Wa430 6H

VEBM350100
(KOHAG SPEC.)
Machine model Serial number
WA430-6 H50051 and up
• This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• WA430-6 mount the SAA6DE114-2 engine.
Notes: CETC-2 informed to KGS on May 18 that EPC control lever was abolished for
KOHAG specification.
Therefore could you please remove the related items when issuing this manual.
© 2005
All Rights Reserved
Printed in Europe 06-05 (01)
Contents
No. of page
00 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-3
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-1
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . .10-1
20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . .20-1
30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . .30-1
90 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-1
00-2 WA430-6
SAFETY SAFETY NOTICE
Safety
Safety notice
Important safety notice
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
General precautions 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always Preparations for work
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
WA430-6 00-3
SAFETY SAFETY NOTICE
Precautions during work 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4 WA430-6
FOREWORD GENERAL
Foreword
General
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
Structure and function and maintenance standard

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

These sections explain checks to be made before and after performing repairs, as well as adjustments
to be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
Disassembly and assembly

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
Notice
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
WA430-6 00-5
FOREWORD HOW TO READ THE SHOP MANUAL
How to read the shop manual Symbols
Volumes So that the shop manual can be of ample practical

Shop manuals are issued as a guide to carrying out use, important safety and quality portions are
repairs. They are divided as follows: marked with the following symbols.
Chassis volume: Issued for every machine model

Engine volume: Issued for each engine series
Electrical volume: Symbol Item Remarks
Attachments volume:
k
Special safety precautions
Safety are necessary when per-
forming the work.
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with Special technical precau-
a
all repairs for any model , it is necessary that chas- tions or other precautions
sis, engine, electrical and attachment volumes be Caution for preserving standards
available. are necessary when per-
forming the work.
Distribution and updating Weight of parts of sys-
4
Any additions, amendments or other changes will be tems. Caution necessary
sent to KOMATSU distributors. Get the most up-to- Weight when selecting hoisting
date information before you start any work. wire, or when working pos-
ture is important, etc.
3
Places that require special
Tightening
attention for the tightening
torque
torque during assembly.
2
Places to be coated with
Coat adhesives and lubricants,
etc.
5
Places where oil, water or
Oil, water fuel must be added, and
the capacity.
6
Places where oil or water
Drain m u st b e d ra i n e d , a n d
quantity to be drained.
00-6 WA430-6
FOREWORD HOISTING INSTRUCTIONS
Hoisting instructions
Hoisting
k Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
with a hoist, etc. In the Disassembly and a serious accident can result. Hooks have max-
assembly section, every part weighing 25 imum strength at the middle portion.
kg or more is indicated clearly with the
symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
k Slinging with one rope may cause turning

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

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

hook.
WA430-6 00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Method of disassembling, connecting push-pull type coupler
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see Testing and adjusting, Releas-
ing residual pressure from hydraulic tank.
k Even if the residual pressure is released from

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

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

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

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

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8 WA430-6
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
WA430-6 00-9
FOREWORD COATING MATERIALS
Coating materials
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10 WA430-6
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to

LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR
Adhesive for cab glass
• Used as primer for sash (Alumite).

Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
WA430-6 00-11
FOREWORD STANDARD TIGHTENING TORQUE
Standard tightening torque

Standard tightening torque table (when using torque wrench)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

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

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

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

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
Table of tightening torques for flared nuts

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

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12 WA430-6
Table of tightening torques for split flange bolts

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
Table of tightening torques for o-ring boss piping joints

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

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

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
Table of tightening torques for o-ring boss plugs

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

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

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
WA430-6 00-13
Tightening torque for 102 and 114 engine series

1) Bolt and nuts
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 0± 12 7.85 ± 1.22
2) Eye joints
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) Tapered screws
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
Tightening torque table for hoses (taper seal type and face seal type)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Nominal thread
Thread size Root diameter
Range Target (mm) size - Threads per (mm) (Reference)
inch, Thread series
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14 WA430-6
FOREWORD ELECTRIC WIRE CODE
Electric wire code

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
Classification by thickness
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm 2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Classification by color and code
Circuits
Priori-
Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1
mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Green Yellow Blue & Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
WA430-6 00-15
FOREWORD CONVERSION TABLE
Conversion table
Method of using the conversion table

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
Example
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in
0 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)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16 WA430-6
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
WA430-6 00-17
Liter to U.S. Gallon

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

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

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

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18 WA430-6
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
WA430-6 00-19
kg/cm 2 to lb/in2
1kg/cm 2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20 WA430-6
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

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

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
WA430-6 00-21
FOREWORD UNITS
Units
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 WA430-6
01 GENERAL
Specification dimension drawing...................... 01-2
Specifications ................................................... 01-3
Weight table ..................................................... 01-7
Table of fuel, coolant and lubricants................. 01-8
WA430-6 01-1
GENERAL SPECIFICATION DIMENSION DRAWING
Specification dimension drawing
WA430-6
Item Unit
(In P-mode)
Machine weight kg 19,000
Normal load kN {kg} 55.0 {5,600}
Bucket capacity m3 3.3
Engine model name – Komatsu SAA6D114-2 Diesel engine
Engine rated output (NET) kW {HP} /rpm 173 {232} /2,000
A Overall length mm 8,521
B Overall height mm 3,380
C Bucket lifting height mm 5,597
D Overall width mm 2,770
E Minimum ground clearance mm 455
F Bucket width mm 2,990
G Dumping clearance Bucket tip/BOC tip mm 3,105/3,015
H Dumping reach Bucket tip/BOC tip mm 1,105/1,150
I Dumping angle deg. 48
Bucket tip/BOC tip mm 6,575/6,610
Min. turning radius
Center of outside tire mm 6,035
1st km/h 7.0
2nd km/h 12.3
Forward
3rd km/h 21.6
4th km/h 37.2
Travel speed
1st km/h 7.6
2nd km/h 12.9
Reverse
3rd km/h 23.0
4th km/h 39.4
a BOC: Abbreviation for Bolt-On Cutting edge
01-2 WA430-6
GENERAL SPECIFICATIONS
Specifications
Machine model name WA430-6

Serial No. H50051 and up
Machine weight kg 19,000
Weight Machine weight (Front wheel) in SAE travel posture kg 9,220
Machine weight (Rear wheel) in SAE travel posture kg 9,780
Bucket capacity (Heaped) m3 3.3
Normal load kN {kg} 55.0 {5,600}
N-mode P-mode
Travel speed (Forward 1st) 5.8 7.0
(Forward 2nd) 10.2 12.3
km/h
(Forward 3rd) 18.1 21.6
(Forward 4th) 30.0 37.2
(Reverse 1st) 6.3 7.6

Perfor-
(Reverse 2nd) 10.7 12.9
mance km/h
(Reverse 3rd) 19.3 23.0
(Reverse 4th) 31.8 39.4
Max. drawbar pull (Forward) 153 {15,600} 166 {16,930}

kN {kg}
(Reverse) 143 {14,580} 155 {15,810}
Gradeability deg. 25
Min. turning radius (Center of outside tire) mm 6,035
Turning radius (Cutting edge/BOC tip)
mm 6,575/6,610
SAE travel posture
Overall length mm 8,521
Overall width (Chassis) mm 2,780
Bucket width mm 2,990
Overall height (Cab top) mm 3,380
Overall height with bucket lifted up mm 5,597
Wheelbase mm 3,300
Tread mm 2,200
Dimen- Minimum ground clearance mm 455
sions Max. hinge pin height mm 4,146
Dumping clearance (Cutting edge/BOC tip) mm 3,100/3,015
Dumping reach (Cutting edge/BOC tip) mm 1,105/1,150
Steering angle deg. 38
Bucket tilt-back angle (Operating posture) 47
deg.
(Max. height) 65
Bucket tilt-forward angle (Max. height) deg. 49
Digging depth, 10° mm 105
WA430-6 01-3

Model name SAA6D114-2
4-cycle, water-cooled, in-line 6-cylinder, direct
Type injection type with turbocharger and
air-cooled aftercooler
l {cc}
Number of cylinders - Bore x Stroke mm 6 - 114 x 135
Total displacement 8.27 {8,270}
N-mode P-mode
kW/rpm 170/1,800 173/2,000
Rated output (NET)
{HP/rpm} {229/1,800} {232/2,000}
Engine
Nm/rpm 1,016/1,300 1,016/1,300
Perfor- Max. torque (NET)
{kgm/rpm} {104/1,300} {104/1,300}
mance
g/kWh
Min. fuel consumption 202 {150} 202 {150}
{g/HPh}
Max. speed at no load rpm 1,915 ± 50 2,245 ± 50
Min. speed at no load rpm 765 (+50/0) 765 (+50/0)
Starting motor 24 V, 7.5 kW
Alternator 24 V, 60 A
Battery (*1) 24 V, 136 Ah, 2 pieces
Torque converter 3-element, 1-stage, 1-phase
Counter-shaft, helical and spur gear,
Transmission constant-mesh type
Power Multi-disc type, hydraulic type, modulating
train Reduction gear unit Spiral bevel gear type, splash lubrication type
Differential Straight bevel gear type
Planetary gear single reduction type, splash
Final drive
lubrication type
Drive wheel Front and rear wheel drive
Axle Front axle Fixed frame, semi-float type
Rear axle Center pin support type, semi-float type
Size 23.5R25EM XHA
Rim size 19.50-25/2.5 ET-40
Tire
Inflation pressure (Front wheel) kPa 350 {3.5}
(Rear wheel) {kg/cm2} 350 {3.5}
4-wheel brake, independent front and rear
Braking method
wheel brakes
Main Type of brake Enclosed wet disc type
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, released hydraulically
*1: The battery capacity (Ah) is the 5-hour rate value.
01-4 WA430-6

Steering method Articulated chassis type
Steering
Driving method Hydraulic drive
Torque converter hydraulic pump
• Type Gear type
• Discharge cm3/rev 112.9
Steering pump
• Type Variable displacement, swash plate, piston type
• Discharge cm3/rev 63
Work equipment hydraulic pump
Hydraulic
pump
• Discharge cm3/rev 90
Cooling fan pump
3
• Discharge cm /rev 30
Emergency steering pump
• Type Gear type
3
• Discharge cm /rev 21
Type Double-acting piston type
Cylinder bore mm 75
Piston rod outside diameter mm 45
Hydraulic Steering Stroke mm 442
equipment cylinder Max. distance between
mm 1,209
centers of pins
Min. distance between
mm 767
centers of pins
Cylinder bore mm 130
Lift Stroke mm 758
Cylinder
cylinder Max. distance between
mm 2,089
centers of pins
mm 1,331
centers of pins
Cylinder bore mm 150
Bucket Stroke mm 535
cylinder Max. distance between
mm 1,725
centers of pins
mm 1,190
centers of pins
WA430-6 01-5

Work equipment control valve
• Type 2-spool type
Control • Set pressure MPa {kg/cm2} 31.4 {320}
valve Steering valve
Hydraulic
• Type Spool type
equipment
• Set pressure MPa {kg/cm2} 24.5 {250}
Cooling fan motor
Motor • Type Fixed displacement, swash plate, piston type
• Motor capacity cm3/rev 28
Work Type of link Single link
equipment Shape of bucket cutting edge Straight cutting edge with BOC
01-6 WA430-6
GENERAL WEIGHT TABLE
Weight table
k This weight table is made for reference in handling or transportation of the components.
Unit: kg

Engine (excluding coolant and oil) 870
Radiator (excluding coolant) 83
Transmission (including torque converter) 845
Center drive shaft 32
Front drive shaft 31
Rear drive shaft 9.8
Front axle 1,109
Rear axle 909
Axle pivot (Rear axle) 102
Rim (1 piece) 192
Tire (1 piece) 23.5R25EM XHA 325
Steering valve 24
Steering cylinder assembly (1 piece) 23
Emergency steering pump 2.6
Emergency steering motor 13
Brake valve (Right) 8.5
Brake valve (Left) 5.3
Hydraulic tank (excluding hydraulic oil) 197
Torque converter hydraulic pump and work equipment hydraulic pump (2-unit type) 38
Steering pump 38
Work equipment PPC valve 3
Work equipment control valve 64
Lift cylinder assembly (1 piece) 141
Bucket cylinder assembly 160
Engine hood 160
Front frame 1,474
Rear frame 1,304
Bucket link 55
Bell crank 316
Lift arm (including bushing) 1,074
Bucket (2,990 mm wide) 1,704
Counterweight 1,200
Fuel tank (excluding fuel) 180
Battery (1 piece) 36
Operator's cab 700
Operator's seat 36
Air conditioner unit 12.5
Floor board 313
Oil cooler 3.9
Torque converter oil cooler 21
Cooling fan pump 25
Cooling fan motor 13
WA430-6 01-7
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
Table of fuel, coolant and lubricants

Lubricants, fuels and filling capacities
Filling
WA430-6 Lubricants and
Temperature Viscosity capaciti
operating Short term Quality grades
rangese ranges es in
mediums
litres
ACEA E7
EO 1540 A -15° up to 50° C SAE 15W-40 *)
or, if not available:
EO 1030 A -20° up to 40° C SAE 10W-30 37
Engine Engine oil DH-1
EO 30 - 0° up to 40° C SAE 30 (32 **)
API CH-4 oder
EO 10 -20° up to 10° C SAE 10W
API CI -4
Powertrain oil TO 10 - -30° up to 50° C SAE 30
ACEA E7 62
Transmission or, if not available:
Engine oil EO 10 -30° up to 40° C SAE 10W *) (54 **)
DH1
API CI-4
Powertrain oil TO 10 - -20° up to 40° C SAE 30
HO46-HM ISO 6743/4

-30° up to 40° C
Hydraulic oil HYD 0530 HVLP, HVLP D ISO VG46 *)
Hydraulic -20° up to 30° C 173
HYD 1030 ISO VG68
system (139**)
ACEA E7
SAE15W-40
or Engine oil EO 10 or, if not available: -30° up to 40° C
SAE 10W-30
API CI-4
AXO SAE 5W-30 *)

Axle oil Shell: DONAX TD5W-30***
Axles with AXO 80 80 W
standard lock ACEA E7 Front 49
differential or Engine oil EO50 or, if not available:: 0° up to 30° C SAE 50 (49**)
API CD
Rear 40
Shell: DONAX TD5W-30*** SAE 5W-30 *)
Axles with lim- (40**)
Esso: TORQUE FLUID 56****
ited slip Axle oil AXO
Mobil: MOBILFLUID 424
differential
Fuchs: TITAN HYDRA ZF20W-40 SAE 20W-40
ASTM D975 No.1 -30° up to -10° C

ASTM D975 No.2 -10° up to 40° C
Fuel tank Diesel fuel CFPP class B 0° up to 40° C ----- 300
DIN-EN 590 CFPP class D -10° up to 40° C
CFPP class F -20° up to 40° C
Multi purpose
Grease nippels grease on a lith- MPG-A KP2N-20 -30° up to 40° C NLGI-No. 2 ---
ium base
Grease nippels
Multi purpose
for central lubri-
grease on a lith- MPG-A KP2N-20 up to -20° C NLGI-No. 2 ---
cation
ium base
(up to -20° C)
Grease nippels
for central lubri- Grease for cen- -40° up to NLGI-No.
MPG-G ----- ---
cation tral lubrications 100° C 00/000
(below -20° C)
Supercoolant AF-NAC
Cooling system Add antifreeze with corrosion resistor 36
Coolant SP-C
* Works filling
** Top-up quantity
*** North American manufacted DONAX TD 20W-40 must not be used.
**** North American manufacted TORQUE FLUID 56 must not be used.
01-8 WA430-6
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
NOTE:
Use only diesel fuel.
The engine mounted on this machine employs electronic control and a high-pressure fuel injection
device to obtain good fuel consumption and good exhaust gas characteristics. For this reason, it
requires high precision for the parts and good lubrication.
If kerosene or other fuel with low lubricating ability is used, there will be a big drop in durability.
Note .1:
Power train of oil has different properties from engine oil. Be sure to use the recommended oil.
Note .2:
Axle oil AXO80 has the function of preventing squealing from the brakes and LSD (Limited Slip Differential).
If only AXO80 is recommended, use Komatsu genuine AXO80 or equivalent.
Note .3:
When the ambient temperature is higher than 45°C (113°F) and the machine operation hour is longer than 12
hours/day, then the use of EO50-CD instead of AXO80 is recommended.
Squealing of the brakes may occur with EO50-CD, but there is no problem with the brake performance or dura-
bility.
Note .5:
Hyper grease (G2-T, G2-TE) has a high performance.
When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and
bushings, the use of G2-T or G2-TE is recommended.
Note .6: Supercoolant (AF-NAC)
1. The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC)
has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or
4000 hours.
Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.
2. For details of the ratio when diluting super coolant with water, see Clean inside of cooling system (4-31) in
Operation manual.
When the machine is shipped from the factory, it may be filled with coolant containing 30% or more Super-
coolant (AF-NAC). In this case, no adjustment is needed for temperatures down to -10°C (14°F). (never
dilute with water)
3. To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercool-
ant between 30% and 68%.
Note .7:
For machines equipped with the limited-slip differential axle, select from the oil given in the table below.
Never use any oil except the oil listed in the table below.
Maker Brand Remarks
SHELL DONAX TD 5W-30 North American manufactured DONAX TD

20W-40 must not be used
ESSO TORQUE FLUID 56 North American manufactured must not be

used
MOBIL MOBILFLUID 424

FUCHS RENOGEAR HYDRA ZF 20W-40
WA430-6 01-9
General Table of fuel, coolant and lubricants
01-10 WA430-6
STRUCTURE AND FUNCTION
10 STRUCTURE AND FUNCTION

Engine mount and transmission mount............ 10-2 Bypass valve.................................................10-219
Cooling system ................................................ 10-3 Lock valve.....................................................10-222
Cooling fan pump ............................................. 10-4 Accumulator (for PPC circuit) .......................10-223
Cooling fan motor........................................... 10-11 Accumulator (for E.C.S.S.) ...........................10-224
Power train unit .............................................. 10-17 Work equipment electric lever ......................10-225
Power train system diagram .......................... 10-18 Work equipment EPC valve..........................10-228
Drive shaft ...................................................... 10-20 Work equipment EPC cut-off solenoid valve 10-231
Torque converter and transmission Work equipment linkage ...............................10-232
piping diagram ............................................... 10-21 Bucket positioner and boom kick-out............10-234
Torque converter............................................ 10-22 Work equipment cylinder ..............................10-240
Transmission.................................................. 10-25 Cab ...............................................................10-241
Transmission control valve ............................ 10-39 Air conditioner...............................................10-242
Axle ................................................................ 10-48 Machine monitor system...............................10-243
Differential ...................................................... 10-50 Machine monitor ...........................................10-249
Limited slip differential ................................... 10-55 Electrical system
Final drive ...................................................... 10-62 (Transmission controller system)..................10-297
Steering piping diagram ................................. 10-67 Transmission controller.................................10-322
Steering column ............................................. 10-68 Electrical system (Work equipment controller sys-
Steering pump................................................ 10-69 tem)...............................................................10-324
Steering valve ................................................ 10-80 Work equipment controller............................10-340
Orbit-roll valve ................................................ 10-95 Electric transmission control .........................10-343
Stop valve ...................................................... 10-99 Kickdown switch and hold switch..................10-347
Steering relief valve ..................................... 10-100 Engine starting circuit ...................................10-348
Steering cylinder .......................................... 10-101 Engine stopping circuit..................................10-350
Emergency steering motor ........................... 10-103 Preheating and post-heating circuit ..............10-351
Emergency steering pump ........................... 10-104 Engine power mode selector circuit..............10-353
Joystick steering lever linkage ..................... 10-105 Turbocharger protection function..................10-354
Steering electric lever .................................. 10-106 Torque derating function...............................10-354
Joystick EPC valve ...................................... 10-108 Automatic warm-up function .........................10-354
Brake piping diagram ................................... 10-110 Parking brake circuit .....................................10-355
Charge valve ................................................ 10-112 Sensors.........................................................10-357
Brake valve .................................................. 10-120
Accumulator (for brake) ............................... 10-128
Brake............................................................ 10-130
Parking brake control ................................... 10-135
Parking brake ............................................... 10-136
Parking brake solenoid valve ....................... 10-138
Emergency parking brake reset valve.......... 10-140
Axle mount and center hinge pin ................. 10-142
Tires ............................................................. 10-146
Hydraulic piping diagram ............................. 10-148
Work equipment control lever linkage .......... 10-151
Hydraulic tank .............................................. 10-152
Torque converter hydraulic pump ................ 10-154
Work equipment hydraulic pump ................. 10-155
Work equipment control valve...................... 10-166
CLSS............................................................ 10-181
Each function and operation of each valve .. 10-184
PPC valve .................................................... 10-204
Stabilizer valve ............................................. 10-214
WA430-6 10-1
STRUCTURE AND FUNCTION ENGINE MOUNT AND TRANSMISSION MOUNT
Engine and cooling related components

Engine mount and transmission mount
Unit: mm
No. Check item Criteria Remedy

Clearance between transmis-
1 sion mount bracket and adjust- 1 – 1.5 Adjust
ment bolt
10-2 WA430-6
STRUCTURE AND FUNCTION COOLING SYSTEM
Cooling system
1. Radiator 5. Reservoir tank

2. Aftercooler 6. Cooling fan
3. Oil cooler 7. Cooling fan motor
4. Torque converter oil cooler
Specifications
Torque converter
Radiator Oil cooler Aftercooler
oil cooler
Model name of core CF19-4 CF40-1 AL-CFT PTO-OL
*1
Fin pitch (mm) 4.0/2 4.5/2 4.0/2
100 x 558 x 12 layers
Total heat dissipation surface (m2) 66.30 4.22 17.55 1.291
Pressure valve cracking pressure 68.6
— — —
(kPa {kg/cm2}) {0.7}
Vacuum valve cracking pressure 0 – 0.49
— — —
(kPa {kg/cm2}) {0 – 0.05}
*1: Size of element
WA430-6 10-3
STRUCTURE AND FUNCTION COOLING FAN PUMP
Cooling fan pump

Model: 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. Control voltage input connector
10-4 WA430-6
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
WA430-6 10-5
Function Structure
• The rotation and torque of the engine are trans- • Cylinder block (7) is supported on shaft (1)
mitted to the shaft of this pump. Then, this pump through spline (a). Shaft (1) is supported on the
converts the rotation and torque into hydraulic front and rear bearings.
energy and discharges hydraulic oil according to • The end of piston (6) has a spherical hollow
the load. which is combined with shoe (5). Piston (6) and
• The discharge of this pump can be changed by shoe (5) form a spherical bearing.
changing the swash plate angle in it. • Shoe (5) is kept pressed against plane (A) of
rocker cam (4) and slid circularly. Rocker cam
(4) slide around ball (11).
• Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
• Cylinder block (7) rotates relatively against valve
plate (8), sealing the hydraulic oil. The hydraulic
balance on the valve plate is maintained proper-
ly.
• The oil in each cylinder of cylinder block (7) can
be sucked and discharged through valve plate
(8).
10-6 WA430-6
Operation
1. Operation of pump
• Cylinder block (7) rotates together with shaft (1). • If center line (X) of rocker cam (4) is equal to the
Shoe (5) slide on plane (A). At this time, rocker axial direction of cylinder block (7) (the swash
cam (4) slants around ball (11). As a result, an- plate angle is 0), there is not a difference be-
gle (a) between center line (X) of rocker cam (4) tween volumes (E) and (F) in cylinder block (7)
and the axis of cylinder block (7) changes. Angle and the oil is not sucked or discharged. (The
(a) is called the swash plate angle. swash plate angle is not set to 0 actually, howev-
• If angle (a) is made between center line (X) of er.)
rocker cam (4) and the axis of cylinder block (7), • In short, swash plate angle (a) is in proportion to
plane (A) works as a cam for shoe (5). the pump discharge.
• Accordingly, piston (6) slide 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).
• In other words, if cylinder block (7) 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 fig-
ure, chamber (F) is at the end of the suction
stroke and chamber (E) is at the end of the dis-
charge stroke.)
WA430-6 10-7
2. Control of discharge
• 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 (10).
• Servo piston (10) reciprocates straight according
to the signal pressure of the servo valve. This
straight motion is transmitted to rocker cam (4).
Then, rocker cam (4) supported on ball (11)
sways around ball (11).
10-8 WA430-6
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
WA430-6 10-9
Function • The output oil of the EPC valve flows in the pis-
• The servo valve works so that the relationship ton chamber to push piston (6). Piston (6) push-
between the current input to the EPC valve and es spool (5) until it is balanced with the spring.
pump swash plate angle will be as shown in the • Then, the land of the servo piston pressure pas-
following figure. sage is connected to the pump discharge pas-
sage by the cut of spool (5) and the discharge
pressure is led to the servo piston.
• The servo piston is pushed up by the rocker cam.
The position feedback is applied and the lever
moves to compress the spring.
• If spool (5) is pushed back, the pump discharge
circuit and the servo piston circuit are shut off.
The pressure in the servo piston chamber lowers
and the rocker cam returns toward the maximum
swash plate angle.
• These processes are repeated until the swash
plate is fixed to a position where the EPC output
pressure is balanced with the spring force.
• Accordingly, as the EPC output pressure is
heightened, the swash plate angle is decreased.
As the EPC output pressure is lowered, the
swash plate angle is increased.
10-10 WA430-6
STRUCTURE AND FUNCTION COOLING FAN MOTOR
Cooling fan motor

Model: LMF28
P : From fan pump

T : From cooler to tank
TC : To tank
Specifications
Model name: LMF28
Capacity: 28.0 cc/rev
Rated flow: 36.1 l/min

Rated speed: 1,290 rpm
Check valve cracking pressure: 0.044 MPa {0.45 kg/cm2}
WA430-6 10-11
1. Output shaft 8. Center spring

2. Case 9. Check valve spring
3. Thrust plate 10. Check valve
4. Piston assembly 11. Pilot valve
5. Cylinder block 12. Reversible valve spool
6. Valve plate 13. Reversible valve spring
7. End cover 14. Safety valve
Unit: mm
Standard size Repair limit
Free length
Installed Installed Installed If damaged or
x Outside Free length
9 Check valve spring length load load deformed,
diameter
replace spring
3.43 N 2.55 N
13.0 x 6.5 7.0 —
{0.35 kg} {0.26 kg}
10-12 WA430-6
1. Hydraulic motor
Function
• This hydraulic motor is a swash plate-type axial
piston motor, which converts the pressure of the
hydraulic oil sent from the hydraulic pump into
revolution.
Principle of operation
• 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).
• The oil sent to one side of cylinder block (5)
force (F1) [F1 = P x xD2/4].

presses pistons (4) (2 or 3 pieces) and generates
• This force is applied to thrust plate (2). Since

thrust plate (2) is fixed to a certain angle ("a" de-
grees) degrees to the output shaft (1), the force
is divided into components (F2) and (F3).
• Radial component (F3) generates torque against
the (Y-Y) line connecting the top dead center and
bottom dead center [T = F3 x ri].
• The combined force of all torque [T = (F3 x ri)]
rotates the cylinder block (5) through the piston.
• Since the cylinder block (5) is coupled with the
output shaft by means of spline, the output shaft
revolves to transmit the torque.
WA430-6 10-13
2. Suction valve
Function (2) When pump is stopped

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

• When the hydraulic oil from the pump is supplied
to port (P) and the pressure on the (MA) side ris-
es and starting torque is generated in the motor,
the motor starts revolution. The oil on the outlet
(MB) side of the motor returns through port (T) to
the tank.
10-14 WA430-6
3. Operation of reversible valve
(1) When reversible valve ON-OFF solenoid is (2) When reversible valve ON-OFF solenoid is
de-energized energized
• If reversible valve ON-OFF solenoid (1) is "de- • If reversible valve ON-OFF solenoid (1) is "ener-
energized", the hydraulic oil from the pump is gized", ON-OFF selector valve (2) changes to let
blocked by ON-OFF selector valve (2) and port the hydraulic oil from the pump flow through port
(C) is connected to the tank circuit. (C) into spool chamber (D).
• Accordingly, reversible valve spool (3) is pushed • The hydraulic oil in chamber (D) pushes revers-
by reversible valve spring (4) to the right to open ible valve spool (3) to the left against reversible
motor port (MA) and then the hydraulic oil flows valve spring (4). As a result, motor port (MB)
in the motor to revolve the motor forward (clock- opens and the hydraulic oil flows in the motor to
wise). revolve the motor in reverse (counterclockwise).
WA430-6 10-15
4. Safety valve
Function
• When the engine is started, the pressure in port
(P) of the fan motor may rise high.
• Safety valve (1) is installed to protect the fan sys-
tem circuit.
Operation
• If the pressure in port (P) exceeds the cracking
pressure of safety valve (1), valve (2) of safety
valve (1) opens to relieve the oil into port (T).
• Accordingly, abnormally high pressure is not
generated in port (P).
10-16 WA430-6
STRUCTURE AND FUNCTION POWER TRAIN UNIT
Power train unit
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
• The power from engine (3) is transmitted through
the flywheel of the engine to torque converter (2).
The turbine of the torque converter is connected
to the input shaft of transmission (1).
• The transmission has 6 hydraulic clutches to set
itself to 4 forward gear speeds and 4 reverse
gear speeds.
• The power from the transmission output shaft is
transmitted through center drive shaft (6), front
drive shaft (7), and rear drive shaft (5) to front
axle (8) and rear axle (4), and then transmitted
through the wheels to the tires.
WA430-6 10-17
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM DIAGRAM
Power train system diagram
10-18 WA430-6
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM DIAGRAM
1. Front axle Outline

2. Differential • The power from engine (15) is transmitted
3. Wet-type multiple disc brake through the flywheel of the engine to torque con-
4. Final drive verter (16).
5. Front drive shaft The torque converter converts the transmitted
6. Center drive shaft torque according to the fluctuation of the load by
7. Parking brake (Wet-type multiple disc) using oil as a medium and transmits the power to
8. Transmission (Counter-shaft type) the input shaft of transmission (8). The engine
9. Rear drive shaft power is also transmitted through the pump drive
10. Rear tire gear of the torque converter to steering pump
11. Final drive (19), cooling fan pump (20), torque converter hy-
12. Wet-type multiple disc brake draulic pump (17), and work equipment hydraulic
13. Differential pump (18) to drive those pumps.
14. Rear axle • The 6 hydraulic clutches of transmission (8) are
15. Engine operated with the directional valve and gearshift
16. Torque converter valve of the transmission valve to set the trans-
17. Torque converter hydraulic pump mission to one of 4 gear speeds in the forward or
18. Work equipment hydraulic pump reverse travel direction.
19. Steering pump • 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 actuated
with the parking brake switch.
• 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).
• The power transmitted to front axle (1) and rear
axle (14) is reduced in speed by the pinion gears
of differentials (2) and (13), and then transmitted
through the differential mechanism to the sun
gear shafts.
• The power of the sun gears is further reduced in
speed by final drives (4) and (11) of the planetary
mechanism, and then transmitted through the
axle shafts to the wheels.
WA430-6 10-19
STRUCTURE AND FUNCTION DRIVE SHAFT
Drive shaft
1. Front drive shaft Outline

2. Flange bearing • The power from the transmission output shaft is
3. Center drive shaft transmitted through center drive shaft (3), front
4. Rear drive shaft drive shaft (1), and rear drive shaft (4) to the front
axle and rear axle.
• When the machine is articulated or when it re-
ceives traveling impacts or working impacts, the
distances between the transmission and the
front and rear axles change. The drive shafts ab-
sorbs the fluctuation of the angle and length with
the universal joints and flange bearing (2) so that
the power will be transmitted without damaging
the parts even when the machine receives the
above impacts and the positions of the compo-
nents change.
10-20 WA430-6
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION PIPING DIAGRAM
Torque converter and transmission piping diagram
1. Hydraulic tank 7. Torque converter oil cooler

2. Cooling fan pump 8. Last chance filter
3. Steering pump 9. Transmission control valve
4. Work equipment hydraulic pump 10. Oil filter
5. Torque converter hydraulic pump 11. Oil filler pipe
6. Transmission assembly
WA430-6 10-21
STRUCTURE AND FUNCTION TORQUE CONVERTER
Torque converter
1. Flywheel 6. Pump
2. Drive case (Number of teeth: 72) 7. PTO drive gear (Number of teeth: 97)
3. Boss 8. Stator shaft
4. Turbine 9. Transmission input shaft
5. Stator
Specifications
3-element, 1-stage,
Type
1-phase
Stall torque ratio 2.47
10-22 WA430-6
Unit: mm

Standard size Tolerance Repair limit
1 Outside diameter of pilot Repair by hard
–0.010
52 51.75 chromium-
–0.040
plating or
Inside diameter of sliding sur- +0.035 replace
2 110 110.5
face of PTO gear seal ring +0.035
+0.10
Wear of stator Width 3
–0.10
2.7
3
shaft seal ring
Thickness 4.3 ±0.1 3.9 Replace
Backlash between PTO drive
4 0.17 – 0.45
gear and PTO driven gear
WA430-6 10-23
Power transmission route Oil flow
• The torque converter is installed between the en- • The oil flows through the main relief valve and its
gine and transmission. pressure is reduced by the torque converter relief
The power from the en gine is transmitted valve, and then it flows through inlet port (A) and
through flywheel (1) to drive case (2). oil passage of stator shaft (1) to pump (2).
Drive case (2), pump (3), and PTO drive gear (4) The oil is given a centrifugal force by pump (2),
are fixed with bolts and rotated with the engine and then it enters turbine (3) to transmit its ener-
directly. gy to turbine (3).
The power of pump (3) rotates turbine (5) by us- The oil from turbine (3) is sent to stator (4), and
ing oil as medium, and then the rotation is trans- then returned to pump (2). A part of this oil is,
mitted through boss (6) to transmission input however, sent from stator (4) through outlet port
shaft (7). (B) to the torque converter oil cooler.
The power of drive case (2) is also used to drive
the gear pump through PTO drive gear (4).
10-24 WA430-6
STRUCTURE AND FUNCTION TRANSMISSION
Transmission
1. Steering and cooling fan pump mounting section 6. Transmission case (Front)
2. Torque converter and work equipment hydraulic 7. Transmission oil filter
pump mounting section 8. Oil level gauge
3. Transmission case (Rear) 9. Flow valve
4. Transmission control valve
5. Main relief and torque converter relief valve
WA430-6 10-25
1. PTO driven gear (Number of teeth: 89) 9. Output shaft

2. PTO drive gear (Number of teeth: 97) 10. Parking brake
3. Torque converter 11. Front coupling
4. Transmission input shaft 12. Lower shaft
5. F clutch 13. 2nd clutch
6. 4th clutch 14. Upper shaft
7. 3rd clutch 15. 1st clutch
8. Rear coupling 16. R clutch
10-26 WA430-6
WA430-6 10-27
Unit: mm

Standard Tolerance Standard Clearance
Clearance between PTO driven size Shaft Hole clearance limit
1
gear shaft and bearing (F) +0.030 –0.000 –0.045 –
65 —
+0.011 –0.015 –0.011
Clearance between PTO driven –0.000 +0.030
2 120 0 – 0.045 —
gear bearing and housing (F) –0.015 +0.000
Clearance between PTO driven +0.020 –0.000 –0.032 –
3 50 —
gear shaft and bearing (R) +0.009 –0.012 –0.009
4 90 0 – 0.045 —
gear bearing and housing (R) –0.015 +0.000
Clearance between input shaft –0.000 +0.030
5 110 0 – 0.045 —
bearing and housing (R) –0.015 +0.000
Clearance between input shaft –0.000 +0.030
6 110 0 – 0.045 —
bearing and housing (F) –0.015 +0.000
Clearance between upper shaft –0.000 +0.030
7 110 0 – 0.045 —
bearing and housing (R) –0.015 +0.000
Clearance between upper shaft –0.000 +0.030
8 120 0 – 0.045 —
bearing and housing (F) –0.015 +0.000
Clearance between lower shaft –0.000 –0.000 –0.035 –
9 100 —
bearing and housing (R) –0.018 –0.035 0.018
Clearance between lower shaft –0.000 –0.000 –0.035 –
10 120 —
bearing and housing (F) –0.018 –0.035 0.018
Clearance between output –0.000 –0.018 –0.058 –
11 130 —
shaft bearing and housing (R) –0.020 –0.058 0.002
Clearance between output +0.030 –0.000 –0.045 –
12 75 —
shaft and bearing (R) +0.011 –0.015 –0.011
Clearance between output –0.000 –0.018 –0.058 –
13 130 —
shaft bearing and housing (F) –0.020 –0.058 0.002
Replace
Clearance between output +0.035 –0.000 –0.055 –
14 85 —
shaft and bearing (F) +0.013 –0.020 –0.013
Inside diameter of seal ring
+0.050
contact surface 60 60.1
+0.030
+0.076
15 Width of seal ring groove 3.2 3.5
+0.030
Width of seal ring 3.1 ±0.05 2.8
–0.000
Thickness of seal ring 2.29 2.1
–0.100
Inside diameter of seal ring +0.050
50 50.1
contact surface +0.030
+0.076
Width of seal ring groove 3.2 3.5
16 +0.030
Width of seal ring 3.1 ±0.05 2.8
–0.000
Thickness of seal ring 2.29 2.1
–0.100
Inside diameter of sliding sur- –0.000
17 95 94.8
face of coupling oil seal (R) –0.087
Inside diameter of sliding sur- –0.000
18 95 94.8
face of coupling oil seal (F) –0.087
Standard clearance Clearance limit
Clearance between retainer
19 0.85 – 1.65
and housing —
(Standard shim thickness: 1.10)
Clearance between cage and 1.18 – 1.94
20 —
case (Standard shim thickness: 1.40)
10-28 WA430-6
1. PTO driven gear (Number of teeth: 85)

2. R idler gear (Number of teeth: 28)
3. Spacer
4. Strainer
5. Drain plug
Unit: mm

Clearance between PTO driven size Shaft Hole clearance limit
6
gear shaft and bearing (F) +0.030 –0.000 –0.045 –
65 —
+0.011 –0.015 –0.011
7 120 0 – 0.045 —
gear bearing and housing (F) –0.015 +0.000
Clearance between PTO driven +0.020 –0.000 –0.032 –
8 50 — Replace
gear shaft and bearing (R) +0.009 –0.012 –0.009
9 90 0 – 0.045 —
gear bearing and housing (R) –0.015 +0.000
Clearance between R idler +0.027 –0.000 –0.039 –
10 50 —
gear bearing and case +0.002 –0.012 –0.002
Clearance between R idler –0.000 –0.021 –0.051 –
11 80 —
gear bearing and R idler gear –0.016 –0.051 –0.005
Outline Table of combinations of clutches and reduction

• The transmission is installed after the torque ratios
converter. The power from the torque converter
is transmitted through the transmission input Gear speed Clutch used Reduction ratio
shaft to the transmission. F1 F x 1st 3.949
• In the transmission, the power of the transmis- F2 F x 2nd 2.228
sion input shaft is changed to the forward 1st – F3 F x 3rd 1.220
4th gear speeds or reverse 1st – 4th gear speeds F4 F x 4th 0.681
by combining the F and R clutches and 4 speed R1 R x 1st 3.696
clutches, and then transmitted to the output R2 R x 2nd 2.086
shaft. R3 R x 3rd 1.142
R4 R x 4th 0.637
WA430-6 10-29
F and R clutches
A. R clutch oil port C. Lubricating oil port

B. F clutch oil port
1. Spacer 6. F clutch
2. Thrust washer 7. F gear (Number of teeth: 40)
3. R gear (Number of teeth: 31) 8. Thrust washer
4. R clutch 9. Spacer
5. F, R cylinder 10. Transmission input shaft
Unit: mm

Clearance in bearing fitting part size Shaft Hole clearance limit
11
of shaft (F) +0.039 –0.000 –0.054 –
60 —
+0.029 –0.015 –0.029
Clearance in bearing fitting part +0.030 –0.000 –0.045 –
12 60 —
of shaft (R) +0.011 –0.015 –0.011
13 Separator plate Thickness 1.7 ±0.05 1.5
Strain — 0.10 0.15
Replace
Thickness 2.2 ±0.08 1.6
14 Friction plate
Strain — 0.10 0.25
Wave spring load (Height: 2.2 1,010 N ±101N 859 N
15
mm) {103 kg} {±10.3 kg} {87.6 kg}
16 Warp of spring plate 1.4 ±0.2 1.2
Thickness of F, R clutch thrust
17 3 ±0.1 2.7
washer
18 End play of R gear 0.30 – 0.70
19 End play of F gear 0.24 – 0.76
10-30 WA430-6
1st and 4th clutch
A. 1st clutch oil port C. Lubricating oil port

B. 4th clutch oil port
1. Idler gear (Number of teeth: 37) 6. 4th clutch

2. Thrust washer 7. 4th gear (Number of teeth: 64)
3. 1st gear (Number of teeth: 26) 8. Thrust washer
4. 1st clutch 9. Spacer
5. 1st and 4th cylinder, idler gear (Number of teeth: 10. Upper shaft
51)
Unit: mm

11
of shaft (F) +0.035 –0.000 –0.050 –
55 —
+0.025 –0.015 –0.025
12 60 —
of shaft (R) +0.020 –0.015 –0.020
Strain — 0.10 0.15
Thickness 2.2 ±0.08 1.6
14 Friction plate Replace
Strain — 0.10 0.25
Wave spring load 1,010 N ±101N 859 N
15
(Height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
Thickness of 1st, 4th clutch
16 3 ±0.1 2.7
thrust washer
Thickness of 1st clutch thrust
17 3 ±0.1 2.7
washer
18 End plate of 1st gear 0.26 – 0.74
19 End play of 4th gear 0.28 – 0.72
20 Snap ring Must not be reused
WA430-6 10-31
2nd and 3rd clutch
A. 2nd clutch oil port C. Lubricating oil port

B. 3th clutch oil port
1. Output gear (Number of teeth: 50) 6. 3rd clutch

2. Thrust washer 7. 3rd gear (Number of teeth: 40)
3. 2nd gear (Number of teeth: 53) 8. Thrust washer
4. 2nd clutch 9. Idler gear (Number of teeth: 28)
5. 2nd and 3rd cylinder, idler gear (Number of teeth: 10. Lower shaft
66)
Unit: mm

11
of shaft (F) +0.050 –0.000 –0.065 –
55 —
+0.040 –0.015 –0.040
12 55 —
of shaft (R) +0.020 –0.015 –0.020
Strain — 0.10 0.15 Replace
Thickness 2.2 ±0.08 1.6
14 Friction plate
Strain — 0.10 0.25
Wave spring load 1,010 N ±101N 859 N
15
(Height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
Thickness of 2nd, 3rd clutch
16 3 ±0.1 2.7
thrust washer
17 End plate of 2nd gear 0.28 – 0.72
18 End plate of 3rd gear 0.28 – 0.72
10-32 WA430-6
Operation of clutch
When clutch is "engaged" (fixed) When clutch is "disengaged" (released)
• The oil sent from the transmission valve flows • The oil sent from the transmission valve is
through the passage in shaft (1) to the back side stopped and the oil pressure applied to the back
of piston (6) and moves piston (6). side of piston (6) lowers.
• If piston (6) moves, it fixes separator plate (2) • Piston (6) is returned to the original position by
and friction plate (3) to each other. As a result, wave spring (7), and then shaft (1) and clutch
shaft (1) and clutch gear (4) become one and the gear (4) are separated from each other.
power is transmitted. At this time, some oil is • When the clutch is disengaged, the oil on the
drained through oil drain hole (5). Since the back side of the piston is drained by the centrifu-
draining rate is low for the oil supply rate, howev- gal force through oil drain hole (5) so that the
er, it does not affect the operation of the clutch. clutch will not be partially engaged.
a Oil drain hole (5) is made for only the 1st, 2nd,
a The 1st, 2nd, and 4th clutches have oil drain

3rd, and 4th clutches.
holes (5) at their pistons, and the 3rd clutch has

oil drain hole (5) at its cylinder.
WA430-6 10-33
Forward 1st gear speed
Operation
• When the transmission is set in the forward 1st • The power from the torque converter is transmit-
gear speed, F clutch (3) and 1st clutch (9) are en- ted through transmission input shaft (1), F clutch
gaged. The power received from the torque con- (3), and F gear (2) to the 1st/4th cylinder gear (7).
v e r t e r to t r a n s m is s i o n in p u t s h a ft ( 1 ) i s • Since 1st clutch (9) is engaged, the power trans-
transmitted to output shaft (22). mitted to 1st/4th cylinder gear (7) is further trans-
• The clutch discs of F clutch (3) and 1st clutch (9) mitted through 1st clutch (9), 1st gear (10), 2nd/
are fixed with the oil pressure applied to the 3rd cylinder gear (16), lower shaft (20), output
clutch piston. gear (19), and output gear (21) to output shaft
(22).
10-34 WA430-6
Forward 2nd gear speed
Operation
• When the transmission is set in the forward 2nd • The power from the torque converter is transmit-
gear speed, F clutch (3) and 2nd clutch (17) are ted through transmission input shaft (1), F clutch
engaged. The power received from the torque (3), F gear (2), 1st/4th cylinder gear (7), upper
converter to transmission input shaft (1) is trans- shaft (12), and idler gear (11) to 2nd gear (18).
mitted to output shaft (22). • Since 2nd clutch (17) is engaged, the power
• The clutch discs of F clutch (3) and 2nd clutch transmitted to 2nd gear (18) is further transmitted
(17) are fixed with the oil pressure applied to the through 2nd clutch (17), 2nd/3rd cylinder gear
clutch piston. (16), lower shaft (20), output gear (19), and out-
put gear (21) to output shaft (22).
WA430-6 10-35
Forward 3rd gear speed
Operation
• When the transmission is set in the forward 3rd • The power from the torque converter is transmit-
gear speed, F clutch (3) and 3rd clutch (15) are ted through transmission input shaft (1), F clutch
engaged. The power received from the torque (3), F gear (2), and 1st/4th cylinder gear (7) to 3rd
converter to transmission input shaft (1) is trans- gear (14).
mitted to output shaft (22). • Since 3rd clutch (15) is engaged, the power
• The clutch discs of F clutch (3) and 3rd clutch transmitted to 3rd gear (14) is further transmitted
(15) are fixed with the oil pressure applied to the through 3rd clutch (15), 2nd/3rd cylinder gear
clutch piston. (16), lower shaft (20), output gear (19), and out-
put gear (21) to output shaft (22).
10-36 WA430-6
Forward 4th gear speed
Operation
• When the transmission is set in the forward 4th • The power from the torque converter is transmit-
gear speed, F clutch (3) and 4th clutch (8) are ted through transmission input shaft (1), F clutch
engaged. The power received from the torque (3), and F gear (2) to 1st/4th cylinder gear (7).
converter to transmission input shaft (1) is trans- • Since 4th clutch (8) is engaged, the power trans-
mitted to output shaft (22). mitted to 1st/4th cylinder gear (7) is further trans-
• The clutch discs of F clutch (3) and 4th clutch (8) mitted through 4th clutch (8), 4th gear (6), idler
are fixed with the oil pressure applied to the gear (13), lower shaft (20), output gear (19), and
clutch piston. output gear (21) to output shaft (22).
WA430-6 10-37
Reverse 1st gear speed
Operation
• When the transmission is set in the reverse 1st • The power from the torque converter is transmit-
gear speed, R clutch (4) and 1st clutch (9) are ted through transmission input shaft (1) and R
engaged. The power received from the torque clutch (4) to R gear (5). Then, its rotation direc-
converter to transmission input shaft (1) is trans- tion is reversed by idler gear (23) and it is further
mitted to output shaft (22). transmitted through idler gear (11) and upper
• The clutch discs of R clutch (4) and 1st clutch (9) shaft (12) to 1st/4th cylinder gear (7).
are fixed with the oil pressure applied to the • Since 1st clutch (9) is engaged, the power transmit-
clutch piston. ted to 1st/4th cylinder gear (7) is further transmitted
through 1st clutch (9), 1st gear (10), 2nd/3rd cylin-
der gear (16), lower shaft (20), output gear (19),
and output gear (21) to output shaft (22).
10-38 WA430-6
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
Transmission control valve
A. 2nd clutch oil pressure pickup port 1. ECMV (For 2nd clutch)
B. 3rd clutch oil pressure pickup port 2. ECMV (For 3rd clutch)
C. 1st clutch oil pressure pickup port 3. ECMV (For 1st clutch)
D. 4th clutch oil pressure pickup port 4. ECMV (For 4th clutch)
E. R clutch oil pressure pickup port 5. ECMV (For R clutch)
F. F clutch oil pressure pickup port 6. ECMV (For F clutch)
G. Main relief oil pressure pickup port 7. Parking brake solenoid valve
H. Torque converter relief pressure pickup port 8. Main relief valve and torque converter relief valve
J. Parking brake oil pressure pickup port 9. Last chance filter
WA430-6 10-39
Operation table of ECMV
ECMV
F R 1st 2nd 3rd 4th
Q Q
Gear speed
Q Q
F1
Q Q
F2
Q Q
F3
Q Q
F4
Q Q
R1
Q Q
R2
Q Q
R3
R4
Outline
• The oil from the pump flows through the flow
valve and oil filter into the transmission control
valve and then is divided into the main relief cir-
cuit and clutch actuation circuit.
• The pressure of the oil sent to the clutch actua-
tion circuit is regulated by the main relief valve,
and then used to actuate the clutch and parking
brake through the last chance filter. The oil re-
lieved from the main relief valve is supplied to the
torque converter.
• When the transmission gear is shifted, the ECMV
increases the clutch oil pressure smoothly ac-
cording to the command current from the trans-
mission controller to reduce the gear shifting
shocks. The ECMV also keeps the clutch pres-
sure constant during travel.
• If the F, R, or 1st – 4th ECMV is selected, the reg-
ulated oil pressure is supplied to the selected
clutch to set the transmission in the desired gear
speed.
10-40 WA430-6
ECMV (Electronic Control Modulation Valve)
a ECMV: Abbreviation for Electronic Control Modulation Valve
A : To clutch
P : From pump
T : Drain
Dr : Drain
P1 : Clutch oil pressure pickup port
1. Fill switch connector

2. Proportional solenoid connector
3. Oil pressure pickup valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
WA430-6 10-41
ECMV for speed clutch
Outline of ECMV ECMV and proportional solenoid

• The ECMV consists of 1 pressure control valve • For each ECMV, 1 proportional solenoid is in-
and 1 fill switch. stalled.
• Pressure control valve The proportional solenoid generates thrust
This valve receives the current sent from the shown below according to the command current
transmission controller with a proportional sole- from the controller.
noid, and then converts it into oil pressure. The thrust generated by the proportional sole-
• Fill switch noid is applied to the pressure control valve
This switch detects that the clutch is filled with oil spool to generate oil pressure. Accordingly, the
and has the following functions. thrust is changed by controlling the command
1. Output a signal (a fill signal) to the controller to current to operate the pressure control valve to
notify that filling is completed when the clutch is control the flow and pressure of the oil.
filled with oil.
2. Keep outputting signals (fill signals) to the con-
troller to notify whether oil pressure is applied or Current - Propulsion force characteristics of pro-
not while oil pressure is applied to the clutch. portional solenoid
Propulsion force - Hydraulic pressure character-

istics of proportional solenoid
Range A: Before shifting gear (when draining)

Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Range E: Start of filling ECMV and fill switch
Range F: Finish of filling • For each ECMV, 1 fill switch is installed.
a The logic is so made that the controller will not

If the clutch is filled with oil, the fill switch is
turned ON by the pressure of the clutch. The oil
recognize completion of filling even if the fill switch pressure is built up according to this signal.
is turned "ON" during triggering (Range D).
10-42 WA430-6
Operation of ECMV Before shifting gear (when draining) (Range A in

• ECMV is controlled with the command current chart)
sent from the controller to the proportional sole-
noid and the fill switch output signal.
The relationship between the proportional sole-
noid command current of ECMV, clutch input
pressure, and fill switch output signal is shown
below.
• While no current is flowing in proportional sole-

noid (1), pressure control valve (3) drains the oil
from clutch port (A) through drain port (T).
At this time, since no oil pressure is applied to oil
pressure pickup valve (4), fill switch (5) is turned
"OFF".
Range A: Before shifting gear (when draining)
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Range E: Start of filling
Range 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).
WA430-6 10-43
During filling (Range B in chart) Pressure regulation (Range C in chart)
• If a current is given to proportional solenoid (1) • If a current flows in proportional solenoid (1), the
while there is not oil in the clutch, a hydraulic solenoid generates thrust in proportion to the
force balanced with the solenoid force is applied current. This thrust of the solenoid is balanced
to chamber (B) and it pushes pressure control with the sum of the thrust generated by the oil
valve (3) to the left. As a result, pump port (P) pressure in clutch port and the reaction force of
and clutch port (A) open, then the oil starts flow- pressure control valve spring (2), and then the
ing into the clutch. When the clutch is filled with pressure is settled.
the oil, oil pressure is applied to oil pressure pick-
up valve (4), and fill switch (5) is turned "ON".
10-44 WA430-6
Main relief valve and torque converter relief valve
A : Drain (Torque converter relief) 1. Body

B : Drain 2. Piston
C : From pump 3. Torque converter relief valve
D : Drain 4. Piston
E : To torque converter 5. Main relief valve
P1 : Main relief oil pressure pickup port
P2 : Torque converter relief pressure pickup port
Unit: mm

Clearance between main relief size Shaft Hole clearance limit
6
valve and valve body –0.035 +0.013 0.035 –
28 0.078
–0.045 +0.013 0.058
Clearance between torque con-
–0.035 +0.013 0.035 –
7 verter relief valve and valve 22 0.078
–0.045 +0.013 0.058
body
Replace
Installed Installed Installed
Free length Free length
8 Main relief valve spring (Outside) length load load
380 N 362 N
122 82.5 118.3
{38.8 kg} {36.9 kg}
314 N 298 N
9 Main relief valve spring (Inside) 108 82.5 104.8
{32.0 kg} {30.4kg}
Torque converter relief valve 153 N 145 N
10 50 42 48.5
spring {15.6 kg} {14.8 kg}
WA430-6 10-45
Outline
Torque converter relief valve Operation of main relief valve

• The torque converter relief valve regulates the
torque converter inlet circuit pressure below the
set pressure to protect the torque converter from
abnormally high pressure.
Set pressure: 0.91 MPa {9.31 kg/cm 2}
(Cracking pressure)
Main relief valve

• The main relief valve regulates the pressure in
the transmission and brake hydraulic circuits be-
low the set pressure.
Set pressure: 2.86 MPa {29.2 kg/cm 2}
(At rated engine speed)
• The oil from the hydraulic pump flows through

Operation the filter, port (C) of the relief valve, and orifice (a)
of spool (1) to chamber (F).
Operation of torque converter relief valve When the circuit is filled with the oil from the
• The oil relieved through the main relief valve pump, the oil pressure starts rising.
flows through port (E) into the torque converter.
It also flows through orifice (b) of spool (1) into
chamber (G).
When the torque converter is filled with oil, the oil
pressure starts rising.
• As the oil pressure in the circuit rises, the oil in

chamber (F) pushes piston (2), the reaction force
of which compresses valve spring (3) and moves
spool (1) to the left to open ports (C) and (E).
Then, the oil from the pump is relieved through
• As the oil pressure in the torque converter rises, ports (C) and (E) into the torque converter.
the oil in chamber (G) pushes piston (2), the re- At this time, the oil pressure in port (C) is 2.86
action force of which compresses valve spring MPa {29.2 kg/cm2} (at the rated engine speed).
(3) and moves spool (1) to the right to open ports
(E) and (A).
Then, the oil in port (E) is relieved through port
(A) and drained into the oil tank.
At this time, the oil pressure in port (E) is 0.91
MPa {9.31 kg/cm2} (cracking pressure).
10-46 WA430-6
Flow valve
A : To transmission valve circuit

B : From pump
C : To transmission lubricating circuit
1. Valve body
2. Valve spool
Unit: mm

Clearance between flow control size Shaft Hole clearance limit
3
valve and valve body –0.020 +0.013
25 0.02 – 0.043 0.06
–0.030 +0.013
Standard size Repair limit Replace
4 Flow control valve spring length load load
79.5 N 75.5 N
63.8 47 61.9
{8.11 kg} {7.7 kg}
Operation
• When the oil flow from the pump to the transmis- • When the oil flow from the pump exceeds the set
sion valve circuit exceeds the set level, the flow level, valve spool (2) moves and a part of the oil
valve supplies a part of the oil to the transmission flows into the transmission lubricating circuit.
lubricating circuit.
WA430-6 10-47
STRUCTURE AND FUNCTION AXLE
Axle
Front axle
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple disc brake
6. Coupling
7. Oil filler and level plug
8. Drain plug
10-48 WA430-6
STRUCTURE AND FUNCTION AXLE
Rear axle
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple disc brake
6. Coupling
7. Oil filler and level plug
8. Drain plug
WA430-6 10-49
STRUCTURE AND FUNCTION DIFFERENTIAL
Differential
Front differential
1. Pinion gear (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)
10-50 WA430-6
Unit: mm

7 Backlash of differential gear 0.18 – 0.23
Adjust
8 Starting torque of bevel gear 35.3 – 52.9 Nm {3.6 – 5.4 kgm} (Outside of bevel gear)
Thickness of pinion gear Standard size Tolerance Repair limit
9
washer 3 ±0.08 2.8 Replace
10 Thickness of side gear washer 4 ±0.05 3.8
Thickness of differential side
11 0.30 – 1.25
bearing carrier shim (Each side) Adjust
12 Backlash of bevel gear 0.30 – 0.41
13 End play of pinion gear 0 – 0.189 Replace
Thickness of shim in differential
14 1.26 ± 0.34 Adjust
housing and cage assembly
size Shaft Hole clearance limit
Clearance in dif-
–0.025 –0.045 –0.085 –
15 ferential side Outer race 160 —
–0.025 –0.085 –0.020
bearing
+0.059 –0.025 –0.079 –
Inner race 105 —
+0.037 –0.020 –0.037
Clearance in +0.025 –0.025 –0.075 –
Outer race 171.45 —
bearing on gear +0.025 –0.050 –0.025
16
side of pinion +0.062 +0.013 –0.062 –
Inner race 76.2 —
shaft +0.043 +0.013 –0.030
Clearance in –0.025 –0.050 –0.075 – Replace
Outer race 150 —
bearing on cou- –0.020 –0.075 –0.030
17
pling side of pin- +0.039 –0.025 –0.054 –
Inner race 70 —
ion shaft +0.020 –0.015 –0.020
Clearance between pinion gear –0.11 +0.05
18 35 0.11 – 0.21 —
and spider –0.16 +0.05
Clearance in piston setting part
–0.125 +0.089 0.125 –
19 of differential housing (Housing 327 —
–0.214 +0.089 0.303
and piston)
–0.110 +0.081 0.110 –
20 of bearing carrier (Piston and 307 —
–0.191 +0.081 0.272
carrier)
WA430-6 10-51
Rear differential
1. Pinion gear (Number of teeth: 12)

2. Shaft
3. Bevel gear (Number of teeth: 41)
4. Sun gear shaft
5. Bevel pinion (Number of teeth: 10)
10-52 WA430-6
Unit: mm

7 Backlash of differential gear 0.13 – 0.18
Adjust
8 Starting torque of bevel gear 13.7 – 37.2 Nm {1.4 – 3.8 kgm} (Outside of bevel gear)
Thickness of pinion gear Standard size Tolerance Repair limit
9
washer 3 ±0.08 2.8 Replace
10 Thickness of side gear washer 4 ±0.05 3.8
Thickness of differential side
11 0.30 – 1.25
bearing carrier shim (Each side) Adjust
12 Backlash of bevel gear 0.25 – 0.33
13 End play of pinion gear 0 – 0.182 Replace
Thickness of shim in differential
14 1.05 ± 0.35 Adjust
housing and cage assembly
Clearance in dif-
–0.016 –0.045 –0.085 –
15 ferential side Outer race 150 —
–0.016 –0.085 –0.029
bearing
+0.059 –0.016 –0.079 –
Inner race 100 —
+0.037 –0.020 –0.037
Clearance in –0.016 –0.054 –0.075 –
Outer race 150 —
bearing on gear –0.020 –0.071 –0.030
16
side of pinion +0.039 –0.016 –0.054 –
Inner race 70 —
shaft +0.020 –0.015 –0.020
Clearance in –0.016 –0.054 –0.082 – Replace
Outer race 140 —
bearing on cou- –0.018 –0.082 –0.036
17
pling side of pin- +0.039 –0.016 –0.054 –
Inner race 65 —
ion shaft +0.020 –0.015 –0.020
Clearance between pinion gear –0.11 +0.05
18 30 0.11 – 0.21 —
and spider –0.16 +0.05
–0.111 +0.081 0.111 –
19 of differential housing (Housing 311 —
–0.190 +0.081 0.271
and piston)
–0.110 +0.079 0.110 –
20 of bearing carrier (Piston and 290.5 —
–0.191 +0.079 0.270
carrier)
WA430-6 10-53
Outline While machine is turning

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

• While the machine is traveling straight, the right
and left wheels rotate at the same speed. Ac-
cordingly, the pinion gears (4) in the differential
assembly do not rotate and the power of carrier
(6) is transmitted through pinion gears (4) and
side gears (3) to right and left sun gear shafts (2)
evenly.
10-54 WA430-6
STRUCTURE AND FUNCTION LIMITED SLIP DIFFERENTIAL
Limited slip differential

Front
1. Plate
2. Disc
3. Pinion (Number of teeth: 12)
4. Washer
6. Bevel pinion
7. Shaft
8. Pressure ring
9. Bevel gear
10. Case
WA430-6 10-55
Unit: mm

11 Thickness of plate 3.1
±0.02 3.0
3.2
12 Thickness of disc 3.2 ±0.07 3.1
4
13 Thickness of washer ±0.05 3.8
4.1
Clearance between disc and
14 0.20 – 0.75
plate
End play of side gear in axial Replace
15 0.15 – 0.35
direction (Each side)
Backlash between case and
16 0 – 0.5
plate
Backlash between side gear
17 0.09 – 0.39
and disc
Clearance between spider and size Shaft Hole clearance limit
18
differential pinion gear –0.110 +0.05 0.110 –
35 —
–0.160 +0.05 0.210
10-56 WA430-6
Rear
1. Plate
2. Disc
3. Pinion (Number of teeth: 12)
4. Washer
6. Bevel pinion
7. Shaft
8. Pressure ring
9. Bevel gear
10. Case
WA430-6 10-57
Unit: mm

11 Thickness of plate 3.1
±0.02 3.0
3.2
12 Thickness of disc 3.2 ±0.07 3.1
2
13 Thickness of washer ±0.03 1.8
2.1
Clearance between disc and
14 0.20 – 0.75
plate
End play of side gear in axial Replace
15 0.15 – 0.35
direction (Each side)
Backlash between case and
16 0 – 0.4
plate
Backlash between side gear
17 0.13 – 0.42
and disc
Clearance between spider and size Shaft Hole clearance limit
18
differential pinion gear –0.110 +0.05 0.110 –
30 —
–0.160 +0.05 0.210
10-58 WA430-6
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 are
through bevel gear (9), case (10), pressure rings (8), 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 is distributed evenly by the differential
generates braking torque in proportion to the torque gears to the right and left. Under this condition, the
transmitted from pressure rings (8) to shaft (7). slip limits of the right and left wheels are the same.
Since the brake torque restricts the rotation of side Accordingly, when th e p ower from the engine
gears (5) and case (10), right and left side gears (5) exceeds the slip limits, both wheels slip and the dif-
cannot rotate freely, thus the operation of the differ- ferential does not work.
ential is restricted. No load is applied to the brake on the back side of
each side gear.
Mechanism of generation of braking torque by
right and left side gears (5)
Shaft (7) is supported on the cam surfaces made on

the surfaces of pressure rings (8) which 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 both pressure rings
(8) 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.
WA430-6 10-59
2. When drive forces of right and left wheels are Difference of wheel drive force in each type of differ-
unbalanced ential when either wheel slips
[When the road conditions (coefficients of friction)
under both wheels and the wheel loads are uneven Wheel drive force
(Drive force of slipping wheel is 1)
and either wheel slips more easily]
Example 1. When either wheel is on soft ground in Slipping Locked Total
wheel wheel (Ratio)
digging work
Example 2. When either wheel is on snow and the Anti-slip differential 1 2.64 3.64 (1.82)
other one is on asphalt in snow remov- Ordinary differential 1 1 2 (1)
ing work
Example 3. When the right and left wheel loads are On a road where either wheel slips easily, the drive
unbalanced in travel on a slope force of the anti-slip differential is 1.82 times as large
The power from the transmission is distributed as that of the ordinary differential.
evenly by the differential gears to the right and left.
If the distributed drive force limits the wheel slip limit While machine is turning
on the slipping side, the excess of the drive force is The differential gears in the anti-slip differential oper-
transmitted through the brake on the back side of ate similarly to those in the ordinary differential.
the side gear and the case to the brake on the oppo- Accordingly, a difference in rotation speed between
site side (locked side) and given to the locked wheel. the outer and inner tires necessary for turning is
Only when the excessive drive force exceeds the generated smoothly.
braking force, the differential starts working.
10-60 WA430-6
Blank for technical reason
WA430-6 10-61
STRUCTURE AND FUNCTION FINAL DRIVE
Final drive
Front
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)
10-62 WA430-6
Unit: mm

Clearance between pinion gear size Shaft Hole clearance limit
6
bearing and shaft +0.013 –0.012 –0.025 –
40 — Replace
+0.002 –0.012 –0.002
Clearance between axle hous- +0.100 +0.100 –0.100 –
7 382 —
ing and ring gear +0.100 +0.100 0.100
Clearance between oil seal and
8 Max. 0.2 Adjust
housing
+0.500 +0.072 –0.500 –
Housing 200 —
Press fitting part +0.300 +0.072 –0.228
9
of axle shaft seal –0.012 –0.300 –0.500 –
Shaft 160 —
–0.063 –0.500 –0.237
Clearance in +0.025 –0.014 –0.085 –
press fitting part of +0.025 –0.060 –0.014
10 Replace
axle housing +0.068 +0.025 –0.068 –
Inner race 133.35 —
bearing +0.043 +0.025 –0.018
Clearance in +0.025 –0.045 –0.110 –
Outer race 160 —
11
axle housing +0.035 –0.012 –0.055 –
Inner race 105 —
bearing +0.013 –0.020 –0.013
12 End play of axle shaft 0 – 0.100 Adjust
+0.025 +0.207 0.120 –
13 Clearance around guide pin 12 — Replace
+0.007 +0.145 0.200
WA430-6 10-63
Rear
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)
10-64 WA430-6
Unit: mm

Clearance between pinion gear size Shaft Hole clearance limit
6
bearing and shaft +0.013 –0.012 –0.025 –
40 — Replace
+0.002 –0.012 –0.002
Clearance between axle hous- +0.100 +0.100 –0.100 –
7 358 —
ing and ring gear +0.030 +0.100 0.070
Clearance between oil seal and
8 Max. 0.2 Adjust
housing
+0.500 +0.072 –0.500 –
Housing 215 —
Press fitting part +0.300 +0.072 –0.228
9
of axle shaft seal –0.012 –0.300 –0.500 –
Shaft 180 —
–0.063 –0.500 –0.237
Clearance in –0.012 –0.045 –0.085 –
Outer race 180 —
press fitting part of –0.025 –0.085 –0.020
10 Replace
axle housing +0.045 –0.012 –0.065 –
Inner race 120 —
bearing +0.023 –0.020 –0.023
Clearance in +0.025 –0.012 –0.077 –
11
axle housing +0.059 +0.025 –0.059 –
Inner race 98.425 —
bearing +0.037 +0.025 –0.012
12 End play of axle shaft 0 – 0.100 Adjust
+0.025 +0.207 0.120 –
13 Clearance around guide pin 12 — Replace
+0.007 +0.145 0.200
WA430-6 10-65
Outline
• The final drive finally reduces the rotation speed
of the engine and increases the drive force.
• Ring gear (4) is press fitted to the axle housing
and fixed with the pin.
• The rotation speed transmitted from the differen-
tial through sun gear shaft (5) is reduced by the
planetary gear unit and the drive force is in-
creased.
The increased drive force is transmitted through
planetary carrier (2) and axle shaft (3) to the tire.
10-66 WA430-6
STRUCTURE AND FUNCTION STEERING PIPING DIAGRAM
Steering piping diagram
1. Steering cylinder (right) 7. Emergency steering pump

2. Steering valve 8. Stop valve (right)
3. Hydraulic tank 9. Stop valve (left)
4. Cooling fan pump 10. Accumulator (for PPC circuit)
5. Steering pump 11. Orbit-roll valve
6. Emergency steering motor 12. Steering cylinder (left)
WA430-6 10-67
STRUCTURE AND FUNCTION STEERING COLUMN
Steering column
1. Steering wheel
2. Steering column
3. Tilt lever
4. Short column
5. Orbit-roll valve
Unit: mm

Clearance between steering
6 shaft and steering column Replace
bushing –0.08 +0.15
19 0.05 – 0.23 0.4
–0.08 +0.05
10-68 WA430-6
STRUCTURE AND FUNCTION STEERING PUMP
Steering pump
Model: LPV63
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
WA430-6 10-69
1. Pump unit
PA : Control basic pressure outlet port

PE : Control pressure input port
PD4 : Drain port
PD5 : Drain port
10-70 WA430-6
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
WA430-6 10-71
2. Servo valve
T : Drain port
P1 : Pump discharge port
PE : Control pressure output port
10-72 WA430-6
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
WA430-6 10-73
Function
• The rotation and torque of the engine are trans-
mitted to the shaft of this pump. Then, this pump
converts the rotation and torque into hydraulic
pressure and discharges hydraulic oil according
to the load.
• The discharge of this pump can be changed by
changing the swash plate angle in it.
Structure
• Cylinder block (6) is supported on shaft (1)
through spline (a). Shaft (1) is supported on the
front and rear bearings.
• The end of piston (5) has a spherical hollow and
is combined with shoe (4). Piston (5) and shoe
(4) form a spherical bearing.
• 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 cir-
cularly. Shoe (4) leads high-pressure oil to form
a static pressure bearing and slides.
balance on the valve plate is maintained properly.
• The oil in each cylinder of cylinder block (6) can be
sucked and discharged through valve plate (7).
10-74 WA430-6
Operation
1. Operation of pump
• Cylinder block (6) rotates together with shaft (1). • If center line (X) of rocker cam (3) is equal to the
Shoe (4) slides on plane (A). At this time, rocker axial direction of cylinder block (6) (the swash
cam (3) slants around ball (9). As a result, angle plate angle is 0), there is not a difference be-
(a) between center line (X) of rocker cam (3) and tween volumes (E) and (F) in cylinder block (6)
the axis of cylinder block (6) changes. Angle (a) and the oil is not sucked or discharged. (The
is called the swash plate angle. swash plate angle is not set to 0 actually, howev-
er.)
• In short, swash plate angle (a) is in proportion to
the pump discharge.
• 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).
• Accordingly, piston (5) slides inside cylinder
block (6) and a difference is made between vol-
umes (E) and (F) in cylinder block (6). As a re-
sult, each piston sucks and discharges oil by (F)
– (E).
charge stroke.)
WA430-6 10-75
2. Control of discharge LS valve

ence between volumes (E) and (F) is increased, Function
or discharge (Q) is increased. Swash plate angle • The LS valve controls the pump discharge ac-
(a) is changed with servo piston (11). cording to the stroke of the control lever, or the
• Servo piston (11) reciprocates straight according demand flow for the actuator.
to the signal pressure of the PC valve and LS • The LS valve detects the demand flow for the ac-
valve. This straight motion is transmitted to rock- tuator from differential pressure ( PLS) be-
er cam (3). Then, rocker cam (3) supported on tween control valve inlet pressure (PPLS) and
case (2) through ball (9) rocks in rotational direc- control valve outlet pressure (PLS) and controls
tions. main pump discharge (Q). ((PPLS) is called the
LS pump pressure, (PLS) the LS pressure, and
( PLS) the LS differential pressure.)
• In other words, the pressure loss caused by flow
of oil through the opening of the control valve
spool (= LS differential pressure PLS) is de-
tected, and then pump discharge (Q) is con-
trolled to keep that pressure loss constant and
supply the pump discharge according to the de-
mand flow for the actuator.
• Main pump discharge pressure (PP), LS pump
pressure (PPLS), and LS pressure (PLS) are led
to the LS valve. The relationship between LS dif-
ferential pressure ( PLS) and pump discharge
(Q) changes as shown below.
10-76 WA430-6
PC valve 3. When pump pressure (PA) is high

Model: LPV63 • The pressure of spool (5) is increased and spool
(3) is a little to the left (Fig. 2). At this time, ports
Function (C) and (B) are connected to each other and the
• The PC valve limits the oil flow to a certain level pressure in the LS valve is pump pressure (PA).
(according to the discharge pressure) even if the • At this time, ports (F) and (G) of the LS valve are
stroke of the control valve is increased extremely connected to each other. As a result, the pres-
so that the horsepower absorbed by the pump sure in port (J) becomes pump pressure (PA)
will not exceed the engine horsepower, as long and servo piston (6) moves to the right.
as pump discharge pressure (PA) is high. • Consequently, the pump discharge is de-
• In other words, the PC valve decreases the creased.
pump discharge when the load is increased and • As servo piston (6) moves, lever (1) moves to the
the pump discharge pressure rises, and increas- right and spring (2) is compressed and its spring
es it when the pump discharge pressure lowers. load is increased. Consequently, spool (3)
• The relationship between the pump pressure moves to the right to disconnect ports (C) and
and pump discharge is shown below. (B), and then drain pressure ports (D) and (C)
are connected.
• As a result, the pressure in port (C) lowers and
the piston pressure is decreased and servo pis-
ton (6) stops moving to the right.
• Accordingly, the stopping position (= pump dis-
charge) of servo piston (6) is decided by the po-
sition where the pressure caused by pressure
(PA) applied to spool (5) is balanced with the
force of spring (2) applied through spool (3) (Fig.
3).
Operation
1. Function of spring
• The spring load of spring (2) at the PC valve is
decided by the position of the swash plate.
• 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

• 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).
• At this time, ports (F) and (G) of the LS valve are
connected to each other. As a result, the pres-
sure in port (J) becomes drain pressure (PT) and
servo piston (6) moves to the left.
• Consequently, the pump discharge is increased.
• 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.
• As a result, the pressure in port (C) rises and the
piston pressure is increased and servo piston (6)
stops moving to the left.
WA430-6 10-77
When load is light

(Fig. 1)
When load is heavy

(Fig. 2)
10-78 WA430-6
When balanced
(Fig. 3)
WA430-6 10-79
STRUCTURE AND FUNCTION STEERING VALVE
Steering valve
P1 : 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
10-80 WA430-6
WA430-6 10-81
1. Relief valve
2. Flow control spool
3. Steering relief valve
4. Steering spool
5. Overload relief valve
Unit: mm

6 Steering spool return spring length load load
56.9 N 45.5 N
37.2 32.0 —
{5.80 kg} {4.64 kg}
8.8 N 7.0 N
7 Poppet spring 20.9 13.2 —
{0.9 kg} {0.72 kg} Replace
147.1 N 117.7 N
8 Flow control spool return spring 69.65 68.5 —
{15.0 kg} {12.0 kg}
182 N 145.6 N
9 Steering relief valve spring 24.0 22.2 —
{18.6 kg} {14.8 kg}
55.3 N 44.2 N
10 Relief valve spring 29.75 26.5 —
{5.64 kg} {4.51 kg}
10-82 WA430-6
Operation of flow amplifier
When spool is in neutral

(When orbit-roll valve is not in operation)
• Since both ports (Pa) and (Pb) are connected through the orbit-roll valve, steering spool (1) is kept in neutral
by right and left return springs (2).
When spool is in operation

(When oil flows in port (Pa))
• The pressure in port (Pa) rises and steering spool (1) compresses left return spring (2) and moves to the left.
• The oil in port (Pa) flows through the hole of spring seat (3) and orifice (a) of steering spool (1) to port (Pb).
• Since port (Pb) is connected through the orbit-roll valve to the drain circuit, the oil in port (Pb) is drained.
• Since the pressure generated in port (Pa) is in proportion to the flow rate of the oil, steering spool (1) moves
to a position at which the oil pressure reduced by orifice (a) is balanced with the tension of return spring (2).
WA430-6 10-83
When spool returns

(When steering wheel is stopped)
• Since both ports (Pa) and (Pb) are connected through the orbit-roll valve, steering spool (1) is kept in neutral
by left return spring (2).
10-84 WA430-6
Operation of flow control spool
When steering spool is in neutral
• The oil from the steering pump flows in port (P). • If the oil pressure in port (Pr) rises above the set
• Since notch (e) is closed, the oil pressure in port pressure, the swash plate angle of the steering
(P) rises and is led through orifice (a) to pressure pump is reduced to reduce the discharge.
receiving chamber (X) to move flow control spool • If the oil pressure in port (P) rises further after the
(1) to the left. discharge of the pump is minimized, flow control
• The oil in pressure receiving chamber (Y) is spool (1) moves to the left further.
drained through orifice (b), notch (f), and port • If the oil pressure in pressure receiving chamber
(T1). (X) rises above the set pressure, notch (d) opens
• If the oil pressure in pressure receiving chamber and the oil in port (P) is drained through notch (d)
(X) rises above the set pressure, flow control and port (T1).
spool (1) moves to the left and notch (c) opens.
• The oil in port (P) flows through notch (c) and port
(Pr) to the LS valve of the steering pump.
• Port (Pr) is connected through orifice (j) to port
(T2).
• 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).
WA430-6 10-85
When steering spool operates
• If steering spool (2) operates, notch (f) closes • The oil returning from the steering cylinder is
and pressure receiving chamber (Y) and port drained through orifice (g) and port (T1).
(T1) are disconnected and notch (e) opens. • Even after flow control spool (1) moves to the
• The oil pressure in pressure receiving chamber right to close notch (d), it moves further to the
(Y) rises and flow control spool (1) moves to the right, as long as the pressure before notch (e) is
right and the open area of notch (d) reduces. below the set pressure.
• The oil before notch (e) is led to pressure receiv- • Since the open area of notch (c) reduces, the oil
ing chamber (X) and the oil after notch (e) is led flow into port (Pr) reduces and the oil pressure in
to pressure receiving chamber (Y). port (Pr) lowers.
• If the oil pressure in pressure receiving chamber • If the oil pressure in port (Pr) lowers, the LS valve
(Y) rises higher than that in port (A), the oil flow- of the steering pump increases the discharge of
ing from orifice (h) pushes and opens load check the pump and keeps the oil pressure in port (Pr)
valve (3) to the left. to the set pressure.
• Since the oil from notch (e) flows through port (A) • Flow control spool (1) is held to a position at
to the steering cylinder, a pressure difference is which the pressure in port (P) is balanced with
made between before and after notch (e). the pressure in port (Pr), thus the discharge of
• Since flow control spool (1) works to keep the dif- the pump is kept constant.
ferential pressure between before and after • If the open rate of notch (e) changes, the oil flow
notch (e) to the set pressure, the oil is discharged changes according to it to keep the oil pressure
to the steering cylinder according to the open in port (Pr) constant.
rate of notch (e).
• The excessive oil from the steering pump is
drained through notch (d) and port (T1).
10-86 WA430-6
Operation of steering valve
Neutral
• Since the steering wheel is not operated, steer-

ing spool (1) does not move.
• The oil from the steering pump flows in port (P).
• 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).
WA430-6 10-87
Turning left
• If the steering wheel is turned to the left, the out-

put pressure from the orbit-roll valve enters port
(Pa) and steering spool (1) is pushed to the right.
• The oil from the steering pump flows in port (P),
and then flows through flow control spool (2) to
steering spool (1).
• Load check valve (3) is pushed and opened to
the left, and then the oil flows to the head side of
the left steering cylinder and to the bottom side of
the right steering cylinder to turn the machine to
the left.
• The oil returning from the right and left steering
cylinders is drained through load check valve (4)
and port (T1).
10-88 WA430-6
Turning right
• 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.
• The oil from the steering pump flows in port (P),
and then flows through flow control spool (2) to
steering spool (1).
• Load check valve (4) is pushed and opened to
the right, and then 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 ma-
chine to the right.
• The oil returning from the right and left steering
cylinders is drained through load check valve (3)
and port (T1).
WA430-6 10-89
Steering relief valve

1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
• The steering relief valve is installed to the steer-
ing valve. It holds the oil pressure in the steering
circuit to the set pressure during the steering op-
eration.
10-90 WA430-6
Operation of steering relief valve
• If the oil pressure in the steering circuit rises to

the level which is set with adjustment screw (1)
and spring (2), pilot poppet (3) opens and the oil
is drained through port (T1).
• The pressures in receiving chambers (X) and (Y)
is unbalanced and flow control spool (4) moves
to the left.
• 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 pres-
sure.
WA430-6 10-91
Overload relief valve Operation
Operation as relief valve
• Port (A) is connected to the cylinder circuit

and port (B) is connected to the drain circuit.
• The oil flows through the hole of poppet (1)
to the inside of relief valve poppet (2).
• Check valve poppet (3) and relief valve pop-
pet (2) are seated securely by the area differ-
ence between diameters (d1) and (d2).
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
Function
• The overload relief valve is installed to the steer-
ing valve. It protects the cylinder circuit from ab-
• If the oil pressure in port (A) rises above the
normally high pressure generated when an
set pressure of the relief valve, pilot poppet
impact is applied to the cylinder while the steer-
(4) is pushed and opened to the right.
ing valve is in neutral.
• The oil flows through pilot poppet (4) and
• If abnormally high pressure is generated on the
hole to port (B).
cylinder side, the overload relief valve works as a
safety valve to prevent breakage of the cylinder
and hydraulic piping.
• If negative pressure is generated on the cylinder
side, the overload relief valve works as a suction
valve to prevent occurrence of vacuum in the cir-
cuit.
10-92 WA430-6
Operation as suction valve
• As pilot poppet (4) opens, the oil pressure on

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

poppet (2) becomes lower than the oil pres-
sure in port (A).
• 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 ab-
normally high pressure.
WA430-6 10-93
Relief valve
1. Plug
2. Spring
3. Valve
4. Valve seat
Function
• 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 pro-
tect the LS circuit of the steering pump from ab-
normally high pressure.
10-94 WA430-6
STRUCTURE AND FUNCTION ORBIT-ROLL VALVE
Orbit-roll valve
P: From charge valve 1. Gerotor

T: Drain 2. Valve body
L: To left stopper valve 3. Drive shaft
R: To right stopper valve 4. Centering spring
5. Needle bearing
6. Bushing
7. Center pin
8. Sleeve
9. Spool
10. Spacer
11. End cap
WA430-6 10-95
Outline Structure
• The orbit-roll valve is connected to the drive shaft • Top (A) of spool (9) is connected to the drive
of the steering column. It changes the oil flow shaft of the steering column and further connect-
from the steering pump to the right and left steered to sleeve (8) through center pin (7) (which is
ing cylinders to change the travel direction of the not in contact with spool (9) while the steering
machine. wheel is in neutral) and centering spring (2).
• The orbit-roll valve is roughly divided into spool • Top (B) of drive shaft (3) is engaged with center
(9) and sleeve (8) which have rotary selecting pin (7) and combined with sleeve (8) in one body,
function and gerotor (5) (combined rotor (5a) and and the bottom is engaged with the spline of rotor
stator (5b)) which operates as a hydraulic motor (5a) of the gerotor (5).
during the normal steering operation and as a • Valve body (4) has 4 ports, which are connected
hand pump (its operating effort is too high for you to the pump circuit, tank circuit, left steering cir-
to operate it actually, however) when the oil is not cuit, and right steering circuit respectively. The
supplied because of a trouble of the steering ports on the pump side and tank side are con-
pump or engine. 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.
10-96 WA430-6
Connection of hand pump and sleeve
• The connections of suction and discharge openings

(P) of the gerotor and sleeve ports are shown in the
above figure.
• If the steering wheel is turned to the right, ports (a),
(c), (e), (g), (i), and (k) are connected to the pump
side by the vertical grooves of the spool. Similarly,
ports (b), (d), (f), (h), (j), and (l) are connected to the
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 con-
nected 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.
If the steering wheel is turned by 90° from the
above condition, the connections are changed as
shown in Fig. 2.
Under this condition, ports (2), (3), and (4) are in
the suction state and connected to ports (k), (a),
and (c). Ports (5), (6), and (7) are in the discharge
state and connected to ports (d), (f), and (h).
• As shown above, the ports in the discharge state of
the gerotor are connected to the ports which are
connected to the steering cylinder. The ports in the
suction state are connected to the pump circuit.
• The internal gear of the gerotor advances by 1 tooth
as the steering wheel rotates by 1/7 of a turn 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.
WA430-6 10-97
Role of centering spring
• 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.
• If the steering wheel is turned, spool (9) com-
presses centering spring (2) and angular dis-
placement (a) is made 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 is
not sent to the steering cylinder any more and its
pressure rises.
To prevent this, when the steering wheel stops
turning, it is returned by the reaction force of
centering spring (2) toward the neutral position
by angular displacement (a) of spool (9) and
sleeve (8).
10-98 WA430-6
STRUCTURE AND FUNCTION STOP VALVE
Stop valve
A : From orbit-roll valve 1. Bellows

B : To steering valve 2. Wiper
DR: Drain 3. Seal
4. Poppet
5. Spring
6. Spool
7. Spring
WA430-6 10-99
STRUCTURE AND FUNCTION STEERING RELIEF VALVE
Steering relief valve
P1: From steering pump Outline

P2: From emergency steering pump • The steering relief valve is installed to the right
T : Drain side of the transmission and used to hold the
S1: Mounting opening of steering pump oil pres- steering oil pressure to the set pressure.
(Cranking pressure at 0.5 l/min)

sure switch (Lo) Set pressure: 1.96 MPa {20 kg/cm2}
S2: Mounting opening of steering pump oil pres-
sure switch (Hi)
S3: Mounting opening of emergency steering oil
pressure switch
1. Block
2. Relief valve
3. Orifice
10-100 WA430-6
STRUCTURE AND FUNCTION STEERING CYLINDER
Steering cylinder
Unit: mm

Clearance between bushing of
1 frame connecting part of cylin-
der rod and mounting pin –0.025 +0.142 0.080 –
50 —
–0.025 +0.080 0.167
Clearance between bushing of
–0.025 +0.142 0.080 –
2 frame connecting part of cylin- 50 —
–0.025 +0.080 0.167 Replace
der bottom and mounting pin
Width of bushing Width of hinge Standard (a + b) clearance
Connecting part of steering
3 Max. 0.5
cylinder and rear frame 60 66
(after shim is adjusted)
Connecting part of steering Max. 0.5
4 60 63
cylinder and front frame (after shim is adjusted)
WA430-6 10-101
STRUCTURE AND FUNCTION STEERING CYLINDER
Unit: mm

Replace
Clearance between piston rod and size Shaft Hole clearance limit
1 pin and
bushing –0.025 +0.141 0.021 –
45 0.505 bushing
–0.064 –0.004 0.205
2 Tightening torque of cylinder head 569 ± 57.0 Nm {58 ± 5.8 kgm}
3 Tightening torque of cylinder piston 785 ± 78.5 Nm {80 ± 8.0 kgm} (Width across flats: 46 mm)
Retighten
Tightening torque of plug on cylin-
4 9.8 – 12.74 Nm {1.0 – 1.3 kgm}
der head port side
10-102 WA430-6
STRUCTURE AND FUNCTION EMERGENCY STEERING MOTOR
Emergency steering motor
1. Terminal E Function
2. Terminal M • When the oil pressure in the steering circuit low-
ers abnormally, the emergency steering motor
drives the emergency steering pump, upon re-
ceiving the signal from the transmission control-
ler.
Specifications
Type Direct current motor

Rated voltage 24 V
Rated output 0.9 kW
WA430-6 10-103
STRUCTURE AND FUNCTION EMERGENCY STEERING PUMP
Emergency steering pump

Model: SBL (1) 21
Unit: mm

Standard clearance Clearance limit
1 Side clearance
0.10 – 0.15 0.19
Clearance between plain bear-
2 0.060 – 0.119 0.20
ing and gear shaft Replace
3 Driven depth of pin –0.5
10 —
–0.5
4 Torque of spline turning shaft 2.0 – 4.9 Nm {0.2 – 0.5 kgm}
Discharge Standard Allowable
Speed
Discharge pressure discharge discharge
(rpm)
— Oil: SAE10WCD (MPa {kg/cm2}) (l/min) (l/min) —
Oil temperature: 45 – 55°C 20.6
3,500 67.6 62.4
{210}
Function
• The emergency steering pump is installed to-
gether 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.
10-104 WA430-6
STRUCTURE AND FUNCTION JOYSTICK STEERING LEVER LINKAGE
Joystick steering lever linkage

(If equipped)
1. Shift up switch 9. Console lock lever

2. Shift down switch 10. Height adjustment lock lever
3. FNR switch 11. Angle and forward/backward adjustment lock le-
4. Joystick steering lever ver
5. Joystick ON/OFF switch 12. Console
6. HI/LOW selector switch 13. Block
7. Horn switch 14. Joystick EPC valve
8. Steering electric lever 15. Orbit-roll valve
WA430-6 10-105
STRUCTURE AND FUNCTION STEERING ELECTRIC LEVER
Steering electric lever

(If equipped)
1. Body Function
2. Piston • The steering electric lever is installed to the left
3. Lever console and connected to the joystick steering
4. Disc lever.
5. Retainer • If the joystick steering lever is operated, disc (4)
6. Lever rotates and pushes down piston (2), and potenti-
7. Potentiometer ometer (7) rotates consequently.
8. Connector • Potentiometer (7) senses the operating angle
(stroke) of the joystick steering lever and outputs
it as a signal voltage to the work equipment con-
troller.
• The potentiometer is installed in the lateral direc-
tion and it outputs the 2 opposite signal voltages
shown in the above figure.
10-106 WA430-6
STRUCTURE AND FUNCTION STEERING ELECTRIC LEVER
Unit: mm

Free length
1 Metering spring length load load If damaged or
diameter
deformed,
5.88 N 4.71 N
49 x 7.0 25 — replace spring
{0.6 kg} {0.48 kg}
73.5 N 58.8 N
2 Centering spring 49.8 x 15.5 32 —
{7.5 kg} {6.0 kg}
WA430-6 10-107
STRUCTURE AND FUNCTION JOYSTICK EPC VALVE
Joystick EPC valve

(If equipped)
Function
• The joystick EPC valve selects the right or left
steering circuit and adjusts the flow rate accord-
ing to the operation of the joystick steering lever.
• The solenoid of the joystick EPC valve receives
signal voltage conformed to the operating angle
(stroke) of the steering electric lever from the
work equipment controller and adjusts the flow
rate in the steering circuit.
• The flow rate in the steering circuit is decided by
the signal voltage from the work equipment con-
troller.
10-108 WA430-6
STRUCTURE AND FUNCTION JOYSTICK EPC VALVE
WA430-6 10-109
STRUCTURE AND FUNCTION BRAKE PIPING DIAGRAM
Brake piping diagram
10-110 WA430-6
STRUCTURE AND FUNCTION BRAKE PIPING DIAGRAM
1. Brake valve (left)

2. Brake valve (right)
3. Hydraulic tank
4. Cooling fan pump
5. Accumulator (for front)
6. Accumulator (for rear)
7. Accumulator (for rear)
8. Accumulator (for front)
9. Charge valve
11. Rear brake
12. Parking brake solenoid valve
13. Parking brake
14. Emergency parking brake reset valve
15. Front brake
WA430-6 10-111
STRUCTURE AND FUNCTION CHARGE VALVE
Charge valve
P : From pump
A : To cooling fan motor
PPC : To PPC valve
ACC1: To right brake valve port PA
ACC2: To right brake valve port PB
To left brake valve port P
T : Drain
S1 : Brake oil pressure switch (low pressure)
S2 : Emergency brake oil pressure switch
G : Accumulator charge pressure pickup port
10-112 WA430-6
1. Valve body Function

2. Sequence valve (H1) • The charge valve keeps the oil pressure from the
3. Relief valve (R2) pump to the set pressure and stores it in the ac-
4. Shuttle valve (S1) cumulator.
5. Priority valve • If the pressure in the accumulator rises, the cir-
6. PPC relief valve (R3) cuit to the cooling fan motor opens and the oil
7. Main relief valve (R1) from the pump is output as cooling fan motor
drive pressure.
• If the oil pressure rises above the set pressure,
the oil from the pump is led to the drain circuit to
reduce the load on the pump.
• The charge valve reduces the pressure of the oil
from the pump and outputs the basic pressure of
the pilot circuit.
WA430-6 10-113
Operation
When oil is not supplied to accumulator (Cut-out state)
• 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).
• Relief valve (1) opens and oil passage (C) is con-
nected to port (T).
• The oil from the pump flows through orifices (a)
and (b) and oil passage (C) to port (T).
• Since the oil pressure is reduced when the oil
flows through orifice (a), a pressure difference is
made between pressure receiving chambers (D)
and (E).
• 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.
• The open area on the side of port (P) and orifice
(c) is reduced and port (P) is connected to port
(A) gradually.
• The oil from the pump flows through port (P), se-
quence valve (7), and port (A) to the cooling fan
motor.
10-114 WA430-6
When oil is supplied to accumulator
1. When oil is supplied to accumulator
• If the pressure in oil passage (B) lowers below

the set pressure of relief valve (1), relief valve (1)
is returned to the left by the tension of springs (3)
and (4).
• Relief valve (1) closes and oil passage (C) is dis-
connected from port (T).
• Since oil passage (C) is disconnected from port
(T), the oil pressure is reduced less when the oil
flows through orifice (a) and the pressure differ-
ence between pressure receiving chambers (D)
and (E) is reduced.
• Priority valve (5) is moved to the left by the ten-
sion of spring (6).
• The open area on the side of port (P) and orifice
(c) is increased and port (P) is disconnected from
port (A) gradually.
• If the oil pressure from the pump becomes higher
than the pressure in ports (ACC1) and (ACC2), it
pushes up check valve (8) and the pressure in
ports (ACC1) and (ACC2) is increased.
• The oil of a certain quantity set by the size (area)
of orifice (c) and the pressure difference between
before and after 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).
WA430-6 10-115
2. When pressure reaches cut-out pressure
• 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).
• Relief valve (1) opens and oil passage (C) is con-
nected to port (T).
• A pressure difference is made between the right
side and left side of piston (2), and piston (2)
moves to the right and opens relief valve (1) forc-
ibly.
• Since pressure receiving chamber (E) of priority
valve (5) is also connected to oil passage (C), the
pressure in pressure receiving chamber (E) is
the drain pressure.
• Since the pressure in pressure receiving cham-
ber (D) also lowers to the level equivalent to the
load of spring (6), oil supply to oil passage (B) is
stopped.
10-116 WA430-6
Main relief valve (R1) PPC relief valve (R3)
• If the pressure in port (P) (pump pressure) rises • If the pressure from port (PPC) (pilot pressure)
above the set pressure, it compresses spring (1) rises above the set pressure, the oil from the
and moves ball (2) to the left. pump compresses spring (1) and moves ball (2)
• The pressure of the oil from the pump is reduced to the left.
when the oil flows through orifice (a), and the • The pressure of the oil from the pump is reduced
pressure difference compresses spring (3) and when the oil flows through orifice (a), and the
moves valve (4) to the left largely. pressure difference compresses spring (3) and
• Since port (P) is connected to port (T) and the moves valve (4) to the left.
pump pressure is drained, the maximum pres- • Since the open area between port (A) and port
sure in the charge circuit is limited to protect the (P) is reduced and the pressure is reduced, the
circuit. pressure in port (P) is not lowered to the set pres-
sure of the relief valve but maintained.
• The pressure in port (A) is kept constant accord-
ing to the open area between port (A) and port
(P) and supplied as the basic pressure of the pi-
lot circuit.
• If abnormal pressure is generated in port (A),
port (A) is connected to port (T) to release the ab-
normal pressure and protect the pilot circuit.
WA430-6 10-117
Sequence valve (H1) Shuttle valve (S1)
• The pressure in port (P) (pump pressure) is ap- • When the pressure in port (ACC1) is higher than
plied to the left end of sequence valve (1) and the that in port (ACC2), shuttle valve (1) moves to
drain pressure is applied to the right end. the left to disconnect port (ACC1) from oil pas-
• If the pump pressure rises above the set pres- sage (B).
sure of spring (2), sequence valve (1) moves to • The open area between port (ACC2) and oil pas-
the right and port (P) is connected to port (A). sage (B) is increased and the oil is supplied to
• The oil from the pump flows through priority valve the accumulator on the port (ACC2) side.
(3) and port (A) to the cooling fan motor and is • When the pressure in port (ACC2) is higher than
used to drive the motor. that in port (ACC1), the oil is supplied to the ac-
• Even when the cooling fan motor drive pressure cumulator on the port (ACC1) side.
is low, the pump pressure is kept above the set • The oil from the pump is supplied first to the low-
pressure of spring (2) so that the accumulator pressure side of the 2 systems.
charge pressure and pilot circuit basic pressure
will not lower.
10-118 WA430-6
WA430-6 10-119
STRUCTURE AND FUNCTION BRAKE VALVE
Brake valve
Brake valve (left)
T: Drain port 1. Brake pedal

A: To right brake valve port PP 2. Rod
P: From charge valve port ACC2 3. Spool
4. Cylinder
10-120 WA430-6
Unit: mm
No. Check item Check item Criteria

Clearance between pedal size Shaft Hole clearance limit
5
mounting hole and pin –0.025 +0.1 0.025 –
10 0.25
–0.075 +0.1 0.175
Clearance between roller and –0.025 +0.1 0.025 –
6 10 0.25
pin –0.075 +0.1 0.175
7 Outside diameter of roller –0.5
30 29.2
–0.5
Replace
Installed Installed
Free length Free length Repair limit
8 Control spring length load
0N
34.7 34.7 33.7 —
{0 kg}
40.3 N
9 Control spring 51.8 49.7 50.8 —
{4.12 kg}
116.4 N
10 Return spring 197.8 58 178 —
{11.88 kg}
16.7 N
11 Return spring 31.5 19.5 28 —
{1.7 kg}
WA430-6 10-121
Brake valve (right)
T : Drain port 1. Brake pedal

A : To rear brake 2. Rod
B : To front brake 3. Piston (pilot)
PA : From charge valve port ACC1 4. Spool
PB : From charge valve port ACC2 5. Cylinder (upper)
PP : From left brake valve port A 6. Spool
7. Cylinder (lower)
10-122 WA430-6
Unit: mm

Clearance between pedal mount- size Shaft Hole clearance limit
8
ing hole and pin –0.025 +0.1 0.025 –
10 0.25
–0.075 +0.1 0.175
–0.025 +0.1 0.025 –
9 Clearance between roller and pin 10 0.25
–0.075 +0.1 0.175
10 Outside diameter of roller –0.5
30 29.2
–0.5
Installed
Free length Installed load Free length Repair limit Replace
11 Control spring length
0N
34.7 34.7 33.7 —
{0 kg}
40.3 N
12 Control spring 51.8 49.7 50.8 —
{4.12 kg}
116.4 N
13 Return spring 197.8 58 178 —
{11.88 kg}
16.7 N
14 Return spring 31.5 19.5 28 —
{1.7 kg}
17.7 N
15 Return spring 17 16.5 — —
{1.8 kg}
WA430-6 10-123
Outline Operation
• There are 2 brake valves installed in parallel to
front lower part of the operator's seat. They are When brake is applied (Right brake valve)
operated by pressing the pedal. Upper section
• If the right pedal is pressed, the oil is supplied to • If pedal (1) is pressed, the pressing effort is
the brake cylinder to operate the brake. transmitted through rod (2) and spring (4) to
• If the left pedal is pressed, the oil is supplied to spool (3).
the right pedal and the brake is operated similarly • If spool (3) lowers, port (PA) is disconnected
to when the right pedal is pressed. from port (T) and the oil from the pump and accu-
• If the left brake pedal is pressed, the transmis- mulator flows through port (PA) to port (A) to op-
sion cut-off switch is operated. As a result, the erate the rear brake cylinder.
transmission control valve is operated electrical-
ly to set the transmission in neutral. Lower section
• If pedal (1) is pressed, the pressing effort is
transmitted through rod (2) and spring (4) to
spool (3).
• The pressing effort transmitted to spool (3) is fur-
ther transmitted through plunger (6) to spool (5).
• If spool (5) lowers, port (PB) is disconnected
from port (T) and the oil from the pump and accu-
mulator flows through port (PB) to port (B) to op-
erate the front brake cylinder.
10-124 WA430-6
When brake is applied (Left brake valve)

• If pedal (7) is pressed, the pressing effort is
transmitted through rod (8) and spring (9) to
spool (10).
• If spool (10) lowers, port (P) is disconnected from
port (T) and the oil from the pump and accumu-
lator flows through port (P) to port (A).
• Since port (A) of the left brake valve is connected
to port (PP) of the right brake valve by the hose,
the oil flowing to port (A) flows further to pilot port
(PP) of the right brake valve.
• The oil flowing to pilot port (PP) flows further
through orifice (d) to chamber (D) and pushes
piston (11) down.
• If piston (11) lowers, spool (3) is lowered through
the spring, and then the brake operates similarly
to when the right brake pedal is pressed.
WA430-6 10-125
Operation of brake when upper valve has trouble Lower section

(Right brake valve) • If ports (PA) and (A) of the upper section are dis-
• Even if the oil leaks from the piping on the upper connected, the front brake cylinder is filled with
side, if pedal (1) is pressed, spool (5) is moved the oil and the pressure in the line between ports
mechanically and the brake on the lower side op- (PB) and (B) rises simultaneously, and then the
erates normally. oil flows through orifice (f) of spool (5) to cham-
ber (F).
Operation of brake when lower valve has trouble • The oil pushes up spool (5) by the moving dis-
(Right brake valve) tance of spool (3) and disconnects port (PB) from
• Even if the oil leaks from the piping on the lower port (B).
side, the brake on the upper side operates nor- • Since port (PB) is kept disconnected from port
mally. (T), the brake is kept operated by the oil pressure
applied to the brake cylinder.
• The operating force of the upper section is bal-
anced with the pedal pressing effort and the op-
erating force of the lower section is balanced with
the operating force of the upper section.
• When spools (3) and (5) are moved to the stroke
end, ports (PA) and (A) connected completely,
and ports (PB) and (B) are also connected com-
pletely. As a result, the oil pressure in the front
and rear brake cylinders is equal to the oil pres-
sure from the pump.
• The braking force can be adjusted by adjusting
the pedal pressing effort until spools (3) and (5)
are moved to the stroke end.
Balancing operation (Right brake valve)

Upper section
• If the rear brake cylinder is filled with oil and the
oil pressure in the line between ports (PA) and
(A) rises, the oil flows through orifice (e) of spool
(3) to chamber (E).
• The oil pushes up spool (3) against spring (4)
and disconnects port (PA) from port (A).
• Since port (PA) is kept disconnected from port
(T), the brake is kept operated by the oil pressure
applied to the brake cylinder.
10-126 WA430-6
When brake is released (Right brake valve)

Upper section
• If pedal (1) is released, the operating pressure
applied to spool (3) is reduced, and spool (3) is
pushed up by the back pressure on the brake cyl-
inder and the tension of the spool return spring.
• Ports (A) and (T) are connected and the back
pressure oil on the brake cylinder is drained
through port (T), thus the rear brake is released.
Lower section
• If spool (3) is pushed up, spool (5) is also pushed
up by the back pressure on the brake cylinder
and the tension of the spool return spring.
• Ports (B) and (T) are connected and the back
pressure oil on the brake cylinder is drained
through port (T), thus the front brake is released.
WA430-6 10-127
STRUCTURE AND FUNCTION ACCUMULATOR (FOR BRAKE)
Accumulator (for brake)

1. Valve
2. Top cover
3. Cylinder
4. Free piston
Function
• The accumulator is installed between the charge
valve and brake valve. The space between cyl-
inder (3) and free piston (4) is filled with nitrogen
gas. The nitrogen gas absorbs the hydraulic
pulses generated by the hydraulic pump and se-
cures the braking force and operability when the
engine stops by utilizing its compressibility.
Specifications
Gas used : Nitrogen gas
Amount of gas : 2,850 cc
Charge pressure : 3.43 ± 0.1 MPa {35 ± 1.0 kg/
cm2}) (at 20°C)
10-128 WA430-6
STRUCTURE AND FUNCTION ACCUMULATOR (FOR BRAKE)
1. Top cover
2. Free piston
3. Cylinder
4. End cover
5. Core
Function
• The accumulator is installed between the brake
valve and brake cylinder. The space between
cylinder (3) and free piston (2) is filled with nitro-
gen gas. The nitrogen gas secures the braking
force and operability when the engine stops by
utilizing its compressibility.
Specifications
Amount of gas : 46 cc
Charge pressure : 0.1 ± 0.02 MPa {1 ± 0.2 kg/cm2})
(at 50°C)
WA430-6 10-129
STRUCTURE AND FUNCTION BRAKE
Brake
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)
10-130 WA430-6
Unit: mm

10 Thickness of inner ring
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 Standard size Tolerance Repair limit Replace
12
brake outer ring 27.8 ±0.1 0.3
Installed height Installed load Installed load
13 Load on spring (on 1 spring)
637 N 510 N
6.5
{65 kg} {52 kg}
Outline
• 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).
• The brake cylinder consists of differential hous-
ing (1) and bearing carrier (2), and piston (3) is
installed in it. Inner ring (5) and outer ring (8) are
coupled with the spline of differential housing (1).
• 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).
WA430-6 10-131
Rear
a The following illustration shows the rear brake having the limited slip differential.
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)
10-132 WA430-6
Unit: mm

10 Thickness of inner ring
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 Standard size Tolerance Repair limit Replace
12
brake outer ring 23.3 ±0.1 0.3
Installed height Installed load Installed load
13 Load on spring (on 1 spring)
460 N 372 N
6.5
{47 kg} {38 kg}
Outline
• 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).
• The brake cylinder consists of differential hous-
ing (1) and bearing carrier (2), and piston (3) is
installed in it. Inner ring (5) and outer ring (8) are
coupled with the spline of differential housing (1).
• 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).
WA430-6 10-133
Operation
When brake is "applied" When brake is "released"

• If the brake pedal is pressed, oil pressure (P) • If the oil pressure is released, piston (2) is re-
supplied from the hydraulic tank through the turned by the returning force of spring (8) and
pump and brake charge valve acts on piston (2) clearance is made between inner ring (3) and
in the brake cylinder to move the piston. outer ring (5), and disc (4) becomes free.
Accordingly, disc (4) between piston (2), inner The linings stuck to disc (4) have cross grooves
ring (3), and outer ring (5) is stopped and the on them. While disc (4) is turning, oil flows in
brake is applied. those grooves to cool the linings.
10-134 WA430-6
STRUCTURE AND FUNCTION PARKING BRAKE CONTROL
Parking brake control
1. Parking brake switch

3. Parking brake solenoid valve
4. Parking brake
5. Emergency parking brake reset valve
Outline
• Parking brake (4) is a wet-type multi-disc brake • While the parking brake is applied (While the so-
built in the transmission. It is installed to the out- lenoid valve is turned "OFF"), the signal from the
put shaft bearing and operated mechanically by transmission controller to the transmission sole-
the pressing force of the spring and released hy- noid valve is stopped to keep the transmission in
draulically. neutral.
• If parking brake switch (1) installed to the opera- • Emergency parking brake reset valve (5) is in-
tor's seat is turned "ON", parking brake solenoid stalled to move the machine when it is stopped
valve (3) installed to transmission control valve (and the parking brake is applied) because of a
(2) shuts off the oil pressure and the parking trouble in the engine or drive system.
brake is applied.
• If parking brake switch (1) is turned "OFF", the
hydraulic force in the cylinder releases the park-
ing brake.
WA430-6 10-135
STRUCTURE AND FUNCTION PARKING BRAKE
Parking brake
1. Output shaft Outline

2. Spring • The parking brake is a wet-type multi-disc brake,
3. Spring which is operated mechanically with the spring
4. Piston and stops output shaft (1).
5. Parking brake oil port • The tension of spring (3) presses disc (7) and
6. Plate plate (6) with piston (4) to stop output shaft (1).
7. Disc • The oil pressure from parking brake oil port (5)
8. Wave spring moves piston (4) to release disc (7) and plate (6).
10-136 WA430-6
STRUCTURE AND FUNCTION PARKING BRAKE
Unit: mm

Installed Installed Allowable
9 Parking brake spring (outside) length load load
1,113 N 1,058 N
94 75.2 91.2
{113.5 kg} {107.8 kg}
583 N 553 N
10 Parking brake spring (inside) 94 75.2 91.2 Replace
{59.4 kg} {56.4 kg}
11 Separate plate Thickness 4.0 ±0.05 3.9
Strain — 0.05 0.25
12 Brake disc Thickness 3.2 ±0.08 2.97
Load of wave spring 1,106 N ±57 N 940N
13
(Height: 3.2 mm) {112.8 kg} {±5.8 kg} {95.9 kg}
WA430-6 10-137
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE
Parking brake solenoid valve
1. Movable core
2. Coil
3. Push pin
4. Spring
5. Spool
6. Valve seat
7. Check valve
10-138 WA430-6
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE
Operation
When parking brake is applied When parking brake is released

(When solenoid is de-energized) (When solenoid is energized)
• If the parking brake switch at the operator's seat • If the parking brake switch is turned "OFF", the
is turned "ON", the solenoid is turned "OFF" and solenoid is turned "ON" and spool (5) moves to
spring (4) pushes spool (5) to the left. According- the right. Accordingly, the oil from the pump
ly, pump port (P) is disconnected from parking flows through port (P), spool (5), and port (A) to
brake port (A) and the oil from the pump does not the parking brake. At the same time, port (T) is
flow to the parking brake. closed and the oil is not drained. As a result, the
• At the same time, the oil from the parking brake spring in the parking brake is pushed back by the
is drained through ports (A) and (T). As a result, oil pressure and the parking brake is released.
the disc in the parking brake is pressed by the
spring and the parking brake is applied.
WA430-6 10-139
STRUCTURE AND FUNCTION EMERGENCY PARKING BRAKE RESET VALVE
Emergency parking brake reset valve

A: From accumulator
B: To parking brake solenoid
1. Grip
2. Valve
Function
• The emergency parking brake reset valve is in-
stalled between the accumulator and parking
brake solenoid in the brake circuit. When the
transmission pump cannot supply oil pressure
because of an engine trouble, etc., the emergen-
cy parking brake reset valve is opened manually
to supply the accumulator charge pressure in the
brake circuit to the parking brake cylinder.
10-140 WA430-6
STRUCTURE AND FUNCTION EMERGENCY PARKING BRAKE RESET VALVE
WA430-6 10-141
STRUCTURE AND FUNCTION AXLE MOUNT AND CENTER HINGE PIN
Axle mount and center hinge pin
1. Front axle Outline

2. Front frame • Front frame (2) and rear frame (4) are coupled
3. Rear axle with each other by the bearing and center hinge
4. Rear frame pin between them.
The right and left steering cylinders connect the
front frame and rear frame. They adjust the
bending angle of the frame, or the turning radius
of the machine.
10-142 WA430-6
Unit: mm

1 Thickness of thrust plate
22 ± 0.5 —
+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 +0.472 0.050 –
190 —
–0.122 +0.472 0.594
Clearance between shaft and –0.005 +0.522 0.055 –
4 170 —
hole on rear support side –0.124 +0.050 0.646
WA430-6 10-143
10-144 WA430-6
Unit: mm

Clearance between upper hinge size Shaft Hole clearance limit
1
pin and rear frame –0.030 +0.071 0.066 –
80 —
–0.049 +0.036 0.120
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 —
pin and spacer (large) –0.049 +0.030 0.079
Clearance between rear frame and –0.036 +0.071 0.072 –
5 95 —
spacer (large) –0.071 +0.036 0.142
Clearance between front frame –0.025 –0.048 –0.088 –
6 130 — Replace
and upper hinge pin bearing –0.025 –0.088 –0.023
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 lower 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 bearing –0.025 –0.088 –0.023
Clearance between rear frame and +0.089 +0.054
10 95 –0.089 – 0 —
bushing +0.054 +0.054
Clearance in seal fitting part of +0.17 +0.054 –0.17 –
11 105 —
lower hinge pin +0.08 +0.054 –0.026
Height of upper hinge pin spacer Standard size Tolerance Repair limit
12
(small) 25.5 ±0.1 —
Height of upper hinge pin spacer
13 56 ±0.1 —
(large)
Standard thickness of shim
14 2.5
between upper hinge and retainer
Standard thickness of shim
15 2.5
between upper hinge and retainer
Standard thickness of shim Adjust
16 2
between lower hinge and retainer
Tightening torque of upper hinge 20 ± 2 Nm {2 ± 0.2 kgm} (When shim is adjusted)
17
pin retainer mounting bolt 98 – 123 Nm {10 – 12.5kgm} (Final value)
Tightening torque of lower hinge 20 ± 2 Nm {2 ± 0.2 kgm} (When shim is adjusted)
18
pin retainer mounting bolt 98 – 123 Nm {10 – 12.5kgm} (Final value)
WA430-6 10-145
STRUCTURE AND FUNCTION TIRES
Tires
The radial tires of this machine have the following features.
• High gripping force • High operator comfort • Less frequency of burst • Less uneven wear
• Low fuel consumption • Long life • Less damage of machine • Less generation of heat
Comparison of structures and characteristics of tires
Radial tire Bias tire
Structure Structure
• The cords of carcass (1) are arranged at right an- • The cords of carcass (1) are arranged bias from
gles to the center line of tread (T) (radially). the center line of tread (T).
• Tread (T) is stabilized and protected by several • Side wall (W) and tread (T) are made one.
strong belts (2).
• Side wall (W) and tread (T) are independent from
each other.
Ground contact characteristics Ground contact characteristics

• Even if the tire is deformed by a load, it does not • If the tire is deformed by a load, the ground con-
move uselessly for ground contact and the tact surface is also deformed and it moves use-
ground contact surface is secured stably. lessly. As a result, the ground contact surface
becomes unstable.
Deformation characteristics Deformation characteristics

• Only side wall (W) which receives loads is de- • Side wall (W) which receives loads and tread (T)
formed and tread (T) made of strong belts (2) move as one unit.
keeps independent stability.
10-146 WA430-6
STRUCTURE AND FUNCTION TIRES
WA430-6 10-147
STRUCTURE AND FUNCTION HYDRAULIC PIPING DIAGRAM
Hydraulic piping diagram
10-148 WA430-6
WA430-6 10-149
1. Stabilizer valve Outline

2. Work equipment control valve • The hydraulic system consists of the work equip-
3. Bucket cylinder ment circuit and steering circuit. The work equip-
4. Steering valve ment circuit controls the operation of the bucket
5. Breather and attachments.
6. Hydraulic tank • The oil from hydraulic tank (6) is sent by work
7. Work equipment PPC valve equipment hydraulic pump (13) to work equip-
8. Cooling fan pump ment control valve (2). If the bucket and lift arm
9. Steering pump spools of the work equipment control valve are in
10. Oil cooler the HOLD position, the oil is sent through the
11. Torque converter oil cooler drain circuit of the work equipment control valve,
12. Torque converter hydraulic pump filtered by the filter in the hydraulic tank, and re-
13. Work equipment hydraulic pump turned to the tank.
14. PPC accumulator • If the work equipment control lever is operated,
15. Charge valve the bucket or lift arm spool of work equipment
16. E.C.S.S. accumulator PPC valve (7) moves to operate each spool of
17. Steering cylinder the work equipment control valve (2) hydraulical-
18. Bypass valve ly. Then, the oil flows from the work equipment
19. Lift cylinder control valve to lift cylinder (19) or bucket cylin-
20. Lock valve der (3) to move the lift arm or bucket.
21. Emergency steering pump • The maximum pressure in the hydraulic circuit is
22. Emergency steering motor controlled with the relief valve in work equipment
23. Cooling fan motor control valve (2). The bucket cylinder circuit is
equipped with the safety-suction valve for pro-
tection of the circuit.
• PPC accumulator (14) is installed to the PPC pi-
lot circuit so that the lift arm can be lowered to the
ground even while the engine is stopped.
• Hydraulic tank (6) is pressurized, enclosed, and
equipped with breather (5) having the relief
valve. Certain pressure is applied to this tank to
prevent generation of negative pressure in the
tank and cavitation in the pump.
• 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 leakage from
the piping, etc., emergency steering motor (22)
drives emergency steering pump (21) so that the
machine can be steered.
• Cooling fan motor (23) installed to the radiator is
driven hydraulically and variably with cooling fan
pump (8).
10-150 WA430-6
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL LEVER LINKAGE
Work equipment control lever linkage
1. Work equipment lock lever

2. Directional selector switch
3. Lift arm control lever
4. Bucket control lever
5. Wrist rest
6. Lever stand angle adjustment lever
7. Work equipment PPC valve
8. Wrist rest height adjustment lever
9. Lock valve
WA430-6 10-151
STRUCTURE AND FUNCTION HYDRAULIC TANK
Hydraulic tank
10-152 WA430-6
STRUCTURE AND FUNCTION HYDRAULIC TANK
1. Oil filler cap Breather

2. Breather
3. Hydraulic tank
4. Sub-tank
5. Hydraulic oil temperature sensor
6. Drain valve
7. Drain plug
8. Sight gauge
9. Bypass valve
10. Filter element
11. Strainer
12. Suction strainer
Outline
• Sub-tank (4) is installed to add an air layer to hy-
draulic tank (3). Accordingly, sub-tank (4) works
as an air chamber and there is not hydraulic oil in
it.
Specifications
Capacity of hydraulic tank (l) 188

Quantity of oil in hydraulic tank (l) 139
Set pressure of bypass valve 0.125
(MPa {kg/cm2}) {1.27}
1. Nut
2. Filter element
3. Poppet
4. Sleeve
Prevention of negative pressure in tank

• Since the tank is pressurized and enclosed, if the
fuel level in it lowers, negative pressure is gener-
ated. At this time, sleeve (4) is opened by the dif-
ferential pressure between the tank pressure
and the atmospheric pressure to prevent gener-
ation of the negative pressure.
(Set pressure of air intake valve:
2.0 ± 0.3 kPa {0.02 ± 0.003 kg/cm2})
Prevention of pressure rise in tank

• While the hydraulic circuit is in operation, the oil
level in the tank varies as the hydraulic cylinders
operate, and the temperature rises. Conse-
quently, the pressure in the tank varies, too.
If the pressure in the tank rises above the set lev-
el, poppet (3) operates to release the pressure
from the tank.
(Set pressure of exhaust valve:
0.1 ± 0.015 MPa {1.0 ± 0.15 kg/cm2})
WA430-6 10-153
STRUCTURE AND FUNCTION TORQUE CONVERTER HYDRAULIC PUMP
Torque converter hydraulic pump

Model: SAL(3)112
Unit: mm

Model Standard clearance Clearance limit
1 Side clearance
SAL (3) 112 0.13 – 0.17 0.21
Clearance between plain bear-
2 SAL (3) 112 0.069 – 0.149 0.20 Replace
ing and gear shaft
Model Standard size Tolerance Repair limit
3 Driven depth of pin –0.5
SAL (3) 112 14 —
–0.5
4 Torque of spline turning shaft 6.9 – 11.8 Nm {0.7 – 1.2 kgm}
Discharge Standard Allowable
Discharge Speed
Model pressure delivery delivery
— Oil: SAE10W (rpm) —
(MPa {kg/cm2}) (l/min) (l/min)
Oil temperature: 45 – 55 °C
SAL (3) 112 2,000 2.94 {30} 217 192
Outline
• The torque converter hydraulic pump is installed
to the PTO shaft of the torque converter and driv-
en by the shaft to supply oil to the torque convert-
er and transmission circuits.
10-154 WA430-6
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC PUMP
Work equipment hydraulic pump

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
P1L : Pump pressure input port POP: External pilot pressure input port
1. Pump unit 2. Servo valve 3. Air bleeder
WA430-6 10-155
1. Pump unit
PA : Control basic pressure output port

PE : Control pressure input port
PD4 : Drain port
PD5 : Drain port
PDE : EPC drain port
PEPC : EPC basic pressure input port
10-156 WA430-6
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
WA430-6 10-157
2. Servo valve
T : Drain port
TM : PC mode selector current
P1 : Pump discharge port
PD : Drain port
PE : Control piston pressure input port
PDE : EPC drain port
PEPC : EPC basic pressure input port
10-158 WA430-6
PDE: EPC drain 1. EPC valve
PC valve LS valve
T : Drain 2. Lever T : Drain 11. Spool
PA : Pump pressure 3. Spring PA : Pump pressure 12. Plug
PM : PC mode selector pressure 4. Retainer PE : Control piston pressure 13. Seat
PPL : PC valve output pressure 5. Seat PLS : LS pressure input 14. Spring
6. Spool PPL : PC valve output pressure 15. Nut
7. Sleeve PPLS: LS pump pressure input 16. Plug
8. Piston
9. Seal
10. Piston
WA430-6 10-159
Function Structure
• The rotation and torque of the engine are trans- • Cylinder block (6) is supported on shaft (1)
mitted to the shaft of this pump. Then, this pump through spline (a). Shaft (1) is supported on the
converts the rotation and torque into hydraulic front and rear bearings.
pressure and discharges hydraulic oil according • The end of piston (5) has a spherical hollow and
to the load. is combined with shoe (4). Piston (5) and shoe
• The delivery of this pump can be changed by (4) form a spherical bearing.
changing the swash plate angle in it. • 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 cir-
cularly. Shoe (4) leads high-pressure oil to form
a static pressure bearing and slides.
balance on the valve plate is maintained proper-
ly.
• The oil in each cylinder of cylinder block (6) can
be sucked and discharged through valve plate
(7).
10-160 WA430-6
Operation • If center line (X) of rocker cam (3) is equal to the

axial direction of cylinder block (6) (the swash
1. Operation of pump plate angle is 0), there is not a difference be-
• Cylinder block (6) rotates together with shaft (1). tween volumes (E) and (F) in cylinder block (6)
Shoe (4) slides on plane (A). At this time, rocker and the oil is not sucked or discharged. (The
cam (3) slants around ball (9). As a result, angle swash plate angle is not set to 0 actually, howev-
(a) between center line (X) of rocker cam (3) and er.)
the axis of cylinder block (6) changes. Angle (a) • In short, swash plate angle (a) is in proportion to
is called the swash plate angle. the pump delivery.
• 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).
• Accordingly, piston (5) slides inside cylinder
block (6) and a difference is made between vol-
umes (E) and (F) in cylinder block (6). As a re-
sult, each piston sucks and discharges oil by (F)
– (E).
charge stroke.)
WA430-6 10-161
2. Control of delivery LS valve

ence between volumes (E) and (F) is increased, Function
or delivery (Q) is increased. Swash plate angle
(a) is changed with servo piston (11). • The LS valve controls the pump delivery accord-
• Servo piston (11) reciprocates straight according ing to the stroke of the control lever, or the de-
to the signal pressure of the PC valve and LS mand flow for the actuator.
valve. This straight motion is transmitted to rock- • The LS valve detects the demand flow for the ac-
er cam (3). Then, rocker cam (3) supported on tuator from differential pressure ( PLS) be-
case (2) through ball (9) rocks in rotational direc- tween control valve inlet pressure (PPLS) and
tions. control valve outlet pressure (PLS) and controls
main pump delivery (Q). ((PPLS) is called the LS
pump pressure, (PLS) the LS pressure, and
( PLS) the LS differential pressure.)
• In other words, the pressure loss caused by flow
of oil through the opening of the control valve
spool (= LS differential pressure PLS) is de-
tected, and then pump delivery (Q) is controlled
to keep that pressure loss constant and supply
the pump delivery according to the demand flow
for the actuator.
• Main pump discharge pressure (PP), LS pump
pressure (PPLS), and LS pressure (PLS) are led
to the LS valve. The relationship between LS dif-
ferential pressure ( PLS) and pump delivery (Q)
changes as shown below.
10-162 WA430-6
PC valve • Consequently, the pump delivery is increased.

• As servo piston (9) moves, lever (2) moves to the
Function left and spring (3) expands and its spring load is
• The PC valve limits the oil flow to a certain level decreased. Consequently, spool (6) moves to
(according to the discharge pressure) even if the the left to disconnect ports (C) and (D), and then
stroke of the control valve is increased extremely pump discharge ports (B) and (C) are connected.
so that the horsepower absorbed by the pump • As a result, the pressure in port (C) rises and the
will not exceed the engine horsepower, as long piston pressure is increased and servo piston (9)
as pump discharge pressure (PA) is high. stops moving to the left.
• In other words, the PC valve decreases the
pump delivery when the load is increased and 3. When pump pressure (PA) is high
the pump discharge pressure rises, and increas- • The pressure of spool (10) is increased and
es it when the pump discharge pressure lowers. spool (6) is a little to the left (Fig. 2). At this time,
• If command current (X) sent to the EPC valve is ports (C) and (B) are connected to each other
increased, the relationship between the pump and the pressure in the LS valve is pump pres-
pressure (PA) and pump delivery (Q) is translat- sure (PA).
ed in proportion to the pressing force of the EPC • At this time, ports (F) and (G) of the LS valve are
valve solenoid. connected to each other. As a result, the pres-
• In other words, since the pressing force of the sure in port (J) becomes pump pressure (PA)
EPC valve solenoid is added to the pressing and servo piston (9) moves to the right.
force on the left side caused by the pump pres- • Consequently, the pump delivery is decreased.
sure applied to spool (6), the relationship be- • As servo piston (9) moves, lever (2) moves to the
tween pump pressure (PA) and (Q) is translated right and spring (3) is compressed and its spring
from [1] to [2] as (X) is increased. load is increased. Consequently, spool (6)
moves to the right to disconnect ports (C) and
(B), and then drain pressure ports (D) and (C)
are connected.
• As a result, the pressure in port (C) lowers and
the piston pressure is decreased and servo pis-
ton (9) stops moving to the right.
• Accordingly, the stopping position (= pump deliv-
ery) of servo piston (9) is decided by the position
where the pressure caused by pressure (PA) ap-
plied to spool (10) is balanced with the force of
spring (3) applied through spool (6) (Fig. 3).
4. When PC mode selector pressure rises or

lower
• The PC-EPC changes the output pressure (PM)
with the input current from the controller similarly
Operation
to when the pressing force of spool (8) changes
and (PA) rises or lowers.
1. Function of spring
• The spring load of spring (3) at the PC valve is
decided by the position of the swash plate.
• If servo piston (6) moves to the right, spring (3) is
compressed through lever (2) and its spring load
changes.
2. When pump pressure (PA) is low

• The pressing force of spool (10) is decreased
and spool (6) 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).
• At this time, ports (F) and (G) of the LS valve are
connected to each other. As a result, the pres-
sure in port (J) becomes drain pressure (PT) and
servo piston (9) moves to the left.
WA430-6 10-163
When load is light

(Fig. 1)
When load is heavy

(Fig. 2)
10-164 WA430-6
When balanced
(Fig. 3)
WA430-6 10-165
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL VALVE
Work equipment control valve

Outline
The control valves of the following 2 types are set.
• 3-spool valve (Without service valve)
a Since each service valve is of add-on type, it can

• 4-spool valve (3-spool valve + service valve)
be added or removed later.
As for outside views and sectional views, only the 4-

spool valve (3-spool valve + service valve) is shown.
C : To controller PP : To main pump

P : From main pump PT : From lift arm lower PPC valve
T : To tank TS : To tank
A2 : To lift cylinder bottom ACC : To E.C.S.S. accumulator
A3 : To bucket cylinder bottom PA2 : From lift arm raise PPC valve
A4 : To service actuator PA3 : From bucket tilt PPC valve
B2 : To lift cylinder head PA4 : From service PPC valve
B3 : To bucket cylinder head PB2 : From lift arm lower PPC valve
B4 : To service actuator PB3 : From bucket dump PPC valve
LS : To pump LS valve PB4 : From service PPC valve
1. Accumulator charge valve 6. Bucket valve

2. Lift arm regeneration valve 7. Lift arm valve
3. Lift check valve 8. E.C.S.S. control valve
4. Top cover 9. PT port block
5. Service valve
a Tighten mounting nuts (10) of top cover (4) in 3 times in the order of [1], [2], [3], and [4].
Tightening torque of 1st time: 58.8 – 68.6 Nm {6 – 7 kgm}
Tightening torque of 2nd time: 78.5 – 88.3 Nm {8 – 9 kgm}
Tightening torque of 3rd time: 98.1 – 113 Nm {10 – 11.5 kgm}
10-166 WA430-6
4-spool valve
WA430-6 10-167
Sectional view
(1/7)
10-168 WA430-6
1. Suction valve (Lift arm bottom)

2. Safety-suction valve (Bucket bottom)
3. Safety-suction valve (Service actuator)
4. Safety-suction valve (Service actuator)
5. Safety-suction valve (Bucket head)
6. Suction valve (Lift arm head)
7. Variable back pressure valve (Lift check valve)
Unit: mm

Free length
8 Suction valve spring length load load deformed,
diameter
replace spring
5.50 N 4.40 N
46.8 x 7.5 40.6 —
{0.56 kg} {0.45 kg}
WA430-6 10-169
(2/7)
10-170 WA430-6
1. Main relief valve

2. Spool (E.C.S.S. control)
3. Spool (Lift arm)
4. Spool (Bucket)
5. Spool (Service)
Unit: mm

Free length
Spool return spring x Outside Free length
6 length load load
(Service) diameter
53.5 N 42.8 N
45.6 x 28 45 —
{5.46 kg} {4.37 kg}
124.8 N 99.8 N
7 Spool return spring (Bucket) 47.8 x 27.4 45 —
{12.7 kg} {10.2 kg}
If damaged or
Spool return spring 136.3 N 109.0 N
8 50.2 x 36 47 — deformed,
(Lift arm) {13.9 kg} {11.1 kg}
replace spring
9 53.2 x 17.2 36.8 —
(Lift arm) {26.8 kg} {21.4 kg}
114 N 91.2 N
10 Spool return spring (Bucket) 47.1 x 27.4 45 —
{11.6 kg} {9.28 kg}
11 57.5 x 25.5 56 —
(Lift arm) {9.43 kg} {7.54 kg}
83.6 N 66.9 N
12 Spool return spring (E.C.S.S.) 61.3 x 28 45 —
{8.52 kg} {6.81 kg}
WA430-6 10-171
(3/7)
10-172 WA430-6
1. Pressure compensation valve F (Lift arm)

2. Pressure compensation valve F (Bucket)
3. Pressure compensation valve F (Service)
4. Pressure compensation valve R (Service)
5. Pressure compensation valve R (Bucket)
6. Pressure compensation valve R (Lift arm)
F: Flow control valve

R: Pressure reducing valve
Unit: mm

Free length
7 Flow control valve spring length load load
diameter
55 N 44 N
33.2 x 9.5 17 — If damaged or
{5.61 kg} {4.49 kg}
deformed,
24.5 N 19.6N replace spring
8 Flow control valve spring 45.7 x 9.5 35 —
{2.5 kg} {2.0 kg}
13.0 N 10.4 N
9 Pressure reducing valve spring 27.5 x 14.2 20.5 —
{1.33 kg} {1.06 kg}
14.0 N 11.2 N
10 Pressure reducing valve spring 27.5 x 14.2 20 —
{1.43 kg} {1.14 kg}
WA430-6 10-173
(4/7)
1. LS pressure pickup plug

2. LS bypass plug
3. Pump pressure pickup plug
10-174 WA430-6
WA430-6 10-175
(5/7)
10-176 WA430-6

2. Variable back pressure valve (Lift check valve)
3. Spool (E.C.S.S. control valve)
4. Accumulator pressure relief plug
5. Accumulator charge valve
Unit: mm

Free length
6 Spring (Lift check valve) length load load
diameter
7.3 N 5.8 N
33.9 x 21 32.5 — If damaged or
{0.74 kg} {0.59 kg}
deformed,
Spring (Pressure reducing 79.4 N 63.5 N replace spring
7 17.6 x 8.1 14.5 —
valve pilot) {8.1 kg} {6.48 kg}
19.6 N 15.7 N
8 Spring 19.2 x 7.2 16.05 —
{2 kg} {1.6 kg}
5.9 N 4.72 N
9 Spring (Check valve) 41.5 x 8.5 31.5 —
{0.6 kg} {0.48 kg}
WA430-6 10-177
(6/7)
10-178 WA430-6
1. Suction valve (A)

2. Suction valve (B)
3. Spool (Lift arm)
4. Pressure compensation valve R
5. Pressure compensation valve F
6. Lift arm regeneration valve
7. Safety-suction valve (A)
8. Safety-suction valve (B)
9. Spool (Bucket)
10. Shuttle valve
F: Flow control valve

R: Pressure reducing valve
Unit: mm

Free length
13 Spring (Check valve) length load load deformed,
diameter
replace spring
5.9 N 4.72 N
41.5 x 8.5 31.5 —
{0.6 kg} {0.48 kg}
WA430-6 10-179
(7/7)
1. Safety-suction valve (A) F: Flow control valve

2. Safety-suction valve (B) R: Pressure reducing valve
3. Spool (Service)
6. Unload valve
10-180 WA430-6
STRUCTURE AND FUNCTION CLSS
CLSS
Outline of CLSS
Features
The CLSS is the abbreviation for Closed center
Load Sensing System, which has the following fea-
tures.
• Fine control performance which is not affected by
load
• Control performance which is secured even in
fine control operation
• Compound operation performance in which oil
flow is divided according to the open area of the
spool
• Saving of energy by variable pump control
Composition
• The CLSS is composed of the variable-capacity
piston pump, control valve, and actuators.
• The pump unit is composed of the main pump,
PC valve, and LS valve.
WA430-6 10-181
Basic principle
1. Control of pump swash plate angle • If the LS differential pressure ( PLS) lowers be-
• The pump swash plate angle (pump delivery) is so low the set pressure of the LS valve (the actuator
controlled that the LS differential pressure load pressure is high), the pump swash plate an-
( PLS), which is the differential pressure be- gle is increased. If the LS differential pressure
tween the pump discharge pressure (PP) and LS rises above the set pressure (the actuator load
pressure (PLS) at the control valve outlet, will be pressure is low), the pump swash plate angle is
constant. decreased.
[LS differential pressure ( PLS) = Pump dis-
charge pressure (PP) – LS pressure (PLS)] LS diff ere ntial press ure ( PLS) and pump
swash plate angle
a For details of operation, see "Work equipment

hydraulic pump".
10-182 WA430-6
2. Pressure compensation control

• The valves (pressure compensation valves) to
balance the load is installed to the outlet side of
the control valve. With these valves, when mul-
tiple actuators are operated simultaneously, the
pressure difference ( P) between the upstream
(inlet) side and downstream (outlet) side of each
valve is kept constant, regardless of the load
(pressure). Consequently, the oil from the pump
is divided (compensated) in proportion to the
open areas (S1) and (S2) of the operated valves.
WA430-6 10-183
STRUCTURE AND FUNCTION EACH FUNCTION AND OPERATION OF EACH VALVE
Each function and operation of each valve

Hydraulic circuit diagram and names of valves
10-184 WA430-6
1. Unload valve
Set pressure: 1.77 MPa {18.0 kg/cm2}
2. Safety-suction valve
Set pressure: 38.2 MPa {390 kg/cm2}
5. Pressure compensation valve
6. Suction valve
8. Variable lift check valve
WA430-6 10-185
Unload valve
1. When control valve is in neutral
T : Tank circuit (pressure) PLS: LS circuit (pressure)

PP : Pump circuit (pressure)
1. Unload valve 3. Spring

2. Sleeve 4. Spool
Function Operation
• When the control valve is in neutral, delivery (Q) • Pump discharge pressure (PP) is applied to left
at the minimum pump swash plate angle is re- end of spool (4) and LS pressure (PLS) is applied
leased to the tank circuit. At this time, pump dis- to the right end.
charge pressure (PP) is set to 1.77 MPa {18.0 • When the control valve is in neutral, LS pressure
kg/cm 2} by spring (3) in the valve. (LS pressure (PLS) is 0. Accordingly, only pump discharge
(PLS) is 0 MPa {0 kg/cm2}) pressure (PP) is applied and it is set with only the
spring load of spring (3).
• If pump discharge pressure (PP) rises to the
spring load of 1.77 MPa {18.0 kg/cm2} of spring
(3), spool (4) moves to the right and pump circuit
(PP) is connected to tank circuit (T) through hole
(a) of sleeve (2).
• By this operation, pump discharge pressure (PP)
is set to 1.77 MPa {18.0 kg/cm 2}.
10-186 WA430-6
2. When control valve is controlled finely


2. Sleeve 4. Spool
Function Operation
• When the control valve is controlled finely, if the • If the control valve is controlled finely, LS pres-
demand flow for the actuator is below the deliv- sure (PLS) is generated and applied to the right
ery at the minimum pump swash plate angle, end of spool (4). Since the open area of the con-
pump discharge pressure (PP) is set to LS pres- trol valve spool is narrow at this time, the differ-
sure (PLS) + 1.77 MPa {18.0 kg/cm2}. ence between the LS pressure (PLS) and pump
If the differential pressure between discharge discharge pressure (PP) is large.
pressure (PP) and LS pressure (PLS) becomes • If the differential pressure between pump dis-
the spring load of spring (3) (1.77 MPa {18.0 kg/ charge pressure (PP) and LS pressure (PLS)
cm 2}), the unload valve opens. Accordingly, LS reaches the spring load (1.77 MPa {18.0 kg/
differential pressure ( PLS) becomes 1.77 MPa cm2}), spool (4) moves to the right and pump cir-
{18.0 kg/cm2}. cuit (PP) is connected to tank circuit (T).
• That is, pump discharge pressure (PP) is set to
the spring force (1.77 MPa {18.0 kg/cm2}) + LS
pressure (PLS) and the LS differential pressure
( PLS) becomes 1.77 MPa {18.0 kg/cm2}.
WA430-6 10-187
3. When control valve is operated


2. Sleeve 4. Spool
Function Operation
• When the control valve is operated, if the de- • If the control valve is operated largely, LS pres-
mand flow for the actuator exceeds the delivery sure (PLS) is generated and applied to the right
at the minimum pump swash plate angle, the oil end of spool (4). At this time, since the open area
flow to tank circuit (T) is stopped and all of pump of the control valve is wide, the difference be-
delivery (Q) is supplied to the actuator circuit. tween LS pressure (PLS) and pump discharge
pressure (PP) is little.
• Accordingly, the differential pressure between
pump discharge pressure (PP) and LS pressure
(PLS) does not reach the spring load of 1.77
MPa {18.0 kg/cm2} of spring (3) and spool (4) is
pushed to the left by spring (3).
• As a result, pump circuit (PP) is disconnected
from tank circuit (T) and all of pump delivery (Q)
is supplied to the actuator circuit.
10-188 WA430-6
Supply of LS pressure
1. Work equipment valve (Lift arm)
Function
• The LS pressure means the actuator load pres- • Both ends of pressure reducing valve (3) has the
sure on the outlet side of the control valve. same area (SA) = (SLS). Actuator circuit pres-
• In the work equipment valve, actually, pressure sure (PA) = (A) is applied to the (SA) side and re-
reducing valve (3) of the pressure compensation duced pump discharge pressure (PP) is applied
valve reduces pump discharge pressure (PP) to to the (SLS) side.
the level of actuator circuit pressure (A), and then • Accordingly, pressure reducing valve (3) is bal-
supplies it to the LS circuit (PLS). anced at a position where actuator circuit pres-
sure (PA) and the pressure in spring chamber
Operation (PLS1) are the same. Pump discharge pressure
• If spool (1) is operated, pump discharge pressure (PP) reduced by cut (d) is supplied as actuator
(PP) flows through flow control valve (2) and cut circuit pressure (A) to LS circuit (PLS).
(a) of the spool to actuator circuit (A).
• Since pressure reducing valve (3) also moves to
the right at this time, pump discharge pressure
(PP) is reduced by the pressure loss in cut (d)
and supplied to LS circuit (PLS), and then further
led to spring chamber (PLS1).
• At this time, LS circuit (PLS) is connected to tank
circuit (T) through LS bypass plug (4).
WA430-6 10-189
2. Work equipment valve (Bucket and service)
Function • At this time, LS circuit (PLS) is connected to tank

• The LS pressure means the actuator load pres- circuit (T) through LS bypass plug (4). (See the
sure on the outlet side of the control valve. section of the LS bypass plug.)
• Actually, pressure reducing valve (3) of the pres- • Actuator circuit pressure (A) is applied to the left
sure compensation valve reduces pump (dis- side of the pressure reducing valve (3) and re-
charge) pressure (PP) to the level of actuator duced pump pressure (PP) is applied to the op-
circuit pressure (PA) = (A), and then supplies it to posite side.
the LS circuit (PLS). • Accordingly, pressure reducing valve (3) is bal-
anced at a position where actuator circuit pres-
Operation sure (A) and the pressure in spring chamber
• If spool (1) is operated, pump discharge pressure (PLS) are the same. Pump discharge pressure
(PP) flows through flow control valve (2), cut (a) (PP) reduced by cut (a) is supplied as actuator
of the spool, and bridge pass (b) to actuator cir- circuit pressure (A) to LS circuit (PLS).
cuit (A).
• Since pressure reducing valve (3) also moves to
the right at this time, pump pressure (PP) is re-
duced by the pressure loss in cut (c) and sup-
plied to LS circuit (PLS), and then further led to
spring chamber (PLS1).
10-190 WA430-6
LS bypass plug
T : Tank circuit (pressure)

PLS : LS circuit (pressure)
1. LS bypass plug
Function
• The LS bypass plug releases residual LS pres-
sure (PLS).
• The LS bypass plug lowers the rising speed of
LS pressure (PLS) and makes pressure loss in
the spool and shuttle valve with the discarded
throttle flow to lower the effective LS differential
pressure and increase the stability.
Operation
• The oil in the LS circuit (PLS) flows through
clearance filter (a) formed by the clearance be-
tween LS bypass plug (1) and valve body, and
then flows through orifice (b) to tank circuit (T).
WA430-6 10-191
Pressure compensation valve
10-192 WA430-6
Function
• If the load pressure is lower than the pressure in
the other actuator and the flow rate starts in-
creasing during compound operation, the pres-
sure compensation valve compensates the
pressure. [At this time, the load pressure in the
other actuator operated for the compound oper-
ation (on the upper side) is higher than the load
pressure on this side (lower side).]
Operation
• If the load pressure in the other actuator (on the
upper side) becomes high, the flow rate in actu-
ator circuit (Aa) on this side (lower side) starts in-
creasing.
• In this case, LS pressure (PLS) in the other actu-
ator is applied to spring chamber (PLS1) to push
pressure reducing valve (1) and flow control
valve (2) to the left.
• Flow control valve (2) reduces the open area be-
tween pump circuit (PP) and spool upstream
(PPA) to make a pressure loss in the line be-
tween (PP) and (PPA).
• Flow control valve (2) and pressure reducing
valve (1) are stopped at a position where the
pressure difference between (PA) and (PLS) ap-
plied to both ends of pressure reducing valve (1)
is the same as the pressure loss made in the line
between (PP) and (PPA) at the front and rear of
flow control valve (2).
• As a result, pressure difference between up-
stream pressure (PPA) and downstream pres-
sure (PA) becomes the same at each spool
operated for the compound operation. Then, the
pump flow is distributed in proportion to the open
area of cut (a) of each spool.
WA430-6 10-193
Area ratio of pressure compensation valve
Function Area ratio (S1):(S2) and compensation charac-

• The pressure compensation valve finely adjusts teristics
the ratio of left area (S1) of flow control valve (2) • When 1.00 : [Pump (discharge) pressure
pressure (PPB)] C [LS cir-

to right area (S2) of pressure reducing valve (1) (PP) – Spool cut upstream
and decides the compensation characteristics
according to the characteristics of each actuator. cuit pressure (PLS) – Actua-
tor circuit pressure (PA) =
S1: Area of flow control valve (2) – Area of piston (A)] and the oil is divided ac-
(3) cording to the opening area
S2: Area of pressure reducing valve (1) – Area of ratio of the spool.
piston (3) • When above 1.00 : (PP) – (PPB) > (PLS) – (PA)
= (A) and less oil is supplied
to the compensated side by
the area ratio of the spool.
• When below 1.00 : (PP) – (PPB) < (PLS) – (PA)
= (A) and more oil is supplied
to the compensated side by
the area ratio of the spool.
10-194 WA430-6
Lift arm regeneration circuit
1. When lift arm is lowered
A : Bottom circuit (pressure) 1. Lift cylinder

B : Head circuit (pressure) 2. Lift arm spool
PP : Pump circuit (pressure) 3. Check valve
Function Operation
• When bottom pressure (A) of lift cylinder (1) is • While the lift arm is being lowered by its weight,
higher than head pressure (B) and the lift arm is pressure (A) on the bottom side of lift cylinder (1)
lowered by its weight, this circuit sends the return is higher than pressure (B) on the head side.
oil on the bottom side to the head side to in- • At this time, a part of the return oil on the bottom
crease the cylinder speed by that amount. side flows through regeneration passages (a) of
lift arm spool (2), pushes check valve (3) open,
and flows into the head side.
• As a result, the lift arm lowering speed is height-
ened.
WA430-6 10-195
Variable lift check valve
Function • When the lift arm lower return oil flows from (A)
• When the lift arm is lowered, the set pressure of to tank (T), it pushes small piston (1) to the right.
the back pressure valve is heightened with the lift Small piston (1) decides the open area of (B) at
arm lower PPC pressure to prevent occurrence the position where the pressure of (A) is bal-
of vacuum (diesel firing) on the cylinder head anced with spring (3), thus back pressure is gen-
side. erated.
• When an operation other than lift arm lowering op- 2. When an operation other than lift arm lower-
eration is carried out, the back pressure valve pis- ing operation is carried out (Lift arm raising,
ton moves to prevent generation of back pressure. bucket dumping, or bucket tilting)
• The pilot pressure is not applied to pilot port (PT)
Operation while an operation other than lift arm lowering
1. When lift arm lowering operation is carried operation is carried out.
out • Under this condition, since small piston (1) and
• If the lift arm lower PPC pressure is applied to large piston (2) are moved to the right by pressure
port (PT), large piston (2) and small piston (1) (A), the back pressure valve does not function.
move to the left.
10-196 WA430-6
E.C.S.S. control valve
Function • While the travel speed is below 5 km/h, the signal

• The controller automatically turns on and off the is not sent to solenoid valve (2) and spool (1) is
accumulator charged with high-pressure gas ac- in neutral. At this time, the line from (PR) to ac-
cording to the travel condition. cumulator (ACC) is opened and accumulator
• The E.C.S.S. control valve gives elasticity to the (ACC) is charged.
vertical movement of the work equipment and re- • If accumulator (ACC) is charged up to the set
duces rocking of the machine body during high- pressure, check valve (5) is closed and the pres-
speed travel to improve the operator comfort and sure in accumulator (ACC) does not rise any
prevent spillage of material for higher working ef- more.
ficiency.
Accumulator pressure relief valve
Operation • If the pressure in accumulator (ACC) needs to be
• If the travel speed exceeds 5 km/h, the signal is relieved for maintenance of the machine, etc.,
sent to solenoid valve (2) and the pressure is ap- loosen plug (3) and nut (4) to open circuits (PR)
plied to (a). and (TS) and relieve the pressure in accumulator
• Spool (1) moves to the right. (ACC).
• 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 E.C.S.S. is turned ON.
WA430-6 10-197
Restriction of lift arm raise stroke
10-198 WA430-6
Function
• If the lift arm is raised and the bucket is operated
simultaneously, the stroke of arm lift spool (3) is
restricted and more oil flows to the bucket. As a
result, the bucket tilting (dumping) speed is in-
creased.
Operation
1. Single operation
• When the lift arm is raised, the PPC pressure is
supplied to (PA2) and lift arm spool (3) and pis-
ton (5) move to the right.
2. Compound operation
• When the lift arm is raised, if bucket dumping op-
eration (PB3) is carried out, (PA3) is connected
through the PPC valve to (T).
• Accordingly, ball (2) of shuttle valve (1) is
pressed to the left and the pressure of (PB3) is
supplied to passage (a).
• The pressure of (PB3) supplied to passage (a)
sure receiving area piston (5) x/4 (ød2 – øc 2) x

pushes piston (5) to the left with the force of pres-
(PB3).
• Accordingly, lift arm spool (3) is pushed to the left
and balanced at the position where [x/4 øb2 x
(PA2)] = [x/4 (ød2 – øc2 ) x (PA3) + Force of
spring (4)].
• As a result, the open area of cut (e) is reduced
and less oil is supplied to port (A2). The exces-
sive oil flows to (B3) and the dumping speed is in-
creased.
WA430-6 10-199
Accumulator charge valve
P : From main pump 1. Screw

PR1 : To E.C.S.S. accumulator 2. Poppet (Safety valve)
PR2 : To solenoid valve basic pressure 3. Spring (Safety valve)
TS1 : To tank 4. Spring (Main pressure reducing valve)
TS2 : To tank 5. Valve pressure reducing valve
TS3 : To tank 6. Poppet (Check valve)
TS4 : To tank 7. Spring (Check valve)
10-200 WA430-6
WA430-6 10-201
1. When valve is in neutral and (P) is low
Function
• The discharge pressure of the main pump is re-
duced and supplied as control pressure to the
solenoid valves, PPC valve, etc.
Operation
• Poppet (2) is pressed by spring (3) against the
seat and the line from port (P) to port (T) is
closed.
• Poppet (6) is pressed to the left and the line from
port (P) to port (PR2) is opened.
• Poppet (6) is moved to the right by pressure (PR)
and the line from (PR) to (ACC) is opened. If
(PR) < (ACC), poppet (6) is pressed to the left by
spring (7) and the line from (PR) to (ACC) is
closed.
10-202 WA430-6
2. When load pressure (P) is high
Operation
• If pressure (PR) rises above the set pressure,
poppet (3) closes and the hydraulic oil flows
through port (P), hole (a) in spool (5), opening of
poppet (2), and tank port (T).
• Accordingly, differential pressure is made be-
tween before and after hole (a) in spool (5) and
spool (5) moves to close the opening between
port (P) and (PR). Pressure (P) is reduced to a
certain pressure (the set pressure) by the open
area at this time and supplied as pressure (PR).
WA430-6 10-203
STRUCTURE AND FUNCTION PPC VALVE
PPC valve
1. Work equipment PPC valve
P : From charge valve

T : To hydraulic tank
P1 : To bucket tilt valve
P2 : To bucket dump valve
P3 : To lift arm raise valve
P4 : To lift arm lower (float) valve
10-204 WA430-6
1. Spool
2. Metering spring
3. Centering spring
4. Rod
5. Lever
6. Ring
7. Plate
8. Piston
9. Retainer
10. Body
WA430-6 10-205
Operation
1. When in neutral
1) PPC valve for bucket 2) PPC valve for lift arm
• Ports (PA) and (PB) of the bucket control valve • Ports (PA) and (PB) of the lift arm control valve
and ports (P1) and (P2) of the PPC valve are and ports (P3) and (P4) 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).
10-206 WA430-6
(Neutral o Fine control mode)

2. When in fine control mode
• If rod (4) and piston (8) are pushed by lever (5),

retainer (9) is pushed and spool (1) is also
pushed down through metering spring (2).
• Accordingly, fine control hole (f) is disconnected
from drain chamber (D) and connected to pump
pressure chamber (PP) almost simultaneously,
and then the pilot oil of the main pump flows from
port (P1) to port (PB).
• If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simulta-
neously to release the pressure in port (P1).
• As a result, spool (1) moves up and down to bal-
ance the force of metering spring (2) with the
pressure in port (P1). The positional relationship
between spool (1) and body (10) (where fine con-
trol hole (f) is between drain chamber (D) and
pump pressure chamber (PP)) does not change
until retainer (9) comes in contact with spool (1).
• Since metering spring (2) is compressed in pro-
portion to the stroke of the control lever, the pres-
sure in port (P1) also rises in proportion to the
stroke of the control lever.
• Accordingly, the control valve spool moves to a
position at which the pressure in the chamber
(PB) (equal to the pressure in port (P1)) is bal-
anced with the force of the control valve spool re-
turn spring.
WA430-6 10-207
3. When in fine control mode 4. When lever is operated to stroke end

(When control lever is returned) • If lever (5) and rod (4) push down piston (8) and
• If lever (5) begins to return, the force of centering retainer (9) pushes down spool (1), fine control
spring (3) and the pressure in port (P1) push up hole (f) is disconnected from drain chamber (D)
spool (1). and connected to pump pressure chamber (PP).
• As a result, fine control hole (f) is connected to • Accordingly, the pilot oil from the main pump
drain chamber (D) and the oil in port (P1) is re- flows through fine control hole (f) and port (P1)
leased. into chamber (PB) and pushes the control valve
• If the pressure in port (P1) lowers too much, spool.
spool (1) is pushed down by metering spring (2) • The oil returning from chamber (PA) flows
and fine control hole (f) is disconnected from through port (P2) and fine control hole (f') into
drain chamber (D) and connected to pump pres- drain chamber (D).
sure chamber (PP) almost simultaneously.
Then, the pump pressure is supplied until the
pressure in port (P1) is restored to the level cor-
responding to the position of the lever.
• When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f') of the valve which is not in operation and
then flows through port (P2) into chamber (PA).
10-208 WA430-6
5. When lift arm is "float" 6. When "float" state of lift arm is reset
• If rod (4) and piston (8) on the "Lower" side of • Lever (5) is returned from the "float" position by
port (P3) are pushed down with lever (5), the de- pushing it down with a force larger than the at-
tent starts operation before the stroke end (the tractive force of the solenoid.
operating effort of the lever becomes heavy). • The "float" state also can be reset and the lever
• If rod (4) is pushed down further, the detent op- can be returned to the "neutral" position by turn-
erates to keep the lift arm floated, even if the le- ing off the current in the solenoid (de-energizing
ver is released. the solenoid).
• At the same time, the control valve is also moved
to the "float" position and the lift arm is floated.
• The lift arm raise and bucket tilt operations are
carried out similarly to the above.
WA430-6 10-209
2. Attachment PPC valve
P : From ACC charge valve 1. Spool

T : To tank 2. Metering spring
P1 : To attachment valve 3. Centering spring
P2 : To attachment valve 4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
9. Filter
10-210 WA430-6
Unit: mm

Standard size Repair limit Replace
Free length
10 Centering spring length load load
diameter If damaged or
36.3 N 30.4 N deformed,
41.1 x 15.5 29.0 —
{3.70 kg} {3.1 kg} replace spring
16.7 N 13.3 N
11 Metering spring 22.7 x 8.10 22.0 —
{1.70 kg} {1.36 kg}
WA430-6 10-211
Operation • The positional relationship between spool (1)

and body (8) (where fine control hole (f) is be-
1. When in neutral tween drain chamber (D) and pump pressure
• Ports (A) and (B) of the control valve and ports chamber (PP)) does not change until retainer (7)
(P1) and (P2) of the PPC valve are connected comes in contact with spool (1).
through fine control hole (f) of spool (1) to drain • Since metering spring (2) is compressed in pro-
chamber (D). portion to the stroke of the control lever, the pres-
sure in port (P1) also rises in proportion to the
stroke of the control lever.
• Accordingly, the control valve spool moves to a
position at which the pressure in the chamber (A)
(equal to the pressure in port (P1)) is balanced
with the force of the control valve spool return
spring.
(Neutral o Fine control mode)

2. When in fine control mode
• If piston (4) is pushed by lever (5), retainer (7) is

pushed and spool (1) is also pushed down
through metering spring (2).
• Accordingly, fine control hole (f) is disconnected
from drain chamber (D) and connected to pump
pressure chamber (PP) almost simultaneously,
and then the pilot oil of the control pump flows
from port (P1) to port (A).
• If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simulta-
neously to release the pressure in port (P1).
• As a result, spool (1) moves up and down to bal-
ance the force of metering spring (2) with the
pressure in port (P1).
10-212 WA430-6
3. When in fine control mode 4. When lever is operated to stroke end

(When control lever is returned) • If lever (5) pushes down piston (4) and retainer
• If lever (5) begins to return, the force of centering (7) pushes down spool (1), fine control hole (f) is
spring (3) and the pressure in port (P1) push up disconnected from drain chamber (D) and con-
spool (1). As a result, fine control hole (f) is connected to pump pressure chamber (PP).
nected to drain chamber (D) and the oil in port • Accordingly, the pilot oil from the control pump
(P1) is released. flows through fine control hole (f) and port (P1)
• If the pressure in port (P1) lowers too much, into chamber (A) and pushes the control valve
spool (1) is pushed down by metering spring (2) spool.
and fine control hole (f) is disconnected from • The oil returning from chamber (B) flows through
drain chamber (D) and connected to pump pres- port (P2) and fine control hole (f') into drain
sure chamber (PP) almost simultaneously. chamber (D).
Then, the pump pressure is supplied until the
pressure in port (P1) is restored to the level cor-
responding to the position of the lever.
• When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f') of the valve which is not in operation and
then flows through port (P2) into chamber (B).
WA430-6 10-213
STRUCTURE AND FUNCTION STABILIZER VALVE
Stabilizer valve
PA : To spring case
PB : From PPC valve
1. Filter 4. Spool
2. Spring 5. Retainer
3. Retainer 6. Spring
Unit: mm

Free length
7 Spool return spring length load load If damaged or
diameter
deformed,
11.5 N 9.2 N
18.4 x 11.5 16 — replace spring
{1.17 kg} {0.94 kg}
87.3 N 69.8 N
8 Spool return spring 21 x 12 19 —
{8.9 kg} {7.1 kg}
Function
• The stabilizer valve chokes the return circuit of • When the temperature is low, the stabilizer valve
main spool (9) to reduce the shock which is opens the return circuit of main spool (9) to re-
made when the work equipment stops. duce delay of the work equipment in response.
10-214 WA430-6
1. When in neutral
Operation
• Spool (4) is set in neutral by springs (2) and (6)
and retainers (3) and (5).
WA430-6 10-215
2. When main spool (9) is moved from neutral position to operating position
Operation
• If the PPC pressure is applied to port (PA), the oil
flows through passages (c) and (d), and orifice
(e) to passage (g).
• At this time, pressure loss is made in orifice (e).
If the differential pressure between pressures
(PA') and (PB') exceeds the load on spring (2),
spool (4) moves to the left and cut (a) opens.
• If cut (a) opens, the oil of PPC flows through pas-
sages (c) and (d), cut (a), and passages (f) and
(g) to the right end of main spool (9).
10-216 WA430-6
3. When main spool (9) is moved from operating position to neutral position
Operation
• When main spool (9) is operated, spool (4) is
pressed to the left by the differential pressure be-
tween before and after cut (a).
• If control lever (10) is returned, pressure (PA)
lowers and spool (4) moves to the right up to the
neutral position.
• During this operation, the oil in the spring case of
the control valve flows through passages (g) and
(f), cut (a), and passages (d) and (c) to the PPC
circuit until cut (a) closes.
• If spool (4) moves to the right and cut (a) closes,
the oil in the spring case flows through passage
(g), orifice (e), and passages (d) and (c) to the
PPC circuit.
• As a result, the line between the spring case and
PPC circuit is choked and the shock made when
the work equipment stops is reduced.
WA430-6 10-217
4. When main spool (9) is moved from operating position to neutral position (at low temperature)
Operation
• When main spool (9) is operated, spool (4) is • When the temperature is low and the viscosity of
pressed to the left by the differential pressure be- the hydraulic oil is high, if the differential pres-
tween before and after cut (a). sure between before and after orifice (e) exceeds
• If control lever (10) is returned, pressure (PA) the load of spring (6), spool (4) moves to the right
lowers and spool (4) moves to the right up to the further and cut (b) opens.
neutral position. • If cut (b) opens, the oil in the spring case flows
• During this operation, the oil in the spring case of through passages (g) and (f), cut (b), and pas-
the control valve flows through passages (g) and sage (d) to passage (c).
(f), cut (a), and passages (d) and (c) to the PPC • As a result, the line between the spring case and
circuit until cut (a) closes. PPC circuit is not choked and the delay of the
• If spool (4) moves to the right and cut (a) closes, work equipment in response is reduced.
the oil in the spring case flows through passage
(g), orifice (e), and passages (d) and (c) to the
PPC circuit.
10-218 WA430-6
STRUCTURE AND FUNCTION BYPASS VALVE
Bypass valve
PP : From work equipment PPC valve port P4 1. Body

A : To lift arm cylinder bottom side 2. Plunger
B : To lift arm cylinder head side 3. Plug
T : Drain 4. Spool
5. Plug
6. Body
7. Union
WA430-6 10-219
Operation
When lift arm is "raised"
• If the lift arm is "raised", the oil on the raise side

of the work equipment PPC valve operates the
work equipment control valve and the oil from the
work equipment pump flows to the lift cylinder
bottom side.
• Since the oil on the lower side of the work equip-
ment PPC valve is drained, the oil in port (PP) is
drained, too.
• Spool (1) is pushed to the left by the tension of
spring (3) and ports (A) and (B) are disconnect-
ed.
• The oil on the lift cylinder head side is drained
through the work equipment control valve into
the hydraulic tank, thus the lift arm rises.
10-220 WA430-6
When lift arm is "lowered"
• If the lift arm is "lowered", the oil on the lower side • When the pressure on the lift cylinder bottom
of the work equipment PPC valve operates the side is higher than the pressure on the head side,
work equipment control valve and the oil from the the hydraulic pressure generated on the lift cylin-
work equipment pump flows to the lift cylinder der bottom side pushes up and opens check
head side. valve plunger (2) and flows through port (B) to
• The oil on the lower side of the work equipment the cylinder head side, thus the lift arm lowers
PPC valve flows to port (PP). smoothly.
• If the pressure in port (PP) exceeds the set pres- • When the pressure on the lift cylinder bottom
sure of spring (3), spool (1) is pushed to the right side is lower than the pressure on the head side,
and ports (A) and (B) are connected. check valve plunger (2) is closed downward to
• When the lift arm is lowered, a part of the oil on prevent the oil on the head side from escaping
the lift cylinder bottom side flows through the into port (A), thus the lowering operation of the lift
work equipment control valve into the hydraulic arm is secured.
tank. At this time, a pressure higher than the
pressure on the cylinder head side may be gen-
erated on the cylinder bottom side by the weight
of the work equipment, however.
WA430-6 10-221
STRUCTURE AND FUNCTION LOCK VALVE
Lock valve
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
• The lock valve is installed between the charge
valve and work equipment PPC valve. If the
work equipment lock lever is set in the "LOCK"
position, the lock valve operates to shut off the oil
in the PPC circuit so that the work equipment
cannot be operated.
10-222 WA430-6
STRUCTURE AND FUNCTION ACCUMULATOR (FOR PPC CIRCUIT)
Accumulator (for PPC circuit)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Outline
• The accumulator is installed between the charge
valve and work equipment PPC valve. Even if
the engine stops with the work equipment 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
Charge pressure : 1.18 MPa {12 kg/cm2} (at 80°C)
Max. using pressure: 6.86 MPa {70 kg/cm2}
WA430-6 10-223
STRUCTURE AND FUNCTION ACCUMULATOR (FOR E.C.S.S.)
Accumulator (for E.C.S.S.)
1. Valve
2. Top cover
3. Cylinder
4. Free piston
Function
• 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 operat-
ing performance by utilizing its compressibility.
Specifications
Amount of gas : 4,000 cc
Charge pressure : 2.94 MPa {30 kg/cm2} (at 20°C)
10-224 WA430-6
STRUCTURE AND FUNCTION WORK EQUIPMENT ELECTRIC LEVER
Work equipment electric lever

(If equipped)
WA430-6 10-225
1. Lever 11. Seat

2. Rod 12. Ball
3. Centering spring 13. Detent spring
4. Metering spring 14. Rod
5. Nut 15. Body
6. Rod 16. Solenoid
7. Detent spring 17. Bushing
8. Retainer 18. Body
9. Lever 19. Retainer
10. Potentiometer 20. Rod
10-226 WA430-6
Function
• If lever (1) is operated, rod (20) moves up and
down and rotates potentiometer (10) according
to the operating distance of the lever.
• The operating angle (stroke) of the control lever
is sensed with the potentiometer and output as a
signal voltage to the controller.
• A potentiometer is installed, and it outputs 2 sig-
nal voltages which are opposite to each other as
shown in Output voltage characteristics.
Operation
When work equipment control lever is operated

• Rod (20) is pushed up by spring (4) according to
the operating distance of lever (1).
• Since lever (9) and rod (14) installed to the rotary
shaft of potentiometer (10) are connected to
each other, potentiometer (10) outputs voltages
according to the vertical stroke of the rod.
When work equipment is operated to "lift arm

lower" (or to "lift arm raise" or "bucket tilt)
• If rod (2) on the "lift arm lower" side is pushed
down by lever (1), ball (12) touches projection (a)
of rod (14) in the middle of the stroke (before
electric detent operation starts).
• If rods (2) and (14) are pushed in further, ball (12) When "lift arm lower" operation of work equip-
pushes up retainer (8) supported on detent ment control lever is reset
spring (7) and escapes out to go over projection • Lever (1) is returned from the "lift arm lower" po-
(a) of rod (14). sition by pushing down rod (20) with a force larg-
• At this time, rod (20) on the opposite side is er than the attractive force of the solenoid. The
pushed up by spring (4). "lift arm lower" state also can be reset and lever
• If rod (20) is pushed up while the current is flow- (1) can be returned to the neutral position by
ing in solenoid (16), nut (5) is attracted by bush- turning off the current in solenoid.
ing (17).
• Accordingly, rod (20) is kept pushed up and the
"lift arm lower" state is kept even if the lever is re-
leased.
WA430-6 10-227
STRUCTURE AND FUNCTION WORK EQUIPMENT EPC VALVE
Work equipment EPC valve

(If equipped)
P1 : From work equipment EPC cut-off solenoid valve 1. Bucket tilt EPC valve
port A 2. Bucket dump EPC valve
C1 : To work equipment control valve "bucket tilt" 3. Lift arm raise EPC valve
C2 : To work equipment control valve "bucket dump" 4. Lift arm lower EPC valve
C3 : To work equipment control valve "lift arm raise" 5. Block
C4 : To work equipment control valve "lift arm lower" 6. Body
T : Drain 7. Spool
8. Spring
9. Push pin
10. Coil
11. Plunger
12. Connector
10-228 WA430-6
Function Operation
When signal current is "0" (When coil is de-ener-

gized)
• While the signal current from the controller is not

flowing in coil (1), coil (1) is "de-energized".
• Accordingly, spool (2) is pressed by spring (3) to
the right.
• Port (P) is closed and the oil from the pump does
not flow in the work equipment control valve.
• The oil from the work equipment control valve is
drained through ports (C) and (T).
• The EPC valve consists of the proportional sole-

noid section and the hydraulic valve section.
• On receiving signal current (i) from the work
equipment controller, the EPC valve generates
EPC output pressure (P) in proportion to the sig-
nal current and outputs it to the control valve.
WA430-6 10-229
When signal current is "small" (Coil is energized When signal current is "maximum" (When coil is
in fine control mode) energized in full operation)
• If a small signal current flows in coil (1), coil (1) is • If the maximum signal current flows in coil (1),
energized and a thrust to the left is generated in coil (1) is energized and the thrust in plunger (4)
plunger (4). becomes maximum.
• Push pin (5) pushes spool (2) to the left and the • Push pin (5) presses spool (2) to the left.
oil from port (P) flows in port (C). • The maximum hydraulic oil flows from port (P) to
• The pressure in port (C) rises. If the total of the port (C) and the pressure in the circuit between
force applied to face (a) of spool (2) and the load the EPC valve and work equipment control valve
of spring (3) exceeds the thrust of plunger (4), becomes maximum.
spool (2) is pushed to the right. • Since port (T) is closed at this time, the oil in port
• Ports (P) and (C) are disconnected from each (C) is not drained.
other and ports (C) and (T) are connected to
each other simultaneously.
• As a result, spool (2) moves to the right or left un-
til the thrust of plunger (4) is balanced with the to-
tal of the pressure in port (C) and the load of
spring (3).
• Accordingly, the EPC valve controls the pressure
of the oil flowing to the work equipment control
valve in proportion to the signal current flowing to
coil (1).
10-230 WA430-6
STRUCTURE AND FUNCTION WORK EQUIPMENT EPC CUT-OFF SOLENOID VALVE
Work equipment EPC cut-off solenoid valve

(If equipped)
P : From pump Function

A : To work equipment EPC valve port P • The work equipment EPC cut-off solenoid valve
T : Drain is installed between the charge valve and work
equipment EPC valve. On receiving the opera-
tion signal from the work equipment controller,
the solenoid is "energized" to cut off the oil flow-
ing to the work equipment EPC valve, thus the
operator cannot operate the work equipment.
WA430-6 10-231
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
Work equipment linkage
10-232 WA430-6
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
Unit: mm

Clearance between bushing
7 and pin at each end of bucket
link –0.036 +0.207 0.156 –
85 1.0
–0.090 +0.120 0.297
–0.036 +0.207 0.156 –
8 and pin connecting lift arm and 85 1.0
–0.090 +0.120 0.297
bucket
–0.036 +0.207 0.156 –
9 and pin connecting lift arm and 95 1.0
–0.090 +0.120 0.297
frame
–0.036 +0.207 0.156 – Replace
10 and pin connecting bucket 110 1.0
–0.090 +0.120 0.297
cylinder bottom and frame (Replace if pin
Clearance between bushing has scuff mark)
–0.036 +0.207 0.156 –
11 and pin connecting bucket 110 1.0
–0.090 +0.120 0.297
cylinder rod and bell crank
–0.036 +0.245 0.181 –
12 and pin connecting bell crank 120 1.0
–0.090 +0.145 0.335
and lift arm
–0.036 +0.207 0.156 –
13 and pin connecting lift cylinder 95 1.0
–0.090 +0.120 0.297
rod and lift arm
–0.036 +0.207 0.156 –
14 and pin connecting lift cylinder 95 1.0
–0.090 +0.120 0.297
bottom and frame
Width of bushing Width of hinge
Standard
Standard Standard
Connecting part of bucket Tolerance Tolerance clearance
15 size size
cylinder and frame
–0.5
110 114 ±1.5 2.5 – 6.0
–0.5 Adjust so that
Connecting part of lift arm and +3 clearance will
16 122 — 129 7.0 – 10.0
frame +0 be below 1.5
Connecting part of lift arm and +1.5 mm on each
17 106 — 108 2.0 – 3.5 side
bucket +0.5
Connecting part of bucket link +2.8 +1.5
18 112.5 116 0.7 – 5.5
and bucket –0.5 +0.5
Connecting part of lift cylinder –0.5 +3
19 90 93.5 3.5 – 7.0
and frame –0.5 +0
Connecting part of bell crank +2.8
20 112.5 117 ±1.5 1.7 – 6.5
and bucket link –0.5
Replace
Connecting part of bell crank +2
21 220 223 ±0.5 0.5 – 3.5
and lift arm +0
Connecting part of bucket –0.5 Adjust so that
22 110 117 ±1.5 5.5 – 9.0
cylinder and bell crank –0.5 clearance will
be below 1.5
Connecting part of lift arm and
23 100 — 106 ±1.5 4.5 – 7.5 mm on each
lift cylinder side
WA430-6 10-233
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
Bucket
Bucket positioner and boom kick-out
1. Proximity switch
2. Bucket cylinder
3. Lever
4. Plate
Unit: mm

Clearance in bucket positioner
5 3–5
proximity switch
Adjust
Clearance in boom kick-out
6 3–5
proximity switch
10-234 WA430-6
Bucket positioner Lift arm kick-out
• The bucket positioner is driven electrically. • The boom kick-out is driven electrically. When
When the bucket is returned to an angle from the the lift arm is raised to an angle before the maxi-
dump position toward the tilt position, the bucket mum position, the boom kick-out returns the lift
positioner returns the bucket control lever from arm control lever from the "raise" position to the
the "tilt" position to the "hold" position to automat- "hold" position to stop the lift arm automatically at
ically stop the bucket at a proper digging angle. the current position.
• Lever (3) is bolted to bucket cylinder rod (2). • Plate (4) is fixed to the lift arm. Proximity switch
Proximity switch (1) is bolted to the cylinder. (1) is fixed to the frame. If the lift arm control le-
• If the bucket control lever is moved from the ver is moved from the "lower" position to the
"dump" position to the "tilt" position, the bucket "raise" position, the lift arm rises. When plate (4)
cylinder rod moves toward the front of the ma- approaches proximity switch (1), proximity
chine. When lever (3) parts from proximity switch (1) senses it and operates to return the lift
switch (1) at a point, proximity switch (1) senses arm control levers to the "hold" position.
it and operates to return the bucket control lever
to the "hold" position.
WA430-6 10-235
Operation of proximity switch
When bucket is tilted
• While the bucket is dumping more than the set • If bucket control lever (7) is moved to the tilt po-
position of the bucket positioner, lever (2) is over sition, dump spool (8) moves to the position of
the sensing face of proximity switch (1), the lamp the arrow and is held at that position by the coil
of which is lighting up. energized by detent solenoid (6). As a result,
At this time, bucket positioner relay (4) is ener- bucket control lever (7) is held at the tilt position
gized and a current flows in detent solenoid (6) and the bucket tilts.
of PPC valve (5) to energize the coil.
10-236 WA430-6
Function of proximity switch
When object of sensing is over sensing face of

proximity switch
Lamp of proximity switch ON

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

face of proximity switch
Lamp of proximity switch OFF

Bucket positioner relay
OFF
switch circuit
OFF
detent solenoid circuit
De-energized
detent solenoid
• If the bucket tilts and parts from the set position

of the bucket positioner, or if lever (2) parts from
the sensing face of proximity switch (1), the lamp
of proximity switch (1) goes off and bucket posi-
tioner relay (4) is turned off. Accordingly, the cir-
cuit of detent solenoid (6) of PPC valve (5) is
turned off to de-energize the coil.
Dump spool (8) at the hold position receives the
reaction force of spring (9) and returns bucket
control lever (7) to the neutral position.
WA430-6 10-237
When lift arm is raised
• While the lift arm (3) is lower than the set position • If the lift arm control lever (7) is moved to the
of the boom kick-out, plate (2) is not over the raise position, lift arm spool (8) moves to the po-
sensing face of proximity switch (1) and boom sition of the arrow and is held at that position by
kick-out relay (4) is turned OFF. The current the coil energized by detent solenoid (6). As a
flows in detent solenoid (6) of PPC valve (5) to result, lift arm control lever (7) is held at the raise
energize the coil. position and lift arm (3) rises.
10-238 WA430-6
Function of proximity switch
When object of sensing is apart from over sens-

ing face of proximity switch
Lamp of proximity switch OFF

Boom kick-out relay switch
OFF
circuit
PPC valve detent solenoid
ON
circuit
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 switch
ON
circuit
PPC valve detent solenoid
OFF
circuit
PPC valve detent solenoid De-energized
• If lift arm (3) rises and parts from the set position
of the kick-out, or if plate (2) comes to over the
sensing face of proximity switch (1), the lamp of
proximity switch (1) lights up and boom kick-out
relay (4) is turned ON. Accordingly, the circuit of
detent solenoid (6) of 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 lift arm control lever (7)
to the neutral position.
WA430-6 10-239
STRUCTURE AND FUNCTION WORK EQUIPMENT CYLINDER
Work equipment cylinder

Lift cylinder
Bucket cylinder
Unit: mm

Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
Clearance
–0.036 +0.257 0.084 – Replace
1 between piston Lift 90 0.647
–0.090 +0.048 0.347 bushing
rod and bushing
–0.036 +0.257 0.084 –
Bucket 90 0.647
–0.090 +0.048 0.347
Tightening torque Lift 373 ± 54.0 Nm {38.0 ± 5.5 kgm}

2
of cylinder head Bucket 490 ± 49.0 Nm {50.0 ± 5.0 kgm}
Tightening torque Lift 294 ± 29.4 Nm {30 ± 3.0 kgm}

3 Retighten
of cylinder piston Bucket 294 ± 29.4 Nm {30 ± 3.0 kgm}
Tightening torque Lift 58.9 – 73.6 Nm {6.0 – 7.5 kgm}
4 of cylinder piston
lock screw Bucket 58.9 – 73.6 Nm {6.0 – 7.5 kgm}
10-240 WA430-6
STRUCTURE AND FUNCTION CAB
Cab
1. Front glass
2. Front wiper
3. Rear wiper
4. Door
5. Air conditioner filter
WA430-6 10-241
STRUCTURE AND FUNCTION AIR CONDITIONER
Air conditioner
Air conditioner piping
1. Air outlet duct 7. Compressor

2. External air intake duct 8. Hot water return piping
3. Internal air intake duct 9. Refrigerant piping
4. External/Internal air changeover damper 10. Hot water take-out piping
5. Receiver tank 11. Air conditioner unit
6. Air conditioner condenser 12. Floor duct
10-242 WA430-6
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
Machine monitor system

General
• In the machine monitor system, each monitor on • The service mode function is used for the ease of
the network monitors and controls the vehicle troubleshooting for the controllers on the network
condition with the sensors installed to various (including the machine monitor itself). The major
parts of the vehicle, and then sends the result as functions used in the service mode are as fol-
network information to the machine monitor, lows.
which displays the information to notify the oper-
ator of the vehicle condition. 1. Display of electrical system failure history
The electrical system failures of each controller
• The machine monitor displays the information in saved in the machine monitor are displayed.
the normal mode or service mode. The information of those failures is deleted with
this function, too.
• The normal mode is used to display the informa-
tion to the operator normally. The major items 2. Display of mechanical system failure history
displayed in this mode are as follows. The vehicle system failures of each controller
saved in the machine monitor are displayed.
1. Items always displayed
• Meters (Speedometer or engine tachometer) 3. Real-time monitor
• Gauges (Engine coolant temperature gauge, The input and output values recognized by each
torque converter oil temperature gauge, hy- controller on the network are displayed in real
draulic oil temperature gauge, and fuel level time.
gauge)
• Pilot indicators 4. Tuning
• Service meter The installation errors and manufacturing dis-
persion of the sensors, proportional solenoid
2. Items displayed when abnormality is detected valves, etc. are corrected and adjusted.
• Caution lamps
• Action code (While an action code is dis- 5. Maintenance monitor
played, if the monitor panel mode selector The set replacement period of a filter or oil is
switch (>) is pressed and released, the fail- changed.
ure code (6 digits) is displayed.) (Change of time of maintenance monitor func-
tion)
3. At the replacement period of a filter or oil, the
character display displays that filter or oil. 6. Initialize
(Maintenance monitor function) This function is used to set the machine monitor
to the state set when delivered.
4. In addition to the above, the odometer can be
displayed, the replacement period of a filter/oil
can be reset, a phone number can be input, a • The machine monitor system consists of the ma-
language can be selected, and the brightness of chine monitor unit, buzzer, switches and sensors
the night lighting for the machine monitor can be to input data to the machine monitor unit, and
adjusted by using the character display and the controllers on the network and their switches and
machine monitor mode selector switch which is sensors.
the operation switch of the character display.
WA430-6 10-243
Each circuit of machine monitor
Starting and lighting
1. Starting switch Connection table of machine monitor connector pins

2. Alternator
3. Turn signal lamp and hazard lamp Connector pin No.
Symbol
4. Flasher unit Speedometer specification
5. Turn signal lamp (Left) a CNL52- 2
6. Turn signal lamp (Right) b CNL52-18
7. Turn signal lamp and hazard lamp relay c CNL52-16
8. Lamp switch d CNL52- 7
9. Small lamp e CNL53-12
10. Headlamp relay f CNL52- 1
11. Headlamp (Low) g CNL54- 5
12. Headlamp (High)
13. Dimmer switch
10-244 WA430-6
Sensing
1. Alarm buzzer Connection table of machine monitor connector pins

2. Air cleaner clogging sensor relay
3. Air cleaner clogging sensor Connector pin No.
Symbol
4. Battery electrolyte level sensor Speedometer specification
5. Steering oil pressure switch a CNL51-14
6. Emergency steering oil pressure switch b CNL53- 3
7. Coolant level sensor c CNL55- 5
8. Brake oil pressure switch d CNL54-16
9. Engine oil level sensor e CNL54- 3
10. Parking brake indicator switch f CNL54-10
11. Fuel level sensor g CNL53- 1
h CNL54-11
13. Torque converter oil temperature sensor
i CNL54- 1
14. Transmission controller
j CNL55- 1
k CNL55- 7
l CNL55- 2
WA430-6 10-245
Power supply and network
1. Monitor panel mode selector switch 1 "U" Connection table of machine monitor connector pins
2. Monitor panel mode selector switch 1 "t"
Connector pin No.
3. Monitor panel mode selector switch 2 "<" Symbol
Speedometer specification
4. Monitor panel mode selector switch 2 ">"
a CNL51- 6
b CNL51- 7
6. Engine controller
c CNL51- 4
d CNL51- 5
e CNL52- 8
f CNL52-17
g CNL54- 7
h CNL54-15
i CNL56- 1
j CNL56- 2
k CNL56- 4
l CNL56- 5
m CNL56- 6
n CNL56- 3
o CNL56- 8
p CNL56- 7
q CNL51- 9
r CNL51-10
s CNL51-17
t CNL51-18
u CNL51-19
v CNL51-20
w CNL52- 9
x CNL53- 6
y CNL54- 9
z CNL55- 6
aa CNL55-11
10-246 WA430-6
Automatic preheater
1. Engine controller Connection table of machine monitor connector pins

2. Engine heater relay
3. Electrical intake air heater Connector pin No.
Symbol
Speedometer specification
a CNL52-11
WA430-6 10-247
S-NET input Items which use S-NET signals

S-NET output Machine monitor Transmission controller
Hydraulic oil temperature Control of fan pump
Coolant temperature Control of fan pump
Torque converter oil temperature Control of fan pump
Emergency steering operation signal Self-check of emergency steering
Sensor adjustment mode signal Correction
Monitor mode switch signal Correction
Machine
Automatic preheater operation signal Self-check of emergency steering
monitor
Transmission trigger reset signal Control of learning
Selection of model Selection of model
Selection of tire Selection of tire
Correction of tire Correction of tire
Controller specification Selection of communication
Optional specification Selection of option
FNR lever and seesaw switch signal Display of FNR
FNR solenoid output signal Display of actual gear speed
1st, 2nd, 3rd, and 4th lever position
Display of 1, 2, 3, and 4
signals
1st, 2nd, 3rd, and 4th solenoid output
Display of actual gear speed
signals
FNR seesaw switch selection signal Indicator
Transmission hold signal Indicator
Auto-shift selection signal Indicator
ECSS (Electronic Controlled Sus-
Transmission pension System) signal Indicator
controller
Fan reverse signal Indicator
Power mode signal Indicator
Trigger-learned signal Control of learning
Transmission error code Display of characters
Engine speed signal Engine tachometer
Travel speed signal Speedometer
Kick-down switch signal
Kick-down mode signal
Buzzer signal Operation buzzer
Input/Output state signal Real-time monitor
10-248 WA430-6
STRUCTURE AND FUNCTION MACHINE MONITOR
Machine monitor
a Monitor lamps 31 and 36 do not operate on this model.
1. Torque converter oil temperature gauge 21. Cooling fan reverse rotation pilot lamp
2. Torque converter oil temperature caution lamp 22. Maintenance caution lamp
3. Engine coolant temperature gauge 23. Battery electrolyte level caution lamp
4. Engine coolant temperature caution lamp 24. Battery charge circuit caution lamp
5. Speedometer or engine tachometer 25. Steering oil pressure caution lamp
6. Turn signal pilot lamp (Left) 26. Emergency steering pilot lamp
7. Head lamp high beam pilot lamp 27. Character display
8. Turn signal pilot lamp (Right) 28. Output mode pilot lamp
9. Hydraulic oil temperature caution lamp 29. Semi auto digging pilot lamp
10. Hydraulic oil temperature gauge 30. Preheating pilot lamp
11. Fuel level caution lamp 31. Auto-grease pilot lamp
12. Fuel level gauge 32. Joystick pilot lamp
13. Central warning lamp 33. Directional selector pilot lamp
14. Brake oil pressure caution lamp 34. Shift indicator
15. Engine oil pressure caution lamp 35. Auto-shift pilot lamp
16. Engine oil level caution lamp 36. Lockup pilot lamp
17. Radiator coolant level caution lamp 37. Shift hold pilot lamp
18. Air cleaner clogging caution lamp 38. Shift lever position pilot lamp
19. Parking brake pilot lamp 39. Brake oil level caution lamp
20. Brake oil temperature caution lamp 40. Transmission oil filter clogging caution lamp
WA430-6 10-249
List of items displayed on monitor
Condition for judging that engine is running:

When either or both of following items 1 and 2 are sensed, the machine monitor judges that the engine is run-
ning.
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: Lighting
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:

Continual (w) > Intermittent (A) > Cancellation of operation > Check of acceptance of operation.
Operating state
Engine is stopped Engine is running
Dimming
Individual display
Individual display
Central warning
Central warning
at night
Alarm buzzer
Alarm buzzer
Display
Q: ON
Display of
Display of
message
message
Category No. Item Device Operating condition Remarks
color
–: OFF
Each controller turns this
E E E E E E E E
lamp ON. Message is
Q
Central Central When error is made Red also displayed on charac-
warning 13 warning LED ter display and turned ON
lamp lamp by caution.
Other than above – – – – – – –
Q
Back When small lamp is
– Back light LED – – – – – – Orange
light turned ON
Other than below – – – – – – –
– Q – – Q –
Pointer: White range: 50 – 120°C
Q
Alarm: Above 120°C Red
w Q Q B@BCNS w Q Q B@BCNS
Torque con- Red range: 120 – 135°C
1 Movement
verter oil Alarm: Above 130°C Red
2
temperature
Indicator: LED When abnormality is
– – – DGE2KX – – – DGE2KX –
detected
Alarm: Above 102°C – Q – – Q – Red
w Q Q B@BCNS w Q Q B@BCNS
Pointer: White range: 50 – 102°C
Q
Engine cool- When engine controller
3 Movement Red Red range: 102 – 135°C
ant detects [C146] (104.4°C )
4 CAN input (J1939)
temperature
Indicator: LED Not displayed when PGN: 65226
Gauges error is made in commu- – – – – – – –
and nication
meters If error is made in commu-
Travel speed
Pointer: nication, condition is held
5 and engine – – – – – – – –
Movement until starting switch is
speed
turned OFF.
w Q Q B@HANS w Q Q B@HANS
Pointer:
Q
9 Hydraulic oil Movement Alarm: Above 110°C Red White range: 50 – 110°C
10 temperature When abnormality is Red range: 110 – 135°C
Indicator: LED – – – DGH2KX – – – DGH2KX –
detected
Pointer:
Q
11 Movement
Above 80 z – Q – – Q –
Fuel level
12
Indicator: LED Red
Lights up when engine

Q
Engine speed is selected in set-
LED – – – – – – Green x 100 r/min
speed ting of service mode
Unit – option
Q
Set with monitor rotary
Travel speed LED switch when engine – – – – – – Green km/h or MPH
speed is not selected
10-250 WA430-6
Operating state
Dimming
Individual display
Individual display
Central warning
Central warning
at night
Alarm buzzer
Alarm buzzer
Display
Q: ON
Display of
Display of
message
message
color
–: OFF
Upper line: F, N, R
Lower line: Gear speed
Actual gear 9-segment If error is made in com- In neutral, gear speed is
34 – – – – – – – Black
speed LCD munication, display is not displayed.
held until starting switch
is turned OFF.
– Q – – Q –
When auto shift is If error is made in commu-
Q
Green
selected nication, display is held
35 Auto shift LED
until starting switch is
Other than above – – – – – – – turned OFF.
– Q – – Q –
When auto shift or shift If error is made in commu-
Q
Green
hold is selected nication, display is held
37 Shift hold LED
Other than above – – – – – – – turned OFF.
Items When F is selected
Q A Q Q – Q –
related to (When engine is
F LED Green
gear stopped, neutral safety
is displayed)
Q – Q – – Q –
shifting
N LED When N is selected Orange
When R is selected
Q A Q Q – Q –
(When engine is
R LED Green If error is made in commu-
Position stopped, neutral safety
is displayed) nication, display is held
38 of shift
Q – Q – – Q –
lever When 4th gear speed is
4 LED Green turned OFF.
selected
Q – Q – – Q –
When 3rd gear speed is
3 LED Green
selected
Q – Q – – Q –
When 2nd gear speed is
2 LED Green
selected
Q – Q – – Q –
When 1st gear speed is
1 LED Green
selected
WA430-6 10-251
Operating state
Dimming
Individual display
Individual display
Central warning
Central warning
at night
Alarm buzzer
Alarm buzzer
Display
Q: ON
Display of
Display of
message
message
color
–: OFF
Linked to turn signal

When turn signal switch
switch.
Q – Q – – Q –
is input
6 Display of Operates even while
LED (Including time when Green
8 direction starting switch is turned
starting switch is turned
OFF (emergency flash-
OFF)
ing).
When high beam is
Q – Q – – Q –
selected
7 High beam LED (When headlamp and Blue
high beam are turned
ON)
Normal oil pressure
– – – – – – –
(CLOSED)
Below specified pres-
sure (front side)
(OPEN), engine is run-
w Q Q 2G42ZG
ning (detecting time is
– – – Red
continued), and 50 sec-
onds after engine is
started
(No detecting time)
Other
symbols Below specified pres-
sure (rear side) (OPEN),
w Q Q 2G43ZG
engine is running
(detecting time is contin- – – – Red
Brake oil ued), and 50 seconds
Q
pressure after engine is started Change is made 50 sec-
14 LED
Accumulator (No detecting time) onds after engine is
pressure Below specified pres- started without stopping
sure (front side) alarm.
(OPEN), engine is run-
– Q – w Q Q
ning (detecting time is
Red
continued), and in 50
seconds after engine is
started
(No detecting time)
Below specified pres-
sure (rear side) (OPEN),
(detecting time is contin- – Q – w Q Q

engine is running
Red
ued), and in 50 seconds
after engine is started
(No detecting time)
10-252 WA430-6
Operating state
Dimming
Individual display
Individual display
Central warning
Central warning
at night
Alarm buzzer
Alarm buzzer
Display
Q: ON
Display of
Display of
message
message
color
–: OFF
Other than below – – – – – – – If abnormality is detected

w Q Q B@BAZG
When engine controller while engine is stopped,
Q
– – – Red
Engine oil detects [C143] alarm is continued even
15 LED
pressure Not displayed when after engine is started.
error is made in commu- – – – – – – – CAN input (J1939)
nication PGN: 65226
Normal oil level If low level is detected
– – – – – – –
Q
(CLOSED) when starting switch is
Engine oil
– Q – B@BAZK –
16 LED turned ON, alarm is con-
level
Low oil level (OPEN) – – Red tinued even after engine
is started.
Normal coolant level
Q
– – – – – – –
Engine cool- (CLOSED)
– Q – B@BCZK – Q – B@BCZK
17 LED
ant level Low coolant level
Red
(OPEN)
Normal (CLOSED) – – – – – – –
– Q – AA1ANX
If abnormality is detected
Q
Sensor 1 detects clog-
Air cleaner – – – Red while engine is stopped,
18 LED ging (OPEN)
clogging alarm is continued even
When sensor 1 detects after engine is started.
– – – DHA4KA – – – –
abnormality
– Q – – Q –
Parking brake is applied When parking brake is
Red
(OPEN) applied, contact is OPEN
Q
Parking and lamp lights up. Indi-
19 LED
brake Parking brake is reset cator is also used as park-
– – – – – – – ing brake dragging
(CLOSED)
prevention LED.
w Q Q B@C7NS w Q Q B@C7NS
Q
Temperature rise (Rear
Brake oil Red
20 LED side)
temperature
When abnormality is
– – – DGR2KA – – – DGR2KA –
detected (Rear side)
Fan forward operation – – – – – – – Fan reverse operation
Other
– Q – – Q –
symbols As indi- As indi- state is displayed.
Q
Fan reverse operation cated at cated at Orange While fan is reversed,
Fan reverse
21 LED right right message of "COOLING
operation
FAN REVERSE" is dis-
– w – – w –
As indi- As indi-
Fan switch disagrees
cated at cated at Orange played on character dis-
with solenoid play.
right right
Ordinary – – – – – – –
– w – E – w – E
More than 30 H before Message is also dis-
Q
–
Maintenance maintenance played on character dis-
22 LED play. Indicator operates
monitor
maintenance or mainte- – Q – E – Q – E
30 H or less before only for 30 seconds after
Red starting switch is turned
nance time ON.
Normal – – – – – – –
– Q – – Q –
Q
Battery elec- Below 2 V D61AZK Red
23 trolyte level LED Option is not installed – – – – – – –
(If equipped)
When abnormality is
– – – DJBAKX – – – DJBAKX –
detected
Normal voltage – – – – – – –
w Q Q AB00AMA
If abnormality is detected
Q
Battery Defective charge – – – Red while engine is stopped,
24 LED
w Q Q
charge When abnormality is alarm is continued even
AB00L6 – – – Red after engine is started.
detected
Steering oil pressure is
– – – – – – –
normal (OPEN)
Operation of When engine is stopped,
emergency if emergency steering
Q
steering normal signal is input,
Steering oil pressure is
Remarks
w Q Q DDS5L6
25 LED controller judges that
(Steering oil low (CLOSED) and
pressure is – – Red emergency steering sys-
engine speed is above
normal) tem is in self-check. If
500 rpm
steering oil pressure is
low during self-check,
indicator lights up.
WA430-6 10-253
Operating state
Dimming
Individual display
Individual display
Central warning
Central warning
at night
Alarm buzzer
Alarm buzzer
Display
Q: ON
Display of
Display of
message
message
color
–: OFF
w Q Q DY30N1 w Q Q DY30N1
Normal oper- Operation of pump (for
ation of more than 1 min) Green
emergency (OPEN)
Q – Q – – Q –
steering Operation of pump (for
26 LED Green
(Emergency less than 1 min) (OPEN)
steering
pump oper- Pump stops (CLOSED) – – – – – – –
ates)
– Q – – Q –
Q
Power mode "P" Green
Selection of power mode
28 Power mode LED Other than power mode
– – – – – – – is displayed.
"P"
Option is not installed – – – – – – –
Automatic digging is not
– – – – – – –
Semiauto- applied
Q – Q – – Q –
matic Automatic digging is
29 LED Green
digging applied
(If equipped)
Lamp does not light up
When error is made in
– – – – – – – when error is made in
communication
communication.
Other than below – – – – – – – If preheating and post-
heating are not performed
– Q – – Q –
because of abnormality
When preheater is (including abnormality in
Red
turned ON
Q
Preheater output section), lamp
30 (Automatic LED does not light up.
Other preheating) Lamp does not light up
symbols when error is made in
– – – – – – – communication.
communication
(Model equipped with
engine controller)
Operation of wheel
– – – – – – –
steering system
– Q – – Q –
Operation of joystick
Q
Joystick Green
system
32 selector LED
A w Q A w Q
(If equipped) Directional lever priority
Green
caution
communication
communication.
When column gear shift
– – – – – – –
is used If joystick is selected
– Q – – Q –
When right FNR switch optionally, directional
Q
Right direc- is used (In seesaw Green lever priority caution
33 tional selec- LED switch mode) flashes joystick indicator.
A w Q A w Q
tor switch Directional lever priority
Green
caution
communication
communication.
10-254 WA430-6
Setting of machine monitor
1. Model selector rotary switch [SW1]

2. Spare rotary switch [SW2]
3. Speedometer and tire size selector rotary switch [SW3]
4. Spare DIP switch [SW5-1]
5. Work equipment/Joystick controller installation setting DIP switch [SW5-2]
7. 4th gear speed use permission setting DIP switch in joystick mode [SW5-4]
8. Engine controller installation setting DIP switch [SW6-1]
In the following cases, check the setting of the rotary switches and DIP switches on the back side of the
machine monitor, and then change it if necessary.
1. When the machine monitor needs to be removed and installed again.

2. When the machine monitor is replaced with new one.
3. When the tire size is changed. (Setting of correction of travel speed)
4. When an optional device is installed or removed.
You can check the setting of each switch with the real-time monitor in the service mode. See "Real-time monitor
function".
• When setting these switches, turn the power OFF and remove the machine monitor. For the removal meth-
od, see "Disassembly and assembly".
• Be sure to set the switches (SW1, SW2, SW3, SW5, and SW6) as specified.
• When turning a rotary switch, use a precision cross-head screwdriver, etc. and turn it carefully.
• The triangular projection of each rotary switch is the setting arrow.
WA430-6 10-255
• When changing a DIP switch, use a precision flat-head screwdriver, etc. and change it carefully.
• Do not touch any part other than the switches inside the grommet.
• You can change and check the setting of the optional items with the option setting function in the service
mode. (See Initial setting/adjustment)
• Some optional items need initial setting. (See Initial setting/adjustment)
• You can perform the initial adjustment with the tuning function in the service mode. (See Initial setting/ad-
justment)
1. Precautions
• Be sure to set each switch as specified.
• When changing each switch, use a precision flat-head screwdriver, etc. and change it carefully.
• After removing the grommet, do not touch any internal part other than the switches.
• Take care that dirt will not enter the machine monitor.
• After finishing setting, return the grommet securely.
2. Setting of model selector rotary switch [SW1]

Since the machine monitor is applicable to many machine models, the machine model on which it is
mounted must be set.
If the machine monitor is replaced, select the current machine model with rotary switch [SW1].
Set rotary switch [SW1] according to the machine model on which it is mounted as shown in the following
table.
Machine model Set position of [SW1] Remarks

WA430-6 5
3. Setting of rotary switch [SW2]

Set rotary switch [SW2] to the following position and do not change it.
Set position of SW2: 0
4. Setting of selection of speedometer and tire size (Setting of rotary switch [SW3])
The machine monitor uses the standard tire size to calculate the travel speed. Accordingly, if the tire size is
changed, change rotary switch [SW3] to correct the indicated travel speed.
Set rotary switch [SW3] according to the tire size as shown in the following table.
Unit of displayed
Set position of [SW3] Tire size Remarks
speed
km/h 0 Large diameter
Used only in country where SI
MPH 1 Large diameter
units are not used.
km/h 6 Small diameter
Used only in country where SI
MPH 7 Small diameter
units are not used.
Tire size WA430-6

20.5-25 (Small diameter) Option
23.5-25 (Large diameter) Standard
• To change the unit of the displayed speed, change the contents of display of the speedometer at the
center of the monitor.
• Change the speedometer to the engine tachometer by optional setting.
• The unit of the odometer in the character display section is displayed according to the above setting.
• The unit of MPH is for only a country where the SI units are not used (but mile is used). Do not set it for
a country where the SI units are used.
• When tires other than the specified ones are used or the displayed speed is different from the actual trav-
el speed because of wear of the tires, you can correct the tire size by optional setting.
10-256 WA430-6
5. Setting of DIP switch [SW5-1]

Set DIP switch [SW5-1] to the following position and do not change it.
Set position of [SW5-1]: OFF
6. Setting of installation of work equipment controller (Setting of DIP switch [SW5-2])

When the work equipment controller is installed or removed, set DIP switch [SW5-2] as shown below.
Set position of [SW5-2] when controller is removed: OFF
Set position of [SW5-2] when controller is installed: ON

8. Setting of permission of using 4th gear speed in joystick mode (Setting of DIP switch [SW5-4])
When the joystick is used and using the 4th gear speed is permitted or prohibited, set DIP switch [SW5-4]
as shown below.
Set position of DIP switch [SW5-4] when using 4th gear speed is prohibited: OFF
Set position of DIP switch [SW5-4] when using 4th gear speed is permitted: ON
• When using the 4th gear speed is permitted, stick the nameplate (Part No.: 421-S33-3130) to the lever
stand to indicate that the 4th gear speed can be used.

Set position of [SW6-1]: ON



WA430-6 10-257
Service mode functions
General
1. Display of electrical system failure history 2. Display of mechanical system failure history
This function is used to check the electrical sys- This function is used to check the mechanical
tem failure history of each controller saved in the system failure history of each controller saved in
machine monitor. For the failure codes dis- the machine monitor. For the failure codes dis-
played in the electrical system failure history, played in the mechanical system failure history,
see "Troubleshooting". After each failure is see "Troubleshooting".
repaired and the normal operation is confirmed, The contents of the mechanical system failure
delete the failure history. history displayed on the character display are as
The contents of the electrical system failure his- follows.
tory displayed on the character display are as
follows.
*** : Number of failure currently dis-

played
*** : Number of failure currently dis- ###### : Unified failure code (6 digits)
played $$$ : Frequency of occurrence of dis-
###### : Unified failure code (6 digits) played failure code
$$$ : Frequency of occurrence of corre- %%%%% : Service meter value at first occur-
sponding failure code rence of displayed failure
%%%%% : Time elapsed after first occur- @@@@@ : Service meter value at latest
rence of displayed failure (Value occurrence of displayed failure
obtained by subtracting service
meter value at first occurrence The failure code of a currently detected failure
from current service meter value) blinks. Up to several vehicle failure codes are
@@@@@ :Time elapsed after latest occur- saved.
rence of displayed failure (Value
obtained by subtracting service
meter value at latest occurrence
from current service meter value)
The failure code of a currently detected failure

blinks. Up to 20 failure codes are saved.
10-258 WA430-6
3. Real-time monitor 4. Tuning

This function is used to check the input and out- This function is used to initialize the sensors,
put signals, etc. recognized by each controller etc. installed to the machine when any sensor,
on the network. EPC valve, controller, etc. is replaced or added.
The contents of the real-time monitor displayed
on the character display are as follows. 5. Maintenance monitor
This function is explained in "Operation and
Maintenance Manual, Operation, Character dis-
play, Display of replacement periods of filters
and oils". It is used to change the replacement
periods of the filters and oils.
6. Selection of options
With this function, you can display installation of
an optional device and change the setting of that
device. Use this function after any optional
device is installed or removed.
7. Setting of machine serial No.

This function is used to display and set the
*** : Real-time monitor item name machine serial Nos. to control the machines.
###### : ID No. given to each real-time monitor
item 8. Initialize
%%% : Data. If a unit (an SI unit) is used, it is This function is used only in the factory. Do not
displayed on the right of the data. use it.
Any 2 items can be displayed simultaneously by

specifying their ID Nos. In this case, they are
displayed on the character display as shown
below.
##### : Specified ID Nos.

%%% : Data. If a unit (an SI unit) is used, it is
displayed on the right of the data.
WA430-6 10-259
Operating method
10-260 WA430-6
Function of displaying electrical system failure history
1. Display of electrical system failure history and selection of clearing entirely the electrical system failure his-
tory
The items are displayed in the sequential order by the latest occurrence time from the latest one.
The items which have not been reset are displayed before the items which have been reset.
Pressing the > switch scrolls the items from the newer ones to the older ones.
Pressing the < switch scrolls the items from the older ones to the newer ones.
After the oldest saved item, the "Select clearing entirely electrical system failure history" screen is dis-
Pressing the t switch changes the screen to the "Select electrical system failure history" screen.
played.
Pressing the U switch changes the screen to the "Clear individually electrical system failure history" screen
or the "Clear entirely electrical system failure history" screen.
2. Selection of electrical system failure history (1st layer)

Pressing the < switch changes the screen to the "Select initialization" screen.
Pressing the > switch changes the screen to the "Select display of mechanical system failure history"
Pressing the t switch changes the screen to the normal screen or alarm screen.
screen.
Pressing the U switch changes the screen to the "Display electrical system failure history" screen.
*1. The number of saved abnormalities is displayed in the ** section (up to 20 items).
WA430-6 10-261
3. Display of electrical system failure history and selection of clearing entirely the electrical system failure his-
tory (2nd layer)
Pressing the > switch scrolls the items from the older ones to the newer ones.
Pressing the t switch changes the screen to the "Select electrical system failure history" screen.
Pressing the < switch scrolls the items from the newer ones to the older ones.
Pressing the U switch changes the screen to the "Clear electrical system failure history" screen.
• If there is only 1 history, the current screen does not change to the "Clear entirely electrical system failure
history" screen (Only the "Clear individually electrical system failure history" screen is displayed).
*1. "Display electrical system failure history" screen

*2. "Display electrical system failure history" screen (Where there is no history)
*3. "Select clearing entirely electrical system failure history" screen
*** : Number of failure currently displayed

###### : Unified failure code (6 digits)
$$$ : Frequency of occurrence of corresponding failure code
%%%%% : Time elapsed after first occurrence of displayed failure (Value obtained by subtracting service
meter value at first occurrence from current service meter value)
@@@@@ : Time elapsed after latest occurrence of displayed failure (Value obtained by subtracting service
meter value at latest occurrence from current service meter value)
10-262 WA430-6
4. Clearing of individual electrical system failure history and clearing of entire electrical system failure history
(3rd layer)
and the t switch is pressed, clearing is executed. If "NO" is selected and the t switch is pressed, clearing
Select "YES" or "NO" with the < or > switch. The cursor (_) blinks on the selected item. If "YES" is selected
is cancelled and the display changes as shown below.

• If clearing is cancelled (NO), the current screen returns to the "Display electrical system failure history"
screen of the corresponding failure.
(Returns to the screen before the "Clear individually electrical system failure history" (Clear entirely elec-
trical system failure history) screen).
• If clearing is executed (YES), the current screen returns to the "Display electrical system failure history"
screen of the corresponding next failure.
After all the failure histories are cleared, the current screen returns to the "Select electrical system failure
history" screen.
By default, the cursor is on NO (cancel) to prevent resetting by an error.
You cannot delete a failure which has not been reset. If you try to do so, the operation cancel peep (for 1
If any failure history is cleared, the operation acceptance peeps (ON for 0.1 sec o OFF for 0.1 sec o ON
sec) is heard.
for 0.1 sec) are heard.

When clearing of all the histories is selected, if there is any history to be cleared, clearing is assumed to be
completed.
*1. "Clear individually electrical system failure history" screen

*2. "Clear entirely electrical system failure history" screen
WA430-6 10-263
Function of displaying mechanical system failure history
1. Display of mechanical system failure history

Pressing the t switch changes the screen to the "Select mechanical system failure history" screen.
2. Selection of mechanical system history (1st layer)

Pressing the > switch changes the screen to the "Select real-time monitor" screen.
Pressing the < switch changes the screen to the "Select display of electrical system failure history" screen.
Pressing the U switch changes the screen to the "Display mechanical system failure history" screen.
*1. The number of saved abnormalities is displayed in the ** section.
10-264 WA430-6
3. Display of mechanical system failure history (2nd layer)

Pressing the t switch changes the screen to the "Select mechanical system failure history" screen.
*1. "Display mechanical system failure history" screen

*2. "Display mechanical system failure history" screen (Where there is no history)
*** : Number of failure currently displayed

###### : Unified failure code (6 digits)
$$$ : Frequency of occurrence of corresponding failure code
%%%%% : Service meter value at first occurrence
@@@@@ : Service meter value at latest occurrence
WA430-6 10-265
Function of real-time monitor
The real-time monitor function displays the information saved in the controllers mounted on the machine in real time.
This function is used for testing, adjusting, or troubleshooting the machine.
This function classifies the items and data by the controllers having them, and then displays the results. It has 2
display modes of the normal display mode and the 2-item display mode for displaying 2 data simultaneously.
1. Selection and display of real-time monitor item

Pressing the > switch changes the screen in the order of controller 1, controller 2, controller 3 --- Select dis-
play of 2 items.
Pressing the < switch changes the screen in the order of Select of display of 2 items, controller 5, controller
Pressing the t switch changes the screen to the "Select real-time monitor" screen.
4, --- controller 1.
When display each controller information is selected: Pressing the U switch changes the screen to the
When display of 2 items is selected: Pressing the U switch changes the screen to the "Select 2 items"
"Display real-time monitor" screen.
screen.
2. Selection of real-time monitor (1st layer)

Pressing the > switch changes the screen to the "Select engine reduced cylinder mode" screen.
Pressing the < switch changes the screen to the "Select display of mechanical system failure history"
screen.
Pressing the U switch changes the screen to the "Select display of information" screen.
10-266 WA430-6
3. Selection of display of information of each controller and selection of display of 2 items (2nd layer)
Pressing the > switch changes the screen to the next selection of information.
Pressing the t switch changes the screen to the "Select real-time monitor" screen.
Pressing the < switch changes the screen to the previous selection of information.
When display of each controller information is selected: Pressing the U switch changes the screen to the
When display of 2 items is selected: Pressing the U switch changes the screen to the "Select 2 items"
"Display real-time monitor" screen.
screen.
*1. "Select display of machine monitor information" screen

*2. "Select display of transmission controller information" screen
*3. "Select display of engine controller information" screen
*4. "Select display of work equipment controller information" screen
*5. "Select display of 2 items" screen.
WA430-6 10-267
4. Display of real-time monitor (3rd layer)

Pressing the > switch changes the screen in the order of No. 1, No. 2, No. 3 ---.
Pressing the t switch changes the screen to the "Select display of each controller information" screen.
Pressing the < switch changes the screen in the order of No. 13, No. 12, No. 11 ---.
Pressing the U switch holds the displayed data. Pressing it again returns the displayed data into the active
state. (When the data are held, the U mark blinks.)
*** : Real-time monitor item name

#### : ID No. of real-time monitor item
%%% : Data. If a unit (an SI unit) is used, it is displayed on the right of the data.
5. Selection of 2 items (3rd layer)

How to input ID
1) When the screen appears, the cursor (_) is displayed at the highest position of "00000".
3) Select a desired digit and press the U switch.

2) Each time the > switch or the < switch is pressed, the digit changes by 1 between 0 and 9.
4) The cursor moves to the 2nd position. Select the digits for the all positions by performing steps 2) and
5) After selecting the digit for the lowest position, press the U switch.
3) above.
7-1) If you press the t switch before finishing entering the ID, the cursor moves to the highest position.
6) If the ID is settled, the screen changes to the "Display 2 items" screen.
7-2) If you press the t switch while the cursor is at the highest position, the screen returns to the "Select
display of 2 items" screen.
10-268 WA430-6
Pressing the t switch changes the screen to the "Select 2 items" screen.
6. Display of 2 items (4th layer)
Pressing the U switch holds the displayed data. Pressing it again returns the displayed data into the active
state. (When the data are held, the U mark blinks.)
##### : ID of specified real-time monitor item

%%% : Data. If a unit (an SI unit) is used, it is displayed on the right of the data.
The first item is displayed on the upper line and the second item is displayed on the lower line.
If an item ID that cannot be displayed is selected on the "Select 2 items" screen, the data section and unit dis-
play section (%%%) are left blank.
WA430-6 10-269
Real-time monitoring items

Machine monitor
Item Real-time monitoring Display of item Display Display Checked

Terminal No. Remarks
ID item (*1) (*2) unit (*3) range (*4) component
Part No. of machine Part No. of ROM
20200 MONITOR ROM – – Monitor –
monitor ROM is displayed
01001 Engine speed ENG SPEED 1 rpm 0 – 3000 Transmission L62-10
40000 Travel speed SPEED 1km/h 0 – 50 Transmission L62-20
04202 Fuel level FUEL SENSOR 1% 0 – 100 Monitor L55- 1
When below
Hydraulic oil
04401 HYD TEMP 1°C 24 – 131 Monitor L55- 7 24°C , display is
temperature
fixed to 24°C
When below
Engine coolant COOLANT
04103 1°C 24 – 131 Monitor L55- 8 24°C , display is
temperature TEMP
fixed to 24°C
When below
Engine coolant
04104 COOLANT Lo 1°C -31 – 91 Monitor J1939 -31°C, display is
temperature (Low)
fixed to -31°C
When below
Torque converter oil
40100 TC OIL TEMP 1°C 24 – 131 Monitor L55- 2 24°C , display is
temperature
fixed to 24°C
04302 Charge level ALTERNATOR R 0.1 V 0.0 – 30.0 Monitor L52-18
40200 Small lamp voltage SMALL LAMP 0.1 V 0.0 – 30.0 Monitor L53-12
Battery electrolyte
40300 BATTERY A2V 0.1 V 0.0 – 30.0 Monitor L55- 5
level A
Battery electrolyte
40301 BATTERY B2V 0.1 V 0.0 – 30.0 Monitor L55-12
level B
06001 Lift arm angle BOOM ANG 1° -41 – 46 Monitor L55-10
Lift arm bottom
40400 BTM PRESS 0.01MPa 0.00 – 50.00 Monitor L55- 9
pressure
40500 Lift arm rod pressure ROD PRESS 0.01MPa 0.00 – 50.00 Monitor L55- 4
40600 Calibration pressure CAL PRESS 0.01MPa 0.00 – 50.00 Monitor Calculated value
40700 Calculated pressure MES PRESS 0.01MPa 0.00 – 50.00 Monitor Calculated value
40800 Classified weight MES LOAD 0.01 t 0.00 – 50.00 Monitor Calculated value
Position of rotary Switch on back
30802 SW1, SW2, SW3 – 0–F Monitor
switch side
Switch on back
30904 Position of DIP switch SW5-1, SW5-2 – OFF/ON Monitor
side
Switch on back
side
Switch on back
side
Switch on back
side
40900 Input signal D_IN_0-7 D-IN--0------7 – 10101010 Monitor Separate sheet
40901 Input signal D_IN_8-15 D-IN--8-----15 – 10101010 Monitor Separate sheet
40902 Input signal D_IN_16-23 D-IN-16-----23 – 10101010 Monitor Separate sheet
*1. All items are displayed although their sensors are not installed to all the models and options.
*2. When displayed, the above items are contracted since the number of displayed letters is limited.
*3. Only the SI units are used.
*4. If a value is below (or above) the display range, the lowest (highest) value of the display range is displayed.
10-270 WA430-6
Transmission controller

Part No. of transmission Part No. of ROM
20201 TRANSM ROM – – Transmission –
controller ROM is displayed
41000 Fan pump target speed FAN PUMP 1 rpm 0 – 3000 Transmission Calculated value
0.01
41100 Left brake pressure LH BRAKE 0.00 – 50.00 Transmission L61-19
MPa
Transmission cut-off 0.01
41200 CUT OFF 0.00 – 50.00 Transmission Calculated value
pressure MPa
41300 Kick-down speed K/D TIMES – – Transmission Calculated value
41301 Average cycle time CYCLE TIME 1 SEC – Transmission Calculated value
31608 F clutch ECMV current ECMV F 1 mA 0 – 1000 Transmission L63- 5
31606 R clutch ECMV current ECMV R 1 mA 0 – 1000 Transmission L63-15
1st clutch ECMV
31602 ECMV 1 1 mA 0 – 1000 Transmission L63-25
current
2nd clutch ECMV
31603 ECMV 2 1 mA 0 – 1000 Transmission L63- 6
current
3rd clutch ECMV
current
4th clutch ECMV
current
Lockup clutch ECMV
31609 ECMV LU 1 mA 0 – 1000 Transmission L63-35
current
41400 Fan pump EPC current FAN EPC 1 mA 0 – 1000 Transmission L63-36
Loader pump EPC
41401 PUMP EPC 1 mA 0 – 1000 Transmission L63-27
current
Transmission oil
41500 ECMV OIL TEMP 1°C 24 – 131 Transmission L61- 9
temperature
Selection of engine
41600 ENGINE MODE – P/N Transmission L61- 6
mode
41700 Selection of shift mode SHIFT MODE – H/M/L Transmission Calculated value
41808 F clutch fill time FILL TIME F 10 msec 0 – 2550 Transmission Calculated value
41806 R clutch fill time FILL TIME R 10 msec 0 – 2550 Transmission Calculated value
41802 1st clutch fill time FILL TIME 1 10 msec 0 – 2550 Transmission Calculated value
41803 2nd clutch fill time FILL TIME 2 10 msec 0 – 2550 Transmission Calculated value
41804 3rd clutch fill time FILL TIME 3 10 msec 0 – 2550 Transmission Calculated value
41805 4th clutch fill time FILL TIME 4 10 msec 0 – 2550 Transmission Calculated value
0/1
31508 F clutch fill time FILL SW (F) – (Normal/ Transmission Calculated value
Abnormal)
0/1
31506 R clutch fill time FILL SW (R) – (Normal/ Transmission Calculated value
Abnormal)
0/1
31502 1st clutch fill time FILL SW (1) – (Normal/ Transmission Calculated value
Abnormal)
0/1
31503 2nd clutch fill time FILL SW (2) – (Normal/ Transmission Calculated value
Abnormal)
0/1
31504 3rd clutch fill time FILL SW (3) – (Normal/ Transmission Calculated value
Abnormal)
0/1
31505 4th clutch fill time FILL SW (4) – (Normal/ Transmission Calculated value
Abnormal)
WA430-6 10-271

Input signal
40905 D-IN--0------7 – 10101010 Transmission Separate sheet
D_IN_0-7
Input signal
40906 D-IN--8-----15 – 10101010 Transmission Separate sheet
D_IN_8-15
Input signal
40907 D-IN-16-----23 – 10101010 Transmission Separate sheet
D_IN_16-23
Input signal
40908 D-IN-24-----31 – 10101010 Transmission Separate sheet
D_IN_24-31
Rear brake oil
30202 R BRAKE OIL 1°C 24 – 131 Transmission L61-20
temperature
Output signal
40915 D-OUT-0-----6 – 101010 Transmission Separate sheet
D_OUT_0-6
Output signal
40914 SOL/O-0----5 – 101010 Transmission Separate sheet
SOL/O_0-5
Engine controller

01002 Engine speed ENG SPEED 1 rpm 0 – 8032 Engine J1939
31701 Position of throttle THROTTLE POS 1% 0.0 – 100 Engine J1939
37300 Fuel consumption FUEL RATE 1 L/h 0.0 – 3213 Engine J1939
Engine coolant COOLANT
04107 1°C -40 – 210 Engine J1939
temperature TEMP
Air intake manifold
37500 MANIFOLD AIR 1°C -40 – 210 Engine J1939
temperature
10-272 WA430-6
How to read input signal (D-IN--0------7) c: The state of the output signal of D-OUT-6 is dis-
Each signal input through the ON/OFF switch to the played.
controller is displayed in the form of D-IN-*
(* is the input No.) ##### : The real-time monitoring item ID No. is dis-
The actual display is as follows. played.
If the input state is displayed as "0", a signal is not
output (OFF).
If the input state is displayed as "1", a signal is out-
put (ON).
How to read output signal (SOL/O--0----5)

Each signal output through the ON/OFF switch to
the controller is displayed in the form of SOL/O-*
(* is the output No.)
The actual display is as follows.
a: The state of the input signal of D-IN-0 is dis-

played.
b: The state of the input signal of D-IN-1 is dis-
played.
c: The state of the input signal of D-IN-7 is dis-
played.
##### : The real-time monitoring item ID No. is dis-

played.
input (OFF).
If the input state is displayed as "1", a signal is input a: The state of the output signal of SOL/O-0 is dis-
(ON). played.
b: The state of the output signal of SOL/O-1 is dis-
played.
How to read output signal (D-OUT--0------6) c: The state of the output signal of SOL/O-5 is dis-
Each signal output through the ON/OFF switch to played.
the controller is displayed in the form of D-OUT-*
(* is the output No.)
The actual display is as follows. ##### : The real-time monitoring item ID No. is dis-
played.
output (OFF).
If the input state is displayed as "1", a signal is out-
put (ON).
a: The state of the output signal of D-OUT-0 is dis-

played.
b: The state of the output signal of D-OUT-1 is dis-
played.
WA430-6 10-273
Machine monitor
Input/
Terminal
Item ID Output Displayed item ON/OFF logic
No.
signal
D-IN- 0 Lamp switch L52- 1 Lighting of headlamp = ON(24V)/OFF(OPEN)
D-IN- 1 No item L52-10 ON(24V)/OFF(OPEN)
D-IN- 2 Starting switch C L52- 2 Start of starting motor=ON(24V)/OFF(OPEN)
Emptiness or abnormality of auto grease tank
40900 D-IN- 4 Auto grease A L52- 3
=ON(24V)/OFF(OPEN)
Operation or abnormality of auto grease
D-IN- 5 Auto grease B L52-12
=ON(24V)/OFF(OPEN)
D-IN- 6 No item L52- 4 ON(24V)/OFF(OPEN)
D-IN-10 No item L52- 6 ON(24V)/OFF(OPEN)
D-IN-11 No item L52-15 ON(24V)/OFF(OPEN)
Lighting of right turn signal lamp
40901 D-IN-12 Right turn signal lamp L52- 7
=ON(24V)/OFF(OPEN)
Lighting of left turn signal lamp
D-IN-13 Left turn signal lamp L52-16
=ON(24V)/OFF(OPEN)
D-IN-14 Monitor panel mode selector switch 1U L52- 8 Pressing of switch=ON(24V)/OFF(OPEN)
D-IN-15 Monitor panel mode selector switch 1t L52-17 Pressing of switch=ON(24V)/OFF(OPEN)
D-IN-16 Brake oil pressure (Front) L53- 1 Normal oil pressure=ON(GND)/OFF(OPEN)
D-IN-17 Brake oil pressure (Rear) L53- 7 Normal oil pressure=ON(GND)/OFF(OPEN)
D-IN-18 No item L53- 2 ON(GND)/OFF(OPEN)
40902
D-IN-20 Clogging of air cleaner L53- 3 No clogging=ON(GND)/OFF(OPEN)
D-IN-23 No item L53-10 ON(GND)/OFF(OPEN)
Operation of parking brake
D-IN-26 Parking brake L54- 1
=ON(GND)/OFF(OPEN)
Normal coolant level (Full)
D-IN-27 Engine coolant level L54-10
=ON(GND)/OFF(OPEN)
40903
D-IN-28 Engine oil pressure L54- 2 Low oil pressure=ON(GND)/OFF(OPEN)
Normal oil leakage (Full)
D-IN-29 Engine oil level L54-11
=ON(GND)/OFF(OPEN)
Operation of emergency steering motor
D-IN-30 Normal emergency steering motor L54- 3
=ON(GND)/OFF(OPEN)
D-IN-31 No item – –
D-IN-32 Load meter subtotal switch L54- 4 Pressing of switch=ON(GND)/OFF(OPEN)
D-IN-33 Load meter cancel switch L54-13 Pressing of switch=ON(GND)/OFF(OPEN)
High beam of headlamp
D-IN-34 Dimmer switch L54- 5
=ON(GND)/OFF(OPEN)
40904 D-IN-35 No item L54-14 ON(GND)/OFF(OPEN)
D-IN-36 Service function 2 L54- 6 ON(GND)/OFF(OPEN)
D-IN-37 Monitor panel mode selector switch 2 > L54-15 Pressing of switch=ON(24V)/OFF(OPEN)
D-IN-38 Monitor panel mode selector switch 2 < L54- 7 Pressing of switch=ON(24V)/OFF(OPEN)
D-IN-39 Low steering oil pressure L54-16 Normal oil pressure=ON(GND)/OFF(OPEN)
10-274 WA430-6
Input/
Terminal
No.
signal
Normal pressure (Applied)
D-IN- 0 Steering pressure switch (N.O.) L61-23
=ON(GND)/OFF(OPEN)
Abnormal pressure (Low)
D-IN- 1 Steering pressure switch (N.C.) L61-17
=ON(GND)/OFF(OPEN)
D-IN- 2 Transmission cut-off switch L61-11 Pressing of switch=ON(GND)/OFF(OPEN)
40905 D-IN- 3 Transmission cut-off set switch L61- 5 Pressing of switch=ON(GND)/OFF(OPEN)
D-IN- 4 ECSS switch L61-24 Pressing of switch=ON(GND)/OFF(OPEN)
D-IN- 5 Torque converter lockup switch L61-18 Pressing of switch=ON(GND)/OFF(OPEN)
D-IN- 6 Kick-down switch L61-12 Pressing of switch=ON(GND)/OFF(OPEN)
D-IN- 7 Power mode selector switch NORMAL L61- 6 POWER mode=ON(GND)/OFF(OPEN)
D-IN- 8 Gearshift lever 1st L63-10 1st=ON(24V)/OFF(OPEN)
D-IN- 9 Gearshift lever 2nd L63-20 2nd=ON(24V)/OFF(OPEN)
D-IN-10 Gearshift lever 3rd L63-30 3rd=ON(24V)/OFF(OPEN)
D-IN-11 Gearshift lever 4th L63-40 4th=ON(24V)/OFF(OPEN)
40906
D-IN-12 Joystick shift-up L63- 9 Pressing of switch=ON(24V)/OFF(OPEN)
D-IN-13 Joystick shift-down L63-19 Pressing of switch=ON(24V)/OFF(OPEN)
D-IN-14 Emergency steering switch L63-29 Pressing of switch=ON(GND)/OFF(OPEN)
D-IN-15 Starting switch C L63-39 Start of starting motor=ON(24V)/OFF(OPEN)
D-IN-16 Directional selector actuation switch L62-35 Pressing of switch=ON(GND)/OFF(OPEN)
D-IN-17 Directional selector switch, joystick forward L62-25 Forward=ON(24V)/OFF(OPEN)
D-IN-18 Directional selector switch, joystick neutral L62-15 Neutral=ON(24V)/OFF(OPEN)
D-IN-19 Directional selector switch, joystick reverse L62- 5 Reverse=ON(24V)/OFF(OPEN)
40907 D-IN-20 Directional lever forward L62-36 Forward=ON(24V)/OFF(OPEN)
D-IN-21 Directional lever neutral L62-26 Neutral=ON(24V)/OFF(OPEN)
D-IN-22 Directional lever reverse L62-16 Reverse=ON(24V)/OFF(OPEN)
Parking brake switch ON
D-IN-23 Neutralizer (Parking brake) signal L62- 6
=ON(24V)/OFF(OPEN)
D-IN-24 F clutch fill switch L62-37 Fill switch ON=ON(GND)/OFF(OPEN)
D-IN-25 R clutch fill switch L62-27 Fill switch ON=ON(GND)/OFF(OPEN)
D-IN-26 1st clutch fill switch L62-17 Fill switch ON=ON(GND)/OFF(OPEN)
D-IN-27 2nd clutch fill switch L62- 7 Fill switch ON=ON(GND)/OFF(OPEN)
40908
D-IN-28 3rd clutch fill switch L62-13 Fill switch ON=ON(GND)/OFF(OPEN)
D-IN-29 4th clutch fill switch L62- 3 Fill switch ON=ON(GND)/OFF(OPEN)
D-IN-30 Lockup clutch fill switch L62- 2 Fill switch ON=ON(GND)/OFF(OPEN)
D-IN-31 Shift hold switch L62-38 Pressing of switch=ON(GND)/OFF(OPEN)
SOL/O-0 Electric emergency steering relay L63- 7 Output ON(24V)/OFF(OPEN)
SOL/O-1 ECSS relay L63-17 Output ON(24V)/OFF(OPEN)
SOL/O-2 Switch pump cut-off L63-27 Output ON(24V)/OFF(OPEN)
40914
SOL/O-3 Neutral output L63-37 Output ON(24V)/OFF(OPEN)
SOL/O-4 Fan pump reverse solenoid L63-28 Output ON(24V)/OFF(OPEN)
SOL/O-5 Fan pump neutral solenoid L63-38 Output ON(24V)/OFF(OPEN)
D-OUT-0 Backup lamp relay L63- 4 Output ON(24V)/OFF(OPEN)
40915
D-OUT-1 Transmission cut-off indicator L63- 8 Output ON(24V)/OFF(OPEN)
WA430-6 10-275
Work equipment controller
Input/
Terminal
No.
signal
D-IN- 0 Joystick ON/OFF switch L71-23 Joystick selected=ON(24V)/OFF(OPEN)
FREE position=ON(24V)/LOCK position
D-IN- 1 Work equipment lock lever switch L71-17
=OFF(OPEN)
40910 D-IN- 3 No item L71- 5 ON(24V)/OFF(OPEN)
D-IN- 8 HI/LOW selector switch L73-10 HI speed selected=ON(GND)/OFF(OPEN)
D-IN- 9 Bucket positioner proximity switch L73-20 Horizontal position=ON(GND)/OFF(OPEN)
D-IN-10 Bucket cylinder full stroke proximity switch L73-30 Stroke end position=ON(GND)/OFF(OPEN)
40911
D-IN-12 Semi auto digging switch HARD L73- 9 Switch pressed=ON(GND)/OFF(OPEN)
D-IN-13 Semi auto digging switch SOFT L73-19 Switch pressed=ON(GND)/OFF(OPEN)
—
40913
D-IN-28 Remote positioner raise/lower set switch RAISE L72-13 Switch pressed=ON(GND)/OFF(OPEN)
D-IN-29 Remote positioner raise/lower set switch LOWER L72- 3 Switch pressed=ON(GND)/OFF(OPEN)
D-IN-30 Remote positioner raise mode switch L72- 2 Switch pressed=ON(GND)/OFF(OPEN)
D-IN-31 Remote positioner lower mode switch L72-38 Switch pressed=ON(GND)/OFF(OPEN)
SOL/O-0 Joystick cut-off relay L73- 7 Output ON(24V)/OFF(OPEN)
SOL/O-1 Detent lift arm RAISE L73-17 Output ON(24V)/OFF(OPEN)
SOL/O-2 Detent lift arm FLOAT L73-27 Output ON(24V)/OFF(OPEN)
40916
SOL/O-3 Detent bucket TILT L73-37 Output ON(24V)/OFF(OPEN)
SOL/O-4 Work equipment EPC cut-off solenoid valve L73-28 Output ON(24V)/OFF(OPEN)
SOL/O-5 No item L73-38 Output ON(24V)/OFF(OPEN)
D-OUT-1 Remote positioner raise indicator lamp L73- 8 Output ON(24V)/OFF(OPEN)
40917
D-OUT-2 Remote positioner lower indicator lamp L73-18 Output ON(24V)/OFF(OPEN)
10-276 WA430-6
(Reference) Inspection with real-time monitor
Example) Measurement of engine speed

Measure the engine speed under the following condition.
Coolant temperature: Within operating range
Hydraulic oil temperature: 45 – 55°C
Power train oil temperature: 70 – 90°C
First, check this condition with the real-time monitor.
Real-time monitor item Display of item Checked component Item ID

Engine coolant temperature (Low) COOLANT Lo Machine monitor 04104
Hydraulic oil temperature HYD TEMP Machine monitor 04401
Torque converter oil temperature TC OIL TEMP Machine monitor 40100
After checking the above items with the real-time monitor, check the engine speed.
Real-time monitor item Display of item Checked component Item ID

Engine speed ENG SPEED Machine monitor 01001
(Reference) Troubleshooting with real-time monitor
Example) The transmission cut-off position cannot be set again.

The transmission cut-off system does not function in the following cases.
• Abnormality in transmission cut-off switch
• Abnormality in transmission cut-off set switch
• Abnormality in left brake pressure sensor
• Abnormality in transmission controller
First, see if the transmission controller has detected abnormality and output the error signal.
If the transmission controller has not detected any error, check the state of the input signal with the real-time
monitor.
1. Check of transmission cut-off selector switch

If it is not judged that the transmission cut-off selector switch is turned ON, the 3rd position is "0".
Real-time monitor item Display of item Terminal No. Item ID

DIN-IN--0------7
D-IN-2 L61-11 40905
40905:**0*****
If it is judged that the transmission cut-off selector switch is turned ON, the 3rd position is "1".
When the switch is operated, if the 3rd position is still "0", the transmission cut-off switch system is judged
abnormal.

DIN-IN--0------7
D-IN-2 L61-11 40905
40905:**1*****
WA430-6 10-277
2. Check of transmission cut-off set switch

If it is not judged that the transmission cut-off set switch is turned ON, the 4th position is "0".

DIN-IN--0------7
D-IN-3 L61-11 40905
40905:**0*****
If it is judged that the transmission cut-off selector switch is turned ON, the 4th position is "1".
When the switch is operated, if the 4th position is still "0", the transmission cut-off set switch system is
judged abnormal.

DIN-IN--0------7
D-IN-3 L61-11 40905
40905:**1*****
3. Check of left brake pressure sensor

Check while the engine is running.
When the cut-off brake is pressed and released, if the pressure does not change, the sensor system is
judged abnormal.
If the brake pedal is pressed fully, the left brake pressure becomes about 5.00 MPa {51 kg/cm2 }. If the
former is released, the latter becomes below 0.5 MPa {5 kg/cm2}.
Even if the engine is stopped, if there is pressure left in the accumulator, the pressure changes. If pressure
is not left, the pressure is below 0.5 MPa {5 kg/cm2}, even if the brake pedal is pressed.

LH BRAKE
Left brake pressure L61-19 41100
41100:*.**MPa
4. Check of set transmission cut-off pressure

See if the set transmission cut-off pressure changes.
1) While the left brake pressure sensor is displayed, press the left brake pedal and set the cut-off position
at arbitrary pressure.
Set the cut-off position at 1.5 MPa {15 kg/cm 2} this time.
Set the cut-off position. ("1.50" is an arbitrary value)
The pressure when the transmission cut-off set switch is pressed and released is saved and set.

LH BRAKE
Left brake pressure L61-19 41100
41100:1.50MPa
2) Check the cut-off set pressure with the real-time monitor.

If the cut-off set pressure displayed on the real-time monitor is almost the same as the pressure set
above, it is normal.
If the cut-off pressure is set below 0.49 MPa {5 kg/cm2}, however, the set value is 0.49 MPa {5 kg/cm2}.
If the former is set above 4.5 MPa {45 kg/cm2}, the set value is 4.5 MPa {45 kg/cm2}.

CUT OFF Calculated
Transmission cut-off pressure 41200
41200:1.50MPa value
10-278 WA430-6
Function of maintenance monitor
1. Selection and display of maintenance monitor item

Pressing the t switch changes the screen to the "Select maintenance monitor function" screen.
Pressing the < switch changes the screen in the order of 13, No. 12, No. 11 ---.
Pressing the U switch changes the screen to the "Change maintenance interval time" screen.
2. Selection of display of maintenance monitor function (1st layer)

Pressing the > switch changes the screen to the "Select option" screen.
Pressing the < switch changes the screen to the "Select tuning" screen.
Pressing the U switch changes the screen to the "Select maintenance monitor item" screen.
WA430-6 10-279
3. Selection of maintenance monitor (2nd layer)

The contents of this display are the same as those of the maintenance monitor of the function opened to the
Pressing the t switch changes the screen to the "Select maintenance monitor function" screen.
operator. Maintenance caution lamp does not light up, however.
Pressing the U switch changes the screen to the "Change maintenance monitor interval time" screen.
*1. "Select maintenance item" screen

*2. Example) When the data is transmission oil filter
## : ID No. of maintenance monitor item

*** : Maintenance monitor item
10-280 WA430-6
4. Change of maintenance interval time (3rd layer)
If you press the t switch, the time is not changed but the screen changes to the "Select maintenance item"
The maintenance interval time can be set freely to 0 – 9999 h.
screen.
At this time, the operation cancel peep (for 1 sec) is heard.
How to input interval

1) When the screen appears, the cursor (_) is blinking at the highest position.
3) Select a desired digit and press the U switch.

2) Each time the > switch or the < switch is pressed, the digit changes by 1 between 0 and 9.
4) The cursor moves to the 2nd position. Select the digits for the all positions by performing steps 2) and
5) After selecting the digit for the lowest position, press the U switch.
3) above.
6-1) If the input interval time is acceptable, the screen changes to the check screen.
6-2) If the input interval time is not acceptable, the time does not change but the screen changes to the
7) If you have input a wrong value, press the t switch to return to the "Select maintenance item" screen
"Select maintenance item" screen. At this time, the operation cancel peep (for 1 sec) is heard.
and repeat the above steps from the first.
## : ID No. of maintenance monitor item

*** : Maintenance monitor item name
%%%% : Current interval time (4 digits)
If there is not a digit in a position of the interval time, input "0". Example) "0012"
WA430-6 10-281
5. Check of change of maintenance interval time (4th layer)
and the t switch is pressed, the change is executed. If "NO" is selected and the t switch is pressed,
Select "YES" or "NO" with the < or > switch. The cursor (_) blinks on the selected item. If "YES" is selected
change is cancelled and the screen changes to the "Select maintenance item" screen.
When the change of the set time is finished, the operation acceptance peeps (ON for 0.1 sec o OFF for
By default, the cursor is on NO (the change not done) to prevent resetting by an error.
0.1 sec o ON for 0.1 sec) are heard.
%%%% : Interval time (4 digits) to be changed
The maintenance interval time is set as shown in the following table, when delivered.
Replacement interval
Item ID No. Display of item name
time (h)
Engine oil 500 01 ENG OIL
Engine oil filter 500 02 ENG FILT
Fuel filter 500 03 FUEL FILT
Corrosion resistor 1,000 06 CORR RES
Transmission oil 1,000 12 TM OIL
Transmission oil filter 1,000 13 TM FILT
Hydraulic oil filter 2,000 04 HYD FILT
Hydraulic tank breather element 2,000 05 HYD BREATH
Hydraulic oil 2,000 10 HYD OIL
Axle oil 2,000 15 AXLE OIL
10-282 WA430-6
Setting required when optional device is installed
When any of the following optional devices is added or replaced, initialize the sensors, solenoids, etc. with the
machine monitor.
Added or replaced optional device Adjustment item

Transmission unit, transmission controller, ECMV Transmission initial learning
Lift arm angle sensor, work equipment controller Adjustment of work equipment lift arm angle
EPC work equipment control lever, work equipment controller, work
Adjustment of EPC work equipment control lever
equipment EPC valve
EPC work equipment 3-piece control lever, work equipment Adjustment of EPC work equipment 3-piece control
controller, work equipment EPC valve lever
Joystick steering lever, work equipment controller, joystick steering
Adjustment of joystick steering
EPC valve
Function of selecting optional device
When any of the following optional devices is added or removed, change the setting of the machine monitor.
When the machine monitor is replaced, set the devices installed optionally to the machine.
Option setting items
Item No. Option item Display in English Remarks

Machine monitor
1 Auto grease AUTO GREASE
2 Battery electrolyte level sensor BAT LIQUID
3 Transmission clogging sensor TRANSM CLOG Not available for this machine
4 Printer PRINTER Not available for this machine
5 High lift arm specification HI LIFT
6 Selection of speedometer and engine tachometer ENGINE RPM *1
7 Selection of short ton SHORT TON Not available for this machine
1 ECSS E. C. S. S.
2 Torque converter lockup LOCK UP Not available for this machine
3 Emergency steering EMER STRG
4 Tire size TIRE SIZE *2
5 Spare switch AUTO RE FAN Not available for this machine
6 Directional selector switch RH FNR SW
1 EPC work equipment control lever EPC LEVER
2 Joystick steering lever JOY STICK
3 EPC work equipment 3-piece control lever EPC 3RD
*1: Setting for selecting display of speedometer and engine tachometer

When rotary switch on back side is km/h: Engine speed (rpm) is displayed by setting ENGINE RPM to ADD.
When rotary switch on back side is MPH: Engine speed (rpm) is displayed by setting ENGINE RPM to ADD.
*2: Adjustment of tire size

When tires other than the specified ones are used or the displayed speed is different from the actual travel
speed because of wear of the tires, correct the tire size to match the displayed speed to the actual travel
speed.
When changing the tire size normally, use rotary switch 3 on the back side and do not use the adjustment
function.
WA430-6 10-283
1. Selection and display of optional item

Pressing the > switch changes the screen in the order of controller 1, controller 2, controller 3 ---.
Pressing the t switch changes the screen to the "Select selection of optional device".
Pressing the < switch changes the screen in the order of controller 5, controller 4, controller 3 ---.
Pressing the U switch changes the screen to the "Display setting condition of optional device" screen.
2. Selection of selection of optional device (1st layer)

Pressing the > switch changes the screen to the "Select setting of machine serial No." screen.
Pressing the < switch changes the screen to the "Select maintenance monitor" screen.
Pressing the U switch changes the screen to the "Select display of information" screen.
10-284 WA430-6
3. Selection of display of setting of each controller (2nd layer)

Pressing the > switch changes the screen to the next selection of display.
Pressing the t switch changes the screen to the "Select selection of optional device" screen.
Pressing the < switch changes the screen to the previous selection of display.
Pressing the U switch changes the screen to the "Display setting condition of optional device" screen.
a The engine controller is installed, but the information on it is not displayed.
*1. "Select display of setting of machine monitor" screen

*2. "Select display of setting of transmission controller" screen
*3. "Select display of setting of engine controller" screen
*4. "Select display of setting of work equipment controller" screen
WA430-6 10-285
4. Display of setting condition of optional device (3rd layer)

Pressing the t switch changes the screen to the "Select display of setting of each controller" screen.
Pressing the < switch changes the screen in the order of No. 13, No. 12, No. 11 ---.
Pressing the U switch changes the display to ADD (has been set) or NO ADD (has not been set), and then
the setting is changed. If the setting is changed, the operation acceptance peeps (ON for 0.1 sec o OFF
for 0.1 sec o ON for 0.1 sec) are heard.
*1. "Select maintenance item" screen

*2. Example) When the data is transmission oil filter
## : ID No. of optional device setting item

*** : Optional device setting item name
Pressing the U switch changes the display of "+@@".

Method of setting tire size
If the setting is changed, the operation acceptance peeps (ON for 0.1 sec o OFF for 0.1 sec o ON for 0.1
sec) are heard.
• Set the tire size only when tires other than the specified ones are installed.
## : ID No. of optional device setting item

*** : Optional device setting item name
@@ : Deviation from setting of DIP switch on back side of machine monitor, which can be set to -12% through
+12% at interval of 2%. (+00, +02, +04, +06, +08, +10, +12, -02, -04, -06, -08, -10, -12, +00 ---)
10-286 WA430-6
Function of setting machine serial No.
1. Selection and display of machine serial No. set- 3. Setting of machine serial No. (2nd layer)
Pressing the t switch changes the screen to the

ting item How to input machine serial No.
1) When the screen appears, the cursor (_) is
Pressing the U switch settles the machine

"Select setting of machine serial No." screen. blinking at the highest position of "50000" or
a "value which has been set".
serial No. 2) Each time the > switch or the < switch is
pressed, the digit changes by 1 between 0
3) Select a desired digit and press the U

and 9.
switch.
4) The cursor moves to the 2nd position.
Select the digits for the all positions by per-
forming steps 2) and 3) above.
tion, press the U switch.

5) After selecting the digit for the lowest posi-
cel peeps (ON for 1 sec o OFF for 1 sec

6) If the serial No. is settled, the operation can-
o ON for 1 sec) are heard.

7) If you have input a wrong value, press the t
switch to return to the "Select setting of
machine serial No." screen and repeat the
2. Selection of setting of machine serial No. (1st above steps from the first.
layer)
Pressing the > switch changes the screen to the
"Select initialization" screen.
Pressing the < switch changes the screen to the
Pressing the t switch changes the screen to the

"Select selection of optional device" screen.
Pressing the U switch changes the screen to

normal screen or alarm screen.
the "Set machine serial No." screen.
WA430-6 10-287
Setting of transmission initial learning
Carry out learning to correct the individual error of the transmission.
1. Resetting learning data

Reset all the learning data saved in the non-volatile memory with the learning data reset command.
1) Hold the t switch and < switch simultaneously for at least 5 seconds to change the screen to the ID
Procedure for displaying transmission initial learning and resetting data
2) Input the ID with the < switch and > switch, and then press the U switch to enter the screen for the ser-
inputting screen (*1).
3) Press the < switch and > switch to display the "Select tuning" screen (*2) and press the U switch to set-
vice person.
tle.
5) Press the U switch, and the "Set transmission initial learning" screen (*4-A or *4-B) appears.
4) Press the < switch and > switch to display setting item No. 1, "Transmission initial learning" screen, (*3).
6-1) If the initial learning has not been carried out, the initial learning incompletion (reset) screen (*4-A)
appears.
7) To reset the initial learning, press the U switch to display the "Check resetting of transmission initial
6-2) If the initial learning has been carried out, the initial learning completion screen (*4-B) appears.
8-1) To reset the initial learning, select "YES" with the < switch and press the t switch.
learning" screen (*5).
After the t switch is pressed, if the initial learning incompletion (reset) screen (*4-A) appears, the ini-
8-2) If you cancel resetting of the initial learning, select "NO" and press the t switch.
tial learning is reset.
After the t switch is pressed, the screen before the U switch was pressed (*4-A or *4-B) appears
and resetting is cancelled.
• If the initial learning is necessary, carry out 1) – 5), and then carry out the resetting operation (up to 8-1)
once while either the screen in 6-1) or the screen in 6-2) is displayed.
*1. "Input ID" screen

*2. "Select tuning" screen
*3. "Transmission initial learning" screen
*4. "Set transmission initial learning" screen (A: Initial learning incompletion, B: Initial learning completion)
*5. "Check resetting of transmission initial learning" screen
10-288 WA430-6
2. Initial learning procedure
Preparation of machine
1. Start the engine.

2. Display the transmission oil temperature (Item ID: 41500, ECMV OIL TEMP) on the real-time monitor.
3. Operate the gearshift lever and directional lever to supply the oil into the transmission.
Gear speed N2 o F2 o F1 o F2 o F3 o F4 o F3 o F2 o N2 o R2 o N2
Holding time 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec
Hold the gearshift lever in each gear speed for the time shown above, and then set it to the next gear speed.
When performing this operation, run the engine at low idle, set the transmission gearshift mode in the MANUAL position,
and turn the transmission cut-off switch OFF (turn the lockup switch OFF).
4. Raise the transmission oil temperature to 55°C – 70°C.

Since learning operation must be performed at the specified oil temperature, adjust the oil temperature.
Check that the machine is normal (it is not indicating failure).
Method of initial learning
1. After the machine is prepared as described above, perform the initial learning (Do not stop the engine).
2. Check that the transmission oil temperature is 55°C – 70°C with the real-time monitor.
a If the initial learning is performed while the oil temperature is out of the specified range, time lags and
If the oil temperature is out of the specified range, be sure to set it in the specified range.
shocks may be made.

3. Operate the transmission with the gearshift lever and directional lever.
Gear speed N2 o F2 o F1 o F2 o F3 o F4 o F3 o F2 o N2 o R2 o N2
Holding time 5 sec 5 sec 5 sec 3 sec 3 sec 3 sec 3 sec 3 sec 3 sec 3 sec 3 sec
Hold the gearshift lever in each gear speed for the time shown above, and then set it to the next gear speed.
When performing this operation, run the engine at low idle, set the transmission gearshift mode in the MANUAL position,
and turn the transmission cut-off switch OFF (turn the lockup switch OFF).
Change the gear speed while driving the machine or pressing the brake pedal.
a When selecting "N2" for the first time, set the gearshift lever to "F2" or "R2", and then set the directional
lever in "N".
Even if you set the directional lever in "N" and then set the gearshift lever in "2", the gear speed does not
change. Accordingly, set the gearshift lever in "2" first and then set the directional lever in "N".
If you have set the directional lever in "N" while the gearshift lever is not in "2", set the directional lever
a Hold the gearshift lever in each gear speed for the specified time.
in "F" or "R" to set the gear speed in "F2" or "R2" and then set the directional lever in "N".
If you move the gearshift lever before the specified time, the initial learning is not completed ("TUNED"
is not displayed).
4. Check that the initial learning is completed ("TUNED" is displayed) on the transmission initial learning set
screen of tuning.
5. If the initial learning is not completed ("INITIAL STATUS" is displayed), repeat steps 3 and 4 until the initial
learning is completed ("TUNED" is displayed).
WA430-6 10-289
Input and output signals
AMP070-20P [CN-L51]
Pin No. Specification I/O Group Form of use Signal name WA430-6 Remarks
1 – – – – – –
Power supply
2 Power supply of small lamp I – – –
(+24 V)
Power supply
3 Power supply of small lamp I – – –
(+24 V)
Power supply NSW power NSW power
4 NSW power supply (+24 V) I –
(+24 V) supply (+24 V) supply (+24 V)
Power supply NSW power NSW power
5 NSW power supply (+24 V) I –
(+24 V) supply (+24 V) supply (+24 V)
Power supply SW power sup- SW power sup-
6 SW power supply (+24 V) I –
(+24 V) ply (+24 V) ply (+24 V)
Power supply SW power sup- SW power sup-
7 SW power supply (+24 V) I –
(+24 V) ply (+24 V) ply (+24 V)
8 — – – – – –
9 GND I – GND GND GND
11 D_OUT_3 (+24 V, sink 200 mA) O A D/O sink – –
Automatic pre-
12 D_OUT_2 (+24 V, sink 200 mA) O A D/O sink –
heater relay
Pre-lubrication
13 D_OUT_1 (+24 V, sink 200 mA) O A D/O sink –
relay
Buzzer 1 Buzzer 1
14 D_OUT_0 (+24 V, sink 200 mA) O A D/O sink (Machine (Machine
monitor) monitor)
Lift arm pres-
Sensor power supply output Sensor power
15 O – sure sensor –
(+24 V) supply
power supply
Lift arm angle
Sensor power supply output Sensor power
16 O – sensor power –
(+5 V) supply
supply
10-290 WA430-6
AMP070-18P (1) [CN-L52]
1 D_IN_0 (24 V, 5 mA) I B D/I (+24 V) High beam Headlamp
2 D_IN_2 (24 V, 5 mA) I B D/I (+24 V) IGN C IGN C
3 D_IN_4 (24 V, 5 mA) I B D/I (+24 V) Auto grease A –
For small
4 D_IN_6 (24 V, 5 mA) I B D/I (+24 V) (Forward) –
models
For small
5 D_IN_8 (24 V, 5 mA) I B D/I (+24 V) (Reverse) –
models
6 D_IN_10 (24 V, 5 mA) I B D/I (+24 V) (Diagnosis IN A) – Spare
Turn signal Turn signal
7 D_IN_12 (NSW24 V, 5 mA) I C D/I (+24 V)
lamp, right lamp, right
U switch input
Machine moni-
Service switch
8 D_IN_14 (NSW24 V, 5 mA) I C D/I (+24 V) tor operation
input
switch
9 GND O – – SIGNAL GND SIGNAL GND
10 D_IN_1 (24 V, 5 mA) I B D/I (+24 V) IGN BR –
Preheater pilot
11 D_IN_3 (24 V, 5 mA) I B D/I (+24 V) IGN R1 IGN R1
lamp
12 D_IN_5 (24 V, 5 mA) I B D/I (+24 V) Auto grease B –
(Directional For small
13 D_IN_7 (24 V, 5 mA) I B D/I (+24 V) –
lever N) models
(HST: For small
14 D_IN_9 (24 V, 5 mA) I B D/I (+24 V) –
Hi/Lo selection) models
(Diagnosis
15 D_IN_11 (24 V, 5 mA) I B D/I (+24 V) – Spare
IN B)
Turn signal Turn signal
16 D_IN_13 (NSW24 V, 5 mA) I C D/I (+24 V)
lamp, left lamp, left
t switch input
Machine moni-
Service switch
17 D_IN_15 (NSW24 V, 5 mA) I C D/I (+24 V) tor operation
input
switch
18 A_IN_0 (0 – 30 V) I H A/I Alternator R Alternator R
AMP070-12P (1) [CN-L53]
Brake oil Brake oil
1 D_IN_16 (24 V/GND, 5 mA) I D D/I (GND)
pressure pressure
Brake oil level
2 D_IN_18 (24 V/GND, 5 mA) I D D/I (GND) – Spare
(Front)
Air cleaner Air cleaner
3 D_IN_20 (24 V/GND, 5 mA) I D D/I (GND)
clogging 1 clogging
4 D_IN_22 (24 V/GND, 5 mA) I D D/I (GND) (Spare) –
Transmission
5 D_IN_24 (24 V/GND, 5 mA) I E D/I (GND) –
filter clogging
6 GND O – GND Sensor GND Sensor GND
Brake oil pres-
7 D_IN_17 (24 V/GND, 5 mA) I D D/I (GND) –
sure (Rear)
Brake oil level
(Rear)
Air cleaner
clogging 2
10 D_IN_23 (24 V/GND, 5 mA) I D D/I (GND) (Spare) –
Seat belt fas-
11 D_IN_25 (24 V/GND, 5 mA) I E D/I (GND) –
tening warning
Small lamp Small lamp
12 A_IN_1 (0 – 30 V) I H A/I
switch switch
WA430-6 10-291
AMP070-18P (2) [CN-L54]
1 D_IN_26 (24 V/GND, 5 mA) I E D/I (GND) Parking brake Parking brake
Engine oil
2 D_IN_28 (24 V/GND, 5 mA) I E D/I (GND) – Spare
pressure
Normal emer- Normal emer-
3 D_IN_30 (24 V/GND, 5 mA) I E D/I (GND)
gency steering gency steering
4 D_IN_32 (24 V/GND, 5 mA) I F D/I (GND) Subtotal switch –
High beam High beam
5 D_IN_34 (24 V/GND, 5 mA) I F D/I (GND)
switch switch
Machine moni- Machine moni-
Service
6 D_IN_36 (24 V/GND, 5 mA) I G D/I (GND) tor display tor operation
function 2
selector switch switch
Machine moni-
Increment
7 D_IN_38 (24 V/GND, 5 mA) I G D/I (GND) < switch input tor operation
switch
switch
(Travel speed For small
8 P_IN_0 (0.5 Vp-p) I M P/I –
sensor) models
9 GND O – GND GND GND
Engine coolant Engine coolant
10 D_IN_27 (24 V/GND, 5 mA) I E D/I (GND)
level level
11 D_IN_29 (24 V/GND, 5 mA) I E D/I (GND) Engine oil level Engine oil level Spare
12 NC I E D/I (GND) NC –
13 D_IN_33 (24 V/GND, 5 mA) I F D/I (GND) Cancel switch –
Lift arm proxim-
14 D_IN_35 (24 V/GND, 5 mA) I F D/I (GND) –
ity switch
Machine moni-
Decrement
15 D_IN_37 (24 V/GND, 5 mA) I G D/I (GND) > switch input tor operation
switch
swith
Operation of Operation of
16 D_IN_39 (24 V/GND, 5 mA) I G D/I (GND) emergency emergency
steering steering
17 P_IN_1 (0.5 Vp-p) I M P/I (Spare) – Pulse input
18 (NC) – – – (NC) –
10-292 WA430-6
AMP070-12P (2) [CN-L55]
Fuel level Fuel level
1 A_IN_2 (High-resistance input) I J A/I
sensor sensor
Torque Torque con-
converter oil verter oil
2 A_IN_4 (High-resistance input) I J A/I
temperature temperature
sensor sensor
Engine coolant
temperature
3 A_IN_6 (High-resistance input) I K A/I sensor (For –
automatic
preheater)
Lift arm oil
4 A_IN_8 (0 – 5 V) I L A/I –
pressure (Rod)
Battery electro-
Battery electro-
5 A_IN_10 (0 – 14 V) – – – lyte level If equipped
lyte level A
(If equipped)
6 GND O – GND SIGNAL GND GND
Hydraulic oil Hydraulic oil
7 A_IN_3 (High-resistance input) I J A/I temperature temperature
sensor sensor
Engine coolant
8 A_IN_5 (High-resistance input) I J A/I temperature –
sensor
Lift arm oil
9 A_IN_7 (0 – 5 V) I L A/I pressure –
(Bottom)
Lift arm angle
10 A_IN_9 (0 – 5 V) I L A/I –
sensor
11 GND O – GND SIGNAL GND GND
Battery electro-
12 A_IN_11 (0 – 14 V) – – – – Spare
lyte level B
WA430-6 10-293
AMP070-12P (3) [CN-L56]
Machine moni-
tor – transmis-
1 S_NET (+) I/O N S_NET sion, work S_NET (+)
equipment con-
troller
Machine moni-
tor – transmis-
2 S_NET (+) I/O N S_NET sion, work S_NET (+)
equipment con-
troller
Machine moni-
tor – transmis-
3 CAN (+) I/O P CAN sion, work CAN (+)
equipment con-
troller
4 S_NET (-) O N S_NET S_NET GND S_NET (-)
5 S_NET (-) O N S_NET S_NET GND S_NET (-)
6 GND O – GND S_NET shield GND
7 GND O – GND CAN shield GND
Machine moni-
tor – transmis-
8 CAN (-) I/O P CAN sion, work CAN (-)
equipment con-
troller
9 (NC)
10 (NC)
11 (NC)
12 (NC)
AMP070-14P [CN-L57]
1 (NC) – – –
RS232C serial
2 RS232C_1_RTS I/O Q –
communication
RS232C serial Personal For monitoring
3 RS232C_1_RD I Q RD
communication computer RX (PC)
4 RS232C_2_RD I R RD NC –
5 RS232C_2_RTS I/O R NC –
BUSY input for
6 – – load meter –
printer
7 (NC) – – –
RS232C serial
8 RS232C_1_CTS I/O Q –
communication
RS232C serial Personal For monitoring
9 RS232C_1_TX O Q TX
communication computer TX (PC)
RS232C serial
10 RS232C_1_SG O Q –
communication
11 RS232C_2_SG O R NC –
12 RS232C_2_TX O R TX NC –
13 RS232C_2_CTS I/O R NC –
14 (NC) – –
10-294 WA430-6
AMP040-8P [CN-L58]
Flash write Do not connect
1 RS232C_0_TXD O S data – wiring harness
(Sending) on machine
Do not connect
Flash write
2 FLASH_SW I S – wiring harness
switch
on machine
3 RS232C_0_TXD O S data – wiring harness
(Sending) on machine
Do not connect
4 (NC) – – (NC) – wiring harness
on machine
5 RS232C_0_RXD I S data – wiring harness
(Receiving) on machine
Do not connect
6 (NC) – – (NC) – wiring harness
on machine
7 RS232C_0_RXD I S data – wiring harness
(Receiving) on machine
Do not connect
8 GND O – GND – wiring harness
on machine
WA430-6 10-295
Setting switches (On circuit board)
Selection of Selection of
1 16 Posi rotary switch 1 I –
model model
Selection of
2 16 Posi rotary switch 2 I – –
specification
Selection of
speedometer Selection of
3 16 Posi rotary switch3 I –
display and speedometer
optional tire
Selection of
common rail
1 26 Posi DIP switch 1 I – –
engine
controller
2 26 Posi DIP switch 2 I – work equip- work equip-
ment controller ment controller
5
3 26 Posi DIP switch 3 I – (Spare) –
permission of permission of
using 4th gear using 4th gear
4 26 Posi DIP switch 4 I –
speed in speed in
joystick joystick
steering mode steering mode
common rail common rail
1 26 Posi DIP switch 5 I –
engine engine
6 controller controller
10-296 WA430-6
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM (TRANSMISSION CONTROLLER SYSTEM)
Electrical system (Transmission controller system)

System diagram
WA430-6 10-297
Control function
1. Gear shifting function

1) Function of electronic modulation
To reduce the shocks made when the gear speed is changed (when the clutch is engaged), the modu-
lation control is applied. The clutch oil pressure is controlled properly 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 controller
memory so that the transmission will be set in any gear speed smoothly.
The modulation control is continued even while the clutch is disengaged to reduce lowering of the
torque.
If an abnormal time lag is made in gear shifting, the learning function corrects the modulation automati-
cally.
2) Automatic gear shifting function

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 gearshift lever.
In the automatic gear shifting operation, the gear is shifted up or down automatically to change the shift
mode according to the engine power mode.
Change of shift mode

The gear is shifted up or down automatically to set the shift mode as shown below, according to setting
of the shift mode (NORMAL/H/L) selector switch and power mode (POWER/NORMAL) selector switch.
Power mode selector Shift mode selector switch

switch MANUAL H L
POWER Manual H-mode L-mode
NORMAL Manual L-mode L-mode
While the engine speed is above 1,000 rpm in the automatic gear shifting operation, the transmission
gear is shifted up and down in the selected shift mode, according to the "Auto-shift points table" saved
in the transmission controller memory and depending on the directional lever, gearshift lever, position of
accelerator pedal, and signals from the sensors.
1] Gearshift lever position "1st" to "4th"

The maximum gear speed (gear shifting rage) used in the automatic gear shifting operation is lim-
ited.
In the automatic gear shifting operation, the vehicle usually starts in the 2nd gear speed. Accord-
ingly, if the gearshift lever is in "4th", the gear is shifted up and down between the 2nd gear speed
and 4th gear speeds. If the kick-down function is used, the vehicle starts in the 1st gear speed.
2] Directional lever position "N"

While the directional lever is in neural, the transmission is fixed to the gear speed before the direc-
tional lever was set in "N". Even if the gearshift lever is operated while the directional lever is in
neutral, the gear speed is not changed.
10-298 WA430-6
3] Directional lever position "F"

When the directional lever is moved from "N" to "F", the transmission outputs the modulation com-
mand to the ECMV of the F clutch and 2nd clutch. (Automatic 2nd-gear speed start)
a) Shifting up (When gearshift lever is in "4th" and auto-shift mode is "H")
When the accelerator pedal is pressed fully and the engine speed is above 1,000 rpm and the
travel speed is above 11.5 km/h, the transmission is set in the 3rd gear speed.
When the travel speed rises further above 20.0 km/h, the transmission is set in the 4th gear
speed.
b) Shifting down (When gearshift lever is in "4th" and auto-shift mode is "H")
When the travel speed lowers below 18.0 km/h while the accelerator pedal is pressed fully (on
an uphill, for example), the transmission is set in the 3rd gear speed.
When the travel speed lowers further below 9.5 km/h, the transmission is set in the 2nd gear
speed.
c) Skip shifting down (When gearshift lever is in "3rd" or "4th" and auto-shift mode is "H")
If the accelerator pedal is released while the vehicle is traveling, the transmission is kept in 3rd
or 4th gear speed until the travel speed lowers to 1 km/h. When the travel speed lowers below
1 km/h, the gear is shifted down to the 2nd.
When the travel speed lowers below 11.5 km/h without changing the transmission from the 3rd
or 4th gear speed, if the accelerator pedal is pressed again fully, the transmission is set in the
2nd gear speed.
4] Directional lever position "R"

Similarly to directional lever position "F", the gear speed is changed according to the gearshift lever,
auto-shift mode, travel speed, position of the accelerator pedal, and "Auto-shift points table".
5] No-shift time
After the transmission gear is shifted, the new gear speed is held for a certain time to prevent shift
hunting. This period is the no-shift time, which varies with the gear shift pattern. (See "Auto-shift
points table".)
3) Shift hold function

The gear speed when the hold switch is pressed is held and the gear is not shifted up even if the travel
speed is increased nor shifted down even if the travel speed is decreased.
The shift hold function is reset by pressing the hold switch again.
When the directional lever, gearshift lever, directional selector switch, or kick-down switch is operated,
the shift hold function is reset automatically.
4) Kick-down function
1] Kick-down in manual shift operation
The kick-down switch operates only in the forward 2nd gear speed (F2). Operation of the kick-
down switch is ignored in any gear speed other than F2. If the directional lever is set in a position
other than F or if the gearshift lever is set in a position other than the "2nd" position, the kick-down
function is reset. After the transmission is set in F1 with the kick-down switch, if the directional lever
is set in the "R" position, the transmission is set in the 2nd gear speed. If the gearshift lever is set in
a position other than the "2nd" position, the transmission is set in the gear speed of that position.
WA430-6 10-299
2] Kick-down in auto-shift operation

The kick-down switch functions regardless of the positions of the directional lever and gearshift
lever.
The gear speed selected by the operation of the kick-down switch depends on the travel speed as
shown in the following table.
After the gear speed is changed by the kick-down operation, it is changed when the travel speed is
increased or the directional lever is operated according to "Auto-shift points table".
Actual gear speed Travel speed Gear speed after shifting No-shift time
2nd All range 1st 5 sec
Below 10.5 km/h 1st 5 sec
3rd 10.5 – below 25 km/h 2nd 4 sec
25 km/h or higher Gear is not shifted (3rd) —
4th 10.5 – below 35 km/h 3rd 4 sec
35 km/h or higher Gear is not shifted (4th) —
5) Transmission protection function

When the directional lever is operated during high-speed travel, engagement of the gear speed clutch is
controlled to protect the transmission.
1] In auto-shift mode
Range A: Travel direction is changed and transmission is set in 2nd gear speed. (Ordinary range)
Range B: Travel direction is changed and transmission is set in 2nd gear speed and alarm buzzer
sounds.
Range C: Travel direction is changed and alarm buzzer sounds. The gear speed clutch is selected
according to the auto-shift points table, and then the gear is shifted down to the 2nd
depending on the travel speed.
2] In manual shift mode (3rd/4th) (Gear speed clutch does not change since gear is shifted manually)
Range A: Travel direction is changed. (Ordinary alarm)
Range B: Travel direction is changed and alarm buzzer sounds.
Range C: Travel direction is changed and alarm buzzer sounds.
6) Travel speed alarm function

If the travel speed exceeds 40 km/h, the alarm buzzer sounds for excessive speed. When the travel
speed lowers below 39.5 km/h, the alarm buzzer stops sounding.
10-300 WA430-6
7) Hunting prevention function

Function
Hunting in F2 and F3 gear speed is detected and prevented.
Control method
The controller judges hunting. If hunting occurs twice or more, the controller holds the transmission at a
gear speed to prevent hunting.
At this time, the transmission is held at a gear speed which takes longer time before the next gear shift-
ing, depending on the hunting condition.
A : Before operation of hunting prevention function

B : After operation of hunting prevention function
a : Ordinary gear shift range
b : Hunting gear shift range
c : Hunting prevention function range (where gear
speed is held)
[Transmission is held at a gear speed which
takes longer time before the next gear shifting]
d : 1st hunting
e : 2nd hunting
t1 : Ordinary (5 seconds or more before next gear
shifting)
t2 : Hunting (Less than 5 seconds before next gear
shifting)
WA430-6 10-301
Auto-shift points table
Shifting up
Position of Travel speed (km/h) No-shift time

accelerator (%) Ordinary Hunting prevention (sec)
0 7 10
20 7 10
F2 to F3 (H)
90 11.5 11.5
100 11.5 11.5
2
0 4 8
20 4 8
F2 to F3 (L)
90 9 10
Engine speed is 100 9 10
above 1,000 rpm 0 15
20 15
F3 to F4 (H)
90 20
100 20
1
0 9
20 9
F3 to F4 (L)
90 16
100 16
Shifting down
Position of Travel speed (km/h) No-shift time

accelerator (%) Ordinary Hunting prevention (sec)
20 6 6
F2 to F3 (H) 90 9.5 9
100 9.5 9
2
20 3 3
F2 to F3 (L) 90 8 7.5
Accelerator pedal 100 8 7.5
"ON" 20 13
F3 to F4 (H) 90 18
100 18
1
20 7
F3 to F4 (L) 90 14
100 14
Accelerator pedal 0 1
F3, F4 to F2 0
"OFF" 20 1
20 7
F3, F4 to F2 (H) 90 11.5
Accelerator pedal 100 11.5
2
"OFF" to "ON" 20 4
F3, F4 to F2 (L) 90 9
100 9
10-302 WA430-6
Auto-shift points
a: Shifting up (Shift mode "H")

b: Shifting up (Shift mode "L")
c: Shifting down (Shift mode "H")
d: Shifting down (Shift mode "L")
2. Control of transmission cut-off

1) Function
When the left brake pedal is pressed, the oil pressure in the brake circuit is sensed by the pressure sen-
sor and the transmission is set in neutral.
You can cut off the transmission at any position by saving the brake pedal pressing position where the
transmission is set in neutral as a brake circuit pressure.
2) Input and output
WA430-6 10-303
3) Contents of control
If pressure of left brake pressure sensor signal exceeds set pressure, transmission
1 Transmission cut-off control
is set in neutral. (When transmission cut-off switch is turned ON)
Condition for
Transmission cut-off switch is ON. (Transmission can be cut off.)
availability
1) Press left brake pedal to position at which you want to set.
2) Press and release transmission cut-off switch.
3) Temporarily save pressure when switch is released. Setting completion buzzer
Setting
sounds (makes peep) twice.
method
4) At this time, the indicator in transmission cut-off switch blinks for 2.5 seconds.
Setting of 5) After blinking of indicator for 2.5 seconds, setting is saved. (Set condition is still
2 transmission held after starting switch is turned OFF.)
cut-off point 1) Press and release transmission cut-off switch.
2) At this time, the indicator in transmission cut-off switch blinks for 2.5 seconds.
3) While indicator in transmission cut-off switch is blinking, press and release
Resetting transmission cut-off switch again.
method 4) Indicator stops blinking and cut-off point is set to default left brake pressure.
Setting cancel buzzer sounds.
5) Set (Default) value is saved. (Set condition is still held after starting switch is
turned OFF.)
4) Outputting conditions for buzzer, indicator (main monitor), and indicator in transmission cut-off switch
Indicator in transmission
Outputting condition Output of buzzer sound Cut-off point
cut-off switch
When transmission cut-off Controlled with value saved
Lighting OFF
switch is ON previous time
Setting completion sound is
While transmission cut-off Pressure when set switch
Blinking made when set switch is
point being set is released is saved
released
When transmission cut-off
Not controlled. Saved
switch is ON and sensor is OFF OFF
value is not changed.
abnormal
Controlled with value saved
previous time
switch is ON and setting OFF OFF
Saved value is not
switch is abnormal
changed.
OFF OFF Not controlled
switch is OFF
5) Settable range of transmission cut-off point
Settable range Note 1: If the point is set below 0.49 MPa {5 kg/cm2}, the set value is assumed to be 0.49
0.49-4.41 MPa MPa {5 kg/cm2}.
{5-45 kg/cm 2} Note 2: If the point is set above 4.41 MPa {45 kg/cm2}, the set value is assumed to be 4.41
MPa {45 kg/cm2}.
The default value is 1.47 MPa {15 kg/cm2}.
Add hysteresis of 0.20 MPa {2 kg/cm2} to the cut-off IN (for neutral) pressure and OUT (reset) pressure.
Example) When cut-off point is set to position of 0.98 MPa {10 kg/cm2} of pressure sensor
Cut-off IN pressure = 0.98 MPa {10 kg/cm2}
Cut-off OUT pressure = 0.78 MPa {8 kg/cm2}
10-304 WA430-6
3. Function of selecting directional selector switch

If the directional selector switch operation switch is turned ON, you can change the travel direction with the
directional selector switch installed to the side of the work equipment control lever without using the direc-
tional lever of the steering column.
1. Transmission controller Input and output signals

2. Directional lever a. Directional lever "F" signal
3. Directional selector switch b. Directional lever "N" signal
4. Directional selector actuation switch c. Directional lever "R" signal
5. Directional selector relay d. Directional selector switch "F" signal
6. Starting switch e. Directional selector switch "N" signal
7. Neutral safety relay f. Directional selector switch "R" signal
8. Starting motor g. Directional selector actuation switch "ON" signal
9. Machine monitor h. S-NET signal
9a. Directional selector pilot lamp i. Neutral signal
1) Use of function of directional selector switch

If the directional selector actuation switch is turned ON, the signal to use the function of the directional
selector switch is input to the transmission controller.
When the directional lever or directional selector switch is selected to be used, both of them must be set
in the "N" position for safety.
Directional selector switch Directional lever

Normal position N N
When directional selector Phenomenon in position other
Error signal is output Error signal is output
switch is selected to be used than normal position
Correcting method Set in N Set in N
Normal position N N
When directional lever is Phenomenon in position other
selected to be used than normal position
2) Changing travel direction with directional selector switch

If the directional lever is in the "N" position under the condition of 1) above, you can change the travel
direction with the directional selector switch. If the directional lever is set in the "F" or "R" position, its
operation is effective regardless of the position of the directional selector switch.
WA430-6 10-305
3) Gear shifting operation when directional selector switch is operated

The transmission gear is shifted as in the ordinary gear shifting operation with the gearshift lever.
Effective switches (levers) when directional selector switch function is installed
Directional Shift mode Gear shifting

Travel direction changing operation
selector actuation selector operation
switch switch Forward-reverse switch Directional lever Gearshift lever
• Operation with switch when in "N"
ON Operation with
MANUAL Operation with switch • Operation with lever first when not in
(Directional lever
"N" (Error signal is output, however)
selector switch is
H/L Max. gear speed
selected) Same as above Same as above
(AUTO) (Limiter)
• Operation with lever
when in "N" Operation with
OFF MANUAL Operation with lever
• Error signal is output lever
(Directional lever when not in "N"
is selected)
H/L Max. gear speed
Same as above Same as above
(AUTO) (Limiter)
4) Safety function for starting engine

When the engine is started, if the directional selector switch is selected but not in the "N" position, the
transmission controller does not output the neutral signal and the engine does not start.
In this case, the neutral caution signal is output.
10-306 WA430-6
4. Function of joystick steering (If equipped)

The joystick steering function controls the travel direction and gear shifting operation.
When the joystick is operated, travel in the 4th gear speed is prohibited for safety.
The work equipment controller controls steering.

3. Joystick steering lever b. Directional lever "N" signal
4. Console lock switch c. Directional lever "R" signal
5. Joystick ON/OFF switch d. FNR switch "F" signal
6. Directional selector relay e. FNR switch "N" signal
7. Starting switch f. FNR switch "R" signal
8. Neutral safety relay g. Shift-up signal
9. Starting motor h. Shift-down signal
10. Machine monitor i. Joystick ON/OFF switch "ON" signal
10a. Directional selector pilot lamp j. S-NET signal
k. Neutral signal
1) Use of joystick steering function

If the console lock lever is set in the "LOCK" position, the console lock switch is turned ON. If the joy-
stick ON/OFF switch is also turned ON, the signal to use the joystick steering function is input.
When the joystick operation or steering operation is selected to be used, the directional lever and FNR
switch must be set in the "N" position for safety.
FNR switch Directional lever Gearshift lever

Normal position N N 1st - 3rd
Phenomenon in
When joystick operation is Error signal is Error signal is Error signal is
position other than
selected to be used output output output
normal position
Correcting method Set in N Set in N Set in 1st - 3rd
Normal position N N Set in any position
Phenomenon in
When steering operation is Error signal is Error signal is
position other than –
selected to be used output output
normal position
Correcting method Set in N Set in N –
WA430-6 10-307
2) Changing travel direction with joystick

direction with FNR switch.
If the directional lever is set in the "F" or "R" position, its operation is effective regardless of the position
of the FNR switch.
3) Gear shifting operation with joystick

• When manual shift is selected
You can change the gear speed with the shift up/down switch at the head of the joystick steering
lever. At this time, the gearshift lever is set in the maximum gear speed position (gear shifting
range).
Example) When the gearshift lever is in the "3rd" position, you can change the gear speed between
the 1st and 3rd with the shift up/down switch. Even if you press the shift up switch while
the 3rd gear speed is selected, the gear is not shifted up to the 4th.
• When auto-shift is selected
The gearshift lever is set in the maximum gear speed position (gear shifting range) and the gear is
shifted automatically. At this time, the shift up/down switch at the head of the joystick steering lever
is ineffective. Even if it is pressed, the gear is not shifted.
• Gear shifting operation with hold switch and kickdown switch
Effective switches (levers) when joystick steering function is installed
Shift Travel direction changing operation Gear shifting operation

Joystick
mode Position of
ON/OFF Shift up Shift down
selector FNR switch Directional lever gearshift
switch switch switch
switch lever
• Operation with Max. gear
switch when in "N" speed
• Operation with Operation Operation (Limiter)
MANUAL Operation with switch
ON lever first when not with switch with switch Only 1st - 3rd
(FNR switch in "N" (Error signal gears are
is selected) is output, however) selectable
Operation Operation
H/L Same as
Same as above Same as above is is
(AUTO) above
ineffective ineffective
• Operation with lever
Operation Operation
when in "N" Operation
OFF MANUAL Operation with lever is is
• Error signal is output with lever
(Directional ineffective ineffective
when not in "N"
lever is
Max. gear
selected) H/L Same as Same as
Same as above Same as above speed
(AUTO) above above
(Limiter)

When the engine is started, if the joystick is selected and the FNR switch is not in the "N" position, the
transmission controller does not output the neutral signal and the engine does not start.
While the joystick steering lever is operated (While it is not in neutral), the network signal from the work
equipment controller prevents outputting of the neutral signal and the engine does not start.
In these cases, the neutral caution signal is output.
10-308 WA430-6
5. E.C.S.S. function
When the vehicle travels at high speed, the damping effect of the accumulator charged with high-pressure
gas and the automatic control of the lift cylinder circuit relief pressure under each travel condition damp the
vertical movement of the work equipment and reduce rocking of the chassis. As a result, the operator com-
fort is improved, spillage of material is prevented, and the working efficiency is improved.
The operating condition of the E.C.S.S. (Electronic Controlled Suspension System) is as follows.
E.C.S.S. (electronic
Lift arm control Travel damper
controlled suspension Gear speed Travel speed Operating condition
lever output
system) switch
Does not operate
OFF All 0 – MAX All OFF
(Being charged)
Does not operate
All 0 – MAX Lower OFF
(Being charged)
Does not operate
1st 0 – MAX All OFF
ON (Being charged)
Does not operate
Condition A All OFF
2nd – 4th (Being charged)
Condition B Other than lower ON Operates

2. E.C.S.S. (Electronic Controlled Suspension Sys- a. E.C.S.S. (Electronic Controlled Suspension Sys-
tem) switch tem) switch "ON" signal
3. Lift arm lower oil pressure switch b. Travel speed signal
4. Speed sensor c. Directional lever "F" signal
5. Directional lever d. Directional lever "N" signal
6. Gearshift lever e. Directional lever "R" signal
7. Travel damper relay f. Gearshift lever "1st" signal
8. Travel damper solenoid valve g. Gearshift lever "2nd" signal
h. Gearshift lever "3rd" signal
i. Gearshift lever "4th" signal
j. Travel damper operation signal
WA430-6 10-309
6. Function of electric emergency steering

1) Operation of electric emergency steering
The oil pressure switch of the steering circuit is monitored constantly. When the steering oil pressure
lowers and the travel speed becomes higher than the emergency steering "ON" speed shown in the fol-
lowing figure, the emergency steering "ON" signal is output to the relay to operate the emergency steer-
ing.
You can operate the emergency steering motor with the emergency steering switch, regardless of the
travel speed and steering oil pressure.

2. Emergency steering switch a. Travel speed signal
3. Emergency steering switch relay b. Steering oil pressure signal (Lo)
4. Emergency steering relay c. Steering oil pressure signal (Hi)
5. Emergency steering electric motor d. Emergency steering switch "ON" signal
6. Emergency steering pump
7. Speed sensor
8. Steering pump oil pressure switch (Lo)
9. Steering pump oil pressure switch (Hi)
10-310 WA430-6
2) Self-check operation of emergency steering

The emergency steering system checks its operation automatically 3 seconds after the starting switch is
turned "ON" (after the monitor check is finished).
The self-check is not performed in the following cases, however.
a) When the starting switch is set in the "START" position and the starting motor starts.
b) While engine is running (When engine speed higher than 500 rpm is sensed).
c) While the steering oil pressure is being sensed.
d) When the automatic preheater operates.
e) When an error related to the emergency steering by the monitor check is sensed.
f) When the engine is not operated for more than 10 seconds (When engine speed higher than 500
rpm is not sensed for more than 10 seconds) after the previous self-check.
During the self-check, the emergency steering "ON" signal is output for up to 3 seconds. If the monitor
senses the emergency steering operating procedure in 3 seconds, it transmits the emergency steering
operation sensing signal through the network and the transmission controller stops the self-check of the
emergency steering. If the transmission controller does not receive the emergency steering operation
sensing signal from the machine monitor in 3 seconds, it outputs the error signal.

2. Emergency steering switch a. Travel speed signal
3. Emergency steering switch relay b. Engine speed signal
4. Emergency steering relay c. Emergency steering switch "ON" signal
5. Emergency steering electric motor d. Emergency steering switch "OFF" signal
6. Emergency steering pump e. Steering oil pressure signal (Lo)
7. Speed sensor f. Steering oil pressure signal (Hi)
8. Engine speed sensor g. S-NET signal
9. Steering pump oil pressure switch (Lo)
10. Steering pump oil pressure switch (Hi)
11. Machine monitor
11a. Steering oil pressure caution lamp
11b. Emergency steering pilot lamp
12. Emergency steering oil pressure switch
13. Steering pump
14. Steering valve
15. Steering cylinder
WA430-6 10-311
7. Function of cooling fan control

1) Control of fan
The cooling fan is driven hydraulically and its speed is controlled by controlling the swash plate of the
fan pump. As a result, the horsepower loss and noise are reduced while the temperature is low.
Then engine coolant temperature, hydraulic oil temperature, and torque converter oil temperature
sensed by the machine monitor are sent through the network to the transmission controller, and then
the swash plate angle of the fan pump is controlled so that the fan speed will be matched to the temper-
ature and engine speed.

2. Machine monitor a. Engine speed signal
3. Engine controller b. S-NET signal
4. Cooling fan pump c. Cooling fan pump swash plate angle control
4a. Swash plate angle control EPC valve signal
5. Engine speed sensor
6. Coolant temperature sensor
8. Torque converter oil temperature sensor
9. Engine
10. Cooling fan motor
11. Radiator
10-312 WA430-6
2) Control of reverse of fan

If the cooling fan reverse rotation switch is operated, the hydraulic fan motor reverse solenoid operates
to reverse the fan.
When the engine speed is 1,500 rpm or higher, the fan pump swash plate angle is set to the "MAX" to
set the fan speed to the maximum and improve the radiator cooling performance. When the engine
speed is below 1,500 rpm, the fan pump swash plate angle is set to the "MIN" to prevent surge oil pres-
sure caused by reverse of the circuit when the fan stops.
The turning direction of the fan can be changed only while the engine is stopped.
Even if the turning direction of the fan is changed while the engine is running (the engine speed is 500
rpm or higher), the operation signal is not output to the reverse solenoid.
Operation of Cooling fan

Cooling fan reverse
cooling fan reverse Fan pump EPC Machine monitor
solenoid output before Engine speed
reverse rotation rotation output indicator
operation of switch
switch solenoid output
OFF From OFF to ON ON MIN speed From OFF to lighting
OFF From ON to OFF Stopped OFF Ordinary From blinking to OFF
(Below 500 From blinking to
ON From OFF to ON ON MIN speed
rpm) lighting
ON From ON to OFF OFF Ordinary From lighting to OFF
OFF From OFF to ON OFF Ordinary From OFF to blinking
OFF From ON to OFF OFF Ordinary From blinking to OFF
Running (500 From blinking to
ON From OFF to ON ON *
rpm or above) lighting
From lighting to
ON From ON to OFF ON *
blinking
*: Fan pump EPC output during reverse operation of pump
Engine speed Below 1,500 rpm 1,500 rpm or higher

EPC control MIN speed MAX speed

2. Cooling fan reverse rotation switch a. Cooling fan reverse rotation switch "ON" signal
3. Cooling fan pump swash plate angle control EPC b. S-NET signal
valve c. Cooling fan pump swash plate angle control
4. Cooling fan reverse rotation solenoid valve signal
5. Machine monitor d. Cooling fan reverse rotation signal
WA430-6 10-313
8. Function of engine overrun prevention

While you are driving down a slope at high speed with the accelerator pedal pressed, if you shift down the
transmission gear, the engine may be overrun by the drive force of the tires.
To prevent this overrun of the engine, the transmission controller restricts the shift-down operation, depend-
ing on the engine speed and transmission output shaft speed (travel speed).
The conditions for applying and resetting protection are as follows.

1) Condition for applying protection: While the condition for applying (A or (B and C)) is satisfied, if the
gear is shifted down, the shift-down signal is not output but the alarm
signal is output for protection.
2) Condition for resetting protection: When the condition for resetting (D and (E or F)) is satisfied, the
alarm signal is stopped and the shift-down signal is output.
Condition for applying (A or (B and C)) Condition for resetting (D and (E or F))
Condition A Condition B Condition C Condition D Condition E Condition F
Gear speed Transmission Transmission Transmission Transmission
to shift down output shaft output shaft Engine speed output shaft output shaft Engine speed
speed speed speed speed
To 3rd gear Below Below
None Min. 2,658 rpm Min. 2,100 rpm None
speed 2,436 rpm 1,900 rpm
To 2nd gear Below Below Below
Min. 2,658 rpm Min. 1,846 rpm Min. 2,100 rpm
speed 2,436 rpm 1,698 rpm 1,900 rpm
To 1st gear Below Below Below
Min. 1,846 rpm Min. 1,107 rpm Min. 2,100 rpm
speed 1,698 rpm 997 rpm 1,900 rpm
3) Condition for resetting protection alarm: In the following cases, the protection alarm output is stopped
and the ordinary control is started again.
a) When the input command and the output command are matched to each other by the operation of
the gearshift lever (gearshift switch).
b) When the shift above the output command is selected by the operation of the gearshift lever (gear-
shift switch).
4) Control during shift-down protection control: While the shift-down protect control is applied, the holding
and kick-down operations are ineffective.
Transmission output shaft speed and travel speed

Protection travel speed (km/h)
WA430-6 (Small diameter tire) WA430-6 (Large diameter tire)
Conversion of transmission output 2,658 30.3 33.2
shaft speed into travel speed 1,846 21.1 23.0
(rpm) 1,107 12.6 13.8
9. Function of troubleshooting
The transmission controller monitors the input and output signals constantly for troubleshooting for the sys-
tem.
If the transmission controller detects abnormality by the self-diagnosis, you can check the information on
that abnormality with the machine monitor. The information of the abnormality is sent through the network
to the machine monitor.
10-314 WA430-6
10. Gear shifting function of multi-function lever (If equipped)

If the FNR switch, kick-down switch, and hold switch are added to the head of the multi-function lever (work
equipment control lever), you can change the travel direction and shift the transmission gear without using
the directional lever and gearshift lever.

3. Multi-function lever b. Directional lever "N" signal
4. Directional selector actuation switch c. Directional lever "R" signal
5. Directional selector relay d. FNR switch "F" signal
6. Starting switch e. FNR switch "N" signal
7. Neutral safety relay f. FNR switch "R" signal
8. Starting motor g. Kick-down signal
9. Machine monitor h. Hold signal
9a. Directional selector pilot lamp i. Directional selector actuation switch "ON" signal
j. S-NET signal
k. Neutral signal
WA430-6 10-315
1) Use of function of FNR switch

If the directional selector actuation switch is turned ON, the signal to use the function of the multi-func-
tion lever for changing the travel direction is input to the transmission controller.
When the directional lever or FNR switch is selected to be used, both of them must be set in the "N"
position for safety.
FNR switch Directional lever

Normal position N N
When FNR switch is Phenomenon in position
selected to be used other than normal position
Normal position N N
When directional lever is Phenomenon in position
selected to be used other than normal position
2) Changing travel direction with FNR switch

direction with the FNR switch. If the directional lever is set in the "F" or "R" position, its operation is
effective regardless of the position of the FNR switch.
3) Gear shifting operation when FNR switch is operated

Effective switches (levers) when directional selector switch function is installed
Directional Gear shifting

Shift mode Travel direction changing operation
selector actuation operation
selector switch
switch FNR switch Directional lever Gearshift lever
• Operation with switch
when in "N"
ON Operation with
MANUAL Operation with switch • Operation with lever first
(Directional selec- lever
when not in "N" (Error sig-
tor switch is
nal is output, however)
selected)
H/L Max. gear speed
(AUTO) (Limiter)
• Operation with lever when
in "N" Operation with
OFF MANUAL Operation with lever
• Error signal is output when lever
(Directional lever is not in "N"
selected)
H/L Max. gear speed
(AUTO) (Limiter)

When the engine is started, if the FNR switch is selected but not in the "N" position, the transmission
controller does not output the neutral signal and the engine does not start.
In this case, the neutral caution signal is output.
5) Shift hold function

The gear speed when the hold switch is pressed is held and the gear is not shifted up even if the travel
speed is increased nor shifted down even if the travel speed is decreased.
The shift hold function is reset by pressing the hold switch again.
When the directional lever, gearshift lever, FNR switch, or kickdown switch is operated, the shift hold
function is reset automatically.
10-316 WA430-6
6) Kickdown function
1] Kickdown in manual shift operation
The kickdown switch operates only in the forward 2nd gear speed (F2). Operation of the kickdown
switch is ignored in any gear speed other than F2. If the directional lever is set in a position other
than F or if the gearshift lever is set in a position other than the "2nd" position, the kickdown function
is reset. After the transmission is set in F1 with the kickdown switch, if the directional lever is set in
the "R" position, the transmission is set in the 2nd gear speed. If the gearshift lever is set in a posi-
tion other than the "2nd" position, the transmission is set in the gear speed of that position.
2] Kickdown in auto-shift operation

The kickdown switch functions regardless of the positions of the directional lever and gearshift
lever.
The gear speed selected by the operation of the kickdown switch depends on the travel speed as
shown in the following table.
After the gear speed is changed by the kickdown operation, it is changed when the travel speed is
increased or the directional lever is operated according to "Auto-shift points table".
Actual gear speed Travel speed Gear speed after shifting No-shift time
2nd All range 1st 5 sec
3rd 10.5 – below 25 km/h 2nd 4 sec
25 km/h or higher Gear is not shifted (3rd) —
4th 10.5 – below 35 km/h 3rd 4 sec
35 km/h or higher Gear is not shifted (4th) —
WA430-6 10-317
11. Function of torque converter hydraulic pump bypass (If equipped)

When the temperature is low, the viscosity of the oil is high and the pump load torque is increased. Conse-
quently, the engine does not start easily.
To solve this problem, when the engine is started at low temperature, the oil in the pump is bypassed to
reduce the pump load.
The conditions for outputting the bypass solenoid operation signal are shown in the following table.
When conditions 1 – 4 in the following table are satisfied, the bypass solenoid operation signal is output.
Condition 1 Starting motor signal C is "ON" or 10 seconds after starting motor signal C is turned "OFF"
Condition 2 Engine coolant temperature: Below -15°C
Condition 3 Engine speed condition A (For prevention of hunting)
Condition 4 Solenoid energizing time: Max. 80 sec (Integrated operating time after starting switch is turned "ON")

2. Torque converter hydraulic pump bypass sole- a. Torque converter hydraulic pump bypass signal
noid valve relay
3. Torque converter hydraulic pump bypass sole-
noid valve
10-318 WA430-6
12. Function of low idle speed increase control

When the travel direction is changed, the low idle speed is kept high for a certain time to reduce the gear
shifting shock.
When the directional lever is set in the forward or reverse position, if the engine speed is below 1,700 rpm
and the travel speed is above 5 km/h, the low idle speed is increased from 765 rpm to 1,000 rpm for 2 sec-
onds.
13. Function of work equipment hydraulic pump control

To prevent the engine from stopping during low idle operation and improve the engine pickup during com-
pound operation, the swash plate angle is so controlled during low idle operation that the pump load on the
engine will be reduced.
The EPC current of the work equipment hydraulic pump is controlled according to the engine speed to
change the discharge characteristics of the work equipment hydraulic pump as shown in the following fig-
ure.
WA430-6 10-319
System circuit diagram
10-320 WA430-6
WA430-6 10-321
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
10-322 WA430-6
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER

DEUTSCH-24P [CN-L61]
Pin Pin
Signal name Input/Output signal Signal name Input/Output signal
No. No.
1 NC Input 13 NC Input
2 Shift mode H Input 14 Shift mode L Input
4 Signal GND – 16 Sensor power supply output (+24 V) Output
5 Transmission cut-off set switch Input 17 Steering pressure switch Input
6 Engine power mode switch Input 18 Lockup selector switch Input
7 Fan reverse switch Input 19 Left brake pressure sensor Input
8 Shift mode M Input 20 Rear brake oil temperature sensor 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 (NO) Input
12 Kickdown switch Input 24 Travel damper operation switch Input
DEUTSCH-40P (1) [CN-L62]

Pin Pin
No. No.
1 NC Output 21 S-NET Input/Output
2 ECMV fill switch lock-up Input 22 CAN0-L Input/Output
3 ECMV fill switch 4th Input 23 CAN1-L Input/Output
4 232C_R x D Input 24 Flash memory write permission signal Input
5 Right FNR (Joystick) forward-reverse R Input 25 Right FNR (Joystick) forward-reverse 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 Low idle switch Output 28 NC Input
9 Engine speed pulse through output Output 29 Pulse GND –
10 Engine speed signal (+) Input 30 NC Input
11 NC Output 31 S-NET GND –
12 CAN shield – 32 CAN0-H Input/Output
13 ECMV fill switch 3rd Input 33 CAN1-H Input/Output
14 232C_T x D Output 34 232C GND –
15 Right FNR (Joystick) forward-reverse N Input 35 Right FNR (Joystick) selector switch Input
16 Directional lever R Input 36 Directional lever F Input
17 ECMV fill switch 1st Input 37 ECMV fill switch F Input
18 DROOP switch Output 38 Shift hold switch Input
19 Travel speed pulse through output Output 39 Pulse GND –
20 Travel speed signal (+) Input 40 NC Input

Pin Pin
No. No.
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 Backup lamp relay Output 24 KEY_signal Input
5 ECMV F Output 25 ECMV 1st Output
6 ECMV 2nd Output 26 ECMV 4th Output
7 Electric emergency steering relay Output 27 Work equipment hydraulic pump EPC Output
8 Indicator built in transmission cut-off switch Output 28 Fan pump reverse solenoid Output
Electric emergency steering manual operation
9 Joystick shift-up switch Input 29 Input
switch
10 Gearshift lever 1st Input 30 Gearshift lever 3rd Input
12 VIS (Solenoid power) Input 32 GND (Controller GND) Input
13 SOL_COM (Solenoid common GND) Input 33 GND (Controller GND) Input
14 KEY_signal Input 34 NC –
15 ECMV R Output 35 ECMV lock-up Output
16 ECMV 3rd Output 36 Fun pump EPC Output
17 Travel damper relay Output 37 Neutral output Output
18 Torque converter charge pump bypass relay Output 38 Fan pump neutral solenoid Output
19 Joystick shift-down switch Input 39 Starting switch terminal C Input
20 Gearshift lever 2nd Input 40 Gearshift lever 4th Input
WA430-6 10-323
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM (WORK EQUIPMENT CONTROLLER SYSTEM)
Electrical system (Work equipment controller system)

(If equipped)
System diagram
10-324 WA430-6
1. Control of work equipment

1) Control with electric control lever
Function of lift arm control
• The EPC valve is controlled according to the operating stroke of the lift arm control lever to operate
the work equipment control valve and control the lift arm.
Function of bucket control

• The EPC valve is controlled according to the operating stroke of the bucket control lever to operate
the work equipment control valve and control the bucket.
Function of 3-spool valve control

• The EPC valve is controlled according to the operating stroke of the 3-spool valve control lever to
operate the work equipment control valve and control the 3-spool valve actuator.
1. Work equipment controller Input and output signals

2. Lift arm control lever a. Lift arm control lever control signal
3. Bucket control lever b. Lift arm raise detent signal
4. 3-spool valve control lever c. Lift arm lower detent signal
5. Lift arm raise EPC valve d. Bucket control lever control signal
6. Lift arm lower EPC valve e. Bucket tilt detent signal
7. Bucket tilt EPC valve f. 3-spool valve control lever control signal
8. Bucket dump EPC valve g. Lift arm raise EPC valve control signal
9. 3-spool valve actuator extract EPC valve h. Lift arm lower EPC valve control signal
10. 3-spool valve actuator retract EPC valve i. Bucket tilt EPC valve control signal
j. Bucket dump EPC valve control signal
k. 3-spool valve actuator extract EPC valve control
signal
l. 3-spool valve actuator retract EPC valve control
signal
WA430-6 10-325
Function of work equipment neutral cut-off

• While the work equipment lock lever is in the "Lock" position, the work equipment EPC cut-off solenoid valve
is energized and the pilot pressure of the work equipment EPC valve is unloaded. Accordingly, the work
equipment does not move even if the operator touches the work equipment control lever by mistake. At this
time, the work equipment controller stops outputting signals to the EPC valve for safety and transmits the
caution signal to the machine monitor.
Work equipment neutral cut-off operation table
Operation by operator Input of controller Output of controller Operation of work equipment

Work equipment lock lever Work equipment EPC cut-off
Work equipment lock lever Work equipment cylinder
lock switch solenoid valve
ON OFF
Free (Raise) Operating
(CLOSE) (OPEN)
OFF ON Stopped
Lock (Lower)
(OPEN) (24 V) (Hydraulic pressure is cut off)

2. Work equipment lock lever lock switch a. Work equipment lock lever "Lock" signal
3. Work equipment lock lever b. Work equipment EPC valve control signal
4. Work equipment EPC valve c. Work equipment EPC cut-off solenoid valve op-
5. Work equipment EPC cut-off solenoid valve eration signal
10-326 WA430-6
2) Control of detent
Function of boom kickout
• If the lift arm control lever is set in the detent position on the "raise" side, the work equipment con-
troller outputs the lift arm raise detent signal, and then the lift arm is kept "raised" even if the lift arm
control lever is released.
If the lift arm rises and the input signal of the boom kick-out proximity switch reaches near the max-
imum height angle, the detent is reset and the lift arm stops rising. At this time, the work equipment
controller controls the lift arm raise EPC valve according to the engine speed (modulation control)
to decelerate the lift arm and reduce the stopping shock.
You can reset the detent by operating the lift arm control lever in the holding direction (manual
reset). If it is reset, the EPC valve controls normally according to the operating stroke of the lever.
Function of lift arm float

• If the lift arm control lever is set in the detent position on the "lower" side, the work equipment con-
troller outputs the lift arm float detent signal, and then the lift arm is kept "lowered" even if the lift arm
control lever is released. At this time, the lift arm cylinder is opened and moved up and down freely
by external forces. Accordingly, if the lift arm is in air, it lowers because of its gravity.
You can reset the detent by operating the lift arm control lever in the holding direction (manual
reset). If it is reset, the EPC valve controls normally according to the operating stroke of the lever.

2. Lift arm control lever a. Lift arm control lever operation signal
3. Lift arm potentiometer b. Lift arm raise detent signal
4. Engine speed sensor c. Lift arm lower detent signal
5. Lift arm raise EPC valve d. Lift arm angle signal
6. Lift arm lower EPC valve e. Engine speed signal
f. Lift arm raise EPC valve control signal
g. Lift arm lower EPC valve control signal
WA430-6 10-327
Function of bucket positioner

• While the bucket is level or lower, if the bucket control lever is set in the detent position on the "tilt" side, the
work equipment controller outputs the bucket tilt detent signal, and then the bucket is kept "tilted" even if the
bucket control lever is released.
If the bucket tilts and the input signal of the bucket positioner proximity switch reaches near the level angle,
the detent is reset and the bucket stops tilting. At this time, the work equipment controller controls the
bucket tilt EPC valve according to the engine speed (modulation control) to decelerate the bucket and
reduce the stopping shock.
You can reset the detent by operating the bucket control lever in the holding direction (manual reset). If it is
reset, the EPC valve controls normally according to the operating stroke of the lever.
While the bucket is tilted below the level position, the detent does not operated even in the bucket control
lever is set in the detent position.

2. Bucket control lever a. Bucket control lever operation signal
3. Bucket positioner proximity switch b. Bucket tilt detent signal
4. Engine speed sensor c. Bucket positioner signal
5. Bucket tilt EPC valve d. Engine speed signal
e. Bucket tilt EPC valve control signal
10-328 WA430-6
2. Control of remote positioner

The operator can set the stopping position of the lift arm freely with the remote positioner so that the lift arm
will start and stop smoothly and the operator can operate the work equipment safely and easily.
Function
When the lift arm is raised or lowered to a set position, the remote positioner decelerates the lift arm to stop.
The work equipment controller constantly monitors the operating direction of the lever with the lift arm con-
trol lever potentiometer and the angle (position) of the lift arm with the lift arm potentiometer.
• When lift arm stops rising (When remote positioner raise mode switch is turned "ON")
If the lift arm control lever is set in the detent position on the "raise" side and the lift arm rises to before
the upper set position, the lift arm raise detent is reset and the lift arm stop modulation control is per-
formed.
While the lift arm control lever is not in the detent position on the "raise" side, the lift arm is raised by the
operation by the operator.
While the remote positioner raise mode switch is "OFF", only the boom kick-out operates.
While the lift arm is level or higher, if the lever is set in the detent position on the "raise" side, only the
boom kick-out operates.
• When lift arm stops lowering (When remote positioner lower mode switch is turned "ON")
If the lift arm control lever is set in the detent position on the "lower" side, the lift arm starts deceleration
10° before the lower set position and the lift arm float detent is reset 4° before the lower set position and
then the lift arm stop modulation control is performed.
If the lift arm control lever is kept as it is, the lift arm starts lowering again.
While the remote positioner lower mode switch is "OFF", only the lift arm float detent operates.
While the lift arm is level or lower, if the lever is set in the detent position on the "lower" side, only the lift
arm float detent operates.

2. Lift arm control lever a. Lift arm control lever operation signal
3. Lift arm potentiometer b. Lift arm raise detent signal
4. Engine speed sensor c. Lift arm lower detent signal
5. Lift arm raise EPC valve d. Lift arm angle signal
6. Lift arm lower EPC valve e. Engine speed signal
7. Remote positioner raise mode switch f. Lift arm raise EPC valve control signal
8. Remote positioner raise/lower set switch g. Lift arm lower EPC valve control signal
9. Remote positioner lower mode switch h. Raise indicator signal
i. Remote positioner raise mode selection signal
j. Remote positioner raise set signal
k. Remote positioner lower set signal
l. Lower indicator signal
m. Remote positioner lower mode selection signal
WA430-6 10-329
Setting of remote positioner selection
Raise stop Lower stop Raise/Lower stop

Remote positioner raise mode switch ON (q) OFF (Q) ON (q)
Remote positioner lower mode switch OFF (Q) ON (q) ON (q)
q : Indicator lamp lights up (Switch is "ON").

Q : Indicator lamp goes off (Switch is "OFF").
Settable range of remote positioner stop position
Raise side (deg.) Lower side (deg.)

0 – 47.0 0 – -42.1
0: Lift arm is level.
Contents of control
Setting of remote positioner raise position
Remote positioner raise
Stopping of raising lift arm (Remote positioner raise mode switch "ON")
stop control
Remote positioner raise mode switch: "ON" (Remote positioner raise operation can be
Condition
stopped)
for setting
Lift arm control lever stroke: Hold (±10%)
1. Raise the lift arm to a desired set position.
2. Press and release "RAISE" of the remote positioner raise/lower set switch.
3. When the switch is released, if the lift arm is in the settable range, the lift arm angle is saved
Setting temporarily and the setting completion buzzer sounds twice (pip, pip). If the lift arm is out of
method the settable range, the setting cancel buzzer sounds.
Setting remote
4. The raise indicator blinks (2.5 seconds).
positioner raise
5. After the indicator blinks for 2.5-second, the setting is saved. (The setting mode is com-
stop position
pleted.) (The setting is still saved after the starting switch is turned "OFF".)
1. During the 2.5 seconds in step 4 of the above setting method (While the raise indicator is
blinking), press and release the "RAISE" of the remote positioner raise/lower set switch
again.
Resetting
2. The raise indicator stops blinking and the raise stop position is set to 0 degrees (level). The
method
setting cancel buzzer sounds.
3. The default value is saved. (The resetting mode is completed.) (The setting is still saved
after the starting switch is turned "OFF".)
Setting of remote positioner lower position

Remote positioner lower
Stopping of lowering lift arm (Remote positioner lower mode switch "ON")
stop control
Remote positioner lower mode switch: "ON" (Remote positioner lower operation can be
Condition
stopped)
for setting
Lift arm control lever stroke: Hold (±10%)
1. Lower the lift arm to a desired set position.
2. Press and release "LOWER" of the remote positioner raise/lower set switch.
3. When the switch is released, if the lift arm is in the settable range, the lift arm angle is saved
Setting temporarily and the setting completion buzzer sounds twice (pip, pip). If the lift arm is out of
Setting remote method the settable range, the setting cancel buzzer sounds.
positioner 4. The lower indicator blinks (2.5 seconds).
lower stop 5. After the indicator blinks for 2.5-second, the setting is saved. (The setting mode is com-
position pleted.) (The setting is still saved after the starting switch is turned "OFF".)
1. During the 2.5 seconds in step 4 of the above setting method (While the lower indicator is
blinking), press and release the "LOWER" of the remote positioner raise/lower set switch
again.
Resetting
2. The lower indicator stops blinking and the lower stop position is set to 0° (level). The setting
method
cancel buzzer sounds.
3. The default value is saved. (The resetting mode is completed.) (The setting is still saved
after the starting switch is turned "OFF".)
10-330 WA430-6
Conditions for outputting signals to buzzer and indicator lamp (Common to raise and lower operations)
Outputting conditions Indicator lamp Buzzer output Stop position

Controlled with value
Remote positioner mode switch is "ON" Lighting up OFF
saved last
2.5 seconds after remote positioner mode When set switch is Controlled with value
Blinking
switch and remote positioner set switch are released, set saved last
(for 2.5 sec or until
turned "ON" or until remote positioner is reset completion buzzer Angle when set switch
reset)
(While sensor is normal) sounds is released is saved
Lift arm angle is out of settable range when When set switch is
saved last
remote positioner mode switch and remote Lighting up released, setting
Saved value is not
positioner set switch are turned "ON" cancel buzzer sounds
changed
Control is not performed
Remote positioner mode switch is "ON" and
OFF OFF Saved value is not
sensor is abnormal
changed
Remote positioner mode switch is "ON" and saved last
Lighting up OFF
remote positioner set switch is abnormal Saved value is not
changed
Remote positioner is reset within 2.5 seconds
When set switch is Controlled with value
after remote positioner mode switch and remote
Lighting up released, setting saved last
positioner set switch are turned "ON" (Remote
cancel buzzer sounds Default value is saved
positioner set switch is turned "ON" again)
Control is not
performed
Remote positioner mode switch is turned "OFF" OFF OFF
Raise/Float detent is
controlled, however
3. Control of semiautomatic digging

You can scoop material loaded into the bucket with only the lift arm control lever and kick-down switch.
Even an unskilled operator can attain working efficiency of a skilled operator.

2. Transmission controller a. Semiautomatic digging "HARD" mode signal
3. Speed sensor b. Semiautomatic digging "SOFT" mode signal
4. Engine speed sensor c. Lift arm control lever operation signal
5. Work equipment control lever d. Bucket control lever operation signal
6. Kickdown switch e. Travel speed signal
7. Semiautomatic digging switch f. Engine speed signal
8. Lift arm EPC valve g. Lift arm EPC valve control signal
9. Bucket EPC valve h. Bucket EPC valve control signal
10. Lift arm potentiometer i. Lift arm angle signal
11. Bucket cylinder full stroke proximity switch j. Bucket cylinder full stroke signal
WA430-6 10-331
1) Conditions for starting semi auto digging

• Turn the semi auto digging switch "ON (SOFT/HARD)".
• Set the lift arm angle to -35° or less (Lower the bucket to the ground).
• While the transmission is in the forward travel position, kick it down to the 1st gear speed with the
kickdown switch.
• The engine speed rises and the travel speed lowers (Travel speed (km/h) < 3.5 x Engine speed (rpm)
/ 2,000).
• Start semi auto digging by "raising" the lift arm.
2) Operation during semi auto digging

1] When the lift arm control lever is returned to "HOLD" after semi auto digging is started
• The bucket starts automatic tilting.
• The travel speed is kept below 1 km/h for 1 second, and then the lift arm starts automatic lifting.
• If the operator performs lift arm raise operation at this time, automatic tilting stops.
2] When the lift arm control lever is set in "detent" position after semi auto digging is started
• If the bucket is empty and the lift arm raise speed does not lower (the rate of 1 deg/sec is con-
tinued for 0.5 seconds), automatic tilting does not start.
• If the lift arm stops rising (the speed of 1 deg/sec stops in 0.5 seconds), the bucket starts auto-
matic tilting.
10-332 WA430-6
3) Finishing semi auto digging

Semiautomatic digging is finished when one of the following conditions is satisfied.
• Set the directional lever in a position other than "Forward".
• The lift arm moves to above the level.
• The bucket moves to the tilting stroke end.
• Tilting operation is performed 6 times in the HARD mode.
4) Semiautomatic digging mode

• SOFT mode
Automatic tilting operation is performed continuously.
If any manual operation is made, however, tilting operation may stop temporarily.
• HARD mode
Automatic tilting operation is performed at intervals of 1.2 seconds.
After tilting operation is repeated 6 times, however, semi auto digging is finished.
WA430-6 10-333
4. Control of joystick steering

You can steer the machine with only the joystick steering lever without using the steering wheel.
Even while the joystick steering system is operating, you can steer with the steering wheel. When the joy-
stick steering lever and steering wheel are operated in the opposite directions, however, the machine artic-
ulates in the direction of the larger steering force.
The travel direction and gear shifting are controlled by the transmission controller.

2. Transmission controller a. Travel speed signal
3. Speed sensor b. Engine speed signal
4. Engine speed sensor c. Joystick "ON" signal
5. Joystick ON/OFF switch d. "HI" mode signal
6. HI/LOW selector switch e. Potentiometer power supply
7. Joystick steering lever angle potentiometer f. Joystick lever angle 1 signal
8. Joystick steering lever angle potentiometer (for g. Potentiometer GND
detecting abnormality) h. Joystick lever angle 2 signal
9. Joystick cut-off relay i. EPC valve GND
10. Steering right EPC valve j. Joystick cut-off signal
11. Steering left EPC valve k. Steering right EPC valve control signal
12. Steering valve l. Steering left EPC valve control signal
13. Orbit-roll valve
14. Steering wheel
15. Steering cylinder
10-334 WA430-6
1) Control of steering
While the machine is steered with the joystick steering system, the articulation speed changes accord-
ing to the joystick steering lever stroke.
The fine operation range of the "LOW" mode is wider than that of the "HI" mode.
2) Control of modulation
While the machine is steered with the joystick steering system, modulation control is performed to
reduce the shocks made at the start and end of each operation.
In the "LOW" mode, the modulation control range is set wider to reduce the shocks more.
While the modulation control is performed, you can steer the machine even during high-speed travel by
heightening the responsibility to the operation of the lever according to the travel speed.
WA430-6 10-335
5. Function of calibration
1) Function of EPC calibration
Dispersion of the starting points of the lift arm, bucket, and joystick steering system caused by the inte-
grated errors of the electric control lever, EPC valve, and work equipment control valve is adjusted.
2) Function of sensor adjustment
The error caused by inaccurate installation of the lift arm potentiometer is offset to sense the position of
the work equipment accurately.
3) Calibration method
Perform calibration with the service mode of the machine monitor. (For details, see "Machine monitor".)
6. Function of troubleshooting
The input and output signals are monitored constantly. If any abnormality is detected by self-diagnosis, the
information on it is transmitted through the network to the machine monitor.
You can check the information on abnormalities with the machine monitor.
10-336 WA430-6
WA430-6 10-337
System circuit diagram
10-338 WA430-6
WA430-6 10-339
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROLLER
10-340 WA430-6

DEUTSCH-24P [CN-L71]
Pin Pin
No. No.
1 Bucket control lever potentiometer B Input 13 Lift arm control lever potentiometer B Input
2 NC Input 14 3-spool valve control lever potentiometer B Input
3 Joystick lever potentiometer B Input 15 NC Input
4 Signal GND – 16 Sensor power supply output (+24 V) Output
5 NC Input 17 Work equipment lock lever lock switch Input
7 Bucket control lever potentiometer A Input 19 Lift arm control lever potentiometer A Input
8 Lift arm potentiometer Input 20 3-spool valve control lever potentiometer A Input
9 Joystick lever potentiometer A Input 21 Analog GND –
10 Signal GND – 22 Potentiometer power supply (+5 V) Output
11 NC Input 23 Joystick ON/OFF switch Input

Pin Pin
No. No.
1 NC Output 21 S-NET Input/Output
2 Remote positioner raise mode switch Input 22 CAN0-L Input/Output
3 Remote positioner lower set switch Input 23 CAN1-L Input/Output
4 232C_R x D Input 24 Flash memory write permission signal Input
8 NC Output 28 NC Input
9 NC Output 29 Pulse GND –
10 Engine speed signal Input 30 NC Input
11 NC Output 31 S-NET GND –
12 CAN shield – 32 CAN0-H Input/Output
13 Remote positioner raise set switch Input 33 CAN1-H Input/Output
14 232C_T x D Output 34 232C GND –
18 NC Output 38 Remote positioner lower mode switch Input
19 NC Output 39 Pulse GND –
20 Travel speed signal Input 40 NC Input

Pin Pin
No. No.
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 NC Output 24 KEY_signal Input
5 Bucket tilt EPC Output 25 3-spool valve extract EPC Output
6 Lift arm raise EPC Output 26 Steering right EPC Output
7 Joystick cut-off Output 27 Lift arm float magnet detent Output
8 Remote positioner RAISE indicator Output 28 Pilot pressure cut-off solenoid Output
9 Semi auto digging HARD mode Input 29 NC Input
10 HI/LOW selector switch Input 30 Bucket cylinder full stroke proximity switch Input
12 VIS (Solenoid power) Input 32 GND (Controller GND) Input
13 SOL_COM (Solenoid common GND) Input 33 GND (Controller GND) Input
14 KEY_signal Input 34 NC –
15 Bucket dump EPC Output 35 3-spool valve retract EPC Output
16 Lift arm lower EPC Output 36 Steering left EPC Output
17 Lift arm raise magnet detent Output 37 Bucket tilt magnet detent Output
18 Remote positioner LOWER indicator Output 38 NC Output
19 Semi auto digging SOFT mode Input 39 NC Input
20 Bucket positioner proximity switch Input 40 NC Input
WA430-6 10-341
10-342 WA430-6
STRUCTURE AND FUNCTION ELECTRIC TRANSMISSION CONTROL
Electric transmission control
WA430-6 10-343
1. Brake valve (Left) 8. Gearshift lever

2. Transmission cut-off switch 9. Directional lever
3. Transmission cut-off set switch 10. Speed sensor
4. Relay box 11. Transmission control valve
5. Fuse box 12. Hold switch
6. Transmission controller 13. Kickdown switch
7. Parking brake switch 14. Left brake pressure sensor
Function
No. Function Operation

Selection of travel direction
1 The travel direction can be changed by operating the directional lever.
and neutral
2 Selection of gear speed The gear speed can be changed by operating the gearshift lever.
The gear can be shifted down by pressing the kickdown switch without operating the
gearshift 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 before the switch is pressed.
If the hold switch is pressed in the auto-shift mode, the current gear speed is held and is
4 Hold not shifted up even if the travel speed is increased. Even if the travel speed lowers, the
gear is not shifted down.
While the transmission cut-off switch is ON, the transmission is set in neutral at the
5 Transmission cut-off
adjusted pressing distance of the brake pedal.
The pressing distance of the brake pedal to set the transmission in neutral with the trans-
6 Transmission cut-off set
mission cut-off function can be adjusted.
Selection of transmission The transmission cut-off function can be turned ON and OFF. While this function is OFF,
7
cut-off the left brake pedal works as the ordinary brake (similarly to the right brake pedal).
While the parking brake is applied, the transmission is set in neutral. With this function,
8 Neutralizer the machine does not travel while the parking brake is applied, thus seizure of the parking
brake is prevented.
While the directional lever is not in "neutral", the engine does not start even if the starting
9 Neutral safety
switch is operated, thus an accident caused by sudden start of the machine is prevented.
When the machine travels in reverse, the backup lamp and backup buzzer are turned ON
10 Alarm
to warn around the machine.
10-344 WA430-6
Combination switch
Outline
• The directional lever has 3 positions and the gearshift lever has 4 positions. The detent mechanism is not
installed to each switch but installed to the body of the combination switch. Each switch is positioned with 2
pins and fixed to the body with 3 screws. If each lever is set in a desired position, the switch connected by
the shaft operates to supply the current to only the circuit of the desired position.
Function
No. Name Operation

1 Directional lever Selects the travel direction and neutral.
2 Gearshift lever Selects a gear speed.
3 Gearshift lever stopper Prevents the gearshift lever from moving to the 3rd or 4th position during work.
4 Turn signal lever Turns the turn signal lamps ON and OFF.
Returns the turn signal lever automatically to neutral when the steering wheel is returned
5 Self-cancel
after turning to the right or left.
6 Lamp switch Turns the headlamp, clearance lamp, tail lamp, and instrument panel lamp ON.
7 Dimmer switch Select the high or low beam of the headlamp.
8 Hazard lamp switch Flashes the right and left turn signal lamps, turn signal pilot lamps, and indicator lamps.
9 Hazard lamp pilot lamp Flashes while the hazard lamp switch is turned ON.
10 Parking brake switch Turns the parking brake ON (applied) and off (released).
WA430-6 10-345
Operation
• Shaft (2) of directional and gearshift lever (1) of
the combination switch is made one with magnet
(3). As lever (1) moves, magnet (3) moves, too.
• Control switch (5) having Hall IC's (4) in it is in-
stalled under magnet (3). Hall IC (4) are ar-
ranged on the board for each position.
• When the directional lever is set in the "F" posi-
tion, magnet (3) comes to just above Hall IC (4)
of the "F" position of the control switch. Magnet
(3) gives magnetism to Hall IC (4) through the
clearance and case (6).
• Hall IC (4) is in the magnetism sensor circuit and
it senses the magnetism of magnet (3) and
sends the signal of the "F" position of the direc-
tional lever to the current amplifier circuit. The
current amplifier circuit outputs the signal to op-
erate the transmission valve.
10-346 WA430-6
STRUCTURE AND FUNCTION KICKDOWN SWITCH AND HOLD SWITCH
Kickdown switch and hold switch
1. Switch A (White wiring harness) Function

2. Switch B (Yellow wiring harness) • These switches are installed to the knob of the lift
3. Spring arm control lever. Switch A (1) works as the kick-
4. Wiring harness down switch and switch B (2) works as the hold
switch.
• Both of switch A (1) and switch B (2) are of mo-
mentary type, that is, their contacts are closed
only while they are pressed.
WA430-6 10-347
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
Engine starting circuit
1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to secure
3. Starting switch safety when the engine is started.
4. Directional lever • The engine does not start while the direction-
5. Directional selector actuation switch al lever is not in "N (Neutral)".
6. Directional selector switch • The engine does not start while the direction-
7. Transmission controller al selector actuation switch is "ON" or while
8. Directional selector relay the directional selector switch is not in "N
9. Neutral safety relay (Neutral)".
10. Starting motor • The engine does not start while the joystick
11. Alternator ON/OFF switch (if equipped) is "ON" or while
12. Engine controller either of the joystick steering lever FNR
13. Short connector switch and joystick steering lever is not in "N
(Neutral)".
10-348 WA430-6
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
Operation
1. When starting switch is turned to "ON" position 3. When starting switch is turned to "START" posi-
• If the starting switch is turned to the "ON" po- tion
sition, terminals B and BR of the starting • If the starting switch is turned to the "START"
switch are closed and the current flows from position, the current flows through the start-
the battery through the starting switch and ing switch terminal C, short connector, and
battery relay coil to the ground and the con- neutral safety relay to the starting motor, and
tacts of the battery relay are closed. As a re- the engine starts.
sult, the power is supplied to each circuit of • While directional lever is not in "Neutral (N)"
the machine. or the directional selector switch is not in
At this time, the ACC signal flows from ter- "Neutral (N)" (if the directional selector
minal ACC of the starting switch into the switch is used) or FNR switch is in "Neutral
engine controller, and the engine is ready to (N)" and joystick steering lever is not in "Neu-
start. tral (N)" (if the joystick steering is used), the
neutral safety relay does not operate and the
2. Neutral safety circuit engine does not start.
• If the directional lever is set in the "N (Neu-
tral)" position, the current flows from contact
N of the directional lever through the direc-
tional selector relay to the neutral safety re-
lay.
• While the directional selector switch is used
(while the directional selector actuation
switch is "ON"), the current flows from the di-
rectional selector actuation switch to the di-
rectional selector relay coil. If the directional
selector switch is in "Neutral (N)", the trans-
missio n con tro ller outp uts the cu rren t
through the directional selector relay to the
neutral safety relay coil.
• While the joystick steering (if equipped) is
used, if the joystick console is lowered and
the console lock lever is set in the "Lock" po-
sition and the joystick ON/OFF switch is
turned "ON", the current flows from the joy-
stick ON/OFF switch to the directional selec-
tor relay coil. At this time, if both of the
joystick steering lever FNR switch and joy-
stick steering lever are in "Neutral (N)", the
transmission controller outputs the current
through the directional selector relay to the
neutral safety relay coil.
(If the joystick steering system is installed,
the console lock switch and joystick ON/
OFF switch are installed instead of the
directional selector switch, and the FNR
switch is installed instead of the directional
selector switch.)
WA430-6 10-349
STRUCTURE AND FUNCTION ENGINE STOPPING CIRCUIT
Engine stopping circuit
Operation
• If the starting switch is set in the "OFF" position,
the current of terminal ACC is cut out and the
ACC signal to the engine controller is cut out ac-
cordingly.
If the ACC signal is cut out, the engine lowers its
speed and stops. Then, the alternator stops
generating and the voltage is not supplied from
the alternator terminal R.
The current from the starting switch terminal BR
is also stopped and the contacts of the battery
relay are opened. Consequently, the power sup-
plied to each circuit of the machine is stopped.
10-350 WA430-6
STRUCTURE AND FUNCTION PREHEATING AND POST-HEATING CIRCUIT
Preheating and post-heating circuit
1. Battery Outline
2. Battery relay • The automatic preheating system is installed so
3. Starting switch that the engine will start easily in a cold district.
4. Engine controller • If the starting switch is set in the "ON" position,
5. Machine monitor the automatic preheating system sets the pre-
6. Electrical intake air heater relay heating time properly according to the coolant
7. Electrical intake air heater temperature.
8. Coolant temperature sensor • If the starting switch is set in the "ON" position,
9. Intake air temperature sensor the preheater pilot lamp of the machine monitor
lights up and the electrical intake air heater pre-
heats the intake air.
The coolant temperature sensor senses the
coolant temperature and the engine controller
sets the preheating time.
• The pilot lamp keeps lighting up during the pre-
heating time. Keep the starting switch in the
"ON" position during this time. If the starting
switch is turned to the "START" position in this
time, preheating is reset.
• After the engine is started, if the intake air tem-
perature is low, the electrical intake air heater op-
erates as the post-heater and the pilot lamp
lights up.
WA430-6 10-351
STRUCTURE AND FUNCTION PREHEATING AND POST-HEATING CIRCUIT
Operation
Preheating operation Post-heating operation

• When the starting switch is turned "ON", the en- • After the engine is started, if the intake air tem-
gine controller starts. At this time, if the coolant perature is -5°C, the engine controller operates
temperature is 4°C or below, the engine control- the heater relay to post-heat the intake air with
ler operates the electrical intake air heater relay the electrical intake air heater as in the preheat-
to preheat the intake air with the electrical intake ing operation.
air heater. • The post-heating time is set as shown below.
• The preheating time is set as shown below.
10-352 WA430-6
STRUCTURE AND FUNCTION ENGINE POWER MODE SELECTOR CIRCUIT
Engine power mode selector circuit
1. Power mode selector switch

3. Machine monitor
4. Engine controller
Function
• If the power mode selector switch is set in the
"POWER" position, the engine power is con-
trolled. If the former is set in the "NORMAL" po-
sition, the working fuel consumption is reduced.
• The switch signal is input to the transmission
controller, which selects a gear speed and travel
speed matched to the power mode in the auto-
shift mode.
Operation
• If the power mode selector switch is set in the
POWER mode, the switch signal is input to the
transmission controller, which sends DROOP
signal "OPEN" to the engine controller, and then
the engine torque curve changes to "POWER".
At this time, the transmission controller also
sends the power mode indicator lighting signal in
the form of an S-NET signal to the machine mon-
itor.
• While the gear speed is the 1st and the travel
speed is 1.05 km/h or below and the accelerator
pedal opening ratio is 78% or higher, however,
the engine power is set in the "NORMAL" mode
to lower the drawbar pull, even if the power mode
selector switch is in the "POWER" position.
WA430-6 10-353
STRUCTURE AND FUNCTION TURBOCHARGER PROTECTION FUNCTION
Turbocharger protection Automatic warm-up function

function • When the engine is started in a cold district, the
• After the engine is started in a cold district, the engine low idle speed is heightened automatical-
engine torque and engine speed are limited for a ly to warm up the engine.
certain time to protect the turbocharger. • When the engine is started, if the coolant temper-
• The engine torque and engine speed are limited ature is 29°C or below, the low idle speed is
according to the coolant temperature when the heightened to 850 rpm. After a certain time, the
engine is started. The turbocharger protection low idle speed is further heightened to 1,000
time is shown in the following table. rpm. The low idle speed is kept at 1,000 rpm ac-
cording to the coolant temperature as shown in
the following figure.
Coolant temperature (°C) Protection time (sec)
• If the coolant temperature exceeds 29°C during
-35 10 the warm-up period, the engine speed returns to
-18 5 760 rpm.
27 0
Torque derating function

• If the coolant temperature rises above the set
temperature, the fuel injection rate is adjusted to
derate the torque for protection of the engine.
• If the coolant temperature is 105°C or higher for
continuous 5 seconds, the torque is derated.
The torque derating percentage is shown in the
following figure.
10-354 WA430-6
STRUCTURE AND FUNCTION PARKING BRAKE CIRCUIT
Parking brake circuit

Operation When starting switch is turned "ON"
1. When parking brake switch is turned "ON"
before starting switch is turned "ON"
1. Parking brake relay

2. Parking brake switch
3. Emergency brake oil pressure switch • While parking brake switch (2) is "ON (applied)",
4. Parking brake solenoid valve the current from the battery relay flows through
5. Transmission controller parking brake switch (2) and parking brake relay
(1) to the chassis ground. The current from the
When starting switch is turned "OFF" battery relay keeps flowing into the coil of parking
• If the starting switch is turned "OFF", the con- brake relay (1) to hold its contacts until the bat-
tacts of battery relay (1) open. Accordingly, the tery relay contacts open and the current does not
current does not flow in the parking brake circuit flow into the parking brake circuit any more.
and the parking brake operates. While the start- • At this time, the current does not flow into parking
ing switch is "OFF", the current does not flow into brake solenoid valve (4) and the parking brake is
parking brake solenoid valve (4) and the parking kept applied.
brake is kept applied, regardless of the position • This signal is input to transmission controller (5)
of the parking brake switch (2) ("ON (applied)" or to keep the transmission in neutral and prevent
"OFF (released)"). the parking brake from dragging while the park-
ing brake is applied.
• If the parking brake switch is turned "OFF (re-
leased)", the current flows through battery relay,
parking brake relay (1), parking brake switch (2),
emergency brake oil pressure switch (3), and
parking brake solenoid valve (4) to the chassis
ground, and the parking brake is released.
WA430-6 10-355
STRUCTURE AND FUNCTION PARKING BRAKE CIRCUIT
2. When parking brake switch is turned "OFF" When main brake oil pressure lowers (emer-
before starting switch is turned "ON" gency brake is applied)
• While the parking brake switch is "OFF (re- • If the main brake oil pressure lowers, the emer-
leased)", the current does not flow into park- gency brake oil pressure switch (3) installed to
ing brake relay (1) and its contacts are open. the charge valve open. As a result, the current
Even if the starting switch is turned "ON" at flowing into parking brake solenoid valve (4) is
this time, the current does not flow in to park- stopped and the oil in the parking brake cylinder
ing brake solenoid valve (4). Accordingly, is drained and the parking brake is applied.
the parking brake is not released automati- • At this time, unlike the case where the parking
cally. brake switch is turned "ON (applied)", the trans-
mission is not set in neutral since the parking
brake release signal is flowing into the travel con-
troller.
• By the above operation, when the emergency
brake is applied, the braking distance can be re-
duced by using the engine as a brake. Even if
the emergency brake is applied, you can move
the machine.
10-356 WA430-6
STRUCTURE AND FUNCTION SENSORS
Sensors
Engine speed sensor
Speed sensor
1. Wire 4. Housing
2. Magnet 5. Connector
3. Terminal
Function
• The engine speed sensor is installed to the ring gear of the flywheel housing and the speed sensor is installed
to the output gear of the transmission case. They generate pulse voltage as the gears rotate.
WA430-6 10-357
Engine oil level sensor
1. Connector 3. Float
2. Bracket 4. Switch
Function
• The engine oil level sensor is installed to the side of the oil pan. If the oil level lowers below the specified
level, the float lowers and the switch is turned "OFF".
Torque converter oil temperature sensor

Hydraulic oil temperature sensor
Transmission oil temperature sensor
Brake oil temperature sensor
1. Connector 3. Thermistor
2. Plug
Function
• Torque converter oil temperature sensor is installed to the outlet tube of the transmission case. The hydraulic
oil temperature sensor is installed to the return tube of the hydraulic tank. The transmission oil temperature
sensor is installed to the transmission case. The brake oil temperature sensor is installed to the rear axle.
They sense change of temperature as change of resistance of the thermistors and generate signals from the
results.
10-358 WA430-6
Transmission cut-off pressure sensor
1. Sensor
2. Lead wire
3. Connector
Function
• The transmission cut-off pressure sensor is in- Relationship between pressure and voltage
stalled to the elbow of brake valve (left) under the
floor. It senses the brake operation pressure and
outputs it as voltage.
WA430-6 10-359
Coolant level sensor
1. Float 3. Connector
2. Sensor 4. Sub-tank
Function
• The coolant level sensor is installed in the bulkhead. If the coolant level lowers below the specified level, the
float lowers and the switch is turned "OFF".
10-360 WA430-6
Fuel level sensor
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
• The fuel level sensor is installed to the side 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 operating
angle and signal voltage is generated from the source voltage according to the change of the resistance.
WA430-6 10-361
Lift arm angle sensor
1. Shaft 4. Rotor
2. Housing 5. Connector
3. Bearing
Function
• The lift arm angle sensor is installed to the front frame. If the lift arm angle changes, the shaft receives the
sliding resistance through the link installed to the lift arm and the lift arm angle is sensed from that sliding
resistance.
10-362 WA430-6
Air cleaner clogging sensor
1. Indicator 3. Adapter
2. Spring 4. Connector
Function
• The air cleaner clogging sensor is installed to the air cleaner outlet. If the air cleaner is clogged and the pres-
sure reaches the specified level (negative pressure), a signal is generated.
Battery electrolyte level sensor
1. Body 4. Packing
2. Connector 5. Pin
3. Filter
Function
• The battery electrolyte level sensor is installed to the battery. If the battery electrolyte level lowers below the
specified level, the sensor tip is exposed to air and a signal of voltage change is generated.
WA430-6 10-363
10-364 WA430-6
TESTING AND ADJUSTING
20 TESTING AND ADJUSTING

Standard value table for engine ....................... 20-2 Testing and adjusting work equipment
Standard value table for chassis ...................... 20-3 oil pressure .....................................................20-66
Posture of machine for measuring performance and Bleeding air from work equipment circuit........20-70
measurement procedure .................................. 20-9 Releasing residual pressure in work equipment cir-
Tools for testing, adjusting, and cuit ..................................................................20-71
troubleshooting .............................................. 20-11 Testing and adjusting bucket positioner .........20-72
Testing and adjusting engine speed .............. 20-13 Testing and adjusting boom kick-out ..............20-73
Measuring exhaust gas color ......................... 20-15 Checking proximity switch operation pilot lamp20-74
Measuring exhaust temperature .................... 20-16 Procedure for testing diodes...........................20-75
Adjusting valve clearance .............................. 20-18 Adjusting machine monitor .............................20-76
Measuring blow-by pressure .......................... 20-20 Special functions of machine monitor .............20-80
Measuring engine oil pressure ....................... 20-21 Pm Clinic inspection table.............................20-112
Measuring intake air (boost) pressure ........... 20-22
Adjusting engine speed sensor ...................... 20-23
Testing and adjusting air conditioner compressor belt
tension ........................................................... 20-24
Bleeding air from fuel circuit........................... 20-25
Adjusting accelerator pedal potentiometer..... 20-26
Adjusting accelerator pedal microswitch ........ 20-27
Adjusting transmission speed sensor ............ 20-28
Measuring directional lever ............................ 20-29
Testing and adjusting power train oil pressure20-30
Flushing procedure for torque converter and trans-
mission hydraulic circuit ................................. 20-38
Method of moving machine when transmission valve
is broken ........................................................ 20-39
Testing and adjusting steering control ........... 20-41
Testing and adjusting steering wheel............. 20-42
Testing and adjusting steering oil pressure ... 20-44
Bleeding air from steering circuit.................... 20-47
Testing hydraulic drive fan ............................. 20-48
Bleeding air from fan motor circuit ................. 20-50
Measuring brake pedal .................................. 20-51
Measuring brake performance ....................... 20-52
Testing and adjusting accumulator
charge pressure ............................................. 20-53
Testing wheel brake oil pressure ................... 20-54
Measuring wear of wheel brake disc.............. 20-56
Bleeding air from wheel brake circuit ............. 20-57
Releasing residual pressure in brake accumulator
circuit.............................................................. 20-57
Testing parking brake performance ............... 20-58
Measuring parking brake oil pressure ............ 20-59
Testing wear of parking brake disc ................ 20-61
Method of releasing parking brake manually . 20-62
Measuring and adjusting work equipment control le-
ver .................................................................. 20-63
Testing and adjusting work equipment PPC oil pres-
sure ................................................................ 20-64
WA430-6 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
Standard value table for engine
Machine Model WA430-6

Engine SAA6D114E-2
Standard value for
Item Measurement Conditions Unit Service limit value
new machine
High idle (N mode) 1,895 ± 50 1,895 ± 50
High idle (P mode) 2,225 ± 50 2,225 ± 50
Engine speed rpm
Low idle (N mode) 765 ± 25 765 ± 25
Low idle (P mode) 765 ± 25 765 ± 25
Exhaust tempera-
All revolution ranges (Atmospheric tem-
ture (Turbocharger °C Max. 550 Max. 600
perature: 20°C)
outlet temperature)
Intake air pressure
At rated output kPa {mmHg} Min. 133.3 {1,000} Min. 113.3 {850}
(Boost pressure)
At sudden acceleration Max. 4.5 Max. 6.5
Exhaust gas color Bosch index
At high idle Max. 1.0 Max. 1.5
Normal tempera- Intake valve 0.31 ± 0.05 0.31 ± 0.05
Valve clearance mm
ture Exhaust valve 0.56 ± 0.05 0.56 ± 0.05
At rated output
Blow-by pressure (Operating range of coolant temperature) kPa {mmH2O} Max. 2.99 {305} Max. 2.99 {305}
(SAE30 oil)
(Operating range of coolant temperature)
0.36 – 0.61
Oil pressure At high idle (15W-40) MPa {kg/cm 2} 0.21 {2.1}
{3.5 – 6.0}
At low idle (15W-40) Min. 0.15 {1.5} 0.07 {0.7}
Oil temperature All engine speed ranges (Inside oil pan) °C 90 – 120 Min. 120
Deflection made by
Idler pulley - Crank
finger pressure of Auto-tensioner Auto-tensioner
pulley
about 58.8 N {6 kg}
Belt tension mm
Deflection made by Air conditioner
finger pressure of compressor - Crank 16 – 20 16 – 20
about 98 N {10 kg} pulley
20-2 WA430-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Standard value table for chassis

*1: The value shows the value before the detent.
Machine model WA430-6

Standard value for
Category Item Measurement conditions Unit Service limit value
new machine
N - FORWARD, • Engine Stopped
Operating effort N {kg} 5.9 +4.9 +0.5
–3.0 {0.6 –0.3 } Max. 16.7 {1.7}
Directional REVERSE • Measure at center of
lever N - FORWARD, lever knob
Travel mm 35 ± 10 35 ± 20
REVERSE
1st – 2nd • Engine stopped 5.9 +4.9
–3.0 {0.6 +0.5
–0.3 } Max. 16.7 {1.7}
Operating effort 2nd – 3rd • Measure at center of N {kg} 5.9 +4.9 {0.6 +0.5
–3.0 –0.3 } Max. 16.7 {1.7}
3rd – 4th lever knob 5.9 +4.9 {0.6 +0.5
Gearshift –3.0 –0.3 } Max. 16.7 {1.7}
lever 1st – 2nd 35 ± 10 35 ± 20
Travel 2nd – 3rd mm 35 ± 10 35 ± 20
HOLD o
3rd – 4th 35 ± 10 35 ± 20
• Engine speed:
Max. 12.8 {1.3} (*1) Max. 19.6 {2.0}
RAISE o
RAISE Low idle
• Hydraulic oil tempera-
ture: Within operating Max. 14.7 {1.5} Max. 22.6 {2.3}
HOLD o
HOLD
range
Max. 12.8 {1.3} (*1) Max. 19.6 {2.0} (*1)
LOWER o
Lift LOWER
arm
— —
LOWER o
Operating HOLD
N {kg}
effort
Max. 15.7 {1.6} Max. 23.5 {2.4}
FLOAT o
FLOAT
Max. 14.7 {1.5} Max. 22.6 {2.3}
HOLD o
Work equip- HOLD
ment control
Max. 17.7 {1.8} Max. 26.5 {2.7}
HOLD o TILT
lever DUMP
Bucket (*1)
Max. 19.6 {2.0} (*1)
TILT o HOLD
Max. 12.8 {1.3}
HOLD o
Max. 14.7 {1.5} Max. 22.6 {2.3}
• Engine speed: (*1) (*1)
43 ± 9 43 ± 18
HOLD o
RAISE Low idle
Lift • Hydraulic oil tempera-
ture: Within operating 43 ± 9 (*1) 43 ± 18 (*1)
HOLD o
arm LOWER
Travel range mm
50 ± 9 50 ± 18
HOLD o
FLOAT
50 ± 9 50 ± 18
HOLD o TILT
Bucket DUMP
43 ± 9 (*1) 43 ± 18 (*1)
• Engine stopped
Play • Machine facing mm Max. 40 Max. 100
straight to front
• Flat, horizontal,
straight, dry paved
6.9 – 12.6
Operating effort road surface N {kg} Max. 19.6 {2.0}
{0.7 – 1.3}
• Engine speed: Low
Steering idle (Bucket empty)
wheel • Engine speed: High
Turns (Not including play) idle Turns 3.7 ± 0.4 3.7 ± 0.8
• Left lock - right lock
• Engine started:
Low idle • Hydraulic oil tempera- 4.4 ± 0.4 Max. 6.9
Operat-
ture: Within operating Sec.
ing time
High idle range 3.7 ± 0.4 Max. 4.5
• Left lock - Right lock
WA430-6 20-3

Standard value for
new machine
• Engine speed: 1,200
rpm
Clearance between front frame and ture: Within operating
Frame mm 40 ± 5 —
rear frame range
• Flat, level, straight,
dry, and paved road
• At max. steering angle

Standard value for
new machine
• Engine started
53.9 – 73.6
Pressing effort • Measure at 150 mm from ful- N {kg} Max. 107.9 {11.0}
{5.5 – 7.5}
Accelerator crum of pedal.
pedal Pressing Neutral (a1) • For measuring posture, see 48 —
deg.
angle Neutral (a3) Fig. A at end of this section 35 ± 1 —
Height of stopper (L) • Engine started mm 56 ± 5 —
• For measuring posture, see 321 ± 32.1
Operating effort N {kg} Max. 451.1 {46.1}
Fig. B at end of this section {32.8 ± 3.3}
Brake pedal Operating Neutral (a1) • Engine speed: Low idle 45 —
deg.
angle Neutral (a2) • Hydraulic oil temperature: 15 +1
+0 —
Within operating range
Play mm 5 ± 0.5 —
Fitting of A • For measuring posture, see Max. 2.5 —
wheel lock ring B Fig. C at end of this section Max. 4.0 —
Tire • Tire inflation pressure: Speci- mm
Clearance of
C fied pressure 2 – 10 —
wheel lock ring
• Engine coolant tem- N mode 1,820 ± 50 1,820 ± 100
Torque converter stall perature: Within oper-
ating range P mode 1,900 ± 100 1,900 ± 200
• Torque converter oil N mode 1,890 ± 100 1,890 ± 200
Engine speed Hydraulic stall temperature: Within rpm
operating range P mode 2,220 ± 100 2,220 ± 200
• Hydraulic oil tempera- N mode 1,810 ± 100 1,810 ± 200
Torque converter stall + ture: Within operating
hydraulic stall range P mode 1,860 ± 100 1,860 ± 200
• Torque converter oil tempera- 2.76 ± 0.2 2.76 ± 0.2
Low idle
Main relief ture: Within operating range {28.2 ± 2} {28.2 ± 2}
pressure 2.89 ± 0.2 2.89 ± 0.2
High idle
{29.5 ± 2.0} {29.5 ± 2.0}
Torque converter relief (Inlet Max. 0.88 Max. 0.88
Transmis-
port) pressure MPa {Max. 9.0} {Max. 9.0}
sion, torque
Torque converter outlet port {kg/cm2} 0.51 ± 0.05 0.51 ± 0.05
converter
oil pressure {5.2 ± 0.53} {5.2 ± 0.53}
1st, 2nd, • Torque converter oil tempera- 2.25 ± 0.15 2.25 ± 0.15
ECMV output 3rd, 4th ture: Within operating range {23.0 ± 1.5} {23.0 ± 1.5}
(Clutch) oil
• Engine: High idle 2.35 ± 0.15 2.35 ± 0.15
pressure F-R • Manual switch ON {24.0 ± 1.5} {24.0 ± 1.5}
• Hydraulic oil temperature:
MPa 24.5 ± 1.23 24.5 +1.23
–2.45
Steering relief pressure Within operating range
{kg/cm }2
{250 ± 12.5} {250 +12.5
• Engine speed: High idle –25 }
Steering • Hydraulic oil temperature:
Within operating range MPa 1.1 – 1.4 0.9 – 1.6
Steering control pressure
• Engine speed: High idle {kg/cm2} {11 – 14} {9 – 16}
• Steering wheel: Neutral
20-4 WA430-6

Standard value for
new machine
• Engine speed: • Point where +0.5 +0.98
Low idle brake oil pres- 5.9 +0 5.9 –0.5
Charge cut-in pressure • Hydraulic oil sure warning
temperature: lamp goes out {60 +5
+0 } {60 +10
–5 }
Within operat- MPa
Accumulator • Point where
ing range {kg/cm2} +0.98 +1.5
oil pressure is 9.8 +0 9.8 –0.5
Charge cut-out pressure going up and
then starts to {100 +10
+0 } {100 +15
–5 }
go down
WA430-6 20-5

Standard value for
new machine
1st 7.0 ± 0.4 7.0 ± 0.5
2nd 12.3 ± 0.6 12.3 ± 0.9
P mode
3rd 21.6 ± 1.1 21.6 ± 1.6
4th 37.2 ± 1.9 37.2 ± 2.8
FORWARD
1st 5.8 ± 0.3 5.8 ± 0.4
2nd 10.2 ± 0.5 10.2 ± 0.8
N mode
3rd 18.1 ± 0.9 18.1 ± 1.4
Travel speed (Bucket 4th 30.0 ± 1.5 30.0 ± 2.3
Power train km/h
empty) 1st 7.6 ± 0.4 7.6 ± 0.6
2nd 12.9 ± 0.6 12.9 ± 1.0
P mode
3rd 23.0 ± 1.2 23.0 ± 1.7
4th 39.4 ± 2.0 39.4 ± 3.0
REVERSE
1st 6.3 ± 0.3 6.3 ± 0.5
2nd 10.7 ± 0.5 10.7 ± 0.8
N mode
3rd 19.3 ± 1.0 19.3 ± 1.4
4th 31.8 ± 1.6 31.8 ± 2.4
• Hydraulic oil temperature: 4.19 ± 0.42 4.19 ± 0.82
Brake oil pressure
Within operating range {42.7 ± 4.3} {42.7 ± 8.6}
• Engine stopped
MPa
• Keep brake pedal depressed at
2
{kg/cm2}
Drop in brake pressure 4.9 MPa {50 kg/cm } and mea- Max. 98 {1.0} Max. 98 {1.0}
sure drop in oil pressure after 5
min.
• Tire inflation pressure: Specified
pressure
• Flat, horizontal, straight, dry
Wheel brake paved road surface
• Speed when applying brake: 35
Performance km/h, braking delay: Within 0.1 m Max. 12 Max. 12
sec.
• Brake pedal operating effort:
Specified operating effort (321 ±
32.1 N {328 ± 3.3kg})
• Measure braking distance
• Oil pressure: 4.9 MPa {50 kg/cm2} Shaft protrusion
Disc wear • Pedal depressed fully mm Shaft protrusion 0 reaches wear limit
position (2.4 mm)
Parking brake oil pressure • Torque converter oil temperature: Min. 2.27 {23.1} Min. 2.27 {23.1}
Within operating range MPa
Parking brake solenoid
• Engine speed: Low idle {kg/cm2} Min. 2.27 {23.1} Min. 2.27 {23.1}
valve basic pressure
• Parking brake: OFF
• Tire inflation pressure: Specified
pressure
Parking brake • Flat paved road with 1/5 (11× 20’)
grade
Performance — Holds in position Holds in position
• Dry, paved road surface
• Machine at operating condition
• For measuring posture, see Figs.
D and E at end of this section
Disc thickness — mm 3.2 ± 0.08 2.97
20-6 WA430-6

Standard value for
new machine
• Hydraulic oil temperature: Within
PPC valve basic pressure operating range 3.72 +0.2
+0 {38 +2
+0 } 3.72 +0.2 +2
–0.2 {38 –2 }
• Engine speed: High idle
Lift arn RAISE, • Hydraulic oil temperature: Within MPa
PPC PPC FLOAT; Bucket operating range {kg/cm2} 3.72 +0.1 +1
–0.1 {38 –1 } 3.72 +0.1 +1
–0.2 {38 –2 }
valve
DUMP, TILT • Engine speed: High idle
output
• Control lever operated fully 2.2 ± 0.25 2.2 ± 0.39
pressure Lift arm LOWER
{22.5 ± 2.5} {22.5 ± 4}
• Hydraulic oil temperature: +1.57
31.4 –3.92
Work equipment relief MPa 31.4 ± 1.57
pressure {kg/cm2} {320 ± 16} {320 +16
• Engine speed: High idle –40 }

2.35 ± 0.29 2.35 ± 0.59
Unload pressure • Engine speed: High idle
{24 ± 3} {24 ± 6}
• Work equipment control lever: Neu-
tral MPa
{kg/cm2}
Within operating range 1.47 ± 0.2 1.47 ± 0.39
LS differencial pressure
• Engine speed: High idle {15 ± 2} {15 ± 4}
• Lift arm lever: at half stroke
N mode 6.9 ± 0.5 Max. 8.7
ture:
Lift arm RAISE
P mode 5.9 ± 0.5 Max. 7.6
• Engine speed:
High idle sec.
N mode 3.3 ± 0.5 Max. 4.4
• Apply no load.
Lift arm LOWER • For measuring posture,
Work
Work see Figs. F and G at P mode 3.3 ± 0.5 Max. 4.4
equipment
equip- end of this section
ment • Hydraulic oil tempera- N mode 1.8 ± 0.3 Max. 2.4
speed Forward ture:
Bucket full P mode 1.8 ± 0.3 Max. 2.4
stroke • Engine speed: N mode 2.6 ± 0.3 Max. 3.4
Backward
High idle P mode 2.3 ± 0.3 Max. 3.0
• No load.
Moving
• For measuring posture, N mode 1.8 ± 0.3 Max. 2.4
bucket
Backward see Figs.H and J at
from level P mode 1.6 ± 0.3 Max. 2.2
end of this section
position
Retraction of lift Within operating range
Max. 20 Max. 24
cylinder rod • Stop engine and leave for 5 min-
utes, then measure for 15 min-
Hydraulic
utes. mm
drift
• Apply no load to bucket and set lift
Retraction of bucket
arm and bucket in level position. Max. 17 Max. 20
cylinder rod
• For measuring posture, see Fig.K
at end of this section
WA430-6 20-7

Standard value Service limit
Category Item Measurement conditions Unit
for new machine value
• Engine speed: High idle
• Engine coolant temperature: Min. 95°C
Max. fan speed • Hydraulic oil temperature: Min. 95°C 1,400 ± 100 1,400 ± 200
• Torque converter oil temperature:
Min. 105°C
rpm
• Engine speed: Low idle
• Engine coolant temperature: Max. 75°C
Hydraulic
Min. fan speed • Hydraulic oil temperature: Max. 75°C 600 ± 50 600 ± 100
drive fan
Max. 85°C
• Engine speed: High idle 11.7 ± 1.2 11.7 ± 1.8
Fan drive pressure
• Engine coolant temperature: Min. 95°C {119 ± 12} {119 ± 18}
MPa
• Hydraulic oil temperature: Min. 95°C
Fan reverse solenoid output {kg/cm2} 11.7 ± 1.2 11.7 ± 1.8
pressure {119 ± 12} {119 ± 18}
Min. 105°C
Clearance of bucket posi- • Hydraulic oil temperature: Within
3–5 —
Proximity tioner switch operating range
mm
switch Clearance of boom kick-out
3–5 —
switch
20-8 WA430-6
TESTING AND ADJUSTINGPOSTURE OF MACHINE FOR MEASURING PERFORMANCE AND MEASURE-
MENT PROCEDURE
Posture of machine for measuring performance and

measurement procedure
a Fig. A a Fig. D
a Fig. B a Fig. E
a Fig. C a Fig. F
WA430-6 20-9
TESTING AND ADJUSTINGPOSTURE OF MACHINE FOR MEASURING PERFORMANCE AND MEASURE-
MENT PROCEDURE
a Fig. G a Fig. K
a Fig. H
a Fig. J
20-10 WA430-6
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Tools for testing, adjusting, and troubleshooting
Symbol
Q'ty
Testing and adjusting item Part No. Part name Remarks
1 799-201-9001 Handy smoke checker 1 Bosch index: Level 0 – 9

Measuring exhaust gas
A Commercially
color 2 Smoke meter 1 —
available
Measuring exhaust temper-
B 799-101-1502 Digital thermometer 1 -99.9 – 1,299°C
ature
Commercially
Adjusting valve clearance C Thickness gauge 1 —
available
Measuring blow-by pressure D 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mm H 2O}
Analog hydraulic Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 1
1 tester {25, 60, 400, 600 kg/cm2}
Measuring engine oil pres-
E 799-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
sure
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
3 6732-81-3170 Adapter 1 Male: M10 x 1.0, Female: R1/8
Measuring intake air (boost) 1 799-201-2202 Boost gauge kit 1 -101 – 200 kPa {-760 – 1,500 mmHg}
F
pressure 2 6732-81-3170 Adapter 1 Male: M10 x 1.0, Female: R1/8
Adjusting accelerator pedal Commercially
G Circuit tester 1 —
potentiometer available
Adjusting accelerator pedal Commercially
H Thickness gauge 1 —
microswitch available
Adjusting directional lever J 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
799-101-5002 1
Testing power train oil pres- 1 tester {25, 60, 400, 600 kg/cm2}
K
sure 799-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
Method of moving machine
when transmission valve is L 794-423-1190 Plug 1 M20 x 1.5
broken
Testing and adjusting steer-
M 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
ing wheel
799-101-5002 1
1 tester {25, 60, 400, 600 kg/cm2}
Testing and adjusting steer-
N 799-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
ing oil pressure
799-101-5220 Nipple 1
2 Size: M10 x 1.25
07002-11023 O-ring 1
1 799-205-1100 Tachometer kit 1 Digital indication: 6 – 99999.9 rpm
799-101-5002 1
2 tester {25, 60, 400, 600 kg/cm2}
Testing hydraulic drive fan P
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
799-101-5220 Nipple 1
3 Size: M10 x 1.25
07002-11023 O-ring 1
799-101-5002 1
1 tester {25, 60, 400, 600 kg/cm2}
Bleeding air from fan motor 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Q
circuit 799-101-5220 Nipple 1
2 Size: M10 x 1.25
07002-11023 O-ring 1
3 799-261-1130 Coupling 1 —
Testing and adjusting accu- 799-101-5002 1
R tester {25, 60, 400, 600 kg/cm2}
mulator charge pressure
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
WA430-6 20-11
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Symbol
Q'ty
Testing and adjusting item Part No. Part name Remarks
1 793-605-1001 Brake test kit 1 —

2 790-101-1430 Coupler 1 —
3 790-101-1102 Pump 1 —
Testing wheel brake oil pres- Male side: M20 x 1.5
S 4 790-301-1720 Adapter 1
sure Female side: R1/8
5 799-101-5160 Nipple 1 —
6 799-401-2220 Hose 1 Length: 5 m
7 790-261-1130 Coupling 1 —
Measuring wear of wheel Commercially
T Slide calipers 1 —
brake disc available
799-101-5002 1
Testing parking brake oil 1 tester {25, 60, 400, 600 kg/cm2}
U
pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm 2}
2 799-401-3200 Adapter (03 Size) 1 —
Testing wear of parking Commercially
V Slide calipers 1 —
brake disc available
Measuring and adjusting 1 79A-264-0021 Push-pull scale 1 —
work equipment control W Commercially
2 Scale 1 —
lever available
799-101-5002 1
1 tester {25, 60, 400, 600 kg/cm2}
Testing and adjusting work
X 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm 2}
equipment PPC oil pressure
799-101-5220 Nipple 1
2 Size: M10 x 1.25
07002-11023 O-ring 1
799-101-5002 1
1 tester {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm 2}
Testing and adjusting work
Y 799-101-5220 Nipple 1 Size: M10 x 1.25
equipment oil pressure 2
07002-11023 O-ring 1 —
Differential pressure
3 799-401-2701 1 —
gauge
Measuring coolant tempera-
– 799-101-1502 Digital thermometer 1 —
ture and oil temperature
Measuring operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
–
and pressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring hydraulic drift of Commercially
– Scale 1 —
stroke available
Measuring work equipment Commercially
– Stopwatch 1 —
speed available
Measuring voltage and Commercially
– Tester 1 —
resistance available
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the controllers,
sensors, actuators, and wiring harnesses, see Troubleshooting, Connectors list and stereogram.
20-12 WA430-6
TESTING AND ADJUSTING TESTING AND ADJUSTING ENGINE SPEED
Testing and adjusting engine 2. Measuring torque converter stall speed

1) Referring to Special function of machine
speed monitor, select the monitoring function in the
k
service mode and display the following 2
Put chocks under the tires.
k
items with the 2-item simultaneous monitor-
When measuring, check that there are no per-
a Monitoring items
ing function.
sons around the machine.
a Measure the engine speed under the following

[1] Code No. 01001: ENG SPEED
[2] Code No. 40100: TC OIL TEMP
condition.
• Coolant temperature:
1. Measuring engine speed (low idle and high

idle)
monitor, select the monitoring function in the
a Monitoring item
service mode and display the engine speed.
Code No. 01001: ENG SPEED

2) Start the engine.
3) Turn the transmission cut-off selector switch
OFF and press the left brake pedal securely.
4) Set the transmission shift mode selector
switch in the MANUAL position.
5) While keeping the directional lever in the N
(Neutral) position, set the gearshift lever in
the 4th position.
6) Release the parking brake.
7) While pressing the brake pedal, set the
directional lever in the F or R position.
k Keep pressing the brake pedal securely.
8) While running the engine at high idle, press
the accelerator pedal gradually. When the
torque converter stalls, measure the engine
2) Start the engine, set it in the measuring con-
a Measure the stall speed 2 – 3 times.
speed.
dition, and measure the engine speed.
a Do not keep stalling the torque converter
for more than 20 seconds. Take care
that the torque converter oil temperature
will not exceed 120°C.
WA430-6 20-13
TESTING AND ADJUSTING TESTING AND ADJUSTING ENGINE SPEED
3. Measuring hydraulic stall speed

monitor, select the monitoring function in the
service mode and display the following 2
items with the 2-item simultaneous monitor-
a Monitoring items
ing function.
[1] Code No. 01001: ENG SPEED

[2] Code No. 04401: HYD TEMP
2) Run the engine at high idle.

3) Relieve the lift arm cylinder or bucket cylin-
der on the extraction side and measure the
engine speed.
4. Measuring torque converter stall and hydrau-

lic stall (full stall) speed
1) Set the machine monitor as in "2. Measuring
torque converter stall speed".
the 4th position.
8) While running the engine at high idle, stall
the torque converter and relieve the lift arm
cylinder or bucket cylinder on the extraction
sid e simu lta n e ou sly a nd m ea su r e the

engine speed at this time.

20-14 WA430-6
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
Measuring exhaust gas color

a Measuring instruments for exhaust gas color
Symbol Part No. Name

1 799-201-9001 Handy smoke checker
A Commercially
2 Smoke meter
available
k When installing and removing the measuring in-
a If an air source and an electric power source are

struments, take care not to touch a hot part.
not available in the field, use handy smoke

checker A1. When recording official data, use
a Measure the exhaust gas color under the follow-

smoke meter A2. 2) Connect the probe hose, receptacle of the
accelerator switch, and air hose to smoke
a Limit the supplied air pressure to 1.5

ing condition. meter A2.
• Engine coolant temperature:
Within operating range MPa {15 kg/cm2}.
3) Connect the power cable to an AC recepta-
a Before connecting the cable, check that

1. Measuring with handy smoke checker A1 cle.
1) Stick a sheet of filter paper to smoke
checker A1. the power switch of the smoke meter is
2) Insert the exhaust gas intake pipe in the turned OFF.
muffler (exhaust pipe). 4) Loosen the cap nut of the suction pump and
a Fit the filter paper securely so that the

3) Run the engine and heighten the engine fit the filter paper.
coolant temperature to the operating range.
4) Accelerate the engine suddenly or run it at exhaust gas will not leak.
high idle and operate the handle of smoke 5) Turn on the power switch of smoke meter
checker A1 so that the filter paper will A2.
absorb the exhaust gas.
6) Start the engine and heighten the engine

5) Remove the filter paper and compare it with coolant temperature to the operating range.
the attached scale. 7) Accelerate the engine suddenly or run it at
6) After finishing measurement, remove the high idle and press the accelerator pedal of
me a s u r in g in s t r u m e n t a n d r e tu r n t h e smoke meter A2 and collect the exhaust
removed parts. gas into the filter paper.
8) Place the contaminated filter paper on the
2. Measuring with smoke meter A2 clean filter paper (at least 10 sheets) in the
1) Insert the probe of smoke meter A2 in the filter paper holder and read the indicated
outlet of the muffler (exhaust pipe) and fix it value.
to the exhaust pipe with a clip. 9) After finishing measurement, remove the
m e a s u r i n g in s t r u me n t a n d r e t u r n t h e
removed parts.
WA430-6 20-15
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
Measuring exhaust
temperature
a Measuring instrument for exhaust temperature

B 799-101-1502 Digital thermometer
k Install and remove the measuring instrument af-
a Measure the exhaust temperature under the fol-

ter the exhaust manifold is cooled.
lowing condition.
4. When measuring the exhaust temperature while
the torque converter is stalled, observe the fol-
lowing procedure.
• To prevent the torque converter from over-
heating, stabilize the exhaust temperature
temporarily by full-stall operation (torque
1. Open the engine left side cover.
converter stall + hydraulic stall), and then
measure the exhaust temperature while only
2. Remove exhaust temperature pickup plug (1)
the torque converter is stalled.
(R1/8).
1) Start the engine and heighten the coolant
temperature to the operating range.
the 4th position.
7) Press the accelerator pedal gradually to the
high idle. While running the engine at high
3. Install sensor [1] of digital thermometer B and idle, stall the torque converter and relieve
a Take care that the wiring harness of the dig-

connect them to meter [2]. the lift arm cylinder or bucket cylinder on the
a Continue this operation until the exhaust

extraction side simultaneously.
ital thermometer will not touch a hot part dur-
ing measurement. temperature reaches about the standard

value of 650°C.

20-16 WA430-6
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
8) After the exhaust temperature is stabilized

about the target level, stop hydraulic relief
and measure the exhaust temperature while
a The exhaust temperature starts lowering

only the torque converter is stalled.
from the level of the full-stall operation.
a If the exhaust temperature does not low-

Record it when it is stabilized.
er but rises, set the temperature high at

the full-stall operation.
5. When measuring maximum exhaust temperature

Operate the machine actually and measure the
a Use the PEAK mode of the thermometer (in

maximum exhaust temperature.
a The exhaust temperature largely depends

which the maximum value can be saved).
on the outside air temperature (intake air

temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it by
a Corrected value [°C] = Measured value + 2 x

the following calculation.
(20 – Outside air temperature)
6. After finishing measurement, remove the mea-

suring instrument and return the removed parts.
WA430-6 20-17
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
Adjusting valve clearance 6. Put bar [1] to the bolt at the end of crank pulley
(7) and rotate the crank pulley forward to set
a Adjusting instrument for valve clearance TDC stamped line (a) on gear cover (8) to
a The No. 1 cylinder is set to the compression

stamped line (b) on the fuel injection pump gear.
Commercially top dead center.
C Thickness gauge
available
1. Open the right and left engine side covers.
2. Remove aftercooler piping (1) and aftercooler

piping bracket (2).
3. Remove muffler brackets (3) and (4).
4. Remove head cover (5).
7. After the No. 1 cylinder is set to the compression

top dead center, make a match mark on the
damper and install a pointer made of a wire, etc.
to gear cover (18).
8. While the No. 1 cylinder is at the compression
marked with q in the valve arrangement draw-

top dead center, adjust the valve clearances
ing.
5. Remove oil feed pipe (6).
20-18 WA430-6
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
9. Rotate the crankshaft forward by 360° and accu-

rately match the match mark made in 7 above
Q.
and measure the valve clearances marked with
a At this time, stamped line (b) on the fuel in-

jection pump gear is matched to stamped
line (c) at the bottom.
10. Insert thickness gauge C in the clearance be-

tween rocker lever (9) and cross head (10).
Then, loosen locknut (12) and adjust the clear-
a With the feeler gauge inserted, turn the ad-

ance with adjustment screw (11).
justment screw to a degree that you can

move the feeler gauge lightly.
11. While securing adjustment screw (11), tighten
3 Locknut: 24 ± 4 Nm {2.45 ± 0.41 kgm}

locknut (12).
a After tightening the locknut, check the valve

clearance again.
WA430-6 20-19
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
Measuring blow-by pressure 8. Press the accelerator pedal gradually to the high
idle. While running the engine at high idle, stall
a Measuring instruments for blow-by pressure the torque converter and measure the blow-by
a Do not keep stalling the torque converter for

pressure.
D 799-201-1504 Blow-by checker more than 20 seconds. Take care that the
torque converter oil temperature will not ex-
a Measure the blow-by pressure under the follow-
a Normally, the blow-by pressure should be
ceed 120°C.
ing condition.
measured while the engine is operated at the
rated output. In the field, however, an ap-
proximate value can be obtained by stalling
a If it is impossible to run the engine at the rat-
the torque converter.
ed output or stall the torque converter, mea-
sure while the engine is running at high idle.
The value obtained in this case is about 80%
1. Stop the engine. Install nozzle [1] and hose [2]
a Precaution for measuring blow-by pressure
of the blow-by pressure at the rated output.
of blow-by checker D to blow-by hose (1) and
connect them to gauge [3].
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, deteri-
oration of oil, high deterioration speed of oil,
etc. which are related to the abnormal blow-
by pressure.
2. Start the engine and heighten the coolant tem-

perature to the operating range.
3. Turn the transmission cut-off selector switch

4. Set the transmission shift mode selector switch

9. After finishing measurement, remove the mea-
in the MANUAL position.
suring instruments and return the removed parts.
5. While keeping the directional lever in the N (Neu-
tral) position, set the gearshift lever in the 4th po-
sition.
6. Release the parking brake.
7. While pressing the brake pedal, set the direction-

al lever in the F or R position.
20-20 WA430-6
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
Measuring engine oil pressure 5. Measure the oil pressure during low idle and high
idle.
a Measuring instruments for engine oil pressure

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
E
2 799-401-2320 Hydraulic tester
3 6732-81-3170 Adapter
a Measure the engine oil pressure under the fol-

lowing condition.
1. Open the engine right side cover. 6. After finishing measurement, remove the mea-
2. Remove engine oil pressure pickup plug (1)
(M10 x 1.0).
3. Install adapter E3 and nipple [1] of hydraulic

tester E1 and connect oil pressure gauge E2
(0.98 MPa {10 kg/cm 2}).
4. Start the engine and heighten the coolant tem-

perature to the operating range.
WA430-6 20-21
TESTING AND ADJUSTING MEASURING INTAKE AIR (BOOST) PRESSURE
Measuring intake air (boost) 3. Start the engine.
pressure 4. Turn the transmission cut-off selector switch
a Measuring instruments for intake air (boost)

pressure 5. Set the transmission shift mode selector switch

in the MANUAL position.
1 799-201-2202 Boost gauge kit
F 6. While keeping the directional lever in the N (Neu-
2 6732-81-3170 Adapter tral) position, set the gearshift lever in the 4th po-
sition.
k When installing and removing the measuring in-
struments, take care not to touch a hot part of 7. Release the parking brake.
a Measure the intake air pressure (boost pressure)

the engine.
8. While pressing the brake pedal, set the direction-
under the following condition. al lever in the F or R position.
• Engine coolant temperature: k Keep pressing the brake pedal securely.
• Hydraulic oil temperature: 9. Press the accelerator pedal gradually to the high
Within operating range idle. While running the engine at high idle, stall
• Torque converter oil temperature: the torque converter and measure the intake air
a Do not keep stalling the torque converter for

Within operating range pressure.
1. Remove intake air pressure pickup plug (1) (M10 more than 20 seconds. Take care that the
x 1.0). torque converter oil temperature will not ex-
ceed 120°C.
2. Install adapter F2 and nipple [1] in boost gauge

kit F1 and connect pressure gauge [2]. 10. After finishing measurement, remove the mea-
20-22 WA430-6
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
Adjusting engine speed

sensor
a If engine speed sensor (1) (E27) or flywheel was
removed and installed, adjust the engine speed
sensor according to the following procedure.
1. Open the engine right side cover.
2. Loosen locknut (3) and screw in engine speed

sensor (1) until its tip touches the tooth tip of fly-
a Before installing the sensor, check that its tip

wheel ring gear (2).
2 Threads: Hydraulic sealant

is free from steel chips and flaws.
3. Return engine speed sensor (1) by 1/2 – 2/3
a After this adjustment, clearance (a) between

turns.
the sensor tip and gear tooth tip is 0.75 –

1.00 mm.
4. While fixing engine speed sensor (1), tighten

locknut (3).
WA430-6 20-23
TESTING AND ADJUSTING TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TEN-
SION
a If the deflection of the belt is abnormal, adjust it

Testing and adjusting air Adjusting
conditioner compressor belt according to the following procedure.

tension
1. Loosen bolts (2) and (3).
Testing
1. Open the engine side cover (left) and remove the 2. Adjust the belt tension by moving air conditioner
a Check for breakage of the pulleys, wear of

belt protection cover (1). compressor (4).
2. Press the intermediate point of the belt between the V-grooves, and contact of the belts and
a If the belt is lengthened to the adjustment

the air conditioner compressor pulley and drive V-grooves.
pulley with a finger and measure deflection (a) of
a Deflection (a) when pressing force is approx. a If the V-belt is replaced, adjust its tension
the belt. limit, cut, or cracked, replace it with new one.
98 N {approx. 10 kg} : 16 – 20 mm again after 1 operating hour.
3. Tighten bots (2) and (3).
4. After finishing adjustment, test the belt tension

again.
20-24 WA430-6
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
Bleeding air from fuel circuit 4) After the engine is started, if it stops
because of unstable condition in it, perform
a If any fuel circuit part (the fuel filter, water sepa- the operation in 2) again, and then start the
rator, etc.) was removed and installed or the fuel engine again.
ran out, bleed air from the fuel circuit according
to the following procedure. 2. Bleeding air after fuel runs out
1) Add at least 40l of fuel to the fuel tank.
1. Bleeding air after fuel filter or water separator 2) Keep the starting switch in the ON position
is removed and installed for 1 minute, and then set it in the OFF posi-
1) If fuel filter (1) or water separator (2) was tion.
removed and installed, bleed air according 3) Repeat the operation in 2) 3 times.
to the following procedure. 4) After keeping the starting switch in the ON
2) Remove fuel filter (1) and fill it with fuel, and position for 1 minute 4 times, start the
then install it again. engine.
5) After the engine is started, if it stops
because of unstable condition in it, perform
the operation in 4) again, and then start the
engine again.
a Fill the fuel filter with clean fuel and take
a Add fuel through inlet ports (a) (8 places)

care that dirt will not enter it.
of the fuel filter. Since hole (b) is the out-

let port (clean side), do not add fuel
a If clean fuel is not available, do not re-

through it.
move the fuel filter but fill it with the fuel

according to the procedure explained in
2 below.
3) Keep the starting switch in the ON position

for 1 minute, and the air is bled from the fuel
circuit automatically.
WA430-6 20-25
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL POTENTIOMETER
Adjusting accelerator pedal

3) Set the pedal to the low idle position and
potentiometer apply DC 5 V to the potentiometer. Turn the
potentiometer to the right or left to set the
Testing tool output voltage in the low idle output voltage
range.
a Operate the pedal 2 – 3 times and check

• Low idle output voltage: 4.1 +0.2–0.1 V
Commercially
G Circuit tester
available
that the output voltage is in the specified
range when the pedal is at the low idle
1. Measuring
position. If the voltage is out of the spec-
Output voltage of accelerator pedal potenti-
a When adjusting the low idle output volt-
ified range, adjust it again.
ometer
1) While running the engine at low idle and
age, operate the pedal 2 – 3 times at a
high idle, measure the output voltage of the
low output voltage position first. Then,
a Connect a T-adapter to accelerator ped-
potentiometer.
turn the potentiometer in the voltage in-
creasing direction to set the output volt-
al potentiometer (L22) and measure the
age in the specified range. Since the
voltage between (1) and ground.
play is made on only one side by this op-
eration, the output voltage is adjusted
easily.
4) Operate the pedal to the high idle position
and check that the output voltage is in the
specified range.
a If the high idle output voltage is out of the

• High idle output voltage: 0.7 ± 0.2 V
specified range, increase or decrease

the low idle output voltage again within
the specified range, and then adjust so
that both low idle and high idle output
voltages will be in the respective speci-
fied ranges.
5) If the high idle output voltage is not set in the
2. Adjusting specified range by the adjustment up to step
Adjusting output voltage of potentiometer 3), pull out pin (4) at the bottom of stopper
1) Remove the potentiometer and check that bolt (3) and turn the stopper bolt to move it
punch mark (2) on the intermediate connec- up or down and set the high idle output volt-
tor (1) between the case and potentiometer
a Set the bolt finally so that pin (4) will be
age in the specified range.
is seen.
2) Put the projected part of the potentiometer
a Since stopper bolt (3) has been adjust-
in the hole at the bottom of the bolt.
in the groove of the intermediate connector
2 Potentiometer mounting face:

and tighten the mounting screw lightly. ed, do not move it unnecessarily.
6) Tighten the potentiometer mounting screw.
2 Potentiometer mounting screw:

CEMEDINE POS SEAL
Adhesive (LT-2)
20-26 WA430-6
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL MICROSWITCH
Adjusting accelerator pedal 4. Installation of case
2 Case mounting face:

1) Install case (1) to body (3).
microswitch
a Apply CEMEDINE POS SEAL to the
CEMEDINE POS SEAL
Testing tool
hatched parts.
Commercially
H Thickness gauge
available
1. Remove the accelerator pedal assembly.
2. Remove case (1).
2 Rod guide mounting face:

2) Install rode guide (7).
CEMEDINE POS SEAL
3. Set rod (2) in contact with body (3) and set guide
(4) in contact with the shoulder of the rod. Then,
insert thickness gauge H between the guide and
bracket and tighten screw (6) so that clearance
(x) between spring guide (4) and bracket (5) will
be in the standard range.
• Clearance (x): 0.1 – 0.2 mm
5. Install accelerator pedal assembly.
WA430-6 20-27
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
3 Nut: 49 – 69 Nm {5.0 – 7.0 kgm}

Adjusting transmission speed 4. Fix sensor (3) with locknut (2).
sensor
a Adjust speed sensor (T19) according to the fol-
lowing procedure.
1. Open cover (1) on the left side of the rear frame.
2. Loosen locknut (2) and screw in sensor (3) until
a Before installing the sensor, check that its tip

its tip touches the tooth tip of gear (4).
2 Threads: Gasket sealant (LG-5)

is free from steel chips and flaws.
a After this adjustment, clearance (a) between

3. Return sensor (3) by 1/2 – 1 turn.
the sensor tip and gear tooth tip is about 1.5

mm.
20-28 WA430-6
TESTING AND ADJUSTING MEASURING DIRECTIONAL LEVER
Measuring directional lever

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 oper-
a Measure the operating effort at each gear

ating direction to measure the operating effort.
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.
WA430-6 20-29
TESTING AND ADJUSTING TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
Testing and adjusting power

train oil pressure
a Testing and adjusting instruments for power train
oil pressure

799-101-5002 Analog hydraulic tester
1
K 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
k Put chocks under the tires.

k Install and remove the measuring instruments
after the oil temperature lowers sufficiently.
a Measure the power train oil pressure under the

following condition.
a Turn the transmission cut-off selector switch

a Open engine side cover (left) and remove the

OFF and use the left brake pedal.
cover on the left side of the rear frame.
Oil pressure measuring point and measuring

gauge
Gauge
No. Measured oil pressure
(MPa {kg/cm2})
1 Main relief pressure 5.9 {60}
2 Torque converter relief pressure 5.9 {60}
3 Torque converter outlet pressure (*) 0.98 {10}
4 Transmission F clutch pressure 5.9 {60}
5 Transmission R clutch pressure 5.9 {60}
6 Transmission 1st clutch pressure 5.9 {60}
7 Transmission 2nd clutch pressure 5.9 {60}
8 Transmission 3rd clutch pressure 5.9 {60}
9 Transmission 4th clutch pressure 5.9 {60}
(*): Measure the torque converter outlet pressure at

the inlet of the torque converter oil cooler.
20-30 WA430-6
Measuring
1. Measuring transmission main relief pressure
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure measuring nipple
a Use the pressure gauge of 2.5 MPa {25

(1).
kg/cm2}.
2) Start the engine and keep the gearshift lever

in the N (Neutral) position.
3) While running the engine at high idle, mea-
sure the oil pressure.
2) Start the engine and keep the gearshift lever

in the N (Neutral) position.
high idle, measure the oil pressure.
4) After finishing measurement, remove the

me as uring in stru men ts a nd retu rn th e
removed parts.
3. Measuring torque converter outlet pressure

1) Remove torque converter oil cooler outlet
pressure measuring plug (3).
mea suring instru men ts a nd re tu rn the
removed parts.
2. Measuring torque converter relief pressure

(inlet pressure)

tester K1 to oil pressure measuring nipple (2).
kg/cm2}.
WA430-6 20-31
2) Connect nipple [2] and oil pressure gauge 2) Connect nipple [2] and oil pressure gauge
a Use the pressure gauge of 0.98 MPa {10 a Use the pressure gauge of 2.5 MPa {25
K2 of hydraulic tester K1. [1] of hydraulic tester K1.
kg/cm 2}. kg/cm2}.
3) Start the engine and keep the gearshift lever 3) Press the brake pedal.
in the N (Neutral) position. 4) Start the engine and turn the parking brake
4) While running the engine at high idle, mea- switch OFF.
sure the oil pressure. 5) Set the transmission shift mode selector
the 4th position.
directional lever in the F position.
sure the F clutch oil pressure.

mea su rin g ins tr ume nts an d re turn the
removed parts.
4. Measuring transmission F clutch oil pressure

1) Remove transmission F clutch oil pressure
measuring plug (4).

mea sur in g instru men ts a nd re turn the
removed parts.
20-32 WA430-6
5. Measuring transmission R clutch oil pres-

sure
1) Remove transmission R clutch oil pressure
measuring plug (5).

removed parts.
2) Connect nipple [2] and oil pressure gauge 6. Measuring transmission 1st clutch oil pres-

[1] of hydraulic tester K1. sure
1) Remove transmission 1st clutch oil pressure
kg/cm2}. measuring plug (6).
3) Press the brake pedal. 2) Connect nipple [2] and oil pressure gauge

4) Start the engine and turn the parking brake [1] of hydraulic tester K1.
switch OFF.
5) Set the transmission shift mode selector kg/cm2}.
the 4th position.
directional lever in the R position.
sure the R clutch oil pressure.
3) Press the brake pedal.

WA430-6 20-33

the 1st position.
pressing the brake pedal, set the directional
lever in the F or R position and then return it
a If the directional lever is in neutral, the

to the N (Neutral) position.
gear speed is not changed even if the

gearshift lever is moved. To avoid this,
perform the above operation.
sure the 1st clutch oil pressure. 3) Press the brake pedal.
the 2nd position.


10) After finishing measurement, remove the perform the above operation.
mea su rin g ins tr ume nts an d re turn the k Keep pressing the brake pedal securely.
removed parts. 9) While running the engine at high idle, mea-
sure the 2nd clutch oil pressure.
7. Measuring transmission 2nd clutch oil pres-
sure
1) Remove transmission 2nd clutch oil pres-
sure measuring plug (7).

removed parts.
2) Connect nipple [2] and oil pressure gauge

[1] of hydraulic tester K1.
kg/cm 2}.
20-34 WA430-6
8. Measuring transmission 3rd clutch oil pres-

sure
1) Remove transmission 3rd clutch oil pres-
sure measuring plug (8).

removed parts.
2) Connect nipple [2] and oil pressure gauge 9. Measuring transmission 4th clutch oil pres-

[1] of hydraulic tester K1. sure
1) Remove transmission 4th clutch oil pressure
kg/cm2}. measuring plug (9).
3) Press the brake pedal. 2) Connect nipple [2] and oil pressure gauge

4) Start the engine. [1] of hydraulic tester K1.
switch in the MANUAL position. kg/cm2}.
the 3rd position.


sure the 3rd clutch oil pressure. 3) Press the brake pedal.
WA430-6 20-35
6) While keeping the directional lever in the N Adjusting

(Neutral) position, set the gearshift lever in 1. Adjusting transmission main relief valve
the 4th position. k When adjusting the main relief valve, stop
a If the transmission main relief pressure is out

7) Release the parking brake. the engine.
pressing the brake pedal, set the directional of the specified range, adjust it according to
lever in the F or R position and then return it the following procedure.

to the N (Neutral) position. 1) Remove plug (10).

sure the 4th clutch oil pressure.
2) Remove inner spring (11) and outer spring

(12).
3) Adjust the main relief pressure by changing
a Standard shim thickness:

the number of shims (13).
a Quantity of adjustment per shim:

0.5 mm (0.5 x 1 piece)
10) After finishing measurement, remove the 0.04 MPa {0.4 kg/cm2}
mea su rin g ins tr ume nts an d re turn the
removed parts.
20-36 WA430-6
2. Adjusting torque converter main relief valve

k When adjusting the torque converter main
a If the torque converter relief pressure (inlet

relief valve, stop the engine.
pressure) is out of the specified range, adjust

it according to the following procedure.
1) Remove plug (14).
2) Remove valve spool (15).

3) Adjust the torque converter relief pressure
a Standard shim thickness:

by changing the number of shims (16).
a Quantity of adjustment per shim:

0.5 mm (0.5 x 1 piece)
0.04 MPa {0.4 kg/cm2}
WA430-6 20-37
TESTING AND ADJUSTING FLUSHING PROCEDURE FOR TORQUE CONVERTER AND TRANSMISSION
HYDRAULIC CIRCUIT
Flushing procedure for torque 3. Fill the transmission case with oil.
• Add oil through oil filler (3) to the specified
converter and transmission level. Run the engine to circulate the oil
hydraulic circuit through the system. Then, check the oil level
a Metal chips and dirt in the torque converter and

again.
5
54 l (Refill capacity)
transmission hydraulic circuit shorten the lives of Transmission case:
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 transmission
is overhauled or repaired.
2. Install a new filter cartridge.

1) Open inspection cover (1) on the left side of
the rear frame. 4. Flush the hydraulic circuit according to the fol-
lowing procedure.
1) Start the engine and run it at low idle without
operating the gearshift lever or directional
a Increase the engine speed to about

lever for about 20 minutes.
a If the engine coolant temperature gauge

1,500 rpm sometimes.
does not rise to the operating range be-

cause of low atmospheric temperature,
continue the warm-up operation further.
2) Operate or drive the machine for at least 20
a Use all the gear speeds (Forward, re-

minutes.
verse, and 1st – 4th).

2) Drain the oil from the filter piping. 3) Run the engine at low idle for about 20
3) Remove transmission oil filter cartridge (2) minute, similarly to 4-1).
and install cartridge (714-07-28712).
5. Replace the filter cartridge.
1) Replace cartridge (1) used for flushing with
new cartridge (714-07-28712), similarly to 2.
k If the cartridge used for flushing is used
for long hours, it is clogged quickly. Ac-
cordingly, be sure to replace it with new
one.
2) Add oil and check the oil level again.
20-38 WA430-6
TESTING AND ADJUSTING METHOD OF MOVING MACHINE WHEN TRANSMISSION VALVE IS BROKEN
Method of moving machine 2. Disconnect wiring connector (2) from each ECMV.
(12 places)
when transmission valve is
broken
a Device for moving machine when transmission
valve is broken

L 794-423-1190 Plug
a Even if you cannot move the machine because of

breakage of a transmission valve part (electrical
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 Arrangement of ECMV's

move the machine from a dangerous job site to
a safety place where you can repair it when you
cannot move it at any gear speed because of
breakage of the transmission control valve. Ac-
cordingly, use this method only when the trans-
mission control valve is broken.
k When moving the machine by this method, ob-
serve the procedure and take care of safety.
k Lower the work equipment to the ground fully,
apply the parking brake, and put chocks under
the tires so that the machine will not move.
k When working, stop the engine.
k When working while the oil temperature is still
high, take care not to burn your body.
1. Remove cover (1) on the left side of the rear
a Remove mud and dirt from around the ECMV.

frame.
WA430-6 20-39
TESTING AND ADJUSTING METHOD OF MOVING MACHINE WHEN TRANSMISSION VALVE IS BROKEN
3. Remove proper 2 ECMV solenoids (3), depend- 4. Press the brake pedal securely.
ing on the moving direction of the machine (for-
ward or reverse) and install plugs L. 5. Start the engine and release the parking brake
a If the parking brake cannot be released be-

• For forward travel: gradually to start and move the machine.
F solenoid and 2nd solenoid
• For reverse travel: cause of a trouble in the electrical system,
a If a wrong solenoid is removed, the transmis-

R solenoid and 2nd solenoid see "Method of releasing parking brake man-
ually".
k Remove the chocks.
a Install each plug L with its projection side to-
sion may be broken. Take care.
k If the engine is started, the transmission is
ward the ECMV. Check that the O-ring is fit- engaged and the machine starts immedi-
a Take care that mud or dirt will not enter the

ted to the mating face. ately. Accordingly, when starting the en-
gine, check the moving direction of the
removed solenoids and valves. machine and secure safety around the ma-
chine thoroughly and keep pressing the
brake pedal.
k After moving the machine, stop the engine,
apply the parking brake, and put chocks un-
der the tires.
6. After moving the machine, remove the devices

and return the removed parts.
20-40 WA430-6
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING CONTROL
Testing and adjusting steering

control
a Measurement conditions
• Hydraulic oil temperature: Within operating range
• Engine speed: 1,200 rpm
• Road surface: Flat, horizontal, dry paved surface
• Tire inflation pressure: Standard presure
Testing
1. Start the engine, operate the steering wheel, and
set the front and rear frames straight.
2. Check the looseness of locknut (2), or stopper
bolt (1).
3. Start the eigine and measure clearance between
the front frame and rear frame stopper when the
a When measureing the clearance, check that

steering wheel is turned fully to the left and right.
the end face of the spool of stop valve (3) is

in contact with the head of the stopper bolt.
Adjusting
1. Adjust the stopper bolt.
1) Screw in stopper bolt (1) to make it the mini-
mum length.
2) Run the engine at low idle and operate the
steering slowly to contact the frame stopper.
3) Turn the stopper bolt until the head of stop-
per bolt (1) contacts the end face of the
spool of the stop valve (3).
4) Set the machine facing straight, and stop
the engine.
5) Loosen stopper bolt (1) 8.5 turns, then lock
it in position with locknut (2).
6) Carry out steps 1) thru 5) for both the left
and right sides.
2. Start the engine and measure clearance "a" be-

tween the front frame and rear frame stopper
when the steering wheel is turned fully to the left
a When measuring the clearance, check that

and right.
the end face of the spool of stop valve (3) is

in contact with the head of the stopper bolt.
WA430-6 20-41
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL
Testing and adjusting steering Measuring operating effort of steering wheel
wheel a Measure the operating effort of the steering
a Testing and adjusting device for steering wheel

wheel under the following condition.
• Road: Flat, level, paved, and dry road
M 79A-264-0021 Push-pull scale
Measuring play of steering wheel • Tire inflation pressure: Specified pressure
a Measure the play of the steering wheel under the

• Engine speed: Low idle (No load on bucket)
following condition. Measuring method

• Engine: Stopped 1. Install push-pull scale M to the steering wheel
• Position of machine: Straight travel position
a Install push-pull scale M to the center.
knob.
Measuring method
1. Move the steering wheel to the right and left 2 –
a After starting the engine, raise the bucket
3 times and check that the steering mechanism
is in neutral, and then make mark (A) on the ma- about 400 mm and release the safety lever.
chine monitor frame.
3. Pull push-pull scale M in the tangential direction
2. Turn the steering wheel to the right and make and read it while the steering wheel is moving
mark (B) at a position where the operating effort
a The operating effort is not the value indicat-
smoothly.
becomes heavy.
ed when the steering wheel starts moving.
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 dis-
tance between marks (B) and (C).
20-42 WA430-6
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL
Measuring operating time of steering wheel
a Measure the operating time of the steering wheel

under the following condition.
• Tire inflation pressure: Specified pressure
• Engine speed: Low idle and high idle
Measuring method
a After starting the engine, raise the bucket

about 400 mm and release the safety lever.
2. Turn the steering wheel to the right or left stroke

end.
3. Turn the steering wheel to the right or left stroke
a Do not turn the steering wheel forcibly but

end and measure the full-stroke time.
turn it at the speed of 60 revolutions per
a While running the engine at low idle and high

minute.
idle, measure the time to turn the steering

wheel to the right and left respectively.
WA430-6 20-43
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING OIL PRESSURE
Testing and adjusting steering

oil pressure
Measuring instruments

1
N
799-101-5220 Nipple (M10 x 1.25)
2
07002-11023 O-ring
a Measure the steering oil pressure under the fol-

lowing condition.
Measuring
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.
1. Steering relief pressure

1) Apply safety bar (1) to the frame.
removed parts.

tester N1 to steering circuit oil pressure
pickup nipple (2) on the left steering cylinder
a Use the oil pressure gauge of 39.2 MPa

head side.
{400 kg/cm2}.
3) Run the engine at high idle and turn the
steering wheel to the left. When the relief
a If the oil pressure pickup plug on the

valve operates, measure the oil pressure.
right steering cylinder head side is re-

moved, install nipple N2 and connect oil
pressure gauge [1] of hydraulic tester
N1, and then turn the steering wheel to
the right and measure the oil pressure.
20-44 WA430-6
a Before testing and adjusting the steering

2. Steering control circuit pressure
control circuit pressure, check that the steer-

ing relief pressure is normal.
k Loosen the oil filler cap of the hydraulic tank
to release the internal pressure of the hy-
draulic tank, then operate the steering
wheel 2 – 3 times to release the residual
pressure from the piping.
1) Remove the steering control circuit pressure
pickup plug (M10 x 1.25) (3) of steering
valve (2).

removed parts.
2) Connect nipple N2 (M10 x 1.25) and oil

pressure gauge [1] of hydraulic tester N1.
{60 kg/cm2}.
3) Start the engine and keep the steering

wheel in neutral and measure the oil pres-
sure at low idle.
Engine speed Steering control circuit pressure

Steering control pressure
Low idle
(See standard values table)
WA430-6 20-45
Adjusting 3. Adjusting steering control circuit pressure

k When adjusting the oil pressure, be sure to stop 1) Remove the floor frame assembly. For
the engine. details, see Disassembly and assembly,
Removal and installation of floor frame
1. Adjusting steering relief pressure assembly.
1) If the steering relief pressure is abnormal, 2) Remove servo assembly (9) from steering
adjust steering relief valve (5) of steering pump assembly (8) and replace it.
valve assembly (4) according to the follow-
ing procedure.
2. Loosen locknut (6) and turn adjustment screw (7)
a If the adjustment screw is

to adjust the pressure.
• turned to the right, the pressure rises.
a Quantity of adjustment per turn of adjust-

• turned to the left, the pressure lowers.
3 Locknut:
ment screw: 14.4 MPa {147 kg/cm2}
a If the relief pressure cannot be measured ac-

26.4 – 30 Nm {2.7 – 3.1 kgm}
curately, do not adjust it.
20-46 WA430-6
TESTING AND ADJUSTING BLEEDING AIR FROM STEERING CIRCUIT
Bleeding air from steering

circuit
a If the steering valve or the steering cylinder was
removed and installed, bleed air from the steer-
ing circuit according to the following procedure.
1. Run the engine idle for about 5 minutes.
2. While running the engine at low idle, steer the
a Stop the piston rod about 100 mm before

machine to the right and left 4 – 5 times.
each stroke end and take care not to relieve

the circuit.
3. While running the engine at high idle, perform the

operation of 2.
4. While running the engine at low idle, move the

piston rod to the stroke end and relieve the cir-
cuit.
WA430-6 20-47
TESTING AND ADJUSTING TESTING HYDRAULIC DRIVE FAN
Testing hydraulic drive fan Tachometer kit P1
a Testing tools for hydraulic drive fan

1 799-205-1100 Tachometer kit
2
P 790-261-1204 Digital hydraulic tester
799-101-5220 Nipple (M10 x 1.25)
3
07002-11023 O-ring
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 3) While running the engine at high idle and
of the hydraulic tank to release the internal pres- low idle, measure the fan speed.
a Measurement condition
sure of the tank. 4) After finishing measurement, remove the
• Engine coolant temperature: Min. 95°C removed parts.
• Hydraulic oil temperature: Min. 95°C
• Torque converter oil temperature: Min. 105°C 2. Measuring fan drive oil pressure
1) Open the radiator grille.
1. Measuring fan speed 2) Remove covers (3) and (4).
1) Open radiator grille (1).
3) Remove fan drive oil pressure pickup plug

2) Set probe [2] to stand [1] of tachometer kit (M10 x 1.25) (6) from the elbow of fan motor
P1 and stick reflection tape [3] to the fan. (5).
20-48 WA430-6
TESTING AND ADJUSTING TESTING HYDRAULIC DRIVE FAN
4) Connect nipple P3 (M10 x 1.25) and oil 3) Remove fan reverse solenoid output pres-

pressure gauge [1] of hydraulic tester P2. sure pickup plug (M10 x 1.25) (7).
{400 kg/cm2}.
4) Connect nipple P3 (M10 x 1.25) and oil

pressure gauge [1] of hydraulic tester P2.
sure the fan drive oil pressure. {400 kg/cm2}.
3. Measuring fan reverse solenoid output pres- 5) Turn the cooling fan reverse switch ON.
sure 6) While running the engine at high idle, measure
a Measure the fan forward and reverse

1) Open the radiator grille. the fan reverse solenoid drive oil pressure.
2) Remove covers (3) and (4).
drive oil pressures. When the fan is re-
versed, check that the solenoid operates
and the specified oil pressure is applied.

removed parts.
WA430-6 20-49
TESTING AND ADJUSTING BLEEDING AIR FROM FAN MOTOR CIRCUIT
Bleeding air from fan motor 3. Remove fan drive oil pressure pickup plug (M10
x 1.25) (5) from the elbow of fan motor (4).
circuit
a Air bleeding tools for fan motor circuit

1
Q 799-101-5220 Nipple (M10 x 1.25)
2
07002-11023 O-ring
3 790-261-1130 Coupling
1. Open radiator grille (1).
4. Install nipple Q2 (M10 x 1.25), connect hose [1]

of hydraulic tester Q1, and connect air bleeder
a Put the outlet end of the hose in an oil receiv-

coupling Q3 to the outlet end of the hose.
er.
2. Remove covers (2) and (3).
5. Run the engine. When the oil flows out of the

outlet end of the hose, stop the engine.
6. After finishing bleeding air, remove the tools and
return the removed parts.
20-50 WA430-6
TESTING AND ADJUSTING MEASURING BRAKE PEDAL
Measuring brake pedal

• Engine: Low idle
Measuring pressing angle of pedal
a Set the push gauge to 150 mm from the ful-

1. Install push gauge [1] to the foot of the measurer.
crum 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 pressing angle a2 from pressing angle
a1 to pressing angle a3 (a2 = a1 – a3).
• a2: Pressing angle when pressing force is
321 ± 32.1 N {32.8 ± 3.3 kg}
WA430-6 20-51
TESTING AND ADJUSTING MEASURING BRAKE PERFORMANCE
Measuring brake performance
a Measure the brake performance under the fol-

lowing condition.
• Braking initial speed: 35 km/h
• Tire size: 23.5-25
• Brake pedal pressing force:
Specified pressing force
321 ± 32.1 N {32.8 ± 3.3 kg}
• Pressing time lag: 0.1 second
Measuring method
1. Start the engine and drive the machine.
2. Set the gear speed selector switch in the 4th po-
sition and run up.
3. When the travel speed becomes the braking ini-
tial speed of 35 km/h, press the left brake pedal
a Decide the approach course and braking

with the specified force.
point in advance and apply the brake at that

braking point.
4. Measure the distance from the braking point to
a Perform the above measurement 3 times

the stop point.
and obtain the average.
20-52 WA430-6
TESTING AND ADJUSTING TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
Testing and adjusting

accumulator charge pressure
a Testing and adjusting instruments for accumula-
tor charge pressure

R
a Measure the accumulator charge pressure under

the following condition.
Within operating range 4. After finishing measurement, remove the mea-
• Hydraulic oil temperature: suring instruments and return the removed parts.
k Put chocks under the tires securely.
k While the engine is stopped, press the brake
a If the accumulator charge cut-out pressure is ad-
Adjusting
pedal at least 100 times to release the pressure justed, the cut-in pressure changes according to
from the accumulator circuit. the valve area ratio.
Measuring 1. Loosen locknut (3) of unload relief valve (accu-

1. Connect oil pressure gauge [1] of hydraulic tester mulator charge cut-out valve) (2) and turn adjust-
R to accumulator charge pressure pickup plug
ment screw (4) to adjust the pressure.
a Use the oil pressure gauge of 39.2 MPa {400

(2) of accumulator charge valve (1).
• turned to the right, the pressure rises.
kg/cm2}.
• turned to the left, the pressure lowers.
3 Locknut:
ment screw: 1.45 MPa {14.8 kg/cm2}
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 moni-
a Cut-in pressure:
tor panel goes off, measure the oil pressure.
a After finishing measurement, check the ac-
5.9 +0.5
–0 MPa {60 +5
–0 kg/cm }
2
cumulator charge cut-in and cut-out pres-
s ures again ac cording to the abov e
3. Measure the accumulator charge cut-out pres- measurement procedure.
sure. After the accumulator charge cut-in opera-
tion, the rising oil pre ssu re ga uge lowers
a Cut-out pressure:
suddenly. Measure the oil pressure at this time.
+0.98 +10
9.8 –0 MPa {100 –10 kg/cm2}
WA430-6 20-53
TESTING AND ADJUSTING TESTING WHEEL BRAKE OIL PRESSURE
Testing wheel brake oil

pressure
a Measuring tools for wheel brake oil pressure

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
a Bleed air by operating pump S3.

4. Loosen bleeder screw (3) to bleed air.
k Apply the parking brake and put chocks under
a Measure the oil pressure of the front brakes

the tires securely.
(right and left) and rear brakes (right and left)
a Measure the wheel brake oil pressure under the

similarly.
following condition.
1. Stop the engine.
2. Remove brake tube (1) of the measured side.

5. Tighten bleeder screw (3). Operate pump S3
3. Remove union (2) and install adapter S4 and nip- and raise the pressure to 4.9 MPa {50 kg/cm2},
a Use the O-ring fitted to the union.

ple S5, and then install brake test kit S1. and then tighten stop valve [1].
20-54 WA430-6
TESTING AND ADJUSTING TESTING WHEEL BRAKE OIL PRESSURE
6. Leave the brake circuit pressurized for 5 minutes
a If the hose is moved while the pressure is

and check lowering of the pressure.
measured, the pressure fluctuates. Accord-
a After testing the pressure, operate pump S3

ingly, do not move the hose.
to lower the pressure in brake test kit S1, and
a After finishing testing, install the brake tube

then remove brake test kit S1.
a After finishing testing, remove the measuring

and bleed air from the brake circuit.
instruments and return the removed parts.
Brake test kit S
WA430-6 20-55
TESTING AND ADJUSTING MEASURING WEAR OF WHEEL BRAKE DISC
Measuring wear of wheel

brake disc
Commercially
T Slide calipers
available
k Stop the machine on a level place and put

chocks under the tires.
1. Remove cap (1).
3 Cap (1):
4. After testing, return cap (1).
2. Lightly press the brake pedal to the stroke end. 29.4 – 39.2 Nm {3.0 – 4.0 kgm}
3. While shaft (2) is pushed in, measure projection
a Keep pressing the brake pedal during mea-

(x) from guide (3) (the wear).
a If shaft (2) is projected from the end of guide

surement.
(3) to the groove on it, replace the disc.

• Wear : (x)
• Wear limit : (y) (2.4 mm)
20-56 WA430-6
TESTING AND ADJUSTING BLEEDING AIR FROM WHEEL BRAKE CIRCUIT
Bleeding air from wheel brake Releasing residual pressure in

circuit brake accumulator circuit
k Stop the machine on a level place and put k When disconnecting any of the following brake
a If a brake circuit part is removed and installed,

chocks under the tires. accumulator pipes, release the residual pres-
sure in that brake circuit.
bleed air from the brake circuit according to the
a Bleed air from the front brake circuit and rear

following procedure. • Pipe between accumulator charge valve and
brake accumulator
brake circuit similarly (2 places each). • Pipe between accumulator charge valve and
parking brake solenoid valve
1. Raise the lift arm and set a stand to it, and then • Pipe between brake accumulator and brake
remove front frame inspection cover (1). valve
1. Stop the engine.
2. Press the brake pedal at least 100 times to re-

lease the pressure from the brake accumulator
circuit.
2. Connect one end of air bleeder hose [1] to bleed-

er screw (2) and put the other end in a container.
3. Run the engine at low idle.
4. Keep pressing the brake pedal.
5. Loosen bleeder screw (2) about 1/2 turn to drain

oil containing bubbles.
6. When oil containing no bubbles flows out, tighten
3 Bleeder screw: 10 – 20 Nm {1 – 2 kgm}

bleeder screw (2).
7. After finishing bleeding air, run the engine at low

idle and check the oil level in the hydraulic tank,
and then add new oil if necessary.
WA430-6 20-57
TESTING AND ADJUSTING TESTING PARKING BRAKE PERFORMANCE
Testing parking brake

performance
• Road: 1/5 gradient (11° 20'), flat, and dry road
• Machine: Ready for operation
Measuring method
1. Start the engine and set the machine in the
straight travel position, and then drive up a slope
of 1/5 gradient with no load in the bucket.
2. Press the brake to stop the machine, set the di-

rectional lever in the N position, and stop the en-
gine.
3. Turn the parking brake switch ON (to park), and

then release the brake gradually. At this time,
a When the engine is stopped, the parking

the machine must not move.
a Measure the parking brake performance on

brake is turned ON (to park) automatically.
an uphill and a downhill.
20-58 WA430-6
TESTING AND ADJUSTING MEASURING PARKING BRAKE OIL PRESSURE
Measuring parking brake oil

pressure
a Measuring instruments for parking brake oil pres-
sure

1
U 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (Size 02)
k Put chocks under the tires.

k Install and remove the measuring instruments
after the oil temperature lowers fully. 3) Connect nipple [2] of hydraulic tester U1
a Measure the parking brake oil pressure under a Use the oil pressure gauge of 5.9 MPa
and oil pressure gauge [1].
the following condition. {60 kg/cm2}.

• Engine coolant temperature: Within operating range
• Power train oil temperature: Within operating range
• Parking brake: OFF
1. Parking brake oil pressure (Parking brake so-

lenoid valve output pressure)
1) Remove rear frame left side cover (1).
4) While running the engine at low idle, mea-

sure the parking brake oil pressure.
2) Remove parking brake oil pressure pickup

plug (R1/8) (2).

removed parts.
WA430-6 20-59
TESTING AND ADJUSTING MEASURING PARKING BRAKE OIL PRESSURE
2. Parking brake solenoid valve basic pressure 4) While running the engine at low idle, mea-
1) Open rear frame left side cover (1). sure the parking brake solenoid valve basic
pressure.
k Keep pressing the brake pedal for safety.
2) Disconnect parking brake solenoid valve

basic pressure hose (3).
removed parts.
3) Install adapter U2 and connect nipple [2]

and oil pressure gauge [1] of hydraulic

tester U1.
{60 kg/cm2}.
20-60 WA430-6
TESTING AND ADJUSTING TESTING WEAR OF PARKING BRAKE DISC
Testing wear of parking brake 4. If depth (a) is above the standard, remove park-
ing brake disc (4) and measure its thickness W,
disc referring to Disassembly and assembly, Remov-
al of parking brake disc.
Measuring tool
a If the parking brake disc thickness is below
• Service limit thickness W: 2.97 mm
the service limit, replace the disc.
Commercially
V Slide calipers
available
a If the parking brake does not work perfectly,

check the parking brake disc for wear according
to the following procedure.
k Lower the work equipment fully and put chocks
under the tires.
k When checking, stop the engine.
1. Drain the oil from the transmission case.
6 Transmission case: 62 l
2. Remove either of 2 plugs (1).
3. Measure depth (a) from the end of cage (2) to

piston (3) with slide calipers V.
• Standard depth (a): Max. 42.3 mm
WA430-6 20-61
TESTING AND ADJUSTING METHOD OF RELEASING PARKING BRAKE MANUALLY
Method of releasing parking 2. Remove 2 cage mounting bolts (2) and screw
a Remove 2 bolts (2) at the diagonal positions.

them in plug (1) holes alternately.
brake manually
a Tighten 2 bolts (2) to pull piston (3) and re-
a The parking brake is controlled hydraulically. If
a Tighten the 2 bolts gradually and evenly.
lease the parking brake.
you cannot release the parking brake because of
a trouble in the transmission, emergency release (After they reach the seats, give about 4
solenoid valve, etc., you can move the machine turns further to them.)
by releasing the parking brake manually.
k Releasing the parking brake manually is a

means to move the machine from a dangerous
job site to a safe place. Apply this means only in
an emergency.
k Lower the work equipment to the ground and put
chocks under the tires to prevent the machine
from moving.
k When applying this means, stop the engine.
a Prepare an oil container to receive oil of

1. Remove 2 plugs (1). (Right and left)
a After releasing the parking brake, apply gas-

about 20l flowing out of the plug hole.
ket sealant (LG-5) to the plug and tighten it. • Refilling with oil (Transmission case)
After releasing the parking brake manually, 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.
20-62 WA430-6
TESTING AND ADJUSTING MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER
Measuring and adjusting work 2. Stroke of work equipment control lever

1) Operate the work equipment control lever
equipment control lever
a Make a mark on the lever knob and mea-
and measure its stroke at each position.
a Measuring and adjusting tools for work equip-

a If the stroke is out of the standard range,
sure the stroke with scale W2.
ment control lever
check for play of the linkage and wear of
the bushing.
1 79A-264-0021 Push-pull scale
W Commercially
2 Scale
available
a Measure and test the work equipment control le-

ver under the following condition.
• Engine speed: Low idle
k Apply the safety bar to the frame.
Measuring
1. Operating effort of work equipment control
lever
1) Fix tool W1 to the work equipment control
a Install tool W1 to the center of the knob.

lever.
a Operate the work equipment control le-

ver at the ordinary operating speed and
measure the minimum necessary effort
to operate the knob.
WA430-6 20-63
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE
Testing and adjusting work 3) Connect nipple X2 and oil pressure gauge

[1] of hydraulic tester X1.
a Testing and adjusting instruments for work
{60 kg/cm2}.

1
X
799-101-5220 Nipple (M10 x 1.25)
2
07002-11023 O-ring
k Loosen the oil filler cap of the hydraulic tank to

release the internal pressure of the hydraulic
tank
k Operate the work equipment control lever 2 – 3
times to release the pressure from the PPC ac-
cumulator circuit. 4) While running the engine at high idle, oper-
a Measure the work equipment PPC oil pressure

• Turn the steering wheel to the right end. ate the work equipment control lever and
measure the PPC basic pressure.
under the following condition.
Measuring
1. PPC valve basic pressure

removed parts.
2. Measuring PPC valve output pressure

1) Raise the lift arm and set a stand to it, and
2) Remove oil pressure pickup plug (3) (M10 x then remove front frame inspection cover
1.25) from the underside of PPC accumula- (4).
tor (2).
20-64 WA430-6
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE
2) Remove the oil pressure pickup plug (M10 x 4) While running the engine at high idle, oper-
a A : Attachment
1.25) (5) of the measured PPC circuit. ate the work equipment control lever and
measure the PPC valve output pressure.
B : Attachment
C : Tilt bucket
D : Dump bucket
E : Raise lift arm
F : Lower and float lift arm

removed parts.
a The PPC relief valve is not adjustable.

Adjusting
a If the PPC oil pressure is out of the standard

range, remove PPC relief valve cartridge assem-
bly (7) from accumulator charge valve assembly
3 PPC relief valve cartridge assembly:

(6) and replace it.
a After replacing the cartridge assembly, measure

25 – 33.9 Nm {2.6 – 3.5 kgm}
the PPC oil pressure again.
3) Connect nipple X2 and oil pressure gauge

[1] of hydraulic tester X1.
{60 kg/cm2}.
WA430-6 20-65
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
Testing and adjusting work 3) Remove front frame inspection cover (1).
equipment oil pressure

a Testing and adjusting instruments for work
equipment oil pressure

1
799-101-5220 Nipple (M10 x 1.25)
Y 2
07002-11023 O-ring
Differential pressure
3 799-401-2701
gauge
a Measure the work equipment oil pressure under 2. Measuring work equipment relief pressure
the following condition. 1) Remove pump pressure pickup plug (M10 x
• Hydraulic oil temperature: Within operating range 1.25) (2) from the work equipment control
valve.
a Note that different actuators relieve different

Combination of actuator and valve
a The No. of each actuator in the following table

valves.
shows the order from the top, when the control

valve is seen from the front of the machine. (The
service actuator is used when 1 attachment is in-
stalled.)
No. Actuator Relieved valve

1 Service Safety valve
2 Bucket Main relief valve
3 Lift arm Main relief valve
1. Preparation work 2) Connect nipple Y2 and oil pressure gauge

1) Raise part (a) of the bucket about 30 – 50 [1] of hydraulic tester Y1.
mm and lower part (b) to the ground.
2) Stop the engine and operate the work equip- {400 kg/cm2}.
ment control lever to check that both parts
(a) and (b) of the bucket are in contact with
a After lowering the bucket to the ground,

the ground.
operate the work equipment control le-

ver 2 – 3 times to release the residual
pressure in the piping.
20-66 WA430-6
3) Start the engine and raise the lift arm about 3. Measuring unload pressure
400 mm. Then, while running the engine at 1) Remove pump pressure pickup plug (M10 x
high idle and tilting back the bucket, mea- 1.25) (2) from the work equipment control valve.
sure the oil pressure.
2) Connect nipple Y2 and oil pressure gauge

k
After measuring the oil pressure, release [1] of hydraulic tester Y1.
the pressure in the circuit according to
the procedure for installing the nipple {60 kg/cm2}.
and oil pressure gauge, and then re-
move the oil pressure gauge and nipple.
3) Start the engine and raise the lift arm about

400 mm. Then, while running the engine at
high idle, set all the levers in neutral and
measure the oil pressure.
k After measuring the oil pressure, release

the pressure in the circuit according to
the procedure for installing the nipple
and oil pressure gauge, and then re-
move the oil pressure gauge and nipple.
WA430-6 20-67
4. Measuring work equipment LS differential
a Before measuring the LS control circuit pres-

pressure 3) Start the engine and raise the lift arm about
400 mm.
sure, check that the work equipment relief 4) While running the engine at high idle, when
pressure and work equipment PPC oil pres- the following condition is satisfied, measure
a To obtain the LS differential pressure, mea-

sure are normal. the pump pressure and LS pressure (actua-
tor load pressure) simultaneously.
sure the pump discharge pressure and LS • When all the levers are in neutral and
a While measuring, take care not to move

pressure simultaneously and calculate the when the lift arm lever is moved halfway
difference between them.
a Calculation of LS differential pressure:

1) Remove pump pressure pickup plug (M10 x the lift arm cylinder to the stroke end.
1.25) (2) and LS pressure pickup plug (M10
x 1.25) (3) from the work equipment control LS differential pressure = Pump dis-
a If the LS differential pressure is as fol-

valve. charge pressure – LS pressure
lows, it is normal.
Position of lever LS differential pressure

Unload pressure (See standard
All levers in neutral
value table)
Lift arm lever in Specified LS differential pressure
half stroke (See standard value table)
2) Install nipple Y2 and connect oil pressure

gauge [1] or differential pressure gauge Y3
a When using differential pressure gauge,

of hydraulic tester Y1.
connect the high pressure side to the

pump pressure side and connect the low
pressure side to the LS pressure side.
Since the differential pressure gauge
needs a 12-V power source, connect it to
a When using oil pressure gauge, use the

a battery. 5) After finishing measurement, remove the
oil pressure gauge of 39.2 MPa {400 kg/ removed parts.
cm2}. k After measuring the oil pressure, release
Since the differential pressure is about the pressure in the circuit according to
2.4 MPa {25 kg/cm2} at maximum, mea- the procedure for installing the nipple
sure it by installing the same gauge to and oil pressure gauge, and then re-
the pickup plugs alternately. move the oil pressure gauge and nipple.
20-68 WA430-6
Adjusting
a The unload valve is not adjustable.
1. Adjusting work equipment (lift arm and buck-

et) main relief valve
1) Adjust main relief valve (6) from work equip-
ment control valve (5).
2) Loosen locknut (7) and turn adjustment

screw (8) to adjust the pressure.
• turned to the right, the pressure ris-

es.
• turned to the left, the pressure low-

ers.
3 Locknut: 29 – 39 Nm {3 – 4 kgm}
ment screw: 12.6 MPa {128 kg/cm 2}
a After finishing measurement, measure

the work equipment relief valve accord-
ing to the above measurement proce-
dure.
WA430-6 20-69
TESTING AND ADJUSTING BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT
Bleeding air from work 5) When hydraulic oil flows out of air bleeder
hose [1] of work equipment pump (1), stop
equipment circuit adding oil.
6) Connect pump drain pipe (4) to hydraulic
1. Bleeding air from work equipment pump tank (3).
(piston pump)
3 Air bleeder:
7) Tighten air bleeder (2).
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
8) Start the engine and run it at low idle for at
least 5 minutes.
2. Bleeding air from work equipment PPC cir-

cuit
1) Keep the work equipment control lever at a
stroke end and relieve the work equipment
circuit for about 1 minute. Perform this
operation 1 time at each stroke end.
3. Bleeding air from cylinder

1) Start the engine and run it at low idle for 5
minutes.
2) Loosen air bleeder (2) of work equipment 2) While running the engine at slow speed,
a Move the piston rod to about 100 mm

pump (1) and connect air bleeder hose [1]. raise and lower the boom 4 – 5 times.
before each stroke end and never re-

lieve the circuit.
3) While running the engine at fuel throttle,
perform the operation in 2). Then, while
running the engine at low idle, move the pis-
ton rod to each stroke end and relieve the
circuit.
4) Perform the operations in 2) and 3) for the
a When the cylinder is replaced, bleed air

bucket cylinder and steering cylinder.
from it before connecting the piston rod.
3) Disconnect pump drain pipe (4) of hydraulic

tank (3).
4) Raise the disconnected pump drain pipe (4)

higher than the pump and add hydraulic oil
through the pipe joint.
20-70 WA430-6
TESTING AND ADJUSTING RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CIRCUIT
Releasing residual pressure in 2) Loosen locknut (4) of ECSS pressure

release plug (3) of work equipment control
work equipment circuit valve (2).
3) Loosen adjustment plug (5) by 1/2 – 1 turn
1. Releasing residual pressure in piping be- to release the pressure in the accumulator.
tween each hydraulic cylinder and control
a When disconnecting the piping between

valve
each hydraulic cylinder and control valve, re-

lease the residual pressure in the circuit ac-
cording to the following procedure.
1) Stop the engine.
2) Loosen the oil filler cap of the hydraulic tank
to release the internal p ressure of the
hydraulic tank.
a After the control levers are operated 2 –

3) Operate the control levers
3 times, the pressure in the PPC accu-

mulator is lost. At this time, start the en-
gine again and run it at low idle for about
5 seconds to heighten the pressure in
the accumulator, and then stop the en-
gine and operate the work equipment
a Repeat the above operation 2 – 3 times

control lever.
to release the residual pressure perfectly.
2. Releasing residual pressure in PPC accumu-
a When disconnecting the piping between the

lator circuit
PPC accumulator and PPC valve, release

the residual pressure in the circuit according
to the following procedure.
• Operate the control levers 2 – 3 times to re- 4) After releasing the residual pressure, return
3 Locknut:
lease the pressure in the circuit. plug (5) and tighten locknut (4) securely.
3. Releasing residual pressure in ECSS circuit 19.6 – 27.5 Nm {2.0 – 2.8 kgm}
(ECSS: Electronic Controlled Suspension
System)
k When disconnecting the piping of the ECSS
circuit (between the ECSS accumulator and
work equipment control valve), release the
pressure in the ECSS accumulator accord-
ing to the following procedure.
1) Raise the lift arm and set a stand to it, and
then remove front frame inspection cover (1).
WA430-6 20-71
TESTING AND ADJUSTING TESTING AND ADJUSTING BUCKET POSITIONER
Testing and adjusting bucket 2) Adjust the shim and proximity switch bracket
mounting bolt so that clearance (a) between
positioner the sensitive surface of proximity switch (1)
a Engine coolant temperature:

and sensor bar (2) will be in the standard
a Clearance (a): 3 – 5 mm
range.
a Hydraulic oil temperature:

a Adjust sensor bar (2) with the shim so that
Within operating range clearance (a) will be in the standard range
through the stroke of the sensor bar.
Testing
1. While the engine is stopped, check that clear- 2. Adjusting mounting position (stopping posi-
ance (a) between proximity switch (1) and sensor tion)
bar (2) is in the standard range. 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 cen-
ter 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.
• 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.)
2. While running the engine at high idle, check the
operating point. (Check 3 times and obtain the
average.)
Adjusting
1. Adjusting clearance
1) Adjust and fix switch nut (4) so that clear-
ance (b) between the end of switch protec-
tor (3) and switch sensitive surface (1) will
a Standard clearance (b): 0.5 – 1.0 mm

be in the standard range.
3 Switch nut:
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
a After adjusting, start the engine, operate the

bucket control lever, and check that the
switch operates at the desired position.
20-72 WA430-6
TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM KICK-OUT
Testing and adjusting boom Adjusting

1. Raise the lift arm to a desired position.
k Be sure to apply the work equipment lock.
kick-out
Testing 2. Loosen 2 bolts (3) and adjust the position of the
1. Start the engine and operate the lift arm control plate so that the lower end of plate (2) will be at
lever to operate proximity switch (1), and then the center of switch (1), and then tighten bolts
a Be sure to apply the work equipment lock.

stop the engine. (3).
2. While the engine is stopped, check that clear-

ance (a) between switch (1) and plate (2) is with-
in the standard range.
3. Adjust and fix switch nut (4) so that clearance (a)

between the sensitive surface of switch (1) and
3 Switch nut:
plate (2) will be in the standard range.
a After adjusting, operate the work equipment,

14.7 – 19.6 Nm {1.5 – 2.0 kgm}
3. While running the engine at high idle, check the and check that the switch operates at the de-
operating point. (Check 3 times and obtain the
sired position.
average.)
WA430-6 20-73
TESTING AND ADJUSTING CHECKING PROXIMITY SWITCH OPERATION PILOT LAMP
Checking proximity switch

operation pilot lamp
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.
• A: Operation pilot lamp (Red)
Positional relationship between Operation pilot

Proximity switch Remarks
proximity switch and sensitive surface lamp
Near ON
Bucket positioner Operates when center of switch is near.
Far OFF
Near ON
Boom kick-out Operates when center of switch is far.
Far OFF
20-74 WA430-6
TESTING AND ADJUSTING PROCEDURE FOR TESTING DIODES
Procedure for testing diodes a In the case of a silicon diode, a value in

the range from 460 to 600 is indicated.
a Test the assembled-type diode (8-pin) and the
single diode (2-pin) according to the following
a The conductive directions of the assembled-type

procedure.
diode are indicated on the surface of the diode as

shown in the following figure.
2. When using analog circuit tester

1) Set the tester in the resistance range.
2) Apply the leads of the tester as explained
b elow a nd check th e mo ve me nt o f the
pointer.
1] Apply the red (+) lead of the tester to the
a The conductive direction of the single diode is in- anode (P) side of the diode and apply
dicated on the surface of the diode as shown in the black (–) lead to the cathode (N)
the following figure. side.
2] Apply the red (+) lead of the tester to the
cathode (N) side of the diode and apply
the black (–) lead to the anode (P) side.
3) Judge the condition of the diode by the
movement of the pointer.
• The pointer does not move in 1] but
moves in 2]: The diode is normal (The
moving range (resistance) depends on
the type and selected range of the tester,
however).
• The pointer moves in both 1] and 2]: The
diode is defective (Internal short circuit).
• The pointer moves in neither of 1] and 2]:
The diode is defective (Internal discon-
nection).
1. When using digital circuit tester
1) Set the tester in the diode range and check
a When an ordinary circuit tester is used,

the indicated value.
the voltage of the internal battery is indi-

cated.
2) Apply the red (+) lead of the tester to the
anode (P) side of the diode and apply the
black (–) lead to the cathode (N) side and
check the indicated value.
3) Judge the condition of the diode by the indi-
cated value.
• The indicated value does not change:
The diode do not have conductivity (De-
fective).
has conductivity (Normal). (See a be-

• The indicated value changes: The diode
low.)
WA430-6 20-75
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
Adjusting machine monitor

Rotary switches (SW1, SW2, and SW3) and DIP switches (SW5 and SW6) of machine monitor
• In the following cases, check the setting of the rotary switches and DIP switches on the back side of the ma-
chine monitor, and then change it if necessary.
• When the machine monitor is removed and installed.
• When the tire size is changed. (Setting of correction of speed)
• When an optional device is installed or removed.
a
• When the machine monitor is replaced with new one. (Service meter and odometer)
When the setting of these switches is changed, the character display section and mode switch must be op-
erated specially. For details, see Structure and function and maintenance standard, Setting necessary to
machine.
• You can check the condition of each switch with the special function (monitoring function) of the machine
a
monitor.
a
When changing any setting of these switches, turn the starting switch OFF and remove the monitor panel.
a
Be sure to set each switch as specified.
a
Do not touch any part other than the switches inside the grommet.
a
When turning a rotary switch, use a precision cross-head screwdriver, etc. and turn it carefully.
a
The triangular projection of each rotary switch is the setting arrow.
When changing a DIP switch, use a precision flat-head screwdriver, etc. and change it carefully.
20-76 WA430-6
• Setting function of each switch
Position when
Switch Position Contents of setting
monitor is delivered
SW1 0–F Selection of machine model 2
SW2 0–F Unused (Fixed to 0) 0
SW3 0–F Selection of speed or tachometer and tire size 0
OFF
1 Unused (Fixed to OFF) ON
ON
OFF Work equipment controller: Not installed
2 OFF
ON Work equipment controller: Installed
SW5
OFF
3 Unused (Fixed to OFF) OFF
ON
OFF Use of 4th gear speed when joystick is used: Prohibited
4 OFF
ON Use of 4th gear speed when joystick is used: Permitted
OFF Engine controller: Not installed
1 OFF
ON Engine controller: Installed
OFF
ON
SW6
OFF
ON
OFF
ON
1. Setting of rotary switch SW1 2. Setting of rotary switch SW2

Since the machine monitor is applicable to many Set rotary switch SW2 to the following position
machine models, the machine model on which it and do not change it.
is mounted must be set. • Set position of SW2: 0
If the machine monitor is replaced, select the
current machine model with rotary switch SW1.
Machine model SW1 Remarks

WA430-6 5
WA430-6 20-77
3. Setting of rotary switch SW3 6. Setting of DIP switch SW5-3

The machine monitor uses the standard tire size Set DIP switch SW5-3 to the following position
to calculate the travel speed. Accordingly, if the and do not change it.
tire size is changed, change rotary switch SW3 • Set position of SW5-3: OFF
a Set rotary switch SW3 according to the tire

to correct the indicated travel speed.
7. Setting of DIP switch SW5-4
size as shown in the following table. When the joystick is used and use of the 4th
gear speed is permitted or prohibited, set DIP
Unit of dis- switch SW5-4 as shown below.
SW3 Tire size Remarks
played speed • Set position of DIP switch SW5-4 when use
Large of 4th gear speed is prohibited: OFF
km/h 0 —
diameter • Set position of DIP switch SW5-4 when use
a When use of the 4th gear speed is permitted,

Used only in country of 4th gear speed is permitted: ON
Large
MPH 1 where SI units are not
diameter
used. stick the nameplate (Part No.: 421-S33-
Small 3130) to the lever stand to indicate that the
km/h 6 —
diameter 4th gear speed can be used.
Used only in country
Small
MPH 7 where SI units are not 8. Setting of DIP switch SW6-1
diameter
used. Set DIP switch SW6-1 to the following position
and do not change it.
Tire size WA430-6 • Set position of SW6-1: ON
20.5 – 25 If equipped
23.5 – 25 STD 9. Setting of DIP switch SW6-2
Set DIP switch SW6-2 to the following position
To change the unit of the displayed speed,
• Set position of SW6-2: OFF
change the contents of display of the speedom-
eter at the center of the monitor.
• The speedometer can be changed to the en-
gine tachometer by optional setting, too.
• The unit of the odometer in the character dis-
play section is displayed according to the
above setting.
• The unit of MPH is for only a country where
the SI units are not used (but mile is used).
Do not set it for a country where the SI units
a If the tire size is changed, change rotary
are used.
switch SW1 to correct the displayed speed.

• When tires other than the specified ones are
used or the displayed speed is different from
the actual travel speed because of wear of
the tires, correct the tire size by optional set-
ting.


When the work equipment controller is installed
or removed, set DIP switch SW5-2 as shown
below.
• When controller is removed
Set position of SW5-2: OFF
• When controller is installed
Set position of SW5-2: ON
20-78 WA430-6
WA430-6 20-79
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR
Special functions of machine monitor

Normal functions and special functions of machine monitor
The machine monitor is equipped with 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 display 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 used displayed and operated by the
operator operating the switches.
2) Special functions: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspection,
maintenance, and troubleshooting.
Operator mode Service mode

1 Service meter 9 Electrical system trouble data display function
2 Odometer display function 10 Mechanical system trouble data display function
3 Filter, oil replacement interval display function 11 Machine data monitoring function
4 Telephone number input function 12 Reduced cylinder mode (*1)
5 Language selection function 13 Adjustment function
6 Monitor brightness adjustment function 14 Filter, oil replacement time setting function
7 Action code display function 15 Option selection function
8 Failure code display function 16 Serial No. setting function
17 Initialize function
*1: Reduced cylinder mode is not effective because engine controller is not applicable.
20-80 WA430-6
Flow of modes and function
WA430-6 20-81
: Reduced cylinder mode is not effective because engine controller is not applicable.
20-82 WA430-6
WA430-6 20-83
a No. 2 – No. 6 give an endless display according

Operator Mode Control switches
Control of the machine monitor display is all carried
a When a failure occurs, the screen changes auto-

to the operation of the switch. out with machine monitor mode selector switches (1)
and (2).
matically to No. 7, regardless of the display The following functions are provided for the buttons
a Regardless of the display screen, if no switch is 1. U: Select, Run

screen. of each switch.
operated for more than 30 seconds, the screen 2. t: Cancel, Release, Select
automatically changes as follows. (YES/NO screen only)
• Goes to No. 1: If there is no failure 3. >: Right, Next, Continue
a From No. 8 the screen changes to No. 1 with the

• Goes to No. 7: If there is failure 4. <: Left, Previous, Return
switch operation, and if no switch is operated for

more than 10 seconds, the screen automatically
changes to No. 7.
a No. 9 – No. 17 give an endless display according

Service Mode
a Once the ID is input and confirmed, it remains ef-

to the operation of the switch.
fective until the starting switch is turned OFF.
Character display section

The character display consists of a top line and bot-
tom line with 16 characters each. A combination of
the following characters (alphabet and numerals)
and symbols is displayed according to the content.
1) Numerals: 1 2 3 . . .
2) Small letters: a b c . . .
3) Capital letters: A B C . . .
4) Katakana: Japanese display only
5) Symbols: @, ¥, $ . . .
6) Special characters
20-84 WA430-6
Operation and displays for operator mode

1. Service meter, time display function
When the starting switch is turned ON, the top
line shows the service meter.
a For details, see the OPERATION AND

MAINTENANCE MANUAL, Machine Monitor
a The replacement interval can be set using

and Other Functions.
2. Travel distance appregate display function Service Mode.

From the normal service meter display, press

the [U] switch to display the odometer. 4. Telephone number input function
The telephone number set inside the machine
MAINTENANCE MANUAL, Machine Monitor monitor can be input, corrected, or cancelled by
a When action code [E03] is displayed, the

and Other Functions. operating the switches.
telephone number is displayed at the same

time as [CALL].

3. Filter, oil replacement interval display function

Filter, oil replacement time display (automatic
display)
1) When the replacement interval for the filters
or oil approaches, this information is auto-
matically displayed on the machine monitor
to recommend the operator to carry out
maintenance.
2) Resetting replacement time (selection menu)
When the maintenance operation for the fil-
ters and oil replacement has completed, the
switches on the machine monitor can be
used to reset the interval.
WA430-6 20-85
5. Language selection function 7. Action code display function

The language used for the machine monitor dis- If any abnormality occurs on the machine, the
a The functions of Service Mode is not includ-

play can be selected by operating the switches. degree of the abnormality is automatically dis-
played as a user code on the machine monitor
ed in the functions for display selection, so to recommend appropriate action to the opera-
a For details, see the OPERATION AND a The diagram on the right shows an example
they are always displayed in English. tor.
MAINTENANCE MANUAL, Machine Monitor of action code [E03] and [CALL + Telephone
a When action codes [E00], [E01], and [E02]

and Other Functions. number] being displayed in turn.
are displayed, [CALL + Telephone number]

is not displayed.
6. Monitor brightness adjustment function

The brightness of the machine monitor can be

adjusted by the switch to 7 levels.

a Correspondence between user code and recommendation to operator
CALL + Telephone
Action Code Action Recommended to Operator
Number
E00 Not displayed • Returns mis-operated switch or lever to normal condition
• Carry out inspection and maintenance after completion of operations or when
E01 Not displayed
changing shifts between operators
• When overrun related display is shown:
Reduce when engine speed and machine speed while continuing operations.
E02 Not displayed
• When overheat related display is shown:
Stop machine and keep engine running at mid-range speed under no load.
E03 Displayed • Stop engine and machine immediately and contact serviceman.
20-86 WA430-6
8. Failure code display function a With the service code display function, the
While the action code is being displayed on the following data are displayed.
machine monitor, press the [>] button once to A. Failure code (location code + problem
a The failure codes detected in the past are di-

display the failure codes for the existing failures. code)
B. Controller codes
vided into failures of the electrical system MON : Machine monitor
and the mechanical system and are record- ENG : Engine controller
ed as trouble data. (For details, see Service TM : Transmission controller
a If more than one failure is occurring, press

Mode.) WRK : Work equipment controller
C. System with problem
the [>] button once more to display the other
a After pressing the [>] button to display all the

failure codes.
existing failures, press the [>] button once

more to return to the service meter display
screen.
If the [>] button is pressed once more, the
failure codes will be displayed again from the
beginning.
If the switch is not operated for 3 seconds,
the display will switch automatically to the
action code screen.
a For details of the displayed failure codes,
a If no switch is operated on the failure code

see FAILURE CODE LIST.
display screen for more than 30 seconds, the

display automatically returns to the action
code display screen.
WA430-6 20-87
Failure codes list
Failure Action
Troubled part Trouble Controller Category of record
code code
1500L0 TORQFLOW transmission Double meshing TM E03 Electrical system
When command current is OFF,
15SAL1 ECMV F clutch TM E03 Electrical system
fill signal is ON
When command current is ON, fill
15SALH ECMV F clutch TM E01 Electrical system
signal is OFF
15SBL1 ECMV R clutch TM E03 Electrical system
fill signal is ON
15SBLH ECMV R clutch TM E01 Electrical system
signal is OFF
15SEL1 ECMV 1st clutch TM E03 Electrical system
fill signal is ON
15SELH ECMV 1st clutch TM E01 Electrical system
signal is OFF
15SFL1 ECMV 2nd clutch TM E03 Electrical system
fill signal is ON
15SFLH ECMV 2nd clutch TM E01 Electrical system
signal is OFF
15SGL1 ECMV 3rd clutch TM E03 Electrical system
fill signal is ON
15SGLH ECMV 3rd clutch TM E01 Electrical system
signal is OFF
15SHL1 ECMV 4th clutch TM E03 Electrical system
fill signal is ON
15SHLH ECMV 4th clutch TM E01 Electrical system
signal is OFF
2F00MA Parking brake Malfunction MON E03 Electrical system
2G42ZG Accumulator Low oil pressure MON E03 Electrical system
989F00 Transmission protection caution TM E00 —
989FKM Transmission protection caution Mistake in operation or setting TM —
989G00 FNR lever priority caution TM E00 —
AA1ANX Air cleaner Clogging MON E01 Mechanical system
Signal disagrees with operating
AB00L6 Alternator MON E03 Electrical system
state of engine
AB00MA Alternator Malfunction MON E03 Mechanical system
B@BAZK Engine oil Low level MON E01 Mechanical system
B@BCZK Coolant Low level MON E01 Mechanical system
B@C7NS Brake oil Overheating TM E02 Mechanical system
B@CENS Torque converter oil Overheating MON E02 Mechanical system
B@GAZK Battery electrolyte Low level MON E01 Electrical system
B@HANS Hydraulic oil Overheating MON E02 Mechanical system
D150KA Emergency steering relay Disconnection TM E03 Electrical system
D150KB Emergency steering relay Short circuit TM E03 Electrical system
D160KA Backup lamp relay Disconnection TM E01 Electrical system
D160KB Backup lamp relay Short circuit TM E01 Electrical system
20-88 WA430-6
Failure Action
code code
D191KA Neutral safety relay Disconnection TM E03 Electrical system
D191KB Neutral safety relay Short circuit TM E01 Electrical system
D192KA Travel damper relay Disconnection TM E01 Electrical system
D192KB Travel damper relay Short circuit TM E01 Electrical system
D193KA Joystick solenoid cut-off relay Disconnection WRK E03 Electrical system
D193KB Joystick solenoid cut-off relay Short circuit WRK E03 Electrical system
D5ZAKB Throttle correction signal Short circuit TM E01 Electrical system
D5ZHL6 Monitor panel terminal C signal MON E01 Electrical system
state of engine
Engine output mode command
D5ZMKB Short circuit TM E01 Electrical system
signal
DAF3KK Monitor panel Low source voltage (input) MON E03 Electrical system
DAF5KP Monitor panel Low output voltage MON E01 Electrical system
DAFBKM Monitor panel Mistake in operation or setting MON E03 Electrical system
Disagreement of model selection
DAFSKQ Monitor panel MON E01 Electrical system
signals
DAQ0KK Transmission controller Low source voltage TM Electrical system
DAQ0KT Transmission controller Abnormality in controller TM Electrical system
Transmission controller load
DAQ2KK Low source voltage (input) TM Electrical system
power supply line
Transmission controller model Disagreement of model selection
DAQ9KQ TM E03 Electrical system
selection wiring harness signals
Defective communication (Abnor-
Monitor panel S-NET communi-
DAQSKR mality in target component sys- MON E03 Electrical system
cation
tem)
DB90KK Work equipment controller Low source voltage (input) WRK E03 Electrical system
Work equipment controller load
DB92KK Low source voltage (input) WRK E03 Electrical system
power supply line
DB95KX Out of input signal range WRK E03 Electrical system
power supply output
Work equipment controller S-
DB9SKR mality in target component sys- MON E03 Electrical system
NET communication
tem)
DD15LD t switch (panel switch 1)

Switch is kept pressed for long
MON E01 Electrical system
time
DD16LD U switch (panel switch 2)

MON E01 Electrical system
time
DD17LD < switch (panel switch 3) MON E01 Electrical system
time
DD18LD > switch (panel switch 4) MON E01 Electrical system
time
Remote positioner raise set Switch is kept pressed for long
DD1ALD WRK E03 Electrical system
switch time
Remote positioner lower set Switch is kept pressed for long
DD1BLD WRK E03 Electrical system
switch time
WA430-6 20-89
Failure Action
code code
DDK3KA FNR switch Disconnection TM E03 Electrical system
DDK3KB FNR switch Short circuit TM E03 Electrical system
DDK4KA Joystick FNR switch Disconnection TM E03 Electrical system
DDK4KB Joystick FNR switch Short circuit TM E03 Electrical system
DDK5LD Joystick shift up/down switch TM E03 Electrical system
time
DDK6KA FNR lever Disconnection TM E03 Electrical system
DDK6KB FNR lever Short circuit TM E03 Electrical system
DDS5KA Steering oil pressure switch Disconnection TM E03 Electrical system
DDS5KB Steering oil pressure switch Short circuit TM E03 Electrical system
DDS5L6 Steering oil pressure switch MON E03 Electrical system
state of engine
DDT0L4 Shift mode selector switch ON/OFF signals disagree TM Electrical system
Transmission cut-off selector Switch is kept pressed for long
DDT4LD TM E01 Electrical system
switch time
DDW9LD Kick-down switch TM E01 Electrical system
time
DDWLLD Hold switch TM E01 Electrical system
time
DF10KA Transmission shift lever Disconnection TM E01 Electrical system
DF10KB Transmission shift lever Short circuit TM E01 Electrical system
Work equipment controller EPC
DFA0KM Mistake in operation or setting WRK E00 —
lever
Transmission valve oil tempera-
DGF1KX Out of input signal range TM Electrical system
ture sensor
DGH2KX Hydraulic oil temperature sensor Out of input signal range MON E01 Electrical system
DGR2KA Brake oil temperature sensor Disconnection TM E01 Electrical system
DGR2KB Brake oil temperature sensor Short circuit TM E01 Electrical system
Torque converter oil tempera-
DGT1KX Out of input signal range MON E01 Electrical system
ture sensor
DHA4KA Air cleaner clogging sensor Disconnection MON E01 Electrical system
Transmission cut-off pressure
DHT1KX Out of input signal range TM E01 Electrical system
sensor
DJB1KX Battery electrolyte level sensor Out of input signal range MON E01 Electrical system
Lift arm lever EPC potentiometer
DK59KA Disconnection WRK E03 Electrical system
(Main)
Lift arm lever EPC potentiometer Short circuit with power supply
DK59KY WRK E03 Electrical system
(Main) line
DK59L8 Analog signals disagree WRK E03 Electrical system
(Main)
DK5AKA Disconnection WRK E03 Electrical system
(Sub)
Lift arm lever EPC potentiometer Short circuit with power supply
DK5AKY WRK E03 Electrical system
(Sub) line
Bucket lever EPC potentiometer
DK5BKA Disconnection WRK E03 Electrical system
(Main)
20-90 WA430-6
Failure Action
code code
Bucket lever EPC potentiometer Short circuit with power supply
DK5BKY WRK E03 Electrical system
(Main) line
DK5BL8 Analog signals disagree WRK E03 Electrical system
(Main)
DK5CKA Disconnection WRK E03 Electrical system
(Sub)
Bucket lever EPC potentiometer Short circuit with power supply
DK5CKY WRK E03 Electrical system
(Sub) line
3rd lever EPC potentiometer
DK5DKA Disconnection WRK E03 Electrical system
(Main)
3rd lever EPC potentiometer Short circuit with power supply
DK5DKY WRK E03 Electrical system
(Main) line
DK5DL8 Analog signals disagree WRK E03 Electrical system
(Main)
DK5EKA Disconnection WRK E03 Electrical system
(Sub)
3rd lever EPC potentiometer Short circuit with power supply
DK5EKY WRK E03 Electrical system
(Sub) line
Joystick steering lever EPC
DK5FKA Disconnection WRK E03 Electrical system
potentiometer (Main)
DK5FKM Mistake in operation or setting WRK E00 —
Joystick steering lever EPC Short circuit with power supply
DK5FKY WRK E03 Electrical system
potentiometer (Main) line
DK5FL8 Analog signals disagree WRK E03 Electrical system
DK5GKA Disconnection WRK E03 Electrical system
potentiometer (Sub)
Joystick steering lever EPC Short circuit with power supply
DK5GKY WRK E03 Electrical system
potentiometer (Sub) line
DKA0KA Lift arm angle sensor Disconnection WRK E01 Electrical system
Short circuit with power supply
DKA0KY Lift arm angle sensor WRK E01 Electrical system
line
DLE2KA Engine speed sensor Disconnection TM E03 Electrical system
DLE2LC Engine speed sensor Speed signals disagree TM E03 Electrical system
Transmission output shaft speed
DLT3KA Disconnection TM E03 Electrical system
sensor
Transmission output shaft speed
DLT3LC Speed signals disagree WRK E01 Electrical system
sensor
DT20KB Transmission cut-off indicator Short circuit TM Electrical system
DT20KZ Transmission cut-off indicator Disconnection or short circuit TM Electrical system
Remote positioner raise indica-
DUM1KB Short circuit WRK E03 Electrical system
tor lamp
Remote positioner lower indica-
tor lamp
DV00KB Warning buzzer Short circuit MON E01 Electrical system
DW4PKA Lift arm raise EPC solenoid Disconnection WRK E03 Electrical system
WA430-6 20-91
Failure Action
code code
DW4PKB Lift arm raise EPC solenoid Short circuit WRK E03 Electrical system
DW4QKA Lift arm lower EPC solenoid Disconnection WRK E03 Electrical system
DW4QKB Lift arm lower EPC solenoid Short circuit WRK E03 Electrical system
DW4RKA Bucket tilt EPC solenoid Disconnection WRK E03 Electrical system
DW4RKB Bucket tilt EPC solenoid Short circuit WRK E03 Electrical system
DW4SKA Bucket dump EPC solenoid Disconnection WRK E03 Electrical system
DW4SKB Bucket dump EPC solenoid Short circuit WRK E03 Electrical system
DW7BKA Fan pump (reverse) solenoid Disconnection TM E01 Electrical system
DW7BKB Fan pump (reverse) solenoid Short circuit TM E01 Electrical system
PPC basic pressure solenoid
DWM1KA Disconnection WRK E01 Electrical system
valve
PPC basic pressure solenoid
DWM1KB Short circuit WRK E01 Electrical system
valve
Lift arm raise magnet detent
DWN6KA Disconnection WRK E01 Electrical system
solenoid
Lift arm raise magnet detent
DWN6KB Short circuit WRK E01 Electrical system
solenoid
Lift arm float magnet detent
solenoid
Lift arm float magnet detent
solenoid
Bucket tilt magnet detent sole-
noid
Bucket tilt magnet detent sole-
noid
DX16KA Fan pump EPC solenoid Disconnection TM E01 Electrical system
DX16KB Fan pump EPC solenoid Short circuit TM E01 Electrical system
DXA1KA Pump PC-EPC valve Disconnection TM E01 Electrical system
DXA1KB Pump PC-EPC valve Short circuit TM E01 Electrical system
DXH4KA 1st clutch ECMV solenoid Disconnection TM E03 Electrical system
DXH4KB 1st clutch ECMV solenoid Short circuit TM E03 Electrical system
DXH5KA 2nd clutch ECMV solenoid Disconnection TM E03 Electrical system
DXH5KB 2nd clutch ECMV solenoid Short circuit TM E03 Electrical system
DXH6KA 3rd clutch ECMV solenoid Disconnection TM E03 Electrical system
DXH6KB 3rd clutch ECMV solenoid Short circuit TM E03 Electrical system
DXH7KA R clutch ECMV solenoid Disconnection TM E03 Electrical system
DXH7KB R clutch ECMV solenoid Short circuit TM E03 Electrical system
DXH8KA F clutch ECMV solenoid Disconnection TM E03 Electrical system
DXH8KB F clutch ECMV solenoid Short circuit TM E03 Electrical system
DXHHKA 4th clutch ECMV solenoid Disconnection TM E03 Electrical system
DXHHKB 4th clutch ECMV solenoid Short circuit TM E03 Electrical system
DXHJKA 3rd extract EPC solenoid Disconnection WRK E03 Electrical system
DXHJKB 3rd extract EPC solenoid Short circuit WRK E03 Electrical system
20-92 WA430-6
Failure Action
code code
DXHKKA 3rd retract EPC solenoid Disconnection WRK E03 Electrical system
DXHKKB 3rd retract EPC solenoid Short circuit WRK E03 Electrical system
Joystick steering right EPC sole-
DXHLKA Disconnection WRK E03 Electrical system
noid
Joystick steering right EPC sole-
DXHLKB Short circuit WRK E03 Electrical system
noid
Joystick steering left EPC sole-
DXHMKA Disconnection WRK E03 Electrical system
noid
Joystick steering left EPC sole-
DXHMKB Short circuit WRK E03 Electrical system
noid
DY30MA Emergency steering motor Malfunction TM E03 Electrical system
DY30MC Emergency steering motor Defective operation TM E03 Electrical system
DY30ME Emergency steering motor Motor cannot be reset MON E02 —
WA430-6 20-93
Procedure for switching to Service Mode and 3) Inputting, confirming ID
a When using Service Mode, carry out the follow- a ID: 6491
screen display Operate the buttons to input the ID.
ing special operation to switch the screen dis- • [>] button : Number at cursor goes up.
play. • [<] button : Number at cursor goes down.
• [U] button: Number at cursor is confirmed.
1) Checking screen display • [t] button : Returns to initial screen
With the machine monitor in the operator mode, (see Note).
check that the screen is one of the following dis- Note: When the cursor is at the left edge, the
plays: Service meter, action code, or failure screen returns to the normal screen
code. (operator mode).
If the cursor is not at the left edge, the
2) Initial screen display for ID input cursor returns to the left edge.
a If more than 60 seconds passes before the

Press the following 2 buttons at the same time
for at least 5 seconds to display the initial screen
display for the ID input. switch on the ID input screen is operated, the
a If the buttons are held pressed for at least 5

• [t] button and [<] button screen returns automatically to the normal
screen.
seconds, the whole screen will give no dis-
play, so check that the screen gives no dis-
play, then release the buttons.
4) Displaying menu initial screen

After all four digits of the ID are confirmed, the
menu initial screen of Service Mode is dis-
a Once the ID has been input and confirmed, it

played.
remains effective until the starting switch is

turned OFF.
20-94 WA430-6
5) Menu selection in Service Mode

Press the [>] or [<] buttons on the menu screen
and the menus of Service Mode are displayed
a The menu is displayed in the places marked

endlessly in the following order.
with [*].
• [>] button : Go on to the next menu
• [<] button : Go back to previous menu
(1) ELECTRICAL FAULT: Trouble data display
function for electrical system
(2) MACHINE FAULT: Trouble data display
function for mechanical system
(3) REAL-TIME MONITOR: Machine data mon-
itoring function
(4) CYLINDER CUT-OUT: Reduced cylinder
mode (This mode is not effective because
engine controller is not applicable.)
(5) TUNING: Adjustment function
(6) MAINTENANCE MONITOR: Filter, oil
replacement interval setting function
(7) OPTION SELECT: Option installation selec-
tion function
(8) MACHINE No. SET: Serial No. setting func-
tion
(9) INITIALIZE: Initialize function (exclusive
function for factory)
6) Completion of mode, function

When operating at any point in any function, it is
possible to finish the mode or function by using
any of the following methods.
(1) When continuing operations in another
mode or function: Press the [t] button and
return to the mode screen to be used or
a Note that if the [t] button is pressed on

menu screen to be used.
the YES/NO screen, the function will be
a If you return to the normal screen (oper-

executed.
ator mode) by mistake, repeat the proce-

dure from Step 1) above (there is no
need to input the ID again).
(2) When completing all operations:
Turn the starting switch OFF.
WA430-6 20-95
9. Electrical system trouble data display function 3) Displayed trouble data

(ELECTRIC FAULT) With the display function for trouble data of
The monitor retains the data for problems that the electrical system, the following data can
occurred in the electrical system in the past as be displayed.
failure codes. They can be displayed as follows. A: Record number
B: Failure code (4-digit location code + 2
1) Menu selection digit problem code
Select the display function for ELECTRIC C: Number of occurrences (number of
FAULT trouble data on the menu screen of occurrences of same code in past)
a The total number of trouble data items

Service Mode. D: Elapsed time 1 (time elapsed on service
meter since first occurrence)
recorded in memory is displayed in the E: Elapsed time 2 (time elapsed on service
a Failure codes for problems that are still

[**] portion. (Recorded up to a maximum meter since last occurrence)
of 20 items)
a For details of the failure codes dis-

existing are shown on a flashing display.
played, see "Failure code list" in the ex-

planation for the failure code display
a Note that with the trouble data display

function.
function and failure code display func-

tion for the electrical system, the dis-
a If no trouble data are recorded, [-] is dis-

played data are partially different.
played on the display portion.
2) Trouble data display

With the menu selected, press the [U] but-
ton and display the trouble data recorded in
memory.
• [U] button: Run menu
20-96 WA430-6
4) Switching trouble data display ii) Press the [U] button once to display the
If the [>] button or [<] button is pressed dur- ALL CLEAR screen (Fig. 6).
ing the display of trouble data, the display • [U] button: Run ALL CLEAR menu
switches to the other recorded trouble data. iii) Operate the buttons according to the
• [>] button: Go on to data for next record explanation on the screen (Fig. 6).
number. • [<] button: Select YES
• [<] button: Go back to data for last record • [>] button: Select NO
a The data for an existing problem (flash-

number. • [t] button: Run
5) Deleting individual trouble data ing display) cannot be deleted.

i) Display the trouble data to be deleted,
then press the [U] button once to dis-
play the individual item CLEAR screen
(Fig. 4).
• [U] button: Display CLEAR screen
ii) Operate the buttons according to the
explanation on the screen (Fig. 4).
• [<] button: Select YES
• [>] button: Select NO
a The data for an existing problem (flash-

• [t] button: Run
ing display) cannot be deleted.
6) Deleting all trouble data

i) Display the trouble data, then press the
[>] button or [<] button to display the
ALL CLEAR menu (Fig. 5).
WA430-6 20-97
10. Mechanical system trouble data display function 3) Display trouble data
(MACHINE FAULT) With the display function for trouble data of
The machine monitor retains the data for prob- the mechanical system, the following data
lems that occurred in the mechanical system in can be displayed (Fig. 3).
the past as failure codes. They can be displayed A: Record number
as follows. B: Failure code (4-digit location code + 2-
digit problem code)
1) Menu selection C: Number of occurrences (number of
Select the display function for MACHINE occurrences of same code in past)
FAULT trouble data on the menu screen of D: Elapsed time 1 (time elapsed on service
a The total number of trouble data items

Service Mode (Fig. 1). meter since first occurrence)
E: Elapsed time 2 (time elapsed on service
a Failure codes for problems that are still

recorded in memory is displayed in the meter since last occurrence)
[**] portion.
a For details of the failure code displayed,

existing are shown on a flashing display.
see "Failure code list" in the explanation
a Note that with the trouble data display

for the failure code display function.
function and failure code display func-

tion for the mechanical system, the dis-
a If no trouble data are recorded, [-] is dis-

played data are partially different.
played on the display portion.
2) Trouble data display

With the menu selected, press the [U] but-
ton and display the trouble data recorded in
memory (Fig. 2: example).
4) Switching trouble data display

If the [>] button or [<] button is pressed dur-
ing the display of trouble data, the display
switches to the other recorded trouble data.
• [>] button: Go on to data for the next
record number
• [<] button: Go back to data for last record
number
a The trouble data for the mechanical sys-

5) Deleting trouble data (not permitted)
tem cannot be deleted.
20-98 WA430-6
11. Machine data monitoring function (REAL-TIME 3) Select sub menu

MONITOR) If the [>] button or [<] button is pressed on
The machine monitor can monitor the condition the sub menu screen, the sub menu dis-
of the machine in real time through the signals plays endlessly in the following order (Fig.
a The sub menu is displayed in the [*] po-

from the sensors installed to various parts of the 3).
machine.
In the machine data monitoring function, the fol- sition.
lowing 2 types of display can be shown. • [>] button: Go on to next menu
• 1st item independent display (for each con- • [<] button: Go back to last menu
troller) (1) MONITOR PANEL: Machine monitor
• 2nd item simultaneous display (code input) system
(2) TRANSMISSION: Transmission control-
1) Menu selection ler system
Select the machine data monitoring function (3) ENGINE: Engine controller system
on the menu screen of the Service Mode (4) BOOM: Work equipment controller sys-
(Fig. 1). tem
(5) 2 ITEM: 2-item display
2) Display sub menu

With the sub menu selected, press the [U]
button and display the initial screen of the
sub menu (Fig. 2).
WA430-6 20-99
4) Setting 1st item individual monitoring 5) Display data for 1st item individual monitor-
i) Select the controller system for monitoring
ing on the sub menu screen (Fig. 4: O n th e 1s t ite m in d iv idu a l mo n ito rin g
Example). screen, the following data are displayed
(Fig. 6).
A: Item display
B: Monitoring data (5-digit)
a For details, see "Monitoring code table".

1: Monitoring data (including unit)
ii) With the sub menu selected, press the

[U] button and display the monitoring
data initial screen.
• [U] button: Run sub menu
iii) Press the [>] button or [<] button to
select the item for monitoring (Fig. 5:
Example).
• [>] button: Go on to next item
a Scroll the monitoring items to dis-

• [<] button: Go back to last item
a If the button is kept pressed, the

play in the internally set order.
a To hold or cancel monitoring data:

items will scroll at high speed.
If the [U] button is pressed during

monitoring, the monitor data is held
and the [U] mark flashes. If the [U]
button is pressed again, it becomes
active again.
20-100 WA430-6
6) Setting 2nd item simultaneous monitoring iv) When both of the monitoring codes
i) Select the 2nd item display on the sub h a v e b e e n c o n fi r m e d , t h e s c r e e n
a To hold or cancel monitoring data:

menu screen. switches to the 2nd item display screen.
ii) With the sub menu selected, press the
[U] button and display the monitoring If the [U] button is pressed during mon-
code input screen. itoring, the monitor data are held and the
• [U] button: Run sub menu [U] mark flashes. If the [U] button is
pressed again, it becomes active again.
iii) Operate each button and input the mon-

itoring code for the 2nd monitoring item 7) Display data for 2nd item simultaneous
directly. monitoring
• [>] button: Number at cursor goes up On the 2nd item simultaneous monitoring
• [<] button: Number at cursor goes screen, the following data are displayed.
down A: Monitoring code 1
• [U] button: Number at cursor is con- 1: Monitoring data 1 (including unit)
firmed B: Monitoring code 2
a For details, see "Monitoring code table".

• [t] button: Returns to code input 2: Monitoring data 2 (including unit)
screen
WA430-6 20-101
Monitoring codes table
Monitor panel (Machine monitor system)

Monitoring Monitoring item Displayed item Data display range Unit
No.
code (*1) (*2) (*3) (*4)
1 20200 Part No. of machine monitor ROM MONITOR ROM Arabic figures Display of condition
2 01001 Engine speed ENG SPEED 0 – 3000 rpm
3 40000 Travel speed SPEED 0 – 50 km/h
4 04202 Fuel level FUEL SENSOR 0 – 100 %
5 04401 Hydraulic oil temperature HYD TEMP 24 – 131 °C
6 04103 Engine coolant temperature COOLANT TEMP 24 – 131 °C
7 04104 Engine coolant temperature (Low temperature) COOLANT Lo -31 – 91 °C
8 40100 Torque converter oil temperature TC OIL TEMP 24 – 131 °C
9 04302 Charge level ALTERNATOR R 0.00 – 30.00 V
10 40200 Small lamp voltage SMALL LAMP 0.00 – 30.00 V
11 40300 Electrolyte level A BATTERY A2V 0.00 – 30.00 V
12 40301 Electrolyte level B BATTERY B2V 0.00 – 30.00 V
13 06001 Lift arm angle BOOM ANG -41 – 46 °
14 40400 Lift arm bottom pressure BTM PRESS 0.00 – 50.00 MPa
15 40500 Lift arm rod pressure ROD PRESS 0.00 – 50.00 MPa
16 40600 Calibration pressure CAL PRESS 0.00 – 50.00 MPa
17 40700 Calculated pressure MES PRESS 0.00 – 50.00 MPa
18 40800 Calculated weight MES LOAD 0.00 – 50.00 t
19 30802 Position of rotary switch SW1, SW2, SW3 0–F Display of condition
20 30904 Position of DIP switch SW5-1, SW5-2 ON/OFF Display of condition
24 40900 Input signal D_IN_0-7 D-IN--0------7 See attached table Display of condition
25 40901 Input signal D_IN_8-15 D-IN--8-----15 See attached table Display of condition
26 40902 Input signal D_IN_16-23 D-IN-16-----23 See attached table Display of condition
*1 : All items are displayed although their sensors are not installed to all the models and options.
*2 : When displayed, the above items are contracted since the number of displayed letters is limited.
*3 : If a value is below (or above) the display range, the display range is displayed.
a
*4 : Only the SI units are used.
Note that each of the following monitoring items shows the information of 2 or 3 systems simultaneously.
No. 19 : Setting condition of rotary switch (3 pieces are displayed simultaneously)
No. 20 : Setting condition of DIP switch (2 pieces are displayed simultaneously)
20-102 WA430-6
Transmission (Transmission controller system)

No.
code (*1) (*2) (*3) (*4)
1 20201 Part No. of transmission controller ROM TRANSM ROM — Display of condition
2 41000 Fan pump target speed FAN PUMP 0 – 3000 rpm
3 41100 Left brake pressure LH BRAKE 0.00 – 50.00 MPa
4 41200 Transmission cut-off pressure CUT OFF 0.00 – 50.00 MPa
5 41300 Kick-down speed K/D TIMES — —
6 41301 Average cycle time CYCLE TIME — sec.
7 31608 F clutch ECMV current ECMV F 0 – 1000 mA
8 31606 R clutch ECMV current ECMV R 0 – 1000 mA
9 31602 1st clutch ECMV current ECMV 1 0 – 1000 mA
10 31603 2nd clutch ECMV current ECMV 2 0 – 1000 mA
11 31604 3rd clutch ECMV current ECMV 3 0 – 1000 mA
12 31605 4th clutch ECMV current ECMV 4 0 – 1000 mA
13 31609 Lockup clutch ECMV current ECMV LU 0 – 1000 mA
14 41400 Fan pump EPC current FAN EPC 0 – 1000 mA
15 41401 Loader pump EPC current PUMP EPC 0 – 1000 mA
16 41500 Transmission oil temperature ECMV OIL TEMP 24 – 131 °C
17 41600 Selection of engine mode ENGINE MODE P/N —
18 41700 Selection of shift mode SHIFT MODE H/L —
19 41808 F clutch fill time FILL TIME F 0 – 2550 msec
20 41806 R clutch fill time FILL TIME R 0 – 2550 msec
21 41802 1st clutch fill time FILL TIME 1 0 – 2550 msec
22 41803 2nd clutch fill time FILL TIME 2 0 – 2550 msec
23 41804 3rd clutch fill time FILL TIME 3 0 – 2550 msec
24 41805 4th clutch fill time FILL TIME 4 0 – 2550 msec
25 31508 Display of F clutch FILL SW (F) 0 – 1 (Normal/Abnormal) Display of condition
26 31506 Display of R clutch FILL SW (R) 0 – 1 (Normal/Abnormal) Display of condition
27 31502 Display of 1st clutch FILL SW (1) 0 – 1 (Normal/Abnormal) Display of condition
28 31503 Display of 2nd clutch FILL SW (2) 0 – 1 (Normal/Abnormal) Display of condition
29 31504 Display of 3rd clutch FILL SW (3) 0 – 1 (Normal/Abnormal) Display of condition
30 31505 Display of 4th clutch FILL SW (4) 0 – 1 (Normal/Abnormal) Display of condition
35 30202 Rear brake oil temperature R BRAKE OIL 24 – 131 °C
36 40915 Output signal D_OUT_0-6 D-OUT-0------6 See attached table Display of condition
37 40914 Output signal SOL/0_0-5 SOL/O-0----5 See attached table Display of condition
*1: All items are displayed although their sensors are not installed to all the models and options.
*2: When displayed, the above items are contracted since the number of displayed letters is limited.
*3: If a value is below (or above) the display range, the display range is displayed.
*4: Only the SI units are used.
WA430-6 20-103
WOK (Work equipment controller system)

No.
code (*1) (*2) (*3) (*4)
1 20202 Part No. of work equipment controller ROM BOOM ROM — Display of condition
2 41900 Lift arm raise EPC current RAISE EPC 0 – 1000 mA
3 41901 Lift arm lower EPC current LOWER EPC 0 – 1000 mA
4 41902 Bucket tilt EPC current TILT EPC 0 – 1000 mA
5 41903 Bucket dump EPC current DUMP EPC 0 – 1000 mA
6 41904 Joystick steering right EPC current RH J/S EPC 0 – 1000 mA
7 41905 Joystick steering left EPC current LH J/S EPC 0 – 1000 mA
8 41906 3-spool valve 1 EPC current 3RD EPC1 0 – 1000 mA
9 41907 3-spool valve 2 EPC current 3RD EPC2 0 – 1000 mA
10 42000 Lever potentiometer voltage lift arn 1 BOOM POT1 0.00 – 5.00 V
11 42001 Lever potentiometer voltage lift arm 2 BOOM POT2 0.00 – 5.00 V
12 42002 Lever potentiometer voltage bucket 1 BUCKET POT1 0.00 – 5.00 V
13 42003 Lever potentiometer voltage bucket 2 BUCKET POT2 0.00 – 5.00 V
14 42004 Lever potentiometer voltage joystick steering 1 J/S POT1 0.00 – 5.00 V
15 42005 Lever potentiometer voltage joystick steering 2 J/S POT2 0.00 – 5.00 V
16 42006 Lever potentiometer voltage 3-spool valve 1 3RD POT1 0.00 – 5.00 V
17 42007 Lever potentiometer voltage 3-spool valve 2 3RD POT2 0.00 – 5.00 V
18 06002 Lift arm angle BOOM ANG -41 – 46 deg.
19 40401 Lift arm bottom pressure BTM PRESS 0.00 – 50.00 MPa
20 42100 Number of lift arm lever operating times BOOM LVR 0 – 25600 x1000
21 42101 Number of bucket lever operating times BUCKET LVR 0 – 25600 x1000
22 42102 Number of 3-spool valve lever operating times 3RD LVR 0 – 25600 x1000
23 01003 Engine speed ENG SPEED 0 – 3000 rpm
24 40001 Travel speed SPEED 0 – 50 km/h
29 40916 Output signal SOL/0_0-5 SOL/0-0----5 See attached table Display of condition
30 40917 Output signal D_OUT_0-6 D-OUT-0------6 See attached table Display of condition
*1: All items are displayed although their sensors are not installed to all the models and options.
*2: When displayed, the above items are contracted since the number of displayed letters is limited.
*3: If a value is below (or above) the display range, the display range is displayed.
*4: Only the SI units are used.
20-104 WA430-6
a ON/OFF switch signals input to controller ii) Method of reading output signal D-OUT-
i) Method of reading input signal D-IN-0.....7 0.....7
• Input status display 0: No input (OFF) • Output status display 0: No output (OFF)
• Input status display 1: Input (ON) • Output status display 1: Output (ON)
(1) : Monitoring code (1) : Monitoring code

(2) : Input status (2) : Output status
Starting from the left, the status is dis- Starting from the left, the status is dis-
played in turn from D-IN-0 to D-IN-7. played in turn from D-OUT-0 to D-
OUT-7.
Monitor Panel
Input/
Monitoring
No. Output Display Item Content of ON/OFF Switch
Code
Signal
D-IN-0 Head lamp Head lamp lights up = ON(24V)/OFF(OPEN)
D-IN-2 Starting switch output Starting motor started = ON(24V)/OFF(OPEN)
1 40900
D-IN-4 Auto grease A Tank empty or abnormal = ON(24V)/OFF(OPEN)
D-IN-5 Auto grease B Operating or abnormal = ON(24V)/OFF(OPEN)
D-IN-12 Turn signal right Right turn signal lights up = ON(24V)/OFF(OPEN)
D-IN-13 Turn signal left Left turn signal lights up = ON(24V)/OFF(OPEN)
D-IN-14 U Switch input
2 40901
Switch pressed = ON(24V)/OFF(OPEN)
D-IN-15 t Switch input Switch pressed = ON(24V)/OFF(OPEN)
D-IN-16 Brake oil pressure (Front) Oil pressure normal = ON(GND)/(OPEN)
3 40902 D-IN-17 Brake oil pressure (Rear) Oil pressure normal = ON(GND)/(OPEN)
D-IN-20 Air cleaner clogging No clogging = ON(GND)/(OPEN)
D-IN-26 Parking brake Parking brake applied = ON(GND)/(OPEN)
D-IN-27 Engine coolant level Coolant level normal = ON(GND)/(OPEN)
4 40903 D-IN-28 Engine oil pressure Drop in oil pressure = ON(GND)/(OPEN)
D-IN-29 Engine oil level Oil level normal = ON(GND)/(OPEN)
D-IN-30 Emergency steering motor normal Emergency steering motor actuated = ON(GND)/(OPEN)
D-IN-32 Load meter sub-total switch Switch pressed = ON(GND)/(OPEN)
D-IN-33 Load meter cancel switch Switch pressed = ON(GND)/(OPEN)
D-IN-34 High beam switch High beam = ON(GND)/(OPEN)
5 40904 D-IN-36 Service function 2 Switch pressed = ON(GND)/(OPEN)
D-IN-37 > Switch input Switch pressed = ON(GND)/(OPEN)
D-IN-38 < Switch input Switch pressed = ON(GND)/(OPEN)
D-IN-39 Drop in steering pressure Oil pressure normal = ON(GND)/(OPEN)
WA430-6 20-105
Transmission Controller
Input/
Monitoring
Code
Signal
D-IN-0 Steering pressure switch (N.O.) Pressure normal ON=(OPEN)/OFF(GND)
D-IN-1 Steering pressure switch (N.C.) Pressure normal ON=(OPEN)/OFF(GND)
D-IN-2 Transmission cut-off switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-3 Transmission cut-off set switch Switch pressed = ON(GND)/OFF(OPEN)
1 40905 D-IN-4 Travel damper selector switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-5 Lock up selector switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-6 Kick-down switch Switch pressed = ON(GND)/OFF(OPEN)
Power mode = ON(GND) /Economy
D-IN-7 Engine power mode
mode(OPEN)
D-IN-8 Shift range 1st 1st = ON(24V)/OFF(OPEN)
D-IN-9 Shift range 2nd 2nd = ON(24V)/OFF(OPEN)
D-IN-10 Shift range 3rd 3rd = ON(24V)/OFF(OPEN)
D-IN-11 Shift range 4th 4th = ON(24V)/OFF(OPEN)
2 40906
D-IN-12 Joystick shift up Switch pressed = ON(24V)/OFF(OPEN)
D-IN-13 Joystick shift down Switch pressed = ON(24V)/OFF(OPEN)
D-IN-14 Electric emergency steering manual switch Switch pressed = ON(24V)/OFF(OPEN)
D-IN-15 Starting switch output Starting motor started = ON(GND)/OFF(OPEN)
D-IN-16 Right FNR (Joystick) selector switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-17 Right seesaw switch & joystick FORWARD FORWARD = ON(24V)/OFF(OPEN)
D-IN-18 Right seesaw switch & joystick NEUTRAL NEUTRAL = ON(24V)/OFF(OPEN)
D-IN-19 Right seesaw switch & joystick REVERSE REVERSE = ON(24V)/OFF(OPEN)
3 40907
D-IN-20 Directional lever FORWARD FORWARD = ON(24V)/OFF(OPEN)
D-IN-21 Directional lever NEUTRAL NEUTRAL = ON(24V)/OFF(OPEN)
D-IN-22 Directional lever REVERSE REVERSE = ON(24V)/OFF(OPEN)
D-IN-23 Neutralizer (Parking brake) signal Parking switch ON = ON(24V)/OFF(OPEN)
D-IN-24 F clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-25 R clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-26 1st clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-27 2nd clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
4 40908
D-IN-28 3rd clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-29 4th clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-30 Lock up clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-31 Shift hold switch Switch pressed = ON(GND)/OFF(OPEN)
D-OUT-0 Backup lamp relay Output ON (24V)/OFF(GND)
5 40915
D-OUT-1 Transmission cut-off indicator Output ON (24V)/OFF(GND)
SOL/O-0 Electric emergency steering relay Output ON (24V)/OFF(GND)
SOL/O-1 ECSS relay Output ON (24V)/OFF(GND)
SOL/O-2 Switch pump cut-off Output ON (24V)/OFF(GND)
6 40914
SOL/O-3 Neutral output Output ON (24V)/OFF(GND)
SOL/O-4 Fan pump reverse rotation solenoid Output ON (24V)/OFF(GND)
SOL/O-5 Fan pump neutral solenoid Output ON (24V)/OFF(GND)
20-106 WA430-6

Input/
Monitoring
Code
Signal
Selection of J/S (Right FNR), ON = (24V) / OFF
D-IN-0 Joystick ON/OFF switch
(OPEN)
1 40910
Working position = ON (24V) / Lock position = OFF
D-IN-1 Work equipment lock lever switch
(OPEN)
Selection of J/S Hi speed = ON (24V) / OFF
D-IN-8 Joystick speed Hi/Lo selector switch
(OPEN)
D-IN-9 Bucket proximity switch (Horizontal) Horizontal position = ON (24V) / OFF (OPEN)
2 40911
D-IN-10 Bucket full stroke switch Stroke end position = ON (24V) / OFF (OPEN)
D-IN-12 Semiautomatic digging hard switch Switch pressed = ON (24V) / OFF (OPEN)
D-IN-13 Semiautomatic digging soft switch Switch pressed = ON (24V) / OFF (OPEN)
D-IN-28 Remote positioner raise set switch Switch pressed = ON (24V) / OFF (OPEN)
D-IN-29 Remote positioner lower set switch Switch pressed = ON (24V) / OFF (OPEN)
3 40913
D-IN-30 Remote positioner raise selector switch Switch pressed = ON (24V) / OFF (OPEN)
D-IN-31 Remote positioner lower selector switch Switch pressed = ON (24V) / OFF (OPEN)
SOL/O-0 Joystick steering EPC cut-off relay Output = ON (24V) / OFF (OPEN)
SOL/O-1 Lift arm raise detent Output = ON (24V) / OFF (OPEN)
4 40916 SOL/O-2 Lift arm float detent Output = ON (24V) / OFF (OPEN)
SOL/O-3 Bucket tilt detent Output = ON (24V) / OFF (OPEN)
SOL/O-4 Work equipment neutral lock solenoid Output = ON (24V) / OFF (OPEN)
D-O-1 Remote positioner raise lamp Output = ON (24V) / OFF (OPEN)
5 40917
D-O-2 Remote positioner lower lamp Output = ON (24V) / OFF (OPEN)
WA430-6 20-107
12. Reduced cylinder mode (CYLINDER CUT-OUT)

This mode is not effective because engine con-
troller is not applicable.
a The machine monitor is used to carry out the

13. Adjustment function (default setting)
default setting when the transmission has

been overhauled or replaced, or the sensors,
EPC valve, controller have been replaced or
added, or when adjusting or compensating
for tolerance in installation or individual dif-
ferences in manufacture.
• Adjustment items
1) Setting initial training of transmis-
sion
2) Adjusting lift arm angle sensor
(RAISE) (for EPC lever)
3) Adjusting lift arm RAISE EPC valve
4) Adjusting lift arm LOWER EPC
valve
5) Adjusting bucket TILT EPC valve
6) Adjusting bucket DUMP EPC valve
7) Adjusting 3-tandem valve EPC
valve (cylinder extension)
8) Adjusting 3-tandem valve EPC
valve (cylinder retraction)
9) Adjusting joystick steering calibra-
tion (right)
10) Adjusting joystick steering calibra-
tion (left)
a For details, see Structure and function and maintenance standard, Settings needed when installing optional
equipment.
20-108 WA430-6
14. Filter, oil replacement interval setting function

The machine monitor can set the maintenance
interval for filters and oil. This forms the base for
the filter and oil replacement interval and dis-
a For details, see Structure and function and

play.
maintenance standard, Maintenance moni-

tor items.
Table of filter and oil replacement interval set items [when shipping]
No. Item Code Display Replacement interval (h)

1 Engine oil 01 ENG OIL 500
2 Engine oil filter 02 ENG OIL FILTER 500
3 Fuel filter 03 FUEL FILTER 500
4 Corrosion resistor 06 CORR RESISTOR 1,000
5 Transmission oil 12 TM OIL 1,000
6 Transmission oil filter 13 TM OIL FILTER 1,000
7 Hydraulic filter 04 HYD OIL FILTER 2,000
8 Hydraulic tank breather element 05 BREATHER ELE 2,000
9 Axle oil 15 AXLE OIL 2,000
10 Hydraulic oil 10 HYD OIL 2,000
WA430-6 20-109
15. Option selection function

• When adding or removing optional equip-
ment, change the setting on the machine
monitor.
• When the machine monitor has been re-
placed, set the status of optional equipment
installed on the machine.
Option set items
Item No. Real-time monitor items English display Remarks

Monitor panel controller
1 Auto grease AUTO GREASE
2 Battery electrolyte level drop sensor BAT LIQUID
3 Transmission clogging sensor TRANSM CLOG
4 Printer PRINTER
5 Lift arm Hi lift specification HI LIFT
6 Speedometer/tachometer display switch ENGINE RPM Use ADD screen to display engine speed
7 Short ton switch SHORT TON Can be switched only when MPH is displayed
1 Travel damper E.C.S.S.
2 Torque converter lock-up LOCK UP
3 Emergency steering EMER STRG
4 Tire size TIRE SIZE Tire compensation for non-specified tires
5 Spare switch SPARE SW
6 Right FNR switch RH FNR SW
1 EPC lever EPC LEVER
2 Joystick JOY STICK
3 EPC 3rd lever EPC 3RD
a There is no set item for engine controller.

a For details, see Structure and function and maintenance standard, Settings needed when installing optional
equipment.
20-110 WA430-6
16. Serial No. setting function

This is used to set the serial number of the machine.
a For details, see Structure and function and main-

tenance standard, Settings needed for the ma-
chine.
a This function is a special function used only

17. Initialize function
at the factory, so it cannot be used when ser-

vicing the machine.
WA430-6 20-111
TESTING AND ADJUSTING PM CLINIC INSPECTION TABLE
Pm Clinic inspection table

WA430-6 Serial No. H50051 and up
Machine serial No. #
Engine serial No.

hour inspection SAA6D114-2 #
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 torque converter oil temperature
Maximum coolant temperature (During operation)
(During operation)
aIf machine is cold, warm it up.

aWorking mode: P-mode
Standard Measure-
Service limit
Item Condition Unit value for new ment Good Bad
value
machine result
Engine at low idle 740 – 790 740 – 790
Engine at high idle 2,175 – 2,275 2,175 – 2,275
Engine at high idle and torque converter
1,800 – 2,000 1,700 – 2,100
stalled
Engine speed rpm
Engine at high idle and work equipment
2,120 – 2,320 2,020 – 2,420
relieved
Torque converter stalled + Work equipment
1,760 – 1,960 1,660 – 2,060
relieved
Engine
Engine at high idle and torque converter kPa Max. 2.99 Max. 2.99
Blow-by pressure
stalled {mmAg} {Max. 305} {Max. 305}
0.36 – 0.61 Min. 0.21
Engine at high idle
Lubricating oil SAE MPa {3.5 – 6.0} {Min. 2.1}
pressure 15W-40 {kg/cm2} Min. 0.15 Min. 0.07
Engine at low idle
{Min. 1.5} {Min. 0.7}
Engine at high idle and torque converter kPa Min. 133.3 Min. 113.3
Boost pressure
stalled {mmHg} {Min. 1,000} {Min. 850}
Engine at high idle and torque converter
Exhaust
stalled °C Max. 550 Max. 600
temperature
Outside temperature: 20°C
aWhen shifting transmission gear to forward/reverse position, apply brake securely. Good Bad
Engine at 2.69 – 3.09 2.69 – 3.09
Main relief high idle {27.5 – 31.5} {27.5 – 31.5}
pressure Engine at 2.56 – 2.96 2.56 – 2.96
• Torque converter oil pressure:
Transmission valve
low idle {26.2 – 30.2} {26.2 – 30.2}

Torque converter Engine at Max. 0.88 Max. 0.88
• Transmission: Neutral
inlet pressure high idle MPa {Max. 9.0} {Max. 9.0}
Torque converter Engine at {kg/cm2} 0.46 – 0.56 0.46 – 0.56
outlet pressure high idle {4.7 – 5.7} {4.7 – 5.7}
1st, 2nd, • Torque converter oil pressure: 2.1 – 2.4 2.1 – 2.4
ECMV output 3rd, 4th Within operating range {21.5 – 24.5} {21.5 – 24.5}
(clutch) pressure • Engine at high idle 2.2 – 2.5 2.2 – 2.5
F, R • Manual switch: ON {22.5 – 25.5} {22.5 – 25.5}
20-112 WA430-6
Standard Measure-
Service limit
value
machine result
Secure frame with safety bar.
Steering
Steering relief 23.3 – 25.7 22.1 – 25.7

Engine at high idle
pressure MPa {237.5 – 262.5} {225 – 262.5}
Steering control • Engine at low idle {kg/cm2} 1.1 – 1.4 0.9 – 1.6
pressure • Steering in neutral {11 – 14} {9 – 16}
Parking brake oil Min. 2.27 Min. 2.27
pressure {Min. 23.1} {Min. 23.1}
Within operating range MPa
Parking brake
• Engine at low idle {kg/cm2} Min. 2.27 Min. 2.27
solenoid valve
• Parking brake: OFF {Min. 23.1} {Min. 23.1}
basic pressure
Parking brake • Test on flat and dry paved slope of 1/5 Machine must Machine must
—
performance (11° 20'). not move. not move.
• Set machine in operating state.
Parking brake
— mm 3.12 – 3.28 2.97
disc thickness
Measure when brake
Charge cut-in • Hydraulic oil 5.9 – 6.4 5.4 – 6.9
oil pressure warning
pressure temperature: {60 – 65} {55 – 70}
lamp goes off.
Within operating
range Measure when brake
Charge cut-out MPa 9.8 – 10.8 9.3 – 11.3
oil pressure starts
pressure • Engine at low idle {kg/cm2} {100 – 110} {95 – 115}
Brake
lowering after rising.

Brake oil 3.8 – 4.6 3.4 – 5.0
pressure {38 – 47} {34 – 51}
• Engine at low idle
Lowering of • Engine: Stopped
kPa
brake oil • Measure lowering of oil pressure from 4.9 Max. 98 {1.0} Max. 98 {1.0}
2 {kg/cm2}
pressure MPa {50 kg/cm } in 5 minutes.
• Test on flat, level, straight, and dry paved
road.
Wheel brake • Braking initial speed: 35 km/h, Delay in
m Max. 12 Max. 12
performance pressing pedal: Max. 0.1 sec
• Brake pedal pressing force: Specified
force, 289 – 353 N {29.5 – 36.1 kg}
• Measure braking distance.
Projection of
Wear of wheel • Oil pressure: 4.9 MPa {5.0 kg/cm2} Projection of
mm shaft to wear
brake disc • Pedal: Stroke end shaft: 0
limit (2.4 mm)
WA430-6 20-113
Standard Measure-
Service limit
value
machine result
Work equipment
29.8 – 33.0 27.4 – 33.0
valve relief Bucket circuit relieved
{3.4 – 336} {280 – 336}
pressure
Work equipment
Work equipment 2.1 – 2.7 1.8 – 3.0
valve unload
control lever in neutral MPa {21 – 27} {18 – 30}
pressure • Hydraulic oil
temperature: {kg/cm2}
Work equipment Work equipment
1.3 – 1.7 1.1 – 1.9
valve LS differential Within operating control lever moved
Work equipment
range {13 – 17} {11 – 19}

pressure halfway
PPC valve basic • Engine at high Work equipment 3.7 – 3.9 3.5 – 3.9
idle
pressure control lever in neutral {38 – 40} {36 – 40}
Rising time 5.4 – 6.4 Max. 7.6
Lift arm speed
Lowering time 2.8 – 3.8 Max. 4.4
SEC
Dumping time 1.5 – 2.1 Max. 2.4
Bucket speed
Tilting time 2.0 – 2.6 Max. 3.0
• Hydraulic oil Bucket cylinder Max. 17 Max. 20
temperature:
Hydraulic drift of mm/
Within operating
work equipment Lift cylinder 15 min. Max. 20 Max. 24
range
• Engine: stopped
Front axle There must not be excessive
Axle
Visual check of
—
differential drain plug Rear axle metal powder.
20-114 WA430-6
WA430-6 20-115
20-116 WA430-6
TROUBLESHOOTING
20 TROUBLESHOOTING
Points to remember when troubleshooting . 20-202
Sequence of events in troubleshooting ....... 20-203
Points to remember when carrying out
maintenance ............................................... 20-204
Testing before troubleshooting ................... 20-212
Classification and procedures of
troubleshooting ........................................... 20-213
Phenomena looking like troubles and
troubleshooting Nos. ................................... 20-216
Connector arrangement drawing and
electric circuit diagram of each system ....... 20-220
Connection table for connector pin numbers 20-251
T-branch box and T-branch table ................ 20-274
Troubleshooting to be taken when
failure code is recorded (Display of code) ... 20-276
Before carrying out troubleshooting for
electrical system (E-mode) ......................... 20-597
Method of using troubleshooting chart ........ 20-778
Table of failure modes and causes ............. 20-783
Method of using troubleshooting charts ...... 20-813
WA430-6 20-201
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
Points to remember when troubleshooting

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
a When operating the machine to reenact

the failure. etc.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
a The basic procedure for troubleshooting

from the problem that has been reported? ure exactly.
2) Was there anything strange about the
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202 WA430-6
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
Sequence of events in troubleshooting
WA430-6 20-203
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Points to remember when Main failures occurring in wiring harness

1) Defective contact of connectors (defective
carrying out maintenance contact between male and female)
Problems with defective contact are likely to
To maintain the performance of the machine over a occur because the male connector is not
long period, and to prevent failures or other troubles properly inserted into the female connector,
before they occur, correct operation, maintenance or because one or both of the connectors is
and inspection, troubleshooting, and repairs must be deformed or the position is not correctly
carried out. This section deals particularly with cor- aligned, or because there is corrosion or
rect repair procedures for mechatronics and is oxidization of the contact surfaces.
aimed at improving the quality of repairs. For this
purpose, it gives sections on "Handling electric
equipment" and "Handling hydraulic equipment"
(particularly gear oil and hydraulic oil).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are 2) Defective crimping or soldering of connec-
more likely to be affected by the direct effects of tors
rain, water, heat, or vibration. Furthermore, dur- The pins of the male and female connectors
ing inspection and repair operations, they are are in contact at the crimped terminal or sol-
frequently removed and installed again, so they dered portion, but if there is excessive force
are likely to suffer deformation or damage. For brought to bear on the wiring, the plating at
this reason, it is necessary to be extremely care- the joint will peel and cause improper con-
ful when handling wiring harnesses. nection or breakage.
20-204 WA430-6
3) Disconnections in wiring 5) Oil or dirt stuck to connector

If the wiring is held and the connectors are If oil or grease are stuck to the connector
pulled apart, or components are lifted with a and an oil film is formed on the mating sur-
crane with the wiring still connected, or a face between the male and female pins, the
heavy object hits the wiring, the crimping of oil will not let the electricity pass, so there
the connector may separate, or the solder- will be defective contact.
ing may be damaged, or the wiring may be If there is oil or grease stuck to the connec-
broken. tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
a When wiping the mating portion of the

tact restorer.
connector, be careful not to use exces-
a If there is oil or water in the compressed

sive force or deform the pins.
air, the contacts will become even dirtier,

so remove the oil and water from the
c omp res sed air comp lete ly b efo re
cleaning with compressed air.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water
should get into the connector, the pins will
be short-circuited by the water, so if any
water gets in, immediately dry the connector
or take other appropriate action before
passing electricity through it.
WA430-6 20-205
2) Removing, installing, and drying connectors

and wiring harnesses
• Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
a Never pull with one hand.

the connectors apart.
3) Action to take after removing connectors

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or
a If the machine is left disassembled for a

water from getting in the connector portion.
long time, it is particularly easy for im-

proper contact to occur, so always cover
the connector.
2) When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
a If the connector is twisted up and down

clip.
or to the left or right, the housing may

break.
20-206 WA430-6
• Connecting connectors 3) Correct any protrusion of the boot and any

1) Check the connector visually. misalignment of the wiring harness
1) Check that there is no oil, dirt, or water For connectors fitted with boots, correct any
stuck to the connector pins (mating por- protrusion of the boot. In addition, if the wir-
tion). ing harness is misaligned, or the clamp is
2) Check that there is no deformation, out of position, adjust it to its correct posi-
a If the connector cannot be corrected

defective contact, corrosion, or damage tion.
to the connector pins.
3) Check that there is no damage or break- easily, remove the clamp and adjust the
a If there is any oil, water, or dirt stuck to

age to the outside of the connector. position.
the connector, wipe it off with a dry cloth. 4) If the connector clamp has been removed,
If any water has got inside the connec- be sure to return it to its original position.
tor, warm the inside of the wiring with a Check also that there are no loose clamps.
dryer, but be careful not to make it too
a If there is any damage or breakage, re-

hot as this will cause short circuits.
place the connector.
• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
2) Fix the connector securely. 1. Male connector, 2. Female connector
Align the position of the connector correctly, • Normal locking state (Horizontal): a, b, d
then insert it securely. • Incomplete locking state (Diagonal): c
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
WA430-6 20-207
• Drying wiring harness 3) Carry out a continuity test on the connector.

If there is any oil or dirt on the wiring harness, After drying, leave the wiring harness dis-
wipe it off with a dry cloth. Avoid washing it in connected and carry out a continuity test to
water or using steam. If the connector must be check for any short circuits between pins
a After completely drying the connector,

washed in water, do not use high-pressure caused by water.
water or steam directly on the wiring harness.
blow it with contact restorer and reas-
If water gets directly on the connector, do as fol- semble.
lows.
1) Disconnect the connector and wipe off the
a If the connector is blown dry with com-

water with a dry cloth.
pressed air, there is the risk that oil in the

air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
a Hot air from the dryer can be used, but

dryer to dry the connector.
regulate the time that the hot air is used

in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
20-208 WA430-6
3) Handling control box 6) Do not place the control box on oil, water, or
1) The control box contains a microcomputer soil, or in any hot place, even for a short
and electronic control circuits. These control time.
all of the electronic circuits on the machine, (Place it on a suitable dry stand).
so be extremely careful when handling the 7) Precautions when carrying out arc welding
control box. When carrying out arc welding on the body,
2) Do not open the cover of the control box disconnect all wiring harness connectors
unless necessary. connected to the control box. Fit an arc
welding ground close to the welding point.
3) Do not place objects on top of the control

box. 2. Points to remember when troubleshooting
4) Cover the control connectors with tape or a electric circuits
vinyl bag. 1) Always turn the power OFF before discon-
Never touch the connector contacts with necting or connect connectors.
your hand. 2) Before carrying out troubleshooting, check
5) During rainy weather, do not leave the con- that all the related connectors are properly
a Disconnect and connect the related con-

trol box in a place where it is exposed to inserted.
rain.
nectors several times to check.
3) Always connect any disconnected connec-
a If the power is turned ON with the con-

tors before going on to the next step.
nectors still disconnected, unnecessary

abnormality displays will be generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related wir-
ing and connectors several times and check
that there is no change in the reading of the
a If there is any change, there is probably

tester.
defective contact in that circuit.
WA430-6 20-209
3. Points to remember when handling hydraulic 3) Sealing openings

equipment After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
With the increase in pressure and precision of vinyl bags to prevent any dirt or dust from enter-
hydraulic equipment, the most common cause of ing. If the opening is left open or is blocked with
failure is dirt (foreign material) in the hydraulic cir- a rag, there is danger of dirt entering or of the
cuit. When adding hydraulic oil, or when disassem- surrounding area being made dirty by leaking oil
bling or assembling hydraulic equipment, it is so never do this.
necessary to be particularly careful. Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
1) Be careful of the operating environment. take it back with you for disposal.
Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
me nt s ho uld be ca rried o ut in a spe cially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test 4) Do not let any dirt or dust get in during refill-
equipment. ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210 WA430-6
5) Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it flows
easily. In ad dition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-
taminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or con-
taminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3?) particles that the filter
bu ilt into th e h yd ra ulic eq u ip men t ca n no t
remove, so it is an extremely effective device.
WA430-6 20-211
TROUBLESHOOTING TESTING BEFORE TROUBLESHOOTING
Testing before troubleshooting

Item Criteria Remedy
1. Check of level and type of fuel – Add oil
2. Check for foreign matter in fuel – Clean or drain
3. Check of level and type of oil in engine oil pan – Add oil
4. Check of coolant level – Add coolant
Lubricating oil 5. Check of air cleaner for clogging – Clean or replace

and coolant 6. Check of level and type of hydraulic oil – Add oil
7. Check of level and type of transmission oil – 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
11. Check of battery terminal cables for looseness and Retighten or
–
corrosion replace
12. Check of alternator terminal cables for looseness and Retighten or
Electrical –
corrosion replace
parts
13. Check of starting motor terminal cables for looseness and Retighten or
–
corrosion replace
14. Check of operation of instruments – Repair or replace
15. Check for abnormal noise and smell – Repair
Hydraulic
and 16. Check for oil leakage – Repair
mechanical 17. Bleeding air – Bleed air
equipment
18. Check of effect of brake – Repair or adjust
Charge or
19. Check of battery voltage (with engine stopped) 20 – 30V
replace
20. Check of battery electrolyte level – Add or replace
21. Check or wires for discoloration, burn, and removal of
– Replace
cover
22. Check for removed wire clamp and drooping wire – Repair
Electrical 23. Check wiring for wetting with water (Check connectors and Disconnect and
equipment –
terminals for wetting with water, in particular) dry connectors
24. Check of slow-blow fuses and fuses for disconnection and
– Replace
corrosion
25. Check of alternator voltage (with engine at medium speed After several-minute
Repair or replace
or higher) operation: 27.5 – 29.5 V
26. Check of operating sound of battery relay (Starting switch
– Replace
OFF ON)
20-212 WA430-6
TROUBLESHOOTING CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
Classification and procedures of troubleshooting
WA430-6 20-213
Classification of troubleshooting
Mode Contents
Display of code Troubleshooting when failure code is displayed
E-mode Troubleshooting for electric system
H-mode Troubleshooting for hydraulic and mechanical system
S-mode Troubleshooting for engine unit
20-214 WA430-6
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).
a Each failure code "flashes" when the trouble corresponding to it is detected. Even if a failure code "lights
Carry out troubleshooting in [Display of failure code] according to the displayed failure code.
up" when the starting switch is turned ON, the trouble corresponding to that failure code may not have
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble cor-
been repaired (Some troubles can be detected by simply turning the starting switch ON).
responding to it has been repaired (For the method of reproducing the failure code, see the troubleshoot-
ing 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 display
mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
a Each failure code "flashes" when the trouble corresponding to it is detected. Even if a failure code "lights
If a failure code is recorded, carry out troubleshooting in [Display of code] according to that failure code.
up" when the starting switch is turned ON, the trouble corresponding to that failure code may not have
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble cor-
been repaired (Some troubles can be detected by simply turning the starting switch ON).
responding to it has been repaired (For the method of reproducing the failure code, see the troubleshoot-
ing 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 troubleshooting
related to that phenomenon in the "E mode", "H mode", or "S mode".
WA430-6 20-215
TROUBLESHOOTING PHENOMENA LOOKING LIKE TROUBLES AND TROUBLESHOOTING NOS.
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
q
1 Action codes are displayed on machine monitor Check failure code
2 If failure code display function is checked, failure codes are displayed
Phenomena related to engine
3 Engine does not start easily (It always takes time to start) E-1 S-1
4 Engine Engine does not crank E-1 S-2 a)
5 does Engine cranks but exhaust smoke does not come out (Fuel is not injected) S-2 b)
6 not start Exhaust smoke comes out but engine does not start (Fuel is injected) S-2 c)
7 Engine speed does not rise sharply (Follow-up performance is low) S-3
8 Engine stops during operation S-4
9 Engine rotation is abnormal (Engine hunts) S-5
10 Output is insufficient (Power is low) S-6
11 Exhaust gas color is bad (Incomplete combustion) S-7
12 Oil is consumed much (or exhaust gas color is bad) S-8
13 Oil becomes dirty quickly S-9
14 Fuel is consumed much S-10
15 Coolant contains oil, blows back, or reduces S-11
16 Oil pressure lamp lights up (Oil pressure lowers) S-12
17 Oil level rises (Water or fuel is mixed in oil) S-13
18 Coolant temperature rises too high (Overheating) S-14
19 Abnormal sound comes out S-15
20 Vibration is excessive S-16
21 Engine speed lowers excessively or engine stalls H-27 (S-4)
22 Engine low idle speed keeps low or high and does not rise E-2
23 Engine power does not change from high or low E-3
Phenomena related to power train
24 Machine does not start H-1
Travel speed is low, rushing force is low, gradeability is low, and transmission gear
25 H-2
is not shifted
26 Large shock is made when machine starts or transmission gear is shifted H-3
27 Large time is made when machine starts or transmission gear is shifted H-4
28 Torque converter oil temperature is high H-5
29 When kick-down switch is turned ON, kick-down operation does not start E-4
30 When hold switch is pressed, holding operation does not start E-5
Transmission is kept in neutral, or brake drags when directional lever is operated
31 E-6
while parking brake is applied
32 Transmission cut-off mode cannot be set or reset E-7
33 Transmission cut-off set cannot be reset E-8
When transmission cut-off function is turned ON, even if left brake pedal is pressed,
34 E-9
transmission is not cut off
35 Gear is not shifted up in automatic shift mode E-10
36 FNR switch mode cannot be set or reset E-11
In joystick mode, engine can be started even if FNR lever or FNR switch is not in N
37 E-12
position
38 While FNR lever is not in F position, F ECMV solenoid operates E-13
39 While FNR lever is not in R position, R ECMV solenoid operates E-14
40 While gearshift lever is not in 1st, 1st ECMV solenoid operates E-15
41 While gearshift lever is not in 2nd, 2nd ECMV solenoid operates E-16
42 While gearshift lever is not in 3rd, 3rd ECMV solenoid operates E-17
43 While gearshift lever is not in 4th, 4th ECMV solenoid operates E-18
20-216 WA430-6
Troubleshooting
display
Phenomena related to steering
44 Machine cannot be steered H-6
45 Machine cannot be steered (Joystick steering) H-7
46 Steering response is low H-8
47 Steering wheel is heavy H-9
48 Steering wheel shakes or makes large shocks H-10
49 Machine is always steered fully to right E-19
50 Machine is always steered fully to left E-20
51 Joystick mode cannot be used or reset E-21
52 Joystick steering speed is low or high (Hi/Lo cannot be changed) E-22
Joystick steering solenoid cannot be turned OFF (Joystick steering cannot be
53 E-23
reset)
While emergency steering switch is not turned ON, emergency steering motor
54 E-24
keeps turning
55 Emergency steering does not function or it always functions E-25
Phenomena related to brake
56 Brake does not work or braking force is low H-11
57 Brake is not reset or it drags H-12
58 Parking brake is not reset or it drags H-13
Phenomena related to work equipment
59 Lift arm does not rise H-14
60 Lift arm speed is low or rising force of lift arm is insufficient H-15
61 When lift arm rises, its speed lowers at specific height H-16
62 Bucket cannot be held with lift arm cylinder (Bucket floats) H-17
63 Hydraulic drift of lift arm is large H-18
64 Lift arm shakes during operation H-19
65 Bucket does not tilt H-20
66 Bucket speed is low or tilt-back force is insufficient H-21
67 Bucket spool lowers during tilt-back operation H-22
68 Bucket cannot be held with bucket cylinder H-23
69 Hydraulic drift of bucket is large H-24
Bucket shakes while machine is traveling with load (Work equipment valve is in
70 H-25
HOLD)
71 Lift arm and bucket control levers do not move smoothly and they are heavy H-26
72 Large shock is made when work equipment starts and stops H-28
73 When work equipment is relieved singly, other work equipment moves H-29
74 Work equipment does not move or cannot be locked E-29
75 Discharge from loader pump does not rise from minimum level E-30
76 Remote positioner raise stop position cannot be set E-31
77 Remote positioner lower stop position cannot be set E-32
78 Remote positioner raise cannot be selected or reset E-33
79 Remote positioner lower cannot be selected or reset E-34
80 Bucket positioner does not function E-35
81 Semiautomatic digging mode cannot be set or reset E-36
82 Semiautomatic digging hard mode cannot be set or reset E-37
83 Semiautomatic digging soft mode cannot be set or reset E-38
84 Travel damper function cannot be used or reset E-39
85 While travel damper switch is not turned ON, travel damper keeps operating E-40
86 Lift arm raise detent cannot be reset E-41
87 Lift arm float detent cannot be reset E-42
88 Bucket tilt detent cannot be reset E-43
89 While work equipment lock lever is in FREE position, work equipment is kept locked E-44
WA430-6 20-217
Troubleshooting
display
90 Lift arm always rises at full speed E-45
91 Lift arm always lowers at full speed E-46
92 Bucket always tilts at full speed E-47
93 Bucket always dumps at full speed E-48
94 3rd valve spool (extract) is extracted at full speed E-49
95 3rd valve spool (retract) is retracted at full speed E-50
96 Bucket positioner, boom kick-out, and float holding system do not function E-51
97 Boom kick-out does not function or cannot be reset E-52
98 Bucket positioner does not function or cannot be reset E-53
99 Lift arm float holding system does not function or cannot be reset E-54
Phenomena related to machine monitor
100 When parking brake is turned ON, parking brake indicator lamp does not light up E-55
When emergency brake operates, brake oil pressure caution lamp does not oper-
101 E-56
ate
102 Air cleaner clogging indicator lamp does not light up E-57
103 Engine oil pressure caution lamp does not light up E-58
104 Radiator coolant level caution lamp does not light up E-59
Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution
105 E-60
lamp does not light up
Torque converter oil temperature gauge does not rise and torque converter oil tem-
106 E-61
perature caution lamp does not light up
Abnormality in t switch (panel switch 1) input

107 Steering oil pressure caution lamp does not light up E-62
Abnormality in U switch (panel switch 2) input

108 E-63
109 E-64
110 Abnormality in < switch (panel switch 3) input E-65
111 Abnormality in > switch (panel switch 4) input E-66
Others
112 Fan speed does not rise from minimum level E-26
113 Fan reverse function cannot be used or reset E-27
114 Turning direction of fan does not change from reverse E-28
115 Wiper does not operate E-67
116 Windshield washer does not operate E-68
117 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off E-69
118 Working lamp does not light up or go off E-70
119 Turn signal lamp and hazard lamp do not light up or go off E-71
120 Brake lamp does not light or it keeps lighting up E-72
121 Backup lamp does not light or it keeps lighting up E-73
122 Backup buzzer does not sound or it keeps sounding E-74
123 While FNR lever is not in R position, backup buzzer keeps sounding E-75
124 Horn does not sound or it keeps sounding E-76
125 Warning buzzer does not sound or it keeps sounding E-77
20-218 WA430-6
WA430-6 20-219
TROUBLESHOOTINGCONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF
EACH SYSTEM
Connector arrangement drawing and electric circuit diagram of

each system
Connectors list
No. of pins Address

Connector Type of
Name of device Stereo- T-cir- WOK- ENG- M-cir-
No. connector
gram cuit circuit circuit cuit
A1 M 6 Air conditioner blower motor and resistor T-2

A2 SWP 6 Air conditioner air mix servomotor U-2
A3 M 2 Air conditioner thermistor U-2
A4 X 2 Air conditioner air servomotor U-8
A5 X 2 Air conditioner condenser switch T-1
A6 YAZAKI 2 Air conditioner Hi-Lo switch T-1
A7 YAZAKI 4 Air conditioner blower relay (Main) W-6
A8 YAZAKI 4 Air conditioner blower relay (Hi) W-6
A9 YAZAKI 4 Air conditioner blower relay (M2) W-6
A10 YAZAKI 4 Air conditioner blower relay (M1) W-5
A11 YAZAKI 4 Air conditioner condenser relay W-5
A12 YAZAKI 4 Air conditioner condenser Hi (1) relay W-5
A13 YAZAKI 4 Air conditioner condenser Hi (2) relay W-4
A14 YAZAKI 4 Air conditioner MAG clutch relay W-4
A20 Terminal 1 Ground (Floor) T-2
Coolant temperature sensor (Automatic air condi-
A21 YAZAKI 2 V-3
tioner model)
Cab temperature sensor (Automatic air conditioner
A22 YAZAKI 2 U-2
model)
Outside temperature sensor (Automatic air condi-
A23 YAZAKI 2 W-4
tioner model)
A24 DT2 2 Diode (Automatic air conditioner model) V-3
A25 DT2 2 Diode (Automatic air conditioner model) V-3
Intermediate connector (Automatic air conditioner
A26 DT1 2 W-3
model)
AL1 M 6 Intermediate connector (Air conditioner relay) U-2
AL2 S(W) 12 Intermediate connector (Air conditioner relay) V-3
B01 DT1 3 Air conditioner condenser motor H-9
B02 DT1 3 Air conditioner condenser motor I-9
Intermediate connector (Air conditioner condenser
BR1 DT2 6 K-3 V-1
motor)
C01 YAZAKI 9 AM/FM radio C-9
C02 08027 2 Speaker (Right) E-9
C03 08027 2 Speaker (Left) G-9
C04 M 2 Front working lamp (Right) B-8
C05 M 2 Front working lamp (Left) B-7
C07 08027 2 Room lamp C-8
C08 M 1 Door switch (Right) (Room lamp) C-8
C09 M 1 Door switch (Left) (Room lamp) B-8
C10 – 2 Cigarette lighter A-7
C12 M 6 Front wiper motor A-7
C15 M 4 Rear wiper motor B-8
KYORITSU
C17 4 Warning lamp switch D-9
ES
Plug con-
C18 1 Warning lamp (Beacon) F-9
nector
20-220 WA430-6
TROUBLESHOOTING CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF
EACH SYSTEM
No. of pins
Address
Connector Type of
No. connector
C19 DT2 6 Glass heater switch D-9

C29 M 1 Glass heater ON E-9
C33 H 1 Rear glass heater E-9
C35 H 1 Rear glass heater H-9
C39 Terminal 1 Ground (Radio) C-9
C40 Terminal 1 Ground (Cab) B-8
C40 Terminal 1 Ground (Side wiper) (Cab) G-9
C41 M 1 Warning lamp F-9
C43 YAZAKI 6 Side wiper switch E-9
C44 08027 4 Side wiper motor, right A-7
C45 M 4 Side wiper motor, left A-7
C46 M 1 Intermediate connector (Power supply) D-9
Air conditioner control amplifier (Automatic air con-
C47 AMP 20 D-9
ditioner model)
C47 Terminal 1 Ground (Beacon lamp) F-9
Air conditioner control amplifier (Automatic air con-
C48 AMP 16 D-9
ditioner model)
C49 SWP 8 Servomotor, left R-1
C50 SWP 8 Servomotor, right M-3
C51 YAZAKI 2 Diode (Automatic air conditioner model) M-3
SHINA-
C54 5 Side wiper G-9
GAWA
CAN1 DT2 3 Resistor N-1 C-1 V-2 J-3 C-2
CAN2 DT2 3 Resistor R-9 W-2 M-1 B-3 M-3
CL1 S 8 Intermediate connector (Glass heater) A-5
CL2 S(L) 12 Intermediate connector (Wiper motor) A-4
CL5 S(W) 16 M-2
model)
CL6 M 6 W-3
model)
CL6 DT2(G) 12 Intermediate connector (Monitor panel controller) M-3 C-2 W-4 C-4
CL7 DT2(Gr) 12 Intermediate connector (Monitor panel controller) M-2 C-2 C-5
CL8 DT2(Gr) 12 Intermediate connector (Monitor panel controller) N-1 C-6
CL9 DT2(G) 8 Intermediate connector (Monitor panel controller) O-1 C-3 C-7
CL10 DT2(Gr) 8 Intermediate connector (Monitor panel controller) O-1 C-1 X-4 J-3 C-3
CL11 M 2 Washer tank B-8
CL20 DT2 2 Intermediate connector (Monitor panel controller) N-2 J-4 C-5
CN55 DT2 2 Intermediate connector (Backup buzzer) L-7
COMBI M 3 Front combination lamp (Right) A-6 W-9
COMBI M 3 Front combination lamp (Left) E-1 W-8
DL DT2(Gr) 12 Download connector W-7 L-9 S-8 H-8
CDL HD10 9 CUMMINS data link connector Q-1 K-9 S-8 H-1 H-8
E01 DT2 2 Intermediate connector (Starting motor) AC-1 R-4 M-1
E02 Terminal 1 Alternator R AJ-1
E03 Terminal 1 Alternator B AI-3
E04 Terminal 1 Alternator E AJ-3
E05 Terminal 1 Engine heater relay AN-2
E06 Terminal 1 Engine heater relay AO-1
E07 Terminal 1 Engine heater relay AM-2
E08 Terminal 1 Electrical intake air heater AN-2
E10 DT2 2 Air conditioner compressor magnetic clutch AE-1
WA430-6 20-221
EACH SYSTEM
No. of pins
Address
Connector Type of
No. connector
E11 DT2 2 Diode (Air conditioner compressor) AF-1

E14 Terminal 1 Ground (Rear frame) Z-6
E26 DT2 2 Engine oil level sensor AM-2 O-2
E27 DT2 2 Engine speed sensor AP-5 W-5
E28 DT2 2 Diode (Engine heater relay) AP-6 D-1
E30 Terminal 1 Starting motor B T-2
E33 DT2 2 Dust indicator AO-9 O-2
ECMB DRC 50 Engine controller AM-2 W-4 A-9 N-1
ER1 DT1(G) 8 Intermediate connector (Engine) AA-1 Q-5 O-3
ER2 HD 14 Intermediate connector (Engine controller) AP-4 R-4 D-7 N-1
ER3 HD 23 Intermediate connector AO-2 R-4 B-6
ER4 DT2 3 Intermediate connector AN-2 M-2 B-3 M-3
ER6 DT2(B) 12 Intermediate connector (Engine) Z-6 Q-4 E-7 O-3
ER7 DT1(B) 12 Intermediate connector (Engine) Z-5 Q-4 E-6
ER8 DT2 3 Intermediate connector (Resistor) AB-1 Q-2 O-2 E-3 O-2
F01 M 6 Intermediate connector (R.H. front lamp) A-5 V-9
F02 M 6 Intermediate connector (L.H. front lamp) D-1 V-8
F03 Terminal 1 Horn (303 Hz) A-1
F04 Terminal 1 Horn (303 Hz) A-1
F05 Terminal 1 Horn (333 Hz) B-1
F06 Terminal 1 Horn (333 Hz) B-1
F09 DT2 3 Bucket positioner proximity switch A-3 W-8
F10 DT2 3 Lift arm positioner proximity switch (Standard) A-1 X-8
F13 DT2 2 Lift arm damper solenoid C-1
F14 DT2 2 Diode (Damper solenoid) C-1
F18 DT2 3 Lift arm angle sensor (For lift arm EPC) A-6 K-2
Bucket positioner proximity switch (For bucket
F19 DT2 3 A-3 K-2
EPC)
F20 DT2 2 Lift arm raise EPC solenoid A-2 K-4
F21 DT2 2 Lift arm lower EPC solenoid A-2 K-3
F22 DT2 2 Bucket tilt EPC solenoid A-1 K-3
F23 DT2 2 Bucket dump EPC solenoid A-1 K-3
F24 DT2 2 ATT. EXE. EPC (if equipped) A-3 K-1
F25 DT2 2 ATT. RET. EPC (if equipped) A-2 K-1
F26 DT2 2 Lift arm EPC cut-off solenoid B-1 K-2
F27 DT2 2 Diode A-4 K-2
F30 Terminal 1 Ground (Front frame) B-1 X-6 U-7
FF1 DT2(G) 12 Intermediate connector (Front lamp) D-1 Q-7
FF2 DT2(Gr) 8 Intermediate connector (Work equipment sensor) D-1 W-6
FL1 S 12 Intermediate connector (Front lamp) W-1 Q-7
Intermediate connector (ECSS cut-off oil pressure
FL2 DT2(Gr) 8 W-1 O-5 V-6
switch)
Intermediate connector (Work equipment connec-
FL7 DT2(Br) 12 M-5 H-3
tor)
Intermediate connector (Work equipment connec-
FL8 DT2(G) 8 M-2 H-2
tor)
FL9 DT2 6 Intermediate connector (ATT EPC solenoid) M-4 H-2
Intermediate connector (ECSS cut-off oil pressure
FL12 DT2 8
switch)
FS1 L 2 Intermediate connector (Fuse box) V-7 I-2 T-2 I-8
FS2 L 2 Intermediate connector (Fuse box) U-8 I-2 U-2 I-8 I-8
20-222 WA430-6
EACH SYSTEM
No. of pins
Address
Connector Type of
No. connector
FS3 S(W) 16 Intermediate connector (Fuse box) U-8 I-2 T-2 J-8 I-8
FS4 S(W) 12 Intermediate connector (Fuse box) U-8 I-2 U-2 J-8
FS5 M 6 Intermediate connector (Fuse box) V-7 J-8
Plug
FS6 1 Intermediate connector (Fuse box) V-8
connector
Plug
FS7 1 Intermediate connector (Fuse box) W-7
connector
FS9 L 2 Intermediate connector (Fuse box) W-3 L-6 K-8
FS10 M 6 Intermediate connector (Fuse box) W-3 L-6
G04 M 2 Rear working lamp (Left) K-9
G05 M 2 Rear working lamp (Right) J-9
Intermediate connector (Fan reverse solenoid, rear
GR1 DT2 4 L-6 V-5
working lamp)
GR2 DT2 2 Fan reverse solenoid K-8 W-5
HEAD M 3 Headlamp (Right) A-6 W-9
HEAD M 3 Headlamp (Left) E-1 W-8
JT1 DT2(B) 8 Centralized connector (Ground) AQ-6 S-7 K-2
JT2 DT2(B) 8 Centralized connector (Shield) AQ-5 S-8
JT3 DT2 6 Centralized connector AQ-4 V-7 I-2
L01 SWP 6 Parking brake switch M-5 E-2 F-2
L02 SWP 6 Dimmer switch, light switch M-5 C-9
L03 SWP 6 Turn and hazard switch M-6 C-8
L04 SWP 14 Shift switch M-5 E-2
L05 DT2 2 Horn switch M-5 J-8
Machine monitor switch (Mode/Cancel selector
L07 DT2 6 Q-1 F-2 E-2
switch)
L08 DT2 6 Machine monitor switch (Screen selector switch) Q-1 E-2
L09 DT1 2 Stop lamp switch Q-1
L10 DT2 3 Left brake pressure sensor R-1 F-2
L11 DT2 2 Air suspension seat S-1
L12 DT2 4 R direction switch O-7 O-6 H-6
L13 DT2 2 Lift arm N lock switch O-7 C-8
L14 DT2 4 Kick-down and hold switch O-7 H-2
L16 M 2 Intermediate connector (DC converter) U-2
L17 M 4 DC24V/DC12V converter W-5
L18 YAZAKI 2 DC12V outlet W-4
L19 M 4 Flasher unit U-8 K-8
L20 M 2 Warning buzzer U-8 J-8
L21 S 10 Front and rear wiper switch M-2
L22 DT2 3 Throttle pedal O-1 L-7
L23 DT2 3 Low idle switch O-1
L25E DT2 2 Lift arm and bucket EPC lever (Joystick model) M-6 E-8
L25S DT2 2 Work equipment lever electrical detent N-7
L26E DT2 2 Lift arm and bucket EPC lever (Joystick model) P-7 E-8
L26S DT2 2 Work equipment lever electrical detent N-6
L27 DT2 2 Lift arm and bucket EPC lever (Joystick model) N-6 D-8
L27S DT2 2 Work equipment lever electrical detent N-7 J-8
L28 DT2 4 Lift arm and bucket EPC lever (Joystick model) P-8 D-8
L29 DT2 4 Lift arm and bucket EPC lever (Joystick model) O-7 E-8
L30 DT2 4 3rd EPC lever (Joystick model) P-8 D-8
L31 M 6 Intermittent wiper timer W-7
WA430-6 20-223
EACH SYSTEM
No. of pins
Address
Connector Type of
No. connector
L34 DT2 4 Joystick steering lever positioner W-6 N-8

L35 DT2 2 Joystick steering right EPC solenoid P-1 F-8
L36 DT2 2 Joystick steering left EPC solenoid P-1 F-8
L37 DTM 12 Joystick steering lever switch M-6 Q-6 C-8
L38 DT2 3 Joystick steering N lock switch W-7 M-8
L39 DT2 6 Joystick steering ON/OFF switch T-1 M-8
L40 DT2 6 Steering speed mode switch S-1 N-8
L41 Relay 6 Joystick steering cut-off relay N-6
Plug
L42 1 Connector (Spare power supply) A-5
connector
Plug
L43 1 Connector (Spare power supply) A-5
connector
L51 AMP070 20 Machine monitor controller M-4 A-3 A-8
L52 AMP070 18 Machine monitor controller M-4 A-2 K-4 A-7
L55 AMP070 12 Machine monitor controller M-3 A-2 W-2 A-4
L56 AMP070 12 Machine monitor controller M-5 A-1 X-2 K-3 A-3
L57 AMP070 14 Machine monitor controller M-4 A-2
L58 AMP040 8 Machine monitor controller M-2 A-1
L61 DRC 24 Transmission controller P-8 A-9 F-8
L62 DRC 40 Transmission controller Q-8 A-8 K-8 K-3 F-8
L63 DRC 40 Transmission controller Q-8 A-6 L-8 F-8
L71 DRC 24 Work equipment controller Q-8 Q-8 A-7 Q-9
L72 DRC 40 Work equipment controller Q-9 Q-7 A-6 K-2 Q-9
L73 DRC 40 Work equipment controller Q-9 Q-7 A-3
L85 DT2 6 Pilot lamp (Engine diagnosis lamp) R-1 L-4
L92 DT2 3 Intermediate connector (Pump bypass relay) R-9 H-2
L93 Relay 5 Pump bypass relay R-9
L100 Terminal 1 Ground (Floor) R-1 N-1 T-1 H-1
L101 S(W) 16 Intermediate connector (Relay sub-unit) T-9 J-2 T-8 K-8
L102 S(L) 16 Intermediate connector (Relay sub-unit) T-9 K-2 U-8 L-8
L103 S(W) 16 Intermediate connector (Relay sub-unit) S-9 K-2 U-8 L-8
L104 S(W) 16 Intermediate connector (Relay sub-unit) T-9 L-2 U-8
L105 S(W) 12 Intermediate connector (Relay sub-unit) T-9 L-2
L106 S(W) 16 Intermediate connector (Relay sub-unit) S-9 M-8
L111 – 5 Winker and hazard relay X-8 K-9
L112 – 5 Air cleaner clogging relay W-8 K-9
L113 – 5 Steering selector relay V-9 K-1 T-9 K-9
L116 – 4 Neutral safety relay W-7 K-1 U-9 L-9
L117 – 4 Backup lamp relay W-7 K-1
L118 – 4 Stop lamp relay W-8
L119 – 4 Horn relay V-8 U-9
L120 – 4 Parking brake relay V-9 L-1 L-9
L123 – 5 Lift arm detent relay (Standard) X-9 U-9
L124 – 5 Bucket detent relay (Standard) X-9 V-9
L125 – 5 Lift arm damper relay W-9 L-1
L126 – 4 Emergency steering relay W-9 L-1
L127 – 4 Front working lamp relay X-8 M-9
L128 – 4 Rear working lamp relay X-9
L129 – 4 Rear glass heater relay W-9
20-224 WA430-6
EACH SYSTEM
No. of pins
Address
Connector Type of
No. connector
L130 – 4 Front lamp relay W-9

LL5 DT1 3 Intermediate connector (Vehicle with joystick) Q-1 O-7 H-6 O-8
LL6 DT2(Gr) 12 Intermediate connector (Vehicle with joystick) Q-1 H-6 O-7
LL7 DT2(G) 12 Intermediate connector (Vehicle with joystick) R-1 O-7 H-5 I-2 O-8
LL8 DT2(Gr) 12 Intermediate connector (Joystick steering switch) R-1 H-4
LR1 DTHD3 1 Intermediate connector (Slow-blow fuse) X-2 O-5 O-3 H-8 O-6
LR2 DT2(G) 12 Intermediate connector (Engine) W-3 O-5 H-7
LR3 DTHD4 1 Intermediate connector (Ground) X-2 H-6 O-6
LR4 L 2 Intermediate connector (Slow-blow fuse) X-1 O-4 O-3 O-5
LR6 L 2 Intermediate connector (Ground) X-2 O-4 O-5
LR7 DT2 6 Intermediate connector (Engine controller) V-1 H-6
LR8 DTHD4 1 Intermediate connector (Ground) X-2 O-4 O-3 H-5 O-5
Intermediate connector (Steering and brake oil
LR9 DT2(G) 12 X-1 O-3 O-5
pressure switch)
Intermediate connector (Starting switch and
LR10 DT2(Gr) 12 X-1 O-3 O-3 H-5 O-4
hydraulic fan)
LR12 DT2(B) 8 Intermediate connector (Engine controller) V-1 O-2 H-4
LR13 DT2 3 Intermediate connector (Resistor) X-2 O-2 P-3 G-3 O-3
LR14 DT2 3 Intermediate connector (Pump bypass solenoid)
R01 Terminal 1 Battery relay L-2
R02 Terminal 1 Slow-blow fuse L-3
R05 Terminal 1 Slow-blow fuse K-2
R06 Terminal 1 Slow-blow fuse K-2
K-2,
R11 Terminal 1 Slow-blow fuse
Z-6
R15 Terminal 1 Emergency steering relay L-1
R16 Terminal 1 Emergency steering relay L-1
R22 Terminal 1 Ground J-9 X-2
R23 Terminal 1 Ground J-9
R24 DT2 2 Diode (Battery relay) J-2 W-6
R25 DT2 2 Diode (Battery relay) J-2 U-1 R-2 C-1 W-6
R26 DT2 2 Diode (Starting motor) I-2 U-1 W-5
R27 DT2 2 Diode (Starting motor) K-3 V-1 W-5
R29 DT2 2 Fan pump EPC A-6 W-3
R30 M 6 Rear combination lamp (Left) L-5 W-6
R31 M 6 Rear combination lamp (Right) H-9 W-7
R32 DT1 2 Coolant level sensor G-9 W-1
R33 DT2 2 Fuel level sensor L-3 W-3
R34 M 2 License lamp L-7 W-3
R36 DT2 3 Steering pump pressure switch (Low) F-1 W-4 W-4
R37 DT2 3 Emergency steering pressure switch F-1 W-3 W-4
R39 DT2 2 Battery electrolyte level sensor L-6 W-2
R43 08027 2 Front windshield washer I-1
R44 DT2 2 Diode (Washer) H-1
R45 08027 2 Rear windshield washer I-2
WA430-6 20-225
EACH SYSTEM
No. of pins
Address
Connector Type of
No. connector
R46 DT2 2 Diode (Washer) H-1

R47 DT2 2 Hydraulic oil temperature sensor D-1 W-3
R50 Terminal 1 Ground (Rear frame) K-8 P-1 P-1 V-1
R51 DT2 2 Emergency brake switch 1 E-1 W-4 W-4
R53 DT2 2 Front brake accumulator low pressure switch F-1 W-4
R55 DT2 6 Cooler tilt switch L-5
R56 DT2 2 Rear brake oil temperature sensor
Intermediate connector (Rear brake oil tempera-
R60 DT2 2 J-2 V-5
ture sensor)
R61 DT2 2 Rear brake oil temperature sensor H-1 W-5
R64 Terminal 1 Ground (Cooler) L-4
R66 DT2 2 Cooler auto-tilt motor I-9
R68 DT2 2 Loader pump PC-EPC solenoid G-1 W-2
R69 DT2 1 Steering pump pressure switch (High) E-1 W-4
R70 DT2 2 ECSS cut-off oil pressure switch C-1 W-6
S01 DT2 6 Front working lamp switch O-1
S02 DT2 6 Rear working lamp switch O-1
S03 DT2 6 Transmission cut-off ON/OFF switch M-4 G-2
S04 DT2 6 Right FNR selector switch N-9 H-8 O-8
S05 DT2 6 Transmission cut-off set switch M-9 I-8
S07 DT2 5 Lift arm damper ON/OFF switch N-1 G-2
S12 DT2 6 Remote positioner set switch (Joystick model) N-7 P-8
S13 DT2 6 Upper remote positioner set switch (Joystick model) N-9 P-8
S14 DT2 6 Lower remote positioner set switch (Joystick model) N-8 Q-8
S15 DT2 6 Automatic digging switch (Joystick model) N-9 R-8
S16 DT2 6 Hydraulic drive fan reverse switch M-9 J-8
S19 DT2 6 Emergency steering check switch M-9 J-8
S21 DT2 4 Engine power mode switch M-7 G-9
S22 08027 4 Auto shift mode switch M-8 H-9
S31 DT1 4 Starting switch N-7 J-2 V-2 K-8 E-8
S32 DT2 2 Starting switch N-7
T01 DT2 2 Transmission 1st clutch solenoid AV-4 V-9
T02 DT2 2 Transmission 2nd clutch solenoid AV-3 V-9
T03 DT2 2 Transmission 3rd clutch solenoid AV-4 V-9
T04 DT2 2 Transmission 4th clutch solenoid AV-5 V-9
T05 DT2 2 Transmission R clutch solenoid AV-6 V-8
T06 DT2 2 Transmission F clutch solenoid AV-6 V-8
T08 DT2 2 Parking brake solenoid AU-2 V-8 I-2
T09 DT2 2 Transmission oil temperature sensor AV-4 V-7
T10 DT2 2 Torque converter oil temperature sensor AQ-7 K-2
T11 DT1 2 Transmission 1st clutch solenoid AV-4 W-8
T12 DT1 2 Transmission 2nd clutch solenoid AU-3 W-8
T13 DT1 2 Transmission 3rd clutch solenoid AV-3 X-8
T14 DT1 2 Transmission 4th clutch solenoid AV-5 X-8
T15 DT1 2 Transmission F clutch solenoid AV-6 X-8
T16 DT1 2 Transmission R clutch solenoid AV-5 X-8
T18 DT2 2 Parking brake indicator switch AU-2 K-2
T19 DT2 2 Travel speed sensor AR-2 W-8
T20 Terminal 1 Ground AU-3 T-6 K-1
T21 DT2 2 Diode AQ-5 V-7 I-2
20-226 WA430-6
EACH SYSTEM
No. of pins
Address
Connector Type of
No. connector
TEL DT2(Gr) 12 Intermediate connector Q-1 K-9 W-2 G-8

W-3,
TL1 HD 31 Intermediate connector (Chassis - Transmission) O-9
AQ-3
W/LAMP M 1 Warning lamp A-4
WA430-6 20-227
EACH SYSTEM
Connector layout drawing
20-228 WA430-6
EACH SYSTEM
WA430-6 20-229
EACH SYSTEM
20-230 WA430-6
EACH SYSTEM
WA430-6 20-231
EACH SYSTEM
20-232 WA430-6
EACH SYSTEM
WA430-6 20-233
EACH SYSTEM
20-234 WA430-6
EACH SYSTEM
WA430-6 20-235
EACH SYSTEM
Transmission controller system circuit diagram (T circuit)
20-236 WA430-6
EACH SYSTEM
a This circuit diagram is made by excerpting the transmission controller system from the general electric circuit
diagram ("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 wiring harness).
WA430-6 20-237
EACH SYSTEM
20-238 WA430-6
EACH SYSTEM
a This circuit diagram is made by excerpting the transmission controller system from the general electric circuit
diagram ("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 wiring harness).
WA430-6 20-239
EACH SYSTEM
Work equipment controller system circuit diagram (WRK circuit)
20-240 WA430-6
EACH SYSTEM
a This circuit diagram is made by excerpting the work equipment controller system from the general electric
circuit diagram ("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 wiring harness).
WA430-6 20-241
EACH SYSTEM
20-242 WA430-6
EACH SYSTEM
a This circuit diagram is made by excerpting the work equipment controller system from the general electric
WA430-6 20-243
EACH SYSTEM
Engine controller system circuit diagram (E circuit)
20-244 WA430-6
EACH SYSTEM
a This circuit diagram is made by excerpting the engine controller system from the general electric circuit dia-
gram ("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 wiring harness).
WA430-6 20-245
EACH SYSTEM
20-246 WA430-6
EACH SYSTEM
Machine monitor system circuit diagram (M circuit)
WA430-6 20-247
EACH SYSTEM
a This circuit diagram is made by excerpting the machine monitor controller system from the general electric
20-248 WA430-6
EACH SYSTEM
WA430-6 20-249
EACH SYSTEM
a This circuit diagram is made by excerpting the machine monitor controller system from the general electric
20-250 WA430-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
Connection table for connector pin numbers

a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
WA430-6 20-251
SWP type connector

No.of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
20-252 WA430-6
SWP type connector

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

Terminal part No.: Terminal part No.:
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
WA430-6 20-253
No.of M type connector

pins Male (female housing) Female (male housing) T-adapter Part No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
20-254 WA430-6
S type connector
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
WA430-6 20-255
S type connector
No.of
pins T-adapter
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
20-256 WA430-6
No.of MIC type connector

7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
WA430-6 20-257
No.of MIC type connector

17 799-601-2730
21 799-601-2740
—
(Q’ty: 50) (Q’ty: 50)
20-258 WA430-6
No.of AMP040 type connector

8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
a Terminal part No.: 79A-222-3470 (No relation with number of pins)
WA430-6 20-259
No.of AMP070 type connector

10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
20-260 WA430-6
No.of L type connector

2 —
— —
No.of Connector for PA

9 —
— —
No.of Bendix MS connector

10 799-601-3460
— —
WA430-6 20-261
No.of KES 1 (Automobile) connector

2 —
Part No.:08027-10210 (Natural color) Part No.:08027-10260 (Natural color)

08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.:08027-10310 Part No.:08027-10360
4 —

08027-10420 (Black) 08027-10470 (Black)
6 —

08027-10620 (Black) 08027-10670 (Black)
20-262 WA430-6
No.of KES 1 (Automobile) connector

8 —

08027-10820 (Black) 08027-10870 (Black)
No.of Connector for relay (Socket type)

5 799-601-7360
— —
6 799-601-7370
— —
WA430-6 20-263
F type connector
No.of
pins T-adapter
Part No.
4 —
— —
20-264 WA430-6
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

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

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

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

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

08191-22205, 08191-22206 08191-23105, 08191-23106
WA430-6 20-265

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

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

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

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
20-266 WA430-6

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

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

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

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

08191-62205, 08191-62206 08191-63105, 08191-63106
WA430-6 20-267

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

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

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

08191-81203, 08191-81204 08191-84103, 08191-84104
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
20-268 WA430-6

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

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

08191-92205, 08191-92206 08191-93105, 08191-93106
WA430-6 20-269
DT Series connector
No.of
pins T-adapter
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
20-270 WA430-6
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
8GR:799-601-9060
8B:799-601-9070
8
8G:799-601-9080
8BR:799-601-9090
12GR:799-601-9110
12B:799-601-9120
12
12G:799-601-9130
12BR:799-601-9140
WA430-6 20-271
No.of DTM Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No.of
pins T-adapter Part
No.
2 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-272 WA430-6
DRC26 Series connector

No.of
pins T-adapter
Male (female housing) Female (female housing)
Part No.
24 799-601-9360
— Part No.: 7821-93-3110
40
799-601-9350
(A)
— Part No.: 7821-93-3120
40
799-601-9350
(B)
— Part No.: 7821-93-3130
50 799-601-4210
— —
WA430-6 20-273
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
T-branch box and T-branch table

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass'y.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
—
Part No. No. of pins
part name
799-601-2600 Measurement box Econo-21P

799-601-3100 Measurement box MS-37P
799-601-3200 Measurement box MS-37P
799-601-3300 Measurement box Econo-24P
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P
799-601-3420 BENDIX (MS) 24P
799-601-3430 BENDIX (MS) 17P
799-601-3440 BENDIX (MS) 17P
799-601-3450 BENDIX (MS) 5P
799-601-3460 BENDIX (MS) 10P
799-601-3510 BENDIX (MS) 5P
799-601-3520 BENDIX (MS) 14P
799-601-3530 BENDIX (MS) 19P
799-601-2910 BENDIX (MS) 14P
799-601-3470 Case
799-601-2710 MIC 5P
799-601-2720 MIC 13P
799-601-2730 MIC 17P
799-601-2740 MIC 21P
799-601-2950 MIC 9P
799-601-2750 ECONO 2P
799-601-2760 ECONO 3P
799-601-2770 ECONO 4P
799-601-2780 ECONO 8P
799-601-2790 ECONO 12P
799-601-2810 DLI 8P
799-601-2820 DLI 12P
799-601-2830 DLI 16P
799-601-2840 Additional cable
799-601-2850 Case
799-601-4210 DEUTSCH 50P
799-601-7010 X 1P
799-601-7020 X 2P
799-601-7030 X 3P
799-601-7040 X 4P
799-601-7050 SWP 6P
799-601-7060 SWP 8P
799-601-7310 SWP 12P
799-601-7070 SWP 14P
799-601-7320 SWP 16P
799-601-7080 M 1P
799-601-7090 M 2P
799-601-7110 M 3P
799-601-7120 M 4P
799-601-7130 M 6P
799-601-7340 M 8P
20-274 WA430-6
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
—
Part No. No. of pins
part name
799-601-7140 S 8P
799-601-7150 S 10P-White
799-601-7160 S 12P-Blue
799-601-7170 S 16P-Blue
799-601-7330 S 16P-White
799-601-7350 S 12P-White
799-601-7180 AMP040 8P
799-601-7190 AMP040 12P
799-601-7210 AMP040 16P
799-601-7220 AMP040 20P
799-601-7230 Short connector X-2
799-601-7240 Case
799-601-7270 Case
799-601-7510 070 10P
799-601-7520 070 12P
799-601-7530 070 14P
799-601-7540 070 18P
799-601-7550 070 20P
799-601-7360 Relay connector 5P
799-601-7370 Relay connector 6P
799-601-7380 JFC connector 2P
799-601-9010 DTM 2P
799-601-9020 DT 2P
799-601-9030 DT 3P
799-601-9040 DT 4P
799-601-9050 DT 6P
799-601-9060 DT 8P-Gray
799-601-9070 DT 8P-Black
799-601-9080 DT 8P-Green
799-601-9090 DT 8P-Brown
799-601-9110 DT 12P-Gray
799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green
799-601-9140 DT 12P-Brown
799-601-9210 HD30 18-8
799-601-9220 HD30 18-14
799-601-9230 HD30 18-20
799-601-9240 HD30 18-21
799-601-9250 HD24 24-9
799-601-9260 HD30 24-16
799-601-9270 HD30 24-21
799-601-9280 HD30 24-23
799-601-9290 HD30 24-31
799-601-9310 Plate For HD30
799-601-9320 Measurement box For DT, HD
799-601-9330 Case
799-601-9340 Case
799-601-9350 DEUTSCH 40P
799-601-9360 DEUTSCH 24P
799-601-9410 For NE, G sensor 2P
For fuel, boost
799-601-9420 3P
press.
799-601-9430 PVC socket 2P
WA430-6 20-275
TROUBLESHOOTING TROUBLESHOOTING TO BE TAKEN WHEN FAILURE CODE IS RECORDED (DIS-
PLAY OF CODE)
Troubleshooting to be taken when failure code is recorded

(Display of code)
20-276 WA430-6
PLAY OF CODE)
Failure codes list

Failure Con- Action
Troubled part Trouble Category of record
code troller code
1500L0 TORQFLOW transmission Double meshing TM E03 Electrical system
When command current is OFF, fill
15SAL1 ECMV F clutch TM E03 Electrical system
signal is ON
15SALH ECMV F clutch TM E01 Electrical system
signal is OFF
15SBL1 ECMV R clutch TM E03 Electrical system
signal is ON
15SBLH ECMV R clutch TM E01 Electrical system
signal is OFF
15SEL1 ECMV 1st clutch TM E03 Electrical system
signal is ON
15SELH ECMV 1st clutch TM E01 Electrical system
signal is OFF
15SFL1 ECMV 2nd clutch TM E03 Electrical system
signal is ON
15SFLH ECMV 2nd clutch TM E01 Electrical system
signal is OFF
15SGL1 ECMV 3rd clutch TM E03 Electrical system
signal is ON
15SGLH ECMV 3rd clutch TM E01 Electrical system
signal is OFF
15SHL1 ECMV 4th clutch TM E03 Electrical system
signal is ON
15SHLH ECMV 4th clutch TM E01 Electrical system
signal is OFF
2F00MA Parking brake Malfunction MON E03 Electrical system
2G42ZG Accumulator Low oil pressure MON E03 Electrical system
989F00 Transmission protection caution TM E00 –
989FKM Transmission protection caution Mistake in operation or setting TM – –
989G00 FNR lever priority caution TM E00 –
AA1ANX Air cleaner Clogging MON E01 Mechanical system
AB00L6 Alternator MON E03 Electrical system
state of engine
AB00MA Alternator Malfunction MON E03 Mechanical system
B@BAZK Engine oil Low level MON E01 Mechanical system
B@BCZK Coolant Low level MON E01 Mechanical system
B@C7NS Brake oil Overheating TM E02 Mechanical system
B@CENS Torque converter oil Overheating MON E02 Mechanical system
B@GAZK Battery electrolyte Low level MON E01 Electrical system
B@HANS Hydraulic oil Overheating MON E02 Mechanical system
D150KA Emergency steering relay Disconnection TM E03 Electrical system
D150KB Emergency steering relay Short circuit TM E03 Electrical system
D160KA Backup lamp relay Disconnection TM E01 Electrical system
D160KB Backup lamp relay Short circuit TM E01 Electrical system
WA430-6 20-277
PLAY OF CODE)
Failure Con- Action

code troller code
D191KA Neutral safety relay Disconnection TM E03 Electrical system
D191KB Neutral safety relay Short circuit TM E01 Electrical system
D192KA Travel damper relay Disconnection TM E01 Electrical system
D192KB Travel damper relay Short circuit TM E01 Electrical system
D193KA Joystick solenoid cut-off relay Disconnection WRK E03 Electrical system
D193KB Joystick solenoid cut-off relay Short circuit WRK E03 Electrical system
D5ZAKB Throttle correction signal Short circuit TM E01 Electrical system
D5ZHL6 Monitor panel terminal C signal MON E01 Electrical system
state of engine
D5ZMKB Engine output mode command signal Short circuit TM E01 Electrical system
DAF3KK Monitor panel Low source voltage (input) MON E03 Electrical system
DAFBKM Monitor panel Mistake in operation or setting MON E03 Electrical system
Disagreement of model selection
DAFSKQ Monitor panel MON E01 Electrical system
signals
DAQ0KK Transmission controller Low source voltage TM Electrical system
DAQ0KT Transmission controller Abnormality in controller TM Electrical system
Transmission controller load power
DAQ2KK Low source voltage (input) TM Electrical system
supply line
Transmission controller model selec- Disagreement of model selection
DAQ9KQ TM E03 Electrical system
tion wiring harness signals
DAQSKR Monitor panel S-NET communication MON E03 Electrical system
mality in target component system)
DB90KK Work equipment controller Low source voltage (input) WRK E03 Electrical system
Work equipment controller load power
DB92KK Low source voltage (input) WRK E03 Electrical system
supply line
Work equipment controller power sup-
DB95KX Out of input signal range WRK E03 Electrical system
ply output
Work equipment controller S-NET Defective communication (Abnor-
DB9SKR MON E03 Electrical system
communication mality in target component system)
DD15LD t switch (panel switch 1) Switch is kept pressed for long time MON E01 Electrical system
DD16LD U switch (panel switch 2) Switch is kept pressed for long time MON E01 Electrical system
DD17LD < switch (panel switch 3) Switch is kept pressed for long time MON E01 Electrical system
DD18LD > switch (panel switch 4) Switch is kept pressed for long time MON E01 Electrical system
DD1ALD Remote positioner raise set switch Switch is kept pressed for long time WRK E03 Electrical system
DD1BLD Remote positioner lower set switch Switch is kept pressed for long time WRK E03 Electrical system
DDK3KA FNR switch Disconnection TM E03 Electrical system
DDK3KB FNR switch Short circuit TM E03 Electrical system
DDK4KA Joystick FNR switch Disconnection TM E03 Electrical system
DDK4KB Joystick FNR switch Short circuit TM E03 Electrical system
DDK5LD Joystick shift up/down switch Switch is kept pressed for long time TM E03 Electrical system
DDK6KA FNR lever Disconnection TM E03 Electrical system
20-278 WA430-6
PLAY OF CODE)
Failure Con- Action

code troller code
DDK6KB FNR lever Short circuit TM E03 Electrical system
DDS5KA Steering oil pressure switch Disconnection TM E03 Electrical system
DDS5KB Steering oil pressure switch Short circuit TM E03 Electrical system
DDS5L6 Steering oil pressure switch MON E03 Electrical system
state of engine
DDT0L4 Shift mode selector switch ON/OFF signals disagree TM Electrical system
DDT4LD Transmission cut-off selector switch Switch is kept pressed for long time TM E01 Electrical system
DDW9LD Kick-down switch Switch is kept pressed for long time TM E01 Electrical system
DDWLLD Hold switch Switch is kept pressed for long time TM E01 Electrical system
DF10KA Transmission shift lever Disconnection TM E01 Electrical system
DF10KB Transmission shift lever Short circuit TM E01 Electrical system
DFA0KM Work equipment controller EPC lever Mistake in operation or setting WRK E00 –
Transmission valve oil temperature
DGF1KX Out of input signal range TM Electrical system
sensor
DGH2KX Hydraulic oil temperature sensor Out of input signal range MON E01 Electrical system
DGR2KA Brake oil temperature sensor Disconnection TM E01 Electrical system
DGR2KB Retarder oil temperature sensor Short circuit TM E01 Electrical system
Torque converter oil temperature sen-
DGT1KX Out of input signal range MON E01 Electrical system
sor
DHA4KA Air cleaner clogging sensor Disconnection MON E01 Electrical system
DHT1KX Transmission cut-off pressure sensor Out of input signal range TM E01 Electrical system
DJB1KX Battery electrolyte level sensor Out of input signal range MON E01 Electrical system
DK59KA Lift arm lever EPC potentiometer (Main) Disconnection WRK E03 Electrical system
DK59KY Lift arm lever EPC potentiometer (Main) Short circuit with power supply line WRK E03 Electrical system
DK59L8 Lift arm lever EPC potentiometer (Main) Analog signals disagree WRK E03 Electrical system
DK5AKA Lift arm lever EPC potentiometer (Sub) Disconnection WRK E03 Electrical system
DK5AKY Lift arm lever EPC potentiometer (Sub) Short circuit with power supply line WRK E03 Electrical system
DK5BKA Disconnection WRK E03 Electrical system
(Main)
DK5BKY Short circuit with power supply line WRK E03 Electrical system
(Main)
DK5BL8 Analog signals disagree WRK E03 Electrical system
(Main)
DK5CKA Bucket lever EPC potentiometer (Sub) Disconnection WRK E03 Electrical system
DK5CKY Bucket lever EPC potentiometer (Sub) Short circuit with power supply line WRK E03 Electrical system
3rd valve lever EPC potentiometer
DK5DKA Disconnection WRK E03 Electrical system
(Main)
DK5DKY Short circuit with power supply line WRK E03 Electrical system
(Main)
DK5DL8 Analog signals disagree WRK E03 Electrical system
(Main)
DK5EKA Disconnection WRK E03 Electrical system
(Sub)
WA430-6 20-279
PLAY OF CODE)
Failure Con- Action

code troller code
DK5EKY Short circuit with power supply line WRK E03 Electrical system
(Sub)
Joystick steering lever EPC potentiom-
DK5FKA Disconnection WRK E03 Electrical system
eter (Main)
DK5FKM Mistake in operation or setting WRK E00 –
eter (Main)
DK5FKY Short circuit with power supply line WRK E03 Electrical system
eter (Main)
DK5FL8 Analog signals disagree WRK E03 Electrical system
eter (Main)
DK5GKA Disconnection WRK E03 Electrical system
eter (Sub)
DK5GKY Short circuit with power supply line WRK E03 Electrical system
eter (Sub)
DKA0KA Lift arm angle sensor Disconnection WRK E01 Electrical system
DKA0KY Lift arm angle sensor Short circuit with power supply line WRK E01 Electrical system
DLE2KA Engine speed sensor Disconnection TM E03 Electrical system
DLE2LC Engine speed sensor Speed signals disagree TM E03 Electrical system
Transmission output shaft speed sen-
DLT3KA Disconnection TM E03 Electrical system
sor
Transmission output shaft speed sen-
DLT3LC Speed signals disagree WRK E01 Electrical system
sor
DT20KB Transmission cut-off indicator Short circuit TM Electrical system
DT20KZ Transmission cut-off indicator Disconnection or short circuit TM Electrical system
DUM1KB Remote positioner raise indicator lamp Short circuit WRK E03 Electrical system
Remote positioner lower indicator
lamp
DV00KB Warning buzzer Short circuit MON E01 Electrical system
DW4PKA Lift arm raise EPC solenoid Disconnection WRK E03 Electrical system
DW4PKB Lift arm raise EPC solenoid Short circuit WRK E03 Electrical system
DW4QKA Lift arm lower EPC solenoid Disconnection WRK E03 Electrical system
DW4QKB Lift arm lower EPC solenoid Short circuit WRK E03 Electrical system
DW4RKA Bucket tilt EPC solenoid Disconnection WRK E03 Electrical system
DW4RKB Bucket tilt EPC solenoid Short circuit WRK E03 Electrical system
DW4SKA Bucket dump EPC solenoid Disconnection WRK E03 Electrical system
DW4SKB Bucket dump EPC solenoid Short circuit WRK E03 Electrical system
DW7BKA Fan pump (reverse) solenoid Disconnection TM E01 Electrical system
DW7BKB Fan pump (reverse) solenoid Short circuit TM E01 Electrical system
DWM1KA PPC basic pressure solenoid valve Disconnection WRK E01 Electrical system
DWM1KB PPC basic pressure solenoid valve Short circuit WRK E01 Electrical system
DWN6KA Lift arm raise magnet detent solenoid Disconnection WRK E01 Electrical system
DWN6KB Lift arm raise magnet detent solenoid Short circuit WRK E01 Electrical system
DWN7KA LIft arm float magnet detent solenoid Disconnection WRK E01 Electrical system
DWN7KB Lift arm float magnet detent solenoid Short circuit WRK E01 Electrical system
20-280 WA430-6
PLAY OF CODE)
Failure Con- Action

code troller code
DWN8KA Bucket tilt magnet detent solenoid Disconnection WRK E01 Electrical system
DWN8KB Bucket tilt magnet detent solenoid Short circuit WRK E01 Electrical system
DX16KA Fan pump EPC solenoid Disconnection TM E01 Electrical system
DX16KB Fan pump EPC solenoid Short circuit TM E01 Electrical system
DXA1KA Pump PC-EPC valve Disconnection TM E01 Electrical system
DXA1KB Pump PC-EPC valve Short circuit TM E01 Electrical system
DXH4KA 1st clutch ECMV solenoid Disconnection TM E03 Electrical system
DXH4KB 1st clutch ECMV solenoid Short circuit TM E03 Electrical system
DXH5KA 2nd clutch ECMV solenoid Disconnection TM E03 Electrical system
DXH5KB 2nd clutch ECMV solenoid Short circuit TM E03 Electrical system
DXH6KA 3rd clutch ECMV solenoid Disconnection TM E03 Electrical system
DXH6KB 3rd clutch ECMV solenoid Short circuit TM E03 Electrical system
DXH7KA R clutch ECMV solenoid Disconnection TM E03 Electrical system
DXH7KB R clutch ECMV solenoid Short circuit TM E03 Electrical system
DXH8KA F clutch ECMV solenoid Disconnection TM E03 Electrical system
DXH8KB F clutch ECMV solenoid Short circuit TM E03 Electrical system
DXHHKA 4th clutch ECMV solenoid Disconnection TM E03 Electrical system
DXHHKB 4th clutch ECMV solenoid Short circuit TM E03 Electrical system
DXHJKA 3rd valve extract EPC solenoid Disconnection WRK E03 Electrical system
DXHJKB 3rd valve extract EPC solenoid Short circuit WRK E03 Electrical system
DXHKKA 3rd valve retract EPC solenoid Disconnection WRK E03 Electrical system
DXHKKB 3rd valve retract EPC solenoid Short circuit WRK E03 Electrical system
DXHLKA Joystick steering right EPC solenoid Disconnection WRK E03 Electrical system
DXHLKB Joystick steering right EPC solenoid Short circuit WRK E03 Electrical system
DXHMKA Joystick steering left EPC solenoid Disconnection WRK E03 Electrical system
DXHMKB Joystick steering left EPC solenoid Short circuit WRK E03 Electrical system
DY30MA Emergency steering motor Malfunction TM E03 Electrical system
DY30MC Emergency steering motor Defective operation TM E03 Electrical system
DY30ME Emergency steering motor Motor cannot be reset MON E02 –
WA430-6 20-281
PLAY OF CODE)
Failure code [1500L0] TORQFLOW transmission : Double meshing
Action code Failure code TORQFLOW transmission: Double meshing

Trouble
E03 1500L0 (Machine monitor system)
Contents of
• A combination for double meshing is input as a fill signal.
trouble
Action of
• Turns the centralized warning lamp and warning buzzer ON.
controller
Problem that
appears on —
machine
Related
—
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal See failure codes "15SAL1", "15SBL1", "15SEL1", "15SFL1", "15SGL1", and "15SHL1".
state
20-282 WA430-6
PLAY OF CODE)
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)
Action code Failure code ECMV F clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SAL1 (Transmission controller system)
Contents of
• When the F ECMV is turned OFF, the F ECMV fill switch signal is input.
trouble
Action of • Judges that the F ECMV fill switch signal is turned ON. Sets the output to N.
controller • Turns the centralized warning lamp and warning buzzer ON.
Problem that
appears on • The machine does not travel.
machine
Related • The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
information 40908, D-IN-24).
aPrepare with starting switch OFF, then start engine and carry out trou-
Cause Standard value in normal state/Remarks on troubleshooting
bleshooting.
• Turn transmission cut-off switch OFF.
Defective F ECMV fill • Turn parking brake switch OFF.
1 switch (Internal short cir- • Keep pressing brake pedal to prevent machine from traveling.
cuit) Directional lever (or
T15 (male) Resistance
Max. 1 z
directional switch)
Between (1) and chas- F
sis ground
aPrepare with starting switch OFF, then carry out troubleshooting with-
Other than above Min. 1 Mz
Possible causes
and standard Grounding fault in wiring
out turning starting switch.
value in normal 2 harness (Contact with
state Between L62 (female) (37) – T15 (female) (1)
ground circuit) Resistance Min. 1 Mz
wiring harness and chassis ground
bleshooting.
• Turn parking brake switch OFF.
Defective transmission con- • Keep pressing brake pedal to prevent machine from traveling.
3
troller
Directional lever (or
L62 Voltage
directional switch)
Between (37) and F Max. 1 V
chassis ground Other than above 20 – 30 V
WA430-6 20-283
PLAY OF CODE)
Circuit diagram related to ECMV F fill switch and R fill switch
20-284 WA430-6
PLAY OF CODE)
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)
Action code Failure code ECMV F clutch: When command current is ON, fill signal is OFF
Trouble
E03 15SALH (Transmission controller system)
Contents of
• When the F ECMV is turned ON, the F ECMV fill switch signal is not input.
trouble
Action of
• Judges that the F ECMV fill switch signal is turned OFF. Uses modulation data without the fill signal.
controller
Problem that
• The machine may not travel.
appears on
• When the travel direction is changed, a shock or a time lag may be made.
machine
Related • The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
bleshooting.
Defective F ECMV fill • Turn parking brake switch OFF.
1 switch (Internal disconnec- • Keep pressing brake pedal to prevent machine from traveling.
tion) Directional lever (or
Max. 1 z
directional switch)
Between (1) and chas- F
sis ground
Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting with-
Possible causes
and standard
ness (Disconnection or out turning starting switch.
Resistance Max. 1 z
value in normal 2
defective contact of con- Wiring harness between L62 (female) (37) –
state
nector)
T15 (female) (1)
bleshooting.
3
troller
L62 Voltage
directional switch)
Between (37) and F Max. 1 V
WA430-6 20-285
PLAY OF CODE)
20-286 WA430-6
PLAY OF CODE)
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)
Action code Failure code ECMV F clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SBL1 (Transmission controller system)
Contents of
• When the R ECMV is turned OFF, the R ECMV fill switch signal is input.
trouble
Action of • Judges that the R ECMV fill switch signal is turned ON. Sets the output to N.
Problem that
machine
Related • The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code:
bleshooting.
Defective R ECMV fill • Turn parking brake switch OFF.
Max. 1 z
directional switch)
Between (1) and chas- R
sis ground
Possible causes
bleshooting.
3
troller
L62 Voltage
directional switch)
Between (27) and R Max. 1 V
WA430-6 20-287
PLAY OF CODE)
20-288 WA430-6
PLAY OF CODE)
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)
Action code Failure code ECMV R clutch: When command current is ON, fill signal is OFF
Trouble
E03 15SBLH (Transmission controller system)
Contents of
• When the R ECMV is turned ON, the F ECMV fill switch signal is not input.
trouble
Action of
• Judges that the R ECMV fill switch signal is turned OFF. Uses modulation data without the fill signal.
controller
Problem that
• The machine may not travel.
appears on
• When the travel direction is changed, a shock or a time lag may be made.
machine
Related • The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code:
bleshooting.
Defective R ECMV fill • Turn parking brake switch OFF.
Max. 1 z
directional switch)
Between (1) and chas- R
sis ground
Possible causes
Resistance Max. 1 z
ground circuit)
bleshooting.
3
troller
L62 Voltage
directional switch)
Between (27) and R Max. 1 V
WA430-6 20-289
PLAY OF CODE)
20-290 WA430-6
PLAY OF CODE)
Failure code [15SEL1] (ECMV (1): When command current is OFF, fill signal is ON)
Action code Failure code ECMV (1): When command current is OFF, fill signal is ON
Trouble
E03 15SEL1 (Transmission controller system)
Contents of
• When the 1st ECMV is turned OFF, the 1st ECMV fill switch signal is input.
trouble
Action of • Judges that the 1st ECMV fill switch signal is turned ON. Turns the speed clutch output OFF.
Problem that
machine
Related • The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code:
bleshooting.
Defective 1st ECMV fill • Turn parking brake switch OFF.
cuit)
Max. 1 z
T11 (male) Shift lever Resistance
Between (1) and chas- 1st
sis ground
Possible causes Grounding fault in wiring

and standard 2 harness (Contact with
value in normal Between L62 (female) (37) – T11 (female) (1)
state wiring harness and chassis ground
bleshooting.
3 • Set MANUAL/AUTO shift selector switch in MANUAL.
troller
• Set directional lever (or directional switch) in F or R.
L62 Shift lever Voltage
Between (17) and 1st Max. 1 V
WA430-6 20-291
PLAY OF CODE)
Circuit diagram related to ECMV 1st, 2nd, 3rd, and 4th fill switches
20-292 WA430-6
PLAY OF CODE)
Failure code [15SELH] (ECMV (1): When command current is ON, fill signal is OFF)
Action code Failure code ECMV (1): When command current is ON, fill signal is OFF
Trouble
E03 15SELH (Transmission controller system)
Contents of
• When the 1st ECMV is turned ON, the 1st ECMV fill switch signal is not input.
trouble
Action of
• Judges that the 1st ECMV fill switch signal is turned OFF. Turns the speed clutch output to OFF.
controller
Problem that
• The machine may not travel in the 1st gear speed.
appears on
• When the 1st gear speed is changed, a shock or a time lag may be made.
machine
Related • The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code:
bleshooting.
Defective 1st ECMV fill • Turn parking brake switch OFF.
cuit)
Max. 1 z
Between (1) and chas- 1st
sis ground
Possible causes
and standard 2
defective contact of con- Wiring harness between L62 (female) (17) – T11
value in normal Resistance Max. 1z
nector)
state (female) (1)
bleshooting.
troller
Between (17) and 1st Max. 1 V
WA430-6 20-293
PLAY OF CODE)
20-294 WA430-6
PLAY OF CODE)
Failure code [15SFL1] (ECMV (2): When command current is OFF, fill signal is ON)
Trouble
E03 15SFL1 (Transmission controller system)
Contents of
• When the 2nd ECMV is turned OF, the 2nd ECMV fill switch signal is input.
trouble
Action of • Judges that the 2nd ECMV fill switch signal is turned ON. Turns the speed clutch output OFF.
Problem that
machine
Related • The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code:
bleshooting.
Defective 2nd ECMV fill • Turn parking brake switch OFF.
cuit)
Max. 1 z
Between (1) and chas- 2nd
sis ground

value in normal Wiring harness between L62 (female) (7) – T12
state (female) (1)
bleshooting.
troller
Between (7) and chas- 2nd Max. 1 V
sis ground Other than above 20 – 30 V
WA430-6 20-295
PLAY OF CODE)
20-296 WA430-6
PLAY OF CODE)
Failure code [15SFLH] (ECMV (2): When command current is ON, fill signal is OFF)
Trouble
E03 15SFLH (Transmission controller system)
Contents of
• When the 2nd ECMV is turned ON, the 2nd ECMV fill switch signal is not input.
trouble
Action of
• Judges that the 2nd ECMV fill switch signal is turned OFF. Turns the speed clutch output to OFF.
controller
Problem that
• The machine may not travel in the 2nd gear speed.
appears on
• When the 2nd gear speed is changed, a shock or a time lag may be made.
machine
Related • The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code:
bleshooting.
Defective 2nd ECMV fill • Turn parking brake switch OFF.
tion)
Max. 1 z
Between (1) and chas- 2nd
sis ground
Possible causes
and standard 2
defective contact of con- Between L62 (female) (7) – T12 (female) (1) wir-
value in normal Resistance Max. 1z
nector)
state ing harness and chassis ground
bleshooting.
troller
Between (7) and chas- 2nd Max. 1 V
WA430-6 20-297
PLAY OF CODE)
20-298 WA430-6
PLAY OF CODE)
Failure code [15SGL1] (ECMV (3): When command current is OFF, fill signal is ON)
Trouble
E03 15SGL1 (Transmission controller system)
Contents of
• When the 3rd ECMV is turned OFF, the 3rd ECMV fill switch signal is input.
trouble
Action of • Judges that the 3rd ECMV fill switch signal is turned ON. Turns the speed clutch output OFF.
Problem that
machine
Related • The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code:
bleshooting.
Defective 3rd ECMV fill • Turn parking brake switch OFF.
cuit)
Max. 1 z
Between (1) and chas- 3rd
sis ground

value in normal Between L62 (female) (13) – T13 (female) (1)
bleshooting.
troller
Between (13) and 3rd Max. 1 V
WA430-6 20-299
PLAY OF CODE)
20-300 WA430-6
PLAY OF CODE)
Failure code [15SGLH] (ECMV (3): When command current is ON, fill signal is OFF)
Trouble
E03 15SGLH (Transmission controller system)
Contents of
• When the 3rd ECMV is turned ON, the 3rd ECMV fill switch signal is not input.
trouble
Action of
• Judges that the 3rd ECMV fill switch signal is turned OFF. Turns the speed clutch output to OFF.
controller
Problem that
• The machine may not travel in the 3rd gear speed.
appears on
• When the 3rd gear speed is changed, a shock or a time lag may be made.
machine
Related • The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code:
bleshooting.
Defective 3rd ECMV fill • Turn parking brake switch OFF.
tion)
Max. 1 z
Between (1) and chas- 3rd
sis ground
Possible causes
Resistance Max. 1 z
and standard 2
value in normal
nector)
state T13 (female) (1)
bleshooting.
troller
Between (13) and 3rd Max. 1 V
WA430-6 20-301
PLAY OF CODE)
20-302 WA430-6
PLAY OF CODE)
Failure code [15SHL1] (ECMV (4): When command current is OFF, fill signal is ON)
Trouble
E03 15SHL1 (Transmission controller system)
Contents of
• When the 4th ECMV is turned OFF, the 4th ECMV fill switch signal is input.
trouble
Action of • Judges that the 4th ECMV fill switch signal is turned ON. Turns the speed clutch output OFF.
Problem that
machine
Related • The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code:
bleshooting.
Defective 4th ECMV fill • Turn parking brake switch OFF.
cuit)
Max. 1 z
Between (1) and chas- 4th
sis ground

value in normal Between L62 (female) (3) – T14 (female) (1) wir-
bleshooting.
troller
Between (3) and 4th Max. 1 V
WA430-6 20-303
PLAY OF CODE)
20-304 WA430-6
PLAY OF CODE)
Failure code [15SHLH] (ECMV (4): When command current is ON, fill signal is OFF)
Trouble
E03 15SHLH (Transmission controller system)
Contents of
• When the 4th ECMV is turned ON, the 4th ECMV fill switch signal is not input.
trouble
Action of
• Judges that the 4th ECMV fill switch signal is turned OFF. Turns the speed clutch output to OFF.
controller
Problem that
• The machine may not travel in the 4th gear speed.
appears on
• When the 4th gear speed is changed, a shock or a time lag may be made.
machine
Related • The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code:
bleshooting.
Defective 4th ECMV fill • Turn parking brake switch OFF.
cuit)
Max. 1 z
Between (1) and chas- 4th
sis ground

Resistance Max. 1 z
value in normal Between L62 (female) (3) – T14 (female) (1) wir-
ground circuit)
bleshooting.
troller
Between (3) and 4th Max. 1 V
WA430-6 20-305
PLAY OF CODE)
20-306 WA430-6
PLAY OF CODE)
Failure code [2F00MA] (Parking brake: Malfunction)
Action code Failure code Parking brake: Malfunction

Trouble
E00 2F00MA (Machine monitor system)
Contents of • While the F or R clutch is operated, the parking brake operation sensor circuit is OPEN. (The neutralizer
trouble does not work.)
Action of
controller
Problem that
appears on • The parking brake drags (is kept operated).
machine
• The input state (ON/OFF) from the parking indicator switch can be checked with the monitoring function
(Code: 40903, D-IN-26).
Related • The input state (ON/OFF) from the directional lever FNR switch can be checked with the monitoring
information function (Code: 40907, D-IN-20, D-IN-21, D-IN-22).
• The input state (ON/OFF) from the parking brake switch can be checked with the monitoring function
(Code: 40907, D-IN-23).

Parking brake
Defective parking brake T18 (male) Resistance
oil pressure
Max. 1 z
1 indicator switch (Internal
Min. 0.6 MPa
disconnection)
{6.1 kg/cm2}
Between (1) and (2)
Max. 0.34MPa
Min. 1 Mz
{3.5 kg/cm2}
Max. 1 z
T01 (male) Parking brake switch Resistance
Defective parking brake ON
2 switch (Internal disconnec- Between (1) and (3)
OFF Min. 1 Mz
tion)
Max. 1 z
ON Min. 1 Mz
Between (2) and (3)
OFF
Between (1) and (2) Constant Min. 1 Mz
Possible causes
and standard out turning starting switch.
value in normal Defective parking brake
10 – 40 z
T08 Resistance
state 3 solenoid (Internal discon-
Max. 1 z
Between (male) (1) and (2)
nection)
Between (female) (2) and chassis ground
Between (male) (1), (2) and chassis ground Min. 1 Mz

Defective emergency brake R51 (male) Brake oil pressure Resistance
Max. 1 z
4 pressure switch (Internal Min. 4.41 MPa
disconnection) {45 kg/cm2}
Between (1) and (2)
Max. 4.41 MPa
Min. 1 Mz
{45 kg/cm2}
Resistance Max. 1 z
Wiring harness between L54 (female) (1) – T18
Grounding fault in wiring
(female) (1)
Resistance Max. 1 z
5 harness (Contact with
ground circuit)
(female) (1)
Resistance Max. 1 z
Wiring harness between L01 (female) (2) – L62
(female) (6)
WA430-6 20-307
PLAY OF CODE)
bleshooting.
Possible causes
Parking brake
and standard L54 Voltage
oil pressure
value in normal 6 Defective machine monitor
state Min. 0.6 MPa
Max. 1 V
Between (1) and {6.1 kg/cm2}
chassis ground Max. 0.34 MPa
20 – 30 V
{3.5 kg/cm2}
20-308 WA430-6
PLAY OF CODE)
Circuit diagram related to parking brake
WA430-6 20-309
PLAY OF CODE)
Failure code [2G42ZG] (Accumulator: Low oil pressure)
Action code Failure code Accumulator: Low oil pressure

Trouble
E00 2G42ZG (Machine monitor system)
Contents of
• Fifty (50) seconds after the engine is started, the brake accumulator pressure sensor circuit is OPEN.
trouble
Action of
controller
Problem that • The brake accumulator oil pressure lowers.
appears on • The brake may not work.
machine • The parking brake may keep working.
Related • The input state (ON/OFF) from the brake oil pressure sensor can be checked with the monitoring func-
information tion (Code: 40902, D-IN-16).

Low brake accumulator oil Check the brake accumulator oil pressure.
1
pressure (See Testing and adjusting)

Defective brake oil pres- R53 (male) Brake oil pressure Resistance
Max. 1 z
2 sure sensor (Internal dis- Min. 5.88 MPa
connection) {60 kg/cm 2}
Between (1) and (2)
Max. 5.88 MPa
Possible causes Min. 1 Mz
{60 kg/cm 2}
and standard
value in normal
state
Resistance Max. 1 z
3
defective contact of con- Between L53 (female) (1) – R53 (female) (1)
nector)

L53 (female) Brake oil pressure Resistance
Max. 1 z
4 Defective machine monitor Min. 5.88 MPa
Wiring harness
{60 kg/cm 2}
between (1) –
Min. 1 Mz
{60 kg/cm 2}
20-310 WA430-6
PLAY OF CODE)
Circuit diagram related to brake accumulator
WA430-6 20-311
PLAY OF CODE)
Failure code [989F00] (Transmission protection caution)
Action code Failure code Transmission protection caution

Trouble
E03 989F00 (Transmission controller system)
• The centralized warning lamp and warning buzzer are turned ON.
• This does not indicate a trouble.
Contents of
• When the gear is shifted down, the travel speed is above the speed limit of the transmission.
trouble
• When the travel direction is changed, the travel speed is above the speed limit of the transmission.
• The travel speed is above 40 km/h.
Action of
• Turns the alarm ON to warn the operator when the travel direction is changed in the auto-shift mode.
controller
Problem that • When the travel direction is changed in the auto-shift mode, the machine may not start in the 2nd gear
appears on speed.
machine • When the operator shifts down the gear at full throttle, the gear may not be shifted down.
Related • See Structure and function and maintenance standard (Transmission protection function, travel speed
information warning function, engine overrun function).
20-312 WA430-6
PLAY OF CODE)
Failure code [989FKM] (Transmission protection caution: Mistake in operation or setting)
Action code Failure code Transmission protection caution: Mistake in operation or setting
Trouble
– 989FKM (Transmission controller system)
Contents of • This does not indicate a trouble.
trouble • The travel speed is above 40 km/h.
Action of
—
controller
Problem that
appears on —
machine
Related • See Structure and function and maintenance standard (Transmission protection function, travel speed
information warning function, engine overrun function).
WA430-6 20-313
PLAY OF CODE)
Failure code [989G00] (FNR lever priority caution)
Action code Failure code FNR lever priority caution

Trouble
E03 989G00 (Transmission controller system)
• The centralized warning lamp and warning buzzer are turned ON.
Contents of • This does not indicate a trouble.
trouble • When the joystick steering or the right FNR switch is used, the shift lever and each FNR selector switch
are positioned abnormally.
Action of
• Use the FNR signal of the shift lever first for control of gear shifting.
controller
Problem that
appears on • The operator cannot control gear shifting with the joystick steering or FNR switch.
machine
Related • See Structure and function and maintenance standard (Right GFNR switch selecting function, Joystick
information steering gear shifting function).
20-314 WA430-6
PLAY OF CODE)
Failure code [AA1ANX] (Air cleaner: Clogging)
Action code Failure code Air cleaner: Clogging

Trouble
E01 AA1ANX (Machine monitor system)
Contents of
• The air cleaner clogging sensor circuit is OPEN.
trouble
Action of
• Turns the air cleaner clogging caution lamp ON.
controller
Problem that
appears on • The engine does not start or pick up easily, its output is insufficient, and its exhaust gas color is bad.
machine
Related • The input state (ON/OFF) from the air cleaner clogging sensor can be checked with the monitoring func-
1 Clogged air cleaner The air cleaner may be clogged. Check it directly.
bleshooting.
E33 (female) Failure code "AA1ANX" Dust indicator
Defective dust indicator
2 Normal
(Internal disconnection) Turned ON
(Air cleaner is normal)
Short (1) with (2)
Defective
Turned OFF
(Air cleaner is clogged)

L112 (male) Resistance
Defective dust indicator Between (1) and (2) 200 – 400z
3 relay (Internal disconnec-
tion) bleshooting.
Failure code "AA1ANX" Dust indicator relay
Possible causes
Turned ON Normal
and standard
value in normal Turned OFF Defective
state
Disconnection in wiring har- out turning starting switch.
Resistance Max. 1 z
ness (Disconnection or Wiring harness between L112 (female) (3) –
4
defective contact of con- E33 (female) (1)
Resistance Max. 1 z
nector) Wiring harness between E33 (female) (2) –
chassis ground
Grounding fault in wiring out turning starting switch.

ground circuit) Between L53 (female) (3) – L112 (female) (4)
Resistance Min.1 Mz
bleshooting.
L53 Dust indicator Voltage
6 Defective machine monitor Normal (Air cleaner is
20 – 30 V
Between (3) and not clogged)
chassis ground Defective (Air cleaner
Max. 1 V
is clogged)
WA430-6 20-315
PLAY OF CODE)
Circuit diagram related to dust indicator
20-316 WA430-6
PLAY OF CODE)
Failure code [AB00L6] (Alternator: Signal disagrees with operation and stop of engine)
Action code Failure code Alternator: Signal disagrees with operation and stop of engine
Trouble
E03 AB00L6 (Machine monitor system)
Contents of
• Before the engine is started, the alternator terminal R input voltage is above 12 V.
trouble
Action of
controller
Problem that
• The engine does not start.
appears on
• After the starting switch is simply turned ON, the service meter advances.
machine
Related • The input state (voltage) from the alternator can be checked with the monitoring function (Code: 04302,
information ALTERNATOR R).
bleshooting.
Defective alternator (Inter- Alternator Engine Voltage
1
nal defect) Between terminal R Running (Throttle:
27.5 – 29.5 V
(E02) and chassis Above 1/2)
ground
aPrepare with starting switch OFF, then turn starting switch ON and car-
Stopped Max. 1 V
Short circuit with power

ry out troubleshooting.
2 source (Contact with 24V
Possible causes circuit) in wiring harness Wiring harness between L52 (female) (18) –
Voltage Max. 1 V
and standard E01 (female) (2) or alternator terminal R (E02)
value in normal
state bleshooting.
Alternator Engine Voltage
3 Defective machine monitor
Between terminal R Running (Throttle:
27.5 – 29.5 V
ground
Stopped Max. 1 V
4 Defective diode (R24) Between L52 (female) (18) – E01 (female) (2) or
alternator terminal R (E02) wiring harness and Voltage Max. 1 V
chassis ground
WA430-6 20-317
PLAY OF CODE)
Circuit diagram related to alternator
20-318 WA430-6
PLAY OF CODE)
Failure code [AB00MA] (Alternator: Malfunction)
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
Action of
controller
Problem that • The battery is deteriorated.
appears on • The engine does not start.
machine • The service meter does not advance.
Related • The input state (voltage) from the alternator can be checked with the monitoring function (Code: 04302,
information ALTERNATOR R).
1 Deteriorated battery The battery may be deteriorated. Check it directly.
bleshooting.
Defective alternator (Inter- Alternator Engine Voltage
2
nal defect) Between terminal R Running (Throttle:
27.5 – 29.5 V
ground
Stopped Max. 1 V
Possible causes ness (Disconnection or out turning starting switch.
Resistance Max. 1 z
3
and standard defective contact of con- Wiring harness between L52 (female) (18) –
value in normal nector)
alternator terminal R (E02)
state
Between L52 (female) (18) – alternator terminal
R (E02) wiring harness and chassis ground
bleshooting.
Alternator Engine Voltage
Running (Throttle:
Between L52 (18) and 27.5 – 29.5 V
Above 1/2)
chassis ground
Stopped Max. 1 V
WA430-6 20-319
PLAY OF CODE)
Circuit diagram related to alternator
20-320 WA430-6
PLAY OF CODE)
Failure code [B@BAZK] (Engine oil: Low level)
Action code Failure code Engine oil: Low level

Trouble
E01 B@BAZK (Machine monitor system)
Contents of
• The engine oil level sensor circuit is OPEN.
trouble
Action of
• Turns the engine oil level caution lamp ON.
controller
Problem that
appears on • The engine oil level is low (The engine may be broken).
machine
Related • The input state (ON/OFF) from the engine oil level sensor can be checked with the monitoring function
information (Code: 40903, D-IN-29).
1 Low engine oil level The engine oil level may be low. Check it directly.
Defective engine oil level out turning starting switch.
Max. 1 z
2 sensor (Internal disconnec- E26 (male) Engine oil level Resistance
tion) Between (1) and Normal
chassis ground
Insufficient (Low) Min. 1 Mz
Possible causes
and standard
value in normal ness (Disconnection or out turning starting switch.
Resistance Max. 1 z
3
state defective contact of con- Wiring harness between L54 (female) (11) –
nector)
E26 (female) (1)
Max. 1 z
L54 (female) Engine oil level Resistance
Wiring harness Normal
between (11) –
Insufficient (Low) Min. 1 Mz
chassis ground
WA430-6 20-321
PLAY OF CODE)
Circuit diagram related to engine oil level sensor
20-322 WA430-6
PLAY OF CODE)
Failure code [B@BCZK] (Coolant: Low level)
Action code Failure code Coolant: Low level

Trouble
E01 B@BCZK (Machine monitor system)
Contents of
• The coolant level sensor circuit is OPEN.
trouble
Action of
• Turns the coolant level caution lamp ON.
controller
Problem that
appears on • The coolant level is low. The engine overheats (The engine may be broken).
machine
Related • The input state (ON/OFF) from the coolant level sensor can be checked with the monitoring function
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 disconnection) Min. 1 Mz
(Abnormal)
Max. 1 z
Between (1) and (2)
Above low level
Possible causes (Normal)
and standard Disconnection in wiring har-
Resistance Max. 1 z
state 3
nector)
R32 (female) (1)

L54 (female) Sub-tank Resistance
4 Defective machine monitor Below low level
Wiring harness Min. 1 Mz
(Abnormal)
Max. 1 z
between (10) –
Above low level
chassis ground
(Normal)
WA430-6 20-323
PLAY OF CODE)
Circuit diagram related to coolant level sensor
20-324 WA430-6
PLAY OF CODE)
Failure code [B@C7NS] (Brake oil: Overheating)
Action code Failure code Brake oil: Overheating

Trouble
E02 B@C7NS (Transmission controller system)
Contents of
• The rear brake overheats.
trouble
Action of • The brake may be damaged.
controller • The rear brake overheat warning is displayed.
Problem that
• The machine may not travel in the 4th gear speed.
appears on
• When the 4th gear speed is changed, a shock or a time lag may be made.
machine
Related • The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the
information monitoring function (Code: 30202, R BRAKE OIL).

Defective rear brake oil R56 (male) Oil temperature Resistance
1 temperature sensor (Inter-
nal defeet) Normal temperature
Possible causes 35 – 50 kz
Between (1) and (2) (25°C)
and standard
100°C 3.1 – 4.5 kz
value in normal
state
Defective transmission con- L61 (female) Oil temperature Resistance
2
troller Normal temperature
Wiring harness 35 – 50 kz
(25°C)
between (20) – (31)
100°C 3.1 – 4.5 kz
WA430-6 20-325
PLAY OF CODE)
Circuit diagram related to rear brake oil temperature sensor
20-326 WA430-6
PLAY OF CODE)
Failure code [B@CENS] (Torque converter oil: Overheating)
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
controller
Problem that
• The torque converter oil overheat warning is turned ON (If the machine is used as it is, the torque con-
appears on
verter may be broken).
machine
Related • The condition (temperature) from the torque converter oil can be checked with the monitoring function
information (Code: 04100, TC OIL TEMP).

Overheating of torque con-
1 The torque converter oil may be overheating. Check it directly.
verter oil

Defective torque converter Torque converter oil
2 oil temperature sensor T10 (male) Resistance
temperature
(Internal defect)
Normal (25°C) 35 – 50 kz
Between (1) and (2)
Possible causes 100°C 3.1 – 4.5 kz
and standard
value in normal Grounding fault in wiring
state 3 harness (Contact with
ground circuit) Between L55 (female) (2) – T10 (female) (1) wir-
Resistance Min. 1 Mz
ing harness and chassis ground

L54 (female) Resistance
4 Defective machine monitor temperature
Wiring harness Normal (25°C) 35 – 50 kz
between (2) –
chassis ground 100°C 3.1 – 4.5 kz
WA430-6 20-327
PLAY OF CODE)
Circuit diagram related to torque converter oil temperature sensor
20-328 WA430-6
PLAY OF CODE)
Failure code [B@GAZK] (Battery electrolyte: Low level)
Action code Failure code Battery electrolyte: Low level

Trouble
E01 B@GAZK (Machine monitor system)
Contents of
• The electrolyte level sensor circuit is OPEN.
trouble
Action of
• Turns the electrolyte level caution lamp ON.
controller
Problem that
appears on • The electrolyte level is low.
machine
Related • The input state (voltage) from the electrolyte level sensor can be checked with the monitoring function
information (Code: 40300, BATTERY A2V).
1 The electrolyte level is low The electrolyte level may be low. Check it directly.

Defective electrolyte level Battery electrolyte
R39 (male) Resistance
Max. 1 z
2 sensor level
(Internal disconnection) Normal level
Between (1) and
chassis ground Insufficient level
Min. 1 Mz
Possible causes (Low level)
and standard Disconnection in wiring
value in normal harness out turning starting switch.
Resistance Max. 1 z
state 3
(Disconnection or defective Wiring harness between L55 (female) (5) – R39
contact of connector)
(female) (1)

Battery electrolyte
Max. 1 z
4 Defective machine monitor level
Wiring harness Normal level
between (5) – chassis Insufficient level
Min. 1 Mz
ground (Low level)
WA430-6 20-329
PLAY OF CODE)
Circuit diagram related to battery electrolyte level sensor
20-330 WA430-6
PLAY OF CODE)
Failure code [B@HANS] (Hydraulic oil: Overheating)
Action code Failure code Hydraulic oil: Overheating

Trouble
E02 B@HANS (Machine monitor system)
Contents of
• The hydraulic oil temperature is above 110°C.
trouble
Action of
controller
Problem that
• The hydraulic oil overheat warning is turned ON (If the machine is used as it is, the pump and cylinder
appears on
seals may be broken).
machine
Related • The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
information monitoring function (Code: 04401, HYD TEMP).
1 Overheating of hydraulic oil The hydraulic oil may be overheating. Check it directly.

Defective hydraulic oil tem-
Hydraulic oil
2 perature sensor (Internal R47 (male) Resistance
temperature
defect)
Normal (25°C) 35 – 50 kz
Between (1) and (2)
100°C 3.1 – 4.5 kz
Possible causes
value in normal out turning starting switch.
state Between L55 (female) (7) – R47 (female) (1)

Hydraulic oil
Wiring harness Normal (25°C) 35 – 50 kz
between (7) –
100°C 3.1 – 4.5 kz
chassis ground
WA430-6 20-331
PLAY OF CODE)
Circuit diagram related to hydraulic oil temperature sensor
20-332 WA430-6
PLAY OF CODE)
Failure code [D150KA] (Emergency steering relay: Disconnection)
Action code Failure code Emergency steering relay: Disconnection

Trouble
E02 D150KA (Transmission controller system)
Contents of • Since the emergency steering relay system is disconnected, signals are not output to the emergency
trouble steering relay.
Action of
controller
Problem that
appears on • The electric emergency steering motor does not turn.
machine
Related • The output state (ON/OFF) to the emergency steering relay can be checked with the monitoring function
information (Code: 40914, SOL/0-0).
Defective emergency steer- out turning starting switch.

1 ing relay (L126) (Internal
200 – 400 z
disconnection)
Between (1) and (2)
Possible causes Disconnection in wiring har- out turning starting switch.

Resistance Max. 1 z
and standard ness (Disconnection or Wiring harness between L63 (female) (7) – L105
value in normal 2
defective contact of con- (female) (9)
Resistance Max. 1 z
state nector) Wiring harness between L105 (female) (10) –
chassis ground

Defective transmission con-
3 L63 (female) Resistance
200 – 400 z
troller
Wiring harness between (7) –
chassis ground
WA430-6 20-333
PLAY OF CODE)
Circuit diagram related to emergency steering relay
20-334 WA430-6
PLAY OF CODE)
Failure code [D150KB] (Emergency steering relay: Short circuit)
Action code Failure code Emergency steering relay: Short circuit

Trouble
E03 D150KB (Transmission controller system)
Contents of • Since the emergency steering relay system is shorted, signals are not output to the emergency steering
trouble relay.
Action of • Turns the output to the emergency steering relay OFF.
Problem that
appears on • The electric emergency steering motor does not turn.
machine
Related • The output state (ON/OFF) to the emergency steering relay can be checked with the monitoring function

200 – 400 z
short circuit)
Between (1) and (2)
Possible causes
ground circuit) Wiring harness between L63 (female) (7) – L105
state Resistance Min. 1 Mz
(female) (9)

200 – 400 z
troller
chassis ground
WA430-6 20-335
PLAY OF CODE)
Circuit diagram related to emergency steering relay
20-336 WA430-6
PLAY OF CODE)
Failure code [D160KA] (Backup lamp relay: Disconnection)
Action code Failure code Backup lamp relay: Disconnection

Trouble
Contents of
• Since the backup lamp relay system is disconnected, signals are not output to the backup lamp relay.
trouble
Action of
• None in particular.
controller
Problem that
appears on • The backup buzzer does not sound. The backup lamp does not light up. (The machine can travel.)
machine
Related • The output state (ON/OFF) to the backup lamp relay can be checked with the monitoring function
information (Code: 40915, D-OUT-0).
Defective backup lamp out turning starting switch.

1 relay (L117) (Internal dis-
200 – 400 z
connection)
Between (1) and (2)

and standard ness (Disconnection or Wiring harness between L63 (female) (4) – L103
value in normal 2 Resistance Min. 1 Mz
chassis ground

200 – 400 z
troller
chassis ground
WA430-6 20-337
PLAY OF CODE)
Circuit diagram related to backup lamp relay
20-338 WA430-6
PLAY OF CODE)
Failure code [D160KB] (Backup lamp relay: Short circuit)
Action code Failure code Backup lamp relay: Short circuit

Trouble
Contents of
• Since the backup lamp relay system is shorted, signals are not output to the backup lamp relay.
trouble
Action of
• Turns the output to the backup lamp relay OFF.
controller
Problem that
appears on • The backup buzzer does not sound. The backup lamp does not light up. (The machine can travel.)
machine
Related • The output state (ON/OFF) to the backup lamp relay can be checked with the monitoring function
information (Code: 40915, D-OUT-0).
Defective backup lamp out turning starting switch.

1 relay (L117) (Internal short
200 – 400 z
circuit)
Between (1) and (2)
Possible causes
(female) (1)

200 – 400 z
troller
chassis ground
WA430-6 20-339
PLAY OF CODE)
20-340 WA430-6
PLAY OF CODE)
Failure code [D191KA] (Neutral safety relay: Disconnection)
Action code Failure code Neutral safety relay: disconnection

Trouble
Contents of
• Since the neutral safety relay system is disconnected, signals are not output to the neutral safety relay.
trouble
Action of • Turns the neutral output OFF.
Problem that
• When the right FNR switch or the joystick mode is turned ON, the engine does not start. (The engine
appears on
can be started in the steering wheel mode, however.)
machine
Related
information
• Set right FNR switch or joystick FNR switch in N.
Defective exchange relay
• Set directional lever in N.
1 (L115) (Internal disconnec-
• Turn right FNR selector switch ON.
tion or short circuit)
When exchange relay (L115) is replaced with a relay of the same type (5-
pin type), if the condition becomes normal, the exchange relay is defec-
tive.
Defective neutral safety out turning starting switch.

200 – 400 z
connection)
Between (1) and (2)
Resistance Max. 1 z
Wiring harness between L63 (female) (37) –
Disconnection in wiring har- L101 (female) (14)
Resistance Max. 1 z
3
defective contact of con- L102 (female) (11)
Resistance Max. 1 z
nector) Wiring harness between L62 (female) (35) –
Possible causes
L101 (female) (11)
Resistance Max. 1 z
and standard
Wiring harness between L101 (female) (12) or
value in normal
L102 (female) (12) – chassis ground
state
• When right FNR switch is installed (Turn right FNR switch operation
switch ON).
L63 Right FNR switch Voltage
Between (37) and N 17 – 30 V
chassis ground
Other than N Max. 1 V
Defective transmission con- ry out troubleshooting.

4
troller • Set directional lever in N.
• When joystick is installed (Turn armrest lock and joystick switch ON).
L63 Operation Voltage
When joystick FNR
switch is in N and joy- 17 – 30 V
stick lever is in neutral
Between (37) and
When joystick FNR
chassis ground Max. 1 V
switch is not in N
When joystick lever is
Max. 1 V
operated
WA430-6 20-341
PLAY OF CODE)
Circuit diagram related to neutral safety relay
20-342 WA430-6
PLAY OF CODE)
Failure code [D191KB] (Neutral safety relay: Short circuit)
Action code Failure code Neutral safety relay: Short circuit

Trouble
Contents of
• Since the neutral safety relay system is shorted, signals are not output to the neutral safety relay.
trouble
Action of
• Turns the output to the neutral safety relay OFF when grounding occurs.
controller
Problem that
• When the right FNR switch or the joystick mode is turned ON, the engine does not start. (The engine
appears on
can be started in the steering wheel mode, however.)
machine
Related
information
• Set right FNR switch or joystick FNR switch in N.
Defective exchange relay
• Turn right FNR selector switch ON.
When exchange relay (L115) is replaced with a relay of the same type (5-
pin type), if the condition becomes normal, the exchange relay is defec-
tive.
Defective neutral safety out turning starting switch.

2 relay (L116) (Internal short
200 – 400 z
circuit)
Between (1) and (2)

3 Resistance Min. 1 Mz
Possible causes Resistance Min. 1 Mz
L102 (female) (11)
and standard
value in normal
state
• When right FNR switch is installed (Turn right FNR switch operation
switch ON).
chassis ground
Other than N Max. 1 V

4
troller • Set directional lever in N.
• When joystick is installed (Turn armrest lock and joystick switch ON).
L63 Operation Voltage
When joystick FNR
switch is in N and joy- 17 – 30 V
stick lever is in neutral
Between (37) and
When joystick FNR
chassis ground Max. 1 V
switch is not in N
When joystick lever is
Max. 1 V
operated
WA430-6 20-343
PLAY OF CODE)
Circuit diagram related to neutral safety relay
20-344 WA430-6
PLAY OF CODE)
Failure code [D192KA] (ECSS relay: Disconnection)
Action code Failure code ECSS relay: Disconnection

Trouble
Contents of
• Since the ECSS relay system is disconnected, signals are not output to the ECSS relay.
trouble
Action of
• Turns the output to the ECSS relay.
controller
Problem that
appears on • The ECSS does not operate.
machine
Related • The output state (ON/OFF) to the ECSS relay can be checked with the monitoring function (Code:
information 40914, SOL/0-1).
Defective ECSS relay out turning starting switch.

200 – 400 z
tion)
Between (1) and (2)

Resistance Max. 1 z
and standard ness (Disconnection or Wiring harness between L63 (female) (17) –
value in normal 2
Resistance Max. 1 z
chassis ground

200 – 400 z
troller
chassis ground
WA430-6 20-345
PLAY OF CODE)
Circuit diagram related to ECSS relay
20-346 WA430-6
PLAY OF CODE)
Failure code [D192KB] (ECSS relay: Short circuit)
Action code Failure code ECSS relay: Short circuit

Trouble
Contents of
• Since the ECSS relay system has a grounding fault, signals are not output to the ECSS relay.
trouble
Action of
• Turns the output to the ECSS relay.
controller
Problem that
appears on • The ECSS does not operate.
machine
Related • The output state (ON/OFF) to the ECSS relay can be checked with the monitoring function (Code:
information 40914, SOL/0-1).
Defective ECSS relay out turning starting switch.

1 (L125) (Internal short cir-
200 – 400 z
cuit)
Between (1) and (2)
Possible causes
ground circuit) Wiring harness between L63 (female) (17) –
L104 (female) (11)

200 – 400 z
troller
chassis ground
WA430-6 20-347
PLAY OF CODE)
20-348 WA430-6
PLAY OF CODE)
Failure code [D193KA] (Joystick solenoid cut-off relay: Disconnection)
Action code Failure code Joystick solenoid cut-off relay: Disconnection

Trouble
E03 D193KA (Work equipment controller system)
Contents of
• The joystick solenoid cut-off relay output system is disconnected.
trouble
Action of • Stops outputting the signal to the joystick solenoid cut-off relay and joystick EPC solenoid.
Problem that
appears on • The operator cannot operate the joystick steering.
machine
• Only for joystick steering (If equipped)
Related
• The output state (ON/OFF) to the joystick solenoid cut-off relay can be checked with the monitoring
information
function (Code: 40916, SOL/0-0).
Defective joystick solenoid out turning starting switch.

1 cut-off relay (L41) (Internal
200 – 400 z
disconnection)
Between (5) and (6)
Possible causes
and standard ness (Disconnection or out turning starting switch.
Resistance Max. 1 z
2
value in normal defective contact of con- Wiring harness between L73 (female) (7) – L41
state nector)
(female) (5)

Defective work equipment
200 – 400 z
controller
chassis ground
WA430-6 20-349
PLAY OF CODE)
Circuit diagram related to joystick solenoid cut-off relay
20-350 WA430-6
PLAY OF CODE)
Failure code [D193KB] (Joystick solenoid cut-off relay: Short circuit)
Action code Failure code Joystick solenoid cut-off relay: Short circuit
Trouble
E03 D193KB (Work equipment controller system)
Contents of
• The joystick solenoid cut-off relay output system has a grounding fault.
trouble
Action of • Stops outputting the signal to the joystick solenoid cut-off relay and joystick EPC solenoid.
Problem that
appears on • The operator cannot operate the joystick steering.
machine
Related
• The output state (ON/OFF) to the joystick solenoid cut-off relay can be checked with the monitoring
information

Defective joystick solenoid
200 – 400 z
1 cut-off relay (L41) (Internal
Between (5) and (6)
short circuit)
Between (5) or (6) and chassis
Min. 1 Mz
Possible causes ground
and standard
value in normal Grounding fault in wiring out turning starting switch.
(female) (5)

200 – 400 z
controller
chassis ground
WA430-6 20-351
PLAY OF CODE)
Circuit diagram related to joystick solenoid cut-off relay
20-352 WA430-6
PLAY OF CODE)
Failure code [D5ZAKB] (Throttle correction signal: Short circuit)
Action code Failure code Throttle correction signal: Short circuit

Trouble
E01 D5ZAKB (Transmission controller system)
Contents of • Since the throttle correction signal (low-idle signal) output system is shorted with the power source, the
trouble throttle correction signal (low-idle signal) is not output.
Action of
• Turns the throttle correction signal (low-idle signal) OFF (Cannot turn it ON).
controller
Problem that
appears on • The operator cannot raise the low-idle speed.
machine
Related
—
information

Between L62 (female) (8) – ECMB (female) (44)
Possible causes circuit) in wiring harness Voltage Max. 1 V
and standard
value in normal
state Defective transmission con- ry out troubleshooting.
2
troller L62 Voltage
Between (8) and chassis ground Max. 1 V
If either of causes 1 and 2 is not the cause of the trouble, the engine con-
3 Defective engine controller
troller may be defective.
WA430-6 20-353
PLAY OF CODE)
Circuit diagram related to low-idle switch
20-354 WA430-6
PLAY OF CODE)
WA430-6 20-355
PLAY OF CODE)
Failure code [D5ZHL6] (Monitor panel terminal C signal: Signal disagrees with operation
and stop of engine)
Action code Failure code Monitor panel terminal C signal: Signal disagrees with operation and stop
Trouble of engine
E01 D5ZHL6 (Machine monitor system)
Contents of • After the engine is started, no signals are input to starting switch terminal C (IGN "C"). (The input circuit
trouble is disconnected or shorted with chassis ground.)
Action of
controller
Problem that
• The engine does not start. (If the circuit is shorted with the chassis ground, fuse (B-1) is broken and
appears on
the operator cannot turn the starting switch ON.)
machine
Related • The input state (ON/OFF) from the starting switch terminal C (IGN "C") can be checked with the moni-
information toring function (Code: 40900, D-IN-2).

Defective fuse (1) of fuse If the fuse is broken, the circuit probably has a grounding fault, etc. (See
1
box B cause 4.)
Defective starting switch out turning starting switch.
Max. 1 z
2 (Internal disconnection or Starting switch Resistance
short circuit) Between terminals B START
and C
Resistance Max. 1 z
and standard 3
defective contact of con- Wiring harness between starting switch terminal
C – L116 (female) (3)
state
Short circuit in wiring har-
4 ness (Contact with ground
circuit) Between starting switch terminal C – L116
(female) (3) wiring harness and chassis ground
L52 Starting switch Resistance
Wiring harness START 20 – 30 V
between (2) –
Other than above Max. 1 V
chassis ground
20-356 WA430-6
PLAY OF CODE)
Circuit diagram related to starting switch signal C
WA430-6 20-357
PLAY OF CODE)
Failure code [D5ZMKB] (Engine output mode command signal: Short circuit)
Action code Failure code Engine output mode command signal: Short circuit
Trouble
E01 D5ZMKB (Transmission controller system)
Contents of • Since the engine output mode command signal (droop signal) output system is shorted with the power
trouble source, the engine output mode command signal (droop signal) is not output.
Action of
• Turns the engine output mode command signal (droop signal) output OFF (Cannot turn it ON).
controller
Problem that
appears on • The engine power is kept high.
machine
Related
—
information

Between L62 (female) (18) – ECMA (female)
Possible causes circuit) in wiring harness Voltage Max. 1 V
(24) wiring harness and chassis ground
and standard
value in normal
state Defective transmission con- ry out troubleshooting.
2
troller L62 Voltage
If either of causes 1 and 2 is not the cause of the trouble, the engine con-
troller may be defective.
20-358 WA430-6
PLAY OF CODE)
Circuit diagram related to engine output mode command signal
WA430-6 20-359
PLAY OF CODE)
20-360 WA430-6
PLAY OF CODE)
Failure code [DAF3KK] (Machine monitor: Low source voltage (input))
Action code Failure code Machine monitor: Low source voltage (input)
Trouble
E01 DAF3KK (Machine monitor system)
Contents of • When the voltage of the SW power supply (power supply for operation) is above 17 V, the voltage of the
trouble NSW power supply (power supply for & memory) is below 17 V.
Action of
controller
Problem that
• The service meter reading is abnormal. The odometer does not advance. Failure history data is not
appears on
saved.
machine
Related
—
information

1
box B cause 3.)

Disconnection in wiring har- Between battery relay terminal B – FS1 (female) Resistance Max. 1 z
ness (Disconnection or (1) wiring harness
Resistance Max. 1 z
2
defective contact of con- Wiring harness between FS1 (male) (1) – L51
nector) (female) (4) or (5)
Resistance Max. 1 z
Wiring harness between L51 (female ) (9), (10),
(17), (18), (19) or (20) – chassis ground
Possible causes out turning starting switch.

and standard Between battery relay terminal B – FS1 (female)
3 harness (Contact with Resistance Min. 1 Mz
value in normal (1) wiring harness and chassis ground
ground circuit)
state Wiring harness between FS1 (female) (1) – L51
(female) (4) or (5)
L51 Voltage
20 – 30 V
ground
4 Defective machine monitor Between (4) or (5) and (9), (10),
20 – 30 V
(17), (18), (19) or (20)
20 – 30 V
ground
Between (6) or (7) and (9), (10),
20 – 30 V
(17), (18), (19) or (20)
WA430-6 20-361
PLAY OF CODE)
Circuit diagram related to monitor panel power supply
20-362 WA430-6
PLAY OF CODE)
Failure code [DAFBKM] (Machine monitor: Mistake in operation or setting)
Action code Failure code Machine monitor: Mistake in operation or setting

Trouble
E03 DAFBKM (Machine monitor system)
Contents of
• Model selection switch (SW1) is set to (A) – (F).
trouble
Action of • Operates on the assumption that the model name is WA430-6.
Problem that
• The displayed travel speed/engine speed and odometer reading are different from actual values.
appears on
• When the gear speed is changed, a large shock is made.
machine
Related
—
information

When nor-
Positions (0) – (9)
Setting of SW1 (on back side of mal
Possible causes 1 Defective setting of model
monitor) When
and standard Positions (A) – (F)
abnormal
value in normal
state If cause 1 is not the cause of the trouble, the machine monitor may be
defective.
2 Defective monitor panel
(Troubleshooting cannot be carried out since the defect is in the machine
monitor.)
WA430-6 20-363
PLAY OF CODE)
Failure code [DAFSKQ] (Machine monitor: Disagreement of model selection signals)
Action code Failure code Machine monitor: Disagreement of model selection signals
Trouble
E01 DAFSKQ (Machine monitor system)
Contents of
• Meter selection switch (SW3) is set to (9) – (F).
trouble
Action of
• Operates on the assumption that km/h is used as the unit for display.
controller
Problem that
• Since the travel speed is calculated with the standard tire, the displayed travel speed and odometer
appears on
reading may be abnormal.
machine
Related • The meter display selection information (SW3) signals (0) – (F) can be checked with the monitoring
information function (Code: 30802, SW3).

When nor-
Positions (0) – (8)
Setting of SW3 (on back side of mal
Possible causes 1 Defective setting of model
monitor) When
and standard Positions (9) – (F)
abnormal
value in normal
state If cause 1 is not the cause of the trouble, the machine monitor may be
defective.
(Troubleshooting cannot be carried out since the defect is in the machine
monitor.)
20-364 WA430-6
PLAY OF CODE)
Failure code [DAQ0KK] (Transmission controller: Low source voltage)
Action code Failure code Transmission controller: Low source voltage

Trouble
– DAQ0KK (Transmission controller system)
Contents of
• The source voltage of the controller is low.
trouble
Action of
• Cannot sense the input signals normally.
controller
Problem that
appears on • The machine cannot operate normally.
machine
Related
—
information

Resistance Max. 1 z
ness (Disconnection or Wiring harness between L63 (female) (1) or (11)
1
defective contact of con- – FS3 (female) (3)
Resistance Max. 1 z
nector) Wiring harness between L63 (female) (21), (31),
(32) or (33) – chassis ground
Possible causes
state Between L63 (female) (1) or (11) – FS3 (female)
Defective transmission con- L63 Voltage
3
troller Between (1) or (11) and chassis
ground 20 – 30 V
(Constant (NSW) power supply)
WA430-6 20-365
PLAY OF CODE)
Circuit diagram related to transmission controller power supply
20-366 WA430-6
PLAY OF CODE)
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)
Action code Failure code Transmission controller: Abnormality in controller

Trouble
E02 DAQ0KT (Transmission controller system)
Contents of
• The information in the ROM (non-volatile memory) of the transmission controller is abnormal.
trouble
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
• Method of reproducing failure code: Turn the starting switch ON.
information

Possible causes
Troubleshooting cannot be carried out since the trouble is in the control-
and standard
Defective transmission con- ler.
value in normal 1
troller (If there is not any visible trouble in the machine, the controller may be
state
used as it is.)
WA430-6 20-367
PLAY OF CODE)
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source volt-
age (input))
Action code Failure code Transmission controller load power supply line: Low source voltage
Trouble (input)
– DAQ2KK (Transmission controller system)
Contents of
• The voltage of the solenoid power supply system is low.
trouble
Action of
• Signals cannot be output to the solenoid.
controller
Problem that
machine
Related
—
information

Resistance Max. 1 z
ness (Disconnection or Wiring harness between L63 (female) (2), (12)
1
defective contact of con- or (22) – FS4 (female) (2)
Resistance Max. 1 z
Possible causes
state Between L63 (female) (2), (12) or (22) – chassis
ground
3
troller Between (2), (12) or (22) and chas-
sis ground 20 – 30 V
20-368 WA430-6
PLAY OF CODE)
Circuit diagram related to transmission controller power supply
WA430-6 20-369
PLAY OF CODE)
Failure code [DAQ9KQ] (Transmission controller model selection wiring harness: Dis-
agreement of model selection signals)
Action code Failure code Transmission controller model selection wiring harness: Disagreement of
Trouble model selection signals
E03 DAQ9KQ (Transmission controller system)
Contents of
• The 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
Problem that
appears on • Gear shifting shocks may be made.
machine
Related
—
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
Wrong selection of control- Set the controller model with the rotary switch of the machine monitor.
value in normal 1
state ler model (See Testing and adjusting.)
20-370 WA430-6
PLAY OF CODE)
Failure code [DAQSKR] (S-NET communication: Defective communication (Abnormality

in target component system))
Action code Failure code S-NET communication: Defective communication (Abnormality in target
Trouble component system)
E03 DAQSKR (Machine monitor system)
Contents of • The S-NET (+) signal line between the monitor panel and transmission controller is disconnected or
trouble shorted with the chassis ground or power source.
Action of
controller
Problem that
• The monitor does not display normally (The shift indicator and travel speed/engine speed are not dis-
appears on
played).
machine
Related
—
information
Resistance Max. 1 z
1
defective contact of con- Wiring harness between L56 (female) (1) or (2)
nector)
– L62 (female) (21)

Between L56 (female) (1) or (2) – L62 (female)
Possible causes ground circuit) Resistance Min. 1 Mz
and standard
value in normal Short circuit with power
state 3 source (Contact with 24V
circuit) in wiring harness Voltage Max. 1 V
L56 Voltage
4 Defective monitor panel
4–8V
ground
Between (1) or (2) and (4) or (5) 4–8V
WA430-6 20-371
PLAY OF CODE)
Circuit diagram related to S-NET communication
20-372 WA430-6
PLAY OF CODE)
Failure code [DB90KK] Work equipment controller: Low source voltage (input)
Action code Failure code Work equipment controller: Low source voltage (input)
Trouble
E03 DB90KK (Work equipment controller system)
Contents of
• The source voltage of the controller is low.
trouble
Action of • Cannot sense the input signals normally.
Problem that
machine
Related
—
information

1
box B cause 3.)

Resistance Max. 1 z
ness (Disconnection or Wiring harness between L73 (female) (1) or (11)
2
defective contact of con- – FS3 (female) (3)
Resistance Max. 1 z
Possible causes
and standard
Between L73 (female) (1) or (11) – FS3 (female)
Defective work equipment L73 Voltage
4
controller Between (1) or (11) and chassis
ground 20 – 30 V
WA430-6 20-373
PLAY OF CODE)
Circuit diagram related to work equipment controller power supply
20-374 WA430-6
PLAY OF CODE)
Failure code [DB92KK] Work equipment controller load power supply line: Low source
voltage (input)
Action code Failure code Work equipment controller load power supply line: Low source voltage
Trouble (input)
E03 DB92KK (Work equipment controller system)
Contents of
• The voltage of the solenoid power supply system is low.
trouble
Action of • Signals cannot be output to the solenoid. (If the voltage is below 18 V, all outputs are turned OFF.)
Problem that
appears on • The operator cannot operate the work equipment.
machine
Related
—
information

Resistance Max. 1 z
ness (Disconnection or Wiring harness between L73 (female) (2), (12)
1
defective contact of con- or (22) – FS4 (female) (5)
Resistance Max. 1 z
Possible causes
and standard Short circuit in wiring har-
value in normal 2 ness (Contact with ground
state Between L73 (female) (2) , (12) or (22) – FS4
circuit) Resistance Min. 1 Mz
Defective work equipment L73 Voltage
3
controller Between (2), (12) or (22) and chas-
(SW power supply)
WA430-6 20-375
PLAY OF CODE)
Circuit diagram related to work equipment controller 24V power supply
20-376 WA430-6
PLAY OF CODE)
Failure code [DK95KX] Work equipment controller power supply output: Out of input sig-
nal range
Action code Failure code Work equipment controller power supply output: Out of input signal range
Trouble
E03 DK95KX (Work equipment controller system)
Contents of
• The 5V sensor power supply system is shorted with the chassis ground.
trouble
Action of • Turns the output to all EPC OFF.
Problem that
appears on • The operator cannot operate the work equipment and joystick.
machine
Related
• Only for joystick steering or EPC lever (If equipped)
information
1 ness (Contact with ground out turning starting switch.
circuit)
Between L71 (female) (22) and chassis ground Resistance Min. 1 Mz

Defective lift arm EPC lever
2 potentiometer (Internal dis-
Between (4) and (1) 2.5 – 3.9 kz
connection or short circuit)
Min. 1 Mz
ground

Defective bucket EPC lever
Between (4) and (1) 2.5 – 3.9 kz
Min. 1 Mz
ground
Possible causes Defective joystick steering out turning starting switch.

and standard EPC lever potentiometer L34 (male) Resistance
4
value in normal (Internal disconnection or Between (4) and (1) 2.5 – 3.9 kz
state short circuit) Between (4) or (1) and chassis
Min. 1 Mz
ground

Defective 3rd EPC lever
Between (4) and (1) 2.5 – 3.9 kz
Min. 1 Mz
ground

Defective lift arm angle
F18 (male) Resistance
Between (C) and (A) 4 – 6 kz
Between (C) or (A) and chassis
Min. 1 Mz
ground
Defective work equipment ry out troubleshooting.

7
controller L71 Voltage
Between (22) and (21) 4.75 – 5.25 V
WA430-6 20-377
PLAY OF CODE)
Circuit diagram related to work equipment controller 5V power supply
20-378 WA430-6
PLAY OF CODE)
Failure code [DB9SKR] (Work equipment controller S-NET communication: Defective

communication (Abnormality in target component system))
Action code Failure code Work equipment controller S-NET communication: Defective communi-
Trouble cation (Abnormality in target component system)
E03 DB9SKR (Machine monitor system)
Contents of • The S-NET (+) signal line between the monitor panel and work equipment controller is disconnected or
trouble shorted with the chassis ground or power source.
Action of
controller
Problem that
• The joystick indicator pilot lamp does not light up.
appears on
• The joystick steering does not operate normally.
machine
Related
—
information
Resistance Max. 1 z
1
defective contact of con- Wiring harness between L56 (female) (1) or (2)
nector)
– L72 (female) (21)

and standard
L56 Voltage
4–8V
ground
Between (1) or (2) and (4) or (5) 4–8V
WA430-6 20-379
PLAY OF CODE)
Circuit diagram related to S-NET communication
20-380 WA430-6
PLAY OF CODE)
Failure code [DD15LD] (t switch (Panel switch 1): Switch is kept pressed for long time)
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 monitor panel mode selector switch 1 "t" (Panel switch 1) is kept CLOSED for
trouble more than continuous 1 minute.
Action of
controller
Problem that
appears on • The operator cannot operate the monitor (cannot enter the service mode).
machine
• The input state (ON/OFF) from the monitor panel mode selector switch 1 "t" (Panel switch 1) can be
Related
• The operator may not be able to use the monitoring function because of the t switch trouble.
checked with the monitoring function (Code: 40901, D-IN-15).
information
Defective t switch (Panel

t switch
1 switch 1) (Internal short cir- L07 (female) Resistance
Max. 1 z
(Panel switch 1)
cuit)
ON
Between (2) and (3)
Possible causes
and standard Short circuit with power ry out troubleshooting.
value in normal 2 source (Contact with 24V
state circuit) in wiring harness Between L52 (female) (17) – L07 (female) (3)
Voltage Max. 1 V
t switch
3 Defective machine monitor L52 Voltage

(Panel switch 1)
Between (17) and ON 20 – 30 V
chassis ground Other than above Max. 1 V
WA430-6 20-381
PLAY OF CODE)
Circuit diagram related to t switch and U switch
20-382 WA430-6
PLAY OF CODE)
Failure code [DD16LD] (U switch (Panel switch 2): Switch is kept pressed for long time)
Action code Failure code U switch (Panel switch 2): Switch is kept pressed for long time
Trouble
Contents of • The input circuit of the monitor panel mode selector switch 2 "U" (Panel switch 2) is kept CLOSED for
Action of
controller
Problem that
appears on • The operator cannot operate the monitor.
machine
• The input state (ON/OFF) from the monitor panel mode selector switch 2 "U" (Panel switch 2) can be
Related
• The operator may not be able to use the monitoring function because of the U switch trouble.
information
Defective U switch (Panel

U switch
Max. 1 z
(Panel switch 2)
cuit)
ON
Between (2) and (1)
Possible causes
and standard Short circuit with power ry out troubleshooting.
value in normal 2 source (Contact with 24V
state circuit) in wiring harness Between L52 (female) (8) – L07 (female) (1) wir-
Voltage Max. 1 V
U switch
3 Defective machine monitor L52 Voltage

(Panel switch 2)
Between (8) and chas- ON 20 – 30 V
sis ground Other than above Max. 1 V
WA430-6 20-383
PLAY OF CODE)
Circuit diagram related to t switch and U switch
20-384 WA430-6
PLAY OF CODE)
Failure code [DD17LD] (< switch (Panel switch 3): Switch is kept pressed for long time)
Action code Failure code < switch (Panel switch 3): Switch is kept pressed for long time
Trouble
Contents of • The input circuit of the monitor panel mode selector switch 3 "<" (Panel switch 3) is kept CLOSED for
Action of
controller
Problem that
machine
• The input state (ON/OFF) from the monitor panel mode selector switch 3 "<" (Panel switch 3) can be
Related
information
• The operator may not be able to use the monitoring function because of the < switch trouble.

Defective < switch (Panel
< switch
Max. 1 z
(Panel switch 3)
cuit)
ON
Between (3) and (2)
Possible causes
and standard Grounding fault in wiring out turning starting switch.
state ground circuit) Between L54 (female) (7) – L08 (female) (3) wir-
< switch
3 Defective monitor panel L54 Voltage
(Panel switch 3)
Between (7) and chas- ON Max. 1 V
WA430-6 20-385
PLAY OF CODE)
Circuit diagram related to > switch and < switch
20-386 WA430-6
PLAY OF CODE)
Failure code [DD18LD] (> switch (Panel switch 4): Switch is kept pressed for long time)
Action code Failure code > switch (Panel switch 4): Switch is kept pressed for long time
Trouble
Contents of • The input circuit of the monitor panel mode selector switch 4 ">" (Panel switch 4) is kept CLOSED for
Action of
controller
Problem that
machine
• The input state (ON/OFF) from the monitor panel mode selector switch 4 ">" (Panel switch 4) can be
Related
information
• The operator may not be able to use the monitoring function because of the > switch trouble.

Defective > switch (Panel
> switch
Max. 1 z
(Panel switch 4)
cuit)
ON
Between (1) and (2)
Possible causes
and standard Grounding fault in wiring out turning starting switch.
state ground circuit) Between L54 (female) (15) – L08 (female) (1)
> switch
(Panel switch 4)
Between (15) and ON Max. 1 V
WA430-6 20-387
PLAY OF CODE)
Circuit diagram related to > switch and < switch
20-388 WA430-6
PLAY OF CODE)
Failure code [DD1ALD] Remote positioner raise set switch: Switch is kept pressed for
long time
Action code Failure code Remote positioner raise set switch: Switch is kept pressed for long time
Trouble
E03 DD1ALD (Work equipment controller system)
Contents of
• Since the remote positioner raise set switch system has a grounding fault, operator cannot set raising.
trouble
• Stops setting the raise set position.
Action of • Stops the remote raise stop operation.
controller • Turns the raise set indicator OFF.
Problem that
appears on • Setting of raise set position
machine
Related • The ON/OFF signals to the remote positioner raise set switch can be checked with the monitoring func-
information tion (Code: 40917, D-OUT-1).

Between L72 (female) (13) – S12 (female) (1)

Remote positioner set
Possible causes Defective remote positioner S12 (male) Resistance
Max. 1 z
switch
and standard 2 set switch (Internal short
Raise
value in normal circuit) Between (1) and (2)
state Other than above Min. 1 Mz
Between (1) or (2) and
– Min. 1 Mz
chassis ground
Defective work equipment Remote positioner set
3 L72 (male) Voltage
controller switch
Between (13) and Raise Max. 1 V
WA430-6 20-389
PLAY OF CODE)
Circuit diagram related to remote positioner set switch
20-390 WA430-6
PLAY OF CODE)
Failure code [DD1BLD] Remote positioner lower set switch: Switch is kept pressed for
long time
Action code Failure code Remote positioner lower set switch: Switch is kept pressed for long time
Trouble
E03 DD1BLD (Work equipment controller system)
Contents of • Since the remote positioner lower set switch system has a grounding fault, operator cannot set lower-
trouble ing.
• Stops setting the lower set position.
Action of • Stops the remote lower stop operation.
controller • Turns the lower set indicator OFF.
Problem that
appears on • Setting of lower set position
machine
Related • The ON/OFF signals to the remote positioner lower set switch can be checked with the monitoring func-
information tion (Code: 40917, D-OUT-2).

Between L72 (female) (3) – S12 (female) (3) wir-

Remote positioner set
Possible causes Defective remote positioner S12 (male) Resistance
Max. 1 z
switch
and standard 2 set switch (Internal short
Lower
value in normal circuit) Between (3) and (2)
state Other than above Min. 1 Mz
– Min. 1 Mz
chassis ground
controller switch
Between (3) and chas- Lower Max. 1 V
WA430-6 20-391
PLAY OF CODE)
Circuit diagram related to remote positioner set switch
20-392 WA430-6
PLAY OF CODE)
Failure code [DDK3KA] (Right FNR switch: Disconnection)
Action code Failure code Right FNR switch: Disconnection

Trouble
E03 DDK3KA (Transmission controller system)
Contents of • Since the right FNR switch input signal system is disconnected or shorted with the chassis ground, the
trouble signal is not input.
Action of • Cannot judge the input signal of the related line.
Problem that
appears on • After stopping the machine, the operator can drive it in the steering wheel mode.
machine
Related • The input signals (ON/OFF) from the right FNR switch can be checked with the monitoring function
information (Code: 40907, D-IN-17, D-IN-18, D-IN-19).
Resistance Max. 1 z
Wiring harness between FS4 (female) (2) – L12
Disconnection in wiring har- (female) (1)
Resistance Max. 1 z
ness (Disconnection or Wiring harness between L62 (female) (25) – L12
1
Resistance Max. 1 z
nector) Wiring harness between L62 (female) (15) – L12
(female) (3)
Resistance Max. 1 z
(female) (4)

Grounding fault in wiring Resistance Min. 1 Mz
(female) (2)
(female) (3)
(female) (4)
Possible causes
value in normal
Max. 1 z
L12 (male) Right FNR switch Resistance
state F
Between (2) and (1)
Max. 1 z
Defective right FNR switch Other than F Min. 1 Mz
3 (Internal disconnection or N
Between (3) and (1)
short circuit)
Max. 1 z
Other than N Min. 1 Mz
R
Between (4) and (1)
Other than R Min. 1 Mz
Between (1), (2), (3) or
– Min. 1 Mz
(4) and chassis ground
• When right FRN switch is installed (Right FNR switch operation switch
is ON)
Defective transmission con- Between (25) and F 20 – 30 V
4
troller chassis ground Other than F Max. 1 V
chassis ground Other than N Max. 1 V
Between (5) and chas- R 20 – 30 V
sis ground Other than R Max. 1 V
WA430-6 20-393
PLAY OF CODE)
Circuit diagram related to right FNR switch
20-394 WA430-6
PLAY OF CODE)
Failure code [DDK3KB] (Right FNR switch: Short circuit)
Action code Failure code Right FNR switch: Short circuit

Trouble
E03 DDK3KB (Transmission controller system)
Contents of
• Since the right FNR switch input signal system is shorted, multiple signals are input.
trouble
Action of • Cannot judge the input signal of the right FNR switch.
Problem that
machine
Related • The input signals (ON/OFF) from the right FNR switch can be checked with the monitoring function
Short circuit with power Voltage Max. 1 V
(female) (2)
(female) (3)
Voltage Max. 1 V
(female) (4)
Max. 1 z
L12 (male) Right FNR switch Resistance
Defective right FNR switch F
Between (2) and (1)
Possible causes
Max. 1 z
2 (Internal disconnection or Other than F Min. 1 Mz
and standard short circuit) N
value in normal Between (3) and (1)
Max. 1 z
state
R
Between (4) and (1)
is ON)
3
troller chassis ground Other than F Max. 1 V
WA430-6 20-395
PLAY OF CODE)
Circuit diagram related to right FNR switch
20-396 WA430-6
PLAY OF CODE)
Failure code [DDK4KA] (Joystick FNR switch: Disconnection)
Action code Failure code Joystick FNR switch: Disconnection

Trouble
Contents of • Since the joystick FNR switch input signal system is disconnected or shorted with the chassis ground,
trouble the signal is not input.
Action of • Cannot judge the input signal of the related line.
Problem that
machine
Related
• The input signals (ON/OFF) from the joystick FNR switch can be checked with the monitoring function
information
(Code: 40907, D-IN-17, D-IN-18, D-IN-19).
Resistance Max. 1 z
Resistance Max. 1 z
1
Resistance Max. 1 z
(female) (3)
Resistance Max. 1 z
(female) (4)

Between L62 (female) (25) – L37 (female) (2)
Possible causes
and standard
value in normal
Max. 1 z
state L12 (male) Joystick FNR switch Resistance
F
Between (2) and (1)
Max. 1 z
Defective joystick FNR Other than F Min. 1 Mz
3 switch (Internal disconnec- N
Between (3) and (1)
Max. 1 z
R
Between (4) and (1)
Between (1), (2), (3) or
– Min. 1 Mz
(4) and chassis ground
• Joystick ON/OFF switch ON
L62 Joystick FNR switch Voltage
4 chassis ground
troller Other than F Max. 1 V
WA430-6 20-397
PLAY OF CODE)
Circuit diagram related to joystick FNR switch
20-398 WA430-6
PLAY OF CODE)
Failure code [DDK4KB] (Joystick FNR switch: Short circuit)
Action code Failure code Joystick FNR switch: Short circuit

Trouble
Contents of
• Since the joystick FNR switch input signal system is shorted, multiple signals are input.
trouble
Action of • Cannot judge the input signal of the joystick FNR switch.
Problem that
machine
Related
• The input signals (ON/OFF) from the joystick FNR switch can be checked with the monitoring function
information
(Code: 40907, D-IN-17, D-IN-18, D-IN-19).
(female) (2)
(female) (3)
Voltage Max. 1 V
(female) (4)
Max. 1 z
L37 (male) Joystick FNR switch Resistance
Defective joystick FNR F
Possible causes Between (2) and (1)
Max. 1 z
and standard 2 switch (Internal short cir- Other than F Min. 1 Mz
value in normal cuit) N
Between (3) and (1)
Max. 1 z
state Other than N Min. 1 Mz
R
Between (4) and (1)
• Joystick ON/OFF switch ON
L62 Joystick FNR switch Voltage
3 chassis ground
troller Other than F Max. 1 V
WA430-6 20-399
PLAY OF CODE)
Circuit diagram related to joystick FNR switch
20-400 WA430-6
PLAY OF CODE)
Failure code [DDK5LD] (Joystick shift-up/down switch: Switch is kept pressed for long
time)
Action code Failure code Joystick shift-up/down switch: Switch is kept pressed for long time
Trouble
E03 DDK5LD (Transmission controller system)
Contents of • Since the joystick shift-up/down switch system is shorted with the power source, the joystick shift-up/
trouble down signal is kept input.
Action of
controller
Problem that • Once the gear is shifted up or down, it cannot be shifted up or down with the joystick shift-up/down
appears on switch.
machine • The gear can be shifted up and down in the auto-shift mode or steering wheel mode.
Related
• The input state (ON/OFF) from the joystick shift-up/down switch can be checked with the monitoring
information
function (Code: 40906, D-IN-12, D-IN-13).

Joystick shift-up/down
Max. 1 z
switch
Defective joystick shift-up/ Shift-up switch pressed
1 down switch (Internal short Between (1) and (6) Shift-up switch
circuit) Min. 1 Mz
released
Max. 1 z
Shift-down switch
pressed
Between (1) and (8)
Shift-down switch
Min. 1 Mz
released

Possible causes 2 source (Contact with 24V
circuit) in wiring harness Between L63 (female) (9) – L37 (female) (6) wir-
and standard Voltage Max. 1 V
value in normal
state
Joystick shift-up/down
L63 Voltage
switch
Shift-up switch pressed 20 – 30 V
Between (9) and chas-
Shift-up switch
sis ground Max. 1 V
released
3 Shift-down switch
troller 20 – 30 V
Between (19) and pressed
chassis ground Shift-down switch
Max. 1 V
released

(female) (8)
WA430-6 20-401
PLAY OF CODE)
Circuit diagram related to joystick shift-up/down switch
20-402 WA430-6
PLAY OF CODE)
Failure code [DDK6KA] (FNR lever signal: Disconnection)
Action code Failure code FNR lever signal: Disconnection

Trouble
Contents of • Since the forward-reverse travel input signal system is disconnected or shorted with the chassis ground,
trouble the signal is not input.
Action of • Cannot judge the input signal of the related line (F, N, or R).
Problem that • The operator cannot drive the machine with the lever in the position where the error is turned ON (For-
appears on ward or reverse).
machine • If the right FNR switch is installed, the operator can drive the machine in the right FNR switch mode.
Related • The input signals (ON/OFF) from the FNR lever switch can be checked with the monitoring function

Directional lever in wrong
1 Check that the lever is not in neutral.
position

Disconnection in wiring har- Wiring harness between L62 (female) (36) – L04 Resistance Max. 1 z
ness (Disconnection or (female) (2)
Resistance Max. 1 z
2
defective contact of con- Wiring harness between L62 (female) (26) – L04
nector) (female) (3)
Resistance Max. 1 z
(female) (4)

and L101 (female) (15) wiring harness and Resistance Min. 1 Mz
chassis ground
ground circuit)
and L101 (female) (15) wiring harness and Resistance Min. 1 Mz
Possible causes chassis ground
and standard Between L62 (female) (16) – L04 (female) (4)
value in normal wiring harness and chassis ground
state
L04 Directional lever Voltage
Between (2) and F 20 – 30 V
Defective directional lever chassis ground Other than F Max. 1 V
4
(Internal disconnection)
Between (4) and R 20 – 30 V
chassis ground
Other than R Max. 1 V
Defective transmission con- chassis ground
5 Other than F Max. 1 V
troller
chassis ground Other than R Max. 1 V
WA430-6 20-403
PLAY OF CODE)
Circuit diagram related to FNR lever signal
20-404 WA430-6
PLAY OF CODE)
Failure code [DDK6KB] (FNR lever signal: Short circuit)
Action code Failure code FNR lever signal: Short circuit

Trouble
Contents of
• Since the forward-reverse travel input signal system is shorted, multiple signals are input.
trouble
Action of • Stops traveling (in neutral).
Problem that • The operator cannot drive the machine with the lever in the position where the error is turned ON (For-
appears on ward or reverse).
machine • If the right FNR switch is installed, the operator can drive the machine in the right FNR switch mode.
Related • The input signals (ON/OFF) from the FNR lever switch can be checked with the monitoring function
and L101 (female) (15) wiring harness and Voltage Max. 1 V
chassis ground
circuit) in wiring harness
and L101 (female) (15) wiring harness and Voltage Max. 1 V
chassis ground
Voltage Max. 1 V
Possible causes L04 Directional lever Voltage
and standard Between (2) and F 20 – 30 V
value in normal Defective directional lever chassis ground Other than F Max. 1 V
2
state (Internal short circuit)
chassis ground
Other than R Max. 1 V
Defective transmission con- chassis ground
3 Other than F Max. 1 V
troller
chassis ground Other than R Max. 1 V
WA430-6 20-405
PLAY OF CODE)
Circuit diagram related to FNR lever signal
20-406 WA430-6
PLAY OF CODE)
Failure code [DDS5KA] (Steering oil pressure switch: Disconnection)
Action code Failure code Steering oil pressure switch: Disconnection

Trouble
E03 DDS5KA (Transmission controller system)
Contents of
• Both of N.C and N.O signals of the steering oil pressure switch are OPENED simultaneously.
trouble
Action of • Turns the electric emergency steering motor relay OFF.
Problem that • Automatic emergency steering does not move (The operation can operate the emergency steering
appears on manually).
machine • The self-check device of the emergency steering does not operate.
• If the steering oil pressure is not applied, operate the emergency steering manually.
Related
• The input state (ON/OFF) from the steering oil pressure switch can be checked with the monitoring func-
information
tion (Code: 40905, D-IN-0, D-IN-1).
Max. 1 z
Defective steering oil pres- R36 (male) Engine Resistance
1 sure switch (Low) (Internal Stopped
disconnection) Running Min. 1 Mz
Max. 1 z
Between (1) and (2)
Open to atmosphere
(Reference)
Max. 1 z
2 sure switch (High) (Internal Stopped
disconnection) Running Min. 1 Mz
Max. 1 z
Between (1) and (2)
Possible causes Open to atmosphere
and standard (Reference)
value in normal
state out turning starting switch.
Resistance Max. 1 z
Disconnection in wiring har- Wiring harness between L61 (female) (17) –
ness (Disconnection or R36 (female) (2)
Resistance Max. 1 z
3
nector) R69 (female) (2)
Resistance Max. 1 z
Wiring harness between R36 (female) (1) or
R69 (female) (1) – chassis ground
L61 Engine Voltage
Defective transmission con- Stopped Max. 1V
4 Between (17) and
troller
chassis ground Running 20 – 30 V
Between (23) and Stopped 20 – 30 V
chassis ground Running Max. 1 V
WA430-6 20-407
PLAY OF CODE)
Circuit diagram related to steering oil pressure switch
20-408 WA430-6
PLAY OF CODE)
Failure code [DDS5KB] (Steering oil pressure switch: Short circuit)
Action code Failure code Steering oil pressure switch: Short circuit
Trouble
E03 DDS5KB (Transmission controller system)
Contents of
• Both of N.C and N.O signals of the steering oil pressure switch are CLOSED simultaneously.
trouble
Action of • Turns the electric emergency steering motor relay OFF.
Problem that • Automatic emergency steering does not move (The operation can operate the emergency steering
appears on manually).
machine • The self-check device of the emergency steering does not operate.
• If the steering oil pressure is not applied, operate the emergency steering manually.
Related
• The input state (ON/OFF) from the steering oil pressure switch can be checked with the monitoring func-
information
tion (Code: 40905, D-IN-0, D-IN-1).
Max. 1 z
R36 (male) Engine Resistance
Defective steering oil pres- Stopped
1 sure switch (Low) (Internal Running Min. 1 Mz
Max. 1 z
Between (1) and (2)
disconnection) Open to atmosphere
(Reference)
– Min. 1 Mz
chassis ground
Max. 1 z
Defective steering oil pres- Stopped
Possible causes 2 sure switch (High) (Internal Running Min. 1 Mz
Max. 1 z
Between (1) and (2)
and standard disconnection) Open to atmosphere
value in normal (Reference)
state Between (1) or (2) and
– Min. 1 Mz
chassis ground

defective contact of con- R36 (female) (2)
R69 (female) (2)
L61 Engine Voltage
Defective transmission con- Stopped Max. 1V
4 Between (17) and
troller
chassis ground Running 20 – 30 V
Between (23) and Stopped 20 – 30 V
chassis ground Running Max. 1 V
WA430-6 20-409
PLAY OF CODE)
20-410 WA430-6
PLAY OF CODE)
Failure code [DDS5L6] (Steering oil pressure switch: Signal disagrees with operation and
stop of engine)
Action code Failure code Steering oil pressure switch: Signal disagrees with operation and stop of
Trouble engine
E03 DDS5L6 (Machine monitor system)
Contents of • While the engine is running at speed higher than 500 rpm, the steering oil pressure switch circuit is
trouble CLOSED.
Action of
controller
Problem that
• Since low steering oil pressure is sensed, the steering operation with the emergency steering pump
appears on
(motor) may be turned ON when the travel speed is above 1 km/h.
machine
Related • The input state (ON/OFF) from the steering oil pressure switch can be checked with the monitoring func-
1 Low steering oil pressure Check the steering oil pressure (See Testing and adjusting).
bleshooting.
Max. 1 z
2 sure switch (Internal short Stopped
circuit) Running Min. 1 Mz
Max. 1 z
Between (1) and (2)
Open to atmosphere
Possible causes (Reference)
and standard
Between L61 (female) (17) – R36 (female) (2)
bleshooting.
Max. 1 z
R61 (female) Engine Resistance
4 Defective machine monitor Stopped
Between (17) and Running Min. 1 Mz
Max. 1 z
chassis ground Open to atmosphere
(Reference)
WA430-6 20-411
PLAY OF CODE)
20-412 WA430-6
PLAY OF CODE)
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)
Action code Failure code Shift mode selector switch: ON/OFF signals disagree
Trouble
– DDT0L4 (Transmission controller system)
Contents of
• The signals input from the manual/auto shift selector switch are combined impossibly.
trouble
Action of
• Selects the manual shift mode.
controller
Problem that
appears on • The position of the manual/auto shift selector switch does not match to the shift mode.
machine
• The input state (H/L) from the manual/auto shift selector switch can be checked with the monitoring
Related
function (Code: 41700 SHIFT MODE)
information
• The operator can check the current shift mode with the automatic shift indicator.

Resistance Max. 1 z
1
defective contact of con- S22 (female) (3)
Resistance Max. 1 z
nector) Wiring harness between L61 (female) (2) – S22
(female) (2)

ground circuit)

and standard S22 (male) Shift mode Resistance
value in normal
Max. 1 z
Defective manual/auto shift Manual Min. 1 Mz
state
Max. 1 z
3 selector switch (Internal Between (4) and (3) Auto (L)
defect) Auto (H)
Manual Min. 1 Mz
Max. 1 z
Between (4) and (2) Auto (L) Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and car-
Auto (H)
L61 (male) Shift mode Voltage
Manual 20 – 30 V
Defective transmission con- Between (14) and
4 Auto (L) Max. 1 V
troller chassis ground
Auto (H) 20 – 30 V
Manual 20 – 30 V
Auto (L) 20 – 30 V
sis ground
Auto (H) Max. 1 V
WA430-6 20-413
PLAY OF CODE)
Circuit diagram related to manual/auto shift selector switch
20-414 WA430-6
PLAY OF CODE)
Failure code [DDT4LD] (Transmission cut-off selector switch: Switch is kept pressed for
long time)
Action code Failure code Transmission cut-off selector switch: Switch is kept pressed for long time
Trouble
E01 DDT4LD (Transmission controller)
Contents of • Since the transmission cut-off set switch system is shorted with the chassis ground, the cut-off set
trouble switch signal is kept input.
Action of
—
controller
Problem that
appears on • The transmission cut-off point cannot be set again.
machine
Related • The input state (ON/OFF) from the transmission cut-off set switch can be checked with the monitoring
information function (Code: 40905, D-IN-3).
Max. 1 z
Defective transmission cut- S05 (male) Cut-off set switch Resistance
1 off set switch (Internal short ON
Between (4) and (3)
circuit) OFF Min. 1 Mz
Possible causes – Min. 1 Mz
chassis ground
and standard
3 L61 (male) Cut-off set switch Voltage
troller
Between (5) and chas- ON Max. 1V
sis ground OFF 20 – 30 V
WA430-6 20-415
PLAY OF CODE)
Circuit diagram related to transmission cut-off set switch
20-416 WA430-6
PLAY OF CODE)
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)
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 with the chassis ground, the kick-down is not turned OFF.
trouble
Action of • Turns the kick-down ON when a grounding fault is detected, then does not control the kick-down.
Problem that
appears on • When grounding occurs, the kick-down is turned ON once.
machine
Related • The input state (ON/OFF) from the kick-down switch can be checked with the monitoring function
Max. 1 z
L14 (male) Kick-down switch Resistance
Defective kick-down switch
1 ON
(Internal short circuit) Between (1) and (2)
OFF Min. 1 Mz
chassis ground
and standard
state ry out troubleshooting.
3 L61 Kick-down switch Voltage
troller
chassis ground OFF 20 – 30 V
WA430-6 20-417
PLAY OF CODE)
Circuit diagram related to kick-down switch and hold switch
20-418 WA430-6
PLAY OF CODE)
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)
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 with the chassis ground, the hold switch cannot be changed.
trouble
Action of • Holds once when a grounding fault occurs, then does not control holding.
Problem that
appears on • Holding is performed when a grounding fault occurs.
machine
Related • The input state (ON/OFF) from the hold switch can be checked with the monitoring function (Code:
Max. 1 z
L14 (male) Hold switch Resistance
Defective hold switch (Inter-
1 ON
nal short circuit) Between (3) and (4)
OFF Min. 1 Mz
chassis ground
and standard
(female) (3)
3 L62 Hold switch Voltage
troller
WA430-6 20-419
PLAY OF CODE)
Circuit diagram related to kick-down switch and hold switch
20-420 WA430-6
PLAY OF CODE)
Failure code [DF10KA] (Gearshift lever: Disconnection)
Action code Failure code Gearshift lever: Disconnection

Trouble
E01 DF10KA (Transmission controller system)
Contents of • Since the gearshift lever input signal system is disconnected or shorted with the chassis ground, the
trouble signal is not input.
• Fixes the gearshift lever to the shift range before the selected shift range input signal cannot be judged
Action of
or it is disconnected.
controller
Problem that
appears on • The transmission is not set to the selected gear speed.
machine
Related • The input state (ON/OFF) from each shift switch can be checked with the monitoring function (Code:
information 40906, D-IN-8, D-IN-9, D-IN-10, D-IN-11)
Resistance Max. 1 z
(female) (1)
Resistance Max. 1 z
Disconnection in wiring har- Wiring harness between L63 (female) (10) – L04
Resistance Max. 1 z
1
Resistance Max. 1 z
(female) (7)
Resistance Max. 1 z
(female) (8)

Possible causes Resistance Min. 1 Mz
value in normal Between L63 (female) (20) – L04 (female) (6)
ground circuit)
L04 Shift range Voltage
Between (5) and 1 20 – 30 V
chassis ground Other than 1 Max. 1 V
Defective shift switch (Inter-
3 Between (6) and 2 20 – 30 V
nal disconnection)
WA430-6 20-421
PLAY OF CODE)
is ON)
Possible causes
and standard Between (10) and 1 20 – 30 V
Defective transmission con- chassis ground Other than 1 Max. 1 V
value in normal 4
troller
state Between (20) and 2 20 – 30 V
Between (30) and 3 20 – 30 V
Between (40) and 4 20 – 30 V
20-422 WA430-6
PLAY OF CODE)
Circuit diagram related to gearshift switch
WA430-6 20-423
PLAY OF CODE)
Failure code [DF10KB] (Gearshift switch: Short circuit)
Action code Failure code Gearshift switch: Short circuit

Trouble
E01 DF10KB (Transmission controller system)
Contents of
• Since the gearshift lever input signal system is shorted, multiple signals are input.
trouble
Action of
• Judges that the shift range of higher gear speed is input.
controller
Problem that
appears on • When the lever is operated, the lower gear speed is not selected.
machine
Related • The input state (ON/OFF) from each shift switch can be checked with the monitoring function (Code:
information 40906, D-IN-8, D-IN-9, D-IN-10, D-IN-11)

Voltage Max. 1 V
1 source (Contact with 24V Voltage Max. 1 V
Voltage Max. 1 V
Voltage Max. 1 V
Defective transmission shift chassis ground Other than 1 Max. 1 V
Possible causes 2 switch (Internal short cir- Between (6) and 2 20 – 30 V
and standard cuit) chassis ground Other than 2 Max. 1 V
value in normal
state
chassis ground
Other than 4 Max. 1 V
is ON)
Between (10) and 1 20 – 30 V
Defective transmission con- chassis ground Other than 1 Max. 1 V
3
troller
Between (20) and 2 20 – 30 V
Between (30) and 3 20 – 30 V
Between (40) and 4 20 – 30 V
20-424 WA430-6
PLAY OF CODE)
Circuit diagram related to gearshift switch
WA430-6 20-425
PLAY OF CODE)
Failure code [DFA0KM] (Work equipment control EPC lever: Mistake in operation or set-
ting)
Action code Failure code Work equipment control EPC lever: Mistake in operation or setting
Trouble
E03 DFA0KM (Work equipment controller system)
Contents of
• A mistake is made in operation of the work equipment control EPC lever neutral system.
trouble
• Stops outputting the signal to the lift arm, bucket, and 3rd lever EPC solenoid.
Action of
(Action to take after error is reset: Return the lever to neutral position once)
controller
Problem that
appears on • The operator cannot operate the work equipment.
machine
• Only for EPC lever (If equipped)
Related
• The state (voltage) from the work equipment control EPC lever can be checked with the monitoring
information
function (Code: 42000 BOOM POT, 42002 BUCKET POT 1 and 42006 3RD POT 1).
Defective lift arm neutral ry out troubleshooting.

1 lock switch (Internal discon- • Set work equipment lock lever in LOCK.
nection or short circuit) L71 Voltage
Defective lift arm EPC lever ry out troubleshooting.

2 potentiometer (Internal dis- • Set lift arm EPC lever in neutral.
Possible causes connection or short circuit) L71 Voltage
and standard
Between (19) and (21) 2.4 – 3.9 V
value in normal
state
Defective bucket EPC lever ry out troubleshooting.
3 potentiometer (Internal dis- • Set bucket EPC lever in neutral.
connection or short circuit) L71 Voltage
Between (7) and (21) 2.4 – 3.9 V
Defective 3rd EPC lever ry out troubleshooting.

4 potentiometer (Internal dis- • Set 3rd EPC lever in neural.
Between (20) and (21) 2.4 – 3.9 V
20-426 WA430-6
PLAY OF CODE)
Circuit diagram related to work equipment control EPC lever
WA430-6 20-427
PLAY OF CODE)
Failure code [DGF1KX] (Transmission oil temperature sensor: Out of input signal range)
Action code Failure code Transmission oil temperature sensor: Out of input signal range
Trouble
– DGF1KX (Transmission controller system)
Contents of • Since the transmission oil temperature sensor signal system is abnormal, the transmission oil temper-
trouble ature signal is out of the normal range.
Action of
• Cannot judge the transmission oil temperature normally.
controller
Problem that
appears on • A shock is made when the gear speed is changed.
machine
Related • The input state (oil temperature) from the transmission oil temperature sensor can be checked with the
information monitoring function (Code: 41500, ECMV OIL TEMP).

Defective transmission oil T09 (male) Oil temperature Resistance
temperature sensor (Inter- Normal temperature
1 35 – 50 kz
nal disconnection or short Between (1) and (2) (25°C)
circuit) 100°C 3.1 – 4.5 kz
Normal Min. 1 Mz
chassis ground
Resistance Max. 1 z
2
defective contact of con- Wiring harness between L61 (female) (9) – T09
Possible causes nector)
(female) (1)
and standard
ground circuit) Between L61 (female) (9) – T09 (female) (1) wir-

circuit) in wiring harness Between L61 (female) (9) – T09 (female) (1) wir-
Voltage Max. 1 V

Defective transmission con- L61 (male) Oil temperature Resistance
5
troller Wiring harness Normal temperature
35 – 50 kz
between (9) – chassis (25°C)
ground 100°C 3.1 – 4.5 kz
20-428 WA430-6
PLAY OF CODE)
Circuit diagram related to transmission oil temperature sensor
WA430-6 20-429
PLAY OF CODE)
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)
Action code Failure code Hydraulic oil temperature sensor: Out of input signal range
Trouble
E01 DGH2KX (Machine monitor system)
Contents of
• The hydraulic oil temperature sensor input voltage is below 0.98 V.
trouble
Action of • Turns the hydraulic oil overheat alarm ON. Does not save the trouble in the machine system trouble
controller history but in the electrical system trouble history.
Problem that
appears on • The hydraulic oil temperature gauge reads MAX.
machine
Related • The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
information monitoring function (Code: 04401, HYD TEMP).

Hydraulic
Defective hydraulic oil tem- oil temperature
1 perature sensor (Internal Normal temperature
35 – 50 kz
short circuit) Between (1) and (2) (25°C)
100°C 3.1 – 4.5 kz
Possible causes Normal Min. 1 Mz
chassis ground
and standard
ground circuit) Between L55 (female) (7) – F28 (female) (1) wir-

Hydraulic
3 Defective machine monitor oil temperature
Wiring harness Normal temperature
35 – 50 kz
ground 100°C 3.1 – 4.5 kz
20-430 WA430-6
PLAY OF CODE)
WA430-6 20-431
PLAY OF CODE)
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection)
Action code Failure code Rear brake oil temperature sensor: Disconnection
Trouble
E01 DGR2KA (Transmission controller system)
Contents of • Since the rear brake oil temperature sensor signal system is disconnected, the rear brake oil tempera-
trouble ture signal is not input.
Action of
• Judges that the rear brake oil temperature is low.
controller
Problem that
appears on • The brake oil temperature alarm does not sound.
machine

Defective rear brake oil R56 (male) Oil temperature Resistance
1 temperature sensor (Inter-
nal disconnection) Normal temperature
35 – 50 kz
100°C 3.1 – 4.5 kz
Resistance Max. 1 z
Possible causes
Disconnection in wiring har- Wiring harness between L61 (female) (20) –
and standard
ness (Disconnection or R61 (female) (1)
Resistance Max. 1 z
value in normal 2
state defective contact of con- Wiring harness between R56 (female) (2) – L63
nector) (female) (21) or (31)
Resistance Max. 1 z
Wiring harness between R56 (female) (2) –
chassis ground

3
35 – 50 kz
ground 100°C 3.1 – 4.5 kz
20-432 WA430-6
PLAY OF CODE)
WA430-6 20-433
PLAY OF CODE)
Failure code [DGR2KB] (Rear brake oil temperature sensor: Short circuit)
Action code Failure code Rear brake oil temperature sensor: Short circuit
Trouble
E01 DGR2KB (Transmission controller system)
Contents of • Since the rear brake oil temperature sensor signal system is shorted with the chassis ground, the rear
trouble brake oil temperature signal is not input.
Action of
• Judges that the rear brake oil temperature is high.
controller
Problem that
appears on • The brake oil temperature alarm keeps sounding.
machine

R56 (male) Oil temperature Resistance
Defective rear brake oil
Normal temperature
1 temperature sensor (Inter- 35 – 50 kz
nal short circuit)
100°C 3.1 – 4.5 kz
chassis ground
and standard
ground circuit) Between L61 (female) (20) – R61 (female) (1)

3
35 – 50 kz
ground 100°C 3.1 – 4.5 kz
20-434 WA430-6
PLAY OF CODE)
WA430-6 20-435
PLAY OF CODE)
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal
range)
Action code Failure code Torque converter oil temperature sensor: Out of input signal range
Trouble
E01 DGT1KX (Machine monitor system)
Contents of
• The torque converter oil temperature sensor input voltage is below 0.98 V.
trouble
Action of • Turns the torque converter oil overheat alarm ON. Does not save the trouble in the machine system
controller trouble history but in the electrical system trouble history.
Problem that
appears on • The torque converter oil temperature gauge reads MAX.
machine
Related • The state (oil temperature) from the torque converter oil temperature sensor can be checked with the
information monitoring function (Code: 40100, TC OIL TEMP).

Torque converter
Defective torque converter oil temperature
1 oil temperature sensor Normal temperature
35 – 50 kz
(Internal short circuit) Between (1) and (2) (25°C)
100°C 3.1 – 4.5 kz
chassis ground
and standard
Between L55 (female) (2) – T10 (female) (1) wir-

Torque converter
3 Defective machine monitor oil temperature
35 – 50 kz
ground 100°C 3.1 – 4.5 kz
20-436 WA430-6
PLAY OF CODE)
WA430-6 20-437
PLAY OF CODE)
Failure code [DHT1KX] (Left brake oil pressure sensor: Out of input signal range)
Action code Failure code Left brake oil pressure sensor: Out of input signal range
Trouble
E01 DHT1KX (Transmission controller system)
Contents of • Since the left brake pressure sensor signal system is abnormal, the left brake pressure sensor signal is
trouble not input.
Action of
• Cancels the transmission cut-off.
controller
Problem that • While the transmission cut-off is turned ON, even if the left brake is pressed, the transmission is not cut
appears on off.
machine (When the transmission cut-off function is used)
• The input state (oil temperature) from the left brake oil pressure sensor can be checked with the moni-
Related
toring function (Code: 41100, LH BRAKE).
information
• This trouble can be checked by pressing the left brake while the transmission cut-off is turned ON.
bleshooting.
• Press left brake.
Defective left brake pres- L10 Voltage
1 sure sensor (Internal dis- Between (B) and (A)
20 – 30 V
connection or short circuit) (Power supply)
Between (C) and (A) (Signal) 0.75 – 5.3 V
Between (C) and (A) (Reference:
0.5 – 1.5 V
When opened to atmosphere)

Disconnection in wiring har- Wiring harness between L61 (female) (19) – L10 Resistance Max. 1 z
ness (Disconnection or (female) (C)
Resistance Max. 1 z
2
Possible causes nector) (female) (B)
Resistance Max. 1 z
and standard Wiring harness between L10 (female) (A) –
value in normal
chassis ground
state
Between L61 (female) (19) – L10 (female) (C)

Between L61 (female) (19) – L10 (female) (C)
bleshooting.
• Press left brake.
5
troller Between (16) and chassis ground
20 – 30 V
(Power supply)
Between (19) and chassis ground
0.75 – 5.3 V
(Signal)
20-438 WA430-6
PLAY OF CODE)
Circuit diagram related to left brake oil pressure sensor
WA430-6 20-439
PLAY OF CODE)
Failure code [DJB1KX] (Battery electrolyte level sensor: Out of input signal range)
Action code Failure code Battery electrolyte level sensor: Out of input signal range
Trouble
E01 DJB1KX (Machine monitor system)
Contents of • Since the battery electrolyte level sensor signal system is abnormal, the battery electrolyte level sensor
trouble input voltage is out of the normal range.
Action of
• Turns the battery electrolyte level caution lamp ON.
controller
Problem that
appears on —
machine
Related • The input state (voltage) from the battery electrolyte level sensor can be checked with the monitoring
information function (Code: 40300, BATTERY A2V).

The battery electrolyte level
1 • The battery electrolyte level may be low. Check it directly.
is low.

Defective battery electro- Battery electrolyte
Max. 1 z
2 lyte level sensor level
(Internal disconnection) Normal level
Between (1) and
chassis ground Insufficient level
(Low level)
and standard
value in normal Disconnection in wiring
harness out turning starting switch.
state
Resistance Max. 1 z
3
(Disconnection or defective Wiring harness between L55 (female) (5) – R39
(female) (1)

Battery electrolyte
Max. 1 z
4 Defective machine monitor level
Wiring harness Normal level
between (5) – chassis Insufficient level
ground Min. 1 Mz
(Low level)
20-440 WA430-6
PLAY OF CODE)
Circuit diagram related to battery electrolyte level sensor
WA430-6 20-441
PLAY OF CODE)
Failure code [DK59KA] Lift arm EPC lever potentiometer (Main): Disconnection
Action code Failure code Lift arm EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK59KA (Work equipment controller system)
Contents of • The lift arm EPC lever potentiometer system is disconnected (The main signal line is disconnected or
trouble shorted with chassis ground).
• Stops outputting the signal to the lift arm EPC solenoid.
Action of
• Stops outputting the signal to the lift arm EPC lever magnet detent.
controller
Problem that
appears on • The lift arm does not move.
machine
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the mon-
information
itoring function (Code: 42000 BOOM POT1).
Disconnection in wiring har-
Resistance Max. 1 z
1
nector)
(female) (3)

and standard
value in normal
state
Between (3) and (1) 2.4 – 2.6 V
Defective work equipment • Set lift arm EPC lever in neutral.
4
controller
L71 Voltage
Between (19) and (21) 2.4 – 2.6 V
20-442 WA430-6
PLAY OF CODE)
Circuit diagram related to lift arm EPC lever potentiometer
WA430-6 20-443
PLAY OF CODE)
Failure code [DK59KY] Lift arm EPC lever potentiometer (Main): Short circuit with
power supply line
Action code Failure code Lift arm EPC lever potentiometer (Main): Short circuit with power supply
Trouble
E03 DK59KY line (Work equipment controller system)
Contents of
• Power supply wiring harness touches the lift arm EPC lever potentiometer main signal wiring harness.
trouble
Action of • Stops outputting the signal to the lift arm EPC solenoid and lift arm EPC lever magnet detent.
Problem that
machine
Related
• The state (voltage) of the lift arm EPC lever potentiometer (Main) can be checked with the monitoring
information
function (Code: 42000 BOOM POT1).
Possible causes wiring harness and chassis ground
and standard Between L71 (female) (19) – (21) wiring harness
Voltage Max. 1 V
value in normal and chassis ground
state
2
controller
L71 (female) Voltage
Between (19) and (21) 2.4 – 2.6 V
20-444 WA430-6
PLAY OF CODE)
WA430-6 20-445
PLAY OF CODE)
Failure code [DK59L8] Lift arm lever EPC potentiometer (Main): Analog signals disagree
Action code Failure code Lift arm lever EPC potentiometer (Main): Analog signals disagree
Trouble
E03 DK59L8 (Work equipment controller system)
Contents of • The input signals of the 2 lift arm EPC lever potentiometer systems (main signal and sub signal) dis-
trouble agree with each other.
Action of • Stops outputting the signal to the lift arm EPC solenoid and lift arm EPC lever magnet detent.
Problem that
machine
Related
• The input state (voltage) from the lift arm EPC lever potentiometers (Main and Sub) can be checked
information
with the monitoring function (Code: 42000 BOOM POT1, 42001 BOOM POT 2).
L28 Lift arm EPC lever Voltage
Neutral 2.4 – 2.6 V
Stroke end on raise
3.9 – 4.4 V
Defective lift arm EPC lever Between (3) and (1) side
potentiometer (Defective Stroke end on lower
1 0.6 – 1.1 V
installation (Looseness, side
play)) Neutral 2.4 – 2.6 V
Stroke end on raise
0.6 – 1.1 V
Between (2) and (1) side
Stroke end on lower
3.9 – 4.4 V
side
Between (4) and (1) Neutral 4.75 – 5.25 V
Possible causes
Resistance Max. 1 z
(female) (3)
Resistance Max. 1 z
(female) (2)
L71 Lift arm EPC lever Voltage
Stroke end on raise
3.9 – 4.4 V
3 Stroke end on lower
controller 0.6 – 1.1 V
side
Stroke end on raise
0.6 – 1.1 V
Stroke end on lower
3.9 – 4.4 V
side
20-446 WA430-6
PLAY OF CODE)
WA430-6 20-447
PLAY OF CODE)
Failure code [DK5AKA] Lift arm EPC lever potentiometer (Sub): Disconnection
Action code Failure code Lift arm EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5AKA (Work equipment controller system)
Contents of • The lift arm EPC lever potentiometer system is disconnected (The sub signal line is disconnected or
Action of • Stops outputting the signal to the lift arm EPC solenoid.
Problem that
machine
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the mon-
information
Resistance Max. 1 z
1
nector)
(female) (2)

and standard
value in normal
state
Between (2) and (1) 2.4 – 2.6 V
4
controller
L71 Voltage
Between (13) and (21) 2.4 – 2.6 V
20-448 WA430-6
PLAY OF CODE)
WA430-6 20-449
PLAY OF CODE)
Failure code [DK5AKY] Lift arm EPC lever potentiometer (Sub): Short circuit with
power supply line
Action code Failure code Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line
Trouble
E03 DK5AKY (Work equipment controller system)
Contents of
• Power supply wiring harness touches the lift arm EPC lever potentiometer sub signal wiring harness.
trouble
Action of • Stops outputting the signal to the lift arm EPC solenoid.
Problem that
machine
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the mon-
information
Voltage Max. 1 V
state
2
controller
L71 Voltage
Between (13) and (21) 2.4 – 2.6 V
20-450 WA430-6
PLAY OF CODE)
WA430-6 20-451
PLAY OF CODE)
Failure code [DK5BKA] Bucket EPC lever potentiometer (Main): Disconnection
Action code Failure code Bucket EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5BKA (Work equipment controller system)
Contents of • The bucket EPC lever potentiometer system is disconnected (The main signal line is disconnected or
Action of • Stops outputting the signal to the bucket EPC solenoid and bucket EPC lever magnet detent.
Problem that
appears on • The bucket does not move.
machine
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the mon-
information
itoring function (Code: 42002 BUCKET POT1).
Resistance Max. 1 z
1
nector)
(female) (3)

Between L71 (female) (7) – L29 (female) (3) wir-
and standard
value in normal
state
Between (3) and (1) 2.4 – 2.6 V
Defective work equipment • Set bucket EPC lever in neutral.
4
controller
L71 Voltage
Between (7) and (21) 2.4 – 2.6 V
20-452 WA430-6
PLAY OF CODE)
Circuit diagram related to bucket EPC lever potentiometer
WA430-6 20-453
PLAY OF CODE)
Failure code [DK5BKY] Bucket EPC lever potentiometer (Main): Short circuit with
power supply line
Action code Failure code Bucket EPC lever potentiometer (Main): Short circuit with power supply
Trouble
E03 DK5BKY line (Work equipment controller system)
Contents of
• Power supply wiring harness touches the bucket EPC lever potentiometer main signal wiring harness.
trouble
Problem that
machine
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the mon-
information
Short circuit with power out turning starting switch.

1 source (Contact with 24V Between L71 (female) (7) – L29 (female) (3) wir-
Possible causes Voltage Max. 1 V
circuit) in wiring harness ing harness and chassis ground
and standard
Between L71 (female) (7) – (21) Voltage Max. 1 V
value in normal
state
Defective work equipment • Set lever in neutral.
2
controller
L71 Voltage
Between (7) and (21) 2.4 – 2.6 V
20-454 WA430-6
PLAY OF CODE)
WA430-6 20-455
PLAY OF CODE)
Failure code [DK5BL8] Bucket EPC lever potentiometer (Main): Analog signals dis-
agree
Action code Failure code Bucket EPC lever potentiometer (Main): Analog signals disagree
Trouble
E03 DK5BL8 (Work equipment controller system)
Contents of • The input signals of the 2 bucket EPC lever potentiometer systems (main signal and sub signal) dis-
Problem that
machine
Related
• The input state (voltage) from the bucket EPC lever potentiometers (Main and Sub) can be checked
information
with the monitoring function (Code: 42002 BUCKET POT1, 42003 BUCKET POT 2).
L29 Bucket EPC lever Voltage
Stroke end on raise
3.9 – 4.4 V
Defective bucket EPC lever Between (3) and (1) side
potentiometer (Defective Stroke end on lower
1 0.6 – 1.1 V
installation (Looseness, side
Stroke end on raise
0.6 – 1.1 V
Stroke end on lower
3.9 – 4.4 V
side
Possible causes
Resistance Max. 1 z
(female) (3)
Resistance Max. 1 z
(female) (2)
L71 Bucket EPC lever Voltage
Stroke end on raise
3.9 – 4.4 V
3 Stroke end on lower
side
Stroke end on raise
0.6 – 1.1 V
Stroke end on lower
3.9 – 4.4 V
side
20-456 WA430-6
PLAY OF CODE)
WA430-6 20-457
PLAY OF CODE)
Failure code [DK5CKA] Bucket EPC lever potentiometer (Sub): Disconnection
Action code Failure code Bucket EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5CKA (Work equipment controller system)
Contents of • The bucket EPC lever potentiometer system is disconnected (The sub signal line is disconnected or
Action of • Stops outputting the signal to the bucket EPC solenoid.
Problem that
machine
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the mon-
information
Resistance Max. 1 z
1
nector)
(female) (2)

and standard
value in normal
state
Between (2) and (1) 2.4 – 2.6 V
4
controller
L71 Voltage
Between (1) and (21) 2.4 – 2.6 V
20-458 WA430-6
PLAY OF CODE)
WA430-6 20-459
PLAY OF CODE)
Failure code [DK5CKY] Bucket EPC lever potentiometer (Sub): Short circuit with
power supply line
Action code Failure code Bucket EPC lever potentiometer (Sub): Short circuit with power supply
Trouble
E03 DK5CKY line (Work equipment controller system)
Contents of
• Power supply wiring harness touches the bucket EPC lever potentiometer sub signal wiring harness.
trouble
Action of • Stops outputting the signal to the bucket EPC solenoid.
Problem that
machine
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the mon-
information
Short circuit with power out turning starting switch.

1 source (Contact with 24V Between L71 (female) (1) – L29 (female) (2) wir-
Possible causes Voltage Max. 1 V
circuit) in wiring harness ing harness and chassis ground
and standard
Between L71 (female) (1) – (21) Voltage Max. 1 V
value in normal
state
2
controller
L71 Voltage
Between (1) and (21) 2.4 – 2.6 V
20-460 WA430-6
PLAY OF CODE)
WA430-6 20-461
PLAY OF CODE)
Failure code [DK5DKA] 3rd valve EPC lever potentiometer (Main): Disconnection
Action code Failure code 3rd valve EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5DKA (Work equipment controller system)
Contents of • The 3rd valve (attachment) EPC lever potentiometer system is disconnected (The main signal line is
trouble disconnected or shorted with chassis ground).
• Stops outputting the signal to the 3rd valve (attachment) EPC solenoid.
Action of
• Stops outputting the signal to 3rd valve (attachment) EPC lever magnet detent.
controller
Problem that
appears on • The 3rd valve (attachment) does not move.
machine
Related
• The input state (voltage) from the 3rd valve (attachment) EPC lever potentiometer (Main) can be
information
checked with the monitoring function (Code: 42006 3RD POT1).
Resistance Max. 1 z
1
nector)
(female) (3)

and standard
value in normal Defective 3rd valve (attach- ry out troubleshooting.
state ment) EPC lever potentiom-
3 • Set 3rd valve (attachment) EPC lever in neutral.
eter (Internal disconnection
L30 Voltage
or short circuit)
Between (3) and (1) 2.4 – 2.6 V
Defective work equipment • Set 3rd valve (attachment) EPC lever in neutral.
4
controller
L71 Voltage
Between (20) and (21) 2.4 – 2.6 V
20-462 WA430-6
PLAY OF CODE)
Circuit diagram related to 3rd valve (attachment) EPC lever potentiometer
WA430-6 20-463
PLAY OF CODE)
Failure code [DK5DKY] 3rd valve EPC lever potentiometer (Main): Short circuit with
power supply line
Action code Failure code 3rd valve EPC lever potentiometer (Main): Short circuit with power supply
Trouble line
E03 DK5DKY (Work equipment controller system)
Contents of • Power supply wiring harness touches the 3rd valve (attachment) EPC lever potentiometer main signal
trouble wiring harness.
Action of • Stops outputting the signal to the 3rd valve (attachment) EPC solenoid.
Problem that
machine
Related
• The input state (voltage) from the 3rd valve (attachment) EPC lever potentiometer (Main) can be
information
Voltage Max. 1 V
state
2
controller
L71 Voltage
Between (20) and (21) 2.4 – 2.6 V
20-464 WA430-6
PLAY OF CODE)
WA430-6 20-465
PLAY OF CODE)
Failure code [DK5DL8] 3rd valve EPC lever potentiometer (Main): Analog signals dis-
agree
Action code Failure code 3rd valve EPC lever potentiometer (Main): Analog signals disagree
Trouble
E03 DK5DL8 (Work equipment controller system)
Contents of • The input signals of the 2 3rd valve (attachment) EPC lever potentiometer systems (main signal and
trouble sub signal) disagree with each other.
Action of • Stops outputting the signal to the 3rd valve (attachment) EPC solenoid and 3rd EPC lever magnet detent.
Problem that
machine
Related
• The input state (voltage) from the 3rd valve (attachment) EPC lever potentiometers (Main and Sub) can
information
be checked with the monitoring function (Code: 42006 3RD POT1, 42007 3RD POT 2).
L29 3rd EPC lever Voltage
Stroke end on extract
1.1 – 1.5 V
Defective 3rd valve (attach- Between (3) and (1) side
ment) EPC lever potentiom- Stroke end on retract
1 3.4 – 4.0 V
eter (Defective installation side
(Looseness, play)) Neutral 2.4 – 2.6 V
1.1 – 1.5 V
Stroke end on retract
3.4 – 4.0 V
side
Possible causes
Resistance Max. 1 z
(female) (3)
Resistance Max. 1 z
(female) (3)
L71 3rd EPC lever Voltage
1.1 – 1.5 V
3 Stroke end on retract
side
1.1 – 1.5 V
Stroke end on retract
3.4 – 4.0 V
side
20-466 WA430-6
PLAY OF CODE)
WA430-6 20-467
PLAY OF CODE)
Failure code [DK5EKA] 3rd valve EPC lever potentiometer (Sub): Disconnection
Action code Failure code 3rd valve EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5EKA (Work equipment controller system)
Contents of • The 3rd valve (attachment) EPC lever potentiometer system is disconnected (The sub signal line is dis-
trouble connected or shorted with chassis ground).
Problem that
machine
Related
• The input state (voltage) from the 3rd valve (attachment) EPC lever potentiometer (Sub) can be
information
Resistance Max. 1 z
1
nector)
(female) (2)

and standard
value in normal Defective 3rd valve (attach- ry out troubleshooting.
state ment) EPC lever potentiom-
3 • Set 3rd valve (attachment) EPC lever in neutral.
eter (Internal disconnection
L30 Voltage
or short circuit)
Between (2) and (1) 2.4 – 2.6 V
4
controller
L71 Voltage
Between (14) and (21) 2.4 – 2.6 V
20-468 WA430-6
PLAY OF CODE)
WA430-6 20-469
PLAY OF CODE)
Failure code [DK5EKY] 3rd valve EPC lever potentiometer (Sub): Short circuit with
power supply line
Action code Failure code 3rd valve EPC lever potentiometer (Sub): Short circuit with power supply
Trouble line
E03 DK5EKY (Work equipment controller system)
Contents of • Power supply wiring harness touches the 3rd valve (attachment) EPC lever potentiometer sub signal
trouble wiring harness.
Problem that
machine
Related
• The input state (voltage) from the 3rd valve (attachment) EPC lever potentiometer (Sub) can be
information
Voltage Max. 1 V
state
2
controller
L71 Voltage
Between (14) and (21) 2.4 – 2.6 V
20-470 WA430-6
PLAY OF CODE)
WA430-6 20-471
PLAY OF CODE)
Failure code [DK5FKA] Joystick EPC lever potentiometer (Main): Disconnection
Action code Failure code Joystick EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5FKA (Work equipment controller system)
Contents of • The joystick EPC lever potentiometer system is disconnected (The main signal line is disconnected or
• Stops outputting the signal to the joystick steering EPC solenoid.
Action of
• Stops outputting the signal to joystick steering EPC lever magnet detent.
controller
Problem that
appears on • The operator cannot steer the machine with the joystick EPC lever.
machine
Related
• The input state (voltage) from the joystick EPC lever potentiometer (Main) can be checked with the
information
monitoring function (Code: 42004 J/S POT1).
aPrepare
Disconnection in wiring har- with starting switch OFF, then carry out troubleshooting with-
Resistance Max. 1 z
1
nector)
(female) (3)

and standard
value in normal Defective joystick EPC ry out troubleshooting.
state lever potentiometer (Inter- • Set joystick steering EPC lever in neutral.
3
nal disconnection or short
L30 Voltage
circuit)
Between (3) and (1) 2.4 – 2.6 V
Defective work equipment • Set joystick steering EPC lever in neutral.
4
controller
L71 Voltage
Between (9) and (21) 2.4 – 2.6 V
20-472 WA430-6
PLAY OF CODE)
Circuit diagram related to joystick EPC lever potentiometer
WA430-6 20-473
PLAY OF CODE)
Failure code [DK5FKM] Joystick EPC lever potentiometer (Main): Mistake in operation
or setting
Action code Failure code Joystick EPC lever potentiometer (Main): Mistake in operation or setting
Trouble
E03 DK5FKM (Work equipment controller system)
Contents of
• A mistake is made in operation of the joystick EPC lever neutral system.
trouble
Action of • Stops outputting the signal to the joystick steering EPC solenoid.
Problem that
machine
Related
• The input state (voltage) from the joystick EPC lever potentiometer (main) can be checked with the
information
monitoring function (Code: 42004, J/S POT1).
20-474 WA430-6
PLAY OF CODE)
WA430-6 20-475
PLAY OF CODE)
Failure code [DK5FKY] Joystick EPC lever potentiometer (Main): Short circuit with
power supply line
Action code Failure code Joystick EPC lever potentiometer (Main): Short circuit with power supply
Trouble
E03 DK5FKY line (Work equipment controller system)
Contents of
• Power supply wiring harness touches the joystick EPC lever potentiometer main signal wiring harness.
trouble
Action of • Stops outputting the signal to the joystick EPC solenoid.
Problem that
machine
Related
• The input state (voltage) from the joystick EPC lever potentiometer (Main) can be checked with the
information
monitoring function (Code: 42004 J/S POT1).

Possible causes ing harness and chassis ground
Voltage Max. 1 V
state
Defective work equipment • Set joystick EPC lever in neutral.
2
controller
L71 Voltage
Between (9) and (21) 2.4 – 2.6 V
20-476 WA430-6
PLAY OF CODE)
WA430-6 20-477
PLAY OF CODE)
Failure code [DK5FL8] Joystick EPC lever potentiometer (Main): Short circuit with
power supply line
Action code Failure code Joystick EPC lever potentiometer (Main): Short circuit with power supply
Trouble line
E03 DK5FL8 (Work equipment controller system)
Contents of • The input signals of the 2 joystick EPC lever potentiometer systems (main signal and sub signal) dis-
Problem that
machine
Related
• The input state (voltage) from the joystick EPC lever potentiometers (Main and Sub) can be checked
information
with the monitoring function (Code: 42004 J/S POT1, 42005 J/S POT 2).
L34 Joystick EPC lever Voltage
Defective joystick EPC Neutral 2.4 – 2.6 V
lever potentiometer (Defec- Between (3) and (1) Right stroke end 1.1 – 1.5 V
1
tive installation (Looseness, Left stroke end 3.5 – 4.0 V
Between (2) and (1) Right stroke end 3.5 – 4.0 V
Left stroke end 1.1 – 1.5 V
Possible causes
and standard Disconnection in wiring har- out turning starting switch.
Resistance Max. 1 z
value in normal ness (Disconnection or Wiring harness between L71 (female) (9) – L34
state 2
Resistance Max. 1 z
(female) (2)
L71 Joystick EPC lever Voltage
3 Between (9) and (21) Right stroke end 1.1 – 1.5 V
controller
Between (3) and (21) Right stroke end 3.5 – 4.0 V
20-478 WA430-6
PLAY OF CODE)
WA430-6 20-479
PLAY OF CODE)
Failure code [DK5GKA] Joystick EPC lever potentiometer (Sub): Disconnection
Action code Failure code Joystick EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5GKA (Work equipment controller system)
Contents of • The joystick EPC lever potentiometer system is disconnected (The sub signal line is disconnected or
Problem that
machine
Related
• The input state (voltage) from the joystick EPC lever potentiometer (Sub) can be checked with the mon-
information
itoring function (Code: 42005 J/S POT2).
Resistance Max. 1 z
1
nector)
(female) (2)

and standard
value in normal Defective joystick EPC ry out troubleshooting.
state lever potentiometer (Inter- • Set joystick steering EPC lever in neutral.
3
nal disconnection or short
L34 Voltage
circuit)
Between (2) and (1) 2.4 – 2.6 V
Defective work equipment • Set joystick steering EPC lever in neutral.
4
controller
L71 Voltage
Between (3) and (21) 2.4 – 2.6 V
20-480 WA430-6
PLAY OF CODE)
WA430-6 20-481
PLAY OF CODE)
Failure code [DK5GKY] Joystick EPC lever potentiometer (Sub): Short circuit with
power supply line
Action code Failure code Joystick EPC lever potentiometer (Sub): Short circuit with power supply
Trouble
E03 DK5GKY line (Work equipment controller system)
Contents of
• Power supply wiring harness touches the joystick EPC lever potentiometer sub signal wiring harness.
trouble
• Stops outputting the signal to the lift arm EPC solenoid until the joystick EPC lever in the neutral position
Action of
is sensed.
controller
Problem that
machine
• Only for joystick steering
Related
• The input state (voltage) from the joystick EPC lever potentiometer (Sub) can be checked with the mon-
information
itoring function (Code: 42005 J/S POT2).
Resistance Max. 1 z
1
nector)
(female) (2)
Possible causes
and standard ry out troubleshooting.
value in normal Between L71 (female) (3) – L34 (female) (2) wir-
state
Defective work equipment • Set joystick EPC lever in neutral.
3
controller
L71 Voltage
Between (3) and (21) 2.4 – 2.6 V
20-482 WA430-6
PLAY OF CODE)
WA430-6 20-483
PLAY OF CODE)
Failure code [DKA0KA] Lift arm angle sensor: Disconnection
Action code Failure code Lift arm angle sensor: Disconnection

Trouble
E03 DKA0KA (Work equipment controller system)
Contents of • The lift arm angle signal system is disconnected or shorted with the chassis ground or the power supply
trouble line is disconnected.
• Controls on the assumption that the lift arm EPC potentiometer signal voltage is the input voltage.
Action of • Resets the remote positioner function.
controller • Resets the semiautomatic digging function.
Problem that
appears on • The remote positioner function and semiautomatic function are not effective.
machine
Related
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function
information
(Code: 06002 BOOM ANG).

Resistance Max. 1 z
ness (Disconnection or Wiring harness between L71 (female) (8) – F18
1
defective contact of con- (female) (B)
Resistance Max. 1 z
F18 (female) (C)

Between L71 (female) (8) – F18 (female) (B)
ground circuit)
Between L71 (female) (22) – F18 (female) (C)
Possible causes
and standard F18 Position of lift arm Voltage
value in normal Between (C) and (A) – 4.75 – 5.25 V
state Defective lift arm angle sen- Raise stroke end 3.5 – 4.0 V
sor (lift arm angle potenti- Between (B) and (A)
(Internal disconnection or aPrepare with starting switch OFF, then carry out troubleshooting with-
Lower stroke end 1.0 – 2.0 V
3 ometer)
short circuit) out turning starting switch.

F18 Resistance
Between (C) or (A) and
Min. 1 Mz
chassis ground
L71 Position of lift arm Voltage
4 Between (22) and
controller In all range 4.75 – 5.25 V
chassis ground
Between (8) and Max. raise position 3.5 – 4.0 V
chassis ground Max. lower position 1.0 – 2.0 V
20-484 WA430-6
PLAY OF CODE)
Circuit diagram related to lift arm angle sensor
WA430-6 20-485
PLAY OF CODE)
Failure code [DKA0KY] Lift arm angle sensor: Short circuit with power supply line
Action code Failure code Lift arm angle sensor: Short circuit with power supply line
Trouble
E03 DKA0KY (Work equipment controller system)
Contents of
• The lift arm angle signal system is shorted or the ground line is disconnected.
trouble
• Controls on the assumption that the lift arm EPC potentiometer signal voltage is the input voltage.
Action of • Resets the remote positioner function.
controller • Resets the semiautomatic digging function.
Problem that
appears on • The remote positioner function and semiautomatic function are not effective.
machine
Related
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function
information
(Code: 06002 BOOM ANG).


Between F18 (female) (1) and chassis ground Resistance Max. 1 z
2
defective contact of con-
nector)
F18 Position of lift arm Voltage
Between (C) and (A) – 4.75 – 5.25 V
Possible causes
and standard Raise stroke end 3.5 – 4.0 V
Defective lift arm angle sen- Between (B) and (A)
value in normal Lower stroke end 1.0 – 2.0 V
3 sor (Internal disconnection
state
or short circuit)
F18 Resistance
Between (C) or (A) and
Min. 1 Mz
chassis ground
L71 Position of lift arm Voltage
4 Between (22) and
controller In all range 4.75 – 5.25 V
chassis ground
Between (8) and Max. raise position 3.5 – 4.0 V
chassis ground Max. lower position 1.0 – 2.0 V
20-486 WA430-6
PLAY OF CODE)
Circuit diagram related to lift arm angle sensor
WA430-6 20-487
PLAY OF CODE)
Failure code [DLE2KA] (Engine speed sensor: Disconnection)
Action code Failure code Engine speed sensor: Disconnection

Trouble
E03 DLE2KA (Transmission controller system)
Contents of
• Since the engine speed sensor system is disconnected, the engine speed signal is not input.
trouble
Action of • Cannot sense the engine speed (Controls on the assumption that the engine speed is 2,100 rpm).
Problem that
machine
Related • The input state (revolving speed) from the engine speed sensor can be checked with the monitoring
information function (Code: 01001, 01003 ENG SPEED).

Resistance Max. 1 z
1
defective contact of con- E27 (female) (1)
Resistance Max. 1 z
Possible causes
E27 (female) (2)
and standard
value in normal Defective engine speed out turning starting switch.
state 2 sensor (Internal disconnec-
500 – 1,000 z
E27 (male) Resistance
tion)
Between (1) and (2)
Defective transmission con- bleshooting.

3
troller L62 Voltage (Measure in AC range)
Between (10) and (39) Min. 0.5 V
20-488 WA430-6
PLAY OF CODE)
Circuit diagram related to engine speed sensor
WA430-6 20-489
PLAY OF CODE)
Failure code [DLE2LC] (Engine speed sensor: Speed signals disagree)
Action code Failure code Engine speed sensor: Speed signals disagree
Trouble
E03 DLE2LC (Transmission controller system)
Contents of • Since the engine speed sensor system is shorted with the chassis ground, the engine speed signal is
trouble not input.
Action of • Cannot sense the engine speed (Controls on the assumption that the engine speed is 2,100 rpm).
Problem that
machine
Related • The input state (revolving speed) from the engine speed sensor can be checked with the monitoring
information function (Code: 01001, 01003 ENG SPEED).

1
nector)
E27 (female) (1)

and standard Defective engine speed
– 1,000 z
E27 (male) Resistance
value in normal 2 sensor (Internal disconnec-
state tion) Between (1) and (2) 500
Min. 1 Mz
chassis ground

3
troller L62 Voltage (Measure in AC range)
Between (10) and (39) Min. 0.5 V
20-490 WA430-6
PLAY OF CODE)
Circuit diagram related to engine speed sensor
WA430-6 20-491
PLAY OF CODE)
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)
Action code Failure code Transmission output shaft speed sensor: Disconnection
Trouble
E03 DLT3KA (Transmission controller system)
Contents of • Since the transmission output shaft speed sensor system is disconnected, the transmission output shaft
trouble speed signal is not input.
Action of • Cannot sense the travel speed.
Problem that
• The displayed travel speed does not rise from 0 km/h.
appears on
• The gear is not shifted up in the auto-shift mode.
machine
Related • The input state (revolving speed) from the transmission output shaft speed sensor can be checked with
information the monitoring function (Code: 40000 SPEED).

Resistance Max. 1 z
1
defective contact of con- T19 (female) (1)
Resistance Max. 1 z
Possible causes
T19 (female) (2)
and standard
value in normal Defective transmission out- out turning starting switch.
state 2 put shaft speed sensor
500 – 1,000 z
Between (1) and (2)

3
500 – 1,000 z
troller L62 Resistance
Between (20) and (39)
20-492 WA430-6
PLAY OF CODE)
Circuit diagram related to transmission output shaft speed sensor
WA430-6 20-493
PLAY OF CODE)
Failure code [DLT3LC] (Transmission output shaft speed sensor: Speed signals dis-
agree)
Action code Failure code Transmission output shaft speed sensor: Speed signals disagree
Trouble
E03 DLT3LC (Transmission controller system)
Contents of
• Since the transmission output shaft speed sensor system is disconnected, the speed signal is not input.
trouble
Action of • Cannot sense the travel speed (Judges that the speed is zero).
Problem that
• The semiautomatic digging function cannot be used.
appears on
• The feeling of the joystick steering lowers.
machine
• If the transmission controller is not detecting failure code "DLT3KA" (Transmission output shaft speed
Related sensor: Disconnection).
information • The input state (speed) from the transmission output shaft speed sensor can be checked with the mon-
itoring function (Code: 40000 SPEED).
Resistance Max. 1 z
Possible causes 1
and standard
nector)
(female) (19)
value in normal
state Grounding fault in wiring
20-494 WA430-6
PLAY OF CODE)
WA430-6 20-495
PLAY OF CODE)
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)
Action code Failure code Transmission cut-off indicator lamp: Short circuit
Trouble
– DT20KB (Transmission controller system)
Contents of • Since the indicator lamp system in the transmission cut-off switch is shorted with the chassis ground,
trouble the signal is not output to the indicator lamp.
Action of
controller
Problem that
appears on • The indicator lamp in the transmission cut-off switch does not light up.
machine
Related • The output state (ON/OFF) to the transmission cut-off indicator lamp can be checked with the monitor-
information ing function (Code: 40915, D-OUT-1).

Possible causes ry out troubleshooting.

Defective indicator lamp in
and standard S03 Cut-off switch Voltage
2 transmission cut-off switch
value in normal (Internal short circuit) ON 17 – 30 V
state Between (5) and (6)
OFF Max. 1 V
3 L63 Cut-off switch Voltage
troller
chassis ground OFF Max. 1 V
20-496 WA430-6
PLAY OF CODE)
Circuit diagram related to transmission cut-off indicator lamp
WA430-6 20-497
PLAY OF CODE)
Failure code [DUM1KB] (Remote positioner raise indicator lamp: Short circuit)
Action code Failure code Remote positioner raise indicator lamp: Short circuit
Trouble
E03 DUM1KB (Work equipment controller system)
Contents of • Since the remote positioner raise indicator lamp system is shorted with the chassis ground, the signal
trouble is not output to the indicator lamp.
Action of
controller
Problem that
appears on • The remote positioner raise indicator lamp does not light up.
machine
Related • The output state (ON/OFF) to the remote positioner raise lamp can be checked with the monitoring func-
information tion (Code: 40917 D-OUT-1).

Defective remote positioner
20 z
S13 (male) Resistance
1 raise indicator lamp (Inter-
nal short circuit) Between (5) and (6) About
Min. 1 Mz
chassis ground
Possible causes
state ground circuit) Between L73 (female) (8) – S13 (female) (5) wir-
Defective work equipment Remote positioner
3 L73 Voltage
controller raise lamp switch
20-498 WA430-6
PLAY OF CODE)
Circuit diagram related to remote positioner raise indicator lamp
WA430-6 20-499
PLAY OF CODE)
Failure code [DUM2KB] (Remote positioner lower indicator lamp: Short circuit)
Action code Failure code Remote positioner lower indicator lamp: Short circuit
Trouble
E03 DUM2KB (Work equipment controller system)
Contents of • Since the remote positioner lower indicator lamp system is shorted with the chassis ground, the signal
trouble is not output to the indicator lamp.
Action of
controller
Problem that
appears on • The remote positioner lower indicator lamp does not light up.
machine
Related • The output state (ON/OFF) to the remote positioner lower lamp can be checked with the monitoring
information function (Code: 40917 D-OUT-2).

Defective remote positioner
20 z
1 lower indicator lamp (Inter-
nal short circuit) Between (5) and (6) About
Min. 1 Mz
chassis ground
Possible causes
state ground circuit) Between L73 (female) (18) – S14 (female) (5)
3 L73 Voltage
controller lower lamp switch
20-500 WA430-6
PLAY OF CODE)
Circuit diagram related to remote positioner lower indicator lamp
WA430-6 20-501
PLAY OF CODE)
Failure code [DV00KB] (Warning buzzer: Short circuit)
Action code Failure code Warning buzzer: Short circuit

Trouble
E01 DV00KB (Machine monitor system)
Contents of
• The warning buzzer output circuit is shorted with the power supply line.
trouble
Action of
• Stops outputting the warning buzzer signal until the starting switch is turned OFF.
controller
Problem that
appears on • The warning buzzer does not sound until the starting switch is turned OFF.
machine
Related
—
information
Defective warning buzzer • 5 seconds or more after starting switch is turned ON
1
(Internal short circuit) L20 (female) Warning buzzer Normal/Defective
Sounds Buzzer is normal
Ground (2)
Does not sound Buzzer is defective

Possible causes Between L51 (female) (14) – L20 (female) (2)
and standard
value in normal
L51 Starting switch Voltage
ON 20 – 30 V
For 2 sec after ON
3 Defective machine monitor (Warning buzzer does Max. 1 V
Between (14) and not sound)
chassis ground For 3 sec from 2 sec
after ON
17 – 30 V
(Warning buzzer
sounds)
20-502 WA430-6
PLAY OF CODE)
Circuit diagram related to warning buzzer
WA430-6 20-503
PLAY OF CODE)
Failure code [DW4PKA] Lift arm raise EPC solenoid: Disconnection
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 system is disconnected, the signal is not output to the lift arm raise
trouble EPC solenoid.
• Stops outputting the signal to the lift arm raise EPC solenoid.
Action of
• Stops outputting the signal to the lift arm raise EPC magnet detent.
controller
Problem that
appears on • The lift arm does not rise.
machine
Related
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function
information
(Code: 41900 RAISE EPC).
Defective lift arm raise EPC out turning starting switch.

1 solenoid (Internal discon-
9 – 10.2 z
nection)
Between (1) and (2)
Possible causes
Resistance Max. 1 z
and standard
value in normal 2
state
Resistance Max. 1 z
nector) Wiring harness between L73 (female) (3) – F20
(female) (2)
Defective work equipment out turning starting switch.

3
9 – 10.2 z
controller L73 (female) Resistance
Between (6) and (3)
20-504 WA430-6
PLAY OF CODE)
Circuit diagram related to lift arm raise EPC solenoid
WA430-6 20-505
PLAY OF CODE)
Failure code [DW4PKB] Lift arm raise EPC solenoid: Short circuit
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 system is shorted with the chassis ground, the signal is not output
trouble to the lift arm raise EPC solenoid.
• Stops outputting the signal to the lift arm raise EPC solenoid.
Action of
• Stops outputting the signal to the lift arm raise EPC magnet detent.
controller
Problem that
appears on • The lift arm does not rise.
machine
Related
information
(Code: 41900 RAISE EPC).

Defective lift arm raise EPC
9 – 10.2 z
1 solenoid (Internal short cir-
Between (1) and (2)
cuit)
ground
and standard
Between L73 (female) (6) – F20 (female) (1) wir-

3
9 – 10.2 z
Between (6) and (3)
20-506 WA430-6
PLAY OF CODE)
WA430-6 20-507
PLAY OF CODE)
Failure code [DW4QKA] Lift arm lower EPC solenoid: Disconnection
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 system is disconnected, the signal is not output to the lift arm low-
trouble er EPC solenoid.
• Stops outputting the signal to the lift arm lower EPC solenoid.
Action of
• Stops outputting the signal to the lift arm lower EPC magnet detent.
controller
Problem that
appears on • The lift arm does not lower.
machine
Related
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring function
information
(Code: 41901 LOWER EPC).
Defective lift arm lower EPC out turning starting switch.

9 – 10.2 z
nection)
Between (1) and (2)
Possible causes
Resistance Max. 1 z
and standard
ness (Disconnection or Between L73 (female) (16) – F21 (female) (1)
value in normal 2
defective contact of con- wiring harness and chassis ground
state
Resistance Max. 1 z
nector) Between L73 (female) (3) – F21 (female) (2) wir-

3
9 – 10.2 z
Between (6) and (3)
20-508 WA430-6
PLAY OF CODE)
Circuit diagram related to lift arm lower EPC solenoid
WA430-6 20-509
PLAY OF CODE)
Failure code [DW4QKB] Lift arm lower EPC solenoid: Short circuit
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 system is shorted with the chassis ground, the signal is not output
trouble to the lift arm lower EPC solenoid.
• Stops outputting the signal to the lift arm lower EPC solenoid.
Action of
• Stops outputting the signal to the lift arm lower EPC magnet detent.
controller
Problem that
appears on • The lift arm does not lower.
machine
Related
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring function
information
(Code: 41901 LOWER EPC).

Defective lift arm lower EPC
9 – 10.2 z
Between (1) and (2)
cuit)
Min. 1 Mz
and standard
state 2 harness (Contact with wiring harness and chassis groundetween L73
ground circuit) (female) (16) – F21 (female) (1) wiring harness Resistance Min. 1 Mz
and chassis ground

3
9 – 10.2 z
20-510 WA430-6
PLAY OF CODE)
WA430-6 20-511
PLAY OF CODE)
Failure code [DW4RKA] Bucket tilt EPC solenoid: Disconnection
Action code Failure code Bucket tilt EPC solenoid: Disconnection

Trouble
E03 DW4RKA (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid system is disconnected, the signal is not output to the bucket tilt EPC
trouble solenoid.
• Stops outputting the signal to the bucket tilt EPC solenoid.
Action of
• Stops outputting the signal to the bucket tilt EPC magnet detent.
controller
Problem that
appears on • The bucket does not tilt.
machine
Related
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
information
(Code: 41902 TILT EPC).
Defective bucket tilt EPC out turning starting switch.

9 – 10.2 z
nection)
Between (1) and (2)
Possible causes
Resistance Max. 1 z
and standard
value in normal 2
state
Resistance Max. 1 z
(female) (2)

3
9 – 10.2 z
Between (5) and (3)
20-512 WA430-6
PLAY OF CODE)
Circuit diagram related to bucket tilt EPC solenoid
WA430-6 20-513
PLAY OF CODE)
Failure code [DW4RKB] Bucket tilt EPC solenoid: Short circuit
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 system is shorted with the chassis ground, the signal is not output to
trouble the bucket tilt EPC solenoid.
• Stops outputting the signal to the bucket tilt EPC solenoid.
Action of
• Stops outputting the signal to the bucket tilt EPC magnet detent.
controller
Problem that
appears on • The bucket does not tilt.
machine
Related
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
information
(Code: 41902 TILT EPC).

Defective bucket tilt EPC
9 – 10.2 z
Between (1) and (2)
cuit)
ground
and standard
Between L73 (female) (5) – F22 (female) (1) wir-

3
9 – 10.2 z
Between (5) and (3)
20-514 WA430-6
PLAY OF CODE)
WA430-6 20-515
PLAY OF CODE)
Failure code [DW4SKA] Bucket dump EPC solenoid: Disconnection
Action code Failure code Bucket dump EPC solenoid: Disconnection

Trouble
E03 DW4SKA (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid system is disconnected, the signal is not output to the bucket
trouble dump EPC solenoid.
Action of • Stops outputting the signal to the bucket dump EPC solenoid.
Problem that
appears on • The bucket does not dump.
machine
Related
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring func-
information
tion (Code: 41903 DUMP EPC).
Defective bucket dump out turning starting switch.

1 EPC solenoid (Internal dis-
9 – 10.2 z
connection)
Between (1) and (2)
Possible causes
Resistance Max. 1 z
and standard
value in normal ness (Disconnection or Wiring harness between L73 (female) (15) –
2
defective contact of con- F23 (female) (1)
state
Resistance Max. 1 z
(female) (2)

3
9 – 10.2 z
20-516 WA430-6
PLAY OF CODE)
Circuit diagram related to bucket dump EPC solenoid
WA430-6 20-517
PLAY OF CODE)
Failure code [DW4SKB] Bucket dump EPC solenoid: Short circuit
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 system is shorted with the chassis ground, the signal is not output
trouble to the bucket dump EPC solenoid.
Action of • Stops outputting the signal to the bucket dump EPC solenoid.
Problem that
appears on • The bucket does not dump.
machine
Related
information
tion (Code: 41903 DUMP EPC).

Defective bucket dump
9 – 10.2 z
1 EPC solenoid (Internal
Between (1) and (2)
short circuit)
ground
and standard
ground circuit) Between L73 (female) (15) – F23 (female) (1)

3
9 – 10.2 z
20-518 WA430-6
PLAY OF CODE)
WA430-6 20-519
PLAY OF CODE)
Failure code [DW7BKA] (Fan pump reverse solenoid: Disconnection)
Action code Failure code Fan pump reverse solenoid: Disconnection

Trouble
E01 DW7BKA (Transmission controller system)
Contents of • Since the fan pump reverse solenoid system is disconnected, the signal is not output to the fan pump
trouble reverse solenoid.
Action of
• Turns the output to the fan pump reverse solenoid OFF.
controller
Problem that
appears on • The fan cannot turn in reverse.
machine
Related • The ON/OFF output signal to the fan pump reverse solenoid can be checked with the monitoring func-
information tion (Code: 40914, SOL/0-4).
Defective fan pump reverse out turning starting switch.

35 – 45 z
GR2 (male) Resistance
nection)
Between (1) and (2)
Possible causes
and standard ness (Disconnection or out turning starting switch.
Resistance Max. 1 z
value in normal 2
state nector)
GR2 (female) (1)

35 – 45 z
troller
chassis ground
20-520 WA430-6
PLAY OF CODE)
Circuit diagram related to fan pump reverse solenoid
WA430-6 20-521
PLAY OF CODE)
Failure code [DW7BKB] (Fan pump reverse solenoid: Short circuit)
Action code Failure code Fan pump reverse solenoid: Short circuit
Trouble
E01 DW7BKB (Transmission controller system)
Contents of • Since the fan pump reverse solenoid system is shorted, the signal is not output to the fan pump reverse
trouble solenoid.
Action of
• Turns the output to the fan pump reverse solenoid OFF.
controller
Problem that
appears on • The fan cannot turn in reverse.
machine
Related • The ON/OFF output signal to the fan pump reverse solenoid can be checked with the monitoring func-
information tion (Code: 40914, SOL/0-4).

Defective fan pump reverse
– 45 z
GR2 (male) Resistance
cuit) Between (1) and (2) 35
Min. 1 Mz
and standard
ground circuit) Between L63 (female) (28) – GR2 (female) (1)

35 – 45 z
troller
chassis ground
20-522 WA430-6
PLAY OF CODE)
Circuit diagram related to fan pump reverse solenoid
WA430-6 20-523
PLAY OF CODE)
Failure code [DWM1KA] Lift arm neutral lock EPC solenoid: Disconnection
Action code Failure code Lift arm neutral lock EPC solenoid: Disconnection
Trouble
E03 DWM1KA (Work equipment controller system)
Contents of • Since the lift arm neutral lock EPC solenoid system is disconnected, the signal is not output to the lift
trouble arm neutral lock EPC solenoid.
Action of
controller
Problem that
• The operator can carry out normal operation of the work equipment. (The work equipment cannot be
appears on
locked with the work equipment lock lever, however.)
machine
Related
• The output state (ON/OFF) to the lift arm neutral lock EPC solenoid can be checked with the monitoring
information
function (Code: 40916 SOL/0-4).
Defective lift arm neutral out turning starting switch.

1 lock EPC solenoid (Internal
35 – 45 z
disconnection)
Between (1) and (2)
Possible causes
Resistance Max. 1 z
and standard
value in normal ness (Disconnection or Wiring harness between L73 (female) (28) –
2
defective contact of con- F26 (female) (1)
state
Resistance Max. 1 z
nector) Wiring harness between F26 (female) (1) –
chassis ground

3
Between (28) – chassis ground Min. 1 Mz
20-524 WA430-6
PLAY OF CODE)
Circuit diagram related to lift arm neutral lock EPC solenoid
WA430-6 20-525
PLAY OF CODE)
Failure code [DWM1KB] (Lift arm neutral lock EPC solenoid valve: Short circuit)
Action code Failure code Lift arm neutral lock EPC solenoid valve: Short circuit
Trouble
E03 DWM1KB (Work equipment controller system)
Contents of • Since the lift arm neutral lock EPC solenoid system is shorted with the chassis ground, the signal is not
trouble output to the lift arm neutral lock EPC solenoid.
Action of
controller
Problem that
• The operator can carry out normal operation of the work equipment. (The work equipment cannot be
appears on
locked with the work equipment lock lever, however.)
machine
Related
information
aCheck the diode (F27). (For the method of checking the diode, see
1 Defective diode (F27)
Testing and adjusting.)

Defective lift arm neutral
35 – 45 z
2 lock EPC solenoid (Internal
Between (1) and (2)
short circuit)
ground
and standard
value in normal
state
Resistance Max. 1 z
F26 (female) (1)
Resistance Max. 1 z
ground circuit)
Wiring harness between F26 (female) (1) –
chassis ground

4
Between (28) – chassis ground Min. 1 Mz
20-526 WA430-6
PLAY OF CODE)
WA430-6 20-527
PLAY OF CODE)
Failure code [DWN6KA] Lift arm raise magnet detent solenoid: Disconnection
Action code Failure code Lift arm raise magnet detent solenoid: Disconnection
Trouble
E03 DWN6KA (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power source system is disconnected, the detent cannot
trouble be controlled.
• Stops outputting the signal to the lift arm raise magnet detent solenoid.
Action of • Stops outputting the signal to the remote positioner raise lamp.
controller • Stops the remote raise function.
Problem that
appears on • The operator can carry out normal operation, although the detent is not turned ON.
machine
Related
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the moni-
information
toring function (Code: 40916 SOL/0-1).

Defective lift arm raise mag-
35 – 45 z
1 net detent solenoid (Inter-
Between (1) and (2)
nal short circuit)
Min. 1 Mz
and standard
Resistance Max. 1 z
2
nector)
L26E (female) (1)
3 L73 Lift arm lever Voltage
controller
Between (17) – Neutral Max. 1 V
chassis ground Max. raise position 17 – 30 V
20-528 WA430-6
PLAY OF CODE)
Circuit diagram related to lift arm magnet detent solenoid
WA430-6 20-529
PLAY OF CODE)
Failure code [DWN6KB] Lift arm raise magnet detent solenoid: Short circuit
Action code Failure code Lift arm raise magnet detent solenoid: Short circuit
Trouble
E03 DWN6KB (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power source system is shorted with the chassis ground,
trouble the detent cannot be controlled.
• Stops outputting the signal to the lift arm raise magnet detent solenoid.
controller • Stops the remote float function.
Problem that
machine
Related
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the moni-
information
Defective lift arm raise mag- out turning starting switch.
35 – 45 z
1 net detent solenoid (Inter- L26 (male) Resistance
nal short circuit) Between (1) and (2)
Between (1) and chassis ground Min. 1 Mz
Possible causes
state Between L73 (female) (17) – L26E (female) (1)

Defective work equipment L73 Lift arm lever Voltage
3
controller
chassis ground Max. raise position 17 – 30 V
20-530 WA430-6
PLAY OF CODE)
WA430-6 20-531
PLAY OF CODE)
Failure code [DWN7KA] Lift arm float magnet detent solenoid: Disconnection
Action code Failure code Lift arm float magnet detent solenoid: Disconnection
Trouble
Contents of • Since the lift arm float magnet detent solenoid power source system is disconnected, the detent cannot
• Stops outputting the signal to the lift arm float magnet detent solenoid.
Action of • Stops outputting the signal to the remote positioner float lamp.
Problem that
machine
Related
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the moni-
information
Defective lift arm float mag- out turning starting switch.

35 – 45 z
nal disconnection)
Between (1) and (2)
Possible causes
Resistance Max. 1 z
value in normal Wiring harness between L73 (female) (27) – L27
ground circuit)
state
(female) (1)
3 L73 (female) Lift arm lever Voltage
controller
chassis ground Float position 17 – 30 V
20-532 WA430-6
PLAY OF CODE)
WA430-6 20-533
PLAY OF CODE)
Failure code [DWN7KB] Lift arm float magnet detent solenoid: Short circuit
Action code Failure code Lift arm float magnet detent solenoid: Short circuit
Trouble
Contents of • Since the lift arm float magnet detent solenoid power source system is shorted with the chassis ground,
• Stops outputting the signal to the lift arm float magnet detent solenoid.
Action of • Stops outputting the signal to the remote positioner float lamp.
Problem that
machine
Related
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the moni-
information

Defective lift arm float mag-
35 – 45 z
Between (1) and (2)
nal short circuit)
ground
and standard

3
35 – 45 z
controller L73 (male) Resistance
20-534 WA430-6
PLAY OF CODE)
WA430-6 20-535
PLAY OF CODE)
Failure code [DWN8KA] Bucket tilt magnet detent solenoid: Disconnection
Action code Failure code Bucket tilt magnet detent solenoid: Disconnection
Trouble
Contents of • Since the bucket tilt magnet detent solenoid power source system is disconnected, the detent cannot
• Stops outputting the signal to the bucket tilt magnet detent solenoid.
Action of • Stops outputting the signal to the remote positioner bucket tilt lamp.
controller • Stops the remote bucket tilt function.
Problem that
machine
Related
• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the monitoring
information
Defective bucket tilt magnet out turning starting switch.

1 detent solenoid (Internal
35 – 45 z
L25E (male) Resistance
disconnection)
Between (1) and (2)
Possible causes
Resistance Max. 1 z
value in normal Wiring harness between L73 (female) (37) –
ground circuit)
state
L25E (female) (1)
3 L73 (female) Bucket lever Voltage
controller
chassis ground Tilt position 17 – 30 V
20-536 WA430-6
PLAY OF CODE)
Circuit diagram related to bucket tilt magnet detent solenoid
WA430-6 20-537
PLAY OF CODE)
Failure code [DWN8KB] Bucket tilt magnet detent solenoid: Short circuit
Action code Failure code Bucket tilt magnet detent solenoid: Short circuit
Trouble
Contents of • Since the bucket tilt magnet detent solenoid power source system is shorted with the chassis ground,
• Stops outputting the signal to the bucket tilt magnet detent solenoid.
Problem that
machine
Related
• The output signal (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the monitor-
information
ing function (Code: 40916 SOL/0-3).

Defective bucket tilt magnet
35 – 45 z
L25E (male) Resistance
1 detent solenoid (Internal
Between (1) and (2)
short circuit)
ground
and standard
Between L73 (female) (37) – L25E (female) (1)

3
35 – 45 z
20-538 WA430-6
PLAY OF CODE)
Circuit diagram related to bucket tilt magnet detent solenoid
WA430-6 20-539
PLAY OF CODE)
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)
Action code Failure code Fan pump EPC solenoid: Disconnection

Trouble
E03 DX16KA (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system is disconnected, the signal is not output to the fan pump EPC
trouble solenoid.
Action of
controller
Problem that
appears on • The fan speed is set to the maximum.
machine
Related • The output state (ON/OFF) to the fan pump EPC solenoid can be checked with the monitoring function
Defective fan pump EPC out turning starting switch.

5 – 10 z
nection)
Between (1) and (2)

Resistance Max. 1 z
value in normal 2
Resistance Max. 1 z
R29 (female) (2)

5 – 10 z
troller
Wiring harness between (36) and
(23)
20-540 WA430-6
PLAY OF CODE)
Circuit diagram related to fan pump EPC solenoid
WA430-6 20-541
PLAY OF CODE)
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)
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 with the chassis ground, the signal is not output to
trouble the fan pump EPC solenoid.
Action of
• Turns the output to the fan pump EPC solenoid OFF.
controller
Problem that
appears on • The fan speed is set to the maximum.
machine
Related • The output state (ON/OFF) to the fan pump EPC solenoid can be checked with the monitoring function

Defective fan pump EPC
5 – 10 z
cuit) Between (1) and (2)
Min. 1 Mz
ground
Possible causes
ground circuit) Wiring harness between L63 (female) (36) –
R29 (female) (1)

5 – 10 z
3 Wiring harness between (36) and
troller
(23)
Between (36) and (32) wiring har-
Min. 1 Mz
ness and chassis ground
20-542 WA430-6
PLAY OF CODE)
WA430-6 20-543
PLAY OF CODE)
Failure code [DXA1KA] (Loader pump PC-EPC solenoid: Disconnection)
Action code Failure code Loader pump PC-EPC solenoid: Disconnection

Trouble
E01 DXA1KA (Transmission controller system)
Contents of • Since the loader pump PC-EPC solenoid system is disconnected, the signal is not output to the loader
trouble pump PC-EPC solenoid.
Action of
controller
Problem that
• The loader pump flow is set to the maximum.
appears on
• When the power mode is selected, the work equipment speed does not change.
machine
Related • The output state (current) to the loader pump PC-EPC solenoid can be checked with the monitoring
information function (Code: 41401 PUMP EPC).
Defective loader pump PC- out turning starting switch.

1 EPC solenoid (Internal dis-
5 – 10 z
connection)
Between (1) and (2)
Resistance Max. 1 z
value in normal 2
Resistance Max. 1 z
state nector) Wiring harness between R68 (female) (2) – L63
(female) (23)

5 – 10 z
troller
(23)
20-544 WA430-6
PLAY OF CODE)
Circuit diagram related to loader pump PC-EPC solenoid
WA430-6 20-545
PLAY OF CODE)
Failure code [DXA1KB] (Loader pump PC-EPC solenoid: Short circuit)
Action code Failure code Loader pump PC-EPC solenoid: Short circuit
Trouble
E01 DXA1KB (Transmission controller system)
Contents of • Since the loader pump PC-EPC solenoid system is shorted with the chassis ground, the signal is not
trouble output to the loader pump PC-EPC solenoid.
Action of
• Turns the output to the loader pump PC-EPC solenoid OFF.
controller
Problem that
• The loader pump flow is set to the maximum.
appears on
• When the power mode is selected, the work equipment speed does not change.
machine
Related • The output state (current) to the loader pump PC-EPC solenoid can be checked with the monitoring
information function (Code: 41401 PUMP EPC).
Defective loader pump PC- out turning starting switch.

1 EPC solenoid (Internal
5 – 10 z
short circuit)
Between (1) and (2)
Possible causes
Resistance Max. 1 z
state

5 – 10 z
troller
(23)
20-546 WA430-6
PLAY OF CODE)
WA430-6 20-547
PLAY OF CODE)
20-548 WA430-6
PLAY OF CODE)
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)
Action code Failure code 1st clutch ECMV solenoid: Disconnection

Trouble
E03 DXH4KA (Transmission controller system)
Contents of
• Since the 1st ECMV solenoid system is disconnected, the signal is not output to the 1st ECMV solenoid.
trouble
Action of
controller
Problem that
• The transmission cannot be set in the 1st. (The machine can travel in any gear speed other than the
appears on
1st.)
machine
Related • The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function
information (Code: 31602, ECMV1).
Defective 1st ECMV sole- out turning starting switch.

1 noid (Internal disconnec-
5 – 15 z
tion)
Between (1) and (2)

Resistance Max. 1 z
value in normal 2
Resistance Max. 1 z
T01 (female) (2)

5 – 15 z
troller
(13)
WA430-6 20-549
PLAY OF CODE)
Circuit diagram related to 1st clutch ECMV solenoid
20-550 WA430-6
PLAY OF CODE)
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)
Action code Failure code 1st clutch ECMV solenoid: Short circuit
Trouble
E03 DXH4KB (Transmission controller system)
Contents of • Since the 1st ECMV solenoid system is shorted with the chassis ground, the signal is not output to the
trouble 1st ECMV solenoid.
Action of • Turns the output to the 1st ECMV solenoid OFF.
Problem that
• The transmission cannot be set in the 1st. (The machine can travel in any gear speed other than the
appears on
1st.)
machine
Related • The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function
5 – 15 z
Defective 1st ECMV sole- T01 (male) Resistance
1
noid (Internal short circuit) Between (1) and (2)
Min. 1 Mz
ground
Possible causes
ground circuit) Between L63 (female) (25) – T01 (female) (1)

5 – 15 z
troller
(13)
Wiring harness between (25) or
Min. 1 Mz
(13) – chassis ground
WA430-6 20-551
PLAY OF CODE)
20-552 WA430-6
PLAY OF CODE)
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)
Action code Failure code 2nd clutch ECMV solenoid: Disconnection

Trouble
Contents of • Since the 2nd ECMV solenoid system is disconnected, the signal is not output to the 2nd ECMV sole-
trouble noid.
Action of
controller
Problem that
• The transmission cannot be set in the 2nd. (The machine can travel in any gear speed other than the
appears on
2nd.)
machine
Related • The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function
Defective 2nd ECMV sole- out turning starting switch.

5 – 15 z
tion)
Between (1) and (2)
Possible causes
Resistance Max. 1 z
and standard
value in normal ness (Disconnection or Wiring harness between L63 (female) (6) – T02
2
state defective contact of con- (female) (1)
Resistance Max. 1 z
nector) Wiring harness between L63 (female) (3) – T02
(female) (2)
Defective transmission con- out turning starting switch.

3
5 – 15 z
troller L63 (female) Resistance
Wiring harness between (6) and (3)
WA430-6 20-553
PLAY OF CODE)
Circuit diagram related to 2nd clutch ECMV solenoid
20-554 WA430-6
PLAY OF CODE)
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)
Action code Failure code 2nd clutch ECMV solenoid: Short circuit
Trouble
Contents of • Since the 2nd ECMV solenoid system is shorted with the chassis ground, the signal is not output to the
trouble 2nd ECMV solenoid.
Action of • Turns the output to the 2nd ECMV solenoid OFF.
Problem that
• The transmission cannot be set in the 2nd. (The machine can travel in any gear speed other than the
appears on
2nd.)
machine
Related • The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function
5 – 15 z
Defective 2nd ECMV sole- T02 (male) Resistance
1
Min. 1 Mz
ground
Possible causes
state ground circuit) Between L63 (female) (6) – T02 (female) (1) wir-
5 – 15 z
Defective transmission con- L63 (female) Resistance
3
troller Wiring harness between (6) and (3)
Wiring harness between (6) or (3) –
Min. 1 Mz
chassis ground
WA430-6 20-555
PLAY OF CODE)
20-556 WA430-6
PLAY OF CODE)
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)
Action code Failure code 3rd clutch ECMV solenoid: Disconnection

Trouble
Contents of • Since the 3rd ECMV solenoid system is disconnected, the signal is not output to the 3rd ECMV sole-
trouble noid.
Action of
controller
Problem that
• The transmission cannot be set in the 3rd. (The machine can travel in any gear speed other than the
appears on
3rd.)
machine
Related • The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function
Defective 3rd ECMV sole- out turning starting switch.

5 – 15 z
tion)
Between (1) and (2)

Resistance Max. 1 z
value in normal 2
Resistance Max. 1 z
state nector) Wiring harness between L63 (female) (3) – T03
(female) (2)

5 – 15 z
troller
(3)
WA430-6 20-557
PLAY OF CODE)
Circuit diagram related to 3rd clutch ECMV solenoid
20-558 WA430-6
PLAY OF CODE)
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)
Action code Failure code 3rd clutch ECMV solenoid: Short circuit
Trouble
Contents of • Since the 3rd ECMV solenoid system is shorted with the chassis ground, the signal is not output to the
trouble 3rd ECMV solenoid.
Action of • Turns the output to the 3rd ECMV solenoid OFF.
Problem that
• The transmission cannot be set in the 3rd. (The machine can travel in any gear speed other than the
appears on
3rd.)
machine
Related • The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function
5 – 15 z
Defective 3rd ECMV sole- T03 (male) Resistance
1
Min. 1 Mz
ground
Possible causes

5 – 15 z
troller
(3)
Wiring harness between (16) or (3)
Min. 1 Mz
– chassis ground
WA430-6 20-559
PLAY OF CODE)
20-560 WA430-6
PLAY OF CODE)
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)
Action code Failure code R clutch ECMV solenoid: Disconnection

Trouble
Contents of
• Since the R ECMV solenoid system is disconnected, the signal is not output to the R ECMV solenoid.
trouble
Action of
controller
Problem that
• The transmission cannot be set in the R (Reverse) position. (The machine can travel in the F (Forward)
appears on
position.)
machine
Related • The output state (current) to the R clutch ECMV solenoid can be checked with the monitoring function
information (Code: 31606, ECMV R).
Defective R ECMV solenoid out turning starting switch.

1
5 – 15 z
(Internal disconnection) T06 (male) Resistance
Between (1) and (2)

Resistance Max. 1 z
value in normal 2
Resistance Max. 1 z
T06 (female) (2)

5 – 15 z
troller
(13)
WA430-6 20-561
PLAY OF CODE)
Circuit diagram related to R clutch ECMV solenoid
20-562 WA430-6
PLAY OF CODE)
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)
Action code Failure code R clutch ECMV solenoid: Short circuit

Trouble
Contents of • Since the R ECMV solenoid system is shorted with the chassis ground, the signal is not output to the R
trouble ECMV solenoid.
Action of • Turns the output to the R ECMV solenoid OFF.
Problem that
• The transmission cannot be set in the R (Reverse) position. (The machine can travel in the F (Forward)
appears on
position.)
machine
Related • The output state (current) to the R clutch ECMV solenoid can be checked with the monitoring function
information (Code: 31606, ECMV R).
5 – 15 z
Defective R ECMV solenoid T06 (male) Resistance
1
Min. 1 Mz
ground
Possible causes

5 – 15 z
troller
(13)
Min. 1 Mz
WA430-6 20-563
PLAY OF CODE)
20-564 WA430-6
PLAY OF CODE)
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)
Action code Failure code F clutch ECMV solenoid: Disconnection

Trouble
Contents of
• Since the F ECMV solenoid system is disconnected, the signal is not output to the F ECMV solenoid.
trouble
Action of
controller
Problem that
• The transmission cannot be set in the F (Forward) position. (The machine can travel in the R (Reverse)
appears on
position.)
machine
Related • The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function
information (Code: 31608, ECMV F).
5 – 15 z
Defective F ECMV solenoid T05 (male) Resistance
1
(Internal disconnection) Between (1) and (2)
Min. 1 Mz
ground
Possible causes
and standard
Resistance Max. 1 z
value in normal
state ness (Disconnection or Wiring harness between L63 (female) (5) – T05
2
Resistance Max. 1 z
nector) Wiring harness between L63 (female) (3) – T05
(female) (2)

3
5 – 15 z
WA430-6 20-565
PLAY OF CODE)
Circuit diagram related to F clutch ECMV solenoid
20-566 WA430-6
PLAY OF CODE)
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)
Action code Failure code F clutch ECMV solenoid: Short circuit

Trouble
Contents of • Since the F ECMV solenoid system is shorted with the chassis ground, the signal is not output to the F
trouble ECMV solenoid.
Action of • Turns the output to the F ECMV solenoid OFF.
Problem that
• The transmission cannot be set in the F (Forward) position. (The machine can travel in the R (Reverse)
appears on
position.)
machine
Related • The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function
information (Code: 31608, ECMV F).
5 – 15 z
Defective F ECMV solenoid T05 (male) Resistance
1
Min. 1 Mz
ground
Possible causes
state ground circuit) Between L63 (female) (5) – T05 (female) (1) wir-
5 – 15 z
Defective transmission con- L63 (female) Resistance
3
troller Wiring harness between (5) and (3)
Wiring harness between (5) or (3) –
Min. 1 Mz
chassis ground
WA430-6 20-567
PLAY OF CODE)
20-568 WA430-6
PLAY OF CODE)
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)
Action code Failure code 4th clutch ECMV solenoid: Disconnection

Trouble
E03 DXHHKA (Transmission controller system)
Contents of
• Since the 4th ECMV solenoid system is disconnected, the signal is not output to the 4th ECMV solenoid.
trouble
Action of
controller
Problem that
• The transmission cannot be set in the 4th. (The machine can travel in any gear speed other than the
appears on
4th.)
machine
Related • The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function
Defective 4th ECMV sole- out turning starting switch.

5 – 15 z
tion)
Between (1) and (2)

Resistance Max. 1 z
value in normal 2
Resistance Max. 1 z
T04 (female) (2)

5 – 15 z
troller
(13)
WA430-6 20-569
PLAY OF CODE)
Circuit diagram related to 4th clutch ECMV solenoid
20-570 WA430-6
PLAY OF CODE)
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)
Action code Failure code 4th clutch ECMV solenoid: Short circuit
Trouble
E03 DXHHKB (Transmission controller system)
Contents of • Since the 4th ECMV solenoid system is shorted with the chassis ground, the signal is not output to the
trouble 4th ECMV solenoid.
Action of • Turns the output to the 4th ECMV solenoid OFF.
Problem that
• The transmission cannot be set in the 4th. (The machine can travel in any gear speed other than the
appears on
4th.)
machine
Related • The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function
5 – 15 z
Defective 4th ECMV sole- T04 (male) Resistance
1
Min. 1 Mz
ground
Possible causes

5 – 15 z
troller
(13)
Min. 1 Mz
WA430-6 20-571
PLAY OF CODE)
20-572 WA430-6
PLAY OF CODE)
Failure code [DXHJKA] (3rd valve extract EPC solenoid: Disconnection)
Action code Failure code 3rd valve extract EPC solenoid: Disconnection
Trouble
E03 DXHJKA (Work equipment controller system)
Contents of • Since the 3rd valve (attachment) extract EPC solenoid system is disconnected, the signal is not output
trouble to the 3rd valve (attachment) extract EPC solenoid.
Action of • Stops outputting the signal to the 3rd valve (attachment) extract EPC solenoid.
Problem that
appears on • The 3rd valve (attachment) is not extracted.
machine
Related
• The output state (current) to the 3rd valve (attachment) extract EPC solenoid can be checked with the
information
monitoring function (Code: 41906, 3RD EPC1).
Defective 3rd valve (attach- out turning starting switch.

1 ment) extract EPC solenoid
9 – 10.2 z
Between (1) and (2)
Resistance Max. 1 z
and standard ness (Disconnection in wir- Wiring harness between L73 (female) (25) –
2
value in normal ing harness or defective F24 (female) (1)
Resistance Max. 1 z
state contact) Wiring harness between L73 (female) (13) –
F24 (female) (2)

9 – 10.2 z
controller
(13)
WA430-6 20-573
PLAY OF CODE)
Circuit diagram related to 3rd valve (attachment) extract EPC solenoid
20-574 WA430-6
PLAY OF CODE)
Failure code [DXHJKB] (3rd valve extract EPC solenoid: Short circuit)
Action code Failure code 3rd valve extract EPC solenoid: Short circuit
Trouble
E03 DXHJKB (Work equipment controller system)
Contents of • Since the 3rd valve (attachment) extract EPC solenoid system is shorted with the chassis ground, the
trouble signal is not output to the 3rd valve (attachment) extract EPC solenoid.
Action of • Stops outputting the signal to the 3rd valve (attachment) extract EPC solenoid.
Problem that
appears on • The 3rd valve (attachment) is not extracted.
machine
Related
information

Defective 3rd valve (attach-
9 – 10.2 z
1 ment) extract EPC solenoid
Between (1) and (2)
(Internal short circuit)
Min. 1 Mz
and standard
ground circuit) Between L73 (female) (25) – F24 (female) (1)

9 – 10.2 z
controller
(13)
WA430-6 20-575
PLAY OF CODE)
20-576 WA430-6
PLAY OF CODE)
Failure code [DXHKKA] (3rd valve retract EPC solenoid: Disconnection)
Action code Failure code 3rd valve retract EPC solenoid: Disconnection
Trouble
E03 DXHKKA (Work equipment controller system)
Contents of • Since the 3rd valve (attachment) retract EPC solenoid system is disconnected, the signal is not output
trouble to the 3rd valve (attachment) retract EPC solenoid.
Action of
• Stops outputting the signal to the 3rd valve (attachment) retract EPC solenoid.
controller
Problem that
appears on • The 3rd valve (attachment) is not retracted.
machine
Related
• The output state (current) to the 3rd valve (attachment) retract EPC solenoid can be checked with the
information
Defective 3rd valve (attach- out turning starting switch.

1 ment) retract EPC solenoid
9 – 10.2 z
Between (1) and (2)
Resistance Max. 1 z
and standard ness (Disconnection in wir- Wiring harness between L73 (female) (35) –
2
value in normal ing harness or defective F25 (female) (1)
Resistance Max. 1 z
state contact) Wiring harness between L73 (female) (13) –
F25 (female) (2)

9 – 10.2 z
controller
(13)
WA430-6 20-577
PLAY OF CODE)
Circuit diagram related to 3rd valve (attachment) retract EPC solenoid
20-578 WA430-6
PLAY OF CODE)
Failure code [DXHKKB] (3rd valve retract EPC solenoid: Short circuit)
Action code Failure code 3rd valve retract EPC solenoid: Short circuit
Trouble
E03 DXHKKB (Work equipment controller system)
Contents of • Since the 3rd valve (attachment) retract EPC solenoid system is shorted with the chassis ground, the
trouble signal is not output to the 3rd valve (attachment) retract EPC solenoid.
Action of
• Stops outputting the signal to the 3rd valve (attachment) retract EPC solenoid.
controller
Problem that
appears on • The 3rd valve (attachment) is not retracted.
machine
Related
information

Defective 3rd valve (attach-
9 – 10.2 z
1 ment) retract EPC solenoid
Between (1) and (2)
(Internal short circuit)
Min. 1 Mz
value in normal ness (Disconnection in wir- out turning starting switch.
state 2
ing harness or defective Between L73 (female) (35) – F25 (female) (1)
contact)

9 – 10.2 z
controller
(13)
WA430-6 20-579
PLAY OF CODE)
20-580 WA430-6
PLAY OF CODE)
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)
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, the signal is not output to the
trouble joystick steering right EPC solenoid.
• Stops outputting the signal to the joystick steering right EPC solenoid.
Action of
• Stops outputting the signal to the joystick solenoid cut-out relay.
controller
Problem that
appears on • The operator cannot steer the machine to the right with the joystick.
machine
• The ON/OFF output signal to the joystick EPC cut-out relay can be checked with the monitoring function
Related
(Code: 40916 SOL/0-0).
information
• The output state (current) to the joystick steering right EPC solenoid can be checked with the monitoring
function (Code: 41904, RH J/S EPC).
Defective joystick steering out turning starting switch.

1 right EPC solenoid (Internal
10 – 15 z
disconnection)
Between (1) and (2)
Resistance Max. 1 z
Disconnection in wiring har- Wiring harness betweenn L73 (female) (26) –
ness (Disconnection in wir- L36 (female) (1)
Resistance Max. 1 z
2
ing harness or defective Wiring harness between L36 (female) (2) – L41
Possible causes
contact) (female) (1)
and standard
Resistance Max. 1 z
state (female) (2)
• Steer to right with joystick steering.
3 cut-out relay (L41) (Internal
When joystick solenoid cut-out relay (L41) is replaced with a relay of the
disconnection)
same type (6-pin type), if the condition becomes normal, the relay is
defective.
Resistance 10 – 15 z
4
controller Wiring harness between L73 (female) (26) – L41
(female) (1)
WA430-6 20-581
PLAY OF CODE)
Circuit diagram related to joystick steering EPC solenoid
20-582 WA430-6
PLAY OF CODE)
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)
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 with the chassis ground, the signal is
trouble not output to the joystick steering right EPC solenoid.
• Stops outputting the signal to the joystick steering right EPC solenoid.
Action of
controller
Problem that
appears on • The operator cannot steer the machine to the right with the joystick.
machine
Related
(Code: 40916 SOL/0-0).
information

Defective joystick steering
10 – 15 z
1 right EPC solenoid (Internal
Between (1) and (2)
short circuit)
Min. 1 Mz
ground

Possible causes 2 harness (Contact with
and standard Between L73 (female) (26) – L36 (female) (1)
state
short circuit)
defective.
4
(female) (1)
WA430-6 20-583
PLAY OF CODE)
20-584 WA430-6
PLAY OF CODE)
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)
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, the signal is not output to the joy-
trouble stick steering left EPC solenoid.
• Stops outputting the signal to the joystick steering left EPC solenoid.
Action of
controller
Problem that
appears on • The operator cannot steer the machine to the left with the joystick.
machine
Related
(Code: 40916 SOL/0-0).
information
• The output state (current) to the joystick steering left EPC solenoid can be checked with the monitoring
function (Code: 41905, LH J/S EPC).
Defective joystick steering out turning starting switch.

1 left EPC solenoid (Internal
10 – 15 z
disconnection)
Between (1) and (2)
Resistance Max. 1 z
Disconnection in wiring har- Wiring harness betweenn L73 (female) (36) –
ness (Disconnection or L35 (female) (1)
Resistance Max. 1 z
2
Possible causes
and standard
Resistance Max. 1 z
state (female) (4)
disconnection)
defective.
4
(female) (3)
WA430-6 20-585
PLAY OF CODE)
20-586 WA430-6
PLAY OF CODE)
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)
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 with the chassis ground, the signal is not
trouble output to the joystick steering left EPC solenoid.
• Stops outputting the signal to the joystick steering left EPC solenoid.
Action of
controller
Problem that
appears on • The operator cannot steer the machine to the left with the joystick.
machine
Related
(Code: 40916 SOL/0-0).
information

Defective joystick steering
10 – 15 z
1 left EPC solenoid (Internal
Between (1) and (2)
short circuit)
ground
and standard
value in normal Disconnection in wiring har-
3
(female) (3)
WA430-6 20-587
PLAY OF CODE)
20-588 WA430-6
PLAY OF CODE)
Failure code [DY30MA] (Emergency steering motor: Malfunction)
Action code Failure code Emergency steering motor: Malfunction

Trouble
E03 DY30MA (Transmission controller system)
Contents of • While the electric emergency steering output is turned OFF, the electric emergency steering motor
trouble (pump) operation signal (S-NET) is output.
Action of • Turns the electric emergency steering relay output OFF.
Problem that • While the operator does not operate the electric emergency steering switch, the electric emergency
appears on steering motor (pump) operates.
machine • The emergency steering operation indicator lights up.
• The input state (ON/OFF) from the emergency steering motor can be checked with the monitoring func-
Related tion (Code: 40903 D-IN-30).
information • The input state (ON/OFF) from the emergency steering pressure switch can be checked with the mon-
itoring function (Code: 40905 D-IN-0, D-IN-1).

Defective emergency steer-
Between (3) and (5)
short circuit) Min. 1 Mz
200 – 400 z
(With relay OFF)
Between (1) or (2)

ing relay (for driving emer-
2 Emergency steering relay Resistance
gency steering motor)
(Internal short circuit) Terminal between disconnected
Min. 1 Mz
relay
Voltage Max. 1V
Short circuit with power wiring harness and chassis ground
3 source (Contact with 24V Between L105 (female) (12) and terminal R15
Voltage Max. 1V
circuit) in wiring harness wiring harness and chassis ground
Possible causes Wiring harness of 396 line (Between emergency
and standard steering relay – emergency steering motor – Voltage Max. 1V
value in normal
chassis ground)
state Disconnection in wiring har-
Resistance Max.1 z
4
defective contact of con- Wiring harness between L54 (female) (3) and
nector)
R37 (female) (2)

Emergency steering
Max.1 z
motor
Stopped
Max.1 z
5 ing pressure switch (Inter-
nal defect) Open to atmosphere
(Reference)
Between (2) and (1)
Operating
(High pressure) Min. 1 Mz
(Operate manually)

200 – 400 z
troller
chassis ground
WA430-6 20-589
PLAY OF CODE)
Circuit diagram related to emergency steering motor
20-590 WA430-6
PLAY OF CODE)
Failure code [DY30MC] (Emergency steering motor: Defective operation)
Action code Failure code Emergency steering motor: Defective operation

Trouble
E03 DY30MC (Transmission controller system)
Contents of • While the electric emergency steering output is turned ON, the electric emergency steering motor
trouble (pump) operation signal (S-NET) is not output.
Action of • Turns the electric emergency steering relay output OFF.
Problem that • While the operator operates the electric emergency steering switch, the electric emergency steering
appears on motor (pump) does not operate.
machine • The emergency steering operation indicator lights up.
Related tion (Code: 40903 D-IN-30).
itoring function (Code: 40905 D-IN-0, D-IN-1).

• When emergency steering relay (L126) is replaced with a relay of the
Defective emergency steer- same type (5-pin type), if the condition becomes normal, the relay is
1 ing relay (L126) (Internal defective.
short circuit)
200 – 400 z
Between (1) or (2)
Resistance Max.1 z
Wiring harness between L105 (female) (12) and
terminal R15
Resistance Max.1 z
Wiring harness between terminal R16 and chas-
ness (Disconnection or
2 sis ground
Resistance Max.1 z
Possible causes defective contact of con-
nector) Wiring harness of 030 line (Between battery
and standard
relay and emergency steering relay)
value in normal
Resistance Max.1 z
state Wiring harness of 396 line (Between emergency
steering relay – emergency steering motor –
chassis ground)

Between L54 (female) (3) and R37 (female) (2)

Emergency steering
Max.1 z
motor
Stopped
Max.1 z
4 ing pressure switch (Inter-
nal defect) Open to atmosphere
(Reference)
Between (2) and (1)
Operating
(High pressure) Min. 1 Mz
(Operate manually)
WA430-6 20-591
PLAY OF CODE)
Emergency steering motor Voltage
5 Stopped Max. 1V
Possible causes ing motor (Internal defect)
Between (+) terminal Operating
and standard
and chassis ground (High pressure) 20 – 30 V
value in normal
state (Operate manually)

200 – 400 z
troller
chassis ground
20-592 WA430-6
PLAY OF CODE)
WA430-6 20-593
PLAY OF CODE)
Failure code [DY30ME] (Emergency steering motor: Motor cannot be reset)
Action code Failure code Emergency steering motor: Motor cannot be reset
Trouble
E03 DY30ME (Machine monitor system)
Contents of
• The emergency steering operation sensor circuit is OPEN for more than continuous 1 minute.
trouble
Action of
controller
• Alarm for 1 minute operation of the emergency steering is turned ON.
Problem that
(The emergency steering motor may be malfunctioning or burning.)
appears on
• While the emergency steering motor is not operating, the indicator lights up.
machine
• The emergency steering operates constantly.
Related tion (Code: 40903, D-IN-30).
itoring function (Code: 40905, D-IN-0, D-IN-1).

Emergency steering
Max.1 z
Defective emergency steer- motor
1 ing pressure switch (Inter- Stopped
nal defect) Operating
Min. 1 Mz
Between (1) and (2) (High pressure)
Max.1 z
Open to atmosphere
(Reference)
Resistance Max.1 z
ness (Disconnection or Wiring harness between L54 (female) (3) and
2
Resistance Max.1 z
nector) Wiring harness between R37 (female) (1) and
chassis ground

and standard Emergency steering
value in normal L54 Voltage
3 Defective machine monitor motor
state
Stopped Max. 1 V
Operating
(High pressure)
Max. 1 z
Defective steering pressure
4 Stopped
switch (Low)
Operating Min. 1 Mz
Max. 1 z
Between (1) and (2)
Open to atmosphere
(Reference)

Defective steering pressure
Max. 1 z
5 Stopped Min. 1 Mz
switch (High)
Operating
Between (1) and (2)
Open to atmosphere
Min. 1 Mz
(Reference)
20-594 WA430-6
PLAY OF CODE)

Disconnection in wiring har- • After starting engine, press left brake pedal.
6 Between L61 (female) (17) and R36 (female) (2)
defective contact of con- Resistance Min.1 Mz
nector)
Between L61 (female) (23) and R69 (female) (2)
Resistance Min.1 Mz

Defective emergency
Defective emergency steer- S19 (male) Resistance
Max. 1 z
steering manual switch
7 ing manual switch (Internal
ON
short circuit) Between (4) and (3)
Possible causes OFF Min. 1 Mz
and standard Between (4) or (3) and
Constant Min. 1 Mz
value in normal chassis ground
state
Short circuit in wiring har- ry out troubleshooting.
8 ness (Short circuit between Between FS4 (female) (4) – S19 (female) (3) or
wiring harnesses) L126 (female) (3) wiring harness and L126 Resistance Min.1 Mz
(female) (5) – R15 wiring harness

short circuit)
Between (3) and (5) Min. 1 Mz

10 ing operation relay (Internal Emergency steering operation
Resistance
short circuit) relay
Between contacts Min. 1 Mz
WA430-6 20-595
PLAY OF CODE)
20-596 WA430-6
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-
MODE)
Before carrying out troubleshooting for electrical system

(E-mode)
a This connection table shows the devices to which each power supply of the fuse box supplies power (A
Connection table of fuse box
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
a When carrying out troubleshooting related to the electrical system, you should check the fuse box to see if
positions).
the power is supplied normally.
WA430-6 20-597
MODE)
Fuse box A
Type of power supply Fuse No Capacity of fuse Destination of power

1 10A Horn and air suspension seat circuit
2 20A Travel control circuit
3 10A Parking brake circuit
4 10A Emergency steering circuit
5 20A Work equipment control circuit
6 20A Rear glass heater circuit
7 20A Wiper and washer circuit
Switch power supply
8 10A Rotary lamp (if equipped) circuit
Slow-blow fuse (120 A)
9 10A Spare
10 10A Rear lamp and brake lamp circuit
11 20A Main lamp circuit
12 10A Right clearance lamp circuit
13 10A Left clearance lamp circuit
14 10A Right headlamp circuit
15 10A Left headlamp circuit
20-598 WA430-6
MODE)
Fuse box B

1 20A Starting switch terminal B circuit
2 10A Hazard lamp circuit
Constant power supply
3 10A Machine monitor A circuit
Slow-blow fuse (30 A)
4 10A Room lamp circuit
5 10A Spare
6 20A Spare
7 10A Turn signal circuit
8 20A Front working lamp circuit
9 20A Rear working lamp circuit
Switch power supply 10 10A Machine monitor B circuit
Slow-blow fuse (120 A) 11 10A Radio
12 10A Spare
13 10A 24V DC-12V DC converter circuit
14 20A Air conditioner A (Air conditioner blower) circuit
15 20A Air conditioner B (Air conditioner main) circuit
WA430-6 20-599
MODE)
Fuse box C

1 10A Engine controller A
2 10A Engine controller B
Constant power supply 3 10A Engine controller C
Slow-blow fuse (40 A) 4 10A Engine controller D
5 10A Engine controller E
6 10A Spare
20-600 WA430-6
MODE)
Locations of fuse boxes and fuse Nos.
WA430-6 20-601
MODE)
E-1. Engine does not start
Contents of
• Engine does not start
trouble
• The engine does not start because of troubles in the starting motor system and starting switch terminal
C signal system.
Related • Check that fuse A (2) and fuse B (1) are normal.
information (If either or both of these fuses are broken, check the related wiring harness for grounding fault.)
• The input state (ON/OFF) from starting switch terminal C can be checked with the monitoring function
(Code: 40906, D-IN-15).

Defective fuse in fuse box If the fuse is broken, the circuit probably has a grounding fault, etc.
1
A (2) or B (1) (See cause 5.)
Specific gravity Min. 1.26
2 Defective battery
Voltage Min. 25 V
Between battery relay terminal R13, R01, or
Voltage 20 – 30 V
R04 and chassis ground
Disconnection in battery Between battery (+) terminal and (-) terminal Voltage 20 – 30 V
relay and wiring harness
(Disconnection or defective out turning starting switch.
contact of connector) Wiring harness between S31 (female) (2) – bat-
tery relay – terminal R13 Continuity Secured
3
• Measure at S31 (female) (2) in diode range.
Resistance Max. 1 z
Wiring harness between battery relay (-) termi-
nal – chassis ground
Possible causes Disconnection in starting bleshooting.

and standard motor and related wiring
Between E01 (1) and chassis ground Voltage 20 – 30 V
value in normal harness (Disconnection or
state defective contact of con-
nector)
Default alternator (regula- ry out troubleshooting.

4
tor) (Internal defect)
Between S31 (1) or (2) – chassis ground Voltage 20 – 30 V
bleshooting.
Between S31 (3) and chassis ground Voltage 20 – 30 V
Disconnection in starting
switch and related wiring out turning starting switch.
Max. 1 z
5 harness Starting switch Resistance
(Disconnection or defective
Max. 1 z
Between B and BR
Between B and C
Resistance Max. 1 z
Wiring harness between S31 (female) (1) and
FS3 (female) (1)
Resistance Max. 1 z
L116 (female) (3)
20-602 WA430-6
MODE)
Disconnection in short con- out turning starting switch.
Resistance Max. 1 z
nector (TEL) and related
Wiring harness between TEL (female) (7) and
6 wiring harness
TEL (female) (8)
Resistance Max. 1 z
contact of connector) Wiring harness between TEL (female) (8) and
L116 (female) (3)
bleshooting.
Between L113 (4) and chassis ground Voltage 20 – 30 V
Between L113 (3) and chassis ground Voltage 20 – 30 V
Between L113 (1) and chassis ground Voltage Max. 1 V
Disconnection in relay out turning starting switch.
200 – 400 z
(L113) and related wiring L113 (Male) Resistance
7 harness
Between (1) and (2)
contact of connector) out turning starting switch.
Resistance Max. 1 z
L116 (female) (1)
Resistance Max. 1 z
L04 (female) (1)
Resistance Max. 1 z
Between L101 (female) (12) – L102 (female)

Possible causes Wiring harness between L116 (female) (5) and
and standard E01 (female) (1) Continuity Secured
value in normal • Measure at L102 (14) in diode range.
Disconnection in neutral
Resistance Max. 1 z
state Wiring harness between L116 (female) (5) and
safety relay (L116) and
8 related wiring harness L63 (female) (39)
Resistance Max. 1 z
(Disconnection or defective Wiring harness between L116 (female) (3) and
contact of connector) S31 (female) (3)
200 – 400 z
L116 (Male) Resistance
Between (1) and (2)
Voltage Max. 1 V
Grounding fault in wiring ry out troubleshooting.

harness Between L63 (female) (39) – L116 (female) (5)
(Contact with ground cir- wiring harness and chassis ground
cuit) Between L116 (female) (3) – S31 (female) (3)
Disconnection in shift out turning starting switch.
switch and related wiring Between L04 (1) or (3) and chassis ground Voltage 20 – 30 V
11 harness
Resistance Max. 1 z
contact of connector) Wiring harness between L04 (female) (1) and
FS4 (female) (2)
WA430-6 20-603
MODE)

• Diode R26 may be replaced.
R26 (Male) Diode range Continuity
Measure at (2) in diode
Secured
range.
(2) – (1)
Not secured
range.
Disconnection in diodes • Diode R27 may be replaced.
R26 and 27 and related wir-
R27 (Male) Diode range Continuity
12 ing harness
(Disconnection or defective Measure at (2) in diode
Secured
contact of connector) range.
(2) – (1)
Not secured
range.
Resistance Max. 1 z
R26 (female) (2) or R27 (female) (2)
Resistance Max. 1 z
Wiring harness between E01 (female) (1) and
R26 (female) (1) or R27 (female) (1)
Between FS3 (1) and chassis ground Voltage 20 – 30 V
Between FS4 (2) and chassis ground Voltage 20 – 30 V
Possible causes Between FS2 (1) and chassis ground Voltage 20 – 30 V
and standard
Between FS1 (1) or (2) and chassis ground Voltage 20 – 30 V
value in normal
state Between LR1 (1) and chassis ground Voltage 20 – 30 V
Between LR4 (1) or (2) and chassis ground Voltage 20 – 30 V
Between slow-blow fuse (constant power sup-
Voltage 20 – 30 V
ply) terminal R02 or R03 – chassis ground
Disconnection in fuse and
related wiring harness
13 out turning starting switch.
Resistance Max. 1 z
contact of connector) Wiring harness between FS1 (female) (1) and
LR1 (male) (1)
Resistance Max. 1 z
Wiring harness between FS1 (female) (2) and
LR4 (male) (1)
Resistance Max. 1 z
Wiring harness between LR4 (male) (2) and
FS2 (female) (1)
stant power supply) terminal R02 – battery relay Resistance Max. 1 z

Wiring harness between slow-blow fuse (con-
terminal R01
Resistance Max. 1 z
Wiring harness between slow-blow fuse termi-
nal R05 – battery relay terminal R04
Defective FNR switch mode
selector switch ry out troubleshooting.
14
(Internal disconnection or S04 Voltage
short circuit)
15 L63 Starting switch Voltage
troller
Between (39) – chassis C (Start) 20 – 30 V
ground Other than above Max. 1 V
20-604 WA430-6
MODE)
Circuit diagram related to engine starting system
WA430-6 20-605
MODE)
E-2. Engine low idle speed keeps low and does not rise or keeps high and does not
lower
Contents of
• Engine low idle speed keeps low and does not rise or keeps high and does not lower
trouble
• Since the throttle correction signal (low idle signal) output system is disconnected or shorted with the
chassis ground, the low idle signal cannot be turned ON (disconnection) or OFF (short circuit with the
chassis ground).
Related
• If the engine speed is kept at low idle, the engine may stall when the machine is steered from one di-
information
rection to the other (disconnection)
• The engine low idle speed keeps high and does not lower (short circuit with the chassis ground).
• If failure code [D5ZAKB] is displayed, carry out troubleshooting for it first.
ness out turning starting switch.
Resistance Max. 1 z
1
(Disconnection or defective Wiring harness between L62 (female) (8) – ER2
(female) (M)

Between L62 (female) (8) – ER2 (female) (M)
value in normal ground circuit) Resistance Min. 1 Mz
state

3
troller L62 Voltage
If none of causes 1 – 3 is the cause of the trouble, the engine controller
may be defective.
20-606 WA430-6
MODE)
Circuit diagram related to low idle switch
WA430-6 20-607
MODE)
E-3. Engine power does not change from high or low
Contents of
• Engine power does not change from high or low
trouble
• Since the engine output mode command signal (droop signal) output system is disconnected or shorted
with the chassis ground, the engine output mode command signal (droop signal) cannot be turned ON
Related
(disconnection) or OFF (short circuit with the chassis ground).
information
• The engine power keeps high (disconnection) or low (short circuit with the chassis ground).
• If failure code [D5ZMKB] is displayed, carry out troubleshooting for it first.
Resistance Max. 1 z
1
(Disconnection or defective Wiring harness between L62 (female) (18) –
ER2 (female) (V)

Between L62 (female) (18) – ER2 (female) (V)
value in normal ground circuit) Resistance Min. 1 Mz
state

3
troller L62 Voltage
If none of causes 1 – 3 is the cause of the trouble, the engine controller
may be defective.
20-608 WA430-6
MODE)
Circuit diagram related to engine output mode command signal
WA430-6 20-609
MODE)
E-4. When kick-down switch is turned ON, kick-down operation does not start
Contents of
• When kick-down switch is turned ON, kick-down operation does not start.
trouble
• The kick-down system is disconnected or shorted with the power source.
Related • The input state (ON/OFF) from the kick-down switch can be checked with the monitoring function
• If failure code [DDW9LD] is displayed, carry out troubleshooting for it first.

Defective fuse (2) of fuse If the fuse is broken, the circuit probably has a grounding fault, short cir-
1
box A cuit, etc. (See cause 4.)
Max. 1 z
L14 (male) Kick-down switch Resistance
2 ON
OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground
Possible causes
Resistance Max. 1 z
and standard
value in normal ness Wiring harness between L61 (female) (12) – L14
3
state (Disconnection or defective (female) (1)
Resistance Max. 1 z
contact of connector) Wiring harness between L14 (female) (2) –
chassis ground

circuit) in wiring harness Between L61 (female) (12) – L14 (female) (1)
Voltage Max. 1 V
5 L61 Kick-down switch Voltage
troller
20-610 WA430-6
MODE)
Circuit diagram related to kick-down switch
WA430-6 20-611
MODE)
E-5. When hold switch is pressed, holding operation does not start
Contents of
• When hold switch is pressed, holding operation does not start.
trouble
• The hold switch system is disconnected or shorted with the power source.
• The hold switch cannot be changed.
Related
• The input state (ON/OFF) from the hold switch can be checked with the monitoring function (Code:
information
40908, D-IN-31).
• If failure code [DDWLLD] is displayed, carry out troubleshooting for it first.

1
Max. 1 z
Defective hold switch L14 (male) Hold switch Resistance
2 (Internal disconnection or ON
Between (3) and (4)
short circuit) OFF Min. 1 Mz
Constant Min. 1 Mz
Disconnection in wiring har- aPrepare with starting switch OFF, then turn starting switch ON and car-
chassis ground
Possible causes
and standard
ness ry out troubleshooting.
value in normal 3
(Disconnection or defective Wiring harness between L62 (female) (38) – L14
(female) (3)
Short circuit with power ry out troubleshooting.

Voltage Max. 1 V
5 L62 Hold switch Voltage
troller
Between (38) and ON Max. 1V
20-612 WA430-6
MODE)
Circuit diagram related to hold switch
WA430-6 20-613
MODE)
E-6. Transmission is kept in neutral, or brake drags when directional lever is operated
while parking brake is applied
Contents of • Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake
trouble is applied.
• The neutralizer signal (parking brake signal) system is abnormal.
Related
• The input state (ON/OFF) from the neutralizer (parking brake) switch can be checked with the monitor-
information
ing function (Code: 40907, D-IN-23).

1
Max. 1 z
L01 (male) Parking brake switch Resistance
Defective parking brake ON
2 Between (1) and (3)
switch (Internal defect) OFF Min. 1 Mz
Max. 1 z
ON Min. 1 Mz
Between (2) and (3)
OFF
10 – 40 z
T08 Resistance
Defective parking brake Between (male) (1) and (2)
Max. 1 z
3
solenoid (Internal defect) Between (female) (2) and chassis
ground
Between (male) (1) or (2) and
Min. 1 Mz
chassis ground
Possible causes
and standard ness out turning starting switch.
Resistance Max. 1 z
value in normal 4
state contact of connector)
L01 (female) (2)

5 source (Contact with 24V Between L62 (female) (6) – L01 (female) (2) or
circuit) in wiring harness T06 (female) (1) wiring harness and chassis Voltage Max. 1 V
ground

6 harness (Contact with Between L62 (female) (6) – L01 (female) (2) or
ground circuit) T06 (female) (1) wiring harness and chassis Resistance Min. 1 Mz
ground
OFF o ON
L62 Parking brake switch Voltage
Defective transmission con- Max. 1 V

7 (Not opened)
troller
Between (6) and chas- Kept in OFF
Max. 1 V
ON o OFF (Opened)
sis ground (Not opened)
20 – 30 V
Kept in ON (Opened) Max. 1 V
20-614 WA430-6
MODE)
Circuit diagram related to parking brake
WA430-6 20-615
MODE)
E-7. Transmission cut-off mode cannot be set or reset
Contents of
• Transmission cut-off mode cannot be set or reset.
trouble
• The transmission cut-off switch system is abnormal.
Related
• The input state (ON/OFF) from the transmission cut-off switch can be checked with the monitoring func-
information
tion (Code: 40905, D-IN-2).

Defective transmission cut- Transmission cut-off
Max. 1 z
off switch switch
1
(Internal disconnection or ON
Between (4) and (3)
Constant Min. 1 Mz
chassis ground
Resistance Max. 1 z
2
Possible causes contact of connector)
S03 (female) (4)
and standard
circuit) in wiring harness Between L61 (female) (11) – S03 (female) (4)
Voltage Max. 1 V

ground circuit) Between L61 (female) (11) – S03 (female) (4)
Defective transmission con- Transmission cut-off
5 L61 Voltage
troller switch
20-616 WA430-6
MODE)
Circuit diagram related to transmission cut-off switch
WA430-6 20-617
MODE)
E-8. Transmission cut-off set cannot be reset
Contents of
• Transmission cut-off set cannot be reset.
trouble
• The transmission cut-off set switch is disconnected or shorted with the power source.
Related • The input state (ON/OFF) from the switch can be checked with the monitoring function (Code: 40905,
information D-IN-3).
• If failure code [DDT4LD] is displayed, carry out troubleshooting for it first.

Defective transmission cut- Transmission cut-off
Max. 1 z
off switch set switch
1
Between (4) and (3)
Constant Min. 1 Mz
chassis ground
Resistance Max. 1 z
2
S03 (female) (4)
and standard
value in normal Short circuit with power ry out troubleshooting.
Voltage Max. 1 V

ground circuit) Between L61 (female) (11) – S03 (female) (4)
Defective transmission con- Transmission cut-off
5 L61 Voltage
troller set switch
20-618 WA430-6
MODE)
Circuit diagram related to transmission cut-off set switch
WA430-6 20-619
MODE)
E-9. When transmission cut-off function is turned ON, even if left brake pedal is
pressed, transmission is not cut off
Contents of • When transmission cut-off function is turned ON, even if left brake pedal is pressed, transmission is not
trouble cut off.
• The left brake pressure sensor system is shorted.
Related • The state (pressure) of the left brake pressure sensor can be checked with the monitoring function
information (Code: 41100, LH BRAKE). (When transmission cut-off switch is turned ON, press the left brake pedal.)
• If failure code [DHT1KX] is displayed, carry out troubleshooting for it first.

• Press the left brake pedal.
Defective left brake pres- L10 Voltage
1 sure sensor Between (B) and (A) (Power
20 – 30 V
(Internal short circuit) source)
Between (C) and (A) (Signal) 0.7 – 5.3 V
Between (C) and (A) (Reference:
0.5 – 1.5 V
Possible causes When open to atmosphere)
and standard
value in normal Short circuit in wiring har- out turning starting switch.
state 2 ness (Short circuit between Between L61 (female) (16) – L10 (female) (B)
wiring harnesses) wiring harness and L61 (female) (19) – L10 Resistance Min. 1 Mz
(female) (C) wiring harness
L61 Voltage
3 Between (16) and chassis ground
troller 20 – 30 V
(Power source)
0.7 – 5.3 V
(Signal)
20-620 WA430-6
MODE)
Circuit diagram related to left brake pressure sensor
WA430-6 20-621
MODE)
E-10. Gear is not shifted up in automatic shift mode
Contents of
• Gear is not shifted up in automatic shift mode
trouble
• The transmission output shaft speed sensor system is shorted with the chassis ground.
• Gear shifting shocks are made.
Related
• The machine can travel in the manual shift mode.
information
• The engine may overrun.
• If failure code [DLT3KA], [DLT3LC] is displayed, carry out troubleshooting for it first.

Defective installation of
Check the clearance between the sensor and gear directly. (See Testing
1 transmission output shaft
and adjusting.)
speed sensor
Defective installation of out turning starting switch.

2 transmission output shaft
500 – 1,000 z
speed sensor
Between (1) and (2)
Possible causes
and standard
ground circuit)
Between L62 (female) (29) – T19 (female) (2)

500 – 1,000 z
troller
(29)
20-622 WA430-6
MODE)
WA430-6 20-623
MODE)
E-11. FNR switch mode cannot be set or reset
Contents of
• FNR switch mode cannot be set or reset.
trouble
• The FNR switch mode selector switch system is abnormal.
(The FNR switch mode is not set (grounding fault), or the steering wheel mode is not set (disconnec-
Related tion).)
information • The state (ON/OFF) of the FNR switch mode selector switch can be checked with the monitoring func-
tion (Code: 40907, D-IN-16).
• Installation of the right FNR switch can be checked in the service mode of the monitor.

Defective FNR switch mode FNR switch mode
S04 (female) Resistance
Max. 1 z
selector switch selector switch
1
Between (4) and (3)
Constant Min. 1 Mz
chassis ground
Resistance Max. 1 z
ness
2 S04 (female) (4)
and standard ry out troubleshooting.
value in normal
Between S04 (female) (3) and chassis ground Voltage 20 – 30 V
state

Defective transmission con- FNR switch mode
5 L62 Voltage
troller selector switch
20-624 WA430-6
MODE)
Circuit diagram related to FNR switch mode selector switch
WA430-6 20-625
MODE)
E-12. In joystick mode, engine can be started even if FNR lever or FNR switch is not in
N position
Contents of
• In joystick mode, engine can be started even if FNR lever or FNR switch is not in N position.
trouble
Related
• The transmission controller neutral output system is shorted with the power source.
information
Possible causes 1 source (Contact with 24V Voltage Max. 1 V
and standard circuit) in wiring harness
value in normal Voltage Max. 1 V
state

2
200 – 400 z
20-626 WA430-6
MODE)
Circuit diagram related to joystick neutral
WA430-6 20-627
MODE)
E-13. While FNR lever is not in F position, F clutch ECMV solenoid operates
Contents of
• While FNR lever is not in F position, F clutch ECMV solenoid operates.
trouble
• The F clutch ECMV solenoid system is shorted with the power source.
• The transmission may be broken.
Related
• The machine may not be able to travel.
information
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function
(Code: 31608, ECMV F).

and standard circuit) in wiring harness Voltage Max. 1 V
value in normal
state
2
5 – 15 z
20-628 WA430-6
MODE)
WA430-6 20-629
MODE)
E-14. While FNR lever is not in R position, R clutch ECMV solenoid operates
Contents of
• While FNR lever is not in R position, R clutch ECMV solenoid operates.
trouble
• The R clutch ECMV solenoid system is shorted with the power source.
Related
information
• The output state (current) to the R clutch ECMV solenoid can be checked with the monitoring function
(Code: 31606, ECMV R).

Possible causes Between L63 (female) (15) – T06 (female) (1)
and standard wiring harness and chassis ground
value in normal
5 – 15 z
troller
(13)
20-630 WA430-6
MODE)
WA430-6 20-631
MODE)
E-15. While gearshift lever is not in 1st, 1st clutch ECMV solenoid operates
Contents of
• While gearshift lever is not in 1st, 1st clutch ECMV solenoid operates.
trouble
• The 1st clutch ECMV solenoid system is shorted with the power source.
Related
information
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function
(Code: 31602, ECMV 1).

value in normal
5 – 15 z
troller
(13)
20-632 WA430-6
MODE)
WA430-6 20-633
MODE)
E-16. While gearshift lever is not in 2nd, 2nd clutch ECMV solenoid operates
Contents of
• While gearshift lever is not in 2nd, 2nd clutch ECMV solenoid operates.
trouble
• The 2nd clutch ECMV solenoid system is shorted with the power source.
Related
information
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function
(Code: 31603, ECMV 2).

value in normal
state
2
5 – 15 z
20-634 WA430-6
MODE)
WA430-6 20-635
MODE)
E-17. While gearshift lever is not in 3rd, 3rd clutch ECMV solenoid operates
Contents of
• While gearshift lever is not in 3rd, 3rd clutch ECMV solenoid operates.
trouble
• The 3rd clutch ECMV solenoid system is shorted with the power source.
Related
information
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function
(Code: 31604, ECMV 3).

value in normal
5 – 15 z
troller
(3)
20-636 WA430-6
MODE)
WA430-6 20-637
MODE)
E-18. While gearshift lever is not in 4th, 4th clutch ECMV solenoid operates
Contents of
• While gearshift lever is not in 4th, 4th clutch ECMV solenoid operates.
trouble
• The 4th clutch ECMV solenoid system is shorted with the power source.
Related
information
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function
(Code: 31605, ECMV 4).

value in normal
5 – 15 z
troller
(13)
20-638 WA430-6
MODE)
WA430-6 20-639
MODE)
E-19. Machine is always steered fully to right
Contents of
• Machine is always steered fully to right
trouble
• Since the joystick steering right EPC solenoid system is shorted with the power source, the joystick
Related
steering right EPC solenoid is turned ON.
information

value in normal
state
2
(female) (1)
20-640 WA430-6
MODE)
Circuit diagram related to joystick steering right EPC solenoid
WA430-6 20-641
MODE)
E-20. Machine is always steered fully to left
Contents of
• Machine is always steered fully to left
trouble
• Since the joystick steering left EPC solenoid system is shorted with the power source, the joystick steer-
Related
ing left EPC solenoid is turned ON.
information

value in normal
state
2
(female) (3)
20-642 WA430-6
MODE)
Circuit diagram related to joystick steering left EPC solenoid
WA430-6 20-643
MODE)
E-21. Joystick mode cannot be used or reset
Contents of
• Joystick mode cannot be used or reset.
trouble
Related • Since the joystick ON/OFF switch system is abnormal, the joystick mode cannot be used or reset.
information • The input state (ON/OFF) from the joystick ON/OFF switch can be checked with the monitoring function
(Code: 40910, D-IN-0).

1

Defective joystick ON/OFF Joystick ON/OFF
Max. 1 z
switch switch
2
Between (4) and (3)
short circuit) Other than above Min. 1 Mz
Constant Min. 1 Mz
chassis ground

Defective joystick N lock
Max. 1 z
L38 (female) Left armrest Resistance
switch
3 Lock
(Internal disconnection or Between (1) and (3)
short circuit) Other than above Min. 1 Mz
Constant Min. 1 Mz
chassis ground
Resistance Max. 1 z
Possible causes Wiring harness between L71 (female) (23) and
and standard Disconnection in wiring har- L39 (female) (4)
Resistance Max. 1 z
value in normal ness
4 Wiring harness between L38 (female) (1) and
state (Disconnection or defective
L39 (female) (3)
Between L38 (female) (3) and chassis ground Voltage 20 – 30 V

5 source (Contact with 24V Between L71 (female) (23) – L39 (female) (4),
circuit) in wiring harness (5) – L40 (female) (5) wiring harness and chas- Voltage Max. 1 V
sis ground
(5) – L40 (female) (5) wiring harness asnd chas- Resistance Max. 1 z
6 harness (Contact with Between L71 (female) (23) – L39 (female) (4),
ground circuit)
sis ground
Joystick ON/OFF
7 L71 switch and joystick N Voltage
controller
lock switch
Between (23) and Both are ON 20 – 30 V
20-644 WA430-6
MODE)
Circuit diagram related to joystick ON/OFF switch
WA430-6 20-645
MODE)
E-22. Joystick steering speed is low or high (Hi/Lo cannot be changed)
Contents of
• Joystick steering speed is low or high (Hi/Lo cannot be changed).
trouble
• Since the joystick steering speed Hi/Lo selector switch system is abnormal, the joystick steering speed
Related
is lowered or heightened (Hi/Lo cannot be changed).
information
• The input state (ON/OFF) from the joystick steering speed Hi/Lo selector switch can be checked with
the monitoring function (Code: 40911, D-IN-8).

1

Joystick steering
Defective joystick steering L40 (female) speed Hi/Lo selector Resistance
speed Hi/Lo selector switch
Max. 1 z
2 switch
(Internal disconnection or
ON
Constant Min. 1 Mz
chassis ground
Resistance Max. 1 z
ness
Possible causes 3 Wiring harness between L73 (10) and L40
Between L40 (female) (3) and chassis ground Resistance Max. 1 z

and standard (female) (4)
value in normal
state aPrepare with starting switch OFF, then turn starting switch ON and car-
Between L73 (10) – L40 (female) (4) wiring har-

Between L73 (10) – L40 (female) (4), (6) wiring
harness asnd chassis ground
Joystick steering
6 L73 speed Hi/Lo selector Voltage
controller
switch
20-646 WA430-6
MODE)
Circuit diagram related to joystick steering speed Hi/Lo selector switch
WA430-6 20-647
MODE)
E-23. Joystick steering solenoid cannot be turned OFF (Joystick steering cannot be
reset)
Contents of
• Joystick steering solenoid cannot be turned OFF (Joystick steering cannot be reset)
trouble
• Since the joystick steering EPC cut-out relay output system is shorted with the power source, the joy-
Related
stick steering solenoid cannot be turned OFF.
information
• The output signal (ON/OFF) to the joystick steering EPC cut-out relay can be checked with the moni-
toring function (Code: 40916, SOL/0-0).

Possible causes Between L73 (female) (7) – L41 (female) (5) wir-
and standard ing harness and chassis ground
value in normal
200 – 400 z
controller
chassis ground
20-648 WA430-6
MODE)
Circuit diagram related to joystick steering EPC cut-out relay
WA430-6 20-649
MODE)
E-24. While emergency steering switch is not turned ON, emergency steering motor
keeps turning
Contents of
• While emergency steering switch is not turned ON, emergency steering motor keeps turning.
trouble
• The emergency steering relay output system is shorted with the power source.
Related
• The output state (ON/OFF) to the emergency steering relay can be checked with the monitoring function
information
(Code: 40914, SOL/0-0).

Possible causes circuit) in wiring harness Between L63 (female) (7) – L126 (female) (1)
Voltage Max. 1 V
value in normal
200 – 400 z
troller
chassis ground
20-650 WA430-6
MODE)
Circuit diagram related to electric emergency steering relay
WA430-6 20-651
MODE)
E-25. Emergency steering does not function or it always functions
Contents of
• Emergency steering does not function or it always functions.
trouble
• The electric emergency steering operation switch is abnormal.
• The input state (ON/OFF) from the emergency steering manual switch can be checked with the moni-
Related toring function (Code: 40906, D-IN-14).
information • The output state (ON/OFF) to the emergency steering relay can be checked with the monitoring function
(Code: 40914, SOL/0-0).
• If failure code [D150KA] or [D150KB] is displayed, carry out troubleshooting for it first.

Emergency steering
1 ing manual switch S19 (male) Resistance
Max. 1 z
manual switch
(Internal defect)
ON
Between (4) and (3)
OFF Min. 1 Mz

2 ing relay (L126)
(Internal defect)
Between (3) and (5) Min. 1 Mz

3 ing operation relay Emergency steering operation relay Resistance
(Internal defect) Between secondary contacts of
Min. 1 Mz
relay
Possible causes
value in normal ness out turning starting switch.
Resistance Max. 1 z
4
state (Disconnection or defective Wiring harness between L63 (female) (29) and
S19 (female) (1)

Grounding fault in wiring S19 (female) (1)
5 harness (Contact with Between L63 (female) (7) – L126 (female) (1),
ground circuit) S19 (female) (1) wiring harness asnd chassis Resistance Min. 1 Mz
ground
Between L126 (female) (5) – R15 wiring har-
ness asnd chassis ground
Defective transmission con- Emergency steering
6 L63 Voltage
troller manual switch
20-652 WA430-6
MODE)
Circuit diagram related to emergency steering
WA430-6 20-653
MODE)
E-26. Fan speed does not rise from minimum level
Contents of
• Fan speed does not rise from minimum level.
trouble
• The fan pump EPC solenoid system is shorted with the power source.
Related
• The output state (ON/OFF) to the fan pump EPC solenoid can be checked with the monitoring function
information
(Code: 40914, SOL/0-5).

Possible causes Between L63 (female) (36) – R29 (female) (1)
value in normal
5 – 10 z
troller
(23)
20-654 WA430-6
MODE)
WA430-6 20-655
MODE)
E-27. Fan reverse function cannot be used or reset
Contents of
• Fan reverse function cannot be used or reset.
trouble
• The fan reverse switch system is disconnected, shorted with the chassis ground, or shorted with the
power source.
Related
(The fan reverse operation cannot be turned ON (Disconnection or grounding fault). The fan reverse
information
operation cannot be turned OFF (Short circuit with power source). )
• If failure code [DW7BKA] or [DW7BKB] is displayed, carry out troubleshooting for it first.

1
Max. 1 z
S16 (male) Fan reverse switch Resistance
2 ON
OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground

Disconnection in wiring har- Wiring harness between L61 (female) (7) – S16 Resistance Max. 1 z
Possible causes 3
and standard
nector) ry out troubleshooting.
value in normal
state Wiring harness between S16 (female) (3) and
Voltage 20 – 30 V
chassis ground.

circuit) in wiring harness Between L61 (female) (24) – R70 (female) (1)
Voltage Max. 1 V

ground circuit) Between L61 (female) (7) – S16 (female) (4) wir-
6 L61 Fan reverse switch Voltage
troller
Between (7) and chas- ON Max. 1V
sis ground OFF 20 – 30 V
20-656 WA430-6
MODE)
Circuit diagram related to fan reverse switch
WA430-6 20-657
MODE)
E-28. Turning direction of fan does not change from reverse
Contents of
• Turning direction of fan does not change from reverse.
trouble
• The fan reverse solenoid system is shorted with the power source.
Related
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function
information
(Code: 40914, SOL/0-4).

Possible causes Between L63 (female) (28) – GR2 (female) (1)
value in normal
35 – 45 z
troller
chassis ground
20-658 WA430-6
MODE)
Circuit diagram related to fan reverse solenoid
WA430-6 20-659
MODE)
E-29. Work equipment does not move or cannot be locked
Contents of
• Work equipment does not move or cannot be locked.
trouble
• Since the work equipment lock switch system is disconnected, shorted, shorted with the chassis
Related ground, or shorted with the power source, the work equipment does not move or cannot be locked.
information • The input state (ON/OFF) from the work equipment lock switch can be checked with the monitoring
function (Code: 40910, D-IN-1).

1

Work equipment lock
Defective work equipment L13 (male) Resistance
Max. 1 z
switch
2 lock switch (Internal discon-
ON
nection or short circuit) Between (1) and (2)
OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground

Resistance Max. 1 z
ness (Disconnection or Wiring harness between FS4 (female) (5) – L13
Possible causes 3
Resistance Max. 1 z
and standard
value in normal
(female) (17)
state

Voltage Max. 1 V
Defective work equipment Work equipment lock
6 L71 Voltage
controller switch
20-660 WA430-6
MODE)
Circuit diagram related to work equipment lock switch
WA430-6 20-661
MODE)
E-30. Discharge from loader pump does not rise from minimum level
Contents of
• Discharge from loader pump does not rise from minimum level.
trouble
• Since the loader pump PC-EPC solenoid system is shorted with the power source, the loader pump dis-
Related charge is minimized.
information • The state (current) of the loader pump PC-EPC solenoid can be checked with the monitoring function
(Code: 41401 PUMP EPC).

Possible causes Between L63 (female) (27) – R68 (female) (1)
value in normal
5 – 10 z
troller
(23)
20-662 WA430-6
MODE)
WA430-6 20-663
MODE)
E-31. Remote positioner raise stop position cannot be set
Contents of
• Remote positioner raise stop position cannot be set.
trouble
• Since the remote positioner raise set switch system is disconnected or shorted with the power source,
Related the remote positioner raise stop position cannot be set.
information • The input state (ON/OFF) from the remote positioner raise set switch can be checked with the monitor-

Defective remote positioner Remote positioner set
Max. 1 z
raise set switch (Internal switch
1
disconnection or short cir- Raise
Between (1) and (2)
cuit) Other than above Min. 1 Mz
Constant Min. 1 Mz
chassis ground

Resistance Max. 1 z
and standard 2
value in normal
nector)
S12 (female) (1)
state
Voltage Max. 1 V
controller switch
Between (13) and Raise Max. 1 V
20-664 WA430-6
MODE)
Circuit diagram related to remote positioner raise set switch
WA430-6 20-665
MODE)
E-32. Remote positioner lower stop position cannot be set
Contents of
• Remote positioner lower stop position cannot be set.
trouble
• Since the remote positioner lower set switch system is disconnected or shorted with the power source,
Related the remote positioner lower stop position cannot be set.
information • The input state (ON/OFF) from the remote positioner lower set switch can be checked with the moni-
toring function (Code: 40913, D-IN-29).

Defective remote positioner Remote positioner set
Max. 1 z
lower set switch (Internal switch
1
disconnection or short cir- Lower
Between (3) and (2)
cuit) Other than above Min. 1 Mz
Constant Min. 1 Mz
chassis ground

Resistance Max. 1 z
and standard 2
defective contact of con- Wiring harness between L72 (female) (3) – S12
value in normal
nector)
(female) (3)
state
circuit) in wiring harness Between L72 (female) (3) – S12 (female) (3) wir-
Voltage Max. 1 V
controller switch
Between (3) and chas- Lower Max. 1 V
20-666 WA430-6
MODE)
Circuit diagram related to remote positioner lower set switch
WA430-6 20-667
MODE)
E-33. Remote positioner raise cannot be selected or reset
Contents of
• Remote positioner raise cannot be selected or reset.
trouble
• Since the remote positioner raise selector switch is disconnected, shorted with the chassis ground, or
Related shorted with the power source, the remote positioner raise cannot be selected or reset.
information • The input state (ON/OFF) from the remote positioner raise selector switch can be checked with the
monitoring function (Code: 40913, D-IN-30).

Defective remote positioner Remote positioner
Max. 1 z
raise selector switch (Inter- raise selector switch
1
nal disconnection or short ON
Between (4) and (3)
Constant Min. 1 Mz
chassis ground

Resistance Max. 1 z
ness (Disconnection or Wiring harness between L72 (female) (2) – S13
2
defective contact of con- (female) (4) or S12 (female) (6)
Resistance Max. 1 z
nector) Wiring harness between FS3 (female) (11) –
Possible causes
S12 (female) (5)
and standard
value in normal
state Grounding fault in wiring ry out troubleshooting.
3 harness (Contact with Between L72 (female) (2) – S13 (female) (4) or
ground circuit) S12 (female) (6) wiring harness and chassis Resistance Min. 1 Mz
ground

4 source (Contact with 24V Between L72 (female) (2) – S13 (female) (4) or
circuit) in wiring harness S12 (female) (6) wiring harness and chassis Voltage Max. 1 V
ground
5 L72 (female) Voltage
controller raise selector switch
20-668 WA430-6
MODE)
Circuit diagram related to remote positioner raise selector switch
WA430-6 20-669
MODE)
E-34. Remote positioner lower cannot be selected or reset
Contents of
• Remote positioner lower cannot be selected or reset.
trouble
• Since the remote positioner lower selector switch is disconnected, shorted with the chassis ground, or
Related shorted with the power source, the remote positioner lower cannot be selected or reset.
information • The input state (ON/OFF) from the remote positioner lower selector switch can be checked with the

Defective remote positioner Remote positioner
Max. 1 z
lower selector switch (Inter- lower selector switch
1
nal disconnection or short ON
Between (4) and (3)
Constant Min. 1 Mz
chassis ground

Resistance Max. 1 z
2
defective contact of con- S14 (female) (4) or S12 (female) (4)
Resistance Max. 1 z
nector) Wiring harness between FS3 (female) (11) –
Possible causes
S12 (female) (5)
and standard
value in normal
state Grounding fault in wiring out turning starting switch.
3 harness (Contact with Between L72 (female) (38) – S14 (female) (4) or
ground

4 source (Contact with 24V Between L72 (female) (38) – S14 (female) (4) or
circuit) in wiring harness S12 (female) (4) wiring harness and chassis Voltage Max. 1 V
ground
5 L72 (female) Voltage
controller lower selector switch
20-670 WA430-6
MODE)
Circuit diagram related to remote positioner lower selector switch
WA430-6 20-671
MODE)
E-35. Bucket positioner does not function
Contents of
• Bucket positioner does not function.
trouble
• Since the bucket positioner proximity switch system is disconnected, shorted with the chassis ground,
Related or shorted, the bucket positioner does not function.
information • The input state (ON/OFF) from the bucket positioner proximity switch can be checked with the monitor-
ing function (Code: 40911, D-IN-9)

1
Resistance Max. 1 z
Disconnection in wiring har- Wiring harness between FS4 (female) (5) – F09
ness (Disconnection or (female) (A)
Resistance Max. 1 z
2
nector) F09 (female) (B)
Resistance Max. 1 z
Wiring harness between F09 (female) (C) and
chassis ground

Grounding fault in wiring Between L73 (female) (20) – F09 (female) (B) or
Possible causes 3 harness (Contact with L104 (7) wiring harness and chassis ground
and standard ground circuit) Between FS4 (female) (5) – F09 (female) (A) or
value in normal L104 (6) or (8) wiring harness and chassis Resistance Min. 1 Mz
state ground

Between L73 (female) (20) – F09 (female) (B) or
L104 (7) wiring harness and chassis ground
Defective bucket positioner ry out troubleshooting.

proximity switch (Internal
5 F09 Position of bucket Voltage
disconnection or short cir-
Below horizontal Max. 1 V
cuit) Between (B) and (C)
Above horizontal 20 – 30 V
6 L73 Position of bucket Voltage
controller
Between (20) and Below horizontal Max. 1V
chassis ground Above horizontal 20 – 30 V
20-672 WA430-6
MODE)
Circuit diagram related to bucket positioner proximity switch
WA430-6 20-673
MODE)
E-36. Semiautomatic digging mode cannot be set or reset
Contents of
• Semiautomatic digging mode cannot be set or reset.
trouble
• Since the bucket cylinder full stroke switch system is disconnected, shorted with the chassis ground, or
Related
shorted, the semiautomatic digging mode is not set or reset.
information
• The input state (ON/OFF) from the bucket cylinder full stroke switch can be checked with the monitoring

1
Resistance Max. 1 z
Disconnection in wiring har- Wiring harness between FS4 (female) (5) – F19
ness (Disconnection or (female) (A)
Resistance Max. 1 z
2
nector) F19 (female) (B)
Resistance Max. 1 z
Wiring harness between F19 (female) (C) and
chassis ground

Grounding fault in wiring Wiring harness between L73 (female) (30) –
3 harness (Contact with F19 (female) (B) wiring harness and chassis Resistance Min. 1 Mz
Possible causes ground circuit) ground
and standard Wiring harness between FS4 (female) (5) – F19
value in normal Resistance Min. 1 Mz
(female) (A) wiring harness and chassis ground
state
4 source (Contact with 24V Wiring harness between L73 (female) (30) –
circuit) in wiring harness F19 (female) (B) wiring harness and chassis Voltage Max. 1 V
ground
Defective bucket cylinder ry out troubleshooting.

full stroke switch (Internal
5 F19 Bucket tilt Voltage
disconnection or short cir-
Other than tilt stroke end Max. 1 V
cuit) Between (B) and (C)
Tilt stroke end 20 – 30 V
6 L73 Bucket tilt Voltage
controller
Between (30) and Other than tilt stroke end Max. 1 V
chassis ground Tilt stroke end 20 – 30 V
20-674 WA430-6
MODE)
Circuit diagram related to bucket cylinder full stroke switch
WA430-6 20-675
MODE)
E-37. Semiautomatic digging hard mode cannot be set or reset
Contents of
• Semiautomatic digging hard mode cannot be set or reset.
trouble
• Since the semiautomatic digging hard switch system is disconnected, shorted with the chassis ground,
Related
or shorted, the semiautomatic digging hard mode is not set or reset.
information
• The input state (ON/OFF) from the semiautomatic digging hard switch can be checked with the moni-

1
box B cuit, etc. (See cause 3.)

Resistance Max. 1 z
ness (Disconnection or Wiring harness between L73 (female) (9) – S15
2
Resistance Max. 1 z
nector) Wiring harness between S15 (female) (2) and
chassis ground

Grounding fault in wiring Between L73 (female) (9) – S15 (female) (1) or
3 harness (Contact with (6) wiring harness and chassis ground
ground circuit) Wiring harness between FS3 (female) (11) –
Possible causes S15 (female) (5) wiring harness and chassis Resistance Min. 1 Mz
and standard ground
value in normal
Between L73 (female) (9) – S15 (female) (1) or
Defective semiautomatic ry out troubleshooting.

digging switch (hard) (Inter- Semiautomatic
5 S15 Voltage
nal disconnection or short digging switch (hard)
circuit) ON Max. 1 V
Between (1) and (2)
Other than ON 20 – 30 V
Defective work equipment Semiautomatic
6 L73 Voltage
controller digging switch (hard)
chassis ground Other than ON 20 – 30 V
20-676 WA430-6
MODE)
Circuit diagram related to semiautomatic digging hard switch
WA430-6 20-677
MODE)
E-38. Semiautomatic digging soft mode cannot be set or reset
Contents of
• Semiautomatic digging soft mode cannot be set or reset.
trouble
• Since the semiautomatic digging soft switch system is disconnected, shorted with the chassis ground,
Related
or shorted, the semiautomatic digging soft mode is not set or reset.
information
• The input state (ON/OFF) from the semiautomatic digging soft switch can be checked with the monitor-

1

Resistance Max. 1 z
2
defective contact of con- S15 (female) (3)
Resistance Max. 1 z
nector) Wiring harness between S15 (female) (2) and
chassis ground

Grounding fault in wiring Between L73 (female) (19) – S15 (female) (3) or
3 harness (Contact with (4) wiring harness and chassis ground
ground circuit) Wiring harness between FS3 (female) (11) –
Possible causes S15 (female) (5) wiring harness and chassis Resistance Min. 1 Mz
and standard ground
value in normal
Between L73 (female) (19) – S15 (female) (3) or
Defective semiautomatic ry out troubleshooting.

digging switch (soft) (Inter- Semiautomatic
5 S15 Voltage
nal disconnection or short digging switch (soft)
circuit) ON Max. 1 V
Between (3) and (2)
Other than ON 20 – 30 V
Defective work equipment Semiautomatic
6 L73 Voltage
controller digging switch (soft)
chassis ground Other than ON 20 – 30 V
20-678 WA430-6
MODE)
Circuit diagram related to semiautomatic digging soft switch
WA430-6 20-679
MODE)
E-39. ECSS function cannot be used or reset
Contents of
• ECSS function cannot be used or reset.
trouble
• The ECSS switch system is abnormal.
Related (The ECSS function cannot be used (disconnection) or reset (grounding fault).)
information • The input state (ON/OFF) from the ECSS switch can be checked with the monitoring function (Code:
40905, D-IN-4).

1
Max. 1 z
Defective ECSS switch S07 (female) ECSS switch Resistance
2 (Internal disconnection or ON
Between (4) and (3)
Constant Min. 1 Mz
chassis ground
bleshooting.
ECSS cut-off pressure
Defective ECSS cut-off switch
pressure switch (Internal OFF
3 Min. 1 Mz
disconnection or short cir- (Other than below)
Max. 1 z
cuit) Between (1) and (2)
ON (Work equipment
lever at LOWER)
Constant Min. 1 Mz
chassis ground
Resistance Max. 1 z
Possible causes
and standard Disconnection in wiring har- Wiring harness between L61 (female) (24) –
value in normal ness (Disconnection or R70 (female) (1)
Resistance Max. 1 z
4
state defective contact of con- Wiring harness between R70 (female) (2) – S07
Resistance Max. 1 z
chassis ground
Short circuit with power Wiring harness between L61 (female) (24) –
5 source (Contact with 24V R70 (female) (1) wiring harness and chassis Voltage Max. 1 V
circuit) in wiring harness ground
Between R70 (female) (2) – S07 (female) (4) or
Voltage Max. 1 V

Grounding fault in wiring Wiring harness between L61 (female) (24) –
6 harness (Contact with R70 (female) (1) wiring harness and chassis Resistance Min. 1 Mz
ground circuit) ground
Between R70 (female) (2) – S07 (female) (4) or
Defective transmission con- L61 ECSS switch Voltage
7
troller
20-680 WA430-6
MODE)
Circuit diagram related to ECSS switch
WA430-6 20-681
MODE)
E-40. While ECSS switch is not turned ON, ECSS keeps operating
Contents of
• While ECSS switch is not turned ON, ECSS keeps operating.
trouble
• The ECSS relay output system is shorted with the power source.
Related
• The output state (ON/OFF) to the ECSS relay can be checked with the monitoring function (Code:
information
40914, SOL/0-1).

value in normal
200 – 400 z
troller
chassis ground
20-682 WA430-6
MODE)
WA430-6 20-683
MODE)
E-41. Lift arm raise detent cannot be reset
Contents of
• Lift arm raise detent cannot be reset.
trouble
• Since the lift arm raise magnet detent output system is shorted with the power source, the raise detent
Related cannot be reset.
information • The operator can carry out normal operation, although the detent is not reset automatically.
• The output state (ON/OFF) to the lift arm raise detent can be checked with the monitoring function
(Code: 40916, SOL/0-1).

Voltage Max. 1 V
value in normal
35 – 45 z
controller
chassis ground
20-684 WA430-6
MODE)
Circuit diagram related to lift arm raise magnet detent
WA430-6 20-685
MODE)
E-42. Lift arm float detent cannot be reset
Contents of
• Lift arm float detent cannot be reset.
trouble
• Since the lift arm float magnet detent output system is shorted with the power source, the float detent
Related cannot be reset.
information • The operator can carry out normal operation, although the detent is not reset automatically.
• The output state (ON/OFF) to the lift arm float detent can be checked with the monitoring function
(Code: 40916, SOL/0-2).

Voltage Max. 1 V
value in normal
35 – 45 z
controller
chassis ground
20-686 WA430-6
MODE)
Circuit diagram related to lift arm float magnet detent
WA430-6 20-687
MODE)
E-43. Bucket tilt detent cannot be reset
Contents of
• Bucket tilt detent cannot be reset.
trouble
• Since the bucket tilt magnet detent output system is shorted with the power source, the tilt detent cannot
Related
be reset.
information
• The output state (ON/OFF) to the bucket tilt detent can be checked with the monitoring function (Code:
40916, SOL/0-3).

Possible causes circuit) in wiring harness Between L73 (female) (37) – L25E (female) (1)
Voltage Max. 1 V
value in normal
35 – 45 z
controller
chassis ground
20-688 WA430-6
MODE)
Circuit diagram related to bucket tilt magnet detent
WA430-6 20-689
MODE)
E-44. While work equipment lock lever is in FREE position, work equipment is kept
locked
Contents of
• While work equipment lock lever is in FREE position, work equipment is kept locked.
trouble
• Since the lift arm neutral lock EPC solenoid output system is shorted with the power source, the lift arm
Related
neutral lock EPC solenoid cannot be turned OFF.
information

1 source (Contact with 24V Between L73 (female) (28) – F26 (female) (1) or
Possible causes circuit) in wiring harness F27 (female) (1) wiring harness and chassis Voltage Max. 1 V
and standard
ground
value in normal
state
35 – 45 z
controller
chassis ground
20-690 WA430-6
MODE)
WA430-6 20-691
MODE)
E-45. Lift arm always rises at full speed
Contents of
• Lift arm always rises at full speed.
trouble
• Since the lift arm raise EPC solenoid system is shorted with the power source, the lift arm raise EPC
Related
solenoid is turned ON.
information
(Code: 41900, RAISE EPC).

circuit) in wiring harness Between L73 (female) (6) – F20 (female) (6)
value in normal
state
2
9 – 10.2 z
20-692 WA430-6
MODE)
WA430-6 20-693
MODE)
E-46. Lift arm always lowers at full speed
Contents of
• Lift arm always lowers at full speed.
trouble
• Since the lift arm lower EPC solenoid system is shorted with the power source, the lift arm lower EPC
Related
information
• The output state (current) of the lift arm lower EPC solenoid can be checked with the monitoring function
(Code: 41901, LOWER EPC).

Possible causes circuit) in wiring harness Between L73 (female) (16) – F21 (female) (1)
Voltage Max. 1 V
value in normal
9 – 10.2 z
controller
(3)
20-694 WA430-6
MODE)
WA430-6 20-695
MODE)
E-47. Bucket always tilts at full speed
Contents of
• Bucket always tilts at full speed.
trouble
• Since the bucket tilt EPC solenoid system is shorted with the power source, the bucket tilt EPC solenoid
Related
is turned ON.
information
• The state (current) of the bucket tilt EPC solenoid can be checked with the monitoring function (Code:
41902, TILT EPC).

circuit) in wiring harness Between L73 (female) (5) – F22 (female) (1)
value in normal
state
2
9 – 10.2 z
20-696 WA430-6
MODE)
WA430-6 20-697
MODE)
E-48. Bucket always dumps at full speed
Contents of
• Bucket always dumps at full speed.
trouble
• Since the bucket dump EPC solenoid system is shorted with the power source, the bucket dump EPC
Related
information
tion (Code: 41903, DUMP EPC).

Voltage Max. 1 V
value in normal
9 – 10.2 z
controller
(3)
20-698 WA430-6
MODE)
WA430-6 20-699
MODE)
E-49. 3rd valve spool (extract) is extracted at full speed
Contents of
• 3rd valve spool (extract) is extracted at full speed.
trouble
• Since the 3rd valve (attachment) extract EPC solenoid is shorted with the power source, the 3rd valve
Related
(attachment) extract EPC solenoid is turned ON.
information

Voltage Max. 1 V
value in normal
9 – 10.2 z
controller
(13)
20-700 WA430-6
MODE)
WA430-6 20-701
MODE)
E-50. 3rd valve spool (retract) is retracted at full speed
Contents of
• 3rd valve spool (retract) is retracted at full speed.
trouble
• Since the 3rd valve (attachment) retract EPC solenoid is shorted with the power source, the 3rd valve
Related
(attachment) retract EPC solenoid is turned ON.
information

Voltage Max. 1 V
value in normal
9 – 10.2 z
controller
(13)
20-702 WA430-6
MODE)
WA430-6 20-703
MODE)
E-51. Bucket positioner, boom kick-out, and float holding system do not function
Contents of
• Bucket positioner, boom kick-out, and float holding system do not function.
trouble
Related • Since the power supply system of the bucket positioner, boom kick-out, and PPC detent is shorted with
information the chassis ground, the bucket positioner, boom kick-out, and float holding system do not function.

1

Between FS4 (female) (5) – L104 (female) (1),
(3), (6), (8), L27S (female) (1), F09 (female) (A),
or F10 (female) (A) wiring harness and chassis
ground
Possible causes Grounding fault in relay

and standard 3 sub-wiring harness (Con-
Wiring harness between L104 (female) (1), (2),
value in normal tact with ground circuit) Resistance Min. 1 Mz
(7), or (12) – chassis ground
state
Grounding fault in relay out turning starting switch.

4 (Contact with ground cir- L104 (male) Resistance
cuit) Wiring harness between (1), (2),
Min. 1 Mz
(6), or (7) – chassis ground
Grounding fault in proximity out turning starting switch.

5 switch (Contact with ground F09 (male), F10 (male) Resistance
circuit) Wiring harness between (A), (B), or
Min. 1 Mz
(C) – chassis ground
20-704 WA430-6
MODE)
Circuit diagram related to bucket positioner, boom kick-out, and PPC detent
WA430-6 20-705
MODE)
E-52. Boom kick-out does not function or cannot be reset
Contents of
• Boom kick-out does not function or cannot be reset.
trouble
Related • Since the boom kick-out proximity switch system, lift arm PPC detent system, or lift arm detent relay
information system is defective, the boom kick-out does not function or cannot be reset.

Defective fuse (2) or (5) of If the fuse is broken, the circuit probably has a grounding fault, short cir-
1
fuse box A cuit, etc. (See cause 6 and 7.)
200 – 400 z
Between (1) and (2)
Defective lift arm detent
2 relay (L123) (Internal
defect) bleshooting.
• Perform boom kick-out operation.
When lift arm detent relay (L123) is replaced with a relay of the same
type, if the condition becomes normal, the lift arm detent relay is defec-
tive.

Defective lift arm PPC
30 – 50 z
L26S (male) Resistance
3 detent (Internal disconnec-
Between (1) and (2)
Min. 1 Mz
and standard
value in normal bleshooting.
state • Replace boom kick-out proximity switch (F10) with bucket positioner
Defective boom kick-out proximity switch (F9).
4 proximity switch (Internal
Boom kick-out proximity switch
defect) Operation of boom kick-out
(F10)
Boom kick-out functions. Abnormal
Boom kick-out does not function. Normal
Resistance Max. 1 z
Wiring harness between FS4 (female) (5) – F10
(female) (A)
Resistance Max. 1 z
Disconnection in wiring har- F10 (female) (B)
Resistance Max. 1 z
5 Wiring harness between F10 (female) (C) and
chassis ground
Resistance Max. 1 z
nector)
L26S (female) (1)
Resistance Max. 1 z
Wiring harness between L26S (female) (2) and
chassis ground
• Boom kick-out does not function in any item.
20-706 WA430-6
MODE)

Between L104 (female) (2) – F10 (female) (2)
• In this case, boom kick-out detent function is Resistance Min. 1 Mz
not effective (Lever returns to neutral posi-
Grounding fault in wiring tion).
6 harness (Contact with Between L104 (female) (5) – L26S (female) (1)
ground circuit) wiring harness and chassis ground
• In this case, no detent functions (Lever re-
Possible causes turns to neutral position).
and standard Between FS4 (female) (5) – F10 (female) (A)
state • In this case, no detent functions (Lever re-
turns to neutral position).
Voltage Max. 1 V
Between L104 (female) (5) – L26S (female) (1)
Voltage Max. 1 V
• In this case, boom kick-out does not function.
(Lever does not return to neutral position)
WA430-6 20-707
MODE)
20-708 WA430-6
MODE)
E-53. Bucket positioner does not function or cannot be reset
Contents of
• Bucket positioner does not function or cannot be reset.
trouble
• Since the bucket positioner proximity switch system, bucket PPC detent system, or bucket detent relay
Related system is defective, the bucket positioner does not function or cannot be reset.
information • The input signal (ON/OFF) from the bucket positioner proximity switch can be checked with the moni-

1
fuse box A cuit, etc. (See cause 6 and 7.)
200 – 400 z
Between (1) and (2)
Defective bucket PPC
2 detent relay (Internal
defect) bleshooting.
• Operate the bucket positioner.
• When bucket detent relay (L124) is replaced with a relay of the same
type, if the condition becomes normal, the bucket detent relay is defec-
tive.

Defective bucket PPC
30 – 50 z
Between (1) and (2)
Min. 1 Mz
ground
Possible causes
and standard
bleshooting.
value in normal
• Replace bucket positioner proximity switch (F09) with boom kick-out
state
Defective bucket positioner proximity switch (F10).
4 proximity switch (Internal Bucket positioner proximity switch
Operation of bucket positioner
defect) (F09)
Bucket positioner functions. Abnormal
Bucket positioner does not
Normal
function.
Resistance Max. 1 z
Wiring harness between FS4 (female) (5) – F09
(female) (A)
Resistance Max. 1 z
Disconnection in wiring har- F09 (female) (B)
Resistance Max. 1 z
5 Wiring harness between F09 (female) (C) and
chassis ground
Resistance Max. 1 z
nector)
L25S (female) (1)
Resistance Max. 1 z
Wiring harness between L25S (female) (2) and
chassis ground
• Bucket positioner does not function in any item.
WA430-6 20-709
MODE)

• In this case, bucket positioner function is not Resistance Min. 1 Mz
effective (Lever does not return to neutral po-
Grounding fault in wiring sition).
6 harness (Contact with Between L104 (female) (9) – L25S (female) (1)
Possible causes • In this case, no detent functions (Lever re-
and standard turns to neutral position).
value in normal Between FS4 (female) (5) – F09 (female) (A)
• In this case, no detent functions (Lever re-
turns to neutral position).
circuit) in wiring harness Between L104 (female) (9) – L25S (female) (1)
Voltage Max. 1 V
• In this case, bucket positioner does not func-
tion (Lever does not return to neutral position).
20-710 WA430-6
MODE)
WA430-6 20-711
MODE)
E-54. Lift arm float holding system does not function or cannot be reset
Contents of
• Lift arm float holding system does not function or cannot be reset.
trouble
• Since the lift arm float PPC detent system is defective, the lift arm float system does not function or can-
Related not be reset.
information • The output state (ON/OFF) to the lift arm float PPC detent can be checked with the monitoring function
(Code: 40916, SOL/0-2).

Defective lift arm float PPC
30 – 50 z
Between (1) and (2)
Possible causes tion)
and standard Min. 1 Mz
ground
value in normal
state
Resistance Max. 1 z
ness (Disconnection or Wiring harness between FS4 (female) (9) –
2
defective contact of con- L27S (female) (1)
Resistance Max. 1 z
nector) Wiring harness between L27S (female) (2) and
chassis ground
20-712 WA430-6
MODE)
WA430-6 20-713
MODE)
E-55. When parking brake is turned ON, parking brake indicator lamp does not light up
Contents of
• When parking brake is turned ON, parking brake indicator lamp does not light up.
trouble
• The parking brake indicator switch circuit is shorted or shorted with the chassis ground.
• When the parking brake switch is operated, the parking brake operation sensor circuit is CLOSED.
• The parking brake does not work.
Related
• The input signal (ON/OFF) from the parking brake indicator switch can be checked with the monitoring
information
• The input signal (ON/OFF) (neutralizer signal) from the parking brake switch can be checked with the
1 Defective parking brake Check the parking brake directly (See Testing and adjusting).

Parking brake oil
pressure
Max. 1 z
Defective parking brake
Min. 0.6 MPa
2 indicator switch (Internal
{6.1 kg/cm2}
Max. 0.34 MPa
Min. 1 Mz
{3.5 kg/cm2}
Constant Min. 1 Mz
chassis ground
Resistance Max. 1 z
(female) (1)
ground circuit)
Between T08 (female) (1) – JT3 (female) (6) wir-

and standard
Max. 1 z
L01 (male) Parking brake switch Resistance
value in normal ON
state Defective parking brake Between (1) and (3)
OFF Min. 1 Mz
4 switch (Internal short cir-
Max. 1 z
cuit) ON Min. 1 Mz
Between (2) and (3)
OFF
Between (1), (2) or (3)
Constant Min. 1 Mz
and chassis ground

Defective parking brake
10 – 40 z
T08 Resistance
Max. 1 z
Between (male) (1) and (2)
cuit)
Between (female) (2) and chassis ground
Between (male) (1) or (2) and chassis ground Min. 1 Mz

Defective emergency brake R51 (male) Brake oil pressure Resistance
Max. 1 z
6 pressure switch (Internal Min.4.41 MPa
short circuit) {45 kg/cm 2}
Between (1) and (2)
Max.4.41 MPa
Min. 1 Mz
{45 kg/cm 2}
20-714 WA430-6
MODE)
bleshooting.
Possible causes
Parking brake oil
and standard L54 (female) Voltage
pressure
value in normal 7 Defective machine monitor
state Min. 0.6 MPa
Max. 1 V
Between (1) and {6.1 kg/cm2}
20 – 30 V
{3.5 kg/cm2}
WA430-6 20-715
MODE)
Circuit diagram related to parking brake indicator switch
20-716 WA430-6
MODE)
E-56. When emergency brake operates, brake oil pressure caution lamp does not
operate
Contents of
• When emergency brake operates, brake oil pressure caution lamp does not operate.
trouble
• The brake accumulator pressure switch circuit is shorted or shorted with the chassis ground.
• When the emergency brake operates, the accumulator pressure sensor circuit is CLOSED (and the
brake oil pressure is judged normal).
Related
• When the emergency brake operates or the brake oil pressure lowers, the brake oil pressure caution
information
lamp does not light up.
• The input signal (ON/OFF) from the brake accumulator pressure switch can be checked with the mon-
itoring function (Code: 40902, D-IN-16).
bleshooting.
R53 (male) Brake oil pressure Resistance
Max. 1 z
Defective brake accumula- Min. 5.88 MPa
1 tor pressure switch (Internal {60 kg/cm2}
Between (1) and (2)
short circuit) Max. 5.88 MPa
Min. 1 Mz
{60 kg/cm2}
Possible causes Constant Min. 1 Mz
chassis ground
and standard

L53 (female) Brake oil pressure Resistance
Max. 1 z
3 Defective machine monitor Min. 5.88 MPa
Wiring harness
{60 kg/cm2}
between (1) and
Max. 5.88 MPa
chassis ground Min. 1 Mz
{60 kg/cm2}
WA430-6 20-717
MODE)
Circuit diagram related to brake accumulator pressure switch
20-718 WA430-6
MODE)
E-57. Air cleaner clogging indicator lamp does not light up
Contents of
• Air cleaner clogging indicator lamp does not light up.
trouble
• The dust indicator circuit is abnormal.
• When the air cleaner is clogged, the sensor circuit is CLOSED (and the air cleaner is not judged
Related
clogged).
information
• The input signal (ON/OFF) from the dust indicator can be checked with the monitoring function (Code:
40902, D-IN-20).
1 Defective dust indicator Check the dust indicator visually.
Defective dust indicator out turning starting switch.

2 relay (Internal disconnec-
200 – 400 z
tion)
Between (1) and (2)

Resistance Max. 1 z
Possible causes
and standard 3
value in normal
Resistance Max. 1 z
nector) Wiring harness between L112 (female) (3) and
state
chassis ground
bleshooting.
L53 Dust indicator Voltage
4 Defective machine monitor Normal (Air cleaner is
20 – 30 V
Between (3) and not clogged)
chassis ground Defective (Air cleaner
Max. 1 V
is clogged)
WA430-6 20-719
MODE)
Circuit diagram related to dust indicator
20-720 WA430-6
MODE)
E-58. Engine oil pressure caution lamp does not light up
Contents of
• Engine oil pressure caution lamp does not light up.
trouble
• The engine oil level sensor circuit is shorted or shorted with the chassis ground.
Related • While the engine oil level is low, the engine oil level sensor circuit is CLOSED.
information • The input signal (ON/OFF) from the engine oil level sensor can be checked with the monitoring function
(Code: 40903, D-IN-29).

Defective engine oil level
Max. 1 z
E26 (male) Engine oil level Resistance
1 sensor (Internal short cir-
Oil level is normal
cuit) Between (1) and
Oil level is insufficient
chassis ground Min. 1 Mz
(low level)
Possible causes
state Between L54 (female) (11) – E26 (female) (1)
Max. 1 z
L54 (female) Engine oil level Resistance
Wiring harness Oil level is normal
between (11) and Oil level is insufficient
Min. 1 Mz
chassis ground (low level)
WA430-6 20-721
MODE)
Circuit diagram related to engine oil level sensor
20-722 WA430-6
MODE)
E-59. Radiator coolant level caution lamp does not light up
Contents of
• Radiator coolant level caution lamp does not light up.
trouble
• The coolant level sensor circuit is shorted or shorted with the chassis ground.
• When the radiator coolant level is low, the radiator coolant level caution lamp does not light up (the en-
Related
gine may be broken).
information
• The input signal (ON/OFF) from the coolant level sensor can be checked with the monitoring function
(Code: 40903, D-IN-27).

R32 (male) Sub-tank Resistance
Below LOW level
Defective coolant level sen- Min. 1 Mz
1 (Abnormal)
Max. 1 z
sor (Internal short circuit) Between (1) and (2)
Above LOW level
(Normal)
Possible causes Constant Min. 1 Mz
chassis ground
and standard

L54 (female) Sub-tank Resistance
3 Defective machine monitor Below LOW level
Wiring harness Min. 1 Mz
(Abnormal)
Max. 1 z
between (10) and
Above LOW level
chassis ground
(Normal)
WA430-6 20-723
MODE)
Circuit diagram related to radiator coolant level sensor
20-724 WA430-6
MODE)
E-60. Hydraulic oil temperature gauge does not rise and hydraulic oil temperature
caution lamp does not light up
Contents of • Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light
trouble up.
• The hydraulic oil temperature sensor circuit is disconnected.
• When the hydraulic oil temperature rises, the hydraulic oil temperature gauge does not rise.
Related • When the hydraulic oil temperature rises to 110°C, the hydraulic oil temperature caution lamp does not
information light up.
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
monitoring function (Code: 04401 HYD TEMP).

Defective hydraulic oil tem- Hydraulic oil
1 perature sensor (Internal temperature
defect) Normal temperature
35 – 50 kz
100°C 3.1 – 4.5 kz
Possible causes
state Wiring harness between L55 (female) (7) – R47
(female) (1)

Hydraulic oil
35 – 50 kz
between (7) and (25°C)
WA430-6 20-725
MODE)
20-726 WA430-6
MODE)
E-61. Torque converter oil temperature gauge does not rise and torque converter oil
temperature caution lamp does not light up
Contents of • Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp
trouble does not light up.
• The torque converter oil temperature sensor circuit is disconnected.
• When the torque converter oil temperature rises, the torque converter oil temperature gauge does not
rise.
Related
• When the torque converter oil temperature rises to 120°C, the torque converter oil temperature caution
information
lamp does not light up.
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked with
the monitoring function (Code: 40100, TC OIL TEMP).

Defective torque converter Torque converter oil
1 oil temperature sensor temperature
(Internal defect) Normal temperature
35 – 50 kz
100°C 3.1 – 4.5 kz
Possible causes
Resistance Max. 1 z
state Wiring harness between L55 (female) (2) – T10
ground circuit)
(female) (1)

35 – 50 kz
between (2) and (25°C)
WA430-6 20-727
MODE)
20-728 WA430-6
MODE)
E-62. Steering oil pressure caution lamp does not light up
Contents of
• Steering oil pressure caution lamp does not light up.
trouble
• The steering oil pressure sensor circuit is disconnected.
Related • While the steering oil pressure is normal, the steering oil pressure switch circuit is kept OPEN.
information • The input state (ON/OFF) from the steering oil pressure switch can be checked with the monitoring func-
tion (Code: 40904. D-IN-39).
bleshooting.
Max. 1 z
1 sure switch (Internal dis- Stopped
connection) Running Min. 1 Mz
Max. 1 z
Between (1) and (2)
Open to atmosphere
(Reference)
Possible causes
Resistance Max. 1 z
state Wiring harness between L54 (female) (16) –
ground circuit)
R36 (female) (2)
bleshooting.
Max. 1 z
L54 (female) Engine Resistance
3 Defective machine monitor Stopped
Wiring harness
Running Min. 1 Mz
Max. 1 z
between (16) and
chassis ground Open to atmosphere
(Reference)
WA430-6 20-729
MODE)
Circuit diagram related to steering oil pressure sensor
20-730 WA430-6
MODE)
E-63. Abnormality in t switch (panel switch 1) input
• Abnormality in t switch (panel switch 1) input

Contents of
The t switch (panel switch 1) circuit is disconnected or shorted with the chassis ground.
trouble
While the t switch (panel switch 1) is turned ON, the input circuit is kept OPEN (the switch is kept OFF).
•
•
Related
The input state (ON/OFF) from the t switch (panel switch 1) can be checked with the monitoring func-
• The operator cannot operate the monitor (cannot enter the service mode and monitoring function).
information
•
tion (Code: 40901. D-IN-15).

1
t switch (Panel switch 1)

Defective t switch (panel
Max. 1 z
2 switch 1) (Internal discon- ON
Between (2) and (3)
nection or short circuit) Other than above Min. 1 Mz
Constant Min. 1 Mz
chassis ground

Resistance Max. 1 z
Possible causes
ness (Disconnection or Between L52 (female) (17) – L07 (female) (3)
and standard 3
Resistance Max. 1 z
value in normal
nector) Wiring harness between L51 (female) (4) or (5)
state
– L07 (female) (2)

ground circuit)
Wiring harness between L51 (female) (4) or (5)
– L07 (female) (2)
t switch (Panel switch 1)

WA430-6 20-731
MODE)
Circuit diagram related to t switch (panel switch 1)
20-732 WA430-6
MODE)
E-64. Abnormality in U switch (panel switch 2) input
• Abnormality in U switch (panel switch 2) input

Contents of
• The U switch (panel switch 2) circuit is disconnected or shorted with the chassis ground.
trouble
• While the U switch (panel switch 2) is turned ON, the input circuit is kept OPEN (the switch is kept
Related OFF).
• The input state (ON/OFF) from the U switch (panel switch 2) can be checked with the monitoring func-
information • The operator cannot operate the monitor (cannot enter the monitoring function).
tion (Code: 40901. D-IN-14).

1
U switch (Panel switch 2)

Defective U switch (panel
Max. 1 z
2 switch 2) (Internal discon- ON
Between (2) and (1)
nection or short circuit) Other than above Min. 1 Mz
Constant Min. 1 Mz
chassis ground

Resistance Max. 1 z
Possible causes
ness (Disconnection or Between L52 (female) (18) – L07 (female) (1)
and standard 3
Resistance Max. 1 z
value in normal
nector) Wiring harness between L51 (female) (4) or (5)
state
– L07 (female) (2)

(female) (1)
ground circuit)
Wiring harness between L51 (female) (4) or (5)
– L07 (female) (2)
U switch (Panel switch 2)

Between (8) and chas- ON 20 – 30 V
sis ground Other than above Max. 1 V
WA430-6 20-733
MODE)
Circuit diagram related to U switch (panel switch 2)
20-734 WA430-6
MODE)
E-65. Abnormality in < switch (panel switch 3) input
Contents of
• Abnormality in < switch (panel switch 3) input
trouble
• The < switch (panel switch 3) circuit is disconnected or shorted with the chassis ground.
• While the < switch (panel switch 3) is turned ON, the input circuit is kept OPEN (the switch is kept OFF).
Related
information
• The input state (ON/OFF) from the < switch (panel switch 3) can be checked with the monitoring func-
tion (Code: 40904. D-IN-38).
Defective < switch (panel out turning starting switch.
Max. 1 z
1 switch 3) (Internal discon- L08 (female) < switch (Panel switch 3) Resistance
nection or short circuit) ON
Between (3) and (2)

Possible causes 2 harness (Contact with
and standard ground circuit) Resistance Min. 1 Mz
(female) (3)
value in normal
state Short circuit with power
4 Defective monitor panel L54 < switch (Panel switch 3) Voltage
WA430-6 20-735
MODE)
Circuit diagram related to < switch (panel switch 3)
20-736 WA430-6
MODE)
E-66. Abnormality in > switch (panel switch 4) input
Contents of
• Abnormality in > switch (panel switch 4) input
trouble
• The > switch (panel switch 4) circuit is disconnected or shorted with the chassis ground.
• While the > switch (panel switch 4) is turned ON, the input circuit is kept OPEN (the switch is kept OFF).
Related
information
• The input state (ON/OFF) from the > switch (panel switch 4) can be checked with the monitoring func-
tion (Code: 40904. D-IN-37).
Defective > switch (panel out turning starting switch.
Max. 1 z
1 switch 4) (Internal discon- L08 (female) > switch (Panel switch 4) Resistance
nection or short circuit) ON
Between (1) and (2)
Resistance Max. 1 z
Possible causes 2
and standard
nector)
(female) (1)
value in normal
state Short circuit with power
4 Defective monitor panel L54 > switch (Panel switch 4) Voltage
WA430-6 20-737
MODE)
Circuit diagram related to > switch (panel switch 4)
20-738 WA430-6
MODE)
E-67. Wiper does not operate
Contents of
(1) Front wiper does not operate.
trouble
Related
• Since the front wiper, switch timer, or wiring harness is defective, the front wiper does not operate.
information

1
C12 Wiper switch Voltage
Between (2) and
Lo 20 – 30 V
chassis ground
Defective front wiper motor
2 Between (1) and
(Internal defect) Hi 20 – 30 V
chassis ground
Between (6) and
– 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 Wiper switch Voltage
Possible causes Between (3) and
– 20 – 30 V
and standard chassis ground
value in normal Defective wiper timer Between (4) and
3 INT 20 – 30 V
state (relay) (Internal defect) chassis ground
Between (2) and
Washer side 20 – 30 V
chassis ground
Repeat 20 to 30 V o
INT (If wiper switch is
0 V o 20 to 30 V o 0 V
Between (5) and
set in INT, voltage is
chassis ground
output intermittently.)
L21 Voltage
Between (7) and chassis ground 20 – 30 V
Defective front wiper switch out turning starting switch.

4
Max. 1 z
(Internal defect) L21 Wiper switch Resistance
Max. 1 z
Between (7) and (5) Lo
Max. 1 z
Between (7) and (4) Hi
Max. 1 z
Between (7) and (2) INT
Between (3) and (5) INT
Other than above – Min. 1 Mz
WA430-6 20-739
MODE)
Resistance Max. 1 z
(female) (4)
Resistance Max. 1 z
Resistance Max. 1 z
ness (Disconnection or Wiring harness between L21 (female) (5) – C12
5
Resistance Max. 1 z
nector) Wiring harness between L21 (female) (4) – C12
(female) (1)
Resistance Max. 1 z
Wiring harness between L31 (female) (6) – C12
(female) (5)
Resistance Max. 1 z
Possible causes
Wiring harness between L21 (female) (7) – FS4
and standard
(female) (7)
value in normal
state
Between L21 (female) (5) – C12 (female) (2)
ground circuit)
Between L21 (female) (7) – FS4 (female) (7)
20-740 WA430-6
MODE)
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 Wiper switch Voltage
Between (2) and
Defective rear wiper motor Lo 20 – 30 V
1 chassis ground
(Internal defect)
Between (1) and
– 20 – 30 V
chassis ground
• If wiper switch is turned OFF while wiper is operating, voltage is applied
between C15 (3) and chassis ground until wiper motor stops.
L21 Voltage
Defective rear wiper switch aPrepare with starting switch OFF, then carry out troubleshooting with-
2
(Internal defect) out turning starting switch.
Max. 1 z
Possible causes L21 Wiper switch Resistance
and standard
Max. 1 z
value in normal Between (8) and (9) OFF
state
Resistance Max. 1 z
Disconnection in wiring har- Wiring harness between L21 (female) (8) – C15
Resistance Max. 1 z
3
defective contact of con- Wiring harness between L21 (female) (9) – C15
Resistance Max. 1 z
(female) (7)

WA430-6 20-741
MODE)
Contents of
(3) Side wiper does not operate.
trouble
Related
• Since the side wiper, switch, or wiring harness is defective, the side wiper does not operate.
information
C44 Side wiper switch Voltage
Between (1) and
Lo 20 – 30 V
Defective right side wiper chassis ground
1
motor (Internal defect) Between (4) and
– (Power) 20 – 30 V
chassis ground
• If side wiper switch is turned OFF while right side wiper is operating,
voltage is applied between C44 (2) and chassis ground until wiper mo-
tor stops.
C45 Side wiper switch Voltage
Between (1) and
Lo 20 – 30 V
Defective left side wiper chassis ground
2
motor (Internal defect) Between (3) and
– (Power) 20 – 30 V
chassis ground
• If side wiper switch is turned OFF while left side wiper is operating, volt-
age is applied between C45 (2) and chassis ground until wiper motor
stops.
Possible causes C43 Voltage
and standard Between (3) and chassis ground
20 – 30 V
value in normal (Power)
state Defective side wiper switch
3
(Internal defect)
Max. 1 z
C43 (female) Side wiper switch Resistance
Max. 1 z
Between (2) and (1) OFF
Resistance Max. 1 z
Disconnection in wiring har- Wiring harness between C43 (female) (2) – C44
ness (Disconnection or (female) (1) or C45 (female) (1)
Resistance Max. 1 z
4
defective contact of con- Wiring harness between C43 (female) (1) – C44
nector) (female) (2) or C45 (female) (2)
Resistance Max. 1 z
Wiring harness between C43 (female) (3) – FS4
(female) (7)

Between C43 (female) (2) – C44 (female) (1) or
C45 (female) (1) wiring harness and chassis Resistance Min. 1 Mz
Grounding fault in wiring ground
ground circuit) Between C43 (female) (1) – C44 (female) (2) or
ground
Between C43 (female) (3) – FS4 (female) (7)
20-742 WA430-6
MODE)
Circuit diagram related to wiper
WA430-6 20-743
MODE)
E-68. Windshield washer does not operate
Contents of
• Windshield washer does not operate.
trouble
• Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the wind-
Related shield washer does not operate.
information • Perform the following troubleshooting when the wiper operates normally. (If the wiper does not operate
normally, carry out troubleshooting for "E-67 Wiper does not operate" first.)
Defective front washer ry out troubleshooting.

1
motor (Internal defect) R43 Voltage
Defective rear washer ry out troubleshooting.

2
motor (Internal defect) R45 Voltage
L21 Voltage
Defective front wiper switch

3 out turning starting switch.
(Internal defect)
Max. 1 z
L21 (male) Washer switch Resistance
ON
Between (7) and (6)
OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground
Possible causes L21 Voltage
and standard
value in normal
state
Max. 1 z
L21 (male) Washer switch Resistance
ON
OFF Min. 1 Mz
Defective rear wiper switch
4 Between (7) or (10)
(Internal defect) Constant Min. 1 Mz
and chassis ground

Washer wiper low
switch
Max. 1 z
Between (7), (9) or (10)
ON
and chassis ground
Between (7), (9) or (10)
Constant Min. 1 Mz
and chassis ground

L31 (male) Washer switch Voltage
Between (3) and
Defective wiper timer Constant 20 – 30 V
5 chassis ground
(relay) (for only front wiper)
Between (2) and
ON 20 – 30 V
chassis ground
Between (5) and
0.2 – 0.8 sec after ON 20 – 30 V
chassis ground
20-744 WA430-6
MODE)
Resistance Max. 1 z
Wiring harness between L21 (female) (6) – R43
(female) (1)
Resistance Max. 1 z
Resistance Max. 1 z
6
Resistance Max. 1 z
R45 (female) (1)
Resistance Max. 1 z
Possible causes
and standard
(female) (7)
value in normal
state
WA430-6 20-745
MODE)
Circuit diagram related to windshield washer
20-746 WA430-6
MODE)
E-69. Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off
Contents of
(1) None of headlamp, clearance lamp, tail lamp, and license lamp does not light up.
trouble
• Since the lamp system main circuit is disconnected or shorted with the chassis ground, none of the
Related lamps lights up.
information • Headlamp at 1st position: Clearance lamp, tail lamp, license lamp, machine monitor night lamp light up.
• Headlamp at 2nd position: Above lamps and headlamp light up.

1

L02 (male) Headlamp switch Resistance
Max. 1 z
OFF Min. 1 Mz
Defective headlamp switch Between (1) and (5)
1st/2nd position
2 (Internal disconnection or
OFF Min. 1 Mz
Possible causes short circuit)
Max. 1 z
and standard Between (1) and (2) 1st position Min. 1 Mz
value in normal 2nd position
state Between (1), (2) or (5)
– Min. 1 Mz
and chassis ground
Resistance Max. 1 z
3
defective contact of con- Wiring harness between fuse B (11) – L160
nector)
(female) (3) or L02 (female) (1)

Between fuse B (11) – L160 (female) (3) or L02
WA430-6 20-747
MODE)
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.
Related
• Carry out the following troubleshooting when the clearance lamp, tail lamp, and license lamp light up
information
and go off normally.

Defective fuse (14) or (15) If the fuse is broken, the circuit probably has a grounding fault, short cir-
1
of fuse box B cuit, etc. (See cause 6.)
200 – 400 z
Defective headlamp relay
Between (1) and (2)
ry out troubleshooting
When headlamp relay (L160) is replaced with a relay of the same type, if
the condition becomes normal, the headlamp relay is defective.

Defective headlamp switch
OFF Min. 1 Mz
Max. 1 z
Between (1) and (2) 1st position Min. 1 Mz
short circuit)
2nd position
Constant Min. 1 Mz
chassis ground

and standard
Max. 1 z
L02 (male) Dimmer switch Resistance
value in normal Low
Defective dimmer switch
state Between (4) and (6)
4 (Internal disconnection or High Min. 1 Mz
short circuit)
Max. 1 z
Low Min. 1 Mz
Between (3) and (6)
High
Between (3), (4) or (6)
Constant Min. 1 Mz
and chassis ground
Resistance Max. 1 z
(female) (1)
Resistance Max. 1 z
chassis ground
Disconnection in wiring har- Wiring harness between FS4 (female) (11) – Resistance Max. 1 z
ness (Disconnection or L160 (female) (3)
Resistance Max. 1 z
5
nector) FS5 (female) (4)
Resistance Max. 1 z
right HEAD (female) (2)
Resistance Max. 1 z
left HEAD (female) (2)
Resistance Max. 1 z
chassis ground
20-748 WA430-6
MODE)

ground circuit)
Between FS5 (female) (5) – right HEAD
Possible causes
Between FS5 (female) (6) – left HEAD (female)
and standard Resistance Min. 1 Mz
value in normal
state
Voltage Max. 1 V
Between FS5 (female) (5) – right HEAD
Voltage Max. 1 V
Between FS5 (female) (6) – left HEAD (female)
Voltage Max. 1 V
Contents of
(3) Headlamp low beam does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low beams) is disconnected or shorted with the
Related
chassis ground.
information
• Carry out the following troubleshooting when the high beam lights up (goes off) normally.

If a specific headlamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Max. 1 z
Defective dimmer switch L02 (male) Dimmer switch Resistance
2 (Internal disconnection or Low
Between (4) and (6)
Possible causes short circuit) High Min. 1 Mz
value in normal Constant Min. 1 Mz
chassis ground
state
Resistance Max. 1 z
3
defective contact of con- Wiring harness between HEAD (1) and L02
nector)
(female) (4)

Between HEAD (1) – L02 (female) (4) wiring
harness and chassis ground
WA430-6 20-749
MODE)
Contents of
(4) Headlamp high beam does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (high beams) is disconnected or shorted with the
Related
chassis ground.
information
• Carry out the following troubleshooting when the low beam lights up (goes off) normally.

If a specific headlamp does not light up, its bulb may be broken or may
1 Broken bulb

Defective dimmer switch L02 (male) Dimmer switch Resistance
Max. 1 z
2 (Internal disconnection or Low Min. 1 Mz
Possible causes High
value in normal Constant Min. 1 Mz
chassis ground
state
Resistance Max. 1 z
3
defective contact of con- Wiring harness between HEAD (3) and L02
nector)
(female) (3)

Between HEAD (3) – L02 (female) (3) wiring
20-750 WA430-6
MODE)
(5) Clearance lamp does not light up or go off.

Contents of
(6) Tail lamp does not light up or go off.
trouble
(7) License lamp does not light up or go off.
Related • The switch, lamp, or wiring harness of the clearance lamp system is defective.
information • Carry out the following troubleshooting when the headlamp lights up.

If a specific lamp does not light up, its bulb may be broken or may have
1 Broken bulb
a defective contact. Check the bulb directly.
Defective fuse (12), (13), or If the fuse is broken, the circuit probably has a grounding fault, short cir-
2
(14) of fuse box B cuit, etc. (See cause 5.)

Defective headlamp switch
Max. 1 z
OFF Min. 1 Mz
Max. 1 z
short circuit) Between (1) and (5) 1st position
2nd position
Constant Min. 1 Mz
chassis ground
Resistance Max. 1 z
FS5 (female) (1)
COMBI (female) (1) or R34 (female) (1) or R30 Resistance Max. 1 z

Wiring harness between FS5 (female) (2) – right
(female) (4)
Resistance Max. 1 z
Wiring harness between FS5 (female) (3) – left
Disconnection in wiring har- COMBI (female) (1) or R31 (female) (4)
Resistance Max. 1 z
4 Wiring harness between right or left COMBI
(female) (2) – chassis ground
Resistance Max. 1 z
Possible causes nector)
Wiring harness between R31 (female) (6) and
and standard chassis ground
Resistance Max. 1 z
value in normal
state
chassis ground
Resistance Max. 1 z
chassis ground
Resistance Max. 1 z
Wiring harness between right and left COMBI
(female) (2) and chassis ground

Grounding fault in wiring Between FS5 (female) (2) – right COMBI
5 harness (Contact with (female) (1), R34 (female) (1), R30 (female) (4),
or circuit branch end wiring harness and chassis
ground
Between FS5 (female) (3) – left COMBI (female)
(1) or R31 (female) (4) wiring harness and chas- Resistance Min. 1 Mz
sis ground
Voltage Max. 1 V
Short circuit with power wiring harness and chassis ground
6 source (Contact with 24V Between FS5 (female) (2) – right COMBI
circuit) in wiring harness (female) (1), R34 (female) (1), or R30 (female) Voltage Max. 1 V
(4)
Between FS5 (female) (3) – left COMBI (female)
Voltage Max. 1 V
(1), or R31 (female) (4)
WA430-6 20-751
MODE)
Circuit diagram related to headlamp, clearance lamp, tail lamp, and license lamp
20-752 WA430-6
MODE)
E-70. Working lamp does not light up or go off
Contents of
(1) Either of front working lamp and rear working lamp does not light up
trouble
• The working lamp system power supply wiring harness is disconnected or shorted with the chassis
Related ground.
information • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance lamp
first.

1
fuse box A cuit, etc. (See cause 3.)
Resistance Max. 1 z
2
and standard defective contact of con- Wiring harness between FS5 (female) (2) – S01
(female) (3) or S02 (female) (3)
state
3 harness (Contact with Between FS5 (female) (2) – S01 (female) (3) or
ground
WA430-6 20-753
MODE)
Contents of
(2) Front working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the front working lamp system is defective
Related
• If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance lamp
information
first.

1
200 – 400 z
Defective front working L127 (male) Resistance
2 disconnection or short cir- aPrepare with starting switch OFF, then turn starting switch ON and car-
lamp relay (L127) (Internal Between (1) and (2)
cuit) ry out troubleshooting.

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.

Front working lamp
Defective front working S01 (male) Resistance
switch
3 lamp switch (Internal dis-
Max. 1 z
OFF Min. 1 Mz
connection or short circuit) Between (3) and (4)
ON
Constant Min. 1 Mz
chassis ground
Resistance Max. 1 z
Possible causes S01 (female) (3)
Resistance Max. 1 z
and standard Wiring harness between S01 (female) (4) and
value in normal
Resistance Max. 1 z
state
4
defective contact of con- chassis ground
Resistance Max. 1 z
nector) Wiring harness between FS3 (female) (7) and
L127 (female) (3)
Resistance Max. 1 z
C04 (female) (1) or C05 (female) (1)
Resistance Max. 1 z
Wiring harness between C04 (female) (2) or
C05 (female) (2) – chassis ground

Between S01 (female) (4) – L127 (female) (1)
Grounding fault in wiring wiring harness and chassis ground
5 harness (Contact with Between FS3 (female) (7) – L127 (female) (3)
Between L127 (female) (5) – C04 (female) (1) or
ground
Short circuit with power Between S01 (female) (4) – L127 (female) (1)
Voltage Max. 1 V
6 source (Contact with 24V wiring harness and chassis ground
circuit) in wiring harness Between L127 (female) (5) – C04 (female) (1) or
C05 (female) (1) wiring harness and chassis Voltage Max. 1 V
ground
20-754 WA430-6
MODE)
Contents of
(3) Rear working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the rear working lamp system is defective.
Related
• If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance lamp
information
first.

1
200 – 400 z
Defective rear working
disconnection or short cir- aPrepare with starting switch OFF, then turn starting switch ON and car-
Between (1) and (2)
lamp relay (L128) (Internal
2
cuit) ry out troubleshooting.
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.

Rear working lamp
Defective rear working S02 (male) Resistance
switch
3 lamp switch (Internal dis-
Max. 1 z
OFF Min. 1 Mz
connection or short circuit) Between (3) and (4)
ON
Constant Min. 1 Mz
chassis ground
Resistance Max. 1 z
Possible causes S02 (female) (3)
Resistance Max. 1 z
and standard Wiring harness between S02 (female) (4) and
value in normal
Resistance Max. 1 z
state
4
defective contact of con- chassis ground
Resistance Max. 1 z
nector) Wiring harness between FS3 (female) (8) and
L128 (female) (3)
Resistance Max. 1 z
G04 (female) (1) or G05 (female) (1)
Resistance Max. 1 z
Wiring harness between G04 (female) (2) or
G05 (female) (2) – chassis ground

Between S02 (female) (4) – L128 (female) (1)
Grounding fault in wiring wiring harness and chassis ground
5 harness (Contact with Between FS3 (female) (8) – L128 (female) (3)
Between L128 (female) (5) – G04 (female) (1) or
G05 (female) (1) wiring harness and chassis Resistance Min. 1 Mz
ground
Short circuit with power Between S02 (female) (4) – L128 (female) (1)
Voltage Max. 1 V
6 source (Contact with 24V wiring harness and chassis ground
circuit) in wiring harness Between L128 (female) (5) – G04 (female) (1) or
G05 (female) (1) wiring harness and chassis Voltage Max. 1 V
ground
WA430-6 20-755
MODE)
Circuit diagram related to working lamp
20-756 WA430-6
MODE)
E-71. Turn signal lamp and hazard lamp do not light up or go off
Contents of
(1) Either of turn signal lamp and hazard lamp does not light up or go off.
trouble
Related
• The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp is defective.
information

1
200 – 400 z
Defective turn signal and
nal disconnection or short aPrepare with starting switch OFF, then turn starting switch ON and car-
Between (1) and (2)
hazard relay (L111) (Inter-
2
circuit) ry out troubleshooting.
When turn signal and hazard relay (L111) is replaced with a relay of the
same type, if the condition becomes normal, the turn signal and hazard
relay is defective.
L111 (male) Voltage
Between (3) and (1) 20 – 30 V
Defective flasher unit (Inter- 20 – 30 V and 0 V are indicated
Between (4) and (1)
3 nal disconnection or short repeatedly.
circuit)
Min. 1 Mz
ground
Possible causes
and standard
Resistance Max. 1 z
state Wiring harness between FS3 (female) (2) and
L101 (female) (1) or (4)
Resistance Max. 1 z
Resistance Max. 1 z
4
Resistance Max. 1 z
chassis ground
Resistance Max. 1 z
(female) (2)

Between FS3 (female) (2) – L101 (female) (1) or
Voltage Max. 1 V
WA430-6 20-757
MODE)
Contents of
(2) Turn signal lamp does not light up or go off.
trouble
Related
• The switch, lamp, or wiring harness of the turn signal lamp system is defective.
information

If a specific turn signal lamp does not light up, its bulb may be broken or
1 Broken bulb
may have a defective contact. Check the bulb directly.

L03 (male) Turn signal lever Resistance
Max. 1 z
Neutral Min. 1 Mz
Defective turn signal lever Between (2) and (3) Right
2 switch (Internal disconnec- Left Min. 1 Mz
tion or short circuit) Neutral Min. 1 Mz
Max. 1 z
Between (2) and (4) Right Min. 1 Mz
Left
Between (2), (3) or (4)
Constant Min. 1 Mz
and chassis ground
Resistance Max. 1 z
Wiring harness between L03 (female) (3) – R31
(female) (1) or right COMBI (female) (3)
Resistance Max. 1 z
Disconnection in wiring har- Wiring harness between L03 (female) (4) – R30
Possible causes (female) (1) or left COMBI (female) (3)
Resistance Max. 1 z
and standard 3
defective contact of con- Wiring harness between R31 (female) (6) and
value in normal
nector) chassis ground
state
Resistance Max. 1 z
chassis ground
Resistance Max. 1 z
Wiring harness between right and left COMBI
(female) (3) and chassis ground

Between L03 (female) (3) – R31 (female) (1) or
right COMBI (female) (3) wiring harness and Resistance Min. 1 Mz
chassis ground
ground circuit)
left COMBI (female) (3) wiring harness and Resistance Min. 1 Mz
chassis ground
right COMBI (female) (3) wiring harness and Voltage Max. 1 V
chassis ground
left COMBI (female) (3) wiring harness and Voltage Max. 1 V
chassis ground
20-758 WA430-6
MODE)
Contents of
(3) Hazard lamp does not light up or go off.
trouble
Related • The switch or lamp of the hazard lamp system is defective.
information • Carry out the following troubleshooting when the turn signal lamp flashes normally.
Max. 1 z
and standard Defective hazard lamp L03 (male) Hazard lamp switch Resistance
value in normal 1 switch (Internal disconnec- Between (2) and (3) or ON
state tion or short circuit) (4) OFF Min. 1 Mz
Between (2), (3), or (4)
Constant Min. 1 Mz
and chassis ground
WA430-6 20-759
MODE)
Circuit diagram related to turn signal lamp and hazard lamp
20-760 WA430-6
MODE)
E-72. Brake lamp does not light or it keeps lighting up
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 may
1 Broken bulb
2
200 – 400 z
Defective stop lamp relay
Between (1) and (2)
When stop lamp relay (L118) is replaced with a relay of the same type, if
the condition becomes normal, the stop lamp relay is defective.
Max. 1 z
Defective stop lamp switch L09 (male) Brake pedal Resistance
4 (Internal disconnection or Pressed
Between (1) and (2)
short circuit) Released Min. 1 Mz
Constant Min. 1 Mz
chassis ground
Possible causes
or L09 (female) (1) wiring harness and chassis Resistance Max. 1 z

value in normal Between FS4 (female) (10) – L118 (female) (3)
state
ground
Resistance Max. 1 z
Disconnection in wiring har- R30 (female) (5) or R31 (female) (5)
Resistance Max. 1 z
5 Wiring harness between L09 (female) (2) and
L118 (female) (1)
Resistance Max. 1 z
nector)
chassis ground
Resistance Max. 1 z
chassis ground
Resistance Max. 1 z
chassis ground

L09 (female) (1), or circuit branch end wiring Resistance Min. 1 Mz
ground circuit)
R31 (female) (5) wiring harness and chassis Resistance Min. 1 Mz
ground
WA430-6 20-761
MODE)

and standard Short circuit with power Between L118 (female) (5) – R30 (female) (5) or
value in normal 7 source (Contact with 24V R31 (female) (5) wiring harness and chassis Voltage Max. 1 V
state circuit) in wiring harness ground
Voltage Max. 1 V
20-762 WA430-6
MODE)
Circuit diagram related to brake lamp
WA430-6 20-763
MODE)
E-73. Backup lamp does not light or it keeps lighting up
Contents of
• Backup lamp does not light or it keeps lighting up.
trouble
Related • The transmission controller monitors the primary circuit of the backup lamp relay for a trouble. (If dis-
information connection or short circuit occurs, failure code D160KA or D160KB is displayed.)

If a specific backup lamp does not light up, its bulb may be broken or may
1 Broken bulb
2
200 – 400 z
Defective backup lamp
connection or short circuit) aPrepare with starting switch OFF, then turn starting switch ON and car-
Between (1) and (2)
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.
Resistance Max. 1 z
Between FS4 (female) (10) – L117 (female) (3)
Disconnection in wiring har- wiring harness and chassis ground
Resistance Max. 1 z
4
Possible causes defective contact of con- R30 (female) (2) or R31 (female) (2)
Resistance Max. 1 z
and standard nector) Wiring harness between R30 (female) (6) and
value in normal chassis ground
Resistance Max. 1 z
state
chassis ground

or circuit branch end wiring harness and chassis Resistance Min. 1 Mz
ground
Between L117 (female) (5) – R30 (female) (2),
R31 (female) (2), or CN 55 (female) (1) wiring Resistance Min. 1 Mz
ground circuit)
Between R30 (female) (6) – chassis ground wir-
Between R31 (female) (6) – chassis ground wir-

6 source (Contact with 24V Between L117 (female) (5) – R30 (female) (2) or
circuit) in wiring harness R31 (female) (2) wiring harness and chassis Voltage Max. 1 V
ground
20-764 WA430-6
MODE)
Circuit diagram related to backup lamp
WA430-6 20-765
MODE)
E-74. Backup buzzer does not sound or it keeps sounding
Contents of
• Backup buzzer does not sound or it keeps sounding.
trouble
Related • The transmission controller monitors the primary circuit of the backup lamp relay for a trouble. (If dis-
information connection or short circuit occurs, failure code D160KA or D160KB is displayed.)
Defective backup buzzer ry out troubleshooting.

1 (Internal disconnection or CN55 Gearshift lever Voltage
short circuit) R Max. 1 V
Between (1) and (2)
Other than R 20 – 30 V
200 – 400 z
Defective backup lamp
aPrepare
Between (1) and (2)
connection or short circuit) with starting switch OFF, then turn starting switch ON and car-
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.
Resistance Max. 1 z
and standard Disconnection in wiring har- Between FS4 (female) (10) – L117 (female) (3)
value in normal ness (Disconnection or wiring harness and chassis ground
Resistance Max. 1 z
3
nector) CN55 (female) (1)
Resistance Max. 1 z
Wiring harness between CN55 (female) (2) and
chassis ground

Between FS4 (female) (10) – L117 (female) (3)
or circuit branch end wiring harness and chassis Resistance Min. 1 Mz
ground
ground circuit)
Between L117 (female) (5) – CN55 (female) (1),
R30 (female) (2), or R31 (female) (2) wiring har- Resistance Min. 1 Mz

5 source (Contact with 24V Between L117 (female) (5) – CN55 (female) (1),
circuit) in wiring harness R30 (female) (2), or R31 (female) (2) wiring har- Voltage Max. 1 V
20-766 WA430-6
MODE)
Circuit diagram related to backup buzzer
WA430-6 20-767
MODE)
E-75. While FNR lever is not in R position, backup buzzer keeps sounding
Contents of
• While FNR lever is not in R position, backup buzzer keeps sounding
trouble
Related
• The backup lamp relay output system is shorted with the power source.
information

value in normal
200 – 400 z
troller
chassis ground
20-768 WA430-6
MODE)
WA430-6 20-769
MODE)
E-76. Horn does not sound or it keeps sounding
Contents of
• Horn does not sound or it keeps sounding.
trouble
Related
• The relay, switch, horn, or wiring harness of the horn system is abnormal.
information

1
200 – 400 z
Defective horn relay (L119)
Between (1) and (2)
short circuit)
When horn relay (L119) is replaced with a relay of the same type, if the
condition becomes normal, the horn relay is defective.
Defective horn switch out turning starting switch.
Max. 1 z
3 (Internal disconnection or Horn switch terminal Horn switch Resistance
short circuit) Between terminal and ON
chassis ground
OFF Min. 1 Mz

Defective joystick horn
Max. 1 z
L37 (male) Horn switch Resistance
switch (if equipped) (Inter-
4 ON
nal disconnection or short Between (9) and (10)
Possible causes Between (9) or (10)
and standard Constant Min. 1 Mz
and chassis ground
value in normal
state ry out troubleshooting. (Disconnect connector and measure on female
side)
F03, F04, F05, F06
Defective horn (Internal dis- Horn switch Voltage
5 (female)
ON 20 – 30 V
Between F03 and F04
OFF Max. 1 V
ON 20 – 30 V
Between F05 and F06
OFF Max. 1 V
Resistance Max. 1 z
Wiring harness between FS4 (female) (1) –
L119 (female) (1) or (3)
Resistance Max. 1 z
Disconnection in wiring har- (female) (1) or L37 (female) (9)
Resistance Max. 1 z
6
defective contact of con- (female) or F04 (female)
Resistance Max. 1 z
nector) Wiring harness between horn switch terminal
and chassis ground
Resistance Max. 1 z
chassis ground
Resistance Max. 1 z
Wiring harness between F04 (female) or F06
(female) – chassis ground
20-770 WA430-6
MODE)

Between FS4 (female) (1) – L119 (female) (1) or
Grounding fault in wiring (3) wiring harness and chassis ground
Possible causes 7 harness (Contact with Between L119 (female) (2) – L05 (female) (1) or
and standard ground circuit) L37 (female) (9) wiring harness and chassis Resistance Min. 1 Mz
value in normal ground
state Between L119 (female) (5) – F03 (female) or
F04 (female) wiring harness and chassis ground

circuit) in wiring harness Between L119 (female) (5) – F03 (female) or
Voltage Max. 1 V
F04 (female) wiring harness and chassis ground
WA430-6 20-771
MODE)
Circuit diagram related to horn
20-772 WA430-6
MODE)
E-77. Warning buzzer does not sound or it keeps sounding
Contents of
• Warning buzzer does not sound or it keeps sounding
trouble
Related
• The warning buzzer output circuit is disconnected or shorted with the chassis ground.
information

1
Defective warning buzzer • Check 5 seconds after starting switch is turned ON.
2
(Internal short circuit) L20 (female) Warning buzzer Normal/Defective
Sounds Buzzer is normal.
Ground (2).
Does not sound. Buzzer is defective.

Resistance Max. 1 z
3
Resistance Max. 1 z
nector) Wiring harness between FS3 (female) (9) – L20
(female) (1)
Possible causes
and standard
Resistance Max. 1 z
state Grounding fault in wiring Between L51 (female) (14) – L20 (female) (2)
4 harness (Contact with wiring harness and chassis ground
(7), or L20 (female) (1) wiring harness and chas- Resistance Max. 1 z
ground circuit) Between FS3 (female) (9) – L51 (female) (6),
sis ground
L51 Starting switch Voltage
ON 20 – 30 V
For 2 sec after ON
5 Defective machine monitor (Warning buzzer does Max. 1 V
Between (14) and not sound)
chassis ground For 3 sec from 2 sec
after ON
17 – 30 V
(Warning buzzer
sounds)
WA430-6 20-773
MODE)
Circuit diagram related to warning buzzer
20-774 WA430-6
MODE)
E-78 Air conditioner does not operate or stop
Contents of
Air conditioner does not operate or stop.
trouble
Related • The following is troubleshooting for only the section between the air conditioner and operator's cab.
information For troubleshooting for the air conditioner unit, see the Shop Manual for the air conditioner.

Defective fuse (14) or (15) If the fuse is broken, the circuit probably has a grounding fault, etc.
1
of fuse box B (See cause 2.)

• When fuse (14) of fuse box B is broken
Between FS3 (female) (15) – A7 (female) (2)
• If fuse (14) of fuse box B is broken while the above troubleshooting re-
sult is normal, relay A7 or blower motor and its connecting wiring har-
ness are defective.
2 harness (Contact with out turning starting switch.
ground circuit) • When fuse (15) of fuse box B is broken
Between FS3 (female) (16) – C48 (female) (3) –
Possible causes A7 (female) (1) – A8 (female) (1) – A9 (female)
and standard (1) – A10 (female) (1) – A11 (female) (1)/(2) – Resistance Min. 1 Mz
value in normal A14 (female) (1)/(2) wiring harness and chassis
state ground
• If fuse (15) of fuse box B is broken while the above troubleshooting re-
sult is normal, each relay or air conditioner control amplifier and its con-
necting wiring harness are defective.
Disconnection or grounding Wiring harness Starting switch Voltage
fault in air conditioner con- between C48 (female) ON 20 – 30 V
trol amplifier power supply (3) – C47 (female) (19)
OFF Max. 1 V
3 or ground wire harness
Resistance Max. 1 z
contact of connector or con- Wiring harness between C48 (female) (3) – C47
tact with ground circuit) (female) (19)
Resistance Max. 1 z
Wiring harness between C47 (female) (19) –
chassis ground
WA430-6 20-775
MODE)
aPrepare with starting switch OFF, then hold starting switch OFF and
ON and carry out troubleshooting in each case.

Relay Starting switch Voltage
Wiring harness ON 20 – 30 V
between A7 (female)
(1) – chassis ground OFF Max. 1 V
between A8 (female)
(1) – (4) OFF Max. 1 V
between A9 (female)
OFF Max. 1 V
(1) – (4)
between A10 (female)
Disconnection or grounding OFF Max. 1 V
(1) – (4)
fault in relay power supply
wiring harness (Disconnec-
Possible causes 4 between A11 (female)
tion or defective contact of OFF Max. 1 V
and standard (1)/(2) – chassis ground
connector or contact with
value in normal ground circuit) Wiring harness ON 20 – 30 V
state between A14 (female)
OFF Max. 1 V
(1)/(2) – chassis ground

Wiring harness between A7 (female) (1) – A8
Resistance Max. 1 z
(female) (1) – A9 (female) (1) – A10 (female) (1)
– A11 (female) (1)/(2) – A14 (female) (1)/(2) –
FS3 (female) (16)
Between A8 (female) (4) – A9 (female) (4) – A10
Resistance Max. 1 z
(female) (4) – A12 (female) (3)/(4) – A13
(female) (3)/(4) wiring harness and chassis
ground
If the above troubleshooting result is normal, each relay and its connect-
ing wiring harness are defective.
Disconnection in condenser
GND wiring harness (Dis- out turning starting switch.
Resistance Max. 1 z
5
connection or defective Between B01 (female) (C) – B02 (female) (C) –
contact of connector) chassis ground
20-776 WA430-6
MODE)
Circuit diagram related to air conditioner
WA430-6 20-777
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
Method of using troubleshooting chart

This troubleshooting chart determines the location from the problem of 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.
20-778 WA430-6
Step 1. Ask operator questions

The questions to ask the operator are given
under the problem. If the answer to the question
matches the content given, the cause given after
the arrow is the probable cause.
Keeping the content of the questions in mind,
read the matrix and proceed with Step 2 and
Step 3 to pinpoint the correct cause.
Example: Steering wheel will not turn

Ask the operator and check the following points.
o Broken part in steering equipment

• Did the problem suddenly start?
o Internal wear, defective seal in steering

• Was the steering wheel heavy before?
related equipment
WA430-6 20-779
Step 2. Checks before troubleshooting

Before measuring the oil pressure or starting the
troubleshooting, confirm the checks before start-
ing items, check for leakage of oil, or for loose
bolts.
This will prevent wasting time when trouble-
shooting.
The items given under Checks before trouble-
shooting are checks that are particularly impor-
tant to make about the condition of the machine
before starting the actual troubleshooting.
Example: Checks before starting troubleshooting

• Is oil level and type of oil in hydraulic tank
correct?
• Is there any oil leakage from steering valve
or demand valve?
• Is steering linkage adjusted properly?
20-780 WA430-6
Step 3. Method of reading matrix

1) Operate the machine when carrying out <Example 1>
troubleshooting of the items in the Diagnosis Remedy
column. If any problems occur as the result No.
Diagnosis
of the troubleshooting, put a check against Steering wheel does not turn in either direction
a When carrying out the troubleshooting,

the item. 1
(left and right)
In Item 1, movement of work equipment is
check the easier items first. It is not nec- 2
abnormal
essary to follow the number order.
Steering wheel turns only in one direction
3
(left or right)
4 Steering wheel is heavy and does not turn
5 Steering circuit oil pressure does not rise at all
2) Find the matching cause in the Cause col-
If a problem is found, the Q marks on the

umn.
same line as the troubleshooting are the

causes. (In Diagnosis item 2 in the same
When there is one Q mark:

diagram below the cause is c or e.)
marked with Q in the same Cause column to

Carry out troubleshooting for the other items
check if the problem occurs, then make
When there are two Q marks:

repairs.
Go to Step 3) to narrow down the cause.
<Example 2>
WA430-6 20-781
3) Operate the machine and carry out trouble-

shooting of the items not checked in Step 1). 6) Repeat the operation in Steps 3), 4), and 5)
Operate the machine in the same way as in until the cause is narrowed down to 1 item
a If cause items are 2 or more, continue

Step 1), and if any problem occurs, put a (1 common item).
check against the item. (In Troubleshooting
item 5 in the diagram below, the problem until number of items becomes mini-
was re-enacted.) mum.
4) Find the matching cause in the cause col-
umn. 7) Remedy
is found, the Q marks on the same line for

In the same way as in Step 2), if a problem After narrowing down the common causes,
X: Replace E: Repair A: Adjust C: Clean

taken the action given in the remedy line.
the troubleshooting item are the causes. (In
Diagnosis 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
a The items that are not common (items

Step 3).
that do not have Q marks in the same

cause common as each other) are prob-
ably not the cause, so they can be elim-
inated.
(The causes for Diagnosis item 2 in the
dia gra m be lo w a re c o r e , a nd the
causes in Diagnosis item 5 are b or e,
so Cause e is the common cause.)
20-782 WA430-6
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
Table of failure modes and causes

Part that can cause failure
Torque converter charging pump
Transmission controller system

Transmission main relief valve
Torque converter relief valve
Torque converter oil cooler
Inside of transmission
Clutch piston seal

Torque converter
Last chance filter
Clutch shaft seal

Clutch piston
Clutch disc
Engine
ECMV
PTO
Failure mode
Machine does not start Q Q Q Q Q Q Q Q Q Q Q

Travel speed is low, rush force is low, gradeability is low, and gear speed does not change Q Q Q Q Q Q Q Q Q Q Q
Power train
Large shocks are made when machine starts and gear is shifted Q Q Q Q Q Q Q Q
Large time lag is made when machine starts and gear is shifted Q Q Q Q Q Q
Torque converter oil temperature is high Q Q Q Q Q Q
Machine cannot be steered Q
Machine cannot be steered [Joystick steering] Q
Q
Steering
Responsibility of steering system is low

Steering wheel is heavy
Steering wheel shakes or makes large shocks
Brake does not work at all or sufficiently
Brake
Brake cannot be reset or it drags

Parking brake cannot be reset or it drags Q
Lift arm does not rise Q
Speed or rising force of lift arm is insufficient
Rising speed of lift arm lowers at certain height
Bucket cannot be held with lift arm cylinder (Bucket floats)
Hydraulic drift of lift arm is large
Lift arm shakes during work
Q
Work equipment
Bucket does not tilt back

Speed or tilt-back force of bucket is insufficient
Speed of bucket lowers 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 are heavy
Engine speed lowers remarkably or engine stalls Q
Large shocks are made when work equipment starts and stops
When work equipment circuit is relieved singly, other work equipment moves
WA430-6 20-783
Q
Q
Transmission breather
Q
Q
Transmission oil temperature sensor
Q
Q
Hydraulic pump shaft seal of work equipment and steering system
20-784
Q
Q
Steering pump
Steering pump servo
Q Q Q
Q
Q
Q
Q
Q
Fan pump (Which is used as PPC pump, too)
Orbit-roll valve
Q Q Q
Q Q Q
Q Q Q
Steering stop valve
TROUBLESHOOTING
Steering main relief valve

Flow control spool of steering valve
Q
Steering spool of steering valve
Overload relief valve of steering valve
Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q Q
Q Q Q Q
Steering cylinder piston seal
Clogging of joystick line filter
Q Q Q Q Q Q
Joystick EPC valve
Q
Steering wheel or steering shaft
Brake piston seal in axle
Q
Brake piston in axle
Brake in axle
Q
Brake lining in axle
Air in brake circuit
Q
Brake valve
Accumulator piston seal
Q
Q
Q
Q
Q Q Q Q Q Q Q Q
Q
Q
Q
Q
Q
Accumulator charge valve
Q
Q
Parking brake solenoid valve
Q Q
Parking brake piston
Q
Q
Q
Q
Parking brake piston seal

Parking brake disc
Q Q
Parking brake switch line wiring harness
Q
Q
PPC valve
Work equipment pump
Q Q
Q Q Q
Q Q Q
Q Q Q
Work equipment pump servo
Work equipment valve body
Q
Q
Work equipment main relief valve
Q Q
Work equipment unload valve
Q Q Q
Lift arm pressure compensation valve
Bucket pressure compensation valve
Troubleshooting No.
TABLE OF FAILURE MODES AND CAUSES
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
Q Q Q Q H-21
Q H-20
H-19
H-18
H-17
H-16
Q Q Q Q Q Q Q Q H-15
H-14
H-13
H-12
H-11
H-10
WA430-6
Safety-suction valve on bucket bottom side of work equipment valve

Part that can cause failure
Safety-suction valve on bucket head side of work equipment valve

Suction valve on lift arm bottom side of work equipment valve
Suction valve on lift arm head side of work equipment valve
Back pressure valve of work equipment valve
Lift arm spool of work equipment valve
Bucket spool of work equipment valve
Lift arm cylinder piston seal

Bucket cylinder piston seal
Troubleshooting No.
ECSS charge valve
Lift arm cylinder
Bucket cylinder
Bypass valve
Failure mode
Machine does not start H-1

Power train
Travel speed is low, rush force is low, gradeability is low, and gear speed does not change H-2
Large shocks are made when machine starts and gear is shifted H-3
Large time lag is made when machine starts and gear is shifted H-4
Torque converter oil temperature is high H-5
Machine cannot be steered H-6
Machine cannot be steered [Joystick steering] H-7
Steering
Responsibility of steering system is low H-8

Steering wheel is heavy H-9
Steering wheel shakes or makes large shocks H-10
Brake does not work at all or sufficiently H-11
Brake
Brake cannot be reset or it drags H-12

Parking brake cannot be reset or it drags H-13
Lift arm does not rise Q Q Q Q H-14
Speed or rising force of lift arm is insufficient Q Q Q Q Q H-15
Rising speed of lift arm lowers at certain height Q H-16
Bucket cannot be held with lift arm cylinder (Bucket floats) Q Q Q H-17
Hydraulic drift of lift arm is large Q Q Q Q H-18
Lift arm shakes during work Q Q Q Q Q H-19
Q Q Q
Work equipment
Bucket does not tilt back H-20

Speed or tilt-back force of bucket is insufficient Q Q Q Q Q H-21
Speed of bucket lowers during tilt-back operation Q H-22
Bucket cannot be held with bucket cylinder Q Q H-23
Hydraulic drift of bucket is large Q Q Q Q H-24
Bucket shakes during travel with load (Work equipment valve is in HOLD) Q Q H-25
Lift arm and bucket control levers do not move smoothly and are heavy H-26
Engine speed lowers remarkably or engine stalls H-27
Large shocks are made when work equipment starts and stops Q Q H-28
When work equipment circuit is relieved singly, other work equipment moves Q Q H-29
WA430-6 20-785
H-1 The machine does not start
Ask the operator about the following: Cause
o Seizure of clutch, breakage of parts

• Has the machine come not to start suddenly? Torque
Torque Main
E
Park-
converter C
con- relief Transmission ing
charging M
Did the machine cause any abnormal noise at the time pump
verter valve
V
brake
and where?
a b c d e f g h i j k l m n o
Inspection before diagnosis
Defective operation of parking brake solenoid valve

Defective operation of torque converter relief valve
• Does the machine monitor function normally?
• Has the machine monitor displayed any failure code of
The relevant clutch piston seal is defective

the electrical system?
The parking brake piston seal is defective

The relevant clutch shaft seal is defective
• Did you smell deteriorated or burnt transmission oil?
Defective operation of relevant ECMV

Set pressure drop of main relief valve
Internal breakage of torque converter
• Have the transmission filter and strainer been clogged?
Internal breakage of transmission

War or seizure of relevant clutch
The charging pump is defective
• Can you find any damage or oil leak from the appear-
Clogging of last chance filter

ance?
Air intake on suction side

• Has the drive shaft been broken?
The PTO is defective

• Have the wheel brake and the parking brake been
Clogging of strainer
locked?
Remedy E E E E E E E
No. X X *1 *1 *1 X X X
Diagnosis X C 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
2 The machine does not start at specific gear speeds Q Q Q Q Q
Q Q
When the transmission oil temperature is low, the charging pump or the
3
transmission filter causes abnormal noise(s)
4 When the transmission oil temperature rises, the machine comes not to start Q Q Q Q
Q Q Q
Metal (Aluminum, copper, iron, etc.) powders are adhered to the transmission
5
filter or the strainer
6 When the stall speed The speed is higher at all gear speeds Q Q Q Q Q Q Q Q
Q Q Q Q Q
of the torque converter
7 is measured The speed is higher at specific gear speeds
8 The oil pressure is low at all gear speeds Q Q Q Q Q Q Q

Q Q Q Q
When the ECMV
9 The oil pressure is low at specific gear speeds
output (Clutch) oil
Q Q
pressure is measured The oil pressure does not become stable as the
10
gauge fluctuates
Q Q Q Q Q Q
When the torque converter relief (Inlet) oil pressure is measured, the oil
11
pressure is low
*1: Proceed to the paragraph of "Defective clutch and ECMV specifying method (Check by failure code)."
20-786 WA430-6
Defective clutch and ECMV specifying method (Check by failure code)
a For the checking method of failure code display, see the para-
a When replacing the ECMV for diagnosis, remove mud and dust
graph of "Special functions of machine monitor."
around the ECMV completely and clean it, and then tighten the
a For the following diagnoses, start the engine and select the man-
mounting bolt with the specified torque.
ual mode:
Table of applicable clutches Clutch Cause

F R 1st 2nd 3rd 4th Transmission ECMV
In the automatic mode q a b c d e f g h i j k l
Q Q Q Q
N
In the manual mode
q 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
F1
Wear or seizure of R clutch disc or wear of piston seal

q q
Wear or seizure of F clutch disc or wear of piston seal
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)
F2
q q
Defective operation of R clutch ECMV (Fill switch)

Gear Speed
Defective operation of F clutch ECMV (Fill switch)

F3
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.
• Even if the gear shift lever is used when the gear speed is N, the
clutch position cannot 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 comes
Q
1 not to be displayed when the F fill switch connector (CN-F.SW) is disconnected.
(2) 15SALH
When the failure code is 15SALH, the failure code comes not to be 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 comes
Q
2 not to be displayed when the R fill switch connector (CN-R.SW) is disconnected.
(2) 15SBLH
When the failure code is 15SBLH, the failure code comes not to be 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 comes
Q
3 not to be displayed when the 1st fill switch connector (CN-1.SW) is disconnected.
(2) 15SELH
When the failure code is 15SELH, the failure code comes not to be 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 comes
Q
4 not to be displayed when the 2nd fill switch connector (CN-2.SW) is disconnected.
(2) 15SFLH
When the failure code is 15SFLH, the failure code comes not to 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 comes
Q
5 not to be displayed when the 3rd fill switch connector (CN-3.SW) is disconnected.
(2) 15SGLH
When the failure code is 15SGLH, the failure code comes not to be 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 comes
Q
6 not to be displayed when the 4th fill switch connector (CN-4.SW) is disconnected.
(2) 15SHLH
When the failure code is 15SHLH, the failure code comes not to be displayed
when the ECMV is replaced with any one other than the 4th clutch ECMV
WA430-6 20-787
H-2 The travel speed is slow, the thrusting force is weak, the uphill traveling power is
weak, and the gear is not shifted
Ask the operator about the following:
o Breakage of related equipment

• Has an abnormality occurred suddenly?
Did any abnormal noise occur at the time and Cause

where?
o Wear of related equipment, defective seal

Torque
• Have any abnormal signs come to occur gradually? Torque E
con- Torque Main Park-
converter C
verter con- relief Transmission ing Others
charging M
oil verter valve brake
Check of abnormality pump V
cooler
• Execute digging and measure traveling speeds on a
level ground and on a slope to check whether the a b c d e f g h i j k l m n o p q r
abnormality actually occurs or is a matter of opera-
Defective seal of work equipment and steering system hydraulic

tor's sense
Breakage of oil cooler and pipe (After torque converter outlet)

Clogging of oil cooler and pipe (After torque converter outlet)
pump shaft (Mixing of hydraulic oil in transmission case)

• Is any failure code of the electrical system displayed
Defective operation of torque converter relief valve

on the machine monitor?
• Are the transmission oil level and the oil type appro-
priate?
• Haven't the transmission filter and strainer been
Defective seal of relevant clutch piston

Defective operation of relevant ECMV
Defective seal of parking brake piston

Drop of main relief valve set pressure
Defective seal of relevant clutch shaft

clogged?

• Is any external oil leak found on the mating faces of

Air intake on pump suction side
pipes and valves around the torque converter and

Oil leak inside torque converter

the transmission?
• Isn't the wheel brake or the parking brake being
dragged?
Clogging of breather
Engine degradation
• Are the tire air pressure and the tread shape appro-
priate?
• Is the operating method correct?
NOTE: When the inspection result was "Engine degra-
dation," proceed to Engine system trouble-
shooting (S Mode).
Remedy C E E E E E E E C E
Note
No. X X X *1 *1 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
Q Q
When the transmission oil temperature is low, the charging
3
pump or 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
Q Q Q
Metal (Aluminum, copper, iron, etc.) powers are adhered to
6
the transmission filter or the strainer
Q Q Q
The engine low idling and high idling speeds are measured to
7
be abnormal
8 When the stall speed The speed is high Q Q Q Q Q Q Q Q Q Q
Q
of the torque
9 converter is measured The speed is low
Q Q Q Q
The oil pressure drops as the
10
temperature rises
Q Q Q Q Q Q Q Q Q
The oil pressure is low at all gear
11 When the ECMV speeds
Q Q Q Q
output (Clutch) oil
pressure is measured The oil pressure is low at specific
12
gear speeds
Q Q
The oil pressure does not become
13
stable as the gauge fluctuates
Q Q Q
When the torque converter relief (Inlet) oil pressure is
14
measured, the oil pressure is low. (Nos. 11-13 are normal.)
Q
When the oil pressure at the torque converter outlet is
15
measured, the oil pressure is low. (No. 14 is normal.)
20-788 WA430-6
a For the checking method of failure code display, see the
paragraph of "Special functions of machine monitor."
a For the following diagnoses, start the engine and select the
manual mode:
Table of applicable clutches Clutch Cause

Q Q Q Q
N
In the manual mode
q q

F1

q q

F2
q q

Gear speed
F3
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
is ON.
Remedy Failure
Diagnosis code
Q
(2) 15SALH
Q
(2) 15SBLH
Q
(2) 15SELH
Q
(2) 15SFLH
Q
(2) 15SGLH
Q
(2) 15SHLH
WA430-6 20-789
H-3 Shocks are large at the times of starting and shifting gear

• Did shocks become large suddenly?
Cause
Did any abnormal noise occur at the time and where?

• Did shocks become large gradually? Torque
Main Park-
converter Transmis-
relief ECMV ing Sensor
charging sion
valve brake
pump
Check of abnormality
• Did any of the following abnormal phenomena occur at the a b c d e f g h i j k l
same time: The traveling speed is slow, the braking is
Defective operation of transmission oil temperature sensor

weak, the uphill travelling power is weak, the gear is not
o Execute H-2
shifted.
Defective return (Release) of relevant clutch piston

Defective operation of relevant ECMV a

Defect of transmission controller system
Defective operation of main relief valve

• Is any failure code of the electrical system displayed on

the machine monitor?

• Are the transmission oil level and the oil type appropriate?

• Haven't the transmission filter and strainer been clogged?
• Is any external oil leak found on the mating faces of pipes
and valves around the torque converter and the transmis-
sion? Clogging of strainer
• Isn't the engine speed high at the time of low idling?
• Isn’t play of each drive shaft large?
Remedy C E E
No. X X *1 *2 *1 *1 X X *2
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 The oil pressure is low at all gear speeds Q Q Q Q Q Q
Q Q Q
When the ECMV output (Clutch)
4 The oil pressure is low at specific gear speeds
Q
oil pressure is measured
5 The oil pressure is high at all gear speeds
a Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting wastes
of pressure control valve spool.
*2: Proceed to the paragraph of "Troubleshooting of transmission controller system (TM mode)."
20-790 WA430-6
a For the checking method of failure code display, see the
paragraph of "Special functions of machine monitor."
a For the following diagnoses, start the engine and select the
manual mode:
Table of Applicable Clutches Clutch Cause

Q Q Q Q
N
In the manual mode
q q

F1

q q

F2
q q

Gear speed
F3
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
is ON.
Remedy Failure
Diagnosis code
Q
(2) 15SALH
Q
(2) 15SBLH
Q
(2) 15SELH
Q
(2) 15SFLH
Q
(2) 15SGLH
Q
(2) 15SHLH
WA430-6 20-791
H-4 Time lag is large at the times of starting and shifting gear

• Did the time lag become large suddenly?
Torque E
Main Trans Park-
converter C
Did any abnormal noise occur at the time and where? relief mis- ing Sensor
charging M
valve sion brake

• Has the time lag become large gradually? pump V
a b c d e f g h i j
Defective operation of transmission oil temperature sensor

• Did any of the following abnormal phenomena occur at the
same time: The traveling speed is slow, the braking is weak, the
o Execute H-2
uphill travelling power is weak, the gear is not shifted
Defective operation of relevant ECMV a



• Is any failure code of the electrical system displayed on the ma-

chine monitor?

• Are the transmission oil level and the oil type appropriate?
Is any external oil leak found on the mating faces of pipes and
valves around the torque converter and the transmission?
Remedy C E E
No. X X *1 *1 X X *2
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
Q Q
When the transmission oil temperature is low, any abnormal noise occurs from the charging
3
pump or the transmission filter
4 The torque converter oil temperature is heated abnormally high Q Q Q Q
5 The oil pressure is low at all gear speeds Q Q Q Q Q
Q Q Q
When the ECMV output (Clutch) oil
6 pressure is measured The oil pressure is low at specific gear speeds
a Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting wastes
of pressure control valve spool.
*2: Proceed to the paragraph of "Troubleshooting of transmission controller system (TM mode)."
20-792 WA430-6
a For the checking method of failure code display, see the para-
graph of "Special functions of machine monitor."
a For the following diagnoses, start the engine and select the man-
ual mode:
Table of Applicable Clutches Clutch Cause

Q Q Q Q
N
In the manual mode
q q

F1

q q

F2
q q

Gear speed
F3
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
is ON.
Remedy Failure
Diagnosis code
Q
(2) 15SALH
Q
(2) 15SBLH
Q
(2) 15SELH
Q
(2) 15SFLH
Q
(2) 15SGLH
Q
(2) 15SHLH
WA430-6 20-793
H-5 The torque converter oil temperature is high

• Does the oil temperature rise when the torque converter Torque
Torque
o Selection of improper gear speed

stalls and does the temperature fall at the time of no load? converter
con- Torque Main Trans-
verter con- relief mis- Others
charging
oil verter valve sion
Did any abnormal noise occur at the time and where? pump
cooler
o Improvement of operating method

• Does the oil temperature rise only at the time of lifting?
a b c d e f g h i j k l
Defective seal of work equipment and steering system hydraulic

Breakage of oil cooler and pipe (After torque converter outlet)
Clogging of oil cooler and pipe (After torque converter outlet)
• Measure the torque converter oil temperature to find if the
pump shaft (Mixing of hydraulic oil in transmission case)

o The torque converter oil temperature gauge is
oil temperature is really high.
defective

• Are the coolant level in the radiator and the belt tension

Oil leak inside torque converter

appropriate?
• Are the oil level in the transmission and the oil type appro-
priate?
Clogging of breather
Engine degradation
• Aren't the transmission filter and the strainer clogged?
NOTE: When the inspection result was "Engine degradation,"
proceed to Engine system troubleshooting (S mode).
Remedy C E E E E E E C E
Note
No.
Diagnosis X X X X X X X X X X X
Q Q
When the transmission oil temperature is low, the charging pump or the transmission
1
filter causes any abnormal noise
Q Q Q Q Q Q Q Q Q Q Q
Traveling speed, braking force and uphill travelling power do not occur at all gear
2
speeds
Q
Traveling speed, braking force and uphill travelling power do not occur at specific
3
gear speeds
4 The transmission oil level rises and falls Q Q Q
Q Q Q
Metal powders (Aluminum, copper, iron, etc.) are adhered to the transmission filter
5
and the strainer
6 The engine low idle and high idle speeds are measured to be abnormal Q Q Q
7 When the stall speed of the torque converter is measured, the speed is high Q Q Q Q Q Q Q Q Q
8 The oil pressure drops as the oil temperature rises Q
9 The oil pressure is low at all gear speeds Q Q Q Q Q
Q
When the ECMV output
10 (Clutch) oil pressure is The oil pressure is low at specific gear speeds
Q Q
measured
The oil pressure does not become stable as the gauge
11
vibrates
Q Q Q
When the torque converter relief (Inlet) oil pressure is measured, the oil pressure is
12
low. (Nos. 9-11 are normal.)
Q
When the oil pressure at the torque converter outlet is measured, the oil pressure is
13
low. (No. 12 is normal.)
20-794 WA430-6
H-6 Steering does not turn
Ask the operator about the following questions. Cause

• Did the problem suddenly start? Hydraulic Charge Orbit- Stop Steering Cylin-
Yes = Related equipment broken pump valve roll valve valve der
• Was there any abnormal noise when this happened? a b c d e f g h i j k
Where did the noise come from?
Checks before troubleshooting
Defective fan pump (which is used for PPC, too)

• Is the oil level in the hydraulic tank correct?
Is the type of oil correct?
Defective actuation of flow control spool

• Is the steering shaft broken?
Air sucked in at suction end of pump
Defective actuation of steering spool

• Is the stop valve stopper properly adjusted?
Defective overload relief valve

• Has the safety bar been removed from the frame?
Defective steering pump
Defective charge valve
Defective piston seal

Defective stop valve
Defective Orbit-roll
Defective PTO
Remedy E E E E E E E E E
No.
Diagnosis X X 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 wheel is heavy 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 Q
8 Abnormal noise comes from around fan pump or hydraulic tank Q Q
Q Q Q Q Q Q Q Q Q
Oil pressure is low or there is no pressure in
9
When steering relief both directions (left or right)
Q Q Q Q
pressure is measured Oil pressure is low or there is no pressure in one
10
direction (left or right)
Q Q Q Q Q
When Orbit-roll output pressure is measured, oil pressure is found to be low or
11
there is no oil pressure
12 When PPC valve (Orbit-roll) Oil pressure is low Q Q Q Q
13 basic 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.
WA430-6 20-795
H-7 Steering does not turn [machine with joystick]

• Did the problem suddenly start? Hydraulic Charge Orbit- Joy- Stop Steering Cylin-
Yes = Related equipment broken pump valve roll stick valve valve der
• Was there any abnormal noise when this a b c d e f g h i j k l m
happened?
Where did the noise come from?
Defective actuation of joystick solenoid valve

Defective actuation of demand spool


• Is the steering shaft broken?
Defective actuation of stop valve

• Is the stop valve stopper properly adjusted?
Defective safety-suction valve

• Has the safety bar been removed from the

frame?

• Is the operation of the steering and the steering
mode switch correct?
Defective PTO
Clogged filter
Remedy E E E E E E C E E E
No.
Diagnosis X X X X X X X X X X X X
Q
Steering does not move (steering wheel
1
mode only)
Q Q
When steering mode switch
Steering does not move (joystick mode
2 is switched
only)
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 Steering wheel is heavy in both directions (left and right) Q Q Q Q
8 Work equipment moves Q Q Q Q Q Q Q Q Q
10 Abnormal noise comes from around PTO Q
11 Abnormal noise comes from around fan pump or hydraulic tank Q Q
Q Q Q Q Q Q Q Q Q Q Q
Oil pressure is low, or there is no pressure
12
When steering relief in both directions (left or right)
Q Q
pressure is measured Oil pressure is low, or there is no pressure
13
in one direction (left or right)
Q Q Q Q Q
When Orbit-roll output pressure is measured, oil pressure is found to be
14
low or there is no oil pressure
Q Q Q Q Q Q
When joystick solenoid valve output pressure is measured, oil pressure is
15
found to be low or there is no oil pressure
16 When PPC valve (Orbit-roll) Oil pressure is low Q Q Q Q
17 basic pressure is measured There is no oil pressure Q Q Q
20-796 WA430-6
H-8 Turning, response of steering is poor

• Did the problem suddenly start? Charge Orbit- Stop Cylin-
Hydraulic pump Steering valve
Yes = Related equipment broken valve roll valve der
• Was there any abnormal noise when this a b c d e f g h i j k l m
happened?
• Where did the noise come from?
• Did the problem gradually appear?

Yes = Wear of related parts, defective seal



Defective steering pump servo

Defective main relief valve

Defective PTO
Remedy E E E E E E E E E E E E
No.
Diagnosis X X X X X X X X X X X X
1 Turning, response of steering is poor in both directions (left and right) Q Q Q Q Q Q Q Q Q Q Q
2 Turning, response of steering is poor in one direction (left or right) Q Q
3 Steering wheel is heavy in both directions Q Q Q Q
5 Work equipment moves Q Q Q Q Q Q Q Q Q
7 Abnormal noise comes from around PTO Q
8 Abnormal noise comes from around steering pump or hydraulic tank Q Q
Q Q Q Q Q Q Q Q Q Q
Oil pressure is low or there is no pressure in both
9
When steering relief directions (left and right)
Q Q
pressure is measured Oil pressure is low or there is no pressure in one
10
directions (left or right)
Q Q Q Q Q
When Orbit-roll output pressure is measured, oil pressure is found to be
11
low
Q Q Q Q
When PPC valve (Orbit-roll) basic pressure is measured, oil pressure is
12
found to be low
Q
When steering pump servo assembly is replaced, oil pressure is found to
13
be normal
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.
WA430-6 20-797
H-9 Steering is heavy
Checking for abnormalities Cause

• Is the steering difficult to turn? Charge Orbit- Stop
Pump S/V Others
Yes = Go to H-7 or H-8 valve roll valve
• Measure the operating effort and turning speed, and check the a b c d e f
Standard value table to see if they are abnormal.
Ask the operator the following questions.
Interference of steering wheel or steering shaft

• Did the problem suddenly start?
Yes = Related equipment broken
• Was there previously any symptom, such as heavy steering?

Yes = Wear of related equipment, defective seal


• Is the tire inflation pressure correct?
Remedy E E E E E E
No.
Diagnosis X X X X X X
1 Steering is heavy when turned in both directions (left and right) Q Q Q Q Q
2 Steering is heavy when turned in one direction (left or right) Q
3 Steering is heavy even when joint between steering shaft and Orbit-roll is disconnected Q
4 Oil pressure is low in both directions (left and right) Q Q Q Q
Q
When steering relief pressure is
5 measured Oil pressure is low in one direction (left and right)
6 When Orbit-roll output pressure is measured, pressure is found to be low Q Q Q Q
7 Oil pressure is low Q Q
Q
When PPC valve (Orbit-roll) basic
8 pressure is measured There is no oil pressure
20-798 WA430-6
H-10 Steering wheel shakes or jerks
Checking for abnormalities Cause

• Is the steering difficult to turn? Charge Orbit- Stop Cylin-
Pump Steering valve
Yes = Go to H-7 valve roll valve der
• Is there any abnormal noise from around the steering a b c d e f g h i
equipment

• Is the steering wheel play correct?
• Is there any abnormality in the connection between the
steering shaft and the Orbit-roll?

• Is the tire inflation pressure correct?

Defective main relief valve

Remedy E E E E E E E E E
No.
Diagnosis X X X X X X X X
1 Steering wheel shakes or jerks in both directions (left and right) Q Q Q Q Q Q Q
2 Steering wheel shakes or jerks in one direction (left or right) Q Q
Q Q
Durring operations or when traveling (steering is neutral), steering wheel shakes
3
or jerks in both directions (left and right)
Q
Durring operations or when traveling (steering is neutral), steering wheel shakes
4
or jerks in one directions (left and right)
Q
Steering wheel jerks or there is excessive shock when steering is operated to end of
5
its stroke
6 Work equipment also jerks Q Q
7 Oil pressure is unstable in both directions (left and right) Q Q Q Q Q Q Q
Q Q
When steering relief
8 pressure is measured Oil pressure is unstable in one direction (left or right)
9 Oil pressure is unstable in both directions (left and right) Q Q Q
Q
When Orbit-roll output
10 pressure is measured Oil pressure is unstable in one direction (left or right)
Q Q
When PPC valve (Orbit-roll) basic pressure is measured, oil pressure is found to be
11
unstable
WA430-6 20-799
H-11 The brake does not work or does not work well
o Breakage of brake
• Has the brake come not to turn suddenly?
a b c d e f g h i j
o Wear of seals, lining, disc

• Has the brake come not to work gradually?
Defective seal of accumulator piston, insufficient gas pressure

Metal contact due to complete wear of brake lining in axle
• Is the hydraulic oil level appropriate?
• Is the play of brake pedal appropriate?
Wear or abnormality of brake lining in axle

Defective operation of brake piston in axle
• Oil leak from brake tube and connector, deformation of tube
• Tire air pressure and state of tire tread
Defective seal of brake piston in axle
Defective operation of charge valve

Defective fan pump (For charge)
Check of Abnormality
The brake in axle is defective
Mixing of air in brake circuit

• Measure the braking force and check referring to the standard value
Defect inside brake valve

table if the brake does not work practically.
Remedy E E E E E E E E E E
No.
Diagnosis X X X X X X X X X
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
Q Q Q Q Q Q
When the four wheels are jacked up, the axle is placed on a table and the brake is applied at the
6
forward 1st speed, only a specific wheel rotates
Q
An airflow is observed in bleeding air from the brake circuit, and the brake returns to normal after
7
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
20-800 WA430-6
H-12 The brake is not released or is dragged
Inspection before diagnosis Cause

• Has the brake pedal returned completely?
• Is the parking brake released completely? a b c
• Abnormal heat of brake
Defect inside brake valve (Sticking of piston)

• Does the machine travel smoothly by inertia on a level ground?
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
2 When the brake pedal is released, oil is drained from the air bleeder, the circuit pressure drops and the brake is released Q
Q Q
The four wheels are jacked up, the axle is placed on a table, the engine is stopped, the parking brake is released and the
3
tires are rotated by hand but a specific tire hardly rotates
WA430-6 20-801
H-13 The brake is not released or dragged

• Check if the emergency parking brake release valve is closed. (When this valve is
open, the parking brake is always released.) a b c d e
• Check if the parking brake is automatically applied when the engine stops.
Being pinched due to peeling of parking brake disk lining

Insufficient oil level due to defect of transmission valve
Broken harness of parking brake switch line

Defective operation of parking brake piston
Defect inside parking brake solenoid valve
Remedy E E E E E
No.
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
• The parking brake is not released even if the emergency parking brake release valve is opened. The
following causes are considered:
a. Defective operation of emergency parking brake release valve
b. Insufficient gas pressure of accumulator for brake or breakage of piston seal
20-802 WA430-6
H-14 Lift arm does not rise
Ask the operator about the following. Cause
o Seizure or breakage of each compo-

• Did the lift arm stop suddenly? Accu-
mula- PPC Work equipment Bypass Cylin-
Tank – Pump tor
valve valve valve der
nent charge
valve
• Did abnormal sound come out when the lift
a b c d e f g h i j k l m n
arm stopped? (From what part)
o Wear of parts and fatigue of springs

• Has the speed lowered?
Internal wear or breakage of valve body (lift arm spool)

Malfunction of lift arm pressure compensation valve
Clogging of pump suction opening or much air in oil
Malfunction of lift arm bottom suction valve

Defective work equipment pump servo

• Is the oil level in the hydraulic tank proper?
Damaged lift arm cylinder piston seal

• Is the stroke of the lift arm control lever
Defective work equipment pump
Malfunction of main relief valve

proper?
Malfunction of unload valve

• Is the engine speed proper?
Malfunction of relief valve

Pump PTO is not driven
Malfunction of spool
E E E E E E E E E E
C C
Remedy
No.
Diagnosis
X X X X X 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 Q
5 Hydraulic pump is making abnormal sound Q Q Q
6 Hydraulic drift of lift arm cylinder is large Q Q Q Q
Q Q
When lift arm and bucket are operated simultaneously, lift arm does
7
not rise
8 Fan does not rotate Q Q Q
Q
When work equipment pump assembly is replaced, lift arm moves
9
normally
WA430-6 20-803
H-15 Lift arm speed is low or rising force of lift arm is insufficient

• Is the stroke of the lift arm control lever Brake
proper? PPC Bypass Cylin-
Tank – Pump charge Work equipment valve
valve valve der
• Is the engine speed proper? valve
• Is work equipment linkage bushing nor-
a b c d e f g h i j k l m n o p
mal
Malfunction and defective adjustment of main relief valve

(Is abnormal sound made)?

Malfunction of bucket pressure compensation valve

• The troubles of the rising force and ris-
Malfunction of lift arm bottom suction valve

ing speed are strongly related to each
other. The rising speed lowers first.

Measure the lift arm rising speed while it
Malfunction of back pressure valve

Malfunction of ECSS charge valve
is loaded and check abnormality with
the standard values table.

E E E E E E E E E E E E
C A C
Remedy
No.
Diagnosis
X X X X X X X X X X X X X X X X
Q Q Q Q Q Q Q Q Q Q
Tilting force and speed of bucket are abnormal and rising
1
speed of lift arm is low
Q Q Q Q Q Q
Tilting force and speed of bucket are normal and rising speed
2
of lift arm is low
3 After oil temperature rises, rising speed lowers more in step 1 Q
5 Hydraulic drift of 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
high
Q
When lift arm and bucket are operated simultaneously, rising
8
speed of lift arm is too low
Q
When work equipment pump assembly is replaced, lift arm
9
moves normally
20-804 WA430-6
H-16 When rising, the lift arm comes to move slowly at specific height
• Deformation of lift arm cylinder in appearance
Cause
• Expansion of lift arm cylinder tube or damage inside
• For other abnormal phenomena during lift arm rise, see "H-15. The lift arm moves slowly or the lift arm rising
force is insufficient."
H-17 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)
See "H-15. The lift arm moves slowly or the lift arm rising force is insufficient."

• Is the stroke of the lift arm control lever appropriate?
Cause
• Defective seat of suction valve on the lift arm cylinder head side of work equipment valve
• Oil leak from lift arm cylinder piston seal
• Imperfect fitting of check valve of bypass valve
H-18 Hydraulic drifts of the lift arm occur often

• Have hydraulic drifts come to occur often suddenly?
Wastes pinched in valve or damage of parts
• Have hydraulic drifts come to occur often gradually?
Wear of parts

• Is the lift arm spool at the neutral position?
The spool detent is defective
• Check the hydraulic drift of the lift arm with the standard values table.
Cause
• Oil leakage in lift arm cylinder
• Imperfect fitting of suction valve on bottom side
• Imperfect fitting of lift arm spool
• Imperfect fitting of back pressure valve spool
H-19 The lift arm wobbles during operation

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-18. Hydraulic drifts of the lift arm occur
often."
2. When the lift arm cylinder cannot lift the machine, see "H-17. The lift arm cylinder cannot hold down the
bucket."
3. When the lift arm cylinder comes to enable to lift the machine after the lift arm is operated several times with
o The cause is vacuum generated inside the cylinder

the normal hydraulic drift and after the lift arm cylinder operates to full stroke
a Frequent hydraulic drifts o The suction valve on the lift arm cylinder rod side is defective
WA430-6 20-805
H-20 Bucket does not tilt back
Ask the operator about the following. Cause
o Seizure or breakage of each component

• Did the bucket stop suddenly? Brake
PPC Cylin-
valve der
Did abnormal sound come out when the bucket valve
stopped? (From what part)
a b c d e f g h i j k l m n
o Wear of parts and fatigue of springs

• Has the speed lowered?
Malfunction of bucket bottom suction valve (Suction safety valve)

Malfunction of bucket bottom safety valve (Suction safety valve)
• Is the oil level in the hydraulic tank proper?

• Is the stroke of the bucket control lever proper?

• Is the engine speed proper?
Internal breakage of valve body (bucket spool)

Damaged bucket cylinder piston seal

Malfunction of main relief valve

Pump PTO is not driven
E E E E E E E E E E E
C C
Remedy
No.
Diagnosis
X X X 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
Q Q Q Q Q Q Q
Bucket can tilt back when not loaded but cannot when used for digging or
4
scooping
6 Hydraulic drift of bucket cylinder is large Q Q Q Q
Q Q
When lift arm and bucket are operated simultaneously, bucket does not
7
tilt back
8 Fan does not rotate Q Q Q
Q
When work equipment pump and servo assembly is replaced, bucket
9
moves normally
20-806 WA430-6
H-21 Bucket speed is low or tilting back force is insufficient

• Is the stroke of the bucket control lever Brake
proper? PPC Cylin-
valve der
• Is the engine speed proper? valve
• Is the work equipment linkage bushing
a b c d e f g h i j k l m n o p
normal
Malfunction and defective adjustment of main relief valve

(Is abnormal sound made)?

Bucket can raise chassis but does not tilt back

• Check by actual operation that the tilting
Lift arm moves but bucket does not tilt back

back force is insufficient.
• Measure the operating speed of the bucket

and check it with the Standard values table.
Malfunction of ECSS charge valve

Malfunction back pressure valve

E E E E E E E E E E E E E
C A C
Remedy
No.
Diagnosis
X X X X X X X X X X X X X X X
Q Q Q Q Q Q Q Q Q Q
Rising force and speed of lift arm are abnormal and tilting back
1
force and speed of bucket are low
Q Q Q Q Q Q
Rising force and speed of lift arm are normal and tilting back force
2
and speed of bucket are low
3 After oil temperature rises, tilting back speed lowers more in step 1. Q
5 Hydraulic drift of 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
7 Relief pressure of relief valve of work equipment valve is too high Q
Q
When lift arm and bucket are operated simultaneously, tilting back
8
speed of lift arm is too low.
Q
When work equipment pump and servo assembly is replaced,
9
bucket moves normally
WA430-6 20-807
H-22 The bucket comes to operate slowly in the midst of tilting-back

• Deformation of bucket cylinder in appearance
Cause
• Expansion of bucket cylinder tube or damage inside
For other abnormal phenomena during bucket operation, see "H-21. The bucket moves slowly or the tilting-
back force is insufficient."
H-23 The bucket cylinder cannot hold down the bucket

See "H-21. The bucket moves slowly or the tilting-back force is insufficient."

• Is the stroke of the bucket control lever appropriate?
Cause
• Defective seat of suction valve on the bucket cylinder head side of work equipment valve
• Oil leak from bucket cylinder piston seal
H-24 Hydraulic drifts of the bucket occur often
• Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
• Have hydraulic drifts come to occur often gradually? o Wear of parts
• Is the bucket spool at the neutral position? o Spool detent is defective

• Refer to the standard value table and check if the hydraulic drift of the bucket occurs often practically
Cause
• Oil leak in bucket cylinder
• Improper adhesion of safety valve (With suction valve) on the bottom side
• Improper oil tight of bucket spool
20-808 WA430-6
H-25 The bucket wobbles during travel with cargo (The work equipment valve is set to
"HOLD")
• Pin of work equipment linkage and "play of bushing" (Is any abnormal noise heard?)
Cause
• Defective seal of bucket cylinder piston
• Defective operation of safety valve (With suction valve) on bucket cylinder head side. For other abnormal
phenomena, refer to diagnoses for relevant abnormal phenomena.
WA430-6 20-809
H-26 The control levers of lift arm and bucket do not move smoothly and heavy
Check of Abnormality Cause

• Refer to the standard value table and check if the lever operating efforts are large PPC valve
practically. 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
E E C
X X E
Remedy
No.
Diagnosis X
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 pressure rises Q Q
3 The levers totally come not to move smoothly during operation irrespective of oil pressure and oil temperature Q Q
20-810 WA430-6
H-27 Engine speed lowers remarkably or engine stalls

• Is the main relief pressure normal?
Cause
• Defective pump servo
• Defective pump unit
• Defective pump servo EPC input voltage
• Defective engine system
H-28 Large shocks are made when work equipment starts and stops
Cause
• Wastes in work equipment valve PPC line
• Defective PPC valve
• Malfunction of control valve spool
WA430-6 20-811
H-29 When work equipment circuit is relieved singly, other work equipment moves
• Pressure is not released properly from main spool of moving equipment o Replace main spool
Cause
20-812 WA430-6
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
Method of using troubleshooting charts

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
WA430-6 20-813
[Questions]
Sections [A] + [B] in the chart on the right corresponds to the items where answers can be obtained from the
user. The items in [B] are items that can be obtained from the user, depending on the user's level.
[Check items]
The serviceman carries out simple inspection to narrow down the causes. The items under [C] in the chart on
the right correspond to this.
The serviceman narrows down the causes from information [A] that he has obtained from the user and the
results of [C] that he has obtained from his own inspection.
20-814 WA430-6
[Troubleshooting]
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been Cause
marked as having the highest probability from infor-
ma tion g ain ed from [Q ues tions] and [Che ck
items].
(1) (2) (3)
(a) w
w
Questions
(A) (b)
(c) w
(d) Q
Q
(B)
(e)
Check items
(C)
i q
q
Troubleshooting
ii
iii q
WA430-6 20-815
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
with Q, and of these, causes that have a high proba-

have a relationship with the Cause items are marked
bility are marked with w.
in turn, and marked the Q or w in the chart for items

Check each of the [Questions] and [Check items]
where the problem appeared. The vertical column

(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
*1. For [Confirm recent repair history] in Causes
and mark the Cause column with E to

the [Questions] Section, ask the user,
use as reference for locating the cause
Defective injection pump (excessive injection)

of the failure. However, do not use this
when making calculations to narrow
*2. Use the E in the Cause column as ref-

down the causes.
Seized turbocharger, interference
Clogged, seized injection nozzle

Worn piston ring, cylinder liner
erence for [Degree of use (Operated

Clogged air cleaner element
for long period)] in the [Questions] Improper injection timing
section as reference. As a rule, do not

use it when calculating the points for
locating the cause, but it c an be
included if necessary to determine the
order for troubleshooting.
*1 Confirm recent repair history

*2 Degree of use Operated for long period E E E
w
20-816 WA430-6
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
WA430-6 20-817
S-7 Exhaust smoke is black (Incomplete combustion)
General causes why exhaust smoke is black
• Insufficient intake of air Causes
• Improper condition of fuel injection

• Excessive injection of fuel
Leakage of air between turbocharger and head
Defective injection pump (plunger seized)

Defective contact of valve and valve seat
Clogged injection nozzle, defective spray

Improper valve clearance

Crushed, clogged muffler
Q : Possible causes (judging from Questions and check items)
Legend
w : Most probable causes (judging from Questions and Check items)

E : Possible causes due to length of use (used for a long period)
q : Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period E E E E
Suddenly became black w Q Q
w Q Q
Questions
Color of exhaust gas Gradually became black

Blue under light load w
Engine oil must be added more frequently w
Suddenly w Q Q Q
Q Q Q Q
Power was lost
Gradually
Non-specified fuel is being used Q Q
Noise of interference is heard from around turbocharger w
Dust indicator lamp is red w
Blow-by gas is excessive w
Engine pickup is poor and combustion is irregular Q w Q Q Q Q
w Q
When exhaust manifold is touched immediately after starting engine, temperature of some
Check items
cylinders is low
Clanging sound is heard from around cylinder head w
Exhaust noise is abnormal Q Q w
Muffler is crushed w
Leakage of air between turbocharger and head, loose clamp w
When turbocharger is rotated by hand, it is found to be heavy q

q
Troubleshooting
When air cleaner element is inspected directly, it is found to be clogged

Speed does not change when operation of certain cylinders is stopped q
When valve clearance is checked directly it is found to be outside standard value q
When muffler is removed, exhaust color returns to normal q
Error code related to fuel injection pump is displayed q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Remedy
20-818 WA430-6
Five causes
Step 1
Clarify the relationship between the three symptoms
in the [Questions] and [Check items] section and the
five Causes items in the vertical column.
Three symptoms
Step 2
Add up the total of Q and w marks where the
horizontal lines for the three symptoms and the
wQw
vertical columns for the causes intersect.
(2) Air leakage between turbocharger and head: QQ

(1) Clogged air cleaner element:
Q
Q
(3) Clogged, seized injection nozzle:
Q
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner element].
and carry out the troubleshooting item marked q. The

Follow this column down to the troubleshooting area
Remedy is given as [Clean], so carry out cleaning,

and the exhaust gas color should return to normal.
WA430-6 20-819
S-1 Starting performance is poor (Starting always takes time)
General causes why exhaust smoke comes out but engine

takes time to start
• Defective electrical system
• Insufficient supply of fuel
Causes
• Insufficient intake of air
• Improper selection of fuel (At ambient temperature of
–10°C or below, ASTM D975 No. 2 diesel fuel is used)
a Battery charging rate
Clogged air breather hole in fuel tank cap

Defetive injection pump (plunger stuck)
Defective contact of valve, valve seat
Defective electrical intake air heater
Leakage, clogging, air in fuel piping

Charging rate
100 % 90 % 80 % 75 % 70 %
Ambient temperature
Defective or deteriorated battery

20°C 1.28 1.26 1.24 1.23 1.22

Clogged fuel filter, strainer
Defective injection nozzle

0°C 1.29 1.27 1.25 1.24 1.23
Clogged water separator

–10°C 1.30 1.28 1.26 1.25 1.24
Defective feed pump

Defective alternator
Defective regulator
• The specific gravity should exceed the value for the
charging rate of 70% in the above table.
• In cold areas the specific gravity must exceed the value
for the charging rate of 75% in the above table.

Gradually became worse w w Q Q Q
w w
Questions
Ease of starting
Starts when warm
Indicator lamp does not light up w
Replacement of filters has not been carried out according to Operation Manual w w w Q Q
Non-specified fuel has being used Q Q Q Q
Battery charge lamp is ON w w
Starting motor cranks engine slowly w
w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low
Engine does not pick up smoothly, and combustion is irregular Q Q w
Mud is stuck to fuel tank cap Q
Check items
w
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump piping sleeve nut is loosened
w w w w
2) Little fuel comes out even when hose flange between fuel filter and fuel injection
pump is loosened
Leakage from fuel piping Q w
There is hunting from engine (rotation is irregular) Q Q w Q
When air cleaner element is inspected directly, it is found to be clogged q

When fuel filter, strainer are inspected directly, they are found to be clogged q q
When water separator is inspected directly, it is found to be clogged q
q
Troubleshooting
Heater mount does not become warm

Yes q
q
Is voltage 26–30V between alternator terminal B and terminal E with engine
at low idle? No
Either specific gravity of electrolyte or voltage of battery is low q
When fuel tank cap is inspected directly, it is found to be clogged q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
20-820 WA430-6
S-2 Engine does not start
(1) Engine does not turn Causes
General causes why engine does not turn
a For seizure inside the engine, carry out the troubleshooting for S-4
• Seizure inside engine
Defective safety relay or safety switch
Defective battery terminal connection

Engine stops during operation.
Defective wiring of starting circuit

• Failure in power train
• Defective electrical system
Defective starting switch

Defective starting motor
Defective battery relay

Broken ring gear
Questions

Degree of use of machine Operated for long period E E
Horn does not sound w Q Q
w
Condition of horn when starting switch is turned
ON Horn volume is low
Speed of rotation is low w
Makes grating noise w w
w
When starting switch is turned to START, pinion
moves out, but Soon disengages pinion again
Makes rattling noise and does not turn Q Q Q
w Q Q
Check items
When starting switch is turned to START, pinion does not move out
When starting switch is turned to ON, there is no clicking sound Q w
Carry out troubleshooting for Defective wiring in starting circuit

Battery terminal is loose w
When battery is checked, battery electrolyte is found to be low w
Specific gravity of electrolyte, voltage of battery is low q
q
For the following conditions 1) – 5), turn the starting switch OFF, connect the cord, and carry out troubleshooting
1) When terminal B and terminal C of starting switch are connected, engine starts
q
Troubleshooting
2) When terminal B and terminal C of starting motor are connected, engine starts
3) When terminal B and terminal C of safety relay are connected, engine starts q
4) When terminal of safety switch and terminal B of starting motor are connected, engine starts q
5) There is no 24V between battery relay terminal b and terminal E q
When ring gear is inspected directly, tooth surface is found to be chipped q

Replace
Replace
Replace
Replace
Replace
Replace
Correct
—
Remedy
WA430-6 20-821
(2) Engine turns but no exhaust smoke comes out Causes

(Fuel is not being injected)
General causes why engine turns but not exhaust smoke comes out

• Supply of fuel impossible
Broken injection pump drive shaft, key

• Supply of fuel extremely small
Seized, broken feed pump piston

• Improper selection of fuel (particularly in winter)
Clogged, leaking fuel piping

Insufficient fuel in tank
Improper fuel used

Questions

Degree of use of machine Operated for long period E E E
Exhaust smoke suddenly stops coming out (when starting again) w w w
Replacement of filters has not been carried out according to Operation Manual w w
Fuel tank is found to be empty w
There is leakage from fuel piping w
Mud is stuck to fuel tank cap w
When fuel filter is drained, fuel does not come out w
w Q Q Q
Check items

1) Little fuel comes out even when hose flange between fuel filter and fuel injection pump is loosened
2) No fuel spurts out even when injection pump piping sleeve nut is loosened w w w
Rust and water are found when fuel tank is drained Q Q Q
Inspect injection pump directly q

q
Troubleshooting
Error code related to fuel injection pump is displayed

Inspect feed pump directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-822 WA430-6
(3) Exhaust smoke comes out but engine does Causes

not start (Fuel is being injected)
Defective, broken valve system (valve, rocker lever, etc.)

General causes why exhaust smoke comes out but engine
does not start

Defective injection pump (plunger stuck)
• Lack of rotating force due to defective electrical system
Leakage, clogging, air in fuel system

Defective electrical intake air heater


• Improper selection of fuel and oil

Improper fuel used

w w
Questions
Suddenly failed to start

When engine is cranked, abnormal noise is heard from around cylinder head w
Replacement of filters has not been carried out according to Operation Manual w w w
Rust and water are found when fuel tank is drained w w
Indicator lamp does not light up w
Starting motor cranks engine slowly w
Mud is stuck to fuel tank cap Q
w
1) Little fuel comes out even when injection pump piping sleeve nut is loosened
w w Q
Check items
2) Little fuel comes out even when hose flange between fuel filter and fuel injection pump is
loosened
w
cylinders is low
When fuel filter is drained, no fuel comes out w
Remove head cover and check directly q

q
Troubleshooting
When water separator is inspected directly, it is found to be clogged

Heater mount does not become warm q
Either specific gravity of electrolyte or voltage of battery is low q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
WA430-6 20-823
S-3 Engine does not pick up smoothly (Follow-up is poor)
General causes why engine does not pick up smoothly Causes


• Improper fuel used

Seized injection pump plunger


Degree of use of machine Operated for long period E E E E E
w w w
Questions
Replacement of filters has not been carried out according to Operation Manual
Non-specified fuel is being used w w w w
Engine pick-up suddenly became poor Q w Q Q
Blue under light load Q w
w w w Q
Color of exhaust gas
Black
w
Check items
Mud is stuck to fuel tank cap

High idle speed under no load is normal, but speed suddenly drops when load is applied w w Q
There is hunting from engine (rotation is irregular) Q w Q Q
w Q
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders
is low

When fuel filter, strainer are inspected directly, they are found to be clogged q
q
Troubleshooting
When water separator is inspected directly, it is found to be clogged

When valve clearance is checked directly, it is found to be outside standard value q
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
20-824 WA430-6
S-4 Engine stops during operations
General causes why engine stops during operations Causes
Broken dynamic valve system (valve, rocker lever, etc.)

• Seized parts inside engine
a If the engine is overheating and the engine stops,

• Overheating
Broken fuel injection pump drive shaft, key

Defective injection pump (plunger stuck)
carry out troubleshooting for overheating.
Broken, seized piston, connecting rod

(See S-14 Coolant temperature becomes too high)
Broken, seized crankshaft bearing

a If the engine stops because of a failure in the power
Broken pump auxiliary equipment
Broken, seized feed pump piston

• Failure in power train

train, carry out troubleshooting for the chassis.
Broken, seized gear train

Failure in power train

Abnormal noise was heard and engine stopped suddenly w w w w w w Q Q w
w Q Q
Questions
Engine overheated and stopped

w Q Q
Condition when engine
stopped Engine stopped slowly
There was hunting and engine stopped w Q Q Q
Non-specified fuel is being used Q Q Q Q
Fuel level lamp lights up w
Leakage from fuel piping w
Engine rotates, but stops when power train is operated w
Does not turn at all w w
w
Check items
Turns in opposite direction

w w
When it is attempted to turn
by hand using barring tool Moves amount of backlash
w
Carry out troubleshooting for Chassis

Shaft does not turn
Metal particles are found when oil is drained w w Q Q
Remove oil pan and inspect directly q q

Remove head cover and inspect directly q
q
Troubleshooting
When gear train is inspected, it does not turn

Rotates when pump auxiliary equipment is removed q
Inspect feed pump directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Add
WA430-6 20-825
S-5 Engine does not rotate smoothly (Hunting)
General causes why engine does not rotate smoothly Causes
Clogged, air in circuit between fuel tank and feed pump

• Air in fuel system
Clogged, air in circuit between feed pump and nozzle

Clogged fuel injector, defective injection
Low idle speed is too low

Q
Questions
Occurs at a certain speed range

Occurs at low idle w Q Q Q Q Q
Q
Condition of hunting
Occurs even when speed is raised
Occurs on slopes w
Rust, water are found when fuel tank is drained Q Q
Check items
Leakage from fuel piping w w

When fuel tank cap is inspected directly, it is found to be clogged q q

Troubleshooting

Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
Add
20-826 WA430-6
S-6 Engine lacks output (or lacks power)
General causes why engine lacks output Causes


• Improper fuel used (if non-specified fuel is used, output drops)
a If there is overheating and lack of output, carry out

• Lack of output due to overheating

Defective westgate diaphragm

Seized injection pump plunger
troubleshooting for S-14 overheating.


Degree of use of machine Operated for long period E E E E E
w w
Questions
Suddenly
Q Q Q Q Q Q
Power was lost
Gradually
Replacement of filters has not been carried out according to Operation Manual w w w
Non-specified fuel is being used w w w w
Black w w
w
Blue under light load
Engine pickup is poor and combustion is irregular w Q Q Q
High idle speed under no load is normal, but speed suddenly drops when load is applied w w Q
w Q
Check items
cylinders is low
There is hunting from engine (rotation is irregular) Q Q Q Q
High idle speed of engine is low Q
Leakage from fuel piping w

q
Troubleshooting
When fuel filter, strainer are inspected directly, they are found to be clogged
When valve clearance is checked directly, it is found to be outside standard value q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
WA430-6 20-827
S-7 Exhaust smoke is black (Incomplete combustion)
General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and cylinder head




Crushed, clogged muffler
Suddenly became black w Q Q
w Q Q
Questions
Color of exhaust gas Gradually became black

Suddenly w Q Q Q
Q Q Q Q
Power was lost
Gradually
Engine pickup is poor and combustion is irregular Q w Q Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low w Q
w
Check items
Clanging sound is heard from around cylinder head

Exhaust noise is abnormal Q Q w
Muffler is crushed w
Leakage of air between turbocharger and head, loose clamp w

q
Troubleshooting
When air cleaner element is inspected directly, it is found to be clogged

When valve clearance is checked directly it is found to be outside standard value q
When muffler is removed, exhaust color returns to normal q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Remedy
20-828 WA430-6
S-8 Oil consumption is excessive (or exhaust smoke is blue)
a Do not run the engine at idle for more than 20 minutes Causes
continuously. (Both low and high idle)
Turbocharger
General causes why oil consumption is excessive
• Abnormal combustion of oil
Worn valve (stem, guide), broken seal

Leakage from oil pan or cylinder head
Worn, broken rear seal, seal surface

• External leakage of oil
Clogged breather or breather hose
Dust sucked in from intake system

Leakage from oil filter or oil cooler
• Wear of lubrication system
Leakage from oil drain plug
Worn seal at turbine end

Worn seal at blower end
Leakage from oil piping
Broken piston ring
Broken oil cooler

w Q
Questions
Oil consumption suddenly increased

Engine oil must be added more frequently w Q
Engine oil becomes contaminated quickly Q w Q
Exhaust smoke is blue under light load w w
Excessive w w Q Q
w
Amount of blow-by gas
None
Area around engine is dirty with oil w w w w
There is oil in engine coolant w
w Q
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

When turbocharger air supply pipe is removed, inside is found to be dirty with oil w
Oil level in clutch or TORQFLOW transmission or damper chamber rises w
Clamps for intake system are loose w
When breather element is inspected, it is found to be clogged with dirty oil q

There is external leakage of oil from engine q q q q
q
Troubleshooting
Pressure-tightness test of oil cooler shows there is leakage

Excessive play of turbocharger shaft q q
Inspect rear seal directly q
When intake manifold is removed, dust is found inside q
When intake manifold is removed, inside is found to be dirty with oil q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
WA430-6 20-829
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly Causes
• Entry of exhaust gas due to internal wear

• Clogging of lubrication passage
• Improper fuel used
Defective seal at turbocharger turbine end

• Improper oil used
• Operation under excessive load
Clogged turbocharger oil drain tube

Clogged breather, breather hose
Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is black

Clogged oil cooler
Clogged oil filter
E E E
Questions
Degree of use of machine Operated for long period

Non-specified oil is being used Q
w
Black
Excessive w Q Q Q
Carry out troubleshooting for "S-7 Exhaust smoke is black".

w
Amount of blow-by gas
None
Q w Q
Check items
When oil filter is inspected, metal particles are found

When exhaust pipe is removed, inside is found to be dirty with oil w
Engine oil temperature rises quickly w
When breather element is inspected directly, hose is broken or is found to be clogged with dirty oil q
q
Troubleshooting
When oil filter is inspected directly, it is found to be clogged

When oil cooler is inspected directly, it is found to be clogged q
Turbocharger oil drain tube is clogged q
Excessive play of turbocharger shaft q
When safety valve is inspected directly, spring is found to be catching or broken q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
20-830 WA430-6
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Causes
• Leakage of fuel
Defective oil seal inside feed pump (piston)

External leakage from fuel piping, fuel filter
Leakage of fuel inside head cover
Defective injection pump plunger
Defective nozzle holder spray
Defective fuel injection timing

E E E
Questions

More than for other machines of same model Q
Condition of fuel consumption Gradually increased Q Q
Suddenly increased Q Q
Black Q Q
Q
Exhaust smoke color
White
There is irregular combustion w
w Q
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
There is external leakage of fuel from engine w
Engine oil level rises and smells of diesel fuel w w

Troubleshooting

Remove feed pump and inspect directly q
Replace
Replace
Correct
Correct
Correct
Adjust
Remedy
WA430-6 20-831
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down
General causes why oil in coolant Causes
• Internal leakage in lubrication system

• Internal leakage in cooling system
Broken cylinder head, head gasket
Internal cracks in cylinder block

Broken oil cooler core, O-ring
Broken power train oil cooler

Holes caused by pitting
E E
Questions

Suddenly increased Q Q Q
Q Q
Oil level
Gradually increased
Hard water is being used as coolant Q Q
Engine oil level has risen, oil is cloudy white w Q Q
Excessive air bubbles inside radiator, spurts back w
Check items
Hydraulic oil, transmission oil is cloudy white w

When hydraulic oil, transmission oil is drained, water is found w
q q
Troubleshooting
Pressure-tightness test of oil cooler shows there is leakage

Pressure-tightness test of cylinder head shows there is leakage q
Remove oil pan and inspect directly q q
Replace
Replace
Replace
Replace
Replace
Remedy
20-832 WA430-6
S-12 Oil pressure caution lamp lights up (Drop in oil pressure)
General causes why oil pressure lamp lights up
• Leakage, clogging, wear of lubricating system

• Defective oil pressure control Causes
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
Leaking, crushed hydraulic piping

Clogged strainer inside oil pan
Clogged oil pipe inside oil pan
Defective oil pressure sensor

Broken suction pipe brazing
Defective oil level sensor

Defective regulator valve
Worn bearing, journal
Defective relief valve

Lack of oil in oil pan
Defective oil pump
Water, fuel in oil

Clogged oil filter
E E E
Questions

Replacement of filters has not been carried out according to Operation Manual w
Non-specified oil is being used Q Q
Caution lamp lights up w Q
Lights up at low idling w Q
Lights up at low, high idling w w w w Q Q Q
w
Condition when oil pressure lamp
lights up Lights up on slopes
Sometimes lights up w w Q Q
There is crushing, leakage from hydraulic piping (external) w
w w
Check items
Oil level sensor lamp lights up

When oil level in oil pan is inspected, it is found to be low w
Metal particles are found when oil is drained w
Metal particles are stuck to oil filter element w Q
Oil is cloudy white or smells of diesel oil w
Carry out troubleshooting

When oil filter is inspected, it is found to be clogged q q for "S-13 Oil level rises".
q q q
Troubleshooting
Remove oil pan and inspect directly

Oil pump rotation is heavy, there is play q
There is catching of relief valve or regulator valve, spring or valve guide is broken q q
When oil level sensor is replaced, oil level sensor lamp goes out q
When oil pressure is measured, it is found to be within standard value q
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
WA430-6 20-833
S-13 Oil level rises (Water, fuel in oil)
a If there is oil in the coolant, carry out troubleshooting for "S-11 Causes
Oil is in coolant, or coolant level goes down".
General causes why oil level rises
Leakage of fuel from piping inside head cover

Defective pump auxiliary equipment seal
• Water in oil (milky white)
• Fuel in oil (diluted, and smells of diesel fuel)
Defective part inside injection pump

Worn, damaged rear seal surface
• Entry of oil from other component
Defective nozzle holder sleeve

Broken oil cooler core, O-ring
Cracks inside cylinder block

Holes made by pitting
Defective thermostat
E E E E
Questions

There is oil in radiator coolant w Q Q Q Q
Fuel must be added more frequently w w
Exhaust smoke is white w Q
When engine is first started, drops of water come from muffler w
w Q
Leave radiator cap open. When engine is run at idle, an abnormal number of bubbles appear, or water
spurts back
Oil level goes down in clutch, TORQFLOW transmission, or damper chamber w
w
Check items
Oil level goes down in hydraulic tank

Engine oil smells of diesel fuel w w
Coolant temperature is low w
Pressure-tightness test of oil cooler shows there is leakage q

Pressure-tightness test of cylinder head shows there is leakage q
q
Troubleshooting
Inspect rear seal directly

When pump auxiliary equipment is removed, seal is found to be damaged q
Remove injection pump and inspect directly q
Defective contact with thermostat seal valve q
Remove oil pan and check directly q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-834 WA430-6
S-14 Coolant temperature becomes too high (Overheating)
General causes why coolant temperature becomes too high Causes
• Lack of cooling air (deformation, damage of fan)

• Drop in heat dissipation efficiency
• Defective cooling circulation system
a Carry out troubleshooting for chassis.
Rise in torque converter oil temperature

• Rise in oil temperature in power train
Defective thermostat (does not open)

Defective coolant temperature gauge

Clogged, crushed radiator fins
Clogged, broken oil cooler

Defective pressure valve
Clogged radiator core
Holes made by pitting

Broken water pump
Lack of coolant
w Q
Questions
Suddenly overheated
w w Q
Condition of overheating
Always tends to overheat
Rises quickly w Q
w
Coolant temperature gauge
Does not go down from red range
Radiator coolant level sensor lights up w
Fan belt whines under sudden load
Cloudy white oil is floating on coolant w
Coolant flows out from overflow hose w
Excessive air bubbles inside radiator, coolant spurts back w
Q w
Check items
Engine oil level has risen, oil is cloudy white

Radiator shroud, inside of underguard are clogged with dirt or mud w
When light bulb is held behind radiator, no light passes through w
Coolant is leaking because of cracks in hose or loose clamps w
Power train oil temperature enters red range faster than engine coolant temperature w
Temperature difference between top and bottom radiator tanks is excessive q

q
Carry out troubleshooting for Chassis

Temperature difference between top and bottom radiator tanks is slight
q
Troubleshooting
When coolant filler port is inspected, core is found to be clogged

When function test is carried out on thermostat, it does not open even at cracking temperature q
When coolant temperature is measured, it is found to be normal q
When oil cooler is inspected directly, it is found to be clogged q
When measurement is made with radiator cap tester, set pressure is found to be low q
Remove oil pan and inspect directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Add
WA430-6 20-835
S-15 Abnormal noise is made
a Judge if the noise is an internal noise or an external noise. Causes
Leakage of air between turbocharger and cylinder head

Broken dynamic valve system (valve, rocker lever, etc.)
General causes why abnormal noise is made
Defect inside muffler (dividing board out of position)

• Abnormality due to defective parts
• Abnormal combustion
Excessive wear of piston ring, cylinder liner

• Air sucked in from intake system
Defective adjustment of valve clearance

Deformed fan, fan belt interference
Clogged, seized injection nozzle
Improper gear train backlash

Missing, seized bushing
Degree of use of machine Operated for long period E
Q Q
Questions
Gradually occurred
Q Q Q
Condition of abnormal noise
Suddenly occurred
w Q Q
Black
Metal particles are found in oil filter w w
Engine pickup is poor and combustion is abnormal w
w Q
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders
is low
Abnormal noise is loud when accelerating engine Q Q Q Q Q
Clanging sound is heard from around cylinder head w w
Leakage of air between turbocharger and cylinder head, loose clamp w
Vibrating noise is heard from around muffler w

Remove gear cover and inspect directly q q
q
Troubleshooting
Speed does not change when operation of certain cylinders is stopped

Fan is deformed, belt is loose q
When valve clearance is checked, it is found to be outside standard value q
Remove cylinder head cover and inspect directly q
When muffler is removed, abnormal noise disappears q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-836 WA430-6
S-16 Vibration is excessive
a If there is abnormal noise together with the vibration, carry out troubleshooting Causes
also for "S-15 Abnormal noise is made".
Defective dynamic valve system (valve, rocker lever, etc. stuck)

General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)

• Improper alignment
Loose engine mounting bolts, broken cushion
Center of engine and power train misaligned

• Abnormal combustion
Broken part inside output shaft (damper)

Worn connecting rod, main bearing
Improper gear train backlash

Worn cam bushing
E E E
Questions

Suddenly increased Q Q
Q Q Q
Condition of vibration
Gradually increased
Non-specified oil is being used Q Q
Metal particles are found in oil filter w w
Metal particles are found when oil is drained w w
Oil pressure is low at low idle Q Q
Q Q
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w
Remove oil pan and inspect directly q

Remove side cover and inspect directly q
q
Troubleshooting
Inspect directly for loose engine mounting bolts, broken cushion

Inspect inside of output shaft (damper) directly q
When face runout and radial runout are inspected, they are found to be incorrect q
Remove front cover and inspect directly q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
WA430-6 20-837
20-838 WA430-6
DISASSEMBLY AND ASSEMBLY
30 DISASSEMBLY AND ASSEMBLY

How to read this manual .................................. 30-2 Removal and installation of counterweight ...30-163
Precautions when performing operation .......... 30-4 Removal and installation of
Special tool list ................................................. 30-6 air conditioner unit ........................................30-164
Sketches of special tools ................................. 30-9
Removal and installation of fuel injection pump as-
sembly............................................................ 30-23
Removal and installation of
fuel injector assembly .................................... 30-27
cylinder head assembly ................................. 30-30
Removal and installation of radiator assembly30-34
Removal and installation of engine assembly 30-36
engine hood assembly ................................... 30-42
fuel tank assembly ......................................... 30-44
Removal and installation of parking brake disc
and plate ........................................................ 30-46
torque converter and transmission assembly 30-49
Disassembly and assembly of
transmission assembly................................... 30-53
Disassembly and assembly of transmission clutch
pack assembly ............................................... 30-66
Disassembly and assembly of parking brake assem-
bly .................................................................. 30-81
torque converter assembly............................. 30-88
front axle assembly ........................................ 30-92
rear axle assembly ......................................... 30-94
Disassembly and assembly of axle housing assem-
bly .................................................................. 30-97
differential assembly .................................... 30-106
steering valve assembly............................... 30-125
hydraulic tank assembly............................... 30-126
hydraulic cylinder ......................................... 30-128
Removal and installation of work equipment 30-135
operator’s cab assembly .............................. 30-140
Removal and installation of operator's cab glass
(Stuck glass) ................................................ 30-143
Removal and installation of operator’s cab and floor
frame assembly............................................ 30-151
Removal and installation of center hinge pin 30-155
WA430-6 30-1
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
How to read this manual

Removal and installation of assemblies
Special tools Installation of parts

• Special tools that are deemed necessary for re- • Except where otherwise instructed, install parts
moval or installation of parts are listed. in the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing parts
kind of information. are shown with [*1] mark in the Installation Sec-
t: Special tools which cannot be substi-

1) Necessity tion, identifying which step the instructions are in-
tended for.
q: Special tools which are very useful if

tuted, should always be used. • Marks shown in the Installation Section stand for
the following.
available, can be substituted with com-
k
mercially available tools. This mark indicates safety-related pre-
cautions which must be followed when
2) Distinction of new and existing special tools doing the work.
a
N: Tools with new part numbers, newly This mark gives guidance or precau-
developed for this model. tions when doing the procedure.
R: Tools with upgraded part numbers,
2
remodeled from already available tools This mark stands for a specific coating
for other models. agent to be used.
3
Blank: Tools already available for other
models, used without any modifica- T h is m a r k in d ica te s th e s p e c ifie d
tion. torque.
5
3) Circle mark (Q) in sketch column: This mark indicates an amount of oil or
A circle mark means that a sketch of the coolant to be added.
special tool is presented in the section of
Sketches of special tools.
a Part No. of special tools starting with 79*T means

Sketches of special tools
• Various special tools are illustrated for the con-
that they are locally made parts and as such not venience of local manufacture.
interchangeable with those made by Komatsu in
Japan e.g. 79*T--- xxx --- xxxx.
Removal of parts
• The Removal Section contains procedures, pre-
cautions and the amount of oil or coolant to be
drained.
• Various symbols used in the Removal Section
are explained and listed below.
k
This mark indicates safety-related pre-
doing the work.
a
This mark gives guidance or precautions
when doing the procedure.
This mark shows that there are instruc-

[*1]
tions or precautions for installing parts.
6
This mark shows oil or coolant to be
drained.
4
This mark shows the weight of a part or a
device.
30-2 WA430-6
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
Disassembly and assembly of assemblies
Special tools Assembly

• Special tools which are deemed necessary for • Section titled Assembly contain procedures, pre-
disassembly and assembly of parts are listed. cautions and the know-how for the work, as well
• List of the special tools contains the following as the amount of oil or water to be added.
kind of information. • Various symbols used in Assembly Section are
t: Special tools which cannot be substi-

1) Necessity explained and listed below.
k
q: Special tools which are very useful if
tuted, should always be used.
available, can be substituted with com- doing the work.
a
mercially available tools. This mark gives guidance or precau-
tions when doing the procedure.
2) Distinction of new and existing special tools
2
N: Tools with new part numbers, newly This mark stands for a specific coating
developed for this model. agent to be used.
3
R: Tools with upgraded part numbers,
remodeled from already available tools Th i s m a rk in d ic a t e s t h e sp e c if ie d
for other models. torque.
5
Blank: Tools already available for other This mark indicates an amount of oil or
models, used without any modifica- coolant to be added.
tion.
3) Circle mark (Q) in sketch column:
A circle mark means that a sketch of the Sketches of special tools
special tool is presented in the section of • Various special tools are illustrated for the con-
Sketches of special tools. venience of local manufacture.
a Part No. of special tools starting with 79*T means

that they are locally made parts and as such not
interchangeable with those made by Komatsu in
Japan e.g. 79*T--- xxx --- xxxx.
Disassembly
• The Disassembly Section contains procedures,
precautions and the amount of oil or coolant to
be drained.
• Various symbols used in the Disassembly Sec-
tion are explained and listed below.
k
doing the work.
a
This mark gives guidance or precautions
when doing the procedure.
This mark shows that there are instruc-

[*1]
tions or precautions for installing parts.
6
This mark shows oil or coolant to be
drained.
WA430-6 30-3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
Precautions when performing operation

Be sure to follow the general precautions given below when performing removal or installation (disassembly or
assembly) of units.
1. Precautions when performing removal work

• If the engine coolant contains antifreeze, dispose of it properly.
• After disconnecting hoses or tubes, cover them or install blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary plac-
es before removal to prevent any mistake during assembly.
• To avoid loosening any wire contacts, do not pull on the wires. In order to prevent excessive force to the
wiring, hold onto the connectors when disconnecting them.
• Fasten tags to wires and hoses to identify them and show their installation position. This helps prevent
any mistakes when re-installing.
• Count and check the number and thickness of the shims and keep them in a safe place.
• When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly

Install the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes

Nominal Number Plug (nut end) Nut (elbow end)
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes

Nominal Number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used:
Nominal Dimensions
Part Number
Number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
30-4 WA430-6
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with two or three drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press-fitting parts, coat the surface with anti-friction compound (LM-P).
• After installing snap rings, check that the snap ring is installed securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect it
securely.
• When using eye bolts, check that there is no deformation or deterioration. Screw them in fully, and align
the direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling the cylinders, pumps and other
hydraulic equipment removed for repair, bleed the air as follows:
1) Start the engine and run it at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinders 4 – 5 times, stopping the
cylinders 100 mm from the end of their stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
a When using the machine for the first time after repair or long storage, follow the same procedure.
4) After doing this run the engine at normal speed.
3. Precautions when completing the operations

• If the engine coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed for repair, bleed the air from the system after
a For details, see Testing and adjusting, Bleeding air.

reassembling the parts.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related
parts.
WA430-6 30-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Special tool list

a Tools with part number 79QT-QQQ-QQQQ can not be supplied (they are items to be locally manufactured).
a Necessity: t:
q:
Cannot be substituted, should always be installed (used)
Extremely useful if available, can be substituted with commercially available
a New/remodel:
part.
N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for
other models.
Blank: Tools already available for other models, used without any modification
a Tools marked Q in the Sketch column are tools introduced in special sketches (See Sketches of special
tools).
Nece- New/
Work item Symbol Part No. Part Name Q’ty Sketch Nature of work, remarks
ssity remodel
t
Separation of gear and
fuel injection pump assem- 1 795-799-1390 Remover 1
shaft
bly A
q
Removal and installation of Tightening of cylinder
2 790-331-1110 Wrench 1
t
cylinder head assembly head bolt
t
Disassembly and assembly 790-501-5200 Unit repair stand 1 Disassembly and assem-
t
of torque converter assem- C 1 790-901-2110 Bracket 1 bly of torque converter
bly assembly
q Q
790-901-2150 Plate 1
q
Disassembly and assembly 793T-607-1240 Bracket 2
1 Rotation of transmission
of transmission assembly
t
01010-81645 Bolt 8
t
790-201-2170 Plate 1
3
t
790-201-2730 Spacer 1 Press fitting of bearing
Disassembly and assembly D 4 796-465-1120
t
Push tool 1
of transmission clutch pack
t
5 793-607-1110 Seal holder 1
assembly Installation of seal ring
6 793-607-1120 Seal holder 1
t
Check of operation of
7 799-301-1500 Oil leak tester kit 1
q Q
clutch
q
Disassembly and assembly 793T-607-1210 Lifting tool 2 Lifting of clutch pack
F 2
of transmission assembly 793-607-1230 Pin 2 assembly
Removal and installation of 793T-607-1190 Bracket t 1 Q
t
parking brake disc, plate Removal and installation
1 722-14-13130 Holder 1
t
Disassembly and assembly of snap ring
of parking brake assembly 01011-62020 Bolt 1
t Q
t
793T-607-1130 Push tool 1
Press fitting of oil seal
t
3 790-101-5421 Grip 1
and dust seal
t Q
01010-81240 Bolt 1
4 793T-607-1140 Spacer 1 Press fitting of dust seal
t Q
Installation of bearing to
5 792T-446-1150 Push tool 1
Disassembly and assembly H boss
t Q
of parking brake assembly Installation of output shaft
6 797T-423-1141 Push tool 1
t Q
bearing
t
793T-512-1110 Push tool 1
t
8 790-101-5421 Grip 1
and dust seal
t Q
01010-51240 Bolt 1
t Q
9 793T-607-1160 Spacer 1 Press fitting of dust seal
t Q
793T-622-1330 Push tool 1
Disassembly and assembly Press fitting of oil seal
t
11 793T-622-1340 Spacer 1
of axle housing assembly and bearing (for front)
790-201-2760 Spacer 1
30-6 WA430-6
Nece- New/
t Q Positioning of oil seal (for

ssity remodel
t
793T-622-1370 Support 2
12
01016-30860 Bolt 6 front)
t Q
13 793T-522-1160 Push tool 1
t Q Press fitting of bearing

sleeve (for rear)
t Q (for rear)
793T-522-1140 Push tool 1
Disassembly and assembly 14
t Q Positioning of oil seal

H 793T-522-1150 Spacer 1
of axle housing assembly
t
793T-522-1170 Support 2
15
sleeve (for rear)
t Q
01010-30860 Bolt 6
22 793T-622-1610 Holder 1 Selection of shim
t Q
Press fitting of bearing
23 797T-423-1290 Push tool 1
t
(for differential)
t
790-501-5200 Unit repair stand 1 Disassembly and assem-
t Q
16 790-901-2110 Bracket 1 bly of differential assem-
bly (for front)
t
790T-901-3440 Plate 1
t
796-765-1110 Push tool 1 Press fitting of pinion
790-201-2750 Spacer 1 gear bearing (for front)
t Q
17
Press fitting of pinion
793T-522-1130 Push tool 1
gear bearing (for rear)
t Q
Assembly of pinion gear
792T-423-1110 Push tool 1 and cage assembly (for
front)
18
t
Assembly of pinion gear
790-201-2740 Spacer 1 and cage assembly (for
t Q
rear)
t
793T-622-1410 Push tool 1
Press fitting of pinion
t
790-101-5421 Grip 1
cage oil seal (for front)
t Q
01010-51240 Bolt 1
19
t
Disassembly of differential 793T-522-1110 Push tool 1
H Press fitting of pinion
t
assembly 790-101-5421 Grip 1
cage oil seal (for rear)
t Q
01010-81240 Bolt 1
t Q
793T-622-1410 Push tool 1
t
793T-622-1420 Spacer 1 Press fitting of pinion
cage dust seal (for front)
t
790-101-5421 Grip 1
t Q
01010-81240 Bolt 1
20
t Q
793T-522-1110 Push tool 1
t
793T-522-1120 Spacer 1 Press fitting of pinion
cage dust seal (for rear)
t
790-101-5421 Grip 1
t
01010-51240 Bolt 1
t
21-1 790-301-1720 Adapter 1
t
21-2 799-101-5002 Hydraulic kit 1 Check for brake oil leak-
age
t
21-3 793-605-1001 Brake tester 1
21-4 790-101-1102 Hydraulic pump 1
t
Measurement of no-load
24 796-751-1510 Wrench 1 differential torque of anti-
t
slip differential
t
1 790-101-2300 Push puller 1
t
2 793-520-2370 Push tool 1
t
3 793-520-2350 Push tool 1 Installation of center
Removal and installation of hinge pin
t
K 4 793-520-2540 Guide 1
center hinge pin
t
5 793-520-2360 Bar 2
t
6 790-101-1102 Hydraulic pump 1
7 790-101-2102 Puller assembly 1 (294kN {30ton})
WA430-6 30-7
Nece- New/
t
ssity remodel
790-502-1003 Repair stand 1 Disassembly and assem-
t
1 bly of hydraulic cylinder
790-101-1102 Hydraulic pump 1
assembly
t
790-102-2303 Removal and installation
Wrench assem-
2 or 1 of cylinder head
bly
790-330-1100 (for steering cylinder)
t
Removal and installation
3 790-302-1390 Socket 1 of piston nut
(for steering cylinder)
t
Wrench assem- Removal and installation
790-102-4300 1
bly of piston assembly (for lift
t
4
arm and bucket cylin-
790-102-4310 Pin 1
t
ders)
t
5 790-720-1000 Expander 1 Installation of piston ring
t
796-720-1640 Ring 1
For steering
t
Disassembly and assembly 07281-00909 Clamp 1
t
of hydraulic cylinder U 796-720-1670 Ring 1
6 For lift arm
assembly
t
07281-01279 Clamp 1
t
796-720-1680 Ring 1
For bucket
t
07281-01589 Clamp 1
790-201-1702 Push tool kit 1
Press fitting of cylinder
790-101-5021 • Grip
head bushing
01010-50816 • Bolt 1
7
790-201-1751 • Push tool 1 For steering
For lift arm
790-201-1841 • Push tool 1
t
and bucket
790-201-1500 Push tool kit 1
Installation of cylinder
790-101-5021 • Grip 1
head dust seal
01010-50816 • Bolt 1
8
790-201-1560 • Plate 1 For steering
For lift arm
790-201-1650 • Plate 1
and bucket
t
Removal and installation of Filling air conditioner with
799-703-1200 Service tool kit 1
engine assembly refrigerant
Removal and installation of 799-703-1100 Vacuum pump t 1 (100 V)
t
operator's cab and floor
1 799-703-1111 Vacuum pump 1 (220 V)
frame assembly
Removal and installation of 799-703-1121 Vacuum pump t 1 (240 V)
t
air conditioner unit assem- X
799-703-1401 Gas leak detector 1
t
bly
t
2-1 793-498-1120 Clear plate 2
t
Removal and installation of 2-2 793-498-1130 Plate 2
operator's cab glass (stuck 2-3 793-498-1110 Magnet 2 Positioning of glass
t
glass) Lifter (Suction
3 793-498-1210 2
cup)
30-8 WA430-6
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D1 Bracket
F2 Lifting tool
WA430-6 30-9
H1 Bracket
H3 Push tool
30-10 WA430-6
H4 Spacer
H5 Push tool
WA430-6 30-11
H6 Push tool
H8 Push tool
30-12 WA430-6
H9 Spacer
H11 Push tool
WA430-6 30-13
H11 Spacer
H12 Support
30-14 WA430-6
H13 Push Tool
H14 Push Tool
WA430-6 30-15
H14 Spacer
H15 Support
30-16 WA430-6
H16 Plate
H17 Push tool
WA430-6 30-17
H18 Push tool
H19/H20 Push tool
30-18 WA430-6
H19/H20 Push tool
H20 Spacer
WA430-6 30-19
H20 Spacer
H22 Holder
9JS02736
30-20 WA430-6
H23 Push tool
WA430-6 30-21
30-22 WA430-6
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
Removal and installation of 5. Disconnect connector (5) and remove bracket

(6).
fuel injection pump assembly
6. Remove fuel hose (7). [*3]
Special tool
7. Remove bracket (8).
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part name
A1 795-799-1390 Remover t 1
Removal
k Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Remove the engine hood assembly. For details,

see Removal and installation of engine hood as-
sembly.
8. Disconnect connectors (9), (10), and (11).
2. Remove tube (1).
3. Remove air intake connector (2) and bracket (3).

[*1]
4. Remove 6 fuel tubes (4) between the fuel injec-

tion pump and fuel injector. [*2]
WA430-6 30-23
10. Remove oil feed pipe (13) and cover (14). 13. Tighten the 2 bolts of tool A1 alternately to loos-
en the fuel injection pump gear and shaft.
11. Set bar [1] to the bolt of crank pulley (15) and ro-
tate the crank pulley forward to match TDC 14. Sling the fuel injection pump assembly tempo-
stamp line (a) of the gear cover to stamp line (b) rarily.
of the fuel injection pump gear.
15. Remove 4 installing nuts (18) and fuel injection
a Take care that the nut and washer will not fall
12. Remove nut (16) and washer (17). pump assembly (19).
in the case. 4 Fuel injection pump assembly: 35 kg
30-24 WA430-6
Installation
1. Install the fuel injection pump assembly.

1) Check that shaft pin (20) is directed right up.
2) While checking that the shaft pin is matched

to cut (a) of the fuel injection pump gear,
install the fuel injection pump assembly.
a Take care that the washer and nut will

4) Install washer (17) and tighten nut (16).
3 Nut: 182 Nm {18.6 kgm}

not fall in the case.
3) Tighten 4 installing nuts (18) of the fuel

injection pump assembly and support brack-
ets (8) and (12).
3 Installing nut and support bracket:

44 Nm {4.5 kgm}
WA430-6 30-25
2. For the rest of the installation work, carry out in-

stallation in the reverse order to removal.
3 Air intake connector U-bolt:

[*1]
10.8 – 26.5 Nm {1.1 – 2.7 kgm}
3 Fuel tube
[*2]
On fuel injection pump side:

24 Nm {2.5 kgm}
On fuel injector side:
38 Nm {3.9 kgm}
3 Fuel hose: 37 Nm {3.8 kgm}

[*3]
Bleeding air
Bleed air from the fuel circuit. For details, see Test-
ing and adjusting, Bleeding air from fuel circuit.
30-26 WA430-6
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
Removal and installation of 5. Remove muffler (4).
fuel injector assembly 4 Muffler assembly: 45 kg
Removal

sembly.
2. Disconnect connector E33 (1).
3. Remove air cleaner and bracket assembly (2).

[*1]
6. Disconnect terminals E07 (6), E05 (7), E06 (8),
and E08 (30) of heater relay (5) and remove
bracket (31). [*2]
7. Remove bracket (9) and air intake connector

(10). [*3]
4. Remove tube (3).
WA430-6 30-27
8. Remove cylinder head cover (11) and gasket. 14. Remove fuel connector (20). [*8]
[*4]
9. Remove 6 fuel tubes (12). [*5]
15. Install bolt [1] (M8 x 1.25) to the top of the fuel in-
jector assembly.
10. Loosen nut (13) and loosen screw (14) by 2 – 3

turns. [*6]
11. Remove rocker arm and rocker shaft assemblies

(15) and (16). [*7]
12. Remove cross heads (24) and (25).
16. Using bar [2], remove fuel injector assembly (21).
13. Remove holders (17), (18), and (19). [*8]
30-28 WA430-6
a Direct the cut side of holder (19) to the air in-

Installation 2) Tighten the mounting bolts of holder (19).
• Carry out installation in the reverse order to re-
moval. take side and install bolts (22) and (23) as
3 Holder mounting bolt:

shown below.
3 Hose clamp:
[*1]
10 Nm {1.02 kgm}
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Terminal E05:
[*2]
1.9 – 2.5 Nm {0.19 – 0.25 kgm}

Terminal E06 and E08:
2.5 – 2.9 Nm {0.25 – 0.3 kgm}
3 Air intake connector U-bolt:

[*3]
10.8 – 26.5 Nm {1.1 – 2.7 kgm}
3 Cylinder head cover mounting bolt:

[*4]
12 Nm {1.2 kgm}
3 Fuel tube
[*5]
On fuel injection pump side:

24 Nm {2.5 kgm}
On fuel injector side:
38 Nm {3.9 kgm}
a Adjust the valve clearance. For details, see

[*6]
Testing and adjusting, Adjusting valve clear-

ance.
2 Rocker shaft mounting bolt:

[*7]
3 Rocker shaft mounting bolt:

Engine oil
60 Nm {6.1 kgm}
[*8]
1) Insert the fuel connector securely until its tip
"a" is fitted to part "b" of the fuel injector.
WA430-6 30-29
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
Removal and installation of 6. Remove muffler (4).
cylinder head assembly 4 Muffler assembly: 45 kg
Special tool
New/Remodel
Necessity
Sketch
Q'ty
A2 790-331-1110 Wrench q 1
Removal
1. Drain the coolant. 7. Disconnect hose (5).
6 Coolant: 36 l

sembly.
4. Remove air cleaner and bracket assembly (2).
[*1]
8. Remove air intake tube (6). [*2]
5. Remove tube (3).
30-30 WA430-6
9. Remove lubrication tubes (7) and (8) and clamp 13. Remove the fuel injector assembly. For details,
(9). [*3] see Removal and installation of fuel injector as-
sembly.
14. Remove push rods (16) and (17).
10. Remove exhaust manifold and turbocharger as-

sembly (10). [*4]
4 Exhaust manifold and turbocharger 15. Remove fuel tube (18) from the rear left of the
assembly: 40 kg cylinder head.
11. Disconnect connectors (11) and (12). 16. Remove support bracket (19) between the cylin-
der head and fuel injection pump. [*6]
12. Remove fuel tubes (13) and (14) and remove fuel
filter and head assembly (15). [*5]
WA430-6 30-31
17. Loosen and remove the cylinder head bolts in the Installation
reverse order of the numbers shown below. [*7] • Carry out installation in the reverse order to re-
moval.
3 Hose clamp:
[*1]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Air intake tube U-bolt:

[*2]
10.8 – 26.5 Nm {1.1 – 2.7 kgm}
3 Lubrication tube (7): 20 Nm {2.0 kgm}

[*3]
Mounting bolt of lubrication tube (8):

27 Nm {2.8 kgm}
18. Lift off cylinder head assembly (20).
4 a Tighten the exhaust manifold mounting bolts

[*4]
Cylinder head assembly: 75 kg
3 Exhaust manifold mounting bolt:

in the order of the numbers shown below.
43 Nm {4.4 kgm}
3 Fuel tubes (13) and (14):

[*5]
37 Nm {3.8 kgm}
3 Support bracket: 44 Nm {4.5 kgm}

[*6]
a Tighten the cylinder head mounting bolts in

[*7]
2 Threads and seat of cylinder head bolt:

the order of the numbers shown below.
19. Remove cylinder head gasket.
Engine oil
3 1st time: 148 Nm {15.1 kgm}

2nd time: 148 Nm {15.1 kgm}
3rd time: Using tool A2, tighten by 90°.
When not using tool A2, make marks
with paint on the bolt heads and cylin-
der head, and then tighten the bolts so
that the mark of each of them will be at
the above angle, using a protractor.
30-32 WA430-6
Refilling with coolant

Add coolant through the coolant filler to the specified
level. Run the engine to circulate the coolant
through the system. Then, check the coolant level
again.
5 Coolant: 36 l
WA430-6 30-33
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
Removal and installation of 5. Remove the clamp of hose (7).
radiator assembly 6. Remove cable (8) from the radiator assembly.
Removal
1. Drain the coolant.
6 Coolant: 36 l

sembly.
3. Disconnect hoses (1) – (4). [*1]
7. Disconnect hose (9). [*2]
4. Remove 4 mounting bolts (5) of the hydraulic oil

cooler assembly. Lower hydraulic oil cooler as-
sembly (6) and move it toward the engine.
a The cover is fixed together with the fan net.

8. Remove cover (10).
30-34 WA430-6
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
9. Disconnect hoses (11) – (13). Installation

moval.
2 Inserting part of hose (3):

[*1]
3 Clamp of hose (3):

Three bond 1208E
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Hose clamp:
[*2]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
2 Right/Left stay mounting bolt:

[*3]
10. Sling the radiator assembly temporarily.
3 Right/Left stay mounting bolt:

Adhesive (LT-2)
11. Remove right and left stays (14) and 2 mounting
3 Mounting bolt:
bolts (15). [*3] 98 – 123 Nm {10 – 12.5 kgm}
157 – 196 Nm {16 – 20 kgm}

level. Run the engine to circulate the coolant through
the system. Then, check the coolant level again.
5 Coolant: 36 l
Bleeding air
Bleed air from the fan motor circuit. For details, see
Testing and adjusting, Bleeding air from fan motor
circuit.
12. Lift off radiator assembly (16).
4 Radiator assembly: 190 kg
WA430-6 30-35
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
Removal and installation of 4. Lift off plate (1).
engine assembly 4 Plate: 25 kg
Special tools
New/Remodel
Necessity
Sketch
Q'ty
799-703-1200 Service tool kit t 1

799-703-1100 Vacuum pump t 1
X1 799-703-1111 Vacuum pump t 1
799-703-1121 Vacuum pump t 1
799-703-1401 Gas leak detector t 1

Removal
k Disconnect the cable from the negative (–) ter- 6. Remove air cleaner and bracket assembly (3).
minal of the battery. [*1]
1. Drain the coolant.
6 Coolant: 36 l
2. Collect the air conditioner refrigerant from the air

conditioner circuit. [*1]

a Disconnect hoses (60) and (61) and remove

sembly.
water separator (63).
7. Remove the bulkhead assembly.

1) Remove the mounting bolts of bracket (4)
and move oil filter (5) to the engine side.
30-36 WA430-6
2) Open the bulkhead top cover. 9) Remove right and left covers (14) under the
3) Disconnect hoses (6) and (7). bulkhead.
4) Remove the mounting bolt of breather hose
(8).
5) Disconnect connector BR1 (9).
6) Remove clamps (10) and (11).
10) Remove bulkhead assembly (15).
4 Bulkhead assembly: 80 kg
7) Remove the 2 upper mounting bolts and 2

lower mounting bolts of tank (12) and lower
the tank.
8. Remove tube (16).
8) Remove cover (13) between the bulkhead

and operator's cab.
WA430-6 30-37
9. Remove muffler assembly (17). 12. Remove hoses (23) – (26). [*3]
4 Muffler assembly: 45 kg
13. Remove ground cable (27) and bracket (28) from

the flywheel housing.
10. Move wiring harnesses (18) and (19) above the
flywheel housing.
14. Disconnect connector E01 (29), terminal E30

(30), and terminal B (31).
11. Disconnect connectors ER2 (20), ER3 (21), and
E27 (22) at the rear left of the engine.
30-38 WA430-6
15. Disconnect terminals E02 (32), E03 (33), and 20. Disconnect terminals E07 (41), E05 (42), E06
E04 (34). (43), and E08 (44) from heater relay (40) above
the engine. [*4]
16. Disconnect hoses (35) and (60).
17. Disconnect tubes (36) and (37) from the air con-
ditioner compressor assembly.
21. Disconnect connectors E26 (45) and ER4 (46)

from the left side of the engine.

18. Remove engine oil drain valve (38) from the fuel
tank.
23. Remove rear drive shaft (48) between the trans-

mission and rear axle. [*5]
19. Disconnect fuel hose (39).
WA430-6 30-39
a When removing the engine assembly, check

24. Support the bottom of the transmission side of 28. Lift off engine assembly (51).
the engine and transmission coupler with jack.
a Set the above jack to prevent the coupler on

[1] that no wires and pipes are connected to the
chassis and take care that the engine as-
the transmission side from lowering when it sembly will not interfere with the chassis.
4
is separated.
Engine assembly: 850 kg
25. Sling the engine assembly temporarily.
26. Remove right and left mounting bolts (49). [*6]
27. Remove 12 coupling bolts (50) of the engine and

transmission and separate them.
30-40 WA430-6
Installation
moval.
a Using tool X1, fill the air conditioner circuit

[*1]
with air conditioner refrigerant (R134a).
3 Hose clamp:
[*2]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
2 Inserting part of hose (25):

[*3]
3 Clamp of hose (25):

Three bond 1208E
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Terminal E05:
[*4]
1.9 – 2.5 Nm {0.9 – 0.25 kgm}

Terminals E06 and E08:
2.5 – 2.9 Nm {0.25 – 0.3 kgm}
a Before tightening the mounting bolts, check

[*5]
that the key way of the spider cap is fitted se-
a Check that the misalignment of the rear axle

curely to the key way of the mating yoke.
and transmission to the right or left is not

larger than 3 mm. If the misalignment ex-
ceeds 3 mm, adjust it by changing the install-
ing position.
3 Drive shaft mounting bolt:

98.1 – 123 Nm {10 – 12.5 kgm}
3 Right/Left mounting bolt:

[*6]
490 – 608 Nm {50 – 62 kgm}

level. Run the engine to circulate the coolant through
the system. Then, check the coolant level again.
5 Coolant: 36 l
WA430-6 30-41
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY
Removal and installation of 4. Remove cover (5).
engine hood assembly
Removal
1. Open the right and left engine side covers and

fan grille.
2. Disconnect hoses (1) and (2) and remove the
a Support the bottom of plate (3) with a block,

mounting bolts of plate (3).
a You cannot remove only plate (3).

etc. 5. Disconnect connectors GR2 (6), CN-55 (7), and
GR1 (8).
3. Remove the mounting bolts of water separator 6. Remove bar (9).

head (4) and fix the water separator to the engine
with ropes, etc.
30-42 WA430-6
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY
7. Remove exhaust pipe (10). 11. Lift off engine hood assembly (14).
4 Engine hood assembly: 340 kg
8. Disconnect hose (11).
Installation
moval.
9. Open the bulkhead top cover and disconnect

hose (12).
WA430-6 30-43
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
Removal and installation of 6. Remove the mounting bolts of oil cooler (5).
fuel tank assembly
Removal
1. Drain the fuel.
6 Fuel tank (when full): 300 l
2. Remove the mounting bolts of engine oil drain

valve (1).
7. Remove the clamp of breather hose (6).
3. Remove clamp (2).
8. Disconnect fuel hoses (7) and (8).

4. Remove the mounting bolts of coolant drain
valve (3).
5. Disconnect connector R33 (4).
30-44 WA430-6
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
9. Remove right and left steps (9) and (10) and 13. Lift off fuel tank assembly (16).
4
brackets (11) and (12).
Fuel tank assembly: 200 kg
10. Support the front bottom of the fuel tank assem-

bly with jack [1].
11. Sling the center of the fuel tank assembly tempo- Installation
a Remove plate (13) and tighten a bolt into the
rarily with a nylon sling, etc. • Carry out installation in the reverse order to re-
moval.
bolt hole to prevent the sling from moving.
3 Fuel tank mounting bolt:

[*1]
12. Remove 2 hydraulic tank assembly mounting
bolts (14) and mounting bolt (15). [*1] 785 – 980 Nm {80 – 100 kgm}
Bleeding air
Bleed air from the fuel circuit. For details, see Test-
ing and adjusting, Bleeding air from fuel circuit.
WA430-6 30-45
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION OF PARKING BRAKE DISC AND PLATE
Removal and installation of 3. Remove bolt (3) and then remove washer (4),
holder (5) and coupling (6). [*2]
parking brake disc and plate
Special tool
New/Remodel
Necessity
Sketch
Q'ty
793T-607-1190 Bracket t 1 Q
H1 772-14-13130 Holder t 1
01011-62020 Bolt t 1
Removal 4. Remove 6 mounting bolts (8) and use forcing

k
a Check the thickness and quantity of the
Park the machine on flat ground and set the screw [1] to remove bearing cage (7). [*3]
safety bar to the frame.
k Lower the work equipment to the ground com-
shims in advance.
pletely and stop the engine. Apply the parking
brake and put the blocks under the wheels. 5. Remove level gauge cover (9). [*4]
1. Drain oil from the transmission case.
2. Remove guard (1), and then disconnect center
a Shorten the center drive shaft.

drive shaft (2) at the transmission side. [*1]
6. Loosen mounting bolts (11) of brake cover (10)

equally, and remove cover (10) and spring (12).
a Since the mounting bolts are pressed with

[*5]
the brake spring, loosen them equally.
30-46 WA430-6
7. Keep guide bolt [2] installed to housing (13). 11. Remove hub (17) and then remove plates (18),
a 10 plates, 9 springs, and 9 discs

springs (19) and discs (20). [*7]
8. Remove bearing assembly (14).
9. Install 2 bolts [3] to piston (15), and gradually pry
a Hold bolt [3] and remove the piston.

the bolt with bar [4] to remove piston (15). [*6]
10. Use tool H1 to push the brake disc and the plate
a For the bolt and holder of tool H1, the cou-

inside, and remove snap ring (16).
pling mounting bolt and holder can be used.
WA430-6 30-47
a Install hub (17) first and then install plates

Installation [*7]
a Be careful so that spring (19) is not pinched

moval. (18), springs (19) and discs (20) in this order.
a When installing the drive shaft, check that

[*1] between them.
the spider cap key is perfectly nested in the

key way of the counter yoke, and the tighten
the bolt.
3 Mounting bolt:
98 – 123Nm {10 – 12.5kgm}
2 Coupling mounting bolt:

[*2]

Adhesive (LT-2)
490 – 608Nm {50 – 62kgm}
a Set the shims to where it was.

[*3]
3 Cage mounting bolt:

Refilling with oil
98 – 123Nm {10 – 12.5kgm} • Add oil through oil filler to the specified level. Run
the engine to circulate the oil through the system.
3 Cover mounting bolt:

[*4] Then check the oil level again.
98 – 123Nm {10 – 12.5kgm} 5 Transmission case: 54 l
a When replacing any parts other than the disc and

3 Cover mounting bolt:
[*5]
plate, referring to section "Removal and installa-
98 – 123Nm {10 – 12.5kgm} tion of parking brake assembly."
2 Piston O-ring: Grease (G2-LI)

[*6]
a Bring the counter mark "a" of the piston to

the counter mark "b" of the housing, and
then install them.
30-48 WA430-6
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANS-
MISSION ASSEMBLY
Removal and installation of 7. Disconnect hoses (4) – (9) of the hydraulic pump.
torque converter and 8. Remove tubes (10) and (11).

transmission assembly
Removal
1. Remove the engine hood. For details, see Re-

moval and installation of engine hood assembly.
2. Remove the bulkhead assembly. For details,

see Removal and installation of engine assem-
bly.
3. Remove the operator's cab and floor frame as-

sembly. For details, see Removal and installa-
tion of operator's cab and floor frame assembly. 9. Disconnect connector R29 (12) under the fan
pump.
4. Drain the oil from the hydraulic tank and trans-
mission case.
6 Hydraulic tank: 139 l

Transmission case: 54 l
5. Remove rear drive shaft (1) between the trans-

mission and rear axle. [*1]
10. Disconnect terminal (13) from the emergency

steering pump and motor assembly and remove
clamp (14).
6. Remove guard (2) and disconnect center drive
a Shorten the center drive shaft.

shaft from the transmission. [*2]
WA430-6 30-49
MISSION ASSEMBLY
12. Disconnect hose (16) from the left side of the ma- 17. Disconnect connectors R37 (24) and R69 (25)
chine. and hoses (26), (27), and (28) on the right side of
the machine.
13. Disconnect hose (17)

14. Remove filler tube (18).
19. Disconnect tube (31).
15. Disconnect connector R68 (19) at the top of the

transmission oil filter and remove clamps (20) 20. Remove tubes (32) and (33) and bracket (34).
and (21).
16. Remove 4 head mounting bolts (22) of the trans-

mission oil filter and fix filter head assembly (23)
to the transmission with ropes, etc.
21. Sling the torque converter and transmission as-

sembly temporarily.
30-50 WA430-6
MISSION ASSEMBLY
22. Set block [1] under the flywheel housing to pre- 25. Lift off torque converter and transmission assem-
a The following photo shows the separated en- a When removing the torque converter and
vent the engine from falling after it is separated. bly (37).
gine. transmission assembly, check that no wires

and pipes are connected to the chassis and
take care that the assembly will not interfere
with the chassis.
4 Torque converter and transmission

assembly: 1,050 kg
23. Remove mount brackets (35) on the right and left

sides of the transmission. [*3]
24. Remove 12 coupling bolts (36) for the engine

and transmission and separate the transmission.
WA430-6 30-51
MISSION ASSEMBLY
Installation

moval.
a Before tightening the mounting bolts, check that

[*1] [*2]
the key way of the spider cap is fitted securely to
a When installing the rear drive shaft, check that

the key way of the mating yoke.
the misalignment of the rear axle and transmis-

sion to the right or left is not larger than 3 mm. If
the misalignment exceeds 3 mm, adjust it by
changing the installing position.
3 Drive shaft mounting bolt:

98.1 – 123 Nm {10 – 12.5 kgm}
3 Transmission mounting bolt:

[*3]
490 – 608 Nm {50 – 62 kgm}
a Adjust both clearances "a" and "b" to 2 mm with

the adjustment bolt and locknut.
Refilling with oil

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the sys-
tem. Then, check the oil level again.
Bleeding air
Bleed air. For details, see Testing and adjusting,
Bleeding air from steering circuit, Bleeding air from
fan motor circuit, Bleeding air from wheel brake cir-
cuit, and Bleeding air from work equipment circuit.
30-52 WA430-6
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY
Disassembly and assembly of 5) Remove steering and fan pump assembly

(8).
transmission assembly
Special tools
New/Remodel
Necessity
Sketch
Q'ty
793T-607-1240 Bracket q 2 Q
q 8
D1
01010-81645 Bolt
793T-607-1210 Lifting tool q 2 Q
q 2
F2
793-607-1230 Pin
2. Remove emergency steering pump and motor
assembly (9) and bracket together.
Removal
1. Hydraulic pump assembly
1) Remove hose (1) and tube (2).
2) Remove bracket (3) and slinger (4).
3. Remove strainer (10).
3) Remove tube (5) and torque converter and

work equipment hydraulic pump assembly
(6).
4) Disconnect breather hose (7).
WA430-6 30-53
a When removing the bolt, fix the holders at

4. Disconnect connector TC. T (11) and hoses (12) 9. Remove cover (21) and level gauge (22).
and (13).
the top and bottom of the level gauge with
5. Remove bracket (14). spanners.
7. Remove oil filter head assembly (16). 11. Transmission control valve assembly
1) Disconnect connectors (60) – (77).
(60): JT1, (61): JT2, (62): F.PS
(63): F.SW, (64): R.PS, (65): R.SW
(66): 4.PS, (67): 4.SW, (68): 1.PS
(69): 1.SW, (70): 3.PS, (71): 3.SW
(72): 2.PS, (73): 2.SW, (74): PB.PS
(75): PB.SW, (76): TM.T, (77): REV
2) Remove bracket (24) and wiring harness
assembly (25) together.
8. Remove block (17), flow control valve (18), tube

(19), and nipple (20).
30-54 WA430-6
3) Sling the transmission control valve assem- 12. Transmission output shaft speed sensor and
bly temporarily. transmission oil temperature sensor
4) Remove the 10 mounting bolts (A, B, C, and Remove transmission output shaft speed sensor
D) and transmission control valve assembly (27) and transmission oil temperature sensor
(26). (28).
13. Torque converter and rear case assembly

1) Install tool D1 to the left and right transmis-
sion mounts installing position.
2) Support tool D1 of the torque converter and
transmission assembly with block [3] and
support torque converter rear case assem-
bly (31) with stand [4].
3) Sling and turn torque converter and rear
case assembly (31) around tool D1 by 90°
and support front case (76) with block [5].
4) Remove 20 case mounting bolts (30).
WA430-6 30-55
5) Use a lever block to temporarily lift torque 15. PTO gear

converter and rear case assembly (31), and 1) Remove snap ring (34).
disconnect and remove the transmission
case with forcing screw [6].
2) Face the PTO side up and set the rear case

to the block.
14. Torque converter assembly 3) Remove snap ring (37), plate (38) and woo-
1) Face the torque converter side down and lift druff thrust plate (39).
rear case assembly (31). Then, set block [7]
a Keep the case upright.

below torque converter assembly (32).
2) Remove stator shaft mounting bolt (33) and

lift the rear case assembly (31) to remove
torque converter assembly (32).
30-56 WA430-6
4) Pull out shaft (40) and remove PTO gear 2) Use tool F2 to lift 1st speed and 4th speed
(41). clutch assembly (45) together with 2nd
speed and 3rd speed clutch assembly (46)
and remove it.
5) Remove snap ring (35) and plate (36) from

shaft (40).
6) Remove bearing (43) and inner race (59) 3) Use eyebolt [11] to lift forward and reverse
a Repeat the same procedures to remove

from shaft (40). clutch assembly (47) and remove it.
the PTO gear on the opposite side. 17. Yoke

Remove yoke (48).
16. Clutch pack assembly

1) Remove seal ring (44) from the shaft. 18. Reverse idler gear
1) Remove bolt (49) and plate (50).
WA430-6 30-57
2) Use puller [12] to remove gear (51) and 3) Remove outer race (58) from cage (56).
bearing (52).
3) Remove bearing (52) and plate (53).
Assembly
19. Bearing (On the 1st speed clutch side)
Remove bearing (54). 1. Cage (on the 2nd speed clutch side)
1) Install outer race (58) to cage (56).
20. Cage (On the 2nd speed clutch side)
1) Remove cover (55).
2) Set removed shim (57) in cage (56) and
a In order to adjust the shim here after the

tack-weld the cage.
a Check the thickness and quantity of

2) Use a forcing screw to remove cage (56).
clutch assembly is assembled.
shims (57) in advance.
2. Bearing (on the 1st speed clutch side)
Use the push-tool to install bearing (54) to the
housing.
30-58 WA430-6
3. Reverse idler gear 4. Yoke

1) Install plate (53). Install yoke (48).
2) Use the push-tool to install bearing (52) with
counter mark B. 5. Clutch assembly
3) Install outer race (52-1) to gear (51). 1) Face the brake side down and set the front
case on the block.
2) Use eyebolt [11] to install forward-reverse
clutch assembly (47).
4) Set spacer (52-2) and install gear (51).

5) Use the push-tool to install the bearing with
counter mark A.
6) Give gear (51) at least 10 turns to fit the 3) Use tool F2 to combine 1st speed and 4th
bearing. speed clutch assembly (45) and 2nd speed
and 3rd speed clutch assembly (46) and
a When it is difficult to set the roller bear-

install them at the same time.
ing on the 1st speed clutch side, remove

the bearing and set it to the shaft side to
install it.
7) Install plate (50) and tighten bolt (49).
2 Bolt: Adhesive (LT-2)
3 Bolt:
98 – 123 Nm {10 – 12.5 kgm}
WA430-6 30-59
4) Install seal ring (44) to the shaft.
3 Seal Ring: Grease (G2-LI)
6. PTO gear
1) Install bearing (60) to rear case (31).
5) Install woodruff thrust plate (39), and plate

(38) and snap ring (37) to the shaft.
2) Use the push-tool to install inner race (59)

and bearing (43) to shaft (40).
3) Install plate (36) and snap ring (35).
4) Set PTO gear (41) to the case and install
a Install the smaller one of the 2 PTO

shaft (40).
gears to the side of locator boss (a).
30-60 WA430-6
a Repeat the same procedures to install

6) Install snap ring (34). 8. Rear case assembly
1) For each clutch assembly, make the exten-
the PTO gear on the opposite side. sion of the seal ring from the shaft equal.
2) Install guide bolt [9] to the front case.
3) Use the lever block to lift rear case assem-
bly (31) and to install it to the shaft of the
clutch assembly.
2 Case mating face:

Gasket sealant (LG-4)
a Apply the gasket sealant as shown in the fol-
a Apply the gasket sealant so that the section-

lowing figure.
al area will be 2 – 5 mm2.
7. Torque converter assembly

1) Set torque converter assembly (32) on the
block [7], and install 1 piece of the guide bolt
[8].
2) Lift rear case (31), meet respective bolt
holes with each other and install the rear
case to the torque converter.
3) Tighten 6 pieces of stator shaft mounting

bolt (33).
2 Bolt: Adhesive (LT-2)

3 Bolt: 98 – 123 Nm {10 – 12.5 kgm}
WA430-6 30-61
4) Tighten 20 pieces of mounting bolt (30). 3) Pull out the shim temporarily set in step 1-
3 Mounting bolt:
2), install cover (56), and tighten all mount-
ing bolts to 9.8 ± 0.98 Nm {1.0 ± 0.1 kgm}.
98 – 123 Nm {10 – 12.5 kgm} 4) Using the hole on the end face of shaft (64)
or the output shaft coupling, give the shaft
a If the bolt torque has changed, repeat

20 turns, and check bolt torque.
steps 3) and 4).

5) When the bolt torque does not change any
more, measure the clearance between the
cage and transmission case at 4 or 3 places
a If the dispersion of the measured values

equally spaced on the periphery.
is larger than 0.15 mm, check the bear-

ing and other parts for improper installa-
tion and then take remedies to reduce
the dispersion to 0.15 mm or less.
9. Adjusting procedures of taper roller bearing

shim of 2nd speed and 3rd speed clutch as-
sembly
1) Face the parking brake side up and set the
transmission assembly on the block.
2) Pull brake piston with bolt (63) to release the
parking brake.
6) Obtain average A of the clearances mea-

sured in step 5).
7) Decide the thickness of shims (57).
+0.30
• Thickness of shims (mm) = A +0.25
8) Select and set shims (57) so that their thick-
ness will be the above value, and then
install cover (56).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
9) Install cover (55).
30-62 WA430-6
10. Transmission output shaft speed sensor and 3) Tighten the 10 mounting bolts (A, B, C, and
transmission oil temperature sensor D).
Install transmission output shaft speed sensor (27)
a For installation of the transmission output

and transmission oil temperature sensor (28).
shaft speed sensor, see Testing and adjust-

ing, Adjusting transmission speed sensor.
2 Oil temperature sensor:

Gasket sealant (LG-5)
29.4 – 49 Nm {3 – 5 kgm}
11. Transmission control valve assembly

1) Install the 2 guide bolts to the transmission
case.
2) Install transmission control valve assembly 4) Install bracket (24) and wiring harness
(26). assembly (25) together.
5) Connect connectors (60) – (77).
(60): JT1, (61): JT2, (62): F.PS
(63): F.SW, (64): R.PS, (65): R.SW
(66): 4.PS, (67): 4.SW, (68): 1.PS
(69): 1.SW, (70): 3.PS, (71): 3.SW
(72): 2.PS, (73): 2.SW, (74): PB.PS
(75): PB.SW, (76): TM.T, (77): REV
WA430-6 30-63
12. Connect hose (23). 17. Install oil filter and head assembly (16).
a When installing the bolt, fix the holders at the

13. Install level gauge (22). 18. Connect hose (15).
top and bottom of the level gauge with span-

ners.
2 Mounting bolt: Adhesive (LT-2)

3 Mounting bolt:
12.7 – 13.7 Nm {1.3 – 1.4 kgm}
14. Install cover (21).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
19. Install bracket (14).
20. Connect hoses (13) and (12) and connector TC.

T (11).
15. Install nipple (20) and tube (19).
3 Tube joint bolt:

9.8 – 12.7 Nm {1.0 – 1.3 kgm}
16. Install flow control valve (18) and block (17).
2 Flow control valve mounting bolt:

21. Install strainer (10).
3 Flow control valve mounting bolt:

Adhesive (LT-2)
29.4 – 39.2 Nm {3.0 – 4.0 kgm}
30-64 WA430-6
a Tighten the mounting bolts according to

22. Install emergency steering pump and motor as- 4) Install slinger (4) and bracket (3).
sembly (9) and bracket together.
the following procedure so that clear-
ance will not be made between slinger
(4) and bracket (3) and between bracket
(3) and hydraulic pump.
1] Tighten the mounting bolts of slinger (4).
2] Tighten the mounting bolts on the hydrau-
lic pump side of bracket (3).
3] Tighten the coupling bolts of slinger (4)
and bracket (3).
5) Install tube (2) and hose (1).
23. Hydraulic pump assembly

1) Install steering and fan pump assembly (8).
2) Connect breather hose (7).

3) Install torque converter and work equipment
hydraulic pump assembly (6) and tube (5).
WA430-6 30-65
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH PACK
ASSEMBLY
Disassembly and assembly of 2. Forward gear

1) Remove spacer (1) and thrust washer (4)
transmission clutch pack and remove forward gear (2).
assembly 2) Remove needle bearing (5) from the forward
gear.
Special tool
New/Remodel
Necessity
Sketch
Q'ty
790-201-2170 Plate t 1
t 1
3
790-201-2730 Spacer
4 796-465-1120 Push tool t 1
t 1
D
5 793-607-1110 Seal holder
6 793-607-1120 Seal holder t 1
7 799-301-1500 Oil leak tester kit t 1 3. End plate
1) Use C clamp [3] or the like to press end
Disassembly plate (6) and to remove snap ring (7).
k When loading the clutch pack on the block, take 2) Remove end plate (6).
care so that the clutch pack may not slip from
your hands with oil and so that your finger may
not get caught between the block and clutch
pack.
Disassembly of forward and reverse clutch packs

[Forward clutch side]
1. Bearing
Install puller [1] and push the shaft with a press,
a When the inner race is removed, the clutch

then remove inner race (3).
assembly drops. So catch the clutch assem-

bly by a cushion seat.
4. Clutch plate
1) Remove spring plate (8) from the housing.
30-66 WA430-6
ASSEMBLY
2) Remove plate (9), disc (10) and spring (11). [Reverse clutch side]
6. Bearing
Install bearing race puller [4] on reverse gear
(16) and use hydraulic cylinder [5] to remove
bearing (15).
3) Remove thrust washer (12).
5. Piston
Make air blow into the forward side oil hole of
the shaft and remove piston (14).
7. Reverse gear
1) Remove spacer (17), thrust washer (18) and
reverse gear (16).
2) Remove needle bearing (19) from the
reverse gear.
8. End plate
9. Clutch plate
a Disassemble procedures 8. – 10. in the

10. Piston
same manner as the procedures 3. – 5. at

the reverse clutch side.
a If the piston is tilted and will not remove,
a If the piston is removed by force, note that

push the piston again.
the inside surface of the cylinder is dam-

aged.
WA430-6 30-67
ASSEMBLY
Disassembly of 1st and 4th clutch pack 3. End plate

[1st clutch side] 1) Use C clamp [8] or the like to press end
plate (36) and remove snap ring (37).
1. Idler gear 2) Remove end plate (36).
Use puller [7] to remove inner race (30) and idler
gear (31).
4. Clutch plate
1) Remove plate (38), disc (39) and spring (40)
2. 1st gear from the housing.
1) Remove snap ring (32) and remove thrust
washer (33) and 1st gear (34).
2) Remove needle bearing (35) from the 1st

gear.
30-68 WA430-6
ASSEMBLY
2) Remove thrust washer (41). 7. 4th gear

1) Remove spacer (44), thrust washer (45) and
5. Piston 4th gear (46).
Make air blow into the reverse side oil hole of 2) Remove needle bearing (47) from the 4th
the shaft and remove piston (42). gear.
8. End plate
9. Clutch plate
a Disassemble procedures 8. – 10. in the

10. Piston

the 1st clutch side.
Disassembly of 2nd and 3rd clutch pack

[3rd clutch side]
1. Bearing
a If the piston is tilted and will not remove, push the 1) Apply puller [10] to 3rd gear (53) and
remove bearing (49) and 4th gear (50).
a If the piston is remove by force, note that the in-
piston again.
side surface of the cylinder is damaged.
[4th clutch side]
6. Bearing
Use puller [9] to pull out 4th gear (46) and
remove inner race (43).
WA430-6 30-69
ASSEMBLY
2. 3rd gear 4. Clutch plate

1) Remove thrust washer (52) and 3rd gear 1) Remove plate (56), disc (57) and spring (58)
(53). from the housing.
2) Remove needle bearing (53a) from 3rd gear 2) Remove thrust washer (58a).
(53).
5. Piston
Make air blow into the 3rd clutch side oil hole of
the shaft and remove piston (59).
3. End plate
plate (54) and remove snap ring (55).
2) Remove end plate (54).
a If the piston is tilted and will not remove, push the
a If the piston is removed by force, note that the in-

piston again.
side surface of the cylinder is damaged.
30-70 WA430-6
ASSEMBLY
[2nd clutch side] a Disassemble procedures 8. – 10. in the

6. Bearing the 3rd clutch side.
1) Use forcing screw [12] to pull out output
gear (60) and remove bearing (60a). Assembly
2) Remove output gear (60).
Assembly of the forward and reverse clutch packs
[Reverse clutch side]
1. Seal ring
a When assembling a new seal ring, use tool

Assemble seal ring (66) in piston (65).
D5 to assemble it after the seal having run in
a If the seal is assembled in the cylinder with-

(it takes two or three minutes).
out making the seal run in, note that the seal
is damaged.
2 Tool D5 inside surface:

Transmission oil
7. 2nd gear
1) Remove thrust washer (62) and 2nd gear
(63).
2. Reverse side piston
a Take care so that the seal ring will not be

1) Install reverse side piston (65).
2) Remove needle bearing (64) from 2nd gear damaged.
2 Seal ring sliding surface:

(63).
Transmission oil
2) Install thrust washer (67).
8. End plate
9. Clutch plate
10. Piston
WA430-6 30-71
ASSEMBLY
3. Clutch plate
1) Alternately assemble plate (68), disc (69)
a Assemble disc (69) after having im-

and spring (70) in this order.
mersed it in clean transmission oil for
a Take care so that spring (70) and disc

two minutes or more.
a Carefully assemble the plate and the

(69) will not overlap.
spring so that they will not bite into the

ring groove of the clutch housing.
5. Reverse gear, bearing

1) Assemble needle bearing (19) in the reverse
gear (16) and install it fitting the internal
gear of the disc.
2) Install thrust washer (18), spacer (17) and
bearing (15) in this order.
a Install it facing identification mark U up-

2) Install spring plate (71)
ward.
3) The clearance "a" between spacer (17) and

thrust washer (18) is within a standard
value.
a Measure the clearance "a" using a dial

Standard value "a": 0.3 – 0.7 mm.
gauge or clearance gauge.
4. End plate
1) Install end plate (72).
plate (72).
3) Install snap ring (73).
30-72 WA430-6
ASSEMBLY
[Forward clutch side]
6. Forward side piston

1) Make the seal ring run in the same manner
as the reverse clutch side and assemble it in
piston (14).
2) Assemble piston (14) in the same manner
as the reverse side piston.

Transmission oil
8. End plate
plate (6) and install snap ring (7).
7. Clutch plate
1) Alternately assemble plate (9), disc (10) and
a Assemble them in the same manner as

spring (11) in this order.
the reverse clutch side.
9. Reverse gear, bearing

1) Assemble needle bearing (5) in the forward
gear (2) and install it fitting the internal gear
of the disc.
2) Install thrust washer (4) and spacer (1).
a Install it facing identification mark U side-

2) Install spring plate (8)
ways.
WA430-6 30-73
ASSEMBLY
3) Press-fit inner race (3) and check that the Assembly of 1st and 4th clutch pack
clearance "b" between spacer (1) and thrust [4th clutch side]
washer (4) is within a standard value.
a Measure the clearance "b" using a dial

1. Seal ring

D6 to assemble it after the seal having run in

Standard value "b": 0.24 – 0.76 mm (it takes 2 or 3 minutes).
is damaged.
2 Tool D6 inside surface:

Transmission oil
10. Clutch pack operation test

Use tool D7 to make compressed air blow in the
a If the gear at the side where air blew in is se-

oil hole of the shaft and each clutch operates.
cured, the clutch operates normally.
2. 4th side piston
a Take care not to damage the seal ring.

1) Install 4th side piston (75).
2 Contact surface of seal ring:

Transmission oil
30-74 WA430-6
ASSEMBLY
3. Clutch plate 5. 4th gear, bearing

Alternately assemble plate (79), disc (80) and 1) Assemble needle bearing (47) in 4th gear
a Assemble disc (80) after having immersed it

spring (81) in this order. (46) and install it fitting the internal gear of
the disc.
in clean transmission oil for two minutes or 2) Install thrust washer (45) and spacer (44),
a Take care so that spring (81) and disc (80)

more. then use tools D3 and D4 to press-fit inner
race (43).
a Carefully assemble plate (79) and spring

will not overlap.
(81) so that they will not bite into the ring

groove of the clutch housing.
4. End plate
a Check that snap ring (83) is correctly in-

plate (82) and install snap ring (83).
serted in the groove.
3) Check that the clearance "c" between

spacer (44) and thrust washer (45) is within
a standard value.
a Measure the clearance "c" using a dial

Standard value "c": 0.28 – 0.72 mm
WA430-6 30-75
ASSEMBLY
[1st clutch side] 8. End plate

6. 1st side piston 1) Install end plate (36).
1) Make the seal ring run in the same manner 2) Use C clamp [8] or the like to press end
as the 4th clutch side and assemble piston plate (36) and install snap ring (37).
(42).
as the 4th clutch side piston.

Transmission oil
9. 1st gear
1) Assemble needle bearing (35) in 1st gear
(34).
2) Install the 1st gear fitting the internal gear of
the disc.
7. Clutch plate
Alternately assemble plate (38), disc (39) and
a Assemble them in the same manner as the

spring (40) in the housing.
4th side.
3) Assemble thrust washer (33) and snap ring
a Use new snap ring (32). (Do not reuse the

(32).
removed snap ring.)
30-76 WA430-6
ASSEMBLY
10. Idler gear 11. Clutch pack operation test

1) Assemble idler gear (31) and use tool D3 to Use tool D7 to make compressed air blow in the

press-fit inner race (30). oil hole of the shaft and each clutch operates.
Assembly of 2nd and 3rd clutch pack

[2nd clutch side]
1. Seal ring

D-6 to assemble it after the seal having run

in (it takes two or three minutes).
is damaged.
2 Tool D-6 inside surface:

2) Check that the clearance "d" between idler
gear (31) and thrust washer (33) is within a
standard value. Transmission oil
a Measure the clearance "d" using a dial

Standard value "d": 0.26 – 0.74 mm
WA430-6 30-77
ASSEMBLY
2. 2nd side piston 4. End plate
a Take care so that the seal ring may not

1) Install 2nd side piston (85). 1) Install end plate (91).
be damaged. plate (91) and install snap ring (92).

Transmission oil
5. 2nd gear
1) Assemble needle bearing (64) in 2nd gear
(63) and install it fitting the internal gear of
a If the internal gear of the disc is not fit,

the disc.
3. Clutch plate assemble needle bearing gently turning

Alternately assemble plate (88), disc (89) and the disc. Take care never to press it
a Assemble disc (89) after having immersed it

spring (90) in this order. strongly.
in clean transmission oil for 2 minutes or
a Take care so that spring (90) and disc (88)

more.
a Carefully assemble the plate and the spring

will not overlap.
so that they will not bite into the ring groove

of the clutch housing.
30-78 WA430-6
ASSEMBLY
6. Idler gear, bearing [3rd clutch side]

1) Install idler gear (60).
7. 3rd side piston
1) Make the seal ring run in the same manner
as the 2nd clutch side and assemble piston
(59).
as the 2nd clutch side piston.

Transmission oil
3) Install thrust washer (58a).
2) Use tool D4 to press-fit bearing (60a).
8. Clutch plate
Alternately assemble plate (56), disc (57) and
a Assemble them in the same manner as the

spring (58) in the housing.
3) Check that the clearance "e" between idler 2nd side.

gear (60) and thrust washer (62) is within a
standard value.
a Measure the clearance "e" using a dial

Standard value "e": 023 – 0.77 mm
WA430-6 30-79
ASSEMBLY
9. End plate 3) Check that the clearance "f" between 4th

Use C clamp [11] or the like to press end plate gear (50) and thrust washer (52) is within a
(54) and remove snap ring (55). standard value.
a Measure the clearance "f" using a dial

Standard value "f": 0.28 – 0.72 mm
10. 3rd gear

1) Assemble needle bearing (53a) in 3rd gear
(53) and install it fitting the internal gear of
the disc. 12. Clutch pack operation test
2) Install thrust washer (52). Use tool D7 to make compressed air blow in the

oil hole of the shaft and each clutch operates.
11. 4th gear, bearing

1) Assemble 4th gear (50).
2) Use tools D4 to press-fit bearing (49).
30-80 WA430-6
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY
Disassembly and assembly of 3. Cage assembly

1) Remove 6 mounting bolts and use forcing
parking brake assembly screw [1] to remove cage assembly (7) and
a For the shim, check the thickness and

shim (8).
Special tools the number of shims.

2) Remove dust seal (9), oil seal (10) and outer
New/Remodel
race (11) from cage (7).
Necessity
Sketch
Q'ty
793T-607-1190 Bracket q 1 Q
1 722-14-13130 Holder q 1
01011-62020 Bolt q 1
793T-607-1130 Push tool q 1 Q
3 790-101-5421 Grip q 1
01010-81240 Bolt q 1
H 4 793T-607-1140 Spacer q 1 Q
5 792T-446-1150 Push tool q 1 Q
6 797T-423-1141 Push tool q 1 Q
793T-512-1110 Push tool q 1 Q 4. Bearing assembly
8 790-101-5421 Grip q 1 1) Remove bearing assembly (12).
q 1
01010-51240 Bolt
2) Remove bearing (14) from boss (13).
9 793T-607-1160 Spacer q 1 Q
Disassembly
1. Coupling (rear drive)

Remove coupling (2).
2. Coupling (front drive)

1) Remove bolt (3) and remove washer (4) and
holder (5).
2) Remove coupling (6).
WA430-6 30-81
5. Spring cover 2) Remove hub (20).

Evenly loosen mounting bolt (15) and remove 3) Remove plate (21), spring (22) and disc
a Because the mounting bolt is pressed with a 10 plates, 9 springs and 9 discs.
cover (16). (23).
the brake spring, evenly loosen the total

number of mounting bolts.
9. Brake housing
Use eyebolt [3] to hang and remove brake hous-
6. Spring ing (24).
Remove spring (17).
7. Piston
Use eyebolt [2] to hang and remove piston (18).
10. Output shaft assembly

1) Use eyebolt [4] to hang and remove output
shaft assembly (27).
2) Remove gear (28) from output shaft assem-
8. Plate, spring, disc bly (27).
1) Use tool H1 to remove snap spring (19). 3) Remove bearing (29).
30-82 WA430-6
11. Oil guide 3) Use tools H8 and H9 to install dust seal

Remove oil guide (30). (32).
12. Outer race, oil seal (rear drive side) 2 Clearance portion between oil seal
1) Remove outer race (31). and dust seal: Silicone grease
2) Remove dust seal (32). (Three bond 1855)
3) Remove oil seal (33).
2. Oil guide
Install oil guide (30).

Assembly
1. Outer race, oil seal (rear drive side)

1) Use push tool [5] to install outer race (31) on
the transmission case.
3. Output shaft assembly

1) Use tool H6 to install bearing (29) on output
a Coat the bearing with oil seal.

shaft (34).
2) Use tool H8 to install oil seal (33) on the
a Lightly cover the inner face of the hous-

transmission case.
ing and wipe off excess liquid gasket.
2 Oil seal press fit surface:

Liquid gasket
(Three bond 1110B)
2 Oil seal lip surface:

Silicone grease
(Three bond 1855)
WA430-6 30-83
a Face the gear with a long flange to the a To measure the rotation torque of only the
2) Install gear (28) on output shaft (34). 5. Install hub (20).
bearing side. bearing accurately, do not install the parking
a Take care so that the oil seal will not be

3) Use eyebolt [4] to install output shaft (27). brake disc, oil seal, and dust seal of the out-
put shaft when assembling step 11.
2 Both ends of the hub:

damaged.
Anti-friction composition (LM-G)
4. Brake housing
1) Install snap ring (25) to brake housing (24)
and install plate (26). 6. Piston
1) Assemble the O-ring in the piston.
2 O-ring: Grease (G2-LI)
a Install the piston aligning the counter

2) Use the eyebolt to install piston (18).
mark "a" of the piston with the counter

mark "b" of the housing.
3) Install spring (17).
2) Install guide bolt [6].

3) Use eyebolt [3] to install brake housing (24)
on the transmission case.
2 O-ring: Grease (G2-LI)
30-84 WA430-6
7. Spring cover 9. Cage assembly

Use eyebolt [3] to install spring cover (16) align- 1) Use push tool [7] to install outer race (11) on
a Check that the spring is correctly contained

ing it to eyebolt [6]. the cage.
in the cover.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a Do not install the shim.

2) Install cage assembly (7).
a When adjusting the shim after installing

the coupling, tighten the bolts perma-
nently.
3 Mounting bolt:
8. Bearing assembly
1) Use tool H5 to install bearing (14) on boss
(13). 9.8 ± 0.98 Nm {1 ± 0.1 kgm}
10. Coupling (front drive)

1) Install coupling (6).
2) Install holder (5) and washer (4) and tighten
bolt (3).
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
2) Install bearing assembly (12).
WA430-6 30-85
11. Adjusting rotation torque of output shaft with 14. Remove cover mounting bolts (15) and then re-
a Do not remove cage mounting bolts (40).

shim move cover (16) and piston (18) together.
1) Tighten 6 cage mounting bolts (40) tempo-
rarily without setting shim (8).
3 Cage mounting bolt (40):

9.8 ± 0.98 Nm {1 ± 0.1 kgm}
2) Rotate the output shaft to the right by 10

turns and to the left by 10 turns, and then
check the tightening torque.
3) If the tightening torque has changed, repeat
1) and 2).
4) When the tightening torque does not change
any more, insert shim (8) and tighten 6 cage
mounting bolts (40) to the specified torque.
3 Cage mounting bolt (40): 15. Plate, spring, disc

98 – 123 Nm {10 – 12.5 kgm} 1) Alternately assemble plate (21), spring (22)
a 10 plates, 9 springs and 9 discs.

and disc (23).
5) Set a torque wrench to the coupling mount-
ing bolt and measure the rotation torque of 2) Use tool H1 to press down the plate and to
the output shaft.
a Take care so that the spring will not be
install snap ring (19).
Adjust the thickness of shim (8) so that the
rotation torque will be in the following stan-
a Check that the snap ring is correctly in-
loaded on the disc.
dard range.
• Rotation torque of output shaft: serted in the groove.
0.49 – 0.98 Nm {0.05 – 0.1 kgm}
6) Make sure that there is no looseness after
the shim is adjusted.
12. Remove coupling (6).
13. Tighten 2 parking brake release bolts B (M12, L

= 45 mm).
30-86 WA430-6
16. Cage assembly 17. Cover and piston assembly

1) Use tool H3 to install oil seal (10) on the 1) Install cover (16) and piston (18), which
a Lightly cover the inner face of the hous-

cage. were removed in step 14, together and
tighten bolts (15).
3 Mounting bolt:
ing and wipe off excess liquid gasket.
2 Oil seal press fit surface: 98 – 123 Nm {10 – 12.5 kgm}

Liquid gasket (Three bond 1110B)
2 Oil seal lip surface:

2) Remove parking brake release bolts B (2
pieces).
Silicone grease (Three bond 1855)
2) Use tools H3 and H4 to install dust seal (9)

on the cage.
2 Clearance portion between the oil

seal and dust seal:
Silicone grease (Three bond 1855)
18. Coupling (Front drive)

1) Install coupling (6).
2) Install holder (5) and washer (4) and tighten
bolt (3).

3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
19. Coupling (Rear drive)

Raise the transmission case assembly and
install coupling (2).
WA430-6 30-87
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
Disassembly and assembly of 2) Disassemble the turbine and case assembly

in the following procedure.
torque converter assembly i) Remove pilot (4).
ii) Remove snap ring (5) and remove plate
(1).
Special tools
New/Remodel
Necessity
Sketch
Q'ty
790-501-5200 Unit repair stand t 1

C 1 790-901-2110 Bracket t 1
790-901-2150 Plate t 1
Disassembly
1. Perform disassembly procedure steps 1 – 4 of

Disassembly and assembly of transmission as- iii) Press the boss portion of turbine (6) and
remove it from case (7).
a Continue the work with the torque converter
sembly.
assembly placed on the block (or install the

torque converter to tool C1.
2. Turbine and case assembly

1) Install the eyebolt on the stator shaft and
remove bolt (2a), then remove stator shaft
and pump assembly (2) from turbine case
assembly (3).
iv) Remove the mounting bolt and discon-

nect turbine (6) and boss (18).
v) Remove bearing (8) from the case.
30-88 WA430-6
3. Stator 6. Bearing
1) Remove snap ring (9). Remove bearing (15) from gear (13).
2) Remove stator (10).
4. Stator shaft Assembly

Use eyebolt [1] to press it from the side of stator
shaft (11) and disconnect it from pump assembly 1. Bearing
(12).
a After having press-fit the bearing, drop the
Install bearing (15) on gear (13).
engine oil by 6 cc and rotate the bearing ten

times.
5. Gear
Remove gear (13) from pump (14).
2. Gear
Install gear (13) on pump (14).
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
WA430-6 30-89
3. Stator shaft 5. Turbine and case assembly

1) Install seal ring (16) on stator shaft (11). 1) Assemble the turbine and the case assem-
2 Seal ring: Grease (G2-LI)

bly in the following procedure.
a Press-fit the ring until it touches the

i) Install bearing (8) on the case.
a Average the overhang of the seal ring.

a After having press-fit the bearing, drop
case.
the engine oil by 6 cc and rotate the

bearing 10 times.
2) Press the inner race side of the bearing and

install pump assembly (12) on shaft (11).
ii) Install boss (18) on turbine (6).

3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
4. Stator
1) Install stator (10).
2) Install snap ring (9).
30-90 WA430-6
iii) Press the inner race of the bearing and

install turbine (6) on case (7).
iv) Install plate (1) and install snap ring (5).

v) Install pilot (4).

3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
2) Install stator shaft and pump assembly (2)

on turbine and case assembly (3).

3 Mounting bolt:
49.0 – 58.8 Nm {5.0 – 6.0 kgm}
WA430-6 30-91
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY
Removal and installation of 5. Disconnect brake hose (4).
front axle assembly
Removal
k Park the machine on flat ground and set the

1. Push up the machine body by work equipment

and put block [1] under the frame in the front of
the front wheel, then raise the front of the ma-
chine body.
k Release the remaining pressure in the brake ac- 6. Disconnect front drive shaft (5). [*2]
cumulator circuit, referring to section "Releasing
remaining pressure in accumulator circuit" in
"Testing and adjusting."
2. Wind a rope around front wheel (1) and sling the

wheel, and then remove mounting bolts (2). [*1]
7. Temporarily lift front axle assembly (6), and re-

move 4 mounting bolts (7) at the left and right.
[*3]
4 Front axle assembly: 1,150 kg
a Remove the opposite side at the same pro-

3. Lift front wheel (1) and remove it.
cedures.
4 Front wheel: 500 kg
4. Remove the cover on the work equipment control

valve.
30-92 WA430-6
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY
Installation
• Carry out installation in reverse order of removal.
3 Front wheel mounting bolt:

[*1]
823 – 1,029 Nm {84 – 105 kgm}

[*2]

3 Front drive shaft mounting bolt:

98.1 – 122.6 Nm {10 – 12.5 kgm}
3 Front axle mounting bolt:

[*3]
1,029 ± 98 Nm {105 ± 10 kgm}
WA430-6 30-93
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY
Removal and installation of 5. Disconnect lubrication tubes (3) and (4).
rear axle assembly
Removal
1. Push up the machine body by work equipment

and put block [1] under the frame in front of the
rear wheel, then raise the rear of the machine
body.
k Release the remaining pressure in the brake ac-

cumulator circuit, referring to section "Releasing 6. Disconnect connector R56 (5), and then remove
remaining pressure in brake accumulator circuit" cover (6).
in "Testing and adjusting."
2. Wind a rope around front wheel (1) and sling the

wheel, and then remove mounting bolts (2). [*1]
7. Disconnect rear drive shaft (7). [*2]

3. Lift rear wheel (1) and remove it.
cedures.
4 Rear wheel: 500 kg
4. Remove the fuel tank assembly, referring to "Re-

moval and installation of fuel tank assembly."
30-94 WA430-6
8. Remove bolt (8) and then remove coupling (9). 11. Pull out the rear frame assembly toward the rear
a If the coupling is not removed, dust seal (13)

[*3] of the chassis and disconnect brake hose (14).
will be damaged easily in section 11.
12. Hold support (15) on transmission jack [2], and

then lower the crane and transmission jack [2]
9. Temporarily lift the rear axle assembly, and re- similarly to remove rear axle assembly (16).
4
move support mounting bolts (10) and (11). [*4]
Rear axle assembly: 1,050 kg
10. Pull out the rear axle assembly toward the rear of
the chassis to disconnect it from the rear frame
a When disconnecting the rear axle assembly,

assembly.
take care not to damage dust seal (13) of

front support (12).
WA430-6 30-95
Installation
3 Rear wheel mounting bolt:

[*1]
823 – 1,029 Nm {84 – 105 kgm}
a Check that the misalignment of the rear axle

[*2]
and transmission to the right or left is not

larger than 3 mm. If the misalignment ex-
ceeds 3 mm, adjust it by changing the install-

ing position.

3 Rear drive shaft mounting bolt:

98.1 – 122.6 Nm {10 – 12.5 kgm}

[*3]

Adhesive (LT-2)
490 – 608 Nm {50 – 62 kgm}
2 Support mounting bolt: Engine oil

[*4]
3 Support mounting bolt:

1,029 ± 98 Nm {105 ± 10 kgm}
30-96 WA430-6
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY

axle housing assembly
Special tools
New/Remodel
Necessity
Sketch
Q'ty
793T-622-1330 Push tool t 1 Q

11 793T-622-1340 Spacer t 1 Q
790-201-2760 Spacer t 1 3. Axle housing assembly
793T-622-1370 Support t 2 Q 1) Temporarily hang axle housing assembly (8)
t 6
12
a When removing the axle housing as-
01016-30860 Bolt and remove the housing mounting bolt.
13 793T-522-1160 Push tool t 1 Q
t 1 Q
H sembly on both left and right, install a
793T-522-1140 Push tool
t 1 Q
14 counter mark to the housing and the dif-
793T-522-1150 Spacer
t 2 Q
ferential case not so as to be mixed.
793T-522-1170 Support 2) Remove axle housing assembly (8).
t 6
15
01010-30860 Bolt
22 793T-622-1610 Holder t 1 Q
23 797T-423-1290 Push tool t 1 Q
Disassembly
a The subsequent photographs and illustrations

are shown using the front axle assembly as an
example, unless otherwise specified.
1. Oil drain
Remove plug (1) and drain oil.
6 Front axle housing: 49 l 3) Change the hanging position of the lifting

6 Rear axle housing: 40 l
tool and raise axle housing assembly (8)
vertically.
2. Axle assembly
a When one-sided housing assembly is re-

Load the axle assembly on block [1].
moved, load the axle assembly on block [1]

so that it will not be tilted.
WA430-6 30-97
4. Planetary carrier assembly 5. Ring gear

1) Remove axle shaft mounting bolt (9) and Use puller [2] to remove ring gear (12) from
hang and remove planetary carrier assem- housing assembly (13) raising the gear on the
a Assemble spacer [3] on the bolt tip of the

bly (10). average.
a Take care so that the pawl of the puller will

puller and adjust the height.
not be removed from the ring gear.
6. Axle shaft
1) Lift axle housing (14)
2) Punch and pull out the end surface of axle
shaft (15) using a copper hammer or the
like.
a Record the thickness of the shim and re-

2) Remove shim (11).
fer to it at assembly.
30-98 WA430-6
7. Axle shaft bearing 9. Planetary carrier

k Do not remove the bearing by applying heat 1) Punch spring pin (21) of planetary carrier
a Take care not to punch the spring pin.

or remove it by fusing it. (20) so that it is contained in shaft (22).
1) Install bearing race puller [4] at the bottom

of bearing (16) and secure it correctly.
2) Tighten the bolt and remove bearing (16).
a Remove sleeve (17a) and the oil seal to-

3) Remove sleeve (17a).
gether from the front axle.
2) Use the press to pull out shaft (22).
3) Pull out spring pin (21) from shaft (22).

4) Remove pinion gear (23) and spacer (24)
from planetary carrier (20).
8. Axle housing
Remove bearing outer races (18) and (19) and
a Remove oil seal (17) from only the rear axle.

oil seal (17) from axle housing (14).
WA430-6 30-99
a Adjust oil seal (17) with tool H12 so that

5) Remove bearing (25) from pinion gear (23). 3) Install tool H12 under oil seal (17).
the top of tool H12 will be lightly in con-

tact with oil seal (17) and the clearance
will be even.
Assembly
1. Axle housing, axle shaft (For front)

1) Press bearing outer races (18) and (19) in
axle housing (14).
2) Use tool H11 to install oil seal (17) together
a Press fit oil seal (17) and bearing (16)

with bearing (16) into axle shaft (15).
until oil seal sleeve (17a) is flush with

face "d" of the axle shaft, and then
check that there is not clearance be-
tween bearing (16) and oil seal sleeve
(17a).
30-100 WA430-6
2. Axle housing, axle shaft (For rear) 3) Use tool H13 to press-fit oil seal sleeve
1) Press-fit bearing outer races (18) and (19) in (17a) on shaft (15).
2 Sleeve installing surface: Axle oil

axle housing (14).
or anti-friction composition (LM-P)
a Check that the dimension "a" from the

bearing installing surface is 10.1 ± 0.2
mm.
2) Use push tool [6] to install oil seal (17) on

housing (14).
2 Oil seal lip surface: Grease (G2-LI)
a Make the flange of the oil seal adhere to

the housing end surface. 4) Use tool H14 to press-fit bearing (16) in axle
• Clearance between the flange of the oil shaft (15).
seal and the housing surface:
Less than 0.2 mm
a Adjust oil seal sleeve (17a) with tool H15

5) Install tool H15 under oil seal sleeve (17a).
so that the top of tool H15 will be lightly

in contact with oil seal sleeve (17a) and
the clearance will be even.
WA430-6 30-101
3. Axle shaft bearing 4. Selection of shim

1) Erect axle shaft (15) on a block and fix it 1) Install planetary carrier (20) to the spline of
securely. axle shaft (15). Install tool H22 and tighten
a Install planetary carrier (20) without the

2) Sling axle housing (14) horizontally and mounting bolt (9) with your fingers.
a Position the front axle housing to oil seal

lower it slowly.
a Before tightening mounting bolt (9), re-

gear.
(17) and insert it by utilizing its weight.
2 Press fitting part of oil seal and

move all adhesive from it and the bolt
hole.
bearing (Front axle): Axle oil 2) While rotating axle housing (14), tighten
a After installing the housing, keep tools

mounting bolt (9).
H12 and H15 installed until step 4). 3 Bolt (9): 39 Nm {4.0 kgm}
3) Using push tool H23, press fit bearing (26) 3) After fitting bearings (16) and (26) thor-
a Turning the axle housing, press fit the

to axle shaft (15). oughly, measure the rotation force at hole
"h" of axle housing (14).
bearing. • Rotation force
2 Periphery of bearing: Axle oil

Front axle: 21.6 – 54.9 N {2.2 – 5.6 kg}
a If the rotation force is below the standard

Rear axle: 49.0 – 93.1 N {5.0 – 9.5 kg}
a Check that oil seal (17) does not lean.

4) Pull out tools H12 and H15 horizontally. range, perform the following work.
i) Remove carrier (20).
ii) Referring to step 3 - 3), press fit bearing
(26) further.
iii) Perform steps 1) - 3), check that the
rotation force is in the standard range.
30-102 WA430-6
a If the rotation force is above the standard 6) Remove planetary carrier (20).
range, perform the following work.
i) Loosen bolt (9) by 1 – 2 turns.
ii) Sling axle shaft and housing assembly
(8) by 20 – 30 mm, holding it by 2 points
as in the installation procedure for the
axle housing.
iii) While rotating axle shaft (15), hit the
flange several times with a copper ham-
mer, etc. to eliminate excessive preload
a Take care not to damage oil seal

on bearings (16) and (26).
(17) by hitting the axle shaft too

much.
• Lowering distance of axle shaft (Ref-
erence value): 0.3 mm 5. Planetary carrier
1) Previously assemble spacer (24) in plane-
iv) Perform steps 2) - 3), check that the
a Assemble the spacer from the brake
tary carrier (20).
rotation force is in the standard range.
housing side.
2) Assemble bearing (25) in gear (23) and lift
spacer (24), then assemble gear (23).
3) Press-fit shaft aligning shaft (22) and spring

pin hole (22a).
2 Shaft: Axle oil
4) Using a depth micrometer, measure dimen-

sion "H" from the end face of tool H22 to that
of the axle shaft.
5) Subtract thickness "t" of tool H22 from
dimension "H" and set the result as (H – t),
and then decide the shim thickness.
+0.05
• Shim thickness = (H – t) 0 mm
WA430-6 30-103
a Align shaft (22) and spring pin hole (21) 7. Planetary carrier assembly
and punch spring pin (21) so as to be 1) Assemble shim (11) selected in item 5) of
made the same level ("j" portion) with procedure 4. on the axle shaft end surface.
carrier (20). 2) Install planetary carrier assembly (10) and
a Correctly degrease and clean the bolt in-

tighten mounting bolt (9).
stalling hole and mounting bolt of the

axle shaft.
k When assembling the planetary carrier,

sufficiently take care so that the finger
will not be caught in the gears.

3 Mounting bolt:
662 – 829 Nm {67.5 – 84.5 kgm}
a Thoroughly clean and assemble the

4) Tap on the end surface of shaft (22) and the shaft end surface and the planetary car-
differential side of gear (23) and push back rier spline portion.
bearing (2 5), then check that the ge ar
rotates gently.
6. Ring gear
Press-fit ring gear (12) in axle housing (14) and
a Assemble the housing by aligning the hous-

insert pin (12a).
a Carefully press-fit the ring gear horizontally

ing and the pin hole of the ring gear.
so that the ring gear will not be tiled.
30-104 WA430-6
3) Referring to step 4-3), check the rotation

force of axle housing (14).
• Starting rotation force:
Front: 21.6 – 54.9 N {2.2 – 5.6 kg}
a If the rotation force is out of the standard

Rear: 49.0 – 93.2 N {5.0 – 9.5 kg}
value, return to procedure 4.

4) Install stand [9] of the dial gauge on axle
housing (14) and measure the end play of
the planetary carrier on the end surface of
the planetary carrier.
• End play of planetary carrier:
0 – 0.1 mm (Reference value.)
3) Tighten the mounting bolt by installing it on

a diagonal line.
3 Housing mounting bolt:

490 – 608 Nm {50 – 62 kgm}
Refilling with oil
• Tighten the drain plug and add axle oil through oil
filler to the specified level, and check the oil level
with oil level plug.
8. Axle housing assembly 5 Front axle housing: 49 l

1) Degrease and clean axle housing (14) and
the installing surface of differential housing
(30) and evenly coat the installing surface
with the liquid gasket.
2 Housing mating face:

Liquid gasket LG-6 (Loctite 515)
2) Horizontally hang axle housing assembly (8)

and quietly assemble it fitting the spline
a Assemble the axle housing assembly

groove and guide bolt [10].
not to damage the brake piston surface

and the plate surface.
WA430-6 30-105
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
a The subsequent photos and illustrations show

Disassembly and assembly of Disassembly
differential assembly the front differential as an example, excluding the
a For the front and rear differentials, the internal

portions described separately.
Special tools
structures are the same, excluding the appear-
New/Remodel
ance.
Necessity
Sketch
1. Brake piping
Q'ty
F/R
Disconnect tube (1).
2. Oil temperature sensor (rear differential)

t 1
Unit repair 1) Remove cover (3).
790-501-5200
stand
t 1
F/R 2) Disconnect the connector and remove oil
16
790-901-2110 Bracket
t 1 Q
temperature sensor (5).
790T-901-3440 Plate F
796-765-1110 Push tool t 1
t 1
F
17 790-201-2750 Spacer
793T-522-1130 Push tool R t 1 Q
792T-423-1110 Push tool F t 1 Q
t 1
18
790-201-2740 Spacer R
793T-622-1410 Push tool t 1 Q
790-101-5421 Grip F t 1
01010-51240 Bolt t 1
t 1 Q
19
793T-522-1110 Push tool
790-101-5421 Grip R t 1
01010-81240 Bolt t 1
H 793T-622-1410 Push tool t 1 Q
t 1 Q
3. Axle housing assembly
793T-622-1420 Spacer
t 1
Remove the axle housing assembly on the left
F
790-101-5421 Grip and right, referring to section, "Disassembly and
01010-81240 Bolt t 1 assembly of axle housing assembly."
t 1 Q
20
793T-522-1110 Push tool
t 1 Q
4. Differential assembly
793T-522-1120 Spacer
t 1
R Put differential assembly (7) on block [1] to
790-101-5421 Grip
t 1 a When using tool H16, remove the cage as-
make it stable. (Otherwise, install to tool H16.)
01010-51240 Bolt
1 790-301-1720 Adapter t 1 sembly according to step 7.
t 1
Hydraulic
2 790-101-5002
kit 5. Cover
t 1
21 Brake F/R Remove cover (8).
3 793-605-1001
tester
t 1
Hydraulic
4 790-101-1102
pump
24 796-751-1510 Wrench F/R t 1
a The symbols in the table denote the following.

F: For front differential
R: For rear differential
30-106 WA430-6
6. Brake 7. Cage assembly

1) Remove shaft (9). 1) Lift the differential case and turn up the cage
2) Remove bolt (10) and also remove outer assembly.
plate (11). 2) Remove bolt (17) and also remove coupling
a Do not remove the protector from the

3) Remove disc (12), spring (13), and plate (19) with protector (18).
a Mark so that the parts on the left and

(14).
coupling unless required.
right are not mixed.
3) Install lift bolt [2] and temporarily lift cage
a Mark index symbols on the cage and dif-

assembly (20).
ferential case so that they smoothly

match at assembly.
4) Remove bolt (21).
5) Screw the forcing screw and pull up the
case assembly until the O-ring appears.
6) Lift the cage assembly and remove it.
4) Blow air into brake tube joint unit (15) and

remove piston (16).
WA430-6 30-107
a Record the number of shims to refer to at

7) Remove shim (22). 9. Differential carrier assembly
1) Remove differential carrier assembly (23)
a Take care not to remove the lift tool.

assembly. from differential case (25).
8. Bearing carrier
1) Temporarily lift differential carrier assembly 2) Remove gear cover (26) from the differential
(23). case.
2) Remove all the bearing carrier attachment 10. Detailed disassembly of differential carrier
a Identify so that the parts on the left and right

bolts, and install guide bolt [3]. assembly (standard spec.)
3) Screw pull-up bolt [4], and remove bearing
a Identify so that the bearing carriers on

carrier (24). are not mixed.
1) Remove plane half cover (28) together with
a Confirm the shim thickness and number a Mark index symbols on plane half cover
the left and right are not mixed. bearing (27).
of shims to refer to at assembly. (28) and bevel gear case flange half
(29).
30-108 WA430-6
2) Remove bearing (27) from plane half (28). 5) Remove spherical washer (37) and pinion
gear (35) from removed spider shaft (36).
3) Remove thrust washer (30) from bevel gear

flange half assembly (29), and also remove 6) Remove side gear (34) and thrust washer
side gear (34). (30).
4) Remove pinion gear (35), spider shaft (36), 7) Reverse bevel gear flange half assembly
and spherical bush (37) together. (29) and remove the bolt. Then remove
bevel gear (43) and bearing (27).
WA430-6 30-109
11. Disassembly of differential carrier assembly 2) Remove 2 plates (61) and 2 discs (62).
a Identify right and left parts to avoid confu-

(Anti-slip differential specification)
sion.
a Put mating marks on cover (58) and

1) Remove cover (58).
case (59) for reference purposes when
a Bearing (57) is installed only to the front.

re-assembling.
a Front
3) Remove pressure ring (63) and side gear

(64).
a Rear
4) Remove pinion gear (65) and spider shaft

(66).
a When removing cover (58), it is removed

with washer (60) fitted in a groove at the
back.
30-110 WA430-6
5) Remove side gear (67) and pressure ring 10) Using push tool [8], remove outer race (75)
(68). from inside of case (59). (Rear)
6) Remove 2 discs (69) and 2 plates (70). 11) Using puller [9], remove bearing (76) from
bearing carrier (24). (Rear)
7) Remove washer (71).
12. Pinion gear and cage

8) Reverse case (59) and remove bolt (72) to 1) Use the press to pull out pinion gear (45)
remove bevel gear (73). from cage (44).
9) Remove bearing (74). (Front)
WA430-6 30-111
2) Remove dust seal (49), oil seal (50), bearing Assembly

(46), and outer races (47), (48) from cage
(44). 1. Pinion gear and cage
1) Install bearing outer races (47) and (48) to
cage (44).
3) Remove spacer (51) and bearing inner race

(52) from pinion gear (45).
2) Use tool H17 to press bearing (52) in pinion
gear (45).
3) Install spacer (51).
30-112 WA430-6
4) Stand pinion gear (45) and install cage (44).

5) Use tool H18 to press bearing (46) in the
a Coat the axle oil on the bearing inner

pinion gear while turning cage (44).
race.
8) Use tool H20 to press dust seal (49) in cage

(44) until its end surface becomes equal to
the one of the cage.
2 Dust seal lip unit:

6) Use push-pull gauge [5] to turn cage (44) Grease (G2-LI)
a Starting rotation force:

and measure the starting rotation force.
a When the starting rotation force exceeds

Max. 58.8 N {6 kg}
the reference value or the cage does not

rotate by hand (rotates heavily), replace
the bearing and spacer. Then confirm
the starting rotation force again.
2. Coupling
Install coupling (19), O-ring (19a), and holder
(17a) to pinion gear (45), and tighten mounting
a In this case, temporarily tighten mounting

bolt (17).
bolt (17). After the coupling is assembled in

the differential case, securely tighten the bolt
a Take care not to damage the seal at insertion

according to step 6-3).
7) Use tool H19 to press oil seal (50) in cage
a Confirm that dimension C is as follows.

(44). of coupling (19).
Front: 14 ± 0.5 mm
Rear: 10 ± 0.5 mm
2 Oil seal lip unit: Grease (G2-LI)
WA430-6 30-113
3. Detailed assembly of differential carrier as- 4) Put bevel gear (43) on block [6], turning
a Assemble the parts on the left and right ac-

sembly (Standard spec.) down the gear side.
5) Install guide bolt [7] to bevel gear (43).
cording to the identification determined at 6) Lift flange half (29), install it to bevel gear
disassembly. (43), and tighten bevel gear mounting bolt
1) Press bearing outer race (24a) in bearing (42).

carriers (24) on the left and right until it
3 Mounting bolt:
reaches the carriers.
Front: 245 – 309 Nm {25 – 31.5 kgm}

Rear: 157 – 196 Nm {16 – 20 kgm}
2) Press bearing (27) in flange half (29).
7) Install thrust washer (30) and side gear (34).
3) Press bearing (27) in plane half (28).
30-114 WA430-6
a When installing, match the mating marks

8) Install pinion gear (35) and spherical washer 12) Install plane half (28) to flange half (29).
(37) to spider shaft (36).
made when removed.
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
9) Install spider shaft (36), pinion gear (35),

and spherical bush (37).
4. Assembly of differential carrier assembly
a Assemble right and left parts according to

(Anti-slip differential specification)
identifications made at the time of taking

them apart.
1) Press bearing outer race (24a) until it comes
into contact with right and left bearing carri-
ers (24). (Front).
10) Assemble side gear (34) in bevel gear

flange half assembly (29).
11) Grease thrust washer (30) and adhere
thrust washer (30) matching the dowel pin of
plane half (28), so that it does not drop at
a Take care of the front and back at as-

assembly.
sembly of the thrust washer.
2 Thrust washer: Grease (G2-LI)
a Take care not to overgrease.

2) Press bearing outer race (24b) until it comes
into contact with right and left bearing carri-
ers (24) using push tool [10]. (Rear)
WA430-6 30-115
3) Press fit bearing (59a) into case (59).

(Front)
4) Press fit bearing (57) into cover (58). (Front)
10) Reverse case (59) and install washer (71),
a When installing the disc, set cuts "a" and

plate (70), and disc (69) in this order.
5) Press fit outer race (75) to case (59). (Rear) "b" accurately.
6) Press fit cover (58) similarly. (Rear) Part No. of disc (t: 3.2mm only)
Front: Part No. 424-22-37411
Rear: Part No. 423-23-37410
2 Plate and disc: Axle oil
7) Place bevel gear (73) on block [6] with the

gear side down.
8) Install guide bolt [7] to bevel gear (73).
9) Lower case (59) and install it in bevel gear
(73) and tighten the bevel gear mounting
bolts.
3 Mounting bolt:
Front :
245 – 309 Nm {25 – 31.5 kgm}
Rear :
157 – 196 Nm {16 – 20 kgm}
30-116 WA430-6
11) Install pressure ring (68) and side gear (67).
12) Install pinion gear (65) and spider shaft (66).
15) Adjust the clearance between the case and

plate.
i) Using depth gauge [11], measure dis-
tance "d" from the end face of case (59)
13) Install side gear (64) and pressure ring (63). to the end face of plate (61).
• Distance "d": 0.2 – 0.75 mm
ii) If distance "d" is out of the standard
range, replace the plate with the one
with proper thickness so that distance
a Replace the plates on both right and

"d" will be in the standard range.
left sides so that the total thickness

of the 2 plates on each side will be
the same, and then perform the
above procedure from step 10).
• Thicknesses of plates
3.1 mm: Front (Part No. 424-22-37451)
Rear (Part No. 56D-22-27451)
3.2 mm: Front (Part No. 424-22-37461)
a When installing the disc, set cuts "a" and

14) Install disc (62) and plate (61) in this order. Rear (Part No. 56D-22-27461)
"b" accurately.
2 Plate and disc: Axle oil
WA430-6 30-117
18) Adjust the axial clearance of the side gear.

i) Using feeler gauges [11], measure
clearance "e" between the side gear
and washer through the shaft holes on
the right and left sides of the anti-slip
differential.
• Clearance "e":
0.15 – 0.35 mm (Both right and left)
ii) If clearance "e" is out of the standard
range, replace the washer with the one
with proper thickness so that the clear-
a When replacing the washer, perform

ance will be in the standard range.
a Thicknesses of washers
the above procedure from step 10).
16) Install washer (60) on cover (58).
Coat the washer with grease thinly and stick Front
it to the cover. 4.0 mm: (Part No. 421-22-27370)
4.1 mm: (Part No. 421-22-27380)
Rear
2.0 mm: (Part No. 423-22-27370)
2.1 mm: (Part No. 423-22-27380)
a Install them by aligning the mating marks

17) Install cover (58) on case (59).
a Bearing (57) is installed on only the front

put when disassembling.
side.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
30-118 WA430-6
19) Measure the differential torque while no load 6. Adjustment of bearing carrier shim
is applied. 1) Lift differential carrier assembly (23) and set
i) Install and fix sun gear shaft (81) to it to differential case (25) installing unit.
either side of the differential carrier
assembly.
ii) Install wrench H24 to the side gear on
the opposite side with the M6 bolt.
iii) Install torque wrench [12] and measure
a When measuring, let the case turn

the rotation torque.
freely.
• Rotation torque (Both front and
rear): Max. 10 Nm {1.0 kgm}
iv) If the rotation torque exceeds the above
value, disassemble the differential car-
rier again and perform steps 15) to 18).
2) Install O-ring (24a) and seal (24b) to bearing

carriers (24) on the left and right.
5. Gear cover
Install gear cover (26) to the differential case.
3) Install guide bolt [3] in the bearing carrier

attachment holes on the left and right of the
differential case.
WA430-6 30-119
4) Install removed shim (22) to bearing carriers 7. Cage assembly

(24) on the left and right, then tighten bear- 1) Insert O-ring (20a) in the groove of cage
ing carrier mounting bolt (24c). assembly (20).
a Tighten the bevel gear while turning it. 2 O-ring: Axle oil
2 Bearing: Axle oil a Coat the oil slightly.
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
2) Install guide bolt [6] to differential carrier

assembly (7), assemble removed shim (22),
a At assembly, turn the thinner side of the

then install cage assembly (20).
5) Use push-pull gauge [5] to measure the pre-
a Starting rotation force:

load of the bevel gear. shim to the cage.
Front: 13.7 – 37.2 N {1.4 – 3.8 kg} 3 Mounting bolt:
a When the starting rotation force is out-

Rear: 35.3 – 52.9 N {3.6 – 5.4 kg} 245 – 309 Nm {25 – 31.5 kgm}
side the reference value, adjust the shim 3) Securely tighten the coupling mounting bolt
thickness. temporarily tightened in step 2.

3 Mounting bolt:
Front:
823 – 1,029 Nm {84 – 105 kgm}
Rear:
490 – 608 Nm {50 – 62 kgm}
30-120 WA430-6
8. Backlash adjustment
1) Use dial gauge [7] to measure the backlash
a Backlash reference value:

of the bevel gear.
Front: 0.30 – 0.41 mm
a Measure the backlash at 3 portions on

Rear: 0.25 – 0.33 mm
the circumference of the bevel gear.

Then confirm that an error for each mea-
surement value is in the range of 0.1
mm.
2) To obtain the backlash in the reference

value, move a part of the shim of the bevel
a At movement of the shim, do not change

gear to the reverse side.
a When the back lash is too high, move a

the total thickness of the left and light.
a When the back lash is too low, move a

part of shim "b" to shim "a".
part of shim "a" to shim "b".
WA430-6 30-121
9. Tooth contact inspection

Knead the red lead with the spindle oil and coat it on 7 – 8 teeth of the bevel gear. While holding down the
bevel gear by hand and braking, turn the pinion gear forward and backward, and inspect the tooth contact.
Follow the procedure to adjust the tooth contact state.
Tooth Contact Cause Adjustment
Correct contact To adjust the pinion gear, increase or
Remain the tow side about 5 mm and decrease the gauge shim.
confirm that all teeth to the heel side To adjust the bevel gear, follow the same pro-
come into contact 50%, centering the cedure as of the backlash.
pitch line.
The bevel pinion gear is too separate 1)Decrease the shim from the pinion gear and
from the gear. approach to the bevel gear.
2)Separate the bevel gear from the pinion
gear and correctly adjust the backlash.
The bevel pinion gear is too near the 1)Increase the shim of the pinion gear and
gear. separate it from the bevel gear.
2)Approach the bevel gear to the pinion gear
and correctly adjust the backlash.
The bevel gear is too near the pinion 1)Decrease the shim of the pinion gear and
gear. approach it to the bevel gear.
2)Separate the bevel gear from the pinion
gear and correctly adjust the backlash.
The bevel gear is too separate from the 1)Increase the shim of the pinion gear and
pinion gear. separate it from the bevel gear.
2)Approach the bevel gear to the pinion gear
and correctly adjust the backlash.
a When adjusting the bevel gear in-out state, do not change the total thickness of the left and right by moving
the shim.
30-122 WA430-6
10. Brake 3) Install outer plate (11) and shaft (9), then
1) Assemble the seal in piston (16) and install tighten bolt (10).
a (15) is the brake tube joint unit.

it to the differential carrier assembly.
4) Send air in brake oil port A and adjust the

piston operation.
2) Install disc (12), spring (13), and plate (14)
a Put a spring on another, matching their

in sequence.
notched parts, and install the springs to-

gether so that the notched parts are in
the range "a" below. (A indicates the
brake oil port.)
11. Cover
Install cover (8) to differential case (7).
2 Cover mounting side:

Liquid gasket (Loctite 515)
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
12. Axle housing

Install the axle housing assembly on the left and
right, referring to section "Assembly of axle
housing assembly."
WA430-6 30-123
13. Brake oil leakage inspection 14. Oil temperature sensor (rear differential)
1) Install tools H21-1 and H21-2 to the brake 1) Install oil temperature sensor (5) and con-
2 Oil temperature sensor screw unit:

tube mounting port A of differential case (7), nect the connector.
then bleed the air from cylinder.

2) Use tool H21-4 to increase the pressure to Liquid gasket (LG-5)
a Leave the unit with

0.1 MPa {1 kg/cm2}.
29.4 – 49.0 Nm {3 – 5 kgm}
0.1 MPa {1 kg/cm2 } for 5 minutes, then
confirm that the pressure lowers to 0 2) Install cover (3).
a If the pressure has lowered, remove the

MPa {0 kg/cm2}.
15. Brake tube
brake piston and check the O-ring, seal, 1) Install tube (1).
etc. for damage, and then assemble
them again.
3) Using tool H21-4, increase the pressure up
a Leave the unit with 4.9 MPa {50 kg/cm2}

to 4.9 MPa {50 kg/cm2}.
for 5 minutes, then confirm that the pres-
a If the pressure has lowered more than

sure lowers up to 0.1 MPa {1 kg/cm 2}.
the above standard value, remove the

brake piston and check the damage of
O-ring and seal then assemble them.
Refilling with oil

• Tighten the drain plug and add axle oil through oil
filler to the specified level, and check the oil level
with oil level plug.
5 Front axle housing: 49 l
30-124 WA430-6
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF STEERING VALVE ASSEMBLY
Removal and installation of Installation

steering valve assembly
Refilling with oil
Removal
k
• Add oil through oil filler to the specified level. Run
Park the machine on flat ground and set the the engine to circulate the oil through the system.
steering to the full left.
Then check the oil level again.

brake and put the blocks under the wheels.
k Loosen the filler cap of the hydraulic tank gradu-
ally to release the residual pressure from the hy-
draulic tank.
1. Disconnect hoses (1) to (5).
2. Disconnect tubes (6) to (8).
3. Temporarily lift steering valve assembly (9) and

remove the mounting bolt of the plate side and
remove it.
4 Steering valve assembly: 30 kg
WA430-6 30-125
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY
Removal and installation of 4. Remove front cover (5) and rear cover (6) of the
hydraulic tank.
hydraulic tank assembly
Removal
k Stop the machine on level ground and set the
k Lower the work equipment to the ground, stop
the engine, apply the parking brake, and lock the
rear tires with chocks.
k Operate the work equipment control lever 2 - 3
times to release the residual pressure from the
accumulator circuit.
1. Lift off floor (1).

4 Floor: 40 kg
5. Lift off ladder (7).

4
a Open oil filler cap (2) and loosen plug (3). [*1]
2. Drain the oil from the hydraulic tank. Ladder: 20 kg
3. Disconnect tube (4).
30-126 WA430-6
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY
7. Disconnect hoses (9) to (15). [*2]
8. Remove tube (16). [*3]
9. Disconnect tube (17) and hose (18).
13. Lift off hydraulic tank assembly (23).

4 Hydraulic tank assembly: 200 kg
10. Disconnect suction hoses (19) and (20).
Installation
moval.
3 Plug (3):
[*1]
11. Sling the hydraulic tank assembly temporarily.
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
12. Remove front mounting bolt (21) and 3 lower
3 Hose (9) clamp:

mounting bolts (22) of the hydraulic tank. [*3]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 U-bolt: 10.8 – 26.5 Nm {1.1 – 2.7 kgm}

[*3]
Refilling with oil

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the sys-
tem. Then, check the oil level again.
Bleeding air
Bleeding air from steering circuit and Bleeding air
from work equipment circuit.
WA430-6 30-127
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER
Disassembly and assembly of Disassembly

1. Cylinder assembly
hydraulic cylinder Set cylinder assembly (1) to tool U1.
Special tool 2. Cylinder head and piston rod assembly

(Steering cylinder)
New/Remodel
1) Use tool U2 to remove cylinder head (2)
Necessity
Sketch
from the cylinder.
Q'ty
790-502-1003 Repair stand t 1

t 1
1
790-101-1102 Hydraulic pump
790-102-2303 t 1
t 1
2 or Wrench assembly
t 1
790-330-1100
3 790-302-1390 Socket
790-102-4300 Wrench assembly t 1
t 1
4
790-101-4310 Pin
5 790-720-1000 Expander t 1
t 1
Ring
796-720-1640
(For steering)
t 1
Clamp 2) Pull out cylinder head and piston assembly
a When the piston rod assembly is pulled

07281-00909 (3) from cylinder (4).
(For steering)
t 1
Ring
796-720-1670 out from the cylinder, oil leaks. Prepare
6 (For lift arm)
t 1
an oil receiver.
Clamp
07281-01279
(For lift arm)
Ring (For bucket) t 1
U
796-720-1680
t 1
Clamp
07281-01589
(For bucket)
790-201-1702 Push tool kit t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
7 • Push tool
790-201-1751 1
(For steering)
• Push tool (For
790-201-1841 1
lift arm, bucket)
790-201-1500 Push tool kit t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
8 • Plate
790-201-1560 1
(For steering)
• Plate (For lift
790-201-1650 1
arm, bucket)
30-128 WA430-6
3. Cylinder head and piston rod assembly (Lift 5. Piston and cylinder head (Lift cylinder and
cylinder and bucket cylinder) bucket cylinder)
1) Remove the mounting bolts of cylinder head 1) Set cylinder head and piston rod assembly
assembly (2). (3) to tool U1.
a When screw (7) is too tightened and it is

2) Pull out cylinder head and piston rod 2) Remove piston assembly set screw (7).
a When the piston rod assembly is pulled

assembly (3) from cylinder (4).
not removed, tighten screw (7) into the
out from the cylinder, oil leaks. Prepare inside once, and apply a tap to the screw
a Screw size: M12 x 1.75

an oil receiver. unit. Then remove it.
4. Piston and cylinder head (Steering cylinder)

1) Set cylinder head and piston rod assembly 3) Use tool U4 to move piston assembly (6).
(3) to tool U1.
a Width across flats of nut: 46 mm

2) Use tool U3 to remove nut (5).
3) Remove piston assembly (6), and then cyl-

inder head assembly (2).
WA430-6 30-129
4) Remove cylinder head assembly (2) from 8. Disassembly of cylinder head assembly
the rod. (Steering cylinder)
1) Remove O-ring and backup ring (12).
2) Remove snap ring (13) and then remove the
dust seal (14).
3) Remove rod packing (15), buffer ring (16)
and bushing (17).
4) Remove O-ring (18).
6. Disassembly of piston assembly (Steering

cylinder)
Remove wear ring (9) and piston ring (10) from
piston (8).
9. Disassembly of cylinder head assembly (Lift

cylinder and bucket cylinder)
1) Remove O-ring and backup ring (12).
2) Remove snap ring (13) and then remove
dust seal (14).
3) Remove rod packing (15), buffer ring (16)
and bushing (17).
7. Disassembly of piston assembly (Lift cylin-

der and bucket cylinder)
1) Remove ring (21), wear ring (9) and piston
ring (10) from piston (8).
2) Remove O-ring and backup ring (11) from
piston (8).
30-130 WA430-6
a Take care not to damage the packing, dust seal,

Assembly 2. Assembly of cylinder head assembly (Lift cyl-
inder and bucket cylinder)
a To insert the backup ring, do not put it in the as-

and O-ring. 1) Use tool U7 to press bushing (17).
2) Assemble buffer ring (16).
sembly unreasonably. Heat it with hot water of 3) Assemble rod packing (15).
about 50 – 60°C, then insert it. 4) Use tool U8 to press dust seal (14) and fix it
with snap ring (13).
1. Assembly of cylinder head assembly (Steer- 5) Install backup ring and O-ring (12).
ing cylinder)
1) Use tool U7 to press bushing (17).
2) Assemble buffer ring (16).
3) Assemble rod packing (15).
4) Use tool U8 to press dust seal (14) and fix it
with snap ring (13).
5) Install backup ring and O-ring (12).
6) Install O-ring (18).
3. Assembly of piston assembly (Steering cylin-

der)
a After setting the piston ring to the tool,

1) Use tool U5 to expand piston ring (10).
turn the handle 8 – 10 times to expand it.
WA430-6 30-131
2) Remove piston ring (10) from tool U5, 5. Cylinder head and piston (Steering cylinder)
assemble it to piston (8). 1) Assemble cylinder head assembly (2), pis-
3) Use tool U6 to tighten piston ring (10). ton assembly (6), and nut (5) to the piston
4) Assemble wear ring (9). rod.
2) Set piston rod (3) to tool U1.
a Width across flats of nut: 46 mm

3) Use tool U3 to tighten nut (5).
2 Piston rod thread portion:

Adhesive (Equivalent to
3 Nut:
Loctite 262)
785 ± 78.5 Nm {80 ± 8.0 kgm}
4. Assembly of piston assembly (Lift cylinder

and bucket cylinder)
a After setting the piston ring to the tool,

1) Use tool U5 to expand piston ring (10).
turn the handle 8 – 10 times to expand it.
6. Cylinder head and piston (Lift cylinder and

bucket cylinder)
1) Assemble cylinder head assembly (2) to pis-
ton rod (19).
2) Set piston rod assembly (19) to tool U1.
2) Remove piston ring (10) from tool U5,

assemble it to the piston (8).
3) Use tool U6 to tighten piston ring (10).
4) Assemble wear ring (9) and ring (21).
a To insert the backup ring, do not put it in

5) Assemble O-ring and backup ring (11).
the assembly unreasonably. Heat it with

hot water of about 50 – 60°C, then insert
it.
30-132 WA430-6
3) Assemble piston assembly (6). • When one or either of the rod and pis-
• When reusing the rod and piston as- ton assembly are replaced with new
a Carefully clean them to eliminate

sembly. one.
i) Use tool U4 to tighten piston assembly
chips and dusts. (8) until it is pressed against rod (19)
3 Piston assembly:
i) Use tool U4 to tighten piston assembly end [C].
(6) until piston and rod screw hole posi-
a Use a file to eliminate burrs and re-

tions "a" match. 294 ± 29.4 Nm {30 ± 3.0 kgm}
turns of the screw.
ii) Process one tapped hole for installing
a Use a drill to horizontally process

screw (7).
3 Screw:
ii) Tighten screw (7).
the V grooves of the screw parts of
58.9 – 73.6 Nm {6 – 7.5 kgm} piston (8) and rod (19).
iii) Fasten the screw at 4 portions b using • Dimensions of screw hole (mm)
drift.
Preparation hole Preparation Tapping
Screw size
drill diameter hole depth depth
10.3 27 12 x 1.75 20
iii) After processing, eliminate chips and

dusts, then carefully clean the tapped
hole part.
WA430-6 30-133
3 Screw:
iv) Tighten screw (7). 8. Cylinder head and piston rod assembly (Lift
cylinder and bucket cylinder)
58.9 – 73.6 Nm {6 – 7.5 kgm} 1) Set cylinder (4) to tool U1.
v) Fasten screw at four portions "b" using 2) Lift cylinder head and piston rod assembly
drift. (3) and assemble to cylinder (4).
3) Tighten the mounting bolt of cylinder head
a Tighten the bolt so that the dimension of

assembly (2).
the leveler plate of the bucket cylinder is
3 Cylinder head mounting bolt:

as shown in the illustration.
Lift cylinder:
373 ± 54 Nm {38.0 ± 5.5 kgm}
Bucket cylinder:
490 ± 49 Nm {50 ± 5.0 kgm}
7. Cylinder head and piston rod assembly

(Steering cylinder)
1) Set cylinder (4) to tool U1.
2) Lift cylinder head and piston rod assembly
(3) and assemble to cylinder (4).
3) Use tool U2 to tighten cylinder head assem-
3 Cylinder head:
bly (2).
569 ± 57.0 Nm {58 ± 5.8 kgm}

4) Remove cylinder assembly (1) from tool U1. 4) Remove cylinder assembly (1) from tool U1.
30-134 WA430-6
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF WORK EQUIPMENT

work equipment
Removal
1. Temporarily lift the bucket link, and remove pin

(1). [*1]
4 Bucket link: 55 kg
a Fix the bucket link to the tilt lever using a
a Check the number and thickness of shims.

wire.
5. Raise the lift arm, then install support stand [2] at
the end of the lift arm, and release the remaining
pressure in the hydraulic piping.
2. Remove bucket hinge installing pin (2). [*2]

k Absolutely do not insert fingers into the pin

hole. 6. Temporarily lift the lift cylinder assembly (6), and

remove pin (5) of rod end. [*4]
a When lowering the lift cylinder, put the block

into the top of the axle.
4 Lift cylinder assembly: 150 kg
3. Move the machine to backward and disconnect

the bucket.
4. Temporarily lift bucket cylinder assembly (3), pull

out rod pin (4). Then disconnect the cylinder rod
a Install block [1] between the cylinder bottom

and tilt lever. [*3]

and frame.
4 Bucket cylinder assembly: 160 kg
WA430-6 30-135
7. Disconnect connector F10 (7). 13. Temporarily lift bucket link assembly (12), and
pull out installing pin (13), then remove it from the
8. Remove boom kick-out switch (8). [*5] tilt lever assembly. [*7]
4 Bucket link assembly: 55 kg
9. Disconnect connector F18 (9).

14. Temporarily lift tilt lever assembly (14), and pull
10. Remove lift arm angle sensor (10).
out installing pin (15).
15. Lift tilt lever assembly (14), and remove it.

4 Tilt lever assembly: 320 kg
11. Temporarily lift the lift arm, tilt lever and bucket
link assembly (10), and pull out installing pin

(11). [*6]
16. Pull out dust seal (17) and bushing (18) from lift
12. Lift the lift arm, tilt lever and bucket link assembly arm (16). [*8]
(10) and remove it.
4 Lift arm, tilt lever and bucket link
assembly: 1,500 kg
30-136 WA430-6
17. Pull out dust seal (19) and bushing (20) from tilt Installation
a Before installing the pin, apply grease and

lever (14). [*8] • Carry out installation in reverse order of removal.
lubricant containing molybdenum disulfide

(LM-P) to the inside wall of the bushing.
[*1]
Installation of bucket link pin
1. Lift the bucket link, align the hole of installing pin
(1) and install cord ring (23).
2. Insert shims so that clearance "a" is equal on the

left and right.
• Clearance "a": Max. 1.5 mm
• Standard shim thickness: 1.5 mm, 3.0 mm
18. Pull out dust seal (21) and bushing (22) from 3. Assemble installing pin (1) and tighten bolt (24)
to lock it.
bucket link (12). [*8]
a Take care that the cord ring is not engaged.

hole.
WA430-6 30-137
[*2] [*4]
Installation of bucket hinge pin Installation of lift cylinder rod pin (rod side)
1. Operate the control lever, align the hole of bucket k When starting the engine, check that the direc-
installing pin (2) and install cord ring (25). tional lever is in neutral and the parking brake is
applied.
2. Insert shims so that clearance "b" is equal on the 1. Insert shims so that clearance "d" is equal on the
left and right. left and right.
• Clearance "b": Max. 1.5 mm • Clearance "d": Max. 1.5 mm
• Standard shim thickness: 1.5 mm, 3.0 mm • Standard shim thickness: 1.5 mm
3. Assemble installing pin (2) and tighten bolt (26) 2. Assemble installing pin (5) and tighten bolt (28)
to lock it. to lock it.
k Absolutely do not insert fingers into the pin k Absolutely do not insert fingers into the pin

hole. hole.
a Adjust the boom kick-out, referring to section

[*5]
[*3]
Installation of bucket cylinder rod pin (rod side) "Testing and adjusting boom kick-out" in "Testing
1. Insert shims so that clearance "c" is equal on the and adjusting."
left and right.
• Clearance "c": Max. 1.5 mm [*6]
• Standard shim thickness: 1.5 mm, 3.0 mm Installation of lift arm pin (Frame side)
1. Insert shims so that clearance "e" is equal on the
2. Assemble installing pin (4) and tighten bolt (27) left and right.
to lock it. • Clearance "e": Max. 1.5 mm
k Absolutely do not insert fingers into the pin • Standard shim thickness: 1.5 mm, 3.0 mm
hole.
2. Assemble installing pin (11) and tighten bolt (29)
to lock it.
hole.
3. Adjust the bucket positioner, referring to section

"Testing and adjusting bucket positioner" in
"Testing and adjusting."
30-138 WA430-6
a Install dust seal (21) with the lip out.

a Part (22) is the bushing.
[*7]
a Fix the bucket link to the tilt lever using a wire.

Installation of bucket link pin
• Dimensions "f": 0.25 – 0.8 mm
1. Align the hole of bucket link installing pin (13) • Dimensions "g": 2 – 3 mm
and install cord ring (30).
2. Assemble installing pin (13) and tighten bolt (31)

to lock it.

hole.
Greasing
a Supply grease until it comes out through the

• Greasing to pins.
3 Pin: Molybdenum disulfide grease (LM-G),

joint.
Hyper white grease (G2-T), or equiva-

lent
[*8]
Use hydraulic cylinder [3], press the bushings to the
lift arm, tilt lever and bucket link and assemble the
2 Bushing: Grease (G2-LI)

dust seal.
a Apply grease to the seal and take care not to
a The following figure shows the bucket link as an

damage the seal.
example.
WA430-6 30-139
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY

operator’s cab assembly
Removal
1. Remove cover (1) between the operator's cab

and bulkhead.
2. Remove right and left covers (2) under the bulk-

head.
4. Remove right and left covers (9).
3. Remove left ladder assembly (3) and the floor
a When removing the left ladder assembly,

above the right ladder.
5. Remove floor mat.
disconnect connectors R43 (4) and R45 (5),
6. Remove covers (10) and (11).
clamp (6), and hoses (7) and (8) inside the
ladder.
4 Left ladder assembly: 60 kg
Right floor: 40 kg
30-140 WA430-6
7. Remove tray (12) and trims (13), (14), and (15). 9. Disconnect connectors CL6 (17), CL7 (18), and
S03 (19) at the front center in the operator's cab.
10. Disconnect connectors CL1 (20), CL2 (21), and

CL5 (22) at the right front in the operator's cab.
8. Disconnect connector (16) at the left front in the

cab.
• L07, L08, S01, S02, S07, CL8, CL9, CL10
12. Remove the operator's cab roof and sling the op-
erator's cab assembly temporarily.
13. Remove mounting bolts (25) and (26). [*1]
WA430-6 30-141
a Check the quantity and positions of the

14. Lift off operator's cab assembly (27). Installation
shims installed to the bolts. [*2] moval.
4 Operator's cab assembly: 700 kg
3 Mounting bolt (25):

[*1]
98 – 123 Nm {10 – 12.5 kgm}

Mounting bolt (26):
471 – 530 Nm {48 – 54 kgm}
a Install shims of the thickness and quantity re-

[*2]
a If the operator's cab assembly was replaced,

corded when removed.
eliminate clearance by adjusting the shims.

• Set shim thickness
Location of bolt (25): 1.0 mm
Location of bolt (26): 0.5, 1.0 mm
30-142 WA430-6
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK
GLASS)
Removal and installation of a If the glass is narrow, you may cut the adhesive
by the following method. Insert a fine wire [2] (pi-
operator's cab glass (Stuck ano wire, etc.) in the adhesive and grip its both
glass) ends with pliers [3], etc. (or hold them by winding
them onto something) and cut the adhesive with
Special tool the wire.
New/Remodel
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
1 793-498-1120 Clear plate t 2

2 2 793-498-1130 Plate t 2
X 3 793-498-1110 Magnet t 2
t 2
Lifter
3 793-498-1210
(Suction cups)
a All sides of each glass of the operator's cab of

Removal
a The broken window glass may be removed with
a Remove the window glass to be replaced ac-

this vehicle are stuck. knife [4] and a screwdriver. (If the screwdriver is
applied directly to the normal window glass, the
a When using knife [4], insert a screwdriver in the

cording to the following procedure. glass will be broken.)
1. Using seal cutter [1], cut the adhesive between cut to widen it and move the knife forward.
broken window glass (1) and operator's cab (2).
2. Remove the window glass.
WA430-6 30-143
GLASS)
Installation
1. Using scraper [5], remove the remaining adhe-
a Do not scratch the paint.

sive.
4. Stick both-sided adhesive tape (4) along the in-

side edge of the glass sticking section.
a When sticking the both-sided adhesive tape,

• Size of both-sided adhesive tape: 7 x 4.8 mm
do not touch the cleaned surface as long as
a Do not remove the release tape of the both-

2. Remove oil, dust, dirt, etc. from the sticking sur- possible.
faces of cab (2) and window glass (3) with white
a If the sticking surfaces are not cleaned well,

gasoline. sided adhesive tape on the glass sticking
side before sticking the glass.
a Clean the all black part on the back side of

the glass may not be stuck perfectly.
a After cleaning the sticking surfaces, leave

the window glass.
them for at least 5 minutes to dry.
a Take care the corner (part b) of both-sided

adhesive tape will not float.
3. When the adhesive was removed with the scrap-

er, if any paint was flaked off, coat the bare part
a If the glass is installed without repairing the

with paint.
a Do not apply paint to a part which will be

bare part, that part will be rusted.
coated with primer.
30-144 WA430-6
GLASS)
a When sticking the both-sided adhesive tape 3) Using tool X3 (suction cups), place window
around a side or a rear window glass, start at glass (3) on tool X2-1 (5 mm spacer) and
center of the top and make a clearance of match it to the operator's cab.
about 5 mm at end joint "c".
4) Check the clearance between window glass

5. Position the replacement glass. (3) and operator's cab (2) on both sides and
1) Stick X2-2 (thin steel sheet) to tool X2-1 adjust it evenly.
(spacer) with adhesive. 5) Stick tape [6] between window glass (3) and
• Spacer thickness "t": 5 mm operator's cab (2) and draw positioning line
2) Match tool X2-3 (magnet) to tools X2-1 and "a".
X2-2 and set them to the 2 lower places of 6) Cut the tape between window glass (3) and
the window glass sticking part of operator's operator's cab (2) with a knife, and then
a Do not remove the tapes left on the window

cab (2). remove the window glass.
glass and operator's cab before installing the

window glass.
WA430-6 30-145
GLASS)
a If the glass primer is applied by mistake,

a The using limit of primer (5) is 4 months after
6. Apply primer.
wipe it off with white gasoline.
the date of manufacture. Do not use primer (If wrong primer is applied, the glass will
a Use the primer within 2 hours after unpack-

(5) after this limit. not be stuck.)
a Even if the primer is packed again just after

ing it.
it is unpacked, use it within 24 hours after it

is unpacked for the first time.
(Discard the primer 24 hours after it is
packed.)
1) Stir the primers for paint and glass suffi-
a If the primer has been stored in a refrig-

ciently before using them.
erator, leave it at the room temperature

for at least half a day before stirring it.
(If the primer is unpacked just after
taken out of the refrigerator, water will
be condensed. Accordingly, leave the
primer at the room temperature for a
sufficient time.)
2) When reusing primer brush (6), wash it in
a After washing the brush, check it again

white gasoline.
a Prepare respective brushes for the paint

for dirt and foreign matter.
primer glass primer.
4) Evenly apply glass primer (8) to the black
2 Glass primer: SUNSTAR GLASS

part of window glass (3) to be stuck.
a Do not apply the primer more than 2

PRIMER 580 SUPRE
times.
(If it is applied more than 2 times, its
a Parts to be coated with primer: Apply the

performance will be lowered.)
primer to the sticking surface of window

3) Evenly apply paint primer (7) to the parts on glass (3) and all over dimension "d" on
the outside of both-sided adhesive tape on both-sided adhesive tape (4) and opera-
operator's cab (2) which will be coated with tor's cab (2).
2 Paint primer:
the adhesive. • Dimension to apply primer "d": 23
SUNSTAR PAINT
a Do not apply the primer to the boarder
mm
a Do not apply the primer more than 2

PRIMER 580 SUPRE
about 5 mm wide between the black part
times.
a After applying the primer, leave it for at
and transparent part of the glass.
(If it is applied more than 2 times, its
a Parts to be coated with primer: Apply the

performance will be lowered.)
a If the paint primer is applied by mistake,
least 5 minutes (within 8 hours) to dry.
primer all over dimension "d" on the out- wipe it off with white gasoline.
side of the both-sided adhesive tape. (If wrong primer is applied, the glass will
• Dimension to apply primer "d": 23 not be stuck.)
a After applying the primer, leave it for at

mm
least 5 minutes (within 8 hours) to dry.
30-146 WA430-6
GLASS)
2) Cut the tip of the adhesive nozzle (11) so

that dimensions "f" and "g" will be as fol-
lows.
• Dimension "f": 10 mm
• Dimension "g": 12 mm
3) Set adhesive cartridge (9) to caulking gun
a An electric caulking gun is more efficient.

[7].
a Use either of the 2 types of the adhesive.

7. Apply adhesive.
2 Adhesive (Summer):
SUNSTAR PENGUINE SEAL
2 Adhesive (Winter):
580 SUPER "S"
SUNSTAR PENGUINE SEAL
a The using limit of the adhesive is 4 months

580 SUPER "W"
after the date of manufacture. Do not use
a Keep the adhesive in a dark place where the

the adhesive after this limit. 4) Remove release tape (13) of the both-sided
adhesive tape on the glass side.
a Never heat the adhesive higher than 30°C.

temperature is below 25°C.
a When reusing the adhesive, remove the all

hardened part from the nozzle tip.
1) Break aluminum seal (10) of the outlet of
adhesive cartridge (9) and install the nozzle.
WA430-6 30-147
GLASS)
5) Apply adhesive (12) to the outside of both-

sided adhesive tape (4) of the operator's
a Before applying the adhesive, check that

cab.
the primer is applied to the surface to

which the adhesive will be applied.
2) Using tool X3, raise and place window glass

(3) on tool X2-1 (5-mm spacer) and stick it
a Match the lines of the match tapes stuck

to the operator's cab.
a Stick the glass within 10 minutes after

in step 5.
a Apply adhesive (12) to dimensions "h" a Before sticking the glass, check that the
applying the adhesive.
and "j" of both-sided adhesive tape (4) of primer is applied to the surface to which
operator's cab (2). the glass will be stuck.
• Dimension "h": 10 mm
• Dimension "j": 12 mm (Approx. twice
a Apply adhesive (12) higher than both-

as high as adhesive tape)
a Apply the adhesive evenly.

sided adhesive tape (4).
a Check clearance "k" between the front

side of the front glass and each side and
adjust it evenly.
• Clearance "k": 5 mm
a If the glass is positioned wrongly, the adhe-

8. Install window glass (3).
sive must be removed and cleaned, and then

the primer and adhesive must be applied
again. Accordingly, position the glass care-
fully when sticking it.
1) Similarly to step 5, match tools X2-1, X2-2,
and X2-3 and set them to the 2 lower places
of the window glass sticking part of opera-
tor's cab (2).
30-148 WA430-6
GLASS)
3) After sticking window glass (3), press it
a Press all over the window glass to the

evenly.
degree that the window glass will be
a Do not press the window glass too

stuck to the both-sided adhesive tape.
strongly.
2) Fill the joint of the glasses with caulking
a The usable period of the following caulk-

material (15).
ing material is 4 months after the date of

manufacture. Do not use the caulking
2 Caulking material:
material after its usable period.
SUNSTAR
PENGUINE SEAL NO. 2505
a Curing time before removing tool X2-1 (5-

9. Cure the stuck window glass for a certain time.
mm spacer) (at temperature of 20°C and hu-
a Curing time before operating vehicle: 1 day

midity of 60%): 10 hours
10. If the front glass and both front glasses are re-
placed, seal them.
1) Stick masking tapes (14) along the parts to
a Stick the masking tapes to both inside

be sealed shown in the figure.
and outside of the operator's cab.
3) Remove the caulking material projected

from the joint with cardboard [8], etc.
4) Remove the masking tapes from the window

glass.
WA430-6 30-149
GLASS)
11. Remove the primer and adhesive from the oper-
a Using white gasoline, wipe off the adhesive

ator's cab and window glass.
a When cleaning the glass, do not give an im-

before it is dried up.
pact to it.
30-150 WA430-6
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF OPERATOR’S CAB AND FLOOR
FRAME ASSEMBLY
Removal and installation of 4. Remove left ladder assembly (3) and the floor
a When removing the left ladder assembly,

above the right ladder.
operator’s cab and floor frame
assembly disconnect connectors R43 (4) and R45 (5),
clamp (6), and hoses (7) and (8) inside the
Special tool ladder.
4 Left ladder assembly: 60 kg
New/Remodel
Right floor: 40 kg
Necessity
Sketch
Q'ty

799-703-1100 Vacuum pump t 1
X1 799-703-1111 Vacuum pump t 1
799-703-1121 Vacuum pump t 1
799-703-1401 Gas leak detector t 1
Removal
1. Collect the air conditioner refrigerant from the air

conditioner circuit. [*1]
2. Remove cover (1) between the operator's cab

and bulkhead.
3. Remove right and left covers (2) under the bulk-

head.
WA430-6 30-151
FRAME ASSEMBLY
6. Disconnect hoses (10) – (16). [*2] 9. Disconnect hoses (20) and (21).
7. Disconnect air conditioner pipes (17) and (18) 10. Disconnect hoses (22) and (23) from the brake
from the right rear of the floor frame. valve.
8. Disconnect hose (19). 11. Disconnect hose (24) from the brake valve.
13. Disconnect 4 hoses (27) from the steering valve.
30-152 WA430-6
FRAME ASSEMBLY
14. Disconnect the following connectors from the left 17. Remove the operator's cab roof and sling the op-
lower part of the floor frame. erator's cab assembly temporarily.
• LR10 (28), LR4 (29), LR6 (30), LR8 (31),
LR9 (32), LR1 (33), LR5 (34), FL1 (35), 18. Remove right and left covers (48) from the front
LR13 (36), LR3 (37), LR2 (38), FL2 (39), of the floor frame.
LT1 (40), LR12 (41), LR7 (42)
19. Remove 4 lock plates (49) and 4 nuts (50). [*3]
15. Disconnect ground cable (43) and hoses (44)

and (45). 20. Lift off operator's cab and floor frame assembly
a When lifting off the assembly, check that no

(51).
wires and pipes are connected to the chas-

sis.
4 Operator's cab and floor frame assem-
bly: 1,300 kg
16. Disconnect hose (46) and bracket (47).
WA430-6 30-153
FRAME ASSEMBLY
Installation
moval.
a Using tool X1, charge the air conditioner circuit

[*1]
with air conditioner refrigerant (R134a).
a Connect the PPC hoses according to their band

[*2]
colors.
• Band colors
Bucket dump (11): Blue
Lift arm lower (12): Yellow
Bucket tilt (13): Green
Lift arm raise (14): White
Attachment (15): Blue and white
Attachment (16): Green and white
3 Floor frame installing nut:

[*3]
1,175 – 1,470 Nm {120 – 150 kgm}
Bleeding air
Bleeding air from steering circuit, Bleeding air from
wheel brake circuit, and Bleeding air from work
equipment circuit.
30-154 WA430-6
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
Removal and installation of 5. Remove center drive shaft (4). [*2]
center hinge pin

Special tool
New/Remodel
Necessity
Sketch
Q'ty
1 790-101-2300 Push puller t 1

2 793-520-2370 Push tool t 1
3 793-520-2350 Push tool t 1
K 4 793-520-2540 Guide t 1
5 793-520-2360 Bar t 2 6. Disconnect connector FF1 (5) and FF2 (6).
6 790-101-1102 Hydraulic pump t 1
7 790-101-2102 Puller assembly t 1
Removal
1. Remove the work equipment assembly, referring
to "Removal and installation of work equipment
assembly."
2. Remove the operator’s cab and floor frame as-

sembly, referring to "Removal and installation of
operator’s cab and floor frame. "

7. Disconnect hoses (7) to (13). [*3]
4. Remove lock bolt (2) and then remove pin (3) of
a The shims are inserted to the steering cylin-

the steering cylinder rod side. [*1]
der rod, check the number and thickness of

shims.
cedures.
WA430-6 30-155
8. Remove clamp (14), then disconnect hoses (15) 11. Jack up front frame (25). While adjusting the
a Tag the disconnected hoses so that it can be

to (21) in the rear frame side. height, insert block [2] on the left and right of the
a Insert roller [3] between block [2] and the

front frame.
identified.
frame so that the front frame can be pulled
out.
9. Disconnect hoses (22) and (23) from the steering

valve.
12. Remove lock bolt (26) and then pull out lower
hinge pin (27). [*4]
10. Jack up rear frame (24). While adjusting the

height, insert block [1] on the left and right of the
a The shims are inserted between the retainer

rear frame. 13. Remove cover (28) at the upper hinge portion.
and the frame, check the number and thick-

ness of shims.
14. Remove lock bolt (29). While adjusting the
a Carefully adjust the height so that the pin can

height, pull out upper hinge pin (30). [*4]
be pulled out by hand.
30-156 WA430-6
15. Remove spacer (31). [*4] 18. Remove retainer (33) from the lower side front

frame. [*4]

ness of shims.
16. Carefully pull out front frame (25) forward and
a Confirm whether the front frame is complete-

disconnect it from rear frame (24).
a Remove the safety bar.

ly disconnected from the rear frame.
a Take care that the lower spacer of the upper a Also remove the dust seal from the frame.
19. Remove dust seal (34) from the retainer. [*4]
a Take care of the balance at disconnection.

hinge does not engage with the rear frame.
20. Remove bearing (35) from the front frame. [*4]
a Pull out the upper and lower bushings of the

17. Pull out bushing (32) from the rear frame. [*4]
lower hinge together.
WA430-6 30-157
21. Remove retainer (36) at the front frame upper 24. Remove bearing (40).

side. [*4]

ness of shims.
Installation
a Adjust the shim so that the maximum of clear-

[*1]
22. Remove dust seal (37) from the retainer.
ance between the frame and the cylinder is 0.5
mm or less.
• Standard shim thickness: 3 mm
2 Cylinder bushing inside surface and

• Shim thickness: 0.5 mm, 1.0 mm
dust seal: Lubricant containing

molybdenum disulfide (LM-P)
a Before tightening the mounting bolts, check that

[*2]
the key way of the spider cap is fitted securely to
3 Center drive shaft mounting bolt:

the key way of the mating yoke.
98.1 – 122.6 Nm {10 – 12.5 kgm}

23. Remove spacer (38) and dust seal (39) from the
a Connect the PPC hoses according to their band

front frame. [*3]
colors.
• Band colors
Bucket dump (8): Blue
Lift arm lower (9): Yellow
Bucket tilt (10): Green
Lift arm raise (11): White
Attachment (12): Blue and white
Attachment (13): Green and white
30-158 WA430-6
a At pressing, turn the dust seal lip outside.

[*4] 5. Press dust seal (37) in retainer (36).
Assembly of the center pin
1. Install tool K1 to the top of the upper hinge of rear
frame (24).
2. Set bearing (40) onto tool K4 and then press the
a At pressing, use tool K4 as a guide.

bearing from upper side.
a Take care that the bearing does not incline.

a Coat the grease to the bearing inside sur-
a The bearing is clearance-adjusted. Bearing

face.
(40) must be replaced together with spacers
2 Bearing inside surface:

(31) and (38).
Lubricant containing molybdenum
2 Spacer (38) inside surface:

disulfide (LM-P)
6. Press dust seal (34) in retainer (33).
Lubricant containing molybdenum 2 Dust seal: Grease (G2-LI)

disulfide (LM-P)
3. Set bearing (35) to the lower hinge of rear frame

(24).
a At pressing, use tool K4 as a guide.

4. Use tool K1, and press bearing (35).
a Take care that the bearing does not incline.

a Coat the grease to the bearing inside sur-
2 Bearing inside surface:

face.

disulfide (LM-P)
WA430-6 30-159
7. Adjusting the shim of the retainer portion (Upper

side).
1) Equally tighten the 3 mounting bolts of
retainer (36), and select a shim so that the
maximum of clearance "a" between the
retainer and the hinge is 0.1 mm or less.
Then assemble the retainer.
3 Mounting bolt:
• Shim thickness: 0.1 mm, 0.5 mm
20 ± 2 Nm {2.0 ± 0.2 kgm}

(At shim adjusting)
2) After adjusting the shim, tighten all the

retainer mounting bolts with the specified
2 Mounting bolt:
torque.
3 Mounting bolt:
Adhesive (Loctite 2701)
98 – 123 Nm {10 – 12.5 kgm}
9. Assemble dust seal (39) and spacer (38) from

lower of the front frame.
a Assemble spacer (38) from lower so that the

2) After adjusting the shim, tighten all the more largely chamfered side facing to the
2 Spacer inside surface:

retainer mounting bolts with the specified bearing side.
2 Mounting bolt:
torque.
3 Mounting bolt:
Adhesive (Locktite 2701) disulfide (LM-P)
98 – 123 Nm {10 – 12.5 kgm}
8. Adjusting the shim of the retainer portion (Lower

side).
1) Equally tighten the 3 mounting bolts of
retainer (33), and select a shim so that the
maximum of clearance "b" between the
retainer and the hinge is 0.1 mm or less.
Then assemble the retainer.
3 Mounting bolt:
• Shim thickness class: 0.1 mm, 0.5 mm
20 ± 2 Nm {2.0 ± 0.2 kgm}

(At shim adjusting)
30-160 WA430-6
10. Press dust seal (34) from upper of the front 13. Install cover (28) to upper hinge pin (30), and

frame. equally tighten the 3 mounting bolts. Then select
2 Dust seal lip unit: Grease (G2-LI)

the shim so that the clearance c between the
hinge and the retainer is 0.2 mm or less, and as-
a Measure the 3 points of the clearance be-

semble the retainer.
11. Use puller [4] to press bushing (32) in the lower
a Press fit both upper and lower bushings sim- a After adjusting the shim, temporarily tighten
hinge of the rear frame. tween the cover and the hinge.
ilarly. the retainer mounting bolt so that it does not

turn.
• Shim thickness class:
3 Mounting bolt:
0.2 mm, 0.5 mm, 1.0 mm
20 ± 2 Nm {2.0 ± 0.2 kgm}

(At shim adjusting)
12. Insert upper hinge pin (30) and assemble spacer

(31).
k Use a bar to mach the pin holes. Absolutely
a Be sure to mach the pin holes.

do not insert fingers.
WA430-6 30-161
14. Tighten all the pin and the retainer mounting
2 Mounting bolt:
bolts with the specified torque.
3 Retainer mounting bolt:

Adhesive (Loctite 2701)
3 Pin mounting bolt:

98 – 123 Nm {10 – 12.5 kgm}
206 ± 20 Nm {21 ± 2 kgm}
15. Tighten lock bolt (29) of upper hinge pin (30).
16. Insert lower hinge pin (27) and install lock bolt
(26).
30-162 WA430-6
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF COUNTERWEIGHT
Removal and installation of 5. Temporarily lift counterweight (5).
counterweight 6. Remove 2 mounting bolts (6) and (7) for each

side, and then lift counterweight (5) and remove
Removal it. [*1]
k
4
Disconnect the cable from the negative (–) ter-
Counterweight: 1,450 kg
1. Open the grille and temporarily lift it.
2. Disconnect left and right damper gas cylinders

(1).
a Disconnect wiring harness clamp from the

3. Disconnect connector G04 (2) and G05 (3).
grille.
Installation
3 Mounting bolt:
[*1]
824 – 1,030 Nm {84 – 105 kgm}
4. Remove the 4 mounting bolts, and then remove

grille (4).
WA430-6 30-163
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT
Removal and installation of air 4. Remove right cover (3) of the operator's seat.
conditioner unit 5. Disconnect connector L11 (4) and remove rear

covers (5) and (6) of the operator's seat.
Special tool
New/Remodel
Necessity
Sketch
Q'ty
t 1
Vacuum pump
799-703-1100
(100V)
t 1
Vacuum pump
X1 799-703-1111
(220V)
t 1
Vacuum pump
799-703-1121
(240V)
799-703-1401 Gas leak detector t 1 6. Remove duct (7).
Removal
brake and put the blocks under the wheels.
1. Collect the air conditioner gas (R134a).
2. Remove the operator’s cab assembly, referring

to section "Removal and installation of operator’s
cab assembly." 7. Disconnect the 7 intermediate connectors of the
fuse box.
a If the heater hose is disconnected, the cool-

3. Disconnect 2 heater hoses (2). • (8): FS7
• (9): FS6
ant leaks. Accordingly, prepare a plug in ad- • (10): FS1
vance. • (11): FS2
• (12): FS5
• (13): FS3
• (14): FS4
30-164 WA430-6
8. Disconnect the 4 connectors in rear of the oper- 12. Disconnect connector A3 (26), A1 (27) and A2
ator's seat. (28).
• (15): L19
• (16): L20
• (17): DL
• (18): L31
9. Remove cool and heat box assembly (19) and
a When removing the cool and heat box as-

remove relay and fuse bracket (20).
sembly, remove the relay installing plate.
13. Remove the mounting bolt of the air conditioner

unit assembly.
14. Lift air conditioner unit assembly (29) and discon-

nect hose (30), and remove it.
10. Disconnect connector A4 (21) and remove inside

and outside switching damper (22).
Installation
a Do not remove the stopper plug until just before

[*1]
11. Loosen the mounting bolts of plate (23) and dis-
a After the tube is disconnected, cover the

connect air conditioner tubes (24) and (25). [*1]
2 O-ring and thread portion:
the tube is connected.
tube with a plug so that no foreign matter will Compressor oil for R134a
contaminate the tube openings. (DENSO: ND-OIL8)
(ZEXEL: ZXL100PG)
3 Tube mounting bolt:

(PAG46 or equivalent)
8 – 12 Nm {0.8 – 1.2 kgm}
Charging the air conditioner gas

• Use tool X1 to charge the air conditioner gas
(R134a) in the air conditioner circuit.
WA430-6 30-165
30-166 WA430-6
OTHERS
90 OTHERS
Power train hydraulic circuit diagram ............... 90-3
Engine electrical circuit diagram ...................... 90-5
Hydraulic circuit diagram.................................. 90-7
Electrical circuit diagram (1/8).......................... 90-9
Electrical circuit diagram (2/8).........................90-11
Electrical circuit diagram (3/8)........................ 90-13
WA430-6 90-1
OTHERS
90-2 WA430-6
OTHERS POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
Power train hydraulic circuit diagram
WA430-6 90-3
OTHERS POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
90-4 WA430-6
OTHERS ENGINE ELECTRICAL CIRCUIT DIAGRAM
Engine electrical circuit diagram
WA430-6 90-5
OTHERS ENGINE ELECTRICAL CIRCUIT DIAGRAM
90-6 WA430-6
Hydraulic circuit diagram
WA430-6 90-7
Electrical circuit diagram (1/8)
WA430-6 90-9
WA430-6 90-11
WA430-6 90-13
WA430-6 90-15
WA430-6 90-17
WA430-6 90-19
WA430-6 90-21
WA430-6 90-23

Wa430 6H

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Wa430 6H

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Formati disponibili

VEBM350100

Machine model Serial number

WA430-6 H50051 and up

• WA430-6 mount the SAA6DE114-2 engine.

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . .10-1

20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . .20-1

30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . .30-1

Important safety notice

General precautions 6. Decide a place in the repair workshop to keep

Structure and function and maintenance standard

Standard value table, Testing and adjusting, and Troubleshoting

Disassembly and assembly

How to read the shop manual Symbols

Volumes So that the shop manual can be of ample practical

Chassis volume: Issued for every machine model

k Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

k Slinging with one rope may cause turning

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

Method of disassembling, connecting push-pull type coupler

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

• Used as lubricant for sliding portion (to

• Used as primer for sash (Alumite).

Standard tightening torque

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

Table of tightening torques for flared nuts

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

Table of tightening torques for split flange bolts

Thread diameter Width across flat Tightening torque

Table of tightening torques for o-ring boss piping joints

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

Table of tightening torques for o-ring boss plugs

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

Tightening torque for 102 and 114 engine series

Electric wire code

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

Classification by color and code

Method of using the conversion table

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

Liter to U.S. Gallon

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

Liter to U.K. Gallon