Manual de Taller WA450-3MC

CEBM003602
WA450-3
WHEEL LOADER
SERIAL NUMBERS WA450-3MC - A31001 and up
SERIAL NUMBERS WA450-3MC - A35001 and up

MATERIAL HANDLER
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed
except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
JULY 1999 Copyright 1999 Komatsu America International Company

FOREWORD
CONTENTS
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 30-1
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
00-2 WA450-3MC
PRODUCT PUBLICATIONS INFORMATION
Various product Parts and Service Publications are available to all KOMATSU construction equipment
owners, including operation and maintenance manuals, parts books and service manuals.
Special publications, such as service tool, air conditioning and turbocharger service manuals are also
available as well as selected Operation and Service manuals in foreign languages.
The Publications listed below are available for this particular machine(s).
DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER:

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB005700
PARTS BOOK - MICROFICHE:

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BEPM005700
OPERATION AND MAINTENANCE MANUAL:

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM003800
SHOP MANUAL
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM003602
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEBM006403
SAFETY MANUAL
Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WLT70-1
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the
Komatsu America International Company Parts Inventory Processing System (PIPS).
If the PIPS system is not available at the distributor location, then the following Requisition for Technical
Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this
page.
pubinfok.fm 4/4/00
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO ö DataKom Publishing Corporation
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
PURCHASE ORDER NO.
SHIP TO ö
ATTN.
STREET ADDRESS ORDER DATE

TYPE or PRINT CITY, STATE, ZIP CODE
ONLY ö
COUNTRY
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE
SERIAL NUMBER MUST BE SHOWN.
PARTS BOOK
PUBLICATION
QTY. PUBLICATION FORM NO. P-Paper MODEL NUMBER SERIAL NUMBER
DESCRIPTION
M-Microfiche
KDC91E 072199 CURRENT PRICES WILL BE CHARGED

FOREWORD
The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ❍ New page to be added Add
● Page to be replaced Replace
( ) Page to be deleted Discard
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
( ) 0-1 1 00-13 10-8 10-37
( ) 0-2 1 00-14 10-9 10-38
( ) 0-3 1 00-15 10-10 10-39
( ) 0-4 1 00-16 10-11 10-40
( ) 0-5 1 00-17 10-12 10-41
( ) 0-6 1 00-18 10-13 10-42
( ) 0-7 1 10-14 10-43
( ) 0-8 1 01-1 10-15 10-44
01-2 10-16 10-45
● 00-1 2 01-3 10-17 10-46
00-2 01-4 10-18 10-47
❍ 00-2-1 2 01-5 10-19 10-48
❍ 00-2-2 2 01-6 10-20 10-49
❍ 00-2-3 2 01-7 10-21 10-50
❍ 00-2-4 2 01-8 10-22 10-51
❍ 00-2-5 2 01-9 10-23 10-52
❍ 00-2-6 2 01-10 10-24 10-53
❍ 00-2-7 2 01-11 10-25 10-54
❍ 00-2-8 2 01-12 10-26 10-55
00-3 01-13 10-27 10-56
00-4 01-14 10-28 10-57
00-5 10-29 10-58
00-6 10-1 10-30 10-59
00-7 10-2 10-31 10-60
00-8 10-3 10-32 10-61
00-9 10-4 10-33 10-62
00-10 10-5 10-34 10-63
00-11 10-6 10-35 10-64
00-12 10-7 10-36 10-65
WA450-3MC WA450-3MC 00-2-1 2

FOREWORD
10-66 10-99 10-132 10-165

10-67 10-100 10-133 10-166
10-68 10-101 10-134 10-167
10-69 10-102 10-135 10-168

10-70 10-103 10-136 10-169
10-71 10-104 10-137 10-170
10-72 10-105 10-138 10-171
10-73 10-106 10-139 10-172
10-74 10-107 10-140 10-173
10-75 10-108 10-141 10-174
10-76 10-109 10-142 10-175

10-77 10-110 10-143 10-176
10-78 10-111 10-144 10-177
10-79 10-112 10-145 10-178

10-80 10-113 10-146 10-179
10-81 10-114 10-147 10-180
10-82 10-115 10-148 10-181

10-83 10-116 10-149 10-182
10-84 10-117 10-150 10-183
10-85 10-118 10-151 10-184
10-86 10-119 10-152 10-185
10-87 10-120 10-153 10-186
10-88 10-121 10-154 10-187
10-89 10-122 10-155 10-188
10-90 10-123 10-156 10-189
10-91 10-124 10-157 10-190

10-92 10-125 10-158 10-191
10-93 10-126 10-159 10-192
10-94 10-127 10-160 10-193

10-95 10-128 10-161 10-194
10-96 10-129 10-162 10-195
10-97 10-130 10-163 10-196

10-98 10-131 10-164 10-197
00-2-2 2 WA450-3MC
FOREWORD
10-198 20-113 1 20-146 1 20-226 1

10-199 20-114 1 20-147 1 20-227 1
10-200 20-115 1 20-148 1 20-228 1
10-201 20-116 1 20-149 1 20-229 1

10-202 20-117 1 20-150 1 20-230 1
10-203 20-118 1 20-151 1 20-231 1
10-204 20-119 1 20-152 1 20-232 1

10-205 20-120 1 20-233 1
10-206 20-121 1 20-201 1 20-234
10-207 20-122 1 20-202 1
10-208 20-123 1 20-203 1 20-301 1
20-124 1 20-204 1 20-302 1
20-1 1 20-125 1 20-205 1 20-303 1
20-2 1 20-126 1 20-206 1 20-304 1

20-3 1 20-127 1 20-207 1 20-305 1
20-4 1 20-128 1 20-208 1 20-306 1
20-5 1 20-129 1 20-209 1 20-307 1

20-6 1 20-130 1 20-210 1 20-308 1
20-7 1 20-131 1 20-211 1 20-309 1
20-8 1 20-132 1 20-212 1 20-310 1

1 20-133 1 20-213 1 20-311 1
20-101 1 20-134 1 20-214 1 20-312 1
20-102 1 20-135 1 20-215 1 20-313 1

20-103 1 20-136 1 20-216 1 20-314 1
20-104 1 20-137 1 20-217 1 20-315 1
20-105 1 20-138 1 20-218 1 20-316 1

20-106 1 20-139 1 20-219 1 20-317 1
20-107 1 20-140 1 20-220 1 20-318 1
20-108 1 20-141 1 20-221 1 20-319 1

20-109 1 20-142 1 20-222 1 20-320 1
20-110 1 20-143 1 20-223 1
20-111 1 20-144 1 20-224 1 20-401 1

20-112 1 20-145 1 20-225 1 20-402 1
WA450-3MC 00-2-3 2
FOREWORD
20-403 1 20-509 1 20-712 1 20-901 1

20-404 1 20-510 1 20-713 1 20-902 1
20-405 1 20-511 1 20-714 1 20-903 1
20-406 1 20-512 1 20-715 1 20-904 1

20-407 1 20-513 1 20-716 1 20-905 1
20-408 1 20-514 1 20-717 1 20-906 1
20-409 1 20-515 1 20-718 1 20-907 1

20-410 1 20-516 1 20-719 1 20-908 1
20-411 1 20-517 1 20-720 1 20-909 1
20-412 1 20-518 1 20-721 1 20-910 1
20-413 1 20-722 1 20-911 1

20-414 1 20-601 1 20-912 1
20-415 1 20-602 1 20-801 1
20-416 1 20-603 1 20-802 1 ❍ 30-1 2
20-417 1 20-604 1 20-803 1 ❍ 30-2 2
20-418 1 20-605 1 20-804 1 ❍ 30-3 2
20-419 1 20-606 1 20-805 1 ❍ 30-4 2
20-420 1 20-607 1 20-806 1 ❍ 30-5 2
20-421 1 20-608 1 20-807 1 ❍ 30-6 2
20-422 1 20-609 1 20-808 1 ❍ 30-7 2
20-423 1 20-610 1 20-809 1 ❍ 30-8 2
20-424 1 20-810 1 ❍ 30-9 2
20-425 1 20-701 1 20-811 1 ❍ 30-10 2
20-426 1 20-702 1 20-812 1 ❍ 30-11 2
20-703 1 20-813 1 ❍ 30-12 2
20-501 1 20-704 1 20-814 1 ❍ 30-13 2
20-502 1 20-705 1 20-815 1 ❍ 30-14 2
20-503 1 20-706 1 20-816 1 ❍ 30-15 2
20-504 1 20-707 1 20-817 1 ❍ 30-16 2
20-505 1 20-708 1 20-818 1 ❍ 30-17 2
20-506 1 20-709 1 20-819 1 ❍ 30-18 2
20-507 1 20-710 1 20-820 1 ❍ 30-19 2
20-508 1 20-711 1 ❍ 30-20 2
00-2-4 2 WA450-3MC
FOREWORD
❍ 30-21 2 ❍ 30-54 2 ❍ 30-87 2 ❍ 30-120 2
❍ 30-22 2 ❍ 30-55 2 ❍ 30-88 2 ❍ 30-121 2
❍ 30-23 2 ❍ 30-56 2 ❍ 30-89 2 ❍ 30-122 2
❍ 30-24 2 ❍ 30-57 2 ❍ 30-90 2 ❍ 30-123 2
❍ 30-25 2 ❍ 30-58 2 ❍ 30-91 2 ❍ 30-124 2
❍ 30-26 2 ❍ 30-59 2 ❍ 30-92 2 ❍ 30-125 2
❍ 30-27 2 ❍ 30-60 2 ❍ 30-93 2 ❍ 30-126 2
❍ 30-28 2 ❍ 30-61 2 ❍ 30-94 2 ❍ 30-127 2
❍ 30-29 2 ❍ 30-62 2 ❍ 30-95 2 ❍ 30-128 2
❍ 30-30 2 ❍ 30-63 2 ❍ 30-96 2 ❍ 30-129 2
❍ 30-31 2 ❍ 30-64 2 ❍ 30-97 2 ❍ 30-130 2
❍ 30-32 2 ❍ 30-65 2 ❍ 30-98 2 ❍ 30-131 2
❍ 30-33 2 ❍ 30-66 2 ❍ 30-99 2 ❍ 30-132 2
❍ 30-34 2 ❍ 30-67 2 ❍ 30-100 2 ❍ 30-133 2
❍ 30-35 2 ❍ 30-68 2 ❍ 30-101 2 ❍ 30-134 2
❍ 30-36 2 ❍ 30-69 2 ❍ 30-102 2 ❍ 30-135 2
❍ 30-37 2 ❍ 30-70 2 ❍ 30-103 2 ❍ 30-136 2
❍ 30-38 2 ❍ 30-71 2 ❍ 30-104 2 ❍ 30-137 2
❍ 30-39 2 ❍ 30-72 2 ❍ 30-105 2 ❍ 30-138 2
❍ 30-40 2 ❍ 30-73 2 ❍ 30-106 2 ❍ 30-139 2
❍ 30-41 2 ❍ 30-74 2 ❍ 30-107 2 ❍ 30-140 2
❍ 30-42 2 ❍ 30-75 2 ❍ 30-108 2 ❍ 30-141 2
❍ 30-43 2 ❍ 30-76 2 ❍ 30-109 2 ❍ 30-142 2
❍ 30-44 2 ❍ 30-77 2 ❍ 30-110 2 ❍ 30-143 2
❍ 30-45 2 ❍ 30-78 2 ❍ 30-111 2 ❍ 30-144 2
❍ 30-46 2 ❍ 30-79 2 ❍ 30-112 2 ❍ 30-145 2
❍ 30-47 2 ❍ 30-80 2 ❍ 30-113 2 ❍ 30-146 2
❍ 30-48 2 ❍ 30-81 2 ❍ 30-114 2 ❍ 30-147 2
❍ 30-49 2 ❍ 30-82 2 ❍ 30-115 2 ❍ 30-148 2
❍ 30-50 2 ❍ 30-83 2 ❍ 30-116 2 ❍ 30-149 2
❍ 30-51 2 ❍ 30-84 2 ❍ 30-117 2 ❍ 30-150 2
❍ 30-52 2 ❍ 30-85 2 ❍ 30-118 2 ❍ 30-151 2
❍ 30-53 2 ❍ 30-86 2 ❍ 30-119 2 ❍ 30-152 2
WA450-3MC 00-2-5 2
FOREWORD
❍ 30-153 2 ❍ 30-186 2 ❍ 30-219 2 ❍ 30-252 2

❍ 30-154 2 ❍ 30-187 2 ❍ 30-220 2 ❍ 30-253 2
❍ 30-155 2 ❍ 30-188 2 ❍ 30-221 2 ❍ 30-254 2
❍ 30-156 2 ❍ 30-189 2 ❍ 30-222 2 ❍ 30-255 2

❍ 30-157 2 ❍ 30-190 2 ❍ 30-223 2 ❍ 30-256 2
❍ 30-158 2 ❍ 30-191 2 ❍ 30-224 2 ❍ 30-257 2
❍ 30-159 2 ❍ 30-192 2 ❍ 30-225 2 ❍ 30-258 2
❍ 30-160 2 ❍ 30-193 2 ❍ 30-226 2 ❍ 30-259 2
❍ 30-161 2 ❍ 30-194 2 ❍ 30-227 2 ❍ 30-260 2
❍ 30-162 2 ❍ 30-195 2 ❍ 30-228 2 ❍ 30-261 2
❍ 30-163 2 ❍ 30-196 2 ❍ 30-229 2 ❍ 30-262 2

❍ 30-164 2 ❍ 30-197 2 ❍ 30-230 2 ❍ 30-263 2
❍ 30-165 2 ❍ 30-198 2 ❍ 30-231 2 ❍ 30-264 2
❍ 30-166 2 ❍ 30-199 2 ❍ 30-232 2 ❍ 30-265 2
❍ 30-167 2 ❍ 30-200 2 ❍ 30-233 2 ❍ 30-266 2
❍ 30-168 2 ❍ 30-201 2 ❍ 30-234 2 ❍ 30-267 2
❍ 30-169 2 ❍ 30-202 2 ❍ 30-235 2 ❍ 30-268 2
❍ 30-170 2 ❍ 30-203 2 ❍ 30-236 2 ❍ 30-269 2
❍ 30-171 2 ❍ 30-204 2 ❍ 30-237 2 ❍ 30-270 2
❍ 30-172 2 ❍ 30-205 2 ❍ 30-238 2 ❍ 30-271 2
❍ 30-173 2 ❍ 30-206 2 ❍ 30-239 2 ❍ 30-272 2
❍ 30-174 2 ❍ 30-207 2 ❍ 30-240 2 ❍ 30-273 2
❍ 30-175 2 ❍ 30-208 2 ❍ 30-241 2 ❍ 30-274 2
❍ 30-176 2 ❍ 30-209 2 ❍ 30-242 2 ❍ 30-275 2
❍ 30-177 2 ❍ 30-210 2 ❍ 30-243 2 ❍ 30-276 2
❍ 30-178 2 ❍ 30-211 2 ❍ 30-244 2 ❍ 30-277 2

❍ 30-179 2 ❍ 30-212 2 ❍ 30-245 2 ❍ 30-278 2
❍ 30-180 2 ❍ 30-213 2 ❍ 30-246 2 ❍ 30-279 2
❍ 30-181 2 ❍ 30-214 2 ❍ 30-247 2 ❍ 30-280 2
❍ 30-182 2 ❍ 30-215 2 ❍ 30-248 2 ❍ 30-281 2
❍ 30-183 2 ❍ 30-216 2 ❍ 30-249 2 ❍ 30-282 2
❍ 30-184 2 ❍ 30-217 2 ❍ 30-250 2 ❍ 30-283 2
❍ 30-185 2 ❍ 30-218 2 ❍ 30-251 2 ❍ 30-284 2
00-2-6 2 WA450-3MC
FOREWORD
❍ 30-285 2 ❍ 30-318 2 40-16

❍ 30-286 2 ❍ 30-319 2 40-17 90-1
❍ 30-287 2 ❍ 30-320 2 40-18 90-2
❍ 30-288 2 ❍ 30-321 2 40-19 90-3

❍ 30-289 2 ❍ 30-322 2 40-20 90-4
❍ 30-290 2 ❍ 30-323 2 40-21 90-5
❍ 30-291 2 ❍ 30-324 2 40-22 90-6

❍ 30-292 2 ❍ 30-325 2 40-23
❍ 30-293 2 ❍ 30-326 2 40-24
❍ 30-294 2 ❍ 30-327 2 40-25
❍ 30-295 2 ❍ 30-328 2 40-26

❍ 30-296 2 ❍ 30-329 2 40-27
❍ 30-297 2 ❍ 30-330 2 40-28
❍ 30-298 2 ❍ 30-331 2 40-29

❍ 30-299 2 ❍ 30-332 2 40-30
❍ 30-300 2 ❍ 30-333 2 40-31
❍ 30-301 2 ❍ 30-334 2 40-32

❍ 30-302 2 40-33
❍ 30-303 2 40-1 40-34
❍ 30-304 2 40-2 40-35

❍ 30-305 2 40-3 40-36
❍ 30-306 2 40-4 40-37
❍ 30-307 2 40-5 40-38

❍ 30-308 2 40-6 40-39
❍ 30-309 2 40-7 40-40
❍ 30-310 2 40-8 40-41

❍ 30-311 2 40-9 40-42
❍ 30-312 2 40-10 40-43
❍ 30-313 2 40-11 40-44

❍ 30-314 2 40-12 40-45
❍ 30-315 2 40-13 40-46
❍ 30-316 2 40-14 40-47

❍ 30-317 2 40-15 40-48
WA450-3MC 00-2-7 2
FOREWORD
00-2-8 2 WA450-3MC
00 FOREWORD
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4
HOW TO READ THE SHOP MANUAL . . . . . . . . . . . . . . . . . . . . . 00-5
HOISTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6
COATING MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-7
STANDARD TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . 00-9
ELECTRIC WIRE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-12
CONVERSION TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13
WA450-3MC 00-1
FOREWORD SAFETY
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine. The service and repair
techniques recommended and described in this manual are both effective and safe methods of operation. Some
of these operations require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises
or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation are extremely dangerous. Read the 7. Before adding oil or making repairs, park the machine
OPERATION & MAINTENANCE MANUAL carefully on hard, level ground, and block the wheels or tracks
before operating the machine. to prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower blade, ripper, bucket or
the precautions given on the decals which are fixed to any other work equipment to the ground. If this is not
the machine. possible, insert the safety pin or use blocks to
prevent the work equipment from falling. In addition,
2. When carrying out any operation, always wear safety be sure to lock all the control levers and hang warning
shoes and helmet. Do not wear loose work clothes, signs on them.
or clothes with buttons missing.
9. When disassembling or assembling, support the
! Always wear safety glasses when hitting parts with a machine with blocks, jacks or stands before starting
hammer. work.
! Always wear safety glasses when grinding parts with 10. Remove all mud and oil from the steps or other
a grinder, etc. places used to get on and off the machine. Always
use the handrails, ladders or steps when getting on
3. If welding repairs are needed, always have a trained, or off the machine. Never jump on or off the machine.
experienced welder carry out the work. When carry- If it is impossible to use the handrails, ladders or
ing out welding work, always wear welding gloves, steps, use a stand to provide safe footing.
apron, glasses, cap and other clothes suited for
welding work. PRECAUTIONS DURING WORK
4. When carrying out any operation with two or more 11. When removing the oil filler cap, drain plug or hydrau-
workers, always agree on the operating procedure lic pressure measuring plugs, loosen them slowly to
before starting. Always inform your fellow workers prevent the oil from spurting out. Before disconnecting
before starting any step of the operation. Before or removing components of the oil, water or air
starting work, hang UNDER REPAIR signs on the circuits, first remove the pressure completely from the
controls in the operator's compartment. circuit.
5. Keep all tools in good condition and learn the correct 12. The water and oil in the circuits are hot when the
way to use them. engine is stopped, so be careful not to get burned.
Wait for the oil and water to cool before carrying out
6. Decide a place in the repair workshop to keep tools any work on the oil or water circuits.
and removed parts. Always keep the tools and parts
in their correct places. Always keep the work area 13. Before starting work, remove the leads from the
clean and make sure that there is no dirt or oil on the battery. ALWAYS remove the lead from the negative
floor. Smoke only in the areas provided for smoking. ( ) terminal first.
NE
G
Never smoke while working.
00-2 WA450-3MC
FOREWORD SAFETY
14. When raising heavy components, use a hoist or ! When installing hoses and wires, be sure that they
crane. Check that the wire rope, chains and hooks will not be damaged by contact with other parts when
are free from damage. Always use lifting equipment the machine is being operated.
which has ample capacity. Install the lifting equip-
ment at the correct places. Use a hoist or crane and 20. When installing high pressure hoses, make sure that
operate slowly to prevent the component from hitting they are not twisted. Damaged tubes are dangerous,
any other part. Do not work with any part still raised so be extremely careful when installing tubes for high
by the hoist or crane. pressure circuits. Also check that connecting parts
are correctly installed.
15. When removing covers which are under pressure or
under pressure from a spring, always leave two bolts 21. When assembling or installing parts, always use the
in position on opposite sides. Slowly release the specified tightening torques. When installing protec-
pressure, then slowly loosen the bolts to remove. tive parts such as guards, or parts which vibrate
violently or rotate at high speed, be careful to check
16. When removing components, be careful not to break that they are installed correctly.
or damage the wiring, Damaged wiring may cause
electrical fires. 22. When aligning two holes, never insert your fingers or
hand. Be careful not to get your fingers caught in a
17. When removing piping, stop the fuel or oil from hole.
spilling out. If any fuel or oil drips on to the floor, wipe
it up immediately. Fuel or oil on the floor can cause 23. When measuring hydraulic pressure, check that the
you to slip, or can even start fires. measuring tool is correctly assembled before taking
any measurements.
18. As a general rule, do not use gasoline to wash parts.
In particular, use only the minimum of gasoline when 24. Take care when removing or installing the tracks of
washing electrical parts. track-type machines. When removing the track, the
track separates suddenly, so never let anyone stand
19. Be sure to assemble all parts again in their original at either end of the track.
places. Replace any damaged part with new parts.
WA450-3MC 00-3
FOREWORD GENERAL
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure
you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop.
For ease of understanding, the manual is divided into the following sections. These sections are further divided into each
main group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant
and lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs. Troubleshooting charts correlating "Problems" to "Causes" are also included
in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each
component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance
notice. Contact your distributor for the latest information.
00-4 WA450-3MC
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark (âãä ....) is

recorded on the bottom outside corner of the page that is
revised or new.
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
REVISIONS
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series Revised pages are recorded in the LIST OF ORIGINAL,
NEW AND REVISED PAGES following the title page.
Electrical volume: E a c h issued as one to cover all
models SYMBOLS
Attachment volume: Each issued as one to cover all
models So that the shop manual can be of ample practical use,
important places for safety and quality are marked with
These various volumes are designed to avoid duplication the following symbols.
of information. Therefore to deal with all repairs for any
model, it is necessary that chassis, engine, electrical and Symbol Item Remarks
attachment be available.
Special safety precautions are nec-
Safety
DISTRIBUTION AND UPDATING essary when performing the work.
Any additions, amendments or other changes will be sent Special technical precautions or
t o your distributor. Get the most up-to-date information
before you start any work. j Caution
o ther precautions for preserving
standards are necessary when
performing the work.
FILING METHOD
Weight of parts or systems. Cau-
tion necessary when selecting
1. See the page number on the bottom of the page. File Weight
hoisting wire or when working pos-
the pages in correct order. ture is important, etc.
2. Following examples show how to read the page Places that require special atten-
number: Tightening
ti on for tightening torque during
torque
Example 1 (Chassis volume): assembly.
10 - 3 Places to be coated with adhesives

Coat
and lubricants etc.
Section number (10. Struc-
ture and Function)
Places where oil, water or fuel
Oil, water
Consecutive page number must be added, and the capacity.
for each item
Places where oil or water must be
Example 2 (Engine volume): Drain
drained, and quantity to be drained.
Refer to the pertinent engine manual.
3. Additional pages: Additional pages are indicated by

a hyphen (-) and numbered after the page number.
File as in the example.
Example (Chassis volume):
10-4
10-4-2 A
10-4-1
Added pages
10-5
WA450-3MC 00-5
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
WARNING: Heavy parts (25 kg or more) must

be lifted with a hoist etc. In the DISASSEM-
BLY AND ASSEMBLY section, every part
weighing 25 kg or more is indicated clearly
with this symbol
3) Do not sling a heavy load with one wire rope alone,

but sling with two or more wire ropes symmetrically
wound on to the load.
! If a part cannot be smoothly removed from the ma-
c hine by hoisting, the following checks should be
WARNING: Slinging with one wire rope may
made:
cause turning of the load during hoisting,
1) Check for removal of all bolts fastening the part to untwisting of the wire rope, or slipping of the
the relative parts. wire rope from its original winding position on
the load, which can result in a dangerous
2) Check for existence of another part causing inter-
accident.
face with the part to be removed.
WIRE ROPES 4) Do not sling a heavy load with wire ropes forming a
wide hanging angle from the hook. When hoisting a
1) Use adequate wire ropes depending on the weight of load with two or more wire ropes, the force subjected
parts to be hoisted, referring to the table below: t o each wire rope will increase with the hanging
angles. The table below shows the variation of allow-
able load (kg) when hoisting is made with two wire
Wire ropes
ropes, each of which is allowed to sling up to 1000 kg
Standard Z or S twist wire ropes without galvanizing
vertically, at various hanging angles.
Wire rope diameter (mm) Allowable load (tons)
When two wire ropes sling a load vertically, up to
10 1 2000 kg of total weight can be suspended. This
11.2 1.4 weight becomes 1000 kg when two wire ropes make
12.5 1.6 a 120E hanging angle. On the other hand, two wire
14 2.2 ropes are subject to an excessive force as large as
16 2.8 4000 kg if they sling a 2000 kg load at a lifting angle
18 3.6 of 150E.
20 4.4
22.4 5.6
30 10
40 18
50 28
60 40
i The allowable load value is estimated to be 1/6 or 1/7

of the breaking strength of the wire rope used.
2) Sling wire wire ropes from the middle portion of the

hook. Slinging near the edge of the hook may cause
the wire rope to slip off the hook during hoisting, and
a serious accident can result. Hooks have maximum
strength at the middle portion.
00-6 WA450-3MC
FOREWORD COATING MATERIALS
COATING MATERIALS
The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Qty Container Main applications, features

• Used to prevent rubber gaskets, rubber cushions and cork plugs
LT-1A 790-129-9030 150 g Tube
from coming out
• Used in places requiring an immediately effective, strong
Polyethylene adhesive. Used for plastics (except polyethylene, polypropylene,
LT-1B 790-129-9050 20 g (x2)
container tetrafluoroethylene, and vinyl chloride), rubber, metal and non-
metal.
Polyethylene • Features: Resistance to heat, chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant purposes for bolts and plugs.
790-129-9060
Adh 1 kg
Set of adhesive
LT-3 Hard agt Can • Used as adhesive or sealant for metal, glass or plastic.
and hardening
500 kg
agent
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used as sealant for machined holes.
container
Holtz
790-126-9120 75 g Tube • Used as heat resisting sealant for repairing engine.
MH 705
• Quick hardening type adhesive.
Three Polyethylene
790-129-9140 50 g • Cure time: 5 sec. to 3 min.
bond 1735 container
• Used mainly for adhesion of metals, rubbers, plastics and woods.
• Quick hardening type adhesive.
Aron-alpha Polyethylene
790-129-9130 2g • Quick cure time, max. strength after 30 minutes.
201 container
• Used mainly for adhesion of metals, rubbers and plastics.
Loctite Polyethylene • Features: Resistance to heat, chemicals
79A-129-9110 50 cc
648-50 container • Used at joint portions subject to high temperature.
• Used as adhesive or sealant for gaskets and packing of power train
LG-1 790-129-9010 200 g Tube
case, etc.
• Features: Resistance to heat
• Used as sealant for flange surfaces and bolts at high temperature
LG-3 790-129-9070 1 kg Can locations; used to prevent seizure.
• Used as sealant for heat resistant gasket for at high temperature
locations such as engine pre-combustion chamber, exhaust pipe.
• Features: Resistance to water, oil
• Used as sealant for flange surface, thread.
LG-4 790-129-9020 200 g Tube • Also possible to use as sealant for flanges with large clearance.
• Used as sealant for mating surfaces of final drive case, transmis-
Gasket sion case.
sealant
• Used as sealant for various threads, pipe joints, flanges.
Polyethylene
LG-5 790-129-9080 1 kg • Used as sealant for tapered plugs, elbows, nipples of hydraulic
container
piping.
• Features: Silicon based, resistant to heat, cold.
LG-6 09940-00011 250 g Tube • Used as sealant for flange surface, thread.
• Used as sealant for oil pan, final drive case, etc.
• Features: Silicon based, quick hardening type.
LG-7 09920-00150 150 g Tube • Used as sealant for flywheel housing, intake manifold, oil pan,
thermostat housing, etc.
Three
790-129-9090 100 g Tube • Used as heat resisting sealant for repairing engine.
bond 1211
LM-G 09940-00051 60 g Can • Used as lubricant for sliding parts (to prevent squeaking).
Molybdenum
disulfide • Used to prevent seizure or scuffing of the thread when press fitting
lubricant LM-P 09940-00040 200 g Tube or shrink fitting.
• Used as lubricant for linkage, bearings, etc.
SYG-350Ll
SYG-400Ll
Lithium g-
G2-L1 SYG-400Ll-A Various Various • General purpose type
rease
SYG-160Ll
SYGA-160CNLl
WA450-3MC 00-7
FOREWORD COATING MATERIALS
Category Code Part No. Qty Container Main applications, features

SSG2-400CA
SYG2-350CA
Calcium • Used for normal temperature, light load bearing at places in
G2-CA SYG2-400CA-A Various Various
grease contact with water or steam.
SYG2-160CA
SYGA-16CNCA
Molybdenum
400 g
disulfide --- SYG2-400M Bellows type • Used for places with heavy load.
(10/case)
grease
00-8 WA450-3MC
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give the standard tightening torques of bolts and nuts.
Exceptions are given in sections of DISASSEMBLY AND ASSEMBLY.
Use these torques for metric bolts and nuts. (Always use torque wrench)
A B
Thread diameter of bolt Width across flats
mm mm NCm
6 10 13.2 ± 1.4
8 13 31.4 ± 2.9
10 17 65.7 ± 6.8
12 19 112 ± 9.8
14 22 177 ± 19
16 24 279 ± 29
18 27 383 ± 39
20 30 549 ± 58
22 32 745 ± 78
24 36 927 ± 98
27 41 1320 ± 140
30 46 1720 ± 190
33 50 2210 ± 240
36 55 2750 ± 290
39 60 3280 ± 340
A B
mm mm NCm
6 10 7.85 ± 1.95
8 13 18.6 ± 4.9
10 14 40.2 ± 5.9
12 27 82.35 ± 7.85
TIGHTENING TORQUE FOR SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
A B
Tightening torque
mm mm NCm
10 14 65.7 ± 6.8
12 17 112 ± 9.8
16 22 279 ± 29
WA450-3MC 00-9
TIGHTENING TORQUE FOR HOSE NUTS
Use these torques for hose nuts.
Nominal Thread diameter Width across flats Tightening torque

No. mm mm NCm
02 14 19 24.5 ± 4.9
03 18 24 49 ± 19.6
04 22 27 78.5 ± 19.6
05 24 32 137.3 ± 29.4
06 30 36 176.5 ± 29.4
10 33 41 196.1 ± 49
12 36 46 245.2 ± 49
14 42 55 294.2 ± 49
TIGHTENING TORQUE OF O-RING BOSS CONNECTORS
Use these torques for o-ring boss connectors.
Nominal A Thread diameter B Width across flats Tightening torque

No. mm mm NCm
02 14 34.3 ± 4.9
03, 04 20 93.1 ± 9.8
Varies depending on type
05, 06 24 142.1 ± 19.6
of connector
10,12 33 421.4 ± 58.8
14 42 877.1 ± 132.3
TIGHTENING TORQUE OF O-RING BOSS CONNECTORS
Use these torques for o-ring boss connectors.
Nominal A Thread diameter B Width across flats Tightening torque

No. mm mm NCm
08 8 14 7.35 ± 1.47
10 10 17 11.27 ± 1.47
12 12 19 17.64 ± 1.96
14 14 22 22.54 ± 1.96
16 16 24 29.4 ± 4.9
18 18 27 39.3 ± 4.9
20 20 30 49 ± 4.9
24 24 32 68.6 ± 9.8
30 30 32 107.8 ± 14.7
33 33 -- 127.4 ± 19.6
36 36 36 151.9 ± 24.5
42 42 -- 210.7 ± 29.4
52 52 -- 323.4 ± 44.1
00-10 WA450-3MC
TIGHTENING TORQUE FOR FLARED NUTS
Use these torques for flared part of nut.
Thread diameter Width across flats Tightening torque

mm mm NCm
14 19 24.5 ± 4.9
18 24 49 ± 19.6
22 27 78.5 ± 19.6
24 32 137.3 ± 29.4
30 36 176.5 ± 29.4
33 41 196.1 ± 49
36 46 245.2 ± 49
42 55 294.2 ± 49
WA450-3MC 00-11
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: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current
Number Dia. Of strand Cross section Applicable circuit
number (mm) rating (A)
of strands (mm) (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 59 Starting (Glow plug)
40 85 0.8 42.73 11.4 135 Starting
60 127 0.8 63.84 13.6 178 Starting
100 217 0.8 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Priority Classification Circuits Charging Ground Starting Lighting Instrument Signal Other
Code W B B R Y G L
1 Primary
Color White Black Black Red Yellow Green Blue
Code WR --- BW RW YR GW LW
2
Color White/Red --- Black/White Red/White Yellow/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/Red
Code WL --- BR RY YG GY LY
4 Auxiliary
Color White/Blue --- Black/Red Red/Yellow Yellow/Green 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 ---

6
Color --- --- --- Red/Blue Yellow/White Green/Blue ---
00-12 WA450-3MC
FOREWORD CONVERSION TABLES
CONVERSION TABLES
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 , then draw a horizontal line from
.
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from .
(3) Take the point where the two lines cross as . This point gives the value when converting from millimeters
to inches. Therefore, 55 millimeters = 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 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 one place
to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to Inches
1 mm = 0.03937 in
mm 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 0.63 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 1.22 1.26 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 1.85 1.89 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 2.48 2.52 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 3.11
80 3.15 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 3.74 3.78 3.819 3.858 3.898
WA450-3MC 00-13
Millimeters to Inches
1 mm = 0.03937 in
mm 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 0.63 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 1.22 1.26 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 1.85 1.89 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 2.48 2.52 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 3.11
80 3.15 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 3.74 3.78 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
kg 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 46.3 48.5 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 94.8 97 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
60 132.28 134.48 136.69 138.89 141.1 143.3 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.6 191.8 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-14 WA450-3MC
Liter to U.S. Gallon

1R = 0.2642 U.S. Gal
R 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 3.17 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.34 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.51 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.68 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.85 16.115 16.379 16.643 16.907 17.171 17.435 17.7 17.964 18.228
70 18.492 18.756 19.02 19.285 19.549 19.813 20.077 20.341 20.605 20.87
80 21.134 21.398 21.662 21.926 22.19 22.455 22.719 22.983 23.247 23.511
90 23.775 24.04 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1R = 0.21997 U.K. Gal
R 0 1 2 3 4 5 6 7 8 9
0 0 0.22 0.44 0.66 0.88 1.1 1.32 1.54 1.76 1.98

10 2.2 2.42 2.64 2.86 3.08 3.3 3.52 3.74 3.95 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
WA450-3MC 00-15
NCm to lbf ft
1 NCm = 7.233 lbf ft
NCm 0 1 2 3 4 5 6 7 8 9
0 0 0.738 1.475 2.213 2.95 3.688 4.425 5.163 5.9 6.638

10 7.376 8.133 8.851 9.589 10.326 11.064 11.801 12.539 13.276 14.014
20 14.752 15.489 16.227 16.965 17.702 18.44 19.177 19.915 20.652 21.39
30 22.128 22.865 23.603 24.341 25.078 25.816 26.553 27.291 28.028 28.766
40 29.504 30.241 30.979 31.717 32.454 33.192 33.929 34.667 35.404 36.142
50 36.880 37.617 38.355 39.093 39.830 40.568 41.305 42.043 42.78 43.518
60 44.256 44.993 45.731 46.469 47.206 47.944 48.681 49.419 50.156 50.894
70 51.632 52.369 53.107 53.845 54.582 55.32 56.057 56.795 57.532 58.270
80 59.008 59.745 60.483 61.221 61.958 62.696 63.433 64.171 64.908 65.646
90 66.384 67.121 67.859 68.597 69.334 70.072 70.809 71.547 72.284 73.022
100 73.76 74.497 75.235 75.973 76.71 77.448 78.185 78.923 79.66 80.398
110 81.136 81.873 82.611 83.349 84.086 84.824 85.561 86.299 87.036 87.774
120 88.512 89.249 89.987 90.725 91.462 92.2 92.937 93.675 94.412 95.15
130 95.888 96.625 97.363 98.101 98.838 99.576 100.313 101.051 101.788 102.526
140 103.264 104.001 104.739 105.477 106.214 106.952 107.689 108.427 109.164 109.902
150 110.640 111.377 112.115 112.853 113.590 114.328 115.065 115.803 116.540 117.278
160 118.016 118.753 119.491 120.229 120.966 121.704 122.441 123.179 123.916 124.654
170 125.392 126.129 126.867 127.605 128.342 129.08 129.817 130.555 131.292 132.03
180 132.768 133.505 134.243 134.981 135.718 136.456 137.193 137.931 138.668 139.406
190 140.144 140.881 141.619 142.357 143.094 143.832 144.569 145.307 146.044 146.782
00-16 WA450-3MC
kg/cm² to lb/in² (psi)

1kg/cm² = 14.2233 lb/in² (psi)
kg/cm² 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

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953 967.2 981.4
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
WA450-3MC 00-17
Temperature
FahrenheitCentigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
r e a d i ng or vise versa is to enter the accompanying table in the center column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees,
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in
the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table
of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1EC = 33.8EF
EC EF EC EF EC EF EC EF
-40.4 -40 -40 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-37.2 -35 -31 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13 -10 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4 -9.4 15 59 10 50 122 29.4 85 185
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30 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 -6.7 20 68 12.8 55 131 32.2 90 194
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15 59 138.2 34.4 94 201.2
-23.3 -10 14 -3.9 25 77 15.6 60 140 35 95 203
-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 -1.1 30 86 18.3 65 149 37.8 100 212
-20 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230
-18.9 -2 28.4 0.6 33 91.4 20 68 154.4 46.1 115 239
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248
-17.8 0 32 1.7 35 95 21.1 70 158 51.7 125 257
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60 140 284
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293
-15 5 41 4.4 40 104 23.9 75 167 65.6 150 302
-14.4 6 42.8 5 41 105.8 24.4 76 168.8 68.3 155 311

-13.9 7 44.6 5.6 42 107.6 25 77 170.6 71.1 160 320
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338
-12.2 10 50 7.2 45 113 26.7 80 176 79.4 175 347
00-18 WA450-3MC
01 GENERAL
SPECIFICATION DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
SELECTION OF FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . 01-7
WA450-3MC 01-1
GENERAL SPECIFICATION DRAWING
SPECIFICATION DRAWING
01-2 WA450-3MC
GENERAL SPECIFICATION DRAWING
NOTE: All dimensions are based with machines equipped with 26.5-25 20PR tires.
WA450-3 WA450-3 Material Handler

A31001 and up A35001 and up
4.2 m³ GP 3.6 m³ EX 3.9 m³ EX 5.2 m³ LM 4.6 m³ GP 4.2 m³ GP

Bucket w/BOCE Bucket w/teeth Bucket w/teeth Bucket w/BOCE Bucket w/BOCE Bucket w/BOCE
1 Wheelbase 3400 mm 3400 mm 3400 mm 3400 mm 3400 mm 3400 mm
Hinge pin, maximum

2 4360 mm 4360 mm 4360 mm 4360 mm 4445 mm 4445 mm
height
3 Hinge pin, carry height 575 mm 575 mm 575 mm 575 mm 575 mm 575 mm
4 Ground clearance 525 mm 525 mm 525 mm 525 mm 525 mm 525 mm
5 Hitch height 1240 mm 1240 mm 1240 mm 1240 mm 1240 mm 1240 mm
6 Overall height, top of stack 3450 mm 3450 mm 3450 mm 3450 mm 3450 mm 3450 mm
7 Overall height, top of cab 3460 mm 3460 mm 3460 mm 3460 mm 3460 mm 3460 mm
8 Bucket width 3170 mm 3190 mm 3170 mm 3170 mm 3170 mm
Bucket weight 2090 kg 2110 kg 2190 kg 2150 kg 2090 kg
Straight 17970 kg 17770 kg 17430 kg 16730 kg 16790 kg

Static tipping
loads
Full turn 40E 15600 kg 15420 kg 15130 kg 14530 kg 14590 kg
9 Dump clearance, 45E 3185 mm 3110 mm 2955 mm 3150 mm 3280 mm
10 Reach @ No. 9 1195 mm 1245 mm 1335 mm 1335 mm 1205 mm
11 Operating height 5960 mm 5915 mm 6125 mm 6050 mm 6050 mm
Ground 8850 mm 8935 mm 9060 mm 9155 mm 8970 mm

12 Overall length
Carry 8850 mm 8920 mm 8990 mm 9060 mm 8940 mm
13 Turning radius 6870 mm 6900 mm 6960 mm 6980 mm 6920 mm
0E 80 mm 100 mm 80 mm 90 mm 90 mm
14 Digging depth
10E 315 mm 345 mm 350 mm 360 mm 330 mm
Break out force 19600 kg 22400 kg 16800 kg 16750 kg 19160 kg
15 Tread 2300 mm 2300 mm 2300 mm 2300 mm 2300 mm 2300 mm
16 Width over tires 3010 mm 3010 mm 3010 mm 3010 mm 3010 mm 3010 mm
WA450-3MC 01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
GP Bucket EX Bucket LM Bucket 4.6 m³ GP Bucket 4.2 m³ GP Bucket
w/BOCE w/teeth W/BOCE W/BOCE W/BOCE
No Ballast 22000 kg 22020 kg 22100 kg 22050 kg 20990 kg
23.5/25-20PR L2
Ballast 22650 kg 22670 kg 22750 kg 22700 kg 21640 kg
23.5/25-20PR L3
Machine 26.5/25-20PR L3
Weight

26.5/25-20PR L4
26.5/25-20PR L5
NOTE 1: The above operating weights include lubricants, coolant, full fuel tank, ROPS cab, front fenders, optional counterweight [see following], and
operator.
NOTE 2: DO NOT use tire ballast with the optional counterweight
Bucket capacity 4.2 m³ 3.6 m³ 5.2 m³ 4.6 m³ 4.2 m³
1st 6.6 km/h 6.6 km/h
2nd 12.3 km/h 12.3 km/h

Forward
3rd 21.8 km/h 21.8 km/h
Performance
4th 43.0 km/h 43.0 km/h

Travel speed
1st 6.8 km/h 6.8 km/h
2nd 12.8 km/h 12.8 km/h

Reverse
3rd 22.7 km/h 22.7 km/h
4th 36.0 km/h 36.0 km/h
Gradability 25 E 25 E
Turning radius 6870 mm 6900 mm 6960 mm 6980 mm 6920 mm
Model Komatsu SA6D125E-2
Type Direct injection
Aspiration Turbo charged and aftercooled
No. of cylinders - bore x stroke 6 - 125 mm x 150 mm
11.04 R
Engine
Piston displacement
Gross power 202 kW

Horsepower rating
@ 2200 rpm Net power 194 kW
Starting motor 24V, 7.5 kW
Alternator 24V, 50 A
Battery 2 x 12V, 170 Ah
01-4 WA450-3MC
GENERAL SPECIFICATIONS

GP Bucket EX Bucket LM Bucket 4.6 m³ GP Bucket 4.2 m³ GP Bucket
w/BOCE w/teeth W/BOCE W/BOCE W/BOCE
Torque converter Three element, single stage, single phase
Transmission Spur gear, constant mesh multiple disc, hydraulic actuated, modulation type
Power train
Reduction gear Spiral bevel gear, splash lubrication

Differential - standard Straight bevel gear, torque proportioning
Differantial - optional Straight bevel gear, limited slip
Final drive Planetary gear, single reduction, splash lubrication
Drive type Front and rear wheel drive
Front axle Fixed frame, full floating type

Axle, wheel
Rear axle Center pin support, full floating type with 30E oscillation
26.5/25-20 PR tires 23.5/25-20 PR tires
Wheel rim 22 x 25 19.5 x 25
Front 3.5 kg/cm 2 4.0 kg/cm 2

Tire inflation
Rear 3.0 kg/cm 2 3.2 kg/cm 2
Steering Brakes
Main service brakes Hydraulically actuated, sealed wet multiple disc at each wheel
Parking brake Spring applied, hydraulic released wet discs inside transmission
system
Type Articulated type
Structure Full hydraulic power steering
Loader 302 R/min
Gear pump Steering 168 R/min

Capacity @ 2140 engine
Hydraulic system
rpm Switch 122 R/min
Pilot 62 Rmin
Relief valve setting 210 kg/cm 2
Boom 2 - 180 x 764 mm

Cylinders
Bucket 1 - 200 x 550 mm
qty - bore x stroke
Steering 2 - 100 x 440 mm
equipment
Linkage type Single link, Z bar

Work
Bucket edge type Flat edge with BOCE [bolt on cutting edge]
WA450-3MC 01-5
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when for use when transporting or handling components.
WA450-3 - A31001 and up WA450-3 Material Handler - A35001 and up
Component kg Component kg
Engine Equipment and PPC pump
Radiator Boom cylinder 192
Torque converter 56 Bucket cylinder - std 228
Transmission with torque converter Bucket cylinder - hi lift 256
Center drive shaft Engine hood with side panel
Front drive shaft Front frame
Rear drive shaft Rear frame
Front axle 1455 Bucket link
Rear axle 1466 Bellcrank
Axle pivot Boom including bushing
Wheel (each) Bucket with bolt on cutting edge
Tire (each) Counterweight
Orbit-roll valve Fuel tank
Steering cylinder (each) 38 Battery (each) 45
Brake valve (R.H.) Floor frame
Hydraulic tank Cab (ROPS) 640
Main control valve Air conditioner unit
Steering and switch pump Operator’s seat
01-6 WA450-3MC
GENERAL FUEL, COOLANT AND LUBRICANTS
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

It is not our policy to approve fuel, coolant and lubricants or to guarantee performance in service. The responsibility for
the quality of the fuel, coolant and lubricant must remain with the supplier. When in doubt, consult your Komatsu
distributor. The specified fuel, coolant and lubricants recommended for this machine are as shown in the following table.
AMBIENT TEMPERATURE EC CAPACITY

RESERVOIR FLUID TYPE
-30 -20 -10 0 10 20 30 40 Specified Refill
SAE 5W-30
Engine with
Engine oil SAE 10W-30 47 R 38 R
filter(s)
SAE 15W-40
Torque converter, SAE 10W

transmission & oil 65 R 60 R
cooler SAE 30W
Engine oil
Service brakes SAE 10W - -
Drive axles Front &

Axle oil See Drive Axle Oil Specifications 65 R 60 R
rear (each)
SAE 10W
Hydraulic system Engine oil SAE 15W-40 210 R 138 R
SAE 10W-30
ASTM D975 No. 2

Fuel tank Diesel fuel 390 R ---
ASTM D975 No. 1
All lubrication Kom atsu Super Grease or NLGI No.2 Multi-purpose

Grease Fill as instructed
fittings lithium grease with 3% molybdenum disulfide
Cooling system Coolant See Coolant Specifications in this section 68 R ---
API: American Petroleum Institute

ASTM: American Society of Testing and Materials
NLGI: National Lubricating Grease Institute
SAE: Society of Automotive Engineers
Specified Capacity: Total amount of oil including oil for components and piping.
Refill Capacity: Amount of oil needed to refill system during normal maintenance.
Other equipment may be necessary when operating the machine at temperatures below -20EC, therefore consult your
Komatsu distributor for your specific needs.
WA450-3MC 01-7
ENGINE OIL SPECIFICATIONS
NORMAL OPERATION tion at high operating temperatures.
Oil performance recommendations are as follows: While SAE 15W-40 multi-viscosity oil is recommended for
most operating climates, refer to the previous table for oil
The use of a quality engine lubricating oil combined with viscosity recommendations for extreme climates.
appropriate oil and filter change intervals are critical
factors in maintaining engine performance and durability. NOTICE:
Limited use of low viscosity oils, such as SAE 10W-30
Komatsu Engine Oil or multi-viscosity engine oil meeting may be used for easier starting and providing sufficient
American Petroleum Institute (API) performance classifi- oil flow at ambient temperatures below -5EC. However,
cation CF-4, CG-4, CF-4/SG or CG-4/SH or MIL-L-2104D continuous use of low viscosity oils can decrease
or E is recommended. engine life due to wear.
NOTICE: Special break-in lubricating oils are not recommended for

Classification CD, CE, CD/SF or CE/SF oils may be a new or rebuilt engine. Use the same type of oil during
used in areas where CF-4, CG-4, CF-4/SG or CG-4/SH the break-in as specified for normal operation.
oil i s not yet available. If API classification CC or
CC/CD is used, reduce the engine oil change interval by Additional information regarding lubricating oil availability
half. throughout the world is available in the "E.M.A. Lubricat-
ing Oils Data Book for Automotive and Industrial Engines.”
A s ulfated ash limit of 1.0 to 1.5 mass percent is sug- The data book may be ordered from the Engine Manufac-
gested for optimum valve and piston deposit and oil turers Association, 401 North Michigan Ave., Chicago, Il
consumption control. The sulfated ash must not exceed U.S.A. 60611. The telephone number is (312) 644-6610.
1.85 mass percent. The sulfated ash limit of 1.85 mass
percent has been placed on all engine lubricating oils ARCTIC OPERATION
recommended for use in the engine. Higher ash oils can
cause valve and/or piston damage and lead to excessive If an engine is operated in ambient temperatures consis-
oil consumption. tently below -23EC and there are no provisions to keep the
engine warm when it is not in operation, use a synthetic
The API service symbol displays the following informa- engine oil API performance classification CF-4, CG-4, CF-
tion. The upper half of the symbol displays the appropri- 4/SG or CG-4/SH with adequate low temperature proper-
a t e oil categories; the lower half may contain words to ties such as SAE 5W-20 or 5W-30. The oil supplier must
describe oil energy conserving features. The center be responsible for meeting the performance service
section identifies the SAE oil viscosity grade. specifications.
Oil viscosity recommendations are as follows: NOTICE:

The use of a synthetic base oil does not justify ex-
The use of a multi-grade lubricating oil has been found to tended oil change intervals. Extended oil change
improve oil consumption control and improve engine intervals can decrease engine life due to factors such
cranking in cold temperatures while maintaining lubrica- as; corrosion, deposits and wear.
01-8 WA450-3MC
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE

BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS
Komatsu Engine Oil or engine oil meeting American NOTICE:

Petroleum Institute (API) performance classification CF-4, Classification CD, CE, CD/SF or CE/SF oils may be
CG-4, CF-4/SG or CG-4/SH or MIL-L-2104D or E si used in areas where CF-4, CG-4, CF-4/SG or CG-4/SH
recommended. oil is not yet available.
DRIVE AXLE OIL SPECIFICATIONS
For drive axle oil, use only the recommended oil as TEXACO . . . . . . . . . . . . . . . . . . . . . . . . . . . TDH OIL
follows: MOBIL . . . . . . . . . . . . . . . . . . . . . . . . . . MOBIL 424
SHELL . . . . . . . . . . . . . . . . . . . . . . DONAX TT or TD Engine oil . . . . . . . . . . . SAE 30 API classification CD
CALTEX . . . . . . . RPM TRACTOR HYDRAULIC FLUID (Might increase brake noise, but it will not affect durability.)
CHEVRON . . . . . . . . . TRACTOR HYDRAULIC FLUID
DIESEL FUEL SPECIFICATIONS
WARNING Never mix gasoline, gasohol and/or is recommended. The use of No. 2-D diesel fuel will result
alcohol with diesel fuel. Mixing these liquids creates in optimum engine performance under most operating
an extreme fire hazard and could lead to an explosion conditions. Fuels with Cetane numbers higher than 40
which could result in personal injury or death. may be needed in high altitudes or extremely low ambient
temperatures to prevent misfires and excessive smoke.
WARNING Never remove the fuel tank filler cap or
refill the fuel tank while the engine is running or when A t operating temperatures below -10EC or extended
hot or when the machine is indoors. Fumes are engine idling, use ASTM Grade No. 1-D diesel fuel. The
dangerous, a spark or flame could result in a fire or use of lighter fuels can reduce fuel economy.
explosion.
Where a winterized blend of Grade No. 2-D and No. 1-D
NOTICE: fuels is available, it may be substituted for Grade No. 1-D
The precise tolerances of diesel fuel injection systems fuel. However, it is the supplier's responsibility to provide
demand that the fuel be kept clean and free of contami- the fuel for the anticipated ambient temperature.
nates or water. Contaminates or water in the system
can cause severe damage to both the injection pump Use a low sulfur content fuel having a cloud point that is
and nozzles. at least 10 degrees below the lowest expected fuel
temperature. Cloud point is the temperature at which
REMARK crystals begin to form in the fuel.
Below -12EC the paraffin in ASTM Grade No. 2-D diesel
fuel will change to wax particles and clog the fuel filters. The viscosity of the fuel must be kept above 1.3 cSt to
For best results use Grade No. 1-D diesel fuel in cold provide adequate fuel system lubrication.
weather.
Optionally, the equivalent grades of recognized Federal
For normal service above -10EC, the use of ASTM Grade Government specifications may be used; the latest
No. 2-D diesel fuel with a minimum Cetane number of 40 revisions of VV-F-800a.
WA450-3MC 01-9
COOLANT SPECIFICATIONS
GENERAL Antifreeze is essential in any climate. It broadens the

operating temperature range by lowering the coolant
Selection and maintenance of the engine coolant is freezing point and by raising its boiling point. Do not use
important to long engine life. The following information more than 50 percent antifreeze in the mixture unless
provides recommendations for selecting the engine additional freeze protection is required. Never use more
coolant and maintaining the supplemental coolant addi- than 68 percent antifreeze under any condition.
tives (SCA).
A n antifreeze concentration greater than 68% will ad-
Heavy duty diesel engines require a balanced coolant vers ely affect freeze protection and heat transfer rates.
mixture of water, antifreeze, and supplemental coolant Antifreeze concentrations between 68 and 100% actually
additives. Supplemental coolant additive recommenda- have a higher freezing point than a 68% antifreeze
tions are included. The coolant mixture must be drained concentration and should not be used due to reduced
and replaced at the specified service interval shown or heat transfer rates.
every two years of operation, whichever comes first.
Ethylene glycol, low silicate antifreeze is recommended.
WATER The antifreeze should contain no more than 0.1% anhy-
drous alkali metasilicate. Low silicate antifreeze is
Use water which has a low mineral content. Water used recommended to avoid the formation of silica-gel (hydro-
in conjunction with antifreeze, coolant filters and inhibited gel). This gel formation can occur when the cooling
water must meet the following standards: system contains an over concentration of high silicate
antifreeze and/or supplemental coolant additive. DO NOT
Total Hardness Not to exceed 170 parts per million (10 use methanol or alcohol as an antifreeze because of its
grains/gallon maximum) to prevent scale deposits. Water low boiling point.
containing dissolved magnesium and calcium (the usual
reason for water hardness) above the specified amount Antifreeze may retain its freeze protection for more than
will cause scale deposits to develop in the engine. one season but coolant conditioners must be added to
maintain corrosion protection. Antifreeze formulated with
Chlorides Not to exceed 40 parts per million (2.5 methox y propanol, or propylene glycol, is not recom-
grains/gallon maximum) to prevent corrosion. mended for this system.
Sulfites Not to exceed 100 parts per million (5.8 NOTICE:

grains/gallon maximum) to prevent corrosion. Do not mix types of antifreeze solutions. Mixed solu-
tions make it impossible to determine the protection
Dissolved Solids Not to exceed 340 parts per million (20 against freezing. Antifreeze containing sealer or anti-
grains/gallon maximum) to minimize sludge deposits, leak additives should NOT be used in this system.
scale deposits, corrosion or a combination of these. Sealer or anti-leak additives will cause plugging prob-
lems in the cooling system.
If any of the above requirements cannot be met, use
distilled, de-ionized, or de-mineralized water. To deter- WARNING Use extreme caution when adding
mine if local water supplies meet these standards, water coolant to a hot radiator to avoid being burned. Wear
samples can be tested by water treatment laboratories. gloves and goggles and keep face away from the filler
S oftened water that is prepared using common salt neck.
(sodium chloride) contains excessive amounts of chlo-
rides and should not be used. Check the solution periodically and at normal operating
temperature, to be sure the cooling system has sufficient
NOTICE: protection against freezing. An antifreeze concentration
Never use water alone in the cooling system because greater than 68% will adversely affect antifreeze protection
rust, scale deposits and corrosion will occur. and heat transfer rates. Antifreeze concentrations be-
tween 68% and 100% actually have a higher freezing
ANTIFREEZE point than a 68% antifreeze concentration and should not
be used due to reduced heat transfer rates. The following
In climates where the temperature is above -34EC use a table shows the approximate percentage of antifreeze
coolant mixture that contains 50 percent antifreeze. solution required for various temperatures.
01-10 WA450-3MC
Percentage of Anti-
Approximate Specific Gravity @
freeze Concentration - Solder corrosion/bloom
Freezing Point 16EC
by Volume - Copper corrosion/erosion/stress cracking
0EC 0 1.000 - Oil fouling
-7EC 15 1.025 - Cylinder liner cavitation corrosion
-12EC 25 1.040 - Aluminum cavitation corrosion
-18EC 33 1.053 - Seal and gasket degradation
-23EC 40 1.062
-29EC 45 1.070 Maintenance of Supplemental Coolant Additives
-34EC 48 1.074
-40EC 53 1.080 Keeping the engine coolant properly inhibited will keep
-46EC 56 1.083 the engine and radiator free of rust, scale deposits and
-51EC 59 1.088 corrosion.
-57EC 62 1.092
-62EC 65 1.095 New machines are delivered with antifreeze protection.
-68EC 67 1.097
Servi ce at a regular scheduled interval specified with a
-69EC 68 1.098
replacement coolant filter.
REMARK Each time the coolant is drained and replaced, the

Do not use a 100% antifreeze solution for freezing coolant must be recharged with supplemental coolant
protection, This will cause severe corrosion in the additives. New coolant can be correctly charged with
cooling system and if not detected will cause radiator coolant additives by using a replacement coolant filter
and oil cooler core damage. Use a water/antifreeze and/or concentrate.
solution as described in the preceding table.
If coolant is added between drain intervals, additional
In tropical climates where antifreeze availability may be coolant additives may be required.
limited, use a corrosion inhibitor or supplemental coolant
additive (SCA), to protect the engine cooling system. Coolant Testing for Conditioner Concentration
SUPPLEMENTAL COOLANT ADDITIVES When the cooling system is maintained as

recommended, the conditioner concentration should be
1. All supplemental cooling system additives, including satisfactory. The SCA concentration must not fall below
those in antifreeze solutions, become depleted 1.0 unit per 3.8 R or exceed 2 units per 3.8 R of coolant.
through normal operation. If the coolant additives in The only accurate method for testing chemical concen-
antifreeze are allowed to become depleted, the trations in coolant with mixed chemical compounds is a
antifreeze becomes corrosive and attacks and coats laboratory analysis.
the metallic surfaces of the cooling system which
reduces heat transfer. Cooling system conditioners NOTICE:
which contain these additives must be added to Inadequate concentration of the coolant additive can
maintain corrosion protection. result in major corrosive damage to cooling system
components. Over-concentration can cause formation
2. SOLUBLE OIL IS NOT RECOMMENDED for use in of gel that can cause restriction, plugging of passages
this engine as its use will reduce heat transfer and and overheating.
allow internal engine damage.
Replenishing Coolant Conditioner
3. There are no miracle additives that will increase heat
transfer or prevent overheating. Conditioned water is Install a precharge coolant filter when the coolant si
still the best coolant. changed or a significant (more than 50%) coolant loss
occurs. Install a service coolant filter as specified. When
4. A corrosion inhibitor/conditioner is recommended to antifreeze is added, add coolant conditioner equal to 1.0
inhibit corrosion in the cooling system for the follow- unit per 3.8 R of antifreeze.
ing reasons:
NOTICE:
! Improved compatibility with high silicate antifreezes Mixing of DCA4 and other supplemental coolant addi-
to minimize hydro-gel formation if over concentration tives is not recommended because there is currently no
occurs. Provides engine protection in the following test kit available to measure concentration levels with
areas: mixed chemical solutions.
WA450-3MC 01-11
Supplemental Coolant Additive Maintenance Guide liter or exceed 0.5 units per liter.
Use supplemental coolant additives to protect the engine

DCA4 UNIT GUIDE
cooling system from corrosion. Antifreeze alone does not
provide enough corrosion protection for a heavy duty Fleetguard Part No. DCA4 Units
diesel engine. Supplemental corrosion protection must be
supplied through periodic additions of supplemental
DCA4 Coolant Filter
additives to the coolant. To protect against corrosion, a
WF-2070 2
new coolant charge must be brought up to 0.26 SCA unit
WF-2071 4
per liter of coolant (initial charge). Maintain the correct
WF-2072 6
SCA concentration by changing the service coolant filter
WF-2073 8
at each engine oil and filter change interval. Each time the
WF-2074 12
coolant is drained and replace, the coolant must be
WF-2075 15
recharged with supplemental coolant additives. Use the
WF-2076 23
appropriate replacement coolant filter listed in following
WF-2077 0
t ables. The coolant mixture must be drained and re-
placed. The amount of a replacement inhibitor is deter- DCA4 Liquid
mined by the length of the service interval and the cooling DCA60L 4
system capacity. Refer to the DCA4 Unit Guide for the DCA80L 1760
selection of the correct filter to replenish the SCA. If
coolant is added between drain intervals, additional SCA DCA4 Powder
will be required. Check the coolant DCA concentration DCA95 20
level anytime make up coolant is added to the system.
The SCA concentration must not fall below 0.13 units per
DCA4 Precharge and Service Filters
System Capacity
Precharge Filter Service Filter
(See NOTE 1) (See NOTE 3)
Liters
19 to 26 WF-2072 WF-2070
30 to 38 WF-2073 WF-2071
42 to 57 WF-2074 WF-2071
61 to 76 WF-2075 WF-2071
80 to 114 WF-2076 WF-2072
118 to 190 (See NOTE 2) WF-2073
NOTE 1 - Aft er draining and replacing coolant, always The answer represents the additional units required to
precharge the cooling system to maintain the precharge the cooling system. Four bottles of powder,
SCA concentration between 1.0 and 2.0 units part number DCA95, will provide a sufficient amount of
per 3.8 R. SCA units (80) to precharge the example cooling system.
NOTICE: When performing service which requires drain-
ing t he cooling system, discard the coolant. ! Install the appropriate service filter at the next and
Reusing coolant can introduce contaminates or subsequent maintenance intervals.
over concentrated chemicals, resulting in
premature failure of cooling system compo- NOTE 3 - Change the coolant filter at every engine oil
nents. and filter change interval to protect the cooling
system.
NOTE 2 - To precharge cooling systems larger than 114
R do the following: Maintain a nominal SCA concentration of 1.0 unit per 3.8
R of coolant in the system. Less than 0.5 units per 3.8 R
! Install appropriate service filter listed in the above indicates an under-concentrated coolant solution. More
table based on cooling system capacity. than 2.0 units per 3.8 R indicates an over-concentrated
Example: 360 R cooling system capacity coolant solution.
-15 Units (1) WF-2075 Filter To check the SCA concentration level, use coolant test
80 Units kit, CC-2626. Instructions are included with the test kit.
01-12 WA450-3MC
SCA Unit Concentration Guide

Number of Solution A Drops to
Coolant Condition Action Required
Cause Color Change
Extremely under-concentrated - less Initially charge the system to a mini-
0 to 10 Drops
than 0.4 SCA units per 3.8 R mum of 1.0 SCA unit per 3.8 R.
Add SCA liquid units to maintain 1.0
Marginally under-concentrated - 0.45 to
11 to 16 Drops SCA unit per 3.8 R minimum or change
0.8 SCA units per 3.8 R
the DCA 4 coolant filter.
Acceptable - 0.85 to 1.3 SCA units per
17 to 25 Drops None.
3.8 R
H i g hly acceptable - 1.35 to 2.0 SCA
26 to 35 Drops None.
units per 3.8 R
Marginally over-concentrated - 2.1 to
36 to 55 Drops Review maintenance practice.
3.3 SCA units per 3.8 R
Drain 50% of the coolant and replace
w i th water antifreeze mixture. Retest
Over 55 Drops Extremely over-concentrated
th e system for correct SCA unit con-
centration.
Cooling System Test Kit
The following cooling system test kit may be purchased from your
distributor.
This Fleetguard ® coolant test kit, part number CC-2626 is used to

check the concentration of coolant additives in the cooling system.
1. Test strip bottles

2. Solution #1 bottle
3. Small plastic container
4. Large plastic cup
5. Syringe
WA450-3MC 01-13
10 STRUCTURE AND FUNCTION
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 HYDRAULIC PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
POWER TRAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 WORK EQUIPMENT SYSTEM DIAGRAM . . . . . . . . . . 10-101
CONVERTER, TRANSMISSION PIPING . . . . . . . . . . . . . 10-5 WORK EQUIPMENT CIRCUIT DIAGRAM . . . . . . . . . . 10-102
TRANSMISSION SYSTEM DIAGRAM . . . . . . . . . . . . . . . . 10-6 WORK EQUIPMENT LEVER LINKAGE . . . . . . . . . . . . 10-103
TRANSMISSION CIRCUIT DIAGRAM . . . . . . . . . . . . . . . 10-7 HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106
TORQUE CONVERTER OIL FILTER . . . . . . . . . . . . . . . 10-11 PPC RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 PPC VALVE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . 10-111
TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . 10-22 CUT OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41 MAIN VALVE - TWO SPOOL [1/2] . . . . . . . . . . . . . . . . . 10-114
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42 MAIN VALVE - THREE SPOOL [1/2] . . . . . . . . . . . . . . . 10-116
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43 WORK EQUIPMENT LINKAGE . . . . . . . . . . . . . . . . . . 10-128
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . 10-48 BUCKET POSITIONER BOOM KICK OUT . . . . . . . . . 10-131
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51 ROPS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
AXLE MOUNT, CENTER HINGE PIN . . . . . . . . . . . . . . . 10-52 HEATER AND DEFROSTER . . . . . . . . . . . . . . . . . . . . 10-138
STEERING PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53 AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54 ELECTRIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . 10-140
STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55 MACHINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . 10-141
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . 10-69 MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142
STOP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73 MAINTENANCE MONITOR . . . . . . . . . . . . . . . . . . . . . 10-146
GROUND DRIVEN STEERING PUMP . . . . . . . . . . . . . 10-74 TRANSMISSION AUTO SHIFT . . . . . . . . . . . . . . . . . . . 10-148
DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75 LOAD METER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 10-153
BRAKE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78 ECSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
BRAKE CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . 10-79 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80 ENGINE START CIRCUIT . . . . . . . . . . . . . . . . . . . . . . 10-175
ACCUMULATOR CHARGE VALVE . . . . . . . . . . . . . . . . . 10-85 ENGINE STOP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . 10-176
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89 PREHEATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . 10-178
SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90 ELECTRIC TRANSMISSION CONTROL . . . . . . . . . . . 10-180
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92 KICK DOWN, HOLD SWITCH . . . . . . . . . . . . . . . . . . . . 10-183
PARKING BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . 10-94 KICK DOWN CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . 10-184
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95 TRANSMISSION CUT OFF SWITCH . . . . . . . . . . . . . . 10-190
PARKING BRAKE SOLENOID VALVE . . . . . . . . . . . . . . 10-96 TRANSMISSION CUT OFF FUNCTION . . . . . . . . . . . . 10-191
PARKING BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 10-97 ELECTRIC PARKING BRAKE CONTROL . . . . . . . . . . 10-194
EMERGENCY RELEASE SOLENOID VALVE . . . . . . . . 10-98
WA450-3MC 10-1
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
1. Transmission 4. Rear axle 7. Front drive shaft

2. Torque converter 5. Rear drive axle 8. Front axle
3. Engine 6. Center drive shaft
OUTLINE
! The motive force from engine (3) passes through the engine
flywheel and is transmitted to the torque converter (2), which is
connected to the input shaft of transmission (1).
! The transmission has six hydraulically actuated clutches, and

t hese provide four speed ranges for both FORWARD and
REVERSE. The transmission speed ranges are selected
manually.
! The motive force from the output shaft of the transmission

passes through center drive shaft (6), front drive shaft (7) and
rear drive shaft (5), and is then transmitted to front axle (8) and
rear axle (4) to drive the wheels.
10-2 WA450-3MC
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
POWER TRAIN SYSTEM
WA450-3MC 10-3
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
1. Front axle OUTLINE
2. Differential ! The motive force from engine (12) passes through the flywheel
and is transmitted to torque converter (13). The torque converter
3. Front drive shaft uses oil as a medium. It converts the transmitted torque in
accordance with the change in load, and transmits the motive
4. Center drive shaft forc e to the input shaft of the transmission. In addition, the
motive force of the engine passes through the pump drive gear
5. Parking brake of the torque converter, and is transmitted to steering pump (16),
switch pump (17), hydraulic pump (14) and PPC pump (15) and
6. Rear drive shaft to drive each pump.
7. Differential ! Trans mission (19) operates the directional spool and speed
spool of the transmission valve through the solenoid valves, and
8. Rear tire actuates the six hydraulically actuated clutches to select one
of the four FORWARD or REVERSE speeds. The transmission
9. Final drive speed range is selected manually.
10. Wet type multiple disc brake ! Parking brake (5) is installed to the front output shaft, and acts
to stop the machine through the solenoid valve and hydraulical
11. Rear axle clutches when the parking brake switch is operated.
12. Engine ! The output shaft of the transmission (19) transmits the power to
the front and rear axles. At the front the power is transmitted to
13. Torque converter front axle (1) through center drive shaft (4), flange bearing (20),
and front drive shaft (3). At the rear, the power is transmitted to
14. Hydraulic pump rear axle (11) through rear drive shaft (6).
15. PPC pump ! The motive force transmitted to front axle (1) and rear axle (11)
has its speed reduced by the bevel gear and pinion gear of
16 Steering pump differentials (2) and (7), and is then transmitted to the sun gear
shaft through the differential mechanism.
17. Switch pump
! The motive force of the sun gear is reduced further by the
18. Trans, converter charging pump planetary mechanism and is transmitted to the wheels through
the axle shaft.
19. Transmission
20. Flange bearing
21. Front tire
22. Final drive
23. Wet type multiple disc brake
10-4 WA450-3MC
STRUCTURE AND FUNCTION TORQUE CONVERTER, TRANSMISSION PIPING
TORQUE CONVERTER, TRANSMISSION PIPING
1. Torque converter charging pump 5. Pilot oil filter

2. Torque converter 6. Transmission control valve
3. Radiator 7. Transmission
4. Oil cooler 8. Oil filter
WA450-3MC 10-5
STRUCTURE AND FUNCTION TRANSMISSION SYSTEM DIAGRAM
TRANSMISSION SYSTEM DIAGRAM
Conditions: Engine at low idle, transmission shift lever at neutral
10-6 WA450-3MC
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
1. Transmission case
2. Strainer
3. Converter charge pump
4. Flow control valve
5. Oil filter
6. Pilot reducing valve
7. Pilot oil filter
8. Priority valve
9. Electronic modulation valve
10. Main relief valve
11. Torque converter
12. Converter outlet valve
13. Oil cooler
14. Transmission lubrication
15. Emergency manual spool
16. Solenoid valve, forward
17. Directional selector valve
18. Solenoid valve, reverse
19. Reverse clutch
20. Forward clutch
21. Solenoid valve, Hi-Lo
22. Hi-Lo selector valve
23. Solenoid valve, range
24. Range selector valve
25. Solenoid valve, parking brake
26. Parking brake valve
27. Parking brake
28. 4th clutch
29. 3rd clutch
30. 2nd clutch
31. 1st clutch
32. Accumulator
WA450-3MC
10-7
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
1. Breather Specifications
2. Housing
3. Hydraulic, PPC tandem pump mount Model . . . . . . . . . . . . . . . . . . . . . . . . . . TCA38-4Z
4. Steering, switch tandem pump mount Type . . . . . . . . . . . . . 3 element, 1 stage, 1 phase
Stall torque ratio . . . . . . . . . . . . . . . . . . . . . . 3:15
10-8 WA450-3MC
5. Flywheel 9. Stator A. Inlet port

6. Drive case 10. Transmission input shaft B. Outlet port
7. Turbine 11. Housing
8. Pump
WA450-3MC 10-9
PATH OF MOTIVE FORCE
! The t orque converter is installed between the engine and the

transmission. The motive force from the engine enters drive case
(6) from flywheel (5). Drive case (6), pump (8), and PTO gear
(drive) (12) each are secured by bolts and are rotated directly by
the rotation of the engine. The motive force of pump (8) uses oil
as a medium to rotate turbine (7) and transmit the motive force
to transmission input shaft (10).
! The motive force of drive case (6) is used as the motive force to
drive the gear pump through PTO gear (drive) (12).
FLOW OF OIL
! The oil supplied from the torque converter charging pump enters
inlet port A, passes through the oil passage of stator shaft (13),
and flows to pump (8). The oil is given centrifugal force by pump
(8), enters turbine (7), and transmits the energy of the oil to the
turbine. Turbine (7) is fixed to transmission input shaft (10), so
the motive force is transmitted to the transmission input shaft.
The oil from turbine (7) is sent to stator (9), and enters the pump
again. However, part of the oil is sent from the stator through
outlet port B to the cooler.
10-10 WA450-3MC
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER
TORQUE CONVERTER OIL FILTER

1. Relief valve
2. Element
3. Center bolt
4. Drain plug
SPECIFICATIONS
Filter mesh size: . . . . . . . . . . . . . . . 10 microns
Filtering area: . . . . . . . . . . . . . . . . . . 8900 cm 2
Relief pressure: . . . . . . . . . . . . . . . . 3.5 kg/cm 2
OPERATION
! The oil from the torque converter charging pump enters filter inlet
port A. It is filtered from outside of element (2) to the inside, and
flows to outlet port B to the transmission control valve.
! If element (2) becomes clogged with dirt, or the oil temperature

is low and the pressure rises at inlet port A, the oil from inlet
port A opens relief valve (1) and flows directly to outlet port B in
order to prevent damage to the pump or element (2).
WA450-3MC 10-11
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
1. Charging pump
2. Transmission input shaft
3. Converter housing
4. Accumulator
5. Oil filter
6. Rear output coupling
7. Transmission
8. Parking brake
9. Front output coupling
10. Oil filter
11. Transmission control valve
12. PTO
13. Transmission oil filler
10-12 WA450-3MC
WA450-3MC 10-13
14. PTO gear, 65 teeth

17. 1st clutch, 26 teeth
18. FORWARD clutch
19. Input gear 29 teeth
21. PTO drive gear, 74 teeth
22. FORWARD gear, 49 teeth
23. REVERSE gear, 47 teeth
24. 3rd and 4th shaft
25. 4th gear, 53 teeth
26. Output shaft
27. Output gear, 43 teeth
28. 3rd gear, 49 teeth
30. 3rd clutch
31. 4th clutch
32. REVERSE and 2nd shaft
33. 2nd gear, 26 teeth
34. 2nd clutch
35. 2nd gear, 50 teeth
36. REVERSE gear
37. FORWARD, 1st shaft
38. 1st gear, 26 teeth
40. Countershaft
41. 4th gear, 27 teeth
OUTLINE
! The transmission is installed behind the torque converter. The

motive force from the torque converter passes through the
transmission input shaft and enters the transmission.
! The transmission uses the combination of the forward or reverse

clutches and the four speed clutches to shift F1 - 4 or R1 - 4,
and transmits the motive force from the input shaft to the output
shaft.
10-14 WA450-3MC
FORWARD AND 1ST CLUTCH
1. Spacer 5. FORWARD, 1st cylinder a. 1st clutch oil port

2. Thrust washer 6. FORWARD clutch b. FORWARD clutch oil port
3. 1st gear 7. FORWARD gear c. Lubrication oil port
4. 1st clutch 8. FORWARD, 1st shaft
REVERSE AND 2ND CLUTCH
1. Spacer 6. 2nd, REVERSE cylinder 11. 2nd, REVERSE shaft

2. Thrust washer 7. REVERSE clutch a. 2nd clutch oil port
3. 2nd gear 8. REVERSE gear b. REVERSE clutch oil port
4. 2nd gear 9. Thrust washer c. Lubrication oil port
5. 2nd clutch 10. Spacer
WA450-3MC 10-15
3RD AND 4TH CLUTCH
6. 3rd, 4th cylinder

1. Spacer 7. 4th gear
2. Thrust washer 8. 4th clutch
3. 3rd gear 9. Thrust washer
4. 3rd gear 10. Spacer
5. 3rd clutch
11. 3rd, 4th shaft

a. 3rd clutch oil port
b. 4th clutch oil port
c. Lubrication oil port
WHEN OPERATED
! The oil sent from the transmission valve passes through the oil
passage inside shaft (1), and goes to the rear face of piston (5)
to actuate the piston.
! When piston (5) is actuated, separator plate (2) is pressed

against clutch disc (3) and forms shaft (1) clutch gear (4) into
one unit to transmit the motive force.
WHEN NOT ACTUATED
! If the oil from the transmission valve is shut off, the pressure of
the oil acting on the rear face of piston (5) drops.
! The piston is returned to its original position by wave spring (6),

so shaft (1) and clutch gear (4) are separated.
10-16 WA450-3MC
FORWARD 1ST
OPERATION
! In FORWARD 1st, FORWARD clutch (18) and 1st clutch (17)

are engaged. The motive force from the torque converter
transmitted to input shaft (2) is transmitted to gear (19), which
is installed to the input shaft.
! The clutch discs of FORWARD clutch (18) and 1st clutch (17)
is engaged by the oil pressure applied to the piston.
! The motive force from the torque converter passes from input
shaft (2) through gear (19) and is transmitted to FORWARD gear
(22). When FORWARD clutch (18) is engaged, the motive force
is transmitted to the FORWARD 1st cylinder.
! The first clutch is engaged, so the motive force transmitted to
the FORWARD 1st cylinder passes through 1st clutch (17) and
is transmitted from 1st gear (38) to 2nd clutch gears (35, 33). It
then passes through 3rd clutch gear (28) and output gear (27)
and is transmitted to output shaft (26).
WA450-3MC 10-17
FORWARD 2ND
OPERATION
! In FORWARD 2nd, FORWARD clutch (18) and 2nd clutch (34)

are engaged. The motive force from the torque converter to input
shaft (2) is transmitted to gear (19).
! The clutch disc of FORWARD clutch (18) and 2nd clutch (34)
are held by hydraulic pressure applied to the clutch piston.
(22). FORWARD clutch (18) is engaged, so the motive force is
transmitted to FORWARD 1st cylinder gear (42).
! The motive force is transmitted to REVERSE 2nd cylinder gear
(43) and REVERSE 2nd shaft (32), which are meshed with the
FORWARD 1st cylinder gear. 2nd clutch (34) is engaged, so the
motive force transmitted to the REVERSE 2nd shaft passes
through the 2nd clutch and goes from 2nd gear (33) through 3rd
gear (28) and output gear (27), and is transmitted to output shaft
(26).
10-18 WA450-3MC
FORWARD 3RD
OPERATION
! In FORWARD 3rd, FORWARD clutch (18) and 3rd clutch (30)

are engaged. The motive force from the torque converter to input
shaft (2) is transmitted to gear (19).
! The clutch discs of FORWARD clutch (18) and 3rd clutch (30)
are held by the hydraulic pressure applied to the clutch piston.
! The motive force is transmitted through REVERSE 2nd cylinder
gear (43) and REVERSE 2nd shaft (32), which is meshed with
the FORWARD 1st cylinder gear, and is transmitted to 3rd, 4th
c y linder gear (44) and 3rd, 4th shaft (24). 3rd clutch (30) is
engaged, so the motive force passes through the 3rd clutch and
goes from 3rd gear (28) through output gear (27), and is trans-
mitted to output shaft (26).
WA450-3MC 10-19
FORWARD 4TH
OPERATION
! In FORWARD 4th, FORWARD clutch (18) and 4th clutch (31)
are engaged. The motive force transmitted from the torque
converter to input shaft (2) is transmitted to gear (19).
! The clutch discs of FORWARD clutch (18) and 4th clutch (31)
are held by the hydraulic pressure applied to the clutch piston.
! The motive force is transmitted through REVERSE 2nd cylinder
gear (43), which is meshed with the FORWARD 1st cylinder
gear, and is transmitted to 3rd, 4th cylinder gear (44) and 3rd,
4th shaft (24). 4th clutch (31) is engaged, so the motive force
transmitted to the 3rd, 4th shaft passes through the 4th clutch
and goes from 4th gear (25) through 4th counter gear (39),
countershaft (40) and 3rd counter gear (39), is transmitted to 3rd
gears (29) and (28), and then passes through output gear (27),
and is transmitted to output shaft (26).
10-20 WA450-3MC
REVERSE 1ST
OPERATION
! In REVERSE 1st, REVERSE clutch (36) and 1st clutch (17) are
engaged. The motive force transmitted from the torque converter
to input shaft (2) is transmitted to gear (19).
! The clutch disc of reverse clutch (36) and 1st clutch (17) are
held by the hydraulic pressure applied to the piston.
shaft (2) through gear (19) and is transmitted to REVERSE gear
(25). When REVERSE clutch (36) is engaged, the motive force
is transmitted to the REVERSE 2nd cylinder.
! The motive force is transmitted to FORWARD 1st cylinder gear
(42) and FORWARD 1st shaft (37), which are meshed with
REVERSE 2nd cylinder gear (43). 1st clutch (17) is engaged,
s o the motive force transmitted to the FORWARD 1st shaft
passes through 1st clutch (17) and is transmitted from 1st gear
(38) to 2nd gears (35, 33), passes through 3rd gear (28) and
output gear (27) and is transmitted to output shaft (26).
WA450-3MC 10-21
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE
1. Upper valve d. Priority pressure measurement port

2. Lower valve e. Pilot pressure port
3. Solenoid valve f. Measurement port for torque converter outlet port oil
4. Electronic modulation valve pressure
5. Emergency manual spool g. To oil cooler
a. Main oil pressure measurement port h. Parking brake oil pressure measurement port
b. Clutch oil pressure measurement port i. From pump
c. Measurement port for torque converter inlet port oil
pressure
OUTLINE
! The oil from the pump passes through the flow valve is traveling. It actuates the proportional solenoid valve
and torque converter oil filter, enters the transmission, according to the command current from the transmis-
and is divided into the pilot circuit and clutch actua- sion controller to control the oil flow and pressure.
tion circuit. The priority valve adjusts delivery pressure This allows the clutch to engage smoothly and
of the pump and ensures the pilot pressure and oil reduces the shock when shifting gear. In addition,
pressure used to release the parking brake. when the machine is traveling, the clutch pressure is
! The pressure of the oil flowing to the clutch circuit is kept constant. The pressure of the oil flowing to the
regulated by the electronic control modulation valve. pilot valve is regulated by the pilot reducing valve, and
The transmission is automatically shifted to the actuates the directional and range spools as the
optimum speed range, and the appropriate clutch is solenoid valves are switched ON or OFF.
actuated. The oil relieved by the main relief valve is ! When the directional and rage spools are switched,
supplied to the torque converter the oil, whose pressure is regulated by the modula-
! The electronic control modulation valve senses the tion valve, is supplied to the selected clutch to provide
travel speed and the engine speed when the machine the necessary speed range.
10-22 WA450-3MC
UPPER VALVE
1. Upper valve body 8. Directional selector valve
2. Emergency manual spool 9. Solenoid valve
3. Pilot reducing valve 10. Range selector valve
4. Converter outlet port valve 11. Priority valve
5. Main relief valve 12. Parking brake valve
6. Electronic control modulation valve 13. Parking brake solenoid valve
7. Lower valve body 14. Hi-Lo selector valve
WA450-3MC 10-23
LOWER VALVE
10-24 WA450-3MC
TRANSMISSION SOLENOID VALVE
1. Solenoid valve [Î] for FORWARD selector 4. Solenoid valve [Ñ] for range selector
2. Solenoid valve [Ï] for REVERSE selector 5. Solenoid valve [Ð] for Hi-Lo selector
3. Solenoid valve [Ò] for parking brake
! The transmission solenoid valve is installed to the lower valve of

the transmission valve. When the speed lever is operated, the
movement is converted to electricity, and this opens or closes
each solenoid valve to move the spool inside the transmission
valve.
! The parking brake solenoid valve is installed to the transmission
lower valve. When the parking brake switch is operated, the
solenoid valve is opened or closed by an electric signal to move
the parking brake spool.
Actuation table for solenoid valve and clutch
Solenoid valve
Clutch Î Ï Ð Ñ Ò
FC1 # #
FC2 #
FC3 # #
FC4 # # #
N
RC 1 # #
RC 2 #
RC 3 # #
RC 4 # # #
Parking brake operated
Parking brake released #
WA450-3MC 10-25
FUNCTION
! When the speed lever in the operator’s cab is operated, the four
solenoid valves installed to the transmission control valve are
switched ON or OFF to actuate the directional selector spool,
Hi-Lo selector spool and range selector spool.
OPERATION
Solenoid Valve OFF
! The oil from pilot reducing valve (1) flows to ports a and b of Hi-
Lo selector spool (2) and range selector spool (3). The oil at a
and b i s blocked by solenoid valves (4) and (5), so selector
spools (2) and (3) are moved to the right in the direction of arrow.
As a result, the oil from the pump flows to the 2nd clutch.
Solenoid Valve ON
! When the speed lever is operated, the drain ports of solenoid

valves (4) and (5) open. The oil at ports a and b of selector
spools (2) and (3) flows from ports c and d to the drain circuit.
Therefore, the pressure in the circuits at ports a and b drops,
and the spools are moved to the left in the direction of the arrow
by return springs (6) and (7). As a result, the oil at port e flows
to the 4th clutch and switches from 2nd to 4th.
10-26 WA450-3MC
FLOW VALVE
1. Valve body a. To transmission clutch circuit

2. Valve spool b. From pump
c. To transmission lubrication circuit
OPERATION
! The oil from the pump flows to the transmission clutch circuit
but when it becomes greater than the specified flow, the flow
valve acts to send oil to the transmission lubrication circuit.
! When the oil from the pump becomes greater than the specified
flow, valve spool (2) moves and part of the oil from the pump
flows to the transmission lubrication circuit.
WA450-3MC 10-27
ACCUMULATOR VALVE
1. Piston (FORWARD clutch) 6. Stopper (2nd clutch)

2. Piston (1st clutch) 7. Stopper (1st clutch)
3. Piston (2nd clutch) 8. Stopper (FORWARD clutch)
4. Body accumulator 9. Spring (FORWARD clutch)
5. Spring (2nd clutch) 10. Spring (1st clutch)
OUTLINE
! The accumulator valve is installed in the FORWARD, 1st, 2nd
clutch circuit. When the transmission shifts gear, the accumula-
tor valve slowly reduces the oil pressure to the clutch that was
first engaged in order to prevent loss of torque and to reduce the
transmission shock when shifting gear. It temporarily stores the
clutch oil pressure in order to allow gear shifting to be carried
out smoot hly without any time lag. To make it possible to
reduce the oil pressure to the clutch slowly, there are throttles
i n s t alled in the directional spool and selector spool of the
transmission control valve.
10-28 WA450-3MC
OPERATION
Shifting Down When Digging [Kick Down F2 º F1]
! When the transmission is in F2, oil pressure is stored in the 2nd

c l utch accumulator. When the kick down is operated, the F1
clut ch is engaged, but the oil pressure in the accumulator is
maintained for the 2nd clutch until the torque is transmitted to
the 1st clutch. In this way, it is possible to shift gear smoothly
without losing the torque.
Moving Out After Digging (F1 º R2).
! When the transmission is in F1, oil pressure is stored in the

a c c umulator for the FORWARD clutch and 1st clutch. When
shifting to R2 after completing digging operations, the R2 clutch
is engaged, but the oil pressure for the FORWARD clutch and
1st clut ch is maintained in the accumulator. This makes it
possible to reduce the loss of torque due to the reaction force to
the product being handled, and to move back smoothly without
shock.
WA450-3MC 10-29
TRANSMISSION OIL PRESSURE SYSTEM DIAGRAM
OPERATION OF FORWARD 1ST
10-30 WA450-3MC
! The oil from the pump passes through the filter, then passes
through the pilot circuit and priority valve, and is divided to the
clutch actuation circuit and the torque converter circuit.
! When the speed lever is operated to F1, FORWARD solenoid
valve (1) is actuated. The oil which was filling port a is drained,
directional spool (4) is moved to the left and clutch oil pressure
port b and FORWARD clutch oil pressure port b are connected.
! A t the same time, oil fills the circuit and pushes the Hi-Lo
selector spool (5) fully to the right to prevent Hi-Lo selector
solenoid valve (2) from being actuated. In addition, the oil is
drained and range selector spool (6) is pushed fully to the left to
actuate range selector solenoid valve (3).
! In this condition, 1st clutch oil pressure port d is connected to
oil pressure port c of the Hi-Lo selector valve and the range
selector valve.
! At the same time the oil flowing through priority valve (7) to the
clutch actuation circuit passes through the modulation valve,
and then flows to the FORWARD clutch and 1st clutch through
directionaI spool (4), Hi-Lo selector spool (5), and range selector
spool (6).
! When the oil completely fills the clutch cylinder, the pressure
rises gradually because of the action of accumulator (8) and
modulation valve (9). When it reaches the set pressure, the
FORWARD and 1st clutches are completely engaged.
DIRECTIONAL SELECTOR VALVE
OPERATION
When at Neutral
! Solenoid valves (4) and (5) are OFF and the drain port is closed.
The oil from the pilot circuit passes through the oil hole in the
emergency manual spool and fills ports a and b of the direc-
tional spool.
! In this condition, P1 plus spring (1) force = P2 plus spring (2)
force, so the balance is maintained. Therefore, the oil at port c
does not go to the FORWARD or REVERSE clutch.
When at FORWARD
! When the directional lever is placed at the FORWARD position,
solenoid valve (4) is switched ON and drain port d opens. The
oil which is filling port a is drained, so P1 plus spring (1) force <
P 2 plus spring (2) force. When this happens, the directional
spool moves to the left, and the oil at port c flows to port e and
is supplied to the FORWARD clutch.
WA450-3MC 10-31
EMERGENCY MANUAL SPOOL
! If t here should be a failure in the electrical system and the

directional solenoid valve cannot be actuated, it is possible to
actuate the FORWARD or REVERSE clutch manually.
WHEN EMERGENCY MANUAL SPOOL IS AT NEUTRAL

! The oil from upper valve [pilot reducing valve] passes around
emergency manual spool (1) and is blocked by solenoid valves
(2) and (3). During normal operations, the emergency manual
spool is at the neutral position.
WHEN EMERGENCY MANUAL SPOOL IS ACTUATED

! When emergency manual spool (1) is pushed in, port a is
connected to the drain port, and the oil in chamber b is drained.
When this happens, directional spool (4) moves to the left in the
direction of the arrow. Oil then flows to the FORWARD clutch
and the clutch is engaged.
PRIORITY VALVE
FUNCTION
! The priority valve regulates the delivery pressure of the pump,
and ensures the pilot pressure and oil pressure for releasing the
parking brake. In addition, if the pressure in the circuit goes
above the specified pressure, it acts as a relief valve to protect
the hydraulic circuit.
Operation
! The oil from the pump is divided into two circuits. The oil in one
circuit enters port a, goes around priority valve (1), passes
through pilot reducing valve (2) of the upper valve, and flows to
the pilot circuit of the lower valve, while the other circuit flows to
priority valve (1).
10-32 WA450-3MC
! The oil flowing to priority valve (1) passes through orifice (2) and
flows to port b. In this way, it overcomes the tension of the
return spring (4), pushes the priority valve (1) to the right in the
direction of the arrow, and flows to port c.
! When the pressure at port b goes above the set pressure, the
priority valve (1) is moved further to the right in the direction of
the arrow, and the oil is drained at port d to protect the circuit.
WA450-3MC 10-33
TORQUE CONVERTER OUTLET PORT VALVE
FUNCTION
! The torque converter outlet port valve is installed in the outlet line
of the torque converter and adjusts the maximum pressure of the
torque converter.
OPERATION
! The oil at port a passes through the orifice in spool (1) and flows
to port c.
! When the pressure at port a rises, the pressure at port c also

rises. This overcomes the tension of spring (2) and moves spool
(1) to the left in the direction of the arrow to allow oil to flow from
port a to port b.
! If t he pressure at port a becomes even higher, spool (1) is

moved further to the left in the direction of the arrow, and the oil
flows from port a to port b and drain port d, cold relief.
10-34 WA450-3MC
PILOT REDUCING VALVE
FUNCTION
! The pilot reducing valve controls the pressure used to actuate

the directional selector spool, Hi-Lo selector spool, range
selector spool and parking brake spool.
OPERATION
! The oil from the pump enters port A, passes through port B of
pilot reducing spool (1), enters spools (2) and (3) in the lower
valve, and fills the pilot circuit. The oil at port B passes through
the orifice and flows to port C.
1. Pilot reducing spool

2. Hi-Lo selector spool
3. Range selector spool
4. Spool return spring
5. Upper transmission valve
6. Pilot filter
7. Solenoid valves
8. Lower transmission valve
Y. Flow from pump
Z. Drain to reservoir
! When the pressure in the pilot circuit rises, the pressure at port
C a l s o rises. This overcomes the tension of spring (4) and
moves pilot reducing spool (1) to the right in the direction of the
arrow. For this reason, port A and port B are shut off, so the
pressure at port C is maintained.
WA450-3MC 10-35
PROPORTIONAL SOLENOID VALVE
1. Body 3. Case 5. Plunger

2. Coil 4. Adjustment screw 6. Shaft
TRANSMISSION SOLENOID VALVE
1. Nut 6. Pin
2. Core 7. Spring
3. Coil 8. Valve seat
4. Plunger 9. Body
5. Spring 10. Connector
10-36 WA450-3MC
ELECTRONIC CONTROL MODULATION VALVE [ECMV]
STRUCTURE OF ECMV
! The ECMV [Electronic Control Modulation Valve] consists of a

proportional solenoid valve and the ECMV spool.
Proportional Solenoid Valve and ECMV
! The proportional solenoic valve generates thrust according to

current from the transmission controller.
! The thrust generated by the proportional solenoid is applied to

the pressure control spool and generates the hydraulic pressure
shown in the diagram on the right. Accordingly, the thrust is
changed and the oil pressure is controlled by controlling the
current.
Operation of ECMV
! The ECMV is controlled with the current from the transmission

controller to the proportional solenoid valve. The relationship
between the hydraulic clutch pressure and the current in the
proportional solenoid in the ECMV is as shown in the diagram
on the right.
WA450-3MC 10-37
Before Shifting Gear
Whether the machine is traveling or the transmission is in neutral,

at least one of the clutches is engaged, and a command current
flows to proportional solenoid valve (1) from the trans controller. The
oil from the priority valve enters port A, passes through throttle B and
flows to port C. The oil in port C passes through port D and enter
port E. The oil in port E pushes out piston (4). The reactive force to
piston (4) moves spool (3) to the right to close throttle B. As a result,
the hydraulic pressure is so maintained that the thrust of shaft (2) of
proportional solenoid valve (1) will be balanced with the reactive
force, hydraulic pressure, of spool (3). The clutch holding pressure
is maintained.
When Shifting Gear [Immediately after Shifting Gear]
The selector spool is changed for shifting the gear and the oil for the
c l utch which has been engaged is drained, then the port to the
c l u t c h to be engaged now is opened. The command current to
proportional solenoid (1) is used as a trigger current just after thew
gear is shifted. Spool (3) is kept pushed to the left and the oil starts
flowing to fill the clutch chamber.
When Shifting Gear [Setting Initial Pressure]
Jus t after oil fills the clutch port, the command current to the
solenoid valve is lowered to the set value for the initial pressure.
Accordingly, the thrust of shaft (2) of the proportional solenoid valve
is reduced and the clutch hydraulic pressure becomes the set value
for the initial pressure.
Adjusting Pressure
When a electric current flows in the proportional solenoid valve (1),

the valve generates a thrust in proportion to the current. The thrust
of s h a f t (2) of solenoid valve (1) is balanced with the hydraulic
pressure of the clutch port applied to spool (3). That is, the clutch
pressure is controlled by controlling the command current flowing in
the solenoid valve (1).
10-38 WA450-3MC
Manual Operation of ECMV
When the electrical system of the transmission controller has

trouc le, the opeator can engage the transmission by manual
operation to move the machine. For details, see the Operation &
Maintenance Manual.
Method of Engaging
1. Disconnect all connectors to the transmission control valve.
2. Remove the manual selector lock plate, then push in or pull out
the spool.
FORWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . Pull out
REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Push in
3. Push in the adjustment screw of the proportional solenoid valve

to the end.
Engaged gear . . . . . . . . . . . . . . . . . . . . . . . 2nd speed
WA450-3MC 10-39
PILOT OIL FILTER
1. Oil filter header SPECIFICATIONS

2. Element
3. Case Filtering area . . . . . . . . . . . . . . . . . . . . 170 cm 2
A. Inlet port Filter mesh size . . . . . . . . . . . . . . . . . . 105 F

B. Outlet port
10-40 WA450-3MC
STRUCTURE AND FUNCTION DRIVE SHAFT
DRIVE SHAFT
1. Front drive shaft

2. Flange bearing
3. Center drive shaft
4. Rear drive shaft
OUTLINE
! The motive force from the engine passes through the torque
converter and the transmission. Some of it is transmitted from
rear drive shaft (4) to the rear axle, while the rest goes from
center drive shaft (3) through flange bearing (2) and front drive
shaft (1) to the front axle.
! The drive shaft has the following purpose in addition to simply

transmitting the power. The drive shaft has a universal joint and
sliding joint to enable it to respond to changes in the angle and
length. This enabled the drive shaft to transmit the motive force
when the machine is articulated and to protect the components
from damage from shock when the machine is being operated
or shock from the road surface when the machine is traveling.
WA450-3MC 10-41
STRUCTURE AND FUNCTION FRONT AXLE
FRONT AXLE
1. Differential 4. Final drive

2. Oil filler 5. Breather
3. Brake 6. Level plug
10-42 WA450-3MC
STRUCTURE AND FUNCTION REAR AXLE
REAR AXLE
1. Final drive 5. Breather

2. Brake 6. Level plug
3. Differential 7. Drain plug
4. Oil filler
WA450-3MC 10-43
STRUCTURE AND FUNCTION DIFFERENTIAL
DIFFERENTIAL
FRONT DIFFERENTIAL
1. Shaft SPECIFICATION
2. Bevel gear, 42 teeth
3. Bevel pinion, 9 teeth Type . . . . . . . . . . . . . . . . . Spiral bevel gear
4. Side gear, 12 teeth [Splash lube]
5. Pinion gear, 9 teeth Reduction ratio . . . . . . . . . . . . . . . . . . . . 4.667
Differential type . . . . . . . Torque proportioning
[Splash lube]
10-44 WA450-3MC
REAR DIFFERENTIAL
1. Shaft SPECIFICATION
2. Bevel gear, 42 teeth
3. Bevel pinion, 9 teeth Type . . . . . . . . . . . . . . . . . Spiral bevel gear
4. Side gear, 12 teeth [Splash lube]
5. Pinion gear, 9 teeth Reduction ratio . . . . . . . . . . . . . . . . . . . . 4.667
Differential type . . . . . . . Torque proportioning
[Splash lube]
WA450-3MC 10-45
OUTLINE
! The motive force from the drive shaft passes through bevel pinion
(1) and is transmitted to bevel gear (5). The bevel gear changes
the direction of the motive force by 90E, and at the same time
reduces the speeed. It then transmits the motive force through
differential (4) to sun gear shaft (2).
WHEN MOVING STRAIGHT FORWARD
! When the machine is driven straight forward, the rotating speed

of the left and right wheels is the same, so pinion gear (4) inside
the differential does not rotate, and the motive force of carrier (6)
is transmitted equally to left and right sun gear shafts (2) via the
pinion gear (4) and side gear (3).
WHEN TURNING
! When turning, the rotating speeds of the left and right wheels is
different, so pinion gear (4) and side gear (3) in the differential
rotate in accordance with the difference between rotating speeds
of the left and right wheels. The motive force of carrier (6) is
transmitted to the sun gear shafts (2).
10-46 WA450-3MC
TORQUE PROPORTIONING DIFFERENTIAL
FUNCTION Standard Torque proportioning
! Because of the nature of their work, 4-wheel drive loaders have

to work in places where the road surface is bad. In such places,
if the tires slip, the ability to work as a loader is reduced, and
also the life of the tire is reduced. The torque proportioning
differential is installed to overcome this problem.
! In structure it resembles the differential of a car, but differential
pinion gear (4) has an odd number of teeth. Because of the
difference in the resistance from the road surface, the position
of meshing of pinion gear (4) and side gear (3) changes, and this
changes the traction of the left and right tires.
OPERATION Spider rotating direction
When Traveling Straight, Equal Resistance from Road Surface

to Left and Right Tires
! If t h e resistance from the road surface to the left and right

wheels is the same, the distance between pinion gear (4) and
meshing point a of left side gear (7) is the same as the distance
between pinion gear (4) and meshing point b of right side gear
(3). Therefore the left side traction TL and the right side traction
TR are balanced.
W hen Traveling on Soft Ground, Resistance from Road Spider rotating direction
Surface to Left and Right Tires Is Different
! On soft ground, if the tire on one side slips, the side gear of the
tire on the side which has least resistance from the road surface
tries to rotate forward. Because of this rotation, the meshing of
pinion gear (4) and side gear changes.
! Ifleft side gear (1) rotates slightly forward, the distance between
the pinion gear and the meshing point a of the left side gear be-
comes longer than the distance between the pinion gear and the
meshing port b of the right side gear. The position is balanced
as follows:
a x TL = b x TR
The ratio between distances to a and b can change to 1 : 1.38.
! Therefore when the ratio of the distances to a and b is less than
1 : 1.38, that is, the difference between the resistance from the
road surface to the left and right tires is less than 38%, the
pinion gear will not rotate freely, so drive force will be given to
bot h side gears, and the tires will not slip. Because of this
effect, the tire life can be increased by 20 to 30%, and at the
same the same time the operating efficiency is also increased.
WA450-3MC 10-47
STRUCTURE AND FUNCTION LIMITED SLIP DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL
1. Plate 5. Cover 9. Pressure ring

2. Disc 6. Side gear 10. Case
3. Washer 7. Pinion 11. Bevel pinion
4. Shaft 8. Shaft
OPERATION OF LIMITED SLIP DIFFERENTIAL
! The power transmitted from the transmission goes from bevel

gear (11) to case (10), pressure ring (9), shaft (8), pinion (7), and
gear (6), and is then divided and sent to left and right shafts (4).
A brake mechanism consisting of disc (2) and plate (1) si
assembled at the rear face of side gear (6), and the brake torque
i s generated in proportion to the torque transmitted from
pressure ring (9) to shaft (8). In order for this brake torque to act
t o s uppress the rotation in relation to side gear (6) and case
(10), it is made difficult for left and right side gears (6) to rotate
mutually, and the action of the differential is suppressed.
10-48 WA450-3MC
MECHANISM FOR GENERATION OF BRAKE TORQUE OF LEFT

AND RIGHT SIDE GEARS
! Shaft (8) is supported by the cam surface cut into the mating
surfaces of left and right pressure rings (9). The power (= torque)
transmitted from pressure ring (9) to shaft (8) is transmitted by
the cam surface, but force Fa to separate left and right pressure
rings (9) is generated in proportion to the torque transmitted by
the angle of this cam surface. This separation load Fa acts as
a brake on the rear face of left and right side gears (6) and
generates brake torque.
WHEN TRAVELING IN STRAIGHT LINE
When There Is No Imbalance Between Drive Force of Left and

Right Wheels
! The road surface condition, friction coefficient, for the left and
right wheels and the load on the wheels are uniform, so there is
no misalignment of the center line of the load to the bucket. The
power from the transmission is divided uniformly to the left and
right by the limited slip differential. Under these conditions, the
limit for wheel slip for the left and right wheels is the same, so
even if the power from the transmission exceeds the wheel slip
limit, the wheels on both sides slip and the differential is not
actuated. No load is applied to the brake at the rear surface of
the side gear.
Whe n There Is Imbalance Between Drive Force of Left and

Right Wheels
! The road surface condition, friction coefficient, for the left and
right wheels and the load on the wheels are not uniform and the
wheel on one side tends to slip more than the wheel on the
other side.
Example 1: When wheel on one side is on soft ground sur-

face during digging operations.
Example 2: W hen wheel on one side is on asphalt surface
and wheel on other side is on snow during snow
clearing operations.
Example 3: When imbalance is created in load on left and
right wheels by traveling on slope.
! The power from the transmission is divided uniformly to the left

and right by the actuating gear. However, if the divided drive
force exceeds the wheel slip limit on the side where the wheel
is slipping, a drive force equal to the excess is sent through the
brake at the rear face of the side gear and the case to the brake
on the opposite side (side where wheel is locked), and si
supplied to the wheel on the side which is locked. If this excess
drive force becomes greater than the braking force, the differen-
tial starts to be actuated.
WA450-3MC 10-49
Difference in wheel drive force for each type of differential when wheel
on one side is slipping.
Wheel drive force

[taken as 1 for wheel that is slipping]
Total
Slipping wheel Locked wheel
[proportional]
Limited slip differential 1 2.64 3.64 [1.53]
Torque proportioning dif-
1 1.38 2.38 [1]
ferential
Normal differential 1 1 2 [0.84]
! On road surfaces where the wheel on one side is likely to slip,

the limited slip differential increases the drive force 1.53 times
that of the torque proportioning differential supplied as standard.
When Turning
The actuating gear built into the limited slip differential is the same
as the gear used on the normal differential, so the difference in
rotation of the inside and outside wheels generated when turning can
be generated smoothly.
10-50 WA450-3MC
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
1. Axle shaft
2. Ring gear, 67 teeth
3. Planet gear, 24 teeth
4. Planetary carrier
5. Sun gear, 17 teeth
6. Wheel
OUTLINE
! The final drive uses a planetary gear mechanism to obtain a

large drive force, and transmits the drive force to the tires.
OPERATION
! The motive force transmitted from the differential to the sun gear
(5) i s t ransmitted to planet gear (3). The planet gear rotates
inside ring gear (2), which is fixed, and transmits the motive
force to wheel (6), which is installed to the planetary carrier.
WA450-3MC 10-51
STRUCTURE AND FUNCTION AXLE MOUNT, CENTER HINGE PIN
AXLE MOUNT, CENTER HINGE PIN
1. Front axle 4. Rear frame 7. Rear axle

2. Front frame 5. Upper hinge pin
3. Rear axle 6. Lower hinge pin
OUTLINE
! Front frame (2) and rear frame (4) are joined by hinge pins (5 and
6) t hrough bearings. In addition, the steering cylinders are
connected to the left and right front and rear frames, and the
angle of articulation of the frame [the turning angle] is adjusted
according to the movement of the cylinders.
10-52 WA450-3MC
STRUCTURE AND FUNCTION STEERING PIPING
STEERING PIPING
1. Main control valve 7. Hydraulic pump
2. Steering valve 8. PPC pump
3. Steering control valve 9. Stop valve
4. Hydraulic tank 10. Steering cylinder (right)
5. Switch pump 11. Steering cylinder (left)
6. Steering pump
WA450-3MC 10-53
STRUCTURE AND FUNCTION STEERING COLUMN
STEERING COLUMN
1. Steering wheel
2. Steering column
3. Joint
4. Steering control valve
10-54 WA450-3MC
STRUCTURE AND FUNCTION STEERING VALVE
STEERING VALVE
1. Safety suction valve A : To steering cylinder

2. Check valve B : To steering cylinder
3. Steering spool Pa : From steering control valve
4. Relief valve Pb : From steering control valve
5. Demand spool P1 : From steering pump
P2 : From switch pump
PB : To main control valve
T : Drain to oil cooler
WA450-3MC 10-55
OPERATION OF DEMAND VALVE
STEERING SPOOL AT NEUTRAL
! The oil from the steering pump enters port A, and the oil from
the switch pump enters port B. When steering spool (2) is at
neutral, pressure receiving chamber (II) is connected to the
drain circuit through orifice b, and notch c is closed. Notch c is
closed, so the pressure of the oil at port A and port B rises and
passes through orifice a, goes to pressure receiving chamber
(I), and moves demand spool (1) to the left in the direction of the
arrow.
! When the pressure at pressure receiving chamber (I) reaches a
certain value [set by spring (5)], notch f opens, and the oil from
the steering pump flows to the drain circuit. At the same time,
notch g closes, and the oil from the switch pump all flows to the
main control valve.
10-56 WA450-3MC
STEERING SPOOL OPERATED
Engine at Low Speed
! When the steering spool (2) is operated, pressure receiving

chamber (II) and the drain circuit are shut off, and at the same
time notch c opens. When this happens, the pressure in the
pressure receiving chamber (II) rises, and demand spool (1)
moves to the right in the direction of the arrow until notch h
clos es. The passage from port B to the main control valve is
shut off, so the oil from the switch pump pushes up merge
chec k valve (3), and merges with the oil at port A from the
steering pump.
! The merged oil passes through notch c and notch d, pushes up
load check valve (4), and flows to the cylinder. The oil returning
from the cylinder passes through notch e and enters the drain
circuit. In this condition, the pressure before passing through
notch c goes to pressure receiving chamber (I), and the
pressure after passing notch c goes to pressure receiving
chamber (II). Demand spool (1) moves to maintain the pressure
difference on the two sides of notch c at a constant value. Ergo,
a flow corresponding to the amount of opening notch c is
discharged from the cylinder port. These pressure differences
[control pressure] are set by spring (5).
WA450-3MC 10-57
Engine at High Speed
! The extra oil from the switch pump is not needed, so the
steering pump pressure rises until notch g closes, and shuts off
the merge passage at port B. The pressure difference on the two
sides of notch c is controlled only by notch f, so the excess oil
from the steering pump is drained from notch f to the drain
circuit. When this happens, notch g is completely closed.
! The oil from the steering pump passes through notch c and
notch d, pushes up load check valve (4), and flows to the
cylinder. The oil returning from the cylinder passes through
notch e and flows to the drain circuit. Notch g is closed, so the
oil from the switch pump is sent from port B to the main control
valve.
10-58 WA450-3MC
STEERING PILOT
1. Steering spool 5. Cap A: From steering control valve

2. Valve housing (body) 6. Capscrew B: From steering control valve
3. Spring seat 7. Flow over notch C: Passage [inside housing]
4. Return spring
SPOOL AT NEUTRAL, STEERING CONTROL VALVE NOT ACTUATED
! When the steering control valve is not actuated, both pilot ports
PiA and PiB are connected through the steering control valve to
the drain circuit, so steering spool (1) is kept at neutral by return
spring (4).
WA450-3MC 10-59
SPOOL ACTUATED, OIL FLOWS TO PORT PiA
! When oil flows to port PiA, the pressure inside the cap at end
A rises and moves steering spool (1) in the direction of the
arrow. The oil entering from port PiA passes through the hole in
spring seat (3), through flow over notch (7) in steering spool (1),
and then flows to the opposite end.
! Port PiB is connected to the drain circuit through the steering
control valve, so the oil flowing to end B is drained. The pressure
generated at port PiA is proportional to the amount of oil flowing
in, so steering spool (1) moves to a position where the opening
of the flow over notch balances the pressure generated with the
force of return spring (4).
10-60 WA450-3MC
SPOOL RETURN, STEERING WHEEL STOPPED, FLOW OF OIL TO PORT PiA CUT
! When the steering wheel is stopped, ports PiA and PiB are both
connected to the drain circuit through the steering control valve.
For this reason, steering spool (1) is returned to the neutral
position by return spring (4).
WA450-3MC 10-61
OPERATION OF STEERING VALVE
NEUTRAL
! The steering wheel is not being operated, so steering spool (1)

does not move.
! The oil from the steering pump enters port A; the oil from the
switch pump enters port B. When the pressure at ports A and
B rises, demand spool (4) moves to the left in the direction of
the arrow. The oil from the steering pump passes through port
C of the spool and is drained. The oil from the switch pump
passes through port D and all flows to the main control valve.
10-62 WA450-3MC
TURNING RIGHT
! When the steering wheel is turned to the right, the pressure oil
from the steering control valve acts on steering spool (1), and
spool moves to the left in the direction of the arrow.
! The oil from the steering pump enters port A, passes through
demand s pool (2), and flows to steering spool (1). It pushes
open load check valve (4) of the spool, and the oil flows to the
bottom end of the left cylinder and the rod end of the right
cylinder to turn the machine to the right. The oil from the left and
right cylinders passes through load check valve (3) of the
steering spool, and is drained. The oil from the switch pump
enters port B, flows through demand spool (2), pushes open
check valve (5), and merges with the oil from the steering pump.
WA450-3MC 10-63
TURNING LEFT
! When the steering wheel is turned to the left, the pressure oil
from the steering control valve acts on steering spool (1), and
spool (1) moves to the right in the direction of the arrow. The oil
from the steering pump enters port A, passes through demand
spool (2), and flows to steering spool (1). It pushes open load
check valve (3) of the spool, and the oil flows to the rod end of
the left cylinder and the bottom end of the right cylinder to turn
the machine to the right.
! The o i l from the left and right cylinders passes through load
check valve (4) of the steering spool, and is drained. The oil from
the switch pump enters port B, flows through demand spool (2),
pushes open check valve (5), and merges with the oil from the
steering pump.
10-64 WA450-3MC
STEERING RELIEF VALVE
FUNCTION
! The steering relief valve is inside the steering valve, and sets the
maximum circuit pressure of the steering circuit when the
s t eering valve is actuated. When the steering valve is being
actuated, if the steering circuit goes above the set pressure of
this valve, oil is relieved from this valve. When the oil is relieved,
the flow control spool of the demand valve is actuated, and the
oil is drained to the steering circuit.
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
WA450-3MC 10-65
OPERATION OF RELIEF VALVE
! When the pressure in the circuit rises, and it reaches the

pressure set by adjustment screw (1) and spring (2), pilot
poppet (4) opens, and the oil is drained. When this happens, the
balance in pressure between pressure receiving chamber (I) and
pressure receiving chamber (II) is lost, so demand spool (6)
moves to the left in the direction of the arrow.
! When demand spool (6) moves, the oil from the steering pump
is drained, and the oil from the switch pump is released to the
main control valve. This prevents the pressure in the steering
circuit from going above the set value.
10-66 WA450-3MC
SAFETY VALVE
FUNCTION
! The overload relief valve is installed to the steering valve. It has

the following two functions: When the steering valve is at neutral,
if any shock is applied to the cylinder, and an abnormal pres-
sure is generated, the oil is relieved from this valve. In this way,
it functions as a safety valve to prevent damage to the cylinder
or hydraulic piping. On the other hand, if negative pressure is
generated at cylinder end, it functions as a suction valve to
prevent a vacuum from forming.
1. Poppet 4. Pilot poppet

2. Relief valve poppet 5. Spring
3. Check valve poppet
OPERATION
Acting as Relief Valve
! Port A is connected to the cylinder circuit and port B is con-

nected to the drain circuit. Oil passes through the hole in poppet
(1) and acts on the different areas of diameters d1 and d2, so
check valve poppet (3) and relief valve poppet (2) are firmly
seated in position.
! When the pressure at port A reaches the set pressure of the

relief valve, pilot poppet (4) opens. The oil flows around pilot
poppet (4), passes through the drill hole, and flows to port B.
! When pilot poppet (4) opens, the pressure at the back of poppet
(1) drops, so poppet (1) moves and is seated with pilot poppet
(4).
WA450-3MC 10-67
! Compared with the pressure at port A, the internal pressure is

low, so relief valve poppet (2) opens. When this happens, the oil
flows from port A to port B, and prevents any abnormal pressure
from forming.
Acting as Suction Valve
! When negative pressure is formed at port A, the difference in

area of diameters d3 and d4 causes check valve poppet (3) to
open. When this happens, the oil from port B flows to port A,
and prevents any vacuum from forming.
10-68 WA450-3MC
STRUCTURE AND FUNCTION STEERING CONTROL VALVE
STEERING CONTROL VALVE
1. Needle bearing 5. Rotor 9 Spool

2. Center spring 6. Cover 10. Stator
3. Drive shaft 7. Center pin 11. Lower cover
4. Valve body 8. Sleeve 12. Check valve
WA450-3MC 10-69
OUTLINE
! The steering control valve is connected directly to the shaft of

the steering wheel. It switches the flow of oil from the steering
pump to the left and right steering cylinders to determine the
direction of travel of the machine.
! The steering valve consists of the following components: rotary
type spool (3) and sleeve (5), which have the function of select-
ing the direction, and the rotor set (8 and 9), which acts as a
hydraulic motor during normal steering operations.
STRUCTURE
! Spool (3) is directly connected to the drive shaft of the steering

wheel, and is connected to sleeve (5) by center pin (4) [it does
not contact the spool when the steering wheel is at neutral] and
centering spring (12). The top of drive shaft (6) is meshed with
c enter pin (4), and forms one unit with sleeve (5), while the
bottom of the drive shaft is meshed with the spline of rotor (8) of
the rotor.
! There are four ports in valve body (2), and they are connected to
the pump circuit, tank circuit, and the circuits at the head end
and bottom end of the steering cylinders. The pump port and
tank port are connected by the check valve inside the body. If
the pump or engine fail, the oil can be sucked in directly from
the tank by this check valve.
10-70 WA450-3MC
CONNECTION BETWEEN HAND PUMP AND SLEEVE
! The diagrams above show the connections with the sleeve ports
used to connect the suction and discharge ports of the rotor. If
the steering wheel has been turned to the right, ports a, c, e, g,
i, and k are connected by the vertical grooves in the spool to the
pump side. At the same time, ports b, d, f, h, j, and l are
connected to the head end of the left steering cylinder in the
same way. In the condition in Figure 1, ports 1, 2, and 3 are the
discharge ports of the rotor set. They are connected to ports l,
b, and d, so the oil is sent to the cylinder. Ports 5, 6, and 7 are
connected and the oil flows in from the pump.
! Ifthe steering wheel is turned 90E, the condition changes to the
condition shown in Figure 2. In this case, ports 1, 2, and 3 are
the suction ports, and are connected to ports i, k, and a. Ports
5, 6, and 7 are the discharge ports, and are connected to ports
d, f, and h.
! In this way, the ports of the rotor acting as delivery ports are
connected to ports which are connected to the end of the
steering valve spool. The ports acting as suction ports are
connected to the pump circuit.
WA450-3MC 10-71
! Adjusting delivery in accordance with angle of steering wheel:

For every 1/7 turn of the steering wheel, the inner teeth of the
rotor gear advance one position so the oil flow from the pump
i s adjusted by this movement. In this way, the oil delivered
from the pump is directly proportional to the amount the
steering wheel is turned.
FUNCTION OF CENTER SPRING
! Centering spring (12) consists of four layers of leaf springs

c rossed to form an X shape. The springs are assembled in
spool (3) and sleeve (5) as shown in the diagram on the right.
! When the steering wheel is turned, the spring is compressed
and a difference in rotation (angle variation) arises between the
spool and the sleeve. Because of this, the ports in the spool and
sleeve are connected and oil is sent to the cylinder. When the
turning of the steering wheel is stopped, the rotor also stops
t urning, so no more oil is sent to the cylinder and the oil
pressure rises.
! To prevent this, when the turning of the steering wheel si

stopped, the action of the centering spring only allows it to turn
by an amount equal to the difference in angle of rotation of the
s l eeve and spool, so the steering wheel returns to NEUTRAL
position.
10-72 WA450-3MC
STRUCTURE AND FUNCTION STOP VALVE
STOP VALVE
1. Boot A : From steering control valve

2. Wiper B : To steering valve
3. Seal DR : To drain
4. Poppet
5. Spring
6. Spool
7. Spring
WA450-3MC 10-73
STRUCTURE AND FUNCTION GROUND DRIVEN STEERING PUMP
GROUND DRIVEN STEERING PUMP
1. Drive gear SPECIFICATIONS

2. Front cover Model . . . . . . . . . . . . . . . . . . . . . . . . . . . SAM (2)-050
3. Gear case Direction of revolution . . . . . . . . . . . . . . Both directions
4. Rear cover Theoretical delivery . . . . . . . . . . . . . . . . . . . . 51 cc/rev
5. Driven gear Max. delivery pressure . . . . . . . . . . . . . . . . 210 kg/cm 2
10-74 WA450-3MC
STRUCTURE AND FUNCTION DIVERTER VALVE
DIVERTER VALVE
1. Diverter valve C. To hydraulic tank

2. Valve body D. Sensor mounting port
3. Check valve E. Pump port
4. Check valve F. Pump port
A. From steering pump G. From hydraulic tank
B. To steering valve
FUNCTION
! Ifthe engine stops or the pump seizes during machine traveling,
and it becomes impossible to steer, the rotation of the transmis-
sion is used to turn the ground driven steering pump to make
steering possible.
WA450-3MC 10-75
OPERATION
PUMP AND ENGINE ARE WORKING NORMALLY
! When the steering pump and engine are working

normally, the hydraulic pump, steering pump, and
switch pump are rotated by the engine. Therefore, oil
is sent to the steering valve, and the machine can be
steered. In addition, the ground driven steering pump
is rotated by the transmission, so oil from port A of
the diverter valve pushes open check valve (2) and
enters port B. Pressure oil from the steering pump is
flowing to port D, so it pushes spool (3) in the direc-
tion of the arrow. As a result, the oil from port B flows
to port C and is drained to the hydraulic tank.
10-76 WA450-3MC
FAILURE IN PUMP OR ENGINE WHEN MACHINE IS TRAVELING
! If there is a failure in the pump or engine when the machine is

traveling, the rotation of the wheels is transmitted through the
transfer to rotate the ground driven steering pump. The steering
pump is not rotating, so no pressure oil is formed at port D. As
a result, spool (3) is pushed in the direction of the arrow by
spring (4). The oil from the ground driven steering pump passes
from port A through port B and flows to the steering valve to
make steering possible.
i The ground driven steering pump is designed so that it can

rotate both directions.
WA450-3MC 10-77
STRUCTURE AND FUNCTION BRAKE PIPING
BRAKE PIPING
1. Right brake valve 7. Accumulator 13. Parking brake

2. Hydraulic oil tank 8. Slack adjuster 14. Left brake valve
3. Parking brake switch 9. Rear brake 15. Front brake
4. Emergency cancel switch 10. PPC brake pump 16. Slack adjuster
5. Rear brake 11. Transmission control valve 17. Front brake
6. Charge valve 12. Parking brake valve
10-78 WA450-3MC
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM
BRAKE CIRCUIT DIAGRAM
1. Work equipment pump 14. Transmission cut off switch

2. PPC and brake pump 15. Right brake valve
3. Strainer 16. Pilot light switch
4. Accumulator charge valve Cut in . . . . . 60 kg/cm 2 17. Rear slack adjuster
Cut out . . 100 kg/cm 2 18. Front slack adjuster
5. Safety relief valve . . . . . . . . . . . . . . . . 140 kg/cm 2 19. Emergency parking brake valve
6. PPC relief valve . . . . . . . . . . . . . . . . . . 38 kg/cm 2 20. Parking brake emergency release solenoid
7. Filter with by pass valve 21. Parking brake emergency release switch
8. Check valve 22. Parking brake
9. Low pressure switch 23. Parking brake pilot light switch
10. Rear brake accumulator 24. Parking brake solenoid
11. Front brake accumulator 25. Parking brake valve
12. Emergency brake switch 26. Transmission pump
13. Left brake valve 27. Parking brake switch
WA450-3MC 10-79
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
RIGHT BRAKE VALVE
1. Brake pedal, left or right brake 9. Spool, left brake

2. Rod, right brake 10. Cylinder, left brake
3. Pilot piston, right brake A Pilot port, right brake
4. Spool, right brake B To rear brake, right brake
5. Upper cylinder, right brake C To front brake, right brake
6. Spool, right brake D Drain, left or right brake
7. Lower cylinder, right brake E To pilot port, left brake
8. Rod, left brake
10-80 WA450-3MC
LEFT BRAKE VALVE
OUTLINE
! There are two brake valves installed in parallel under the front of
t he operators cab, and these are actuated by depressing the
pedal. When the right pedal is depressed, oil is sent to the
brake cylinder to apply the brakes.
! When the left pedal is depressed, oil is sent to the right pedal
to apply the brakes in the same way as when the right pedal is
depressed. In addition, the left brake pedal operates the
transmission cut off switch to actuate the transmission solenoid
valve electrically and set the transmission to neutral.
WA450-3MC 10-81
OPERATION
BRAKE APPLIED, RIGHT BRAKE VALVE
Upper Portion
! W hen brake pedal (1) is depressed, the operating force si

transmitted to spool (3) through rod (2) and spring (4). When the
spool (3) goes down, drain port a is closed, and the oil from the
pump and accumulator flows from port A to port C and actuates
the rear brake cylinders.
Lower Portion
! W hen brake pedal (1) is depressed, the operating force si

transmitted to spool (3) through rod (2) and spring (4). When
spool (3) goes down, spool (5) is also pushed down by plunger
(6). When this happens, drain port b is closed, and the oil from
the pump and accumulator flows from port B to port D and
actuates the front brake cylinders.
BRAKE APPLIED, LEFT BRAKE PEDAL
! When pedal (7) is depressed, spool (10) is pushed up by rod (8)

and spring (9), and drain port c is closed. The oil from the pump
and the accumulator flows from port E to port F. Port F of the left
brake valve and port Pp of the right brake valve are connected by
a hose, so the oil flowing to port F flows to pilot port Pp of the
right brake valve. The oil entering pilot port Pp enters port G from
orifice d, and pushes piston (11). The spring pushes spool (3)
down, s o the operation is the same as when the right brake
valve is depressed.
10-82 WA450-3MC
APPLYING BRAKE WHEN UPPER VALVE FAILS

Right brake valve
! Even if there is leakage of oil in the upper piping, spool (5) is

moved down mechanically when pedal (1) is depressed, and the
lower portion is actuated normally. The upper brake is not
actuated.
APPLYING BRAKE WHEN LOWER VALVE FAILS

Right brake valve
! Even if there is leakage of oil in the lower piping, the upper

portion is actuated normally.
WHEN ACTUATION IS BALANCED
Upper Portion
When oil fills the rear brake cylinder and the pressure between port
A and port C becomes high, the oil entering port H from orifice e of
spool (3) pushes against spring (4). It pushes up spool (3) and shuts
off the circuit between port A and port C. When this happens, drain
port a stays closed, so the oil entering the brake cylinder is held and
the brake remains applied.
Lower portion
! When spool (3) in the upper portion moves up and the circuit
between port A and port C is shut off, oil also fills the front brake
cylinder at the same time, so the pressure in the circuit between
port B and port D rises. The oil entering port J from orifice f of
spool (5) pushes up spool (5) by the same amount that spool (3)
moves, and shuts off port B and port D. Drain port b is closed,
so the oil entering the brake cylinder is held, and the brake is
applied.
! The pressure in the space in the upper portion is balanced with

the operating force of the pedal, and the pressure in the space
in the lower portion is balanced with the pressure in the space
in the upper portion. When spools (3) and (5) move to the end of
their stroke, the circuits between ports A and C and between
ports B and D are fully opened, so the pressure in the space in
the upper and lower portions and the pressure in the left and
right brake cylinders is the same as the pressure from the
pump. Therefore, up to the point where the piston moves to the
end of its stroke, the effect of the brake can be adjusted by the
amount that the pedal is depressed.
WA450-3MC 10-83
BRAKE RELEASED
Right brake valve
Upper Portion
! When pedal (1) is released and the operating force is removed

from t h e top of the spool, the back pressure from the brake
cylinder and the force of the spool return spring move spool (3)
up. Drain port a is opened and the oil from the brake cylinder
flows to the hydraulic tank return circuit to release the rear
brake.
Lower Portion
! When the pedal is released, spool (3) in the upper portion moves
up. At the same time, the back pressure from the brake cylinder
and the force of the spool return spring move spool (3) up. Drain
port b is opened and the oil from the brake cylinder flows to the
hydraulic tank return circuit to release the front brake.
10-84 WA450-3MC
STRUCTURE AND FUNCTION ACCUMULATOR CHARGE VALVE
ACCUMULATOR CHARGE VALVE
FUNCTION
! The ac cumulator charge valve is actuated to maintain the oil

pressure from the pump at the specified pressure and to store
it in the accumulator.
! When the oil pressure reaches the specified pressure, the oil
from the pump is connected to the drain circuit to reduce the
load on the pump.
A : To PPC valve
ACC : To brake valve
PP : To brake valve
P : From pump
T: Drain
WA450-3MC 10-85
1. Valve body
2. Main relief valve, R3
3. Relief valve, R1
4. PPC relief valve, R2
5. Relief valve, H1
10-86 WA450-3MC
OPERATION
When No Oil Is Being Supplied to Accumulator
CUT OUT CONDITION
! The pressure at port B is higher than the set pressure of the

relief valve R1, so piston (8) is forcibly pushed up by the oil
pressure at port B. Poppet (6) is opened, so port C and port T
are short circuited.
! The spring chamber at the right end of spool (15) is connected

to port C of the relief valve R1, so the pressure becomes the tank
pressure. The oil from the pump enters port P, pushes spool
(15) to the right at a low pressure equivalent to the load on
spring (14), and flows from port A to the PPC valve. At the same
time, it also passes through orifices (17), (18), and (16), and
flows to the tank.
When Oil Is Supplied to Accumulator
CUT IN CONDITION
! When the pressure at port B is lower than the set pressure of

the relief valve R1, piston (8) is pushed back down by spring (5).
Valve seat (7) and poppet (6) are brought into tight contact, and
port C and port T are shut off.
! The spring chamber at the right end of spool (15) also is shut
off from port T, so the pressure rises, and the pressure at port
P also rises in the same way.
! When the pressure at port P goes above the pressure at port B,

accumulator pressure, the supply of oil to the accumulator
starts immediately. In this case, it is decided by the size of
orifice (17) and the pressure difference, equivalent to the load on
spring (14), generated on both sides of the orifice. A fixed
amount is supplied regardless of the engine speed, and the
remaining oil flows to port A.
WA450-3MC 10-87
WHEN CUT OUT PRESSURE IS REACHED
! When the pressure at port B, accumulator pressure, reaches

the set pressure of the relief valve R1, poppet (6) separates from
valve seat (7), so an oil flow is generated and the circuit is
relieved.
! W hen the circuit is relieved, a pressure differential [)P] is

generated above and below piston (8), so piston (8) moves up,
poppet (6) is forcibly opened, and port C and port T are short
circuited.
! The spring chamber at the right end of spool (15) is connected

to port C of the relief valve R1, so the pressure becomes the tank
pressure.
! The pressure at port P drops in the same way to a pressure

equivalent to the load on spring (14), so the supply of oil to port
B is stopped.
Safety Relief Valve, R3
! If the pressure at port P, pump pressure, goes above the set

pressure of the relief valve R3, the oil from the pump pushes
spring (3). Ball (11) is pushed up and the oil flows to the tank
circuit, so this sets the maximum pressure in the brake circuit
and protects the circuit.
10-88 WA450-3MC
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR
1. Valve
2. Top cover
3. Cylinder
4. Piston
FUNCTION
! The accumulator is installed between the charge valve and the

brake valve. It is charged with nitrogen gas between cylinder (3)
and free piston (4), and uses the compressibility of the gas to
absorb the pulse of the hydraulic pump or to maintain the
braking force and to make it possible to operate the machine if
the engine should stop.
SPECIFICATIONS
Gas used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nitrogen gas

Charge amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 cc
Charging pressure . . . . . . . . . . . . . . . 35 ± 1.5 kg/cm 2 @ 50E C
WA450-3MC 10-89
STRUCTURE AND FUNCTION SLACK ADJUSTER
SLACK ADJUSTER
1. Bleeder 5. Spring
2. Cylinder
3. Check valve A. Inlet port
4. Piston B. Outlet port
FUNCTION
! The slack adjuster is installed in the brake oil line from the brake
valve to the brake piston. It provides a fixed time lag when the
brake is applied.
SPECIFICATIONS
Piston actuation pressure: . . . . . . . . . . . . . . . . . 0.1 + 00.1 kg/cm 2

Check valve cracking pressure . . . . . . . . . . . . 9.5 ± 0.5 kg/cm 2
Check valve closing pressure . . . . . . . . . . . . . . . 6 ± 0.5 kg/cm 2
10-90 WA450-3MC
STRUCTURE AND FUNCTION SLACK ADJUSTER
OPERATION
When Brake Pedal Is Depressed
! Before the brake is depressed, piston (4) is returned by the

distance of full stroke S. When the brake pedal is depressed, oil
discharged from the brake valve flows from port P of the slack
adjuster and is divided to left and right cylinders (2), where it
moves piston (4) by stroke S to the left and right.
! When this is done, brake piston (7) moves by a distance of

stroke S. In this condition, the closer the clearance between the
brake piston and disc is to zero, the greater the braking force
becomes.
! If the brake pedal is depressed further, and the oil pressure

discharged from the brake valve goes above the set pressure,
check valve (3) opens and the pressure is applied to port C to
act as the braking force. Therefore, when the brake is applied,
the time lag is a fixed value.
When Brake Pedal Is Released
! When the brake is released, piston (4) is returned by brake

return spring (8) by an amount equivalent to the oil for stroke S,
and the brake is released. In other words, return stroke T of
brake piston (7) is determined by the amount of oil for stroke S
of the slack adjuster. The time lag of the brake is always kept
constant regardless of the wear of the brake disc.
WA450-3MC 10-91
STRUCTURE AND FUNCTION BRAKE
BRAKE
1. Guide pin 5. Outer gear, 138 teeth

2. Return spring 6. Inner gear, 105 teeth
3. Cylinder 7. Plate
4. Brake piston 8. Disc
10-92 WA450-3MC
STRUCTURE AND FUNCTION BRAKE
FUNCTION
! Servi ce brakes are wet type, multiple-disc brakes and are

installed to all four wheels.
OPERATION
! When the brake pedal is depressed, the pressure oil from the
brake valve moves brake piston (4) to the right in the direction of
the arrow. This brings disc (8) and plate (7) into contact, and
friction is generated between the disc and plate. The wheel is
rotating together with the disc, so the machine speed is reduced
and the machine is stopped by this friction.
! When the brake pedal is released, the pressure at the back face
of brake piston (4) is released, so the piston is moved to the left
in the direction of the arrow by the force of return spring (2), and
the brake is released.
WA450-3MC 10-93
STRUCTURE AND FUNCTION PARKING BRAKE CONTROL
PARKING BRAKE CONTROL
1. Parking brake switch 4. Parking brake solenoid valve

2. Parking brake emergency release switch 5. Transmission, built in parking brake
OUTLINE
! The parking brake is a wet type multiple disc brake built into the
transmission. It is installed to the output shaft bearing, and uses
the pushing force of a spring to apply the brake mechanically
and hydraulic power to release the brake. When parking brake
switch (1) installed in the operators compartment is switched
ON, parking brake solenoid valve (4) installed to transmission
control valve (3) shuts off the oil pressure and applies the
parking brake. When the parking brake switch is turned OFF,
the oil pressure in the cylinder releases the parking brake.
! When the parking brake is applied, the neutralizer relay shuts
off the electric current to the transmission solenoid valve and
keeps the transmission at neutral. Emergency release switch
(2) for the parking brake is installed for use when moving the
mac hine if it has stopped, the parking brake is automatically
applied, because of trouble in the engine or drive system.
10-94 WA450-3MC
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
1. Output shaft 2. Disc 3. Plate 4. Piston 5. Spring
OUTLINE
! The parking brake is wet type multiple disc brake. It is actuated

mechanically by a spring and applies the braking force to output
shaft (1) of the transmission.
! The pushing force of spring (5) pushes piston (4) and plate (3)
and disc (2) into contact and applies the braking force to stop
output shaft (1).
WA450-3MC 10-95
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE
1. Coil
2. Valve
3. Spring
4. Body
A. IN port
B. OUT port
FUNCTION
! This solenoid valve is controlled by the parking brake switch in

the operators compartment and acts to switch the flow of oil to
the parking brake.
OPERATION
Parking Brake Applied
! When the parking brake switch in the operators compartment is

turned ON, the solenoid valve is turned OFF, electric current is
cut, and the oil in the pilot circuit from the transmission pump
flows from the IN port to the OUT port and opens the drain
circuit.
Parking Brake Released
! When the parking brake switch in the operators compartment is

turned OFF, the solenoid valve is turned ON, electric current
flows. The valve closes and the flow of oil in the pilot circuit to
the drain circuit is shut off.
10-96 WA450-3MC
STRUCTURE AND FUNCTION PARKING BRAKE VALVE
PARKING BRAKE VALVE

FUNCTION
! The parking brake valve is installed inside the transmission

control valve and lower valve, and controls the parking brake
cylinder.
OPERATION
Parking Brake Applied
! When the parking brake switch is turned ON, solenoid valve (1)
is turned OFF and the drain circuit is opened. The oil in the pilot
circuit from the pump then flows to drain circuit.
! The oil in the main circuit is shut off by spool (2), and the oil in
t he brake cylinder flows to the drain circuit. Therefore, the
parking brake is applied by the force of the spring in the parking
brake cylinder.
Parking Brake Released
! When the parking brake switch is turned OFF, solenoid valve (1)
i s turned ON, and the drain circuit is closed. When the oil
pressure at port a rises, it pushes against spring (3) and moves
spool (2) to the right in the direction of the arrow. This shuts off
the drain circuit of the brake cylinder, so the oil from the main
circuit flows from port b to port c to actuate the brake cylinder
and release the parking brake.
WA450-3MC 10-97
STRUCTURE AND FUNCTION PBER SOLENOID VALVE
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE

1. Valve
2. Solenoid valve
A : To parking brake
B : From parking brake valve
C : From pilot circuit
T : Drain
P : From brake, accumulator circuit
FUNCTION
! The emergency release solenoid valve is installed between the

transmission and the transmission control valve. If the engine
fails, and no oil pressure is supplied from the transmission
pump, it is possible to actuate the solenoid for the parking brake
release switch in the operator's compartment. This allows the
accumulator charge pressure in the brake circuit to flow to the
parking brake cylinder.
OPERATION
! When parking brake emergency release switch â is turned ON,

solenoid valve ã is actuated and the pressure stored in accumu-
lator ä enters from port P. The circuit is switched by the pilot
pressure, so the oil flows from port A to the parking brake to
release the parking brake.
10-98 WA450-3MC
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
1. Main control valve 10. Accumulator

2. Bucket cylinder 11. Radiator
3. Steering valve 12. Hydraulic pump
4. Hydraulic tank 13. PPC, brake pump
5. PPC valve 14. Steering cylinder
6. Solenoid valve 15. Boom cylinder
7. Switch pump 16. Ground driven steering pump
8. Steering pump 17. Diverter valve
9. Check valve
WA450-3MC 10-99
STRUCTURE AND FUNCTION HYDRAULIC PIPING
OUTLINE
! The hydraulic system consists of work equipment circuit and the

steering circuit. The work equipment circuit controls the
actuation of in the bucket and attachments.
! The oil in hydraulic tank (4) is sent to main control valve (1) by
hydraulic pump (12). If the spools for the bucket and boom in the
main control valve are at the HOLD position, the oil flows to the
drain circuit of the main control valve, is filtered by the filter
inside the hydraulic tank, and then returns to the tank.
! When the work equipment control levers are operated, the PPC
valve bucket spool or boom spool is actuated, and the spools of
the main control valve are actuated by hydraulic pressure to
send the oil from the main control valve to boom cylinder (15) or
bucket cylinder (2) to operate the boom or bucket.
! Control of the maximum pressure in the hydraulic circuit is

carried out by the relief valve inside the main control valve. A
safety suction valve is installed in the bucket cylinder circuit to
protect the circuit.
! Accumulator (10) is installed in the PPC pilot circuit, and makes

it pos sible to lower the boom to the ground even when the
engine has stopped.
! Hydraulic tank (4) is a pressurized sealed type and has a

breather equipped with a relief valve. This makes it possible to
pressurize the inside of the tank and also to prevent negative
pressure, thereby preventing cavitation of the pump.
10-100 WA450-3MC
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULICS
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
1. Hydraulic tank
2. Oil filter
3. Breather
4. Converter charge pump
5. Equipment pump
6. PPC brake pump
7. Steering pump
8. Switch pump
9. Filter
10. Accumulator charge valve
11. Accumulator
12. PPC valve
13. Steering valve
14. Flow control valve
15. Relief valve
16. Steering spool
Over
17. Load relief suction valve
18. Steering cylinder
19. Steering control valve
20. Cut off valve
21. Relief valve
22. Bucket spool
23. Safety suction valve
24. Float selector valve
25. Unload valve
26. Boom spool
27. Suction valve
28. Slow return valve
29. Lift cylinder
30. Dump cylinder
31. Oil cooler
32. Flow switch
33. Stop valve
34. Emergency steering pump
35. Divider valve
WA450-3MC
10-101
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULICS
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
Conditions: Engine at low idle, work equipment control levers at hold
10-102 WA450-3MC
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT LEVER LINKAGE
1. Boom lever 7. Attachment lever

2. Kick down switch 8. Solenoid valve for bucket lever
3. Hold switch 9. Solenoid valve for boom lever
4. Cancel for load meter 10. Safety lever
5. Bucket lever 11. PPC valve
6. Subtotal switch for load meter
WA450-3MC 10-103
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
1. Filter suction valve 4. Oil filler
2. Oil filter 5. Sight gauge
3. Breather 6. Hydraulic tank
10-104 WA450-3MC
STRUCTURE AND FUNCTION HYDRAULIC TANK
BREATHER
PREVENTING NEGATIVE PRESSURE INSIDE TANK
! The tank is a pressured sealed type, so if the oil level inside the
tank goes down, there will be a negative pressure in the tank.
If this happens, a poppet is opened by the difference between
the pressure inside the tank and the atmospheric pressure, and
air is let in to prevent negative pressure from forming inside the
tank.
PREVENTING RISE IN PRESSURE INSIDE TANK
! Ifthe pressure in the circuit rises above the set pressure during
operations because of the change in oil level in the hydraulic
cylinders or the rise in the temperature, the sleeve is actuated
to release the pressure in side the tank.
1. Body
2. Filter element
3. Poppet
4. Sleeve
WA450-3MC 10-105
STRUCTURE AND FUNCTION PPC VALVE
PPC VALVE
P : From PPC tank P3 : To boom cylinder bottom end

P1 : To bucket cylinder bottom end P4 : To bucket cylinder head end
P2 : To boom cylinder head end T : Drain
10-106 WA450-3MC
1. Bolt
2. Piston 4. Collar 7. Metering spring
3. Plate 5. Retainer 8. Valve
6. Centering spring 9. Body
FUNCTION
! The PPC valve is installed at the bottom of the work equipment

control lever and is connected by a linkage to the control lever.
Oil from the PPC pump flows to the end of each spool of the
main control valve in accordance with control lever movements,
and this actuates the spool. Thus, operating force of the control
lever is small to reduce operator fatigue.
OPERATION OF PPC VALVE

(At neutral)
The oil from the pump enters port P. The circuit is closed valve is drained from port f of spool (8). In addition, the oil
by spool (8), so the oil is drained from relief valve (1). At at port PB1 is drained from port g of spool (10).
the s ame time, the oil at port PA1 of the main control
WA450-3MC 10-107
FUNCTION OF PPC VALVE
The PPC valve supplies oil under pressure from the charging pump
to the side face of the spool of each control valve, according to the
amount of travel of the control lever. This pressure oil actuates the
spool.
OPERATION
Control Lever at Hold
Ports P A 1, P4, PB1 and P1 are connected to drain chamber D

through fine control hole f in valve (8).
Control Lever Operated Slightly, Fine Control
! When piston (2) starts to be pushed by plate (10), retainer (5) is

pushed. Valve (8) is also pushed by spring (7) and moves down.
When this happens, fine control hole f is shut off from drain
chamber D. At almost the same time it is connected to pump
pressure chamber PP, and the pilot pressure of the control valve
is sent through fine control hole f to port P4. When the pressure
at port P4 rises, valve (8) is pushed back. Fine control hole f is
shut off from pump pressure chamber PP. At almost the same
time it is connected to drain chamber D, so the pressure at port
P4 escapes to drain chamber D. Valve (8) moves up and down
until the force of spring (7) is balanced with the pressure of port
P4.
! The position of valve (8) and body (9), when fine control hold f is
midway between drain chamber D and pump pressure chamber
P P , does not change until the head of valve (8) contacts the
bottom of piston (2). Ergo, spring (7) is compressed in propor-
tion to the travel of the control lever, so the pressure at port P4
also rises in proportion to the travel of the control lever. The
spool of the control valve moves to a position where the pressure
of port PA1 (same as pressure at port P4) and the force of the
return spring of the control valve are balanced.
10-108 WA450-3MC
Control Lever Moved Back from Slightly Operated Position to

Hold, Fine Control
! When plate (10) starts to be pushed back, piston (2) is pushed

up by a force corresponding to the force of centering spring (6)
and the pressure at port P4. At the same time, fine control hole
f of valve (8) is connected to drain chamber D, so the oil at port
P4 escapes. If the pressure at port P4 drops too far, valve (8) is
pushed down by spring (7). Fine control hole f is shut off from
drain chamber D, and at almost the same time it is connected
to pump pressure chamber PP. The pump pressure is supplied
until the pressure at port PA1 returns to a pressure equivalent to
the position of the lever.
! When the spool of the control valve returns, the oil in drain
chamber D flows in from fine control hole f1 of the valve which
has not moved. The extra oil then flows through port P1 to
chamber PB1.
Control Lever Operated to End of Travel
! Plate(10) pushes piston (2) down, and piston (2) forcibly pushes
in valve (8). Fine control hole f is shut off from drain chamber D
and is connected to pump pressure chamber PP. Ergo, pressure
oil from the charging pump passes through fine control hole f
and flows from port P4 to chamber PA1 to push the spool of the
control valve. The oil returning from chamber PB1 flows from port
P1 through fine control hole f1 to drain chamber D.
WA450-3MC 10-109
STRUCTURE AND FUNCTION PPC RELIEF VALVE
PPC RELIEF VALVE
1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw
FUNCTION
! The PPC relief valve is between the PPC, brake pump and the
PPC valve. When the PPC pump is not being actuated, or when
any abnormal pressure is generated, the oil sent from the pump
is relieved from this valve to prevent any damage to the pump or
circuit.
OPERATION
! The relief valve is installed to the charge valve. Port A is con-

nected to the pump circuit and port C is connected to the drain
circuit. The oil passes through the orifice in main valve (1) and
fills port B. In addition, pilot poppet (4) is seated in valve seat
(3).
! When the pressure at port A and port B reaches the set

pressure, pilot poppet (4) opens and the oil pressure at port B
escapes from port D to port C to lower the pressure at port B.
! When pressure at port B goes down, a difference in pressure is

generated at ports A and B by the orifice of main valve (1). Main
valve (1) is opened by the pressure at port A and the oil at port
A is drained to port C to relieve the circuit.
10-110 WA450-3MC
STRUCTURE AND FUNCTION PPC VALVE ACCUMULATOR
PPC VALVE ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
SPECIFICATIONS
Type of gas . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . Nitrogen

Gas amount . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . 500 cc
Max. actuation pressure .. . . . . . . . . . . . . . . . . . . . 35 kg/cm 2
Min. actuation pressure ... . . . . . . . . . . . . . . . . . . . 12 kg/cm 2
FUNCTION
! The accumulator is installed between the hydraulic pump and

the P P C valve. Even if the engine stops when the boom is
raised, it is possible to lower the boom and bucket under their
own weight by using the pressure of the nitrogen gas com-
pressed inside the accumulator to send the pilot oil pressure to
actuate the main control valve.
OPERATION
! After the engine stops, if the PPC valve is at hold, chamber A

inside the bladder is compressed by the oil pressure in chamber
B.
! When the PPC valve is operated, the oil pressure in chamber B
goes below 30 kg/cm 2. When this happens, the bladder si
expanded by the pressure of the nitrogen gas in chamber A, and
the oil inside chamber B is used as the pilot pressure to actuate
the main control valve.
WA450-3MC 10-111
STRUCTURE AND FUNCTION CUT OFF VALVE
CUT OFF VALVE
FUNCTION 1. Unload valve

2. Check valve
! The cut off valve is installed between the switch pump and the 3. Cut off relief valve
main c ontrol valve. Depending on the operating conditions, it 4. Screen
switches oil from the switch pump to the main control valve or to
the drain circuit. The cut off valve is operated by hydraulic C. From pump
pressure. P. From steering valve
T1. To tank
T2. To tank
10-112 WA450-3MC
STRUCTURE AND FUNCTION CUT OFF VALVE
OPERATION
CUT OFF OPERATION CONDITIONS
# : Cut off, drain

$ : Not actuated, to main control valve
More than 140 kg/cm2 Less than 140 kg/cm2

# $
MAIN CONTROL VALVE AT HOLD
! The oil from the switch pump [the oil from the steering valve]
pushes up check valve (2), merges with the oil from the hydrau-
lic pump and flows to the main control valve.
MAIN CONTROL VALVE ACTIVATED
When Hydraulic Pump Pressure Is Lower than Cut off Pressure

! In the same way at when the main control valve is at hold, the
oil at the switch pump [the oil from the steering valve] presses
up check valve (2), merges with the oil from the hydraulic pump
and flows to the main control valve.
When Hydraulic Pump Pressure Is Higher than Cut off Pressure

! Cut off relief valve (3) opens and the pilot oil flows in the direction
of the arraow. When this happens, a difference in pressure [)P]
is generated between P2 and P1, so unload valve (1) is open.
Ergo, t he oil from the switch pump [the oil from the steering
valve] is drained.
WA450-3MC 10-113
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE - TWO SPOOL [1/2]
PA1 : From PPC valve P4 A1 : To dump cylinder rod end

PA2 : From PPC valve P2 A2 : To lift cylinder rod end
PB1 : From PPC valve P1 B1 : To dump cylinder head end
PB2 : From PPC valve P3 B2 : To boom cylinder head end
P : From pump D1 : Drain port
P1 : From PPC valve P2 D2 : Drain port
P2 : From PPC valve P3 T : Drain port
10-114 WA450-3MC
[2/2]
1. Main relief valve 6. Valve body

2. Bucket spool return spring 7. Suction valve
3. Boom spool return spring 8. Unload valve
4. Boom spool 9. Float selector valve
5. Bucket spool 10. Safety suction valve
WA450-3MC 10-115
MAIN CONTROL VALVE - THREE SPOOL [1/2]
MA1 : From PPC valve B1 : To dump cylinder head end

MA2 : From PPC valve B2 : To boom cylinder head end
MA3 : From PPC valve B3 : To boom cylinder head end
MB1 : From PPC valve P : From pump
MB2 : From PPC valve D1 : Drain port
MB3 : From PPC valve D2 : Drain port
A1 : To dump cylinder rod end T : Drain port
A2 : To lift cylinder rod end
A3 : To attachment cylinder rod end
10-116 WA450-3MC
[2/2]
1. Main relief valve 7. Check valve

2. Attachment spool 8. Unload valve
3. Bucket spool 9. Suction valve
4. Boom spool 10. Safety suction valve
5. Return spring 11. Float selector valve
6. Valve body
WA450-3MC 10-117
RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
FUNCTION
! The relief valve is installed to the inlet portion of the main control
valve. If the oil goes above the set pressure, the relief valve
drains the oil to the tank to set the maximum pressure for the
work equipment circuit, and to protect the circuit.
OPERATION
! Port A is connected to the pump circuit and port C is connected

to the drain circuit. The oil passes through the orifice in main
valve (1), and fills port B. Pilot poppet (3) is seated in valve seat
(2).
! Ifthe pressure inside ports A and B reaches the set pressure of

pilot poppet spring (4), pilot poppet (3) opens and the oil
pressure at port B escapes from port D to port C, so the
pressure at port B drops.
! When the pressure at port B drops, a difference in pressure

between ports A and B is created by the orifice of main valve (1).
The main valve is pushed open and the oil at port A passes t-
hrough port C, and the abnormal pressure is released to the
drain circuit.
! The set pressure can be changed by adjusting the tension of

pilot poppet spring (4). To change the set pressure, remove the
cap nut, loosen the locknut, then turn adjustment screw (5) to
adjust the set pressure as follows:
TIGHTEN to INCREASE pressure
LOOSEN to DECREASE pressure
10-118 WA450-3MC
SAFETY SUCTION VALVE
1. Suction valve 4. Pilot piston

2. Main valve 5. Suction valve spring
3. Main valve spring 6. Valve body
FUNCTION
The safety valve is in the bucket cylinder circuit inside main control
valve. If any abnormal pressure is generated by any shock to the
cylinder when the main control valve is at neutral position, this valve
relieves the abnormal pressure to prevent damage to the cylinder.
OPERATION
Safety Valve
! Port A is connected to the cylinder circuit and port B is con-

nected to drain circuit. The oil pressure at port A is sent to port
D from the hole in pilot piston (4). It is also sent to port C by the
orifice formed from main valve (2) and pilot piston (4). It is also
sent tp port C by the orifice formed from main valve (2) and pilot
piston (3). Pilot piston (4) is secured to the safety valve, and the
size of the cross-sectional surface [cross-sectional area] has
the following relationship: d2 > d1 > d3 > d4.
! Ifabnormal pressure is created at port A, suction valve (1) is not

actuated because of relationship d2 > d1, but relationship
between port A and port C is d3 > d4, so the main valve (2)
rec eives oil pressure equivalent to the difference between the
areas of d3 and d4. If the oil pressure reaches the force [set
pressure] of main valve spring (3), main valve (2) is actuated, and
the oil from port A flows to port B.
Suction Valve
! If any negative pressure is generated at port A, port D is
connected with port A, so there is also negative pressure at port
D. The tank pressure of port B is applied to port E, so the safety
valve receives oil pressure a, which is equal to the difference in
the area of d2 and d1 because of the tank pressure at port E.
Ergo, oil pressure e moves the valve in the direction of opening,
and oil pressure a acts to move suction valve (1) in the direction
of closing. When the pressure at port A drops and comes close
to negative pressure, it becomes lower than hydraulic pressure
e. The relationship becomes oil pressure e > oil pressure a plus
force of valve spring (5), and suction valve (1) opens to let the oil
from port B flow into port A and prevent any negative pressure
from forming at port A.
WA450-3MC 10-119
SUCTION VALVE
1. Main poppet
2. Sleeve
3. Spring
FUNCTION
! This valve acts to prevent negative pressure from forming in the

circuit.
OPERATION
If negative pressure is generated at port A [boom cylinder rod end,

when a pressure lower than tank circuit port B is generated], main
poppet (1) is opened because of the difference in area between d1
and d2, and oil flows from port B at the tank end to port A at the
cylinder port end.
10-120 WA450-3MC
FLOAT SELECTOR VALVE AND UNLOAD VALVE
FUNCTION
! The float selector valve and unload valve are inside the main
control valve. When the boom lever is operated to the FLOAT
position, the float selector valve detects this, and it is actuated
t o actuat e the unload valve and set the boom to the FLOAT
position.
OPERATION
! If the boom lever is pushed further from the LOWER position, it

i s set to the FLOAT position and the PPC valve is set to the
same condition as for the LOWER position. The pressure at port
A becomes high pressure and the pressure at port B becomes
low pressure. The oil from the steering valve fills chamber F and
chamber E.
! Ifthe difference in pressure between port A and port B becomes

great er than the specified pressure, float selector valve (2) is
moved to the right, and port C and port D open. When port C is
opened, the oil pressure in chamber E drops, unload valve (4) is
moved up in the direction of the arrow, and the oil from the
steering valve flows to the drain circuit, and also flows to the rod
end of the lift cylinder. The oil at the bottom end of the lift
cylinder is connected to the drain circuit and forms the FLOAT
position.
WA450-3MC 10-121
BOOM AND BUCKET SPOOL HOLD POSITION
OPERATION
! The oil enters port A from the pump, and the maximum pressure
i s s et by relief valve (11). Bucket spool (1) is at the HOLD
position, so the bypass circuit is open, and the oil at port A
passes around the spool and flows to port B. Boom spool (2) is
also at HOLD, so the bypass circuit is open and the oil at port
B passes around the spool, enters port C of the drain circuit,
passes through the filter, and returns to the tank. The oil from
the PPC pump passes through check valve (13), and enters port
L of the PPC valve. However, the boom and bucket levers are at
the HOLD position, so the oil returns to the hydraulic tank from
the PCC relief valve (12).
10-122 WA450-3MC
BOOM SPOOL AT RAISE POSITION
OPERATION
! When boom lever (3) is pulled, oil flows from port L of the PCC
valve to port N and port S. The oil at port T passes through port
M and flows to the drain circuit. The oil pressure at port S
presses boom spool (2) and sets it to the RAISE position. The
oil from the pump passes through the bypass circuit of the
bucket spool and flows to the bypass circuit of boom spool (2).
The bypass circuit is closed by the spool, so the oil pushes
open check valve (10). The oil flows from port H to port I, and
flows to the cylinder bottom. At the same time, the oil at the
cylinder rod end enters drain port C from port K and returns to
the tank, causing the boom to raise.
WA450-3MC 10-123
BOOM SPOOL AT LOWER POSITION
OPERATION
! When boom lever (3) is pushed, oil flows from PPC valve port L
to port M and port T. Oil at port S flows to the drain circuit. The
oil pressure at port T pushes boom spool (2) to the LOWER
position. The oil from the pump passes through the bucket spool
bypass circuit and flows to the boom spool (2) bypass circuit.
The bypass circuit is closed by boom spool, so the oil pushes
open check valve (10). The oil flows from port J to port K and to
the cylinder rod end. At the same time, the oil at the cylinder
bottom enters drain port C from port I and returns to the tank.
Ergo, the boom goes down.
10-124 WA450-3MC
BOOM SPOOL AT FLOAT POSITION
OPERATION
! When boom lever (3) is pressed to the FLOAT position, the PPC
valve spool moves beyond the LOWER position to the FLOAT
position. The pressure oil at port L flows to port M, and at the
same time, it also flows to port T. In addition, the pressurized oil
at port S flows to port N. The pressurized oil at port T pushes
boom spool (2) to the LOWER position. Ergo, the oil at the
c y l inder rod end flows from port J to port C, and flows to the
drain circuit. The oil at the cylinder bottom flows from port I to
port C, and then flows to the drain circuit. Ergo, the boom is set
to the FLOAT condition.
WA450-3MC 10-125
BUCKET SPOOL AT DUMP POSITION
OPERATION
! When bucket lever (4) is pushed, the pressure oil at port L of the
PPC valve flows from port Q to port V. In addition, the oil at port
R flows to the drain circuit. The pressure oil at port V moves
bucket spool (1) to the DUMP position. The bypass circuit is
c l osed by bucket spool (1),so the oil at port A pushes open
check valve (9). The oil from check valve (9) flows from port F to
port G, and then flows to the cylinder rod end. At the same time,
the oil at the cylinder bottom flows from port D to drain port C,
and returns to the tank, so the bucket is dumped.
10-126 WA450-3MC
BUCKET SPOOL AT TILT POSITION
OPERATION
! When bucket lever (4) is pulled, the oil pressure at port L of the
PPC valve flows from port P to port R. In addition, the oil at port
V flows to the drain circuit. The pressure oil at port R moves
bucket spool (1) to the TILT position. The bypass circuit is
closed by bucket spool (1), so the oil from port A pushes open
check valve (9). The oil from check valve (9) flows from port D to
port E, and then flows to the cylinder bottom. At the same time,
the oil at the cylinder rod end flows from port G to the drain port
C, and returns to the tank, so the bucket is tilted.
WA450-3MC 10-127
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
1. Bucket 4. Boom cylinder

2. Bellcrank 5. Boom
3. Bucket cylinder 6. Bucket link
10-128 WA450-3MC
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
WA450-3MC 10-129
STRUCTURE AND FUNCTION BUCKET
BUCKET
1. Bucket
2. Bolt on cutting edge
3. Bucket tooth
10-130 WA450-3MC
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK OUT
BUCKET POSITIONER AND BOOM KICK OUT
1. Proximity switch
2. Proximity switch
3. Bucket cylinder rod
4. Lever
5. Plate
WA450-3MC 10-131
BUCKET POSITIONER
! The bucket positioner is an electrically actuated system which

is used to set the bucket to the desired angle when the bucket
is moved from the DUMP position to the TILT position. When the
bucket reaches the desired position, the bucket lever is returned
from the TILT position to the HOLD position, and the bucket is
automatically set to the suitable digging angle. Lever (4) is
secured to bucket cylinder rod (3) by bolts. In addition, proximity
switch (1) fixed to the cylinder by bolts. When the bucket is
moved from the DUMP position to the TILT position, the bucket
cylinder rod moves to the left, and at the same time, lever (4)
also moves to the left. Proximity switch (1) separates from lever
(4) at the desired position, and the bucket lever is returned to
neutral.
BOOM KICK OUT
! The boom kick out is an electrically actuated system. It acts to

move the boom lever to the HOLD position and stop the boom
at the desired position before the boom reaches the maximum
height. Plate (5) is fixed to the boom. In addition, proximity
switch (2) is fixed to the frame. When the boom is moved from
the LOWER position to the RAISE position, the boom rises, and
when it reaches the desired position, the proximity switch and
lever come together and the system is actuated to return the
boom lever to the HOLD position.
10-132 WA450-3MC
BOOM PROXIMITY SWITCH
RAISE
! When the boom is lower than the set position for the kick out,
the detector (steel plate) is not above the detection surface of
the proximity switch, so the proximity switch load circuit is shut
off. The relay switch is turned OFF and the current for the
solenoid is shut off.
! When the boom lever is moved to the RAISE position, the boom
spool is held at the RAISE position by the cam follower and cam
on the lever, and the boom rises.
WA450-3MC 10-133
! When the boom rises and reaches the set position for the kick
out, in other words, the detector [steel plate] is in position on
the detection surface of the proximity switch, an electric current
is sent to the solenoid by the action of the proximity switch and
relay circuit. As a result, the solenoid is actuated, and the cam
i s pulled away from the cam detent, so the boom spool is
returned to the HOLD position by the return spring.
ACTION OF PROXIMITY SWITCH
Wh en detector is in position at detec- When detector is separated from de-

Position
tion surface of proximity switch tection surface of proximity switch
Proximity switch actuation display Lights up Goes out
Proximity switch load circuit (relay switch
Current flows Current is shut off
circuit)
Relay switch load circuit (solenoid circuit) Current flows Current is shut off
10-134 WA450-3MC
BUCKET PROXIMITY SWITCH
TILT
! When the bucket is lower than the set position for the auto
leveler, the detector [steel plate] is not above the detection
surface of the bucket proximity switch, so electric current flows
in the proximity switch load circuit. The relay switch is turned
OFF and the current for the solenoid is shut off.
! When the bucket lever is moved to the TILT position, the bucket
spool is held at the TILT position by the cam follower and cam
on the lever, and the bucket tilts.
WA450-3MC 10-135
! When the bucket tilts and reaches the set position for the
bucket leveler, in other words, the detector [steel plate] sepa-
rates from the detection surface of the proximity switch, electric
current is sent to the solenoid by the action of the proximity
switch and relay circuit. As a result, the solenoid is actuated,
and the cam is pulled away from the cam detent, so the DUMP
spool is returned to the HOLD position by the return spring.
ACTION OF PROXIMITY SWITCH
Wh en detector is in position at detec- When detector is separated from de-

Position
tion surface of proximity switch tection surface of proximity switch
Proximity switch actuation display Lights up Goes out
Proximity switch load circuit (relay switch
Current flows Current is shut off
circuit)
Relay switch load circuit (solenoid circuit) Current is shut off Current flows
10-136 WA450-3MC
STRUCTURE AND FUNCTION ROPS CAB
ROPS CAB
1. Front glass
2. Front wiper
3. Rear wiper
4. Door
WA450-3MC 10-137
STRUCTURE AND FUNCTION HEATER AND DEFROSTER
HEATER AND DEFROSTER
1. Vent
2. Window defroster
3. Vent
4. Control unit
10-138 WA450-3MC
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
1. Vent 5. Air conditioner condenser

2. Window defroster 6. Compressor
3. Vent 7. Air conditioner condenser
4. Dry receiver 8. Air conditioner unit
WA450-3MC 10-139
STRUCTURE AND FUNCTION ELECTRIC CIRCUIT DIAGRAM
ELECTRIC CIRCUIT DIAGRAM
Refer to Foldouts 1 through 4 in Section 90 at the end of this manual
10-140 WA450-3MC
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
1. Main monitor 4. Transmision controller

2. Maintenance monitor 5. ECSS controller
3. Buzzer
OUTLINE
! The machine monitor system uses the sensors and other

devices installed to various parts of the machine to observe the
condition of the machine. It processes this information swiftly
and displays it on the monitor panel to inform the operator of the
condition of the machine.
! The machine monitor system consists of the main monitor,
maintenance monitor, sensors, switches, relays, alarm buzzer,
and power source.
! The displays can be broadly divided into the following: Cautions
displayed on the monitors [abnormalities in the machine where
an alarm is given] and normal conditions which are always
displayed on the instrument panel [pilot lamps and readings for
the gauges, speedometer, and service meter]. There are also
various switches built into the monitor panel which function to
operate the machine.
i When the optional controller is installed, the main monitor
communicates with the controller through the network wiring and
functions to display the controller failure action code and failure
code together with the time elapsed since the failure [trouble
data display mode].
WA450-3MC 10-141
STRUCTURE AND FUNCTION MAIN MONITOR
MAIN MONITOR
1. CHECK lamp 8. Speedometer 15. Front working lamp switch

2. CAUTION lamp 9. Parking brake 16. Rear working lamp switch
3. Ground driven steering actuated 10. Ground driven steering normal 17. Transmission cut off switch
4. Left turn signal 11. Shift hold 18. Auto shift select switch
5. Right turn signal 12. Failure action code Lamp ON - Manual
6. Hi beam 13. Switches Lamp OFF - Auto shift
7. Shift indicator 14. ECSS switch
OUTLINE
! The main motor has a display function for the speedometer and
other gauges and a switching function to control the electric
components and controllers. One CPU [Central Processing Unit]
is installed internally, and this processes the signals from the
s ensors and outputs the display. A liquid crystal display and
LEDs are used for the display. The switches are embossed
sheet switches.
10-142 WA450-3MC
MAIN MONITOR DISPLAY FUNCTION
Category Symbol Display item Display range Display method

When abnormality is displayed on Display flashes, see Maintenance Moni-
Check Check
maintenance monitor tor Display Function
Ground driven
When actuated Display flashes
steering actuated
Parking brake actuated, transmis-
Display flashes and buzzer sounds
Caution sion not at neutral
Caution Display flashes, buzzer may also sound
When abnormality is displayed on
see Maintenance Monitor Display Func-
maintenance monitor
tion
High beam When operated Display lights up
Turn signals When operated Display lights up

Display lights up. Buzzer sounds when
Parking brake When operated parking brake is applied and shift lever
is not at N
Pilot Ground driven When normal [oil is flowing in hy-

Display lights up
steering normal draulic circuit]
L i ghts up. Light up time changes ac-
cording to engine coolant temperature
Preheating When preheating
when start switch is ON, see Preheating
Output Function
Shift hold When shift is held Display lights up
D i gital display, switches between ta-

Speedometer Travel speed 0 to 99 km/h [mph]
chometer and speedometer
Shift indicator Shift indicator 1st through 4th, N Digital display
When controller detects failure and

D i g i tal display, buzzer sounds, for de-
action by operator is needed, CALL
Failure code Failure code tails of the travel data display mode, see
is displayed, or CALL and EGG
Trouble Data Display Mode
[action code] are displayed in turn
MAIN MONITOR SWITCH FUNCTION
Item Function Display Actuation
ECSS function is actuated or stopped each time switch is Lights up ECSS function actuated
ECSS
pressed Goes out ECSS function stopped
Lights up Front working lamp lights up
Front working lamp lights up or goes out each time switch
Front working lamp Front working lamp goes
is pressed when side lamps light Goes out
out
Rear working lamp lights up or goes out each time switch Lights up Rear working lamp lights up
Rear working lamp
is pressed when side lamps light Goes out Rear working lamp goes out
Transmission cut Transmission cut off function is actuated or stopped each Lights up Cut off function actuated
off time switch is pressed Goes out Cut off function stopped
Auto shift mode switches to manual mode when switch is Lights up Manual shift mode
Manual
pressed Goes out Auto shift mode
WA450-3MC 10-143
PREHEATING OUTPUT FUNCTION
Item Actuation
Power source
Start signal
[terminal C]
Display
Electric intake air heater Output
Relationship between engine coolant temperature and display and output time
Display time:
T1 [sec]
Output time:
T2 [sec]
Engine coolant temperature EC
10-144 WA450-3MC
TROUBLE DATA DISPLAY MODE
i When the optional controller is installed.
Item Switch operation Actuation
With engine stopped and start switch All switch displays [LEDs] go out, and failure code is
turned ON, press 2nd switch from top on displayed on speedometer display and time elapsed
left side of main monitor [switch below s i n c e failure is displayed on failure action code
ground driven steering display] and front display.
working lamp switch simultaneously for at 1 Failure code is a two digit display given in numbers
least five seconds. or letters. The display for the failure now occurring
flashes and the display of past failures lights up. If
Method of switching to
there is no failure, CC is displayed [000 is dis -
trouble data display mode
played for time elapsed since failure]
2 The time elapsed since failure is displayed as a
three digit number to show how long ago the failure
occurred [the oldest failure time is displayed]. Any
time greater than 999H is displayed as 999H.
3 Amaximum of nine items are stored in memory for
the failure code.
Press front working lamp switch Failure code and time elapsed since failure change
to next item.
Method of sending failure

code
Press rear working lamp switch for at

least two seconds
Failure code and time elapsed since failure being

displayed are cleared.
Clearing failure code
Failure code for problem now occurring, flashing
display cannot be cleared.
Press 2nd switch from top on left side of

main monitor [switch below ground driven
Resetting from travel data
steering display] and front working lamp Changes to normal display
display mode
s w i tch simultaneously for at least five
seconds, or start the engine.
WA450-3MC 10-145
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
MAINTENANCE MONITOR
Check items [Checks before starting] Gauge items

1. Engine coolant level 7. Fuel level
2. Engine oil level 8. Engine coolant temperature
Caution items [warning items] 9. Torque converter oil temperature
3. Engine oil pressure 10. Service meter
4. Battery charge 11. Service meter numeric display
5. Brake oil pressure 12. Service meter RUN pilot lamp
6. Air cleaner 13. Monitor module
14. Switch module
OUTLINE
! The maintenance monitor has a display function for the caution

items and gauges. The maintenance monitor consists of the
monitor module, switch module, service meter, case, and other
mechanisms. The monitor module has a built in CPU [Central
Processing Unit]. It processes the signal from the sensors, and
carries out the display and output. A liquid crystal display and
LEDs are used for the display portions. The switches are
embossed sheet switches.
10-146 WA450-3MC
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
MAINTENANCE MONITOR DISPLAY FUNCTION
Category Symbol Item Range Method
Displays when engine is stopped and start switch

Engine coolant level
is ON
Check Below low level Display when normal . . . . . . . . . . . . . . . . . . OFF
Display when abnormal . . . . . . . . . . . . Flashes
Engine oil level CHECK lamp flashes
Engine coolant level Below low level

Displays when engine is running
Display when normal . . . . . . . . . . . . . . . . . . OFF
Engine oil pressure
Below specified pres-
CAUTION lamp flashes, buzzer sounds
sure
Brake oil pressure
Engine coolant temp Above 102EC Buzzer sounds if above 105EC
Converter oil temp Above 120EC Buzzer sounds if above 130EC

Caution
Displays when engine is running

Fuel level Below low level
CAUTION lamp flashes
Wh en charge is abnor-
Battery charge Displays when engine is running
mal
Above specified negative CHECK lamp flashes
Air cleaner
pressure
Actuated when charge is normal

Service meter 0 to 9999.9 hours
Service Advances . . . . . . . . . . . . . . . . . . . 1 for every hour
meter
Indicator Lights up when service meter is running
All lamps light up below applicable level

Fuel level
Flashes . . . . . . . . . . . . . . . . . . . . When level is 1
One place lights up to show applicable level

Gauges Engine coolant temp
Flashes . . . . . . . . . . . . . . . . When level is 6 or 7
One place lights up to show applicable level

Converter oil temp
Flashes . . . . . . . . . . . . . . . . When level is 6 or 7
WA450-3MC 10-147
STRUCTURE AND FUNCTION TRANSMISSION AUTO SHIFT
TRANSMISSION AUTO SHIFT
SYSTEM STRUCTURE DIAGRAM
No. Input No. Output

D D
1 Directional switch signal (1) F SOL
D D
2 Speed range switch signal (2) R SOL
3 Transmission cut off signal D D (3) Hi-Lo SOL
4 Kick down switch signal D D (4) SP SOL

Transmission
D controller A
5 Hold switch signal (5) Modulation valve solenoid
D P
6 Neutralizer relay signal (6) Engine speed signal
P A : Analog signal D
7 Travel speed signal D : Digital signal (7) Kick down signal
P : Pulse signal
8 Engine speed signal P D (8) Alarm buzzer signal
N : Network signal
9 Model selection signal D N (9) Hold signal
D N
10 Manual switch signal (10) Buzzer signal
N
(11) Failure code
D
(12) Manual signal
CONTROL FUNCTION
Auto shift
Hold function
Kick down function
Safety function
Troubleshooting
OUTLINE
! The auto shift control system receives the position signals from
the directional lever and range lever, the engine speed signal,
travel speed signal, and signals from other switches. The
t ransmission controller drives the speed solenoid valve and
automatically carries out shift control to select the optimum
speed range for the transmission.
10-148 WA450-3MC
SHIFT CONTROL SYSTEM FUNCTION Transmission solenoid output
Speed Solenoid Clutch

INPUT SIGNALS
range F R HL SP F R 1 2 3 4
Directional lever: This lever selects F [forward], R
[reverse], and N [neutral]. N ±
F1 ± ± ± ±
S p e e d lever: This selects the optimum speed range
when using auto shift forward or reverse. Normally, if the F2 ± ± ±
speed lever is at position 2 or higher, the transmission will
be set to 2nd when the machine starts. When the auto F3 ± ± ± ±
shift is used, and the gear shift lever is moved 4 3 3 3 2 3
F4 ± ± ± ± ±
1 when the machine is traveling with the transmission in
force, the transmission will also shift down immediately 4 R1 ± ± ± ±
3 3 3 2 3 1. Priority given to speed lever.
R2 ± ± ±
Engine speed sensor: When the engine is running at low
R3 ± ± ± ±
speed, < 1450 rpm, the auto shift is stopped. When
shifting between forward and reverse or when coasting, R4 ± ± ± ± ±
the present speed range is maintained and the shift shock
is reduced. When the machine is traveling in 2nd, and the
Modulation output: There is a data map for each shift
engine speed changes from low speed, <1450 rpm, to
pattern, and the solenoid command current is controlled
high speed, >1450 rpm, the speed range is kept at 2nd to
according to the data to reduce the shift shock when
allow the machine to accelerate more easily.
engaging the clutches.
T r a vel speed sensor: The speed range is determined
Hold, maintain present speed range: When the hold
according to the travel speed. In addition, the change in
switch is turned ON, the existing speed range is held, and
speed is determined from the pulse count to decide
even if the travel speed goes down, the transmission does
whether to shift up or down.
not shift down. However, if the direction of travel is shifted
between forward and reverse, the transmission shifts
Neutralizer: The parking brake actuation signal is input
down, and then it shifts up to the speed range according
to the controller and the transmission is shifted to neutral.
t o t he change in the conditions. This prevents any
unnecessary shift down on level ground or unnecessary
Transmission cut off signal: When the controller
shift up when traveling downhill.
receives the transmission cut off signal, it shifts the
transmission to neutral. After the signal is canceled, it
Kick down function: The operator can override all the
selects a speed range that matches the travel speed at
automatic conditions and shift down forcibly to 1st, when
that point.
traveling below 12.1 km/h in 4th or 3rd, or when at any
speed in 2nd. When the transmission has been shifted to
OUTPUT SIGNALS
1st by the kick down, the switch pump cut off signal to
the electronic governor controller is switched ON. When
Transmission solenoid output: The F and R solenoids
the travel speed increases, the transmission is shifted up
correspond to the F and R positions of the directional
in accordance with the auto shift up conditions, or it is
lever. Positions 1 to 4 of the speed lever actuate the Hi-Lo
shift ed to 2nd when the direction is shifted between
solenoid and speed solenoid to select the clutches to give
forward and reverse. This function is also available when
the 1st thru 4th transmission speeds. This combination is
holding speed range, hold with engine at low speed.
then output to the transmission.
WA450-3MC 10-149
SHIFT CHARACTERISTICS In area B, the transmission reverses, but the speed range
shifts down to 2nd in accordance with the travel speed.
Auto shift: When the engine speed is higher than 1450 Then, after the actual direction of travel of the machine
rpm, the transmission is shifted as follows according to changes to the same direction as the directional lever, the
the travel speed; Directional lever at F, speed lever at 4 transmission shifts up in accordance with the travel
Shift up speed, to prevent damage to the clutch. However, when
1. When s t arting, the transmission is set to the F2 the hold function is ON, the transmission does not shift
torque converter range. down.
2. When the accelerator pedal is depressed, the engine Example:
speed rises and the machine travels faster. If the Directional lever . . . . . . . . . . . . . . . . . . F 3 N 3 R
engine speed continues to rise and the travel speed Transmission output . . . . . F4 3 N 3 R4 3 R3 3 R2
reaches 10.2 km/h, the transmission is shifted up to The t ransmission shifts down while the machine is
F3. If there is insufficient acceleration, the transmis- coasting in forward . . . . . . . . . . . . . . . R2 3 R3 3 R4
sion s hifts up when the travel speed reaches 10.7 [The machine shifts up when traveling in reverse]
km/h. However, if the speed lever is at 1, the transmission
3. Immediately after the transmission shifts up, the remains in 1st.
engine speed will drop momentarily, but if the ma-
chine continues to travel faster and the travel speed Switching, F-N-F [R-N-R]: A speed range that matches
reaches 18 km/h, the transmission is shifted up to the speed is selected.
F4.
Shift down Skip shift: When the machine is coasting in 3rd or 4th,
1. If t h e machine is traveling in F4 and the load in- <1400 rpm, and the accelerator pedal is depressed >1400
creases, the transmission will shift down to F3 if the rpm, the speed range is held if the travel speed is more
travel speed drops below 16 km/h. than 8 km/h. If the travel speed is less than 8 km/h, the
2. If the travel speed drops further to 10.7 km/h, the transmission is shifted down to 2nd to make it easier to
transmission is shifted down to F2. If there is insuffi- accelerate.
cient deceleration, the transmission shifts down when
the travel speed reaches 10.2 km/h. With the auto No shift time: This is the time that the speed range is
shift, the transmission does not shift down to F1 even held after shifting. The speed cannot be shifted until this
if the travel speed drops. Normally, the transmission time has elapsed, to prevent shift hunting. No shift time
shifts to F1 only if the speed lever is placed at 1 or if differs according to the shift conditions.
the kick down switch is pressed.
Reverse, directional lever at R, speed lever at 4. The
transmission range is shifted according to the travel
speed in the same way as for Step 1.
Changing Direction: If travel speed and engine speed

are in area A, the transmission shifts to 2nd speed in the
same direction as the directional lever regardless of the
speed range. Following this, the transmission shifts up to
match the travel speed.
Example:
Directional lever . . . . . . . . . . . . . . . . . . F 3 N 3 R
Transmission output . . . . . F4 3 N 3 R2 3 R3 3 R4
Shift pattern between F and R
10-150 WA450-3MC
Gear shift characteristics Ne utral safety: When the directional lever is at any
position other than N, the transmission is set in neutral
Item Clutch Speed - km/h No shift time
and the machine does not start even if the starting switch
1 3 2 Min. 5.3 (5.5) 2
is turned ON. This condition is canceled if the directional
2 3 3 Min. 10.2 (10.7) 2
1. Normal gear shift 3 3 4 Min. 18 1 lever is returned to the N position, to prevent unexpected
4 3 3 < 16 1 movement of the machine when the engine is started.
3 3 2 < 10.7 (10.2) 2
Alarm buzzer range when shifting between F and R
2. Engine speed 432 <1 0
<1450 332 >1 0
3. Engine speed 432 <8 2
<1450 3 >1450 332 <8 2
132 Min. 5.3 0
4. Shift up when Hold is
233 Min. 10.2 0
on
334 Min. 18 0
231 Whole range 5
5. Kick down - OFF 3 ON 331 < 12.1 5
431 < 12.1 5
6. Directional lever, area
432 2
A
332 See Note 1 2
F3N3R
132 2 Speed lever priority: If the speed lever is shifted down
R3N3F
when traveling downhill, the transmission is shifted down
7. Directional lever, area
34 Min. 18 0 immediately to make use of the braking force of engine.
B
33 16 to < 18 0
F3N3R
See Note 2 0
R3N3F Manual shift: If there should be any disconnection in the
8. Directional lever 34 Min. 18 0 travel speed sensor or any other failure, and the input of
F3N3F 33 10.2 to < 18 0 the t ravel speed stops, the lever operation becomes
R3N3R 32 < 10.2 0 manual.
Example:
Note 1: Engine speed < 2000 rpm and travel speed < 16 Directional lever F . . . . . . . . . . Speed lever 4 3 F4
km/h, or travel speed < 13 km/h. Directional lever R . . . . . . . . . Speed lever 2 3 R2
Note 2: W hen engine speed is > 2000 rpm and travel
speed is 13 km/h to 18.0 km/h TROUBLESHOOTING
SAFETY FUNCTION The controller always observes if the electronic devices,

the solenoids which receive the controller output signals,
Alarm buzzer: If the direction of travel is switched and the engine speed sensor and travel speed sensor
between forward and reverse in area C, travel speed > 13 which take in the input signals, are functioning normally.
km/h and engine speed > 1800 rpm, or travel speed > 14 If there is any abnormality in any of these devices, the
km/h, the alarm buzzer will sound to prevent damage to controller judges the condition and functions to inform the
the clutch. operator of the decision with the alarm buzzer, and at the
same time, to display the abnormality as a failure code on
N priority for directional lever: The controller is the main monitor.
equipped with an interlock function which always gives
the neutral output when the lever is at N.
WA450-3MC 10-151
TRANSMISSION CONTROLLER
CONNECTOR SIGNALS
L29 L30 L31
1 NETWORK signal 1 Directional switch F 1

2 2 Range switch 2 2
PO
3 Modulation valve, Solenoid S 3 Range switch 4 3
PO
4 4 Neutralizer relay signal 4 Travel speed signal, S
5 5 Manual switch 5 Engine speed signal

6 6 6
7 7 7
PO
8 Power source input, 24V S 8 8 Manual signal output
9 GND 9 Signal GND output 9
10 Hi-Lo Solenoid 10 10
11 SP Solenoid 11 Directional switch N 11
NE
12 NETWORK signal 12 Directional switch R 12 Travel speed signal, G
PO
13 Sensor power source, 24V S 13 Range switch 1 13
NE
14 Modulation valve, Solenoid G 14 Range switch 3 14 Engine speed signal output
15 15 15 Buzzer signal output
16 16 Transmission cut off switch 16
PO
17 Solenoid power source input, 24V S 17 Kick down switch
PO
18 Power source input, 24V S 18 Hold switch
19 GND 19
20 R, Solenoid 20
21 F, Solenoid
10-152 WA450-3MC
STRUCTURE AND FUNCTION LOAD METER SYSTEM
LOAD METER SYSTEM
Load meter controller

1. Total print switch 5. Adjustment switch 9. Remain switch
2. Subtotal print switch 6. Mode selector switch 10. Display panel - total and remaining
3. Increment switch 7. Calibration switch 11. Display panel - bucket
4. Shift switch 8. Subtotal mode 12. Feed switch
FUNCTION
! The load meter is a system to convert the lift cylinder oil

pressure to the weight of the load and then display it.
1. Boom lever
2. Kick down switch
3. Cancel button
4. Bucket lever
5. Subtotal print switch
Right console box
WA450-3MC 10-153
ADJUSTING LOAD MEASUREMENT POINTS
! To improve the position when measuring, perform the following

operation.
1. Tilt the bucket fully back and raise the boom until the arm is in
the horizontal position, boom height H.
2. Watch indicator (2) on the proximity switch (1) located on the

right boom. Adjust the sensor plate (3) as follows:
a) Bucket on ground . . . . . . . . . . . . Indicator (2) lights up.

b) Boom horizontal, H . . . . . . . . . . . Indicator (2) goes out
! The mounting position of the proximity switch (1) and sensor

plate (3) is set per the following.
Proximity switch mounting (4) . . . . . . . . . . 2 to 5 mm

Sensor plate mounting (5) . . . . Slightly above center
3. After performing the calibration, load the bucket with a known w-

eight. If the load displayed on the meter is too low, raise the
boom height setting. If the load displayed on the meter is too
high, lower the boom height setting. Adjust the calibration again.
10-154 WA450-3MC
CALIBRATION, ADJUSTING 0 POINT
i To ensure that the measurements are accurate, always carry

out calibration, adjust the 0 point before using.
CHECK BEFORE ADJUSTING
Before adjusting, check that CAL is flashing in the upper display

panel. If there is a different display, do as follows.
WHEN IN SUBTOTAL MODE, GREEN LED LIGHTS UP
If both the top and bottom display panels show 0.00 tons, press the
CAL switch (*) and the display will change to CAL.
i Calibration cannot performed when the subtotal and the weight

in the bucket are displayed. Always press the CAL switch (*)
after setting the display to 0.00 ton to delete the subtotal.
WHEN IN THE REMAIN MODE, RED LED LIGHTS UP
If t h e top display (REMAIN) shows target production and if the

bottom display (WEIGHT) shows 0.00, press the CAL switch (*) to
display CAL.
i Calibration cannot carried out when there is any other display.

Always press the CAL switch (*) to set the REMAIN display to
the target production amount.
ADJUSTING
i Carry out the adjustment when CAL is flashing.
1. A fter the engine reaches operating temperature, empty the

bucket and tilt it forward.
2. With the engine at rated speed, raise the boom until the buzzer
sounds. When the buzzer sounds, the calibration is complete.
CHECKING CALIBRATION
i Check as follows to see if it is necessary to carry out calibra-

tion, adjusting the 0 point.
1. Press the CAL switch (*) twice to make SCHEC flash. In the
same way as for calicration, warm up the engine fully, empty the
bucket and tilt fully.
2 When E-21 is displayed in the upper display panel, press the

CAL switch (*) to delete the error message and perform the
calibration.
i Ifthe display returns to the display shown before the calibration

check, there is no need to perform the calibration. Check the
calibration once a week - once every month.
WA450-3MC 10-155
MEASURING
i The load meter can be used to measure the following two items,
so select the appropriate item.
! Measuring SUBTOTAL: Use to find the amount loaded into a

dump truck, the amount loaded into a hopper, the production for
half a day, etc.; the data can accumulate for a maximum of 500
loads.
! Measuring REMAIN: This can be set feely to any value up to a

max of 500.00 ton when loading a constant amount [to avoid
overloading, or to distribute material, etc.].
MEASURING SUBTOTAL
1. Check that the green LED â for the SUBTOTAL 5. If the measured data is not needed, press the data
display lights up. control button on the control lever. The data will be
canceled and the display will return to the display
i If the red LED ã for the REMAIN display lights up, before the measurement.
press the MODE switch ä for about 3 seconds to
light up green LED â. i The data can only be cancelled while the weight of
the buc ket load is displayed in the lower display
2. If the CAL switch å is pressed, the data in the panel [. 15 seconds].
SUBTOTAL display can be erased.
i SUBTOTAL can display the data toal for a maximum
i When the CAL switch å is pressed, the data stored of 500 bucket loads.
in the load meter storage device is also erased.
Check that you do not need the data before pressing 6. To set the upper display panel [SUBTOTAL] to 0.00
the switch. ton, press SUBTOTAL switch æ to print out the
present production amount or press CAL switch å to
3. When the target material has been loaded into the delete the data from the storage device.
bucket, tilt the bucket fully and raise the boom.
! To ensure the precise measurement, raise the boom
4. At the same time as the buzzer sounds, the weight and keep the boom control lever fully open until the
of the load in the bucket is displayed in the lower buzzer sounds to indicate the completion of the
display panel [weight] and the sub total is displayed measurement. After the buzzer sounds to indicate
in the upper display panel [SUBTOTAL]. completion of the measurement, dump the load.
10-156 WA450-3MC
MEASURING REMAIN
1. Check that the red LED â for the REMAIN display this REMAIN display panel å and the dsiplay of the
lights up. weight inside the bucket shown in lower display panel
ç can be used to judge how much of the load in the
i If the green LED ã for the SUBTOTAL display lights bucket should loaded to reach the target production
up, press the MODE switch ä for . 3 seconds so amount.
that the red LED â lights up.
7. If the values in the REMAIN display å and lower
2. To return the REMAIN display å to the target display panel ç are close and all of the load in the
production amount, press the CAL switch æ. buc ket is loaded, press the SUBTOTAL switch è
after loading and this will print out the amount loaded.
i For details of changing the target production amount, If it not needed to print out or write the data to
See Setting Target Production Amount in Remain memory, press CAL switch æ. This will display the
Mode. target production amount in REMAIN display å and
will complete the preperations for the next loading.
3. When the target material has been loaded into the
bucket, tilt the bucket fully and raise the boom. 8. When using the REMAIN display å and lower display
panel ç to adjust the amount to load from the bucket,
4. At the same time as the buzzer sounds the weight of tilt the bucket back after loading the adjusted
the load in the bucket is displayed in the lower amount, set the boom horizontal, then lower it
display panel ç [WEIGHT]. A value showing the midway between the horizontal position and the
previous REMAIN amount minus the load in the ground.Run the engine at mid range speed and raide
bucket is displayed in the upper display panel å. the boom intil the buzzer sounds to indicate the end
of measurement. As a result, the amount remaining
5. If the measured data is not needed, press the data inside the bucket will be subtracted and the amount
c ancel button on the control lever. The data will be remaining to the target production amount will be
canc elled and the display will return to the display displayed. This operation can be repeated to enable
before the measurement. the target production amount to be loaded accurately.
If the value in the REMAIN display å is 0 tons or near
i The data can be cancelled only while the weight of he t hat amount, the loading of the target amount si
bucket is displayed in the lower display panel ç [. 15 completed. Press the SUBTOTAL switch è to print
sec]. out the data for the amount loaded.
6. If the target production will be exceeded if the amount 9. If an amount exceeding the target production has
that has been weighed is loaded as it is. REMAIN been loaded while adjusting the amount loaded, the
display å will be negative, but 3 seconds later it will display in REMAIN display å will be a negative value
return to the display that was previously shown and showing the amount that has been loaded in excess
s t art to flash. The lower display panel ç normally and the buzzer will sound intermittenly at the same
displays 0 tons 15 seconds after measurement [after time. There will be no more further measurement of
the buzzer sounds]. But in this case, it will continue the amount loaded. Press the SUBTOTAL switch è
to display the weight inside the bucket. The amonut to print out the data for the amount loaded.
remaining to reach the target production amonut for
WA450-3MC 10-157
10. When SUBTOTAL switch è is pressed, if there is any load left

in bucket, that amount can be loaded as it is next. REMAIN
display å shows the amount remaining in the bucket subtracted
from the target production amount, and the amount remaining in
the bucket is displayed in the lower display ç for 15 seconds.
This is stored in the memory as the first bucket loaded to the
next load, so load it as it is. As long as the target production
amount is not changed, the following kind of operation can be
carried out.
[Example]: Continuous work, such as when 2-½ buckets are

loaded onto one load, the remaining ½ bucket can be
loaded onto a second loadand following this, 2 further
buckets are loaded on that load.
After SUBTOTAL switch è is pressed, if the amount remaining

in the bucket is not needed and it is dumped, press the cancel
button at the tip of the work equipment control lever knob.
REMAIN display å will change the target production amount.
This cancel function is only effective for the 15 seconds during
which the amount remaining in the bucket is displayed on the
lower display panel.
11. If the remaining load is left in the bucket and the boom is raised
without pressing SUBTOTAL switch è, the load meter will take
an abnormal action and !!! display will flash onlower display
panel ç and the buzzer will sound intermittenly.
In this condition, no measurements can be carried out, so

pressed the CAL switch æ once to display the target production
amount in REMAIN display å and 0.00 in the lower display
panel ç. In this condition, raise the boom.
! To ensure precision of the measurement, raise the boom and

keep the boom control lever fully open until the buzzer sounds
t o indicate completion of the measurement. After the buzzer
sounds, empty the bucket.
10-158 WA450-3MC
SETTING TARGET AMOUNT IN REMAIN MODE
i The target production amount in the REMAIN mode is set as

follows.
1. Check that the red LED â of the REMAIN display is flashing.
2. When the ADJ switch ã is pressed, the lowest digit will flash.
3. When the SFT switch ä is pressed, the next digit on the left will
start to flash.
4. When the INC switch å is pressed, the number that is flashing

will increase one at a time.
5. When the set target production amount is obtained, press the

ADJ switch ã to stop the flashing and complete the setting.
[Example]: 500.00 tons, press ADJ ã once, SFT ä four times,

INC å five times then ADJ ã to set.
i The maximum value for the target production amount is 500.00

tons.
WA450-3MC 10-159
PRINTING DATA
There are two types of data that can be printed out: the SUBTOTAL
data and the TOTAL data. The data cannot be printed out while the
amount loaded in the bucket is being displayed.
PRINTING SUBTOTAL
Pres s the SUBTOTAL switch to print out the data. The switch is
installed to the load meter itself and the work equipment control
lever. The content of the display is as follows:
! SUBTOTAL mode
" Date of print out
" Time of print out
" Amount of each load
" Total load
After the SUBTOTAL is printed, the SUBTOTAL display becomes

0.00 (0.0) tons. If no new measurement is performed, the same data
can be printed as many times as desired.
! REMAIN mode
" Date of print out
" Time of print out
" Target production amount
" Amount of each load
" Total load
PRINTING TOTAL
When the TOTAL switch is pressed, the data in the load meter
storage device is all erased and all of the measured loads are printed
out as a total. To erase the data, see Deleting Data from Storage
Device.
i The value for the TOTAL is the accumulated total for the data,
regardless of what data has been printed out for the SUBTOTAL.
The loads are added until the total reaches a maximum of 16,
772.15 tons.
i If all the data is erased from memory before starting work and
the TOTAL is printed out at the end the days work, the print out
will give the total amount loaded for that day.
10-160 WA450-3MC
DELETING DATA FROM STORAGE DEVICE
The data in the data storage device inside the load meter is kept
even when the power is turned off. To delete the data do as follows:
1. Press the TOTAL switch and SUBTOTAL switch at the same

time and CLEA will flash in the upper display panel.
2. Keep both of the switches pressed and the display will change
to 0.00 and the data in the storage device will be erased.
WA450-3MC 10-161
SETTING TIME ON CLOCK
There is a clock built into the load meter. This clock is used to give
the date and time when printing out the data. Adjust the time as
follows.
1. Check that the green LED â of the SUBTOTAL display si

flashing.
2. Press the MODE switch ã and ADJ switch ä at the same time
and keep them pressed for 3 seconds to switch to the clock
mode. In the clock mode, the dash will be flashing.
3. Press the ADJ switch ä to switch to the adjustment mode and

the last digit will flash.
4. Press the INC switch and the flashing digit will increase one at
a time.
5. When the SFT switch æ is pressed, the flashing digit will move
one place to the left. When the left digit of the hour/min setting
i s flashing, the display will change to the month/day setting.
When the left digit of the month setting flashes, the display will
change to the year setting. After setting the year, the display
will change back to the time display.
6. After seeting the clock, press ADJ switch ä to set to the time
display mode.
7. If the MODE switch ã is pressed, the display will return to the

SUBTOTAL mode.
10-162 WA450-3MC
REPLACING PRINTER PAPER
If the printer runs out of paper, install a new roll of paper as follows:
1. Raise the acryl dust cover.
2. Open the paper cover to the front.
3. Remove the tab from the roll of paper and cut off the first 5 cm
of the roll.
4. Insert the paper as follows. With the red arrow on the outside
face of the roll at the top, insert the paper lightly into the printer.
WA450-3MC 10-163
5. Press the FEED switch and the printer will feed the paper.
6. When inserting the paper roll, be careful that the paper does not
bend too sharply.
10-164 WA450-3MC
TROUBLESHOOTING FUNCTION
The load meter is equipped with a troubleshooting function. If any

one of the displays given below appears press the CAL switch once
to cancel the error code. If the error code appears continuously, note
the details of the error display.
Error display Probable location of problem

E-8 Defective load meter
E-01 Defective sensor, disconnection in harness
Defective sensor, harness in contact with sensor
E-11
power line
E-31 Short circuit in the sensor power source
E-33 Drop in voltage of internal battery
PAGE Paper jam
SPARE PARTS
When changing the printer paper or the internal battery, use the part
numbers listed below.
Item Part No. Name

Printer paper 7818-27-2910 Paper
Internal battery 7818-27-2860 Battery
WA450-3MC 10-165
STRUCTURE AND FUNCTION ECSS
ECSS
ELECTRONIC CONTROLLED SUSPENSION SYSTEM - ECSS
! The system uses work equipment hydraulic oil and an accumu-

lator charged with high pressure gas to provide suspension
s y s t e m control. The ECSS controller actuates the solenoid
valves, relieving pressure in the work equipment and switching
on a n d off the accumulator, in accordance with the travel
condition of the machine. That gives resilience to the up and
down movement of the work equipment and suppresses chassis
vibration when traveling at high speed. In this way, it improves
the ride for the operator, prevents spillage of the load, and
improves the operating efficiency.
! Special solenoid valves [ON-OFF valves] are used to control the
on/off switching of the accumulator [high pressure, low pressure]
and the opening and closing of the relief valves.
STRUCTURE OF SYSTEM
! The ECSS consists of the following electronic devices.

" ECSS controller [M type]
" Input devices: system switch, pressure switch [boom
c y linder bottom pressure], travel speed sensor, model
selection wiring harness, speed range selection wiring
harness
" Output devices: solenoid valves, relief valve, high pressure
accumulator, low pressure accumulator
10-166 WA450-3MC
CONTENT OF CONTROL
! In response to the input on the left side of the table below, the
controller carries out the output on the right side to control the
system.
Input Output
Switch system ON-OFF Speed range (Note 2) Travel speed Pressure Solenoid (1) Solenoid (2) Solenoid (3)
[Note 1] Hi-Lo Speed [Note 3 switch (relief) (high pressure) (low pressure)
1 OFF -- -- -- -- X X X
ON ON
2 ON OFF Min. 5 km/h ON O O X
OFF OFF
ON ON
3 ON ON OFF Min. 5 km/h OFF O O O
OFF OFF
4 OFF ON -- -- X X X
Min. 5 km/h
5 -- -- -- X X X
[Note 4]
Note 1 The ECSS system is switched on/off by operat- Note 3 Input pulse frequency when travel speed is 1
ing the ECSS switch on the main monitor. When km/h . . . . . . . . . . . . . . . . . . . . . . . 44.46 Hz
the system is on, the ECSS LED display on the
main monitor lights up. The on/off condition of the Note 4 If the travel speed exceeds 5 km/h when the
system is retained even after the engine stops or output is off, the output is turned on. When the
the starting switch is turned off. The next time output is on, the output stays on until the travel
that the starting switch is turned on, the system speed reaches 3 km/h, and when the travel
i s set to the same condition as before it was speed goes below 3 km/h, the output is turned
turned off. off.
Main monitor function
Start ing switch OFF ö Machine stops ö Starting
switch ON
Note 2 Relationship between speed range signal and

shift position
Speed range
Shift position
Hi-Lo Speed
1st OFF ON
2nd OFF OFF
3rd ON OFF
4th ON ON
ON: +24V OFF: OPEN
WA450-3MC 10-167
SELF DIAGNOSTIC FUNCTION
! This function continuously observes the condition of the system,

and displays its condition [LED code, see table below] in the
controller self diagnostic display portion.
! If there is any abnormality in the controller itself or in the input
or output devices, the controller carries out troubleshooting of
the abnormality. It turns all the output off and displays the error
code [failure code] in the self diagnostic display portion and the
main monitor.
LED Codes
LED display Content Condition
04 Selects model as WA450-3

Normal
55 Pressure switch on, displays when on
d0 Error in solenoid, relief system
d1 Error in solenoid, high pressure system
Error d2 Error in solenoid, low pressure system

Abnormal
code
d3 Travel speed sensor system
Model selection, nonavailable combina-

d4
tion is selected
Displays on Controller
! Error code displays [E]ö[dx], where x is a numeral from 0 to 4

in the table above, repeatedly in turn.
! If more than one abnormality occurs at the same time, all the
appropriate error codes are displayed in turn.
! When the starting switch is turned off, controller power off) the
error codes are reset and not written to memory.
! W hen checking the LED display, read the code with the
connector facing down.
Displays on Main Monitor
! For details, see MAIN MONITOR TROUBLE DATA DISPLAY.
10-168 WA450-3MC
CONTROLLER
INPUT OUTPUT SIGNALS 1. Controller 2. Self diagnostic display

CN1 CN2 CN3
No. Name Type No. Name Type No. Name Type
1 Serial signal --- 1 Model selector Input 1 --- ---
2 --- --- 2 GND Input 2 --- ---
3 --- --- 3 GND Input 3 --- ---
PO
4 --- --- 4 GND Input 4 Travel speed sensor S Input
5 --- --- 5 --- --- 5 --- ---
6 --- --- 6 --- --- 6 --- ---
7 --- --- 7 --- --- 7 --- ---
8 Power source input --- 8 Pressure switch Input 8 --- ---
9 GND --- 9 --- --- 9 --- ---
10 --- --- 10 --- --- 10 --- ---
11 Solenoid, low pressure Output 11 --- --- 11 --- ---
NE
12 Serial signal --- 12 --- --- 12 Travel speed sensor G Input
13 --- --- 13 Travel speed, Hi-Lo Input 13 --- ---
14 --- --- 14 Travel speed, Speed Input 14 --- ---
15 --- --- 15 SAS SW Input 15 --- ---
16 --- --- 16 --- --- 16 --- ---
17 Solenoid power source --- 17 --- ---
18 Power source input --- 18 --- ---
19 GND --- 19 --- ---
20 Solenoid, high pressure Output 20 --- ---
21 Solenoid, relief Output
WA450-3MC 10-169
STRUCTURE AND FUNCTION SENSORS
SENSORS
FUNCTION
! The sensors are contact type with one end grounded to the
chassis. The signal from the sensor is input directly to the
monitor panel, and when the contacts are closed, the panel
judges the signal to be normal. The engine oil pressure uses a
relay to reverse the sensor signal.
When
Sensor detection item Method Normal
abnormal
Speedometer Electro-magnetic --- ---
Engine oil level Contact ON OFF
Radiator coolant level Contact ON OFF
Engine oil pressure Contact OFF ON
Engine coolant tempera-
Resistance -- --
ture
Converter oil temperature Resistance -- --
Engine speed Electro-magnetic -- --
Fuel level Resistance -- --
SPEEDOMETER SENSOR
1. Magnet 3. Case 5. Connector

2. Terminal 4. Boot
FUNCTION
! The speedometer sensor is installed to the transmission output

gear. A pulse voltage is generated by the rotation of the gear
teeth, and the signal is sent to the machine monitor to display
the travel speed.
10-170 WA450-3MC
ENGINE OIL LEVEL SENSOR
1. Connector 2. Bracket 3. Float 4. Switch
FUNCTION
! The sensor is installed to the side face of the oil pan. When the
oil goes below the specified level, the float goes down and the
switch is turned off. This makes the maintenance monitor flash
to warn of the fault. The check lamp also lights up at the same
time as a warning.
RADIATOR COOLANT LEVEL SENSOR
1. Float 2. Sensor 3. Connector
FUNCTION
! This sensor is installed to the top of the radiator. If the coolant

goes below the specified level, the float goes down and the
switch is turned OFF. The caution lamp and alarm buzzer are
also actuated at the same time to warn of the fault.
WA450-3MC 10-171
ENGINE OIL PRESSURE SENSOR
1. Plug 3. Contact 5. Spring

2. Contact ring 4. Diaphragm 6. Terminal
FUNCTION
! This sensor is installed to the engine block and the diaphragm
detects the oil pressure. If the pressure goes below the set
pressure, the switch turns on and a relay is actuated to turn the
output off. This makes the maintenance monitor flash to warn of
the fault. The caution lamp and alarm buzzer are also actuated
at the same time to warn of the fault.
ENGINE WATER TEMPERATURE SENSOR
1. Connector 2. Plug 3. Thermistor

FUNCTION
! This sensor is installed to the engine cylinder block. The change
in the temperature changes the resistance of the thermistor, and
a signal is sent to the maintenance monitor to display the
temperature. If the display on the monitor reaches the specified
position, the lamp flashes and the buzzer sounds to warn of the
fault.
10-172 WA450-3MC
TORQUE CONVERTER OIL TEMPERATURE SENSOR
1. Connector 2. Plug 3. Thermistor

FUNCTION
! This sensor is installed to the transmission case. Changes there
in temperature change the resistance of the sensor thermistor,
and a signal is sent to the maintenance monitor to display the
temperature. If the display on the maintenance monitor reaches
the specified position, the lamp flashes and the buzzer sounds
to warn of the fault.
ENGINE SPEED SENSOR
FUNCTION
! The engine speed sensor is installed to the ring gear portion of

the flywheel housing. A pulse voltage is generated by the
rotation of the gear teeth, and a signal is sent to the controller
and monitor panel.
WA450-3MC 10-173
FUEL LEVEL SENSOR
1. Connector 3. Arm 5. Spring 7. Spacer

2. Float 4. Body 6. Contact
FUNCTION
! The fuel level sensor is installed to the side face of the fuel tank.
The float moves up and down as the level of the fuel changes.
As the float moves up and down, the arm actuates a variable
resistance, and this sends a signal to the maintenance monitor
to display the fuel level. When the display on the maintenance
monitor reaches the specified level, the warning lamp flashes.
10-174 WA450-3MC
STRUCTURE AND FUNCTION ENGINE CIRCUITS
ENGINE START CIRCUIT
7. 80 amp fuse 13. Neutral relay

1. Alternator 8. 120 amp fuse 14. Shift lever
2. Starter motor 9. 30 amp fuse 15. Engine stop motor relay
3. Batteries 10. Start switch 16. Engine stop motor
4. Battery relay 11. Electric air intake heater
5. 10 amp fuse 12. Heater signal
6. Slow blow fuse box
WA450-3MC 10-175
ENGINE START CIRCUIT ENGINE STOP CIRCUIT
FUNCTION FUNCTION
! There is a neutral safety circuit which prevents the The system is equipped with an electrical fuel cut device
engine from being started if the directional lever is not [engine stop motor] which makes it possible to start or
at the N [Neutral] position. This is to ensure safety stop the engine by turning the start switch ON or OFF.
when starting the engine. This improves the ease of operation.
OPERATION OPERATION
! When the directional lever is placed at the N position, When the start switch is turned OFF, start switch termi-
the neutral contacts of the directional lever switch are nals B , BR and C are opened. The current in the stop
closed. In this condition, if the start switch is turned motor relay is shut off by the start switch, so the coil is
to the START position, electric current flows in circuit not excited. Therefore, terminals 3 and 6 are closed.
from the battery PO
SL starting switch terminal B L The current from the battery flows from engine stop motor
starting switch terminal C L starting motor terminal terminals A to C L relay terminals 6 to 3 L motor to
C L starting motor terminal E L ground. rotate the motor. The cable is pulled in.
W hen the motor rotates, terminal D also rotates at the
! In addition, electric current flows from starting switch same time. When the non-continuous portion of terminal
terminal BR L stop motor relay terminal 1 to 2 L D reaches terminal C, the circuit from terminal A to C
ground, and the relay coil is excited. opens, and the current from the battery to the motor is
shut off. The motor attempts to continue rotating under
! The electric current from the battery flows from engine inertia, but when the continuous portion of terminal D
stop motor terminal A to B L relay terminal 5 to 3 L contacts terminal C, both poles of the motor are con-
terminal L motor, and rotates the motor. The cable nected to the ground, and the motor stops rotating.
extends. In this condition, the stop motor table is completely pulled
in, and the fuel injection pump lever is set to the STOP
! When the motor rotates, terminal D also rotates at position to stop the engine.
the same time. When the non continuous portion of
terminal D reaches terminal B, the circuit from
terminal A to B opens, and the current from the
battery to the motor is shut off. The motor attempts
t o c ontinue rotating under inertia, but when the
continuous portion of terminal D contacts terminal B,
both poles of the motor are connected to the ground,
and the motor stops rotating.
! In this condition, the stop motor cable is completely

extended, and the fuel injection pump lever is set to
the FULL position to place it in the operating condi-
tion.
! In addition, the current flows from start switch termi-

nal BR L battery relay coil L ground, and the battery
relay switch is closed.
! A circuit is formed from the battery L battery relay L

starting motor terminal B, so the engine starts. If the
directional lever is not at the N position, circuit is not
formed, so the engine does not start.
10-176 WA450-3MC
ENGINE STOP CIRCUIT
7. 80 amp fuse 13. Neutral relay

1. Alternator 8. 120 amp fuse 14. Shift lever
2. Starter motor 9. 30 amp fuse 15. Engine stop motor relay
3. Batteries 10. Start switch 16. Engine stop motor
4. Battery relay 11. Electric air intake heater
5. 10 amp fuse 12. Heater signal
6. Slow blow fuse box
WA450-3MC 10-177
PREHEATING CIRCUIT
1. Starting motor 7. 120 amp fuse 13. Shift switch

2. Batteries 8. 30 amp fuse 14. Neutral relay
3. Coolant temperature sensor 9. Main monitor 15. Start switch
4. Battery relay 10. Electric air intake heater 16. 10 amp fuse
5. Slow blow fuse 11. Heater relay 17. To alternator
6. 80 amp fuse 12. Preheating relay
10-178 WA450-3MC
PREHEATING CIRCUIT
OUTLINE
! To improve the ease of starting in cold areas, an automatic

preheating system is installed. This system helps to reduce the
preheating time and also automatically sets the preheating time
to match the engine coolant temperature when the start switch
is operated.
! When the start switch is turned to the ON position, the preheat-

ing pilot lamp on the main monitor lights up and preheating is
carried out on the intake air for the electric intake air heater.
! The engine coolant temperature is detected by the coolant

temperature sensor, and the preheating time is set by the
controller built into the main monitor.
! While the pilot lamp is illuminated, preheating is being carried

out, so the start switch must be kept at the ON position. If the
starting switch is turned to the START position while the pilot
lamp is ON, the preheating is canceled.
OPERATION
! When the start switch is turned to the ON position, a circuit is

formed from start switch terminal BR L controller inside main
motor L preheating output L ground. The preheating relay coil
i s excited, so the preheating relay is actuated to actuate the
heater relay.
! Current flow from the battery L battery relay L heater relay L

elec trical intake air heater to carry out preheating. When the
preheating completion signal is sent from the controller, the
preheating relay and heater relay are turned OFF and the
preheating is completed.
WA450-3MC 10-179
STRUCTURE AND FUNCTION ELECTRIC TRANSMISSION CONTROL
ELECTRIC TRANSMISSION CONTROL
1. Trans cut off selector switch 6. Maintenance monitor 11. Trans cut off switch
2. Parking brake 7. Relays 12. Left brake valve
3. Directional lever 8. Fuse boxes 13. Right brake valve
4. Speed lever 9. Trans control valve 14. Trans controller
5. Kick down switch 10. Speed sensor
FUNCTION
1 Select F, R, and N positions Using directional lever
2 Select speed range Using speed lever
When traveling in F2, it is possible to shift down to 1st using this switch without using the speed lever. If directional
3 Kick down switch
lever is operated to R or N, speed range automatically returned to 2nd.
4 Transmission cut off function Transmission is shifted to neutral when left brake is operated
Select whether or not to actuate the trans cut off function. This allows the same or greater ease of operation as
5 Transmission cut off selector function conventional loaders with the left brake when carrying out work or when loading or unloading the machine from a
trailer.
6 Neutralizer To prevent parking brake seizure when traveling with it applied, trans shifts to neutral when parking brake is applied.
If the directional lever is not at the N position, the engine will not start when the starting switch is turned. This
7 Neutral safety function
prevents the machine from moving suddenly.
8 Warning function When traveling in reverse, the backup lamp lights up and the backup horn sounds to warn people in the area.
10-180 WA450-3MC
COMBINATION SWITCH
OUTLINE
! The directional lever has three positions and the speed lever
switch has four positions. As an individual part, the switch does
not have a detent mechanism; the detent mechanism is in the
combination switch. Each switch is positioned by two pins, and
i s sec ured to the body by three screws. When each lever is
operated to the desired position, the switch, which is intercon-
nected by a shaft, acts to allow electric current to flow to that
circuit only.
GENERAL LOCATIONS, FUNCTION
1 Directional lever switch Switches between F, R, and N

2 Speed lever switch Selects speed range
3 Speed lever stopper Stopper used to prevent speed lever from entering 3rd or 4th during operations
4 Turn signal indicators Direction indicator lamps used when turning left or right
5 Self cancel Turn signal lever automatically returns to center position after machines turns.
6 Lamp switch Switches on clearance lamp, head lamp, parking lamp, etc.
7 Dimmer switch Selects high beam for travel and low beam for passing
8 Hazard switch Makes both left and right turn signal indicator lamps flash at the same time
9 Emergency flashing pilot lamp Flashes at the same time as the emergency flashing lamp flashes
10 Parking brake switch Applies or releases parking brake
WA450-3MC 10-181
OPERATION
! Direc tional lever (1) and shaft (2) of the combination switch
speed lever form one unit with magnet (3). Magnet (3) also
moves together with lever (1).
! Control switch (5) with built in hole (4) is installed at the bottom
of magnet (3), and hole (4) is positioned on the board to match
each position.
! When directional lever (1) is operated to the F position, magnet

(3) is immediately above hole (4) for the F position of the control
switch. The magnetism from magnet (3) passes through the gap
and case (6), and magnetism is applied to hole (4).
! When this happens, hole (4) is inside a magnetism detection

circuit, so it detects the magnetism of magnet (3) and sends the
F position signal to the electric current amplification circuit. In
the electric current amplification circuit, a signal is output to
actuate the transmission.
10-182 WA450-3MC
STRUCTURE AND FUNCTION KICK DOWN, HOLD SWITCH
KICK DOWN, HOLD SWITCH

1. Kick down switch
2. Spring
3. Wiring harness
4. Spring
5. Hold switch
KICK DOWN SWITCH
OPERATION
! The kick down, shifting down from 2nd L 1st is actuated only
when traveling in F2.
! When traveling in F2, if it is desired to shift down to 1st without

operating the speed lever, operate the kick down switch on the
boom lever to ON to shift down to F1.
! After this, even if the kick down switch is pressed, the transmis-
sion is kept at F1.
CANCELLATION
! When directional lever is at N
! When directional lever is at R
! When speed lever is not at 2nd
! When start switch is OFF
HOLD SWITCH
! The hold switch is installed to the boom lever, and when the
boom hold switch is pressed, the speed range displayed on the
main monitor transmission indicator is hold.
! Press the hold switch again to cancel.
WA450-3MC 10-183
STRUCTURE AND FUNCTION KICK DOWN CIRCUIT DIAGRAM
KICK DOWN CIRCUIT DIAGRAM
NORMAL OPERATION - F2
10-184 WA450-3MC
1. Parking switch 8. Stop lamp 15. Main monitor

2. Parking brake safety switch 9. Neutral relay 16. Speed lever
3. Parking brake solenoid valve 10. Stop lamp relay 17. Batteries
4. Transmission cut off switch 11. Neutralizer relay 18. F solenoid
5. Stop lamp switch 12. Transmission controller 19. R solenoid
6. Starting motor C terminal 13. Hold switch 20. Speed solenoid
7. Start switch C terminal 14. Kick down switch 21. Hi-Lo solenoid
DIRECTIONAL LEVER SET TO F KICK DOWN SWITCH OPERATED

! When the directional lever is set to the F position,
electric current flows from the battery L directional
PO
S
WHEN KICK DOWN SWITCH IS PRESSED ON
lever switch terminal 1 to 2 L transmission controller ! When t he kick down switch is pressed, electric
FORWARD terminal 1, and flows as the FORWARD current flows from the transmission controller kick
output signal from terminal 21 L FORWARD solenoid down terminal 17 and enters the controller. The kick
(1) L ground, and the solenoid valve is actuated. down circuit is formed inside the controller, so the
! When the parking brake is released, the current flows solenoid output signal flows from terminals 21 and 11
from the battery PO
L parking brake safety relay
S
to FORWARD solenoid 1 and speed solenoid 4. The
terminal 5 to 3 L parking brake switch terminal 3 to solenoid valves are actuated and the transmission is
2 L neutralizer relay terminal 1 to 2 L ground, and set to F1.
neutralizer relay terminal 3 to 5 are connected. ! This kick down circuit continues to be actuated from
this point even if the kick down switch is returned.
SPEED LEVER SET TO 2ND [Self hold circuit]
! When the speed lever is at position 2, no electric ! In this way, when the speed lever is at F2, the trans-
current flows to Hi-Lo solenoid (3), R solenoid (2), or mission is automatically shifted to F1 when the kick
speed solenoid (4). In this condition, the transmission down switch is pressed.
valve is set to F2 by the action of F solenoid (1). No ! At the same time, it will be held in F1 by the self hold
current flows, if the kick down is not pressed. There- function of the kick down relay even when the kick
fore, the kick down relay is not actuated, and the down switch is released. However many times the
transmission is held in F2. k i c k down switch is pressed, the transmission will
stay in F1.
SOLENOID ACTUATION TABLE
Solenoid F1 F2 F3 F4 N R1 R2 R3 R4
FORWARD 1 # Ê # # Solenoid F1 F2 F3 F4 N R1 R2 R3 R4
REVERSE 2 # # # # FORWARD 1 Ê # # #
Hi-Lo select 3 # # # # REVERSE 2 # # # #
Speed select 4 # # # # Hi-Lo select 3 # # # #

Speed select 4 Ê # # #

WA450-3MC 10-185
KICK DOWN SWITCH OPERATED
KICK DOWN SWITCH OPERATED
10-186 WA450-3MC
CANCELING KICK DOWN SWITCH, CASE 1
WA450-3MC 10-187

DIRECTIONAL LEVER MOVED TO N OR R CANCELING KICK DOWN SWITCH, CASE 2

! When the directional lever is moved to the R position,
the F terminal contacts are turned OFF, so the SPEED LEVER MOVED TO 1ST, 3RD OR 4TH
electric current stops flowing from the battery L
PO
S
! If t he speed lever is operated to any position other
speed lever switch terminal 1 to 2 L transmission than 2nd, terminal 2 of the lever is switched off, so
controller. the electric current stops flowing from the battery PO
S
! The forward circuit in the transmission controller is L speed lever switch terminal 1 to 6 L transmission
opened, so no electric current flows to the kick down controller.
circ uit. In this way, the self hold circuit of the kick ! Therefore, the kick down circuit connected to the 2nd
down is canceled, so solenoid 4 is no longer actu- circuit also is shut off inside the transmission control-
ated. When the directional lever is moved to the N ler, and solenoid 4 no longer is actuated.
position, the actuation is the same as above and the ! When the speed lever is moved to position 3, sole-
kick down relay is canceled. In addition, the forward noid 3 is actuated. In addition, the directional lever is
circuit also is opened, so solenoid 1 is no longer at the F position, so solenoid 1 is actuated. There-
actuated. fore, solenoids 1 and 3 are actuated and the trans-
! When the directional lever is moved to the R position, mission is set to F3.
the reverse circuit is formed from the battery L
PO
S
speed lever terminal 1 to 4 L transmission controller

reverse terminal 12 L inside of controller. Current
flows from the output signal terminal 20 L reverse
solenoid 2 L ground, and the reverse solenoid valve
is actuated. Therefore, only the reverse solenoid 2 is
actuated, and the transmission is set to R2.

Solenoid F1 F2 F3 F4 N R1 R2 R3 R4
FORWARD 1 # # # # Solenoid F1 F2 F3 F4 N R1 R2 R3 R4
FORWARD 1 # # Ê #
REVERSE 2 # Ê # #
Hi-Lo select 3 # # # # REVERSE 2 # # # #
Speed select 4 # # # # Hi-Lo select 3 Ê # # #

Speed select 4 # # # #

10-188 WA450-3MC
WA450-3MC 10-189
STRUCTURE AND FUNCTION TRANSMISSION CUT OFF SWITCH
TRANSMISSION CUT OFF SWITCH
1. Case 4. Red vinyl tape 7. Cover

2. Seal film 5. Tube 8. Spring
3. Disc 6. Connector
OUTLINE
! When the left brake pedal is operated, the switch detects the oil
pressure in the brake circuit, shuts off the power to the solenoid
valve circuit for the directional clutch, and shifts the transmission
to neutral.
SPECIFICATIONS
Voltage value Min. . . . . . . . . . . . . . . . . . . . . . . . 18 V

Max. . . . . . . . . . . . . . . . . . . . . . 30 V
Current value Min. . . . . . . . . . . . . . . . . . . . . . . . 5 mA
Max. . . . . . . . . . . . . . . . . . . . . . 0.1 A
10-190 WA450-3MC
STRUCTURE AND FUNCTION TRANSMISSION CUT OFF FUNCTION
TRANSMISSION CUT OFF FUNCTION
TRANSMISSION CUT OFF SELECTOR SWITCH ON
WA450-3MC 10-191

OUTLINE
! If the transmission cut off selector switch on the main monitor

is turned on, pilot lamp lights, the transmission cut off switch
installed to the left brake pedal is actuated. When the left brake
pedal is operated, the brakes are applied, and the transmission
is shifted to neutral at the same time. If the transmission cut off
selector switch is set to the off position, pilot lamp goes out,
and the transmission is not shifted to neutral even when brake
is operated, so the left brake functions only as a brake in the
same way as the right brake.
OPERATION
Transmission Cut off Selector Switch On

! If the transmission cut off selector switch is turned on, the
current from the transmission cut off switch, main monitor, is
shut off, and current flows only from the transmission cut off
switch L terminal 16 of the transmission cut off circuit in the
transmission controller. Voltage is applied to transmission
control valve solenoids F and R.
! When left brake pedal is depressed, the contacts of transmis-
sion cut off switch are opened so the voltage to solenoids R and
F is shut off. As a result, the brakes are applied as normal, and
the transmission also is shifted to neutral at the same time.
Transmission Cut Off Selector Switch Off

! When the transmission cut off selector switch is turned off, the
current flows from the cut off switch [main monitor] L terminal
16 of transmission cut off circuit in the transmission controller.
In this condition, voltage is applied to transmission solenoids F
and R regardless of the position of the transmission cut off
switch. As a result, even when left brake pedal is depressed, the
transmission is not shifted to neutral.
10-192 WA450-3MC
TRANSMISSION CUT OFF SELECTOR SWITCH OFF
WA450-3MC 10-193
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
ELECTRIC PARKING BRAKE CONTROL
OUTLINE
1. Parking brake switch
! The parking brake is a wet type multiple disc brake built into the 2. Parking brake emergency release switch
transmission. When an electric current flows to the parking
3. Parking brake safety relay
brake valve (solenoid valve), the oil pressure from the transmis-
sion pump is applied to the parking brake cylinder and the 4. Neutralizer relay
parking brake is released. 5. Parking brake emergency release relay
! When the electric current is cut, the oil pressure from the 6. Accumulator
transmission pump is shut off, and the oil inside the parking
7. Charge valve
brake cylinder passes through the parking brake valve and is
drained. The parking brake then is applied by the force of the 8. Parking brake emergency release valve
brake spring. 9. Transmission control valve
10. Parking brake solenoid valve
FUNCTION
11. Parking brake
Applying and Releasing Parking Brake
! The parking brake is applied or released by using the parking
brake switch, combination switch.
Automatic Parking Brake

! W hen the engine stops, start switch off, the parking brake is
automatically applied to prevent the machine from running away
when the operator is away from his seat.
10-194 WA450-3MC
Emergency Brake
! If the pressure in the oil pump drops because of damage to the
hydraulic circuit and the braking force cannot be ensured, the
parking brake is applied automatically to act as an emergency
brake.
Parking Brake Safety

! It is dangerous if the parking brake can be released simply by
turning the start switch on after the automatic parking brake has
been applied. Therefore, to ensure safety, the system is
designed so the brake cannot be released unless the start
switch is turned on and then the parking brake switch is also
turned on.
Neutralizer
! The parking brake may seize if the machine is driven with the
parking brake still applied. To prevent this problem, the caution
lamp lights up and the alarm buzzer sounds to warn the operator
of the mistaken operation. In addition to this, when the parking
brake is applied, the transmission is forcibly shifted to neutral to
make it impossible to drive the machine. However, the braking
distance will increase if the transmission is shifted to neutral
when the emergency brake is applied. It may also be necessary
to move the machine if it stops in places where it is prohibited
t o stop, such as on railway crossings. To overcome this, the
circuit is designed so that the transmission is not shifted to
neutral when the emergency brake is applied.
Parking Brake Emergency Release Solenoid Valve

! Ifthe supply of pressured oil from the transmission pump should
stop because of some failure, it is possible to actuate the
emergency relief solenoid valve with the parking brake emer-
gency release switch in the operator's compartment. This sends
the accumulator charge pressure in the brake piping to the
parking brake cylinder to release the parking brake.
PARKING BRAKE EMERGENCY RELEASE SWITCH

Terminal No. L
Lever position Î Ï Ð Ñ
OFF
ON ± ± ± ±
WA450-3MC 10-195
EMERGENCY BRAKE SWITCH
1. Case
2. Cover
3. Vinyl tape
4. Tube
5. Connector
PARKING BRAKE SAFETY RELAY

NEUTRALIZER RELAY
1. Case
2. Base
Terminal No.L
Current between 1 and 2 Ð Ò Ó
ON ± ±
OFF ± ±
10-196 WA450-3MC
OPERATION
START SWITCH OFF
WA450-3MC 10-197
1. Batteries 7. Emergency brake switch, accumilator mounted

2. Battery relay 8. Parking brake solenoid valve
3. Parking brake switch 9. Transmission controller
4. Parking brake safety relay 10. 10 amp fuse
5. Neutralizer relay 11. Directional lever
6. Alternator 12. Start switch
START SWITCH OFF
! When the start switch is turned off, the battery relay is opened,
so electricity does not flow to the parking brake circuit. For this
reason, if the start switch is at the off position, no electric
current flows to the parking brake solenoid valve, regardless of
whether the parking brake switch is on [applied] or off [released],
so the parking brake is actuated, automatic parking brake.
STARTING SWITCH ON
Parking Brake Switch Is On Before Start Switch Is Turned On
! The electric current flows in circuit from the battery L start

PO
S
switch L battery relay coil L ground, so the battery relay is

closed. When this happens, electric current flows in circuit from
the battery PO
S L battery relay L parking brake switch terminal
1 to 3 L parking brake safety relay terminal 1 to- 2 L ground.
In this way, the parking safety relay is actuated and safety relay
terminals 3 to 5 are closed.
! When this happens, circuit is formed from the battery L
PO
S
battery relay L parking safety relay terminal 5 to 3 L parking

safety relay terminal 1 to 2 L ground. From this point, the
parking safety relay is in the condition of circuit until the start
switch is turned off.
! In this condition, electric current does not flow to the parking
brake solenoid valve, so the parking brake is actuated.
! In addition, in this condition, neutralizer relay terminals 3 and 5
are open, so electric current does not flow to the transmission
directional circuit, and the transmission is shifted to neutral.

10-198 WA450-3MC
STARTING SWITCH ON
Parking Brake Switch Is On Before Start Switch Is Turned On
WA450-3MC 10-199
STARTING SWITCH ON
Parking Brake Switch Is Off Before Start Switch Is Turned On
10-200 WA450-3MC

Parking Brake Switch Is Off Before Start Switch Is Turned On
! Electric current flows in circuit from the battery L start switch

PO
S
L battery relay coil L ground, so the battery relay is closed.

However, in this case, the parking brake switch is off, so the
parking safety relay is not actuated. For this reason, the electric
current does not flow to the parking brake solenoid valve, so
after the automatic parking brake is applied, the parking brake
i s not released automatically even when the start switch is
turned on.
! In addition, the electric current does not flow to the transmission
directional circuit, so the machine does not move.
PARKING BRAKE SWITCH OFF
Parking Brake Switch Is Turned from On to Off after the Start

Switch Is Turned On
! Ifthe parking brake switch is turned from on to off, the circuit for
terminals 2 and 3 of the parking brake switch is connected, and
the parking brake safety relay is also actuated. For this reason,
electric current flows in circuit from the battery L battery
PO
S
relay L parking brake safety relay L parking brake switch, and

then flows to circuits given below.
! This circuit is formed from the emergency brake switch L
parking brake solenoid valve L ground, and the parking brake is
released.
! This circuit is formed from the battery PO
L battery relay L
S
neutralizer relay terminal 3 to 5 L transmission directional

circuit, so when the directional lever is operated, the machine
will move.

WA450-3MC 10-201
PARKING BRAKE SWITCH OFF

Parking Brake Switch Is Turned from On to Off after the Start Switch Is Turned On
10-202 WA450-3MC
PARKING BRAKE SWITCH ON
WA450-3MC 10-203

PARKING BRAKE SWITCH ON
! If the parking brake switch is turned on after carrying out

operations with the parking brake switch off, the circuit in the
diagram above is formed.
! Electric current does not flow to the parking brake solenoid
valve, so the oil pressure from the transmission pump to the
parking brake cylinder is shut off. At the same time, the oil
pressure inside the parking brake cylinder passes through the
parking brake valve and is drained, so the parking brake is
applied by the force of the spring.
! In addition, at the same time, the neutralizer relay is reset, so
the circuit between terminals 3 and 5 is opened, and no
electricity flows to the transmission directional circuit, so the
transmission is shifted to neutral. This kind of neutralizer relay
shuts off the electric current going to the transmission solenoid
valve when the parking brake is applied and shifts the transmis-
sion to neutral to prevent seizure of the parking brake if the
operator should drive the machine with the parking brake still
applied.
WHEN MAIN BRAKE OIL PRESSURE DROPS
! If the oil pressure in the main brake line drops, the emergency
brake switch installed to the accumulator is opened.
! For this reason, the electric current stops flowing to the parking
brake solenoid valve, so the oil pressure inside the parking brake
cylinder is drained and the parking brake is applied. However,
in this case, the condition is different from the case where the
parking brake switch is on, because there is electric current
flowing to the neutralizer relay coil.
! For this reason, electric current flows to the transmission
directional circuit, and it is possible to engage the transmission
clutch. In this way, it is possible to use the engine brake when
the emergency brake is applied, so braking distance becomes
short er. At the same time, if the emergency brake has been
applied and it is necessary to move the machine, for example,
if the emergency brake is applied when the machine is on a
railway crossing, it is possible to move the machine by operat-
ing the transmission lever.

10-204 WA450-3MC
WHEN MAIN BRAKE OIL PRESSURE DROPS
WA450-3MC 10-205
PARKING BRAKE EMERGENCY RELEASE
PARKING BRAKE EMERGENCY RELEASE
1. Batteries 6. Alternator
2. Battery relay 7. Brake ACC low pressure switch
3. Parking brake emergency release switch 8. Parking brake emergency release solenoid valve
4. Maintenance monitor 9. Start switch
5. Alamr buzzer
OPERATION
! Ifthe machine stops because of engine trouble, the oil pressure
from the transmission pump to the parking brake cylinder is shut
off, and the parking brake is applied. When this happens, oil
pressure in the main brake line is stored in the accumulator.
When the emergency release switch is turned on, the buzzer
sounds, and at the same time, electric current flows to the
emergency parking brake release solenoid valve.
! The oil pressure stored in the accumulator in the main brake line
then flows to the parking brake cylinder to release the parking
brake.
! The emergency release switch should normally be kept at the
OFF position and should be returned to the OFF position after
the emergency release.
10-206 WA450-3MC
FUNCTION OF PARKING BRAKE NEUTRALIZER RELAY
OUTLINE
! When the parking brake is applied, this relay keeps the trans-
mission at neutral to prevent dragging of the parking brake due
to mistaken operation.
FUNCTION OF PARKING BRAKE NEUTRALIZER RELAY
1. Parking brake switch 6. Neutral relay 11. Hold switch

2. Transmission cut off switch 7. Neutralizer relay 12. Kick down switch
3. To battery power source 8. Starter motor terminal C 13. Transmission combination switch
4. Parking brake solenoid valve 9. Start switch terminal C 14. Main monitor
5. Parking brake safety relay 10. Transmission controller 15. 10 amp fuse
OPERATION
! W hen the parking brake is on, electric current flows from the
battery relay L parking brake switch terminal 1 to 3 L parking
brake safety relay terminal 1 L ground. For this reason, the
safety relay coil is actuated, terminals 3 and 5 of the safety
relay are connected, and this circuit is formed.
! When the parking brake is actuated, no electric current flows to
the neutralizer relay coil, so terminal 3 and terminal 5 of the
neutralizer relay are separated. No electric current flows to the
t ransmission directional circuit, so when the parking brake is
applied, the transmission is kept at neutral.
! When the engine is started with the parking brake switch off, the
circuit is not formed, so it is necessary to turn the parking brake
switch on to form the circuit.
WA450-3MC 10-207
20 TESTING AND ADJUSTING
STANDARD VALUE TABLES FOR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2

STANDARD VALUE FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
STANDARD VALUE TABLES FOR ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
TESTING AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201
ENGINE SYSTEM - S MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-301
MAIN MONITOR SYSTEM - M MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-401
MAINTENANCE MONITOR SYSTEM - K MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501
ELECTRICAL SYSTEM - E MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-601
TRANSMISSION CONTROLLER SYSTEM - A MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-701
HYDRAULIC AND MECHANICAL SYSTEM - T MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-801
ECSS - E MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-901
i When using the standard value table to make judgement for testing and adjusting, and troubleshooting, the
following precautions are necessary.
1. The standard values in the table are the values for a new machine and are given as reference values for the time
when the machine is shipped from the factory. These values should be used as a guide when estimating wear and
tear after the machine is operated, and when carrying out repairs.
2. The permissible values given in the table are values estimated based on the results of various tests carried out on
the machines shipped from the factory, so they should be used together with the information on the repair condition
and other information such as the operating history of the machine when judging the condition of the machine.
3. These standard values do not form a basis for judging claims.
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert
the safety pins, and use blocks to prevent the machine from moving.
WARNING! When carrying out work together with other workers, always use signals and do not let unauthorized
people near the machine.
WARNING! When checking the coolant level, always wait for the coolant to cool down. If the radiator cap is
removed while the coolant is still hot, the coolant will spurt out and cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
WA450-3MC 20-1 Î
TESTING AND ADJUSTING STANDARD VALUE TABLES FOR ENGINE
STANDARD VALUE TABLES FOR ENGINE
Machine model WA450-3MC and WA450-3MC Material Handler
Engine SA6D125E-2
Item Measurement Unit Standard value Permissible value
High idle 2400 ± 50 2400 ± 100
Engine speed Low idle rpm 765 ± 15 765 ± 50
Rated speed 2200 ---
Sudden acceleration Max 6 8

Bosch
Exhaust gas color
index
High idle Max 1 2
Intake valve 0.33 ---

Valve clearance - cold mm
Exhaust valve 0.71 ---
Oil temp, 40 to 60E C -

Compression pressure,
Engine speed, 200 to 250 kg/cm2 32 22
SAE 30 oil
rpm
Blow by pressure Coolant temp at operating

mmH2O Max 150 300
SAE 30 oil range, at rated output
At high idle SAE30 3 to 5 2.1
At low idle SAE30 Min 1.5 0.7

Oil pressure with coolant 2
kg/cm
temp at operating range
At high idle SAE10W 2.5 to 4.5 1.8
At low idle SAE10W Min 1 0.7
Oil temperature Whole speed range EC 80 to 110 120
Fuel injection timing Before top dead center E 16 ± 0.5 ± 0.5
Deflection force of belt

Belt tension when pressed with finger mm 10 7 to 13
force of . 6 kg
20-2 Î WA450-3MC
TESTING AND ADJUSTING STANDARD VALUE FOR CHASSIS
STANDARD VALUE FOR CHASSIS
Category Item Measurement conditions Unit Standard value Permissible value
Operating effort N 68.6 to 73.6 112.8

Accelerator pedal
"1 48 ---
E
Operating angle
deg
"2 30 ---
Stopper height L mm 44.5 to 54.5 ---

Directional lever
+ 0.5
N to For 5.9 ! 0.3 Max 16.7
Operating effort N
+ 0.5
N to Rev 5.9 ! 0.3 Max 16.7
N to For 25 to 45 15 to 55
Travel mm
N to Rev 25 to 45 15 to 55
Engine stopped + 0.5
1st to 2nd 5.9 ! 0.3 16.7
Speed control lever
Operating effort 2nd to 3rd Converter oil temp, 60 to 80 EC N + 0.5

16.7
5.9 ! 0.3
+ 0.5
3rd to 4th 5.9 ! 0.3 16.7
1st to 2nd 25 to 45 15 to 55
Travel 2nd to 3rd mm 25 to 45 15 to 55
3rd to 4th 25 to 45 15 to 55
Engine speed
Torque converter stall Coolant temp gauge - green 2150 to 2350 2050 to 2450
range
Hydraulic stall rpm 2160 to 2360 2060 to 2460
Converter oil temp, 60 to 80 EC
Full stall Hydraulic oil temp, 45 to 55 EC 1770 to 2170 1670 to 2270
+ 1.5
Rated speed 29 ± 1.5 29 ! 4.5
Priority pressure
+ 1.5
Low idle 25 ± 1.5 25 ! 4.0
Transmission valve
+ 0.5
Converter outlet
Rated speed 4.5 ± 0.5 4.5 ! 1.0
port pressure + 1.5
kg/cm2
Low idle 3.5 ± 1.5 29 ! 4.5

Converter oil temp, 60 to 80 EC
+1
Pilot pressure 10 ± 1 10 !2
+ 2.0
Clutch pressure 23 ± 2 23 ! 4.5
+ 1.5
Parking brake Rated speed 29 ± 1.5 29 ! 4.5
pressure Low idle 25 ± 1.5
+ 1.5
25 ! 4.0
Tire inflation pressure Specified value

A Max 2.5 ---
Fitting of lock ring
Tire
B mm Max 4 ---
Clearance of lock ring C 2 to 10 ---

Engine stopped, machine facing
Play mm Max 20 50
Steering wheel
straight to front
Flat horizontal straight dry paved
Operating effort N 9.8 to 14.7 22.5
road surface
Low idle Max 4.5 6.8
Operating time Hydraulic oil temp, 45 to 55 EC Sec
High idle Max 3.2 4.8
WA450-3MC 20-3 Î

Frame
Clearance between front frame Hydraulic oil temp, 45 to 55 EC

mm 40 ± 5 ---
and rear frame - stopper bolt Engine speed, 1200 rpm
Steering
kg/cm2
Hydraulic oil temp, 45 to 55 EC
valve
+5 + 10
Relief pressure 210 !4 210 !6
Engine speed, high idle

Operating effort N 294 ± 29.4 421.7
"1 45 ---
Operating angle
Deg E
+1
"2 15 0 ---
Brakes
Play "3 5 ± 0.5 ---

Flat, horizontal, straight, dry paved road
surface
Speed when applying brake: 20 km/h,
Performance braking delay: 0.1sec m Max 5 5
Brake pedal operating force: 27 kg
Tire inflation pressure: Specified pres-
sure
Drop in hydraulic pressure 50 kg/cm2 in 5 minutes kg/cm2 Max 5 5

Disc wear Piston stroke mm 1.2 to 4.7 6.2
Point where brake
Accumulator
+2 +2
Charge cut in pressure oil pressure warn- 60 0 60 ! 10
Hydraulic oil temp, ing lamp goes out
kg/cm2
45 to 55 EC
Engine speed, high Point where oil
idle pressure is going + 10
Charge cut out pressure up and then starts 100 0 90 to 110
to go down
Tire inflation pressure: Specified
pressure
Parking brake
Flat paved road with 1/5 (11E20')

Performance grade
--- Stopped ---
Dry road surface, machine at operat-
ing condition
Disc thickness mm 3.2 ± 0.08 2.83
Hold L Raise Max 2.4 3.6

Raise L Hold Max 1.6 2.4
Hold L Lower Hydraulic oil temp, 45 to 55 EC Max 2.5 3.8
Operating effort
Lift arm
Work equipment control lever
Lower L Hold Engine speed, low idle --- ---

Lower L Float N Max 3.5 5.3
Float L Hold Max 1.5 2.3
Hold L Dump Max 2.4 3.6
Bucket Hold L Tilt Max 2.4 3.6
Tilt L Hold Max 1.5 2.3
Hold L Raise Hydraulic oil temp, 45 to 55 EC 52 to 82 37 to 97
Lift arm Hold L Lower Engine speed, low idle 38 to 68 23 to 83
Travel
Hold L Float mm 52 to 82 37 to 97
Hold L Dump 45 to 75 30 to 90
Bucket
Hold L Tilt 45 to 75 30 to 90
20-4 Î WA450-3MC
kg/cm2 kg/cm2
control

valve
Main
+ 10 + 10
Relief pressure 210 - 3 210 - 3
valve
PPC
+2 +4
Relief pressure 38 0 38 - 2
Hydraulic drift Work equipment speed
Lift arm lifting time 5.5 ± 0.3 7.0

Lift arm lowering time 3.7 ± 0.3 5.1
Sec
Bucket dumping time Engine speed, high idle 1.4 ± 0.3 2.1
Steering valve; neutral no load
Bucket tilting At full stroke 1.9 ± 0.3 2.7
Boom
time Bucket horizontal 1.2 ± 0.3 1.8

Boom cylinder rod retraction Leave for 5 min. after stopping en- Max 30 36
gine. Then measure for next 15 min. mm
Bucket cylinder rod retraction Bucket empty, lift arm, bucket hori- Max 20 24
zontal
Clearance of bucket positioner
Proximity
3 to 5 ---
switch
switch
Hydraulic oil temp, 45 to 55 EC mm
Clearance of boom kick out
3 to 5 ---
switch
WA450-3MC 20-5 Î
TESTING AND ADJUSTING STANDARD VALUE TABLES FOR ELECTRICAL PARTS
STANDARD VALUE TABLES FOR ELECTRICAL PARTS
Component Connector Inspection Judgement table Measurement

If the condition is as shown in the following table, the
connector
sensor is normal
Short
Short connector connected . . . . . . . . . Display goes out Start switch on
R06 disconnected . . . . . . . . . . . . . . . . Display lights up
Water level sensor R06
continuity
sensor is normal
Check
Coolant level normal . . . . . . . . . . . . . . . . . . . Continuity Start switch off
Coolant level abnormal . . . . . . . . . . . . . . . No continuity
chassis ground
Connect to
sensor is normal
Chassis ground connected . . . . . . . . . . Monitor goes off Start switch on
E10 disconnected . . . . . . . . . . . . . . . . Monitor lights up
Engine oil level sensor E10
continuity
sensor is normal
Check
Engine oil level normal . . . . . . . . . . . . . . . . . Continuity Start switch off

Engine oil level abnormal . . . . . . . . . . . . . No continuity

resistance
Converter oil temp sensor T07 sensor is normal

Measure
Normal temp 25EC . . . . . . . . . . . . . . . . . . 38 to 48 kS Start switch off

Engine coolant temp sensor E06 100EC . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 to 3.9 kS

resistance
sensor is normal
Measure
+1
Fuel level sensor R07 Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3 S Start switch off
Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 95 kS
Measure
voltage
With engine running, ½ throttle or more . . . . . 27.5 to 29.5 V

Alternator --- i If the battery is old, or after starting in cold temperatures, the Start engine
voltage may not rise quickly.
chassis ground
Connect to
sensor is defective
Terminal harness disconnected . . . . . Monitor goes out Start switch on
Connected to chassis ground . . . . . . . Monitor lights up
Engine oil pressure sensor ---
continuity
sensor is normal
Check
Oil pressure above 0.7 kg/cm2 . . . . . . . . . No continuity Start engine

2
Oil pressure below 0.3 kg/cm . . . . . . . . . No continuity

connector
sensor is defective
Short
Short connector connected . . . . . . . . . Monitor goes out Start switch on

T06 disconnected . . . . . . . . . . . . . . . . Monitor lights up
Parking brake switch T08
continuity
sensor is normal
Check
Oil pressure above 6.1 kg/cm2 . . . . . . . . . . . Continuity Start engine

2
Oil pressure below 3.5 kg/cm . . . . . . . . . No continuity
20-6 Î WA450-3MC

connector
sensor is defective
Short
B08, B13 disconnected . . . . . . . . . . . . Monitor lights up
Brake ACC low pressure B08
switch B13 If the condition is as shown in the following table, the
continuity
sensor is normal
Check
Oil pressure above 60 kg/cm2 . . . . . . . . . . . . Continuity Start switch off
2
Oil pressure below 40 kg/cm . . . . . . . . . . No continuity
connector
sensor is defective
Short
B09, B10 disconnected . . . . . . . . . . . . Monitor lights up
B09
Emergency brake switch
B10 If the condition is as shown in the following table, the
continuity
sensor is normal
Check
Oil pressure above 45 kg/cm2 . . . . . . . . . . . . Continuity Start switch off

2
Oil pressure below 32 kg/cm . . . . . . . . . . No continuity
Measure
voltage
With engine running, ½ throttle or more . . . . . 27.5 to 29.5 V

Terminal R and
Alternator i If the battery is old, or after starting in cold temperatures, Start engine
chassis
the voltage may not rise quickly.
Main monitor
resistance
sensor is normal E05 to GND

Measure
Engine coolant tempera- Start switch off

ture sensor
E05 Normal temp, 25EC, E05 to GND . . . . . . . . . . . . 2 kS Disconnect E05
5EC, E05 to GND . . . . . . . . . . . . . . . . . . . . . . . . 4 kS
resistance

Measure
sensor is normal Start switch off

Speed sensor T06
Between 1 to 2 . . . . . . . . . . . . . . . . . . . . 500 to 1000 S Disconnect T06
Normal if within the following range

resistance
Measure
F solenoid T01 Between Î and Ï . . . . . . . . . . . . . . . . . . . . . 46 to 58 S Start switch off

Connector disconnected
Between Î and chassis . . . . . . . . . . . . . . . . 1 MS or >

resistance
Measure
R solenoid T02 Between Î and Ï . . . . . . . . . . . . . . . . . . . . . 46 to 58 S Start switch off

Transmission controller

resistance
Measure
HL solenoid T03 Between Î and Ï . . . . . . . . . . . . . . . . . . . . . 46 to 58 S Start switch off


resistance
Measure
Speed solenoid T04 Between Î and Ï . . . . . . . . . . . . . . . . . . . . . 46 to 58 S Start switch off


resistance
Measure
EMCV solenoid T12 Between Î and Ï . . . . . . . . . . . . . . . . . . . . . 46 to 58 S Start switch off

WA450-3MC 20-7 Î
resistance resistance resistance

If the condition is as shown in the following table, it is
Measure Measure Measure

normal Start switch off
Relief solenoid AF4
Between 1 and 2 . . . . . . . . . . . . . . . . . . . . . . 20 to 40 S Disconnect AF4

High pressure solenoid AF5
ECSS controller

Low pressure solenoid AF6
resistance
normal, between 1 and 2
Measure
Start switch off
Pressure switch AF7 Oil pressure above 55 kg/cm2 . . . . . . . . . . . . Continuity Disconnect AF7
2
resistance Oil pressure below 45 kg/cm . . . . . . . . . . No continuity

Measure

Speed sensor T06
Between 1 and 2 . . . . . . . . . . . . . . . . . . . . . . 20 to 40 S Disconnect T06
20-8 Î WA450-3MC
TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . 20-102
ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-103
INTAKE AIR PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-104
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
EXHAUST COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
EXHAUST TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-107
BLOW BY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-108
COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-109
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110
FUEL INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111
ENGINE STOP MOTOR CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-114
FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-117
SPEED CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
STALL SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
POWER TRAIN OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-122
EMERGENCY MANUAL SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-123
TIRE AND WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-124
STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125
STEERING CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-127
STEERING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-128
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-129
BRAKE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130
BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-131
BRAKE DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-132
BLEED AIR FROM BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 20-133
ACCUMULATOR CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . 20-134
PARKING BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . 20-135
MANUAL RELEASE OF PARKING BRAKE . . . . . . . . . . . . . . . . . . . 20-136
WEAR OF PARKING BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . 20-137
WORK EQUIPMENT CONTROL LEVER . . . . . . . . . . . . . . . . . . . . 20-138
WORK EQUIPMENT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-144
BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-146
BOOM KICK OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-147
LOAD METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-149
MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-151
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-152
WA450-3MC 20-101 Î
TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING

Check or measurement item Symbol Part No. Part Name Remarks
Display L . . . . . . . . . . 60 to 2000 rpm

Engine speed A 799-203-9000 Multi-tachometer
H . . . . . . . . . 60 to 19999 rpm
799-101-5002 Hydraulic tester Gauges . . . . . . . 25, 60, 400 600 kg/cm2
Oil pressure B 790-261-1203 Digital hydraulic tester Gauge . . . . . . . . . . . . . . . . . 700 kg/cm2
799-401-2320 Hydraulic gauge Range . . . . . . . . . . . . . . . 0 to 10 kg/cm2
Boost pressure C 799-201-2202 Pressure gauge Range . . . . . . . . . . -760 to 1500 mmHg
Valve clearance D Commercially available Feeler gauge
1 799-201-9000 Handy Smoke Checker Discoloration 0 to 70%, with standard

Exhaust color E color. Discoloration % x 1/10 = Bosch
2 Commercially available Smoke meter index.
1 799-101-1502 Digital temperature gauge

Temperature F
2 799-201-1110 Wiring harness
1 799-201-1511 Tool
2 799-201-1541 Gauge Kit No. . . . . . . . . . . . . . . . 799-201-1504

Blow by pressure G
3 799-201-1571 Tube Range . . . . . . . . . . . . . 0 to 500 mmH2O
4 799-201-1450 Adapter
1 795-502-1590 Compression gauge

Range . . . . . . . . . . . . . . . 0 to 70 kg/cm2
Compression tester H Kit Part No. . . . . . . . . . . . 795-502-1205
2 795-502-1360 Adapter
1 79A-264-0020 Range . . . . . . . . . . . . . . . . . . . 0 to 294N

Operating effort J Push pull scale
2 79A-264-0091 Range . . . . . . . . . . . . . . . . . . . 0 to 490N
Stroke, hydraulic drift K Commercially available Scale
Work equipment speed L Commercially available Stop watch
799-601-7400
Troubleshooting of wiring har-
nesses and sensors
M T-adapter
799-601-7230
Measuring voltage and resis-

tance values
N 79A-264-0211 Tester
Fuel injection timing P 795-471-1200 Gauge
Clearance Q Commercially available Feeler gauge
Wear of parking brake R Commercially available Calipers
1 793-520-1803 Brake test kit

Brake oil pressure S
2 170-21-11190 Nipple
Boom drop prevention tool T 793-463-1100 Stopper
1 709-261-1131 Tee
Accumulator charge pressure U 2 799-101-5160 Connector
3 799-101-5170 Hose
20-102 Î WA450-3MC
TESTING AND ADJUSTING ENGINE SPEED
ENGINE SPEED
WARNING! When removing or installing the measuring
equipment, be careful not to touch any high temperature parts.
MEASUREMENT CONDITIONS
Coolant temperature . . . . . . . . . . . . . . . . . Within operating range
Power train oil temperature . . . . . . . . . . . . . . . . . . . . . . 70 to 90EC
Hydraulic oil temperature . . . . . . . . . . . . . . . . . . . . . . . 45 to 55EC
1. Remove cover (1).
2. Install the sensor of multi tachometer A to the speed pick up

port, then connect to tachometer.
WARNING! When carrying out the measurement, be careful

not to touch any high temperature parts.
3. Start the engine, and measure the engine speed at low and high
idle.
i When measuring items other than above, ie converter stall, see

the procedure for each item.
WA450-3MC 20-103 Î
TESTING AND ADJUSTING INTAKE AIR PRESSURE
INTAKE AIR PRESSURE

equipment or when carrying out the measurements, be careful
not to touch any high temperature parts or rotating parts.
1. Remove air supply pressure measurement plug (1).
2. Install the coupler (a) of oil pressure gauge kit B.
3. Connect the oil pressure measurement hose (b) of oil pressure

gauge kit B to the coupler and pressure gauge C [-760 to 1500
mmHg].
WARNING! When carrying out the measurement, be careful

not to touch any high temperature parts.
Note: Run the engine at a mid range speed or above, and use the
self seal portion of the gauge to bleed the oil from inside the
hose.
i Insert the gauge about half way, and repeatedly open the self
seal portion to bleed the oil. The gauge does not work if there is
any oil inside the hose, so always be sure to bleed all the oil.
4. Run the engine at near the rated speed and measure the
pressure indicated by the gauge.
20-104 Î WA450-3MC
TESTING AND ADJUSTING VALVE CLEARANCE
VALVE CLEARANCE
1. Remove the cylinder head cover (1).
2. Rotate the crankshaft in the normal direction to align TOP 1.6

line on the crankshaft pulley with pointer (2) when the #1
cylinder is at compression top dead center. When rotating,
check the movement of the valves.
3. When #1 cylinder is at compression top dead center, Adjust the

valves marked Ê. When #6 cylinder is at compression top dead
center, adjust the valves marked #.
Valve arrangement chart.
Cylinder No. 1 2 3 4 5 6
Intake valve Ê Ê # Ê # #
Exhaust valve Ê # Ê # Ê #
4. To adjust the valve clearance, loosen locknut (6) of adjustment

screw (5), then insert feeler gauge G between cross head (4)
and rocker arm lever (3), and turn adjustment screw (5) until the
clearance is a sliding fit.
5. Tighten locknut (4) to hold the adjustment screw in position.
Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 ± 7 NCm
i After adjusting #1 cylinder at compression top dead center, it is

also possible to turn the crankshaft 120E each time and adjust
the valve clearance of the intake and exhaust valves of each
cylinder according to the firing order.
i The firing order is as follows . . . . . . . . . . . . 1 - 5 - 3 - 6 - 2 - 4
i For details of the valve clearance, see the STANDARD VALUE

TABLE.
i After tightening the locknut, check the valve clearance again.
WA450-3MC 20-105 Î
TESTING AND ADJUSTING EXHAUST COLOR
EXHAUST COLOR
! When measuring in the field when there is no air or power
supply, use handy smoker checker E1; when recording official
data, use smoke meter E2. Raise the coolant temperature to the
operating range before measuring.

equipment, be careful not to touch any high temperature part.
MEASURING WITH HANDY SMOKE CHECKER E1
1. Fit filter paper in tool E1.
2. Insert the exhaust gas intake port into the exhaust pipe, acceler-
ate the engine suddenly, and at the same time operate the
handle of tool E1 to catch the exhaust gas on the filter paper.
3. Remove the filter paper and compare it with the scale provided
to judge the condition.
MEASURING WITH SMOKE METER E2
1. Insert the probe of tool E2 into the outlet port of exhaust pipe,
then tighten the clip to secure it to the exhaust pipe.
2. Connect the probe hose, accelerator switch plug, and air hose
to tool E2.
Air supply pressure . . . . . . . . . . . . . . . . . . . < 15 kg/cm2
3. Connect the power cord to the AC power source socket.
i When connecting the port, check first that the power switch of
tool E2 is off.
4. Loosen the cap nut of the suction pump, then fit the filter paper.
i Fit the filter paper securely so that the exhaust gas does not
leak.
5. Turn the power switch of tool E2 on. Accelerate the engine

suddenly, and at the same time, depress the accelerator pedal
of tool E2 and catch the exhaust gas color on the filter paper.
6. Lay the filter paper used to catch the exhaust gas color on top
of unused filter papers, 10 sheets or more, inside the filter paper
holder, and read the indicated value.
20-106 Î WA450-3MC
TESTING AND ADJUSTING EXHAUST TEMPERATURE
EXHAUST TEMPERATURE
WARNING! The temperature sensor is installed to the exhaust
manifold, so if the machine has been operated, wait for the
manifold to cool down before installing the sensor.
i Raise the coolant temperature to the operating range before

measuring.
1. Remove plug (1) from the exhaust manifold.
2. Install temperature sensor (2).
Temperature sensor
6215-11-8180 . . . . . . . . . . . . . . . . . . cable length: 610 mm
6215-11-8170 . . . . . . . . . . . . . . . . . . cable length: 490 mm
3. Connect to digital temperature gauge F1 with wiring harness F2.
MEASUREMENT PROCEDURE
1. Measuring at converter stall
i If the exhaust gas temperature is measured only at torque

converter stall, and this is continued until the sensor core heats
up and a stable value is obtained, the torque converter will
overheat.
a. Use the full stall (converter stall plus hydraulic relief) to

raise the exhaust gas temperature.
b. From the above condition, cancel the hydraulic relief, and

carry out only converter stall.
i The temperature will start to go down. If it does not go down and

continues to go up, make the temperature setting at (a) higher.
c. When the temperature starts to go down, record the stable

temperature.
2. Measuring maximum value for exhaust gas temperature
a. Carry out actual work and measure the maximum value

when operating.
i Using the PEAK mode function, the maximum value of the

temperature gauge can be recorded.
WA450-3MC 20-107 Î
TESTING AND ADJUSTING BLOW BY PRESSURE
BLOW BY PRESSURE
MEASUREMENT CONDITIONS.
Coolant temperature . . . . . . . . . . . . . . . . . Within operating range
1. Install tools G4 and G1 to the tip of engine breather hose (1),

then connect tools G2 and G3.
2. Run the engine at the rated output and measure the blow by
pressure.
WARNING! When measuring the blow by pressure, be careful

not to touch any high temperature parts or rotating parts.
i The blow by should be measured with the engine running at

rated output.
! When measuring in the field, a similar value can be obtained at

stall speed.
! If it is impossible to check at rated output or stall speed, mea-

sure at high idle. In this case, the blow by value will be about
80% of the value at rated output.
i Blow by varies greatly according to the condition of the engine.

Therefore, if the blow by value is considered abnormal, check
for problems connected with defective blow by, such as exces-
sive oil consumption, defective exhaust gas color, and prema-
turely dirty or deteriorated oil.
20-108 Î WA450-3MC
TESTING AND ADJUSTMENT COMPRESSION PRESSURE
COMPRESSION PRESSURE
WARNING! When measuring the compression pressure, be
careful not to touch the exhaust manifold or muffler, or to get
your clothes caught in the fan, fan belt or other rotating parts.
i Warm up engine before measuring the compression pressure.

Oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 to 60EC
1. Adjust valve clearance. For details, see VALVE CLEARANCE.
2. Remove spill tube (1) and disconnect fuel injection pipe (2).
3. Remove nozzle holder (3) from each cylinder to be measured.
i When removing nozzle holder (3), assemble bolt (a) to the spill
tube mount and twist with bar (b) to remove. Be careful not to let
dirt or dust get in.
4. Install adapter H2 in the mount of the nozzle holder of the

cylinder to be measured, and tighten to the specified torque.
Adapter torque . . . . . . . . . . . . . . . . . . . . . . . . 22 ± 3 NCm
5. Connect compression gauge H1 to adapter H2.
6. Disconnect connector (5) of stop motor (4), set to the NO

INJECTION position, then crank the engine with the starting
motor and measure the compression pressure at the point
where the pressure gauge indicator remains steady.
i If the fuel control lever is not set to the NO INJECTION position,

fuel will spurt out.
i If the adapter mount is coated with a small amount of oil, it will

reduce leakage.
i For details of the standard value for the compression pressure,

see STANDARD VALUE TABLE FOR ENGINE.
i If the measurement is carried out with the manual emergency

stop cable disconnected, an error message will light up on the
monitor panel, so delete the error message after measuring.
WA450-3MC 20-109 Î
TESTING AND ADJUSTING ENGINE OIL PRESSURE
ENGINE OIL PRESSURE

WARNING! When measuring, be careful not to let your clothes
get caught in any rotating part.
i Always stop the engine before removing or installing any oil

pressure sensor or oil pressure gauge.
i When measuring the oil pressure, always measure at the

specified oil temperature.
1. Remove oil pressure sensor (1).
2. Install tool B.
Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 kg/cm2
3. Start the engine, and measure the oil pressure.
20-110 Î WA450-3MC
TESTING AND ADJUSTING FUEL INJECTION TIMING
FUEL INJECTION TIMING

TESTING
1. Disconnect fuel injection pipe (1) and spill tube (2).
2. Remove two nozzle holder mounting bolts (3).
3. Screw bolt (a) into spill tube mount, then use bar (b) to lever out
nozzle holder (4).
i Be careful not to let any dirt or dust get in.
4. Rotate the crankshaft, align pointer (6) with the stamped line on
vibration damper (5), and set #1 cylinder to the TOP position.
! When doing this, check that fuel injection timing line (a) on the
fuel injection pump is near line (b) on the fuel injection pump
body.
WA450-3MC 20-111 Î
5. Set dial gauge P to the nozzle holder hole where the nozzle
holder has been removed.
! Set the magnet stand of dial gauge P in a stable position where

it is possible to install the magnet stand.
6. Set the tip of dial gauge P in contact with the top of the piston,
then set the scale of dial gauge P to 0 when the piston is at top
dead center.
i Rotate the crankshaft in the normal direction and in the reverse

direction in turn to align the top dead center. Record the value
indicated on the dial gauge P.
7. Rotate the crankshaft . 45E in the reverse direction from the #1

cylinder at top.
8. Rotate the crankshaft again slowly in the normal direction and

set to the specified piston position.
i Always rotate the crankshaft in the normal direction to align the

position.
Specified dimension c . . . . . . . . . . . . . . . . 3.8 ± 0.2 mm
9. When the piston is on the specified piston position, check that

fuel injection timing line (a) on the fuel injection pump is aligned
with line (b) on the fuel injection pump body.
20-112 Î WA450-3MC
Adjusting fuel injection timing
1. If the test shows that the fuel injection timing lines are not
properly aligned, adjust as follows.
a) Loosen mounting bolts (7).
b) Move coupling (8) to align lines (a) and (b) then tighten bolts
(7).
Bolt (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 ± 5 NCm
2. Remove dial gauge P, then install nozzle holder(4) and tighten

bolts (3).
Nozzle holder bolt . . . . . . . . . . . . . . . . . . . . . 22 ± 3 NCm
3. Install spill tube (2).
Spill tube joint bolt . . . . . . . . . . . . . . . . . . . . . 25 ± 5 NCm
4. Install fuel injection pipe (1).
Fuel injection pipe sleeve nut . . . . . . . . . . . . 24 ± 1 NCm
WA450-3MC 20-113 Î
TESTING AND ADJUSTING ENGINE STOP MOTOR CABLE
ENGINE STOP MOTOR CABLE

1. Temporarily install ball joint (3) to cable (2) of engine stop motor
(1).
i Screw in fully, then turn back . ½ turn, then install the ball joint
to the stop lever of the injection pump.
2. Pull stop lever (4) of the injection pump by hand to the engine
stop position, no injection of fuel, and temporarily assemble the
cable to the bracket. When this is done, secure the cable at a
point where stop lever (4) contacts engine STOP stopper (5),
and temporarily assemble to the bracket (7) with locknut (6).
i Engine stop motor (1) is at the engine STOP position with cable
(2) pulled. Stop lever (4) of the fuel injection pump is at the RUN
position when the lever is free. It is pulled by a spring to the RUN
side.
3. Adjust stop lever (4) of the injection pump and STOP stopper (5)
at the stop end so that clearance a is 1 to 2 mm.
i Adjust with nut (6) which secures the cable to the bracket or
carry out fine adjustment by changing the depth that ball joint (3)
is screwed in.
4. Tighten all nuts and bolts.
20-114 Î WA450-3MC
TESTING AND ADJUSTING ENGINE STOP MOTOR CABLE
5. Turn the engine starting switch repeatedly to the ON and OFF

positions, and check that the engine stop motor and cable work
smoothly, then carry out the following checks again.
a) Check visually that there is slack in the engine stop motor

cable when the engine is running, and that the stop lever of
the fuel injection pump has returned fully to the RUN
position.
b) Check that the clearance between the stop lever and

stopper at the STOP end is 1 to 2 mm when the engine is
stopped.
i With the engine stop motor, there are built in limit switches at
both ends of the cable stroke.
Engine stop motor stroke . . . . . . . . . . . . . . . . . . . . . 35 mm
Fuel injection pump stop lever stroke . . . . . . . . . . . 30 mm
i When the engine is running, there is slack in the engine stop

motor cable, and the RUN position is maintained by the action
of a spring. This is frequently built into the fuel injection pump.
i There is a loose spring inside the engine stop motor, and this
absorbs the error in the stop motor when the engine is stopped.
However, if this is absorbed by the loose spring in the engine
stop motor, force is brought to bear on the injection pump, so
depending on the machine model, this system may not be
possible to use. With such models, there is a danger of prob-
lems arising with the injection pump if the clearance between
the stop lever and the stopper at the STOP end is set to 0 when
the engine is stopped.
i Problems caused by improper adjustment of engine stop motor

cable
• When engine stop motor cable is

pulled and clearance between stop • Engine does not stop
lever and Stop stopper is too large
• When cable is free and clearance • Engine does not give full output be-
between stop lever and Run stop- cause of drop in amount of fuel in-
per is too large jected
WA450-3MC 20-115 Î
TESTING AND ADJUSTING FAN BELT TENSION
FAN BELT TENSION

TESTING FAN BELT TENSION
Measure the deflection (a) of the belt when it is pushed with a finger
force (. 59 N) at point midway between the fan pulley (1) and the
alternator pulley (2).
i Belt deflection (a) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm
ADJUSTING BELT
1. Loosen alternator mount bolt (1) and adjust plate mounting bolt
(2).
2. Loosen the locknut, then tighten adjustment nut (3) to adjust the
tension of the belt.
3. After adjusting the belt tension to the standard value, tighten the
locknut, then tighten adjust plate mounting bolt (2) and alterna-
tor mount bolt (1).
20-116 Î WA450-3MC
TESTING AND ADJUSTING ACCELERATOR PEDAL
ACCELERATOR PEDAL
Engine coolant temperature . . . . . . . . . . . . . . Gauge green range
OPERATING FORCE OF ACCELERATOR PEDAL
Measuring
1. Set push pull scale J2 at a position 150 mm (a) pedal fulcrum

(b).
i Put the center of push pull J2 scale in contact with a point 150
mm from the pedal fulcrum.
2. Start the engine, then measure the maximum value when the
pedal is moved from the pushed position, low idle, to the end of
its travel at high idle.
Testing and adjusting
1. Stop the engine.
2. Remove cable (1) at the bottom of the accelerator pedal, and

check that there is no stiffness in plate (2) or any other part
under the pedal.
3. Connect cable (1) at the bottom of the pedal, disconnect it again

at the injection pump connection, and check that there is no
stiffness in rod (3) or ball joint (4).
i Carry out the above inspection, and adjust or replace parts if

necessary. Then carry out the measurement of the operating
force again to check that it is within the standard value.
WA450-3MC 20-117 Î
TESTING AND ADJUSTING ACCELERATOR PEDAL
OPERATING ANGLE OF ACCELERATOR PEDAL
Measuring
1. Stop the engine.
2. Put angle gauge in contact with the accelerator pedal, and

measure operating angle [" = "1 - "2] when the pedal is
operated from low idle ["1] position to high idle ["2] position.
Adjusting
1. Remove the cover at the bottom of the cab, and open the
inspection cover of the engine hood.
2. Loosen nut (1), and adjust bolt (2) so that installed height L of
the accelerator pedal stopper is within a range of 49.5 ± 5 mm.
3. Loosen locknut (3) and adjust the length of the cable so that the
injection pump governor lever contacts the high idle stopper
when the accelerator pedal is depressed.
i Check that the injection pump governor contacts the low idle
stopper when the accelerator pedal is let back to the low idle
position.
i Adjust the travel of the governor lever with joint (4).
Cable joint nut . . . . . . . . . . . . . . . . . . . . . . . . 14 ± 1 NCm
i After carrying out the above adjustment, measure each part

again and check that it is within the standard value.
20-118 Î WA450-3MC
TESTING AND ADJUSTING SPEED CONTROL LEVER
SPEED CONTROL LEVER

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopped
Torque converter oil temperature . . . . . . . . . . . . . . . . . 60 to 80EC
OPERATING FORCE
! Install push pull scale J2 or a spring balance to the center of the

control lever knob, and measure the operating force when the
lever is pulled in the direction of operation.
i Carry out the measurement for each speed range.
TRAVEL
! Make mark (1) at the center of the control lever knob, and
measure the travel when the lever is operated in the direction of
operation.
WA450-3MC 20-119 Î
TESTING AND ADJUSTING STALL SPEED
STALL SPEED
Engine coolant temperature . . . . . . . . . . . . Green range of gauge
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High idle
Converter oil temperature . . . . . . . . . . . . . . . . . . . . . . . 60 to 80EC
i Check that low idle and high idle are the standard values.
i Before measuring each stall speed, install multi tachometer A

to speed pickup port (1) on the engine block. Check that the
engine speed is the standard value. If it is not within the standard
range, check for loose linkage or play.
WARNING! Apply the parking brake and put blocks under the
tires.
CONVERTER STALL SPEED
1. Start the engine and run at low idle.
2. Release the parking brake.
3. Place the speed lever at the highest position for FORWARD or

REVERSE.
4. Use the brakes to stop the machine, then use multi tachometer
A to measure the speed when the engine is run at high idle.
i Turn transmission cut off selector switch (2) OFF and use the
left brake. Check that the pilot lamp goes out.
i Do not keep the stall condition for more than 20 seconds. Make
sure that the converter oil temperature does not exceed 120EC.
20-120 Î WA450-3MC
TESTING AND ADJUSTING STALL SPEED
HYDRAULIC STALL SPEED
1. Start the engine and run at high idle.
2. Operate the lever to the DUMP or LIFT position to operate the

cylinder to the end of its stroke and actuate the relief valve in the
main control valve.
3. Use multi tachometer A to measure the engine
i Do not keep the stall condition for more than 20 seconds.

Operate the control lever quickly.
FULL STALL SPEED
! Measure the engine speed when the converter stall and

hydraulic stall are both carried out at the same time.
i Before measuring the full stall, check that the converter stall
and hydraulic stall speeds are normal. If either of the stall
speeds are abnormal, correct the problem and measure again.
WA450-3MC 20-121 Î
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
POWER TRAIN OIL PRESSURE

Engine coolant temperature . . . . . . . . . . . Green range on gauge
Torque converter oil temperature . . . . . . . . . . . . . . . . . 60 to 80EC
tires.
PREPARATORY WORK
i The following preparatory work is necessary when measuring all

oil pressures.
• Remove cover (1) on the left side of the rear frame. Turn
transmission cut off selector switch (2) OFF and use the left
brake. Check that the pilot lamp is OFF.
• Remove the plug from the measurement port of the transmis-
sion valve. Install hydraulic tester kit B to the measurement
port, extend the gauge to the operators compartment, then
start the engine and measure the pressure. Check that no oil
is leaking from any connection.
MEASUREMENT METHOD
Priority Pressure - P1
Start the engine, run at low idle, and measure the pressure at the
rated speed.
Torque Converter Outlet Port Pressure - P2

Start the engine, run at low idle, and measure the pressure at the
rated speed.
Pilot Pressure - P3
Start the engine and measure the pressure.
Clutch Pressure - P4
Start the engine, release the parking brake, place the directional
lever at neutral, and measure the pressure when the speed lever is
operated.
Parking Brake Pressure - P5

Start the engine, and measure the pressure when the parking brake
is released.
20-122 Î WA450-3MC
TESTING AND ADJUSTING EMERGENCY MANUAL SPOOL
EMERGENCY MANUAL SPOOL

OUTLINE
The transmission valve is controlled electrically, but if there should

be any failure in the electrical system, or if there is any failure in the
solenoid valve or spool and the machine cannot move, it is possible
to operate the emergency manual spool to move the machine.
WARNING! This operation of the spool is designed only for use

if the machine cannot be moved because of a failure in the
transmission control, and it is necessary to move the machine
from a dangerous working area to a safe place where repairs
can be carried out. This spool must not be operated except
when there has been a failure.
WARNING! When carrying out this operation, keep strictly to

the order of operation and pay careful attention to safety when
moving the machine.
WARNING! To prevent the machine from moving, lower the

bucket to the ground, apply the parking brake, and put blocks
under the tires.
WARNING! Always stop the engine before operating the spool.
1. Remove cover (1) from the left side of the rear frame. Remove
lock plate (3) from emergency manual spool (2) of the transmis-
sion valve.
i The lock plate can be removed by loosening the mounting bolts.
2. Operate emergency spool (2) to the operating position accord-

ing to the direction of movement of the machine, forward or
reverse.
• REVERSE: Push spool in until it detents . . . . . . . . . . 8 mm
• FORWARD: Pull spool out until it detents . . . . . . . . . 8 mm
3. Check that the area around the machine is safe, then remove
the blocks from under the tires.
4. Sit in the operator's seat and depress the left brake pedal fully.
Start the engine, then release the parking brake and slowly let
the brake pedal out to start the machine.
WARNING! When the engine is started, the transmission is

also engaged and the machine will start, so always check
carefully that the area around the machine and in the direction
of travel is safe, and keep the brake pedal depressed fully when
starting the engine.
5. After moving the machine, stop the engine, then apply the
parking brake and put blocks under the tires. Return the manual
spool to the neutral position and install the lock plate.
WA450-3MC 20-123 Î
TESTING AND ADJUSTING
TIRE AND WHEEL

Tire inflation pressure . . . . . . . . . . . . . . . . . . . . Specified pressure
METHOD OF MEASURING
Fitting of Wheel Lock Ring
Using feeler gauge Q, measure dimensions a and b at four places

around the circumference.
Clearance of Wheel Lock Ring
Measure dimension c.
20-124 Î WA450-3MC
TESTING AND ADJUSTING STEERING WHEEL
STEERING WHEEL
PLAY OF STEERING WHEEL
Measurement Conditions
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopped
Machine posture . . . . . . . . . . . . . . . . . . . . Facing straight forward
Method of Measurement
1. Move the steering wheel 2 or 3 times lightly to the left and right,
check that the steering mechanism is at the neutral position,
then make a mark on the outside frame of the machine monitor.
2. Turn the steering wheel to the right, and make a mark at the
position where the operating force starts to become heavy,
when the steering valve lever starts to move.
3. Turn the steering wheel to the left in the opposite direction from
Step 2, and make a mark at the point where the operating force
becomes heavy, when the steering valve lever starts to move.
Then measure the distance in a straight line between the marks
made in Step 2 and 3.
OPERATING FORCE OF STEERING WHEEL
Road surface . . . . . . . . . . . . . . Flat, horizontal, dry paved surface

Engine speed . . . . . . . . . . . . . . . . . . . . . . . Low idle, bucket empty
Measurement Method
1. Install push pull scale J2 to the steering wheel knob.
2. Start the engine, raise the bucket . 400 mm and remove the
safety bar.
3. Pull push pull scale in the tangential direction and measure the
value when the steering wheel moves smoothly.
i Avoid measuring when the steering wheel starts to move.
WA450-3MC 20-125 Î
TESTING AND ADJUSTING STEERING WHEEL
OPERATING TIME FOR STEERING WHEEL
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low and high idle
Measurement Method
1. Start the engine, raise the bucket . 400 mm and remove the
safety bar.
2. Operate the steering wheel to the end of its stroke to turn the
machine to the left or right.
3. Measure the time taken to operate the steering wheel to the end
of the stroke to the right (left).
i Operate the steering wheel as quickly as possible without using

force. Carry out the measurements both at low idle and high
idle, and to both the left and right.
20-126 Î WA450-3MC
TESTING AND ADJUSTING STEERING CONTROL
STEERING CONTROL
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 rpm
Tire inflation pressure . . . . . . . . . . . . . . . . . . . . Standard pressure
TESTING
1. Start the engine and operate the steering to set the front and
rear frames straight.
2. Check the looseness of locknut (2) of stopper bolt (1).
3. Start the engine and measure clearance between the front

frame and rear frame stopper when the steering wheel is turned
fully to the left and right.
i When measuring the clearance, check that 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.
a) Screw in stopper bolt (1) to make it the minimum length.
b) Run the engine at low idle and operate the steering slowly
to contact the frame stopper.
c) Turn the stopper bolt until the head of stopper bolt (1)
contacts the end face of the spool of stop valve (3).
d) Set the machine facing straight, and stop the engine.
e) Loosen stopper bolt (1) 8½ turns, then lock it in position with

locknut (2).
f) Carry out steps a) through e) for both the left and right
sides.
2. Start the engine and measure clearance a between the front

frame and rear frame stopper when the steering wheel is turned
fully to the left and right.
i When measuring the clearance, check that the end face of the
spool of stop valve (3) is in contact with the head of the stopper
bolt.
WA450-3MC 20-127 Î
TESTING AND ADJUSTING STEERING OIL PRESSURE
STEERING OIL PRESSURE

Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 to 55EC
MAIN RELIEF PRESSURE
WARNING! Loosen the oil filler cap to release the pressure

inside the hydraulic tank, then turn the steering wheel several
times to release the remaining pressure inside the piping.
1. Apply safety bar (1) to the frame.
2. Remove measurement plug (2) for the right turn steering circuit.
3. Install hydraulic tester kit B to the measurement port.
4. Start the engine, run the engine at high idle, then turn the
steering wheel to the right and measure the pressure when the
relief valve is actuated.
i To measure the pressure when turning the steering wheel to the

left, remove the plug for the left turn steering circuit.
ADJUSTING
WARNING! Always stop the engine before adjusting the

pressure.
1. Stop the engine.
2. Loosen locknut (3) of steering relief valve in steering valve, then

turn adjustment screw (4) to adjust.
One 360E turn of screw . . . . . . . . . . . . . . . . 151 kg/cm2
i Turn the adjustment screw to adjust the set pressure as follows.

i Do not carry out any adjustment if the relief pressure cannot be

measured accurately.
20-128 Î WA450-3MC
TESTING AND ADJUSTING BRAKE PEDAL
BRAKE PEDAL
Engine coolant temperature . . . . . . . . . . . . . . Green range gauge
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low idle
OPERATING FORCE OF PEDAL
1. Install push gauge a to the operators foot. Align the center of the
push gauge with the center of the pedal.
2. Start the engine, run at low idle, and measure the operating
force when the pedal is depressed.
TRAVEL OF PEDAL
1. Install push gauge to the operators foot. Align the center of the
push gauge with the center of the pedal.
2. Start the engine, and measure pedal angle when running at low
idle, and pedal angle when the pedal is depressed with a force
of 30 kg.
i Install angle gauge b to the brake pedal when measuring.
PEDAL PLAY
1. Start the engine.
2. Push the brake pedal lightly by hand, and measure pedal angle
when the pedal starts to become heavy.
WA450-3MC 20-129 Î
TESTING AND ADJUSTING BRAKE OIL PRESSURE
BRAKE OIL PRESSURE

Engine coolant temperature . . . . . . . . . . . . . . Green range gauge
Brake oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50kg/cm2
WARNING! Put blocks securely under the tires.
TESTING
1. Remove bleeder screw (1) and nipple (3), then install tool S2,
nipple (3), and tool S1 in order in the mount of bleeder screw
(1).
2. Start the engine and bleed the air.
i This operation is carried out with two workers. One worker

operates the brake pedal while the other worker bleeds the air
from bleeder screw (2). Turn the transmission cut off switch on.
3. Depress the left brake, set the gauge reading to 50 kg/cm2, then
leave for 5 minutes and measure the drop in the pressure.
4. After measuring, stop the engine, loosen the bleeder screw to

lower the pressure, then remove tools S1 and S2.
i After completing the operation, bleed the air from the brake
circuit again.
20-130 Î WA450-3MC
TESTING AND ADJUSTING BRAKE PERFORMANCE
BRAKE PERFORMANCE
Travel speed . . . . . . . . . . . . . . 20 km/h when brakes are applied
Delay in applying brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 sec
MEASUREMENT METHOD
1. Start the engine and move the machine.
2. Set the speed lever to the highest speed position and drive the
machine.
3. When the travel speed reaches 20 km/h, depress the left brake
pedal with the specified operating force.
i Before carrying out this operation, determine the run up path

and the point for applying the brakes, then apply the brakes
when the machine reaches that point. Switch the transmission
cut off switch on, when carrying out this operation.
4. Measure the distance from the point where the brakes were
applied to the point where the machine stopped. Repeat this
measurement three times and take the average.
1. Run up path
2. Operation point, foot on brake
3. Braking effect starts
4. Stopping point
5. Stopping distance
WA450-3MC 20-131 Î
TESTING AND ADJUSTING BRAKE DISC WEAR
BRAKE DISC WEAR

Brake oil pressure . . . . . . . . . . . . . . . . . . . . . Specified 50 kg/cm2
WARNING! Park the machine on horizontal ground and put

blocks securely under the tires.
MEASUREMENT METHOD
1. Remove plug (1).
2. Depress the brake pedal fully.
3. Use calipers R to measure depth a from the end face of the

housing to the spring guide.
i When measuring, keep the brake pedal depressed.
4. Install a vinyl hose to bleeder (2), then loosen the bleeder and
drain the brake oil.
i After draining the brake oil, check that the brake piston has
returned to the end of its stroke.
5. Measure depth b from the end face of the housing to the spring
guide pin.
CALCULATING PISTON STROKE
S [stroke] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a - b
S [stroke] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. 6.2 mm
20-132 Î WA450-3MC
TESTING AND ADJUSTING BLEED AIR FROM BRAKE SYSTEM
BLEED AIR FROM BRAKE SYSTEM

WARNING! Put blocks securely under the tires.
1. Remove cap (1) of the bleeder screw, insert a vinyl hose into the
screw, and insert the other end in a container.
2. Start the engine.
3. Depress the brake pedal, then loosen the bleeder screw and
bleed the air.
i This operation is carried out with two workers. One worker

operates the brake pedal while the other worker bleeds the air
from the bleeder screw. When depressing the brake pedal, use
the left pedal.
4. When no more bubbles come out with the fluid from the hose,
depress the pedal fully and tighten the bleeder screw while the
oil is still flowing.
i Repeat the operation to bleed the air from the other cylinders,
and after completing the operation, check the level in the oil
tank and add more oil if necessary. To bleed the air completely,
bleed the air first from the cylinder which is farthest from the
brake pedal.
WA450-3MC 20-133 Î
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
ACCUMULATOR CHARGE PRESSURE

WARNING! Stop the engine, then depress the brake pedal at

least 100 times to release the pressure inside the accumulator
circuit.
1. Disconnect accumulator inlet port hose (1), then install tools U1,
U2, and U3 and 400 kg/cm 2 oil pressure gauge
2. Measure the accumulator charge cut in pressure. Start the

engine, run at low idle, and measure the oil pressure when the
brake oil pressure warning pilot lamp on the maintenance
monitor goes out.
3. Measure the accumulator charge cut out pressure. After the

accumulator charge cut in, the pressure rises. Measure the oil
pressure at the point where the oil pressure gauge indicator
suddenly drops after rising.
ADJUSTING
i When the accumulator charge cut out pressure is adjusted, the

cut in pressure also changes because of the valve area ratio.
For this reason, there is no cut in pressure adjustment screw.
1. Loosen locknut (3) of accumulator charge cutout valve (2), then

turn adjustment screw (4) to adjust.
i Turn the adjustment screw to adjust as follows.

To INCREASE pressure . . . . . . . . . . . . . . . . . . . Clockwise.
To DECREASE pressure . . . . . . . . . . . . Counterclockwise.
One 360E turn of screw . . . . . . . . . . . . . . . . . . 57 kg/cm2
Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ± 1 NCm
i After completion of the adjustment, repeat the above procedure

for testing to check the accumulator charge cut in pressure and
cut out pressure again.
20-134 Î WA450-3MC
TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE
PARKING BRAKE PERFORMANCE

Road surface . . . Sloped, dry paved surface of 1/5 grade, 11E20'
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating condition
i Keep parking forced release switch (1) at the rear of the

operator's seat at the OFF position.
MEASUREMENT METHOD
1. Start the engine, set machine facing in a straight line, then drive
the machine up a 1/5 grade slope a with the bucket empty.
2. Depress the brake, stop the machine, set the directional lever to
the neutral position, then stop the engine.
3. Turn the parking brake switch on, then gradually release the
brake pedal and check that the machine is held in position.
i When the engine is stopped, the parking brake is automatically

switched on.
i Carry out the measurement in two ways; Once with the machine
facing uphill, and once more with the machine facing downhill.
WA450-3MC 20-135 Î
TESTING AND ADJUSTING MANUAL RELEASE OF PARKING BRAKE
MANUAL RELEASE OF PARKING BRAKE

i The parking brake is controlled by hydraulic pressure, so if there
should be any failure in the transmission and it becomes
impossible to release the parking brake, it is possible to release
it manually to move the machine.
WARNING! The manual release of the parking brake is de-

signed only to move the machine from a dangerous working
area to a safe place where repairs can be carried out. This
method must not be used except when there has been a failure.

bucket to the ground and put blocks under the tires.
WARNING! Always stop the engine before carrying out this

procedure.
1. Loosen bolt (1), then remove lock plate (2) from bolt (3), three
places.
2. Tighten bolts (3) at three places in turn as far as the mounting

position for the plate at portion a, then install lock plate (2) at
portion a.
i Tighten all three bolts uniformly a little at a time. Bolt (3) pushes
piston (4) and (5) and releases the parking brake.
3. Tighten bolt (1) to secure lock plate (2) in position.
20-136 Î WA450-3MC
TESTING AND ADJUSTING WEAR OF PARKING BRAKE DISC
WEAR OF PARKING BRAKE DISC
i If the parking brake becomes weak, measure the piston stroke

as follows.

bucket to the ground and put blocks under the tires.
WARNING! Always stop the engine before carrying out this

procedure.
1. Loosen bolt (1), then remove lock plate (2) from parking brake
manual release bolt (3), three places.
2. Measure dimension a with the three manual release bolts (3) in

contact lightly with brake pistons (4) and (5).
3. Tighten the three manual release bolts (3) in turn and measure
dimension b when brake pistons (4) and (5) are pushed in fully.
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L = a - b
Max. 9.9 mm
i If the piston stroke is greater than 9.9 mm, check thickness W

of brake disc (6). For details, see REMOVAL OF PARKING
BRAKE DISC.
Dimension W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Min 2.83 mm
WA450-3MC 20-137 Î
TESTING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER
WORK EQUIPMENT CONTROL LEVER

Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low idle
WARNING! Install the safety bar to the frame.
MEASUREMENT METHOD
Operating Force of Lever
1. Install push pull scale J2 to the work equipment control lever

and measure the operating force.
i Install the push pull scale to the center of the knob. Operate the
control lever at the same speed as for normal operations, and
measure the minimum value for the force needed to operate the
knob.
Travel of Lever
1. Measure travel L at each position when operating the work

equipment control lever.
LIFT ARM BUCKET

1. Hold 5. Hold
2. Raise 6. Dump
3. Lower 7. Tilt
4. Float
i Mark the lever knob and use scale K to measure.
ADJUSTING
1. Remove cover (1).
20-138 Î WA450-3MC
TESTING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER
2. With solenoid (6) pulled, fix the solenoid in position so that the
clearance between cam (3) and roller (4) is dimension a.
Dimension a . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 0.5 mm
i Set the bucket lever and lift arm lever at the HOLD position. If
cam (3), roller (4), or spring (5) is/are broken, replace them
before adjusting.
3. Boom Lever; Operate the boom lever and adjust the length
of rod (2) so that roller (4) is dimension b at the notch at both
ends of cam (3).
Dimension b . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 1 mm
4. Bucket Lever; Operate the lift lever and adjust the length of
rod (2) so that roller (4) is dimension C at the notch at both ends
of cam (3).
Dimension c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 1 mm
WA450-3MC 20-139 Î
TESTING AND ADJUSTING WORK EQUIPMENT PRESSURE
WORK EQUIPMENT PRESSURE

tires.
PPC RELIEF VALVE PRESSURE
Measuring
1. Raise boom (1), set support (2) or stopper T in position under

the lift arm, then remove cover (3).

inside the hydraulic tank, then operate the bucket control lever
at least 40 times between TILT and HOLD to completely release
the pressure in the accumulator.
i After operating the bucket lever, operate the bucket lever to the
DUMP position and check that the bucket does not dump.
Always stop the engine before operating the lever.
2. Remove plug (4) for measuring the hydraulic pressure in the

dump cylinder circuit of the main control valve.
i Install the 90E elbow in the hydraulic tester kit to the measure-
ment port, then connect the hose. Check that there is no oil
leakage from any joint. Use a hose which is long enough to
reach the operators compartment.
4. Start the engine, raise the lift arm . 400 mm, then operate the
control lever to tilt back the bucket, and measure the pressure
when the relief valve is actuated.
i Be careful not to apply pressure suddenly to the oil pressure

gauge.
WARNING! When removing the oil pressure gauge, release

the pressure inside the circuit in the same way as when installing
the gauge.
20-140 Î WA450-3MC
Adjusting
WARNING! Always stop the engine when adjusting the oil

pressure.
1. Stop the engine and remove cover (1).
2. Loosen locknut (2), then turn adjustment screw (3) to adjust.
One 360E turn of screw . . . . . . . . . . . . . . . . . 18 kg/cm2


WA450-3MC 20-141 Î
WORK EQUIPMENT RELIEF VALVE PRESSURE
Measurement Method

inside the hydraulic tank, then operate the control lever several
times to release the remaining pressure inside the piping.
i When operating each lever, set the bucket so that portion a is

raised 30 to 50 mm, then lower portion b to the ground and stop
the engine.
i After operating each lever, check that both bottom surfaces of

the bucket (portions a and b) contact the ground surface.
1. Remove oil pressure measurement plug (1) from the bucket

cylinder circuit.
i Check that there is no oil leakage from any joint. Use a hose
which is long enough to reach the operators compartment.
3. Start the engine, raise the lift arm . 400 mm, then operate the
control lever to tilt back the bucket, and measure the pressure
when the relief valve is actuated.
i Be careful not to apply pressure suddenly to the oil pressure

gauge.
WARNING! When removing the oil pressure gauge, release

the pressure inside the circuit in the same way as when installing
the gauge.
20-142 Î WA450-3MC
Adjusting
WARNING! Always stop the engine when adjusting the oil

pressure.
1. Raise boom (1), set support (2) or stopper T in position under

the boom, then remove cover (3).
2. Remove locknut (4) of the relief valve.
3. Turn adjustment screw (5) to adjust.
One 360E turn of screw . . . . . . . . . . . . . . . . . 53 kg/cm2


WA450-3MC 20-143 Î
TESTING AND ADJUSTING WORK EQUIPMENT
WORK EQUIPMENT
Steering position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutral
MEASUREMENT METHOD
Boom Raise Time
Set the bucket at the lowest position from the ground with the bucket
tilted back fully, then raise it and measure the time taken for the
bucket to reach the maximum boom height.
Boom Lower Time
Set the bucket horizontal, then lower the boom from the maximum
height and measure the time taken for the bucket to reach the
lowest position from the ground.
Bucket Dump Time
Raise the boom to the maximum height, and measure the time
taken to move the bucket from the tilted back position to the fully
dumped position.
Bucket Tilt Time
1. Raise the boom to the maximum height, and measure the time
taken to move the bucket to the fully tilted back position.
2. Set the bucket horizontal to the ground and measure the time
taken to move the bucket from the horizontal position to the fully
tilted back position.
20-144 Î WA450-3MC
TESTING AND ADJUSTING WORK EQUIPMENT
MEASURING WORK EQUIPMENT DRIFT

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal, no load
i Apply the safety lock to the work equipment control levers.

Never go under the work equipment. Stop the engine, leave for
5 minutes, then measure for 15 minutes.
Measurement Method
1. Set the boom and bucket in a horizontal position, then stop the
engine.
2. Leave for 5 minutes, then start the measurement.
3. Wait for 15 minutes, then measure retraction amount a of the

bucket cylinder rod and retraction amount b of the boom
cylinder rod.
WA450-3MC 20-145 Î
TESTING AND ADJUSTING BUCKET POSITIONER
BUCKET POSITIONER
TESTING
1. Stop the engine and check that the clearance between switch
(1) and angle (2) is the standard value.
2. Start the engine, run at idle and check the actuation position.
Check three times and take the average value.
ADJUSTING
1. Lower the bucket to the ground, operate the bucket to the

desired digging angle, then return the lever to HOLD and stop
the engine.
2. Adjust nut (6) of switch (1) so that clearance a from the tip of
switch protector (3) to the switch sensing surface is the standard
value, then secure the switch in position.
Clearance a . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.0 mm
Switch mounting nut . . . . . . . . . . . . . . . . . . . 18 ± 2 NCm
3. Using shims, adjust clearance b between the sensing surface of

switch (1) and angle (2) to the standard value, then secure in
position.
i Use shims to adjust the angle so that the clearance between the
switch sensing surface and the angle is within the standard
value for the whole stroke of the angle, then secure in position.
Check that the center of the switch sensing surface and the
angle do not move, then secure in position.
i After adjusting, operate the bucket lever, check that the

positioner is actuated at the desired position, then secure in
position.
Clearance b . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 to 5 mm
20-146 Î WA450-3MC
TESTING AND ADJUSTING BOOM KICK OUT
BOOM KICK OUT

TESTING
1. Stop the engine, and check that the clearance between switch
(1) and plate (2) is the standard value.
2. Start the engine, run at high idle and check the actuation
position. Check three times and take the average value.
ADJUSTING
1. Raise the boom to the desired height, return the boom lever to
the HOLD position, then stop the engine.
WARNING! Always apply the safety lock to the work equipment

control lever.
2. Adjust the position of the plate so that the center of switch (1) is
aligned with the top of plate (2), then secure in position.
3. Secure the switch in position so that clearance a between the

sensing surface of the switch and plate (2) is the standard value.
Clearance a . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 to 5 mm
Switch mounting nut . . . . . . . . . . . . . . . . . . . . 18 ± 2 NCm
i After adjusting, operate the boom lever and check that the kick-
out is actuated at the desired position.
WA450-3MC 20-147 Î
TESTING AND ADJUSTING BOOM KICK OUT
PROXIMITY SWITCH ACTUATION PILOT LAMP (RED)
The proximity switch is equipped with a pilot lamp which shows when
it is being actuated, so use this when adjusting.
Proximity switch actua-

tion pilot lamp
Lights up Goes out
When detector (1) is positioned at detection Whendetector (1) has moved away from detec-
Detector position
surface of proximity switch (2) tion surface of proximity switch (2)
Bucket positioner
Boom kick out
20-148 Î WA450-3MC
TESTING AND ADJUSTING LOAD METER
LOAD METER
LOAD METER SENSOR
Testing
1. Stop the engine, and check that the clearance between switch
(1) and plate (2) is the standard value.
2. Start the engine, run at low idle and check the actuation
position. Check three times and take the average value.
Adjusting
1. Raise the boom until the arm is in the horizontal position, return
the boom lever to the HOLD position, then stop the engine.
i The horizontal position of the boom means that the difference

of height between the boom pivot (h1) and bucket hinge pin (h2)
is within 20 mm.
WARNING! Always apply the safety lock to the work equipment

control lever.
2. Adjust the position of the plate (3) so that the indicator lamp (2)
of the switch (1) goes out.
3. Secure the switch in position so that clearance a between the

sensing surface of the switch and plate (2) is the standard value.
Clearance a . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 to 5 mm
Switch mounting nut . . . . . . . . . . . . . . . . . . . . 18 ± 2 NCm
i After adjusting, operate the boom lever and check that the kick-
out is actuated at the desired position.
LOAD METER POSITION
i To improve the position when measuring, carry out the following

operation periodically.
1. Measure load of unknown weight and check that the measure-

ments are within standard tolerance.
i Load = Rated load to ½ rated load . . . . . . . . . . . . . . . . . ± 2%
Less than ½ rated load . . . . . . . . . . . . . . . . . . . . ± 3%
2. If the load displayed is to high, lower the boom height setting

and adjust the calibration again.
3. If the load displayed is to low, raise the boom height setting and
adjust the calibration again.
WA450-3MC 20-149 Î
TESTING AND ADJUSTING LOAD METER
PROXIMITY SWITCH ACTUATION PILOT LAMP (RED)
The proximity switch is equipped with a pilot lamp which shows when
it is being actuated, so use this when adjusting.
Proximity switch actua-

tion pilot lamp
Lights up Goes out
When detector (1) is positioned at detection Whendetector (1) has moved away from detec-
Detector position
surface of proximity switch (2) tion surface of proximity switch (2)
Load meter
20-150 Î WA450-3MC
TESTING AND ADJUSTING MAIN MONITOR
MAIN MONITOR
i The speedometer on the main monitor is a common part for all
machines, and the input signal for the travel speed differs
according to the machine, so it is necessary to adjust the
monitor for use with the particular model.
i In addition, the tire diameter also differs according to the type of

tire fitted, so it is necessary to adjust to give the correct travel
speed.
i It is also necessary to change the switches if the optional ECSS

is installed.
ADJUSTMENT PROCEDURE
i Turn off the power, then remove the machine monitor and
adjust the switches at the back.
Setting Machine Model
1. Remove the rubber caps from dip switches (1), (2), (3) and (4).
2. When the rubber cap [switches 1, 2 and 3] is removed, a rotary

switch can be seen inside. Using a flat head screwdriver, turn
this switch to adjust it to the settings in the table below.
Switch 1 Switch 2 Switch 3

Tire size
Model selection Speedometer Tachometer
26.5/25-20PR 4 7 0
23.5/25-20PR 4 C 0
Amount of correction [%] for switch (2) only.
0 1 2 3 4 5 6 7
% +14 +12 +10 +8 +6 +4 +2 0
8 9 A B C D E F
% 0 -2 -4 -6 -8 -10 -12 -14
3. When the cap is removed from dip switch (4), an ON/OFF

switch can be seen. Adjust the setting if the ECSS is installed.
Switch 4
Switch Without ECSS With ECSS
1 ON ON
2 ON ON
3 ON OFF
4 ON ON
4. After completing the adjustment, fit the rubber caps securely

and install the main monitor.
WA450-3MC 20-151 Î
TESTING AND ADJUSTING FUEL LEVEL SENSOR
FUEL LEVEL SENSOR

i If there is a marked difference between the actual amount of
fuel remaining in the fuel tank and the display on the fuel gauge,
the fuel tank is full but the fuel gauge does not indicate FULL,
check the fuel level sensor as an individual part and measure
the resistance at the three positions for the float.
Measuring
i Connect one end of the probe of terminal (1), contact the other
probe with terminal (2), and measure the resistance.
Resistance for Fuel Level Sensor
FULL ½ EMPTY
+1 + 10
10 - 3 S 32 S 85 0 S
i The resistance values are only given as a guideline.
20-152 Î WA450-3MC
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202
SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . 20-204
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-212
METHOD OF USING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-213
CONNECTOR TYPES AND MOUNTING LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . 20-224
WA450-3MC 20-201 Î
TROUBLESHOOTING POINTS TO REMEMBER
POINTS TO REMEMBER WHEN TROUBLESHOOTING

WARNING! Stop the machine in a level place, and shooting in accordance with the fixed procedure.
check that the safety pin, blocks, and parking brake
are securely fitted. 2. Points to ask user or operator
1) Have any other problems occurred apart from
WARNING! When carrying out the operation with the problem that has been reported?
two or more workers, keep strictly to the agreed 2) Was there anything strange about the machine
signals, and do not allow any unauthorized person to before the failure occurred?
come near. 3) Did the failure occur suddenly, or were there
problems with the machine condition before this?
WARNING! If the radiator cap is removed when the 4) Under what conditions did the failure occur?
engine is hot, hot water may spurt out and cause 5) Had any repairs been carried out before the
burns, so wait for the engine to cool down before failure? When were these repairs carried out?
starting troubleshooting. 6) Has the same kind of failure occurred before?
WARNING! Be extremely careful not to touch any 3. Check before troubleshooting

hot parts or to get caught in any rotating parts. 1) Check the oil level
2) Check for any external leakage of oil from the
WARNING! When disconnecting wiring, always piping or hydraulic equipment.
disconnect negative terminal of the battery first. 3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
WARNING! When removing the plug or cap from a 5) Other maintenance items can be checked exter-
location which is under pressure from oil, water, or nally, so check any item that is considered to be
air, always release the internal pressure first. When necessary.
installing measuring equipment, be sure to connect
it properly. 4. Confirming failure
! Confirm the extent of the failure yourself, and judge
The aim of troubleshooting is to pinpoint the basic cause whether to handle it as a real failure or as a problem
of the failure, to carry out repairs swiftly, and to prevent with the method of operation, etc.
reoccurrence of the failure. When carrying out trouble- i When operating the machine to reenact the trouble-
shooting, and important point is of course to understand shooting symptoms, do not carry out any investigation
the structure and function. However, a short cut to or measurement that may make the problem worse.
effective troubleshooting is to ask the operator various
questions to form some idea of possible causes of the 5. Troubleshooting
failure that would produce the reported symptoms. ! Use the results of the investigation and inspection in
Items 2 to 4 to narrow down the causes of failure,
1. When carrying out troubleshooting, do not hurry to then use the troubleshooting flow chart to locate the
disassemble the components. If components are position of the failure exactly. The basic procedure for
disassembled immediately any failure occurs: troubleshooting is as follows.
! Parts that have no connection with the failure or other 1) Start from the simple points.
unnecessary parts will be disassembled. 2) Start from the most likely points.
! It will become impossible to find the cause of the 3) Investigate other related parts or information.
failure.
It will also cause a waste of man hours, parts, or oil or 6. Measures to remove root cause of failure
grease, and at the same time, will also lose the ! Even if the failure is repaired, if the root cause of the
confidence of the operator. For this reason, when failure is not repaired, the same failure will occur
carrying out troubleshooting, it is necessary to carry again. To prevent this, always investigate why the
out thorough investigation and to carry out trouble- problem occurred. Then, remove the root cause.
20-202 Î WA450-3MC
TROUBLESHOOTING SEQUENCE OF EVENTS
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop Job site
Step 1
Examination, Confirmation of Symptoms
Ring! Ring!
1) When a request for repairs is received, first ask the following points.
! Name of customer
! Type, PIN of machine
! Details of job site, etc.
2) Ask questions to gain an outline of the problem
! Condition of failure
! Work being carried out at time of failure
! Operating environment
! Past history, details of maintenance, etc.
Breakdown!
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the shop

manual to find locations of possible causes.
Step 8
Step 8
Repair at workshop
Repair at job site
Step 3
Preparation of troubleshooting tools
Machine
1) Look at the table of troubleshooting tools in the volume
shop manual and prepare the necessary tools.
! T-adapter Hurray, its repaired
! Hydraulic pressure gauge kit, etc. Shop manual
2) Look in the parts book and prepare the necess-
ary replacement parts.
Step 4
Go to job site
Step 7
! Pinpoint locations of failure
! Decide action to take
1) Before starting troubleshooting, locate and repair any

simple failures
! Check before starting items
! Other check items
2) See the Troubleshooting Section of the shop manual,
Step 5 select a troubleshooting flowchart that matches the
Ask operator questions to confirm details of failure symptoms and carry out troubleshooting.
! Was there anything strange about the machine

before the failure occurred
! Did the failure occur suddenly
! Had any repairs been carried out before the failure
Step 6
Re-enact failure
! Drive and operate the machine to confirm the condition before the failure
occurred
WA450-3MC 20-203 Î
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they
occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section
deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For
this purpose, it gives sections on Handling electric equipment and Handling hydraulic equipment, particularly gear oil
and hydraulic oil.
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT

HANDLING WIRING HARNESSES AND CONNECTORS
Wiring harnesses consist of wiring connecting one component to

another one, connectors used for connecting and disconnecting
one wire from another wire, and protectors or tubes used for
protecting the wiring. Compared with other electrical components
fitted in boxes or cases, wiring harnesses are more likely to be
affected by the direct effects of rain, water, heat, or vibration.
Furthermore, during inspection and repair operations, they are fre-
quently removed and installed again, so they are likely to suffer
deformation or damage. For this reason, it is necessary to be
extremely careful when handling wiring harnesses.
Main Failures Occurring in Wiring Harness
1) Faulty Contact of Connectors, Faulty Contact Between Male

and Female
Problems with faulty contact are likely to occur because the

male connector is not properly inserted into the female
connector, or because one or both of the connectors is
deformed or the position is not correctly aligned, or because
there is corrosion or oxidization of the contact surfaces.
2) Faulty Crimping or Soldering of Connectors
The pins of the male and female connectors are in contact at

the crimped terminal or soldered portion, but if there is
excessive force brought to bear on the wiring, the plating at
the joint will peel and cause improper connection or break-
age.
20-204 Î WA450-3MC
3) Disconnections in Wiring
If the wiring is held and the connectors are pulled apart, or

components are lifted with a crane with the wiring still con-
nected, or a heavy object hits the wiring, the crimping of the
connector may separate, or the soldering may be damaged,
or the wiring may be broken.
4) High Pressure Water Entering Connector
The connector is designed to make it difficult for water to

enter, drip proof structure, but if high pressure water is
sprayed directly on the connector, water may enter the con-
nector, depending on the direction of the water jet. As already
said, the connector is designed to prevent water from enter-
ing, but at the same time, if water does enter, it is difficult for
it to be drained. Therefore, if water should get into the connec-
tor, the pins will be short circuited by the water, so if any water
gets in immediately dry the connector or take other appropri-
ate action before passing electricity through it.
5) Oil or Dirt Stuck to Connector
If oil or grease are stuck to the connector and an oil film is

formed on the mating surface between the male and female
pins, the oil will not let the electricity pass, so there will be
faulty contact. If there is oil or grease stuck to the connector,
wipe it off with a dry cloth or blow it dry with compressed air
and spray it with a contact restorer.
i When wiping the mating portion of the connector, be careful

not to use excessive force or deform the pins.
i If there is oil or water in the compressed air, the contacts will

become even dirtier, so remove the oil and water from the
compressed air completely before cleaning with compressed
air.
WA450-3MC 20-205 Î
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 connectors held by a screw, loosen the
screw fully, then hold the male and female connectors in each
hand and pull apart. For connectors which have a lock
stopper, press down the stopper with your thumb and pull the
connectors apart. Never pull with one hand.
2) When Removing from Clips
When removing a connector from a clip, pull the connector in

a parallel direction to the clip.
i If the connector is twisted up and down or to the left or right,

the housing may break.
3) Action to Take after Removing Connectors
After removing any connector, cover it with a vinyl bag to

prevent any dust, dirt, oil, or water from getting in the connec-
tor portion.
i If the machine is left disassembled for a long time, it is

particularly easy for improper contact to occur, so always
cover the connector.
20-206 Î WA450-3MC
Packard Company Connectors
1) When removing the connectors from the clips, pull the

connector in a parallel direction to the clip
i If the connector is twisted to the left and right or up and down,

the housing may break.
2) When disconnecting male and female connectors, release

the lock and pull in parallel with both hands. Never try to pull
out with one hand.
Connecting Connectors
1) Check the Connector Visually
a) Check that there is no oil, dirt, or water stuck to the connec-

tor pins (mating portion).
b) Check that there is no deformation, faulty contact, corro-

sion, or damage to the connector pins.
c) Check that there is no damage or breakage to the outside

of the connector.
WA450-3MC 20-207 Î
i If there is any oil, water, or dirt stuck to the connector, wipe

it off with a dry cloth. If any water has got inside the connec-
tor, warm the inside of the wiring with a dryer, but be careful
not to make it too hot as this will cause short circuits. If there
is any damage or breakage, replace the connector.
2) Fix the Connector Securely
Align the position of the connector correctly, then insert it

securely. For connectors with lock stopper, push in the
connector until the stopper clicks into position.
3) Correct any protrusion of the boot and any misalignment of

the wiring harness For connectors fitted with boots, correct
any protrusion of the boot. In addition, if the wiring harness is
misaligned, or the clamp is out of position, adjust it to its
correct position.
i If the connector cannot be corrected easily, remove the clamp

and adjust the position.
4) If the connector clamp has been removed, be sure to return

it to its original position. Check also that there are no loose
clamps.
Drying Wiring Harness
If there is any oil or dirt on the wiring harness, wipe it off with a dry
cloth. Avoid washing it in water or using steam. If the connector
must be washed in water, do not use high pressure water or steam
directly on the wiring harness. If water gets directly on the connec-
tor, do as follows.
1) Disconnect the connector and wipe off water with a dry cloth.
i If the connector is blown dry with compressed air, there is the

risk that oil in the air may cause faulty contact, so remove all
oil and water before blowing with air.
2) Dry the inside of the connector with a dryer. If water gets

inside the connector, use a dryer to dry the connector.
i Hot air from the dryer can be used, but regulate the time that
the hot air is used in order not to make the connector or
related parts too hot, as this will cause deformation or dam-
age to the connector.
20-208 Î WA450-3MC
3) Carry out a continuity test on the connector. After drying, leave

the wiring harness disconnected and carry out a continuity test
to check for any short circuits between pins caused by water.
i After completely drying the connector, blow it with contact

restorer and reassemble.
HANDLING CONTROL BOX
1) The control box contains a microcomputer and electronic

control circuits. These control all of the electronic circuits on
the machine, so be extremely careful when handling the
control box.
2) Do not open the cover of the control box unless necessary.
3) Do not place objects on top of the control box.
4) Cover the control connectors with tape or a vinyl bag. Never

touch the connector contacts with your hand.
5) During rainy weather, do not leave the control box in a place

where it is exposed to rain.
6) Do not place the control box on oil, water, or soil, or in any hot
place, even for a short time, place it on a suitable dry stand.
7) Precautions when carrying out arc welding. When carrying out

arc welding on the body, disconnect all wiring harness
connectors connected to the control box. Fit an arc welding
ground close to the welding point.
WA450-3MC 20-209 Î
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS

1) Always turn the power OFF before disconnecting or connect
connectors.
2) Before carrying out troubleshooting, check that all the related

connectors are properly inserted.
i Disconnect and connect the related connectors several times

to check.
3) Always connect any disconnected connectors before going on

to the next step.
i If the power is turned ON with the connectors still discon-

nected, unnecessary abnormality displays will be generated.
4) When carrying out troubleshooting of circuits; measuring the

voltage, resistance, continuity, or current, move the related
wiring and connectors several times and check that there is
no change in the reading of the tester.
i If there is any change, there is probably faulty contact in that

circuit.
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT

With the increase in pressure and precision of hydraulic equipment,
the most common cause of failure is dirt (foreign material) in the
hydraulic circuit. When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment, it is necessary to be particularly
careful.
BE CAREFUL OF THE OPERATING ENVIRONMENT
Avoid adding hydraulic oil, replacing filters, or repairing the

machine in rain or high winds, or places where there is a lot of
dust.
DISASSEMBLY AND MAINTENANCE WORK IN THE FIELD
If disassembly or maintenance work is carried out on hydraulic

equipment in the field, there is danger of dust entering the
equipment. It is also difficult to confirm the performance after
repairs, so it is desirable to use unit exchange. Disassembly and
maintenance of hydraulic equipment should be carried out in a
specially prepared dust proof workshop, and the performance
should be confirmed with special test equipment.
20-210 Î WA450-3MC
SEALING OPENINGS
After any piping or equipment is removed, the openings should be

sealed with caps, tapes, or vinyl bags to prevent any dirt or dust
from entering. If the opening is left open or is blocked with a rag,
there is danger of dirt entering or of the surrounding area being
made dirty by leaking oil so never do this. Do not simply drain oil
out on to the ground, collect it and ask the customer to dispose of
it, or take it back with you for disposal.
DO NOT LET ANY DIRT OR DUST GET IN DURING REFILLING

OPERATIONS.
Be careful not to let any dirt or dust get in when refilling with
hydraulic oil. Always keep the oil filler and the area around it
clean, and also use clean pumps and oil containers. If an oil
cleaning device is used, it is possible to filter out the dirt that has
collected during storage, so this is an even more effective method.
CHANGE HYDRAULIC OIL WHEN THE TEMPERATURE IS HIGH.
When hydraulic oil or other oil is warm, it flows easily. In addition,

the sludge can also be drained out easily from the circuit together
with the oil, so it is best to change the oil when it is still warm.
When changing the oil, as much as possible of the old hydraulic
oil must be drained out. Do not drain the oil from the hydraulic
tank; also drain the oil from the filter and from the drain plug in the
circuit. If any old oil is left, the contaminants and sludge in it will
mix with the new oil and will shorten the life of the hydraulic oil.
FLUSHING OPERATIONS
After disassembling and assembling the equipment, 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.
CLEANING OPERATIONS
After repairing the hydraulic equipment; pump, control valve, etc.

or when running the machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning
equipment is used to remove the ultra fine [about 3F] particles that
the filter built into the hydraulic equipment cannot remove, so it is
an extremely effective device.
WA450-3MC 20-211 Î
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
value
1. Check fuel level --- Add fuel
Lubricating oil, coolant
2. Check for impurities in fuel --- Clean, drain

3. Check hydraulic oil level --- Add oil
4. Check hydraulic strainer --- Clean, drain
5. Check engine oil level, type of oil --- Add oil
6. Check coolant level --- Add water
7. Check dust indicator for clogging --- Clean or replace
8. Check hydraulic filter --- Replace
equipment
1. Check for looseness, corrosion of battery terminal, wiring --- Tighten or replace
Electrical
2. Check for looseness, corrosion of alternator terminal, wiring --- Tighten or replace
3. Check for looseness, corrosion of starter motor terminal, wiring --- Tighten or replace
mechanical
1. Check for abnormal noise, smell --- Repair

equipment
Hydraulic
2. Check for oil leakage --- Repair

3. Carry out air bleeding --- Bleed air
1. Check battery voltage, engine stopped 20 to 30 V Replace
Electrics, electrical equipment
2. Check battery electrolyte level --- Add or replace

3. Check for discolored, burnt, exposed wires --- Replace
4. Check for missing wiring clamps, hanging wiring --- Repair
5. Check for water leaking on wiring --- Disconnect and dry
6. Check for blown, corroded fuses --- Replace
7. Check alternator voltage, ½ throttle or above 27.5 to 29.5 V Replace
8. Check operating sound of battery relay, when switch is turned
--- Replace
On/Off
20-212 Î WA450-3MC
TROUBLESHOOTING METHOD OF USING CHARTS
METHOD OF USING CHARTS

CATEGORY OF TROUBLESHOOTING CODE NUMBER
Troubleshooting Code No. Component

S-±± Troubleshooting of engine related parts
M-±± Troubleshooting of machine monitor
K-±± Troubleshooting of maintenance monitor system
E-±± Troubleshooting of electrical system
A-±± Troubleshooting of transmission controller
T-±± Troubleshooting of hydraulic and mechanical system
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE

TROUBLESHOOTING CODE NUMBER AND PROBLEM
1. The title of the troubleshooting chart gives the troubleshooting code, service code, and failure mode, problem with
the machine. < See Example 1 >
DISTINGUISHING CONDITIONS
1. Even with the same failure mode, problem, the method of troubleshooting may differ according to the model,
component, or problem. In such cases, the failure mode, problem, is further divided into sections marked with small
letters, for example a, so go to the appropriate section to carry out troubleshooting. < See Example 2 > If the
troubleshooting table is not divided into sections, start troubleshooting from the first check item in the failure mode.
METHOD OF FOLLOWING TROUBLESHOOTING CHART
1. Check or measure the item inside , and according to the answer follow either the YES line or the NO line
to go to the next .
Note: The number written at the top right corner of the is an index number; it does not indicate the order to follow.
2. Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause
column. Check the cause and take the action given in the Remedy column on the right. < See Example 3 >
3. Below the there are the methods for inspection or measurement, and the judgement values. If the judgement
values below the are correct or the answer to the question inside the is YES, follow the YES line; if the
judgement value is not correct, or the answer to the question is NO, follow the NO line.
4. Below the is given the preparatory work needed for inspection and measurement, and the judgement values.
If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may
cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or
measurement, always read the instructions carefully, and start the work in order from Item 1.
GENERAL PRECAUTIONS
1. When carrying out troubleshooting for the failure mode (problem), precautions that apply to all items are given at
the top of the page and marked with i < See Example 4 >.
2. The precautions marked i are not given in the , but must always be followed when carrying out the check inside
the .
WA450-3MC 20-213 Î
TROUBLESHOOTING TOOLS
1. When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR
TESTING, ADJUSTING, AND TROUBLESHOOTING.
INSTALLATION POSITION, PIN NUMBER
1. A diagram or chart is given for the connector type, installation position, and connector pin number connection. When
carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and
measurement of the wiring connector number appearing in the troubleshooting flow chart for each failure mode,
problem.
< Examples >
1. M-15 Abnormality in buzzer

2. a) Buzzer does not sound when start switch is turned on, during self check
3.
Cause Remedy
YES Defective contact or
After inspec-
dis-connection in har-
tion, repair or
ness between L06-8
replace
1 and L43
Does buzzer sound
1. Turn start switch on YES Defective buzzer Replace
2. Contact L43 to chassis ground 2
Is voltage between L42 and chassis

NO ground normal
1. 20 to 30 V Defective contact or
After inspec-
2. Turn start switch on dis-connection in har-
tion, repair or
ness between L42 and
NO replace
FS2
4.
i Before carrying out troubleshooting, check that all the related connectors are properly inserted.
i Always connect any disconnected connectors before going on the next step.
20-214 Î WA450-3MC
METHOD OF USING CHARTS

This troubleshooting chart is divided into three sections: questions,
check items, and troubleshooting. The questions and check items
are used to pinpoint high probability causes that can be located from
the failure symptoms or simple inspection without using trouble-
shooting tools. Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make final confirmation.
Questions
Sections A plus 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.
Troubleshooting
Troubleshooting is carried out in the order of probability, starting
with the causes that have been marked as having the highest
probability from information gained from Questions and Check
items.
WA450-3MC 20-215 Î
The basic method of using the troubleshooting chart is as follows.

Items listed for Questions and Check items that have a relationship
with the Cause items are marked with Ì, and of these, causes that
have a high probability are marked with Ê.
Check each of the Questions and Check items in turn, and marked
the Ì or Ê in the chart for 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 the Questions Section,

ask the user, and mark the Cause column with Ë to use as
reference for locating the cause of the failure. However, do
not use this when making calculations to narrow down the
causes.
2 Use the Ë in the Cause column as reference for Degree of

use, Operated for long period in the Questions section as
reference. As a rule, do not use it when calculating the points
for locating the cause, but it can be included if necessary to
determine the order for troubleshooting.
20-216 Î WA450-3MC
METHOD OF USING MATRIX TROUBLESHOOTING TABLES

The troubleshooting tables use the same method as for other
troubleshooting table (YES/NO type) to locate the causes of failures
in the machine. The troubleshooting tables are divided broadly into
categories for the main components, such as the steering system
and work equipment hydraulic system. Follow the procedure given
below and carry out troubleshooting to locate problems accurately
and swiftly.
Step 1. QUESTIONING THE OPERATOR Steering does not work»Symptom [Example 1]
The questions to ask the operator are given below the failure Ask the operator about the following points.
symptom. If the answers to the questions match the information ! Did the steering suddenly stop working? º
given, follow the arrow to reach the probable cause of the failure. Breakage in steering equipment
Consider the contents of the questions and consult the table while ! Had the steering gradually been becoming
heavy? º Internal wear of steering equipment,
proceeding to Steps 2 and 3 to grasp the true cause.
defective seal
Step 2. CHECKS BEFORE TROUBLESHOOTING
Checks before starting [Example 2]
First check the Checks Before Starting items, before starting the
main troubleshooting and measuring the hydraulic pressure, and ! Is the oil level and type of oil in the hydraulic
tank correct?
check for oil leakage and loose bolts. These checks may avoid time
! Is there any leakage of oil from the steering
wasted on unnecessary troubleshooting. The given items must be control valve?
considered particularly for that symptom before starting trouble-
shooting.
[Example 1]
Step 3. USING CROSS REFERENCE TABLE
1. Operate the machine to carry out the checks in the trouble-

shooting item column. Mark the items where the results match
the symptom.
i It is not necessary to follow the troubleshooting checks in order;

follow an order which is easiest to carry out troubleshooting.
[Example 2]
2. Find the appropriate cause from the cause column. If the
symptom appears, the Ì marks on that line indicate the possible
causes. For item No. 2 in the table on the right, the possible
causes are core.
If there is only one Ì; Carry out the other troubleshooting items,

where the same cause is marked with Ì, check if the symptom
appears, then repair.
If there are two Ìs; Go on to Step 3) to narrow down the

possible causes.
20-218 Î WA450-3MC
3. Operate the machine and check the troubleshooting items other

than those in Step 1. Operate the machine and check the items
in the same way as in Step 1, and if the symptom appears, mark
that item. In the chart on the right, the symptom appears again
for item 5.
4. Find the appropriate cause from the cause column. In the same
way as in Step 2, if the symptom appears, the Ì marks on that
line indicate the possible causes. For item No.5 in the table on
the right, the possible causes are b or e.
5. Narrow down the possible causes. There is one common cause

among the causes located in Steps 2 and 4. One cause marked
Ì appears on the line for both items. This cause is common to
both the symptoms in troubleshooting Steps 1 and 3.
i The causes which are not common to both troubleshooting
items, which are not marked Ì for both symptoms are unlikely
causes, so ignore them. In the example given on the right, the
causes for Troubleshooting Item 2 are c or e, and the causes
for Troubleshooting Item 5 are b or e, so cause e is common to
both.
6. Repeat the operations in Steps 3, 4 and 5 until one common

cause remains.
i If the causes cannot be narrowed down to one cause, narrow
the causes down as far as possible.
7. Remedy; If the causes are narrowed down to one common

cause, take the action given in the remedy column. The symbols
given in the remedy column indicate the following:
X, Replace; r, Repair; A, Adjust; C, Clean
WA450-3MC 20-219 Î
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

i The Locale column in the following tables show the location in the connector arrangement drawing.
CONNECTOR PIN ARRANGEMENT - 1 OF 2
CN Type Pins Mounting location Locale CN Type Pins Mounting location Locale
B01 X 2 Condenser motor left K7 LR1 S 12 Floor wiring harness C7
B03 Con 2 Front washer tank H9 LR2 SWP 14 Floor wiring harness B8
B04 Con 2 Rear washer tank G9 LR3 SWP 8 Floor wiring harness C7
B07 X 2 Condenser motor right G9 LR4 SWP 14 Floor wiring harness B7
BR1 SWP 6 Bulkhead wiring harness I3 LR5 X 4 Floor wiring harness C7
C01 M 6 Front wiper motor D7 LR6 L 2 Floor wiring harness B7
C02 M 4 Radio E7 R06 X 2 Radiator level sensor J9
C03 M 2 Working lamp right F8 R07 X 2 Fuel level sensor K4
C04 M 2 Working lamp left F8 R08 M 6 Left rear combination lamp K6
C06 Con 2 Room lamp F8 R09 M 6 Right rear combination lamp I9
C07 M 4 Rear wiper motor F8 R18 Con 1 License lamp K7
E06 Con 2 Coolant temperature sensor J8 R19 Con 1 License lamp K7
ER1 SWP 14 Engine wiring harness K5 T01 X 2 F solenoid H2
ER2 SWP 8 Engine wiring harness K4 T02 X 2 R solenoid I3
F01 M 3 Head lamp right B6 T03 X 2 Hi Lo solenoid H2
F02 M 3 Combination lamp right B5 T04 X 2 Speed solenoid H2
F03 M 3 Combination lamp left F1 T05 X 2 Parking brake solenoid G2
F04 M 3 Head lamp left F1 T06 X 2 Speed sensor G2
F05 X 3 Bucket positioner B5 T07 X 2 Converter oil temperature sensor I3
F06 X 3 Boom kick out E1 T08 X 2 Parking brake indicator sensor G2
FR1 S 10 Rear frame wiring harness F1 T11 X 2 Emergency steering switch E8
FR2 X 4 Rear frame wiring harness G2 TL1 SWP 8 Floor wiring harness C7
GR1 3 Intermediate connector K6 TL2 SWP 6 Floor wiring harness B7
GW1 M 2 Working lamp J8
20-220 Î WA450-3MC
CONNECTOR PIN ARRANGEMENT DIAGRAM - 1 OF 2
WA450-3MC 20-221 Î
CONNECTOR PIN ARRANGEMENT DIAGRAM - 2 OF 2
20-222 Î WA450-3MC
CONNECTOR PIN ARRANGEMENT - 2 OF 2
CN Type Pins Mounting location Locale CN Type Pins Mounting location Locale
A5 M 2 Temperature sensor Q1 FS6 M 4 Fuse box Q5
A6 SWP 6 Servo motor P1 L01 SWP 6 Trans combination switch M1
A7 M 6 Blower motor resistor Q1 L02 SWP 6 Trans combination switch M1
A8A S 16 Air conditioner relay R5 L03 SWP 6 Trans combination switch M5
A8B S 4 Air conditioner relay R5 L04 SWP 14 Trans combination switch M2
A9 --- 4 Blower relay [MAIN] R3 L05 AMP40 20 Main monitor M3
A10 --- 4 Blower relay [Hi] R4 L06 AMP40 16 Main monitor M4
A11 --- 4 Blower relay [M2] R3 L07 AMP40 12 Main monitor M3
A12 --- 4 Conditioner relay [MAIN] R2 L08 AMP40 8 Main monitor M3
A13 --- 4 Blower relay [M1] R4 L09 M 4 Starting switch M3
A14 --- 4 Right condenser relay [Hi] R2 L10 S 10 Wiper switch P1
A15 --- 4 Left condenser relay [Hi] R2 L12 X 2 Transmission cut off switch O1
A16 --- 4 Condenser relay R3 L15 M 4 Kick down and hold switch ---
CL1 S 12 Cab harness M2 L16 KES1 2 Boom kick out solenoid ---
CL2 S 16 Air conditioner M1 L17 KES1 2 Bucket positioner solenoid ---
CL3 S 8 Air conditioner N1 L18 AMP40 16 Sub monitor O6
E03 SWP 8 Engine stop motor V8 L19 AMP40 8 Sub monitor P6
E04 X 3 RPM sensor X5 L21 KES1 2 Sub monitor O6
E05 1 PIN 1 Coolant temperature sensor W9 L22 AMP40 2 Sub monitor O6
E06 X 2 Coolant temperature sensor T7 L29 MIC 21 Transmission controller N6
E08 --- 1 Heater relay U8 L30 AMP40 20 Transmission controller N6
E09 --- 1 Heater relay V9 L31 AMP40 16 Transmission controller N6
E10 X 1 Engine oil level sensor U1 L48 KES0 5 Bucket relay Q7
E11 X3 L49 KES0 5 Boom relay Q8
E12 X 1 Compressor clutch U7 L52 KES0 5 Hazard relay N8
E13 X 2 Starting motor X2 L53 KES0 5 Stop lamp relay N7
E14 W2 L54 KES0 5 Back up lamp relay O9
E15 --- 1 Alternator S5 L55 KES0 5 Horn relay Q9
E16 --- 1 Alternator S5 L56 KES0 5 Preheating relay Q9
E17 --- 1 Alternator S7 L57 KES0 5 Neutral relay N8
E19 1 PIN 1 Dust indicator X6 L58 KES0 5 Neutralizer relay N8
E20 1 PIN 1 Dust indicator X5 L59 KES0 5 Parking safety relay O9
ER1 SWP 14 Engine wiring harness W2 L60 KES0 6 Front work lamp relay P9
ER2 SWP 8 Engine wiring harness V1 L61 KES0 6 Rear work lamp relay P9
FS1 L 2 Fuse box Q6 L62 KES0 5 Engine stop relay P9
FS2 S 12 Fuse box Q6 L63 1 PIN 1 Horn switch M2
FS3 M 6 Fuse box Q6 L64 KES0 5 Engine oil pressure relay N9
FS4 L 2 Fuse box Q6 L80 KES0 5 Dust indicator relay Q8
FS5 M 6 Fuse box Q5 L81 X 2 Stop light switch O1
WA450-3MC 20-223 Î
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

i 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 connectors
Pins
Male (female housing) Female (male housing)
20-224 Î WA450-3MC
SWP type connectors

Pins
12
14
16
WA450-3MC 20-225 Î
M type connectors
Pins
20-226 Î WA450-3MC
S type connectors
Pins
10
12
16
WA450-3MC 20-227 Î
MIC type connectors

Pins
13
17
21
20-228 Î WA450-3MC
AMP040 type connectors

Pins
12
16
20
WA450-3MC 20-229 Î
AMP070 type connectors

Pins
14
18
20-230 Î WA450-3MC
L type connectors
Pins
WA450-3MC 20-231 Î
Automobile connector
Pins
20-232 Î WA450-3MC
Relay connector
Pins
WA450-3MC 20-233 Î
TROUBLESHOOTING OF ENGINE SYSTEM
S MODE
S-1 Starting performance is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-302 Î
S-2 Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-303 Î
S-3 Engine does not pick up smoothly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-306 Î
S-4 Engine stops during operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-307 Î
S-5 Engine does not rotate smoothly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-308 Î
S-6 Engine lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-309 Î
S-7 Exhaust gas is black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-310 Î
S-8 Oil consumption is excessive or exhaust gas is blue . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-311 Î
S-9 Oil becomes contaminated quickly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-312 Î
S-10 Fuel consumption is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-313 Î
S-11 Oil is in coolant, coolant spurts or coolant level goes down . . . . . . . . . . . . . . . . . . . 20-314 Î
S-12 Oil pressure lamp lights up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-315 Î
S-13 Oil level rises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-316 Î
S-14 Coolant temperature becomes too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-317 Î
S-15 Abnormal noise is made . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-318 Î
S-16 Vibration is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-319 Î
WA450-3MC 20-301 Î
TROUBLESHOOTING S-1
S-1 Starting performance is poor

General causes why starting performance is poor
! Defective electrical system ! Insufficient intake of air
! Insufficient supply of fuel ! Improper selection of fuel
Causes
Battery charging rate
Defective injection pump [rack, plunger stuck]

100% 90% 80% 75% 70%
20EC 1.28 1.26 1.24 1.23 1.22
Defective contact of valve, valve seat
Leakage, clogging, air in fuel system

Defective intake heater [ribbon type]
0EC 1.29 1.27 1.25 1.24 1.23
Clogged fuel tank air breather hole

Defective or deteriorated battery
-10EC 1.30 1.28 1.26 1.25 1.24
Clogged air cleaner element
Clogged feed pump strainer

Clogged fuel filter, strainer
i At ambient temperature of 10EC or below, use ASTM D975 No. 1
Defective injection nozzle

Worn piston ring, cylinder
Defective injection timing

! 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
Defective alternator
Defective regulator
75% in the above table.
Ì Possible cause [ judging from Questions and Check items]

Ê Most probable causes [ judging from Questions and Check items]
Ë Possible causes due to length of use [used for a long period]
Confirm recent repair history

Degree of use of machine Operated for long time Ë Ë Ë Ë
Gradually became worse Ê Ê Ì Ì Ì
Ease of starting
Questions
Starts when warm Ê Ê

Indicator lamp does not light up Ê
Engine oil must be added more frequently Ê
Filter replacement not performed per O&MM Ê Ê Ê Ì Ì
Dust indicator is red Ê
Non specified fuel has been used Ì Ì Ì Ì
Battery charge lamp is on Ê Ê
Starting motor cranks engine slowly Ê
Temperature of some cylinders are low immediately after starting engine Ê
Engine does not pick up smoothly and combustion is irregular Ì Ì Ê
Check items
Blow by gas is excessive Ê

Match marks on fuel injection pump are out of alignment Ê
Mud is stuck to fuel tank cap Ì
Engine cranked with Little fuel comes out even when pump sleeve nut is loosened Ê
starting motor Little fuel comes out even when fuel filter air bleed plug is loosened Ê Ê Ê
Leakage from fuel piping Ì Ê
There is hunting from engine [rotation is irregular] Ì Ì Ê Ì
When compression pressure is measured, it is found to be low Í Í
When air cleaner is inspected directly, it is found to be clogged Í
When fuel filter, strainer are inspected directly, they are found to be clogged Í Í
When feed pump strainer is inspected directly, it is found to be clogged Í
Troubleshooting
Heater mount does not become warm Í

Voltage is 26 to 30 V between alternator terminal B and terminal E with engine at Yes Í
low idle No Í
Either specific gravity of electrolyte or voltage of battery is low Í
Speed of some cylinders does not change when operating on reduced cylinders Í
When check is made using delivery method, injection timing is found to be incorrect Í
When control rack is pushed, it is found to be heavy or does not return [when blind plug is removed,
it can be seen that plunger control sleeve does not move
Í
When fuel cap is inspected directly, it is found to be clogged Í
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Repair
Adjust
Clean
Clean
Clean
Clean
Remedy
20-302 Î WA450-3MC
TROUBLESHOOTING S-2
S-2 Engine does not start

(1) Engine does not start
General causes why engine does not turn
! Internal parts of engine seized
i If internal parts of the engine are seized, carry out trouble-
shooting for Engine stops during operations.
! Failure in power train
! Faulty electrical system
Causes
Defective adjustment of engine stop motor wire

Defective safety relay or safety switch
Defective battery terminal connection

Defective wiring of starting circuit
Defective engine stop motor

Defective starter motor
Defective battery relay
Defective start switch

Broken ring gear

Í Items to confirm the cause

Questions
Degree of use Operated for long period Ë Ë

Horn does not sound Ê Ì Ì
Condition of horn when start switch is turned on
Horn sound level is low Ê
Rotating speed is low Ê
When start switch is turned to START, pinion moves out, Makes grating sound Ê Ê
but Soon disengages again Ê
Check items
Makes rattling noise and does not turn Ì Ì Ì

When start switch is turned to START, pinion does not move out Ê Ì Ì
When start switch is turned to ON, there is no clicking sound Ì Ê
Carry out troubleshooting for starting circuit
Battery terminal is loose Ê

When start switch is turned to ON, linkage does not move Ê Ê
When battery is checked, battery electrolyte is found to be low Ê
Specific gravity of electrolyte, voltage of battery is low Í
1) When terminal B and C of start switch are connected, engine starts Í
Troubleshooting
For following condition, 1)

through 5), turn start switch 2) When terminal B and C of start motor are connected, engine starts Í
OFF, connect the cord and 3) When terminal B and C of safety relay are connected, engine starts Í
carry out troubleshooting at 4) When safety switch terminal and starter motor terminal B are connected, engine starts
ON
Í
5) There is no 24V voltage between battery relay terminal B and E Í
When ring gear is inspected directly, tooth surface is found to be chipped Í
Does not move even when engine stop motor linkage is disconnected Í Í
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
WA450-3MC 20-303 Î
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust gas comes out
General causes why engine turns but no exhaust gas comes out
! Supply of fuel impossible
! Supply of fuel is extremely small
! Improper selection of fuel, particularly in winter
Causes
i Standards for use of fuel, per ASTM
Defective injection pump [rack, plunger seized]

Ambient temperature EC
Fluid type
-30 -20 -10 0 10 20 30 40
Broken injection pump drive shaft, key

D975 No 2

Diesel
Seized, broken feed pump piston

fuel
D975 No 1
Defective engine stop motor

Clogged, leaking fuel piping

Improper fuel used

Lack of fuel

Confirm recent history
Degree of use Operated for long period Ë Ë Ë
Questions
Exhaust gas suddenly stops coming out [when starting again] Ê Ê Ê

Filter replacement not performed per O&MM Ê Ê
Fuel tank is found to be empty Ê
There is leakage from fuel piping Ê
Mud is stuck to fuel tank cap Ê
When start switch is turned ON, linkage does not move Ê
Check items
When fuel filter is drained, fuel does not come out Ê

1) Injection pump coupling does not rotate Ê
Engine cranked with starter
motor
2) No fuel comes out even when fuel filter air bleed plug is loosened Ê Ì Ì Ì
3) No fuel spurts out even when injection pipe sleeve is loosened Ê Ê Ê
Rust and water are found when fuel is drained Ì Ì
Check injection pump directly Í
Troubleshooting
When control rack is pushed, it is found to be heavy or does not return Í

Check feed pump directly Í
When fuel filter, strainer are inspected directly, they are found to clogged Í Í
Does not even move when engine stop motor linkage is disconnected Í
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Clean
Clean
Remedy
Add
20-304 Î WA450-3MC
TROUBLESHOOTING S-2
(3) Exhaust gas comes out but engine does not start
i General causes why exhaust gas comes out but engine does ! Insufficient supply of fuel
not start. ! Insufficient intake of air
! Lack of rotating force due to faulty electrical system ! Improper selection of fuel and oil
Causes
Defective broken valve system [valve, rocker etc.]

Defective intake heater [ribbon heater type]
Clogged injection nozzle, defective spray

Leakage, clogging, air in fuel system

Improper fuel used

Confirm recent history

Degree of use Operated for long period Ë Ë Ë Ë
Suddenly failed to start Ê Ê
When engine is cranked, abnormal noise is heard from around head Ê
Questions

Non specified fuel has been used Ì Ì
Filter replacement not performed per O&MM Ê Ê Ê
Rust is found when fuel is drained Ê Ê
Indicator lamp does not light up Ê
Starting motor cranks engine slowly Ê
Mud is stuck to fuel tank cap Ì
Check items
When fuel lever is placed at FULL position, it does not contact stopper Ì
Engine is cranked with 1) Little fuel comes out even when injection pump sleeve nut is loosened Ê
starter motor 2) Little fuel comes out even when fuel filter air bleed plug is loosened Ê Ê Ì
Temperature of some cylinders are low immediately after starting engine Ê
When fuel filter is drained no fuel comes out Ê
Remove head cover and check directly Í
When compression pressure is measured, it is found to be low Í
Troubleshooting
When fuel filter, strainer are inspected directly, they are found to be clogged Í Í
When air element is inspected directly, it is found to be clogged Í
Heater mount does not become warm Í
Either specific gravity of electrolyte or voltage of battery is low Í
When feed pump is operated, there is no response or pump is heavy Í
Replace
Replace
Replace
Replace
Repair
Repair
Clean
Clean
Clean
Clean
Clean
---
Remedy
WA450-3MC 20-305 Î
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly

General causes why engine does not pick up smoothly
! Insufficient intake of air ! Improper condition of fuel injection
! Insufficient supply of fuel ! Improper fuel used
Causes

Seized turbocharger, interference
Seized injection pump plunger

Improper valve clearance


Degree of use Operated for long period Ë Ë Ë Ë Ë
Questions
Non specific fuel has been used Ê Ê Ê Ê

Rust and water are found when fuel is drained Ê Ê
Noise of interference is heard from around turbocharger Ê
Engine pick up suddenly becomes poor Ì Ê Ì Ì
Blue under light load Ê
Color of exhaust gas
Black Ê Ê Ê Ì
Check items
Clanging sound is heard from around cylinder head Ê

High idle speed, no load normal, but speed suddenly drops when load is applied Ê Ê Ì
There is hunting from engine [rotation is irregular] Ì Ê Ì
Temperature of some cylinders are low immediately after starting engine Ê Ì
When fuel filter, strainer are inspected directly, they are found to be clogged Í
Troubleshooting
When turbocharger is rotated by hand, it is found to be heavy Í
When valve clearance is checked directly, it is found to be outside standard value Í
When feed pump is operated, operation is too light or too heavy Í
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Clean
Clean
Clean
Clean
Remedy
20-306 Î WA450-3MC
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why the engine stops during operations.
! Seized parts inside engine ! Failure in power train
! Insufficient supply of fuel i If the engine stops because of failure in the
! Engine overheating power train, carry out troubleshooting for the
i If there is overheating and the engine stops, carry chassis.
out troubleshooting for overheating.
Causes

Broken valve system [valve, rocker etc.]
Broken, seized piston connecting rod

Broken, seized crankshaft bearing
Broken pump auxiliary equipment

Broken fuel pump drive shaft, key
Broken seized feed pump piston
Failure in chassis power train

Clogged, leaking fuel lines

Broken, seized gear train
Lack of fuel

Abnormal noise was heard and engine stopped suddenly Ê Ê Ê Ê Ê Ê Ì Ì Ê
Condition when en- Engine overheated and stopped Ê Ì Ì
Questions
gine stopped Engine stopped slowly Ê Ì Ì

There was hunting and engine stopped Ê Ì Ì Ì
Fuel gauge lamp lights up Ê
Fuel tank is found to be empty Ê
Non specified fuel has been used Ì Ì Ì Ì
When fuel feed pump is operated, there is no response or it is heavy Ì Ì Ê
Engine turns but stops when transmission control lever is operated Ê
Check items
Does not turn at all Ê Ê
Carry out troubleshooting in chassis volume

Try to turn by hand Turns in opposite direction Ê
using barring tool Moves amount of backlash Ê Ê
Shaft does not turn Ê
Rust and water are found when fuel is drained Ê Ê
Metal particles are found when oil is drained Ê Ê Ì Ì
Remove oil pan and check directly Í Í
Troubleshooting
When gear train is inspected, it does not turn Í

Turns when pump auxiliary equipment is removed Í
Check feed pump directly Í
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Clean
---
Remedy
Add
WA450-3MC 20-307 Î
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly

General causes why the engine does not rotate smoothly
! Air in fuel system
! Defective governor mechanism
Causes
Clogged, air in circuit between fuel tank and feed pump

Clogged, air in circuit between feed pump and nozzle
Defective operation of control rack
Defective adjustment of governor
Defective operation of governor

Low speed is too low

Lack of fuel

Occurs at certain speed range Ê Ê Ê Ì
Questions
Occurs at low idle Ì Ê Ì Ì Ì Ì

Condition of hunting
Occurs even when speed is raised Ì Ì Ì Ì
Occurs on slopes Ê
Fuel tank is found to empty Ê
Rust is found when fuel is drained Ì Ì
Leakage from fuel piping Ê Ê
Check items
1) No response, light, return is quick Ê Ê

When feed pump is operated
2) No response, light, return is normal Ê
Engine speed sometimes rises too high Ê Ê
Engine is sometimes difficult to stop Ê Ê
Seal on injection pump has come off Ê Ê
When governor lever is moved, it is found to be stiff Í Í
Troubleshooting
When injection pump is tested, governor is found to be improperly adjusted Í

When fuel cap is inspected directly, it is found to be clogged Í Í
When fuel filter, strainer is inspected directly, it is found to be clogged Í
Repair
Repair
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
20-308 Î WA450-3MC
TROUBLESHOOTING S-6
S-6 Engine lacks power

General causes why the engine lacks output
! Insufficient intake of air ! Lack of output due to overheating
! Insufficient supply of fuel i If there is overheating and insufficient output, carry
! Improper condition of fuel injectors out troubleshooting for overheating.
! Improper fuel used, if non specified fuel is used,
output drops
Causes
Bent fuel lever linkage, defective adjustment


Seized injection pump plunger




Suddenly Ê
Questions
Power was lost

Gradually Ì Ì Ì Ì Ì Ì
Non specified fuel has been used Ê Ê Ê Ê
Black Ê Ê
Noise of interference heard from around turbocharger Ê
Check items
Engine pick up is poor and combustion is irregular Ê Ì Ì Ì

High idle speed, no load normal, but speed suddenly drops when load is applied Ê Ê Ì
There is hunting from engine [rotation is irregular] Ì Ì Ì Ì
High idle speed of engine is low Ì Ê
Leakage from fuel piping Ê
Troubleshooting
When lever is placed at FULL position, it does not contact stopper Í
When feed pump is operated, operation is too light or too heavy Í
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
WA450-3MC 20-309 Î
TROUBLESHOOTING S-7
S-7 Exhaust gas is black

General cause why exhaust gas is black
! Insufficient intake of air
! Improper condition of fuel injections
! Excessive injection of fuel
Causes
Leakage of air between turbocharger and head

Defective injection pump [excessive injection]

Clogged, seized injection nozzle


Crushed, clogged muffler

Improper injection timing

Suddenly became black Ê Ì Ì
Questions
Color of exhaust gas Gradually became black Ê Ì Ì

Suddenly Ê Ì Ì Ì
Power was lost
Gradually Ì Ì Ì Ì
Engine pick up is poor and combustion is irregular Ì Ê Ì Ì Ì Ì
Check items
Temperature of some cylinders are low immediately after stating engine Ê Ì

Match marks on fuel injection pump are out of alignment Ê
Seal on injection pump has come off Ê
Exhaust noise is abnormal Ì Ì Ê
Muffler is crushed Ê
Leakage of air between turbocharger and head, loose clamp Ê
When air cleaner is inspected directly, it is found to be clogged Í
Troubleshooting

Injection pump test shows that injection amount is incorrect Í
When muffler is removed, exhaust gas color returns to normal Í
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean
Remedy
20-310 Î WA450-3MC
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive or exhaust gas is blue

i Do not run the engine at idle for more than 20 minutes continu-
ously, [both low and high idle].
General causes why oil consumption is excessive.
! Abnormal combustion of oil
! External leakage of oil
! Wear of lubrication system
Causes
Leakage from oil pan, cylinder head, etc.
Worn seal at turbine end of turbocharger

Worn seal at blower end of turbocharger
Worn valve [stem, guide], broken seal

Worn, broken rear seal, seal surface
Dust sucked in from intake system
Clogged breather or breather hose
Leakage from oil cooler, oil filter
Worn piston ring, cylinder liner
Leakage from oil drain plug

Leakage from oil piping

Broken piston ring
Broken oil cooler


Questions

Oil consumption suddenly increased Ê Ì
Engine oil must be added more frequently Ê Ì
Engine oil becomes contaminated quickly Ì Ê Ì
Exhaust gas is blue under light load Ê Ê
Abnormally excessive Ê Ê Ì Ì
Amount of blow by gas
None Ê
Check items
Area around engine is dirty with oil Ê Ê Ê Ê

There is oil in engine coolant Ê
When exhaust pipe is removed, inside is found to be dirty with oil Ê Ì
Inside of turbocharger intake pipe is dirty with oil Ê
Oil level inside torque converter housing chamber rises Ê
Clamps for intake system are loose Ê
When breather element is inspected, it is found to be clogged with dirty oil Í
Troubleshooting
There is external leakage of oil from engine Í Í Í Í

Pressure tightness test of oil cooler shows there is leakage Í
Excessive play of turbocharger shaft Í Í
Check rear seal directly Í
When intake manifold is removed, dust is found inside Í
When intake manifold is removed, it is found to be dirty with oil Í
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Clean
Remedy
WA450-3MC 20-311 Î
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly.
! Intake of exhaust gas due to internal wear
! Clogging of lubrication passage
! Improper combustion
! Improper oil used
! Operation under excessive load
Causes
Defective seal at turbocharger turbine end

Clogged turbocharger drain pipe
Clogged breather, breather tube
Worn valve, valve guide

Defective safety valve

Exhaust gas is black
Clogged oil cooler
Clogged oil filter


Questions

Non specified fuel has been used Ì
Black Ê
Check items
Abnormally excessive Ê Ì Ì Ì
Carry out troubleshooting for Exhaust is black

Amount of blow by gas
None Ê
Oil filter caution lamp stays on even when oil pressure rises Ê Ì
When oil filter is inspected, metal particles are found Ì Ê Ì
When exhaust pipe is removed, inside is found to be dirty with oil Ê
Engine oil temperature rises quickly Ê
Troubleshooting
When breather element is inspected directly, it is found to be clogged with dirty oil or hose is broken Í
When oil filter is inspected directly, it is found to be clogged Í
When oil cooler is inspected directly, it is found to be clogged Í
Turbocharger drain tube is clogged Í
Excessive play of turbocharger shaft Í
When safety valve is directly inspected, spring is found to be catching or broken Í
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
---
Remedy
20-312 Î WA450-3MC
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
! Leakage of fuel
! Improper condition of fuel injection
! Excessive injection of fuel
Causes
External leakage from fuel piping, fuel filter
Defective adjustment of fuel lever linkage

Defective seal inside feed pump [piston]
Leakage of fuel inside head cover
Defective injection pump plunger
Defective injection nozzle spray
Improper fuel injection timing


Questions

More than for other machines of same model Ê Ì
Condition of fuel consumption Gradually increased Ì Ì
Suddenly increased Ì Ì
Black Ê Ì Ì Ì
Exhaust gas color
White Ì
Check items
There is irregular combustion Ê

Match mark on injection pump is misaligned Ê
There is external leakage of fuel from engine Ê
Engine oil level rises and smells of diesel fuel Ì Ê Ê
Engine low idle speed is high Ì Ê
Injection pump test shows that injection amount is excessive Í
Troubleshooting
Speed of some cylinders does not change when operating on educed cylinders Í
Remove feed pump and check directly Í
When engine speed is measured, low idle speed is found to be high Í
Replace
Replace
Repair
Repair
Repair
Adjust
Adjust
Adjust
Remedy
WA450-3MC 20-313 Î
S-11 Oil is in coolant, coolant spurts or coolant level goes down

General causes why oil is in coolant
! Internal leakage in lubrication system
! Internal leakage in cooling system
Causes
Broken liner o-ring, holes caused by pitting

Broken oil cooler for power train
Internal cracks in cylinder block

Broken oil cooler core, o-ring
Insufficient protrusion of liner

Broken head, head gasket

Questions

Suddenly increased Ì Ì Ì
Oil level
Gradually increased Ì Ì
Hard water is being used as coolant Ì Ì
Check items
Engine oil level has risen, oil is cloudy white Ê Ì Ì

Excessive air bubbles inside radiator, spurts back Ê Ê
Hydraulic oil, torque converter transmission oil is cloudy white Ê
When hydraulic oil, torque converter transmission oil is drained, water is found Ê
Í Í
Troubleshooting
Pressure tightness test of oil cooler shows there is leakage

Pressure tightness test of cylinder head shows there is leakage Í
Remove cylinder head and check directly Í
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-314 Î WA450-3MC
S-12 Oil pressure lamp lights up

General causes why oil pressure lamp illuminates
! Leakage, clogging, wear of lubrication system
! Defective oil pressure control
! Improper oil used, improper viscosity
! Deterioration of oil due to overheating
Causes
i Standards for engine oil selection, per ASTM
Ambient temperature EC
Fluid type
-30 -20 -10 0 10 20 30 40
SAE 30
Clogged, broken oil pipe inside oil pan
Leaking, crushed hydraulic piping

SAE 10W
Clogged strainer inside oil pan

Engine oil
Defective oil pressure sensor

Broken suction pipe brazing
SAE 10W-30
Defective oil level sensor

Defective regulator valve
Insufficient oil in oil pan
SAE 15W-40
Defective relief valve

Worn bearing journal
Defective oil pump

Clogged oil filter
Water, fuel in oil

Questions

Filter replacement not performed per O&MM Ê
Caution lamp lights up Ê Ì
Lights up at low idle Ê Ì
Condition when oil pressure Lights up at low, high idle Ê Ê Ê Ê Ì Ì Ì
lamp lights up Lights up on slopes Ê
Check items
Sometimes lights up Ê Ê Ì Ì
There is clogging, leakage from hydraulic piping [external] Ê
Oil level sensor lamp lights up Ê Ê
When oil level in oil pan is checked, it is found to be low Ê
Metal particles are found when oil is drained Ê
Metal particles are stuck to oil filter element Ê Ì
Oil is cloudy white or smells of diesel oil Ê
When oil filter is inspected directly, it is found to be clogged Í Í
Troubleshooting
Remove oil pan and check directly Í Í Í

Oil pump rotation is heavy, there is play Í ®
There is catching of relief valve, regulator valve, spring or valve guide is broken Í Í
When oil level sensor is replaced, oil pressure sensor lamp goes out Í
When oil pressure is measured it is found to be within standard value Í
Replace
Replace
Replace
Repair
Repair
Adjust
Adjust
Clean
Clean
Clean
Clean
---
Remedy
Add
® Carry out Troubleshooting for Oil level rises
WA450-3MC 20-315 Î
S-13 Oil level rises

i If there is oil in the coolant, carry out troubleshooting for Oil is in
Coolant.
General causes why oil level rises;
! Coolant in oil, cloudy white
! Fuel in oil; diluted and smells of diesel fuel
! Entry of oil from other component
Causes
Broken head, head gasket [including precombustion chamber]

Clogged water pump breather hole, defective seal
Defective seal of pump or auxiliary equipment

Leakage of fuel from piping inside head cover
Defective inside injection pump [flange type]
Damaged liner o-ring, holes made by pitting

Worn, damaged rear seal surface
Defective nozzle holder sleeve
Broken oil cooler core, o-ring
Cracks inside cylinder block

Defective thermostat seal

Questions

There is oil in radiator coolant Ê Ì Ì Ì Ì
Exhaust gas is white Ê Ì Ì
When engine is first started, drops of moisture come from muffler Ê
Engine at idle, radiator cap off, abnormal number of bubbles appear or water spurts back Ê Ì
Check items
Water pump breather hole clogged with mud Ê

When water pump breather hole is clean, coolant comes out Ê
Oil level goes down in transmission Ê
Oil level goes down in hydraulic tank Ê
Engine oil smells of diesel fuel Ê Ê Ê
Fuel is added more frequently Ê Ê Ê
Pressure tightness test of oil cooler shows there is leakage Í
Pressure tightness test of cylinder head shows there is leakage Í
Troubleshooting
Remove water pump and check directly Í

Check rear seal directly Í
When pump auxiliary equipment is removed, seal is found to be broken Í
Remove injection pump and check directly Í
There is improper contact of thermostat seat valve Í
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
20-316 Î WA450-3MC
S-14 Coolant temperature becomes too high

General causes why coolant temperature becomes to high
! Lack of cooling air; deformation, damage of fan
! Drop in heat dissipation efficiency
! Defective cooling circulation system
! Rise in power train oil temperature
i Carry out troubleshooting for chassis.
Causes
Damaged liner o-ring, holes made by pitting

Rise in torque converter oil temperature
Defective coolant temperature gauge
Defective thermostat [does not open]
Fan belt slipping, worn fan pulley

Clogged, crushed radiator fin
Broken head, head gasket

Clogged, broken oil cooler
Defective pressure valve
Clogged radiator core

Broken water pump
Insufficient coolant

Questions
Suddenly overheated Ê Ì Ì
Condition of overheating
Always tends to overheat Ê Ê Ì Ì
Rises quickly Ê Ì
Coolant temperature gauge
Does not go down from red range Ê
Radiator coolant level sensor lights up Ê
Fan belt whines under sudden load Ê
Cloudy white oil is floating on coolant Ê
Coolant flows out from overflow hose Ê
Excessive bubbles in radiator, water spurts back Ê
Check items
Engine oil level has risen, oil is cloudy white Ì Ê

There is play when fan pulley is rotated Ê
Radiator shroud, inside of under guard are clogged with dirt or mud Ê Ê
When light is held behind radiator, no light passes through Ê
Coolant is leaking because of cracks in hose or loose clamps Ê
Belt tension is found to slack Ê
Power train oil temperature enters red range before engine coolant temperature Ê
Temperature differences between top and bottom radiator tanks is excessive Í
Temperature differences between top and bottom radiator tanks is slight Í
Troubleshooting
When coolant filler port is inspected, the core is found to be clogged Í

Thermostat function test is done, it does not open even at the cracking temperature Í
When coolant temperature is measured, it is found to be normal Í ®
When oil cooler is inspected directly, it is found to be clogged Í
When radiator cap is tested, set pressure is found to be low Í
Remove oil pan and check directly Í
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
®
---
Carry out troubleshooting for chassis Remedy

Add
WA450-3MC 20-317 Î
S-15 Abnormal noise is made

i Judge if the noise is an internal noise or an external noise.
General causes why abnormal noise is made
! Abnormality due to defective parts
! Abnormal combustion noise
! Air sucked in from intake system
Causes
Defect inside muffler [dividing board out of position]

Leakage of air between turbocharger and head
Broken valve system [valve, rocker, etc.]

Improper adjustment of valve clearance
Deformed fan, interference of fan belt
Clogged, seized injection nozzle

Worn piston ring, cylinder liner
Improper gear train backlash

Missing, seized bushing

Degree of use Operated for long period Ë
Questions
Gradually occurred Ì Ì
Condition of abnormal noise
Suddenly occurred Ì Ì Ì
Black Ê Ì Ì
Metal particles are found in oil filter Ê Ê
Check items

Engine pick up is poor and combustion is irregular Ê
Temperature of cylinders are low immediately after starting engine Ê Ì
Abnormal noise is loud when accelerating engine Ì Ì Ì Ì Ì Ì
Clanging sound is heard from around cylinder head Ê Ê
Leakage of air between turbocharger and head, loose clamp Ê
Vibrating noise is heard from around muffler Ê
When compression pressure is measured, it is found to low Í
Remove gear cover and check directly Í Í
Troubleshooting
Fan is deformed or belt is loose Í
Remove cylinder head cover and check directly Í
When muffler is removed, abnormal noise disappears Í
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Adjust
Adjust
Remedy
20-318 Î WA450-3MC
S-16 Vibration is excessive

i If there is any abnormal noise together with the vibration, carry
out troubleshooting for Abnormal noise is made.
General cause why vibration is excessive
! Defective parts; abnormal wear, breakage
! Improper alignment
! Abnormal combustion
Causes
Misalignment between power train and engine

Loose engine mounting bolts, broken cushion
Broken part inside output shaft [damper]
Valve system [valve, rocker, etc,] stuck

Worn connecting rod, main bearing
Improper gear train backlash

Worn balancer, cam bushing
Worn support pilot


Questions

Suddenly increased Ì Ì
Condition of vibration
Gradually increased Ì Ì Ì Ì
Metal particles are found in oil filter Ê Ê
Metal particles are found when oil is drained Ê Ê
Check items
Oil pressure is low at low idle Ì Ì

Vibration occurs at mid range speed Ì Ì
Vibration follows engine speed Ì Ì Ì Ì Ì
Exhaust gas is black Ê Ì
Remove oil pan check directly Í
Remove side cover and check directly Í
Troubleshooting
Check directly for worn support pilot, play Í

Check directly for loose engine mounting bolts, broken cushion Í
Check inside of output shaft directly Í
When radial run out, face run out are measured, they are found to be outside standard value Í
Remove front cover and check directly Í
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Remedy
WA450-3MC 20-319 Î
TROUBLESHOOTING OF
MAIN MONITOR SYSTEM
M MODE
FAILURE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
M-1 Main monitor does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404
M-2 When start switch is turned ON and engine is started, all lamps stay lit . . . . . . . . . . . 20-405
M-3 Speedometer display does not work properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406
M-4 Abnormality in shift indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-407
M-5 High beam does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-409
M-6 Turn signal display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410
M-7 Abnormality in parking display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-411
M-8 Abnormality in preheating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412
M-9 Tail lights do not illuminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414
M-10 Abnormality in front working lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-415
M-11 Abnormality in rear working lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-417
M-12 Abnormality in transmission cut off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418
M-13 Abnormality in parking brake dragging warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-419
M-14 When parking brake drag warning is given, buzzer and caution lamp are
actuated continuously or they are not actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-420
M-15 Abnormality in buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-421
M-16 Condition of monitor switches is not stored in memory . . . . . . . . . . . . . . . . . . . . . . . . 20-422
M-17 Abnormality in failure display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-423
M-18 Abnormality in ground driven steering normal display . . . . . . . . . . . . . . . . . . . . . . . . . 20-424
M-19 Abnormality in ground driven steering actuation display . . . . . . . . . . . . . . . . . . . . . . . 20-425
M-20 Abnormality in ECSS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-426
WA450-3MC 20-401 Î
TROUBLESHOOTING FAILURE CODE
FAILURE CODE
OUTLINE
The speedometer display on the main monitor is used to display the
troubleshooting for each control system. The nature of the trouble-
shooting is displayed as the failure action code, failure code, and the
time elapsed since failure. The signals between the main monitor
and each controller are transmitted in serial through the network
circuit. Only the engine controller uses a special parallel signal.
ABNORMALITY IN FAILURE ACTION CODE < Example >

When action code CALL is displayed
This code informs the operator directly of the abnormality, and takes
action, such as stopping the machine immediately. There are four
types of action code: E00, E01+CALL (E01 and CALL are displayed
alternately), E03+CALL, and CALL. If a failure occurs suddenly, one
of these codes is shown on the speedometer display. For details of
the action taken by operator for the action codes, see ACTION
CODE.
FAILURE CODE AND ELAPSED TIME

The failures detected by each controller are changed to a code and
displayed. It is possible to tell from this code which system in which < Example >
controller has failed, so carry out troubleshooting for the applicable When failure code 41
controller. For failures that have occurred and been reset, the failure has occurred 27 hours b4
code and the time elapsed since failure are displayed to make it
easy to check failures that are not occurring at present. The failure
codes for failures that are now occurring flash, and the codes for
failures that are not occurring light up. For details of the method of
operating and transferring data to the trouble data display mode, see
STRUCTURE AND FUNCTION for the main monitor.
Note: If the engine is not stopped, it is impossible to switch to the

trouble data display mode, so the codes for failures which can
only be detected when the engine is operating light up.
For the correspondence between the failure codes for each con-
troller and the failed system, see Item 5.
20-402 Î WA450-3MC
TROUBLESHOOTING FAILURE CODE
ACTION CODE
Action code: E ~ ~ + CALL means that E ~ ~ and CALL are displayed alternately
Transmission control system

Action code Buzzer Action by operator
Problem system Action of machine
Does not shift gear automatically Normal operation possible using
E00 Speed sensor system [disconnection] No
[gear must be shifted manually] manual gear shifting
Travel under own power pos-
Hi-Lo solenoid, speed solenoid sys- Transmission range fixed [1st to
E01+CALL Yes sible, call for service after mov-
tem 3rd, depending on case]
ing to safe place
Neutral, [directional solenoid out
Shift lever system
put OFF] Actuate EM [emergency man-
ual] spool, open modulation so-
Neutral [directional, modulation
E03+CALL Directional solenoid system Yes lenoid manually. These actions
solenoid output OFF]
make it possible to travel under
Neutral [directional, modulation own power. Call for service
Modulation solenoid system
solenoid output OFF]
Neutral [directional, modulation Stop machine immediately, turn
Short circuit with power supply on
CALL solenoid output OFF], possible Yes start switch OFF, then call for
modulation solenoid wiring harness
that controller is burnt out service
FAILURE CODE
Code Transmission control system

10 Modulation solenoid system
11 Modulation solenoid system
12 F solenoid valve system
13 R solenoid valve system
14 Hi-Lo solenoid valve system
16 Speed solenoid system
17 Parking brake system
20 Directional lever input system
21 Speed lever input system
22 Speed sensor input system
23 Engine speed input system
Code ECSS control system

d0 Relief valve solenoid
d1 High pressure solenoid system
d2 Low pressure solenoid system
d3 Speed sensor system
d4 Abnormality in model selection
WA450-3MC 20-403 Î
TROUBLESHOOTING M-1
M-1 Main monitor does not work

i Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Yes
1 Defective main monitor Replace
Is voltage between L05-1, 2 to

3 normal
1) 20 to 30 V Yes Defective contact or disconnec-
Repair or
2) Start switch ON tion in harness between L05-1, 2
replace
2 and FS2-9
Is there continuity between
No L05-3 and chassis ground
1) Start switch OFF Defective contact or disconnec-
Repair or
2) Disconnect L05 tion in harness between L05-3
No replace
and R11
20-404 Î WA450-3MC
TROUBLESHOOTING M-2
M-2 When start switch is turned ON and engine is started, all lamps stay lit
Cause Remedy
Yes
Is voltage between L05-4 and chassis ground
normal
1) 20 to 30 V Defective contact or disconnection in Repair or
2) Start switch to START No harness between L05-4 and L57-3 replace
WA450-3MC 20-405 Î
TROUBLESHOOTING M-3
M-3 Speedometer display does not work properly

i Check that the gap between the speed sensor and gear is normal.
Cause Remedy
Yes
Yes Is resistance between L07-1 and 2

normal
1) 500 S to 1 kS Defective contact or disconnection in
Repair or
2) Start switch OFF harness between L07-1, 2 to TL2-1, 2 to
No replace
1 3) Disconnect L07 T06-1, 2
Is resistance between T06-1 and 2
normal
1) 500 S to 1 kS Defective speed sensor Replace
2) Start switch OFF No
3) Disconnect T06
20-406 Î WA450-3MC
TROUBLESHOOTING M-4
M-4 Abnormality in shift indicator

i Check that the transmission shifts.
Cause Remedy
(a) Stays at N even when directional lever is at F
Yes
Is voltage between L08-7 and chassis ground normal

1) 20 to 30 V
Defective contact or disconnection in harness Repair or
2) Start switch ON
No between L08-7 and L04-2 replace
3) Directional lever - F
(b) Stays at N even when directional lever is at R

Yes

1) 20 to 30 V
Defective contact or disconnection in harness Repair or
2) Start switch ON
No between L08-8 and L04-4 replace
3) Directional lever - R
(c) Does not display N even when directional lever is at N and

displays R when directional lever is at F
Yes

1) 0 to 5 V Contact of power source with harness be-
Repair or
2) Start switch ON tween L08-8 and L04-4 or defective control
No replace
3) Directional lever - N lever
(d) Does not display N even when directional lever is at N and

displays F when directional lever is at R
Yes

1) 0 to 5 V Contact of power source with harness be-
Repair or
2) Start switch ON tween L08-7 and L04-2 or defective control
No replace
3) Directional lever - N lever
(e) Does not display 1st, 4th

Yes

1) Disconnect L05 Defective contact or disconnection in harness Repair or
2) 50 to 70 S No between L05-12 and L29-11 replace
(f) Does not display 3rd, 4th

Yes

1) Disconnect L05 Defective contact or disconnection in harness Repair or
2) 50 to 70 S No between L05-13 and L29-10 replace
WA450-3MC 20-407 Î
TROUBLESHOOTING M-4
20-408 Î WA450-3MC
TROUBLESHOOTING M-5
M-5 High beam does not light up

i Before beginning troubleshooting, check that the lamp bulb is not blown.
Cause Remedy
Yes
Yes Is there continuity between L06-13 and

chassis ground
1) Start switch OFF. Defective contact or disconnection in har- Repair or
1 2) Disconnect L06. No ness between L06-13 and L02- 3 replace
3) Dimmer switch: Hi beam
Is voltage between L06-12 and
chassis ground normal
1) 20 to 30 V Defective contact or disconnection in har- Repair or
2) Start switch ON No ness between L06-12 and FS2- 2 replace
WA450-3MC 20-409 Î
TROUBLESHOOTING M-6
M-6 Turn signal display does not light up

i Before beginning troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not blown.
Cause Remedy
(a) LH Turn signal does not light up
Yes

normal
1) Repeat 0 V and 20 to 30 V Defective contact or disconnection in har- Repair or
2) Start switch ON No ness between L06-14 and L03-4 replace
(b) RH Turn signal does not light up

Yes

normal
1) Repeat 0 V and 20 to 30 V Defective contact or disconnection in har- Repair or
2) Start switch ON No ness between L06-15 and L03-3 replace
20-410 Î WA450-3MC
TROUBLESHOOTING M-7
M-7 Abnormality in parking display

i Before beginning troubleshooting, check that the lamp bulb illuminates.
Cause Remedy
(a) Parking lamp does not light
Yes Defective parking brake
Replace
1 indicator switch
Continuity between T08-1 and
2
1) Disconnect T08 Yes
2) Start switch ON 2 Defective main monitor Replace
3) Parking switch ON
No chassis ground normal
1) 20 to 30 V Harness between L06-11
Repair or
2) Start switch ON to TL2-3 to T08-1 short-
No replace
3) Parking switch ON ing with chassis ground
(b) Parking lamp stays lit

Yes
Yes Is voltage between L06-11 and

1) 0 to 2 V Defective contact or dis-
2) Start switch ON connection in harness be- Repair or
3) Parking switch OFF No tween L06-11 to TL2-3 to replace
2 T08-1
Yes Is there continuity between
T08-2 and chassis ground
1) Disconnect T08 Defective contact or dis-
connection in harness be- Repair or
No tween T08-2 to TL1-8 to replace
1 chassis ground
T08-1 and 2
1) Disconnect T08
Defective parking brake
2) Start switch ON Replace
No indicator switch
3) Parking switch OFF
WA450-3MC 20-411 Î
TROUBLESHOOTING M-8
M-8 Abnormality in preheating system

i Check that the water temperature is below 5EC.
(a) Does not carry out preheating Cause Remedy
(1) Monitor display also does not light up

Yes
2 Defective monitor panel Replace
Yes Is resistance between L05-7

and chassis ground normal
1) Disconnect L05 Harness between L05-7
Repair or
2) Start switch OFF to LR4-2 to ER1-8 to E05
No replace
1 3) Min 4 kS shorting with ground
Is resistance between E05 and
1) Disconnect E05
Defective engine coolant
2) Start switch OFF Replace
No temperature sensor
3) Min 4 kS
(2) Only monitor display lights up

Yes
2 Defective glow plug Replace
Yes Is voltage between E07 and

1) 20 to 30 V Yes
2) Start switch ON 3 Defective heater relay Replace
Is voltage between E08 and

2) Start switch ON connection in harness Repair or
No between E08 and slow replace
1 blow fuse
Is voltage between E09-1 and
2 normal
2) Start switch ON connection in harness
Repair or
be-tween L56-3 to LR4-7
No replace
to ER1-4 to E0901 or
E09-2 to ER2-5 to ground
(b) Always carries out preheating for 1 minute

i Check that the coolant temp is below 10EC Yes
Defective main monitor Replace
2
1) Max 8 kS Defective contact or dis-
2) Start switch OFF connection in harness Repair or
3) Disconnect L05 No between L05-7 to LR4-2 replace
1 to ER1-8 to E05
1) Max 8 kS
Defective coolant temper-
No ature sensor
3) Disconnect E05
20-412 Î WA450-3MC
TROUBLESHOOTING M-8
(c) Preheating stays on Cause Remedy
Yes
Does preheating stop

1) Start switch ON Yes Defective preheating re-
2) Disconnect L06 Replace
3 lay
Repair or
2) Start switch ON and L56-2 shorting with
No replace
2 chassis ground
No Does preheating stop
1) Start switch ON Contact of power source

Repair or
2) Remove preheating relay with harness between
No replace
L56-3 to LR4-7 to L05-19
(d) Preheating time becomes shorter or there is fluctuation

Yes

1) Max 0.1 V Defective contact of har-
2) Start switch ON ness between L05-3 to Repair or
No LR5-3 to R11 to chassis replace
2 ground
1) Are temp and resistance Defective contact of har-
values as shown in Table ness between L05-7 to Repair or
1 No LR4-2 to ER1-8 to E05 or replace
1 2) Start switch OFF leak from chassis ground
1) Are temp and resistance
values as shown in Table Defective coolant temper-
Replace
1 ature sensor
2) Start switch OFF No
Table 1 [Tolerance ± 0.5 kS]

Temperature [EC] - 10 -8 -6 -4 -2 0 2 4
Resistance value [kS] 7.7 7.1 6.5 6.0 5.5 5.1 4.7 4.3
WA450-3MC 20-413 Î
TROUBLESHOOTING M-9
M-9 Tail lights do not illuminate

i Before beginning troubleshooting, check that the lamp bulb illuminates.
Cause Remedy
Yes

1) 20 to 30 V
Defective contact or disconnection in har-
2) Start switch to START Repair or replace
No ness between L05-16 and FS2-5
3) Side lamp switch ON
20-414 Î WA450-3MC
TROUBLESHOOTING M-10
M-10 Abnormality in front working lamp

i Before beginning troubleshooting, check that the monitor lighting is illuminated.
(a) Neither monitor display nor front working lamp lights up Cause Remedy
Defective contact or
Yes disconnection in har- Repair or
ness between L60-1 replace
1 to L05-17, CL1-7
Is voltage between
L60-1 and chassis
ground normal
1) 20 to 30 V Yes Defective front work-
3 ing lamp relay
Yes Is voltage between

L60-6 and chassis
ground normal
1) 0 to 3 V Defective contact or
2) Start switch ON Yes disconnection in har- Repair or
ness between L06- 1 replace
4 to L60-6
Is voltage between
L06-1 and chassis
No ground normal
1) 20 to 30 V Defective main moni-
2 No tor
Is voltage between
L60-2, 5 and chassis
No ground normal
2) Start switch ON disconnection in har- Repair or
No ness between L60- 2, replace
5 to FS5-1
(b) Working lamp lights up but monitor display does not light up
Yes Defective main moni-
Replace
1 tor
Is voltage between
L05-17 and chassis
ground normal
No ness between L05- 17 replace
to L60-1
(c) Monitor lights up but working lamp does not light up

disconnection in har-
Repair or
ness between L60- 1
replace
to CL1-7 to front lamp
or blown bulb
WA450-3MC 20-415 Î
TROUBLESHOOTING M-10, M-11
M-10, M-11 CIRCUIT DIAGRAM
20-416 Î WA450-3MC
M-11 Abnormality in rear working lamp

i Before beginning troubleshooting, check that the monitor lighting is illuminated.
(a) Neither monitor display nor rear working lamp lights up Cause Remedy
Yes disconnection in har- Repair or
ness between L61-1 replace
1 to L05-18, LR1-12
Is voltage between
L61-1 and chassis
ground normal
1) 20 to 30 V Yes Defective rear working
3 lamp relay

L61-6 and chassis
ground normal
2) Start switch ON Yes disconnection in har- Repair or
ness between L06- 2 replace
4 to L61-6
Is voltage between
L06-2 and chassis
No ground normal
1) 20 to 30 V Defective main moni-
2 No tor
Is voltage between
No ground normal
No ness between L61- 2, replace
5 to FS5-2
(b) Working lamp lights up but monitor display does not light up
Yes Defective main moni-
Replace
1 tor
Is voltage between
L05-18 and chassis
ground normal
No ness between L05- 18 replace
to L61-1
(c) Monitor lights up but working lamp does not light up

disconnection in har-
Repair or
ness between L61- 1
replace
to LR1-12 to rear
lamp or blown bulb
WA450-3MC 20-417 Î
M-12 Abnormality in transmission cut off

(a) When monitor switch is pressed, trans cut off function is not actuated Cause Remedy
and display goes out
(b) Monitor display goes out but trans cut off function is actuated when left
brake pedal is depressed
Yes Defective contact or dis-
Repair or
connection in harness be-
replace
1 tween L06-3 and L30-16
1) 0 to 3 V
2) Start switch ON Defective main monitor Replace
3) Disconnect L12 No
(c) Monitor display goes out but trans cut off function is always actuated
Repair or
replace
L12-2 and chassis ground
1) Disconnect L12 Defective contact or dis-
No tween L12-2 and chassis replace
1 ground
L12-1 and 2
1) Disconnect L12 Defective cut off switch Replace
No
(d) Cut off function is always actuated regardless of monitor display
Yes
1 Defective trans controller Replace
No tween L60-16 to L06-3, replace
L12-1
(e) Monitor display lights up but cut off function is not actuated
Yes
1 Defective cut off switch Replace
Does cut off function work
1) Disconnect L12 Yes
No Does cut off function work

2) Start switch ON 3 Defective trans controller Replace
Is voltage between L30-16
No and chassis ground normal
1) Disconnect L12 and L06 Short with ground in har-
Repair or
2) Start switch ON ness between L06-3 to
No replace
3) 0 to 3 V L30-16 to L12-1
20-418 Î WA450-3MC
M-13 Abnormality in parking brake dragging warning

(a) When parking brake is applied, buzzer sounds intermittently even when Cause Remedy
directional lever is at N and caution lamp flashes
Yes

Repair or
2) Start switch ON connection in harness be-
No replace
tween L05-8 and L04-3
(b) When parking brake is applied, buzzer does not sound and caution lamp
does not illuminate even when directional lever is at any position but N
Yes

1) 0 to 5 V Yes Contact of power source
Repair or
2) Start switch ON with harness between L05-
replace
2 8 and L04-3
Is resistance between L05-8
No and 3 normal
1) 3 to 4 kS
2) Start switch OFF Defective main monitor Replace
WA450-3MC 20-419 Î
M-14 When parking brake drag warning is given, buzzer and caution lamp are
actuated continuously or they are not actuated
(a) Actuated continuously Cause Remedy
Yes Defective maintenance

Replace
2 monitor
Yes Does buzzer stop and lamp go
out
1) Start switch ON Defective contact or dis-
Repair or
2) Connect L19-5 to ground connection in harness be-
No replace
1 tween L07-6 and L19- 5
Does buzzer stop and lamp go
out
1) Start switch ON
2) Connect L07-6 to ground No
(b) Not actuated

Replace
2 monitor
Yes Does buzzer stop and lamp
work
1) Start switch ON Defective contact or dis-
Repair or
2) Disconnect L19 connection in harness be-
No replace
1 tween L07-6 and L19- 5
Does buzzer stop and lamp
work
1) Start switch ON Defective main monitor Replace
20-420 Î WA450-3MC
M-15 Abnormality in buzzer

(a) Buzzer does not sound for 3 seconds when start switch is turned ON Cause Remedy

Repair or
replace
1 tween L06-8 and L43
Does buzzer stop
1) Start switch ON Yes
2) Contact L43 to ground 2 Defective buzzer Replace
Is voltage between L42 and

Repair or
No replace
tween L42 and FS2-9
(b) Buzzer always sounds

Yes
Does buzzer stop

1) Start switch ON. Yes Go to troubleshooting for
2) Disconnect L06 ---
2 maintenance monitor
No Does buzzer stop
1) Start switch ON. Yes Harness between L06-8

Repair or
2) Disconnect L19 and L43 short circuiting
replace
3 with chassis ground
No Does buzzer stop
1) Start switch ON. Defective buzzer Replace

WA450-3MC 20-421 Î
M-16 Condition of monitor switches is not stored in memory

Cause Remedy
Yes

Repair or
No replace
tween L07-10 and L09-2
20-422 Î WA450-3MC
M-17 Abnormality in failure display mode

Cause Remedy
(a) Failure display mode does not work
Yes

1) 0 to 5 V Contact of power source
2) Start switch ON with harness between L05-
Repair or
5 to LR4-6 to ER1-9 to al-
No replace
ternator terminal R or de-
fective alternator
(b) Time for time elapsed since failure does not advance
Yes

1) 20 to 30 V Contact of power source
2) Start engine with harness between L05-
Repair or
5 to LR4-6 to ER1-9 to al-
No replace
ternator terminal R or de-
fective alternator
WA450-3MC 20-423 Î
M-18 Abnormality in ground driven steering normal display

Cause Remedy
(a) Ground driven steering normal display does not light up
Yes Fault ground driven steer-
Replace
1 ing normal sensor
T10-1 and 2

Repair or
2) Start switch ON to TL1-2 to T10-1 shorting
No replace
with ground
(b) Ground driven steering normal display stays illuminated

Yes

2) Start switch ON connection in harness be- Repair or
No tween L05-10 to TL1-2 to replace
2 T10-1
1 chassis ground
T10-1 and 2
1) Disconnect T10 Fault ground driven steer-
No ing normal sensor
20-424 Î WA450-3MC
M-19 Abnormality in ground driven steering actuation display

Cause Remedy
(a) Ground driven steering actuation display does not light up
Yes Fault ground driven steer-
Replace
1 ing function sensor
T11-1 and 2

Repair or
No replace
with ground
(b) Ground driven steering actuation display stays illuminated

Yes

Repair or
No replace
2 with ground
1 chassis ground
T11-1 and 2
1) Disconnect T11 Fault ground driven steer-
No ing actuation sensor
WA450-3MC 20-425 Î
M-20 Abnormality in ECSS system

Cause Remedy
(a) Display does not change when switch is pressed
Defective maim monitor Replace
(b) Monitor display lights up but ECSS function does not work
Yes
2
Defective ECSS controller ®
Yes Is voltage between DP2-1 and
Repair or
No replace
1 tween L06-7 and DP2-1
1) 0 to 3 V Defective maim monitor Replace
2) Start switch ON No
® Go to Troubleshooting for ECSS controller.
20-426 Î WA450-3MC
TROUBLESHOOTING OF
MAINTENANCE MONITOR SYSTEM
K MODE
K-1 When start switch is turned ON, all lamps on maintenance monitor do not light up for 3 seconds
maintenance monitor does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502
K-2 When start switch is turned ON, all lamps on maintenance monitor illuminate, but do not go out . . . . . . 20-502
K-3 When engine is started immediately after start switch is turned ON, all lamps on maintenance
monitor do not go out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-503
K-4 When start switch is turned ON (engine stopped), CHECK items flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-504
K-5 When start switch is turned ON, engine started, CAUTION items flash . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-505
K-6 CAUTION items are flashing, but alarm buzzer does not sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-509
K-7 There is no abnormality in monitor display, but alarm buzzer sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
K-8 CHECK or CAUTION items are flashing, but CHECK or CAUTION lamp does not light up . . . . . . . . . . . 20-511
K-9 There is no abnormality in maintenance monitor display, but CHECK or CAUTION lamp lights up . . . . . 20-512
K-10 Night lighting does not light up when lamp switch is turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-513
K-11 Night lighting lights up even when lamp switch is OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
K-12 Service meter does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-515
K-13 Service meter is running even when engine is stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-515
K-14 Abnormality in gauge items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-516
WA450-3MC 20-501 Î
TROUBLESHOOTING K-1, K-2
K-1 When start switch is turned ON, all lamps on maintenance monitor do not
light up for 3 seconds, maintenance monitor does not work
Cause Remedy
(a) All lamps on maintenance monitor do not light up for 3 seconds
Replace
1 monitor module
Is voltage between L18-1, 2 to
3 normal
1) 20 to 30 V Defective contact, or dis-
2) Start switch ON Yes connection in harness be- Repair or
replace har-
tween L18-1, 2 to FS2-9 to ness or re-
fuse box to FS1-2 or failed place fuse
3 fuse
Yes Is voltage between FS1-2 and
2) Disconnect FS1 connection in harness be- Repair or
replace har-
3) Start switch ON tween FS1-2 to LR6-1 to ness or re-
No slow blow fuse to battery place fuse
2 relay, or failed fuse
1) Start switch OFF Defective contact, or dis-
2) Disconnect L18 connection in harness be- Repair or
No tween L18-3 to LR4-12 to replace
chassis ground
(b) Some lamps do not illuminate

Defective maintenance
Replace
monitor module
K-2 When start switch is turned ON, all lamps on maintenance monitor
illuminate, but do not go out
Cause Remedy
Defective maintenance
Replace
monitor module
20-502 Î WA450-3MC
TROUBLESHOOTING K-3
K-3 When engine is started immediately after start switch is turned ON, all
lamps on maintenance monitor do not go out
Cause Remedy

Replace
1 monitor module
When starting engine, is volt-
age between L19-1 and chas-
sis ground normal
3) Crank engine and measure No tween L19-1 and neutral replace
while motor is turning relay
WA450-3MC 20-503 Î
TROUBLESHOOTING K-4
K-4 When start switch is turned ON (engine stopped), CHECK items flash
(a) Engine oil level display flashes Cause Remedy

i Before starting troubleshooting, check the engine oil level again.
Replace
2 monitor module
2) Disconnect NE18 connection in harness be- Repair or
No tween NL18-13 to LR4-4 to replace
1 ER1-3 to E10-1
NE10-1 and chassis ground
1) Start switch OFF Defective engine oil level
2) Disconnect NE10 Replace
No sensor
(b) Engine coolant level display flashes Cause Remedy

i Before starting troubleshooting, check the engine coolant level again.
Replace
3 monitor module
2 R06-1
R06-1 and chassis ground
2) Disconnect R06 connection in harness be- Repair or
No tween R06-2 and chassis replace
1 ground
R06-2 and 1
1) Start switch OFF Defective radiator coolant
2) Disconnect R06 Replace
No level sensor
20-504 Î WA450-3MC
TROUBLESHOOTING K-5
K-5 When start switch is turned ON, engine started, CAUTION items flash
Cause Remedy
(a) Engine oil pressure display flashes
Yes Defective engine oil pres-
Replace
1 sure sensor
Does display go out when ring
terminal is removed
1) Start engine Yes Defective maintenance
Replace
3 monitor module
1) Disconnect L18 Defective contact, or dis- Repair or
2) Start switch OFF connection in harness be- replace har-
tween L18-10 to engine oil ness or
No pressure relay to chassis Replace
2 ground, or defective relay relay
Is voltage between ring termi-
No nal and chassis ground normal
1) 20 to 30 V Contact of ground with har- Repair or

2) Remove ring terminal. ness between ring terminal replace har-
3) Start engine to ER1-2 to LR4-3 to en- ness or
No gine oil pressure relay, or Replace
defective relay relay
WA450-3MC 20-505 Î
TROUBLESHOOTING K-5
Cause Remedy
(b) Battery charge level display flashes
Replace
2 monitor module
1) 20 to 30 V Disconnection in harness
2) Start engine between L18-12 to LR4-6 Repair or
No to ER1-9 to alternator ter- replace
1 minal R
Is voltage between alternator
terminal R and chassis
ground normal
1) 20 to 30 V Defective alternator Replace
2) Start engine No
20-506 Î WA450-3MC
TROUBLESHOOTING K-5
Cause Remedy
(c) Brake oil pressure display flashes

4 Replace
monitor module
L18-11 and chassis
ground normal
1) Start engine Defective contact or dis- Repair or
2) 0 - 3V connection in harness replace
between L18-11 to LR2- harness
No 8 to BR1-6 to B08-1 or or replace
3 defective diode diode
Yes Is there continuity
between B13-2 and
chassis ground
1) Start switch Defective contact or dis-
OFF connection in harness
Repair or
2) Disconnect B13 between B08-2 and B13-
No replace
1 or between B13-2 to
2 BR1-4 to chassis ground
Yes Is there continuity
between B08-1 and 2
1) Start engine Defective brake accumu-
2) Disconnect B08 lator charge oil pressure Replace
1 No switch - B08 end
Is there continuity
between B13-1 and 2
1) Start engine Defective brake accumu-
2) Disconnect B13 lator charge oil pressure Replace
No switch - B13 end
WA450-3MC 20-507 Î
TROUBLESHOOTING K-5
Cause Remedy
(d) Air cleaner display flashes
Yes Defective dust indicator
Replace
1 sensor
Does display go out
1) Start engine Yes Defective maintenance

2) Disconnect E19 Replace
3 monitor module
tween L18-15 and L80-3 or replace har-
No between L80-6 to LR5-2 to ness or re-
chassis ground, or defec- place relay
2 tive dust indicator relay
1) Start switch ON Short circuit, or contact of
2) Disconnect E19 harness between E19-1 to Repair or
3) 20 to 30 V ER1-5 to LR4-5 to L80-2 replace har-
No with chassis ground or ness or re-
defective dust indicator place relay
relay
20-508 Î WA450-3MC
TROUBLESHOOTING K-6
K-6 CAUTION items are flashing, but alarm buzzer does not sound
i The buzzer does not sound for CHARGE or ENGINE OIL LEVEL.
Cause Remedy

Replace
2 monitor module
Yes Does buzzer sound when L19-4

is connected to chassis
ground
1) Start switch ON Yes Defective contact or dis-
connection in harness be- Replace
Does buzzer sound when L43-1
is connected to chassis g-
No round
1) Start switch ON Defective buzzer Replace
1 No
2) Disconnect L42 disconnection in harness Repair or
3) Start switch ON No between L42-1 to FS2-9 to replace
+24 V
WA450-3MC 20-509 Î
TROUBLESHOOTING K-7
K-7 There is no abnormality in monitor display, but alarm buzzer sounds

i Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
Cause Remedy
Yes Defective buzzer Replace

1
1) Start switch OFF Yes Contact of chassis ground
Repair or
2) Disconnect L43 with harness between L19-
replace
2 4 and L43-1
1) Start switch OFF Defective maintenance
No monitor module
20-510 Î WA450-3MC
TROUBLESHOOTING K-8
K-8 CHECK or CAUTION items are flashing, but CHECK or CAUTION lamp
does not light up
i Before carrying out troubleshooting, check that there are no failed lamp bulbs.
Cause Remedy
(a) CHECK lamp
Replace
1 monitor module
Does check lamp illuminate
when L19-2 is connected to
chassis ground
1) Disconnect L19 Yes Defective contact, or dis-
Repair or
replace
Does check lamp illuminate
No chassis ground
1) Disconnect L06
(b) CAUTION lamp

Replace
1 monitor module
Does caution lamp illuminate
chassis ground
1) Disconnect L19 Yes Defective contact, or dis-
Repair or
replace
Does caution lamp illuminate
No chassis ground
1) Disconnect L06
WA450-3MC 20-511 Î
TROUBLESHOOTING K-9
K-9 There is no abnormality in maintenance monitor display, but CHECK or

CAUTION lamp lights up
i Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
Cause Remedy
(a) CHECK lamp
Yes Contact of chassis ground
Repair or
with harness between L19-
replace
1 2 and L06-10
Is there continuity between L19-2
and chassis ground
No monitor module
(b) CAUTION lamp

Yes Contact of chassis ground
Repair or
with harness between L19-
replace
1 3 and L06-9
and chassis ground
No monitor module
20-512 Î WA450-3MC
TROUBLESHOOTING K-10
K-10 Night lighting does not light up when lamp switch is turned ON
i Before carrying out troubleshooting, check that there are no failed lamp bulbs.
Cause Remedy
Yes Disconnection in harness

Replace
1 of lamp holder
Is voltage between L21-1 and 2 nor-
mal?
1) 20 to 30 V
Defective contact, or dis-
2) Disconnect L21 Repair or
3) Start switch ON No replace
tween L21-1 and FS2-5
4) Lamp switch ON
WA450-3MC 20-513 Î
K-11 Night lighting lights up even when lamp switch is OFF

Cause Remedy
Yes Contact of +24 V with har-

Repair or
ness between FS2-4 to
replace
2 fuse box to FS2-5 to L21-1
Yes Is voltage between FS2-4 and
1) 0V Contact of +24 V with har-
Repair or
2) Disconnect FS2 ness between L02-5 and
No replace
1 3) Lamp switch OFF FS2-4
4) Start switch ON
Is lamp switch normal
1) Start switch OFF
2) Disconnect L02
3) Check that continuity be-
tween L02-1 and 5 is as Defective lamp switch Replace
shown in table below when No
lamp switch is turned ON
OFF
Switch Continuity
ON Continuity
OFF NO continuity
20-514 Î WA450-3MC
TROUBLESHOOTING K-12, K-13
K-12 Service meter does not work

Cause Remedy
Yes
1 Defective service meter Replace

1 normal
2) Start engine Yes connection in harness be-
Repair or
3) Disconnect L22 tween L22-2 to LR4-6 to
replace
ER1-9 to alternator termi-
3 nal R
2 chassis ground
Is voltage between alternator
terminal R and chassis
No ground normal
1) 20 to 30 V
Defective alternator Replace
2) Start engine No
K-12, K13 Related electric circuit diagram
K-13 Service meter is running even when engine is stopped

Cause Remedy
Yes
1 Defective service meter Replace

1 normal
1) 0 to 4 V R e p l a c e
Faulty alternator, or contact of harness
2) Start switch ON alternator or
between L22-2 to LR4-6 to ER1-9 to
3) Disconnect L22 No Repair or
alternator terminal R with + 24 V
replace harness
WA450-3MC 20-515 Î
K-14 Abnormality in gauge items

Abnormality in fuel gauge

i Before carrying out troubleshooting, check the fuel level again.
Cause Remedy
(1) Little or nothing is displayed in the display area.
Yes
1 Defective fuel sensor Replace
Does fuel gauge show FULL

1) Disconnect R07 Yes Defective maintenance
2) Connect short connector to Replace
3 monitor module
R07
3) Start switch ON Yes Is there continuity between
1) Start switch OFF. Defective contact, or dis-
2) Connect short connector connection in harness be- Repair or
to R07 No tween R07-1 to LR4-10 to replace
2 3) Disconnect L18 L18-6
No R07-2 and chassis ground
2) Disconnect R07 connection in harness be- Repair or
No tween R07-2 and chassis replace
ground
(2) Display always shows FULL and does not move

Yes
1 Defective fuel sensor Replace
Do all display areas on fuel

gauge go out
1) Disconnect R07 Yes Contact of chassis ground
Repair or
2) Start switch ON with harness between
replace
2 R07-1 to LR4-10 to L18 -6
No R07-1 and chassis ground
2) Disconnect R07 Replace
No monitor module
20-516 Î WA450-3MC
Abnormality in engine coolant temperature gauge
Cause Remedy
(1) Nothing is displayed in the display area
Yes Defective engine coolant
Replace
1 temperature sensor
Does engine coolant tempera-
ture gauge display minimum
level
1) Disconnect E06 Contact of chassis ground
2) Start switch ON Yes with harness between E06- Repair or
1 to ER1-6 to LR4-1 to replace
2 L18-4
No E06-1 and chassis ground
2) Disconnect E06 Replace
No monitor module
(2) Display shows lowest level and does not move

Yes Defective engine coolant
Replace
1 temperature sensor
Do all display areas on engine
coolant temperature gauge go
out
1) Disconnect E06 Yes Defective maintenance
3 monitor module
E06
1) Start switch OFF. Defective contact, or dis-
2) Connect short connector connection in harness be- Repair or
to E06 No tween E06-1 to ER1-6 to replace
2 3) Disconnect L18 LR4-1 to L18-4
No E06-2 and chassis ground
2) Disconnect E06 connection in harness be- Repair or
No tween E06-2 to ER1-7 to replace
chassis ground
WA450-3MC 20-517 Î
Abnormality in torque converter oil temperature gauge
Cause Remedy
(1) Nothing is displayed in the display area
Yes Defective torque converter
Replace
1 oil temperature sensor
Does torque converter oil tem-
perature gauge display mini-
mum level
1) Disconnect T0& Yes Contact of chassis ground
Repair or
2) Start switch ON with harness between E07-1
replace
2 to TL2-4 to L18-5
No T07-1 and chassis ground
1) Start switch OFF Defective maintenance mon-
2) Disconnect T07 Replace
No itor module
(2) Display shows lowest level and does not move

Yes Defective torque converter
Replace
1 oil temperature sensor
Do all display areas on gauge
go out
1) Disconnect T07 Yes Defective maintenance mon-
3 itor module
T07
1) Start switch OFF. Defective contact or discon-
Repair or
2) Connect short connector nection in harness between
No replace
2 to T07 T07-1 to TL2-4 to L18-4
3) Disconnect L18
No T07-2 and chassis ground
1) Start switch OFF Defective contact or discon-
2) Disconnect T07 nection in harness between Repair or
No T07-2 to TL2-5 to LR4-12 to replace
chassis ground
20-518 Î WA450-3MC
TROUBLESHOOTING OF
ELECTRICAL SYSTEM
E MODE
E-1 Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-603 Î
E-2 Engine does not stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-606 Î
E-3 Engine stops when machine is traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-607 Î
E-4 Parking brake does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608 Î
E-5 Parking brake is applied when machine is traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609 Î
E-6 Parking brake is released when starting switch is turned ON . . . . . . . . . . . . . . . . . . . . 20-610 Î
E-7 Transmission does not change to neutral when parking brake is applied . . . . . . . . . . 20-610 Î
WA450-3MC 20-601 Î
TROUBLESHOOTING
MEMORANDA
20-602 Î WA450-3MC
TROUBLESHOOTING E-1
E-1 Engine does not start

i When connecting or disconnecting the T adapter [or socket adapter] or short connector to carry out checks, always
turn the start switch OFF before starting.
i When connecting the T adapter [or socket adapter], connect to the specified connector.
i After checking, connect the disconnected connectors and disconnect the T adapter immediately to return to the
original condition before going on to the next check.
(a) Starting motor does not turn Cause Remedy
Yes
3 Defective starting motor Replace
Yes Is voltage between starting motor

terminal B and chassis 20 to 30
V
1) Start switch on Yes Defective contact or disconnec-
tion in cable between battery Repair or replace
5 relay and starting motor
Yes Is voltage between both battery
relay terminals and chassis 20 to
30 V
1) Start switch ON C NO for both terminals: Defec-
2) Check voltage between chas- tive contact or disconnection
sis and both terminals con- in harness between battery
Repair or replace
nected by thick cable No and relay
C NO for one terminal: Defec-
4 tive battery relay
Is actuating sound heard
No from battery relay
1) Start switch ON ø OFF Yes
2 6 Defective battery relay Replace
Yes
Is voltage 20 to 30 V between
Is there continuity between start-
No both connection terminals of R12
ing motor terminal E and chassis
B from next page º and R13 of battery relay
1) Start switch on 1) Start switch ON Defective contact or disconnec-

tion in harness between start
Yes switch terminal BR to L09-2 to
LR4-9 to R03 [diode] to R12 or Repair or replace
defective contact, or disconnec-
tion in harness between R13 and
chassis ground
Is voltage between start
switch terminal BR and
No chassis 20 to 30 V
1) Start switch ON Defective start switch Replace
No
Defective contact or disconnec-

tion in starting motor ground Repair or replace
1 No cable
chassis 20 to 30 V
1) Disconnect E13
2) Directional lever - N
No
ö Go to A on next page
3) Start switch to START
WA450-3MC 20-603 Î
TROUBLESHOOTING E-1
E-1
Cause Remedy
Yes
Defective neutral relay Replace

Yes tion in harness between L57-3 to
Repair or replace
LR4-8 to R01/02 [diode] to ER1-
3 10 to E13-1
chassis 20 to 30 V
1) Disconnect L57 Defective contact or disconnec-
2) Start switch START Yes tion in harness between start
Repair or replace
switch terminal C to L09-3 to
5 L57-5
Yes Is voltage between start switch
terminal C and chassis 20 to 30
V
1) Start switch START Defective start switch Replace
1 4 No
Is voltage between start switch
Does starting motor turn when
A ö from 20-603 re-lay is replaced
terminal B and chassis 20 to 30
No V
1) Repalce neutral relay [L57] 1) Start switch OFF Defective contact or disconnec-
with stop lamp relay [L53] tion in harness between start
2) Directional lever N switch terminal B to L09-1 to
Repair or replace
3) Start switch START No FS3-4 to fuse to FS3-6 to LR5-1
to R17 to slow blow fuse 30A to
2 battery relay
Is voltage between L57-1 and 2
No 20 to 30 V
1) Disconnect L57. Yes Defective contact or disconnec-
2) Directional lever N tion in harness between L04-3 to Repair or replace
3) Start switch START 8 L57-1
chassis 20 to 30 V
1) Connect T-adapter to L04 Defective directional lever switch Replace
7 No
2) Directional lever N
Yes Is voltage between L04-1 and 3) Start switch ON
chassis 20 to 30 V
2) Start switch ON Yes tion in harness between battery
relay to slow blow fuse 80A to Repair or replace
R15 to LR6-1 to FS1-2 to fuse to
6 10 FS2-8 to L04-1
Yes Is voltage between both battery

relay terminals and chassis 20 to
No and chassis
30 V
1) Start switch OFF 1) Start switch ON C NO for both terminals: Defec-
2) Disconnect L57 2) Check voltage between chas- tive contact or disconnection
sis and both terminals con- in harness between battery
Repair or replace
nected by thick cable No and battery relay
C NO for one terminal: Defec-
9 tive battery relay
Is actuating sound heard from

No battery relay
1) Start switch ON ø OFF No

ö B go to page 20-603
tion in harness between L57-2 Repair or replace
No and chassis ground
20-604 Î WA450-3MC
TROUBLESHOOTING E-1
(b) Starting motor turns
Cause Remedy
Yes Defective adjustment of wire

between engine stop motor and Adjust
1 lever
Does engine stop motor
work
1) Start switch ON ø OFF Defective engine stop motor or
and check visually Yes defective contact or disconnec-
Repair or replace
tion in harness between E03-8 to
3 ER2-5 to chassis ground
Yes Is voltage between E03-7 and
chassis 20 to 30 V
1) Connect T adapter to E03 Yes
2) Start switch ON 4 Defective engine stop relay Replace
Does engine stop motor work

No when relay is replaced
1) Replace engine stop relay L62 Yes
with stop lamp relay L53 7 Defective engine stop motor Replace
2) Start switch ON ø OFF and
Yes Is there continuity between E03-
check visually
5 and 7
1) Disconnect E03 Defective contact or disconnec-
2) Start switch ON tion in harness between E03-5 to
ER2-3 to LR3-5 to L62-5 or be- Repair or replace
No tween E03-7 to ER2-4 to LR3-6
6 to L62-3
Yes Is there continuity between L62-
2 and chassis
1) Start switch OFF Defective contact or disconnec-
2) Disconnect L62 tion in harness between L62-2 Repair or replace
5 No and chassis ground
No chassis 20 to 30 V
2) Start switch ON tion in harness between L62-1 Repair or replace
2 No and L09-2
Is voltage between E03-4
No and chassis 20 to 30 V
1) Start switch OFF Failed fuse or defective contact
2) Disconnect E03 or disconnection in harness be-
Repair or replace
No tween F2-11 to LR-3 to ER2-1 to
E03-4
WA450-3MC 20-605 Î
TROUBLESHOOTING E-2
E-2 Engine does not stop

Cause Remedy
Yes Defective adjustment be-

tween fuel shut off sole- Adjust
1 noid and injector pump
Does engine stop mo-
tor work
1) Start switch ON to Yes Defective engine stop
OFF and check Replace
2 motor
visually
Is voltage between E03-
No 7 and 8, 20 to 30 V
1) Connect T adapter Defective contact or dis-

to E03-8 connection in harness
2) Start switch OFF Yes between E03-3 to ER2-2
Repair or
to LR3-4 to L62 or be-
replace
tween L62-3 to LR3-6 to
ER2-4 to E03-7 or defec-
3 tive relay L62

No 3 and 8, 20 to 30 V
1) Connect T adapter Yes Defective engine stop

to E03 Replace
4 motor
2) Start switch OFF
No 4 and 8, 20 to 30 V
1) Connect T adapter Defective contact or dis-

to E03 connection in harness
Repair or
between E03-4 to ER2-2
No replace
to LR3-3 to FS2-11 or
blown fuse
20-606 Î WA450-3MC
TROUBLESHOOTING E-3
E-3 Engine stops when machine is traveling

i Check if the starting motor turns. If it does not turn, check E-1 (a) (Engine does not start).
Cause Remedy
Yes Defective adjustment be-

tween engine stop motor Adjust
1 and stop lever
Does engine stop motor work
1) Start switch ON ø OFF Yes Defective engine stop mo-
and check visually Replace
2 tor
Is voltage between Eo3-7 and
8 switch between 0 V to 20 to
No 30 V
1) Connect T adapter to E03 Yes Defective engine stop relay Replace
2) Start switch ON ø OFF 3
No 1 20 to 30 V
1) Disconnect L62 [engine Defective contact or dis-
stop relay] connection in harness be- Repair or
2) Start switch ON No tween start switch terminal replace
BR to L09-2 to L62-1
WA450-3MC 20-607 Î
TROUBLESHOOTING E-4
E-4 Parking brake does not work

i When carrying out troubleshooting of the brake system, stop the machine on flat ground.
Cause Remedy
(a) Parking brake has no effect when parking brake switch is turned ON
Replace
1 switch
Is problem removed when L01
is disconnected
1) Disconnect L01 Yes Contact of harness at L01- Repair or
2) Start engine [charge brake 2 2 and 3 end replace
oil pressure]
No L01-2 and 3
1) Disconnect L01 Yes Defective parking brake
3 solenoid
3) Disconnect L58
4) Disconnect L59 Is voltage between T05-1 and
No chassis . 0 V
1) Connect T adapter to T05
2) Start engine [charge brake Contact of harness at L01- Repair or
oil pressure] No 2 and 1 end replace
3) Parking brake switch ON
(b) Parking brake has no effect when brake pressure drops
Yes Faulty emergency brake

Replace
1 switch B09
Is problem removed when B09
is disconnected
1) Start switch ON Yes Faulty emergency brake
2) Parking brake switch ON Replace
2 switch B10
ø OFF
Is problem removed when B10
No is disconnected
1) Start switch ON
Defective parking brake
2) Parking brake switch ON Replace
No solenoid
ø OFF
20-608 Î WA450-3MC
TROUBLESHOOTING E-1
E-5 Parking brake is applied when machine is traveling
i When carrying out troubleshooting of the brake system, stop the machine on flat ground. Table 1
i When connecting or disconnecting the T adapter [or socket adapter] or short connector to carry out checks, always Operation Between terminal 2 to 3 Between terminal 1 to 3
turn the start switch OFF before starting. ON (parking) No continuity Continuity
i After checking, connect the disconnected connectors and disconnect the T adapter immediately to return to the OFF (travel) Continuity No continuity
Cause Remedy
Y Defective parking brake solenoid Replace

2
e
Is there continuity be- s
tween T05-2 and
Y chassis
e N
s 1) Disconnect T05 o Defective contact, or disconnec-
2) Start switch OFF tion in harness between T05-2 Repair or replace
and chassis
Defective parking brake safety

Replace
Y relay
e
s
Faulty emergency brake switch Replace
Y
e
s Defective contact, or disconnec-
tion in harness between B10-2 Repair or replace
4 11 Y and T05-1
e
Is problem removed
Voltage between B10-1 and s
when safety relay is
Y Y chassis 20 to 30 V
replaced
e e N
s 1) Replace parking s 1) Disconnect B10 o Defective contact, or disconnec-
brake safety relay 2) Start switch ON tion in harness between B09-1 Repair or replace
1 [L59] with stop 10 3) Parking brake switch and B10-1
Is voltage between T05-1 lamp relay [L53] Is voltage between B09-1 ON ø OFF
and chassis 20 to 30 V 2) Start engine and chassis 20 to 30 V
Y
[Charge brake oil N
1) Connect T adapter to e 1) Disconnect B09 Defective contact, or disconnec-
pressure] o
T05 s 2) Start switch ON tion in harness between B09-1 Repair or replace
2) Start engine [Charge 5 9 3) Parking brake switch and L01-2
brake oil pressure] N ON ø OFF
o Is problem removed Is there continuity be-
when short connector tween L59-2 and
is connected Y chassis
e N
1) Connect short s 1) Disconnect L59 o Defective contact, or
connector to B09 2) Start switch OFF disconnection in harness be- Repair or replace
and B10 8 tween L59-2 and chassis
2) Start engine Is voltage between L59-1
[Charge brake oil and chassis 20 to30 V
Y
pressure]
e 1) Disconnect L59 N Defective contact, or
s 2) Start switch ON o disconnection in harness
Repair or replace
3) Parking brake switch between L59-1 and L01-3 or
7 ON FS2-7 and L01-1
Is there continuity be-
Y tween L59-1 and 3
N
e 1) Disconnect L59 Defective contact, or
o
s 2) Start switch OFF disconnection in harness Repair or replace
3 6 between L59-1 and 3
N N
o Continuity of L01-1, 2 o Is voltage between
3 as shown in Table L59-5 and chassis 20
1 to 30 V
N
1) Disconnect L01 1) Disconnect L59 o Defective contact, or
2) Start switch OFF 2) Start switch ON disconnection in harness Repair or replace
between L59-5 to FS2-7 to fuse
N
o
Defective parking brake switch Replace
WA450-3MC 20-609 Î
TROUBLESHOOTING E-6
E-6 Parking brake is released when starting switch is turned ON

i When connecting the T adapter (or socket adapter], connect to the specified connector.
Cause Remedy

Replace
1 safety relay
Is problem removed when re-
lay is replaced
1) Replace parking safety re- Yes Defective parking brake
lay L59 with stop lamp re- Replace
2 switch
lay L53
2) Start engine [Charge brake Is problem removed when L01
oil pressure] No is disconnected
3) Start switch ON
1) Disconnect L01 Yes Contact of harness at L59- Repair or
2) Start engine [charge brake 3 5 and 3, 1 replace
oil pressure]
3) Start switch ON Is there continuity between
No L59-3 and 5
1) Disconnect L59
Contact of harness at L01- Repair or
2) Start switch OFF
No 1 and 2 replace
3) Parking brake switch OFF
E-7 Transmission does not change to neutral when parking brake is applied
Cause Remedy
Abnormal contact of har-

Yes ness between L58-5 to
Repair or
L12-1, L65-3 or between
replace
L12-2 to L65-5, L66-1,
1 L67-1 with +24 V harness
Is voltage between neutralizer
relay to L58-5 to chassis 20 to
30 V
1) Disconnect neutralizer L58
2) Start switch ON
3) Shift directional lever be- Defective neutralizer relay Replace
tween F N and R and No
check each voltage
20-610 Î WA450-3MC
TROUBLESHOOTING OF
TRANSMISSION CONTROLLER SYSTEM
A MODE
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-702
WHEN CARRYING OUT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-702
FAILURE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-702
TABLE OF FAILURE MODES AND CAUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-703
A-1 Failure code [10] Modulation valve solenoid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-704
A-2 Failure code [11] Short circuit in power supply for modulation valve solenoid system . . . . . 20-705
A-3 Failure code [12] F solenoid signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-706
A-4 Failure code [13] R solenoid signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-707
A-5 Failure code [14] Abnormality in Hi Lo solenoid signal system . . . . . . . . . . . . . . . . . . . . . . . 20-708
A-6 Failure code [16] Abnormality in speed solenoid signal system . . . . . . . . . . . . . . . . . . . . . . . 20-709
A-7 Failure code [17] Brake output signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-710
A-8 Failure code [20] Abnormality in directional lever signal system . . . . . . . . . . . . . . . . . . . . . . 20-711
A-9 Failure code [21] Abnormality in speed lever signal system . . . . . . . . . . . . . . . . . . . . . . . . . . 20-712
A-10 Failure code [22] Abnormality in travel speed signal system . . . . . . . . . . . . . . . . . . . . . . . 20-713
A-11 Failure code [23] Abnormality in engine speed signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-714
A-12 Hold switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-715
A-13 Kick down switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-716
A-14 Transmission cut off signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-717
A-15 Neutralizer relay signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-718
A-16 Buzzer signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-719
A-17 Network signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-720
A-18 Controller power source system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-721
WA450-3MC 20-701 Î
TROUBLESHOOTING
FUNCTION
The control mechanism of the transmission controller consists of
controller, sensors, switches, solenoid and buzzer. The controller
receives the input signal, processes it, and carries out the auto shift
control by controlling the solenoid to a transmission range that
matches the travel speed.
WHEN CARRYING OUT TROUBLESHOOTING

The controller has a troubleshooting function, and when a failure is
detected, the buzzer sounds to warn the operator that there has
been a failure, and the display also shows the failure code on the
main monitor. However, A-12 to A-18 are for the when there is no
display in the display area, but there is an abnormality in the control.
FAILURE CODE
No. Failure code Failure
A-1 10 Abnormality in modulation solenoid signal system
A-2 11 Abnormality in modulation solenoid signal system
A-3 12 Abnormality in F solenoid signal system
A-4 13 Abnormality in R solenoid signal system
A-5 14 Abnormality in Hi Lo solenoid signal system
A-6 16 Abnormality in speed solenoid signal system
A-7 17 Abnormality in brake signal system
A-8 20 Abnormality in directional lever signal system
A-9 21 Abnormality in speed lever signal system
A-10 22 Abnormality in travel speed sensor signal system
A-11 23 Abnormality in engine speed sensor signal system
A-12 --- Hold switch signal system
A-13 --- Kick down switch signal system
A-14 --- Transmission cut off signal system
A-15 --- Neutralizer signal system
A-16 --- Alarm buzzer signal system
A-17 --- Network signal system
A-18 --- Abnormality in controller power supply voltage
20-702 Î WA450-3MC
TROUBLESHOOTING
TABLE OF FAILURE MODES AND CAUSES
Cause of failure Related equipment
Reference items when no failure code is displayed

Engine speed sensor signal system
Travel speed sensor signal system
Modulation valve solenoid system
Speed control lever signal system
Controller power supply system

Directional lever signal system
Alarm buzzer signal system

Transmission cut off signal
Hold switch signal system
Neutralizer signal system

Kick down signal system
Model selection harness

Speed solenoid system
Network signal system

Hi Lo solenoid system
R solenoid system
F solenoid system
Failure mode
10
Failure code 12 13 14 16 11 20 21 22 23 --- --- --- --- --- --- --- --- ---
Impossible to travel ° ° ° ° ° ° ° 14 15 18
Auto shift does not work ° ° ° °
Position of directional lever and direction of travel do not match °
Machine travels forward when directional lever is not at F position °
Machine travels in reverse when directional lever is not at R position °
Transmission does not shift down in accordance with travel speed ° ° °
Transmission does not shift up in accordance with travel speed ° °
Transmission stays same range as speed lever regardless of travel speed °
There is excessive shock when shifting gears ° ° °
There is shift hunting when traveling °
There is shift hunting when shifting gears ° °
Transmission range cannot be controlled with speed lever °
Shift cannot be held ° 12
Transmission does not shift to 1st with kick down switch ° 13
No power for loading operations when kick down switch is ON
Transmission is not cut off when left brake is operated ° 14
Machine can travel when parking brake is applied ° 15
Alarm buzzer does not sound when travel direction is switched between
° 16
forward and reverse when traveling at high speed
Alarm buzzer does not stop ° 16
Main monitor does not display transmission controller information, alarm

° 17
buzzer, failure code, etc.
Model selection does not work °
WA450-3MC 20-703 Î
TROUBLESHOOTING A-1
A-1 Failure code [10] Modulation valve solenoid system

i When disconnecting connectors to connect the T adapter [or socket adapter], always turn the start switch OFF.
Cause Remedy
Yes
2 Defective controller Replace
Yes Is insulation between L29-3

and chassis normal
1) Disconnect L29 Yes Short circuit with ground in
Repair or
2) Min 1 MS harness between L29-3,
replace
3 14 to TL2-7, 8 to T12-1, 2
Is insulation between T12-1
No and chassis normal
1) Disconnect T12 Defective modulation sole-
2) Min 1 MS Replace
1 No noid valve
and 14 normal
1) Disconnect L29 Defective contact, discon-
2) 12 to 15 S Yes nection or short circuit in Repair or
harness between L29-13, replace
4 14 to TL2-7, 8 to T12-1, 2
Is resistance between T12-1
No and 2 normal
1) Disconnect T12 Defective modulation sole-
2) 12 to 15 S Replace
No noid valve
20-704 Î WA450-3MC
TROUBLESHOOTING A-2
A-2 Failure code [11] Short circuit in power supply for modulation valve
solenoid system
Cause Remedy
Yes
Yes Is voltage between T12-1 and

chassis normal
1) Disconnect T12 Short circuit of solenoid
2) Max 1 V Replace
2 No power supply
3) Start switch ON
chassis normal
1) Disconnect L29 and T12 Short circuit with power
2) Max 1 V supply in harness between Repair or
3) Start switch ON No L29-14 to TL2-8 to T12-2 replace
1 to solenoid
chassis normal
1) Disconnect L29 and T12 Short circuit with power
2) Max 1 V supply in harness between Repair or
3) Start switch ON No L29-3 to TL2-7 to T12-1 to replace
solenoid
WA450-3MC 20-705 Î
TROUBLESHOOTING A-3
A-3 Failure code [12] F solenoid signal system

Cause Remedy
Yes

and 19 normal
1) Disconnect L29 and T1R • Faulty contact or discon-
2) 46 to 58 S nection in harness be-
tween L29-21 to TL1- 3
Yes to T01-1 or short circuit
Repair or
with ground
replace
• Disconnection in har-
ness between T01-2
2 and chassis
No and 2 normal
1) Disconnect T01
Defective F solenoid Replace
2) 46 to 58 S No
20-706 Î WA450-3MC
TROUBLESHOOTING A-4
A-4 Failure code [13] R solenoid signal system

Cause Remedy
Yes

and 19 normal
1) Disconnect L29 and T1R • Faulty contact or discon-
2) 46 to 58 S nection in harness be-
tween L29-20 to TL1- 4
Yes to T02-1 or short circuit
Repair or
with ground
replace
• Disconnection in har-
ness between T02-2
2 and chassis
No and 2 normal
1) Disconnect T02
Defective R solenoid Replace
2) 46 to 58 S No
WA450-3MC 20-707 Î
TROUBLESHOOTING A-5
A-5 Failure code [14] Abnormality in Hi Lo solenoid signal system

Cause Remedy
Yes

and 19 normal
1) Disconnect L29 and L05 Harness between L29-10
2) 46 to 58 S Yes to TL1-5, L05-13 short cir-
Repair or
cuiting with chassis ground
replace
or disconnection faulty
3 contact
Yes Is resistance between TL1-5
and chassis normal
1) Disconnect TL1 • Short circuit with chas-
2) 46 to 58 S sis ground, d-
isconnection, defective
contact in harness be- Repair or
No tween TL1-5 and T03-1 replace
• Disconnection in
harness between T03-2
2 and chassis
No and 2 normal
1) Disconnect T03
Defective Hi Lo solenoid Replace
2) 46 to 58 S No
20-708 Î WA450-3MC
TROUBLESHOOTING A-6
A-6 Failure code [16] Abnormality in speed solenoid signal system

Cause Remedy
Yes

and 19 normal
1) Disconnect L29 and L05 Harness between L29-11
2) 46 to 58 S Yes to TL1-6, L05-12 short cir-
Repair or
cuiting with chassis ground
replace
or disconnection faulty
3 contact
Yes Is resistance between TL1-6
and chassis normal
1) Disconnect TL1 • Short circuit with
2) 46 to 58 S chassis ground,
disconnection, defective
contact in harness be- Repair or
No tween TL1-6 and T04-1 replace
• Disconnection in
harness between T04-2
2 and chassis
No and 2 normal
1) Disconnect T04
Defective speed solenoid Replace
2) 46 to 58 S No
WA450-3MC 20-709 Î
TROUBLESHOOTING A-7
A-7 Failure code [17] Brake output signal system

Cause Remedy
Yes Defective controller Replace

1
and chassis normal
1) Disconnect L31 Resistance value
2) 4 to 7 S • If > 1 MS; Disconnect be-
tween L31-16 and chassis Repair or
No • If < 10 S; Short circuit with replace
ground in harness between
L31-16 and resistance
20-710 Î WA450-3MC
TROUBLESHOOTING A-8
A-8 Failure code [20] Abnormality in directional lever signal system

i Check that there is no abnormality in the combination switch for the directional and speed levers.
Cause Remedy
Yes

9 normal
1) Directional lever at R; 20 • Short circuit with chas-
to 30 V sis ground, disconnec-
Other than R; 0 V tion or defective contact
2) Start switch ON in harness between
L30-2 to L04-4 to direc- Repair or
No tional and speed lever replace
switch
• Short circuit with ground
in harness between L30-
2 12 and L08-8
9 normal
1) Directional lever at F; 20 to • Short circuit with chas-
30 V sis ground, disconnec-
Other than F; 0 V tion or defective contact
2) Start switch ON in harness between L30-
Repair or
1 to L04-2 to directional
No replace
and speed lever switch
1 1 and L08-7
9 normal
1) Directional lever at N; 20 to • Short circuit with chas-
30 V sis ground, disconnec-
Other than N; 0 V tion or defective contact
2) Start switch ON in harness between L30-
11 to L04-3 to d- Repair or
No irectional and speed replace
lever switch
11 and L05-8
WA450-3MC 20-711 Î
TROUBLESHOOTING A-9
A-9 Failure code [21] Abnormality in speed lever signal system
Cause Remedy

4
Yes Is voltage between L30-
3 and 8 normal
1) Speed lever at 4th 20 Short circuit with chassis
to 30 V ground, disconnection or
Other than 4th; 0 V defective contact in har- Repair or
2) Start switch ON No ness between L30-3 to replace
L04-8 to directional and
3 speed lever switch
14 and 9 normal
1) Speed lever at 3rd Short circuit with chassis
20 to 30 V ground, disconnection or
Other than 3rd; 0 V defective contact in har- Repair or
2 and 9 normal
1) Speed lever at 2nd Short circuit with chassis
Other than 2nd; 0 V defective contact in har- Repair or
Is voltage between L30-
13 and 9 normal
1) Speed lever at 1st Short circuit with chassis
Other than 1st; 0 V defective contact in har- Repair or
speed lever switch
20-712 Î WA450-3MC
TROUBLESHOOTING A-10
A-10 Failure code [22] Abnormality in travel speed signal system

Cause Remedy
Yes

and 12 normal
2) 0.5 to 1 kS 2 Defective speed sensor Replace

No and 2 normal
2) 0.5 to 1 kS Yes connection in harness be- Repair or
tween L31-2, 12 to TL2-1, replace
3 2 to T06-1, 2
Is insulation between L31-4
No ,12 and chassis normal
1) Disconnect L31 and T06 Short circuit with ground in
Repair or
harness between L31-4,
No replace
12 to TL2-1, 2 to T06-1,2
WA450-3MC 20-713 Î
A-11 Failure code [23] Abnormality in engine speed signal

i Check that there is no error message for the engine speed signal for the engine throttle controller.
Cause Remedy
Yes
Yes Is continuity between L31-5

and 12 normal
1) Disconnect L31, E04, and Defective contact or dis-
L07 connection in harness be- Repair or
2) Short circuit E04-2, 3 No tween L31-5, 12 to E04-2, replace
1 3
Is insulation between L31-5,
12 and chassis normal
1) Disconnect L31, E04 and Short circuit with ground in
L07 harness between L31-5,12 Repair or
2) Min. 1 MS No to L07-3, 2, between L31- replace
5, 12 to E04-2, 3
20-714 Î WA450-3MC
A-12 Hold switch system

Cause Remedy
Yes
Is continuity between L30-18

and chassis normal
1) Disconnect L30 Short circuit with ground,
2) Hold switch: Yes disconnection or defective Repair or
OFF . . . . . Min. 1 MS contact in harness replace
OFF . . . . . Min. 1 MS 2 between L30-18 and L15-3
No and 4 normal
1) Disconnect L15
2) Hold switch:
ON . . . . . . . Max. 1 S Defective hold switch Replace
OFF . . . . . Min. 1 MS No
WA450-3MC 20-715 Î
A-13 Kick down switch system

Cause Remedy
Yes

and chassis normal
1) Disconnect L30 Short circuit with ground,
2) Kick down switch: Yes disconnection or defective Repair or
ON . . . . . . . Max. 1 S contact in harness replace
OFF . . . . . Min. 1 MS 2 between L30-17 and L15-1
No and 2 normal
1) Disconnect L15
2) Kick down switch:
Defective kick down switch Replace
ON . . . . . Max. 1 S No
OFF . . . Min. 1 MS
20-716 Î WA450-3MC
A-14 Transmission cut off signal system

Cause Remedy
Yes

and chassis normal
1) Disconnect L30 • Short circuit with g-
2) Trans cut off switch: round, disconnection or
ON . . . . . . . Max. 1 S defective contact in
OFF . . . . . Min. 1 MS Yes harness between L30- Repair or
16 and L12-1 replace
2 16 and L06-3
No and 2 normal
1) Disconnect L12
2) Trans cut off switch: Defective transmission cut
Replace
ON . . . . . Max. 1 S No off switch
OFF . . . Min. 1 MS
WA450-3MC 20-717 Î
A-15 Neutralizer relay signal system

i Check that the parking brake works normally.
Cause Remedy
Yes
1 Controller Replace
Is voltage between L30-

4 and 9 normal
1) Insert T adapter Yes
2) Start switch ON 4 Neutralizer relay Replace
3) Park brake switch:
ONºOFF Yes Is resistance between
L29-13 and L30-4 nor-
4) 20 to 30 V
mal
1) Disconnect L29, L30 Contact or break in har-
and L58 ness between L29-13 Repair or
2) Short circuit L58-3 No to L58-5, L58-3 to L30- replace
3 and 5 4
3) Max. 1 S
1 and chassis normal
1) Disconnect L58 Short, contact or break
Repair or
2) Start switch ON in harness between
replace
2 3) Park brake switch: No L58-1 and L01- 2
ONºOFF
Is resistance between
4) 20 to 30 V
L58-2 and chassis nor-
No mal
1) Disconnect L58. Contact or break in har-
Repair or
2) Max. 1S ness between L58-2
No replace
and chassis
20-718 Î WA450-3MC
A-16 Buzzer signal system

i Check that the main monitor and alarm buzzer work properly.
Cause Remedy
Yes
Yes Is continuity between L31-15

and chassis normal
1) Disconnect L31 and L08 Defective contact or
Repair or
2) Short circuit L08-6 to disconnection in harness
No replace
1 chassis between L31-15 and L08-6
3) Max 1 S
Is insulation between L31-15
and chassis normal
1) Disconnect L31 and L08 Short w/ground in harness Repair or
2) Min. 1 MS No between L31-15 and L08-6 replace
WA450-3MC 20-719 Î
A-17 Network signal system

Cause Remedy

4
Yes Is continuity between
mal
1) Disconnect L30 and Short w/ground in har-
Repair or
L08 ness between L30-9
replace
3 2) Short circuit L08-2, 4 No and L08-2, 4
to chassis
Yes Is insulation between 3) Max. 1 S
mal
Repair or
L08 ness between L30-9
No replace
2 2) Min. 1 MS and L08-2, 4
Yes Is continuity between
normal
1) Disconnect L29 and Disconnection or defec-
L08 tive contact in harness Repair or
2) Short circuit L08-1, 3 No between L29-1, 12 and replace
1 to chassis L08-1, 6
3) Max. 1 S
Is insulation between
normal
Repair or
L08 ness between L29-1,
replace
2) Min. 1 MS No 12 and L08-1, 3
20-720 Î WA450-3MC
A-18 Controller power source system

i Check that fuse for the transmission controller power source is not blown.
Cause Remedy

1
Is voltage between L29-8, 17,
18 to 9, 19 normal
1) Insert T adapter Short circuit with chassis
2) 20 to 30 V Yes ground, defective contact Repair or
or disconnection between replace
2 L29-8, 17, 18 and FS5-6
Is continuity between L29-9, 19
No and chassis normal
1) Disconnect L29 Defective contact or dis-
2) Max. 1 S connection in harness be- Repair or
No tween L29-9, 19 to LR5-3 replace
to chassis ground
WA450-3MC 20-721 Î
TROUBLESHOOTING OF
HYDRAULIC AND MECHANICAL SYSTEM
T MODE
T-1 Machine does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-802
T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes . . . . . . . . . . . . 20-803
T-3 Excessive shock when starting machine or shifting gears . . . . . . . . . . . . . . . . . . . . . . . 20-804
T-4 Excessive time lag when starting machine or shifting gear . . . . . . . . . . . . . . . . . . . . . . 20-805
T-5 Torque converter oil temperature is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-806
T-6 Steering does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-807
T-7 Steering wheel is heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-808
T-8 Steering wheel shakes or jerks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-809
T-9 Machine deviates to one side when traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-809
T-10 Turning radius is different between left and right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-809
T-11 Brakes do not work or braking effect is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-810
T-12 Brakes are not released or brakes drag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-811
T-13 Parking brake is not released or brake drags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-812
T-14 Boom does not rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-813
T-15 Boom movement is slow or boom lacks lifting power . . . . . . . . . . . . . . . . . . . . . . . . . . 20-814
T-16 When boom is raised, it moves slowly at a certain height . . . . . . . . . . . . . . . . . . . . . . . 20-815
T-17 Bucket cannot be pushed with boom cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-815
T-18 Excessive hydraulic drift of boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-815
T-19 Boom shakes during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-815
T-20 Boom drops momentarily when control lever is operated from HOLD to RAISE . . . . 20-815
T-21 Bucket does not tilt back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-816
T-22 Bucket movement is slow or tilt back lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-817
T-23 Bucket movement becomes slow during tilt back operation . . . . . . . . . . . . . . . . . . . . . 20-818
T-24 Bucket cannot be pushed with bucket cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-818
T-25 Excessive hydraulic drift of bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-818
T-26 Bucket shakes during loading operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-818
T-27 Bucket dumps momentarily when control lever is operated from HOLD to TILT . . . . 20-818
T-28 Boom, bucket control levers are heavy or do not move smoothly . . . . . . . . . . . . . . . . 20-819
WA450-3MC 20-801 Î
TROUBLESHOOTING T-1
T-1 Machine does not move

Ask the operator the following questions correct
! Did the problem suddenly start? ! Is the transmission filter or strainer clogged
Yes ± Internal part seized or broken ! Does the electrical circuit of the transmission control
! Was there any abnormal noise when this happened work properly
Yes ± Component broken. ! Is the transmission oil deteriorated and smells burned
! Is there any damage or leakage of oil that can be
Checks before troubleshooting seen externally
! Does the machine monitor function properly ! Is the drive shaft broken
! Is the transmission oil level correct and the type of oil ! Is the wheel brake or parking brake locked
Causes
®1 ®2 ®3 ®4 ®5
Excessive seal leakage in parking brake

Breakage inside [bearing, turbine, stator,
Defective operation [dirt caught, scuffing,
Internal breakage [abnormal spool wear]

Defective operation of clutch pressure
Excessive leakage from clutch seals

®1 Charge pump
®2 Torque converter
Defective operation of solenoid valve

®3 Transmission control valve
®4
Defective operation of relief valve

Transmission
®5 Accumulator valve
Air sucked in at suction end
Defective clutch operation

No drive [defective PTO]
Internal breakage
Internal breakage
Clogged orifice
Defective
Problem a b c d e f g h I j k l m n o
1 Does not start in any transmission range ° ° ° ° ° ° ° ° ° ° ° °
2 Does not start in certain transmission ranges ° ° ° ° ° ° °
3 Does not start when oil temperature rises ° ° ° °
4 Converter stall speed does not go to specified speed in any transmission range ° ° ° ° °
5 Converter stall speed does not go to specified speed in certain transmission ranges ° ° °
6 Converter charge pressure does not rise ° ° ° ° °
7 Trans clutch pressure does not rise in any speed range ° ° ° ° ° ° °
8 Trans clutch pressure does not rise in certain speed ranges ° ° ° °
9 Metal particles stuck to filter or strainer ° ° ° °
Replace ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Correct ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Remedy
Adjust
Clean ¯
20-802 Î WA450-3MC
TROUBLESHOOTING T-2
T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes
Checking for abnormalities correct
! Measure digging operations and speed when travel- ! Is the transmission filter or strainer clogged
ing on level ground and on slopes, and check if there ! Is there any oil leaking from the joints of the piping or
is actually an abnormality or whether it is just the feel- valves
ing of the operator. ! Is there any dragging of the wheel brake or parking
brake
Checks before troubleshooting ! Is the tire inflation pressure and tread pattern normal
! Is the transmission oil level correct and the type of oil ! Is the method of operation correct
Causes
®1 ®2 ®3 ®4 ®5 ®6 ®7
Internal breakage [abnormal wear of

Work equipment and steering pump seal
Internal oil leakage [seal ring, bushing
Internal defect [wear, scratches on spool,
Excessive leakage from parking brake

Internal breakage [bearing, turbine, sta-
Transmission clutch piston seal leakage

®1 Charging pump
Clogged torque converter cooler circuit

Transmission clutch shaft seal leakage
®4 Torque converter transmission circuit
Clogged transmission breather

Breakage inside transmission
®6 Others
Defect in engine related part

®7
Defective modulation valve

Cut off valve
Defective relief valve
Clogged orifice
Defective
Defective
Problems a b c d e f g h I j k l m n o p q r
1 Abnormality in all transmission ranges ° ° ° ° ° ° ° ° ° ° ° °
2 Abnormality in certain transmission ranges ° ° ° ° ° °
3 When oil temperature is low, abnormal noises comes from charging pump °
4 Torque converter oil over heats ° ° ° ° ° ° ° °
5 Abnormality in high and low idle speeds ° ° °
6 Abnormality in each engine stall speed ° ° ° ° °
7 Torque converter relief pressure is low ° ° ° ° °
8 Low in every transmission range ° ° ° ° ° °
Transmission
9 Low in certain transmission ranges ° ° ° ° °
clutch pressure
10 Indicator is unstable and fluctuates violently °
11 Transmission oil level changes ° ° ° °
12 Metal particles stuck to transmission strainer or torque converter filter ° ° °
13 Valve does not cut off even when pressure in equipment circuit is high °
Replace ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Correct ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Remedy
Adjust
Clean ¯ ¯
WA450-3MC 20-803 Î
TROUBLESHOOTING T-3
T-3 Excessive shock when starting machine or shifting gears

Checking for abnormalities chine of the same class and the shock is found to be
It is difficult to measure if the shock is excessive or greater.
normal, so judge that the shock is excessive in the
following cases. Checks before troubleshooting
! When it is clear that the shock has become greater ! Is the engine idle speed too high
than before. ! Is there play in any of the drive shafts
! When the machine is compared with another ma-
Causes
®1 ®2 ®3
Clogged drain around circumference of

Defective check valve of directional valve
Defective operation of clutch pressure
Defective operation of drain check valve of directional spool

Defective operation of modulation valve
®2 Transmission
Defective operation
Problems a b c d e f
1 Shock is excessive in every transmission range ° ° ° °
2 Shock is excessive in certain transmission ranges ° °
3 Clutch pressure is too high °
Replace ¯ ¯ ¯ ¯ ¯
Correct ¯ ¯ ¯ ¯ ¯ ¯
Remedy
Adjust
Clean ¯
20-804 Î WA450-3MC
TROUBLESHOOTING T-4
T-4 Excessive time lag when starting machine or shifting gear

Ask the operator the following questions Checks before troubleshooting
! Was there excessive time lag ! Is the transmission oil level correct and the type of oil
! Was there any abnormality in the travel speed or correct
thrusting force ! Is there any oil leaking from the joints of the piping or
! Was there any lack of power when traveling up valves
slopes
Yes ± Go to T-2
Causes
®1 ®2 ®3
Defective check valve of directional valve
Internal breakage [broken spring, worn

Leakage due to wear of piston, spool or
Defective operation of modulation valve
Transmission housing to valve leakage

®2 Transmission
Clutch pack piston seal leakage

Clutch shaft seal ring leakage
Clogged orifice
Problems a b c d e f g h
1 Time lag is excessive in every transmission range ° ° ° °
2 Time lag is excessive in certain transmission ranges ° ° ° °
3 Clutch pressure is low in every transmission range ° °
4 Clutch pressure is low in transmission ranges where time lag is excessive ° ° ° ° °
Replace ¯ ¯ ¯ ¯ ¯ ¯ ¯
Correct ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Remedy
Adjust
Clean ¯
WA450-3MC 20-805 Î
TROUBLESHOOTING T-5
T-5 Torque converter oil temperature is high

Ask the operator the following questions correct
! Does oil temperature rise during torque converter ! Is the transmission oil level correct and the type of oil
stall and go down when there is no load correct
Yes ± Selection of transmission range ! Is the transmission filter or strainer clogged
! Does oil temperature rise only when carrying out
scooping work Checking for abnormalities
Yes ± Improvement in method of operation ! Measure the torque converter oil temperature. Is it
actually high
Checks before troubleshooting No ± Defective oil temperature gauge
! Are the radiator coolant level and fan belt tension
Causes
®1 ®2 ®3 ®4 ®5
Equipment/steering pump shaft seal

Internal leakage [seal ring, bushing, etc.]
Defective air bleeding of converter cooler

Defective clutch pressure regulator valve
Internal breakage [bearing, turbine, sta-
®1 Charging pump
Defective torque converter relief valve

®3 Transmission
®4 Torque converter transmission circuit
®5 Others
Clogged transmission breather
Defect in engine related part

Internal breakage
Defective pump
Problems a b c d e f g h I j k
1 When oil temperature is low, abnormal noises come from charging pump °
2 Abnormality in high and low idle speeds ° ° ° °
3 Abnormality in each engine stall speeds ° ° ° ° °
4 Abnormality in travel speed, thrusting force and gradeabilty in all transmission ranges ° ° ° ° ° ° ° ° ° °
5 Abnormality in travel speed, thrusting force and gradeabilty in certain transmission ranges °
6 Torque converter relief pressure is low ° ° ° ° °
7 Low in every transmission range ° ° ° °
Transmission clutch
8 Low in certain transmission ranges °
pressure
9 Indicator is unstable and fluctuates violently °
10 Transmission oil level changes ° ° °
11 Metal particles stuck to transmission strainer or torque converter filter ° ° °
Replace ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Correct ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Remedy
Adjust
Clean ¯
20-806 Î WA450-3MC
TROUBLESHOOTING T-6
T-6 Steering does not turn

Ask the operator the following questions Checks before troubleshooting
! Did the problem suddenly happen ! Is the oil level and type of oil in the hydraulic tank
± Part broken in steering related equipment correct
! Had the steering been heavy before or had there ! Has the safety bar been removed from the frame
been any other symptoms
± Internal wear or defective seal in steering related
equipment
Causes
®1 ®2 ®3
®1 Hydraulic pump or PTO
®2 Steering valves
Defective pilot pressure load portion

®3 Others
Steering, switch, PPC pump broken

Defective steering relief valve
Oil divided at steering valve
Internal defect in stop valve

Defective demand spool
Internal defect in orbitrol

Defective spool
Problems a b c d e f g h I
1 Steering does not turn in either direction ° °
2 Same as item 1 but there is abnormality in movement of work equipment °
3 Steering does not turn in one direction [left or right] °
4 Steering wheel is heavy and does not turn ° ° ° ° °
5 There is no rise at all in steering circuit pressure ° ° ° °
6 Steering wheel turns, but steering does not turn in either direction ° ° ° °
7 Steering wheel turns, but steering turns only in one direction [left or right] ° °
Replace ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Correct ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Remedy
Adjust
Clean
i There is a close relationship between the steering circuit and the work equipment circuit, so if any abnormality is
felt in the steering, check the operating condition of the work equipment.
WA450-3MC 20-807 Î
TROUBLESHOOTING T-7
T-7 Steering wheel is heavy

Ask the operator the following questions ! Is there any oil leakage from the hydraulic hoses,
! Did the problem suddenly start valves, or cylinders
± Part broken in steering related equipment ! Is there any scuffing of the center hinge pin bearing
! Had the steering been heavy before or had there or steering cylinder pin or bushing
been any other symptoms ! Tire inflation pressure
± Internal wear or defective seal in steering related
equipment Checking for abnormalities.
! Measure the operating force of the steering wheel
Checks before troubleshooting. and the time taken to turn the steering wheel, and
! Is the oil level and type of oil in the hydraulic tank compare with Standard Value Tables to judge if there
correct is any abnormality
! Is there any abnormality in the column
®1 ®2 ®3
Defective steering cylinder, leakage past

Return filter clogged, by pass valve de-
®1 Hydraulic pump or PTO
®2 Steering valves
Defective pilot pressure load portion

®3 Others
Steering, switch, PPC pump broken
Internal defect in steering valve

Defective steering relief valve
Oil divided at steering valve
Internal defect in stop valve

Defective demand spool
Oil cooler clogged

1 Steering wheel is heavy when turned in either direction [left and right] ° ° ° ° ° °
2 Steering is heavy when turned in one direction [left and right] ° ° ° °
3 Steering is particularly heavy when engine is running at low speed ° ° °
4 Boom RAISE lacks speed with engine at full throttle ° °
5 Steering wheel is heavy and there is jerking ° °
6 Hydraulic oil over heats °
7 Pressure in steering circuit is low ° ° ° °
8 Pressure rises in steering cylinder return piping ° °
Replace ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Correct ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Remedy
Adjust ¯
Clean ¯ ¯
i There is a close relationship between the steering circuit and the work equipment circuit, so if any abnormality is
felt in the steering, check the operating condition of the work equipment.
20-808 Î WA450-3MC
TROUBLESHOOTING T-8 T-9 T-10
T-8 Steering wheel shakes or jerks

Checks before troubleshooting
! Is the oil level and type of oil in the hydraulic tank Checking for abnormalities
correct ! Drive the wheel loader in a safe place and check how
! Is there any abnormality in the column the steering wheel wobbles and under what con-
! Is there any play in the center hinge pin bearing or ditions
steering cylinder pin or bushing i If there is wobble of the steering wheel and in addition
! Is there any variation in the tire inflation pressure. the steering wheel is heavy or there are other prob-
! Is there any play in the steering lems, go to T-7.
Causes
®1 ®2
®1 Steering valves
®2 Steering cylinders
Internal defect in orbitrol relief valve

Defective steering safety valve
Selector spool out of position
Internal defect
Problems a b c d
1 Steering wheel wobbles when traveling on rough road surfaces ° ° °
2 Steering wheel wobbles or suddenly turns when operating or traveling °
3 Steering wheel wobbles when traveling at speed ° ° ° °
4 Body wobbles when engine is started °
Replace ¯ ¯ ¯ ¯
Correct ¯ ¯ ¯ ¯
Remedy
Adjust ¯
Clean
T-9 Machine deviates to one side when traveling

Cause ± Defective steering valve
! Spool out of position
Leakage of oil inside steering cylinder
Variation in tire inflation pressure
T-10 Turning radius is different between left and right

Cause ± Dividing of steering to left and right, lock
position of stopper [At end of steering, relief
noise can be heard from valve]
WA450-3MC 20-809 Î
TROUBLESHOOTING T-11
T-11 Brakes do not work or braking effect is poor

Ask the operator the following questions ! Is there any leakage of oil from the brake tube or
! Did the problem suddenly start connector or deformation of the tube
Yes ± Brake equipment broken ! Is the tire inflation pressure and tread pattern normal
! Did the problem gradually appear
Yes ± Deterioration of seal, wear of lining, disc Checking for abnormalities
! Measure the braking force and compare with the
Checks before troubleshooting Standard Value Table to check if the braking effect is
! Is the hydraulic oil level correct poor
! Is the brake pedal play correct
Cause
Wear or other abnormality of brake lining

Defective operation of brake piston inside
Contact due to complete wear of brake

Defective brake piston seal inside axle
Defective operation of charge valve

Defective brake portion inside axle
Defective charging pump, scuffing

Defective accumulator piston seal
Defective inside brake valve
Air in brake circuit
Problems a b c d e f g h I j
1 Resistance is low when brake pedal is depressed ° ° ° °
2 Brake pedal is heavy when it is depressed °
3 Abnormal operating force is needed to obtain specified braking force ° ° ° ° °
4 Abnormal noise is heard from axle when brake is applied ° °
5 Machine cannot travel [lacks rim pull] °
6 Set axles on stands, when brakes are applied only certain wheels rotate ° ° ° ° ° °
7 Air can be seen flowing out when air is bled from brake circuit, returns to normal after air is bled °
8 Abnormal oil leakage is found when checking leakage of oil inside axle °
9 Many metal particles are found in axle oil °
10 No abnormality in operating force or travel of brake pedal, but braking effect is poor ° ° ° °
11 Number of times of braking effect is small when engine is stopped ° ° ° °
12 Accumulator is not charged, buzzer sounds ° ° °
13 There is a time lag in effect of brake °
Replace ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Correct ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Remedy
Adjust
Clean
20-810 Î WA450-3MC
T-12 Brakes are not released or brakes drag

Checks before troubleshooting Checking for abnormalities
! Does the brake pedal come back fully ! Is there any abnormal heat from the brakes
! Is the parking brake fully released ! Travel smoothly under inertia on level ground
Causes
Defective operation of brake piston inside

Defect inside brake valve [piston stuck]
Abnormality in brake lining inside axle
Problems a b c
1 Brakes remain applied even when brake pedal is released ° ° °
2 When brake pedal is released and oil is bled, circuit pressure goes down and brake is released °
3 Set axles on stand. Engine off, parking brake released, certain wheels are heavy when they are rotated by hand ° °
Replace ¯ ¯ ¯
Correct ¯ ¯ ¯
Remedy
Adjust
Clean
WA450-3MC 20-811 Î
T-13 Parking brake is not released or brake drags

Checks before troubleshooting In such a case, the probable cause follows:
! Is the emergency parking brake cancel switch OFF [it a. Faulty operation of emergency parking brake
is always canceled when this switch is ON] cancel valve
! Is the parking brake always applied automatically b. Breakage in wiring harness in line for emergency
when the engine is stopped parking brake cancel switch
! When emergency parking brake switch is turned ON, c. Insufficient gas pressure in brake accumulator,
parking brake is not released. damaged piston seal
Causes
Catching due to peeling of parking brake

Defect inside parking brake solenoid
Insufficient pressure due to defective
Broken harness in parking brake switch

Defective operation of parking brake
Defective operation of emergency cancel
Problems a b c d e f
1 When parking brake switch is turned OFF, parking brake is not released ° ° ° ° ° °
2 When parking brake switch is OFF and engine is stopped, parking brake is not applied ° °
3 When parking brake switch is ON, parking brake effect is weak ° °
Replace ¯ ¯ ¯ ¯ ¯
Correct ¯ ¯ ¯ ¯ ¯ ¯
Remedy
Adjust
Clean
20-812 Î WA450-3MC
T-14 Boom does not rise

Ask the operator the following questions. Yes ± Wear of internal parts, spring deterioration
! Did the problem suddenly start
Yes ± Equipment seized, damaged. Was there any Checks before troubleshooting
abnormal noise when this happened [from where] ! Is the hydraulic oil level correct
! Was there previously any symptom, such as the ! Is the travel of the boom control lever and spool
speed becoming slow properly adjusted
Causes
®1 ®2 ®3 ®4 ®5
Clogged suction port of pump or aerated
Breakage inside valve body [boom spool]

®1 Tank to pump
Defective operation of main relief valve

®2 Steering valve
Defective hydraulic and switch pump
Defective operation of demand valve
Damaged boom cylinder piston seal

®3 PPC valve
®4

Main control valve
®5 Cylinder
Defective operation of spool

Defective PPC pump
No drive for pump
1 Bucket cannot be operated and boom cannot be raised ° ° ° ° ° ° ° °
2 Chassis can be raise with boom but boom cannot be raised ° ° °
3 Bucket can be operated but boom cannot be raised ° ° °
4 Boom can be raised when there is no load but cannot be raised when there is a load ° ° °
5 Abnormal noise comes from hydraulic pump ° ° °
6 Excessive hydraulic drift of boom cylinder ° °
7 When engine is running at full throttle, steering operation is to light and fast °
8 When engine is running at full throttle, steering operation is heavy and slow ° °
Replace ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Correct ¯ ¯ ¯ ¯ ¯ ¯
Remedy
Adjust ¯
Clean ¯
WA450-3MC 20-813 Î
T-15 Boom movement is slow or boom lacks lifting power

! Is the travel of the boom control lever and main ! There is a strong connection between lifting power
control valve spool properly adjusted and speed, so this problem first appears as a lack of
! Is there any seizure of the work equipment linkage [Is lifting speed. Measure the boom lifting speed when
there any abnormal noise] the bucket is loaded and use the Standard Value
Table to judge if there is any abnormality.
Causes
®1 ®2 ®3 ®4 ®5 ®6
Defective operation of main relief valve or
Defective operation of cut off valve or

Breakage or wear inside valve body
®1 Tank to pump
®2 Steering valve
Defective operation of demand spool

Damaged boom cylinder piston seal

®3 PPC valve
®4

Main control valve
®5 Cylinder
®6 Cut off valve

Problems a b c d e f g h I
1 Bucket tilting power and speed are abnormal and boom lifting speed is slow ° ° ° ° °
2 Bucket tilting power and speed are normal but boom lifting speed is slow ° ° °
3 As in item 1, but lifting speed is particularly slow when oil temperature rises °
4 Abnormal noise comes from hydraulic pump ° °
5 When engine is running at full throttle, steering operation is too light and fast °
6 When engine is running at full throttle, steering operation is heavy and slow ° °
7 Excessive hydraulic drift of cylinder ° °
8 Relief pressure of relief valve in main control valve is low ° ° ° °
9 Relief pressure of relief valve in main control valve is too high °
Replace ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Correct ¯ ¯ ¯ ¯ ¯ ¯ ¯
Remedy
Adjust ¯
Clean ¯
20-814 Î WA450-3MC
TROUBLESHOOTING T-16 T-17 T-18 T-19 T-20
T-16 When boom is raised, it moves slowly at a certain height

Checks before troubleshooting ! Swelling or internal damage to boom cylinder tube
! Can any deformation be seen in the boom cylinder
i For other abnormalities when the boom is raised, see
Cause T-15
T-17 Bucket cannot be pushed with boom cylinders

See T-15
Cause
Checks before troubleshooting ! Defective seating of suction valve at boom cylinder
! Is the stroke of the boom spool in the main control rod end of main control valve
valve properly adjusted ! Oil leakage from boom cylinder piston seal
T-18 Excessive hydraulic drift of boom

Ask the operator the following questions. ! Is the boom spool at the neutral position
! Did the problem suddenly start Yes ± Seized link bushing, defect in spool detent
Yes ± Dirt caught in valve, broken part
! Did the problem gradually appear Troubleshooting and Cause
Yes ± Worn parts ! When measuring the hydraulic drift, is there any
sound of oil leakage from inside the boom cylinder
Checks before troubleshooting Yes ± Faulty cylinder packing
T-19 Boom shakes during operation

When digging or leveling operations are carried out with 2. If the chassis cannot be raised with the boom cylin-
the boom control lever at HOLD, the bucket and boom ders, see T-17
move up and down to follow the shape of the ground. 3. If the hydraulic drift of the boom is normal, operate
the boom several times, and operate the boom
Troubleshooting and Cause cylinders to the end of there stroke. Is it now possible
Measure the hydraulic drift of the boom and check if it is to raise the chassis with the boom cylinders
possible to lift the chassis with the boom cylinders. Yes ± Vacuum had formed inside cylinder
1. If the hydraulic drift of the boom cylinders is outside i However, if this problem appears frequently, the
the standard value, see T-18 suction valve at the boom cylinder rod end is faulty.
T-20 Boom drops momentarily when control lever is operated from HOLD to
RAISE
Checking problem condition returns to normal.
! When the engine is run at low idle and the boom
control lever is operated slowly from HOLD to RAISE, Cause
the boom goes down under its own weight. When the ! Faulty seating of check valve for boom spool in main
lever is operated fully to the RAISE position, the control valve.
WA450-3MC 20-815 Î
T-21 Bucket does not tilt back

Ask the operator the following questions. Yes ± Wear of internal parts, deterioration in spring
! Did the problem suddenly start?
Yes ± Equipment seized, damaged. Was there any Checks before troubleshooting
abnormal noise when this happened [from where] ! Is the travel of the bucket control lever and spool
! Was there previously any symptom, such as the properly adjusted
speed becoming slow
Causes
®1 ®2 ®3 ®4 ®5
Breakage inside valve body [bucket

®1 Tank to pump
Defective operation of main relief valve

®2 Steering valve
Damaged bucket cylinder piston seal

Defective operation of demand valve

®3 PPC valve
®4

Main control valve
®5 Cylinder

Defective PPC pump
No drive for pump
1 Boom cannot be operated and bucket cannot be tilted back ° ° ° ° ° ° °
2 Chassis can be raise with bucket but bucket cannot be tilted back ° ° °
3 Boom can be operated but bucket cannot be tilted back ° ° °
4 Bucket can be tilted back when there is no load but cannot be tilted back during digging or loading ° °
5 Abnormal noise comes from hydraulic pump ° ° °
6 Excessive hydraulic drift of bucket cylinder ° °
7 When engine is running at full throttle, steering operation is to light and fast °
8 When engine is running at full throttle, steering operation is heavy and slow °
Replace ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Correct ¯ ¯ ¯ ¯ ¯ ¯
Remedy
Adjust ¯
Clean ¯
20-816 Î WA450-3MC
T-22 Bucket movement is slow or tilt back lacks power

! Is the travel of the bucket control lever and main ! Check if there is lack of tilt back power during actual
control valve spool properly adjusted operations.
! Is there any seizure of the work equipment linkage [Is ! Measure the speed of the bucket and use the Stan-
there any abnormal noise] dard Value Table to check if there is any abnormality
Causes
®1 ®2 ®3 ®4 ®5 ®6
Defective operation of safety valve at

Defective operation of main relief valve or
Defective operation of cut off valve or

Breakage or wear inside valve body
®1 Tank to pump
®2 Steering valve
Damaged bucket cylinder piston seal

Defective operation of demand spool
®3 PPC valve
®4

Main control valve
®5 Cylinder
®6 Cut off valve

1 Boom lifting power and speed are abnormal and bucket tilt back power or speed are abnormal ° ° ° ° ° °
2 Boom lifting power and speed are normal but bucket tilt back power or speed are abnormal ° ° ° °
3 As in item 1, but problem particularly bad when oil temperature rises °
4 Abnormal noise comes from hydraulic pump ° °
5 When engine is running at full throttle, steering operation is too light and fast °
6 When engine is running at full throttle, steering operation is heavy and slow °
7 Excessive hydraulic drift of bucket cylinder ° ° °
8 Relief pressure of relief valve in main control valve is low ° ° ° °
9 Relief pressure of relief valve in main control valve is too high ° °
Replace ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Correct ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯
Remedy
Adjust ¯
Clean ¯
WA450-3MC 20-817 Î
TROUBLESHOOTING T-23, T-24, T-25
T-23 Bucket movement becomes slow during tilt back operation

Checks before troubleshooting ! Swelling or internal damage to bucket cylinder tube
! Can any deformation be seen in the bucket cylinder ! For other abnormalities when the bucket is operated,
see T- 22
Cause
T-24 Bucket cannot be pushed with bucket cylinder

See T-22
Cause
Checks before troubleshooting ! Faulty seating of safety valve [with suction valve] at
! Is the stroke of the bucket spool in the main control bucket cylinder rod end of main control valve
valve properly adjusted ! Oil leakage from bucket cylinder piston seal
T-25 Excessive hydraulic drift of bucket

Ask the operator the following questions. Checking for abnormalities
! Did the problem suddenly start ! Use the Standard Value Table to check if the hydrau-
Yes ± Dirt caught in valve, broken part lic drift of the bucket is actually excessive.
! Did the problem gradually appear
Yes ± Worn parts Cause
! Oil leakage inside bucket cylinder
Checks before troubleshooting ! Faulty seating of safety valve [with suction valve] at
! Is the bucket spool at the neutral position bottom end
Yes ± Seized link bushing, defect in spool detent ! Faulty oil tightness of bucket spool
T-26 Bucket shakes during loading operation

Checks before troubleshooting ! Faulty bucket cylinder piston seal
! Is there play in the work equipment linkage pin, ! Faulty operation of safety valve [with suction valve] at
bushing [is there any abnormal noise] bucket cylinder rod end. If any other problem occurs
at the same time, carry out troubleshooting according
Cause to the nature of the problem.
T-27 Bucket dumps momentarily when control lever is operated from HOLD to
TILT
Checking problem the condition returns to normal.
! When the engine is run at low idle and the bucket
control lever is operated slowly from HOLD to TILT, Cause
the bucket dumps momentarily under its own weight. ! Faulty seating of check valve for bucket spool in main
When the lever is operated fully to the TILT position, control valve
20-818 Î WA450-3MC
T-28 Boom, bucket control levers are heavy or do not move smoothly
Checking for abnormalities
! Check the values in the Standard Value Table to
check if the operating force of the lever is actually
excessive.
Causes
®1 ®2 ®3
Seizure, stiffness of rotating portion of
Defective out of roundness of valve body
Defective out of roundness of valve body

Defective clearance between valve body
Deformation due to uneven torque on
Defective clearance between valve body

®1 Control lever
®2 PPC valve
®3 Main control valve
Catching of valve spool detent

Dirt caught in valve spool
Dirt caught in valve spool

Bent valve spool
Bent spool
1 Levers are heavy when there is a load and pressure is high ° ° ° ° °
2 Levers become heavy as oil temperature changes ° ° ° ° °
3 Levers become heavy at place during operation regardless of pressure or temperature °
4 Levers are always heavy during operation regardless of pressure or temperature ° ° ° ° ° °
5 Levers are still heavy after control lever link is disconnected at valve connection °
Replace ¯ ¯ ¯
Correct ¯ ¯ ¯
Remedy
Adjust
Clean ¯
WA450-3MC 20-819 Î
TROUBLESHOOTING OF
ECSS - E MODE
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . 20-902
D-1 ECSS does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-903
D-2 ECSS cannot be canceled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-908
D-3 Output is turned ON, travel speed does not become 5 km/h . . . . . . . . . . . . . . . . . . . . 20-909
D-4 Output is turned ON when transmission is in 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-909
D-5 Output is turned ON when transmission is in 4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-910
D-6 Controller LED code is not displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-911
D-7 ECSS is abnormal, but main monitor does not give abnormality display . . . . . . . . . . . 20-911
WA450-3MC 20-901 Î
TROUBLESHOOTING JUDGEMENT TABLE
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM
Error code Self diagnosis table (abnormality display)
Troubleshooting
Solenoid high Solenoid low Travel speed Model se-
Solenoid relief code when no ab-
pressure sys- pressure sys- sensor sys- lection ab-
system normality display is
tem tem tem normality
given
Failure mode d0 d1 d2 d3 d4
ECSS does not work or does not work

D-1 (a) D-1 (b) D-1 (c) D-1 (d) D-1 (e) D-1 (f)
properly
ECSS cannot be canceled D-2
Output is turned ON, but travel speed does

D-3
not become 5 km/h [deviates]
Output is turned ON when transmission is

D-4
in 1st
Output is turned ON when transmission is

D-5
in 4th
LED code display is not given D-6
ECSS is abnormal, but main monitor does

D-7
not give abnormality display
20-902 Î WA450-3MC
TROUBLESHOOTING D-1
D-1 ECSS does not work

i Carry out troubleshooting with the start switch ON.
i Check that the ECSS switch on the main monitor is ON.
Cause Remedy
3
Displaying [d0] Go to item (a) ---
Displaying [d1] Go to item (b) ---
Displaying [d2] Go to item (c) ---

2
Which code is monitor display-
ing 6
Displaying [d3] Go to item (d) ---
Displaying [d4] Go to item (e) ---

1
Is there an abnormality display
Go to item (f) ---
Cause Remedy
(a) Error code [d0] is displayed
Yes
Is resistance between AL1-21

1) Disconnect AL1 Yes
2) DC resistance: 20 to 40 S 2 Defective solenoid Replace

No AL1-21 and chassis ground
1) Disconnect AL1 and AF4 Yes Disconnection in harness
Repair or
2) Connect short connector between AL1-21 to SAS-4
replace
to AF4 3 to AF4-1
No AF4-2 and chassis ground
1) Disconnect AF4 Disconnection in harness
Repair or
between AF4-2 to TL1-8 to
No replace
CL1-12 to chassis ground
WA450-3MC 20-903 Î
TROUBLESHOOTING D-1
Cause Remedy
(b) Error code [d1] is displayed
Yes


Repair or
replace
to AF5 3 to AF5-1
Repair or
No replace
Cause Remedy
(c) Error code [d2] is displayed
Yes


Repair or
replace
to AF6 3 to AF6-1
Repair or
No replace
D1 (a), (b) or (c) Related electric circuit diagram
20-904 Î WA450-3MC
TROUBLESHOOTING D-1
Cause Remedy
(d) Error code [d3] is displayed
Yes
1 Defective speed sensor Replace
Does error display go off

1) Connect short connector to Yes
T06 2 Defective controller Replace
2) Start switch: OFF ö ON
No AL3-4 and 12
1) Disconnect AL3 Disconnection in harness
Repair or
No replace ®
to T06 or AL3-12 to SAS-10
® If any other controller is abnormal, check all harnesses for the speed sensor system.
D1 (d) Related electric circuit diagram
Cause Remedy
(e) Error code [d4] is displayed
Yes
Yes Is continuity of harnesses nor-

mal
1) Disconnect AL2 Disconnection in harness
Repair or
2) Is continuity between AL2- between AL2 and AL4 or
No replace
1 1 thru 4 and ground as in contact with ground
table
Is connection of harnesses
normal
1) Disconnect AL4 Faulty contact, or discon-
2) Is continuity between AL4- nection in harness Repair or
1, 2, 3, 5 to ground as in No between AL4 and ground replace
table or contact with ground
1 2 3 4 5
AL4 Yes Yes Yes --- No
AL2 No Yes Yes Yes ---
D1 (e) Related electric circuit diagram
WA450-3MC 20-905 Î
TROUBLESHOOTING D-1
(f) No abnormality display is given
Cause Remedy
[1] Does not work at all
Yes
Is voltage between AL2-15 and

1) 0 to 3 V Yes
2) Start switch ON 2 Defective main monitor ®
3) ECSS switch ON
1) 20 to 30 V Disconnection in harness
Repair or
2) Disconnect L06 between AL2-15 to DP2-1
No replace
to L06-7
® Go to troubleshooting of Main Monitor
D1 ( f ) [1] Related electric circuit diagram
Cause Remedy
[2] Works when bucket is loaded but not when empty
Yes Defective pressure switch

or faulty chassis hydraulic Replace
2 system
AF7-1 and 2
1) Start switch ON Yes Contact of chassis ground
Repair or
2) Disconnect AF7 with harness between AL2-
replace
3) Empty bucket 3 8 to SAS-7 to AF7-1
1) Start switch ON Defective monitor Replace
1 No
Does controller LED display 55
1) Start switch ON Defective chassis hydrau-
2) Empty bucket ---
No lic system
20-906 Î WA450-3MC
TROUBLESHOOTING D-1
D1 ( f ) [2] [3] Related electric circuit diagram
Cause Remedy
[2] Works when bucket is empty but not when loaded
Yes Defective chassis hydrau-
---
1 lic system
Does controller LED display 55
1) Start switch ON Yes
2) Load bucket 3 Defective controller Replace
Yes Is voltage between AL2-8 and

3) Load bucket tween AL2-8 to SAS-7 to Repair or
No AF7-1, or between AF7-2 replace
to SAS-8 to AL4-4 to chas-
2 sis ground
No AF7-1 and 2
1) Start switch ON Defective pressure switch
2) Disconnect AF7 or faulty chassis hydraulic Replace
3) Load bucket No system
WA450-3MC 20-907 Î
TROUBLESHOOTING D-2
D-2 ECSS cannot be canceled

i Check that the ECSS switch on the main monitor is OFF.
Cause Remedy
Yes
Is voltage between AL2-15 and

1) 20 to 30 V Yes Contact of chassis ground
Repair or
2) Start switch ON with harness between AL2-
replace
3) ECSS switch OFF 2 15 to DP2-1 to L06-7
1) Disconnect AL2
2) Disconnect L06 Defective main monitor ®
No
® Go to troubleshooting of Main Monitor
20-908 Î WA450-3MC
TROUBLESHOOTING D-3 D-4
D-3 Output is turned ON, travel speed does not become 5 km/h (Deviates at
around 5 km/h)
Cause Remedy
Yes Defective speed sensor or

Replace or
defective mount of speed
adjust
2 sensor
Yes Is monitor speed display incor-
rect
1) Start engine Defective controller Replace
1 No
Is machine model code normal
1) Check LED display code
2) See Structure and Func- Go to D-1 (e) ---
tion for details of codes No
D-4 Output is turned ON when transmission is in 1st
Cause Remedy
Yes

1) Disconnect AL2 Defective contact or dis-
2) 50 to 70 S connection in harness be- Repair or
No tween AL2-14 to SAS-3 to replace
speed solenoid
WA450-3MC 20-909 Î
TROUBLESHOOTING D-5
D-5 Output is turned ON when transmission is in 4th

Cause Remedy
Yes

2) 50 to 70 S connection in harness be- Repair or
No tween AL2-13 to SAS-2 to replace
Hi Lo solenoid
20-910 Î WA450-3MC
TROUBLESHOOTING D-6 D-7
D-6 Controller LED code is not displayed

Cause Remedy
Yes
Is power source voltage nor-

mal
1) 20 to 30 V Yes Defective contact or dis-
Repair or
2) Measure voltage between connection in harness be-
replace
AL1-8, 18 to 9, 19 3 tween AL1-8, 18 to DP1-1
Yes Is voltage between DP1-1 and
1) 20 to 30 V Abnormality in fuse box Repair
2 No
2) Disconnect DP1
No AL1-9, 19 to chassis ground
Repair or
tween AL1-9, 19 to SAS-1
No replace
to TL1-8 to CL1-12 to
chassis ground
D-7 ECSS is abnormal, but main monitor does not give abnormality display
Cause Remedy
Check that the ECSS control- Go to troubleshooting of

---
ler is displaying an error code main monitor
WA450-3MC 20-911 Î
30 DISASSEMBLY AND ASSEMBLY
12
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
WHEN REMOVING OR INSTALLING UNIT ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
PRECAUTIONS DURING OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK . . . . . . . . . . . . . . . . . . . . . . . . 30-7
PRECAUTIONS WHEN COMPLETING THE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 ..
STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
TORQUE CONVERTER, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
TRANSMISSION CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
FORWARD, 1st Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
REVERSE, 2ND CLUTCH ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-63
3RD, 4TH CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70
FORWARD, 1ST CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70
REVERSE, 2ND CLUTCH ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74
3RD, 4TH CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-78
PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86
TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-93
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94
WA450-3MC 30-1 2
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99
TRANSMISSION ACCUMULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107
DRIVE SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-120
FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-124
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-124
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-130
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-130
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133
DIFFERENTIAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-140
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-150
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-150
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-153
CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-158
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-158
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-169
Upper hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-170
Connection of frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-171
Lower hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-171
Upper hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-173
STEERING VALVE (ORIBITROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-176
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-176
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-178
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-179
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-179
Control Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
Control Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184
STEERING DEMAND VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-188
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-188
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-189
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-190
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-195
STEERING AND SWITCH PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-204
STEERING CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-210
RIGHT BRAKE VALVE (TANDEM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-212
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-212
30-2 2 WA450-3MC
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-213
LEFT BRAKE VALVE (SINGLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-216
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-216
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217
SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-220
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-221
WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-222
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-222
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-228
PARKING BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
ACCUMULATOR CHARGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-242
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-244
HYDRAULIC TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-246
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-246
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-248
WORK EQUIPMENT, PPC PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-250
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-250
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-254
PPC VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-256
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-256
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-258
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-259
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-260
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-262
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-262
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-265
DISASSEMBLY (2-SPOOL VERSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-266
Hydraulic Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-267
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-267
Spools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-267
ASSEMBLY (2-SPOOL VERSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-268
Spools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-269
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-269
Hydraulic Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-271
DISASSEMBLY (3-SPOOL VERSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-272
Hydraulic Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-273
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-275
Spools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-275
Spools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-279
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-279
Hydraulic Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-283
DUMP CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-284
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-284
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-286
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-288
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-288
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-290
WA450-3MC 30-3 2
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-292
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-292
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-295
WORK EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-300
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-300
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-304
Bucket and bucket link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-304
Dump cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-304
Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-304
Lift arm, bellcrank, bucket link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-304
Bellcrank, bucket link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-305
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-306
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-306
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-307
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-308
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-308
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-310
CAB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-312
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-312
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-313
MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-314
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-314
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-315
MAINTENANCE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-316
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-316
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-316
AIR CONDITIONER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-318
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-318
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-324
AIR CONDITIONER CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-326
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-326
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-328
RECEIVER-DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-330
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-330
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-331
AIR CONDITIONER COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-332
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-332
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-333
30-4 2 WA450-3MC
DISASSEMBLY AND ASSEMBLY HOW TO USE THIS MANUAL
12
HOW TO USE THIS MANUAL
WHEN REMOVING OR INSTALLING UNIT ASSEMBLIES

A. When removing or installing a unit assembly, the order of work and techniques used are given for the removal opera-
tion; the order of work for the installation operation is not given.
B. Any special techniques applying only to the installation procedure are marked with and the same mark is placed
after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
Example Explanation
(COMPONENT) REMOVAL Title of operation

WARNING! Safety precautions to observe when performing an operation
1. XXX Text of or name of procedural step
A. Text of procedural step if 1 was procedural name
★ Technique or important point
Reference to a special technique during assembly or installation (note that

this symbol is right-aligned).
(Component/assembly) See Lubricant and Coolant Table
(COMPONENT) INSTALLATION Title of operation
• Installation is the reverse of removal. Overall directive
Special technique during assembly or installation (note that this symbol is

left-aligned).
★ Technique or important point
(Component/assembly) Specification
1. General precautions
When carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS
WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when performing out the operation.
2. Listing of special tools

For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see
the SPECIAL TOOL LIST later in this section.
WA450-3MC 30-5 2
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
12
PRECAUTIONS DURING OPERATION
Be sure to follow the general precautions given below when carrying out removal or installation (disassembly or assembly) of
units.
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK

• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places before removal
to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the con-
nectors.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws alternately.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after
removal.
★ Precautions when handling piping during disassembling
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal Sleeve nut (elbow end) Use the two items

Plug (nut end)
number below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes
Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
30-6 2 WA450-3MC
3) If the part is not under hydraulic pressure, the following corks can be used:
Dimensions
Nominal
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
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 fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.
• When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the direction of the
hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equip-
ment removed for repair, always bleed the air as follows:
A. Start the engine and run it at low idle.
B. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping 100 mm from end of
its stroke.
WA450-3MC 30-7 2
C. Operate all hydraulic cylinders 3 - 4 times to the end of their stroke, then stop the engine and
loosen air bleed plug (1) to bleed the air from the hydraulic tank. After bleeding the air,
tighten plug (1).
Plug: 11.3 ± 1.5 N•m (8.3 ± 1.1 lbf ft)
D. Next, raise the engine speed and repeat step 3 to bleed the air.
Repeat this operation until no more air comes out from the
plug hole.
E. Run the engine at normal speed.

★ Follow the same procedure when using the machine for the first
time after repair or long storage.
PRECAUTIONS WHEN COMPLETING THE OPERATIONS

• If the 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, such as hydraulic cylinders, pumps, or motors, have been removed for repair, bleed
air from the system after reassembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.
30-8 2 WA450-3MC
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
12
SPECIAL TOOL LIST
Nature of work Symbol Part no. Part Name Qty. Remarks
For FORWARD/
1 793-615-1310 Lifting tool (A) 1
1st clutch
Installation,
removal of
For REVERSE/
clutch pack
2 793-615-1320 Lifting tool (B) 2 2nd, 3rd, 4th
Disassembly, assembly of clutch
* Transmission assembly
A
* Transmission clutch pack 3 793-615-1330 Pin 3 Installation, removal of clutch pack
assembly
For FORWARD,
4 793-615-1220 Holder 1
REVERSE piston
Jig for settling
piston seal ring
For 1st - 4th pis-
5 793-615-1210 Holder 1
ton
B 793-520-2410 Bracket 1
Removal of front differential
assembly C 793-520-2510 Bracket 1
Disassembly, assembly of
D 790-520-2620 Plate 1
differential assembly
E 790-425-1620 Fixture 3
F 790-425-1630 Fixture 3
final drive assembly
G 793-520-2320 Fixture 2
H 790-101-1002 Pump 1
I 790-101-2102 Puller 1
J 790-101-2300 Push-puller 1
Installation of center hinge
1 793-520-2370 Push-tool 1
pin
2 793-520-2350 Push-tool 1
K
3 793-520-2540 Guide 1
4 793-520-2360 Bar 2
793-463-1110 Stopper 2
01011-51845 Bolt 2
Removal of slack adjuster
L
assembly
01643-31845 Washer 2
01580-11815 Nut 2
1 793-415-1150 Plate 1
Removal of parking brake
M 2 01010-51085 Bolt 4
disc
3 01580-11008 Nut 4
WA450-3MC 30-9 2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
790-502-1003
Cylinder repair
or 1
N 790-502-2000 stand
790-101-1102 Pump 1
Removal, instal-
O 790-330-1100 Wrench assembly 1 lation of round
head screw
Steering
Socket (width cylinder Removal instal-
P 799-302-1280 across flats: 55 1 lation of nylon
mm) nut
790-101-5021 Grip 1
Press-fitting of coil bushing
Kit P/N 790-201-1702
01010-50816 Bolt 1
Q 790-201-1930 Push tool 1 Lift cylinder
790-201-1850 Push tool 1 Dump cylinder
Disassembly, assembly of 790-201-1761 Push tool 1 Steering cylinder

hydraulic cylinder
1 790-720-1000 Expander 1 Installation of piston ring
796-720-1690 Ring 1
Lift cylinder
07281-01919 Clamp 1
R 796-720-1690 Ring 1
2 Dump cylinder
07281-02169 Clamp 1
796-720-1660 Ring 1
Steering cylinder
07281-01159 Clamp 1
790-101-5021 Grip 1 Insertion of dust seal

Kit P/N 790-201-1500
01010-50816 Bolt 1
S 790-201-1660 Plate 1 Dump cylinder
790-201-1570 Plate 1 Steering cylinder
790-201-1990 Plate 1 Lift cylinder
1 793-520-2680 Installer 1
2 790-425-1640 Eye bolt 2

T 3 793-570-1010 Push plate 1
brake assembly
4 793-425-1620 Fixture 3
5 790-425-1630 Fixture 3
NOTE: Refer to ENGINE SHOP MANUAL for special tool of disassembly and assembly of engine components (engine oil
cooler, fuel injection pump, water pump, turbocharger, nozzle holder, thermostats, cylinder head etc.).
30-10 2 WA450-3MC
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
12
STARTING MOTOR
REMOVAL
WARNING! Disconnect the ground cable from the

negative (-) terminal of the battery before
proceeding.
WARNING! Stop the machine on level ground and

install the safety bar on the frame. Lower
the bucket to the ground and stop the
engine. Then apply the parking brake and
block the wheels to prevent the machine
from moving.
1. Open the engine hood side cover and lock it into position.
2. Unplug the wiring connector (1) and ground cable from the starting
motor.
3. Disconnect the wiring (2).
4. Remove the starting motor assembly (3).
INSTALLATION
• Installation is the reverse of removal.
★ Connect the ground cable (4) securely after installing the starting
motor (3).
WA450-3MC 30-11 2
DISASSEMBLY AND ASSEMBLY ALTERNATOR
12
ALTERNATOR
REMOVAL

from moving.
WARNING! Disconnect the cable from the negative (-)

terminal of the battery.
1. Open the engine hood side cover and lock it in position.
2. Disconnect the 3 sets of wiring (1) from the alternator.

★ Label the wiring with tags to ease reconnection later.
3. Loosen the mounting bolt and nut (2), then loosen the adjustment plate
mounting bolt (3).
4. Loosen the locknut (4) and adjustment nut (5), love the alternator (6)
towards the engine, then remove the fan belt (7). Use a wrench (2) to
lift the tensioner (3) and release the drive belt tension, then remove the
belt (4).
5. Remove the mounting bolt and nut (2), remove the adjustment plate mounting bolt, then remove the alternator (6).
INSTALLATION
★ Adjust the fan belt tension as detailed in Section 20, TESTING AND ADJUSTING.
30-12 2 WA450-3MC
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
12
ENGINE COMPONENTS
Refer to the Engine Shop Manual for procedures relating to the following:
• Engine Oil Cooler
• Fuel Injection Pump
• Water Pump
• Turbocharger
• Nozzle Holder Assembly
• Thermostat
• Cylinder Head
WA450-3MC 30-13 2
DISASSEMBLY AND ASSEMBLY RADIATOR
12
RADIATOR
REMOVAL
WARNING! Stop the machine on level ground

and install the safety bar on the
frame. Lower the bucket to the
ground and stop the engine. Then
apply the parking brake and block the
wheels to prevent the machine from
moving.
WARNING! Perform the oil return operation for

the air conditioner compressor (set
the fan switch to the maximum posi-
tion, run the engine at low idle, and
operate the air conditioner for five
minutes). Then use a manifold gauge
and release the refrigerant slowly
from the valve of the compressor.
WARNING! Loosen the oil filler cap slowly to

release the pressure inside the
hydraulic tank. Loosen the plugs (1)
and (2) on top of the hydraulic tank
filter to prevent the oil from the tank
from flowing out. Then operate the
steering wheel and control levers
several times to release the remain-
ing pressure in the hydraulic piping.
WARNING! Disconnect the cable from the nega-

tive (-) terminal of the battery before
proceeding.
1. Loosen the drain valve (3) and drain the coolant.
Coolant: 68 L (18 U.S. gal.)
★ Dispose of the coolant as directed by law.
30-14 2 WA450-3MC
12
2. Radiator guard removal
A. Remove the 4 radiator guard mounting bolts, then unplug the

working lamp wiring connectors (4).
B. Lift off the radiator guard (5).
3. Hood removal
A. Unplug the electric wiring connector (6) inside the rear left of the
hood.
B. Remove the left and right radiator baffles (7).
C. Sling the hood (a), remove the front and rear, left and right mount-
ing bolts (9) and the 3 top front mounting bolts (10), then lift off
the hood
Hood assembly: 184 kg (406 lb)
WA450-3MC 30-15 2
12
4. Unplug the radiator coolant level sensor connector (4-1) from the top
of the radiator.
5. Hose disconnections
★ Plug the open hose ends to prevent the entry of dirt or dust.
A. Disconnect the radiator drain hose (11) from the radiator.
B. Disconnect the radiator lower hose (12) from the radiator.
C. Disconnect the oil cooler hoses (13) from the radiator.
D. Disconnect the upper hoses (14 and 15), and the radiator spill pipe
(16) from the radiator.
6. Remove the radiator fan guard (17) and radiator stay (18).
7. Remove the fan mounting bolts (19), then remove the fan.
8. Sling the radiator assembly (20), then remove the mounting bolts (21)
and lift the radiator free.
Radiator: 220 kg (485 lb)
30-16 2 WA450-3MC
12
INSTALLATION
★ Be careful not to twist or crimp the hoses during installation.
★ Add water/coolant through water filler to the specified level.
★ Run the engine to circulate the coolant through the system, then check the coolant level again.
Coolant (radiator): 65 L (17 U.S. gal.)

Coolant (sub-tank): 3 L (0.79 U.S. gal.)
WA450-3MC 30-17 2
DISASSEMBLY AND ASSEMBLY ENGINE
12
ENGINE
REMOVAL

from moving.
WARNING! Loosen the oil filler cap slowly to release

the pressure inside the hydraulic tank.
Loosen the plugs (1 and 2) on top of the
tank filter to prevent the oil from the tank
from flowing out. Then operate the steer-
ing wheel and control levers several times
to release the remaining pressure in the
hydraulic piping.
WARNING! Operate the bucket control levers at least

40 times TILT <–> HOLD to relieve pres-
sure inside the accumulator.
WARNING! Depress the brake pedal at least 17 times

to relieve pressure inside the brake accu-
mulator.
WARNING! Perform the oil return operation when

releasing the refrigerant from the air con-
ditioner, then use a manifold gauge and
release the refrigerant slowly from the
core of the compressor high-pressure and
low pressure valves.

1. Remove the radiator as described earlier in this section.
30-18 2 WA450-3MC
2. Electric wiring disconnections
★ Label the wiring as disconnections are completed to ease recon-
nections later.
A. Unplug the CNER1 connector (4) and the CNER2 connector (5)
of the engine wiring harness (3).
B. Disconnect the slow-blow fuse 120A connector (6) and 80A con-
nector (7).
C. Disconnect the cable (8) between the starting motor and battery
relay.
D. Disconnect the starting motor ground cable.
3. Fuel hose disconnections:

★ Label the hoses during the disconnections to ease reconnections
later.
★ Fit plugs into the hose ends after completing disconnections to
prevent the entry of dust and dirt.
A. Disconnect the fuel tank hose (9) at the feed pump end.
B. Disconnect the fuel return hose (10) at the injection pump end.
C. Disconnect the spill hose (11) at the fuel tank end.
4. Air conditioner and heater hose disconnections:

★ Label the hoses during the disconnections to ease reconnections
later.
★ Fit plugs into the hose ends after completing disconnections to
A. Disconnect the a/c hoses (12 and 13) from the compressor.
B. Disconnect the heater hoses (14 and 15) from the engine.
5. Brake piping, accelerator cable disconnections
A. Disconnect the hoses (16 and 17) between the right brake valve
and the accumulator at the pedal end.
★ Remove the clamps (2 places) of the brake hoses under the
floorboard.
B. Disconnect the hose (18) between the left brake valve and accu-
mulator at the pedal end.
C. Disconnect the accelerator cable (19) at the bottom of the pedal.

★ Remove the cable clamp under the floor board.
WA450-3MC 30-19 2
D. Disconnect the hose (20) between the PPC accumulator and PPC
valve inside the bulkhead at the accumulator end.
E. Disconnect the hose (22) from the radiator sub-tank (21) and hose
(24) from the windshield washer tank (23) at the tank end.
★ Remove the hoses from the hose clamp.
F. Air conditioner hose disconnections

★ Plug the open hose ends after completing disconnections to
• Disconnect the hose (25) between the compressor and con-
denser at the condenser end.
★ Remove the hose clamp inside the bulkhead.

• Disconnect the hose (26) between the air conditioner unit and the receiver at the receiver end.
★ Remove the hose clamp inside the bulkhead.
6. Bulkhead removal
A. Remove the cover (28) at the bottom front of the bulkhead (27).
B. Install eyebolts at the top 4 corners of the bulkhead (27), then

sling and remove the bottom mounting bolts (29).
Bulkhead: 135 kg (298 lb)

(includes accumulator charge valve)
C. Raise the bulkhead (27) straight up approximately 400 mm (18

in.).
★ The bulkhead come close to the cab when it is lifted, so be
careful not to hit anything.
★ Place blocks to the left and right on opposite sides to prevent
the bulkhead from falling after it has been raised.
30-20 2 WA450-3MC
7. Fuel control cable disconnection
A. Disconnect the fuel control cable (30) from the ball joint (31).
B. Remove the fuel control cable from the bracket (32).
8. Remove the rear drive shaft (33) and set an adjustable height support
stand under the transmission (34).
★ Place the stand securely so that it does not slip out of position.
★ Adjust the stand to the exact height of the transmission.
9. Engine removal
A. Remove the engine oil drain valve (35) and radiator coolant drain
valve (36) from the fuel tank.
B. Sling the engine assembly (37), remove the mounting bolts (38) of
the flywheel and torque converter housing.
★ Depending on the lifting tool, remove the muffler and then
sling.
Engine assembly: 1,150 kg (2,535 lb)
WA450-3MC 30-21 2
C. Remove the engine mounting bolt (39), then lift off the engine
assembly (37).
★ Note the positioning of the cushion and spacer for reference

in installation.
★ The flywheel ring gear and torque converter ring gear and
shaft are mated, so keep the engine assembly level when rais-
ing the engine.
★ Ensure that all wiring and piping have been removed before
continuing with engine removal.
30-22 2 WA450-3MC
12
INSTALLATION
★ Installation is the reverse of removal.
• Connect the hoses according to the labels or tags installed during disassembly.
• Ensure that the wiring connectors are tight and secure.
• Install the radiator as detailed earlier in this section.
• Install the air conditioner compressor as detailed later in this section.
Compressor hose: 7.9 - 11.8 N•m (5.8 - 8.7 lbf ft)
Accelerator cable mounting bolt: 53.9 ± 5 N•m

(39.8 ± 3.7 lbf ft)
Condenser hose: 19.6 - 24.5 N•m (14.5 - 18.1 lbf ft)
Receiver hose: 3.9 - 6.9 N•m (2.9 - 5.1 lbf ft)
★ Clean the connection and mating surface of the drive shaft before installing.
Drive shaft mounting bolt: 112.8 ± 9.8 N•m

(83.2 ± 7.2 lbf ft)
★ Ensure that the rubber cushions are positioned as they were before removal.
Mounting bolt: 926.7 ± 103 N•m (683.5 ± 76 lbf ft)
WA450-3MC 30-23 2
12
★ When connecting the engine to the torque converter:

• Adjust the height so the torque converter pilot can enter smoothly.
• Do not force the connection.
• Use new o-rings for the torque converter and flywheel housing.
O-ring at torque converter and engine flywheel mating sur-

face: Soapy water
★ Refill with hydraulic oil
A. Tighten the drain plugs (1 and 2) at the top of the hydraulic tank
filter.
B. Add hydraulic oil through the oil filler to the specified level.
Plug at top of filter: 11.8 ± 1 N•m (8.7 ± 0.7 lbf ft)
★ Fill the air conditioner with new refrigerant.

• Observe and follow these precautions when recharging the a/c
system:
★ Keep the work area ambient temperature higher than 3 °C (37 °F). The system will not work if the temperature is
lower.
★ Always use the repeat vacuum method to completely evacuate the system. (Vacuum attained: Minimum 750
mmHg
★ Use only R134a refrigerant.
★ Charge the system with 1.5 - 1.6 kg (3.3 - 3.5 lb) of refrigerant.
★ Hold the can of refrigerant can right side up. Do not allow liquid refrigerant into the system.
★ Do not operate the compressor before charging the system with refrigerant.
30-24 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-25 2
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
12
TORQUE CONVERTER, TRANSMISSION
REMOVAL

from moving.

Loosen the plugs (1 and 2) on top of the
tank filter to prevent the oil from the tank
from flowing out. Then operate the steer-
ing wheel and control levers several times
hydraulic piping.
WARNING! Operate the bucket control levers at least

40 times TILT <–> HOLD to relieve pres-
sure inside the accumulator.

to relieve pressure inside the brake accu-
mulator.
WARNING! Perform the oil return operation when

releasing the refrigerant from the air con-
ditioner, then use a manifold gauge and
core of the compressor high-pressure and
low pressure valves.

30-26 2 WA450-3MC
1. Remove the covers (3) at the bottom of the cab.
2. Remove the left and right ladders (3-1).
Ladder rail (right): 64.5 kg (142.2 lb)
Ladder rail (left): 59.5 kg (131.2 lb)
WA450-3MC 30-27 2
12
3. Disconnect the following electric wiring.
★ Label the wiring as disconnections are completed to aid during
reconnection.
A. Transmission wiring TL1 and TL2 (4 and 5).
B. Floor wiring harnesses LR5, LR6, LR3, LR4, LR1 and LR2 (6, 7,
8, 9, 10 and 11).
4. Disconnect the PPC piping.

★ Label the hoses as disconnections are completed to aid reconnec-
tions later.
★ Plug the open hose ends to prevent entry of dust and dirt.
A. The hose (12) of PPC valve port P2, the hose (13) of port P4, the
hose (14) of port P3, and the hose (15) of port P1 at the valve end.
B. The hose (16) between the PPC accumulator and the PPC valve at
the valve end.
C. The hose (17) of the PPC valve drain port at the valve end.
30-28 2 WA450-3MC
12
5. Disconnect the brake piping
★ Label the hoses as disconnections are completed to aid during
reconnection.
A. The hoses (18 and 19) between the right brake valve and accumu-
lator at the pedal end.
★ Remove the 2 brake hose clamps under the floor board.
B. The hose (20) between the left brake valve and accumulator at the
pedal end.
C. Right brake valve drain hose (21) and left brake valve drain hose
(22) at the rear frame portion.
D. The hose (23) between the front brake and right brake valve at the
center hinge pin.
6. Disconnect the air conditioning piping.

★ Label the hoses as disconnections are completed to aid during
reconnection.
A. Remove the covers (40) at the bottom of the front bulkhead.
B. Disconnect the hose (24) between the compressor and the a/c unit
at the unit end.
C. Disconnect the hose (25) between the receiver and the a/c unit at
the unit end.
D. Disconnect the heater piping (26 and 27) at the a/c unit end.
WA450-3MC 30-29 2
12
7. Disconnect the accelerator cable (28) under the pedal.
★ Remove the cable clamp at the floor board.
8. Disconnect the following steering valve piping:
A. Hose (20) from between the steering valve (L port) and the
stop valve (left-hand)
B. Hose (20-1) from between the steering valve (R port) and the
stop valve (right-hand)
C. Hose (20-2) from between the steering valve (P port) and the
accumulator charge valve
D. Hose (20-3) from between the steering valve (T port) and the
drain line
9. Cab and floorboard
A. Remove the mounting cover (31) of the floor board (30), then
remove the 4 viscous damper mounting nuts (32) that secure
the floor board in place.
30-30 2 WA450-3MC
12
B. Install the lifting tool to the cab (33), then lift the cab free.
★ Raise the cab slowly, then check to make sure that all parts have been removed before
lifting the cab off completely.
ROPS cab and floor assembly: 1,100 kg (2,425 lb)
10. Removing the bulkhead
A. Piping inside the bulkhead:
i. Disconnect the hose (39) between the air conditioner com-

pressor and condenser at the condenser end.
★ Plug the open hose and condenser connector to pre-
vent the entry of dirt and dust.
ii. Disconnect the hose (34) between the PPC accumulator and PPC valve inside the
bulkhead.
iii. Disconnect the hose (36) of the radiator sub-tank (35) and the hose (38) of the
window washer tank (37) at the tank end.
★ Remove the hose from the hose clamp.
WA450-3MC 30-31 2
B. Bulkhead
i.Remove the mounting bolts (42) at the top of the hood

(41) and bulkhead (39-1).
★ Be careful not to lose the washers and rubber of the
mounting portion.
ii. Install eyebolts at the top 4 corners of the bulkhead (39-1),

then sling and remove the bottom mounting bolts.
Bulkhead (including accumulator and charge pump):

135 kg (298 lb)
11. Hydraulic piping
★ Tag the hoses while completing the disconnections to ease
reconnections later.
A. Disconnect the loader pump suction tube (43) and steering

pump suction tube (44) at the pump end.
B. Remove the hydraulic tank hose (45), remove the tube mount-
ing bolts (43-1), then remove the tube (43).
C. Disconnect the tube (46) between the loader pump and main
control valve at the pump end and center hinge pin end, then
remove the tube.
D. Disconnect the PPC pump tube (47) at the pump end.
E. Disconnect the tube (48) between the steering pump and steer-
ing valve at the pump end and center hinge pin end, then
remove the tube.
F. Disconnect the tube (49) between the switch pump and steering
valve at the pump end and center hinge pin end, then remove
the tube.
G. Disconnect the tube (50) between the steering valve and cooler
at the center hinge pin.
30-32 2 WA450-3MC
12
12. Transmission and cooler piping
A. Disconnect the hose (51) between the transmission control

valve and cooler and hose (52) between the cooler and trans-
mission at the valve and transmission ends.
B. Disconnect the hose (53) between the transmission oil filter

and control valve at the valve end.
C. Disconnect the transmission pump outlet hose (54) at the pump end.
D. Disconnect the hoses (55, 56 and 57) between the parking

brake emergency release valve and the parking brake at the
parking brake control valve hose end.
★ Remove the clamps mounted at the transmission and rear
frame.
E. Remove the mounting bolts of the transmission filler tube (58),

rotate it to the transmission side, then lock it in place with the
mounting bolts.
WA450-3MC 30-33 2
12
13. Drive shaft removal
A. Disconnect the center drive shaft (59) at the transmission end.
★ Move the disconnected drive shaft to the side.
Center drive shaft: 32 kg (70.5 lb)
B. Remove the rear drive shaft (60).
Rear drive shaft: 19 kg (42 lb)
★ Etch matching marks on both the center and rear couplings

to aid reassembly later.
14. Torque converter and transmission assembly
A. Install a block ➀ between the bottom of the engine flywheel

and the rear axle to prevent the engine from falling when trans-
mission and torque converter are removed.
30-34 2 WA450-3MC
B. Install eyebolts to top of transmission oil filter and top of the
pump mounting gear case of the torque converter and transmis-
sion assembly (61).
Torque converter, transmission assembly

(including pump, filter, etc.): 1,070 kg (2,359 lb)
C. Remove mounting bolts (62) of torque converter and transmis-

sion case, and engine flywheel housing.
D. Remove mount bolts (63) and (64) of torque converter and

transmission assembly, and raise approximately 200 mm, then
remove mount bracket (65).
★ Do this on both the left and right.
E. Lift off torque converter and transmission assembly (61).

★ Check that it does not hit against any other parts, and lift
off slowly.
★ Check that all parts have been removed before lifting off.
WA450-3MC 30-35 2
12
INSTALLATION
Air conditioner unit hose:

29.4 - 34.3 N•m (21.7 - 25.3 lbf ft)
Receiver hose: New refrigerant compressor oil (ND-OIL8)
Receiver hose: New refrigerant compressor oil (ND-OIL8)
Cable locknut: 53.9 ± 5 N•m (39.8 ± 3.7 lbf ft)
★ Align securely with the notch hole of the viscous damper washer, then tighten.
Air conditioner condenser hose: New refrigerant compressor

oil (ND-OIL8)
Air conditioner unit hose:

19.6 - 24.5 N•m (14.5 - 18.1 lbf ft)
★ Use only new O-rings.

★ Install the clamps before connecting the hoses and tubes.
30-36 2 WA450-3MC
12
Mounting bolt: 112.8 ± 9.8 N•m (83.2 ± 7.2 lbf ft)
★ Check that the match marks are aligned.
★ Remove the block at the bottom of the flywheel housing.
★ Use only new O-rings.
Mounting bolt: 68.6 ± 5 N•m (50.6 ± 3.7 lbf ft)
★ Align the pin hole securely.
Mounting hole of bracket (65):

279.5 ± 29.4 N•m (206.1 ± 21.7 lbf ft)
Mounting bolt (63):

926.7 ± 103 N•m (683.5 ± 76.0 lbf ft)
★ Adjust so that the clearance a at the center bolt (64) = 1.0 - 1.5
mm (0.039 - 0.059 in.)
Set bolt: 122.6 ± 24.5 N•m (90.4 ± 18.1 lbf ft)
Set bolt: Thread-tightener (LT-2)
• Refill with hydraulic oil
A. Tighten the drain plugs (1 and 2) at the top of the hydraulic tank
filter.
B. Add hydraulic oil through the oil filler to the specified level.
• Bleed the brake line and the steering line as described in Section 20, TESTING AND ADJUSTING
WA450-3MC 30-37 2
12
• Observe and follow these precautions when recharging the a/c system:
lower.
★ Always use the repeat vacuum method to completely evacuate the system.
★ (Vacuum attained: Minimum 750 mmHg
30-38 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-39 2
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
12
TORQUE CONVERTER
DISASSEMBLY
1. Turbine case assembly
A. Remove the stator shaft and pump assembly (2) from the tur-
bine and case assembly (3).
B. Disassemble the turbine and case assembly as follows.
i. Remove the pilot (4).
ii. Remove the snap ring (5), then remove the plate (1).
iii. Push the boss portion of turbine (6) and remove it from
case (7).
30-40 2 WA450-3MC
iv. Remove the mounting bolts and disconnect the turbine (6)
and boss (18).
v. Remove the bearing (8) from the case.
2. Stator
A. Remove the snap ring (9).
B. Remove the stator (10).
3. Use jacking screws ➀ to push from the stator shaft (11) end and dis-
connect it from the pump assembly (12).
4. Remove the gear (13) from the pump (14).
WA450-3MC 30-41 2
12
5. Remove the bearing (15) from the gear (13).
ASSEMBLY
1. Assemble the bearing (15) to the gear (13).
2. Assemble the gear (13) to the pump.
3. Stator shaft
A. Assemble the seal ring (16) to the stator shaft (11).
Seal ring: Grease (G2-L1)
★ Ensure that the extension of the seal ring is uniform.
30-42 2 WA450-3MC
12
B. Push the inner race end of the bearing and assemble the pump
assembly (12) to the stator shaft (11).
4. Stator
A. Install stator (10).
B. Install snap ring (9).
5. Turbine and case assembly
A. Assemble the turbine and case assembly as follows.
i. Assemble the bearing (8) to the case.

★ Press-fit until the ring contacts the case.
ii. Assemble the boss (18) to the turbine (6).
Mounting bolt: Thread tightener (LT-2)
WA450-3MC 30-43 2
iii. Push the inner race of the bearing and install the turbine
(6) to the case (7).
iv. Fit the plate (1) and install the snap ring (5).
v. Install the pilot (4).
B. Install the turbine and case assembly (3) to the stator shaft and
pump assembly (2).
Mounting bolt: Thread-tightener (LT-2)
30-44 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-45 2
DISASSEMBLY AND ASSEMBLY TRANSMISSION
12
TRANSMISSION
DISASSEMBLY
1. Coupling
A. Pull out the lower rear coupling (1).
B. Remove the lower front coupling (2) and mounting bolt (3),
then remove the coupling.
C. Remove the sensors.
2. Remove the mounting bolts (5) of the accumulator valve (4), then
remove the accumulator valve and gasket.
★ Protect the valve in a plastic bag or similar manner to prevent
the entry of dirt and debris.
A. Remove the control valve inlet elbow (6) and elbow (7) which
goes to the cooler.
B. Remove the mounting bolt (9) marked with ~ in the accompa-

nying illustration of the control valve (8). Install an eyebolt,
then sling the control valve assembly.
★ Eyebolt: M = 12 mm
Transmission control valve: 55 kg (121 lb)
C. Remove the mounting bolts (9) and remaining bolts (marked

with ▲), then lift off the control valve assembly.
★ Protect the valve in a plastic bag or similar manner to pre-
vent the entry of dirt and debris.
4. Remove the mounting bolts (11) of the flow valve (10), then
remove the flow valve and O-ring.
★ Remove the hose from the pump and the hose from the oil fil-
ter.
• Tag the hoses while completing the disconnections to ease
★ Protect the valve in a plastic bag or similar manner to prevent
the entry of dirt and debris.
5. Transmission oil filter
A. Remove the inlet and outlet hoses of the oil filter (12).
★ Tag the hoses while completing the disconnections to ease reconnections later.
B. Remove the mounting bolt of the bracket (13), then remove the bracket together with the oil filter.
30-46 2 WA450-3MC
6. Remove the mounting bolts (15) of the filler tube (14), then remove the filler tube.
7. Transmission and torque converter charging pump
A. Remove the delivery hose (20) and the hose (19) and tubes (17
and 18) at the suction end of the charging pump.
B. Remove the mounting bolts (21) of the charging pump (16),

then remove the pump and O-ring.
★ Protect the valve in a plastic bag or similar manner to pre-
vent the entry of dirt and debris.
8. Install the transmission assembly to a support stand.
Transmission assembly: 950 kg (2,094 lb)
★ Be sure to support the transmission where shown in the illus-

tration.
9. Remove the mounting bolts of the torque converter case (22), then
remove the torque converter case from the transmission case.
★ To prevent damage, lift the torque converter case slowly and
perpendicular to the transmission case
Torque converter case: 160 kg (353 lb)
WA450-3MC 30-47 2
12
Torque Converter
1. Torque converter
A. Remove the 6 bolts installing the torque converter case (22)

and the torque converter.
B. Fit the lifting tool to the gear portion of the drive case (24) of
the torque converter assembly (23) and lift off the drive case
from the torque converter case (22).
Torque converter assembly: 56 kg (123 lb)
2. PTO gear
A. PTO idler assembly
i. Remove the lock bolts (26) of the idler shaft (25), then
remove the idler shaft, O-ring and gear assembly (28).
ii. Remove the nut (29) from the gear assembly (31), then
remove the idler hub (30).
iii. Remove the snap ring (32) and spacer (33) from the gear
(31), then remove the bearing (34).
30-48 2 WA450-3MC
12
B. PTO gear
i. Remove the snap ring (35), then the lower ring (36), and
remove the split spacer (37).
ii. Pull out the shaft (38) and remove the gear (39).
iii. Remove the snap rings (40 and 42), then remove the bear-
ings (41 and 43).
iv. Remove the PTO gear on the opposite side in the same
manner.
WA450-3MC 30-49 2
12
Transmission
1. Remove the input shaft assembly.
2. 1st, FORWARD clutch
A. Remove the seal rings (1) from the clutch shaft.
B. Install the lifting tools A1, A2 and A3 to the 1st, FORWARD

clutch shaft, then lift off the clutch.
1st, FORWARD clutch: 76.5 kg (168.7 lb)
3. Install the lifting tools A1, A2 and A3 to the 2nd, REVERSE clutch
shaft and 3rd, 4th clutch shaft, then lift off the clutches at the same
time and remove them.
2nd, REVERSE clutch: 91 kg (201 lb)
3rd, 4th clutches: 96 kg (212 lb)
4. Driven gear
A. Install a puller to the countershaft (2) and bearing (3), remove

the bearing, then remove the gear (4) from the shaft.
B. Remove the snap ring (5), then remove the gear (6).
C. Remove the shaft (2), then use a puller to remove the bearing
(7).
★ When positioning the puller, use a block at the end face of
the clutch shaft during the removal.
WARNING! There is oil on the shaft and gears. Be

careful to prevent them from slipping.
Equipment damage may result if the
gears or shaft are dropped.
5. Disassemble the parking brake. for details, see PARKING BRAKE, Disassembly, elsewhere in this section.
30-50 2 WA450-3MC
6. Output shaft
A. Remove the mounting bolts (9) of the gear cover (8), then
remove the cover.
B. Thread an eyebolt into the end of the output shaft (10), then use
the eyebolt to lift the output shaft free.
Output shaft (including gear): 33 kg (73 lb)
C. Remove the snap ring (12) from the output gear (11), use a
puller to remove the inner bearing (13), then remove the output
gear from the shaft.
D. Use a puller to remove the inner bearing (14) from the opposite
side of the output shaft.
★ When positioning the puller, use a block at the end face of
the shaft during the removal.
WARNING! There is oil on the shaft and gears.

Be careful to prevent them from slip-
ping. Equipment damage may result
if the gears or shaft are dropped.
E. Remove the bearing outer race (15) from the transmission case.
F. Remove the oil seal (16) and dust seal (17) from the rear cou-
pling.
WA450-3MC 30-51 2
12
A. Remove the O-rings (17-1 and 18) from the transmission case.
B. Remove the bearing (19) and snap ring (20) of the driven gear
from the case.
30-52 2 WA450-3MC
12
ASSEMBLY
A. Press-fit the bearing (19) of the driven gear to the transmission

case, then install the snap ring (20).
B. Install the O-rings (17-1 and 18) to the transmission case.
2. Output shaft
A. Press-fit the bearing outer race (15) to the transmission case.
B. Press-fit the bearing inner race (14) at the output shaft rear
coupling end.
★ Press-fit the bearing securely so that there is no clearance
at the end-face of the bearing.
C. Install the snap ring (12) to the output shaft (10), then install
the output gear (11) and press-fit the inner bearing (13).
WA450-3MC 30-53 2
12
D. Thread an eyebolt into the end of the output shaft (10), then use
the eyebolt to lift and install the shaft to the transmission case.
E. Install the gear cover (8) to the case with the mounting bolt (9).
3. Assemble the parking brake. For details, see PARKING BRAKE

ASSEMBLY later in this section.
4. Install the rear coupling oil seal (16) and dust seal (17) to the trans-
mission case so that they are at the position given below:
★ a: 50 ± 0.2 mm (2.00 ± 0.008 in.)
★ b: 35 ± 0.2 mm (1.38 ± 0.008 in.)
Oil seal, lip of dust seal: Grease (G2-L1)
5. Counter gear
A. Install the snap ring (5) and gear (6) to the shaft (2), then press-
fit the bearing (7).
B. Install the snap ring and gear (4) onto the opposite end of the
shaft (2), then press-fit the bearing (3).
6. Install lifting tools A2 and A3 to the 2nd, REVERSE clutch shaft

and the 3rd, 4th clutch shaft, raise the clutches at the same time, and
install them in the transmission case.
★ Use the lifting tool to raise the 2nd, REVERSE and 3rd, 4th
clutches at the same time, and turn the 3rd, 4th clutches at an
angle to allow assembly.
7. Install lifting tools A1 and A3 to the 1st, FORWARD clutch shaft,

then install the clutch in the transmission case.
30-54 2 WA450-3MC
8. Install the seal rings (1) to the shafts of the 1st, FORWARD clutch
shaft, then install the 2nd, REVERSE clutch and then the 3rd, 4th
clutch.
9. Assemble the input shaft assembly and gear to the transmission

case.
★ Installed dimension of the input shaft bushing:
c = 2.0 ± 0.5 mm (0.079 ± 0.020 in.)
★ Press-fit securely so that there is no clearance at the end face of
the bearing.
A. PTO gear
i. Install the bearings (41 and 43) to the case, then secure
them with snap rings (40 and 42).
★ Press-fit securely so that there is no clearance at the
end face of the bearing.
ii. Set the gear (39) inside the case, and insert the shaft (38)
from the outside of the case.
★ Be careful of the gear mounting position.
iii. Set the split spacer (37) in position, then install the ring (36) and secure it with a snap ring (35).
WA450-3MC 30-55 2
B. PTO idler assembly
i. Press-fit the bearing (34) to the gear (31), then install the
spacer (33) and secure it with a snap ring (35).
★ Be sure to include the spacer in the assembly.
★ Press-fit securely so that there is no clearance at the
end face of the bearing.
ii. Install the idler hub (30) to the gear assembly and tighten
with nut (29).
Nut: 784.5 ± 49.0 N•m (578.6 ± 36.1 lbf ft)
iii. Set the gear assembly (28) inside the case, insert the O-
ring in the case, install the idler shaft (25), and tighten
with lock bolts (26).
Idler shaft mounting bolt:

112.8 ± 4.9 N•m (83.2 ± 3.6 lbf ft)
C. Torque converter
i. Install the lifting tool to the gear portion of the drive case
(24) of the torque converter assembly (23), and set it to the
torque converter case (22).
ii. Tighten the bolts (22-1) that secure the torque converter
case (22) and torque converter.
Torque converter mounting bolt:

112.8 ± 9.8 N•m (83.2 ± 7.2 lbf ft)
30-56 2 WA450-3MC
12
11. Coat the flange surface of the transmission case with gasket sealant,
then set the torque converter case (22) in position and tighten the
mounting bolts.
Transmission case flange surface:

Gasket sealant (Three Bond 1207B)
Torque converter case mounting bolt:

112.8 ± 9.8 N•m (83.2 ± 7.2 lbf ft)
WA450-3MC 30-57 2
12
12. Transmission, torque converter charging pump
A. Install the O-ring to the charging pump (16), then set the pump
to the transmission case and tighten the mounting bolts (21).
★ Before installing the pump, insert the pump drive shaft
inside the torque converter input shaft assembly.
Pump mounting bolt:

279.4 ± 29.4 N•m (206.1 ± 21.7 lbf ft)
B. Install O-rings to the tubes (17 and 18) at the suction side of the
charging pump (16), then connect the hose (19) and tighten it.
Install the O-ring to the hose (20) at the discharge side also,
then tighten it.
Tube (17, 18) mounting bolt:

112.8 ± 9.8 N•m (83.2 ± 7.2 lbf ft)
Hose clamp: 4.4 ± 0.5 N•m (3.2 ± 0.4 lbf ft)
13. Fit the filler tube (14) with the mounting bolt (15) temporarily, and
move the tube towards the inside of the transmission.
★ After mounting the transmission on the machine, move the
filler tube to the specified position.
14. Transmission oil filter
A. Install the oil filter bracket (13) and filter to the transmission.
Oil filter mounting bolt: 68.6 ± 4.9 N•m

(50.6 ± 3.7 lbf ft)
Filter bracket mounting bolt:

112.8 ± 9.8 N•m (83.2 ± 7.2 lbf ft)
B. Install the inlet and outlet hoses to the oil filter (12).
Hose connection: 176.5 ± 29.4 N•m (130.2 ± 21.7 lbf ft)
30-58 2 WA450-3MC
12
A. Install the gasket to the transmission end, then thread an eye-

bolt into the part of the control valve (8) marked with a in the
illustration, and set the valve to the transmission.
B. Remove the eyebolt and install mounting bolts to the locations

marked with ▲ and ~, then tighten the mounting bolts.
Flow valve mounting bolt: Thread tightener (LT-2)
Flow valve mounting bolt:

34.3 ± 4.9 N•m (25.3 ± 3.6 lbf ft)
C. Install the elbow (7) which leads to the cooler and the inlet elbow (6) to the control valve.
16. Install an O-ring to the flow valve (10), then install the valve to the
transmission case with mounting bolts (11).
Flow valve mounting bolt: Thread tightener (LT-2)
Flow valve mounting bolt:

34.3 ± 4.9 N•m (25.3 ± 3.6 lbf ft)
17. Install an O-ring to the accumulator valve (4) and secure it in place
with mounting bolts (5)
18. Couplings
A. Install the front coupling (2) to the output shaft and tighten the O-ring and washer with a coupling mounting bolt (3).
Coupling mounting bolt:

926.2 ± 98.1 N•m (683.5.1 ± 72.4 lbf ft)
B. Install the rear coupling (1) to the rear end of the output shaft.
WA450-3MC 30-59 2
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
12
TRANSMISSION CLUTCH PACK
DISASSEMBLY
FORWARD, 1st Clutch Assembly
1. Assembly of FORWARD clutch pack assembly

★ Use tools A1 and A2 to lift the clutch pack assembly, and
install the assembly to the lifting stand 1.
FORWARD, 1st clutch assembly: 76.5 kg (168.7 lb)
A. Remove 3 seal rings (1) installed to shaft.
B. Bearing, thrust washer
i. Install puller to end face of shaft, and remove bearing (2).

★ When setting the puller in position, install a block to
the end face of the clutch shaft before proceeding.
ii. Remove the thrust washer (3) and spacer (4) from the
shaft.
C. Needle bearing, FORWARD gear
i. Remove needle bearing (5) and FORWARD gear (6) from

the shaft.
ii. Remove the thrust washer (7) and spacer (7-4).
30-60 2 WA450-3MC
12
D. Push the end plate (8) with tool 2 (in diagram below), remove
snap ring (9), then remove the end plate (8) from the clutch
case (10).
E. Remove the separator plates (12), disc plates (11) and wave
springs (13) from inside clutch (10).
★ Be careful not to let the separator plates or disc plates
catch in the clutch case ring groove.
F. Remove the FORWARD piston (14) from inside clutch case,

then remove piston seals (15) and (16) from piston.
WA450-3MC 30-61 2
2. Disassembly of 1st clutch pack
★ Turn over the FORWARD clutch case and set it to the stand 3
WARNING! There is oil on the clutch pack, so be

careful not to let it slip when turning it
over.
A. Bearing, thrust washer
i. Remove roller bearing and outer race, then install puller to

end face of shaft, and remove bearing inner (17).
the end face of the clutch shaft before carrying out the
operation.
ii. Remove thrust washer (18) and spacer (19) from shaft.
B. Needle bearing, 1st gear
i. Remove needle bearing (20) and 1st gear (21) from the
shaft.
ii. Remove thrust washer (22) and spacer (22-1).
C. Push the end plate (8) towards the 1st clutch end with the tool
2, remove the snap ring (9), then remove end plate from the
clutch case (10).
30-62 2 WA450-3MC
12
D. Remove separator plates (12), disc plates (11), and wave
springs (13) from inside clutch case (10).
E. Remove 1st piston (23) from inside clutch case, then remove
piston seals (24) and (25) from piston.
★ The shape of the 1st piston is different from the shape of
the FORWARD piston on the opposite side.
REVERSE, 2ND CLUTCH ASSEMBLY
1. Disassembly of the REVERSE clutch pack

★ Use tools A1 and A2 to lift the clutch pack assembly and install
it to the stand 1.
REVERSE, 2nd clutch assembly: 90 kg
A. Remove the 3 seal rings (1) installed to the shaft.
i. Install puller to the end face of shaft, and remove the bear-
ing (2).
operation.
WA450-3MC 30-63 2
12
C. Needle bearing, REVERSE gear
i. Remove needle bearing (5) and REVERSE gear (6) from

shaft.
ii. Remove thrust washer (7) and spacer (7-1)
D. Push the end plate (8) with tool 2, remove snap ring (9), then
remove end plate from clutch case (10).
E. Remove the separator plates (12), disc plates (11), and wave
springs (13) from inside clutch case.
F. Remove the REVERSE piston (14) from inside clutch case,

then remove piston seals (15) and (16) from piston.
30-64 2 WA450-3MC
12
2. Disassembly of 2nd clutch pack
★ Turn over the REVERSE clutch case and set it to the stand
3.

over.

operation.
B. Needle bearing, 2nd gear
i. Remove needle bearing (20) and 2nd gear (21) from shaft.
C. Push the end plate (8) at 2nd clutch end with tool 2, remove
snap ring (9), then remove end plate from clutch case (10).
WA450-3MC 30-65 2
D. Remove the separator plates (12), disc plates (11), and wave
E. Remove the 2nd piston (23) from inside the clutch case, then
remove piston seals (24) and (25) from the piston.
★ The shape of the 2nd piston is different from the shape of
the REVERSE piston on the opposite side.
3RD, 4TH CLUTCH ASSEMBLY
1. Disassembly of 4th clutch pack

★ Lift the clutch pack assembly with lifting tools A1 and A2, and
install to stand 1.
3rd, 4th clutch assembly: 96 kg (211.6 lb)
A. Remove the 3 seal rings (1) installed to the shaft.
i. Install the puller to end face of shaft, and remove bearing

(2).
operation.
shaft.
30-66 2 WA450-3MC
C. Needle bearing, 4th gear
i. Remove the needle bearing (5) and 4th gear (6) from the
shaft.
ii. Remove the thrust washer (7) and spacer (7-1).
D. Push the end plate (8) with tool 2, remove the snap ring (9),
then remove end plate from the clutch case (10).
E. Remove the separator plates (12), disc plates (11), and wave
F. Remove the 4th piston (14) from inside clutch case, then
remove piston seals (15) and (16) from the piston.
WA450-3MC 30-67 2
2. Disassembly of the 3rd clutch pack
★ Turn over the 4th clutch case and set to stand 3.

over.

operation.
shaft.
B. Needle bearing, 3rd gear
i. Remove the needle bearing (20) and 3rd gear (21) from the
shaft.
3rd gear: 29 kg (63.9 lb)
C. Push the end plate (8) at 3rd clutch end with tool 2, remove
snap ring (9), then remove the end plate from the clutch case
(10).
30-68 2 WA450-3MC
D. Remove separator plates (12), disc plates (11), and wave
E. Remove the 3rd piston (23) from inside clutch case, then
remove piston seals (24) and (25) from piston.
★ The shape of the 3rd piston is different from the shape of
the 4th piston on the opposite side.
WA450-3MC 30-69 2
12
ASSEMBLY
FORWARD, 1ST CLUTCH ASSEMBLY
When assembling the FORWARD, 1st clutch, always check dimen-

sion A of the FORWARD clutch case.
• A: 90.5 mm (3.56 in.)
1. Assembly of FORWARD clutch pack
A. Install piston seals (15) and (16) to FORWARD piston (14),

then install inside clutch case.
★ Use only new piston seal rings.
★ After assembling the seal rings to piston, set to tools A4

and A5 and settle for at least 5 seconds.
★ Carry out the settling operation for each piston.
Outer circumference of seal ring, contact surface:

Oil (EO10-CD)
30-70 2 WA450-3MC
B. Install separator plates (12), disc plates (11), and wave springs
(13) inside clutch case (10).
★ Before assembling the clutch disc plates, put them in a
soaking bath for at least 2 minutes.
• Oil: EO10-CD (API 10W-CD Class or above)
C. Assemble the end plate (8) to the clutch case (10), then use tool
2 to push the end plate into place, then secure it with a snap
ring (9).
D. Needle bearing, FORWARD gear
i. Assemble the spacer (7-1) and thrust washer (7) inside

clutch case in order.
★ Warm the spacer to 80 - 120 °C (176 - 248 °F) for
approximately 80 minutes before assembling.
Thrust washer (7): Oil (EO10-CD)
ii. Install the FORWARD gear (6) to the shaft, then assemble
the needle bearing (5).
WA450-3MC 30-71 2
12
E. Bearing, thrust washer
i. Assemble the thrust washer (3) and spacer (4) to the shaft
in the order.
★ Warm the bearing (2) and spacer (4) to 80-120 °C
(176-248 °F) for approximately 80 minutes before
assembling them to the shaft.
★ Check that there is no clearance when press-fitting the
bearing.
ii. Press-fit the bearing (2) to the shaft.

★ Check the dimension of clearance B between the spacer (4) and thrust washer (3) after press-fitting the bear-
ing.
★ B: 0.27 - 1.23 mm (0.011 - 0.048 in.) (FORWARD clutch end)
F. Install the 3 seal rings (1) to the shaft.
2. Assembly of 1st clutch pack
A. Install piston seals (24) and (25) to the 1st piston (23), then
install inside clutch case.
★ Replace the piston seal rings with new parts.
30-72 2 WA450-3MC
★ Perform the settling operation for each piston.

Oil (EO10-CD)
B. Install separator plates (12), disc plates (11) and wave springs
★ Before assembling clutch disc plates (1), soak them in a
bath for at least 2 minutes.
★ Oil: EO10-CD (API 10W-CD Class or above)
C. Assemble the end plate (8) to the clutch case (10), then push
with tool 2, and secure with a snap ring (9).
D. Needle bearing, 1st gear
i.Assemble spacer (22-1) and thrust washer (22) inside

★ Before assembling the spacer, warm it up at 80 - 120 °C
(176 - 248 °F) for 80 minutes.
ii. Install the 1st gear (21) to the shaft, then assemble the nee-
dle bearing (20).
WA450-3MC 30-73 2
i.Assemble the thrust washer (18) and spacer (19) to shaft in

order.
★ Before assembling bearing (17) and spacer (19), warm
them up at 80 - 120 °C (176 - 248 °F) for 80 minutes.
★ When press-fitting the bearing, check that there is no
clearance.
ii. Press-fit the bearing (17) to the shaft.

★ After press-fitting the bearing, check the dimension of clearance C between spacer (19) and thrust washer (18).
★ C: 0.14 - 1.36 mm (0.006 - 0.054 in.) (1st clutch end)
REVERSE, 2ND CLUTCH ASSEMBLY

When assembling the REVERSE, 2nd clutch, always check dimension
D of the REVERSE clutch case.
★ D: 90.5 mm (3.56 in.)
1. Assembly of REVERSE clutch pack
A. Install piston seals (15) and (16) to REVERSE piston (14),

then install inside clutch case.
30-74 2 WA450-3MC

Oil (EO10-CD)
★ Before assembling the clutch disc plates (11), soak them in
a bath for at least 2 minutes.
C. Assemble the end plate (8) to clutch case (10), then push with
tool 2, and secure with snap ring (9).
Thrust washer: Oil (EO10-CD)
D. Needle bearing, REVERSE gear
i.Assemble spacer (7-1) and thrust washer (7) inside clutch

case in order.
(176 - 248 °F) for 80 minutes.
ii. Install REVERSE gear (6) to shaft, and assemble needle

bearing (5).
WA450-3MC 30-75 2
i.Assemble thrust washer (3) and spacer (4) to shaft in

order.
★ Before assembling bearing (2) and spacer (4), warm them
up at 80 - 120 °C (176 - 248 °F) for 80 minutes.
clearance.
ii. Press-fit bearing (2) to shaft.

★ After press-fitting the bearing, check the dimension of clearance E between spacer (4) and thrust washer (3).
★ E: 0.27 - 1.23 mm (0.011 - 0.048 in.) (REVERSE clutch end)
F. Install the 3 seal rings (1) to shaft.
2. Assembly of 2nd clutch pack
A. Install piston seals (24) and (25) to 2nd piston (23), then install
to clutch case.
30-76 2 WA450-3MC
Outer circumference of seal ring, contact surface: Oil (EO10-

CD)
★ Before assembling clutch disc plates (11), put them in a
C. Assemble end plate (8) to clutch case (10), then push with tool
2, and secure with snap ring (9).
D. Needle bearing, 2nd gear
i.Assemble spacer (22-1) and thrust washer (22) inside

(176 - 248 °F) for 80 minutes.
ii. Install 2nd gear (21) to shaft, and assemble needle bearing
(20).
WA450-3MC 30-77 2
i. Assemble thrust washer (18) and spacer (19) to shaft in

order.
★ Before assembling bearing (17) and spacer (19),
warm them up at 80 - 120 °C (176 - 248 °F) for 80
minutes.
clearance.

★ After press-fitting the bearing, check the dimension of clearance F between spacer (19) and thrust washer (18).
★ F: 0.34 - 1.56 mm (0.013 - 0.061 in.) (2nd clutch end)
3RD, 4TH CLUTCH ASSEMBLY
1. Assembly of 4th clutch pack
A. Install piston seals (15) and (16) to 4th piston (14), then install
inside clutch case.


Oil (EO10-CD)
30-78 2 WA450-3MC
★ Oil: EOI O-CD (API 10W-CD Class or above)
D. Needle bearing, 4th gear
i. Assemble spacer (7-1) and thrust washer (7) inside clutch

case in order.
★ Before assembling the spacer, warm it up at 80 - 120
°C (176 - 248 °F) for 80 minutes.
ii. Install 4th gear (6) to shaft, and assemble needle bearing
(5).

order.
★ Before assembling bearing (2) and spacer (4), warm
them up at 80 - 120 °C (176 - 248 °F) for 80 minutes.
clearance.
WA450-3MC 30-79 2
★ After press-fitting the bearing, check the dimension of
clearance G between spacer (4) and thrust washer (3).
★ G: 0.37 - 1.33 mm (0.015 - 0.052 in.) (4th clutch end)
F. Install 3 seal rings (1) to shaft.
2. Assembly of 3rd clutch pack
A. Install piston seals (24) and (25) to 3rd piston (23), then install
to clutch case.


Oil (EO10-CD)
30-80 2 WA450-3MC
D. Needle bearing, 3rd gear
i. Assemble spacer (22-1) and thrust washer (22) inside

★ Before assembling the spacer, warm it up at 80 - 120
°C (176 - 248 °F) for 80 minutes.
ii. Install 3rd gear (21) to shaft, and assemble needle bearing
(20).

order.
★ Before assembling bearing (17) and spacer (19),
warm them up at 80 - 120 °C (176 - 248 °F) for 80
minutes.
clearance.
WA450-3MC 30-81 2
★ After press-fitting the bearing, check the dimension of
clearance H between spacer (19) and thrust washer
(18).
★ H: 0.34 - 0.56 mm (0.013 - 0.022 in.) (3rd clutch end)
30-82 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-83 2
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
12
PARKING BRAKE
DISASSEMBLY

from moving.
★ Release the parking brake before continuing.
1. Loosen drain plug and drain transmission oil.
Transmission: 40 L (10.6 U.S. gal.)
2. Remove the drive shaft guard and disconnect lower front drive
shaft (1) at transmission end.
★ Move the disconnected drive shaft to the right end.
3. Suction tube
A. Remove mounting bolt (3) and washer (4) of coupling (2) at

front end of transmission, then remove coupling.
B. Remove suction tube (5) at transmission end.
4. Parking brake
A. Remove lock plates (7) of manual release bolts (6) and parking
brake, then remove 3 release bolts (6).
B. Remove parking brake case (8).
30-84 2 WA450-3MC
C. Remove mounting bolts (10) of housing (9), then remove the
housing.
D. Remove spline hub (12) and piston (13) from output shaft (11),
then remove springs (14) and (15).
E. Remove mounting bolts (17) of retainer (16), then remove

retainer and shim (18).
★ Check the number and thickness of the shims, and keep in
a safe place.
★ Sling the output shaft to prevent it from falling.
F. Remove bearing race from retainer (16), then remove bearing

inner race from output shaft (11).
WA450-3MC 30-85 2
12
ASSEMBLY
1. Parking brake
A. Press-fit bearing outer race to retainer (16), and bearing inner

race to the output shaft (11).
B. Install output shaft to transmission case, then insert shim (18)

in retainer (16), and tighten with mounting bolts (17).
★ Keep the output shaft horizontal when raising it.
C. Adjusting shim
i. Assemble shim of standard value, then tighten the retainer

(16) with 3 bolts.
★ Standard shim thickness: 1.2 mm (0.047 in.)
★ Assemble retainer (16) so that the 4 casting holes are

at the bottom.
ii. Adjust shim so that rotating torque of output shaft is 9.8 -

98.1 N•cm (0.80 - 8.7 lbf in.).
★ When doing this, check that there is no end play.
D. Install springs (14) and (15) to retainer, then install piston (13)
and spline hub (12) to output shaft (11).
Tip of spline hub: Grease (LM-G)
30-86 2 WA450-3MC
E. Set brake housing assembly (9) to transmission front case, and
install brake piston pushing tool 4.
F. Push in piston (13) with bolt of pushing tool, and tighten with 3
housing mounting bolts (10).
★ Mesh the spline hub and disc before starting.
G. Install the parking brake case (8).
H. Install the parking brake manual release bolts (6), and secure
them with lock plates (7).
2. Suction tube
A. Install the suction tube (5).

★ Use a new O-ring.
WA450-3MC 30-87 2
12
3. Tighten transmission front coupling (2), O-ring and washer (4) with
mounting bolt (3).
End face of coupling: Anti-friction compound (LM-G)
4. Drive shaft
A. Connect front drive shaft (1).

★ Clean the connection and mating surface of the drive shaft
before installing.
Drive shaft: 112.8 ± 9.8 N•m (83.2 ± 7.2 lbf ft)
B. Install drive shaft guard.
5. Refilling with oil
A. Tighten drain plug and add transmission oil.
★ Run the engine to circulate the oil through the system. Then check the oil level again.
30-88 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-89 2
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
12
TRANSMISSION CONTROL VALVE
REMOVAL

from moving.
WARNING! Disconnect the cable from the negative

terminal (-) of the battery.
1. Remove left ladder (1).
Ladder (left): 59.5 kg (131.2 lb)
2. Covers
A. Remove left side cover of rear frame.
B. Remove bottom cover of cab.
C. Remove front cover (3-1) of bulkhead.
30-90 2 WA450-3MC
3. Electric wiring
A. Disconnect wiring TL1 (4) and TL2 (5) for transmission.
B. Disconnect floor wiring harnesses LR5 (6), LR6 (7), LR3 (8), LR4 (9), LR1 (10), and
LR2 (11).
C. Disconnect solenoid valve wiring (12) of transmission control

valve at connector.
★ Tag the connectors during disconnection to ease reconnec-
tion later.
WA450-3MC 30-91 2
12
4. Hydraulic piping
A. Disconnect hose (13) between transmission, torque converter

charging pump and the flow valve at flow valve end.
B. Disconnect hose (14) between flow valve and transmission oil

filter at flow valve end.
C. Disconnect hose (15) between transmission oil filter and trans-

mission control valve at the control valve end.
D. Disconnect hose (16) between transmission control valve and cooler at the control valve end.
★ Fit blind plugs in the hoses to prevent the entry of dirt or

dust.
5. Remove flow valve (17) from transmission case.
A. Remove the mounting bolt (18) and replace it with an eyebolt

(M: 12 mm).
B. Sling the control valve (20) in preparation for removal.
Transmission control valve: 55 kg (121 lb)
C. Remove the remaining mounting bolts (indicated by ▲ in the

illustration), then lift off the transmission control valve assem-
bly (20).
★ Remove the gasket from the control valve.
30-92 2 WA450-3MC
12
INSTALLATION
Hose connection: 176.5 ± 29.4 N•m (18.0 ± 3.0 lbf ft)
★ When installing the control valve, be careful not to bump the solenoid valve or other components.
★ Use a new gasket.
Mounting bolt (marked with ▲): Thread tightener (LT-

2)
WA450-3MC 30-93 2
12
DISASSEMBLY
1. Remove mounting bolt (3) (marked with ▲) of the upper valve
assembly, then remove the gasket (4).
★ After gasket removal, cover the valve opening with tape to pre-
vent the entrance of dirt or dust.
2. Upper valve disassembly
A. Manual valve
i. Loosen the mounting bolt (2) of the lock plate (1), remove
the lock plate, pull out the manual valve spool (3), then
remove the O-ring (4).
ii. Remove the plug (5) from the valve body.
B. Electronically-controlled modulation valve (ECMV)
i. Remove mounting bolts (7) of ECMV (6), then remove

valve and O-ring (8).
ii. Remove mounting bolts (10) of connector bracket (9),

then remove the bracket.
iii. Remove the remaining mounting bolt (10) of the upper left
cover (11), then remove the cover and gasket (12).
★ After gasket removal, cover the valve opening with
tape to prevent the entrance of dirt or dust.
30-94 2 WA450-3MC
C. Modulation valve
i. Remove the modulation valve (14) from the upper valve

body (13).
ii. Remove the spring (15) and modulation piston (16) from
the modulation valve (14).
★ After removal, cover the opening with tape to prevent
the entrance of dirt or dust.
D. Main relief valve
i. Remove the valves (18 and 19) and spring (20) from the
main relief valve (17). Then remove the main relief valve
from the valve body.
ii. Remove the main relief spring (21).

E. Remove the dummy spool (22), torque converter outlet spring

(23) and torque converter outlet valve (24) from the valve
body.
★ After removal, cover the opening with tape to prevent the
entrance of dirt or dust.
F. Pilot valve
i. Remove the mounting bolts (26) from the upper right

cover (25), then remove the cover and gasket (27).
ii. Remove the pilot valve (28) and pilot spring (29) from the
valve body.
WA450-3MC 30-95 2
3. Lower valve disassembly
A. Solenoid valve, pilot filter
i. Remove the directional selector solenoid valve (1) and O-

ring from the lower valve.
ii. Remove the Hi-Lo selector solenoid valve (2), the range
selector solenoid valve (3), and O-ring from the lower
valve.
iii. Remove the parking brake solenoid valve (4) and O-ring
from the lower valve.
iv. Remove the pilot filter from the lower valve.
B. Remove the mounting bolts (6) of lower left cover (5), then
remove the cover and gasket (7).
C. Directional selector valve
i. Remove front return spring (9) and sleeve (10) of direc-

tional valve from valve body (8), then remove the valve
spool (11).
30-96 2 WA450-3MC
D. Hi-Lo selector valve
i. Remove the spool (12) of Hi-Lo valve from the valve

body.
ii. Remove the plug (13) from the spool (12), then remove
the spring (14) and ball (15).
E. Range selector valve
i. Remove the spool (16) of the range selector valve from the
valve body.
ii. Remove the plug (17) from the spool (16), then remove
the spring (18) and ball (19).
F. Remove spool (20) and stopper (21) of priority valve from

valve body.
G. Remove spool (22) and return spring (23) of parking brake

valve from valve body.
WA450-3MC 30-97 2
H. Lower right cover
i. Remove mounting bolts (25) of lower right cover (24)

then remove cover and gasket (26).
ii. Remove the right return spring (27) and sleeve (28) of
directional valve, return springs (29 and 30) of the Hi-Lo
selector valve and range selector valve, and spring (31) of
priority valve from valve body.
30-98 2 WA450-3MC
12
ASSEMBLY
1. Assembly of lower valve assembly
A. Lower right cover
i. Install the right return spring (27) and sleeve (28) of direc-
tional valve, return springs (29 and 30) of Hi-Lo selector
valve and range selector valve, and spring (31) of priority
valve to the valve body.
★ Free height of spring (27): 42 mm (1.65 in.)
★ Free height of springs (29) and (30): 48 mm (1.89 in.)
ii. Install gasket (26), and tighten the lower right cover (24)
with mounting bolts (25).
Lower right cover mounting bolt:

31.4 ± 2.9 N•m (23.2 ± 2.1 lbf ft)
B. Install the spool (22) and return spring (23) of parking brake
valve to the valve body.
★ Free height of spring: 46 mm (1.81 in.)
Outside circumference of parking brake valve spool:

Oil (EO10-CD)
C. Install spool (20) and stopper (21) of priority valve into the
valve body.
Outside circumference of priority valve spool:

Oil (EO10-CD)
WA450-3MC 30-99 2
12
D. Range selector valve
i.Install the spring (18), ball (19), and plug (17) to the spool
(16).
★ Free height of spring: 23.5 mm (0.925 in.)
Range selector spool plug (17):

9.8 - 12.8 N•m (7.2 - 9.4 lbf ft)
Range selector spool plug (17):

Thread tightener (LT-2)
ii. Install the range selector valve spool (16) to the valve
body.
Outside circumference of range selector spool:

Oil (EO10-CD)
E. Hi-Lo selector valve
i. Install spring (14), ball (15), and plug (13) to spool (12).
★ Free height of spring: 23.5 mm (0.925 in.)
Hi-Lo selector spool plug (13):

9.8 - 12.8 N•m (7.2 - 9.4 lbf ft)
Hi-Lo selector spool plug (13):

Thread-tightener (LT-2)
ii. Install spool (12) of Hi-Lo valve to valve body.
Outside circumference of Hi-Lo selector spool:

Oil (EO10-CD)
F. Install the front return spring (9) and sleeve (10) of the direc-
tional selector valve to valve body (8), then install the valve
spool (11).
★ Free height of spring: 42 mm (1.65 in.)
Outside circumference of directional selector

valve spool: Oil (EO10-CD)
30-100 2 WA450-3MC
12
G. Install the gasket (7) to the valve body, and set the lower left
cover (5) in position, then tighten it in place with mounting
bolts (6).
Lower left cover mounting bolt:

31.4 ± 2.9 N•m (23.2 ± 2.1 lbf ft)
H. Solenoid valve, pilot filter
i. Install the pilot filter to the lower valve.
Filter mounting bolt: 68.6 ± 4.9 N•m

(50.6 ± 3.6 lbf ft)
ii. Install the O-ring to the lower valve, then install the park-
ing brake solenoid valve (4).
iii. Install the O-ring to the lower valve, then install the Hi-Lo
selector solenoid valve (2) and range selector solenoid
valve (3).
iv. Install the O-ring to the lower valve, then install direc-
tional selector solenoid valve (1).
★ Check that the O-ring is fitted securely.
★ Assemble the part of parking brake solenoid valve (4)
with the OUT stamp.
Solenoid valve (1) - (4): 1.7 ± 1 N•m

(1.25 ± 0.74 lbf ft)
WA450-3MC 30-101 2
12
2. Assembly of upper valve assembly
A. Pilot valve
i. Install pilot valve (28) and pilot spring (29) to the valve
body.
Outside circumference of pilot valve spool:

Oil (EO10-CD)
ii. Install gasket (27), and set the upper right cover (25) in
position, then tighten it in place with the mounting bolts
(26).
Upper right cover mounting bolt:

31.4 ± 2.9 N•m (23.2 ± 2.1 lbf ft)
B. Install the torque converter outlet valve (24), torque converter

outlet spring (23), and dummy spool (22) to the valve body.
Outside circumference of torque converter outlet

valve spool, dummy spool: Oil (EO10-CD)
C. Main relief valve
i. Install main valve spring (21).
ii.
Install valves (18) and (19), and spring (20) to main relief
valve (17), then install main relief valve (17) to valve
body.
Outside circumference of valves (18) and (19):

Oil (EO10-CD)
Outside circumference of main relief valve spool:

Oil (EO10-CD)
30-102 2 WA450-3MC
12
D. Modulation valve
i. Install spring (15) and modulation piston (16) to modula-

tion valve (14).
ii. Install modulation valve (14) to valve body (13).

Outside circumference of modulation valve spool, pis-

ton: Oil (EO10-CD)
E. Electronically-controlled modulation valve (ECMV)
i. Install gasket (12), and set upper left cover (11) in posi-
tion, then tighten with mounting bolts (10) together with
connector bracket (9).
★ Use a new part for the gasket.
Upper left cover mounting bolt:

31.4 ± 2.9 N•m (23.2 ± 2.1 lbf ft)
ii. Install O-ring (8), and tighten ECMV (6) with mounting
bolts (7).
★ Check that the O-ring is fitted securely.
ECMV mounting bolt (7):

11.8 - 14.7 N•m (8.7 - 10.8 lbf ft)
F. Manual valve
i. Install plug (5) to valve body.
ii. Assemble manual valve spool (3) and install O-ring (4),
then secure lock plate (1) with mounting bolt (2).
Outside circumference of manual valve spool:

Oil (EO10-CD)
Plug (4): 39.2 ± 4.9 N•m (28.9 ± 3.6 lbf ft)
Lock plate mounting bolt:

53.9 ± 19.6 N•m (39.8 ± 14.5 lbf ft)
WA450-3MC 30-103 2
3. Assembly of the upper and lower valve
Install the gasket (4), then install the upper valve assembly with the
mounting bolts (3) (indicated by ▲ in the illustration.
30-104 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-105 2
DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE
12
TRANSMISSION ACCUMULATOR VALVE
DISASSEMBLY
1. Remove mounting bolts (2) of cover (1) from accumulator valve
assembly, then remove cover and O-ring (3).
2. Accumulator valve
A. Remove accumulator valves (5) from FORWARD, 1st, and 2nd

ports in accumulator body (4).
B. Remove accumulator spring (6) and stopper (7) from FOR-

WARD port.
C. Remove accumulator spring (6) and stopper (7) from 1st port.
D. Remove accumulator spring (6) and stopper (7) from 2nd port
.
30-106 2 WA450-3MC
DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE
12
ASSEMBLY
1. Accumulator valve
A. Install accumulator spring (6) and stopper (7) to FORWARD,

1st and 2nd ports.
★ Free height of accumulator spring: 1st = 145 mm (5.71
in.); 2nd = 158 mm (6.22 in.); FORWARD = 185 mm
(7.28 in.)
★ Length of accumulator stopper: 1st = 105 mm (4.13 in.);
2nd = 125 mm (4.92 in.); FORWARD = 136 mm (5.35 in.)
B. Install accumulator valves (5) to each port.
Outside circumference of accumulator valve:

Oil (EO10-CD)
2. Install top cover (1) and O-ring (3) to accumulator body (4), and
tighten with mounting bolts (2).
Cover mounting bolt:

34.3 ± 4.9 N•m (25.3 ± 3.6 lbf ft)
WA450-3MC 30-107 2
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT ASSEMBLY
12
DRIVE SHAFT ASSEMBLY
DISASSEMBLY
A. Remove coupling and tube (1).

★ Make match marks a to prevent the coupling from being
installed in the opposite direction.
★ The cover (11) is caulked at 4 places with a punch, so do

not remove it unless necessary.
★ When removing cover (11), be careful not to damage
cover (11) or tube (1).
★ When removing the caulking, use a screwdriver to raise
the caulked portion.
B. Loosen bolt (2), and remove coupling (3) and retainer.

★ Make match marks to prevent the coupling from being
installed in the opposite direction.
C. Use a press to remove the flange bearing (4).
30-108 2 WA450-3MC
12
2. Center drive shaft, rear drive shaft
★ Carry out the same operation as in Step A for the front drive shaft.
★ When removing the rear drive shaft, push it in towards the transmission.
3. Spider, bearing
A. Remove bolts (6) of spider and bearing assembly (5), and tap
with plastic hammer to remove.
B. Remove strap (8) of spider (7), and pull out the bearing cap
(10).
★ Use the same procedure for the front, center, and rear drive
shafts.
WA450-3MC 30-109 2
12
ASSEMBLY
1. Spider, bearing
A. Insert bearing cap (10) in mount of spider (7).

★ If the spider and bearing cap is worn, replace the spider
and bearing as a set.
★ When welding strap (8) of the cap, be careful not to dam-
age the bearing with the heat.
★ Assemble so that the grease nipples are facing in the same
direction.
★ Use the same procedure for the front, center, and rear drive
shafts.
B. Set spider and bearing assembly (5) to the drive shaft mount,
and lock them in place with bolt (6).
Bearing cap: Grease (G2-L1)
A. Press-fit flange bearing (4).

★ Do not knock the flange bearing in directly with a ham-
mer.
B. Align match marks, and tighten coupling (3) and retainer (9)
with mounting bolt (2).
★ Torque the bolt as specified after installing to the machine.
Spline portion: Grease (G2-L1)
Mounting bolt:
926.7 ± 98.1 N•m (683.5 ± 72.4 lbf ft)
30-110 2 WA450-3MC
C. Align match marks, and install coupling and tube (1).
★ Check that the couplings are facing in the same direction.
★ If the spline is worn, replace the whole drive shaft assem-
bly.
Spline portion: Grease (G2-L1)
★ If cover (11) has been removed, carry out the operation in

the following order.
Insert seal and washer in cover (11) and tube (1), assemble
cover (11), then caulk with a punch at points on diametrically
opposite sides.
3. Center, rear drive shaft

★ Carry out the same operation as in Step C for the front drive shaft.
WA450-3MC 30-111 2
DISASSEMBLY AND ASSEMBLY FRONT AXLE
12
FRONT AXLE
REMOVAL

from moving.
WARNING! Release the remaining pressure inside

piping. For details, see REMOVAL OF
RADIATOR ASSEMBLY.
• Jack up the axle, and set block 1 under the front frame.
1. Sling the left and right tires and wheels (1) of the front axle, then
remove mounting nuts and lift off.
Tire, wheel (26.5-R25 tire): 675 kg (1,488 lb)
2. Disconnect the front drive shaft (2) from the front axle.
Front drive shaft: 40 kg (88.2 lb)
★ Make match marks on the drive shaft and the coupling.
30-112 2 WA450-3MC
12
3. Brake piping
A. Remove the cover of plate at front of front frame, disconnect

front brake piping and tube (3) between brake valve and slack
adjuster at slack adjuster end.
B. Remove tubes (4) and (5) between slack adjuster and left and
right wheel cylinders.
★ After disconnecting the piping, fit plugs to prevent the
entry of dirt or dust.
4. Front axle
A. Sling one end of front axle housing and fit a jack under other
end.
B. Fit jack under differential case.
C. Remove mounting bolts (7), then use hoist and jack to maintain
balance and lift off.
★ Be careful not to let slack adjuster on top of axle housing

hit frame.
Front axle: 1,455 kg (3,208 lb)
D. Pull out the front axle from chassis.
WA450-3MC 30-113 2
12
INSTALLATION
Tire mounting nut: 470.7 ± 49.0 N•m (347.2 ± 36.1 lbf ft)
★ Remove the block from under the front frame.
★ Clean the connections and mating surface of the drive shaft.
Drive shaft mounting bolt:

112.8 ± 9.8 N•m (83.2 ± 7.2 lbf ft)
Front axle mounting bolt:

1,618.1 ± 166.7 N•m (1,193.5 ± 1230 lbf ft)
• Bleed the air from the brake system and carry out an actuation check.
• Add hydraulic oil through the oil filter of the hydraulic tank to the specified level.
30-114 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-115 2
DISASSEMBLY AND ASSEMBLY REAR AXLE
12
REAR AXLE
REMOVAL

from moving.
WARNING! Release the remaining pressure inside

RADIATOR ASSEMBLY.
• Jack up the axle, and set block 1under the rear frame.
1. Sling left and right tires and wheels (1) of rear axle, then remove
mounting nuts and lift off.
30-116 2 WA450-3MC
2. Disconnect rear drive shaft (2) from rear axle.
3. Brake piping
A. Disconnect rear brake piping and hose (3) between brake valve
and slack adjuster at slack adjuster end.
★ Always remove the brake tubes before removing the axle.
There is danger that they may be crushed when the axle is
lifted off.
4. Disconnect the grease tubes (6) and (7) from rear axle support.
5. Rear axle, support
A. Secure axle support and rear axle with chain.
B. Sling rear axle housing with nylon lifting tool, and remove
both left and right mounting bolts (8).
Rear axle, support: 1,600 kg (1,323 lb)
WA450-3MC 30-117 2
C. Pull out rear axle and support together from chassis, then lower.
★ Maintain the balance of the axle when lowering it.

★ Remove the axle after removing the fuel tank.
★ For details, see REMOVAL OF FUEL TANK.
30-118 2 WA450-3MC
12
6. Rear support
A. Sling rear support of rear axle and support assembly, and

remove thrust cap (9).
B. Remove thrust washer (10), thrust plate (11) and thrust washer
(12) from rear axle.
C. Lift off rear support.
Rear support: 146 kg (326 lb)
D. Remove packing (14) and bushing (15) from rear support.
7. Front support
A. Remove retainer (18) of front support, then remove O-ring and packing.
B. Remove packing (16) and bushing (17) from front support.
WA450-3MC 30-119 2
12
INSTALLATION
Tire mounting nut: 470.7 ± 49 N•m (347.2 ± 36 lbf ft)
★ Remove the block from under the rear frame.

112.8 ± 9.8 N•m (83.2 ± 7.2 lbf ft)
Axle support mounting bolt:

1,029.7 ± 98.7 N•m (759.5 ± 72.8 lbf ft)
★ After installing the rear axle, install the fuel tank.

★ For details, see INSTALLATION OF FUEL TANK.
★ Secure the rear axle and the axle support (rear support) with a chain.
★ Be careful not to damage the packing with the rear axle coupling.
Rear axle front mount: Grease (G2-L1)
Thrust cap mounting bolt: 279.5 ± 29.4 N•m (206.1 ± 21.7

lbf ft)
Thrust cap mounting bolt: Thread-tightener (LT-2)
30-120 2 WA450-3MC
12
Thrust washer: Grease (G2-L1)
Thrust plate mounting bolt:

279.5 ± 29.4 N•m (206.1 ± 21.7 lbf ft)
Thrust plate mounting bolt: Thread-tightener (LT-2)
★ Pay attention to the direction of the packing, fit it securely in

the groove, and assemble it so that the lip is not turned over.
★ Check that the slit in the bushing is facing the side.
Rear axle mount: Grease (G2-L1)
★ Set so that the chamfered side of the bushing is on the axle

housing side, and assemble so that the clearance is clearance b.
★ Clearance b: Min. 0.5 mm (0.020 in.)
the groove, and assemble so that the lip is not turned over.
★ Install the bushing and packing to the front support in the same
way as for the rear support.
★ Clearance c: Min. 0.5 mm (0.020 in.)
WA450-3MC 30-121 2
12
★ Use new O-rings and packing.

the groove, and assemble so that the lip is not turned over.
Retainer mounting bolt: Thread tightener (LT-2)
• Bleed the air from the brake system and carry out an actuation
check.
• Add hydraulic oil through the oil filler of the hydraulic tank to the specified level.
30-122 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-123 2
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
12
FRONT DIFFERENTIAL
REMOVAL

from moving.
WARNING! Release the remaining pressure in the

RADIATOR ASSEMBLY.
• Jack up the axle, and set block 1 under the front frame.
1. Sling the left and right tires and wheels (1) of front axle, then
remove mounting nuts, and lift off.
2. Drive shaft
A. Disconnect front drive shaft (2) from front axle.
Front drive shaft: 40 kg (88 lb)
★ Make match marks on the drive shaft and coupling.
B. Remove flange bearing (2-1), and move front drive shaft

towards right side.
30-124 2 WA450-3MC
12
3. Position the plug (3-1) at the bottom, then remove it and drain oil.
Axle oil: 65 L (10.6 U.S. gal.)
4. Remove cover (3), then remove O-ring (4).
5. Use jacking screws (Thread diameter = 12 mm, Pitch = 1.75 mm),

pull out axle shaft (5) approximately 200 mm (7.87 in.) together
with the sun gear (6).
6. Slack adjuster
A. Remove following hydraulic piping clamps.

• Clamps for tube (7) between slack adjuster and axle.
★ Remove both the left and right clamps.
• Clamp for tube (8) between slack adjuster and brake
chamber.
B. Remove mounting bolts of slack adjuster bracket (9), and

insert block between slack adjuster and axle.
★ When removing the differential, set the bracket at a height
where there is no interference.
7. Differential
A. Remove 2 mounting bolts of differential (10), and install guide

bolts (Thread Diameter = 14 mm, Pitch = 2 mm, Length = 50
mm).
★ Screw in the thread of the guide bolts fully.
★ First, thread in the guide bolts, then remove the remaining
mounting bolts.
B. Fit lifting tool 2 to differential case (11).
WA450-3MC 30-125 2
12
C. Install the jacking screws, and pull differential (10) along guide
bolt to pull it out approximately 20 mm (0.79 in.) from axle
housing.
★ Be careful not to damage the O-ring of the differential.
D. Install tools B and C to jack, and insert between differential

and axle housing, then install differential (10) to tool B.
E. Adjust height of lifting tool and jack, and remove differential

(10), slowly.
Differential: 235 kg (518 lb)
F. Operate jack, and pull differential out from the chassis, then
remove O-ring (13).
30-126 2 WA450-3MC
12
INSTALLATION
Tire mounting nut: 470.7 ± 49 N•m (1,037.7 ± 108 lbf ft)
• Fit flange bearing (2-1) temporarily.

• Connect front drive shaft (2) to the differential and the center
drive shaft ends.
• Tighten flange bearing (2-1) fully.
★ When connecting the drive shaft, clean the mating surface
of the spider and the coupling, then install.
Flange bearing mounting bolt: 549.2 ± 58.8 N•m

(1,210.8 ± 129.6 lbf ft)
Use a new O-ring.
• Adjust the lifting tool and the height of the jack for the differ-
ential, and assemble the differential along the guide bolt.
★ Fit the O-ring securely in the groove, and be careful that it
does not get caught when installing.
• When the clearance between axle housing (12) and differential
(I0) is approximately 20 mm (0.79 in.), remove installation
tool B and tighten the mounting bolts uniformly.
Differential mounting bolt: Thread-tightener (LT-2)
Differential mounting bolt: 176.5 ± 19.6 N•m (389.1 ±

43.2 lbf ft)
WA450-3MC 30-127 2
12

• Refilling with oil
• Tighten the drain plug and add oil through the level plug to the specified level.
• Set the machine with the drain plug immediately at the bottom, then add oil through the level plug.
Axle oil: 65 L (17 U.S. gal.)
★ For details, see TESTING AND ADJUSTING, Bleeding Air.
30-128 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-129 2
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL
12
REAR DIFFERENTIAL
REMOVAL

from moving.

RADIATOR ASSEMBLY.
• Jack up the axle, and set block 1 under the rear frame.
1. Sling left and right tires and wheels (1) of rear axle, then remove
mounting nuts, and lift off.
Wheel with 26.5-R25 tire: 675 kg (1,488 lb)
30-130 2 WA450-3MC
2. Disconnect the rear drive shaft (2) from rear axle.
3. Brake piping
A. Disconnect hose (3) (between brake valve and slack adjuster)

of rear brake piping at slack adjuster end.
★ Always remove the brake tubes before removing the axle.
There is danger that they may be crushed when the axle is
lifted off.
4. Disconnect the grease tubes (6) and (7) from rear axle support.
5. Rear axle support
A. Secure axle support and rear axle with chain.
B. Sling rear axle housing with nylon lifting tool, and remove
both left and right mounting bolts (8).
Rear axle and support: 1,600 kg (3,527 lb)
WA450-3MC 30-131 2
C. Pull out both the rear axle and support from the chassis, then lower.
★ Maintain the balance of the axle when lowering it.

★ Remove the axle after removing the fuel tank.
★ For details, see REMOVAL OF FUEL TANK.
6. Set plug (9-1) immediately at bottom, then remove it and drain oil.
Axle oil: 65 L (17 U.S. gal.)
7. Remove cover (9), then remove O-ring (10).
8. Use jacking screws (Thread diameter = 12 mm, Pitch = 1.75 mm) to

pull out the axle shaft (11) and sun gear (12) approximately 200
mm (8.00 in.).
9. Remove cover (13) from axle, then remove slack adjuster (14)
together with bracket.
10. Use jacking screws to lift off the rear differential (15), then remove
O-ring from rear differential.
Rear differential: 244 kg (538 lb)
30-132 2 WA450-3MC
12
INSTALLATION
Tire mounting nut: 470.7 ± 49 N•m (347.2 ± 36.1 lbf ft)
★ Remove the block from under the rear frame.

112.8 ± 9.8 N•m (83.2 ± 7.2 lbf ft)
Axle support mounting bolt:

1,029.7 ± 98.1 N•m (759.4 ± 72.4 lbf ft)
★ After installing the rear axle, install the fuel tank.

★ For details of the installation of the fuel tank, see INSTALLATION OF FUEL TANK.
★ When installing the rear axle to the chassis, be extremely careful not to damage the bushing and packing of the front
support with the differential coupling.
★ Secure the rear axle and the support (rear end) with a chain, then install to the chassis.
Rear axle front support portion: Grease (G2-L1)
★ When inserting axle shaft (11), rotate the differential coupling lightly by hand to install. Do not push it in by force.
WA450-3MC 30-133 2
12

★ Fit the O-ring securely in the groove, and be careful that it does not get caught when installing.
Differential mounting bolt: Thread tightener (LT-2)
Differential mounting bolt:

176.5 ± 19.6 N•m (130.2 ± 14.5 lbf ft)

• Tighten the drain plug and add oil through the level plug to the specified level.
★ Set the machine with the drain plug immediately at the bottom, then add oil through the level plug.
★ For details, see TESTING AND ADJUSTING, Bleeding Air.
30-134 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-135 2
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
12
DIFFERENTIAL
DISASSEMBLY
1. Differential gear
A. Remove ring gear adjustment bolt.
B. Loosen adjustment ring lock bolt, and remove lock plate (1).
★ Rotate the adjustment ring, and separate the differential
gear from the pinion gear.
C. Remove bearing cap (2).

★ Check the match marks on the left and right bearing caps.
Make new match marks if the old match marks cannot be
seen.
D. Remove adjustment ring (3) and bearing cup (4).
E. Remove differential gear (5) from differential case.

★ The pilot bearing will hit the carrier, so tip it over slightly
to the right when lifting it off.
Differential gear assembly: 75 kg (165 lb)
30-136 2 WA450-3MC
2. Plain half
A. Remove bearing (6).
B. Remove plain half (7).

★ Check the match marks. Make new match marks if the old
match marks cannot be seen.
C. Remove side gear (8), cross shaft (9), thrust washer (10), and
pinion gear (11).
3. Ring gear, flange half
A. Remove bearing (12).
B. Remove mounting bolts, then remove ring gear (13) and flange
half (14).
4. Turn over differential gear.
WA450-3MC 30-137 2
5. Pinion gear
A. Loosen mounting bolts of coupling (15).

★ Leave the coupling temporarily fitted.
B. Remove the pinion gear (17) from the differential case (16).
★ Check the shim thickness and use as a guide when assem-
bling.
6. Pinion shaft
A. Use a press to remove the pinion shaft (18) from the cage (19).
B. Remove bearing cups (20) and (21) from the cage (19).
30-138 2 WA450-3MC
C. Remove pilot bearing (22) and bearing (23) from the pinion
shaft (18).
★ Do not remove pilot bearing (22) and bearing (23) unless
necessary.
★ Use the same procedure to disassemble the front differen-
tial.
WA450-3MC 30-139 2
12
ASSEMBLY
★ When replacing the pinion or ring gear, always replace them as a
set, and be careful not to mix them with other sets.
★ Replace the flange half and plain half also as a set.
1. Pinion shaft
A. Press-fit pilot bearing (22) to pinion shaft (18).
B. Press-fit bearing (23) to pinion shaft (18).

★ Press-fitting force for bearing (23), pilot bearing (22): 49
kN (11,015.6 lbf)
C. Press-fit bearing cups (20) and (21) to cage (19).

★ Press-fitting force for bearing cup: 49 kN (11,015.6 lbf)
Inside diameter of cage, outside diameter of cup:

Axle oil
D. Assemble cage (19) to pinion shaft (18), then assemble the

spacer (25).
2. Adjusting preload
A. Press-fit the bearing (24) to pinion shaft (18).
B. Push bearing with press, and measure rotating force of cage

with a spring balance.
Bearing portion: Axle oil
★ Coat the bearing portion fully with oil, and settle it before
measuring.
★ Press force: 202 kN (45,411 lbf)
★ Reading of spring balance: Maximum 14.7 N (3,304.7 lbf)
30-140 2 WA450-3MC
12
C. If the measured value is not within the standard value, replace
bearings (23) and (24) and spacer (25) with new parts, then
adjust again.
D. If the measured value is within the standard value, check that

the end play of cage is also within the standard value.
★ End play: Maximum 0.212 mm (0.008 in.)
3. Pinion gear
A. Press-fit oil seal (27) and dust seal (27A) to cage (26).
★ Use a new oil seal and dust seal, and be careful they are
install facing in the correct direction.
Lip of oil seal, lip of dust seal: Grease (G2-L1)
Press-fitting portion of oil seal, dust seal:

Thread-tightener (LT-2)
B. Install O-rings (26A) and (15A), then install cage (26) and cou-
pling (15).

926.7 ± 103 N•m (683.5 ± 76 lbf ft)
C. Assemble pinion gear assembly (17) to differential case (16)

without installing shims.
Cage mounting bolt:

176.5 ± 19.6 N•m (130.2 ± 14.5 lbf ft)
WA450-3MC 30-141 2
12
D. Install tool D to differential case (16).
E. Measure distance L from tool D to pinion gear, and calculate

shim thickness.
★ When replacing the bearing, pinion gear, and ring gear,
use the above procedure to adjust the shim.
Shim thickness:
Standard value - (L - thickness of tool)
★ Standard value: (243 + a) - (115 + b)
F. Assemble pinion gear (17) and shim to differential case (16),

and tighten mounting bolts.
Mounting bolt:
176.5 ± 19.6 N•m (130.2 ± 14.5 lbf ft)
30-142 2 WA450-3MC
12
4. Ring gear
A. Knock pin (27) into flange half (14) so that it protrudes dis-
tance a from case.
★ a = 3.5 mm (0.14 in.)
B. Press-fit bearing (12) to flange half (14).
C. Install flange half (14) to ring gear (13).
5. Install washer (28) and assemble side gear (8). Insert the washer
securely to the pin inside the case.
Washer (both faces): Grease (G2-L1)
WA450-3MC 30-143 2
12
6. Assemble pinion gear (11) and thrust washer (10) to cross shaft (9).
★ Align the stopper position of the thrust washer when assem-
bling.
Thrust washer (gear contact surface): Axle oil
7. Plain half
A. Knock pin (27) into plain half (7) so that it protrudes distance a
from plain half.
★ a = 3.5 mm (0.138 in.)
B. Install washer (28), and assemble side gear (8).

★ Insert the washer securely to the pin inside the case.
Washer: Grease (G2-L1) (both faces)
C. Press-fit bearing (6) to plain half (7).
D. Install plain half (7).

★ Insert cross shaft (9) securely in the groove of the case and
plain half.
★ Check match marks, then set in position and install.
Mounting bolt:
176.5 ± 19.6 N•m (130.2 ± 14.5 lbf ft)
30-144 2 WA450-3MC
12
8. Differential gear
A. Raise gear (5), and assemble bearing cup (4) to bearing, then
install to case.
B. Align with thread of differential case (16), and install adjust-

ment ring (3).
C. Align match mark and install bearing cap (2).

★ Be careful not to damage the thread of the cap.
9. Adjusting preload of bearing
A. Turn adjustment bearing ring with a bar until ring gear contacts
pinion gear, and adjust until there is no more backlash.
★ Rotate the bearing sufficiently to give complete contact
between the bearing and other contact parts, then tap the
ring gear with a copper hammer.
★ Coat the bearing well with oil.
★ If the adjustment ring on one side is loosened one turn,
tighten the adjustment ring on the other side by one turn.
B. Install a spring balance to ring gear, and measure free rotation

torque.
★ Free rotation torque: 19.6 - 24.5 N (4.4 - 5.5 lbf)
★ Target value: 24.5 N (5.5 lbf)
WA450-3MC 30-145 2
12
10. Adjusting tooth contact and backlash
A. Adjust the backlash as follows:
i. Adjust the ring gear with the adjustment ring.

★ When doing this, turn the adjustment rings on both sides by the same amount in the same direction.
ii. Put a dial gauge in contact with tooth face of outside edge
of ring gear, then turn adjustment ring to adjust.
★ Keep the pinion gear fixed in position and measure at
3 or 4 places.
★ Backlash: 0.30 - 0.41 mm (0.012 - 0.016 in.)
B. Adjust the tooth contact as follows:
i. Mix red lead (minimum) with oil, then coat the tooth face of 7 or 8 teeth of the ring gear.
ii. Rotate the pinion gear forward and in reverse and check the tooth contact.
★ Use the procedure on the next page to judge the tooth contact and perform the adjustment.
30-146 2 WA450-3MC
12
11. Adjusting tooth contact
Coat face of 7 or 8 teeth of bevel gear lightly with red lead (minimum). Hold the bevel gear by hand to act as a brake,
rotate the pinion gear forward and backward and inspect the pattern left on the teeth.
WA450-3MC 30-147 2
12
12. After completing the adjustment of the tooth contact, wipe off the
red lead and install lock plate (1).
Mounting bolt:
176.5 ± 19.6 N•m (130.2 ± 14.5 lbf ft)
13. After carrying out all adjustments, screw in bolt (29) until it con-
tacts rear face of the ring gear, then turn back 1/2 turn and tighten
locknut (30).
Adjustment bolt: Gasket sealant (LG-5)
Locknut: 225.6 ± 19.6 N•m (166.4 ± 14.5 lbf ft)
30-148 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-149 2
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
FINAL DRIVE
DISASSEMBLY

from moving.

RADIATOR ASSEMBLY.
• Jack up the axle and set block 1 under the front frame.
1. Jack up the axle, insert a support stand under axle, then lift off tire
and wheel (1).
★ After removing the tire and wheel, set the support stand under
the axle housing portion.
2. Position the plug (2) at bottom, then remove it and drain oil.
30-150 2 WA450-3MC
3. Remove the cover (3), then remove O-ring (4).
4. Use jacking screws (Thread diameter = 12 mm, Pitch = 1.75 mm) to

pull out axle shaft (5) approximately 200 mm (8.00 in.).
5. Remove 3 mounting bolts, and lift off planetary carrier (6).

★ Make match marks to use as a guide when assembling.
★ Keep the carrier balanced and remove it slowly.
Planetary carrier: 86 kg (189.6 lb)
6. Ring gear
A. Using tools E and F, secure wheel hub (8) and brake (9) in
position.
★ Install tools E and F at three, equally-spaced places, then
use a washer to adjust the clearance.
B. Remove mounting bolts of retainer (10), then remove ring gear

(11).
★ Check the number and thickness of the shims between the
retainer and axle housing, and keep in a safe place.
Ring gear: 35 kg (77.2 lb)
WA450-3MC 30-151 2
7. Disassembly of planetary carrier
A. Using press, pull out shaft (12), and remove pinion gear (13).
★ Lock ball (14) is inserted in the shaft, so be careful not to
lose the ball.
★ Write the number on the case and distinguish the parts to
prevent the removed parts from being mixed with other
parts.
B. Remove bearing (17) from pinion gear (13).

★ The bearings are settled in sets, so distinguish them to pre-
vent them from being mixed with other sets.
8. Disassembly of ring gear
A. Remove lock plate (21) from ring gear hub (20), then remove
ring gear (22).
B. Use jacking screws (Thread diameter = 12 mm, Pitch = l.75

mm, Length = 70 mm) to remove the bearing (23) from ring
gear hub (20).
30-152 2 WA450-3MC
12
ASSEMBLY
1. Assembly of ring gear
A. Press-fit bearing (23) to ring gear hub (20).

★ After press-fitting, check that there is no clearance from
the rib.
B. Set ring gear hub (20) to ring gear (22), and install lock plate
(21).
★ Assemble the lock plates with the wide lock plates on the
inside.
★ Remove all oil and grease from the tap holes for the bolts.
2. Assembly of planetary carrier
A. Assemble bearing (17) to pinion gear (13), and insert from bot-
tom of carrier, then use lifting bar 1 to set to carrier mount.
★ Assemble all 3 pinion gears to the carrier.
B. Align carrier and gear hole, then press-fit the cooled shaft (12).
WARNING! Do not touch the cooled shaft directly

by hand. Personal injury may result.
★ Press-fit so that the lock ball hole is on the outside. Stop

just before the hole and align the hole.
★ Cool the shaft at -30 °C (-22 °F) for 20 minutes.
WA450-3MC 30-153 2
12
C. Assemble lock ball (14) to shaft, and press-fit shaft again.
★ After press-fitting the shaft, check that the gear rotates
smoothly.
3. Ring gear
A. Raise ring gear (11), and insert in axle housing.

★ Align the spline groove and insert slowly.
B. Tighten retainer (10) temporarily with 3 mounting bolts, and

remove tools E and F.
★ Remove all oil and grease from the retainer mounting bolt
holes.
★ Tighten the retainer temporarily without fitting any shim.
★ Rotate wheel hub (8) to settle the bearing, and tighten so
that the torque is constant.
Retainer mounting bolt: 72.6 ± 1 N•m (53.5 ± 0.74 lbf

ft)
C. Use depth micrometer from measurement hole of retainer (10)

to measure clearance a between the end face of the retainer and
the end face of housing.
★ Measure at two places and take the average.
★ Shim thickness = Clearance a + 0.3 mm (0.012 in.).
★ Select the shim thicknesses to give the minimum
number of shims.
★ Shim thickness: 1.0 mm (0.039 in.), 0.5 mm (0.020
in.), 0.2 mm (0.008 in.), 0.05 mm (0.002 in.)
30-154 2 WA450-3MC
12
D. Install tool G to brake and wheel hub (8), then remove retainer,
install selected shim, and install retainer again.
★ When assembling the shim, always install tool G first.
★ Rotate wheel hub (8) and tighten uniformly until the
torque is the specified torque.
Mounting bolt: 176.5 ± 19.6 N•m

(130.2 ± 14.5 lbf ft)
4. Assemble the O-ring to the wheel hub (8), then raise the planetary
carrier (6), and install.
★ Align the mounting holes and install slowly so that the O-ring
does not come out of position.
5. Install the axle shaft (5).

★ If the sun gear is not already aligned, rotate the wheel hub to
align the position.
6. Insert O-ring (4) in groove of cover, and install cover (3).
WA450-3MC 30-155 2
12
7. Install tire and wheel, then remove support.
Mounting nut: 470.7 ± 49 N•m (48.0 ± 5.0 lbf ft)

Width across flats: 30 mm
8. Tighten drain plug and add oil through level plug (24) to specified
level.
A. Set the machine with the drain plug immediately at the bottom,
then add oil through the level plug.
Axle oil (front and rear): 65 L (17.2 U.S. gal.)
30-156 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-157 2
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
12
CENTER HINGE PIN
REMOVAL

from moving.

RADIATOR ASSEMBLY.
• Remove plugs (1) and (2) at the top of the hydraulic tank filter, and prevent the oil
inside the tank from flowing.
WARNING! Operate the bucket control lever at least

40 times TILT <-> HOLD to release the
pressure inside the accumulator.

to release the pressure inside the brake
accumulator.
WARNING! When releasing the refrigerant from the

air conditioner, carry out the oil return
operation, then use a gauge manifold and
core of the compressor high-pressure
and low-pressure valves.
1. Remove covers (3) at bottom of cab.
30-158 2 WA450-3MC
2. Remove left and right ladders (3-1).
Ladder rail (right): 64.5 kg (142 lb)

Ladder rail (left): 59.5 kg (131 lb)
3. Disconnect the following electric wiring.
A. Disconnect front frame wiring FR1 (4) and FR2 (5).
B. Disconnect transmission wiring TL1 (6) and TL2 (7).
C. Disconnect floor wiring harnesses LR5 (8), LR6 (9), LR3 (10),
LR4 (11), LR1 (12), and LR2 (13).
★ Label the connectors for easier reconnection later.
WA450-3MC 30-159 2
4. PPC piping
A. Disconnect hoses (14), (15), (16), (17), and (18) between PPC
valve and main control at connection inside front frame.
B. Disconnect hose (20) of PPC valve port P2, hose (21) of port
P4, hose (22) of port P3, and hose (23) of port P1 at valve end.
• Disconnect hose (24) between PPC accumulator and PPC
valve at valve end.
• Disconnect hose (25) of PPC valve drain port at valve end.
★ Tag and mark the hoses during disconnection to ease
reconnection during installation.
★ After disconnecting the hoses, fit plugs to prevent the
5. Brake piping
A. Disconnect hoses (26) and (27) between right brake valve and
accumulator at pedal end.
★ Remove 2 brake hose clamps under floor board.
B. Disconnect hose (28) between left brake valve and accumula-

tor at pedal end.
C. Disconnect right brake valve drain hose (30) and left brake
valve drain hose (31) at rear frame.
30-160 2 WA450-3MC
12
D. Disconnect hose (32) between front brake and right brake valve at center hinge pin.
6. Air conditioner piping
A. Remove the cover (3-1) at the bottom of the bulkhead.
B. Disconnect hose (33) between compressor and air conditioner unit at unit end.
C. Disconnect hose (34) between receiver and air conditioner unit at unit end.
D. Disconnect heater piping (35) and (36) at air conditioner unit end.
7. Disconnect accelerator cable (37) under pedal.
WA450-3MC 30-161 2
8. Disconnect following pipings from steering valve.
A. Hose (37-1) between steering valve (L port) and stop valve

(left-hand)
B. Hose (37-2) between steering valve (R port) and stop valve

(right-hand)
C. Hose (37-3) between steering valve (P port) and accumulator

charge valve
D. Hose (37-4) between steering valve (T port) and drain line
9. Cab, floor board
A. Remove mounting cover (39) of floor board (38), then remove

the 4 viscous damper mounting nuts (40) holding floor board.
B. Fit the lifting tool to cab (41) and lift off the cab.
★ Raise the cab slowly and check that all parts have been
removed before lifting off.
Cab, floor assembly: 1,100 kg (2,425 lb)
30-162 2 WA450-3MC
10. Remove left and right steering cylinder pins (42) at rod end.
11. Stop valve
A. Disconnect hose (43) between steering valve and stop valve

(right-hand), and hose (43-1) between stop valve (right-hand)
and steering valve at stop valve side.
B. Disconnect hose (43-2) between steering valve and stop valve

(left-hand), and hose (43-3) between stop valve (left-hand) and
steering valve at stop valve side.
C. Remove stop valve (left and right side) (43-4) and stop bolt
(left and right side) (43-5).
D. Remove fitting bracket (43-6) for hose between steering valve and stop valve at frame side.
12. Remove PPC hoses, bracket (44), and clamps (45) and (46) at cen-
ter pin, and move towards rear frame.
WA450-3MC 30-163 2
13. Hydraulic hoses
A. Disconnect hose (47) between steering and cooler.
B. Disconnect hose (48) between hydraulic pump and main con-

trol valve.
C. Disconnect main control valve drain hose (49).
D. Disconnect hose (50) between switch pump and steering valve

and hose (51) between steering pump and steering valve.
E. Remove hose mount bracket (52).

★ After disconnecting the hoses, mark with a tag to distinguish when installing.
★ After disconnecting the hoses, fit plugs to prevent the entry of dirt or dust.
14. Remove drive shaft guard (53), disconnect center drive shaft (54) at
flange bearing end, then move drive shaft to side.
Center drive shaft: 32 kg (70.5 lb)
15. Supporting frame
A. Jack up rear frame to adjust height, then insert blocks.

★ Insert blocks under the rear frame on the left and rear
sides.
30-164 2 WA450-3MC
B. Jack up front frame to adjust height, then insert blocks. Put
rollers between block and frame so that front frame can be
pulled out.
★ Insert blocks under the front frame on the left and right
sides.
16. Remove lock bolt, then remove lower hinge pin (55).
17. Upper hinge pin
A. Remove mounting bolts, then remove retainer (56).

retainer and frame, and keep in a safe place.
B. Remove lock bolt (57-1), then adjust height and remove upper
hinge pin (57).
★ Adjust the height carefully and make it possible to remove
the pin by hand.
C. Remove spacer (58).
WA450-3MC 30-165 2
18. Pull out front frame towards front slowly, and disconnect the frame.
★ Be careful that the spacer at the bottom of the upper hinge does
not catch in the rear frame.
★ Be careful of the balance when disconnecting.
★ Be careful not to forget to disconnect any part.
★ Remove the safety bar.
19. Lower hinge
A. Pull out bushing (59) from rear frame.

★ Remove the lower hinge bushings at both the top and bot-
tom.
B. Remove retainer (60).

C. Remove dust seal (61) from retainer.

★ Remove the dust seal at the frame end also.
30-166 2 WA450-3MC
D. Remove bearing (62).
20. Upper hinge pin
A. Remove mounting bolts, then remove retainer (63).

B. Remove dust seal (64) from retainer.
WA450-3MC 30-167 2
12
C. Remove spacer (65) and dust seal (66) from front frame.
D. Remove bearing (67).
30-168 2 WA450-3MC
12
INSTALLATION
A/C unit hose: 29.4-34.3 N•m (21.7-25.3 lbf ft)
Air conditioner hose:

New refrigerant compressor oil (ND-OIL8)
Receiver hose:
New refrigerant compressor oil (ND-OIL8)
Cable locknut: 53.9 ± 4.9 N•m (39.8 ± 3.6 lbf ft)
★ Align securely with the notch hole of the viscous damper washer, then tighten.
Install stop bolt (left and right) at the position shown in the right
figure.
★ For bolt adjustment procedure, see the related portion of
TESTING AND ADJUSTING section.
★ Align the match marks exactly.

112.8 ± 9.8 N•m (83.2 ± 7.2 lbf ft)
WA450-3MC 30-169 2
Outside circumference of lower hinge pin:

Grease (G2- L1)
Upper hinge
A. Insert upper hinge pin (57), and assemble spacer (58).
Outside circumference of hinge pin:

Grease (G2-L1)
B. Install retainer (56) to the upper hinge pin, tighten with 3 bolts,
then select shims so that clearance a between hinge and
retainer is below 0.2 mm (0.008 in.), and assemble.
★ When adjusting the shims, tighten retainer mounting bolts
temporarily to prevent from turning.
★ Tighten the retainer mounting bolts to the specified torque,
then tighten the pin mounting bolts.
Pin mounting bolt: 205.9 ± 19.6 N•m

(151.9 ± 14.5 lbf ft) (when adjusting shims)
Pin mounting bolt: 205.9 ± 19.6 N•m

(151.9 ± 14.5 lbf ft)
Retainer mounting bolt: 107.9 ± 9.8 N•m

(79.6 ± 7.2 lbf ft)
30-170 2 WA450-3MC
Connection of frame
WARNING! Always use a bar when aligning the pin
holes. Never insert your fingers.
★ Align the pin holes exactly.
Lower hinge
A. Using tools H, I, Kl, K2, and K3, press-fit the bearing (62) and
spacer (69) to the front frame.
★ When press-fitting, use tool K3 as a guide.
★ Be careful not to fit the bearing at an angle.
★ Fill the inside of the bearing with grease.
★ When assembling the bearing, be careful not to forget to
assemble the spacer.
★ The bearing clearance is adjusted, so do not change the
combination with the spacer.
★ When replacing, always replace as a set.
B. Press-fit dust seal (61) to retainer (60).

★ Press-fit so that the dust seal lip surface is facing the out-
side.
Lip of oil seal: Grease (G2-L1)
WA450-3MC 30-171 2
C. Tighten retainer (60) with 3 mounting bolts, select shims so
that maximum clearance a between retainer and hinge is less
than 0.1 mm (0.004 in.), then assemble.

(when adjusting shims)
D. Press-fit dust seal (70) to frame.

side.
E. Press-fit bushing (59) to lower hinge of rear frame with a press.
30-172 2 WA450-3MC
Upper hinge
A. Assemble tools H, I, J, K2, K3, and K4 to top of front frame

upper hinge. Set bearing (67) in tool K1, then set to press-fit-
ting portion from above and press-fit.
★ When press-fitting, use tool K3 as a guide.
★ Be careful not to fit the bearing at an angle.
★ Fill the inside of the bearing with grease.
★ When assembling the bearing, be careful not to forget to
assemble spacer (68).
★ The bearing clearance is adjusted, so do not change the
combination with spacer (68).
★ When replacing, always replace as a set.
WA450-3MC 30-173 2
12
B. Press-fit dust seal (64) to retainer (63).
★ Press-fit so that the dust seal lip surface faces the outside.
C. Tighten retainer (63) with 3 mounting bolts, select shims so

that maximum clearance a between retainer and hinge is less
than 0.1 mm (0.004 in.), then assemble.

(when adjusting shims)
D. Assemble dust seal (66) and spacer (65) from under front
frame.
side.
★ Assemble from below so that the large chamfered side of
spacer (65) is on the bearing side.
30-174 2 WA450-3MC
12
• Tighten drain plugs (1) and (2) at the top of the hydraulic tank filter, and add hydraulic oil
through the oil filler to the specified level.
• Bleeding air
★ Bleed air from brake line.
• For details of the procedure for bleeding the air, see TESTING AND ADJUSTING.
★ Bleed air from steering line.
• For details of the procedure for bleeding the air, see TESTING AND ADJUSTING.
• Fill the air conditioner with new refrigerant.

★ Precautions when filling air conditioner line with new refrigerant
• Keep the temperature inside the room at above 3 °C (37.4 °F). If the temperature is below 3 °C (37.4 °F), the
system will not work.
• Use R134a as the refrigerant.
• When filling with refrigerant, always use the repeat vacuum method to completely evacuate. (Attainment of vac-
uum: Minimum 750 mmHg)
• Charge with 1.5 - 1.6 kg (3.3 - 3.5 lb) of refrigerant.
• Do not use the can of refrigerant upside-down or use any other mistaken method. Be careful not to let. liquid
freon get into the refrigerating system.
• Do not operate the compressor before charging with refrigerant.
WA450-3MC 30-175 2
DISASSEMBLY AND ASSEMBLY STEERING VALVE (ORIBITROL)
12
STEERING VALVE (ORIBITROL)
REMOVAL

from moving.
★ After the engine is stopped, operate the steering wheel 2 or 3 times leftward and rightward, and make the steering
valve neutral.
1. Remove the cover (1) on the lower portion of the cab.
2. Steering valve
A. Remove cover (2) on the steering column.
B. Loosen the bolts and remove column joint (3) from the steering
gear shaft.
★ Mark the match mark on the joint and the steering valve.
30-176 2 WA450-3MC
12
3. Disconnect following pipings from the steering valve.
A. Disconnect hose (4) between steering valve (L port) and stop

valve (L.H.) at the steering valve side, and remove nipple (5).
B. Disconnect hose (6) between steering valve (R port) and stop

valve (R.H.) at the steering valve side, and remove nipple (5).
C. Disconnect hose (7) between steering valve (P port) and accu-

mulator charge valve at the steering valve side, and remove
nipple (5).
D. Disconnect hose (8) between steering valve (T port) and drain

line, and remove nipple (9).
4. Steering valve
Remove mount bolts of bracket (10) and remove it along with the
steering valve (11).
Steering valve: 8 kg (17.6 lb)
WA450-3MC 30-177 2
12
INSTALLATION
• Installation is the reverse of removal
Column connecting bolt:

55.9 ± 7.9 N•m (41.2 ± 5.8 lbf ft)
Steering valve mounting bolt:

52.0 ± 6.9 N•m (38.4 ± 5.1 lbf ft)
Bracket mounting bolt:

88.3 ± 34.3 N•m (65.1 ± 25.3 lbf ft)
★ Align the spline of the steering column side with the spline of the steering valve side.
• Add hydraulic oil to the hydraulic tank to the specified level through the oil filler, start the engine, and allow the oil to cir-
culate through the piping. Then the check the oil level again and add more if necessary.
30-178 2 WA450-3MC
12
DISASSEMBLY
★ Use a wire brush to remove all the dirt and dust stuck to the joint around the outside circumference of the unit.
★ Carry out the operation in a clean place to prevent dirt or dust from sticking to the valve.
★ As far as possible, hold the valve in a vice when disassembling.
Rotor
1. Set rotor side facing up, and hold mounting flange lightly in vice
1.
★ Put a copper plate in contact with the vice and be careful not to
tighten the vice too hard.
2. Remove screw (1), then remove end cap (2).
3. Remove O-ring (3) from end cap (2).
4. Pull out rotor set (4), then remove the O-ring (5).
★ Be careful not to drop the star inside the rotor set.
5. Remove spacer (6).
WA450-3MC 30-179 2
12
6. Remove drive shaft (7).
7. Remove spacer plate (8).
8. Remove O-ring (9) from housing (10).
Control Side
1. Remove housing (10) from vice, and place on a clean cloth.

★ Be careful not to damage the finished surface.
2. Raise tip of snap ring (11) with screwdriver, and remove from hous-
ing.
3. Turn spool and sleeve to place pin in a horizontal position, then

push in spool and sleeve with your thumb, and remove bushing (12)
from housing.
4. Remove X-ring seal (13) from bushing (12).
5. Remove dust seal (14) from bushing (12) with screwdriver.

★ Be careful not to damage the bushing.
30-180 2 WA450-3MC
12
6. Remove 2 bearing races (15) and thrust needle (16) from spool and
sleeve.
7. Pull out-spool and sleeve assembly (17) from housing (10) in the
direction of the arrow.
★ To prevent the spool and sleeve assembly from catching in the
housing, rotate the spool and sleeve assembly slowly to the left
and right when pulling out from the housing.
8. Pull out pin (18) from spool and sleeve assembly (17).
9. Push spool (20) inside sleeve (19) slightly to front, and remove 6
centering springs (21) from spool (20) carefully by hand.
10. Turn spool (20) slowly and pull out from rear of sleeve (19) (in the
direction of the arrow).
11. Remove O-ring (22) from housing.
12. Remove set screw (23) from housing.
13. Screw a threaded bar into check sheet (24), and pull out check sheet
(24).
14. Remove O-rings (25) and (26) from check sheet (24).
15. Tap housing, and remove ball (27) and retainer (28).
WA450-3MC 30-181 2
12
ASSEMBLY
★ Check all parts for damage or burrs.
★ Wash all metal parts in clean solvent and blow dry with air.
★ Do not use a file or polish any part with rough sandpaper.
★ Coat the O-rings with clean grease. (No need to put grease on new X-ring seals)
★ Coat the O-ring for the rotor set with a small amount of grease.
Control Side
1. Insert retainer (28) in housing with tweezers.

★ Check that the retainer is not inserted at an angle.
2. Insert ball (27).
3. Fit O-rings (26) and (25) in check sheet (24), and push check sheet
(24) into housing.
★ Be careful to set the top and bottom of the check sheet facing in
the correct direction.
4. Install set screw (23).

★ Check that the set screw is set in slightly from the end face of the housing.
Set screw: 11.8 N•m (8.7 lbf ft)
Set screw: Adhesive (LT-2)
5. Assemble spool (20) and sleeve (19) so that spring groove is on

same side.
★ Rotate the spool and slide it in.
★ Grip the splined portion of the spool lightly and check that the
spool rotates smoothly inside the sleeve.
★ If there are match marks, check that the match marks are
aligned.
30-182 2 WA450-3MC
12
6. Align spring groove positions of spool (20) and sleeve (19), and set
on flat plate, then insert spring (21) in spring groove.
★ Set so that the notches at both ends are at the bottom.
7. Insert pin (18) in spool and sleeve assembly (17).
8. Insert spool and sleeve assembly (17) in housing (10) in the direc-
tion of the arrow.
A. Keep pin horizontal and rotate to left and right a little at a time
to insert.
★ Be extremely careful not to get it caught.
B. Make the spool and sleeve assembly flush with the rear end
face of the housing.
★ If it is inserted beyond the end face, the pin will fall out.
C. Check that spool and sleeve rotate smoothly inside housing.
9. Install O-ring (22) to housing (10).
10. Fit 2 bearing races (15) and thrust needle (16) in the case (10).
WA450-3MC 30-183 2
11. Insert dust seal (14) in bushing (12).
12. Insert X-ring seal (13) in bushing (12).
13. Insert bushing (12) in spool, and rotate to install.

• Tap with a plastic hammer to assemble to the specified posi-
tion.
• It must be in contact horizontally with the bearing race.
14. Fit snap ring (11) in housing.
Rotor
1. Hold flange of housing lightly in vice.

★ Be careful not to tighten the vice too hard.
★ Check that the spool and sleeve are set in slightly from the
housing surface with 14 holes.
30-184 2 WA450-3MC
12
2. Insert O-ring (9) in housing.
3. Put on spacer plate (8), and align positions of bolt hole and tap hole
of housing.
4. Turn spool and sleeve assembly to make pin (18) and port surface
of housing parallel, then mesh pin and yoke of drive shaft (7).
★ To position accurately, draw a line on the end face of the drive
shaft spline.
5. Insert O-ring (5) in rotor set (4).
6. Make O-ring (5) end of rotor set to spacer plate end, then align
insert portion of star of rotor (4) with drive.
A. Check that lines A,B,C, and D are all parallel.
B. Without removing joint of drive (7), position bolt holes of rotor

set.
★ This procedure is very important for determining the valve
timing of unit.
WA450-3MC 30-185 2
12
7. Insert spacer (6) inside rotor set.
8. Set end cap (2) on rotor set, and align bolt hole.
9. Coat thread of screw with grease, and tighten end cap.

★ Install the handle to the spool, then check that the spool rotates.
End cap mounting screw:

First step: 14.7 N•m (10.8 lbf ft)
Second step: 27.0 ± 1.5 N•m (19.9 ± 1.1 lbf ft)
30-186 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-187 2
DISASSEMBLY AND ASSEMBLY STEERING DEMAND VALVE
12
STEERING DEMAND VALVE
REMOVAL

from moving.

RADIATOR ASSEMBLY.
• Remove plugs (1) and (2) at the top of the hydraulic tank filter, and
prevent the oil inside the tank from flowing out.
1. Remove the covers (3) from under the cab.
2. Hydraulic piping
Disconnect following tubes and hoses at steering valve end.
A. Disconnect hose (4) between stop valve (R.H.) and steering

valve at steering valve side.
B. Disconnect hose (4-1) between stop valve (L.H.) and steering

valve at steering valve side.
C. Disconnect tube (5) between steering pump and steering valve

port (P1).
D. Disconnect tube (6) between switch pump and steering valve

port (P2).
E. Disconnect hose (7) from steering valve port (PB) to cut-off

valve.
F. Disconnect tube (8) at steering valve port (A) and tube (9) at
port (B).
G. Disconnect steering valve drain port tube (10).

★ After disconnecting the tubes and hoses, fit plugs to pre-
vent the entry of dirt or dust.
30-188 2 WA450-3MC
12
3. Sling the steering valve (11), then remove mounting bolt (12), and lift off steering valve.
Steering valve: 24 kg (52.9 lb)
★ Carry out the removal operation with two people.
WARNING! The steering valve has oil on it so be

careful not to let it slip.
INSTALLATION
• Installation is the reverse of removal

★ When installing the tube, remove the clamp to prevent any force from being brought to bear on the tube.

Tighten the plug at the top of the hydraulic tank filter, and add hydraulic oil through the oil filler to the specified level.
WA450-3MC 30-189 2
12
DISASSEMBLY
★ Use a wire brush to remove the dirt and debris from the exterior of the unit.
★ Perform this procedure in a clean work area to prevent dirt or dust from sticking to the valve.
★ Use a vise to hold the steering valve during disassembly whenever possible. Be careful not to tighten the vise so much that
it damages the valve.
1. Remove the safety valve assembly (1).

★ The set pressure of the safety valve is fixed. Therefore, do
NOT disassemble the safety valve.
2. Remove the main relief valve assembly (2).

★ The set pressure of the main relief valve is fixed. Therefore, do
NOT disassemble the main relief valve.
3. Removing the demand spool.
A. Remove the plug (3).
30-190 2 WA450-3MC
B. Remove the spring (4).
C. Remove the demand spool (5).

★ Remove the demand spool slowly so as not to damage the
spool.
★ Check the number and thickness of any shims that are
installed, then store the shims in a clean, safe place.
D. Remove the plug (6).
4. Removing the steering spool
A. Remove the 2 bolts (7).

★ There are 2 bolts and one case on each side of the valve
body. Remove the other case bolts on the other side of the
valve body also at this time.
WA450-3MC 30-191 2
B. Remove the case (8) and spring (9).
★ Remove the case on the other side of the valve body also
at this time.
C. Remove the spring seat (10).

★ Remove the spring seat slowly so as not to damage the
spool.
★ Remove the spring seat from the other side of the valve
body also at this time.
D. Remove the steering spool assembly (13)

★ Remove the spool assembly slowly so as not to bend it or
damage it in any other way.
★ Remove the poppets from both ends to prevent them from
falling into the valve body.
30-192 2 WA450-3MC
12
5. Disassembling the steering spool assembly
A. Remove the cap screw (14).

★ This screw was coated with Loctite adhesive #271 at the
factory during installation. Use industrial dryer or electric
heat gun to heat the screw to 200 - 250 °C (392 - 482 °F)
before attempting to remove the cap screw.
B. Remove the spring (15) and poppet (16).

★ Remove the spring and poppet from the other side also at
this time.
6. Disassembling the check valve
A. Remove the plug (17).
B. Remove the spring (18) and poppet (19).
WA450-3MC 30-193 2
C. Remove the plug (20).
30-194 2 WA450-3MC
12
ASSEMBLY
★ Check all parts for damage or burrs.
★ Wash all metal parts in clean solvent and blow dry with air.
★ Do not use a file or polish any part with rough sandpaper.
★ Coat the O-rings with clean grease.
1. Install an O-ring to the plug (20), then thread the plug into the valve
body.
Plug: 93.2 ± 4.9 N•m (68.7± 3.6 lbf ft)
2. Assembling the check valve
A. Install the poppet (19) and spring (18).
B. Install an O-ring to the plug (17), then thread the plug into the
valve body.
Plug: 63.7 ± 4.9 N•m (47± 3.6 lbf ft)
WA450-3MC 30-195 2
12
3. Assembling the steering spool
A. Install the poppet (16) and spring (15) to the spool.
B. Install an O-ring to the cap screw (14), then thread the cap
screw onto the steering spool.
Spool thread: Loctite adhesive #271
Cap screw: 8.8 ± 1.0 N•m (6.5 ± 0.74 lbf ft)
4. Installing the demand spool
A. Install an O-ring to the plug (6), then thread the plug into the
valve body.
Plug: 137.3 ± 2.0 N•m (101.3 ± 1.5 lbf ft)
B. Insert the demand spool (5) in the valve body.

★ Remember to install any shims that were present during
disassembly.
★ Insert the spool slowly and carefully so as not to damage
the spool or the valve body.
C. Install the demand valve spring (4).
30-196 2 WA450-3MC
D. Install an O-ring and backup ring to the plug (3), then thread
the plug into the valve body.
Plug: 137.3 ± 2.0 N•m (101.3 ± 1.5 lbf ft)
5. Installing the steering spool assembly
A. Insert the steering spool assembly (13) into the valve body.
★ Ensure that portion A of the spool faces the correct direc-
tion.
B. Install the spring seat (10).
C. Install the spring (9).

★ Install the other spring and seat to the opposite side of the
valve body at this time.
D. Install an O-ring to the case (8), then install the case onto the
valve body.
E. Install the bolt (7) that secures the case to the valve body.
Bolt: 41.2 ± 2.0 N•m (30.4 ± 1.5 lbf ft)
★ Install the other case and bolts to the opposite side of the
valve body at this time.
WA450-3MC 30-197 2
6. Install the main relief valve assembly (2) to the valve body.
Main relief valve assembly:

73.5 ± 4.9 N•m (54.2 ± 3.6 lbf ft)
7. Install the safety valve assembly (1) to the valve body.
Safety valve assembly:

73.5 ± 4.9 N•m (54.2 ± 3.6 lbf ft)
30-198 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-199 2
DISASSEMBLY AND ASSEMBLY STEERING AND SWITCH PUMP
12
STEERING AND SWITCH PUMP
REMOVAL

from moving.

RADIATOR ASSEMBLY.
inside the tank from flowing out.


accumulator.

30-200 2 WA450-3MC
2. Remove left and right ladders (3-1)

3. Brake piping, accelerator cable
★ Remove brake hose clamps at two points under floor
board.
B. Disconnect hose (6) between left brake valve and accumulator

at pedal end.
C. Disconnect accelerator cable (7) under pedal.
D. Disconnect hose (8) between PPC accumulator and PPC valve

inside bulkhead at accumulator end.
WA450-3MC 30-201 2
12
E. Disconnect hose (10) of radiator sub-tank (9) and hose (12) of
window washer tank (11) at tank end.
★ Remove the hoses from the hose clamps.
F. Air conditioner hoses
i. Disconnect hose (13) between compressor and condenser

at condenser end.
★ Remove the hose clamps inside the bulkhead.
ii. Disconnect hose (14) between air conditioner unit and

receiver at receiver end.

★ After removing the hoses, fit plugs to prevent the entry of dirt or dust.
4. Bulkhead
A. Remove cover (3-1) at bottom front face of bulkhead.
B. Remove top mounting bolts (18) holding bulkhead (15) and hood (17).
★ Be careful not to lose the rubber and washers of the mounting portion.
30-202 2 WA450-3MC
C. Install eyebolts at top 4 corners of bulkhead (17), then sling
and remove the bottom mounting bolts (19).
Bulkhead: 135 kg (297.6 lb)

(including accumulator, charge valve)
D. Raise bulkhead (17) straight up for approximately 400 mm

(15.7 in.).
★ The bulkhead comes near the cab when it is lifted, so be
★ To prevent the bulkhead from falling after it is raised,
place blocks on the left and right at opposite ends.
5. Pump piping
A. Disconnect suction tube (20) between hydraulic tank and steer-

ing pump at pump end.
B. Disconnect tube (21) between steering pump and steering

valve at pump end.
C. Disconnect tube (22) between switch pump and steering valve

at pump end.
★ After disconnecting the tubes, fit plugs to prevent the entry
of dirt or dust.
6. Remove mounting bolts (24) of steering and switch pump assembly (23), then remove pump assembly.
Steering, switch pump assembly: 24 kg (52.9 lb)
WA450-3MC 30-203 2
12
INSTALLATION
Accelerator cable mounting nut:

53.9 ± 4.9 N•m (39.8 ± 3.6 lbf ft)

Tighten drain plugs (1) and (2) at the top of the hydraulic tank filter, and add hydraulic oil
• Bleeding air
★ Bleed air from brake line. For details of the procedure for bleeding the air, see TEST-
ING AND ADJUSTING.
★ Bleed air from steering line. For details of the procedure for bleeding the air, see
TESTING AND ADJUSTING.

• Keep the temperature inside the room at above 3 °C (37.4 °F). If the temperature is below 3 °C (37.4 °F), the sys-
tem will not work.
30-204 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-205 2
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
12
STEERING CYLINDER
REMOVAL

from moving.

RADIATOR ASSEMBLY.
1. Disconnect steering cylinder rod and bottom hoses (1) and (2) at
cylinder end.
★ After removing the hoses, fit plugs to prevent the entry of dirt
or dust.
2. Steering cylinder
A. Remove rod bolt, then remove pin (3).
30-206 2 WA450-3MC
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
B. Disconnect bottom grease tube (4).
C. Remove bottom bolt, then remove pin (5).

★ Check the shim thickness and use as a guide when assem-
bling.
D. Remove steering cylinder (6).

★ Carry out the removal operation with two people.
★ Be careful not to scratch the cylinder rod.
Steering cylinder: 38 kg (83.8 lb)
INSTALLATION

★ Adjust the shims so that clearance a is the standard value.

• Clearance a = Maximum 0.5 mm (0.20 in.)
★ Remove all grease and oil from the cylinder pin, and wipe off
the grease that is pushed out.
WA450-3MC 30-207 2
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
12
BRAKE VALVE
REMOVAL

from moving.
WARNING! Operate the control levers several times

hydraulic piping. Then loosen the oil filler
cap slowly to release the pressure inside
the hydraulic tank.
WARNING! Depress the brake pedal slowly at least

17 times to relieve pressure inside the
accumulator. If necessary, repeat this
until there is no resistance when the
brake pedal is depressed.
1. Remove the covers (1) under the cab.
30-208 2 WA450-3MC
12
2. Removing the right brake valve piping
A. Disconnect the hoses (2) and (3) from between the accumulator
and brake valve. Remove the adapters (4) and (5) at the valve
end.
B. Disconnect the brake valve drain hose and tube (6) at the valve
end.
C. Disconnect the hose (7) going to the left brake valve at the
valve end.
D. Disconnect the tube (8) to the front brake and the tube (9) to the rear brake at the valve end.
3. Removing the left brake valve piping
A. Disconnect the tube (10) and hose from the accumulator to the
left brake valve at the valve end.
B. Disconnect the left and right brake valve hoses and elbow (11)
at the brake valve end.
C. Remove the brake valve drain tube (12) and hose at the valve
end.
★ Fit covers to the openings to prevent dirt or water from entering the connections and hoses.
4. Unplug the brake valve switch sensor wiring connector (13).
5. Pull out the cotter pin (16) of the pedal hinge pin (15) near the bot-
tom of the brake pedal (14), then remove the hinge pin and pedal.
6. Removing the right and left brake valves
A. Remove the brake valve mounting bolts (17), disconnect the

mounting flange (18) and body (19), then pull out the cap (20).
B. Remove the mounting flange bolts, then remove the mounting

flange from the floor portion.
WA450-3MC 30-209 2
12
INSTALLATION
★ Use new O-rings.
Mounting bolts: 66.2 ± 7.4 N m (48.8 ± 5.5 lbf ft)
★ Bleed the brake system of air after reassembly as detailed in Section 20, TESTING AND ADJUSTING, Bleeding the
air from the brake system.
30-210 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-211 2
DISASSEMBLY AND ASSEMBLY RIGHT BRAKE VALVE (TANDEM)
12
RIGHT BRAKE VALVE (TANDEM)
DISASSEMBLY
1. Bracket assembly
A. Remove the seat (1), pedal stopper (2) and boot (3) from the
brake valve.
B. Remove the bracket assembly mounting bolts (5), then remove

the bracket assembly (4).
C. Remove the oil seal (6) from the upper portion of the brake
valve.
2. Valve
A. Use the mounting bolts (5) to secure the valve to a jig 1, then
place the jig in a vise.
★ Illustration dimensions are in millimeters (mm).
★ Make match marks before beginning disassembly.
B. Remove the valve mounting bolts (10), then remove the S-cyl-
inder assembly (7).
C. Remove the S-cylinder plug (13), then remove the spring (14)
and O-ring.
D. Remove the spring (11) and O-ring (12), then remove the P-
cylinder assembly (8).
★ Remove the spring (15) from inside the plunger of the P-
cylinder assembly.
E. Remove the holder (16), springs (17), (18) and (19), and O-
ring (20) from the T-flange assembly (9).
★ The cylinders, plungers and spools inside the T-flange
assembly and the S-cylinder and P-cylinder are factory-
manufactured as sets, so be careful not to mix these items.
★ Fit seals to prevent the entrance of dirt or dust and be care-
ful not to damage the cylinders or flange assembly.
30-212 2 WA450-3MC
12
ASSEMBLY
1. Valve
A. Use the mounting bolts (5) to secure the T-flange assembly (9)
to the jig, then secure the jig to the vise.
B. Install springs (19), (18) and (17) to the T-flange assembly (9)
in this order, then install the holder (16) on the top spring (17).
C. Install the O-ring (20) to the T-flange assembly (9).

O-ring: Lithium grease
D. Set the P-cylinder assembly (8) to the T-flange assembly (9).

★ Align the match marks during assembly.
E. Install the spring (11) and spring (15) inside the plunger of the
P-cylinder assembly to the P-cylinder assembly (8).
F. Install an O-ring (12) to the P-cylinder assembly (8).

G. Set the S-cylinder assembly (7) to the P-cylinder assembly (8), and secure it in place with the mounting bolts (10).
Mounting bolts: 58.8 - 73.6 N•m (43.4 - 54.3 lbf ft)
H. Install the spring (14) and O-ring to the S-cylinder assembly (7), then tighten with plug (13).
Plug threads: Thread-tightener (Thread lock 1303B)
Plug: 152.0 ± 24.5 N•m (112.1 ± 18.1 lbf ft)
WA450-3MC 30-213 2
12
2. Remove the valve from the jig 1.
A. Set the T-flange assembly face up, then install the oil seal (6).
★ Use a new oil seal
Lip of the oil seal: Lithium grease
B. Install the bracket assembly (4) and tighten the mounting bolts (5).
C. Install the seat (1), pedal stopper (2) and boot (3) to the valve.
30-214 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-215 2
DISASSEMBLY AND ASSEMBLY LEFT BRAKE VALVE (SINGLE)
12
LEFT BRAKE VALVE (SINGLE)
DISASSEMBLY
1. Bracket assembly
A. Remove the seat (1), pedal stopper (2) and boot (3) from the
brake valve.
B. Remove the bracket assembly mounting bolts (5), then remove

the bracket assembly (4).
C. Remove the oil seal (6) from the upper portion of the brake
valve.
2. Valve
A. Use the mounting bolts (5) to secure the valve to a jig 1, then
place the jig in a vise.
★ Illustration dimensions in millimeters (mm).
★ Make match marks before beginning disassembly.
B. Remove the valve mounting bolts (9), then remove the S-cylin-
der assembly (7).
C. Remove the S-cylinder plug (10), then remove the spring (11)
and O-ring (12).
D. Remove the holder (13), springs (14) and (15), and O-ring (16)
from the S-flange assembly (8).
★ The cylinders, plungers and spools inside the S-flange
assembly and the S-cylinder are factory-manufactured as
sets, so be careful not to mix these items.
★ Fit seals to prevent the entrance of dirt or dust and be care-
ful not to damage the cylinders or flange assembly.
30-216 2 WA450-3MC
DISASSEMBLY AND ASSEMBLY LEFT BRAKE VALVE (SINGLE)
12
ASSEMBLY
1. Use the mounting bolts (5) to secure the S-flange assembly (8) to
the jig 1, then secure the jig to the vise.
A. Install springs (14) and (15) to the S-flange assembly (8) in this
order, then install the holder (13) on the top spring (17).
B. Install the O-ring (20) to the T-flange assembly (9).

C. Set the S-cylinder assembly (7) to the S-flange assembly (8),

and secure it in place with the mounting bolts (5).
D. Install the spring (11) and O-ring (12) to the S-cylinder assem-
bly (7), then tighten with plug (10).
Plug threads: Thread tightener (Thread lock 1303B)
Plug: 152.0 ± 24.5 N•m (112.1 ± 18.1 lbf ft)
2. Remove the valve from the jig 1.
A. Set the S-flange assembly face up, then install the oil seal (6).
★ Use a new oil seal
Lip of the oil seal: Lithium grease
B. Install the bracket assembly (4) and tighten the mounting bolts
(5).
Mounting bolts: 58.8 - 73.6 N m (43.4 - 54.3 lbf ft)
C. Install the seat (1), pedal stopper (2) and boot (3) to the valve.
WA450-3MC 30-217 2
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
12
SLACK ADJUSTER
REMOVAL

install -the safety bar on the frame. Lower
from moving.

Then operate the steering wheel and con-
trol levers several times to release the
remaining pressure in the hydraulic pip-
ing.
WARNING! Release the pressure inside the accumu-

lator by depressing the brake pedal
slowly and repeatedly (at least 17 times)
until there is no more reaction when the
brake pedal is depressed.
1. Raise lift arm and set tool L to lift arm cylinder rod.
★ When not using tool L, set a stand under the lift arm.
2. Remove cover (1) at front of front frame.
30-218 2 WA450-3MC
12
3. Brake piping
A. Disconnect tube (2) between slack adjuster and brake valve at

adjuster end.
★ For the rear, remove slack adjuster cover (4) and discon-
nect tube (3).
B. Disconnect tubes (5) between slack adjuster and left and right
brake pistons at slack adjuster end.
4. Remove mounting bolts, then remove slack adjuster (6).
INSTALLATION
★ Tighten the mounting bolts temporarily, then tighten them fully after connecting the piping.

Add hydraulic oil through the oil filler to the specified level.
• Bleeding air
★ Bleed air from brake line and check that there is no leakage at the connections. For details of the procedure for bleed-
ing the air, see TESTING AND ADJUSTING.
★ Bleed the air from the slack adjuster end.
WA450-3MC 30-219 2
12
DISASSEMBLY
1. Remove the bleeder (2) from the slack adjuster body (1).
2. Remove the mounting bolts, then disconnect the body (1) and cylin-
der (4) together with bracket (3).
WARNING! There is spring tension inside the cyl-

inder, so hold the contact surfaces
and be careful during removal.
3. Piston
A. Remove the spring (5) and o-ring (6).
B. Remove the piston (7), then remove the o-ring.

★ Use a rod (10 mm/0.39 in. diameter) to slowly push out
the piston.
★ Be careful not to damage the thread with the rod.
4. Poppet
A. Remove the cover (8) from the cylinder (4), then remove the
plug (9), spring (10), and poppet (11).
★ When removing the poppet, blow in air from the oil hole
in the cylinder.
★ Hold the oil port of the cylinder by hand, and do not pump
in air suddenly.
★ Be careful to keep the original poppet (11) with its cylin-
der (4).
★ If replacement is required, replace the poppet and cylinder
as an assembly.
B. Remove the o-ring (12) from the poppet.
30-220 2 WA450-3MC
12
ASSEMBLY
1. Poppet
A. Fit the O-ring (12) onto the poppet (11).
B. Install the poppet (11), spring (10), plug (9), and cover (8), then
assemble the cylinder (4).
2. Piston
A. Install the o-ring (13) onto the piston (7).
B. Insert the piston (7) into the cylinder (4).

★ Check that the piston moves smoothly.
3. Cylinder
A. Install the o-ring (6) and spring (5) in the cylinder.

★ Installed load of spring: 43.1 N (9.7 lbf ft)
B. Install the body (1) and cylinder (4) together with the bracket
(3).
4. Install the bleeder (2).
WA450-3MC 30-221 2
DISASSEMBLY AND ASSEMBLY WHEEL BRAKE
12
WHEEL BRAKE
DISASSEMBLY

from moving.

RADIATOR ASSEMBLY.
1. Jack up the axle, set blocks under the front frame, then insert stand under axle.
2. Lift off tire and wheel (1).
3. After removing the tire and wheel, set a stand also under the axle
housing.
4. Position the oil drain plug (2) at the bottom, then remove the plug
and drain oil from case.
5. Remove the cover (3), then remove the O-ring (4).
30-222 2 WA450-3MC
6. Use jacking screws (Thread diameter = 12 mm, Pitch = l.75 mm) to
pull out the axle shaft (5) approximately 200 mm (8.00 in.).
7. Remove 3 mounting bolts, and lift off planetary carrier (6).

★ Make match marks and use as a guide when assembling.
★ Be careful of the center of gravity and remove slowly.
Planetary carrier: 86 kg (189.6 lb)
8. Ring gear
A. Using tools T4 and T5, secure wheel hub (8) and brake (9).
★ Install tools T4 and T5 at three equally spaced places, then
use a washer to adjust the clearance.
B. Remove mounting bolts of retainer (10), then remove ring gear

(11).
retainer and the axle housing, and keep in a safe place.
Ring gear: 35 kg (77 lb)
WA450-3MC 30-223 2
12
9. Brake, wheel hub
A. Remove brake tube (12).
B. Sling brake and wheel hub (13), then remove mounting bolts
and lift off.
Brake, wheel hub: 195 kg (430 lb)
10. Remove the bearing (14), O-ring (15), trunnion (16), and O-ring of
the trunnion mount portion from axle housing.
Trunnion: 54 kg (119 lb)
11. Piston, cylinder
A. Position the wheel hub (17) at the bottom, then remove tool T4.
B. Use eyebolts to lift off the cylinder assembly (18).
Cylinder assembly: 63 kg (139 lb)
30-224 2 WA450-3MC
C. Remove the O-ring (19) from the cylinder assembly.
D. Using tool T3, pull out pin (20) from cylinder assembly, and
remove rod (21) and piston return spring (22).
★ The pin is small, so be careful not to lose it.
E. Blow in air from brake oil filler (23) to push out piston (24).
★ Hold one end of the piston by hand, blow in air slowly,
and be careful not to let the piston fly out.
★ Be careful not to damage the piston.
F. Remove seals (25) and (26) from piston (24).
WA450-3MC 30-225 2
12
12. Outer gear
A. Remove O-ring (28) from outer gear (27).
B. Remove plates (29) and discs (30) from outer gear in order,
then remove spacer (31).
★ When removing the discs, make match marks on the inner
gear and disc, outer gear and plate, and on the spacer.
★ The plates are made of a soft material, so remove them
extremely carefully and be careful not to damage them.
C. Using tool T2, lift off outer gear (27) from wheel hub (35), and
remove seal ring (32) and O-ring (33).
D. Remove oil seal (34) from outer gear (27).
13. Remove mounting bolts, then remove inner gear (36) from wheel
hub (35).
30-226 2 WA450-3MC
12
14. Wheel hub
A. Remove the seal ring (37) and O-ring (38) from the wheel hub
(35).
B. Remove the bearing cups (39) and (40) from the wheel hub
(35).
WA450-3MC 30-227 2
12
ASSEMBLY
1. Wheel hub
A. Press-fit bearing cups (39) and (40) to wheel hub (35).
B. Install O-ring (38) to seal ring (37), and using tool T1, install to
wheel hub.
★ Use alcohol to completely remove the white powder from
the O-ring.
★ Remove all oil and grease from the O-ring contact surface
of the seal ring and retainer.
★ Be careful not to twist or otherwise damage the O-ring
when installing it.
2. Install the inner gear (36) to wheel hub (35).
30-228 2 WA450-3MC
3. Outer gear
A. Press-fit-oil seal (34) to outer gear (27).

★ When press-fitting the oil seal, be careful of the direction
of the oil seal breather hole.
WA450-3MC 30-229 2
12
B. Install O-ring (33) to seal ring (32), and using tool T1, install to
outer gear (27).
★ Use alcohol to completely remove the white powder from
the O-ring.
★ Remove all oil and grease from the O-ring contact surface
of the seal ring and outer gear.
★ Tighten tool T2 uniformly so that there is no twisting of
the O-ring for the seal ring. After press-fitting, measure
height t at 4 places around the circumference and check
that the difference in the measurements is within 1 mm.
30-230 2 WA450-3MC
12
C. Using tool T2, assemble outer gear (27) to wheel hub (35).
★ When assembling, check that there are no scratches on the
seal ring mating surface.
★ Check that the seal ring is not installed at an angle.
Mating surface of seal ring: Axle oil
D. Align match marks on outer gear (27) and spacer (31), plates
(29), and on discs (30) and inner gear, then assemble plates and
discs in turn.
★ Set with the chamfered side of the spacer facing down.
★ Check that the final plate is meshed securely with the
outer gear spline.
★ Soak the discs in brake oil for at least 30 minutes before
assembling.
★ Align the match marks on the discs and inner gear when
assembling.
E. Install O-ring (28) to outer gear (27).
WA450-3MC 30-231 2
4. Piston, cylinder
A. Install seals (25) and (26) to piston (24).

★ Fit the seal in the groove securely.
Seal: Brake oil
B. Press-fit piston (24) to cylinder (41).

★ When press-fitting the piston, tap with a plastic hammer.
Do not use a steel or copper hammer.
★ Coat the press-fitting portion of the piston and the outside
circumference of the piston with brake oil.
Sliding surface of piston: Brake oil
C. Use tool T3 to insert piston return spring (22) and rod (21) in
cylinder assembly, and lock with pin (20).
D. Install O-ring (19) to the cylinder assembly.
30-232 2 WA450-3MC
E. Use eyebolts to install cylinder assembly (18).

(130.2 ± 14.5 lbf ft)
F. Position the wheel hub (35) at bottom, then use tools T4 and
T5 to tighten it uniformly so that it does not come out.
5. Axle housing
A. Install O-ring to trunnion and axle housing, and tighten with

bolts.
Mounting bolt: 34 ± 5 N•m (25 ± 3.7 lbf ft)
B. Install O-ring (15) to trunnion (16), and press-fit bearing (14).

6. Brake, wheel hub
A. Raise brake and wheel hub (13), and set to axle housing mount,
then tighten with mounting bolts.
★ Be careful of the center of gravity and raise the brake hori-
zontally.
★ If it is forced in, the O-ring will be twisted and damaged,
so align the center and install slowly.
Mounting bolt: 926.7 ± 103 N•m (683.5 ± 76 lbf ft)
WA450-3MC 30-233 2
B. Install brake tube (12).
7. Ring gear
A. Raise ring gear (11) and set in mounting position, then install
to axle housing.
★ Align the spline groove and install slowly.
B. Tighten retainer (10) with 3 bolts temporarily, and remove

tools T4 and T5.
★ Temporarily tighten the retainer without inserting shims.
★ Rotate the wheel hub to settle the bearing and tighten uni-
formly until the torque is the specified torque.
Retainer mounting bolt: 73.6 ± 1 N•m (54.3 ± 0.74 lbf ft)
C. Measure clearance b between end face of housing and end face

of retainer from measurement hole of retainer (10) with depth
micrometer.
★ Measure at two places and take the average.
★ Shim thickness = Clearance b + 0.3 mm
★ Select the shim thickness to give the minimum number of
shims.
★ Shim thickness: 1.0 mm, 0.5 mm, 0.2 mm, 0.05 mm
D. Install tools T4 and T5 to brake and wheel hub, remove

retainer, install selected shims, then install retainer.
★ When assembling the shim, always install tools T4 and T5
first.
★ Rotate the wheel hub and tighten uniformly until the
torque is the specified torque.

(130.2 ± 14.5 lbf ft)
30-234 2 WA450-3MC
8. Assemble O-ring to wheel hub (8), then raise planetary carrier (6),
set in mounting position, and install.
A. Use a new O-ring.
B. Align the mounting holes and install slowly so that the O-ring
does not come out of position.
9. Install axle shaft (5).

★ Rotate the wheel hub to align the position when installing the
sun gear.
10. Fit O-ring into groove of cover, and install cover (3).
11. Install tire and wheel (1) and remove stand.
Mounting nut: 476.7 ± 49.0 N•m (351.6 ± 36 lbf ft)
12. Refilling with oil
A. Tighten drain plug of axle, and add oil through oil filler (42) to
specified level.
★ Set the machine with the drain plug immediately at the
bottom, then add oil through the level plug.

(both front and rear)
B. Connect hose between hydraulic tank and brake chamber, and

add hydraulic oil through oil filler of hydraulic tank to speci-
fied level.
WA450-3MC 30-235 2
13. Testing, adjusting brake
A. Bleed air from brake line and adjust brake. For details, see TESTING AND ADJUSTING.
B. After completing all of the operations, check for any leakage of brake oil. For details, see TESTING AND ADJUST-
ING.
30-236 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-237 2
DISASSEMBLY AND ASSEMBLY PARKING BRAKE DISC
12
PARKING BRAKE DISC
REMOVAL

engine. Then block the wheels to prevent
the machine from moving.
★ Do not apply the parking brake.
1. Loosen drain plug and drain transmission oil.
2. Remove guard of drive shaft, and disconnect lower front drive shaft
(1) at transmission end.
★ Move the lower drive shaft to the right after disconnecting it.
3. Suction tube
A. Remove mounting bolt (3) and washer (4) of coupling (2) at

front of transmission, then remove coupling.
B. Remove suction tube (5) at transmission end.
4. Parking brake
A. Remove lock plates (7) of parking brake manual release bolts

(6), then remove 3 release bolts.
B. Remove parking brake case (8).
C. Screw in 3 manual jacking bolts (6), and release parking brake.

★ Distance L to screw in bolt = 28 mm (1.10 in.)
★ Thread in all three bolts uniformly.
30-238 2 WA450-3MC
12
D. Set length of bolt of tools M1, M2, and M3 to L1, then tighten
with coupling mounting bolt (3).
★ Length of bolt of tool L1: 65 mm (2.56 in.)
E. Remove snap ring (9) from case, then remove tools M1, M2,
and M3.
F. Remove end plate (10), plate, disc, and wave spring from case.
WA450-3MC 30-239 2
12
INSTALLATION
Drive shaft: 142.8 ± 9.8 N•m (105.3 ± 7.2 lbf ft)

921.8 ± 98.1 N•m (679.9 ± 72.4 lbf ft)
End face of coupling: Anti-friction compound (LM-G)
Insert the plates and discs in the case in order, and assemble the
wave springs between the plates.
★ When assembling end plate (10), pay attention to the tool mark
(one groove) on the face.
• Tighten the drain plug of the transmission, and add oil.
★ Run the engine to circulate the oil through the system. Then
check the oil level again.
30-240 2 WA450-3MC
DISASSEMBLY AND ASSEMBLY ACCUMULATOR CHARGE VALVE
12
ACCUMULATOR CHARGE VALVE
REMOVAL
WARNING! Stop the engine, then depress the

brake pedal at least 100 times to
relieve pressure inside the accumula-
tor circuit.
1. Disconnect P port hose (1).
2. Disconnect PP port hose (2).
3. Disconnect ACC port hose (3).
4. Disconnect A port hose (4).
5. Disconnect T port hose (5).
6. Disconnect P port hose (6).
7. Remove the accumulator charge valve assembly (7).
INSTALLATION
Add hydraulic oil through the oil filler to the specified level. Then
check the oil level again.
WA450-3MC 30-241 2
12
DISASSEMBLY
30-242 2 WA450-3MC
1. R3 safety relief valve
A. Remove the nut (1), then remove the adjustment screw (2).
B. Remove the shim (3), spring (4), and ball (5).

★ Check the number and thickness of the shims, and store them in a safe clean place,
2. R1 relief valve
A. Remove the nut (6), then remove the adjustment screw (7).
B. Remove the shim (8), spring (9), and retainer (10).

★ Check the number and thickness of the shims, and store them in a safe clean place,
C. Remove the plug (11), then remove the retainer (12).
3. R2 PPC relief valve
A. Remove the relief valve assembly (13).
B. Remove the O-ring (14) and the 2 backup rings (15) from the relief valve assembly.
4. H1 relief valve
A. Remove the plug (16), then remove the spring (17).
B. Remove the spool (18).

★ The spool forms an assembly with the valve case. Therefore, if there is any damage, replace the spool and valve
as an assembly.
C. Remove the snap ring (19), then remove the filter (20) from the spool.
5. Bushing
A. Remove the bushing (21).
B. Remove the snap ring (22), then remove the filter (23) from the bushing.
WA450-3MC 30-243 2
12
ASSEMBLY
30-244 2 WA450-3MC
1. Bushing
A. Fit the filter (23) to the bushing (21), and secure it in place with the snap ring (22).
★ Assemble the filter so that the end where the outside circumference is not rounded faces the bushing.
B. Fit the O-ring and install the bushing (21) to the valve body (24).
Plug: 29.4 ± 39.2 N•m (21.7 ± 28.9 lbf ft)
2. H1 relief valve
A. Fit the filter (20) to the spool (18) and secure it in place with the snap ring (19).
★ Assemble the filter so that the end where the outside circumference is not rounded faces the bushing.
B. Assemble the spool (18).

★ The spool forms an assembly with the valve case. Therefore, if there is any damage, replace the spool and valve
as an assembly.
C. Assemble the spring (17), then fit the O-ring and install the plug (18).
Plug: 53.9 - 68.6 N•m (39.8 - 50.6 lbf ft)
3. R2 PPS relief valve
A. Install the O-ring (14) and both backup rings (15) to the relief valve assembly (13).
B. Fit the remaining O-ring and install the relief valve assembly (13).
Relief valve: 78.5 - 88.3 N•m (57.9 - 65.1 lbf ft)
4. R1 relief valve
A. Assemble the retainer (12), then fit the O-ring and install the plug (11).
Plug: 30.4 - 37.3 N•m (22.4 - 27.5 lbf ft)
B. Assemble the retainer (10) and spring (9).
C. Assemble the shims (8) to the adjustment screw (7).
D. Fit the O-ring, then fit the adjustment screw (7) and secure it in place with the nut (6).
Nut: 9.8 - 11.8 N•m (7.2 - 8.7 lbf ft)
5. R3 safety relief valve
A. Assemble the ball (5) and spring (4).
B. Assemble the shims (3) to the adjustment screw (2).
C. Fit the O-ring, then fit the adjustment screw (2) and secure it in place with the nut (1).
Nut: 9.8 - 11.8 N•m (7.2 - 8.7 lbf ft)
WA450-3MC 30-245 2
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
HYDRAULIC TANK
REMOVAL

from moving.
WARNING! Relieve the remaining pressure in the pip-

ing. For details, see REMOVAL OF RADI-
ATOR.
1. Draining oil
A. Remove cover (1) on top of ladder, then remove plugs (1) and
(2) at the top of the hydraulic tank filter, and prevent the oil
B. Remove plug (4) under hydraulic tank, then loosen valve (5)
and drain hydraulic oil.
Hydraulic tank: 192 L (50.7 U.S. gal.)
30-246 2 WA450-3MC
2. Ladder/floor
A. Sling right ladder/floor assembly (3-1), then remove mounting

bolts and lift the ladder/floor off.
★ Keep the ladder/floor balanced when lifting it off.
Ladder/floor: 63 kg (139 lb)
3. Hydraulic piping
A. Loosen clamp of hose (7) between hydraulic tank and hydrau-

lic pump and disconnect at tank end.
B. Disconnect return tube (8) between main control valve and

hydraulic tank at tank end.
C. Disconnect tube (9) between steering valve, hydraulic cooler,

and hydraulic tank at tank end.
D. Disconnect hose (10) between hydraulic tank and brake valve

at tank end.
E. Disconnect hose (11) between hydraulic tank and PPC valve at

tank end.
F. Disconnect hose (12) between hydraulic tank and steering

valve at tank end.
G. Disconnect hose (13) between hydraulic tank and PPC relief

valve at tank end.
★ After disconnecting the hoses and tubes, mark with a tag
to distinguish when installing.
★ After disconnecting the hoses and tubes, fit plugs to pre-
WA450-3MC 30-247 2
4. Sling the hydraulic tank (14), then remove mounting bolts and lift
off.
★ Raise the hydraulic tank slightly and lift it off to the outside of
the machine.
Hydraulic tank: 191 kg (421 lb)
INSTALLATION
Hydraulic tank filter plug
Plug on top of filter: 11.8 ± 1 N•m (8.7 ± 0.74 lbf ft)
Installation of tubes (8) and (9)

• Tighten the plug on the top of the hydraulic tank filter, and add hydraulic oil through the oil filler to the specified
level.
Hydraulic tank: 192 L (50.7 U.S. gal.)
• For details of the bleeding air from the brake system and the hydraulic line, see TESTING AND ADJUSTING.
30-248 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-249 2
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT, PPC PUMP ASSEMBLY
12
WORK EQUIPMENT, PPC PUMP ASSEMBLY
REMOVAL

from moving.

RADIATOR ASSEMBLY.


accumulator.

30-250 2 WA450-3MC
3. Brake piping, accelerator cable
★ Remove 2 brake hose clamps under floor board.
B. Disconnect hose (6) between left brake valve and accumulator

at pedal end.
C. Disconnect accelerator cable (7) under pedal.
D. Disconnect hose (8) between PPC accumulator and PPC valve

inside bulkhead at accumulator end.
WA450-3MC 30-251 2
12
E. Disconnect hose (10) of radiator sub-tank (9) and hose (12) of
window washer tank (11) at tank end.
★ Remove the hoses from the hose clamps.
F. Air conditioner hoses
i. Disconnect hose (13) between compressor and condenser

at condenser end.
ii. Disconnect hose (14) between air conditioner unit and

receiver at receiver end.

★ After removing the hoses, fit plugs to prevent the entry of dirt or dust.
4. Bulkhead
A. Remove cover (16) at bottom front face of bulkhead (15).
B. Remove top mounting bolts (18) holding bulkhead (15) and

hood (17).
★ Be careful not to lose the rubber and washers of the
mounting portion.
C. Install eyebolts at top 4 corners of bulkhead (17), then sling

and remove bottom mounting bolts (19).
Bulkhead: 135 kg (297.6 lb)

(including accumulator, charge valve)
D. Raise bulkhead (17) straight up approximately 400 mm (15.7

in.).
★ The bulkhead comes near the cab when it is lifted, so be
★ To prevent the bulkhead from falling after it is raised,
place blocks on the left and right at opposite ends.
30-252 2 WA450-3MC
5. Pump piping
A. Disconnect suction tube (20) between hydraulic tank and

hydraulic, PPC pump at pump end.
B. Disconnect tube (21) between hydraulic pump and main con-

trol valve at pump end.
C. Disconnect tube (22) between PPC pump and charge valve at

pump end.
★ After disconnecting the tubes, fit plugs to prevent the entry
of dirt or dust.
6. Remove mounting bolts (24) of hydraulic and PPC pump assembly (23), then remove pump assembly.
Hydraulic, PPC pump assembly: 28 kg (61.7 lb)
WA450-3MC 30-253 2
12
INSTALLATION
Accelerator cable mounting nut:

53.9 ± 4.9 N•m (39.8 ± 3.6 lbf ft)

Tighten drain plugs (1) and (2) at the top of the hydraulic tank filter, and add hydraulic oil through the oil filler to the spe
c-
ified level.
• Bleeding air
★ Bleed air from brake line. For details of the procedure for bleeding the air, see TESTING AND ADJUSTING.
★ Bleed air from steering line. For details of the procedure for bleeding the air, see TESTING AND ADJUSTING.

• Keep the temperature inside the room at above 3 °C (37.4 °F). If the temperature is below 3 °C (37.4 °F), the sys-
tem will not work.
30-254 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-255 2
DISASSEMBLY AND ASSEMBLY PPC VALVE ASSEMBLY
12
PPC VALVE ASSEMBLY
REMOVAL

from moving.

RADIATOR ASSEMBLY.

30-256 2 WA450-3MC
3. Hydraulic piping
A. Disconnect hose (4) of PPC valve port P2, hose (5) of port P4,
hose (6) of port P3, and hose (7) of port P1 at valve end.
B. Disconnect hose (8) between PPC accumulator and PPC valve

at valve end.
C. Disconnect hose (9) of PPC valve drain port at valve end.

★ After disconnecting the hoses, mark with a tag to distin-
guish when installing.
4. Remove side cover (11) of console box (10).
5. PPC valve
A. Remove joints (13) and (14) of rod installed to PPC valve

assembly (12).
B. Remove mounting bolts (15) of PPC valve assembly, then

remove valve assembly.
PPC valve assembly: 3 kg (6.6 lb)
WA450-3MC 30-257 2
INSTALLATION
Tighten drain plugs (1) and (2) at the top of the hydraulic tank filter, and add hydraulic oil through the oil filler to the spe
c-
ified level.
• Bleeding air
Bleed air from PPC line. For details of the procedure for bleeding the air, see TESTING AND ADJUSTING.
30-258 2 WA450-3MC
12
DISASSEMBLY
1. Remove the bolt (1), then remove the plate (2).
2. Remove the seals (3), then remove the spools (4).

★ Of the 4 spools, make a distinguishing mark on the boom
LOWER spool and check the mounting position for later reas-
sembly.
3. Remove the collar (5) from each of the spools (4).
4. Remove the valve assemblies (6) from the body (7).
5. Remove the collar (8), then the retainer (9), spring (10) and shim
(11) from each of the valves.
★ Note the number of thickness of any shims, and store them
safely away for later reassembly.
6. Remove the springs (13) from the valve body (7).

★ Mark each spring differently as it is removed. The springs are
unique to their own hydraulic ports and are identified by the
number of coils.
WA450-3MC 30-259 2
12
ASSEMBLY
1. Insert the springs (13) into the valve body (7).
★ The springs are unique to their own hydraulic ports and are
identified by the number of coils.
Port Position No. of Spring
Coils
P1 bucket TILT
P2 boom 11
RAISE
P3 boom
LOWER
14
P4 bucket
DUMP
★ The location of each port is stamped on the valve body.
2. Assemble the shim (11), spring (10) and retainer (9) onto each
valve (12), then install the collar (8).
3. Insert each of the valve assemblies (6) into the valve body (7).
4. Fit a new O-ring to each collar (5), install the collars to the spools
(4), then install the four spools into the valve body.
★ Be sure to install the spools in their original locations, espe-
cially the boom LOWER spool which was marked during dis-
assembly.
5. Fit new seals (3) in place, then install the plate (2).
6. Install the bolt (1).
Bolt: 44.1 ± 4.9 N•m (32.5 ± 3.6 lbf ft)
30-260 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-261 2
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
12
MAIN CONTROL VALVE
REMOVAL

from moving.

RADIATOR ASSEMBLY.
• Remove plugs (1) and (2) at the top of the hydraulic tank filter,
and prevent the oil inside the tank from flowing out.
1. Remove inspection cover (3) of front frame.
2. Dump cylinder
A. Disconnect connector (4) of bucket positioner wiring.
B. Disconnect grease hose (5) at front frame end.
C. Disconnect rod hose (6) at cylinder end.
D. Disconnect bottom hose (7) at cylinder end.
30-262 2 WA450-3MC
E. Sling dump cylinder (10), and remove lock bolt, then remove
pins (8) and (9).
★ When slinging, be careful of the center of gravity and sling

from two points.
★ Check the number and thickness of the shims, and keep in
a safe place.
F. Lift off dump cylinder (10).
Dump cylinder: 227 kg (500.4 lb)
WA450-3MC 30-263 2
12
3. Disconnect following hydraulic piping.
A. Disconnect tube (11) between hydraulic pump and valve at

main control valve end.
B. Disconnect hose (12) between cut-off valve and main control

valve at main control valve end.
C. Disconnect tubes (13) and (14) between main control valve and
dump cylinder at valve end.
D. Disconnect tubes (15) and (16) between main control valve and
lift cylinder at valve end.
E. Disconnect drain tube (17) of main control valve at valve end.
F. Disconnect tubes (18), (19), (20), (21), (22), and (23) between
PPC valve and main control valve at main control valve end.
★ After disconnecting the tubes and hoses, mark with a tag
to distinguish when installing.
4. Remove mounting bolt (26), then use eyebolts to lift off the main
control valve (25).
Main control valve: 95 kg (209 lb)
30-264 2 WA450-3MC
12
INSTALLATION
★ Install the hoses without twisting or interference.

Bucket cvlinder
A. Align-the bottom pin hole, assemble shims so that the total for
clearance a between the cylinder and frame is within the stan-
dard value, then install pin (9).
★ Clearance a: 1.5 mm (0.059 in.)
B. Align the rod pin hole and assemble pin (8).
WARNING! Always use a bar when aligning the

pin holes. Never insert your fingers.

★ Be careful that the O-ring does not get caught when installing.
★ Before tightening fully, install the clamps that were removed.
★ When setting the valve in the mounting position, pay attention to the balance and be careful not to hit any other part
inside the frame.

Tighten drain plugs (1) and (2) at the top of the hydraulic tank filter, and add hydraulic oil
• Bleed air from hydraulic line. For details, see TESTING AND ADJUSTING.
WA450-3MC 30-265 2
12
DISASSEMBLY (2-SPOOL VERSION)
30-266 2 WA450-3MC
12
Hydraulic Lines
★ Be careful to keep the various components separate and not mixed with similar items.
1. Disconnect tube (2) from the bucket spool nipple (5) at location a and the tee fitting (4) at location b.
2. Remove the tee fitting (4) and nipple (5) from locations b and a.
3. Disconnect both hoses (3) from their elbow connectors (6) at the boom spool.
4. Disconnect the other ends of hoses (3) from the tee fittings (4), then remove the hoses (1).
5. Remove both tee fittings (4), nipple (5) and o-rings.
6. Remove the elbow fittings (6) and o-rings from the spool cases.
Valves
1. Remove the relief valve assembly (26) from the main control valve body (1).
2. Remove both of the safety valve assemblies (27) from the main control valve body (1).
★ The safety valves cannot be adjusted unless they are installed on the main control valve body. Therefore. do not disas-
semble the safety valves.
3. Remove the suction valve assembly (28) from the main control valve body (1).
4. Remove the float selector valve assembly (29) from the main control valve body (1).
5. Remove both load check valve assemblies from the top of the main valve body. This requires removing the bolts, plate
(30), o-ring, spring (31) and valve (32). Discard the o-ring.
6. Remove the float unload valve assembly from the rear of the main control valve body. This includes the bolts, washers,
flange (33), o-ring, spring (34), seal (35) and valve (36).
Spools
Boom and Bucket Spools
★ Remove one spool assembly completely before continuing on to remove the other spool assembly.
1. While supporting the spool case assembly, loosen and remove the bolts and washers from the sleeve (7) and case (11).
2. Carefully remove the case assembly and inspect the spacer (8), spring (9), piston (10), spring (12) and retainer (13) for
wear and/or damage. Discard both o-rings (15).
3. Remove the spool assembly (14) with both plugs (16) still attached. Inspect the spool (15) for wear and/or damage.
★ Even though the plugs may fall free from the spool anyway, it is best to leave them installed unless the spool is to be
replaced.
4. Complete steps 1 and 2 to remove the opposing spool case assembly (17, 18, 19, 20, 21, 22, 23, 24, and 25) from the other
side of the control valve body (1) and inspect them for wear and/or damage. Discard both o-rings (15).
WA450-3MC 30-267 2
12
ASSEMBLY (2-SPOOL VERSION)
30-268 2 WA450-3MC
12
Spools
Boom and Bucket Spools
★ Refer to the Komatsu publication Guidance for Reusable Parts: Hydraulic Control Valves (form no. SEBG4200) for pho-
tographs and text of acceptable and not acceptable wear
★ Install one spool assembly completely before continuing on to the other spool assembly.
★ To prevent leakage, always use new o-rings.
1. Push spool (14) into body (1).
2. Assemble retainer (25), spring (24), and retainer (23) to case (21).
3. Assemble spacer (18), spring (19), piston (20), and spring (22) to sleeve (17), then fit a new o-ring and assemble to case
(21).
4. Fit another new o-ring to the case (21) and install the case assembly to the main valve body (1) using the washers and
bolts removed earlier.
5. Assemble retainer (13) and spring (12) to case (11), then fit a new o-ring.
6. Assemble spacer (8), spring (9), and piston (10) to sleeve (7), then fit another new o-ring and assemble to case (11).
7. Install the case assembly to main valve body (1) using the washers and bolts removed earlier.
8. Repeat steps 1 through 7 to install the other spool assembly.
Valves
★ Install one valve assembly completely before continuing on to the other valve assembly.
1. Assemble the float unload valve (36), seal (35), and spring (34) to the rear of the main valve body (1), then fit a new o-
ring, install the flange (33) and secure it with the bolts and washers removed earlier.
2. Assemble both load check valve assemblies to the top of the main valve body. Each valve assembly includes the valve
(32) and spring (31), a new o-ring, the plate (30) and the bolts removed earlier.
3. Fit a new o-ring and install the float selector valve assembly (29).
4. Fit a new o-ring and install suction valve (28).
Suction valve assembly:

225.6 ± 9.8 N•m (166.4 ± 7.2 lbf ft)
5. Fit a new o-ring and install both safety valve assemblies (27).

225.6 ± 9.8 N•m (166.4 ± 7.2 lbf ft)
WA450-3MC 30-269 2
12
ASSEMBLY (2-SPOOL VERSION)
30-270 2 WA450-3MC
6. Fit a new o-ring and install the main relief valve assembly (26).

321.7 ± 47.1 N•m (237.3 ± 34.7 lbf ft)
Hydraulic Lines
1. Install the elbow fittings (6) and new o-rings in the boom spool case ends.
2. Install both nipples (5), all three tees (4) and new o-rings.
Nipple and tee: 29.4 ± 4.9 N•m (21.7 ± 3.6 lbf ft)
3. Install the hoses (3) and tubes (2).
Hose sleeve nut: 91.2 ± 12.8 N•m (67.3 ± 9.4 lbf ft)
Tube sleeve nut: 49.0 ± 19.6 N•m (36 ± 14.5 lbf ft)
WA450-3MC 30-271 2
12
DISASSEMBLY (3-SPOOL VERSION; HYDRAULIC LINES)
30-272 2 WA450-3MC
12
Hydraulic Lines
1. Disconnect the tube (12) from the bucket spool nipple (10) at location a. It is not necessary to disconnect tube (12) from
tube (11).
2. Disconnect both ends of tube (11) from the auxilary spool nipple at location b and the boom spool tee fitting (9) at loca-
tion c.
3. Remove the tee fitting (9) and nipple (10) from locations b and c.
4. Disconnect both hoses (1) from their elbow connectors (2 and 3) at the boom spool.
5. Disconnect the other ends of hoses (1) from the tee fittings (6), then remove the hoses (1).
6. Remove both tee fittings (6), the nipple (7) and o-rings (5).
7. Remove the elbow fittings (2 and 3) and o-rings (4) from the spool cases.
WA450-3MC 30-273 2
12
DISASSEMBLY (3-SPOOL VERSION; VALVES, SPOOLS, OTHER)
30-274 2 WA450-3MC
Valves
1. Remove the relief valve assembly (49) from the main control valve body (1).
2. Remove the four safety valve assemblies (50) from the main control valve body (1).
★ The safety valves cannot be adjusted unless they are installed on the main control valve body. Therefore. do not disas-
semble the safety valves.
3. Remove the suction valve assembly (51) from the main control valve body (1).
4. Remove the float selector valve assembly (52) from the main control valve body (1).
5. Remove all three load check valve assemblies from the top of the main valve body. This requires removing the bolts (25),
plate (23), o-ring (24), spring (22) and valve (21). Discard the o-ring.
6. Remove the float unload valve assembly from the rear of the main control valve body. This includes the bolts (31), wash-
ers (32), flange (29), o-ring (30), spring (28), seal (27) and valve (26).
Spools
Boom Spool
1. Support the case assembly at location a, then loosen and remove the bolts (19) and washers (20) from the sleeve (48) and
case (14).
2. Carefully remove the assembly and inspect the spacer (47), spring (45), piston (17), spring (10) and retainer (9) for wear
and/or damage. Discard both o-rings (15).
3. Remove the spool (5) with both plugs (6) still attached. Inspect the spool for wear and/or damage.
replaced.
4. Complete steps 1 and 2 to remove the boom spool case assembly (19, 20, 48, 47, 45, 17, 15, 41, 46, 13, 43 and 9) from the
other side of the control valve body (1) at location d and inspect them for wear and/or damage.
Bucket Spool
1. Support the case assembly at location b, then loosen and remove the bolts (19) and washers (20) from the sleeve (18) and
case (8).
replaced.
4. Complete steps 1 and 2 to remove the bucket spool case assembly (19, 20, 48, 47, 45, 17, 15, 41, 46, 13, 43 and 9) from
the other side of the control valve body (1) at location e and inspect them for wear and/or damage.
WA450-3MC 30-275 2
12
DISASSEMBLY (3-SPOOL VERSION; VALVES, SPOOLS)
30-276 2 WA450-3MC
12
Auxilary Spool
1. Support the case assembly at location c, then loosen and remove the bolts (19) and washers (20) from the sleeve (18) and
case (14).
replaced.
4. Complete steps 1 and 2 to remove the auxilary spool case assembly (items 19, 20, 18, 47, 44, 16, 15, 40, 12, 13, 42 and 7)
from the other side of the control valve body (1) at location e and inspect the assembly for wear and/or damage.
WA450-3MC 30-277 2
12
ASSEMBLY (3-SPOOL VERSION; VALVES, SPOOLS)
30-278 2 WA450-3MC
12
Spools
Boom, Bucket and Auxilary Spools
★ Install one spool assembly completely before continuing on to the other spool assembly.
★ To prevent leakage, always use new o-rings.
1. Push the boom spool (5) into body (1).
2. Assemble retainer (9), spring (43), and retainer (46) to case (13).
3. Assemble spacer (47), spring (45), piston (17), and spring (41) to sleeve (48), then fit a new o-ring (15) and assemble to
case (13).
4. Fit another new o-ring to the case (13), then install the case assembly to the main valve body (1) at location d using the
washers (20) and bolts (19) removed earlier.
5. Assemble retainer (9) and spring (10) to the case (14), then fit a new o-ring (15).
6. Assemble spacer (47), spring (45), and piston (17) to the sleeve (48), then fit another new o-ring (15) and assemble to case
(14).
7. Fit a new o-ring (15) and install the case assembly to the other side of the main valve body (1) at location a using the
washers (20) and bolts (19) removed earlier.
8. Repeat steps 1 through 7 to install the bucket and auxilary spool assemblies.
Valves
★ Install one valve assembly completely before continuing on to the other valve assembly.
1. Assemble the float unload valve (26), seal (27), and spring (28) to the rear of the main valve body (1), then fit a new o-
ring (30), install the flange (29) and secure it with the bolts (31) and washers (32) removed earlier.
2. Assemble all three load check valve assemblies to the top of the main valve body. Each valve assembly includes a valve
(21) , spring (22), a new o-ring (24), the plate (23) and the bolts (25) removed earlier.
Mounting bolt: 78.4 - 98.1 N•m (57.8 - 72.4 lbf ft)
3. Fit a new o-ring and install the float selector valve assembly (52).
Float selector valve assembly:

58.8 - 78.5 N•m (43.4 - 57.9 lbf ft)
4. Fit a new o-ring and install suction valve (51).
Suction valve assembly:

215.7 - 235 N•m (159.1 - 173.3 lbf ft)
WA450-3MC 30-279 2
12
ASSEMBLY (3-SPOOL VERSION; VALVES, SPOOLS)
30-280 2 WA450-3MC
5 Fit a new o-ring and install all four safety valve assemblies (50).

215.7 - 235.4 N•m (159.1 - 173.6 lbf ft)
6. Fit a new o-ring and install the main relief valve assembly (49).

274 - 368 N•m (202.1 - 271.4 lbf ft)
WA450-3MC 30-281 2
12
ASSEMBLY (3-SPOOL VERSION; HYDRAULIC LINES)
30-282 2 WA450-3MC
12
Hydraulic Lines
1. Install the elbow fittings (2 and 3) and o-rings (4) to the spool cases.
Elbow fittings:
78.5 - 103 N•m (57.9 - 76.0 lbf ft)
2. Install both tee fittings (6), the nipple (7) and o-rings (5).
Tree fittings:
29.4 - 39.2 N•m (21.7 - 28.9 lbf ft)
3. Connect the ends of hoses (1) to the tee fittings (6).
Hose collar nut:

29.4 - 68.6 N•m (21.7 - 50.6 lbf ft)
4. Connect both hoses (1) to their elbow connectors (2 and 3) at the boom spool.
Hose collar nut:

29.4 - 68.6 N•m (21.7 - 50.6 lbf ft)
5. Install the nipple (10) at location b and the tee fitting (9) at location c.
6. Connect both ends of tube (11) to the auxilary spool nipple at location b and the boom spool tee fitting (9) at location c.
Tube collar nut:

19.6 - 29.4 N•m (14.5 - 21.7 lbf ft)
7. Connect the tube (12) to the bucket spool nipple (10) at location a.
Tube collar nut:

19.6 - 29.4 N•m (14.5 - 21.7 lbf ft)
WA450-3MC 30-283 2
DISASSEMBLY AND ASSEMBLY DUMP CYLINDER
12
DUMP CYLINDER
REMOVAL

from moving.

RADIATOR ASSEMBLY.
1. Disconnect connector (1) of bucket positioner wiring.
2. Disconnect grease hose (2) at front frame end.
3. Hydraulic piping
A. Disconnect rod hose (3) at cylinder end.
B. Disconnect bottom hose (4) at cylinder end.

30-284 2 WA450-3MC
4. Dump cylinder
A. Sling the dump cylinder (7), then remove lock bolts, and
remove pin (5) and pin (6).
★ When slinging, be careful of the center of gravity and sling

from two points.
★ If there are shims installed, check the number and thick-
ness of the shims, and keep in a safe place.
B. Lift off dump cylinder (1).
Bucket cylinder: 227 kg (500.4 lb)
WA450-3MC 30-285 2
12
INSTALLATION

★ Install the hoses without twisting or interference.
Dump cylinder
A. Align the bottom pin hole, assemble shims so that the total for
clearance a between the cylinder and frame is within the stan-
dard value, then install pin (6).
★ Clearance a: 1.5 mm (0.059 in.)
B. Align the rod pin hole and assemble pin (5).

• After completing the assembly, add hydraulic oil through the

oil filler of the hydraulic tank to the specified level.
• Bleed air from hydraulic line. For details of the procedure for bleeding the air, see TESTING AND ADJUSTING.
30-286 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-287 2
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
12
LIFT CYLINDER
REMOVAL

from moving.

RADIATOR ASSEMBLY.
1. Rod pin
A. Sling boom cylinder (1), then remove lock bolt of rod pin, and
remove pin (2).

B. Start engine, and use control lever to retract cylinder rod on

side that was removed.
★ Retract to a point 20 mm (0.79 in.) before the end of the
stroke.
2. Hydraulic piping
A. Disconnect cylinder rod from connecting portion.
B. Disconnect cylinder bottom tube (5) and hose (6) at connecting

portion.

30-288 2 WA450-3MC
3. Lift cylinder
A. Remove the lock bolt of cylinder bottom pin, then remove pin
(7).

B. Lift off the lift cylinder (1).

★ Be careful of the center of gravity and lift off slowly.
★ Be careful not to damage the cylinder portion.
Boom cylinder: 192 kg (423 lb)
WA450-3MC 30-289 2
12
INSTALLATION
Start the engine, operate the control levers, and extend the rod.
Align the pin holes and assemble shims so that clearance a is uni-
form on the left and right, then install the pin.
★ Clearance a: Maximum 1.5 mm (0.059 in.)
Align the pin at the cylinder bottom, assemble shims so that the
total for clearance b between the cylinder and frame is within the
standard value, then install the pin.

★ Clearance b: Maximum 1.5 mm (0.059 in.)
30-290 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-291 2
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDERS
12
HYDRAULIC CYLINDERS
DISASSEMBLY
1. Install the cylinder assembly (1) in tool N.
2. Cylinder head, piston rod assembly:
A. Steering cylinder assembly
i. Use tool O to remove the cylinder head (2) from cylinder.
ii. Pull out and remove the cylinder head/piston rod assembly
(3) from the cylinder (4).
★ Place a suitable container under the cylinder to catch
the oil that drains from the cylinder when the cylinder
head/piston rod assembly is removed.
B. Lift, dump cylinder assembly
i. Remove mounting bolts of cylinder head (2).

★ Width across flats:
• Lift cylinder = 27 mm
• Dump cylinder = 30 mm
30-292 2 WA450-3MC
ii. Pull out and remove the cylinder head/piston rod assembly
(6) from the cylinder (7).
★ Place a suitable container under the cylinder to catch
the oil that drains from the cylinder when the cylinder
head/piston rod assembly is removed.
3. Cylinder head
i. Install the cylinder head and piston rod assembly (3) in

tool N.
ii. Use tool P to remove the nut (8).

★ Width across flats of nut: 55 mm
iii. Remove the piston (9), then remove the cylinder head (2).
i. Install the cylinder head and piston rod assembly (6) in

tool N.
ii. Remove the piston mounting bolt (10), then remove the
spacer (11), piston (12) and cylinder head (5).
4. Remove the O-ring and backup ring (14) from the piston rod (13).
★ Rod of lift, dump cylinder only
WA450-3MC 30-293 2
5. Remove the wear ring (15) and piston ring (16) from the pistons (9)
and (12).
6. Disassembly of cylinder head assembly
i. Remove the snap ring (17), then remove the dust seal (18).
ii. Remove the rod packing (19), then remove the bushing
(20) from the cylinder head (2).
iii. Remove the O-ring and backup ring (21).
i. Remove snap ring (22), then remove dust seal (23).
ii. Remove rod packing (24) and buffer ring (24-1), then
remove bushing (25) from cylinder head (2).
iii. Remove O-ring and backup ring (26).
30-294 2 WA450-3MC
12
ASSEMBLY
★ Clean all parts, and check for dirt or damage. Coat the sliding sur-
faces of all parts with engine oil before installing. Be careful not to
damage the rod packing, dust seals or O-rings when assembling.
1. Assembly of cylinder head assembly
A. Lift, dump cylinder assembly
i. Use tool Q to press-fit the bushing (25) to the cylinder

head (2).
ii. Install the rod packing (24) and buffer ring (24-1).
iii. Use tool S to fit the dust seal (23), then install the snap
ring (22).
iv. Install the O-ring and backup ring (26).

★ Do NOT force the backup ring into position. Instead, heat the ring in warm water (50 - 60 °C/122 - 140 °F)
for at least several minutes to expand the backup ring before fitting it.
WA450-3MC 30-295 2
12
B. Steering cylinder assembly
i. Using tool Q, press-fit bushing (20) to cylinder head (2).
ii. Install rod packing (19).
iii. Using tool S, install the dust seal (18) to the cylinder head.
iv. Install the snap ring (17).
v. Install the O-ring and backup ring (21).

★ Do NOT force the backup ring into position. Instead,
heat the ring in warm water (50 - 60 °C/122 - 140 °F)
for at least several minutes to expand the backup ring
before fitting it.
30-296 2 WA450-3MC
12
2. Assembly of the piston assembly
A. Use tool R1 to expand the piston ring (16).

★ Set the piston ring on the expander and turn the handle 8 -
10 times to expand the ring.
B. Remove the piston ring (16) from tool R1, then assemble the
ring onto pistons (12) and (9).
C. Use tool R2 to compress the piston ring (16).
D. Assemble the wear ring (15).
3. Install the O-ring and backup ring (14) onto the piston rod (13).
★ Do NOT force the backup ring into position. Instead, heat the
ring in warm water (50 - 60 °C/122 - 140 °F) for at least sev-
eral minutes to expand the backup ring before fitting it.
4. Cylinder head, piston rod assembly
A. Lift, dump cylinder assembly
i. Secure the piston rod assembly (6) to tool N.
ii. Install the cylinder head (2), piston (12) and spacer (11)
onto the piston rod, then tighten the mounting bolt (10).
Mounting bolt for lift cylinder and dump cylinder:

110.8 ± 12.8 N•m (81.7 ± 9.4 lbf ft)
WA450-3MC 30-297 2
12
i. Secure the piston rod assembly (3) to tool N.
ii. Assemble the cylinder head (2) and piston (9) to piston
rod.
iii. Install the nut (8) and use tool P to tighten the nut (8).
Thread of piston rod: Thread tightener (LT-2)
Nut: 1,422.0 ± 142.2 N•m (1,048.8 ± 104.9 lbf ft)

(Width across flats: 55 mm)
5. Cylinder head
A. Lift, dump cylinder
i. Secure the cylinder (7) onto tool N.
ii. Assemble the cylinder head/piston rod assembly (6) to the

cylinder (7).
iii. Secure the cylinder head (2) to the cylinder (7).
Lift cylinder mounting bolt:

343.2 ± 34.3 N•m (253.1 ± 25.3 lbf ft)
Dump cylinder mounting bolt:

490.3 ± 49.0 N•m (361.3 ± 36 lbf ft)
iv. Remove the cylinder assembly (1) from tool N.
30-298 2 WA450-3MC
12
i. Secure the cylinder (4) to tool N.
ii. Raise the cylinder head/piston rod assembly (3) and

assemble it to the cylinder (4).
iii. Using tool O, install the cylinder head (2) to the cylinder
(4).
Cylinder head: 784.5 ± 78.5 N•m

(578.6 ± 57.9 lbf ft)
iv. Bend the lock of the cylinder head (2) into the notch at the
cylinder end.
v. Remove the cylinder assembly (1) from tool N.
WA450-3MC 30-299 2
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
12
WORK EQUIPMENT
REMOVAL

from moving.

RADIATOR ASSEMBLY.
1. Bucket link, hinge pin
A. Sling bucket link (1), and remove mounting pin (2).

★ Remove the cord ring.
★ Secure bucket link (1) to the bellcrank with wire.
B. Remove bucket hinge mounting pin (3).

WARNING! Never insert your fingers in the pin

hole. Severe personal injury may
result.
C. Move machine to rear and disconnect bucket (4).
30-300 2 WA450-3MC
2. Sling the dump cylinder (5), then remove mounting pin (6), and dis-
connect cylinder rod and bellcrank (7).
★ Fit a lifting tool to the bucket cylinder and fix it to the rear.
Dump cylinder: 227 kg (500.5 lb)
3. Sling the boom cylinder (8), then remove mounting pin (9).
★ Set a stand under the tip of the boom.

★ Insert a block on top of the axle, then lower the cylinder.
★ Check the number and thickness of any shims, and keep them
in a safe place.
Boom cylinder: 192 kg (423 lb)
4. Lift arm, bellcrank, bucket link
A. Remove boom kick-out switch (10).
B. Sling boom assembly (11), then remove boom mounting pin

(12), and lift off boom assembly.
Lift arm assembly: 2,100 kg (4,629.7 lb)

(including bellcrank, bucket link, bellcrank pin)
★ If there are shims installed at the connection of the front

frame and boom, check the number and thickness of the
shims, and keep in a safe place.
5. Bellcrank, bucket link
A. Sling bucket link (1), then remove mounting pin (13), and lift
off from bellcrank (7).
Bucket link: 89 kg (196.2 lb)
WA450-3MC 30-301 2
B. Sling the bellcrank (7), then remove the mounting pin (14), and
lift off from boom assembly (11).
★ Carry out the mounting pin removal operation with two
people.
Bellcrank: 410 kg (903.9 lb)

Mounting pin: 40 kg (88.2 lb)
6. Dust seals, bushings
A. Pull out dust seal (15) and bushing from the lift arm (11).
B. Pull out dust seal (17) and bushing (18) from the bellcrank (7).
30-302 2 WA450-3MC
C. Pull out dust seal (19) and bushing (20) from bucket link (1).
WA450-3MC 30-303 2
12
INSTALLATION

Bucket and bucket link

★ Be careful that the cord ring does not get caught.
★ Clearance c at mount portion: 1.5 mm (0.059 in.)
• Grease all the pins after completing the assembly.
Dump cylinder
★ After assembling the mounting pin, remove the block.
Lift cylinder
★ Clearance b at mount portion: Maximum 1.5 mm (0.059 in.)
WARNING! Before starting the engine, place the

directional lever at the N position,
and check that the parking brake is
applied.
Lift arm, bellcrank, bucket link

★ Clearance a at mount portion: Maximum 1.5 mm (0.059 in.)
★ After assembling the pin, set a stand under the tip of the lift
arm.
30-304 2 WA450-3MC
12
Bellcrank, bucket link

★ Secure the bucket to the bellcrank with wire.
★ Be careful that the cord ring does not get caught.
Use a press to press-fit the bushing to the bucket link, bellcrank,

and boom. After press-fitting, assemble the dust seal.
Inside surface of bushing: Grease (G2-L1)
WA450-3MC 30-305 2
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
12
COUNTERWEIGHT
REMOVAL

from moving.
1. Sling radiator guard, and remove 4 mounting bolts, then disconnect

the connector (1) of rear working lamp wiring.
2. Lift off radiator guard (3).
3. Sling the small counterweight (3-1), remove the mounting bolts (3)
and lift away the counterweight.
Small counterweight: 400 kg (881.8 lb)
4. Sling the large counterweight (4), then remove mounting bolts and
lift it away.
Counterweight: 1,600 kg (3,527.4 lb)
★ When removing the counterweight, be careful not to damage

the battery box.
30-306 2 WA450-3MC
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
12
INSTALLATION
★ When installing the counterweights, be careful not to hit or damage the battery box.
WA450-3MC 30-307 2
DISASSEMBLY AND ASSEMBLY FUEL TANK
12
FUEL TANK
REMOVAL

from moving.
1. Radiator guard
A. Remove the 4 radiator guard mounting bolts, then disconnect

the connector (1) of rear working lamp wiring.
B. Lift off radiator guard (3).
2. Loosen the drain valve and drain fuel.
Fuel: 390 L (103 U.S. gal.)
3. Remove the engine oil drain valve (4) and the radiator drain valve
(5) from the fuel tank.
4. Fuel tube, wiring clamp
A. Disconnect hose (6) between fuel tank and feed pump, fuel return hose (7), and spill hose
(8) at tank end.
30-308 2 WA450-3MC
12
B. Disconnect wiring connector (9) for fuel sensor.
C. Remove clamps at fuel tank mounting bolt for steering oil

cooler hose and hose going to transmission cooler.
D. Remove fuel tank air bleed tube (10).
5. Fuel tank
A. Put pallet under fuel tank (11), then put blocks so that tank
does not tilt, and support tank with pallet truck.
Fuel tank: 260 kg (573.2 lb)
B. Remove fuel tank mounting bolts (12).
C. Pull out fuel tank (11) from rear of chassis.

★ With the tank balanced, operate the pallet truck to remove
the tank.
WA450-3MC 30-309 2
12
INSTALLATION
★ When installing the fuel tank, keep it horizontal, and set it in

position on the machine.
★ Tighten the bolts in the following order: left, rear, right.
Fuel tank mounting bolt:

926.7 ± 104.9 N•m (683.5 ± 77.4 lbf ft)
• Tighten the drain valve and add oil through oil filler.
30-310 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-311 2
DISASSEMBLY AND ASSEMBLY CAB ASSEMBLY
12
CAB ASSEMBLY
REMOVAL
WARNING! Stop the machine on level ground

and install the safety bar on the
frame. Lower the bucket to the
ground and stop the engine. Then
apply the parking brake and block the
wheels to prevent the machine from
moving.
1. Remove mounting bolts (3) of left and right dashboards (1) and (2).
2. Remove right cover (4).
3. Remove left cover (5).
4. Disconnect electric wiring at connector (6).
5. Disconnect window washer hose (7).

★ Tag the hose during disconnection to ease reconnection later.
6. Remove mounting bolts (8) of left and right dashboards, then

remove left and right dashboards (1) and (2).
7. Remove steering post and cab mounting bolts (9).
30-312 2 WA450-3MC
DISASSEMBLY AND ASSEMBLY CAB ASSEMBLY
12
8. Remove covers (10) under cab.
9. Remove the 8 floor and cab mounting bolts (15, marked with ✰ in
the illustration) and the 6 mounting bolts (16, marked with X).
10. Lift off the cab (14).
A. Keep the cab horizontal and lift it off slowly.
B. Remove the plugs on top of the cab, and install eyebolts.
ROPS cab: 710 kg (1,565.3 lb)
INSTALLATION
WA450-3MC 30-313 2
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
12
MAIN MONITOR
REMOVAL

from moving.

1. Remove the dashboards (1) and (2).
2. Remove the steering post cover mounting bolts (3) and (4).
3. Remove the steering post cover (5).
4. Remove the plastic mounting bolt caps (7) of steering post cover
(6), then remove the bolts.
5. Remove the mounting bolt caps from the steering post cover (8),
then remove the mounting bolts (9).
★ Tip the steering post cover to the front.
30-314 2 WA450-3MC
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
12
6. Remove the bracket (10) at rear of the main monitor.
7. Remove the 8 mounting bolts (12) of the main monitor (11).

★ Do not bump, jar or otherwise damage the main monitor during
removal.
8. Unplug the wiring connectors (13), (14), (15) and (16) from the
main monitor, then remove the main monitor (11).
INSTALLATION
★ Fit the connector lock securely.
WA450-3MC 30-315 2
DISASSEMBLY AND ASSEMBLY MAINTENANCE MONITOR
12
MAINTENANCE MONITOR
REMOVAL

from moving.
1. Remove cover (1) of right console box.
2. Disconnect connectors (2), (3), and (4) for maintenance monitor

wiring and bulb wiring (5) from maintenance monitor.
3. Remove mounting bolts (7) of maintenance monitor (6), then

remove maintenance monitor (6).
INSTALLATION
30-316 2 WA450-3MC
DISASSEMBLY AND ASSEMBLY MAINTENANCE MONITOR
12
MEMORANDUM
WA450-3MC 30-317 2
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
12
AIR CONDITIONER UNIT
REMOVAL

from moving.

(-) terminal of the battery.
1. Remove the cover under the cab.
2. Complete the oil return operation for the compressor, then use a manifold gauge and release refrigerant slowly from the
compressor high-pressure and low-pressure valves.
★ Procedure for oil return operation:
• Set the fan switch to maximum position.
• Run the engine at low idle.
• Operate air conditioner for five minutes.
WARNING! The refrigerant can cause blindness.

Wear protective goggles when working
on the air conditioning system.
3. Remove the heater hose clamps (1-3) and (1-4).
4. Remove covers (2) and (3) at rear of cab.

★ Slide the operator's seat to the front, then tip it forward.
★ Remove blind cap (3-1).
★ Remove 2 bolts and loosen 6 bolts.
30-318 2 WA450-3MC
5. Remove five mounting bolts of cover (4), then remove the cover.
6. Remove the seat support cover (5).
7. Remove the mounting bolts (7) inside the fuse box and the hot/cool
box, then remove cool and hot box assembly (6).
8. Remove fuse box assembly bracket (8) from right console box.
WA450-3MC 30-319 2
9. Remove connectors (9), (10), (11), (12), (13) and (14) from fuse
box assembly bracket, and place the fuse box assembly on the right
console box temporarily.
★ Label the connectors with tags to identify them when install-
ing.
10. Disconnect the floor wiring connectors (15), (16), and (17) from air
conditioner unit wiring, then disconnect air conditioner relay wiring
connector (18).
11. Remove the left console box cover (19).
12. Remove the left console box mounting bolts (20) and (21), then
remove the left console box (22).
30-320 2 WA450-3MC
13. Remove the mounting bolts (24) of the air conditioner unit (23).
14. Remove the mounting bolts (26) from the air conditioner unit (23)
and air conditioner damper (25).
★ Loosen the mounting bolt (27).
★ Loosen the 4 mounting bolts at the cab end.
15. Disconnect the air conditioner tubes (28) and (29) from the air con-
ditioner unit.
★ Check that the pressure has been relieved.

★ Remove the clamp.
16. Remove the cover (30) at rear right of cab.
WA450-3MC 30-321 2
17. Remove the air conditioner filter (31), then remove the duct mount-
ing bolts (32).
18. Remove the connecting bolts (33) of the air conditioner unit (23)
and air conditioner damper (25).
19. Remove the clamp bolt (34) of the air conditioner wiring connector
(16).
20. Disconnect the heater hoses (35) and (36) from the air conditioner
unit, then remove the air conditioner unit (23).
★ Air conditioner unit assembly: 38 kg (83.8 lb)
30-322 2 WA450-3MC
12
21. Disconnect the air conditioner damper wiring connector (37) from
the floor wiring, then remove the air conditioner damper (25).
★ Take steps to prevent the entry of dust or water after complet-
ing the disconnects.
WA450-3MC 30-323 2
12
INSTALLATION
Tube mounting bolt: 9.8 ± 2.0 N•m (7.2 ± 1.5 lbf ft)
O-ring: Compressor oil for new refrigerant (ND-OIL8)
★ Pass the air conditioner drain hose through the floor support grommet.

lower.
mmHg
★ Check the compressor oil level.
★ Specified oil level: 150 +14/-0 cc (ND-OIL8)
30-324 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-325 2
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
12
AIR CONDITIONER CONDENSER
REMOVAL

from moving.

and low-pressure valves,
1. Open inspection cover (1) at the top of the bulkhead.
30-326 2 WA450-3MC
12
2. Open the inspection covers (2) and (3-1) at both sides.
3. Unplug the electric wiring (4) and (5) of the condenser.
4. Disconnect the left condenser hoses (6) and (7) and right condenser
hoses (8) and (9).
★ After disconnecting the hoses and dry receiver connections, fit
plugs to prevent the entry of dirt or dust.
5. Remove the condenser mounting bolts (10), then remove the left
condenser (11) and right condenser (12).
★ The working space is very confined, so be careful when per-
forming the removal operation not to damage any components.
WA450-3MC 30-327 2
12
INSTALLATION
★ Do not remove the plugs from the hoses or condenser connections until immediately before installing.
★ Be careful not to twist or otherwise damage the hoses during installation.
Hose, connection: Compressor oil for new refrigerant

(ND-OIL8)
Condenser top connection:

19.6 - 24.5 N•m (14.5 - 18.1 lbf ft)
Condenser bottom connection:
11.8 - 14.7 N•m (8.7 - 10.8 lbf ft)

lower.
mmHg
30-328 2 WA450-3MC
12
MEMORANDUM
WA450-3MC 30-329 2
DISASSEMBLY AND ASSEMBLY RECEIVER-DRIER
12
RECEIVER-DRIER
REMOVAL

from moving.

and low-pressure valves,
1. Open inspection cover (1) at the top of the bulkhead.
2. Disconnect hoses (2) and (3) of the receiver-drier.

★ After disconnecting the hoses and receiver-drier connections,
fit plugs to prevent the entry of dirt or dust.
3. Remove mounting U-bolt (5) of receiver-drier, then remove

receiver-drier.
30-330 2 WA450-3MC
DISASSEMBLY AND ASSEMBLY RECEIVER-DRIER
12
INSTALLATION
★ Do not remove the plugs from the hoses or receiver-drier connections until immediately before installing.
★ Be careful not to twist the hoses during installation.

(ND-OIL8)
Receiver-drier connection: 4 - 6.8 N•m (3.0 - 5.0 lbf ft)
Receiver-drier mounting U-bolt:

10.8 - 26.5 N•m (8.0 - 19.5 lbf ft)

lower.
mmHg
WA450-3MC 30-331 2
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
12
AIR CONDITIONER COMPRESSOR
REMOVAL

from moving.

1. Open engine side cover (1) on the right side of the machine.
2. Disconnect electric wiring connector (2) of compressor clutch.
3. Disconnect hoses (3) and (4).

★ After disconnecting the hoses and compressor connections, fit
plugs to prevent the entry of dirt or dust.
4. Remove compressor adjustment bolt (5) and mounting bolt (6),

remove V-belt, then remove air conditioner compressor (7).
30-332 2 WA450-3MC
12
INSTALLATION
★ Do not remove the plugs in the hoses or connections until immediately before installing.
★ Be careful not to twist or otherwise damage the hoses during installation.

(NB-OIL8),
Connection nuts of hoses (3), (4):

7.9 - 11.8 N•m (5.82 - 8.7 lbf ft)
★ Adjust the V-belt. For details, see TESTING AND ADJUSTING.

★ Keep the work area ambient temperature higher than 3 °C (37 °F). The system will not work if the tempera-
ture is lower.
mmHg
WA450-3MC 30-333 2
12
MEMORANDUM
30-334 2 WA450-3MC
40 MAINTENANCE STANDARD
ENGINE AND TRANSMISSION MOUNT . . . . . . . . . . . . . . . . . . . . 40-2

TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
FORWARD, 1ST CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6
REVERSE, 2ND CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-7
3RD, 4TH CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-8
TRANSMISSION VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-9
DRIVE SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-13
AXLE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-14
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-15
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-16
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-18
LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23
STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-24
STEERING CYLINDER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . 40-25
SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-26
LEFT BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-27
RIGHT BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-28
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-29
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30
TORQUE CONVERTER, TRANSMISSION PUMP . . . . . . . . . . . . . 40-31
STEERING, SWITCH PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-32
EQUIPMENT, PPC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-33
2 SPOOL CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-34
3 SPOOL CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-36
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-38
CUT OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-39
CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40
WORK EQUIPMENT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 40-42
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-44
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-45
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-46
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-47
BUCKET POSITIONER AND BOOM KICK OUT . . . . . . . . . . . . . . . 40-48
WA450-3MC 40-1
MAINTENANCE STANDARD ENGINE AND TRANSMISSION MOUNT
ENGINE AND TRANSMISSION MOUNT
Unit - mm
No. Check item Criteria Remedy
1 Clearance between transmission bracket and adjustment bolt 1 to 1.5 Adjust
40-2 WA450-3MC
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
Unit - mm
N Criteria
Check item Remedy
o Standard size Tolerance Repair limit
- 0.010
1 Outside diameter of pilot 78 77.75
- 0.040
+ 0.035
2 Inside diameter of seal ring contact surface 110 0 110.5
- 0.01 Repair
Width 3 - 0.03 2.7
3 Stator shaft seal ring wear
Thickness 4.3 ± 0.1 3.9
4 PTO drive driven gear backlash 0.18 to 0.49
WA450-3MC 40-3
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION Unit - mm
Criteria
No. Check item Standard Tolerance Standard Clearance Remedy
size Shaft Hole clearance limit
+ 0.024 0
1 Pump drive shaft and bearing clearance 65 + 0.011 - 0.015 - 0.039 to - 0.011 ---
0 + 0.030
2 Pump drive gear bearing and housing clearance 120 0 to 0.045 ---
- 0.015 0
+ 0.020 0
3 Pump drive shaft and bearing clearance 50 - 0.032 to - 0.009 ---
+ 0.009 - 0.012
0 + 0.030
4 Pump drive gear bearing and housing clearance 90 - 0.015 0 0 to 0.045 ---
+ 0.012 0
5 Idler gear shaft and bearing clearance 65 + 0.007 - 0.015 - 0.027 to - 0.007 ---
0 - 0.030
6 lder gear bearing and idler gear clearance 120 - 0.018 - 0.052 - 0.052 to - 0.012 ---
+ 0.025 0
7 Pump drive shaft and bearing clearance 40 - 0.037 to - 0.009 ---
+ 0.009 - 0.012
0 + 0.030
8 Pump drive gear bearing and housing clearance 80 0 to 0.043 ---
- 0.013 0
+ 0.025 0
9 Input shaft and bearing clearance 45 + 0.009 - 0.012 - 0.037 to - 0.009 ---
0 + 0.030
10 Input shaft and housing clearance 100 - 0.015 0 0 to 0.045 ---
+ 0.035 0
11 Input shaft gear and bearing clearance 90 + 0.013 - 0.020 - 0.055 to - 0.013 ---
0 + 0.030
12 Input shaft gear bearing and housing clearance 160 0 to 0.055 ---
- 0.025 0
0 - 0.018
13 Output shaft bearing and housing clearance 130 - 0.058 to 0 ---
- 0.018 - 0.058
Replace
+ 0.030 0
14 Output shaft and bearing clearance 75 + 0.011 - 0.015 - 0.045 to - 0.011 ---
0 - 0.018
15 Output shaft bearing and housing clearance 150 - 0.018 - 0.058 - 0.058 to 0 ---
+ 0.035 0.0
16 Output shaft and bearing clearance 85 + 0.013 - 0.020 - 0.055 to - 0.013 ---
0 + 0.030
17 Front F/1st clutch bearing and housing clearance 160 0 to 0.055 ---
- 0.025 0
0 + 0.030
18 Rear F/1st clutch bearing and housing clearance 160 0 to 0.055 ---
- 0.025 0
0 + 0.030
19 Front R/2nd clutch bearing and housing clearance 160 - 0.025 0 0 to 0.055 ---
0 + 0.030
20 Rear R/2nd clutch bearing and housing clearance 160 - 0.025 0 0 to 0.055 ---
0 + 0.030
21 Rear 3rd/4th clutch bearing and housing clearance 130 - 0.018 0 0 to 0.048 ---
0 + 0.030
22 Front 3rd/4th clutch bearing and housing clearance 160 0 to 0.055 ---
- 0.025 0
+ 0.025 0
23 Rear countershaft and bearing clearance 45 - 0.037 to - 0.009 ---
+ 0.009 - 0.012
0 + 0.030
24 Rear countershaft bearing and housing clearance 100 - 0.015 0 0 to 0.045 ---
+ 0.025 0
25 Front countershaft and bearing clearance 40 + 0.009 & - 0.012 - 0.037 to - 0.009 ---
0 + 0.030
26 Front countershaft bearing and housing clearance 80 - 0.013 0 0 to - 0.043 ---
Standard size Tolerance Clearance limit
+ 0.050
Inside diameter of seal ring fitting face 55 55.1
0
+ 0.076
Seal ring groove width 3.2 3.5
0
27
Seal ring width 3.1 ± 0.05 2.8
0 Replace
Seal ring thickness 2.29 ! 0.13 2.1
Outside diameter of sliding face of coupling oil seal 0

28 105 ! 0.087 104.8
R
Outside diameter of sliding face of coupling oil seal 0
29 105 104.8
F ! 0.087
Standard clearance Clearance limit

30 Output shaft cover and housing clearance 0.5 to 1.4 ---
Adjust
31 Free turning torque of output shaft 0.098 to 0.98 NCm
40-4 WA450-3MC
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
WA450-3MC
40-5
MAINTENANCE STANDARD FORWARD, 1ST CLUTCH
FORWARD, 1ST CLUTCH
Unit - mm
Criteria
No Check item Standard Tolerance Standard Allowable Remedy
size Shaft Hole clearance clearance
+ 0.030 0
1 Forward bearing to shaft clearance 75 - 0.045 to - 0.011 ---
+ 0.011 - 0.015
Replace
+ 0.049 0
2 1st bearing to shaft clearance 75 + 0.036 - 0.015 - 0.064 to - 0.036 ---
Seperator plate thickness 2.0 ± 0.05 1.8

3
Seperator plate flatness --- 0.05 0.15
Friction plate thickness 3.2 ± 0.08 2.75

4
Friction plate flatness --- 0.1 0.25
Replace
5 1st gear wave spring load 3.2 mm tall 2481 N ± 224 N 2109 N
6 Forward wave spring load 3.2 mm tall 1106 N ± 57 N 940 N
7 1st gear thrust washer thickness 4 ± 0.1 3.7
8 Forward thrust washer thickness 4 ± 0.1 3.7
40-6 WA450-3MC
MAINTENANCE STANDARD REVERSE, 2ND CLUTCH
REVERSE, 2ND CLUTCH
Unit - mm
Criteria
+ 0.030 0
1 Reverse bearing to shaft clearance 75 - 0.045 to - 0.011 ---
+ 0.011 - 0.015
Replace
+ 0.071 0
2 2nd bearing to shaft clearance 75 + 0.061 - 0.015 - 0.086 to - 0.061 ---

3

4
Friction plate flatness --- 0.1 0.25
Replace
5 2nd gear wave spring load 3.2 mm tall 2481 N ± 224 N 2109 N
6 Reverse wave spring load 3.2 mm tall 1106 N ± 57 N 940 N
7 2nd gear thrust washer thickness 4 ± 0.1 3.7
8 Reverse thrust washer thickness 4 ± 0.1 3.7
WA450-3MC 40-7
MAINTENANCE STANDARD 3RD, 4TH CLUTCH
3RD, 4TH CLUTCH
Unit - mm
Criteria
+ 0.030 0
1 3rd/4th rear bearing to shaft clearance 75 - 0.045 to - 0.011 ---
+ 0.011 - 0.015
Replace
+ 0.071 0
2 3rd/4th front bearing to shaft clearance 75 + 0.061 - 0.015 - 0.086 to - 0.061 ---

3

4
Friction plate flatness --- 0.1 0.25 Replace
5 Wave spring load 3.2 mm tall 2481 N ± 224 N 2109 N
6 3rd gear thrust washer thickness 4 ± 0.1 3.7
7 4th gear thrust washer thickness 4 ± 0.1 3.7
40-8 WA450-3MC
MAINTENANCE STANDARD TRANSMISSION VALVES
TRANSMISSION VALVES
UPPER VALVE
Unit - mm
Criteria
- 0.035 + 0.013
1 Pilot valve and body clearance 19 - 0.045 0 0.035 to 0.058 0.08
- 0.035 + 0.013
2 Main relief valve and body clearance 25 - 0.045 0 0.035 to 0.058 0.08
- 0.020 + 0.018
3 Main relief valve and load piston 15 - 0.030 0 0.020 to 0.048 0.07
- 0.035 + 0.013
4 Modulation valve and body clearance 19 - 0.045 0 0.035 to 0.058 0.08 Replace
- 0.035 + 0.013
5 Converter reg valve and body clearance 25 - 0.045 0 0.035 to 0.058 0.08
- 0.020 + 0.011
6 Emergency spool and body clearance 14 - 0.030 0 0.020 to 0.041 0.06
- 0.035 + 0.012
7 Modulation valve and load piston clearance 6 - 0.045 0 0.035 to 0.057 0.08
Standard size Clearance limit
Free length Installed height Installed load Free length Installed load
8 Main relief valve spring 170.5 132 412 N 165.4 391 N

9 Fill valve spring 23.8 13 8.8 N 23.1 8.4 N
10 Torque converter reg valve spring 65 62 70.6 N 63.1 67.1 N Replace
11 Pilot valve spring 59.8 37 267 N 58 253 N
12 Load piston spring 26 19 5.7 N 25.2 5.4 N
WA450-3MC 40-9
LOWER VALVE
Unit - mm
Criteria
No. Check item Standard Tolerance Standard Allowable Remedy
- 0.020 + 0.013
1 F-R selector spool and body clearance 19 0.020 to 0.043 0.06
- 0.030 0
- 0.020 + 0.013
2 Hi-Lo selector spool and body clearance 19 - 0.030 0 0.020 to 0.043 0.06
- 0.020 + 0.013
3 Range slector spool and body clearance 19 - 0.030 0 0.020 to 0.043 0.06 Replace
- 0.035 + 0.013
4 Prioroty valve and body clearance 19 - 0.045 0 0.035 to 0.058 0.08
- 0.020 + 0.013
5 Parking brake valve and body clearance 25 0.020 to 0.043 0.06
- 0.030 0
6 F-R selector spool spring 42 32 78.9 N 40.7 75 N

7 Hi-Lo range selector spool spring 48 36.7 69.8 N 46.1 66.3 N
Replace
8 Priority valve spring 125.5 111.3 570 N 121.7 541 N
9 Parking brake valve spring 46 37 81.4 N 44.6 77.4 N
40-10 WA450-3MC
FLOW VALVE
Unit - mm
Criteria
- 0.020 + 0.013
1 Flow control valve and body clearance 25 0.020 to 0.043 0.06 Replace
- 0.030 0

2 Flow control valve spring 63.8 47 79.5 N 61.9 75.5 N Replace
WA450-3MC 40-11
ACCUMULATOR VALVE
Unit - mm
Criteria
- 0.035 + 0.025
1 Accumulator valve and body clearance 32 - 0.045 0 0.035 to 0.070 0.09 Replace

2 Accumulator valve spring 184.8 165 319 N 179.3 303 N Replace
40-12 WA450-3MC
MAINTENANCE STANDARD DRIVE SHAFTS
DRIVE SHAFTS
WA450-3MC 40-13
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
Unit - mm
Criteria
No Check item Remedy
Standard size Tolerance Repair limit
0
1 Thrust plate thickness 20 ---
- 0.15
Replace
+ 0.3
2 Wear plate thickness 5 - 0.1 ---
Standard Tolerance Standard Clearance

Hole and shaft at front support clear- - 0.056 + 0.439

3 275 - 0.137 + 0.023 0.079 to 0.576 ---
ance
Replace
Hole and shaft at rear support clear- - 0.043 + 0.455
4 170 - 0.106 + 0.027 0.070 to 0.561 ---
ance
40-14 WA450-3MC
MAINTENANCE STANDARD FRONT AXLE
FRONT AXLE
WA450-3MC
40-15
MAINTENANCE STANDARD REAR AXLE
REAR AXLE
40-16 WA450-3MC
MAINTENANCE STANDARD MEMORANDA
MEMORANDA
WA450-3MC 40-17
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
40-18 WA450-3MC
MAINTENANCE STANDARD DIFFERENTIAL
Unit - mm
Criteria
No Check item Standard Tolerance Standard Clearance Remedy
0 + 0.054
1 Side bearing clearance [outer race] 160 0.014 to 0.079 ---
- 0.025 + 0.014
+ 0.059 0
2 Side bearing clearance [inner race] 105 + 0.037 - 0.020 -0.079 to -0.037 ---
Pinion shaft bearing clearance [outer + 0.025 - 0.025

3 146.05 -0.075 to -0.025 ---
race] 0 - 0.050
Pinion shaft bearing clearance [inner + 0.064 + 0.013

4 69.85 + 0.051 0 -0.064 to -0.038 ---
race]
Pinion shaft bearing clearance [inner + 0.051 + 0.013 Replace

5 69.85 + 0.038 0 -0.051 to -0.025 ---
race]
0 + 0.030
6 Pilot bearing clearance [outer race] 110 0.010 to 0.045 ---
- 0.015 + 0.010
+ 0.050 0
7 Pilot bearing clearance [inner race] 50 + 0.054 - 0.012 -0.062 to -0.034 ---
- 0.020 + 0.046
8 Differential carrier and cage clearance 190 0.030 to 0.106 ---
- 0.060 + 0.010
- 0.06 + 0.100
9 Spider and pinion gear clearance 34.93 - 0.11 + 0.050 0.110 to 0.210 ---
10 Side gear washer thickness 4 ± 0.05 3.8

+ 0.090 Replace
11 Pinion gear washer thickness 1.5 0.135
+ 0.010
Standard size Repair limit
12 Bevel gear backlash 0.3 to 0.41 ---
13 Differential gear backlash 0.10 to 0.43 ---
14 Pinion gear end play Max 0.21

Replace
15 Pinion shaft bearing preload Rotating force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. 51.1 N
Rotating force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 to 24.5 N

16 Differential side bearing preload
[Target 24.5 N]
17 Bevel gear rear face runout Max 0.1
WA450-3MC 40-19
MAINTENANCE STANDARD LIMITED SLIP DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL
40-20 WA450-3MC
MAINTENANCE STANDARD LIMITED SLIP DIFFERENTIAL
Unit - mm
Criteria
0 + 0.054
1 Side bearing clearance [outer race] 160 0.014 to 0.079 ---
- 0.025 + 0.014
+ 0.059 0
2 Side bearing clearance [inner race] 105 + 0.037 - 0.020 -0.079 to -0.037 ---
Pinion shaft bearing clearance [outer + 0.025 - 0.025

3 146.05 -0.075 to -0.025 ---
race] 0 - 0.050
Pinion shaft bearing clearance [inner + 0.064 + 0.013

4 69.85 + 0.051 0 -0.064 to -0.038 ---
race]
Pinion shaft bearing clearance [inner + 0.051 + 0.013 Replace

5 69.85 -0.051 to -0.025 ---
race] + 0.038 0
0 + 0.030
6 Pilot bearing clearance [outer race] 110 0.010 to 0.045 ---
- 0.015 + 0.010
+ 0.050 0
7 Pilot bearing clearance [inner race] 50 + 0.054 - 0.012 -0.062 to -0.034 ---
- 0.020 + 0.046
8 Differential carrier and cage clearance 190 0.030 to 0.106 ---
- 0.060 + 0.010
- 0.11 + 0.005
9 Spider and pinion gear clearance 35 - 0.16 0 0.110 to 0.210 ---
10 Plate thickness 3.4 to 3.5 ± 0.03 3.3

+ 0.040 Replace
11 Pinion gear washer thickness 3.6 - 0.030 3.55
12 Bevel gear backlash 0.3 to 0.41 ---
13 Disc and plate clearance 0.2 to 0.4
14 Pinion gear end play Max 0.21

Replace
15 Pinion shaft bearing preload Rotating force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. 51.1 N
Rotating force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 to 24.5 N

16 Differential side bearing preload
[Target 24.5 N]
17 Bevel gear rear face runout Max 0.1

Standard size Tolerance Allowable limit
18 Washer thickness 4.0 to 4.1 ± 0.05 3.8
19 Side gear end play [one side] 0.2 to 0.4

Replace
20 Case and plate backlash 0 to 0.5
21 Disc and side gear backlash 0.13 to 0.36
WA450-3MC 40-21
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
Unit - mm
Criteria
+ 0.013 0
1 Planetary shaft and bearing clearance 45 - 0.025 to 0 ---
0 - 0.012
Replace
+ 0.040 0
2 Ring gear hub and bearing clearance 180 -0.065 to -0.015 ---
+ 0.015 - 0.025
3 Spacer thickness 26 ± 0.1 25.5

4 Planet gear and sun gear backlash 0.19 to 0.43
Replace
5 Planet gear and ring gear backlash 0.19 to 0.53
6 Wheel hub shim thickness 2.025 ± 1.25
40-22 WA450-3MC
MAINTENANCE STANDARD STEERING COLUMN
STEERING COLUMN
Unit - mm
Criteria
Steering shaft and column bearing clear- 0 + 0.15

1 19 - 0.08 - 0.05 0.05 to 0.23 0.4 Replace
ance
WA450-3MC 40-23
MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
Unit - mm
Criteria
No Check item Standard size Repair limit Remedy
Free length Installed length Installed load Free length Installed load
1 Steering spool return spring 37.2 32.0 56.9 N --- 47.1 N
2 Load check valve spring 20.9 13.2 9.3 N --- 7.8 N
3 Demand spool return spring 75.1 68.5 136.1 N --- 114.7 N Replace
4 Relief valve spring 24.0 22.2 182.4 N --- 145.1 N
5 Check valve return spring 21.6 17.0 2.3 N --- 1.8 N
40-24 WA450-3MC
MAINTENANCE STANDARD STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
Unit - mm
Criteria
0 + 0.150
1 Pin and rod end bushing clearance 55 0.050 to 0.196 ---
- 0.046 + 0.050
Replace
0 + 0.200
2 Pin and head end bushing clearance 55 0.100 to 0.246 ---
- 0.046 + 0.100
Width of boss Width of hinge Clearance - a% b
Max 0.5
3 Cylinder and rear frame connection 65 + 0.8 71.5 ± 1
0 [after shim adjustment]
Replace
+ 0.8 Max 0.5
4 Cylinder and front frame connection 65 67 ± 1
0 [after shim adjustment]
WA450-3MC 40-25
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
Unit - mm
Criteria
- 0.030 + 0.074
1 Body and piston clearance 55 0.030 to 0.150 0.25 Replace
- 0.076 0
Free length Test height Test load Free length Test load
2 Slack adjuster spring 198 38 43.2 N

Replace
3 Return spring 39.2 33 66.7 N
40-26 WA450-3MC
MAINTENANCE STANDARD LEFT BRAKE VALVE
LEFT BRAKE VALVE
Unit - mm
Criteria
- 0.025 + 0.1
1 Pedal mount and bracket hole clearance 10 0.025 to 0.175 0.25
- 0.075 0
Replace
- 0.025 + 0.1
2 Roller and pin clearance 10 0.025 to 0.175 0.25
- 0.075 0
0
3 Outside diameter of roller 30 29.2 Replace
- 0.5

4 Control spring 34 33.5 3.8 N 33
5 Control spring 46.3 46 11.8 N 45.3

Replace
6 Return spring 86.2 58 60.8 N 78
7 Return spring 31.5 19.5 16.7 N 28
WA450-3MC 40-27
MAINTENANCE STANDARD RIGHT BRAKE VALVE
RIGHT BRAKE VALVE
Unit - mm
Criteria
No Check item Tolerance Clearance Remedy
Std size Standard clearance
Shaft Hole limit
- 0.025 + 0.1
1 Pedal mount and bracket hole clearance 10 0.025 to 0.175 0.25
- 0.075 0
Replace
- 0.025 + 0.1
2 Roller and pin clearance 10 0.025 to 0.175 0.25
- 0.075 0
0
3 Outside diameter of roller 30 29.2 Replace
- 0.5
4 Control spring 34 33.5 3.8 N 33
5 Control spring 46.3 46 11.8 N 45.3
6 Return spring 86.2 58 60.8 N 78 Replace
7 Spring 31.5 19.5 16.7 N 28
8 Return spring 31.5 19.5 16.7 N 28
40-28 WA450-3MC
MAINTENANCE STANDARD BRAKE
BRAKE
Unit - mm
Criteria
1 Return spring 75.6 66.2 568.8 N 74.7 511.9 N Replace

2 Plate thickness 2.3 ± 0.08 2.0

3 Disc thickness 3.8 ± 0.1 3.5
4 Disc and plate assembly thickness 38.9 ± 1.16 35.0
+ 0.097
5 Piston seal contact surface wear 420 0 --- Replace
+ 0.089
6 Piston seal contact surface wear 383 0 ---
7 Outer gear and plate backlash 0.21 to 0.65

8 Inner gear and disc backlash 0.31 to 0.74
WA450-3MC 40-29
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
Unit - mm
Criteria
Thickness 4 ± 0.5 3.9

1 Seperator plate
Distortion --- 0.05 0.6
Replace
2 Brake disc thickness 3.2 ± 0.08 3.05
3 Wave spring load 3.2 mm high 1106 N ± 57 N 940 N

4 Outer brake spring 77.7 54 1397 N 75.4 1328 N

Replace
5 Inner brake spring 77.8 54 536 N 75.5 510 N
40-30 WA450-3MC
MAINTENANCE STANDARD TORQUE CONVERTER, TRANSMISSION PUMP
TORQUE CONVERTER, TRANSMISSION PUMP
Unit - mm
Criteria
Model Standard clearance Clearance limit
1 Side clearance SAR(3)100 0.13 to 0.18 0.22

Replace
2 Plain bearing and gear shaft clearance SAR(3)100 0.06 to 0.149 0.20
Model Standard size Tolerance Repair limit

0
3 Pin depth SAR(3)100 14 - 0.5 --- Replace
4 Spline shaft rotating torque 6.9 to 11.8 NCm ---
Model RPM kg/cm 2 Std R/min Limit R/min
5 Discharge . . . . . . . . oil temp 45E to 55E C SAR(3)100 2500 30 241 221
WA450-3MC 40-31
MAINTENANCE STANDARD STEERING, SWITCH PUMP
STEERING, SWITCH PUMP
Unit - mm
Criteria
SAR(3)71
1 Side clearance 0.10 to 0.15 0.19
SAR(3)50
Replace
SAR(3)71
2 Plain bearing and gear shaft clearance 0.06 to 0.149 0.20
SAR(3)50
SAR(3)71
0
3 Pin depth 14 --- Replace
- 0.5
SAR(3)50
SAR(3)71 158 146

5 Discharge . . . . . . . . oil temp 45E to 55E C 2500 210 ---
SAR(3)50 112 102
40-32 WA450-3MC
MAINTENANCE STANDARD EQUIPMENT, PPC PUMP
EQUIPMENT, PPC PUMP
Unit - mm
Criteria
SAR(4)140 0.11 to 0.16

1 Side clearance 0.19
SAR(1)28 0.10 to 0.15
Replace
SAR(4)140 0.06 to 0.140
2 Plain bearing and gear shaft clearance 0.20
SAR(1)28 0.064 to 0.119
SAR(4)140 21
0
3 Pin depth --- Replace
- 0.5
SAR(1)28 10
SAR(4)140 210 287 266

5 Discharge . . . . . . . . oil temp 45E to 55E C 2200 ---
SAR(1)28 30 59 52
WA450-3MC 40-33
MAINTENANCE STANDARD 2 SPOOL CONTROL VALVE
2 SPOOL CONTROL VALVE
40-34 WA450-3MC
Unit - mm
Criteria
1 Spool return spring - large 64.4 62.2 190.2 N --- 152.0 N
2 Spool return spring - small 18.6 14.9 112.8 N --- 90.2 N
7 Spool return spring - small 42 42 0 --- ---
9 Spool return spring - small 62.6 52 31.4 N --- 25.5 N
10 Spool return spring 62.6 52 31.4 N --- 25.5 N
11 Check valve spring 78.2 52 18.8 N --- 14.7 N
12 Float selector valve spring 53 42.1 137.3 N --- 109.8 N
13 Unload valve spring 82.7 47 49.1 N --- 39.2 N
WA450-3MC 40-35
3 SPOOL CONTROL VALVE
40-36 WA450-3MC
Unit - mm
Criteria
9 Spool return spring - small 62.6 52 31.4 N --- 25.5 N
10 Spool return spring 62.6 52 31.4 N --- 25.5 N
11 Check valve spring 78.2 52 18.8 N --- 14.7 N
12 Float selector valve spring 53 42.1 137.3 N --- 109.8 N
13 Unload valve spring 82.7 47 49.1 N --- 39.2 N
WA450-3MC 40-37
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
Unit - mm
Criteria
Bucket dump
1 Centering spring Arm lower 52.8 36.0 29.4 N --- 23.5 N
Bucket tilt
2 Centering spring Arm raise 52.8 36.0 39.2 N --- 31.4 N Replace
3 Metering spring 31.4 29.4 16.7 N --- 13.7 N
40-38 WA450-3MC
MAINTENANCE STANDARD CUT OFF VALVE
CUT OFF VALVE
Unit - mm
Criteria
1 Unload valve spring 37 30 35.3 N --- 28.4 N

Replace
2 Check valve spring 33 20 1.7 N --- 1.4 N
WA450-3MC 40-39
MAINTENANCE STANDARD CENTER HINGE PIN
CENTER HINGE PIN
40-40 WA450-3MC
MAINTENANCE STANDARD CENTER HINGE PIN
Unit - mm
Criteria
Shaft Hole limit
- 0.030 + 0.071
1 Upper pin and rear frame clearance 80 0.066 to 0.147 ---
- 0.076 + 0.036
- 0.030 + 0.060
2 Upper hinge and small spacer clearance 80 - 0.076 + 0.030 0.060 to 0.136 ---
- 0.030 0
3 Upper hinge and bearing clearance 80 0.015 to 0.076 ---
- 0.076 - 0.015
- 0.030 + 0.030
4 Upper hinge and large spacer clearance 80 - 0.076 0 0.030 to 0.106 ---
- 0.036 + 0.071
5 Rear frame and large spacer clearance 95 - 0.071 + 0.036 0.072 to 0.142 ---
Replace
0 - 0.048
6 Front frame and upper bearing clearance 130 -0.088 to -0.023 ---
- 0.025 - 0.088
- 0.030 + 0.067
7 Lower pin and rear bushing clearance 80 - 0.076 + 0.027 0.057 to 0.143 ---
- 0.030 0
8 Lower pin and bearing clearance 80 0.015 to 0.076 ---
- 0.076 - 0.015
0 - 0.048
9 Front frame and lower bearing clearance 130 - 0.025 - 0.088 -0.088 to -0.023 ---
+ 0.170 + 0.054
10 Lower pin seal clearance 105 + 0.080 0 -0.170 to -0.026 ---
11 Upper hinge small spacer height 36 ± 0.1 ---

Replace
12 Upper hinge large spacer height 61.5 ± 0.1
Standard size Standard clearance Clearance limit
13 Shim value for upper hinge and retainer 1
14 Shim value for upper hinge and retainer 2
19.6 ± 2 NCm Adjust with shim

15 Upper hinge retainer bolt torque Replace
112.8 ± 9.8 NCm Final valve
19.6 ± 2 NCm Adjust with shim

16 Upper hinge retainer bolt torque
205.9 ± 19.6 NCm Final valve
WA450-3MC 40-41
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
40-42 WA450-3MC
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
Unit - mm
Criteria
No Check item Std Tolerance Clearance Remedy
Standard clearance
size limit
Shaft Hole
- 0.036 + 0.207
1 Pin to link bushing clearance 95 0.156 to 0.297 1
- 0.090 + 0.120
- 0.036 + 0.207
2 Boom and bucket pin and bushing clearance 95 - 0.090 + 0.120 0.156 to 0.297 1
- 0.036 + 0.207
3 Boom and frame pin and bushing clearance 110 0.156 to 0.297 1
- 0.090 + 0.120
- 0.036 + 0.207
4 Cylinder and frame pin and bushing clearance 120 - 0.090 + 0.120 0.156 to 0.297 1
Replace
[Replace if there is scuffing
Cylinder and bellcrank pin and bushing clear- - 0.036 + 0.207 on pin]
5 120 0.156 to 0.297 1
ance - 0.090 + 0.120
- 0.043 + 0.395
6 Boom and bellcrank pin and bushing clearance 125 0.338 to 0.501
- 0.106 + 0.295
- 0.036 + 0.207
7 Boom at cylinder pin and bushing clearance 110 - 0.090 + 0.120 0.156 to 0.297 1
- 0.036 + 0.207
8 Cylinder at frame pin and bushing clearance 110 0.156 to 0.297 1
- 0.090 + 0.120
Width of boss Width of hinge Clearance
+ 0.8
9 Bucket cylinder and frame 128 0 128 ± 0.8 1.4 to 3.8
+2.5
10 Boom and frame 127 ± 2.3 130 0.7 to 7.8
0
Replace
+1.5 [Inspect shims on both
11 Boom and bucket 119 ± 2.3 122 0 0.7 to 6.8 sides so that clearance is
l e s s than 1.5 mm on both
sides]
+3 + 1.5
12 Bucket and link 138 143 2 to 7
- 0.5 0
+ 0.8 + 0.5
13 Boom cylinder and frame 120 125 2.2 to 5.5
0 0
+3
14 Bellcrank to link 138 - 0.5 143 ± 1.5 1 to 5.5
15 Bellcrank and boom 220 ± 0.5 223 ± 0.5 2 to 4 Replace
+ 0.8
16 Bucket cylinder at bellcrank 115 0 118 ± 1.5 1.2 to 3
Adjust with shims so that

17 Boom cylinder at boom 111 ± 2.5 114 ± 1.5 0 to 6 clearance is less than 2 mm
on both sides
WA450-3MC 40-43
MAINTENANCE STANDARD BOOM CYLINDER
BOOM CYLINDER
Unit - mm
Criteria
Shaft Hole limit
- 0.036 + 0.222
1 Cylinder rod and bushing clearance 95 - 0.090 + 0.047 0.083 to 0.312 ---
- 0.036 + 0.350
2 Mounting pin and rod eye clearance 110 - 0.090 + 0.200 0.236 to 0.440 1.0 Replace
- 0.036 + 0.207
3 Mounting pin and bushing clearance 110 - 0.090 + 0.120 0.156 to 0.297 1.0
+0.30
4 Inside diameter of cylinder barrel 180 0 --- Replace
40-44 WA450-3MC
MAINTENANCE STANDARD BUCKET CYLINDER
BUCKET CYLINDER
Unit - mm
Criteria
Shaft Hole limit
- 0.036 + 0.257
1 Cylinder rod and bushing clearance 100 0.084 to 0.347 ---
- 0.090 + 0.048
- 0.036 + 0.207
2 Mounting pin and bushing clearance 120 - 0.090 + 0.120 0.156 to 0.297 1.0 Replace
- 0.036 + 0.207
+0.30
WA450-3MC 40-45
MAINTENANCE STANDARD STEERING CYLINDER
STEERING CYLINDER
Unit - mm
Criteria
Shaft Hole limit
- 0.025 + 0.164
1 Cylinder rod and bushing clearance 50 - 0.087 + 0.007 0.032 to 0.251 ---
0 + 0.174
2 Mounting pin and rod eye clearance 55 - 0.046 + 0.100 0.100 to 0.220 1.0 Replace
0 + 0.174
+0.20
40-46 WA450-3MC
MAINTENANCE STANDARD BUCKET
BUCKET
Unit - mm
Criteria
1 Wear of bucket tooth 50 18.5 Replace
2 Bucket tooth mount clearance Max. 0.5 Adjust or replace
3 Cutting edge wear 93 Turn or replace
WA450-3MC 40-47
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK OUT
BUCKET POSITIONER AND BOOM KICK OUT
Unit - mm
No Check item Criteria Remedy
1 Bucket positioner switch clearance 3 to 5
Adjust
2 Boom kick out switch clearance 3 to 5
40-48 WA450-3MC
90 OTHERS
ELECTRICAL CIRCUIT DIAGRAM (1 OF 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2

ELECTRICAL CIRCUIT DIAGRAM (2 OF 4) . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .90-3
ELECTRICAL CIRCUIT DIAGRAM (3 OF 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
ELECTRICAL CIRCUIT DIAGRAM (4 OF 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
WA320-3MC 90-1

Manual de Taller WA450-3MC

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Manual de Taller WA450-3MC

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CEBM003602

SERIAL NUMBERS WA450-3MC - A35001 and up

JULY 1999 Copyright 1999 Komatsu America International Company

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . 10-1

20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 30-1

40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:

PARTS BOOK - MICROFICHE:

OPERATION AND MAINTENANCE MANUAL:

Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WLT70-1

STREET ADDRESS ORDER DATE

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

KDC91E 072199 CURRENT PRICES WILL BE CHARGED

● Page to be replaced Replace

( ) Page to be deleted Discard

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( ) 0-2 1 00-14 10-9 10-38

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( ) 0-5 1 00-17 10-12 10-41

( ) 0-6 1 00-18 10-13 10-42

( ) 0-7 1 10-14 10-43

( ) 0-8 1 01-1 10-15 10-44

01-2 10-16 10-45

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00-3 01-13 10-27 10-56

00-4 01-14 10-28 10-57

00-5 10-29 10-58

00-6 10-1 10-30 10-59

00-7 10-2 10-31 10-60

00-8 10-3 10-32 10-61

00-9 10-4 10-33 10-62

00-10 10-5 10-34 10-63

00-11 10-6 10-35 10-64

00-12 10-7 10-36 10-65

WA450-3MC WA450-3MC 00-2-1 2

10-66 10-99 10-132 10-165

10-68 10-101 10-134 10-167

10-69 10-102 10-135 10-168

10-71 10-104 10-137 10-170

10-72 10-105 10-138 10-171

10-73 10-106 10-139 10-172

10-74 10-107 10-140 10-173

10-75 10-108 10-141 10-174

10-76 10-109 10-142 10-175

10-78 10-111 10-144 10-177

10-79 10-112 10-145 10-178

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