shaft
t 1
Press fit of dust seal on
t 1
Q the front side of output
shaft
t 1
Q Press fit of oil and dust
seals on the rear side of
t 1
output shaft
t 1
Press fit of dust seal on
t 1
Q the rear side of output
shaft
q 1
Fixing torque converter
q 1
assembly
q 1 N Q
t 1
of stator shaft locknut
Removal of stator shaft
q 1
and bearing
Removal of boss and
q 1
bearing ring
WA470-7
Symbol
Disassembly and
assembly of torque
converter assembly
790-201-2660 Plate
q 1
38
792T-415-1410 Spacer
q 1
39
790-201-2750 Spacer
q 1
40
790-201-2680 Plate
q 1
41
42
790-201-2220
791-830-1770
Commercially
available
790-101-2501
790-101-3201
790-201-1310
Commercially
available
790-201-1410
790-101-2510
790-101-2520
791-112-1180
790-101-2540
790-101-2450
790-201-2860
790-101-3501
790-201-1320
Plate
Push tool
q 1
q 1
Puller
q 1
Push puller
Bearing puller
Plate
t 1
t 1
t 1
Puller
t 1
Plate
Block
Screw
Nut
Washer
Adapter
Spacer
Puller
Plate
t
t
t
t
t
t
t
t
t
44
45
B
46
WA470-7
Part name
37
43
Disassembly and
assembly of
transmission clutch
pack assembly
Part No.
47
793-415-1170 Seal holder
Sketch
Work
Necessity
Q'ty
New/Redesign
Details of work and

remarks
Removal of bearing and

housing
Assembly of turbine and
Q
case
Press fit of bearing into
housing
guide
Removal of stator shaft
into bearing
Removal of F and R
clutch bearings and
spacers
Removal of 1st clutch
bearing
1
1
1
1
1
1
1
1
1

of 1st and 2nd clutch
snap rings
t 1
48
793T-607-1420 Push tool
q 1
49
793T-607-1370 Seal holder
t 1
50
796T-467-2160 Push tool
t 1
51
799-301-1500 Oil leak tester
t 1
52
t 1
53
792T-446-1150 Push tool
t 1
54
t 1
55
795-102-2730 Collar
t 1
Removal of 2nd clutch

bearing and hub
Installation of seal ring
to 3rd piston
Press fit of spacer into
3rd clutch
to 4th piston
2nd and 4th clutches
Press fit of bearing and
spacer into R clutch
Operation check of
clutch
to 1st and 2nd pistons
Press fit of inner races
into 2nd clutch
to F and R pistons
1st clutch
50-13
Symbol
D1
Part name
1 790-501-5000 Unit repair stand

2 790-901-2110 Bracket
3 790T-901-3440 Plate
D2
793T-622-2570 Eyebolt
D3
790-201-2730 Spacer
D4
D5
D6
D7
1
2
1
2
1
2
1
2
D9
D10
793T-615-1730
790-201-2770
790-201-2780
793T-623-1210
796-765-1110
790-201-2750
796-765-1110
792T-413-1120
Spacer
Spacer
Spacer
Spacer
Push tool
Spacer
Push tool
Push tool
D8
Disassembly and
assembly of
differential assembly
Part No.
1
2
3
1
2
3
4
D11
793T-622-1310
790-101-5421
01010-51240
793T-622-1310
793T-622-1320
790-101-5421
01010-51240
Push tool
Grip
Bolt
Push tool
Spacer
Grip
Bolt
793T-622-1360 Push tool

1 793T-622-2560 Wrench
D12
01316-10616 Bolt
793T-615-1730 Spacer
D13
799-101-5230
07002-11423
2 793-605-1001
3 790-101-1102
1
D14
D15
D16
Disassembly and
assembly of axle
housing assembly
50-14
D17
Adapter
O-ring
Brake tester
Hydraulic pump
799-301-1500 Oil leak tester kit

1
2
1
2
3
4
5
6
Commercially
available
790-201-1410
793T-622-2520
790-101-2520
791-112-1180
790-101-2540
790-101-2620
790-101-2570
q 1
q 1
q 1
Sketch
Work
Necessity
Q'ty
New/Redesign
Details of work and

remarks
Fixing differential
assembly
Removal of cage
t 2 N Q
assembly
Removal of cage and
q 1
pinion gear
q 1
Q Press fit of outer races
into cage
q 1
q 1
q 1 N Q into cage
t 1
pinion gear
t 1
t 1
t 1
Q pinion gear
Measurement of starting
q 1
torque
t 1
Q
Press fit of oil seal into
t 1
cage
t 1
t 1
Q
t 1
Q Press fit of dust seal into
cage
t 1
t 1
t 1
Q
case and cover
t 1 N Q Measurement of
differential torque under
t 2
no load
q 1
Q into bearing carrier
t 1
t 1
Check for oil leakage.
t 1
t 1
Checking operation of
t 1
piston
Puller
t 1
Plate
Block
Screw
Nut
Washer
Leg
Plate
t
t
t
t
t
t
t
Removal of ring gear

1
1 N Q
1
1
Removal of axle shaft
and bearing
1
2
4
WA470-7
Disassembly and
assembly of axle
housing assembly
Symbol
Part No.
7
8
D17 9
10
11
1
D18 2
3
790-101-2560
790-101-2740
790-201-1410
790-101-2102
790-101-1102
790-101-2800
793T-622-2530
01643-32060
D20
793T-622-2550 Spacer
q 1
1 793T-622-1330 Push tool

2 793T-622-1340 Spacer
1 793T-622-1370 Support
2 01010-50830 Bolt
t
t
t
t
1
1
2
6
D23
793T-622-2510 Spacer
t 1
D24
793T-622-1510 Holder
t 1
D25
q 1
E1
F3
F4
F5
Push puller
Push tool
Push tool
Guide
Bar
Nut
Hydraulic pump
Puller (30 ton)
Repair stand
1
2
3
4
5
6
7
8
1
790-101-2300
793-520-2370
793-520-2350
793-520-2540
793-520-2360
791-112-1180
790-101-1102
790-101-2102
790-502-1003
790-101-1102 Hydraulic pump
1
2
1
2
1
2
3
4
5
Socket
790-302-1280 (width across flats:
55 mm)
790-330-1100 Wrench assembly
790-102-4310 Pin
790-720-1000 Expander
796-720-1650 Ring
07281-01029 Clamp
796-720-1680 Ring
07281-01589 Clamp
F2
WA470-7
2
2
1
1
1
1
2
2
q 1
F1
Disassembly and
assembly of hydraulic
cylinder assembly
t
t
t
t
t
t
t
t
793T-622-2540 Spacer
D22
Removal and
installation of center
hinge pin
Nut
Adapter
Plate
Puller assembly
Hydraulic pump
Bearing puller
Bolt
Washer
D19
D21
Disassembly and
assembly of axle
housing assembly
Disassembly and
assembly of
differential assembly
Part name
t
t
t
t
t
t
t
t
t
1
1
1
1
2
2
1
1
1
Sketch
Work
Necessity
Q'ty
New/Redesign
Details of work and

remarks

and bearing

Q bearing
Q into axle housing
Q into axle housing
Q Press fit of oil seal and
Q bearing into axle shaft
Q Adjusting the installed
position of oil seal
Press fit of axle shaft
Q into bearing
Q Selection of shims
Measurement of starting
torque
Installation of upper
hinge pin
t 1
Disassembly and
cylinder assembly
t 1
For steering cylinder

piston nut
t
t
t
t
t
t
t
t
t
1
1
1
1
1
1
1
1
1
For steering cylinder

cylinder head
For lift cylinder and
bucket cylinder piston
For piston ring assembly
50-15
Symbol
F6
Disassembly and
cylinder assembly
F7
Removal and
installation of
operator's cab glass
(adhered window
glass)
50-16
X2
X3
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
Part No.
790-201-1500
790-101-5021
01010-50816
790-201-1570
790-201-1990
790-201-1660
790-201-1702
790-101-5021
01010-50816
790-201-1761
790-201-1930
790-201-1851
793-498-1120
793-498-1130
793-498-1110
Part name
Push tool kit

Grip
Bolt
Plate
Plate
Plate
Push tool kit
Grip
Bolt
Push tool
Push tool
Push tool
Clear plate
Plate
Magnet
793-498-1210 Lifter (suction cup)
t 1
1
1
1
t 1
1
t 1
1
1
1
1
1
t 2
t 2
t 2
t 2
Sketch
Work
Necessity
Q'ty
New/Redesign
Details of work and

remarks
For cylinder dust seal
For cylinder head

bushing
Installation of operator's
cab glass
WA470-7

Sketches of special tools
(WA470-3531-066-A-00-A)
A6: Bracket
A8: Push tool
WA470-7
50-17

A11-1: Push tool
A11-2: Guide bolt
50-18
WA470-7

A11-3: Push tool
A11-4: Push tool
WA470-7
50-19

A11-5: Guide
A11-6: Spacer
50-20
WA470-7

A15: Push tool
A16: Installer
WA470-7
50-21

B1: Bracket
B2: Plate
50-22
WA470-7

B3: Plate
B5: Lifting tool
WA470-7
50-23

B6: Lifting tool
B6: Bar
50-24
WA470-7

B7: Plate
B7: Push tool
WA470-7
50-25

B8: Bracket
B8: Plate
50-26
WA470-7

B9: Bolt
B10: Sleeve
WA470-7
50-27

B15: Push tool
B16: Push tool
50-28
WA470-7

B18: Push tool
B19: Push tool
WA470-7
50-29

B20: Push tool
B23: Push tool
50-30
WA470-7

B24: Push tool
B29: Push tool
WA470-7
50-31

B30: Spacer
B31: Push tool
50-32
WA470-7

B32: Spacer
B33: Plate
WA470-7
50-33

B38: Spacer
B48: Push tool
50-34
WA470-7

B49: Seal holder
B50: Push tool
WA470-7
50-35

B52: Seal holder
B53: Push tool
50-36
WA470-7

B54: Seal holder
D1-3: Plate
WA470-7
50-37

D2: Eyebolt
D4-1 and D13: Spacer
50-38
WA470-7

D5-2: Spacer
D7-2: Push tool
WA470-7
50-39

D9-1 and D10-1: Push tool
D10-2: Spacer
50-40
WA470-7

D11: Push tool
D12-1: Wrench
WA470-7
50-41

D17-1: Block
D18-2: Bolt
50-42
WA470-7

D19: Spacer
D20: Spacer
WA470-7
50-43

D21-1: Push tool
D21-2: Spacer
50-44
WA470-7

D22-1: Support
D23: Spacer
WA470-7
50-45

D24: Holder
50-46
WA470-7

(ALL-R401-001-K-00-A)
Removal and installation of supply pump assembly
(WA470-AD70-924-K-00-A)
Symbol
Part No.
1
2
A
3
4
795-630-5500
01010-81090
01643-31032
6212-82-0110
Part name
Standard puller
Bolt
Washer
Wrench
Necessity
Q'ty
a Special tools
t
t
t
t
1
2
2
1
k Place

turn the parking brake switch to ON position.
k Set
the frame lock bar to LOCK position, and

chock the wheels.
3. Remove case (6) of KCCV ventilator. [*1]

4. Remove oil filler pipe (7).
k Lower
the work equipment to the ground,

and set the work equipment lock switch to
LOCK.
k Turn
the starting switch to OFF position, and

stop the engine.
k Turn

position, and remove the key. (For details,
see Testing and adjusting, "Handling battery
disconnect switch".)
a When removing or installing fuel piping, be

careful that foreign matter does not enter in it. If
any dirt or dust sticks the parts of the fuel system,
clean it off thoroughly with clean fuel.
Removal
(WA470-AD70-520-K-00-A)
1. Open full-length fender (1) and side cover (2).
5.
6.
7.
8.
Disconnect fuel hose (8).

Remove overflow valve (9). [*2]
Remove cover (10).
Remove bolt (11), loosen bolt (12), and slide
cover (13) to the right side.
a Bolts (12) cannot be removed.

9. Remove joint bolt (14). [*3]
10.Remove all the clamps of fuel tube (15), and
slide fuel tube (15).
2. Disconnect connectors PCV1 (3), PCV2 (4) and

G (5).
WA470-7
50-47

17.Remove the supply pump lower brackets (26)

and (27).
11.Remove joint bolt (16), and disconnect fuel tube

(17). [*4]
12.Remove joint bolt (18), and disconnect fuel tube
(19). [*4]
18.Remove rubber cover (28) on the front side of

the engine.
a Identify the installation positions of joint bolts

(16) and (18).
13.Remove fuel tube (20). [*5]
14.Remove lubrication tube (21) and bracket (211).

15.Remove fuel spray prevention caps (22) and
(23).
16.Remove high-pressure fuel pipes (24) and (25).
50-48
19.Rotate the crankshaft forward (in the direction of

the arrow) by using crank pulley mounting bolt
(29), and align the center point (a) between "2.5
TOP" and "3.4 TOP" stamp lines on damper (30)
with pointer (31).
a At this time, the stamp line of "1.6 TOP" is
almost at the bottom.
Width across flats of crank pulley mounting
bolt: 24 mm
WA470-7

23.Loosen nut (35) by approximately 2 turns.
24.Install tools A1, A2, and A3.

25.Tighten the center bolt of tool A1, and separate
supply pump drive gear (36) from shaft (37).
26.Remove A1, A2, and A3, and remove nut (35).
27.To prevent supply pump drive gear (36) from
falling off, install A1, A2, and A3 again.
20.Open cover (32).
21.Remove cover (33). [*6]
28.Remove mounting bolts (38) (4 pieces), and

remove supply pump assembly (39).
22.Check that the supply pump drive gear forcing

tap is aligned with cover mounting bolt hole (34)
as described above. If it is not aligned with the
bolt hole, rotate the crankshaft 1 more turn.
WA470-7
50-49

Installation
(WA470-AD70-720-K-00-A)
a Observe the following about fuel high-pressure

pipes.
k KOMATSU
recommend to use the Komatsu

genuine fuel high-pressure pipe clamps and
observe the tightening torque indicated.
k Do
not bend the fuel high-pressure pipe to

correct before installing.
k Before
installing the fuel high-pressure pipe,

check it for the following.
If the fuel high-pressure pipe has any defect,
replace it with a new one since fuel may leak.
Check that the taper seal portion of the
connection (portion (a): 2 mm area from
the tip-end) is free from visually
recognizable longitudinal slits (b) or
spotty dents (c).
Make sure that part (d) (end of taper seal:
2 mm from the tip-end) is free from steps
which can be felt by your fingernail.
(Namely, this portion must be free from
fatigue.)
3. Finger-tighten mounting bolts (38) (4 pieces).

a When reusing mounting bolt (38), apply the
adhesive (LT-2) to the threaded part.
Adhesive (LT-2)
4. Remove tools A1, A2 and A3.
5. Check that shaft key (40) of the supply pump is
aligned with the keyway of the drive gear, and
then install nut (35).
3 Mounting nut (35):
176 to 196 Nm {18 to 20 kgm}
6. Install brackets (26) and (27) by finger-tightening
the bolt.
1. When supply pump assembly (39) is the state

shown in the figure, make sure that shaft key
(40) faces directly above.
2. Install supply pump assembly (39), aligning shaft
key (40) with keyway (a) on the gear.
50-50
WA470-7

17.Fasten clamps (47) and (48) to the specified

torque.
3 Mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
18.Tighten mounting bolts (49) of bracket (21-1) to
19.Tighten mounting bolts (50) of bracket (45) to
21.Tighten bolt (52) to the specified torque.
22.Install lubrication tube (21) to the specified
torque.
3 Joint bolt
(cylinder block side):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
(Supply pump side):
7.9 to 12.7 Nm {0.8 to 1.3 kgm}
7. Fasten fuel high-pressure pipes (24) and (25) by
hands.
8. Install the preceding fuel high-pressure pipe
clamp and bracket by finger-tightening the bolt.
9. Fasten lubrication tube (21) by hands.
10.Tighten sleeve nuts of fuel high-pressure pipes
(24) and (25) to the specified torque.
3 Sleeve nut
(both common rail side and supply
pump side):
39.2 to 44.1 Nm {4 to 4.5 kgm}
11.Tighten supply pump mounting bolts (38) to the
specified torque.
59 to 74 Nm {6.0 to 7.5 kgm}
12.Tighten the mounting bolts (2 pieces) of bracket
(26) at supply pump side to the specified torque.
3 Supply pump side mounting bolt:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
13.Tighten bolts (41) and (42) in this order to the
specified torque.
14.Install fuel spray prevention caps (22) and (23).
a Install the cap with its slit facing as follows.
Fuel spray prevention cap (22):
Cylinder block side
Fuel spray prevention cap (23): Downward
15.Install brackets (43), (44), (45), (46) and (21-1)
by finger-tightening the bolt.
16.Fasten clamps (47) and (48) by hands.
WA470-7
25.Perform the subsequent installation in the

reverse order to removal.
[*1]
a Tighten case (6) fully by hands, and retighten it
by 1/15 to 2/15 turns (1 to 2 ribs of ring) by using
tool A4.
50-51

3 Case (6) (reference value):

36.6 to 44.7 Nm {3.7 to 4.6 kgm}
[*2]
3 Overflow valve (9):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
[*3]
3 Joint bolt (14):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
[*4]
a Install joint bolts (16) and (18) while confirming
discrimination mark put at disassembly.
3 Joint bolts (16) and (18):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
[*5]
3 Joint bolt of fuel tube (20) (supply pump
side):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
3 Joint bolt of fuel tube (20) (fuel filter
side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*6]
3 Cover (33) mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
Air bleeding
Bleed air in the fuel system. For details, see
Testing and adjusting, "Bleeding air in circuit".
Checking for fuel leakage
Check for fuel leakage. For details, see Testing
and adjusting, "Testing fuel circuit for leakage".
50-52
WA470-7

Removal and installation of injector assembly
(WA470-AE60-924-K-00-A)
Symbol
A4
Part No.
Part name
6212-82-0110 Wrench
Necessity
Q'ty
a Special tools
t 1
k Place

k Set

chock the wheels.
k Lower

LOCK.
5. Remove case (3) of KCCV ventilator, fuel filter

(4), fuel prefilter (5), and oil filter (6). [*1]
k Turn

stop the engine.
k Turn

a When removing or installing fuel piping, be

careful not to let foreign matter enter. If any dirt
or dust sticks on the parts of the fuel system,
clean it off thoroughly with clean fuel.
Removal
(WA470-AE60-520-K-00-A)
1. Remove the KDPF assembly. For details, see

"Removal and installation of KDPF assembly".
2. Remove the air cleaner assembly. For details,
see "Removal and installation of air cleaner
assembly".
3. Remove clamps (1) (3 places).
6. Disconnect following connectors and move the

wiring harness.
G(7)
PCV1(8)
PCV2(9)
POIL(10)
SEGR(11)
EGR-SOL(12)
VGT-SOL(13)
PCCV(14)
PIM(15)
4. Sling and remove bracket (2).

4 Bracket (2):
40 kg
WA470-7
50-53

9. Remove spill tube (23-1). [*2]

10.Disconnect fuel injector connectors (24) (6
places).
a Disconnect fuel injector connectors
1) Apply flat-head screwdriver [1] to stepped
part (a) and push stopper (b).
2) Move flat-head screwdriver [1] in direction x
to disconnect connector (c).
VGT-REV(16)
SVGT(17)
PDOSER(18)
SOV1(19)
SOV2(20)
7. Remove bracket (21).
8. Remove tubes (22) and (23).
11.Remove mounting bolts (26) of bracket (25).

12.Remove bracket (27) and clamp inside.
13.Remove fuel high-pressure pipe clamps (28) (4
pieces) and (29) (6 pieces).
50-54
WA470-7

19.Remove mounting bolts (38) to remove rocker

arm and shaft assembly (39).
a Loosen lock nuts (40), and then loosen
adjustment screws (41) thoroughly so that
excessive force does not apply to the push
rods when the rocker arms are installed.
14.Remove fuel spray prevention caps (30) and

(31) (6 pieces each).
a Figure shows the state without surrounding
parts for explanation. (Mixing connector does
not need to be removed.)
15.Remove fuel high-pressure pipes (32) (6
pieces).
16.Remove cylinder head covers (33) (6 pieces).
20.Remove injector assembly (42).

a Before removing the injector, record the
cylinder number to be removed and the
character string (M) listed on the QR code
tab (Q) on the injector as a set.
a Read character string (M) in the order of the
arrow shown in the figure.
a Be sure to check that the recorded character
string is correct.
17.Loosen nut (34) (2 pieces) thoroughly.

a Loosen the nuts alternately.
18.Remove mounting bolt (36) of holder (35) and
then reposition injector harness (37) out of the
way.
WA470-7
a Do not damage and remove QR code tab (Q)

attached to the injector head.
(Reference: The QR code or character string
indicates the compensation value for fuel
injection of the injector, which is specific to
each injector.)
50-55

Installation
(WA470-AE60-720-K-00-A)
a Wash off and remove dirt and dust attached on

the parts near harness connectors to prevent
them from entering connectors.
a Use clean engine oil when applying engine oil to
O-rings and lubricated portions.
1. When replacing the injector assembly or engine
controller assembly, write the character string
into the engine controller according to the
following procedure. For details, see Testing and
adjusting, "Writing compensation values at
replacement of injector and engine controller".
1) Remove mounting bolt (44) of holder (43).
1) Note the number of cylinder to which a new

injector is installed and character string (M)
listed on the QR code tab at the top of the
injector as a set.
a Read character string (M) in the order
indicated by the arrow in the figure.
a Be sure to check that the noted character
string is correct.
2) Write the noted character string into the
engine controller.
2) Insert "L" shaped bar [1] into inlet connector

(a) of the injector, and then pry up injector
assembly (42).
a Never grip the solenoid valve at the top of
the fuel injector with pliers, etc. to pull out
the injector.
3) Remove injector assembly (42) and holder
(43) as a unit.
50-56
a Be sure to write the noted character string

into the cylinder number column of the
cylinder to which the injector is installed.
a If the character strings are not written
correctly, the engine may not operate
normally.
(Reference: The QR code or character
string indicates the difference of
compensation value for fuel injection of
the injector, which is specific to each
injector.)
WA470-7

insertion portion, and lightly tighten it so that

it matches to inlet connector (c).
a Lightly tighten sleeve nut on the common
rail side.
6) Tighten holder (43) to the specified torque.
a While pulling the pipe of high-pressure
fuel pipe in the opposite direction of the
injector, tighten mounting bolt (44).
3 Holder mounting bolt (44):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a Separate high-pressure fuel pipe after
tightening holder.
2. Install the injector assembly according to the

1) Check that the injector assembly mounting
bore in the cylinder head is free from dust.
2) Install gasket (45) and O-rings (46) and (47)
to injector assembly (42).
a Install O-ring (46) to groove (a). Do not
install it to groove (b).
2 O-ring:
Engine oil
3) Insert holder (43) to injector assembly (42),
then insert it further into the injector
assembly mounting hole.
a Refer to the cylinder number recorded
when removed it, install the correct
injector.
a Be careful not to damage QR code tab
attached to the top of the injector
assembly (42) and do not remove it.
a Align inlet connector (c) with highpressure fuel pipe insertion portion of the
rocker housing.
4) Install the spherical washer (48) to bolt (44)
and lightly tighten holder (43).
2 Spherical washer (48):
Engine oil
5) Insert sleeve nut (49) of the high-pressure
fuel pipe to the high-pressure fuel pipe
WA470-7
50-57

3. Install locker arm and shaft assembly according

1) Set rocker arm and shaft assembly (39).
a Install the rocker arm shaft (50) with its
larger mounting hole end down and with
its ball plug (51) side facing to front of
engine.
2) Check that the ball of adjustment screw (41)
is fitted in push rod socket (52) and tighten
mounting bolt (38).
5. Install the O-ring and cylinder head cover (33).

a Installing the O-ring without a twist.
3 Mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}
a Clean the oil hole of mounting bolt (38)

and install it.
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
3) Adjust the valve clearance. For details, see
Testing and adjusting, "Testing and adjusting
valve clearance".
6. Install the high-pressure fuel pipes according to

k KOMATSU
recommends to use the

Komatsu genuine high-pressure fuel pipe
clamps and observe the tightening torque
indicated.
k Do
not bend the fuel high-pressure pipe

to correct before installing.
k Before
4. Install the injector harness (37) according to the

1) Tighten holders (35) with bolts (36).
3 Bolt (36):
27 to 34 Nm {2.8 to 3.5 kgm}
2) Set the harness terminal to the top of the
injector and tighten 2 nuts (34) alternately.
3 Nut (34):
2.0 to 2.4 Nm {0.2 to 0.24 kgm}
50-58
installing the fuel high-pressure

pipe, check it for the following.
If the high-pressure fuel pipe has any
defect, replace it with a new one since
fuel may leak.
Check that the taper seal portion of the
connection (portion (a): 2 mm area
from the tip-end) is free from visually
recognizable longitudinal slits (b) or
spotty dents (c).
Be sure that part (d) (2 mm from the
tip-end) is free from steps which can
be felt by your fingernail. (Namely, this
portion must be free from fatigue.)
WA470-7

1) Finger-tighten sleeve nuts of fuel highpressure fuel pipe (32).

a Loosen all clamps of the high-pressure
fuel pipe.
2) Tighten sleeve nut of high-pressure fuel pipe
(32) to the specified torque.
3 Sleeve nut (for both sides):
39.2 to 44.1 Nm {4 to 4.5 kgm}
3) Install fuel spray prevention caps (30) and
(31) to each high-pressure fuel pipe.
a When installing the cut-out portion, face it
as follows.
Fuel spray prevention cap (31):
Downward
Fuel spray prevention cap (30): Toward
cylinder block
4) Finger-tighten all the following clamps and
brackets.
Clamps (29) (6 pieces)
Bracket (53) (5 pieces)
Brackets (54) and (27)
5) Fasten clamp (29) to the specified torque.
3 Mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
6) Install brackets (53) and (54) to the specified
torque.
7) Finger-tighten four clamps (28).
8) Finger-tighten clamp (55) and bracket (27)
and install it to the specified torque.
3 Mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
9) Install bracket (27) to the specified torque.
10)Install clamp (28) to the specified torque.
7. Perform the subsequent installation in the

reverse order of removal.
[*1]
a Tighten case (3) of KCCV ventilator until it
cannot be rotated by hands and then use tool
A4 to retighten it by 1/15 to 2/15 turn (1 to 2
threads of ring rib).
3 Case (3) (reference value):
36.6 to 44.7 Nm {3.7 to 4.6 kgm}
3 Mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
WA470-7
50-59

a After the packing contacts the seal surface,

tighten the filters (4) to (6) as follows.
Fuel filter (4): 3/4 turn
Fuel pre-filter (5): 1/2 to 3/4 turn
Oil filter (6): 3/4 to 1 turn
2 Packing: Engine oil
[*2]
3 Joint bolt of spill tube (23-1):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Air bleeding
Bleed air in the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
Checking for fuel leakage
Check for fuel leakage. For details, see
Testing and adjusting, "Testing fuel circuit for
leakage".
50-60
WA470-7

Removal and installation of fuel doser assembly
(WA470-A9H6-924-K-00-A)
k Place
the machine on a level ground and turn

the parking brake switch to ON position.
k Set
the frame lock bar to LOCK position and

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA470-A9H6-520-K-00-A)
Installation
(WA470-A9H6-720-K-00-A)
1. Install heat insulator (10) to fuel doser assembly

(8).
2. Insert bolts (7) into fuel doser assembly (8),
install gasket (9) to the fuel doser assembly, and
then install them to the exhaust connector.
3 Bolt (7) (width across flats 8 mm):
8.5 to 9.5 Nm {0.87 to 0.97 kgm}
a Bolt (7), gasket (9) and heat insulator (10) to
be used must be new ones.
2.
3.
4.
5.
6.
Disconnect connector DOSER (3).

Remove clamps (4) (3 pieces).
Disconnect fuel hose (5). [*1]
Disconnect coolant hose (6). [*2]
Remove bolts (7) (2 pieces) (8 mm of width
across flats), and remove fuel doser assembly
(8).
a Install gasket (9) so that its stepped portion

becomes convex against the exhaust
connector.
3. Perform subsequent installation in the reverse

order of removal.
WA470-7
50-61

[*1]
3 Sleeve nut of fuel hose (5):
14.7 4.9 Nm {1.5 0.5 kgm}
[*2]
3 Joint bolt of coolant hose (6):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
a After installing the fuel doser assembly, run the
engine at low idle for approximately 3 minutes.
Then stop the engine and check the fuel doser
for water and fuel circuits for leakage.
50-62
WA470-7

Removal and installation of cylinder head assembly
(WA470-A100-924-K-00-A)
Symbol
Part No.
790-331-1110
793T-601-1410
A
01011-81040
6
01643-31032
01580-01008
Part name
Wrench
Bracket
Bolt
Washer
Nut
Necessity
Q'ty
a Special tools
q
t
t
t
t
1
1
2
2
2
k Place

6. Remove tubes (3) and (4). [*1]
k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

see Testing and adjusting, "Handling of
battery disconnect switch".)
Removal
(WA470-A100-520-K-00-A)
1. Drain the coolant.

6 Radiator: 75 l
2. Remove engine hood assembly. For details, see
"Removal and installation of engine hood
assembly".
3. Remove the KDPF assembly. For details, see
"Removal and installation of KDPF assembly".
4. Remove clamps (1) (3 pieces).
7. Remove the following connectors, and remove

the wiring harness.
G (5)
PCV1 (6)
PCV2 (7)
POIL (8)
VGT-SOL (9)
5. Sling bracket (2), and remove it.

4 Bracket (2):
40 kg
WA470-7
50-63

SEGR (10)
EGR-SOL (11)
INJ (12)
DOSER (13)
PAMB (14)
SVGT (15)
VGT-REV (16)
PDOSER (17)
SOV1 (18)
PCCV (19)
8. Remove covers (20) to (22).

10.Remove brackets (25) and oil filter (26) together
as a unit.
11.Disconnect hose (27), and remove fuel prefilter

(28). [*3]
12.Remove fuel tubes (29) and (30). [*4]
13.Remove filter head assembly (31).
14.Remove tube (32).

16.Remove dosing valve (34). [*6]
19.Remove fuel tubes (37) and (38). [*8]
a To disconnect fuel tube (38) on the priming
pump side, remove joint bolt (40) with nut
(39) fixed.
50-64
WA470-7

24.Remove air conditioner compressor belt (47).

For details, see "Removal and installation of air
conditioner compressor belt". [*11]
25.Remove the clamp of tubes (44) and (45).
26.Disconnect connector E10 (50), and tilt air
conditioner compressor (51) forward.
27.Disconnect terminal E07B (52). [*12]

28.Remove the clamp and move the wiring harness
(53).
20.Remove filter head (41), and fuel filter (42)

together as a unit.
29.Remove tubes (54) and (55). [*13]

30.Remove EGR valve assembly (56).
21.Disconnect hose (43). [*9]

22.Remove the clamp and joint bolt of tubes (44)
and (45). [*10]
23.Remove KCCV assembly (46).
31.Remove bracket (57).
WA470-7
50-65

4 Mixing connector (63):

40 kg
32.Disconnect hose (58) on the aftercooler side.

[*14]
33.Remove mounting bolts (59) to (61) (2 pieces
each) of air intake connector.
36.Remove oil filler pipe (64).

37.Remove the injector assembly. For details, see
"Removal and installation of injector assembly".
38.Remove tube clamp (65) at the rear of the air

intake manifold.
39.Disconnect connector TIM (66).
34.Remove clamp (62).
40.Remove mounting bolts (24 pieces), and

remove air intake manifold (67). [*15]
4 Air intake manifold (67):
30 kg
35.Sling mixing connector (63), and remove it.
50-66
WA470-7

41.Remove exhaust tube (68). [*16]
47.Remove covers (81) and (82).
42.Disconnect connector DOSER (69), and remove

the clamp of the wiring harness.
43.Remove the clamp of tubes (70) and (71).
44.Loosen clamp (72), and remove hose (73),
connector (74) and bracket (75) together as a
unit. [*17]
48.Remove brackets (83) and (84). [*20]
45.Remove hose (76). [*18]

46.Remove tube (77), hose (78) and brackets (79)
and (80) together as a unit. [*19]
49.Remove tubes (85) to (88). [*21]

a To remove tube (88), remove joint bolts (881).
WA470-7
50-67

50.Remove tubes (89) and (90). [*22]

56.Remove tubes (98) and (99). [*23]
57.Remove tube (100). [*24]
58.Remove tube (101). [*25]
59.Remove cover (102).
52.Remove EGR cooler assembly (92).
60.Disconnect hoses (103) to (105), and remove

tubes (106) to (108). [*26]
61.Remove tube (109). [*27]
53.Remove clamp (93), and remove bracket (94).

54.Remove clamp (95), and remove bracket (96).
50-68
WA470-7

65.Remove tube (115). [*30]

66.Remove brackets (116) to (120).
62.Remove clamps (110) and (111), and remove

bracket (112). [*28]
67.Remove head cover (121).
a The head cover has been already removed
in "Removal and installation of injector
assembly". Note that it has been installed
loosely to prevent foreign material from
entering.
63.Sling the KVGT assembly and exhaust manifold.

64.Remove the exhaust manifold mounting bolt,
and then remove KVGT assembly (113) and
exhaust manifold (114) together as a unit. [*29]
4 KVGT assembly and exhaust
manifold:
55 kg
WA470-7
68.Remove push rod (122). [*31]

69.Remove crossheads (123). [*32]
50-69

a Install the cylinder head assembly aligning its

dowel hole to the dowel pin.
2. Tighten the cylinder head mounting bolts.
1) Check the mounting bolts on following
conditions. If any bolt meets either condition,
do not use it but replace it with a new one.
The number of tightening times reaches 6
times (5 punch marks).
Stem length (a) of bolt: 171.4 mm or
above
70.Remove rocker housing (124). [*33]
2) Tighten the mounting bolts from 1 to 6 in

order.
71.Remove mounting bolts, sling cylinder head
assembly (125), and remove it.
4 Cylinder head assembly (125):
20 kg
2 Cylinder head mounting bolt

(threaded part and seat surface):
Molybdenum disulphide lubricant
(LM-P) or engine oil
3 Cylinder head mounting bolt:
1st time: 98 9.8 Nm {10 1 kgm}
2nd time: 166.6 to 176.4 Nm {17 to
18 kgm}
(Target: 176.4 Nm {18 kgm})
3rd time: By using tool A5,
retighten the bolt by 90 to 120
degrees.
(Target: 120 degrees)
Installation
(WA470-A100-720-K-00-A)
1. Install the cylinder head assembly.

a Place the cylinder head gasket on the
cylinder block after checking that the cylinder
head mounting face on the cylinder block
and the inside of each cylinder is free from
dust or foreign matters.
a When installing the cylinder head gasket,
check that the grommets do not peel off or
are not lost.
50-70
WA470-7

3 Hose clamp:
4.4 0.49 Nm {0.45 0.05 kgm}
[*2]
a Install tubes (23) and (24) according to the
a If tool A5 is not used, put mark (b) on

cylinder head and bolt with paint etc., and
retighten bolt by 90 to 120 degrees
(target 120 degrees).
3) After tightening, put a punch mark (c) on
each bolt head to indicate the number of
tightening.
1. Tighten the mounting bolts of the oil filter bracket

lightly.
2. Install tubes (23) and (24), and tighten bolt (A)
and (B) lightly.
3. Tighten bolts (B) and (A) in this order to the
specified torque.
4. Tighten the mounting bolts of the oil filter bracket
to the specified torque.
5. Install cushion (C) and fasten clamp (D).
a Install cushion (C) so that slit position (a)
faces outside of clamp (D).
a When a new bolt is used, do not put a

punch mark on its head.
4) Tighten cylinder head auxiliary bolt (7).

3 Cylinder head mounting auxiliary
bolt (7):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
[*3]
a After the packing touches the seal surface,
tighten fuel prefilter (28) by 1/2 to 3/4 turns.
2 Packing: Engine oil
[*4]
3. Perform the subsequent installation in the

reverse order to removal.
[*1]
WA470-7
a Install tubes (29) and (30) according to the

1. Loosen elbow (A) at filter head side and elbow
(B) at merge-divider block side in advance.
2. Install tubes (29) and (30), and fasten the sleeve
nuts on both ends.
50-71

3 Sleeve nut:
43 to 47 Nm {4.4 to 4.8 kgm}
3. Secure elbows (A) and (B) to prevent them from
rotation, and tighten the nuts.
3 Nut:
84 to 132 Nm {8.5 to 13.5 kgm}
a Tighten the overflow valve at supply side of fuel

tube (35) to the following torque.
3 Overflow valve:
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
[*7]
3 Joint bolt of fuel tube (36) (supply pump
side):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
3 Joint bolt of fuel tube (36) (fuel filter
side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*8]
3 Joint bolts at dosing valve side of fuel
tubes (37) and (38):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*5]
3 Joint bolts of fuel tube (33) (both sides):
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
[*6]
a Tighten joint bolts (A) and (B) to the following
torque.
3 Joint bolt of fuel tube (37) (fuel filter side

and aggregate block side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
a Tighten joint bolt (40) at priming pump side of
fuel tube (38) with nut (39) secured.
3 Joint bolt (40):
11.6 to 13.6 Nm {1.2 to 1.4 kgm}
3 Joint bolt (A) (M10 x 1.0):

9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3 Joint bolt (B) (M12 x 1.5):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*9]
3 Hose clamp:
3.3 0.49 Nm {0.34 0.05 kgm}
50-72
WA470-7

[*10]
3 Joint bolt of tubes (44) and (45) (cylinder
block side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Joint bolt of tubes (44) and (45) (KCCV
side):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*11]
a Adjust the air conditioner compressor belt
tension. For details, see Testing and adjusting,
"Testing and adjusting air conditioner
compressor belt tension".
[*12]
3 Terminal E07B(52):
5.88 to 7.84 Nm {0.6 to 0.8 kgm}
[*15]
a Tighten the intake manifold mounting bolts in the
order shown in the figure.
3 Air intake manifold mounting bolt:
59 to 74 Nm {6.0 to 7.5 kgm}
[*13]
3 Joint bolt of tube (54) (both ends):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Tube (55) joint bolt:
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
3 Sleeve nut of tube (55):
24 to 27 Nm {2.4 to 2.7 kgm}
[*14]
a Install the hose and clamp at aftercooler side in
the dimensions as follows.
Dimensions (a) and (b): 10 mm
Dimension (c): 75 mm
Angle (d): 35 degrees
3 Clamp:
10.5 0.5 Nm {1.07 0.05 kgm}
a Install the hose and clamp at intake connector

side in the dimensions as follows.
Dimension (e): 75 mm
Dimensions (f) and (g): 10 mm
3 Clamp:
10.5 0.5 Nm {1.07 0.05 kgm}
WA470-7
[*16]
a Install exhaust tube (68) according to the
1. Remove plug (A).
2. Install tool (A6) to exhaust connector (B).

3. Install exhaust tube (68) to exhaust connector
(B) loosely.
2 Thread part of bolt at exhaust
connector side:
50-73

4. Tighten bolts and nuts (C) (2 pieces) of KDPF

side flange lightly.
5. Tighten nuts (D) (4 pieces) of flange at exhaust
connector side to the specified torque.
3 Clamp of hose :
10.5 0.5 Nm {1.07 0.05 kgm}
3 Nut (D):
78.5 to 88.3 Nm {8 to 9 kgm}
6. Remove tool A6.
7. Tighten plug (A) to the specified torque.
2 Threaded part of plug (A):
3 Plug (A):
42.1 to 70.6 Nm {4.3 to 7.2 kgm}
a Install hose and clamp at aftercooler side in the

dimensions as follows.
Dimension (d): 75 mm
Dimensions (e) and (f): 10 mm
[*17]
a Set clamp (72) to level, adjust the direction of
clamp, and tighten it to the following torque.
3 Clamp (72):
10.5 0.5 Nm {1.07 0.05 kgm}
[*19]
a Install clamps (2 pieces) of hose (78) with its
screws to be same direction.
3 Clamp of hose (78):
10.5 0.5 Nm {1.07 0.05 kgm}
[*18]
a Install clamps (both ends) of hose with its
screws to be opposite direction (shifted by 180
degrees).
a Install hose and clamp at KVGT side in the
50-74
[*20]
a Apply seizure prevention compound (LC-G) to
mounting bolts (A) of bracket (83).
WA470-7

3 Mounting bolt (A):

68.6 to 73.5 Nm {7 to 7.5 kgm}
2 Mounting bolt of bracket (112):

[*29]
a Install the exhaust manifold according to the
1. Install ring (114-4) to intermediate manifold (1141).
[*21]
3 Tube (85) mounting bolts (both ends):
59 to 74 Nm {6 to 7.5 kgm}
3 Joint bolts (88-1):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*22]
2 Both ends (a) of intermediate manifold

(114-1):
Heat-resistant sealant (HOLTS MH705
or equivalent)
2. Install manifolds (114-2) and (114-3) to
intermediate manifold (114-1).
3. Set the exhaust manifolds with the gasket to the
intermediate manifold, and then finger-tighten all
mounting bolts 2 or 3 threads.
4. Tighten mounting bolts (A), (B), and (C) to the
specified torque, and then tighten other
mounting bolts.
3 Mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
3 Joint bolt of tubes (89) and (90):

19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*23]
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Sleeve nut of tubes (98) and (99):
24 to 27 Nm {2.4 to 2.7 kgm}
[*24]
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*25]
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
24 to 27 Nm {2.4 to 2.7 kgm}
[*26]
3 Hoses (103) and (104) and tube (106) joint
bolt:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Sleeve nut of hose (105):
14.7 4.9 Nm {1.5 0.5 kgm}
[*30]
[*27]

24 to 27 Nm {2.4 to 2.7 kgm}
[*28]
WA470-7
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

[*31]
a Check that the tip of push rod is fitted in the
socket of cam follower securely.
50-75

[*32]
a Adjust the crosshead according to the following
procedure.
1. Loosen lock nut (126) and back off adjustment
screw (127).
2. While pressing the top of crosshead (123) lightly,
tighten adjustment screw (127).
3. When adjustment screw (127) touches the valve
stem, tighten it further by 20 degrees.
4. With the adjustment screw in this position,
2 Crosshead guide and top of
crosshead:
Engine oil
3 Lock nut (126):
58.7 5.9 Nm {6.0 0.6 kgm}
[*33]
3 Rocker housing mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
Adjust the valve clearance. For details, see
Testing and adjusting, "Adjusting valve
clearance".
Refilling of coolant (radiator)
Refill with the coolant to the specified level
through the water filler port. Run the engine to
circulate the coolant through system. Then
check the coolant level again.
5 Radiator:
75 l
50-76
WA470-7

Removal and installation of engine hood assembly
(WA470-H540-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
5. Disconnect hose (4).

a Install a plug to the hose connection portion.
(WA470-H540-520-K-00-A)
1. Remove the air cleaner assembly For details,

see "Removal and installation of air cleaner
assembly".
a Remove the cover on the other side as well.
6. Remove the mounting bolts of cover (5).

a Do not remove cover (5) at this time.
7. Sling the engine hood assembly.

8. Remove mounting bolts (6) (4 pieces) on the
hydraulic oil side.
4. Remove clamp (3).
WA470-7
50-77

9. Remove mounting bolts (7) and (8).

a Remove the mounting bolts on the other side
as well.
Installation
(WA470-H540-720-K-00-A)
Perform installation in the reverse order of

removal.
10.Sling engine hood assembly (9), and remove it.

4 Engine hood assembly:
300 kg
50-78
WA470-7

Removal and installation of grille assembly
(WA470-H54E-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal

a Install the cover to prevent foreign matter
from entering air cleaner inlet (A) and KDPF
outlet (B).
(WA470-H54E-520-K-00-A)
1. Remove caps (1) (8 pieces) of the engine upper

cover and inner bolts (8 pieces).
a Remove the caps and bolts indicated by the
arrows.
a Do not remove the bolts marked with e.
(Otherwise the door hinge is removed and
adjustment during installation process
becomes difficult.)
4. Pull out frame (4) downward and remove it.
2. Sling and remove cover (2).

4 Cover (2):
70 kg
WA470-7
5. Open full-length fender (5) on the right and left

side of the machine body, and then open side
cover (6).
50-79

6. Remove frame (7) on the left side of the

machine body.
8. Remove the mounting bolts of cover (9).
9. Disconnect connector GR1 (10).
10.Remove frame (11) on the right side of the

machine body.
11.Disconnect hose (12).
12.Remove mounting bolt (13) at the top of the

engine hood.
a Remove them on the other side in the same
way.
13.Open the grille at the rear of the machine body,

and remove mounting bolt (14).
14.Remove mounting bolt (15) at the bottom of the

grille assembly.
way.
50-80
WA470-7

4 Grille assembly:
130 kg

Installation
(WA380-H54E-720-K-00-A)
Perform installation in the reverse order to

removal.
17.Disconnect connectors R59 (18) and R89 (19).
18.Remove cap (20).
19.Sling grille assembly (21), and remove it.
WA470-7
50-81

Removal and installation of cooling system assembly

k Place

(WA470-B000-924-K-00-A)
7. Remove brackets (5) and (6).
k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
8. Disconnect hose (7) on the right side of the

machine.
(WA470-B000-520-K-00-A)

6 Radiator:
75 l
2. Remove the grille assembly. For details, see
"Removal and installation of grille assembly".
3. Remove the aftercooler. For details, see
"Removal and installation of aftercooler."
4. Disconnect radiator lower hose (1). [*1]
5. Disconnect hose (2) from hydraulic oil cooler
piping.
9. Remove clamp (8) on the left side of the

machine.
10.Disconnect radiator upper hoses (9) and (10).

[*2]
6. Disconnect hoses (3) and (4).
50-82
WA470-7

a Install hose and the clamp in the dimensions as

follows.
Dimension (d): 5 mm
Dimension (e): 8.8 mm
Dimension (f): 53 mm
2 Hose insertion portion (both ends):
Liquid gasket (LG-10)
3 Clamp of hose (both end):
8.8 0.5 Nm {0.9 0.05 kgm}
11.Remove stay (11) and plates (12) at the bottom

of the fan guard.
[*2]
12.Remove the mounting bolts(3 pieces each) on
the right and left, sling cooling system assembly
(13), and remove it.
4 Cooling system assembly (13):
400 kg
a When installing the clamps of hose (9), set the

screws 180 degrees apart from each other in the
Dimension (a): 55.5 mm
Dimension (b): 9 mm
Dimension (c): 5 mm
2 Hose (9) insertion portion:
3 Clamp of hose:
8.8 0.5 Nm {0.9 0.05 kgm}
Installation
(WA470-B000-720-K-00-A)

removal.
[*1]
a When installing the clamps of hose, set the
screws 180 degrees apart from each other, in
the direction as follows.
Radiator side: Toward the bottom
Power train oil cooler side: Toward the top
WA470-7
a Install hose (10) and the clamp in the

Dimension (d): 12.5 mm
50-83

Refilling of coolant (radiator)

through the coolant filler port. Run the engine to
5 Radiator:
75 l
50-84
WA470-7

Removal and installation of radiator core assembly
(WA470-B222-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA470-B222-520-K-00-A)
1. Remove the cooling system assembly (1) and

stably place it on block [1]. For details, see
"Removal and installation of cooling system
assembly".
2. Remove hoses (2) and (3). [*1]
8. Sling radiator core assembly (13), and remove it.

a Remove the assembly on the other side in
the same way.
4 Radiator core assembly (13):
40 kg
Installation
3. Disconnect hoses (4) to (6), and then remove

joint (7).
4. Remove hose (8). [*2]
5. Remove plates (9) and (10).
6. Remove bolt (11).
(WA470-B222-720-K-00-A)

removal.
[*1]
a Install hose (3) and the clamp in the dimensions
as follows.
Dimension (a): 28 mm
Dimension (b): 5 mm
3 Clamp:
4.4 0.49 Nm {0.45 0.05 kgm}
7. Remove mounting bolts (12).
WA470-7
50-85

[*1] [*2]
a When installing the clamps of hoses (2) and (8),
set the screws 180 degrees apart from each
other, in the direction as follows.
Hose (2): Toward the bottom
Hose (8): Toward the top
a Install hoses (2), (8) and their clamps in the
a The figure shows an example of hose (8). Note
that the dimensions are the same as those of
hose (2).
Dimensions (a) and (d): 9 mm
Dimensions (b) and (c): 4 mm
Dimensions (e) and (f): 53.5 mm
2 Insertion portion (both ends) of hoses (2)
and (8):
3 Clamps (both ends) of hoses (2) and (8):
8.8 0.5 Nm {0.9 0.05 kgm}
50-86
WA470-7

Removal and installation of aftercooler
(WA470-A9A0-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA470-A9A0-520-K-00-A)
3. Remove air conditioner condenser assembly (1).

conditioner condenser assembly".
a Do not disconnect hoses (2) and (3)
4. Remove cover (4) and move air conditioner
condenser assembly (1) toward the engine side.
1. Remove caps (A) (8 pieces) of the engine upper

arrows.
(Otherwise, the door hinge is removed and
becomes difficult.)
2. Sling cover (B), and remove it.

4 Cover (B):
70 kg
6. Disconnect hose (5). [*1]
WA470-7
50-87

Installation
(WA470-A9A0-720-K-00-A)

removal.
[*1]
screws 180 degrees apart from each other.
a Install hose and the clamp in the dimensions
as follows.
8. Sling aftercooler (7), and remove mounting bolts
(4 pieces).
9. Slide aftercooler (7) to the left side of the
machine body, and place it on block [1]
temporarily.
10.Sling aftercooler (7) from the outside of the
engine hood again, and remove it.
3 Clamp:
10.5 0.5 Nm {1.07 0.05 kgm}
4 Aftercooler:
25 kg
[*2]
a Install hose and the clamp in the dimensions
as follows.
3 Clamp:
10.5 0.5 Nm {1.07 0.05 kgm}
50-88
WA470-7

WA470-7
50-89

Removal and installation of hydraulic oil cooler
(WA470-B8P0-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA470-B8P0-520-K-00-A)
1. Drain the hydraulic oil.

6 Hydraulic tank:
173 l
a Perform the same work on the opposite side.
3. Remove mounting bolt (3), and move case (4).

4. Disconnect hoses (5) and (6) on the cooling fan
motor side.
6. Remove bolts (8) to (10), and move the bracket
and piping together as a unit.
50-90
9. Remove mounting bolt (13) and remove

hydraulic piping flange bolt (14).
way. The positions of the mounting bolt and
of the hydraulic piping flange bolt on the
opposite side must be turned upside down.
WA470-7

10.Pull out hydraulic oil cooler (15) from the right

side of the machine, and remove it.
Installation
(WA470-B8P0-720-K-00-A)

removal.
Refilling of oil
Refill with oil to the specified level through the oil
filler port. Start the engine to circulate the
hydraulic oil through the system. Then check the
oil level again.
5 Hydraulic tank:
173 l
WA470-7
50-91

Removal and installation of power train oil cooler assembly
(WA470-B850-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal

cover (4).
(WA470-B850-520-K-00-A)

6 Radiator: 75 l
2. Drain the power train oil.
6 Transmission case: 65 l
3. Remove caps (1) (8 pieces) of the engine upper
arrows.
becomes difficult.)

7. Remove covers (6) to (8).
8. Remove bolts (9) to (11) and move the bracket
and piping together as a unit.
9. Disconnect hose (11-1).
4. Sling cover (2), and remove it.

4 Cover (1):
70 kg
50-92
WA470-7

10.Remove bracket (12) (2 pieces) mounting bolts,

and remove receiver drier (13).
11.Remove clamp (14), and disconnect hose (15).
13.Remove clamp (17), and move hose (16).

16.Remove hose (20). [*2]
17.Remove mounting bolts (21).

18.Remove the clamps of hoses (22) and (23), and
pull out power train oil cooler assembly (24) from
the hose. [*3]
19.Sling power train oil cooler assembly (24), and

place it on the left side of the machine body
temporarily.
20.Sling power train oil cooler assembly (24) from
the outside of the engine hood, and remove it.
4 Power train oil cooler assembly (24):
30 kg
WA470-7
50-93


follows.
Dimension (d): 5 mm
Dimension (e): 8.8 mm
2 Hose insertion portion (both ends):
3 Clamp of hose (both end):
8.8 0.5 Nm {0.9 0.05 kgm}
Installation
(WA470-B850-720-K-00-A)

removal.
[*1]
follows.
[*3]
8.8 0.5 Nm {0.9 0.05 kgm}
[*2]
screws 180 degrees apart from each other, in
the direction as follows.
Radiator side: Toward the bottom
Power train oil cooler side: Toward the top
50-94
Refilling of oil
filler port. Run the engine to circulate the power
WA470-7

train oil through the system. Then check the oil

level again.
5 Transmission case:
65 l
Refilling with coolant
5 Radiator: 75 l
WA470-7
50-95

Removal and installation of engine assembly
(WA470-A000-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
5. Remove clamp (6) on the front right of the fuel

tank.
6. Remove mounting bolt (7) of drain hose.
(WA470-A000-520-K-00-A)

6 Radiator:
75 l
2. Remove the engine hood assembly. For details,
see "Removal and installation of engine hood
assembly".
3. Disconnect connectors ER2 (1), ER1 (2) and
ER3 (3) at the bottom of the hydraulic tank on
the left side of the machine body.
4. Disconnect terminals (4) and (5) and remove the

harness clamp on the side of the engine on the
left side of the machine body.
50-96
8. Disconnect connector E28 (9).

9. Remove fuel feed pump (10) and bracket (10)
together as a unit.
WA470-7

11.Disconnect fuel hoses (12) and (13).
16.Disconnect hose (21) and ground cable (22).
12.Remove clamps (14) and (15).

18.Disconnect connector CAN1 (24) on the side of

the engine on the right side of the machine.
15.Disconnect terminal E07A (19) and connector

ER4 (20).
19.Disconnect hoses (25) to (27). [*2]
WA470-7
50-97

24.Sling damper (33), remove mounting bolts (6

pieces), and remove it. [*3]
4 Damper (33):
15 kg
25.Remove plate (34).
21.Remove upper clamp (29) between the engine

and transmission.
22.Remove U-bolt (30), and remove bracket (31).
50-98
WA470-7

26.Disconnect terminals E02 (35) and E04 (36),

and remove the harness clamp.
27.Remove air conditioner compressor belt (37).

conditioner compressor belt".
28.Remove the clamps of hoses (38) and (39).
29.Disconnect connector E10 (40).
30.Remove air conditioner compressor (41), and fix
it on the machine body side.
32.Sling the engine assembly.

33.Remove connection bolts (42) (12 pieces)
between the engine and transmission.
34.Remove engine mount mounting bolts (43) (2

pieces). [*4]
35.Sling engine assembly (44) and remove it.

a Check that all wiring and pipes are
disconnected.
31.Set jack [1] under the transmission.
a This prevents the transmission from lowering
during separation of the engine assembly.
a When removing wiring and pipes, be careful

to prevent interference with the parts of the
machine body.
4 Engine assembly (44):
1,600 kg
WA470-7
50-99

Installation
(WA470-A000-720-K-00-A)
[*2]

removal.
[*1]
a When installing the clamps (both ends) of hose

(25), set the screws 180 degrees apart from
each other.
a For the aftercooler side of hose, install the hose

and clamp on in the dimensions as follows.
3 Clamp of hose (25) (both end):

10.5 0.5 Nm {1.07 0.05 kgm}

3 Clamp:
10.5 0.5 Nm {1.07 0.05 kgm}
a For the air intake connector side of hose, install

the hose and clamp on in the dimensions as
follows.
Dimensions (f) and (g): 10 mm
a Install hose (25) and the clamp on KVGT side in

the dimensions as follows.
Dimension (a) and (b): 10 mm
a Install hose (25) and clamp on the aftercooler

Dimension (e) and (f): 10 mm
3 Clamp:
10.5 0.5 Nm {1.07 0.05 kgm}
50-100
WA470-7


Dimension (b): 7 mm
a Install hose (27) and the clamp on the engine

Dimension (e): 5 mm

8.8 0.5 Nm {0.9 0.05 kgm}
[*3]
3 Damper (33) mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
[*4]
a When installing the clamps (both ends) of hose

(27), set the screws 180 degrees apart from
each other.
a Install cushion (45) of the engine mount portion

with its mark (a) facing to the outside of machine
body.
3 Engine mount mounting bolt:
455 to 565 Nm {46.5 to 58 kgm}
2 Hose (27) insertion portion (both ends):

8.8 0.5 Nm {0.9 0.05 kgm}
a Install hose (27) and the clamp on the radiator
Dimension (a): 55.5 mm
Dimension (b): 9 mm
Dimension (c): 5 mm
Refilling of oil
oil level again.
5 Radiator:
75 l
WA470-7
50-101

Removal and installation of engine front oil seal
(WA470-A350-924-K-00-A)
Symbol
Part No.
Part name
7
8
A
9
10
795-931-1100
795T-521-1140
01010-61650
01643-31645
Seal puller assembly

Push tool
Bolt
Washer
Necessity
Q'ty
a Special tools
q
t
t
t
1
1
3
9
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA470-A350-520-K-00-A)
1. Remove the aftercooler. For details, see

"Removal and installation of aftercooler."
5. Sling damper (4), remove mounting bolts (6

4 Damper (4):
15 kg
6. Sling crank pulley (5), remove mounting bolts (6

3. Remove air conditioner compressor belt (2). For
details, see "Removal and installation of air
4. Remove alternator belt (3). For details, see
"Removal and installation of alternator belt".
50-102
4 Crank pulley (5):

15 kg
WA470-7

7. Remove engine front oil seal (6).

a Before removal, tap engine front oil seal (6)
to unstick it.
a Be careful not to damage the oil seal contact
surfaces on front cover (7) and crankshaft
(8).
a If it is difficult to remove engine front oil seal
(6), remove it according to the following
procedure.
1) Drill several holes about 3 mm in diameter in
engine front oil seal (6).
a Remove all the chips.
2) Change the tip part of tool A7 to the drill type
one. Insert it to the hole as described above.
3) Pull slide hammer [SH] of tool A7 forward,
and remove engine front oil seal (6) by using
impact power of the hammer.
a Perform this work evenly at several
places so that engine front oil seal (6) is
not tilted.
Installation
(WA470-A350-720-K-00-A)
1. Install engine front oil seal (6) according to the

a Before installation, check that end surfaces
and oil seal lip sliding surface of the
crankshaft and the front cover are free from
flaws, burrs, rust, etc.
1) Set engine front oil seal (6) to front cover (7),
and then use a plastic hammer to install the
seal until oil seal lip (a) fits on to crankshaft
(8).
a Install the engine front oil seal (6) in the
direction as shown in the figure.
a Tap evenly on all around engine front oil
seal (6) to press fit it in place while using
care not to deform the seal.
a Take care not to let oil seal lip (a) get
caught on crankshaft (8).
2 Engine front oil seal (8) (50 to 80 %
of lip space volume):
Grease (G2-LI)
Tool A7
2) Install tool A8 and tighten them evenly until

tool A9 (bolt) (3 pieces) hit. Press-fit engine
front oil seal (6) to front cover (7).
a Do not install tool A10 (washer) to tool A9
(bolt).
WA470-7
50-103

3) Remove tool A9 (bolt) (3 pieces) and install

tool A10 (washer) (3 pieces) to those tools
A9 (bolt) respectively.
4) Install tools A9 (bolt) (3 pieces) again and
tighten them evenly until the end face of tool
A8 hits the end face of front cover (7). Pressfit engine front oil seal (6).
a Press fit depth (b) between engine front
oil seal (6) and end face of front cover (7):
16 (+1/0) mm
a Press fit depth (c) between engine front

oil seal (6) and end face of crankshaft (8):
9.2 (+1/0) mm

order of removal.
[*1]
3 Damper (4) mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
[*2]
3 Crank pulley (5) mounting bolt:
M14: 157 to 196 Nm {16 to 20 kgm}
M16: 245 to 309 Nm {25 to 31.5 kgm}
50-104
WA470-7

Removal and installation of engine rear oil seal
(WA470-A510-924-K-00-A)
Symbol
7
1
2
3
11
4
A
5
6
1
12
2
13
Part No.
Part name
Seal puller
795-931-1100 assembly
795T-401-1310 Push tool
795T-401-1320 Guide bolt
795T-601-1310 Push tool
795T-401-1330 Push tool
795T-401-1340 Guide
795T-401-1350 Spacer
Bolt: (M16 x 2.0,
01010-61660 stem length: 60)
Bolt: (M16 x 2.0,
01010-61640 stem length: 40)
01643-31645 Washer (t = 4.5)
Necessity
Q'ty
a Special tools
q 1
t
t
t
t
t
t
1
3
1
1
1
1
t 1
4. Remove rear oil seal (4) according to the

1) Slightly tap rear oil seal (4) to unstick it from
flywheel housing (5).
t 1
t 1
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA470-A510-520-K-00-A)
1. Remove the engine assembly. For details, see

"Removal and installation of engine assembly".
2. Sling flywheel (1), and install guide bolt [1].
3. Remove mounting bolt (2), pull out flywheel (1),
and remove it. [*1]
2) If the seal is sleeved, cut sleeve (7), and

remove it by using a chisel and a hammer.
a Be careful not to damage crankshaft (6).
3) Hang the tip of tool A7 on the metal ring of
rear oil seal (4), and remove the seal by
using impact power of slide hammer (SH).
(Perform this work evenly so that the rear oil
seal is not tilted.)
a Do not use a drill as metal chips may
enter the engine.
a If any chips are generated, remove them
completely.
Tool A7
4 Flywheel (1):
30 kg
WA470-7
50-105

a Seal type is double seal (Inside of

flywheel housing is wet).
a Clean, degrease, and dry the contacting

surface against flywheel housing (5).
a The left one in the following figure shows

the standard oil supply seal and the right
one shows the sleeved seal.
a Before installing rear oil seal (4), ensure that

the end corner and lip sliding surface of the
crankshaft, and flywheel housing (5) are free
from scratches, burrs, sharp fins, rust, etc.
a When installing rear oil seal (4), do not apply
oil or grease to the crankshaft and seal lip
surface (around the crankshaft). Thoroughly
wipe off oil or grease from the crankshaft.
Installation
(WA470-A510-720-K-00-A)
1. Install the rear oil seal according to the following

procedure.
a When installing rear oil seal (4), check the
wear of the crankshaft and select "standard
seal (A)" or "sleeved seal (B)".
a If the wear depth of the shaft is 10 mm or less
and no scratch is present, install "standard
seal (A)". Otherwise, install "sleeved seal
(B)".
(8): Inner plastic tube/installation guide
(7): Sleeve
1) Installation of standard oil seal

a Before installing the oil seal, check that
the end corner and oil seal lip sliding
surface of the crankshaft and the housing
are free from scratches, sharp fins, burrs,
rust, etc.
a Do not remove inner plastic tube/installation

guide (8) before installing rear oil seal (4).
a When installing the oil seal, do not apply

oil or grease to the crankshaft and seal lip.
Thoroughly wipe off oil or grease from the
crankshaft.
a Handle sleeve (7) and rear oil seal (4) as an

assembly and never separate them from
each other.
a Never remove the inner plastic tube of the

standard seal of spare part just before
installation.
a The left one in the following figure shows the

standard seal and the right one shows the
sleeved seal.
1] Install tool A11-1 to the rear end of

crankshaft, and screw in tool A11-2 (3
pieces) lightly.
a At this stage, tool A11-2 has a little
play.
50-106
WA470-7

a Be careful not to damage the seal lip

surface when removing inner plastic
tube (4a).
2] Insert tool A11-5 into tool A11-1, adjust

the position of tool A11-1 so that the
centers of crankshaft (6) and tool A11-1
are aligned, and then tighten tool A11-2 to
secure them.
7] Attach tool A12-1 (bolt: stem length 60

mm) and tool A13 to tool A11-3, and
insert tool A11-6 (spacer) to tool A12-1.
8] Put tool A11-3 on tool A11-1, and install
them guided by tool A11-2.
3] Remove tool A11-5, and check the

are aligned
4] Apply the larger inside diameter side "a"
of inner plastic tube (4a) to the end of tool
A11-1.
a Take care not to put the wrong end.
5] Put both of your hands to the metal ring of

seal (4) and push in the seal evenly
6] After pushing in seal (4), remove inner
plastic tube (4a).
9] Tighten tool A12-1 (bolt: stem length 60

mm) fully until it stops, and insert the
seal.
10]Remove tool A11-3 and remove tool A116 (spacer).
11]Exchange tool A12-1 (bolt: stem length
60 mm) with tool A12-2 (bolt: stem length
40 mm), and install tool A11-3 again.
a Install tool A11-3 without tool A11-6
(spacer).
WA470-7
50-107

12]Tighten tool A12-2 (bolt: stem length 40

seal.
13]After inserting the seal, remove tool A113, tool A11-2 and tool A11-1.
a Wipe off the dirt in the sealant applied
to periphery of the seal.
2] Insert tool A11-5 into tool A11-1, adjust

the position of tool A11-1 so that the
are aligned, and then tighten tool A11-2 to
secure them.
2) Installation of sleeved oil seal

a Before installing the oil seal, check that
the end corner and oil seal lip sliding
surface of the crankshaft and the housing
are free from scratches, sharp fins, burrs,
rust, etc.
a When installing the oil seal, do not apply
oil or grease to the crankshaft and gap
between sleeve (4b) and seal lip.
Thoroughly wipe off oil or grease from the
crankshaft.
3] Remove tool A11-5, and check the

centers of the crankshaft and tool A11-1
are aligned
4] Apply liquid gasket to inside of sleeve of
sleeved seal, and insert sleeved seal (4)
to tool A11-1.
a When inserting the seal, place
chamfered side (4b) of sleeve to the
end of tool A11-1.
2 Inside surface of sleeve:
a Handle seal (4) and sleeve (4b) as

assembled state, and never remove seal
(4) from sleeve (4b).
1] Install tool A11-1 to the rear end of
crankshaft, and screw in tool A11-2 (3
pieces) lightly.
a At this stage, tool A11-2 has a little
play.
5] Attach tool A12-1 (bolt: stem length 60
mm) and tool A13 to tool A11-4, and
50-108
WA470-7

insert tool A11-6 (spacer) to tool A12-1

(bolt: stem length 60 mm).
6] Put tool A11-4 on tool A11-1, and install
them guided by tool A11-2.

order to removal.
[*1]
a Tighten the flywheel (1) mounting bolts in the
numerical order shown in the figure.
2 Threaded part of flywheel (1) mounting
bolt:
Engine oil
3 Flywheel (1) mounting bolt
1st time: 147 19.6 Nm {15 2.0 kgm}
2nd time: 289.1 19.6 Nm {29.5 2.0
kgm}
7] Tighten tool A12-1 (bolt: stem length 60

seal.
8] Remove tool A11-4 and remove spacer
A11-6.
9] Exchange tool A12-1 (bolt: stem length
60 mm) with tool A12-2 (bolt: stem length
40 mm), and install tool A11-4 again.
10]Tighten tool A12-2 (bolt: stem length 40
seal.
11]After inserting the seal, remove tool A114, tool A11-2 and tool A11-1.
a Wipe off the dirt in the sealant applied
to periphery of the seal.
WA470-7
a By using dial gauge [2], measure the facial

runout and radial runout.
Facial runout: Max. 0.17 mm
Radial runout: Max. 0.13 mm
50-109

Removal and installation of cooling fan and cooling fan motor

assembly (WA470-B5L0-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
6. Remove guard (10).
(WA470-B5L0-520-K-00-A)

6 Hydraulic tank: 173l
l
2. Open grille (1), and remove cover (2).
7. Remove lock plate (11) and nut (12). [*1]

8. Tighten nut (12) by 2 to 3 turns to install it
loosely.
3. Disconnect connectors R59 (3) and R89 (4).

4. Disconnect hoses (5) to (7).
9. Separate cooling fan (13) from the cooling fan

motor by using puller [1].
5. Pull lever (8) downward, and open cooling fan

assembly (9).
50-110
WA470-7

Installation
(WA470-B5L0-720-K-00-A)

removal.
[*1]
a Install lock plate (11) and nut (12) according to
1. Tighten nut (12) to the following torque.
3 Nut (12):
132 to 157 Nm {13.5 to 16 kgm}
2. Retighten sleeve nut (12).
10.Remove nut (12) to remove cooling fan (13).
11.Remove connector (14) from the bracket.

12.Remove upper mounting bolts (2 pieces) (15)
and install guide bolt [2].
13.Remove lower mounting bolts (2 pieces) (15),
and pull out cooling fan motor assembly (16).
a Align the positions of mounting bolt holes (a)

on both faces of lock plate (11) so that
retightening of nut (12) can be done with
minimum volume.
3. Tighten the mounting bolt of lock plate (11).
Refilling of oil
oil level again.
l
WA470-7
50-111

Removal and installation of KDPF assembly
(WA470-A9H0-924-K-00-A)
Symbol
Part No.
A14
4000-01650
Part name
Necessity
Q'ty
a Special tools
Bolt
q 1
k Place

k Set

chock the wheels.
k Lower

LOCK.
2. Sling cover (2), and remove it.

4 Cover (2):
70 kg
k Turn

stop the engine.
k Turn

k Since
KDPF is heated to 500C or above,

start the work after KDPF cools down.
k Check
for any accumulated combustibles

(dry leaves, twigs, etc.) on the KDPF, and
remove them if they are accumulated.
k The
KDPF will break if dropped or bumped.

Handle it with care. Do not reuse a damaged
part.

a Install the cover to prevent foreign matter
from entering air cleaner inlet (A) and KDPF
outlet (B).
k Keep
the record for each KDPF unit to check

the service life, and never use the KDPF
exceeding its service life.
Removal
(WA470-A9H0-520-K-00-A)
1. Remove eight caps (1) of the engine upper

cover and eight inner bolts.
arrows.
a Do not remove the bolts marked with .
becomes difficult.)
50-112
4. Pull out frame (4) downward and remove it.
WA470-7


cover (6).
8. Remove tube (10).

9. Remove mounting bolts (11) (8 pieces) of KDPF
assembly bracket.
6. Remove covers (7) and (8) on the the right and

left sides of the engine.
10.Disconnect connectors E25 (12) and E26 (13) at

the top of KDPF assembly.
11.Remove KDPF assembly (14) and bracket

together as a unit.
4 KDPF assembly (14) and bracket:
115 kg
7. Remove bolts (9) (4 pieces) on the inlet side of

KDPF.
WA470-7
50-113

12.Place the KDPF assembly on a level ground.

13.Remove exhaust pipe (15).
2. Tighten bolts (16) (4 pieces).
3. Install U-bolt (17).

14.Sling the KDPF assembly.
15.Remove bolts (16) (4 pieces) and U-bolt (17).
16.Sling KDPF assembly (14), and remove
brackets (18) and (19).
4 KDPF assembly (14):
75 kg
a Use a plastic hammer, etc. to tap the top of

the U-bolt to eliminate the clearance between
U-bolt and KDPF assembly.
4. Install washer (20) and tighten nuts (21) evenly.
3 Nut (21):
14.7 to 34.3 Nm {1.5 to 3.5 kgm}
5. Tighten four lock nuts (22) evenly.
3 Nut (22):
21 to 49 Nm {2.1 to 5.0 kgm}
6. Check that distances (a) between tip end of Ubolt (17) and nut (22) are even on both sides.
7. Rotate nut (21) lightly in the loosening direction.
Installation
(WA470-A9H0-720-K-00-A)
1. Sling KDPF assembly (14) and lower it to

brackets (18) and (19).
75 kg
50-114
8. Install exhaust pipe (15).
WA470-7

a At this time, check that bellows portion (A) of

pipe (23) is not deformed.
9. Install KDPF assembly (14) and bracket together

as a unit.
4 KDPF assembly (14) and bracket:
115 kg
10.Tighten eight mounting bolts (11) of KDPF

assembly bracket lightly.
13.If the above clearance (b) exceeds the standard

procedure.
1) Push the KDPF assembly by hands to adjust
the position in the lateral and vertical
directions.
2) Loosen bolt (16) and nuts (21) and (22) insert
tool A14 to the position in the figure to adjust
the position in the vertical direction.
3) After the adjustment, proceed with steps 2 to
7 again.
4) Remove tool A14.
11.Tighten bolts (9) (4 pieces) on the inlet side of

KDPF lightly.
2 Threaded portion of bolt (9):
12.Check that clearance (b) between the flanges is
in the following dimensions.
a Measure clearance (b) at 4 positions on each
flange surface in total.
Clearance (b): Max. 2 mm (including
gasket thickness)
WA470-7
14.Tighten bolts (9) (4 pieces) on the inlet side of

KDPF to the specified torque.
3 Bolt (9):
78.5 to 88.3 Nm {8.0 to 9.0 kgm}
50-115

15.Tighten mounting bolts (11) (8 pieces) of KDPF

assembly bracket to the specified torque.
16.Install tube (10).
17.Connect connectors E25 (12) and E26 (13) at

the top of the KDPF assembly.
18.Perform subsequent installation in the reverse

order of removal.
50-116
WA470-7

Disassembly and assembly of KDPF assembly
(WA470-A9H0-926-K-00-A)
k Since
KDPF and KDOC are heated to 500C

or above, be careful not to get burn injury.
k Stop
the engine, wait until piping around the

engine cools down, then remove the KDPF.
k When
cleaning, replacing, or disposing the

KDPF or KCSF, use a dust mask during the
work to prevent inhaling accumulated soot,
ash, mat material or powder of precious
metals inside the KDPF.
k When
installing KCSF, be careful about its

installed direction.
k Handle
the KDPF with care since an impact

on it, for instance, dropping it, causes it to
damage. And be sure not to use a damaged
part.
k Keep
record of each KDPF unit to control its

service life, and never use a KDPF after its
service life has elapsed.
a Since the V-clamp and band used for the KDPF

are made of stainless steel, avoid using an
impact wrench for removal and installation of
nuts. Otherwise threaded portions can be
damaged.
a When removing a gasket or band, prepare new
ones at hand.
a In the following procedures, the size of some
tools to be used is expressed in both units of min
and inch, however, general tools are available
for them.
Disassembly
(WA470-A9H0-530-K-00-A)
1. Preparation
1) Use lifting tool [1] to lift KDPF assembly (1).
Place blocks [2] to 4 places under it to
support the assembly securely.
70 kg
a Place block [2] at a position where it does
not touch the piping and bands of the
KDPF.
a Place cloth or the like on the supporting
portion of block [2] to prevent damage on
the KDPF.
a Dimensions of blocks [2] are shown in the
following figure.
WA470-7
2) Mark at 3 points (a), (b), and (c) of each body

connection.
(A): Connection between inlet and KDOC
(B): Connection between KDOC and
KCSF
(C): Connection between KCSF and
outlet
a These marks are required to facilitate
angle adjustment of KDPF inlet and outlet
flanges in assembly work.
(2): Inlet body
(3): KDOC body
(4): KCSF body
(5): Outlet body
50-117

a Disconnect connector (10) according to

1] Slide the lever of the connector in the
direction of the arrow to unlock.
2] While pressing the knob on the upper

portion of the connector, pull out the
connector in the direction of the arrow.
2. KDOC inlet and outlet temperature sensors

1) Put a match mark for each installed position
of harness clip band (6), and harness clamps
(7) and (8).
2) Disconnect harness clip band (6), and
harness clamps (7) and (8).
Width across flats of harness clamp
mounting bolt: 14 mm
3) Disconnect KDOC inlet temperature sensor
connector (9) from TEMP1 of temperature
sensor consolidation box (11).
4) Disconnect KDOC outlet temperature sensor
connector (10) from TEMP2 of temperature
50-118
5) Loosen mounting nut (12) and remove

KDOC inlet temperature sensor (13).
Width across flats of mounting nut (12):
14 mm
a To remove temperature sensor (13), hold
metal portion (d) and pull it straight in the
direction of the arrow.
WA470-7

a When removing the temperature sensor,

pull the sensor straight until it completely
comes out of the mounting hole of KDPF.
(The sensor is inserted in KDPF
approximately 100 mm.)
6) Loosen mounting nut (12a) and remove
KDPF outlet temperature sensor (14).
Width across flats of mounting nut (12a):
14 mm
a Disconnect connector (17) according to

1] Slide the lever of the connector in the
direction of the arrow to unlock.
2] While pressing the knob on the upper

portion of the connector, pull out the
connector in the direction of the arrow.

1) Remove harness clip (16) from bracket (15).
Width across flats of mounting bolt: 14
mm
2) Disconnect extension harness connector
(17) of the KDPF outlet temperature sensor
from TEMP3 of temperature sensor
consolidation box (11).
WA470-7
3) Loosen mounting nut (18) and remove KDPF

outlet temperature sensor (19).
14 mm
50-119


4. Remove the differential pressure sensor pipings

and the differential pressure sensor in the
1) Remove clamp (20).
Width across flats of clamp (20) mounting
bolt: 10 mm
2) Remove clamp (21).
Width across flats of clamp (21) mounting
bolt: 14 mm
3) By using the tool (long socket), remove band
(28).
a Put match marks on band (28) before
removing them.
Width across flats of band (28) tightening
nut: 7/16 in. (11.1 mm)
5) Loosen nuts on the body side of the

differential pressure sensor piping.
Width across flats of nut (24) of pipe (25):
11/16 in. (17.46 mm)
Width across flats of nut (26) of pipe (27):
5/8 in. (15.88 mm)
6) Disconnect connectors (22) and (23) for
differential pressure sensor pipes (25) and
(27).
a While pressing lock (f) on the fitting of the
connector, pull out the connector in the
a Lock (f) of the fitting of differential
pressure sensor pipe (22) is located on
its back.
7) Remove differential pressure sensor (31)
and sensor table (29) as a unit.
a When removing the differential pressure
sensor (31), take extreme care since it
breaks easily.
a Band (28) is made of stainless steel,

accordingly never use an impact wrench
for tightening. (The threaded portion may
be damaged.)
a Discard band (28) because reuse of the
band is not allowed.
4) Bind sensor table (29) by using string, etc. to
fix it.
50-120
WA470-7

2] Remove mounting bolt (32) and remove

temperature sensor consolidating box
(11) from sensor table (29).
Width across flats of mounting bolt
(32): 10 mm
5. Body
a Before removing each body, record the
mounting position of each harness bracket.
8) Remove differential pressure sensor pipes

(25) and (27).
a To remove differential pressure sensor
pipes (25) and (27), vertically pull them
out because those pipes are inserted in
the KCSF and outlet body.
1) Place blocks [2] at 4 places under them to

support the assembly securely.
2) Remove mounting bolts (33) (12 pieces) at
each connection between bodies, and then
remove backup plate (34) and hangers (36)
and (37).
Width across flats of mounting bolt (33):
14 mm
3) Remove harness bracket (38).
4) Disconnect inlet body (2), KDOC body (3),
KCSF body (4), and outlet body (5).
a Support KDOC body (3) with your hand
because its lower part is not supported
with blocks [2].
5) Remove gaskets (35) from between the
bodies.
a Discard gaskets (35) because reuse of the
gaskets is not allowed.
9) Remove mounting bolt (30) and remove

differential pressure sensor (31) from sensor
table (29).
Width across flats of mounting bolt (30):
10 mm
10)When replacing temperature sensor
consolidating box (11), remove it according
1] Disconnect all of the temperature sensor
connectors from temperature sensor
consolidation box (11).
WA470-7
Assembly
(WA470-A9H0-710-K-00-A)
1. Body
50-121

1) Place blocks [2] at 4 places under the bodies

to support the assembly securely.
a Use the blocks used at disassembly.
2) Set inlet body (2), KDOC body (3), KCSF
body (4), and outlet body (5).
3) Set them by aligning match marks (a), (b),
and (c) made at disassembly.
a If they are assembled with match marks
displaced, the flanges of KDPF inlet and
outlet are installed at wrong angle,
causing defective installation of exhaust
pipe to the inlet and slanted installation of
tail pipe to the outlet.
4) Install gaskets (35) between the bodies.
a Use new gaskets (35).
5) Install backup plate (34), hangers (36) and
(37), and harness bracket (38).
6) Install and lightly tighten mounting bolts (33a),
(33b), and (33c), 12 bolts each at connection
between the bodies.
a The figure shows the view from the inlet side

(upstream side).
*1: Bolt that tightens also hanger
*2: Bolt that tightens also harness bracket
(A): Connection between inlet and KDOC
(B): Connection between KDOC and KCSF
(C): Connection between KCSF and outlet
a Install mounting bolts (33a), (33b), and

(33c) from the direction shown in the
following figure.
Install mounting bolts (33a) and (33b)
from the upstream side.
Install mounting bolt (33c) from the
downstream side.
7) Tighten mounting bolts (33a), (33b), and
(33c) to the specified torque.
Width across flats of mounting bolts (33a),
(33b), and (33c): 14 mm
2 Mounting bolts (33a), (33b), and
(33c):
Seizure
(LC-G)
prevention
compound
3 Mounting bolts (33a), (33b), and

(33c):
59 to 74 Nm {6.0 to 7.6 kgm}
a Installed positions of backup plates (34a) and

(34b) are shown in the following figure.
a Install backup plates while aligning lower flat
part (h) of each backup plate not to cause a
step.
50-122
WA470-7

1] Set sensor table (29) to the installed

position.
2] By using the tool (long socket), partially
tighten band (28).
Width across flats of band (28)
tightening nut: 11.1 mm {7/16 inch}
a Once the band is tightened, folding marks
are made on it by the edges of fixed parts.
Since the folding marks can loose the
band, replace the band with a new one.
a The nut of band (28) is to be tightened to
the specified torque after the KDPF
differential pressure sensor pipe is
installed.
2. Install the differential pressure sensor pipings

and the differential pressure sensor in the
1) When temperature sensor consolidating box
(11) is replaced, install it according to the
1] Install remove temperature sensor
consolidation box (11) to sensor table
(29).
(32): 10 mm
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
2] Install all the temperature sensor
connectors to temperature sensor
consolidating box (11).
2) When the KDPF differential pressure sensor
is replaced, install it according to the
1] Install sensor table (29) to KDPF
differential pressure sensor (31).
(30): 10 mm
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
2] Install the KDPF differential pressure
sensor pipe.
3) When the KCSF is replaced, install the
sensor table according to the following
procedure.
WA470-7
3. KDPF differential pressure sensor pipe

1) Temporarily assemble the following.
(27): Differential pressure sensor Lo pipe
(25): Differential pressure sensor Hi pipe
(20): Clamp
(21): Clamp
2) Install pipe connectors (22) and (23) to the
differential pressure sensor in the direction
indicated as arrows.
a Check that locking sound is heard when
pipe connectors (22) and (23) are
inserted.
3) Position differential pressure sensor pipes
(25) and (27), and check that they are not
unnecessarily stressed.
4) Tighten band (28) to the specified torque.
50-123

Width across flats of band (28) tightening

nut: 11.1 mm {7/16 inch}
3 Nut of band (28):
6.3 to 8.3 Nm {0.64 to 0.85 kgm}
a Band (28) is made of stainless steel,
accordingly never use an impact wrench
for tightening. (The threaded portion may
be damaged.)
5) Tighten differential pressure sensor Lo pipe
mounting nut (26) to the specified torque.
15.88 mm {5/8 inch}
13.6 to 19.0 Nm {1.39 to 1.94 kgm}
6) Tighten differential pressure sensor Hi pipe
mounting nut (24) to the specified torque.
17.46 mm {11/16 inch}
24.5 to 36.5 Nm {2.5 to 3.7 kgm}
mm
3 Mounting bolt:
11.8 to 26.0 Nm {1.1 to 2.7 kgm}
mm

1) Install KDPF outlet temperature sensor (19).
Width across flats of mounting nut: 14
mm
3 Mounting nut:
24 to 36 Nm {2.45 to 3.67 kgm}
3 Mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
2) Install harness clip (16) to bracket (15).

mm
3 Mounting bolt:
11.8 to 26.0 Nm {1.1 to 2.7 kgm}
3) Connect extension harness connector (17) of
the KDPF outlet temperature sensor to
TEMP3 of temperature sensor consolidation
box (11).
50-124
WA470-7

a Installed positions of KDOC inlet

temperature sensor (13), outlet
temperature sensor (14), harness clip
band (6), and harness clamps (7) and (8)
are shown in the following figure.
(Installed positions of the clamps are for
reference.)
5. KDOC inlet and outlet temperature sensors

1) Install KDOC outlet temperature sensor (14).
Width across flats of mounting nut (12a):
14 mm
3 Mounting nut (12a):
24 to 36 Nm {2.45 to 3.67 kgm}
2) Install KDOC inlet temperature sensor (13).
14 mm
24 to 36 Nm {2.45 to 3.67 kgm}
3) Connect KDOC outlet temperature sensor

connector (10) to TEMP2 of temperature
4) Connect KDOC inlet temperature sensor
connector (9) to TEMP1 of temperature
5) Place harness clip band (6) to the position
marked at disassembly, and bind the
harnesses.
a Use a new harness clip band.
6) Place harness clamps (7) and (8) to the
positions marked at disassembly, and install
them to the bracket.
mm
3 Mounting bolt:
11.8 to 26.0 Nm {1.1 to 2.7 kgm}
WA470-7
50-125

Removal and installation of KCCV assembly

k Place

(WA470-A180-924-K-00-A)
8. Remove mounting bolts (4 pieces), and remove

KCCV assembly (9).
k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Installation
(WA470-A180-720-K-00-A)

removal.
[*1]
6 Radiator: 75 l
2. Open full - fender (1) and side cover (2).

3.3 0.49 Nm {0.34 0.05 kgm}
Removal
(WA470-A180-520-K-00-A)
a When check valve (A) at the bottom of hose (5)

is removed, install it with following direction.
(a): KCCV ventilator side (gray)
(b): Cylinder block side (black)
[*2]
3 Clamp of blowby hose (6):
4.4 0.49 Nm {0.45 0.05 kgm}
[*3]
3 Joint bolt of tubes (7) and (8) (KCCV
side):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
4. Disconnect connector PCCV (4).
6. Disconnect blowby hoses (6) (2 pieces) on the
tube side. [*2]
7. Remove the joint bolt and clamp of tubes (7) and
(8). [*3]
50-126
3 Joint bolt of tubes (7) and (8) (cylinder

block side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
WA470-7


5 Radiator: 75 l
WA470-7
50-127

Removal and installation of KVGT assembly
(WA470-AA10-924-K-00-A)
Symbol
A
Part No.
Part name
15 795T-621-2820 Push tool

16 795T-621-2810 Installer
Necessity
Q'ty
a Special tools
t 1
t 1
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA470-AA10-520-K-00-A)
5. Remove heat insulation cover (3).

6. Remove cover (4) and bracket (5).
6 Radiator: 75 l
2. Remove caps (A) (8 pieces) of the engine upper
arrows.
becomes difficult.)
7. Disconnect connectors SVGT (6) and VGT-REV

(7).
3. Sling cover (B) and remove it.

4 Cover (B): 70 kg
50-128
WA470-7

8. Disconnect connector DOSER (8), and remove

all the harness clamps.
9. Remove all the clamps of tubes (9) to (11).
17.Remove joint bolt (22). [*5]

10.Disconnect hoses (12) to (14).
11.Disconnect hose (15) on the air cleaner side. [*1]

12.Remove the clamp of hose (16). [*2]
14.Remove air intake connector (18) and hoses
(15) and (16) together as a unit.
15.Remove bolts (20) (4 pieces) of the flange of

tube (19). [*3]
16.Remove bracket (21). [*4]
WA470-7
19.Remove fuel doser assembly (24). For details,

see "Removal and installation of fuel doser
assembly".
20.Remove U-bolt (25).
22.Loosen the clamp of hose (27), and pull out tube
(28). [*6]
23.Remove joint bolt (29). [*7]

24.Remove all the clamps of tubes (30) and (31).
Loosen the sleeve nut on the front cover side.
[*7]
25.Remove tubes (32) and (33). [*8]
50-129

3 Clamp of hose:
10.5 0.5 Nm {1.07 0.05 kgm}
26.Remove mounting bolts (2 pieces) and nuts (2

pieces). Sling KVGT assembly (34) and remove
it. Place it on the blocking tool [1] temporarily.
[*9]
27.Sling KVGT assembly (34) again from outside of
the engine hood, and remove it.
[*2]
a Install hose and clamp in the dimension as
follows.
4 KVGT assembly: 35 kg
Dimensions (a) and (c): 10 mm

Dimension (b): 43 mm
3 Clamp of hose:
10.5 0.5 Nm {1.07 0.05 kgm}
[*3]
2 Bolt (20):
3 Bolt (20):
78.5 to 88.3 Nm {8 to 9 kgm}
[*4]
Installation
(WA470-AA10-720-K-00-A)

removal.
[*1]
a Install hose and clamp in the dimension as
follows.
50-130

68.6 to 73.5 Nm {7.0 to 7.5 kgm}
[*5]
3 Joint bolt (22):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*6]
WA470-7

a Install clamps (both ends) of hose (27) with its

screws to be same direction.
10.5 0.5 Nm {1.07 0.05 kgm}
2. By using tool A15, install seal (37) to oKVGT

housing (36).
a Drive in tool A15 until it touches flange
surface (c) of KVGT housing (36).
a Clearance (d) between KVGT housing (36)
and seal (37) becomes following dimension.
Clearance (d): 3 mm
[*7]
3 Joint bolt (29):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Sleeve nut at front cover side of tubes
(30) and (31):
24 to 27 Nm {2.4 to 2.7 kgm}
[*8]
24 to 27 Nm {2.4 to 2.7 kgm}
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*9]
2 KVGT assembly (34) mounting bot and
nut:
3 KVGT assembly (34) mounting bot and
nut:
68.6 to 73.5 Nm {7 to 7.5 kgm}
a When exhaust connector (35) is removed, install
it according to the following procedure.
3. Install bracket (21).

a Lightly tighten the mounting bolts.
4. Install plug (38) to exhaust connector (35).
3 Plug (38):
2.9 to 5.9 Nm {0.3 to 0.6 kgm}
5. Install seal ring (39) to exhaust connector (35).
a Install seal ring (39) with its stamp mark (R)
facing the KVGT housing.
6. Fix tool A16 to exhaust connector (35) with bolt
[1].
7. Install exhaust connector (35) to KVGT housing
(36).
a Push in tool A16 until its end face touches
flange surface (c) of KVGT housing (36).
8. Fix KVGT housing (36) and tool A16 with bolt
[2].
a Check that dimensions (e) and (f) are the
following value.
9. Tighten bolt (40).
10.Tighten the mounting bolts of bracket (21) to the
specified torque.
68.6 to 73.5 Nm {7.0 to 7.5 kgm}
11.Remove tool A16.
1. Install the KVGT assembly.

WA470-7
50-131


5 Radiator: 75 l
50-132
WA470-7

Removal and installation of EGR (Exhaust Gas Recirculation) valve

assembly (WA470-A9K1-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
5. Remove connecting bolts (9) (4 pieces) from

tube (8).
6. Remove mounting bolts (2 pieces), and remove
EGR valve assembly (10).
(WA470-A9K1-520-K-00-A)

Installation
(WA470-A9K1-720-K-00-A)

removal.
[*1]

24.5 to 34.3 Nm {2.5 to 3.5 kgm}
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
3 Tube (7) sleeve nut:
24 to 27 Nm {2.4 to 2.7 kgm}
3. Disconnect connectors SEGR (4) and EGR-SOL

(5).
WA470-7
50-133

Removal and installation of EGR (Exhaust Gas Recirculation) cooler

assembly (WA470-A9L0-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal

6. Remove tubes (8) to (10). [*3]
a To remove tube (9), remove the upper joint
bolt.
(WA470-A9L0-520-K-00-A)

6 Radiator: 75 l
3. Remove heat insulation plates (3) and (4).
7. Remove connecting bolts (12) (4 pieces) from

tube (11).
8. Remove EGR cooler assembly (13).
4. Remove tube (5). [*1]
50-134
WA470-7

Installation
(WA470-A9L0-720-K-00-A)

removal.
[*1]
3 Tube (5) mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
[*2]
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*3]
3 Upper joint bolt of tube (9):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
5 Radiator: 75 l
WA470-7
50-135

Removal and installation of air cleaner assembly
(WA470-A910-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
6. Remove band (7), and remove air cleaner

assembly (8). [*2]
(WA470-A910-520-K-00-A)

2. Disconnect connector R93 (3).

Installation
(WA470-A910-720-K-00-A)

removal.
[*1]
a Install the hose and clamp at KVGT side in the
dimension as follows.
3 Clamp of hose (both ends):

10.5 0.5 Nm {1.07 0.05 kgm}
50-136
WA470-7

[*2]
a Install the clamp so that inlet (A) of air cleaner is
not caught by seal (9).
a Install air cleaner assembly (8) so that band (7)

and dust outlet port (B) are following
dimensions.
3 Band (7):
10.5 0.5 Nm {1.07 0.05 kgm}
WA470-7
50-137

Removal and installation of air conditioner compressor belt
(WA470-AT50-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA470-AT50-520-K-00-A)
1. Open full-length fender (1) and the side cover

(2).
Installation
(WA470-AT50-720-K-00-A)

removal.
a Adjust the belt tension. For details, see Testing
and adjusting, "Testing and adjusting air
conditioner compressor belt tension".
release it, and open covers (4) and (5).
3. Loosen bolts (6) and (7).

4. Loosen nut (8) and bolt (9), and slide air
conditioner compressor (10) in the direction
indicated by the arrow.
5. Remove air conditioner compressor belt (11).
50-138
WA470-7

Removal and installation of alternator belt
(WA470-AKM4-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA470-AKM4-520-K-00-A)
1. Remove air conditioner compressor belt. For

Installation
(WA470-AKM4-720-K-00-A)

removal.
and adjusting, "Testing and adjusting alternator
belt tension".
release it, and open cover (4).
4. Remove cover (5) and handrail (6).
5. After loosening bolts (7) and (8), loosen locknut
(9).
6. Loosen adjustment nut (10), and move
alternator (11) in the direction of the arrow.
7. Remove alternator belt (12).
WA470-7
50-139

Removal and installation of fuel tank assembly
(WA470-AD10-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

4. Disconnect fuel hoses (4) and (5).
a When removing and installing the fuel piping,

take extreme care not to allow foreign matters to
enter the fuel piping. If dust, etc. sticks to any
part, wash that part thoroughly with clean fuel.
a Note the connector numbers and installed
positions of the wirings and hoses before
disconnecting them.
a When disconnecting wiring and hoses, be
careful not to damage or deform them by
tightening clips and clamps. Remove clips and
clamps in advance if they may damage wiring or
hoses.
Removal
5. Disconnect fuel hose (6) on the right front side of

the fuel tank.
(WA470-AD10-520-K-00-A)
1. Drain fuel.
6 Fuel tank (when the tank is full):
380 l
6. Remove plate (7) and step (8).

a Remove the mounting bolts on the other side
in the same way.
7. Remove engine oil drain port (9).
8. Remove coolant drain port (10).
50-140
WA470-7

11.Remove all the clamps of hose (13).

12.Remove breather (14), and move it toward the
fuel tank side.
13.Sling fuel tank assembly (15) by using belt sling

[1] and wire [2], and support it by using jack [3].
14.Remove mounting bolt (16) (1 pieces each) on
the right and left side and mounting bolt (17).
Slowly lower the crane and jack [3]. [*1]
a Check that all harnesses and pipes are
disconnected.
9. Disconnect connector R33 (11) on the left side of

the fuel tank, and remove the harness clamp.
a Remove coolant drain hose clamp (18) on

the left side in the process of lowering the
fuel tank assembly.
4 Fuel tank assembly (15): 210 kg
15.Lower the crane and jack until the bottom of the
fuel tank assembly is in parallel with the ground.
16.Place fuel tank assembly on pallet jack, etc. and
pull it out of the machine.
10.Remove coolant drain hose clamps (12) (2

pieces) on the left side of the fuel tank.
a Remove another clamp in the process of
removing the fuel tank assembly.
WA470-7
50-141

Installation
(WA470-AD10-720-K-00-A)

removal.
[*1]
3 Mounting bolts (16) and (17):
785 to 980 Nm {80 to 100 kgm}
50-142
WA470-7

Power train
Power train
(ALL-C100-001-K-00-A)
Removal and installation of torque converter and transmission

assembly (WA470-R406-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
9. Remove tube (2).

10.Disconnect hoses (3) and (4), and remove block
(5).
(WA470-R406-520-K-00-A)

l
2. Drain the transmission oil.
3. Remove full-length fender assembly. For details,
see "Removal and installation of full-length
fender assembly".
assembly".
5. Remove the hydraulic tank assembly. For details,
see "Removal and installation of hydraulic tank
assembly".
6. Remove the operator's cab and floor frame
assembly. For details, see "Removal and
installation of operator's cab and floor frame
assembly".
7. Remove all piping connected to the pump. For
details, see "Removal and installation of steering
lubrication pump and power train pump
assembly".
8. Remove all piping connected to the pump. For
details, see "Removal and installation of work
equipment pump and cooling fan pump
assembly".
a Remove bracket (1).
WA470-7
11.Remove the cover on the right side of the

machine body and disconnect hose (6).
12.Disconnect ground cable (6-1).
13.Remove tube (7). [*1]

14.Remove the clamp (8), and move harnesses (9)
and (10).
50-143

Power train

19.Remove the mounting bolt of block (18) and
move it.
15.Remove bracket (11), and move the

corresponding piping.
20.Remove brackets (19) to (21).
a To remove bracket (21) ,disconnect
connector R100A (22).
16.Remove cover (12) on the right side of the

machine body.
a Remove the cover on the rear side as well.

22.Remove clamps (25) and (26), and the bracket
immediately beneath them.
50-144
WA470-7

Power train

24.Disconnect hoses (28) and (29).
28.Set blocks [1] under the flywheel housing.

25.Remove rear drive shaft (30) and center drive
shaft (31). [*2]
a The figure shows the state without the torque

converter and transmission assembly for
illustration purposes.
a Make a matchmark on the coupling and drive

shaft, and then remove them.
26.Remove oil filler pipe (32).
27.Remove drain port (33) on the left side of the
machine body.
a Using block [1] prevents the combined part

on the engine side from lowering during
separation of the torque converter and
transmission assembly.
29.Sling the torque converter and transmission

assembly.
30.Remove transmission mount bracket (34).
1) Remove right and left engine mount bolts
(35). [*3]
2) Remove mounting bolts (36) (2 pieces) on
the upper side of left and right transmission
mount brackets (34) and bolt (37). [*4]
3) Use jack [2] to raise the bottom surface of the
transmission to the position where mounting
WA470-7
50-145

Power train
bolts (2 pieces) on the lower side of left and

right transmission mount brackets (34) can
be removed.
4) Remove mounting bolts (2 pieces) on the
lower side and remove left and right
transmission mount brackets (34). [*5]
33.Sling and remove the torque converter and

transmission assembly (40).
4 Torque converter and transmission
assembly (40):
1,500 kg
Installation
(WA470-R406-720-K-01-A)

removal.
[*1]
2 Hose insertion portion of tube (7):
3 Hose clamp of tube (7):
8.8 0.5 Nm {0.9 0.05 kgm}
[*2]
31.Remove U-bolt (38).
32.Remove connecting bolts (39) (12 pieces)
between the engine and torque converter.
50-146
a Tighten drive shaft mounting bolts according to

1. Check that the mating yoke and the seat of the
drive shaft spider are free from rust, foreign
material (masking material), bruise, etc.
2. Set the yoke key slot in the vertical position,
place the drive shaft on the lower part of the
faucet joint portion, and insert the key into the
key slot.
3. Lightly tighten upper and lower bolts (4 pieces
each) until the spider contacts the seat of the
yoke.
WA470-7

Power train
a Use a plastic (or copper) hammer to tap them

for contacting if fit of keyway portion and
faucet joint is hard. (Do not use a hard metal
hammer since it can damage the cross
bearing)
3 Mounting bolt of drive shaft (30) and
(31):
98 to 123 Nm {10 to 12.5 kgm}
[*3]
3 Engine mounting bolt (35):
455 to 565 Nm {46.5 to 58 kgm}
[*4]
3 Transmission mounting bolt (37):
455 to 565 Nm {46.5 to 58 kgm}
[*5]
a Adjust the clearance (a) between the
transmission mount bracket and front and rear
stopper bolt (41) to the following value, and
Clearance (a): 2 mm
Refilling of oil
oil level again.
l
Transmission case: 65 l
Air bleeding
Bleed air from each part. For details, see Testing
and adjusting.
WA470-7
50-147

Power train
Disassembly and assembly of transmission assembly
(WA470-CF00-926-K-00-A)
2
3
4
5
7
B
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Part No.
793T-607-1550
01051-62240
01643-32260
793T-607-1260
01016-51645
01016-51690
01010-81245
793T-607-1570
790-102-1891
793T-607-1220
793-607-1230
793T-607-1280
01016-31245
01580-11210
01017-30250
01643-32060
01580-12016
793T-607-1290
04530-11628
793T-607-1310
793T-607-1520
2989-01-1220
01643-33080
01017-31420
793T-607-1330
793T-607-1340
01010-80820
01643-30823
793T-607-1350
04530-11018
793T-607-1560
01017-51630
01643-31645
790-201-2660
792-135-3360
792-822-1430
790-201-2860
792T-227-1110
792T-423-1320
790-201-2680
794T-425-1110
793T-615-1810
791T-630-2410
790-201-2220
790-201-2160
793T-607-1420
793T-623-1170
50-148
Part name
Bracket
Bolt
Washer
Plate
Bolt
Bolt
Bolt
Plate
Nut wrench
Lifting tool
Pin
Lifting tool
Bolt
Nut
Bolt
Washer
Nut
Bar
Eyebolt
Plate
Push tool
Bolt
Washer
Bolt
Bracket
Plate
Bolt
Washer
Bolt
Eyebolt
Sleeve
Bolt
Washer
Plate
Plate
Plate
Spacer
Push tool
Push tool
Plate
Push tool
Push tool
Push tool
Plate
Plate
Push tool
Push tool
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
q
q
q
q
t
t
q
t
t
t
q
q
t
t
1
1
1
1
1
1
4
1
1
1
1
2
4
4
2
4
4
1
1
1
1
1
1
8
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Symbol
Part No.
Necessity
Q'ty
Symbol
Necessity
Q'ty
a Special tools
Part name
t 1
q 1
q 1
1
1
1
q 1
t 1
t 1
t 1
t 1
t 1
t 1
t 1
t 1
25 790-445-3810 Push tool

26 790-201-2860 Spacer
790-101-5401 Push tool kit
790-101-5421 Grip
27
790-101-5441 Plate
01010-51240 Bolt
28 790-434-1470 Push tool
793T-607-1430 Push tool
B
29 790-101-5421 Grip
01010-51240 Bolt
30 793T-607-1140 Spacer
793T-607-1440 Push tool
31 790-101-5421 Grip
01010-51240 Bolt
32 793T-607-1450 Spacer
Disassembly
(WA470-CF00-530-K-00-A)
a Be careful not to damage parts during

disassembly (also during transporting and
storing them).
If you damaged a part and the damage is
repairable, repair it before assembly.
If the damage is not repairable (when the repair
can affect part's dimension, precision, surface
roughness, etc.), replace the part with a new one.
1. Place the torque converter and transmission
assembly on a level place, and stabilize it by
using block, etc.
2. Remove steering pump and power train pump
assembly (A).
4 Steering pump and power train pump
assembly:
85 kg
3. Remove work equipment pump and cooling fan

pump assembly (B).
WA470-7

Power train
4 Work equipment pump and cooling

fan pump assembly:
160 kg
3) Disconnect hose (6) and remove flange (7).
4. Remove emergency steering pump and motor

assembly (1) and bracket (2).
4) Remove tube (8) and filter assembly (9).
5. Disconnect all the connectors, and remove the

wiring harnesses.
a For details of the connectors, see
Troubleshooting, "Connector list and layout".
6. Piping, sensor and ECMV assembly
1) Remove tube (3).
5) Remove tubes (10) and (10a).

6) Remove transmission output shaft speed
sensor (11).
2) Remove tube (4) and gauge (5).
7) Remove transmission oil temperature sensor

(12).
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Power train
8) Remove torque converter outlet pressure

sensor (13) and torque converter oil
temperature sensor (13-1).
9) Remove tube (14).
12)By using guide bolt [2], remove R ECMV

assembly (20), 2nd ECMV assembly (21),
3rd ECMV assembly (22), block (23), and
filter (24) together with plate (25).
10)By using guide bolt [1], remove L/C ECMV

assembly (15-1), F ECMV assembly (15), 1st
ECMV assembly (16), and 4th ECMV
assembly (17) together with plate (18).
13)Remove transmission input shaft speed

sensor (26).
7. Coupling and strainer

11)Remove torque converter inlet pressure
sensor (19-1) and main relief valve (19).
50-150
1) remove coupling (27) and strainer (28).
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Power train
8. Preparation for removal of rear and 2nd clutch

pack assembly
4) Install tool B2.
a At this time, install the tool for removing the R

and 2nd clutch pack assembly.
1) Remove cage (29).
9. Disconnection of front case and rear case
2) Remove holder (30) and plate (31).
1) Place the torque converter and transmission

assembly on a level place with the torque
converter side up and stabilize it by using
blocks, etc.
2) Sling rear case (32) and remove the
connecting bolts between the front case and
the rear case.
3) By using forcing screw [3] (M12 x 1.75),
separate the front case and the rear case.
4) Sling and remove rear case assembly (32).
3) Install the bolt (M20 x 2.5) of tool B2 to

transfer shaft 1 (68).
10.Disconnection of torque converter assembly

a When removing the bearing outer races from
the front case and the rear case, take
extreme care not to damage the cases.
If any portion is scratched, modify it smoothly.
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Power train
1) Place the assembly with the torque converter

side of the rear case up on a level place and
stabilize it by using blocks, etc.
2) Remove the mounting bolts of housing (33).
3) By using forcing screw [4] (M12 x 1.75),
separate the housing and the rear case.
4) Sling and remove housing (33).
9) Remove bolts (39) (10 pieces).

a Remove cover (40) when necessary.
a Install bolt (M10 x 1.5) to the forcing tap to
remove.
5) Turn over the rear case and stabilize it by

using blocks, etc.
6) Remove snap ring (34), then remove bearing
(35).
10)Sling and remove rear case (41) and

separate torque converter assembly (41a).
a The shape of torque converter assembly
shown in the figure is different from the
real one.
7) Install bolts [5] (M10 x 1.5) to the tapped
holes and remove spacer (36).
8) Remove thrust plate (37) and snap ring (38).
a For disassembly and assembly procedure of

torque converter assembly, see
"Disassembly and assembly of torque
converter assembly".
11.PTO assembly
a Disassemble the right and left PTO
assemblies in the same procedure.
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Power train
1) Remove the mounting bolts of PTO

assembly (42).
2) By using forcing screws [7] (M12 x 1.75),
sling and remove PTO assembly (42).
12.Rear case
Remove outer races (50), (51), and (52) from the
rear case.
3) By using tool B3, fix gear (43).
4) By using tool B4, remove nut (44).
5) Remove cage (45) and bearing (46).

6) Remove bearing (47) from gear (43).

the front case and the rear case, be careful
not to damage the cases.
13.Input shaft and gear

1) Remove input shaft (53).
2) Remove seal ring (54), thrust bearing (55),
thrust plate (56), and inner race (57) from
input shaft (53).
7) Remove outer races (48) and (49) and snap

ring (45a) from cage (45).
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Power train
3) Remove gear (58).
2) By using tool B5, sling and remove F and 1st

clutch assembly (64).
4) Remove inner race (58a) from gear (58).

3) Install tool B6 to R and 2nd clutch pack
assembly (65) and 3rd and 4th clutch pack
assembly (66), then sling them.
4) While tightening the bolt installed in the
center of tool B2 in Step 8-4), sling and
remove R/2nd clutch pack assembly (65)
and 3rd/4th clutch pack assembly (66).
a Remove them by separating inner race
(67) and transfer shaft 1 (68).
2 Threaded portion and end face of
center bolt of tool B2:
5) Remove bearing (60) from front case (59).
14.Clutch pack assembly

1) Remove seal rings (61), (62), and (63) from
each clutch pack assembly.
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Power train
a For the disassembly and assembly

procedure of the clutch pack assembly, see
"Disassembly and assembly of transmission
clutch pack assembly".
15.Parking brake
1) Remove coupling (69).
5) Loosen bolts (74) (4 pieces) and bolts (75)

(12 pieces) gradually and evenly to remove.
7) Remove springs (77) and (78).

8) By using eyebolt (M12 x 1.75), remove piston
(79).
2) Remove the mounting bolts of cage (71).
remove cage (71).
9) Remove O-rings (80) and (81) and backup

rings (82) and (83) from piston (79).
4) Remove dust seal (72) and oil seal (73) from
cage (71).
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Power train
13)Remove spacer (90).

14)Install bolts (M10 x 1.5) to the tapped holes
and remove hub (91).
15)Remove plate (92).
10)By using tool B1, push spacer (84) to

remove ring (85).
16)Remove the mounting bolts of retainer (93).

17)By using forcing screws [12], remove
retainer (93).
11)Install bolts [11] (M8 x 1.25) to the tapped

holes and remove spacer (86).
18)Remove outer race (94) from retainer (93).
12)Remove plates (87) (7 pieces), springs (88)

(6 pieces), and discs (89) (6 pieces).
19)Remove shims (95).
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Power train
a When removing the bearing outer races

from the front case and the rear case, be
careful not to damage the cases.
If any portion is scratched, modify it
smoothly.
20)Sling and remove housing (96).
16.Transfer shaft 2 and transfer gear 2

1) Remove the mounting bolts of cage (105).
remove cage (105).
21)Install eyebolts (M22 x 1.5) to the tapped

holes of the shaft and sling and remove shaft
and gear assembly (97).
3) Remove outer race (106) from cage (105).

from the cage, take extreme care not to
damage the cage.
smoothly.
22)Remove bearing (99), spacer (100), gear
(101), and bearing (102) from shaft (98)
23)Remove cover (103) and outer race (104).

WA470-7
4) Remove shims (107).

5) Remove snap ring (107a) and plate (107b).
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Power train
6) Install tool B7 to transfer shaft 2 (108) and

transfer gear 2 (109).
17.Transfer gear 1
7) Tighten the outside bolts of tool B7 to
separate and remove transfer shaft 2 (108)
from transfer gear 2 (109).
a Tighten all the outside bolts evenly.
2 Threaded portion and end face of
outside bolt:
8) Remove bearings (108a) and (108b) from
9) Move transfer gear 2 (109) sideways to
remove.
10)Remove outer race (111) from front case
(110).
a Transfer shaft 1 is removed together with the

R and 2nd clutch pack assembly.
the front case and the rear case, take
extreme care not to damage the cases.
1) Remove inner race (112) and bearing (113).
a After removing bearing (113), remove the
remaining plate [a component part of
bearing (113)].

from the front case and the rear case,
take extreme care not to damage the
cases.
smoothly.
2) Remove transfer gear 1 (114).
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Power train
3) Remove spacer (115) from transfer gear 1

(114).
2) Remove outer race (120) from cage (118).

from the cage, take extreme care not to
damage the cage.
smoothly.
4) Remove snap ring (116), then remove

bearing (118) from front case (117).
19.Retainer
1) Remove retainer (121) from front case (117).
2) Remove dust seal (122) and oil seal (123)
from retainer (121).
18.Cage
1) Remove cage (118) and shim (119) from
front case (117).
Assembly
(WA470-CF00-710-K-00-A)
a Before assembly, remove all liquid gasket

sticking to the mating face of the case.
a Clean all parts and check them for dirt or
damage before assembling.
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Power train
a Press-fit the outer race and inner race of each

bearing until they are seated on the case or
shaft, and check the feeler gauge (thickness:
0.05 mm) cannot be inserted.
a After installing each bearing, drip at least 6 cc of
power train oil (TO10) to them and rotate them at
least 10 turns.
a When expansion-fit a bearing, drip at least 6 cc
of power train oil (TO10) to it and rotate it at least
10 turns before cooling it in dry ice.
a Check that snap ring is fitted to the groove
securely.
1. Retainer
a Part b:
Fill 40 to 60% of the clearance between
the main lip of oil seal (123) and the lip of
dust seal (122), and the clearance
between the dust seal and the oil seal
with grease (G2-S or G2-LI).
a Part c:
Grease may protrude into the clearance
between the oil seal and the dust seal.
Note, however, that excessively applied
grease can be mistaken for oil leakage.
1) Thinly apply liquid gasket (LG-5) to the oil

seal fitting face of retainer (121).
2) By using tool B31, press fit oil seal (123) to
retainer (121).
a Dimension (a) becomes 18.9 0.2 mm.
5) Install retainer (121) to front case (117).
3) By using tools B31 and B32, press-fit dust

seal (122).
a Dimension (b) becomes 9.9 0.2 mm.
2. Cage
1) By using tool B11, press fit outer race (120)
to cage (118).
2 Inner periphery of outer race:
Power train oil (TO10)
4) Apply and fill grease as shown in the

following figure.
a Part a:
Apply grease (G2-S or G2-LI) to the lip
ends (3 places).
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Power train

2) Install shim (119) and cage (118) to front

case (117) loosely.
2 Periphery of O-ring:
Grease (G2-LI)
a Set the total thickness of shim (119) to be
2.2 to 2.5 mm.
2) By using tool B13, press fit outer race (106)

to cage (105).
a After completion of assembly of

transmission assembly, adjust shim (119).
3. Bearing for transfer shaft 1

1) Install snap ring (116) to front case (117).
2) By using tool B12, press-fit bearing (118).
3) By using tools B15 and B16, press-fit

bearings (108a) and (108b) to transfer shaft
2 (108).
4) Apply oil to bearings (108a) and (108b) and
rotate the bearing at least 10 turns to spread
the oil.
2 Bearing:
4. Transfer shaft 2 and transfer gear 2

1) By using tools B13 and B14, press fit outer
race (111) to front case (110).
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Power train
5) Install tool B8 to transfer gear 2 (109).

6) Heat transfer gear 2 (109) with tool B8
installed in a heating cabinet.
a Heat at temperature below 145C for at
least 2 hours.
11)Set heated transfer gear 2 (109) and tool B8

as a set in the front case (110).
k Do
not hold transfer gear 2 (109) and

tool B8 with bare hands.
2 Inner periphery of gear:

12)Check that the inside faces of transfer gear 2
(109) and outer race (111) are aligned each
other.
13)Insert transfer shaft 2 (108) slowly into
a Insert the shaft until it stops.
7) Install tool B9 to transfer shaft 2 (108).

8) Refrigerate transfer shaft 2 (108) with tool B9
installed in a freezer for at least 1 hour.
9) Refrigerate plate (107b) in the freezer.
a The refrigerating time of the plate may be
shorter than that of transfer shaft 2 (108).
10)Check that the temperature difference
between transfer gear 2 (109) and transfer
shaft (108) is at least 140C.
a Once the shaft is positioned, do not raise

it. (At the moment when the shaft is
raised, the temperature difference
between the shaft and gear is lost and
they may be fixed together)
14)Check that level difference (b) between
transfer shaft 2 (108) and transfer gear 2
(109) is in the following range by using a
depth gauge.
Dimension (b): -0.4 to 0.4 mm
a If dimension (b) is out of the standard
value, separate the shaft and gear
immediately. Eliminate the cause, and
then repeat the procedure from step 6).
15)Leave the shaft and gear as they are for at
least 20 minutes until their temperature
decreases to the normal temperature.
16)Rotate transfer shaft 2 (108) to check that it
is press fitted to transfer gear 2 (109) (the
shaft and gear do not slip on each other).
a Do not raise transfer shaft 2 (108).
17)Remove tools B8 and B9.
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Power train
5. Parking brake
1) By using tools B17 and B18, press fit outer
race (104) to the front case.
2) Install cover (103).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
18)Install plate (107b) and snap ring (107a).
19)Install cage (105) lightly.

a After adjusting the shims in the following
step 5-9), fasten cage (105) to the
specified torque.
Grease (G2-LI)
3) Install gear (101) and spacer (100) to shaft

(98).
a When installing gear (101), direct the side
of the tapped holes downward.
4) By using tools B19 and B20, press fit
bearings (99) and (102) to shaft (98).
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Power train
2 Bearings (99) and (102):

6) Sling down and install housing (96).

Grease (G2-LI)
7) By using tool B13, press fit outer race (94) to

retainer (93).
5) Install eyebolts (M22 x 1.5) to the tapped

holes of the shaft and sling down and install
the shaft and gear assembly (97).
8) Adjust the shim of the output shaft according

1] Install retainer (93) without installing shim
(95).
3 Mounting bolt:
9.80 0.98 Nm {1 0.1 kgm}
2] Rotate shaft (98) 10 turns each clockwise
and counterclockwise, and then check
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Power train
that the tightening torque of the mounting

bolt of retainer (93) has not changed.
5] to 7] until the value is in the preceding

range.
a If the tightening torque has changed

0.98 Nm {0.1 kgm} or more, repeat
steps 1] and 2].
a If the shim thickness is increased by

0.1 mm, the rotating torque changes
-5.88 to -1.96 Nm {-0.60 to -0.20
kgm}.
9) Adjust the shim of the transfer 2 shaft

1] Install cage (105) without installing shim
(107).
Grease (G2-LI)
3] Loosen the mounting bolts of retainer

(93) and measure rotating torque (A) of
shaft (98) by using torque wrench [22].
4] Remove retainer (93) and select and
install shims for shim (95) so that their
total thickness is as follows.
Set shim thickness (mm):
0.15, 0.20, 0.50
Total shim thickness (mm):
1.3 (+0.25 / -0.45)
5] Tighten retainer (93) to the following
torque.
3 Mounting bolt:
98.0 to 122.5 Nm {10 to 12.5
kgm}
6] By using torque wrench [22], measure
rotating torque (B) of shaft (98).
7] Check that value (B - A) obtained by
subtracting rotating torque (A) from
rotating torque (B) is as follows.
B - A = 0.49 to 2.94 Nm {0.05 to 0.3
kgm}
8] If value (B - A) is out of the preceding
range, increase or decrease the
thickness of shim (95) and repeat steps
WA470-7
3 Mounting bolt:
9.80 0.98 Nm {1 0.1 kgm}
2] Rotate shaft (98) 10 turns each clockwise
and counterclockwise, and then check
that the tightening torque of the mounting
bolt of cage (105) has not changed.
a If the tightening torque has changed
0.98 Nm {0.1 kgm} or more, repeat
steps 1] and 2].
3] Measure clearance (c) at equally spaced
3 places on the periphery and calculate
the average value.
a If the difference between the
maximum and minimum ones of the 3
measured values is larger than 0.15
mm, the bearing may not be installed
properly or there may be another
cause. So inspect and modify it.
4] Loosen the mounting bolts of cage (105).
5] Select and install shims for shim (107) so
that their total thickness is the average
clearance (c) obtained in step 3] plus
0.15 to 0.21 mm.
6] Tighten cage (105) mounting bolt.
3 Mounting bolt:
98.0 to 122.5 Nm {10 to 12.5
kgm}
7] By using torque wrench [22], measure
rotating torque (C) of shaft (98).
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Power train
8] Check that value (C - B) obtained by

subtracting rotating torque (B) measured
in step 8)-6] from rotating torque (C) is as
follows.
C - B = 0.49 to 2.94 Nm {0.05 to 0.3
kgm}
9] If value (C - B) is out of the preceding
range, increase or decrease the
thickness of shim (107) and repeat steps
6] to 8] until the value is in the preceding
range.
a If the shim thickness is increased by
0.1 mm, the rotating torque changes
-6.86 to -1.96 Nm {-0.70 to -0.20
kgm}.
13)Install bolts [11] (M8 x 1.25) to the tapped

holes and install spacer (86).
10)Install plate (92).
Grease (G2-LI)
a Direct the side having level difference

down when installing.
11)Install hub (91) and spacer (90).
2 Both end faces of hub and spacer:
Molybdenum disulfide lubricant or
molybdenum disulfide grease (LMG)
14)By using tool B1, push spacer (84) to install

ring (85).
12)Install plates (87) (7 pieces), springs (88) (6

pieces), and discs (89) (6 pieces).
a Install these parts in the order shown in
the figure and take care that springs (88)
are not caught.
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Power train
15)Install O-rings (80) and (81) and backup

rings (82) and (83) to piston (79).
2 Outside faces of O-ring and
backup ring:
Grease (G2-LI)
18)Install cover (76).

19)Tighten bolts (75) (12 pieces) and bolts (74)
(4 pieces) gradually and evenly.
a Check that the dowel pin on the cover
side is aligned with the hole on the piston.
16)By using eyebolts (M12 x 1.75), install piston
(79) to housing (96).
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
a At this time, align matchmarks (a) on the

housing side and piston side.
20)Thinly apply liquid gasket (LG-5) to the oil

seal fitting face of cage (71).
21)By using tool B29, press-fit oil seal (73).
a Dimension (a) becomes 19 0.2 mm.
17)Install springs (77) and (78).

22)By using tools B29 and B30, press-fit dust
seal (72).
a Dimension (b) becomes 10 0.2 mm.
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Power train
23)Apply and fill grease as shown in the

following figure.
a Part a:
Apply grease (G2-S or G2-LI) to the lip
ends (3 places).
25)Install coupling (69).

2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
662 to 829 Nm {67.5 to 84.5 kgm}
a Part b:
Fill 40 to 60% of the clearance between
the main lip of oil seal (73) and the lip of
dust seal (72) and the clearance between
the dust seal and the oil seal with grease
(G2-S or G2-LI).
a Part c:
Grease may protrude into the clearance
between the oil seal and the dust seal.
Note, however, that excessively applied
grease can be mistaken for oil leakage.
6. Clutch pack assembly
1) Turn over the front case.
2) By using tool B6, install R and 2nd clutch
pack assembly (65) and 3rd and 4th clutch
pack assembly (66) simultaneously to the
front case.
24)Install cage (71).

Grease (G2-LI)
3) By using tool B5, install F, 1st clutch pack

assembly (64).
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Power train
4) Install seal rings (61), (62), and (63) to each

clutch pack assembly.
a When installing seal rings (61) for the F
and 1st clutch pack and seal rings (63) for
the R and 2nd clutch pack, check that
there are oil grooves on their sides.
3) Install gear (58).

a Check that the height difference between
the meshed 3 gears is 3 mm or less.
If the position of gear (140) is higher, F
and 1st clutch pack assembly (64) may
be stopped at the faucet joint portion.
2 Periphery of seal ring:

Grease (G2-LI)
4) By using tool B23, press-fit inner race (57) to

input shaft (53).
7. Input shaft and gear
1) By using tool B21, press fit bearing (60) to
front case (59).
2 Bearing:
5) Install thrust plate (56), thrust bearing (55),

and seal rings (54).
a When installing seal rings (54), check that
there are oil grooves on its sides.
2) By using push tool B22, press-fit inner race
(58a) to gear (58).
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Grease (G2-LI)
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Power train
6) Install input shaft (53).
1) Install snap ring (45a) to cage (45).

2) By using tool B24, press fit outer races (48)
and (49) to cage (45).
8. Rear case
By using tool B13, press fit outer races (50), (51),
and (52) to the rear case.
a Press fit bearing outer race (50) for the taper
roller bearing to the portion where there is
identification hole (a).

gear (43).
2 Bearing:
4) Install cage (45) and bearing (46).
2 Bearing:
5) Finger-tighten nut (44).
a Direct the chamfered side down.
6) Rotate gear (43) at least 10 turns to spread
oil.
9. PTO assembly
a Assemble the right and left PTO assemblies
in the same procedure.
a When installing inner race and outer race of
the bearing, check that their manufacturing
numbers and match symbols (A) or (B) are
the same.
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Power train
7) By using tool B3, fix gear (43).

8) By using tool B4, tighten nut (44).
2 Nut:
Adhesive (LT-2)
3 Nut:
392.3 to 441.3 Nm {40 to 45 kgm}
2) By using tool B26, press fit cover (40) and

tighten bolts (39) (10 pieces).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
9) Install PTO assembly (42).

Grease (G2-LI)
3) Install snap ring (38) and thrust plate (37).
10.Installation of torque converter assembly

1) Sling and lower rear case (41) onto torque
converter assembly (41a).
a The shape of torque converter shown in
the figure is different from the real one.
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Power train
6) Turn over the rear case and stabilize it by

using blocks, etc.
7) By using guide bolts [17], install housing
(33).
Grease (G2-LI)
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
4) By using tool B27, install spacer (36).
11.Joint of front case and rear case

a Secure the front case with its mating surface
level.
5) By using tool B28, press fit bearing (35) and
install snap ring (34).
2 Bearing:
a Sling down the rear case with its mating

surface level. (If front case and rear case are
jointed while they are slung inclined, inner
parts may be damaged.)
1) Apply liquid gasket to the mating faces of the
front case and rear case as shown in the
following figure.
a (A) indicates that there are forcing taps on
the mating case.
2 Mating face of case:
2) By using guide bolts [18], sling and lower

rear case (32) to install.
3 Connecting bolt:
98 to 123 Nm {10 to 12.5 kgm}
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Power train
2 Bearing:
6) Remove cage (29).
12.Transfer gear 1, bearing, and cage

1) Place the assembly with the front case side
up on a level place and stabilize it by using
blocks, etc.
2) Install transfer gear 1 (114) to transfer shaft 1
(68).
3) By using tool B10, install spacer (115) to
2 Both end surfaces of spacer and
end surface (a part) of transfer
gear 1 (114):
7) By using plate [20] (outside diameter: 100

mm, thickness: approximately 10 mm) and
bolt [21] (M20 x 2.5, stem length:
approximately 70 mm), press fit inner race
(112) and spacer (31).

8) Install holder (30).

2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
4) Install bearing inner ring (130).
a This is a component part of bearing (113).
a When installing this part, direct the side of
the rounded end corner down.
2 Both end faces of bearing inner
ring:
5) Fasten cage (29) with bolts [19] (M12 x 1.5,
stem length: 80 to 40 mm) until it touches the
front case, then press fit bearing (113).
a At this time, do not fit the O-ring to cage
(29).
WA470-7
9) Install cage (29).

Grease (G2-LI)
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Power train
10)If value (E - D) is out of the preceding range,

increase or decrease the thickness of shim
(119) and repeat steps 7] to 9] until the value
is in the preceding range.
a If the shim thickness is increased by 0.1
mm, the rotating torque changes -5.88 to
-1.96 Nm {-0.60 to -0.20 kgm}.
13.Adjustment of shims of F and 1st shafts

1) Install cage (118) without installing shim
(119).
Grease (G2-LI)
3 Mounting bolt:
9.80 0.98 Nm {1 0.1 kgm}
2) Rotate the F and 1st shafts 10 turns each
clockwise and counterclockwise, and then
check that the tightening torque of the
mounting bolt of cage (118) has not changed.
a Install bolts (M12 x 1.75) to the F and 1st
shafts, and rotate them.
a If the tightening torque has changed 0.98
Nm {0.1 kgm} or more, repeat steps 1)
and 2).
3) Measure clearance (d) at equally spaced 3
places on the periphery and calculate the
average value.
4)
5)
6)
7)
a If the difference between the maximum

and minimum ones of the 3 measured
values is larger than 0.15 mm, the
bearing may not be installed properly or
there may be another cause. So inspect
and modify it.
Loosen the mounting bolts of cage (118).
By using torque wrench [22], measure
rotating torque (D).
Select and install shims for shim (119) so that
their total thickness is average clearance (d)
obtained in step 3) plus 0.18 to 0.24 mm.
Tighten cage (118) mounting bolt.
3 Mounting bolt:
11)Check that the F and 1st shaft have no end

play.
a Install a bolt (M12 x 1.75, stem length:
Min. 140 mm) to each shaft and measure
end play by using a dial gauge.
12)Install cover (131).
Grease (G2-LI)
14.Coupling and strainer

1) Place the torque converter and transmission
assembly on a level place and stabilize it by
using block, etc.
2) Install coupling (27) and strainer (28).
98.0 to 122.5 Nm {10 to 12.5 kgm}

8) By using torque wrench [22], measure
rotating torque (E) of the F and 1st shafts.
9) Check that value (E - D) obtained by
subtracting rotating torque (D) measured in
step 5) from rotating torque (E) is as follows.
E - D = 0.49 to 2.94 Nm {0.05 to 0.3 kgm}
50-174
WA470-7

Power train
3 Torque converter inlet pressure

sensor:
29.4 to 34.3 Nm {3.0 to 3.5 kgm}
15.Piping, sensor and ECMV assembly

1) Install transmission input speed sensor (26).
dust and flaws.
2 Threaded part of sensor:
5) By using guide bolt [1], install L/C ECMV

assembly (15-1), F ECMV assembly (15), 1st
ECMV assembly (16), and 4th ECMV
assembly (17) together with plate (18).
3 39.2 to 49 Nm {4 to 5 kgm}
2) By using guide bolt [2], install R ECMV

assembly (20), 2nd ECMV assembly (21),
3rd ECMV assembly (22), block (23), and
filter (24) together with plate (25).
6) Install tube (14).

7) Install torque converter outlet pressure
sensor (13).
3 Torque converter outlet pressure
sensor:
29.4 to 49 Nm {3.0 to 5.0 kgm}
8) Install torque converter oil temperature
sensor (13-1).
2 Threaded portion of torque
converter oil temperature sensor:
3 Torque converter oil temperature
sensor:
29.4 to 49 Nm {3.0 to 5.0 kgm}
3) Install main relief valve (19).

3 Mounting bolt:
44.1 to 53.9 Nm {4.5 to 5.5 kgm}
4) Install torque converter inlet pressure sensor
(19-1).
WA470-7
50-175

Power train
3 Joint bolt
M8: 19.6 to 29.4 Nm {2.0 to 3.0
kgm}
M12: 34.3 to 44.1 Nm {3.5 to 4.5
kgm}
9) Install transmission oil temperature sensor

(12).
3 Sensor:
29.4 to 49 Nm {3 to 5 kgm}
12)Install tube (8) and filter assembly (9).

10)Install transmission output shaft speed
sensor (11).
1] Loosen lock nut (132).
2] Tighten it until the end of sensor (11)
lightly touches tooth tip of gear (133).
a Check that the sensor tip is free from
iron dust and flaws.
3] Return sensor (11) by a half to 1 turn.
a Clearance (a) between the sensor tip
and gear (133) tooth tip is adjusted to
approximately 0.75 to 1.5 mm.
4] Secure sensor (11) with lock nut (132).
13)Install flange (7) and connect hose (6).
3 Lock nut:
49 to 96 Nm {5.0 to 7.0 kgm}
11)Install tubes (10) and (10a).
50-176
WA470-7

Power train
14)Install tube (4) and gauge (5).

2 Gauge mounting bolt:
Adhesive (LT-2)
3 Gauge mounting bolt:
12.7 to 13.7 Nm {1.3 to 1.4 kgm}
15)Install tube (3).

3 Tube mounting joint:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
18.Install work equipment pump and cooling fan

pump assembly (B).
fan pump assembly:
160 kg
19.Install steering pump and power train pump

assembly (A).
assembly:
85 kg
16.Connect the connectors.

a For details of the connectors, see
Troubleshooting, "Connector list and layout".
17.Install emergency steering pump and motor
assembly (1) and bracket (2).
WA470-7
50-177

Power train
Disassembly and assembly of torque converter assembly
(WA470-CD00-926-K-00-A)
Symbol
Part No.
Part name
790-501-5000
33 790-901-2110
793T-613-1510
34 792-213-1110
35 790-201-2650
36 790-201-2740
B
37 790-201-2660
38 792T-415-1410
39 790-201-2750
40 790-201-2680
41 790-201-2220
42 791-830-1770
Disassembly
Unit repair stand

Bracket
Plate
Wrench
Plate
Spacer
Plate
Spacer
Spacer
Plate
Plate
Push tool
Necessity
Q'ty
a Special tools
q
q
t
t
q
q
q
q
q
q
q
q
1
1
1
1
1
1
1
1
1
1
1
1
(WA470-CD00-530-K-00-A)
a Take care not to damage parts during

storing them). If you damaged a part and the
damage is repairable, repair it before assembly.
3) Remove bolts (6) (12 pieces) to remove

pump (7).
1. Place torque converter assembly (1) on blocks.

(Or install it to tool B33.)
2. Stator shaft and pump assembly
1) Install eyebolts to the stator shaft, remove
the bolt (2), and remove stator shaft and
pump assembly (3).
4) By using tool B35, separate stator shaft (5)

and bearing (8).
2) By using tool B34, remove nut (4).

a Install bolts (M12 x 1.75) (2 pieces) to the
bottom of stator shaft (5) diagonally and
fix them by using bar [1].
50-178
WA470-7

Power train
5) Remove seal ring (9) from stator shaft (5).
6) Separate gear (10) and guide (11).

7) Remove bearing (8) from guide (11).
4. Turbine and case assembly

1) Remove pilot (22).
2) Remove snap ring (23) to remove plate (24).

3. Stator assembly
1) Remove stator assembly (13).
2) Remove upper and lower snap rings (14) and
remove race and free wheel assembly (15)
from stator (16).
3) By using tool B36, separate boss (25) and

bearing (26).
3) Remove bushing (18) from the race and free

wheel assembly.
a Take care not to lose ball (21).
4) Remove snap ring (19-1) to remove free
wheel (19) from race (20).
WA470-7
50-179

Power train
4) Remove the mounting bolts to disconnect

turbine (27) and boss (25).
Assembly
5. Complete housing assembly
1) Remove the mounting bolts to separate
complete housing (28) and case (29).
(WA470-CD00-710-K-00-A)
1. Complete turbine
Install turbine (27) to boss (25).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
2) Remove piston (30) from complete housing

(28).
3) Remove seal ring (31) from piston (30).
4) Remove seal ring (32) from complete
housing (28).
5) By using tool B37, remove bearing (33) from
complete housing (28).
6) Remove discs (34) (2 pieces) and plate (35)

from case (29).
2. Turbine and case

Set complete turbine (36) to tool B38 and set
case (29).
3. Disc and plate

Install discs (34) (2 pieces) and plate (35) to
case (29).
2 Disc sliding surface:
50-180
WA470-7

Power train
4. Complete housing assembly

1) Install seal ring (32) to complete housing
(28).
a Install seal rings (32) as shown in the
figure.
Grease (G0-LI or G2-LI)
4) By using eyebolts [5] (M12 x 1.75), sling

complete housing assembly (37) and set it to
case (29).
5) Tighten mounting bolts (38).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
2) Install seal ring (31) to piston (30).

a Install seal rings (31) as shown in the
figure.
Grease (G0-LI or G2-LI)
3) Install piston (30) to complete housing (28).
5. Bearing
By using tool B39, press fit bearing (33).
a After press fitting the bearing, drip at least 6
cc of power train oil (TO10) to it and rotate it
10 turns.
6. Plate and snap ring

Install spacer (24) and snap ring (23).
WA470-7
50-181

Power train
a Make a mark with paint on the race to

indicate the side to which the free wheel
is installed.
(Make mark (P) at a position where you
can see it after installing the bushing.)
7. Pilot
Install pilot (22).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
2) Expansion-fit bushings (18) together with

balls (21) to race (20).
8. Stator assembly
1) Install snap ring (19-1) and free wheel (19) to
race (20).
a Apply power train oil (TO10) to the sliding

surfaces of the bushings.
a Apply power train oil (TO10) to the sliding

surface of the free wheel.
a Assemble so that arrow (C) indicated on
the end face of the free wheel cage is as
shown in the figure.
a Arrow (D) indicates the free rotation
direction of the free wheel.
a Take care not to damage sprag (A) of the
free wheel.
a Install the free wheel so that its drag clip
(B) is not hitched in ball groove (E) of the
race.
a Insert the free wheel into the race with
your hands.
(Do not drive the free wheel with a
hammer, etc.)
50-182
3) Install snap ring (14-1) to stator (16).

4) Install race and free wheel assembly (15) to
stator (16) and install snap ring (14).
a Assemble race and free wheel assembly
(15) and stator (16) as shown in the
figure.
WA470-7

Power train
2) Install guide (11) to gear (10).
9. Stator shaft and pump assembly

guide (11).
a Check that the manufacturing number (P
No.) of the inner and outer races and
match mark (A) are identical at the
position shown in the figure.
3) Install seal ring (9) to stator shaft (5).

Grease (G2-LI)
a After press fitting the bearing, apply at

least 6 cc of power train oil (TO10) to it
and rotate it at least 10 turns to spread
the oil.
4) By using tools B41 and B42, press fit stator

shaft (5) to bearing (8) and gear (10).
WA470-7
50-183

Power train
5) Install pump (7) and tighten bolts (6).

2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
6) By using tool B34, tighten nut (4).

a Install bolts (M12 x 1.75) (2 pieces) to the
bottom of stator shaft (5) diagonally and
fix them by using bar [1].
10.Stator assembly and turbine and case assembly

1) Set stator assembly (13) to stator shaft (5).
2) Check that the stator rotates as follows when
seen from the boss side (input side: view A).
Clockwise: Free rotation
Counterclockwise: Locked
3) By using eyebolts [9] (M12 x 1.75), sling and

lower turbine and case assembly (40) and
tighten bolts (2) lightly.
4) Turn over the torque converter assembly and
tighten bolts (2).
2 Nut:
Adhesive (LT-2)
2 Bolt:
3 Nut:
441 to 490 Nm {45 to 50 kgm}
3 Bolt:
50-184
Adhesive (LT-2)
49.0 to 58.8 Nm {5.0 to 6.0 kgm}
WA470-7

Power train
Disassembly and assembly of transmission clutch pack assembly
(WA470-
CF60-924-K-00-A)
a Special tools
43
44
45
B
46
47
48
49
50
51
52
53
54
55
Part No.
Part name
Commercially
available or
790-101-2501
790-101-3201
790-201-1310
Commercially
available
790-201-1410
790-101-2510
790-101-2520
791-112-1180
790-101-2540
790-101-2450
790-201-2860
790-101-3501
790-201-1320
793-415-1170
793T-607-1420
793T-607-1370
796T-467-2160
799-301-1500
793T-607-1380
792T-446-1150
793T-607-1390
795-102-2730
Disassembly
Necessity
Q'ty
Symbol
By using tool B43, remove bearing (1).
Puller
q 1
Push puller
t 1
Bearing puller
Plate
t 1
t 1
Puller
q 1
Plate
Block
Screw
Nut
Washer
Adapter
Spacer
Puller
Spacer
Seal holder
Push tool
Seal holder
Push tool
Oil leak tester
Seal holder
Push tool
Seal holder
Collar
t
t
t
t
t
t
t
t
t
t
q
t
t
t
t
t
t
t
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2. Spacer
1) Remove snap ring (2).
2) By using tool B43, remove spacer (3).
(WA470-CF60-520-K-00-A)
k When
placing a clutch pack on blocks, etc.,

degrease its surface sufficiently so that it
does not slip and fall off your hands.
a Take care not to damage parts during

storing them).
If you damaged a part and the damage is
repairable, repair it before assembly.
3. F clutch gear
1) Remove bearing (4).
a Never pry the gear by applying a bar to it

because doing so damages the gear and
housing. Be sure to use bearing pullers for
disassembly.
Assembly of F and 1st clutch pack assembly
[F clutch]
1. Bearing
WA470-7
50-185

Power train
2) Remove F clutch gear (5).
3) Remove plate (6) and bearing (7) from F

clutch gear (5).
5. Plate, disc, and spring

Remove plate (10), disc (11), and spring (12).
6. Plate and bearing

Remove plate (13) and bearing (14).
4. End plate
1) Using vise [3], press end plate (8).
3) Remove end plate (8).
50-186
7. Piston
1) By using bolts [4] (M8 x 1.25), remove piston
(15).
WA470-7

Power train
1) By using tool B44, remove bearing (20).
2) Remove snap ring (16) to remove lubricating

piston (17) from piston (15).
2) Remove spacer (21) and washer (22).
3) Remove 1st clutch gear (23).
3) Remove seal rings (18) and (19) from piston

(15).
[1st clutch]
8. Bearing and 1st clutch gear
WA470-7
4) Remove bearing (24) from 1st clutch gear

(23).
9. Washer
50-187

Power train
Remove washer (25).
10.End plate

(31).
1) Using tool B45, press end plate (26).

Assembly of R and 2nd clutch pack assembly
11.Plate, disc, and spring

12.Piston
1) By using bolts [7] (M8 x 1.25), remove piston
(31).
50-188
[R clutch]
1. Bearing
By using tool B43, remove bearing (34).
2. Spacer
WA470-7

Power train
2) Remove bearing (40) from R clutch gear

(39).
2) By using tool B43, remove spacer (36).

5. Plate and bearing
Remove plate (41) and bearing (42).
3. Bearing and plate

Remove bearing (37) and plate (38).
6. End plate
1) By using vise [10] and push tool [11], press
end plate (43).
4. R clutch gear
1) Remove R clutch gear (39).

WA470-7
50-189

Power train
8. Piston
1) By using bolts [12] (M8 x 1.25), remove
piston (48).
2) Remove snap ring (49) to remove lubricating

piston (50) from piston (48).

(48).
50-190
[2nd clutch]
9. Transfer shaft 1
1) Remove transfer shaft 1 (53).
2) Remove inner race (54) from transfer shaft 1

(53).
10.Bearing and hub

1) Remove snap ring (55) and ring (56).
WA470-7

Power train
2) By using tool B46, remove bearing (57) and

hub (58) as a unit.
13.Piston
piston (64).
11.End plate

WA470-7

(64).
Assembly of 3rd and 4th clutch pack assembly

[4th clutch]
1. Bearing
1) By using tool B43, remove bearing (67) and
plate (68).
50-191

Power train
4. End plate
2. Ring, cover, and collar

1) Remove ring (70) and cover (71).

2) Remove collar (72) and seal ring (73).
6. Plate, bearing, and washer

Remove plate (80), bearing (81), and washer
(82).
3. Cylinder assembly
By using bolts (M8 x 1.25) remove cylinder
assembly (74).
7. Piston
piston (83).
50-192
WA470-7

Power train
[3rd clutch]
9. Bearing, spacer, and plate
a Stick tapes, etc. to bearing sliding surface
(a) of the shaft for protection.
2) Remove spacer (90).

(83).
3) Remove spacers (91) and (92).
8. 4th gear
1) Remove 4th gear (86).
4) Remove bearing (93) and plate (94).
2) Remove plate (87) and bearing (88) from 4th

gear (86).
10.3rd gear
1) Remove 3rd gear (95).
WA470-7
50-193

Power train
2) Remove bearing (96) from 3rd gear (95).
13.Piston
1) Remove piston (102).
11.End plate

50-194
2) Remove seal rings (103) and (104) from

piston (102).
14.Plate, bearing, and washer

Remove plate (105), bearing (106), and washer
(107).
WA470-7

Power train
2) Using tool B47, fit seal rings (103) and (104)

to piston (102).
a Leave it for 2 to 3 minutes as it is.
Assembly
(WA470-CF60-720-K-00-A)
a Clean all parts and check them for dirt or

damage before assembling.
a Press-fit the inner race of each bearing until it
reaches to the end face of the shaft.
3) Install piston (102).

2 Seal ring contact surface:
a After installing each bearing, drip at least 6 cc of

power train oil (TO10) to it and rotate it at least
10 turns.
a Check that snap ring is fitted to the groove

securely.
a Immerse the disc in clean power train oil for 2
minutes or longer before assembling it.
a Press fit each bearing so that no clearance is
made between it and its mating parts in the axial
direction.
Assembly of 3rd and 4th clutch pack assembly
[3rd clutch]
Install plate (105), bearing (106), and washer
(107).

Install plate (99), disc (100), and spring (101) in
this order.
a Be careful not to install plate (105) and

washer (107) in the reverse order (The
washer is thinner than the plate).
4. End plate
2) Install snap ring (98).
2. Piston
1) Install seal rings (103) and (104) to piston
(102) as shown in the figure.
WA470-7
a Check that the snap ring is fitted in the

groove securely.
a Check that the end plate is returned to the
snap ring position.
50-195

Power train
a Check that the match marks (numbers)

stamped on the right and left spacers are
the same, and fit them together without
leaving a gap.
2 Spacer (91):
5. 3rd gear
1) Install bearing (96) to 3rd gear (95).
3) By using tool B48, press fit spacer (90).

a When press fitting it, direct the concave
side down.
2) Install 3rd gear (95).
4) Install bearing (89) and plate (87).
6. Bearing, spacer, and plate

1) Install plate (94) and bearing (93).
7. Check of clearance
Move 3rd gear (95) up and down and check that
dimension (a) is in the standard value by using a
dial gauge.
Dimension (a): 0.14 to 1.03 mm
2) Install spacers (92) and (91).
50-196
WA470-7

Power train
[4th clutch]
8. Piston
1) Install seal rings (84) and (85) to piston (83)
as shown in the figure.
2) By using tool B49, fit seal rings (84) and (85)
to piston (83).

Install plate (77), disc (78), and spring (79) in this
order.
11.End plate
groove securely.
3) By using eyebolts [17] (M8 x 1.25), install
piston (83).

snap ring position.

12.4th gear
Install 4th gear (86) to cylinder assembly (74).
Install washer (82), bearing (81), and plate (80).
a When installing plate (80), direct the
protruded side up.
WA470-7
50-197

Power train
13.4th gear and cylinder assembly

1) Install bearing (88) to the shaft.

3 Mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgm}
3) Install ring (70).
2 Both end faces of ring:
2) Install 4th gear and cylinder assembly (108).
15.Bearing
1) By using tool B50, press fit bearing (69).
2 Both end faces of bearing:
14.Ring, cover, and collar
1) Install seal rings (73) and collars (72).
Grease (G2-LI)
2) Install plate (68) and bearing (67).
50-198
WA470-7

Power train

to piston (64).
16.Check of clearance
Move 4th gear (86) up and down and check that
dimension (b) is in the standard value by using a
dial gauge.
Dimension (b): 1.75 to 3.25 mm
3) By using bolts [15] (M8 x 1.25), install piston

(64).
17.Operation check of clutch

By using tool B51, supply compressed air to the
oil hole of the shaft to check that the 3rd and 4th
clutches operate.
a If the gear on the side to which air is supplied
is locked, the operation of the clutch is
normal.

order.
3. End plate
Assembly of R and 2nd clutch pack assembly
[2nd clutch]
1. Piston
WA470-7

groove securely.
50-199

Power train

snap ring position.
6. Transfer shaft 1
4. Hub
Install hub (58).
1) By using tool B53, press fit inner race (54) to

2) Install transfer shaft 1 (53).

5. Bearing
1) By using tool B50, press fit bearing (57).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
2) Install ring (56) and snap ring (55).
[R clutch]
7. Piston
to piston (48).
50-200
WA470-7

Power train
3) Install dowel pin (50a) and lubricating piston

(50) to piston (48).

order.
a Check that it is fitted in the groove

securely.
9. End plate
1) By using vise [10] and push tool [11], press
end plate (43).
groove securely.
snap ring position.
5) By using eyebolts [12] (M8 x 1.25), install

piston (48).
10.Plate and bearing
Install plate (41) and bearing (42).
WA470-7
50-201

Power train
11.R clutch gear

1) Install bearing (40) to R clutch gear (39).
2) Install R clutch gear (39).
14.Bearing
12.Bearing and plate

Move R clutch gear (39) up and down and check
that dimension (c) is in the standard value by
using a dial gauge.
Dimension (c): 0.28 to 0.95 mm
13.Spacer
50-202
WA470-7

Power train

(31).

oil hole of the shaft to check that the R and 2nd
clutches operate.
normal.
Assembly of F and 1st clutch pack assembly

[1st clutch]
1. Piston
to piston (31).

order.
3. End plate
groove securely.
snap ring position.
4. Washer
Install washer (25).
WA470-7
50-203

Power train
5. 1st clutch gear

1) Install bearing (24) to 1st clutch gear (23).
2) Install 1st clutch gear (23).
7. Bearing
8. Check of clearance
Move 1st clutch gear (23) up and down and
check that dimension (d) is in the standard value
by using a dial gauge.
Dimension (d): 0.1 to 1.1 mm
6. Washer and spacer

Install washer (22) and spacer (21).
a When installing spacer (21), direct the
chamfered side up.
[F clutch]
9. Piston
to piston (15).
50-204
WA470-7

Power train
3) Install dowel pin (17a) and lubricating piston

(17) to piston (15).
10.Plate and bearing

a Check that it is fitted in the groove

securely.

order.
12.End plate
(15).
WA470-7

groove securely.
snap ring position.
50-205

Power train
15.Spacer
13.F clutch gear

1) Install bearing (7) and plate (6) to F clutch
gear (5) in this order.
2) Install F clutch gear (5).

16.Bearing
14.Bearing
Install bearing (4).
Move F clutch gear (5) up and down and check
that dimension (e) is in the standard value by
using a dial gauge.
Dimension (e): 0.28 to 0.95 mm
50-206
WA470-7

Power train

oil hole of the shaft to check that the F and 1st
clutches operate.
normal.
WA470-7
50-207

Power train
Removal and installation of front axle assembly

k Place

(WA470-DA20-924-K-00-A)
4 Front tire and rim assembly:

700 kg
k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
6. Disconnect brake hose (4).
(WA470-DA20-520-K-00-A)
1. Start the engine, set the bucket in the dumping

position, raise the machine gradually so that the
front tires are lifted off the ground by
approximately 5 cm.
2. Set stand [1] under the front frame.
7. Remove the mounting bolts to remove front

drive shaft (5). [*2]
a Make matchmarks on the coupling and drive
3. Remove front cover (2) of the front frame.
8. Sling front axle assembly, and set jack [2] under

the the assembly.
4. Sling the front tire and rim assembly (3) by using
the belt sling.
5. Remove the mounting bolts to remove the front
tire and rim assembly. [*1]
50-208
WA470-7

Power train
9. Remove mounting bolt (6) of the front axle

assembly, and remove front axle assembly (7)
while slowly lowering the jack and hoist. [*3]
4 Front axle assembly (7):
1,300 kg
Installation
(WA470-DA20-720-K-00-A)

removal.
[*1]
3 Mounting bolt of front tire and rim
assembly:
823 to 1,029 Nm {84 to 105 kgm}
[*2]
3 Drive shaft mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
[*3]
3 Mounting bolts of front axle assembly:
1,617 167 Nm {165 17 kgm}
Air bleeding
Bleed air from the brake circuit. For details, see
brake circuit".
WA470-7
50-209

Power train
Removal and installation of rear axle assembly

k Place

(WA470-DAC0-924-K-00-A)
6. Set jack [3] under the counterweight to support

the rear frame end.
k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA470-DAC0-520-K-00-A)
1. Remove full-length fenders on the right and left

sides. For details, see "Removal and installation
of full-length fender assembly".
2. Place block [1] between the right and left rear
axles and rear frame.
3. Start the engine, set the bucket in the dumping

position, raise the machine gradually so that
front tires are lifted off the ground.
4. Place stand [2] under the rear frame.
7. Wind the rear tire and rim assembly (3) with the
belt sling, and sling them.
8. Remove the mounting bolts, and remove the
rear tire and rim assembly (3). [*1]
4 Rear tire and rim assembly:
700 kg
9. Remove the fuel tank assembly. For details, see

"Removal and installation of fuel tank assembly".
10.Remove cover (4) on left side.
11.Disconnect connector R60 (5) and clamp (5a).

5. Tilt the bucket slowly to lower the front tires to
the ground thoroughly, and raise the rear tires
above the ground.
50-210
WA470-7

Power train
12.Disconnect clamps (6) (2 places).

a Another is in the upper part of the figure.
16.Disconnect rear drive shaft (12). [*2]

13.Disconnect grease tubes (7) and (8).

17.Remove cover (13a).
14.Remove step (9) on the right side.

18.Remove emergency steering relay (13).
a Otherwise the mounting bolt on the rear left
side of the rear axle is not removed.
15.Disconnect brake hoses (10) and (11).
WA470-7
50-211

Power train
4 Rear axle and support assembly:

1,500 kg
19.Sling the rear axle assembly, and set jack [4]

under rear support (14).
20.Remove mounting nuts (15) on the right and left
sides of the rear support. [*3]
24.Sling one side of the rear axle assembly with a

crane and support the opposite side by using
pallet jack [6], forklift, etc.
25.Pull out the rear axle and rear support assembly
(16) in a lateral direction of the machine. Sling
the rear axle and rear support assembly (16)
again to install them stably.
21.Fix rear supports (14) on the right and left sides

of rear axle assembly (15) by using lever block
[5].
a This prevents the rear support from rotating
during removal.
22.Pull out the rear axle assembly and rear support

together as a unit toward the rear of the machine
by using the jack and crane.
26.Remove retainer (18) of front support (17) on the

machine body side. [*4]
a Pull them out until the supporting portion at

the front of the rear axle is removed from the
front support.
23.Remove the rear axle and rear support
assembly (16) while slowly lowering the jack and
crane.
50-212
WA470-7

Power train
30.Remove thrust washer (23) from the rear

support.
31.Remove the mounting bolt to remove thrust
plate (24) and thrust washer (23). [*8]
32.Remove rear support (14).
4 Rear support: 150 kg
33.Remove packing (25) and bushing (26) from the
rear support. [*9]
27.Remove packing (19) from retainer (18). [*5]
Installation
28.Remove packing (20) and bushing (21) from the

front support. [*6]
(WA470-DAC0-720-K-00-A)

removal.
[*1]
3 Mounting bolt of rear tire and rim
assembly:
823 to 1,029 Nm {84 to 105 kgm}
[*2]
3 Rear drive shaft mounting bolts:
98 to 123 Nm {10 to 12.5 km}
[*3]
2 Rear axle mounting bolt:
Engine oil
3 Rear axle assembly mounting bolt:
1,180 to 1,470 Nm {120 to 150 kgm}
29.Sling rear support (14), and remove thrust cap

(22). [*7]
[*4]
2 Front support retainer mounting bolt:
Adhesive (LT-2)
3 Front support retainer mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
[*5]
a Securely install packing (19) to the groove with
its lip facing to the machine front.
[*6]
its lip facing to the axle housing side.
WA470-7
50-213

Power train
a Install bush (21) with chamfer (c) facing to the

axle housing side so that clearance (d) is in the
Clearance (d): 0.5 mm
2 Contacting surface of front support
bushing:
Grease (G2-LI)
Air bleeding
brake circuit".
[*7]
2 Thrust cap mounting bolt:
Adhesive (LT-2)
3 Thrust cap mounting bolt:
245 to 308 Nm {25 to 31.5 kgm}
[*8]
2 Thrust plate mounting bolt:
Adhesive (LT-2)
3 Thrust plate mounting bolt:
245 to 308 Nm {25 to 31.5 kgm}
[*9]
its lip facing to the axle housing side.
a Install bush (26) with chamfer (a) facing to the
axle housing side so that clearance (b) is in the
Clearance (d): 0.5 mm
2 Contacting surface of support bushing:
Grease (G2-LI)
50-214
WA470-7

Power train
Disassembly and assembly of axle housing assembly
(WA470-DA04-924-K-00-A)
Symbol
D16
2
1
2
3
4
5
D17 6
7
8
9
10
11
1
D18 2
3
D19
D20
1
D21
2
1
D22
2
D23
D24
D25
Part No.
Commercially
available
790-201-1410
793T-622-2520
790-101-2520
791-112-1180
790-101-2540
790-101-2620
790-101-2570
790-101-2560
790-101-2740
790-201-1410
790-101-2102
790-101-1102
790-101-2800
793T-622-2530
01643-32060
793T-622-2540
793T-622-2550
793T-622-1330
793T-622-1340
793T-622-1370
01010-50830
793T-622-2510
793T-622-1510
79A-264-0021
Part name
Necessity
Q'ty
a Special tools
Puller
q 1
Plate
Block
Screw
Nut
Washer
Leg
Plate
Nut
Adapter
Plate
Puller assembly
Hydraulic pump
Bearing puller
Bolt
Washer
Spacer
Spacer
Push tool
Spacer
Support
Bolt
Spacer
Holder
Push-pull scale
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
q
q
t
t
t
t
t
t
q
1
1
1
1
2
4
2
2
1
1
1
1
2
2
1
1
1
1
2
6
1
1
1
a The following photos and illustrations show the

front axle housing as an example.
a The front and rear axle housings have different
appearance but have the same internal
structure.
Disassembly
(WA470-DA04-520-K-00-A)
1. Draining oil
Remove oil plug (1) to drain oil.
2. Axle assembly
Place the axle assembly on blocks [1].
a Set blocks [1] so that the assembly does not
lean when one axle housing assembly is
removed.
3. Axle housing assembly

1) Sling axle housing assembly (8), and remove
the housing mounting bolts.
a When removing both right and left axle
housing assemblies, put a match mark on
each housing and the differential case to
prevent confusion.
2) Remove axle housing assembly (8).
4 Axle housing assembly:
280 kg
6 Axle oil
Front axle: 57l
l
Rear axle: 56l
l
WA470-7
50-215

Power train
3) Change the sling application position and set

axle housing assembly (8) straight up.
4. Planetary carrier assembly:

1) Remove axle shaft mounting bolt (9), and
sling and remove planetary carrier assembly
(10).
a Be careful not to damage washer (9a).
5. Ring gear
By using tool D16, pull up ring gear (12) evenly
to remove it from axle housing assembly (13).
a Install a plate to the bolt end at the center of
tool D16 to adjust the height of the bolt.
a Be careful that the hooks of tool D16 do not
come off the ring gear.
4 Planetary carrier assembly:

65 kg
6. Axle shaft
1) Set axle housing (14) so that it does not fall
down.
2) By using tool D17, push down axle shaft (15),
and separate it from bearing (26).
3) Sling axle housing (14).

a Note the thickness of shims for assembly
purpose.
50-216
WA470-7

Power train
8. Axle housing
Remove outer races (18) and (19) from axle
housing (14).
7. Axle shaft bearing

k Do
not heat or flame-cut the bearing to

remove it.
1) Install bolts (b) to bolt holes (a) of tool D18.
1) Drive spring pin (21) of the planetary carrier
into shaft (20) so that the pin does not
protrude from in shaft (22).
a Be careful not to drive in spring pin (21)
insufficiently.
a After driving in, rotate the gear and check
that shaft (22) rotates.
2) Install tool D18 to the bottom of bearing (16)

and fix it securely.
3) Insert washers (c) between bolts (c) and
flange face.
4) Loosen bolts (b), and remove bearing (16).
5) Remove oil seal (17).
2) Pull out shaft (22) by using a press.
3) Pull out spring pin (21) from removed shaft
(22).
WA470-7
50-217

Power train
Assembly
(WA470-DA04-720-K-00-A)
1. Axle housing
1) By using tool D19, press fit outer race (18) to
axle housing (14).
4) Remove planetary gear (23), holder (24), and

washer (9a) from planetary carrier (20).
2) By using tool D20, press fit outer race (19) to

axle housing (14).
5) Remove bearing (25) from planetary gear

(23).
50-218
WA470-7

Power train
2. Axle shaft
1) By using tool D21, press fit oil seal (17) and
bearing (16) simultaneously to axle shaft
(15).
a Press fit until oil seal sleeve (17a) is flush
with face "d" of the axle shaft and check
that there is no gap to bearing (16).
3. Axle housing and shaft

1) Install tool D22-1 under oil seal (17).
a Adjust tool D22-2 so that the top face of
tool 22-1 touches oil seal (17) lightly and
an even clearance is made between
them.
2 Press-fit portion of oil seal and

bearing:
Axle oil
2 Oil seal lip:
Grease (G2-LI)
a Apply a grease evenly without surge to
opposite side (P part) of oil seal rip.
a Apply to 40 to 60 % of the total volume of
the lip space uniformly.
2) Sling axle housing (14) horizontally and
lower it slowly while positioning it to oil seal
(17) described above.
a Insert the axle housing by utilizing its
weight.
a After installing the axle housing, leave
tool D22 installed until step 3).
3) By using tool D23, press fit bearing (26) to
axle shaft (15).
WA470-7
50-219

Power train
2 Bearing roller part:

Axle oil
Rear axle:
28.4 to 54.9 N {2.9 to 5.6 kg}
Press-fitting force of bearing (26): 32.36

3.24 kN (3,300 330 kg)
4) Remove tool D22-2 described above and pull

out tool D22-1 horizontally.
a Pull out tool D22-1 while pressing it
against the end face of axle housing (14).
a Check that oil seal (17) is not tilted.
6) If the starting torque is out of the standard

value, perform the following work.
a When starting torque is below standard
value
4. Selection of shims
1) Install planetary carrier (20) to the spline of
axle shaft (15).
2) Install tool D24 and finger-tighten mounting
bolt (9).
a Install planetary carrier (20) without the
gear.
a Remove all adhesive sticking to mounting
bolt (9) and its hole.
3) Tighten mounting bolt (9) while rotating axle
housing (14).
4) Rotate axle housing (14) to fit bearings (16)
and (26) thoroughly.
5) Install tool D25 to hole (h) of axle housing
(14) to measure the starting torque.
Starting torque
Front axle:
30.4 to 57.8 N {3.1 to 5.9 kg}
50-220
1] Remove planetary carrier (20).

2] Press-fit bearing (26) further according to
step 3.-3).
3] Perform steps 1) through 5) and check
that the starting torque is in the standard
value.
a When starting torque is over standard
value
1] Loosen bolt (9) 1 to 2 turns.
2] Sling axle shaft and housing assembly (8)
approximately 20 to 30 mm by 2-point
sling method.
3] While rotating axle shaft (15), hit its
flange several times with a copper
hammer, etc. in the arrow direction to
relieve excessive preload on bearings
(16) and (26).
a TBe careful not to hit axle shaft (15)
too much to avoid damage to oil seal
(17).
Lowering distance of axle shaft
(Reference value): 0.3 mm
WA470-7

Power train
4] Perform steps 3) through 5) and check

that the starting torque is in the standard
value.
2) Install holder (24) and washer (9a) into

planetary carrier (20).
a Thinly apply grease to the mounting face
on the holder side of washer (9a).
2 Planetary carrier side contact
surface of holder (24):
Molybdenum disulfide
(LM-S or LM-P)
3) Install planetary gear (23).
7) By using a depth micrometer, measure

distance H between the end faces of tool
D24 and axle shaft.
8) Subtract thickness (t) of tool D24 from
dimension H and set the result as (H - t) and
determine the shim thickness from it.
Shim thickness (mm) = (H - t) -0.05/0
9) Remove planetary carrier (20).
lubricant
4) Press fit shaft (22) while aligning spring pin

holes (22a) of the shaft and planetary carrier.
2 Shaft:
Axle oil
5) Drive in spring pin (21) until it is flush with
planetary carrier (20) (part j).
1) Install bearing (25) to planetary gear (23).
WA470-7
50-221

Power train
1) Install shims (11) selected in Steps 4 to 8) to

the end face of axle shaft.
6) Tap the end face of shaft (22) and the

differential side of planetary gear (23) to push
back bearing (25). Then, check that
planetary gear (23) rotates smoothly.
2) Install planetary carrier assembly (10).

3) Tighten mounting bolts (9).
a Before starting the above work, be sure to
degrease and clean axle shaft bolt
mounting holes and mounting bolts.
a Before installation, clean the shaft end
face and the spline of planetary carrier.
k When
installing planetary carrier

assembly (10), take extreme care not
to get your fingers caught in the gear,
etc.
6. Ring gear
1) Press fit ring gear (12) to axle housing (14).
a When installing ring gear (12), direct its
chamfered side down and align its pin
holes with those of axle housing (14).
a Press fit ring gear (12) horizontally, while
taking care not to slant it.
2) Insert pins (12a) (6 pieces).
a When inserting them, take care not to hit
ring gear (12).
2 End face of planetary carrier

assembly (10) (bearing contact
surface):
(LM-S or LM-P)
lubricant
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
Front axle:
824 to 1,030 Nm {84 to 105 kgm}
Rear axle:
662 to 829 Nm {67.5 to 84.5 kgm}
7. Planetary carrier assembly:
50-222
WA470-7

Power train
4) Rotate axle housing (14) to fit the bearings

thoroughly.
5) Install tool D25 to hole (h) of axle housing
(14) to measure the starting torque.
Starting torque
Front axle:
30.4 to 115.6 N {3.1 to 11.8 kg}
Rear axle:
28.4 to 129.3 N {2.9 to 13.2 kg}
a If the starting torque is out of the standard
value, perform adjustment again from
Step 4.-6).
6) Install dial gauge [4] to axle housing (14) and
check that the planetary carrier has no end
play in its end face.
3) Install guide bolt [5].

4) Sling axle assembly (8) horizontally and
install it slowly, while aligning it with the
spline groove and guide bolts [5].
a Be careful not to damage the brake piston
surface and plate surface when installing
the assembly.
5) Tighten the mounting bolts in diagonal order.
3 Housing mounting bolt:
490 to 608 Nm {50 to 62 kgm}

1) Degrease and clean the mounting faces of
axle housing (14) and differential housing.
2) Apply liquid gasket (A) without a break.
a Apply liquid gasket at the center of mating
surface in the drawing.
2 Housing mating surface:
Liquid gasket (Locktite 515)
9. Refilling of oil
1) Tighten drain plug (1) and add oil to the
specified level through the oil filler port.
5 Axle oil
Front axle: 57 l
Rear axle: 56 l
WA470-7
50-223

Power train
2) Check the oil level by using oil filler port/ oil

level gauge (1-1).
50-224
WA470-7

Power train
Disassembly and assembly of differential assembly

a Special tools
2. Oil temperature sensor (rear differential)
Part No.
1 790-501-5000
2 790-901-2110
3 790T-901-3440
D2
793T-622-2570
D3
790-201-2730
1 793T-615-1730
D4
2 790-201-2770
1 790-201-2780
D5
2 793T-623-1210
1 796-765-1110
D6
2 790-201-2750
1 796-765-1110
D7
2 792T-413-1120
D8
79A-264-0021
1 793T-622-1310
D9 2 790-101-5421
3 01010-51240
1 793T-622-1310
2 793T-622-1320
D10
3 790-101-5421
4 01010-51240
D11 793T-622-1360
1 793T-622-2560
D12
2 01316-10616
D13 793T-615-1730
799-101-5230
1
07002-11423
D14
2 793-605-1001
3 790-101-1102
D15
799-301-1500
D25 79A-264-0021
D1
Part name
Unit repair stand
Bracket
Plate
Eyebolt
Spacer
Spacer (F)
Spacer (R)
Spacer (F)
Spacer (R)
Push tool
Spacer
Push tool (F)
Push tool (R)
Push-pull scale
Push tool
Grip
Bolt
Push tool
Spacer
Grip
Bolt
Push tool
Wrench
Bolt
Spacer
Adapter
O-ring
Brake tester
Hydraulic pump
Oil leak tester kit
Push - pull scale
Necessity
Q'ty
Symbol
q
q
q
t
q
q
q
q
q
t
t
t
t
q
t
t
t
t
t
t
t
t
t
t
q
t
t
t
t
t
q
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
(F): For front differential

(R): For rear differential
Disassembly
(WA470-DC10-924-K-00-A)
(WA470-DC10-520-K-00-A)
a Photos and illustrations, except those which

indicate the component name, show the front
differential.

2) Disconnect connector (4) and remove oil
temperature sensor (5).
3. Rear support (rear differential)
Remove rear support (6). For details, see
"Removal and installation of rear axle assembly".

Remove the right and left axle housing
assemblies. For details, see "Disassembly and
assembly of axle housing assembly".
5. Differential assembly
Place differential assembly (7) on blocks [1] and
stabilize it. (Or install it to tool D1.)
a When using tool D1, remove the cage
assembly referring to Step 8.
6. Cover
Remove cover (8).
a The front and rear differentials have different

external appearance and shape but have the
same internal structure.
1. Brake piping
1) Remove tube (1).
2) Remove slack adjuster (2). (Front differential)
a The slack adjuster of the rear differential
is installed to the rear frame.
WA470-7
50-225

Power train
7. Brake
1) Remove sun gear shaft (9).
2) Remove bolts (10) and remove outer plate
(11).
3) Remove plates (12), wave springs (13) and
discs (14).
a Put a mark on them to avoid confusion
between the right and left side parts.
8. Cage assembly
1) Sling the differential case, and set it with
cage assembly (20) up.
2) Remove mounting bolts (21).
a Put a match mark on the cage and
differential case for assembly purpose.
3) Tighten the forcing screws to raise cage
assembly (20) until you can see the O-ring.
4) By using tool D2, remove cage assembly

(20).
4 Cage assembly:
60 kg
4) Supply air into brake oil port (15), and

remove piston (16).
50-226
WA470-7

Power train
3) Remove all the mounting bolts of bearing

carrier (24) and install guide bolts [3].
4) Tighten forcing screws [4] to remove bearing
carrier (24).
a Make bearing carriers on the right and left
sides identifiable to prevent confusion.
a Note the thickness and number of shims
used for assembly purpose.

a Note the number of shims used for
assembly purpose.
5) Remove outer race (24a) and seals (24b)

and (24c) from bearing carrier (24).
9. Bearing carrier
1) Set the differential case so that the mounting
face of the cover removed in step 6 is up.
2) Sling differential carrier assembly (23).
a The figure shows the limited slip
differential specification.)
10.Differential carrier assembly
1) Remove differential carrier assembly (23)
from differential case (25).
a Be careful that the sling does not come
off.
WA470-7
50-227

Power train
a The figure shows the limited slip

differential specification.
4 Differential carrier assembly:
110 kg
3) Remove washer (64) and side gear (65).

4) Remove spider shaft (66) and pinion gear
(67) together as a unit.
2) Remove gear cover (26) from the differential

case.
5) Remove spherical washer (68), pinion gear

(67), and bushing (69) from spider shaft (66).
11.Disassembly of differential carrier assembly

(Conventional differential specification)
1) Remove case (62).
6) Remove side gear (70) and washer (71) from

case (72).
2) Remove bearing (63) from case (62).
50-228
WA470-7

Power train
7) Remove bevel gear (73) and bearing (74)

from case (72).
12.Disassembly of differential carrier assembly

(Limited slip differential specification)
2) Remove bearing (27) from cover (28).
3) Remove plates (31) (2 pieces) and discs (32)

(2 pieces).
a Identify parts on the right and left sides to

prevent confusion.
1) Remove cover (28) and bearing (27) together
as a unit.
a Put a match mark on cover (28) and case
(29) for assembly purpose.
4) Remove pressure ring (33) and side gear

(34).
a Washer (30) is attached to back side

groove of removed cover (28).
WA470-7
50-229

Power train
5) Remove pinion (35) and spider shaft (36).
6) Remove side gear (37) and pressure ring

(38).
13.Pinion and cage

1) Remove mounting bolts (17) to remove
holder (17a).
2) Remove coupling (19) and protector (18)
together.
a Do not remove protector (18) from
coupling (19) except when necessary.
3) Remove O-ring (19a).
7) Remove discs (39) (2 pieces) and plates (40)

(2 pieces).
8) Remove washer (41).
4) By using tool D3 and a press, pull pinion

gear (45) out of cage (44).
5) Remove dust seal (49), oil seal (50), bearing
(46), and outer races (47) and (48) from cage
(44).
9) Turn over case (29), and remove bolts (42) to

remove bevel gear (43) and bearing (29a).
6) Remove bearing inner race (52) from pinion

gear (45).
50-230
WA470-7

Power train
a After press-fitting the bearing, check that

there is no clearance between it and
pinion.
Assembly
(WA470-DC10-720-K-00-A)
1. Pinion and cage

1) By using tool D4, press-fit outer race (47) to
cage (44).
a After press-fitting the outer race, check
that there is no clearance between it and
cage.
4) Set pinion gear (45) upright and install cage

(44).
5) By using tool D7, press-fit bearing (46) to
pinion (45) while rotating cage (44).
Press-fitting force of bearing (26): 24.5 to
29.4 kN {2,500 to 3,000 kg}
3 Bearings (46) and (52):
Axle oil
2) By using tool D5, press-fit outer race (48) to

cage (44).
a After press-fitting the outer race, check
that there is no clearance between it and
cage.
6)
7)
8)
9)
Install protector (18) to coupling (19).

Install coupling (19) to pinion gear (45).
Measure thickness (h) of holder (17a).
Install holder (17a), and tighten bolt (17)
lightly.
3 Bolt (17):
117.6 Nm {12 kgm}

10)Insert the depth gauge to hole (A) for shim
adjustment, and measure dimension (j) from
the end face of holder (17a) to the end face
of pinion gear (45).
11)Calculate clearance (k) between holder (17a)
and pinion gear (45), and record it.
3) By using tool D6, press-fit bearing (52) to
pinion (45).
WA470-7
Clearance (k) = dimension (j) - thickness

(h)
12)Remove bolt (17), holder (17a) and coupling
(19), and then release the pre-load of
bearing.
50-231

Power train
a Select thickness of shims (45a) based on

clearance (k) calculated in Step 11).
Shim thickness (t) = clearance (k) +
0.07
Set shim thickness (mm): 0.15, 0.18,
0.2, 0.5mm
17)Install coupling (19) and holder (17a), then
tighten bolt (17).
13)Install tool D25 to hole (B) of cage (44) to

measure the starting torque.
Starting torque (at release): Max. 13.6 N
{1.4 kg}
3 Bolt (17):
824 to 1030 Nm {84 to 105 kgm}
18)Rotate cage (44) clockwise and
counterclockwise 10 turns or more each.
19)Install tool D25 to hole (B) of cage (44) to
measure the starting torque.
Starting torque (front differential):
13.6 to 45.4 N {1.4 to 4.7 kg}
Starting torque (rear differential):
13.6 to 59.7 N {1.4 to 6.1 kg}
20)If the starting torque is out of the standard
value, adjust shim (45a) thickness and
repeat Steps 17) to 19).
a Check that the starting torque is in the
standard value.
a Variation of the starting torque per 0.01
mm of shim thickness is as follows.
14)If the starting torque exceeds the standard

value, hit the end face of pinion gear (45)
with a copper hammer, etc. in the arrow
direction to relieve excessive pre-load of
bearing.
Front differential: 8.8 N {0.88 kg}

Rear differential: 12.2 N {1.22 kg}
21)After checking that the starting torque is in
the standard value, remove bolt (17), holder
(17a), shim (45a) and coupling (19).
22)By using tool D9, press fit oil seal (50) to

cage (44).
15)Perform Step 13) again and check that the
starting torque is in the standard value.
16)Install shim (45a).
a Press so that dimension C is 14 0.5

mm.
2 Oil seal lip:
Grease (G2-LI)
a Apply a grease evenly without surge to
opposite side (P part) of oil seal rip.
50-232
WA470-7

Power train
2 Bolt (17):
Adhesive (LT-2)
3 Bolt (17):
824 to 1,030 Nm {84 to 105 kgm}
2) Install plug (17b).
3. Assembly of differential carrier assembly

(Limited slip differential specification)
23)By using tool D10, press fit dust seal (49) to

cage (44).
2 Dust seal lip:
a Assemble parts of right and left cases

referring to identification marks made in
disassembly.
1) By using tool D11, press fit bearing (29a) to
case (29).
cover (28).
Grease (G2-LI)
2. Coupling
1) Install coupling (19), O-ring (19a), shim (45a),
and holder (17a) to pinion gear (45), and
tighten bolt (17).
3) Place bevel gear (43) on blocks [6] with its

gear side down.
4) Install guide bolts [7] to bevel gear (43).
5) Sling case (29) down and install it to bevel
gear (43), then tighten bevel gear mounting
bolts (42).
a Be careful not to damage the seal when

installing coupling (19).
2 Mounting bolt:
2 Bearing side end face of coupling

(19):
3 Mounting bolt:
(LM-S or LM-P)
WA470-7
lubricant
Adhesive (LT-2)
245 to 309 Nm {25 to 31.5 kgm}
50-233

Power train
7) Install pressure ring (38) and side gear (37).
6) Turn over case (29), and install washer (41),

plate (40), and disc (39) in this order.
8) Install pinion gear (35) and spider shaft (36).
a When installing the disc, positions of

notches (a) and (b) must be aligned.
a Since the disc has different thickness
depending on the differential, see the
following when installing it.
Front differential
Outside diameter: 198 mm, thickness: 3.6
mm
Rear differential
Outside diameter: 185 mm, thickness 3.2
mm
2 Plate and disc:
9) Install side gear (34) and pressure ring (33).
Axle oil
10)Install disc (32) and plate (31) in this order.

a For the installation procedure, see step
6).
50-234
WA470-7

Power train
11)Adjust clearance (g) between cover (28) and

plate (31).
1] By using depth gauge [11], measure
dimension (d) between end faces of case
(29) and plate (31) while applying a load
of 686 N {70 kg}.
2] Measure dimension (f) from the end face
of cover (28) to the flange.
3] Calculate clearance (g) by the following
expression and check that it is in the
standard value.
Clearance (g) = d f = 0.2 to 0.75 mm
4] When clearance (g) is out of the standard
value, select the thickness of plate (31) to
set the clearance in the standard value.
a In order to keep the same plate
thickness (sum of 2 plates) on the
right and left sides, replace them at
the same time. Then, install them
according to the preceding procedure
from step 7).
12)Install washer (30) to cover (28).

a Apply a thin film of grease to the washer
and attach it to the cover.
Types of shim thickness: 3.1 mm and

3.2 mm
13)Install bearing (27) and cover (28) together

to case (29).
a When installing, align the match marks
made during disassembly.
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
WA470-7
50-235

Power train
1] Install sun gear shafts (9) to the right and

left sides of the differential carrier
assembly.
2] Fix the sun gear shaft on one side.
3] Install tool D12 and torque wrench [12] to
the other sun gear shaft to measure the
rotating torque.
a When measuring, keep the differential
case rotating freely.
14)Adjusting clearance in axial direction of the

side gear.
1] By using a feeler gauge, measure
clearances (e1) and (e2) between the
side gears (34) and (37) and washers
(30) and (41) respectively through the
right and left shaft hole of the limited slip
differential.
Clearances (e1) and (e2)
Front differential:
0.2 to 0.4 mm
Rear differential:
0.15 to 0.35 mm
2] If the differential assembly is placed
vertically as shown in the figure,
clearance (e1) becomes zero.
Accordingly, measure clearance (e2).
Clearance (e2): 0.4 to 0.8 mm
3] When clearances (e1) and (e2) are out of
the standard value, select the washer
thickness to set the clearances within the
standard value.
a When replacing the washer, install it
according to the same procedure as
the preceding steps 6) and after.
Types of shim thickness: 4.0 mm and
4.1 mm
Rotating torque
Front differential:
Max. 15 Nm {1.5 kgm}
Rear differential:
Max. 10 Nm {1.0 kgm}
4] If the rotating torque exceeds the
standard value, disassemble the
differential carrier assembly again and
repeat the preceding steps 12) and 15).
4. Assembly of differential carrier assembly

(Conventional differential specification)
case (72).
2) Install bevel gear (73) to case (72).
2 Bevel gear mounting bolt:
Adhesive (LT-2)
3 Bevel gear mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}
15)Measure the differential torque under no

load.
3) Install washer (71) and side gear (70) to case
(72).
50-236
WA470-7

Power train
4) Install bushing (69), pinion gear (67), and

spherical washer (68) to spider shaft (66).
8) Install case (62).

3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
5) Install pinion gear (67) and spider shaft (66)

as a unit.
6) Install side gear (65) and washer (64).
5. Gear cover
Install gear cover (26) to the differential case.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}

case (62).
6. Shim adjustment of bearing carrier

1) Sling differential carrier assembly (23) and
set it to its installed position in differential
case (25).
WA470-7
50-237

Power train
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
2) By using tool D13, press fit outer races (24a)

to the right and left bearing carriers (24).
3) Install seals (24b) and (24c) to the bearing
carrier.
6) Rotate the bevel gear at least 10 turns each

clockwise and counterclockwise to fit it.
7) By using tool D8 or a spring scale, measure
the starting torque of the bevel gear.
a Measure at the maximum diameter
position of the bevel gear.
Starting torque:
Front differential:
19.6 to 27.4 N {2.0 to 2.8 kg}
Rear differential:
21.6 to 30.4 N {2.2 to 3.1 kg}
4) Install guide bolts [3] to the right and left

bearing carrier mounting holes of the
differential case.
a If the starting torque is out of the standard

value, adjust it by increasing or
decreasing the shim thickness.
a Thickness of shims on each side must be
0.3 to 1.25 mm.
Set shim thickness:
0.05 mm, 0.2 mm, 0.3 mm, 0.8 mm
5) Install the right and left bearing carriers (24)

together with a shim (80).
a Select a proper shim, referring to the
thickness and quantity of the shims on
the right and left sides checked during
disassembly.
7. Cage assembly
1) Fit O-ring (20a) in the groove of cage
assembly (20).
a Rotate the bevel gear when tightening

them.
2 O-ring:
2 Bearing: Axle oil
a Thinly apply oil.
50-238
Axle oil or grease (G2LI)
WA470-7

Power train
2) Install guide bolts [6] to differential case (25).

3) Install standard shims (22) (of the quantity
and thickness checked during disassembly).
a Set the thinner shims on the cage side.
a Determine the final quantity and
thickness of the shims after adjusting the
backlash in step 8 and checking the
contacts in step 9.
4) By using tool D2, install cage assembly (20).
3 Mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}
8. Adjusting backlash
1) Using dial gauge [7], measure the backlash
of bevel gear.
a Measure the backlash at 3 points on the
periphery of the bevel gear and check
that the dispersion of the measured
values is 0.1 mm or less.
Standard backlash: 0.30 to 0.41 mm
2) If the backlash is out of the standard value,

adjust the shims according to the following
procedure.
a Moving of shims must not vary the sum of
thicknesses of the right and left shims.
a If the backlash is over the standard value,
move a part of shims (a) to shims (b).
a If the backlash is below the standard
value, move a part of shims (b) to shims
(a).
9. Checking tooth contact

1) Thinly apply red lead to the tooth surface of
the pinion gear, then rotate the bevel gear
back and forth to check the tooth contact
patterns left on the bevel gear.
2) Center of tooth contact must be at the
midportion of tooth height and must also be
at approximately 33% (x) position of tooth
length measured from the small end (C). The
width of the tooth contact must be 30 to 60%
(y) of the tooth length. And check that tooth
tip (A), dedendum (B), small end (C) and
large end (D) are all not exposed to strong
contact.
a If the differential is adjusted in this way,
correct tooth contact is ensured when the
load is applied.
WA470-7
50-239

Power train
10.Adjusting tooth contact

If no correct tooth contact pattern is found in the
testing, adjust it according to the following
procedure.
a Adjustment is done by increasing or
decreasing shims (a) and (b) (to move the
bevel gear) and increasing or decreasing
shims (d) (to move the pinion gear).
When the pinion gear is too close to the bevel

gear
a Tooth contact pattern is as shown in the
figure.
1) Increase shims (d) to move the pinion gear in
direction (E).
2) Adjust shims (a) and (b) to move the bevel
gear in direction (F).
a In order not to change the preload of the

bearing, do not change the total thickness of
shims (a) and (b).
a After adjusting tooth contact, check the
backlash again.
When the bevel gear is too close to the pinion

gear
When the pinion is too far from the bevel gear

figure.

figure.
1) Decrease shims (d) to move the pinion gear
in direction (C).
gear in direction (D).
1) Decrease shims (d) to move the pinion gear

in direction (C).
gear in direction (D).
50-240
WA470-7

Power train
When the bevel gear is too far from the pinion

gear
figure.
1) Increase shims (d) to move the pinion gear in
direction (E).
gear in direction (F).
a Leave the pressure at 4.9 MPa {50 kg/

cm2} for 5 minutes and check that
pressure drop is 0.1 MPa {1.0 kg/cm2} or
less.
a If oil leakage is detected, remove the
brake piston and check the O-ring and
seal for any damage. Then install them
again.
11.Brake
1) Install the seal to piston (16), and install the
piston to the differential and carrier
assembly.
a (15) is the brake oil port.
2 Seal:
Grease (G2-LI)
5) Install disc (12), wave spring (13), and plate

(14) in this order.
a When installing disc (12), positions of
holes (H) (6 places) must be aligned.
a When installing wave spring (13), set cuts
(a) at intervals of 120 degrees.
2) Install tool D14 to brake oil port (15) of

differential case (25) and bleed air from the
cylinder.
3) Operate tool D14 to increase the pressure to
1.4 MPa {14 kg/cm2}}.
a If the wave spring is installed in the same

direction, their returning force is uneven.
Take care.
a Leave the pressure at 1.4 MPa {14 kg/

cm2} for 5 minutes and check that
pressure drop is 0.3 MPa {3.5 kg/cm2} or
less.
4) If oil leakage is not found in the preceding
check, increase the pressure further to 4.9
MPa {50 kg/cm2}.
WA470-7
50-241

Power train
Front differential
6) Install outer plate (11) and sun gear shaft (9),

and tighten mounting bolt (10).
Rear differential
3 Bolt (10):
27 to 34 Nm {2.8 to 3.5 kgm}
7) By using tool D15, supply air to brake oil port

(15) to allow the piston to move smoothly.
12.Cover
Install cover (7) to differential case (8).
a Apply liquid gasket (A) without a break.
a Apply liquid gasket (A) at the center of
mating surface in the drawing.
2 Cover mounting surface:
Liquid gasket (Locktite 515)
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
50-242
13.Axle housing
Install the right and left axle housing assemblies.
For details, see "Disassembly and assembly of
axle housing assembly".
14.Rear support (rear differential)
Install rear support (6). For details, see
"Removal and installation of rear axle assembly".
15.Oil temperature sensor (rear differential)
1) Install oil temperature sensor (5) and connect
connector (4).
2 Threaded portion of oil
temperature sensor:
3 Oil temperature sensor:
29.4 to 49.0 Nm {3 to 5 kgm}
WA470-7

Power train

3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
16.Brake piping
1) Install slack adjuster (2). (Front differential)
2) Install tube (1).
17.Refilling of oil
1) Tighten drain plug (1-2) and add oil to the
specified level through the oil filler port.
5 Axle oil
Front axle: 57 l
Rear axle: 56 l
2) Check the oil level by using oil filler port/ oil

level gauge (1-1).
WA470-7
50-243

Steering system
Steering system
(ALL-F000-001-K-00-A)
Removal and installation of steering valve assembly

Removal
(WA470-F570-520-K-00-A)
(WA470-F570-924-K-00-A)
5. Remove covers (2) and (3).
1. Turn the steering wheel fully to the left.

2. Raise the boom and support it by jack [1].
k Support
the boom securely.
k Place

turn the parking brake switch to ON
position.
k Chock
the wheels.
k Lower

LOCK.
k Turn
the starting switch to OFF position,

and stop the engine.
7. Disconnect hoses (6) to (8) from the steering

valve.
8. Disconnect hose (9) from tube (11).
k Turn


l
4. Remove cover (1) of the front frame.
9. Remove U-bolts (10) (6 places). [*1]

10.Disconnect tubes (11) to (14).
50-244
WA470-7

Steering system

oil level again.
l
Air bleeding
Bleed air from each part. For details, see Testing
and adjusting.
11.Sling steering valve assembly (15).

a Pass lifting tool [2] between the front frame
and operator's cab.
12.Remove the mounting bolt, and remove steering
valve assembly (15) toward the right side of the
machine body.
4 Steering valve assembly (15): 30 kg
Installation
(WA470-F570-720-K-00-A)

removal.
[*1]
3 U-bolt (10):
10.8 to 26.5 Nm {1.1 to 2.7 kgm}
Refilling of oil
WA470-7
50-245

Brake system
Brake system
(ALL-G000-001-K-00-A)
Removal and installation of brake charge valve assembly
(WA470-G2H0-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA470-G2H0-520-K-00-A)

l
2. Remove fender cover (1).
3. Remove covers (2) and (3).
Installation
(WA470-G2H0-720-K-00-A)

removal.
Refilling of oil
oil level again.
4.
5.
6.
7.
Disconnect hose (4).

Remove tubes (5) and (6).
Disconnect hoses (7) to (10).
Remove mounting bolts (3 pieces) from inside of
the machine, and remove brake charge valve
assembly (11).
50-246

l
Air bleeding
brake circuit".
WA470-7

Brake system
Removal and installation of parking brake disc and plate
(WA470-GJ72-924-K-00-A)
Symbol
B 1
Part No.
Part name
793T-607-1550 Bracket
01051-62240 Bolt
01643-32260 Washer
Necessity
Q'ty
a Special tools
t 1
t 1
t 1
k Place

k Set

chock the wheels.
k Lower

LOCK.
6. Remove mounting bolts (6) (2 pieces), and

tighten them alternately into plug mounting part
(a). [*4]
a Remove bolts (6) (2 pieces) on the diagonal
positions.
k Turn
a Piston (7) is pulled back by tightening bolts

(6), then the parking brake is released.
k Turn
a Tighten the bolts (2 pieces) gradually and

evenly.

stop the engine.
Removal
(WA470-GJ72-520-K-00-A)
(Tighten the bolts approximately three turns

after it contacts the seat surface.)
7. Remove remaining bolts (6) (2 pieces). [*4]
8. Among 12 bolts (8), remove all the bolts other
than 2 bolts diagonally installed. [*5]
1. Drain oil from the transmission case.

2. Remove oil filler pipe (1).
3. Remove guard (2) and disconnect center drive
shaft (3) from the transmission.
a Retract the center drive shaft. [*1]
4. Remove coupling (4). [*2]
5. Remove plug (5). [*3]
9. Set jack [1] under cover (9).
WA470-7
50-247

Brake system
10.Install guide bolt [2], and remove the bolts

remained in step 8. [*5]
11.By using forcing screw [3] (M12 x 1.75),
separate cover (9) and piston together as a unit
from housing (10). [*6]
k Remove
cover (9) from guide bolt [2]

while supporting the cover by 2 persons
and slowly lower jack [1].
4 Cover and piston assembly: 35 kg

15.Remove plates (13) (7 pieces), springs (14) (6
pieces), and discs (15) (6 pieces). [*8]
12.To prevent housing (10) from removing,

diagonally install 2 bolts (8) removed in step 8.
13.By using tool B1, push spacer (11) to remove
ring (12).
Installation
(WA470-GJ72-720-K-00-A)

removal.
[*1]
a Tighten drive shaft mounting bolts according to
1. Check that the mating yoke and the seat of the
drive shaft spider are free from rust, foreign
material (masking material), bruise, etc.
2. Set the yoke key slot in the vertical position,
place the drive shaft on the lower part of the
faucet joint portion, and insert the key into the
key slot.
3. Lightly tighten the four upper and lower bolts
until the spider contacts the seat of the yoke.
a Use a plastic (or copper) hammer to tap them
for contacting if fit of keyway portion and
faucet joint is harder. (Do not use a hard
metal hammer since it can damage the cross
bearing)
3 Mounting bolt:
98.1 to 122.6 Nm {10 to 12.5 kgm}
[*2]
14.Install bolts [4] (M8 x 1.25) to the tapped holes
and remove spacer (11). [*7]
50-248
2 Mounting bolt of coupling (4):

Adhesive (LT-2)
WA470-7

Brake system
3 Mounting bolt of coupling (4):

662 to 829 Nm {67.5 to 84.5 kgm}
[*3]
3 Plug (5):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*4]
3 Housing mounting bolt:
98.1 to 122.6 Nm {10 to 12.5 kgm}
[*5]
3 Cover mounting bolts:
98.1 to 122.6 Nm {10 to 12.5 kgm}
[*6]
2 O-ring of piston:
Grease (G2-LI)
[*7]
2 O-ring of spacer:
Grease (G2-LI)
[*8]
a Install plate (13), spring (14) and disc (15) in the
order indicated in the figure.
a Be careful that spring (14) does not get caught.
Refilling of oil
filler port. Run the engine to circulate the oil
through the system. Then check the oil level
again.
WA470-7
50-249

(ALL-DT00-001-K-00-A)
Removal and installation of center hinge pin
(WA470-H1L2-924-K-00-A)
Symbol
Part No.
1 790-101-2300
2 793-520-2370
3 793-520-2350
4 793-520-2540
E
5 793-520-2360
6 791-112-1180
7 790-101-1120
8 790-101-2102
Part name
Push puller
Push tool
Push tool
Guide
Bar
Nut
Hydraulic pump
Puller (30 ton)
Necessity
Q'ty
a Special tools
t
t
t
t
t
t
t
t
1
1
1
1
2
2
1
1
5. Set jack [3] under the counterweight.
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
6. Remove the mounting bolts, and remove front

drive shaft (1). [*1]
(WA470-H1L2-520-K-00-A)
1. Remove the work equipment assembly. For

details, see "Removal and installation of work
equipment assembly".
assembly".
3. After removing the work equipment assembly,
sling the boom foot pin installation part (hole on
the front frame side) by using the belt sling.
4. Support the rear frame (34) by using jack [1] and
put blocks [2] under its right and left to adjust its
height.
7. Remove lock bolt (2a), and remove right and left

pins (2) on the rod side of the steering cylinder.
[*2]
a After removing the pins, retract the piston
rods of the cylinders.
a Record the number and thickness of the
shims on the frame.
50-250
WA470-7

8. Disconnect connectors FR1 (3), FR2 (4), FR3

(5), and FR4 (6).
15.Disconnect hoses (17) to (20) on the front frame

side.
16.Disconnect hose (21) on the front frame side.

11.Remove clamp (8a).
17.Disconnect hoses (22) and (23) from steering

valve (24).

13.Remove clamps (14a) and (15a).
18.Remove lock bolt (25a) and pull out lower hinge

pin (25). [*3]
WA470-7
50-251

19.Remove bolts (26) (4 pieces) and spacer (27).

[*4]
20.Remove bolts (28) (6 pieces) and remove
retainer (29). [*5]
shims between the retainer and frame.
21.Remove plate (30), and pull out upper hinge pin

(31). [*6]
a Adjust the heights of the front and rear
frames by using the jacks so that pins can be
removed by hand.
a Check that all pipings and harnesses are

disconnected.
a Be careful that the lower spacer of the upper
hinge is not caught in the rear frame.
a Slide the crane forward while slinging the
front frame.
24.Remove the mounting bolt from the upper hinge

pin of front frame (33), and remove retainer (36).
[*8]
22.Remove spacer (32).

25.Remove dust seal (37) from retainer (36). [*9]
23.Pull out front frame (33) forward slowly to

disconnect it from rear frame (34). [*7]
a Remove the frame lock bar in advance.
a When disconnecting, be careful of the
balance.
50-252
26.Remove spacer (38) and dust seal (39) from the

lower side of the upper hinge pin of front frame
(33). [*10]
27.Remove bearing (40) from the upper hinge pin
of front frame (33). [*11]
WA470-7

28.Remove bushings (41) on the top and bottom

from the lower hinge of rear frame (34). [*12]
31.Remove dust seal (44) from the lower hinge of

front frame (33), and remove bearing (45). [*15]
29.Remove the mounting bolt from the lower hinge

of front frame (33), and remove retainer (42).
[*13]
Installation

(WA470-H1L2-720-K-00-A)

removal.
[*1]
3 Drive shaft mounting bolts:
98 to 123 Nm {10 to 12.5 kgm}
[*2]
a Adjust clearance (a) and (b) of the mounting
surfaces of the cylinder and frame to the
specified value by using shims.
Clearance (a) and (b): Max. 0.5 mm
a Be sure to provide clearance.
30.Remove dust seal (43) from retainer (42). [*14]
[*8], [*9], [*10], [*11]

WA470-7
50-253

a Assemble the upper hinge pin according to the

1. Install tools E1 to E8 to top of the upper hinge
pin of front frame (33), set bearing (40) on tool
E1, and install it from upper side to press-fit
portion to press-fit.
a When press-fitting it, use tool E4 as a guide.
a Be careful that the bearing does not tilt.
a When replacing bearing (40), replace it as a
set with spacers (32) and (38).
a For spacers (32) and (38), see steps 22 and
26.
between retainer and hinge to the specified

value.
Clearance (d): Max. 0.1 mm (average)
3 Mounting bolt:
20 2 Nm {2 0.2 kgm}
4. After adjustment using shims, tighten every
retainer mounting bolt to the specified torque.
2 Mounting bolt:
Liquid adhesive (Loctite LT-2)
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
2 Inner portion of bearing: Grease (G2LI)
2. Press fit dust seal (37) to retainer (36).

a When press-fitting it, direct dust seal lip
surface outward.
a Insert it to the position 3.2 mm lower than the
top edge surface.
2 Dust seal lip:
Grease (G2-LI)
2 Outer periphery of metal outer ring of
dust seal:
Adhesive (Loctite No. 601)
5. Install dust seal (39) and spacer (38) from the

bottom of front frame (33).
surface outward.
a When installing spacer (38) from the bottom,
direct its larger chamfered-side to bearing.
a Insert dust seal (39) to 1.5 mm below the end
face of boss.
3. Tighten retainer (36) evenly using 3 mounting

bolts. Select shims to adjust clearance (b)
50-254
WA470-7

[*12], [*13], [*14], [*15]

a Install the lower hinge according to the following
procedure.
1. Press fit bearing (45) to front frame (33) with
tools E1 to E8.
a When press-fitting it, use tool E1 as a guide.
a Be careful that the bearing does not tilt.
2 Inner portion of bearing:
Grease (G2-L1)
3. Lightly tighten retainer (42) evenly using 3

mounting bolts. Select shims to adjust clearance
(e) between retainer and hinge to the specified
value.
Clearance (e): Max. 0.1 mm (average)
3 Mounting bolt:
20 2 Nm {2.0 0.2 kgm}
4. After adjustment using shims, tighten every
retainer mounting bolt to the specified torque.
2 Mounting bolt:
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
2. Press fit dust seal (43) to retainer (42).

surface outward.
2 Dust seal lip surface:
Grease (G2-L1)
dust seal:
Liquid adhesive (Loctite 601)
5. Press-fit dust seal (44) from top of front frame.

surface outward.
WA470-7
50-255

2 Dust seal lip:

Grease (G2-L1)
dust seal
Adhesive (Loctite No. 601)
6. Using press, etc., press-fit bushing (41) to lower
hinge of rear frame (34).
3. Install retainer (29) to upper hinge pin (31) using

spacer (27) and mounting bolt (26).
3 Pin mounting bolt (26):
20 2 Nm {2.0 0.2 kgm}
4. Tighten retainer (29) evenly using three
mounting bolts (28). Measure clearance (c)
between hinge and retainer in two places and
calculate the average value to select shims.
[*3], [*4], [*5], [*6], [*7]
Clearance (c): Max. 0.2 mm
a Install the front frame and rear frame according

3 Retainer mounting bolt (28):
k When
aligning mounting holes for the pin,

use a bar and the like. Never insert your
finger into the holes.
a Be sure to align pin holes accurately.

1. Insert upper hinge pin (31) and install spacer
(32).
20 2 Nm {2.0 0.2 kgm}

5. Tighten pin (31), retainer (29), and mounting bolt
(28) to the specified torque.
2 Pin and retainer mounting bolts (26)
and (28):
3 Pin mounting bolt (26):
206 19.6 Nm {21 2 kgm}
3 Retainer mounting bolt (28):
98 to 123 Nm {10 to 12.5 kgm}
2. Install plate (30) by tightening it lightly to prevent

upper hinge pin (31) from removing.
6. Tighten the mounting bolts of plate (30) to the
specified torque.
50-256
WA470-7

7. Insert lower hinge pin (25) and tighten lock bolt

(25a).
WA470-7
50-257

Removal and installation of counterweight assembly
(WA470-H700-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
4. Disconnect connector R20 (10) on the left inside

the rear frame.
a Remove the harness clamp and pull out the
harness toward outside the machine body.
(WA470-H700-520-K-00-A)
1. Open full - fender (1) and side cover (2).

a Open them on the other side in the same
way.
5. Disconnect connector R21 (11) on right inside

the rear frame.
a Remove the harness clamp and pull out the
harness toward the outside the machine
body.
2. Remove cover (3) and plate (4).
way.
6. Remove battery (12).

a Remove it on the other side in the same way.
3. Disconnect terminals (5) and (6), and remove
plates (7) to (9).
4 Battery (12): 50 kg
50-258
WA470-7

10.Remove mounting bolts (2 pieces) and remove

counterweight assembly (16). [*2]
4 Counterweight assembly (16):
1,700 kg
7. Remove mounting bolts (4 pieces) and remove

additional counterweight (13). [*1]
4 Additional counterweight (13): 390 kg
Installation
(WA470-H700-720-K-00-A)

removal.
[*1]
3 Additional counterweight (13) mounting
bolt:
1,520 to 1,912 Nm {155 to 195 kgm}
[*2]
8. Open the grille at the rear of the machine body
and remove pin (14).
3 Counterweight assembly (16) mounting

bolts:
1,520 to 1,912 Nm {155 to 195 kgm}
9. Remove cover (15) at the rear of the fuel tank.
WA470-7
50-259

Removal and installation of full-length fender assembly
(WA470-H560-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA470-H560-520-K-00-A)
1. Open and sling full-length fender assembly (1).

2. Remove mounting bolts (2) (4 pieces) from the
bottom and sling and remove full-length fender
assembly (1).
4 Full-length fender assembly (1): 75 kg
Installation
(WA380-H560-720-K-00-A)
Perform installation in the reverse order to removal.
50-260
WA470-7

Hydraulic system
Hydraulic system
(ALL-C000-001-K-00-A)
Removal and installation of hydraulic tank assembly
(WA470-PM30-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA470-PM30-520-K-00-A)

l
2. Remove full-length fender assembly. For details,
see ""Removal and installation of full-length
fender assembly"".
assembly".
4. Remove cover (1) under the hydraulic tank.
7. Disconnect hoses (7) to (9) on the left side of the

hydraulic tank.
a Remove it on the other side as well.
5. Disconnect hose (2) on the right side of the

hydraulic tank.
WA470-7

9. Remove clamps of harness (11) (2 pieces).
50-261

Hydraulic system
13.Remove mounting bolt of breather (17), remove

all the clamps of hose (18), and move it.
10.Disconnect tubes (12) to (14) from the hydraulic

tank.
14.Remove cover (19) at the top of the hydraulic
tank.

15.Sling the hydraulic tank assembly.
16.Remove mounting bolts (20) (3 pieces) each on
the right and left sides.
12.Sling and remove bracket (16).

4 Bracket (16): 30 kg
17.Sling hydraulic tank assembly (21), and remove
it.
4 Hydraulic tank assembly (21): 280 kg
50-262
WA470-7

Hydraulic system
Installation
(WA470-PM30-720-K-00-A)

removal.
Refilling of oil
oil level again.
l
Air bleeding
Bleed air from the circuit. For details, see Testing
and adjusting, "Bleeding air from work
equipment circuit".
WA470-7
50-263

Hydraulic system
Removal and installation of control valve assembly

Removal
(WA470-R404-924-K-00-A)
(WA470-R404-520-K-00-A)
1. Turn the steering wheel fully to the left.

2. Raise the boom and support it by jack [1].
k Support
the boom securely.
5. Disconnect connectors F25 (2), F24 (3), and

F22 (4). Move the harnesses.
6. Remove bracket (4-1).
k Place

turn the parking brake switch to ON
position.
k Chock
the wheels.
k Lower

LOCK.
k Turn
the starting switch to OFF position,

and stop the engine.
7. Disconnect connectors F26 (5), F20 (6), F23 (7),

and F21 (8). Move the harnesses.
k Turn

see Testing and adjusting, "Handling
k Release
remaining pressure from the area

between the hydraulic cylinders and
control valves and from the ECSS
(Electronically Controlled Suspension
System) circuit. For details, see Testing
and adjusting, "Releasing remaining
pressure from work equipment circuit".

l
4. Remove cover (1) of the front frame.
50-264
WA470-7

Hydraulic system
15.Disconnect tubes (22) and (23). Fix them to the

machine body side by using a rope, etc.
9. Disconnect connector F10 (11).

16.Remove mounting bolts (24) (4 pieces) on the
bottom of the control valve.

17.Sling control valve assembly (25), and remove
it.
4 Control valve assembly (25): 140 kg
12.Remove U-bolts (17) and (18).

14.Remove tubes (20) and (21).
WA470-7
50-265

Hydraulic system
Installation
(WA470-R404-720-K-00-A)

removal.
Refilling of oil
oil level again.
l
Air bleeding
Bleed air from the circuit. For details, see Testing
and adjusting, "Bleeding air from work
equipment circuit".
50-266
WA470-7

Hydraulic system
Removal and installation of steering pump and power train pump

assembly (WA470-C200-924-K-01-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal

11.Disconnect tube (10).
(WA470-C200-520-K-01-A)

l
assembly".
3. Remove hydraulic tank assembly. For details,
assembly".
assembly".
5. Remove tube (1).
12.Disconnect connector R90 (11).
13.Sling steering pump and power train pump

assembly (12) and remove them. [*1]

9. Remove tube (8).
WA470-7

assembly (12):
80 kg
50-267

Hydraulic system
Installation
(WA470-C200-720-K-01-A)

removal.
[*1]
2 Hose insertion portion of tube (1):
3 Hose clamp of tube (1):
8.8 0.5 Nm {0.9 0.05 kgm}
[*2]
3 Mounting bolt of steering pump and
power train pump assembly (12):
235 to 285 Nm {23.5 to 29.5 kgm}
Refilling of oil
oil level again.
l
Air bleeding
Bleed air. For details, see Testing and adjusting,
"Bleeding air from steering cylinder circuit".
50-268
WA470-7

Hydraulic system
Removal and installation of work equipment pump and cooling fan pump
assembly (WA470-C200-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
11.Sling the work equipment pump and cooling fan

pump assembly (10), and remove them. [*2]
fan pump assembly (10):
(WA470-C200-520-K-00-A)

l
assembly".
3. Remove hydraulic tank assembly. For details,
assembly".
assembly".
5. Remove steering pump and power train pump
installation of steering lubrication pump and
power train pump assembly".
6. Remove hose (1). [*1]
7. Disconnect tube (2).
160 kg
Installation
(WA470-C200-720-K-00-A)

removal.
[*1]
8.8 0.5 Nm {0.9 0.05 kgm}
[*2]
3 Mounting bolt of work equipment pump
and cooling fan pump assembly (10):
235 to 285 Nm {23.5 to 29.5 kgm}
9. Disconnect connectors R29 (7) and R71 (8), and

remove the connectors from the brackets.
Refilling of oil
oil level again.
a Remove the harness clamp as well.

WA470-7
50-269

Hydraulic system

l
Air bleeding
Bleed air. For details, see Testing and adjusting,
"Bleeding air from work equipment circuit" and
"Bleeding air from hydraulic fan circuit".
50-270
WA470-7

Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly
Symbol
Part No.
Part name
1 790-502-1003 Cylinder repair stand

2 790-101-1102 Hydraulic pump
Socket (width across
F2
90-302-1280 flats: 55 mm)
1 790-330-1100 Wrench assembly
F3
F4
2 790-102-4310 Pin
1 790-720-1000 Expander
2 796-720-1650 Ring (*1)
F5 3 07281-01029 Clamp (*1)
4 796-720-1680 Ring (*2)
5 07281-01589 Clamp (*2)
1 790-201-1500 Push tool kit
2 790-101-5021 Grip
3 01010-50816 Bolt
F6
4 790-201-1570 Plate
5 790-201-1990 Plate
6 790-201-1660 Plate
1 790-201-1702 Push tool kit
2 790-101-5021 Grip
3 01010-50816 Bolt
F7
4 790-201-1761 Push tool
5 790-201-1930 Push tool
6 790-201-1851 Push tool
F1
Necessity
Q'ty
a Special tools
t 1
t 1
(WA470-PPZ0-924-K-00-A)
3) Pull out cylinder head and piston rod

assembly (3) from cylinder (4), sling them,
and remove them.
a When the piston rod assembly is pulled
out of the cylinder, oil flows out. So
prepare a container to receive the oil.
t 1
t
t
t
t
t
t
t
t
t
t
1
1
1
1
1
1
1
1
1
1
1
1
1
t 1
1
t 1
1
1
1
1
1
4) Set cylinder head and piston rod assembly

(3) on tool F1.
5) By using tool F2, remove nut (5).
a Width across flats of nut: 55 mm
6) Remove piston (6) and remove cylinder head
(2).
*1: For steering cylinder

*2: For lift cylinder and bucket cylinder
Disassembly
(WA470-PPZ0-520-K-00-A)
1. Disassembling cylinder head for steering

cylinder and piston assembly
1) Set cylinder assembly (1) on tool F1.
2) By using tool F3-1 or F3-2, remove cylinder
head (2) from the cylinder.
2. Disassembling lift cylinder, cylinder head for

bucket cylinder, and piston rod assembly
1) Set cylinder assembly (1) on tool F1.
2) Remove mounting bolt of cylinder head (2).
Cylinder
Lift cylinder
Bucket cylinder
WA470-7
Width across flats of bolt

(mm)
27
30
50-271

Hydraulic system
3) Pull out cylinder head and piston rod

assembly (3) from cylinder (4) while slinging
them, and remove them.
a When the piston rod assembly is pulled
out of the cylinder, oil flows out. So
prepare a container to receive the oil.
a If screw (7) is punched securely and hard

to remove, tighten it further once. Then
tap its threaded portion with tap [1] and
remove the screw.
6) By using tool F4, remove piston assembly

(6).
4) Set cylinder head and piston rod assembly
(3) on tool F1.
5) Remove lock screw (7) of the piston
assembly from piston (6).
a When tool F4 is not used, use drilled

holes (p) (10 mm in diameter: 2 places) to
loosen the piston assembly.
7) Remove head assembly (2).
a This screw is for both lift cylinders and

bucket cylinders.
Size: M12 x 1.75
50-272
WA470-7

Hydraulic system
3. Disassembly of piston assembly

[Steering cylinder]
Remove wear ring (8) and piston ring (9) from
piston (6).
[Lift cylinder and bucket cylinder]

1) Remove the O-ring and backup ring (11).
2) Remove snap ring (12) and remove dust seal
(13).
3) Remove rod packing (14).
4) Remove buffer ring (15).
5) Remove snap ring (16a) and remove
bushing (16).

Remove wear ring (8), piston ring (9), the O-ring,
backup ring (10) and ring (10a) from piston (6).
Assembly
(WA470-PPZ0-720-K-00-A)
a Take care not to damage packings, dust seals,

O-rings, etc.
a When installing the backup ring, do not install it
forcibly. Warm it in hot water (temperature is
approximately 50 to 60C), and then install it.
1. Assembly of cylinder head assembly
a When using tool F6 (plate) and F7 (push tool),
refer following.
4. Disassembly of cylinder head assembly
[Steering cylinder]
1) Remove the O-ring and backup ring (11).
2) Remove snap ring (12) and remove dust seal
(13).
3) Remove rod packing (14).
4) Remove buffer ring (15).
5) Remove snap ring (16a) and remove
bushing (16).
6) Remove O-ring (17).
WA470-7
F6-4, F7-4: Steering cylinder

F6-5, F7-5: Lift cylinder
F6-6, F7-6: Bucket cylinder
[Steering cylinder]
1) By using tool F7, press-fit bushing (16) and
install snap ring (16a).
2) Install buffer ring (15).
3) Install rod packing (14).
4) By using tool F6, install dust seal (13) and
secure it with snap ring (12).
5) Install the backup ring and O-ring (11).
6) Install O-ring (17).
50-273

Hydraulic system
2. Assembly of piston assembly

1) By using tool F5-1, expand piston ring (9).
a Set the piston ring to the tool and rotate
the handle 8 to 10 turns to expand the
piston ring.
2) Remove piston ring (9) from tool F5-1 and
install it to piston (6).
3) Compress piston ring (9) by using tool F5.
a When using tool F5 (ring and clamp),
refer following combination.

1) By using tool F7, press-fit bushing (16) and
install snap ring (16a).
2) Install buffer ring (15).
3) Install rod packing (14).
4) By using tool F6, install dust seal (13) and
secure it with snap ring (12).
5) Install the backup ring and O-ring (11).
F5-2, 3: Steering cylinder

F5-4, 5: Bucket cylinder and lift
cylinder
4) Install wear ring (8).
5) Install the backup ring, O-ring (10) and ring
(10a). (Lift cylinder and bucket cylinder)
a When installing the backup ring, do not
install it forcibly but warm it in hot water at
approximately 50 to 60C, and then install
it.
a Steering cylinder is shown below.
50-274
WA470-7

Hydraulic system
5) Sling and install cylinder head and piston rod

assembly (3) to cylinder (4).
6) By using tool F3-1 or F3-2, install cylinder
head (2) to cylinder(4).
3 Cylinder head:
677 67.5 Nm {69 6.9 kgm}
7) Bend the lock of cylinder head (2) toward the
cut-out portion of the cylinder side.
8) Remove cylinder assembly (1) from tool F1.
a Lift cylinder and bucket cylinder are shown

below.
3. Assembly of cylinder head and piston rod for

steering cylinder
1) Set piston rod assembly (3) on tool F1.
2) Install cylinder head (2) and piston (6) to the
piston rod.
3) Install nut (5) and tighten it by using tool F2.
2 Threaded part of piston rod:
Adhesive (Loctite No. 262 and
equivalent)
3 Nut:
1.67 0.17 kNm {170 17 kgm}
(width across flats: 55 mm)
4) Set cylinder (4) to tool F1.
WA470-7
4. Assembly of cylinder head and piston rod for lift

cylinder and bucket cylinder
1) Set piston rod assembly (3) on tool F1.
2) Install head assembly (2).
3) Assemble piston assembly (6) according to

When reusing the rod and piston
assembly (6)
50-275

Hydraulic system
1] Screw in piston assembly (6), and tighten

it until the screw holes are matched by
using tool F4.
a Clean them thoroughly and remove all
chips and dirt.
a Remove burrs and sharp edges from
threaded part by using a file.
2] Make 1 threaded hole for installing screw

(7).
a Drill a hole in horizontal into the Vgroove where piston (6) and the
threads of rod (3) mesh with each
other.
Drilling dimensions (mm)
2] Tighten screw (7).
2 Threaded part of screw:
equivalent)
3 Screw (7):
58.9 to 73.6 Nm {6 to 7.5 kgm}
3] Punch 4 places on the circumference of
the threaded part [2] with a punch.
4] Apply torque of 41.2 to 88.2 Nm {4.2 to 9
kgm} to screw (7) in the direction of
loosening. Check the screw does not
loose.
a Make the hole in following

dimensions.
Tap to be used: M12 x 1.75

Tap drill hole diameter: 10.3 mm
Tap drill hole depth: 27 mm
Tapping depth: 20 mm
3] After making the hole, remove all chips

and dirt, and clean the hole thoroughly.
4] Tighten screw (7).
2 Threaded part of screw:
equivalent)
When either or both of the rod and piston
assembly (5) are new
1] Screw in piston assembly (6) until it
reaches rode end (r), and then tighten it
to the specified torque by using tool F4.
3 Piston assembly (6):
294 29.4 Nm {30 3.0 kgm}
50-276
3 Screw (7):
58.9 to 73.6 Nm {6 to 7.5 kgm}
5] Punch 4 places on the circumference of
the threaded part with a punch.
6] Apply torque of 41.2 to 88.2 Nm {4.2 to 9
kgm} to screw (7) in the direction of
loosening. Check the screw does not
loose.
WA470-7

Hydraulic system
4) Set cylinder (4) to tool F1.

5) Sling and install cylinder head and piston rod
assembly (3) to cylinder (4).
6) Install cylinder head (2) to cylinder (4).
3 Mounting bolt:
373 54 Nm {38.0 5.5 kgm}
(lift cylinder)
530 78.5 Nm {54 8 kgm}
(bucket cylinder)
WA470-7
50-277

Work equipment
Work equipment
(ALL-L000-001-K-00-A)
Removal and installation of work equipment assembly
(WA470-L100-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
5. Sling bucket cylinder (3).

6. Remove pin (4) to separate the cylinder rod from
the bell crank. [*3]
4 Bucket cylinder (3): 210 kg
(WA470-L100-520-K-00-A)
1. Sling the bucket link, and remove pin (1). [*1]

a By using the lever block, fix the bucket link.
a If shims are inserted, check and record the
number and thickness.
2. Remove pins (2) on the right and left sides. [*2]
3. Start the engine and travel the machine in
reverse direction to separate the bucket from the
boom.
7. Remove cover (5a).
8. Disconnect connector F30 (5b).
4. Set supporting stand [1] at the boom end and

release remaining pressure in the piping.
9. Sling lift cylinder (6) and remove pin (6a). [*4]
a Lower the lift cylinder after placing a block [2]
on the top of axle.
4 Lift cylinder: 200 kg
50-278
WA470-7

Work equipment
a When slinging, insert block [3].

14.Pull out pin (9) to remove boom, bell crank and
bucket link assembly (8). [*6]
4 Boom, bell crank and bucket link
assembly:
1,950 kg
10.Remove cover (7a).
15.Sling bucket link (11) and pull out pin (12) and
remove it.
4 Bucket link: 90 kg
11.Disconnect connector F11 (7b).
12.Remove bolts (2 pieces) and remove boom
angle sensor assembly (7). [*5]
16.Remove covers (12a) and (12b).

13.Sling the boom, bell crank and bucket link
assembly (8).
WA470-7
50-279

Work equipment
17.Disconnect connector (12c).

18.Remove bucket angle sensor unit (12). [*7]
19.Sling bell crank (13) and pull out pin (14) and
remove it. [*8]
21.Remove dust seal (18) and bushing (19) from

bell crank (13). [*9]

bucket linkage (11). [*9]
4 Bell crank angle: 390 kg

boom (15). [*9]
Installation
(WA470-L100-720-K-00-A)

removal.
k When
aligning the mounting holes for the pin,

never insert your fingers in the holes.
k Before
starting the engine, check that the

directional lever is in the neutral position and
the parking brake is applied.
[*1]
a Install the bucket link according to the following
procedure.
50-280
WA470-7

Work equipment
1. Sling bucket link (11) and install O-ring (22).

2. Align the pin hole positions of bucket (23) and
bucket link (11).
k When
aligning mounting holes for the pin,

never insert your fingers in the holes.
[*5]
k Do
not insert your finger to the pin hole.
a Be careful that the O-ring does not get

caught.
3. Insert the shim so that clearance (a) is even on
right and left sides. Install pin (1) and lock it with
the bolt.
Set shim thickness: 1.5 mm, 3.0 mm
For checking operation after adjustment of

installation position, see Testing and Adjusting,
"Testing and adjusting boom position detection
lever".
[*6]
a Install the boom, bell crank and bucket linkage
assembly according to the following procedure.
1. Sling boom, bell crank and bucket linkage
assembly to align the pin hole positions of front
frame (25) and lift arm (15).
k Do
2. Insert the shim so that clearance (d) is even on

right and left sides. Install pin (10) and lock it
with the bolt.
Clearance (d): Max. 1.5 mm
Set shim thickness: 1.0 mm, 1.5 mm, 3.0 mm
k After
installing the pin, install the support

stand at the end of the boom.
[*2]
a Install the pin according to the following
procedure.
1. Install O-ring (24) to bucket (23).
2. Use the lift arm control lever to align the pin hole
positions of bucket (23) and lift arm (15).
k Do
a Take care so that the O-ring does not get

caught.
3. Insert the shim so that clearance (b) is even on
right and left sides. Install pin (1) and lock it with
the bolt.
Clearance (b): Max. 1.5 mm
Set shim thickness: 1.5 mm, 3.0 mm
[*7]
a For checking operation after adjustment of
installation position, see Testing and Adjusting,
"Testing and adjusting bucket position detection
lever".
[*8]
a Fix the bucket link to the bell crank by using the
lever block.
[*9]
a Press-fit the bushings by using puller [4], etc.
2 Inner surface of bushing:
Molybdenum disulfide lubricant (LM-P)
[*3] [*4]
WA470-7
a The following figure shows the boom as an

example.
50-281

Work equipment
a Install the dust seal with its lip (a) facing outside.
a The following figure shows the boom (bucket
side).
Greasing
Grease each pin after installation is completed.
2 Pins:
Molybdenum disulfide grease (LM-G)
50-282
WA470-7

(ALL-K000-001-K-00-A)
Removal and installation of operator's cab and floor frame

assembly (WA470-K000-924-K-00-A)
k Place

k Set

chock the wheels.
4. Remove the hydraulic tank assembly. For details,

assembly".
5. Remove covers (1) on right and left sides.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

k Loosen
the cap of the hydraulic tank slowly

to release the pressure in the hydraulic tank.
6. Remove right fender rubber cover (2).
k If
you disconnect the heater hose when the

coolant in the radiator is still hot, you may be
scalded. Wait until the coolant temperature
drops before starting the work.
k Collect
the refrigerant (air conditioner gas:

R134a) from the air conditioner circuit.

a Ask a qualified person for collecting, adding, and
conditioner gas: R134a).
k If

from frostbite. Accordingly, put on the
protective eyeglasses, gloves and working
suits with long sleeves for collecting and
filling operations.
Removal
(WA470-K000-520-K-00-A)
1. Collect refrigerant (air conditioner gas: R134a).

[*1]
Refrigerant to be collected: 1,100 50 g
2. Remove the full-length fender assembly. For
details, see "Removal and installation of fulllength fender assembly".
assembly".
WA470-7
8. Disconnect connectors R43 (5) and R45 (6) of

washer tank (4).
R43 (front: black), R45 (rear: white)
9. Disconnect washer hoses (7).
a Remove clamp (7a) as well.
50-283

13.Remove mounting bolts (14a) (4 pieces), and

remove brake valve (14) from bracket (14b).
a Lower brake valve (14) and hose together as
a unit.
10.Remove toolbox (8).
14.Disconnect connectors (9 pieces) from harness

(15).
Front side, from top: L36A, RVC, LR5, LR7,
LR8, LR9, LR12, LR6, and LR2
Back side, from top: LR3, LR4, and LR11
11.Disconnect connector L09 (9).

a Remove clamp (9a) as well.
15.Disconnect ground cable (16) to (18).
12.Disconnect hoses (10) to (13), from the Orbitrol

valve.
16.Remove clamp (19) and disconnect connectors

LR1 (20) and LT1 (21).
a Since the connector LR1 is secured with
screws, loosen them before disconnecting
the connector. And be sure to prevent the
rubber seal at the edge from coming off. [*2]
50-284
WA470-7

17.Remove air conditioner hoses (22) and (23), and

remove heater hoses (24) and (25). [*3]
20.Remove the monitor controller assembly. For

details, see "Removal and installation of monitor
controller assembly."
21.Remove mounting bolts (27) of operator's cab
and floor frame assembly.
18.Remove the floor mat, and mounting bolts (23)

of the operator's cab and floor frame assembly.
a Remove only bolts (2 pieces) in front.
22.Remove mounting bolts (28) (4 pieces) of

viscous mount lock plates under the floor frame.
23.Remove lock bolts (29) (4 pieces) and stopper
mounting bolts (30) (4 pieces). [*4]
19.Remove grommet (25) inside shoes box (24),

and remove mounting bolts (26) of operator's
cab and floor frame assembly.
24.Sling operator's cab and floor frame assembly
(31), and remove them.
a Before removing the assembly, check that all
wiring and piping are disconnected.
4 Operator's cab and floor frame
assembly (31):
1,000 kg
WA470-7
50-285

Installation
(WA470-K000-720-K-00-A)

removal.
[*1]
[*4]
3 Stopper mounting bolt (30):
1,180 to 1,470 Nm {120 to 150 kgm}
a Refill the air conditioner circuit with refrigerant

(air conditioner gas: R134a).
a Filling quantity: 1,100 50 g
[*2]
When connecting connector LR1 (20), take care
that the protect rubber seal at the end does not
get caught.
3 Screw:
2.2 to 2.8 Nm {0.23 to 0.29 kgm}
[*3]
a When connecting the air conditioner hose, be
careful of the followings.
1. Do not remove stoppers plugging piping until
installation of piping is started.
2. Be careful that dirt, dusts, or water do not enter
into air conditioner tubes when installing them.
3. Check that the O-ring is installed to the air
conditioner tube connection before installation.
4. Check that the O-ring is not damaged or
deteriorated.
5. Apply compressor oil for refrigerant (R134a) to
the O-ring when connecting the refrigerant
piping.
2 O-ring and threaded portion:
Compressor oil for R134a
(DENSO: ND-OIL8, VALEO THERMAL
SYSTEMS: ZXL100PG, SANDEN: SP10 (equivalent to PAG46))
a Tighten sleeve nuts (22a) and (23a) at hose
connections to the following torque.
3 Sleeve nut (22a):
30 to 35 Nm {3.1 to 3.6 kgm}
3 Sleeve nut (23a):
12 to 15 Nm {1.2 to 1.5 kgm}
50-286
WA470-7

Removal and installation of operator's cab glass (stuck window

glass) (WA380-K183-924-K-00-A)
Symbol
Part No.
Part name
1 793-498-1120 Clear plate

2 2 793-498-1130 Plate
X
3 793-498-1110 Magnet
Lifter (suction
3 793-498-1210 cup)
Necessity
Quantity
New/Redesign
Sketch
a Special tools
a When the glass surface is narrow, you can

use an ultrafine wire (piano wire, etc.) [2] and
pliers [3]. In this case, clip both ends of wire
with pliers (or wind wire around pliers) and
insert wire to the position where adhesive
stays to cut it off.
t 2
t 2
t 2
t 2
k Stop

apply the parking brake.
k Set
the lock bar to the front and rear frames

to lock them and chock wheels.
k Lower
the work equipment to the ground.
k Stop
the engine, turn the battery disconnect

switch to the OFF position, and remove the
key.
a Place the machine at the place where it is not

wet or windy. Open the door either on right or left.
Do not close the door until cure of the glass
replacement is finished.
(Because the glass may be dropped by
increasing of internal pressure inside the cab if
the door is opened or closed.)
Removal
a When you use a seal cutter or ultrafine wire,

take care not to damage parts in the
operator's cab (such as resin covers).
a When removing shattered window glass, it is
allowed to use cutter knife [4] and a
screwdriver. (Applying a screwdriver directly
to an unbroken window glass most possibly
ends up breaking the glass.)
a When using a cutter knife [4], insert a flat
head screwdriver to the cutting edge to cut
through while widening the cutting edge.
(WA380-K183-520-K-00-A)
a All-stuck window glass is employed for the

operator's cab installed on this machine.
a Remove the window glass to be replaced
1. By using seal cutter [1], cut off the adhesive
between damaged window glass (1) and
operator' cab (2).
2. Remove the window glass.
Installation
(WA380-K183-720-K-00-A)
1. By using scraper [5], eliminate adhesives left on

the bonding surface.
a Since adhesive left on a part of the bonding
surface of the operator's cab can detach and
drop the window glass, adhesive must be
completely removed.
WA470-7
50-287

a Take care not to damage the painted surface

when cleaning adhesive.
2. Using white gasoline, remove oil, dusts and

stains from bonding surfaces on operator's cab
(2) and window glass (3)
a Clean them thoroughly since insufficient
cleaning induces defective adhesion.
a Black-colored portions on the rear side of
window glasses must be entirely cleaned.
4. Attach dam rubber (double-coated adhesion

tape) (4) along the inner edge of window glass
mounting surface.
Size of dam rubber: 7 x 4.8 mm
a When attaching dam rubber, try as much as
possible not touch cleaned surfaces.
a Do not remove the release tape on glassbonding side of dam rubber until installation
of window glass is started.
a After cleaning, leave them as is five minutes

for natural drying.
a Take care not to allow dam rubber (4) to peel

off from the cab surface at corner portion (b).
3. If you have peeled off painting unintentionally
while removing adhesives using a scraper, coat
such portions with paint.
a Installing a window glass on unpainted
surfaces can gather rust there.
a Do not paint the portions that are coated with
primer.
50-288
WA470-7

a For the right and left windows and rear

window, dam rubber is attached all around
them. Start bonding of dam rubber from the
upper center position of the window and,
after bonding it almost around the window,
stop at a point about 5 mm away from
starting point "c" to leave the clearance.
5. Perform position alignment of replacing window

glasses.
1) Using an adhesive, stick X2-2 (thin steel
plate) to tool X2-1 (spacer).
Thickness (t) of spacer: 5 mm
2) Attach tool X2-3 (magnet) to tools X2-1 and
X2-2, and set them in two lower window
glass installed positions of operator's cab (2).
and fit the window glass to the operator's

cab.
4) Check clearance between window glass (3)

and operator's cab (2) on both sides. Adjust
the window glass so that uniform clearance
is obtained on both sides.
5) Attach tape [6] between window glass (3)
and operator' cab (2), and draw a line (a) on
the tape for position alignment.
6) Using a knife, cut the tape at a position
between window glass (3) and operator's cab
(2), and remove the window glass.
a Do not remove tapes left on the window
glass and operator's cab until installation
of window glass is started.
6. Apply primer.
a Since useful life of primer (5) is four months
from the date of production, be sure not to
use an overdue primer.
a Make sure to use primer within two hours
from opening its cap.
3) By using tool X3 (suction cup), place window

glass (3) on tool X2-1 (5 mm thick spacer)
WA470-7
a Even when it is plugged again immediately

after opening, be sure to use it within 24
hours from opening.
(A primer must be disposed when 24 hours have
elapsed from opening.)
1) Agitate both primers for paint surface and
glass sufficiently before use.
50-289

a When a primer was chilled-stored in a

depository, leave it half a day in room
temperature before agitating it.
(Bedewing of a primer results if you
immediately open the lid of a primer that has
been chilled-stored in a depository until then.
So it must be exposed to room temperature
for a sufficient period of time.)
2) When reusing a brush (6) for applying a
primer, clean it using white gasoline before
use.
a After cleaning, check again that the brush
is free from stains or fouling.
a A separate brush must be prepared for
the primer for paint surface and that for
glass.
4) Apply primer (8) for glass uniformly to the

black portions on bonding surface of window
glass (3).
3) Apply primer (7) for paint surface uniformly to
the portion outside the dam rubber (4) of
operator's cab (2) to which adhesive is
applied.
2 Primer for paint surface:
SUNSTAR paint surface primer
580 SUPER
a Two times are the upper limit of primer
application.
(Application beyond two times cause
degradation.)
a Coating position: Entire area of dimension
"d" located outside the dam rubber.
Primer coating dimension "d": 23 mm
a After coating, leave the coated surface for
more than five minutes (but no longer
than 8 hours) for natural drying.
a If a wrong primer such as glass primer is
applied, wipe it out completely using
white gasoline.
(A wrong primer disables the intended
adhesion.)
50-290
2 Primer for glass:

SUNSTAR
SUPER
Glass
Primer
580
a Two times are the upper limit of primer

application.
(Application beyond two times cause
degradation.)
a Coating position: Apply the primer to the
entire area of dimension "d" where
window glass (3) bonds to the operator's
cab. Dimension "d" is relative to dam
rubber (4) and operator's cab (2).
Primer coating dimension "d": 23 mm
a Do not apply the primer to about 5 mm of
the border area between the black and
transparent portions on the window glass.
a After coating, leave the coated surface for
more than five minutes (but no longer
than 8 hours) for natural drying.
a If a wrong primer such as paint surface
primer is applied, wipe it out completely
using white gasoline.
(A wrong primer disables the intended
adhesion.)
WA470-7

2) Cut the tip of adhesive nozzle (11) to

dimensions "f" and "g" shown in the figure.
Dimension "f": 10 mm
Dimension "g": 12 mm
7. Apply adhesive.
a Two adhesives must be selectively used
depending on the season.
2 Adhesive (summer):
SUNSTAR Penguin Seal 580 SUPER
"S"
2 Adhesive (winter):
SUNSTAR Penguin Seal 580 SUPER
"W"
3) Set adhesive cartridge (9) on caulking gun

[7].
a A better workability is obtainable from a
power caulking gun.
a Since useful life of adhesive is four months

from the date of production, be sure not to
use an overdue adhesive.
a Adhesives must be stored at 25C or lower in
a dark and cool place.
a It is strictly prohibited to heat an adhesive
beyond 30C.
a When reusing an adhesive, remove cured
adhesive at the nozzle tip completely.
1) Unwrap aluminum dehumidification film (10)
at the mouth of adhesive cartridge (9) and
install the nozzle.
WA470-7
4) Remove the release tape (13) on the glass

side of dam rubber.
50-291

a If you fail in alignment of glass bonding

position, you must clean the installed
position and apply primer again. Therefore,
carefully position the window glass before
bonding.
1) Combine tools X2-1, X2-2 and X2-3 in the
same manner as in step 5, and set them in
two lower window glass installed positions of
operator's cab (2).
5) Apply adhesive (12) to outside portion of

dam rubber (4) on the operator's cab.
a Check again that the primer is applied to
the adhesive coating surface before
application of adhesive.
2) By using tool X3, bring up window glass (3)

and place it on tools X2-1 (5 mm thick
spacer). Then bond the window glass to the
operator's cab.
a Install the window glass aligning the lines
drawn in step 5 on the tapes for position
alignment.
a Apply adhesive (12) to dimensions "h"
and "j" shown in the figure, which are
relative to dam rubber (4) of operator's
cab (2).
Dimension "h": 10 mm
a Glass bonding work must be finished

within 10 minutes from application of
adhesive.
a Check again that the primer is applied to
the bonding surface on the window glass,
then install the glass.
a Height of applied adhesive (12) must be

higher than that of dam rubber (4).
a Height of applied adhesive must be
uniform.
a Check that clearances "k" between the

front glass and right and left front glasses
of the front window are the same.
Clearance "k": 5 mm
8. Install window glass (3).
50-292
WA470-7

3) After bonding window glass (3), fasten it

uniformly.
a Fasten the entire circumference using the
force enough for the window glass to
adhere to the dam rubber.
a Avoid pressing too hard.
2) Refill with caulking agent (15).

a Since useful life of the following caulking
agent is four months from the date of
production, be sure not to use an overdue
caulking agent.
9. Cure the bonded window glass for some time.
2 Caulking agent:
SUNSTAR Penguin Seal No.2505
a Curing time until tool X2-1 (5 mm thick

spacer) is allowed to be removed
(temperature 20C/humidity 60%): Ten hours
a Curing time from application of adhesive to
machine operation: 24 hours (one day)
10.When front glass or right and left front glasses
are replaced, seal the clearance between them.
1) Paste masking tape (14) along the sealed
portion as shown in the figure.
a Paste masking tape on both inside and
outside of the operator's cab.
3) Remove extra caulking agent protruded out
of spaces between window glasses by using
a cardboard [8] or the like.
WA470-7
50-293

4) Remove masking tape from the window

glass.
11.Clean off primers and adhesives adhering to the
operator's cab and window glasses.
a By using white gasoline, wipe off adhesives
before it is dried up.
a Avoid giving impacts to window glassed in
the cleaning.
50-294
WA470-7

Removal and installation of operator's seat assembly
(WA380-K2Q0-924-K-00-A)
k Stop

k Set

k Lower
k Stop
the engine and turn the battery

disconnect switch to the OFF position and
remove the key.
Removal
(WA380-K2Q0-520-K-00-A)
Upper seat assembly

1. Remove wiring clamp (1) and remove connector
(2).
4. Remove upper seat assembly (6).
2. Remove wiring clamp (3) and remove wiring

connector (4).
a Since a crane is not usable in the ROPS cab,

make up a team with two persons when
removing upper seat assembly (6).
4 Upper seat assembly (6):
30 kg
a Remove four upper seat assembly mounting
bolts (5), then right console base (7) will be
detached. Take care of it since it inclines to
the right console side.
Suspension assembly
1. Remove four mounting bolts (8) of suspension
assembly (9), and remove it.
3. Remove four upper seat assembly mounting

bolts (5).
a Upper seat assembly mounting bolt (5):
Hexagonal socket head bolt (M8)
WA470-7
a Since a crane is not usable in ROPS cab,

make up a team with two persons when
removing suspension assembly (9).
4 Suspension assembly (9):
25 kg
50-295

Installation
(WA380-K2Q0-720-K-00-A)

removal.
[*1]
Install seatbelt with installed angle 40 deg. (on right
and left).
50-296
WA470-7

Removal and installation of seat belt
(WA380-K2Q3-924-K-00-A)
k Stop

k Set

k Lower
k Stop
the engine and turn the battery

disconnect switch to the OFF position and
remove the key.
Removal
(WA380-K2Q3-520-K-00-A)
1. Remove clamp (1) and disconnect wiring

connector (2).
2. Remove seat belt mounting bolts (3) to remove
seat belt (4). [*1]
Installation
(WA380-K2Q3-720-K-00-A)

removal.
[*1]
3 Seat belt assembly mounting bolt:
37.2 to 41.2 Nm {3.8 to 4.2 kgm}
WA470-7
50-297

Removal and installation of air conditioner unit assembly
(WA470-K540-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

k If
you disconnect the heater hose when the

coolant in the radiator is still hot, you may be
scalded. Wait until the coolant temperature
drops before starting the work.
3. Remove the rearview monitor assembly

1) Disconnect connectors (5) (3 places) and
ground terminals (6) (2 places) , and remove
wiring clips (7).
2) Remove mounting bolts (8a) (4 pieces) to
remove rearview monitor assembly (8).
k Before
disconnecting the air conditioner

hoses, collect the refrigerant (air conditioner
gas: R134a) from the air conditioner circuit.

conditioner gas: R134a). (Only registered
persons can work.)
k If

from frostbite.
Put on protective eyeglasses, gloves and
working clothes with long sleeves while
collecting the refrigerant or filling the air
conditioner circuit with the refrigerant.
Removal
(WA470-K540-520-K-00-A)

[*1]
2. Remove the plastic cover (black) according to
4. Remove the plastic cover (gray) according to the

1) Disconnect the connectors of each switch,
cigarette lighter (9), and sunlight sensor (10).
2) Remove mounting bolts (11), 11a (6 pieces)
of the plastic cover and mounting bolt (12a)
(1 piece) of switch panel mounting bracket.
3) Pull out the rearview monitor harness from
the through hole of plastic cover (12) and
remove the plastic cover.
a Leave the switch panel and cigarette
lighter installed to the plastic cover.
1) Pull out face grills (1) at 2 places on the right

and left sides.
2) Remove mounting bolts (2) 2 pieces each on
the front, right, and left sides, and disconnect
the connectors of switches (3) (2 places).
3) Disconnect clips (4) (2 pieces) near the glass
to remove the plastic cover (black).
50-298
WA470-7

6. Remove the right side drink box cover according

1) Loosen clamp screw (20) of air conditioner
duct hose, and pull out the hose (21).
2) Remove mounting bolts (22) (6 places) to
remove right side drink box cover (23).
5. Remove the machine monitor assembly

1) Disconnect machine monitor wiring
connectors (13) to (16) and key switch wiring
connector (17).
2) Remove mounting bolts (18) (2 pieces) of the
machine monitor bracket to remove machine
monitor assembly (19).
7. Remove the left recirculation air filter cover

1) Remove sheet metal cover (24) and
recirculation air filter (25).
2) Remove cover mounting screws (26) (6
places).
3) Remove recirculation air sensor (27) from the
cover and remove recirculation air filter cover
(28).
WA470-7
50-299

9. Remove the air conditioner duct according to the

1) Remove duct mounting bolts (33) (4 places)
to remove face duct (34).
2) Pull out defroster duct (35) rearward of the
machine.
10.Tilt the steering column rearward of the machine

8. Remove the windshield wiper according to the

1) Disconnect connector (29) and washer hose
(30).
2) Remove wiper blade (31) from outside of the
cab and remove wiper motor (32) from inside
of the cab.
1) Remove pipe bracket mounting bolts (36) (4

pieces).
2) Remove floor bolts (37) (2 places) of the
steering column bracket and tilt the whole
steering column rearward.
11.Remove the air conditioner unit according to the

1) Disconnect connector AL1 (38), air
conditioner controller (39), and outer sensor
connector (40).
2) Remove clip (41) (1 place) of the air
conditioner harness.
50-300
WA470-7

4) Remove mounting bolts (48) (4 places) of air

conditioner unit (42) to remove the air
conditioner unit.
3) Disconnect heater hoses (43) and (44), air

conditioner tubes (45) and (46), and drain
hoses (47) (2 pieces) under the right of the
air conditioner unit. [*2]
a After disconnecting the piping, plug the
openings on the air conditioner unit side
and piping side to prevent entry of foreign
material.
Installation
(WA470-K540-720-K-00-A)
perform installation in the reverse order to

removal.
[*1]
a Refill the air conditioner circuit with refrigerant
(air conditioner gas: R134a).
Filling quantity: 1,100 50 g
[*2]
a When connecting the air conditioner circuit
piping, observe the following:
1. Do not remove stoppers plugging piping until
installation of piping is started.
2. Take care that dirt, dusts, or water do not
enter into air conditioner tubes when
installing them.
3. Check that the O-ring is installed to the air
conditioner tube connection before
installation.
4. Check that the O-ring is not damaged or
deteriorated.
5. Apply compressor oil for refrigerant (R134a)
to the O-ring when connecting the refrigerant
piping.
WA470-7
50-301


Compressor oil for R134a
(DENSO: ND-OIL8, VALEO THERMAL
SYSTEMS: ZXL100PG (equivalent to
PAG46), SANDEN: SP-10)
a Tighten mounting bolts (A) and (B) at hose
connections to the following torque.
3 Mounting nut (A):
12 to 15 Nm {1.2 to 1.5 kgm}
3 Mounting nut (B):
30 to 35 Nm {3.1 to 3.6 kgm}
50-302
WA470-7

Removal and installation of air conditioner compressor assembly
(WA470-
K590-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

k Before

hoses, collect the refrigerant (R134a) from
the air conditioner circuit.

filling operations of the refrigerant (R134a).
(Only registered persons can work.)

[*1]
4. Remove air conditioner compressor belt (4). For
conditioner compressor belt". [*2]
6. Disconnect tubes (6) and (7). [*3]
7. Remove mounting bolts (4 pieces) and remove
air conditioner compressor assembly (8).
a Never release the refrigerant (R134a) to the

atmosphere.
k If
refrigerant gas (R134a) gets in your eyes,

you may lose your sight. And if it touches
your skin, you may suffer from frostbite.
Removal
(WA470-K590-520-K-00-A)
Installation
(WA470-K590-720-K-00-A)

removal.
[*1]
a Fill it with refrigerant (air conditioner gas:
R134a).
Filling quantity: 1,100 50 g
[*2]
and adjusting, "Testing and adjusting air
conditioner compressor belt tension".
[*3]
a When connecting the air conditioner circuit

piping, observe the following:
Do not remove the plug from the fitting until just
before connecting the pipe.
WA470-7
50-303

Be careful that dirt, dusts, or water do not enter

into the air conditioner piping when installing
them.
deteriorated.
When connecting air conditioner piping, apply
compressor oil for new refrigerant (R134a) to the
O-rings and threaded portions.
Compressor oil (DENSO: ND-OIL8)
3 Mounting bolt of tubes (6) and (7):
20 to 25 Nm {2.0 to 2.6 kgm}
50-304
WA470-7

Removal and installation of air conditioner condenser assembly
(WA470-K580-
924-K-00-A)
k Place

k Set

chock the wheels.

[*1]
Refrigerant to be collected: 1100 50 g
3. Remove clamps (3) and (4) and disconnect
hoses (5) and (6). [*2]
k Lower

LOCK.
k Turn

stop the engine.
k Turn

k Before

hoses, collect the refrigerant (air conditioner
gas: R134a) from the air conditioner circuit.

conditioner gas: R134a). (Only registered
persons can work.)

5. Remove mounting bolts (2 pieces each) on the
right and left sides and remove air conditioner
condenser assembly (8).

k If

from frostbite.
Removal
(WA470-K580-520-K-00-A)

Installation
(WA470-K580-720-K-00-A)

removal.
[*1] [*2]
a When connecting air conditioner circuit piping,
observe the following:
Do not remove the plug from the fitting until just
before connecting the pipe.
Be careful that dirt, dusts, or water do not enter
into the air conditioner piping.
deteriorated.
Apply compressor oil for new refrigerant (air
conditioner gas: R134a) to the O-rings and
threaded portions.
WA470-7
50-305


Compressor oil (DENSO: ND-OIL8)
When tightening the sleeve nut of air conditioner
pipes, tighten them by using 2 wrenches.
3 Screw size (M6 x 1.0) (width across
flats: 10 mm):
8 to 12 Nm {0.8 to 1.2 kgm}
a Fill it with refrigerant (air conditioner gas:
R134a).
Filling quantity: 1100 50 g
50-306
WA470-7

Electrical system
Electrical system
(ALL-RA1D-001-K-00-A)
Removal and installation of machine monitor assembly
(WA380-Q170-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
Installation
(WA380-Q170-720-K-00-A)

removal.
(WA380-Q170-520-K-00-A)
1. Remove two mounting bolts (1) each on front,

right and left sides, and remove cover (2).
2. Remove four bracket mounting bolts (3).
3. Disconnect harness connectors (4) to (6).

4. Remove eight mounting bolts (7), and remove
machine monitor assembly (8).
WA470-7
50-307

Electrical system
Removal and installation of engine controller assembly
(WA470-AP70-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
5. Disconnect connectors J2 (6), J1 (7), and EC3

(8).
(WA470-AP70-520-K-00-A)

7. Remove mounting bolt (10), and remove engine
controller assembly (11).

3. Remove the fuel feed pump and bracket (4)
together as a unit.
Installation
(WA470-AP70-720-K-00-A)

removal.
50-308
a When the engine controller assembly have been

replaced, write the injector compensation value
described on the old engine controller to the new
one. For details, see Testing and adjusting,
"Writing compensation values at replacement of
injector and engine controller".
WA470-7

Electrical system
Removal and installation of work equipment controller assembly
(WA380-PT10-
924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
5. Disconnect connectors M01B (7), L18A (8), and

L18B (9).
(WA380-PT10-520-K-00-A)
1. Fold operator's seat (1) forward.

2. Remove four box mounting bolts (2), and
remove the box.
7. Remove three controller fixing bolts (11).
3. Remove four top cover mounting bolts (3), and

remove the top cover (4). [*1]
8. Disconnect connectors L71 (12), L72 (13), and

L73 (14).
9. Remove bolts (15) and (16), and remove work
equipment controller assembly (17).
4. Remove bolts (5) and (6), two bolts each.
WA470-7
50-309

Electrical system
Installation
(WA380-PT10-720-K-00-A)

removal.
[*1]
circumference of clearance (a) becomes Min. 2
mm.
50-310
WA470-7

Electrical system
Removal and installation of transmission controller assembly
(WA380-CV10-924-K-
00-A)
k Place

k Set

chock the wheels.
Installation
(WA380-CV10-720-K-00-A)

removal.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA380-CV10-520-K-00-A)
1. Remove the monitor controller assembly. For

details, see "Removal and installation of monitor
controller assembly."
2. Disconnect connectors L61 (1), L62 (2), and L63
(3).
3. Remove wiring anti-vibration bolt (4).
4. Remove two bolts (5), and remove transmission

controller assembly (6).
WA470-7
50-311

Electrical system
Removal and installation of monitor controller assembly
(WA380-Q180-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
5. Disconnect connectors M01B (7), L18A (8), and

L18B (9).
(WA380-Q180-520-K-00-A)

2. Remove four box mounting bolts (2), and
remove the box.
7. Unlock connectors (11) and (12).

a Shift lever (c) inward while pressing tab (b).
(Unlock the connector as shown in the
following right figure.)
3. Remove four top cover mounting bolts (3), and
remove the top cover (4). [*1]
8. Disconnect connectors (11), (12), and (13) from

monitor controller assembly (13).
4. Remove bolts (5) and (6), two bolts each.
50-312
WA470-7

Electrical system
9. Remove two controller fixing bolts (15), and

remove monitor controller assembly (14).
Installation
(WA380-Q180-720-K-00-A)

removal.
[*1]
circumference of clearance (a) becomes Min. 2
mm.
WA470-7
50-313

Electrical system
Removal and installation of mass air flow and temperature sensor
(WA470-
A96H-924-K-00-A)
k Place

k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA470-A96H-520-K-00-A)

3. Remove mass air flow and temperature sensor
(4).
Installation
(WA470-A96H-720-K-00-A)

removal.
50-314
WA470-7

Electrical system
Removal and installation of KOMTRAX terminal assembly

k Place

(WA380-Q210-924-K-00-A)
Connector (9): Communication antenna

5. Remove four bolts (10), and remove KOMTRAX
terminal (11).
k Set

chock the wheels.
k Lower

LOCK.
k Turn

stop the engine.
k Turn

Removal
(WA380-Q210-520-K-00-A)

2. Remove six box mounting bolts (2), and remove
cover (3).
Installation
(WA380-Q210-720-K-00-A)

removal.
3. Remove three bolts (4) and remove cover (5).
4. Remove connectors (6) to (9).

(GPS)
Connector (7): Machine main wiring harness
(AMP18P)
(AMP12P)
WA470-7
50-315

Electrical system
50-316
WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model
Serial Number
WA470-7
10001 and up
60 Maintenance standard
8 60 Maintenance standard
WA470-7
60-1
Table of contents
Table of contents
(ALL-0310-002-A-00-A)
60 Maintenance standard................................................................................................................... 60-1

Cooling fan pump ................................................................................................................. 60-4
Cooling fan motor................................................................................................................. 60-7
Power train................................................................................................................................. 60-9
Drive shaft ........................................................................................................................... 60-9
Transmission ..................................................................................................................... 60-12
3rd, 4th clutch ECMV.......................................................................................................... 60-24
Axle .................................................................................................................................. 60-27
Differential ......................................................................................................................... 60-29
Final drive ......................................................................................................................... 60-39
Steering system........................................................................................................................ 60-41
Steering column................................................................................................................. 60-41
Steering pump ................................................................................................................... 60-42
Steering valve.................................................................................................................... 60-46
Steering cylinder ................................................................................................................ 60-48
Emergency steering pump .................................................................................................. 60-51
Brake system ........................................................................................................................... 60-52
Charge valve ..................................................................................................................... 60-52
Slack adjuster .................................................................................................................... 60-54
Brake ................................................................................................................................ 60-55
Parking brake .................................................................................................................... 60-57
Parking brake solenoid valve .............................................................................................. 60-58
Undercarriage and frame........................................................................................................... 60-59
Axle mount and center hinge pin.......................................................................................... 60-59
Hydraulic system ...................................................................................................................... 60-63
Hydraulic tank.................................................................................................................... 60-63
Double type gear pump ...................................................................................................... 60-64
Work equipment pump........................................................................................................ 60-65
Control valve ..................................................................................................................... 60-67
Work equipment ....................................................................................................................... 60-76
Work equipment linkage ..................................................................................................... 60-76
Bucket .............................................................................................................................. 60-80
Work equipment cylinder .................................................................................................... 60-81
60-2
WA470-7

No.
1
Item
Clearance between
transmission mounting
bracket and adjustment
bolt
WA470-7
(ALL-R401-001-K-00-A)
(WA470-A001-034-K-00-A)
Criteria
2 to 2.5
Unit: mm
Remedy
Adjust
60-3
Cooling fan pump
Cooling fan pump
60-4
(WA380-B450-034-K-00-A)
WA470-7
Cooling fan pump
WA470-7
60-5
Cooling fan pump
Servo valve
60-6
(WA380-B4H0-034-K-00-A)
WA470-7
Cooling fan motor
Cooling fan motor
WA470-7
(WA470-B5L0-034-K-00-A)
60-7
Cooling fan motor
No.
Item
Spool return spring
Check valve spring
60-8
Criteria
Standard dimension
Free
Load at
Installed
length x
installed
length
outside
length
diameter
58.8 N
38.1 x 17.6
35
{6 kg}
3.43 N
13.0 x 6.5
7
{0.35 kg}
Unit: mm
Remedy
Repair limit
Free
length
Load at
installed
length
47.1 N
{4.8 kg}
2.75 N
{0.28 kg}
Replace
spring if
damaged or
deformed
WA470-7
Drive shaft
Power train
Drive shaft
WA470-7
(ALL-C100-001-K-00-A)
(WA470-D510-034-K-00-A)
60-9
Torque converter
Torque converter
60-10
(WA470-CD00-034-K-00-A)
WA470-7
Torque converter
No.
Item
Outside diameter of pilot
Inside diameter of seal

ring contact surface of
pilot
3 ring contact surface of
clutch piston
clutch housing
PTO drive gear
Inside diameter of free
6 wheel rolling surface of
race
Outside diameter of free
7 wheel rolling surface of
stator shaft
Inside diameter of sliding
8 portion of bushing
Thickness of sliding
9 portion of bushing
10 Thickness of clutch plate
11 Thickness of clutch disc
Backlash between PTO
12 drive gear and PTO gear
2
WA470-7
Unit: mm
Remedy
Criteria
Standard
dimension
Tolerance
Repair limit
78
-0.010
-0.040
77.95
35
+0.025
0
35.5
270
+0.081
0
270.1
335
+0.089
0
335.1
150
+0.040
0
150.5
102.555
0.008
102.585
83.6
+0.004
-0.009
83.57
83.71
+0.015
0
83.79
0.05
5.5
5
5
0.1
0.1
4.5
4.5
Repair by hard
chrome plating
or replace
Repair by hard
chrome plating
or replace
Replace
0.17 to 0.45
60-11
Transmission
Transmission
60-12
(WA470-CF00-034-K-00-A)
WA470-7
Transmission
WA470-7
60-13
Transmission
No.
4
5
6
7
8
10
11
12
13
Item
Standard
clearance
-0.035 to
0.015
Allowable
clearance
45
+0.030
+0.015
0
-0.012
-0.042 to
-0.015
140
0
-0.018
-0.012
-0.052
-0.052 to
0.006
80
+0.045
+0.030
0
-0.015
-0.060 to
-0.030
65
0
-0.019
0
-0.015
-0.015 to
0.019
110
0
-0.018
-0.016
-0.038
-0.038 to
0.002
120
0
-0.018
0
-0.035
-0.035 to
0.018
150
0
-0.018
0
-0.040
-0.040 to
0.018
120
0
-0.015
0
-0.035
-0.035 to
0.015
120
0
-0.015
0
-0.035
-0.035 to
0.015
160
0
-0.025
-0.012
-0.052
-0.052 to
0.013
75
+0.035
+0.022
0
-0.015
-0.050 to
-0.022
120
0
-0.018
-0.016
-0.038
-0.038 to
0.002
65
+0.041
+0.022
0
-0.015
-0.056 to
0.022
130
0
-0.020
-0.012
-0.052
-0.052 to
0.010
75
+0.051
+0.032
0
-0.015
-0.066 to
0.032
130
0
-0.020
-0.020
-0.045
-0.045 to 0
75
+0.039
+0.020
0
-0.015
-0.054 to
-0.020
160
0
-0.025
-0.012
-0.052
-0.052 to
0.013
Standard
Clearance between input dimension
gear bearing and front
case
100
Clearance between input
gear bearing and input
gear
shaft bearing and rear
case
shaft bearing and input
shaft
shaft thrust bearing and
input shaft
Clearance between
upper shaft bearing and
cage
Clearance between
upper shaft bearing and
rear case
Clearance between
transfer shaft 1 bearing
and front case (rear)
Clearance between
middle shaft bearing and
rear case
Clearance between lower
shaft bearing and rear
case
Clearance between
and front case (front)
Clearance between
and transfer shaft 1
Clearance between
and cage
Clearance between
and transfer shaft 2
(front)
Clearance between
and front case
Clearance between
and front case (rear)
Clearance between
output shaft bearing and
retainer
Clearance between
output shaft (front)
Clearance between
front case
60-14
Unit: mm
Remedy
Criteria
Tolerance
Shaft
Hole
0
0
-0.015
-0.035
Replace
WA470-7
Transmission
No.
Item
Clearance between
output shaft (rear)
Clearance between
14 transfer shaft 2 and
transfer gear 2
15 input shaft
16
17
18
19
Width of seal ring groove

of input shaft
upper shaft and middle
shaft
of upper shaft and middle
shaft
lower shaft
of lower shaft
Outside diameter of oil
seal contact surface of
front coupling
Outside diameter of oil
seal contact surface of
rear coupling
Clearance between
20 upper shaft cage and
front case
21 shaft cage and front case
Clearance between
22 output shaft retainer and
housing
Free rotating torque
difference of output shaft
23 between before and after
shim adjustment
WA470-7
Unit: mm
Remedy
Criteria
75
+0.039
+0.020
0
-0.015
-0.054 to
-0.020
128
+0.110
+0.092
0
-0.025
-0.135 to
-0.092
-0.092
Standard
dimension
60
3.2
Tolerance
Repair limit
+0.05
0
+0.076
0
60.1
3.5
55
+0.05
0
55.1
3.2
+0.076
0
3.5
50
+0.05
0
50.1
3.2
+0.076
0
3.5
95
0
-0.087
94.8
105
0
-0.087
104.8
Standard clearance
1.51 to 2.15 (standard shim
thickness: 1.83)
thickness: 1.47)
Replace
Allowable clearance

thickness: 1.52)
0.49 to 2.94 Nm {0.05 to 0.3 kgm}
60-15
Transmission
No.
Item
Criteria
Standard
dimension
Clearance between PTO

gear bearing and cage
1
Clearance between PTO

gear bearing and PTO
gear
60-16
Unit: mm
Remedy
110
60
Tolerance
Standard
clearance
Allowable
clearance
Shaft
0
-0.015
Hole
-0.006
-0.028
-0.028 to
0.009
+0.021
0.002
0
-0.015
-0.036 to
-0.002
Replace
WA470-7
Transmission
F and 1st clutches
No.
1
(WA470-CF82-034-K-00-A)
Item
Standard
Clearance between input dimension
shaft (front)
50
Standard
clearance
-0.050 to
-0.020
Allowable
clearance

shaft (rear)
+0.035
+0.020
-0.050 to
-0.020
Thickness
Distortion
Thickness
4 F clutch plate
Distortion
Thickness
5 1st clutch disc
Distortion
Thickness
6 F clutch disc
Distortion
Load of 1st clutch wave
7 spring [Test height: 3.0
mm]
Load of F clutch wave
8 spring [Test height: 3.2
mm]
Thickness of thrust
9 washer (front)
Thickness of thrust
10 washer (rear)
3
Unit: mm
Remedy
Criteria
Tolerance
Shaft
Hole
+0.035
0
+0.020
-0.015
1st clutch plate
WA470-7
55
0
-0.015
Standard
dimension
Tolerance
Repair limit
1.8
0.06
1.6
0.05
0.15
0.05
1.8
0.1
0.15
+0.05
-0.10
2.55
0.1
0.25
3.2
0.08
2.82
0.1
0.25
902 N
{92 kg}
90 N
{9.2 kg}
767 N
{78.2 kg}
1,106 N
{113 kg}
57 N
{5.8 kg}
942 N
{96.1 kg}
0.1
2.7
0.2
3.7
Replace
60-17
Transmission
R, 2nd clutch
(WA470-CFJ1-034-K-00-A)
No.
Item
Clearance between
transfer shaft
Clearance between
transfer shaft
Clearance between
middle shaft (front)
Clearance between
middle shaft (rear)
Thickness
Distortion
Thickness
R clutch plate
Distortion
Thickness
2nd clutch disc
Distortion
Thickness
R clutch disc
Distortion
Load of 2nd clutch wave
spring [Test height: 3.0
mm]
2nd clutch plate
60-18
Unit: mm
Remedy
Criteria
Tolerance
Shaft
Hole
+0.045
0
+0.030
-0.020
Standard
clearance
-0.065 to
-0.030
Allowable
clearance
120
0
-0.015
+0.016
-0.006
-0.006 to
+0.031
55
+0.035
+0.020
0
-0.015
-0.050 to
-0.020
55
+0.035
+0.020
0
-0.015
-0.050 to
-0.020
Standard
dimension
85
Standard
dimension
Tolerance
Repair limit
1.8
0.06
1.6
0.05
0.15
0.05
1.8
0.1
0.15
+0.05
-0.10
2.55
0.1
0.25
3.2
0.08
2.82
0.1
0.25
902 N
{92 kg}
90 N
{9.2 kg}
767 N
{78.2 kg}
Replace
WA470-7
Transmission
No.
9
Item
Load of R clutch wave
mm]
WA470-7
Unit: mm
Remedy
Criteria
1,106 N
{113 kg}
57 N
{5.8 kg}
942 N
{96.1 kg}
60-19
Transmission
3rd, 4th clutch
No.
1
(WA470-CFK1-034-K-00-A)
Criteria
Tolerance
Standard
Clearance between lower dimension
Shaft
Hole
shaft bearing and lower
+0.035
0
shaft
55
+0.020
-0.015
Standard
Tolerance
dimension
+0.050
3rd and 4th clutches
60
0
+0.076
3.2
of 3rd and 4th clutches
0
Thick1.7
0.05
ness
3rd clutch plate
Distor
0.05
tion
Thick2
0.05
ness
4th clutch plate
Distor
0.1
tion
Thick2.2
0.08
ness
3rd clutch plate
Distor
0.1
tion
Thick3.2
0.08
ness
4th clutch disc
Distor
0.1
tion
Load of 3rd clutch wave
1,010 N
101 N
{103
kg}
{10.3
kg}
mm]
Load of 4th clutch wave
813 N
40 N
{83 kg}
{4.1 kg}
mm]
60-20
Unit: mm
Remedy
Item
Standard
clearance
-0.050 to
-0.020
Allowable
clearance
Repair limit
60.1
3.5
1.5
0.15
1.8
Replace
0.15
1.6
0.25
2.82
0.25
859 N
{87.6 kg}
691 N
{71 kg}
WA470-7
(WA470-CJA0-034-K-00-A)
Left valve assembly
WA470-7
60-21
RIght valve assembly
60-22
WA470-7
clutch ECMV
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV
(WA470-CJJ0-
034-K-00-A)
WA470-7
60-23
(WA470-CJJ0-034-K-01-A)
60-24
WA470-7
Lockup clutch ECMV
Lockup clutch ECMV
(WA380-CDT8-034-K-00-A)

a Do not disassemble this ECMV since it needs to be adjusted for maintaining the performance after
assembly.
WA470-7
60-25
No.
1
Item
Standard
Clearance between main dimension
relief valve and valve
body
28
Criteria
Tolerance
Shaft
Hole
-0.035
+0.013
-0.045
0
Clearance between
torque converter relief
valve and valve body
-0.035
-0.045
Main relief valve spring

(outside)
Main relief valve spring

(inside)
Torque converter relief

valve spring
60-26
22
(WA470-C156-034-K-00-A)
+0.013
0
Standard dimension
Load at
Free
Installed
installed
length
length
length
275 N
108
79.5
{28.0 kg}
326 N
108
79.5
{33.3 kg}
163 N
50
41.5
{16.5 kg}
Unit: mm
Remedy
Standard
clearance
0.035 to
0.058
0.035 to
0.058
Allowable
clearance
0.078
0.078
Repair limit
Load at
Free
installed
length
length
261 N
104.8
{26.6 kg}
309 N
104.8
{31.5 kg}
154 N
48.5
{15.7 kg}
Replace
WA470-7
Axle
Axle
(HM300-DA00-001-K-00-A)
Front axle
WA470-7
(WA470-DA20-034-K-00-A)
60-27
Axle
Rear axle
60-28
(WA470-DAC0-034-K-00-A)
WA470-7
Differential
Differential
(WA380-DC10-001-K-60-A)
Front conventional differential
WA470-7
(WA470-DC70-034-K-00-A)
60-29
Differential
60-30
WA470-7
Differential
No.
1
2
3
4
5
6
7
Item
Thickness of pinion
washer
Thickness of side gear
washer
Starting torque of bevel
gear
Shim thickness at
differential side bearing
carrier (each side)
Backlash of bevel gear
End play of pinion
(or starting torque)
Shim thickness at
differential housing and
cage assembly
Location of piston of
differential housing
(housing and piston)
bearing carrier (piston
and carrier)
Outer
Clearance of
race
10 differential side
Inner
bearing
race
Outer
Clearance of
race
bearing on
11
pinion shaft gear Inner
side
race
Outer
Clearance of
race
bearing on
12 pinion shaft
Inner
coupling side
race
9
WA470-7
Unit: mm
Remedy
Criteria
Standard
dimension
3
4
Tolerance
Repair limit
0.08
2.8
0.05
3.8
Replace
19.6 to 27.4 N {2.0 to 2.8 kg} (outside of bevel gear)

Adjust
0.30 to 1.25
0.30 to 0.41
0 to 0.210
{1.5 to 1.7 kg (cage bolt hole portion)}
Replace
Adjust
1.49 0.38
Standard
dimension
346
326
160
105
180.975
76.2
160
75
Tolerance
Shaft
Hole
-0.125
+0.089
-0.214
0
Standard
clearance
0.125 to
0.303
Allowable
clearance
-0.125
-0.214
+0.089
0
0.125 to
0.303
0
-0.025
+0.059
+0.037
+0.025
0
+0.065
+0.046
0
-0.025
+0.039
+0.020
-0.045
-0.085
0
-0.020
-0.025
-0.054
+0.013
0
-0.050
-0.075
0
-0.015
-0.085 to
-0.020
-0.079 to
-0.037
-0.079 to
-0.025
-0.065 to
-0.033
-0.075 to
-0.025
-0.054 to
-0.020
Replace
60-31
Differential
Rear conventional differential
60-32
(WA470-DCD0-034-K-00-A)
WA470-7
Differential
WA470-7
60-33
Differential
No.
1
2
3
4
5
6
7
Item
Thickness of pinion
washer
Thickness of side gear
washer
Starting torque of bevel
gear
Shim thickness at
differential side bearing
carrier (each side)
Backlash of bevel gear
End play of pinion
(or starting torque)
Shim thickness at
differential housing and
cage assembly
differential housing
(housing and piston)
bearing carrier (piston
and carrier)
Outer
Clearance of
race
10 differential side
Inner
bearing
race
Outer
Clearance of
race
bearing on
11
pinion shaft gear Inner
side
race
Outer
Clearance of
race
bearing on
12 pinion shaft
Inner
coupling side
race
9
60-34
Unit: mm
Remedy
Criteria
Standard
dimension
3
4
Tolerance
Repair limit
0.08
2.8
0.05
3.8
Replace
21.6 to 30.4 N {2.2 to 3.1 kg} (outside of bevel gear)

Adjust
0.30 to 1.25
0.30 to 0.41
0 to 0.200
{1.0 to 1.1 kg (cage bolt hole portion)}
Replace
Adjust
1.26 0.34
Standard
dimension
327
307
160
105
171.45
76.2
150
70
Tolerance
Shaft
Hole
-0.125
+0.089
-0.214
0
Standard
clearance
0.125 to
0.303
-0.110
-0.191
+0.081
0
0.110 to
0.272
0
-0.025
+0.059
+0.037
+0.025
0
+0.065
+0.046
0
-0.020
+0.039
+0.020
-0.045
-0.085
0
-0.020
-0.025
-0.054
+0.013
0
-0.050
-0.075
0
-0.015
-0.085 to
-0.020
-0.079 to
-0.037
-0.079 to
-0.025
-0.065 to
-0.033
-0.075 to
-0.030
-0.054 to
-0.020
Allowable
clearance
Replace
WA470-7
Differential
Front limited slip differential
(WA470-DCH3-034-K-00-A)
(if equipped)
WA470-7
60-35
Differential
No.
1
Item
Thickness of washer
Thickness of plate
Thickness of disc
7
8
Clearance between
spider and differential
pinion
Backlash between case
and plate
Clearance between disc
and plate
(total of clearances on
both sides)
Backlash between side
gear and disc
Axial end play of side
gear (one side)
60-36
Unit: mm
Remedy
Criteria
Standard
Tolerance
dimension
4
0.05
4.1
3.1
0.02
3.2
3.6
0.07
Tolerance
Standard
dimension
Shaft
Hole
-0.11
+0.05
35
-0.16
0
Repair limit
3.8
3.0
Standard
clearance
0.110 to
0.210
3.5
Allowable
clearance
Replace
0 to 0.5
0.2 to 0.75 (when a load of 70 kg is applied)
0.13 to 0.32
0.2 to 0.4 (when measured at one side), 0.4 to 0.8 (when
measured at both sides)
WA470-7
Differential
Rear limited slip differential
(WA470-DCH4-034-K-00-A)
(if equipped)
WA470-7
60-37
Differential
No.
1
Item
Thickness of washer
Thickness of plate
Thickness of disc
7
8
Clearance between
spider and differential
pinion
Backlash between case
and plate
Clearance between disc
and plate
(total of clearances on
both sides)
Backlash between side
gear and disc
Axial end play of side
gear (each side)
60-38
Unit: mm
Remedy
Criteria
Standard
Tolerance
dimension
4
0.05
4.1
3.1
0.02
3.2
3.2
0.07
Tolerance
Standard
dimension
Shaft
Hole
-0.110
+0.05
35
-0.160
0
Repair limit
3.8
3
Standard
clearance
0.110 to
0.210
3.1
Allowable
clearance
Replace
0 to 0.5
0.2 to 0.75 (when a load of 70 kg is applied)
0.09 to 0.39
0.15 to 0.35 (when measured at one side), 0.3 to 0.7 (when
measured at both sides)
WA470-7
Final drive
Final drive
(WA470-DF10-034-K-00-A)
*1: 8 is equipped only for the front axle not for the rear axle.
WA470-7
60-39
Final drive
Front
No.
1
2
3
Item
Clearance between
planetary gear bearing
and shaft
Clearance between axle
housing and ring gear
Difference between oil
seal and the end of
housing
HousPress fitting
ing
portion of axle
shaft seal
Shaft
Clearance at
press fitting
portion of axle
hosing bearing
Clearance at
press fitting
portion of axle
hosing bearing
Outer
race
Inner
race
Outer
race
Inner
race
Clearance of guide pin
Thickness of washer
Standard
dimension
45
404
Criteria
Tolerance
Shaft
Hole
+0.013
0
+0.002
-0.012
+0.1
+0.1
0
0
Unit: mm
Remedy
Standard
clearance
-0.025 to
-0.002
Allowable
clearance
-0.1 to 0.1
Adjust
Max. 0.2
+0.500
+0.300
0
160
-0.063
+0.025
196.85
0
+0.068
133.35
+0.043
+0.025
177.8
0
+0.058
114.3
+0.036
+0.025
12
+0.007
Standard
dimension
2
200
+0.072
0
-0.300
-0.500
-0.014
-0.060
+0.025
0
-0.014
-0.060
+0.025
0
+0.207
+0.145
Replace
-0.050 to
-0.028
-0.500 to
-0.237
-0.085 to
-0.014
-0.068 to
-0.018
-0.085 to
-0.014
-0.058 to
-0.011
0.120 to
0.200
Replace
Tolerance
Repair limit
0.05
1.8
Rear
No.
1
2
3
Item
Clearance between
planetary gear bearing
and shaft
Clearance between axle
housing and ring gear
Difference between oil
seal and the end of
housing
HousPress fitting
ing
portion of axle
shaft seal
Shaft
Clearance at
press fitting
portion of axle
hosing bearing
Clearance at
press fitting
portion of axle
hosing bearing
Outer
race
Inner
race
Outer
race
Inner
race
Clearance of guide pin
60-40
Standard
dimension
40
382
Criteria
Tolerance
Shaft
Hole
+0.013
0
+0.002
-0.012
+0.1
+0.1
0
0
Unit: mm
Remedy
Standard
clearance
-0.025 to
-0.002
Allowable
clearance
-0.1 to 0.1
Adjust
Max. 0.2
200
160
196.85
133.35
160
105
12
+0.500
+0.300
0
-0.063
+0.025
0
+0.068
+0.043
0
-0.025
+0.035
+0.013
+0.025
+0.007
+0.072
0
-0.300
-0.500
-0.014
-0.060
+0.025
0
-0.045
-0.085
0
-0.020
+0.207
+0.145
Replace
-0.050 to
-0.228
-0.500 to
-0.237
-0.085 to
-0.014
-0.068 to
-0.018
-0.085 to
-0.020
-0.055 to
-0.013
0.120 to
0.200
Replace
WA470-7
Steering column
Steering system
Steering column
No.
(ALL-F000-001-K-00-A)
(WA380-F171-034-K-00-A)
Item
Clearance between
steering shaft and column
bushing
Standard
dimension
19
WA470-7
Unit: mm
Remedy
Criteria
Tolerance
Shaft
Hole
0
-0.08
+0.15
+0.05
Standard
clearance
Allowable
clearance
0.05 to 0.23
0.4
Replace
60-41
Steering pump
Steering pump
60-42
(WA470-F220-034-K-00-A)
WA470-7
Steering pump
Pump body
WA470-7
60-43
Steering pump
60-44
WA470-7
Steering pump
Servo valve
WA470-7
(WA380-F2J0-034-K-00-A)
60-45
Steering valve
Steering valve
60-46
(WA470-F570-034-K-00-A)
WA470-7
Steering valve
No.
Item
Steering spool return

spring
Poppet spring
Flow control spool return

spring
Steering relief valve spring
Relief valve spring
WA470-7
Criteria
Standard dimension
Load at
installed
Free
Installed
length of
length
length
spring
179.7 N
65.0
35.2
{18.3 kg}
3.0 N
20.9
18.3
{0.3 kg}
147.1 N
69.7
68.5
{15.0 kg}
100.9 N
24.0
23.9
{10.3 kg}
55.3 N
29.8
26.5
{5.64 kg}
Unit: mm
Remedy
Repair limit
Load at
installed
Free
length of
length
spring
143.8 N
{14.7 kg}
2.4 N
{0.24 kg}
117.7 N
{12.0 kg}
80.7 N
{8.2 kg}
44.2 N
{4.51 kg}
Replace
60-47
Steering cylinder
Steering cylinder
60-48
(WA470-F6L0-034-K-00-A)
WA470-7
Steering cylinder
No.
1
Item
Clearance between
frame connecting part
bushing of cylinder rod
and mounting pin
Clearance between
frame connecting part
bushing of cylinder
bottom and mounting pin
Standard
dimension
55
55
Criteria
Tolerance
Shaft
Hole
0
+0.174
-0.046
+0.100
0
-0.046
Width of boss
3
+0.174
+0.100
: mm
Remedy
Standard
clearance
0.100 to
0.220
0.100 to
0.220
Width of hinge
Connecting part of
Standard
Standard
steering cylinder and rear dimension Tolerance dimension Tolerance
frame
0
-1
65
71.5
-0.5
+1
Connecting part of
steering cylinder and
front frame
WA470-7
65
0
-0.5
67
-0.5
+0.5
Allowable
clearance
1.0
Replace
bushing and
pin
1.0
Standard
clearance
5.5 to 7.5
1.5 to 3
Adjust the
clearance
between
frame and
cylinder to
become more
than 0 mm
and less than
0.5 mm by
using shims.
60-49
Steering cylinder
No.
1
2
3
4
Item
Clearance between
piston rod and bushing
Tightening torque of
cylinder head
cylinder piston
Tightening torque of plug
on cylinder head port side
60-50
Standard
dimension
50
Criteria
Tolerance
Shaft
Hole
-0.025
+0.152
-0.064
-0.005
Unit: mm
Remedy
Standard
clearance
0.020 to
0.216
Allowable
clearance
0.516
Replace
bushing
677 67.5 Nm {69 6.9 kgm}

1670 167 Nm {170 17.0 kgm} (width across flats: 55
mm)
Retighten
19.6 to 27.4 Nm {2.0 to 2.8 kgm}
WA470-7
(WA380-F940-034-K-00-A)
(if equipped)
No.
Item
Side clearance
Clearance between plain

bearing inside diameter and
gear shaft outside diameter
Pin driving depth
Torque of splined shaft
Unit: mm
Remedy
Criteria
Standard clearance
0.10 to 0.15
Allowable clearance
0.19
0.060 to 0.119
0.20
Repair limit
Allowance
0
10
-0.5
2.0 to 4.9 Nm {0.2 to 0.5 kgm}
Replace
Standard dimension
WA470-7
60-51
Charge valve
Brake system
Charge valve
60-52
(ALL-G000-001-K-00-A)
(WA380-G2H0-034-K-00-A)
WA470-7
Charge valve
WA470-7
60-53
Slack adjuster
Slack adjuster
(WA470-G310-034-K-00-A)
Unit: mm
No.
1
Criteria
Tolerance
Standard
Clearance between body dimension
Shaft
Hole
and piston
-0.030
+0.074
55
-0.076
0
Standard dimension
Load at
Free
Installed
installed
length
length
Check valve
length
66.7 N
38.8
33
{6.8 kg}
43.1 N
Slack adjuster spring
198
38
{4.4 kg}
60-54
Remedy
Item
Standard Allowable
clearance clearance
0.030 to
0.25
0.150
Repair limit
Free
length
Allowable
load
Replace
WA470-7
Brake
Brake
Front
No.
1
2
3
(WA380-G160-001-K-60-A)
(WA470-G16H-034-K-00-A)
Item
Thickness of plate
Thickness of brake disc
Depth of lining groove
Thickness of lining
Wear of disc contact
surface of plate
Load of spring
WA470-7
Unit: mm
Remedy
Criteria
Standard
dimension
6
3.2
6.5
0.7 (Min.)
1.0
37.4
Tolerance
Repair limit
0.1
0.1
0.15
0.9 (Min.)
5.5
2.7
5.7
0.4
Allowable wear
0.3
Repair limit
Load at installed
length
1,374 N
{140 kg}
0.1
Standard dimension
Load at installed
Installed length
length
1,718 N
7.53
{175.3 kg}
Replace
60-55
Brake
Rear
No.
1
2
3
(WA470-G16K-034-K-00-A)
Item
Thickness of plate
Thickness of brake disc
Depth of lining groove
Thickness of lining
Wear of disc contact
surface of plate
Load of spring
60-56
Unit: mm
Remedy
Criteria
Standard
dimension
6
3.2
6.5
0.7 (Min.)
1.0
21.2
Tolerance
Repair limit
0.1
0.1
0.15
0.9 (Min.)
5.5
2.7
5.7
0.4
Allowable wear
0.3
Repair limit
Load at installed
length
1,225 N
{125 kg}
0.1
Standard dimension
Load at installed
Installed length
length
1,691 N
7.53
{172.6 kg}
Replace
WA470-7
Parking brake
Parking brake
No.
(WA470-GJ20-034-K-00-A)
Item
Parking brake spring

(outside)
Parking brake spring

(inside)
ThickPlate
ness
Distortion
Thickness
Disc
Distortion
Load of wave spring (Test
height: 3.2 mm)
WA470-7
Criteria
Repair limit
Standard dimension
Load at
Load at
Free
Installed
installed Free length installed
length
length
length
length
1,284 N
1,220 N
94
72.3
91
{131 kg}
{124 kg}
672 N
638 N
94
72.3
91
{69 kg}
{66 kg}
Standard
Repair limit
Tolerance
dimension
2.0
0.05
1.8
0.15
0.2
3.2
0.10
2.75
0.2
0.3
735 N
{75 kg}
216 N
{22 kg}
519 N
{53 kg}
Unit: mm
Remedy
Replace
60-57
60-58
(WA470-GJD0-034-K-00-A)
WA470-7
(ALL-DT00-001-K-00-A)
WA470-7
(WA470-H1K0-034-K-00-A)
60-59
No.
1
Item
Thickness of thrust plate
Criteria
Standard
dimension
20
Thickness of wear plate
Standard
Clearance between shaft dimension
and hole on front support
side
240
Clearance between shaft

and hole on rear support
side
60-60
Unit: mm
Remedy
190
Tolerance
0
-0.15
+0.3
-0.1
Tolerance
Shaft
Hole
-0.050
+0.439
-0.122
+0.023
-0.012
-0.137
+0.455
+0.027
Repair limit
Standard
clearance
0.073 to
0.561
Allowable
clearance
0.039 to
0.592
Replace
WA470-7
WA470-7
60-61
No.
1
Item
Clearance between
upper hinge pin and rear
frame
Clearance between
upper hinge pin and
spacer (small)
Clearance between
3 upper hinge pin and
bearing
Clearance between
4 upper hinge pin and
spacer (large)
Clearance between rear
5 frame and spacer (large)
Clearance between front
6 frame and upper hinge
bearing
7 hinge pin and rear frame
bushing
8 hinge pin and bearing
Clearance between front
9 frame and lower hinge
bearing
Clearance between rear
10 frame and bushing
Clearance at seal press
11 fitting part of lower hinge
pin
2
Height of upper hinge

12 spacer (small)
13
14
15
16
17
18
Height of upper hinge

spacer (large)
Standard shim thickness
between upper hinge and
retainer
between upper hinge and
retainer
between lower hinge and
retainer
upper hinge retainer
mounting bolt
lower hinge retainer
mounting bolt
60-62
Standard
dimension
80
Criteria
Tolerance
Shaft
Hole
-0.030
+0.060
-0.049
+0.030
Unit: mm
Remedy
Standard
clearance
0.060 to
0.109
Allowable
clearance
80
-0.030
-0.049
+0.060
+0.030
0.060 to
0.109
80
-0.030
-0.049
0
-0.015
0.015 to
0.049
80
-0.030
-0.049
+0.060
+0.030
0.060 to
0.109
95
-0.036
-0.071
+0.071
+0.036
0.072 to
0.142
130
0
-0.025
-0.048
-0.088
-0.088 to
-0.023
80
-0.030
-0.076
+0.067
+0.027
0.057 to
0.143
80
-0.030
-0.076
0
-0.015
0.015 to
0.076
130
0
-0.025
-0.048
-0.088
-0.088 to
-0.023
95
+0.089
+0.054
+0.054
0
-0.089 to 0
105
+0.17
+0.08
+0.054
0
-0.17 to
-0.026
Standard
dimension
36
61.5
Replace
Tolerance
Repair limit
0.1
0.1
1
2
1
Adjust
20 2 Nm {2 0.2 kgm} (for shim adjustment)

98 to 123 Nm {10 to 12.5 kgm} (final value)
20 2 Nm {2 0.2 kgm} (for shim adjustment)
98 to 123 Nm {10 to 12.5 kgm} (final value)
WA470-7
Hydraulic tank
Hydraulic system
Hydraulic tank
WA470-7
(D65-PM10-001-K-00-A)
(WA470-PM30-034-K-00-A)
60-63
(WA470-RA1S-034-K-00-A)
Power train charge pump and power train lubrication pump
No.
Item
Side clearance
Clearance between plain

bearing inside
circumference and gear
shaft outside
circumference
Model
SAL (3) 80
SAL (1) 32
SAL (3) 80
Allowable clearance
0.19
0.19
0.20
SAL (1) 32
0.060 to 0.119
0.20
Model
3
Pin driving depth
Pin driving depth
Torque of splined shaft
60-64
Unit: mm
Remedy
Criteria
Standard clearance
0.10 to 0.15
0.10 to 0.15
0.060 to 0.149
Standard
dimension
Allowance
0
-0.5
0
SAL (1) 32
14
-0.5
0
SAL (1) 32
10
-0.5
8.8 to 16.7 Nm {0.9 to 1.7 kgm}
SAL (3) 80
14
Repair limit
Replace
WA470-7
Work equipment pump
Work equipment pump
WA470-7
(WA470-C200-034-K-00-A)
60-65
Work equipment pump
60-66
WA470-7
Control valve
Control valve
(WA470-R404-034-K-00-A)
a In this section, the 4-spool valve (with ECSS control valve) is explained.
WA470-7
60-67
Control valve
No.
Item
Check valve spring
60-68
Criteria
Standard dimension
Free
Load at
Installed
length x
installed
length
outside
length
diameter
29.4 N
38.9 x 11.5
30.0
{3.0 kg}
Unit: mm
Remedy
Repair limit
Free
length
Load at
installed
length
23.5 N
{2.4 kg}
Replace
spring if
damaged or
deformed
WA470-7
Control valve
WA470-7
60-69
Control valve
No.
Item
Spool return spring
Spool return spring
Spool return spring
Spool return spring
Spool return spring
60-70
Criteria
Standard dimension
Free
Load at
Installed
length x
installed
length
outside
length
diameter
393 N
54.5 x 34.8
51.2
{40.1 kg}
417 N
54.2 x 34.8
51.2
{42.5 kg}
263 N
66.9 x 36.1
65.0
{26.8 kg}
274 N
53.2 x 22.3
33.0
{27.9 kg}
352 N
58.1 x 33.0
51.5
{35.8 kg}
Unit: mm
Remedy
Repair limit
Free
length
Load at
installed
length
314 N
{32.1 kg}
334 N
{34.0 kg}
210 N
{21.4 kg}
219 N
{22.3 kg}
282 N
{28.6 kg}
Replace
spring if
damaged or
deformed
WA470-7
Control valve
No.
Item
Suction valve spring
WA470-7
Criteria
Standard dimension
Free
Load at
Installed
length x
installed
length
outside
length
diameter
5.5 N
46.8 x 7.5
40.6
{0.56 kg}
Unit: mm
Remedy
Repair limit
Free
length
Load at
installed
length
4.4 N
{0.45 kg}
Replace
spring if
damaged or
deformed
60-71
Control valve
60-72
WA470-7
Control valve
WA470-7
60-73
Control valve
No.
Item
Suction valve spring
Check valve spring
Valve spring
60-74
Criteria
Standard dimension
Free
Load at
Installed
length x
installed
length
outside
length
diameter
3.04 N
62.5 x 20.0
39.0
{0.31 kg}
5.88 N
41.5 x 8.5
31.5
{0.6 kg}
19.6 N
19.2 x 7.2
16.1
{2.0 kg}
Unit: mm
Remedy
Repair limit
Free
length
Load at
installed
length
2.45 N
{0.25 kg}
4.71 N
{0.48 kg}
15.7 N
{1.6 kg}
Replace
spring if
damaged or
deformed
WA470-7
Control valve
WA470-7
60-75
Work equipment
(ALL-L000-001-K-00-A)
60-76
(WA470-LB31-034-K-00-A)
WA470-7
WA470-7
60-77
No.
1
Item
Standard
Clearance between
dimension
bushing and pin of
connecting parts at both
95
ends of bucket link
Clearance between
bushing and pin of
95
connecting part of boom
and bucket
Clearance between
bushing and pin of
110
connecting part of boom
and frame
Clearance between
bushing and pin of
120
connecting part of bucket
cylinder bottom and
frame
Clearance between
bushing and pin of
120
connecting part of bucket
cylinder rod and bell
crank
Clearance between
bushing and pin of
125
connecting part of bell
crank and boom
Clearance between
bushing and pin of
110
connecting part of lift
cylinder rod and boom
Clearance between
bushing and pin of
connecting part of lift
110
cylinder bottom and
frame
60-78
Criteria
Tolerance
Shaft
Hole
-0.036
+0.207
-0.090
+0.120
Unit: mm
Remedy
Standard
clearance
0.156 to
0.297
Allowable
clearance
1.0
-0.036
-0.090
+0.207
+0.120
0.156 to
0.297
1.0
-0.036
-0.090
+0.215
+0.139
0.175 to
0.305
1.0
-0.036
-0.090
+0.207
+0.120
0.156 to
0.297
1.0
-0.036
-0.090
+0.207
+0.120
0.156 to
0.297
1.0
-0.043
-0.106
+0.395
+0.295
0.338 to
0.501
1.0
-0.036
-0.090
+0.205
+0.127
0.163 to
0.295
1.0
-0.036
-0.090
+0.205
+0.127
0.163 to
0.295
Replace
(Replace if pin
has scuff
mark, as well)
1.0
WA470-7
No.
Item
Width of boss
10
11
12
13
14
15
16
Unit: mm
Remedy
Criteria
Width of hinge
Connecting part of bucket Standard Tolerance Standard Tolerance

dimension
dimension
cylinder and frame
0
125
128
0.8
-0.5
+2.5
Connecting part of boom
127
2.3
130
and frame
0
+1.5
119
2.3
122
and bucket
0
+3
+1.5
Connecting part of bucket
138
143
link and bucket
-0.5
0
0
+2.5
Connecting part of lift
110
115
cylinder and frame
-0.5
0
+3
Connecting part of bell
138
143
1.5
crank and bucket link
-0.5
Connecting part of bell
220
0.5
223
0.5
crank and boom
0
Connecting part of bucket
115
118
1.5
cylinder and bell crank
-0.5

17 and lift cylinder
WA470-7
109
2.3
114
0.5
Standard
clearance
2.2 to 4.3
0.7 to 7.8
0.7 to 6.8
Adjust
clearance on
each of right
and left sides
to 1.5 mm or
less with
shims
2 to 7
5 to 8
0.5 to 7
Replace
2 to 4
1.5 to 5.0
1.2 to 8.8
Adjust
clearance on
each of right
and left sides
to 1.5 mm or
less with
shims
60-79
Bucket
Bucket
No.
1
2
3
(WA470-LB00-034-K-00-A)
Item
Wear of bucket tooth (if
equipped)
Clearance at bucket tooth
(if equipped) location
Wear of bolt-on cutting
edge
60-80
Unit: mm
Remedy
Criteria
Standard dimension
50
Repair limit
18.5
Max. 0.5
93
Replace
Adjust or
replace
Turn 180 deg.
or replace
WA470-7
Work equipment cylinder
(WA470-PPZ0-034-K-00-A)
Lift cylinder
Bucket cylinder
No.
Item
Clearance
between piston
rod and bushing
Tightening
torque of
cylinder head
Tightening
torque of
cylinder piston
Tightening
torque of
cylinder piston
lock screw
WA470-7
Cylinder
name
Standard
dimension
Lift
95
Bucket
100
Criteria
Tolerance
Shaft
Hole
Unit: mm
Remedy
Standard
clearance
Lift
-0.036
+0.222
0.083 to
0.312
-0.090
+0.047
-0.036
+0.257
0.083 to
0.347
-0.090
+0.047
373 54 Nm {38.0 5.5 kgm}
Bucket
530 78.5 Nm {54.0 8.0 kgm}
Lift
294 29.4 Nm {30 3.0 kgm}
Bucket
294 29.4 Nm {30 3.0 kgm}
Lift
58.9 to 73.6 Nm {6.0 to 7.5 kgm}
Bucket
58.9 to 73.6 Nm {6.0 to 7.5 kgm}
Allowable
clearance
0.612
Replace
bushing
0.647
Retighten
60-81
60-82
WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model
Serial Number
WA470-7
10001 and up
80 Appendix
9 80 Appendix
WA470-7
80-1
80 Appendix
Table of contents
Table of contents
(ALL-0310-002-A-00-A)
80 Appendix...................................................................................................................................... 80-1
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-6
Outline of refrigeration cycle.................................................................................................. 80-7
Air conditioner unit ............................................................................................................... 80-9
Dual pressure switch .......................................................................................................... 80-14
Air conditioner controller ..................................................................................................... 80-15
Compressor....................................................................................................................... 80-16
Condenser ........................................................................................................................ 80-17
Receiver drier .................................................................................................................... 80-18
Sunlight sensor .................................................................................................................. 80-20
Outer temperature sensor (outside air temperature sensor) ................................................... 80-21
Procedure for testing and troubleshooting ............................................................................ 80-22
Circuit diagram and arrangement of connector pins............................................................... 80-24
System diagram................................................................................................................. 80-27
Parts and connectors layout................................................................................................ 80-30
Testing with self-diagnosis function ...................................................................................... 80-35
How to open the electrical system abnormality record screen in service mode of the machine
monitor ................................................................................................................ 80-36
Testing temperature control system ..................................................................................... 80-38
Testing vent (mode) changeover.......................................................................................... 80-40
Testing FRESH/RECIRC air changeover.............................................................................. 80-42
Check evaporator temperature sensor ................................................................................. 80-44
Testing relays .................................................................................................................... 80-46
Failure code list related to air conditioner.............................................................................. 80-52
Failure code [879AKA] A/C Inner Sensor Open Circuit .......................................................... 80-53
Failure code [879AKB] A/C Inner Sensor Short Circuit........................................................... 80-55
Failure code [879BKA] A/C Outer Sensor Open Circuit.......................................................... 80-57
Failure code [879BKB] A/C Outer Sensor Short Circuit .......................................................... 80-59
Failure code [879CKA] Ventilating Sensor Open Circuit ......................................................... 80-61
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-63
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................................................ 80-65
Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-67
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-70
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does
not operate).......................................................................................................... 80-73
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-76
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-79
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-82
Troubleshooting with gauge pressure................................................................................... 80-84
Connection of service tool................................................................................................... 80-87
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit................................................................................................................... 80-89
Handling of compressor oil.................................................................................................. 80-91
80-2
WA470-7
80 Appendix
Precautions for refrigerant

Precautions for refrigerant
(ALL-K500-001-K-02-A)
(ALL-K512-012-K-00-A)
k Collect
the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before
disconnecting the air conditioner hoses to replace the air conditioner unit or condenser, the air
conditioner compressor, receiver drier, etc.
a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a). (Only registered person can work.)
a Never release the refrigerant (R134a) to the atmosphere.
k If
refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin,
you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long
sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.
WA470-7
80-3
80 Appendix
Air conditioner component
(WA470-K500-04D-K-00-A)
1. Compressor
2. Condenser
3. Receiver drier
4. Hot water piping
5. Hot water return piping
6. Refrigerant piping
7. Dual pressure switch
8. Sight glass
80-4
WA470-7
80 Appendix
9. Air conditioner controller

10. Air conditioner unit
11. Recirculation air filter
12. Fresh air filter
13. Machine monitor
14. Sunlight sensor
Specifications
(WA470-K500-030-K-00-A)
Refrigerant
Refrigerant refill amount (g)
R134a
1,100 50
A. Vents for front glass defroster

B. Vents for face
C. Vents for foot
D. Recirculation air inlet
E. Fresh air inlet
WA470-7
80-5
80 Appendix
Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle

Cycle
(Component)
Location
Function
State of
refrigerant
80-6
Compression
(Compressor)
Engine
compartment
Circulates
refrigerant gas and
increases its
temperature and
pressure so that it
can be liquefied
easily in condenser.
(Compression of
refrigerant)
Gas o gas
Adiabatic
compression
Condensation
(Condenser)
Front of radiator
Condenses
refrigerant to
discharge heat
absorbed in
evaporator.
(condensation of
refrigerant)
Gas o liquid
Constant pressure
change
(ALL-K500-042-K-00-A)
Expansion
(Expansion valve)
In operator's cab
(Built in air conditioner
unit)
Lowers temperature
and pressure of
refrigerant liquid and
gas for easy
evaporation with
throttle. Controls flow
rate, too.
(Throttle action of
refrigerant)
Liquid o liquid, gas
Adiabatic expansion
Evaporation
(Evaporator)
In operator's cab
(Built into air
conditioner unit)
By evaporating
refrigerant, absorb
heat from the air
around the evaporator,
and cools the
surrounding air.
(Evaporation of
refrigerant)
Liquid, gas o gas
Constant pressure
change
WA470-7
80 Appendix
Outline of refrigeration cycle
(HM300-K500-04A-K-00-A)
Regeneration cycles are composed of the following four processes. Refrigerant circulates around the
system repeatedly changing its phase from liquid o gas o liquid.
Compression (Compressor)
The compressor sucks in the refrigerant that has been vaporized in the evaporator and compresses it into
a state where it can be easily liquefied at the ambient temperature.
The gaseous refrigerant sucked into the compressor cylinder is compressed to a temperature and
pressure at which it can be easily liquefied when cooled to the ambient temperature.
Condensation (Condenser)
The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant sent from
the compressor.
The heat released to the outside from the condenser is called condensation heat.
The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in
the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of
the compressor.
The refrigerant liquefied in the condenser is sent to the receiver drier, where moisture is removed.
In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist.
The temperature (condensation temperature) and the pressure (condensation pressure) at which the
gaseous refrigerant is liquefied are proportional to each other.
Reference: The pressure varies depending on the condensation temperature of the refrigerant.
Expansion (Expansion valve)
The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be
easily evaporated by the throttle action (*1).
The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated before it
is sent to the evaporator is called expansion.
The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow rate
simultaneously.
The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of
heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
The expansion valve controls the refrigerant feed rate so that the optimum quantity of liquid refrigerant is
supplied to the evaporator.
(*1) Throttle action
If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to
the flow will be generated.
The liquid expands when it passes through the narrow section and rushes into the passage where the
sectional area is larger, and consequently, its pressure and temperature are reduced.
No heat is transferred from or to the outside during the throttle action.
Evaporation (Evaporator)
The evaporator evaporates the liquid refrigerant (superheated vapor).
The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation
heat) from the air around the cooling fins (air in the cab).
After the heat has been removed, the cooled air is sent into the cab by the blower fan, reducing the
temperature inside the cab.
The mist refrigerant that has been sent from the expansion valve coexists with the evaporated refrigerant
in the evaporator
The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid
refrigerant is evaporated are proportional to each other.
The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the evaporator
as low as possible so that the liquid refrigerant can be evaporated at a much lower temperature.
Relationship between refrigerant and defective air conditioning
The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat
from inside the cab.
If there is an insufficient quantity of refrigerant, all of it will be evaporated while it is passing through the
evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.
WA470-7
80-7
80 Appendix
If there is excessive refrigerant, not all of it will be evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the compressor to compress the liquid and may damage the
components.
If water gets into the refrigeration circuit, it will freeze at a small hole in the expansion valve, lower the
refrigerant flow, and may result in defective air conditioning.
80-8
WA470-7
80 Appendix
(WA380-K540-041-K-00-A)
a This air conditioner unit is auto temperature control type.
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to compressor)
C: Hot water inlet
D: Hot water outlet
1. Evaporator
2. Heater core
3. Expansion valve
4. Blower fan and blower motor
5. Vent (mode) changeover servomotor
6. Air mix door
7. Air mix servomotor
Vent (mode) changeover door
8. Face door
9. Foot door
10. Defroster door
11. FRESH/RECIRC air changeover servomotor
12. FRESH/RECIRC air changeover servomotor
13. Blower amplifier
14. Evaporator temperature sensor
15. Inner sensor (inside air temperature sensor)
WA470-7
80-9
80 Appendix
16. Compressor clutch relay

17. Blower OFF relay
18. Fuse
19. Dual pressure switch
Function
(WA380-K540-042-K-00-A)
The air conditioner unit consists of evaporator (1) and heater core (2), and is used to cool down or warm
up the air in the cab.
Temperature control
When temperature control switches on the switch panel are operated, the set temperature data is sent
through the monitor controller to the air conditioner controller located at the front right of the operator's cab.
The air conditioner controller controls air mix servomotor (7) to change the angle of air mix door (6) so that
the set temperature is reached
Over-cooling (Freezing) prevention
Evaporator temperature sensor (14) varies the resistance of its resistor according to temperature.
The air conditioner controller converts the change in resistance of evaporator temperature sensor (14) into
the change in voltage to determine the temperature of evaporator (1).
The air conditioner controller drives compressor clutch relay (16) to run the compressor for cooling. If the
controller determines that cooling is excessive, it stops the compressor to prevent freezing of evaporator
(1).
a Compressor clutch relay (16) disengages if dual pressure switch (19) detects an abnormal refrigerant
pressure.
ON/OFF of air blow
When switches [AUTO] and [A/C] on switch panel are operated, the set data is sent to the air conditioner
controller through the monitor controller.
Blower OFF relay (17) engages when it receives signals from the air conditioner controller.
When blower OFF relay (17) engages, voltage is applied to terminals of blower motor (4) through blower
amplifier (13). As the result, blower motor (4) starts to run and air is sent.
Air flow adjustment
When switches of air flow adjustment on switch panel are operated, the set data is sent to the air
conditioner controller through the monitor controller. The air conditioner controller uses blower amplifier
(13) to control blower motor (4) so that the selected air flow is obtained.
Vent (mode) changeover
When vent switches on the switch panel are operated, the vent mode data is sent to the air conditioner
controller through the monitor controller. The air conditioner controller controls mode changeover
servomotor (5) to open and close mode changeover doors (8) to (10) so that the selected vents are
available.
FRESH/RECIRC air changeover
When the FRESH/RECIRC air changeover switch is operated, the set data of FRESH/RECIRC air
changeover is sent to the air conditioner controller through the monitor controller. The air conditioner
controller controls FRESH/RECIRC air changeover servomotor (11) to open or close FRESH/RECIRC air
changeover door (12).
Automatic mode of air conditioner
Inner sensor (inside air temperature sensor) (15) varies resistance of its resistor according to temperature.
The air conditioner controller converts the change in resistance of inside air temperature sensor (15) into
the change in voltage to determine the room temperature.
The air conditioner controller checks the voltage of inside air temperature sensor (15) and controls the
room temperature so that it matches the setting made on the machine monitor.
The air conditioner controller also takes into consideration data from the sunlight sensor and the outer
sensor (outside air temperature sensor) when adjusting the room temperature.
a The door is the same as the damper.
80-10
WA470-7
80 Appendix
Functions of major components
(ALL-K540-001-K-00-A)
a For details of the numbers in the following sentence, see Air conditioner unit.
Evaporator
(WA380-K549-042-K-00-A)
Evaporator (1) is cooled by low-pressure and low-temperature refrigerant gas sent from expansion valve
(3).
The air sent by blower motor (4) is cooled and dehumidified as well when the air passes through the fins of
the evaporator.
Heater core
(WA380-K547-042-K-00-A)
Heater core (2) is heated by hot water (engine coolant) sent from the engine.
Air sent by blower motor (4) is heated when it passes through the fins of the heater core (2).
Evaporator temperature sensor
(WA380-K5FF-042-K-00-A)
Evaporator temperature sensor (14) is installed to evaporator (1) with the holder and changes its
resistance according to the temperature of the evaporator (1).
The air conditioner controller determines the evaporator temperature from the voltage value of the
evaporator temperature sensor (14) and turns the compressor on/off to prevent freeze of the evaporator
(1).
Resistance value between terminals
At 0 C: 6.65 kz
At 25 C: 2.0 kz
Inner sensor
(WA380-K55W-042-K-00-A)
The inner sensor (inside air temperature sensor) (15) is installed at the recirculation air suction port of the
air conditioner unit and changes the resistance of its resistor according to the temperature inside the cab.
The air conditioner controller converts this resistance value into the voltage value to determine the
temperature inside the cab.
Resistance: At 0 C: 7.2 kz
At 25 C: 2.2 kz
Blower amplifier
(WA380-K55Z-042-K-00-A)
The blower amplifier (4) receives signal current from the air conditioner controller and controls the blower
motor speed.
WA470-7
80-11
80 Appendix
Blower OFF relay
(WA380-K55D-042-K-00-A)
The coil of blower OFF relay (17) is energized or de-energize by signal current from the air conditioner
controller. When the coil of blower OFF relay (17) is energized and blower OFF relay (17) engages, blower
motor (4) is powered.
Compressor clutch relay
(WA380-K5FE-042-K-00-A)
Signal current, that is sent from the air conditioner controller according to the operation of dual pressure
switch (14), controls the coil of compressor clutch relay (16). When the relay coil is energize to engage
compressor clutch relay (16), the electromagnetic clutch of compressor engages and the compressor
starts to run.
Servomotor
80-12
(WA380-K5D2-042-K-00-A)
WA470-7
80 Appendix
a Servomotors are used for the temperature control (air mix), vent (mode) changeover, and FRESH/
RECIRC air changeover.
When each switch on the machine monitor is pressed, the air conditioner controller applies 12 V power
between terminals (1) and (2) of the servomotor. (Rotation direction switches according to the polarity of
supply voltage.)
The servomotor contains a variable resistor, and its resistance value changes as the motor rotates.
The air conditioner controller applies a voltage of 5 V to the variable resistor and determines the motor
rotation angle from the potential difference.
When the door (damper) reaches the position specified by using the switch, the air conditioner controller
stops the supply of power to the servomotor, then the corresponding door stops.
Example of air mix servomotor (actuator)
The air mix actuator installed at the center of the air conditioner unit opens or closes the air mix door
through the linkage.
The air mix actuator has a potentiometer the voltage of which corresponds to the rotation angle of its shaft.
When the target position of air mix door is specified by using the temperature set switch, etc., the air
conditioner controller checks the current angle of the door from the voltage of potentiometer built in the
actuator, and determines the direction (polarity of voltage to be applied between terminals (1) and (2)) in
which the motor rotates. When the controller applies 12 V between terminals (1) and (2) and the motor
starts to rotates, the voltage of potentiometer changes according to the rotation angle of motor shaft.
When the air conditioner controller recognizes the voltage of potentiometer that shows the target door
position is reached, it stops the motor by stopping the supply of power between terminals (1) and (2).
When the air conditioner controller cannot recognize the potential voltage that corresponds to the
command to the servomotor, it generates a air conditioner failure code to inform the machine monitor of
failure in air conditioner system. Failure code [879EMC] or [879FMC] is displayed on the electrical system
failure record screen of the machine monitor.
a No failure code is prepared for failures in the FRESH/RECIRC air changeover servomotor.
a Do not try to drive a servomotor by supplying power directly between servomotor terminals (6) and (7)
during inspection.
Expansion valve
(WA380-K548-042-K-00-A)
The expansion valve converts high-pressure and high-temperature liquid refrigerant sent from the receiver
drier to low-pressure, low-temperature misty refrigerant through the throttle action.
Changing the throttle rate of this valve controls the amount of refrigerant flowing to the air conditioner unit
according to the temperature in the operator's cab.
The temperature of air blown out through the fins of evaporator (1) depends on the flow rate of refrigerant
that enters evaporator (1).
a Use 4-mm hexagonal wrench
3 Expansion valve mounting bolt:
6.9 Nm {0.7 kgm}
WA470-7
80-13
80 Appendix
Dual pressure switch
(WA380-K5FG-042-K-00-A)
a The dual pressure switch is installed to the refrigerant piping near the air conditioner unit.
The dual pressure switch turns "OFF" when it detects abnormally low refrigerant pressure in low-pressure
line or abnormally high refrigerant pressure in high-pressure line.
When the dual pressure switch turns "OFF", the compressor clutch relay disengages. Thus, the
electromagnetic clutch of the compressor is disengaged and air conditioner components are protected.
a LA or lower: Abnormally low pressure in low-pressure line

a HA or higher: Abnormally high pressure in high-pressure line
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
80-14
WA470-7
80 Appendix
Air conditioner controller
Air conditioner controller
(WA380-K5G4-041-K-00-A)
a For the operation of this controller, see "System chart".
WA470-7
80-15
80 Appendix
Compressor
Compressor
(WA380-K590-041-K-00-A)
A: Refrigerant inlet (from air conditioner unit)

B: Refrigerant outlet (to condenser)
Specification
(WA380-K590-044-K-00-A)
Number of cylinders - Bore x Stroke

Piston displacement (cc/rev)
Max. allowable speed (rpm)
Compressor oil to use
Compressor oil refill amount (cc)
Function
7 29.3 x 27.4
129.2
4,000
SANDEN: SP-10
135
(WA380-K590-042-K-00-A)
The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator
into a misty refrigerant at high pressure and high temperature so that it will be easily regenerated
(liquefied) at the normal temperature.
Built-in electromagnetic clutch is connected according to the temperature of evaporator and pressure of
refrigerant. Then compressor starts to run.
80-16
WA470-7
80 Appendix
Condenser
Condenser
(WA380-K580-041-K-00-A)

B: Refrigerant outlet (to receiver dryer)
Specifications
(WA470-K580-030-K-00-A)
Fin pitch (mm)

Total heat dissipation area (m2)
Max. operating pressure (MPa {kg/cm2})
Function
1.5
9.33
3.6 {36}
(WA380-K580-042-K-00-A)
The condenser liquefies high-pressure and high-temperature misty refrigerant sent from the compressor
by taking the heat from the refrigerant.
a If its cooling fins are crushed or clogged with dirt and dust, heat exchange efficiency lowers. Accordingly,
the condenser cannot liquefy the refrigerant entirely. If this happens, the circuit pressure in the refrigerant
cycle increases resulting in unnecessary load on the engine and poor cooling effect. Take care not to
crush the fins in handling and daily maintenance of the condenser.
WA470-7
80-17
80 Appendix
Receiver drier
Receiver drier
(WA380-K5E2-041-K-00-A)

B: Refrigerant outlet (to air conditioner unit)
1. Sight glass
Specifications
(WA380-K5E2-030-K-00-A)
Effective volume (cm3)

Weight of desiccating agent (g)
Function
578
300
(WA380-K5E2-042-K-00-A)
The receiver drier stores High-pressure and high-temperature liquid refrigerant sent from the condenser. If
bubbles are mixed in the liquid refrigerant depending on heat radiation condition of the condenser, the
receiver drier liquefies the refrigerant completely.
The built-in filter and desiccating agent eliminate foreign substances in the circulation circuit and water
content in the refrigerant.
The flow of refrigerant can be checked through sight glass (1).
80-18
WA470-7
80 Appendix
Receiver drier
If bubbles are seen in the refrigerant through sight glass (1) 5 minutes after the engine is started and the
A/C switch is turned on, the quantity of refrigerant is insufficient. If no bubble is seen, the air conditioner
system is filled with proper amount of refrigerant.
Note that no bubble is observed in the case where the system has no refrigerant (or excessive refrigerant).
WA470-7
80-19
80 Appendix
Sunlight sensor
Sunlight sensor
(WA380-K5FH-042-K-00-A)
Outline
The sunlight sensor is installed on top of the machine monitor.
This sensor uses a photo diode to determine the intensity of sunlight and converts it into current.
Only when the air conditioner is on AUTO mode, the air conditioner controller controls the blower motor
and the air mix servomotor with the data of the sunlight sensor in order to adjust the temperature and air
flow.
Voltages between terminals are almost as follows when the sunlight sensor receives sunlight on its optical
receiver.
Direct light: 0.45 V
Cloudy day: 0.35 V
Indoor: 0.2 V
80-20
WA470-7
80 Appendix
Outer temperature sensor (outside air temperature
sensor)
Outer temperature sensor (outside air temperature sensor)
(WA380-K55C-042-K-00-A)
Outline
The outer sensor (outside air temperature sensor) is installed under the operator's cab.
The outer sensor varies resistance of its resistor according to temperature.
The air conditioner controller determines the ambient temperature by converting the changes in the
resistance of the outer sensor resistor into voltage changes.
The air conditioner controller controls the blower motor and the air mix servomotor with the data of the
outer sensor in order to adjust the temperature and air flow.
Resistance value between terminals
At 0 C: 6.2 kz
At 25 C: 2.2 kz
WA470-7
80-21
80 Appendix
Procedure for testing and troubleshooting
(WA380-K500-422-K-00-A)
The air conditioner is provided with self-diagnosis function in order to test its main components. Specifically, it
can test the operation of sensors and servo motor.
If a troubled section is detected , every part of that section must be inspected.
1. After basic test, find the troubled section according to the detected trouble of the air conditioner.
2. Narrow down the sections with the self-diagnosis function (See "Inspection by self-diagnosis function").
However, if the air conditioner unit does not operate at all, check to see whether power is supplied to the
air conditioner controller normally, and also check to see whether CAN communication between machine
monitor and air conditioner controller operates normally.
If any part of the air conditioner unit is operating, power is supplied to the air conditioner controller, and
CAN communication between machine monitor and air conditioner controller is normal.
3. After finding out the defective part, inspect its component and repair the failure.
Basic flow of testing and troubleshooting
*1 Error display on machine monitor and Abnormality Record screen.

*2 Simple checking of refrigerant volume through sight glass.
Start the engine, turn the air conditioner switch ON, and check after 5 minutes.
A) When bubbles are continually seen, the quantity of refrigerant is insufficient
B) When bubbles are seen intermittently, the quantity of refrigerant is proper
C) When no bubble is seen (i.e., the liquid is clear), the system has too much refrigerant or no refrigerant
Use the above as a guideline since there are exceptions.
See "Troubleshooting with gauge pressure" and judge by the gauge pressure.
80-22
WA470-7
80 Appendix
S: Condition viewed through sight glass

R: Receiver drier internal condition
LR: Liquid refrigerant
*3 If the refrigerant leaks from a place, the compressor oil circulating in the air conditioner circuit also leaks
from that place.
In such a case, retighten according to the tightening torque table in "Precautions for disconnecting and
connecting air conditioner piping."
*4: Start the engine, turn the air conditioner switch ON, and check.
WA470-7
80-23
80 Appendix
Circuit diagram and arrangement of connector pins
(WA470-K500-051-K-00-A)
1/3
80-24
WA470-7
80 Appendix
2/3
WA470-7
80-25
80 Appendix
3/3
a Note that "W/L" and "WL", for example express the same thing.
80-26
WA470-7
80 Appendix
System diagram
System diagram
(WA380-K5F0-051-K-00-A)
a This air conditioner unit is auto temperature control type.
WA470-7
80-27
80 Appendix
System diagram
Input and output signals of the air conditioner controller

a A connector label is not attached to the air conditioner controller.
Connector [1]: AMP 040-16 (T-adapter: 799-601-7210)
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Symbol
MODE output 1
MODE output 2
F/R output 1
F/R output 2
OFF RELAY
Mg C output
24V POWER
Potentio GND
SENSOR GND
GND
Signal name
Mode output 1
Mode output 2
FRESH/RECIRC air output 1
FRESH/RECIRC air output 2
Blower OFF relay output
Electromagnetic clutch output
24 V power supply
Potentiometer GND
Sensor GND
GND
Input/Output
Output
Output
Output
Output
Output
Output
Input
Input
Input
Input
Connector [2]: AMP 040-20 (T-adapter: 799-601-7220)

Pin No.
Symbol
12 CAN_L
3 CAN_H
45 Potentio 5V
6 T in (INNER SENSOR)
7 EVA SENSOR
8 T out (OUTER SENSOR)
9
10
11
12
13
SUN LIGHT SENSOR

MODE potentio
Blow gate
14
15
16
17
18
19
20
AM potentio
Blow F/B
AM output 2
AM output 1
F/R Potentio
Signal name
CAN communication signal (L)
CAN communication signal (H)
Potentiometer 5 V power supply
Inside air temperature sensor
Evaporator temperature sensor
Outer temperature sensor (outside
air temperature sensor)
Sunlight sensor
Mode potentiometer signal
Blower gate output
FRESH/RECIRC air potentiometer
signal
Air mix potentiometer signal
Blower feedback signal
Air mix output 2
Air mix output 1
Input/Output
Input/Output
Input/Output
Output
Input
Input
Input
Input
Input
Output
Input
Input
Input
Output
Output
Note: Never connect pins marked with -. Malfunctions or failures may occur.
80-28
WA470-7
80 Appendix
System diagram
Operation of air conditioner controller

1. The monitor controller gets input from air conditioner control switches on the switch panel through LIN
communication. The air conditioner controller communicates with the monitor controller through CAN
communication to receive input from air conditioner control switches. The air conditioner controller uses
the information to control the air conditioner.
2. The air conditioner controller controls three servomotors located inside the air conditioner unit in order to
perform temperature control (air mix), vent (mode) changeover, and FRESH/RECIRC air changeover.
3. The air conditioner controller controls ON/OFF of the blower OFF relay (switch for blowing air) and
compressor clutch relay (switch for running the compressor).
4. The air conditioner controller controls the air flow volume by using the blower amplifier.
a The blower amplifier has a fuse for temperature in it.
5. The air conditioner controller determines the evaporator temperature using the evaporator temperature
sensor.
6. In order to prevent freezing of the evaporator, the air conditioner controller controls the compressor by
turning the compressor clutch relay ON and OFF.
a When the dual pressure switch detects an abnormal pressure (i.e., it turns off), the compressor stop
running because the compressor clutch relay disengages without through the air conditioner controller.
7. When the air conditioner is on AUTO mode, it adjust the room temperature to the set temperature based
on the data from the sunlight sensor, inner sensor (inside air temperature sensor), and outer sensor
(outside air temperature sensor).
8. The air conditioner controller has a self-diagnosis function and informs the machine monitor of an error if it
detects the error. Then failure code [879***] is displayed on the electrical system failure record screen of
WA470-7
80-29
80 Appendix
Parts and connectors layout
(WA380-K500-055-K-00-A)
a The number of unlabeled connector is shown in [ ].

Connector of air conditioner unit
80-30
WA470-7
80 Appendix
[1], [2] Air conditioner controller connectors

[3] Sunlight sensor connector
[4] Inside air temperature sensor connector
[5] Evaporator temperature sensor connector
[6] Outside air temperature sensor connector
[7] Air mix actuator connector
[8] Vent mode actuator connector
[9] FRESH/RECIC air changeover actuator connector
[11] Pressure switch connector
[12] Blower OFF relay connector
[13] Blower amplifier connector
[14] Compressor clutch relay connector
a Fuses are provided at two locations; inside the air conditioner unit (harness) and the fuse box at rear left of
operator's seat (double arrangement).
1. Open the cover of fuse box at the rear left of the operator's seat. See Troubleshooting, "Location of
fuses".)
Fuse No. 8 in fuse box 1: 20 A
For power supply of blower (fan)
For air conditioner compressor
For power supply of air conditioner unit
Part No. of fuse
5 A: 08041-00500
20 A: 08041-02000
3. A 5 A fuse and a 15 A fuse (part P) are provided on the right side of air conditioner unit (2).
a Identify the 5 A fuse and 15 A fuse by harness color. (See "Circuit diagram".)
WA470-7
80-31
80 Appendix
Part No. of fuse

5 A: 08041-00500
15 A: 08041-01500
4. Chassis harness connector AL1 is provided under air conditioner controller (3).
a [1], [2], and [14] are symbols used on the circuit diagram.
5. Pressure switch connector [11] is installed to the air conditioner tube on the right side of the air conditioner
unit.
80-32
WA470-7
80 Appendix
6. Remove left cover (4) and find inside air temperature sensor (5) on its back.
7. Outside air temperature sensor (7) and its connector are under the bottom-right of the operator's cab.
8. Intermediate connector LR1 is at the bottom-left of the floor frame.
WA470-7
80-33
80 Appendix
a Connector LR1 is DRC-70, so handle it with care. See the following.

How to disconnect connector LR1
Remove the connector straight slowly and check it for breakage and coming off of the seal and
sticking of foreign matter.
a If the seal is defective, replace it.
How to install connector LR1
1) Check that the seal is installed to the plug correctly.
2) Check that the key can be fitted to the key way on the receptacle (it must be in the correct
direction).
3) Match the connector on the plug side straight with the receptacle (since the seal is projected), and
fit the connector lightly while checking that the seal does not roll up.
4) Tighten the hexagonal head bolt at the center of the connector by 2 to 3 turns.
5) Connect the connector on the plug side fully and adjust it so that the clearance between it and
receptacle will be even when viewed from each direction.
6) Tighten the lock bolt to the specified torque.
3 Hexagonal head lock bolt:
2.8 0.3 Nm {0.28 0.03 kgm}
a Take care not to tightening the lock bolt excessively. Doing so can break the connector and it cannot be
locked.
80-34
WA470-7
80 Appendix
Testing with self-diagnosis function
Testing with self-diagnosis function

Testing
(HM300-Q19Y-001-K-00-A)
(WA380-Q19Y-360-K-00-A)
On the air conditioner operation screen of the machine monitor, the system performs various self-diagnosis
such as the communication between the machine monitor and air conditioner controller, inside air
temperature sensor, outside air temperature sensor, evaporator temperature sensor, sunlight sensor,
temperature control system, and vent (mode) changeover system. If any failure is detected, the "Air
conditioner system condition monitor" appears on the screen.
a Once a failure is detected in the self-diagnosis, the error condition is not canceled even if the failed part
returns to normal. The self-diagnosis error condition is canceled by turning the starting switch to OFF
position.
a The system performs self-diagnosis of various sensors. If any failure is detected, a failure code is
displayed on the electrical systems abnormality record screen in the service mode of the machine monitor,
.
a FRESH/RECIRC air changeover servomotor is not checked in the self-diagnosis.
WA470-7
80-35
80 Appendix
How to open the electrical system abnormality record
screen in service mode of the machine monitor
How to open the electrical system abnormality record screen in service

mode of the machine monitor (WA380-Q19Y-100-K-00-A)
Overview of machine monitor operating procedure
Normal screen
O While pressing [R], press (1), (2), and (3) in this order.
Service menu (Mode)
O Press [R] twice. Press "check mark" (4).
03 Abnormality record
O Press [R] once. Press "check mark" (4).
02 Electrical Systems screen
Detailed description of machine monitor operating procedure
1. On the normal operation screen, while pressing "friangle mark" [R] (6), press number key (1), (2), and (3)
in this order.
2. On the service menu screen, press the "triangle mark" [R] twice, and then select "03 Abnormality
Record".
3. Press the "check mark" (described previously) to confirm.
4. On the abnormality record screen, press the "triangle mark" [R] once, and then select "02 Electrical
Systems".
5. Press the "check mark" (described previously) to confirm.
80-36
WA470-7
80 Appendix
How to open the electrical system abnormality record
screen in service mode of the machine monitor
a For details, see the failure code list related to air conditioner
Failure code
879AKA
879AKB
879BKA
879BKB
879CKA
879CKB
879DKZ
879EMC
879FMC
DAZ9KQ

A/C Inner Sensor Open Circuit
A/C Inner Sensor Short Circuit
A/C Outer Sensor Open Circuit
A/C Outer Sensor Short Circuit
Ventilating Sensor Open Circuit
Ventilating Sensor Short Circuit
Sunlight Sensor Open or Short Circuit
Ventilation Dumper Abnormality
Air Mix Dumper Abnormality
A/C Model Selection Abnormality
DAZQKR
CAN2 Discon (Aircon ECU)
Remarks
*
*
*
*
*
See Chapter 40,
"Troubleshooting by failure
code"
**
*: See Part and connectors layout for each sensor connector.

**: Troubleshooting is not performed by the air conditioner unit but by the machine monitor.
a The A/C inner sensor means the inside (air) temperature sensor.
a The A/C outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The ventilation damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).
WA470-7
80-37
80 Appendix
Testing temperature control system
(WA380-K558-001-K-00-A)
k Place
the machine on a level ground, turn parking brake switch to PARK position, and chock
wheels.
a Note the connector numbers and installed positions before disconnecting wiring harnesses and hoses.
Testing
(WA380-K558-360-K-00-A)
The mixing ratio of hot air sent from the heater to cool air from the evaporator, those are mixed at the air
mix section in the air conditioner unit, is controlled by changing the angle of the damper. Temperature
control is performed as mentioned above. The vent mode actuator changes the damper angle through the
links and a cam. Visually check this cam.
a If failure code [879EMC] is displayed on the electrical system abnormality record screen, the air
conditioner controller does not drive the vent mode actuator because of the self-diagnosis error condition.
(2): Air conditioner unit
2. Check connector [7] for poor contact.

3. If failure code [879EMC] is displayed on the electrical system abnormality record screen (see "Testing with
self-diagnosis function"), check whether cam (3) stops halfway, and remove the cause (catching,
interference, foreign matters) to repair it..
4. Turn off power of the air conditioner once, and turn the starting switch to OFF position. (To cancel selfdiagnosis error condition)
5. Turn the starting switch to ON position, then turn on power of the air conditioner.
6. Operate the temperature adjustment switch (see "Testing with self-diagnosis function") and check whether
cam (3) moves between the points of 18 C and 32 C smoothly as shown in the following figures.
a If the links mentioned above do not move smoothly, clean and grease the links.
2 Link: Grease (G2-LI)
(8): Air mix actuator
80-38
WA470-7
80 Appendix
a For electrical failures, see Troubleshooting, "Failure code [879FMC] Air Mix Damper Abnormality".
WA470-7
80-39
80 Appendix
Testing vent (mode) changeover
(HM300-K5FR-001-K-00-A)
k Place
wheels.
Testing
(WA380-K5FR-360-K-00-A)
The vent (mode) is set to any modes, mainly to any one of Defroster, Foot, and Face modes, by changing
the angles of three dampers. The vent mode actuator changes the damper angle through the links and a
cam. Visually check the links and cam.
a To cancel self-diagnosis error condition, turn the starting switch to OFF position.
a If failure code [879EMC] is displayed on the electrical system abnormality record screen, the air
conditioner controller does not drive the vent mode actuator because of self-diagnosis error condition.

3. If failure code [879EMC] is displayed on the electrical system abnormality record screen, operate the
mode switch and defroster switch to check whether any of links (3) and (4) and cam (5) stop halfway. If
either of them is stopped, remove the cause (catching, interference, foreign matters) to repair it.
4. Turn off power of the air conditioner once, and turn the starting switch to OFF position. (To cancel selfdiagnosis error condition)
5. Turn the starting switch to ON position, then turn on power of the air conditioner.
6. Operate the mode switch and defroster switch to check that links (3) and (4) and cam (5) move normally.
(6): Vent mode actuator
FACE
a Photo shows the case where the set temperature is 18 C.
a When a vent mode other than FACE is selected, links (3) and (4) and cam (5) are positioned as shown in
the following photos.
a Photos show the case where the set temperature is 18 C.
80-40
WA470-7
80 Appendix
FACE/FOOT
FOOT
FOOT/DEF
DEF
a For electrical failures, see Troubleshooting, "Failure code [879EMC] Ventilation Damper Abnormality".
WA470-7
80-41
80 Appendix
Testing FRESH/RECIRC air changeover
(WA380-K5D2-001-K-00-A)
k Place
wheels.
Testing
(WA380-K5D2-360-K-00-A)
FRESH/RECIRC air changeover is performed by changing the angle of the damper. FRESH/RECIRC air
changeover actuator changes the damper angle through the lever. Visually check opening and closing of this
damper.
a In the self-diagnosis, only motor locking is checked.
(No failure code is generated because check for open circuit and short circuit is not performed.)
a The air conditioner controller does not drive the FRESH/RECIRC air changeover actuator if any failure
found in the self-diagnosis still exists.
1. Remove cover (1), and remove inner sensor (inside air temperature sensor) (2) from the back of the cover.
2. Check connector [9] of the FRESH/RECIRC air changeover actuator for poor contact.
3. When no failure is found in the self-diagnosis, check whether lever (3) or FRESH/RECIRC air changeover
damper (4) is stopped halfway. If either of them is stopped, remove the cause (catching, interference,
foreign matters) to repair it.
4. If no failure is found in the self-diagnosis, turn on the air conditioner and operate FRESH/RECIRC air
changeover switch to check whether FRESH/RECIRC air changeover damper (4) opens and closes
normally.
80-42
WA470-7
80 Appendix
a Photo shows the case where RECIRC air setting is selected.
a If FRESH air setting is selected, lever (3) is positioned as shown in the following photo.
WA470-7
80-43
80 Appendix
Check evaporator temperature sensor
(WA500-K5FF-360-K-00-A)
k Place
the machine on a level ground, turn parking brake switch to the PARK position, stop the
engine, and chock wheels.
k Turn
the battery disconnect switch to the OFF position and remove the key.
Check when error occurs with self-diagnosis.
To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.

3. Turn the starting switch to the OFF position, and disconnect connector [5].
4. Measure the resistance between terminals of connector [5] (evaporator temperature sensor side).
Standard value: 6.65 kz (at 0C)
2.0 kz (at 25C)
80-44
WA470-7
80 Appendix
If there is an abnormality, remove the air conditioner unit (see Disassembly and Assembly "Removal of
Ar Conditioner Unit"), remove evaporator temperature sensor (4) from evaporator (3) and replace it
(see a development of "Air Conditioner Unit").
a Precaution when replacing the evaporator temperature sensor (mounting position of evaporator
temperature sensor)
Place the evaporator with its flange for inlet/outlet at right side. Install the evaporator temperature
sensor with its end at 80 5 mm below from the upper end of fin and at the center of the 12th fin from
the right. (Insert center holder (5) in the 11th fin and fix it.)
a If error occurs with self-diagnosis and evaporator temperature sensor is normal, either air conditioner
controller or wiring harness is defective. (See failure code [879CKA], [879CKB].
WA470-7
80-45
80 Appendix
Testing relays
Testing relays
(WA380-K5FE-360-K-00-A)
a If air conditioner is normal (cool) and air blow out , it is normal. Skip trouble shooting.
a Listen closely to the relay to check whether or not it is defective.
There are two relays as follows. (See "Parts and connectors layout".)
Blower OFF relay: ON/OFF of fan motor (connector [12])
Compressor relay: ON/OFF of air conditioner compressor (clutch) (connector [14])
a To check blower OFF relay, hot water hose should be removed. Otherwise it cannot be checked.
2. Turn starting switch to ON position (engine stopped), turn main switch of air conditioner ON, then blower
OFF relay is turned ON if it is normal. Check that a click is heard.
3. Turn air conditioner switch to ON position, compressor relay is turned ON if it is normal. Check that a click
is heard.
a The controller panel will not turn on the compressor relay in the following cases.
1) When evaporator temperature is 3C or below (with evaporator temperature sensor)
2) When the pressure switch detects abnormality (it is turned OFF).
80-46
WA470-7
80 Appendix
Testing relays
a When fan noise is too loud to hear the compressor relay, perform the following.
1) Turn main switch to OFF position, and disconnect battery ground cable.
2) Disconnect connector [12].
3) Test the relay after connecting battery ground cable.
Checking relay unit
1. The coil resistance between terminal (1) and (2) is 320 z
2. When voltage is not generated between terminal (1) and (2), terminal (3) is not connected to terminal
(4).
3. When voltage is generated between terminal (1) and (2), terminal (3) is connected to terminal (4).
WA470-7
80-47
80 Appendix
Troubleshooting chart 1
(PC220-3840-421-A-00-A)
Numbers in T represent the item numbers in the troubleshooting quick reference table.
1. Lowered cooling performance
2. Lowered heating performance
80-48
WA470-7
80 Appendix
(WA380-3840-421-A-00-A)
1. Blower fan motor does not operate or rotation speed does not match air flow setting.
a See "Troubleshooting for blower motor system (No air comes or air flow is abnormal)" in Electrical
system troubleshooting.
Probable cause
Check method
Defective blower OFF relay See "Testing relays"
Check for coming off of connector, etc.
Wire breakage or defective
See "Troubleshooting for blower motor system" and
contact of connector
"Parts and connectors layout".
Use two lead wires to check blower motor with
multimeter. If no continuity is found, blower motor is
defective.
Defective blower motor
See "Troubleshooting for blower motor system" and
"Parts and connector layout".
Operate fan switches to select settings in order and
Defective blower amplifier
check fan speed.
Remedy
Replace.
Repair open section.
Connect connector
correctly.
Replace.
Replace.
2. During cooling, blower fan motor is normal but air flow is very light.
Probable cause
Large duct resistance
Air leakage
Obstruction on evaporator
suction side
Defective evaporator
temperature sensor
Poor contact of evaporator
temperature sensor
Defective expansion valve
Check method
Check filter for clogging and duct for crushing.
Check joint of duct.
Check duct for defective sealing and coming off.
Remedy
Repair.
Check evaporator for dirt and obstruction
Remove obstruction
and clean.
Repair or replace.
Evaporator is frozen.
Check sensor fixing clip, check sensor for dirt and dust.
Repair or replace.
Check air conditioner hose near pressure switch for frost
(if evaporator is freezing further).
a The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.
3. Pressure abnormality (high-pressure/low-pressure) during cooling.
Probable cause
Check method
On the cooling cycle using R134a as refrigerant, the

amount of refrigerant cannot be checked through sight
glass.
Specifically, perform checking with the gauge manifold
connected.
Overcharge with refrigerant
Sight glass is provide for check of refrigerant flow.
Insufficient refrigerant
Normal refrigerant pressure range

Pressure of low-pressure line: Approx. 0.13 to 0.2 MPa
{1.3 to 2.0 kg/cm2}
Failure judgement from
Pressure of high-pressure line: Approx. 1.5 to 1.7 MPa
refrigerant pressures at
{15 to 17 kg/cm2}
compressor inlet and outlet
Under following conditions. Temperature inside cab: 30
to 35 C
Engine speed: Approx. 1500 rpm
Remedy
Repair leaking part,
then fill with proper
quantity of refrigerant
again
Collect refrigerant,
then fill with proper
quantity of refrigerant
again.
See Troubleshooting
with gauge pressure.
4. Compressor does not rotate or does not rotate smoothly.

a See "Troubleshooting for compressor and refrigerant system (Air is not cooled)" in Electrical system
troubleshooting.
WA470-7
80-49
80 Appendix
Failed part
Probable cause
Compressor
Loosened belt
belt
Internal defect of
compressor
Compressor
Insufficient compressor oil
Seizing of compressor
Drop of battery voltage
Open or short circuit in coil
Electromagnetic clutch Open circuit in wiring
harness or defective
connection of ground cable
Defective compressor
Relay
clutch relay
Abnormal refrigerant
Refrigerant
pressure (actuation of
pressure
pressure switch)
Pressure
Defective pressure switch
switch
Check method
Remedy
Check belt for excessive undulation.
Adjust belt tension.
Check belt for slipping.
Repair or replace.
Check compressor for overheating.
See "Handling of
compressor oil".
Charge battery.
Replace.
Check clutch for slipping.

Check by using multimeter.
Check ground cable and its connection.
See "Troubleshooting for compressor and Repair.
refrigerant system".
See "Testing relays"
Replace.
See "Troubleshooting with gauge

pressure".
See "Troubleshooting
with gauge pressure".
See "Troubleshooting for compressor and

Replace.
refrigerant system".
5. Blower fan motor is normal but air flow is insufficient.

Probable cause
Large duct resistance
Air leakage through duct
joints
Clogging of heater core
fins
6. Check of hot water
Check method
Check filter for clogging and duct for crushing.
Check joint of duct.
Check duct for defective sealing and coming off.
Remedy
Repair.
Check heater core fins for clogging
Repair.
Probable cause
Low engine coolant
temperature
Low engine coolant level
Insufficient circulation of
engine coolant
Reversed connection of IN
and OUT heater hoses
7. Fan speed
Check method
Warm up engine, and then check engine coolant
temperature
Check coolant level in radiator.
Check engine coolant piping for clogging.
(Hose, pipe, and core)
Probable cause
Lowered fan speed
(Defective EPC or
hydraulic system of fan
motor)
Check destination of heater hoses.
Check method
See Shop manual, Chapter 30, Testing and adjusting,
"Testing hydraulic driven fan".
Repair.
Remedy
Find out cause.
Add coolant.
Bleed air or correct.
Repair.
Remedy
Repair.
8. Others
Probable cause
Temperature control does
not work.
Check method
See "Testing temperature control" and Troubleshooting,
"Failure code [879FMC] Air Mix Damper Abnormality".
See "Testing vent (mode) changeover and
Vent (mode) changeover
Troubleshooting, "Failure code [879EMC] Ventilation
does not work.
Damper Abnormality".
See "Testing FRESH/RECIRC air changeover" and
FRESH/RECIRC air
Troubleshooting related to "FRESH/RECIRC air
changeover does not work.
changeover".
Excessive compressor oil See "Handling of compressor oil".
Water leakage into the cab Check drain hole for clogging.
80-50
Remarks
Common to cooling
and heating
Cooling only
WA470-7
80 Appendix
(ALL-5170-421-A-03-A)

Failure
Related information
Failure symptom that appears on machine

Cause

[Information described]
Procedure
Measuring location
a "Between A and B" denotes measuring voltage or resistance, etc.

between A and B.
Probable cause of failure
Criteria to determine probable causes

(Perform troubleshooting
Remarks for judgment of Good or No good

according to these.)
[Notes on troubleshooting]
(1) pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (-) tester leads
as shown below unless otherwise specified.
Connect the plus (+) lead to a pin or harness indicated in the
front.
Connect the minus (-) lead to a pin or harness indicated in the
rear.
Defective
(2) Example of troubleshooting done by testing multiple items
a Normal in 1 but abnormal in 2
At this time, "Defective component" shown at left 3 is applied.
a If a wiring harness is burnt, replace it.

[Defective wiring harness]
Open circuit
Connection of connector is defective or wiring harness is broken.
Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
Hot short circuit
A harness not to be connected to the power (24V) circuit comes into contact with the power (24V) circuit
accidentally.
Short circuit
An independent wire in the harness abnormally comes into contact with another independent wire. (poor
insulation at connector and others)
Related circuit diagram
This is the extracted circuit diagram related to failure
Indicates connector No., and pin No.
See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for
connector location
The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr:
Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
N.C.: Normally closed (Normally ON)
[1], [2], ... are numbers of unlabeled connectors.
The arrow (io) indicates their rough installation position on the machine.
WA470-7
80-51
80 Appendix
Failure code list related to air conditioner
Failure code list related to air conditioner

Failure code
879AKA
879AKB
879BKA
879BKB
879CKA
879CKB
879DKZ
879EMC
879FMC
DAZ9KQ
DAZQKR
Failure (Displayed on
screen)
A/C Inner Sensor Open
Circuit
A/C Inner Sensor Short
Circuit
A/C Outer Sensor Open
Circuit
A/C Outer Sensor Short
Circuit
Ventilating Sensor
Open Circuit
Ventilating Sensor
Short Circuit
Sunlight Sensor Open
or Short Circuit
Ventilation Dumper
Abnormality
Air Mix Dumper
Abnormality
A/C Model Selection
Abnormality
CAN2 Discon (Aircon
ECU)
(WA380-K500-441-K-00-A)
Applicable
component
Action
level
MON
MON
MON
MON
MON
MON
MON
MON
L01
MON
L01
MON
MON
L01
History
category
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Remarks
For each connector of
sensor, see "Parts and
connectors layout".
connectors layout".
connectors layout".

connectors layout".
See Chapter 40,

"Troubleshooting by failure
code"
a The "air conditioner inner sensor" means the inside (air) temperature sensor.
a The "air conditioner outer sensor" means the outside (air) temperature sensor.
a The "ventilating sensor" means the evaporator temperature sensor (frost sensor).
a The "ventilation damper" means the vent (mode) changeover damper (door).
a The "air mix damper" means the temperature adjustment (air mix) damper (door).
a Troubleshooting for the troubles which do not display failure codes are listed below the failure code
[879FMC].
"Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)"
"Troubleshooting for compressor and refrigerant system (Air is not cooled)"
"Troubleshooting for blower motor system (No air comes out or air flow is abnormal)"
"Troubleshooting for FRESH/RECIRC air changeover"
80-52
WA470-7
80 Appendix

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA500_7-879AKA-400-A-Z0-A)
Open circuit in air conditioner inside air temperature sensor

Failure code
Failure
879AKA
Open circuit of inside air temperature sensor inlet line is detected by air conditioner
controller.
Free angle control by air mix control and set temperature
Control of mode and blower: Cancel of AUTO control
The air conditioner does not operate in AUTO mode.
For each connector location, see "Parts and connectors layout".
For pin location of each connector, see "Circuit diagram and arrangement of connector
pins".
T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
The T-adapter is not prepared for the other connectors.
Cause
Defective inside air

temperature sensor

1. Turn the starting switch to the OFF position.
2. Disconnect connector [4] and connect T-adapters to male side.
Tempera7.2 kz
ture: 0C
Resis- Between [4] (male) (1) and (2)
tance
Tempera2.2 kz
ture: 25C
2. Disconnect connectors [1] and [2], and connect T-adapters to each
female side.
Open or short circuit in wiring a The resistance is same as the resistance of inside air temperature
harness
sensor measured in above.
TemperaResis- Between [2] (female) (6) and [1]
7.2 to 2.2
ture: 0 to
(female) (10)
tance
kz
25C
Open circuit in wiring harness 1. Turn the starting switch to the OFF position.
2. Disconnect connectors [1], [2] and [4], and connect T-adapters to
female side of [1] and [2].
Max. 1 z
Resis- Between [1] (female) (10) and [4] (female) (2)
tance
Between [2] (female) (6) and [4] (female) (1)
Max. 1 z
controller
defective.
WA470-7
80-53
80 Appendix
Circuit diagram related to temperature sensor of air conditioner
80-54
WA470-7
80 Appendix

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA500_7-879AKB-400-A-Z0-A)
Short circuit in air conditioner inside air temperature sensor

Failure code
Failure
879AKB
Short circuit of inside air temperature sensor inlet line is detected by air conditioner
controller.
Free angle control by air mix control and set temperature
Control of mode and blower: Cancel of AUTO control
The air conditioner does not operate in AUTO mode.
pins".
Cause
Defective inside air

temperature sensor

Tempera7.2 kz
ture: 0C
tance
Tempera2.2 kz
ture: 25C
female side.
Open or short circuit in wiring a The resistance is same as the resistance of inside air temperature
harness
7.2 to 2.2
ture: 0 to
(female) (10)
tance
kz
25C
Short circuit in wiring harness 2. Disconnect connectors [1], [2] and [4], and connect T-adapters to
Resis- Between [1] (female) (10) and [2] (female) (6),
Min. 1 Mz
or between [4] (female) (1) and (2)
tance
Ground fault in wiring harness 2. Disconnect connectors [2] and [4], and connect T-adapter to female
side of [2].
Resis- Between ground and [2] (female) (6) or [4]
Min. 1 Mz
(female) (1)
tance
controller
defective.
WA470-7
80-55
80 Appendix
80-56
WA470-7
80 Appendix

Action level
L100a
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA500_7-879BKA-400-A-Z0-A)
Open circuit in air conditioner outside air temperature

sensor
879BKA
Open circuit of outside air temperature sensor inlet line is detected by air conditioner
controller.
Failure code
Failure
Controls with ambient temperature fixed at 25C.

Air conditioner in AUTO mode is controlled without using outside air temperature sensor.
pins".
Cause
Defective outside air

temperature sensor

Tempera6.2 kz
ture: 0C
tance
Tempera2.2 kz
ture: 25C
female side.
Open or short circuit in wiring a The resistance is same as the resistance of outside air temperature
harness
6.2 to 2.2
ture: 0 to
(female) (10)
tance
kz
25C
Max. 1 z
tance
Max. 1 z
controller
defective.
WA470-7
80-57
80 Appendix
80-58
WA470-7
80 Appendix

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA500_7-879BKB-400-A-Z0-A)
Short circuit in air conditioner outside air temperature

sensor
879BKB
Short circuit of outside air temperature sensor inlet line is detected by air conditioner
controller.
Failure code
Failure
Controls with ambient temperature fixed at 25C.

Air conditioner in AUTO mode is controlled without using outside air temperature sensor.
pins".
Cause
Defective outside air

temperature sensor

Tempera6.2 kz
ture: 0C
tance
Tempera2.2 kz
ture: 25C
female side.
Open or short circuit in wiring a The resistance is same as the resistance of outside air temperature
harness
6.2 to 2.2
ture: 0 to
(female) (10)
tance
kz
25C
Min. 1 Mz
tance
side of [2].
Min. 1 Mz
(female) (1)
tance
controller
defective.
WA470-7
80-59
80 Appendix
80-60
WA470-7
80 Appendix

Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA500_7-879CKA-400-A-Z0-A)
Open circuit in evaporator temperature (frost) sensor

Failure code
Failure
879CKA
Open circuit of evaporator temperature sensor inlet line is detected by air conditioner
controller.
Stops control of compressor.
The air conditioner does not cool the air. (Air conditioner compressor clutch is always
OFF.)
The ventilating sensor means the evaporator temperature sensor.
pins".
See "Check evaporator temperature sensor".
Cause
temperature sensor

Tempera6.65 kz
ture: 0C
tance
Tempera2.0 kz
ture: 25C
female side.
Open or short circuit in wiring a The resistance is same as the resistance of evaporator temperature
harness
6.65 to 2.0
ture: 0 to
(female) (10)
tance
kz
25C
Max. 1 z
tance
Max. 1 z
controller
defective.
WA470-7
80-61
80 Appendix
80-62
WA470-7
80 Appendix

Action level
L100a
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
(WA500_7-879CKB-400-A-Z0-A)
Evaporator temperature (frost) sensor short circuit

Failure code
Failure
879CKB
Short circuit of evaporator temperature sensor inlet line is detected by air conditioner
controller.
Stops control of compressor.
The air conditioner does not cool the air. (Air conditioner compressor clutch is always
OFF.)
The ventilating sensor means the evaporator temperature sensor.
pins".
See "Check evaporator temperature sensor".
Cause
temperature sensor

Tempera6.65 kz
ture: 0C
ResisBetween [5] (male) (1) and (2)
tance
Tempera2.0 kz
ture: 25C
female side.
Open or short circuit in wiring a The resistance is same as the resistance of evaporator temperature
harness
TemperaBetween [2] (female) (7) and [1]
Resis6.65 to 2.0
ture: 0 to
(female) (10)
tance
kz
25C
Min. 1 Mz
tance
side of [2].
Min. 1 Mz
(female) (1)
tance
controller
defective.
WA470-7
80-63
80 Appendix
80-64
WA470-7
80 Appendix
Failure code [879DKZ] Sunlight Sensor Open or Short
Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
(WA500_7-879DKZ-
441-A-Z0-A)
Action level
Detail of
failure
Action of
controller
Problem on
machine
Related
information
No.
Failure code
879DKZ
Failure
Sunlight Sensor Open or Short Circuit

Short or open circuit of sunlight sensor inlet line is detected by air conditioner controller.
Controls air conditioner in AUTO mode without sunlight compensation.
Even if the sunlight changes at AUTO mode of air conditioner, the temperature or air flow
of vent dos not change.
pins".
Cause

2. Disconnect connector [3], and remove the sunlight sensor.
a When measuring resistance between terminals of sunlight sensor, if
resistance range of tester is used, sunlight sensor may be damaged,
therefore, always check that tester is in voltage mode before
measuring.
1
Defective sunlight sensor
a Check that the voltage between sunlight sensor terminals changes

in accordance with the intensity of sunlight exposed to sunlight
sensor.
a Following voltage is reference value.
Direct
sunlight
Voltage
Between sunlight sensor terminals
Cloudy
Indoor
Approx.
0.45 V
Approx.
0.35 V
Approx.
0.2 V

female side.
2
Open or short circuit in wiring a The voltage is same as the voltage of sunlight sensor measured in
harness
above.
Approx.
Voltage Between [2] (female) (9) and [1] (female) (10)
0.2 to 0.45
V
Open circuit in wiring harness 2. Disconnect connectors [1], [2] and [3], and connect T-adapters to
Between [1] (female) (10) and [3] (harness
Max. 1 z
Resis- side) (W)
tance
Between [2] (female) (9) and [3] (harness side)
Max. 1 z
(RB)
side of [2].
Min. 1 Mz
(harness side) (RB)
tance
controller
defective.
WA470-7
80-65
80 Appendix
Failure code [879DKZ] Sunlight Sensor Open or Short
Circuit
Circuit diagram related to sunlight sensor
80-66
WA470-7
80 Appendix

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
(WA500_7-879EMC-400-A-Z0-A)
Abnormality in actuator of vent (mode) changeover damper

Failure code
Failure
879EMC
Abnormality in dive line of vent changeover, i.e. mode actuator (open or sort circuit), or
abnormality that rotation angle of mode actuator does not reach the target value, or
abnormality in potentiometer voltage is detected by air conditioner controller.
Stops mode actuator for vent mode.
Vent is not changed over even defroster switch or mode switch is pressed.
The ventilation damper means the vent (mode) changeover damper (door).
Even if link is disconnected (see "Check vent (mode)"), it is judged normal by selfdiagnosis if the voltage of potentiometer in actuator is correct when the current flows to
vent (mode) actuator by switch operation.
Air mix actuator and vent (mode) actuator are identical actuator, so maximum operating
angles are same. Accordingly, operation of actuator can be tested by connecting
connector [8] to connector [7].
Prepare a new actuator and connect connector [8] to it and check if the actuator operates.
With this test, you can also judge if the original vent (mode) actuator is defective.
For each connector, see "Parts and connectors layout".
pins".
a Since T-adapter is not prepared for other connectors, check the acting signal with air
conditioner controller.
No.
1
Cause
Defective vent (mode)
changeover system

actuator (unit test)
WA470-7

See "Testing vent (mode) changeover".
a Check for contact of connector [8] and mechanical failure
(disconnection or interference of link).
2. Disconnect connector [8] and perform troubleshooting without
turning the starting switch to the ON position.
Between [8] (actuator side) (1) and (2) (with no
Approx.
180 z
Approx.
Resisopen or short circuit)
4.7 kz
tance
Approx.
580 z to
4.1 kz
80-67
80 Appendix
No.
Cause

2. Disconnect connectors [1] and [2], and insert T-adapters.
3. Turn the starting switch to the ON position.
Voltage Between [2] (5) and [1] (9)
5V
1.
2.
3.
4.

actuator, defective air
conditioner harness,
defective air conditioner
controller

harness

controller

(defective switch)
80-68
Turn the starting switch to the OFF position.

Disconnect connectors [1] and [2], and insert T-adapters.
Turn the starting switch to the ON position.
Be ready with FACE by operating vent switch on the air conditioner
operation screen.
5. Change it to DEFROSTER by operating vent switch on the air
conditioner operation screen.
a The voltage is generated between connector [1] (2) and [1] (3) for
approx. 3 seconds (only while door moves).
a The voltage between connector [2] (5) and [1] (16) changes for
approx. 3 seconds (only while door moves). (When door stops, the
voltage is stabilized to fixed value.)
Between [1] (2) (+) and [1] (3) (-)
a When vent is changed from DEFROSTER Approx. 12
V
to FACE, the polarity of voltage becomes
Voltage
reverse.
Varies
Between [2] (11) (+) and [1] (9) (-)
within
max. 5 V
a Perform when test result for cause 2 is normal and that for cause 3 is
abnormal.
Check by referring to circuit diagram.
a When test result for cause 2 is normal and that for cause 3 is
abnormal and that for cause 4 is normal, air conditioner controller is
defective.
2. Display the air conditioner operation screen on the machine monitor.
Operate the vent switch to change the LCD
display as FACE, FACE and REAR, FOOT and LCD display changes
FCE and REAR, FOOT, FOOT and
to each mode.
DEFROSTER, DEFRSTER.
WA470-7
80 Appendix
Circuit diagram related to vent (mode) changeover
WA470-7
80-69
80 Appendix

Action level
L01
Detail of
failure
Action of
controller
Problem on
machine
Related
information
(WA500_7-879FMC-400-A-Z0-A)
Abnormality in air mix (temperature control) damper

actuator
879FMC
Abnormality in dive line of temperature control air mix actuator (open or sort circuit), or
abnormality that open/close of temperature control air mix actuator does not reach the
target value, or abnormality in potentiometer voltage is detected by air conditioner
controller.
Failure code
Failure
Stops mode actuator for air mix.

Temperature control of vent does not work.
a A/M means air mix temperature control of cool air and warm air.
Even if link is disconnected (see "Check temperature control"), it is judged normal by selfdiagnosis if the voltage of potentiometer in actuator is correct when the current flows to air
mix actuator by switch operation.
Air mix actuator and vent (mode) actuator are identical actuator, so maximum operating
angles are same. Accordingly, operation of actuator can be tested by connecting
connector [7] to connector [8].
Prepare a new actuator and connect connector [7] to it and check if the actuator operates.
With this test, you can also judge if the original air mix actuator is defective.
pins".
No.
1
Cause
Defective air mix damper
system
Defective air mix actuator

(unit test)
80-70

See "Testing temperature control system"
a Check for contact of connector [7] and mechanical failure
(disconnection or interference of link).
turning the starting switch to the ON position.
Approx.
180 z
Approx.
4.7 kz
tance
Approx.
580 z to
4.1 kz
WA470-7
80 Appendix
No.
Cause

2. Disconnect connectors [1] and [2], and insert T-adapters.
5V
1.
2.
3.
4.
Defective air mix actuator,

harness, defective air

Disconnect connectors [1] and [2], and insert T-adapters.
Be ready with COOL MAX by operating temperature control switch
on the air conditioner operation screen.
5. Change to HOT MAX by operating temperature control switch on the
air conditioner operation screen.
approx. 3 seconds (only while door moves).
a The voltage between connector [2] (16) and [1] (9) changes for
approx. 3 seconds (only while door moves). (When door stops, the
voltage is stabilized to fixed value.)
Between [2] (20) (+) and [2] (19) (-)
Approx. 12
a When vent is changed from HOT MAX to
V
COOL MAX, the polarity of voltage
Voltage
becomes reverse.
Varies
Between [2] (16) (+) and [1] (9) (-)
within
max. 5 V

harness

controller

(defective switch)
WA470-7
a Perform when test result for cause 2 is normal and that for cause 3 is
abnormal.
defective.
LCD display changes
Press temperature control switch.
between 18 to 32 C.
80-71
80 Appendix
Circuit diagram related to temperature control (A/M)
80-72
WA470-7
80 Appendix
A-1 Troubleshooting for power supply and CAN
communication system (Air conditioner does not
operate)
A-1 Troubleshooting for power supply and CAN communication system

(Air conditioner does not operate) (WA500_7-FJ0-400-A-Z0-A)
Air conditioner does not operate due to a failure of power supply or CAN communication
system.
Problem on [DAZQKR] is displayed on the "Electric Systems" screen of machine monitor.
machine No air blows out (Blower motor does not rotate).
Failure
a The machine monitor, monitor controller, engine controller, transmission controller, work
equipment controller, KOMTRAX and air conditioner controller are connected via CAN
communication.
[DAZQKR] is displayed on the "Electric Systems" screen of machine monitor in the following
cases. All of 1), 2), and 3) below will be covered here.
1. The air conditioner controller is receiving no power.
2. The air conditioner controller is broken.
3. No communication is possible between the air conditioner controller and the monitor
controller.
Referring to "Check by self-diagnosis function", display the "Electrical Systems" screen on
the machine monitor to check whether CAN communication is abnormal or not. An
abnormality in CAN communication refers to the state in which CAN communication
Related
between the air conditioner controller on the front right of the cab and the monitor controller
information
is disabled.
For all of 1, 2, and 3 above, abnormality of CAN communication is displayed. ([DAZQKR] is
displayed.)
Ground cable of air conditioner is connected in machine wiring harness together with
electrical equipment of machine.
pins".
In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for
compressor and refrigerant system".
a The T-adapter is not prepared for the other connectors.
No.
Cause

(ground)

3. Disconnect connector [1] from the air conditioner controller and
connect T-adapter to the female side.
Resistance Between [1] (female) (16) (black) and ground
Max. 1 z
Blown fuse

2. Referring to "Parts and connectors layout", check fuse No. 15 (5A)
in fuse box 2.
a
1.
2.
3.
WA470-7
If the fuse in cause 2 is blown, replace it in advance.

Disconnect connector [1] from the air conditioner controller and
connect T-adapter to the female side.
4. Turn the battery disconnect switch to the ON position
20 to 30
Voltage Between [1] (female side) (8) and (16)
V
80-73
80 Appendix
operate)
No.
Cause

a If a fuse is blown again in the above test, perform the following
procedure.
(Replace blown fuse in advance.)
2. Disconnect fuse No. 15 in fuse box 2.
3. Disconnect connectors AL1 and [1], and connect T-adapters to
each female side.

Resistance
Open circuit in CAN

communication line
(Communication between
monitor controller and air
conditioner controller is
disable.)
a In case of abnormality, there is short circuit

in the air conditioner harness.
Between [1] (female) (8) and ground
Min. 1
Mz

in the air conditioner harness.
Between [1] (female) (8) and (16)
Min. 1
Mz

in the chassis harness.
Between AL1 (female) (1) and ground
Min. 1
Mz
a When the fuse which is described in related information is not blown,

and test result for cause 3 is abnormal, check referring to the circuit
diagram.
a Terminating registers: Approx. 120 z are located inside of machine
monitor and engine. Those two registers are connected in parallel,
the combined register is approx. 60 z.
3. Disconnect connectors [1] and [2], and connect T-adapters to the
harness side.
Approx.
Resistance Between [2] (female) (2) and (3)
60 z
a Perform when above test result is abnormal.
a When above test result is abnormal and below test result is
abnormal, cab harness is abnormal.
a When above test result is abnormal and below test result is normal,
air conditioner harness is abnormal.
a Terminating registers: Approx. 120 z are located inside of machine
monitor and engine. Those two registers are connected in parallel,
the combined register is approx. 60 z.
3. Disconnect connectors AL1, and connect T-adapter to female side.
Approx.
Resistance Between AL1 (female) (4) and (6)
60 z

controller
Replace the air conditioner controller.
When test result for cause 1 through 7 is normal, monitor controller is

defective.
80-74
WA470-7
80 Appendix
operate)
Circuit diagram related to power supply and CAN communication
WA470-7
80-75
80 Appendix
A-2 Troubleshooting for compressor and refrigerant
system (Air is not cooled)
A-2 Troubleshooting for compressor and refrigerant system (Air is not

cooled) (WA470_7-FKE-400-A-Z0-A)
Failure
Problem on
machine
Related
information
Air is not cooled due to compressor or refrigerant system failure.

When engine is started and A/C switch is pressed on air conditioner screen of machine
monitor, air is not cooled as displayed on screen.
Air conditioner compressor does not operate.
Abnormal refrigerant pressure is not detected with self-diagnosis function.
If the refrigerant pressure is abnormal, the compressor will not be turned on, and air will
not be cooled.
a Abnormal refrigerant pressure indicates that the dual pressure switch is OFF, i.e. switch
side terminals of connector [11] are not ON.
An air conditioner may not be turned on at 3 C or below (normal).
If 5A fuse of air conditioner harness is blown, air will not come out. (See "Troubleshooting
of blower motor system".)
For each connector and fuse, see "Parts and connectors layout".
pins".
a T-adapter is provided only for connectors [1], [2], AL1 and E10.
No.
1
2

Cause
Defective 5A fuse of air
conditioner harness
Defective fuses No. 8 and 9 in If fuse is blown, circuit probably has ground fault.
fuse box 1
3. Disconnect connector [11] of dual pressure switch.
Defective dual pressure

switch
a In certain cases, the dual pressure switch may be operating

normally and set to the OFF position, therefore, if abnormality is
indicated (i.e., switch in the OFF position) on the following, attach a
pressure gauge to the air conditioner compressor and check the
refrigerant pressure. (See "Troubleshooting with gauge pressure.")
Max. 1 z
tance
k When
replacing the dual pressure switch, refrigerant must be

collected in advance.
2. Disconnect connector E10 from the air conditioner compressor and
connect the T-adapter to the male side.

compressor
80-76
a Check connection of the air conditioner compressor ground cable.

(See "Parts and connectors layout".)
Between E10 (male) (1) and (2) (coil
Approx. 15
z
Resis- resistance of air conditioner compressor)
tance
Min.
1 Mz
WA470-7
80 Appendix
No.
Cause

Referring to "Testing relays", check sound when compressor clutch
relay is turned ON.
a If the sound of blower is large and you cannot hear the sound when
compressor clutch relay is turned ON, turn the starting switch to the
OFF position and disconnect connector [12] of blower off relay.
Clicking sound is heard: A
a When A above is abnormal and B below is normal and C below is
abnormal (if the relay is normal), go to cause 6.
Defective compressor clutch

relay (does not turn ON)

2. Disconnect connector [14] and troubleshoot in that condition.
Resis- Between [14] (male) (1) and (2) (coil
Approx.
resistance)
tance
320 z B
2. Disconnect connector [14].
3. Use a wire to short-circuit (3) (red) and (4) (green line on red base)
of connector [14] (wiring harness side). (This forces the compressor
to operate without using the relay.)
Air is cooled: C
2. Disconnect connector [1] and fuse No. 8 in fuse box 1.
a Make sure that result of check of cause 1 is normal (pressure switch

is ON) and result of check of cause 2 is normal (air conditioner
compressor is normal).
Between connector [1] (7) and fuse No. 8 in
Approx.
Resis- fuse box 1.
320 z
tance
(Coil resistance of compressor clutch relay)
(pressure switch is ON)
2. Disconnect connector [14] and fuse No. 9 in fuse box 1.
Between fuse No. 9 in fuse box 1 and [14]
Max. 1 z
Resis- (female) (3)
Between [14] (female) (4) and chassis ground Approx. 15
tance
z
(Air conditioner compressor coil resistance)
a
1.
2.
Ground fault in wiring harness 3.
4.
If fuse is blown, replace it in advance.

Remove fuses 8 and 9 in fuse box 1.
Remove 15A fuse of air conditioner harness
Disconnect connectors E10, [1] and [14], and connect T-adapter to
female side of E10 and [1].
Min. 1 Mz
Resis- Between fuse No. 8 in fuse box 1 and ground
Min. 1 Mz
tance
Between fuse No. 9 in fuse box 1 and ground
Min. 1 Mz

controller
WA470-7

2. Disconnect connectors [14] and [1], and connect T-adapter to
harness side of [1].
Resis- Between (7) and (8) of harness side of [1]
Min. 1 Mz
tance
2. Insert T-adapters into connector [1].
4. Display the air conditioner operation screen on the machine monitor
and press the A/C switch.
Max. 1 V
80-77
80 Appendix
No.
Cause

10
(defective switch)

2. Press the air conditioner switch of the switch panel.
Monitor Display the air conditioner operation screen on the machine
display monitor.
Circuit diagram related to compressor and refrigerant system
a Each actuator is commonly used.
80-78
WA470-7
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
A-3 Troubleshooting for blower motor system (No air comes out or air
flow is abnormal) (WA500_7-FK3-400-A-Z0-A)
Failure
Problem on
machine
Related
information
No air comes out or air flow is abnormal due to blower motor system failure.
LCD of machine monitor on air conditioner operation screen lights up normally but air
does not come out.
Air flow does not match fan switch setting on air conditioner operation screen.
This failure is not checked with self-diagnosis function.
When engine coolant temperature is 60C or below, the air flow at 0 or LO is controlled by
cold air blowing out prevention control. (Normal)
During cooling, if the air flow becomes abnormal after a certain time, the evaporator may
be frozen.
This may be due to the followings.
1. Defective compressor clutch relay (remains turned ON) (see Item A of cause 5 of
"Troubleshooting for compressor and refrigerant system")
2. Evaporator temperature sensor mounting holder has come off. (Since air conditioner
unit must be removed and disassembled in order to check the holder, replace the air
conditioner unit with new one.)
3. Improper adjustment of the expansion valve (Remove air conditioner unit and replace
expansion valve.)
When air comes out, fuse and relay are normal, and defective wiring harness is unlikely.
For each connector, relay and blower amplifier, see "Parts and connectors layout".
pins".
a Since the blower motor is located at the bottom of the air conditioner unit, its
troubleshooting or troubleshooting by disconnecting connectors (10) and (15) is not
available as long as it is installed on the machine.
During heating, if air comes out but air flow is abnormal, blower amplifier is defective.
a The blower motor cannot be replaced unless the air conditioner unit is once removed.
a The T-adapter is not prepared for the other connectors.
No.
1
2
Cause
Defective 5A or 15A fuse of
air conditioner harness
box 1

Referring to "Testing relays", check sound when blower
OFF relay is turned ON.
Defective blower OFF relay

(does not turn ON)
Click is
heard:
a Perform when "no click is heard" on above check.

2. Replace blower OFF relay and compressor relay.
a See "Testing relays"
4. Turn ON main power supply of air conditioner.
a If air comes out, original blower OFF relay is defective.
a When test result for cause 3 is abnormal and relay is normal, go to
test for cause 5.
WA470-7
80-79
80 Appendix
No.
Cause

2. Disconnect connector [13].
4. Turn ON main power supply of air conditioner.
a Measure blower amplifier input voltage, between terminal (3) and (1)
of connector [13] (gate voltage).
Voltage Between [13] (female) (3) and (1)
Max. 10 V
Description for 1 to 4 are the same as above.
5. Press fan switch on switch panel from MIN to MAX.
Varies
Voltage Between [13] (female) (3) and (1)
within max.
10 V
Defective blower amplifier
a When blower amplifier is normal, followings are all normal. However,

the converse is not always correct. (Troubleshooting for important
amplifier portion cannot be performed as a unit.)
2. Disconnect connector [13] and troubleshoot in that condition
(connector [13] remains disconnected).
Resis- Between [13] (blower amplifier side) (1) and (3) 4.7 kz 5
tance
%
* Check in diode range.
No
Between [13] (blower amplifier side) (2) (+) and continuity
(1) (-)
Continuity
* Check in diode range.
Between [13] (blower amplifier side) (2) (-) and Continuity
(1) (+)

harness side.
Between [1] (female) (6) and fuse No. 8 in fuse Approx. 320
z
Resis- box 1 (coil resistance of relay)
Between [2] (female) (12) and [1] (female) (16) Approx. 4.7
tance
kz
(Internal resistance of blower amplifier)
or defective blower motor
(replace air conditioner as a 1. Turn the starting switch to the OFF position.
2. Disconnect connectors [1], [2], [12] and [13], and then connect Tunit)
adapters to female side of [1] and [2].
Max. 1 z
Resistance

harness
80-80
a Includes blower motor resistance.

Between [2] (female) (18) and [12] (harness
side) (4)
Between fuse No. 8 in fuse box 1 and [12]
(harness side) (3)
Continuity
Max. 1 z
a
1.
2.
3.
If fuse is blown, replace it in advance.

Remove fuse No. 8 in fuse box 1.
Disconnect connectors [1], [2], [12] and [13], and then connect Tadapters to female side of [1] and [2].
Between fuse No. 8 in fuse box 1 and ground
Min. 1 Mz
Resis- Between [2] (female) (18) and ground
Min. 1 Mz
tance
Min. 1 Mz
Between [2] (female) (12) and ground
WA470-7
80 Appendix
No.
Cause

controller

(defective switch)
1.
2.
3.
4.

Disconnect connectors (1) and (2), and then insert T-adapters.
Press fan switch on air conditioner operation screen (at any air flow).
Approx. 10
Between [2] (12) and [1] (16)
V
Voltage
Between [1] (6) and (16)
Max. 1 V

LCD display of air flow
Press fan switch from MIN to MAX.
varies from MIN to
MAX.
Circuit diagram related to blower motor
WA470-7
80-81
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover

Failure
Problem on
machine
Related
information
(WA500_7-FKF-400-A-Z0-A)
FRESH/RECIRC air changeover does not work.

When FRESH/RECIRC air selector switch of machine monitor is operated, recirculated or
fresh air does not change over.
(FRESH/RECIRC air changeover door (damper) does not rotate)
FRESH/RECIRC air changeover is not checked with self-diagnosis function.
See "Testing FRESH/RECIRC air changeover door (damper)".
Operating angle of FRESH/RECIRC air changeover servomotor is 90 degrees.
pins".
No.
1
Cause
Defective FRESH/RECIRC air a Operate FRESH/RECIRC air selector switch and check mechanical
changeover door (damper)
failure (disconnection or interference of lever) of FRESH/RECIRC
system
air changeover door (damper).
turning starting switch to the ON position.
Between [9] (actuator side) (1) and (2) (with no Approx.
Defective FRESH/RECIRC air
180 z
changeover actuator (unit test)
Between [9] (actuator side) (4) and (6) (with no Approx.
4.7 kz
tance
Approx.
580 z to
4.1 kz
2. Disconnect connectors (1) and (2), and then insert T-adapters.
4. Be ready with RECIRC by operating FRESH/RECIRC air selector
switch on the air conditioner operation screen.
5. Be ready with FRESH by operating FRESH/RECIRC air selector
switch on the air conditioner operation screen.
Defective FRESH/RECIRC air
changeover actuator,
approximately 3 seconds (only while door moves to FRESH
position).
harness, defective air
approximately 3 seconds (only while door moves to RECIRC
position). (When door stops, the voltage is stabilized to fixed value.)
Approx. 12
Between [1] (4) (+) and [1] (5) (-)
V
Voltage
Varies
Between [2] (13) (+) and [1] (9) (-)
within
max. 5 V

harness
a Perform when test result for cause 2 is normal and that for cause 3
is abnormal.

controller
defective.
80-82
WA470-7
80 Appendix
No.
Cause
(defective switch)

2. Display the air conditioner operation screen on the machine
monitor.
Display of Recirc/
Press FRESH/RECIRC air selector switch.
Fresh changes.
Circuit diagram related to FRESH/RECIRC air changeover
WA470-7
80-83
80 Appendix
Troubleshooting with gauge pressure
(WA380-3840-362-A-00-A)
Perform troubleshooting according to the gauge pressures of high-pressure and low-pressure lines of the
cooling cycle. For details, see "Connection of service tool".
a Note that the gauge pressure changes significantly depending on weather and operating condition of the
machine.
Pressure of high-pressure line is too high: Min. approx. 2.5 MPa {25 kg/cm 2}
Pressure of high-pressure line is too low: Max. approx. 1 MPa {10 kg/cm 2}
Pressure of low-pressure line is too high: Min. approx. 0.3 MPa {3 kg/cm 2}
Pressure of low-pressure line is too low: Maxn. approx. 0.05 MPa {0.5 kg/cm 2}
a Dual pressure switch installed in the high-pressure line turns "OFF" to protect the air conditioner circuit if
the pressure of the high-pressure or low-pressure line is abnormal.
<Measurement condition for pressure>
Item
Ambient temperature
Engine speed
Air conditioner switch
Fan switch
Set temperature
Condition value
20 to 50 C
Low idle
ON
HI
Cool-Max

a The switch outputs "ON" signal when the pressures are normal, and "OFF" signal when it detects an
abnormal pressure for compressor operation.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
80-84
WA470-7
80 Appendix
Indicated gauge
pressure
<Pressure is
normal>
<Pressure of
both highpressure and
low-pressure
lines are too
low>
Low-pressure
line gauge
reads vacuum
<Pressure of
both highpressure and
low-pressure
lines are too
high>
WA470-7
Cause
Check method
Remedy
Air conditioner cycle is operating normally.

If any cooling trouble (poor cooling) is recognizes, the cause is in
other system.
Pressure of high-pressure line: Approx. 1.5 to 1.7 MPa {15 to 17 kg/

cm2}
Pressure of low-pressure line: Approx. 0.13 to 0.2 MPa {1.3 to 2.0 kg/
cm2}
then fill up with
Bubbles can be seen through sight
proper quantity of
Insufficient refrigerant
glass. *1, *3
refrigerant again.
*2
Temperature difference is
recognized between inlet and
Replace.
Clogging of receiver drier
outlet pipes of receiver drier.
*2
Tank is frosty.
Clean or replace.
Clogging of expansion valve
Expansion valve is frosty.
*2
Replace.
Gas leakage at thermoprobe of
Low-pressure line gauge reads
expansion valve
vacuum.
*2
Repair or replace.
Evaporator is frozen.
Replace receiver
Flow rate of refrigerant is reduced drier.
Defective evaporator temperature
due to freezing.
sensor or defective contact of
(If air conditioner is set to Cool
sensor (coming off of mounting
then fill up with
Max. and HI fan speed modes,
clip)
proper quantity of
later its cooling performance
refrigerant again.
lowers.)
*2
Piping between receiver drier and
compressor is clogged or crushed. Clean or replace.
Clogging or crushing of piping
If clogged completely, low*2
pressure line gauge reads vacuum
then fill up with
proper quantity of
Filling of too much refrigerant
Connect gauge manifold.
refrigerant again.
*2
Clean condenser,
repair fins, or repair
Check condenser for dirt, fins for
Defective cooling of condenser
clogging or crushing, and cooling or replace cooling
fan.
fan for defective rotation.
*2
Improper adjustment of
Bubbles can be seen through sight Replace.
expansion valve (valve is opened
glass. *3
*2
too wide)
Evacuate air
conditioner and
Bubbles can be seen through sight then fill up with
Air sucked in cooling cycle parts
proper quantity of
glass. *3
refrigerant again
*2
80-85
80 Appendix
Indicated gauge
pressure
<Pressure of
high-pressure
line is too high
and that of lowpressure line is
too low>
<Pressure of
high-pressure
line is too low
and that of lowpressure line is
too high>
Cause
Check method
Remedy
Clean inside of
cooling cycle parts
or replace them.
*2
Clogged or crushed piping

between compressor and
condenser
Remarkable temperature
difference is recognized across
clogged part.
Defective compressor
(compression trouble of
compressor)
Pressures of high-pressure and

low-pressure lines are almost the
same while compressor is running. Replace.
*2
Compressor has seized and is
extremely hot.
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2:
k When
replacing cooling cycle parts, be sure to collect refrigerant. For details, see "Precautions for
refrigerant". After replacing parts, fill the air conditioner circuit with refrigerant.
*3: The sight glass is provided on the air conditioner hose close by the receiver drier (see "Air conditioner
component parts).
80-86
WA470-7
80 Appendix
Connection of service tool
(WA380-K500-061-K-00-A)
k Place
wheels.
k Turn
the battery disconnect switch to the OFF position and remove the key.
a Following service tool kit is used for work with refrigerant R134a.
Symbol
X
Part No.
799-703-1200
Part name
Service tool kit
Service tool kit X

(1): Gauge manifold
(2): Red high-pressure line charging hose
(3): Blue low-pressure line charging hose
(4): Large diameter quick joint (for high-pressure line)
(5): Small diameter quick joint (for low-pressure line)
(a): Note that the threads are coarse and the hoses are relatively easy to loosen.
Connect the gauge manifold, hoses and other service tools according to the following procedure.
1. Close high-pressure line valve (6) and low-pressure line valve (7) of gauge manifold (1).
2. Connect the red high-pressure charging hose (2) to the HI line side of the gauge manifold (1) and the blue
low-pressure charging hose (3) to the LO line side.
3. Connect quick joints (4) and (5) to each hose.
4. Connect quick joints (4) and (5) to service valves (8) and (9) of high- and low-pressure piping respectively.
Part (10) is the air conditioner compressor.
WA470-7
80-87
80 Appendix
A: From operator's cab

B: To condenser
80-88
WA470-7
80 Appendix
Precautions for disconnecting and connecting hoses
and tubes in air conditioner circuit
Precautions for disconnecting and connecting hoses and tubes in air

conditioner circuit (WA380-K5B0-924-K-00-A)
Precautions for disconnection
k Collect
the refrigerant (Air conditioner gas: R134a) from the air conditioner circuit before
disconnecting air conditioner hoses to replace the air conditioner unit, air conditioner compressor,
condensor or receiver drier and so on.
a Ask a qualified person for collecting, adding and filling operations of the refrigerant (R134a).(Only
registered person can work.)
a Never release the refrigerant (R134a) to the atmosphere.
k If
refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skins,
you may suffer from frostbite. Accordingly, put on the protective eyeglasses, gloves and working
suits with long sleeves while you are collecting or adding the refrigerant (R134a).
When loosening the air conditioner hose nut after collecting the refrigerant, be sure to use two wrenches.
Use one wrench to fix one nut and the other wrench to loosen the other nut.
For the disconnected air conditioner piping, take measures to prevent dirt, dust, and water from entering
the hose.
Precautions for connection
When connecting air conditioner piping, apply compressor oil (SP-10) for use with R134a to the O-ring.
(See "Handling of compressor oil".)
Do not apply oil to the threads of a bolt, nut or union, however.
a An O-ring is fitted to every joint of the air conditioner piping.
Do not reuse an O-ring that was used once because it is deformed and deteriorated. When removing the
O-ring, use a flexible tool (tooth pick, etc.) in order not to damage the piping.
When connecting the piping, press the pipe until it is seated and finger-tighten the bolt or nut fully.
Be sure to use two wrenches to tighten each nut. Use one wrench to fix one nut and the other wrench
(torque wrench) to tighten the other nut to the specified torque.
a Example of fitting of O-ring
Table of tightening torque for refrigerant pipe joint.

Thread size
M6 x 1.0
M8 x 1.25
M16 x 1.5
M22 x 1.5
M24 x 1.5
WA470-7
Tightening torque: Nm {kgm}

8 to 12 {0.8 to 1.2}
20 to 25 {2.0 to 2.6}
12 to 15 {1.2 to 1.5}
20 to 25 {2.0 to 2.6}
30 to 35 {3.1 to 3.6}
80-89
80 Appendix
Precautions for disconnecting and connecting hoses
and tubes in air conditioner circuit
1. Engine
2. Compressor
3. Condenser
4. Receiver drier
5. Air conditioner unit
80-90
WA470-7
80 Appendix
Handling of compressor oil
(WA380-K594-212-K-00-A)
1. Management of compressor oil (SANDEN: SP-10 for use with R134a)

Although compressor oil differs from engine oil in that it does not need regular checking or filling, the following
types of problem can occur if the amount in the system is too high or too low.
Condition
Insufficient oil
Excessive oil
Content
Lubrication trouble and seizure of compressor
Lowered cooling performance
(Excessive oil sticks to parts and lowers heat exchange performance.)
Accordingly, compressor oil must be added to the specified level, similarly to refrigerant.
2. Filling of compressor oil
k Collect
refrigerant before disconnecting air conditioner hoses because refrigerant is harmful and
also has an adverse environmental effect.
k If
refrigerant gets in your eyes, you may lose your sight. Be sure to put on protective
eyeglasses.
a If oil for use with CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken
or seized.
Be sure to use the oil for use with R134a (SANDEN: SP-10).
a Oil for use with R134a is extremely hygroscopic, and therefore, cap the oil container immediately after use
to limit contact with air.
Store the oil can in a dry and ventilated place.
a Precautions for using oil
Do not allow the oil for use with R134a to come into contact with painted surfaces (except baking finish
surfaces) on acrylic plastic or polystyrene plastic because it may dissolve these plastics.
Check compressor oil in the following cases, and then add new oil if necessary.
When much refrigerant is discharged because of leakage.
When the compressor has trouble and is replaced
When a cycle parts such as condenser, receiver drier, evaporator unit, etc. is replaced
Quantity of oil to be added when cycle part is replaced
Air conditioner part
Air conditioner unit, evaporator
Condenser
Receiver drier
Each hose (running from cab through M24 joint to compressor)
Each hose (running from cab through M24 joint, receiver drier, and condenser
to compressor)
Refill capacity (cm3)

Approx. 40
Approx. 40
Approx. 20
Approx. 30
Approx. 15
3. Replacement of compressor
When compressor is damaged due to seizure, etc.
WA470-7
80-91
80 Appendix
Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil extremely.
In this case, flush the air conditioner circuit and replace the compressor and receiver drier.
The compressor oil is removed from the air conditioner circuit by flushing. Accordingly, install a new
compressor that is filled with the specified quantity (180 cc) of the oil.
Other cases
a New compressor is filled with 135 cc of compressor oil.
1.
1) Prepare an oil container and drain oil from the used compressor.
2) Measure the quantity of the drained oil with a measuring cylinder, and note the quantity.
3) Drain following quantity of oil from the new compressor.

Quantity to be drained = 135 cc - "Noted quantity"
Example
Example: If 30 cc of oil was drained from the removed compressor, the quantity to be drained from the
new compressor is be 105 cc (i.e., 135 - 30 cc).
4. Compressor oil for O-ring
Whenever connecting piping or hoses, apply the compressor oil (SP-10) to O-rings in order to prevent
leakage of refrigerant.
80-92
WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model
Serial Number
WA470-7
10001 and up
90 Diagrams and drawings

10 90 Diagrams and drawings
WA470-7
90-1

Table of contents
Table of contents
(ALL-0310-002-A-00-A)
90 Diagrams and drawings................................................................................................................. 90-1

Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram of power train .................................................................................. 90-7
Hydraulic circuit diagram....................................................................................................... 90-9
Electric circuit diagram .............................................................................................................. 90-11
Symbols in electric circuit diagram ....................................................................................... 90-11
Electrical circuit diagram of machine body ............................................................................ 90-15
Electrical circuit diagram of floor .......................................................................................... 90-25
90-2
WA470-7

Symbols in hydraulic circuit diagram
Hydraulic circuit diagram
(ALL-C000-001-K-90-A)
(PC220-0000-007-K-00-A)
(Rev. 2010/03)
WA470-7
90-3

90-4
WA470-7

WA470-7
90-5

90-6
WA470-7

Hydraulic circuit diagram of power train
(WA470-C100-054-K-00-A)
WA4707
a This diagram covers optional components that are unavailable in some areas.
WA470-7
90-7

90-8
WA470-7

WA470-7
WA470-7
WA470-7
90-9

Symbols in electric circuit diagram
Electric circuit diagram
(ALL-0000-001-K-90-A)
(PC220-0000-008-K-00-A)
(Rev. 2010/03)
WA470-7
90-11

90-12
WA470-7

WA470-7
90-13

90-14
WA470-7
Electric circuit diagram of machine body (1/5)

WA470-7
WA470-7
WA470-7
90-15

WA470-7
WA470-7
WA470-7
90-17

WA470-7
WA470-7
WA470-7
90-19

WA470-7
WA470-7
WA470-7
90-21

WA470-7
WA470-7
WA470-7
90-23
Electrical circuit diagram of floor (1/8)

WA470-7
WA470-7
a This diagram covers optional components that are unavailable in some models or some areas.
WA470-7
90-25

WA470-7
WA470-7
WA470-7
90-27

WA470-7
WA470-7
WA470-7
90-29

WA470-7
WA470-7
WA470-7
90-31

WA470-7
WA470-7
WA470-7
90-33

WA470-7
WA470-7
WA470-7
90-35

WA470-7
WA470-7
WA470-7
90-37

WA470-7
WA470-7
WA470-7
90-39
INDEX
INDEX
3rd, 4th clutch............................................... 10-65
3rd, 4th clutch ECMV .......................... 10-88, 60-24
A
A-1 Troubleshooting for power supply and
CAN communication system (Air conditioner
does not operate) ........................................ 80-73
A-2 Troubleshooting for compressor and
refrigerant system (Air is not cooled) ............. 80-76
A-3 Troubleshooting for blower motor system
(No air comes out or air flow is abnormal) ...... 80-79
A-4 Troubleshooting for FRESH/RECIRC air
changeover ................................................ 80-82
Accumulator (for brake) ............................... 10-167
Accumulator (for ECSS) .............................. 10-238
Accumulator (for PPC circuit) ....................... 10-237
Accumulator charge valve ........................... 10-232
Adjusting rearview camera angle ................. 30-216
Adjusting replaced, reassembled or added
sensor, controller, etc. with machine monitor......30125
Adjusting transmission input speed sensor...... 30-51
Adjusting transmission output speed sensor.... 30-50
Adjustment of lever detent position and work
equipment starting current ......................... 10-283
Air conditioner component ............................... 80-4
Air conditioner controller ................................ 80-15
Air conditioner unit .......................................... 80-9
Auto idle stop function ................................. 10-275
Auto-kickdown function ............................... 10-261
Automatic warm-up function ........................ 10-249
Axle................................................. 10-101, 60-27
Axle mount and center hinge pin ........ 10-177, 60-59
B
Battery disconnect switch function................ 10-254
Bleeding air from fuel system ......................... 30-31
Bleeding air from hydraulic fan circuit ........... 30-108
Bleeding air from steering cylinder circuit. ....... 30-81
Bleeding air from wheel brake circuit .............. 30-97
Bleeding air from work equipment circuit ....... 30-117
Brake......................................................... 10-168
Brake valve ................................................ 10-160
Bucket ............................................. 10-240, 60-80
C
Check evaporator temperature sensor............ 80-44
Check sheet ............................................... 30-221
Circuit diagram and arrangement of connector
pins ........................................................... 80-24
Classification and procedures for
troubleshooting ........................................... 40-40
WA470-7
CLSS......................................................... 10-217
Coating materials list....................................... 50-6
Combination switch..................................... 10-343
Compressor ................................................. 80-16
Condenser ................................................... 80-17
Configuration and function of refrigeration
cycle ............................................................ 80-6
Connection of service tool ............................. 80-87
Connector contact identification ..................... 40-62
Connector list and layout ............................... 40-48
Control function when brake accumulator is
charged.................................................... 10-269
Control valve .............................................. 10-208
Conversion table .......................................... 00-61
Cooling fan motor .................................10-39, 60-7
Cooling fan pump .................................10-30, 60-4
Cooling system............................................. 10-27
D
Differential........................................ 10-103, 60-29
Directional switch control function ................ 10-274
Disassembly and assembly of axle housing
assembly.................................................. 50-215
Disassembly and assembly of differential
assembly.................................................. 50-225
Disassembly and assembly of hydraulic
cylinder assembly ..................................... 50-271
Disassembly and assembly of KDPF assembly ...50117
Disassembly and assembly of torque converter
assembly.................................................. 50-178
Disassembly and assembly of transmission
assembly.................................................. 50-148
Disassembly and assembly of transmission
clutch pack assembly ................................ 50-185
Double type gear pump ..................... 10-186, 60-64
Drive shaft............................................10-49, 60-9
Dual pressure switch..................................... 80-14
E
E-1 Engine does not start ............................ 40-870
E-2 Manual preheating system does not work .....40876
E-3 Automatic preheating system does not
work......................................................... 40-879
E-4 While preheating is working, preheating
monitor does not light up............................ 40-881
E-5 All of LCD unit, LED unit and meter unit on
machine monitor display nothing ................ 40-883
E-6 LCD unit on machine monitor displays
nothing..................................................... 40-886
E-7 Backlight of LCD unit on machine monitor
is abnormal (Backlight goes out or flickers).. 40-888
INDEX
E-8 LCD on machine monitor does not display

properly.................................................... 40-890
E-9 Meter unit display on machine monitor is
abnormal.................................................. 40-892
E-10 Night lighting lamp of meter unit on
machine monitor is abnormal ..................... 40-895
E-11 Caution LED on machine monitor is
abnormal.................................................. 40-898
E-12 LED of switch panel on machine monitor
is abnormal or switches does not operate
properly.................................................... 40-900
E-13 Two switches operation of switch panel
on machine monitor does not function ......... 40-902
E-14 Switch panel buzzer of machine monitor
is abnormal............................................... 40-905
E-15 Rearview monitor does not light up or
backlight flickers ....................................... 40-907
E-16 Rearview monitor images are not
displayed clearly ....................................... 40-910
E-17 Rearview monitor brightness cannot be
adjusted ................................................... 40-913
E-18 Night lighting lamp of rearview monitor is
abnormal.................................................. 40-916
E-19 Some items of gauges and caution lamps
on machine monitor are not displayed
properly.................................................... 40-918
E-20 Parking brake indicator lamp does not
light when the parking brake is set to ON
(Parking) position ...................................... 40-919
E-21 When brake accumulator oil pressure
drops, the brake oil pressure caution lamp
does not light ............................................ 40-923
E-22 Air cleaner clogging indicator lamp does
not light .................................................... 40-925
E-23 Radiator coolant level caution lamp does
not light .................................................... 40-926
E-24 Indication of hydraulic oil temperature
gauge does not increase, or hydraulic oil
temperature caution lamp does not light ...... 40-928
E-25 Indication of torque converter oil
temperature gauge does not increase, or
torque converter oil temperature caution lamp
does not light ............................................ 40-930
E-26 Fuel level gauge does not indicate correct
level......................................................... 40-931
E-27 Seat belt caution lamp indication is
abnormal.................................................. 40-933
E-28 Horn does not sound ........................... 40-934
E-29 Horn does not stop sounding ............... 40-937
E-30 Alarm buzzer does not sound............... 40-939
E-31 When starting switch is in ON position,
alarm buzzer does not stop sounding.......... 40-940
E-32 Kickdown does not work when kickdown
switch is turned ON ................................... 40-941
E-33 The hold switch does not work when it is
pressed.................................................... 40-943
E-34 Parking brake does not work even if it is
applied, or the brake drags when parking
brake is released and FR drive is operated.. 40-945
E-35 Transmission cut-off mode is not selected

or not released.......................................... 40-948
E-36 Transmission cut-off setting cannot be
released ................................................... 40-950
E-37 Directional selector (FNR) switch mode is
not selected or not released ....................... 40-952
E-38 When operating engine power selection
switch, engine power selection function does
not operate properly .................................. 40-954
E-39 Flow of loader pump does not increase
from the minimum rate ............................... 40-956
E-40 ECSS function cannot be selected or
cannot be released.................................... 40-957
E-41 None of headlamp, clearance lamp, and
tail lamp lights ........................................... 40-959
E-42 Clearance lamp and tail lamp do not light
up or go out or go out ................................ 40-961
E-43 Both High and Low beams of headlamp
do not light up or go out ............................. 40-964
E-44 Low beam of headlamp does not light up
or go out................................................... 40-968
E-45 High beam of headlamp does not light up
or go out................................................... 40-970
E-46 Front working lamp does not light up or
go out ...................................................... 40-972
E-47 Rear working lamp does not light up or go
out ........................................................... 40-975
E-48 All of turn signal lamps and hazard lamps
do not light up or go out ............................. 40-978
E-49 Turn signal lamps do not light up or go
out ........................................................... 40-981
E-50 Hazard lamp does not light up or go out 40-984
E-51 Brake lamp does not light up or stays
lighted ...................................................... 40-987
E-52 Backup lamp does not light or continues
to light ...................................................... 40-990
E-53 Backup buzzer does not sound or
continues to sound .................................... 40-993
E-54 Front wiper does not operate................ 40-995
E-55 Rear wiper does not operate ................ 40-998
E-56 Window washer does not operate....... 40-1000
E-57 Fuel feed pump does not operate or stop
automatically .......................................... 40-1003
E-58 KOMTRAX system does not operate
normally ................................................. 40-1005
EGR cooler .................................................. 10-17
EGR system circuit diagram .......................... 10-14
EGR system piping drawing........................... 10-12
EGR valve ................................................... 10-15
Electrical circuit diagram of floor..................... 90-25
Electrical circuit diagram of machine body....... 90-15
Emergency steering motor........................... 10-150
Emergency steering pump................. 10-151, 60-51
Engine control system ................................. 10-243
Engine output limit function.......................... 10-248
Engine power mode selector circuit .............. 10-247
Engine related parts ................................10-4, 60-3
Explanation of terms for maintenance standard ...0027
WA470-7
INDEX
F
Fabrication of dummy temperature sensor (for
KDOC and KDPF temperature sensors)...... 40-117
Fabrication of short-circuit connector (for
CA1883 and CA3135) ............................... 40-118
Failure code [1500L0] Double Engagement of
T/M Clutches ............................................ 40-133
Failure code [15SAL1] Release Trouble of
ECMV (Forward) ....................................... 40-134
Failure code [15SALH] Malfunction of ECMV
(Forward) ................................................. 40-136
Failure code [15SBL1] Release Trouble of
ECMV (Reverse)....................................... 40-138
Failure code [15SBLH] Malfunction of ECMV
(Reverse) ................................................. 40-140
Failure code [15SEL1] Release Trouble of
ECMV (1st)............................................... 40-142
Failure code [15SELH] Malfunction of ECMV
(1st) ......................................................... 40-144
Failure code [15SFL1] Release Trouble of
ECMV (2nd) ............................................. 40-146
Failure code [15SFLH] Malfunction of ECMV
(2nd) ........................................................ 40-148
Failure code [15SGL1] Release Trouble of
ECMV (3rd) .............................................. 40-150
Failure code [15SGLH] Malfunction of ECMV
(3rd)......................................................... 40-152
Failure code [15SHL1] Release Trouble of
ECMV (4th) .............................................. 40-154
Failure code [15SHLH] Malfunction of ECMV
(4th) ......................................................... 40-156
Failure code [2F00MA] Failure of Parking
Brake Circuit............................................. 40-158
Pressure Low (Front)................................. 40-162
Pressure Low (Rear) ................................. 40-164
Failure code [879AKA] A/C Inner Sensor Open
Circuit ............................................ 40-166, 80-53
Failure code [879AKB] A/C Inner Sensor Short
Circuit ............................................ 40-167, 80-55
Failure code [879BKA] A/C Outer Sensor
Open Circuit ................................... 40-168, 80-57
Failure code [879BKB] A/C Outer Sensor Short
Circuit ............................................ 40-169, 80-59
Failure code [879CKA] Ventilating Sensor
Open Circuit ................................... 40-170, 80-61
Failure code [879CKB] Ventilating Sensor
Short Circuit ................................... 40-171, 80-63
Failure code [879DKZ] Sunlight Sensor Open
or Short Circuit................................ 40-172, 80-65
Failure code [879EMC] Ventilation Damper
Abnormality .................................... 40-173, 80-67
Failure code [879FMC] Air Mix Damper
Abnormality .................................... 40-174, 80-70
Failure code [989A00] Engine Overrun
Prevention Activated ................................. 40-175
WA470-7
Failure code [989L00] Engine Controller Lock

Caution 1 ................................................. 40-176
Failure code [989M00] Engine Controller Lock
Caution 2 ................................................. 40-177
Failure code [989N00] Engine Controller Lock
Caution 3 ................................................. 40-178
Failure code [A1U0N3] HC desorb request 1. 40-179
Failure code [A1U0N4] HC desorb request 2. 40-181
Failure code [AA10NX] Air Cleaner Clogging. 40-183
Failure code [B@BAZG] Eng Oil Press Low .. 40-185
Failure code [B@BAZK] Engine Oil Level Low ....40186
Failure code [B@BCNS] Eng Water Overheat .....40188
Failure code [B@BCZK] Eng Water Level Low ....40189
Failure code [B@CENS] T/C Oil Temp.
Overheat .................................................. 40-191
Failure code [B@HANS] HYD Oil Temp.
Overheat .................................................. 40-192
Failure code [CA1117] Persistent Data Lost
Error ........................................................ 40-288
Failure code [CA115] Eng Ne and Bkup Speed
Sens Error ................................................ 40-193
High Error................................................. 40-194
Low Error ................................................. 40-196
Failure code [CA131] Throttle Sensor High
Error ........................................................ 40-198
Failure code [CA132] Throttle Sensor Low
Error ........................................................ 40-200
High Error................................................. 40-202
Low Error ................................................. 40-204
Failure code [CA144] Coolant Temp Sens High
Error ........................................................ 40-206
Failure code [CA145] Coolant Temp Sens Low
Error ........................................................ 40-208
High Error................................................. 40-210
Low Error ................................................. 40-212
Failure code [CA1664] KDOC Malfunction .... 40-289
Failure code [CA1691] Regeneration
Ineffective................................................. 40-292
High Error................................................. 40-295
Low Error ................................................. 40-296
High Error................................................. 40-298
Low Error ................................................. 40-300
Low Error ................................................. 40-214
High Error................................................. 40-302
INDEX

Low Error ................................................. 40-304
Failure code [CA1883] KDPF Delta P Sens In
Range Error.............................................. 40-306
Error 1...................................................... 40-309
Error 2...................................................... 40-312
High Error................................................. 40-317
Low Error ................................................. 40-319
Failure code [CA1925] Dosing Fuel Valve 1 In
Range Error.............................................. 40-322
Sens High Error ........................................ 40-324
Sens Low Error ......................................... 40-326
In Range Error .......................................... 40-328
Servo Error............................................... 40-329
Failure code [CA1977] Fuel Doser Open/Short
Error ........................................................ 40-331
Failure code [CA1993] KDPF Delta Pressure
Low Error ................................................. 40-333
High Error................................................. 40-335
Low Error ................................................. 40-337
Failure code [CA221] Ambient Press Sens
High Error................................................. 40-216
Failure code [CA222] Ambient Press Sens Low
Error ........................................................ 40-218
Failure code [CA2249] Rail Press Very Low
Error 2...................................................... 40-339
Failure code [CA2265] Fuel Feed Pump Open
Error ........................................................ 40-340
High Error................................................. 40-220
High Error................................................. 40-344
Low Error ................................................. 40-346
Failure code [CA234] Eng Overspeed........... 40-221
Open Error ............................................... 40-348
Short Error................................................ 40-350
Failure code [CA2357] EGR Valve Servo Error ....40352
Failure code [CA238] Ne Speed Sensor
Supply Volt Error ....................................... 40-222
Failure code [CA2381] KVGT Pos Sens High
Error ........................................................ 40-353
Failure code [CA2382] KVGT Pos Sens Low
Error ........................................................ 40-355
Failure code [CA2383] KVGT Solenoid Open
Error ........................................................ 40-357
Failure code [CA2386] KVGT Solenoid Short

Error ........................................................ 40-359
Failure code [CA2387] KVGT Servo Error ..... 40-361
Failure code [CA239] Ne Speed Sens Supply
Volt High Error .......................................... 40-223
Failure code [CA2555] Grid Htr Relay Volt Low
Error ........................................................ 40-362
Failure code [CA2556] Grid Htr Relay Volt High
Error ........................................................ 40-364
Failure code [CA2266] Fuel Feed Pump Short
Error ........................................................ 40-342
Failure code [CA2637] KDOC Face Plugging 40-366
Failure code [CA2639] Manual Stationary
Regeneration Request............................... 40-368
Failure code [CA271] IMV/PCV1 Short Error . 40-224
Failure code [CA272] IMV/PCV1 Open Error . 40-225
Failure code [CA273] PCV2 Short Error ........ 40-226
High Error................................................. 40-371
Low Error ................................................. 40-373
Failure code [CA274] PCV2 Open Error........ 40-227
Failure code [CA2741] Dosing Fuel Valve
Swap Error ............................................... 40-375
Failure code [CA2765] Inj Trim Data Error ..... 40-377
Servo Error............................................... 40-378
Failure code [CA2881] Dosing Fuel Pressure
Low Error 1 Failure code [CA2881] Dosing
Fuel Pressure Low Error 1 ......................... 40-381
Sens High Error ........................................ 40-386
Sens Low Error ......................................... 40-388
Sens In Range Error.................................. 40-390
Failure code [CA3167] Fuel Doser Degradation...40393
Error ........................................................ 40-228
Error ........................................................ 40-230
Error ........................................................ 40-232
Error ........................................................ 40-234
Failure code [CA3251] KDOC Inlet Temp High
Error ........................................................ 40-396
Failure code [CA3253] KDOC Temp Error Non Regeneration..................................... 40-399
High Error 1 .............................................. 40-402
Failure code [CA3255] KDPF Temp Error - Non
Regeneration............................................ 40-405
High Error 1 .............................................. 40-409
Error ........................................................ 40-236
WA470-7
INDEX

High Error 2 .............................................. 40-412
High Error 2 .............................................. 40-415
Sensor Low Error ...................................... 40-418
Sensor High Error ..................................... 40-421
In Range Error .......................................... 40-425
Sens Low Error ......................................... 40-430
Sens High Error ........................................ 40-433
Sens In Range Error.................................. 40-437
Sens High Error ........................................ 40-442
Error ........................................................ 40-238
Sens Low Error ......................................... 40-446
Sens In Range Error Failure code [CA3322]
KDPF Outlet Temp Sens In Range Error ..... 40-449
Sup Volt High Error.................................... 40-454
Sup Volt Low Error .................................... 40-456
Failure code [CA343] ECM Critical Internal
Failure ..................................................... 40-240
Failure code [CA351] Injectors Drive Circuit
Error ........................................................ 40-241
Low Error ................................................. 40-242
High Error................................................. 40-244
Low Error ................................................. 40-246
High Error................................................. 40-248
Failure code [CA431] Idle Validation Sw Error .....40249
Failure code [CA432] Idle Validation Process
Error ........................................................ 40-252
Failure code [CA441] Battery Voltage Low
Error ........................................................ 40-255
Failure code [CA442] Battery Voltage High
Error ........................................................ 40-257
Failure code [CA449] Rail Press Very High
Error ........................................................ 40-258
Failure code [CA451] Rail Press Sensor High
Error ........................................................ 40-259
Failure code [CA452] Rail Press Sensor Low
Error ........................................................ 40-261
Failure code [CA515] Rail Press Sens Sup Volt
High Error................................................. 40-263
Failure code [CA516] Rail Press Sens Sup Volt
Low Error ................................................. 40-265
WA470-7
Failure code [CA553] Rail Press High Error 1 40-267

Error 1...................................................... 40-268
Error 2...................................................... 40-269
Failure code [CA559] Rail Press Low Error ... 40-270
Failure code [CA595] Turbo Speed High Error
2.............................................................. 40-274
Failure code [CA687] Turbo Speed Low Error .....40275
Failure code [CA689] Eng Ne and Speed
Sensor Error ............................................. 40-277
Failure code [CA691] Intake Air Temp Sensor
High Error................................................. 40-279
Failure code [CA692] Intake Air Temp Sensor
Low Error ................................................. 40-281
Failure code [CA697] ECM Internal Temp
Sensor High Error ..................................... 40-283
Failure code [CA698] ECM Int Temp Sensor
Low Error ................................................. 40-284
Failure code [CA731] Eng Bkup Speed Sens
Phase Error .............................................. 40-285
Failure code [CA778] Eng Bkup Speed Sensor
Error ........................................................ 40-286
Emerg. Steering Relay .............................. 40-458
Failure code [D150KB] Ground Fault of Emerg.
Steering Relay .......................................... 40-460
Failure code [D150KY] Hot Short of
Emergency Steering Relay ........................ 40-462
Backup Lamp Relay Output ....................... 40-464
Backup Lamp Relay Output ....................... 40-466
Failure code [D160KY] Hot Short of Backup
Lamp Relay Output ................................... 40-468
Neutral Output Relay ................................. 40-470
Failure code [D191KB] Ground Fault of Neutral
Output Relay ............................................ 40-472
Failure code [D191KY] Hot Short of Neutral
Output Relay ............................................ 40-474
Failure code [D192KA] Disconnection of ECSS
Solenoid................................................... 40-476
Failure code [D192KB] Ground Fault of ECSS
Solenoid................................................... 40-478
Failure code [D192KY] Hot Short of ECSS
Solenoid................................................... 40-479
Failure code [D19JKZ] Personal Code Relay
Abnormality .............................................. 40-480
Failure code [D1E6KA] Disconnection of
Parking Brake Relay.................................. 40-482
Failure code [D1E6KB] Ground Fault of
Parking Brake Relay.................................. 40-484
Failure code [D1E6KY] Hot Short of Parking
Brake Relay.............................................. 40-486
Failure code [D5ZHKA] Failure of Key SW C
Signal ...................................................... 40-488
INDEX
Failure code [D5ZHKB] Key SW C Signal

Short Circuit ............................................. 40-490
Failure code [D5ZHKZ] Failure of Key SW C
Signal ...................................................... 40-492
Failure code [D5ZHL6] Disconnection of Key
SW C ....................................................... 40-494
Failure code [D811MC] KOMTRAX Error ...... 40-496
Failure code [D862KA] GPS Antenna Open
Circuit ...................................................... 40-497
Failure code [D8ALKA] Operating Lamp Open
Circuit (KOMTRAX)................................... 40-498
Failure code [D8ALKB] Operating Lamp Short
Circuit (KOMTRAX)................................... 40-500
Failure code [D8AQK4] CAN2 Discon
(KOMTRAX) 2 .......................................... 40-502
Failure code [D8AQKR] CAN2 Discon
(KOMTRAX) ............................................. 40-503
Failure code [DAF0KT] Abnormality of Nonvolatile Memory (MON).............................. 40-505
Failure code [DAF0MB] Monitor ROM
Abnormality .............................................. 40-506
Failure code [DAF0MC] Monitor Error ........... 40-507
Failure code [DAF3KK] Controller Power
Source Low (MON) ................................... 40-508
Failure code [DAF8KB] Camera Power Supply
Short Circuit ............................................. 40-510
Failure code [DAFDKB] Monitor 12V Power
Output Short Circuit................................... 40-511
Failure code [DAFGMC] GPS Module Error .. 40-513
Failure code [DAFLKA] Operating Lamp Open
Circuit (MON)............................................ 40-514
Failure code [DAFLKB] Operating Lamp Short
Circuit (MON)............................................ 40-516
Failure code [DAFQKR] CAN2 Discon
(Monitor) .................................................. 40-518
Failure code [DAQ0KT] Abnormality of Nonvolatile Memory (T/M) ................................ 40-522
Failure code [DAQ0MC] T/M Con Error......... 40-523
Failure code [DAQ1KA] Disconnection of Key
SW ACC (T/M).......................................... 40-524
Failure code [DAQ2KK] Solenoid Power
Source Low (T/M) ......................... 40-519, 40-526
Failure code [DAQ4KB] Ground Fault of Sol.
Self-Holding Relay .................................... 40-529
Failure code [DAQ9KQ] Inconsistency of
Model Selection (T/M) ............................... 40-531
Failure code [DAQLKA] Operating Lamp Open
Circuit (T/M).............................................. 40-532
Failure code [DAQLKB] Operating Lamp Short
Circuit (T/M).............................................. 40-534
Failure code [DAQQKR] CAN2 Discon
(Transmission Con) ................................... 40-536
Failure code [DAQRKR] CAN1 Discon
(Transmission Con) ................................... 40-537
Failure code [DAQRMA] Inconsistency of
Option Selection (T/M)............................... 40-538
Failure code [DAZ9KQ] A/C Model Selection
Abnormality .............................................. 40-539
Failure code [DAZQKR] CAN2 Discon (Aircon

ECU) ....................................................... 40-540
Failure code [DB2QKR] CAN2 Discon (Engine
Con) ........................................................ 40-541
Failure code [DB2RKR] CAN1 Discon (Engine
Con) ........................................................ 40-546
Failure code [DB90KK] Drop in BBC Controller
Main Power Source ................................... 40-551
Failure code [DB90KT] Abnormality of Nonvolatile Memory (BBC)............................... 40-553
Failure code [DB90MC] BBC Error ............... 40-554
Failure code [DB91KA] Disconnection of Key
SW ACC (BBC)......................................... 40-555
Failure code [DB92KK] Solenoid Power
Source Low (BBC) .................................... 40-557
Source 1 .................................................. 40-559
Source 2 .................................................. 40-561
Failure code [DB99KQ] Inconsistency of Model
Selection (BBC) ........................................ 40-563
Failure code [DB9LKA] Operating Lamp Open
Circuit (BBC) ............................................ 40-564
Failure code [DB9LKB] Operating Lamp Short
Circuit (BBC) ............................................ 40-566
Failure code [DB9QKR] CAN2 Discon (Bucket
Boom Con) ............................................... 40-568
Failure code [DB9RKR] CAN1 Discon (Bucket
Boom Con) ............................................... 40-569
Failure code [DB9RMA] Inconsistency of
Option Selection (BBC).............................. 40-570
Source ..................................................... 40-573
Source ..................................................... 40-571
Failure code [DD1ALD] Ground Fault of
Remote Positioner Set SW ........................ 40-575
Failure code [DDAAL6] Discon Engine
Shutdown Secondary Switch...................... 40-577
Failure code [DDB6L4] Neutral Signal
Malfunction............................................... 40-579
Failure code [DDD1LD] Failure of Bucket
Positioner Set Switch ................................ 40-582
Failure code [DDK3KA] FNR SW Input Signal
Disconnection........................................... 40-584
Failure code [DDK3KB] FNR SW Input Signal
Short Circuit ............................................. 40-587
Failure code [DDK6KA] FNR Lever Input
Signal Disconnection................................. 40-589
Failure code [DDK6KB] FNR Lever Input
Signal Short Circuit ................................... 40-592
Failure code [DDNRKY] Hot Short of Work
Equipment Lock SW.................................. 40-594
Failure code [DDT0L4] Failure of Shift Mode
Select SW ................................................ 40-596
Cut Off Set SW Signal ............................... 40-598
Cut Off SW Signal ..................................... 40-600
WA470-7
INDEX
Failure code [DDW9LD] Ground Fault of

Kickdown Switch....................................... 40-602
Failure code [DDWLLD] Ground Fault of T/M
Shift Hold SW ........................................... 40-604
Failure code [DF10KA] Disconnection of Shift
Lever Input ............................................... 40-606
Failure code [DF10KB] Ground Fault of Shift
Lever Input ............................................... 40-608
Failure code [DGF1KA] Disconnection of T/M
Oil Temp. Sensor ...................................... 40-611
Failure code [DGF1KB] Ground Fault of T/M
Oil Temp. Sensor ...................................... 40-613
Failure code [DGH2KX] Out of Range of HYD
Oil Temp. Sensor ...................................... 40-615
Failure code [DGR2KB] Ground Fault of Brake
Oil Temp. Sensor ...................................... 40-617
Failure code [DGR2KZ] Failure of Brake Oil
Temp. Sensor ........................................... 40-618
Failure code [DGT1KA] Disconnection of T/C
Oil Temp. Sensor ...................................... 40-620
Failure code [DGT1KB] Ground Fault of T/C
Oil Temp. Sensor ...................................... 40-623
Failure code [DH21KA] Failure of Loader
Pump Press. Sensor ................................. 40-625
Failure code [DH21KB] Loader Pump Press.
Sensor Short Circuit .................................. 40-627
Failure code [DHA4KA] Failure of Air Cleaner
Sensor Circuit ........................................... 40-629
Failure code [DHPCKX] Out of Range of Boom
Bottom Press. Sensor................................ 40-631
Failure code [DHPCKX] Out of Range of Boom
Head Press. Sensor .................................. 40-633
Failure code [DHT1KX] Out of Range of T/M
Cut Off Press. Sensor................................ 40-635
Input Pressure Sensor ............................... 40-637
Output Pressure Sensor ............................ 40-639
Failure code [DHT8KA] Failure of Steering
Pump Press. Sensor ................................. 40-641
Failure code [DHT8KB] Steering Pump Press.
Sensor Short Circuit .................................. 40-643
Failure code [DHT8ZG] Steering Oil Pressure
Low ......................................................... 40-645
Failure code [DHUDKA] Failure of Emrg.
Steering Press. Sensor.............................. 40-646
Failure code [DHUDKB] Emrg. Steering Press.
S. Short Circuit.......................................... 40-648
Failure code [DJF1KA] Disconnection of Fuel
Level Sensor ............................................ 40-650
Failure code [DK55KA] Failure of FNR Lever
Potentio ................................................... 40-652
Failure code [DK55KY] Hot Short of FNR Lever
Potentio Circuit ......................................... 40-655
Failure code [DK55L5] Failure of FNR Lever
Potentio ................................................... 40-657
Failure code [DK59KA] Failure of Boom Lever
Potentio (Main) ......................................... 40-658
WA470-7
Failure code [DK59KY] Hot Short of Boom

Lever Potentio (Main) ................................ 40-661
Failure code [DK59L8] Boom Lever Potentio
(Main & Sub) Disagree .............................. 40-664
Failure code [DK5AKA] Failure of Boom Lever
Potentio (Sub)........................................... 40-668
Failure code [DK5AKY] Hot Short of Boom
Lever Potentio (Sub) ................................. 40-671
Failure code [DK5BKA] Failure of Bucket Lever
Potentio (Main) ......................................... 40-674
Failure code [DK5BKY] Hot Short of Bucket
Lever Potentio (Main) ................................ 40-677
Failure code [DK5BL8] Bucket Lever Potentio
(Main&Sub) Disagree ................................ 40-680
Failure code [DK5CKA] Failure of Bucket
Failure code [DK5CKY] Hot Short of Bucket
Failure code [DK5DKA] Failure of 3rd Lever
Potentio (Main) ......................................... 40-690
Failure code [DK5DKY] Hot Short of 3rd Lever
Potentio (Main) ......................................... 40-693
Failure code [DK5DL8] 3rd Lever Potentio
(Main & Sub) Disagree .............................. 40-695
Failure code [DK5EKA] Failure of 3rd Lever
Potentio (Sub)........................................... 40-698
Failure code [DK5EKY] Hot Short of 3rd Lever
Potentio (Sub)........................................... 40-701
Failure code [DKA0KA] Failure of Boom Angle
Sensor ..................................................... 40-703
Failure code [DKA0KY] Hot Short of Boom
Angle Sensor Circuit.................................. 40-705
Failure code [DKA0L0] Boom Angle Sensor
Dislocation ............................................... 40-707
Failure code [DKA1KA] Failure of Bucket
Angle Sensor............................................ 40-709
Failure code [DKA1KY] Hot Short of Bucket
Angle Sensor Circuit.................................. 40-711
Failure code [DLF1KA] Disconnection of T/M
Input Speed Sensor .................................. 40-713
Failure code [DLF1LC] Failure of T/M Input
Speed Sensor........................................... 40-715
Failure code [DLM3KA] Disconnection of
Radiator Fan Speed Sensor....................... 40-717
Failure code [DLM3LC] Failure of Radiator Fan
Speed Sensor........................................... 40-719
Failure code [DLT3KA] Disconnection of
Output Speed Sens. (Main)........................ 40-721
Failure code [DLT3LC] Failure of Output Speed
Sensor (Main) ........................................... 40-723
Failure code [DPQ1KR] LIN Discon (Switch
Panel) ...................................................... 40-725
Failure code [DPQ2KR] LIN Discon (LED Unit)....40728
Failure code [DPQ3KR] LIN Discon (Rear View
Monitor).................................................... 40-731
Failure code [DSJ0KR] CAN2 Discon (Meter
Unit)......................................................... 40-734
INDEX
Failure code [DT20KB] Ground Fault of T/M

Cut Off Indicator........................................ 40-736
Failure code [DT22KB] Ground Fault of Work
Equip. Lock Indic....................................... 40-738
Failure code [DV00KB] Ground Fault of Buzzer
Output...................................................... 40-740
Failure code [DW4QKA] Disconnection of
Boom EPC Solenoid (Lower) ..................... 40-748
Failure code [DW4PKA] Disconnection of
Boom EPC Solenoid (Raise) ...................... 40-742
Failure code [DW4PKB] Ground Fault of Boom
EPC Solenoid (Raise)................................ 40-744
Failure code [DW4PKY] Hot Short of Boom
EPC Solenoid (Raise)................................ 40-746
Failure code [DW4QKB] Ground Fault of Boom
EPC Solenoid (Lower) ............................... 40-750
Failure code [DW4QKY] Hot Short of Boom
EPC Solenoid (Lower) ............................... 40-752
Failure code [DW4RKA] Disconnection of
Bucket EPC Sol. (Tilt) ................................ 40-754
Failure code [DW4RKB] Ground Fault of
Bucket EPC Solenoid (Tilt)......................... 40-756
Failure code [DW4RKY] Hot Short of Bucket
EPC Solenoid (Tilt).................................... 40-758
Failure code [DW4SKA] Disconnection of
Bucket EPC Sol. (Dump) ........................... 40-760
Failure code [DW4SKB] Ground Fault of
Bucket EPC Solenoid (Dump) .................... 40-762
Failure code [DW4SKY] Hot Short of Bucket
EPC Solenoid (Dump) ............................... 40-764
Failure code [DW7BKA] Disconnection of Fan
Reverse Solenoid ..................................... 40-766
Failure code [DW7BKB] Ground Fault of
Radiator Fan Rev. Sol................................ 40-768
Failure code [DW7BKY] Hot Short of Radiator
Fan Rev. Sol. ............................................ 40-770
Failure code [DWM1KA] Disconnection of
Neutral Lock Solenoid ............................... 40-771
Failure code [DWM1KB] Ground Fault of
Neutral Lock Solenoid ............................... 40-773
Failure code [DWM1KY] Hot Short of Neutral
Lock Solenoid ........................................... 40-775
Detent Solenoid (Boom) ............................ 40-777
Detent Solenoid (Boom) ............................ 40-779
Solenoid (Boom) ....................................... 40-781
Detent Solenoid (Bucket) ........................... 40-783
Detent Solenoid (Bucket) ........................... 40-785
Solenoid (Bucket)...................................... 40-787
Failure code [DX16KA] Disconnection of Rad.
Fan Pump EPC Sol. .................................. 40-789
Failure code [DX16KB] Ground Fault of Rad.
Fan Pump EPC Sol. .................................. 40-791
Failure code [DX16KY] Hot Short of Radiator

Fan Pump EPC Sol. .................................. 40-793
Failure code [DXA1KA] Disconnection of
Loader Pump EPC Solenoid ...................... 40-795
Failure code [DXA1KB] Ground Fault of
Loader Pump EPC Solenoid ...................... 40-797
Failure code [DXA1KY] Hot Short of Loader
Pump EPC Solenoid ................................. 40-799
Failure code [DXANKA] Disconnection of
Steering Pump EPC Sol............................. 40-801
Failure code [DXANKB] Ground Fault of
Steering Pump EPC Solenoid .................... 40-803
Failure code [DXANKY] Hot Short of Steering
Pump EPC Solenoid ................................. 40-805
ECMV Solenoid (Lockup)........................... 40-806
Failure code [DXH1KB] Ground Fault of ECMV
Solenoid (Lockup) ..................................... 40-808
Solenoid (Lockup) ..................................... 40-810
ECMV Solenoid (1st) ................................. 40-812
Solenoid (1st) ........................................... 40-814
Solenoid (1st) ........................................... 40-816
ECMV Solenoid (2nd)................................ 40-818
Solenoid (2nd) .......................................... 40-820
Solenoid (2nd) .......................................... 40-822
ECMV Solenoid (3rd) ................................ 40-824
ECMV Solenoid (Reverse) ......................... 40-830
Solenoid (3rd) ........................................... 40-826
Solenoid (3rd) ........................................... 40-828
Solenoid (Reverse) ................................... 40-832
Solenoid (Reverse) ................................... 40-834
ECMV Solenoid (Forward) ......................... 40-836
Solenoid (Forward).................................... 40-838
Solenoid (Forward).................................... 40-840
Failure code [DXHHKA] Disconnection of
ECMV Solenoid (4th)................................. 40-842
Failure code [DXHHKB] Ground Fault of
ECMV Solenoid (4th)................................. 40-844
Failure code [DXHHKY] Hot Short of ECMV
Solenoid (4th) ........................................... 40-846
Failure code [DXHJKA] Disconnection of 3rd
EPC Solenoid (EXT).................................. 40-848
WA470-7
INDEX
Failure code [DXHJKB] Ground Fault of 3rd

EPC Solenoid (EXT).................................. 40-850
Failure code [DXHJKY] Hot Short of 3rd EPC
Solenoid (EXT) ......................................... 40-852
Failure code [DXHKKA] Disconnection of 3rd
EPC Solenoid (RET) ................................. 40-854
Failure code [DXHKKB] Ground Fault of 3rd
EPC Solenoid (RET) ................................. 40-856
Failure code [DXHKKY] Hot Short of 3rd EPC
Solenoid (RET) ......................................... 40-858
Failure code [DY30MA] Malfunction 1 of
Emerg. Steering Motor............................... 40-860
Failure code [DY30MC] Malfunction 2 of
Emerg. Steering Motor............................... 40-863
Failure code [DY30ME] Emerg. Steering LongTime Activated .......................................... 40-867
Failure code [LA00L3] Failure of Fan Reverse .....40869
Failure code list related to air conditioner ........ 80-52
Failure codes table ..................................... 40-119
Failure mode and cause table .....................40-1011
Fan 100% setting function ........................... 10-270
Final drive ........................................ 10-113, 60-39
Flushing procedure for torque converter and
transmission hydraulic circuit ....................... 30-52
Forward and reverse clutch ECMV and 1st and
2nd clutch ECMV .............................. 10-81, 60-23
Front brake oil pressure switch..................... 10-347
Function..................................................... 10-254
Fuse location table...................................... 40-104
H
H-1 Machine does not move off.................. 40-1019
H-2 Torque converter lockup clutch is not
disengaged (engine stalls) ....................... 40-1022
H-3 Torque converter lockup clutch is not
engaged................................................. 40-1023
H-4 Travel speed is slow, bucket thrust force is
weak, gradability is low, or gear speed does
not shift .................................................. 40-1024
H-5 Large shock is made when machine starts
or gear is shifted ..................................... 40-1027
H-6 Machine starts or gear speed shifts with
long time lag ........................................... 40-1029
H-7 Torque converter oil temperature is high .......401031
H-8 Machine does not turn......................... 40-1033
H-9 Turning response is poor ..................... 40-1035
H-10 Steering wheel is heavy to turn .......... 40-1037
H-11 Machine sways or large shocks are made
while machine turns................................. 40-1038
H-12 Turning radius differs between right and
left turns ................................................. 40-1040
H-13 Wheel brakes do not work or are weak .......401041
H-14 Wheel brakes are not released or drag .......401043
WA470-7
H-15 Parking brake does not work or it is weak....401044

H-16 Parking brake is not released or drags
(including emergency release system) ...... 40-1045
H-17 Boom does not rise ........................... 40-1046
H-18 Boom moves slow or boom lacks lifting
force ...................................................... 40-1048
H-19 Rising boom slows down at certain height ...401050
H-20 Lift cylinders do not serve to hold bucket
on ground............................................... 40-1051
H-21 Hydraulic drift of boom is large ........... 40-1052
H-22 Boom moves up and down during
operation................................................ 40-1053
H-23 Bucket does not tilt back.................... 40-1054
H-24 Bucket moves slow or bucket lacks tiltback force .............................................. 40-1056
H-25 Bucket decelerates during tilt-back
operation................................................ 40-1058
H-26 Bucket cylinder does not hold bucket on
ground ................................................... 40-1059
H-27 Hydraulic drift of bucket is large.......... 40-1060
H-28 Bucket tilts back and forth during carrying
load (work equipment valve in HOLD) ....... 40-1061
H-29 Boom and bucket control levers do not
move smoothly and are heavy to move ..... 40-1062
H-30 Operating work equipment causes
engine speed to lower significantly or engine
to stall .................................................... 40-1063
H-31 Large shocks are made when work
equipment starts to move and stops.......... 40-1064
H-32 When certain work equipment stalls
hydraulically, other work equipment moves........401066
H-33 E.C.S.S. (travel damper) does not work
and machine pitches and bounces............ 40-1067
H-34 Bucket does not stop at the position
which is set with remote bucket positioner . 40-1068
H-35 Fan speed is abnormal (too high or low,
or does not rotate) ................................... 40-1069
H-36 Unusual noise is heard from around fan......401070
Handling battery disconnect switch .............. 30-218
Handling cylinder cutout mode operation ........ 30-34
Handling equipment of fuel system devices..... 00-29
Handling no injection cranking operation......... 30-35
Handling of compressor oil ............................ 80-91
Handling of electrical equipment .................... 00-36
Handling of hydraulic equipment .................... 00-31
Handling of intake system parts ..................... 00-30
Handling voltage circuit of engine controller .. 30-217
How to open the electrical system abnormality
record screen in service mode of the machine
monitor....................................................... 80-36
How to read electric wire code ....................... 00-44
How to read the shop manual ........................ 00-25
How to read this manual .................................. 50-4
Hydraulic circuit diagram ................................. 90-9
Hydraulic circuit diagram of power train............. 90-7
INDEX
Hydraulic component layout......................... 10-180

Hydraulic tank .................................. 10-183, 60-63
I
Important safety notice .................................. 00-18
Information described in troubleshooting table
(H-mode)................................................ 40-1007
Information in troubleshooting table ...... 40-46, 80-51
Information mentioned in troubleshooting table
(S mode) ................................................ 40-1071
Inspection procedure before troubleshooting... 40-17
K
KCCV layout drawing .................................... 10-19
KCCV ventilator............................................ 10-21
KDPF .......................................................... 10-23
KOMTRAX system ..................................... 10-320
KVGT ............................................................ 10-6
L
Layout of brake parts .................................. 10-152
Layout of steering parts ............................... 10-115
List of abbreviation........................................ 00-56
Lockup clutch ECMV........................... 10-95, 60-25
LS valve..................................................... 10-125
M
Main relief and torque converter relief valve ... 10-99,
60-26
Method of disconnecting and connecting of
push-pull type coupler ................................. 00-33
Method of releasing parking brake manually . 30-103
O
Orbit-roll valve ............................................ 10-143
Ordinary functions and special functions of
machine monitor ....................................... 30-128
Outer temperature sensor (outside air
temperature sensor) .................................... 80-21
Outline of refrigeration cycle ............................ 80-7
Overload relief valve ................................... 10-139
P
Parking brake ................................... 10-172, 60-57
Parking brake control .................................. 10-171
Parking brake control system ....................... 10-250
Parking brake emergency release valve ....... 10-176
Parking brake oil pressure switch ................. 10-349
Parking brake solenoid valve ............. 10-173, 60-58
Parts and connectors layout .......................... 80-30
PC-EPC valve ............................................ 10-203
PC valve .................................................... 10-126
Pm Clinic service ........................................ 30-220
10
Power train piping drawing............................. 10-50

Power train system ....................................... 10-46
Practical use of KOMTRAX............................ 00-51
Precautions for disconnecting and connecting
hoses and tubes in air conditioner circuit ....... 80-89
Precautions for KDPF (KCSF and KDOC)
Cleaning and Replacement........................ 40-107
Precautions for refrigerant ............................... 80-3
Precautions on troubleshooting of machine
monitor..................................................... 40-110
Precautions when performing operation.......... 00-47
Preheating system ...................................... 10-245
Preparation work for troubleshooting of
electrical system ......................................... 40-34
Procedure for testing and troubleshooting ....... 80-22
Procedures for cleaning fuel doser ................. 30-43
Processing procedure of harness checker for
troubleshooting of machine monitor LCD unit.....40112
R
Real-time monitoring function of transmission
controller .................................................. 10-276
Real-time monitoring function of work
equipment controller.................................. 10-292
Rear brake oil pressure switch ..................... 10-348
Rear view monitor system ........................... 10-317
Receiver drier............................................... 80-18
Releasing remaining pressure from work
equipment circuit....................................... 30-118
Releasing remaining pressure in brake
accumulator circuit ...................................... 30-99
Relief valve ................................................ 10-142
Remote positioner function .......................... 10-285
Removal and installation of aftercooler ........... 50-87
Removal and installation of air cleaner
assembly.................................................. 50-136
Removal and installation of air conditioner
compressor assembly ............................... 50-303
compressor belt ........................................ 50-138
condenser assembly ................................. 50-305
Removal and installation of air conditioner unit
assembly.................................................. 50-298
Removal and installation of alternator belt ..... 50-139
Removal and installation of brake charge valve
assembly.................................................. 50-246
Removal and installation of center hinge pin.. 50-250
Removal and installation of control valve
assembly.................................................. 50-264
Removal and installation of cooling fan and
cooling fan motor assembly........................ 50-110
Removal and installation of cooling system
assembly.................................................... 50-82
Removal and installation of counterweight
assembly.................................................. 50-258
WA470-7
INDEX
Removal and installation of cylinder head

assembly.................................................... 50-63
Removal and installation of EGR (Exhaust Gas
Recirculation) cooler assembly................... 50-134
Removal and installation of EGR (Exhaust Gas
Recirculation) valve assembly .................... 50-133
Removal and installation of engine assembly .. 50-96
Removal and installation of engine controller
assembly.................................................. 50-308
Removal and installation of engine front oil
seal ......................................................... 50-102
Removal and installation of engine hood
assembly.................................................... 50-77
Removal and installation of engine rear oil seal ...50105
Removal and installation of front axle assembly...50208
Removal and installation of fuel doser
assembly.................................................... 50-61
Removal and installation of fuel tank assembly....50140
Removal and installation of full-length fender
assembly.................................................. 50-260
Removal and installation of grille assembly ..... 50-79
Removal and installation of hydraulic oil cooler....5090
Removal and installation of hydraulic tank
assembly.................................................. 50-261
Removal and installation of injector assembly . 50-53
Removal and installation of KCCV assembly . 50-126
Removal and installation of KDPF assembly . 50-112
Removal and installation of KOMTRAX
terminal assembly ..................................... 50-315
Removal and installation of KVGT assembly . 50-128
Removal and installation of machine monitor
assembly.................................................. 50-307
Removal and installation of mass air flow and
temperature sensor ................................... 50-314
Removal and installation of monitor controller
assembly.................................................. 50-312
Removal and installation of operator's cab and
floor frame assembly ................................. 50-283
Removal and installation of operator's cab
glass (stuck window glass)......................... 50-287
Removal and installation of operator's seat
assembly.................................................. 50-295
Removal and installation of parking brake disc
and plate .................................................. 50-247
Removal and installation of power train oil
cooler assembly.......................................... 50-92
Removal and installation of radiator core
assembly.................................................... 50-85
Removal and installation of rear axle assembly ...50210
Removal and installation of seat belt............. 50-297
Removal and installation of steering pump and
power train pump assembly ....................... 50-267
Removal and installation of steering valve
assembly.................................................. 50-244
WA470-7
Removal and installation of supply pump

assembly.................................................... 50-47
Removal and installation of torque converter
and transmission assembly........................ 50-143
Removal and installation of transmission
controller assembly ................................... 50-311
Removal and installation of work equipment
assembly.................................................. 50-278
controller assembly ................................... 50-309
pump and cooling fan pump assembly ........ 50-269
Retrieval of disabled machine due to
transmission valve failure............................. 30-54
ROPS cab.................................................. 10-242
S
S-1 When starting switch is turned to START
position, engine is not cranked ................. 40-1072
S-2 The engine cranks but exhaust smoke
does not come out................................... 40-1073
S-3 Fuel is injected but engine does not start
(incomplete combustion, engine seems to
start but does not) ................................... 40-1074
S-4 Engine startability is poor..................... 40-1075
S-5 Engine does not pick-up smoothly ........ 40-1077
S-6 Engine stops during operation.............. 40-1079
S-7 Engine runs rough or is unstable .......... 40-1081
S-8 Engine lacks power............................. 40-1082
S-9 KDPF gets clogged in a short time........ 40-1084
S-10 Engine oil consumption is excessive... 40-1086
S-11 Engine oil becomes contaminated early ......401087
S-12 Fuel consumption is excessive........... 40-1088
S-13 Oil is in coolant (or coolant spurts or
coolant level goes down) ......................... 40-1089
S-14 Oil pressure drops............................. 40-1090
S-15 Fuel mixes into engine oil .................. 40-1091
S-16 Water mixes into engine oil (milky)...... 40-1092
S-17 Coolant temperature rises too high
(overheating) .......................................... 40-1093
S-18 Unusual noise is heard ...................... 40-1094
S-19 Vibration is excessive........................ 40-1095
S-20 Air cannot be bled from fuel circuit ...... 40-1096
S-21 Active regeneration is executed
frequently ............................................... 40-1097
S-22 Active regeneration takes a long time . 40-1098
S-23 White smoke is exhausted during active
regeneration ........................................... 40-1099
Self-diagnosis function of work equipment
controller .................................................. 10-292
Semi auto-digging function .......................... 10-288
Sensor....................................................... 10-350
Sequence of events in troubleshooting ........... 40-13
Servo valve ..............................10-123, 60-6, 60-45
Sketch of tools for testing and adjusting ............ 30-8
Sketches of special tools ............................... 50-17
Slack adjuster............................................. 10-164
11
INDEX
Special functions of machine monitor............ 30-127

Special tools list............................................ 50-10
Specification .................................................. 01-5
Specification drawing ...................................... 01-3
Standard tightening torque table .................... 00-52
Standard value table for electrical system ....... 20-18
Standard value table for engine........................ 20-3
Standard value table for machine ..................... 20-5
Steering column ............................... 10-116, 60-41
Steering cylinder........................................... 60-48
Steering relief valve .................................... 10-137
Steering valve ............................................ 10-129
Stop lamp oil pressure switch....................... 10-348
Stop valve .................................................. 10-149
Sunlight sensor............................................. 80-20
Symbols in electric circuit diagram.................. 90-11
Symbols in hydraulic circuit diagram................. 90-3
Symptom and troubleshooting numbers.......... 40-43
System chart of hydraulic and mechanical
systems ................................................. 40-1008
System diagram ........................................... 80-27
System operating lamp function ................... 10-252
T
T-branch box and T-branch adapter table........ 40-98
Table of fuel, coolant, and lubricants ............... 01-13
Testing and adjusting air conditioner
compressor belt tension............................... 30-39
Testing and adjusting boom position detection
lever ........................................................ 30-124
Testing and adjusting brake pedal linkage ....... 30-84
Testing and adjusting bucket position detection
lever ........................................................ 30-123
Testing and adjusting of accumulator charge
pressure..................................................... 30-86
Testing and adjusting power train oil pressure . 30-58
Testing and adjusting steering circuit oil
pressure..................................................... 30-78
Testing and adjusting steering stopper valve ... 30-82
Testing and adjusting valve clearance ............ 30-16
Testing and adjusting work equipment EPC oil
pressure................................................... 30-110
Testing and adjusting work equipment oil
pressure................................................... 30-113
Testing blowby pressure ................................ 30-22
Testing boost pressure .................................. 30-12
Testing braking performance.......................... 30-85
Testing compression pressure ....................... 30-18
Testing diodes ............................................ 30-219
Testing directional lever ................................. 30-73
Testing drive shaft for looseness, backlash,
and damage ............................................... 30-57
Testing EGR valve and KVGT oil pressures..... 30-25
Testing engine piping for damage and
looseness................................................... 30-38
Testing engine speed .................................... 30-10
Testing exhaust gas color .............................. 30-14
Testing fan pump circuit oil pressure ............. 30-106
12
Testing fan speed ....................................... 30-105

Testing FRESH/RECIRC air changeover ........ 80-42
Testing fuel circuit for leakage ........................ 30-33
Testing fuel pressure ..................................... 30-26
Testing fuel return rate and leakage ................ 30-27
Testing lowering of wheel brake pressure........ 30-94
Testing of brake accumulator nitrogen gas
pressure and procedure for charging brake
accumulator with nitrogen gas ...................... 30-88
Testing of ECSS accumulator nitrogen gas
pressure and procedure for charging
accumulator with nitrogen gas .................... 30-119
Testing of installed condition of cylinder head
and manifolds ............................................. 30-37
Testing of KDPF and muffler stack for
looseness and damage ............................... 30-36
Testing oil leakage from axle final drive ........... 30-56
Testing parking brake oil pressure ................ 30-101
Testing parking brake performance............... 30-100
Testing relays ............................................... 80-46
Testing steering wheel................................... 30-74
Testing temperature control system ................ 80-38
Testing vent (mode) changeover .................... 80-40
Testing wear of wheel brake disc........ 30-96, 30-102
Testing wheel brake oil pressure .................... 30-92
Testing with self-diagnosis function................. 80-35
Testing work equipment control lever .............. 30-76
Throttle position sensor ............................... 10-341
Tire............................................................ 10-178
Tools for testing and adjusting.......................... 30-4
Torque converter................................. 10-54, 60-10
Transmission................................................ 60-12
Transmission control ..................................... 10-51
Transmission control valve .................. 10-78, 60-21
Transmission controller ............................... 10-331
Transmission controller system .................... 10-256
Troubleshooting chart 1................................. 80-48
Troubleshooting chart 2................................. 80-49
Troubleshooting points .................................. 40-11
Troubleshooting with gauge pressure ............. 80-84
W
Weight table ................................................. 01-11
Work equipment control............................... 10-182
Work equipment control system ................... 10-277
Work equipment controller ........................... 10-327
Work equipment cylinder ............................... 60-81
Work equipment electric lever ...................... 10-337
Work equipment linkage .................... 10-239, 60-76
Work equipment lock solenoid valve............. 10-236
Work equipment pump ................................ 10-187
Writing compensation values at replacement of
injector and engine controller ....................... 30-46
WA470-7
WA470-7 WHEEL LOADER

Form No. SEN06006-02
2012
KOMATSU
All Rights Reserved
Printed in Japan 1012

Wa470 7

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00 Index and foreword

00 Index and foreword

00 Index and foreword ....................................................................................................................... 00-1

00 Index and foreword

Steering pump ................................................................................................................. 10-117

00 Index and foreword

Standard value table for machine .......................................................................................... 20-5

00 Index and foreword

Method of releasing parking brake manually ....................................................................... 30-103

00 Index and foreword

Failure code [15SGLH] Malfunction of ECMV (3rd).............................................................. 40-152

00 Index and foreword

00 Index and foreword

Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-359

00 Index and foreword

Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-503

00 Index and foreword

00 Index and foreword

00 Index and foreword

Failure code [DY30ME] Emerg. Steering Long-Time Activated ............................................. 40-867

00 Index and foreword

00 Index and foreword

00 Index and foreword

Disassembly and assembly of transmission clutch pack assembly ....................................... 50-185

00 Index and foreword

Steering valve.................................................................................................................... 60-46

00 Index and foreword

Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-70

00 Index and foreword

Foreword, safety and general information

handling causes an extreme

Before performing any greasing or repairs, read

1. Always wear the protective eyeglasses when

knowledge of welding perform the work. When

00 Index and foreword

steps when getting on or off the machine. Never

When removing piping, prevent the fuel or oil

00 Index and foreword

Keep putting on the gloves during sling work.

Use the specified eye bolts and fix wire ropes,

with one rope may cause turning

Hanging angle must be 60 degrees or smaller as

Do not use twisted or kinked wire ropes.

When installing wire ropes to an angular load,

00 Index and foreword

Precautions for using overhead traveling crane

hoist or crane must be used to sling the

Before starting work, check the wire ropes,

a The allowable load is calculated as one sixth of

replacing the air conditioner unit, air

a Ask a qualified person for collecting, adding and

refrigerant gas (air conditioner gas: R134a)

When loosening the nuts fixing air conditioner

00 Index and foreword

Check that the O-ring is not damaged or

When tightening nuts of the air conditioner

For tightening torques, see "Others",

00 Index and foreword

Turn the starting switch to the OFF position to

Fire caused by fuel, oil, coolant or window

Fire caused by accumulation or attachment

00 Index and foreword