SM Wa480 & 450-6 Sen00809-01d

SEN00809-01
Shop
Manual
WA450-6
WA480-6
WHEEL LOADER
SERIAL NUMBERS WA450-6 66001 and up
WA480-6 85001 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2006 Komatsu

Printed in U.S.A.
Komatsu America Corp.
September 2006
SEN00818-01
WHEEL LOADER 1SHOP MANUAL
WA450-6
WA480-6
(KA SPEC.)
Machine model Serial number

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
00 Index and foreword 1

Index
Composition of shop manual................................................................................................................ 2

Table of contents .................................................................................................................................. 4
WA450-6, WA480-6 (KA SPEC.) 1

SEN00818-01 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00809-01
00 Index and foreword SEN00810-01

Index SEN00818-01 q
Foreword and general information SEN00819-00
01 Specification SEN00811-00
Specification and technical data SEN00820-00
10 Structure, function and maintenance standard SEN00812-00

Engine and cooling system SEN01159-00
Power train SEN01161-00
Steering system SEN01163-00
Brake system SEN01166-00
Undercarriage and frame SEN01168-00
Hydraulic system, Part 1 SEN01170-00
Work equipment SEN01173-00
Cab and its attachments SEN01176-00
Electrical system, Part 1 SEN01178-00
20 Standard value table SEN00813-01

Standard service value table SEN01300-01 q
30 Testing and adjusting SEN00814-00

Testing and adjusting, Part 1 SEN01586-00 Q
40 Troubleshooting SEN00815-00
Failure code table and fuse locations SEN01676-00 Q
General information on troubleshooting SEN01677-00 Q
Troubleshooting by failure code (Display of code), Part 1 SEN01678-00 Q
2 WA450-6, WA480-6 (KA SPEC.)


Troubleshooting of electrical system (E-mode) SEN01688-00 Q
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01689-00 Q
Troubleshooting of engine (S-mode) SEN01690-00 Q
90 Diagrams and drawings SEN00817-00

Hydraulic diagrams and drawings SEN00821-00
Electrical diagrams and drawings SEN00822-00
WA450-6, WA480-6 (KA SPEC.) 3

Table of contents 1
00 Index and foreword
Index SEN00818-01
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN00819-00

Foreword and general information .............................................................................................. 2
Safety notice ............................................................................................................................ 2
How to read the shop manual.................................................................................................. 6
Explanation of terms for maintenance standard ...................................................................... 8
Handling electric equipment and hydraulic component ........................................................... 10
How to read electric wire code................................................................................................. 18
Method of disassembling and connecting push-pull type coupler ........................................... 21
Standard tightening torque table.............................................................................................. 24
Conversion table...................................................................................................................... 28
01 Specification
Specification and technical data SEN00820-00
Specification and technical data .................................................................................................. 3
Specification dimension drawing.............................................................................................. 3
Specifications........................................................................................................................... 4
Weight table ............................................................................................................................. 8
Table of fuel, coolant and lubricants ........................................................................................ 10
10 Structure, function and maintenance standard

Engine and cooling system SEN01159-00
Engine and cooling system ......................................................................................................... 2
Engine mount and transmission mount ................................................................................... 2
Cooling system ........................................................................................................................ 3
Cooling fan pump..................................................................................................................... 4
Cooling fan motor .................................................................................................................... 12
Power train SEN01161-00
Power train .................................................................................................................................. 3
Power train............................................................................................................................... 3
Power train system diagram .................................................................................................... 4
Drive shaft................................................................................................................................ 6
Power train piping diagram ...................................................................................................... 7
Torque converter...................................................................................................................... 8
Transmission............................................................................................................................ 16
Flow control valve .................................................................................................................... 33
Transmission control valve ...................................................................................................... 34
ECMV ...................................................................................................................................... 36
Main relief valve and torque converter relief valve .................................................................. 42
Axle.......................................................................................................................................... 44
Differential................................................................................................................................ 48
Limited slip differential ............................................................................................................. 53
Final drive ................................................................................................................................ 60
Steering system SEN01163-00
Steering system........................................................................................................................... 2
Steering piping diagram ........................................................................................................... 2
Steering column ....................................................................................................................... 3
Steering pump.......................................................................................................................... 4
Steering valve .......................................................................................................................... 17
Orbit-roll valve.......................................................................................................................... 32
4 WA450-6, WA480-6 (KA SPEC.)

Stop valve ................................................................................................................................ 36

Steering relief valve ................................................................................................................. 37
Steering cylinder ...................................................................................................................... 38
Emergency steering motor ...................................................................................................... 40
Emergency steering pump....................................................................................................... 41
Brake system SEN01166-00
Brake system .............................................................................................................................. 2
Brake piping diagram............................................................................................................... 2
Charge valve ........................................................................................................................... 3
Brake valve.............................................................................................................................. 10
Accumulator (for brake) ........................................................................................................... 15
Slack adjuster .......................................................................................................................... 16
Brake ....................................................................................................................................... 18
Parking brake control............................................................................................................... 23
Parking brake .......................................................................................................................... 24
Parking brake solenoid valve................................................................................................... 26
Emergency parking brake release valve ................................................................................. 28
Undercarriage and frame SEN01168-00
Undercarriage and frame ............................................................................................................ 2
Axle mount and center hinge pin ............................................................................................. 2
Tires......................................................................................................................................... 6
Hydraulic system, Part 2 ............................................................................................................. 2
Hydraulic piping diagram ......................................................................................................... 2
Work equipment control lever linkage ..................................................................................... 5
Hydraulic tank.......................................................................................................................... 6
Power train pump .................................................................................................................... 8
Work equipment pump ............................................................................................................ 10
Work equipment control valve ................................................................................................. 30
CLSS ....................................................................................................................................... 41
Each function and operation of each valve.............................................................................. 46
Hydraulic system, Part 2 ............................................................................................................. 2
PPC valve................................................................................................................................ 2
Accumulator (for PPC circuit) .................................................................................................. 8
Accumulator (for ECSS) .......................................................................................................... 9
Work equipment SEN01173-00
Work equipment .......................................................................................................................... 2
Work equipment linkage .......................................................................................................... 2
Bucket...................................................................................................................................... 5
Bucket positioner and boom kick-out....................................................................................... 6
Work equipment cylinder ......................................................................................................... 12
Cab and its attachments SEN01176-00
Cab and its attachments.............................................................................................................. 3
Cab .......................................................................................................................................... 3
Air conditioner.......................................................................................................................... 4
Electrical system, Part 1.............................................................................................................. 2
Machine monitor system.......................................................................................................... 2
Machine monitor ...................................................................................................................... 7
Electrical system (Transmission controller system)................................................................. 2
Transmission controller............................................................................................................ 26
WA450-6, WA480-6 (KA SPEC.) 5


Electric transmission control .................................................................................................... 2
Combination switch.................................................................................................................. 4
Kickdown switch and hold switch............................................................................................. 6
KOMTRAX terminal system..................................................................................................... 8
Engine starting circuit .............................................................................................................. 10
Engine stopping circuit............................................................................................................. 12
Preheating circuit ..................................................................................................................... 13
Engine power mode selector circuit......................................................................................... 14
Engine output derating function ............................................................................................... 15
Automatic warm-up function .................................................................................................... 15
Parking brake circuit ................................................................................................................ 16
Sensor ..................................................................................................................................... 18
20 Standard value table

Standard service value table SEN01300-01
Standard service value table ....................................................................................................... 2
Standard value table for engine ............................................................................................... 2
Standard value table for chassis.............................................................................................. 3
30 Testing and adjusting

Testing and adjusting, Part 1 SEN01586-00
Testing and adjusting, Part 1 ....................................................................................................... 3
Tools for testing, adjusting, and troubleshooting...................................................................... 3
Measuring engine speed ......................................................................................................... 6
Measuring exhaust gas color................................................................................................... 8
Measuring exhaust temperature .............................................................................................. 9
Adjusting valve clearance ........................................................................................................ 11
Measuring compression pressure............................................................................................ 13
Measuring blow-by pressure.................................................................................................... 15
Measuring engine oil pressure................................................................................................. 16
Measuring intake air (boost) pressure ..................................................................................... 18
Handling fuel system equipment.............................................................................................. 19
Releasing residual pressure in fuel system ............................................................................. 19
Testing fuel pressure................................................................................................................ 20
Testing fuel return and leak amount......................................................................................... 21
Bleeding air from fuel circuit .................................................................................................... 24
Testing fuel circuit for leakage ................................................................................................. 26
Handling of reduced cylinder mode operation ......................................................................... 27
Handling of no injection cranking operation............................................................................. 27
Handling controller voltage circuit............................................................................................ 28
Testing and adjusting air conditioner compressor belt tension ................................................ 31
Testing and adjusting alternator belt tension ........................................................................... 32
Adjusting transmission speed sensor ...................................................................................... 33
Measuring directional lever...................................................................................................... 35
Measuring and adjusting power train oil pressure ................................................................... 36
Procedure for flushing torque converter and transmission hydraulic circuit ............................ 51
Method of moving machine when transmission valve is broken.............................................. 52
Testing and adjusting steering stop valve ................................................................................ 55
Testing and adjusting steering wheel....................................................................................... 57
Testing steering oil pressure .................................................................................................... 59
Bleeding air from steering circuit ............................................................................................. 62
Testing and adjusting, Part 2 ....................................................................................................... 3
Testing hydraulic drive fan ....................................................................................................... 3
Bleeding air from hydraulic drive fan circuit ............................................................................. 5
6 WA450-6, WA480-6 (KA SPEC.)

Measuring brake pedal ............................................................................................................ 7

Measuring brake performance................................................................................................. 9
Testing and adjusting accumulator charge pressure ............................................................... 10
Testing wheel brake oil pressure ............................................................................................. 11
Measuring wear of wheel brake disc ....................................................................................... 13
Bleeding air from wheel brake circuit....................................................................................... 14
Releasing residual pressure in brake accumulator circuit ....................................................... 15
Testing parking brake performance ......................................................................................... 15
Measuring parking brake oil pressure ..................................................................................... 16
Manual release method for parking brake ............................................................................... 19
Measuring and adjusting work equipment control lever .......................................................... 20
Measuring and adjusting work equipment PPC oil pressure ................................................... 21
Measuring and adjusting work equipment oil pressure ........................................................... 24
Bleeding air from work equipment circuit................................................................................. 28
Releasing residual pressure in work equipment circuit ........................................................... 29
Testing and adjusting bucket positioner................................................................................... 30
Testing and adjusting boom kick-out ....................................................................................... 32
Checking proximity switch operation pilot lamp....................................................................... 33
Procedure for testing diodes.................................................................................................... 34
Preparation work for troubleshooting for electrical system ...................................................... 35
Starting KOMTRAX terminal operations .................................................................................. 38
Indicator lamps of KOMTRAX terminal.................................................................................... 42
Adjusting machine monitor ...................................................................................................... 45
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ...... 46
Testing and adjusting, Part 3....................................................................................................... 2
Special functions of machine monitor (EMMS)........................................................................ 2
Pm-click inspection table ......................................................................................................... 63
40 Troubleshooting
Failure code table and fuse locations SEN01676-00
Failure code table and fuse locations.......................................................................................... 2
Failure code table .................................................................................................................... 2
Fuse locations ......................................................................................................................... 14
General information on troubleshooting SEN01677-00
General information on troubleshooting ...................................................................................... 2
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting ................................................................................... 3
Testing before troubleshooting ................................................................................................ 4
Classification and procedures of troubleshooting.................................................................... 5
Information contained in troubleshooting table ........................................................................ 8
Connection table for connector pin numbers ........................................................................... 10
T-branch box and T-branch adapter table ............................................................................... 33
Troubleshooting by failure code (Display of code), Part 1 SEN01678-00
Troubleshooting by failure code (Display of code), Part 1........................................................... 3
Failure code [1500L0] (TORQFLOW transmission: Double meshing)..................................... 3
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) .... 4
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) ... 6
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON).... 8
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)... 10
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) . 12
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 14
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 16
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 18
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON). 20
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) 22
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) . 24
WA450-6, WA480-6 (KA SPEC.) 7

Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) 26
Failure code [2F00MA] (Parking brake: Malfunction) .............................................................. 28
Failure code [2G43ZG] (Accumulator: Low oil pressure)......................................................... 30
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) .................................... 32
Failure code [AA1ANX] (Air cleaner: Clogging) ....................................................................... 4
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).............. 6
Failure code [AB00MA] (Alternator: Malfunction) .................................................................... 8
Failure code [B@BAZG] (Rotation derating by low engine oil pressure)................................. 10
Failure code [B@BAZK] (Engine oil: Low level) ...................................................................... 13
Failure code [B@BCNS] (Coolant: Overheating)..................................................................... 14
Failure code [B@BCZK] (Coolant: Low level).......................................................................... 16
Failure code [B@C7NS] (Brake oil: Overheating) ................................................................... 18
Failure code [b@CENS] (Torque converter oil: Overheating).................................................. 20
Failure code [B@CENS] (Torque converter oil: Overheating) ................................................. 22
Failure code [B@HANS] (Hydraulic oil: Overheating) ............................................................. 24
Failure code [CA111] (Abnormality in engine controller).......................................................... 26
Failure code [CA115] (Engine Ne or Bkup speed sensor error) .............................................. 29
Failure code [CA122] (Charge pressure sensor high error)..................................................... 30
Failure code [CA123] (Charge pressure sensor low error) ...................................................... 32
Failure code [CA131] (Throttle sensor high error) ................................................................... 34
Failure code [CA132] (Throttle sensor low error)..................................................................... 36
Failure code [CA135] (Engine oil pressure sensor high error)................................................. 38
Failure code [CA141] (Engine oil pressure sensor low error) .................................................. 40
Failure code [CA144] (Coolant sensor high error) ................................................................... 42
Failure code [CA145] (Coolant sensor low error) .................................................................... 44
Failure code [CA153] (Charge temperature sensor high error) ............................................... 46
Failure code [CA154] (Charge temperature sensor low error)................................................. 48
Failure code [CA187] (Sensor power supply 2 low error) ........................................................ 50
Failure code [CA221] (Atmospheric pressure sensor high error) ............................................ 51
Failure code [CA222] (Atmospheric pressure sensor low error).............................................. 53
Failure code [CA227] (Sensor power supply 2 high error)....................................................... 54
Failure code [CA234] (Engine overspeed)............................................................................... 56
Failure code [CA238] (Ne speed sensor power supply error).................................................. 58
Failure code [CA263] (Fuel temperature sensor high error) .................................................... 4
Failure code [CA265] (Fuel temperature sensor low error) ..................................................... 6
Failure code [CA271] (PCV1 Short circuit) .............................................................................. 8
Failure code [CA272] (PCV1 Disconnection)........................................................................... 10
Failure code [CA273] (PCV2 Short circuit) .............................................................................. 12
Failure code [CA274] (PCV2 Disconnection)........................................................................... 14
Failure code [CA322] (Injector #1 (L/B #1) open/short error) .................................................. 16
Failure code [CA342] (Calibration code inconsistency) ........................................................... 28
Failure code [CA351] (Injectors drive circuit error) .................................................................. 29
Failure code [CA352] (Sensor power supply 1 low error) ........................................................ 31
Failure code [CA386] (Sensor power supply 1 high error)....................................................... 32
Failure code [CA431] (Idle validation switch error) .................................................................. 34
Failure code [CA432] (Idle validation action error) .................................................................. 36
Failure code [CA441] (Battery voltage low error)..................................................................... 38
Failure code [CA442] (Battery voltage high error) ................................................................... 41
8 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA449] Common rail pressure high error 2 ....................................................... 43

Failure code [CA451] (Common rail pressure sensor high error)............................................ 44
Failure code [CA452] (Common rail pressure sensor low error) ............................................. 46
Failure code [CA553] (Common rail pressure high error 1)..................................................... 47
Failure code [CA554] (Common rail pressure sensor in-range error) ..................................... 48
Failure code [CA559] (Supply pump pressure very low error)................................................. 49
Failure code [CA689] (Engine Ne speed sensor error) ........................................................... 53
Failure code [CA731] (Engine Bkup speed sensor phase error) ............................................. 55
Failure code [CA757] (All continuous data lost error) .............................................................. 55
Failure code [CA778] (Engine Bkup speed sensor error) ........................................................ 56
Failure code [CA1228] (EGR valve servo error 1)................................................................... 58
Failure code [CA1625] (EGR valve servo error 2)................................................................... 59
Failure code [CA1633] (KOMNET datalink timeout error) ....................................................... 60
Failure code [CA2185] (Throttle sensor supply voltage high error) ......................................... 62
Failure code [CA2186] (Throttle sensor power supply low error) ............................................ 63
Failure code [CA2249] (Supply pump pressure very low error 2)............................................ 3
Failure code [CA2271] (EGR valve lift sensor high error) ....................................................... 4
Failure code [CA2272] (EGR valve lift sensor low error) ......................................................... 6
Failure code [CA2351] (EGR valve solenoid operation short circuit) ...................................... 7
Failure code [CA2352] (EGR valve solenoid operation disconnect)........................................ 9
Failure code [CA2555] (Intake heater relay disconnection error) ............................................ 10
Failure code [CA2556] (Intake heater relay short circuit error)................................................ 12
Failure code [D150KA] (Emergency steering relay: Disconnection)........................................ 14
Failure code [D150KB] (Emergency steering relay: Short circuit) ........................................... 16
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line) ....... 18
Failure code [D160KA] (Backup lamp relay: Disconnection)................................................... 20
Failure code [D160KB] (Backup lamp relay: Short circuit) ...................................................... 22
Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit) ........................... 24
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) ...................... 26
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) .......................... 28
Failure code [D191KY]
(Joystick steering neutral safety relay: Short circuit with power supply line) .................... 30
Failure code [D192KA] (ECSS solenoid: Disconnection) ........................................................ 32
Failure code [D192KB] (ECSS solenoid: Short circuit)............................................................ 33
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)........................ 34
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)......................... 35
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit) ............................ 37
Failure code [D193KY]
(Joystick steering solenoid cut relay: Short circuit with power supply line)....................... 39
Failure code [D5ZHKA] (Terminal C signal: Disconnection) .................................................... 41
Failure code [D5ZHKB] (Terminal C signal: Short circuit)........................................................ 45
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)............................. 48
Failure code [D5ZHL6]
(Terminal C signal: Signal does not match engine running or stopped state)................... 53
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)............................ 56
Failure code [DAF3KK] (Machine monitor: Low source voltage (input)).................................. 58
Failure code [DAF5KP] (Machine monitor: Low output voltage).............................................. 60
Failure code [DAFRKR] (CAN communication with machine monitor:
Defective communication (Abnormality in target component system)) ............................. 64
Failure code [DAQ0KK] (Transmission controller: Low source voltage).................................. 3
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) .......................... 5
Failure code [DAQ2KK]
(Transmission controller load power supply line: Low source voltage (input)).................. 6
WA450-6, WA480-6 (KA SPEC.) 9

Failure code [DAQ9KQ]

(Transmission controller model selection: Disagreement of model selection signals) ...... 8
Failure code [DAQRKR] (CAN communication with transmission controller:
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) ....................... 11
Failure code [DB2RKR] (CAN communication with engine controller:
Defective communication (Abnormality in target component system) .............................. 12
Failure code [DB90KK] Work equipment controller: Low source voltage (input) ..................... 14
Failure code [DB90KT] Work equipment controller: Abnormality in controller ......................... 16
Failure code [DB92KK]
Work equipment controller load power supply line: Low source voltage (input) ............... 17
Failure code [DB95KX]
Work equipment controller power supply output: Out of input signal range...................... 19
Failure code [DB99KQ]
(Work equipment controller model selection: Disagreement in model selection signals) . 22
Failure code [DB9RKR] CAN communication with work equipment controller:
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) ................... 25
Failure code [DB9RMC]
(CAN communication with transmission controller: Defective operation) ......................... 26
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time ........ 30
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time ....... 32
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time ......... 34
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time ......... 36
Failure code [DD1ALD]
Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time .... 38
Failure code [DD1BLD]
Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time ... 40
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time ..... 42
Failure code [DD1FLD]
Load meter mode selector switch (A/B): Switch is kept pressed for long time ................. 44
Failure code [DD1GLD]
Load meter mode selector switch (+/–): Switch is kept pressed for long time .................. 46
Failure code [DD1HLD]
(Load meter display selector switch: Switch is kept pressed for long time) ...................... 48
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time) ............... 50
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time) 52
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree) ........ 54
Failure code [DDD1LD]
(Remote positioner bucket angle set switch: Switch is kept pressed for long time).......... 58
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) ............................... 4
Failure code [DDK3KA] (Right FNR switch: Disconnection).................................................... 6
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection).................................. 9
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree) .. 12
Failure code [DDK6KA] (FNR lever switch: Disconnection) .................................................... 14
Failure code [DDK6KB] (FNR lever switch: Short circuit) ........................................................ 18
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) ..................... 20
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time) 22
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) ................. 24
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) .......................... 26
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) ..... 28
Failure code [DF10KA] (Transmission shift lever switch: Disconnected)................................. 30
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) ................................... 34
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected) ...................... 36
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) ......................... 38
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)........... 40
10 WA450-6, WA480-6 (KA SPEC.)

Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected) ......................... 42
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) ........ 44
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) 46
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range) 4
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) . 6
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range) .... 8
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection).............................. 10
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit) ................................. 12
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)................. 14
Failure code [DK59KY]
(Lift arm EPC lever potentiometer (Main): Short circuit with power supply line) ............... 17
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) .. 20
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection).................. 23
Failure code [DK5AKY]
(Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line) ................ 26
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) ................. 29
Failure code [DK5BKY]
(Bucket EPC lever potentiometer (Main): Short circuit with power supply line) ................ 32
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) .. 35
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) .................. 38
Failure code [DK5CKY]
(Bucket EPC lever potentiometer (Sub): Short circuit with power supply line) ................. 41
Failure code [DK5DKA]
(3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection) ................. 44
Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main):
Short circuit with power supply line) ................................................................................. 47
Failure code [DK5DL8]
(3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree).. 49
Failure code [DK5EKA]
(3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection)................... 52
Failure code [DK5EKY]
(3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line) ....... 56
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) .. 3
Failure code [DK5FKY]
(Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line) .. 6
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)... 8
Failure code [DK5GKY]
(Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line).. 11
Failure code [DK5FL8]
(Joystick steering EPC lever potentiometer (Main): Analog signals disagree) ................. 13
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) .............................................. 16
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line).............. 18
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) ........................................... 20
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) ................. 22
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range). 24
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) ............................ 26
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) ............... 28
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) .............. 30
Failure code [DV00KB] (Alarm buzzer: Short circuit) .............................................................. 32
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) ................................... 34
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)....................................... 36
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)... 38
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) .................................. 40
WA450-6, WA480-6 (KA SPEC.) 11

Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...................................... 41
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) . 42
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) ........................................ 44
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)............................................ 45
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)........ 46
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) ................................... 3
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)....................................... 4
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line) .. 5
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) ............................................. 7
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)................................................. 8
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)............. 9
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection) ...................... 11
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit) .......................... 12
Failure code [DW7DKY]
(Hydraulic drive fan neutral solenoid: Short circuit with power supply line) ...................... 13
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) .................. 14
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) ...................... 16
Failure code [DWM1KY]
(Work equipment neutral lock solenoid: Short circuit with power supply line)................... 18
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) ................... 20
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) ....................... 22
Failure code [DWN6KY]
(Lift arm raise magnet detent solenoid: Short circuit with power supply line) ................... 24
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) .................... 26
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) ........................ 28
Failure code [DWN7KY]
(Lift arm float magnet detent solenoid: Short circuit with power supply line) .................... 30
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)......................... 32
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) ............................ 34
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) 36
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) ......................................... 38
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)............................................. 39
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)......... 40
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) .......................................... 42
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit).............................................. 44
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line).......... 46
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)....................................... 48
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) .......................................... 50
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) ...... 52
Troubleshooting by failure code (Display of code), Part 10......................................................... 4
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) ..................................... 4
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) ......................................... 6
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)..... 8
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) ...................................... 10
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit).......................................... 12
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...... 14
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)......................................... 16
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) ............................................ 18
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) ........ 20
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) ......................................... 22
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)............................................. 24
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)......... 26
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...................................... 28
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) ......................................... 30
12 WA450-6, WA480-6 (KA SPEC.)

Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line) ..... 32
Failure code [DXHJKA] (3-spool valve extend EPC solenoid: Disconnection) ........................ 34
Failure code [DXHJKB] (3-spool valve extend EPC solenoid: Short circuit) ........................... 36
Failure code [DXHJKY]
(3-spool valve extend EPC solenoid: Short circuit with power supply line)....................... 38
Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection) ........................ 40
Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit) ........................... 42
Failure code [DXHKKY]
(3-spool valve retract EPC solenoid: Short circuit with power supply line) ....................... 44
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection) ...................... 46
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit).......................... 48
Failure code [DXHLKY]
(Joystick steering right EPC solenoid: Short circuit with power supply line) ..................... 50
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) ....................... 52
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) ........................... 54
Failure code [DXHMKY]
(Joystick steering left EPC solenoid: Short circuit with power supply line) ....................... 56
Troubleshooting of electrical system (E-mode) SEN01688-00
Troubleshooting of electrical system (E-mode) ........................................................................... 3
Before carrying out troubleshooting for electrical system........................................................ 3
Information in troubleshooting table ........................................................................................ 6
E-1 Engine does not start ........................................................................................................ 8
E-2 Wiper does not operate..................................................................................................... 14
E-3 Windshield washer does not operate................................................................................ 18
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off ............. 21
E-5 Working lamp does not light up or go off........................................................................... 29
E-6 Turn signal lamp and hazard lamp do not light up or go off .............................................. 34
E-7 Brake lamp does not light or it keeps lighting up .............................................................. 40
E-8 Backup lamp does not light or it keeps lighting up ............................................................ 42
E-9 Backup buzzer does not sound or it keeps sounding ....................................................... 44
E-10 Horn does not sound or it keeps sounding ..................................................................... 46
E-11 Alarm buzzer does not sound or it keeps sounding ........................................................ 48
E-12 Air conditioner does not operate or stop ......................................................................... 50
E-13 The KOMTRAX system does not work properly ............................................................. 53
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01689-00
Troubleshooting of hydraulic and mechanical system (H-mode) ................................................ 3
Method of using troubleshooting chart .................................................................................... 3
Table of failure modes and causes .......................................................................................... 6
H-1 The machine does not start .............................................................................................. 10
H-2 Torque converter lockup is not switched off (engine stalls)
[Machine with lockup clutch (if equipped)] ........................................................................ 12
H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)] ... 13
H-4 The travel speed is slow, the thrusting force is weak,
the uphill traveling power is weak, and the gear is not shifted.......................................... 14
H-5 Shocks are large at the times of starting and shifting gear ............................................... 16
H-6 Time lag is large at the times of starting and shifting gear................................................ 18
H-7 The torque converter oil temperature is high .................................................................... 20
H-8 Steering does not turn....................................................................................................... 21
H-9 Steering does not turn [Machine with joystick steering (if equipped)] ............................... 22
H-10 Steering response is low................................................................................................. 23
H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)] ...... 24
H-12 Steering is heavy ............................................................................................................ 25
H-13 When machine turns, it shakes or makes large shocks.................................................. 26
H-14 When machine turns, it shakes or makes large shocks
[machine with joystick steering (if equipped)] ................................................................... 27
H-15 The wheel brake does not work or does not work well ................................................... 28
H-16 The wheel brake is not released or it drags.................................................................... 29
WA450-6, WA480-6 (KA SPEC.) 13

H-17 The parking brake does not work or does not work well................................................. 30
H-18 The parking brake is not released or it drags (including emergency release system) .... 31
H-19 Lift arm does not rise ...................................................................................................... 32
H-20 Lift arm speed is low or rising force of lift arm is insufficient ........................................... 33
H-21 When rising, the lift arm comes to move slowly at specific height .................................. 34
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats) .................................. 34
H-23 Hydraulic drifts of the lift arm is large .............................................................................. 34
H-24 The lift arm wobbles during operation............................................................................. 34
H-25 Bucket does not tilt back ................................................................................................. 35
H-26 Bucket speed is low or tilting back force is insufficient ................................................... 36
H-27 The bucket comes to operate slowly in the midst of tilting-back ..................................... 37
H-28 The bucket cylinder cannot hold down the bucket .......................................................... 37
H-29 Hydraulic drifts of the bucket is large .............................................................................. 37
H-30 The bucket wobbles during travel with cargo
(The work equipment valve is set to “HOLD”) ................................................................... 37
H-31 Lift arm and bucket control levers do not move smoothly and are heavy ....................... 38
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls ...... 39
H-33 Large shock is made when work equipment starts and stops......................................... 39
H-34 When work equipment circuit is relieved singly, other work equipment moves .............. 39
H-35 ECSS does not operate, and pitching, bouncing occur .................................................. 40
Troubleshooting of engine (S-mode) SEN01690-00
Troubleshooting of engine (S-mode) ........................................................................................... 3
Method of using troubleshooting chart..................................................................................... 3
S-1 Starting performance is poor. ............................................................................................ 6
S-2 Engine does not start ........................................................................................................ 8
S-3 Engine does not pick up smoothly .................................................................................... 12
S-4 Engine stops during operation .......................................................................................... 13
S-5 Engine does not rotate smoothly....................................................................................... 14
S-6 Engine lacks output (or lacks power) ................................................................................ 15
S-7 Exhaust smoke is black (Incomplete combustion) ............................................................ 16
S-8 Oil is consumed much (or exhaust gas color is blue)........................................................ 18
S-9 Engine oil becomes contaminated quickly ........................................................................ 19
S-10 Fuel consumption is excessive ....................................................................................... 20
S-11 Coolant contains oil (blows back or reduces) .................................................................. 21
S-12 Oil pressure drops........................................................................................................... 22
S-13 Oil level rises (Water, fuel in oil) ...................................................................................... 23
S-14 Coolant temperature rises too high (Overheating) .......................................................... 25
S-15 Abnormal noise is made.................................................................................................. 26
S-16 Vibration is excessive...................................................................................................... 27
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN00821-00
Hydraulic diagrams and drawings ............................................................................................... 2
Power train hydraulic circuit diagram....................................................................................... 2
Hydraulic circuit diagram ......................................................................................................... 5
Electrical diagrams and drawings SEN00822-00
Electrical diagrams and drawings................................................................................................ 3
Electrical circuit diagram (1/2) ................................................................................................. 3
Electrical circuit diagram (2/2) ................................................................................................. 5
14 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 15

SEN00818-01
WA450-6, WA480-6 (KA SPEC.) Wheel loader

Form No. SEN00818-01
16
SEN00819-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
00 Index and foreword 1

Foreword and general information
Foreword and general information .................................................................................................................. 2
Safety notice ........................................................................................................................................ 2
How to read the shop manual .............................................................................................................. 6
Explanation of terms for maintenance standard................................................................................... 8
Handling electric equipment and hydraulic component...................................................................... 10
How to read electric wire code ........................................................................................................... 18
Method of disassembling and connecting push-pull type coupler...................................................... 21
Standard tightening torque table ........................................................................................................ 24
Conversion table ................................................................................................................................ 28
WA450-6, WA480-6 (KA SPEC.) 1

Foreword and general information (Rev. 2005/11)
Safety notice 1
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before welding work, alw ays wear w elding
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to 1 Good arrangement
keep tools and removed parts. Always
2 Correct work clothes
keep the tools and parts in their correct
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water, 4 Making and checking signs
or oil on the floor. Smoke only in the areas Prohibition of operation and handling by
5
provided for smoking. Never smoke while unlicensed workers
working. 6 Safety check before starting work
3) When carrying out any operation, always Wearing protective goggles
wear safety shoes and helmet. Do not 7
(for cleaning or grinding work)
wear loose work clothes, or clothes with
Wearing shielding goggles and protectors
buttons missing. 8
(for welding work)
q Always wear safety glasses when hit-
ting parts with a hammer. 9 Good physical condition and preparation
q Always wear safety glasses when Precautions against work which you are
10
grinding parts with a grinder, etc. not used to or you are used to too much
4) When carrying out any operation with 2 or
more workers, always agree on the oper-
ating procedure before starting. Always 2. Preparations for work
inform your fellow workers before starting 1) Before adding oil or making any repairs,
any step of the operation. Before starting park the machine on hard and level
work, hang UNDER REPAIR signs in the ground, and apply the parking brake and
operator's compartment. block the wheels or tracks to prevent the
5) Only qualified workers must carry out work machine from moving.
and operation which require license or 2) Before starting work, lower the work
qualification. equipment (blade, ripper, bucket, etc.) to
6) Keep all tools in good condition, learn the the ground. If this is not possible, insert
correct way to use them, and use the the lock pin or use blocks to prevent the
proper ones of them. Before starting work, work equipment from falling. In addition,
thoroughly check the tools, machine, fork- be sure to lock all the control levers and
lift, service car, etc. hang warning signs on them.
2 WA450-6, WA480-6 (KA SPEC.)

3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When larly careful to check that they are
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
WA450-6, WA480-6 (KA SPEC.) 3

4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with one rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 WA450-6 WA480-6 (KA SPEC.)

q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
WA450-6, WA480-6 (KA SPEC.) 5

How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
6 WA450-6 WA480-6 (KA SPEC.)

3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
WA450-6, WA480-6 (KA SPEC.) 7

Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
8 WA450-6 WA480-6 (KA SPEC.)

2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the size of a hole is smaller than the be replaced or repaired.
size of a shaft because of the standard
size and tolerance, the difference between
these sizes is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
WA450-6, WA480-6 (KA SPEC.) 9

Handling electric equipment and hydraulic component 1

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

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

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
10 WA450-6 WA480-6 (KA SPEC.)

3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
splash water over the connector. The con-
nector is designed to prevent water from
entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the con-
nector, the pins will be short-circuited by
the water, so if any water gets in, immedi-
ately dry the connector or take other
appropriate action before passing electric-
ity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
WA450-6, WA480-6 (KA SPEC.) 11

3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
12 WA450-6 WA480-6 (KA SPEC.)

2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
3) Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.
1. Male connector
2. Female connector
q Normal locking state (Horizontal): a,
b, d
q Incomplete locking state (Diagonal): c
WA450-6, WA480-6 (KA SPEC.) 13

4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the com-
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
14 WA450-6 WA480-6 (KA SPEC.)

4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
WA450-6, WA480-6 (KA SPEC.) 15

Points to remember when handling hydraulic equipment

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

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

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

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
16 WA450-6 WA480-6 (KA SPEC.)

5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
WA450-6, WA480-6 (KA SPEC.) 17

How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-

General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
18 WA450-6 WA480-6 (KA SPEC.)

2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
WA450-6, WA480-6 (KA SPEC.) 19

3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
20 WA450-6 WA480-6 (KA SPEC.)

Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (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 receiving container.
2. 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 portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
WA450-6, WA480-6 (KA SPEC.) 21

Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
22 WA450-6 WA480-6 (KA SPEC.)

Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
WA450-6, WA480-6 (KA SPEC.) 23

Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
24 WA450-6 WA480-6 (KA SPEC.)

2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

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

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
WA450-6, WA480-6 (KA SPEC.) 25

5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolt BANJO bolt
mm Nm kgm Nm kgm
6 10 ± 2 1.02 ± 0.20 8± 2 0.81 ± 0.20
8 24 ± 4 2.45 ± 0.41 10 ± 2 1.02 ± 0.20
10 43 ± 6 4.38 ± 0.61 12 ± 2 1.22 ± 0.20
12 77 ± 12 7.85 ± 1.22 24 ± 4 2.45 ± 0.41
14 – – 36 ± 5 3.67 ± 0.51
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
26 WA450-6 WA480-6 (KA SPEC.)

8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
WA450-6, WA480-6 (KA SPEC.) 27

Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
28 WA450-6 WA480-6 (KA SPEC.)

Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
WA450-6, WA480-6 (KA SPEC.) 29

Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
30 WA450-6 WA480-6 (KA SPEC.)

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
WA450-6, WA480-6 (KA SPEC.) 31

Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
32 WA450-6 WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 33

SEN00819-00

34
SEN00820-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
01 Specification 1
Specification and technical data
Specification and technical data...................................................................................................................... 3
Specification dimension drawing .......................................................................................................... 3
Specifications ....................................................................................................................................... 4
Weight table ......................................................................................................................................... 8
Table of fuel, coolant and lubricants ................................................................................................... 10
WA450-6, WA480-6 (KA SPEC.) 1

SEN00820-00 01 Specification
2 WA450-6, WA480-6 (KA SPEC.)

Specification and technical data 1

Specification dimension drawing1
WA450-6 WA480-6
Check item Unit
(In P-mode) (In P-mode)
Machine weight (With BOC) kg 22,100 24,245
Normal load kN {kg} 65.9 {6,720} 76.7 {7,820}
Bucket capacity (Heaped, with BOC) m3 4.2 4.6
Engine model name — Komatsu SAA6D125E-5 Diesel engine
Engine rated output
• Net [ISO 9249/SAE J1349] (*1) kW {HP}/rpm 203 {272}/2,000 223 {299}/2,000
• Gross [SAE J1955] (*2) 204 {273}/2,000 224 {300}/2,000
A Overall length (with BOC) mm 8,825 9,170
B Overall height mm 3,500 3,500
C Overall height with bucket lifted up mm 5,960 6,175
D Overall width mm 3,010 3,010
E Minimum ground clearance mm 525 525
F Bucket width mm 3,170 3,170
G Dumping clearance Bucket tip/BOC tip mm 3,270/3,185 3,300/3,205
H Dumping reach Bucket tip/BOC tip mm 1,190/1,235 1,370/1,410
I Dumping angle deg. 45 45
Bucket tip/BOC tip mm 7,610/7,640 7,670/7,700
Min. turning radius
Center of outside tire mm 6,630 6,630
Tolerable drawbar pull load kN{kg} 135 {13,720} 137 {13,930}
1st (Forward/reverse) 6.3/6.7 6.3/6.6
2nd (Forward/reverse) 12.1/12.8 12.2/12.9
Travel speed km/h
3rd (Forward/reverse) 21.7/23.0 21.7/22.9
4th (Forward/reverse) 34.9/36.0 34.5/35.6
*1: Indicates the value at the minimum speed of cooling fan.
*2: Indicates the value of the engine alone (without cooling fan).
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of
an independent engine. While, net denotes the value measured of an engine under the condition essentially the
same as that when it is installed on machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
WA450-6: 191 kW {256 HP}/2,000 rpm
WA480-6: 211 kW {283 HP}/2,000 rpm
a BOC: Abbreviation for Bolt-On Cutting edge
WA450-6, WA480-6 (KA SPEC.) 3

Specifications 1
Machine model name WA450-6 WA480-6

Serial No. 66001 and up 85001 and up
Machine weight kg 22,100 24,245
Machine weight (Front wheel) in SAE
Weight
kg 9,945 10,910
travel posture
Machine weight (Rear wheel) in SAE
kg 12,155 13,335
travel posture
Bucket capacity (Heaped) m3 4.2 4.6
Normal load kN{kg} 65.9 {6,720} 76.7 {7,820}
E-mode P-mode E-mode P-mode
Travel speed (Forward 1st) 5.3 6.3 5.7 6.3
(Forward 2nd) 10.2 12.1 11.0 12.2
km/h
(Forward 3rd) 18.1 21.7 19.5 21.7
(Forward 4th) 27.3 34.9 30.8 34.5
Performance
(Reverse 1st) 5.6 6.7 6.0 6.6

(Reverse 2nd) 10.8 12.8 11.6 12.9
km/h
(Reverse 3rd) 19.2 23.0 20.6 22.9
(Reverse 4th) 28.2 36.0 31.8 35.6
Maximum drawbar pull (Forward) 172 {17,500} 192 {19,600} 175 {17,800} 195 {19,900}
kN{kg}
(Reverse) 162 {16,500} 181 {18,500} 165 {16,800} 183 {18,700}
Gradeability deg. 25 25
Min. turning radius
mm 6,630 6,630
(Center of outside tire)
Turning radius (Cutting edge/BOC tip)
mm 7,610/7,640 7,670/7,700
SAE travel posture
Overall length (With BOC) mm 8,825 9,170
Overall width mm 3,010 3,010
Bucket width (With BOC) mm 3,170 3,170
Overall height (Cab top) mm 3,500 3,500
Overall height with bucket lifted up mm 5,960 6,175
Wheelbase mm 3,450 3,450
Tread mm 2,300 2,300
Minimum ground clearance mm 525 525
Dimension
Max. hinge pin height mm 4,360 4,505

Dumping clearance
mm 3,270/3,185 3,300/3,205
(Teeth edge/BOC tip)
Dumping reach
mm 1,190/1,235 1,370/1,410
(Teeth edge/BOC tip)
Steering angle deg. 35 35
Bucket tilt-back angle
(Operating posture) deg. 50 52
(Max. height) 65 60
Bucket tilt-forward angle (Max. height) deg. 45 49
Digging depth, 10°
mm 265/315 305/355
(Cutting end/BOC tip)
4 WA450-6, WA480-6 (KA SPEC.)


Model name SAA6D125E-5
4-cycle, water-cooled, in-line 6-cylinder, direct injection type
Model
with turbocharger and air-cooled aftercooler
Cylinder bore × Cylinder stroke mm 125 × 150
Total piston displacement l{cc} 11.04 {11,040}
Rated output
Performance (In P-mode)
• Net [ISO 9249/SAE J1349] (*1) 203 {272}/2,000 223 {299}/2,000

kW{HP}/rpm
• Gross [SAE J1995] (*2) 204 {273}/2,000 224 {300}/2,000
Engine
Max. torque (*1) Nm{kgm}/rpm 1,307 {133}/1,450 1,360 {139}/1,400

g/kWh
Min. fuel consumption 192 {143} 192 {143}
{g/HPh}
Max. speed at no load rpm 2,170 ± 50 2,190 ± 50
Min. speed at no load rpm 800 (+50/0) 800 (+50/0)
Starting motor 24 V, 7.5 kW 24 V, 7.5 kW
Alternator 24 V, 50 A 24 V, 50 A
Battery (*3) 24 V, 140 Ah × 2 pcs 24 V, 140 Ah × 2 pcs
Torque converter 3-element, 1-stage, 1-phase
Counter-shaft, helical and spur gear constant-mesh type,
Transmission
Power train
multi-disc type, hydraulic type, modulating

Reduction gear unit Spiral bevel gear type, splash lubrication type
Differential system Straight bevel gear type
Planetary gear single reduction type and
Final drive
splash lubrication type
Drive wheel Front and rear wheel drive
Axle
Front axle Fixed frame, semi-float type

Rear axle Center pin supporting, semi-float type
Size 26.5R25A 26.5R25A
Rim size 22.00-25WTB 22.00-25WTB
Tires
Inflation pressure (Front wheel) kPa 451 {4.6} 451 {4.6}

(Rear wheel) {kg/cm2} 353 {3.6} 353 {3.6}
Braking method 4-wheel brake, independent front and rear wheel brakes
Type of brake Enclosed wet disc type
Main
Drive method Hydraulic drive

Brake
Operating method With hydraulic booster

Braking method Transmission output shaft brake
Parking
Type of brake Wet disc type

Drive method Driven with spring, hydraulically released type
Steering method Articulated chassis type
Steering
Drive method Hydraulic drive
*1: Indicates the value at the minimum speed of cooling fan.

*2: Indicates the value of the engine alone (without cooling fan).
*3: The battery capacity (Ah) indicates the 5-hour rate value.
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of
an independent engine. While, net denotes the value measured of an engine under the condition essentially the
same as that when it is installed on machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
WA450-6: 191 kW {256 HP}/2,000 rpm
WA480-6: 211 kW {283 HP}/2,000 rpm
WA450-6, WA480-6 (KA SPEC.) 5


Power train pump
• Type Gear type Gear type
• Delivery 3
cm /rev 125.1 125.1
Steering pump
Variable displacement, Variable displacement,
• Type
swash plate, piston type swash plate, piston type
• Delivery cm3/rev 90 90
Hydraulic pump
Work equipment hydraulic pump

• Type
Cooling fan pump
• Type
Emergency steering pump
• Type Gear type Gear type
• Delivery 3
cm /rev 21 21
Hydraulic system
Model Double-acting piston type Double-acting piston type

Cylinder bore mm 90 90
Steering cylinder
Piston rod outside diameter mm 50 50

Travel mm 441 441
Max. distance between cen-
mm 1,296 1,296
ters of pins
Min. distance between cen-
mm 855 855
ters of pins
Lift cylinder
Cylinder
Travel mm 764 881

mm 2,167 2,382
ters of pins
mm 1,403 1,501
ters of pins
Bucket cylinder

Travel mm 575 572
mm 1,795 1,855
ters of pins
mm 1,220 1,283
ters of pins
6 WA450-6, WA480-6 (KA SPEC.)


Work equipment control valve
• Type 2-spool type 2-spool type
Control valve
• Set pressure MPa {kg/cm }2

34.3 {350} 34.3 {350}
Hydraulic system
Steering valve
• Type Spool type Spool type
• Set pressure MPa {kg/cm2} 24.5 {250} 24.5 {250}
Cooling fan motor
Fixed displacement, swash Fixed displacement, swash
Motor
• Type
plate, piston type plate, piston type
• Motor capacity cm3/rev 28 28
Type of link Single link Single link
Work equipment
Straight cutting edge with Straight cutting edge with

Shape of bucket cutting edge
BOC BOC
WA450-6, WA480-6 (KA SPEC.) 7

Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Engine (excluding coolant and oil) 1,280 1,280
Cooling assembly (excluding coolant and oil) 147 147
• Radiator (1 piece) 20 20
• Aftercooler 26 26
• Oil cooler 14 14
Torque converter oil cooler 25 25
Cooling fan pump 25 25
Cooling fan motor 14 14
Transmission (including torque converter)
Without lockup clutch 949 949
With lockup clutch 988 988
Center drive shaft 32 32
Front drive shaft 40 40
Rear drive shaft 22 21
Front axle
With conventional differential 1,250 1,285
With limited slip differential 1,260 1,301
Rear axle
With conventional differential 1,142 1,266
With limited slip differential 1,154 1,282
Axle pivot (Rear axle) 144 144
Wheel [22.00-25WTB] (1 piece) 251 251
Tire [26.5R25 A] (1 piece) 435 435
Power train pump 20 20
Work equipment hydraulic pump 75 75
Steering pump 38 38
Work equipment control valve 108 108
Work equipment PPC valve 4 4
Brake valve 7 7
Steering valve 24 24
Emergency steering motor 13 13
Emergency steering pump 3 3
Steering cylinder assembly (1 piece) 37 37
Lift cylinder assembly (1 piece) 185 196
Bucket cylinder assembly 206 264
Front frame 1,840 1,960
Rear frame 1,745 1,745
Counterweight 2,050 3,135
Engine hood assembly 466 466
• Hood body 295 295
• • Side door (1 piece) 37 37
• Hydraulic tank (excluding hydraulic oil) 171 171
Fuel tank (excluding fuel) 211 211
8 WA450-6, WA480-6 (KA SPEC.)

Unit: kg
Lift arm (including bushing) 1,470 1,571
Bucket link 89 108
Bell crank 390 410
Bucket (3,170 mm wide, including BOC) 2,011 2,259
Operator's cab (including floor assembly) 945 945
Operator seat 35 35
Air conditioner unit 5 5
Battery (1 piece) 47 47
WA450-6, WA480-6 (KA SPEC.) 9

Table of fuel, coolant and lubricants 1

a For details of the notes (Note. 1, Note. 2 …) in the table, see the Operation and Maintenance Manual.
10 WA450-6, WA480-6 (KA SPEC.)

Unit: l
WA450-6 WA480-6
Supply point
Specified capacity Refill capacity Specified capacity Refill capacity
Engine oil pan 47 38 47 38
Transmission case 65 54 65 54
Hydraulic system 270 173 275 173
Axle (Front/Rear) 60/56 60/56 59/59 59/59
Fuel tank 413 — 413 —
Coolant system 61 — 61 —
WA450-6, WA480-6 (KA SPEC.) 11

SEN00820-00

12
SEN01159-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine and cooling system ............................................................................................................................. 2
Engine mount and transmission mount................................................................................................ 2
Cooling system..................................................................................................................................... 3
Cooling fan pump ................................................................................................................................. 4
Cooling fan motor............................................................................................................................... 12
WA450-6, WA480-6 (KA SPEC.) 1

SEN01159-00 10 Structure, function and maintenance standard
Engine and cooling system 1

Engine mount and transmission mount 1
Unit: mm
No. Check item Criteria Remedy
Clearance between transmis-
1 sion mount bracket and adjust- 1 – 1.5 Adjust
ment bolt
2 WA450-6, WA480-6 (KA SPEC.)

Cooling system 1
1. Radiator 6. Power train oil cooler

2. Aftercooler 7. Reservoir tank
3. Oil cooler 8. Cooling fan
4. Condenser 9. Cooling fan motor
5. Receiver
Specifications
Radiator Oil cooler Aftercooler Power train oil cooler
Model name of core AL WAVE-4 CF40-1 AL WAVE PTO-OL
*1
Fin pitch (mm) 3.5/2 3.5/2 4.0/2
100 × 558 × 20-stage
Total heat dissipation
55.14 × 2 6.15 × 2 23.32 2.152
surface (m2)
Pressure valve
70 ± 15
cracking pressure — — —
{0.7 ± 0.15}
(kPa {kg/cm2})
Vacuum valve
0–5
cracking pressure — — —
{0 – 0.05}
(kPa {kg/cm2})
*1: Size of element
WA450-6, WA480-6 (KA SPEC.) 3

Cooling fan pump 1

Type: LPV30
P1: Pump discharge port TO: Drain port

PE: Control piston pressure input port PEPC: EPC valve basic pressure input port
PH: Pump discharge pressure output port PAEPC: EPC output pressure pickup plug
PS: Pump suction port
1. Servo valve
2. Air bleeder
3. Command current input connector
4 WA450-6, WA480-6 (KA SPEC.)

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
WA450-6, WA480-6 (KA SPEC.) 5

Function
q The rotation and torque of the engine are
transmitted to the shaft of this pump. Then, this
pump converts the rotation and torque into
hydraulic energy and discharges hydraulic oil
according to the load.
q It is possible to change the delivery by chang-
ing the swash plate angle.
Structure
q Cylinder block (7) is supported to shaft (1) by
spline (a), and shaft (1) is supported by the
front and rear bearings.
q The tip of piston (6) is a concave ball, and shoe
(5) is caulked to it to form one unit. Piston (6)
and shoe (5) form a spherical bearing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface as it
slides in a circle. Rocker cam (4) also slides
around ball (11) using it as fulcrum.
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
q Cylinder block (7) carries out rotation relative
to valve plate (8) while sealing the pressurized
oil, and this surface ensures that the hydraulic
balance is maintained correctly.
q And oil in each cylinder chamber of cylinder
block (7) is available for suction or discharge
through valve plate (8).
6 WA450-6, WA480-6 (KA SPEC.)

Operation
1. Operation of pump q When center line (X) of rocker cam (4) is the
q Cylinder block (7) rotates together with shaft same as the axial direction of cylinder block (7)
(1) and shoe (5) slides on plane (A). At this [swash pl at e angle = 0] , the differen ce
time, rocker cam (4) slants around ball (11), between volumes (E) and (F) inside cylinder
changing the angle of inclination (a) of the cen- block (7) is 0, so pump does not suck and dis-
ter line (X) of rocker cam (4) in the axial direc- charge, and no pumping is carried out. [The
tion of cylinder block (7). Angle (a) is called the swash plate angle is not set to 0 actually, how-
swash plate angle. ever.]
q If angle (a) is made between center line (X) of q In short, swash plate angle (a) is in proportion
rocker cam (4) and the axis of cylinder block to the pump delivery.
(7), plane (A) works as a cam for shoe (5).
q Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between
volumes (E) and (F) in cylinder block (7). As a
result, each piston (6) sucks and discharges oil
by (F) – (E).
q In other words, cylinder block (7) rotates, and
the volume of chamber (E) becomes smaller,
so pressurized oil is discharged during this
process. At the same time, the volume of
chamber (F) becomes larger and the oil is
sucked in this process. [In the figure, chamber
(F) is at the end of the suction stroke and
chamber (E) is at the end of the discharge
stroke.]
WA450-6, WA480-6 (KA SPEC.) 7

2. Control of delivery
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is
increased, or delivery (Q) is increased. Swash
plate angle (a) is changed with servo piston
(10).
q Servo piston (10) reciprocates straight accord-
ing to the signal pressure of the servo valve.
This straight line motion is transmitted to
rocker cam (4). Then, rocker cam (4) sup-
ported on ball (11) sways around ball (11).
8 WA450-6, WA480-6 (KA SPEC.)

Servo valve
P: EPC valve basic pressure

T: Drain
PE: Control piston pressure
PH: Pump discharge pressure
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
WA450-6, WA480-6 (KA SPEC.) 9

Function q Then, the land of the servo piston pressure

q The servo valve controls the current input to passage is connected to the pump discharge
the EPC valve and pump delivery (Q) so that passage by the notch of spool (5) and the dis-
they will be related as shown in the diagram. charge pressure is led to the servo piston.
q When the rocker cam is pushed up by the
servo piston, a position feedback is applied
and lever (2) moves to compress spring (8).
q When spool (5) is pushed back, the pump dis-
charge circuit and the servo piston circuit are
cut off.
q Pressure in the servo piston chamber drops
and the rocker cam returns in the direction of a
maximum swash plate angle.
q These processes are repeated until the swash
plate is fixed to a position where the EPC out-
put pressure is balanced with spring (8) force.
q The greater the EPC output pressure, the
smaller the swash plate angle. Conversely, the
q The output pressure of the EPC valve flows in smaller the EPC output pressure, the greater
the piston chamber to push piston (6). the swash plate angle.
q Piston (6) pushes spool (5) until it is balanced
with the spring.
10 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 11

Cooling fan motor 1

Type: LMF28
P: From fan pump

T: From cooler to tank
TC: To tank
Specifications
Type: LMF28
Capacity: 28.0 cc/rev
Rated speed: 1,600 rpm
Rated flow rate: 44.8 l/min
Check valve cracking pressure: 44.1 kPa {0.45 kg/cm2}
12 WA450-6, WA480-6 (KA SPEC.)

1. Output shaft 7. End cover

2. Case 8. Center spring
3. Thrust plate 9. Check valve
4. Piston assembly 10. Pilot valve
5. Cylinder block 11. Spool for reversible valve
6. Valve plate 12. Safety valve
Unit: mm
Standard size Repair limit
Free length
Installed Installed Free Installed
× Outside
13 Spool return spring length load length load If damaged or
diameter
deformed,
58.8 N 47.1 N replace spring
44.84 × 12 33 —
{6 kg} {4.8 kg}
1.96 N 1.57 N
14 Check valve spring 13.0 × 6.5 9.5 —
{0.2 kg} {0.16 kg}
WA450-6, WA480-6 (KA SPEC.) 13

1. Hydraulic motor
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y – Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses piston (4) [2 or 3 pieces], and gener-
ates force (F1) [F1 = P × xD2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a°)
degrees to output shaft (1), the force is divided
into components (F2) and (F3).
q The radial component (F3) generates torque [T
= F3 × ri] against the (Y – Y) line connecting
the top dead center and bottom dead center.
q The result of this torque [T = s(F3 × ri)] rotates
cylinder block (5) through the piston.
q Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to trans-
mit the torque.
14 WA450-6, WA480-6 (KA SPEC.)

2. Suction valve
Function 2) When the pump is stopped

q If the fan pump stops, the pressurized oil does q If the engine is stopped and the input revolu-
not flow into the motor. Since the motor contin- tion of the fan pump lowers to 0 rpm, the pres-
ues revolution because of the force of inertia, surized oil from the pump is not supplied to
however, the pressure on the outlet side of the port (P) any more. As the pressurized oil is not
motor rises. supplied to (MA) side of the motor, the motor
q When the oil stops flowing in from inlet port (P), speed lowers gradually to stop.
suction valve (1) sucks in the oil on the outlet q If the motor shaft is revolved by the force of
side and supplies it to port (MA) where there is inertia while the oil flow in (P) is reducing, the
not sufficient oil to prevent cavitation. oil in port (T) on the outlet side is sent by suc-
tion valve (1) to (MA) side to prevent cavitation.
Operation
1) When pump is started

q If the pressurized oil from the pump is supplied
to port (P) and the pressure on (MA) side rises
and starting torque is generated in the motor,
the motor starts revolution. The pressurized oil
on the motor outlet (MB) side of the motor
returns through port (T) to the tank.
WA450-6, WA480-6 (KA SPEC.) 15

3. Operation of reversible valve
1) When the ON/OFF solenoid is de-energized. 2) When the ON/OFF solenoid is energized.
q If ON/OFF solenoid (1) is “de-energized”, the q If ON/OFF solenoid (1) is “energized”, ON/OFF
pressurized oil from the pump is blocked by selector valve (2) changes to let the pressur-
ON/OFF selector valve (2), and port (C) opens ized oil from the pump flow through port (C)
for the tank circuit. into spool chamber (D).
q Spool (3) is pushed to the right by spring (4). q The pressurized oil in chamber (D) pushes
q Motor port (MA) opens and pressurized oil valve spool (3) to the left against spring (4).
flows in to revolve the motor in forward (clock- q Motor port (MB) opens and pressurized oil
wise). flows in to revolve the motor in reverse (coun-
terclockwise).
16 WA450-6, WA480-6 (KA SPEC.)

4. Safety valve
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.
Operation
q 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 pres-
surized oil into port (T).
q By this operation, generation of abnormal pres-
sure in port (P) is prevented.
WA450-6, WA480-6 (KA SPEC.) 17

SEN01159-00

18
SEN01161-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)

Power train
Power train...................................................................................................................................................... 3
Power train ........................................................................................................................................... 3
Power train system diagram................................................................................................................. 4
Drive shaft ............................................................................................................................................ 6
Power train piping diagram .................................................................................................................. 7
Torque converter .................................................................................................................................. 8
Transmission ...................................................................................................................................... 16
Flow control valve .............................................................................................................................. 33
Transmission control valve................................................................................................................. 34
ECMV................................................................................................................................................. 36
Main relief valve and torque converter relief valve............................................................................. 42
Axle .................................................................................................................................................... 44
Differential .......................................................................................................................................... 48
WA450-6, WA480-6 (KA SPEC.) 1

Limited slip differential........................................................................................................................ 53

Final drive........................................................................................................................................... 60
2 WA450-6, WA480-6 (KA SPEC.)

Power train 1
Power train 1
1. Transmission 5. Rear drive shaft

2. Torque converter 6. Center drive shaft
3. Engine 7. Front drive shaft
4. Rear axle 8. Front axle
Outline
q The power from engine (3) is transmitted q The power from the transmission output shaft
through the flywheel of the engine to torque is transmitted through center drive shaft (6),
converter (2). The turbine of the torque con- front drive shaft (7), and rear drive shaft (5) to
verter is connected to the input shaft of trans- front axle (8) and rear axle (4), and then trans-
mission (1). mitted through the wheels to the tires.
q The transmission has 6 hydraulic clutches to
set itself to 4 forward gear speeds and 4
reverse gear speeds.
WA450-6, WA480-6 (KA SPEC.) 3

Power train system diagram 1
4 WA450-6, WA480-6 (KA SPEC.)

1. Front axle Outline

2. Differential q The power from engine (15) is transmitted
3. Wet-type multiple disc brake through the flywheel of the engine to torque
4. Final drive converter (16).
5. Front drive shaft The torque converter converts the transmitted
6. Center drive shaft torque according to the fluctuation of the load
7. Parking brake (wet-type multiple disc) by using oil as a medium and transmits the
8. Transmission (counter-shaft type) power to the input shaft of transmission (8).
9. Rear drive shaft The engine power is also transmitted through
10. Rear tire the pump drive gear of the torque converter to
11. Final drive steering pump (19), cooling fan pump (20),
12. Wet-type multiple disc brake power train pump (17) and work equipment
13. Differential hydraulic pump (18) to drive respective pumps.
14. Rear axle q The 6 hydraulic clutches of transmission (8)
15. Engine are operated with the directional valve and
16. Torque converter gear shift valve of the transmission valve to set
17. Power train pump the transmission to one of 4 gear speeds in the
18. Work equipment hydraulic pump forward or reverse travel direction.
19. Steering pump q Parking brake (7) is a wet-type multiple disc
20. Cooling fan pump brake, which is installed to the front side of the
21. Flange bearing output shaft and used to stop the machine. It is
22. Front tire operated by the solenoid valve which is actu-
ated with the parking brake switch.
q The power of transmission (8) is transmitted to
the front and rear axles.
On the front side, the power is transmitted
through center drive shaft (6), flange bearing
(21), and front drive shaft (5) to front axle (1).
On the rear side, the power is transmitted
through rear drive shaft (9) to rear axle (14).
q The power transmitted to front axle (1) and
rear axle (14) is reduced in speed by the pinion
of differentials (2) and (13), and then transmit-
ted through the differential mechanism to the
sun gear shafts.
q The power of the sun gears is further reduced
in speed by final drives (4) and (11) of the plan-
etar y mechanis m, and then tr ansmitted
through the axle shafts to the wheels.
WA450-6, WA480-6 (KA SPEC.) 5

Drive shaft 1
a Figure indicates WA480-6.
1. Front drive shaft Outline

2. Flange bearing q The power from the transmission output shaft
3. Center drive shaft is transmitted through center drive shaft (3),
4. Rear drive shaft front drive shaft (1), and rear drive shaft (4) to
the front axle and rear axle.
q When the machine is articulated or when it
receives traveling impacts or working impacts,
the distances between the transmission and
the front and rear axles change. The drive
shafts absorb fluctuations in the angle and
length with the universal joints and flange
bearing (2) so that the power will be transmit-
ted without damaging the parts even when the
machine is exposed to above impacts or
changes in the component positions.
6 WA450-6, WA480-6 (KA SPEC.)

Power train piping diagram 1
1. Cooling fan pump 7. Transmission ECMV

2. Steering pump 8. Work equipment hydraulic pump
3. Hydraulic tank 9. Oil filler pipe
4. Power train oil cooler 10. Oil filter
5. Power train pump 11. Transmission assembly
6. Last chance filter
WA450-6, WA480-6 (KA SPEC.) 7

Torque converter 1
Without lockup clutch
1. Pilot 7. Pump
2. Flywheel 8. PTO gear
3. Drive case 9. PTO drive gear (Number of teeth: 99)
4. Boss 10. Stator shaft
5. Turbine 11. Input shaft
6. Stator
Specifications
Type 3-element, 1-stage, 1-phase
Stall torque ratio 2.47
8 WA450-6, WA480-6 (KA SPEC.)

Unit: mm
Standard size Tolerance Repair limit
1 Outside diameter of pilot –0.010 Repair by hard
78 77.95
–0.040 chromium-plating or
Inside diameter of PTO gear seal +0.035 replace
110 110.5
ring contact surface +0.000
2 –0.00
Wear of stator shaft seal Width 3 2.7
–0.10
ring
Thickness 4.3 ±0.1 3.9 Replace
Backlash between PTO drive gear
3 0.17 – 0.45
and PTO gear
WA450-6, WA480-6 (KA SPEC.) 9

Power transmitting route Oil flow
q The power from engine is transmitted to drive q The oil flows through the main relief valve and
case (2) through flywheel (1). its pressure is reduced to below the set pres-
q The power being transmitted to drive case (2) sure by the torque converter relief valve, and
rotates pump (3) and PTO drive gear (4). then it flows through inlet port (A) and oil pas-
q The power transmitted to pump (3) rotates tur- sage of stator shaft (1) to pump (2).
bine (6) and boss (7) using oil as the medium, q The oil is given centrifugal force by pump (2)
and is then transmitted to transmission input and flows into turbine (3) to transmit its energy
shaft (8). to turbine (3).
q The power transmitted to PTO drive gear (4) is q The oil from turbine (3) is sent to stator (4) and
also used as power for driving the pump after flows into pump (2) again. However, part of the
being transmitted through PTO gear (5). oil passes between turbine (3) and stator (4)
and is sent from outlet port (B) to the oil cooler
to be cooled. It is then used to lubricate the
transmission.
10 WA450-6, WA480-6 (KA SPEC.)

With lockup clutch
1. Pilot 10. PTO drive gear (Number of teeth: 99)

2. Flywheel 11. Stator shaft
3. Lockup clutch housing 12. Guide
4. Boss 13. Input shaft
5. Turbine 14. Free wheel
6. Drive case 15. Race
7. Stator 16. Lockup clutch disc
8. Pump 17. Lockup clutch piston
9. PTO gear
Specifications
Type 3-element, 1-stage, 2-phase
Stall torque ratio 2.26
WA450-6, WA480-6 (KA SPEC.) 11

12 WA450-6, WA480-6 (KA SPEC.)

Unit: mm
1 Outside diameter of pilot –0.010
78 77.95
–0.040 Repair by hard
Inside diameter of pilot seal ring +0.025 chromium-plating or
2 35 35.5 replace
contact surface +0.000
Inside diameter of clutch piston seal +0.081
260 260.1
3 –0.01
Wear of clutch housing Width 5 4.5
–0.04 Replace
seal ring
Thickness 6 ±0.15 5.85
Inside diameter of clutch housing +0.089
4 340 340.1 Repair by hard
seal ring contact surface +0.000
chromium-plating or
Inside diameter of PTO drive gear +0.040 replace
120 120.5
seal ring contact surface +0.000
5 –0.00
Wear of stator shaft seal Width 3.95 3.56
–0.10 Replace
ring
Thickness 4.6 ±0.1 4.14
Repair by hard
Inside diameter of stator shaft seal +0.030
6 60 60.5 chromium-plating or
replace
Inside diameter of free wheel trans-
7 91.661 ±0.008 91.691
fer surface of race
Inside diameter of free wheel trans- +0.008
8 72.661 72.631
fer surface of stator shaft –0.005
Inside diameter of bushing sliding +0.015
9 72.775 72.855
part +0.000 Replace
–0.0
10 Thickness of bushing sliding part 5 4.5
–0.1
11 Thickness of clutch disc 5 ±0.1 4.5
Backlash between PTO drive gear
12 0.17 – 0.45
and PTO gear
WA450-6, WA480-6 (KA SPEC.) 13

Power transmitting route
When lockup clutch is “disengaged” When lockup clutch is “engaged”
q When lockup clutch (4) is “disengaged”, drive q When lockup clutch (4) is “engaged”, drive
case (3), boss (9) and turbine (8) are sepa- case (3), boss (9) and turbine (8) are con-
rated from each other. nected.
Above state enables the torque converter to Above state enables the torque converter to
carry out the normal functions. carry out the lockup function.
q The power from engine is transmitted to clutch q The power from engine is transmitted to clutch
housing (2) through flywheel (1). housing (2) through flywheel (1).
q The power being transmitted to clutch housing q The power being transmitted to clutch housing
(2) rotates drive case (3), pump (5) and PTO (2) rotates drive case (3), pump (5) and PTO
drive gear (6). drive gear (6).
q The power transmitted to pump (5) rotates tur- q Since lockup clutch (4) is fixed, the power
bine (8) and boss (9) using oil as the medium, transmitted to drive case (3) rotates boss (9)
and is then transmitted to transmission input directly and is then transmitted to transmission
shaft (10). input shaft (10).
q The power transmitted to PTO drive gear (6) is q The power transmitted to PTO drive gear (6) is
also used as power for driving the pump after also used as power for driving the pump after
being transmitted through PTO gear (7). being transmitted through PTO gear (7).
14 WA450-6, WA480-6 (KA SPEC.)

Oil flow
q The oil flow passes through the main relief

valve and its pressure is reduced to below the
set pressure by the torque converter relief
valve. The oil then flows through inlet port (A)
and the oil passage of stator shaft (1) and
guide (2) to pump (3).
q The oil is provided with centrifugal force from
pump (3) and then it enters turbine (4) to trans-
mit its energy to turbine (4).
q The oil from turbine (4) is sent to stator (5) and
then returned to pump (3) again. Part of this oil
flows between turbine (4) and stator (5) to out-
let port (B). It is then cooled in the oil cooler
and then used for lubrication of the transmis-
sion.
WA450-6, WA480-6 (KA SPEC.) 15

Transmission 1
a Transmission with lockup clutch
16 WA450-6, WA480-6 (KA SPEC.)

A: From power train pump Outline

B: From torque converter oil cooler q The transmission employed consists of the
C: Transmission lubricating oil pressure pickup counter-shaft constant gear mesh mechanism
port and disc clutch that provides “4 forward gear
D: Torque converter outlet port oil pressure pickup speeds and 4 reverse gear speeds.”
port q The transmission selects one rotation direction
E: To power train oil cooler and gear speed by fixing the counter-shaft
F: Parking brake oil pressure pickup port type, constant mesh gear mechanisms and 2
G: To power train pump out of 6 sets disc clutch with the oil pressure by
H: Clutch oil pressure pickup port ECMV operation.
J: Main relief oil pressure pickup port q The transmission transmits the power being
K: Torque converter relief pressure pickup port transmitted to the transmission input shaft to
the output shaft after selecting a single speed
1. Work equipment hydraulic pump and cooling from the 1st to 4th speeds both in the forward
fan pump mounting port and reverse travel. In this case, the gear speed
2. Steering and power train pump mounting port change is done by F and R clutches plus com-
3. Oil filler pipe mounting port binations of 4 speed clutches.
4. Front coupling
5. Torque converter Number of plates and discs used
6. Transmission case (rear) Clutch No. Number of plates Number of discs
7. Last chance filter R clutch 16 15
8. Main relief valve and torque converter relief
F clutch 16 15
valve
1st clutch 9 8
9. Parking brake indicator switch
10. Oil level gauge 4th clutch 8 7
11. Transmission speed sensor 2nd clutch 11 10
12. Transmission oil filter 3rd clutch 8 7
13. Transmission control valve
14. Breather
15. Drain plug Combinations of clutches at respective gear
16. Rear coupling speeds and reduction ratio
17. Transmission lubricating oil temperature sensor Gear speed Clutch used Reduction ratio
18. Transmission case (front)
Forward 1st speed F × 1st 4.623
19. Torque converter outlet port oil temperature
Forward 2nd F × 2nd 2.346
sensor
20. Flow control valve Forward 3rd F × 3rd 1.257
Forward 4th F × 4th 0.709
Neutral — —
Reverse 1st speed R × 1st 4.351
Reverse 2nd R × 2nd 2.208
Reverse 3rd R × 3rd 1.183
Reverse 4th R × 4th 0.667
WA450-6, WA480-6 (KA SPEC.) 17

1. PTO gear A (Number of teeth: 87) 10. Output gear (Number of teeth: 65)
2. PTO drive gear (Number of teeth: 99) 11. Parking brake
3. Torque converter 12. Front coupling
4. Input shaft 13. Lower shaft
5. F clutch 14. 2nd clutch
6. 4th clutch 15. Upper shaft
7. 3rd clutch 16. 1st clutch
8. Rear coupling 17. R clutch
9. Output shaft
18 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 19

20 WA450-6, WA480-6 (KA SPEC.)

Unit: mm
Standard Tolerance Standard Clearance

Clearance between PTO gear A size Shaft Hole clearance limit
bearing and rear case (front)
1 –0.000 +0.030
120 0 – 0.045 —
–0.015 +0.000
Clearance between PTO gear A +0.030 –0.000 –0.045 –
65 —
bearing and PTO gear A shaft (front) +0.011 –0.015 –0.011
Clearance between PTO gear A –0.000 +0.030
90 0 – 0.045 —
bearing and rear case (rear) –0.015 +0.000
2
Clearance between PTO gear A +0.020 –0.000 –0.032 –
50 —
bearing and PTO gear A shaft (rear) +0.009 –0.012 –0.009
Clearance between input shaft –0.000 +0.030
3 100 0 – 0.045 —
bearing and front case –0.015 +0.000
Clearance between input shaft –0.000 +0.030
4 130 0 – 0.048 —
bearing and rear case –0.018 +0.000
Clearance between upper shaft –0.000 +0.030
5 130 0 – 0.048 —
bearing and front case –0.018 +0.000
Clearance between upper shaft –0.000 +0.030
6 130 0 – 0.048 —
bearing and rear case –0.018 +0.000
Clearance between lower shaft –0.000 –0.000 –0.035 –
7 120 —
bearing and cage –0.018 –0.035 0.018
Clearance between lower shaft –0.000 –0.000 –0.035 –
8 120 —
bearing and rear case –0.018 –0.035 0.018
Clearance between output shaft –0.000 –0.018 –0.058 –
145 —
bearing and retainer –0.020 –0.058 0.002
9
Clearance between output shaft +0.045 –0.000 –0.065 –
95 —
bearing and spacer +0.023 –0.020 –0.023
Clearance between output shaft –0.000 –0.018 –0.058 –
140 — Replace
bearing and front case –0.020 –0.058 0.002
10
Clearance between output shaft +0.039 –0.000 –0.059 –
80 —
bearing and output shaft +0.020 –0.020 –0.020
Inside diameter of input shaft seal
60 60.1
11 +0.00
+0.076
Width of input shaft seal ring groove 3.2 3.5
+0.000
Inside diameter of upper shaft seal +0.05
50 50.1
12
Width of upper shaft seal ring +0.076
3.2 3.5
groove +0.000
Inside diameter of lower shaft seal +0.05
50 50.1
13
Width of lower shaft seal ring +0.076
3.2 3.5
groove +0.000
Outside diameter of front coupling –0.000
14 95 94.8
oil seal contact surface –0.087
Outside diameter of rear coupling –0.000
15 105 104.8
oil seal contact surface –0.087
Standard clearance Clearance limit
16 Clearance between cage and case 1.23 – 2.01
—
(Standard shim thickness: 1.45)
Clearance between retainer and 0.73 – 1.53
17 —
case (Standard shim thickness: 0.95)
Free rotational torque of output
18 0.49 – 0.98 Nm {0.05 – 0.10 kgm}
shaft
WA450-6, WA480-6 (KA SPEC.) 21

Unit: mm

Clearance between PTO gear B size Shaft Hole clearance limit
bearing and rear case (front)
1 –0.000 +0.030
120 0 – 0.045 —
–0.015 +0.000
Clearance between PTO gear B +0.030 –0.000 –0.045 –
65 —
bearing and PTO gear B shaft (front) +0.011 –0.015 –0.011
Clearance between PTO gear B –0.000 +0.030
90 0 – 0.045 —
bearing and rear case (rear) –0.015 +0.000
2 Replace
Clearance between PTO gear B +0.020 –0.000 –0.032 –
50 —
bearing and PTO gear B shaft (rear) +0.009 –0.012 –0.009
Clearance between R idler gear –0.000 –0.024 –0.059 –
90 —
bearing and front case –0.018 –0.059 0.006
3
Clearance between R idler gear +0.032 –0.000 –0.047 –
55 —
bearing and R idler gear +0.002 –0.015 –0.002
Clearance between holder and Standard clearance Clearance limit

4
case 0.03 – 0.73 —
5. PTO gear B (Number of teeth: 87)

6. R idler gear (Number of teeth: 28)
7. Stainer
22 WA450-6, WA480-6 (KA SPEC.)

F and R clutches
A: R clutch oil port C: Lubricating oil port

B: F clutch oil port
1. R clutch gear (Number of teeth: 30) 4. F clutch

2. R clutch 5. F clutch gear (Number of teeth: 40)
3. F and R cylinders 6. Input shaft
Unit: mm

Clearance between input shaft size Shaft Hole clearance limit
7
bearing and input shaft (front)
+0.034 –0.000 –0.049 –
55 —
+0.021 –0.015 –0.021
Clearance between input shaft +0.054 –0.000 –0.069 –
8 60 —
bearing and input shaft (rear) +0.044 –0.015 –0.044
9 Clutch plate Thickness 1.7 ±0.05 1.5
Strain — 0.1 0.15 Replace
Clutch disc Thickness 2.2 ±0.08 1.6
10
(R clutch) Strain — 0.1 0.25

11
(F clutch) Strain — 0.1 0.25
Load of wave spring 1,010 N ±101 N 859 N
12
[Testing height: 2.2 mm] {103 kg} {±10.3 kg} {87.6 kg}
13 Warp of spring plate 1.4 ±0.2 1.2
14 Thickness of thrust washer 3 ±0.1 2.7
WA450-6, WA480-6 (KA SPEC.) 23

F and R clutches
With lockup clutch
A: R clutch oil port C: Lubricating oil port

B: F clutch oil port D: Lockup clutch oil port
1. R clutch gear (Number of teeth: 30) 4. F clutch

2. R clutch 5. F clutch gear (Number of teeth: 40)
3. F and R cylinders 6. Input shaft
Unit: mm

Clearance between input shaft size Shaft Hole clearance limit
7
bearing and input shaft (front)
+0.034 –0.000 –0.049 –
55 —
+0.021 –0.015 –0.021
Clearance between input shaft +0.054 –0.000 –0.069 –
8 60 —
bearing and input shaft (rear) +0.044 –0.015 –0.044
Strain — 0.1 0.15 Replace
10
(R clutch) Strain — 0.1 0.25

11
(F clutch) Strain — 0.1 0.25
12
13 Warp of spring plate 1.4 ±0.2 1.2
14 Thickness of thrust washer 3 ±0.1 2.7
24 WA450-6, WA480-6 (KA SPEC.)

1st and 4th clutches
A: 4th clutch oil port C: Lubricating oil port

B: 1st clutch oil port
1. Upper shaft 5. 1st and 4th cylinders (Number of teeth: 51)

2. Upper gear (Number of teeth: 36) 6. 4th clutch
3. 1st clutch gear (Number of teeth: 23) 7. 4th clutch gear (Number of teeth: 64)
4. 1st clutch
Unit: mm

Clearance between upper shaft size Shaft Hole clearance limit
8
bearing and upper shaft (front) +0.054 –0.000 –0.069 –
60 —
+0.044 –0.015 –0.044
Clearance between upper shaft +0.054 –0.000 –0.069 –
9 60 —
bearing and upper shaft (rear) +0.044 –0.015 –0.044
Strain — 0.1 0.15
Replace
Thickness 2.2 ±0.08 1.6
11 Clutch disc
Strain — 0.1 0.25
12
Thickness of thrust washer
13 3 ±0.1 2.7
(1st clutch)
14 3 ±0.1 2.7
(1st and 4th clutches)
15 Snap ring Reuse after disassembly not allowed
WA450-6, WA480-6 (KA SPEC.) 25

2nd and 3rd clutches
A: 2nd clutch oil port C: Lubricating oil port

B: 3rd clutch oil port
1. Lower shaft 5. 2nd and 3rd cylinders (Number of teeth: 68)

2. Lower gear A (Number of teeth: 53) 6. 3rd clutch
3. 2nd clutch gear (Number of teeth: 54) 7. 3rd clutch gear (Number of teeth: 41)
4. 2nd clutch 8. Lower gear B (Number of teeth: 29)
Unit: mm

Clearance between lower shaft size Shaft Hole clearance limit
9
bearing and lower shaft (front)
+0.055 –0.000 –0.070 –
65 —
+0.045 –0.015 –0.045
Clearance between lower shaft +0.039 –0.000 –0.054 –
10 55 —
bearing and lower shaft (rear) +0.020 –0.015 –0.020
Thickness 1.7 ±0.05 1.5
11 Clutch plate
+0.1 Replace
Strain — 0.15
+0.0
Thickness 2.2 ±0.08 1.6
12 Clutch disc
Strain — 0.1 0.25
13
14 3 ±0.1 2.7
(2nd and 3rd clutches)
15 Snap ring Reuse after disassembly not allowed
26 WA450-6, WA480-6 (KA SPEC.)

Operation of the disc clutch
When clutch is “engaged” (fixed) When clutch is “disengaged” (released)
q The oil sent from the ECMV flows through the q When the oil sent from the ECMV is shut off,
oil passage of shaft (1), is pressure-fed to the pressure of the oil acting on the back face of
back side of piston (2), and pushes piston (2) piston (2) goes down.
to the right. q Piston (2) is pushed back to the left by repul-
q Piston (2) compresses plates (3) and discs (4) sive force of wave spring (7).
and the rotation of discs (4) is stopped by the q The friction force between plates (3) and discs
frictional force. (4) is eliminated and shaft (1) and clutch gear
q As the internal teeth of disc (4) are meshed (5) are released.
with clutch gear (5), shaft (1) and clutch gear q When the clutch is released, the oil in the back
(5) transfer the power as a unit. side of piston is drained by the centrifugal force
q The oil is drained from oil drain hole (6), but the through oil drain hole (6) to prevent the clutch
drain amount is less than the amount of oil from being partially applied.
supplied, so there is no influence on the actua-
tion of the clutch.
a Oil drain hole (6) is made of only with the 1st,
2nd, 3rd, and 4th clutches.
WA450-6, WA480-6 (KA SPEC.) 27

Power transmitting route

Forward 1st speed
q When the transmission is set in the forward 1st q Since 1st clutch (9) is engaged, the power
gear speed, F clutch (2) and 1st clutch (9) are transmitted to 1st and 4th cylinders (7) is fur-
engaged. The power from the torque converter ther transmitted through 1st clutch (9) and 1st
to transmission input shaft (1) is then transmit- gear (11) to 2nd and 3rd cylinders (13) and
ted to output shaft (23). lower shaft (20).
q F clutch (2) and 1st clutch (9) fix respective q The power transmitted to lower shaft (20) is
clutch discs with the oil pressure applied to the then transmitted to output shaft (23) through
clutch piston. lower gear A (21) and output gear (22).
q F clutch (2) is engaged at this point. Thus, the
power transmitted from the torque converter to
input shaft (1) is transmitted through F clutch
(2) and F gear (4) to the 1st and 4th cylinders
(7).
28 WA450-6, WA480-6 (KA SPEC.)

Forward 2nd speed
q When the transmission is set in the forward q 2nd clutch (17) is engaged at this point. Thus,
2nd gear speed, F clutch (2) and 2nd clutch the power transmitted to 2nd gear (15) is trans-
(17) are engaged. The power from the torque mitted through 2nd clutch (17) to 2nd and 3rd
converter to transmission input shaft (1) is then cylinders (13) and lower shaft (20).
transmitted to output shaft (23). q The power transmitted to lower shaft (20) is
q F clutch (2) and 2nd clutch (17) fix respective then transmitted to output shaft (23) through
clutch discs using the oil pressure applied to lower gear A (21) and output gear (22).
the clutch piston.
(7).
q The power transmitted to 1st and 4th cylinders
(7) is then transmitted to 2nd gear (15) through
upper shaft (8) and upper gear (14).
WA450-6, WA480-6 (KA SPEC.) 29

Forward 3rd speed
q When the transmission is set to the forward 3rd q 3rd clutch (18) is engaged at this point. Thus,
gear speed, F clutch (2) and 3rd clutch (18) are the power transmitted to 1st and 4th cylinders
engaged. The power from the torque converter (7) is further transmitted through 3rd gear (16)
to transmission input shaft (1) is then transmit- and 3rd clutch (18) to 2nd and 3rd cylinders
ted to output shaft (23). (13) and lower shaft (20).
q F clutch (2) and 3rd clutch (18) fix respective q The power transmitted to lower shaft (20) is
clutch discs using the oil pressure applied to then transmitted to output shaft (23) through
the clutch piston. lower gear A (21) and output gear (22).
(7).
30 WA450-6, WA480-6 (KA SPEC.)

Forward 4th speed
q When the transmission is set to the forward 4th q 4th clutch (10) is engaged at this point. Thus,
gear speed, F clutch (2) and 4th clutch (10) are the power transmitted to 1st and 4th cylinders
engaged. The power from the torque converter (7) is further transmitted through 4th clutch
to transmission input shaft (1) is then transmit- (10) and 4th gear (12) to lower gear B (19) and
q F clutch (2) and 4th clutch (10) fix respective q The power transmitted to lower shaft (20) is
(7).
WA450-6, WA480-6 (KA SPEC.) 31

Reverse 1st speed
q When the transmission is set to the reverse 1st q Since 1st clutch (9) is engaged, the power
gear speed, R clutch (3) and 1st clutch (9) are transmitted to 1st and 4th cylinders (7) is fur-
engaged. The power from the torque converter ther transmitted through 1st clutch (9) and 1st
to transmission input shaft (1) is then transmit- gear (11) to 2nd and 3rd cylinders (13) and
q R clutch (3) and 1st clutch (9) fix respective q The power transmitted to lower shaft (20) is
q R clutch (3) is engaged at this point. Thus, the
input shaft (1) is transmitted through R clutch
(3) and R gear (5) to R idler gear (6).
q The power being reversed on R idler gear (6)
is transmitted through upper gear (14) and
upper shaft (8) to 1st and 4th cylinders (7).
32 WA450-6, WA480-6 (KA SPEC.)

Flow control valve 1
A: To transmission valve circuit

B: From power train pump
C: To transmission lubricating circuit
Unit: mm

Clearance between flow control size Shaft Hole clearance limit
1
valve and body
–0.020 +0.013 0.020 –
25 0.063
–0.030 +0.000 0.043
Standard size Repair limit Replace
Installed
Free length Installed load Free length Installed load
2 Flow control valve spring length
79.5 N 75.5 N
63.8 47 61.9
{8.11 kg} {7.7 kg}
3. Valve body Operation

4. Flow control valve q As the oil flow from the power train pump to the
transmission valve circuit exceeds the set
level, flow control valve (4) moves to diverge
part of the oil from the pump to the transmis-
sion lubricating circuit.
WA450-6, WA480-6 (KA SPEC.) 33

Transmission control valve 1

34 WA450-6, WA480-6 (KA SPEC.)

A: F clutch oil pressure pickup port Operation table of ECMV

B: R clutch oil pressure pickup port ECMV
C: Lockup clutch oil pressure pickup port F R 1st 2nd 3rd 4th L/U
Gear speed
D: 4th clutch oil pressure pickup port
F1 Q Q
E: 1st clutch oil pressure pickup port
F: 3rd clutch oil pressure pickup port F2 Q Q
G: 2nd clutch oil pressure pickup port F3 Q Q Q
H: From parking brake emergency release valve F4 Q Q Q
J: To parking brake
R1 Q Q
K: Parking brake indicator switch mounting port
L: Parking brake oil pressure pickup port R2 Q Q
M: From charge pump R3 Q Q Q
R4 Q Q Q
1. F clutch ECMV
L/U: Indicates the lockup clutch ECMV (if equipped).
2. R clutch ECMV
3. Lockup clutch ECMV
4. 4th clutch ECMV q The oil from the pump flows through the flow
5. 1st clutch ECMV control valve and oil filter to the transmission
6. 3rd clutch ECMV front case. The oil is then diverged to the main
7. 2nd clutch ECMV relief circuit and clutch actuation circuit.
8. Parking brake solenoid valve q The pressure of the oil sent to the clutch actua-
9. Last chance filter tion circuit is regulated by the main relief valve,
10. Main relief valve and torque converter relief and then used to actuate the clutch and park-
valve ing brake through the last chance filter. The oil
relieved from the main relief valve is supplied
to the torque converter.
q 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.
q If the F, R, or 1st – 4th ECMV is selected, the
regulated oil pressure is supplied to the
selected clutch to set the transmission in the
desired gear speed.
q In the 3rd and 4th speed travel, the lockup
clutch ECMV (if equipped) operates at a speed
above that being specified from the transmis-
sion controller.
WA450-6, WA480-6 (KA SPEC.) 35

ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch *1: The pressure control valve spool used for F, R,

P: From pump 4th, 1st, 3rd and 2nd clutches is not identical
T: Drain with that for the lockup clutch.
DR: Drain
P1: Clutch oil pressure pickup port *2: The information printed on the nameplate for F,
R, 4th, 1st, 3rd and 2nd clutches is not identi-
1. Fill switch connector cal with that for the lockup clutch.
2. Proportional solenoid connector
3. Oil pressure detection valve Clutch used Printing on nameplate
4. Fill switch F, R, 4th, 1st, 3rd and 2nd L*******
5. Proportional solenoid Lockup E*******
6. Pressure control valve (*1)
7. Nameplate (*2)
36 WA450-6, WA480-6 (KA SPEC.)

ECMV for gear speed clutch ECMV and proportional solenoid

q For each ECMV, 1 proportional solenoid is
Outline of ECMV installed.
q The ECMV consists of 1 pressure control valve The proportional solenoid generates thrust
and 1 fill switch. shown below according to the command cur-
q Pressure control valve rent from the controller.
This valve receives the current sent from the The thrust generated by the proportional sole-
transmission controller with a proportional noid is applied to the pressure control valve
solenoid, and then converts it into oil pressure. spool to generate oil pressure as shown in the
q Fill switch figure below. Accordingly, the thrust is changed
This switch detects that the clutch is filled with by controlling the command current to operate
oil and has the following functions. the pressure control valve to control the flow
1. Outputs a signal (a fill signal) to the controller and pressure of the oil.
to notify that filling is completed when the
clutch is filled with oil. Current – propulsion force characteristics of
2. Keeps outputting signals (fill signals) to the proportional solenoid
controller to notify whether oil pressure is
applied or not while oil pressure is applied to
the clutch.
Propulsion force – Hydraulic pressure charac-

teristics of proportional solenoid
ECMV and fill switch

q For each ECMV, 1 fill switch is installed.
Range A: Before shifting gear (When draining) If the clutch is filled with oil, the fill switch is
Range B: During filling turned “ON” by the pressure of the clutch. The
Range C: Pressure regulation oil pressure is built up according to this signal.
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).
WA450-6, WA480-6 (KA SPEC.) 37

Operation of ECMV Before shifting gear (when draining) (Range A

q ECMV is controlled with the command current in chart)
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.
q Under the condition where any current is not

sent to the proportional solenoid (1), pressure
control valve (3) drains the oil from clutch port
(A) through drain port (T).
Also at this time, fill switch (5) is turned “OFF”
because oil pressure is not applied to pressure
Range A: Before shifting gear (When draining) detection valve (4).
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).
38 WA450-6, WA480-6 (KA SPEC.)

During filling (Range B in chart) Pressure adjustment (Range C in chart)
q If current is applied to proportional solenoid (1) q As current is conducted to proportional sole-

with no oil in the clutch, the oil pressure force noid (1), the solenoid generates thrust in pro-
balanced with the solenoid force is applied to portion to the current. The pressure is settled
chamber (B) and pushes pressure control as the sum of this thrust of the solenoid, thrust
valve (3) to the left. This opens pump port (P) generated by the oil pressure in clutch port and
and clutch port (A) to feed oil in the clutch. the repulsive force of pressure control valve
When the clutch is filled with oil, pressure spring (2) is balanced.
detection valve (4) actuates to turn “ON” fill
switch (5).
WA450-6, WA480-6 (KA SPEC.) 39

ECMV for lockup clutch
Outline Operation
q This valve is used to switch the clutch in order When traveling in torque converter range
to regulate the clutch oil pressure to the set
pressure.
Since the modulation waveform is used for the
pressure application characteristics to the
clutch, ECMV is capable of connecting the
lockup clutch smoothly, thereby reducing
shocks resulting from gear shift. Above also
prevents generation of peak torque in the
power train. These arrangements make the
machine comfortable to operator and enhance
durability of the power train.
When changing from torque converter travel to

direct travel
q When traveling in torque converter range, cur-

rent is not supplied to proportional solenoid (1).
Pressure control valve (3) drains the oil from
clutch port (A) through drain port (T), and
lockup clutch is “released”.
Also at this time, fill switch (5) is turned “OFF”
because oil pressure is not applied to pressure
detection valve (4).
40 WA450-6, WA480-6 (KA SPEC.)

When traveling in direct range

(Torque converter travel o direct travel)
During filling Pressure adjustment
q When traveling in direct (lockup) range, current q As current is conducted to proportional sole-
is supplied to proportional solenoid (1), the oil noid (1), the solenoid generates thrust in pro-
pressure force balanced with the solenoid portion to the current. The pressure is settled
force is applied to chamber (B) and pushes as the sum of this thrust of the solenoid, thrust
pressure control valve (3) to the left. As a generated by the oil pressure in clutch port and
result, pump port (P) and clutch port (A) are the repulsive force of pressure control valve
opened and oil starts filling the clutch. If the spring (2) is balanced.
clutch is filled with oil, oil pressure detection
valve (4) is operated, and fill switch (5) is
turned “ON”.
WA450-6, WA480-6 (KA SPEC.) 41

Main relief valve and torque converter relief valve 1
Unit: mm

Clearance between main relief size Shaft Hole clearance limit
1
valve and valve body
–0.035 +0.013 0.035 –
28 0.078
–0.045 +0.000 0.058
Clearance between torque con- –0.035 +0.013 0.035 –
2 22 0.078
verter relief valve and valve body –0.045 +0.000 0.058
Installed Replace
3 Main relief valve spring (outside) length
380 N 362 N
122 82.5 118.3
{38.8 kg} {36.9 kg}
314 N 298 N
4 Main relief valve spring (inside) 108 82.5 104.8
{32.0 kg} {30.4 kg}
153 N 145 N
5 Torque converter relief valve spring 50 42 48.5
{15.6 kg} {14.8 kg}
6. Body A: Drain (Torque converter relief)

7. Piston B: Drain
8. Torque converter relief valve C: From pump
9. Piston D: Drain
10. Main relief valve E: To torque converter
P1: Main relief oil pressure pickup port
P2: Torque converter relief pressure pickup port
42 WA450-6, WA480-6 (KA SPEC.)

Outline Operation of main relief valve
Torque converter relief valve

q The torque converter relief valve constantly
regulates the torque converter inlet circuit
pressure below the set pressure to protect the
torque converter from abnormally high pres-
sure.
Set pressure: 0.91 MPa {9.31 kg/cm2}
(Cracking pressure)
Main relief valve

q The main relief valve regulates the pressure in
the transmission and parking brake hydraulic
circuits to the set pressure. q The oil from the hydraulic pump flows to cham-
Set pressure: 2.87 MPa {29.3 kg/cm2} ber (F) through the filter, port (C) of the relief
(At rated engine speed) valve and orifice (a) of main relief valve (1).
Operation
Operation of torque converter relief valve
q As the oil pressure in the circuit goes beyond

the set pressure, the oil conducted to chamber
(F) pushes piston (2) and the resulting resist-
ing force pushes spool (1) leftward, opening
q The oil from the main relief valve is conducted
ports (C) and (E).
to the torque converter through port (E) and, at
Above operation conducts the oil from port (E)
the same time, also conducted to chamber (G)
to the torque converter.
through orifice (b) of torque converter relief
valve (3).
q As the oil pressure to the torque converter
goes beyond the set pressure, the oil con-
ducted to chamber (G) pushes piston (4) and
the resulting resisting force pushes torque con-
verter relief valve (3) rightward, opening ports
(E) and (A).
As the result, the oil in port (E) is drained
through port (A).
WA450-6, WA480-6 (KA SPEC.) 43

Axle 1
Front axle 1
WA450-6
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multi-disc brake
6. Coupling
7. Oil filler and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
11. Brake wear gauge
44 WA450-6, WA480-6 (KA SPEC.)

WA480-6
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
6. Coupling
8. Drain plug
9. Brake oil port
10. Air bleeder
WA450-6, WA480-6 (KA SPEC.) 45

Rear axle 1
WA450-6
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
6. Coupling
8. Drain plug
9. Brake oil port
10. Air bleeder
46 WA450-6, WA480-6 (KA SPEC.)

WA480-6
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
6. Coupling
8. Drain plug
9. Brake oil port
10. Air bleeder
WA450-6, WA480-6 (KA SPEC.) 47

Differential 1
Front differential 1
1. Pinion (Number of teeth: 12)

2. Shaft
3. Bevel gear (Number of teeth: 41)
4. Sun gear shaft
5. Bevel pinion (Number of teeth: 10)
6. Side gear (Number of teeth: 24)
48 WA450-6, WA480-6 (KA SPEC.)

Unit: mm
7 Thickness of pinion washer
3 ±0.08 2.8 Replace
8 Thickness of side gear washer 4 ±0.05 3.8
9 Starting torque of bevel gear 31.4 – 51.0 N {3.2 – 5.2 kg} (Outside of bevel gear) Adjust
Thickness of shim in side bearing
10 0.30 – 1.25
carrier (one side) Adjust
11 Backlash of bevel gear 0.30 – 0.41
End play of pinion
12 0 – 0.200 {1.5 – 1.7 kg (At cage blot hole)} Replace
{or force to rotate}
Thickness of shim in housing and
13 1.49 ± 0.38 Adjust
cage assembly
WA450-6, WA480-6 (KA SPEC.) 49

Rear differential 1

2. Shaft
4. Sun gear shaft
5. Bevel pinion (Number of teeth: 10)
50 WA450-6, WA480-6 (KA SPEC.)

WA450-6
Unit: mm
3 ±0.08 2.8 Replace
10 0.30 – 1.25
End play of pinion
13 1.26 ± 0.34 Adjust
cage assembly
WA480-6
Unit: mm
3 ±0.08 2.8 Replace
10 0.30 – 1.25
End play of pinion
13 1.49 ± 0.38 Adjust
cage assembly
WA450-6, WA480-6 (KA SPEC.) 51

Outline When machine is turning

q The power from the engine is transmitted to q While the machine is turning, the right and left
the front and rear axles through the torque wheels rotate at different speeds. Accordingly,
converter, transmission and drive shaft. pinion (4) and side gear (3) in the differential
q In each axle, the direction of the power is rotate and transmit the power of carrier (6) to
changed by 90° and the speed is reduced by sun gear shafts (2), depending on the differ-
bevel pinion (1) and bevel gear (5). Then, the ence in rotation speed between the right and
power is transmitted through pinion (4) to sun left wheels.
gear shafts (2).
q Speed of the power transmitted to the sun gear
is further reduced by the final drive of the plan-
etary gear type, and then transmitted to the
axle shafts and wheels.
While machine is traveling straight

q While the machine is traveling straight, the
right and left wheels rotate at the same speed.
Accordingly, pinion (4) in the differential
assembly do not rotate and the power of car-
rier (6) is transmitted through pinion (4) and
side gear (3) to right and left sun gear shafts
(2) evenly.
52 WA450-6, WA480-6 (KA SPEC.)

Limited slip differential 1

(If equipped)
a The figure shows the front axle.
1. Plate
2. Disc
4. Washer
7. Shaft
8. Pressure ring
9. Case
WA450-6, WA480-6 (KA SPEC.) 53

54 WA450-6, WA480-6 (KA SPEC.)

WA450-6 Front
WA480-6 Front
Unit: mm
1 Thicknesses of washers 4
±0.05 3.8
4.1
3.4
2 Thickness of plate ±0.03 3.3
3.5
+0.04
3 Thickness of disc 3.6 3.55
–0.03
Standard Standard size Standard Clearance

Clearance between spider and size Shaft Hole clearance limit
4
differential pinion –0.11 +0.05 0.110 –
35 —
–0.16 +0.05 0.210
Piston assembling section on
–0.125 +0.089 0.125 –
5 differential housing 346 —
–0.214 +0.081 0.303
(housing and piston)
Piston assembling section on bear-
–0.125 +0.089 0.125 –
6 ing carrier 326 —
–0.214 +0.081 0.303
(piston and carrier)
Replace
–0.081 –0.045 –0.085 –
Outer race 160 —
Clearance of differential –0.025 –0.085 –0.020
7
side bearing +0.059 –0.020 –0.079 –
Inner race 105 —
+0.037 –0.020 –0.037
+0.025 –0.025 –0.079 –
Outer race 180.975 —
Clearance of bearing on –0.015 –0.054 –0.025
8
pinion shaft gear side +0.065 +0.013– –0.065 –
Inner race 76.2 —
+0.046 0.015 –0.033
–0.015 –0.050 –0.075 –
Clearance of bearing on Outer race 160
–0.025 –0.075 –0.025
—
9 pinion shaft coupling
side +0.039 –0.015 –0.054 –
Inner race 75 —
+0.020 –0.015 –0.020
10 Backlash of case and plate 0 – 0.5
Clearance between disc and plate
11 0.2 – 0.6
(Total clearance on both sides)
12 Backlash of side gear and disc 0.13 – 0.32
End play of side gear in axial
13 0.2 – 0.4
direction (one side)
WA450-6, WA480-6 (KA SPEC.) 55

WA450-6 Rear
Unit: mm
±0.05 3.8
4.1
3 2.9
2 Thickness of plate ±0.02
3.1 3
+0.04
3 Thickness of disc 3 2.95
–0.03

4
differential pinion
–0.11 +0.05 0.110 –
35 —
–0.16 +0.05 0.210
Piston assembling section on differ- –0.125 +0.089 0.125 –
5 327 —
ential housing (housing and piston) –0.214 +0.081 0.303
Piston assembling section on bearing –0.110 +0.081 0.110 –
6 307 —
carrier (piston and carrier) –0.191 +0.081 0.272
–0.018 –0.045 –0.085 –
Outer race 160 — Replace
7
side bearing +0.059 –0.020 –0.079 –
Inner race 105 —
+0.037 –0.020 –0.037
+0.025 –0.025 –0.075 –
Clearance of bearing on +0.081 –0.050 –0.025
8
pinion shaft gear side +0.062 +0.013 –0.062 –
Inner race 76.2 —
+0.043 +0.081 –0.030
–0.015 –0.050 –0.075 –
–0.020 –0.075 –0.030
—
side +0.039 –0.015 –0.054 –
Inner race 70 —
+0.020 –0.015 –0.020
11 0.2 – 0.6
13 0.15 – 0.35
56 WA450-6, WA480-6 (KA SPEC.)

WA480-6 Rear
Unit: mm
±0.05 3.8
4.1
3 2.9
2 Thickness of plate ±0.02
3.1 3
+0.04
3 Thickness of disc 3 2.95
–0.03

4
differential pinion
–0.11 +0.05 0.110 –
35 —
–0.16 +0.05 0.210
Piston assembling section on differ- –0.125 +0.089 0.125 –
5 346 —
ential housing (housing and piston) –0.214 +0.081 0.303
Piston assembling section on bearing –0.125 +0.089 0.125 –
6 326 —
carrier (piston and carrier) –0.214 +0.081 0.303
–0.018 –0.045 –0.085 –
Outer race 160 — Replace
7
side bearing +0.059 –0.020 –0.079 –
Inner race 105 —
+0.037 –0.020 –0.037
+0.025 –0.025 –0.079 –
Clearance of bearing on +0.081 –0.054 –0.025
8
pinion shaft gear side +0.065 +0.013 –0.065 –
Inner race 76.2 —
+0.046 +0.081 –0.033
–0.015 –0.050 –0.075 –
–0.025 –0.075 –0.025
—
side +0.039 –0.015 –0.054 –
Inner race 75 —
+0.020 –0.015 –0.020
11 0.2 – 0.4
13 0.2 – 0.4
WA450-6, WA480-6 (KA SPEC.) 57

Operation of limited slip differential While machine is traveling straight

The power from the transmission is transmitted 1. When drive forces of right and left wheels
through bevel gear (6), case (9), pressure rings (8), are balanced
shaft (7), and pinion (3) to side gears (5), and then [When the road conditions (coefficients of friction)
distributed to the right and left shafts. under both wheels and the wheel loads are even
The brake unit consisting of disc (2) and plate (1) is and the center of load is at the center of the bucket]
installed to the back side of each side gear (5). It The power from the transmission is distributed
generates braking torque in proportion to the torque evenly by the differential gears to the right and left.
transmitted from pressure rings (8) to shaft (7). Under this condition, the slip limits of the right and
Since the brake torque restricts the rotation of side left wheels are the same. Accordingly, even if the
gears (5) and case (9), right and left side gears (5) power from the transmission may exceed the slip
cannot rotate freely, thus the operation of the differ- limits, both wheels slip and the differential does not
ential is restricted. work.
No load is applied to the brake on the back side of
Mechanism of generation of braking torque by each side gear.
right and left side gears (5)
Shaft (7) is supported on the cam surfaces being
provided on the surfaces of pressure rings (8) that
are facing each other.
The power (= torque) transmitted from pressure
rings (8) to shaft (7) is transmitted on the cam sur-
faces. Force (Fa) to separate pressure rings (8)
from each other is generated by inclination of the
cam surfaces in proportion to the transmitted
torque.
Separating load (Fa) acts on the brake on the back
side of each side gear (5) to generate braking
torque.
58 WA450-6, WA480-6 (KA SPEC.)

2. When drive forces of right and left wheels

are unbalanced
[When the road conditions (coefficients of friction) Difference in wheel drive force by type of differen-
under both wheels and the wheel loads are uneven tials when either wheel slipped
and either wheel slips more easily]
Wheel drive force
Example 1: When either wheel is on soft ground (Drive force of slipping wheel is 1)
in digging work
Slipping Locked Total
Example 2: When either wheel is on snow and wheel wheel (Ratio)
the other one is on asphalt in snow
Limited slip differential 1 2.64 3.64 (1.82)
removing work
Normal differential 1 1 2 (1)
Example 3: When the right and left wheel loads
are unbalanced in travel on a slope
On a road where either wheel slips easily, the drive
The power from the transmission is evenly divided
force of the limited slip differential increases to 1.82
between the right and left by the differential gear. If,
times of the normal differential.
however, the divided drive force exceeds the wheel
slip limit of the slip side, surplus of the driving force
When machine is turning
is transmitted to the opposite side (lock side) brake
The same differential gears as that for the normal
through the brake and case on the gear back side.
differential are employed for the limited slip differ-
Then the power is distributed to the lock side
ential. Thus, they allow to smoothly generate a dif-
wheel.
ference in rotation speed between the outer and
The differential starts working only as this surplus
inner tires that is necessary for tuning.
portion of the drive force has exceeded the braking
force.
WA450-6, WA480-6 (KA SPEC.) 59

Final drive 1
WA450-6
1. Planetary gear (Number of teeth: 26)

2. Planetary carrier
3. Axle shaft
4. Ring gear (Number of teeth: 69)
5. Sun gear shaft (Number of teeth: 15)
60 WA450-6, WA480-6 (KA SPEC.)

WA450-6 Front
Unit: mm

Clearance between planetary gear size Shaft Hole clearance limit
6
bearing and shaft +0.013 –0.012 –0.025 –
45 — Replace
+0.002 –0.012 –0.002
Clearance between axle housing +0.1 +0.1
7 403.4 –0.1 – 0.1 —
and ring gear +0.0 +0.0
Clearance between oil seal and
8 Max. 0.2 Adjust
housing
+0.500 +0.072 –0.050 –
Housing 210 —
Press fitting part of axle +0.300 +0.072 –0.028
9
shaft seal –0.063 –0.300 –0.500 –
Shaft 160 —
–0.063 –0.500 –0.237
+0.025 –0.014 –0.085 –
Clearance of press fit- Outer race 196.85 —
+0.025 –0.060 –0.014
10 ting part of axle housing Replace
bearing +0.068 +0.025 –0.068 –
Inner race 133.35 —
+0.043 +0.025 –0.018
+0.025 –0.014 –0.085 –
+0.025 –0.060 –0.014
11 ting part of axle housing
bearing +0.058 +0.025 –0.058 –
+0.036 +0.025 –0.011
12 End play of axle shaft 0 – 0.1 Adjust
+0.025 +0.207 0.120 –
13 Clearance of guide pin 12 — Replace
+0.007 +0.145 0.200
WA450-6, WA480-6 (KA SPEC.) 61

WA480-6
1. Planetary gear (Number of teeth: 26)

2. Planetary carrier
3. Axle shaft
4. Ring gear (Number of teeth: 69)
5. Sun gear shaft (Number of teeth: 15)
62 WA450-6, WA480-6 (KA SPEC.)

WA480-6 Front
Unit: mm

6
45 — Replace
+0.002 –0.012 –0.002
7 404 –0.1 – 0.1 —
8 Max. 0.2 Adjust
housing
+0.500 +0.072 –0.050 –
Housing 240 —
9
shaft seal –0.063 –0.300 –0.500 –
Shaft 180 —
–0.063 –0.500 –0.237
+0.025 –0.014 –0.085 –
+0.025 –0.060 –0.014
bearing +0.068 +0.025 –0.068 –
+0.043 +0.025 –0.018
+0.025 –0.014 –0.085 –
+0.025 –0.060 –0.014
bearing +0.058 +0.025 –0.058 –
+0.036 +0.025 –0.011
+0.025 +0.207 0.120 –
+0.007 +0.145 0.200
WA450-6, WA480-6 (KA SPEC.) 63

WA450-6 Rear
Unit: mm

6
40 — Replace
+0.002 –0.012 –0.002
7 382 –0.1 – 0.1 —
8 Max. 0.2 Adjust
housing
+0.500 +0.072 –0.050 –
Housing 200 —
9
shaft seal –0.063 –0.300 –0.500 –
Shaft 160 —
–0.063 –0.500 –0.237
+0.025 –0.014 –0.085 –
+0.025 –0.060 –0.014
bearing +0.068 +0.025 –0.068 –
+0.043 +0.025 –0.018
–0.063 –0.045 –0.085 –
Clearance of press fit- Outer race 160 —
–0.025 –0.085 –0.020
bearing +0.035 –0.063 –0.055 –
Inner race 105 —
+0.013 –0.020 –0.013
+0.025 +0.207 0.120 –
+0.007 +0.145 0.200
64 WA450-6, WA480-6 (KA SPEC.)

WA480-6 Rear
Unit: mm

6
45 — Replace
+0.002 –0.012 –0.002
7 403.4 –0.1 – 0.1 —
8 Max. 0.2 Adjust
housing
+0.500 +0.072 –0.050 –
Housing 240 —
9
shaft seal –0.063 –0.300 –0.500 –
Shaft 180 —
–0.063 –0.500 –0.237
+0.025 –0.014 –0.085 –
+0.025 –0.060 –0.014
bearing +0.068 +0.025 –0.068 –
+0.043 +0.025 –0.018
+0.025 –0.014 –0.085 –
+0.025 –0.060 –0.014
bearing +0.058 +0.025 –0.058 –
+0.036 +0.025 –0.011
+0.025 +0.207 0.120 –
+0.007 +0.145 0.200
WA450-6, WA480-6 (KA SPEC.) 65

Outline
q The final drive finally reduces speed of the
power from the engine to increase the drive
force.
q Ring gear (4) is press fitted to the axle housing
and fixed with the pin.
q Speed of the power transmitted being from the
differential through sun gear shaft (5) is
reduced by the planetary gear unit to increase
the drive force.
The increased drive force is transmitted
through planetary carrier (2) and axle shaft (3)
to the tire.
66 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 67

SEN01161-00

68
SEN01163-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)

Steering system
Steering system .............................................................................................................................................. 2
Steering piping diagram ....................................................................................................................... 2
Steering column ................................................................................................................................... 3
Steering pump ...................................................................................................................................... 4
Steering valve..................................................................................................................................... 17
Orbit-roll valve .................................................................................................................................... 32
Stop valve........................................................................................................................................... 36
Steering relief valve............................................................................................................................ 37
Steering cylinder................................................................................................................................. 38
Emergency steering motor ................................................................................................................. 40
Emergency steering pump ................................................................................................................. 41
WA450-6, WA480-6 (KA SPEC.) 1

Steering system 1
Steering piping diagram 1
1. Steering cylinder (right) 8. Emergency steering motor (if equipped)

2. Steering valve 9. Steering relief valve (if equipped)
3. Orbit-roll valve 10. Stop valve (left)
4. Stop valve (right) 11. Accumulator (for PPC circuit)
5. Power train pump 12. Emergency steering pump (if equipped)
6. Steering pump 13. Steering cylinder (left)
7. Hydraulic tank
2 WA450-6, WA480-6 (KA SPEC.)

Steering column 1
1. Steering wheel
2. Steering column
3. Tilt lever
4. Short column
5. Orbit-roll valve
Unit: mm

Clearance between steering shaft size Shaft Hole clearance limit
6 Replace
and column bushing 0 +0.15 0.05 –
19 0.4
–0.08 +0.05 0.23
WA450-6, WA480-6 (KA SPEC.) 3

Steering pump 1
Model: LPV90
P1 : Pump discharge port PD2 : Drain plug

PD : Drain port PEN : Control pressure pickup plug
PS : Pump suction port PLS : Load pressure input port
P1C : Pump pressure pickup plug POP : External pilot pressure input port
P1L : Pump pressure input port
1. Pump unit 2. Servo valve 3. Air bleeder
4 WA450-6, WA480-6 (KA SPEC.)

Pump unit
PA : Control basic pressure outlet port

PE : Control pressure input port
PD4 : Drain port
PD5 : Drain port
WA450-6, WA480-6 (KA SPEC.) 5

1. Bearing
2. Shaft
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Shoe retainer
11. Servo piston
12. Spring
13. Oil seal
14. Ball
6 WA450-6, WA480-6 (KA SPEC.)

Function q The oil in each cylinder of cylinder block (6)

q The rotation and torque of the engine are can be sucked and discharged through valve
transmitted to the shaft of this pump. Then, this plate (7).
pump converts the rotation and torque into
hydraulic pressure and discharges hydraulic oil
according to the load.
q The discharge of this pump can be changed by
changing the swash plate angle in it.
Structure
q Cylinder block (6) is supported on shaft (1)
through spline (a). Shaft (1) is supported on
the front and rear bearings.
q The end of piston (5) has a spherical hollow
and is combined with shoe (4). Piston (5) and
shoe (4) form a spherical bearing.
q Rocker cam (3) is supported on case (2) and
ball (9) and has plane (A). Shoe (4) is kept
pressed against the plane of rocker cam (3)
and slid circularly. Shoe (4) leads high-pres-
sure oil to form a static pressure bearing and
slides.
q Piston (5) in each cylinder of cylinder block (6)
moves relatively in the axial direction.
q Cylinder block (6) rotates relatively against
valve plate (7), sealing the hydraulic oil. The
hydraulic balance on the valve plate is main-
tained properly.
WA450-6, WA480-6 (KA SPEC.) 7

Operation
1) Operation of pump q If center line (X) of rocker cam (3) is equal to

q Cylinder block (6) rotates together with shaft the axial direction of cylinder block (6) (the
(1). Shoe (4) slides on plane (A). At this time, swash plate angle is 0), there is not a differ-
rocker cam (3) slants around ball (9). As a ence between volumes (E) and (F) in cylinder
result, angle (a) between center line (X) of block (6) and the oil is not sucked or dis-
rocker cam (3) and the axis of cylinder block charged. (The swash plate angle is not set to 0
(6) changes. Angle (a) is called the swash actually, however.)
plate angle. q In short, swash plate angle (a) is in proportion
to the pump discharge.
q If angle (a) is made between center line (X) of

rocker cam (3) and the axis of cylinder block
(6), plane (A) works as a cam for shoe (4).
q Accordingly, piston (5) slides inside cylinder
block (6) and a difference is made between
volumes (E) and (F) in cylinder block (6). As a
result, each piston sucks and discharges oil by
(F) – (E).
q In other words, if cylinder block (6) rotates and
the volume of chamber (E) is decreased, the
oil is discharged from chamber (E). On the
other hand, the volume of chamber (F) is
increased and the oil is sucked in chamber (F).
(In the figure, chamber (F) is at the end of the
suction stroke and chamber (E) is at the end of
the discharge stroke.)
8 WA450-6, WA480-6 (KA SPEC.)

2) Control of discharge
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is
increased, or discharge (Q) is increased.
Swash plate angle (a) is changed with servo
piston (11).
q Servo piston (11) reciprocates straight accord-
ing to the signal pressure of the PC valve and
LS valve. This straight motion is transmitted to
rocker cam (3). Then, rocker cam (3) sup-
ported on case (2) through ball (9) rocks in
rotational directions.
WA450-6, WA480-6 (KA SPEC.) 9

Servo valve
P1 : Pump discharge port

PE: Control pressure output port
T : Drain port
10 WA450-6, WA480-6 (KA SPEC.)

PC valve LS valve
T : Drain PA : Pump pressure input
PA : Pump pressure input PE : Control piston pressure
PPL : PC valve output pressure PLS : LS pressure input
PPL : PC valve output pressure
PPLS: LS pump pressure input
1. Lever 10. Nut

2. Spring 11. Plate
3. Retainer 12. Plug
4. Seat 13. Spring
5. Spool 14. Seat
6. Sleeve 15. Plug
7. Piston 16. Spool
8. Seal 17. Plug
9. Piston
WA450-6, WA480-6 (KA SPEC.) 11

LS valve PC valve
Model: LPV63
Function
q The LS valve controls the pump discharge Function
according to the stroke of the control lever, or q The PC valve limits the oil flow to a certain
the demand flow for the actuator. level (according to the discharge pressure)
q The LS valve detects the demand flow for the even if the stroke of the control valve is
actuator from differential pressure ( PLS) increased extremely so that the horsepower
between control valve inlet pressure (PPLS) absorbed by the pump will not exceed the
and control valve outlet pressure (PLS) and engine horsepower, as long as pump dis-
controls main pump discharge (Q). ((PPLS) is charge pressure (PA) is high.
called the LS pump pressure, (PLS) the LS q In other words, the PC valve decreases the
pressure, and ( PLS) the LS differential pres- pump discharge when the load is increased
sure.) and the pump discharge pressure rises, and
q In other words, the pressure loss caused by increases it when the pump discharge pres-
flow of oil through the opening of the control sure lowers.
valve spool (= LS differential pressure PLS) q The relationship between the pump pressure
is detected, and then pump discharge (Q) is and pump discharge is shown below.
controlled to keep that pressure loss constant
and supply the pump discharge according to
the demand flow for the actuator.
q Main pump discharge pressure (PP), LS pump
pressure (PPLS), and LS pressure (PLS) are
led to the LS valve. The relationship between
LS differential pressure ( PLS) and pump dis-
charge (Q) changes as shown below.
Operation
1) Function of spring
q The spring load of spring (2) at the PC valve is
decided by the position of the swash plate.
q If servo piston (6) moves to the right, spring (2)
is compressed through lever (1) and its spring
load changes.
2) When pump pressure (PA) is low

q The pressing force of spool (5) is decreased
and spool (3) is a little to the right (Fig. 1). At
this time, ports (C) and (D) are connected to
each other and the pressure in the LS valve is
drain pressure (PT).
q At this time, ports (F) and (G) of the LS valve
are connected to each other. As a result, the
pressure in port (J) becomes drain pressure
(PT) and servo piston (6) moves to the left.
q Consequently, the pump discharge is
increased.
q As servo piston (6) moves, lever (1) moves to
the left and spring (2) expands and its spring
load is decreased. Consequently, spool (3)
moves to the left to disconnect ports (C) and
(D), and then pump discharge ports (B) and
(C) are connected.
12 WA450-6, WA480-6 (KA SPEC.)

q As a result, the pressure in port (C) rises and

the piston pressure is increased and servo pis-
ton (6) stops moving to the left.
3) When pump pressure (PA) is high

q The pressure of spool (5) is increased and
spool (3) is a little to the left (Fig. 2). At this
time, ports (C) and (B) are connected to each
other and the pressure in the LS valve is pump
pressure (PA).
q At this time, ports (F) and (G) of the LS valve
are connected to each other. As a result, the
pressure in port (J) becomes pump pressure
(PA) and servo piston (6) moves to the right.
q Consequently, the pump discharge is
decreased.
q As servo piston (6) moves, lever (1) moves to
the right and spring (2) is compressed and its
spring load is increased. Consequently, spool
(3) moves to the right to disconnect ports (C)
and (B), and then drain pressure ports (D) and
(C) are connected.
q As a result, the pressure in port (C) lowers and
the piston pressure is decreased and servo
piston (6) stops moving to the right.
q Accordingly, the stopping position (= pump dis-
charge) of servo piston (6) is decided by the
position where the pressure caused by pres-
sure (PA) applied to spool (5) is balanced with
the force of spring (2) applied through spool (3)
(Fig. 3).
WA450-6, WA480-6 (KA SPEC.) 13

When load is light

(Fig. 1)
When load is heavy

(Fig. 2)
14 WA450-6, WA480-6 (KA SPEC.)

When balanced
(Fig. 3)
WA450-6, WA480-6 (KA SPEC.) 15

16 WA450-6, WA480-6 (KA SPEC.)

Steering valve 1
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
WA450-6, WA480-6 (KA SPEC.) 17

18 WA450-6, WA480-6 (KA SPEC.)

1. Relief valve
2. Flow control spool
3. Steering relief valve
4. Steering spool
5. Overload relief valve
Unit: mm
Installed
6 Steering spool return spring length
58.0 N 46.4 N
37.0 32.1 —
{5.9 kg} {4.7 kg}
3.0 N 2.4 N
7 Poppet spring 20.9 18.3 —
{0.3 kg} {0.24 kg} Replace
147.1 N 117.7 N
8 Flow control spool return spring 69.7 68.5 —
{15.0 kg} {12.0 kg}
100.9 N 80.7 N
9 Steering relief valve spring 24.0 23.9 —
{10.3 kg} {8.2 kg}
55.3 N 44.2 N
10 Relief valve spring 29.8 26.5 —
{5.64 kg} {4.51 kg}
WA450-6, WA480-6 (KA SPEC.) 19

Operation of flow amplifier
When spool is at neutral

(When Orbit-roll valve is not in operation)
q Since both ports (Pa) and (Pb) are connected through the Orbit-roll valve to the drain circuit, steering
spool (1) is kept at neutral position by right and left return springs (2).
When spool is in operation

(When oil flows in port (Pa))
q The pressure in port (Pa) rises and steering spool (1) compresses left return spring (2) and moves to the
left.
q The oil in port (Pa) flows through the hole of spring seat (3) and orifice (a) of steering spool (1) to port
(Pb).
q Since port (Pb) is connected through the Orbit-roll valve to the drain circuit, the oil in port (Pb) is drained.
q Since the pressure generated in port (Pa) is in proportion to the flow rate of the oil, steering spool (1)
moves to a position where the oil pressure reduced by orifice (a) is balanced with the repulsive force of
return spring (2).
20 WA450-6, WA480-6 (KA SPEC.)

When spool is returned

(When steering wheel is stopped)
q Since both ports (Pa) and (Pb) are connected through the Orbit-roll valve to the drain circuit, steering
spool (1) is driven back to neutral by left return spring (2).
WA450-6, WA480-6 (KA SPEC.) 21

Operation of flow control spool
When steering spool is at neutral position
q The oil from the steering pump flows in port q If the oil pressure in port (Pr) rises above the
(P). set pressure, the swash plate angle of the
q Since notch (e) is closed, the oil pressure in steering pump is reduced to reduce the deliv-
port (P) is increased and then led through ori- ery.
fice (a) to pressure receiving chamber (X) to q If the oil pressure in port (P) keeps rising after
move flow control spool (1) to the left. the delivery of the pump is minimized, flow
q The oil in pressure receiving chamber (Y) is control spool (1) moves to the left further.
drained from port (T1) through orifice (b) and q If the oil pressure in pressure receiving cham-
notch (f). ber (X) rises above the set pressure, notch (d)
q If the oil pressure in pressure receiving cham- opens and the oil in port (P) is drained through
ber (X) rises above the set pressure, flow con- notch (d) and port (T1).
trol spool (1) moves to the left to open notch
(c).
q The oil in port (P) flows through notch (c) and
port (Pr) to the LS valve of the steering pump.
q Port (Pr) is connected through orifice (j) to port
(T2).
q The oil pressure in port (Pr) is set between the
pump pressure and drain pressure of port (T2)
because of the passing resistance of notch (c)
and orifice (j).
22 WA450-6, WA480-6 (KA SPEC.)

When steering spool operates
q If steering spool (2) operates, notch (f) closes q The excessive oil from the steering pump is
and pressure receiving chamber (Y) and port drained through notch (d) and port (T1).
(T1) are disconnected and notch (e) opens. q The oil returning from the steering cylinder is
q The oil pressure in pressure receiving chamber drained through orifice (g) and port (T1).
(Y) rises and flow control spool (1) moves to q Even after flow control spool (1) moves to the
the right and the open area of notch (d) right to close notch (d), it moves further to the
reduces. right, as long as the pressure before notch (e)
q The oil before notch (e) is led to pressure is below the set pressure.
receiving chamber (X) and the oil after notch q Since the open area of notch (c) reduces, the
(e) is led to pressure receiving chamber (Y). oil flow into port (Pr) is reduced and the oil
q If the oil pressure in pressure receiving cham- pressure in port (Pr) lowers.
ber (Y) rises higher than that in port (A), the oil q If the oil pressure in port (Pr) lowers, the LS
flowing from orifice (h) pushes and opens load valve of the steering pump increases the deliv-
check valve (3) to the left. ery of the pump to keep the oil pressure in port
q Since the oil from notch (e) flows through port (Pr) to the set pressure.
(A) to the steering cylinder, a pressure differ- q Flow control spool (1) is held at a position
ence is made between before and after notch where the pressure in port (P) is balanced with
(e). the pressure in port (Pr), thus the delivery of
q Since flow control spool (1) works to keep the the pump is kept constant.
differential pressure between before and after q If the open rate of notch (e) changes, the steer-
notch (e) to the set pressure, the oil is dis- ing pump discharges the amount of oil corre-
charged to the steering cylinder according to sponding to the open rate of notch (e) in order
the open rate of notch (e). to keep the oil pressure in port (Pr) constant.
WA450-6, WA480-6 (KA SPEC.) 23

Operation of steering valve
At neutral
q Since the steering wheel is not operated,

steering spool (1) does not move.
q The oil from the steering pump flows in port
(P).
q If the oil pressure in port (P) rises, flow control
spool (2) moves to the left and the oil from the
steering pump is drained through notch (a) and
port (T1).
24 WA450-6, WA480-6 (KA SPEC.)

Turning left
q If 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.
(P), and then flows through flow control spool
(2) to steering spool (1).
q Load check valve (3) is pushed to the left and
opened, conducting oil 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.
q The oil returning from the right and left steering
cylinders is drained through load check valve
(4) and port (T1).
WA450-6, WA480-6 (KA SPEC.) 25

Turning right
q If 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.
(P), and then flows through flow control spool
(2) to steering spool (1).
q Load check valve (4) is pushed to the right and
opened, conducting 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.
q The oil returning from the right and left steering
cylinders is drained through load check valve
(3) and port (T1).
26 WA450-6, WA480-6 (KA SPEC.)

Steering relief valve

1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
q The steering relief valve is installed to the
steering valve. It maintains the oil pressure in
the steering circuit to the set pressure during
the steering operation.
WA450-6, WA480-6 (KA SPEC.) 27

Operation of steering relief valve
q If the oil pressure in the steering circuit rises to

the level being set with adjustment screw (1)
and spring (2), pilot poppet (3) opens and the
oil is drained through port (T1).
q Pressure balance between receiving chambers
(X) and (Y) is lost and flow control spool (4)
moves to the left.
q As flow control spool (4) operates, the oil from
the steering pump is drained and the pressure
in the steering circuit is kept below the set
pressure.
28 WA450-6, WA480-6 (KA SPEC.)

Overload relief valve

Operation
Operation as relief valve
q Port (A) and port (B) are connected to the cyl-

inder circuit and drain circuit, respectively.
q The oil flows through the hole of poppet (1) to
the inside of relief valve poppet (2).
q Check valve poppet (3) and relief valve poppet
(2) are seated securely by the area difference
between diameters (d1) and (d2).
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
Function
q The overload relief valve is installed to the q If the oil pressure in port (A) rises above the
steering valve. It protects the cylinder circuit set pressure of the relief valve, pilot poppet (4)
from abnormally high pressure that can be is pushed and opened to the right.
generated if an impact is applied to the cylinder q The oil flows through pilot poppet (4) and hole
while the steering valve is in neutral. to port (B).
q If abnormally high pressure is generated on
the cylinder side, the overload relief valve
works as a safety valve to prevent breakage of
the cylinder and hydraulic piping.
q If negative pressure is generated on the cylin-
der side, the overload relief valve works as a
suction valve to prevent occurrence of vacuum
in the circuit.
WA450-6, WA480-6 (KA SPEC.) 29

Operation as suction valve
q As pilot poppet (4) opens, the oil pressure

inside of poppet (1) lowers. q If negative pressure is generated in port (A), it
q Poppet (1) moves to the right to seat pilot pop- acts on the area difference between diameters
pet (4). (d3) and (d4) and pushes and opens check
valve poppet (3) to the right.
q The oil flows through port (B) to port (A) to pre-
vent occurrence of vacuum.
q The oil pressure of inside of relief valve poppet

(2) becomes lower than the oil pressure in port
(A).
q The oil pushes and opens relief valve poppet
(2) to the right and flows through port (A) to
port (B), thus the circuit is protected from
abnormally high pressure.
30 WA450-6, WA480-6 (KA SPEC.)

Relief valve
1. Plug
2. Spring
3. Valve
4. Valve seat
Function
q The relief valve is installed to the steering
valve. If the oil pressure in port (Pr) rises
above the set pressure, the relief valve
relieves the oil to protect the LS circuit of the
steering pump from abnormally high pressure.
WA450-6, WA480-6 (KA SPEC.) 31

Orbit-roll valve 1
P: From charge valve 1. Gerotor

T: Drain 2. Valve body
L: To left stop valve 3. Drive shaft
R: To right stop valve 4. Centering spring
5. Needle bearing
6. Bushing
7. Center pin
8. Sleeve
9. Spool
10. Spacer
11. End cap
32 WA450-6, WA480-6 (KA SPEC.)

Outline Structure
q The Orbit-roll valve is connected to the drive q Top (A) of spool (9) is connected to the drive
shaft of the steering column. It changes the oil shaft of the steering column and further con-
flow from the steering pump to the right or left nected to sleeve (8) through center pin (7)
steering cylinder to decide the travel direction (which is not in contact with spool (9) while the
of the machine. steering wheel is in neutral) and centering
q The Orbit-roll valve is roughly divided into spring (2).
spool (9) and sleeve (8) which have rotary q Top (B) of drive shaft (3) is engaged with cen-
selecting function and gerotor (5) (combined ter pin (7) and united with sleeve (8) and the
rotor (5a) and stator (5b)) which operates as a bottom is engaged with the spline of rotor (5a)
hydraulic motor during the normal steering of the gerotor (5).
operation and as a hand pump (its operating q Valve body (4) has 4 ports that are connected
effort is too high for you to operate it actually, to the pump circuit, tank circuit, left steering cir-
however) when the oil is not supplied because cuit, and right steering circuit, respectively. The
of a trouble of the steering pump or engine. ports on the pump side and tank side are con-
nected by the check valve in the body. If the
pump or engine fails, the oil can be sucked
through this check valve directly from the tank
side.
WA450-6, WA480-6 (KA SPEC.) 33

Connection of hand pump and sleeve
q Above figure shows the suction and discharge

ports (P) of the gerotor and connections with the
sleeve ports.
q If the steering wheel is turned to the right, ports
(a), (c), (e), (g), (i), and (k) will be connected to
the pump side by the vertical grooves of the
spool. Similarly, ports (b), (d), (f), (h), (j), and (l)
will be connected to the right steering cylinder
head side.
Under the condition in Fig. 1, the ports (1), (2),
and (3) are in the discharge state of the gerotor
and connected to ports (l), (b), and (d) and the
oil is sent to the steering cylinder. Ports (5), (6),
and (7) are also connected and the oil from the
pump flows in them.
Fig. 2 shows the state that has resulted from
turning the steering wheel by 90° continued
from above condition. Under this state, ports
(2), (3), and (4) are in the suction state and con-
nected to ports (k), (a), and (c). Ports (5), (6),
and (7) are in the discharge state and con-
nected to ports (d), (f), and (h).
q As shown above, the ports in the discharge
state of the gerotor are connected to the ports
being connected to the steering cylinder. The
ports in the suction state are connected to the
pump circuit.
q The internal gear of the gerotor advances by 1
tooth with every 1/7 turn of the steering wheel
and discharges the oil from the pump according
to the steering angle of the steering wheel.
Accordingly, the discharge amount varies in pro-
portion to the steering angle of the steering wheel.
34 WA450-6, WA480-6 (KA SPEC.)

Role of centering spring
q Centering spring (2) is composed of 4 X-

shaped leaf springs and 2 flat leaf springs and
installed between spool (9) and sleeve (8) as
shown in the figure.
q If the steering wheel is turned, spool (9) com-
presses centering spring (2) and angular dis-
placement (a) is generated between spool (9)
and sleeve (8).
As a result, the ports of spool (9) and sleeve
(8) are connected and the oil is sent to the
steering cylinder. When the steering wheel
stops turning, the gerotor also stops turning.
Then, the oil to the s teer ing cylinder is
stopped, increasing the pressure.
To prevent this, when the steering wheel
stopped turning, gerotor is turned by the reac-
tion force of centering spring (2) by angular
displacement (a) of spool (9) and sleeve (8) by
the reaction force of centering spring (2) to
return the steering wheel to the “neutral” posi-
tion.
WA450-6, WA480-6 (KA SPEC.) 35

Stop valve 1
A: From Orbit-roll valve 1. Boot

B: To steering valve 2. Wiper
DR: Drain 3. Seal
4. Poppet
5. Spring
6. Spool
7. Spring
36 WA450-6, WA480-6 (KA SPEC.)

Steering relief valve 1

(if equipped)
P1: From steering pump Outline

P2: From emergency steering pump q The steering relief valve is installed to the right
T: Drain side of the transmission and used to hold the
S1. Steering pump oil pressure switch (Low) steering oil pressure to the set pressure.
S2: Steering pump oil pressure switch (Hi) Set pressure: 1.96 MPa {20 kg/cm2}
S3: Emergency steering oil pressure switch (Cracking pressure at 0.5 l/min)
1. Block
2. Relief valve
3. Orifice
WA450-6, WA480-6 (KA SPEC.) 37

Steering cylinder 1
Unit: mm

Clearance between bushing in cyl- size clearance limit
Shaft Hole
1 inder rod frame connection part and
mounting pin 0 +0.174 0.100 –
55 —
–0.046 +0.100 0.220
Clearance between bushing in cyl-
0 +0.174 0.100 –
2 inder bottom frame connection part 55 —
–0.046 +0.100 0.220
and mounting pin Replace
Standard clearance (clear-
Boss width Hinge width
Connecting part of steering cylinder ance of a + b)
3
and rear frame Max. 6
65 71
(after shim is adjusted)
Connecting part of steering cylinder Max. 1.5
4 65 66.5
and front frame (after shim is adjusted)
38 WA450-6, WA480-6 (KA SPEC.)

Unit: mm

Clearance between piston rod and size Shaft Hole clearance limit Replace pin and
1
bushing bushing
–0.025 +0.152 0.020 –
50 0.505
–0.064 –0.005 0.216
2 Tightening torque of cylinder head 677±67.5 Nm {69±6.9 kgm}
3 Tightening torque of cylinder piston 16,700±170 Nm {170±17.0 kgm} (Width across flat: 55 mm)
Retighten
Tightening torque of cylinder head
4 9.8 – 12.74 Nm {1.0 – 1.3 kgm}
port side plug
WA450-6, WA480-6 (KA SPEC.) 39

Emergency steering motor 1

(if equipped)
1. Terminal E Function
2. Terminal M q When the oil pressure in the steering circuit
lowers abnormally, the emergency steering
motor drives the emergency steering pump
responding to the signal from the transmission
controller.
Specifications
Model name Direct current motor

Rated voltage 24 V
Rated output 0.9 kW
40 WA450-6, WA480-6 (KA SPEC.)

Emergency steering pump 1

(if equipped)
Type: SBL(1)21
Unit: mm
Standard clearance Clearance limit
1 Side clearance
0.10 – 0.15 0.19
Clearance between plain bearing
2 inside diameter and gear shaft out- 0.060 – 0.119 0.20
Replace
side diameter
3 Driven depth of pin 0
10 —
–0.5
4 Torque of spline turning shaft 2.0 – 4.9 Nm {0.2 – 0.5 kgm}
Allowable
Speed Discharge pressure Standard delivery
Delivery delivery
(rpm) (MPa {kg/cm2}) (l/min) —
— Discharge oil: SAE10WCD (l/min)
Oil temperature: 45 – 55°C 20.6
3,500 67.6 62.4
{210}
Function
q The emergency steering pump is installed
together with the emergency steering motor to
the right side of the transmission. When the
engine stops or the oil pressure in the steering
circuit lowers below the specified level, the
emergency steering pump supplies oil to the
steering circuit.
WA450-6, WA480-6 (KA SPEC.) 41

SEN01163-00

42
SEN01166-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)

Brake system
Brake system .................................................................................................................................................. 2
Brake piping diagram ........................................................................................................................... 2
Charge valve ........................................................................................................................................ 3
Brake valve ........................................................................................................................................ 10
Accumulator (for brake)...................................................................................................................... 15
Slack adjuster..................................................................................................................................... 16
Brake.................................................................................................................................................. 18
Parking brake control ......................................................................................................................... 23
Parking brake ..................................................................................................................................... 24
Parking brake solenoid valve ............................................................................................................. 26
Emergency parking brake release valve ............................................................................................ 28
WA450-6, WA480-6 (KA SPEC.) 1

Brake system 1
Brake piping diagram 1
1. Brake valve 7. Rear brake

2. Accumulator (for rear) 8. Parking brake solenoid valve
3. Accumulator (for front) 9. Parking brake
4. Cooling fan pump 10. Emergency parking brake release valve
5. Hydraulic tank 11. Charge valve
6. Slack adjuster 12. Front brake
2 WA450-6, WA480-6 (KA SPEC.)

Charge valve 1
P: From pump
A: To cooling fan motor
PPC : To PPC valve
ACC1: To brake valve port PA
ACC2: To brake valve port PB
T: Drain
S1: Brake oil pressure switch (Low)
S2: Emergency brake oil pressure switch
G: Accumulator charge pressure pickup port
WA450-6, WA480-6 (KA SPEC.) 3

1. Valve body Function

2. Sequence valve (H1) q The charge valve maintains the oil pressure
3. Relief valve (R2) from the pump to the set pressure and accu-
4. Shuttle valve (S1) mulates it in the accumulator.
5. Priority valve q If the pressure is accumulated in the accumu-
6. PPC relief valve (R3) lator, the circuit to the cooling fan motor opens
7. Main relief valve (R1) and the oil from the pump is output as cooling
fan motor drive pressure.
q As the oil pressure rises above the set pres-
sure, the oil from the pump is led to the drain
circuit to reduce the load on the pump.
q The charge valve reduces the pressure of the
oil from the pump and outputs the basic pres-
sure of the pilot circuit.
4 WA450-6, WA480-6 (KA SPEC.)

Operation
When oil is not supplied to accumulator (Cut-out state)
q Since the pressure in oil passage (B) is higher

than the set pressure of relief valve (1), piston
(2) is pushed to the right by the oil pressure
from oil passage (B).
q Relief valve (1) opens and oil passage (C) is
connected to port (T).
q The oil from the pump flows through orifices (a)
and (b) and oil passage (C) to port (T).
q Since the oil pressure is reduced before and
after orifice (a), a pressure difference is made
between pressure receiving chambers (D) and
(E).
q If the pressure in pressure receiving chamber
(D) becomes higher than the set pressure of
priority valve (5), priority valve (5) compresses
spring (6) and moves to the right.
q The open area on the side of port (P) and ori-
fice (c) is reduced and port (P) is connected to
port (A) gradually.
q The oil from the pump flows through port (P),
sequence valve (7), and port (A) to the cooling
fan motor.
WA450-6, WA480-6 (KA SPEC.) 5

When oil is supplied to accumulator

1. Cut-in state
q If the pressure in oil passage (B) goes below

the set pressure of relief valve (1), relief valve
(1) is returned to the left by the repulsive force
of springs (3) and (4).
q Relief valve (1) closes and oil passage (C) is
disconnected from port (T).
q Since oil passage (C) is disconnected from
port (T), pressure drop through orifice (a) is
reduced and the pressure difference between
pressure receiving chambers (D) and (E) is
reduced.
q Priority valve (5) is moved to the left by the
repulsive force of spring (6).
q The open area on the side of port (P) and ori-
fice (c) is increased and port (P) is discon-
nected from port (A) gradually.
q If the oil pressure from the pump becomes
higher than the pressure in ports (ACC1) and
(ACC2), it pushes up check valve (8), starting
feeding of pressure from ports (ACC1) and
(ACC2) to the accumulator.
q The oil of a specific quantity being set by the
size (area) of orifice (c) and the pressure differ-
ence between through it (equivalent to the load
of spring (6)) is supplied through port (ACC1)
and (ACC2) to the accumulator. The excessive
oil flows to ports (A) and (PPC).
6 WA450-6, WA480-6 (KA SPEC.)

2. When cut-out pressure is reached
q If 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).
q Relief valve (1) opens and oil passage (C) is
connected to port (T).
q A pressure difference is generated between
the right side and left side of piston (2), and
piston (2) moves to the right and opens relief
valve (1) forcibly.
q Since pressure receiving chamber (E) of prior-
ity valve (5) is also connected to oil passage
(C), the pressure in pressure receiving cham-
ber (E) is set to the drain pressure.
q Since the pressure in pressure receiving
chamber (D) also goes low by the level equiva-
lent to the load of spring (6), oil supply to oil
passage (B) is stopped.
WA450-6, WA480-6 (KA SPEC.) 7

Main relief valve (R1) PPC relief valve (R3)
q If the pressure in port (P) (pump pressure) q If the pressure from port (PPC) (pilot pressure)
rises above the set pressure, it compresses rises above the set pressure, the oil from the
spring (1) and moves ball (2) to the left. pump compresses spring (1) and moves ball
q The pressure of the oil from the pump is (2) to the left.
reduced through orifice (a), and the resulting q The pressure of the oil from the pump is
pressure difference compresses spring (3) and reduced when the oil flows through orifice (a),
moves valve (4) to the left largely. and the pressure difference compresses spring
q Port (P) being connected to port (T) drains the (3) and moves valve (4) to the left.
pump pressure and, thereby, regulates the q Since the open area between port (PPC) and
maximum pressure in the charge circuit to pro- port (P) is reduced and the pressure drop
tect the circuit. results, the pressure in port (P) is at the current
level without being not lowered to the set pres-
sure of the relief valve.
q The pressure in port (PPC) is adjusted to a
specific desired level according to the open
area between port (PPC) and port (P) and sup-
plied as the basic pressure of the pilot circuit.
q If abnormal pressure is generated in port
(PPC), port (PPC) is connected to port (T) to
release the abnormal pressure and protect the
pilot circuit.
8 WA450-6, WA480-6 (KA SPEC.)

Sequence valve (H1) Shuttle valve (S1)
q The pressure in port (P) (pump pressure) is q When the pressure in port (ACC1) is higher
applied to the left end of sequence valve (1) than that in port (ACC2), shuttle valve (1)
and the drain pressure is applied to the right moves to the left to disconnect port (ACC1)
end. from oil passage (B).
q If the pump pressure rises above the set pres- q The open area between port (ACC2) and oil
sure of spring (2), sequence valve (1) moves to passage (B) is increased and the oil is supplied
the right and port (P) is connected to port (A). to the accumulator on port (ACC2) side.
q The oil from the pump flows through priority q When the pressure in port (ACC2) is higher
valve (3) and port (A) to the cooling fan motor than that in port (ACC1), the oil is supplied to
and is used to drive the motor. the accumulator on port (ACC1) side.
q Even when the cooling fan motor drive pres- q The oil from the pump is supplied first to the
sure is low, the pump pressure is kept above low-pressure side of the 2 systems.
the set pressure of spring (2) to protect the
accumulator charge pressure and pilot circuit
basic pressure from going low.
WA450-6, WA480-6 (KA SPEC.) 9

Brake valve 1
PA: From charge valve ACC1 port TA: Plug

PB: From charge valve ACC2 port TB: Drain
A: To rear brake SA: Stop lamp oil pressure switch
B: To front brake SB: Plug
1. Piston 4. Spool (for front)

2. Spool (for rear) 5. Cylinder (for front)
3. Cylinder (for rear)
10 WA450-6, WA480-6 (KA SPEC.)

Outline
q The brake valve is installed in the lower front
side of the operator's seat. Pressing the brake
pedal conducts oil to the brake piston, operat-
ing the brake.
q The left side and right side brake pedals are
mechanically interlocked. Pressing one of the
pedals operates another pedal at the same
time.
q As the brake pedal is pressed, the transmis-
sion cut-off oil pressure sensor is operated,
sending the signal to the transmission control-
ler and, as the result, setting the transmission
to neutral electrically.
Operation
When the brake pedal is pressed down
q Brake pedal (1) pressing effort is transmitted to

spool (5) through rod (2), piston (3) and spring
(4).
q As spool (5) is pushed to the right, port (TA) is
closed and the oil from the pump activates the
rear brake after being conducted through accu-
mulator, port (PA), port (A) and rear brake pis-
ton.
q As spool (5) is pushed rightward, spool (6) is
also pushed rightward, closing port (TB). The
oil from the pump flows through the accumula-
tor, port (PB) and port (B) to the front brake pis-
ton to activate the front brake.
WA450-6, WA480-6 (KA SPEC.) 11

When brake of one side operated

(When the other brake failed)
q When only one of the brakes failed due to leak-

age of oil in the front or rear brake system,
brake pedal (1) pressing effort is capable of
mechanically moving spools (5) and (6) to the
right.
Thus, the oil from the pump is normally sup-
plied to the healthy brake piston, enabling it to
continue the operation. The brake, therefore, is
capable of stopping the machine as needed to
ensure the intended safety level.
12 WA450-6, WA480-6 (KA SPEC.)

Balancing operation
q As the rear brake piston is filled with oil and the

oil pressure rises between port (PA) and port
(A), the oil being conducted to chamber (E)
through orifice (c) of spool (5) pushes spool (5)
leftward resisting repulsive force of spring (4).
As the result, port (PA) and port (A) are discon-
nected.
At this time, port (TA) remains closed. Thus,
the oil conducted to the brake piston is
retained and the brake remains operable.
q At the same time as spool (5) moved to the left,
the front brake piston is filled up with oil,
increasing the oil pressure between port (PB)
and port (B). Thus, the oil conducted to cham-
ber (F) through orifice (d) of spool (6) pushes
back spool (6) in leftward by the move distance
of spool (5). As the result, port (PB) and port
(B) are disconnected.
At this time, port (TB) remains closed. Thus,
the oil conducted to the brake piston is
retained and the brake remains operable.
q Oil pressure in the rear brake circuit [port (A)
side] and the brake pedal pressing effort are
balanced and oil pressure in the front brake cir-
cuit [port (B) side] and oil pressure in the rear
brake circuit [port (A) side] are balanced.
As spools (5) and (6) are driven in rightward to
the stroke end, port (PA) and port (A) as well
as port (PB) and port (B) are opened com-
pletely. Thus, pressure of oil to the front and
rear brake circuits becomes equal to the oil
pressure from the pump.
Thus, the braking force is adjustable by adjust-
ing the brake pedal pressing effort until spools
(5) and (6) are driven in rightward to the stroke
end.
WA450-6, WA480-6 (KA SPEC.) 13

When brake pedal is released
q Releasing brake pedal (1) releases the pedal

pressing effort being applied to spool (5).
q As spool (5) is pushed back to the left by back
pressure of the rear brake piston and repulsive
force of spring (7), port (PA) is closed and the
oil in the rear brake piston is conducted
through port (A) to port (TA) and then drained
from port (TB) to the hydraulic tank. As the
result, the rear brake is released.
q At the same as spool (5) is moved to the left,
spool (6) is also pushed back to the left by
back pressure of the front brake piston and
repulsive force of spring (7). Thus, port (PB) is
closed and the oil in the front brake piston is
conducted through port (B) to port (TB) and
then drained from port (TB) to the hydraulic
tank. As the result, the rear brake is released.
14 WA450-6, WA480-6 (KA SPEC.)

Accumulator (for brake) 1

1. Valve
2. Top cover
3. Cylinder
4. Free piston
Function
q The accumulator is installed between the
charge valve and brake valve. The space
between cylinder (3) and free piston (4) is filled
with nitrogen gas. The nitrogen gas absorbs
the hydraulic pulses generated by the hydrau-
lic pump and secures the braking force and
operability when the engine is stopped by uti-
lizing its compressibility.
Specifications
Gas used: Nitrogen gas
Amount of gas: 2,850 cc
Charging gas pressure:3.43 ± 0.1 MPa
{35 ± 1.0 kg/cm2} (At 20°C)
Max. pressure used: 20.6 MPa {210 kg/cm2}
WA450-6, WA480-6 (KA SPEC.) 15

Slack adjuster 1
A: Inlet port
B: Outlet port
1. Bleeder
2. Cylinder
3. Check valve
4. Piston
5. Spring
Unit: mm
Clearance between cylinder size Shaft Hole clearance limit
6
body and piston –0.030 +0.074 0.030 –
55 0.25
–0.076 +0.074 0.150
Installed Installed Installed Replace
Free length Free length
7 Check valve spring length load load
66.7 N
38.8 33 — —
{4.4 kg}
43.1 N
8 Slack adjuster spring 198 38 — —
{4.4 kg}
16 WA450-6, WA480-6 (KA SPEC.)

Outline q As the brake valve is kept pressed down

q The slack adjuster is installed on the brake oil further, oil pressure from the brake valve
line leading to the brake piston from the brake exceeds the specified level to open check
valve, and functions to keep the time lag during valve (3) to apply pressure to port (C),
brake operation at a fixed level. generating the braking force.
Thus, the time lag as the brake is oper-
Specifications ated is maintained at a constant level.
Unit: MPa {kg/cm2}

Piston operating pressure 0.01 – 0.02 {0.1 – 0.2}
Check valve cracking
0.93 ± 0.05 {9.5 ± 0.5}
pressure
Check valve closing pressure 0.60 ± 0.05 {6.0 ± 0.5}
Operation
1. When the brake pedal is pressed down
q Before the brake is pressed down, piston
(4) is restored as much as the amount of
stroke (S) (a full stroke). When the brake
pedal is pressed down, oil discharged 2. When the brake pedal is released
from the brake valve branches into right q When the brake is released, return spring
and left cylinders (2) from port (P) of the (7) of the brake restores piston (4) as
slack adjuster to move piston (4) as much much as the amount of oil of stroke (S)
as the amount of stroke (S) to the right and the brake returns to its released state.
and the left. In other words, return stroke (T) of brake
piston (6) depends on the amount of oil of
stroke (S) the slack adjuster and the brak-
ing time lag remains constant regardless
of the amount of wear of the brake disc.
q As the result, brake piston (6) is moved by

stroke (S). Clearance between the brake
piston and disc at this point becomes 0
(zero) but the braking force is not gener-
ated.
WA450-6, WA480-6 (KA SPEC.) 17

Brake 1
Front
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Disc (3 pieces)
18 WA450-6, WA480-6 (KA SPEC.)

Unit: mm
10 Thickness of plate
6 ±0.1 5.5
Thickness of brake disc 6.5 ±0.15 5.7
11 Depth of lining groove 0.8 (Min.) — 0.4
Thickness of lining 1.0 0.9 (Min.) —
Wear of disc contact surface of Wear limit Replace
12 41.3 ±0.1
brake outer ring 0.3
Load of spring Installed height Installed load Installed load
13
(When 2 pieces are piled) 1,578 N 1,264 N
7.4
{161 kg} {129 kg}
Outline
q The front brake is a wet-type multi-disc brake,
which consists of piston (3), inner ring (5), disc
(9), outer ring (8), and spring (4).
q The brake cylinder consists of differential
housing (1) and bearing carrier (2). And piston
(3) is assembled to them.
Inner ring (5) and outer ring (8) are coupled
with the spline of differential housing (1).
q Disc (9) has liners stuck to its both sides and is
installed between inner ring (5) and outer ring
(8), and they are coupled together by the
spline of sun gear shaft (6).
WA450-6, WA480-6 (KA SPEC.) 19

Rear
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Disc (3 pieces)
20 WA450-6, WA480-6 (KA SPEC.)

WA450-6 Rear
Unit: mm
6 ±0.1 5.5
12 27.8 ±0.1
13
7.4
{156 kg} {125 kg}
WA480-6 Rear
Unit: mm
6 ±0.1 5.5
12 41.3 ±0.1
13
7.4
{161 kg} {129 kg}
Outline
q The rear brake is a wet-type multi-disc brake,
which consists of piston (3), inner ring (5), disc
(9), outer ring (8), and spring (4).
q The brake cylinder consists of differential
housing (1) and bearing carrier (2). And piston
(3) is assembled to them.
Inner ring (5) and outer ring (8) are coupled
with the spline of differential housing (1).
q Disc (9) has liners stuck to its both sides and is
installed between inner ring (5) and outer ring
(8), and they are coupled together by the
spline of sun gear shaft (6).
WA450-6, WA480-6 (KA SPEC.) 21

Operation
When brake is operated When brake is released
q As the brake pedal is pressed, oil pressure (P) q If the oil pressure is released, piston (2) is
being supplied through the hydraulic tank, brake returned by the returning force of spring (8)
charge valve to the brake cylinder acts on piston and clearance is made between inner ring (3)
(2) in the brake cylinder to move the piston. and outer ring (5), and disc (4) becomes free.
Accordingly, disc (4) between piston (2), inner The linings stuck to disc (4) have cross
ring (3), and outer ring (5) is stopped and the grooves on them. While disc (4) is turning, oil
brake is applied to the machine. flows in those grooves to cool the linings.
22 WA450-6, WA480-6 (KA SPEC.)

Parking brake control 1
1. Parking brake switch

2. Valve assembly
3. Parking brake solenoid valve
4. Parking brake
5. Emergency parking brake release valve
Outline
q Parking brake (4) is a wet-type multi-disc brake q While the parking brake is applied (While the
built in the transmission. It is installed to the solenoid valve is turned “OFF”), the signal from
output shaft bearing and operated mechani- the transmission controller to the transmission
cally by the pressing force of the spring and solenoid valve is stopped by the neutralizer
released hydraulically. signal to keep the transmission in neutral.
q If parking brake switch (1) installed to the oper- q Emergency parking brake release valve (5) is
ator's seat is turned “ON”, parking brake sole- installed to move the machine when it is
noid valve (3) installed to valve assembly (2) stopped (and the parking brake is applied)
shuts off the oil pressure and the parking brake because of a trouble in the engine or drive sys-
is applied. tem.
q If parking brake switch (1) is turned “OFF”, the
hydraulic force in the cylinder releases the
parking brake.
WA450-6, WA480-6 (KA SPEC.) 23

Parking brake 1
1. Output shaft Outline

2. Spring (Outside) q The parking brake is a wet-type multi-disc
3. Spring (Inside) brake being operated mechanically with
4. Piston springs (2) and (3) to apply braking to output
5. Parking brake oil port shaft (1).
6. Plate q The tension of springs (2) and (3) presses disc
7. Disc (7) against plate (6) with piston (4) to stop out-
8. Wave spring put shaft (1).
q When releasing, the oil pressure from parking
brake oil port (5) operates piston (4) to release
the pressing being applied to disc (7) and plate
(6).
24 WA450-6, WA480-6 (KA SPEC.)

Unit: mm
Basic dimensions Repair limit
Installed Installed Installed
Parking brake spring Free length Free length
9 length load load
(outside)
1,066 N 1,013 N
94 76 91.2
{108.7 kg} {103.3 kg}
Parking brake spring 557 N 529 N
10 94 76 91.2
(inside) {56.8 kg} {54.0 kg}
Basic dimensions Tolerance Repair limit Replace
Thick-
11 Plate 4.0 ±0.05 3.9
ness
Strain — 0.05 0.6
Thick-
12 Disc 3.2 ±0.08 2.97
ness
13
(Testing height: 3.2 mm) {112.8 kg} {±5.8 kg} {95.9 kg}
WA450-6, WA480-6 (KA SPEC.) 25

Parking brake solenoid valve 1
1. Valve assembly
2. Coil (ON/OFF type)
3. Push pin
4. Spring
5. Spool
6. Valve block
7. Check valve
26 WA450-6, WA480-6 (KA SPEC.)

Operation
When parking brake is applied When parking brake is released

(When solenoid is de-energized) (When solenoid is energized)
q Setting the parking brake switch to “ON” sets q Setting the parking brake switch to “OFF” sets
coil (1) to “OFF”. As the result, spool (2) is coil (1) to “ON”, moving spool (2) upward.
pushed back downward by the repulsive force q The pressurized oil from the pump flows to the
of spring (3). parking brake through port (P), inside of spool
q Pump port (P) is disconnected from parking (2) and port (A). At the same time, port (T) is
brake port (A), stopping flow of the oil from the closed and the oil is not drained.
pump to the parking brake. At the same time, q As oil pressure is applied to the back side of
the oil that was working as back pressure of the piston, it compresses the spring, separat-
the parking brake is drained through port (A) ing the plate and disc from each other. As the
and port (T). result, the parking brake is released.
q As the back pressure of the piston is drained,
the piston being pushed back by the spring
contacts the plate and disc closely to enable
the parking brake.
WA450-6, WA480-6 (KA SPEC.) 27

Emergency parking brake release valve 1
A: From accumulator
B: To parking brake solenoid valve
1. Grip
2. Valve
Function
q The emergency parking brake release valve is
installed between the accumulator and parking
brake solenoid in the brake circuit. When sup-
ply of oil pressure from the power train pump is
stopped because of an engine trouble, etc.,
opening the valve with manually allows con-
ducting the accumulator charge pressure in the
brake circuit to the parking brake cylinder.
28 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 29

SEN01166-00

30
SEN01168-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)

Undercarriage and frame
Undercarriage and frame ................................................................................................................................ 2
Axle mount and center hinge pin.......................................................................................................... 2
Tires ..................................................................................................................................................... 6
WA450-6, WA480-6 (KA SPEC.) 1

Undercarriage and frame 1

Axle mount and center hinge pin 1
1. Front axle Outline

2. Front frame q Front frame (2) and rear frame (4) are coupled
3. Rear axle with each other by the bearing with center
4. Rear frame hinge pin between them. The right and left
steering cylinders connect the front frame and
rear frame. They adjust the bending angle or
the turning radius of the frame according to
move of the cylinder.
2 WA450-6, WA480-6 (KA SPEC.)

Unit:
1 Thickness of thrust plate –0.15
20 —
–0.15
+0.3
2 Thickness of wear plate 5 —
–0.1
Standard Tolerance Standard Clearance Replace
Clearance between shaft and size Shaft Hole clearance limit
3
hole on front support side –0.050 +0.439 0.073 –
240 —
–0.122 +0.023 0.561
Clearance between shaft and –0.012 +0.455 0.039 –
4 190 —
hole on rear support side –0.137 +0.027 0.592
WA450-6, WA480-6 (KA SPEC.) 3

4 WA450-6, WA480-6 (KA SPEC.)

Unit:
Clearance between upper hinge size Shaft Hole clearance limit
1
pin and rear frame –0.030 +0.060 0.060 –
80 —
–0.049 +0.030 0.109
Clearance between upper hinge –0.030 +0.060 0.060 –
2 80 —
pin and spacer (small) –0.049 +0.030 0.109
Clearance between upper hinge –0.030 –0.015 0.015 –
3 80 —
pin and bearing –0.049 –0.015 0.049
Clearance between upper hinge –0.030 +0.030 0.030 –
4 80 —
and spacer (large) –0.049 +0.030 0.079
Clearance between rear frame –0.036 +0.071 0.072 –
5 95 —
and spacer (large) –0.071 +0.036 0.142
Clearance between front frame –0.025 –0.048 –0.088 –
6 130 —
and upper hinge bearing –0.025 –0.088 –0.023
Replace
Clearance between lower hinge –0.030 +0.067 0.057 –
7 80 —
pin and rear frame bushing –0.076 +0.027 0.143
Clearance between upper hinge –0.030 –0.015 0.015 –
8 80 —
pin and bearing –0.076 –0.015 0.076
Clearance between front frame –0.025 –0.048 –0.088 –
9 130 —
and lower hinge pin –0.025 –0.088 –0.023
Clearance between rear frame +0.089 +0.054 –0.089 –
10 95 —
and bushing +0.054 +0.054 0
Clearance in lower hinge pin +0.17 +0.054 –0.17 –
11 105 —
and seal press fitting part +0.08 +0.054 –0.026
Height of upper hinge spacer Standard size Tolerance Repair limit
12
(smaller one) 36 ±0.1 —
Height of upper hinge spacer
13 61.5 ±0.1 —
(larger one)
Standard thickness of shim
14 between upper hinge and 1
retainer
Standard thickness of shim
15 between upper hinge and 2
retainer
Standard thickness of shim Adjust
16 between lower hinge and 1
retainer
Tightening torque of upper 20 ± 2 Nm {2 ± 0.2 kgm} (When shim is adjusted)
17
hinge retainer mounting bolt 98 – 123 Nm {10 – 12.5 kgm} (Final value)
Tightening torque of lower 20 ± 2 Nm {2 ± 0.2 kgm} (When shim is adjusted)
18
hinge retainer mounting bolt 98 – 123 Nm {10 – 12.5 kgm} (Final value)
WA450-6, WA480-6 (KA SPEC.) 5

Tires 1
The radial tires employed on this machine provides the following features to the machine.
q Large gripping force, high operator comfort, fewer frequency of burst and less uneven wear.
q Enhanced fuel consumption, longer life, less machine damage and less heat generation.
Comparison of structures and characteristics of tires

Radial tire Bias tire
Structure Structure
q The cords of carcass (1) are arranged at right q The cords of carcass (1) are arranged bias
angles to the center line of tread (T) (radially). from the center line of tread (T).
q Tread (T) is stabilized and protected by several q Side wall (W) and tread (T) are integral.
strong belts (2).
q Side wall (W) and tread (T) are independent Ground contact characteristics
from each other.
q If the tire is deformed by a load, the ground
contact surface is also deformed, leading to
Ground contact characteristics
wasteful moves. As a result, the ground con-
q Even if the tire is deformed by a load, it does tact surface becomes unstable.
not move uselessly in ground contact and uni-
form ground contact surface is secured stably. Deformation characteristics
q Side wall (W) which receives loads and tread
Deformation characteristics (T) move as one unit.
q Only side wall (W) is deformed as load is
applied and tread (T) made of strong belts (2)
keeps stability independently.
6 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 7

SEN01168-00

8
SEN01170-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)

Hydraulic system, Part 1
Hydraulic system, Part 2 ................................................................................................................................. 2
Hydraulic piping diagram...................................................................................................................... 2
Work equipment control lever linkage .................................................................................................. 5
Hydraulic tank ...................................................................................................................................... 6
Power train pump ................................................................................................................................. 8
Work equipment pump ....................................................................................................................... 10
Work equipment control valve ............................................................................................................ 30
CLSS.................................................................................................................................................. 41
Each function and operation of each valve ........................................................................................ 46
WA450-6, WA480-6 (KA SPEC.) 1

Hydraulic system, Part 2 1

Hydraulic piping diagram 1
2 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 3

1. Work equipment control valve Outline

2. Bucket cylinder q The hydraulic system consists of the work
3. Steering valve equipment circuit and steering circuit. The
4. Cooling fan pump work equipment circuit controls the operation
5. Work equipment PPC valve of the bucket and attachments.
6. Work equipment pump q The oil from hydraulic tank (7) is sent by work
7. Hydraulic tank equipment pump (6) to work equipment control
8. Oil filler cap and breather valve (1). If the bucket and lift arm spools of
9. Oil cooler the work equipment control valve are in the
10. Power train oil cooler HOLD position, the oil is sent through the drain
11. Steering pump circuit of the work equipment control valve, fil-
12. Power train pump tered by the filter in the hydraulic tank, and
13. PPC accumulator returned to the tank.
14. Charge valve q If the work equipment control lever is operated,
15. ECSS accumulator the bucket or lift arm spool of work equipment
16. Steering cylinder PPC valve (5) moves to operate each spool of
17. Lift cylinder the work equipment control valve (1) hydrauli-
18. Emergency steering pump (if equipped) cally. Then, the oil flows from the work equip-
19. Emergency steering motor (if equipped) ment control valve to lift cylinder (17) or bucket
20. Cooling fan motor cylinder (2) to move the lift arm or bucket.
q The maximum pressure in the hydraulic circuit
is controlled with the relief valve in work equip-
ment control valve (1). The bucket cylinder cir-
cuit is equipped with the safety-suction valve
for protection of the circuit.
q PPC accumulator (13) is installed to the PPC
pilot circuit so that the lift arm can be lowered
to t he gr o un d ev e n wh i le t he en gi ne is
stopped.
q Hydraulic tank (7) is pressurized, enclosed,
and equipped with oil filler cap and breather (8)
having the relief valve. It pressurizes the tank
and, at the same time, prevents generation of
negative pressure in the tank to prevent cavita-
tion on the pump.
q This machine is equipped with the emergency
steering system. If the machine cannot be
steered normally because of a stall of the
engine, a trouble in the steering pump, oil leak-
age from the piping, etc., emergency steering
motor (19) drives emergency steering pump
(18) so that the machine can be steered.
(if equipped)
q Cooling fan motor (20) installed to the radiator
is driven hydraulically and variably with cooling
fan pump (4).
4 WA450-6, WA480-6 (KA SPEC.)

Work equipment control lever linkage 1
1. Lift arm control lever

2. Bucket control lever
3. Work equipment lock lever
4. Armrest
5. Work equipment PPC valve
6. Lever stand forward/backward adjustment
lever
7. Arm rest height and angle adjustment lever
WA450-6, WA480-6 (KA SPEC.) 5

Hydraulic tank 1
6 WA450-6, WA480-6 (KA SPEC.)

1. Oil filler cap and breather Breather

2. Hydraulic tank
3. Drain valve
4. Drain plug
5. Sight gauge
6. Stainer
7. Filter element
8. Bypass valve
9. Suction strainer
Specifications
Capacity of hydraulic tank (l) 256
Quantity of oil in hydraulic tank (l) 173
Set pressure of bypass valve 0.15 ± 0.03 1. Filter element
(MPa {kg/cm2}) {1.53 ± 0.31} 2. Bottom plate
3. Gasket
4. Seam valve
5. Spring
Prevention of negative pressure in tank

q Since the tank is pressurized and enclosed, if
the oil level in it lowers, negative pressure is
generated.
At this time, seam valve (4) is opened by the
differential pressure between the tank pressure
and the atmospheric pressure to prevent gen-
eration of the negative pressure.
(Set pressure of air intake valve:
0 – 5.1 kPa {0 – 0.05 kg/cm2})
Prevention of pressure rise in tank

q While the hydraulic circuit is in operation, the
oil level in the tank rises as the hydraulic cylin-
ders operate, and the temperature rises. Con-
sequently, the pressure in the tank rises, too.
If the pressure in the tank rises above the set
level, bottom plate (2) is pushed up to release
the pressure from the tank and thus to prevent
pressure rise in the tank.
(Set pressure of exhaust valve:
75 ± 15 kPa {0.76 ± 0.15 kg/cm2})
WA450-6, WA480-6 (KA SPEC.) 7

Power train pump 1

Model: SAL(4)125
Unit: mm
Type Standard clearance Clearance limit
1 Side clearance
SAL(4)125 0.11 – 0.16 0.20
Clearance between plain bear-
2 ing inside diameter and gear SAL(4)125 0.06 – 0.14 0.20
Replace
shaft outside diameter
Type Standard size Tolerance Repair limit
3 Driven depth of pin 0
SAL(4)125 21 —
–0.5
4 Torque of spline turning shaft 9.8 – 14.7 Nm {1.0 – 1.5 kgm}
Discharge
Standard Allowable
Delivery Speed pressure
Type delivery delivery —
— Oil: EO10-CD (rpm) (MPa
(l/min (l/min
Oil temperature: 45 – 55°C {kg/cm2})
SAL(4)125 2,200 2.9 {30} 264.2 233.9
Outline
q The power train pump is installed to the PTO
shaft of the torque converter and driven by the
shaft to supply oil to the torque converter and
transmission circuits.
8 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 9

Work equipment pump 1

Type: HPV95
10 WA450-6, WA480-6 (KA SPEC.)

Outline
q The pump unit is composed of the variable
capacity swash plate type piston pump, PC
valve, LS valve, and EPC valve.
IM: PC mode selector current

PA: Pump discharge port
PB: Pump pressure input port
PC: Pump discharge pressure pickup port
PD1: Case drain port
PD2: Drain plug
PEN: Control pressure pickup port
PEPB: EPC basic pressure pickup port
PEPC: EPC basic pressure port
PLS: Load pressure input port
PLSC: Load pressure pickup port
PM: PC mode selector pressure pickup port
PS: Pump suction port
1. Main pump
2. LS valve
3. PC valve
4. PC-EPC valve
WA450-6, WA480-6 (KA SPEC.) 11

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
12 WA450-6, WA480-6 (KA SPEC.)

Function q Piston (6) carries out relative movement in the

q The pump converts the engine and torque rota- axial direction inside each cylinder chamber of
tion transmitted to its shaft to oil pressure and cylinder block (7).
delivers pressurized oil corresponding to the q Cylinder block (7) seals the pressurized oil to
load. valve plate (8) and carries out relative rotation.
q It is possible to change the delivery by chang- q This surface is designed so that the oil pres-
ing the swash plate angle. sure balance is maintained at a suitable level.
q The oil inside each cylinder chamber of cylin-
Structure der block (7) is suctioned and discharged
q Cylinder block (7) is supported to shaft (1) by through valve plate (8).
spline (12).
q Shaft (1) is supported with bearings (13).
q The end of piston (6) has a spherical hollow
and is combined with shoe (5).
q Piston (6) and shoe (5) form a spherical bear-
ing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
q Rocker cam (4) conducts high pressure oil to
cylinder surface (B) with cradle (2), which is
secured to the case, and forms a static pres-
sure bearing when it slides.
WA450-6, WA480-6 (KA SPEC.) 13

Operation of pump q As center line (X) of rocker cam (4) matches

q Cylinder block (7) rotates together with shaft the axial direction of cylinder block (7) (swash
(1), and shoe (5) slides on flat surface (A). plate angle (a) = 0), the difference between
q When this happens, rocker cam (4) moves volumes (E) and (F) inside cylinder block (7)
along cylindrical surface (B), so angle (a) becomes 0.
between center line (X) of rocker cam (4) and q Suction and discharge of pressurized oil is not
the ax ial di rec tio n of cy li nder b loc k (7) carried out in this state. Namely pumping
changes. action is not performed. (Actually, however, the
q Angle (a) is called the swash plate angle. swash plate angle is not set to 0)
q With center line (X) of rocker cam (4) at swash

plate angle (a) in relation to the axial direction
of cylinder block (7), flat surface (A) acts as a
cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) sucks and discharges the oil
by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
14 WA450-6, WA480-6 (KA SPEC.)

Control of delivery
q If swash plate angle (a) becomes larger, the
difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q Servo piston (10) is used for changing swash
plate angle (a).
q Servo piston (10) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) through slider (14).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (10) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pres-
sure chamber of the small diameter piston
side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (10).
WA450-6, WA480-6 (KA SPEC.) 15

LS valve
PA: Pump port 1. Sleeve

PDP: Drain port 2. Piston
PLP: LS control pressure output port 3. Spool
PLS: LS pressure input port 4. Spring
PP: Pump port 5. Seat
PPL: Control pressure input port 6. Sleeve
PSIG: Drain port 7. Plug
8. Locknut
Function
q The LS (load sensing) valve detects the load
and controls the delivery.
q This valve controls pump delivery (Q) accord-
ing to differential pressure (dPLS)
[ = (PP) – (PLS)] (called LS differential pres-
sure) between pump discharge pressure (PP)
and control valve outlet port pressure (PLS).
q Main pump pressure (PP), pressure (PLS)
(called the LS pressure) coming from the con-
trol valve output, and pressure (PSIG) (called
the LS selector pressure) from the proportional
solenoid valve enter this valve.
16 WA450-6, WA480-6 (KA SPEC.)

Operation
1) When the control valve is situated at neutral
q The LS valve is a 3-way selector valve, with q Pump pressure (PP) is present in port (J) on
pressure (PLS) (LS pressure) from the inlet the small diameter side of the piston.
port of the control valve brought to spring q According to the difference in the areas on
chamber (B), and pump discharge pressure servo piston (10), servo piston (10) moves in to
(PP) brought to port (H) of sleeve (1). the direction of minimizing the swash plate
q Magnitude of the force resulting from this LS angle.
pressure (PLS), force of spring (4) and the
pump discharge pressure (self pressure) (PP)
determine the position of spool (3).
q Before starting engine, servo piston (10) is
pressed to the right. (See the figure to the
right)
q If the control lever is in neutral at start of the
engine, LS pressure (PLS) is set to 0 MPa {0
kg/cm2}. (It is connected with the drain circuit
through the control valve spool.)
q Spool (3) is pushed to the right, and port (C)
and port (D) will be connected.
q Shuttle valve output pressure (PPH) enters the
large diameter side of the piston from port (K).
WA450-6, WA480-6 (KA SPEC.) 17

2) Action for the direction of maximizing the pump delivery
q When the difference between pump discharge

pressure (PP) and LS pressure (PLS), in other
wo r ds , L S d iff er e nti a l p re s s ur e ( dP L S)
becomes smaller [for example, when the area
of opening of the control valve becomes larger
and pump discharge pressure (PP) drops],
spool (3) is pushed to the left by the combined
force of LS pressure (PLS) and the force of
spring (4).
q When spool (3) moves, port (D) and port (E)
are interconnected and connected to the PC
valve.
q The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K)
becomes drain pressure (PT). (The operation
of the PC valve is explained later.)
q The pressure at the large diameter end of
servo piston (10) becomes drain pressure
(PT), and pump pressure (PP) enters port (J)
at the small diameter end, so servo piston (10)
is pushed to the left side. Therefore, servo pis-
ton (10) is moved in the direction to make the
delivery larger.
18 WA450-6, WA480-6 (KA SPEC.)

3) Action for the direction of minimizing the pump delivery
q If LS differential pressure (dPLS) becomes

larger (for example, when the area of control
valve opening becomes smaller and the pump
pressure (PP) increases), spool (3) is pressed
to the right by the force of pump pressure (PP).
q As a result of the movement of spool (3), shut-
tle valve output pressure (PPH) flows from port
(C) to port (D), then from port (K) to the large
diameter side of the piston.
q While main pump pressure (PP) is present in
port (J) of the smaller diameter side of the pis-
ton, servo piston (10) is pressed to the right by
its area difference between the larger and the
smaller diameter sides. As the result, servo
piston (10) moves in the direction to minimize
the swash plate angle.
WA450-6, WA480-6 (KA SPEC.) 19

4) When servo piston is balanced
q Let us take the area receiving the pressure at q The force of spring (4) is adjusted to determine
the large diameter end of the piston as (A1), the balanced stop position of this spool (3) at
the area receiving the pressure at the small the center of the standard when (PP) – (PLS) =
diameter end as (A0), and the pressure flowing 1.4 MPa {14 kg/cm2}.
into the large diameter end of the piston as
(PEN).
q If the main pump pressure (PP) of the LS valve
and the combined force of spring (4) and LS
pressure (PLS) are balanced, and the relation-
ship is (A0) × (PP) = (A1) × (PEN), servo pis-
ton (10) will stop in that position.
q And the swash plate of the pump will be held in
an intermediate position. [Spool (3) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the dis-
tance from port (C) to port (D) is almost the
same.]
q The formula (A0) : (A1) = 3 : 5 represents the
relation of pressure receiving areas across the
end of servo piston (10). And (PP) : (PEN) C 5 :
3 represents the pressure applied across the
piston when balanced.
20 WA450-6, WA480-6 (KA SPEC.)

PC valve
PA: Pump port 1. Plug

PA2: Pump pressure pilot port 2. Servo piston assembly
PDP: Drain port 3. Pin
PM: Mode selector pressure pilot port 4. Spool
PPL: Control pressure output port (to LS valve) 5. Retainer
6. Seat
7. Cover
8. Wiring
Function
q PC valve controls the flow to a certain rate cor-
responding to the discharge pressure irrespec-
tive of how much the control valve stroke is
increased, when pump discharge pressure
(PP1) (self pressure) and (PP2) (other pump
pressure) are high.
q Uprise in the pump discharge pressure due to
increased load during work results in reducing
the pump delivery.
q If the pump discharge pressure drops, it
increases the delivery from the pump.
q In this case, relation between the mean dis-
charge pressure of the front and rear pumps
[(PP1) + (PP2)]/2 and pump delivery (Q) will
become as shown in the right figure if the rela-
tion is represented as the parameter of the cur-
rent value (X) to be given to PC-EPC valve
solenoid.
q The controller continues counting the actual
engine speed.
q During low speed, command current flows
from the controller to PC-EPC valve solenoid
according to the engine speed to reduce the
pump delivery.
WA450-6, WA480-6 (KA SPEC.) 21

Operation
1) When the actuator load is small and pump pressures (PP1) and (PP2) are low
Action of PC-EPC valve solenoid (1) a Other pump pressure denotes the pressure of
q Command current (X) is being sent to PC-EPC the pump situated on the opposite side.
valve solenoid (1) from the pump controller. For the front pump pressure, the other pump
q This command current (X) works on PC-EPC pressure is that of the rear pump.
valve and output the signal pressure to change And for the rear pump pressure, the other
the force of pushing piston (2). pump pressure is that of the front pump.
q Spool (3) stops at a position where the com-
bined force pressing spool (3) becomes bal-
anced between a set force of spring (4) and
pump pressure (PP1) (self pressure) and
(PP2) (other pump pressure).
q The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
q The size of command current (X) is determined
by the nature of the operation (lever opera-
tion), the selected working mode, and the set
value and actual value of the engine speed.
22 WA450-6, WA480-6 (KA SPEC.)

Action of spring q If port (E) and port (G) of the LS valve are con-
q The load of spring (4) at the PC valve is deter- nected, the pressure entering the large diame-
mined by the position of the swash plate. ter end of the piston from port (J) becomes
q Spring load changes as servo piston (9) makes drain pressure (PT), and servo piston (9)
spring (4) elongate or contract. moves to the left side.
q If the command current (X) to PC-EPC valve q The pump delivery will be set to the increasing
solenoid (1) changes, so does the force push- trend.
ing piston (2). q Spring (4) extends as servo piston (9) moves
q The load of spring (4) also changes according and weakens the spring force.
to the PC-EPC valve solenoid command cur- q As the spring force is weakened, spool (3)
rent (X). moves to the right, the connection between
q Port (C) of the PC valve is connected to port port (C) and port (D) is shut off and the pump
(E) of the LS valve. discharge pressure ports (B) and (C) are con-
q Self pressure (PP1) enters port (B) and the nected.
small diameter end of servo piston (9), and q The pressure on port (C) rises and the pres-
other pump pressure (PP2) enters port (A). sure on the large diameter end of the piston
q When pump pressures (PP1) and (PP2) are also rises. Thus, the leftward move of servo
small, spool (3) will be positioned in the left piston (9) is stopped.
side. q Stop position of servo piston (9) (= pump deliv-
q Ports (C) and (D) are connected, and the pres- ery) is determined by a position where press
sure entering the LS valve becomes drain force generated by pressures (PP1) and (PP2)
pressure (PT). on spool (3) and other press force by PC-EPC
valve solenoid are balanced with the force of
spring (4).
WA450-6, WA480-6 (KA SPEC.) 23

2) When the actuator load is large, and the pump discharge pressure is high
Outline Operation
q When the load is large and pump discharge q When port (E) and port (G) of the LS valve are
pressures (PP1) and (PP2) are high, the force connected, this pressure from port (J) enters
pushing spool (3) to the right becomes larger the large diameter end of servo piston (9),
and spool (3) will be moved to the position stopping servo piston (9).
shown in above figure. q If main pump pressure (PP2) increases further
q Part of the pressure to be conducted from port and spool (3) moves further to the right, main
(C) to LS valve flows from port (B) to ports (C) pump pressure (PP1) flows to port (C) and acts
and (D) through LS valve. At the end of this to make the pump delivery the minimum.
flow, level of this pressure becomes approxi- q When servo piston (9) moves to the right,
mately half of main pump pressure (PP2). springs (4) and (6) are compressed and push
back spool (3).
q When spool (3) moves to the left, the openings
of port (C) and port (D) become larger.
q The pressure on port (C) (= J) is decreased
and the rightward move of servo piston (9) is
stopped.
q The position in which servo piston (9) stops at
this time is further to the right than the position
when pump pressures (PP1) and (PP2) are low.
24 WA450-6, WA480-6 (KA SPEC.)

q The relationship between the average pump

pressure (PP1 + PP2)/2 and average pump
delivery (Q) becomes as shown below.
q If command voltage (X) sent to PC-EPC valve

solenoid (1) increases further, the relationship
between average pump pressure (PP1 + PP2)/
2, and pump delivery (Q) is proportional to the
force of the PC-EPC valve solenoid and moves
in parallel.
q Namely, the force of PC-EPC valve solenoid
(1) is added to the pushing force to the right
because of the pump pressure applied to spool
(3), so the relationship between the average
pump pressure (PP1 + PP2)/2 and pump deliv-
ery (Q) moves from (A) to (B) as command
current (X) is increased.
WA450-6, WA480-6 (KA SPEC.) 25

PC-EPC valve
C: To PC valve
P: From pilot pump
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
26 WA450-6, WA480-6 (KA SPEC.)

Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- 1) When signal current is 0
tion. (Coil is de-energized)
q On receiving signal current (i) from the control- q When there is no signal current flowing from
ler, the EPC valve generates EPC output pres- the controller to coil (2), coil (2) is de-ener-
sure in proportion to the signal current and gized.
outputs it to the PC valve. q Spool (5) is pushed to the left by spring (4).
q Port (P) is closed and the oil from the pilot
pump does not flow to the PC valve.
q The oil from the PC valve is drained through
ports (C) and (T) to the tank.
WA450-6, WA480-6 (KA SPEC.) 27

2) When signal current is very small 3) When signal current is maximum

(coil is energized) (coil is energized)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energized, and a propulsion force energized.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressure on port (C) increases and the force to q Spool (5) is pushed toward the right side by rod
act on spool (5) surface and the spring load on (6).
spring (4) become larger than the propulsion q Hydraulic oil from port (P) flows to port (C) with
force of plunger (7). maximum flow rate. As the result, the circuit
q Spool (5) is pushed to the left, and port (P) is pressure between the EPC and PC valves
shut off from port (C). becomes maximum.
q Port (C) and port (T) are connected. q Since port (T) is closed, pressurized oil does
q Spool (5) moves so that the propulsion force of not flow to the tank.
plunger (7) may be in balance with pressure of
port (C) + spring load of spring (4).
q Circuit pressure between the EPC valve and
PC valve is controlled in proportion to the size
of the signal current.
28 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 29

Work equipment control valve 1

Outline
As for outside views and sectional views, only the 3-spool valve (with ECSS control valve) is shown.
A1 : To bucket cylinder bottom

A2 : To lift arm cylinder bottom
ACC : To ECSS accumulator
B1 : To bucket cylinder head
B2 : To lift arm cylinder head
CAC : Pressure pick-up port
CLS : Pressure pick-up port
CP : Pressure sensor installation port
CP1 : Pressure pick-up port
CR : Pressure pick-up port
P : From front work equipment pump
PA1 : From bucket dump pilot pressure
PA2 : From lift arm raise pilot pressure
PACC : From ECSS controller
PB1 : From bucket tilt pilot pressure
PB2 : From lift arm lower pilot pressure
PLS : To work equipment pump LS port
PP : From pilot pump
PPS : To work equipment pump
T : To tank
TS : To tank
1. Bucket valve
2. Lift arm valve
3. ECSS control valve
4. Cover A
5. Cover B
6. Lift arm suction valve
7. Accumulator charge valve
30 WA450-6, WA480-6 (KA SPEC.)

Outside view
WA450-6, WA480-6 (KA SPEC.) 31

Sectional view
(1/6)
32 WA450-6, WA480-6 (KA SPEC.)

1. Load check valve (bucket cylinder bottom)

2. Load check valve (lift cylinder bottom)
3. Pressure compensation valve (lift cylinder head)
4. Pressure compensation valve (bucket cylinder head)
Unit: mm
Free length
Installed Installed Installed If damaged or
× Outside Free length
5 Check valve spring length load load deformed,
diameter
replace spring
29.4 N 23.5 N
38.9 × 11.5 30.0 —
{3.0 kg} {2.4 kg}
WA450-6, WA480-6 (KA SPEC.) 33

(2/6)
34 WA450-6, WA480-6 (KA SPEC.)

1. Spool (ECSS)
2. Spool (Lift arm)
3. Spool (Bucket)
Unit: mm
Free length
× Outside
4 Spool return spring length load length load
diameter
388 N 311 N
56.0 × 33.5 51.5 —
{39.6 kg} {31.7 kg}
If damaged or
351 N 280 N
5 Spool return spring 58.1 × 33 51.5 — deformed,
{35.8 kg} {28.6 kg}
replace spring
400 N 320 N
6 Spool return spring 70.5 × 36.4 65 —
{40.8 kg} {32.6 kg}
265 N 212 N
7 Spool return spring 53.2 × 22.3 33 —
{27.0 kg} {21.6 kg}
380 N 304 N
8 Spool return spring 56.8 × 33.8 51.5 —
{38.7 kg} {31.0 kg}
WA450-6, WA480-6 (KA SPEC.) 35

(3/6)
1. Safety-suction valve (Bucket cylinder bottom)

2. Safety-suction valve (Lift cylinder bottom)
3. Safety-suction valve (Lift cylinder head)
4. Safety-suction valve (Bucket cylinder head)
36 WA450-6, WA480-6 (KA SPEC.)

(4/6)
Bucket valve
1. Load check valve (tilt)

2. Pressure compensation valve (dump)
3. Safety-suction valve (tilt)
4. Spool
5. Safety-suction valve (dump)
WA450-6, WA480-6 (KA SPEC.) 37

(5/6)
38 WA450-6, WA480-6 (KA SPEC.)

Lift arm valve

1. Load check valve (raise)
2. LS shuttle valve
3. Pressure compensation valve (lower)
4. Safety-suction valve (lower)
5. Suction valve (lower and float)
6. Spool
7. Safety-suction valve (raise)
ECSS valve
8. Spool
9. EPC valve
Unit: mm
Basic dimensions Repair limit
Free length
× Outside
11 Suction valve spring length load length load
diameter
If damaged or
3.04 N 2.45 N
62.5 × 20.0 39.0 — deformed,
{0.31 kg} {0.25 kg}
replace spring
5.88 N 4.71 N
12 Check valve spring 41.5 × 8.5 31.5 —
{0.6 kg} {0.48 kg}
19.6 N 15.7 N
13 Valve spring 19.2 × 7.2 16.1 —
{2.0 kg} {1.6 kg}
WA450-6, WA480-6 (KA SPEC.) 39

(6/6)
1. Unload valve
2. Main relief valve
3. LS bypass plug
40 WA450-6, WA480-6 (KA SPEC.)

CLSS 1
Outline of CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with a variable capacity
tem, and has the following features: piston pump, control valves, and respective
actuators.
q Fine control not influenced by load q The hydraulic pump is configured with pump
q Controllability enabling digging even with fine body, PC valve and LS valve.
control
q Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
WA450-6, WA480-6 (KA SPEC.) 41

Basic principle q The pump swash plate angle shifts toward the
maximum position if LS differential pressure
Pump swash plate angle control (dPLS) is lower than the set pressure of the LS
q The pump swash plate angle (pump delivery) valve (when the actuator load pressure is
is so controlled that the LS differential pressure high).
(dPLS), which is the differential pressure q If it becomes higher than the set pressure
between the pump discharge pressure (PPS) (when the actuator load pressure is low), the
and LS pressure (PLS) (the actuator load pres- pump swash plate angle shifts toward the mini-
sure) at the control valve outlet, will be con- mum position.
stant.
q [LS differential pressure (dPLS) = Pump dis- LS differential pressure (dPLS) and pump
charge pressure (PPS) – LS pressure (PLS)] swash plate angle
a For details of functions, see the “Hydraulic

pump” paragraph.
42 WA450-6, WA480-6 (KA SPEC.)

Pressure compensation control
q The valve (pressure compensation valve) to q This prevents the bucket from becoming inop-
balance the load is installed to the lift cylinder erable because of excessive oil flow to the lift
head outlet side of the control valve. cylinder head due to the lowering of lift arm
q When actuators are operated simultaneously, under its own weight and compound operation
the pressure difference (dP) between the of the bucket.
upstream (inlet port) and downstream (outlet
port) of the spool of each valve becomes the
same regardless the size of the load (pres-
sure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of openings
(S1) and (S2) of each valve.
WA450-6, WA480-6 (KA SPEC.) 43

44 WA450-6, WA480-6 (KA SPEC.)

1. Bucket valve
2. Lift arm valve
3. ECSS valve
4. Bucket spool
5. Lift arm spool
6. ECSS spool
7. Pressure compensation valve
8. Suction valve
9. Load check valve
11. Main relief valve
Set pressure: 34.3 ± 0.5 MPa {350 ± 5 kg/cm2}
12. Unload valve
Cracking pressure: 1.96 ± 0.2 MPa {20 ± 2 kg/cm2}
13. Safety-suction valve
14. Safety-suction valve
WA450-6, WA480-6 (KA SPEC.) 45

Each function and operation of each valve 1

Pressure compensation valve 1
(Installed on the cylinder head side of the lift arm valve)
1) When a high load is applied to the lift arm
1. Main pump 4. Piston

2. Valve 5. Spring
3. Shuttle valve 6. LS shuttle valve
Function q Shuttle valve (3) of the pressure compensation

q High load pressure is generated during inde- valve moves to the right.
pendent operation of the lift arm and com- q Actuator circuit pressure (B) and spring cham-
pound operation with the bucket. ber (C) is connected.
q When the lift arm load pressure becomes q Accordingly, piston (4) is pressed by spring (5)
higher than the bucket, the pressure compen- to the left.
sation valve operates as a load check valve to q Also valve (2) is pressed by piston (4) to the
prevent reverse oil flow in the circuit. left and pump outlet circuit (A) is closed. This
prevents reverse flow of oil from actuator cir-
Operation cuit (B) to pump outlet circuit (A).
q Actuator circuit pressure (B) becomes higher
than pump discharge pressure (PPS) and LS
pressure (PLS).
46 WA450-6, WA480-6 (KA SPEC.)

2) Compound operation (Lift arm lower + bucket tilt)
Function q Outlet pressure (A) (spool meter-in down-

q If the load pressure is lower than the bucket stream pressure) becomes equal to the bucket
and the flow rate starts increasing during com- outlet pressure.
pound operation, the pressure compensation q Pump pressure (PPS) (spool meter-in
valve compensates the pressure. upstream pressure) becomes equal for all
q On the bucket side, the load pressure is higher actuators.
and the flow rate starts to decrease. q Pump pressure (PPS) and outlet pressure (A)
becomes equal for all spools.
Operation q Pump flow rate is distributed in proportion to
q If the load pressure on the bucket side rises the opening area of respective spools.
during compound operation, the flow rate of
actuator circuit pressure (B) starts to increase.
q As LS pressure (PLS) rises on the bucket side,
shuttle valve (3) of the pressure compensation
valve is pressed to the left.
q Hydraulic oil flows through the internal pas-
sage of piston (4) to spring chamber (C).
q Piston (4) and valve (2) are pressed to the left
and the outlet side of pump circuit (PPS) is cut
off.
WA450-6, WA480-6 (KA SPEC.) 47

Shuttle valve in the pressure compensation valve
If holding pressure of port (B) > LS pressure in spring chamber (C)
1. Hydraulic pump
2. Valve
3. Shuttle valve
4. Piston
Function
q Shuttle valve (3) is pressed to the right by port
(B) pressure and ports (B) and (D) are cut off.
q Holding pressure of port (B) is led to spring
chamber (C) and piston (4) is pressed to the
left to prevent it from being separated from
valve (2).
48 WA450-6, WA480-6 (KA SPEC.)

Area ratio of pressure compensation valve
Function
q The state of division changes according to the
area ratio of pressure compensation portions
(A1) and (A2). Area ratio = (A2)/(A1)
q Since the area ratio is less than 1, spool meter-
in downstream pressure < maximum load
pressure, and the oil flow is divided greater
than by the area ratio of the opening.
WA450-6, WA480-6 (KA SPEC.) 49

Supply of LS pressure
(LS shuttle valve)
1. Hydraulic pump 5. Check valve

2. Main spool 6. LS circuit
3. Pressure compensation valve 7. LS shuttle valve
4. Valve
Function Operation
q The LS pressure (PLS) means the actuator q If main spool (2) is operated, pump discharge
load pressure on the outlet side of the control pressure (PPS) flows to actuator circuit (B).
valve. q Pump discharge pressure (PPS) is led through
q Pressure compensation valve (3) upstream orifice (a) of main spool (2) to LS circuit (PLS).
pressure (spool meter-in downstream pres- q When actuator circuit (B) rises to necessary
sure) is led through main spool (2) to LS shut- pressure level, pump discharge pressure
tle valve (7). (PPS) rises.
q Connected to actuator port (B) through valve q Check valve (5) in main spool (2) opens and
(4), and makes LS pressure C actuator load the high pressure in LS circuit (PLS) flows out
pressure. to actuator circuit (B).
q Inlet pore (a) inside main spool (2) has a small q Pressure in LS circuit (PLS) becomes approxi-
diameter concurrently serving as a throttle. mately equal to that of actuator circuit pressure
(B).
50 WA450-6, WA480-6 (KA SPEC.)

LS bypass plug 1
1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass plug
6. LS circuit
Function
q Releases the residual pressure in LS pressure
circuit (6) from orifices (a) and (b).
q Slows down the rising rate of LS pressure to
prevent a sudden change of hydraulic pres-
sure.
q Bypass flow from LS bypass plug (5) causes a
pressure loss to be generated due to the circuit
resistance between throttle (c) of main spool
(2) and LS shuttle valve (4).
q Effective LS differential pressure drops to
improve a dynamic stability of the actuator.
WA450-6, WA480-6 (KA SPEC.) 51

ECSS control valve 1
Function
q The controller automatically turns on and off
the accumulator charged with high-pressure
gas according to the travel condition.
q The ECSS control valve gives elasticity to the
vertical movement of the work equipment and
reduces rocking of the machine body during
high-speed travel to improve the operator com-
fort and prevent spillage of material for higher
working efficiency.
52 WA450-6, WA480-6 (KA SPEC.)

Operation Accumulator pressure relief valve

q If the travel speed exceeds 5 km/h, the signal q If the pressure in accumulator (ACC) needs to
is sent to solenoid valve (2) and the pressure is be relieved, loosen plug (3) and nut (4) to open
applied to (a). circuits (PR) and (TS).
q Spool (1) moves to the left.
q As spool (1) moves, the line from (PR) to accu-
mulator (ACC) is closed and the lines from
(A2) to accumulator (ACC) and from (B2) to (T)
are opened. As a result, the ECSS is turned
ON.
q While the travel speed is below 4 km/h, the sig-
nal is not sent to solenoid valve (2) and spool
(1) is in neutral. At this time, the line from (PR)
to accumulator (ACC) is opened and accumu-
lator (ACC) is charged.
q If accumulator (ACC) is charged up to the set
pressure, check valve (5) is closed and the
pressure in accumulator (ACC) does not rise
any more.
WA450-6, WA480-6 (KA SPEC.) 53

Restriction on lift arm raise stroke 1
54 WA450-6, WA480-6 (KA SPEC.)

Function
q If the lift arm is raised and the bucket is oper-
ated simultaneously, the stroke of lift arm spool
(3) is restricted and more oil flows to the
bucket. As a result, the bucket tilting (dumping)
speed is increased.
Operation
1) Single operation
q When the lift arm is raised, the PPC pressure
is supplied to (PA2) and lift arm spool (3) and
piston (5) move to the left.
2) Compound operation
q When the lift arm is raised, if bucket dumping
operation (PB1) is carried out, (PA1) is con-
nected through the PPC valve to (T).
q Accordingly, ball (2) of check valve (1) is
pushed rightward, conducting pressure of
(PB1) to passage (a).
q The pressure of (PB1) conducted to passage
(a) pushes piston (5) right with the force of
pressure receiving area piston (5) [x/4 (φd2 –
φc2) × (PB1)].
q Accordingly, lift arm spool (3) is pushed right-
ward and then it balances at the stroke where
the force is set to the following value. [x/4φb2 ×
(PA2)] = [(x/4 (φd2 – φc2) × (PB1) + Spring (4)].
q As a result, the open area of notch (e) is
reduced and less oil is supplied to port (A2).
The excessive oil flows to (B1) and the dump-
ing speed is increased.
WA450-6, WA480-6 (KA SPEC.) 55

Accumulator charge valve 1
CR : Pressure pickup port

P : From main pump
PP : To the accumulator through ECSS spool
TS1 : To tank
TS2 : To tank
TS3 : To tank
1. Screw
2. Poppet (Safety valve)
3. Spring (Safety valve)
4. Spring (Main pressure reducing valve)
5. Pressure reducing valve spool
6. Poppet (Check valve)
7. Spring (Check valve)
56 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 57

1) When valve is in neutral and (P) is low
Function
q The discharge pressure of the hydraulic pump
is reduced and the oil is supplied to the ECSS
accumulator.
Operation
q Poppet (2) is pressed by spring (3) against the
seat and the line from port (P1) to port (T) is
closed.
q Poppet (6) is pressed to the left and the line
from port (P1) to port (PR) is closed.
q Poppet (6) is moved to the right by pressure
(P1) and the line from (P1) to (PR) is opened.
If (P1) < (PR), poppet (6) is pressed to the left
by spring (7) and the line from (P1) to (PR) is
closed.
58 WA450-6, WA480-6 (KA SPEC.)

2) When load pressure (P) is high
Operation
q If pressure (P) rises above the set pressure,
poppet (3) opens and the hydraulic oil flows
through port (P1), hole (a) in spool (5), opening
of poppet (2), and tank port (T).
q Accordingly, differential pressure is made
before and after hole (a) in spool (5) and spool
(5) moves to close the opening between ports
(P) and (P1). Pressure (P) is reduced to a cer-
tain pressure (the set pressure) by the open
area at this time and supplied as pressure
(P1).
WA450-6, WA480-6 (KA SPEC.) 59

SEN01170-00

60
SEN01172-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)

Hydraulic system, Part 2
Hydraulic system, Part 2 ................................................................................................................................. 2
PPC valve ............................................................................................................................................ 2
Accumulator (for PPC circuit)............................................................................................................... 8
Accumulator (for ECSS)....................................................................................................................... 9
WA450-6, WA480-6 (KA SPEC.) 1

Hydraulic system, Part 2 1

PPC valve 1
Work equipment PPC valve
P: From charge valve P3: To lift arm valve (Raise)

P1: To bucket valve (Tilt) P4: To bucket valve (Dump)
P2: To lift arm valve (Lower, float) T: To hydraulic tank
2 WA450-6, WA480-6 (KA SPEC.)

1. Spool
2. Metering spring
3. Centering spring
4. Rod
5. Lever
6. Ring
7. Plate
8. Piston
9. Retainer
10. Body
WA450-6, WA480-6 (KA SPEC.) 3

Operation
1. When in neutral
1) PPC valve for bucket 2) PPC valve for lift arm
q Ports (PA) and (PB) of the bucket control valve q Ports (PA) and (PB) of the lift arm control valve
and ports (P1) and (P4) of the PPC valve are and ports (P2) and (P3) of the PPC valve are
connected through fine control hole (f) of spool connected through fine control hole (f) of spool
(1) to drain chamber (D). (1) to drain chamber (D).
4 WA450-6, WA480-6 (KA SPEC.)

2. During fine control 3. During fine control

(Neutral o fine control) (When control lever is returned)
q If rod (4) and piston (8) are pushed by lever q If lever (5) begins to return, the force of center-
(5), retainer (9) is pushed and spool (1) is also ing spring (3) and the pressure in port (P1)
pushed downward through metering spring (2). push up spool (1).
q As fine control hole (f) is disconnected from q Because of this, fine control hole (f) is con-
drain chamber (D), it is connected to pump nected to drain chamber (D), and the pressur-
pressure chamber (PP) almost simultaneously, ized oil at port (P1) is released.
and then the pilot oil of the main pump flows q If the pressure at port (P1) goes down too far,
from port (P1) to port (PB). spool (1) is pushed down by metering spring
q If the pressure in port (P1) rises, spool (1) is (2). Fine control hole (f) is shut off from drain
pushed back and fine control hole (f) is discon- chamber (D), and almost simultaneously, it is
nected from pump pressure chamber (PP) and connected to pump pressure chamber (PP).
connected to drain chamber (D) almost simul- Pump pressure is supplied until the pressure at
taneously to release the pressure in port (P1). port (P1) recovers to a pressure equivalent to
q As a result, spool (1) moves up and down to the position of the lever.
balance the force of metering spring (2) with q When the control valve spool returns, the oil in
the pressure in port (P1). The positional rela- drain chamber (D) flows in through fine control
tionship between spool (1) and body (10) hole (f') of the valve which is not in operation
(where fine control hole (f) is between drain and then flows through port (P4) into chamber
chamber (D) and pump pressure chamber (PA).
(PP)) does not change until retainer (9) comes
in contact with spool (1).
q Since metering spring (2) is compressed in
proportion to the stroke of the control lever, the
pressure in port (P1) also rises in proportion to
the stroke of the control lever.
q The control valve spool moves to a position
where the pressure in chamber (PB) (equal to
the pressure in port (P1)) is balanced with the
force of the control valve spool return spring.
WA450-6, WA480-6 (KA SPEC.) 5

4. At full stroke 5. When lift arm is “float”
q If lever (5) and rod (4) push down piston (8) q If rod (4) and piston (8) on the “Lower” side of
and retainer (9) pushes down spool (1), fine port (P3) are pushed down with lever (5), the
control hole (f) is disconnected from drain detent starts operation before the stroke end
chamber (D) and connected to pump pressure (the operating effort of the lever becomes
chamber (PP). heavy).
q The pilot oil from the main pump flows through q If rod (4) is pushed down further, the detent
fine control hole (f) and port (P1) into chamber operates to keep the lift arm in “float” state
(PB) to push the control valve spool. even if the lever is released.
q The oil returning from chamber (PA) flows q At the same time, the control valve is also
through port (P4) and fine control hole (f') into moved to the “Float” position to keep the lift
drain chamber (D). arm in float condition.
6 WA450-6, WA480-6 (KA SPEC.)

6. When “float” state of lift arm is reset

q Lever (5) is returned from the “float” position by
pushing it down with a force larger than the
attractive force of the solenoid.
q The “float” state also can be reset and the
lever can be returned to the “neutral” position
by turning off the current in the solenoid (de-
energizing the solenoid).
q The lift arm raise and bucket tilt operations are

carried out similarly to the above.
WA450-6, WA480-6 (KA SPEC.) 7

Accumulator (for PPC circuit) 1

1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port
Outline
q The accumulator is installed between the
charge valve and work equipment PPC valve.
Even if the engine stops with the work equip-
ment raised, the pressure of the compressed
nitrogen gas in the accumulator applies the
pilot oil pressure to the work equipment control
valve so that the work equipment will lower by
its weight.
Specifications
Amount of gas: 500 cc
Charged gas pressure: 1.18 MPa {12 kg/cm2} (at 80°C)
Max. pressure used: 3.92 MPa {40 kg/cm2}
8 WA450-6, WA480-6 (KA SPEC.)

Accumulator (for ECSS) 1

1. Valve
2. Top cover
3. Cylinder
4. Free piston
Function
q The accumulator is installed to the lift cylinder
bottom circuit. The space between cylinder (3)
and free piston (4) is filled with nitrogen gas.
The nitrogen gas absorbs the oil pressure
pulses generated on the lift cylinder bottom
side during travel for higher travel performance
and operating performance by utilizing its com-
pressibility.
Specifications
Amount of gas: 4,000 cc
Charged gas pressure: 2.94 MPa {30 kg/cm2} (at 20°C)
Max. operating pressure: 40 MPa {408 kg/cm2}
WA450-6, WA480-6 (KA SPEC.) 9

SEN01172-00

10
SEN01173-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)

Work equipment
Work equipment .............................................................................................................................................. 2
Work equipment linkage....................................................................................................................... 2
Bucket .................................................................................................................................................. 5
Bucket positioner and boom kick-out ................................................................................................... 6
Work equipment cylinder.................................................................................................................... 12
WA450-6, WA480-6 (KA SPEC.) 1

Work equipment 1
Work equipment linkage 1
2 WA450-6, WA480-6 (KA SPEC.)

1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
WA450-6
Unit: mm

Clearance between bushing and pin size Shaft Hole clearance limit
7
at each end of bucket link
–0.036 +0.207 0.156 –
95 1.0
–0.090 +0.120 0.297
Clearance between bushing and pin –0.036 +0.207 0.156 –
8 95 1.0
connecting lift arm and bucket –0.090 +0.120 0.297
9 110 1.0
connecting lift arm and frame –0.090 +0.120 0.297
Clearance between bushing and pin con- –0.036 +0.207 0.156 – Replace (Replace
10 necting bucket cylinder bottom and frame
120 1.0
–0.090 +0.120 0.297 pin when it has
Clearance between bushing and pin con- scuff marks, too.)
–0.036 +0.207 0.156 –
11 necting bucket cylinder rod and bell 120 1.0
crank –0.090 +0.120 0.297

12 125 1.0
connecting bell crank and lift arm –0.106 +0.145 0.351
Clearance between bushing and pin con- –0.036 +0.207 0.156 –
13 necting lift cylinder rod and lift arm
110 1.0
–0.090 +0.120 0.297
Clearance between bushing and pin
–0.036 +0.207 0.156 –
14 connecting lift cylinder bottom and 110 1.0
–0.090 +0.120 0.297
frame
Standard
Standard Standard clearance
Connecting part of bucket cylinder Tolerance Tolerance
15 size size
and frame
–0.5
125 128 ±0.8 2.2 – 4.3
–0.5 Adjust shim so
Connecting part of lift arm and +2.5 that clearance
16 127 ±2.3 130 0.7 – 7.8
frame +0.5 may be set to 1.5
Connecting part of lift arm and +1.5 mm or smaller on
17 119 ±2.3 122 0.7 – 6.8 each side
bucket +0.5
Connecting part of bucket link and +3.5 +1.5
18 138 143 2–7
bucket –0.5 +0.5
Connecting part of lift cylinder and –0.5 +2.5
19 110 115 5–8
frame –0.5 +0.5
Connecting part of bell crank and +3.5
20 138 143 ±1.5 0.5 – 7
bucket link –0.5
Replace
Connecting part of bell crank and lift
21 220 ±0.5 223 ±0.5 2–4
arm
Connecting part of bucket cylinder –0.5 Adjust shim so
22 115 118 ±1.5 1.5 – 5.0
and bell crank –0.5 that clearance
may be set to 1.5
Connecting part of lift arm and lift mm or smaller on
23 109 ±2.3 114 ±1.5 1.2 – 8.8
cylinder each side
WA450-6, WA480-6 (KA SPEC.) 3

WA480-6
Unit: mm

Clearance between bushing and pin size Shaft Hole clearance limit
7
at each end of bucket link
–0.036 +0.307 0.256 –
110 1.0
–0.090 +0.220 0.397
8 110 1.0
connecting lift arm and bucket –0.090 +0.220 0.397
9 110 1.0
connecting lift arm and frame –0.090 +0.120 0.297
Clearance between bushing and pin con- –0.036 +0.307 0.256 – Replace (Replace
10 necting bucket cylinder bottom and frame
120 1.0
–0.090 +0.220 0.397 pin when it has
Clearance between bushing and pin con- scuff marks, too.)
–0.036 +0.307 0.256 –
11 necting bucket cylinder rod and bell 120 1.0
crank –0.090 +0.220 0.397

12 125 1.0
connecting bell crank and lift arm –0.106 +0.145 0.351
Clearance between bushing and pin con- –0.036 +0.207 0.156 –
13 necting lift cylinder rod and lift arm
110 1.0
–0.090 +0.120 0.297
Clearance between bushing and pin
–0.036 +0.207 0.156 –
14 connecting lift cylinder bottom and 110 1.0
–0.090 +0.120 0.297
frame
Standard
Standard Standard clearance
Connecting part of bucket cylinder Tolerance Tolerance
15 size size
and frame
–0.5
140 143 ±0.8 2.2 – 4.3
–0.5 Adjust shim so
Connecting part of lift arm and +2.5 that clearance
16 127 ±2.3 130 0.7 – 7.8
frame +0.5 may be set to 1.5
mm or smaller on
Connecting part of lift arm and +1.5
17 140 ±2.3 143 0.7 – 6.8 each side
bucket +0.5
Connecting part of bucket link and +3.5 +1.5
18 140 143 0–5
bucket –0.5 +0.5
Connecting part of lift cylinder and –0.5 +2.5
19 110 115 5–8
frame –0.5 +0.5
Connecting part of bell crank and +3.5 +1.5
20 140 143 0–5
bucket link –0.5 +0.5
Replace
Connecting part of bell crank and lift
21 245 ±0.5 248 ±0.5 2–4
arm
Connecting part of bucket cylinder –0.5 Adjust shim so
22 140 143 ±1.5 1.5 – 5.0
and bell crank –0.5 that clearance
may be set to 1.5
Connecting part of lift arm and lift mm or smaller on
23 109 ±2.3 114 ±1.5 1.2 – 8.8
cylinder each side
4 WA450-6, WA480-6 (KA SPEC.)

Bucket 1
1. Bucket
2. Wear plate
3. Bolt-on cutting edge (BOC)
4. Bucket teeth (if equipped)
Unit: mm
5 Wear of bucket tooth Replace
50 18.5
Clearance in bucket teeth mounting
6 Max. 0.5 — Adjust or replace
parts
7 Wear of cutting edge 93 — Reverse or replace
WA450-6, WA480-6 (KA SPEC.) 5

Bucket positioner and boom kick-out 1
1. Proximity switch
2. Bucket cylinder
3. Angle
4. Lift arm
5. Plate
Unit: mm
Clearance between bucket posi-
6 3–5
tioner proximity switch and angle
Adjust
Clearance between boom kick-out
7 3–5
proximity switch and plate
6 WA450-6, WA480-6 (KA SPEC.)

Bucket positioner Boom kick-out
q The bucket positioner is driven electrically. q The boom kick-out is driven electrically. As the
When the bucket is returned to an angle from lift arm is raised to a specific angle before
the dump position toward the tilt position, the reaching the maximum height, the boom kick-
bucket positioner returns the bucket control out returns the lift arm control lever from the
lever from the “tilt” position to the “hold” posi- “raise” position to the “hold” position to stop the
tion to automatically stop the bucket at a lift arm automatically at a desired height.
proper digging angle. q Plate (5) is fixed to lift arm (4). And proximity
q Angle (3) is fixed to the rod side of bucket cyl- switch (1) is fixed to the front frame.
inder (2). And proximity switch (1) is fixed to q Moving the lift arm control lever from “lower”
the cylinder side. position to “raise” position moves lift arm (4)
q Moving the bucket control lever from “dump” upward.
position to “tilt” position moves the rod of
bucket cylinder (2) toward the machine front As plate (5) comes to a specific position, prox-
side. imity switch (1) detects that it is in the sensing
face, and returns the lift arm control lever to
As angle (3) moves a specific distance, prox- “hold” position.
imity switch (1) detects that it is away from the
sensing face, and returns the bucket control
lever to “hold” position.
WA450-6, WA480-6 (KA SPEC.) 7

Operation of proximity switch
When bucket is tilted
q While the bucket is dumping more than the q Shifting bucket control lever (7) toward the tilt
position being set from the bucket positioner, position moves spool (8) to the position of the
angle (2) moves on to the sensing face of prox- arrow. And spool is held there by the energized
imity switch (1), turning on the proximity switch coil of detent solenoid (6). As a result, bucket
lamp. control lever (7) is held at the tilt position and
At this point, bucket positioner relay (4) is ener- the bucket tilts.
gized and current flows to detent solenoid (6)
of work equipment PPC valve (5) to energize
the coil.
8 WA450-6, WA480-6 (KA SPEC.)

a The power supply for detent solenoid (6) oper-

ation is turned “ON” or “OFF” by alternator
relay (11).
Detent solenoid (6) circuit is cut off since L sig-
nal from alternator (10) is not sent to alternator
relay (11) as long as the engine is stopped.
As the result, bucket control lever (7) cannot
be moved and held in the tilt position as long
as angle (2) is positioned in sensing face of
proximity switch (1).
Function of proximity switch
When object of sensing is over sensing face of

proximity switch
Lamp of proximity switch ON

Bucket positioner relay ON
Work equipment PPC valve detent
ON
solenoid circuit
Energized
solenoid
When object of sensing is apart from sensing

face of proximity switch
Lamp of proximity switch OFF

Bucket positioner relay OFF
OFF
solenoid circuit
De-energized
solenoid
q As the bucket is tilted and moved away from

the position set by the positioner – in other
words, as angle (2) moves away from the
sensing face of proximity switch (1), the lamp
of proximity switch (1) goes off and bucket
positioner relay (4) is turned off.
Accordingly, the circuit of detent solenoid (6) of
work equipment PPC valve (5) is turned OFF
to de-energize the coil. Held lift arm spool (8)
receives the reaction force of spring (9) and
returns bucket control lever (7) to the neutral
position.
WA450-6, WA480-6 (KA SPEC.) 9

When lift arm is raised
q While lift arm (3) is lower than the position q Shifting lift arm control lever (7) upward moves
being set from the boom kick-out, plate (2) is spool (8) to the position of the arrow. And spool
not on the sensing face and the lamp of prox- is held there by the energized coil of detent
imity switch (1) goes off. solenoid (6). As the result, lift arm control lever
At this point, boom kick-out relay (4) is turned (7) is held at the raise position and raising of lift
off and current is conducted to detent solenoid arm (3) is continued.
(6) of work equipment PPC valve (5) to ener-
gize the coil.
10 WA450-6, WA480-6 (KA SPEC.)

a The power supply for detent solenoid (6) oper-

ation is turned “ON” or “OFF” by alternator
relay (11).
Detent solenoid (6) circuit is turned off since L
signal from alternator (10) is not sent to alter-
nator relay (11) as long as the engine is
stopped.
As the result, lift arm control lever (7) cannot
be moved and held in the raise side as long as
plate (2) is not positioned in sensing face of
proximity switch (1).
Function of proximity switch
When object of sensing is apart from sensing

face of proximity switch
Lamp of proximity switch OFF

Boom kick-out relay OFF
PPC valve detent solenoid circuit ON
PPC valve detent solenoid Energized
When object of sensing is over sensing face of

proximity switch
Lamp of proximity switch ON

Boom kick-out relay ON
PPC valve detent solenoid circuit OFF
PPC valve detent solenoid De-energized
q As raised lift arm (3) comes to the set position

of the boom kick-out, or if plate (2) comes in
the sensing face of proximity switch (1), the
lamp of proximity switch (1) lights up and cur-
rent is conducted to boom kick-out relay (4).
Accordingly, the circuit of detent solenoid (6) of
work equipment PPC valve (5) is cut off, de-
energizing the coil. Held lift arm spool (8)
receives the reaction force of spring (9) and
returns lift arm control lever (7) to the neutral
position.
WA450-6, WA480-6 (KA SPEC.) 11

Work equipment cylinder 1

Lift cylinder
Bucket cylinder
Unit: mm
Cylinder Standard Tolerance Standard Clearance

name size Shaft Hole clearance limit
Clearance –0.036 +0.222 0.083 –

between piston Lift 95 0.612
–0.090 +0.047 0.312
1 Replace bushing
rod and bush-
–0.036 +0.257 0.083 –
ing WA450 100 0.647
–0.090 +0.047 0.347
Bucket
–0.036 +0.261 0.083 –
WA480 110 0.651
–0.090 +0.047 0.351
Tightening Lift 373 ± 54 Nm {38.0 ± 5.5 kgm}

2 torque of cylin- WA450 530 ± 78.5 Nm {54.0 ± 8.0 kgm}
der head Bucket
WA480 892 ± 137 Nm {91.0±14 kgm}
Tightening torque of Lift 294 ± 29.4 Nm {30 ± 3.0 kgm} Retighten

3
cylinder piston Bucket 294 ± 29.4 Nm {30 ± 3.0 kgm}
Tightening torque of Lift 58.9 – 73.6 Nm {6.0 – 7.5 kgm}
4 cylinder piston lock
screw Bucket 58.9 – 73.6 Nm {6.0 – 7.5 kgm}
12 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 13

SEN01173-00

14
SEN01176-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)

Cab and its attachments
Cab and its attachments ................................................................................................................................. 3
Cab....................................................................................................................................................... 3
Air conditioner ...................................................................................................................................... 4
WA450-6, WA480-6 (KA SPEC.) 1

2 WA450-6, WA480-6 (KA SPEC.)

Cab and its attachments 1

Cab 1
1. Front working lamp

2. Door (left)
3. Air conditioner external air filter
4. Front glass
5. Front wiper
6. KOMTRAX communication antenna
7. KOMTRAX GPS antenna
8. Radio antenna
9. Door (right)
10. Rear wiper
WA450-6, WA480-6 (KA SPEC.) 3

Air conditioner 1
Air conditioner piping diagram
4 WA450-6, WA480-6 (KA SPEC.)

1. Hot water take-out piping Specifications

2. Power train oil cooler
Refrigerant used R134a
3. Condenser
4. Receiver Refrigerant refilling volume (g) 1,100
5. Hot water return piping
6. Compressor
7. Refrigerant piping
8. External air filter
9. Internal/external air changeover damper
10. Blower unit
11. Air conditioner unit
12. Dual pressure switch
13. Air outlet duct
14. Cool and hot box
15. Internal air filter
16. Solar radiation sensor (machine equipped
with automatic air conditioner)
WA450-6, WA480-6 (KA SPEC.) 5

Refrigerant circuit diagram
1. Engine
2. Compressor
3. Condenser
4. Receiver
5. Air conditioner unit
6. Dual pressure switch
Table of tightening torque for refrigerant piping adapter

Unit: Nm {kgm}
Air conditioner unit refrigerant inlet 12 – 15 {1.2 – 1.5}
7
side (Screw size: M16 × 1.5)
Air conditioner unit refrigerant outlet 30 – 35 {3.1 – 3.6}
8
side (Screw size: M24 × 1.5)
8 – 12 {0.8 – 1.2}
9 Receiver refrigerant piping set bolt
(Screw size: M16 × 1.0)
Retighten
Compressor refrigerant piping lock 20 – 25 {2.0 – 2.6}
10
bolt (Screw size: M8 × 1.25)
12 – 15 {1.2 – 1.5}
11 Condenser refrigerant inlet side
20 – 25 {2.1 – 2.6}
12 Condenser refrigerant outlet side
6 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 7

Air conditioner unit
8 WA450-6, WA480-6 (KA SPEC.)

A: From receiver Outline

B: To compressor q The vertical air conditioner unit on which evap-
C: Hot water inlet orator (1) and heater core (2) is synchronized
D: Hot water outlet with the blower and intake unit to generate cool
and hot air.
1. Evaporator q The temperature adjusting switch on the air
2. Heater core conditioner panel controls air mix dampers (3)
3. Air mix damper (upper) and (4) to adjust the spurting out temperature.
4. Air mix damper (lower)
5. Expansion valve Cooler
6. Blower controller q The cooler circulates refrigerant through evap-
7. Blower motor relay orator (1) to cause heat exchange (dehumidifi-
8. Compressor clutch relay cation and cooling).
9. Air mix damper actuator q Air taken in by the blower and intake unit is
10. Evaporator temperature sensor cooled with evaporator (1) and then blown out
11. Dual pressure switch from the grille through the duct.
12. Mode selector damper actuator
(machine equipped with automatic air condi- Heater
tioner)
q The heater circulates engine coolant in heater
13. Mode selector damper (machine equipped
core (2) to cause heat exchange (heating).
with automatic air conditioner)
q Air taken in by the blower and intake unit is
heated with heater core (2) and then blown out
from the grille through the duct.
WA450-6, WA480-6 (KA SPEC.) 9

Functions of major components

Evaporator Mode selector damper actuator (Machine
q Evaporator fin is cooled by the low-pressure, equipped with automatic air conditioner)
low-temperature refrigerant gas being sent q Receiving signal current from the air condi-
from the expansion valve. Air from the blower tioner panel, the actuator starts the built-in
motor is cooled and dehumidified when pass- motor to open or close the mode selector
ing through the fin. damper through the link mechanism.
q The motor rotation direction is determined from the
Heater core mode selector switch on the air conditioner panel.
q Fin of the heater core is heated by the hot q Rotation of the motor is stopped as the con-
water (cooling water) being sent from the tact, which is to move interlocked with the
engine. Air from the blower motor is heated as motor, moves away or signal current from the
it passes through the fin. air conditioner panel is turned “OFF”.
Expansion valve Evaporator temperature sensor

q This valve converts high-pressure, high-tem- q In order to prevent freezing of the evaporator, it
perature liquid refrigerant from the receiver to senses the evaporator temperature and sends
low-pressure, low-temperature misty refriger- necessary signals to the air conditioner panel.
ant through the throttling function. The signal sent to the air conditioner panel is
It controls flow rate of refrigerant by changing used to control the compressor. As the result,
level of throttling depending on the thermal temperature of the air blown out of the grille is
load in the operator's cab. adjusted depending on the volume of refriger-
ant circulated in the evaporator.
Blower controller
q It controls the blower motor speed receiving Dual pressure switch
signal current from the air conditioner panel. q If abnormally low or high pressure was gener-
ated in the refrigerant circulation circuit, this
Blower motor relay switch releases the magnet clutch of the com-
q Signal current from the air conditioner panel pressor to protect a series of cooler-related
controls the relay coil. As the relay coil is ener- equipment.
gized and the switch is turned “ON”, power is
supplied to the blower motor.
Compressor clutch relay

q Signal current from the air conditioner panel by
dual pressure switch is used for controlling the
relay coil. As the relay coil is energized and the
switch is turned “ON”, the magnet clutch of the
compressor is connected.
Air mix damper actuator

q It starts the built-in motor receiving signal cur-
rent from the air conditioner panel in order to
LA: 0.20 MPa {2 kg/cm2}
open or close the air mix damper through the
LB: 0.02 MPa {0.2 kg/cm2}
link mechanism.
HA: 3.14 MPa {32 kg/cm2}
q The motor rotating direction is determined as
HB: 0.59 MPa {6 kg/cm2}
the air conditioner panel reads the position of
the potentiometer being built in the actuator.
Solar radiation sensor
This reading is done as the target temperature
is set from the temperature adjustment switch (Machine equipped with automatic air conditioner)
on the air conditioner panel. q The solar radiation sensor is installed in the
q Rotation of the motor is stopped as the con- upper left side corner of the dashboard.
tact, which is to move interlocked with the q Sensing intensity of sunlight, this sensor sends
motor, moves away or signal current from the the corresponding signal to the air conditioner
air conditioner panel is turned “OFF”. panel. The signal sent to the air conditioner
panel is used to control the blower motor and
compressor.
10 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 11

Blower and intake unit 1
12 WA450-6, WA480-6 (KA SPEC.)

1. Blower motor assembly Functions of major components

2. Internal/external air changeover damper actu- Blower motor assembly
ator q It suctions air by rotating the fin installed on the
3. Internal/external air changeover damper blower motor. And it is also used for sending
4. Internal air temperature sensor (machine the absorbed air to the evaporator and heater
equipped with automatic air conditioner) core.
5. External air temperature sensor (machine
equipped with automatic air conditioner) Internal/external air changeover damper actua-
tor
q Receiving signal current from the air condi-
tioner panel, it starts the built-in motor to open
or close the internal/external air changeover
damper through the link mechanism.
q The motor rotation direction is determined from
the internal/external air changeover switch on
the air conditioner panel.
q Rotation of the motor is stopped as the con-
tact, which is to move interlocked with the
motor, moves away or signal current from the
air conditioner panel is turned “OFF”.
Internal air temperature sensor

External air temperature sensor
(Machine equipped with automatic air condi-
tioner)
q Sensing internal and external air temperature,
the sensors send the corresponding signal to
the air conditioner panel. The signal sent to the
air conditioner panel is used to control the
compressor. As the result, temperature of the
air blown out of the grille is adjusted depending
on the volume of refrigerant circulated in the
evaporator.
WA450-6, WA480-6 (KA SPEC.) 13

Compressor 1
A: From air conditioner unit Function

B: To condenser q Other than circulating the refrigerant, it com-
presses the refrigerant gas from the evapora-
tor to high-pressure, high-temperature misty
refrigerant so that it may be easily regenerated
(liquefied) at normal temperature.
q Its built-in magnet clutch turns on or off
depending on the evaporator temperature and
refrigerant pressure.
Specifications
Number of cylinders – Bore ×
7 – 29.3 × 27.4
Stroke (mm)
Piston capacity (cc/rev) 129.2
Allowable maximum speed
4,000
(rpm)
Refrigerant oil used Sanden: SP-10
Refrigerant oil refilling volume
135
(cc)
14 WA450-6, WA480-6 (KA SPEC.)

Condenser 1
A: From compressor Function

B: To receiver q It cools and liquefies the high-pressure and
high-temperature misty refrigerant from the
compressor.
a If the fin crushes or is clogged with dusts, heat

exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavail-
able. As the result, pressure in the refrigerant
circulation circuit will be increased, applying
extra load to the engine or degrading the cool-
ing effect. Thus, care must be used in its han-
dling and daily inspection.
Specifications
Fin pitch (mm) 1.5
Total heat dissipation surface
9.33
(m2)
Max. pressure used
3.6 {36}
(MPa {kg/cm2})
WA450-6, WA480-6 (KA SPEC.) 15

Receiver
A: From condenser Function

B: To air conditioner unit q It is used to store liquefied high-pressure, high-
temperature misty refrigerant from the con-
1. Sight glass denser. It is capable of completely liquefying
the refrigerant even when bubbles are con-
tained in the refrigerant due to the condenser
condition in heat dissipation.
q It eliminates foreign substances in the circula-
tion circuit and water content in the refrigerant
by use of the built-in filter and desiccating
agent.
q Sight glass (1) allows inspecting flow of the
refrigerant.
Specifications
Effective cubic capacity (cm3) 578
Weight of desiccating agent (g) 300
16 WA450-6, WA480-6 (KA SPEC.)

Air conditioner panel

Manual air conditioner specification
Display unit
Display Displayed Display Display
No. Display method Remarks
category items range color
Spurting out See above All segments below applicable level come
1
temperature drawing on (8-step display)
Gauges
Air blasting vol- See above All segments below applicable level come
2
ume drawing on (4-step display)
The display indicates which is currently tak-
Circulation of When circulating Liquid
ing place – internal air circulation or exter- Black
internal air and internal air and crystal
3 nal air introduction – responding to the
introduction of introducing
operation of the internal/external air
Pilot external air external air
changeover switch.
When air condi-
Turns “ON” air conditioner switch, this lamp
4 Air conditioner tioner switch is
lights up.
turned “ON”
Switch block
No. Type Function Operation
It is used for selecting the internal air circulation or external air Internal air circulation
Internal/external air introduction IO
5
changeover switch (The pilot indication on the display unit varies depending on the External air introduc-
given setting.) tion
It turns on or off the cooling and the dehumidifying heating func-
6 Air conditioner switch OFF i o ON
tion.
This switch turns on or off the main power of the air conditioner.
ON: Display unit indicates the setting being specified when
7 Main power switch OFF i o ON
power was turned “OFF”.
OFF: Turns off the display unit and stops the fan.
It controls volume of air sent from the fan.
8 Fan switch LO i o HI
(Adjusted in 4 steps [LO, M1, M2, HI])
Low temperature
Temperature adjusting It is used to control spurting out temperature.
9 IO
switch (8-step adjustment)
High temperature
WA450-6, WA480-6 (KA SPEC.) 17

Automatic air conditioner specification
Display unit
Display Displayed Display Display
No. Display method Remarks
category items range color
Spurting out
Indicator panel temperature Displays the spurting out temperature.
(Spurting out (0 – 99.9°C)
1 Indicator
temperature, If an actuator or sensor fails, 3-digit failure
failure code) [*1]
alphanumeric character (failure code) are
Failure code
displayed.
All segments below applicable level come
Air blasting vol- See above fig-
2 Gauge on
ume ure
(4-step display)
The display indicates which is currently tak-
Circulation of When circulating
ing place-internal air circulation or external
internal air and internal air and
3 air introduction-responding to the operation
introduction of introducing
of the internal/external air changeover
external air external air Liquid
switch. Black
crystal
When air condi-
Turns “ON” air conditioner switch, this lamp
4 Air conditioner tioner switch is
lights up.
turned “ON”
When auto-
Pilot
(Automatic air matic air condi- This lamp lights up as the automatic air
5
conditioner) tioner switch is conditioner switch is turned “ON”.
turned “ON”
When defroster
Spurting from The lamp lights up as the defroster switch is
6 switch is turned
defroster turned “ON”.
“ON”
When FACE or The display switches between FACE spurt-
7 Mode selection FOOT spurting ing and FOOT spurting responding to the
is turned on mode selector switch operation.
*1: For details of the failure code, see Testing and adjusting.
18 WA450-6, WA480-6 (KA SPEC.)

Switch block
No. Name Function Operation
It is used for selecting the internal air circulation or external air Internal air circulation
Internal/external air introduction IO
8
changeover switch (The pilot indication on the display unit varies depending on the External air introduc-
given setting.) tion
It turns on or off the cooling and the dehumidifying heating func-
9 Air conditioner switch OFF i o ON
tion.
It turns on or off main power supply of the air conditioner. ON:
10 Main power switch Settings done during “OFF” are indicated on the display unit. OFF i o ON
OFF: Turns off the display unit lamp and stops the fan.
It controls volume of air sent from the fan.
11 Fan switch LO i o HI
(Adjusted in 4 steps [LO, M1, M2 and HI])
Low temperature
Temperature adjusting It is used to control spurting out temperature.
12 IO
switch (0 – 99.9°C)
High temperature
Automatic air conditioner It turns on or off the cooling and the dehumidifying heating func-
13 OFF i o ON
switch tion.
It switches the spurting out mode between the FACE and FOOT
14 Mode selector switch (The pilot indication on the display unit varies depending on the FACE i o FOOT
given setting.)
15 Defroster switch It turns on or off spurting out from the defroster. OFF i o ON
WA450-6, WA480-6 (KA SPEC.) 19

Outline
q CPU (central processing unit) installed on the
panel processes input signals from respective
sensors and operation signals of the panel
switches to display and output them.
q The self-diagnosis function of CPU makes the
troubleshooting easier.
Input and output signals

JAE IL-AG5-14P [CN-C48] JAE IL-AG5-22P [CN-C47]
Input and Input and
Pin Pin
Signal name output Signal name output
No. No.
signals signals
1 GND — 1 NC —
2 Sensor ground — 2 NC —
Internal/external air changeover damper 3 Blower motor relay Input
3 Input
actuator limiter Internal/external air changeover damper
4 Output
4 External air temperature sensor Input actuator output 1
5 Evaporator temperature sensor Input Internal/external air changeover damper
5 Output
actuator output 2
6 Internal air temperature sensor Input
6 Mode selector actuator output 2 Output
7 Starting switch (ON) Input
7 Mode selector actuator output 1 Output
8 Night lamp signal Input
8 Air mix damper actuator output 2 Output
9 NC —
9 Air mix damper actuator output 1 Output
10 NC —
Actuator potentiometer power supply (5
11 NC — 10 —
V)
12 NC —
11 NC —
13 Day light sensor 2 Input
12 NC —
14 Day light sensor 1 Output
13 NC —
14 NC —
15 Magnet clutch Input
16 Air mix damper actuator limiter Input
17 Mode selector actuator limiter Input
18 Air mix damper actuator potentiometer Input
19 Mode selector actuator potentiometer Input
20 Blower gate Input
21 Blower feedback Input
22 Actuator potentiometer ground —
20 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 21

SEN01176-00

22
SEN01178-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)

Electrical system, Part 1
Electrical system, Part 1 ................................................................................................................................. 2
Machine monitor system ...................................................................................................................... 2
Machine monitor................................................................................................................................... 7
WA450-6, WA480-6 (KA SPEC.) 1

Electrical system, Part 1 1

Machine monitor system 1
Outline
q In the machine monitor system, each controller 4. In addition to the above, the following display,
on the network monitors and controls the setting and adjustment functions are provided
machine condition with the sensors installed to using the character display and the machine
various parts of the machine, and then sends monitor mode selector switch, which is the
the result as network information to the operation switch of the character display.
machine monitor, which displays the informa- 1) Display the odometer
tion to notify the operator of the machine condi- 2) Reset the filter or oil replacement time
tion. 3) Input the telephone number
4) Select the language
q The machine monitor displays the information 5) Adjust the brightness of the night lighting
in the operator mode or service mode. for the machine monitor
6) Travel speed/engine speed display select-
q The operator mode is used to display the infor- ing function
mation to the operator normally. The major 7) Function for setting display/no-display of
functions used in the operator mode are as fol- travel speed or engine speed to the char-
lows. acter display
1. Items always displayed

q Meters (Speedometer or engine tachometer)
q Gauges (Engine coolant temperature
gauge, torque converter oil temperature
gauge, hydraulic oil temperature gauge,
and fuel level gauge)
q Pilot indicators
q Service meter
The following items are displayed according to
the set state of the optional device selecting
function.
q Travel speed or engine speed indication
on the character display
2. Items displayed when abnormality is detected

q Caution lamps
q Action code (While an action code is dis-
played, if the monitor panel mode selector
switch (>) is pressed and released, the
failure code (6 digits) is displayed.))
3. At the replacement period of a filter or oil, the

character display displays that filter or oil.
(Maintenance monitoring function)
2 WA450-6, WA480-6 (KA SPEC.)

q The service mode function is provided for the 10. Machine serial number input function
ease of troubleshooting for the controllers on Enters the machine serial number to identify
the network (including the machine monitor the machine.
itself). The major functions used in the service
mode are as follows. 11. Model selection function
Enter the information of applicable model.
1. Electrical system failure history display function
The electrical system failures of each controller 12. Initialize function
saved in the machine monitor are displayed. This function is used to set the machine moni-
The information of those failures is also tor to the state set when the machine is deliv-
deleted with this function. ered.
2. Mechanical system failure history display function

The mechanical system failures of each con-
troller saved in the machine monitor are dis-
played.
3. Real-time monitoring function

The input and output signals recognized by
each controller on the network are displayed in
real time.
4. Engine reduced-cylinder function

This function is used for the purpose of speci-
fying cylinder having defective combustion by
stopping fuel injection to each cylinder from the
fuel injector.
5. No injection cranking function

Before restarting engine after a long-term stor-
ing of the machine, this function is used to
lubricate the engine internally.
6. Adjustment function
Functions are provided to correct and adjust
the installation errors and manufacturing dis-
persion of the sensors, solenoid valves, etc.
Function for changing control characteristics is
provided on user request.
7. Maintenance monitoring function

Changes the filter or oil replacement time and
makes ON-OFF selection of the function.
8. Operating information display function

Displays fuel consumption per operating hour.
9. Function of selecting optional device

Verifies the installation of optional devices or
changes their setting.
WA450-6, WA480-6 (KA SPEC.) 3

System circuit diagram

a Items marked with *1 in drawing may or may not installed.
4 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 5

6 WA450-6, WA480-6 (KA SPEC.)

Machine monitor 1
1. Torque converter oil temperature gauge 23. Cooling fan reverse rotation pilot lamp
2. Torque converter oil temperature caution lamp 24. Maintenance caution lamp
3. Engine coolant temperature gauge 25. Battery electrolyte level caution lamp (*2)
4. Engine coolant temperature caution lamp 26. Battery charge circuit caution lamp
5. Speedometer or engine tachometer 27. Steering pump oil pressure caution lamp (*2)
6. Turn signal pilot lamp (Left) 28. Emergency steering
7. Headlamp high beam pilot lamp pilot lamp (*2)
8. Turn signal pilot lamp (Right) 29. Meter display pilot lamp
9. Hydraulic oil temperature caution lamp 30. Character display
10. Hydraulic oil temperature gauge 31. Power mode pilot lamp
11. Fuel level caution lamp 32. Semi auto digging pilot lamp (*1)
12. Fuel gauge 33. Preheater pilot lamp
13. Centralized warning lamp 34. Auto grease pilot lamp (*1)
14. Brake oil pressure caution lamp 35. Joystick pilot lamp (*2)
15. Engine oil pressure caution lamp 36. Directional selector pilot lamp (*1)
16. Water separator caution lamp (*1) 37. Economy operation pilot lamp
17. Engine oil level caution lamp 38. Shift indicator
18. Radiator coolant level caution lamp 39. Auto-shift pilot lamp
19. Transmission oil filter clogging caution lamp (*1) 40. Torque converter lockup
20. Air cleaner clogging caution lamp pilot lamp (*2)
(machine equipped with KOMTRAX) 41. Shift hold pilot lamp
21. Parking brake pilot lamp 42. Shift lever position pilot lamp
22. Brake oil temperature caution lamp
*1: Not used by this model

*2: (if equipped)
WA450-6, WA480-6 (KA SPEC.) 7

List of items displayed on monitor

Condition for judging that engine is running:
When either one or both of following items 1 and 2 is or are sensed, the machine monitor judges that the
engine is running.
1. The engine speed is above 500 rpm.
2. There is alternator voltage (R) and there is terminal (C) input after the starting switch is turned “ON”.
Q: ON
w: Flashing (1.6 sec., 50% duty)
A: Intermittent (Period: 240 msec., “ON”: 80 msec., “OFF”: 160 msec.)
E: As per separate setting condition
Priority of sounding of buzzer: Flashing (w) > Intermittent (A) > Cancellation of operation> Check of accep-
tance of operation.
Detect- Operating condition

ing time
(sec) Engine stopped Engine is running
Central warning lamp

Display of message
Display of message
Individual display
Individual display
Category No. Check item Device Operating condition Remarks
Alarm buzzer
Alarm buzzer
Display color
Detection
Reset
Turned ON with errors (E03 and

E02) of each controller, simulta-
When error is made E E E E E E E E
Central neously displaying the message
Central warn- on the character display.
Red
warning 13 LED
ing
lamp For other than above, see
“Operating condition, central — — — — — —
warning lamp” of other items.
White
When lamp switch is other
Back light — Back light LED — — — — — —
than “OFF”
Other than below — — — — — — White range: 50 – 120°C

Red range: 120 – 135°C
Pointer: Alarm: Min. 120°C 10 1 — Q — — Q — When the sensor is grounded:
1 Torque con- Movement Max.
Red
verter oil tem- Alarm: Min. 130°C 10 1 w Q Q B@CENS w Q Q B@CENS When the sensor is discon-
2 perature Caution nected or hot short-circuited: Min.
lamps: LED
When abnormality is detected
20 5 — — — DGT1KX — — — DGT1KX
(out of input signal range)
Other than below — — — — — —
Alarm: Min. 102°C 3 0 — Q — — Q — White range: 50 – 102°C
Pointer:
3 Engine cool- Movement Alarm: Min. 105°C w Q Q B@BCNS w Q Q B@BCNS
When the sensor is grounded:
Red
ant tempera-
When abnormality is detected Max.
4 ture Caution — — — CA144 — — — CA144 When the sensor is discon-
lamps: LED (high temperature)
nected or hot short-circuited: Min.
— — — CA145 — — — CA145
Gauges (low temperature)
and When engine speed display is
meters Engine Speed — — — — — — (Selectable with the machine
Pointer: selected monitor setting)
5 —
Movement When travel speed display is Displays “0” when error is made
Travel speed — — — — — — in communication.
selected
Other than below — — — — — — White range: 50 – 100°C

Pointer:
9 Movement Alarm: Min. 100°C 10 1 w Q Q B@HANS w Q Q B@HANS
Hydraulic oil When the sensor is grounded:
Red
temperature Max
10 Caution When abnormality is detected
20 5 — — — DGH2KX — — — DGH2KX When the sensor is discon-
lamps: LED (out of input signal range)
nected or hot short-circuited: Min
Max: 10 z
Other than below — — — — — — Min: 85 z
Pointer:
11 Movement
When the sensor is grounded:
Red
Fuel level
Full
12 Caution
When the sensor is discon-
lamps: LED Min. 80 z 10 1 — Q — — Q — nected or hot short-circuited:
Empty
Operates when charging nor-

Service meter — — — — — — Displays various codes and items
mally at 1 : 1 to the clock time
Black
Character
30 LCD according to the machine condi-
display Converts travel speed pulse
Odometer — — — — — — tion and switch operation.
into travel distance
8 WA450-6, WA480-6 (KA SPEC.)


ing time

Display of message
Display of message
Individual display
Individual display
Alarm buzzer
Alarm buzzer
Display color
Detection
Reset
x 100 r/min
Green
When engine speed display is
Engine Speed 0 0 — Q — — Q — (Selectable with the machine
selected
monitor setting)
Unit 29 LED
km/h or MPH
Green
When travel speed display is
Travel speed 0 0 — Q — — Q — (Selectable with the machine
selected
monitor setting)
In neutral, gear speed is not dis-

played.
Black
Actual gear 9-segment Left side: F, N, R
38 — — — — — — If error is made in communica-
speed LCD Right side: Gear speed
tion, condition is held until start-
ing switch is turned “OFF”.
When auto-shift is selected 0 0 — Q — — Q — If error is made in communica-
Green
39 Auto shift LED tion, condition is held until start-
Other than above — — — — — — ing switch is turned “OFF”.
Torque When lockup operates 0 0 — — — — Q — If error is made in communica-
Green
40 converter LED tion, condition is held until start-
lockup Other than above — — — — — — ing switch is turned “OFF”.
When auto shift or shift hold is If error is made in communica-

0 0 — Q — — Q —
Green
41 Shift hold LED selected tion, condition is held until start-
Other than above — — — — — — ing switch is turned “OFF”.
Items When F is selected
Green
related to F LED (When engine is stopped, neu- 1 0 A Q Q — Q —
gear shift- tral safety is displayed)
ing Directional
Orange
lever N LED When N is selected 0 0 — Q — — Q —
position
When R is selected
Green
R LED (When engine is stopped, neu- 1 0 A Q Q — Q —
tral safety is displayed)
If error is made in communica-
42 tion, condition is held until start-
Green Green Green Green

When 4th gear speed is
4 LED 0 0 — Q — — Q — ing switch is turned “OFF”.
selected
When 3rd gear speed is

3 LED 0 0 — Q — — Q —
Gear shift selected
lever
position When 2nd gear speed is
2 LED 0 0 — Q — — Q —
selected
When 1st gear speed is

1 LED 0 0 — Q — — Q —
selected
When turn signal lever and

Green
6 Hazard lamp operates when

Turn signal LED hazard lamp switch signal is 0 0 — Q — — Q —
8 starting switch is turned “OFF”
input
When the head lamp is set to
High beam of high beam
Blue
7 LED 0 0 — Q — — Q —
head lamp (When head lamp and dimmer
switch are turned “ON”)
Normal oil pressure

— — — — — —
(CLOSED)
Below set pressure (front)

(OPEN)
(Detect time continues) and 30 5 1 — Q — w Q Q 2G42ZG
seconds after starting engine
(No detection time)
Below set pressure (rear)

Other (OPEN)
symbols (Detect time continues) and 30 5 1 — Q — w Q Q 2G43ZG
Brake oil seconds after starting engine
Red
14 LED
pressure (No detection time)
Below set pressure (front)

(OPEN)
(Detect time continues) and 30 1 1 — Q — w Q Q
(No detection time)
Below set pressure (rear)

(OPEN)
(Detect time continues) and 30 1 1 — Q — w Q Q
(No detection time)
Normal oil pressure

Engine oil — — — — — —
(CLOSED)
Red
15 LED
pressure
Low oil pressure (OPEN) w Q Q B@BAZG w Q Q B@BAZG
WA450-6, WA480-6 (KA SPEC.) 9


ing time

Display of message
Display of message
Individual display
Individual display
Alarm buzzer
Alarm buzzer
Display color
Detection
Reset
If low level is detected when start-
Normal oil level (CLOSED) — — — — — — ing switch is turned “ON”, alarm is
continued even after engine is
Engine oil
Red
17 LED started until adequate oil level is
level
reached. Don't check the oil level
Low oil level (OPEN) 2 1 — Q — B@BAZK — — — for 300 sec, after stopping the
engine.
Normal coolant level

Radiator — — — — — —
(CLOSED)
Red
18 LED
coolant level
Low coolant level (OPEN) 30 1 — Q — B@BCZK — Q — B@BCZK
Air cleaner Normal (CLOSED) — — — — — —
Red
20 LED
clogging Clogging (OPEN) 2 1 — — — — Q — AA1ANX
Operation (OPEN) — Q — — Q —
Released (CLOSED) — — — — — —
Red
21 Parking brake LED
Engine is running, parking
brake is ON and the direc- 0 0 — — — A Q Q
tional lever is at other than “N”

Temperature rise (Oil temper-
ature: Min. 120°C) 5 5 — Q — — Q —
(alarm)
Temperature rise (1 or 2)
To be released if the oil tempera-
Brake oil 1. Oil temperature: Min. 130°C
Red
22 LED 5 5 w Q Q B@C7NS w Q Q B@C7NS ture is detected consecutively at
temperature 2. Oil temperature: Min.125°C
lower than 125°C for 5 sec.
and travel speed min. 35 km/h

Other — — — DGR2KA — — — DGR2KA
(disconnection)
symbols
— — — DGR2KX — — — DGR2KX
(out of input signal range)
Normal 0 0 — — — — — —
Cooling fan While fan is reversed, message
Orange
23 reverse LED Reverse 0 0 — Q — Remarks — Q — Remarks of “COOLING FAN REVERSE” is

rotation displayed on character display.
Selecting reverse rotation 0 0 — w — — w —
Ordinary — — — — — —
Maintenance Message is simultaneously dis-
Red
24 LED 30 hours or less before main-

monitor — Q — E — Q — E played on the character display.
tenance or maintenance time
Appropriate level — — — — — —
Battery elec-
Red
25 LED Max. 2 V 10 1 — Q — B@GAZK — Q — B@GAZK

trolyte level
Sensor not installed — — — — — —
Normal voltage — — — — — — If abnormality is detected when
starting switch is turned “ON”,
Engine is running, alternator alarm is continued even after
voltage is in short and no 30 1 — — — w Q Q AB00MA engine is started.
Battery starter signal C is input.
Red
26 LED
charge circuit <Voltage hysteresis>
When abnormality is detected Abnormal o Normal judgement:
(Unmatched engine condition 3 1 w Q Q AB00L6 — — — Min. 12 V
and the signal) Normal o Abnormal judgment:
Max. 5 V
Normal (OPEN) 1 1 — — — — — — The emergency steering function
can be enabled only when “ADD”
Steering oil is selected for “13. EMERG S/T”
Remarks
Red
27 LED Steering oil pressure is low

pressure (CLOSED) and engine speed 3 1 — — w Q Q DDS5L6 item using the optional device
is above 500 rpm selecting function of the machine
monitor.
Operation (for more than 1 The emergency steering function

1 1 w Q Q w Q Q
min) (OPEN) can be enabled only when “ADD”
Green
Emergency is selected for “13. EMERG S/T”

28 LED Operation (for less than 1 min)
steering 1 1 — Q — — Q — item using the optional device
(OPEN)
selecting function of the machine
Other monitor.
Stop (CLOSED) — — — — — —
symbols
Power mode selector switch
0 0 — Q — — Q —
“P-mode”
Green
31 Power mode LED

Power mode selector switch
— — — — — —
“E-mode”
10 WA450-6, WA480-6 (KA SPEC.)


ing time

Display of message
Display of message
Individual display
Individual display
Alarm buzzer
Alarm buzzer
Display color
Detection
Reset
Semi auto digging switch
— — — — — —
“OFF”
Green
Semiauto- Not to be displayed when error is
32 LED
matic digging Semi auto digging switch made in communication
0 0 — Q — — Q —
“SOFT” or “HARD”
Red
33 Preheater LED
When preheater is turned ON 0 0 — Q — — Q —
Not in operation — — — — — —
Operation 1 1 — Q — — Q —
w w
Green
34 Auto grease LED Tank empty 3 1 — 1 — — 1 —
Hz Hz
w w
Abnormal 3 1 — 2 — — 2 —
Hz Hz
When using steering wheel — — — — — —
Other When joystick is operating 0 0 — Q — — Q — The joystick steering function can

symbols be enabled only when “J/S” is
Selection caution to joystick
0 0 A w Q A w Q selected for “14. J/S-FNR SW”
steering
Green
item using the “optional device
35 Joystick LED
FNR switch neutral caution selecting function” of the machine
when starting switch is turned 0 0 A w Q A w Q monitor.
to “ON” Not to be displayed when error is
made in communication.
Directional lever priority cau-
1 0 A w Q A w Q
tion
When using directional lever — — — — — —

The directional selector switch
When directional selector can be enabled only when “FNR
0 0 — Q — — Q — SW” is selected for “14. J/S-FNR
Directional switch is operating
Green
SW” item using the “optional
36 selector LED Directional lever priority cau-
0 0 A w Q A w Q device selecting function” of the
switch tion machine monitor. Not to be dis-
played when error is made in
Directional selector switch
0 0 A w Q A w Q communication.
neutral caution
Economy Other than below 0 0 — — — — — —

Green
37 mode of LED
operation Economy mode operation 0 0 — Q — — Q —
WA450-6, WA480-6 (KA SPEC.) 11

Machine monitor operation switch

Speedometer specification
1. Machine monitor mode selector switch 1

12 WA450-6, WA480-6 (KA SPEC.)

Setting of machine monitor
1. Spare rotary switch (SW1)

4. Spare DIP switch (SW5-1)
a It is prohibited to change setting of spare rotary switch and DIP switch.
Function of troubleshooting
q The machine monitor monitors the input and output signals constantly for troubleshooting for the sys-
tem.
q If the transmission controller detects abnormality by the self-diagnosis, abnormality information is for-
warded to the machine monitor over the network.
q Abnormality information can be checked on the character display using the failure code display mode of
the machine monitor.
WA450-6, WA480-6 (KA SPEC.) 13

Character display function

q Machine monitor display and setting can be changed by using the character display.
q The range operator is enabled to operate in is within the portion of the “Operator mode” in the figure
below.
a For the operating method in the operator mode, see the Operation and maintenance manual.
*1: In an ID entered in the “ID entry” screen is once approved, display changes directly to the “Select func-
tion” screen without displaying the “ID entry” screen until the starting switch is turned “OFF”.
14 WA450-6, WA480-6 (KA SPEC.)

Operator mode function

Self-check screen (0th layer)
q Self-check is conducted for 3 seconds automatically when starting switch is turned to “ON”.
q During a self-check, entry through the machine monitor operating switch is not accepted.
q After ending the self-check, the self-check screen automatically moves to 1st layer.
Normal screen (1st layer)

q If the item of “10. RPM/SPEED” is set to “ADD” in the “optional device selecting function” of machine
monitor, engine speed is displayed to the character display when the travel speed is displayed at the
center of the monitor.
q When the engine speed is displayed at the center of the monitor, travel speed is displayed to the charac-
ter display.
q Pressing the “U” switch changes the screen to the 2nd layer.
1. Engine speed display

2. Travel speed display
A. In the case of “km/h” display

B. In the case of “MPH” display
a When trying to display travel speed on the character display by “MPH”, display is disabled unless the
setting is made to “Non-SI unit specification” in the “Factory mode” of the machine monitor.
WA450-6, WA480-6 (KA SPEC.) 15

Failure code screen (1st layer)

q Pressing the “>” switch when the Warning screen is on display changes display to the failure code
screen.
q If multiple failure codes are present, each pressing of the “>” switch displays them from the item of
higher priority downward. If items have the same priority, the item that occurred most recently will be dis-
played first
Example of a failure code screen (Simultaneously occurring errors: D191KA, B@BCZK, CA431)
*1: The screen automatically returns to the Warning screen if the switch is not pressed more than 10 sec-
onds in the normal screen display.
*2: The screen returns to the Warning screen if the switch is not pressed more than 30 seconds in the fail-
ure code screen or if a new alarm is turned ON.
*3: Pressing the “>” switch in the normal screen before 10 seconds lapse changes display to the initial fail-
ure code screen.
16 WA450-6, WA480-6 (KA SPEC.)

Display of functions opened to the operator (2nd layer or below)

q Certain menus are not displayed unless the items in the “Optional device selection function” of the
machine monitor are set.
q Pressing “U” switch enables to select each menu.
q For the 2nd layer down, the screen automatically returns to the screen of the 1st layer if the switch is not
pressed more than 60 seconds in the screen display of each menu.
q The language will be displayed as set in the “Language selection function”. The figure shows a case
when “ENGLISH” is selected.
a See the Operation and maintenance manual for details of each menu.
*1: These menus are displayed when “ADD” is selected for “10. RPM/SPEED” item using the “optional
device selecting function” of the machine monitor.
*2: These menus are displayed when “ADD” is selected for “9. RPM OPT” item using the “optional device
selecting function” of the machine monitor.
WA450-6, WA480-6 (KA SPEC.) 17

Service mode functions

q The machine monitor is provided with service mode function for the ease of troubleshooting for the con-
trollers on the network (including the machine monitor itself).
q Initial setting of the sensors and optional setting can be made in the service mode of the machine moni-
tor.
Procedure for switching to Service mode

1. Checking of the screen display 3. ID input and confirmation
Check that the character display is set to the Operate the machine monitor mode selector
1st layer screen in the operator mode. switches 1 and 2 and enter ID. (ID: 6491)
2. Display of ID input initial screen

Pressing “U” switch and “<” switch simulta-
neously for 5 seconds or more, the ID entry ini-
tial screen appears.
a Pressing down the two switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the switches.
1) The cursor (C) is located at the highest-

order digit. Pressing “<” or “>” switch
changes the value of this digit in the range
of “0” to “9”.
2) Press “U” switch to settle the selection
with a target value.
a The cursor moves to the 2nd digit
position.
3) Confirm the values for the 2nd digit and
onward following the same procedure.
a When you have entered a wrong
value to a position, if the cursor is
located elsewhere than the highest-
order digit, press “t” switch to move
the cursor to the highest-order digit to
enable to input correct value. In this
case, values that had been entered
remain as they are until modified.
a Pressing “t” switch when the cursor
is located at the highest-order digit,
the screen returns to the “1st layer” of
the operator mode.
a If switch is not operated more than 60
seconds on the “ID input” screen, it
automatically returns to the “1st layer”
screen of the operator mode.
4) If ID is acknowledged upon confirming the
4th digit, the screen changes to the “Elec-
trical system failure history” selector
screen.
18 WA450-6, WA480-6 (KA SPEC.)

Service mode menu
a Pressing “<” or “>” switch on the menu screen switches individual menus of the service mode sequen-
tially and endlessly.
a Pressing “U” switch on the target menu screen changes the screen to the detailed screen of the same
menu.
a Pressing “t” switch on the menu screen returns the screen to the 1st layer of the operator mode.
WA450-6, WA480-6 (KA SPEC.) 19

Electrical system failure history display func- Rear-time monitoring function (REAL-TIME
tion (ELECTRIC FAULT) MONITOR)
a “**” field displays total number of the failure q The function is used to check on the input/out-
history currently recorded. (Max. 20 histories to put signals, etc. each controller on the network
be stored) recognizes.
q The history is used to check on the electrical a For the operating procedure of this function,
system failures of each controller saved in the see “Special functions of machine monitor
machine monitor. After repairing the failure (EMMS)” in Testing and adjusting.
content and verifying normal function, the fail-
ure history may be erased. Engine reduced-cylinder function (CYLINDER
a For the operating procedure of this function, CUT-OUT)
see “Special functions of machine monitor
(EMMS)” in Testing and adjusting.
Mechanical system failure history display func-

tion (MACHINE FAULT)
q This function is used for the purpose of speci-

fying cylinder having defective combustion by
stopping fuel injection to each cylinder from the
fuel injector.
a For the operating procedure of this function,
a “**” field displays total number of the failure see “Special functions of machine monitor
history currently recorded. (Max. 20 histories to (EMMS)” in Testing and adjusting.
be stored)
q The history is used to check on the mechanical

system failures of each controller saved in the
machine monitor.
20 WA450-6, WA480-6 (KA SPEC.)

No injection cranking function (NO INJECTION) Maintenance monitoring function (MAINTE-

NANCE MONITOR)
q Before restarting engine after a long-term stor-

ing of the machine, this function is used to q This function is used for changing the filter and
lubricate the engine internally. oil replacement timing and making ON/OFF
a For the operating procedure of this function, selection of this function.
see “Special functions of machine monitor a For the operating procedure of this function,
(EMMS)” in Testing and adjusting. see “Special functions of machine monitor
Adjustment function (TUNING)
Operating information display function (OPER-
ATION INFO)
q This function is used for correcting and adjust-

ing the installation errors and manufacturing
dispersion of the sensors, solenoid valves, etc. q This function is used for displaying fuel con-
Function for changing control characteristics is sumption per operating hour.
provided on user request. a For the operating procedure of this function,
These functions are also used when sensors, see “Special functions of machine monitor
valves and controllers are replaced or added. (EMMS)” in Testing and adjusting.
WA450-6, WA480-6 (KA SPEC.) 21

Optional device selecting function (OPTIONAL Model selection function (MACHINE WA480
SELECT) TIRE26.5)
q This function is used for verifying the installed q This function is used for displaying or changing
state of optional devices or when changing the setting of model information (machine
their setting. name and tire size).
This function is also used for installing or a For the operating procedure of this function,
removing optional devices. see “Special functions of machine monitor
a For the operating procedure of this function, (EMMS)” in Testing and adjusting.
(EMMS)” in Testing and adjusting. Initialize function (INITIALIZE)
Machine serial number input function

(MACHINE No. SET)
q This function is used to set the machine moni-

tor to the state set when delivered.
a Since this function is specially handled by the
q This function is used for displaying or entering factory, no modification is allowed.
the serial number of machine.
Set machine serial number is used for control-
ling the machine.
22 WA450-6, WA480-6 (KA SPEC.)


AMP070-20P[CN-L51]
Pin No. Specification I/O Group Form of use Signal name Remarks
1 (NC) — — — —
Power supply
2 Power supply of small lamp I — —
(+24 V)
Power supply
3 Power supply of small lamp I — —
(+24 V)
Constant power
4 NSW power supply (+24 V) I — NSW power supply (+24 V)
supply (+24 V)
Constant power
5 NSW power supply (+24 V) I — NSW power supply (+24 V)
supply (+24 V)
Power supply
6 SW power supply (+24 V) I — SW power supply (+24 V)
(+24 V)
Power supply
7 SW power supply (+24 V) I — SW power supply (+24 V)
(+24 V)
8 (NC) — — — —
9 GND I — GND GND
10 GND I — GND GND
D_OUT_3
11 O A D/O sink —
(+24 V, sink 200 mA)
D_OUT_2
12 O A D/O sink —
(+24 V, sink 200 mA)
D_OUT_1
13 O A D/O sink —
(+24 V, sink 200 mA)
D_OUT_0
14 O A D/O sink Alarm buzzer 1 (Machine monitor)
(+24 V, sink 200 mA)
Sensor power supply Sensor power
15 O — —
output (+24 V) supply
Sensor power supply Sensor power
16 O — —
output (+5 V) supply
WA450-6, WA480-6 (KA SPEC.) 23

AMP070-18P(1)[CN-L52]
D_IN_0
1 I B D/I(+24 V) Head lamp
(24 V, 5 mA)
D_IN_2
2 I B D/I(+24 V) Starting switch C signal
(24 V, 5 mA)
D_IN_4
3 I B D/I(+24 V) —
(24 V, 5 mA)
D_IN_6
4 I B D/I(+24 V) —
(24 V, 5 mA)
D_IN_8
5 I B D/I(+24 V) —
(24 V, 5 mA)
D_IN_10
6 I B D/I(+24 V) —
(24 V, 5 mA)
D_IN_12
7 I C D/I(+24 V) Turn signal lamp, right
(NSW24 V, 5 mA)
D_IN_14
8 I C D/I(+24 V) U switch
(NSW24 V, 5 mA)
9 GND O — GND Signal GND
D_IN_1
10 I B D/I(+24 V) —
(24 V, 5 mA)
D_IN_3
11 I B D/I(+24 V) —
(24 V, 5 mA)
D_IN_5
12 I B D/I(+24 V) —
(24 V, 5 mA)
D_IN_7
13 I B D/I(+24 V) —
(24 V, 5 mA)
D_IN_9
14 I B D/I(+24 V) —
(24 V, 5 mA)
D_IN_11
15 I B D/I(+24 V) —
(24 V, 5 mA)
D_IN_13
16 I C D/I(+24 V) Turn signal lamp, left
(NSW24 V, 5 mA)
D_IN_15
17 I C D/I(+24 V) t switch
(NSW24 V, 5 mA)
A_IN_0
18 I H A/I Alternator R signal
(0 – 30 V)
AMP070-12P(1)[CN-L53]
D_IN_16
1 I D D/I(GND) Brake oil pressure (Front)
(24 V/GND, 5 mA)
D_IN_18
2 I D D/I(GND) —
(24 V/GND, 5 mA)
D_IN_20
3 I D D/I(GND) Clogging of air cleaner
(24 V/GND, 5 mA)
D_IN_22
4 I D D/I(GND) —
(24 V/GND, 5 mA)
D_IN_24
5 I E D/I(GND) —
(24 V/GND, 5 mA)
6 GND O — GND Sensor GND
D_IN_17
7 I D D/I(GND) Brake oil pressure (Rear)
(24 V/GND, 5 mA)
D_IN_19
8 I D D/I(GND) —
(24 V/GND, 5 mA)
D_IN_21
9 I D D/I(GND) —
(24 V/GND, 5 mA)
D_IN_23
10 I D D/I(GND) —
(24 V/GND, 5 mA)
D_IN_25
11 I E D/I(GND) —
(24 V/GND, 5 mA)
A_IN_1
12 I H A/I Small lamp switch
(0 – 30 V)
24 WA450-6, WA480-6 (KA SPEC.)

AMP070-18P(2)[CN-L54]
D_IN_26
1 I E D/I(GND) Parking brake
(24 V/GND, 5 mA)
D_IN_28
2 I E D/I(GND) —
(24 V/GND, 5 mA)
D_IN_30
3 I E D/I(GND) Normal emergency steering
(24 V/GND, 5 mA)
D_IN_32
4 I F D/I(GND) Subtotal switch
(24 V/GND, 5 mA)
D_IN_34
5 I F D/I(GND) Dimmer switch
(24 V/GND, 5 mA)
D_IN_36
6 I G D/I(GND) —
(24 V/GND, 5 mA)
D_IN_38
7 I G D/I(GND) < switch
(24 V/GND, 5 mA)
P_IN_0
8 I M P/I —
(0.5 Vp-p)
9 GND O — GND GND
D_IN_27
10 I E D/I(GND) Coolant level
(24 V/GND, 5 mA)
D_IN_29
11 I E D/I(GND) Engine oil level
(24 V/GND, 5 mA)
12 (NC) — — — —
D_IN_33
13 I F D/I(GND) Cancel switch
(24 V/GND, 5 mA)
D_IN_35
14 I F D/I(GND) —
(24 V/GND, 5 mA)
D_IN_37
15 I G D/I(GND) > switch
(24 V/GND, 5 mA)
D_IN_39
16 I G D/I(GND) Operation of emergency steering
(24 V/GND, 5 mA)
P_IN_1
17 I M P/I —
(0.5 Vp-p)
18 (NC) — — — —
AMP070-12P(2)[CN-L55]
A_IN_2
1 I J A/I Fuel level sensor
(High-resistance input)
A_IN_4 Torque converter oil temperature
2 I J A/I
(High-resistance input) sensor
A_IN_6
3 I K A/I —
(Low-resistance input)
A_IN_8
4 I L A/I —
(0 – 5 V)
A_IN_10
5 — — — Battery electrolyte level If equipped
(0 – 14 V)
6 GND O — GND GND
A_IN_3
7 I J A/I Hydraulic oil temperature sensor
A_IN_5
8 I J A/I Brake oil temperature sensor
A_IN_7
9 I L A/I —
(0 – 5 V)
A_IN_9
10 I L A/I —
(0 – 5 V)
11 GND O — GND GND
A_IN_11
12 — — — —
(0 – 14 V)
WA450-6, WA480-6 (KA SPEC.) 25

AMP070-12P(3)[CN-L56]
1 S_NET(+) I/O N S-NET —
2 S_NET(+) I/O N S-NET —
3 CAN(+) I/O P CAN CAN(+)
4 S_NET(–) O N S-NET —
5 S_NET(–) O N S-NET —
6 GND O — GND GND
7 GND O — GND —
8 CAN(–) I/O P CAN CAN(-)
9 (NC) — — — —
10 (NC) — — — —
11 (NC) — — — —
12 (NC) — — — —
AMP070-14P[CN-L57]
1 (NC) — — — —
2 RS232C_1_RTS I/O Q — —
3 RS232C_1_RD I Q RD —
4 (NC) — — — —
5 (NC) — — — —
6 I — — —
7 (NC) — — — —
8 RS232C_1_CTS I/O Q — —
9 RS232C_1_TX O Q TX —
10 RS232C_1_SG O Q — —
11 (NC) — — — —
12 (NC) — — — —
13 (NC) — — — —
14 (NC) — — — —
26 WA450-6, WA480-6 (KA SPEC.)

AMP040-8P[CN-L58]
Do not connect wiring
1 RS232C_0_TXD O S — —
harness on machine
2 FLASH_SW I S — —
harness on machine
3 RS232C_0_TXD O S — —
harness on machine
4 (NC) — — — —
harness on machine
5 RS232C_0_RXD I S — —
harness on machine
6 (NC) — — — —
harness on machine
7 RS232C_0_RXD I S — —
harness on machine
8 GND O — — —
harness on machine
Setting switches (On circuit board)

Switch
Specification I/O Group Form of use Signal name Remarks
No.
1 16 Posi rotary switch 1 I — — (Spare)
1 26 Posi DIP switch 1 I — — (Spare)
5
6
WA450-6, WA480-6 (KA SPEC.) 27

SEN01178-00

28
SEN01179-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)

Electrical system (Transmission controller system) ............................................................................. 2
Transmission controller ...................................................................................................................... 26
WA450-6, WA480-6 (KA SPEC.) 1


Electrical system (Transmission controller system) 1
a Except where otherwise specified, the displayed travel speed in this document represents the one when
26.5 – 25 tire is worn.
Transmission controller gear shifting control function

Electronic modulation function
q To reduce the shocks made when the gear speed is changed (when the clutch is engaged), the modula-
tion control is applied. The clutch oil pressure is controlled optimally to suit for the condition of the
hydraulic circuit, depending on the engine speed, transmission oil temperature, travel speed, and gear
shifting pattern and according to the transmission modulation data table saved in the transmission con-
troller memory so that the transmission will be set in any gear speed (including the lockup clutch)
smoothly.
The modulation control is continued even while the clutch is disengaged in order to reduce lowering of
the torque.
If an abnormal time lag is made in gear shifting, the learning function corrects the modulation automati-
cally.
Gear shifting display function

q The transmission controller displays the state of input signals related to gear shift by sending them to
the machine monitor via network.
1. Directional indicators
The shift lever position pilot lamps of the machine monitor indicate state of the directional lever based on
the input data to the transmission controller.
When the directional lever is at the neutral position and no input signal is sent to the transmission con-
troller, all the shift lever position pilot lamps of the machine monitor go off.
If two independent signals were sent to the transmission controller by accident, two shift lever position
pilot lamps of the machine monitor may turn on.
As the directional lever is set to “R (Reverse)”, the transmission controller activates the back-up lamp
relay to light the reverse lamp and sound the back-up alarm.
2. Gear speed indicators

The shift lever position pilot lamps of the machine monitor indicate state of the gear shift lever based on
the input data to the transmission controller.
When the gear shift lever is at the neutral position and no input signal is sent to the transmission control-
ler, all the shift lever position pilot lamps of the machine monitor go off.
If two independent signals were sent to the transmission controller by accident, precedence is given to
the higher gear speed. Thus, the shift lever position pilot lamps of the machine monitor may indicate a
gear shift lever position not identical with its actual position.
3. Display of actual gear speed

The shift indicator of the machine monitor indicates state of the directional lever and gear shift lever
being based on the output data from the transmission controller.
When the directional lever is at “N (Neutral)”, the indicator displays “N”. And when the directional lever is
at “F (Forward)” or “R (Reverse)”, the indicator displays gear speed along with “F” or “R”.
When the parking brake is in operation, the gear speed signal is not usually output. Thus, the indicator
constantly displays “N”. It also displays “N” if the transmission is set to the neutral while the transmission
cut-off is activated.
2 WA450-6, WA480-6 (KA SPEC.)

Automatic gear shifting function

q The transmission gear can be shifted by the automatic gear shifting operation in which the gear speed is
selected automatically according to the travel speed or by the manual gear shifting operation in which
the gear speed is selected with the gear shift lever.
q Operating the transmission shift mode selector switch allows switching the shift mode. As the auto shift
is selected, the auto-shift pilot lamp of the machine monitor comes on.
q In the auto shift mode, either shifting up or shifting down as well as ON or OFF of the lockup clutch (if
equipped) is selected depending on the state of the power mode.
q The auto shift comprises two modes “H” and “L”. The shift modes shown in the following table are turned
on depending on the state of the transmission shift mode selector switch and the power mode selector
switch.
Power mode selector Transmission shift mode selector switch

switch H L MANUAL
P-mode Auto-shift H-mode Auto-shift L-mode Manual shift mode
E-mode Auto-shift L-mode Auto-shift L-mode Manual shift mode
q In the auto shift, the transmission controller selects either shifting up or down based on the “Auto-shift
points table” stored on it after referencing the directional lever position, gear shift lever position, travel
speed, accelerator pedal opening ratio and engine speed.
1. When the gear shift lever position is in “1st” to “4th”

The maximum gear speed (gear shifting range) used in the automatic gear shifting operation is limited.
In the automatic gear shifting operation, the machine usually starts in the 2nd gear speed. Accordingly, if
the gear shift lever is in “4th”, the gear is shifted up or down between the 2nd gear speed and 4th gear
speed. When the kick-down function is turned on, however, shifting down to the 1st also becomes avail-
able.
2. When the directional lever in “N (Neutral)” position

When the directional lever is set to “N (Neutral)”, actual transmission gear speed is fixed to the one that
had been selected prior to setting the lever to “N (Neutral)”.
When the directional lever is set to “N (Neutral)”, operating the gear shift lever does not change the gear
seed. Namely, the gear speed prior to the lever operation remains unchanged. Change of the gear
speed becomes available only when the directional lever is set to “F (Forward)” or “R (Reverse)”.
WA450-6, WA480-6 (KA SPEC.) 3

Auto-shift points table

q The relationship among transmission output shaft speed, engine mode, shift switch, and gear shifting
operation are shown below.
WA450-6
Unit: rpm
Engine mode and shift switch
Power mode Economy mode
Shift switch H Shift switch L Shift switch H Shift switch L
Gear shifting
F1oF2 369 – 406 340 – 369 369 – 406 340 – 369
operation
F2oF3 665 – 812 259 – 627 665 – 812 259 – 627
F2oF3
731 – 827 591 – 650 731 – 827 591 – 650
when hunting is prevented
F3oF3 (lockup) 988 – 1,182 775 – 1,034 1,016 – 1,145 775 – 1,034
F3oF2 (lockup)
1,433 1,433 1,233 1,233
F3oF4 1,108 – 1,403 627 – 1,145 1,108 – 1,403 627 – 1,145
F4oF4 (lockup) 1,533 – 1,920 1,551 1,533 – 1,920 1,551
F4 (lockup) oF4 1,458 – 1,847 1,477 1,458 – 1,847 1,477
F4oF3 960 – 1,256 553 – 997 960 – 1,256 553 – 997
F3 (lockup) oF3 913 – 1,108 701 – 960 941 – 1,071 701 – 960
F3oF2 443 – 739 222 – 553 443 – 739 222 – 553
F3oF2
443 – 672 222 – 332 443 – 672 222 – 332
a The transmission output shaft speed of 1 rpm corresponds to 0.0135 km/h.
WA480-6
Unit: rpm
Engine mode and shift switch
Power mode Economy mode
Shift switch H Shift switch L Shift switch H Shift switch L
Gear shifting
F1oF2 369 – 406 340 – 369 369 – 406 340 – 369
operation
F2oF3 665 – 812 259 – 655 665 – 812 259 – 655
F2oF3
731 – 827 591 – 687 731 – 827 591 – 687
F3oF3 (lockup) 988 – 1,182 775 – 1,034 1,016 – 1,145 775 – 1,034
F3oF2 (lockup)
1,433 1,433 1,233 1,233
F3oF4 1,108 – 1,440 627 – 1,182 1,108 – 1,440 627 – 1,182
F4oF4 (lockup) 1,533 – 1,920 1,551 1,533 – 1,920 1,551
F4 (lockup) oF4 1,458 – 1,847 1,477 1,458 – 1,847 1,477
F4oF3 960 – 1,256 591 – 1,034 960 – 1,256 591 – 1,034
F3 (lockup) oF3 913 – 1,108 701 – 960 941 – 1,071 701 – 960
F3oF2 443 – 739 222 – 591 443 – 739 222 – 591
F3oF2
443 – 672 222 – 369 443 – 672 222 – 369
a The transmission output shaft speed of 1 rpm corresponds to 0.0135 km/h.
4 WA450-6, WA480-6 (KA SPEC.)

Shift hold function

q The shift hold function maintains the gear speed chosen from the hold switch when the auto shift mode
was selected. It does not allow shifting up as the travel speed is increased. And it also does not allow
shifting down as the travel speed is decreased.
q The shift hold pilot lamp of the machine monitor remains turned on as long as the shift hold function is
turned on. Pressing the hold switch again resets the shift hold function and turns off the pilot lamp.
q The shift hold function is automatically reset as the directional lever, gear shift lever or kickdown switch
is operated. In such case, the torque converter lockup is turned off.
Kickdown function
1. In manual-shift mode
When the directional lever is set to “F (Forward)” and the gear shift lever to “2nd”, pressing the kickdown
switch changes the gear speed to 1st.
Operation of the kickdown switch is ignored if the directional lever is set to a position other than “F (For-
ward)” or if the gear shift lever is set to a position other than the “2nd” position.
The kickdown function is reset if the directional lever is operated after the actual gear speed has been
changed to “1st” or the gear shift lever is set to any position other than “2nd”. After the function is reset,
the gear speed is changed to the one being selected from the gear speed lever.
2. In auto-shift mode
The kickdown function is enabled when the directional lever is set to a position other than “N (Neutral)”
and the gear shift lever is set to a position other than the “1st” position.
The kickdown switch allows changing the gear speed as shown in the following table.
The kickdown function is reset if the directional lever is operated after the actual gear speed is changed
or the no-shift time for hunting prevention elapses. After the reset, the auto shift based on “Auto-shift
points table” is turned on.
Transmission output shaft speed [rpm] as

Gear speed prior Gear speed after
kickdown switch is pressed No-shift time [sec]
to kickdown kickdown
(Reference: Travel speed [km/h])
2nd T/C All range 1st T/C 5
Below 775 (10.5) 1st T/C 5
3rd T/C
775 (10.5) or above 2nd T/C 4
Below 775 (10.5) 1st T/C 5
4th T/C
775 (10.5) or above 3rd T/C 4
Below 775 (10.5) 1st T/C 5
3rd L/U
775 (10.5) or above 3rd T/C (*1)
Below 775 (10.5) 1st T/C 5
4th L/U
775 (10.5) or above 4th T/C (*1)
T/C: Stands torque converter travel.
L/U: Stands direct travel (lockup operation).
*1: When the lockup function was reset from the kickdown switch, following operations alone turn
it on again.
q Torque converter lockup switch is turned “OFF” once and then turned “ON” again.
q Current travel speed is increased to or beyond a specific level. Here the specific level denotes
the speed that starts activating the lockup corresponding to the “Auto-shift points table”
3. When forward 1st is selected

When “E-mode” is selected for the power mode and the gear speed is set to forward 1st, pressing the
kickdown switch changes the power mode to “P-mode”.
The power mode switching function is enabled, independent of the auto or manual shift, only when for-
ward 1st is selected and it is reset as any actual gear speed other than 1st is selected.
WA450-6, WA480-6 (KA SPEC.) 5

Function of torque converter lockup

(If equipped)
q Turning ON the torque converter lockup switch, independent of the shift mode, the torque converter
lockup function prepared for automatic control of the lockup operation.
q The torque converter lockup pilot lamp of the machine monitor remains turned on as long as the lockup
operation is continued.
q The operation gear speed of lockup is as follows.
Transmission shift mode Lockup operation gear speed (Lockup operates: Q)

selector switch F1 F2 F3 F4 R1 R2 R3 R4
H (*1) Q (*1) Q
L (*1) Q (*1) Q
MANUAL Q Q Q Q
*1: When the gear shift lever is set to “4th” in the auto-shift mode, the lockup function is not activated at 3rd
speed.
The lockup function is turned on at 3rd speed if the gear shift lever is set to “3rd”.
1. Lockup operation travel speed

“Auto-shift points table” lists the lockup operation travel speeds. When the manual shift is selected, the
same travel speeds as that of the auto-shift H-mode turn on the lockup.
2. Function of lockup protection

The lockup function is operated only when the machine travel direction coincided with the directional
lever position.
<Judging the machine travel direction>
1) The machine is judged as stopped prior at start of the transmission controller (starting switch “ON”),
or the transmission output shaft speed is below 260 rpm.
2) From above state, if the transmission output shaft speed reached 260 rpm level or above and the
directional lever was set to “F (Forward)”, the machine should be judged as traveling forward. If the
lever was set to “R (Reverse)”, the machine is traveling reverse.
a When the transmission output shaft speed is 260 rpm, the travel speed is approximately 3.2 km/h.
6 WA450-6, WA480-6 (KA SPEC.)

Function of hunting prevention

q The transmission controller detects and prevents hunting that can result from shifting the gear from 2nd
to 3rd and 3rd to 2nd in the auto shift mode.
q If gear shifts of 2nd to 3rd to 2nd to 3rd are performed within 5 seconds from the previous gear shift,
hunting is thought to have occurred, and the gear speed is selected from 2nd or 3rd, whose operation
time is longer.
q As the hunting prevention function is turned on, the shift point in the hunting prevention section in “Auto-
shift points table” is applied to the next automatic gear shifting.
q Currently turned on hunting prevention function is reset as the next gear shifting (including the direction
switching operation and kickdown operation) is done. As the hunting prevention function is reset, the
ordinary auto shift point is restored.
q The transmission controller resets the lockup if ON/OFF of the 3rd lockup occurred consecutively within
5 seconds. For the next lockup, the transmission controller applies the auto-shift point in the hunting
prevention section of “Auto-shift operating points table”.
q The hunting prevention function related to the lockup is turned in the manual shift mode, too, if the con-
troller judges hunting is present.
Transmission initial learning and ECMV current adjustment

q Adjusting the “Transmission initial learning setting” and “Transmission ECMV current adjustment” items
by use of the adjustment function of the machine monitor allows correcting variations of the transmis-
sion itself as well as ECMV.
q Ignoring above adjustment can lead to generation of gear shifting shocks or time lag.
a For the adjustment procedure, see “Special functions of machine monitor (EMMS)” in Testing and
adjusting.
Changing shift points

q The transmission controller has the function of adjusting the gear shift points of “L-mode” in auto-shift.
q When hunting is induced by some conditions unique to a worksite, the transmission controller can adjust
the shift up and down travel speeds by adjusting the “Adjustment of transmission L-mode shift point”
item by use of the adjustment function of the machine monitor.
adjusting.
4th gear speed derating function

q Restriction of operation at 4th gear speed becomes available by selecting “ADD” for “23. FORBID 4TH”
item using the “optional device selecting function” of the machine monitor.
a For the setting procedure, see “Special functions of machine monitor (EMMS)” in Testing and adjusting.
WA450-6, WA480-6 (KA SPEC.) 7

Function of transmission controller protection

Protection function prepared for direction selection
q When the directional lever is operated during high-speed travel (3rd/4th), engagement of the speed
clutch is controlled to protect the transmission.
1. In manual-shift mode
Range X:Travel direction is changed. (Ordinary range)
Range Y: Travel direction is changed and alarm buzzer sounds.
Range Z: Travel direction is changed and alarm buzzer sounds.
2. In auto-shift mode
Range X:Travel direction is changed and transmission is set to 2nd gear speed. (Ordinary range)
Range Y: Travel direction is changed, transmission is set to 2nd gear speed and alarm buzzer sounds.
Range Z: Travel direction is changed and alarm buzzer sounds. Gear speed is switched to 3rd or 4th
depending on the given travel speed. If the travel speed continues to slow down, gear speed is
shifted down to 2nd gear speed.
a Shifting up and down as well as kickdown operation is not accepted for 2 seconds succeeding to opera-
tion of the directional selector switch. When shifting up or down is done from the gear shift lever, wait for
2 seconds before starting gear shifting.
In the auto-shift mode, it is prohibited to turn on shifting up until the speed is once decelerated to 2nd.
Transmission output shaft speed [rpm]

Engine speed [rpm]
A 960 (13) D 1,700
B 1,034 (14) E 1,900
C 1,181 (16)
8 WA450-6, WA480-6 (KA SPEC.)

Function of shift down protection

q In order to protect the engine and pump, this function rejects the shifting down operation as long as the
machine is traveling at a speed higher than the set one.
q The alarm buzzer is sounded as long as the shift down protection function is turned on.
q The buzzer sounds are continued until the gear speed position of the gear shift lever coincides with the
actual gear speed. Thus, shifting up operation can stop the alarm buzzer sounds even if the travel
speed is not slowed down.
q The shift down protection is enabled also for the kickdown operation in the auto-shift mode. If the kick-
down switch is pressed while the machine is traveling at a higher speed than that specified in the pro-
tecting conditions, this function rejects the kickdown switch and sounds the alarm buzzer for 3 seconds.
q The operating condition of shift down protection function is as follows.

Targeted gear (Reference: Travel speed [km/h])
speed of shift down
Condition for applying protection Condition for resetting protection
To 3rd gear speed 2,227 (30.2) or above Below 2,005 (27.2)
To 2nd gear speed 1,470 (19.9) or above Below 1,322 (17.9)
To 1st gear speed 1,061 (14.3) or above Below 951 (12.9)
Function of engine overrun prevention

q As the transmission output shaft speed reached a level corresponding to the engine speed of 2,500 rpm
or above, this function resets the lockup automatically in order to prevent the engine overrun.
q The alarm buzzer is sounded as long as the engine overrun prevention function is turned on.
q The lockup reset state is maintained for 5 seconds after it has been reset. After 5 seconds from the
reset, the transmission output shaft speed reached a level corresponding to the engine speed of below
2,500 rpm, this function applies the lockup again.
q The operating condition of the engine overrun prevention function is as follows.

Actual gear speed
F3 1,961 (26.6)
F4 3,526 (47.8)
R3 2,113 (28.6)
R4 3,748 (50.8)
Maximum travel speed derating function

q As the transmission output shaft speed reached a level corresponding to the travel speed of 40 km or
above, this function resets the lockup in order for the safety.
q The alarm buzzer is sounded as long as the maximum travel speed derating function is turned on.
q The lockup reset state is maintained for 5 seconds after it has been reset. After 5 seconds from the
reset, as the transmission output shaft speed reached a level corresponding to the travel speed of below
38 km, this function stops the alarm buzzer but maintains the lockup in the reset state.
q When the lockup clutch is not installed on the machine, alarm buzzer alone will be sounded.
q The operating condition of the maximum travel speed derating function is as follows.

Threshold value
Lockup resetting operation 2,953 (40.0)
Completion of lockup resetting operation 2,805 (38.0)
Operation of alarm buzzer 2,953 (40.0)
Resetting of alarm buzzer 2,916 (39.5)
WA450-6, WA480-6 (KA SPEC.) 9

Function of neutralizer
q When the parking brake switch is turned “ON”, this function holds the transmission at neutral position,
independent of the directional lever and gear shift lever positions, in order to prevent dragging of the
parking brake.
q The safety mechanism employed on the parking brake circuit maintains the parking brake operative
when the currently turned “OFF” starting switch is turned “ON”. Thus, when the starting switch is turned
“ON”, the transmission is always set to the neutral independent of the directional lever and gear shift
lever positions.
Engine control function

Power mode selecting function
q Setting the power mode selector switch to “P-mode” sends the P-mode torque curve information to the
engine controller. At the same time, above operation sends information of the power mode to the moni-
tor panel, lighting up the power mode pilot lamp.
Engine stall prevention control

q When the engine speed is low, switching the travel direction during high-speed travel results in applying
counter torque from tires to the engine, potentially inducing the risk of the engine stall.
q In order to prevent the engine stop, this function sends the specified throttle (accelerator pedal) lower
limit position value to the engine controller as the travel direction is switched.
Economy operation pilot lamp function

q In order to prompt the operator for the low fuel consumption operation, this function lights up the econ-
omy operation pilot lamp as long as the low fuel consumption operation is continued.
q The conditions for lighting up the economy operation pilot lamp is as follows.
Power mode Economy operation pilot lamp lighting condition

The low fuel consumption operation is turned on in this mode independent of the run-
E-mode
ning or operating state. Thus, the lamp is constantly lighted.
The lamp is lighted when the accelerator pedal opening ratio is maintained below
P-mode
75% for more than 0.5 seconds.
q The economy operation pilot lamp can be constantly turned off by selecting “NO ADD” for “19. ECO
LAMP” item using the optional device selecting function of the machine monitor.
10 WA450-6, WA480-6 (KA SPEC.)

Cooling fan control function
1. Transmission controller Input and output signals

2. Machine monitor
Transmission controller
3. Engine controller
a. CAN signal
4. Cooling fan pump
b. Cooling fan pump swash plate angle control
4a. Swash plate angle control EPC valve
signal
5. Cooling fan motor
c. Cooling fan reverse rotation signal
5a. Cooling fan reverse rotation solenoid valve
d. Cooling fan automatic reverse rotation signal
6. Cooling fan reverse rotation switch
e. Cooling fan manual reverse rotation signal
9. Hydraulic oil temperature sensor
Machine monitor
10. Torque converter oil temperature sensor
f. CAN signal
11. Coolant temperature sensor
g. “U” switch signal
12. Engine speed sensor
h. “t” switch signal
13. Engine
i. “>” switch signal
14. Radiator
j. “<” switch signal
k. Hydraulic oil temperature signal
l. Torque converter oil temperature signal
Engine controller
m. CAN signal
n. Engine speed signal
o. Coolant temperature signal
WA450-6, WA480-6 (KA SPEC.) 11

Fan control
q Employment of the hydraulically driven cooling fan as well as controlling its speed through control of the
hydraulic pump swash plate allows reducing the horsepower loss and noises in low temperature envi-
ronment.
q Engine speed and coolant temperature received by the engine controller and hydraulic oil temperature
and torque converter oil temperature received by the machine monitor are sent to the transmission con-
troller via the network.
q Based on the received information, the transmission controller sends the signal current to the swash
plate angle control EPC valve on the cooling fan pump, so that the valve may control the swash plate
angle in order to set the fan speed to a level suitable for the given temperature level and the engine
speed.
Fan speed in accordance with temperature
*1: The target fan speed is determined based on the coolant temperature, hydraulic oil temperature or
torque converter oil temperature data, whichever is higher.
*2: Within this range, the fan speed is set according to the coolant temperature, hydraulic oil temperature or
torque converter oil temperature.
Pump protection function

q In order to prevent overrun of the cooling fan motor, this function minimizes the swash plate angle of the
cooling fan pump as the engine speed reached 2300 rpm or above.
q If the transmission controller fails to recognize the engine speed and respective temperature data due to
a failure on the network communication, this function sends a specific command current (677 mA) to the
swash plate angle control EPC valve on the pump so that the pump may work functionally-equivalent to
a fixed pump.
12 WA450-6, WA480-6 (KA SPEC.)

Control at start of engine

q At start of the engine, a fan control approach different from the usual temperature-based one is
employed.
Range A: When engine is stopped [When starting switch 1-stage “ON“]

q Engine speed is not recognizable as long as it is stopped. Thus, this function sends the command cur-
rent of 677 mA to the swash plate angle control EPC valve on the pump.
Range B: While cranking is taking place

q While cranking is taking place to start the engine, this function sends the command current of 800 mA to
the swash plate angle control EPC valve on the pump in order to reduce the torque needed for starting
the engine.
Range C: For 30 seconds from start of engine.

q This function controls the pump swash plate angle in such that the fan minimum speed may be set to
750 rpm or equivalent. Setting the fan speed at this level allows the cooling fan pump to feed enough
refilling oil to the brake accumulator.
a When the fan speed exceeded 750 rpm because of the temperature condition, precedence is given to
the basic control.
Range D: Basic control

q Denotes the ordinary fan control as described in the section of “Fan speed in accordance with tempera-
ture”.
WA450-6, WA480-6 (KA SPEC.) 13

Fan reverse rotation function

q As the fan reverse rotation switch is pressed for cleaning of the radiator core, the cooling fan reverse
rotation solenoid valve of the cooling fan motor is activated, and the fan starts rotating in reverse.
1. Fan manual reverse rotation function

The operator can select the fan rotation direction as he chooses by setting the fan reverse rotation
switch to “MANUAL”.
As long as switching of the fan rotation direction is taking place, the pilot lamps of the fan reverse rota-
tion switch and the machine monitor keep blinking to inform the operator that the switching is underway.
And when the fan rotation is reversed responding to the high engine speed, high coolant or oil tempera-
ture, this lamp also keeps on blinking until the preparation for switching is completed.
As the fan rotation switching condition is met, this function sends the accelerator opening ratio-restrict-
ing signal to the engine controller so that the engine speed may not reach 1,200 rpm or above while the
switching is underway.
As long as the fan reverse rotation is continued, the pilot lamp of the fan reverse rotation switch and the
machine monitor remains turned on.
The fan rotation is switched from “forward” to “reverse” as every condition in the following table is met.
Condition 1 The fan reverse rotation switch is set “MANUAL”.

Engine speed over 500 rpm below 1,200 rpm.
Condition 2
[In order to prevent generation of peak pressure at switching of the rotation direction.]
Coolant temperature is below 90°C.
Condition 3
[In order to prevent overheat.]
Hydraulic oil temperature is below 90°C.
Condition 4
Torque converter oil temperature is below 90°C.
Condition 5
30 seconds have passed after the engine is started (after engine speed reached 500 rpm or above).
Condition 6
[In order to secure enough oil to be fed to the brake accumulator.]
The fan rotation is switched from “reverse” to “forward” as any of the following conditions is met.
While the fan reverse rotation was taking place, the fan reverse rotation switch was set to MANUAL
Condition 1
again and the engine speed went below 1,200 rpm.
Condition 2 The engine speed went below 1,200 rpm after 10 minutes from start of the fan reverse rotation.
Condition 3 Engine has stopped.
2. Overheat prevention function

If overheat occurs is recognized of the coolant temperature, hydraulic oil temperature or torque con-
verter oil temperature during the fan reverse rotation (thermometer caution lamp of the machine monitor
comes on), this function forcibly stops the reverse rotation and turns on the forward rotation in order to
increase air flow to the radiator.
3. Fan speed during reverse rotation

While the fan reverse rotation is continued, this function sets the fan speed to the maximum by cutting
off the command current to the swash plate angle control EPC valve of the fan pump (the command cur-
rent is forced to 0 mA).
Setting the fan speed to the maximum increases air flow to the radiator core maximum, making the
cleaning work easier.
14 WA450-6, WA480-6 (KA SPEC.)

4. Fan automatic reverse rotation function

Setting the fan reverse rotation switch to “AUTO” allows changing the fan rotation direction switching
cycle and the reverse rotation duration at a specific interval.
As long as switching of the fan rotation direction is taking place, the pilot lamps of the fan reverse rota-
tion switch and the machine monitor keep blinking to inform the operator that the switching is underway.
And when the fan rotation is reversed responding to the high engine speed, high coolant or oil tempera-
ture, this lamp also keeps on blinking until the preparation for switching is completed.
As the fan rotation switching condition is met, this function sends the accelerator opening ratio-restrict-
ing signal to the engine controller so that the engine speed may not reach 1,200 rpm or above while the
switching is underway.
As long as the fan reverse rotation is continued, the pilot lamp of the fan reverse rotation switch and the
machine monitor remains turned on.
The fan rotation is switched from “forward” to “reverse” as every condition in the following table is met.
Condition 1 The fan reverse rotation switch is set “AUTO”.

Coolant temperature is below 90°C.
Condition 2
Hydraulic oil temperature over 50°C and below 90°C.
Condition 3
[90°C of the upper limit is set in order to prevent overheat.]
Torque converter oil temperature is below 90°C.
Condition 4
30 seconds have passed after the engine is started (after engine speed reached 500 rpm or above).
Condition 5
[In order to secure enough oil to be fed to the brake accumulator.]
Condition 6 The fan rotation direction switching cycle or the reverse rotation duration has elapsed.
The fan rotation is switched from “reverse” to “forward” as any of the following conditions is met.
While the fan reverse rotation was taking place, the fan reverse rotation switch was set to “AUTO”.
Condition 1
And then the hydraulic oil temperature went to 50°C or above.
After the fan rotation direction switching cycle or the reverse rotation duration has elapsed, the
Condition 2
hydraulic oil temperature went to 50°C or above.
Condition 3 Engine has stopped.
5. Adjustment of the automatic fan switching cycle to reverse rotation and duration
Any cycle is settable for the switching cycle of fan rotation direction and also any duration is settable for
the reverse rotation duration by adjusting the items “Automatic fan switching cycle to reverse rotation”
and “Reverse rotation duration” with the adjusting function of the machine monitor.
adjusting.
WA450-6, WA480-6 (KA SPEC.) 15

Work equipment swash plate control function

q The work equipment swash plate control function comprises the functions named “Engine stall preven-
tion control at low idle” and “Pickup auxiliary function when engine speed is low”. Comparing results of
calculations done on respective functions, this function select the data that makes the work equipment
pump discharge smaller (the data that sets a larger value for the command current to the swash plate
angle control EPC valve).
q A balance between the work capability and drawbar pull in respective modes is achieved by switching
from the pump discharge-reducing pressure to another. This change is done by switching the power
mode using the power mode selector switch.
Engine stall prevention control at low idle

q Engine stall can result from radical increase in load at low idle. In order to prevent this trouble when the
engine is below low idle, this function restricts the pump delivery at high pressure by controlling the
pump swash plate angle through EPC.
In P-mode
Engine speed (rpm) 700 710 770 780 790
EPC valve command
800 500 330 200 0
current (mA)
In E-mode
Engine speed (rpm) 700 710 770 780 790
EPC valve command
800 500 330 330 330
current (mA)
Oil pressure – flow rate characteristics when control is done with command current to swash plate angle
control EPC valve of work equipment pump
A: When EPC valve command current is 0 mA

B: When EPC valve command current is 300 mA
C: When EPC valve command current is 500 mA
D: When EPC valve command current is 800 mA
16 WA450-6, WA480-6 (KA SPEC.)

Pickup auxiliary function when engine speed is low

q Compound operation of the work equipment and steering at a low engine speed can make the engine
pickup poor because the work equipment pump suction torque becomes larger compared with the
torque generated with the engine.
q It is an auxiliary function prepared to help improving the engine pickup. As the accelerator pedal is
pressed from a low engine speed, this function sends the command current corresponding to the steer-
ing oil pressure to the swash plate angle control EPC valve of the work equipment pump in order to alle-
viate the load by controlling the pump swash plate.
1. Command current to swash plate angle control EPC valve of work equipment pump
This function stores the EPC valve command current value data corresponding to the data of engine
speed, accelerator opening ratio and steering oil pressure. It selects an optimum pump delivery by
choosing the data with the lowest current value.
When the pump delivery increased (when the command current is decreased), this function prevents
sudden operation of the work equipment due to radical increase in flow rate by restraining 120 mA or
greater fluctuations within 0.1 second.
When the pump delivery decreased (when the command current is increased), this function prevents
sudden stop of the work equipment due to radical decrease in flow rate by restraining 60 mA or greater
fluctuations within 0.1 second.
In P-mode
Engine speed (rpm) 900 1,400 1,420 2,200
EPC valve command current (mA) 800 800 200 0
Accelerator pedal opening ratio (%) 0 38 40 100

Steering pump oil pressure (MPa {kg/cm2}) 0 {0} 7.9 {80} 19.6 {200} 34.3 {350}
In E-mode
Engine speed (rpm) 900 1,400 1,420 2,200
Accelerator pedal opening ratio (%) 0 38 40 100

Steering pump oil pressure (MPa {kg/cm2}) 0 {0} 7.9 {80} 19.6 {200} 34.3 {350}
WA450-6, WA480-6 (KA SPEC.) 17

Transmission cut-off function

q The transmission cut-off oil pressure sensor detects the brake pilot pressure as the brake pedals of both
sides are pressed and sets the transmission to the neutral.
q The transmission can be cut-off at any position by saving the pressure at the brake pressing position as
the brake pilot oil pressure at which the transmission is set to the neutral.
1. Contents of control
• As the transmission cut-off operating conditions are met, the transmission is set to the
neutral.
Outline
• As the transmission cut-off reset conditions are met, the transmission is released and the
transmission gear speed is controlled by the modulation.
<Operating conditions at 1st and 2nd gear speeds>
• When the transmission cut-off switch is turned “ON” and the brake pilot oil pressure
Transmission became larger than the cut-off IN pressure.
Operating
cut-off control < Operating conditions at 3rd and 4th gear speeds>
condition
• When the transmission cut-off switch is turned “ON” and the brake pilot oil pressure
became larger than the cut-off IN pressure while the accelerator pedal opening ratio is
maintained at less than 30%.
If any of the following conditions is met, the cut-off is reset.
Reset
• The transmission cut-off switch is turned “OFF”.
condition
• The brake pilot oil pressure is below the cut-off OUT pressure.
Settable
• When the transmission cut-off switch is turned “ON”.
conditions
1) Press the brake pedal up to a desired setting position. (Setting is available without press-
ing the brake pedal)
2) Press the transmission cut-off set switch.
3) This function recognizes the brake pilot pressure at which the switch was pressed.
<When the position is within the settable range>
The brake pilot pressure at which the switch was pressed is temporarily stored.
Setting <When the position is out of the settable range>
method The upper limit or lower limit brake pilot pressure within the settable range is temporarily
Setting of the stored.
transmission This function sends the information to the machine monitor via the network needed by it
cut-off point to sound the set completion buzzer (beep).
4) The pilot lamp contained in the transmission cut-off switch blinks for 2 seconds.
5) Set value is saved. (The setup mode ends)
a The setting is held after the starting switch is turned “OFF”.
1) From step 4) of the setting method (the pilot lamp contained in the transmission cut-off
switch blinks for 2 seconds), press the transmission cut-off set switch again.
2) As the blinking ends, the cut-off point is set as the default brake pilot oil pressure. This
Resetting
function sends the information to the machine monitor via the network needed by it to
method
sound the setting cancel buzzer (beep).
3) Set (Default) value is saved. (The setup mode ends)
a The setting is held after the starting switch is turned “OFF”.
18 WA450-6, WA480-6 (KA SPEC.)

2. Outputting conditions
Pilot lamp contained in Buzzer command
Outputting conditions transmission cut-off (Communication Cut-off point
switch output)
Controlled with the
When transmission cut-off switch is “ON“ ON Not issued
value saved last
As the set switch
When transmission cut-off switch is “ON” and
Blinks is pressed, set Brake pilot oil pressure
transmission cut-off set switch is “ON”
(For 2 seconds or completion as the set switch is
For 2.5 seconds or until reset (sensor normal)
until reset) buzzer sounds pressed is saved
Up to setting methods 2) – 5)
(beep)
Not issued No control is turned on
When transmission cut-off switch is “ON” and
Remains turned off (Error buzzer is Saved value is not mod-
transmission cut-off pressure sensor is abnormal
sounded) ified
Not issued Controlled with value
When transmission cut-off switch is “ON” and (Machine monitor saved last
ON
transmission cut-off set switch is abnormal displays an error Saved value is not mod-
indication) ified
As the set switch
When transmission cut-off switch is “ON” and is pressed, set- Default value of brake
transmission cut-off set switch is “ON” ON ting cancel pilot oil pressure is
Reset is done within 2.5 seconds buzzer sounds saved
(beep)
When transmission cut-off switch is “OFF“ OFF Not issued Not controlled
a Shift indicator of machine monitor displays “N” as long as cut-off is continued. (Directional output signal “N”)
a As long as cut-off is continued, gear speed change from the gear shift lever is unavailable. (Gear speed
change when transmission is at neutral is prohibited)
After the cut-off is reset, connecting F or R clutch enables the gear speed change.
a When the cut-off had been turned on after selecting 1st speed with the kickdown switch, 1st speed is
selected after the reset regardless of the shift mode being selected.
a When the lockup is turned on, the cut-off is activated only after the lockup is reset.
3. Settable range of transmission cut-off point
Settable range
Note 1: When the specified cut-off point is below 0.49 MPa {5 kg/cm2}, it is assumed
0.49 – 4.41 MPa as 0.49 MPa {5 kg/cm2}.
{5 – 45 kg/cm2} Note 2: When specified cut-off point is 4.41 MPa {45 kg/cm2} or above, it is assumed
as 4.41 MPa {45 kg/cm2}.
The default value is 1.47 MPa{15 kg/cm2}
Hysteresis of 0.20 MPa {2 kg/cm2} is set for the cut-off IN (for neutral) pressure and OUT (reset) pressure.
Example) When the pressure sensor is set at a position where the pressure is 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}
WA450-6, WA480-6 (KA SPEC.) 19

ECSS function
1. Transmission controller Outline

2. gear shift lever
q When the machine travels at high speed, the
3. Speed sensor
damping effect of the accumulator charged
4. ECSS switch
with high-pressure gas and the automatic con-
5. ECSS cut-off oil pressure switch
trol of the lift cylinder circuit relief pressure
6. 1st clutch ECMV
under each travel condition damp the vertical
7. 2nd clutch ECMV
movement of the work equipment and reduce
8. 3rd clutch ECMV
rocking of the chassis. As a result, the operator
9. 4th clutch ECMV
comfort is improved, spillage of material is pre-
10. ECSS solenoid valve
vented, and the working efficiency is improved.
Setting method
a. Gear shift lever “1st” signal q The ECSS can be enabled only when “ADD” is
b. Gear shift lever “2nd” signal selected for “20. E.C.S.S.” item using the
c. Gear shift lever “3rd” signal optional device selecting function of the
d. Gear shift lever “4th” signal machine monitor.
e. Travel speed signal a For the setting procedure, see “Special func-
f. Pulse GND tions of machine monitor (EMMS)” in Testing
g. ECSS switch “ON” signal and adjusting.
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. ECSS operation signal
20 WA450-6, WA480-6 (KA SPEC.)

Operation
q The operating condition of ECSS is as follows.
Output shaft speed [rpm]

ECSS cut-off oil pressure ECSS operation
ECSS switch Gear speed (Reference: Travel speed
switch signal
[km/h])
OFF Full speed ON/OFF
Full speed 0 – MAX ON (Lift arm in operation)
OFF
1st
ON
Max. 221 (3) OFF (Lift arm stopped)
2nd – 4th
Min. 369 (5) ON
ECSS switching point A B

221 369
(Reference: Travel speed
(3) (5)
[km/h])
WA450-6, WA480-6 (KA SPEC.) 21

Electric emergency steering function

(if equipped)
1. Transmission controller Input and output signals

2. Emergency steering switch Transmission controller
3. Emergency steering switch relay a. CAN signal
4. Emergency steering relay b. Emergency steering switch signal
5. Emergency steering electric motor c. Steering oil pressure signal (Lo)
6. Emergency steering pump d. Steering oil pressure signal (Hi)
7. Machine monitor e. Emergency steering operation signal
7a. Steering oil pressure caution lamp f. Travel speed signal
7b. Emergency steering pilot lamp
9. Speed sensor Machine monitor
10. Engine speed sensor g. CAN signal
11. Steering pump oil pressure switch (Lo) h. Emergency steering operation signal
12. Steering pump oil pressure switch (Hi) i. Steering oil pressure signal (Lo)
13. Emergency steering oil pressure switch
14. Steering pump
15. Steering valve Engine controller
16. Steering cylinder j. CAN signal
k. Engine speed signal
22 WA450-6, WA480-6 (KA SPEC.)

Outline
q This function constantly monitors state of the oil pressure switch of the steering circuit. If the steering oil
pressure goes low and the transmission output shaft speed (travel speed) goes to or above the emer-
gency steering “ON” value shown in the figure, it outputs the emergency steering operation signal to the
emergency steering switch relay to activate the emergency steering.
q The emergency steering switch allows operating the emergency steering motor regardless of the steer-
ing oil pressure or the transmission output shaft speed (travel speed).
a Continuous operation by use of the emergency steering switch shall be no longer than 60 seconds.
a Travel speed when the emergency steering is operated shall be 5 km/h maximum.
Emergency steering
A B
switching point
140 148
(Reference: Travel speed
(1.9) (2.0)
[km/h])
Setting method
q The emergency steering function can be enabled only when “ADD” is selected for “13. EMERG S/T”
item using the optional device selecting function of the machine monitor.
Self-check operation of emergency steering

q The emergency steering system checks its operation automatically 3 seconds after the starting switch is
turned “ON” (after self-check of the machine monitor finished).
The self-check, however, is not performed in the following cases.
1) When the starting switch is set in the “START” position and the starting motor starts.
2) When the engine is already run.
(When the detected engine speed was above 500 rpm.)
3) While the steering oil pressure is being sensed.
4) When the automatic preheater operates.
5) When an error related to the emergency steering was detected in the process of self-check by the
machine monitor.
6) When the engine was not started for 10 seconds or longer after the preceding self-check.
(When the detected engine speed did not reach 500 rpm for 10 seconds or longer.)
q As self-check of the emergency steering is started, the emergency steering operation signal is output for
up to 3 seconds.
q When the machine monitor detected the emergency steering operation pressure within 3 seconds, the
machine monitor transmits the emergency steering operation sensing signal to the transmission control-
ler through network. Receiving the signal, it ends self-check of the emergency steering.
q If the machine monitor fails to detect the emergency steering operation pressure within 3 seconds, the
transmission controller becomes unable to recognize the emergency steering operation sensing signal
from the machine monitor and thus generates an error message.
WA450-6, WA480-6 (KA SPEC.) 23

System circuit diagram

24 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 25

Transmission controller 1
26 WA450-6, WA480-6 (KA SPEC.)


DEUTSCH-24P [CN-L61]
Pin No. Signal name Input/Output signal Pin No. Signal name Input/Output signal
1 Cooling fan automatic reverse rotation switch Input 13 Work equipment pump oil pressure sensor Input
2 Torque converter lockup switch Input 14 NC —
3 Steering pump oil pressure sensor Input 15 NC —
4 Signal GND — 16 Sensor power supply output (+24 V) Output
5 Transmission cut-off set switch Input 17 Steering pressure switch (Lo) Input
6 ECSS switch Input 18 Shift mode H Input
7 Cooling fan reverse rotation switch Input 19 Brake pressure sensor Input
8 NC Input 20 Memory reset Input
9 Transmission oil temperature sensor Input 21 Analog GND —
10 Signal GND — 22 Potentiometer power supply (+5 V) Output
11 Transmission cut-off switch Input 23 Steering pressure switch (Hi) Input
12 2-stage low idle switch Input 24 Shift mode L Input
DEUTSCH-40P(1) [CN-L62]
Pin No. Signal name Input/Output signal Pin No. Signal name Input/Output signal
1 NC — 21 NC —
2 Kickdown switch Input 22 CAN0-L Input and output
3 ECMV fill switch 4th Input 23 NC —
4 NC — 24 NC —
5 Directional selector switch (J/S FNR SW) R Input 25 Directional selector switch (J/S FNR SW) F Input
6 Neutralizer (parking brake) signal Input 26 Directional lever N Input
7 ECMV fill switch 2nd Input 27 ECMV fill switch Switch R Input
8 NC — 28 Power mode switch Input
9 NC — 29 Pulse GND —
10 NC — 30 NC —
11 NC — 31 NC —
12 NC — 32 CAN0-H Input and output
13 ECMV fill switch 3rd Input 33 NC —
14 NC — 34 NC —
15 Directional selector switch (J/S FNR SW) N Input 35 Starting switch C signal Input
16 Directional lever R Input 36 Directional lever F Input
17 ECMV fill switch 1st Input 37 ECMV fill switch F Input
18 NC — 38 Hold switch Input
19 NC — 39 NC —
20 Speed sensor Input 40 NC —
DEUTSCH-40P(2) [CN-L63]
Input/Output sig- Input/Output sig-
Pin No. Signal name Pin No. Signal name
nal nal
1 VB (Controller power) Input 21 GND (Controller GND) Input
2 VIS (Solenoid power) Input 22 VIS (Solenoid power) Input
3 SOL_COM (Solenoid common GND) Input 23 SOL_COM (Solenoid common GND) Input
4 Back-up lamp relay Output 24 Starting switch ACC signal Input
5 ECMV F Output 25 ECMV 1st Output
6 ECMV 2nd Output 26 ECMV 4th Output
7 Emergency steering switch relay Output 27 Work equipment pump EPC Output
8 Pilot lamp contained in transmission cut-off switch Output 28 Fan fan pump reverse rotation solenoid Output
9 Joystick shift-up switch Input 29 Emergency steering switch Input
10 Gear shift lever 1st Input 30 Gear shift lever 3rd Input
11 VB (Controller power) Input 31 GND (Controller GND) Input
12 VIS (Solenoid power) Input 32 GND (Controller GND) Input
13 SOL_COM (Solenoid common GND) Input 33 GND (Controller GND) Input
14 Starting switch ACC signal Input 34 NC —
15 ECMV R Output 35 ECMV L/U Output
16 ECMV 3rd Output 36 Cooling fan pump EPC Output
17 Travel damper solenoid Output 37 Neutral output Output
18 P/T pump bypass solenoid relay Output 38 NC —
19 Joystick shift-down switch Input 39 Directional selector switch actuation switch Input
20 Gear shift lever 2nd Input 40 Gear shift lever 4th Input
WA450-6, WA480-6 (KA SPEC.) 27

SEN01179-00

28
SEN01180-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)

Electric transmission control ................................................................................................................ 2
Combination switch .............................................................................................................................. 4
Kickdown switch and hold switch ......................................................................................................... 6
KOMTRAX terminal system ................................................................................................................. 8
Engine starting circuit ......................................................................................................................... 10
Engine stopping circuit ....................................................................................................................... 12
Preheating circuit ............................................................................................................................... 13
Engine power mode selector circuit ................................................................................................... 14
Engine output derating function ......................................................................................................... 15
Automatic warm-up function............................................................................................................... 15
Parking brake circuit........................................................................................................................... 16
Sensor................................................................................................................................................ 18
WA450-6, WA480-6 (KA SPEC.) 1


Electric transmission control 1
2 WA450-6, WA480-6 (KA SPEC.)

1. Transmission controller 8. Fuse box

2. Hold switch 9. Transmission cut-off oil pressure sensor
3. Kickdown switch 10. Brake valve
4. Parking brake switch 11. gear shift lever
5. Transmission cut-off switch 12. Directional lever
6. Transmission cut-off set switch 13. Speed sensor
7. Relay 14. Transmission ECMV
Function
No. Function Operation

Selection of travel direction and
1 The travel direction can be changed by operating the directional lever.
neutral
2 Selection of gear speed The gear speed can be changed by operating the gear shift lever.
The kickdown switch allows shifting down the gear without resorting to the gear
shift lever. In the manual gear shift mode, the gear can be shifted down to the 1st
3 Kickdown only while the transmission is in the forward 2nd. In the auto-shift mode, the gear
can be shifted down according to the gear speed and travel speed being selected
before the switch was pressed.
If the hold switch is pressed in the auto-shift mode, the current gear speed is held
4 Hold and is not shifted up even if the travel speed is increased. Even if the travel speed
is slowed down, the gear is not shifted down.
When the transmission cut-off switch is turned “ON”, the transmission is set to the
5 Transmission cut-off
neutral at the adjusted pressing distance of the brake pedal.
The transmission cut-off function allows adjusting the brake pedal pressing dis-
6 Transmission cut-off set
tance at which the transmission is set to the neutral.
The transmission cut-off function can be turned ON and OFF. While this function
7 Transmission cut-off selection is “OFF”, the left brake pedal works as the ordinary brake (similarly to the right
brake pedal).
While the parking brake is applied, it sets the transmission to the neutral. This
8 Neutralizer function prevents seizure of the parking brake by disabling the machine to travel
while the parking brake is applied.
This function disables starting the engine if the directional lever is not set to “N
9 Neutral safety
(Neutral)”. In this way, it prevents accidents caused by sudden start.
In the reverse travel, this function alerts nearby people by activating the backup
10 Alarm
lamp and backup buzzer.
WA450-6, WA480-6 (KA SPEC.) 3

Combination switch 1
Outline
q The directional lever has 3 positions and the gear shift lever has 4 positions. The detent mechanism is
not provided to each switch but installed to the body of the combination switch. Each switch is posi-
tioned with 2 pins and fixed to the body with 3 screws. As a lever is shifted to any position, the switch
connected with the shaft operates to conduct the current only to that circuit.
Function
No. Name Operation
1 Directional lever Selects the travel direction and neutral.
2 gear shift lever Selects a gear speed.
3 gear shift lever stopper Makes the gear shift lever not movable to the 3rd or 4th during work.
4 Turn signal lever Turns the turn signal lamps ON and OFF.
After turning to the right or left, setting the steering wheel back returns the turn
5 Self-cancel
signal lever automatically to the neutral.
6 Lamp switch Turns the headlamp, clearance lamp, tail lamp, and instrument panel lamp ON.
7 Dimmer switch Selects the high or low beam of the headlamp.
Flashes the right and left turn signal lamps, turn signal pilot lamps, and indicator
8 Hazard lamp switch
lamps.
9 Hazard lamp pilot lamp Starts flashing as the hazard lamp switch is turned “ON”.
4 WA450-6, WA480-6 (KA SPEC.)

Operation
q Shaft (2) of directional and gear shift lever (1)

of the combination switch is made one with
magnet (3). As lever (1) moves, magnet (3)
moves, too.
q Control switch (5) having Hall IC (4) is installed
under magnet (3). Hall IC (4) are arranged on
the board for each position.
q As the directional lever is set to “F (Forward)”,
magnet (3) comes right above Hall IC (4) of “F”
position of the control switch. Magnet (3) pro-
vides magnetism to Hall IC (4) moving through
the space between the clearance and case (6).
q Hall IC (4) is set in the magnetism sensor cir-
cuit. Upon detecting the magnetism of magnet
(3), it sends the “F (Forward)” position signal of
the directional lever to the current amplifier cir-
cuit. The current amplifier circuit outputs the
signal to operate the transmission ECMV.
WA450-6, WA480-6 (KA SPEC.) 5

Kickdown switch and hold switch 1
1. Switch A (White wiring harness) Function

2. Switch B (Yellow wiring harness)
q These switches are installed to the knob of the
3. Spring
lift arm control lever. Switch A (1) works as the
4. Harness
kickdown switch and switch B (2) works as the
hold switch.
q Both of switch A (1) and switch B (2) are of
momentary type, that is, their contacts are
closed only while they are pressed.
6 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 7

KOMTRAX terminal system 1
q The KOMTRAX terminal sends various information on the machine by a wireless communication.The
KOMTRAX operator refers to this information in the office, and various services can be provided for the
customer.
a To be provided with the KOMTRAX terminal service, it is necessary to sign up separately.
Information that can be sent from the KOMTRAX terminal is as follows:

1. Traveling map
2. Service meter
3. Location information
4. Error history
8 WA450-6, WA480-6 (KA SPEC.)

KOMTRAX terminal
1. Communication antenna connector

2. GPS antenna connector
3. Machine harness connector (DEUTSCH-40P)

DEUTSCH-40P [CN-L80]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 NC — 21 Operation mode selection 1 Input
2 NC — 22 Operation mode selection 2 Input
3 NC — 23 NC —
4 NC — 24 NC —
5 NC — 25 NC —
6 NC — 26 NC —
7 CAN0_L Input/Output 27 Starting switch C signal Input
8 CAN0_H Input/Output 28 Alternator R signal Input
9 NC — 29 NC —
10 NC — 30 NC —
11 NC — 31 NC —
12 NC — 32 NC —
13 NC — 33 NC —
14 NC — 34 NC —
15 NC — 35 NC —
16 NC — 36 Starting switch ACC signal Input
17 NC — 37 Power supply GND —
18 NC — 38 Power supply GND —
19 NC — 39 Constant power supply (24 V) Input
20 Immobilize signal Output 40 Constant power supply (24 V) Input
Outline
q The KOMTRAX controller can send informa- q There are the LED lamp and the 7-segment
tion via wireless communication antenna, indicator lamp in the display area, and these
acquiring various information of the machine lamps are used for the testing and the trouble-
from the network signal in the machine and the shooting.
input signal. Also, the controller incorporates
CPU (Central Processing Unit) and provide the
wireless communication function and the GPS
function.
WA450-6, WA480-6 (KA SPEC.) 9

Engine starting circuit 1
1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to
3. Slow-blow fuse secure safety when the engine is started.
4. Fuse box 1 q The engine can not be started while the
5. Fuse box 2 directional lever is not in N (Neutral).
6. Starting switch
7. Directional lever 2. The KOMTRAX engine cut circuit is employed
8. Neutral safety relay to disable the engine from starting when the
9. KOMTRAX engine cut-out relay KOMTRAX receives an engine cut command
10. Transmission controller neutral safety relay issued through external operation.
11. Starting motor safety relay
12. Starting motor
13. Alternator
14. Transmission controller
16. Machine monitor
17. KOMTRAX controller
18. Engine controller cut-out relay
19. CAN resistor
10 WA450-6, WA480-6 (KA SPEC.)

Operation
1. When starting switch is turned “ON”
q As the starting switch is turned “ON”, ter-
minals B and BR of the starting switch are
closed and the current flows from the bat-
tery through the starting switch and bat-
tery relay coil to the ground, thereby
closing the contact of the battery relay. As
a result, the power is supplied to each cir-
cuit of the machine.
At this time, the ACC signal is sent from
terminal ACC of the starting switch to the
engine controller, readying the engine for
startup.
2. Neutral safety circuit

q Setting the directional lever to “N (Neu-
tral)” conducts the current from contact N
of the directional lever to the coil of the
neutral safety relay.
3. When starting switch is set to “START”

q As the starting switch is set to “START”,
the current flows through the starting
switch terminal C, KOMTRAX engine cut-
out relay, neutral safety relay and trans-
mission controller neutral safety relay to
the starting motor safety relay to start the
engine.
q When the directional lever is set to any
position other than “N (Neutral)”, the neu-
tral safety relay is not activated and inter-
rupts the engine startup.
q As KOMTRAX controller receives the
externally applied engine cut-out com-
mand, KOMTRAX engine cut-out relay is
activated, shutting down the circuit from
the starting switch C terminal to the starting
motor safety relay. Thus, engine startup
becomes unavailable.
WA450-6, WA480-6 (KA SPEC.) 11

Engine stopping circuit 1
Operation
q Setting the starting switch to “OFF” cuts off
ACC signal from the starting switch terminal
ACC to the engine controller.
q Although ACC signal is cut off, the engine con-
troller keeps the engine controller cut-out relay
working to maintain the current flow to the
engine controller until its internal processing is
complete.
q As ACC signal is cut off, the engine lowers its
speed and stops. At the same time, the alter-
nator stops power generation. Thus, supply of
voltage from the alternator terminal R is
aborted.
And the current from the starting switch termi-

nal BR is also stopped and the contacts of the
battery relay are opened. Consequently, the
power supplied to each circuit of the machine
is stopped.
12 WA450-6, WA480-6 (KA SPEC.)

Preheating circuit 1
1. Battery Outline
2. Battery relay q The automatic preheating system is installed so
3. Slow-blow fuse that the engine will start easily in a cold district.
4. Fuse box 1 q The automatic preheating system is capable of
5. Starting switch cutting the preheating time short as the starting
6. Engine controller switch is set to “ON”. This system is also capa-
7. Machine monitor ble of automatically setting the preheating
8. Electrical intake air heater relay duration referencing temperature of intake air.
9. Electrical intake air heater q Setting the starting switch to “ON” lights the
10. Engine coolant and intake manifold intake air preheater pilot lamp of the machine monitor
temperature sensor and starts preheating of intake air with the
electrical intake air heater.
The engine controller sets the preheating dura-
tion referencing the temperature being sent
from the engine coolant sensor and the intake
manifold intake air temperature sensor.
q The pilot lamp remains turned on as long as
preheating is continued. Keep the starting
switch in the “ON” position during this time.
Setting the starting switch to “START” from this
state resets preheating.
Operation
q Set the starting switch to “ON” to start the
engine controller. If, at this point, the engine
coolant temperature or intake manifold intake
air temperature is below the setting, the engine
controller starts up the electrical intake air
heater relay immediately after the starting
switch is turned “ON” to initiate preheating by
the electrical intake air heater.
q The preheating time is set as shown below.
WA450-6, WA480-6 (KA SPEC.) 13

Engine power mode selector circuit 1
1. Power mode selector switch

3. Machine monitor
Function
q Setting the power mode selector switch to “P-
mode” increases the engine output to the max-
imum. And setting the switch to “E-mode”
reduces the working fuel consumption.
q Receiving the switch signal, the transmission
controller selects a gear speed and travel
speed matched to the power mode in the auto-
shift mode.
Operation
q Setting the power mode selector switch to “P-
mode” sends the switch signal to the transmis-
sion controller and CAN signal to the engine
controller, changing the engine torque perfor-
mance curve into “P-mode”. At the same time,
the transmission controller sends the power
mode pilot lamp lighting signal to the machine
monitor using the CAN signal format.
14 WA450-6, WA480-6 (KA SPEC.)

Engine output derating function 1 Automatic warm-up function 1

q If the engine controller detects a failure, it pro- q When starting the engine in a cold district, this
tects the engine by derating the engine torque function warms it up by increasing the engine
or speed. low idle speed.
q Following figure shows the engine torque per- q If the coolant temperature is below 20°C at
formance when the torque was derated. starting of the engine, this function increases
the low idle speed to 1,020 rpm. The time
required for increasing the low idle speed
depends on the coolant temperature as shown
in the figure below.
q If the coolant temperature reaches 30°C or
above or the accelerator pedal opening ratio
remains at 70% or above for 3 seconds mini-
mum during this process, the automatic warm-
up function is automatically reset and the
engine speed returns to 800 rpm.
A: Maximum torque point is derated by approx. 30%

B: Rated output point is derated by approx. 50%
q Following figure shows the engine torque per-

formance when the engine speed was derated.
A: Derated near to the engine speed at maximum

torque point
WA450-6, WA480-6 (KA SPEC.) 15

Parking brake circuit 1 When starting switch is turned “ON”

1. When parking brake switch was turned “ON
Operation
(applied)” prior to turning “ON” of starting
switch
1. Parking brake relay

2. Parking brake switch
q While parking brake switch (2) is turned
3. Brake oil pressure caution relay
“ON (applied)”, current from the battery
4. Rear brake oil pressure switch
relay flows through parking brake switch
5. Emergency brake oil pressure switch
(2) to the coil of parking brake relay (1)
6. Parking brake solenoid valve
and closes the contact.
q As parking brake relay (1) contact is
8. Machine monitor
closed, current from the battery relay
keeps on flowing to the coil, holding the
When starting switch is turned “OFF”
relay contact, until current from the battery
q Turning the starting switch “OFF” opens con- relay is cut off.
tact of parking brake relay (1). Thus, current to q At this time, current does not flow to park-
the parking brake circuit is stopped and opera- ing brake solenoid valve (6). Thus, the
tion of the parking brake is started. Accord- parking brake remains being applied.
ingly, when the starting switch is turned “OFF”, q Recognizing the operation signal from
current is not conducted to parking brake sole- parking brake switch (2), transmission
noid valve (6) regardless of the position of controller (7) sets the transmission to the
parking brake switch (2). And the parking neutral as long as the parking brake is
brake remains being applied. applied so that its dragging may not result.
q Turning “OFF (released)” the parking
brake switch then conducts current from
the battery relay through parking brake
relay (1), parking brake switch (2), emer-
gency brake oil pressure switch (5) to
parking brake solenoid valve (6) to release
the parking brake.
16 WA450-6, WA480-6 (KA SPEC.)

2. When parking brake switch was turned “OFF When low oil pressure occurred on main
(released)” prior to turning “ON” of starting brake (when emergency brake is applied)
switch
q If oil pressure of the main brake goes low,

q While the parking brake switch is “OFF contact of rear brake oil pressure switch
(released)”, the current does not flow to (4) with the high operating pressure set-
parking brake relay (1) and its contacts ting opens first, cutting off current to coil of
remain open. brake oil pressure caution relay (3).
q Turning “ON” the starting switch from this q Then contact of brake oil pressure caution
state does not conduct current to parking relay (3) opens, cutting off current to
brake solenoid valve (6). Accordingly, the m ac hi ne mon it o r ( 8) . A s t he r es ul t ,
parking brake is not released automati- machine monitor generates the alarm.
cally. q Then contact of emergency brake oil pres-
sure switch (5), the operating pressure
setting of which is lower than that of rear
brake oil pressure switch (4), opens cut-
ting off current to parking brake solenoid
valve (6). As the result, the parking brake
is applied.
q In this case, unlike when the parking
brake switch was turned “ON (applied)”,
flow of the operation signal from parking
brake switch (2) to the transmission con-
troller (7) is maintained. Thus, transmis-
sion is not set to the neutral.
q Therefore, when the emergency brake is
applied, using the engine brake in parallel
allows not only reducing the braking dis-
tance but also moving the machine should
the emergency brake is applied.
WA450-6, WA480-6 (KA SPEC.) 17

Sensor 1
Speed sensor
1. Wire 4. Housing
2. Magnet 5. Connector
3. Terminal
Function
q Being set in the output gear of the transmission case, this sensor outputs pulsed voltage sensing the
gear speed.
Torque converter oil temperature sensor

Hydraulic oil temperature sensor
Transmission oil temperature sensor
Brake oil temperature sensor
1. Connector 3. Thermistor
2. Plug
Function
q The torque converter oil temperature sensor is installed on the transmission case (rear). The hydraulic
oil temperature sensor is installed on the return line block of the hydraulic tank. The transmission oil
temperature sensor is installed on the transmission case (front). And the brake oil temperature sensor is
installed on the rear axle. They convert changes in temperature to changes in resistance of the ther-
mistors to output the results in signals.
18 WA450-6, WA480-6 (KA SPEC.)

Work equipment pump oil pressure sensor

Steering pump oil pressure sensor
1. Plug
2. Sensor
3. Connector
Function
q The work equipment pump oil pressure sensor Output characteristics
is installed on the work equipment control
valve and the steering pump oil pressure sen-
sor is installed on the block of the steering
pump discharge line. They are used for detect-
ing the pump discharge pressure and output it
in variable voltages.
WA450-6, WA480-6 (KA SPEC.) 19

Transmission cut-off oil pressure sensor
1. Sensor
2. Lead wire
3. Connector
Function
q Being installed on the tube of the front brake Output characteristics
line situated under the floor, this sensor out-
puts the brake operating pressure in variable
voltage.
20 WA450-6, WA480-6 (KA SPEC.)

Coolant level sensor
1. Float 3. Connector
2. Sensor 4. Sub-tank
Function
q This sensor is installed under the platform situated on the right side of the operator seat. As the coolant
level goes below the specified level, the float is lowered and the switch is turned “OFF”.
WA450-6, WA480-6 (KA SPEC.) 21

Fuel level sensor
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
The float moves the variable resistor through the arm. The resistance changes according to the operat-
ing angle and signal voltage is generated from the source voltage according to the change of the resis-
tance.
22 WA450-6, WA480-6 (KA SPEC.)

Air cleaner clogging sensor
1. Indicator 3. Adapter
2. Spring 4. Connector
Function
q The air cleaner clogging sensor is installed in the air cleaner outlet. It outputs the signal as the air
cleaner is clogged and the pressure is decreased to the specified level (negative pressure).
WA450-6, WA480-6 (KA SPEC.) 23

Accelerator pedal sensor
1. Pedal
2. Connector
3. Sensor
Function
q This sensor is installed on the surface of the Output characteristics
floor. It outputs the accelerator signal or idle
validation signal depending on the accelerator
pressing angle.
Accelerator signal
q Magnitude of the accelerator pedal displace-
ment being detected by the potentiometer
inside the sensor is output in variable voltage
from No. 2 pin.
Idle validation signal

q The switch inside the sensor detects the accel-
erator pedal operation. As the accelerator
pedal is released, it outputs the signal being
entered to No. 5 pin from No. 4 pin. And as the
accelerator pedal is pressed, it outputs the sig-
nal being entered to No. 6 pin from No. 4 pin.
24 WA450-6, WA480-6 (KA SPEC.)

Boom kick-out proximity switch

Bucket positioner proximity switch
1. Switch 3. Operation indication lamp

2. Locknut 4. Connector
Function
q The boom kick-out proximity switch is installed in the lift arm left side connecting part to the left side of
the front arm. And the bucket positioner proximity switch is installed on the bucket cylinder. As long as
the plate is positioned on the detector plane, the switch lights up the operation indication lamp and turns
itself “ON”.
WA450-6, WA480-6 (KA SPEC.) 25

SEN01180-00

26
SEN01300-01
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
20 Standard value table 1

Standard service value table
Standard service value table ........................................................................................................................... 2
Standard value table for engine ........................................................................................................... 2
Standard value table for chassis .......................................................................................................... 3
WA450-6, WA480-6 (KA SPEC.) 1

SEN01300-01 20 Standard value table
Standard service value table 1

Standard value table for engine 1
Machine model WA450-6, WA480-6

Engine SAA6D125E-5
Standard value Service limit
Item Measurement condition Unit for new machine value
WA450-6 WA480-6 WA450-6 WA480-6
1,880 2,020 1,880 2,020
High idle (E-mode)
± 50 ± 50 ± 50 ± 50
2,170 2,190 2,170 2,190
Engine speed High idle (P-mode) rpm ± 50 ± 50 ± 50 ± 50
Low idle (E-mode) 800 (+50/0) 800 (+50/0)
Low idle (P-mode) 800 (+50/0) 800 (+50/0)
Exhaust temperature
Whole speed range
(Turbocharger outlet °C Max. 700 Max. 700
(Ambient temperature: 20°C)
temperature)
Intake air pressure kPa Min. 107 Min. 120 87 100
At rated output
(Boost pressure) (mmHg) {Min. 800} {Min. 900} {650} {750}
At sudden acceler- Discol-
Engine coolant temperature: ation Max. 25 —
Exhaust gas color oration
Within operating range
At high idle % — —
Air intake valve 0.33 —
Valve clearance Normal temperature mm
Exhaust valve 0.71 —
At rated output
kPa Max. 1.27 1.96
Blow-by pressure Engine coolant temperature:
(mmH2O) {Max. 130} {200}
At rated output
0.29 – 0.69 0.18
Engine coolant temperature: SAE0W30EOS
{3.0 – 7.0} {1.8}
Within operating range SAE5W40EOS MPa
Oil pressure SAE10W30DH
At low idle {kg/cm2}
SAE15W40DH Min. 0.05 0.03
Engine coolant temperature: SAE30DH
{Min. 0.5} {0.3}
Oil temperature All engine speed ranges (Inside oil pan) °C 90 – 110 120
Deflection made by finger Alternator –
13 —
pressure of about 58.8 N {6 kg} crankshaft pulley
Belt tension Air conditioner mm
Deflection made by finger
compressor – 25 – 26 25 – 26
pressure of about 98 N {10 kg}
crankshaft pulley
2 WA450-6, WA480-6 (KA SPEC.)

Standard value table for chassis 1

* : The value shows the value before the detent.
Machine model WA450, 480-6
Directional lever Category

WA450-6 WA480-6 WA450-6 WA480-6
No
Operating 5.9 (+4.9/–3.0)
FORWARD, N {kg} Max. 16.7 {1.7}
effort {0.6 (+0.5/–0.3)}
REVERSE • Engine stopped
No • Measure at center of lever knob
Travel FORWARD, mm 35 ± 10 35 ± 20
REVERSE
5.9 (+4.9/–3.0)
1st o 2nd Max. 16.7 {1.7}
{0.6 (+0.5/–0.3)}
Operating 5.9 (+4.9/–3.0)
Gear shift lever
2nd o 3rd N {kg} Max. 16.7 {1.7}

effort {0.6 (+0.5/–0.3)}
• Engine stopped 5.9 (+4.9/–3.0)
3rd o 4th • Measure at center of lever knob Max. 16.7 {1.7}
{0.6 (+0.5/–0.3)}
1st 2nd 35 ± 10 35 ± 20
Travel 2nd 3rd mm 35 ± 10 35 ± 20
3rd 4th 35 ± 10 35 ± 20
HOLD o
Max. 12.8 {1.3} (*) Max. 19.6 {2.0} (*)
RAISE
RAISE o
Max. 14.7 {1.5} Max. 22.6 {2.3}
HOLD
HOLD o
Max. 12.8 {1.3} (*) Max. 19.6 {2.0} (*)
LOWER
Lift arm
LOWER o
— —
Operating effort
HOLD
• Engine speed: Low idle
LOWER o
• Hydraulic oil temperature: N {kg} Max. 15.7 {1.6} Max. 23.5 {2.4}
FLOAT
Work equipment control lever
FLOAT o
Max. 14.7 {1.5} Max. 22.6 {2.3}
HOLD
HOLD o
Max. 17.7 {1.8} Max. 26.5 {2.7}
DUMP
HOLD o
Bucket Max. 12.8 {1.3} (*) Max. 19.6 {2.0} (*)
TILT
TILT o
Max. 14.7 {1.5} Max. 22.6 {2.3}
HOLD
HOLD
43 ± 9 (*) 43 ± 18 (*)
RAISE
HOLD
Lift arm 43 ± 9 (*) 43 ± 18 (*)
LOWER
• Engine speed: Low idle
Travel
HOLD
• Hydraulic oil temperature: mm 50 ± 9 50 ± 18
FLOAT
HOLD o
50 ± 9 50 ± 18
DUMP
Bucket
HOLD o
43 ± 9 (*) 43 ± 18 (*)
TILT
WA450-6, WA480-6 (KA SPEC.) 3


Category

WA450-6 WA480-6 WA450-6 WA480-6
• Engine stopped
Play mm Max. 20 Max. 50
• Machine facing straight to front
• Flat, level, straight, dry, and paved road
6.9 – 12.6 Max. 19.6
Operating effort • Engine speed: Low idle N {kg}
Steering wheel
{0.7 – 1.3} {Max. 2.0}

(Bucket empty)
• Engine speed: High idle
Turns (Not including play) Turns 3.5 ± 0.4 3.5 ± 0.8
• Left lock – right lock
• Engine started
Low idle 4.1 ± 0.4 Max. 6.2
Operating • Hydraulic oil temperature:
Sec.
time Within operating range
High idle • Left lock – right lock 3.5 ± 0.4 Max. 5.3
• Engine speed: 1,200 rpm

• Hydraulic oil temperature:
Frame
Clearance between front Within operating range

mm 43 ± 5 —
frame and rear frame • Flat, level, straight, dry, and paved
road
• At max. steering angle
• Engine started
29.4 – 58.6
Accelerator pedal
Pressing effort • Measure at 150 mm from fulcrum of N {kg} —

{3.0 – 6.0}
pedal.
aFor measuring posture, see Fig. A at
Neutral (a1) 45 ± 2 —
Pressing end of this section
deg.
angle • Engine started
Max. (a2) • a2 = a1 – a3 17 ± 2 —
aFor measuring posture, see Fig. B at 323 ± 30 Min. 264

Pressing effort N {kg}
Brake pedal
end of this section {32.9 ± 3.0} {Min. 26.9}

Pressing Neutral (a1) • Engine speed: Low idle 53 —
angle Max. (a2) deg. 15 (+1/0) —
Play 5±1 —
Fitting of wheel lock A aFor measuring posture, see Fig. C at Max. 2.5 —
ring B end of this section Max. 4.0 —
Tires
• Tire inflation pressure: Specified pres- mm

Clearance of wheel sure
C 2 – 10 —
lock ring
1,800 1,900 1,800 1,900
E-mode
± 50 ± 50 ± 100 ± 100
Torque converter stall
2,020 2,030 2,020 2,030
P-mode
• Coolant temperature: ± 50 ± 50 ± 100 ± 100
Engine Speed
Within operating range 1,870 1,970 1,870 1,970

• Torque converter oil temper- E-mode ± 100 ± 100 ± 200 ± 200
Hydraulic stall ature: Within operating rpm
range 2,140 2,150 2,140 2,150
P-mode
• Hydraulic oil temperature: ± 100 ± 100 ± 200 ± 200
Within operating range 1,850 1,850 1,850 1,850
E-mode
Torque converter stall + ± 100 ± 100 ± 200 ± 200
hydraulic stall 1,980 1,850 1,980 1,850
P-mode
± 100 ± 100 ± 200 ± 200
4 WA450-6, WA480-6 (KA SPEC.)


Category

WA450-6 WA480-6 WA450-6 WA480-6
2.78 ± 0.2 2.78 ± 0.2
Low idle
Main relief {28.3 ± 2} {28.3 ± 2}
pressure Engine speed: 2.93 ± 0.2 2.93 ± 0.2
Transmission, torque converter
2,000 rpm • Torque converter oil temperature: {29.9 ± 2.0} {29.9 ± 2.0}
Within operating range (60 – 80°C)
Torque converter relief • Engine speed: 2,000 rpm Max. 0.93 Max. 0.93
(inlet) oil pressure {Max. 9.5} {Max. 9.5}
Torque converter outlet port MPa 0.59 ± 0.05 0.59 ± 0.05
oil pressure {kg/cm2} {6 ± 0.5} {6 ± 0.5}
1st, 2nd, 3rd, 2.31 ± 0.15 2.31 ± 0.15
4th • Torque converter oil temperature: {23.5 ± 1.5} {23.5 ± 1.5}
ECMV output
Within operating range (60 – 80°C) 2.06 ± 0.15 2.06 ± 0.15
(clutch) oil F–R
• Engine speed: 2,000 rpm {21.0 ± 1.5} {21.0 ± 1.5}
pressure
Lockup • Manual switch: ON 2.40 ± 0.15 2.40 ± 0.15
(if equipped) {24.5 ± 1.5} {24.5 ± 1.5}
24.5 ± 1.23 24.5 (+1.23/–2.45)
Steering relief pressure Within operating range
{250 ± 12.5} {250 (+12.5/–25)}
Steering
MPa
• Hydraulic oil temperature: {kg/cm2}
Within operating range 1.1 – 1.3 0.9 – 1.5
Steering control pressure
• Engine speed: Low idle {11 – 13} {9 – 15}
• Steering wheel: Neutral
• Point where
brake oil pres- 5.9 (+0.5/0) 5.9 (+0.98/–0.5)
Charge cut-in pressure
• Engine speed: sure warning {60 (+5/0)} {60 (+10/–5)}
Accumulator
Low idle lamp goes out

MPa
• Hydraulic oil tem- • Point where oil
{kg/cm2}
perature: pressure is
Within operating range going up and 9.8 (+0.98/0} 9.8 (+1.5/–0.5}
Charge cut-out pressure
{100 (+10/0)} {100 (+15/–5)}
then starts to
go down
6.3 6.3 6.3 6.3
1st
± 0.3 ± 0.3 ± 0.4 ± 0.4
12.1 12.2 12.1 12.2
2nd
± 0.6 ± 0.6 ± 0.8 ± 0.9
P-mode
Power transmitting system
21.7 21.7 21.7 21.7

3rd
± 1.1 ± 1.1 ± 1.5 ± 1.5
34.9 34.5 34.9 34.5
4th
Travel speed FOR- ± 1.7 ± 1.7 ± 2.4 ± 2.4
km/h
(Bucket empty) WARD 5.3 5.7 5.3 5.7
1st
± 0.3 ± 0.3 ± 0.4 ± 0.4
10.2 11.0 10.2 11.0
2nd
± 0.5 ± 0.6 ± 0.7 ± 0.8
E-mode
18.1 19.5 18.1 19.5
3rd
± 0.9 ± 1.0 ± 1.3 ± 1.4
27.3 30.8 27.3 30.8
4th
± 1.4 ± 1.5 ± 1.9 ± 2.2
WA450-6, WA480-6 (KA SPEC.) 5


Category

WA450-6 WA480-6 WA450-6 WA480-6
6.7 6.6 6.7 6.6
1st
± 0.3 ± 0.3 ± 0.5 ± 0.5
12.8 12.9 12.8 12.9
2nd
± 0.6 ± 0.6 ± 0.9 ± 0.9
P-mode
Power transmitting system
23.0 22.9 23.0 22.9

3rd
± 1.2 ± 1.1 ± 1.6 ± 1.6
36.0 35.6 36.0 35.6
4th
Travel speed ± 1.8 ± 1.8 ± 2.5 ± 2.5
REVERSE km/h
(Bucket empty) 5.6 6.0 5.6 6.0
1st
± 0.3 ± 0.3 ± 0.4 ± 0.4
10.8 11.6 10.8 11.6
2nd
± 0.5 ± 0.6 ± 0.8 ± 0.8
E-mode
19.2 20.6 19.2 20.6
3rd
± 1.0 ± 1.0 ± 1.3 ± 1.4
28.2 31.8 28.2 31.8
4th
± 1.4 ± 1.6 ± 2.0 ± 2.2
• Hydraulic oil temperature: 4.8 ± 0.4 Min. 4.2
Brake oil pressure
Within operating range {48.9 ± 4.1} {Min. 42.7}
MPa
• Engine stopped
Lowering of brake oil pres- {kg/cm2} Max. 0.49 Max. 0.49
• Measure lowering of oil pressure from
sure {Max. 5.0} {Max. 5.0}
4.9 MPa {50 kg/cm2} in 5 min.
• Tire inflation pressure:
Specified pressure
Wheel brake
• Flat, level, straight, dry, and paved

road
Performance • Speed when applying brake: 20 km/h, m Max. 5 Max. 5
braking delay: Within 0.1 sec.
• Brake pedal operating effort: Specified
operating effort 323 ± 30 N {32.9 ± 3 kg}
• Measure braking distance
Shaft protrusion
• Oil pressure: 4.9 MPa {50 kg/cm2} reaches wear
Disc wear mm Shaft protrusion 0
• Pedal depressed fully limit position
(Max. 2.4 mm)
• Torque converter oil temperature: Min. 2.27 Min. 2.27
Parking brake oil pressure
Within operating range MPa {Min. 23.1} {Min. 23.1}
Parking brake solenoid valve • Engine speed: Low idle {kg/cm2} Min. 2.27 Min. 2.27
basic pressure • Parking brake: OFF {Min. 23.1} {Min. 23.1}
Parking brake
• Tire inflation pressure:

Specified pressure
• Flat paved road with 1/5 (11° 20')
Performance grade. Dry, paved road surface — Holds in position Holds in position
• Machine at operating condition
aFor measuring posture, see Figs. D
and E at end of this section
Disc thickness mm 3.2 ± 0.08 2.97
6 WA450-6, WA480-6 (KA SPEC.)


Category

WA450-6 WA480-6 WA450-6 WA480-6
3.72 (+0.2/0) 3.72 (+0.2/–0.2)
PPC valve basic pressure Within operating range
{38 (+2/0)} {38 (+2/–2)}
Lift arm
RAISE, MPa
PPC
• Hydraulic oil temperature: 3.72 (+0.1/–0.1) 3.72 (+0.1/–0.2)

PPC valve FLOAT; {kg/cm2}
Within operating range {38 (+1/–1)} {38 (+1/–2)}
output pres- Bucket
DUMP, TILT • Engine speed: High idle
sure
• Control lever operated fully
Lift arm 2.2 ± 0.25 2.2 ± 0.39
LOWER {22.5 ± 2.5} {22.5 ± 4}
Work equipment relief pres- 34.3 ± 1.77 34.3 (+1.77/–4.41)
sure {350 ± 18} {350 (+18/–45)}
1.96 ± 0.20 1.96 ± 0.40
Unload pressure • Engine speed: High idle MPa
{20 ± 2} {20 ± 4}
• Work equipment control lever: Neu- {kg/cm2}
tral
Within operating range 1.37 ± 0.2 1.37 ± 0.39
LS differential pressure
• Engine speed: High idle {14 ± 2} {14 ± 4}
• Lift arm lever: at half stroke
6.3 7.1 Max. Max.
E-mode
• Hydraulic oil temperature: ± 0.5 ± 0.5 8.4 9.5
Lift arm RAISE Within operating range 5.8 6.6 Max. Max.
• Engine speed: High idle P-mode
± 0.5 ± 0.5 7.7 8.8
• Apply no load
aFor measuring posture, see E-mode 3.8 3.9 Max. Max.
Figs. F and G at end of this ± 0.5 ± 0.5 5.1 5.2
Lift arm LOWER
Work equipment
section 3.7 3.8 Max. Max.

Work equipment speed
P-mode
± 0.5 ± 0.5 4.9 5.1
1.8 2.1 Max. Max.
E-mode
± 0.3 ± 0.3 2.4 2.8
Forward Sec.
1.6 1.9 Max. Max.
P-mode
Bucket • Hydraulic oil temperature: ± 0.3 ± 0.3 2.1 2.5
full stroke Within operating range 2.6 3.1 Max. Max.
• Engine speed: High idle E-mode
± 0.3 ± 0.3 3.5 4.1
Backward • Apply no load
aFor measuring posture, see P-mode 2.4 2.8 Max. Max.
Figs.H and J at end of this ± 0.3 ± 0.3 3.2 3.7
Moving section 1.6 2.1 Max. Max.
E-mode
bucket ± 0.3 ± 0.3 2.1 2.8
Backward
from level 1.5 1.9 Max. Max.
position P-mode
± 0.3 ± 0.3 2.0 2.5
Retraction of lift arm cyl- Within operating range Max. 30 Max. 36
Hydraulic drift
inder rod • Stop engine and leave for 5 minutes,

then measure for 15 minutes.
mm
• Apply no load to bucket and set lift
Retraction of bucket cyl- arm and bucket in level position.
aFor measuring posture, see Fig. K at Max. 20 Max. 24
inder rod
end of this section
WA450-6, WA480-6 (KA SPEC.) 7


Category

WA450-6 WA480-6 WA450-6 WA480-6
• Engine coolant temperature: Min.
95°C
Max. fan speed 1,600 ± 100 1,600 ± 200
• Hydraulic oil temperature: Min. 95°C
• Torque converter oil temperature:
Min. 105°C
• Engine speed: Low idle rpm
• Engine coolant temperature:
Max. 75°C
Min. fan speed • Hydraulic oil temperature: Max. 75°C 600 ± 50 600 ± 100
Hydraulic drive fan

Max. 85°C
• Air conditioner: OFF
Min. 95°C 17.3 ± 1.7 17.3 ± 2.6
Fan drive pressure
• Hydraulic oil temperature: Min. 95°C {176 ± 18} {176 ± 26}
Min. 105°C MPa
• Engine speed: High idle {kg/cm2}
Fan reverse solenoid output Min. 95°C 17.3 ± 1.7 17.3 ± 2.6
pressure • Hydraulic oil temperature: Min. 95°C {176 ± 18} {176 ± 26}
Min. 105°C
8 WA450-6, WA480-6 (KA SPEC.)

Machine posture and procedure for performance measurement
a Fig. A a Fig. D
a Fig. B a Fig. E
a Fig. C a Fig. F
WA450-6, WA480-6 (KA SPEC.) 9

a Fig. G a Fig. K
a Fig. H
a Fig. J
10 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 11

SEN01300-01

12
SEN01586-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
30 Testing and adjusting 1

Testing and adjusting, Part 1
Testing and adjusting, Part 1........................................................................................................................... 3
Tools for testing, adjusting, and troubleshooting .................................................................................. 3
Measuring engine speed...................................................................................................................... 6
Measuring exhaust gas color ............................................................................................................... 8
Measuring exhaust temperature .......................................................................................................... 9
Adjusting valve clearance ...................................................................................................................11
Measuring compression pressure ...................................................................................................... 13
Measuring blow-by pressure .............................................................................................................. 15
Measuring engine oil pressure ........................................................................................................... 16
Check of exhaust gas recirculation (EGR) system............................................................................. 17
Measuring intake air (boost) pressure................................................................................................ 18
Handling fuel system equipment ........................................................................................................ 19
Releasing residual pressure in fuel system........................................................................................ 19
Testing fuel pressure .......................................................................................................................... 20
Testing fuel return and leak amount ................................................................................................... 21
Bleeding air from fuel circuit............................................................................................................... 24
WA450-6, WA480-6 (KA SPEC.) 1

SEN01586-00 30 Testing and adjusting
Testing fuel circuit for leakage ............................................................................................................ 26

Handling of reduced cylinder mode operation.................................................................................... 27
Handling of no injection cranking operation ....................................................................................... 27
Handling controller voltage circuit ...................................................................................................... 28
Check of muffler and muffler stack for looseness and damage.......................................................... 29
Check of muffler function.................................................................................................................... 29
Check of installed condition of cylinder head and manifolds.............................................................. 30
Check of engine piping for damage and looseness ........................................................................... 30
Testing and adjusting air conditioner compressor belt tension........................................................... 31
Testing and adjusting alternator belt tension ...................................................................................... 32
Adjusting transmission speed sensor................................................................................................. 33
Adjusting directional lever length........................................................................................................ 34
Adjusting gear shift lever length ......................................................................................................... 34
Measuring directional lever ................................................................................................................ 35
Measuring and adjusting power train oil pressure.............................................................................. 36
Procedure for flushing torque converter and transmission hydraulic circuit ....................................... 51
Method of moving machine when transmission valve is broken ........................................................ 52
Check of axle final drive for oil leakage.............................................................................................. 54
Check of drive shafts for looseness, play and damage ...................................................................... 54
Testing and adjusting steering stop valve........................................................................................... 55
Testing and adjusting steering wheel ................................................................................................. 57
Testing steering oil pressure............................................................................................................... 59
Bleeding air from steering circuit ........................................................................................................ 62
2 WA450-6, WA480-6 (KA SPEC.)

Testing and adjusting, Part 1 1

Tools for testing, adjusting, and troubleshooting 1
Testing and Sym- Q'ty
Part No. Part Name Remarks
adjusting item bol
1 799-201-9001 Handy smoke checker 1 Bosch index: Level 0 – 9
Measuring exhaust gas
A Commercially
color 2 Smoke meter 1
available
Adjusting valve Commercially
B Clearance gauge 1
clearance available
1 795-502-1590 Gauge assembly 1 0 – 6.9 MPa {0 – 70 kg/cm2}
Measuring compression
C 2 795-471-1420 Adapter 1
pressure
3 6217-71-6112 Gasket 1
Measuring blow-by
D 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
Pressure gauge:2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
E
pressure 2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
799-101-5230 Nipple 1 14 × 1.5 mm
3
6215-81-9720 O-ring 1
Measuring intake air
F 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
(boost) pressure
1 {25, 60, 400, 600 kg/cm2}
Measuring fuel 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
G
compression 2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
6732-81-3170 Adapter 1 10 × 1.0 mm o R1/8
3
6215-81-9710 O-ring 1
1 6151-51-8490 Spacer 1
2 6206-71-1770 Joint 1
Commercially
3 Hose 1
available
Measuring fuel return Commercially
H 4 Hose 1
rate and leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Measuring directional
J 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
lever
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Testing power train oil
K
pressure 2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
799-101-5220 Nipple 1 10 × 1.25 mm
3
07002-11023 O-ring 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
Method of moving
machine when trans- L 794-423-1190 Plug 1 20 × 1.5 mm
mission valve is broken
WA450-6, WA480-6 (KA SPEC.) 3

Testing and Sym-

Part No. Part Name Q'ty Remarks
adjusting item bol
Testing and adjusting
M 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
steering wheel
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting 799-101-5220 Nipple 1 10 × 1.25 mm
N
steering oil pressure 2
07002-11023 O-ring 1
3 799-401-2701 Differential pressure gauge 1
4 799-401-3200 Adapter 1 Size 03
1 799-205-1100 Tachometer kit 1 Digital indication: 6 – 99999.9 rpm
Testing hydraulic drive Pressure gauge:2.5, 5.9, 39.2, 58.8 MPa
P 799-101-5002 Hydraulic tester 1
fan 2 {25, 60, 400, 600 kg/cm2}
Bleeding air from 1 {25, 60, 400, 600 kg/cm2}
Q
hydraulic drive fan circuit 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
2 790-261-1130 Coupling 1
Testing and adjusting Pressure gauge:2.5, 5.9, 39.2, 58.8 MPa
accumulator charge R {25, 60, 400, 600 kg/cm2}
pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
1 793-605-1001 Brake test kit 1
2 790-101-1430 Coupler 1
3 790-101-1102 Pump 1
Testing wheel brake oil
S 4 790-301-1720 Adapter 1 20 × 1.5 mm o R1/8
pressure
5 799-101-5160 Nipple 1
6 799-401-2220 Hose 1 Length: 5 m
7 790-261-1130 Coupling 1
Measuring wear of Commercially
T Slide calipers 1
wheel brake disc available
1 {25, 60, 400, 600 kg/cm2}
Testing parking brake 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
U
oil pressure
799-101-5220 Nipple 1 10 × 1.25 mm
2
07002-11023 O-ring 1
Testing wear of parking Commercially
V Slide calipers 1
brake disc available
Measuring and adjust- 1 79A-264-0021 Push-pull scale 1
ing work equipment W Commercially
control lever 2 Scale 1
available
799-101-5002 Analog hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting
work equipment PPC X 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
oil pressure 799-101-5220 Nipple 1
2 10 × 1.25 mm
07002-11023 O-ring 1
4 WA450-6, WA480-6 (KA SPEC.)

Testing and Sym-

Part No. Part Name Q'ty Remarks
adjusting item bol
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
work equipment oil Y
799-101-5220 Nipple 1 10 × 1.25 mm
pressure 2
07002-11023 O-ring 1
3 799-401-2701 Differential pressure gauge 1
Measuring coolant,
oil and exhaust Z 799-101-1502 Digital thermometer 1
temperature
Measuring operating 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
effort and pressing —
force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially

— Scale 1
hydraulic drift available
Measuring work Commercially
— Stopwatch 1
equipment speed available
Measuring voltage and Commercially
— Tester 1
resistance available
Removal and installation
Commercially 3.26 mm torque wrench
of boost pressure and — Torque wrench 1
available (KTC Q4T15 or equivalent)
temperature sensor
of engine oil pressure — (Under setting) Deep socket 1 27 mm deep socket
sensor
Commercially 21 mm deep socket
of engine coolant — Deep socket 1
available (MITOLOY 4ML-21 or equivalent)
temperature sensor
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting of the control-
lers, sensors, actuators, and wiring harnesses, see Troubleshooting, “T-branch box and T-branch table”.
WA450-6, WA480-6 (KA SPEC.) 5

Measuring engine speed 1 2. Measuring torque converter stall speed

1) Referring to “Special function of machine
k Put chocks under the tires. monitor”, select the real time monitoring
k When measuring, check that there are no function of the service mode.
persons around the machine. 2) Select the two-item simultaneous monitor-
ing (2 ITEMS) and then enter the following
a Measure the engine speed under the following code numbers directly.
condition. a Monitoring items
q Engine coolant temperature: [1] Code No.01001: ENG SPEED
Within operating range (Engine speed)
q Hydraulic oil temperature: [2] Code No.40100: TC OIL TEMP
Within operating range (Torque converter oil temperature)
q Torque converter oil temperature:
1. Measuring engine speed (low idle and high

idle)
1) Referring to “Special function of machine
monitor”, select the real time monitoring
function of the service mode.
2) Display “ENG SPEED” from the monitor-
ing items of the machine monitor.
a Monitoring item: ENG SPEED
Code No. 01001: ENG SPEED
(Engine speed)
3) Start the engine.

4) Turn the transmission cut-off selector
switch OFF and press the left brake pedal
securely.
5) Turn the torque converter lockup switch (if
equipped) OFF.
6) Set the transmission auto shift and man-
ual shift selector switch in the MANUAL
position.
7) While keeping the directional lever or for-
ward-reverse switch at the N (Neutral)
position, set the gearshift lever or gear
shift switch to the 4th position.
3) Start the engine, set it in the measuring 8) Release the parking brake.
condition, and measure the engine speed. 9) While pressing the brake pedal, set the
directional lever or switch to the F (for-
ward) or R (reverse) position.
k Keep pressing the brake pedal
securely.
10) While running the engine at high idle,
press the accelerator pedal gradually.
When the torque converter stalls, mea-
sure the engine speed.
a Measure the stall speed 2 – 3 times.
a Do not keep stalling the torque con-
verter for more than 20 seconds. Take
care that the torque converter oil tem-
perature will not exceed 120°C.
a Measure the torque converter stall
speed when the power mode and
economy mode are turned on.
6 WA450-6, WA480-6 (KA SPEC.)

3. Measuring hydraulic stall speed 4. Measuring torque converter stall and

1) Referring to “Special function of machine hydraulic stall (full stall) speed
monitor”, select the real time monitoring 1) Set the machine monitor as in “2. Measur-
function of the service mode. ing torque converter stall speed”.
2) Select the two-item simultaneous monitor- 2) Start the engine.
ing (2 ITEMS) and then enter the following 3) Turn the transmission cut-off selector
code numbers directly. switch OFF and press the left brake pedal
a Monitoring items securely.
[1] Code No.01001: ENG SPEED 4) Turn the torque converter lockup switch (if
(Engine speed) equipped) OFF.
[2] Code No. 04401: HYD TEMP 5) Set the transmission auto shift and man-
(hydraulic oil temperature) ual shift selector switch in the MANUAL
position.
6) While keeping the directional lever at N
(Neutral) position, set the gearshift lever in
the 4th position.
7) Release the parking brake.
8) While pressing the brake pedal, set the
directional lever to the F (forward) or R
(reverse) position.
securely.
9) While running the engine at high idle, stall
the torque converter and relieve the lift
arm cylinder or bucket cylinder on the
extraction side simultaneously and mea-
3) Run the engine at high idle. sure the engine speed at this time.
4) Relieve the lift arm cylinder or bucket cyl- a Do not keep stalling the torque con-
inder on the extraction side and measure verter for more than 20 seconds. Take
the engine speed. care that the torque converter oil tem-
a Measure the hydraulic stall speed perature will not exceed 120°C.
when the power mode and economy a Measure the full stall speed when the
mode are turned on. power mode and economy mode are
turned on.
WA450-6, WA480-6 (KA SPEC.) 7

Measuring exhaust gas color 1

a Measuring instruments for exhaust gas color
Symbol Part No. Part Name
1 799-201-9001 Handy smoke checker
A Commercially
2 Smoke meter
available
k When installing and removing the measuring

instruments, take care not to touch a hot part.
a If an air source and an electric power source
are not available in the field, use handy smoke
checker A1. When recording official data, use
smoke meter A2.
a Measure the exhaust gas color under the fol- 2) Connect the probe hose, receptacle of the
lowing condition. accelerator switch, and air hose to smoke
q Engine coolant temperature: Within oper- meter A2.
ating range a Keep the pressure of the supplied
compressed air at 1.5 MPa {15 kg/
1. Measuring with handy smoke checker A1 cm2} or below.
1) Stick a sheet of filter paper to smoke 3) Connect the power cable to a 100 V AC
checker A1. receptacle.
2) Insert the exhaust gas intake pipe in the a Confirm that the smoke meter power
muffler (exhaust pipe). switch is in the OFF position, before con-
3) Start the engine and heighten the engine necting the power cable to an outlet.
coolant temperature to the operating range. 4) Loosen the cap nut of the suction pump
4) Accelerate the engine suddenly or run it at and fit the filter paper.
high idle and operate the handle of smoke a Fit the filter paper securely so that the
checker A1 so that the filter paper will exhaust gas will not leak.
absorb the exhaust gas. 5) Turn on the power switch of smoke meter A2.
5) Take out the filtering paper and compare it 6) Start the engine and keep it running until
with the attached scale for judgement. the engine coolant temperature rises to
6) Remove the measurement tool after the the operating range.
measurement, and make sure that the 7) Accelerate the engine suddenly or run it at
machine is back to normal condition. high idle and press the accelerator pedal
of smoke meter A2 and collect the
2. Measuring with smoke meter A2 exhaust gas into the filter paper.
1) Insert the probe of smoke meter A2 in the 8) Put the polluted filtering paper on non-pol-
outlet of the muffler (exhaust pipe) and fix luted filtering paper (more than 10 sheets)
it to the exhaust pipe with a clip. in the filtering paper holder, and read the
indicated value.
9) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
8 WA450-6, WA480-6 (KA SPEC.)

Measuring exhaust temperature 1 3. Install sensor [1] and connect them to digital
temperature gauge [2].
a Measuring instrument for exhaust temperature a Clamp the wiring harness of the digital
temperature gauge so that it will not touch
Symbol Part No. Part name
a hot part during measurement.
Z 799-101-1502 Digital temperature gauge
k Install and remove the measuring instru-

ment after the exhaust manifold is cooled.
a Measure the exhaust temperature under the
following condition.
q Coolant temperature: Within operating
range
q Hydraulic oil temperature: Within operat-
ing range
q Power train oil temperature: Within operat-
ing range
1. Open the left side cover of the engine and

remove turbocharger heat insulation cover (1).
2. Remove exhaust temperature measurement 4. Procedure for periodic measurement done in

plug (2). preventive maintenance
a To prevent the torque converter from over-
heating, increase the exhaust temperature
once through full-stall operation (torque
converter stall + hydraulic stall), and then
measure the exhaust temperature while
only the torque converter is stalled.
1) Start the engine and heighten the coolant
temperature to the operating range.
2) Turn off the transmission cut-off switch
and press the left brake pedal securely.
position.
4) Set the gear shift lever or gear shift switch
to the 4th speed while keeping the direc-
tional lever, joystick steering directional
switch or right directional switch at the N
(Neutral) position.
5) Release the parking brake.
WA450-6, WA480-6 (KA SPEC.) 9

6) While pressing the brake pedal, set the 5. Procedure for measuring the maximum
directional lever, joystick steering direc- exhaust temperature
tional switch or right directional switch to Operate the machine actually and measure the
the F (forward) or R (reverse) position. maximum exhaust temperature.
k Keep pressing the brake pedal a Use the PEAK mode of the thermometer
securely. (in which the maximum value can be
7) Press the accelerator pedal gradually to saved).
the high idle. While running the engine at a The exhaust temperature largely depends
high idle, stall the torque converter and on the outside air temperature (intake air
relieve the lift arm cylinder or bucket cylin- temperature of the engine). Accordingly, if
der on the extraction side simultaneously. any abnormal value is obtained, correct it
(full stall) by the following calculation.
a Increase the exhaust temperature to a Corrected value [°C] = Measured value +
about 650°C (the state of (a) in the 2 x (20 – Outside air temperature)
figure).
a Do not keep stalling the torque con- 6. Remove the measurement tool after the mea-
verter for more than 20 seconds. Take surement, and make sure that the machine is
care that the torque converter oil tem- back to normal condition.
perature will not exceed 120°C.
8) As the exhaust temperature reached
about 650°C, release the hydraulic relief
and then decrease the exhaust tempera-
ture by stalling torque converter alone.
(the state of (b) in the figure)
a The exhaust temperature starts low-
ering from the level of the full-stall
operation. Measure the exhaust tem-
perature as it stabilized. (the state of
(c) in the figure)
a If the exhaust temperature rises in
stead of going down, set a higher full
stall temperature than the current one
(650°C).
10 WA450-6, WA480-6 (KA SPEC.)

Adjusting valve clearance 1 3. While the No.1 cylinder is at the compression

top dead center, adjust the clearance of valve
a Adjusting instrument for valve clearance marked with q in the valve arrangement figure.
Commercially
B Clearance gauge
available
a Adjust the valve clearance in the following con-

dition.
q Engine coolant temperature: Within operating
range
1. Remove 6 cylinder head covers (1), referring

to the section “Removal and installation of cyl-
inder head assembly” in Disassembly and
assembly.
4. To adjust the valve clearance, insert clearance

gauge B into clearance (b) between rocker
arm (4) and crosshead (5), and adjust the
valve clearance with adjustment screw (6).
a With the clearance gauge inserted, turn
the adjustment screw so that clearance
gauge can move with a light force.
5. While holding adjustment screw (6), tighten

locknut (7).
3 Locknut:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.
2. Rotate the crankshaft forward, align of damper
“1.6TOP” stamp line (a) to pointer (8), and then
set the No.1 cylinder to the compression top
dead center.
a Always crank forward using damper
mounting bolt (width across flats: 24 mm)
to prevent loosening the bolt.
a When No. 1 cylinder is at the compression
top dead center, the rocker arms on both
intake side and exhaust side can be
moved by the valve clearance with the
hand. If the rocker arms cannot be moved,
rotate the crankshaft one more turn.
q After finishing the adjustment of all the

valves marked with q, rotate the crank-
shaft 360° forward and align “1.6TOP”
stamp line (a) of the damper to pointer (8)
in order to set the No.6 cylinder to the
compression top dead center.
WA450-6, WA480-6 (KA SPEC.) 11

6. While the No. 6 cylinder is at the compression

top dead center location, adjust the clearance
of valve marked with Q in the valve arrange-
ment figure.
a Procedure for the adjustment is as same
as 6) and 7).
7. It also can be done by rotating the crankshaft

forward by 120° at one time and adjusting the
va lve cl eara nce of eac h c yli nder in the
sequence of the firing order.
a Firing order: 1 – 5 – 3 – 6 – 2 – 4
8. After finishing adjustment, set to the original

condition.
3 Cylinder head cover mounting bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
3 Air intake connector hose clamp bolt:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Air cleaner intake hose clamp bolt:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Air cleaner mounting band bolt:
9.8 – 11.76 Nm {1.0 – 1.2 kgm}
12 WA450-6, WA480-6 (KA SPEC.)

Measuring compression pressure1 a Lead a wire under the fuel pipe which
comes out sideways from the injector and
a Measuring instruments for compression pres- pull up the wire to remove injector (do not
sure ply the upper part of the injector to remove
it).
1 795-502-1590 Compression gauge
C 2 795-471-1420 Adapter
3 6217-71-6112 Gasket
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the
engine is warmed up.
(Engine oil temperature: 40 – 60°C)
1. Remove 6 cylinder head covers (1), referring

to the section “Removal and installation of cyl-
inder head assembly” in Disassembly and 4. Install gasket C3 and install adapter C2 to the
assembly. mounting hole of the injector and connect com-
pression gauge C1.
a Fix the adapter with the holder for injector.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Leakage can be prevented by applying a
little amount of engine oil to the fitting
faces of the adapter and gauge.
5. Install rocker arm assembly (4) and adjust

valve clearance.
3 Rocker arm assembly mounting bolts:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Refer to “Adjusting valve clearance”.
2. Set cylinder to be tested at compression top

dead center and remove rocker arm assembly
(4).
a Refer to “Adjusting valve clearance”.
3. Disconnect the fuel high-pressure tube (5) and

injector harness (6), and remove injector (7).
a Before disconnecting the fuel high-pres-
sure tube, loosen all the intermediate
clamps on the tube.
a To remove injector harness from injector,
disconnect the terminal in the injector side
and the bracket in the rocker housing side
and pull them out of the rocker arm hous-
ing. (Loosen 2 terminal nuts alternately.)
WA450-6, WA480-6 (KA SPEC.) 13

6. Disconnect connector EGC3 of engine control- 8) Tighten the clamping bolt of the fuel pip-
ler. ing.
3 Clamping bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
k Be sure to disconnect the connector.

3
Otherwise, engine may start during the
Rocker arm assembly mounting
measurement and this may create a
bolts:
dangerous condition.
k
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
Since connector (EGC3) includes the
a Adjust valve clearance referring to
power source circuit of engine control-
“Adjusting valve clearance”.
3 Cylinder head cover mounting bolt:
ler, cover the connector on the harness
side with a vinyl sheet, etc. to prevent
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
electric leakage and ground fault.
a Adjust mode of the monitor panel “no
injection cranking mode” can be set.
7. Crank the engine with the starting motor and

check the compression pressure.
a Measure the pressure when the pointer of
the gauge is stabilized.
8. When the checking is completed, remove the

instruments and reinstall the removed parts.
a Install the injector, injector harness and
fuel high-pressure tube according to fol-
lowing procedure.
1) Install O-ring and gasket to injector (7).
2) Set holder (8) to injector (7) and install it
temporarily to the cylinder head integrally.
3) Tighten mounting bolt (9) with spherical
washer (10) to install injector to cylinder
head.
2 Spherical surface section of spheri-
cal washer: Engine oil (SAE30DH)
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
4) Insert harness (6) into rocker arm housing
and fix with mounting bolt (11).
5) Insert harness (6) into holder (12).
6) Tighten 2 nuts at the end of harness (6)
onto injector (7) alternately.
3 Nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm}
7) Tighten tube (5) to injector (7).
3 Sleeve nut:
39.2 – 49.0 Nm {4 – 5 kgm}
14 WA450-6, WA480-6 (KA SPEC.)

Measuring blow-by pressure 1 9. While pressing the brake pedal, set the direc-
tional lever or switch to the F (forward) or R
a Blow-by pressure measurement tools (reverse) position.
Symbol Part No. Part Name k Keep pressing the brake pedal securely.
D 799-201-1504 Blow-by checker

10. Press the accelerator pedal gradually to the
a Measure the blow-by pressure under the fol- high idle. While running the engine at high idle,
lowing condition. stall the torque converter and measure the
q Engine coolant temperature: blow-by pressure.
Within operating range a Do not keep stalling the torque converter
q Hydraulic oil temperature: for more than 20 seconds. Take care that
Within operating range the torque converter oil temperature will
q Torque converter oil temperature: not exceed 120°C.
Within operating range a Normally, the blow-by pressure should be
measured while the engine is operated at
1. Pull out blow-by hose (1) at the right side of the the rated output. In the field, however, an
rear axle on the right side of the chassis. approximate value can be obtained by
stalling the torque converter.
2. Stop the engine. Install nozzle [1] and hose [2] a If it is impossible to run the engine at the
of blow-by checker D to blow-by hose (1) and rated output or stall the torque converter,
connect them to gauge [3]. measure while the engine is running at
high idle. The value obtained in this case
is about 80% of the blow-by pressure at
the rated output.
a Precaution for measuring blow-by pressure
The blow-by pressure may vary largely
with the engine condition. If the measured
value is judged abnormal, check for
increase of oil consumption, bad exhaust
gas color, deterioration of oil, high deterio-
ration speed of oil, etc. which are related
to the abnormal blow-by pressure.
3. Start the engine and increase the engine cool-

ant temperature to the operating range.
4. Turn the transmission cut-off selector switch

OFF and press the left brake pedal securely.
5. Turn the torque converter lockup switch (if

equipped) OFF.
6. Set the transmission auto shift and manual

shift selector switch in the MANUAL position.
11. Remove the measurement tool after the mea-
surement, and make sure that the machine is
7. While keeping the directional lever or forward-
back to normal condition.
reverse switch at the N (Neutral) position, set
the gear shift lever or gear shift switch to the
4th position.
8. Release the parking brake.
WA450-6, WA480-6 (KA SPEC.) 15

Measuring engine oil pressure 1 4. Start the engine and heighten the coolant tem-
perature to the operating range.
a Engine oil pressure measurement tools
Symbol Part No. Part Name 5. While running the engine at low idle and high
idle, measure the oil pressure.
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
E 2 799-401-2320 Hydraulic tester
799-101-5230 Nipple (14 × 1.5 mm)
3
6215-81-9720 O-ring
a Measure the engine oil pressure under the fol-

lowing condition.
q Engine coolant temperature:
1. Open the engine right side cover.
2. Remove oil pressure inspection plug (1).

6. Remove the measurement tool after the mea-
surement, and make sure that the machine is
3. Install nipple E3 (14 × 1.5 mm) and then con-

nect hydraulic tester E2 (0.98 MPa {10 kg/
cm2).
16 WA450-6, WA480-6 (KA SPEC.)

Check of exhaust gas

recirculation (EGR) system 1
Check that the exhaust gas recirculation (EGR)
system is functioning normally.
Check that the EGR valve is opened and closed

normally by checking for the "EGR valve servo
abnormality" indicated by troubleshooting code.
If the EGR system has abnormality, repair it.
See Troubleshooting volume.
WA450-6, WA480-6 (KA SPEC.) 17

Measuring intake air (boost) 5. Run the engine at medium or higher speed to
pressure 1 drain the oil from the hose.
a Insert the connecting parts of the gauge
a Measuring instruments for intake air (boost) and hose about a half and open the self-
pressure seal on the hose side repeatedly, and the
Symbol Part No. Part Name oil will be drained.
a If Pm kit (A) is available, you may drain
F 799-201-2202 Boost gauge kit
the oil by using the oil draining coupling
(790-261-1130) in that kit.
k When installing and removing the measur-
a If the oil is left in the hose, the gauge does not
ing instruments, take care not to touch a
work. Accordingly, be sure to drain the oil.
hot part of the engine.
a Measure the intake air pressure (boost pres-
6. Turn the transmission cut-off selector switch
sure) under the following condition.
OFF and press the left brake pedal securely.
7. Turn the torque converter lockup switch (if
q Hydraulic oil temperature:
equipped) OFF.
q Torque converter oil temperature:
8. Set the transmission auto shift and manual
shift selector switch in the MANUAL position.
1. Open the engine right side cover.
9. While keeping the directional lever or forward-
reverse switch at the N (Neutral) position, set
2. Remove air boost pressure pickup plug (1)
the gear shift lever or gear shift switch to the
(R1/8).
4th position.
10. Release the parking brake.
11. While pressing the brake pedal, set the direc-

tional lever to the F (forward) or R (reverse)
position.
k Keep pressing the brake pedal securely.
12. Press the accelerator pedal gradually to the

high idle. While running the engine at high idle,
stall the torque converter and measure the
intake air pressure (boost pressure).
a Do not keep stalling the torque converter
for more than 20 seconds. Take care that
3. Install nipple [1] in boost gauge kit F and con- the torque converter oil temperature will
nect pressure gauge [2]. not exceed 120°C.
4. Start the engine and increase the coolant tem- 13. Remove the measurement tool after the mea-
perature to the operating range. surement, and make sure that the machine is
18 WA450-6, WA480-6 (KA SPEC.)

Handling fuel system equipment 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacement of fuel filter car- stopped.
tridge a Before the fuel circuit is tested and its parts are
The fuel filter cartridge used must be a genuine removed, the residual pressure in the fuel cir-
Komatsu part. cuit must be released completely. Accordingly,
The fuel injection pump and nozzle of the com- observe the following.
mon rail type fuel injection system (CRI) are k Before testing the fuel system or removing
consisted of more precision parts than those its parts, wait at least 30 seconds after stop-
used for the current pumps and nozzles. This ping the engine until the residual pressure
system, therefore, employs a special filter with in the fuel circuit is released. (Do not start
highly efficient filtering performance to prevent the work just after stopping the engine
mixing of foreign substances. Thus, substitut- since there is residual pressure.)
ing it with a non-genuine filter could cause
troubles in the fuel system. It is strictly prohib-
ited to use such part.
WA450-6, WA480-6 (KA SPEC.) 19

Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
G 2 799-401-2320 Hydraulic tester {1.5 – 3 kg/cm2}
6732-81-3170 Adapter (10 x 1.0 mm o PT1/8)
3
6215-81-9710 O-ring
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the fuel fil-
ter to the supply pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Remove fuel pressure pickup plug (1) from the

fuel filter head.
4. After finishing testing, remove the testing tools

and return the removed parts.
2. Install adapter G3 and nipple [1] of hydraulic

tester G1 and connect it to hydraulic tester G2.
20 WA450-6, WA480-6 (KA SPEC.)

Testing fuel return and leak amount 1
a Testing tools for fuel return and leak amount 1. Preparation work
1) Remove tube (3) between common rail (1)
Symbol Part No. Part name and return block (2).
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
Commercially
3 Hose
available
H Commercially
4 Hose
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
a Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
2) Insert spacer H1 to return block (2) side
and retighten it with the currently removed
joint bolt.
a Be sure to fit the gaskets to both ends
of the spacer.
WA450-6, WA480-6 (KA SPEC.) 21

3) Insert joint H2 to common rail (1) side and a If the leakage from the pressure lim-
retighten it with the currently removed joint iter is in the following range, it is nor-
bolt. mal.
a Be sure to fit the gaskets to both ends Engine speed Leaking amount
of the joint. (rpm) (cc/min)
4) Connect inspection hose H3 to the tip of
Equivalent to rated
joint H2. Max. 10
operation
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
5) After finishing testing, stop the engine.
3. Testing return rate from injector

a During testing injector return amount,
keep the end of hose H3 connected to
2. Testing leakage from pressure limiter pressure limiter and insert the other end to
1) Adjust routing to prevent its slacking of oil pan (receiver).
inspection hose H3 and insert the hose 1) Disconnect fuel return hose (4) of return
end to the oil pan (saucer). block (2).
2) Referencing “Measuring engine speed”, a Block the fuel hose side with plugs,
set up the condition necessary for check- etc. and fix it to the frame.
ing the engine speed. Plug: 07376-70315
3) Start the engine and operate at the equiv-
alent to rated operation (torque converter
stall load).
4) After making sure that the engine speed is
stabilized, measure leakage volume per
minute by use of measuring cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
22 WA450-6, WA480-6 (KA SPEC.)

2) Connect inspection hose H4 to return

block (2) side.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
3) Adjust routing to prevent its slacking of
inspection hose H4 and insert the hose
end to the oil pan (container).
7) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
4) Referencing “Measuring engine speed”,

set up the condition necessary for check-
ing the engine speed.
5) Start the engine and operate at the equiv-
alent to rated operation (torque converter
stall load).
6) After making sure that the engine speed is
stabilized, measure return rate per minute
by use of measuring cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
WA450-6, WA480-6 (KA SPEC.) 23

Bleeding air from fuel circuit 1
a Bleed the air as follows if the engine has run 2. Remove air bleeding plug (3) of fuel main filter
out of fuel or the fuel circuit equipment has (2) and operate priming pump (4).
been removed and installed. a Operate until fuel flows through plug hole
and when fuel is confirmed, install the
1. Remove fuel pre-filter (1), fill up fuel inside and plug.
reinstall. 3 Air bleeding plug:
a When filling, use clean fuel and be careful 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
not to let dirt get in.
a Add fuel through inlet port (a) areas (8 3. There can be following two cases concerning
places) of the filter. Area (b) is the outlet the reason why the engine does not start up
port after the fuel has been filtered (clean easily after bleeding air from the common rail
side), so never add fuel from here. fuel injection system (CRI) even after carrying
a If clean fuel is not available, do not out the items 1 and 2 above.
remove the filter. Operate the priming a If the air has not been bled completely and
pump to fill the filter with fuel. remained in the circuit, cranking the
engine with the starting motor cannot
bleed air in a short period of time. Thus
the engine start-up becomes difficult.
1) In the cases that the fuel has run out, that
the fuel filter has been replaced or that
some fuel device has been removed and
installed.
q Most of the fuel is left in the fuel cir-
cuit, so the engine may be started
after bleeding air with the air bleeding
procedure introduced in the item 1
and 2 above.
24 WA450-6, WA480-6 (KA SPEC.)

2) In the case that a number of fuel devices q Still continue to operate the prim-
have been removed and installed in ing pump until it becomes harder
course of engine overhauling. to operate and a relief noise (a
q Since little fuel is left in the fuel circuit, high pitch noise) of overflow
so air cannot be eliminated com- valve (7) in the supply pump is
pletely by the air bleeding methods heard. It requires approx. 50
introduced in the item 1 and 2 above times of operation to reach that
(ordinary method). In that case, stage.
bleed air in the following procedure. 4] Tighten bolt of priming pump (4) to fix.
5] Crank the engine with the starting
motor and start the engine.
a Do not operate the starting motor
continuously for more than 20
seconds. Moreover try to start up
the engine only after 2 minutes
pause.
a If the engine does not start up
even after repeating to crank for
20 seconds 4 times, insufficient
air bleeding is suspected. In that
case, start the air bleeding steps
once again from step 1].
4. Loosen air bleeder (6) of the fuel supply pump

1] Remove air bleeding plug (3) of fuel
and operate priming pump (4) 90 to 100 times.
main filter (2) and operate priming
a Operate priming pump until fuel flows
pump (4).
through air bleeder and when fuel is con-
q Bleeding air
firmed, tighten air bleeder and operate
Operate the priming pump until
several times more until priming pump
fuel flows through plug hole and
becomes stiff.
3 Air bleeder:
when fuel is confirmed, tighten
the plug.
3 Air bleeding plug:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
5. Crank the engine with the starting motor and
2] Remove fuel pressure measuring
start the engine.
plug (5) for the fuel filter and operate
a The air in the high-pressure circuit is bled
priming pump (4).
automatically if the engine is cranked.
q Operate the priming pump until
a If the engine does not start, there still may
fuel flows through plug hole and
be air in the low-pressure circuit. In this
when fuel is confirmed, tighten
case, repeat the above procedure from
the plug.
3 Fuel measuring plug:
step 2.
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3] Loosen air bleeder (6) of fuel supply
pump (after loosening locknut) and
operate priming pump (4) from 90 to
100 times.
q Operate the priming pump until
fuel flows through air bleeder (6)
and when fuel i s confir med,
tighten the plug.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
WA450-6, WA480-6 (KA SPEC.) 25

Testing fuel circuit for leakage 1 9. Inspect the fuel piping and the devices for fuel
leakage.
k Very high pressure is generated in the high- a Inspect the high-pressure circuit parts
pressure circuit of the fuel system. If fuel concentration on the areas coated with the
leaks while the engine is running, it is dan- color checker, for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
and installing its components, check for a If any fuel leakage is not detected, inspec-
fuel leakage according to the following pro- tion is completed.
cedure.
a Clean and degrease the engine and the parts
around it in advance so that you can inspect it
easily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at a speed less than 1,000 rpm

and stop it after its rotation is stabilized.
3. Inspect the fuel piping and the devices for fuel

leakage.
a Inspect the high-pressure circuit parts
concentration on the areas coated with the
color checker, for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4. Run the engine at low idle.

leakage.
6. Run the engine at high idle.

leakage.
8. Run the engine at high idle to apply load to the

engine.
a Relieve by tilting the blade or raising the
ripper.
26 WA450-6, WA480-6 (KA SPEC.)

Handling of reduced cylinder Handling of no injection cranking

mode operation 1 operation 1
a Reduced cylinder mode operation means to a No injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The purpose and effect of this operation are as follows.
poses and effects of this operation are as fol- q Before the engine is started after it or the
lows. engine unit has been stored for a long period,
1. This operation is used to find out a cylinder the no injection cranking is performed to lubri-
which does not output power normally (or, cate the engine parts and protect them from
combustion in it is abnormal). seizure.
2. When engine speed and output do not change a To implement no injection cranking operation,
from the normal operation (all cylinder operat- see “Special functions of monitor panel”.
ing mode) even though the fuel injection has
been cut out for any cylinder, the cylinder is
suspected to be defective.
The following problems can be considered:
q Leaking of cylinder head gasket
q Defective injection of injector
q Defective piston, piston ring or cylinder
liner
q Defective valve mechanism (valve sys-
tem)
q Defective electrical system
3. Since the injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, the reduced cylinder mode
operation can be obtained by easier operations
of the switches when compared with the
mechanical fuel injection system. This allows
to narrow down the causes of the incident eas-
ily.
a To implement reduced cylinder mode
operation, see “Special functions of moni-
tor panel”.
WA450-6, WA480-6 (KA SPEC.) 27

Handling controller voltage circuit1

1. Disconnection or connection of the connector
between the engine controller and engine must
be done after turning off the starting switch.
2. It is prohibited to start the engine when T-

adapter is inserted or connected, for trouble-
shooting purpose, to the connector between
the engine controller and engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
28 WA450-6, WA480-6 (KA SPEC.)

Check of muffler and muffler Check of muffler function 1

stack for looseness and damage 1 q Check the muffler for abnormal sound and dif-
1. Check the muffler and muffler stack visually for ference in sound from a new machine. If it
a crack and damage. If any part is damaged, makes abnormal sound, repair it, referring to
replace it. the Troubleshooting Volume.
2. Check the mounting bolts and nuts of the muf-

fler and muffler stack for looseness. If they are
loosened, retighten them.
WA450-6, WA480-6 (KA SPEC.) 29

Check of installed condition of Check of engine piping for

cylinder head and manifolds 1 damage and looseness 1
Check the installed condition of the cylinder head Air intake and exhaust systems:
and air intake manifold and exhaust manifold. If Check the piping for damage, looseness of the
they are loosened, retighten them. mounting bolts and nuts, and suction of air and
a For the tightening torque, see the "Disassem- leakage of exhaust gas through the joints. If it
bly and assembly" volume. is loosened or damaged, retighten or repair.
Cooling system:
Check the piping for damage, looseness of the
mounting bolts and nuts, and leakage of water
through the joints. If it is loosened or dam-
aged, retighten or repair.
Fuel system:
Check the piping for damage, looseness of the
mounting bolts and nuts, and leakage of fuel
through the joints. If it is loosened or dam-
aged, retighten or repair.
30 WA450-6, WA480-6 (KA SPEC.)

Testing and adjusting air Adjusting

conditioner compressor belt a If the deflection of the belt is abnormal, adjust it
tension 1 according to the following procedure.
1. Loosen air conditioner compressor mounting

Testing bolts (3).
1. Open engine right side cover (1).
2. Loosen locknut (4) and adjust the air condi-
tioner compressor belt tension by turning
adjustment bolt (5).
3. After adjusting the tension, tighten locknut (4)

and air conditioner compressor mounting bolts
(3).
a If the V-belt is replaced, adjust its tension
again after 1 operating hour.
2. Remove cover (2).
3. Press the intermediate point between air con-

ditioner compressor pulley and drive pulley
with a finger and measure deflection (a).
a Pressing force: Approx. 98 N {Approx. 10
kg}
a Deflection (a): 25 – 26 mm
WA450-6, WA480-6 (KA SPEC.) 31

Testing and adjusting alternator Adjusting

belt tension 1 a If the deflection is out of the standard range,
adjust it according to the following procedure.
Testing 1. Loosen locknut (1) and bolts (2) and (3).

1. Open rear frame left side cover (1).
2. Move alternator (5) with adjustment nut (4) to
adjust the tension of belt (6).
3. Tighten bolts (3) and (2) and tighten locknut

(1).
3 Bolt (3): 107.8 – 147 Nm {11 – 15 kgm}
3 Bolt (2): 28.4 – 38.2 Nm {2.9 – 3.9 kgm}
a After adjusting, test the belt tension again.
2. Remove cover (2).
3. Press the intermediate point of the belt

between alternator pulley and crankshaft pul-
ley with a finger and measure deflection (a) of
the belt.
a Pressing force: Approx. 58.8 N {Approx. 6 kg}
a Deflection (a): 13 – 16 mm
32 WA450-6, WA480-6 (KA SPEC.)

Adjusting transmission speed 3. Return sensor (3) by 1/2 – 1 turn.

sensor 1 a Adjust clearance (a) between the sensor
tip and gear (4) tooth tip to approx. 0.75 –
1.5 mm.
1. Open inspection cover (1) on the left side of
the rear frame. 4. Fix sensor (3) with locknut (2).
3 Nut: 69 – 74 Nm {7.0 – 7.5 kgm}
2. Loosen locknut (2) and screw in sensor (3)

until its tip comes in contact with a tooth tip of
gear (4).
a Before installing the sensor, check that its
tip is free from a steel chip, flaw, etc.
a Apply gasket sealant between the case
and threaded part of the sensor.
2 Threaded part: Gasket sealant (LG-5)
WA450-6, WA480-6 (KA SPEC.) 33

Adjusting directional lever Adjusting gear shift lever length 1

length 1 Lever (4) can be adjusted to 3 lengths ((A), (B) and
Lever (1) can be adjusted to 2 lengths ((A) and (B)). (C)). To adjust it, remove screw (5) from the under-
To adjust it, remove screw (3) from the underside of side of its knob (6). Slide knob (6) and tighten
its knob (2). Slide knob (2) and tighten screw (3) screw (5) again.
again. a When the machine is shipped, the knob is
a When the machine is shipped, the knob is installed to position (B).
installed to position (A). 3 Tightening torque for screw (5):
3 Tightening torque for screw (3): 0.784 ± 0.098 Nm {8 ± 1 kgcm}

0.784 ± 0.098 Nm {8 ± 1 kgcm} 2 Screw: LOCTITE (Threebond 1301B)
2 Screw: LOCTITE (Threebond 1301B)
34 WA450-6, WA480-6 (KA SPEC.)

Measuring directional lever 1

Measuring instrument
J 79A-264-0021 Push-pull scale
k Put chocks under the tires securely.
Operating effort of directional lever

1. Stop the engine.
2. Install tool J or a spring balance to a point 10

mm from the control lever end and pull it in the
operating direction to measure the operating
effort at that time.
a Measure the operating effort at each gear
speed.
Stroke of directional lever

1. Stop the engine.
2. Make mark (a) at the center of the control lever

knob. Move the knob in the operating direction
and measure its stroke.
WA450-6, WA480-6 (KA SPEC.) 35

Measuring and adjusting power train oil pressure 1
36 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 37

a Testing and adjusting instruments for power 1. Remove rear frame left side cover (21).
train oil pressure 2. Open engine right side cover (23).
1
K 2 799-401-2320 Hydraulic tester
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
Oil pressure measuring point and measuring

gauge
Measuring
No. Measured oil pressure gauge
MPa {kg/cm2}
1 Main relief pressure 5.9 {60}
2 Torque converter relief pressure 2.5 {25}
3 Torque converter outlet pressure 0.98 {10}
4 Lockup clutch pressure 5.9 {60}
5 Transmission F clutch pressure 5.9 {60}
6 Transmission R clutch pressure 5.9 {60}
7 Transmission 1st clutch pressure 5.9 {60}
8 Transmission 2nd clutch pressure 5.9 {60}
9 Transmission 3rd clutch pressure 5.9 {60}
10 Transmission 4th clutch pressure 5.9 {60}
11 Lubrication pressure 0.98 {10}
12 Parking brake pressure 5.9 {60}
k Put chocks under the tires.

a Measure the power train oil pressure under the
q Transmission oil temperature:
a Turn the transmission cut-off selector switch
OFF and use the left brake.
a The torque converter exit pressure is mea-
sured at the oil cooler entrance.
38 WA450-6, WA480-6 (KA SPEC.)

Measurement 2) Start the engine and keep the directional

1. Measuring transmission main relief pressure lever or switch at the N (Neutral) position.
a Location of transmission main relief pres- 3) While running the engine at low idle and
sure pickup nipple (1) 2,000 rpm, measure the transmission
main relief pressure.
4) After finishing measurement, remove the

measuring instruments and return the
removed parts.
1) Connect oil pressure gauge [1] of hydrau-

lic tester K1 to nipple (1).
a Use the oil pressure gauge of 5.9
MPa {60 kg/cm2}.
WA450-6, WA480-6 (KA SPEC.) 39

2. Measuring torque converter relief pressure 2) Start the engine and keep the directional
(inlet pressure) lever or switch at the N (Neutral) position.
a Location of torque converter relief pres- 3) While running the engine at 2,000 rpm,
sure (inlet pressure) pickup nipple (2) measure torque converter relief pressure
(inlet pressure).

removed parts.

lic tester K1 to nipple (2).
a Use the oil pressure gauge of 2.5 MPa
{25 kg/cm2}.
40 WA450-6, WA480-6 (KA SPEC.)

3. Measuring torque converter outlet pressure 3) Start the engine and keep the directional
a Location of torque converter outlet pressure lever or switch at the N (Neutral) position.
pickup plug (3) 4) While running the engine at 2,000 rpm,
measure torque converter outlet pressure.

1) Remove torque converter outlet pressure

pickup plug (3) (10 × 1.25 mm).
2) Connect nipple K3 and oil pressure gauge
[1] in hydraulic tester K2.
{10 kg/cm2}.
WA450-6, WA480-6 (KA SPEC.) 41

4. Measuring lockup clutch pressure (Lockup 3) Turn the torque converter lockup switch
clutch specification) ON.
k This measurement is done in the travel- 4) Set the transmission auto shift and man-
ing condition. Reasonable care, there- ual shift selector switch in the AUTO posi-
for e , m us t be pai d to s a fet y of tion.
surrounding area. 5) Start the engine and turn the parking
1) Remove lockup clutch pressure pickup brake switch OFF.
plug (4) (10 × 1.25 mm). 6) Set the gear shift lever or gear shift switch
to 3rd position.
7) Start traveling while setting the directional
lever or switch to the F (forward) position.
8) Measure the lockup clutch oil pressure as
the lockup pilot lamp came on while travel-
ing is continued with the engine at 2,000
rpm.


{60 kg/cm2}.
k The measurement is made with the

machine travelling, so check carefully
that the surrounding area is safe.
42 WA450-6, WA480-6 (KA SPEC.)

5. Measuring F (forward) clutch pressure 3) Set the transmission auto shift and man-
1) Remove F (forward) clutch pressure ual shift selector switch in the MANUAL
pickup plug (5) (10 × 1.25 mm). position.
4) Press the brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) While keeping the directional lever or
switch at N (Neutral) position, set the
gearshift lever to the 4th position.
directional lever or switch to F (forward).
securely.
k The machine will move, so check
carefully that the surrounding area
is safe.
8) While running the engine at 2,000 rpm,
measure the F (forward) clutch oil pressure.

a Use the oil pressure gauge of 5.9 MPa 9) Remove the measurement tool after the
{60 kg/cm2}. measurement, and make sure that the
WA450-6, WA480-6 (KA SPEC.) 43

6. Measuring R (reverse) clutch pressure 3) Set the transmission auto shift and man-
1) Remove R (reverse) clutch pressure ual shift selector switch in the MANUAL
pickup plug (6) (10 × 1.25 mm). position.
brake switch OFF.
gearshift lever in the 4th position.
directional lever or switch to R (reverse).
securely.
is safe.
measure the R (reverse) clutch oil pressure.

a Use the oil pressure gauge of 5.9 MPa 9) Remove the measurement tool after the
{60 kg/cm2}. measurement, and make sure that the
44 WA450-6, WA480-6 (KA SPEC.)

7. Measuring 1st clutch pressure 3) Set the transmission auto shift and man-
1) Remove 1st clutch pressure pickup plug ual shift selector switch in the MANUAL
(7) (10 × 1.25 mm). position.
brake switch OFF.
gearshift lever in the 1st position.
7) While pressing the brake pedal with the
engine at low idle, set the directional lever
or switch to the F (forward) or R (reverse)
position once and then return it to N (Neu-
tral) again.
securely.
is safe.
a If the directional lever or switch is in N
(Neutral), the gear speed is not
changed even if the gearshift lever is
moved. To avoid this, perform the
above operation.
measure the 1st clutch oil pressure.

{60 kg/cm2}.

WA450-6, WA480-6 (KA SPEC.) 45

8. Measuring 2nd clutch pressure 3) Set the transmission auto shift and man-
1) Remove 2nd clutch pressure pickup plug ual shift selector switch in the MANUAL
(8) (10 × 1.25 mm). position.
brake switch OFF.
gearshift lever in the 2nd position.
tral) again.
securely.
is safe.
above operation.
measure the 2nd clutch oil pressure.

a Use the oil pressure gauge with
capacity 5.9 MPa {60 kg/cm2}.

46 WA450-6, WA480-6 (KA SPEC.)

9. Measuring 3rd clutch pressure 7) While pressing the brake pedal with the
1) Remove 3rd clutch pressure pickup plug engine at low idle, set the directional lever
(9) (10 × 1.25 mm). or switch to the F (forward) or R (reverse)
tral) again.
securely.
is safe.
above operation.
measure the 3rd clutch oil pressure.

[1] in hydraulic tester K1. 9) Remove the measurement tool after the
a Use the oil pressure gauge of 5.9 MPa measurement, and make sure that the
{60 kg/cm2}. machine is back to normal condition.

position.
brake switch OFF.
gearshift lever in the 3rd position.
WA450-6, WA480-6 (KA SPEC.) 47

10. Measuring 4th clutch pressure 3) Set the transmission auto shift and man-
1) Remove 4th clutch pressure pickup plug ual shift selector switch in the MANUAL
(10) (10 × 1.25 mm). position.
brake switch OFF.
gearshift lever in the 4th position.
tral) again.
securely.
is safe.
above operation.
measure the 4th clutch oil pressure.

{60 kg/cm2}.

48 WA450-6, WA480-6 (KA SPEC.)

11. Measuring lubrication pressure 3) Start the engine and keep the directional
1) Remove lubrication pressure pickup plug lever or switch at the N (Neutral) position.
(11) (10 × 1.25 mm). 4) Measure the lubricating oil pressure while
the engine is running at 2,000 rpm.


{10 kg/cm2}.
WA450-6, WA480-6 (KA SPEC.) 49

Adjustment 2) Remove inner spring (14) and outer spring

1. Adjusting transmission main relief valve (15).
k Stop the engine before starting adjust- 3) Adjust the pressure by changing the num-
ment of the transmission main relief ber of shims (16).
valve. a Standard shim thickness:
a If the transmission main relief pressure is 2.5 mm (0.5 × 5 piece)
out of the specified range, adjust it accord- a Quantity of adjustment per shim:
ing to the following procedure. 0.04 MPa {0.4 kg/cm2}
1) Remove plug (13) from transmission and
torque converter relief valve (12).
50 WA450-6, WA480-6 (KA SPEC.)

Procedure for flushing torque 3. Fill the transmission case with oil.
converter and transmission q Add oil through oil filler (3) to the specified
level. Run the engine to circulate the oil
hydraulic circuit 1 through the system. Then, check the oil
a Metal chips and dirt in the torque converter and level again.
5
transmission hydraulic circuit shorten the lives
Transmission case: 54 l (Refill capacity)
of the torque converter and transmission and
can cause internal breakage. Accordingly,
flush the hydraulic circuit to remove the metal
chips and dirt.
1. Flush the hydraulic circuit in the following

cases.
1) When metal chips are circulated in the
hydraulic circuit because of damage of the
torque converter, transmission, or another
hydraulic device.
2) When the torque converter or transmis-
sion is overhauled or repaired.
2. Install a new filter cartridge.

1) Open inspection cover (1) on the left side 4. Flush the hydraulic circuit according to the fol-
of the rear frame. lowing procedure.
1) Start the engine and run it at low idle with-
out operating the gearshift lever or direc-
tional lever for about 20 minutes.
a Increase the engine speed to about
1,500 rpm sometimes.
a If the engine coolant temperature
gauge does not rise to the operating
range because of low ambient tem-
perature, continue the warm-up oper-
ation further.
2) Operate or drive the machine for at least
20 minutes.
a Use all the gear speeds (Forward,
reverse, and 1st – 4th).
3) Run the engine at low idle for about 20
2) Drain the oil from the filter piping.
minutes, similarly to 4-1).
3) Remove transmission oil filter cartridge (2)
5. Replace the filter cartridge.
and install cartridge (714-07-28712).
1) Replace cartridge (1) used for flushing
with new cartridge (714-07-28712), simi-
larly to 2.
k If the cartridge used for flushing is
used for long hours, it is clogged
quickly. Accordingly, be sure to
replace it with new one.
2) Add oil and check the oil level again.
WA450-6, WA480-6 (KA SPEC.) 51

Method of moving machine when transmission valve is broken 1

a Locations of ECMV assemblies and connector Nos.
a Device for moving machine when transmission k Lower the work equipment to the ground
valve is broken fully, apply the parking brake, and put
chocks under the tires to prevent the
machine from moving.
L 794-423-1190 Plug k When working, stop the engine.
k When working while the oil temperature is
a Even if you cannot move the machine because still high, take care not to burn your body.
of breakage of a transmission valve part (elec-
trical system, solenoid valve, spool, etc.), you
can move it by installing plugs L.
k Installation of plugs L to the ECMV is a
means to move the machine from a danger-
ous job site to a safe place where you can
repair it when you cannot move it at any
gear speed because of breakage of the
transmission control valve. Accordingly,
use this method only when the transmis-
sion control valve is broken.
k When moving the machine by this method,
observe the procedure and take care of
safety.
52 WA450-6, WA480-6 (KA SPEC.)

1. Remove left side cover (1) from the rear frame.

a Remove mud and dirt from around the
ECMV.
2. Disconnect all the connectors from each ECMV

(12 pieces, lockup clutch spec: 14 pieces).
4. Press the brake pedal securely.
5. Start the engine, release the parking brake,

and then release the brake pedal gradually to
start and move the machine.
a If the parking brake cannot be released
3. Remove 2 ECMV solenoids (3) from the 2nd because of a trouble in the electrical sys-
ECMV and F or R ECMV and install plugs L. tem, see “Method of releasing parking
q For forward travel: F solenoid and 2nd brake manually”.
solenoid k Remove the chocks.
q For reverse travel: R solenoid and 2nd k If the engine is started, the transmis-
solenoid sion is engaged and the machine starts
a If a wrong solenoid is removed, the trans- immediately. Accordingly, when start-
mission may be broken. Take care. ing the engine, check the moving direc-
a Install each plug L with its projection side tion of the machine and secure safety
toward the ECMV. Check that the O-ring is around the machine thoroughly and
fitted to the mating face. keep pressing the brake pedal.
a Take care that mud or dirt will not enter the k After moving the machine, stop the
removed solenoids and valves. engine, apply the parking brake, and
put chocks under the tires.
WA450-6, WA480-6 (KA SPEC.) 53

Check of axle final drive for oil Check of drive shafts for
leakage 1 looseness, play and damage 1
Check axle final drive (1) for oil leakage. Check the drive shafts for damage, abnormal play
and looseness of the connecting bolts and nuts. If
If oil is leaking, check and repair the seals and they are loosened or damage, retighten or repair.
bearings.
a See the "Disassembly and assembly" volume. Check the cross member of each universal joint by
moving it up, down, to the right and left and in both
rotating directions.
Check the sliding parts of the front drive shaft by

moving them up or in both rotating directions sev-
eral times.
a For the tightening torque, see the "Disassem-
bly and assembly" volume.
54 WA450-6, WA480-6 (KA SPEC.)

Testing and adjusting steering Adjusting

stop valve 1 a When the clearance between the front and
rear frames is out of the specified range, adjust
Testing it according to the following procedure.
1. Straighten the front frame and rear frame. 1. Loosen locknut (2) and tighten stopper bolt (1)
2. Make sure locknut (2) of stopper bolt (1) is not to minimize distance (a) so that it will not touch
loosened. the end of steering stop valve (3) when the
machine is steered.
3. Start the engine and turn the steering wheel to

the right and left. Measure the clearance 2. Run the engine at low idle and then bring front
between the front frame stopper and rear frame and rear frame into contact each other
frame stopper when above operation is exe- by turning the steering wheel slowly.
cuted. k Use care in this operation so that your
k Stop the engine before measuring the body or arm may not be caught
clearance. between the front and rear frames.
a If the checkup is not available because of 3. Stop the engine and loosen stopper bolt (1)
missing frame stopper and the like, do until it touches the end of steering stop valve
necessary repair and then make sure (3).
clearance is provided on both sides. 4. Run the engine at low idle and return the steer-
ing wheel gradually at least 10°.
WA450-6, WA480-6 (KA SPEC.) 55

5. Loosen stopper bolt (1) by 8.5 turns (Distance

c: Approx. 15 mm) and fix it with locknut (2).
a Adjust the right and left sides by steps 1 –
5 above.
6. Start the engine, turn the steering wheel, and

check that there is a clearance between front
frame (4) and rear frame (5) when steering
stop valve (3) touches stopper bolt (1) and the
steering wheel is stopped.
56 WA450-6, WA480-6 (KA SPEC.)

Testing and adjusting steering Measuring operating effort of steering wheel

wheel 1 a Measure the operating effort of the steering
wheel under the following condition.
a Testing and adjusting device for steering wheel q Road: Flat, level, paved, and dry road
Symbol Part No. Part name q Engine coolant temperature:
M 79A-264-0021 Push-pull scale
q Tire inflation pressure: Specified pressure
Measuring play of steering wheel
q Engine: Low idle (No load on bucket)
a Measure the play of the steering wheel under
the following condition.
Measuring method
q Engine: Stopped
q Position of machine: Straight travel condition 1. Install push-pull scale M to the steering wheel
knob.
Measuring method a Install push-pull scale M to the center.
1. Move the steering wheel to the right and left 2 – 3
2. Start the engine.
times and check that the steering mechanism is
a After starting the engine, raise the bucket
in neutral, and then make mark (A) on the
about 400 mm and release the frame lock
machine monitor frame.
lever.
2. Turn the steering wheel to the right and make
3. Pull push-pull scale M in the tangential direc-
mark (B) at a position where the operating
tion and read it while the steering wheel is
effort becomes heavy.
moving smoothly.
a The operating effort is not the value indi-
cated when the steering wheel starts mov-
ing.
3. Turn the steering wheel to the left and make

mark (C) at a position where the operating
effort becomes heavy. Then, measure the
straight distance between marks (B) and (C).
WA450-6, WA480-6 (KA SPEC.) 57

Measuring operating time of steering wheel

a Measure the operating time of the steering
wheel under the following condition.
q Road: Flat, level, paved, and dry road
q Tire inflation pressure: Specified pressure
q Engine speed: Low idle and high idle
Measuring method
1. Start the engine.
a After starting the engine, raise the bucket
about 400 mm and release the frame lock
lever.
2. Turn the steering wheel to the right or left

stroke end.
3. Turn the steering wheel to the right or left

stroke end and measure the full-stroke time.
a Do not turn the steering wheel forcibly but
turn it at the speed of 60 revolutions per
minute.
a While running the engine at low idle and
high idle, measure the time to turn the
steering wheel to the right and left respec-
tively.
58 WA450-6, WA480-6 (KA SPEC.)

Testing steering oil pressure 1 1. Steering relief pressure

1) Remove steering circuit oil pressure
a Measuring instruments for steering oil pressure pickup plug (2) (10 × 1.25 mm) on the right
Symbol Part No. Part Name steering cylinder head side.
1
799-101-5220 Nipple (10 × 1.25 mm)
N 2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
4 799-401-3200 Adapter (Size 03)
a Measure the steering oil pressure under the

2) Connect nipple N2 and oil pressure gauge
[1] of hydraulic tester N1.
Measuring
{400 kg/cm2}.
k Loosen the oil filler cap of the hydraulic
tank to release the internal pressure of the
hydraulic tank, then operate the steering
wheel 2 – 3 times to release the residual
pressure from the piping.
k Apply frame lock lever (1).
WA450-6, WA480-6 (KA SPEC.) 59

3) Run the engine at high idle and turn the 2) Install adapter N4 and connect hose (4).
steering wheel to the right. When the 3) Connect nipple N2 (10 × 1.25 mm) and oil
steering relief valve operates, measure pressure gauge [1] of hydraulic tester N1.
the oil pressure. a Use the oil pressure gauge of 5.9 MPa
a When the gauge was connected to {60 kg/cm2}.
steering circuit pickup plug at the
head of the left side steering cylinder,
measure the pressure by turning the
steering wheel to the left.
4) Run the engine at low idle, keep the steer-

ing wheel in neutral, and measure the oil
pressure.

removed parts.
2. Steering pilot circuit pressure

1) Disconnect steering control circuit pres-
sure hose (4) of steering valve assembly
(3) through the clearance between the
front side of the operator's cab and front
frame.

removed parts.
60 WA450-6, WA480-6 (KA SPEC.)

Adjusting 2. Adjusting steering control circuit pressure

k When adjusting the oil pressure, be sure to 1) Remove the floor frame assembly. For
stop the engine. details, see Disassembly and assembly,
1. Steering relief pressure “Removal and installation of floor frame
1) If the steering relief pressure is abnormal, assembly”.
adjust steering relief valve (5) of steering 2) Remove servo assembly (9) from steering
valve assembly (3) according to the fol- pump assembly (8) and install new one.
lowing procedure.
2) Loosen locknut (6) and turn adjustment

screw (7) to adjust the pressure.
a Adjustment screw:
q Turned to the right, the pressure
rises.
q Turned to the left, the pressure
lowers.
a Quantity of adjustment per turn of
adjustment screw:
Per turn:
17.8 MPa {181.5 kg/cm2}
3 Locknut:
27 – 31 Nm {2.8 – 3.2 kgm}
WA450-6, WA480-6 (KA SPEC.) 61

Bleeding air from steering circuit1 2. Bleeding air from steering cylinder circuit.
1) Run the engine at idle for about 5 minutes.
a Before starting the operation, make sure the
specified level of hydraulic oil is provided. 2) While running the engine at low idle, steer
a If the steering valve or the steering cylinder the machine to the right and left 4 – 5
was removed and installed, bleed air from the times.
steering circuit according to the following pro- a Stop the piston rod about 100 mm
cedure. before each stroke end and take care
not to relieve the circuit.
1. Bleeding air from steering pump
1) Remove cover (1) under the left of the 3) While running the engine at high idle, per-
operator's cab. form the operation of 2).
4) While running the engine at low idle, move

the piston rod to the stroke end and
relieve the circuit.
2) While the engine is stopped, loosen air

bleeder (2) of the steering pump and con-
nect air bleeder hose [1].
3) As oil free from air started to flow out of air

bleeder (2), tighten air bleeder (2).
3 Air bleeder:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4) Start the engine and run it at low idle for 5
minutes minimum.
62 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 63

SEN01586-00

64
SEN01587-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)

Testing hydraulic drive fan.................................................................................................................... 3
Bleeding air from hydraulic drive fan circuit ......................................................................................... 5
Measuring brake pedal......................................................................................................................... 7
Testing and adjusting brake pedal linkage ........................................................................................... 8
Measuring brake performance ............................................................................................................. 9
Testing and adjusting accumulator charge pressure.......................................................................... 10
Testing wheel brake oil pressure.........................................................................................................11
Measuring wear of wheel brake disc.................................................................................................. 13
Bleeding air from wheel brake circuit ................................................................................................. 14
Releasing residual pressure in brake accumulator circuit.................................................................. 15
Testing parking brake performance .................................................................................................... 15
Measuring parking brake oil pressure ................................................................................................ 16
Testing wear of parking brake disc ..................................................................................................... 18
Manual release method for parking brake.......................................................................................... 19
Measuring and adjusting work equipment control lever ..................................................................... 20
WA450-6, WA480-6 (KA SPEC.) 1

Measuring and adjusting work equipment PPC oil pressure.............................................................. 21

Measuring and adjusting work equipment oil pressure ...................................................................... 24
Bleeding air from work equipment circuit ........................................................................................... 28
Releasing residual pressure in work equipment circuit ...................................................................... 29
Testing and adjusting bucket positioner ............................................................................................. 30
Testing and adjusting boom kick-out .................................................................................................. 32
Checking proximity switch operation pilot lamp.................................................................................. 33
Procedure for testing diodes .............................................................................................................. 34
Preparation work for troubleshooting for electrical system................................................................. 35
Starting KOMTRAX terminal operations............................................................................................. 38
Indicator lamps of KOMTRAX terminal .............................................................................................. 42
Adjusting machine monitor ................................................................................................................. 45
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ................. 46
2 WA450-6, WA480-6 (KA SPEC.)


Testing hydraulic drive fan 1 Tachometer kit P1
a Testing tools for hydraulic drive fan

1 799-205-1100 Tachometer kit
P 799-101-5002 Hydraulic tester
2
k Set the bucket bottom horizontally and

lower it to the ground, and then put chocks
under the tires.
k When removing the oil pressure pickup
plug and disconnecting the hose, loosen
the oil filler cap of the hydraulic tank to 3) While running the engine at high idle and
release the internal pressure of the tank. low idle, measure the fan speed.
a Measurement condition 4) After finishing measurement, remove the
q Engine coolant temperature: Min. 95°C measuring instruments and return the
q Hydraulic oil temperature: Min. 95°C removed parts.
q Torque converter oil temperature: Min. 105°C
1. Measuring fan speed

1) Open radiator grille (1).
2) Set probe [2] to stand [1] of tachometer kit

P1 and stick reflection tape [3] to the fan.
WA450-6, WA480-6 (KA SPEC.) 3

2. Measuring fan drive oil pressure 4) While running the engine at high idle,
1) Open radiator grille (1). measure the fan drive oil pressure.
2) Remove cover (2). 5) After finishing measurement, remove the

removed parts.

lic tester P2 to pressure pickup nipple (3).
{400 kg/cm2}.
4 WA450-6, WA480-6 (KA SPEC.)

Bleeding air from hydraulic drive 3) As oil free from air started to flow out of air
fan circuit 1 bleeder (2), tighten air bleeder (2).
3 Air bleeder:
a Testing tools for bleeding air from hydraulic drive 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
fan circuit 4) Start the engine and run it at low idle for 5
Symbol Part No. Part Name minutes minimum.
1 2. Bleeding air from fan motor circuit
Q 790-261-1204 Digital hydraulic tester 1) Open radiator grille (1).
2 790-261-1130 Coupling
a Before starting the operation, make sure the

specified level of hydraulic oil is provided.
1. Bleeding air from fan pump

1) Remove cover (1) under the right of the
operator's cab.
2) Remove cover (2).
2) While the engine is stopped, loosen air

bleeder (2) of the fan pump and connect
air bleeder hose [1].
WA450-6, WA480-6 (KA SPEC.) 5

3) Connect hose [1] of hydraulic tester Q1 to

pressure pickup nipple (3) and connect air
bleeder coupling Q2 to the outlet end of
the hose.
a Put the outlet end of the hose in an oil
receiver.
4) Run the engine. When the oil flows out of

the outlet end of the hose, stop the
engine.
5) After finishing bleeding air, remove the
tools and return the removed parts.
6 WA450-6, WA480-6 (KA SPEC.)

Measuring brake pedal 1

a Measurement condition
q Engine speed: Low idle
Measuring pressing angle of pedal

1. Install push gauge [1] to the foot of the mea-
surer.
a Set the push gauge in a position 150 mm
from the fulcrum of the pedal.
2. While running the engine at low idle, measure

pedal pressing angle (a1).
3. Apply angle gauge [2] to the brake pedal and

measure neutral angle (a1) and maximum
pressing angle (a2).
q (a2): Pressing angle at pressing effort of
323 ± 30 N {32.9 ± 3.0 kg}
WA450-6, WA480-6 (KA SPEC.) 7

Testing and adjusting brake pedal

linkage 1
Testing
1. Check linkage mounting pin (7), pin hole of
lever (6) and lever bushing for play, and adjust
them if necessary.
2. Check that the link length (a = 200 mm) is in

the standard range.
a Measure the distance between the cen-
ters of pin (6) and ball joint (3).
3. Measure the moving distance of rod (8) and

check that clearance (b) is in the standard
range.
a At this time, the brake pedal must be in
contact with the stopper.
4. Check the bolts and nuts of each part for

looseness. If they are loosened, retighten.
Adjusting
1. Adjusting link length (a)
1) Remove pin (5), ball joint (3) and rod (1).
2) Loosen locknut (4) and adjust the link
length by turning yoke (2) and ball joint
(3).
3) After adjusting link length (a), connect the
link to the brake pedal.
a Standard length (a): 213 mm
2. Adjusting rod play (b)

1) Loosen locknut (7) and turn rod (8) to set
its tip to the booster push rod and then
return it 1/4 turns.
a Moving distance in 1/2 turn: 0.75 mm
2) Tighten nut (7).
a Standard play (b): 0 – 0.3 mm
8 WA450-6, WA480-6 (KA SPEC.)

Measuring brake performance 1
a Measure the brake performance under the fol- Measuring method

lowing condition. 1. Start the engine and drive the machine.
q Road: Flat, level, paved, and dry road
q Braking initial speed: 20 km/h 2. Set the gear shift lever or gear shift switch to
q Tire inflation pressure: Specified pressure 4th position for run up.
q Tire size: 26.5-25
q Brake pedal pressing force: Specified press- 3. When the travel speed becomes the braking
ing force initial speed of 20 km/h, press the left brake
323 ± 30 N {32.9 ± 3 kg} pedal with the specified force.
q Pressing time lag: 0.1 second a Decide the approach course and braking
point in advance and apply the brake at
that braking point.
4. Measure the distance from the braking point to

the stop point.
a Perform the above measurement 3 times
and obtain the average.
WA450-6, WA480-6 (KA SPEC.) 9

Testing and adjusting 3. Measure the accumulator charge cut-out pres-

accumulator charge pressure 1 sure. After the accumulator charge cut-in oper-
ation, the rising oil pressure gauge lowers
a Testing and adjusting instruments for accumula- suddenly. Measure the oil pressure at this time.
tor charge pressure a Cut-out pressure: 9.8 (+0.98/0) MPa
Symbol Part No. Part Name {100 (+10/0) kg/cm2}
799-101-5002 Analog hydraulic tester
R
a Measure the accumulator charge pressure

under the following condition.
q Engine coolant temperature: Within oper-
ating range
ing range
k Put chocks under the tires securely.
Measuring
1. Connect oil pressure gauge [1] of hydraulic tester 4. After finishing measurement, remove the mea-
R to accumulator charge pressure pickup plug suring instruments and return the removed
(2) of accumulator charge valve (1). parts.
{400 kg/cm2}. Adjusting
a If the accumulator charge cut-out pressure is
adjusted, the cut-in pressure changes accord-
ing to the valve area ratio.
1. Loosen locknut (4) of unload relief valve (accu-

mulator charge cut-out valve) (3) and turn
adjustment screw (5) to adjust the pressure.
a If the adjustment screw is
q Turned to the right, the pressure rises.
q Turned to the left, the pressure lowers.
a Quantity of adjustment per turn of adjust-
ment screw: 1.45 MPa {14.8 kg/cm2}
3 Locknut: 11.8 – 16.7 Nm {1.2 – 1.7 kgm}
2. Measure the accumulator charge cut-in pres-

sure. While running the engine at low idle,
when the brake oil pressure caution lamp on
the machine monitor goes off, measure the oil
pressure.
a Cut-in pressure: 5.9 (+0.5/0) MPa
{60 (+5/0) kg/cm2}
a After finishing measurement, check the

accumulator charge cut-in and cut-out
pressures again according to the above
measurement procedure.
10 WA450-6, WA480-6 (KA SPEC.)

Testing wheel brake oil pressure 1 2. Remove brake tube (2) of the measured side.
a Measuring tools for wheel brake oil pressure 3. Remove union (3) and install adapter S4 and
Symbol Part No. Part Name nipple S5, and then install brake test kit S1.
a Use the O-ring fitted to the union.
1 793-605-1001 Brake test kit
2 790-101-1430 Coupler
3 790-101-1102 Pump
S 4 790-301-1720 Adapter
5 799-101-5160 Nipple
6 799-401-2220 Hose
7 790-261-1130 Coupling
k Apply the parking brake and put chocks

under the tires securely.
a Measure the oil pressure of the front brakes
(right and left) and rear brakes (right and left)
similarly.
a Measure the wheel brake oil pressure under
q Engine coolant temperature: Within operating
range
q Hydraulic oil temperature: Within operating range
1. Remove front frame inspection cover (1).

k When raising the lift arm to remove the
inspection cover, place a stand under it
to support securely.
4. Loosen bleeder screw (4) to bleed air.

a Bleed air by operating pump S3.
WA450-6, WA480-6 (KA SPEC.) 11

5. Tighten bleeder screw (4). Operate pump S3

and raise the pressure to 4.9 MPa {50 kg/cm2},
and then tighten stop valve [1].
6. Leave the brake circuit pressurized for 5 min-

utes and check lowering of the pressure.
a If the hose is moved while the pressure is
me as ur ed , the p re s su r e flu c tua tes .
Accordingly, do not move the hose.
a After testing the pressure, operate pump
S3 to lower the pressure in brake test kit
S1, and then remove brake test kit S1.
a After finishing testing, install the brake
tube and bleed air from the brake circuit.
a After finishing testing, remove the measuring
instruments and return the removed parts.
Brake test kit S
12 WA450-6, WA480-6 (KA SPEC.)

Measuring wear of wheel brake

disc 1
Commercially
T Slide calipers
available
k Stop the machine in a level place and put

chocks under the tires.
1. Remove cap (1).
2. Lightly press the brake pedal to the stroke end.
3. While shaft (2) is pushed in, measure projec-

tion (x) (wear volume) from guide (3) using a
slide caliper T.
a Keep pressing the brake pedal during
measurement.
a If shaft (2) is projected from the end of
guide (3) to the groove on it, replace the
disc.
q Wear: (x)
Wear limit (y): Max. 2.4 mm
4. After testing, return cap (1).

3 Cap (1): 29.4 – 39.2 Nm {3.0 – 4.0 kgm}
WA450-6, WA480-6 (KA SPEC.) 13

Bleeding air from wheel brake 5. Connect hose [1] to bleeder screw (3) of the
circuit 1 wheel brake and place hose [1] in the oil pan.
k Stop the machine in a level place and put

a If a brake circuit part is removed and installed,
bleed air from the brake circuit according to the
following procedure.
a Bleed air from the front brake circuit and rear
brake circuit similarly (3 places each).
1. Start the engine to accumulate pressure in the

accumulator and then stop the engine.
2. Remove front frame inspection cover (1).
6. Press the brake pedal and then loosen bleeder

screw (3) to bleed air.
a Return the brake pedal slowly after tight-
ening bleeder screw (3).
7. Repeat this operation until the oil flowing

through hose [1] becomes free from bubbles.
Then press the pedal fully and tighten bleeder
screw (2) while the oil is flowing.
8. Bleed air from other brake cylinders, too, using

the same procedure.
a When a complete bleeding is required, it is
3. Connect hose [1] to bleeder screw (2) of the advisable to start the operation from the
slack adjuster and place hose [1] in the oil pan. brake cylinder situated farthest from the
brake pedal.
a As accumulated pressure in the accumu-
lator is decreased, start the engine to
accumulate pressure in the accumulator.
Then bleed air using 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, add oil up
to the specified level.
4. Press the brake pedal and then loosen bleeder

screw (2) to bleed air.
a Return the brake pedal slowly after tight-
ening bleeder screw (2).
14 WA450-6, WA480-6 (KA SPEC.)

Releasing residual pressure in Testing parking brake

brake accumulator circuit 1 performance 1
k Before disconnecting any of the following a Measurement condition
brake accumulator circuits, release resid- q Tire inflation pressure: Specified pressure
ual pressure in that brake circuits. q Road: 1/5 gradient (11° 20'), flat, and dry road
q Machine: Ready for operation
q Piping between accumulator charge valve and
brake accumulator Measuring method
q Between accumulator charge valve and park- 1. Start the engine and set the machine in the
ing brake solenoid valve straight travel position, and then drive up a
q Piping between brake accumulator and brake slope of 1/5 gradient with no load in the bucket.
valve on both sides
2. Press the brake to stop the machine, set the
1. Stop the engine. directional lever in the N position, and stop the
engine.
2. Press the brake pedal at least 100 times to
release the pressure from the brake accumula- 3. Turn the parking brake switch ON (to park),
tor circuit. and then release the brake 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 Measure the parking brake performance
on an uphill and a downhill.
WA450-6, WA480-6 (KA SPEC.) 15

Measuring parking brake oil 2) Remove parking brake pressure pickup

pressure 1 plug (2).
a Measuring instruments for parking brake oil

pressure
1
U
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
k Put chocks under the tires.

k Install and remove the measuring instru-
ments after the oil temperature lowers fully.
a Measure the parking brake oil pressure under

q Power train oil temperature:
1. Parking brake pressure

1) Remove rear frame left side cover (1).
3) Connect nipple U2 and oil pressure gauge

[1] of hydraulic tester U1.
a Use the oil pressure gauge with
capacity 5.9 MPa {60 kg/cm2}.
16 WA450-6, WA480-6 (KA SPEC.)

4) Run the engine at low idle and measure

the parking brake pressure.
k Keep pressing the brake pedal for
safety.
a Measure the oil pressure at turning
OFF of the parking brake.

WA450-6, WA480-6 (KA SPEC.) 17

Testing wear of parking brake disc1 4. If depth (a) is above the standard, remove
parking brake disc (4) and measure its thick-
Measuring instruments ness (W), referring to Disassembly and assem-
Symbol Part No. Part Name bly, “Removal of parking brake disc”.
Commercially q Service limit thickness (W): 2.97 mm
V Slide calipers a If the parking brake disc thickness is
available
below the service limit, replace the disc.
a If the parking brake does not work effectively,

check the parking brake disc for wear accord-
ing to the following procedure.
k Lower the work equipment fully and put
k When checking, stop the engine.
1. Drain the oil from the transmission case.

6 Transmission case: 54 l (refill capacity)
2. Remove either of 2 plugs (1).
q Refilling with oil (Transmission case)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
3. Measure depth (a) from the end of cage (2) to

piston (3) with slide calipers V.
q Standard depth (a): Max. 41.3 mm
18 WA450-6, WA480-6 (KA SPEC.)

Manual release method for 2. Remove 2 gauge mounting bolts (2), and
parking brake 1 tighten to plug mounting portion in turn.
a Remove 2 bolts (2) on opposite sides.
a The parking brake is controlled by hydraulic a When bolts (2) are screwed in, piston (3)
pressure, so if there should be any failure in is pulled and the parking brake is
the transmission or the emergency release released.
solenoid and it becomes impossible to release a Tighten the 2 bolts uniformly a little at a
the parking brake, it is possible to release it time. (Tighten approx. 4.5 turns after the
manually to move the machine. bolts contacts the seat.)
k The manual release of the parking
brake is designed only to move the
machine from a dangerous working
area to a safe place where repairs can
be carried out. This method must not
be used except in an emergency.
k To prevent the machine from moving,
lower the bucket to the ground and put
blocks under the tires.
k Always stop the engine before carrying
out this procedure.
1. Remove 2 plugs (1). (left and right)

a Approx. 20 l of oil will come out from the
plug mount, so prepare a container to
catch it. q Refilling with oil (transmission case)
a After releasing the parking brake, coat the After carrying out the manual release method
plug with gasket sealant (LG-5) and for the parking brake, add oil through the oil
tighten it. filler to the specified level. Run the engine to
circulate the oil through the system, then check
the oil again.
WA450-6, WA480-6 (KA SPEC.) 19

Measuring and adjusting work 2. Stroke of work equipment control lever

equipment control lever 1 1) Operate the work equipment control lever
and measure its stroke at each position.
a Measuring and adjusting tools for work equip- a Apply a mark to the lever knob and
ment control lever measure the stroke with scale W2.
Symbol Part No. Part name a If the stroke is out of the standard
range, check for play of the linkage
1 79A-264-0021 Push-pull scale
and wear of the bushing.
W Commercially
2 Scale
available
a Measure and test the work equipment control

lever under the following condition.
ing range
q Engine speed: Low idle
k Apply the frame lock bar to the frame.
Measuring
1. Operating effort of work equipment control
lever
1) Install and fix tool W1 to the work equip-
ment control lever.
a Install tool W1 to the center of the knob.
a Operate the work equipment control
lever at the ordinary operating speed
and measure the minimum necessary
effort to operate the knob.
20 WA450-6, WA480-6 (KA SPEC.)

Measuring and adjusting work 3) Connect nipple X2 and oil pressure gauge
equipment PPC oil pressure 1 [1] of hydraulic tester X1.
a Measuring and adjusting instruments for work {60 kg/cm2}.
equipment PPC oil pressure
1
X
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
k Loosen the oil filler cap of the hydraulic

tank gradually to release the internal pres-
sure of the hydraulic tank
k Operate the work equipment control lever 2
– 3 times to release the pressure from the
PPC accumulator circuit. 4) While running the engine at high idle,
a Measure the work equipment PPC oil pressure operate the work equipment control lever
under the following condition. and measure the PPC basic pressure.
ing range
Measuring
1. PPC valve basic pressure
1) Remove rear frame left side cover (1).

removed parts.
2) Remove oil pressure pickup plug (3) (10 ×

1.25 mm) from the underside of PPC accu-
mulator (2).
WA450-6, WA480-6 (KA SPEC.) 21

2. Measuring PPC valve output pressure 3) Connect nipple X2 and oil pressure gauge
1) Remove front frame inspection cover (4). [1] of hydraulic tester X1.
k When raising the lift arm to remove a Use the oil pressure gauge of 5.9 MPa
the inspection cover, place a stand {60 kg/cm2}.
under it to support securely.

2) Remove oil pressure pickup plug (10 × operate the work equipment control lever
1.25 mm) (5) of the measured PPC circuit. and measure the PPC valve output pres-
a A: Attachment sure.
B: Attachment
C: Lower and float lift arm
D: Raise lift arm
E: Dump bucket
F: Tilt bucket

removed parts.
22 WA450-6, WA480-6 (KA SPEC.)

Adjusting
a The PPC relief valve is not adjustable.
a Remove PPC relief valve cartridge assembly

(8) from accumulator charge valve assembly
(7) and replace it.
3 PPC relief valve cartridge assembly:
25 – 33.9 Nm {2.6 – 3.5 kgm}
a After replacing the cartridge assembly, mea-
sure the PPC oil pressure again.
WA450-6, WA480-6 (KA SPEC.) 23

Measuring and adjusting work 3) Remove front frame inspection cover (1).
k When raising the lift arm to remove
equipment oil pressure 1
the inspection cover, place a stand
a Measuring and adjusting instruments for work under it to support securely.
equipment oil pressure
1
Y 799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
a Measure the work equipment oil pressure

under the following condition.
ing range
Combination of actuator and valve 2. Measuring work equipment relief pressure

a Note that different actuators relieve different 1) Remove pump pressure pickup plug (10 ×
valves. 1.25 mm) (2) from the work equipment
a The No. of each actuator in the following table control valve.
shows the order from the top, when the control
valve is seen from the front of the machine.
(The attachment actuator is used when 1
attachment is installed.)
No. Actuator Relieved valve
1 Attachment Safety valve
2 Lift arm Main relief valve
Tilt Safety valve
3 Bucket
Dump Main relief valve
1. Preparation work
1) Raise part (a) of the bucket about 30 – 50
mm and lower part (b) to the ground. 2) Connect nipple Y2 and oil pressure gauge
2) Stop the engine and operate the work [1] of hydraulic tester Y1.
equipment control lever to check that both a Use the oil pressure gauge of 39.2 MPa
parts (a) and (b) of the bucket are in con- {400 kg/cm2}.
tact with the ground.
a After lowering the bucket to the
ground, operate the work equipment
control lever 2 – 3 times to release
the residual pressure in the piping.
24 WA450-6, WA480-6 (KA SPEC.)

3) Start the engine and raise the lift arm to 2) Connect nipple Y2 and oil pressure gauge
the level position. Then, while running the [1] of hydraulic tester Y1.
engine at high idle and dumping the a Use the oil pressure gauge of 5.9 MPa
bucket, measure the oil pressure. {60 kg/cm2}.
k After measuring the oil pressure, 3) Start the engine and raise the lift arm
release the pressure in the circuit about 400 mm. Then, while running the
according to the procedure for engine at high idle, set all the levers in
installing the nipple and oil pres- neutral and measure the oil pressure.
sure gauge, and then remove the
oil pressure gauge and nipple.
3. Measuring unload pressure

1) Remove pump pressure pickup plug (10 ×
1.25 mm) (2) from the work equipment
control valve.
k After measuring the oil pressure,

release the pressure in the circuit
according to the procedure for
installing the nipple and oil pres-
sure gauge, and then remove the
oil pressure gauge and nipple.
WA450-6, WA480-6 (KA SPEC.) 25

4. Measuring work equipment LS differential

pressure
a Before measuring the LS control circuit
pressure, check that the work equipment
relief pressure and work equipment PPC
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 differ-
ence between them.
1) Remove pump pressure pickup plug (10 ×

1.25 mm) (2) and LS pressure pickup plug
(10 × 1.25 mm) (3) from the work equip- 3) Start the engine and raise the lift arm
ment control valve. about 400 mm.
when the following condition is satisfied,
measure the pump pressure and LS pres-
sure (actuator load pressure) simulta-
neously.
q When all the levers are in neutral and
when the lift arm lever is moved half-
way
a While measuring, take care not to
move the lift arm cylinder to the
stroke end.
a Calculation of LS differential pressure:
LS differential pressure = Pump dis-
charge pressure – LS pressure
2) Install nipple Y2 and connect oil pressure a If the LS differential pressure is as fol-
gauge [1] of hydraulic tester Y1 or differ- lows, it is normal.
ential pressure gauge Y3.
Position of lever LS differential pressure
a When using the differential pressure
gauge, connect the high pressure Unload pressure
All levers in neutral
side to the pump pressure side and (See standard value)
connect the low pressure side to the Specified LS differential
Lift arm lever in LIFT stroke
LS pressure side. position
pressure
Since the differential pressure gauge (See standard value)
needs a 12V power source, connect it
to a battery.
a When using the oil pressure gauge,
use the oil pressure gauge of 39.2 MPa
{400 kg/cm2}.
Since the differential pressure is about
1.5 MPa {15 kg/cm 2 } at maximum,
measure it by installing the same gauge
to the pickup plugs alternately.
26 WA450-6, WA480-6 (KA SPEC.)

5) After finishing measurement, remove the a After finishing measurement, mea-

measuring instruments and return the sure the work equipment relief valve
removed parts. according to the above measurement
k After measuring the oil pressure, procedure.
release the pressure in the circuit
according to the procedure for 2. Adjusting LS differential pressure
installing the nipple and oil pres- 1) Remove the floor frame assembly. For
sure gauge, and then remove the details, see Disassembly and assembly,
oil pressure gauge and nipple. “Removal and installation of floor frame
assembly”.
Adjusting 2) Remove LS valve (9) from work equip-
a The unload valve is not adjustable. ment pump assembly (8) and replace it.
1. Adjusting work equipment relief pressure

1) Adjust main relief valve (5) from work
equipment control valve (4).
2) Loosen locknut (6) and turn adjustment

screw (7) to adjust the pressure.
a If the adjustment screw is
q Turned to the right, the pressure
rises.
q Turned to the left, the pressure
lowers.
a Quantity of adjustment per turn of
adjustment screw:
12.6 MPa {128 kg/cm2}
3 Locknut:
29.4 – 39.2 Nm {3 – 4 kgm}
WA450-6, WA480-6 (KA SPEC.) 27

Bleeding air from work equipment 2. Air bleeding from hydraulic cylinder
circuit 1 1) Start the engine and run it at low idle for 5
minutes minimum.
1. Bleeding air from work equipment pump 2) While running the engine at low idle, repeat
(piston pump) raising and lowering of the lift arm 4 – 5
1) Remove cover (1) under the right of the times.
operator's cab. a Do not operate the piston rod beyond
a position 100 mm in front of the
stroke end to prevent relieving.
3) Implement operation of 2) above with the
engine at high idle. Then operate the pis-
ton rod to the stroke end at low idle to
relieve it.
4) Implement the same operation as 2) and
3) above for the bucket and steering, too.
a When a cylinder is replaced, this
operation should be implemented
before connecting the piston rod.
2) Stop the engine and then loosen air

bleeder (2) of work equipment pump to
connect air bleeding hose [1].
3) When hydraulic oil containing no bubbles

flows out of air bleeder hose [1], tighten
the air bleeder.
3 Air bleeder:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4) Start the engine and run it at low idle for 5
minutes minimum.
28 WA450-6, WA480-6 (KA SPEC.)

Releasing residual pressure in 2) Loosen locknut (4) of ECSS pressure

work equipment circuit 1 relief plug (3) on work equipment control
valve (2).
1. Releasing residual pressure from the cir- 3) Loosen adjustment plug (5) 1/2 – 1 turn to
cuit between respective hydraulic cylinders release the accumulator pressure.
and control valve
a When disconnecting the pipes between
respective hydraulic cylinders and work
equipment, release the residual pressure
in the circuit according to the following
procedure.
1) Stop the engine.
2) Loosen the oil filler cap gradually to
release the internal pr essure of the
hydraulic tank
3) Set the work equipment lock lever to free
position.
4) Turn the starting switch ON.
5) Release residual pressure operating the
work equipment lever.
2. Releasing residual pressure from ECSS

(travel damper) circuit
k When disconnecting the piping of the
travel damper circuit (between the
accumulator for ECSS and work equip-
ment control valve), release pressure
of t h e a c c u m u l a t o r f o r t h e E C S S
according to the following procedure.
1) Remove inspection cover (1) on the front
frame.
k When raising the lift arm to remove
the inspection cover, place a stand
under it to support securely. 4) After releasing residual pressure, tighten
plug (5) and locknut (4) securely in this
order.
a Loosen locknut (4) to the maximum
before tightening plug (5). After tight-
ening plug (5), tighten locknut (4).
3 Plug:
19.6 – 27.5 Nm {2.0 – 2.8 kgm}
3 Locknut:
19.6 – 27.5 Nm {2.0 – 2.8 kgm}
WA450-6, WA480-6 (KA SPEC.) 29

Testing and adjusting bucket Adjusting

positioner 1 1. Adjusting clearance
1) Adjust and fix switch nut (4) so that clear-
ance (b) between the end of switch pro-
a Engine coolant temperature: Within operating tector (3) and switch sensitive surface (1)
range will be in the standard range.
a Hydraulic oil temperature: Within operating range a Standard clearance (b): 0.5 – 1.0 mm
3 Switch nut:
Testing 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
1. While the engine is stopped, check that clear-
ance (a) between proximity switch (1) and sen-
sor bar (2) is in the standard range.
a Clearance (a): 3 – 5 mm
2) Adjust and fix the shim and proximity

switch bracket mounting bolt so that clear-
ance (a) between the sensitive surface of
proximity switch (1) and sensor bar (2) will
2. While running the engine at middle speed be in the standard range.
(1,500 rpm), check the operating point. (Check a Clearance (a): 3 – 5 mm
3 times and obtain the average.) a Adjust sensor bar (2) with the shim so
that clearance (a) will be in the stan-
dard range through the stroke of the
sensor bar.
30 WA450-6, WA480-6 (KA SPEC.)

2. Adjusting mounting position

(stopping position)
1) Lower the bucket to the ground and set it
to a desired cutting angle, and then return
the lever to the holding position and stop
the engine.
2) Loose 2 mounting bolts (5) and adjust the
position of switch protector (3) so that the
rear end of sensor bar (2) will be at the
center of the sensitive surface of proximity
switch (1), and then tighten 2 mounting
bolts (5).
3) Check again that clearance (a) between
proximity switch (1) and sensor bar (2) is 3
– 5 mm.
q You may check by turning the starting
switch ON and turning the pilot lamp
ON and OFF. (When the pilot lamp is
turned OFF, the bucket stops.)
a After adjusting, start the engine, oper-

ate the bucket control lever, and
check that the switch operates at the
desired position.
WA450-6, WA480-6 (KA SPEC.) 31

Testing and adjusting boom kick- Adjusting

out 1 1. Raise the lift arm to a desired position.
k Be sure to apply the work equipment
lock lever.
Testing
1. Start the engine and operate the lift arm control 2. Loosen 2 bolts (3) and adjust the position of
lever to operate proximity switch (1), and then plate (2) so that its lower end will be at the cen-
stop the engine. ter of switch (1), and then tighten bolts (3).
k Be sure to apply the work equipment
lock lever.
2. While the engine is stopped, check that clear-

ance (a) between switch (1) and plate (2) is
within the standard range.
a Clearance (a): 3 – 5 mm
3. Adjust and fix switch nut (4) so that clearance

(a) between the sensitive surface of switch (1)
and plate (2) will be in the standard range.
3 Switch nut:
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
a After adjusting, operate the work equip-
ment, and check that the switch operates
3. While running the engine at high idle, check at the desired position.
the operating point. a Clearance (a): 3 – 5 mm
(Check 3 times and obtain the average.)
32 WA450-6, WA480-6 (KA SPEC.)

Checking proximity switch

operation pilot lamp 1
Proximity switch operation pilot lamp (Red)

The proximity switch has a pilot lamp to indicate its
operating condition. Use this pilot lamp when
adjusting the proximity switch.
q A: Operation pilot lamp (Red)
Positional relationship between sensitive surface

Proximity switch Operation pilot lamp Remarks
of proximity switch and sensing object
Near ON Operates when center of
Bucket positioner
Far OFF switch is near
Near ON Operates when center of
Boom kick-out
Far OFF switch is far
WA450-6, WA480-6 (KA SPEC.) 33

Procedure for testing diodes 1

a Check an assembled-type diode (8 pins) and
independent diode (2 pins) in the following
manner.
a The conductive directions of the assembled-
type diode are indicated on the surface of the
diode as shown in the following figure.
2. When using analog type circuit tester

1) Switch the testing mode to resistance
range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
1] Put the red probe (+) of the test lead
to the anode (P) and the black probe
a The conductive directions of the single diode is (–) to the cathode (N) of diode.
indicated on the surface of the diode as shown 2] Apply the red (+) lead of the tester to
in the following figure. the cathode (N) side of the diode and
apply the black (–) lead to the anode
(P) side.
3) Determine if a specific diode is good or no
good by the way the pointer swings.
q With the connection 1] above, the
pointer is not moved. It swings, how-
ev er, when the c onnec tion 2] is
employed. Normal (However, magni-
tude of the pointer's move (indicating
the resistance value) varies depend-
ing on the given tester model and the
measurement range selected).
q The pointer swings with both the con-
nections of 1] and 2]: Defective
1. When using digital type circuit tester (Internal short circuit)
1) Switch the testing mode to diode range q The pointer does not swing with both
and confirm the indicated value. the connections of 1] and 2]: Defec-
a Voltage of the battery inside is dis- tive (Internal breaking of wire)
played with conventional circuit testers.
2) Put the red probe (+) of the test lead to the
anode (P) of and the black probe (–) to the
cathode (N) of diode, and confirm the indi-
cated value.
3) Determine acceptability of the diode from
the indicated value.
q Indicated value remains unchanged:
Conduction is absent (Failure)
q The indicated value changes: The
diode has conductivity (Normal) (See
a below.)
a A value between 460 to 600 is indi-
cated for silicon diodes.
34 WA450-6, WA480-6 (KA SPEC.)

Preparation work for

troubleshooting for electrical
system 1
a When carrying out troubleshooting for an elec-
trical circuit related to the machine monitor,
transmission controller, work equipment con-
troller, or KOMTRAX terminal, expose the
related connectors according to the following
procedure.
a Disconnect and connect the connectors of spe-
cial lock types according to the following pro-
cedure.
1. Machine monitor 2) Remove interior cover (2) from the front

1) Disconnect the following connectors from left side.
cover (1). a Remove the cap and mounting bolts.
q Connector L01:Parking brake switch 3) Remove cover (1).
q Connector L07:Machine monitor mode
selector switch 1
q Connector L08:Machine monitor mode
selector switch 2
q Connector S01:Front working lamp
switch
q Connector S02:Rear working lamp
switch
q Connector S07:ECSS switch
(If equipped)
a Pull the switch out of the cover and
disconnect each connector.
a If you insert your hands from under
the cover and disconnect a connector
forcibly, you many damage the con-
4) Remove 3 bracket mounting bolts (4) of
nector or switch. Take care.
machine monitor (3) and reverse the
machine monitor.
a Take care not to pull the wiring har-
ness forcibly.
WA450-6, WA480-6 (KA SPEC.) 35

5) Connect diagnosis T-adapters to connec- 2. Transmission controller

tors L51, L52, L53, L54, L55, L56, and 1) Remove covers (6) and (7) from the rear
L57 of machine monitor (5). of the cab.
2) Connect diagnosis T-adapters to connec-

tors L61, L62, and L63 of transmission
controller (8).
a If the connectors cannot be discon-
nected and connected easily, remove
the transmission controller.
a Since the connectors are secured
with screws, loosen those screws
before disconnecting.
a When connecting the connectors
again, tighten their screws to the
specified torque.
3 Screw:
2.2 – 2.8 Nm {0.23 – 0.29 kgm}
36 WA450-6, WA480-6 (KA SPEC.)

3. Work equipment controller (if equipped) 4. KOMTRAX controller

1) Remove covers (6) and (7) from the rear 1) Remove cover (10)
of the cab.
2) Connect diagnosis T-adapter to connec-

2) Connect diagnosis T-adapters to connector L80 of KOMTRAX terminal (11).
tors L71, L72, and L73 of work equipment a If the connector cannot be discon-
controller (9). nected and connected easily, remove
a If the connectors cannot be discon- the KOMTRAX terminal.
nected and connected easily, remove a Since the connector is secured with
the work equipment controller. screws, loosen those screws before
a Since the connectors are secured disconnecting.
with screws, loosen those screws a When connecting the connector again,
before disconnecting. tighten its screws to the specified
a When connecting the connectors torque.
again, tighten their screws to the 3 Screw:
specified torque. 2.2 – 2.8 Nm {0.23 – 0.29 kgm}
3 Screw:
2.2 – 2.8 Nm {0.23 – 0.29 kgm}
WA450-6, WA480-6 (KA SPEC.) 37

Starting KOMTRAX terminal 3) When about 3 to 5 seconds elapsed after

operations 1 the starting switch was set to ACC, make
sure that the 7-segment indicator lamp
In the case where the KOMTRAX terminal has changes to hyphen “–” on the KOMTRAX
already been installed at the plant before ship- terminal.
ment:
a Implement the following procedure in the case
where the KOMTRAX terminal has already
been installed at the plant before shipment (as
standard equipment).
1. Notification of model, part number, and

serial number
Notify the KOMTRAX operations administrator
of model, part number, and serial number.
2. Registration of machine
The KOMTRAX operations administrator shall
use a KOMTRAX client PC to register the
machine.
a Refer to “Manual for KOMTRAX opera-
tions administrator” for the procedure.
a Now the terminal is ready for use.
In the case where the KOMTRAX terminal is ret-

rofitted:
a When retrofitting the KOMTRAX terminal after
shipment (retro-fitted machine), follow the
steps below.
1. Station opening check in machine side

a Complete steps 3) to 5) within 60 sec-
onds. If 60 seconds or above elapsed,
4) Disconnect check connector 1, and wait
begin with step 1) again.
for about 3 to 5 seconds as it is.
1) Turn OFF the starting switch and then,
a Ensure that the connector is discon-
a ft e r m a k i n g s u r e 5 s e c o n d s h a v e
nected.
elapsed, proceed to the next step.
5) Reconnect check connector 1, and wait
2) Visually check that check connectors 1
for about 3 to 5 seconds as it is.
and 2 are connected.
a If the KOMTRAX terminal detects that
q Check connector 1: CHK0
the connector was disconnected and
q Check connector 2: CHK1
connected, the dot on the 7-segment
indicator lamp blinks a few times.
38 WA450-6, WA480-6 (KA SPEC.)

6) Make sure that the 7-segment indicator a As [Normal] is indicated, proceed to

lamp is indicated normally on the the next step.
KOMTRAX terminal. a If “–” remains displayed, execute
a If so, the 7-segment indicator lamp will steps 1) to 5) again.
indicate characters “d”, “0”, and “–”
repeatedly for 30 seconds after step 5)
was ended.
a Those characters, even if displayed
normally, will change to a character
other than hyphen “–”after 30 sec-
onds or above elapsed.
The display may change to a charac-
ter other than “0” even within 30 sec-
onds.
7) Turn the starting switch to START position

for about 3 to 5 seconds, and make sure
that the engine does not start.
a If the engine starts, re-execute the
procedure above from step 1).
a Do not return the starting switch to
OFF position.
8) Turn the starting switch from ACC position
to START position again, and make sure
that the engine starts.
9) Make sure that the KOMTRAX terminal's
indicator lamps are normally turned on.
a Move on to the next step if you can
check that the display is [Normal]. (It
takes from 90 seconds to 15 minutes
before the display turns normal.)
a If [GPS position data detection trou-
ble] is indicated, check if there is any
abnormality on the GPS antenna or
cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [Reception trouble] is indicated,
check if there is any abnormality on
the appearance of the communication
antenna or cable. If there is any
abnormality, repair it then repeat from
procedure 1) again.
a If [GPS position data detection trouble
and reception trouble] is indicated,
check if there is any abnormality on
the GPS antenna/cable or communi-
cation antenna/cable. If there is any
abnormality, repair it and start from
procedure 1) again.
WA450-6, WA480-6 (KA SPEC.) 39

a If [Network trouble] is indicated, 10) Turn the starting switch OFF.

check the display of [LED-C4] refer- 11) Make sure that the 7-segment indicator
ring to “Lamp display of KOMTRAX lamp is displayed normally after 5 seconds
terminal”. If the CAN is not recog- elapsed.
nized, check the CAN harness of the a When [Normal] appears, station
KOMTRAX terminal, and then if there opening check is completed.
is any abnormality, repair it and start a If [Abnormal] appears, station open-
from procedure 1) again. ing check does not end normally, so
[A]: Normal you should perform the procedure
[B]: GPS position data detection trou- above from step 1) again.
ble a If station opening check ends nor-
[C]: Reception trouble mally, it should not be rechecked.
[D]: GPS position data detection trou-
ble and reception trouble
[E]: Network trouble
12) When station opening check ended nor-

m a l l y, a c o m m u n i c a t i o n w i t h t h e
KOMTRAX server starts automatically,
and settings are stored in KOMTRAX.
(This requires about 25 minutes to 4
hours.)
a During this time, you may turn the
s tarti ng swi tch off and star t th e
engine.
a During the communication and check
above, you should park the machine
outside to enable a frequent commu-
nication with the ORBCOMM satellite.
The station opening check may not
be completed in doors that cause
radio waves from the satellite to be
intercepted.
40 WA450-6, WA480-6 (KA SPEC.)

2. Application for the start of use

a Application for the start of use should be
made only after the sign-up test is fin-
ished.
1) Notify the KOMTRAX operations adminis-
trator of the following information about
the machine that completed the station
opening check in the machine side.
1] Information (model, part number, and
serial number) about the machine
that completed the station opening
check in the machine side
2] Part number and serial number of
KOMTRAX terminal
3] Value of service meter when the
KOMTRAX terminal was installed (in
0.1 hours)
2) The KOMTRAX operations administrator

shall use a KOMTRAX client PC to regis-
ter the machine.
a Refer to “Manual for KOMTRAX oper-
ations administrator” for the proce-
dure.
a Now the terminal is ready for use.
WA450-6, WA480-6 (KA SPEC.) 41

Indicator lamps of KOMTRAX terminal 1
LED lamps for CPU 7-segment and dot displays for CPU
1. LED-C1 (State of R or ACC signal) 7. 7 segments (Number of unsent mails)
2. LED-C2 (Starting output state) 8. Dot (GPS positioning state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download write state)
6. LED-C6 (Download write state)
42 WA450-6, WA480-6 (KA SPEC.)

In the KOMTRAX system, various information and processing details are displayed on the LED on the upper
surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Before using the KOMTRAX system, make sure that the application for starting its use is completed as well
as the station opening check in the machine side.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable should not be broken and normally be connected to the KOMTRAX
terminal.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
Check of terminal LED displays

1. Meaning of CPU LED displays
a The LED displays should be checked with the starting switch ON, starting switch START, or with the
engine started.
Display
No. LED Name/function Description
(*1)
ON Starting switch ACC signal: ON, Alternator R signal: ON
States of starting switch Fast blink Starting switch ACC signal: OFF, Alternator R signal: ON
1 LED-C1 ACC signal and alternator R
signal Slow blink Starting switch ACC signal: ON, Alternator R signal: OFF
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF
ON Engine control signal: ON
2 LED-C2 State of engine control signal
OFF Engine control signal: OFF
ON S-NET: Connected, Starting switch C signal: OFF
States of S-NET connection Fast blink Starting switch C signal: ON
3 LED-C3
and starting switch C signal Slow blink (Not used)
OFF S-NET: Not connected, Starting switch C signal: OFF
ON CAN: Connected (without fuel sensor)
Fast blink CAN: Connected (with fuel sensor)
4 LED-C4 State of CAN connection
Slow blink CAN: Not connected (with fuel sensor)
OFF CAN: Not connected (without fuel sensor)
5 LED-C5 1-LED ON Download write mode (system administrator only function)

Download write state
2-LED
6 LED-C6 Normal operation mode
OFF
*1: Blink types and blink times

Fast blink: Blinks in about 1-second cycle
Slow blink: Blinks in about 4-second cycle
WA450-6, WA480-6 (KA SPEC.) 43

2. Contents of 7-segment and dot displays for CPU

a The LED display should be checked with the starting switch turned ON.
Display
No. LED Name/function Description
(*2)
The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by “9”.) Light-on indicates that the
Number of unsent displayed
machine is in process of capturing the satellite.
7 7 segments mails, satellite
capture state The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by “9”.) Fast blink indicates that the
fast blink
satellite is not captured.
GPS positioning was completed. (The position can be con-
ON
GPS positioning firmed. *3)
8 Dot
status GPS positioning was not completed. (The position cannot be
OFF
confirmed. *3)
*2: Blink types and blink times

Fast blink: Blinks in about 0.5-second cycle
Slow blink: Blinks in about 2.0-second cycle
*3: Supplementary explanation of GPS positioning status
One or more minute may be taken until GPS positioning is completed after the starting switch was
turned ON even in an outdoor service area.
GPS positioning will fail in a weak signal or non-service area.
44 WA450-6, WA480-6 (KA SPEC.)

Adjusting machine monitor 1
Rotary switches (SW1, SW2, and SW3) and DIP switches (SW5 and SW6)
q Do not change the setting of the rotary switches (SW1, SW2, and SW3) and DIP switches (SW5 and
SW6) on the back side of the machine monitor.
WA450-6, WA480-6 (KA SPEC.) 45

Adjusting replaced, reassembled or added sensor, controller, etc. with

machine monitor 1
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, initialize the sensors,
solenoids, etc. with the machine monitor.
a Adjust the items in alphabetical order (A –) with the machine monitor.
Replaced, reassembled, or added component or option Adjustment item
Machine monitor D, E, F
Change of tire size J
Transmission A, B, C
Transmission controller A, B, C, D, E
Transmission ECMV solenoid A, B, C
Work equipment controller G, H
Taking automobile inspection E
Addition or removal of option E
Adjustment item Contents of adjustment Description No.

A Resetting transmission initial learning 7-2 (*1)
B Transmission initial learning 7-2 (*1)
C Adjustment of transmission ECMV current 7-1 (*1)
D Selection of machine model 12 (*1)
E Selection of option 10 (*1)
F Inputting of machine serial No. 11 (*1)
*1: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)”
46 WA450-6, WA480-6 (KA SPEC.)

2. Adjustment for user's needs

If the user makes the following indications or requests, change or adjust the items shown below with the
machine monitor.
Contents of indication/request Adjustment item
Change indication unit of speedometer G
Turn ECO lamp OFF H
Change interval of fan automatic reverse operation (Automatic reverse fan specification) J
Change continuance of fan automatic reverse operation (Automatic reverse fan specification) K
Travel speed is indicated too quickly/slowly L
Turn engine speed/travel speed on character display OFF M
Adjustment item Contents of change/adjustment Description No. (*1)

G Setting of option/Selection of speed unit 10
H Setting of option/Selection of indication of ECO lamp 10
Adjustment of sensor/Adjustment of interval of fan automatic
J 7–18
reverse operation
Adjustment of sensor/Adjustment of continuance of fan automatic
K 7–19
reverse operation
L Setting of option/Change of tire size 10
Setting of option/Change of indication of engine speed or travel
M 10
speed on normal screen of character display
*1: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)”
a Change of the indication unit of the speedometer and weight meter of the specification for the SI unit
countries cannot be set.
WA450-6, WA480-6 (KA SPEC.) 47

SEN01587-00

48
SEN01588-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)

Special functions of machine monitor (EMMS) .................................................................................... 2
Pm-click inspection table.................................................................................................................... 63
WA450-6 WA480-6 (KA SPEC.) 1


Special functions of machine monitor (EMMS) 1
Normal functions and special functions of machine monitor
The machine monitor is equipped with the normal functions and special functions. Various items of data are
displayed on the character display in the middle of the machine monitor.
Depending on the internal setting of the machine monitor, the display items are divided into automatic dis-
play items and items displayed when the machine monitor switches are operated.
1) Normal functions: Operator mode
Functions for which the content is normally displayed or which can be displayed and operated by the
operator operating the switches.
a See the Operation and maintenance manual for details of the operator mode.
2) Special functions: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspec-
tion, maintenance, and troubleshooting.
Operator mode Service mode
1 Service meter/clock display function (*2) 1 Electrical system fault history display function
2 Load meter function (If equipped) (*1) 2 Mechanical system fault history display function
3 Odometer display function 3 Real-time monitoring function
4 Maintenance monitoring function 4 Engine reduced-cylinder function
5 Telephone number input function 5 No injection cranking function
6 Language selection function 6 Adjustment function
7 Monitor brightness adjustment function ⇔ 7 Maintenance monitoring function
8 Time adjustment function (*2) 8 Operating information display function
Travel speed/engine speed display selecting
9 9 Optional device selecting function
function
Travel speed/engine speed display/non-display
10 10 Machine serial number input function
selecting function (*3)
11 Action code display function 11 Model selection function
12 Failure code display function 12 Initialize function
*1: This display is not available when the load meter function is turned off through OPT selection of service mode.
*2: This display is not available when the travel speed/engine speed display selecting function is turned off through OPT
selection of service mode.
*3: If the speed/engine speed indicated on character display is turned OFF optionally in the service mode, it is not indi-
cated.
2 WA450-6 WA480-6 (KA SPEC.)

Functions and flow of the service mode
WA450-6 WA480-6 (KA SPEC.) 3

4 WA450-6 WA480-6 (KA SPEC.)

WA450-6 WA480-6 (KA SPEC.) 5

Operator mode 3. Odometer display function

a Following overviews the operator mode. Press [U] switch from the ordinary service
a See the section “Structure, function and main- meter and clock display screen to display the
tenance standard” or the Operation and main- odometer.
tenance manual for details of the operator The load meter specifications displays the
mode. odometer as [<] switch is pressed succeeding
to display of the load meter function.
1. Service meter/clock display function a For details, see the “Other functions of
Turning on the starting switch displays the ser- machine monitor” of the “Operation” sec-
vice meter in the upper space and the clock in tion in the Operation and maintenance
the lower space. manual.
2. Load meter function (if equipped) 4. Maintenance monitoring function

Press [U] switch from the ordinary service 1) Filter, oil replacement time display (auto-
meter and clock display screen to display the matic display)
load meter function. As the filter or oil replacement time draws
a For more information, see the section close, the machine monitor automatically
Structure, function and maintenance stan- displays its information to alert operator's
dard, “Load meter function”, and Attach- attention.
ment options, “Using load meter” of the 2) Resetting replacement time (selection
Operation and maintenance manual. menu)
As maintenance operation for a filter or oil
is completed, the machine monitor allows
resetting the time interval through the
switch operation.
6 WA450-6 WA480-6 (KA SPEC.)

5. Telephone number input function 7. Monitor brightness adjustment function

Telephone numbers are entered through the Brightness of the machine monitor is adjustable
switch operation. And modification or cancella- in seven levels through the switch operation.
tion of the phone numbers in the machine a Adjustment of brightness is available in
monitor is also available through the switch two approaches – adjustment of the moni-
operation. tor alone and separate adjustment of the
a When action code [E03] is displayed, a monitor and liquid crystal.
phone number is displayed along with a For details, see the “Other functions of
[CALL]. machine monitor” of the Operation section
a For details, see the “Other functions of in the Operation and maintenance manual.
machine monitor” of the Operation section
in the Operation and maintenance man-
ual.
6. Language selection function

Switch operation allows selecting a display lan-
guage of the machine monitor.
a Functions of the service mode are con-
stantly displayed in English since they are
exempted from the display selection func-
tion.
a A desired language is selectable from
English, Japanese, German, French, Ital-
ian, Spanish and Swedish.
a For details, see the “Other functions of
machine monitor” of the Operation section 8. Time adjustment function
in the Operation and maintenance man- The time indicated by the clock of the machine
ual. monitor is adjustable.
in the Operation and maintenance manual.
WA450-6 WA480-6 (KA SPEC.) 7

9. Travel speed/engine speed display select- 11. Action code display function
ing function If a trouble occurs, the machine monitor dis-
A unit to be used for the machine monitor plays an action code corresponding to the seri-
speed display is selectable from km/h and ousness of the trouble to alert the operator for
MPH. It is also possible to turn on or off the dis- appropriate actions.
play of the travel speed and engine speed. a The figure below shows an example of the
a For details, see the “Other functions of screen on which action code [E03] and
machine monitor” of the Operation section [CALL + Telephone number] are alter-
in the Operation and maintenance man- nately displayed.
ual. a When action code [E01] or [E02] is dis-
played, [CALL + Telephone number] is not
displayed.
10. Travel speed/engine speed display/non-dis-

play selecting function
A unit for the machine monitor speed display is
selectable from km/h and MPH. It is also possi-
ble to turn on or off display of the travel speed
and engine speed.
in the Operation and maintenance man-
ual.
8 WA450-6 WA480-6 (KA SPEC.)

a Action codes and actions alerted to operator

CALL + Tele-
Action code Actions recommended to operator
phone number
• Do necessary testing and/or servicing as the current work is over or at
E01 Not displayed
shift of the operator.
• When an overrun-related item is displayed
Slow down the engine or machine speed.
E02 Not displayed
• When an overheat-related item is displayed
Stop the machine and run the engine at mid speed with no load.
E03 Displayed • Stop the engine and machine immediately and contact a serviceman.
12. Failure code display function a The service code display function displays
Pressing [>] switch once while an action is dis- the following information.
played on the machine monitor displays the A: Failure code (location code + problem
failure code corresponding to the failure cur- code)
rently warned. B: Controller code
a The failure codes detected in the past are MON: Machine monitor
divided into failures of the electrical sys- TM: Transmission controller
tem and the mechanical system and are WRK: Work equipment controller
recorded as fault history. (For details, see ENG: Engine controller
“Service mode”.) C: The system where failure occurred
a When two or more failures are involved,
pressing [>] switch displays further codes.
a If [>] switch is pressed again after it was
pressed to display every involved failure
code, the service meter display screen will
be restored.
Pressing [>] switch one more time dis-
plays the failure codes from the first.
If [>] switch is not touched for 3 seconds,
the action code display screen is automat-
ically displayed.
a For details of a displayed failure code, see

“Failure code list”.
a If any switch operation is not done for 30
seconds or more on the failure code dis-
play screen, the action code display
screen is automatically turned on.
WA450-6 WA480-6 (KA SPEC.) 9

Service mode (*1): When the cursor is located at the left-

1. Procedure for switching to Service mode most position, pressing the switch
and screen display restores the normal screen (Operator
When using Service mode, carry out the fol- mode).
lowing special operation to switch the screen When the cursor is at a location other
display. than the leftmost position, pressing
1-1. Checking screen display the switch returns the cursor to the
Make sure that the machine monitor is set to leftmost position.
the operator mode and any of “Service meter”, If any switch operation is not done for
“Action code” or “Failure code” is displayed on 60 seconds or more from ID input
the screen. screen, the normal screen is automat-
1-2. Displaying ID input initial screen ically turned on.
Hold down [t] switch and [<] switch simulta-
neously for 5 seconds minimum to open ID
input initial screen.
a Holding down the two switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the buttons.
1-4. Displaying menu initial screen

a After settling 4-digit ID, turn on the menu
initial screen of Service mode.
a Once entered and settled, an ID remains
effective until the starting switch is turned
off.
1-3. Inputting and confirming ID

Operate the buttons to input the ID.
q ID: 6491
1) Cursor (C) is positioned at the highest-
order digit. Pressing [<] and [>] switches
changes the value of this digit in the range
of 0 – 9.
2) Press [U] switch when the intended value
appeared to specify it.
a The cursor moves to the 2nd digit.
3) Set the value in the same order and then
press [U] switch.
a When you have entered a wrong value to
a position except the highest-order digit, 1-5. Selecting service mode menu
move to the highest-order digit using [t] a Pressing [<] and [>] switches from the
switch to repeat the procedure from the menu screen displays Service mode
first. In this case, values that had been menus endlessly in the following order.
entered remain as they are until modified. a The menus are displayed in the field indi-
When the cursor is at the highest-order cated with [*] mark.
digit, it can move to the higher layer using [1] ELECTRIC FAULT: Electrical system
[t] switch. (*1). fault history display function
[2] MACHINE FAULT: Mechanical sys-
tem fault history display function
[3] REAL-TIME MONITOR: Real-time
monitoring function
10 WA450-6 WA480-6 (KA SPEC.)

[4] CYLINDER CUT-OUT: Engine 2. Electrical system fault history display func-
reduced-cylinder function tion (ELECTRIC FAULT)
[5] NO INJECTION: No injection crank- The machine monitor records the past failures
ing function in the electric system as the failure codes. The
[6] TUNING: Adjustment function failure codes are displayed from the following
[7] MAINTENANCE MONITOR: Mainte- operations.
nance monitoring function 2-1. Selecting the menu
[8] OPERATION INFO: Operating infor- Select the ELECTRIC FAULT from the menu
mation display function screen of Service mode.
[9] OPTIONAL SELECT: Optional device a [**] field displays total number of the fault
selecting function history currently recorded (up to 20
[10] MACHINE No. SET: Machine serial cases).
number input function
[11] MACHINE: Model selection function
[12] INITIALIZE: Initialize function (Func-
tion specialized for plant)
a The menu is indicated in the parts of [*].
2-2. Displaying fault history

Press [U] button while the menu is selected to
display the recorded fault history.
1-6. Completion of mode and function

Either of the following procedures ends a
mode or function independent of the function
being selected and the layer in which it is used.
1) When the operation is to be continued
using another mode or function: Press [t]
switch to return to the mode screen or
menu screen to be used next.
a Note, however, that [t] switch functions
as an execution key on [YES/NO] screen.
a When the normal screen (Operator mode)
was inadvertently turned on, repeat above
steps from 1) (input of the ID is not neces- 2-3. Displayed fault history
sary). The electric system fault history display func-
2) When ending an operation completely: tion displays the following information.
Turn the starting switch off from the cur- A: Record number
rent state. B: Failure code (Location code in four digits +
Problem code in two digits)
C: Number of occurrences (number of occur-
rences of same code in past)
D: Elapsed time 1 (Elapsed time on service
meter from the first occurrence)
E: Elapsed time 2 (Elapsed time on service
meter from the last occurrence)
a The code of a failure currently occurring is
indicated in flashing.
WA450-6 WA480-6 (KA SPEC.) 11

a For details of a displayed failure code, see 2-6. Deleting all fault history
“Failure code list” of the failure code dis- 1) Press [<] or [>] switch while the fault his-
play function. tory is on the screen to display the ALL
a Note that part of the information displayed CLEAR menu screen.
from the electrical system fault history dis-
play function and the failure code display
function is not identical.
a When the requested fault history is not
recorded, [–] is indicated in the display
space.
2) Press [U] switch to display the ALL

CLEAR screen.
3) Select “YES” or “NO” using [<] or [>]
switch.
a The selected cursor will start flashing. If
“ YE S” is s elec t ed a nd [t] s witc h is
2-4. Switching fault history display pressed, the information will be deleted. If
Pressing [<] or [>] switch while a set of fault “NO” is selected and [t] switch is
history is on the screen displays another set of pressed, deletion is cancelled and the
recorded fault history. "Maintenance interval change item"
2-5. Deleting individual fault history screen is restored.
1) Press [U] switch while the target fault his- a By default, the cursor is set to NO (cancel)
tory of deletion is on the screen to turn on to prevent resetting error.
CLEAR screen. a Information of the currently occurring fail-
2) Select “YES” or “NO” using [<] or [>] switch. ure is not deletable.
“Y ES” i s s ele cted and [t] s witc h i s
pressed, the information will be deleted. If
“NO” is selected and [t] switch is
pressed, deletion is cancelled and the
"Maintenance interval change item"
screen is restored.
a By default, the cursor is set to NO (cancel)
to prevent resetting error.
a Information of the currently occurring fail-
ure is not deletable.
12 WA450-6 WA480-6 (KA SPEC.)

3. Mechanical system fault history display 3-3. Displayed fault history

function (MACHINE FAULT) The mechanical system fault history display
The machine monitor records the past failures function displays the following information.
in the mechanical system as the failure codes.
The failure codes are displayed from the fol- A: Record number
lowing operations. B: Failure code (Location code in four digits +
3-1. Selecting the menu Problem code in two digits)
a Select MACHINE FAULT from the menu C: Number of occurrences (number of occur-
screen of Service mode. rences of same code in past)
a [**] field displays total number of the fault D: Elapsed time 1 (Elapsed time on service
history currently recorded. meter from the first occurrence)
E: Elapsed time 2 (Elapsed time on service
meter from the last occurrence)
a The code of a failure currently occurring is
indicated in flashing.
a For details of a displayed failure code, see
"Failure code list" of the failure code dis-
play function.
a Note that part of the information displayed
from the mechanical system fault history
display function and the failure code dis-
play function is not identical.
a When the requested fault history is not
recorded, [–] is indicated in the display
space.
3-2. Displaying fault history
Press [U] switch while the menu is selected to
display the recorded fault history.
3-4. Switching fault history display

Pressing [<] or [>] switch while a set of fault
history is on the screen displays another set of
recorded fault history.
3-5. Deleting fault history (Not available)
The fault history of the mechanical system is
not deletable.
WA450-6 WA480-6 (KA SPEC.) 13

4. Real-time monitoring function 4-3. Selecting sub menu

(REAL-TIME MONITOR) a Press [<] or [>] switch from the sub menu
The machine monitor checks state of the screen to display the sub menus endlessly
machine on real-time basis referencing signals in the following order.
of the sensors being installed in various parts a The sub menus are displayed in the field
of the machine. indicated with [*] mark.
The real-time monitoring functions displays fol- [1] MONITOR PANEL: Machine monitor
lowing two types of information. system
q 1 item independent display [2] TRANSMISSION: Transmission con-
(for each controller) troller system
q 2 items simultaneous display [3] BOOM: Work equipment controller
(code input) system (*1)
4-1. Selecting the menu [4] ENGINE: Engine controller system
Select REAL-TIME MONITORING from the [5] 2 ITEMS: 2 items display
menu screen of Service mode. *1: The menu is indicated in the parts of
[*].
4-2. Displaying sub menu

Press [U] switch while the menu is selected to 4-4. Setting the 1 item individual monitoring
display the sub menu initial screen. 1) Select the target controller system of mon-
itoring from the sub menu screen.
2) Press [U] switch while the sub menu is

selected to display the MONITOR PANEL
screen.
14 WA450-6 WA480-6 (KA SPEC.)

3) Press [<] or [>] switch to select a monitor- 4-5. Setting 2 items simultaneous monitoring
ing item. 1) Select 2 ITEMS from the sub menu
a The monitoring items are scrolled accord- screen.
ing to the internally set order. 2) Press [U] switch while the sub menu is
a Holding down [U] switch turns on high- selected to display the monitoring code
speed scrolling. input screen.
a Holding and cancelling the monitoring
data: Pressing [U] switch while the moni-
toring is in progress holds the monitoring
data and [U] mark starts flashing.Press-
ing [U] switch again restores the active
state.
1] This cursor (C) is located at the high-

est-order digit. Pressing [<] or [>]
switch changes the value of this digit
in the range of 0 – 9.
2] Press [U] switch when the intended
value appeared to specify it as the set
4) Display data for 1 item individual monitor- value.
ing a The cursor moves to the 2nd position.
The 1 item individual monitoring screen 3] Set the value in the same order and
displays the following information. then press [U] switch.
A: Item display a When you have entered a wrong
B: Monitoring codes (5 digits) value to a position except the highest-
1: Monitoring data order digit, the cursor can move to the
(including the unit used) highest-order digit using [t] switch
a See the “Real-time monitoring code and repeat the procedure from the
list” for details. first. In this case, values that had
been entered remain as they are until
modified. When the cursor is at the
highest-order digit, it can move to the
higher layer using [t] switch.
WA450-6 WA480-6 (KA SPEC.) 15

3) As both monitoring codes are settled, the

2 ITEMS screen will be turned on.
a Holding and cancelling the monitoring
data:
Pressing [U] switch while the monitoring
is in progress holds the monitoring data
and [U] mark starts flashing.Pressing [U]
switch again restores the active state.
4) Display data for 2 items simultaneous

monitoring
a The 2 items simultaneous monitoring
screen displays the following information.
A: Monitoring code 1
1: Monitoring data 1 (including the unit
used)
B: Monitoring code 2
2: Monitoring data 2 (including the unit
used)
a See the “Real-time monitoring code list”
for details.
16 WA450-6 WA480-6 (KA SPEC.)

WA450-6 WA480-6 (KA SPEC.) 17

Real-time monitoring code table

MONITOR PANEL [Machine monitor system]
Monitoring item Indication item Data indication range
No. Monitoring code
(*1) (*2) (*3)
1 20200 Part No. of monitor software VERSION Arabic numerals
2 20221 Version of application software VERSION (APP) Arabic numerals
3 20222 Version of data VERSION (DATA) Arabic numerals
4 01001 Engine speed ENG SPEED 0 – 3000
5 40000 Travel speed SPEED 0 – 50
6 04202 Fuel level FUEL SENSOR 0 – 100
7 04207 Fuel level FUEL SENSOR 0.00 – 5.00
8 04103 Engine coolant temperature COOLANT TEMP –40 – 210
9 40100 Torque converter oil temperature TC OIL TEMP 24 – 131
10 40101 Torque converter oil temperature TC OIL TEMP 0.00 – 5.00
11 04401 Hydraulic oil temperature HYD TEMP 24 – 131
12 04404 Hydraulic oil temperature HYD TEMP 0.00 – 5.00
13 30202 Rear brake oil temperature R BRAKE OIL 24 – 131
14 30205 Rear brake oil temperature R BRAKE OIL 0.00 – 5.00
15 04302 Battery charge level ALTERNATOR R 0.00 – 30.00

16 40200 Small lamp voltage SMALL LAMP 0.00 – 30.00
17 40300 Electrolyte level A BATTERY A 0.00 – 30.00
18 40301 Electrolyte level B BATTERY B 0.00 – 30.00
19 06001 Boom angle BOOM ANG –90 – 90
18 WA450-6 WA480-6 (KA SPEC.)


Unit Remarks
Contents of indication in normal state
(*4) (*5)
Indication of
As per part No. of software
condition
Indication of
As per version No. of application software
condition
Indication of
As per version No. of data
condition
Low idle : 800 (+50/0) rpm
High idle: WA450:2170 ± 50 rpm (P-mode)
1880 ± 50 rpm (E-mode) rpm
WA480:2190 ± 50 rpm (P-mode)
2020 ± 50 rpm (E-mode)
WA450: F1/R1: 6.3/6.7 km/h±5% (P-mode)
F2/R2: 12.1/12.8 km/h±5% (P-mode)
F3/R3: 21.7/23.0 km/h±5% (P-mode)
F4/R4: 34.9/36.0 km/h±5% (P-mode)
km/h
WA480: F1/R1: 6.3/6.6 km/h±5% (P-mode)
F2/R2: 12.2/12.9 km/h±5% (P-mode)
F3/R3: 21.7/22.9 km/h±5% (P-mode)
F4/R4: 34.5/35.6 km/h±5% (P-mode)
0 – 100% %
Gauge FULL (100%, 10 z): 0.31 V
When sensor is disconnected or has hot short: Gauge
Gauge 1/2 (50%, 24 z): 0.69 V
V EMPTY
Caution (80 z): 1.74 V
When sensor has ground fault: Gauge FULL
Gauge EMPTY (0%, 85 z): 1.81 V
Engine coolant temperature: Max. 100°C
Depends on condition of machine (°C) °C
Data are received from engine controller
Depends on condition of machine (°C) °C Overheating: 120°C
Gauge enters red range(120°C): 1.62 V When sensor is disconnected or has hot short: Gauge MIN
V
(80°C): 2.91 V When sensor has ground fault: Gauge MAX
Depends on condition of machine (°C) °C Hydraulic tank oil temperature Max. 100°C
Gauge enters red range(120°C): 1.62 V When sensor is disconnected or has hot short: Gauge MIN
V
(80°C): 2.91 V When sensor has ground fault: Gauge MAX
Depends on condition of machine (°C) °C
(120°C): 1.62 V
V
1(80°C): 2.91 V
Depends on condition of machine (0.0 – 30 V) V
Depends on condition of machine (0.0 – 30 V) V
Min. 2 V V Only when option is set
— V Unused
WA450:
Standard boom
Boom at max. height: 45.7 ± 2.0 deg
Boom at min. height: –40.3 ± 3.0 deg
High lift boom
deg (°) Only when load meter option is set
WA480:
Standard boom
WA450-6 WA480-6 (KA SPEC.) 19


Monitoring item Indication item Data indication range
No. Monitoring code
(*1) (*2) (*3)
20 06003 Boom angle BOOM ANG 0.00 – 5.00
21 40400 Boom bottom pressure BOOM BTM PRESS 0.00 – 50.00
22 40402 Boom bottom pressure BOOM BTM PRESS 0.00 – 5.00
23 40500 Boom head pressure BOOM HEAD PRESS 0.00 – 50.00
24 40501 Boom head pressure BOOM HEAD PRESS 0.00 – 5.00
25 40600 Calibration pressure CAL PRESS 0.00 – 50.00

26 40800 Weight calculated by load meter MES LOAD 0.00 – 50.00
27 30802 Setting condition of rotary switch SW1, SW2, SW3 F, F, F
28 30904 Setting condition of DIP switch SW5-1, SW5-2 ON/OFF, ON/OFF
32 40900 Input signal D_IN_0-7 D-IN--0------7 See separate table
37 40925 Output signal D_OUT_0-3 D-OUT--0--3 See separate table
*1: All items, including ones for which sensors are not installed on some models and optional components,
are displayed.
*2: Abbreviated as number of characters is limited.
*3: A number below (above) the display range is fixed within the display range.
20 WA450-6 WA480-6 (KA SPEC.)


Unit Remarks
(*4) (*5)
WA450:
Standard boom
Boom at max. height: 3.77 ± 0.3 V
Boom at min. height: 1.38 ± 0.5V
High lift boom
Boom at max. height: 3.88 ± 0.3 V V Only when load meter option is set
Boom at min. height: 1.49 ± 0.5 V
WA480:
Standard boom
Boom at max. height: 3.78 ± 0.3 V
Boom at min. height: 1.35 ± 0.5V
Depends on condition MPa Only when load meter option is set
20 MPa: 0.5 V
10 MPa: 1.3 V
V Only when load meter option is set
20 MPa: 2.1 V
50 MPa: 4.5 V
Only when optional load meter is set, rated load is applied,

Depends on condition MPa engine speed is high idle, lift arm lever is operated to
stroke end, and arm is level: Approx. 0.5 MPa {5.1 kg/cm2}
50 MPa: 0.5 V
10 MPa: 1.3 V
V Only when load meter option is set
20 MPa: 2.1 V
50 MPa: 4.5 V
— MPa Unused
Load weight (t) ton Only when load meter option is set
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
*4: If a unit is necessary, the SI unit is used.

*5: If a code or a monitoring item is displayed on the machine monitor but cannot be monitored, “Unused for
this machine” is entered.
WA450-6 WA480-6 (KA SPEC.) 21

MON [Mechanical monitor system]

Monitoring Input/Output
No. Displayed items Description of ON/OFF switch
codes signal
D-IN-0 Head lamp high beam Lighting of head lamp = ON (24 V)/OFF (OPEN)
D-IN-1 — —
D-IN-2 Starting switch C Starting switch = ON (24 V)/OFF (OPEN)
D-IN-3 — —
Auto grease A
1 40900 D-IN-4 (Applicable to a machine equipped with Tank empty or failed = ON (24 V)/OFF (OPEN)
optional auto grease)
Auto grease B
D-IN-5 (Applicable to a machine equipped with In operation or failed = ON (24 V)/OFF (OPEN)
optional auto grease)
D-IN-6 — —
D-IN-7 — —
D-IN-8 — —
D-IN-9 — —
Load meter mode selector switch (A/B)
D-IN-10 (Applicable to a machine equipped with Pressing of switch = ON (24 V)/OFF (OPEN)
optional load meter)
Load meter mode selector switch (+/–)
D-IN-11 (Applicable to a machine equipped with Pressing of switch = ON (24 V)/OFF (OPEN)
2 40901 optional load meter)
Lighting of turn signal right lamp = ON (GND)/OFF
D-IN-12 Turn signal right
(OPEN)
Lighting of turn signal left lamp = ON (GND)/OFF
D-IN-13 Turn signal left
(OPEN)
D-IN-14 U switch Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-15 t switch Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-16 Brake oil pressure (front) Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-17 Brake oil pressure (rear) Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-18 — —
D-IN-19 — —
3 40902 D-IN-20 Clogged air cleaner No clogging = ON (GND)/OFF (OPEN)
D-IN-21 — —
D-IN-22 — —
Load meter total weight indication selector
D-IN-23 Pressing of switch = ON (GND)/OFF (OPEN)
switch (if equipped)
D-IN-24 — —
D-IN-25 — —
D-IN-26 Parking brake Parking brake operation = ON (GND)/OFF (OPEN)
D-IN-27 Engine coolant level Normal coolant level = ON (GND)/OFF (OPEN)
4 40903 D-IN-28 — —
D-IN-29 Engine oil level Low oil level = ON (GND)/OFF (OPEN)
Emergency steering normal Emergency steering normal = ON (GND)/OFF
D-IN-30
(Machine with optional emergency steering) (OPEN)
D-IN-31 — —
22 WA450-6 WA480-6 (KA SPEC.)

MON [Mechanical monitor system]

No. Displayed items Description of ON/OFF switch
codes signal
Load meter subtotal switch
(Load meter specification)
Load meter cancel switch
D-IN-34 High beam (dimmer switch) High beam = ON (GND)/OFF (OPEN)
5 40904 D-IN-35 Working fuel consumption display switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-36 Service 2 mode ON = ON(GND)/OFF(OPEN)
D-IN-37 [>] switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-38 [<] switch Pressing of switch = ON (GND)/OFF (OPEN)
Emergency steering operation (Machine Emergency steering operation = ON (GND)/OFF
D-IN-39
with optional emergency steering) (OPEN)
D-OUT-0 Alarm buzzer Output ON = (24 V)/OFF (OPEN)
D-OUT-1 — —
6 40952
D-OUT-2 — —
D-OUT-3 — —
WA450-6 WA480-6 (KA SPEC.) 23

TRANSMISSION [Transmission controller system]

Monitoring Monitoring item Indication item Data indication range
No.
code (*1) (*2) (*3)
1 20201 Part No. of transmission controller ROM VERSION Arabic numerals
2 20223 Version No. of application software VERSION APP 20223
3 20224 Version No. of data VERSION DATA 20224
4 41600 Selection of engine mode ENGINE MODE Arabic numerals
5 41400 Fan pump EPC current (command) FAN EPC DIR 0 – 1000
6 93400 Fan reverse switch input FAN REVERSE SW Arabic numerals
7 95200 Loader pump oil pressure PUMP PRESS 0.00 – 50.00
8 95201 Input voltage of loader pump oil pressure PUMP PRESS 0.00 – 5.00
9 95100 Output command value of loader pump EPC PUMP EPC DIR 0 – 1000
10 95300 Steering pump oil pressure S/T OIL PRESS 0.00 – 50.00
11 95301 Input voltage of steering pump oil pressure S/T OIL PRESS 0.00 – 5.00
12 31400 Transmission output shaft speed T/M SPEED: OUT 0 – 32767
13 41203 Setting of transmission cut-off operation T/M CUT SET 0 – 50.0
14 41201 Transmission cut-off pressure T/M CUT OFF P 0.00 – 5.00
15 41202 Transmission cut-off sensor input voltage T/M CUT OFF P 0.00 – 5.00
16 93600 Transmission oil temperature T/M OIL TEMP 0 – 150
17 93601 Transmission oil temperature sensor input voltage T/M OIL TEMP 0.00 – 5.00
24 WA450-6 WA480-6 (KA SPEC.)


Unit Remarks
(*4) (*5)
Indication of
As per part No. of software
condition
Indication of
As per version No. of application software
condition
Indication of
As per version No. of data
condition
0: Power mode Indication of

2: Economy mode condition
0 – 1000 [mA]
When engine speed is below 500 rpm = 670 mA
While engine is cranked (C terminal is operated) = 800 mA mA
While fan is being prepared for reverse operation = 800 mA
While fan is operated in reverse = 0 mA
0: When fan reverse switch is in FORWARD

Indication of
1: While manual reverse switch is operated
condition
2: When fan reverse switch is in AUTO REVERSE
When work equipment is in neutral: 2.0 ± 2.0 MPa

MPa
When work equipment circuit is relieved: 34.3 ± 2.0 MPa
When work equipment is in neutral: 0.70 ± 0.2 V

V
When work equipment circuit is relieved: 3.26 ± 0.2 V
P-mode: 0 ± 10 mA
mA
E-mode: 350 ± 10 mA
When steering is in neutral: 2.0 ± 2.0 MPa

Nm
When steering circuit is relieved: 24.4 ± 2.0 MPa
When steering is in neutral: 0.70 ± 0.2 V

V Not used
When steering circuit is relieved: 2.44 ± 0.2 V
0 – 32767 [min-1]
0 km/h = 0 rpm
10 km/h = 738 rpm
rpm Equipped with 26.5 – 25 tires
20 km/h = 1476 rpm
30 km/h = 2215 rpm
40 km/h = 2953 rpm
Indicated value changes according to cut-off setting

0.00 – 50.0 [MPa] MPa
operation
When foot brake is released: 0.00 ± 0.1 MPa

0.00 – 5.00 [MPa] MPa When foot brake is pressed: Indicated value changes
according to brake pressing operation
When foot brake is released: 1.00 ± 0.1 V

0.00 – 5.00 [V] V When foot brake is pressed: Indicated value changes
according to brake pressing operation
0 – 150 [°C] °C
0.00 – 5.00 [V]

4.72 V = 0°C
4.33 V = 30°C
V
3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
WA450-6 WA480-6 (KA SPEC.) 25


No.
code (*1) (*2) (*3)
18 95400 Throttle correction command output THROTTLE MOD –100 – 100
19 44200 Throttle upper limit value output THROT LIMIT UP 0 – 100.0
20 44201 Throttle lower limit value output THROT LIMIT LO 0 – 100.0
21 93801 Acceleration mode THROTTLE MODE Arabic numerals
22 95000 Lockup selector switch input signal LOCK UP SW Arabic numerals
23 31602 1st ECMV current (command) ECMV 1 DIR 0 – 1000
24 31603 2nd ECMV current (command) ECMV 2 DIR 0 – 1000
25 31604 3rd ECMV current (command) ECMV 3 DIR 0 – 1000
26 31605 4th ECMV current (command) ECMV 4 DIR 0 – 1000
27 31608 F (Forward) ECMV current (command) ECMV F DIR 0 – 1000
28 31609 Lockup clutch ECMV current (command) ECMV LU DIR 0 – 10000
29 31606 R (Reverse) ECMV current (command) ECMV R DIR 0 – 1000
ECSS (Electronically Controlled Suspension System)

30 93300 ECSS V DIR 0 – 1000
solenoid valve current (command)
0 – 2.55
31 41802 1st fill time FILL TIME 1
(When not filled: 0)
0 – 2.55
32 41803 2nd fill time FILL TIME 2
0 – 2.55
33 41804 3rd fill time FILL TIME 3
0 – 2.55
34 41805 4th fill time FILL TIME 4
0 – 2.55
35 41808 F (Forward) fill time FILL TIME F
0 – 2.55
36 41806 R (Reverse) fill time FILL TIME R
38 40906 Input signal D_IN_8-15 D-IN--8-----15 See separate table
39 40907 Input signal D_IN_16-23 D-IN-16-----23 See separate table
26 WA450-6 WA480-6 (KA SPEC.)


Unit Remarks
(*4) (*5)
0 [%] % 0% is always indicated
100% is usually indicated
%
When F1 drive is limited: Limit data is indicated
0% is usually indicated
When engine stall prevention device operates,
Changing operation from F2 to R2: Max. 15%
%
Changing operation from R2 to F2: Max. 25%
When 2-stage low idle system operates:
As per idle set value
Changes according to operation of accelerator pedal

When accelerator pedal is released = 0
When accelerator pedal is pressed partially (Release
Indication of
side) = 1
condition
When accelerator pedal is pressed partially (Pressing
side) = 2
When accelerator pedal is pressed fully = 3
0: Lockup selector switch OFF Indication of

1: Lockup selector switch ON condition
Indicated value changes when clutch is used
mA
0 – 1000 [mA]
mA
0 – 1000 [mA]
mA
0 – 1000 [mA]
mA
0 – 1000 [mA]
mA
0 – 1000 [mA]
mA
0 – 1000 [mA]
mA
0 – 1000 [mA]
Solenoid valve OFF: 0 [mA]
mA
Solenoid valve ON: 800 [mA]
Each time clutch is used, previous fill time is indicated
sec
0 – 2.55 [sec], When not filled: 0
sec
sec
sec
sec
sec
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
WA450-6 WA480-6 (KA SPEC.) 27


No.
code (*1) (*2) (*3)
42 40949 Output signal D_OUT_0-7 D-OUT-0------7 See separate table
43 40950 Output signal D_OUT_8-15 D-OUT-8-----15 See separate table
44 40951 Output signal D_OUT_16-23 D-OUT-16----23 See separate table
45 94100 Clutch trigger initial learning flag TRIG FR1234 0/1(ON/OFF)
28 WA450-6 WA480-6 (KA SPEC.)


Unit Remarks
(*4) (*5)
Indication of
condition
Indication of
Unused for this machine
condition
Indication of
Unused for this machine
condition
0: ON Indication of
1: OFF condition
*1: All items, including ones for which sensors are not installed on some models and optional components,
are displayed.
*2: Abbreviated as number of characters is limited.
*3: A number below (above) the display range is fixed within the display range.
*4: If a unit is necessary, the SI unit is used.
*5: If a code or a monitoring item is displayed on the machine monitor but cannot be monitored, “Unused for
this machine” is entered.
WA450-6 WA480-6 (KA SPEC.) 29

TM [Transmission controller system]

No. Indication item Function of ON/OFF switch
codes signal
Steering pump pressure is applied
D-IN-0 Steering pressure switch (Normally open)
= ON (GND) /OFF (OPEN)
Steering pump pressure is applied
D-IN-1 Steering pressure switch (Normally closed)
= ON (OPEN) /OFF (GND)
D-IN-2 Transmission cut-off switch Pressing switch = ON (GND) /OFF (OPEN)
D-IN-3 Transmission cut-off set switch Pressing switch = ON (GND) /OFF (OPEN)
1 40905
D-IN-4 Shift mode L Shift mode L = ON (GND) /OFF (OPEN)
D-IN-5 Shift mode H Shift mode H = ON (GND) /OFF (OPEN)
D-IN-6 2-stage low idle selector switch (if equipped) Pressing switch = ON (24 V) /OFF (OPEN)
D-IN-7 ECSS selector switch Pressing switch = ON (24 V) /OFF (OPEN)
D-IN-8 • Gearshift lever 1st • Gearshift lever 1st = ON (24 V) /OFF (OPEN)
D-IN-9 • Gearshift lever 2nd • Gearshift lever 2nd = ON (24 V) /OFF (OPEN)
D-IN-10 • Gearshift lever 3rd • Gearshift lever 3rd = ON (24 V) /OFF (OPEN)
D-IN-11 • Gearshift lever 4th • Gearshift lever 4th = ON (24 V) /OFF (OPEN)
2 40906
• Joystick steering shift-up switch
D-IN-12 • Shift-up switch = ON (24 V) /OFF (OPEN)
(if equipped)
• Joystick steering shift-down switch
D-IN-13 • Shift-down switch = ON (24 V) /OFF (OPEN)
(if equipped)
D-IN-14 Electric emergency steering manual switch Pressing switch = ON (24 V) /OFF (OPEN)
Right FNR (directional) or joystick steering

D-IN-15 Pressing switch = ON (24 V) /OFF (OPEN)
selector switch (if equipped)
D-IN-16 C terminal signal Start of starting motor = ON (24 V) /OFF (OPEN)
Right FNR (directional) switch or joystick

D-IN-17 steering (directional) switch F (Forward) F (Forward) = ON (24 V) /OFF (OPEN)
(if equipped)
D-IN-18 steering (directional) switch N (Neutral) N (Neutral) = ON (24 V) /OFF (OPEN)
(if equipped)
3 40907 D-IN-19 steering (directional) switch R (Reverse) R (Reverse) = ON (24 V) /OFF (OPEN)
(if equipped)
D-IN-20 FNR (Directional) lever F (Forward) F (Forward) = ON (24 V) /OFF (OPEN)
D-IN-21 FNR (Directional) lever N (Neutral) N (Neutral) = ON (24 V) /OFF (OPEN)
D-IN-22 FNR (Directional) lever R (Reverse) R (Reverse) = ON (24 V) /OFF (OPEN)
D-IN-23 Parking brake (Neutralizer) signal Parking brake = ON (24 V) /OFF (OPEN)
30 WA450-6 WA480-6 (KA SPEC.)


codes signal
ECMV fill switch F (Forward)
D-IN-24 ECMV fill switch F (Forward)
ECMV fill switch R (Reverse)
D-IN-25 ECMV fill switch R (Reverse)
D-IN-26 ECMV fill switch 1st ECMV fill switch 1st = ON (GND) /OFF (OPEN)
D-IN-27 ECMV fill switch 2nd ECMV fill switch 2nd = ON (GND) /OFF (OPEN)
4 40908
D-IN-28 ECMV fill switch 3rd ECMV fill switch 3rd = ON (GND) /OFF (OPEN)
D-IN-29 ECMV fill switch 4th ECMV fill switch 4th = ON (GND) /OFF (OPEN)
D-IN-30 Kick-down switch Pressing switch = ON (GND) /OFF (OPEN)
D-IN-31 Shift hold switch Pressing switch = ON (GND) /OFF (OPEN)
Engine mode selector switch (Power mode)

D-IN-32 Engine mode selector switch
D-IN-33 — —
D-IN-34 — —
D-IN-35 — —
5 40942
D-IN-36 — —
D-IN-37 — —
D-IN-38 — —
D-IN-39 — —
D-OUT-0 Electric emergency steering relay Output ON = ON (24 V) /OFF (OPEN)
D-OUT-1 ECSS solenoid Output ON = ON (24 V) /OFF (OPEN)
D-OUT-2 — —
D-OUT-3 Neutral safety relay Output ON = ON (24 V) /OFF (OPEN)

6 40949
D-OUT-4 Fan reverse solenoid Output ON = ON (24 V) /OFF (OPEN)
Low-temperature bypass solenoid

D-OUT-5 Output ON = ON (24 V) /OFF (OPEN)
(if equipped)
D-OUT-6 — —
D-OUT-7 — —
WA450-6 WA480-6 (KA SPEC.) 31


codes signal
D-OUT-8 — —
D-OUT-9 — —
D-OUT-10 — —
D-OUT-11 — —
7 40950
D-OUT-12 — —
D-OUT-13 — —
D-OUT-14 — —
D-OUT-15 — —
D-OUT-16 Transmission cut-off indicator Output ON = ON (24 V) /OFF (OPEN)
D-OUT-17 Low-temperature bypass solenoid Output ON = ON (24 V) /OFF (OPEN)
D-OUT-18 Backup lamp relay Output ON = ON (24 V) /OFF (OPEN)
D-OUT-19 — —
8 40951
D-OUT-20 — —
D-OUT-21 — —
D-OUT-22 — —
D-OUT-23 — —
32 WA450-6 WA480-6 (KA SPEC.)

WA450-6 WA480-6 (KA SPEC.) 33

ENG [Engine controller system]

Monitoring Monitoring items Displayed items Data display range Unit Remarks
No.
code (*1) (*2) (*3) (*4) (*5)
Status
1 20400 Hardware serial No. ECM S/N Arabic numerals
display
2 03200 Battery voltage POWER SUPPLY 0.0 – 480.0 V
3 01002 Engine speed ENG SPEED 0 – 4000 rpm
4 04104 Engine coolant temperature COOLANT TEMP –40 – 210 °C
5 04105 Engine coolant temperature sensor voltage COOLANT TEMP 0.00 – 5.00 V
6 37200 Engine oil pressure sensor ENG OIL PRESS –99.9 – 999.9 kPa
7 37201 Engine oil pressure sensor voltage ENG OIL PRESS 0.00 – 5.00 V
8 42700 Engine oil temperature ENG OIL TEMP –40 – 210 °C
9 42702 Engine oil temperature sensor voltage ENG OIL TEMP 0.00 – 5.00 V
10 36400 Common rail pressure RAIL PRESS 0 – 400 MPa
11 36402 Common rail pressure sensor voltage RAIL PRESS 0.00 – 5.00 V
12 37400 Atmospheric pressure AMBIENT PRESS –99.9 – 999.9 kPa
13 37402 Atmospheric pressure sensor voltage AMBIENT PRESS 0.00 – 5.00 V
14 18400 Air intake temperature INTAKE TEMP –50 – 200 °C
15 18401 Air intake temperature sensor voltage INTAKE TEMP 0.00 – 5.00 V
16 04204 Fuel temperature FUEL TEMP –40 – 210 °C
17 14201 Fuel temperature sensor voltage FUEL TEMP 0.00 – 5.00 V
18 18500 Boost temperature CHG TEMP –50 – 200 °C
19 18501 Boost temperature sensor voltage CHG TEMP 0.00 – 5.00 V
20 36500 Boost pressure CHG PRESS-A –99.9 – 999.9 kPa
21 36502 Boost pressure sensor voltage CHG PRESS-A 0.00 – 5.00 V
22 17900 EGR valve differential pressure EGR DIF PRESS –99.9 – 999.9 kPa
EGR valve differential pressure sensor
23 17901 EGR DIF PRESS 0.00 – 5.00 V
voltage
24 18000 EGR valve inlet pressure EGR IN PRESS-A –99.9 – 999.9 kPa
25 18002 EGR valve inlet pressure sensor voltage EGR IN PRESS-A 0.00 – 5.00 V
26 18100 EGR valve position EGR VALVE POS 0.00 – 99.99 mm
27 18101 EGR valve position sensor voltage EGR VALVE POS 0.00 – 5.00 V
28 18700 Engine output torque OUTPUT TORQUE –24000 – 24000 Nm
29 36700 Equivalent torque TORQUE RATIO 0 – 100 %
30 31706 Final accelerator position FINAL THROTTLE 0 – 100 %
31 37300 Momentary fuel consumption FUEL RATE 0.0 – 999.9 1/h
32 18600 Final injection volume command (in weight) INJECT COMMAND 0 – 1000 mg
33 36300 Final injection timing command TFIN INJECT TIMING –180.0 – 180.0 CA
34 31701 Accelerator pedal position THROTTLE POS 0 – 100 %
35 31707 Accelerator pedal sensor voltage THROTTLE POS 0.00 – 5.00 V
36 18200 Bypass valve position BPS VALVE POS 0.00 – 99.99 mm
37 18202 Bypass valve position sensor voltage BPS VALVE POS 0.00 – 5.00 V
Status
38 18300 Idle validation signal IVS 1 ON/OFF
display
Status
39 18301 Idle validation signal IVS 2 ON/OFF
display
40 18900 Engine controller internal temperature ECM IN TEMP –40 – 210 °C
Final common rail pressure command
41 36200 PRESS COMMAND 0 – 400 MPa
PFIN
42 17201 PCV valve close timing (BTDC standard) PCV TIMING 180.0 – 180.0 CA
34 WA450-6 WA480-6 (KA SPEC.)

ENG [Engine controller system]

Monitoring Monitoring items Displayed items Data display range Unit Remarks
No.
code (*1) (*2) (*3) (*4) (*5)
Status
43 17500 Selection of engine mode POWER MODE 0–4
display
Status
44 18800 Water-in-fuel sensor WATER IN FUEL ON/OFF Not used
display
Incoming value is
displayed as is Status
45 00400 Name of selected model (upper 8 digits) MACHINE ID (H)
(Upper 8 digits of display
16 characters)
Incoming value is
displayed as is Status
46 00401 Name of selected model (lower 8 digits) MACHINE ID (L)
(Lower 8 digits of display
16 characters)
Incoming value is
Status
47 20216 Build version BUILD VER displayed as is
display
(8 characters)
Incoming value is
Status
48 20217 Calibration data version CAL VER displayed as is
display
(8 characters)
*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the
range.
*4: SI units alone are employed whenever a unit is needed.
*5: An item that does not allow monitoring is indicated as "Not used" though its code and item name may be
displayed on the machine monitor.
WA450-6 WA480-6 (KA SPEC.) 35

5. Engine reduced-cylinder function (CYLIN- 3) Selecting a cylinder to be reduced

DER CUT-OUT) Using [<] or [>] switch, select a cylinder to
The engine reduced-cylinder function denotes be reduced from No. 1 – No. 6 cylinders
setting the injector of a single cylinder or two or and then settle the selected cylinder using
more cylinders to electrically no injection state [U] switch.
and turns on the operation on reduced-cylinder a The cylinder to be reduced is selectable
condition. When any cylinders of the engine while the engine is run.
were suspected for abnormal output (combus- a Any number of cylinders can be reduced –
tion), this approach is used to single out the a single unit or two or more units.
failed cylinder. q [>] switch: Advances the cursor right-
1) Selecting the menu ward
Display the CYLINDER CUT-OUT screen q [<] switch: Advances the cursor left-
from the menu screen of Service mode. ward
q [U] switch: Settles the cylinder to be
reduced (the cursor starts flashing
after the settlement)
q [t] switch: Restores the CYLINDER
CUT-OUT screen
2) Displaying sub menu

Press [U] switch while the menu i s
selected to display the sub menu.
a As the reduced-cylinder command is

issued from the engine controller to the
cylinder to be reduced, the bottom of the
stopped cylinder number turns to black.
36 WA450-6 WA480-6 (KA SPEC.)

4) Cancelling a reduced cylinder 2) Pressing [U] switch sets up the no injec-

Using [<] or [>] switch, select the currently tion cranking.
stopped cylinder and then press [U] a If this screen does not appear as [U]
switch to cancel the reduced-cylinder switch is hit, a communication error should
command from the engine controller. The be suspected.
black display will disappear.
a If the no injection cranking is selected as

6. No injection cranking function the engine is running, the engine stop
The machine monitor is equipped with the instruction screen will appear.
function capable of lubricating the engine a In such case, stop the engine once and
through no injection cranking. When a machine then do the set up again.
has been stored for a long time, this function is
used to lubricate the engine prior to its restart
in order to prevent its wear or damages out of
oil.
The no injection cranking must be set up while
the engine is stopped.
1) Selecting menu
Display the NO INJECTION screen from
menu screen of Service mode.
WA450-6 WA480-6 (KA SPEC.) 37

7. Adjustment function (TUNING) 7-1. Adjustment of transmission ECMV current

The machine monitor implements initial setting 7-1-1. Preparations for transmission ECMV current
after disassembly or replacement of the trans- adjustment
mission, or after replacement or addition of 1) Display the REAL-TIME MONITOR from
sensor and EPC valve or controller. Through the menu screen of Service mode.
the initial setting, the machine monitor corrects
and adjusts the installation error or manufac-
turing variations of individual parts.
a Adjustment function
Re
No. Adjustment item
marks
Adjustment of transmission ECMV
7-1
current
7-2 Setting of transmission initial learning
Adjustment of transmission L mode
7-3
gearshift point
Adjustment of lift arm angle sensor
7-4 (*1)
(raise) (for EPC lever)
Adjustment of neutral zone dispersion 2) Press [U] switch to display the sub menu
7-5 (*1)
of lift arm raise lever and EPC and then select TRANSMISSION using [<]
Adjustment of neutral zone dispersion or [>] switch. (TRANSMISSION screen)
7-6 (*1)
of lift arm lower (float) lever and EPC
Adjustment of neutral zone dispersion
7-7 (*1)
of bucket tilt lever and EPC
7-8 (*1)
of bucket dump lever and EPC
7-9 of 3rd (3-spool valve) EPC cylinder (*1)
extension lever and EPC
7-10 of 3rd (3-spool valve) EPC cylinder (*1)
retraction lever and EPC
Adjustment of starting point disper-
7-11 sion of joystick steering right lever (*1)
and EPC
Adjustment of starting point disper-
3) Press [U] switch to settle the real-time
7-12 sion of joystick steering left lever and (*1) monitoring of the transmission controller.
EPC a As the selection is settled, the application
program version of the transmission con-
7-13 Change of lift arm lever pattern (*1)
troller will be displayed.
7-14 Change of bucket lever pattern (*1) q [20223] : ID number of display item
Adjustment of lift arm lower stop mod- q [******]: Display of data
7-15 (*1)
ulation (Program version)
Adjustment of pump cut-off pressure
7-16 (*1)
during raise of lift arm
7-17 (*1)
(upper) (Load meter specification)
7-18 (*1)
(lower) (Load meter specification)
Adjustment of 2-stage low idle throttle
7-19 (*1)
position
Adjustment of interval of fan auto-
7-20
matic reverse operation
Adjustment of continuance of fan
7-21
automatic reverse operation
(*1): This item is not used.
38 WA450-6 WA480-6 (KA SPEC.)

4) Using [<] or [>] switch, move the cursor to

Operat-
the T/M OIL TEMP screen.
ing 1 2 3 4
q [93600]: ID number of transmission order
control oil temperature
Gear
q [******]: Display of transmission con- N2 F2 F1 F2
speed
trol oil temperature
Holding Min. 2 Min. 2 Min. 2 Min. 2
time sec. sec. sec. sec.
Operat-
ing 5 6 7 8
order
Gear
F3 F4 F3 F2
speed
Operat-
ing 9 10 11
order
Gear
7-1-2. Conformation of transmission oil tempera- N2 R2 N2
speed
ture control
Holding Min. 2 Min. 2 Min. 2
1) Start the engine, press the brake pedal
time sec. sec. sec.
fully and then release the parking brake.
2) Set the transmission shift mode in MAN-
UAL, set the FNR (directional) lever or joy-
7-1-3. Adjustment of transmission ECMV current
stick steering FNR (directional) switch or
a Targets of correction are 6 types – F (forward),
right FNR (directional) switch in F (for-
R (reverse), 1st, 2nd, 3rd and 4th. As the
ward), and set the gearshift lever or gear-
engine is started, correction of all of above
shift switch in the 4th position. (F4)
clutches is started automatically.
3) Make sure from “7-1-1 Preparations for
a Since the learning operation requires the spec-
transmission ECMV current adjustment”
ified oil temperature, the oil temperature must
that the transmission controlled oil tem-
be adjusted to 55 – 70°C range.
perature is 55 – 70°C.If it is out of the
1) Turn on the starting switch (engine is not
range, stall the torque converter and
started) and then display T/M OIL TEMP
adjust the temperature to 55 – 70°C.
referencing “7-1-1 Preparations for trans-
4) Return the FNR (directional) lever or joy-
mission ECMV current adjustment”.
2) Run the engine at low idle, release the
right FNR (directional) switch to N (Neu-
accelerator pedal, set the FNR (direc-
tral) and check that the oil leak tester is 55
tional) lever or joystick steering FNR
– 70°C after 3 minutes.
(directional) switch or right FNR (direc-
5) Operate the FNR (directional) lever or joy-
tional) switch in N (Neutral), and check
that the transmission control oil tempera-
right FNR (directional) switch and gear-
ture is 55 – 70°C.
shift lever or gearshift switch as shown
below to circulate the oil through the trans-
mission.
a When performing the following opera-
tion, run the engine at low idle, turn
manual switch ON, turn the torque
converter lockup switch OFF, and turn
lockup switch OFF.
a Make sure the machine is normal
(failure is not detected).
a When stalling the torque converter,
use care it may not be overheated.
WA450-6 WA480-6 (KA SPEC.) 39

3) Display the TUNING screen from the 7) Using [U] switch, select AUTO from the
menu screen of Service mode. automatic correction (AUTO) and manual
correction (MANUAL) selection screen to
settle the automatic correction.
4) Hold down [U] switch for 5 seconds mini-

mum to display 01: TM TRIGGER screen.
a Selecting ECMV TUNING AUTO displays
IP in the character display, automatically
starting transmission ECMV current
adjustment.
5) Using [<] or [>] switch from the sub menu,

select 02: ECMV TUNING.
Operat-
1 2 3 4
ing order
IP [IP F-1] [IP F-2] [IP F-3] [IP F-4]
ECMV/
F/1st F/2nd F/3rd F/4th
fre-
time time time time
quency
Operat-
5 6 7 8
ing order
IP [IP R-1] [IP R-2] [IP R-3] [IP R-4]
ECMV/
R/1st R/2nd R/3rd R/4th
6) Press [U] switch to settle the adjustment fre-
time time time time
quency
item.
Operat-
9 10 11 12
ing order
IP [IP 1-1] [IP 1-2] [IP 1-3] [IP 1-4]
ECMV/
1st/1st 1st/2nd 1st/3rd 1st/4th
fre-
time time time time
quency
40 WA450-6 WA480-6 (KA SPEC.)

Operat- a Codes for abnormal end

13 14 15 16
ing order Reason CODE
IP [IP 2-1] [IP 2-2] [IP 2-3] [IP 2-4] Deviation from correc-
1
ECMV/ tion condition
2nd/1st 2nd/2nd 2nd/3rd 2nd/4th
fre- Absence of fill 2
time time time time
quency
In excess of correc-
3
Operat- tion value
17 18 19 20
ing order
a If abnormal end code “1” (NG1: Deviation
IP [IP 3-1] [IP 3-2] [IP 3-3] [IP 3-4] from correction condition) was displayed,
ECMV/
3rd/1st 3rd/2nd 3rd/3rd 3rd/4th
set the condition again referencing “7-1-1
fre- Preparations for transmission ECMV cur-
time time time time
quency rent adjustment” and repeat the correction.
a If abnormal end code “2” (NG2: Absence
Operat-
21 22 23 24 of fill) was displayed, implement trouble-
ing order
shooting of the failure codes 15STLH and
IP [IP 4-1] [IP 4-2] [IP 4-3] [IP 4-4] DXHTKA. If the state is normal, repeat the
ECMV/ operation starting from “7-1-1 Prepara-
4th/1st 4th/2nd 4th/3rd 4th/4th
fre-
time time time time
tions for transmission ECMV current
quency adjustment” and repeat the correction.
(The value of T depends on the applica-
8) As the correction is normally completed, ble gear speed.)
OK is displayed in the character display. a If the abnormal end code “3” (NG3: In
excess of correction value) was displayed,
execute the troubleshooting of failure
code 15STL1. Then after making sure the
condition is normal, implement “7-1-1
Preparations for transmission ECMV cur-
rent adjustment” again. (The value of T
depends on the applicable gear speed.)
9) As the operation ended normally, turn the
starting switch off and the corrected value
will be stored on the transmission control-
ler after 3 seconds.
a When it is required to turn on the starting
switch immediately after the adjustment,
maintain the starting switch, just in case,
a If the correction is not normally ended, the at off position for 10 seconds minimum
code for abnormal end will be indicated. and then turn it on.
(Following shows an example of the oper-
ation in which the 1st time correction of
the 3rd position has ended abnormally).
WA450-6 WA480-6 (KA SPEC.) 41

7-2. Setting of transmission initial learning 5) Press [U] switch to settle the adjustment
When initializing all the past initial trigger learn- item. As the item is settled, the initial
ing data stored on the transmission controller, learning reset screen appears.
employ the following procedure. a If the initial learning is not done, INITIAL
7-2-1. Reset of initial learning STATUS will be displayed.
1) Turn on the starting switch. (Engine does
not start)
2) Set the FNR (directional) lever or joystick
steering FNR (directional) switch or right
FNR (directional) switch in N (Neutral).
3) Display the TUNING screen from the
a When the initial learning is completed,

TUNED will be displayed.
4) Hold down [U] switch for 5 seconds mini-

mum to display 01: TM TRIGGER screen.
1] When TUNED is displayed, press [U]

switch to display the initial learning
reset screen.
2] Press [<] or [>] switch from the initial
learning reset screen to move the cur-
sor to YES position and then press
[t] switch to reset the initial learning.
3] When suspending the reset opera-
tion, select NO from above 2] or press
[t] switch on TUNED screen.
42 WA450-6 WA480-6 (KA SPEC.)

7-2-2. Preparations for transmission initial learning 4) Using [U] switch, settle 2 items display of
1) Display the REAL-TIME MONITOR from the transmission control oil temperature
the menu screen of Service mode. and the trigger learning display.
a Content of the trigger learning is displayed
for each of F, R, 1st, 2nd, 3rd and 4th
clutch in the figure.
q 0: Learning not done yet
q 1: Learning completed
2) Press [U] switch to display the sub menu,

select 2 ITEMS using [<] or [>] switch and
then settle the selection using [U] switch.
(SEL ITEMS 1,2 screen)
7-2-3. Implementation of transmission initial learn-

ing
a Before starting the transmission initial learning,
be sure to implement “7-1 Adjustment of trans-
mission ECMV current” and “7-2-1 Reset of ini-
tial learning”. Then start the initial learning
according to the following procedure.
a Implement the gearshift operation using actual
travel, bench travel or while pressing the wheel
brake.
k When actual travel is employed for the
operation, be sure to choose a spacious
field while paying reasonable care to the
3) From the SEL ITEMS 1,2 screen, enter ID environment.
number 93600 of the transmission control a When executing the operation, the engine shall
oil temperature and ID number 94100 for be set to low idle, manual switch to ON and
displaying the trigger learning. lockup switch to OFF.
a Referring to “4-5. Setting 2 items 1) Start the engine, press the brake pedal
simultaneous monitoring”. fully and then release the parking brake.
2) Set the transmission shift mode in MAN-
UAL, set the FNR (directional) lever or joy-
right FNR (directional) switch in F (for-
ward), and set the gearshift lever or gear-
shift switch in the 4th position.
3) Make sure from “7-2-2 Preparations for
transmission initial learning” that the trans-
mission control oil temperature is 55 –
70°C. If it is out of the range, stall the
torque converter and adjust the tempera-
ture to 55 – 70°C. (If the initial learning is
performed while the oil temperature is out
of the specified range, time lags and gear-
shift shocks can result).
WA450-6 WA480-6 (KA SPEC.) 43

4) Operate the FNR (directional) lever or joy- q The shift point that is used when the hunt-
stick steering FNR (directional) switch or ing prevention function is turned on.
right FNR (directional) switch and gear- q The shift down point that is used when the
shift lever or gearshift switch as shown accelerator is set to idle.
below to perform the initial learning. a After a shift point adjustment is done, confirma-
tion on the machine must be done.
Operating
1 2 3 4 7-3-1. Clearing an adjusted shift point
order
1) Display the TUNING screen from the
Gear
N2 F2 F1 F2 menu screen of Service mode.
speed
Operating
5 6 7 8
order
Gear
F3 F4 F3 F2
speed
Operating
9 10 11
order
Gear
N2 R2 N2
speed
Holding Min. 4 Min. 4 Min. 4 2) Hold down [U] switch for 5 seconds mini-
time sec. sec. sec. mum to display 01: TM TRIGGER screen.
a Hold the gear shift lever in each gear

speed for more than the specified time.
a If the gear shift lever is operated before
the specified time is reached, the initial
learning is not completed (TUNED is not
displayed).
7-2-4. Conformation of completion of transmission

initial learning
1) Referencing “7-2-2 Preparations for trans-
mission initial learning”, make sure 111111
is marked on ID number 94100, indicating
that the initial learning is completed.
2) Press [t] switch to end confirmation of the
initial learning. 3) Using [<] or [>] switch, select 04: SHIFT
rpm screen from the sub menu.
7-3. Adjustment of transmission L mode shift point
function
a This function is used for modifying the shift
point when the shift mode switch is at L posi-
tion by adding a correction amount.
a The factory default setting of the correction
amount shall be 0.
a The shift point depends on the engine mode.
When this function is used, however, the same
correction value is applied independent of the
engine mode.
a Some of the shift points being adjusted with
the shift point adjustment function may not
include the following shift patterns.
44 WA450-6 WA480-6 (KA SPEC.)

4) Press [U] switch to settle the selection.

a As the selection is settled, 0: ALL 2) Press [U] switch to settle the selection.
CLEAR will be displayed in the lower a As the selection is settled, the Shift
space. point adjusting value input screen will
5) Press [U] switch to settle ALL CLEAR. appear.
a As all the stored values are cleared, a This screen displays the currently
the screen returns to the shift point entered shift point adjusting value.
adjustment item. a Adjusting value input screen when
a If [t] switch is pressed in place of [U] Adjusting value = 0
switch, the stored value is not cleared
and the screen returns to the adjust-
ment items.
7-3-2. Adjusting a shift point

a This operation allows changing a gear shift
trav el speed when L auto- shift mode is
selected.
a Gear shift patterns are changed as shown below.
No. Gear shift pattern to be changed

0 ALL CLEAR
1 F2T/C → F3T/C
3 F3 T/C → F4 T/C
3) Press [<] or [>] switch to select a desired
6 F4T/C → F3T/C adjusting value.
7 F3 T/C → F2 T/C a When adjusting a shift point, 50 rpm
8 F3L/U ON of the transmission output shaft
speed is used as a unit.
9 F3L/U OFF
a Adjusting the transmission output shaft
10 F4L/U ON speed by 50 rpm changes the travel
11 F4L/U OFF speed by approximately 0.759 km/h.
• T/C: Torque converter travel q Selecting +50 rpm increases the
• L/U: Lockup travel speed by approximately 0.7 km/h.
(only for lockup specification) q Selecting –50 rpm decreases the
speed by approximately 0.7 km/h.
4) After selecting a desired setting data,
<Gear shift pattern change procedure> press [t] switch to end the setup proce-
a As an example of a gear shift pattern change, dure.
following describes the procedure for changing
the gear shift travel speed pattern from F2T/C
to F3T/C. (The same applies to other gear shift
patterns, too.)
1) Select 04: SHIFT rpm screen using [U]
switch and then select 01: F2T/C → F3T/C
using [<] or [>] switch.
WA450-6 WA480-6 (KA SPEC.) 45

7-4. Adjustment of lift arm angle sensor (raise) (for 7-19. Adjustment of 2-stage low idle throttle position
EPC lever) a This item is not used.
a This item is not used.
7-5. Adjustment of neutral zone dispersion of lift

arm raise lever and EPC
7-6. Adjustment of neutral zone dispersion of lift

arm lower (float) lever and EPC
7-7. Adjustment of neutral zone dispersion of

bucket tilt lever and EPC
7-8. Adjustment of neutral zone dispersion of

bucket dump lever and EPC
7-9. Adjustment of neutral zone dispersion of 3rd

(3-spool valve) EPC cylinder extension lever
and EPC
7-10. Adjustment of neutral zone dispersion of 3rd

(3-spool valve) EPC cylinder retraction lever
and EPC
7-11. Adjustment of starting point dispersion of joy-

stick steering right lever and EPC
7-12. Adjustment of starting point dispersion of joy-

stick steering left lever and EPC
7-13. Change of lift arm lever pattern

7-14. Change of bucket lever pattern

7-15. Adjustment of lift arm lower stop modulation

7-16. Adjustment of pump cut-off pressure during

raise of lift arm
7-17. Adjustment of lift arm angle sensor (upper)

7-18. Adjustment of lift arm angle sensor (lower)

46 WA450-6 WA480-6 (KA SPEC.)

7-20. Adjustment of interval of fan automatic 3) With the [<] and [>] switches, select 22:
reverse operation (Automatic reverse fan (if Adjust interval of fan automatic reverse
equipped) specification) operation.
a This function is used to change the inter-
val of the forward and reverse operations
of the fan when the fan automatic reverse
operation is selected.
a The interval of the fan automatic reverse
operation is adjustable in the range from
0.1 h (6 minutes) to 200 h. It must be set
to at least twice the continuance of the fan
automatic reverse operation, however,
and cannot be set shorter than twice.
a When the machine is delivered, the inter-
val of fan automatic reverse operation is
set to 2.0 h.
a When the machine is delivered, the con-
tinuance of the fan automatic reverse 4) Press the [U] switch to settle.
operation is set to 2 minutes. a If the [U] switch is pressed, the screen
1) On the service mode menu screen, dis- to adjust the interval of fan automatic
play the TUNING screen. reverse operation is displayed.
5) With the [<] and [>] switches, select an
interval in the range from “0.1” to “200”
(Unit: h).
6) Press the [t] switch to settle the setting.
a The selected interval of fan automatic
reverse operation is not changed to a
value less than twice the continuance
of the fan automatic reverse operation.
2) Hold down the [U] switch for at least 5

seconds to display 01: Transmission trig-
ger adjustment select screen.
WA450-6 WA480-6 (KA SPEC.) 47

7-21. Adjustment of continuance of fan automatic 3) With the [<] and [>] switches, select 23:
reverse operation (Automatic reverse fan (if Adjust continuance of fan automatic
equipped) specification) reverse operation.
a This function is used to change the contin-
uance of the reverse operation when the
fan automatic reverse operation is
selected.
a The continuance of the fan automatic
reverse operation is adjustable in the
range from 0.5 minutes to 10 minutes. It
must be set to below 1/2 of the interval of
the fan automatic reverse operation, how-
ever, and cannot be set longer than 1/2.
a When the machine is delivered, the con-
tinuance of fan automatic reverse opera-
tion is set to 2.0 minutes.
a When the machine is delivered, the inter-
val of the fan automatic reverse operation 4) Press the [U] switch to settle.
is set to 2.0 h. a If the [U] switch is pressed, the
1) On the service mode menu screen, dis- screen to adjust the continuance of
play the TUNING screen. fan automatic reverse operation is
displayed.
5) With the [<] and [>] switches, select a con-
tinuance in the range from “0.5” to “10”
(Unit: minute).
6) Press the [t] switch to settle the setting.
a The selected continuance of fan auto-
matic reverse operation is not
changed to a value longer than 1/2 of
the interval of the fan automatic
reverse operation.
2) Hold down the [U] switch for at least 5

seconds to display 01: Transmission trig-
ger adjustment select screen.
48 WA450-6 WA480-6 (KA SPEC.)

8. Maintenance monitoring function

The maintenance function offers the following
capabilities in the maintenance of filters and
oils.
q Change of maintenance interval time
q Selection between enabling or disabling
timer by item
q Setting of a default value
q Selection between enabling or disabling
timer for items
8-1. Changing maintenance interval time
1) Display the MAINTENANCE MONITOR
screen from the menu screen of Service
mode.
2) Press [U] switch to display 01: ENG OIL

screen.
a The lower left side space indicates the
time remained up to the replacement.
a The lower right side space indicates the
cumulative replacement frequencies.
3) Using [<] or [>] switch, select the item for
which the maintenance interval is to be
changed from the following.
WA450-6 WA480-6 (KA SPEC.) 49

List of maintenance items
Indication of items on the Replacement

Item ID No.
character display interval time (H)
Engine oil 01 ENG OIL 500
Engine oil filter 02 ENG FILT 500
Fuel pre-filter 41 FUEL P FILT 500
Fuel filter 03 FUEL FILT 1000
Corrosion resistor (if equipped) 06 CORR RES 1000
Transmission oil 12 TM OIL 1000
Transmission oil filter 13 TM FILT 1000
Hydraulic oil filter 04 HYD FILT 2000
Hydraulic tank breather element 05 HYD BREATH 2000
Hydraulic oil 10 HYD OIL 2000
Axle oil 15 AXLE OIL 2000
4) Settle the target items of interval change a When you have entered a wrong value to
by use of [U] switch. a position except the highest-order digit,
move to the highest-order digit using [t]
switch and repeat the procedure from the
first. In this case, the value that had been
entered remains as it is until modified.
When the cursor is at the highest-order
digit, move to the higher layer using [t]
switch.
5) Maintenance interval time change proce-

dure
1] This cursor is located at the highest-
order digit. Pressing [<] or [>] switch
changes the value of this digit in the
range of 0 – 9.
2] Press [U] switch when the intended
value appeared to specify it as the set
value.
a The cursor moves to the 2nd digit.
3] Set the values up to the lowest-order
digit in the same order and then press
[U] switch.
q When the input interval time is within
the setting range: The screen
changes to the check screen.
q When the entered interval time is out
of the setting range: The entered
interval time does not replace the cur-
rent value and the input screen will be
restored.
a The shortest interval time value is 50 h.
50 WA450-6 WA480-6 (KA SPEC.)

6) Select “YES” or “NO” using [<] or [>] a When “Timer by item” is disabled, the
switch. order of display becomes OFF o ON.
a The selected cursor will start flashing. If a The default display is ON.
“Y ES” i s s elec ted and [t] s witc h is
maintenance interval change item screen
is restored.
a When an interval time is changed, the
timer remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
2) Press [U] switch from this state.
a If “Timer by item” is disabled, OFF will be
displayed in the upper column.
8-2. Selection between enabling or disabling timer

by item
1) Pressing [<] or [>] switch from 8-1-3) Inter-
val time change screen displays the a If “Timer by item” is enabled, ON will be
“Selection between enabling or disabling displayed in the upper column.
timer by item” screen.
a When “Timer by item” is enabled, the
order of display is ON o OFF.
WA450-6 WA480-6 (KA SPEC.) 51

3) Select “YES” or “NO” using [<] or [>] 3) Press [U] switch from this state.
switch. 4) Select “YES” or “NO” using [<] or [>] switch.
a The selected cursor will start flashing. If a The selected cursor will start flashing. If
“Y ES” i s s ele cted and [t] s witc h i s “ YE S” is s elec t ed a nd [t] s witc h is
pressed, the information will be deleted. If pressed, the change will be enabled If
“NO” is selected and [t] switch is “NO” is selected and [t] switch is
pressed, deletion is cancelled and the pressed, the change will not be imple-
maintenance interval change item screen mented and the maintenance monitoring
is restored. screen will be restored.
a By default, the cursor is set to NO (cancel) a By default, the cursor is set to NO (cancel)
a An interval time is changed, the timer
remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
8-3. Changing set default value.

1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
a If the default value setting is executed, all

the currently changed interval times are
returned to the default values. It is executed
on every item independent of whether or not
the function is enabled for a specific item.
a Timer remaining time shall be Default
v alue – E lapsed time s ince the las t
replacement.
a Executing the default value setting does
not affect the reset frequency. Namely, it
remains the same as before this operation
was executed.
2) Using [<] or [>] switch, select the INITIALIZE a Set enable for enable or disable of individ-
screen from the following table. ual items.
8-4. Selection between timer stop for all items and

enable by item
1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
52 WA450-6 WA480-6 (KA SPEC.)

2) Using [<] or [>] switch, select the ALL 5) Press [U] switch from the ALL ITEMS o
ITEMS OFF OR ON screen from the fol- OFF screen or the ALL ITEMS o ON
lowing table. screen.
a When [U] switch is pressed from the ALL
ITEMS o OFF screen, OFF will be is dis-
played in the upper space.
3) Press [U] switch to display the ALL

ITEMS o OFF screen.
a When [U] switch is pressed from the ALL

ITEMS o ON screen, ON will be is dis-
played in the upper space.
6) Select “YES” or “NO” using [<] or [>]
switch.
“ YE S” is s elec t ed a nd [t] s witc h is
maintenance interval change item screen
is restored.
4) Press [<] or [>] switch when selecting the to prevent resetting error.
ALL ITEMS o ON.
WA450-6 WA480-6 (KA SPEC.) 53

7) As the timer stop for all items is executed: 9. Operating information display function
a The timer function for all items is stopped It is a fuel consumption-related function and
a n d t h e M A I NT E N A NC E M O NI TO R displays the following information.
screen is restored. q Fuel consumption ratio and average fuel
a Setting for individual items is also disabled. consumption
a If cancelled: The operation is cancelled q Cumulative fuel consumption and travel
a n d t h e M A I NT E N A NC E M O NI TO R distance
screen is restored. q Cumulative fuel consumption and elapsed
8) When timer enable for all items is executed: time
a Interval time being set for all items is exe- q Loaded volume and loading frequency
cuted to the set value before disabled (This display is available only when the
i nd e p e nd e n t o f wh e th e r o r n ot i t i s load meter is installed.)
enabled or disabled for a specific item. 1) Selecting menu
a The timer remaining time is reset. (The Display the OPERATION INFO screen
reset frequency remains the same as from the menu screen of Service mode.
before the resetting.)
a The MAINTENANCE MONITOR screen is
restored.
a Setting for individual items is also enabled.
a If cancelled: The operation is cancelled
a n d t h e M A I NT E N A NC E M O NI TO R
screen is restored.
2) Press [U] switch to display the fuel con-

sumption ratio and average fuel consump-
tion screen.
3) Using [<] or [>] switch, select the item to
be displayed from 1] – 4] on the fuel con-
sumption ratio and average fuel consump-
tion screen.
1] Fuel consumption ratio and average
fuel consumption screen
a The upper column displays fuel con-
sumption [L/km or L/mile] per 1 km (or
1 mile) from the last resetting.
q Above value is computed from the
fuel consumption ratio and travel dis-
tance (odometer distance).
q The counting is stopped at 99999.9,
the upper limit.
a The lower column displays the aver-
age fuel consumption [L/h] from the
last resetting.
the upper limit.
a Calculation is done only for the dura-
tion in which the engine is run.
54 WA450-6 WA480-6 (KA SPEC.)

a The lower column displays the

elapsed time [h] from the last reset-
ting.
the upper limit.
tion in which the engine is run.
2] Cumulative fuel consumption and travel

distance
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
the upper limit.
a The lower column displays the travel 4] Loaded volume and loading frequency
distance [km or mile] from the last screen
resetting. a The upper column displays the
q The unit km or mile shall be selected loaded volume [ton] from the last
depending on that used on the odom- resetting.
eter. q Upper limit: Counting is stopped at
q The counting is stopped at 99999.9, 199999999.9 or 999999999.9.
the upper limit. q Short ton or metric ton depends on
a Calculation is done only for the dura- optional setting.
tion in which the engine is run. a The lower column displays the load-
ing frequency from the last resetting.
q Upper limit: Counting starts stopped
at 65000 or 99999999999.
tion in which the engine is run and the
optional device is used.
3] Cumulative fuel consumption and

elapsed time
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
the upper limit.
WA450-6 WA480-6 (KA SPEC.) 55

4) Deleting display data 7] Press [U] switch when the intended

a Data on screens 5) – 8) allow deletion. value appeared to specify it as the set
a Select a desired item and then delete it value.
using [U] switch. a The cursor moves to the 2nd digit.
a Use [t] switch when canceling deletion of 8] Set the values up to the lowest digit in
data. the same order as above and then
press [U] switch to settle.
a As the selection is settled, the pre-
ceding screen is restored.
a If [t] switch is pressed before finish-
ing entering, the cursor moves to the
[+] and [–] position. In this case, the
value remains unchanged. Pressing
[t] switch again restores the preced-
ing screen.
a If the value is not in the –50 – +50
range, pressing [U] switch at the low-
est digit just moves the cursor the [+]
and [–] position and the value
remains as it is.
5) Setting gain correction
a Gain correction denotes the function of
correcting cumulative fuel consumption.
a Gain correction is available only from the
fuel consumption ratio and average fuel
consumption screen.
1] After deleting data (RESET screen),
press [<] or [>] switch to display the
current set value.
2] Pressing [U] switch displays the cor-

rection screen.
a Default value: 0.0%
a This setting allows correcting the
cumulative fuel consumption in the
range of –50.0 to +50.0.
3] Move the cursor to [+] or [–].
4] Pressing [<] or [>] switch alternately
displays [+] and [–].
5] Press [U] switch to settle [+] or [–].
a The cursor moves to the highest-
order digit of the set value.
6] Pressing [<] or [>] switch changes the
value of this digit in the range of 0 – 9.
56 WA450-6 WA480-6 (KA SPEC.)

10. OPTIONAL SELECT function

a The procedure for setting an option is as follows; Set the option and turn the starting switch OFF. After
the power for each controller is turned OFF (about 15 seconds), turn the starting switch ON again, and
the option is effective.
a Before setting an option, check that the machine model has been selected. (Select the machine model
before setting the option.)
a Optional component setting table
Item Setting at
Item Display in English Contents of selection
No. delivery
Set following items according to boom specification.

Boom specification LIFT BOOM 1 STD • If standard boom is used, select “STD”.
• If high lift boom (optional) is used, select “HI LIFT”.
Auto grease AUTO GREASE 2 NO ADD If there is option, select “ADD”.
Electrolyte level sensor BAT LIQUID 3 NO ADD If there is option, select “ADD”.
Transmission filter
TRANSM CLOG 4 NO ADD If there is option, select “ADD”.
clogging sensor
Printer PRINTER 5 NO ADD If there is option, select “ADD”.
Set to “0” normally and do not change.
Tire size TIRE SIZE 6 0 If after than “0” is selected, only the travel speed in monitor
changes.
Selection of short ton SHORT TON 7 NO ADD Since setting is made specially in factory, it cannot be changed.
Unit of travel speed SPEED (UNIT) 8 MPH Since setting is made specially in factory, it cannot be changed.
Machine which must take
RPM OPT 9 NO ADD Select “NO ADD” and do not change it.
automobile inspection
Indication of engine
Normally select “ADD” and do not change it.
speed/travel speed on
RPM/SPEED 10 ADD If “NO ADD” is selected, engine speed or travel speed in the
normal screen of
character display is not displayed.
character display
Load meter LOAD METER 11 NO ADD Select “NO ADD” and do not change it.
Emergency steering EMERG S/T 13 ADD If option is not installed, select “NO ADD”.
When joystick steering or right FNR (directional) switch is
Joystick steering and/or installed, set necessary items.
right FNR (directional) J/S-FNR SW 14 NON • When only steering wheel is used, set “NON”.
switch are/is not installed • When joystick steering is set, set “J/S”.
• When right FNR (directional) switch is set, set “FNR SW”.
Joystick steering 4th and
J/S 4TH L/U 15 ADD “NO ADD” is selected, 4th and lockup clutch do not operate in
lockup clutch function
joystick steering mode.
Low-temperature bypass
BYPASS SOL 16 NO ADD If there is option, select “ADD”.
solenoid function
Loader pump high altitude
HIGHLAND MD 17 NO ADD Select “NO ADD” and do not change it.
mode
Tooth mode TOOTH MODE 18 ADD Normally select “ADD” and do not change it.
Operation of ECO lamp ECO LAMP 19 ADD If “NO ADD” is selected, ECO lamp in monitor always stays
OFF.
ECSS E.C.S.S 20 NO ADD If there is option, select “ADD”.
Torque converter lockup LOCK UP 22 NO ADD If there is option, select “ADD”.
If there is option, select “ADD”.
Prohibition of 4th FORBID 4TH 23 NO ADD If “ADD” is selected, transmission is not set in 4th in auto-shift
and manual shift modes.
Throttle lock THROT LOCK 24 NO ADD Select “NO ADD” and do not change it.
Work equipment controller WORK LOCK 29 NO ADD If controller is installed, select “ADD”.
EPC 3-piece lever EPC 3RD 31 NO ADD If there is option, select “ADD”.
EPC lever EPC LEVER 32 NO ADD If there is option, select “ADD”.
WA450-6 WA480-6 (KA SPEC.) 57

1) Display the OPTIONAL SELECT screen

from the menu screen of Service mode.
2) Hold down [U] switch for 5 seconds or

longer.
3) The 1: LIFT BOOM screen will appear.
a If the [t] switch is pressed, the
screen returns to the OPTIONAL
SELECT screen.
58 WA450-6 WA480-6 (KA SPEC.)

a Be sure to start setting of each option on BOOM TYPE OPTION SELECT screen. After chang-
ing or settling the option, set other items in order on the next AUTO GREASE OPTION
SELECT screen and the following screens.
WA450-6 WA480-6 (KA SPEC.) 59

10-1. Change or settlement of “BOOM TYPE OPTION 10-3. Setting tire deflection option
SELECT” a Select the tire deflection option from the list of
a If the [U] switch is pressed on the BOOM installed optional devices and their setting.
TYPE OPTION SELECT screen, “STD” or a Pressing [U] switch sequentially displays
“HI LIFT” is selected alternately. [@@]% in the following order.
a If “STD” or “HI LIFT” is selected, the oper- a The display progresses from +00 through –10.
ation receiving sound (beep) is made. Pressing [U] switch at this point returns the
q STD: Standard boom display to +00.
q HILIFT: High lift boom (Optional)
Order No.1 No.2 No.3 No.4 No.5 No.6 No.7
10-2. Option setting/not setting selection @@ +00 +02 +04 +06 +08 +10 +12
a Among the items included in the list of
installed optional devices and their setting, Order No.8 No.9 No.10 No.11 No.12 No.13 No.14
the option setting/not setting selection @@ –02 –4 –6 –8 –10 –12 +00
applies to the following items.
a If the options are not selected, the option a As the display is switched, the sound (beep)
non-selection screen (NO ADD) is displayed. indicating acceptance of the operation will be
generated.
a If the options are selected, the option

elected screen (ADD) is displayed. 10-4. Storing option selection
1) When the option selection was changed,
turn off the starting switch once to stop the
controller operation completely. (After turn-
ing off the starting switch, wait for 15 sec-
onds without doing any switch operation.)
2) The specified option selection is enabled
as the starting switch is turned on.
a Whenever an option selection is made, turn
off the starting switch once and then turn it
on again in approximately 15 seconds.
a [U] switch allows alternately displaying

the option non-selection screen and the
option-selected screen.
60 WA450-6 WA480-6 (KA SPEC.)

11. Machine serial number input function 12. Machine model select function (MACHINE)
1) Display the MACHINE No. SET screen a The setting of the machine model of the
from the menu screen of Service mode. machine monitor can be changed with the
machine model select function.
a If the machine monitor is initialized, per-
form the machine model select operation
first.
a If the machine model select operation is
performed, the setting of options is reset.
Accordingly, start with the option select
operation and select all the options.
12-1. Implementing the model change

1) Display the MACHINE screen from the
a The currently selected machine model
and tire size are displayed on the lower
2) Press [U] switch to display the MACHINE line.
No. screen. q WA380 TIRE 23.5
3) Enter the serial number according to the q WA380 TIRE 20.5
following procedure. q WA430 TIRE 26.5
a The cursor is positioned at the high- q WA430 TIRE 23.5
est-order digit. q WA470 TIRE 26.5
1] Pressing [<] or [>] switch increases or q WA470 TIRE 23.5
decreases the value at the cursor q WA480
position. Select a desired value using
these switches. ex. WA380
2] Press [U] switch to settle the selec-
tion.
a The cursor moves to the digit situated
immediately on the right hand.
3] Set the values up to the lowest digit in
the same order as above and then
press [U] switch to settle.
a As the selection is settled, the imme-
diately preceding screen is restored.
a Pressing [t] switch while entry is taking
place will move the cursor the highest-
order digit. In this case, repeat entry
from the highest-order digit.
a If [t] switch is pressed while the cur-
sor is at the highest-order digit, the 2) Hold down [U] switch for 5 seconds to
immediately preceding screen will be display the model selection screen.
restored.
WA450-6 WA480-6 (KA SPEC.) 61

3) With the [<] and [>] switches, select the 13. Initialize function
machine model or tire size. This function is used only in the factory. It is,
Select model and tire size based on therefore, not used for a service purpose.
installed tire.
Machine
Tire size Display
model
WA470
26.5 – 25
Tire 26.5
WA450
WA470
23.5 – 25
Tire 26.5
WA480 26.5 – 25 WA480
a If wrong model and tire are set,
machine does not work correctly.
a Press [t] switch when stopping the model
selection.
a As the operation is stopped, the sound
(beep) indicating acceptance of the opera-
tion will be generated, restoring the
MACHINE screen.
4) With the [U] switch, settle the changed
machine model and tire size.
a As the selection is settled, the sound
(beep) indicating acceptance of the opera-
tion will be generated, restoring the
MACHINE screen.
a Check that the desired machine model
and tire size are displayed on the machine
model select screen.
12-2. Storing model change

1) When the model change was done, turn off
the starting switch once to stop the controller
operation completely. (After turning off the
starting switch, wait for 15 seconds without
doing any switch operation.)
2) The model being selected as the starting
switch is turned on is validated.
a Whenever a model change was done, turn
off the starting switch once and then turn it
on again in approximately 15 seconds.
62 WA450-6 WA480-6 (KA SPEC.)

Pm-click inspection table 1

WA450-6 Serial No. 66001 and up
Machine serial No. #
Engine serial No.

hour inspection SAA6D125E-5 #
Work instruction No. Date of execution Service meter Inspector
Year: Month: Day: hours
Interview with operator and walk-around check

Is there abnormality before starting inspection? Outside temperature
Max. °C
Min. °C
Altitude m
Maximum coolant temperature (overheated)? Maximum torque converter oil temperature

(During operation) (overheated)? (During operation)
a If machine is cold, warm it up.

a Working mode: P-mode
Standard
Service limit Measure-
Item Condition Unit value for new Good Bad
value ment result
machine
Engine at low idle 800 – 850 800 – 850
Engine at high idle 2,120 – 2,220 2,120 – 2,220
Engine at high idle and torque converter
1,970 – 2,070 1,920 – 2,120
stalled
Engine speed rpm
Engine at high idle and work equipment
2,040 – 2,240 1,940 – 2,340
relieved
Torque converter stalled + Work equipment
1,880 – 2,080 1,780 – 2,180
relieved
At rated output
kPa Max. 1.27 1.96
Blow-by pressure Engine coolant temperature: operating
Engine
{mmH2O} {Max. 130} {200}

range
At rated output
SAE0W30EOS 0.29 – 0.69 0.18
Engine coolant tempera-
SAE5W40EOS {3.0 – 7.0} {1.8}
Lubricating oil ture: operating range MPa
SAE10W30DH
pressure At rated output {kg/cm2}
SAE15W40DH Min. 0.05 0.03
SAE30DH {Min. 0.5} {0.3}
ture: operating range
kPa Min. 107 87
Boost pressure At rated output
{mmHg} {Min. 800} {650}
Exhaust Engine at all speed range
°C Max. 700 Max. 700
temperature Outside temperature: 20°C
a When shifting transmission gear to forward/reverse position, apply brake securely. Good Bad
2.73 – 3.13 2.73 – 3.13
Engine at high idle
Main relief {27.9 – 31.9} {27.9 – 31.9}
pressure • Torque converter oil
2.58 – 2.98 2.58 – 2.98
Engine at low idle temperature: Within
{26.3 – 30.3} {26.3 – 30.3}
operating range
Torque converter Max. 0.93 Max. 0.93
Engine at high idle • Engine speed:
inlet pressure {Max. 9.5} {Max. 9.5}
Transmission valve
2,000 rpm
Torque converter 0.54 – 0.64 0.54 – 0.64
Engine at high idle
outlet pressure MPa {5.5 – 6.5} {5.5 – 6.5}
1st {kg/cm2}
2nd • Torque converter oil 2.15 – 2.45 2.15 – 2.45
3rd temperature: {22 – 25} {22 – 25}
ECMV output 4th Within operating range
(clutch) pressure F • Engine speed: 1.91 – 2.21 1.91 – 2.21
R 2,000 rpm {19.5 – 22.5} {19.5 – 22.5}
• Manual switch: ON
2.25 – 2.55 2.25 – 2.55
Lockup
{23 – 23} {23 – 23}
WA450-6 WA480-6 (KA SPEC.) 63

Pm-click inspection table

Standard
value ment result
machine
Secure frame with frame lock bar.
Steering
MPa 23.3 – 25.7 22.0 – 25.7

Steering relief pressure Engine at high idle
{kg/cm2} {237.5 – 262.5} {225 – 262.5}
Torque converter oil temperature: Within operat-
Parking brake inlet ing range MPa Min. 2.27 Min. 2.27
pressure Engine at low idle {kg/cm2} {Min. 23.1} {Min. 23.1}
As parking brake is released
Tire inflation pressure: Specified pressure
Parking brake
Test on flat and dry paved slope of 1/5 (11° 20'). — Stopped Stopped
performance
Set machine in operating state.
Parking brake disc
mm 3.12 – 3.28 2.97
thickness
Measure when brake
5.9 – 6.4 5.4 – 6.88
Charge cut-in pressure oil pressure warning
Hydraulic oil temperature: lamp goes off. {60 – 65} {55 – 70}
Engine at low idle Measure when brake
9.8 – 10.78 9.4 – 11.3
Brake
Charge cut-out pressure oil pressure starts

MPa {100 – 110} {95 – 115}
lowering after rising.
{kg/cm2}
Hydraulic oil temperature: Within operating range 4.4 – 5.2 Min. 4.2
Brake oil pressure
Engine at low idle {44.8 – 53} {Min. 42.7}
Engine: Stopped
Lowering of brake oil Max. 0.49 Max. 0.49
Measure lowering of oil pressure from 4.9 MPa
pressure {Max. 5.0} {Max. 5.0}
{50 kg/cm2} in 5 minutes.
Test on flat, level, straight, and dry paved road.
Braking initial speed: 20 km/h,
Wheel brake performance Delay in pressing pedal: Max 0.1 sec m Max. 5 Max. 5
Brake pedal pressing force:
Specified force, 293 – 353 Nm {29.9 – 35.9 kg}
Measure braking distance.
Wear of wheel brake disc Measure with disc wear indicator. mm 0 Max. 2.4
Work equipment valve relief 32.5 – 36.1 29.9 – 36.1
Bucket circuit relieved
pressure MPa {332 – 368} {305 – 368}
Work equipment valve LS P-mode Work equipment control {kg/cm2} 1.17 – 1.57 0.98 – 1.76
differential pressure Hydraulic oil tempera- lever moved halfway {12 – 16} {10 – 18}
Work equipment
ture: Within operating Rising time 5.3 – 6.3 Max. 7.7

Lift arm speed range
Engine at high idle Lowering time 3.2 – 4.2 Max. 4.9
sec
Bucket full stroke time 2.1 – 2.7 Max. 3.2
Bucket tilt back speed
Bucket at level time 1.2 – 1.8 Max. 2.0
Hydraulic oil tempera- Bucket cylinder Max. 20 Max. 24
Hydraulic drift of work ture: Within operating mm/
equipment range 15 min.
Engine: Stopped Lift cylinder Max. 30 Max. 36
Engine speed: High idle

Engine coolant temperature: Min. 95°C
Max. fan speed 1,500 – 1,700 1,400 – 1,800
Hydraulic oil temperature: Min. 95°C
Torque converter oil temperature: Min. 105°C
Engine speed: Low idle rpm
Hydraulic drive fan
Min. fan speed Hydraulic oil temperature: Max. 75°C 550 – 650 500 – 700
Torque converter oil temperature: Max. 85°C
Air conditioner: OFF
Engine coolant temperature: Min. 95°C 15.6 – 19.0 14.7 – 19.9
Fan drive pressure
Hydraulic oil temperature: Min. 95°C {158 – 194} {150 – 202}
Torque converter oil temperature: Min. 105°C MPa
Engine speed: High idle {kg/cm2}
Fan reverse solenoid Engine coolant temperature: Min. 95°C 15.6 – 19.0 14.7 – 19.9
output pressure Hydraulic oil temperature: Min. 95°C {158 – 194} {150 – 202}
Draining of differential Front axle There must not be
Axle
—
Visual check of plug Rear axle excessive metal powder.
Memo
64 WA450-6 WA480-6 (KA SPEC.)

Pm-click inspection table 1

Machine serial No. #
Engine serial No.

hour inspection SAA6D125E-5 #
Work instruction No. Date of execution Service meter Inspector
Year: Month: Day: hours
Interview with operator and walk-around check

Is there abnormality before starting inspection? Outside temperature
Max. °C
Min. °C
Altitude m
Maximum coolant temperature (overheated)? Maximum torque converter oil temperature

(During operation) (overheated)? (During operation)
a If machine is cold, warm it up.

a Working mode: P-mode
Standard
value ment result
machine
Engine at low idle 800 – 850 800 – 850
Engine at high idle 2,140 – 2,290 2,140 – 2,290
Engine at high idle and torque converter
1,980 – 2,080 1,930 – 2,130
stalled
Engine speed rpm
Engine at high idle and work equipment
2,050 – 2,250 1,950 – 2,350
relieved
Torque converter stalled + Work equipment
1,750 – 1,950 1,650 – 2,050
relieved
At rated output
kPa Max. 1.27 1.96
Blow-by pressure Engine coolant temperature: operating
Engine
{mmH2O} {Max. 130} {200}

range
At rated output
SAE0W30EOS 0.29 – 0.69 0.18
SAE5W40EOS {3.0 – 7.0} {1.8}
Lubricating oil ture: operating range MPa
SAE10W30DH
pressure At rated output {kg/cm2}
SAE15W40DH Min. 0.05 0.03
SAE30DH {Min. 0.5} {0.3}
ture: operating range
kPa Min. 120 100
Boost pressure At rated output
{mmHg} {Min. 900} {750}
Exhaust Engine at all speed range
°C Max. 700 Max. 700
temperature Outside temperature: 20°C
a When shifting transmission gear to forward/reverse position, apply brake securely. Good Bad
2.73 – 3.13 2.73 – 3.13
Engine at high idle
Main relief {27.9 – 31.9} {27.9 – 31.9}
pressure • Torque converter oil
2.58 – 2.98 2.58 – 2.98
Engine at low idle temperature: Within
{26.3 – 30.3} {26.3 – 30.3}
operating range
Torque converter Max. 0.93 Max. 0.93
Engine at high idle • Engine speed:
inlet pressure {Max. 9.5} {Max. 9.5}
Transmission valve
2,000 rpm
Torque converter 0.54 – 0.64 0.54 – 0.64
Engine at high idle
outlet pressure MPa {5.5 – 6.5} {5.5 – 6.5}
1st {kg/cm2}
2nd • Torque converter oil 2.15 – 2.45 2.15 – 2.45
3rd temperature: {22 – 25} {22 – 25}
ECMV output 4th Within operating range
(clutch) pressure F • Engine speed: 1.91 – 2.21 1.91 – 2.21
R 2,000 rpm {19.5 – 22.5} {19.5 – 22.5}
• Manual switch: ON
2.25 – 2.55 2.25 – 2.55
Lockup
{23 – 23} {23 – 23}
WA450-6 WA480-6 (KA SPEC.) 65

Pm-click inspection table

Standard
value ment result
machine
Secure frame with frame lock bar.
Steering
MPa 23.3 – 25.7 22.0 – 25.7

Steering relief pressure Engine at high idle
{kg/cm2} {237.5 – 262.5} {225 – 262.5}
Torque converter oil temperature: Within operat-
Parking brake inlet ing range MPa Min. 2.27 Min. 2.27
pressure Engine at low idle {kg/cm2} {Min. 23.1} {Min. 23.1}
As parking brake is released
Parking brake
Test on flat and dry paved slope of 1/5 (11° 20'). — Stopped Stopped
performance
Set machine in operating state.
Parking brake disc
mm 3.12 – 3.28 2.97
thickness
Measure when brake
5.9 – 6.4 5.4 – 6.88
Charge cut-in pressure oil pressure warning
Hydraulic oil temperature: lamp goes off. {60 – 65} {55 – 70}
Engine at low idle Measure when brake
9.8 – 10.78 9.4 – 11.3
Brake
Charge cut-out pressure oil pressure starts

MPa {100 – 110} {95 – 115}
lowering after rising.
{kg/cm2}
Hydraulic oil temperature: Within operating range 4.4 – 5.2 Min. 4.2
Brake oil pressure
Engine at low idle {44.8 – 53} {Min. 42.7}
Engine: Stopped
Lowering of brake oil Max. 0.49 Max. 0.49
Measure lowering of oil pressure from 4.9 MPa
pressure {Max. 5.0} {Max. 5.0}
{50 kg/cm2} in 5 minutes.
Test on flat, level, straight, and dry paved road.
Braking initial speed: 20 km/h,
Wheel brake performance Delay in pressing pedal: Max 0.1 sec m Max. 5 Max. 5
Brake pedal pressing force:
Specified force, 293 – 353 Nm {29.9 – 35.9 kg}
Measure braking distance.
Wear of wheel brake disc Measure with disc wear indicator. mm 0 Max. 2.4
Work equipment valve relief 32.5 – 36.1 29.9 – 36.1
Bucket circuit relieved
pressure MPa {332 – 368} {305 – 368}
Work equipment valve LS P-mode Work equipment control {kg/cm2} 1.17 – 1.57 0.98 – 1.76
differential pressure Hydraulic oil tempera- lever moved halfway {12 – 16} {10 – 18}
Work equipment
ture: Within operating Rising time 5.3 – 6.3 Max. 7.7

Lift arm speed range
Engine at high idle Lowering time 3.2 – 4.2 Max. 4.9
sec
Bucket full stroke time 2.1 – 2.7 Max. 3.2
Bucket tilt back speed
Bucket at level time 1.2 – 1.8 Max. 2.0
Hydraulic oil tempera- Bucket cylinder Max. 20 Max. 24
Hydraulic drift of work ture: Within operating mm/
equipment range 15 min.
Engine: Stopped Lift cylinder Max. 30 Max. 36

Engine coolant temperature: Min. 95°C
Max. fan speed 1,500 – 1,700 1,400 – 1,800
Hydraulic oil temperature: Min. 95°C
Engine speed: Low idle rpm
Hydraulic drive fan
Min. fan speed Hydraulic oil temperature: Max. 75°C 550 – 650 500 – 700
Torque converter oil temperature: Max. 85°C
Air conditioner: OFF
Engine coolant temperature: Min. 95°C 15.6 – 19.0 14.7 – 19.9
Fan drive pressure
Hydraulic oil temperature: Min. 95°C {158 – 194} {150 – 202}
Torque converter oil temperature: Min. 105°C MPa
Engine speed: High idle {kg/cm2}
Fan reverse solenoid Engine coolant temperature: Min. 95°C 15.6 – 19.0 14.7 – 19.9
output pressure Hydraulic oil temperature: Min. 95°C {158 – 194} {150 – 202}
Draining of differential Front axle There must not be
Axle
—
Visual check of plug Rear axle excessive metal powder.
Memo
66 WA450-6 WA480-6 (KA SPEC.)

WA450-6 WA480-6 (KA SPEC.) 67

SEN01588-00

68
SEN01676-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
40 Troubleshooting 1
Failure code table and fuse locations
Failure code table and fuse locations ............................................................................................................. 2
Failure code table................................................................................................................................. 2
Fuse locations .................................................................................................................................... 14
WA450-6, WA480-6 (KA SPEC.) 1

SEN01676-00 40 Troubleshooting
Failure code table and fuse locations 1

Failure code table 1
Failure Action Category of Reference
Troubled part Trouble Controller
code code record document No.
TORQFLOW Electrical
1500L0 Double meshing TM E03
transmission system
When command current is Electrical
15SAL1 ECMV F clutch TM E03
OFF, fill signal is ON system
15SALH ECMV F clutch TM E01
ON, fill signal is OFF system
15SBL1 ECMV R clutch TM E03
15SBLH ECMV R clutch TM E01
15SEL1 ECMV 1st clutch TM E03
15SELH ECMV 1st clutch TM E01
When command current is Electrical Troubleshooting
15SFL1 ECMV 2nd clutch TM E03
OFF, fill signal is ON system by failure code,
When command current is Electrical Part 1
15SFLH ECMV 2nd clutch TM E01 SEN01678-00
15SGL1 ECMV 3rd clutch TM E03
15SGLH ECMV 3rd clutch TM E01
15SHL1 ECMV 4th clutch TM E03
15SHLH ECMV 4th clutch TM E01
Electrical
2F00MA Parking brake Malfunction MON E03
system
Mechanical
2G43ZG Accumulator Low oil pressure MON E03
system
Electrical
44K0L4 Bucket positioner ON/OFF signals disagree WRK E01
system
Mechanical
AA1ANX Air cleaner Clogging MON E01
system
Signal does not match
Electrical
AB00L6 Alternator engine running or stopped MON E03
system
state
Mechanical
AB00MA Alternator Malfunction MON E03
system Troubleshooting
Derating of speed by by failure code,
Mechanical
B@BAZG engine oil pressure — ENG E03 Part 2
system
reduction SEN01679-00
Mechanical
B@BAZK Engine oil Low oil pressure MON E01
system
Mechanical
B@BCNS Coolant Overheating ENG E02
system
Mechanical
B@BCZK Coolant Low oil pressure MON E01
system
2 WA450-6, WA480-6 (KA SPEC.)


Mechanical
B@C7NS Brake oil Overheating MON E02
system
Mechanical
b@CENS Torque converter oil Overheating MON E02
system
Mechanical
B@CENS Torque converter oil Overheating MON E02
system
Mechanical
B@HANS Hydraulic oil Overheating MON E02
system
Engine controller Electrical
CA111 — ENG E03
internal failure system
Abnormality in engine Electrical
CA115 — ENG E03
Ne, Bkup speed sensor system
Abnormally high level in Electrical
CA122 — ENG E03
charge pressure sensor system
Abnormally low level in Electrical
CA123 — ENG E03
charge pressure sensor system
Abnormally high level in Electrical
CA131 — ENG E03
throttle sensor system
Abnormally low level in Electrical
CA132 — ENG E03
throttle sensor system
Engine oil pressure Electrical
CA135 — ENG E01
sensor high error system
Engine oil pressure Electrical Troubleshooting
CA141 — ENG E01 by failure code,
sensor low error system
Part 2
Abnormally high level in
Electrical SEN01679-00
CA144 coolant temperature — ENG E01
system
sensor
Abnormally low level in
Electrical
CA145 coolant temperature — ENG E01
system
sensor
Electrical
CA153 charge temperature — ENG E01
system
sensor
Electrical
CA154 charge temperature — ENG E01
system
sensor
Sensor power supply 2 Electrical
CA187 — ENG E03
voltage low error system
Ambient pressure Electrical
CA221 — ENG E01
Ambient pressure Electrical
CA222 — ENG E01
CA227 — ENG E03
voltage high error system
Mechanical
CA234 Engine overspeed — ENG E02
system
Ne speed sensor supply Electrical
CA238 — ENG E03
power voltage error system
WA450-6, WA480-6 (KA SPEC.) 3


Fuel temperature Electrical
CA263 — ENG E01
Fuel temperature Electrical
CA265 — ENG E01
Electrical
CA271 Short circuit in PCV1 — ENG E03
system
Electrical
CA272 Disconnection in PCV1 — ENG E03
system
Electrical
CA273 PCV2 short circuit — ENG E03
system
Electrical
CA274 PCV2 disconnection — ENG E03
system
Disconnection or short
Electrical
CA322 circuit in injector #1 — ENG E03
system
(L/B #1) system
Electrical
system
(L/B #5) system
Electrical
system
(L/B #3) system
Electrical
system
(L/B #6) system
Disconnection or short Troubleshooting
Electrical
CA331 circuit in injector #2 — ENG E03 by failure code,
system
(L/B #2) system Part 3
Disconnection or short SEN01680-00
Electrical
system
(L/B #4) system
Engine control data Electrical
CA342 — ENG E03
incompatibility system
Injectors drive circuit Electrical
CA351 — ENG E03
error system
CA352 — ENG E03
voltage low error system
CA386 — ENG E03
voltage high error system
Abnormality in idle Electrical
CA431 — ENG E01
validation switch system
Abnormality in
Electrical
CA432 processing of idle — ENG E03
system
validation
Abnormally low power Electrical
CA441 — ENG E03
supply voltage system
Abnormally high power Electrical
CA442 — ENG E03
supply voltage system
Abnormally high Electrical
CA449 — ENG E03
common rail pressure 2 system
Electrical
CA451 common rail pressure — ENG E03
system
sensor
4 WA450-6, WA480-6 (KA SPEC.)


Electrical
CA452 common rail pressure — ENG E03
system
sensor
Abnormally high Electrical
CA553 — ENG E03
common rail pressure 1 system
Supply pump pressure Electrical
CA559 — ENG E03
very low error 1 system
CA689 — ENG E03
Ne speed sensor system
Intake air temperature Electrical
CA691 — ENG E01
Intake air temperature Electrical
CA692 — ENG E01
Abnormality in engine
Electrical Troubleshooting
CA731 Bkup speed sensor — ENG E03
system by failure code,
phase
Part 3
Loss of all data in Electrical SEN01680-00
CA757 — ENG E03
engine controller system
CA778 — ENG E03
Bkup speed sensor system
Electrical
CA1228 EGR valve servo error 1 — ENG E03
system
Electrical
CA1625 EGR valve servo error 2 — ENG E03
system
Abnormality in Electrical
CA1633 — ENG E03
KOMNET system
Throttle sensor power
Electrical
CA2185 supply voltage high — ENG E03
system
error
Throttle sensor power Electrical
CA2186 — ENG E03
supply voltage low error system
Supply pump pressure Electrical
CA2249 — ENG E03
very low error 2 system
EGR valve lift sensor Electrical
CA2271 — ENG E03
high error system
EGR valve lift sensor Electrical
CA2272 — ENG E03
low error system Troubleshooting
EGR valve solenoid by failure code,
Electrical Part 4
CA2351 operation short circuit — ENG E03
system SEN01681-00
error
EGR valve solenoid
Electrical
CA2352 operation disconnection — ENG E03
system
error
Disconnection in intake Electrical
CA2555 — ENG E01
air heater relay system
WA450-6, WA480-6 (KA SPEC.) 5


Short circuit in intake air Electrical
CA2556 — ENG E01
heater relay system
Emergency steering Electrical
D150KA Disconnection TM E03
relay system
D150KB Short-circuit TM E03
relay system
D150KY Power supply line short TM E03
relay system
Electrical
D160KA Backup lamp relay Disconnection TM E01
system
Disconnection or short cir- Electrical
D160KB Backup lamp relay TM E01
cuit system
Electrical
D160KZ Backup lamp relay Short-circuit TM E01
system
Joystick steering neural Electrical
D191KA Disconnection TM E01
safety relay system
D191KB Short-circuit TM E01
safety relay system
D191KY Power supply line short TM E01
safety relay system
Electrical
D192KA ECSS solenoid Disconnection TM E01
system
Electrical
D192KB ECSS solenoid Short-circuit TM E01
Electrical by failure code,
D192KY ECSS solenoid Power supply line short TM E01 Part 4
system
SEN01681-00
Joystick steering Electrical
D193KA Disconnection WRK E03
solenoid cut-off relay system
D193KB Short-circuit WRK E03
D193KY Power supply line short WRK E03
Electrical
D5ZHKA Terminal C signal Disconnection TM E01
system
Electrical
D5ZHKB Terminal C signal Short-circuit TM E01
system
Disconnection or short cir- Electrical
D5ZHKZ Terminal C signal WRK E01
cuit system
Signal does not match
Electrical
D5ZHL6 Terminal C signal engine running or stopped MON E01
system
state
Electrical
DA80L4 Auto grease controller ON/OFF signals disagree MON —
system
Hydraulic oil Electrical
DAF3KK Low source voltage (input) MON E03
temperature system
DAF5KP Low output voltage MON E01
temperature system
Defective communication
CAN communication Electrical
DAFRKR (Abnormality in target com- TM E03
with machine monitor system
ponent system)
6 WA450-6, WA480-6 (KA SPEC.)


Electrical
DAQ0KK Transmission controller Low source voltage TM E03
system
Electrical
DAQ0KT Transmission controller Abnormality in controller TM E01
system
Transmission controller Electrical
DAQ2KK Low source voltage (input) TM E03
load power supply line system
Transmission controller Disagreement of model Electrical
DAQ9KQ MON E03
model selection selection signals system
CAN communication Defective communication
Electrical
DAQRKR with transmission (Abnormality in target com- MON E03
system
controller ponent system)
Transmission controller Electrical
DAQRMA Malfunction MON E03
option setting system
Defective communication
CAN communication Electrical
DB2RKR (Abnormality in target com- MON E03
with engine controller system
ponent system)
Work equipment Electrical
DB90KK Low source voltage (input) WRK E03
controller system
DB90KT Abnormality in controller WRK E01
controller system
Work equipment
Electrical
DB92KK controller load power Low source voltage (input) WRK E03
system
supply line
Work equipment
Electrical
DB95KX controller power supply Out of input signal range WRK E03
output
by failure code,
Work equipment Part 5
Disagreement of model Electrical
DB99KQ controller model MON E03 SEN01682-00
selection signals system
selection
CAN communication Defective communication
Electrical
DB9RKR with work equipment (Abnormality in target com- TM E03
system
controller ponent system)
DB9RMA Malfunction MON E03
controller option setting system
CAN communication
Electrical
DB9RMC with work equipment Defective operation WRK E03
system
controller
Switch is kept pressed for Electrical
DD15LD t switch (Panel switch 1) MON E01
long time system
DD16LD U switch (Panel switch 2) MON E01
long time system
DD17LD < switch (Panel switch 3) MON E01
long time system
DD18LD > switch (Panel switch 4) MON E01
long time system
Remote positioner
DD1ALD raise/lower set switch WRK E01
long time system
(RAISE)
Remote positioner
DD1BLD raise/lower set switch WRK E01
long time system
(LOWER)
Load meter subtotal Switch is kept pressed for Electrical
DD1CLD MON E01
switch long time system
WA450-6, WA480-6 (KA SPEC.) 7


Load meter mode
DD1FLD selector switch MON E01
long time system
(A/B)
Load meter mode
DD1GLD selector switch MON E01
long time system
(+/–)
Load meter display Switch is kept pressed for Electrical Troubleshooting
DD1HLD MON E01
selector switch long time system by failure code,
Switch is kept pressed for Electrical Part 5
DD1NLD Fan reverse switch TM E01
long time system SEN01682-00
Fan automatic reverse Switch is kept pressed for Electrical
DD1NL4 TM E01
Parking brake switch Electrical
DDB6L4 ON/OFF signals disagree TM E03
(Neutralizer) system
Remote positioner Switch is kept pressed for Electrical
DDD1LD WRK E01
bucket angle set switch long time system
DDE5MA Malfunction MON E01
drive switch system
Electrical
DDK3KA Right FNR switch Disconnection TM E03
system
Joystick steering FNR Electrical
DDK4KA Disconnection TM E03
switch system
Joystick steering shift- Electrical
DDK5L4 ON/OFF signals disagree TM E01
up and down switch system
Electrical
DDK6KA FNR lever switch Disconnection TM E03
system
Electrical
DDK6KB FNR lever switch Short-circuit TM E03
system
Steering pressure Electrical
DDS5KA Disconnection TM E01
switch system
Steering pressure Electrical
DDS5KB Short-circuit TM E01
switch system
Shift mode selector Electrical Troubleshooting
DDT0L4 ON/OFF signals disagree TM E01
switch system by failure code,
Transmission cut-off set Switch is kept pressed for Electrical Part 6
DDT4LD TM E01 SEN01683-00
DDW9LD Kickdown switch TM E01
long time system
DDWLLD Hold switch TM E01
long time system
Load meter cancel Switch is kept pressed for Electrical
DDY0LD MON E01
Transmission shift lever Electrical
DF10KA Disconnection TM E01
switch system
Transmission shift lever Electrical
DF10KB Short-circuit TM E01
switch system
Transmission oil Electrical
DGF1KA Disconnection TM E01
temperature sensor system
Transmission oil Electrical
DGF1KB Short-circuit TM E01
DGH2KX Out of input signal range MON E01
8 WA450-6, WA480-6 (KA SPEC.)


Rear brake oil Electrical
DGR2KA Disconnection MON E01
temperature sensor system Troubleshooting
Rear brake oil Electrical by failure code,
DGR2KX Out of input signal range MON E01
temperature sensor system Part 6
Torque converter oil Electrical SEN01683-00
DGT1KX Out of input signal range MON E01
Lift arm cylinder bottom Electrical
DHPCKX Out of input signal range MON E01
pressure sensor system
Lift arm cylinder head Electrical
DHPDKX Out of input signal range MON E01
pressure sensor system
Left brake pressure Electrical
DHT1KX Out of input signal range TM E01
sensor system
Steering pump pressure Electrical
DHT8KA Disconnection TM E01
sensor system
Steering pump pressure Electrical
DHT8KB Short-circuit TM E01
sensor system
Lift arm EPC lever Electrical
DK59KA Disconnection WRK E03
potentiometer (Main) system
DK59KY Power supply line short WRK E03
DK59L8 Analog signals disagree WRK E03
DK5AKA Disconnection WRK E03
potentiometer (Sub) system
DK5AKY Power supply line short WRK E03
Bucket EPC lever Electrical Troubleshooting
DK5BKA Disconnection WRK E03
potentiometer (Main) system by failure code,
Bucket EPC lever Electrical Part 7
DK5BKY Power supply line short WRK E03
potentiometer (Main) system SEN01684-00
Bucket EPC lever Electrical
DK5BL8 Analog signals disagree WRK E03
DK5CKA Disconnection WRK E03
DK5CKY Power supply line short WRK E03
3-spool valve
Electrical
DK5DKA (attachment) EPC lever Disconnection WRK E03
system
potentiometer (Main)
3-spool valve
Electrical
DK5DKY (attachment) EPC lever Power supply line short WRK E03
system
3-spool valve
Electrical
DK5DL8 (attachment) EPC lever Analog signals disagree WRK E03
system
3-spool valve
Electrical
DK5EKA (attachment) EPC lever Disconnection WRK E03
system
potentiometer (Sub)
3-spool valve
Electrical
DK5EKY (attachment) EPC lever Power supply line short WRK E03
system
potentiometer (Sub)
WA450-6, WA480-6 (KA SPEC.) 9


Joystick steering EPC
Electrical
DK5FKA lever potentiometer Disconnection WRK E03
system
(Main)
Electrical
DK5FKY lever potentiometer Power supply line short WRK E03
system
(Main)
Electrical
DK5GKA lever potentiometer Disconnection WRK E03
system
(Sub)
Electrical
DK5GKY lever potentiometer Power supply line short WRK E03
system
(Sub)
Electrical
DK5FL8 lever potentiometer Analog signals disagree WRK E03
system
(Main and sub)
Electrical
DKA0KA Lift arm angle sensor Disconnection WRK E01
system
Electrical
DKA0KY Lift arm angle sensor Power supply line short WRK E01
system
Electrical
DKA0L0 Lift arm angle sensor Double meshing WRK E01
system
Transmission output Electrical
DLT3KA Short-circuit TM E03
shaft speed sensor system
Transmission output Electrical
DLT3LC Out of input signal range TM E03
shaft speed sensor system Troubleshooting
Transmission cut-off Electrical by failure code,
DT20KB Short-circuit TM E01 Part 8
indicator lamp system
SEN01685-00
Remote positioner raise
DUM1KB Short-circuit WRK — —
set indicator lamp
Remote positioner
DUM2KB Short-circuit WRK — —
lower set indicator lamp
Electrical
DV00KB Warning buzzer Short-circuit MON E01
system
Lift arm raise EPC Electrical
DW4PKA Disconnection WRK E03
solenoid system
DW4PKB Short-circuit WRK E03
solenoid system
DW4PKY Power supply line short WRK E03
solenoid system
Lift arm lower EPC Electrical
DW4QKA Disconnection WRK E03
solenoid system
DW4QKB Short-circuit WRK E03
solenoid system
DW4QKY Power supply line short WRK E03
solenoid system
Electrical
DW4RKA Bucket tilt EPC solenoid Disconnection WRK E03
system
Electrical
DW4RKB Bucket tilt EPC solenoid Short-circuit WRK E03
system
Electrical
DW4RKY Bucket tilt EPC solenoid Power supply line short WRK E03
system
10 WA450-6, WA480-6 (KA SPEC.)


Bucket dump EPC Electrical
DW4SKA Disconnection WRK E03
solenoid system
DW4SKB Short-circuit WRK E03
solenoid system
DW4SKY Power supply line short WRK E03
solenoid system
Electrical
DW7BKA Fan reverse solenoid Disconnection TM E01
system
Electrical
DW7BKB Fan reverse solenoid Short-circuit TM E01
system
Electrical
DW7BKY Fan reverse solenoid Power supply line short TM E01
system
Hydraulic drive fan Electrical
DW7DKA Disconnection TM E01
neutral solenoid system
DW7DKB Short-circuit TM E01
DW7DKY Power supply line short TM E01
Work equipment neutral Electrical
DWM1KA Disconnection WRK E01
lock solenoid system
DWM1KB Short-circuit WRK E01
lock solenoid system
DWM1KY Power supply line short WRK E01
lock solenoid system Troubleshooting
Lift arm raise magnet Electrical by failure code,
DWN6KA Disconnection WRK E01
detent solenoid system Part 9
Lift arm raise magnet Electrical SEN01686-00
DWN6KB Short-circuit WRK E01
detent solenoid system
Lift arm raise magnet Electrical
DWN6KY Power supply line short WRK E01
Lift arm float magnet Electrical
Bucket tilt magnet Electrical
Electrical
DX16KA Fan pump EPC Disconnection TM E01
system
Electrical
DX16KB Fan pump EPC Short-circuit TM E01
system
Electrical
DX16KY Fan pump EPC Power supply line short TM E01
system
Electrical
DXH1KA Lockup ECMV solenoid Disconnection TM E01
system
WA450-6, WA480-6 (KA SPEC.) 11


Electrical
DXH1KB Lockup ECMV solenoid Short-circuit TM E01
system
Electrical
DXH1KY Lockup ECMV solenoid Power supply line short TM E03
1st clutch ECMV Electrical by failure code,
DXH4KA Disconnection TM E03
solenoid system Part 9
1st clutch ECMV Electrical SEN01686-00
DXH4KB Short-circuit TM E03
solenoid system
1st clutch ECMV Electrical
DXH4KY Power supply line short TM E03
solenoid system
2nd clutch ECMV Electrical
solenoid system
solenoid system
solenoid system
3rd clutch ECMV Electrical
solenoid system
solenoid system
solenoid system
R clutch ECMV Electrical
solenoid system
solenoid system
solenoid system
Electrical Troubleshooting
DXH8KA F clutch ECMV solenoid Disconnection TM E03
system by failure code,
Electrical Part 10
DXH8KB F clutch ECMV solenoid Short-circuit TM E03 SEN01687-00
system
Electrical
DXH8KY F clutch ECMV solenoid Power supply line short TM E03
system
4th clutch ECMV Electrical
DXHHKA Disconnection TM E03
solenoid system
DXHHKB Short-circuit TM E03
solenoid system
DXHHKY Power supply line short TM E03
solenoid system
3-spool valve extract Electrical
DXHJKA Disconnection WRK E03
EPC solenoid system
DXHJKB Short-circuit WRK E03
EPC solenoid system
DXHJKY Power supply line short WRK E03
EPC solenoid system
3-spool valve retract Electrical
DXHKKA Disconnection WRK E03
EPC solenoid system
DXHKKB Short-circuit WRK E03
EPC solenoid system
12 WA450-6, WA480-6 (KA SPEC.)


DXHKKY Power supply line short WRK E03
EPC solenoid system
Joystick steering right Electrical
DXHLKA Disconnection WRK E03
EPC solenoid system
DXHLKB Short-circuit WRK E03
EPC solenoid system
DXHLKY Power supply line short WRK E03
EPC solenoid system Troubleshooting
Joystick steering left Electrical by failure code,
DXHMKA Disconnection WRK E03
EPC solenoid system Part 10
Joystick steering left Electrical SEN01687-00
DXHMKB Short-circuit WRK E03
EPC solenoid system
Joystick steering left Electrical
DXHMKY Power supply line short WRK E03
EPC solenoid system
Electrical emergency Electrical
DY30MA Malfunction TM E01
steering pump system
Electrical emergency Electrical
DY30MC Defective operation TM E03
steering pump system
a Those failure codes to which the corresponding number is not indicated in the action code space are not
displayed on the ordinary screen if a failure is found. They are just recorded in the abnormality record
(electrical system and mechanical system) of the service menu.
a The category of record is used for indicating to which of the electrical and mechanical system of the ser-
vice menu's abnormality record a given failure is classified.
WA450-6, WA480-6 (KA SPEC.) 13

Fuse locations 1
Connection table of fuse box and slow blow fuse
a This connection table indicates the devices to which the power of the fuse box and slow blow fuse is
supplied. (A switch power supply is a device which supplies power while the starting switch is in the ON
position and a constant power supply is a device which supplies power while the starting switch is in the
OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and
slow blow fuse to see if the power is supplied normally.
Fuse box A
Capacity of
Type of power supply Fuse No. Destination of power
fuse
1 10 A Horn circuit
2 10 A Transmission controller (A) circuit
3 5A Parking brake circuit
4 5A Emergency steering circuit
Work equipment positioner circuit
5 10 A
Constant power sup- Work equipment controller (A) circuit (if equipped)
ply slow-blow fuse 6 10 A Rear lamp and brake lamp circuit
(50 A) 7 20 A Wiper and washer circuit
8 20 A Air conditioner (A) circuit
9 5A Air conditioner (B) circuit
Machine monitor (B) circuit
10 10 A
Load meter printer (if equipped) circuit
11 20 A Main lamp circuit
Switch power supply 12 10 A Clearance lamp (right) circuit
lamp switch 13 10 A Clearance lamp (left) circuit
Switch power supply 14 10 A Headlamp (right) circuit
head lamp relay 15 10 A Headlamp (left) circuit
14 WA450-6, WA480-6 (KA SPEC.)

Fuse box B
Capacity of
Type of power supply Fuse No. Destination of power
fuse
1 20 A Starting switch terminal B circuit
2 10 A Hazard lamp circuit
3 10 A
Constant power KOMTRAX circuit
supply slow-blow 4 10 A Room lamp circuit
fuse (50 A) Transmission controller (B) circuit
5 5A
Work equipment controller (B) circuit (if equipped)
6 30 A Engine controller (A) circuit
7 10 A Spare 1
8 10 A Front working lamp circuit
9 10 A Rear working lamp circuit
10 20 A Car radio circuit and 12 V converter circuit
Switch power supply
11 10 A Turn signal lamp circuit
slow-blow fuse (50 A)
12 20 A Yellow rotary lamp circuit (if equipped)
13 10 A KOMTRAX (A) circuit (if equipped)
14 20 A Rear glass heater circuit
Switch power supply
15 5A Engine controller (B) circuit
starting switch ACC
Slow blow fuse

Slow-blow Capacity of
Type of power supply Destination of power
fuse No. fuse
Spare 1, engine controller (A) circuit, transmission controller (B)
circuit, work equipment controller (B) circuit (if equipped), room
Constant power
1 50 A lamp circuit, machine monitor (B) circuit, KOMTRAX (B) circuit (if
supply
equipped), hazard lamp circuit and starting switch (B) terminal
circuit
Main lamp circuit, machine monitor (A) circuit, load meter printer
(if equipped) circuit, air conditioner (B) circuit, air conditioner (A)
circuit, wiper and washer circuit, back-up lamp and brake lamp
2 50 A circuit, work equipment positioner circuit, work equipment con-
troller (A) circuit (if equipped), emergency steering circuit (if
equipped), parking brake circuit, transmission controller (A) cir-
Switch power supply cuit and horn circuit
Rear glass heater circuit, KOMTRAX (A) circuit (if equipped), yel-
low rotary lamp circuit (if equipped), turn signal lamp circuit, car
3 50 A radio circuit, cigar lighter circuit, 12 V converter circuit, air sus-
pension seat (if equipped) circuit, rear working lamp circuit and
front working lamp circuit
4 120 A Heater relay circuit
WA450-6, WA480-6 (KA SPEC.) 15

Locations and numbers of fuse boxes and slow blow fuse
16 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 17

SEN01676-00

18
SEN01677-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points to remember when troubleshooting........................................................................................... 2
Sequence of events in troubleshooting ................................................................................................ 3
Testing before troubleshooting ............................................................................................................. 4
Classification and procedures of troubleshooting ................................................................................ 5
Information contained in troubleshooting table..................................................................................... 8
Connection table for connector pin numbers ..................................................................................... 10
T-branch box and T-branch adapter table .......................................................................................... 33
WA450-6, WA480-6 (KA SPEC.) 1

General information on troubleshooting 1

Points to remember when troubleshooting 1
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to
carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro-
cedure.
2. Points to ask 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 this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Are abnormal symptoms detected in the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a
problem of handling, operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part
exactly.
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
Even if the immediate failure is repaired, the same failure may occur again, unless the root cause
of the failure is repaired. To prevent this, always investigate why the cause of the failure
occurred. Then, remove the root cause.
2 WA450-6, WA480-6 (KA SPEC.)

Sequence of events in troubleshooting 1
WA450-6, WA480-6 (KA SPEC.) 3

Testing before troubleshooting 1
Item Criteria Remedy
1. Check of level and type of fuel — Add fuel
2. Check for foreign matter in fuel

— Clean or drain
Check fuel filter and fuel pre-filter for clogging
3. Check of level and type of oil in engine oil pan Between H and L Add oil
Lubricating oil and coolant
Between FULL and

4. Check of coolant level Add coolant
LOW
5. Check of air cleaner for clogging No red Clean or replace
6. Check of level and type of hydraulic oil Between H and L Add oil
7. Check of level and type of transmission oil Between H and L Add oil
8. Check of engine oil filter for clogging — Replace
9. Check of hydraulic oil filter for clogging — Replace
10. Check of transmission oil filter for clogging — Replace
Retighten or
11. Check of battery terminal cables for looseness and corrosion —
replace
Electrical parts
12. Check of alternator terminal cables for looseness and Retighten or

—
corrosion replace
13. Check of starting motor terminal cables for looseness and Retighten or
—
corrosion replace
14. Check of operation of instruments — Repair or replace

mechanical equipment
15. Check for abnormal noise and smell — Repair

Hydraulic and
16. Check for oil leakage — Repair
17. Bleeding air — Bleed air
18. Check of effect of brake — Repair or adjust
19. Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace
20. Check of battery electrolyte level Between U.L and L.L Add or replace
21. Check wires for discoloration, burn, and removal of cover — Replace
Electrical equipment
22. Check for removed wire clamp and drooping wire — Repair
23. Check wiring for wetting with water (Check connectors and Disconnect and dry
—
terminals for wetting with water, in particular) connectors
24. Check of slow-blow fuses and fuses for disconnection and
— Replace
corrosion
25. Check of alternator voltage (with engine at medium speed or After several-minute
Repair or replace
higher) operation: 27.5 – 29.5 V
26. Check of operating sound of battery relay (Starting switch
— Replace
OFF o ON)
4 WA450-6, WA480-6 (KA SPEC.)

Classification and procedures of troubleshooting 1

Classification of troubleshooting
Mode Contents
Display of
Troubleshooting by failure code (Display of code)
code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, display the failure code in the failure code display
mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
Carry out troubleshooting in [Display of failure code] according to the displayed failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
2. Procedure for troubleshooting to be taken when failure code is recorded:

If an action code is not displayed on the machine monitor, check for a failure code in the failure code dis-
play mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
If a failure code is recorded, carry out troubleshooting in [Display of code] according to that failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is
not recorded:
If a failure code is not recorded in the machine monitor (EMMS), a trouble 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 looking like a trouble again and select the same phenomenon from
the table of “Phenomena looking like troubles and troubleshooting Nos.”, and then carry out trouble-
shooting related to that phenomenon in the “E-mode”, “H-mode”, or “S-mode”.
WA450-6, WA480-6 (KA SPEC.) 5

Phenomena looking like troubles and troubleshooting Nos.
Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
Phenomena related to action codes and failure codes
1 Action codes are displayed on machine monitor Check failure code
2 If failure code display function is checked, failure codes are displayed q
Phenomena related to engine
3 Engine does not start easily E-1 S-1
4 Engine does not turn E-1 S-2 a)
5 Engine turns but no exhaust smoke comes out S-2 b)
Engine does not start
Exhaust smoke comes out but engine does not
6 S-2 c)
start (Fuel is injected)
7 Engine does not pick up smoothly S-3
8 Engine stops during operation H-2 S-4
9 Engine does not rotate smoothly S-5
10 Engine lacks output (or lacks power) S-6
11 Exhaust smoke is black (Incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Oil becomes contaminated quickly S-9
14 Fuel consumption is excessive S-10
15 Coolant contains oil (blows back or reduces) S-11
16 Oil pressure drops S-12
17 Oil level rises (Water or fuel is mixed in oil) S-13
18 Coolant temperature is too high (Overheating) S-14
19 Abnormal noise is made S-15
20 Vibration is excessive S-16
Phenomena related to power train
21 Machine does not start H-1
Torque converter lockup is not switched (engine stalls)
22 H-2
[Lockup clutch specification (If equipped)]
Torque converter lockup is not turned on
23 H-3
[Lockup clutch specification (If equipped)]
Travel speed is slow, the thrusting force is weak, the uphill traveling
24 H-4
power is weak, and the gear is not shifted
25 Large shocks are made when machine starts and gear is shifted H-5
26 Large time lag is made when machine starts and gear is shifted H-6
27 Torque converter oil temperature is high H-7
Phenomena related to steering
28 Steering does not turn H-8
29 Steering does not turn [Joystick steering specification (If equipped)] H-9
30 Steering response is low H-10
31 Steering response is low [Joystick steering specification (If equipped)] H-11
32 Steering is heavy H-12
33 Steering wheel shakes or makes large shocks H-13
Steering wheel shakes or makes large shocks [Joystick steering
34 H-14
specification (If equipped)]
6 WA450-6, WA480-6 (KA SPEC.)

Phenomena related to brake

35 Wheel brake does not work or braking force is low H-15
36 Wheel brake is not reset or drags H-16
37 Parking brake does not work or braking force is low H-17
Parking brake does not reset or drags (including emergency release
38 H-18
system)
Phenomena related to work equipment
39 Lift arm does not rise H-19
40 Lift arm speed is low or rising force of lift arm is insufficient H-20
41 When lift arm rises, its speed lowers at specific height H-21
42 Bucket cannot be held with lift arm cylinder (Bucket floats) H-22
43 Hydraulic drift of lift arm is large H-23
44 Lift arm shakes during operation H-24
45 Bucket does not tilt-back H-25
46 Bucket speed is low or tilt-back force is insufficient H-26
47 Bucket speed lowers during tilt-back operation H-27
48 Bucket cannot be held with bucket cylinder H-28
49 Hydraulic drift of bucket is large H-29
Bucket shakes while machine is traveling with load (Work equipment
50 H-30
valve is in HOLD)
Lift arm and bucket control levers do not move smoothly and are
51 H-31
heavy
Engine speed lowers remarkably or engine stalls during work equip-
52 H-32
ment control
53 Large shock is made when work equipment starts and stops H-33
When work equipment is relieved singly, other work equipment
54 H-34
moves
55 ECSS does not operate, and pitching or bouncing occurs H-35
Others
56 Wiper does not operate E-2
57 Windshield washer does not operate. E-3
Headlamp, clearance lamp, tail lamp, and license lamp do not light up
58 E-4
or go off
59 Working lamp does not light up or go off E-5
60 Turn signal lamp and hazard lamp do not light up or go off E-6
61 Brake lamp does not light or it keeps lighting up E-7
62 Backup lamp does not light or it keeps lighting up E-8
63 Backup buzzer does not sound or it keeps sounding E-9
64 Horn does not sound or it keeps sounding E-10
65 Alarm buzzer does not sound or it keeps sounding E-11
66 Air conditioner does not operate or stop E-12
67 KOMTRAX system does not operate normally E-13
WA450-6, WA480-6 (KA SPEC.) 7

Information contained in troubleshooting table 1

Action code Failure code
Monitor Trouble Problem that appears on machine
Monitor display
display
Contents of
State where the monitor panel or controller detects the trouble
trouble
Action of Action taken by machine monitor or controller to protect system or devices when engine con-
controller troller detects trouble
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related
Information related to detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting
<Described contents>
• Standard value in normal state to judge assumed cause
(good or not)
1 • Remarks required to judge whether the cause is good
<Phenomenon of defective wiring harness>

• Disconnection in wiring
The connector connection is defective or the wiring harness
is disconnected.
• Grounding fault
A harness not connected to ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes
into contact with the power (24 V) circuit.
• Short circuit
Possible causes Possible causes of trouble A harnesses of an independent circuit abnormally comes
and standard is assumed to be detected into contact with one of another circuit.
value in normal (The order number indicates
state a serial number, not a priority <Notes on troubleshooting>
sequence.) (1) Method of indicating connector number and handling T-
branch
For troubleshooting, insert or connect T-branch adapter
3 as shown below unless especially specified.
• When “male” or “female” is not indicated for a con-
nector number, disconnect the connector, and insert
the T-branch adapter in both the male and female.
• When “male” and “female” is indicated for a connec-
tor number, disconnect the connector, and insert the
T-branch adapter in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
leads as shown below unless especially specified.
2 • Connect the plus (+) lead to a pin or harness indi-
cated in the front.
• Connect the minus (–) lead to a pin or harness indi-
cated in the rear.
8 WA450-6, WA480-6 (KA SPEC.)

Related circuit diagram
This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model – No. of pins) (Color)
• "Connector No. and pin No." from each branching/
merging point: Shows the ends of branch or source of
merging within the parts of the same wiring harness.
• Arrow (io): Roughly shows the location on the
machine.
WA450-6, WA480-6 (KA SPEC.) 9

Connection table for connector pin numbers 1

a The terms male and female refer to the pins, while the terms male housing and female housing refer to
the mating portion of the housing.
10 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 11

12 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 13

14 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 15

16 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 17

18 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 19

20 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 21

22 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 23

24 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 25

26 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 27

28 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 29

30 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 31

32 WA450-6, WA480-6 (KA SPEC.)

T-branch box and T-branch adapter table 1

a The vertical column shows part number of T-branch box or T-branch, and horizontal column shows part
number of T-branch.
T-branch adapter kit
No. of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Others
Connector type or
Part No. ID symbol
part name
799-601-2600 T-branch box (For ECONO) 21 q q q q q q

799-601-3100 T-branch box (For MS) 37 q
799-601-3200 T-branch box (For MS) 37 q
799-601-3300 T-branch box (For ECONO) 24 q
799-601-3360 · Plate for MS (24 pins) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Additional cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4210 Adapter for DRC 50 DRC50 q
799-601-7010 Adapter for X (T-branch) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
WA450-6, WA480-6 (KA SPEC.) 33

No. of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Others
Connector type or
Part No. ID symbol
part name
799-601-7070 Adapter for SWP 14 SW14P q q

799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-branch) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (white) 10 S10P q q q q
799-601-7160 Adapter for S (blue) 12 S12P q q q
799-601-7170 Adapter for S (blue) 16 S16P q q q q
799-601-7330 Adapter for S (white) 16 S16PW q
799-601-7350 Adapter for S (white) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q
799-601-9060 Adapter for DT (gray) 8 DT8GR q q
799-601-9070 Adapter for DT (black) 8 DT8B q q
799-601-9080 Adapter for DT (green) 8 DT8G q q
799-601-9090 Adapter for DT (brown) 8 DT8BR q q
799-601-9110 Adapter for DT (gray) 12 DT12GR q q
799-601-9120 Adapter for DT (black) 12 DT12B q q
799-601-9130 Adapter for DT (green) 12 DT12G q q
799-601-9140 Adapter for DT 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
34 WA450-6, WA480-6 (KA SPEC.)

No. of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Others
Connector type or
Part No. ID symbol
part name

799-601-9310 Plate for HD30 (24 pins) q q q
799-601-9320 T-branch box (For DT HD) 12 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410 Adapter for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 3 A3 q
799-601-9430 2 P q
799-601-9440 Adapter for engine (CRI-T2) 3 1,2,3 q
795-799-5520 Adapter for engine (HPI-T2) 2 S q
Adapter for engine (HPI-T2)
795-799-5530 2 C q
Adapter for engine (HPI-T2)
795-799-5540 2 A q
795-799-5460 Cable for engine (HPI-T2) 3 q
799-601-4160 Adapter for engine (CRI-T3) 2 OIL q
799-601-4130 Adapter for engine (CRI-T3) 3 FCIN q
799-601-4140 Adapter for engine (CRI-T3) 3 FCIG q
799-601-4150 Adapter for engine (CRI-T3) 3 FCIB q
799-601-4180 Adapter for engine (CRI-T3) 3 FCIP3 q
799-601-4230 Adapter for engine (CRI-T3) 4 1,2,3,4 q
799-601-4260 Adapter for controller (ENG) 4 DTP4 q
799-601-4210 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4280 Box for controller (PUMP) 121 q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9370 Adapter for controller (HST) 26 HST26A q
WA450-6, WA480-6 (KA SPEC.) 35

SEN01677-00

36
SEN01678-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
Troubleshooting by failure code
(Display of code), Part 1
Troubleshooting by failure code (Display of code), Part 1 .............................................................................. 3
Failure code [1500L0] (TORQFLOW transmission: Double meshing) ................................................. 3
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)................. 4
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)................ 6
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) ................ 8
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) ............. 10
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) ............ 12
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) ........... 14
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) ........... 16
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) .......... 18
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) ........... 20
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) .......... 22
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)............ 24
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)........... 26
WA450-6, WA480-6 (KA SPEC.) 1

Failure code [2F00MA] (Parking brake: Malfunction) ......................................................................... 28

Failure code [2G43ZG] (Accumulator: Low oil pressure) ................................................................... 30
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)............................................... 32
2 WA450-6, WA480-6 (KA SPEC.)

Troubleshooting by failure code (Display of code), Part 1 1

Failure code [1500L0] (TORQFLOW transmission: Double meshing) 1
Action code Failure code TORQFLOW transmission: Double meshing
Trouble
E03 1500L0 (Transmission controller)
Contents of
• A combination for double meshing is input as a fill signal.
trouble
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The transmission may be broken.
appears on
• The machine does not travel.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 See failure codes [15SAL1], [15SBL1], [15SEL1], [15SFL1], [15SGL1], and [15SHL1].
state
WA450-6, WA480-6 (KA SPEC.) 3

Failure code [15SAL1] (ECMV F clutch: When command current is OFF,

fill signal is ON) 1
Action code Failure code ECMV F clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SAL1 (Transmission controller)
Contents of • When F ECMV solenoid output is turned OFF, F ECMV fill switch signal ON is input, and clutch is not
trouble released.
• Judges that the F ECMV fill switch signal is turned ON.
controller • Even if cause of failure disappears, system does not reset itself until FNR (directional) lever, joystick
steering FNR (directional) switch or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • F travel is enabled, but R travel is disabled.
machine
• The output state (current value) to the F clutch ECMV solenoid can be checked with the monitoring
function (Code: 31608, ECMV F DIR).
Related
• The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-24).
• Method of reproducing failure code: Start engine
Causes Standard value in normal state/Remarks on troubleshooting

When there is no residual pressure other than the F clutch oil pres-
1 F clutch oil pressure error sure, the failure code is displayed. (See Troubleshooting of hydrau-
lic and mechanical system (H-mode)
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cut-off switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
FNR (directional)
Defective F ECMV fill switch lever, joystick steer-
2
(Internal short circuit) ing
F.SW (male) Resistance
FNR (directional)
switch or right FNR
(directional) switch
Between (1) and F (Forward) Max. 1 z
Possible causes
and standard chassis ground Other than above Min. 1 Mz
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Grounding fault in wiring har- without turning starting switch ON.
3 ness
(Contact with ground circuit) Wiring harness between L62 (female) (37) – Resis- Min.
F.SW (female) (1) and chassis ground tance 1 Mz
troubleshooting.
FNR (directional)
Defective transmission con- lever, joystick steer-
4
troller ing
L62 Voltage
FNR (directional)
switch or right FNR
Between (37) and F (Forward) Max. 1 V
chassis ground Other than above 8 – 10 V
4 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission F clutch
WA450-6, WA480-6 (KA SPEC.) 5

Failure code [15SALH] (ECMV F clutch: When command current is ON,

fill signal is OFF) 1
Action code Failure code ECMV F clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SALH (Transmission controller)
Contents of
• When F ECMV solenoid output is turned ON, F ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the F ECMV fill switch signal is turned OFF.
controller • If problem is removed, system is returned to normal operating state.
Problem that
appears on • When the travel direction is changed, a shock or a time lag may be made.
machine
• This failure code may also be displayed immensely after replacement of the transmission oil.
• The output state (current value) to the F clutch ECMV solenoid can be checked with the monitoring
function (Code: 31608, ECMV F DIR).
Related
• The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-24).
• Method of reproducing failure code: Start engine and then set FNR (directional) lever, joystick steer-
ing FNR (directional) switch, or right FNR (directional) switch to F (forward).

This failure code is displayed if there was no F clutch oil pressure
1 F clutch oil pressure error when F ECMV solenoid output is turned ON. (See Troubleshooting
of hydraulic and mechanical system (H-mode)
troubleshooting.
FNR (directional)
Defective F ECMV fill switch lever, joystick steer-
2
(Internal disconnection) ing
F.SW (male) Resistance
FNR (directional)
switch or right FNR
Between (1) and F (Forward) Max. 1 z
Possible causes
value in normal Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
state ness without turning starting switch ON.
3
(Disconnection or defective Wiring harnesses between L62 (female) (37) Resis-
contact in connector) Max. 1 z
– F.SW (female) (1) tance
troubleshooting.
FNR (directional)
4
troller ing
L62 Voltage
FNR (directional)
switch or right FNR
Between (37) and F (Forward) Max. 1 V
6 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission F clutch
WA450-6, WA480-6 (KA SPEC.) 7

Failure code [15SBL1] (ECMV R clutch: When command current is OFF,

fill signal is ON) 1
Action code Failure code ECMV R clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SBL1 (Transmission controller)
Contents of • When R ECMV solenoid output is turned OFF, R ECMV fill switch signal ON is input, and clutch is not
trouble released.
• Judges that the R ECMV fill switch signal is turned ON.
controller • Even if cause of failure disappears, system does not reset itself until FNR (directional) lever, joystick
Problem that
appears on • The machine can travel in the R position, but cannot travel in the F position.
machine
• The output state (current value) to the R clutch ECMV solenoid can be checked with the monitoring
function (Code: 31606, ECMV R DIR).
Related
• The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-25).

When there is no residual pressure other than the F clutch oil pres-
1 F clutch oil pressure error sure, the failure code is displayed. (See Troubleshooting of hydrau-
lic and mechanical system (H-mode)
troubleshooting.
FNR (directional)
Defective R ECMV fill switch lever, joystick steer-
2
R.SW (male) Resistance
FNR (directional)
switch or right FNR
Between (1) and R (Reverse) Max. 1 z
Possible causes
3 ness
(Contact with ground circuit) Wiring harness between L62 (female) (27) – Resis- Min.
R.SW (female) (1) and chassis ground tance 1 Mz
troubleshooting.
FNR (directional)
4
troller ing
L62 Voltage
FNR (directional)
switch or right FNR
Between (27) and R (Reverse) Max. 1 V
8 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission R clutch
WA450-6, WA480-6 (KA SPEC.) 9

Failure code [15SBLH] (ECMV R clutch: When command current is ON,

Action code Failure code ECMV R clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SBLH (Transmission controller)
Contents of • When R ECMV solenoid output is turned ON, clutch does not mesh because R ECMV fill switch ON
trouble signal is not input and the condition requires to set the engine speed at 500 rpm or below.
Action of • Judges that the R ECMV fill switch signal is turned OFF.
Problem that
appears on • When the travel direction is changed, a shock or a time lag may be made.
machine
• The output state (current value) to the R clutch ECMV solenoid can be checked with the monitoring
function (Code: 31606, ECMV R DIR).
Related
• The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-25).
• Method of reproducing failure code: Start engine, then set FNR (directional) lever, joystick steering
FNR (directional) switch, or right FNR (directional) switch to R (reverse).

This failure code is displayed if there was no F clutch oil pressure
F (forward) clutch oil pres-
1 when F ECMV solenoid output is turned ON. (See Troubleshooting
sure error
of hydraulic and mechanical system (H-mode)
troubleshooting.
FNR (directional)
Defective R ECMV fill switch lever, joystick steer-
2
R.SW (male) Resistance
FNR (directional)
switch or right FNR
Between (1) and R (Reverse) Max. 1 z
Possible causes
value in normal Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
state ness without turning starting switch ON.
3
– R.SW (female) (1) tance
troubleshooting.
FNR (directional)
4
troller ing
L62 Voltage
FNR (directional)
switch or right FNR
Between (27) and R (Reverse) Max. 1 V
10 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission R clutch
WA450-6, WA480-6 (KA SPEC.) 11

Failure code [15SEL1] (ECMV 1st clutch: When command current is

OFF, fill signal is ON) 1
Action code Failure code ECMV 1st clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SEL1 (Transmission controller)
Contents of • When 1st ECMV solenoid output is turned OFF, 1st ECMV fill switch signal ON is input, and clutch is
trouble not released.
• Judges that the 1st ECMV fill switch signal is turned ON.
• Holds 2nd, 3rd, and 4th proportional solenoid outputs OFF.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until FNR (directional) lever, joystick
Problem that
appears on • The machine can travel at 1st, but not at 2nd, 3rd, and 4th.
machine
• The output state (current value) to the 1st clutch ECMV solenoid can be checked with the monitoring
function (Code: 31602, ECMV 1 DIR).
Related
• The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-26).

When there is not residual pressure other than the 1st clutch oil
pressure, the failure code is displayed.
1 1st clutch oil pressure error
(See Troubleshooting of hydraulic and mechanical system (H-
mode)
troubleshooting.
Defective 1st ECMV fill
2 • Keep pressing brake pedal to prevent machine from traveling.
switch (Internal short circuit)
1.SW (male) Shift lever Resistance
Between (1) and 1st (1st speed) Max. 1 z
chassis ground Other than above Min. 1 Mz
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 3 ness
state (Contact with ground circuit) Wiring harness between L62 (female) (17) – Resis- Min.
1.SW (female) (1) and chassis ground tance 1 Mz
troubleshooting.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission con- position.
4
troller • Set FNR (directional) lever, joystick steering FNR
(directional) switch or right FNR (directional) switch to the F (for-
L62 Shift lever Voltage
Between (17) and 1st (1st speed) Max. 1 V
12 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission 1st clutch
WA450-6, WA480-6 (KA SPEC.) 13

Failure code [15SELH] (ECMV 1st clutch: When command current is ON,
Action code Failure code ECMV 1st clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SELH (Transmission controller)
Contents of
• When 1st ECMV solenoid output is turned ON, 1st ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 1st ECMV fill switch signal is turned OFF.
Problem that
• The machine may not travel at 1st speed.
appears on
• When the 1st gear speed is changed, a shock or a time lag may be made.
machine
• The output state (current value) to the 1st clutch ECMV solenoid can be checked with the monitoring
Related • The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code:
information 40908, D-IN-26).
• Method of reproducing failure code: Start the engine, set the manual/auto shift selector switch in the
MANUAL position, set FNR (directional) lever, joystick steering FNR (directional) switch or right FNR
(directional) switch to the F (forward) or R (reverse), then set shift lever to 1st speed position.

This code failure is displayed if 1st clutch oil pressure were absent
when 1st ECMV solenoid output is turned ON.
1 1st clutch oil pressure error
mode)
troubleshooting.
Defective 1st ECMV fill • Turn parking brake switch OFF.
2 switch (Internal disconnec- • Keep pressing brake pedal to prevent machine from traveling.
tion) 1.SW (male) Shift lever Resistance
Between (1) and 1st (1st speed) Max. 1 z
Possible causes Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
and standard ness without turning starting switch ON.
value in normal 3
state contact in connector) Max. 1 z
– 1.SW (female) (1) tance
troubleshooting.
4
Between (17) and 1st (1st speed) Max. 1 V
14 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission 1st clutch
WA450-6, WA480-6 (KA SPEC.) 15

Failure code [15SFL1] (ECMV 2nd clutch: When command current is

Action code Failure code ECMV 2nd clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SFL1 (Transmission controller)
Contents of • When 2nd ECMV solenoid output is turned OFF, 2nd ECMV fill switch signal ON is input, and clutch
trouble is not released.
• Judges that the 2nd ECMV fill switch signal is turned ON.
• Holds 1st, 3rd, and 4th proportional solenoid outputs OFF.
Action of
controller
Problem that
appears on • The machine can travel at 2nd, but not at 1st, 3rd, and 4th.
machine
• The output state (current value) to the 2nd clutch ECMV solenoid can be checked with the monitor-
ing function (Code: 31603, ECMV 2 DIR).
Related
• The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-27).

When there is no residual pressure other than the 2nd clutch oil
1 2nd clutch oil pressure error
mode)
troubleshooting.
Defective 2nd ECMV fill
Between (1) and 2nd (2nd speed) Max. 1 z
troubleshooting.
4
Between (7) and 2nd (2nd speed) Max. 1 V
16 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission 2nd clutch
WA450-6, WA480-6 (KA SPEC.) 17

Failure code [15SFLH] (ECMV 2nd clutch: When command current is

ON, fill signal is OFF) 1
Action code Failure code ECMV 2nd clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SFLH (Transmission controller)
Contents of
• When 2nd ECMV solenoid output turned ON, 2nd ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 2nd ECMV fill switch signal is turned OFF.
Problem that
• The machine may not travel at 2nd speed.
appears on
• When the 2nd gear speed is changed, a shock or a time lag may be made.
machine
• The output state (current value) to the 2nd clutch ECMV solenoid can be checked with the monitor-
ing function (Code: 31603, ECMV 2 DIR).
Related • The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code:
• Method of reproducing failure code: Start engine, set the manual/auto shift selector switch in the
(directional) switch to the F (forward), R (reverse), then set shift lever to 2nd speed position.

This failure code is displayed if 2nd clutch oil pressure were absent
when 2nd ECMV solenoid output is turned ON.
1 2nd clutch oil pressure error
mode)
troubleshooting.
Defective 2nd ECMV fill • Turn parking brake switch OFF.
Between (1) and 2nd (2nd speed) Max. 1 z
value in normal 3
– 2.SW (female) (1) and chassis ground tance
troubleshooting.
4
Between (7) and 2nd (2nd speed) Max. 1 V
18 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission 2nd clutch
WA450-6, WA480-6 (KA SPEC.) 19

Failure code [15SGL1] (ECMV 3rd clutch: When command current is

Action code Failure code ECMV 3rd clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SGL1 (Transmission controller)
Contents of • When 3rd ECMV solenoid output is turned OFF, 3rd ECMV fill switch signal ON is input, and clutch is
• Judges that the 3rd ECMV fill switch signal is turned ON.
• Holds 1st, 2nd, and 4th proportional solenoid outputs OFF.
Action of
controller
Problem that
appears on • The machine can travel at 3rd, but not at 1st, 2nd, and 4th.
machine
• The output state (current value) to the 3rd clutch ECMV solenoid can be checked with the monitoring
Related
• The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-28).

When there is no residual pressure other than the 3rd clutch oil
1 3rd clutch oil pressure error
mode)
troubleshooting.
Defective 3rd ECMV fill
Between (1) and 3rd (3rd speed) Max. 1 z
troubleshooting.
4
Between (13) and 3rd (3rd speed) Max. 1 V
20 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission 3rd clutch
WA450-6, WA480-6 (KA SPEC.) 21

Failure code [15SGLH] (ECMV 3rd clutch: When command current is

Action code Failure code ECMV 3rd clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SGLH (Transmission controller)
Contents of • When 3rd ECMV solenoid output is turned ON, clutch does not mesh because 3rd ECMV fill switch
trouble ON signal is not input and the condition requires to set the engine speed at 500 rpm or below.
Action of • Judges that the 3rd ECMV fill switch signal is turned OFF.
Problem that
• The machine may not travel at 3rd speed.
appears on
• When the 3rd gear speed is changed, a shock or a time lag may be made.
machine
• This code may also be displayed immensely after replacement of the transmission oil.
Related • The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code:
(directional) switch to the F (forward), R (reverse), and then set shift lever to 3rd speed position.

This failure code is displayed if 3rd clutch oil pressure were absent
when 3rd ECMV solenoid output is turned ON.
1 3rd clutch oil pressure error
mode)
troubleshooting.
Defective 3rd ECMV fill • Turn parking brake switch OFF.
Between (1) and 3rd (3rd speed) Max. 1 z
value in normal 3
troubleshooting.
4
Between (13) and 3rd (3rd speed) Max. 1 V
22 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission 3rd clutch
WA450-6, WA480-6 (KA SPEC.) 23

Failure code [15SHL1] (ECMV 4th clutch: When command current is

Action code Failure code ECMV 4th clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SHL1 (Transmission controller)
Contents of • When 4th ECMV solenoid output is turned OFF, 4th ECMV fill switch signal ON is input, and clutch is
• Judges that the 4th ECMV fill switch signal is turned ON.
• Holds 1st, 2nd, and 3rd proportional solenoid outputs OFF.
Action of
controller
Problem that
appears on • The machine can travel at 4th, but not at 1st, 2nd, and 3rd.
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31605, ECMV 4 DIR).
Related
• The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-29).

When there is no residual pressure other than the 4th clutch oil
1 4th clutch oil pressure error
mode)
troubleshooting.
Defective 4th ECMV fill
Between (1) and 4th (4th speed) Max. 1 z
troubleshooting.
4
troller • Set FNR (directional) lever, joystick steering FNR (directional)
switch or right FNR (directional) switch to the F (forward) or R
(reverse) position.
Between (3) and 4th (4th speed) Max. 1 V
24 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission 4th clutch
WA450-6, WA480-6 (KA SPEC.) 25

Failure code [15SHLH] (ECMV 4th clutch: When command current is

Action code Failure code ECMV 4th clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SHLH (Transmission controller)
Contents of
• When 4th ECMV solenoid output is turned ON, 4th ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 4th ECMV fill switch signal is turned OFF.
Problem that
• The machine may not travel at 4th speed.
appears on
• When the 4th gear speed is changed, a shock or a time lag may be made.
machine
• This code may also be displayed immensely after replacement of the transmission oil.
• The output state (current value) to the 4th clutch ECMV solenoid can be checked with the monitoring
function (Code: 31605, ECMV 4).
Related • The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code:
(directional) switch to the F (forward), R (reverse), then set shift lever to 4th speed position.

This failure code is displayed if 4th clutch oil pressure were absent
when 4th ECMV solenoid is turned ON.
1 4th clutch oil pressure error
mode)
troubleshooting.
Defective 4th ECMV fill • Turn parking brake switch OFF.
Between (1) and 4th (4th speed) Max. 1 z
value in normal 3
troubleshooting.
4
troller • Set FNR (directional) lever, joystick steering FNR (directional)
switch or right FNR (directional) switch to the F (forward) or R
(reverse) position.
Between (3) and 4th (4th speed) Max. 1 V
26 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission 4th clutch
WA450-6, WA480-6 (KA SPEC.) 27

Failure code [2F00MA] (Parking brake: Malfunction) 1

Action code Failure code Parking brake: Malfunction
Trouble
E03 2F00MA (Machine monitor system)
Contents of
• While the F or R clutch is operated, the parking brake operation sensor circuit remains OPEN.
trouble
Problem that
appears on • Although the parking brake lamp is turned on, a gear speed other than neutral is actually selected.
machine
• This code may also be displayed if engine stalls or the emergency brake is operated while the
machine is traveling.
Related
• The input state (ON/OFF) from the brake parking indicator switch can be checked with the monitor-
information
ing function (Code: 40903, D-IN-26).

a Prepare with starting switch OFF, disconnect PB.SW connector
and then start the engine to carry out troubleshooting.
Defective parking brake indi-
1 cator switch PB.SW (male) Parking brake Resistance
(Internal disconnection) Released Max. 1 z
Between (1) and (4)
Operating Min. 1 Mz
value in normal 2
(Disconnection or defective Wiring harness between L54 (female) (1) – Resis-
state contact) Max. 1 z
PB.SW (female) (1) tance
troubleshooting.
Parking brake oil
3 Defective machine monitor L54 Voltage
pressure
Between (1) and Released Max. 1 V
chassis ground Operating 20 – 30 V
28 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to parking brake
WA450-6, WA480-6 (KA SPEC.) 29

Failure code [2G43ZG] (Accumulator: Low oil pressure) 1

Action code Failure code Accumulator: Low oil pressure
Trouble
E03 2G43ZG (Machine monitor system)
Contents of • After the engine is started, the brake accumulator pressure sensor circuit once reaches the specified
trouble pressure, then the circuit conditions turns to OPEN.
Problem that
• Low brake accumulator oil pressure
appears on
• The brake may not work.
machine
• The input state (ON/OFF) from the brake oil pressure sensor can be checked with the monitoring
Related
function (Code: 40902, D-IN-17).
information

Low brake accumulator oil Check the brake accumulator oil pressure.
1
pressure (See Testing and adjusting.)
troubleshooting.
Brake accumulator oil
R54 (Male) Resistance
pressure
Defective brake oil pressure
2 sensor Pressure normal
(Internal disconnection) Min. 5.88 MPa Max. 1 z
Min. {60 kg/cm2}
Between (1) and (2)
Low pressure
Max. 3.92 MPa Min. 1 Mz
Max. {40 kg/cm2}
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard
Disconnection in wiring har- without turning starting switch ON.
value in normal
state ness Wiring harness from L53 (female) (7) to R54 Resis-
3 Max. 1 z
(Disconnection or defective (female) (1) tance
contact) Wiring harness from R54 (female) (2) to Resis-
Max. 1 z
chassis ground tance
without turning starting switch ON.
Brake accumulator oil
L53 (female) Resistance
pressure
4 Defective machine monitor Pressure normal

Min. 5.88 MPa Max. 1 z
Wiring harnesses Min. {60 kg/cm2}
between (7) – chassis
ground Low pressure
Max. 3.92 MPa Min. 1 Mz
Max. {40 kg/cm2}
30 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to brake accumulator
WA450-6, WA480-6 (KA SPEC.) 31

Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) 1

Action code Failure code Bucket positioner: ON/OFF signals disagree
Trouble
E01 44K0L4 (Work equipment controller system)
• The signals input from the bucket proximity switch are combined impossibly.
• After bucket level-over signal ON and full stroke signal OFF were continued for 3 seconds, full stroke
Contents of signal ON was detected for one second.
trouble • After bucket level-over signal ON and full stroke signal OFF were continued for 3 seconds, bucket
level-over signal OFF was detected for one second.
• If problem is removed, system is returned to normal operating state.
Action of
• Judged to be below bucket level.
controller
Problem that
appears on • Bucket lever does not function
machine
• Only for electric lever (If equipped)
• The input state (ON/OFF) from the bucket cylinder full stroke proximity switch can be checked with
the monitoring function (Code: 40911, D-IN-8).
Related
• The input state (ON/OFF) from the bucket cylinder level proximity switch can be checked with the
information
monitoring function (Code: 40911, D-IN-9).
• Method of reproducing failure code: Start engine, then drive the bucket slowly between the full tilt
and full dump position.

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Defective bucket cylinder
level proximity switch F09 Position of bucket Voltage
1
(Internal disconnection or Between (A) and (C) Constant 20 – 30 V
short circuit) Below horizontal Max. 1 V
Between (B) and (C)
Above horizontal 8 – 10 V
Defective bucket cylinder full F19 Position of bucket Voltage
stroke proximity switch
2 Between (A) and (C) Constant 20 – 30 V
(Internal disconnection or
short circuit) Tilt full stroke 8 – 10 V
Between (B) and (C) Other than tilt full
Max. 1 V
Possible causes stroke
and standard a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har-
value in normal without turning starting switch ON.
ness
state 3
(Disconnection or defective Wiring harness between F19 (female) (B) – Resis-
L73 (female) (10) tance
Grounding fault in wiring har- without turning starting switch ON.
4 ness
(Contact with ground circuit) Wiring harness between F09 (female) (B) – Resis-
Min. 1 Mz
L73 (female) (20) and chassis ground tance
L73 Position of bucket Voltage
Defective work equipment Between (20) and Below horizontal Max. 1 V
5
controller chassis ground Above horizontal 8 – 10 V
Tilt full stroke 8 – 10 V
Between (10) and
chassis ground Other than tilt full
Max. 1 V
stroke
32 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to bucket proximity switch
WA450-6, WA480-6 (KA SPEC.) 33

SEN01678-00

34
SEN01679-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
Failure code [AA1ANX] (Air cleaner: Clogging) ................................................................................... 4
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) .......................... 6
Failure code [AB00MA] (Alternator: Malfunction)................................................................................. 8
Failure code [B@BAZG] (Rotation derating by low engine oil pressure) ........................................... 10
Failure code [B@BAZK] (Engine oil: Low level)................................................................................. 13
Failure code [B@BCNS] (Coolant: Overheating) ............................................................................... 14
Failure code [B@BCZK] (Coolant: Low level) .................................................................................... 16
Failure code [B@C7NS] (Brake oil: Overheating).............................................................................. 18
Failure code [b@CENS] (Torque converter oil: Overheating) ............................................................ 20
Failure code [B@CENS] (Torque converter oil: Overheating)............................................................ 22
Failure code [B@HANS] (Hydraulic oil: Overheating)........................................................................ 24
Failure code [CA111] (Abnormality in engine controller) .................................................................... 26
Failure code [CA115] (Engine Ne or Bkup speed sensor error) ......................................................... 29
WA450-6, WA480-6 (KA SPEC.) 1

Failure code [CA122] (Charge pressure sensor high error) ............................................................... 30

Failure code [CA123] (Charge pressure sensor low error)................................................................. 32
Failure code [CA131] (Throttle sensor high error).............................................................................. 34
Failure code [CA132] (Throttle sensor low error) ............................................................................... 36
Failure code [CA135] (Engine oil pressure sensor high error) ........................................................... 38
Failure code [CA141] (Engine oil pressure sensor low error)............................................................. 40
Failure code [CA144] (Coolant sensor high error).............................................................................. 42
Failure code [CA145] (Coolant sensor low error) ............................................................................... 44
Failure code [CA153] (Charge temperature sensor high error).......................................................... 46
Failure code [CA154] (Charge temperature sensor low error) ........................................................... 48
Failure code [CA187] (Sensor power supply 2 low error)................................................................... 50
Failure code [CA221] (Atmospheric pressure sensor high error) ....................................................... 51
Failure code [CA222] (Atmospheric pressure sensor low error) ........................................................ 53
Failure code [CA227] (Sensor power supply 2 high error) ................................................................. 54
Failure code [CA234] (Engine overspeed) ......................................................................................... 56
Failure code [CA238] (Ne speed sensor power supply error) ............................................................ 58
2 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 3


Failure code [AA1ANX] (Air cleaner: Clogging) 1
Action code Failure code Air cleaner: Clogging
Trouble
E01 AA1ANX (Machine monitor system)
Contents of
• When the engine is started, the air cleaner clogging sensor circuit is OPEN.
trouble
Action of • Turns the air cleaner clogging caution lamp ON.
Problem that
• The engine does not start or pick up easily, its output is insufficient, and its exhaust gas color is
appears on
black.
machine
• The input state (ON/OFF) from the air cleaner clogging sensor can be checked with the monitoring
Related
information

1 Clogged air cleaner The air cleaner may be clogged. Check it directly.
Defective dust indicator troubleshooting.
2
(Internal short circuit) Replace the dust If the condition becomes normal, the trouble
indicator is attributable to defective indicator.
L112 (Male) Resistance
Defective dust indicator relay
Between (1) and (2) 200 – 400 z
(L112)
3 a Prepare with starting switch OFF, then start engine and carry out
short circuit) troubleshooting.
When dust indicator relay (L112) is replaced with a relay of the
same type (5-pin type), if the condition becomes normal, the
Possible causes exchange relay is defective.
state
ness Wiring harnesses between L112 (female) Resis-
4 Max. 1 z
(Disconnection or defective (2) – E45 (female) (1) tance
contact in connector) Wiring harnesses between E45 (female) (2) Resis-
Max. 1 z
– chassis ground tance
5 ness
(Contact with ground circuit) Wiring harness between L112 (female) (2) Resis-
Min. 1 Mz
– E45 (female) (1) and chassis ground tance
troubleshooting.
L53 Dust indicator Voltage
6 Defective machine monitor Normal (Air cleaner is
20 – 30 V
Between (3) and normal)
chassis ground Defective (Air cleaner
Max. 1 V
is clogged)
4 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to dust indicator
WA450-6, WA480-6 (KA SPEC.) 5

Failure code [AB00L6] (Alternator: Signal disagrees with operating state

of engine) 1
Action code Failure code Alternator: Signal disagrees with operating state of engine
Trouble
E03 AB00L6 (Machine monitor system)
Contents of
• When engine is stopped, alternator terminal R input voltage is above 12 V.
trouble
• Turns the charge circuit error caution lamp ON.
Action of
controller
Problem that
appears on • After the engine is started, just turning on the starting switch runs the service meter.
machine
• The input state (voltage) from the alternator can be checked with the monitoring function (Code:
Related
04302, ALTERNATOR R).
information

troubleshooting.
Alternator Engine Voltage
Defective alternator
1 Wiring harness Running (Throttle:
(Internal trouble) 27.5 – 29.5 V
between terminal R Above 1/2)
(E02) – chassis
ground Holds in position Max. 1 V
Possible causes
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal Hot short in wiring harness and carry out troubleshooting.
2
state (Contact with 24V circuit) Wiring harnesses between terminal R (E02)
Voltage Max. 1 V
– L52 (female) (18), – circuit branch end
troubleshooting.
L52 Engine Voltage
3 Defective machine monitor
Running (Throttle:
Between (18) and 27.5 – 29.5 V
Above 1/2)
chassis ground
Holds in position Max. 1 V
6 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to alternator
WA450-6, WA480-6 (KA SPEC.) 7

Failure code [AB00MA] (Alternator: Malfunction) 1

Action code Failure code Alternator: Malfunction
Trouble
E03 AB00MA (Machine monitor system)
Contents of
• While the engine is running, the alternator terminal R input voltage is below 5 V.
trouble
• Turns the charge circuit failure caution lamp ON.
Action of
controller
• If problem is removed (min. 1 V), system is returned to normal operating state.
Problem that
appears on • Deterioration of battery or insufficient charging
machine
• The input state (voltage) from the alternator can be checked with the monitoring function (Code:
Related
04302, ALTERNATOR R).
information

1 The battery is deteriorated. The battery may be deteriorated. Check it directly.
troubleshooting.
Alternator Engine Voltage
Defective alternator
2 Wiring harness Running (Throttle:
(Internal trouble) 27.5 – 29.5 V
between terminal R Above 1/2)
(E02) – chassis
ground Holds in position Max. 1 V
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes ness without turning starting switch ON.
3
and standard (Disconnection or defective Wiring harnesses between terminal R (E02) Resis-
value in normal – L52 (female) (18) tance
state a Prepare by turning starting switch OFF and then start engine to
Grounding fault in wiring har- carry out troubleshooting.
4 ness Wiring harness between terminal R (E02) –
(Contact with ground circuit) L52 (female) (18) – circuit branch end and Resis-
Min. 1 Mz
tance
chassis ground
troubleshooting.
L52 Engine Voltage
Running (Throttle:
Between (18) and 27.5 – 29.5 V
Above 1/2)
chassis ground
Holds in position Max. 1 V
8 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to alternator
WA450-6, WA480-6 (KA SPEC.) 9

Failure code [B@BAZG] (Rotation derating by low engine oil pressure)1

Action code Failure code Rotation derating by low engine oil pressure
Trouble
E03 B@BAZG (Engine controller system)
Contents of
• While engine was operating, engine oil pressure became lower than operating range.
trouble
Action of • Limit output for travel (Limit injection rate and engine speed)
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output lowers.
machine
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitoring
function (Code: 37200 ENG OIL PRESS).
Related
• The input state (voltage) from the engine oil pressure sensor can be checked with the monitoring
information
• Method of reproducing failure code: Start engine.

Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
ply system shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
POIL Voltage
Defective oil pressure sensor
2 Between (1) and (2) Power supply 4.75 – 5.25 V
(Internal defect)
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller for
another cause of trouble before judgment
Disconnection in wiring Wiring harness between EC1 (female) (37) – Resis-
Max. 1 z
harness (Disconnection in POIL (female) (1) tance
Possible causes 3
wiring or defective contact in Wiring harness between EC1 (female) (47) – Resis-
and standard connector) Max. 1 z
POIL (female) (2) tance
value in normal
state Wiring harness between EC1 (female) (13) – Resis-
Max. 1 z
Wiring harness between EC1 (female) (37) – Resis-
Ground fault in wiring Min. 1 Mz
POIL (female) (1) and chassis ground tance
4 harness (Short circuit with
GND circuit) Wiring harness between EC1 (female) (47) – Resis-
Min. 1 Mz
Min. 1 Mz
5 Defective engine controller EC1 Voltage
Between
Power supply 4.75 – 5.25 V
(37) and (47)
10 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to engine oil pressure sensor
WA450-6, WA480-6 (KA SPEC.) 11

12 WA450-6, WA480-6 (KA SPEC.)

Failure code [B@BAZK] (Engine oil: Low level) 1

Action code Failure code Engine oil: Low level
Trouble
E01 B@BAZK (Machine monitor system)
• While engine is stopped, the engine oil level sensor circuit was detected to have remained in OPEN
condition for more than 2 seconds.
Contents of
(This error, however, is not detected for 5 minutes from the engine stop)
trouble
• An error being detected at stopping the engine remains as the error after the engine is started again
until the normal condition is recovered.
Action of • Turns the engine oil level caution lamp ON.
Problem that
appears on • The engine oil level is low (The engine may be broken).
machine
• The input state (ON/OFF) from the engine level sensor can be checked with the monitoring function
Related
(Code: 40903, D-IN-29).
information

1 Low engine oil level The engine oil level may be low. Check it directly.
Defective engine oil level E26 (male) Engine oil level Resistance
2 sensor
(Internal disconnection) Oil level is normal Max. 1 z
Between (1) and
chassis ground Oil level is insuffi-
Min. 1 Mz
Possible causes cient (low level)
and standard Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
value in normal ness without turning starting switch ON.
state 3
contact) Max. 1 z
– E26 (female) (1) tance
L54 (female) Engine oil level Resistance
Wiring harness Oil level is normal Max. 1 z
between (11) – chas- Oil level is insuffi-
sis ground Min. 1 Mz
cient (low level)
Circuit diagram related to engine oil level sensor
WA450-6, WA480-6 (KA SPEC.) 13

Failure code [B@BCNS] (Coolant: Overheating) 1

Action code Failure code Coolant: Overheating
Trouble
E02 B@BCNS (Engine controller system)
Contents of
• While the engine is run, the engine coolant temperature exceeded the operating range.
trouble
Action of • Limits output and continues operation.
Problem that
machine
• The input state (temperature) from the engine coolant temperature sensor can be checked with the
monitoring function (Code: 04104, COOLANT TEMP).
• The input state (voltage) from the engine coolant temperature sensor can be checked with the moni-
Related
toring function (Code: 04105, COOLANT TEMP).
information
• if failure code [CA144] (Engine coolant temperature sensor high error) or [CA145] (Engine coolant
temperature sensor high error) is indicated, carry out troubleshooting for it first.

Engine coolant overheat Overheating of engine coolant can be suspected. Check the tem-
1
(When the system is normal) perature to locate and eliminate the cause.
Defective coolant tempera- without turning starting switch ON.
2 ture sensor
TWTR (male) Resistance
(Internal trouble)
Between (A) and (B) 0.18 – 160 kz
Possible causes
and standard
value in normal
state ness Wiring harness between EC1 (female) (15) – Resis-
3 Max. 1 z
(Disconnection or defective TWTR (female) (B) tance
contact in connector) Wiring harness between TWTR (female) (A) Resis-
Max. 1 z
– EC1 (female) (38) tance
4 Defective engine controller
EC1 (male) Resistance
Between (15) and (38) 0.18 – 160 kz
14 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to coolant temperature sensor
WA450-6, WA480-6 (KA SPEC.) 15

Failure code [B@BCZK] (Coolant: Low level) 1

Action code Failure code Coolant: Low level
Trouble
E01 B@BCZK (Machine monitor system)
Contents of
• The coolant level sensor circuit is OPEN (circuit was in this condition for 30 seconds)
trouble
Action of • Turns the coolant level caution lamp ON.
Problem that
appears on • The coolant level is low. The engine overheats (The engine may be broken).
machine
• The input state (ON/OFF) from the coolant level sensor can be checked with the monitoring function
Related
(Code: 40903, D-IN-27).
information

1 Low coolant level The coolant level may be low. Check it directly.
R32 (Male) Sub-tank Resistance
Defective coolant level sen-
2 Below LOW level
sor (Internal short circuit) Max. 1 z
(Abnormal)
Between (1) and (2)
Above LOW level
Min. 1 Mz
(Normal)
and standard Disconnection in wiring har- without turning starting switch ON.
value in normal ness Wiring harness between L54 (female) (10) – Resis-
state 3 Max. 1 z
(Disconnection or defective R32 (female) (1) tance
contact) Wiring harness from R32 (female) (2) and Resis-
Max. 1 z
L54 (female) Sub-tank Resistance
4 Defective machine monitor Below LOW level
Wiring harness Max. 1 z
(Abnormal)
between (10) – chas-
sis ground Above LOW level
Min. 1 Mz
(Normal)
16 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to coolant level sensor
WA450-6, WA480-6 (KA SPEC.) 17

Failure code [B@C7NS] (Brake oil: Overheating) 1

Action code Failure code Brake oil: Overheating
Trouble
E02 B@C7NS (Machine monitor system)
• Brake oil temperature was above 130°C for 5 seconds.
Contents of
• When travel speed was above 35 km/h, brake oil temperature, 125°C and above, was detected con-
trouble
tinuously for 5 seconds.
Problem that
• Brake oil temperature caution lamp lights up
appears on
• The brake may be damaged.
machine
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the
monitoring function (Code: 30202, R BRAKE OIL).
Related
• The input state (voltage) from the rear brake oil temperature sensor can be checked with the moni-
information
toring function (Code: 30205, R BRAKE OIL).

Brake may overheat because brake was operated improperly during
1 Defective brake operation travel.
• Instruct the operator on the correct way of operating the brake.
Defective rear brake oil tem- Rear brake oil tem-
2 perature sensor (Internal perature
Possible causes
and standard defect) 25°C (Normal tem-
35 – 50 kz
value in normal Between (1) and (2) perature)
state 100°C 3.1 – 4.5 kz
Rear brake oil tem-
L55 (female) Voltage
3 Defective machine monitor perature
Wiring harnesses 25°C (Normal tem-
4.4 – 4.6 V
between (8) – chassis perature)
ground 100°C 2.1 – 2.3 V
18 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to rear brake oil temperature sensor
WA450-6, WA480-6 (KA SPEC.) 19

Failure code [b@CENS] (Torque converter oil: Overheating) 1

Action code Failure code Torque converter oil: Overheating
Trouble
E02 b@CENS (Machine monitor system)
Contents of
• The torque converter oil temperature is above 120°C.
trouble
Action of • If cause of failure disappears, system resets itself. (120°C and below was detected continuously for 1
controller seconds.)
Problem that
• The torque converter oil temperature caution lamp is turned ON (If the machine is used as it is, the
appears on
torque converter may be broken).
machine
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked
with the monitoring function (Code: 40100, TC OIL TEMP).
Related
• The input state (voltage) from the torque converter oil temperature sensor can be checked with the
information
monitoring function (Code: 40101, TC OIL TEMP).

Torque converter oil may overheat due to torque converter stall, etc.
Overheating of torque con-
1 (See Troubleshooting of hydraulic and mechanical system (H-
verter oil
mode).)
Defective torque converter Torque converter oil
TC.T (male) Resistance
2 oil temperature sensor (Inter- temperature
Possible causes
and standard nal defect) 25°C (Normal tem-
35 – 50 kz
state 100°C 3.1 – 4.5 kz
Torque converter oil
3 Defective machine monitor temperature
25°C (Normal tem-
Between (2) and 4.4 – 4.6 V
perature)
chassis ground
100°C 2.1 – 2.3V
20 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to torque converter oil temperature sensor
WA450-6, WA480-6 (KA SPEC.) 21

Failure code [B@CENS] (Torque converter oil: Overheating) 1

Action code Failure code Torque converter oil: Overheating
Trouble
E02 B@CENS (Machine monitor system)
Contents of
• The torque converter oil temperature is above 130°C.
trouble
Action of
• If cause of failure disappears, system resets itself. (130°C and below was detected continuously for 1
controller
seconds.)
Problem that
• The torque converter oil temperature caution lamp is turned ON (If the machine is used as it is, the
appears on
torque converter may be broken).
machine
Related
information

Torque converter oil may overheat due to torque converter stall, etc.
Overheating of torque con-
1 (See Troubleshooting of hydraulic and mechanical system (H-
verter oil
mode).)
2 oil temperature sensor (Inter- temperature
Possible causes
and standard nal defect) 25°C (Normal tem-
35 – 50 kz
state 100°C 3.1 – 4.5 kz
25°C (Normal tem-
Between (2) and 4.4 – 4.6 V
perature)
chassis ground
100°C 2.1 – 2.3 V
22 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 23

Failure code [B@HANS] (Hydraulic oil: Overheating) 1

Action code Failure code Hydraulic oil: Overheating
Trouble
E02 B@HANS (Machine monitor system)
Contents of
• The hydraulic oil temperature is above 100°C (this level was detected for 10 seconds)
trouble
Problem that
• The hydraulic oil overheat warning is turned ON (If the machine is used as it is, the pump and cylin-
appears on
der seals may be broken).
machine
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
monitoring function (Code: 04401, HYD TEMP).
Related
• The input state (voltage) from the hydraulic oil temperature sensor can be checked with the monitor-
information
ing function (Code: 04404, HYD TEMP).

1 Overheating of hydraulic oil The hydraulic oil may be overheating.
Defective hydraulic oil tem- Hydraulic oil tempera-
2 perature sensor ture
Possible causes (Internal trouble) 25°C (Normal tem-
35 – 50 kz
and standard Between (1) and (2) perature)
value in normal 100°C 3.1 – 4.5 kz
state
Hydraulic oil tempera-
3 Defective machine monitor ture
Wiring harnesses 25°C (Normal tem-
4.4 – 4.6 V
between (7) – chassis perature)
ground 100°C 2.1 – 2.3 V
24 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to hydraulic oil temperature sensor
WA450-6, WA480-6 (KA SPEC.) 25

Failure code [CA111] (Abnormality in engine controller) 1

Action code Failure code Abnormality in engine controller
Trouble
E03 CA111 (Engine controller system)
Contents of
• Internal defect occurred in controller.
trouble
Action of
controller
Problem that
appears on • Operations are continued, but engine may stop during operations or may not start in stopped state.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Defective fuse No. 6 of fuse If the fuse is burnt, the circuit probably has a grounding fault.
1
box B (See cause 6.)
L171 (male) Resistance
Defective engine control cut Between (1) and (2) 200 – 400 z
2 relay (L171) (Internal discon- a Prepare with starting switch OFF, then turn starting switch ON
nection or short circuit) and carry out troubleshooting.
When engine control cut relay (L171) is replaced with a relay of the
same type, if the condition becomes normal, engine control cut relay
(L171) is defective.
and standard without turning starting switch ON.
value in normal L172 (male) Resistance
state
Defective engine control cut Between (1) and (2) 200 – 400 z
3 relay (L172) (Internal discon- a Prepare with starting switch OFF, then turn starting switch ON
nection or short circuit) and carry out troubleshooting.
When engine control cut relay (L172) is replaced with a relay of the
same type, if the condition becomes normal, engine control cut relay
(L172) is defective.
D11, D12 (male) Diode range Continuity
Defective diode (D11, D12)
4 Between D11 Measure at (2) in
(Internal disconnection)
(1) and (2) diode range.
Continue
Between D12 Measure at (2) in
(1) and (2) diode range.
26 WA450-6, WA480-6 (KA SPEC.)


Disconnection in wiring Wiring harness between fuse No. 6 of fuse Resis-
Max. 1 z
harness (Disconnection in box B – L171 or L172 (female) (3) tance
5
wiring or defective contact in Wiring harness between L171 (female) (5), Resis-
connector) Max. 1 z
L172 (female) (5) – EC3 (female) (3), (4) tance
Wiring harness between EC3 (female) (1), Resis-
Max. 1 z
(2) – chassis ground tance
Possible causes
and standard
value in normal
state Wiring harness between fuse No. 6 of fuse
Ground fault in wiring Resis-
box B – L171, L172 (female) (3) and chassis Min. 1 Mz
6 harness (Short circuit with tance
ground
GND circuit)
Wiring harness between L171 (female) (5),
Resis-
L172 (female) (5) – EC3 (female) (3), (4) and Min. 1 Mz
tance
chassis ground
EC3 Voltage
Between (1), (2) – (3), (4) 20 – 30 V
WA450-6, WA480-6 (KA SPEC.) 27

Circuit diagram related to engine controller power supply
28 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA115] (Engine Ne or Bkup speed sensor error) 1

Action code Failure code Engine Ne or Bkup speed sensor error
Trouble
Contents of
• Abnormality occurred in Ne and Bkup speed sensor circuits at the same time.
trouble
Action of • Stop the engine.
Problem that
• The engine does not start. (if engine has been stopped.)
appears on
• Engine stops.(if engine has been running.)
machine
Related
information

Defective Ne speed sensor
1 Carry out troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
2 Carry out troubleshooting for failure code [CA778].
system
Ne speed sensor may be installed defectively. Check it directly.
Defective installation of Ne
Possible causes 3 (Defective installation of sensor itself, internal defect of flywheel,
speed sensor
and standard etc.)
value in normal Bkup speed sensor may be installed defectively. Check it directly.
state Defective installation of Bkup
4 (Defective installation of sensor itself, internal defect of supply
speed sensor
pump, etc.)
Defective sensor connection Ne and Bkup speed sensors may be connected defectively
5
(Improper connection) (improper connection). Check them directly.
If causes 1 – 5 are not the cause of the trouble, the engine control-
6 Defective engine controller ler may be defective. (Since trouble is in system, troubleshooting
cannot be carried out.)
WA450-6, WA480-6 (KA SPEC.) 29

Failure code [CA122] (Charge pressure sensor high error) 1

Action code Failure code Charge pressure sensor high error
Trouble
Contents of
• High voltage is detected in charge pressure sensor (boost pressure sensor) circuit.
trouble
• Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2}), and continues opera-
Action of
tion.
controller
Problem that
appears on • Engine does not accelerate smoothly.
machine
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: 36500 CHG PRESS-A).
Related
• The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
information
with the monitoring function (Code: 36502 CHG PRESS-A).

Defective power supply sys-
If failure code [CA187] or [CA227] is displayed, carry out trouble-
1 tem of charge pressure sen-
shooting for it first.
sor (boost pressure sensor)
Defective charge pressure PIM Voltage
2 sensor (boost pressure sen- Between (1) and (3) Power supply 4.75 – 5.25 V
sor) (Internal defect)
Charge pressure sensor voltage is measured with wiring harness
connected. Accordingly, if voltage is abnormal, check wiring harness
and controller for another cause of trouble before judgment.
Possible causes without turning starting switch ON.
and standard
value in normal Disconnection in wiring Wiring harness between EC1 (female) (37) – Resis-
Max. 1 z
state harness (Disconnection in PIM (female) (1) tance
3
connector) Max. 1 z
PIM (female) (2) tance
Max. 1 z
PIM (female) (3) tance
PIM (female) (1) and chassis ground tance
Min. 1 Mz
Min. 1 Mz
30 WA450-6, WA480-6 (KA SPEC.)


Wiring harness between EC1 (female) (37) –
Resis-
PIM (female) (1) and between EC1 (female) Min. 1 Mz
tance
Short circuit in wiring (47) – PIM (female) (2)
5 harness (with another wiring Wiring harness between EC1 (female) (37) –
Possible causes harness) Resis-
and standard tance
(44) – PIM (female) (3)
value in normal
state Wiring harness between EC1 (female) (47) –
Resis-
tance
(44) – PIM (female) (3)
Between
(37) and (47)
Circuit diagram related to charge pressure sensor
WA450-6, WA480-6 (KA SPEC.) 31

Failure code [CA123] (Charge pressure sensor low error) 1

Action code Failure code Charge pressure sensor low error
Trouble
Contents of
• Low voltage is detected in charge pressure sensor (boost pressure sensor) circuit.
trouble
• Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2}), and continues opera-
Action of
tion.
controller
Problem that
appears on • Engine does not accelerate smoothly.
machine
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: 36500 CHG PRESS-A).
Related
• The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
information
with the monitoring function (Code: 36502 CHG PRESS-A).
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA122].
state
32 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 33

Failure code [CA131] (Throttle sensor high error) 1

Action code Failure code Throttle sensor high error
Trouble
Contents of
• High voltage was detected in the throttle sensor signal circuit.
trouble
Action of • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
Problem that
appears on • The engine does not reach full throttle.
machine
• The input state (accelerator pedal opening ratio) from the throttle sensor can be checked with the
monitoring function (Code: 31701, THROTTLE POS).
Related
• The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
information
31707, THROTTLE POS).

Defective throttle sensor If failure code [CA2185] is indicated simultaneously, carry out trou-
1
power supply system bleshooting for it first.
PD Accelerator pedal Voltage
All range (Power sup-
Between (1) and (3) 4.75 – 5.25 V
Defective accelerator pedal ply)
2
(Internal trouble) When released 0.50 – 0.80 V
Between (2) and (3)
When pressed 3.70 – 4.00 V
Hot short (Short circuit with and carry out troubleshooting.
3 5V, 24V circuit) in wiring har-
Possible causes Wiring harness between EC2 (female) (9) –
ness Voltage Max. 1 V
and standard PD (female) (2) and chassis ground
value in normal
state
Short circuit in wiring har- without turning starting switch ON.
4 ness Wiring harness between EC2 (female) (9) –
(with another wiring harness) PD (female) (2), EC2 (female) (22) – PD Resis-
Min. 1 Mz
tance
(female) (1)
Connecting parts among fuel control dial, engine unit wiring har-
ness, and engine controller are suspected. Inspect them directly.
Defective wiring harness
5 • Loose connector, broken lock, broken seal
connector
• Corrosive, bent, broken, forced-in, or extended pin
• Humidity in connector, entry of dirt or dust, poor insulation
EC2 Accelerator pedal Voltage
6 Defective engine controller Between (22) and All range
4.75 – 5.25 V
(23) (Power supply)
When released 0.50 – 0.80 V
Between (9) and (23)
34 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to throttle sensor
WA450-6, WA480-6 (KA SPEC.) 35

Failure code [CA132] (Throttle sensor low error) 1

Action code Failure code Throttle sensor low error
Trouble
Contents of
• Low voltage was detected in the throttle sensor signal circuit.
trouble
Problem that
machine
• The input state (accelerator pedal opening ratio) from the throttle sensor can be checked with the
monitoring function (Code: 31701, THROTTLE POS).
Related
• The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
information
31707, THROTTLE POS).

Defective throttle sensor If failure code [CA2186] is indicated simultaneously, carry out trou-
1
power supply system bleshooting for it first.
PD Accelerator pedal Voltage
All range (Power sup-
Between (1) and (3) 4.75 – 5.25 V
Defective accelerator pedal ply)
2
(Internal trouble) When released 0.50 – 0.80 V
Between (2) and (3)
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
3
Possible causes (Short circuit with ground cir- Wiring harness between EC2 (female) (9) – Resis-
and standard cuit) Min. 1 Mz
PD (female) (2) and chassis ground tance
value in normal
state
4 ness Wiring harness between EC2 (female) (9) –
(with another wiring harness) PD (female) (2), PD (female) (23) – PD Resis-
Min. 1 Mz
tance
(female) (3)
connector
EC2 Accelerator pedal Voltage
6 Defective engine controller Between (22) and All range (Power sup-
4.75 – 5.25 V
(23) ply)
When released 0.50 – 0.80 V
36 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to throttle sensor
WA450-6, WA480-6 (KA SPEC.) 37

Failure code [CA135] (Engine oil pressure sensor high error) 1

Action code Failure code Engine oil pressure sensor high error
Trouble
Contents of
• High voltage is detected in engine oil pressure sensor circuit.
trouble
Action of
• Sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues operation.
controller
Problem that
appears on —
machine
Related
information

Defective power supply
If failure code [CA187] or [CA227] is also indicated, carry out trou-
1 system of engine oil pressure
bleshooting for it first.
sensor
POIL Voltage
Defective engine oil pressure
sensor (Internal defect)
and standard
Max. 1 z
state harness (Disconnection in POIL (female) (1) tance
3
connector) Max. 1 z
Max. 1 z
Min. 1 Mz
Min. 1 Mz
38 WA450-6, WA480-6 (KA SPEC.)


Resis-
POIL (female) (1) and between EC1 (female) Min. 1 Mz
tance
Short circuit in wiring (47) – POIL (female) (2)
and standard tance
(13) – POIL (female) (3)
value in normal
Resis-
tance
(13) – POIL (female) (3)
Between
(37) and (47)
Circuit diagram related to engine oil pressure sensor
WA450-6, WA480-6 (KA SPEC.) 39

Failure code [CA141] (Engine oil pressure sensor low error) 1

Action code Failure code Engine oil pressure sensor low error
Trouble
Contents of
• Low voltage is detected in engine oil pressure sensor circuit.
trouble
Action of
• Sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues operation.
controller
Problem that
appears on —
machine
Related
information

and standard
state
40 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 41

Failure code [CA144] (Coolant sensor high error) 1

Action code Failure code Coolant sensor high error
Trouble
Contents of
• High voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes engine coolant temperature (at 90°C) and continues operation.
controller
Problem that
• Exhaust smoke becomes white
appears on
• Overheat prevention function does not function.
machine
Related
information

Defective coolant tempera- without turning starting switch ON.
1 ture sensor
TWTR (male) Resistance
(Internal trouble)
Between (A) and (B) 0.18 – 160 kz
ness Wiring harness between EC1 (female) (15) – Resis-
2 Max. 1 z
(Disconnection or defective TWTR (female) (A) tance
contact in connector) Wiring harness between EC1 (female) (38) – Resis-
Max. 1 z
TWTR (female) (B) tance
value in normal Short circuit in wiring har-
state 3 ness Wiring harness among all pins between EC1
(with another wiring harness) (female) (15) – EC1 (female) Resis-
Min. 1 Mz
(With all connectors of wiring harness distance
connected)
Connecting parts among coolant temperature sensor, engine wiring
harness, and engine controller are suspected. Inspect them directly.
connector
EC1 (female) Resistance
Between (15) and (38) 0.18 – 160 kz
42 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 43

Failure code [CA145] (Coolant sensor low error) 1

Action code Failure code Coolant sensor low error
Trouble
Contents of
• Low voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes engine coolant temperature (at 90°C) and continues operation.
controller
Problem that
appears on
• Overheat prevention function does not function.
machine
Related
information

Defective coolant tempera-
1 ture sensor TWTR (male) Resistance
(Internal trouble) Between (A) and (B) 0.18 – 160 kz
Between (B) and chassis ground Min. 1 Mz
2
(Short circuit with ground cir- Wiring harness between EC1 (female) (15) – Resis-
cuit) Min. 1 Mz
TWTR (female) (A) and chassis ground tance
Possible causes Short circuit in wiring har- without turning starting switch ON.
and standard 3 ness Wiring harness among all pins between EC1
value in normal (with another wiring harness) (female) (15) – EC1 (female) (With all con- Resis-
Min. 1 Mz
state tance
nectors of wiring harness disconnected)
Connecting parts among coolant temperature sensor, engine wiring
connector
Between (15) and (38) 0.18 – 160 kz
Between (15) and
Min. 1 Mz
chassis ground
44 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 45

Failure code [CA153] (Charge temperature sensor high error) 1

Action code Failure code Charge temperature sensor high error
Trouble
Contents of • High voltage is detected in temperature signal circuit of boost pressure sensor and temperature sen-
trouble sor.
Action of
• Fixes charge temperature (boost temperature) at 70°C and continues operation.
controller
Problem that
appears on
• Boost temperature-based engine protection function does not function.
machine
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: 18500, CHG TEMP).
Related
• The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: 18501, CHG TEMP).
Defective [temperature sig- a Prepare with starting switch OFF, then carry out troubleshooting
nal circuit] of boost pressure without turning starting switch ON.
1
sensor, temperature sensor TIM (male) Resistance
2 Max. 1 z
(Disconnection or defective TIM (female) (A) tance
Max. 1 z
TIM (female) (B) tance
Short circuit in wiring har-
value in normal
3 ness Wiring harness among all pins between EC1
state Resis-
(with another wiring harness) (female) (23) – EC1 (female) (With all con- Min. 1 Mz
tance
nectors of wiring harness disconnected)
Connecting parts among boost pressure sensor/temperature sen-
sor, engine wiring harness, and engine controller are suspected.
Defective wiring harness Inspect them directly.
4
connector • Loose connector, broken lock, broken seal
Between (23) and (47) 0.18 – 160 kz
46 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to charge temperature sensor
WA450-6, WA480-6 (KA SPEC.) 47

Failure code [CA154] (Charge temperature sensor low error) 1

Action code Failure code Charge temperature sensor low error
Trouble
Contents of • Low voltage is detected in temperature signal circuit of boost pressure sensor and temperature sen-
trouble sor.
Action of
• Fixes charge temperature (boost temperature) at 70°C and continues operation.
controller
Problem that
appears on
• Boost temperature-based engine protection function does not function.
machine
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: 18500, CHG TEMP).
Related
• The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: 18501, CHG TEMP).

Defective [temperature sig- without turning starting switch ON.
nal circuit] of boost pressure TIM (male) Resistance
1
sensor, temperature sensor
Between (A) and chassis ground Min. 1 Mz
2
(Short circuit with ground cir- Wiring harness between EC1 (female) (23) – Resis-
cuit) Min. 1 Mz
TIM (female) (A) and chassis ground tance
Possible causes Short circuit in wiring har- without turning starting switch ON.
and standard 3 ness Wiring harness among all pins between EC1
(with another wiring harness) (female) (23) – EC1 (female) (With all con- Resis-
value in normal Min. 1 Mz
tance
state nectors of wiring harness disconnected)
Connecting parts among boost pressure sensor/temperature sen-
sor, engine wiring harness, and engine controller are suspected.
Defective wiring harness Inspect them directly.
4
connector • Loose connector, broken lock, broken seal
Between (23) and (47) 0.18 – 160 kz
Between (23) and
Min. 1 Mz
chassis ground
48 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to charge temperature sensor
WA450-6, WA480-6 (KA SPEC.) 49

Failure code [CA187] (Sensor power supply 2 low error) 1

Action code Failure code Sensor power supply 2 voltage low error
Trouble
Contents of
• Low voltage is detected in sensor power supply 2 (5 V) circuit.
trouble
• Bkup speed sensor operates with signal from Ne speed sensor.
• Engine oil pressure sensor sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues
operation.
• Atmospheric pressure sensor sets atmospheric pressure to default (52.44 kPa {0.53 kg/cm2}), and
continues operation.
Action of
• Charge pressure sensor sets charge pressure to fixed value (400 kPa {4.1 kg/cm2}), and continues
controller
operation.
• EGR inlet pressure sensor sets EGR inlet pressure to default (102 kPa {1.04 kg/cm2}), and limits out-
put to continue operation.
• EGR valve lift sensor limits output and closes EGR valve.
Problem that
machine
Related
information

and standard
state
50 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA221] (Atmospheric pressure sensor high error) 1

Action code Failure code Atmospheric pressure sensor high error
Trouble
Contents of
• High voltage is detected in atmospheric pressure sensor circuit.
trouble
Action of
• Sets atmospheric pressure to default (52.44 kPa {0.53 kg/cm2}), and continues operation.
controller
Problem that
machine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: 37400 AMBIENT PRESS).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: 37402 AMBIENT PRESS).

Defective power supply sys-
If failure code [CA187] or [CA227] is displayed, carry out trouble-
1 tem of atmospheric pressure
shooting for it first.
sensor
PAMB Voltage
Defective atmospheric pres-
sure sensor (Internal defect)
and standard
Max. 1 z
state harness (Disconnection in PAMB (female) (1) tance
3
connector) Max. 1 z
PAMB (female) (2) tance
Max. 1 z
PAMB (female) (3) tance
PAMB (female) (1) and chassis ground tance
Min. 1 Mz
Min. 1 Mz
WA450-6, WA480-6 (KA SPEC.) 51


Resis-
PAMB (female) (1) and between EC1 Min. 1 Mz
tance
Short circuit in wiring (female) (38) – PAMB (female) (2)
Possible causes 5 harness (with another wiring Wiring harness between EC1 (female) (37) –
harness) Resis-
and standard PAMB (female) (1) and between EC1 Min. 1 Mz
tance
value in normal (female) (3) – PAMB (female) (3)
Resis-
PAMB (female) (2) and between EC1 Min. 1 Mz
tance
(female) (3) – PAMB (female) (3)
EC1 Voltage
Between (37) and (38) 4.75 – 5.25 V
Circuit diagram related to atmospheric pressure sensor
52 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA222] (Atmospheric pressure sensor low error) 1

Action code Failure code Atmospheric pressure sensor low error
Trouble
Contents of
• Low voltage is detected in atmospheric pressure sensor circuit.
trouble
Action of
• Sets atmospheric pressure to default (52.44 kPa {0.53 kg/cm2}) and continues operation.
controller
Problem that
machine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: 37400 AMBIENT PRESS).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: 37402 AMBIENT PRESS).

and standard
state
WA450-6, WA480-6 (KA SPEC.) 53

Failure code [CA227] (Sensor power supply 2 high error) 1

Action code Failure code Sensor power supply 2 high error
Trouble
Contents of
• High voltage is detected in sensor power supply 2 (5 V) circuit.
trouble
• Bkup speed sensor operates with signal from Ne speed sensor.
• Engine oil pressure sensor sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues
operation.
• Atmospheric pressure sensor sets atmospheric pressure to default (52.44 kPa {0.53 kg/cm2}), and
continues operation.
Action of
• Charge pressure sensor (boost pressure sensor) sets charge pressure to fixed value (400 kPa {4.1
controller
kg/cm2}), and continues operation.
• EGR inlet pressure sensor sets EGR inlet pressure to default (102 kPa {1.04 kg/cm2}), and limits out-
put to continue operation.
• EGR valve lift sensor limits output and closes EGR valve.
Problem that
machine
Related
information

1 Defect in related system If another code is displayed, carry out troubleshooting for it.
Bkup speed sensor
G connector
system
Disconnect device
Defective sensor (Internal suggested on the Oil pressure sensor POIL connector
2
defect) right. At this time, if Charge pressure
PIM connector
failure code is not sensor
indicated, the device Atmospheric
is defective. PAMB connector
Possible causes pressure sensor
and standard EGR valve lift sensor SEGR connector
value in normal
state
Disconnection in wiring without turning starting switch ON.
harness (Disconnection in Wiring harness between EC1 (female) (37) – Resis-
3 Max. 1 z
wiring or defective contact in each sensor (female) tance
connector) Wiring harness between EC1 (female) (47) – Resis-
Max. 1 z
each sensor (female) tance
Ground fault in wiring
4 harness (Short circuit with Min. 1 Mz
each sensor (female) and chassis ground tance
GND circuit)
Min. 1 Mz
each sensor (female) and chassis ground tance
54 WA450-6, WA480-6 (KA SPEC.)


Short circuit in wiring without turning starting switch ON.
Possible causes 5 harness (with another wiring Wiring harness between EC1 (female) (37) –
harness) Resis-
and standard each sensor (female) and between EC1 Min. 1 Mz
tance
value in normal (female) (47) – each sensor (female)
state a Prepare with starting switch OFF, then turn starting switch ON
EC1 Voltage
Between (37) and (47) 4.75 – 5.25 V
Circuit diagram related to sensor power supply 2 (5 V)
WA450-6, WA480-6 (KA SPEC.) 55

Failure code [CA234] (Engine overspeed) 1

Action code Failure code Engine overspeed
Trouble
Contents of
• Engine speed exceeded operating range.
trouble
Action of • Reduce fuel injection rate until engine speed lowers in operating range.
Problem that
appears on • Engine speed changes.
machine
Related • Engine speed can be checked by monitoring function (Code: 01002 ENG SPEED).
information • Method of reproducing failure code: Start engine and keep running at high idle.

Possible causes
and standard The method of using the installed machine may be improper, so
2 Usage is improper.
value in normal instruct the operator on how to use the machine properly.
state If causes 1 and 2 are not the cause of the trouble, the engine con-
3 Defective engine controller troller may be defective. (Since trouble is in system, troubleshooting
cannot be carried out.)
56 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 57

Failure code [CA238] (Ne speed sensor power supply error) 1

Action code Failure code Ne speed sensor power supply error
Trouble
Contents of
• Low voltage is detected in Ne speed sensor power supply (5 V) circuit.
trouble
Action of • Controls with signal from Bkup speed sensor.
Problem that
• Engine stops during operations. (When engine Bkup speed sensor is also defective)
appears on
• Engine cannot be started during operations. (When engine Bkup speed sensor is also defective)
machine
Related
information

Disconnect device
Defective Ne speed sensor suggested on the
1
(Internal defect) right. At this time, if
Ne speed sensor NE connector
failure code is not
indicated, the device
is defective.
2 Max. 1 z
wiring or defective contact in NE (female) (1) tance
connector) Wiring harness between EC1 (female) (48) – Resis-
Possible causes Max. 1 z
NE (female) (2) tance
and standard
state without turning starting switch ON.
NE (female) (1) and chassis ground tance
GND circuit)
Min. 1 Mz
harness) Resis-
NE (female) (1) and between EC1 (female) Min. 1 Mz
tance
(48) – NE (female) (2)
EC1 Voltage
Between (16) and (48) 4.75 – 5.25 V
58 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to Ne speed sensor power supply
WA450-6, WA480-6 (KA SPEC.) 59

SEN01679-00

60
SEN01680-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
Failure code [CA263] (Fuel temperature sensor high error) ................................................................ 4
Failure code [CA265] (Fuel temperature sensor low error).................................................................. 6
Failure code [CA271] (PCV1 Short circuit)........................................................................................... 8
Failure code [CA272] (PCV1 Disconnection) ..................................................................................... 10
Failure code [CA273] (PCV2 Short circuit)......................................................................................... 12
Failure code [CA274] (PCV2 Disconnection) ..................................................................................... 14
Failure code [CA322] (Injector #1 (L/B #1) open/short error)............................................................. 16
Failure code [CA342] (Calibration code inconsistency) ..................................................................... 28
WA450-6, WA480-6 (KA SPEC.) 1

Failure code [CA351] (Injectors drive circuit error)............................................................................. 29

Failure code [CA352] (Sensor power supply 1 low error)................................................................... 31
Failure code [CA386] (Sensor power supply 1 high error) ................................................................. 32
Failure code [CA431] (Idle validation switch error)............................................................................. 34
Failure code [CA432] (Idle validation action error) ............................................................................. 36
Failure code [CA441] (Battery voltage low error) ............................................................................... 38
Failure code [CA442] (Battery voltage high error).............................................................................. 41
Failure code [CA449] Common rail pressure high error 2.................................................................. 43
Failure code [CA451] (Common rail pressure sensor high error)....................................................... 44
Failure code [CA452] (Common rail pressure sensor low error) ........................................................ 46
Failure code [CA553] (Common rail pressure high error 1) ............................................................... 47
Failure code [CA554] (Common rail pressure sensor in-range error) ................................................ 48
Failure code [CA559] (Supply pump pressure very low error) ........................................................... 49
Failure code [CA689] (Engine Ne speed sensor error) ...................................................................... 53
Failure code [CA731] (Engine Bkup speed sensor phase error)........................................................ 55
Failure code [CA757] (All continuous data lost error)......................................................................... 55
Failure code [CA778] (Engine Bkup speed sensor error)................................................................... 56
Failure code [CA1228] (EGR valve servo error 1).............................................................................. 58
Failure code [CA1625] (EGR valve servo error 2).............................................................................. 59
Failure code [CA1633] (KOMNET datalink timeout error) .................................................................. 60
Failure code [CA2185] (Throttle sensor supply voltage high error) .................................................... 62
Failure code [CA2186] (Throttle sensor power supply low error) ....................................................... 63
2 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 3


Failure code [CA263] (Fuel temperature sensor high error) 1
Action code Failure code Fuel temperature sensor high error
Trouble
Contents of
• High voltage is detected in fuel temperature sensor circuit.
trouble
Action of
• Sets fuel temperature to fixed value (90°C), and continues operation.
controller
Problem that
appears on —
machine
• The input state (temperature) from the fuel temperature sensor can be checked with the monitoring
function (Code: 04204 FUEL TEMP).
Related
• The input state (voltage) from the fuel temperature sensor can be checked with the monitoring func-
information
tion (Code: 14201 FUEL TEMP).

Defective fuel temperature without turning starting switch ON.
1
sensor (Internal defect) TFUEL (male) Fuel temperature Resistance
Between (A) and (B) 10 – 100°C 0.6 – 20 kz
2 Max. 1 z
Possible causes wiring or defective contact in TFUEL (female) (A) tance
and standard connector) Wiring harness between EC1 (female) (47) – Resis-
value in normal Max. 1 z
TFUEL (female) (B) tance
state
TFUEL (female) (A) and chassis ground tance
GND circuit)
EC1 (female) Fuel temperature Resistance
4 Defective engine controller Between
10 – 100°C 0.6 – 20 kz
(30) and (47)
4 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to fuel temperature sensor
WA450-6, WA480-6 (KA SPEC.) 5

Failure code [CA265] (Fuel temperature sensor low error) 1

Action code Failure code Fuel temperature sensor low error
Trouble
Contents of
• Low voltage is detected in fuel temperature sensor circuit.
trouble
Action of • Injection rate by fuel temperature sensor is compensated with coolant temperature sensor (If coolant
controller temperature sensor is abnormal, the controller sets to fixed value (90°C) and continues operation.)
Problem that
appears on
machine
• The input state (temperature) from the fuel temperature sensor can be checked with the monitoring
function (Code: 04204 FUEL TEMP).
Related
• The input state (voltage) from the fuel temperature sensor can be checked with the monitoring func-
information
tion (Code: 14201 FUEL TEMP).

and standard
value in normal Carry out trouble shooting for failure code [CA263].
state
6 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 7

Failure code [CA271] (PCV1 Short circuit) 1

Action code Failure code PCV1 short circuit
Trouble
Contents of
• Short circuit was detected in supply pump PCV1 circuit.
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

Defective supply pump PCV1 (male) Resistance
1
PCV1 (Internal short circuit) Between (1) and (2) 2.3 – 5.3 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Grounding fault in wiring
2 harness (Contact with Min. 1 Mz
PCV1 (female) (1) and chassis ground tance
Possible causes ground circuit)
and standard Min. 1 Mz
value in normal
and carry out troubleshooting
Hot short in wiring harness Wiring harness between EC1 (female) (4) –
3 Voltage Max. 1 V
(Contact with 24 V circuit) PCV1 (female) (1) and chassis ground
Voltage Max. 1 V
PCV1 (female) (2) and chassis ground
Between (4) and (5) 2.3 – 5.3 z
Min. 1 Mz
chassis ground
8 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to supply pump PCV1
WA450-6, WA480-6 (KA SPEC.) 9

Failure code [CA272] (PCV1 Disconnection) 1

Action code Failure code PCV1 disconnection
Trouble
Contents of
• Disconnection was detected in supply pump PCV1 circuit.
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

Defective supply pump PCV1 PCV1 (male) Resistance
1
(Internal disconnection) Between (1) and (2) 2.3 – 5.3 z
Min. 1 Mz
chassis ground
Disconnection in wiring
2 harness (Disconnection or Max. 1 z
PCV1 (female) (1) tance
Possible causes defective contact of connector)
and standard Max. 1 z
value in normal
state a Prepare with starting switch OFF, then carry out troubleshooting
ground circuit)
Min. 1 Mz
Between (4) and (5) 2.3 – 5.3 z
Min. 1 Mz
chassis ground
10 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 11

Failure code [CA273] (PCV2 Short circuit) 1

Action code Failure code PCV2 short circuit
Trouble
Contents of
• Short circuit was detected in supply pump PCV2 circuit.
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

Defective supply pump PCV2 (male) Resistance
1
PCV2 (Internal short circuit) Between (1) and (2) 2.3 – 5.3 z
Min. 1 Mz
chassis ground
Possible causes ground circuit)
value in normal
and carry out troubleshooting
3 Voltage Max. 1 V
(Contact with 24 V circuit) PCV2 (female) (1) and chassis ground
Voltage Max. 1 V
PCV2 (female) (2) and chassis ground
Between (9) and (10) 2.3 – 5.3 z
Min. 1 Mz
chassis ground
12 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 13

Failure code [CA274] (PCV2 Disconnection) 1

Action code Failure code PCV2 disconnection
Trouble
Contents of
• Disconnection was detected in supply pump PCV2 circuit.
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

Defective supply pump PCV2 without turning starting switch ON.
1
(Internal disconnection) PCV2 (male) Resistance
Between (1) and (2) 2.3 – 5.3 z
2 harness (Disconnection or Max. 1 z
defective contact of connector)
Possible causes Max. 1 z
and standard
ground circuit)
Min. 1 Mz
Between (9) and (10) 2.3 – 5.3 z
Min. 1 Mz
chassis ground
14 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 15

Failure code [CA322] (Injector #1 (L/B #1) open/short error) 1

Action code Failure code Injector #1 (L/B #1) open/short error
Trouble
Contents of
• Disconnection or short circuit was detected in injector #1 circuit.
trouble
Action of
controller
Problem that
• Engine output lowers.
appears on
• Speed does not become stable.
machine
Related
information

Defective injector #1 CN1 (male) Resistance
1
(Internal defect) Between (1) and (2) 0.4 – 1.1 z
Min. 1 Mz
chassis ground
2 Max. 1 z
wiring or defective contact in CN1 (female) (1) tance
Possible causes connector) Wiring harness between EC1 (female) (53) – Resis-
CN1 (female) (2) tance
value in normal
CN1 (female) (1) and chassis ground tance
GND circuit)
Min. 1 Mz
Between (45) and (53) 0.4 – 1.1 z
Min. 1 Mz
chassis ground
16 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to injector #1
WA450-6, WA480-6 (KA SPEC.) 17


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
chassis ground
2 Max. 1 z
value in normal
GND circuit)
Min. 1 Mz
Between (46) and (60) 0.4 – 1.1 z
Min. 1 Mz
chassis ground
18 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 19


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
chassis ground
2 Max. 1 z
value in normal
GND circuit)
Min. 1 Mz
Between (55) and (52) 0.4 – 1.1 z
Min. 1 Mz
chassis ground
20 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 21


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
chassis ground
2 Max. 1 z
value in normal
GND circuit)
Min. 1 Mz
Between (57) and (59) 0.4 – 1.1 z
Min. 1 Mz
chassis ground
22 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 23


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
chassis ground
2 Max. 1 z
value in normal
GND circuit)
Min. 1 Mz
Between (54) and (51) 0.4 – 1.1 z
Min. 1 Mz
chassis ground
24 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 25


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
chassis ground
2 Max. 1 z
value in normal
GND circuit)
Min. 1 Mz
Between (56) and (58) 0.4 – 1.1 z
Min. 1 Mz
chassis ground
26 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 27

Failure code [CA342] (Calibration code inconsistency) 1

Action code Failure code Engine controller data inconsistency
Trouble
Contents of
• Data inconsistency occurred in engine controller.
trouble
Action of
controller
Problem that
• Normal operation is continued; however, the machine may stop during travel or may not start in
appears on
stopped state.
machine
Related
information

and standard
state
28 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA351] (Injectors drive circuit error) 1

Action code Failure code Injectors drive circuit error
Trouble
Contents of
• Abnormality occurred in injector drive power supply circuit.
trouble
Action of • Limits output and continues operation (limits common rail pressure).
• Exhaust smoke is black.
Problem that
• There is irregular combustion.
appears on
• Engine output drops.
machine
• The engine does not start.
Related
information

Defective fuse No. 6 of fuse
2 If the fuse is broken, the circuit probably has a grounding fault, etc.
box B
Defective engine control cut- Between (1) and (2) 200 – 400 z
3 out relay (L171) (Internal dis- a Prepare with starting switch OFF, then turn starting switch ON
connection or short circuit) and carry out troubleshooting.
When engine control cut-out relay (L171) is replaced with a relay of
the same type, if the condition becomes normal, the engine control
cut-out relay 1 is defective.
Possible causes
and standard L172 (male) Resistance
value in normal Defective engine control cut- Between (1) and (2) 200 – 400 z
state 4 out relay (L172) (Internal dis- a Prepare with starting switch OFF, then turn starting switch ON
cut-out relay 2 is defective.
Disconnection in wiring har- Wiring harness between fuse No. 6 of fuse Resis- Max.
ness box B – L171, L172 (female) (3) tance 0.5 z
5
(Disconnection or defective Wiring harness between L171 (female) (5), Resis- Max.
contact in connector) L172 (female) (5) – EC3 (female) (3), (4) tance 0.5 z
Max. 1 z
If causes 1 – 5 are not detected, engine controller may be defective.
6 Defective engine controller (Since trouble is in the system, troubleshooting cannot be carried
out.)
WA450-6, WA480-6 (KA SPEC.) 29

30 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA352] (Sensor power supply 1 low error) 1

Action code Failure code Sensor power supply 1 low error
Trouble
Contents of
• Low voltage is detected in sensor power supply 1 (5 V) circuit.
trouble
Action of • Common rail pressure sensor: Limits output for travel (Limits common rail pressure)
Problem that
appears on • Engine output drops.
machine
Related
information

and standard
state
WA450-6, WA480-6 (KA SPEC.) 31

Failure code [CA386] (Sensor power supply 1 high error) 1

Action code Failure code Sensor power supply 1 high error
Trouble
Contents of
• HIgh voltage is detected in sensor power supply 1 (5 V) circuit.
trouble
Action of • Common rail pressure sensor: Limits output for travel (Limits common rail pressure)
Problem that
machine
Related
information

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
Disconnect device
Defective sensor suggested on the
2
(Internal defect) right. At this time, if Common rail
PFUEL
failure code is not pressure sensor
indicated, the device
is defective.
3 Max. 1 z
wiring or defective contact in PFUEL (female) (1) tance
PFUEL (female) (3) tance
value in normal
state
PFUEL (female) (1) and chassis ground tance
GND circuit)
Min. 1 Mz
harness) Resis-
PFUEL (female) (1) and between EC1 Min. 1 Mz
tance
(female) (47) – PFUEL (female) (3)
EC1 Voltage
Between (33) and (47) 4.75 – 5.25 V
32 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to sensor power supply 1 (5 V)
WA450-6, WA480-6 (KA SPEC.) 33

Failure code [CA431] (Idle validation switch error) 1

Action code Failure code Idle validation switch error
Trouble
Contents of
• Abnormality occurred in idle validation switch circuit
trouble
Action of
• Operates at position of throttle of throttle sensor.
controller
Problem that
appears on —
machine
• The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring func-
tion (Code: 18300, IVS 1).
Related
information

PD Signal name Voltage
Defective accelerator pedal Between (5) and (4) Signal 1 See Fig. 1 on the next
1
(Internal trouble) Between (6) and (4) Signal 2 page
Disconnection in wiring har- Wiring harness between EC2 (female) (11) – Resis-
Max. 1 z
ness PD (female) (5) tance
2
(Disconnection or defective Wiring harness between EC2 (female) (1) – Resis-
PD (female) (6) tance
Possible causes
PD (female) (4) tance
value in normal
Wiring harness among all pins between EC2
Resis-
(female) (11) – EC2 (female) (PD, too, is dis- Min. 1 Mz
tance
connected.)
Short circuit in wiring har-
3 ness Resis-
(with another wiring harness) tance
connected.)
Between EC2 (female) (11) – EC3 (female) Resis-
Min. 1 Mz
(3) (PD, too, is disconnected.) tance
Between EC2 (female) (1) – EC3 (female) Resis-
Min. 1 Mz
(3) (PD, too, is disconnected.) tance
Connecting parts among accelerator pedal, engine unit wiring har-
connector
34 WA450-6, WA480-6 (KA SPEC.)


and standard
EC2 (female) Signal name Voltage
value in normal 5 Defective engine controller
state Between (11) and
Signal 1
(32) See Fig. 1
Between (1) and (32) Signal 2
Circuit diagram related to accelerator pedal
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A: Voltage when pedal opened + 0.03 ×
(Voltage when pedal pressed – Voltage
when pedal opened)
B: Voltage when pedal opened + 0.1 ×
when pedal opened)
WA450-6, WA480-6 (KA SPEC.) 35

Failure code [CA432] (Idle validation action error) 1

Action code Failure code Idle validation action error
Trouble
Contents of
• Signals from the idle validation switch and throttle sensor do not agree (they are contradictory)
trouble
1. When the idle validation switch recognized the accelerator pedal is OFF and the throttle sensor, on
the contrary, recognized the accelerator pedal is ON: Control the opening ratio of the throttle to 0%
after the accelerator pedal is OFF and then control the opening ratio of the throttle to 50% while after
Action of the accelerator pedal is ON.
controller 2. When the idle validation switch recognized the accelerator pedal is ON and the throttle sensor, on
the contrary, recognized the accelerator pedal is OFF: Control the opening ratio of the throttle to 0%
(fix to the low idling).
Problem that
appears on • Engine speed does not rise from low idle.
machine
Related
information

PD Signal name Voltage
Between (5) and (4) Signal 1 See Fig. 1 on the next
1 Defective accelerator pedal
Between (6) and (4) Signal 2 page
Possible causes 2 Max. 1 z
(Disconnection or defective PD (female) (1) tance
and standard contact in connector)
value in normal Wiring harness between EC2 (female) (9) – Resis-
Max. 1 z
state PD (female) (2) tance
Short circuit in wiring har- Resis-
3 ness tance
connected.)
(with another wiring harness)
Resis-
tance
connected.)
Connecting parts among accelerator pedal, engine unit wiring har-
connector
36 WA450-6, WA480-6 (KA SPEC.)


and standard
EC2 (female) Accelelator pedal Voltage
value in normal 5 Defective engine controller
Signal 1
(32) See Fig. 1
Between (1) and (32) Signal 2
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A: Voltage when pedal opened + 0.03 ×
when pedal opened)
B: Voltage when pedal opened + 0.1 ×
when pedal opened)
WA450-6, WA480-6 (KA SPEC.) 37

Failure code [CA441] (Battery voltage low error) 1

Action code Failure code Battery voltage low error
Trouble
Contents of
• Low voltage (Max. 6 V) occurred in controller power supply voltage circuit.
trouble
Action of
controller
Problem that
• Engine stops
appears on
• Starting performance is poor
machine
Related
information

Loose, corroded battery ter-
1 Inspect battery terminal directly for loose and corrosion.
minal
a Prepare with starting switch OFF, then turn starting switch OFF
and START and carry out troubleshooting.
2 Defective battery voltage Battery (1 piece) Starting switch Voltage
Between (+) and (–) OFF Min. 12 V
terminals START Min. 6.2 V
Defective fuse No. 6 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
3
Possible causes When engine control cut-out relay (L171) is replaced with a relay of
and standard the same type, if the condition becomes normal, the engine control
value in normal cut-out relay (L171) is defective.
state
cut-out relay (L172) is defective.
Disconnection in wiring har- Wiring harness between fuse No. 6 of fuse Resis-
Max. 1 z
ness box B – L171 or L172 (female) (3) tance
6
(Disconnection or defective Wiring harness between L171 (female) (5), Resis-
L172 (female) (5) – EC3 (female) (3), (4) tance
Max. 1 z
38 WA450-6, WA480-6 (KA SPEC.)


Wiring harness between fuse No. 6 of fuse
Resis-
Ground fault in wiring harness box B – L171, L172 (female) (3) and chassis Min. 1 Mz
7 tance
(Contact with ground circuit) ground
Resis-
L172 (female) (5) – EC (3), (4) and chassis Max. 1 z
tance
ground
Wiring harness among pins between EC3
Resis-
(female) (3), (4) – EC3 (female) (1), (2) Min. 1 Mz
tance
Possible causes (With battery terminal disconnected)
Short circuit in wiring harness
and standard 8
(with another wiring harness) Wiring harness among all pins between EC3 Resis-
value in normal (female) (3), (4) – EC2 (female) Min. 1 Mz
tance
state (With battery terminal disconnected)
Resis-
(female) (1), (2) – EC2 (female) Min. 1 Mz
tance
(With battery terminal disconnected)
Connecting parts among fuse No. 6 of fuse box B, engine unit wiring
connector
10 Defective engine controller EC3 (female) Starting switch Voltage
Between (3), (4) and ON Min. 24 V
(1), (2) START Min. 12 V
WA450-6, WA480-6 (KA SPEC.) 39

40 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA442] (Battery voltage high error) 1

Action code Failure code Battery voltage high error
Trouble
Contents of
• High voltage (min. 36V) occurred in controller power supply voltage circuit.
trouble
Action of
controller
Problem that
appears on • Engine may stop.
machine
Related
information

1 Defective battery voltage
Battery Voltage
Between (+) and (–) terminals Less than 32 V
Possible causes a Prepare with starting switch OFF, then start engine and carry out
and standard troubleshooting.
value in normal 2 Defective alternator E02 (male) Engine speed Voltage
state
Between (1) and
Min. medium speed 27.5 – 29.5 V
chassis ground
EC3 (female) Voltage
Between (3), (4) and (1), (2) Less than 32 V
WA450-6, WA480-6 (KA SPEC.) 41

42 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA449] Common rail pressure high error 2 1

Action code Failure code Common rail pressure high error 2
Trouble
Contents of
• There is high pressure error (level 2) in common rail pressure sensor circuit.
trouble
Problem that
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: 36400 RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: 36402 RAIL PRESS).

and standard
state
WA450-6, WA480-6 (KA SPEC.) 43

Failure code [CA451] (Common rail pressure sensor high error) 1

Action code Failure code Common rail pressure sensor high error
Trouble
Contents of
• Common rail pressure sensor circuit is abnormally high.
trouble
Problem that
machine
Related
information

Defective common rail pres- If failure code [CA352] or [CA386] is also indicated, carry out trou-
1
sure sensor power system bleshooting for it first.
PFUEL Voltage
Defective common rail pres- Between (1) and (3) Power supply 4.75 – 5.25 V
2
sure sensor (Internal defect) Between (2) and (3) Signal 0.25 – 4.6 V
Possible causes
and standard
Max. 1 z
state harness (Disconnection in PFUEL (female) (1) tance
3
connector) Max. 1 z
Max. 1 z
Min. 1 Mz
Min. 1 Mz
44 WA450-6, WA480-6 (KA SPEC.)


Resis-
tance
Short circuit in wiring (female) (25) – PFUEL (female) (2)
and standard tance
value in normal
state Resis-
tance
Between (33) and (47) 4.75 – 5.25 V
Between (25) and (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
WA450-6, WA480-6 (KA SPEC.) 45

Failure code [CA452] (Common rail pressure sensor low error) 1

Action code Failure code Common rail pressure sensor low error
Trouble
Contents of
• Common rail pressure sensor circuit is abnormally low.
trouble
Problem that
machine
Related
information

and standard
state
46 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA553] (Common rail pressure high error 1) 1

Action code Failure code Common rail pressure high error 1
Trouble
Contents of
• There is high pressure error (level 1) in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

2 Use of improper fuel Fuel used may be improper. Check it directly. (Viscosity is high)
Defective electrical system of Electrical system of common rail pressure sensor may be defective.
3
Possible causes common rail pressure sensor Carry out troubleshooting for failure code [CA451].
and standard Defective mechanical system
value in normal Mechanical system of common rail pressure sensor may be defec-
4 of common rail pressure sen-
state tive. Check it directly.
sor
Spring damage, seat wear, or ball stuck of overflow valve is sus-
5 Defective overflow valve
pected. Check it directly.
6 Clogged overflow pipe Overflow pipe may be clogged. Check it directly.
7 Defective pressure limiter Pressure limiter may be damaged mechanically. Check it directly.
WA450-6, WA480-6 (KA SPEC.) 47

Failure code [CA554] (Common rail pressure sensor in-range error) 1

Action code Failure code Common rail pressure sensor in-range error
Trouble
Contents of
• In-range error occurred in common rail pressure sensor circuit.
trouble
Problem that
machine
Related
information

and standard
state
48 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA559] (Supply pump pressure very low error) 1

Action code Failure code Supply pump pressure very low error 1
Trouble
Contents of
• There is no-pressure feed error (level 1) in supply pump.
trouble
Action of • Limits common rail pressure.
Problem that
machine
Related
information

2 Use of improper fuel Fuel used may be improper. Check it directly.
a For more information on troubleshooting, see Note 1. For check
of pressure in fuel low pressure circuit, see Testing and adjusting,
Defect in low pressure “Testing fuel pressure”.
3
circuit parts
Pressure in fuel Min. 0.15 MPa
low-pressure circuit {Min. 1.5 kg/cm2}
4 Clogged fuel filter, strainer a For more information on troubleshooting, see Note 2.
Electrical system of supply pump PCV may be defective. Carry out
Defective electrical system of
5 troubleshooting for failure code [CA271], [CA272], [CA273], or
supply pump PCV
[CA274].
Defective common rail Mechanical system of common rail pressure sensor may be defec-
6
Possible causes pressure sensor tive. Check whether wiring harness is damaged.
and standard a For check of leakage through pressure limiter, see Testing and
value in normal adjusting, “Testing fuel return rate and leakage”.
state 7 Defective pressure limiter
Max. 10 cc/min
Leakage through pressure limiter
(at full stall or relief)
a For check of limited return rate (spill) from injector, see Testing
and adjusting, “Testing fuel return rate and leakage”.
Speed at rated operation Limited return (spill) rate from
(stall load) injector
8 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 causes 1 – 8 are not the cause of the trouble, supply pump may
9 Defective supply pump
be defective.
<Using check sheet>

While carrying out troubleshooting above, record troubleshooting contents on the “Check sheet for no-pres-
sure feed” attached separately.
WA450-6, WA480-6 (KA SPEC.) 49

Note 1: When low-pressure circuit is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
50 WA450-6, WA480-6 (KA SPEC.)

Check sheet for no-pressure feed

Machine model WA450-6 Working No.
Model serial No. # Checked on / /
Engine SAA6D125E-5 Service meter h
Engine serial No. # Worker name
A. Visual check Good Bad

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) Good Bad
3 Checking error and failure codes / / / /
Checking monitoring information
Standard value Measured
Code Display item Check conditions Unit Good Bad
(Reference value) value
Low idle (P-mode) rpm 800 +50
+50
01002 Engine speed High idle (P-mode) rpm 2,170 ± 50

Full stall (P-mode) rpm 1,980 ± 100
Position of accelerator Low idle % 0
31701
pedal High idle % 100
Common rail pressure
4 36200 Rating or equivalent MPa
command
36400 Common rail fuel pressure Rating or equivalent MPa
Low idle CA — — —
36300 Injection timing command High idle CA — — —
Rating or equivalent CA — — —
kPa Min. 107
36500 Boost pressure Rating or equivalent — —
{mmHg} {Min. 800}
04104 Engine coolant temperature Low idle °C — — —
04204 Fuel temperature Low idle °C — — —
Checking cylinder cut-out operation (Engine speed)
Function Cut-out cylinder Check conditions Unit Good Bad
Cylinder 1 Low idle rpm — — —
5 Cylinder 2 Low idle rpm — — —
Cylinder
cut-out
function

C. Checking fuel circuit pressure Check conditions Unit Good Bad
MPa Min. 0.15
6 Pressure in fuel low-pressure circuit High idle
{kg/cm2} {Min. 1.5}
D. Checking strainer, filter Good Bad

7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve

E. Checking leakage and fuel return rate Check conditions Unit Good Bad
11 Leakage through pressure limiter No load, full stall, or relief cc/min Max. 10
Rating or equivalent Speed:
cc/min 960
<by model> 1,600 rpm
Rating or equivalent
cc/min 1,020
12 Return rate from injector cc/min 1,080 Return rate:
cc/min 1,140
cc/min 1,200
WA450-6, WA480-6 (KA SPEC.) 51

Check sheet for no-pressure feed

Machine model WA480-6 Working No.
Model serial No. # Checked on / /
Engine SAA6D125E-5 Service meter h
Engine serial No. # Worker name
A. Visual check Good Bad

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) Good Bad
3 Checking error and failure codes / / / /
Checking monitoring information
Code Display item Check conditions Unit Good Bad
Low idle (P-mode) rpm 800 +50
+50
01002 Engine speed High idle (P-mode) rpm 2,190 ± 50

Full stall (P-mode) rpm 1,850 ± 100
Position of accelerator Low idle % 0
31701
pedal High idle % 100
Common rail pressure
4 36200 Rating or equivalent MPa
command
36400 Common rail fuel pressure Rating or equivalent MPa
Low idle CA — — —
36300 Injection timing command High idle CA — — —
Rating or equivalent CA — — —
kPa Min. 120
36500 Boost pressure Rating or equivalent — —
{mmHg} {Min. 900}
04104 Engine coolant temperature Low idle °C — — —
04204 Fuel temperature Low idle °C — — —
Checking cylinder cut-out operation (Engine speed)
Function Cut-out cylinder Check conditions Unit Good Bad
5 Cylinder 2 Low idle rpm — — —
Cylinder
cut-out
function

C. Checking fuel circuit pressure Check conditions Unit Good Bad
MPa Min. 0.15
6 Pressure in fuel low-pressure circuit High idle
{kg/cm2} {Min. 1.5}
D. Checking strainer, filter Good Bad

7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve

E. Checking leakage and fuel return rate Check conditions Unit Good Bad
11 Leakage through pressure limiter No load, full stall, or relief cc/min Max. 10
Rating or equivalent Speed:
cc/min 960
cc/min 1,020
12 Return rate from injector cc/min 1,080 Return rate:
cc/min 1,140
cc/min 1,200
52 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA689] (Engine Ne speed sensor error) 1

Action code Failure code Engine Ne speed sensor error
Trouble
Contents of
• Error was detected in engine Ne speed sensor circuit.
trouble
Action of • Operates the engine with signal from engine Bkup speed sensor.
Problem that
• Engine stops during operations. (When engine Bkup speed sensor is also defective)
appears on
• Engine cannot be started during stop. (When engine Bkup speed sensor is also defective)
machine
Related
information

Defective sensor power If failure code [CA238] is displayed, carry out troubleshooting for it
1
supply system first.
Max. 1 z
harness (Disconnection in NE (female) (1) tance
2
connector) Max. 1 z
Max. 1 z
Min. 1 Mz
Possible causes Wiring harness between EC1 (female) (27) – Resis-
Min. 1 Mz
and standard NE (female) (3) and chassis ground tance
Resis-
tance
Short circuit in wiring (48) – NE (female) (2)
harness) Resis-
tance
(27) – NE (female) (3)
Resis-
tance
(27) – NE (female) (3)
Defective installation of
Installation of Ne speed sensor (clearance error) or speed sensor
5 sensor or defective speed
parts (fly wheel) may be defective. Check it directly.
sensor parts
If causes 1 – 4 are not the cause of the trouble, engine Ne speed
Defective engine Ne speed
6 sensor may be defective. (Since trouble is in system, troubleshoot-
sensor
ing cannot be carried out.)
If causes 1 – 4 are not the cause of the trouble, engine controller
7 Defective engine controller may be defective. (Since trouble is in system, troubleshooting can-
not be carried out.)
WA450-6, WA480-6 (KA SPEC.) 53

Circuit diagram related to engine Ne speed sensor
54 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA731] (Engine Bkup speed sensor phase error) 1

Action code Failure code Engine Bkup speed sensor phase error
Trouble
Contents of
• There is phase error in engine Bkup speed sensor circuit.
trouble
Action of • Controls the engine with signal from engine Ne speed sensor.
Problem that
• Engine stops during operations. (When engine Ne speed sensor is also defective)
appears on
• Engine cannot be started during stop. (When engine Ne speed sensor is also defective)
machine
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out troubleshoot-
and standard 1
sensor system ing for failure code [CA689].
value in normal
state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trouble-
2
speed sensor system shooting for failure code [CA778].
Failure code [CA757] (All continuous data lost error) 1

Action code Failure code All continuous data lost error
Trouble
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
appears on • Operations are continued, but engine may stop during operations or may not start in stopped state.
machine
Related
information

and standard
state
WA450-6, WA480-6 (KA SPEC.) 55

Failure code [CA778] (Engine Bkup speed sensor error) 1

Action code Failure code Engine Bkup speed sensor error
Trouble
Contents of
• Error was detected in engine Bkup speed sensor circuit.
trouble
Action of • Operates the engine with signal from engine Ne speed sensor.
Problem that
• Engine stops during operations. (When engine Ne speed sensor is also defective)
appears on
• Engine cannot be started during stop. (When engine Ne speed sensor is also defective)
machine
Related
information

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
supply system shooting for it first.
Max. 1 z
harness (Disconnection in G (female) (1) tance
2
connector) Max. 1 z
G (female) (2) tance
Max. 1 z
G (female) (3) tance
G (female) (1) and chassis ground tance
Possible causes Min. 1 Mz
and standard
value in normal Min. 1 Mz
state
Resis-
G (female) (1) and between EC1 (female) Min. 1 Mz
tance
Short circuit in wiring (47) – G (female) (2)
harness) Resis-
tance
(26) – G (female) (3)
Resis-
tance
(26) – G (female) (3)
If causes 1 – 4 are not the cause of the trouble, engine Bkup speed
Defective engine Bkup
5 sensor may be defective. (Since trouble is in system, troubleshoot-
speed sensor
ing cannot be carried out.)
56 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to engine Bkup speed sensor
WA450-6, WA480-6 (KA SPEC.) 57

Failure code [CA1228] (EGR valve servo error 1) 1

Action code Failure code EGR valve servo error 1
Trouble
Contents of
• There is servo error (level 1) of EGR valve.
trouble
Action of • Performs open control.
Problem that
appears on —
machine
Related
information

a For check of engine oil pressure, see Testing and adjusting,
“Testing engine oil pressure”.
Engine Engine oil pressure
Defective engine oil pressure
2 Low idle 0.08 MPa {0.8 kg/cm2}
system (main circuit)
High idle 0.21 MPa {2.1 kg/cm2}
Possible causes If engine oil pressure is not normal, carry out troubleshooting (S-
and standard mode) for mechanical system. (S-12 Oil pressure drops)
value in normal Defective EGR valve oil Oil pump or relief valve for EGR valve circuit may be defective.
state 3
pump Check it directly.
Defective EGR valve oil Oil pressure supply piping for EGR valve circuit may be defective.
4
pressure supply piping Check it directly.
Defective EGR valve oil Oil pressure return piping for EGR valve circuit may be defective.
5
pressure return piping Check it directly.
6 Defective EGR valve EGR valve may be damaged mechanically. Check it directly.
58 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA1625] (EGR valve servo error 2) 1

Action code Failure code EGR valve servo error 2
Trouble
Contents of
• There is servo error (level 2) of EGR valve.
trouble
• Limits output and continues operation.
Action of
• Close EGR and bypass valves.
controller
Problem that
machine
Related
information

and standard
state
WA450-6, WA480-6 (KA SPEC.) 59

Failure code [CA1633] (KOMNET datalink timeout error) 1

Action code Failure code KOMNET datalink timeout error
Trouble
Contents of • Engine controller detected a communication error in the KOMNET communication circuit used for the
trouble communication between the pump controllers and machine monitor.
• Continues the operation from the default mode.
Action of
controller
Problem that
• KOMNET communication information may not be transmitted correctly to cause incorrect operation
appears on
of machine. (Problem depends on failure occurrence location.)
machine
Related
information

CAN1 (male) Resistance
Defective CAN end point Between (A) and (B) 110 – 140 z
1
resistance a Prepare with starting switch OFF, then carry out troubleshooting
Between (A) and (B) 110 – 140 z
value in normal Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
state (47) – L62 (female) (22), (32) tance
Max. 1 z
Disconnection in wiring har- (47) – L56 (female) (3), (8) tance
ness Wiring harness between EC2 (female) (46), Resis-
2 Max. 1 z
(Disconnection or defective (47) – L72 (female) (22), (32) tance
contact in connector) Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – L80 (female) (7), (8) tance
Max. 1 z
(47) – CAN1 (female) (A), (B) tance
Max. 1 z
60 WA450-6, WA480-6 (KA SPEC.)


Wiring harness between EC2 (female) (46),
Resis-
(47) – L62 (female) (22), (32) and chassis Min. 1 Mz
tance
ground
Resis-
tance
ground
Ground fault in wiring har- Wiring harness between EC2 (female) (46),
Resis-
ness (47) – L72 (female) (22), (32) and chassis Min. 1 Mz
3 tance
Possible causes (Short circuit with ground cir- ground
and standard cuit) Wiring harness between EC2 (female) (46),
value in normal Resis-
state tance
ground
Resis-
(47) – CAN1 (female) (A), (B) and chassis Min. 1 Mz
tance
ground
Resis-
tance
ground
Defective machine monitor, a If above troubleshootings 1 – 3 have not identified the cause of
transmission controller, work the trouble, failure on the machine monitor, transmission control-
4 equipment controller, engine ler, work equipment controller, engine controller or KOMTRAX
controller or KOMTRAX ter- terminal should be suspected. (Since trouble is in system, trou-
minal bleshooting cannot be carried out.)
Circuit diagram related to CAN communication
WA450-6, WA480-6 (KA SPEC.) 61

Failure code [CA2185] (Throttle sensor supply voltage high error) 1

Action code Failure code Throttle sensor supply voltage high error
Trouble
Contents of
• High voltage (min. 5.25V) occurred in throttle sensor power supply circuit.
trouble
Problem that
machine
Related
information

Short circuit in wiring harness Resis-
1 (female) (22) – EC2 (female) (PD, too, is dis- Min. 1 Mz
(with another wiring harness) tance
connected.)
Possible causes
and standard Between EC2 (female) (22) – EC3 (female) Resis-
Min. 1 Mz
value in normal (3) (PD, too, is disconnected.) tance
state Connecting parts among fuel control dial, engine unit wiring har-
connector
(Since trouble is in system, troubleshooting cannot be carried out.)
62 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA2186] (Throttle sensor power supply low error) 1

Action code Failure code Throttle sensor power supply voltage low error
Trouble
Contents of
• Low voltage occurred in throttle sensor power supply circuit.
trouble
Problem that
machine
Related
information

Ground fault in wiring harness without turning starting switch ON.
1
(Contact with ground circuit) Wiring harness between EC2 (female) (22) – Resis-
Min. 1 Mz
PD (female) (1) and chassis ground tance
Possible causes Short circuit in wiring harness
2
and standard (with another wiring harness) Wiring harness among all pins between EC2 Resis-
value in normal (female) (9) – EC2 (female) (PD, too, is dis- Min. 1 Mz
tance
state connected.)
connector
WA450-6, WA480-6 (KA SPEC.) 63

SEN01680-00

64
SEN01681-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
Failure code [CA2249] (Supply pump pressure very low error 2) ........................................................ 3
Failure code [CA2271] (EGR valve lift sensor high error) .................................................................... 4
Failure code [CA2272] (EGR valve lift sensor low error) ..................................................................... 6
Failure code [CA2351] (EGR valve solenoid operation short circuit) ................................................... 7
Failure code [CA2352] (EGR valve solenoid operation disconnect) .................................................... 9
Failure code [CA2555] (Intake heater relay disconnection error)....................................................... 10
Failure code [CA2556] (Intake heater relay short circuit error) .......................................................... 12
Failure code [D150KA] (Emergency steering relay: Disconnection) .................................................. 14
Failure code [D150KB] (Emergency steering relay: Short circuit) ...................................................... 16
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line).................. 18
Failure code [D160KA] (Backup lamp relay: Disconnection) ............................................................. 20
Failure code [D160KB] (Backup lamp relay: Short circuit) ................................................................. 22
Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit) ...................................... 24
WA450-6, WA480-6 (KA SPEC.) 1

Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) ................................. 26
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)..................................... 28
Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line). 30
Failure code [D192KA] (ECSS solenoid: Disconnection) ................................................................... 32
Failure code [D192KB] (ECSS solenoid: Short circuit)....................................................................... 33
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line) .................................. 34
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection).................................... 35
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit) ....................................... 37
Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line) ... 39
Failure code [D5ZHKA] (Terminal C signal: Disconnection)............................................................... 41
Failure code [D5ZHKB] (Terminal C signal: Short circuit) .................................................................. 45
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) ....................................... 48
Failure code [D5ZHL6] (Terminal C signal:
Signal does not match engine running or stopped state) ......................................................... 53
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree) ...................................... 56
Failure code [DAF3KK] (Machine monitor: Low source voltage (input)) ............................................ 58
Failure code [DAF5KP] (Machine monitor: Low output voltage) ........................................................ 60
Defective communication (Abnormality in target component system)) ..................................... 64
2 WA450-6, WA480-6 (KA SPEC.)


Failure code [CA2249] (Supply pump pressure very low error 2) 1
Action code Failure code Supply pump pressure very low error 2
Trouble
Contents of
• No-pressure feed (2) occurred in common rail circuit.
trouble
Action of • Limits output and continues operation.
Problem that • Starting performance is poor
appears on • Exhaust smoke is black.
machine • Engine output lowers.
the monitoring function (Code: 36400, RAIL PRESS).
Related
information
function (Code: 36402, RAIL PRESS).

and standard
value in normal 1 Carry out troubleshooting for failure code [CA559].
state
WA450-6, WA480-6 (KA SPEC.) 3

Failure code [CA2271] (EGR valve lift sensor high error) 1

Action code Failure code EGR valve lift sensor high error
Trouble
Contents of
• High voltage is detected in EGR valve lift sensor circuit.
trouble
Action of
• Closes EGR valve.
controller
Problem that
machine
• The input state (position: mm) from the EGR valve lift sensor can be checked with the monitoring
function (Code: 18100 BPS VALVE POS).
Related
• The input state (voltage) from the EGR valve lift sensor can be checked with the monitoring function
information
(Code: 18101 BPS VALVE POS).

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
supply system shooting for it first.
Defective EGR valve lift SEGR Voltage
2 sensor Between (1) and (2) Power supply 4.75 – 5.25 V
(Internal defect)
and standard Disconnection in wiring Wiring harness between EC1 (female) (37) – Resis-
harness SEGR (female) (1) tance
state 3
(Disconnection or defective Wiring harness between EC1 (female) (47) – Resis-
SEGR (female) (2) tance
Max. 1 z
SEGR (female) (3), (4) tance
Min. 1 Mz
Ground fault in wiring harness SEGR (female) (1) and chassis ground tance
4
Min. 1 Mz
SEGR (female) (2) and chassis ground tance
Min. 1 Mz
SEGR (female) (3), (4) and chassis ground tance
4 WA450-6, WA480-6 (KA SPEC.)


without turning staring switch ON.
Resis-
SEGR (female) (1) and EC1 (female) (19) – Min. 1 Mz
tance
SEGR (female) (3), (4)
Short circuit in wiring harness
5
Possible causes (with another wiring harness) Wiring harness between EC1 (female) (37) – Resis-
and standard SEGR (female) (1) and EC1 (female) (19) – Min. 1 Mz
tance
value in normal SEGR (female) (3), (4)
Resis-
SEGR (female) (2) and EC1 (female) (19) – Min. 1 Mz
tance
SEGR (female) (3), (4)
EC1 Voltage
Between (37) and (47) 4.75 – 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
WA450-6, WA480-6 (KA SPEC.) 5

Failure code [CA2272] (EGR valve lift sensor low error) 1

Action code Failure code EGR valve lift sensor low error
Trouble
Contents of
• Low voltage is detected in EGR valve lift sensor circuit.
trouble
Action of
controller
Problem that
machine
• The input state (position: mm) from the EGR valve lift sensor can be checked with the monitoring
function (Code: 18100 BPS VALVE POS).
Related
• The input state (voltage) from the EGR valve lift sensor can be checked with the monitoring function
information
(Code: 18101 BPS VALVE POS).

and standard
state
6 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA2351] (EGR valve solenoid operation short circuit) 1

Action code Failure code EGR valve solenoid operation short circuit error
Trouble
Contents of
• Short circuit was detected in drive circuit of EGR valve solenoid.
trouble
Action of
controller
Problem that
machine
Related
information

Defective EGR valve solenoid without turning starting switch ON.
1
(Internal defect) EGR (male) Resistance
Between (1) and (2) 10 – 21 z
harness Wiring harness between EC1 (female) (22) – Resis-
2 Max. 1 z
(Disconnection or defective EGR (female) (1) tance
Max. 1 z
EGR (female) (2) tance
and standard
value in normal Ground fault in wiring harness Wiring harness between EC1 (female) (22) – Resis-
3 Min. 1 Mz
state (Contact with ground circuit) EGR (female) (1) and chassis ground tance
Min. 1 Mz
EGR (female) (2) and chassis ground tance
4 Voltage Max. 1 V
(Contact with 24 V circuit) EGR (female) (1) and chassis ground
Voltage Max. 1 V
EGR (female) (2) and chassis ground
Between (22) and (11) 10 – 21 z
WA450-6, WA480-6 (KA SPEC.) 7

Circuit diagram related to EGR valve solenoid & lift sensor
8 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA2352] (EGR valve solenoid operation disconnect) 1

Action code Failure code EGR valve solenoid operation disconnection error
Trouble
Contents of
• Disconnection error was detected in drive circuit of EGR valve solenoid.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
WA450-6, WA480-6 (KA SPEC.) 9

Failure code [CA2555] (Intake heater relay disconnection error) 1

Action code Failure code Intake heater relay disconnection error
Trouble
Contents of
• There is disconnection in intake air heater relay.
trouble
Action of
• None in particular.
controller
Problem that
• Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temper-
appears on
ature)
machine
Related • Method of reproducing failure code: Turn the starting switch ON when coolant temperature is –4°C or
information less.

without turning starting switch ON. (Test relay unit).
Between E06 and chassis Resistance
Defective heater relay ground 300 – 600 z
1
(Internal disconnection) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Test by replacing relay unit.)
When heater relay is replaced with a relay of the same type, if the
condition becomes normal, the heater relay is defective.
2 Max. 1 z
(Disconnection or defective E06 tance
Possible causes contact in connector) Wiring harness between primary side of Resis-
heater relay – chassis ground tance
value in normal
(with another wiring harness) (female) (40) – EC2 (female) (E06, too, is Resis-
Min. 1 Mz
tance
disconnected.)
Connecting parts among heater relay, engine unit wiring harness,
and engine controller are suspected. Inspect them directly.
connector
5 Defective engine controller EC2 (female) Resistance
Between (40) and chassis
300 – 600 z
ground
10 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to intake heater relay
WA450-6, WA480-6 (KA SPEC.) 11

Failure code [CA2556] (Intake heater relay short circuit error) 1

Action code Failure code Intake heater relay short circuit error
Trouble
Contents of
• There is short circuit in intake air heater relay.
trouble
Action of
controller
Problem that
• Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temper-
appears on
ature)
machine
Related • Method of reproducing failure code: Turn the starting switch ON when coolant temperature is –4°C or
information less.

without turning starting switch ON. (Test relay unit).
Between E06 and chassis Resistance
Defective heater relay ground 300 – 600 z
1
(Internal short circuit) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Test by replacing relay unit.)
When heater relay is replaced with a relay of the same type, if the
condition becomes normal, the heater relay is defective.
Ground fault in wiring har- without turning starting switch ON.
2 ness
Min. 1 Mz
Possible causes E06 tance
and standard
value in normal
state
(with another wiring harness) (female) (40) – EC2 (female) (E06, too, is Resis-
Min. 1 Mz
tance
disconnected.)
Connecting parts among heater relay, engine unit wiring harness,
and engine controller are suspected. Inspect them directly.
connector
5 Defective engine controller EC2 (female) Resistance
Between (40) and
300 – 600 z
chassis ground
12 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to intake heater relay
WA450-6, WA480-6 (KA SPEC.) 13

Failure code [D150KA] (Emergency steering relay: Disconnection) 1

Action code Failure code Emergency steering relay: Disconnection
Trouble
E03 D150KA (Transmission controller)
Contents of • Since the emergency steering relay output system is disconnect, signals are not output to the emer-
trouble gency steering relay.
Action of
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
controller
Problem that • If abnormality is detected in the steering pressure, operation of the automatic emergency steering
appears on becomes unavailable.
machine • Self-check of the emergency steering is ended abnormally.
• The output state (ON/OFF) to the emergency steering relay can be checked with the monitoring
Related
function (Code: 90949, D-OUT-0).
information
• Method of reproducing failure code: Start engine, then operate the steering.

When emergency steering relay (L126) is replaced with a relay of
Defective emergency steer- the same type, if the condition becomes normal, the emergency
1 ing relay (L126) (Internal dis- steering relay is defective.
connection) a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes
and standard Between (1) and (2) 200 – 400 z
ness Wiring harness between L63 (female) (7) – Resis-
2 Max. 1 z
(Disconnection or defective L126 (female) (1) tance
contact in connector) Wiring harness between L126 (female) (2) – Resis-
Max. 1 z
Defective transmission con- without turning starting switch ON.
3
troller L63 (female) Resistance
Between (7) and chassis ground 200 – 400 z
14 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to emergency steering relay
WA450-6, WA480-6 (KA SPEC.) 15

Failure code [D150KB] (Emergency steering relay: Short circuit) 1

Action code Failure code Emergency steering relay: Short circuit
Trouble
E03 D150KB (Transmission controller)
Contents of • Since the emergency steering relay output system is shorted, signals are not output to the emer-
trouble gency steering relay.
Problem that • If abnormality is detected in the steering pressure, operation of the automatic emergency steering
appears on becomes unavailable.
machine • Self-check of the emergency steering is ended abnormally.
Related
information
• Method of reproducing failure code: Start engine and then operate the steering.

the same type, if the condition becomes normal, the emergency
steering relay is defective.
Defective emergency steer-
1 ing relay (L126) (Internal a Prepare with starting switch OFF, then carry out troubleshooting
short circuit) without turning starting switch ON.
Possible causes
value in normal Between (1), (2) and chassis
state Min. 1 Mz
ground
2 ness (Short circuit with GND
circuit) Wiring harness between L63 (female) (7) – Resis-
Min. 1 Mz
3
16 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 17

Failure code [D150KY] (Emergency steering relay: Short circuit with

power supply line) 1
Action code Failure code Emergency steering relay: Short circuit with power supply line
Trouble
E03 D150KY (Transmission controller)
Contents of • Since the emergency steering relay output system is shorted with the power source, signal output to
trouble the emergency steering relay is continued.
Problem that
• The emergency steering is activated during travel (resulting in seizure of the emergency steering
appears on
motor).
machine
Related
information

the same type, if the condition becomes normal, the emergency
steering relay is defective.
Defective emergency steer-
1 ing relay (L126) (Internal a Prepare with starting switch OFF, then carry out troubleshooting
short circuit) without turning starting switch ON.
Possible causes
state Min. 1 Mz
ground
Hot short in wiring harness and carry out troubleshooting.
2
(Contact with 24V circuit) Wiring harness between L63 (female) (7) –
Voltage Max. 1 V
L126 (female) (1) and chassis ground
3
18 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 19

Failure code [D160KA] (Backup lamp relay: Disconnection) 1

Action code Failure code Backup lamp relay: Disconnection
Trouble
• Since the backup lamp relay output system is disconnected, signals are not output to the backup
Contents of lamp relay.
trouble • Since the backup lamp relay output system is shorted with the power source, signal output to the
backup lamp lay is continued.
Action of • Turns the output to the backup lamp relay OFF.
• The backup lamp does not light up (disconnection).
Problem that
• The backup buzzer does not sound (disconnection).
appears on
• The backup lamp remains turned on (hot short).
machine
• The backup buzzer sound does no stop (hot short).
• The output state (ON/OFF) to the backup lamp relay can be checked with the monitoring function
Related (Code: 90951, D-OUT-20).
information • Method of reproducing failure code: Turn the starting switch ON, and set FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch to R (reverse).

When backup lamp relay (L117) is replaced with a relay of the same
type, if the condition becomes normal, the backup lamp relay is
Defective backup lamp relay defective.
1
(L117) (Internal short circuit)
Between (1) and (2) 200 – 400 z
Possible causes 2 Max. 1 z
and standard
state chassis ground tance
3
Voltage Max. 1 V
FNR (directional)
lever, joystick steer-
Defective transmission con- L63 ing FNR (directional) Voltage
4
troller switch or right FNR
Between (4) and R (Reverse) 20 – 30 V
chassis ground Other than above Max. 1 V
20 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to backup lamp relay
WA450-6, WA480-6 (KA SPEC.) 21

Failure code [D160KB] (Backup lamp relay: Short circuit) 1

Action code Failure code Backup lamp relay: Short circuit
Trouble
Contents of • Since the backup lamp relay output system is shorted, signals are not output to the backup lamp
trouble relay.
Action of • Turns the output to the backup lamp relay OFF.
Problem that
• The backup lamp does not light up.
appears on
• The backup buzzer does not sound.
machine

Defective backup lamp relay defective.
1
(L101) (Internal short circuit)
Between (1) and (2) 200 – 400 z
Possible causes
value in normal 2 ness (Contact with ground
state circuit) Wiring harness between L63 (female) (4) – Resis-
Min. 1 Mz
FNR (directional)
3
22 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 23

Failure code [D160KZ] (Backup lamp relay: Disconnection or short

circuit) 1
Action code Failure code Backup lamp relay: Disconnection or short circuit
Trouble
E01 D160KZ (Transmission controller)
Contents of • Since the backup lamp relay output system is shorted, signals are not output to the backup lamp
trouble relay.
• Turns the output to the backup lamp relay OFF.
Action of
• When ground fault occurred, even if cause of failure disappears, system does not reset itself until
controller
starting switch is turned OFF.
Problem that
• The backup lamp does not light up.
appears on
• The backup buzzer does not sound.
machine

defective.
Defective backup lamp relay a Prepare with starting switch OFF, then carry out troubleshooting
1
(L101) (Internal short circuit) without turning starting switch ON.
Between (1) and (2) 200 – 400 z
Between (1), (2) and chassis
ground
and standard
state
2 ness (Contact with ground
circuit) Wiring harness between L63 (female) (4) – Resis-
Max. 1 z
FNR (directional)
3
24 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 25

Failure code [D191KA] (Joystick steering neutral safety relay:

Disconnection) 1
Action code Failure code Joystick steering neural safety relay: Disconnection
Trouble
E01 D191KA (Work equipment controller system)
Contents of • Since the output system of the joystick steering neutral safety relay is disconnected, signals are not
trouble output to the neutral safety relay.
Action of
controller
• While operating joystick steering, engine can be started (Steering moves immediately after engine
Problem that
start).
appears on
• Starting of the engine is available even when the joystick steering FNR (directional) switch or right
machine
FNR (directional) switch is not set to N (neutral).
• When the neutral position adjustment (initial setting) is not done for the joystick steering, the neutral
safety relay does not work.
• The output state (ON/OFF) to the neutral safety relay can be checked with the monitoring function
Related
(Code: 40954, D-OUT-20).
information
• Only for joystick steering
• Method of reproducing failure code: Turn the starting switch ON and operate the joystick steering
(with the engine being stopped).

Defective joystick steering without turning starting switch ON.
1 neutral safety relay (L113)
Between (1) and (2) 200 – 400 z
Possible causes
and standard ness Wiring harness between L63 (female) (37) – Resis-
2 Max. 1 z
value in normal (Disconnection or defective L113 (female) (1) tance
state contact in connector) Wiring harness between L113 (female) (2) – Resis-
Max. 1 z
Defective work equipment • Operate the joystick steering lever.
3
controller L63 Voltage
20 – 30 V
ground
26 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to joystick steering neutral safety relay
WA450-6, WA480-6 (KA SPEC.) 27

Failure code [D191KB] (Joystick steering neutral safety relay: Short

circuit) 1
Action code Failure code Joystick steering neural safety relay: Short circuit
Trouble
E01 D191KB (Work equipment controller system)
Contents of • Since the output system of the joystick steering neutral safety relay is shorted, signals are not output
trouble to the neutral safety relay.
Action of • Turns the output to the joystick steering neutral safety relay OFF.
• While operating joystick steering, engine can be started (Steering moves immediately after engine
Problem that
start).
appears on
• Starting of the engine is available even when the joystick steering FNR (directional) switch or right
machine
FNR (directional) switch is not set to N (neutral).
• As long as the failure code is turned on, the work equipment controller does not output signals to the
joystick steering neutral safety relay.
Related
• The output state (ON/OFF) to the neutral safety relay can be checked with the monitoring function
information
(Code: 40954, D-OUT-20).

Defective joystick steering L113 (male) Resistance
(Internal short circuit) Between (1) and (2) 200 – 400 z
Min. 1 Mz
ground
Possible causes
state (Contact with ground circuit) Wiring harness between L63 (female) (37) – Resis-
Min. 1 Mz
3
20 – 30 V
ground
28 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 29

Failure code [D191KY] (Joystick steering neutral safety relay: Short

circuit with power supply line) 1
Action code Failure code Joystick steering neutral safety relay: Short circuit with power supply
Trouble
E01 D191KY line (Work equipment controller system)
Contents of • Since the output system of the joystick steering neutral safety relay is shorted with the power source,
trouble signals are not output to the neutral safety relay.
Action of • Turns the output to the joystick steering neutral safety relay OFF.
Problem that
appears on • The engine does not start.
machine
• As long as the failure code is turned on, the work equipment controller does not output signals to the
Related joystick steering neutral safety relay.
information • The output state (ON/OFF) to the neutral safety relay can be checked with the monitoring function
(Code: 40954, D-OUT-20).

Min. 1 Mz
ground
Possible causes
2
state (Contact with 24V circuit) Wiring harness between L63 (female) (37) –
Voltage Max. 1 V
3
20 – 30 V
ground
30 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 31

Failure code [D192KA] (ECSS solenoid: Disconnection) 1

Action code Failure code ECSS solenoid: Disconnection
Trouble
Contents of • Since the ECSS solenoid system is disconnected, no current flows when ECSS solenoid output is
trouble turned ON.
Action of • None in particular.
Problem that
appears on • The ECSS does not operate.
machine
• The output state (ON/OFF) to the ECSS solenoid can be checked with the monitoring function
(Code: 90949, D-OUT-1).
Related
• Applicable only to ECSS specification machines (if equipped)
information
• Method of reproducing failure code: Turn the starting switch ON, ECSS switch ON and drive the
machine at any gear speed other than 1st speed.

Defective ECSS solenoid without turning starting switch ON.
1
(Internal disconnection) F13 (male) Resistance
Between (1) and (2) 5 – 15 z
Possible causes Disconnection in wiring har- without turning starting switch ON.
value in normal 2 Max. 1 z
(Disconnection or defective F13 (female) (1) tance
state contact in connector) Wiring harness between F13 (female) (2) – Resis-
Max. 1 z
Defective transmission con-
3 L63 (female) Resistance
troller
Wiring harness between (17) –
5 – 15 z
(13)
Circuit diagram related to ECSS solenoid
32 WA450-6, WA480-6 (KA SPEC.)

Failure code [D192KB] (ECSS solenoid: Short circuit) 1

Action code Failure code ECSS solenoid: Short circuit
Trouble
Contents of • Since the ECSS solenoid system is shorted, abnormal current flowed when ECSS solenoid output is
trouble ON
Action of • Turns the output to the ECSS solenoid OFF.
Problem that
• The ECSS does not operate.
appears on
• The wiring harness or controller may be burnt out.
machine
(Code: 90949, D-OUT-1).
Related
• Applicable only to ECSS specification machines (if equipped)
information
• Method of reproducing failure code: Turn the starting switch ON, ECSS switch ON and drive the
machine at any gear speed other than 1st speed.

Defective ECSS solenoid F13 (male) Resistance
1
Min. 1 Mz
Possible causes chassis ground
value in normal Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between L63 (female) (17) – Resis-
Min. 1 Mz
F13 (female) (1) and chassis ground tance
Defective transmission con- L63 (female) Resistance
3
troller
(17) – (13) 5 – 15 z
(17), (13) – chassis ground Min. 1 Mz
WA450-6, WA480-6 (KA SPEC.) 33

Failure code [D192KY] (ECSS solenoid: Short circuit with power supply
line) 1
Action code Failure code ECSS solenoid: Short circuit with power supply line
Trouble
E01 D192KY (Transmission controller)
Contents of • Since the ECSS solenoid system is shorted with the power source, abnormal voltage was applied
trouble when ECSS solenoid output was turned OFF.
Action of
controller
Problem that
appears on • The ECSS keeps operating.
machine
information • Applicable only to ECSS specification machines (if equipped)

Defective ECSS solenoid F13 (male) Resistance
1
Min. 1 Mz
Possible causes ground
state 2
Voltage Max. 1 V
F13 (female) (1) and chassis ground
Defective transmission con- L63 (female) Resistance
3
troller
(17) – (13) 5 – 15 z
(17), (13) – chassis ground Min. 1 Mz
34 WA450-6, WA480-6 (KA SPEC.)

Failure code [D193KA] (Joystick steering solenoid cut relay:

Disconnection) 1
Action code Failure code Joystick steering solenoid cut-out relay: Disconnection
Trouble
E03 D193KA (Work equipment controller system)
Contents of • Since the output system of the joystick steering solenoid cut-out relay is disconnected, signals are
trouble not output to the joystick steering solenoid cut-out relay.
• Stops output of signal to the joystick steering right and left solenoids.
Action of • Stops output of signal to the joystick steering cut-out relay.
Problem that
appears on • The operator cannot operate the joystick steering.
machine
• The output state (ON/OFF) to the joystick steering solenoid cut-out relay can be checked with the
monitoring function (Code: 40953, D-OUT-8).
Related
information

1 neutral cut-out relay (L41)
Between (1) and (2) 200 – 400 z
Possible causes
2 Max. 1 z
state contact in connector) Wiring harness between L41 (female) (6) – Resis-
Max. 1 z
3
Between (26) and
20 – 30 V
chassis ground
WA450-6, WA480-6 (KA SPEC.) 35

Circuit diagram related to joystick steering solenoid cut-out relay
36 WA450-6, WA480-6 (KA SPEC.)

Failure code [D193KB] (Joystick steering solenoid cut relay: Short

circuit) 1
Action code Failure code Joystick steering solenoid cut-out relay: Short circuit
Trouble
E03 D193KB (Work equipment controller system)
Contents of • Since the output system of the joystick steering solenoid cut-out relay is shorted, signals are not out-
trouble put to the joystick steering solenoid cut-out relay.
controller • Turn the centralized warning lamp and alarm buzzer ON.
Problem that
machine
Related
information

1 cut-out relay (L41) (Internal
short circuit) Between (1) and (2) 200 – 400 z
Min. 1 Mz
ground
Possible causes
Min. 1 Mz
3
controller L73 Resistance
Between (26) and
20 – 30 V
chassis ground
WA450-6, WA480-6 (KA SPEC.) 37

38 WA450-6, WA480-6 (KA SPEC.)

Failure code [D193KY] (Joystick steering solenoid cut relay: Short

Action code Failure code Joystick steering solenoid cut-out relay: Short circuit with power
Trouble
E03 D193KY supply line (Work equipment controller system)
Contents of • Since the output system of the joystick steering solenoid cut-out relay is shorted with the power
trouble source, signals are not output to the joystick steering solenoid cut-out relay.
Problem that
machine
Related
information

1 cut-out relay (L41) (Internal
Between (1) (2) and chassis
Min. 1 Mz
ground
Possible causes
Ground fault in wiring har- and carry out troubleshooting.
state (Contact with ground circuit) Wiring harness between L73 (female) (26) – Voltage Max. 1 V
3
Between (26) and
20 – 30 V
chassis ground
WA450-6, WA480-6 (KA SPEC.) 39

40 WA450-6, WA480-6 (KA SPEC.)

Failure code [D5ZHKA] (Terminal C signal: Disconnection) 1

Action code Failure code Terminal C signal: Disconnection
Trouble
E01 D5ZHKA (Transmission controller)
Contents of • Terminal C system is disconnected or shorted with the chassis ground (Engine speed is above 500
trouble rpm and no starting switch terminal C signal has been input.)
Problem that
appears on • Starting performance is poor
machine
• The input state (ON/OFF) to the transmission controller from starting switch terminal C can be
Related
checked with the monitoring function (Code: 40907, D-IN-16).
information
• Method of reproducing failure code: Set the starting switch to START position

1
a Prepare with starting switch OFF, then turn starting switch ON,
OFF or START and carry out troubleshooting
Defective starting switch S40 Starting switch Resistance
2
START Max. 1 z
Between (1) and (3)
OFF, ON Min. 1 Mz
Disconnection in wiring har- Wiring harness between S40 (female) (3) – Resis-
Max. 1 z
ness W60 (female) (3) tance
3
(Disconnection or defective Wiring harness between W60 (female) (6) – Resis-
Possible causes Wiring harness between L116 (female) (3) – Resis-
value in normal
state
Wiring harness between S40 (female) (3) –
Resis-
W60 (female) (3), – circuit branch end and Min. 1 Mz
tance
Grounding fault in wiring har- chassis ground
4 ness Wiring harness between W60 (female) (6) –
(Contact with ground circuit) L116 (female) (5), – circuit branch end and Resis-
Min. 1 Mz
tance
chassis ground
Wiring harness between L116 (female) (3) –
Resis-
L62 (female) (35), – circuit branch end and Min. 1 Mz
tance
chassis ground
Defective transmission con- L62 Starting switch Voltage
5
troller
Between (35) and START 20 – 30 V
chassis ground OFF, ON Max. 1 V
WA450-6, WA480-6 (KA SPEC.) 41

Circuit diagram related to engine starting system (C terminal signal)
42 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 43

44 WA450-6, WA480-6 (KA SPEC.)

Failure code [D5ZHKB] (Terminal C signal: Short circuit) 1

Action code Failure code Terminal C signal: Short circuit
Trouble
E01 D5ZHKB (Transmission controller)
Contents of • Terminal C system is shorted with the power source (Engine speed is above 500 rpm and starting
trouble switch terminal C signal has been input.).
Action of • Engine start assistance is not working.
Problem that
appears on • Starting performance is poor
machine
• The input state (ON/OFF) to the transmission controller from starting switch terminal C can be
Related
information

1
START Max. 1 z
Between (1) and (3)
OFF, ON Min. 1 Mz
after engine start and during engine operation
Possible causes W60 (female) (3), – circuit branch end and Voltage Max. 1 V
and standard chassis ground
value in normal Hot short in wiring harness
2 Wiring harness between W60 (female) (6) –
state (Contact with 24V circuit)
L116 (female) (5), – circuit branch end and Voltage Max. 1 V
chassis ground
chassis ground
Defective transmission con- L62 Starting switch Voltage
3
troller
WA450-6, WA480-6 (KA SPEC.) 45

46 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 47

Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)1

Action code Failure code Terminal C signal: Disconnection or short circuit
Trouble
E01 D5ZHKZ (Work equipment controller system)
Contents of • Terminal C system is disconnected (Engine speed is above 500 rpm and no starting switch terminal
trouble C signal has been input.)
Problem that • Engine starts when work equipment control lever is not at Neutral (disconnection)
appears on • Relieving of residual pressure on the work equipment becomes unavailable if the engine stopped
machine (hot short).
• The input state (ON/OFF) to the work equipment controller from starting switch terminal C can be
Related
information

1
2
START Max. 1 z
Between (1) and (3)
OFF, ON Min. 1 Mz
Max. 1 z
3
Wiring harness between L116 (female) (3) – Resis-
Max. 1 z
Possible causes
and standard
value in normal Wiring harness between S40 (female) (3) –
Resis-
state W60 (female) (3), – circuit branch end and Min. 1 Mz
tance
Min. 1 Mz
tance
chassis ground
Resis-
tance
chassis ground
W60 (female) (3), – circuit branch end and Voltage Max. 1 V
chassis ground
Hot short in wiring harness
5 Wiring harness between W60 (female) (6) –
(Contact with 24V circuit)
chassis ground
chassis ground
48 WA450-6, WA480-6 (KA SPEC.)

Possible causes a Prepare with starting switch OFF, then turn starting switch ON,
and standard OFF or START and carry out troubleshooting
value in normal Defective work equipment L72 Starting switch Voltage
6
state controller
WA450-6, WA480-6 (KA SPEC.) 49

50 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 51

52 WA450-6, WA480-6 (KA SPEC.)

Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine
running or stopped state) 1
Action code Failure code Terminal C signal: Signal does not match engine running or stopped
Trouble
E01 D5ZHL6 state (Machine monitor system)
Contents of • Terminal C system is disconnected or shorted with the chassis ground (Engine speed is above 500
trouble rpm and voltage is supplied to the alternator R terminal.)
Problem that
appears on • The engine does not start.
machine
• The input state (ON/OFF) to the machine monitor from the starting switch terminal C can be checked
Related
with the monitoring function (Code: 40900, D-IN-2).
information

Defective starting switch S40 Starting switch Voltage
1
Max. 1 z
2
Max. 1 z
Possible causes L52 (female) (2) tance
state
Resis-
W60 (female) (3), – circuit branch end and Min. 1 Mz
tance
Min. 1 Mz
tance
chassis ground
Resis-
tance
chassis ground
4 Defective machine monitor L52 Starting switch Voltage
WA450-6, WA480-6 (KA SPEC.) 53

54 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 55

Failure code [DA80L4] (Auto grease controller: ON/OFF signals

disagree) 1
Action code Failure code Auto grease controller: ON/OFF signals disagree
Trouble
— DA80L4 (Machine monitor system)
Contents of
• 24V signal has been input to the auto grease sensor A/B circuits at the same time.
trouble
Problem that
• Auto grease does not work.
appears on
• Auto grease lamp goes off.
machine
• The input state (ON/OFF) from the auto grease controller can be checked with the monitoring func-
Related tion (Code: 40900, D-IN-4 and D-IN-5).
information • Applicable only to machines equipped with auto grease function (if equipped)
• Method of reproducing failure code: Turn the starting switch and auto grease start button ON

1
(Contact with 24V circuit) Wiring harness between L52
Voltage Max. 1 V
(female) (3) – R38 (female) (2)
Defective auto grease con-
2 a Refer to and carry out troubleshooting for auto grease system.
troller
Possible causes and carry out troubleshooting.
and standard Auto-grease
L52 Auto grease Voltage
value in normal lamp
state In operation Max. 1 V ON
Between (3) With empty tank 20 – 30 V Flashing (1 Hz)
3 Defective machine monitor and chassis
ground Max. 1 V Flashing (2 Hz)
When abnormal
20 – 30 V OFF
In operation 20 – 30 V ON
Between (12) With empty tank Max. 1 V Flashing (1 Hz)
and chassis
ground Max. 1 V Flashing (2 Hz)
When abnormal
20 – 30 V OFF
56 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to auto grease
WA450-6, WA480-6 (KA SPEC.) 57

Failure code [DAF3KK] (Machine monitor: Low source voltage (input)) 1

Action code Failure code Machine monitor: Low source voltage (input)
Trouble
E03 DAF3KK (Machine monitor system)
Contents of • When the voltage of the switch power supply (power supply for operation) is above 17 V, the voltage
trouble of the constant power supply (power supply for the memory) is below 17 V.
Problem that
• The service meter reading is abnormal, the odometer does not advance and failure history data is
appears on
not saved.
machine
Related
information

ness Wiring harness between FS1 (male) (1) – Resis-
1 Max. 1 z
(Disconnection or defective fuse No. 3 of fuse box B tance
Possible causes contact) Wiring harness between fuse No. 3 of fuse Resis-
Max. 1 z
and standard box B – L51 (female) (4), (5) tance
Grounding fault in wiring har-
2 ness Wiring harness between fuse No. 3 of fuse
(Contact with ground circuit) box B – L51 (female) (4), (5) and chassis Resis-
Min. 1 Mz
tance
ground
Since trouble is in system, troubleshooting cannot be carried out.
(Replace the machine monitor)
58 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to machine monitor power supply
WA450-6, WA480-6 (KA SPEC.) 59

Failure code [DAF5KP] (Machine monitor: Low output voltage) 1

Action code Failure code Machine monitor: Low output voltage
Trouble
E01 DAF5KP (Machine monitor system)
Contents of • When the voltage of the switch power supply (power supply for operation) is above 17 V, the voltage
trouble of the sensor is below 5 V.
controller • Even if cause of failure disappears, system does not reset itself until it is restarted.
Problem that
appears on • Machine monitor does not display load.
machine
Related • Only for electric lever (if equipped)
information • Method of reproducing failure code: Turn the starting switch ON.

F15 (male) Resistance
Between (C) and (A) 5 kz ± 20%
Between (A), (B), (C) and chas-
Min. 1 Mz
sis ground
Defective lift arm angle sen- a Prepare with starting switch OFF, then turn starting switch ON
1
sor (Internal short circuit) and carry out troubleshooting.
F15 Lift arm cylinder Voltage
Between (C) and (A) Constant 4.85 – 5.15 V
Constant 0.83 – 4.17 V
Possible causes Between (B) and (A) At max. length 3.50 – 4.17 V
and standard
value in normal At min. length 0.83 – 1.88 V
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
Defective lift arm bottom a Prepare with starting switch OFF, then turn starting switch ON
2 pressure sensor and carry out troubleshooting.
(Internal short circuit) Lift arm bottom pres-
F16 (male) Voltage
sure
Between (C) and (B) Constant 4.85 – 5.15 V
Between (C) and (A) When released 0.50 – 0.90 V
When relieved 3.02 – 3.42 V
60 WA450-6, WA480-6 (KA SPEC.)


Min. 1 Mz
chassis ground
Defective lift arm head pres- a Prepare with starting switch OFF, then turn starting switch ON
3 sure sensor and carry out troubleshooting.
(Internal short circuit) Lift arm head pres-
F17 (male) Voltage
sure
Between (C) and (B) Constant 4.85 – 5.15 V
Possible causes
Between (C) and (A) When released 0.50 – 0.90 V
and standard
value in normal When relieved 3.02 – 3.42 V
Between L51 (female) (16) – F15 (female) Resis-
Grounding fault in wiring har- (C) wiring harness and chassis ground Min. 1 Mz
tance
4 ness
Min. 1 Mz
F16 (female) (B) and chassis ground tance
Min. 1 Mz
F17 (female) (B) and chassis ground tance
5 Defective machine monitor L51 Lift arm cylinder Voltage
Between (16) and
chassis ground
WA450-6, WA480-6 (KA SPEC.) 61

Circuit diagram related to machine monitor 5V sensor power supply
62 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 63


Defective communication (Abnormality in target component system)) 1
Action code Failure code CAN communication with machine monitor: Defective communica-
Trouble tion (Abnormality in target component system) (Transmission con-
E03 DAFRKR troller system)
Contents of
• Transmission controller cannot get information from machine monitor
trouble
Action of
• Uses CAN information that was sent from machine monitor before the occurrence of the error.
controller
Problem that
appears on • The monitor does not display normally
machine
Related
information

1
value in normal Wiring harness between L62 (female) (22), Resis-
Max. 1 z
Wiring harness between L62 (female) (22), Resis-
Max. 1 z
ness Wiring harness between L62 (female) (22), Resis-
2 Max. 1 z
(Disconnection or defective (32) – EC2 (female) (46), (47) tance
contact in connector) Wiring harness between L62 (female) (22), Resis-
Max. 1 z
(32) – L80 (female) (7), (8) tance
Max. 1 z
Max. 1 z
64 WA450-6, WA480-6 (KA SPEC.)


Resis-
tance
ground
Resis-
tance
ground
Grounding fault in wiring har- Resis-
(32) – EC2 (female) (46), (47) and chassis Min. 1 Mz
3 ness tance
Possible causes ground
(Contact with ground circuit)
and standard Wiring harness between L62 (female) (22),
state tance
ground
Resis-
tance
ground
Resis-
tance
ground
WA450-6, WA480-6 (KA SPEC.) 65

SEN01681-00

66
SEN01682-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
Failure code [DAQ0KK] (Transmission controller: Low source voltage) .............................................. 3
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) ....................................... 5
Failure code [DAQ2KK] (Transmission controller load power supply line:
Low source voltage (input)) ........................................................................................................ 6
Failure code [DAQ9KQ] (Transmission controller model selection:
Disagreement of model selection signals).................................................................................. 8
Failure code [DAQRKR] (CAN communication with transmission controller:
Defective communication (Abnormality in target component system))....................................... 9
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) ..................................11
Defective communication (Abnormality in target component system) ...................................... 12
Failure code [DB90KK] Work equipment controller: Low source voltage (input)................................ 14
Failure code [DB90KT] Work equipment controller: Abnormality in controller ................................... 16
WA450-6, WA480-6 (KA SPEC.) 1

Failure code [DB92KK] Work equipment controller load power supply line:
Low source voltage (input)........................................................................................................ 17
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range . 19
Failure code [DB99KQ] (Work equipment controller model selection:
Disagreement in model selection signals) ................................................................................ 22
Failure code [DB9RKR] CAN communication with work equipment controller:
Defective communication (Abnormality in target component system)) ..................................... 23
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) ............................. 25
Failure code [DB9RMC] (CAN communication with transmission controller: Defective operation) .... 26
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time................... 30
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time.................. 32
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time.................... 34
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time.................... 36
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise):
Switch is kept pressed for long time ......................................................................................... 38
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower):
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time ................ 42
Failure code [DD1FLD] Load meter mode selector switch (A/B):
Failure code [DD1GLD] Load meter mode selector switch (+/–):
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time) . 48
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time) .......................... 50
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time) .......... 52
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree) ................... 54
Failure code [DDD1LD] (Remote positioner bucket angle set switch:
Switch is kept pressed for long time) ........................................................................................ 58
2 WA450-6, WA480-6 (KA SPEC.)


Failure code [DAQ0KK] (Transmission controller: Low source voltage) 1
Action code Failure code Transmission controller: Low source voltage
Trouble
E03 DAQ0KK (Transmission controller)
• Voltage of constant power supply (battery direct power supply) of the transmission controller is low.
Contents of
• Voltage of constant power supply (battery direct power supply) is below 18 V and engine speed is
trouble
above 500 rpm.
• Cannot sense the input signals normally.
Action of
• Sets all the controller output to OFF (neutral hold state).
controller
FNR (directional) switch or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The machine cannot move (transmission is stuck in Neutral).
machine
Related
information

If the slow-blow fuse is shut down, the circuit probably has a
1 Defective slow-blow fuse
grounding fault, etc. (See cause 4.)
2
Disconnection in wiring har- Wiring harness between emergency steering Resis-
Max. 1 z
ness relay R02 – slow-blow fuse R02 tance
3
(Disconnection or defective Wiring harness between slow-blow fuse R03 Resis-
– fuse No. 5 of fuse box B tance
Wiring harness between fuse No. 5 of fuse Resis-
Max. 1 z
box B – L63 (female) (1), (11) tance
Possible causes
state Wiring harness between emergency steering
Resis-
relay R02 – slow-blow fuse R02 and chassis Min. 1 Mz
tance
Grounding fault in wiring har- ground
4 ness Wiring harness between slow-blow fuse R03
(Contact with ground circuit) – fuse No. 5 of fuse box B and chassis Resis-
Min. 1 Mz
tance
ground
Resis-
box B – L63 (female) (1), (11), – circuit Min. 1 Mz
tance
branch end and chassis ground
5 L63 Voltage
troller
Between (1), (11) and (21), (31),
20 – 30 V
(32), (33)
WA450-6, WA480-6 (KA SPEC.) 3

4 WA450-6, WA480-6 (KA SPEC.)

Failure code [DAQ0KT] (Transmission controller: Abnormality in

controller) 1
Action code Failure code Transmission controller: Abnormality in controller
Trouble
E01 DAQ0KT (Transmission controller)
• The information in the ROM (non-volatile memory) of the transmission controller is abnormal.
Contents of
• The battery direct power is not available immediately after the starting switch is OFF. Thus, the end-
trouble
ing process is not normally executed.
Action of • Sets the internal adjustment values to the default values.
Problem that
appears on • The gear shifting feeling of the transmission may become bad.
machine
Related
information

Possible causes
and standard Since trouble is in system, troubleshooting cannot be carried out.
value in normal Defective transmission con- (If there is no visible trouble on the machine, it is allowed to use the
1
state troller transmission controller without modifying the initial setting or initial
adjustment.)
WA450-6, WA480-6 (KA SPEC.) 5

Failure code [DAQ2KK] (Transmission controller load power supply

line: Low source voltage (input)) 1
Action code Failure code Transmission controller load power supply line: Low source voltage
Trouble
E03 DAQ2KK (input) (Transmission controller system)
• The voltage of the 24 V solenoid power supply system is low.
Contents of
• Detection conditions: Terminal C input is turned OFF, constant power supply (battery direct power
trouble
supply) is above 20 V and solenoid power supply is below 18 V
• Strain itself not to display failure codes that may be false detected due to low 24 V solenoid source
voltage
Action of
controller
• Even if cause of failure disappears, system does not reset itself until directional lever, joystick steer-
ing FNR (directional) switch or directional selector switch is set to N (Neutral).
Problem that
• The machine cannot move (transmission is stuck in Neutral).
appears on
• When the current fan rotation is reverse, its rotating direction is switched to forward.
machine
Related
information

1
(Disconnection or defective Wiring harness between L63(female) (2), Resis-
(12), (22) – fuse No. 2 of fuse box A tance
and standard
2 ness Wiring harness between L63(female) (2),
(Contact with ground circuit) (12), (22) – fuse No. 14 of fuse box A and Min. 1 Mz
state tance
chassis ground
3 L63 Voltage
troller
Between (2), (12) (22) and (21),
20 – 30 V
(31), (32), (33)
6 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission controller power supply
WA450-6, WA480-6 (KA SPEC.) 7

Failure code [DAQ9KQ] (Transmission controller model selection:

Disagreement of model selection signals) 1
Action code Failure code Transmission controller model selection: Disagreement of model
Trouble
E03 DAQ9KQ selection signals (Machine monitor system)
Contents of
• The transmission controller model is mistaken for another one.
trouble
• Operates on the assumption that the controller model which has been used before occurrence of the
Action of failure code is still used.
• Does not display failure codes which may be false detected.
Problem that
appears on • Continuing the travel in this condition can damage the transmission.
machine
Related
information

Possible causes Set the model using the adjustment function of the service mode of
Improper machine monitor
and standard 1 the machine monitor (See Special functions of machine monitor
model selection
value in normal (EMMS) in Testing and adjusting)
state Transmission controller part Confirm the part number of the transmission controller. It must be
2
number error replaced if it is not the specified controller.
8 WA450-6, WA480-6 (KA SPEC.)

Failure code [DAQRKR] (CAN communication with transmission

controller: Defective communication (Abnormality in target component
system)) 1
Action code Failure code CAN communication with transmission controller: Defective commu-
Trouble nication (Abnormality in target component system) (Machine moni-
E03 DAQRKR tor system)
Contents of
• Machine monitor cannot get information from transmission controller
trouble
• Uses CAN information that was sent from transmission controller before the occurrence of the error.
Action of
controller
Problem that
machine
Related
information

1
Max. 1 z
Max. 1 z
2 Max. 1 z
Max. 1 z
(32) – L80 (female) (7), (8) tance
Max. 1 z
Max. 1 z
WA450-6, WA480-6 (KA SPEC.) 9


Resis-
tance
ground
Resis-
tance
ground
3 ness tance
ground
Possible causes Wiring harness between L62 (female) (22),
Resis-
and standard (32) – L80 (female) (7), (8) and chassis Min. 1 Mz
tance
value in normal ground
state Wiring harness between L62 (female) (22),
Resis-
tance
ground
Resis-
tance
ground
a Power supply circuit or grounding circuit may be defective.
Defective power supply cir-
4 Confirm that there is no disconnection of the circuit or defective
cuit of transmission controller
mating of the connector.
10 WA450-6, WA480-6 (KA SPEC.)

Failure code [DAQRMA] (Transmission controller option setting:

Malfunction) 1
Action code Failure code Transmission controller option setting: Malfunction
Trouble
E03 DAQRMA (Machine monitor system)
Contents of • Disagreement between the option setting done by the machine monitor and the option recognition by
trouble done the transmission controller.
Action of • The transmission controller follows the option setting being recognized by itself.
Problem that
appears on • The option setting does not work normally.
machine
Related
information

Adjust the option setting using the adjustment function of the
Possible causes 1 Defective option setting machine monitor (See Special functions of machine monitor
and standard (EMMS) in Testing and adjusting)
value in normal The machine monitor may be defective. (Since trouble is in system,
state 2 Defective machine monitor
troubleshooting cannot be carried out.)
Defective transmission con- The transmission controller may be defective. (Since trouble is in
3
troller system, troubleshooting cannot be carried out.)
WA450-6, WA480-6 (KA SPEC.) 11


Defective communication (Abnormality in target component system) 1
Action code Failure code CAN communication with engine controller: Defective communica-
Trouble tion (Abnormality in target component system) (Transmission con-
E03 DB2RKR troller system)
Contents of • Communication via CAN signal line between the transmission controller and engine controller is
trouble defective.
• Uses CAN information that was sent from engine controller before the occurrence of the error.
• Fixes the recognition value of engine speed to 2,100 rpm.
Action of
• Holds recognized position of accelerator at 80%.
controller
Problem that
machine
Related
information

1
value in normal Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
Max. 1 z
ness Wiring harness between EC2 (female) (46), Resis-
2 Max. 1 z
contact in connector) Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – L80 (female) (7), (8) tance
Max. 1 z
Max. 1 z
12 WA450-6, WA480-6 (KA SPEC.)


Resis-
tance
ground
Resis-
tance
ground
3 ness tance
ground
Possible causes Wiring harness between EC2 (female) (46),
Resis-
tance
state Wiring harness between EC2 (female) (46),
Resis-
tance
ground
Resis-
tance
ground
a Power supply circuit or grounding circuit may be defective.
Defective power supply cir-
4 Confirm that there is no disconnection of the circuit or defective
cuit of engine controller
mating of the connector.
WA450-6, WA480-6 (KA SPEC.) 13

Failure code [DB90KK] Work equipment controller: Low source voltage

(input) 1
Action code Failure code Work equipment controller: Low source voltage (input)
Trouble
E03 DB90KK (Work equipment controller system)
Contents of • Voltage of work equipment controller UNSW power supply (battery direct power supply) is low.
trouble • Voltage of constant power supply (battery direct power supply) is 18 V or less
• Does not display failure codes other than this code if voltage of constant power supply (battery direct
power supply) remains under 18 V for more than 2 seconds.
Action of • Even if cause of failure disappears, system does not reset itself until the joystick steering lever and
controller work equipment lever are once set to N (Neutral).
• Cannot operate normally since it cannot sense the input signals properly.
Problem that
appears on • The machine cannot operate normally.
machine
Related
information

If the slow-blow fuse is shut down, the circuit probably has a
grounding fault, etc. (See cause 4.)
2
Disconnection in wiring har- Wiring harness between emergency steering Resis-
Max. 1 z
ness relay R02 – slow-blow fuse R02 tance
3
(Disconnection or defective Wiring harness between slow-blow fuse R03 Resis-
– fuse No. 3 of fuse box B tance
Max. 1 z
box B – L73 (female) (1), (11) tance
Possible causes
state Wiring harness between emergency steering
Resis-
relay R02 – slow-blow fuse R02 and chassis Min. 1 Mz
tance
Grounding fault in wiring har- ground
(Contact with ground circuit) – fuse No. 3 of fuse box B and chassis Resis-
Min. 1 Mz
tance
ground
Resis-
box B – L73 (female) (1), (11) and chassis Min. 1 Mz
tance
ground
Defective work equipment
5 L73 Voltage
controller
Between (1), (11) and (21), (31),
20 – 30 V
(32), (33)
14 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to work equipment controller power supply
WA450-6, WA480-6 (KA SPEC.) 15

Failure code [DB90KT] Work equipment controller: Abnormality in

controller 1
Action code Failure code Work equipment controller: Abnormality in controller
Trouble
E01 DB90KT (Work equipment controller system)
Contents of • The information in the ROM (non-volatile memory) of the work equipment controller system is abnor-
trouble mal.
• Sets the internal adjustment values to the default values.
Action of
controller
Problem that
• The machine may false detect errors.
appears on
• Performance degrades since the machine is controlled with improper data.
machine
Related
information

and standard
value in normal Defective work equipment Since trouble is in system, troubleshooting cannot be carried out.
1
state controller Replace the work equipment controller.
16 WA450-6, WA480-6 (KA SPEC.)

Failure code [DB92KK] Work equipment controller load power supply

line: Low source voltage (input) 1
Action code Failure code Work equipment controller load power supply line: Low source volt-
Trouble
E03 DB92KK age (input) (Work equipment controller system)
• The voltage of the 24V solenoid power supply system is low.
Contents of
• Detection conditions: Terminal C input is turned OFF, constant power supply (battery direct power
trouble
supply) is above 20 V and solenoid power supply is below 18 V
• Cannot supply voltage to the solenoid. (If the voltage is below 18 V, all outputs are turned OFF.)
controller • Even if cause of failure disappears, system does not reset itself until the joystick steering lever and
work equipment lever are once set to N (Neutral).
Problem that
appears on • Work equipment does not move
machine
Related
information

If the slow blow fuse is shut down, the circuit probably has a ground-
ing fault, etc. (See cause 4.)
2
box A (See cause 4.)
Disconnection in wiring har- Wiring harness between battery R04 – slow- Resis-
Max. 1 z
ness blow fuse R10 tance
3
(Disconnection or defective Wiring harness between slow-blow fuse Resis-
R06A – fuse No. 5 of fuse box A tance
Max. 1 z
Possible causes box A – L73 (female) (2), (12), (22) tance
state
Wiring harness between battery relay R06A Resis-
Min. 1 Mz
– slow-blow fuse R10 and chassis ground tance
Resis-
(Contact with ground circuit) – fuse No. 5 of fuse box A and chassis tance
Min. 1 Mz
ground
Resis-
box A – L73 (female) (2), (12), (22) and Min. 1 Mz
tance
chassis ground
5 L73 Voltage
controller
Between (2), (12), (22) and (21),
20 – 30 V
(31), (32), (33)
WA450-6, WA480-6 (KA SPEC.) 17

Circuit diagram related to work equipment controller 24V power supply
18 WA450-6, WA480-6 (KA SPEC.)

Failure code [DB95KX] Work equipment controller power supply output:

Out of input signal range 1
Action code Failure code Work equipment controller power supply output: Out of input signal
Trouble
E03 DB95KX range (Work equipment controller system)
Contents of
• Nominal voltage output of 5V sensor power supply system is out of range (Outside 4.7 – 5.3 V)
trouble
• Cannot sense the input signals normally due to abnormal potentiometer signal.
Action of
controller
Problem that
• The operator cannot operate the work equipment (Machine stop entirely).
appears on
• Following potentiometer error results
machine
Related
information

Defective joystick steering
lever potentiometer L34 (male) Resistance
1
(Internal disconnection or Between (4) and (1) 4 – 6 kz
short circuit)
Min. 1 Mz
ground
Defective 3-spool valve EPC
lever potentiometer L30 (male) Resistance
2
(Internal disconnection or Between (4) and (1) 2.5 – 3.9 kz
short circuit)
Min. 1 Mz
ground
Defective lift arm EPC lever L28 (male) Resistance
Possible causes 3 potentiometer (Internal dis-
connection or short circuit) Between (4) and (1) 2.5 – 3.9 kz
and standard
Min. 1 Mz
state ground
Defective bucket EPC lever
potentiometer L29 (male) Resistance
4
(Internal disconnection or Between (4) and (1) 2.5 – 3.9 kz
short circuit)
Min. 1 Mz
ground
Defective lift arm potentiome- F18 (male) Resistance
5
ter Between (C) and (A) 5 kz ± 20%
Between (A), (C) and chassis
Min. 1 Mz
ground
6 ness
(Contact with ground circuit) Between L71 (female) (22) and chassis Resis-
Min. 1 Mz
ground tance
WA450-6, WA480-6 (KA SPEC.) 19


Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal Defective work equipment
7
state controller L71 Voltage
Between (22) and (10) 4.85 – 5.15 V
20 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to work equipment controller 5 V power supply
WA450-6, WA480-6 (KA SPEC.) 21

Failure code [DB99KQ] (Work equipment controller model selection:

Disagreement in model selection signals) 1
Action code Failure code Work equipment controller model selection: Disagreement in model
Trouble
E03 DB99KQ selection signals (Machine monitor system)
Contents of
• Work equipment controller model is mistaken for another one.
trouble
• Operates on the assumption that the controller model which has been used before occurrence of the
Action of failure code is still used.
controller • Does not display failure codes which may be false detected.
Problem that
appears on • Work equipment does not operate normally
machine
Related
information

Possible causes Set the model using the adjustment function of the service mode of
Improper machine monitor
and standard 1 the machine monitor (See Special functions of machine monitor
model selection
value in normal (EMMS) in Testing and adjusting)
state Work equipment controller Confirm the part number of the work equipment controller. It must be
2
part number error replaced if it is not the specified controller.
22 WA450-6, WA480-6 (KA SPEC.)

Failure code [DB9RKR] CAN communication with work equipment

controller: Defective communication (Abnormality in target component
system)) 1
Action code Failure code Can communication with work equipment controller: Defective com-
Trouble munication (Abnormality in target component system) (Transmis-
E03 DB9RKR sion controller system)
Contents of
• Machine monitor cannot get information from work equipment controller
trouble
Action of • Uses CAN information that was sent from work equipment controller before the occurrence of the
controller error.
Problem that
machine
Related
information

1
Max. 1 z
state (32) – EC2 (female) (46), (47) tance
Max. 1 z
2 Max. 1 z
Max. 1 z
(32) – L80 (female) (7), (8) tance
Max. 1 z
Max. 1 z
WA450-6, WA480-6 (KA SPEC.) 23


Resis-
tance
ground
Resis-
tance
ground
3 ness tance
ground
Possible causes Wiring harness between L62 (female) (22),
Resis-
tance
Resis-
tance
ground
Resis-
tance
ground
Defective power supply a Power supply circuit or grounding circuit may be defective.
4 circuit of work equipment Confirm that there is no disconnection of the circuit or defective
controller mating of the connector.
24 WA450-6, WA480-6 (KA SPEC.)

Failure code [DB9RMA] (Work equipment controller option setting:

Malfunction) 1
Action code Failure code Work equipment controller option setting: Malfunction
Trouble
E03 DB9RMA (Machine monitor system)
Contents of • Disagreement between the option setting done by the machine monitor and the option recognition by
trouble done the work equipment controller.
Action of • The work equipment controller follows the option setting being recognized by itself.
Problem that
appears on • The optional device does not work normally.
machine
Related
information

Adjust the option setting using the adjustment function of the
Possible causes 1 Defective option setting
machine monitor (See Testing and adjusting)
and standard
value in normal Defective work equipment Transmission controller may be defective
2
state controller (Since trouble is in system, troubleshooting cannot be carried out.)
The machine monitor may be defective
WA450-6, WA480-6 (KA SPEC.) 25

Failure code [DB9RMC] (CAN communication with transmission

controller: Defective operation) 1
Action code Failure code CAN communication with transmission controller: Defective opera-
Trouble
E03 DB9RMC tion (Work equipment controller system)
• Communication via CAN signal line between the work equipment controller – transmission controller,
Contents of
engine controller and machine monitor is defective.
trouble
• Turns the centralized warning lamp and alarm buzzer.
<Relevant to the transmission controller>
• Judges that the travel speed is at 0 km/h.
• Turns neutral safety relay OFF (The engine can be started)
• Uses CAN information that was sent from transmission controller before the occurrence of the error.
Action of
<Relevant to engine controller>
controller
• Judges engine speed is at 1,500 rpm.
• Uses CAN information that was sent from engine controller before the occurrence of the error.
<Relevant to machine monitor>
• Judges that the emergency steering is not in operation.
• Uses CAN information that was sent from machine monitor before the occurrence of the error.
<Relevant to transmission controller>
• The operator may not use semiautomatic digging occasionally or cannot use it entirely.
• Joystick steering does not work (Joystick steering specification)
• Starting becomes available only when the joystick steering is not at neutral
<Relevant to engine controller>
Problem that • Semiautomatic digging is available (constant digging speed)
appears on • Defective lift arm positioner and bucket positioner stop position (calculation of pump delivery
machine becomes unavailable)
• Engine does not pick up smoothly (swash plate of supply pump remains at MAX)
<Relevant to machine monitor>
• When the emergency steering is operated, false detection of the power supply error might result
• If disconnection occurs while the emergency steering is in operation, detection of the power supply
error becomes unavailable
Related • Method of reproducing failure code: Turn the starting switch ON or start the engine to resume the
information normal operation

Possible causes CAN1 (male) Resistance
and standard
value in normal 1
state resistance a Prepare with starting switch OFF, then carry out troubleshooting
26 WA450-6, WA480-6 (KA SPEC.)


Max. 1 z
(32) – L56 (female) (3), (8) tance
Max. 1 z
2 Max. 1 z
Max. 1 z
(32) – L80 (female) (7), (8) tance
Max. 1 z
Max. 1 z
Possible causes Resis-
and standard tance
ground
value in normal
Resis-
tance
ground
Ground fault in wiring har- Resis-
3 ness (Contact with ground tance
ground
circuit)
Resis-
tance
ground
Resis-
tance
ground
Resis-
tance
ground
WA450-6, WA480-6 (KA SPEC.) 27

28 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 29

Failure code [DD15LD] t switch (Panel switch 1): Switch is kept

pressed for long time 1
Action code Failure code t switch (Panel switch 1): Switch is kept pressed for long time
Trouble
E01 DD15LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 1 “t” (Panel switch 1) is kept CLOSED
trouble for more than continuous 1 minute.
Action of
controller
Problem that
• The operator cannot operate the monitor (cannot enter the service mode).
appears on
• Some characters do not appear on the character display.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 1 “t” (Panel switch 1) can
Related be checked with the monitoring function (Code: 40901, D-IN-15).
information • The operator may not be able to use the monitoring function because of the t switch trouble.

Defective t switch (Panel t switch
1 switch 1) (Internal short cir- L07 (male) Resistance
(Panel switch 1)
cuit)
ON Max. 1 z
Between (4) and (5)
Other than above Min. 1 Mz
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
t switch
(Panel switch 1)
Between (17) and ON 20 – 30 V
30 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to t switch and U switch
WA450-6, WA480-6 (KA SPEC.) 31

Failure code [DD16LD] U switch (Panel switch 2): Switch is kept

Action code Failure code U switch (Panel switch 2): Switch is kept pressed for long time
Trouble
Contents of • The input circuit of the machine monitor mode selector switch 2 “U” (Panel switch 2) is kept
trouble CLOSED for more than continuous 1 minute.
Action of
controller
Problem that
• The operator cannot operate the monitor (cannot turn on the service mode).
appears on
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 2 “U” (Panel switch 2)
Related can be checked with the monitoring function (Code: 40901, D-IN-14).
information • The operator may not be able to use the monitoring function because of the U switch trouble.

Defective U switch (Panel U switch
1 switch 2) (Internal short cir- L07 (male) Resistance
(Panel switch 2)
cuit)
ON Max. 1 z
Between (5) and (6)
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
U switch
(Panel switch 2)
32 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to t switch and U switch
WA450-6, WA480-6 (KA SPEC.) 33

Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed
for long time 1
Action code Failure code < switch (Panel switch 3): Switch is kept pressed for a long time
Trouble
Contents of • The input circuit of the machine monitor mode selector switch 3 “<” (Panel switch 3) is kept CLOSED
Action of
controller
Problem that
• The operator cannot operate the monitor.
appears on
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 3 “<” (Panel switch 3) can
information • The operator may not be able to use the monitoring function because of the “<” switch trouble.

Defective < switch (Panel < switch
1 switch 3) (Internal short cir- L08 (female) Resistance
(Panel switch 3)
cuit)
ON Max. 1 z
Between (4) and (5)
Possible causes
Min. 1 Mz
< switch
3 Defective machine monitor L54 (female) Voltage
(Panel switch 3)
Between (7) and ON Max. 1 V
34 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to > switch and < switch
WA450-6, WA480-6 (KA SPEC.) 35

Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed
for long time 1
Action code Failure code > switch (Panel switch 4): Switch is kept pressed for long time
Trouble
Contents of • The input circuit of the machine monitor mode selector switch 4 “>” (Panel switch 4) is kept CLOSED
Action of
controller
Problem that
• The operator cannot operate the monitor.
appears on
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 4 “>” (Panel switch 4) can
information • The operator may not be able to use the monitoring function because of the > switch trouble.

Defective > switch (Panel > switch
1 switch 4) (Internal short cir- L08 (female) Resistance
(Panel switch 4)
cuit)
ON Max. 1 z
Between (5) and (6)
Possible causes
Min. 1 Mz
> switch
(Panel switch 4)
36 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to > switch and < switch
WA450-6, WA480-6 (KA SPEC.) 37

Failure code [DD1ALD] Remote positioner raise/lower set switch (raise):

Switch is kept pressed for long time 1
Action code Failure code Remote positioner raise/lower set switch (raise): Switch is kept
Trouble
E01 DD1ALD pressed for long time (Work equipment controller system)
Contents of • Since the remote positioner raise/lower set switch (raise) system is shorted, operator cannot set rais-
trouble ing.
• Stops setting the lift arm raise set position.
Action of • Stops the remote raise stop operation.
controller • Turns the lift arm raise set indicator OFF.
Problem that
• The operator cannot set the lift arm raise set position.
appears on
• Remote positioner raise stop control is not available.
machine
• The input state (ON/OFF) from the remote positioner raise/lower set switch (raise) can be checked
Related
information

Remote positioner
Defective remote positioner S14 (male) Resistance
raise/lower set switch
1 raise/lower set switch (raise)
Raise Max. 1 z
(Internal short circuit) Between (5) and (6)
Possible causes Constant Min. 1 Mz
chassis ground
and standard
state 2 ness
Min. 1 Mz
S14 (female) (6) and chassis ground tance
Defective work equipment Remote positioner
3 L72 (male) Voltage
controller raise/lower set switch
Between (13) and Raise Max. 1 V
38 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to remote positioner raise/lower set switch
WA450-6, WA480-6 (KA SPEC.) 39

Failure code [DD1BLD] Remote positioner raise/lower set switch

(lower): Switch is kept pressed for long time 1
Action code Failure code Remote positioner raise/lower set switch (lower): Switch is kept
Trouble
E01 DD1BLD pressed for long time (Work equipment controller system)
Contents of • Since the remote positioner raise/lower set switch (lower) system is shorted, operator cannot set
trouble lowering.
• Stops setting the lift arm lower set position.
Action of • Stops the remote lower stop operation.
controller • Turns the lift arm lower set indicator OFF.
Problem that
• The operator cannot set the lower set position.
appears on
• Remote positioner lower stop control is not available.
machine
• The input state (ON/OFF) from the remote positioner raise/lower set switch (lower) can be checked
Related
information

Remote positioner
Defective remote positioner S14 (male) Resistance
raise/lower set switch
1 raise/lower set switch
Lower Max. 1 z
chassis ground
and standard
state 2 ness
Min. 1 Mz
controller raise/lower set switch
Between (3) and Lower Max. 1 V
40 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to remote positioner raise/lower set switch
WA450-6, WA480-6 (KA SPEC.) 41

Failure code [DD1CLD] Load meter subtotal switch: Switch is kept

Action code Failure code Load meter subtotal switch: Switch is kept pressed for long time
Trouble
E01 DD1CLD (Machine monitor system)
Contents of • Since the load meter subtotal switch system is shorted, the load meter subtotal switch does not func-
trouble tion.
Action of
controller
Problem that
• The total amount of load cannot be set to 0 on the screen.
appears on
• Printer (if equipped) is not available
machine
• The input state (ON/OFF) from the load meter subtotal switch can be checked with the monitoring
Related function (Code: 40904, D-IN-32).
information • Only for load meter (if equipped)

Load meter subtotal
Defective load meter subtotal switch
1
switch (Internal short circuit) ON Max. 1 z
Between (3) and (4)
OFF Min. 1 Mz
chassis ground
and standard
state 2 ness
Min. 1 Mz
Load meter subtotal
3 Defective machine monitor L54 (male) Voltage
switch
chassis ground OFF 20 – 30 V
42 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to load meter cancel & subtotal switch
WA450-6, WA480-6 (KA SPEC.) 43

Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch
is kept pressed for long time 1
Action code Failure code Load meter mode selector switch (A/B): Switch is kept pressed for
Trouble
E01 DD1FLD long time (Machine monitor system)
Contents of • The input circuit of the load meter mode selector switch (A/B) is kept CLOSED for more than contin-
trouble uous 1 minute
Action of
controller
Problem that
• The working object cannot be changed.
appears on
machine
• The input state (ON/OFF) from the load meter mode selector switch (A/B) can be checked with the
Related monitoring function (Code: 40901, D-IN-10).

Load meter mode
Defective load meter mode S31 (male) Resistance
selector switch (A/B)
1 selector switch (A/B) (Inter-
ON Max. 1 z
nal short circuit) Between (5) and (6)
OFF Min. 1 Mz
chassis ground
and standard
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state Hot short in wiring harness and carry out troubleshooting.
2
Voltage Max. 1 V
S31 (female) (6) and chassis ground
Load meter mode
selector switch (A/B)
chassis ground OFF Max. 1 V
44 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 45

Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch
is kept pressed for long time 1
Action code Failure code Load meter mode selector switch (+/–): Switch is kept pressed for
Trouble
E01 DD1GLD long time (Machine monitor system)
Contents of • The input circuit of the load meter mode selector switch (+/–) is kept CLOSED for more than continu-
trouble ous 1 minute
Action of
controller
Problem that
• The operator cannot make settings of load meter addition mode.
appears on
machine
• The input state (ON/OFF) from the load meter mode selector switch (+/–) can be checked with the
Related monitoring function (Code: 40901, D-IN-11).

Load meter mode
Defective load meter mode S31 (male) Resistance
selector switch (+/–)
1 selector switch (+/–) (Internal
ON Max. 1 z
short circuit) Between (4) and (5)
OFF Min. 1 Mz
chassis ground
and standard
2
Voltage Max. 1 V
Load meter mode
selector switch (+/–)
46 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to load meter mode selector switch
WA450-6, WA480-6 (KA SPEC.) 47

Failure code [DD1HLD] (Load meter display selector switch: Switch is

kept pressed for long time) 1
Action code Failure code Load meter display selector switch: Switch is kept pressed for long
Trouble
E01 DD1HLD time (Machine monitor system)
Contents of • Since the load meter display selector switch system is shorted, the load meter display selector switch
trouble does not function.
Action of
controller
Problem that
• Unable to display cumulative data
appears on
machine
• The input state (ON/OFF) from the load meter display selector switch can be checked with the moni-
Related toring function (Code: 40902, D-IN-23).

Load meter display
Defective load meter display S31 (male) Resistance
selector switch
1 selector switch (Internal
ON Max. 1 z
OFF Min. 1 Mz
chassis ground
and standard
state 2 ness
Min. 1 Mz
Load meter display
selector switch
48 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to load meter display selector switch
WA450-6, WA480-6 (KA SPEC.) 49

Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for
long time) 1
Action code Failure code Fan reverse switch: Switch is kept pressed for long time
Trouble
E01 DD1NLD (Transmission controller system)
Contents of • Since the fan reverse switch system is shorted with the power source, the fan reverse switch
trouble remains at ON position.
Action of
controller
Problem that
appears on • Fan remains in the reverse rotation
machine
• The input state (ON/OFF) from the fan reverse switch can be checked with the monitoring function
Related
(Code: 93400, FAN REVERSE SW).
information

S16 (male) Fan reverse switch Resistance
Defective fan reverse switch
1 ON Max. 1 z
OFF Min. 1 Mz
chassis ground
and standard
2
Voltage 20 – 30 V
Defective transmission L61 (male) Fan reverse switch Voltage
3
controller
50 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to the fan reverse switch & fan automatic reverse switch
WA450-6, WA480-6 (KA SPEC.) 51

Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept

pressed for long time) 1
Action code Failure code Fan automatic reverse switch: Switch is kept pressed for long time
Trouble
E01 DD1NL4 (Transmission controller system)
Contents of • Since the fan automatic reverse switch system is shorted with the power source, the fan automatic
trouble reverse switch function becomes unavailable.
Action of
• The automatic reverse switch is OFF.
controller
Problem that
appears on • Automatic reversing of the fan becomes unavailable
machine
• The input state (ON/OFF) from the fan reverse switch can be checked with the monitoring function
Related
(Code: 93400, FAN REVERSE SW).
information

Fan automatic reverse
Defective fan automatic S16 (male) Resistance
switch
1 reverse switch (Internal short
ON Max. 1 z
circuit) Between (3) and (4)
OFF Min. 1 Mz
chassis ground
and standard
2
Voltage 20 – 30 V
Defective transmission Fan automatic reverse
controller switch
52 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to the fan reverse switch & fan automatic reverse switch
WA450-6, WA480-6 (KA SPEC.) 53

Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF

signals disagree) 1
Action code Failure code Parking brake switch (Neutralizer): ON/OFF signals disagree
Trouble
E03 DDB6L4 (Transmission controller system)
• Controller outputs a failure signal when the following conditions are all met
Contents of 1) Parking brake switch signal ON (neutralizer signal OPEN)
trouble 2) Parking brake released (by CAN communication from the machine monitor)
3) Hydraulic oil temperature above 25°C
Problem that
• Forward and reverse travel of the machine become unavailable. Or the parking brake indicator
appears on
remains unlighted.
machine
• The input state (ON/OFF) from the parking indicator switch to the machine monitor can be checked
• The input state (ON/OFF) from the parking brake switch can be checked with the monitoring function
(Code: 40907, D-IN-23).
• If failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) is indicated,
Related carry out troubleshooting for it first.
information • If failure code [DAFRKR] (CAN communication with machine monitor: Defective communication
(Abnormality in target component system)) is indicated, carry out troubleshooting for it first.
• Above is sometimes detected if the emergency parking brake switch is set to ON (release side) when
the parking brake switch is turned ON (parking side).
• Method of reproducing failure code: Turn the starting switch ON and turn the parking brake switch
ON.

Parking brake oil
PB.SW (male) Resistance
pressure
Defective parking brake indi- When parking brake is
1 cator switch released, Min. 0.61 Max. 1 z
(Internal disconnection) MPa {Min. 6.2 kg/cm2}
Between (1) and (2) When parking brake
Possible causes
applied, Max. 0.34
MPa {Max. 3.5 kg/
value in normal
cm2}
state
L01 (male) Parking brake switch Resistance
Defective parking brake ON Min. 1 Mz
2 switch (Internal disconnec- Between (3) and (4)
OFF Max. 1 z
tion)
ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Between (3) and (6) Constant Min. 1 Mz
54 WA450-6, WA480-6 (KA SPEC.)


Disconnection in wiring har- Wiring harness between L54 (female) (1) – Resis-
Max. 1 z
ness PB.SW (female) (1) tance
3
(Disconnection or defective Wiring harness between PB.SW (female) (2) Resis-
contact) Max. 1 z
– chassis ground tance
Possible causes
value in normal
L62 (male) Parking brake switch Voltage
Defective transmission con- ON Max. 1 V
4
troller
Between (6) and Turn on the starting
chassis ground switch and turn on the
20 – 30 V
parking brake switch,
then turn it off.
WA450-6, WA480-6 (KA SPEC.) 55

Circuit diagram related to parking brake switch
56 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 57

Failure code [DDD1LD] (Remote positioner bucket angle set switch:

Switch is kept pressed for long time) 1
Action code Failure code Remote positioner bucket angle set switch: Switch is kept pressed
Trouble
E01 DDD1LD for long time (Work equipment controller system)
• Unable to set the bucket to a specified angle due to ground fault in the remote positioner bucket
Contents of
angle set switch system.
trouble
• Detected continuous operation for 30 seconds and longer.
Action of • Judges that remote positioner bucket angle set switch is turned ON
• Remote positioner raise set: Setting is changed to upward by 1° (degree) and the monitor displays
Problem that the changed angle.
appears on • Remote lower set: Setting is changed to downward by 1° (degree) and the monitor displays the
machine changed angle.
• Change of setting to upward or downward becomes unavailable.
• The input state (ON/OFF) from the remote positioner bucket angle set switch can be checked with
the monitoring function (Code: 40911, D-IN-10, D-IN-11).
Related
• Only for electric lever (if equipped)
information
• Method of reproducing failure code: Turn the starting switch and remote positioner bucket angle set
switch ON

Remote positioner
S14 (male) bucket angle set Resistance
switch
Defective remote positioner
1 bucket angle set switch Downward ON Max. 1 z
Between (4) and (5)
(Internal short circuit) OFF Min. 1 Mz
Upward ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Between (4), (5), (6)
Constant Min. 1 Mz
and chassis ground
Possible causes
and standard
value in normal Grounding fault in wiring har-
state Wiring harness between L73 (female) (30) – Resis-
2 ness Min. 1 Mz
Min. 1 Mz
Remote positioner
L73 (female) bucket angle set Voltage
Defective work equipment switch
3
controller Downward ON Max. 1 V
Between (40) and
Between (30) and Upward ON Max. 1 V
58 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to remote positioner bucket angle set switch
WA450-6, WA480-6 (KA SPEC.) 59

SEN01682-00

60
SEN01683-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) ............................................ 4
Failure code [DDK3KA] (Right FNR switch: Disconnection) ................................................................ 6
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) .............................................. 9
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree) ............. 12
Failure code [DDK6KA] (FNR lever switch: Disconnection) ............................................................... 14
Failure code [DDK6KB] (FNR lever switch: Short circuit) .................................................................. 18
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) ............................... 20
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time) ....... 22
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)............................ 24
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) ..................................... 26
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)................ 28
Failure code [DF10KA] (Transmission shift lever switch: Disconnected) ........................................... 30
Failure code [DF10KB] (Transmission shift lever switch: Short circuit).............................................. 34
WA450-6, WA480-6 (KA SPEC.) 1

Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected) ................................. 36

Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit).................................... 38
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) ..................... 40
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected) .................................... 42
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)................... 44
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) .......... 46
2 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 3


Failure code [DDE5MA] (Emergency steering drive switch:
Malfunction) 1
Action code Failure code Emergency steering drive switch: Malfunction
Trouble
E01 DDE5MA (Machine monitor system)
Contents of • When engine stopped, detected steering pump pressure because of ground fault in the emergency
trouble steering drive switch system.
Action of
controller
Problem that
appears on —
machine
• The input state (ON/OFF) from the emergency steering motor can be checked with the monitoring
Related
information

troubleshooting.
• Relieve the steering circuit
Defective emergency steer- Steering relief oil

R37 (male) Resistance
1 ing drive switch pressure
(Internal trouble) Low Min. 1 Mz
Between (1) and (2)
Normal Max. 1 z
chassis ground
and standard
state 2 ness
Min. 1 Mz
R37 (female) (2) and chassis ground tance
troubleshooting.
• Relieve the steering circuit
3 Defective machine monitor Steering relief oil
pressure
Between (3) and Low 20 – 30 V
chassis ground Normal Max. 1 V
4 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to emergency steering drive switch
WA450-6, WA480-6 (KA SPEC.) 5

Failure code [DDK3KA] (Right FNR switch: Disconnection) 1

Action code Failure code Right FNR switch: Disconnection
Trouble
E03 DDK3KA (Transmission controller system)
Contents of • Since the right FNR (directional) switch input signal system is disconnected or shorted, the right FNR
trouble (directional) switch signal is not recognized.
• Sets to neutral.
controller • Even if cause of failure disappears, system does not reset itself until the right FNR (directional)
switch is set to N (Neutral).
Problem that • Machine travel with the right FNR (directional) switch becomes unavailable.
appears on • Travel with FNR (directional) lever is available.
machine • Shift lever position pilot lamp goes off.
• The input signals (ON/OFF) from the right FNR (directional) switch or joystick steering FNR (direc-
tional) switch can be checked with the monitoring function (Code: 40907, D-IN-17, D-IN-18 or D-IN-
Related 19).
information • Only for right FNR (directional) switch (if equipped)
• Method of reproducing failure code: Turn the starting switch ON, turn the directional selector ON/
OFF switch ON, then operate the FNR (directional) switch.

1
Right FNR
F (Forward) Max. 1 z
Between (1) and (2)
Defective right FNR (direc- Other than above Min. 1 Mz
tional) switch
2 N (Neutral) Max. 1 z
(Internal disconnection or Between (1) and (3)
short circuit) Other than above Min. 1 Mz
Possible causes R (Reverse) Max. 1 z
and standard Between (1) and (4)
value in normal
state Between (1), (2), (3),
(4) and chassis Constant Min. 1 Mz
ground
Max. 1 z
Disconnection in wiring har- box A – L12 (female) (1) tance
3 Max. 1 z
Max. 1 z
Max. 1 z
6 WA450-6, WA480-6 (KA SPEC.)


Min. 1 Mz
box A – L12 (female) (1) tance
4 ness Min. 1 Mz
Min. 1 Mz
and standard
state and carry out troubleshooting.
• Turn on the directional selector ON/OFF switch
Right FNR
L62 Voltage
Defective transmission con- Between (25) and F (Forward) 20 – 30 V
5
troller chassis ground Other than above Max. 1 V
Between (15) and N (Neutral) 20 – 30 V
WA450-6, WA480-6 (KA SPEC.) 7

Circuit diagram related to right FNR (directional) switch
8 WA450-6, WA480-6 (KA SPEC.)

Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) 1

Action code Failure code Joystick steering FNR switch: Disconnection
Trouble
Contents of • Since the input signal system of the joystick steering FNR (directional) switch is disconnected or
trouble shorted, joystick steering FNR (directional) switch signals are not input.
controller • Even if cause of failure disappears, system does not reset itself until the joystick steering FNR (direc-
tional) switch is set to N (Neutral).
Problem that • Machine travel with the joystick steering FNR (directional) switch becomes unavailable.
appears on • Travel with FNR (directional) lever is available.
• The input signals (ON/OFF) from the right FNR (directional) switch or joystick steering FNR (direc-
tional) switch can be checked with the monitoring function (Code: 40907, D-IN-17, D-IN-18 or D-IN-
Related 19).
information • Only for joystick steering (if equipped)
• Method of reproducing failure code: Turn the starting switch ON, turn the joystick ON/OFF switch
ON, then operate the joystick steering FNR (directional) switch.

Defective fuse No.2 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
1
Joystick steering FNR
F (Forward) Max. 1 z
Between (1) and (2)
Defective joystick steering Other than above Min. 1 Mz
FNR (directional) switch
2 N (Neutral) Max. 1 z
(Internal disconnection or Between (1) and (3)
short circuit) Other than above Min. 1 Mz
Possible causes R (Reverse) Max. 1 z
and standard Between (1) and (4)
value in normal
state Between (1), (2), (3),
(4) and chassis Constant Min. 1 Mz
ground
Max. 1 z
Disconnection in wiring har- box A – L37 (female) (1) tance
3 Max. 1 z
Max. 1 z
Max. 1 z
WA450-6, WA480-6 (KA SPEC.) 9


Min. 1 Mz
box A – L37 (female) (1) and chassis ground tance
4 ness Min. 1 Mz
Min. 1 Mz
and standard
• Turn on joystick ON/OFF switch
Joystick steering FNR
L62 Voltage
Defective transmission con- Between (25) and F (Forward) 20 – 30 V
5
troller chassis ground Other than above Max. 1 V
10 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to joystick steering FNR (directional) switch
WA450-6, WA480-6 (KA SPEC.) 11

Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF

signals disagree) 1
Action code Failure code Joystick steering shift-up/down switch: ON/OFF signals disagree
Trouble
E01 DDK5L4 (Transmission controller system)
Contents of • Since the joystick steering shift up and down switch system is shorted with the power source, multi-
trouble ple signals are input.
Action of • Turns off the shift-up/down function of the joystick steering.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Shift up or down from the joystick steering is disabled.
machine
• The input signals (ON/OFF) from the joystick steering shift-up/down switch can be checked with the
Related monitoring function (Code: 40906, D-IN-12 or D-IN-13).
information • Method of reproducing failure code: Turn the starting switch ON, turn the joystick ON/OFF switch
ON, then turn the joystick steering shift-up/down switch ON.

Joystick steering
shift-up/down switch
Shift down ON Min. 1 Mz
Between (1) and (5)
Shift down OFF Max. 1 z
Defective joystick steering Shift down ON Max. 1 z

Between (1) and (6)
1 shift-up/down switch Shift down OFF Min. 1 Mz
(Internal short circuit) Shift up ON Min. 1 Mz
Between (1) and (7)
Shift up OFF Max. 1 z
Shift up ON Max. 1 z
Between (1) and (8)
Shift up OFF Min. 1 Mz
Possible causes Between (5), (6), (7),
and standard (8) and chassis Constant Min. 1 Mz
2 ness Min. 1 Mz
Min. 1 Mz
• Turn on joystick ON/OFF switch
Joystick steering
L63 Resistance
Defective transmission con- shift-up/down switch
3
troller Shift down ON Max. 1 z
Between (19) and
chassis ground Shift down OFF Min. 1 Mz
Between (9) and Shift up ON Max. 1 z
chassis ground Shift up OFF Min. 1 Mz
12 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to joystick steering shift-up/down switch
WA450-6, WA480-6 (KA SPEC.) 13

Failure code [DDK6KA] (FNR lever switch: Disconnection) 1

Action code Failure code FNR lever switch: Disconnection
Trouble
Contents of • Since the FNR (directional) lever switch signal system is disconnected or shorted, all the lever sig-
trouble nals are not input
• When the joystick steering ON/OFF switch is set to OFF, set it to Neutral.
• When the ON-OFF switch of right FNR switch or joystick steering ON/OFF switch is set to ON:
1) The controller operation follows the right FNR (directional) switch or joystick steering FNR (direc-
Action of tional) switch.
controller 2) The controller assumes that FNR (directional) lever switch is set to Neutral.
• Even if cause of failure disappears, system does not reset itself until FNR (directional) lever is set to
N (Neutral).
Problem that • Machine travel with the FNR (directional) lever switch is unavailable.
appears on • Travel is available with right FNR (directional) switch or joystick steering FNR (directional) switch.
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related
function (Code: 40907, D-IN-20, D-IN-21 or D-IN-22).
information
• Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever

1
FNR (directional)
L04 Voltage
lever
Between (1) and (10) Constant 20 – 30 V
Defective FNR (directional)
2 lever switch (Internal discon- Between (3) and (10) N (Neutral) 20 – 30 V
nection or short circuit) Other than above Max. 1 V
F (Forward) 20 – 30 V
Possible causes Other than above Max. 1 V
and standard R (Reverse) 20 – 30 V
value in normal Between (4) and (10)
state Other than above Max. 1 V
Max. 1 z
Max. 1 z
ness L04 (female) (4) tance
3
Max. 1 z
Max. 1 z
14 WA450-6, WA480-6 (KA SPEC.)


Min. 1 Mz
4 ness Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
and standard L04 (female) (2) and chassis ground tance
FNR (directional)
L62 Voltage
lever
5 chassis ground Other than above Max. 1 V
troller
Between (36) and F (Forward) 20 – 30 V
WA450-6, WA480-6 (KA SPEC.) 15

Circuit diagram related to FNR (directional) lever switch
16 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 17

Failure code [DDK6KB] (FNR lever switch: Short circuit) 1

Action code Failure code FNR lever switch: Short circuit
Trouble
E03 DDK6KB (Transmission controller system)
Contents of • Since the FNR (directional) lever switch signal system is shorted with power source, multiple FNR
trouble (directional) lever switch signals are input.
• As the ON-OFF switch of right FNR switch or joystick steering ON/OFF switch is switched ON o
Action of
OFF o ON, the controller operation follows the right FNR (directional) switch or joystick steering
controller
FNR (directional) switch.
• Even if cause of failure disappears, system does not reset itself until FNR (directional) lever is set to
N (Neutral).
• Machine travel with the FNR (directional) lever switch is unavailable.
Problem that
• Multiple shift lever position pilot lamps light up.
appears on
• Travel is enabled by using right FNR (directional) switch or joystick steering FNR (directional) switch
machine
after setting the shift to neutral.
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related function (Code: 40907, D-IN-20, D-IN-21 or D-IN-22).
information • Only for steering wheel (Standard)
• Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever

FNR (directional)
L04 Voltage
lever
Defective FNR (directional)
1 lever switch (Internal short F (Forward) 20 – 30 V
circuit) Other than above Max. 1 V
N (Neutral) 20 – 30 V
Other than above Max. 1 V
and standard Wiring harness between L62 (female) (16) –
value in normal Voltage Max. 1 V
Hot short in wiring harness L04 (female) (4)
state 2
Voltage Max. 1 V
L04 (female) (3)
Voltage Max. 1 V
L04 (female) (2)
FNR (directional)
L62 Voltage
lever
3 chassis ground Other than above Max. 1 V
troller
Between (36) and F (Forward) 20 – 30 V
18 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to FNR (directional) lever switch
WA450-6, WA480-6 (KA SPEC.) 19

Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals

disagree) 1
Action code Failure code Shift mode selector switch: ON/OFF signals disagree
Trouble
E01 DDT0L4 (Transmission controller system)
Contents of • The signals input from the transmission manual/auto shift selector switch are combined in an impos-
trouble sible manner.
Action of • Selects the manual shift mode.
Problem that
• The position of the transmission manual/auto shift selector switch does not match the shift mode dur-
appears on
ing auto shift.
machine
• The input state (H/L) from the transmission manual/auto shift selector switch can be checked with
Related the monitoring function (Code: 40905, D-IN-4 or D-IN-5).
information • The operator can check the current shift mode with the automatic shift pilot lamp.

S22 (male) Shift mode Resistance
Manual shift Min. 1 Mz
Between (1) and (2) Auto (L) Max. 1 z
Defective transmission man- Auto (H) Min. 1 Mz
1 ual/auto shift selector switch
Manual shift Min. 1 Mz
(Internal defect)
Between (1) and (4) Auto (L) Min. 1 Mz
Auto (H) Max. 1 z
Manual shift Max. 1 z
Between (3) and (4) Auto (L) Min. 1 Mz
Auto (H) Min. 1 Mz
2
Possible causes (Disconnection or defective Wiring harness between L61 (female) (24) – Resis-
and standard contact in connector) Max. 1 z
S22 (female) (2) tance
value in normal
3 ness
Min. 1 Mz
4
Voltage Max. 1 V
L61 Shift mode Voltage
Manual shift Max. 1 V
Defective transmission con- Between (18) and
5 Auto (L) Max. 1 V
troller chassis ground
Auto (H) 20 – 30 V
Manual shift Max. 1 V
Between (24) and
Auto (L) 20 – 30 V
chassis ground
Auto (H) Max. 1 V
20 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission manual/auto shift selector switch.
WA450-6, WA480-6 (KA SPEC.) 21

Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept

Action code Failure code The transmission cut-off set switch: Switch is kept pressed for long
Trouble
E01 DDT4LD time (transmission controller system)
Contents of • Since the transmission cut-off set switch system is shorted, normal transmission cut-off becomes
trouble unavailable.
Action of
controller
Problem that
appears on • The transmission is cut off at an unintended position.
machine
• The input state (ON/OFF) from the transmission cut-off set switch can be checked with the monitor-
Related
ing function (Code: 40906, D-IN-9).
information

Transmission cut-off
Defective transmission cut- S05 (male) Resistance
set switch
1 off set switch
ON Max. 1 z
OFF Min. 1 Mz
chassis ground
and standard
state 2 ness
Min. 1 Mz
Defective transmission con- Transmission cut-off
troller set switch
Between (5) and ON Max. 1 z
chassis ground OFF Min. 1 Mz
22 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission cut-off set switch
WA450-6, WA480-6 (KA SPEC.) 23

Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for

long time) 1
Action code Failure code Kick-down switch: Switch is kept pressed for long time
Trouble
E01 DDW9LD (Transmission controller system)
Contents of
• Since the kick-down switch system is shorted, kick-down becomes unavailable.
trouble
• Implements kick-down once at occurrence of the ground fault. After that, kick-down control is not
Action of
executed.
controller
• If cause of failure disappears, system resets itself.
Problem that
• When ground fault occurs, turns the kick-down ON once.
appears on
• No kick down is executed after that.
machine
• The input state (ON/OFF) from the kick-down switch can be checked with the monitoring function
Related
(Code: 40908, D-IN-30).
information

L14 (male) Kick-down switch Resistance
Defective kick-down switch
1 ON Max. 1 z
OFF Min. 1 Mz
chassis ground
and standard
state 2 ness
Min. 1 Mz
Defective transmission con- L62 Kick-down switch Voltage
3
troller
24 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to kick-down switch and hold switch
WA450-6, WA480-6 (KA SPEC.) 25

Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long
time) 1
Action code Failure code Hold switch: Switch is kept pressed for long time
Trouble
E01 DDWLLD (Transmission controller system)
Contents of
• Since the hold switch system is shorted, holding of signals becomes unavailable.
trouble
Action of • Holds once when a grounding fault occurs, then does not control holding.
Problem that
appears on • When ground fault occurs, turns the hold switch once.
machine
• The input state (ON/OFF) from the hold switch can be checked with the monitoring function (Code:
Related
40908, D-IN-31).
information

L04 (male) Hold switch Resistance
Defective hold switch
1 ON Max. 1 z
OFF Min. 1 Mz
chassis ground
and standard
state 2 ness
Min. 1 Mz
Defective transmission con- L62 Hold switch Voltage
3
troller
26 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to kick-down switch and hold switch
WA450-6, WA480-6 (KA SPEC.) 27

Failure code [DDY0LD] (Load meter cancel switch: Switch is kept

Action code Failure code Load meter cancel switch: Switch is kept pressed for long time
Trouble
E01 DDY0LD (Machine monitor system)
Contents of
• The load meter cancel switch is shorted and load meter cancel switch does not function.
trouble
Action of
controller
Problem that
appears on • Cancellation of calculated load becomes unavailable
machine
• The input state (ON/OFF) from the load meter cancel switch can be checked with the monitoring
Related function (Code: 40904, D-IN-33).
information • Only for load meter (if equipped).

Load meter cancel
Defective load meter cancel switch
1
switch (Internal short circuit) ON Max. 1 z
Between (1) and (2)
OFF Min. 1 Mz
chassis ground
and standard
state 2 ness
Min. 1 Mz
Load meter cancel
switch
28 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 29

Failure code [DF10KA] (Transmission shift lever switch: Disconnected)1

Action code Failure code Transmission shift lever switch: Disconnected
Trouble
E01 DF10KA (Transmission controller system)
Contents of • Since the transmission shift lever switch input signal system is disconnected or shorted, the signal is
trouble not input.
Action of • Fixes to the shift range before the abnormality occurred
Problem that
• The transmission is not set to the selected gear speed.
appears on
• Shift indicator displays the shift range before the abnormality occurred
machine
• The input state (ON/OFF) from each shift switch can be checked with the monitoring function (Code:
Related
40906, D-IN-8, D-IN-9, D-IN-10 or D-IN-11)
information
• Method of reproducing failure code: Turn the starting switch ON and operate shift lever

L04 Shift range Voltage
1st (1st speed) 20 – 30 V
Defective transmission shift Other than above Max. 1 V
1 lever switch
2nd (2nd speed) 20 – 30 V
(Internal disconnection) Between (6) and (10)
3rd (3rd speed) 20 – 30 V
Possible causes 4th (4th speed) 20 – 30 V
and standard Other than above Max. 1 V
value in normal
Max. 1 z
Max. 1 z
Disconnection in wiring har- L04 (female) (5) tance
2 Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
30 WA450-6, WA480-6 (KA SPEC.)


Min. 1 Mz
Grounding fault in wiring har- L04 (female) (5) and chassis ground Min. 1 Mz
tance
3 ness
Min. 1 Mz
Min. 1 Mz
value in normal
Between (10) and 1st (1st speed) 20 – 30 V
Defective transmission con- 2nd (2nd speed) 20 – 30 V
4 Between (20) and
troller
Between (30) and 3rd (3rd speed) 20 – 30 V
Between (40) and 4th (4th speed) 20 – 30 V
WA450-6, WA480-6 (KA SPEC.) 31

Circuit diagram related to transmission shift lever switch
32 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 33

Failure code [DF10KB] (Transmission shift lever switch: Short circuit) 1

Action code Failure code Transmission shift lever switch: Short circuit
Trouble
E01 DF10KB (Transmission controller system)
Contents of • Since the transmission shift lever switch input signal system is shorted with the power source, multi-
trouble ple transmission shift lever switch signals are input.
Action of • Uses the shift range input to the higher gear speed
Problem that • Specified gear speed is not available (1st speed or 2nd speed not selectable from the transmission
appears on shift lever)
machine • Shift indicator indicates the shift range input to the higher gear speed.
• The input state (ON/OFF) from each shift switch can be checked with the monitoring function (Code:
Related
40906, D-IN-8, D-IN-9, D-IN-10 or D-IN-11)
information
• Method of reproducing failure code: Turn the starting switch ON and operate shift lever

1st (1st speed) 20 – 30 V
Defective transmission shift
1 lever switch 2nd (2nd speed) 20 – 30 V
(Internal short circuit) Other than above Max. 1 V
3rd (3rd speed) 20 – 30 V
4th (4th speed) 20 – 30 V
Possible causes Voltage Max. 1 V
and standard
value in normal Hot short in wiring harness Wiring harness between L63 (female) (20) –
2 Voltage Max. 1 V
state (Contact with 24V circuit) L04 (female) (6) and chassis ground
Voltage Max. 1 V
Voltage Max. 1 V
Between (10) and 1st (1st speed) 20 – 30 V
Defective transmission con- 2nd (2nd speed) 20 – 30 V
3 Between (20) and
troller
Between (30) and 3rd (3rd speed) 20 – 30 V
Between (40) and 4th (4th speed) 20 – 30 V
34 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission shift lever switch
WA450-6, WA480-6 (KA SPEC.) 35

Failure code [DGF1KA] (Transmission oil temperature sensor:

Disconnected) 1
Action code Failure code Transmission oil temperature sensor: Disconnected
Trouble
E01 DGF1KA (Transmission controller system)
• Since the transmission oil temperature sensor signal system is disconnected, the signal level is
Contents of
higher than normal range (Transmission oil temperature sensor signal voltage: Min. 4.56 V (Max.
trouble
15°C)) and the torque converter oil temperature sensor signal voltage: Min. 3.7 V (Max. 5.5°C).
Action of • Cannot judge the transmission oil temperature normally.
Problem that
appears on • Gear shifting shocks can result.
machine
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with
the monitoring function (Code: 93600 T/M OIL TEMP).
• The input state (voltage) from the transmission oil temperature sensor can be checked with the mon-
itoring function (Code: 93601, T/M OIL TEMP).
Related
information

Defective transmission oil Transmission oil
temperature sensor (Internal TM.T (male) Resistance
1 temperature
disconnection or short cir-
cuit) 25°C
35 – 50 kz
Between (1) and (2) (Normal temperature)
100°C 3.1 – 4.5 kz
and standard Disconnection in wiring
value in normal harness Wiring harness between L61 (female) (9) – Resis-
2 Max. 1 z
state (Disconnection or defective TM.T (female) (1) tance
contact in connector) Wiring harness between TM.T (female) (2) – Resis-
Max. 1 z
Transmission oil
Defective transmission L61 (female) Resistance
3 temperature
controller
25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
36 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission oil temperature sensor
WA450-6, WA480-6 (KA SPEC.) 37

Failure code [DGF1KB] (Transmission oil temperature sensor: Short

circuit) 1
Action code Failure code Transmission oil temperature sensor: Short circuit
Trouble
E01 DGF1KB (Transmission controller system)
Contents of • Due to grounding fault in transmission oil temperature sensor signal system, the signal level is lower
trouble than normal range (Transmission oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of • Cannot judge the transmission oil temperature normally.
Problem that
appears on • Gear shifting shocks can result.
machine
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with
the monitoring function (Code: 93600, T/M OIL TEMP).
Related
• The input state (voltage) from the transmission oil temperature sensor can be checked with the mon-
information
itoring function (Code: 93601, T/M OIL TEMP).

Defective transmission oil Transmission oil
TM.T (male) Resistance
1 temperature sensor (Internal temperature
short circuit) 25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
Possible causes
and standard Grounding fault in wiring without turning starting switch ON.
value in normal 2 harness
Min. 1 Mz
TM.T (female) (1) and chassis ground tance
Transmission oil
3 temperature
controller
25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
38 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission oil temperature sensor
WA450-6, WA480-6 (KA SPEC.) 39

Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input

signal range) 1
Action code Failure code Hydraulic oil temperature sensor: Out of input signal range
Trouble
E01 DGH2KX (Machine monitor system)
Contents of • Due to grounding fault in hydraulic oil temperature sensor signal system, the signal level is lower
trouble than normal range (Hydraulic oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of
controller
Problem that
appears on • The hydraulic oil temperature gauge reads MAX position
machine
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
monitoring function (Code: 04401, HYD TEMP).
Related
• The input state (voltage) from the hydraulic oil temperature sensor can be checked with the monitor-
information
ing function (Code: 04404, HYD TEMP).

Defective hydraulic oil Hydraulic oil
1 temperature sensor temperature
(Internal short circuit) 25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
Possible causes
Min. 1 Mz
Hydraulic oil
25°C
Between (7) and 35 – 50 kz
(Normal temperature)
chassis ground
100°C 3.1 – 4.5 kz
40 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to hydraulic oil temperature sensor
WA450-6, WA480-6 (KA SPEC.) 41

Failure code [DGR2KA] (Rear brake oil temperature sensor:

Disconnected) 1
Action code Failure code Rear brake oil temperature sensor: Disconnected
Trouble
E01 DGR2KA (Machine monitor system)
Contents of
• Disconnection in the rear brake oil temperature sensor signal system
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

Defective rear brake oil Rear brake oil
disconnection) 25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
2 Max. 1 z
state (Disconnection or defective R60 (female) (1) tance
contact in connector) Wiring harness between R60 (female) (2) – Resis-
Max. 1 z
Rear brake oil
25°C
chassis ground
100°C 3.1 – 4.5 kz
42 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 43

Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input
signal range) 1
Action code Failure code Rear brake oil temperature sensor: Out of input signal range
Trouble
E01 DGR2KX (Machine monitor system)
• Due to grounding fault in the rear brake oil temperature sensor signal system, the signal level is
Contents of
lower than normal range (Rear brake oil temperature sensor signal voltage: Max. 0.97 V (Min.
trouble
150°C))
Action of
controller
Problem that
appears on —
machine
Related
information

Defective rear brake oil Rear brake oil
short circuit) 25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
Possible causes
Min. 1 Mz
Rear brake oil
25°C
chassis ground
100°C 3.1 – 4.5 kz
44 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 45

Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of

input signal range) 1
Action code Failure code Torque converter oil temperature sensor: Out of input signal range
Trouble
E01 DGT1KX (Machine monitor system)
Contents of • Due to grounding fault in the torque converter oil temperature sensor signal system, the signal level
trouble is lower than normal range (Transmission oil temperature signal voltage: Max. 0.97 V (Min. 150°C))
Action of
controller
Problem that
appears on • The torque converter oil temperature gauge reads MAX position
machine
Related
information

1 oil temperature sensor temperature
(Internal short circuit) 25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
Possible causes
Max. 1 z
TC.T (female) (1) and chassis ground tance
25°C
chassis ground
100°C 3.1 – 4.5 kz
46 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 47

SEN01683-00

48
SEN01684-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)........... 4
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range).............. 6
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)................. 8
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection) ........................................ 10
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)............................................ 12
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) ........................... 14
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main):
Short circuit with power supply line) ......................................................................................... 17
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)............. 20
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) ............................ 23
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub):
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) ............................ 29
WA450-6, WA480-6 (KA SPEC.) 1

Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main):

Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) ............. 35
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) ............................. 38
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub):
Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main):
Disconnection) .......................................................................................................................... 44
Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main):
Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main):
Analog signals disagree) .......................................................................................................... 49
Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub):
Disconnection) .......................................................................................................................... 52
Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub):
2 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 3


Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out
of input signal range) 1
Action code Failure code Lift arm cylinder bottom pressure sensor: Out of input signal range
Trouble
E01 DHPCKX (Machine monitor system)
• Due to disconnection or grounding fault in the lift arm cylinder bottom pressure sensor signal, the lift
arm cylinder bottom pressure sensor voltage is lower than normal range (Lift arm bottom pressure
Contents of sensor signal voltage: Below 0.3 V)
trouble • Due to hot short circuit in the lift arm cylinder bottom pressure sensor signal, the lift arm cylinder bot-
tom pressure sensor voltage is higher than normal range (Lift arm cylinder bottom pressure sensor
signal voltage: Min. 4.7 V)
Action of
controller
Problem that
machine
• The input state (oil pressure) from the lift arm cylinder bottom pressure sensor can be checked with
the monitoring function (Code: 40400, BOOM BTM PRESS).
Related • The input state (voltage) from the lift arm cylinder bottom pressure sensor can be checked with the
information monitoring function (Code: 40402, BOOM BTM PRESS).
• Only for load meter (if equipped)
• Method of reproducing failure code: Start engine and perform lift arm lever operation

Check the failure code comes not to be displayed when the lift arm
cylinder bottom pressure sensor is replaced.
a Prepare with starting switch OFF, then start engine, raise the lift
Defective lift arm cylinder arm and carry out troubleshooting.
bottom pressure sensor F16 Lift arm Voltage
1
Between (B) and (A) Constant 4.85 – 5.15 V
short circuit)
Between (C) and (A) Neutral 0.50 – 0.90 V
Lift arm bottom relief 3.02 – 3.42 V
and standard
value in normal Disconnection in wiring Wiring harness between L51 (female) (16) – Resis-
Max. 1 z
state harness F16 (female) (B) tance
2
(Disconnection in wiring Wiring harness between L55 (female) (9) – Resis-
harness or defective contact) Max. 1 z
F16 (female) (C) tance
Wiring harness between F16 (female) (A) – Resis-
Max. 1 z
Grounding fault in wiring Resis-
F16 (female) (B), – circuit branch end and Min. 1 Mz
3 harness tance
chassis ground
Resis-
F16 (female) (C), – circuit branch end and Min. 1 Mz
tance
chassis ground
4 WA450-6, WA480-6 (KA SPEC.)


Hot short in wiring harness F16 (female) (B), – circuit branch end and Voltage Max. 1 V
4
(Contact with 24V circuit) chassis ground
Possible causes F16 (female) (C), – circuit branch end and Voltage Max. 1 V
value in normal a Prepare with starting switch OFF, then start engine, raise the lift
state arm and carry out troubleshooting.
L51, L55 Lift arm Voltage
Between L51 (16)
5 Defective machine monitor Constant 4.85 – 5.15 V
and chassis ground
Between L55 (9) and
Neutral 0.50 – 0.90 V
chassis ground
Lift arm bottom relief 3.02 – 3.42 V
Circuit diagram related to lift arm cylinder bottom pressure sensor
WA450-6, WA480-6 (KA SPEC.) 5

Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of
Action code Failure code Lift arm cylinder head pressure sensor: Out of input signal range
Trouble
E01 DHPDKX (Machine monitor system)
• Due to disconnection or grounding fault in the lift arm cylinder head pressure sensor signal, the lift
arm cylinder head pressure sensor voltage is lower than normal range (Lift arm cylinder head pres-
Contents of sure sensor signal voltage: Below 0.3 V)
trouble • Due to hot short circuit in the lift arm cylinder head pressure sensor signal, the lift arm cylinder head
pressure sensor voltage is higher than normal range (Lift arm cylinder head pressure sensor signal
voltage: Min. 4.7 V)
Action of
controller
Problem that
machine
• The input state (oil pressure) from the lift arm cylinder head pressure sensor can be checked with the
monitoring function (Code: 40500, BOOM HEAD PRESS).
Related • The input state (voltage) from the lift arm cylinder head pressure sensor can be checked with the
information monitoring function (Code: 40501, BOOM HEAD PRESS).
• Only for load meter (if equipped)
• Method of reproducing failure code: Start engine and perform lift arm lever operation

Check the failure code comes not to be displayed when the lift arm
cylinder bottom pressure sensor is replaced.
a Prepare with starting switch OFF, then start engine, lower the lift
Defective lift arm cylinder arm and carry out troubleshooting.
head pressure sensor F17 (male) Lift arm Voltage
1
short circuit)
Between (C) and (A) Neutral 0.50 – 0.90 V
Lift arm head relief 3.02 – 3.42 V
and standard
value in normal Disconnection in wiring Wiring harness between L51 (female) (16) – Resis-
Max. 1 z
state harness F17 (female) (B) tance
2
F17 (female) (C) tance
Wiring harness between F17 (female) (A) – Resis-
Max. 1 z
F17 (female) (B), – circuit branch end and Min. 1 Mz
3 harness tance
chassis ground
Resis-
F17 (female) (C), – circuit branch end and Min. 1 Mz
tance
chassis ground
6 WA450-6, WA480-6 (KA SPEC.)


Hot short in wiring harness F17 (female) (B), – circuit branch end and Voltage Max. 1 V
4
(Contact with 24V circuit) chassis ground
Possible causes F17 (female) (C), – circuit branch end and Voltage Max. 1 V
value in normal a Prepare with starting switch OFF, then start engine, raise the lift
state arm and carry out troubleshooting.
L51, L55 Lift arm Voltage
Between L51 (16)
5 Defective machine monitor Constant 4.85 – 5.15 V
and chassis ground
Between L55 (4) and
Neutral 0.50 – 0.90 V
chassis ground
Lift arm head relief 3.02 – 3.42 V
Circuit diagram related to lift arm cylinder head pressure sensor
WA450-6, WA480-6 (KA SPEC.) 7

Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of

Action code Failure code Transmission cut-off pressure sensor: Out of input signal range
Trouble
E01 DHT1KX (Transmission controller system)
Contents of • Due to grounding fault in transmission cut-off pressure sensor signal system, the signal level is lower
trouble than normal range.
• Turns off the transmission cut-off function
• Does not allow changing the transmission cut-off set
Action of
controller
steering FNR (directional) switch or right FNR (directional) switch is set to N (Neutral). Or the trans-
mission cut-off switch must be turned off.
Problem that
• The transmission cut-off indicator goes off.
appears on
• The transmission cut-off does not work.
machine
• Input voltage of the transmission cut-off pressure sensor is max. 0.3 V
• The input state (oil pressure) from the transmission cut-off pressure sensor can be checked with the
Related monitoring function (Code: 41201, T/M CUT OFF P).
information • The input state (voltage) from the transmission cut-off pressure sensor can be checked with the mon-
itoring function (Code: 41202, T/M CUT OFF P).
• Method of reproducing failure code: Turn the starting switch and the transmission cut-off switch ON.

• Transmission cut-off switch is ON.
R73 Brake Voltage
When brake is
0.9 – 1.1 V
Defective transmission released
1 cut-off pressure sensor When the left brake
(Internal short circuit) pedal is pressed 1.1 – 5.1 V
Between (C) and (A) down
When the right brake
pedal is pressed 1.1 – 5.1 V
down
Possible causes Other than above 0.9 – 5.1 V

value in normal Grounding fault in wiring without turning starting switch ON.
state 2 harness
Min. 1 Mz
R73 (female) (C) and chassis ground tance
L61 Brake Voltage
When brake is
0.9 – 1.1 V
released
Defective transmission When the left brake
3
controller pedal is pressed 1.1 – 5.1 V
Between (19) and down
chassis ground
When the right brake
pedal is pressed 1.1 – 5.1 V
down
Other than above 0.9 – 5.1 V
8 WA450-6, WA480-6 (KA SPEC.)


Possible causes
Disconnection of harness Between L61 (female) (16) and R73 (female) Resis-
(Disconnection of harness, (B) tance
value in normal 4
state defective contact or improper Between L61 (female) (19) and R73 (female) Resis-
mating of connector) Max. 1 z
(C) tance
Resis-
Between R73 (female) (A) and R22 Max. 1 z
tance
Circuit diagram related to transmission cut-off pressure sensor
WA450-6, WA480-6 (KA SPEC.) 9

Failure code [DHT8KA] (Steering pump pressure sensor:

Disconnection) 1
Action code Failure code Steering pump pressure sensor: Disconnection
Trouble
E01 DHT8KA (Transmission controller system)
Contents of • Due to disconnection or ground fault in steering pump pressure sensor system, the signal level is
trouble lower than normal range. (Steering pump pressure sensor signal voltage: Max. 0.3 V)
Action of • Judges the steering pump pressure is absent
Problem that
appears on • Engine does not pickup smoothly at low speed
machine
• The input state (oil pressure) from the steering pump pressure sensor can be checked with the mon-
itoring function (Code: 95300, S/T OIL PRESS).
Related
• The input state (voltage) from the steering pump pressure sensor can be checked with the monitor-
information
ing function (Code: 95301, S/T OIL PRESS).

troubleshooting.
Steering pump
R86 Voltage
pressure
Defective steering pump Constant 0.50 – 4.50 V
1 pressure sensor (Internal When steering is in
disconnection or short circuit) 0.50 – 0.90 V
Between (C) and (A) neutral
When steering is
3.02 – 3.42 V
relieved
ingly, if voltage is abnormal, check wiring harness and controller,
too, for another cause of trouble, and then judge.
Possible causes
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
and standard
harness without turning starting switch ON.
value in normal 2
state (Disconnection or defective Wiring harness between L61 (female) (3) – Resis-
R86 (female) (C) tance
Grounding fault in wiring without turning starting switch ON.
3 harness
Min. 1 Mz
troubleshooting.
Steering pump
L61 Voltage
pressure
Defective transmission
4 Constant 0.50 – 4.50 V
controller
When steering is in
Between (3) and 0.50 – 0.90 V
neutral
chassis ground
When steering is
3.02 – 3.42 V
relieved
10 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to steering pump pressure sensor
WA450-6, WA480-6 (KA SPEC.) 11

Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)1

Action code Failure code Steering pump pressure sensor: Short circuit
Trouble
E01 DHT8KB (Transmission controller system)
Contents of • Due to hot short circuit in the steering pump pressure sensor signal system, the signal level is higher
trouble than normal range. (Steering pump pressure sensor signal voltage: Min. 4.7 V)
Action of • Judges the steering pump pressure is absent
Problem that
appears on • Engine does not pickup smoothly at low speed
machine
• The input state (oil pressure) from the steering pump pressure sensor can be checked with the mon-
itoring function (Code: 95300, S/T OIL PRESS).
Related
• The input state (voltage) from the steering pump pressure sensor can be checked with the monitor-
information
ing function (Code: 95301, S/T OIL PRESS).

troubleshooting.
Steering pump
R86 Voltage
pressure
Defective steering pump oil
pressure sensor
1 When steering is in
(Internal disconnection or 0.50 – 0.90 V
short circuit) Between (C) and (A) neutral
When steering is
3.02 – 3.42 V
relieved
Possible causes
ingly, if voltage is abnormal, check wiring harness and controller,
and standard
too, for another cause of trouble, and then judge.
value in normal
Hot short in wiring harness without turning starting switch ON.
2
(Contact with 24 V circuit) Wiring harness between L61 (female) (3) – Resis-
Min. 1 Mz
troubleshooting.
Steering pump
L61 Voltage
pressure
3 Constant 0.50 – 4.50 V
controller
When steering is in
Between (3) and 0.50 – 0.90 V
neutral
chassis ground
When steering is
3.02 – 3.42 V
relieved
12 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to steering pump pressure sensor
WA450-6, WA480-6 (KA SPEC.) 13

Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main):

Disconnection) 1
Action code Failure code Lift arm EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK59KA (Work equipment controller system)
• Due to disconnection or grounding fault in the lift arm EPC lever potentiometer (Main) system, the
Contents of
signal voltage is lower than normal range (Lift arm EPC lever potentiometer (Main) signal voltage:
trouble
Max. 0.3 V)
• If the lift arm EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
controller • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000, BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective lift arm EPC lever • Work equipment lock lever: Free
potentiometer L28 Lift arm EPC lever Voltage
1
short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
Possible causes Lever in neutral 2.40 – 2.60 V
and standard Raise operation
value in normal 3.69 – 4.09 V
(Before detent)
state
Raise operation
Between (3) and (1) 3.91 – 4.31 V
(Detent position)
Lower operation
0.91 – 1.31 V
(Before detent)
Float operation 0.69 – 1.09 V
Disconnection in wiring Wiring harness between L71 (female) (19) – Resis-
Max. 1 z
harness L28 (female) (3) tance
2
Max. 1 z
14 WA450-6, WA480-6 (KA SPEC.)


Grounding fault in wiring Wiring harness between L71 (female) (19) – Resis-
Min. 1 Mz
3 harness L28 (female) (3) and chassis ground tance
(Contact with ground circuit) Wiring harness between L71 (female) (22) –
Resis-
tance
chassis ground
Possible causes
• Work equipment lock lever: Free
and standard
value in normal L71 Lift arm EPC lever Voltage
(10)
Defective work equipment Lever at neutral 2.40 – 2.60 V
4
controller Raise operation
3.69 – 4.09 V
(Before detent)
Between (19) and Raise operation
3.91 – 4.31 V
(10) (Detent position)
Lower operation
0.91 – 1.31 V
(Before detent)
WA450-6, WA480-6 (KA SPEC.) 15

Circuit diagram related to lift arm EPC lever potentiometer
16 WA450-6, WA480-6 (KA SPEC.)

Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short
Action code Failure code Lift arm EPC lever potentiometer (Main): Short circuit with the power
Trouble
E03 DK59KY supply line (Work equipment controller system)
Contents of • Due to hot short circuit in the lift arm EPC lever potentiometer (Main) system, the signal voltage is
trouble higher than normal range (Lift arm EPC lever potentiometer (Main) signal voltage: Min. 4.7 V).
• If the lift arm EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
(Neutral).
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective lift arm EPC lever
1 potentiometer L28 Lift arm EPC lever Voltage
(Internal short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
Possible causes
and standard Lever at neutral 2.40 – 2.60 V
value in normal Raise operation
3.69 – 4.09 V
state (Before detent)
Raise operation
Between (3) and (1) 3.91 – 4.31 V
(Detent position)
Lower operation
0.91 – 1.31 V
(Before detent)
Hot short in wiring harness Voltage Max. 1 V
2 L28 (female) (3) and chassis ground
chassis ground
WA450-6, WA480-6 (KA SPEC.) 17


L71 Lift arm EPC lever Voltage
Between (22) and
Possible causes Constant 4.85 – 5.15 V
(10)
and standard
value in normal 3
state controller Raise operation
3.69 – 4.09 V
(Before detent)
3.91 – 4.31 V
Lower operation
0.91 – 1.31 V
(Before detent)
18 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 19

Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog
signals disagree) 1
Action code Failure code Lift arm EPC lever potentiometer (Main): Analog signals disagree
Trouble
E03 DK59L8 (Work equipment controller system)
• Lift arm EPC lever potentiometer (Main & Sub) input signals disagree with each other.
Contents of
(Lift arm EPC lever potentiometer signal voltage (sum of Main and Sub): Max. 4.7 V) or
trouble
(Lift arm EPC lever potentiometer signal voltage (sum of Main and Sub): Min. 5.3 V)
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality
±5%, as the regular potentiometer.
• Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neu-
Action of
trality ±5%.
controller
• Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on neutral.
machine • If both Main and Sub potentiometers are abnormal, lift arm does not move.
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Between (4) and (1) Constant 4.85 – 5.15 V
Possible causes Lever at neutral 2.40 – 2.60 V
and standard Defective lift arm EPC lever
Raise operation
value in normal potentiometer 3.69 – 4.09 V
1 (Before detent)
state (Internal disconnection or
short circuit) Raise operation
Between (3) and (1) 3.91 – 4.31 V
(Detent position)
Lower operation
0.69 – 1.09 V
(Before detent)
Lever at neutral 2.40 – 2.60 V
Raise operation
0.91 – 1.31 V
(Before detent)
Raise operation
Between (2) and (1) 0.69 – 1.09 V
(Detent position)
Lower operation
3.69 – 4.09 V
(Before detent)
20 WA450-6, WA480-6 (KA SPEC.)


Max. 1 z
Disconnection in wiring L28 (female) (2) tance
harness Wiring harness between L71 (female) (19) – Resis-
2 Max. 1 z
(Disconnection in wiring L28 (female) (3) tance
harness or defective contact) Wiring harness between L71 (female) (22) – Resis-
Max. 1 z
Max. 1 z
Grounding fault in wiring Min. 1 Mz
3 harness
Min. 1 Mz
Min. 1 Mz
L28 (female) (4), – circuit branch end tance
Voltage Max. 1 V
Hot short in wiring harness L28 (female) (2)
4
Possible causes (Contact with 24V circuit) Wiring harness between L71 (female) (19) –
and standard Voltage Max. 1 V
L28 (female) (3)
value in normal
state Voltage Max. 1 V
L28 (female) (4), – circuit branch end
Between (22) and
(10)
Raise operation
0.91 – 1.31 V
(Before detent)
0.69 – 1.09 V
Defective work equipment (10) (Detent position)
5
controller Float operation 3.69 – 4.09 V
Lower operation
3.91 – 4.31 V
(Before detent)
Raise operation
3.69 – 4.09 V
(Before detent)
3.91 – 4.31 V
Lower operation
0.91 – 1.31 V
(Before detent)
WA450-6, WA480-6 (KA SPEC.) 21

22 WA450-6, WA480-6 (KA SPEC.)

Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub):

Disconnection) 1
Action code Failure code Lift arm EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5AKA (Work equipment controller system)
• Due to disconnection or grounding fault in the lift arm EPC lever potentiometer (Sub) system, the sig-
Contents of
nal voltage is lower than normal range (Lift arm EPC lever potentiometer (Sub) signal voltage: Max.
trouble
0.3 V).
• If the lift arm EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
• Turns the centralized warning lamp and the alarm buzzer ON.
controller
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective lift arm EPC lever • Work equipment lock lever: Free
potentiometer L28 Lift arm EPC lever Voltage
1
short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
and standard Raise operation
value in normal 0.91 – 1.31 V
(Before detent)
state
Raise operation
Between (2) and (1) 0.69 – 1.09 V
(Detent position)
Lower operation
3.69 – 4.09 V
(Before detent)
Max. 1 z
2
Max. 1 z
WA450-6, WA480-6 (KA SPEC.) 23


Min. 1 Mz
Resis-
tance
chassis ground
Possible causes
and standard
value in normal L71 Lift arm EPC lever Voltage
(10)
4
controller Raise operation
0.91 – 1.31 V
(Before detent)
0.69 – 1.09 V
Lower operation
3.69 – 4.09 V
(Before detent)
24 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 25

Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short
Action code Failure code Lift arm EPC lever potentiometer (Sub): Short circuit with the power
Trouble
E03 DK5AKY supply line (Work equipment controller system)
Contents of • Due to hot short circuit in the lift arm EPC lever potentiometer (Sub) system, the signal voltage is
trouble higher than normal range (Lift arm EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V).
• If the lift arm EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of • Turns the centralized warning lamp and the alarm buzzer ON.
(Neutral).
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective lift arm EPC lever
1 potentiometer L28 Lift arm EPC lever Voltage
(Internal short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
Possible causes
value in normal Raise operation
0.91 – 1.31 V
state (Before detent)
Raise operation
Between (2) and (1) 0.69 – 1.09 V
(Detent position)
Lower operation
3.69 – 4.09 V
(Before detent)
chassis ground
26 WA450-6, WA480-6 (KA SPEC.)


Between (22) and
Possible causes Constant 4.85 – 5.15 V
(10)
and standard
value in normal 3
state controller Raise operation
0.91 – 1.31 V
(Before detent)
0.69 – 1.09 V
Lower operation
3.69 – 4.09 V
(Before detent)
WA450-6, WA480-6 (KA SPEC.) 27

28 WA450-6, WA480-6 (KA SPEC.)

Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main):

Disconnection) 1
Action code Failure code Bucket EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5BKA (Work equipment controller system)
• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Main) system, the
Contents of
signal voltage is lower than normal range (Bucket EPC lever potentiometer (Main) signal voltage:
trouble
Max. 0.3 V)
• If the bucket EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns on the centralized warning lamp the and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002, BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective bucket EPC lever and carry out troubleshooting.
potentiometer • Work equipment lock lever: Free
1
L29 Bucket EPC lever Voltage
short circuit)
Possible causes Between (4) and (1) Constant 4.85 – 5.15 V
value in normal
Tilt operation
state 3.69 – 4.09 V
(Before detent)
Between (3) and (1)
Tilt operation
3.91 – 4.31 V
(Detent position)
Full dump operation 0.69 – 1.09 V
Max. 1 z
2
Max. 1 z
WA450-6, WA480-6 (KA SPEC.) 29


Min. 1 Mz
3 harness L29 (female) (3) tance
Resis-
tance
chassis ground
value in normal • Work equipment lock lever: Free
state L71 Bucket EPC lever Voltage
Between (22) and
Defective work equipment (10)
4
controller Lever at neutral 2.40 – 2.60 V
Tilt operation
3.69 – 4.09 V
(Before detent)
Tilt operation
3.91 – 4.31 V
(Detent position)
30 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to bucket EPC lever potentiometer
WA450-6, WA480-6 (KA SPEC.) 31

Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short

Action code Failure code Bucket EPC lever potentiometer (Main): Short circuit with the power
Trouble
E03 DK5BKY supply line (Work equipment controller system)
Contents of • Due to hot short circuit in the bucket EPC lever potentiometer (Main) system, the signal voltage is
trouble higher than normal range (Bucket EPC lever potentiometer (Main) signal voltage: Min. 4.7 V)
• If the bucket EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns on the centralized warning lamp and the alarm buzzer ON.
(Neutral).
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
1 potentiometer (Internal short • Work equipment lock lever: Free
circuit) L29 Bucket EPC lever Voltage
Possible causes
and standard
value in normal Lever at neutral 2.40 – 2.60 V
state Tilt operation
3.69 – 4.09 V
(Before detent)
Between (3) and (1)
Tilt operation
3.91 – 4.31 V
(Detent position)
2 L29 (female) (3)
chassis ground
32 WA450-6, WA480-6 (KA SPEC.)


Possible causes Between (22) and
and standard Constant 4.85 – 5.15 V
value in normal 3
state controller Lever at neutral 2.40 – 2.60 V
Tilt operation
3.69 – 4.09 V
(Before detent)
Tilt operation
3.91 – 4.31 V
(Detent position)
WA450-6, WA480-6 (KA SPEC.) 33

34 WA450-6, WA480-6 (KA SPEC.)

Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog

signals disagree) 1
Action code Failure code Bucket EPC lever potentiometer (Main): Analog signals disagree
Trouble
E03 DK5BL8 (Work equipment controller system)
• Bucket EPC lever potentiometer (Main & Sub) input signals disagree with each other. (Bucket EPC
Contents of
lever potentiometer signal voltage (sum of Main and Sub): Max. 4.7 V) or (Bucket EPC lever potenti-
trouble
ometer signal voltage (sum of Main and Sub): Min. 5.3 V)
Action of
trality ±5%.
controller
• Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N
(Neutral).
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on neutral.
machine • If both Main and Sub potentiometers are abnormal, bucket does not move.
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Possible causes
and standard Defective bucket EPC lever Between (4) and (1) Constant 4.85 – 5.15 V
value in normal potentiometer
1 Lever at neutral 2.40 – 2.60 V
state (Internal disconnection or
short circuit) Tilt operation
3.69 – 4.09 V
(Before detent)
Between (3) and (1)
Tilt operation
3.91 – 4.31 V
(Detent position)
Tilt operation
0.91 – 1.31 V
(Before detent)
Between (2) and (1)
Tilt operation
0.69 – 1.09 V
(Detent position)
WA450-6, WA480-6 (KA SPEC.) 35


Max. 1 z
2 Max. 1 z
Max. 1 z
Max. 1 z
Min. 1 Mz
Grounding fault in wiring L29 (female) (2) and chassis ground tance
3 harness Wiring harness between L71 (female) (7) – Resis-
(Contact with ground circuit) L29 (female) (3) and chassis ground Min. 1 Mz
tance
Resis-
tance
chassis ground
Possible causes Wiring harness between L71 (female) (1) –
and standard Voltage Max. 1 V
value in normal Hot short in wiring harness
4 Wiring harness between L71 (female) (7) –
state (Contact with 24V circuit) Voltage Max. 1 V
chassis ground
Between (22) and
(10)
Tilt operation
3.69 – 4.09 V
Defective work equipment (Before detent)
5 Between (7) and (10)
controller Tilt operation
3.91 – 4.31 V
(Detent position)
Tilt operation
0.91 – 1.31 V
(Before detent)
Tilt operation
0.69 – 1.09 V
(Detent position)
36 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 37

Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub):

Disconnection) 1
Action code Failure code Bucket EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5CKA (Work equipment controller system)
• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Sub) system, the sig-
Contents of
nal voltage is lower than normal range (Bucket EPC lever potentiometer (Sub) signal voltage: Max.
trouble
0.3 V).
• If the bucket EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
controller
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
potentiometer • Work equipment lock lever: Free
1
L29 (male) Bucket EPC lever Voltage
short circuit)
Tilt operation
0.91 – 1.31 V
(Before detent)
Possible causes Between (2) and (1)
and standard Tilt operation
0.69 – 1.09 V
value in normal (Detent position)
state Full dump operation 3.91 – 4.31 V
Max. 1 z
2
Max. 1 z
Min. 1 Mz
Resis-
tance
chassis ground
38 WA450-6, WA480-6 (KA SPEC.)


value in normal 4
Tilt operation
0.91 – 1.31 V
(Before detent)
Tilt operation
0.69 – 1.09 V
(Detent position)
WA450-6, WA480-6 (KA SPEC.) 39

40 WA450-6, WA480-6 (KA SPEC.)

Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short

Action code Failure code Bucket EPC lever potentiometer (Sub): Short circuit with the power
Trouble
E03 DK5CKY supply line (Work equipment controller system)
Contents of • Due to hot short circuit in the bucket EPC lever potentiometer (Sub) system, the signal voltage is
trouble higher than normal range (Bucket EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V).
• If the bucket EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
(Neutral).
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
1 potentiometer (Internal short • Work equipment lock lever: Free
circuit) L29 Bucket EPC lever Voltage
Possible causes
and standard
state Tilt operation
0.91 – 1.31 V
(Before detent)
Between (2) and (1)
Tilt operation
0.69 – 1.09 V
(Detent position)
chassis ground
WA450-6, WA480-6 (KA SPEC.) 41


value in normal 3
Tilt operation
0.91 – 1.31 V
(Before detent)
Tilt operation
0.69 – 1.09 V
(Detent position)
42 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 43

Failure code [DK5DKA] (3-spool valve (attachment) EPC lever

potentiometer (Main): Disconnection) 1
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Main): Discon-
Trouble
E03 DK5DKA nection (Work equipment controller system)
• Due to disconnection or grounding fault in the 3-spool valve (attachment) EPC lever potentiometer
Contents of
(Main), the signal voltage is lower than normal range (3-spool valve (attachment) EPC lever potenti-
trouble
ometer (Main) signal voltage: Max. 0.3 V)
• If the 3-spool valve (attachment) EPC lever potentiometer (Sub) is normal, the Sub potentiometer is
in control.
Action of
controller
• Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC
lever is set to N (Neutral).
Problem that
appears on —
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure
code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional
setting of the machine monitor.)
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
Related
checked with the monitoring function (Code: 42006, 3RD POT1).
information
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (sub) can be
• Method of reproducing failure code: Turn the starting switch ON and operate the 3-spool valve
(attachment) lever.

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3) or (4) and
Min. 1 Mz
chassis ground
and standard Defective 3-spool valve and carry out troubleshooting.
value in normal (attachment) EPC lever • Work equipment lock lever: Free
1
state potentiometer (Internal dis-
connection or short circuit) 3-spool valve (attach-
L30 Voltage
ment) EPC lever
Full extension
3.91 – 4.31 V
Between (3) and (1) operation
Full retraction
0.69 – 1.09 V
operation
44 WA450-6, WA480-6 (KA SPEC.)


Max. 1 z
2
Max. 1 z
Min. 1 Mz
Possible causes 3 harness L30 (female) (3) and chassis ground tance
and standard (Contact with ground circuit) Wiring harness between L71 (female) (22) –
state tance
chassis ground
3-spool valve (attach-
L71 Voltage
ment) EPC lever
Defective work equipment Between (22) and
4 Constant 4.85 – 5.15 V
controller (10)
Full extension
Between (20) and 3.91 – 4.31 V
operation
(10)
Full retraction
0.69 – 1.09 V
operation
WA450-6, WA480-6 (KA SPEC.) 45

Circuit diagram related to 3-spool valve (attachment) EPC lever potentiometer
46 WA450-6, WA480-6 (KA SPEC.)

Failure code [DK5DKY] (3-spool valve (attachment) EPC lever

potentiometer (Main): Short circuit with power supply line) 1
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Main): Short
Trouble
E03 DK5DKY circuit with power supply line (Work equipment controller system)
• Due to hot short circuit in the 3-spool valve (attachment) EPC lever potentiometer (Main) system the
Contents of
signal voltage is higher than normal range (3-spool valve (attachment) EPC lever potentiometer
trouble
(Main) signal voltage: Max. 4.7 V)
• If the 3-spool valve (attachment) EPC lever potentiometer (Sub) is normal, the Sub potentiometer is
in control.
Action of
controller
Problem that
appears on —
machine
Related
information
(attachment) lever.

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective 3-spool valve and carry out troubleshooting.
(attachment) EPC lever • Work equipment lock lever: Free
1
potentiometer (Internal short
circuit) 3-spool valve (attach-
Possible causes L30 Voltage
ment) EPC lever
and standard
value in normal Between (4) and (1) Constant 4.85 – 5.15 V
state Lever at neutral 2.40 – 2.60 V
Full extension
3.91 – 4.31 V
Full retraction
0.69 – 1.09 V
operation
chassis ground
WA450-6, WA480-6 (KA SPEC.) 47


• Work equipment lock lever: Lock
ment) EPC lever
and standard
value in normal 3 Constant 4.85 – 5.15 V
controller (10)
state
Full extension
Between (20) and 3.91 – 4.31 V
operation
(10)
Full retraction
0.69 – 1.09 V
operation
48 WA450-6, WA480-6 (KA SPEC.)

Failure code [DK5DL8] (3-spool valve (attachment) EPC lever

potentiometer (Main): Analog signals disagree) 1
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Main): Analog
Trouble
E03 DK5DL8 signals disagree (Work equipment controller system)
• The 3-spool valve (attachment) EPC lever potentiometer (Main & Sub) input signals disagree with
Contents of each other. (3-spool valve (attachment) EPC lever potentiometer signal voltage (sum of Main and
trouble Sub): Max. 4.7 V) or (3-spool valve (attachment) EPC lever potentiometer signal voltage (sum of
Main and Sub): Min. 5.3 V)
Action of
trality ±5%.
controller
• If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
Problem that
neutral.
appears on
• If both Main and Sub potentiometers are abnormal, 3-spool valve (attachment) cylinder does not
machine
move.
Related
information
(attachment) lever.

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Possible causes 3-spool valve (attach-
and standard Defective 3-spool valve L30 Voltage
(attachment) EPC lever ment) EPC lever
value in normal 1
state potentiometer (Internal dis- Between (4) and (1) Constant 4.85 – 5.15 V
connection or short circuit) Lever at neutral 2.40 – 2.60 V
Full extension
3.91 – 4.31 V
Full retraction
0.69 – 1.09 V
operation
Full extension
0.69 – 1.09 V
Full retraction
3.91 – 4.31 V
operation
WA450-6, WA480-6 (KA SPEC.) 49


Max. 1 z
2 Max. 1 z
Max. 1 z
Max. 1 z
Min. 1 Mz
Grounding fault in wiring L30 (female) (2) and chassis ground tance
3 harness Wiring harness between L71 (female) (20) – Resis-
(Contact with ground circuit) L30 (female) (3) and chassis ground Min. 1 Mz
tance
Resis-
tance
chassis ground
and standard Wiring harness between L71 (female) (14) –
Voltage Max. 1 V
value in normal L30 (female) (2) and chassis ground
state Hot short in wiring harness
(Contact with 24V circuit) Voltage Max. 1 V
chassis ground
L71 Voltage
ment) EPC lever
Between (22) and
(10)
5 Full extension
controller Between (20) and 0.69 – 1.09 V
operation
(10)
Full retraction
0.64 – 1.14 V
operation
Full extension
Between (14) and 0.69 – 1.09 V
operation
(10)
Full retraction
3.91 – 4.31 V
operation
50 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 51

Failure code [DK5EKA] (3-spool valve (attachment) EPC lever

potentiometer (Sub): Disconnection) 1
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Sub): Discon-
Trouble
E03 DK5EKA nection (Work equipment controller system)
• Due to disconnection or grounding fault in the 3-spool valve (attachment) EPC lever potentiometer
Contents of
(Sub), the signal voltage is lower than normal range (3-spool valve (attachment) EPC lever potenti-
trouble
ometer (Sub) signal voltage: Max.0.3 V).
• If the 3-spool valve (attachment) EPC lever potentiometer (Main) is normal, the Main potentiometer
Action of is in control.
Problem that
appears on —
machine
Related
information
(attachment) lever.

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
(attachment) EPC lever • Work equipment lock lever: Lock
1
potentiometer (Internal dis-
connection or short circuit) 3-spool valve (attach-
L30 Voltage
Possible causes ment) EPC lever
and standard Between (4) and (1) Constant 4.85 – 5.15 V
state
Full extension
0.69 – 1.09 V
Full retraction
3.91 – 4.31 V
operation
Max. 1 z
2
Max. 1 z
52 WA450-6, WA480-6 (KA SPEC.)


Min. 1 Mz
Resis-
tance
chassis ground
value in normal • Work equipment lock lever: Lock
state 3-spool valve (attach-
L71 Voltage
ment) EPC lever
4 Constant 4.85 – 5.15 V
controller (10)
Full extension
Between (14) and 0.69 – 1.09 V
operation
(10)
Full retraction
3.91 – 4.31 V
operation
WA450-6, WA480-6 (KA SPEC.) 53

54 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 55

Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub):

Short circuit with power supply line) 1
Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Sub): Short
Trouble
E03 DK5EKY circuit with power supply line (Work equipment controller system)
• Due to hot short circuit in the 3-spool valve (attachment) EPC lever potentiometer (Sub) system, the
Contents of
signal voltage is higher than normal range (3-spool valve (attachment) EPC lever potentiometer
trouble
(Sub) signal voltage: Min. 4.7 V).
• If the 3-spool valve (attachment) EPC lever potentiometer (Main) is normal, the Main potentiometer
is in control.
Action of
controller
Problem that
appears on —
machine
Related
information
(attachment) lever.

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3) or (4) and
Min. 1 Mz
chassis ground
(attachment) EPC lever • Work equipment lock lever: Free
1
potentiometer (Internal short
circuit) 3-spool valve (attach-
ment) EPC lever
and standard
value in normal Between (4) and (1) Constant 4.85 – 5.15 V
state Lever at neutral 2.40 – 2.60 V
Full extension
0.69 – 1.09 V
Full retraction
3.91 – 4.31 V
operation
chassis ground
56 WA450-6, WA480-6 (KA SPEC.)


ment) EPC lever
and standard
value in normal 3 Constant 4.85 – 5.15 V
controller (10)
state
Full extension
Between (14) and 0.69 – 1.09 V
operation
(10)
Full retraction
3.91 – 4.31 V
operation
WA450-6, WA480-6 (KA SPEC.) 57

SEN01684-00

58
SEN01685-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) .............. 3
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main):
Short circuit with power supply line) ........................................................................................... 6
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) ............... 8
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub):
Short circuit with power supply line) ..........................................................................................11
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main):
Analog signals disagree) .......................................................................................................... 13
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)......................................................... 16
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) ........................ 18
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) ...................................................... 20
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) ........................... 22
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range) ........... 24
WA450-6, WA480-6 (KA SPEC.) 1

Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) ....................................... 26
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) .......................... 28
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) ......................... 30
Failure code [DV00KB] (Alarm buzzer: Short circuit) ......................................................................... 32
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) .............................................. 34
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) ................................................. 36
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) ............. 38
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)............................................. 40
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) ................................................ 41
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) ............ 42
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)................................................... 44
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) ...................................................... 45
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) .................. 46
2 WA450-6, WA480-6 (KA SPEC.)


Failure code [DK5FKA] (Joystick steering EPC lever potentiometer
(Main): Disconnection) 1
Action code Failure code Joystick steering EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5FKA (Work equipment controller system)
• Due to disconnection or grounding fault in the joystick steering EPC lever potentiometer (Main) sys-
Contents of
tem, the signal voltage is lower than normal range (Joystick steering EPC lever potentiometer (Main)
trouble
signal voltage: Max. 0.3 V)
• If the joystick steering EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
controller • Even if cause of failure disappears, system does not reset itself until the joystick steering EPC lever
is set to N (Neutral).
Problem that
appears on —
machine
• When the joystick steering ON/OFF switch is set to OFF, this failure code is not displayed.
• The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked
Related with the monitoring function (Code: 42004, J/S POT1).
information • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked
with the monitoring function (Code: 42005, J/S POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3) or (4) and
Min. 1 Mz
chassis ground
EPC lever potentiometer a Prepare with starting switch OFF, then turn starting switch ON
1 and carry out troubleshooting.
short circuit) Joystick steering EPC
L34 Voltage
lever
Possible causes
and standard Between (3) and (1) Left turning 1.14 – 1.54 V
value in normal Right turning 3.46 – 3.86 V
state
Max. 1 z
2
Max. 1 z
3 harness Min. 1 Mz
Min. 1 Mz
WA450-6, WA480-6 (KA SPEC.) 3


Possible causes Joystick steering EPC

L71 Voltage
and standard lever
value in normal Defective work equipment Between (22) and
4 Constant 4.85 – 5.15 V
state controller (10)
Between (9) and (10) Left turning 1.14 – 1.54 V
Right turning 3.46 – 3.86 V
4 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to joystick steering EPC lever potentiometer
WA450-6, WA480-6 (KA SPEC.) 5

Failure code [DK5FKY] (Joystick steering EPC lever potentiometer

(Main): Short circuit with power supply line) 1
Action code Failure code Joystick steering EPC lever potentiometer (Main): Short circuit with
Trouble
E03 DK5FKY the power supply line (Work equipment controller system)
• Due to hot short circuit in the joystick steering EPC lever potentiometer (Main) system, the signal
Contents of
voltage is higher than normal range. (Joystick steering EPC lever potentiometer (Main) signal volt-
trouble
age: Max. 4.7 V)
• If the joystick steering EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Problem that
appears on —
machine

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3) or (4) and
Min. 1 Mz
chassis ground
Defective joystick steering a Prepare with starting switch OFF, then turn starting switch ON
1 EPC lever potentiometer and carry out troubleshooting.
(Internal short circuit)
L34 Voltage
lever
Possible causes Between (3) and (1) Left turning 1.14 – 1.54 V
and standard
Hot short in wiring harness Wiring harness between L71 (female) (9) –
2 Voltage Max. 1 V
(Contact with 24V circuit) L34 (female) (3) and chassis ground
Voltage Max. 1 V
L71 Voltage
lever
3 (22) – (10) Constant 4.85 – 5.15 V
controller
6 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 7

Failure code [DK5GKA] (Joystick steering EPC lever potentiometer

(Sub): Disconnection) 1
Action code Failure code Joystick steering EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5GKA (Work equipment controller system)
• Due to disconnection or grounding fault in the joystick steering EPC lever potentiometer (Sub) sys-
Contents of
tem, the signal voltage is lower than normal range (Joystick steering EPC lever potentiometer (Sub)
trouble
signal voltage: Max. 0.3 V)
• If the joystick steering EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
controller
Problem that
appears on —
machine

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3) or (4) and
Min. 1 Mz
chassis ground
L34 Voltage
lever
Possible causes
state
Max. 1 z
2
Max. 1 z
3 harness Min. 1 Mz
Min. 1 Mz
8 WA450-6, WA480-6 (KA SPEC.)


Possible causes Joystick steering EPC

L71 Voltage
and standard lever
value in normal Defective work equipment Between (22) and
4 Constant 4.85 – 5.15 V
state controller (10)
WA450-6, WA480-6 (KA SPEC.) 9

10 WA450-6, WA480-6 (KA SPEC.)

Failure code [DK5GKY] (Joystick steering EPC lever potentiometer

(Sub): Short circuit with power supply line) 1
Action code Failure code Joystick steering EPC lever potentiometer (Sub): Short circuit with
Trouble
E03 DK5GKY power supply line (Work equipment controller system)
• Due to hot short circuit in the joystick steering EPC lever potentiometer (Sub) system, the signal volt-
Contents of
age is higher than normal range. (Joystick steering EPC lever potentiometer (Sub) signal voltage:
trouble
Min. 4.7 V)
• If the joystick steering EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Problem that
appears on —
machine

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3) or (4) and
Min. 1 Mz
chassis ground
L34 Voltage
lever
Possible causes Between (2) and (1) Left turning 3.46 – 3.86 V
and standard Right turning 1.14 – 1.54 V
value in normal
state
2 Voltage Max. 1 V
Voltage Max. 1 V
L71 Voltage
lever
3 Constant 4.85 – 5.15 V
controller (10)
WA450-6, WA480-6 (KA SPEC.) 11

12 WA450-6, WA480-6 (KA SPEC.)

Failure code [DK5FL8] (Joystick steering EPC lever potentiometer

(Main): Analog signals disagree) 1
Action code Failure code Joystick steering EPC lever potentiometer (Main): Analog signals
Trouble
E03 DK5FL8 disagree (Work equipment controller system)
• Joystick steering EPC lever potentiometer (Main & Sub) input signals disagree with each other. (Joy-
Contents of
stick steering EPC lever potentiometer signal voltage (both Main and Sub): Max. 4.7 V) or (Joystick
trouble
steering EPC lever potentiometer signal voltage (both Main and Sub): Min 5.3 V)
Action of
trality ±5%.
controller
• Even if cause of failure disappears, system does not reset itself until the joystick steering EPC lever
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the joystick steer-
appears on ing EPC lever is set to neutral.
machine • If both Main and Sub potentiometers are abnormal, steering cylinder does not move.

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3) or (4) and
Min. 1 Mz
chassis ground
Defective joystick steering and carry out troubleshooting.
EPC lever potentiometer Joystick steering EPC
1 L34 Voltage
(Internal disconnection or lever
short circuit)

state
Max. 1 z
2 Max. 1 z
Max. 1 z
Max. 1 z
WA450-6, WA480-6 (KA SPEC.) 13


Grounding fault in wiring Min. 1 Mz
3 harness
Min. 1 Mz
Min. 1 Mz
Voltage Max. 1 V
Hot short in wiring harness L34 (female) (2) and chassis ground
4
Possible causes (Contact with 24V circuit) Wiring harness between L71 (female) (9) –
Voltage Max. 1 V
and standard L34 (female) (3) and chassis ground
value in normal Wiring harness between L71 (female) (22) –
state Voltage Max. 1 V
L71 Voltage
lever
Between (22) and
(10)
5 Lever at neutral 2.40 – 2.60 V
controller
14 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 15

Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) 1

Action code Failure code Lift arm angle sensor: Disconnection
Trouble
E01 DKA0KA (Work equipment controller system)
Contents of • Due to disconnection or ground fault in lift arm angle sensor system, the signal voltage is lower than
trouble normal range (Lift arm angle sensor signal: Max. 0.3 V).
• Judges that lift arm is at the lowest position.
• Resets the remote positioner function.
• Resets semi auto digging function.
Action of • No PC control while the lift arm is rising.
controller • When the remote positioner down setting is ON, turns OFF the lift arm float detent, and when the
remote positioner down setting is OFF, usually operates the lift arm float detent.
• Turns the lift arm up detent OFF
Problem that • Remote positioner malfunction (operation is not stopped)
appears on • Malfunctioning in semi-auto digging operation (operation is stopped)
machine • No PC control while the lift arm is rising
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function
(Code: 06002, BOOM ANG).
• The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function
Related
information
• If failure code [DAF5KP] (Machine monitor: Low output voltage) is displayed, carry out troubleshoot-
ing for it first.

Between (A) and (C) 5 kz ± 20%
Min. 1 Mz
chassis ground
Defective lift arm angle sen-
1 sor (Internal disconnection or a Prepare with starting switch OFF, then start engine and carry out
short circuit) troubleshooting.
F18 Lift arm position Voltage
Possible causes Between (B) and (A) Up stroke end 3.50 – 4.17 V
and standard Lower stroke end 0.83 – 1.88 V
value in normal
state
Disconnection in wiring Wiring harness between F18 (female) (A) – Resis-
Max. 1 z
harness chassis ground tance
2
(Disconnection in wiring Wiring harness between F18 (female) (B) – Resis-
Wiring harness between F18 (female) (C) – Resis-
Max. 1 z
Grounding fault in wiring Wiring harness between F18 (female) (B) – Resis- Min.
3 harness L71 (female) (8) and chassis ground tance 1 Mz
(Contact with ground circuit) Wiring harness between F18 (female) (C) –
Resis- Min.
L71 (female) (22), – circuit branch end and
tance 1 Mz
chassis ground
16 WA450-6, WA480-6 (KA SPEC.)


Possible causes troubleshooting.
and standard L71 Lift arm position Voltage
value in normal Defective work equipment
4
state controller Constant 0.83 – 4.17 V
Between (8) and
Up stroke end 3.50 – 4.17 V
chassis ground
Lower stroke end 0.83 – 1.88 V
Circuit diagram related to lift arm angle sensor
WA450-6, WA480-6 (KA SPEC.) 17

Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power
supply line) 1
Action code Failure code Lift arm angle sensor: Short circuit with power supply line
Trouble
E01 DKA0KY (Work equipment controller system)
Contents of • Due to hot short circuit in the lift arm angle sensor system, the signal voltage is higher than normal
trouble range (Lift arm angle sensor signal: Min. 4.7 V).
• Judges that lift arm is at the highest position.
• No PC control while the lift arm is rising.
Action of
• When the remote positioner down setting is ON, turns OFF the lift arm float detent, and when the
controller
• Even if cause of failure disappears, system does not reset itself until lift arm lever is set to N (Neu-
tral).
Problem that • Remote positioner malfunction
appears on • Faulty semi-auto digging operation
Related
information

Min. 1 Mz
chassis ground
Defective lift arm angle a Prepare with starting switch OFF, then start engine and carry out
1
sensor (Internal short circuit) troubleshooting.
F18 Lift arm position Voltage
Possible causes
Between (B) and (A) Up stroke end 3.50 – 4.17 V
and standard
value in normal Lower stroke end 0.83 – 1.88 V
Wiring harness between F18 (female) (B) –
Wiring harness between F18 (female) (C) –
chassis ground
troubleshooting.
Defective work equipment L71 Lift arm position Voltage

3
controller Constant 0.83 – 4.17 V
Between (8) and
chassis ground
18 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 19

Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) 1

Action code Failure code Lift arm angle sensor: Double meshing
Trouble
E01 DKA0L0 (Work equipment controller system)
Contents of • Due to lift arm angle sensor dislocation, lift arm angle is not detectable correctly. (Lift arm angle
trouble upper limit +5° and above or lift arm angle lower limit +5° or above)
• No PC control while the lift arm is rising.
Action of
• When the remote positioner down setting is ON, turns OFF the lift arm float detent, and when the
controller
Problem that • Remote positioner malfunction (operation is not stopped)
appears on • Malfunctioning in semiautomatic digging operation (operation is stopped)
• This failure code is sometimes displayed if the initial setting of the lift arm angle sensor was not
appropriate.
Related
information
• Method of reproducing failure code: Start engine and set the lift arm to up or down stroke end

Defective lift arm angle sen- a Adjustment of lift arm angle sensor may be defective. Check it
1
sor adjustment directly (see Testing and adjusting).
Min. 1 Mz
chassis ground
Defective lift arm angle a Prepare with starting switch OFF, then start engine and carry out
2
Possible causes sensor (Internal short circuit) troubleshooting.
and standard
value in normal F18 Lift arm position Voltage
state Between (C) and (A) Constant 4.85 – 5.15 V
Between (B) and (A) Up stroke end 3.50 – 4.17 V
troubleshooting.
Defective work equipment L71 Lift arm position Voltage

3
controller Constant 0.83 – 4.17 V
Between (8) and
chassis ground
20 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 21

Failure code [DLT3KA] (Transmission output shaft speed sensor:

Disconnection) 1
Action code Failure code Transmission output shaft speed sensor: Disconnection (Transmis-
Trouble
E03 DLT3KA sion controller system)
• Due to disconnection in the transmission output shaft speed sensor system, the signal voltage is out-
side the higher limit.
Contents of
• This failure code appears under the following conditions.
trouble
1) Input voltage is 1.5 V or above
2) Pulse has not been input
• In the auto-shift mode, changes the shift mode to the manual mode.
• In the auto-shift mode, changes the mode for transmitting signal to the machine monitor to the man-
ual mode.
• When the manual shift mode is turned on, normal control is carried out.
Action of
• Releases the lockup clutch (if equipped).
controller
• When the 1st speed is set, the controller constantly turns on the torque derating function.
• Maintains the travel speed that had been set prior to the failure.
• The auto-shift mode is not turned on (the manual shift mode is selected)
• Lockup becomes unavailable
Problem that • Travel speed derating function is unavailable
appears on • Transmission protection function is unavailable
machine • When the 1st speed is set, digging torque is reduced.
• Gear shifting shocks are made.
• The auto-shift pilot lamp goes off.
• The input state (speed) from the transmission output shaft speed sensor can be checked with the
Related
monitoring function (Code: 31400, T/M SPEED OUT).
information
• Method of reproducing failure code: Start engine and move the machine

Defective adjustment of a The transmission output shaft speed sensor adjustment may be
1 transmission output shaft defective. Check it directly (see Testing and adjusting, Adjusting
speed sensor transmission speed sensor).
Defective transmission output without turning starting switch ON.
2 shaft speed sensor
REV OUT (male) Resistance
Possible causes (Internal disconnection)
and standard Between (1) and (2) 500 – 1,000 z
state Disconnection in wiring without turning starting switch ON.
3 harness
Max. 1 z
REV OUT (female) (2) tance
Defective transmission without turning starting switch ON.
4
controller L62 Resistance
Between (20) and (29) 500 – 1,000 z
22 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission output shaft speed sensor
WA450-6, WA480-6 (KA SPEC.) 23

Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of

Action code Failure code Transmission output shaft speed sensor: Out of input signal range
Trouble
E03 DLT3LC (Transmission controller system)
• Due to ground fault in the transmission output shaft speed sensor system, the signal voltage is lower
than the normal range.
• Failure detection condition
1) If the current travel speed – 15 km/h or above – were changed (reduced) by 5 km/h or more and
Contents of the pulse is 10 msec or above, the travel speed immediately preceding the change is maintained.
trouble (If pulse update of the transmission output shaft speed sensor is continued 50 msec or more and
the travel speed pulse input voltage below 1.5 V is detected 5 times or more, the currently held
immediately preceding travel speed is canceled.)
2) When the output is not set to N, an error is turned on if the immediately preceding travel speed is
held for more than 10 seconds.
• In the auto-shift mode, changes the shift mode to the manual mode.
• In the auto-shift mode, changes the mode for transmitting signal to the machine monitor to the man-
ual mode.
Action of • When the manual shift mode is turned on, normal control is carried out.
controller • Controls the operation by determining the output shaft speed from the input shaft speed and the gear
speed reduction ratio.
• Resets the torque converter lockup.
• The auto-shift mode is not turned on (the manual shift mode is selected)
• Torque converter lockup becomes unavailable.
Problem that
• Travel speed derating function is unavailable
appears on
• Transmission protection function is unavailable
machine
• When the 1st speed is set, digging torque goes low.
• Gear shifting shocks are made.
• The input state (speed) from the transmission output shaft speed sensor can be checked with the
Related
monitoring function (Code: 31400, T/M SPEED OUT).
information
• Method of reproducing failure code: Start engine and move the machine

Defective adjustment of a The transmission output shaft speed sensor adjustment may be
1 transmission output shaft defective. Check it directly (see Testing and adjusting, Adjusting
speed sensor transmission speed sensor).
Defective transmission output REV OUT (male) Resistance
2 shaft speed sensor
(Internal short circuit) Between (1) and (2) 500 – 1,000 z
Possible causes Between (1), (2) and
Min. 1 Mz
3 Max. 1 z
(Disconnection in wiring REV OUT (female) (2) tance
Max. 1 z
REV OUT (female) (1) tance
4
Voltage Max. 1 V
REV OUT (female) (2) and chassis ground
24 WA450-6, WA480-6 (KA SPEC.)


and standard
Defective transmission L62 Resistance
value in normal 5
state controller Between (20) and (29) 500 – 1,000 z
Min. 1 Mz
chassis ground
Circuit diagram related to transmission output shaft speed sensor
WA450-6, WA480-6 (KA SPEC.) 25

Failure code [DT20KB] (Transmission cut-off indicator lamp: Short

circuit) 1
Action code Failure code Transmission cut-off indicator lamp: Short circuit
Trouble
E01 DT20KB (Transmission controller system)
Contents of • Since the transmission cut-off indicator lamp system is shorted, output signals are not entered to the
trouble indicator lamp.
Action of • Turns off the transmission cut-off indicator lamp.
Problem that
appears on • Transmission cut-off indicator lamp does not light up.
machine
Related
• Method of reproducing failure code: Start engine and turn transmission cut-off switch ON.
information

Defective transmission cut-off S03 (male) Resistance
1 indicator lamp (LED)
(Internal short circuit) Between (2) and (1) Min. 1 Mz (No continuity)
Min. 1 Mz
ground
Possible causes
S03 (female) (1) and chassis ground tance 1 Mz
Defective work equipment Transmission cut-off
3 L63 Voltage
controller switch
26 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to transmission cut-off indicator lamp
WA450-6, WA480-6 (KA SPEC.) 27

Failure code [DUM1KB] (Remote positioner raise set indicator lamp:

Short circuit) 1
Action code Failure code Remote positioner raise set indicator lamp: Short circuit
Trouble
— DUM1KB (Work equipment controller system)
Contents of • Since the remote positioner raise set indicator lamp system is shorted, output signal are not entered
trouble to the indicator lamp.
Action of • Turns off the remote positioner raise set indicator output.
Problem that
appears on • Remote positioner raise set indicator lamp does not light up.
machine
• The output state (ON/OFF) to the remote positioner raise set indicator lamp can be checked with the
Related
information

• See Testing and adjusting, Diode inspection procedure.
1 raise set indicator lamp S14 (male) Resistance
(LED) (Internal short circuit) Between (2) and (1) Min. 1 Mz (No continuity)
Min. 1 Mz
state 2 harness
Min. 1 Mz
3 L73 Voltage
controller raise
Between (8) and When used 20 – 30 V
chassis ground When not used. Max. 1 V
28 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to remote positioner raise/lower set indicator lamp
WA450-6, WA480-6 (KA SPEC.) 29

Failure code [DUM2KB] (Remote positioner lower set indicator lamp:

Short circuit) 1
Action code Failure code Remote positioner lower set indicator lamp: Short circuit
Trouble
— DUM2KB (Work equipment controller system)
Contents of • Since the remote positioner lower set indicator lamp system is shorted, output signals are not
trouble entered to the indicator lamp.
Action of • Turns off the remote positioner lower set indicator output.
Problem that
appears on • Remote positioner lower set indicator lamp does not light up.
machine
• The output state (ON/OFF) to the remote positioner lower set indicator lamp can be checked with the
Related
information

• See Testing and adjusting, Diode inspection procedure.
1 lower set indicator lamp S14 (male) Resistance
(LED) (Internal short circuit) Between (2) and (3) Min. 1 Mz (No continuity)
Min. 1 Mz
state 2 harness
Min. 1 Mz
3 L73 Voltage
controller lower
Between (18) and When used 20 – 30 V
chassis ground When not used. Max. 1 V
30 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to remote positioner raise/lower set indicator lamp
WA450-6, WA480-6 (KA SPEC.) 31

Failure code [DV00KB] (Alarm buzzer: Short circuit) 1

Action code Failure code Alarm buzzer: Short circuit
Trouble
E01 DV00KB (Machine monitor system)
Contents of
• The alarm buzzer output circuit is shorted with the power source.
trouble
Action of • Stops alarm buzzer output.
Problem that
appears on • Alarm buzzer does not sound.
machine
• The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function (Code:
Related
40952, D-OUT-0).
information

1
Voltage Max. 1 V
Possible causes
and standard
• Remove the buzzer, then connect +24 V to L20 (male) (1) and
value in normal
Defective alarm buzzer GND to L20 (male) (2).
state 2
(Internal short circuit) Alarm buzzer is
Alarm buzzer sounds
normal
Defective alarm
Alarm buzzer does not sound
buzzer
• When above 1) and 2) are normal, failure on the machine monitor
can be suspected.
32 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to alarm buzzer
WA450-6, WA480-6 (KA SPEC.) 33

Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) 1

Action code Failure code Lift arm raise EPC solenoid: Disconnection
Trouble
E03 DW4PKA (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid output signal system is disconnected, no current flows when
trouble the lift arm raise EPC solenoid output is ON.
Problem that
appears on • Lift arm does not rise
machine
• The output state (current value) to the lift arm raise EPC solenoid can be checked with the monitor-
Related
ing function (Code: 41900, RAISE EPC DIR).
information
• Method of reproducing failure code: Engine started + lift arm raise

Defective lift arm raise EPC without turning starting switch ON.
1 solenoid (Internal disconnec-
3 (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
value in normal harness Wiring harness between L73 (female) (6) – 3 Resis-
2 Max. 1 z
state (Disconnection in wiring (female) (1) tance
harness or defective contact) Wiring harness between L73 (female) (3) – 3 Resis-
Max. 1 z
(female) (2) tance
Defective work equipment without turning starting switch ON.
3
controller L73 (female) Resistance
Between (6) and (3) 5 – 15 z
Circuit diagram related to lift arm raise EPC solenoid
34 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 35

Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) 1
Action code Failure code Lift arm raise EPC solenoid: Short circuit
Trouble
E03 DW4PKB (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid signal system is shorted, abnormal current flows when the lift
trouble arm raise EPC solenoid output is turned ON.
• Stops outputting the signal to the lift arm raise EPC solenoid.
Action of • Stops outputting the signal to the lift arm raise detent.
Problem that
appears on • Lift arm does not rise
machine
Related
information
• Method of reproducing failure code: Engine started + lift arm raise

Defective lift arm raise EPC 3 (male) Resistance
1
solenoid (Internal short circuit) Between (1) and (2) 5 – 15 z
Min. 1 Mz
chassis ground
Possible causes
state (Contact with ground circuit) Wiring harness between L73 (female) (6) – 3 Resis-
Min. 1 Mz
(female) (1) and chassis ground tance
Defective work equipment L73 (female) Resistance
3
controller Between (6) and (3) 5 – 15 z
Min. 1 Mz
chassis ground
36 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 37

Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with
Action code Failure code Lift arm raise EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4PKY (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid signal system is shorted with the power source, abnormal volt-
trouble age is applied when the lift arm raise EPC solenoid output is OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipment do not work.
appears on
• The lift arm raise EPC solenoid may be burnt out.
machine
• The output state (current value) to the lift arm lower EPC solenoid can be checked with the monitor-
ing function (Code: 41901, LOWER EPC DIR).
• The output state (current value) to the bucket tilt EPC solenoid can be checked with the monitoring
function (Code: 41902, TILT EPC DIR).
Related
• The output state (current value) to the bucket dump EPC solenoid can be checked with the monitor-
information
ing function (Code: 41903, DUMP EPC DIR).
• The output state (current value) to the 3-spool valve (attachment) extend EPC solenoid can be
checked with the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current value) to the 3-spool valve (attachment) retract EPC solenoid can be

Defective lift arm raise EPC 3 (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
state (Contact with 24V circuit) Wiring harness between L73 (female) (6) – 3
Voltage Max. 1 V
(female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
38 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 39

Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) 1

Action code Failure code Lift arm lower EPC solenoid: Disconnection
Trouble
E03 DW4QKA (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid output signal system is disconnected, no current flows when
trouble the lift arm lower EPC solenoid output is ON.
Action of
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF
controller
once.
Problem that
appears on • Lift arm does not lower.
machine
Related
information
• Method of reproducing failure code: Start engine and lower the lift arm.

Defective lift arm lower EPC without turning starting switch ON.
4 (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
2 Max. 1 z
state (Disconnection in wiring 4 (female) (1) tance
harness or defective contact) Wiring harness between L73 (female) (3) – 4 Resis-
Max. 1 z
(female) (2) tance
3
Between (16) and (3) 5 – 15 z
Circuit diagram related to lift arm lower EPC solenoid
40 WA450-6, WA480-6 (KA SPEC.)

Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) 1
Action code Failure code Lift arm lower EPC solenoid: Short circuit
Trouble
E03 DW4QKB (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid signal system is shorted, abnormal current flows when the lift
trouble arm lower EPC solenoid output is ON.
• Stops outputting the signal to the lift arm lower EPC solenoid.
Action of • Stops outputting the signal to the lift arm float magnet detent.
Problem that
appears on • Lift arm does not lower.
machine
Related
information
• Method of reproducing failure code: Start engine and lower the lift arm.

Defective lift arm lower EPC 4 (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
4 (female) (1) and chassis ground tance
3
Min. 1 Mz
chassis ground
WA450-6, WA480-6 (KA SPEC.) 41

Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with
Action code Failure code Lift arm lower EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4QKY (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid signal system is shorted with the power source, abnormal volt-
trouble age is applied when the lift arm lower EPC solenoid output is OFF.
Problem that
appears on
• The lift arm lower EPC solenoid may be burnt out.
machine
Related
information

Defective lift arm lower EPC 4 (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
4 (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
42 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 43

Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) 1

Action code Failure code Bucket tilt EPC solenoid: Disconnection
Trouble
E03 DW4RKA (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid output signal output signal system is disconnected, no current
trouble flows when the bucket tilt EPC solenoid output is ON.
Problem that
appears on • Bucket does not tilt.
machine
Related
information
• Method of reproducing failure code: Start engine and tilt the bucket.

Defective bucket tilt EPC without turning starting switch ON.
1 (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
value in normal harness Wiring harness between L73 (female) (5) – 1 Resis-
2 Max. 1 z
state (Disconnection in wiring (female) (1) tance
Max. 1 z
1 (female) (2) tance
3
Between (5) and (13) 5 – 15 z
Circuit diagram related to bucket tilt EPC solenoid
44 WA450-6, WA480-6 (KA SPEC.)

Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) 1

Action code Failure code Bucket tilt EPC solenoid: Short circuit
Trouble
E03 DW4RKB (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid signal system is shorted, abnormal current flows when the bucket
trouble tilt EPC solenoid output is ON.
• Stops outputting the signal to the bucket tilt EPC solenoid.
Action of • Stops outputting the signal to the bucket tilt detent.
Problem that
appears on • Bucket does not tilt.
machine
Related
information
• Method of reproducing failure code: Start engine and tilt the bucket.

Defective bucket tilt EPC 1 (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
state (Contact with ground circuit) Wiring harness between L73 (female) (5) – 1 Resis-
Min. 1 Mz
3
Min. 1 Mz
chassis ground
WA450-6, WA480-6 (KA SPEC.) 45

Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with
Action code Failure code Bucket tilt EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4RKY (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid signal system is shorted with the power source, abnormal voltage
trouble is applied when the bucket tilt EPC solenoid output is OFF.
Problem that
appears on
• The bucket tilt EPC solenoid may be burnt out.
machine
Related
information

Defective bucket tilt EPC 1 (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
state (Contact with 24V circuit) Wiring harness between L73 (female) (5) – 1
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
46 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 47

SEN01685-00

48
SEN01686-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) ............................................... 3
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) ................................................... 4
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line) ............... 5
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection).......................................................... 7
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) ............................................................. 8
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) ......................... 9
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection) ..................................11
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit) .................................... 12
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line) 13
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)............................. 14
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) ................................ 16
Failure code [DWM1KY] (Work equipment neutral lock solenoid:
WA450-6, WA480-6 (KA SPEC.) 1

Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) .............................. 20
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit).................................. 22
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid:
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) ............................... 26
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)................................... 28
Failure code [DWN7KY] (Lift arm float magnet detent solenoid:
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) ................................... 32
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)....................................... 34
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) ......... 36
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection).................................................... 38
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) ....................................................... 39
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) ................... 40
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)..................................................... 42
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) ........................................................ 44
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) .................... 46
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) ................................................. 48
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)..................................................... 50
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)................. 52
2 WA450-6, WA480-6 (KA SPEC.)


Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) 1
Action code Failure code Bucket dump EPC solenoid: Disconnection
Trouble
E03 DW4SKA (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid output signal system is disconnected, no current flows when
trouble the bucket dump EPC solenoid output is ON.
Problem that
appears on • Bucket does not dump.
machine
Related
information
• Method of reproducing failure code: Start engine and dump the bucket.

Defective bucket dump EPC without turning starting switch ON.
2 (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
2 Max. 1 z
state (Disconnection in wiring 2 (female) (2) tance
Max. 1 z
2 (female) (1) tance
3
Between (15) and (13) 5 – 15 z
Circuit diagram related to bucket dump EPC solenoid
WA450-6, WA480-6 (KA SPEC.) 3

Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) 1

Action code Failure code Bucket dump EPC solenoid: Short circuit
Trouble
E03 DW4SKB (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid signal system is shorted, abnormal current flows when the
trouble bucket dump EPC solenoid output is ON.
• Stops outputting the signal to the bucket dump EPC solenoid.
Action of
controller
Problem that
• Bucket does not dump.
appears on
machine
Related
information
• Method of reproducing failure code: Start engine and dump the bucket.

Defective bucket dump EPC 2 (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
2 (female) (1) and chassis ground tance
3
Min. 1 Mz
chassis ground
4 WA450-6, WA480-6 (KA SPEC.)

Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with
Action code Failure code Bucket dump EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4SKY (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid signal system is shorted with the power source, abnormal volt-
trouble age is applied when the bucket dump EPC solenoid output is OFF.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/dump, 3-spool valve (attachment)
Problem that
appears on
• The bucket dump EPC solenoid may be burnt out.
machine
Related
information

Defective bucket dump EPC 2 (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
2 (female) (1) and chassis ground
Defective work equipment F23 (female) Resistance
3
Min. 1 Mz
chassis ground
WA450-6, WA480-6 (KA SPEC.) 5

6 WA450-6, WA480-6 (KA SPEC.)

Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) 1

Action code Failure code Fan reverse solenoid: Disconnection
Trouble
E01 DW7BKA (Transmission controller system)
Contents of • Since the fan reverse solenoid system is disconnected, no current flows when the fan reverse sole-
trouble noid output is ON.
Action of • Disables the automatic fan reverse function (OPT).
Problem that
• The automatic fan reverse function is disabled in the case of automatic fan reverse function (OPT)
appears on
specification.
machine
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function
Related
(Code: 40949, D-OUT-4).
information

Defective fan reverse solenoid without turning starting switch ON.
1
(Internal disconnection) G11 (male) Resistance
Between (1) and (2) 35 – 45 z
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L63 (female) (28) – Resis-
value in normal 2 Max. 1 z
(Disconnection or defective G11 (female) (1) tance
state contact in connector) Wiring harness between G11 (female) (2) – Resis-
Max. 1 z
3 G11 (female) Resistance
controller
Between (28) and
35 – 45 z
chassis ground
Circuit diagram related to fan reverse solenoid
WA450-6, WA480-6 (KA SPEC.) 7

Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) 1

Action code Failure code Fan reverse solenoid: Short circuit
Trouble
E01 DW7BKB (Transmission controller system)
Contents of • Since the fan reverse solenoid system is shorted, abnormal current flows when the fan reverse sole-
trouble noid output is turned on.
• Turns the output to the fan reverse solenoid OFF.
Action of
• Disables the automatic fan reverse function (OPT).
controller
Problem that • The fan cannot turn in reverse by operating the fan reverse switch.
appears on • The automatic fan reverse function is disabled in the case of automatic fan reverse function (OPT)
machine specification.
Related
(Code: 40949, D-OUT-4).
information

Defective fan reverse solenoid G11 (male) Resistance
1
Min. 1 Mz
state 2 harness
Min. 1 Mz
G11 (female) (1) and chassis ground tance
controller
Between (28) and
35 – 45 z
chassis ground
8 WA450-6, WA480-6 (KA SPEC.)

Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power
supply line) 1
Action code Failure code Fan reverse solenoid: Short circuit with power supply line
Trouble
E01 DW7BKY (Transmission controller system)
Contents of • Since the fan reverse solenoid system is shorted with the power source, abnormal voltage is applied
trouble when the fan reverse switch output is OFF.
Action of • Disables the automatic fan reverse function (OPT).
• The automatic fan reverse function is disabled in the case of automatic fan reverse function (OPT)
Problem that
specification.
appears on
• Forward rotation of the fan becomes unavailable.
machine
• Overheating can result.
Related
(Code: 40949, D-OUT-4).
information

Defective fan reverse solenoid G11 (male) Resistance
1
Min. 1 Mz
state 2
Voltage Max. 1 V
G11 (female) (1) and chassis ground
controller
Between (28) and
35 – 45 z
chassis ground
WA450-6, WA480-6 (KA SPEC.) 9

10 WA450-6, WA480-6 (KA SPEC.)

Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid:

Disconnection) 1
Action code Failure code Hydraulic drive fan neutral solenoid: Disconnection
Trouble
E01 DW7DKA (Transmission controller system)
Contents of
• An error was detected on the hydraulic drive fan neutral solenoid.
trouble
Action of
controller
Problem that
appears on —
machine
Related
• Setting of the hydraulic drive fan neutral solenoid is not available on WA380-6.
information

and standard Defective optional setting is suspected.
value in normal 1 Referring to “10. Optional device selecting function” in “Special functions of machine monitor
state (EMMS)” in “Testing and adjusting”, check that AUTO RE FAN is set to “None”.
WA450-6, WA480-6 (KA SPEC.) 11

Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short

circuit) 1
Action code Failure code Hydraulic drive fan neutral solenoid: Short circuit
Trouble
E01 DW7DKB (Transmission controller system)
Contents of
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

12 WA450-6, WA480-6 (KA SPEC.)

Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short

Action code Failure code Hydraulic drive fan neutral solenoid: Short circuit with power supply
Trouble
E01 DW7DKY line (Transmission controller system)
Contents of
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

WA450-6, WA480-6 (KA SPEC.) 13

Failure code [DWM1KA] (Work equipment neutral lock solenoid:

Disconnection) 1
Action code Failure code Work equipment neutral lock solenoid: Disconnection
Trouble
E01 DWM1KA (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system is disconnected, no current flows when the
trouble work equipment neutral lock solenoid output is ON.
• Stops outputting the signal to the work equipment solenoid according to an input signal from the work
Action of
equipment lock lever.
controller
Problem that
• Each work equipment solenoid lock normally works according to an input signal from the work equip-
appears on
ment lock lever.
machine
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the
Related monitoring function (Code: 40952, D-OUT-0).
information • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
lever to the LOCK position

1 neutral lock solenoid
Between (1) and (2) 35 – 45 z
2 Max. 1 z
state (Disconnection in wiring F26 (female) (1) tance
harness or defective contact) Wiring harness between F26 (female) (2) – Resis-
Max. 1 z
3
14 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to work equipment neutral lock solenoid
WA450-6, WA480-6 (KA SPEC.) 15

Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short

circuit) 1
Action code Failure code Work equipment neutral lock solenoid: Short circuit
Trouble
E01 DWM1KB (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system is shorted, abnormal current flows when the
trouble work equipment neutral lock solenoid output is turned on.
• Turns off the output to the work equipment neutral lock solenoid.
Action of • Stops outputting the signal to the work equipment solenoid according to an input signal from the work
controller equipment lock lever.
Problem that • Each work equipment solenoid lock normally works according to an input signal from the work equip-
appears on ment lock lever.
machine • The wiring harness or controller may be burnt out.
Related monitoring function (Code: 40952, D-OUT-0).
information • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
lever to the LOCK position

Defective work equipment F26 (male) Resistance
Min. 1 Mz
chassis ground
Possible causes F27 (male) Diode range Continuity
Defective diode (F27)
and standard 2 Measured from (2)
(Internal short circuit) Between (2) and (1) Continue
value in normal side
state
Measured from (1)
Between (1) and (2) Continuity absent
side
3 harness
Min. 1 Mz
4
16 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 17

Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short

Action code Failure code Work equipment neutral lock solenoid: Short circuit with power sup-
Trouble
E01 DWM1KY ply line (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system is shorted with power source, abnormal volt-
trouble age is applied when the work equipment neutral lock solenoid output is OFF.
• Turns off the output to the work equipment neutral lock solenoid.
Action of • Stops outputting the signal to the work equipment solenoid according to an input signal from the work
controller equipment lock lever.
Problem that
appears on • All work equipment do not move.
machine
• Removing (disconnecting) the connector of the work equipment neutral lock solenoid enables oper-
ating the work equipment.
Related
information

Defective work equipment F26 (male) Resistance
Min. 1 Mz
chassis ground
Possible causes F27 (male) Diode range Continuity
Defective diode (F27)
and standard 2 Measured from (2)
(Internal short circuit) Between (2) and (1) Continue
value in normal side
state
Measured from (1)
Between (1) and (2) No continuity
side
3
Voltage Max. 1 V
4
18 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 19

Failure code [DWN6KA] (Lift arm raise magnet detent solenoid:

Disconnection) 1
Action code Failure code Lift arm raise magnet detent solenoid: Disconnection
Trouble
E01 DWN6KA (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system is disconnected, no current
trouble flows when the lift arm raise magnet detent solenoid output is ON.
• Keeps normal output condition to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp.
controller
Problem that
• The lift arm remote positioner raise does not function.
appears on
• Holding the lift arm at the raise detent position becomes unavailable.
machine
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952, D-OUT-1).
information
• Method of reproducing failure code: Engine started + lift arm raise detent

Defective lift arm raise magnet without turning starting switch ON.
1 detent solenoid
L26E (male) Resistance
Between (1) and (2) 35 – 45 z
Possible causes
and standard 2 Max. 1 z
(Disconnection or defective L26E (female) (1) tance
value in normal
contact) Wiring harness between L26E (female) (2) – Resis-
state Max. 1 z
Defective work equipment L73 Lift arm lever Voltage
3
controller Neutral Max. 1 V
Between (17) and
chassis ground Raise detent
20 – 30 V
operation
20 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to lift arm EPC lever
WA450-6, WA480-6 (KA SPEC.) 21

Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short
circuit) 1
Action code Failure code Lift arm raise magnet detent solenoid: Short circuit
Trouble
E01 DWN6KB (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system is shorted, abnormal current
trouble flows when the lift arm raise magnet detent solenoid output is ON.
• Stops outputting the signal to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp to stop raise stop control.
controller
Problem that
• The lift arm remote positioner raise does not function.
appears on
• Holding the lift arm at the raise detent position becomes unavailable.
machine
Related
information
• Method of reproducing failure code: Engine started + lift arm raise detent

Defective lift arm raise magnet L26E (male) Resistance
1 detent solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
L26E (female) (1) and chassis ground tance
3
Between (17) and
20 – 30 V
operation
22 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 23

Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short
Action code Failure code Lift arm raise magnet detent solenoid: Short circuit with power sup-
Trouble
E01 DWN6KY ply line (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system is shorted with the power
trouble source, abnormal voltage is applied when the lift arm raise magnet detent solenoid output is ON.
• Stops outputting the signal to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp to stop raise stop control.
controller
• If you perform lift arm raise detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform lift arm detent operation, return of the left arm lever to neutral is affected by the
machine
suction power of the magnet (lever control is deteriorated).
Related
information

Defective lift arm raise magnet L26E (male) Resistance
1 detent solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
L26E (female) (1) and chassis ground
3
Between (17) and
20 – 30 V
operation
24 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 25

Failure code [DWN7KA] (Lift arm float magnet detent solenoid:

Disconnection) 1
Action code Failure code Lift arm float magnet detent solenoid: Disconnection
Trouble
Contents of • Since the lift arm float magnet detent solenoid power supply system is disconnected, no current
trouble flows when the lift arm float magnet detent solenoid output is ON.
• Keeps normal output condition to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
Problem that
• The lift arm remote positioner lower does not function.
appears on
• Holding the lift arm at the float detent position becomes unavailable.
machine
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the mon-
Related
information
• Method of reproducing failure code: Start engine and perform lift arm float detent operation.

Defective lift arm float magnet without turning starting switch ON.
1 detent solenoid
Between (1) and (2) 35 – 45 z
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L73 (female) (27) – Resis-
2 Max. 1 z
state contact) Wiring harness between L27 (female) (2) – Resis-
Max. 1 z
3
controller
Between (27) and Neutral Max. 1 V
chassis ground Float detent operation 20 – 30 V
26 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 27

Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short
circuit) 1
Action code Failure code Lift arm float magnet detent solenoid: Short circuit
Trouble
Contents of • Since the lift arm float magnet detent solenoid power supply system is shorted, abnormal current
trouble flows when the lift arm float magnet detent solenoid output is turned on.
• Stops outputting the signal to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
Problem that
• The lift arm remote positioner lower does not function.
appears on
• Holding the lift arm at the float detent position becomes unavailable.
machine
Related
information
• Method of reproducing failure code: Start engine and perform lift arm float detent operation.

Defective lift arm float magnet L27 (male) Resistance
1 detent solenoid
Min. 1 Mz
state 2 harness
Min. 1 Mz
3
controller
28 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 29

Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short
Action code Failure code Lift arm float magnet detent solenoid: Short circuit with power sup-
Trouble
E01 DWN7KY ply line (Work equipment controller system)
Contents of • Since the lift arm float magnet detent solenoid power supply system is shorted with the power
trouble source, abnormal voltage is applied when the lift arm float magnet detent solenoid output is OFF.
• Stops outputting the signal to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp to stop lower stop control.
controller
• If you perform lift arm float detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform lift arm detent operation, return of the left arm lever to neutral is affected by the
machine
Related
information

Defective lift arm float magnet L27 (male) Resistance
1 detent solenoid
Min. 1 Mz
state 2
Voltage Max. 1 V
3
controller
30 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 31

Failure code [DWN8KA] (Bucket tilt magnet detent solenoid:

Disconnection) 1
Action code Failure code Bucket tilt magnet detent solenoid: Disconnection
Trouble
Contents of • Since the bucket tilt magnet detent solenoid power supply system is disconnected, no current flows
trouble when the bucket tilt magnet detent solenoid output is ON.
Action of • Keeps normal output condition to the bucket tilt magnet detent solenoid.
Problem that
• Bucket leveler does not work.
appears on
• Holding the bucket at the tilt detent position becomes unavailable.
machine
• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the moni-
Related
toring function (Code: 40952, D-OUT-3).
information
• Method of reproducing failure code: Engine started + bucket tilt detent

Defective bucket tilt magnet without turning starting switch ON.
1 detent solenoid
L25E (male) Resistance
Between (1) and (2) 35 – 45 z
Possible causes
and standard 2 Max. 1 z
(Disconnection or defective L25E (female) (1) tance
value in normal
contact) Wiring harness between L25E (female) (2) – Resis-
state Max. 1 z
Defective work equipment L73 Bucket lever Voltage
3
Between (37) and
chassis ground Bucket detent
20 – 30 V
operation
32 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to bucket EPC lever
WA450-6, WA480-6 (KA SPEC.) 33

Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short

circuit) 1
Action code Failure code Bucket tilt magnet detent solenoid: Short circuit
Trouble
Contents of • Since the bucket tilt magnet detent solenoid power supply system is shorted, abnormal current flows
trouble when the bucket tilt magnet detent solenoid output is ON.
Action of • Stops outputting the signal to the bucket tilt magnet detent solenoid.
Problem that
• Bucket leveler does not work.
appears on
• Holding the bucket at the tilt detent position becomes unavailable.
machine
Related
information
• Method of reproducing failure code: Engine started + bucket tilt detent

Defective bucket tilt magnet L25E (male) Resistance
1 detent solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
L25E (female) (1) and chassis ground tance
3
Between (37) and
20 – 30 V
operation
34 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 35

Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted

with the power source) 1
Action code Failure code Bucket tilt magnet detent solenoid: Shorted with the power source
Trouble
E01 DWN8KY (Work equipment controller system)
Contents of • Since the bucket tilt magnet detent solenoid power supply system is shorted with the power source,
trouble abnormal voltage is applied when the bucket tilt magnet detent solenoid output is ON.
Action of • Stops outputting the signal to the bucket tilt magnet detent solenoid.
• If you perform bucket tilt detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform bucket detent operation, return of the bucket lever to neutral is affected by the
machine
Related
information

Defective bucket tilt magnet L25E (male) Resistance
1 detent solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
L25E (female) (1) and chassis ground
3
Between (37) and
20 – 30 V
operation
36 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 37

Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) 1

Action code Failure code Fan pump EPC solenoid: Disconnection
Trouble
E01 DX16KA (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system is disconnected, no current flows when the fan pump EPC
trouble solenoid output is ON.
Action of
controller
Problem that
appears on • The fan speed is set to the maximum.
machine
• The output state (current) to the fan pump EPC solenoid can be checked with the monitoring function
Related
(Code: 41400, FAN EPC DIR).
information

Defective fan pump EPC without turning starting switch ON.
1 solenoid
Between (1) and (2) 5 – 10 z
2 Max. 1 z
state (Disconnection or defective R29 (female) (2) tance
Max. 1 z
R29 (female) (1) tance
3
Between (36) and (23) 5 – 10 z
Circuit diagram related to fan pump EPC solenoid
38 WA450-6, WA480-6 (KA SPEC.)

Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) 1

Action code Failure code Fan pump EPC solenoid: Short circuit
Trouble
E01 DX16KB (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system is shorted, abnormal current flows when the fan pump
trouble EPC solenoid output is ON.
Action of • Turns the output to the fan pump EPC solenoid OFF.
Problem that
appears on • The fan speed is set to the maximum.
machine
Related
(Code: 41400 FAN EPC DIR).
information

Defective fan pump EPC R29 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
WA450-6, WA480-6 (KA SPEC.) 39

Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with
Action code Failure code Fan pump EPC solenoid: Short circuit with power supply line
Trouble
E01 DX16KY (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system is shorted with the power source, abnormal voltage is
trouble applied when the fan pump EPC solenoid output is OFF.
Action of • Turns the output to the fan pump EPC solenoid OFF.
Problem that
appears on • The fan speed is minimized.
machine
Related
(Code: 41400, FAN EPC DIR).
information

Defective fan pump EPC R29 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
R29 (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
40 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 41

Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) 1

Action code Failure code Lockup ECMV solenoid: Disconnection
Trouble
E01 DXH1KA (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system is disconnected, no current flows when the lockup solenoid
trouble output is ON.
• Stops outputting the signal to the lockup ECMV solenoid.
Action of
• Determines that the lockup fill switch is OFF.
controller
Problem that
appears on • Torque converter lockup is not turned on
machine
• The output state (current) to the lockup ECMV solenoid can be checked with the monitoring function
Related (Code: 31609 ECMV LU DIR).
information • Method of reproducing failure code: Start engine, turn the torque convertor lockup switch ON, and
drive the machine.

Defective lockup ECMV sole- without turning starting switch ON.
1
noid (Internal disconnection) LC.PS (male) Resistance
Between (1) and (2) 5 – 15 z
2 Max. 1 z
state (Disconnection or defective LC.PS (female) (2) tance
contact of connector) Wiring harness between L04 (female) (35) – Resis-
Max. 1 z
LC.PS (female) (1) tance
3
Between (23) and (35) 5 – 15 z
Circuit diagram related to lockup ECMV solenoid
42 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 43

Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) 1

Action code Failure code Lockup ECMV solenoid: Short circuit
Trouble
E01 DXH1KB (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system is short with the chassis ground, abnormal current flowed
trouble when the lockup solenoid output was ON.
• Stops outputting the signal to the lockup ECMV solenoid.
Action of
• Determines that the lockup fill switch is OFF.
controller
Problem that
appears on • Torque converter lockup is not turned on.
machine
Related
(Code: 31609 ECMV LU DIR).
information
• Method of reproducing failure code: Engine started + torque convertor lockup switch ON + Travel

Defective lockup ECMV sole- LC.PS (male) Resistance
1
noid (Internal short circuit) Between (1) and (2) 5 – 15 z
Min. 1 Mz
chassis ground
Possible causes
Max. 1 z
LC.PS (female) (1) and chassis ground tance
3
Min. 1 Mz
chassis ground
44 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 45

Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with

Action code Failure code Lockup ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH1KY (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the lockup ECMV solenoid output was OFF.
• Keeps the transmission in neutral.
• Releases the transmission from neutral if you move the FNR (directional) lever, joystick steering
Action of FNR (directional) switch, or right FNR (directional) switch to N (neutral).
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that • Neutral is held until the FNR (directional) lever, joystick steering FNR (directional) switch, or right
appears on FNR (directional) switch is set to N (neutral).
machine • The lockup clutch is always in the meshed state.
Related
(Code: 31609 ECMV LU DIR).
information

Defective lockup ECMV sole- LC.PS (male) Resistance
1
noid (Internal short circuit) Between (1) and (2) 5 – 15 z
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L04 (female) (35) –
Voltage Max. 1 V
LC.PS (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
46 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 47

Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) 1

Action code Failure code 1st clutch ECMV solenoid: Disconnection
Trouble
Contents of • When the 1st clutch ECMV solenoid system is disconnected, no current flows when 1st clutch ECMV
• Stops outputting the signal to the 1st clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 1st (The machine can travel in any gear speed other than 1st),
machine
• The output state (current value) to the 1st (1st speed) clutch ECMV solenoid can be checked with the
monitoring function (Code: 31602, ECMV 1 DIR).
Related
• Method of reproducing failure code: Turn on the starting switch, set the transmission auto-shift/man-
information
ual shift selector switch in the MANUAL position and select 1st using the shift down switch or move
the gear shift lever to 1st.

Defective 1st clutch ECMV without turning starting switch ON.
1.PS (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
2 Max. 1 z
state (Disconnection or defective 1.PS (female) (2) tance
Max. 1 z
1.PS (female) (1) tance
3
Between (25) and (13) 5 – 15 z
48 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to 1st clutch ECMV solenoid
WA450-6, WA480-6 (KA SPEC.) 49

Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) 1

Action code Failure code 1st clutch ECMV solenoid: Short circuit
Trouble
Contents of • Since the 1st ECMV solenoid system is shorted, abnormal current flows when 1st clutch ECMV sole-
trouble noid output is ON.
• Stops outputting the signal to the 1st clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 1st (The machine can travel in any gear speed other than 1st),
machine
Related
information
ual shift selector switch in the MANUAL position and select 1st using the shift down switch or move
the gearshift lever to 1st.

Defective 1st clutch ECMV 1.PS (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
1.PS (female) (1) and chassis ground tance
3
Min. 1 Mz
chassis ground
50 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 51

Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with
Action code Failure code 1st clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • Since the 1st ECMV solenoid system is shorted with the power source, abnormal voltage is applied
trouble when 1st clutch ECMV solenoid output is OFF.
• Stops outputting the signal to the 2nd, 3rd, and 4th clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the
Action of speed clutch output is OFF (other than 1st speed).
Problem that
appears on • The transmission does not shift into 2nd, 3rd, nor 4th (the machine can travel at 1st).
machine
Related
information

Defective 1st clutch ECMV 1.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
1.PS (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
52 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 53

SEN01686-00

54
SEN01687-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
Troubleshooting by failure code (Display of code), Part 10 ............................................................................ 4
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) .................................................. 4
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) ..................................................... 6
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line) ................. 8
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)................................................. 10
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) .................................................... 12
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) ................ 14
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) ................................................... 16
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) ....................................................... 18
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)................... 20
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection).................................................... 22
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) ....................................................... 24
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) ................... 26
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) ................................................ 28
WA450-6, WA480-6 (KA SPEC.) 1

Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) .................................................... 30
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)................ 32
Failure code [DXHJKA] (3-spool valve extend EPC solenoid: Disconnection)................................... 34
Failure code [DXHJKB] (3-spool valve extend EPC solenoid: Short circuit) ...................................... 36
Failure code [DXHJKY] (3-spool valve extend EPC solenoid: Short circuit with power supply line) .. 38
Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection)................................... 40
Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit) ...................................... 42
Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line) .. 44
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)................................. 46
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit) .................................... 48
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line) 50
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) .................................. 52
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)...................................... 54
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line) . 56
2 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 3


Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) 1
Action code Failure code 2nd clutch ECMV solenoid: Disconnection
Trouble
Contents of • When the 2nd clutch ECMV solenoid system is disconnected, no current flows when 2nd clutch
trouble ECMV solenoid output is ON.
• Stops outputting the signal to the 2nd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 2nd (The machine can travel in any gear speed other than 2nd.)
machine
• The output state (current value) to the 2nd (2nd speed) clutch ECMV solenoid can be checked with
the monitoring function (Code: 31603, ECMV 2 DIR).
Related
information
ual shift selector switch in the MANUAL position, and select 2nd using the shift down switch or mov-
ing the gear shift lever to 2nd.

Defective 2nd clutch ECMV without turning starting switch ON.
tion)
Between (1) and (2) 5 – 15 z
2 Max. 1 z
Max. 1 z
3
Between (6) and (3) 5 – 15 z
4 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to 2nd clutch ECMV solenoid
WA450-6, WA480-6 (KA SPEC.) 5

Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) 1

Action code Failure code 2nd clutch ECMV solenoid: Short circuit
Trouble
Contents of • Since the 2nd clutch ECMV solenoid system is shorted, abnormal current flows when 2nd clutch
• Stops outputting the signal to the 2nd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 2nd (The machine can travel in any gear speed other than 2nd.)
machine
• The output state (current value) to the 2nd (2nd speed) clutch ECMV solenoid can be checked with
the monitoring function (Code: 31603, ECMV 2 DIR).
Related
information
ual shift selector switch in the MANUAL position, and select 2nd using the shift down switch or mov-
ing the gear shift lever to 2nd.

Defective 2nd clutch ECMV 2.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
6 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 7

Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with
Action code Failure code 2nd clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • When the 2nd clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 2nd clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 3rd, and 4th clutch ECMV solenoids.
Action of speed clutch output is OFF (other than 2nd speed).
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 1st, 3rd, nor 4th (the machine can travel at 2nd).
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring func-
Related
tion (Code: 31603 ECMV 2 DIR).
information

Defective 2nd clutch ECMV 2.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L04 (female) (6) –
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
8 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 9

Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) 1

Action code Failure code 3rd clutch ECMV solenoid: Disconnection
Trouble
Contents of • Since the 3rd clutch ECMV solenoid system is disconnected, no current flows when 3rd clutch ECMV
• Stops outputting the signal to the 3rd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 3rd (The machine can travel in any gear speed other than 3rd.)
machine
Related
information
ual shift selector switch to the MANUAL position, and select 3rd using the shift down switch or mov-
ing the gear shift lever to 3rd.

Defective 3rd clutch ECMV without turning starting switch ON.
tion)
Between (1) and (2) 5 – 15 z
2 Max. 1 z
Max. 1 z
3
Between (16) and (3) 5 – 15 z
10 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to 3rd clutch ECMV solenoid
WA450-6, WA480-6 (KA SPEC.) 11

Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) 1

Action code Failure code 3rd clutch ECMV solenoid: Short circuit
Trouble
Contents of • Since the 3rd clutch ECMV solenoid system is shorted, abnormal current flows when 3rd clutch
• Stops outputting the signal to the 3rd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 3rd (The machine can travel in any gear speed other than 3rd.)
machine
Related
information
ual shift selector switch to the MANUAL position, and select 3rd using the shift down switch or mov-
ing the gear shift lever to 3rd.

Defective 3rd clutch ECMV 3.PS (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
12 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 13

Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with
Action code Failure code 3rd clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • Since the 3rd ECMV solenoid system is shorted with the power source, abnormal voltage is applied
trouble when 3rd clutch ECMV solenoid output is OFF.
• Stops outputting the signal to the 1st, 2nd, and 4th clutch ECMV solenoids.
Action of speed clutch output is OFF (other than 3rd speed).
Problem that
appears on • The transmission does not shift into 1st, 2nd or 4th (the machine can travel at 3rd).
machine
Related
information

Defective 3rd clutch ECMV 3.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
14 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 15

Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) 1

Action code Failure code R clutch ECMV solenoid: Disconnection
Trouble
Contents of • When the R (Reverse) clutch ECMV solenoid system is disconnected, no current flows when R
trouble (Reverse) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the R (Reverse) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the R (Reverse) position (the machine can travel at F (Forward)).
machine
• The output state (current value) to the R (reverse) clutch ECMV solenoid can be checked with the
Related monitoring function (Code: 31606, ECMV R DIR).
information • Method of reproducing failure code: Turn the starting switch ON and set FNR (directional) lever, joy-
stick steering FNR (directional) switch or right FNR (directional) switch to R (reverse).

Defective R (Reverse) clutch without turning starting switch ON.
1 ECMV solenoid
R.PS (male) Resistance
Between (1) and (2) 5 – 15 z
2 Max. 1 z
state (Disconnection or defective R.PS (female) (2) tance
Max. 1 z
R.PS (female) (1) tance
3
Between (15) and (13) 5 – 15 z
16 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to R (Reverse) clutch ECMV solenoid
WA450-6, WA480-6 (KA SPEC.) 17

Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) 1

Action code Failure code R clutch ECMV solenoid: Short circuit
Trouble
Contents of • Since the R (Reverse) clutch ECMV solenoid system is shorted, abnormal current flows when R
trouble (Reverse) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the R (Reverse) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the R (Reverse) position (the machine can travel at F (Forward)).
machine
Related monitoring function (Code: 31606, ECMV R DIR).
stick steering FNR (directional) switch or right FNR (directional) switch to R (reverse).

Defective R (Reverse) clutch R.PS (male) Resistance
1 ECMV solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
R.PS (female) (1) and chassis ground tance
3
Min. 1 Mz
chassis ground
18 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 19

Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with

Action code Failure code R clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • Since the R (Reverse) ECMV solenoid system is shorted with the power source, abnormal voltage is
trouble applied when the R (Reverse) ECMV solenoid output is OFF.
• Outputs the signal to the R (Reverse) clutch ECMV solenoid when the directional lever or directional
switch is in R (Reverse).
Action of • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or F (Forward).
Problem that
appears on • The machine can travel in the R (Reverse) position alone.
machine
Related
monitoring function (Code: 31606, ECMV R DIR).
information

Defective R (Reverse) clutch R.PS (male) Resistance
1 ECMV solenoid (Internal
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
R.PS (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
20 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 21

Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) 1

Action code Failure code F clutch ECMV solenoid: Disconnection
Trouble
Contents of • Since the F (Forward) clutch ECMV solenoid system is disconnected, no current flows when F (For-
trouble ward) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the F (Forward) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the F (Forward) position (the machine can travel at R (Reverse)).
machine
• The output state (current value) to the F (Forward) clutch ECMV solenoid can be checked with the
Related monitoring function (Code: 31608, ECMV F DIR).
stick steering FNR (directional) switch, or right FNR (directional) switch to F (forward).

Defective F (Forward) clutch without turning starting switch ON.
1 ECMV solenoid (Internal dis-
F.PS (male) Resistance
connection)
Between (1) and (2) 5 – 15 z
2 Max. 1 z
state (Disconnection or defective F.PS (female) (2) tance
Max. 1 z
F.PS (female) (1) tance
3
Between (5) and (3) 5 – 15 z
22 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to F (Forward) clutch ECMV solenoid
WA450-6, WA480-6 (KA SPEC.) 23

Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) 1

Action code Failure code F clutch ECMV solenoid: Short circuit
Trouble
Contents of • When the F (Forward) clutch ECMV solenoid system is shorted, abnormal current flows when F (For-
trouble ward) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the F (Forward) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the F (Forward) position (the machine can travel at R (Reverse)).
machine
Related monitoring function (Code: 31608, ECMV F DIR).
stick steering FNR (directional) switch, or right FNR (directional) switch to F (forward).

Defective F (Forward) clutch F.PS (male) Resistance
1 ECMV solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
F.PS (female) (1) and chassis ground tance
3
Min. 1 Mz
chassis ground
24 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 25

Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with

Action code Failure code F clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • Since the F (Forward) ECMV solenoid system is shorted with the power source, abnormal voltage is
trouble applied when the F (Forward) ECMV solenoid output is OFF.
• Outputs the signal to the F (Forward) clutch ECMV solenoid when the directional lever or directional
switch is in F (Forward).
Action of • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or R (Reverse).
Problem that
appears on • The machine can travel in the F (Forward) position alone.
machine
Related
monitoring function (Code: 31608, ECMV F DIR).
information

Defective F (Forward) clutch F.PS (male) Resistance
1 ECMV solenoid (Internal
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
F.PS (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
26 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 27

Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) 1

Action code Failure code 4th clutch ECMV solenoid: Disconnection
Trouble
E03 DXHHKA (Transmission controller system)
Contents of • Since the 4th clutch ECMV solenoid system is disconnected, no current flows when 4th clutch ECMV
• Stops outputting the signal to the 4th clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 4th (The machine can travel in any gear speed other than 4th.)
machine
Related
• Method of reproducing failure code: Turn the starting switch ON, set the transmission auto-shift/man-
information
ual shift selector switch in the MANUAL position, and select 4th using the shift down switch or mov-
ing the gear shift lever to 4th.

Defective 4th clutch ECMV without turning starting switch ON.
1 solenoid
Between (1) and (2) 5 – 15 z
2 Max. 1 z
Max. 1 z
3
Between (26) and (13) 5 – 15 z
28 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to 4th clutch ECMV solenoid
WA450-6, WA480-6 (KA SPEC.) 29

Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) 1

Action code Failure code 4th clutch ECMV solenoid: Short circuit
Trouble
E03 DXHHKB (Transmission controller system)
Contents of • Since the 4th clutch ECMV solenoid system is shorted, abnormal current flows when 4th clutch
• Stops outputting the signal to the 4th clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 4th (The machine can travel in any gear speed other than 4th.)
machine
Related
• Method of reproducing failure code: Turn the starting switch ON, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 4th using the shift down switch or moving
the gear shift lever to 4th.

Defective 4th clutch ECMV 4.PS (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
30 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 31

Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with
Action code Failure code 4th clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXHHKY (Transmission controller system)
Contents of • Since the 4th ECMV solenoid system is shorted with the power source, abnormal voltage is applied
trouble when 4th clutch ECMV solenoid output is OFF.
• Stops outputting the signal to the 1st, 2nd, and 3rd clutch ECMV solenoids.
Action of speed clutch output is OFF (other than 4th speed).
Problem that
appears on • The transmission does not shift into 1st, 2nd or 3rd (the machine can travel at 4th).
machine
Related
information

Defective 4th clutch ECMV 4.PS (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
32 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 33

Failure code [DXHJKA] (3-spool valve extend EPC solenoid:

Disconnection) 1
Action code Failure code 3-spool valve extend EPC solenoid: Disconnection
Trouble
E03 DXHJKA (Work equipment controller system)
Contents of • Since the 3-spool valve (attachment) extend EPC solenoid output signal system is disconnected, no
trouble current flows when the 3-spool valve (attachment) extend EPC solenoid output is ON.
• Continues outputting.
Action of
controller
Problem that
appears on • The 3-spool valve (attachment) cylinder is not extended.
machine
code is displayed, select “None” in the EPC 3-spool lever setting on the optional setting of the
machine monitor.)
Related
information
• 3-spool valve (attachment)-equipped model specification only
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) extend
Defective 3-spool valve a Prepare with starting switch OFF, then carry out troubleshooting
(attachment) extend EPC without turning starting switch ON.
1
solenoid F24 (male) Resistance
(Internal disconnection) Between (1) and (2) 5 – 15 z
2 Max. 1 z
Max. 1 z
F24 (female) (1) tance
3
Between (25) and (3) 5 – 15 z
34 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to 3-spool valve (attachment) extend EPC solenoid
WA450-6, WA480-6 (KA SPEC.) 35

Failure code [DXHJKB] (3-spool valve extend EPC solenoid: Short

circuit) 1
Action code Failure code 3-spool valve extend EPC solenoid: Short circuit
Trouble
E03 DXHJKB (Work equipment controller system)
Contents of • Since the 3-spool valve (attachment) extend EPC solenoid output signal system is shorted, abnormal
trouble current flows when the 3-spool valve (attachment) extend EPC solenoid output is ON.
• Stops outputting the signal to the 3-spool valve (attachment) extend EPC solenoid.
Action of • Stops outputting the signal to all work equipment detent.
Problem that
• The 3-spool valve (attachment) cylinder is not extended.
appears on
machine
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. If this failure
machine monitor.
Related
information
checked with the monitoring function (Code: 41906 3RD EPC1 DIR).
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) extend
(attachment) extend EPC without turning starting switch ON.
1
Possible causes
Min. 1 Mz
3
Between (25) and (3) 5 – 15 z
36 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 37

Failure code [DXHJKY] (3-spool valve extend EPC solenoid: Short

Action code Failure code 3-spool valve extend EPC solenoid: Short circuit with power supply
Trouble
E03 DXHJKY line (Work equipment controller system)
• Since the 3-spool valve (attachment) extend EPC solenoid output signal system is shorted with the
Contents of
power source, abnormal voltage is applied when the 3-spool valve (attachment) extend EPC sole-
trouble
noid output is OFF.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment)
Action of extend/retract EPC solenoids.
Problem that
• The 3-spool valve (attachment) cylinder is not extended.
appears on
• The 3-spool valve (attachment) extend EPC solenoid may be burnt out.
machine
machine monitor.
Related
information
(attachment) extract EPC without turning starting switch ON.
1
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Between (25) and (3) 5 – 15 z
38 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 39

Failure code [DXHKKA] (3-spool valve retract EPC solenoid:

Disconnection) 1
Action code Failure code 3-spool valve retract EPC solenoid: Disconnection
Trouble
E03 DXHKKA (Work equipment controller system)
Contents of • Since the 3-spool valve (attachment) retract EPC solenoid output signal system is disconnected, no
trouble current flows when the 3-spool valve (attachment) retract EPC solenoid output is ON.
• Continues outputting.
Action of
controller
Problem that
appears on • The 3-spool valve (attachment) cylinder is not retracted.
machine
machine monitor.
Related
information
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) retract
(attachment) retract EPC without turning starting switch ON.
1
2 Max. 1 z
Max. 1 z
F24 (female) (1) tance
3
Between (25) and (3) 5 – 15 z
40 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to 3-spool valve (attachment) retract EPC solenoid
WA450-6, WA480-6 (KA SPEC.) 41

Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short

circuit) 1
Action code Failure code 3-spool valve retract EPC solenoid: Short circuit
Trouble
E03 DXHKKB (Work equipment controller system)
Contents of • Since the 3-spool valve (attachment) retract EPC solenoid output signal system is shorted, abnormal
trouble current flows when the 3-spool valve (attachment) retract EPC solenoid output is ON.
• The output to the 3-spool valve (attachment) retract EPC solenoid is stopped.
Action of • Stops outputting the signal to all work equipment detent.
Problem that
• The 3-spool valve (attachment) cylinder is not retracted.
appears on
machine
machine monitor.
Related
information
• Method of reproducing failure code: Engine started + 3-spool valve (attachment) retract
1
Possible causes
Min. 1 Mz
3
Between (25) and (3) 5 – 15 z
42 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 43

Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short

Action code Failure code 3-spool valve retract EPC solenoid: Short circuit with power supply
Trouble
E03 DXHKKY line (Work equipment controller system)
• Since the 3-spool valve (attachment) retract EPC solenoid output signal system is shorted with the
Contents of
power source, abnormal voltage is applied when the 3-spool valve (attachment) retract EPC solenoid
trouble
output is OFF.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment)
Action of extract/retract EPC solenoids.
Problem that
• The 3-spool valve (attachment) cylinder is not retracted.
appears on
• The 3-spool valve (attachment) retract EPC solenoid may be burnt out.
machine
machine monitor.
Related
information
1
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Between (25) and (3) 5 – 15 z
44 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 45

Failure code [DXHLKA] (Joystick steering right EPC solenoid:

Disconnection) 1
Action code Failure code Joystick steering right EPC solenoid: Disconnection
Trouble
E03 DXHLKA (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system is disconnected, no current flows when the joy-
trouble stick steering right EPC solenoid output is ON.
• Stops outputting the signal to the joystick steering right and left EPC solenoids.
Action of • Stops outputting the signal to the joystick steering solenoid cut-off relay.
Problem that
• Steering control with the joystick steering becomes unavailable (steering control from the handle
appears on
mode is available).
machine
• The output state (current value) to the joystick steering right EPC solenoid can be checked with the
monitoring function (Code: 41904, J/S EPC DIR RH).
• The output state (ON/OFF) to the joystick steering solenoid cut-off relay can be checked with the
Related
information
• When the failure code (D193KA, D193KB or D193KY) for the joystick steering solenoid cut-off relay
system is displayed at the same time, carry out troubleshooting for it first.
• Method of reproducing failure code: Start engine and steer to the right using the joystick steering.

1 right EPC solenoid
Between (1) and (2) 5 – 15 z
Defective joystick steering Between (5) and (6) 200 – 400 z
2 cut-off relay (L41) a Prepare with starting switch OFF, then turn starting switch ON
(Internal disconnection) and carry out troubleshooting.
When joystick steering cut-off relay (L41) is replaced with a relay of
Possible causes the same type, if the condition becomes normal, the joystick steer-
and standard ing cut-off relay is defective.
Max. 1 z
3
Max. 1 z
Defective work equipment Joystick steering
4 L73 Voltage
controller lever
(23) Full right steering 5 – 10 V
46 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to joystick steering right EPC solenoid
WA450-6, WA480-6 (KA SPEC.) 47

Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short

circuit) 1
Action code Failure code Joystick steering right EPC solenoid: Short circuit
Trouble
E03 DXHLKB (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system is shorted, abnormal current flows when the
trouble joystick steering right EPC solenoid output is ON.
Problem that
appears on
mode is available).
machine
Related
information
• Method of reproducing failure code: Start engine and steer to the right using the joystick steering.

Min. 1 Mz
chassis ground
Possible causes 2 cut-off relay (L41) a Prepare with starting switch OFF, then turn starting switch ON
and standard (Internal disconnection) and carry out troubleshooting.
value in normal
state
the same type, if the condition becomes normal, the joystick steer-
ing cut-off relay is defective.
3 harness
Min. 1 Mz
4
Min. 1 Mz
chassis ground
48 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 49

Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short

Action code Failure code Joystick steering right EPC solenoid: Short circuit with power supply
Trouble
E03 DXHLKY line (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system is shorted with the power source, abnormal
trouble voltage is applied when the joystick steering right EPC solenoid output is OFF.
Problem that
appears on
mode is available).
machine
Related
information

Min. 1 Mz
chassis ground
value in normal
state
3
Voltage Max. 1 V
4
Min. 1 Mz
chassis ground
50 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 51

Failure code [DXHMKA] (Joystick steering left EPC solenoid:

Disconnection) 1
Action code Failure code Joystick steering left EPC solenoid: Disconnection
Trouble
E03 DXHMKA (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system is disconnected, no current flows when the joy-
trouble stick steering left EPC solenoid output is ON.
Problem that
appears on
mode is available).
machine
• The output state (current) to the joystick steering left EPC solenoid can be checked with the monitor-
Related
ing function (Code: 41905, J/S EPC DIR LH).
information
• Method of reproducing failure code: Start the engine and steer to the left using the joystick steering.

1 left EPC solenoid
Between (1) and (2) 5 – 15 z
2 cut-off relay (L41) a Prepare with starting switch OFF, then turn starting switch ON
(Internal disconnection) and carry out troubleshooting.
Possible causes When joystick steering cut-off relay (L41) is replaced with a relay of
and standard the same type, if the condition becomes normal, the joystick steer-
value in normal ing cut-off relay is defective.
state
Max. 1 z
3
Max. 1 z
4
Between (38) and (23) 5 – 15 z
52 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to joystick steering left EPC solenoid
WA450-6, WA480-6 (KA SPEC.) 53

Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short

circuit) 1
Action code Failure code Joystick steering left EPC solenoid: Short circuit
Trouble
E03 DXHMKB (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system is shorted, abnormal current flows when the joy-
trouble stick steering left EPC solenoid output is ON.
Problem that
appears on
mode is available).
machine
Related
information
• Method of reproducing failure code: Start the engine and steer to the left using the joystick steering.

1 left EPC solenoid
Min. 1 Mz
chassis ground
value in normal
state
3 harness
Min. 1 Mz
4
Min. 1 Mz
chassis ground
54 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 55

Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short

Action code Failure code Joystick steering left EPC solenoid: Short circuit with power supply
Trouble
E03 DXHMKY line (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system is shorted with the power source, abnormal volt-
trouble age is applied when the joystick steering left EPC solenoid output is OFF.
Problem that
appears on
mode is available).
machine
Related
information

1 left EPC solenoid
Min. 1 Mz
chassis ground
value in normal
state
3
Voltage Max. 1 V
4
Min. 1 Mz
chassis ground
56 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 57

SEN01687-00

58
SEN01688-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
Troubleshooting of electrical system
(E-mode)
Troubleshooting of electrical system (E-mode)............................................................................................... 3
Before carrying out troubleshooting for electrical system .................................................................... 3
Information in troubleshooting table ..................................................................................................... 6
E-1 Engine does not start..................................................................................................................... 8
E-2 Wiper does not operate ............................................................................................................... 14
E-3 Windshield washer does not operate .......................................................................................... 18
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off........................ 21
E-5 Working lamp does not light up or go off ..................................................................................... 29
E-6 Turn signal lamp and hazard lamp do not light up or go off......................................................... 34
E-7 Brake lamp does not light or it keeps lighting up ......................................................................... 40
E-8 Backup lamp does not light or it keeps lighting up ...................................................................... 42
E-9 Backup buzzer does not sound or it keeps sounding .................................................................. 44
E-10 Horn does not sound or it keeps sounding ................................................................................ 46
E-11 Alarm buzzer does not sound or it keeps sounding ................................................................... 48
WA450-6, WA480-6 (KA SPEC.) 1

E-12 Air conditioner does not operate or stop.................................................................................... 50

E-13 The KOMTRAX system does not work properly ........................................................................ 53
2 WA450-6, WA480-6 (KA SPEC.)

Troubleshooting of electrical system (E-mode) 1

Before carrying out troubleshooting for electrical system 1
Connection table of fuse box and slow blow fuse
a This connection table indicates the devices to which the power of the fuse box and slow blow fuse is
supplied. (A switch power supply is a device which supplies power while the starting switch is in the ON
position and a constant power supply is a device which supplies power while the starting switch is in the
OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and
slow blow fuse to see if the power is supplied normally.
Fuse box A
Capacity of
Type of power supply Fuse No Destination of power
fuse
1 10 A Horn circuit
2 10 A Transmission controller (A) circuit
3 5A Parking brake circuit
4 5A Emergency steering circuit (if equipped)
Work equipment positioner circuit
5 10 A
Switch power supply Work equipment controller (A) circuit (if equipped)
Slow-blow fuse 6 20 A Rear lamp and brake lamp circuit
(50 A) 7 20 A Wiper and washer circuit
8 20 A Air conditioner (A) circuit
9 5A Air conditioner (B) circuit
10 10 A
Load meter printer (if equipped) circuit
11 20 A Main lamp circuit
Switch power supply 12 10 A Clearance lamp (right) circuit
Lamp switch 13 10 A Clearance lamp (left) circuit
Switch power supply 14 10 A Headlamp (right) circuit
Head lamp relay 15 10 A Headlamp (left) circuit
WA450-6, WA480-6 (KA SPEC.) 3

Fuse box B
Capacity of
Type of power supply Fuse No Destination of power
fuse
1 20 A Starting switch circuit
2 10 A Hazard lamp circuit
Constant power 3 10 A
KOMTRAX circuit (if equipped)
supply
4 10 A Room lamp circuit
Slow-blow fuse
(50 A) Transmission controller (B) circuit
5 5A
Work equipment controller (B) circuit (OPT)
6 30 A Engine controller (A) circuit
7 10 A Spare 1
8 10 A Front working lamp circuit
9 10 A Rear working lamp circuit
Switch power supply 10 20 A Car radio circuit and 12V converter circuit
Slow-blow fuse 11 10 A Turn signal lamp circuit
(50 A) 12 20 A Yellow rotary lamp circuit (if equipped)
13 10 A Air suspension seat
14 20 A Rear glass heater circuit
Switch power supply
15 5A Engine controller (B) circuit
Starting switch ACC
Slow blow fuse

Slow-blow Capacity of
Type of power supply Destination of power
fuse No. fuse
Spare 1, engine controller (A) circuit, transmission controller (B)
Constant power circuit, work equipment controller (B) circuit (if equipped), room
1 50 A
supply lamp circuit, machine monitor (B) circuit, KOMTRAX (B) circuit (if
equipped), hazard lamp circuit and starting switch circuit
Main lamp circuit, machine monitor (B) circuit, load meter printer
(if equipped) circuit, air conditioner (B) circuit, air conditioner (A)
circuit, wiper and washer circuit, rear lamp and brake lamp cir-
2 50 A cuit, work equipment positioner circuit, work equipment controller
(A) circuit (if equipped), emergency steering circuit (if equipped),
parking brake circuit, transmission controller (A) circuit and horn
circuit
Switch power supply
Rear glass heater circuit, air suspension seat, yellow rotary lamp
circuit (if equipped), turn signal lamp circuit, car radio circuit, 12V
3 50 A
converter circuit, rear working lamp circuit and front working lamp
circuit
4 120 A Heater relay circuit
5 120 A Charging circuit
4 WA450-6, WA480-6 (KA SPEC.)

Locations and numbers of fuse boxes and slow blow fuse
WA450-6, WA480-6 (KA SPEC.) 5

Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Trouble Problem that appears on machine
Related
Information related to detected trouble or troubleshooting
information
<Described contents>
• Standard value in normal state required to judge the
assumed cause (good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or wiring harness is
disconnected.
• Ground fault
A harness not connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
A harness not connected to the power (24 V) circuit comes
2
into contact with the power (24 V) circuit.
• Short circuit
Possible causes Causes by which a trouble is A harness of an independent circuit abnormally comes into
and standard assumed to be defected contact with one of another circuit.
value in normal (The order number indicates
state a serial number, not a priority <Notes on troubleshooting>
sequence.) (1) Method of indicating connector numbers and handling of T-
adapter
For troubleshooting, insert or connect T-adapter shown
3
below unless especially specified.
• When “male” or “female” is not indicated for a connector
number, disconnect the connector, and insert the T-
adapters in both the male and female.
• When “male” or “female” is indicated for a connector
number, disconnect connector, and insert the T-adapter
in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
leads as shown below unless especially specified.
4
• 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.
Related circuit diagram
This is the excerpted circuit diagram related to troubleshooting

• Connector No.: Indicates (Model – No. of pins) (Color).
• “Connector No. and pin No.” from each branching/merging point: indicate
the ends of branch or source of merging within the parts of the same wir-
ing harness
• Arrow (io): Roughly indicates mounting place on machine.
6 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 7

E-1 Engine does not start 1

Contents of
• The engine does not start.
trouble
• The engine does not start, because the starting motor does not run due to troubles in the starting
motor system and starting switch terminal C signal system.
• Check that No. 1 fuse of fuse box B is normal.
(If it is broken, check the related wiring harness for grounding fault.)
• The input state (ON/OFF) to the machine monitor from the starting switch terminal C can be checked
Related with the monitoring function (Code: 40900, D-IN-2).
information • The input state (ON/OFF) to the transmission controller from starting switch terminal C can be
• The input state (ON/OFF) to the work equipment controller from the starting switch terminal C can be
• If failure codes D5ZHKA, D5ZHKB, D5ZHKZ, D5ZH16, DDK3KA, DDK4KA, DDK6KA, DDK6KB, and
DB2RKR are indicated, curry out troubleshooting for it first.

Specific gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
Defective battery relay The battery relay can be judged normal if operating sounds are audible
2 (Internal disconnection or when the starting switch is operated.
short circuit) • Starting switch operation in the order of OFF o ON o OFF
Defective fuse No. 2 of If the fuse is burn, the circuit probably has a grounding fault, etc. (See
3
fuse box B cause 15.)
a Prepare with starting switch OFF (with wiring harness connected),
then turn starting switch START and carry out troubleshooting
Starting motor Voltage
Between terminals B and
Power supply input 20 – 30 V
E
Defective starting motor
4 Between terminal R E01
(Internal trouble) Battery input Max. 1 V
and terminal E
Between terminal C E01
Starting input 20 – 30 V
Possible and terminal E
causes and If the starting motor does not run even if power supply input, battery
standard value input and starting input is normal, the starting motor is defective.
in normal state
a Prepare with starting switch OFF, then turn starting switch ON and
Defective alternator carry out troubleshooting.
5
(Internal trouble) Wiring harness between alternator terminal R (1)
Voltage Max. 1 V
– chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting with
starting OFF and START each.
Defective starting switch S40 (male) Position of switch Resistance
6
OFF Min. 1 Mz
Between (1) and (3)
START Max. 1 z
carry out troubleshooting.
Defective FNR (direc- FNR (directional)
tional) lever switch L04 Voltage
7 lever
short circuit)
N (Neutral). 20 – 30 V
8 WA450-6, WA480-6 (KA SPEC.)


a Prepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.
Defective joystick steering Joystick steering FNR

FNR (directional) switch (directional) switch
8
(Internal disconnection or N (Neutral). Max. 1 z
Constant Min. 1 Mz
chassis ground
Right FNR (direc-
tional) switch
Defective right FNR (direc-
tional) switch N (Neutral). Max. 1 z
9 Between (1) and (3)
(Internal disconnection or Other than above Min. 1 Mz
short circuit)
Constant Min. 1 Mz
chassis ground
D04 (male) Diode range Continuity
Measure at (2) in
Defective diodes (D04, Between (2) and (1) Continue
diode range.
10 D05) (Internal disconnec-
tion) a Prepare with starting switch OFF, then carry out troubleshooting with-
D05 (male) Diode range Continuity
Measure at (2) in
Between (2) and (1) Continue
Possible diode range.
causes and a Prepare with starting switch OFF, then carry out troubleshooting with-
standard value out turning starting switch ON.
in normal state
Defective joystick safety Between (1) and (2) 200 – 400 z
11 relay (L113) a Prepare with starting switch OFF, then turn starting switch to START
(Internal trouble) and carry out troubleshooting.
When joystick safety relay (L113) is replaced with a relay of the same
type, if the condition becomes normal, the joystick safety relay is defec-
tive.
Defective neutral safety Between (1) and (2) 200 – 400 z
12 relay (L116) a Prepare with starting switch OFF, then turn starting switch to START
When neutral safety relay (L116) is replaced with a relay of the same
type, if the condition becomes normal, the neutral safety relay is defec-
tive.
L171 (male), L172 (male) Resistance
Defective engine control Between (1) and (2) 200 – 400 z
13 cut-out relays (L171, a Prepare with starting switch OFF, then turn starting switch to START
L172) (Internal defect) and carry out troubleshooting.
When engine control cut-out relay (L171, L172) is replaced with a relay
of the same type, if the condition becomes normal, the engine control
cut-out relay is defective.
WA450-6, WA480-6 (KA SPEC.) 9


W60 (male) Resistance
Defective KOMTRAX Between (1) and (2) 200 – 400 z
14 engine cut-out relay (W60) a Prepare with starting switch OFF, then turn starting switch to START
When KOMTRAX engine cut-out relay (W60) is replaced with a relay of
the same type, if the condition becomes normal, the KOMTRAX engine
cut-out relay is defective.
Wiring harness between battery relay R04 – Resis-
Max. 1 z
starting motor terminal B tance
Wiring harness between starting motor terminal Resis-
Max. 1 z
E – chassis ground tance
Wiring harness between S40 (female) (3) – W60 Resis-
Max. 1 z
(female) (3) tance
Wiring harness between W60 (female) (6) – Resis-
Max. 1 z
Max. 1 z
(female) (1) tance
Possible Wiring harness between W60 (female) (2) – L80 Resis-
Max. 1 z
causes and (female) (20) tance
standard value Wiring harness between L116 (female) (3) – Resis-
in normal state Max. 1 z
Wiring harness between L04 (female) (3) – L116 Resis-
Disconnection in wiring Max. 1 z
(female) (1) tance
harness
15 (Disconnection in wiring Max. 1 z
harness or defective con-
tact) Wiring harness between L113 (female) (3) – D05 Resis-
Max. 1 z
(female) (2) tance
Wiring harness between D05 (female) (1) – E01 Resis-
Max. 1 z
(female) (1) tance
Max. 1 z
Max. 1 z
Wiring harness between S40 (female) (2) – L171 Resis-
Max. 1 z
(male) (1), L172 (male) (1) tance
Wiring harness between L171 (male) (2), L172 Resis-
Max. 1 z
(male) (2) – EC2 (female) (33) tance
Wiring harness between fuse No. 6 of fuse box B Resis-
Max. 1 z
– L171 (male) (3), L172 (male) (3) tance
Wiring harness between L171 (male) (4), L172 Resis-
Max. 1 z
(male) (4) – EC3 (female) (3), (4) tance
Wiring harness between EC3 (female) (1), (2) – Resis-
Max. 1 z
10 WA450-6, WA480-6 (KA SPEC.)


Wiring harness between battery relay R04 –
Resis-
starting motor terminal B (E30) and chassis Min. 1 Mz
tance
ground
Wiring harness between S40 (male) (3) – W60
Resis-
(female) (3), – circuit branch end and chassis Min. 1 Mz
tance
ground
Wiring harness between W60 (female) (6) – Resis-
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Ground fault in wiring har- L113 (female) (6) and chassis ground tance
ness Wiring harness between L04 (female) (3) – L116 Resis-
16 Min. 1 Mz
(Contact with ground cir- (female) (1) and chassis ground tance
cuit) Wiring harness between L113 (female) (3) – D05 Resis-
Min. 1 Mz
Wiring harness between D05 (female) (1) – E01 Resis-
Min. 1 Mz
Possible (female) (1) and chassis ground tance
causes and Wiring harness between L63 (female) (37) – Resis-
standard value Min. 1 Mz
in normal state
Wiring harness between S40 (female) (2) – L171 Resis-
Min. 1 Mz
(male) (1) and chassis ground tance
Wiring harness between fuse No. 6 of fuse box B
Resis-
– L171 (male) (3), L172 (male) (3) and chassis Min. 1 Mz
tance
ground
Wiring harness between L171 (male) (4), L172
Resis-
(male) (4) – EC3 (female) (3), (4) and chassis Min. 1 Mz
tance
ground
Hot short in wiring harness Wiring harness between alternator terminal R

17
(Contact with 24V circuit) E02 – E01 (female) (2), – circuit branch end and
chassis ground (Note: if hot short occurs across Voltage Max. 1 V
them, the charging lamp will be lighted as the
starting switch is ON.
Defective transmission Work equipment
18 L63 Voltage
controller control lever
WA450-6, WA480-6 (KA SPEC.) 11

Circuit diagram related to engine starting system
12 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 13

E-2 Wiper does not operate 1

Contents of
(1) Front wiper does not operate.
trouble
Related
• The front wiper does not operate due to the defective front wiper switch, timer, or wiring harness.
information

1
C12 Front wiper switch Voltage
Between (6) and
Constant 20 – 30 V
chassis ground
Defective front wiper motor Between (2) and
2 Lo 20 – 30 V
(Internal defect) chassis ground
Between (1) and
Hi 20 – 30 V
chassis ground
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between C12 (5) and chassis ground until wiper motor
stops.
L31 Front wiper switch Voltage
Possible Between (3) and
causes and chassis ground
standard value Defective wiper timer (relay) Between (4) and
in normal state 3 INT 20 – 30 V
(Internal defect) chassis ground
Between (2) and
Washer side 20 – 30 V
chassis ground
INT (If wiper switch is
Between (5) and Repeat 20 to 30 V o
set in INT, voltage is
chassis ground 0V
output intermittently.)
L21 Voltage
Between (7) and chassis ground 20 – 30 V
Defective front wiper switch
4 L22 Front wiper switch Resistance
(Internal defect)
Between (7) and (5) Lo Max. 1 z
Between (7) and (4) Hi Max. 1 z
Between (7) and (2) INT Max. 1 z
Between (3) and (5) INT Max. 1 z
14 WA450-6, WA480-6 (KA SPEC.)


Max. 1 z
Disconnection in wiring harness
5 (Disconnection or defective Max. 1 z
C12 (female) (2) tance
contact in connector)
Max. 1 z
fuse No. 7 of fuse box A, – circuit branch end tance
Max. 1 z
Possible
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
in normal state Wiring harness between L21 (female) (3) –
Resis-
tance
chassis ground
C12 (female) (2), – circuit branch end and Min. 1 Mz
6 harness tance
chassis ground
Resis-
fuse No. 7 of fuse box A, – circuit branch end Min. 1 Mz
tance
and chassis ground
Resis-
tance
chassis ground
WA450-6, WA480-6 (KA SPEC.) 15

Contents of
(2) Rear wiper does not operate.
trouble
Related
• Since the rear wiper switch or wiring harness is defective, the rear wiper does not operate.
information

C15 Rear wiper switch Voltage
Between (1) and
Defective rear wiper motor chassis ground
1
(Internal trouble) Between (2) and
ON 20 – 30 V
chassis ground
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between C15 (1) and chassis ground until wiper motor
stops.
L21 Voltage
Defective rear wiper switch a Prepare with starting switch OFF, then carry out troubleshooting
2 without turning starting switch ON.
(Internal trouble)
L21 Rear wiper switch Resistance
Possible Between (7) and (9) ON Max. 1 z
causes and Between (8) and (9) OFF Max. 1 z
standard value
in normal state Other than above Min. 1 Mz
Max. 1 z
Disconnection in wiring C15 (female) (1) tance
3 Max. 1 z
(Disconnection or defective C15 (female) (3) tance
Max. 1 z
Wiring harness between C15 (female) (4) – Resis-
Max. 1 z
Resis-
Ground fault in wiring harness chassis ground tance
4
Min. 1 Mz
C15 (female) (3) and chassis ground tance
Min. 1 Mz
C15 (female) (2) and chassis ground tance
16 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to wiper
WA450-6, WA480-6 (KA SPEC.) 17

E-3 Windshield washer does not operate 1

Contents of
Windshield washer does not operate.
trouble
• Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the
Related windshield washer does not operate.
information • Perform the following troubleshooting when the wiper operates normally. (If the wiper does not oper-
ate normally, carry out troubleshooting for “E-2 Wiper does not operate” first.)

Defective front washer motor and carry out troubleshooting.
1
(Internal defect) R43 Voltage
Defective rear washer motor and carry out troubleshooting.
2
(Internal defect) R45 Voltage
L21 Voltage
Defective front wiper switch without turning starting switch ON.
3
(Internal defect) Washer switch for
front wiper
ON Max. 1 z
Between (7) and (6)
OFF Min. 1 Mz
Possible Between (7), (6) and

Constant Min. 1 Mz
standard value a Prepare with starting switch OFF, then turn starting switch ON
in normal state and carry out troubleshooting.
L21 Voltage
Defective rear wiper switch without turning starting switch ON.
4
(Internal defect) Washer switch for
rear wiper
ON Max. 1 z
OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground
Washer switch for
L31 (male) Voltage
front wiper
Defective wiper timer (relay) Between (3) and
5 Constant 20 – 30 V
(for only front wiper) chassis ground
Between (2) and
ON 20 – 30 V
chassis ground
Between (5) and
0.2 – 0.8 sec after ON 20 – 30 V
chassis ground
18 WA450-6, WA480-6 (KA SPEC.)


Max. 1 z
Disconnection in wiring R43 (female) (1), – L31 (female) (2) tance
harness Wiring harness between L21(female) (7) – Resis-
6 Max. 1 z
(Disconnection or defective fuse No. 7 of fuse box A tance
Max. 1 z
R45 (female) (1) tance
Possible Wiring harness between R43 (female) (2), Resis-
causes and Max. 1 z
R45 (female) (2) – chassis ground tance
standard value
in normal state
Resis-
R43 (female) (1), – L31 (female) (2), – circuit Min. 1 Mz
tance
Ground fault in wiring harness
7
fuse No. 7 of fuse box A, – circuit branch end Min. 1 Mz
tance
and chassis ground
Resis-
R45 (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground
WA450-6, WA480-6 (KA SPEC.) 19

Circuit diagram related to windshield washer
20 WA450-6, WA480-6 (KA SPEC.)

E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light
up or go off 1
Contents of
(1) Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off.
trouble
• Since the lamp system main circuit is disconnected or shorted with the chassis ground, none of the
lamps lights up.
• Headlamp at SMALL position: Clearance lamp, tail lamp, license lamp, machine monitor night lamp
light up.
• Headlamp at HEAD position: Above lamps and headlamp light up.
Related
• The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked
information
with the monitoring function (Code: 40200, SMALL LAMP).
• The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked
• The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be

1
L02 (male) Lamp switch Resistance
OFF Min. 1 Mz
Defective lamp switch Between (1) and (5)
SMALL or HEAD Max. 1 z
2 (Internal disconnection or
short circuit) OFF Min. 1 Mz
Possible Between (1) and (2) SMALL Min. 1 Mz
causes and
HEAD Max. 1 z
standard value
in normal state Between (1), (2), (5)
Constant Min. 1 Mz
and chassis ground
3
(Disconnection or defective Wiring harness between fuse No. 11 of fuse Resis-
connector contact) Max. 1 z
4
(Contact with ground circuit) Wiring harness between fuse No. 11 of fuse Resis-
box A – L02 (female) (1), – circuit branch Min. 1 Mz
tance
end and chassis ground
WA450-6, WA480-6 (KA SPEC.) 21

Contents of
(2) Either of headlamp (low and high beams) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low and high beams) is defective.
• Carry out the following troubleshooting when the clearance lamp, tail lamp, and license lamp light up
and go off normally.
Related
information

Defective fuses No. 15 and If the fuse is burn, the circuit probably has a grounding fault, etc.
1
No. 14 of fuse box A (See cause 6.)
Between (1) and (2) 200 – 400 z
Defective headlamp relay
2 a Prepare with starting switch OFF, then turn starting switch ON
(L131)
When headlamp relay (L131) is replaced with a relay of the same
type, if the condition becomes normal, the headlamp relay is defec-
tive.
Possible without turning starting switch ON.
causes and L02 (male) Headlamp switch Resistance
standard value Defective lamp switch OFF Min. 1 Mz
in normal state 3 (Internal disconnection or
short circuit) Between (1) and (2) SMALL Min. 1 Mz
HEAD Max. 1 z
Constant Min. 1 Mz
chassis ground
L02 (male) Dimmer switch Resistance
Defective dimmer switch Low Min. 1 Mz

Between (6) and (3)
4 (Internal disconnection or High Max. 1 z
short circuit) Low Max. 1 z
Between (6) and (4)
High Min. 1 Mz
Between (3), (4), (6)
Constant Min. 1 Mz
and chassis ground
22 WA450-6, WA480-6 (KA SPEC.)


Max. 1 z
Max. 1 z
Disconnection in wiring har- chassis ground tance
ness Wiring harness between fuse No. 11 of fuse Resis-
5 Max. 1 z
(Disconnection or defective box A – L131 (female) (3) tance
contact in connector) Wiring harness between L131(female) (5) – Resis-
Max. 1 z
fuses No. 15, No. 14 of fuse box A tance
Max. 1 z
box A – left HEAD (female) (B) tance
Max. 1 z
box A – right HEAD (female) (B) tance
Resis-
tance
chassis ground
Possible
Wiring harness between L131(female) (5) –
causes and Resis-
Ground fault in wiring harness fuses No. 15, No. 14 of fuse box A and chas- Min. 1 Mz
standard value 6 tance
(Contact with ground circuit) sis ground
in normal state
Resis-
box A – left HEAD (female) (B) and chassis Min. 1 Mz
tance
ground
Resis-
box A – right HEAD (female) (B) and chassis Min. 1 Mz
tance
ground
• Headlamp switch is OFF
chassis ground
7 fuses No. 15, No. 14 of fuse box A and chas- Voltage Max. 1 V
sis ground
box A – left HEAD (female) (B) and chassis Voltage Max. 1 V
ground
box A – right HEAD (female) (B) and chassis Voltage Max. 1 V
ground
WA450-6, WA480-6 (KA SPEC.) 23

Contents of
(3) Headlamp (low beam) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low beam) is disconnected or shorted with the
chassis ground.
• Carry out the following troubleshooting when the high beam lights up (goes off) normally.
Related
information

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb
may have a defective contact. Check the bulb directly.

Between (6) and (3)
Possible short circuit) Low Max. 1 z
causes and Between (6) and (4)
High Min. 1 Mz
standard value
in normal state Between (3), (4), (6)
Constant Min. 1 Mz
and chassis ground
3
(Disconnection or defective Wiring harness between HEAD (female) (A) Resis-
– L02 (female) (4) tance
Ground fault in wiring harness without turning starting switch ON.
4
(Contact with ground circuit) Wiring harness between HEAD (female) (A) Resis-
Min. 1 Mz
– L02 (female) (4) and chassis ground tance
24 WA450-6, WA480-6 (KA SPEC.)

Contents of
(4) Headlamp (high beam) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (high beam) is disconnected or shorted with the
chassis ground.
• Carry out the following troubleshooting when the low beam lights up (goes off) normally.
Related
information

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb

Between (6) and (3)
short circuit) Low Max. 1 z
Possible Between (6) and (4)
causes and High Min. 1 Mz
standard value Between (3), (4), (6)
in normal state Constant Min. 1 Mz
and chassis ground
3
(Disconnection or defective Wiring harness between HEAD (female) (C) Resis-
– L02 (female) (3) tance
4
(Contact with ground circuit) Wiring harness between HEAD (female) (C) Resis-
– L02 (female) (3), – circuit branch end and Min. 1 Mz
tance
chassis ground
WA450-6, WA480-6 (KA SPEC.) 25

Contents of (5) Clearance lamp does not light up or go off.

trouble (6) Tail lamp does not light up or go off.
• Defective switch, lamp, or wiring harness of the clearance lamp or tail lamp system.
Related • When the headlamp and turn signal lamp light up.
information • The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked
with the monitoring function (Code: 40200, SMALL LAMP).

If a specific lamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Defective fuses No. 13 and If the fuse is burn, the circuit probably has a grounding fault, etc.
2
No. 12 of fuse box A (See cause 5.)
L02 (male) Headlamp switch Resistance
OFF Min. 1 Mz
Defective lamp switch Between (1) and (5)
SMALL or HEAD Max. 1 z
short circuit) OFF Min. 1 Mz
Between (1) and (2) SMALL Min. 1 Mz
HEAD Max. 1 z
Between (1), (2), (5)
Constant Min. 1 Mz
and chassis ground
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and without turning starting switch ON.
standard value
in normal state Wiring harness between L02 (female) (5) – Resis-
fuses No. 13, No. 12 of fuse box A tance
harness
4 Wiring harness between fuse No. 12 of fuse
(Disconnection or defective Resis-
contact in connector) box A – right COMBI (female) (A), – R31 Max. 1 z
tance
(female) (4)
Max. 1 z
box A – left COMBI (female) (A) tance
Resis-
fuses No. 13, No. 12 of fuse box A and chas- Min. 1 Mz
tance
sis ground
5
(Contact with ground circuit) Wiring harness between fuse No. 12 of fuse Resis-
box A – right COMBI (female) (A), – R31 Min. 1 Mz
tance
Resis-
box A – left COMBI (female) (A) and chassis Min. 1 Mz
tance
ground
26 WA450-6, WA480-6 (KA SPEC.)


• Headlamp switch is OFF
Possible fuses No. 13, No. 12 of fuse box A, – circuit Voltage Max. 1 V
causes and branch end and chassis ground
standard value Hot short in wiring harness
6 Wiring harness between fuse No. 12 of fuse
in normal state (Contact with 24V circuit)
box A – right COMBI (female) (A), – R31
Voltage Max. 1 V
(female) (4), – circuit branch end and chas-
sis ground
box A – left COMBI (female) (A), – circuit Voltage Max. 1 V
WA450-6, WA480-6 (KA SPEC.) 27

Circuit diagram related to headlamp, clearance lamp and tail lamp
28 WA450-6, WA480-6 (KA SPEC.)

E-5 Working lamp does not light up or go off 1

Contents of
(1) Front working lamp does not light up or go off.
trouble
Related • The switch, lamp, or wiring harness of the front working lamp system is defective
information • When the rear working lamp lights up (goes off)

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
or may have a defective contact. Check the bulb directly.
2
Between (1) and (2) 200 – 400 z
Defective front working lamp
relay (L127)
When front working lamp relay (L127) is replaced with a relay of the
same type, if the condition becomes normal, the front working lamp
relay is defective.
Possible Front working lamp
Defective front working lamp S01 (male) Resistance
causes and switch
standard value 4 switch (Internal disconnection
ON Max. 1 z
in normal state or short circuit) Between (5) and (6)
OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground
Max. 1 z
box B – S01 (female) (6) tance
Wiring harness between S01 (female) (5) – Resis-
Max. 1 z
5 Max. 1 z
(Disconnection or defective chassis ground tance
contact in connector) Wiring harness between fuse No. 8 of fuse Resis-
Max. 1 z
box B – L127 (female) (3) tance
Max. 1 z
C04 (female) (1), – C05 (female) (1) tance
Wiring harness between C04 (female) (2), Resis-
Max. 1 z
C05 (female) (2) – chassis ground tance
WA450-6, WA480-6 (KA SPEC.) 29


Min. 1 Mz
box B – S01 (female) (6) and chassis ground tance
Min. 1 Mz
Ground fault in wiring harness L127 (female) (1) and chassis ground tance
6
(Contact with ground circuit) Wiring harness between fuse No. 8 of fuse
Resis-
box B – L127 (female) (3) and chassis Min. 1 Mz
tance
ground
Resis-
Possible C04 (female) (1), – C05 (female) (1), – circuit Min. 1 Mz
tance
causes and branch end and chassis ground
• Front working lamp switch turned off
Voltage Max. 1 V
box B – S01 (female) (6) and chassis ground
box B – L127 (female) (3) and chassis Voltage Max. 1 V
ground
C04 (female) (1), – C05 (female) (1), – circuit Voltage Max. 1 V
30 WA450-6, WA480-6 (KA SPEC.)

Contents of
(2) Rear working lamp does not light up or go off.
trouble
Related • The switch, lamp, or wiring harness of the rear working lamp system is defective.
information • When the front working lamp and side working lamp (if equipped) light up (go off)

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
2
Between (1) and (2) 200 – 400 z
Defective rear working lamp
relay (L128)
When rear working lamp relay (L128) is replaced with a relay of the
same type, if the condition becomes normal, the rear working lamp
relay is defective.
Defective rear working lamp Rear working lamp

Possible S02 (male) Resistance
switch switch
causes and 4
standard value (Internal disconnection or ON Max. 1 z
in normal state OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground
Max. 1 z
box B – S02 (female) (6) tance
Max. 1 z
harness Max. 1 z
5 chassis ground tance
(Disconnection or defective
contact in connector) Wiring harness between fuse No. 9 of fuse Resis-
Max. 1 z
box B – L128 (female) (3) tance
Resis-
G04 (female) (2), – G05 (female) (2), – cir- Max. 1 z
tance
cuit branch end
Wiring harness between G04 (female) (1), Resis-
Max. 1 z
G05 (female) (1) – chassis ground tance
WA450-6, WA480-6 (KA SPEC.) 31


Max. 1 z
box B – S02 (female) (6) and chassis ground tance
Max. 1 z
Ground fault in wiring harness L128 (female) (1) and chassis ground tance
6
(Contact with ground circuit) Wiring harness between fuse No. 9 of fuse
Resis-
box B – L128 (female) (3) and chassis Max. 1 z
tance
ground
Resis-
Possible G04 (female) (2), – G05 (female) (2), – cir- Max. 1 z
tance
causes and cuit branch end and chassis ground
• Front working lamp switch turned off
Voltage Max. 1 V
box B – S02 (female) (6) and chassis ground
box B – L128 (female) (3) and chassis Voltage Max. 1 V
ground
G04 (female) (2), – G05 (female) (2), – cir- Voltage Max. 1 V
cuit branch end and chassis ground
32 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to working lamp
WA450-6, WA480-6 (KA SPEC.) 33

E-6 Turn signal lamp and hazard lamp do not light up or go off 1
Contents of
(1) Either of turn signal lamp and hazard lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp system is defective.
• The input state (ON/OFF) to the machine monitor from the turn signal lamp & hazard lamp switch
Related
(right turn signal lamp) can be checked with the monitoring function (Code: 40901, D-IN-12).
information
• The input state (ON/OFF) to the machine monitor from the turn signal lamp & hazard lamp switch (left
turn signal lamp) can be checked with the monitoring function (Code: 40901, D-IN-13).

Defective No. 11 and No. 2 If the fuse is burn, the circuit probably has a grounding fault, etc.
1
fuses of fuse box B (See cause 6.)
Between (1) and (2) 200 – 400 z
2 Defective hazard relay (L111)
Possible When hazard relay (L111) is replaced with a relay of the same type,
causes and if the condition becomes normal, the hazard relay is defective.
L19 Voltage
Between (3) and (1) 20 – 30 V
Defective flasher unit 20 – 30 V and 0 V are indicated
Between (4) and (1)
3 (Internal disconnection or repeatedly.
short circuit) a Prepare with starting switch OFF, then carry out troubleshooting
Min. 1 Mz
chassis ground
34 WA450-6, WA480-6 (KA SPEC.)


Turn signal lamp and
hazard lamp switches
Turn signal lamp
Min. 1 Mz
lever: Left
Turn signal lamp
Min. 1 Mz
lever: Neutral
Between (2) and (3)
Turn signal lamp
Max. 1 z
lever: Right
Hazard lamp switch:
Max. 1 z
ON
Turn signal lamp
Defective turn signal lamp and Max. 1 z
lever: Left
hazard lamp switches (Inter-
4 Turn signal lamp
nal disconnection or short cir- Min. 1 Mz
cuit) lever: Neutral
Between (2) and (4)
Turn signal lamp
Min. 1 Mz
lever: Right
Hazard lamp switch:
Max. 1 z
ON
Hazard lamp switch:
Max. 1 z
ON
Between (1) and (5)
Possible Hazard lamp switch:
Min. 1 Mz
causes and OFF
standard value Between (1), (2), (3),
in normal state (4) or (5) and chassis Constant Min. 1 Mz
ground
Max. 1 z
ness L19 (female) (3) tance
5
Max. 1 z
Ground fault in wiring harness Wiring harness between L111 (female) (3) – Resis-
6 Min. 1 Mz
(Contact with ground circuit) L19 (female) (3) and chassis ground tance
Min. 1 Mz
7 Voltage Max. 1 V
Voltage Max. 1 V
WA450-6, WA480-6 (KA SPEC.) 35

Contents of
(2) Turn signal lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the turn signal lamp system is defective.
• When the hazard lamp lights up.
Related • The input state (ON/OFF) to the machine monitor from the turn signal lamp and hazard lamp switch
information (right turn signal lamp) can be checked with the monitoring function (Code: 40901, D-IN-12).
• The input state (ON/OFF) to the machine monitor from the turn signal lamp and hazard lamp switch
(left turn signal lamp) can be checked with the monitoring function (Code: 40901, D-IN-13).

If a specific turn signal lamp does not light up, its bulb may be bro-
1 Broken bulb
ken or may have a defective contact. Check the bulb directly.
Turn signal lamp and
hazard lamp switches
Turn signal lamp
Min. 1 Mz
lever: Left
Turn signal lamp
Min. 1 Mz
lever: Neutral
Between (2) and (3)
Turn signal lamp
Max. 1 z
lever: Right
Defective turn signal lamp and Hazard lamp switch:
Max. 1 z
hazard lamp switches (Inter- ON
2
nal disconnection or short cir- Turn signal lamp
cuit) Max. 1 z
lever: Left
Turn signal lamp
Min. 1 Mz
lever: Neutral
Between (2) and (4)
Turn signal lamp
Min. 1 Mz
lever: Right
Hazard lamp switch:
Max. 1 z
ON
Possible
causes and Between (2), (3), (4)
Constant Min. 1 Mz
standard value and chassis ground
in normal state a Prepare with starting switch OFF, then carry out troubleshooting
Max. 1 z
R31 (female) (1), – right COMBI (female) (C) tance
Max. 1 z
Disconnection in wiring har- R30 (female) (1), – left COMBI (female) (C) tance
ness Wiring harness between R30 (female) (4) – Resis-
3 Max. 1 z
(Disconnection or defective chassis ground tance
contact in connector) Wiring harness between R31 (female) (4) – Resis-
Max. 1 z
Wiring harness between right COMBI Resis-
Max. 1 z
(female) (B) – chassis ground tance
Wiring harness between left COMBI (female) Resis-
Max. 1 z
(B) – chassis ground tance
Resis-
Ground fault in wiring harness R31 (female) (1), – right COMBI (female) Min. 1 Mz
4 tance
(Contact with ground circuit) (C), – circuit branch end and chassis ground
Resis-
R30 (female) (1), – left COMBI (female) (C), Min. 1 Mz
tance
– circuit branch end and chassis ground
36 WA450-6, WA480-6 (KA SPEC.)


Possible
causes and Wiring harness between L03 (female) (3) –
standard value Hot short in wiring harness R31 (female) (1), – right COMBI (female) Voltage Max. 1 V
5
in normal state (Contact with 24V circuit) (C), – circuit branch end and chassis ground
R30 (female) (1), – left COMBI (female) (C), Voltage Max. 1 V
WA450-6, WA480-6 (KA SPEC.) 37

Contents of
(3) Hazard lamp does not light up or go off.
trouble
Related • The switch or lamp of the hazard lamp is defective.
information • Carry out the following troubleshooting when the turn signal lamp flashes normally.

1
Between (1) and (2) 200 – 400 z
2 Defective hazard relay (L111)
When hazard relay (L111) is replaced with a relay of the same type,
if the condition becomes normal, the hazard relay is defective.
L03 (male) Hazard lamp switch Resistance
Between (2) and (3), ON Max. 1 z
Defective hazard lamp switch (4) OFF Min. 1 Mz
short circuit) ON Max. 1 z
Between (1) and (5)
OFF Min. 1 Mz
Between (1), (2), (3),
(4) or (5) and chassis Constant Min. 1 Mz
ground
Possible
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
in normal state Wiring harness between fuse No. 2 of fuse Resis-
harness box B – L111 (female) (1), (5) tance
4
Max. 1 z
Ground fault in wiring harness Resis-
5 box B – L111 (female) (1), (5) and chassis Min. 1 Mz
(Contact with ground circuit) tance
ground
Min. 1 Mz
• When hot short resulted on the wiring harnesses of the following
two circuits
6
(Contact with 24V circuit) R31 (female) (1), – right COMBI (female) Voltage Max. 1 V
(C), – circuit branch end and chassis ground
R30 (female) (1), – left COMBI (female) (C), Voltage Max. 1 V
38 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to turn signal lamp and hazard lamp
WA450-6, WA480-6 (KA SPEC.) 39

E-7 Brake lamp does not light or it keeps lighting up 1

Contents of
Brake lamp does not light or it keeps lighting up.
trouble
Related
• The lamp or wiring harness of the brake lamp system is abnormal.
information

If a specific brake lamp does not light up, its bulb may be broken or
1 Broken bulb
2
Defective brake lamp relay
Between (1) and (2) 200 – 400 z
(L118)
short circuit) and carry out troubleshooting.
When brake lamp relay (L118) is replaced with a relay of the same
type, if the condition becomes normal, the brake lamp relay is defec-
tive.
Defective brake lamp switch L09 (male) Brake pedal Resistance

4 (Internal disconnection or Press Max. 1 z
Released Min. 1 Mz
Possible Between (1), (2) and
Constant Min. 1 Mz
standard value a Prepare with starting switch OFF, then carry out troubleshooting
in normal state without turning starting switch ON.
Max. 1 z
box A – L118 (female) (3), – L09 (female) (1) tance
Max. 1 z
5
Max. 1 z
R30 (female) (5), – R31 (female) (5) tance
Wiring harness between R30 (female) (4), Resis-
Max. 1 z
R31 (female) (4) – chassis ground tance
Resis-
box A – L118 (female) (3), – L09 (female) (1), Min. 1 Mz
tance
Ground fault in wiring harness – circuit branch end and chassis ground
6
Min. 1 Mz
Resis-
R30 (female) (5), – R31 (female) (5) and Min. 1 Mz
tance
chassis ground
40 WA450-6, WA480-6 (KA SPEC.)


Possible and carry out troubleshooting.
standard value Hot short in wiring harness Voltage Max. 1 V
R30 (female) (5), – R31 (female) (5) and Voltage Max. 1 V
chassis ground
Circuit diagram related to brake lamp
WA450-6, WA480-6 (KA SPEC.) 41

E-8 Backup lamp does not light or it keeps lighting up 1

Contents of
Backup lamp does not light or it keeps lighting up.
trouble
• The transmission controller monitors the primary circuit of the backup lamp relay for a trouble.
Related
(If disconnection or short circuit occurs in the primary side of the back lamp relay, failure code
information
[D160KA], [D160KB] or [D160KZ] is indicated. Carry out troubleshooting for it first.)

If a specific backup lamp does not light up, its bulb may be broken
1 Broken bulb
2
Defective backup lamp relay Between (1) and (2) 200 – 400 z
3 (L117) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting.
defective.
Max. 1 z
Max. 1 z
R30 (female) (2), – R31 (female) (2) tance
Possible
standard value Disconnection in wiring L117 (female) (1) Resis-
Max. 1 z
in normal state harness • As a failure is detected, failure code tance
4
(Disconnection or defective [D160KA] is indicated.
contact in connector) Wiring harness between L117 (female) (2) –
chassis ground Resis-
Max. 1 z
• As a failure is detected, failure code tance
[D160KA] is indicated
Wiring harness between R30 (female) (4) – Resis-
Max. 1 z
Wiring harness between R31 (female) (4) – Resis-
Max. 1 z
Resis-
box A – L117 (female) (3), – circuit branch Min. 1 Mz
tance
end and chassis ground
Ground fault in wiring harness Wiring harness between L117 (female) (5) –
5 Resis-
(Contact with ground circuit) R30 (female) (2), – R31 (female) (2), – circuit Min. 1 Mz
tance
L117 (female) (1) and chassis ground Resis-
Min. 1 Mz
[D160KB] or [D160KZ] is displayed
42 WA450-6, WA480-6 (KA SPEC.)


Possible a Prepare with starting switch OFF, then turn starting switch ON
causes and and carry out troubleshooting.
standard value Hot short in wiring harness
R30 (female) (2), – R31 (female) (2), – circuit Voltage Max. 1 V
WA450-6, WA480-6 (KA SPEC.) 43

E-9 Backup buzzer does not sound or it keeps sounding 1

Contents of
Backup buzzer does not sound or it keeps sounding.
trouble
• The transmission controller monitors the primary circuit of the backup lamp relay for a trouble.
Related (If disconnection or ground fault occurs in the primary side of the back lamp relay, failure code
information [D160KA], [D160KB] or [D160KZ] is indicated. In such case, give precedence to the troubleshooting
of the failure indicated with the code.)

Defective backup buzzer
1 (Internal disconnection or GR10 Gear shift lever Voltage
short circuit) R 20 – 30 V
Between (1) and (2)
Other than R Max. 1 V
2
Defective backup lamp relay Between (1) and (2) 200 – 400 z
3 (L101) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting.
defective.
causes and
standard value Max. 1 z
in normal state
Max. 1 z
GR10 (female) (1) tance
Disconnection in wiring Wiring harness between L63 (female) (4) –
harness L117 (female) (1) Resis-
4 Max. 1 z
(Disconnection or defective • As a failure is detected, failure code tance
contact in connector) [D160KA] is indicated.
chassis ground Resis-
Max. 1 z
[D160KA] is indicated.
Wiring harness between GR10 (female) (2) – Resis-
Max. 1 z
Resis-
Ground fault in wiring harness box A – L117 (female) (3) and chassis Min. 1 Mz
5 tance
(Contact with ground circuit) ground
Resis-
GR10 (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground
44 WA450-6, WA480-6 (KA SPEC.)


L117 (female) (1), – circuit branch end and
Ground fault in wiring harness Resis-
5 chassis ground Min. 1 Mz
Possible (Contact with ground circuit) tance
• As a failure is detected, failure code
causes and [D160KB] or [D160KZ] is indicated
standard value
in normal state a Prepare with starting switch OFF, then turn starting switch ON
GR10 (female) (1), – circuit branch end and Voltage Max. 1 V
chassis ground
Circuit diagram related to backup buzzer
WA450-6, WA480-6 (KA SPEC.) 45

E-10 Horn does not sound or it keeps sounding 1

Contents of
Horn does not sound or it keeps sounding (Steering wheel specification).
trouble
Related
• The relay, switch, horn, or wiring harness of the horn system is abnormal.
information

1
Defective horn relay (L119)
Between (1) and (2) 200 – 400 z
short circuit) a Prepare with starting switch OFF, then turn starting switch ON
When horn relay (L119) is replaced with a relay of the same type, if
the condition becomes normal, the horn relay is defective.
Defective steering wheel horn
switch Steering wheel horn
3 L05 (male) Resistance
(Internal disconnection or switch
short circuit) Between (1) and ON Max. 1 z
chassis ground OFF Min. 1 Mz
Defective joystick lever horn
switch Joystick lever horn
4 L37 (male) Resistance
(Internal disconnection or switch
Possible short circuit) ON Max. 1 z
causes and Between (9) and (10)
standard value OFF Min. 1 Mz
in normal state a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Disconnect connector and mea-
sure on female side)
Defective horn F03, F05 Horn switch Voltage
5 (Internal disconnection or ON Max. 1 V
Between F03 (2) and
short circuit)
(1) OFF 20 – 30 V
Between F05 (2) and ON Max. 1 V
(1) OFF 20 – 30 V
Max. 1 z
box A – L119 (female) (1), (3) tance
Max. 1 z
Disconnection in wiring L05 (female) (1), – L37 (female) (9) tance
6 Max. 1 z
(Disconnection or defective F03 (female) (2), – F05 (female) (2) tance
contact in connector) Wiring harness between F03 (female) (1) – Resis-
Max. 1 z
F05 (female) (1) – chassis ground tance
Wiring harness between steering wheel horn Resis-
Max. 1 z
switch – chassis ground tance
Max. 1 z
46 WA450-6, WA480-6 (KA SPEC.)


Possible
causes and Wiring harness between fuse No. 1 of fuse
Resis-
standard value Ground fault in wiring harness box A – L119 (female) (1), (3), – circuit Min. 1 Mz
7 tance
in normal state (Contact with ground circuit) branch end and chassis ground
Resis-
F03 (female) (2), – F05 (female) (2), – circuit Min. 1 Mz
tance
Circuit diagram related to horn
WA450-6, WA480-6 (KA SPEC.) 47

E-11 Alarm buzzer does not sound or it keeps sounding 1

Contents of
• Alarm buzzer does not sound or it keeps sounding.
trouble
• Disconnection or ground fault in alarm buzzer output circuit
Related • The output state (ON/OFF) from the alarm buzzer to the machine monitor can be checked with the
information monitoring function (Code: 40952, D-OUT-0).
• If failure code [DV00KB] (Alarm buzzer: Short circuit) is indicated, carry out troubleshooting for it first.

1
• Remove the buzzer then connect +24 V to L20 (male) (1) and
Defective alarm buzzer GND to L20 (male) (2).
2
(Internal short circuit) Alarm buzzer is
Alarm buzzer sounds
normal
Defective alarm
Alarm buzzer does not sound
buzzer
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and Disconnection in wiring har- without turning starting switch ON.
standard value ness Wiring harness between fuse No. 10 of fuse Resis-
in normal state 3 Max. 1 z
(Disconnection or defective box A – L20 (female) (1) tance
Max. 1 z
Ground fault in wiring harness Resis- Min.
4 box A – L20 (female) (1), – circuit branch end
(Contact with ground circuit) tance 1 Mz
and chassis ground
Wiring harness between L20 (female) (2) – Resis- Min.
L51 (female) (14) and chassis ground tance 1 Mz
• When above 1 – 4 are normal, failure on the machine monitor can
be suspected.
48 WA450-6, WA480-6 (KA SPEC.)

Circuit diagram related to alarm buzzer
WA450-6, WA480-6 (KA SPEC.) 49

E-12 Air conditioner does not operate or stop 1

Contents of
Air conditioner does not operate or stop.
trouble
• The following is troubleshooting applicable only to the power supply and GND circuit between the air
Related
conditioner and operator's cab. For troubleshooting of the air conditioner unit, see the Shop Manual
information
for the air conditioner.

Defective No. 13 and No. 12
fuses of fuse box A or defec-
If the fuse is burn, the circuit probably has a grounding fault, etc.
1 tive 5 A and 15 A fuses of the
(See cause 2.)
main circuit in the air condi-
tioner unit.
• When fuse No. 8 of fuse box A is blown
box A – 5A fuse of air conditioner main cir- Resis- Min.
cuit, – 15A fuse in the air conditioner and tance 1 Mz
chassis ground
• When fuse No. 9 of fuse box A is broken
Resis- Min.
box A – compressor clutch relay and chassis
Grounding fault in power tance 1 Mz
ground
2 supply wiring harness
(Contact with ground circuit) a Prepare with starting switch OFF, then carry out troubleshooting
causes and • When 5A fuse of the air conditioner unit main circuit is broken
standard value Wiring harness between 5A fuse of air condi-
in normal state tioner unit main circuit – C48 (female) (7), – Resis- Min.
pressure switch, – blower OFF relay primary tance 1 Mz
side and chassis ground
• When 15A fuse of the air conditioner unit is broken
Wiring harness between 15A fuse of air con-
Resis- Min.
ditioner unit – blower OFF relay and chassis
tance 1 Mz
ground
C48 Starting switch Voltage
Defective A/C control panel ON 20 – 30 V

Between (7) and (1)
power supply and disconnec- OFF Max. 1 V
3 tion of GND wring harness a Prepare with starting switch OFF, then carry out troubleshooting
(disconnection or defective without turning starting switch ON.
contact in connector)
Max. 1 z
box A – C48 (female) (7) tance
Wiring harness between C48 (female) (1) – Resis-
Max. 1 z
50 WA450-6, WA480-6 (KA SPEC.)


Blower OFF relay,
Starting switch Voltage
pressure switch
Blower OFF relay ON 20 – 30 V
(15A fuse line) and
Blower OFF relay (5A ON 20 – 30 V

fuse line of main cir-
cuit) and chassis OFF Max. 1 V
ground
Pressure switch ON 20 – 30 V
Possible
Disconnection in wiring har- (5A fuse line of main
causes and
ness of relay power supply circuit) and chassis OFF Max. 1 V
standard value 4
(Disconnection or defective ground
in normal state
contact in connector) a Prepare with starting switch OFF, then carry out troubleshooting
Resis-
box A – blower OFF relay (on the 15A fuse Max. 1 z
tance
line)
Resis-
box A – blower OFF relay (on the 5A fuse line Max. 1 z
tance
of main circuit)
Resis-
box A – pressure switch (on the 5A fuse line Max. 1 z
tance
of main circuit)
Wiring harness between pressure switch – Resis-
Max. 1 z
compressor clutch relay tance
WA450-6, WA480-6 (KA SPEC.) 51

Circuit diagram related to air conditioner
52 WA450-6, WA480-6 (KA SPEC.)

E-13 The KOMTRAX system does not work properly 1

Trouble • The KOMTRAX system does not work properly.
• If the KOMTRAX system administrator asks you to check whether any defect occurs in the machine
Related
system, carry out the following troubleshooting.
information
• A defect in the KOMTRAX system, if any, does not appear especially as a defective phenomenon.

1 Defective power supply L80 Signal Voltage
Between (39), (40) – Constant power
20 – 30 V
(37) and (38) supply
a Turn the starting switch ON, then start engine and carry out trou-
bleshooting.
LED (6) Normal state
LED-C1 ON
Defective starting switch a Prepare with starting switch OFF, then start engine and carry out
2 ACC signal and alternator R troubleshooting.
signal L80 Signal Voltage
Between (36) and
Starting switch ACC 20 – 30 V
(37), (38)
Between (28) – (37),
Alternator R 20 – 30 V
(38)
and standard Defective starting switch C
value in normal 3 L80 Signal Voltage
signal
Starting switch C 20 – 30 V
(37), (38)
a Turn the starting switch ON, and carry out troubleshooting.
LED-C4 ON
Defective CAN connection
4 a Prepare with starting switch OFF, then carry out troubleshooting
state
L80 (female) Signal Resistance
Between (7) and (8) CAN 40 – 80 z
5 Number of unsent mails LED (7) Normal state
7 segments 0–9
Defective GPS positioning Dot ON
6
status
One or more minute may be taken until GPS positioning is com-
pleted after the starting switch was turned ON even in an outdoor
service area.
WA450-6, WA480-6 (KA SPEC.) 53

Lamp display section of KOMTRAX terminal L80 connector
LED for communication module

1. LED-A1 (power indicator lamp)
2. LED-A2 (within communication range lamp)
3. LED-A3 (on communicating lamp)
4. LED-A4 (internal transmission lamp)
5. LED-A (internal reception lamp)
CPU LED
6. LED-C1 (R signal and ACC signal status)
7. LED-C2 (starting output status)
8. LED-C3 (S-NET, C signal status)
9. LED-C4 (CAN status)
10. LED-C5 (download writing condition)
11. LED-C6 (download writing condition)
7 segments and dot for CPU
12. 7 segments (number of mails not yet sent)
13. Dot (GPS positioning in progress)
54 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 55

SEN01688-00

56
SEN01689-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
Troubleshooting of hydraulic and
mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... 3
Method of using troubleshooting chart ................................................................................................. 3
Table of failure modes and causes....................................................................................................... 6
H-1 The machine does not start......................................................................................................... 10
H-2 Torque converter lockup is not switched off (engine stalls)
[Machine with lockup clutch (if equipped)].................................................................................. 12
H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)].............. 13
H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak,
and the gear is not shifted .......................................................................................................... 14
H-5 Shocks are large at the times of starting and shifting gear.......................................................... 16
H-6 Time lag is large at the times of starting and shifting gear .......................................................... 18
H-7 The torque converter oil temperature is high............................................................................... 20
H-8 Steering does not turn ................................................................................................................. 21
H-9 Steering does not turn [Machine with joystick steering (if equipped)].......................................... 22
WA450-6, WA480-6 (KA SPEC.) 1

H-10 Steering response is low............................................................................................................ 23

H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]................. 24
H-12 Steering is heavy ....................................................................................................................... 25
H-13 When machine turns, it shakes or makes large shocks ............................................................ 26
H-14 When machine turns, it shakes or makes large shocks
[machine with joystick steering (if equipped)]............................................................................ 27
H-15 The wheel brake does not work or does not work well.............................................................. 28
H-16 The wheel brake is not released or it drags............................................................................... 29
H-17 The parking brake does not work or does not work well ........................................................... 30
H-18 The parking brake is not released or it drags (including emergency release system)............... 31
H-19 Lift arm does not rise ................................................................................................................. 32
H-20 Lift arm speed is low or rising force of lift arm is insufficient...................................................... 33
H-21 When rising, the lift arm comes to move slowly at specific height............................................. 34
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)............................................. 34
H-23 Hydraulic drifts of the lift arm is large......................................................................................... 34
H-24 The lift arm wobbles during operation ....................................................................................... 34
H-25 Bucket does not tilt back............................................................................................................ 35
H-26 Bucket speed is low or tilting back force is insufficient .............................................................. 36
H-27 The bucket comes to operate slowly in the midst of tilting-back................................................ 37
H-28 The bucket cylinder cannot hold down the bucket..................................................................... 37
H-29 Hydraulic drifts of the bucket is large......................................................................................... 37
H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”) .... 37
H-31 Lift arm and bucket control levers do not move smoothly and are heavy.................................. 38
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls ................ 39
H-33 Large shock is made when work equipment starts and stops ................................................... 39
H-34 When work equipment circuit is relieved singly, other work equipment moves ......................... 39
H-35 ECSS does not operate, and pitching, bouncing occur ............................................................. 40
2 WA450-6, WA480-6 (KA SPEC.)

Troubleshooting of hydraulic and mechanical system (H-mode) 1

Method of using troubleshooting chart 1
This troubleshooting chart determines the location from the problem occurring on the machine and catego-
rizes the problem under one of the main components, such as the steering system or work equipment
hydraulic system. Use the following procedure to carry out accurate troubleshooting swiftly.
Step 1. Ask operator questions Step 3. Method of reading matrix

q The questions to ask the operator are given 1. Operate the machine when carrying out trou-
under the problem. If the answer to the ques- bleshooting of the items in the Diagnosis col-
tion matches the content given, the cause umn. If any problems occur as the result of the
given after the arrow is the probable troubleshooting, put a check against the item.
cause.Keeping the content of the questions in a When carrying out the troubleshooting,
mind, read the matrix and proceed with Step 2 check the easier items first. It is not neces-
and Step 3 to pinpoint the correct cause. sary to follow the number order.
[Example]
Example: Steering does not turn
Ask the operator and check the following points. Remedys
No.
q Did the problem suddenly start? Diagnosis
o Related equipment broken Steering does not turn in both directions (left
1
q Was the steering wheel heavy before? and right)
o Wear of related parts, defective seal Steering turns only in one direction (left or
2
right)
Step 2. Checks before troubleshooting Steering is heavy when turned in both direc-
q Before measuring the oil pressure or starting 3
tions (left and right)
the troubleshooting, confirm the checks before Steering wheel is heavy in one direction (left
starting items, check for leakage of oil, or for 4
or right)
loose bolts. This will prevent wasting time
5 Work equipment moves
when troubleshooting. The items given under
“Checks before troubleshooting” are checks
that are particularly important to make about 2. Find the matching cause in the Cause column.
the condition of the machine before starting the In the same way as in Step 2), if a problem is
actual troubleshooting. found, the Q marks on the same line for the
troubleshooting item are the causes. (In Diag-
Example: Checks before starting troubleshoot- nosis item 2 in the same diagram below the
ing cause is (c) or (e).)
q Is oil level and type of oil in hydraulic tank cor- When there is one Q mark:
rect? Carry out troubleshooting for the other items
q Is there any oil leakage from steering valve or marked with Q in the same Cause column to
demand valve? check if the problem occurs, then make
q Is steering linkage adjusted properly? repairs.
When there are two Q marks:
Go to Step 3) to narrow down the cause.
WA450-6, WA480-6 (KA SPEC.) 3

3. Operate the machine and carry out trouble- 6. Repeat the operation in Steps 3, 4, and 5 until
shooting of the items not checked in Step 1. the cause is narrowed down to 1 item (1 com-
Operate the machine in the same way as in mon item).
Step 1, and if any problem occurs, put a check a If cause items are 2 or more, continue until
against the item. (In Troubleshooting item 5 in number of items becomes minimum.
the diagram below, the problem was re-
enacted.) 7. Remedy
After narrowing down the common causes,
4. Find the matching cause in the Cause column. take the action given in the remedy line.
In the same way as in Step 2), if a problem is Marks and remedies in remedy line
found, the Q marks on the same line for the ×: Replace E: Repair A: Adjust C: Clean
troubleshooting item are the causes. (In Diag-
nosis item 5 in the diagram below the cause is
(b) or (e).)
5. Narrow down the causes.

Of the causes found in Step 2) and Step 4),
there are common items (Q marks on the line
for each Diagnosis item and in the same
Cause column as each other) that have
causes common with the problem items found
in the troubleshooting in Step 1) and Step 3).
a The items that are not common (items that
do not have Q marks in the same cause
common as each other) are probably not
the cause, so they can be eliminated. (The
causes for Diagnosis item 2 in the dia-
gram below are (c) or (e), and the causes
in Diagnosis item 5 are (b) or (e), so
Cause (e) is the common cause.)
4 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 5

Table of failure modes and causes 1

Part that can cause failures
Clogging of torque converter charging pump strainer

Clogging or air intake on torque converter charging
Drop of transmission main relief valve set pressure

Defective operation of torque converter relief valve
Clogged or broken torque converter oil cooler
Defective torque converter charging pump
Internal breakage of torque converter
Clogging of last chance filter

Defective regulator valve
The PTO is defective
pump suction side

Defective engine
Failure mode
Machine does not start Q Q Q Q Q Q Q Q

Torque converter lockup is not switched off (engine stalls) [Lockup clutch specification (if
equipped)]
Power train
Torque converter lockup is not turned on [Lockup clutch specification (if equipped)] Q Q
Travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the
Q Q Q Q Q Q Q Q Q Q
gear is not shifted
Large shocks are made when machine starts and gear is shifted Q Q Q Q Q
Large time lag is made when machine starts and gear is shifted Q Q Q Q Q
Torque converter oil temperature is high Q Q Q Q Q Q Q
Steering does not turn Q
Steering does not turn [Joystick steering specification (if equipped)] Q
Steering response is low Q
Steering
Steering response is low [Joystick steering specification (if equipped)] Q

Steering is heavy
Steering wheel shakes or makes large shocks
Steering wheel shakes or makes large shocks [Joystick steering specification (if equipped)]
Wheel brake does not work or braking force is low
Wheel brake does not reset or drag
Brake
Parking brake does not work or braking force is low

The parking brake is not released or it drags (including emergency release system)
Lift arm does not rise Q
Lift arm speed is low or rising force of lift arm is insufficient
When lift arm rises, its speed lowers at specific height
The lift arm cylinder cannot hold down the bucket (Bucket floats)
Hydraulic drift of lift arm is large
Lift arm shakes during operation
Bucket does not tilt Q
Work equipment
Bucket speed is low or tilt-back force is insufficient

Bucket speed goes low during tilt-back operation
Bucket cannot be held with bucket cylinder
Hydraulic drift of bucket is large
Bucket shakes during travel with load (Work equipment valve is in HOLD)
Lift arm and bucket control levers do not move smoothly and they are heavy
Large engine speed reduction or engine stall occurs during work equipment control Q
Large shock is made when work equipment starts and stops
When work equipment is relieved singly, other work equipment moves
ECSS does not operate, allowing pitching or bouncing to occur
6 WA450-6, WA480-6 (KA SPEC.)

Q
Q
Q
Q
Q
Defective operation of relevant ECMV
Q Q
Defect of transmission controller system
Q
Q
Internal breakage of transmission
Q Q
Q
Q Q
War or seizure of relevant clutch
Q
Low oil pressure due to defective transmission valve
Defective clutch piston
The relevant clutch piston seal is defective
40 Troubleshooting
Q Q
Q Q Q
Q Q
Q Q
Defective seal of relevant clutch shaft
Q
Q Q Q
Clogging of transmission breather
Q
Q
Defective transmission oil temperature sensor
Q
Defective transmission output shaft speed sensor
WA450-6, WA480-6 (KA SPEC.)

Defective seal of work equipment and steering system
Q
Q
hydraulic pump shaft
Clogging or air intake on steering pump suction side
Q Q
Defective steering pump
Q Q
Q Q Q
Defective steering pump servo
Defective Orbit-roll
Q Q
Q
Defective steering stop valve
Defective steering main relief valve
Defective flow control spool
Q
Defective steering spool of steering valve
Defective overload relief valve
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 Q Q Q Q Q
Defective seal of steering cylinder piston
Clogging of joystick steering solenoid valve line filter
Q
Q Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q
Defective joystick steering solenoid valve
Q
Defective steering wheel or steering shaft
Defective seal of brake piston
Q
Defective operation of brake piston
Failure inside wheel brake valve
Q
Q Q Q Q
Wear or abnormality of wheel brake disc
Contact of metallic site due to complete wear on
Q
Q
wheel brake disc
Q
Q
Q
Q
Q
Q
Defective fan pump

Q Q
Q Q
Q Q
Q Q
Clogging or air intake on fan pump suction side

Q Air in wheel brake circuit
Q Q Q Q
Defective brake valve
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-35
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
7
SEN01689-00
Part that can cause failures
Defective operation of check valve (between last chance filter

Gas leakage from accumulator, defective seal of piston
Damages on parking brake switch line wiring harness
Defective operation of parking brake solenoid valve

Defective parking brake emergency release valve
Defective accumulator charge valve
Defective parking brake spring

and parking brake solenoid)
Failure mode
Machine does not start Q Q Q

Torque converter lockup is not switched off (engine stalls) [Lockup clutch specification (if equipped)]
Power train
Torque converter lockup is not turned on [Lockup clutch specification (if equipped)]
Travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted
Large shocks are made when machine starts and gear is shifted
Large time lag is made when machine starts and gear is shifted
Torque converter oil temperature is high
Steering does not turn Q
Steering does not turn [Joystick steering specification (if equipped)] Q
Steering response is low Q
Steering
Steering response is low [Joystick steering specification (if equipped)] Q

Steering is heavy Q
Steering wheel shakes or makes large shocks Q
Steering wheel shakes or makes large shocks [Joystick steering specification (if equipped)] Q
Wheel brake does not work or braking force is low Q Q
Wheel brake does not reset or drag
Brake
Parking brake does not work or braking force is low Q Q Q

Parking brake cannot be reset or it drags Q Q Q
Lift arm does not rise Q
Lift arm speed is low or rising force of lift arm is insufficient Q
When lift arm rises, its speed lowers at specific height
The lift arm cylinder cannot hold down the bucket (Bucket floats)
Hydraulic drift of lift arm is large
Lift arm shakes during operation
Bucket does not tilt Q
Work equipment
Bucket speed is low or tilt-back force is insufficient Q

Bucket speed lowers during tilt-back operation Q
Bucket cannot be held with bucket cylinder
Hydraulic drift of bucket is large
Bucket shakes while machine is traveling with load (Work equipment valve is in HOLD)
Lift arm and bucket control levers do not move smoothly and are heavy
Engine speed lowers remarkably or engine stalls during work equipment control
Large shock is made when work equipment starts and stops
When work equipment is relieved singly, other work equipment moves
ECSS. does not operate, and pitching or bouncing occurs Q
8 WA450-6, WA480-6 (KA SPEC.)

Q
Defective operation of parking brake piston
Q
Q
Q
Q
The parking brake piston seal is defective
Q
Wear of parking brake disc
Q
Pinching due to peeling of parking brake disc
Defective harness of parking brake switch line
Q
Q
Q
Q
Q
Q
Q
Q
Q
Clogging or air intake on work equipment pump suction side
40 Troubleshooting
Q
Defective work equipment controller
Defective work equipment pump
Q Q
Defective work equipment pump servo
Q
Q
Defective work equipment valve body
WA450-6, WA480-6 (KA SPEC.)

Defective work equipment main relief valve
Q Q Q Q Q
Q Q Q Q Q
Q Q Q Q Q
Q Q Q Q Q
Defective work equipment unload valve
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
Q Q Q Q Q Q
Defective lift arm spool of work equipment valve
Q Q
Q Q
Q
Q
Q
Q
Q
Defective bucket spool of work equipment valve
Malfunction of lift arm pressure compensation valve of work
Q
Q
Q
Q
Q
Q
Q
Q
Q
equipment
Defective safety-suction valve on bucket head side of work
Q
Q
equipment valve
Defective safety-suction valve on bucket bottom side of work
Q
Q
Q
Q
Q
equipment valve
Q
Q
Q
Q
Q
Q
Q
Malfunction of PPC valve spool
Q Q
Defective PPC valve body
Malfunction of bucket pressure compensation valve of work
Q
Q
Q
Q
Q
equipment
Q
Q
Q
Q
Malfunction of work equipment back pressure valve
Q
Q
Q
Defective lift arm cylinder
Q
Defective bucket cylinder
Q
Q
Q
Q
Q
Defective seal of lift arm cylinder piston
Q
Q
Q
Q
Q
Q
Defective seal of bucket cylinder piston
Q
Defective stroke of lift arm EPC lever
Q
Defective stroke of bucket EPC lever
Q
Defect in electric system of lift arm or bucket EPC lever
Q
Clearance error of pin or bush of working equipment linkage
Q
Defective ECSS solenoid valve
Q
Q
Q
Q
Q
Q
Q
Defective ECSS charge valve
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-35
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
9
SEN01689-00
H-1 The machine does not start 1

Ask the operator about the following ques- Causes
tions.
Parking brake emergency

Defective main relief
q Has the machine come not to start sud-
Torque converter
Torque converter
charging pump
Parking brake
Transmission
release valve
denly?
Check valve
ECMV
o Seizure of clutch, breakage of parts
valve
Did any abnormal noise occur at the time
and where?
Testing before troubleshooting

q Does the machine monitor function nor- a b c d e f g h i j k l m n o p q
mally?
(between last chance filter and parking brake solenoid)

q Is any failure code of the electrical system
Defective operation of parking brake solenoid valve

displayed on the machine monitor?
q Are the transmission oil level and the oil type
Defective operation of spool of parking brake

appropriate?

q Did you smell deteriorated or burnt transmis-

Drop of main relief valve set pressure

sion oil? Clogging or air intake on suction side
Defective operation of check valve

Haven't the transmission filter and strainer
War or seizure of relevant clutch

q The charging pump is defective
been clogged?

Can you find any damage or oil leak from
emergency release valve

q
the appearance?
Clogging of strainer
q Has the drive shaft been broken?

q Have the wheel brake and the parking brake
been locked?
Remedy E E E E E E E E E
No. x x * * * x x x
Diagnosis x C x x x x x x x
1 The machine does not start at all gear speeds Q Q Q Q Q Q Q Q Q Q Q Q Q
2 The machine does not start at specific gear speeds Q Q Q Q Q
When the transmission oil temperature is low, the charg-
3 ing pump or the transmission filter causes any abnormal Q Q
noise
When the transmission oil temperature rises, the machine
4 Q Q Q Q
comes not to start
Metal (Aluminum, copper, iron, etc.) powders are adhered
5 Q Q Q
to the transmission filter or the strainer
The speed is higher at all gear
6 When the stall speed of Q Q Q Q Q Q Q Q
speeds
the torque converter is
measured The speed is higher at specific
7 Q Q Q Q Q
gear speeds
The oil pressure is low at all
8 Q Q Q Q Q Q Q
gear speeds
When the ECMV output The oil pressure is low at spe-
9 Q Q Q Q
(Clutch) oil pressure is cific gear speeds
measured
The oil pressure does not
10 become stable as the gauge Q Q
vibrates
When the torque converter relief (Inlet) oil pressure is
11 Q Q Q Q Q Q
measured, the oil pressure is low
*: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
10 WA450-6, WA480-6 (KA SPEC.)

* Defective clutch and ECMV specifying method (Check by

failure code)
a For the checking method of failure code display, see the
paragraph of “Special functions of machine monitor.”
a When replacing the ECMV for troubleshooting, remove mud
and dust around the ECMV completely and clean it, and then
tighten the mounting bolt with the specified torque. Causes
a For the following diagnoses, start the engine and select the Transmission ECMV
manual mode: a b c d e f g h i j k l
Clutch
Table of Applicable Clutches
F R 1st 2nd 3rd 4th
In the automatic mode q
Wear or seizure of 2nd clutch disc or wear of piston seal

Wear or seizure of 3rd clutch disc or wear of piston seal
Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
N
Wear or seizure of R clutch disc or wear of piston seal

Wear or seizure of F clutch disc or wear of piston seal
In the manual mode Q Q Q Q
Defective operation of 2nd clutch ECMV (Fill switch)

Defective operation of 3rd clutch ECMV (Fill switch)
Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
Defective operation of R clutch ECMV (Fill switch)
Defective operation of F clutch ECMV (Fill switch)
F1 q q
F2 q q
Gear Speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
a When the gear speed is N in the manual mode, the clutch of

the gear speed (Marked with Q), to which the gear shift lever
is set, is ON.
q Even if the gear shift lever is used when the gear speed is N,
the clutch position can not be changed.
Remedy Failure
No. x x x x x x x x x x x x
Diagnosis code
(1) The code is not displayed at R1 – R4 but is displayed at F1 – F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1 – F4 but is displayed at R1 – R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is
(2) disconnected. When the failure code is 15SFLH, the failure code comes not to 15SFLH Q
be displayed when the ECMV is replaced with any one other than the 2nd
clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV
WA450-6, WA480-6 (KA SPEC.) 11

H-2 Torque converter lockup is not switched off (engine stalls) [Machine
with lockup clutch (if equipped)] 1
Checks before troubleshooting Cause
q Is the oil level of transmission case appropriate? a b
Defective operation of lockup clutch ECMV
Wear or seizure of lockup clutch disc

Remedy
No. x x
Diagnosis
1 Lockup oil pressure does not drop to 0 Q
2 Lockup cannot be turned off even when the lockup oil pressure is 0 Q
12 WA450-6, WA480-6 (KA SPEC.)

H-3 Torque converter lockup is not switched on [Machine with lockup

clutch (if equipped)] 1
Ask the operator about the following: Cause
q Has the lockup come not to turn on suddenly? a b c d e f g
o Seizure or breakage inside torque converter
Drop of transmission main relief valve set pressure

q Did any abnormal noise occur at the time? o Breakage of parts
Checks before troubleshooting
Defective operation of lockup clutch ECMV

q Is the oil level of transmission case appropriate?
Defective seal of lockup clutch piston

Wear or seizure of lockup clutch disc
q Is there any external oil leakage?
Defective seal of lockup clutch shaft

Check of abnormality

Crack on lockup clutch case
q Main relief oil pressure
q Lockup oil pressure
q Travel speed
Remedy
E
No. Diagnosis Transmission x x x x C x
x
controller self-diagnosis code
1 Main relief oil pressure is low Q
2 Main relief oil pressure is normal, but lockup oil pressure is low or 0 Q Q Q Q Q
3 Main relief oil pressure and oil pressure is normal, but lockup oil pressure is low or 0 Q
4 Time to lockup actuation takes long 15SJLH Q
WA450-6, WA480-6 (KA SPEC.) 13

H-4 The travel speed is slow, the thrusting force is weak, the uphill
traveling power is weak, and the gear is not shifted 1
Ask the operator about the following questions. Causes
q Has the abnormality occurred suddenly?
Torque converter
Torque converter
Torque converter
Defective main
charging pump
o Breakage of related equipment
Parking brake
Transmission
relief valve
oil cooler
Did any abnormal noise occur at the time and where?
Others
ECMV
q Have any abnormal signs come to occur gradually?
o Wear of related equipment, defective seal
Checking for abnormalities

a b c d e f g h i j k l m n o p q r
q Execute digging and measure traveling speeds on a
level ground and on a slope to check whether the
Defective seal of work equipment and steering system hydraulic pump shaft
abnormality actually occurs or is a matter of operator's
sense
Breakage of oil cooler and pipe (After torque converter outlet)

q Is any failure code of the electrical system displayed
Clogging of oil cooler and pipe (After torque converter outlet)

on the machine monitor?
q Are the transmission oil level and the oil type appropri-
ate?

q Haven't the transmission filter and strainer been
clogged?
(Mixing of hydraulic oil in transmission case)

Clogging or air intake on pump suction side
q Is any external oil leak found on the mating faces of

pipes and valves around the torque converter and the


transmission?

q Isn't the wheel brake or the parking brake being
The charging pump is defective
dragged? Oil leak inside torque converter

q Are the tire air pressure and the tread shape appropri-
ate?
q Is the operating method correct?
Clogging of breather
Note Engine degradation

NOTE: When the inspection result was “Engine degrada-
tion,” proceed to Engine system troubleshooting
(S mode).
Remedy C E E E E E E E C E
No. x x x * * x x
Diagnosis x x x x x x x x x x
1 Any abnormality occurs at all gear speeds Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
2 Any abnormality occurs at specific gear speeds Q Q Q Q
When the transmission oil temperature is low, the charging pump or
3 Q Q
the transmission filter causes any abnormal noise
4 The torque converter oil temperature rises abnormally high Q Q Q Q Q Q Q Q Q Q Q
5 The transmission oil level rises or falls Q Q Q Q Q
Metal powders (Aluminum, copper, iron, etc.) are adhered to the
6 Q Q Q
transmission filter and the strainer
The engine low idle and high idle speeds are measured to be abnor-
7 Q Q Q
mal
8 When the stall speed of the The speed is high Q Q Q Q Q Q Q Q Q Q
9 torque converter is measured The speed is low Q
The oil pressure drops as the tem-
10 Q Q Q Q
perature rises
The oil pressure is low at all gear
11 Q Q Q Q Q Q Q Q Q
When the ECMV output (Clutch) speeds
oil pressure is measured The oil pressure is low at specific
12 Q Q Q Q
gear speeds
The oil pressure does not become
13 Q Q
stable as the gauge vibrates
When the torque converter relief (Inlet) oil pressure is measured, the
14 Q Q Q
oil pressure is low. (No. 11 – 13 are normal.)
When the oil pressure at the torque converter outlet is measured,
15 Q
the oil pressure is low. (No. 14 is normal.)
14 WA450-6, WA480-6 (KA SPEC.)


failure code)
Causes
tighten the mounting bolt with the specified torque.
Transmission ECMV
a For the following diagnoses, start the engine and select the
Clutch
F R 1st 2nd 3rd 4th

N


F1 q q
F2 q q
Gear Speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

is set, is ON.
Remedy Failure
Diagnosis code
1
2
ECMV
clutch ECMV
ECMV
ECMV
WA450-6, WA480-6 (KA SPEC.) 15

H-5 Shocks are large at the times of starting and shifting gear 1
q Did shocks become large suddenly?
Torque converter
charging pump
Defective main
Parking brake
Transmission
relief valve
Sensors
ECMV
q Did shocks become large gradually?
Testing before troubleshooting a b c d e f g h i j k l

q Did any of the following abnormal phenomena occur at the same
Defective return (Release) of relevant clutch piston

time: The traveling speed is slow, the braking is weak, the uphill
travelling power is weak, the gear is not shifted. o Execute H-4


Defective operation of relevant ECMV a
Defect of transmission controller system

Defective operation of main relief valve

q Is any failure code of the electrical system displayed on the
machine monitor?

q Are the transmission oil level and the oil type appropriate?

q Haven't the transmission filter and strainer been clogged?
q Is any external oil leak found on the mating faces of pipes and
valves around the torque converter and the transmission?
q Isn't the engine speed high at the time of low idling?
q Isn't play of each drive shaft large?
q Is the initial learning of transmission completed?
(Refer to the section “Testing and adjusting”.)
Remedy C E E
No. x x * ** * * x x **
Diagnosis x x x
1 Shocks are large at all gear speeds Q Q Q Q Q Q Q Q
2 Shocks are large at specific gear speeds Q Q Q Q Q Q
3 When the ECMV output The oil pressure is low at all gear speeds Q Q Q Q Q Q
4 (Clutch) oil pressure is The oil pressure is low at specific gear speeds Q Q Q
5 measured The oil pressure is high at all gear speeds Q
a Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
**: Proceed to the paragraph of “Troubleshooting of transmission controller system (TM mode).”
16 WA450-6, WA480-6 (KA SPEC.)


failure code)
Causes
Transmission ECMV
Clutch
F R 1st 2nd 3rd 4th

N


F1 q q
F2 q q
Gear Speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

is set, is ON.
Remedy Failure
Diagnosis code
1
2
ECMV
clutch ECMV
ECMV
ECMV
WA450-6, WA480-6 (KA SPEC.) 17

H-6 Time lag is large at the times of starting and shifting gear 1
Ask the operator about the following:
q Did the time lag become large suddenly? Cause
Torque converter
Main relief valve

charging pump
Parking brake
Transmission
Has the time lag become large gradually?
Sensor
q
ECMV
q Did any of the following abnormal phenomena occur at the same time: a b c d e f g h i j
The traveling speed is slow, the braking is weak, the uphill travelling

power is weak, the gear is not shifted. o Execute H-4

Defective operation of relevant ECMV a

q Is any failure code of the electrical system displayed on the machine
monitor?

q Are the transmission oil level and the oil type appropriate?

q Haven't the transmission filter and strainer been clogged?
q Is any external oil leak found on the mating faces of pipings and valves
around the torque converter and the transmission?
Remedy C E E
No. x x * * x x **
Diagnosis x x x
1 Time lag is large at all gear speeds Q Q Q Q Q Q Q
2 Time lag is large at specific gear speeds Q Q Q Q
When the transmission oil temperature is low, any abnormal noise occurs from the
3 Q Q
charging pump or the transmission filter
4 The torque converter oil temperature is heated abnormally high Q Q Q Q
5 When the ECMV output (Clutch) The oil pressure is low at all gear speeds Q Q Q Q Q
6 oil pressure is measured The oil pressure is low at specific gear speeds Q Q Q
a Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
**: See Troubleshooting by failure code (Display of code)
18 WA450-6, WA480-6 (KA SPEC.)


failure code)
Causes
Transmission ECMV
Clutch
F R 1st 2nd 3rd 4th

N


F1 q q
F2 q q
Gear Speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

is set, is ON.
Remedy Failure
Diagnosis code
1
2
ECMV
clutch ECMV
ECMV
ECMV
WA450-6, WA480-6 (KA SPEC.) 19

H-7 The torque converter oil temperature is high 1

q Does the oil temperature rise when the torque converter
Torque converter
Torque converter
Torque converter
charging pump
Transmission
stalls and does the temperature fall at the time of no
Main relief
oil cooler
Others
load? o Selection of improper gear speed
q Does the oil temperature rise only at the time of lifting?
o Improvement of operating method
a b c d e f g h i j k l
Defective seal of work equipment and steering

q Measure the torque converter oil temperature to find if
(Mixing of hydraulic oil in transmission case)

the oil temperature is really high.
o The torque converter oil temperature gauge is defective


Oil leak inside torque converter

Breakage of oil cooler and pipe
Clogging of oil cooler and pipe
Are the coolant level in the radiator and the fan belt ten-
(After torque converter outlet)
(After torque converter outlet)

q
system hydraulic pump shaft

sion appropriate?
q Are the oil level in the transmission and the oil type
Clogging of breather
appropriate?
Note Engine degradation

q Haven't the transmission filter and strainer been Clogging of strainer
clogged?
NOTE:When the inspection result was “Engine degradation,”
proceed to Engine system troubleshooting (S mode).
Remedy C E E EEEE C E
No. x x
Diagnosis x x x x x x x x x
When the transmission oil temperature is low, the charging
1 Q Q
pump or the transmission filter causes any abnormal noise
Traveling speed, braking force and uphill travelling power do not
2 Q Q Q Q Q Q Q Q Q Q Q
occur at all gear speeds
Traveling speed, braking force and uphill travelling power do not
3 Q
occur at specific gear speeds
4 The transmission oil level rises or falls Q Q Q
Metal powers (Aluminum, copper, iron, etc.) are adhered to the
5 Q Q Q
transmission filter and the strainer
The engine low idle and high idle speeds are measured to be
6 Q Q Q
abnormal
When the stall speed of the torque converter is measured, the
7 Q Q Q Q Q Q Q Q Q
speed is high
The oil pressure drops as the tempera-
8 Q
ture rises
The oil pressure is low at all gear
9 When the ECMV output speeds Q Q Q Q Q
(Clutch) oil pressure is
The oil pressure is low at specific gear
10 measured Q
speeds
The oil pressure does not become sta-
11 Q Q
ble as the gauge vibrates
When the torque converter relief (Inlet) oil pressure is mea-
12 Q Q Q
sured, the oil pressure is low. (No. 9 – 11 are normal.)
When the oil pressure at the torque converter outlet is mea-
13 Q
sured, the oil pressure is low. (No. 12 is normal.)
20 WA450-6, WA480-6 (KA SPEC.)

H-8 Steering does not turn 1

Did the problem suddenly start? o Breakage of related equipment
Defective stop valve

q
Hydraulic cylinder
Hydraulic pump
Did the machine cause any abnormal noise at the time and where?
Steering valve
Charge valve
q Is oil level in hydraulic tank correct? Is the type of oil correct?
q Is the steering shaft broken?
q Is the steering stop valve properly adjusted?
q Has the lock bar been removed from the frame? a b c d e f g h i j k
Defect in steering cylinder (defective piston seal)

Defective actuation of steering spool

Malfunction of flow control spool

Defective brake pump

Remedy E EEEEEEE
No. E x x
Diagnosis x x x x x x x x
1 Steering does not turn in both directions (left and right) Q Q Q Q Q Q Q Q Q
2 Steering turns only in one direction (left or right) Q Q
3 Steering is heavy when turned in both directions (left and right) Q Q Q Q
4 Steering wheel is heavy in one direction (left or right) Q
5 Work equipment moves Q Q Q Q Q Q Q
6 Work equipment does not move Q Q Q Q
7 Abnormal noise comes from around PTO Q
8 Abnormal noise comes from fan pump or hydraulic tank Q Q
Oil pressure is low or there is no oil pressure in both
9 Q Q Q Q Q Q Q Q Q
When steering relief directions (left and right)
pressure is measured Oil pressure is low or there is no oil pressure in one
10 Q Q
direction (left or right)
When Orbit-roll output pressure is measured, oil pressure is found to be low or
11 Q Q Q Q Q
there is no oil pressure
12 When Orbit-roll basic Oil pressure is low Q Q Q Q
13 pressure is measured There is no oil pressure Q Q Q
a There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is left in the steering, check the operation of the work equipment also.
WA450-6, WA480-6 (KA SPEC.) 21

H-9 Steering does not turn [Machine with joystick steering (if equipped)]1
Ask the operator about the following questions.
q Did the problem suddenly start? Causes

Hydraulic cylinder
Did the machine cause any abnormal noise at the time and
Hydraulic pump
Steering valve
Charge valve
where?
Joystick
q Is the steering shaft broken?
q Is the steering stop valve properly adjusted? a b c d e f g h i j k l m
q Has the safety bar been removed from the frame?

q Is the connect of the connector of joystick steering ON/OFF
switch correct?

Air sucked in at suction end of pump

Malfunction of stop valve
Defective fan pump
Clogged line filter
Remedy E EEEE C EEE
No. E x x x
Steering does not move (steering wheel mode
1 Q
When joystick ON/OFF only)
2 switch is operated Steering does not move (joystick mode only) Q Q
3 Steering does not move in either mode Q Q Q Q Q Q Q Q Q Q
4 Steering does not turn in both directions (left and right) Q Q Q Q Q Q Q Q Q Q Q
5 Steering turns only in one direction (left or right) Q Q
6 Joystick steering is heavy in both directions (left and right) Q Q Q Q
7 Joystick steering is heavy in one direction (left or right) Q
8 Work equipment moves Q Q Q Q Q Q Q Q Q
11 Abnormal noise comes from around fan pump or hydraulic tank Q Q
Oil pressure is low or there is no oil pressure in
When steering relief both directions (left and right)
pressure is measured Oil pressure is low or there is no oil pressure in
13 Q Q
one direction (left or right)
When Orbit-roll output pressure is measured, oil pressure is found to be
14 Q Q Q Q Q
low or there is no oil pressure
When joystick steering EPC solenoid valve output pressure is measured,
15 Q Q Q Q Q Q
oil pressure is found to be low or there is no oil pressure
16 When Orbit-roll basic Oil pressure is low Q Q Q Q
17 pressure is measured There is no oil pressure Q Q Q
22 WA450-6, WA480-6 (KA SPEC.)

H-10 Steering response is low 1

q Did the problem suddenly start? Causes

Hydraulic cylinder
Hydraulic pump
Steering valve
Charge valve
where?
q Did the problem gradually appear?
o Wear of related parts, defective seal

q Is oil level in hydraulic tank correct? Is the type of oil correct? a b c d e f g h i j k l m



Defective main relief valve
Defective steering spool


Defective fan pump
Remedy E EEEEEEEEE E
No. E x
Diagnosis x x x x x x x x x x x
Turning, response of steering wheel is poor in both directions (left and
right)
2 Turning, response of steering wheel is poor in one direction (left or right) Q Q
3 Steering wheel is heavy in both directions (left and right) Q Q Q Q
5 Work equipment moves Q Q Q Q Q Q Q Q Q
8 Abnormal noise comes from around fan pump or hydraulic tank Q Q
Oil pressure is low or there is no oil pressure in
9 Q Q Q Q Q Q Q Q Q Q
When steering relief both directions (left and right)
pressure is measured Oil pressure is low or there is no oil pressure in
10 Q Q
one direction (left or right)
When Orbit-roll output pressure is measured, oil pressure is found to be
11 Q Q Q Q Q
When Orbit-roll basic pressure is measured, oil pressure is found to be
12 Q Q Q Q
When steering pump servo assembly is replaced, oil pressure is found to
13 Q
be normal
WA450-6, WA480-6 (KA SPEC.) 23

H-11 Turning, response of steering is poor [machine with joystick

steering (if equipped)] 1
Did the problem suddenly start?

q
Hydraulic cylinder
Joystick steering
Steering pump
solenoid valve
Steering valve
Charge valve
where?
q Did the problem gradually appear?
o Wear of steering related parts, defective seal
Testing before troubleshooting a b c d e f g h i j k l m n






Defective fan pump
Clogged line filter

Remedy E EEEE C EEEE E
No. E x x
Diagnosis x x x x x x x x x x x
Turning, response of joystick steering is poor in both directions (left
1 Q Q Q Q Q Q Q Q Q Q Q Q
and right)
Turning, response of joystick steering is poor in one direction (left or
2 Q Q
right)
3 Joystick steering is heavy in both directions (left and right) Q Q Q
4 Joystick steering wheel is heavy in one direction (left or right) Q
5 Work equipment moves Q Q Q Q Q Q Q Q Q Q
8 Abnormal noise comes from around hydraulic tank Q Q
Oil pressure is low or there is no oil pressure
When steering relief in both directions (left and right)
pressure is measured Oil pressure is low or there is no oil pressure
10 Q Q
in one direction (left or right)
When joystick steering solenoid valve output pressure is measured, oil
11 Q Q Q Q Q Q
pressure is found to be low or there is no oil pressure
When steering pump servo assembly is replaced, oil pressure is found
12 Q
to be normal
24 WA450-6, WA480-6 (KA SPEC.)

H-12 Steering is heavy 1

Check of abnormality Causes
Is the steering difficult to turn? o See H-8 or H-9

q
Hydraulic pump
Steering valve
Charge valve
Measure the operating effort and turning speed, and check the Standard value table to
Others
see if they are abnormal.

q Did the problem suddenly start? o Breakage of related equipment broken
q Was there previously any symptom that may lead to heavy steering? a b c d e f
o Wear of steering related parts, defective seal
Defective actuation of steering wheel or steering shaft

q Is the tire inflation pressure correct?


Defective fan pump
Remedy E E E E E E
No.
Diagnosis x x x x x x
1 Steering wheel is heavy when turned in both directions (left and right) Q Q Q Q Q
3 Steering wheel is heavy even when joint between steering shaft and Orbit-roll is disconnected Q
Oil pressure is low or there is no oil pressure in both directions (left and
4 Q Q Q Q
When steering relief right)
pressure is measured Oil pressure is low or there is no oil pressure in one direction (left or
5 Q
right)
When Orbit-roll output pressure is measured, oil pressure is found to be low or there is no oil
6 Q Q Q Q
pressure
7 When Orbit-roll basic Oil pressure is low Q Q
8 pressure is measured There is no oil pressure Q
WA450-6, WA480-6 (KA SPEC.) 25

H-13 When machine turns, it shakes or makes large shocks 1

q Is the steering difficult to turn? o See H-8 Causes
q Is there any abnormal noise from around the steering equipment

Hydraulic pump
Steering valve
Charge valve
Cylinder
q Is the steering wheel play correct?
q Is there any abnormality in the connection between the steering shaft and
the Orbit-roll?
a b c d e f g h i


Defective fan pump
Remedy E E E E E E EE
No. E
Diagnosis x x x x x x x x
1 When machine turns, it shakes or jerks in both directions (left and right) Q Q Q Q Q Q Q
2 When machine turns, it shakes or jerks in one directions (left or right) Q Q
3 During operations or when traveling (steering is neutral), the machine shakes or jerks Q Q Q
Steering wheel jerks or there is excessive shock when steering is operated to end of
4 Q
its stroke
5 Work equipment also jerks Q Q
Oil pressure is unstable in both directions
6 Q Q Q Q Q Q Q
When steering relief pressure is mea- (left and right)
sured Oil pressure is unstable in one direction
7 Q Q
(left or right)
8 Q Q Q
When Orbit-roll discharge pressure (left and right)
(steering pilot pressure) was measured Oil pressure is unstable in one direction
9 Q
(left or right)
10 When Orbit-roll basic pressure is measured, oil pressure is found to be unstable Q Q
26 WA450-6, WA480-6 (KA SPEC.)

H-14 When machine turns, it shakes or makes large shocks [machine

with joystick steering (if equipped)] 1
Checking for abnormalities Causes
Is the steering difficult to turn? o See H-9
Joystick steering solenoid valve

q
q Is there any abnormal noise from around the steering equipment

Hydraulic pump
Steering valve
Charge valve
Cylinder
q Has the machine monitor displayed any failure code?
o See the troubleshooting by failure code (Display of code)
q Is play of the steering wheel appropriate?
q Is there any abnormality in the connection between the steering shaft and
the Orbit-roll?
a b c d e f g h i
Malfunction of the joystick steering solenoid valve


Malfunction of stop valve
Defective fan pump
Remedy E E EEE EE
No. x E
Diagnosis x x x x x x x
1 When machine turns, it shakes or jerks in both directions (left and right) Q Q Q Q Q Q Q
2 When machine turns, it shakes or jerks in one directions (left or right) Q Q
3 During operations or when traveling (steering is neutral), the machine shakes or jerks Q Q Q
Steering wheel jerks or there is excessive shock when steering is operated to end of
4 Q
its stroke
5 Work equipment also jerks Q Q
6 Q Q Q Q Q Q Q
When steering relief pressure is mea- (left and right)
sured Oil pressure is unstable in one direction
7 Q Q
(left or right)
8 When output pressure from the joystick Q Q Q
(left and right)
steering solenoid valve (steering pilot cir-
cuit pressure) was measured Oil pressure is unstable in one direction
9 Q
(left or right)
When basic pressure of joystick steering (Orbit-roll basic pressure) is measured, oil
10 Q Q
pressure is found to be unstable
WA450-6, WA480-6 (KA SPEC.) 27

H-15 The wheel brake does not work or does not work well 1
Has the brake come not to turn suddenly? o Breakage of brake
Charge valve
q
Wheel brake
Accumulator
Brake valve
Fan pump
q Has the brake come out to work gradually?
Others
o Weakening of seals and wear of lining and disc

q Is the hydraulic oil level appropriate? a b c d e f g h i j
Is the play of brake pedal appropriate?
Defective seal of accumulator piston, insufficient gas pressure

q
q Oil leak from brake tube and connector and deformation of tube
Metal contact due to complete wear of brake disc in axle

q Tire air pressure and state of tire tread

q Test the effectiveness of the brake referring to “Measuring brake perfor-
mance” in “Testing and adjusting” to check whether the abnormality actu-
Defective operation of brake piston in axle
Wear or abnormality of brake disc in axle

ally occurs or is a matter of operator's sense
Defective seal of brake piston in axle

Defective operation of charge valve
The brake in axle is defective
Mixing of air in brake circuit

Defective brake valve
Defective fan pump
Remedy E E E E E E E E E
No. E
1 When the brake pedal is stepped on, only a little resistance is felt Q Q Q Q
2 When the brake pedal is stepped on, a strong resistance is felt Q
3 To get the specified braking force, an abnormal leg-power is required Q Q Q Q Q
4 When the brake works, an abnormal noise occurs from the axle brake Q Q
5 The machine does not travel well (insufficient drawbar pull) Q
When the four wheels are jacked up, the axle is placed on a table and the brake is
6 Q Q Q Q Q Q
applied at the forward 1st speed, only a specific wheel rotates
An airflow is observed in bleeding air from the brake circuit, and the brake returns
7 Q
to normal after the bleeding
8 Brake oil leaks abnormally from the axle during inspection Q
9 Much metal powders are mixed in the axle oil Q
10 The brake pedal leg-power and stroke are normal, but the brake does not work well Q Q Q Q
11 The brake does not work often when the engine is stopped Q Q Q Q
12 The accumulator is not charged, and a buzzer sounds Q Q Q
13 The brake works after some time lag Q
28 WA450-6, WA480-6 (KA SPEC.)

H-16 The wheel brake is not released or it drags 1

Testing before troubleshooting Causes
Has the brake pedal returned completely?
Wheel brake
q
Brake valve
q Is the parking brake released completely?

q Abnormal heat of brake
a b c
q Does the machine travel smoothly by inertia on a level ground?
Defect inside brake valve (Sticking of piston)
Defective operation of brake piston in axle

Abnormal lining of brake in axle
Remedy E E E
No.
Diagnosis x x x
1 The brake pedal is released, but the brake is still applied Q Q Q
When the brake pedal is released, oil is drained from the air bleeder, the circuit pressure drops and the
2 Q
brake is released
The four wheels are jacked up, the axle is placed on a table, the engine is stopped, the parking brake is
3 Q Q
released and the tires are rotated by hand but a specific tire hardly rotates
WA450-6, WA480-6 (KA SPEC.) 29

H-17 The parking brake does not work or does not work well 1
Has the brake come not to work suddenly? o Breakage of related equipment
Parking brake
q
Solenoid
Did the machine cause any abnormal noise at the time and where?
Valve
q Has the brake come not to work gradually?
Checks before troubleshooting a b c d e

q Isn't the parking brake emergency release switch turned ON?
Defective parking brake emergency release valve

q Hasn't the mechanical release of parking brake performed?

Defective parking brake solenoid valve
Defective parking brake spring
Wear of parking brake disc

Remedy E E
No. x x x
Diagnosis x x
1 The parking brake is not applied even if the engine stops Q Q Q
2 When wear of parking brake disc is checked, the disc thickness is lower than standard value Q
With the parking brake switch ON, there is no oil pressure
3 When the parking brake inlet pressure (Normal) Q Q
is measured
4 With the parking brake switch ON, there is a oil pressure Q Q Q
With the parking brake switch ON, there is no oil pressure
5 When the parking brake solenoid valve (Normal) Q Q
output pressure is measured
6 With the parking brake switch ON, there is a oil pressure Q
30 WA450-6, WA480-6 (KA SPEC.)

H-18 The parking brake is not released or it drags (including emergency

release system) 1
Check if the parking brake emergency release switch is not turned ON?
Transmission valve
q
q Check if the parking brake is automatically applied when the engine stops.
Wiring harness
Parking brake
Solenoid
a b c d e
Insufficient oil level due to defect of transmission valve

Damages on parking brake switch line wiring harness
Pinching due to peeling of parking brake disc
Defect inside parking brake solenoid valve
Remedy E E EE
No. E
Diagnosis x x x x
1 When the parking brake switch is off, the parking brake is not released Q Q Q Q Q
2 When the parking brake switch is off, the brake is not applied even if the engine stops Q
3 When the parking brake switch is on, the parking brake does not work well Q Q
q The parking brake is not released even if the emergency parking brake release valve is opened.
The following causes are considered:
a. Malfunction of emergency parking brake release valve
b. Insufficient gas pressure of accumulator for brake or breakage of piston seal
WA450-6, WA480-6 (KA SPEC.) 31

H-19 Lift arm does not rise 1

Ask the operator about the following. Causes
Did the lift arm stop suddenly?
Accumulator charge valve

q
Work equipment valve

o Seizure or breakage of each component
Did abnormal sound come out when the lift arm stopped? (From
Tank – Pump
PPC valve
what part)
Cylinder
q Has the speed lowered? o Wear of parts and fatigue of springs

q Is the oil level in the hydraulic tank proper?
q Is the stroke of the lift arm control lever proper?
q Is the engine speed proper? a b c d e f g h i j k l
Malfunction of lift arm pressure compensation valve

Internal breakage of valve body (lift arm spool)
Damaged lift arm cylinder piston seal

Malfunction of main relief valve

Malfunction of unload valve
Malfunction of relief valve
Malfunction of spool
Defective fan pump
Remedy C E E E E EEEE
No. x x x
Diagnosis E x x x x x x x x
1 Bucket does not move and lift arm does not rise Q Q Q Q Q Q Q
2 Lift arm can raise chassis but does not rise Q Q Q
3 Bucket moves but lift arm does not rise Q Q Q Q
4 Lift arm can rise when not loaded but cannot when loaded Q Q Q Q Q
5 Hydraulic pump is making abnormal sound Q Q Q
6 Hydraulic drift of lift arm cylinder is large Q Q
7 When lift arm and bucket are operated simultaneously, lift arm does not rise Q Q
8 Fan does not rotate Q Q Q
When work equipment pump and servo assembly is replaced, lift arm moves
9 Q
normally
32 WA450-6, WA480-6 (KA SPEC.)

H-20 Lift arm speed is low or rising force of lift arm is insufficient 1
Is the stroke of the lift arm control lever proper?

q

q Is the engine speed proper?
q Is the work equipment linkage bushing normal (Is abnormal
Bypass valve
Tank – Pump
PPC valve
sound made)?
Cylinder
q The troubles of the rising force and rising speed are
strongly related to each other. The rising speed lowers first.
Measure the lift arm rising speed while it is loaded and
check abnormality with the standard values table. a b c d e f g h i j k l m n o
Internal wear or breakage of valve body (lift arm spool)

Malfunction of bucket pressure compensation valve
Damaged lift arm cylinder piston seal

Malfunction of ECSS charge valve
Malfunction back pressure valve

Defective fan pump
A
Remedy C E E E E EEEEE
No. x E x x x
Diagnosis E x x x x x x x x x
x
Tilting force and speed of bucket are abnormal and rising speed of
lift arm is low
Tilting force and speed of bucket are normal and rising speed of lift
2 Q Q Q Q Q
arm is low
3 After oil temperature rises, tilting back speed lowers more in step 1. Q
5 Hydraulic drift of the cylinder is large Q Q Q
6 Relief pressure of relief valve of work equipment valve is low Q Q Q Q Q Q
7 Relief pressure of relief valve of work equipment valve is too high Q
When lift arm and bucket are operated simultaneously, rising speed
8 Q
of lift arm is too low
When work equipment pump and servo assembly is replaced, lift
9 Q
arm moves normally
WA450-6, WA480-6 (KA SPEC.) 33

H-21 When rising, the lift arm comes to move slowly at specific height 1
q Deformation of lift arm cylinder in appearance
Cause
q Expansion of lift arm cylinder tube or damage inside
a For other abnormal phenomena during lift arm rise, see “H-20 Lift arm speed is low or rising force of lift
arm is insufficient”
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats) 1
See “H-20 Lift arm speed is low or rising force of lift arm is insufficient.”

q Is the stroke of the lift arm control lever appropriate?
Cause
q Defective seat of suction valve on the lift arm cylinder head side of work equipment valve
q Oil leakage from seal of lift arm cylinder piston
q Defective stroke of lift arm EPC lever (if equipped)
H-23 Hydraulic drifts of the lift arm is large 1

q Have hydraulic drifts come to be large suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to be large gradually? o Wear of parts
q Is the lift arm spool at the neutral position? o The spool detent is defective
q Check the hydraulic drift of the lift arm with the standard values table.
Cause
q Oil leakage in lift arm cylinder
q Imperfect fitting of lift arm spool
H-24 The lift arm wobbles during operation 1

The bucket and the lift arm moves up and down as the topography goes in digging or leveling with the lift arm
control lever in the HOLD position.
Diagnosis and Cause
Check at first the hydraulic drift and if the lift arm cylinder can lift the machine
1. When the hydraulic drift is more than the standard value, see “H-23 Hydraulic drifts of the lift arm is
large.”
2. When the lift arm cylinder cannot lift the machine, see “H-22. The lift arm cylinder cannot hold down the
bucket (bucket floats).”
3. When the lift arm cylinder comes to enable to lift the machine after the lift arm is operated several times
with the normal hydraulic drift and after the lift arm cylinder operates to full stroke o The cause is vac-
uum generated inside the cylinder
a Frequent hydraulic drifts o The suction valve on the lift arm cylinder head side is defective
34 WA450-6, WA480-6 (KA SPEC.)

H-25 Bucket does not tilt back 1

Ask the operator about the following. Causes
Did the bucket stop suddenly?

q

o Seizure or breakage of each component
Did abnormal sound come out when the lift arm stopped?
Tank – Pump
PPC valve
(From what part)
Cylinder
q Has the speed lowered?
o Wear of parts and fatigue of springs

q Is the oil level in the hydraulic tank proper?
q Is the stroke of the bucket control lever proper? a b c d e f g h i j k l m n
Malfunction of bucket bottom suction valve (suction safety valve)

Malfunction of bucket bottom safety valve (suction safety valve)
q Has the machine monitor displayed any failure code?
o See Troubleshooting by Failure Code (Display of code)

Internal breakage of valve body (bucket spool)
Damaged bucket cylinder piston seal


Defective fan pump
C
Remedy C E E E E EEEE E
No. x E x x
Diagnosis E x x x x x x x x x
x
1 Lift arm does not move and bucket does not tilt back Q Q Q Q Q Q Q
2 Bucket can raise chassis but does not tilt back Q Q Q
3 Lift arm moves but bucket does not tilt back Q Q Q Q
Bucket can tilt back when not loaded but cannot when used for digging
4 Q Q Q Q Q Q Q
or scooping
6 Hydraulic drift of bucket cylinder is large Q Q Q Q
When lift arm and bucket are operated simultaneously, bucket does
7 Q Q
not tilt back
8 Fan does not rotate Q Q Q —
When work equipment pump and servo assembly is replaced, lift arm
9 Q
moves normally
WA450-6, WA480-6 (KA SPEC.) 35

H-26 Bucket speed is low or tilting back force is insufficient 1

Is the stroke of the bucket control lever proper?

q

q Is the work equipment linkage bushing normal (Is abnor-
Tank – Pump
PPC valve
mal sound made)?
Cylinder
q Check by actual operation that the tilting back force is
insufficient.
q Measure the operating speed of the bucket and check it
with the standard values table. a b c d e f g h i j k l m n o p
Malfunction of bucket bottom suction valve (suction safety valve)

Malfunction of bucket bottom safety valve (suction safety valve)
Malfunction and defective adjustment of main relief valve

Internal breakage of valve body (bucket spool)

Damaged bucket cylinder piston seal

Malfunction of ECSS charge valve
Malfunction back pressure valve

Defective fan pump
A C
Remedy C E E E E EEE EEE
No. x E E x x
Diagnosis E x x x x x x x x x x
x x
Rising force and speed of lift arm are abnormal and tilting back
force and speed of bucket are low
Rising force and speed of lift arm are normal and tilting back
2 Q Q Q Q Q Q
force and speed of bucket are low
After oil temperature rises, tilting back speed lowers more in
3 Q
step 1.
5 Hydraulic drift of the cylinder is large Q Q Q Q
6 Relief pressure of relief valve of work equipment valve is low Q Q Q Q Q Q Q
Relief pressure of relief valve of work equipment valve is too
7 Q
high
When lift arm and bucket are operated simultaneously, tilting
8 Q
back speed of bucket is too low.
When work equipment pump and servo assembly is replaced,
9 Q —
bucket moves normally
36 WA450-6, WA480-6 (KA SPEC.)

H-27 The bucket comes to operate slowly in the midst of tilting-back 1

q Deformation of bucket cylinder in appearance
Cause
q Expansion of bucket cylinder tube or damage inside
For other abnormal phenomena during bucket operation, see “H-26 Bucket speed is low or tilting back
force is insufficient.”
H-28 The bucket cylinder cannot hold down the bucket 1

See “H-26. The bucket moves slowly or the tilting back force is insufficient.”
q Is the stroke of the bucket control lever appropriate?
Cause
q Defective seat of suction safety valve on the bucket cylinder head side of work equipment valve
q Oil leak from bucket cylinder piston seal
q Defective stroke of bucket EPC lever (if equipped)
H-29 Hydraulic drifts of the bucket is large 1

q Have hydraulic drifts come to be large suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to be large gradually? o Wear of parts
q Is the bucket spool at the neutral position? o The spool detent is defective
q Refer to the standard value table and check if the hydraulic drift of the bucket occurs often practically
Cause
q Oil leak in bucket cylinder
q Improper adhesion of suction safety valve on the bottom side
q Improper oil tight of bucket spool
H-30 The bucket wobbles during travel with cargo (The work equipment
valve is set to “HOLD”) 1
q Pin of work equipment linkage and “play of bushing” (Is any abnormal noise heard?)
Cause
q Defective seal of bucket cylinder piston
q Defective operation of suction safety valve on bucket cylinder head side. For other abnormal phenom-
ena, refer to diagnoses for relevant abnormal phenomena.
WA450-6, WA480-6 (KA SPEC.) 37

H-31 Lift arm and bucket control levers do not move smoothly and are
heavy 1
Checking for abnormalities Causes
q Refer to the standard value table and check if the lever operating efforts are large practi- PPC valve
cally. a b c d
Improper roundness between PPC valve body and spool

Improper clearance between PPC valve body and spool
Foreign matter pinched in PPC valve spool

The PPC valve spool is bent
Remedy EE C
No. x
Diagnosis x x E
1 When the machine is loaded and the oil pressure rises, the levers come not to move smoothly Q Q
2 The levers come not to move smoothly as the oil temperature rises Q Q
The levers totally come not to move smoothly during operation irrespective of oil pressure and oil tem-
3 Q Q
perature
38 WA450-6, WA480-6 (KA SPEC.)

H-32 During operation of the machine, engine speed lowers remarkably

or engine stalls 1
Is the working equipment main relief pressure normal?
Cause
q Defective work equipment pump servo
q Defective working equipment pump unit
q Defective working equipment pump servo EPC input voltage
q Defective engine system
H-33 Large shock is made when work equipment starts and stops 1
Cause
q Wastes in work equipment valve PPC line
q Defective PPC valve
q Defective operation of control valve spool
q Defect in electrical system of lift arm or bucket EPC lever (if equipped)
H-34 When work equipment circuit is relieved singly, other work

equipment moves 1
Cause
q Pressure is not released properly from main spool of moving equipment o Replace main spool
WA450-6, WA480-6 (KA SPEC.) 39

H-35 ECSS does not operate, and pitching, bouncing occur 1

Did pitching, bouncing occur suddenly? o Breakage of related equipment
Solenoid valve
q
Accumulator
Controller
Sensor
q Has pitching, bouncing occurred gradually? o Wear of related equipment, defective seal

q Is the state of ECSS switch proper? a b c d
Defective transmission output shaft speed sensor

Defective operation of work equipment controller
Gas leakage from accumulator, defective seal
Defective ECSS solenoid valve
Remedy A
No. x x x
Diagnosis x
1 The ECSS actuation speed (5 km/h) largely fluctuates Q Q
2 The ECSS does not operate under no load Q Q
3 When the ECSS operates under load, the lift arm lowers the maximum distance (30 cm or more) Q
4 The ECSS does not operate at all Q Q Q Q
40 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 41

SEN01689-00

42
SEN01690-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode)............................................................................................................... 3
Method of using troubleshooting chart ................................................................................................. 3
S-1 Starting performance is poor.......................................................................................................... 6
S-2 Engine does not start..................................................................................................................... 8
S-3 Engine does not pick up smoothly............................................................................................... 12
S-4 Engine stops during operation ..................................................................................................... 13
S-5 Engine does not rotate smoothly ................................................................................................. 14
S-6 Engine lacks output (or lacks power)........................................................................................... 15
S-7 Exhaust smoke is black (Incomplete combustion)....................................................................... 16
S-8 Oil is consumed much (or exhaust gas color is blue) .................................................................. 18
S-9 Engine oil becomes contaminated quickly................................................................................... 19
S-10 Fuel consumption is excessive.................................................................................................. 20
S-11 Coolant contains oil (blows back or reduces) ............................................................................ 21
S-12 Oil pressure drops ..................................................................................................................... 22
S-13 Oil level rises (Water, fuel in oil) ................................................................................................ 23
S-14 Coolant temperature rises too high (Overheating) .................................................................... 25
WA450-6, WA480-6 (KA SPEC.) 1

S-15 Abnormal noise is made ............................................................................................................ 26

S-16 Vibration is excessive ................................................................................................................ 27
2 WA450-6, WA480-6 (KA SPEC.)

Troubleshooting of engine (S-mode) 1

Method of using troubleshooting chart 1
The troubleshooting chart consists of “questions”, “check items”, “causes”, and “troubleshooting” blocks.
The “questions” and “check items” narrow down the causes to highly probable “causes” by simple inspection
or from symptoms without using a diagnostic tool.
Then, the final verifications of “causes” are carried out by checking the narrowed down “causes” in the order
of their probability with diagnostic tools or by direct inspection following the “troubleshooting” procedure.
Questions:
Information to be obtained by questioning the user
or operator, and which corresponds to the sections
(A) and (B) in the right chart.
Section (A) includes basic information, and section
(B) contains items which can be obtained depend-
ing on the level of the user or operator.
Check items:
Items checked by the serviceman in order to nar-
row down the causes, section (C) of the right chart
is corresponding to them.
Causes:
Items to be narrowed down by the questions and
check items.
The serviceman narrows down the causes to highly
probable causes according to the information from
(A), (B) and (C).
Troubleshooting:
Items to be verified at the end in order to check if
the narrowed down causes are the true factors
causing the failure. The verification is carried out
by applying diagnostic tools or implementing direct
inspection in the order of probability.
This troubleshooting chart marks the content of the

questions and check items with E, Q or w accord-
ing to their closer relationship with the causes.
E : A cause that can be referred to in relation to
the question or check item.
Q : A cause that is related to the question or check
item.
w : A cause particularly probable among those
marked with Q above.
a Count the priority level of each marking as w >
Q when determining the cause.
Don't count E when determining the cause.
The item with this marking may be counted,
however, if no difference is present than this
and the cause cannot be determined.
WA450-6, WA480-6 (KA SPEC.) 3

<Example of troubleshooting> Exhaust smoke is black (incomplete combustion)

Let us now assume that a defect, “Color of exhaust smoke is black” occurs, the [questions] and [check items]
are implemented, and the following 3 symptoms corresponds: [Color of exhaust gas gradually became
black.], [Power was lost gradually.] and [Red dust indicator is displayed.].
4 WA450-6, WA480-6 (KA SPEC.)

The 5 items of [causes] and the 3 items of [questions] and [check items] have a cause-and-effect relation-
ship.
The “Step 1” to “Step 3” in the below figure, will explain how to narrow down the [causes] from the cause-and
effect relationship and lead to [troubleshooting].
WA450-6, WA480-6 (KA SPEC.) 5

S-1 Starting performance is poor. 1

General causes why starting performance is poor Cause
Defective electrical system
Cracked EGR cooler (Coolant in exhaust piping)

q
q Insufficient supply of fuel
Leaking or clogged fuel piping, entry of air

Insufficient intake of air
Clogged air breather hole of fuel tank cap

Defective contact of valve and valve seat
q
Defective alternator (generator section)

Defective alternator (regulator section)
q Improper selection of fuel
Stuck, seized supply pump plunger

Coolant in exhaust piping
Defective intake air heater system

q
Defective or deteriorated battery

Clogged feed pump gauze filter
a The common rail fuel injection system (CRI) recog-
Clogged air cleaner element

nizes the fuel injection timing electrically. Accordingly,
Clogged fuel filter, element

Worn piston ring, cylinder
even if the starting operation is carried out, the engine
may not start until the crankshaft revolves 2 turns at
Defective injector
maximum. This phenomenon does not indicate a trou-
ble, however.
Confirm recent repair history

Degree of use of machine Operated for long period E E E E E
Became worse gradually Q Q w w Q Q
Starting performance
Engine starts easily when warm w w
Non-specified fuel is being used Q Q Q Q
Questions
Replacement of filters has not been carried out according to Operation and Main-
w w w Q Q
tenance Manual
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does
w
not indicate normally (if monitor is installed)
During operation, charge level monitor indicates abnormal charge (if monitor is
w w
installed)
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Starting motor cranks engine slowly Q w
If air bleeding plug of fuel filter is removed, fuel does
w w
While engine is cranked not flow out
with starting motor If spill hose from injector is disconnected, little fuel
Check items
w
spills
When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze
q
flows out (*1)
When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter, strainer directly q
Troubleshooting
Inspect gauze filter of feed pump directly q

Carry out troubleshooting by failure code “Loss of pressure feed from supply
q
pump (*2)”
When a cylinder is cut out for reduced cylinder mode operation, engine speed
q
does not change with some cylinders
When starting switch is turned to HEAT, intake air heater mount does not become
q
warm
Is voltage 20 – 30 V between alternator terminal R and terminal E Yes q
with engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are
q
low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
6 WA450-6, WA480-6 (KA SPEC.)

*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of gas piping to EGR cooler outlet and check the flowout of coolant.
Condensed water from cooled exhaust gas may come out in small quantity but it poses no problem if col-
orless and transparent.
*2: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
WA450-6, WA480-6 (KA SPEC.) 7

S-2 Engine does not start 1

a) Engine does not crank Cause
Cracked EGR cooler (coolant mixing in the exhaust)

General causes why engine does not turn
Seizure inside engine
Defective starting motor (Safety relay section)

q
o See the troubleshooting for “S-4 Engine stops during opera-
tions”.
Defective starting motor (Motor section)

Defective battery terminal connection
q Coolant mixing inside cylinder causing water hammer
Electrical system is not normal
Defective wiring of starting circuit

q

q Defective drive unit on applicable machine side
Damaged flywheel ring gear

o Carry out troubleshooting on applicable machine side
Defective starting switch

Defective battery relay
Check recent repair history
Questions
Degree of machine
Machine operated for long period EEE
operation
Condition of horn when Does not sound. Q Q w
starting switch is turned ON Horn volume is low w
Battery electrolyte level is low w
Battery terminal is loose w
No operating sound from battery relay when starting switch is turned ON Q w
When starting switch is turned to START, pinion does not move out Q Q w
Check items
Speed of rotation is low Q w

When starting switch is set Makes grating noise w w
to START, the starting pin-
ion comes out, but Soon disengages pinion again w
Makes rattling noise and does not turn w Q Q w
Removing EGR cooler outlet gas piping causes coolant containing antifreeze to flow out
q
Carry out troubleshooting in E-mode
(*1)
Inspect flywheel ring gear directly q
Specific gravity of electrolyte and voltage of battery are low q
Troubleshooting
There is no voltage (20 – 30 V) between battery relay

q
terminal B and terminal E
Turn the starting switch When terminal B and terminal C of starting switch are
q
OFF, connect the cord, then connected, engine starts
turn starting switch ON and When the safety relay outlet terminal B and terminal C
carry out troubleshooting q
are connected, engine starts
When the safety relay outlet terminal B and terminal C
q
are connected, engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
8 WA450-6, WA480-6 (KA SPEC.)


WA450-6, WA480-6 (KA SPEC.) 9

b) Engine turns but no exhaust smoke comes out Cause
Defective operation of overflow valve (not closing)

General causes why engine turns but no exhaust smoke
comes out
Fuel is not being supplied
Clogged air breather hole in fuel tank cap

q
Seizure or abnormal wear of feed pump
Wrong connection of supply pump PCV

q Supply of fuel extremely small
Stuck or seized supply pump plunger

Leakage, clogging, air in fuel piping
Improper selection of fuel (particularly in winter)
Defective operation of flow damper

q
Broken supply pump shaft, key
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Improper fuel used
Degree of machine
Questions
Machine operated for long period EEE

operation
Exhaust smoke suddenly stops coming out (when starting again) w Q w w w EE
Replacement of filters has not been carried out according to Operation
w w E Q
& Maintenance Manual
Fuel tank is found to be empty w
Clogged air breather hole in fuel tank cap Q w
Rust and water are detected when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, no fuel is inside the fuel filter w w
Leakage from fuel piping w
Check items
No response or heavy resistance felt when operating priming pump w Q Q

and the air breathing plug is removed from
Q Q w Q
When engine is cranked the fuel filter, fuel fails to discharge
with starting motor, Spill flow drops, when spill hose is separated
Q w w w w Q
from injector
Air is discharged when the air is bled from the fuel system q
Inspect the fuel filter directly q
Troubleshooting
Inspect fuel feed pump gauze filter directly q

Inspect feed pump directly q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q q q q
Carry out troubleshoot by “PCV1 Error (:2) or PCV2 Error (*3)” q
Inspect overflow valve directly q
Engine can start when operated in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Add
Remedy
10 WA450-6, WA480-6 (KA SPEC.)

c) Exhaust smoke comes out but engine does not start Cause
(Fuel is being injected)
Defective coolant temperature sensor or defective wiring harness

General causes why exhaust smoke comes out but engine
does not start
q Rotating force in short due to defective electrical system
Supply of fuel small
Wear of valve system (valve, rocker lever, etc.)

q
q Small air intake
Clogged injection nozzle, defective spray


Defective intake air heater system

Worn piston ring, cylinder liner
Clogged fuel filter, strainer

Improper fuel used
Degree of machine
Machine operated for long period E E E E
operation
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

Replacement of filters has not been carried out according to Operation & Maintenance
w w w
Manual
Engine oil replenishment increasing w
Preheat monitor not indicating normal operation during preheating or at low temper-
w
ature (when monitor installed)
Dust indicator turned red (with indicator installed) w
Clogged air breather hole in fuel tank cap Q
Rust and water are detected when fuel tank is drained w w
When fuel filter is removed, no fuel is inside the fuel filter w
Starting motor cranks engine slowly w
When engine is cranked, abnormal noise is heard from around cylinder head w
Check items
When engine is and the air breathing plug is removed from the fuel filter, fuel
Q w w
cranked with starting fails to discharge
motor, Spill flow drops, when spill hose is separated from injector w
When exhaust manifold is touched immediately after starting engine, temperature of
w
some cylinders is low

Inspect valve system directly q
When compression pressure is measured, the oil pressure is low q
Troubleshooting
Inspect the fuel filter, strainer directly q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q
Testing a single unit injector indicates defective spraying q
Specific gravity of electrolyte and voltage of battery are low q
Coolant temperature gauge indication is not normal (when the gauge is installed) q
Intake air heater mount does not warm up during preheating operation q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
WA450-6, WA480-6 (KA SPEC.) 11

S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Cause
q Insufficient intake of air
Defective operation of flow damper (excessive injector leakage)

q Fuel injection condition not normal
q Controller in derate control mode
(Controlling injection capacity (output) due to an error in
the electrical system)
Clogged injection nozzle, defective spray

Seizure or interference of turbocharger

q EGR valve is stuck in open state

(Shortage of air intake due to excessive EGR gas)


Improper valve clearance
Stuck EGR valve
Degree of machine
Machine operated for long period E E E E E E
operation
Questions
Engine pick-up suddenly became poor Q w Q Q Q

Non-specified fuel is being used w w w w
Replacement of filters has not been carried out according to Operation & Maintenance
w w w
Manual
Engine oil replenishment increasing w
Dust indicator is red (with indicator installed) w
Clogged air breather hole in fuel tank cap w
Q w
Blue under light load w
Color of exhaust gas
Check items
Black w Q w w
When engine is cranked, abnormal noise is heard from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q

Carry out troubleshoot by “EGR Valve Servo Error (*1)” q
When compression pressure is measured, the oil pressure is low q q
Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
Speed of some cylinders does not change when operated in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
12 WA450-6, WA480-6 (KA SPEC.)

S-4 Engine stops during operation 1

General causes why engine stops during operations Cause
q Seizure inside engine
Broken auxiliary equipment (pump, compressor, etc.)

Breakage of valve system (valve, rocker lever, etc.)
q Overheating
q Defective drive unit on applicable machine side:

o Carry out troubleshooting on applicable machine
Broken, seized piston or connecting rod

side.
Broken, seized crankshaft metal
Leakage, clogging in fuel piping
Broken supply pump shaft, key

Broken, seized feed pump
Broken, seized gear train
Defective power train

Degree of machine
Machine operated for long period E E
operation
Abnormal noise was heard and engine stopped sud-
w w w w Q w Q w w
denly
Questions
Condition when Engine overheated and stopped w Q Q

engine stopped
Engine stopped slowly w Q Q
There was hunting and engine stopped w Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation &
w w
Maintenance Manual
Fuel level monitor indicates low fuel level (with monitor installed) w
Fuel tank is found to be empty w
Metal particles are found when oil pan is drained w w Q Q
Check items
Does not turn at all w w

When engine is Turns in opposite direction w
cranked manually Moves by the amount of gear backlash w w
Supply pump shaft does not turn w
Engine rotates, but stops when loaded on the machine side w

Carry out troubleshooting
Inspect piston and connecting rod directly. q

q
Troubleshooting
Inspect crankshaft metal directly

in the H-mode.
Inspect gear train directly q

Inspect feed pump directly q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q q
Engine rotates when auxiliary equipment (pump, compressor) is removed q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Add
Remedy
—
WA450-6, WA480-6 (KA SPEC.) 13

S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly: Causes
q Air in fuel system
Defective operation of flow damper (Excessive leakage from injector)

q Defective speed sensor (Error at degree that it is not indicated)
q Defective EGR valve
Clogged injector, defective spray (dirt in injector)
Defective Bkup speed sensor or wiring harness

Defective Ne speed sensor or wiring harness
Leaking or clogged fuel piping, entry of air
Defective operation of EGR valve

Low idle speed is set too low.
Clogged fuel filter or strainer

Confirm recent repair history.
Degree of use of machine Operated for long period E E E
Occurs at a certain speed range Q Q Q Q
Questions
Occurs at low idle. w Q Q Q Q Q Q Q

Condition of hunting
Occurs even when speed is raised Q Q Q Q
Occurs on slopes w Q Q
Replacement of filters has not been carried out according to Operation and Main-
w w
tenance Manual.
When fuel tank is inspected, it is found to be empty. w
Air breather hole in fuel tank cap is clogged. w
Check items
Rust or water are observed when fuel tank is drained. Q Q

Fuel is leaking from fuel piping. w
When priming pump is operated, it makes no reaction or it is heavy. w Q Q
Carry out troubleshooting by failure code “Abnormal EGR valve servo (*1)”. q
When air is bled from fuel system, air comes out q
Inspect feed pump gauze filter directly q
Troubleshooting
Inspect fuel filter and strainer directly. q

When a specific cylinder is cut out for reduced cylinder mode operation, engine
q q
speed does not change.
Carry out troubleshooting by failure code “Abnormal engine Ne speed sensor
q
(*2)”
Carry out troubleshooting by failure code “Abnormal engine Bkup speed sensor
q
(*3)”
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Clean
Clean
Refill
Remedy
*1: Failure codes [CA1228] and [CA1625]

*2: Failure code [CA689]
*3: Failure code [CA778]
14 WA450-6, WA480-6 (KA SPEC.)

S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Cause
Defective fuel temperature sensor or defective wiring harness

Defective charge pressure sensor or defective wiring harness
Defective mounting of charge pressure sensor (air leak)

q Overheating
Defective drive of injector (signal or solenoid)

o See the troubleshooting for “S-14 Coolant

Clogged fuel injector, defective injection

temperature too high (Overheat)”

(Controlling injection capacity (output) due to an
Leakage, clogging in fuel piping

Air leakage from air intake pipe

error in the electrical system)

Confirm recent repair history
Degree of use of machine Operated for long period E E E E E
Suddenly Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q Q
Replacement of filters not carried out according to Operation & Maintenance
w
Manual
Engine oil must be added more frequently Q Q Q
Output reduces after a break w
Black w w
When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low
Check items
When engine is cranked, interfering noise is heard from around turbocharger w

High idle speed of engine is low Q
High idle speed under no load is normal, but speed suddenly drops when load
w w Q
is applied
Engine does not pick up smoothly, and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q
Inspect intake air piping directly q
When boost pressure is measured, the oil pressure is low q q q
Troubleshooting

Inspect fuel filter, strainer directly q
Check the mount of boost pressure sensor directly q
Carry out troubleshoot by “Chg Air Press Sensor Error (*2)” q
Carry out troubleshoot by “Fuel Temp Press Sensor Error (*3)” q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
WA450-6, WA480-6 (KA SPEC.) 15

S-7 Exhaust smoke is black (Incomplete combustion) 1

General causes why exhaust smoke is black Cause

Air leakage between turbocharger and cylinder head

Overheating
Clogged fuel spill piping (on the cylinder head side)

q
o See the troubleshooting for “S-14 Coolant
temperature too high (Overheat)”
Defective contact of valve or valve seat

(Controlling injection capacity (output) due to an

Clogged EGR gas pressure piping
error in the electrical system)

q EGR valve is stuck in open state
Improper injection pressure

(Shortage of air intake due to excessive EGR
Abnormal wear of injector

Crushed, clogged muffler
Improper injection timing

Clogged, seized injector
gas)
q Clogged EGR gas pressure piping
Stuck EGR valve

(Entry of exhaust gas in intake air at accelera-
tion and deceleration)

Degree of machine
Machine operated for long period E E E E E
operation
Suddenly became black w Q Q Q Q
Questions
Color of exhaust gas Gradually became black w w Q Q Q

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Leakage of air between turbocharger and cylinder head, loose clamp w
Operated in low-temperature mode during normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine,
Q w
temperature of some cylinders is low
Check items

Torque converter stall or high pump relief speed (excessive fuel injection) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly, and combustion is irregular Q Q Q Q Q Q w
Spill flow is excessive when spill hose is separated from injector w
Carry out troubleshoot by “EGR Valve Servo Error (*1)” q
Inspect EGR gas pressure piping directly (*2) q
Troubleshooting

When muffler is removed, exhaust color returns to normal q
Carry out troubleshoot by “Rail Press Very Low Error (*3)” q q
Speed of some cylinders does not change when operated in reduced cyl-
q
inder mode
Inspect fuel spill piping (on the cylinder head side) directly q
Carry out troubleshoot by “Coolant Temp Sensor Error (*4)” q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
16 WA450-6, WA480-6 (KA SPEC.)

*2: EGR gas pressure piping
Remove 2 EGR gas pressure pipes (2) and check the clogging in the inside.
WA450-6, WA480-6 (KA SPEC.) 17

S-8 Oil is consumed much (or exhaust gas color is blue) 1

General causes why oil consumption is excessive Cause
q Abnormal oil combustion
Turbocharger
Worn or damaged valve (stem, guide, and seal)
q Extended operation for long hours in low or high
idle (continuous no load operation for 20 minutes
Leakage from oil pan, cylinder head, etc.

and longer inhibited)
q Oil leakage to outside
Clogged breather or breather hose

Dust sucked in from intake system
Wear of lubricating system
Worn, damaged rear seal surface

Oil leakage from EGR valve stem
q
Leakage from oil drain plug

Wear of seal at blower end
Worn seal at turbine end
Leakage from oil cooler
Leakage from oil piping

Leakage from oil filter
Broken piston ring
Broken oil cooler

Degree of machine
Questions
Machine operated for long period EEEE E

operation
Oil consumption suddenly increased w Q
Engine oil must be added more frequently Q w Q
Engine oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
Pipe clamps for intake system are loose w
Inside of turbocharger air intake outlet pipe is contaminated with oil w
Inside of turbocharger exhaust outlet pipe is contaminated with oil Q w
Check items
There is oil in the coolant w

Oil level in clutch or damper chambers on increasing w
Color of exhaust gas blue under light load Q w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is contaminated abnormally q
Excessive play of turbocharger shaft q q
Troubleshooting
When EGR valve is removed, exhaust port is contaminated with oil q

Inspect breather, breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
18 WA450-6, WA480-6 (KA SPEC.)

S-9 Engine oil becomes contaminated quickly 1

General causes why oil becomes contaminated quickly Cause
q Entry of exhaust gas due to internal wear
Clogged lubricating drain tube of turbocharger

q Clogging of lubrication route
Defective seal at turbocharger turbine end

q Improper fuel is being used
q Improper oil is being used
q Operated under excessive load
Clogged breather, breather hose

Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is black

Worn EGR valve guide
Clogged oil cooler

Clogged oil filter
Degree of machine
Machine operated for long period EEEE
Questions
operation
Non-specified fuel is being used Q
Engine oil replenishment increasing Q w
Oil filter clogging monitor indicates clogging when the oil temperature rises (with the
w Q
monitor installed)
Metal particles are found when oil is drained in oil filter Q Q w
Inside of exhaust pipe is contaminated with oil w
Engine oil temperature rises quickly w
Check items

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

When EGR valve is removed, exhaust port is contaminated with oil q
Troubleshooting
When compression pressure is measured, the oil pressure is low q q (See S-7)
Inspect breather, breather hose directly q
Inspect oil cooler directly q
Inspect oil filter directly q
There is catching or breakage to the oil filter safety valve spring q
Inspect turbocharger lubricating drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
—
WA450-6, WA480-6 (KA SPEC.) 19

S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Cause
q Leakage of fuel

q Fuel injection condition (fuel pressure and injection timing) not nor-
mal
q Excessive fuel injection
Fuel leakage from fuel filter, piping, etc.
Defective common rail fuel pressure

Leakage of fuel inside head cover
Defective supply pump plunger

Defective feed pump oil seal
Defective injector operation

Defective injector spray
Questions
Degree of machine operation Machine operated for long period EE E

More than for other machines of same model Q Q Q Q
Condition of fuel
Gradually increased Q Q
consumption
Suddenly increased Q Q
Fuel leakage to outside w
There is irregular combustion w
Oil increasing of smelling of diesel oil w w
w
Check items
Low idle speed is too high Q

Torque converter stall or hydraulic pump relief speed is high Q
Black Q Q Q Q
White Q
Remove head cover and inspect directly q

Inspect feed pump oil seal directly q
Troubleshooting

Speed of some cylinders does not change when operated in reduced cylinder mode q
Spill flow is excessive when spill hose is separated from injector q
Carry out troubleshoot by “Coolant Temp Sensor Error (*2)” q
Check by the monitoring function q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
20 WA450-6, WA480-6 (KA SPEC.)

S-11 Coolant contains oil (blows back or reduces) 1

General causes why oil in coolant Cause
q Internal leakage of lubricating system
Hole drilled by damages or pitching of cylinder liner O-ring

q Internal leakage of cooling system
Broken hydraulic oil cooler, power train oil cooler

Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Internal cracks in cylinder block
Broken oil cooler core, O-ring

Questions
Degree of machine operation Machine operated for long period E E

Suddenly increased Q Q Q
Oil level
Hard water is being used as coolant Q Q
Oil level has risen, oil is milky Q Q w
Excessive air bubbles inside radiator, coolant spurts back w w
Check items
Hydraulic oil or power train oil is milky w
When hydraulic oil or power train oil is drained, water is discharged w
Pressure-tightness test of cylinder head shows there is leakage q

Troubleshooting
Carry out
Inspect cylinder block, liner directly q q troubleshooting
Inspect cylinder liner directly q on applicable
machine side
Replace
Replace
Replace
Replace
Replace
Remedy
—
WA450-6, WA480-6 (KA SPEC.) 21

S-12 Oil pressure drops 1

General causes why oil pressure drops Cause
q Leakage, clogging, wear of lubrication system
Defective hydraulic sensor or defective wiring harness

Defective oil level sensor or defective wiring harness
q Hydraulic control is not normal
Leakage, crushing or clogging of hydraulic piping

q Wrong fuel selection (viscosity not appropriate)
q Oil deteriorated by overheating
Clogging or breakage of pipe inside oil pan
Leakage from EGR hydraulic piping

Clogged strainer inside oil pan
Defective oil pump relief valve
Defective EGR oil pump

Wear of metal journal
Lack of oil in oil pan
Defective oil pump
Clogged oil filter

Water, fuel in oil
Degree of machine
Machine operated for long period E E E E
Questions
operation
Oil pressure monitor indicates low pressure level (with monitor installed) Q w
Replacement of filters has not been carried out according to Operation &
w
Maintenance Manual
Indicates a drop of hydraulic pressure during low idle w Q Q
Oil pressure monitor Indicates a drop of oil pressure during low and high Q w w w Q Q Q
(With monitor idle
installed) Indicates a drop of oil pressure on a slope w
Indicates a drop of oil pressure occasionally w Q Q
Oil level monitor indicates low level (with monitor installed) w w
Oil pan oil level is in short w
Leakage or crushing with external hydraulic piping w w
Check items
Oil is cloudy white or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil is drained from oil filter w Q Q
Metal particles are detected in oil filter q

Inspect oil pan strainer, pipe directly q q
Oil pump rotation is heavy, there is play q
Troubleshooting
Oil pump relief valve, spring is fatigued or damaged q

See S-13
Inspect oil filter directly q

Relief valve of EGR oil pump is damaged or has oil leak q
Inspect EGR hydraulic piping directly q
Carry out troubleshoot by “Eng Oil Press Sensor Error (*1)” q
Replacing the oil level sensor will cause the oil pressure monitor to be dis-
q
played normally.
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Add
Remedy
—
22 WA450-6, WA480-6 (KA SPEC.)

S-13 Oil level rises (Water, fuel in oil) 1

General causes why oil level rises Cause
q Coolant mixing in the oil (oil turns cloudy)
Clogging of water pump drain hole (breather hole) or defective seal

q Fuel in oil (smells diluted diesel fuel)
a If oil mixes with the coolant, carry out troubleshooting by “S-11
Defective seal of auxiliary equipment (pump or compressor)

Coolant contains oil”

Cracked EGR cooler (mixing of coolant)
Leakage of fuel inside head cover
Worn, damaged rear seal surface

Internal cracks in cylinder block
Broken oil cooler core, O-ring
Defective thermostat sheet

Defect inside supply pump
Questions
Degree of machine operation Machine operated for long period EE E E

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q w
There is oil in the coolant Q Q Q w
Engine oil smells of diesel fuel w w
Oil is milky Q Q w
After starting engine, drops of water come from muffler Q Q
Leave radiator cap open. When engine is run at idle, an abnormal number of bub-
w Q
bles appear or water spurts back
Check items
Exhaust gas is white Q Q

Clogged water pump drain hole (breather hole) w
Water comes out when water pump drain hole (breather hole) is cleaned w
Oil level in clutch or damper chambers on applicable machine side decreasing w
Hydraulic tank oil level is decreasing w
Removing EGR cooler outlet gas piping causes coolant containing antifreeze to
q
flow out (*1)
Remove head cover and inspect directly q
Troubleshooting
Inspect cylinder block, liner directly q q

Inspect rear oil seal directly q
Remove water pump and inspect directly q
Remove thermostat cover and inspect directly q
Remove supply pump and inspect directly q
Inspect the seal of auxiliary machine directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
WA450-6, WA480-6 (KA SPEC.) 23


24 WA450-6, WA480-6 (KA SPEC.)

S-14 Coolant temperature rises too high (Overheating) 1

General causes why coolant temperature becomes too Cause
high

q Lack of cooling air (deformation, damages of fan)
q Drop in heat dissipation efficiency
q Defect in the coolant circulation system
q Power train oil temperature on applicable machine
side is rising:
Defective radiator cap (pressure valve)

o Carry out troubleshoot on applicable machine side
Slipping of fan belt, wear of fan pulley

Water leakage to outside EGR cooler
Defective coolant temperature gauge

Rise of power train oil temperature

Defective operation of thermostat
Clogged, crushed radiator fins
Clogged, broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Degree of machine
Machine operated for long period E E E E E
Questions
operation
Suddenly increased Q Q w Q
Condition of overheating
Always tends to overheat Q w w Q
Coolant temperature gauge Rises quickly Q w
(when installed) Does not go down from red range w
Radiator coolant level monitor indicates low level (with monitor installed) Q w
Engine oil level has risen, oil is cloudy white w Q
Fan belt tension is low w
Turning the fan pulley causes a looseness. w
Cloudy white oil is floating on coolant w
Excessive air bubbles inside radiator, coolant spurts back w
When light bulb is held behind radiator, no light passes through w
Check items
Radiator shroud and inside of underguard are clogged with dirt or mud w w
Coolant leakage from cracks in the radiator hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden load w
Power train oil temperature gauge enters red range faster than engine coolant
temperature gauge (when oil temperature and coolant temperature gauge are w
installed)
Inspect coolant leakage from EGR cooler directly q

Inspect cylinder liner directly q
Carry out troubleshooting on
applicable machine side
Inspect oil cooler directly q

Troubleshooting
Temperature difference between top and bottom radiator tanks is excessive q

When function test is carried out on thermostat, it does not open even at crack-
q
ing temperature
Temperature difference between top and bottom radiator tanks is slight q
Inspect radiator core directly q
When function test is carried out on the radiator cap, cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy
—
WA450-6, WA480-6 (KA SPEC.) 25

S-15 Abnormal noise is made 1

General causes why abnormal noise is made Cause
q Abnormality due to defective parts
Defective fuel injection timing (abnormal low coolant temperature sensor)

q Abnormal combustion
q Air sucked in from intake system
a Judge if noise is from inside or outside before proceed-
ing with troubleshooting
a When engine is not fully warmed up, engine noise rises
slightly because of operation in the low temperature
Air leakage between turbocharger and cylinder head
Defect inside muffler (dividing board out of position)

Breakage of valve system (valve, rocker lever, etc.)
mode. This is not abnormal, however.
a When engine is accelerated, it enters acceleration mode,
Cracks or gas leakage from EGR gas piping
Deformed fan, loose fan belt or interference

Excessive wear of piston ring, cylinder liner
where engine noise remains slightly higher for about 5

seconds maximum. This is not abnormal, however.
Missing, seized gear train bushing

Improper gear train backlash
Dirt caught in the injector

Clogged, seized injector
Degree of machine operation Machine operated for long period E
Questions
Condition of abnormal noise
Suddenly increased Q Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil is drained in oil filter w w
Leakage of air between turbocharger and cylinder head w
When engine is cranked, abnormal noise is heard from around EGR gas piping w
When engine is cranked, abnormal noise is heard from around cylinder head w w
When engine is cranked, abnormal noise is heard from around muffler w
Check items

w Q
Black Q w Q
Engine pickup is poor and combustion is abnormal w
Abnormal noise is loud when accelerating engine Q Q Q Q

Inspect EGR gas piping directly q
Troubleshooting
When muffler is removed, abnormal noise disappears q

Inspect gear train directly q q
Inspect fan and fan belt directly q
Abnormal noise is emitted only when starting engine q
Check by the realtime monitoring function q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
26 WA450-6, WA480-6 (KA SPEC.)

S-16 Vibration is excessive 1

General causes why vibration is excessive Cause
q Defective parts (abnormal wear, breakage, etc.)
Breakage of damper or power train output shaft

Loose engine mounting bolts, broken cushion
q Alignment with applicable machine side is not normal
Stuck valve system (valve, rocker lever, etc.)

q Abnormal combustion
Wear of front support spigot joint portion

a If there is abnormal noise together with the vibration, carry out trou-
Worn main metal, connecting rod metal

bleshooting also for “S-15 Abnormal noise is made”.
Center of engine and power train

Improper gear train backlash

Worn camshaft bushing
Questions
Degree of machine operation Machine operated for long period E E E E

Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q Q
Metal particles are found when oil is drained in oil filter w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q Q
Exhaust smoke color is black w

Inspect main metal, connecting rod metal directly q
Inspect gear train directly q
Troubleshooting
Inspect camshaft bushing directly q

Check by the realtime monitoring function q
Inspect engine mount bolt, cushion directly. q
When face runout and radial runout are inspected, they are found to be incorrect q
Inspect front support spigot directly q
Inspect inside of output shaft or damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Remedy
WA450-6, WA480-6 (KA SPEC.) 27

SEN01690-00

28
SEN00821-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Hydraulic diagrams and drawings................................................................................................................... 2
Power train hydraulic circuit diagram ................................................................................................... 2
Hydraulic circuit diagram...................................................................................................................... 5
WA450-6 WA480-6 (KA SPEC.) 1

SEN00821-00 90 Diagrams and drawings
Hydraulic diagrams and drawings 1

Power train hydraulic circuit diagram 1
2 WA450-6 WA480-6 (KA SPEC.)

With lockup clutch
WA450-6 WA480-6 (KA SPEC.) 3

4 WA450-6 WA480-6 (KA SPEC.)

Hydraulic circuit diagram
Hydraulic circuit diagram WA450-6, WA480-6 (KA SPEC.) 1
SEN00821-00
WA450-6, WA480-6 (KA SPEC.) 5
WA450-6 WA480-6 (KA SPEC.) 7

SEN00821-00

8
SEN00822-00
WA450-6
WA480-6
(KA SPEC.)

WA450-6 66001 and up
WA480-6 85001 and up
(KA SPEC.)
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical diagrams and drawings ................................................................................................................... 3
Electrical circuit diagram (1/2).............................................................................................................. 3
Electrical circuit diagram (2/2).............................................................................................................. 5
WA450-6, WA480-6 (KA SPEC.) 1

2 WA450-6, WA480-6 (KA SPEC.)

Electrical circuit diagram (1/2)
Electrical diagrams and drawings WA450-6, WA480-6 (KA SPEC.)
SEN00822-00
WA450-6, WA480-6 (KA SPEC.) 3
WA450-6, WA480-6 (KA SPEC.)
SEN00822-00
WA450-6, WA480-6 (KA SPEC.) 5
WA450-6, WA480-6 (KA SPEC.) 7

SEN00822-00


SM Wa480 & 450-6 Sen00809-01d

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Copyright 2006 Komatsu

WHEEL LOADER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual................................................................................................................ 2

WA450-6, WA480-6 (KA SPEC.) 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00809-01

00 Index and foreword SEN00810-01

10 Structure, function and maintenance standard SEN00812-00

20 Standard value table SEN00813-01

30 Testing and adjusting SEN00814-00

2 WA450-6, WA480-6 (KA SPEC.)

Troubleshooting by failure code (Display of code), Part 5 SEN01682-00 Q

90 Diagrams and drawings SEN00817-00

WA450-6, WA480-6 (KA SPEC.) 3

Foreword and general information SEN00819-00

10 Structure, function and maintenance standard

4 WA450-6, WA480-6 (KA SPEC.)

Stop valve ................................................................................................................................ 36

WA450-6, WA480-6 (KA SPEC.) 5

Electrical system, Part 3 SEN01180-00

20 Standard value table

30 Testing and adjusting

6 WA450-6, WA480-6 (KA SPEC.)

Measuring brake pedal ............................................................................................................ 7

WA450-6, WA480-6 (KA SPEC.) 7

8 WA450-6, WA480-6 (KA SPEC.)

Failure code [CA449] Common rail pressure high error 2 ....................................................... 43

WA450-6, WA480-6 (KA SPEC.) 9

Failure code [DAQ9KQ]

10 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 11

12 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 13

90 Diagrams and drawings

14 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 15

WA450-6, WA480-6 (KA SPEC.) Wheel loader

WHEEL LOADER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

WA450-6, WA480-6 (KA SPEC.) 1

Foreword and general information (Rev. 2005/11)

1. General precautions 7) If welding repairs are needed, always

2 WA450-6, WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 3

4. Precautions for sling work and making

4 WA450-6 WA480-6 (KA SPEC.)

WA450-6, WA480-6 (KA SPEC.) 5

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

6 WA450-6 WA480-6 (KA SPEC.)

q Revised edition mark

Symbol Item Remarks