SM Wa 200-5 PDF

SEBM033307
MACHINE MODEL SERIAL NUMBER
WA200-5 65001 and up

WA200PT-5 65001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may re-
quire.
Materials and specifications are subject to change without notice.
• WA200, 200PT-5 mounts the SAA6D102E-2-A engine.

For details of the engine, see the 102 Series Engine Shop Manual.
© 2011
All Rights Reserved 00-1
Printed in Japan 01-11 (7)
CONTENTS
No. of page
01 GENERAL ................................................................................................................ 01-1
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD .............................................. 10-1
20 TESTING AND ADJUSTING ...................................................................... 20-1
30 DISASSEMBLY AND ASSEMBLY .......................................................... 30-1
90 OTHERS .................................................................................................................... 90-1
00-2 WA200-5
(2)
LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Q Page to be newly added Add
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are not revised at this time.

Time of Time of Time of Time of Time of
Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
q 00-1 (7) 01-1 10-19 10-48 10-77
00-2 (2) 01-2 (3) 10-20 (3) 10-49 10-78
q 00-2-1 (7) 01-3 (3) 10-21 (3) 10-50 10-79
q 00-2-2 (7) 01-4 (4) 10-22 10-51 10-80
00-2-3 (5) 01-5 (3) 10-23 10-52 (3) 10-81
00-2-4 (5) 01-6 (3) 10-24 10-53 10-82
00-2-5 (5) 01-7 (3) 10-25 10-54 10-83
00-3 01-8 (3) 10-26 10-55 10-84
00-4 01-9 (4) 10-27 10-56 (3) 10-85
00-5 10-28 10-57 10-86
00-6 10-29 10-58 10-87
00-7 10-1 (3) 10-30 10-59 10-88
00-8 10-2 10-31 10-60 10-89
00-9 10-3 10-32 10-61 10-90
00-10 10-4 10-33 10-62 10-92
00-11 10-5 (5) 10-34 10-63 10-93
00-12 10-5-1 (5) 10-35 10-64 10-94
00-13 10-6 10-36 10-65 10-95
00-14 10-8 10-37 10-66 10-96
00-15 10-9 10-38 10-67 10-98 (3)
00-16 10-10 10-39 10-68 10-99 (3)
00-17 10-11 10-40 10-69 10-99-1 (3)
00-18 10-12 (6) 10-41 10-70 10-99-2 (3)
00-19 10-13 10-42 10-71 10-100 (3)
00-20 10-14 10-43 10-72 10-100-1 (3)
00-21 10-15 10-44 10-73 10-100-2 (3)
00-22 10-16 10-45 10-74 10-100-3 (3)
10-17 10-46 10-75 10-101
10-18 10-47 10-76 10-102
WA200-5 00-2-1
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10-104 10-139 10-167 20-1 (4) 20-134 (4)
10-105 10-139-1 (3) 10-168 20-2 (4) 20-135 (1)
10-106 10-139-2 (3) 10-169 20-3 (4) 20-136 (1)
10-107 10-140 (4) 10-170 20-4 (4) 20-137 (1)
10-107-1 (3) 10-140-1 (4) 10-171 20-5 (4) 20-138 (1)
10-107-2 (3) 10-141 (3) 10-172 20-6 (4) q 20-139 (7)
10-107-3 (3) 10-142 (3) 10-173 20-140 (1)
10-107-4 (3) 10-143 (3) 10-174 20-101 (4) 20-141 (4)
10-108 10-144 (3) 10-175 20-102 (4) 20-142 (4)
10-109 10-145 (3) 10-176 20-103 (4) 20-143 (1)
10-110 10-146 (3) 10-177 20-104 (4) 20-144 (1)
10-111 10-146-1 (3) 10-178 20-105 (4) 20-145 (1)
10-112 10-146-2 (3) 10-179 20-106 (4) 20-146 (1)
10-113 10-146-3 (3) 10-180 20-107 (4) 20-147 (1)
10-114 10-146-4 (3) 10-181 20-108 (1) 20-148 (1)
10-115 10-146-5 (3) 10-182 20-109 (4) 20-149 (1)
10-116 10-146-6 (3) 10-183 20-110 (4) 20-150 (1)
10-117 10-146-7 (3) 10-184 (3) 20-111 (1) 20-151 (4)
10-118 10-146-8 (3) 10-185 (3) 20-112 (1) 20-152 (1)
10-119 10-147 (3) 10-186 20-113 (1) 20-153 (1)
10-120 10-147-1 (3) 10-187 20-114 (1) 20-154 (1)
10-121 10-147-2 (3) 10-188 20-115 (1) 20-155 (4)
10-122 10-148 10-189 20-116 (1) 20-156 (4)
10-123 10-150 10-190 20-117 (4) 20-157 (1)
10-124 10-151 (6) 10-191 20-118 (4) 20-158 (1)
10-125 10-152 10-192 20-119 (4) 20-159 (4)
10-126 10-153 10-193 20-120 (4) 20-160 (4)
10-127 10-154 10-194 20-121 (1) 20-161 (4)
10-128 10-155 10-195 20-122 (1) 20-162 (4)
10-129 10-156 10-196 20-123 (4) 20-163 (4)
10-130 10-157 10-197 (3) 20-124 (1) 20-164 (4)
10-131 10-158 10-198 20-125 (4) 20-165 (4)
10-132 10-159 10-199 20-126 (4) 20-166 (4)
10-132-1 (3) 10-160 10-200 20-127 (1) 20-167 (4)
10-132-2 (3) 10-161 10-201 20-128 (1) 20-168 (4)
10-134 10-162 10-202 20-129 (4) 20-169 (4)
10-135 10-163 10-203 (3) 20-130 (4) 20-170 (4)
10-136 10-164 10-204 20-131 (1) 20-171 (4)
10-137 10-165 20-132 (1)
10-138 (3) 10-166 (4) 20-133 (4) 20-201 (4)
00-2-2 WA200-5
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(7)

20-202 (4) 20-243 (1) 20-351 (4) 20-435 (4) 20-519 (4)
20-203 (1) 20-244 (1) 20-352 (4) 20-436 (4) 20-520 (4)
20-204 (1) 20-245 (1) 20-353 (4) 20-437 (4) 20-521 (4)
20-205 (1) 20-246 (1) 20-354 (4) 20-438 (4) 20-522 (4)
20-206 (1) 20-247 (1) 20-355 (4) 20-439 (4) 20-523 (4)
20-207 (1) 20-248 (1) 20-356 (4) 20-440 (4) 20-524 (4)
20-208 (1) 20-250 (1) 20-357 (4) 20-442 (4) 20-525 (4)
20-209 (1) 20-251 (1) 20-443 (4) 20-526 (4)
20-210 (1) 20-252 (1) 20-401 (4) 20-444 (4) 20-528 (4)
20-211 (1) 20-253 (1) 20-402 (4) 20-445 (4) 20-529 (4)
20-212 (1) 20-254 (1) 20-403 (4) 20-446 (4) 20-531 (4)
20-213 (4) 20-404 (4) 20-447 (4) 20-532 (4)
20-214 (4) 20-301 (4) 20-405 (4) 20-448 (4) 20-533 (4)
20-215 (4) 20-302 (4) 20-406 (4) 20-449 (4) 20-534 (4)
20-216 (4) 20-303 (4) 20-407 (4) 20-450 (4) 20-535 (4)
20-218 (1) 20-304 (4) 20-408 (4) 20-451 (4) 20-536 (4)
20-219 (1) 20-305 (4) 20-409 (4) 20-452 (4) 20-537 (4)
20-220 (1) 20-306 (4) 20-410 (4) 20-453 (4) 20-538 (4)
20-221 (1) 20-307 (4) 20-411 (4) 20-454 (4) 20-539 (4)
20-222 (1) 20-308 (4) 20-412 (4) 20-455 (4) 20-540 (4)
20-223 (1) 20-309 (4) 20-413 (4) 20-456 (4) 20-541 (4)
20-224 (1) 20-310 (4) 20-414 (4) 20-457 (4) 20-542 (4)
20-225 (1) 20-311 (4) 20-415 (4) 20-458 (4) 20-544 (4)
20-226 (1) 20-312 (4) 20-416 (4) 20-545 (4)
20-227 (4) 20-313 (4) 20-417 (4) 20-501 (4) 20-546 (4)
20-228 (4) 20-314 (4) 20-418 (4) 20-502 (4) 20-548 (4)
20-229 (1) 20-315 (4) 20-419 (4) 20-503 (4) 20-549 (4)
20-230 (1) 20-316 (4) 20-420 (4) 20-504 (4) 20-550 (4)
20-231 (1) 20-317 (4) 20-422 (4) 20-506 (4) 20-551 (4)
20-232 (1) 20-318 (4) 20-423 (4) 20-507 (4) 20-552 (4)
20-233 (1) 20-319 (4) 20-424 (4) 20-508 (4) 20-553 (4)
20-234 (1) 20-320 (4) 20-426 (4) 20-510 (4) 20-554 (4)
20-235 (1) 20-321 (4) 20-427 (4) 20-511 (4) 20-555 (4)
20-236 (1) 20-322 (4) 20-428 (4) 20-512 (4) 20-556 (4)
20-237 (1) 20-323 (4) 20-429 (4) 20-513 (4) 20-557 (4)
20-238 (1) 20-324 (4) 20-430 (4) 20-514 (4) 20-558 (4)
20-239 (4) 20-325 (4) 20-431 (4) 20-515 (4) 20-559 (4)
20-240 (4) 20-326 (4) 20-432 (4) 20-516 (4) 20-560 (4)
20-241 (4) 20-327 (4) 20-433 (4) 20-517 (4) 20-561 (4)
20-242 (4) 20-328 (4) 20-434 (4) 20-518 (4) 20-562 (4)
WA200-5 00-2-3
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20-563 (4) 20-704 (1) 30-18 (2) 30-58 (2) 30-98 (2)
20-564 (4) 20-705 (1) 30-19 (2) 30-59 (2) 30-99 (2)
20-565 (4) 20-706 (1) 30-20 (2) 30-60 (2) 30-100 (2)
20-566 (4) 20-707 (1) 30-21 (2) 30-61 (2) 30-101 (2)
20-567 (4) 20-708 (1) 30-22 (2) 30-62 (2) 30-102 (4)
20-568 (4) 20-709 (1) 30-23 (2) 30-63 (2) 30-103 (4)
20-569 (4) 20-710 (1) 30-24 (2) 30-64 (2) 30-104 (2)
20-570 (4) 20-711 (1) 30-25 (2) 30-65 (2) 30-105 (2)
20-571 (4) 20-712 (1) 30-26 (2) 30-66 (2) 30-106 (4)
20-572 (4) 20-713 (1) 30-27 (2) 30-67 (2) 30-107 (4)
20-573 (4) 20-714 (1) 30-28 (2) 30-68 (2) 30-108 (4)
20-715 (1) 30-29 (2) 30-69 (2) 30-109 (4)
20-601 (4) 20-716 (1) 30-30 (2) 30-70 (2) 30-110 (4)
20-602 (4) 20-717 (1) 30-31 (2) 30-71 (2) 30-110-1 (4)
20-603 (1) 20-718 (1) 30-32 (2) 30-72 (2) 30-111 (2)
20-604 (1) 20-719 (4) 30-33 (2) 30-73 (4) 30-112 (2)
20-605 (1) 20-720 (4) 30-34 (2) 30-74 (4) 30-113 (2)
20-606 (1) 20-721 (4) 30-35 (2) 30-75 (2) 30-114 (2)
20-607 (1) 20-722 (4) 30-36 (2) 30-76 (2) 30-115 (2)
20-608 (1) 20-723 (1) 30-37 (2) 30-77 (2) 30-116 (2)
20-609 (1) 20-724 (1) 30-38 (2) 30-78 (2) 30-117 (4)
20-610 (1) 30-39 (2) 30-79 (2) 30-118 (4)
20-611 (1) 30-40 (2) 30-80 (2) 30-119 (2)
20-612 (1) 30-1 (2) 30-41 (2) 30-81 (4) 30-120 (2)
20-613 (1) 30-2 (2) 30-42 (2) 30-82 (4) 30-121 (2)
20-614 (1) 30-3 (2) 30-43 (2) 30-83 (4) 30-122 (2)
20-615 (1) 30-4 (2) 30-44 (2) 30-84 (2) 30-123 (2)
20-617 (1) 30-5 (2) 30-45 (2) 30-85 (4) 30-124 (2)
20-618 (1) 30-6 (2) 30-46 (2) 30-86 (4) 30-125 (2)
20-619 (1) 30-7 (4) 30-47 (2) 30-87 (2) 30-126 (2)
20-620 (1) 30-8 (4) 30-48 (2) 30-88 (2) 30-127 (2)
20-621 (1) 30-9 (2) 30-49 (2) 30-89 (2) 30-128 (2)
20-622 (1) 30-10 (2) 30-50 (2) 30-90 (2) 30-129 (2)
20-623 (1) 30-11 (2) 30-51 (2) 30-91 (2) 30-130 (2)
20-624 (1) 30-12 (2) 30-52 (2) 30-92 (2) 30-131 (2)
20-625 (4) 30-13 (2) 30-53 (2) 30-93 (2) 30-132 (2)
30-14 (2) 30-54 (2) 30-94 (2) 30-133 (4)
20-701 (4) 30-15 (4) 30-55 (2) 30-95 (2) 30-134 (4)
20-702 (4) 30-16 (2) 30-56 (2) 30-96 (2) 30-135 (4)
20-703 (1) 30-17 (2) 30-57 (2) 30-97 (2) 30-136 (4)
00-2-4 WA200-5
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30-137 (2) 90-19

30-138 (2) 90-21
30-139 (2) 90-23
30-140 (2) 90-25
30-141 (2) 90-27
30-142 (2) 90-29
30-143 (2) 90-31 (3)
30-144 (2)
30-145 (2)
30-146 (2)
30-147 (2)
30-148 (2)
30-149 (2)
30-150 (2)
30-151 (2)
30-152 (2)
30-153 (2)
30-154 (2)
30-155 (2)
30-156 (2)
30-157 (2)
30-158 (4)
30-159 (2)
30-160 (2)
30-161 (4)
30-162 (2)
30-163 (2)
30-164 (2)
90-1 (3)
90-3
90-4-1 (3)
90-5
90-7
90-9
90-11
90-13
90-15
90-17 (3)
WA200-5 00-2-5
(5)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

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

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

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
4
10 - 3 tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine)
5
Places where oil, water or
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
6
item. Places where oil or water
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
k Heavy parts (25 kg or more) must be lifted

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

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

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

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

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

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

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

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

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

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

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

LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

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

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

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

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

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

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

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

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

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

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

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

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

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
10 0 2 1.02 0 0.20
24 0 4 2.45 0 0.41
6
43 0 6 4.38 0 0.61
8
77 0 12 7.85 0 1.22
10
12
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
802 0.81 0 0.20
10 0 2 1.02 0 0.20
6
12 0 2 1.22 0 0.20
8
24 0 4 2.45 0 0.41
10
36 0 5 3.67 0 0.51
12
14
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
301 0.31 0 0.10
802 0.81 0 0.20
1 / 16
12 0 2 1.22 0 0.20
1/8
15 0 2 1.53 0 0.20
1/4
24 0 4 2.45 0 0.41
3/8
36 0 5 3.67 0 0.51
1/2
60 0 9 6.12 0 0.92
3/4
1
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

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

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

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

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

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

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

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

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

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

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
GENERAL
01 GENERAL
General assembly drawings ......................................................................................................................... 01-2

Specifications ............................................................................................................................................... 01-3
Weight table .................................................................................................................................................. 01-7
List of lubricant and coolant .......................................................................................................................... 01-9
WA200-5 01-1
GENERAL GENERAL ASSEMBLY DRAWINGS
GENERAL ASSEMBLY DRAWINGS
Item Unit WA200-5 WA200PT-5

Operating weight (With BOC) kg 9,470 10,340
Rated load kN {kg} 31.4 {3,200} 28.2 {2,880}
Bucket capacity (piled) (With BOC) m3 2.0 1.8
Engine model — KOMATSU SAA6D102E-2-A Diesel engine
Flywheel horse power kW {HP} / rpm 92 {123} / 2,000
A Overall length (With BOC) mm 6,895 7,255
B Overall height mm 3,110 3,110
C Overall height when bucket is raised mm 4,885 5,005
D Overall width mm 2,375 2,375
E Min. ground clearance mm 425 425
F Bucket width mm 2,550 2,550
G Dumping clearance Tip of bucket/Tip of BOC mm 2,820 / 2,760 2,785 / 2,725
H Dumping reach Tip of bucket/Tip of BOC mm 975 / 1,000 1,065 / 1,090
I Bucket dump angle deg. 45 45
Tip of bucket/Tip of BOC mm 5,625 / 5,650 5,740 / 5,765
Min. turning radius
Center of outside wheel mm 4,880 4,880
F1 km / h 4.0 – 13.0 4.0 – 13.0
F2 km / h 13.0 13.0
F3 km / h 20.0 20.0
F4 km / h 34.5 34.5
Travel speed
R1 km / h 4.0 – 13.0 4.0 – 13.0
R2 km / h 13.0 13.0
R3 km / h 20.0 20.0
R4 km / h 34.5 34.5
01-2 WA200-5
(3)
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model WA200-5 WA200PT-5
Serial No. 65001 and up
Operating weight (With BOC) kg 9,470 10,340

Weight
Distribution (front) SAE travel posture kg 3,795 4,585

Distribution (rear) SAE travel posture kg 5,675 5,755
Bucket capacity (piled) (With BOC) m³ 2.0 1.8
Rated load kN {kg} 31.4 {3,200} 28.2 {2,880}
Travel speed FORWARD 1st km / h 4.0 – 13.0 4.0 – 13.0
FORWARD 2nd km / h 13.0 13.0
FORWARD 3rd km / h 20.0 20.0
FORWARD 4th km / h 34.5 34.5
REVERSE 1st km / h 4.0 – 13.0 4.0 – 13.0
Performance
REVERSE 2nd km / h 13.0 13.0

REVERSE 3rd km / h 20.0 20.0
REVERSE 4th km / h 34.5 34.5
Max. rimpull FORWARD kN {kg} 86 {8,800} 86 {8,800}
REVERSE kN {kg} 86 {8,800} 86 {8,800}
Gradeability deg. 25 25
(Center of outside
Min. turning radius wheel) mm 4,880 4,880
Min. turning radius [SAE travel posture]

(Tip of bucket/Tip of BOC) mm 5,625 / 5,650 5,740 / 5,765
Overall length (with BOC) mm 6,895 7,255

Overall width (chassis) mm 2,375 2,375
Bucket width (with BOC) mm 2,550 2,550
Overall height (top of cab) mm 3,110 3,110
Overall height (Bucket approx. raised to
max.) mm 4,885 5,005
Wheel base mm 2,840 2,840

Tread mm 1,930 1,930
Dimensions
Min. ground clearance mm 425 425

Max. height of bucket hinge pin mm 3,635 3,765
Dumping clearance (Tip of bucket/Tip of BOC) mm 2,820 / 2,760 2,785 / 2,725
Dumping reach (Tip of bucket/Tip of BOC) mm 975 / 1,000 1,065 / 1,090
Steering angle deg. 40 40
Bucket tilt angle (travel posture) deg. 48 48
Bucket tilt angle (max. height) deg. 67 60
Bucket dump angle (max. height) deg. 46 53
Digging depth (10° dump)
(Tip of bucket/Tip of BOC) mm 285 / 320 310 / 350
WA200-5 01-3
(3)
Model SAA6D102E-2-A
4-cycle, water-cooled, in-line, 6-cylinder,
Type direct injection with turbocharger, air-cooled after cooler
No. of cylinders - bore x stroke mm 6 – 102 x 120
Piston displacement l {cc} 5.88 {5,880}
Flywheel horsepower kW / rpm 92 / 2,000
{HP / rpm} {123 / 2,000}
Engine
Maximum torque Nm / rpm 576 / 1,400

{kgm / rpm} {58.8 / 1,400}
Min. fuel consumption ratio g / kWh {g / HPh} 224 {167}
High idle speed rpm 2,225
Low idle speed rpm 825
Starting motor 24 V 4.5 kW
Alternator 24 V 35 A
Battery (*1) 24 V 88 Ah x 2 pcs.
HST pump Variable displacement swash plate type piston pump
HST motor 1 Variable displacement bent axis type piston motor
HST motor 2 Variable displacement bent axis type piston motor
Power train
Multiple shaft planetary compound-type, spur gear

Transfer constant mesh-type, 2 alternative power systems
Reduction gear Spiral bevel gear, splash lubrication type
Differential Straight bevel gear type, torque portioning
Final drive Planetary gear 1-stage, splash lubrication type
Drive type Front and rear wheel drive
Axle
Front axle Fixed to frame, semi-floating type

Rear axle Center pin support, semi-floating type
Tire size 17.5–25–12PR
Rim size 25x13.00
Tire
Inflation pressure Front tire kPa {kg / cm²} 294 {3.0}

Rear tire kPa {kg / cm²} 294 {3.0}
4 wheel braking, Front and rear wheel independent sys-
Braking system tem control
Main brake Brake type Enclosed wet multiple disc type

Operation method Hydraulically controlled
Brakes
Control method Hydraulic power servo assisted brake

Braking system Speed change gear output shaft braking
Brake type Wet multiple disc type
Parking brake
Operation method Mechanical type
Control method Hand lever type
*1: Battery capacity (Ah) shows the rate of 5 hours.
01-4 WA200-5
(4)
Type Articulated steering

Steering
control
Control Hydraulic control
Steering pump
• Type Gear type
• Delivery l / min 95
Work equipment pump
• Type Gear type
Hydraulic pump
Brake and cooling fan pump
• Type Gear type
Transfer lubrication pump
• Type Gear type
Type Reciprocating piston type
Steering cylinder
Cylinder inner diameter mm 70

Piston rod diameter mm 40
Hydraulic system
Stroke mm 453
Max. length between pins mm 1,271
Min. length between pins mm 818
Type Reciprocating piston type
Cylinder inner diameter mm 120
Lift cylinder
Piston rod diameter mm 65

Stroke mm 673.5
Max. length between pins mm 1,817.5
Cylinder
Min. length between pins mm 1,144

Type Reciprocating piston type Reciprocating piston type
Bucket cylinder
Cylinder inner diameter mm 130 160

Piston rod diameter mm 65 80
Stroke mm 493 604
Max. length between pins mm 1,447 2,319
Min. length between pins mm 954 1,715
Type — Reciprocating piston type
Coupler plunger
Cylinder inner diameter mm — 35

Piston rod diameter mm — 20
Stroke mm — 214
Max. length between pins mm — 586
Min. length between pins mm — 372
WA200-5 01-5
(3)
Work equipment control valve

• Type 2-spool type 3-spool type
Control valve
Hydraulic system
• Set pressure MPa {kg / cm²} 19.9 {203} 19.9 {203}

Steering valve
• Type Orbit-roll type
• Set pressure MPa {kg / cm²} 20.6 {210}

Cooling fan motor
Motor
• Type Fixed displacement piston type

equipment
Link type Single link Parallel link

Work
Bucket edge type Flat blade with top BOC Flat blade with top BOC
01-6 WA200-5
(3)
GENERAL WEIGHT TABLE
WEIGHT TABLE
a This weight table is a guide for use when transporting or handling components.
Unit: kg
Serial Numbers 65001 and up

Engine (without coolant and oil) 608 608
Cooling assembly (without coolant) 54 54
Cooling fan motor 6 6
Damper 3 3
HST pump 60 60
HST motor 1 34 34
HST motor 2 34 34
Transfer 187 187
Front drive shaft 15 15
Rear drive shaft 4 4
Front axle 522 522
Rear axle 492 492
Axle pivot (rear axle) 79 79
Wheel (each) 77 77
Tire (each) 103 103
Orbit-roll valve 7 7
Priority valve 6 6
Steering cylinder assembly (each) 18 18
Brake valve 10 10
Hydraulic tank (without hydraulic oil) 54 54
4-gear pump unit 21 21
Work equipment PPC valve 3 3
Attachment PPC valve — 1
Work equipment control valve 19 26
Lift cylinder assembly (each) 77 77
Bucket cylinder assembly 76 155
Engine hood (with side panel) 120 120
Front frame 750 997
Rear frame 680 680
WA200-5 01-7
(3)
GENERAL WEIGHT TABLE
Unit: kg
Serial Numbers 65001 and up

Lift arm (including bushing) 540 509
3
Bucket (2.0m , including BOC) 785 —
3
Bucket (1.8m , including BOC) — 780
Bell crank 140 85
Quick coupler — 260
Coupler plunger Ass’y — 4
Bucket link 23 62
Counterweight 1,140 1,140
Additional counterweight (1 piece) 153 153
Fuel tank (without fuel) 79 79
Battery (each) 33 33
Operator’s Cab (including air conditioner and interior parts) 755 755
Operator’s seat 41 41
01-8 WA200-5
(3)
GENERAL LIST OF LUBRICANT AND COOLANT
LIST OF LUBRICANT AND COOLANT

For details of the notes (Note 1, Note 2, ---) in the table, see the Operation and Maintenance Manual.
Unit: l
CAPACITY Specified Refill
Engine oil pan 20 19.5

Transfer case 7.0 5.5
Hydraulic system 120 58
Axle (each) 18 18
Fuel tank 175 —
Cooling system 17.0 —
WA200-5 01-9
(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD
Engine mount and transfer mount ....................10-2 Hydraulic tank .............................................. 10-101
Damper.............................................................10-3 4-gear pump unit.......................................... 10-104
Cooling system ................................................. 10-4 Accumulator (for ppc circuit) ........................ 10-106
Transfer oil cooler.............................................10-5 Lock valve .................................................... 10-107
Power train .......................................................10-6 Bypass valve............................................. 10-107-1
Power train system diagram .............................10-8 Quick coupler valve................................... 10-107-4
Drive shaft (propeller shaft) ............................10-10 E.C.S.S. valve.............................................. 10-108
HST hydraulic piping diagram ........................10-11 Accumulator (for E.C.S.S.)........................... 10-110
HST pump ......................................................10-12 Hydraulic piping of cooling system............... 10-111
High-pressure relief valve...............................10-14 Cooling fan motor......................................... 10-112
Low-pressure relief valve................................10-16 Work equipment control valve...................... 10-114
HST charge pump ..........................................10-17 Work equipment PPC valve ......................... 10-127
Speed-related valve (DA valve)......................10-18 Attachment PPC valve ................................. 10-134
High-pressure cut-off valve.............................10-19 Work equipment linkage .............................. 10-138
HST motor ......................................................10-20 Bucket .......................................................... 10-140
EP servo valve................................................10-23 Control of bucket positioner, boom kick-out,
HA servo valve ...............................................10-24 and dump speed.................................... 10-141
Forward-reverse shuttle valve ........................10-25 Work equipment cylinder ............................. 10-147
Transfer ..........................................................10-26 Air conditioner .............................................. 10-148
Clutch solenoid valve......................................10-37 Machine monitoring system ......................... 10-150
Axle.................................................................10-38 Machine monitor .......................................... 10-159
Differential ......................................................10-40 List of items displayed on monitor................ 10-160
Limited-slip differential....................................10-46 Electrical system (HST controller system) ... 10-186
Final drive .......................................................10-50 HST controller .............................................. 10-190
Axle mounting and center hinge pin ...............10-52 Engine start circuit ....................................... 10-191
Steering piping................................................10-57 Engine stop circuit........................................ 10-193
Steering column..............................................10-58 Preheating circuit ......................................... 10-194
Priority valve ...................................................10-59 Parking brake circuit .................................... 10-195
Orbit-roll valve ................................................10-62 Electronically controlled suspension system 10-198
2-way restrictor valve......................................10-70 Sensors........................................................ 10-199
Cushion valve .................................................10-71
Steering cylinder.............................................10-72
Emergency steering piping .............................10-74
Emergency steering valve ..............................10-75
Brake piping....................................................10-78
Brake valve.....................................................10-79
Inching valve...................................................10-83
Charge valve ..................................................10-84
Accumulator (for brake) ..................................10-88
Slack adjuster .................................................10-89
Brake ..............................................................10-92
Parking brake control......................................10-95
Parking brake .................................................10-96
Hydraulic piping ..............................................10-98
Work equipment lever linkage ......................10-100
WA200-5 10-1
(3)
ENGINE MOUNT AND TRANSFER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MOUNT
ENGINE MOUNT AND TRANSFER MOUNT
10-2 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DAMPER
DAMPER
Unit: mm
No. Check item Criteria Remedy
Distance between HST pump Standard size Repair limit

1 Adjust
mounting face and tip of boss 75.1 ± 0.8
Wear of internal teeth of cou-
2 Repair limit: 1.0 Replace
pling (plastic)
3. Coupling Outline
4. Boss • The damper reduces the torsional vibration
5. HST pump input shaft caused by fluctuation of the engine torque to
6. Cover protect the drive system after the engine from
7. Flywheel the torsional vibration.
• The power from the engine is transmitted
through flywheel (7) to coupling (3), which ab-
sorbs the torsional vibration, and then transmit-
ted through boss (4) to the HST pump.
WA200-5 10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
1. Oil cooler 4. Reservoir tank

2. After cooler 5. Cooling fan
3. Radiator 6. Cooling fan motor
Specification
Radiator Oil cooler After cooler
Core type AL WAVE–4 CF40–1
Fin pitch (mm) 3.5 / 2 3.5 / 2 4.0 / 2
Total heat radiating area (m2) 27.9 4.67 7.23
Pressure valve opening pressure 68.6

— —
(kPa {kg/cm2}) {0.7}
Vacuum valve opening pressure 0 – 4.9

— —
(kPa {kg/cm2}) {0 – 0.05}
10-4 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER OIL COOLER
TRANSFER OIL COOLER

Serial No. 65001 – 65628
Specification
Transfer oil cooler
Core type CF40–1
Fin pitch (mm) 4.5 / 2
Total heat radiating area (m2) 1.42
WA200-5 10-5
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER OIL COOLER
10-5-1 WA200-5
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
1. Engine
2. Damper
3. HST pump
4. 4-gear pump unit
5. High-pressure hose
6. HST motor 1
7. HST motor 2
8. Transfer
9. Front drive shaft
10. Front axle
11. Rear drive shaft
12. Rear axle
10-6 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM
POWER TRAIN SYSTEM DIAGRAM
10-8 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM
1. Engine Outline
2. Damper • The power of engine (1) is transmitted to HST
3. HST pump pump (3) through damper (2) which is installed
4. Steering pump to the flywheel and which absorbs the torsional
5. Work equipment pump vibration of the power,
6. Brake and cooling fan pump • The power of engine (1) is also transmitted to
7. Transfer lubricating oil pump HST pump (3), HST charge pump built in HST
8. High-pressure hose pump (3), steering pump (4) connected to HST
9. HST motor 1 pump (3), work equipment pump (5), brake and
10. HST motor 2 cooling fan pump (6), and transfer lubricating oil
11. Emergency steering valve (If equipped) pump (7).
12. Transfer • HST pump (3) is equipped with the forward-re-
13. Transfer clutch verse shifting valve and servo piston, which
14. Parking brake changes the discharge direction and discharge
15. Front drive shaft rate of HST pump (3) continuously by changing
16. Front axle the swash plate angle.
17. Differential • HST motors (9) and (10) are installed to transfer
18. Wet multiple disc brake (12) and connected to HST pump (3) by high-
19. Final drive pressure hose (8).
20. Front tire • The turning direction and speed of HST motors
21. Rear drive shaft (9) and (10) are changed by the hydraulic power
22. Rear axle of HST pump (3) to control the travel direction
23. Differential and travel speed of the machine.
24. Wet multiple disc brake • The power of HST motor 1 (9) is transmitted
25. Final drive through transfer clutch (13) in transfer (12) to the
26. Rear tire output shaft.
The power of HST motor 2 (10) is transmitted
through the gear in transfer (12) to the output
shaft.
• Parking brake (14) is installed on the rear side in
transfer (12). It operates the wet multiple disc
brake to stop the machine according to the oper-
ation of the parking brake lever.
• The power for the front side is transmitted
through front drive shaft (15) to front axle (16).
The power for the rear side is transmitted
through rear drive shaft (21) to rear axle (22).
• The power transmitted to axles (16) and (22) is
reduced in speed by the pinion gears of differen-
tials (17) and (23), and then transmitted through
the sun gear shaft to the sun gear.
• The power of the sun gear is reduced in speed
by the planetary mechanisms of final drives (19)
and (25), and then transmitted through the axle
shaft and wheels to tires (20) and (26).
WA200-5 10-9
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE SHAFT (PROPELLER SHAFT)
DRIVE SHAFT (PROPELLER SHAFT)
1. Front axle Outline

2. Front drive shaft • The power from the output shaft of the transfer
3. Transfer is transmitted through front drive shaft (2) and
4. Rear drive shaft rear drive shaft (4) to front axle (1) and rear axle
5. Rear axle (5).
• When the machine is articulated or it receives an
impact from the road during travel or a working
impact, the positions of the transfer and front
and rear axles change. The drive shafts can
change their angles and lengths by means of the
universal joints and sliding joints so that the
power will be transmitted without damaging any
part even when the positions of the components
change because of the impacts.
10-10 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST HYDRAULIC PIPING DIAGRAM
HST HYDRAULIC PIPING DIAGRAM
1. Hydraulic tank
2. HST pump
3. Clutch solenoid valve
4. HST oil filter
5. HST motor 1
6. HST motor 2
WA200-5 10-11
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST PUMP
HST PUMP
a HST: Abbreviation for Hydro Static Transmission
1. Forward-reverse shifting solenoid valve Specifications

2. High-pressure cut-off valve
Model A4VG90DA
3. Speed-related valve (DA valve)
4. Charge pump Variable displacement swash
Type
5. Low-pressure relief valve plate type piston pump
6. Servo cylinder Theoretical capacity
7. High-pressure relief valve 0 – 90
(cc / rev)
8. Control plate
9. Cylinder block Set pressure of high-pressure
44.1 {450}
relief valve (MPa {kg/cm2})
10. Piston
11. Swash plate Set pressure of high-pressure Effective differential pressure
cut-off valve (MPa {kg/cm2}) 41.2 {420}
Set pressure of low-pressure

2.45 {25}
10-12 WA200-5
(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST PUMP
Operation
Flow of power Flow of oil

• The HST pump is installed to the coupling which • As swash plate (11) of the HST pump slants, pis-
is installed to the engine flywheel. tons (10) in contact with its surface reciprocate
• The power of the engine is transmitted from the and work as pumps to suck and discharge the oil
flywheel through the coupling to the HST pump. in cylinder block (9).
• The HST pump is equipped with forward-reverse • As a result, high-pressure oil flows in a constant
shifting solenoid valve (1) and servo cylinder (6). direction into the HST motor.
If the operator operates for forward or reverse • If swash plate (11) slants in the opposite direc-
travel, forward-reverse shifting solenoid valve tion, the sucking and discharging directions of
(1) operates and swash plate (11) in the HST the oil are reversed, that is, the oil flows in the
pump slants to reverse the oil flow. opposite direction. While swash plate (11) is in
• Cylinder block (9) and pistons (10) in it rotate to- neutral, pistons (10) do not reciprocate, thus
gether with drive shaft (12) and the tips of pis- they do not discharge any oil.
tons (10) slide on swash plate (11) which does • The strokes of pistons (10) are changed to con-
not rotate. The pump has 9 pistons (10) in it. trol the travel speed by increasing or decreasing
inclination (angle) of swash plate (11).
• If the quantity of the oil in the low-pressure circuit
(the return circuit from the motor to the pump)
becomes insufficient because of leakage from
the HST pump, HST motor, and control valve,
the charge pump adds oil through speed-related
valve (3) and check valve of high-pressure relief
valve (7).
WA200-5 10-13
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HIGH-PRESSURE RELIEF VALVE
HIGH-PRESSURE RELIEF VALVE
1. Nut Function
2. Locknut • The high-pressure relief valve is installed to the
3. Poppet spring HST pump. If the oil pressure in the high-pres-
4. Check spring sure circuit between the HST pump and HST
5. Main piston motor rises higher than the set pressure, the
6. Valve seat high-pressure relief valve drains the oil into the
7. Pilot poppet low-pressure circuit.
8. Adjustment screw The high-pressure relief valve controls the max-
imum pressure in the circuit to protect the circuit
with this function.
• If the quantity of the oil in the circuit becomes in-
sufficient, the high-pressure valve leads oil in
from the HST charge pump to prevent cavitation.
10-14 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HIGH-PRESSURE RELIEF VALVE
Operation
• Port A is connected to the high-pressure circuit • If the oil pressure in port A and chamber B
of the HST pump and ports C and D are con- reaches the set pressure of poppet spring (3), pi-
nected to the low-pressure circuit of the HST lot poppet (7) opens and the oil in chamber B
pump. flows through chamber D to port C, and the oil
The oil fills chamber B through the orifice of pressure in chamber B lowers consequently.
main piston (5). If the oil pressure in chamber B lowers, a pres-
Pilot poppet (7) is seated on valve seat (6). sure difference is made between port A and
chamber B by the orifice of main piston (5). As
a result, main piston (5) is pushed open and the
oil in port A flows into port C to relieve the abnor-
mal pressure.
• The set pressure can be adjusted by increasing

or decreasing the tension of poppet spring (3).
To adjust the set pressure, remove the nut and
loosen the locknut. If the adjustment screw is
tightened, the set pressure is heightened. If the
former is loosened, the latter is lowered.
• If the oil pressure in port A lowers below that in
port C, check spring (4) pushes back main pis-
ton (5) and the oil in port C flows through cham-
ber D into port A so that the quantity of the oil in
port A will not become insufficient.
WA200-5 10-15
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LOW-PRESSURE RELIEF VALVE
LOW-PRESSURE RELIEF VALVE
Operation
• Port A is connected to the HST pump charge cir-
cuit and port B is connected to the drain circuit.
If the oil pressure is below the set pressure, the
oil does not flow into port B.
• If the pressure in port A reaches the set pres-
sure for some reason, piston (3) opens and the
oil in port A flows into port B, and the oil pressure
in port A lowers consequently.
• The set pressure can be adjusted by increasing
or decreasing the tension of spring (4).
To adjust the set pressure, loosen locknut (1)
and turn adjustment screw (2). If the adjustment
1. Locknut screw is tightened, the set pressure is height-
2. Adjustment screw ened. If the former is loosened, the latter is low-
3. Piston ered.
4. Spring
Function
• The low-pressure relief valve is installed to the
HST pump. If the oil pressure in the low-pres-
sure circuit between the HST pump and HST
motor rises higher than the set pressure, the
low-pressure relief valve drains the oil into the
hydraulic tank.
The low-pressure relief valve controls the pres-
sure in the HST pump charge circuit to protect
the circuit with this function.
10-16 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST CHARGE PUMP
HST CHARGE PUMP
1. Cover bolt Specifications

2. Pump gear
3. Key Gear pump
Type
4. Coupling (Inscribed type)
5. Drive shaft
6. Plate Theoretical capacity
19.6
7. Charge pump cover (cc/rev)
8. Crescent divider board
Function
Outline • The HST charge pump is connected to drive
• The HST charge pump is built in the HST pump shaft (5) of the HST pump and rotated by cou-
and driven together with the HST pump to sup- pling (4).
ply oil to the HST speed-related valve and low- • The HST charge pump has pump gear (2) and
pressure relief valve of the HST pump. crescent divider board (8) in it and sucks and
• The HST charge pump sucks in oil from the hy- discharges the oil in the direction shown in the
draulic tank. above figure.
WA200-5 10-17
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPEED-RELATED VALVE (DA VALVE)
SPEED-RELATED VALVE (DA VALVE)
1. Locknut
2. Adjustment screw
3. Poppet spring
4. Spring seat
5. Pilot poppet
Function
• The speed-related valve is installed to the HST
pump and used to divide the oil from the HST
charge pump into two parts. One part flows
through a throttle valve to the forward-reverse
shifting solenoid valve of the HST pump and the
other part flows to the low-pressure relief valve
of the HST pump.
Operation
• Port A is connected to the HST pump charge cir-
cuit. Port D is connected to the low-pressure re-
lief valve circuit. Port C is connected to the
forward-reverse shifting solenoid valve circuit.
• The oil from the HST charge pump always flow
through the throttle valve of pilot poppet (5),
chamber B, and port D to the low-pressure relief
valve.
As the hydraulic pressure from the HST charge
pump is applied a differential pressure is gener-
ated between port A and chamber B because of
the throttle valve of pilot poppet (5). Since this
differential pressure moves pilot poppet (5), the
oil flows from chamber B through port C to the
forward-reverse shifting solenoid valve.
• Pilot poppet (5), poppet spring (3), and spring
seat (4) are used as a set. To change the set
pressure, loosen locknut (1) and turn the adjust-
ment screw (2). If the adjustment screw is tight-
ened, the set pressure is lowered. If the former
is loosened, the latter is heightened.
10-18 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HIGH-PRESSURE CUT-OFF VALVE
HIGH-PRESSURE CUT-OFF VALVE
1. Adjustment screw
2. Locknut
3. Spring
4. Spool
5. Piston
6. Barrel
7. Shuttle spool
8. Valve seat
Function
• The high-pressure cut-off valve is installed to the
HST pump. If the oil pressure in the high-pres-
sure circuit between the HST pump and HST
motor rises higher than the set pressure, the
high-pressure cut-off valve drains the oil from
the servo cylinder circuit into the hydraulic tank
to control the maximum pressure in the HST
pump circuit.
Operation
• Port A is connected to the high-pressure circuit
during reverse travel. Port B is connected to the
high-pressure circuit during forward travel. Port
Pc is connected to the speed-related valve, and
port T is connected to the drain circuit.
• If the pressure on the port A side rises high for
some reason, shuttle spool (7) is pushed down
and the circuit on port B side is closed. At the
same time, piston (5) is pushed up by the hy-
draulic pressure on port A side and spring (3) is
compressed and spool (4) is also pushed up.
Then, ports Pc and T are opened and the hy-
draulic oil in the speed-related valve circuit flows
into the drain port.
As a result, the oil pressure in port Pc lowers and
the swash plate angle of the HST pump reduces,
and consequently the discharge reduces and
the abnormal pressure in the HST pump circuit
lowers.
WA200-5 10-19
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST MOTOR
HST MOTOR
a HST: Abbreviation for Hydro Static Transmission
HST motor 1
1. Drive shaft Specifications

2. Piston
Model A6VM80EP
3. Cylinder block
4. Port plate Variable displacement bent
Type
axis type piston motor
5. EP servo valve
Theoretical capacity (cc/rev) 0 – 80
Set pressure of high-pressure
44.1 {450}
Set pressure of high-pressure Effective differential pressure
2.45 {25}
10-20 WA200-5
(3)
HST motor 2
1. Drive shaft Specifications

2. Piston
Model A6VM80HA
3. Cylinder block
4. Port plate Variable displacement bent
Type
axis type piston motor
5. HA servo valve
6. Forward-reverse shuttle valve Theoretical capacity (cc/rev) 43 – 80
Set pressure of high-pressure
44.1 {450}
Set pressure of high-pressure Effective differential pressure
2.45 {25}
WA200-5 10-21
(3)
Principle Operation
• Let's assume that a shaft of a disc is supported • The hydraulic oil sent from the HST pump flows
and the disc can rotate freely. If force F is ap- in the inlet port of the HST motor and gives hy-
plied bias to this disc, it is divided into compo- draulic pressure to the back side of pistons (2).
nent force F1 at right angles to the disc and Accordingly, drive shaft (1) rotates because of
component force F2 in the peripheral direction of inclination of pistons (2) and cylinder block (3).
the disc. Component force F2 rotates the disc to • The oil from the HST pump flows between the
the right. forward-reverse shifting solenoid valve and ser-
• If force F', not force F, is applied to the disc, it is vo cylinder into forward-reverse shuttle valve (6)
divided into component forces F1' and F2' simi- of the HST motor. The oil from the forward or re-
larly to the above and force F2' rotates the disc verse high-pressure discharge side of the HST
to the left motor flows into forward-reverse shuttle valve
(6). If a load is applied to the motor connected
to servo valve (5) in the HST motor, the oil flows
into the servo cylinder of the HST motor be-
cause of the pressure difference from forward-
reverse shuttle valve (6) side, thus cylinder block
(3) is inclined more.
Structure
• There are 7 pistons (2) installed to the disc por-

tion of the drive shaft (1) as if they are spherical
joints. They are set in cylinder block (3) at a cer-
tain angle to drive shaft (1).
• As the external load on the HST motor is in-
creased by servo valve (5) and forward-reverse
shuttle valve (6), inclination of pistons (2) is in-
creased. As a result, the revolving speed is low-
ered but the torque is increased.
10-22 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EP SERVO VALVE
EP SERVO VALVE
1. Motor 1 solenoid valve Operation

2. EP servo valve • Suction force F1 of motor 1 solenoid valve (1)
3. Spring and force F2 of spring (3) are applied to EP ser-
4. Servo cylinder vo valve (2).
• If the current given to motor 1 solenoid valve (1)
Function is little (F1 < F2), EP servo valve (2) leads the
• The EP servo valve is installed to the rear part of hydraulic pressure of the motor high-pressure
HST motor 1 and used to change the displace- circuit to the small diameter (S) side of servo cyl-
ment of the motor according to the current given inder (4) and releases the hydraulic pressure on
to motor 1 solenoid valve (1). the large diameter (L) side into the tank (motor
housing). As a result, servo cylinder (4) moves
toward the min side.
• If the current given to motor 1 solenoid valve (1)
is large (F1 > F2), EP servo valve (2) leads the
hydraulic pressure to the large diameter (L) side.
As a result, servo cylinder (4) moves toward the
max side because of the area difference be-
tween the small diameter (S) side and large di-
ameter (L) side.
• The force of spring (3) changes according to the
position of servo cylinder (4) (the displacement
of the motor).
Accordingly, the displacement of the motor is
controlled by the current given to motor 1 sole-
noid valve (1) so that suction force F1 will be bal-
anced with spring force F2.
WA200-5 10-23
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HA SERVO VALVE
HA SERVO VALVE
1. Motor 2 solenoid valve Operation

2. HA servo valve • When the load on the machine is small, HA ser-
3. Servo cylinder vo valve (2) leads the hydraulic pressure on the
side selected by the forward-reverse shuttle
Function valve to the small diameter (S) side of servo cyl-
• The HA servo valve is installed to the rear part of inder (3) and releases the hydraulic pressure on
HST motor 2 and used to control the position of the large diameter (L) side into the tank (motor
servo cylinder (3) (the displacement of the mo- housing) to minimize the displacement of the
tor) to meet the motor output to the external load motor.
on the motor. The displacement is controlled • When a large load is applied to the machine on
with the hydraulic pressure in the circuit selected a uphill, etc., HA servo valve (2) leads the hy-
by the forward-reverse shuttle valve. draulic pressure to the large diameter (L) side.
As a result, servo cylinder (3) moves toward the
max side because of the area difference be-
tween the small diameter (S) side and large di-
ameter (L) side. At this time, the displacement
of the motor becomes largest and the motor
generates large torque.
• If motor 2 solenoid valve (1) is energized, HA
servo valve (2) leads the hydraulic pressure to
the large diameter (L) side and the displacement
of the motor becomes largest, regardless of the
load on the machine.
10-24 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FORWARD-REVERSE SHUTTLE VALVE
FORWARD-REVERSE SHUTTLE VALVE
1. Forward-reverse shifting solenoid valve Operation

2. Forward-reverse shuttle valve • The electric signals given to the forward-reverse
shifting solenoid valve of the HST pump are
Function used for forward-reverse shifting solenoid valve
• The forward-reverse shuttle valve is installed to (1) and linked to the forward-reverse shifting
the rear part of HST motor 2 and used to grasp mechanism.
and change the position of the forward-reverse • Forward-reverse shuttle valve (2) changes the
shifting solenoid valve to control where to lead hydraulic pressure applied to the HA servo valve
the hydraulic pressure for the HA servo valve. according to the forward-reverse shifting com-
Accordingly, shock made when the oil pressure mand.
changes for gear shifting are reduced.
WA200-5 10-25
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER
TRANSFER
a. Clutch port Relationship between transfer clutch and trans-

b. Lubricating oil inlet port fer clutch pressure at each gear speed
c. Lubricating oil suction port
Gear
Transfer clutch Transfer clutch pressure
speed
1. Transfer
2. Parking brake lever 1st Engaged OFF
3. HST motor 2 mount
2nd Engaged OFF
4. HST motor 1 mount
5. Oil filler pipe Travel speed Travel speed Travel speed Travel speed
0 – 10km/h 10 – 20km/h 0 – 10km/h 10 – 20km/h
3rd
Outline Engaged Disengaged OFF ON
• The transfer is equipped with 2 HST motors.
The engine speed is changed to the forward 1st Travel speed Travel speed Travel speed Travel speed
0 – 10km/h 10 – 34.5km/h 0 – 10km/h 10 – 34.5km/h
– 4th and rear 1st – 4th gear speeds by combin- 4th
ing the output and revolving direction of the HST Engaged Disengaged OFF ON
motor and the transfer clutch.
Note: The travel speed when tires of 17.5 – 25 size
are used is shown in the table.
10-26 WA200-5
1. HST motor 1 8. Motor 1 gear (Number of teeth: 43)

2. Input shaft 9. Sun gear (Number of teeth: 28)
3. Transfer clutch 10. Parking brake
4. Carrier 11. Rear coupling
5. Ring gear (Number of teeth: 80) 12. Output gear (Number of teeth: 58)
6. Planetary gear (Number of teeth: 24) 13. Output shaft
7. Planetary shaft 14. Front coupling
WA200-5 10-27
Input shaft portion
Unit: mm
Standard Tolerance Standard Clearance

Clearance between input shaft size Shaft Hole clearance limit
1
and bearing (F)
++0.011 +0 -0.023 –
ø50 –
+-0.005 -0.012 0.005
Clearance between input shaft ++0 ++0.013 -0.006 –
2 ø80 –
bearing and cage (F) -0.013 -0.006 0.026
Clearance between input shaft +0.011 +0 -0.023 – Replace
3 ø50 –
and bearing (M) -0.005 -0.012 0.005
Clearance between input shaft +0 ++0.013 -0.006 –
4 ø80 –
bearing and ring gear (M) -0.013 -0.006 0.026
Clearance between input shaft +0.011 +0 -0.023 –
5 ø45 –
and bearing (R) -0.005 -0.012 0.005
Clearance between input shaft +0 +0.013 -0.006 –
6 ø75 –
bearing and carrier (R) -0.013 -0.006 0.026
10-28 WA200-5
Clearance between press-fit +0.039 +0 -0.054 –

7 ø55 –
shaft and bearing +0.020 -0.015 -0.020
Clearance between press-fit +0 -0.016 -0.038 –
8 ø100 –
shaft bearing and motor 1 gear -0.018 -0.038 0.002
Clearance between piston and -0.085 +0.040 0.085 –
9 ø177 –
spacer -0.125 +0 0.165
Clearance between piston and -0.550 +0.046 0.550 –
10 ø222 –
cage -0.650 +0 0.696
Clearance between clutch +0.061 +0.046 -0.061 –
11 ø200 –
housing and front case +0.015 +0 0.031
Standard size Tolerance Repair limit
Thickness of separator plate
12 1.7 ±0.05 1.6
Distortion of separator plate – 0.05 0.15
Thickness of friction plate 2.2 ±0.08 1.8
13
Distortion of friction plate – 0.02 0.25
Load on wave spring (Height: 1,010 N ±101 N 804 N
14
2.2 mm) {103 kg} {±10.3 kg} {82 kg}
Inside diameter of contact face +0.021
ø25 ø25.1
of seal ring +0
+0.15
Width of groove of seal ring 2.5 2.7
15 +0.10
Replace
-0.01
Width of seal ring 2.5 2.3
-0.03
Thickness of seal ring 1.2 ±0.1 1.05
ø70 ø70.1
of seal ring +0
+0.15
Width of groove of seal ring 3 3.3
16 +0.10
-0.01
Width of seal ring 3 2.7
-0.03
Thickness of seal ring 2.9 ±0.1 2.75
ø120 ø120.5
of seal ring +0
+0.1
Width of groove of seal ring 4.5 5.0
17 +0
+0
Width of seal ring 4.36 3.9
-0.1
Thickness of seal ring 3 ±0.1 2.7
Backlash between motor 1 gear
18 0.170 – 0.453
and output gear
Side clearance of planetary
— 0.35 – 0.80
gear (on both sides)
WA200-5 10-29
Output shaft portion
10-30 WA200-5
Unit: mm

Clearance between output size Shaft Hole clearance limit
1
shaft and bearing (F)
+0.030 +0 -0.045 –
ø 60 –
+0.011 -0.015 -0.011
Clearance between output +0 -0.015 -0.040 –
2 ø 110 –
shaft bearing and cage (F) -0.018 -0.040 0.003
Clearance between output +0.030 +0 -0.045 –
3 ø 65 –
shaft and bearing (R) +0.011 -0.015 -0.011
Clearance between output +0 -0.015 -0.040 –
4 ø 120 –
shaft bearing and rear case (R) -0.018 -0.040 0.003
Clearance between oil seal and +0.170 +0.054 -0.170 –
5 ø 100 –
cage (F) +0.080 +0 -0.026 Replace
Clearance between dust seal +0.400 +0.054 -0.400 –
6 ø 100 –
and cage (F) +0.200 +0 -0.146
Clearance between oil seal and +0.170 +0.054 -0.170 –
7 ø 100 –
cage (R) +0.080 +0 -0.026
Clearance between dust seal +0.400 +0.054 -0.400 –
8 ø 100 –
and cage (R) +0.200 +0 -0.146
Inside diameter of sliding sur-
9 0
face of coupling oil seal (F) ø 75 74.8
-0.074
Inside diameter of sliding sur- 0
10 ø 75 74.8
face of coupling oil seal (R) -0.074
Standard Clearance
Clearance between cage and Standard size
11 clearance limit
front case
0.7 0.1 – 1.3 – Adjust shim
Free rotation torque of output
12 3.9 – 5.9 Nm {0.4 – 0.6 kgm}
shaft
WA200-5 10-31
10-32 WA200-5
1. HST motor 2
2. Motor 2 gear (Number of teeth: 43)
3. Strainer
4. Drain plug
5. Speed sensor
Unit: mm

Clearance between input shaft size Shaft Hole clearance limit
6
and bearing
+0.030 +0 -0.045 –
ø 55 –
+0.011 -0.015 -0.011
Replace
Clearance between input shaft +0 +0.022 -0.013 –
7 ø 90 –
bearing and cage -0.015 -0.013 0.037
Backlash between motor 2 gear
8 0.170 – 0.453
and output gear
WA200-5 10-33
Operation of clutch
When clutch is ON (fixed) When clutch is OFF (released)
• If the oil from the clutch solenoid valve is shut • The oil sent from the clutch solenoid valve is
off, piston (2) is moved to the right by the tension sent by pressure to the back side of piston (2)
of spring (1). and it pushes back spring (1) and piston (2)
Plates (3) and discs (4) are fixed to each other moves to the left. The friction force of plates (3)
and rotation of discs (4) is stopped by their fric- and discs (4) is lost and ring gear (5) is set in
tion force and ring gear (5) meshed with the in- neutral.
ternal teeth is fixed. • Wave springs (6) installed between plates (3) re-
turn piston (2) quickly and separate plates (3)
and discs (4) to prevent increase of slip loss
when the clutch is disengaged.
10-34 WA200-5
Low-speed mode
Operation
• In the low-speed mode, transfer clutch (1) is
fixed and the power of both HST motor 1 (2) and
HST motor 2 (3) is transmitted to output shaft
(11).
• The power of HST motor 1 (2) is transmitted
through input shaft (4), sun gear (5), planetary
gear (6), carrier (7), motor 1 gear (8), and output
gear (10) to output shaft (11).
through motor 2 gear (9) and output gear (10) to
output shaft (11).
WA200-5 10-35
High-speed mode
Operation
• In the high-speed mode, transfer clutch (1) is re-
leased and HST motor 1 (2) stops. Accordingly,
the power of only HST motor 2 (3) is transmitted
to output shaft (11).
through motor 2 gear (9) and output gear (10) to
output shaft (11).
10-36 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLUTCH SOLENOID VALVE
CLUTCH SOLENOID VALVE
P: From HST charge pump Operation

A: To transfer clutch • When the current of the input signal is large, the
T: To drain port hydraulic oil of the transfer clutch is drained.
• As the current of the input signal is reduced, the
1. Clutch solenoid valve hydraulic pressure of the transfer clutch is
2. Plunger heightened.
3. Coil • After the current of the input signal is reduced
4. Push pin until the hydraulic pressure of the transfer clutch
5. Spring reaches the hydraulic pressure sent from the
6. Spool HST charge pump, the hydraulic pressure of the
7. Body transfer clutch is kept at the hydraulic pressure
sent from the HST charge pump even if the cur-
rent of the input signal is reduced further.
WA200-5 10-37
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AXLE
AXLE
FRONT AXLE
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Shaft
8. Oil filler port / level plug
9. Slack adjuster
10.Oil temperature sensor
11. Draing plug
10-38 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AXLE
REAR AXLE
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler port / level plug
8. Slack adjuster
9. Draing plug
WA200-5 10-39
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
FRONT DIFFERENTIAL
1. Pinion gear (Number of teeth: 9)

2. Shaft
3. Bevel gear (Number of teeth: 43)
4. Sun gear shaft
5. Bevel pinion (Number of teeth: 12)
6. Side gear (Number of teeth: 12)
10-40 WA200-5
Unit: mm
7 Backlash of differential gear 0.1 – 0.25 Replace

8.82 – 20.58 N {0.9 – 2.1 kg}
8 Starting force of bevel gear Adjust
(At outside surface of bevel gear)
9 Pinion gear washer thickness
3 ± 0.08 2.8 Replace
10 Side gear washer thickness 2 ± 0.05 1.8
Thickness of shim at differential
11 0.50 – 1.35
side bearing carrier (Each side) Adjust
12 Backlash of bevel gear 0.20 – 0.33
13 End play of bevel pinion 0.002 – 0.162 Replace
14 0.50 – 1.23 Adjust
housing and gauge assembly

size Shaft Hole clearance limit
Clearance of differ- Outer +0.025 -0.004 -0.054 –
15 ø 112.713 —
ential side bearing race +0 -0.029 -0.004
Inner +0.066 +0.013 -0.066 –
ø 69.85 —
race +0.045 +0 -0.032
Outer +0 -0.048 -0.088 –
Clearance of bear- race ø 130 —
-0.018 -0.088 -0.030
16 ing on gear side of
pinion shaft Inner +0.039 +0 -0.054 –
ø 60 —
race +0.020 -0.015 -0.020
Outer +0 -0.041 -0.076 –
-0.015 -0.076 -0.026
17 ing on coupling
side of pinion shaft Inner +0.039 +0 -0.054 – Replace
ø 55 —
race +0.020 -0.015 -0.020
Clearance between pinion gear -0.06 +0.10 0.11 –
18 ø 28 —
and spider -0.11 +0.05 0.21
Clearance of piston fitting por-
-0.110 +0.081 0.110 –
19 tion of differential housing ø 261 —
-0.191 +0 0.272
(Housing and piston)
-0.100 +0.072 0.100 –
20 tion of bearing carrier (Piston ø 241 —
-0.172 +0 0.244
and carrier)
Clearance Outer +0 +0 -0.035 –

ø 110 —
between drive race -0.015 -0.035 0.015
21
shaft and bearing Inner +0.018 +0 -0.03 –
of cage ø 50 —
race +0.002 -0.012 -0.002
WA200-5 10-41
REAR DIFFERENTIAL
1. Pinion gear (Number of teeth: 9)

2. Shaft
3. Bevel gear (Number of teeth: 43)
4. Sun gear shaft
5. Bevel pinion (Number of teeth: 12)
6. Side gear (Number of teeth: 12)
10-42 WA200-5
Unit: mm
7 Backlash of differential gear 0.15 – 0.35 Replace

8.82 – 20.58 N {0.9 – 2.1 kg}
8 Starting force of bevel gear Adjust
(At outside surface of bevel gear)
9 Pinion gear washer thickness
3 ± 0.08 2.8 Replace
10 Side gear washer thickness 2 ± 0.05 1.8
11 0.50 – 1.35
side bearing carrier (Each side) Adjust
12 Backlash of bevel gear 0.20 – 0.33
13 End play of bevel pinion 0.002 – 0.162 Replace
14 0.50 – 1.23 Adjust
housing and gauge assembly

size Shaft Hole clearance limit
Clearance of differ- Outer +0.025 -0.004 -0.054 –
15 ø 112.713 —
ential side bearing race +0 -0.029 -0.004
Inner +0.066 +0.013 -0.066 –
ø 69.85 —
race +0.045 +0 -0.032
Outer +0 +0.048 -0.088 –
-0.018 -0.088 -0.030
16 ing on gear side of
pinion shaft Inner +0.039 +0 -0.054 –
ø 60 —
race +0.020 -0.015 -0.020
Outer +0 -0.041 -0.076 – Replace
-0.015 -0.076 -0.026
17 ing on coupling
side of pinion shaft Inner +0.039 +0 -0.054 –
ø 55 —
race +0.020 -0.015 -0.020
Clearance between pinion gear -0.06 +0.10 0.110 –
18 ø 28 —
and spider -0.11 +0.05 0.210
-0.110 +0.081 0.110 –
19 tion of differential housing ø 261 —
-0.191 +0 0.272
(Housing and piston)
-0.100 +0.072 0.100 –
20 tion of bearing carrier (Piston ø 241 —
-0.172 +0 0.244
and carrier)
WA200-5 10-43
Outline When turning

• The power transmitted to the front and rear axles • When turning, the rotating speed of the left and
is turned by 90 degrees and reduced in speed, right wheels is different, so pinion gear (4) and
and then transmitted through pinion gear (4) to side gear (3) inside the differential transmit the
sun gear shaft (2). power of carrier (6) to sun gear shaft (2) while ro-
• The power of the sun gear is further reduced by tating in accordance with the difference between
the planetary gear type final drive and is trans- the left and right rotating speeds.
mitted to the axle shaft and wheels.
When traveling in a straight line

• When traveling in a straight line, the rotating
speed of the left and right wheels is the same, so
pinion gear (4) inside the differential assembly
does not rotate. The power of carrier (6) passes
through pinion gear (4) and side gear (3), and is
transmitted equally to the left and right sun gear
shafts (2).
10-44 WA200-5
Torque proportioning differential
Outline Travel on soft ground (When the road

• A 4-wheel-drive wheel loader, as a construction resistances under both tires are different)
machine, must naturally work on places where • When the tires slips on soft ground, the side
the ground condition is bad. If its tires slip in gear of the tire on the less road resistance side
such places, its function lowers and the lives of turns forward. As a result, the meshing points of
the tires are shortened. To solve this problem, pinion gear (4) and the side gears change.
the torque proportioning differential is used. • If left side gear (7) turns forward a little, distance
• Differential pinion gear (4) of this differential has "a" from the pinion gear to the meshing point of
an odd number of teeth. The meshing points of the left side gear becomes longer than distance
pinion gear (4) and side gears (3) change ac- "b" to the meshing point of the right side gear,
cording to the difference of the road resistance. and then "a" and "b" are balanced at a point
Consequently, the traction forces of the tires on where a x TL = b x TR. The ratio of a:b changes
both sides change. up to 1:1.38, depending on the meshing condi-
tion.
• Accordingly, the pinion gear does not run idle
and the drive force is transmitted to both side
gears and the tires do not slip until the ratio of
a:b becomes 1:1.38, or the difference between
the road resistances under both tires becomes
38%.
• The lives of the tires are lengthened 20 - 30%
and the working capacity is increased by the
above effect.
Operation
Straight travel (When the road resistances under

both tires are the same)
• When the road resistances under the both tires
are the same, distance "a" from differential pin-
ion (4) to the meshing point of left side gear (7)
and distance "b" to the meshing point of right
side gear (3) are the same.
• Accordingly, left traction force TL and right trac-
tion force TR are balanced.
WA200-5 10-45
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIMITED-SLIP DIFFERENTIAL
LIMITED-SLIP DIFFERENTIAL
1. Plate
2. Disc
3. Pinion (Number of teeth:12)
4. Washer
5. Side gear(Number of teeth:24)
6. Bevel pinion
7. Shaft
8. Pressure ring
9. Bevel gear
10. Case
10-46 WA200-5
Unit: mm

11 Plate thickness 3
± 0.02 2.9
3.1
+0.04
12 Disc thickness 2.5 2.45
-0.03
13 Washer thickness 2 ± 0.05 1.8
Clearance between disc and
14 0.20 – 0.6
plate (Total of both sides)
End play (one end ) of side Replace
15 0.13 – 0.36
gear in axial direction
Backlash between case and
16 0 – 0.5
plate
Backlash between side gear
17 0.13 – 0.32
and disc

Clearance between spider and size Shaft Hole clearance limit
18
differential pinion gear
-0.110 +0.05 0.110 –
ø 25.4 —
-0.160 +0 0.210
WA200-5 10-47
Operation of limited-slip differential When traveling in a straight line
1. When there is no imbalance between drive

The power is transmitted from bevel gear (9) to case
force of left and right wheels [Road surface
(10), pressure ring (8), shaft (7), pinion (3), and side
gear (5), and is divided to the left and right shafts. condition (friction coefficient) and load for left
The brake system, consisting of discs (2) and plates and right wheels are uniform and load on bucket
(1) is installed at the rear face of side gear (5). A is centered exactly]
brake torque is generated that is proportional The power is divided equally to the left and right
to the torque transmitted from pressure ring (8) to by the differential gear. In this case, the wheel
shaft (7). slip limit of the left and right wheels is the same,
This brake torque acts to limit the rotation in relation so even if the power from the engine exceeds
to side gear (5) and case (10), so it is difficult for left the wheel slip limit, both wheels will slip and the
and right side gears (5) to rotate mutually and the op- differential will not be actuated.
eration of the differential is limited. There is no load on the brake at the rear face of
the side gears.
Brake torque generation mechanism of left and
right side gears (5).
Shaft (7) is supported at the cam surface cut into the
facing surfaces of left and right pressure rings (8).
The power (torque) transmitted from pressure rings
(8) to shaft (7) is transmitted at the cam surface, but
force Fa separating left and right pressure rings (8)
is generated in proportion to the torque transmitted
according to the angle of this cam surface.
This separation load Fa acts on the brake at the rear
face of left and right side gears (5) and generates
the brake torque.
10-48 WA200-5
2. When there is imbalance between drive force Difference in wheel drive force for each type of differ-
of left and right wheels [Road surface condi- ential when wheel on one side slips
tion (friction coefficient) and load for left and Wheel drive force
right wheels are not uniform and it is easier for (Ratio when slipping wheel is
wheel on one side to slip] set to 1)
Example 1. When digging, and wheel on one Slipping Locked Total
side is on soft surface wheel wheel (ratio)
Example 2. When clearing snow, and wheel on Limited-slip differential
1 2.64
3.64
one side is on snow and wheel on other side is (option) (1.53)
on asphalt Torque proportioning
1 1.38 2.38 (1)
Example 3. When traveling on slope, and there differential (standard)
is imbalance between load on left and right Normal differential 1 1 2 (0.84)
wheels
The power from transfer is divided equally to
the left and right by the side gear. However, On road surfaces where the wheel on one side is
when the drive force exceeds the wheel slip likely to slip, the limited-slip differential increases
limit on the side where the wheel is slipping, the the drive force by 1.53 times more than the torque
amount of the force exceeding the wheel slip proportioning differential.
limit passes through the brake and case at the
rear face of the side gear and is transmitted to When turning
the brake on the opposite side (locked side) and The differential gears built into a limited-slip differen-
is sent to the wheel on the locked side. tial are the same as the gears used in a normal dif-
If this excess portion of the drive force becomes ferential, so the difference in rotation between the
greater than the braking force, the differential inside and outside wheels when turning the machine
starts to work. can be generated smoothly.
WA200-5 10-49
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
1. Planet gear (No. of teeth: 26)

2. Planetary carrier
3. Axle shaft
4. Ring gear (No. of teeth: 69)
5. Sun gear shaft (No. of teeth: 15)
10-50 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
Tolerance
Standard Standard Clearance
Clearance between pinion gear size Clearance limit
6 Shaft Hole
bearing and shaft
Replace
ø 33.338 +0.025 +0.013 -0.025 – —
+0.013 +0 0
7 Clearance between axle housing ø 276 +0.100 +0.100 -0.100 – —

and ring gear +0.030 +0 +0.070
8 Clearance between oil seal and Max. 0.2 Adjust

housing
Housing ø 140 +0.400 +0.063 -0.400 – —

Press-fitting portion +0.200 +0 -0.137
9 of axle shaft seal
Shaft ø 105 +0 -0.200 -0.400 – —
-0.054 -0.400 -0.146
+0 -0.028 -0.068–
Clearance at press- Outer race ø 130
-0.025 -0.068 -0.003
—
10 fitting portion of axle Replace
housing bearing Inner race ø 85 +0.045 +0 -0.065 – —
+0.023 -0.020 -0.023
+0 -0.028 -0.068 –
Clearance at press- Outer race ø 125
-0.018 -0.068 -0.010
—
11 fitting portion of axle
housing bearing Inner race ø 80 +0.030 +0 -0.045 – —
+0.011 -0.015 -0.011
End play of axle shaft 0 – 0.1

12 Adjust
Starting torque of axle shaft Max. 10.8 Nm {1.1 kgm}
13 Clearance of guide pin ø 12 +0.025 +0.207 0.120 – — Replace

+0.007 +0.145 0.200
Outline
• The final drive finally reduces the speed of the
power transmitted from the HST motor through
the transfer to the axle and increases the drive
force.
• Ring gear (4) is press fitted to the axle housing
and is fixed in position by a pin.
• The power transmitted from the differential and
passing through sun gear shaft (5) has its speed
reduced by the planetary gear mechanism and
the drive force increased.
The increased drive force passes through plan-
etary carrier (2) and axle shaft (3) and is trans-
mitted to the wheels.
WA200-5 10-51
AXLE MOUNTING AND CENTER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HINGE PIN
AXLE MOUNTING AND CENTER HINGE PIN

a The following drawing shows WA200-5
.
10-52 WA200-5
(3)
1. Front axle Outline

2. Tension bolt • Since front axle (1) receives forces directly dur-
3. Front frame ing work, it is fixed to front frame (3) directly with
4. Center hinge pin tension bolts (2).
5. Rear axle • Rear axle (5) rocks at the center of rear frame (6)
6. Rear frame so that each tire will keep in contact with ground
7. Additional counterweight (If equipped) even when the machine travels on soft ground.
8. Counterweight • Front frame (3) and rear frame (6) are connected
by center hinge pin (4) with the bearing between
them. The steering cylinders on both sides con-
nect front frame (3) and rear frame (6) and move
to adjust the bending angle, or the turning radi-
us.
WA200-5 10-53
10-54 WA200-5
Unit: mm

Clearance between upper size clearance limit
Shaft Hole
1 hinge pin and rear frame
(small) -0.038 +0.100 0.038 –
ø 50 –
-0.068 +0 0.168
Clearance between upper -0.038 +0.250 0.038 –
2 ø 50 –
hinge pin and spacer -0.068 +0 0.318
Clearance between upper -0.038 +0 0.026 –
3 ø 50 –
hinge pin and bearing -0.068 -0.012 0.068
Clearance between upper -0.073 0.023 –
4 ø 66 ±0.050 –
hinge pin and rear frame (large) -0.103 0.153
Replace
Clearance between front frame +0 -0.020 -0.120 –
5 ø 105 –
and upper hinge bearing -0.015 -0.120 -0.005
Clearance between lower hinge -0.050 +0.067 0.077 –
6 ø 69.85 –
pin and rear frame bushing -0.060 +0.027 0.127
Clearance between lower hinge -0.050 +0.053 0.078 –
7 ø 69.85 –
pin and bearing -0.060 +0.028 0.113
Clearance between front frame +0 -0.050 –
8 ø 88.9 ±0.050 –
and lower hinge bearing -0.020 0.070
Clearance between rear frame +0.084 +0.054 -0.084 –
9 ø 80 –
and bushing +0.059 +0 -0.005
10 Height of upper hinge spacer
23 ±0.1 –
Standard shim thickness of
11 1.3
upper hinge and retainer
Adjust
12 0.8
upper hinge and retainer
Tightening torque for upper 3.92 – 5.88 Nm {0.4 – 0.6 kgm} (When adjusting shim)
13
hinge retainer mounting bolt 59 – 74 Nm {6.0 – 7.5 kgm} (Final value)
WA200-5 10-55
Unit: mm

1 Thickness of thrust plate +0
10 –
-0.15
+0.3
2 Thickness of thrust washer 5 –
-0.1
Standard Tolerance Standard Clearance Replace

Clearance between hole and size Shaft Hole clearance limit
3
shaft at front support end
-0.043 +0.550 0.093 –
ø 170 –
-0.106 +0.050 0.656
Clearance between hole and -0.043 +0.550 0.093 –
4 ø 170 –
shaft at rear support end -0.106 +0.050 0.656
5 0.2 –
thrust cap
10-56 WA200-5
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING PIPING
STEERING PIPING
1. Steering cylinder (right)

2. Orbit-roll valve
3. Hydraulic oil tank
4. Priority valve
5. Steering pump
6. 2-way restrictor valve
7. Cushion valve
8. Steering cylinder (left)
WA200-5 10-57
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING COLUMN
STEERING COLUMN
1. Steering wheel
2. Steering column
3. Orbit-roll valve
4. Tilt lever
Unit: mm

Clearance between steering size Shaft Hole clearance limit
5 Replace
shaft and column bushing
+0 +0.15 0.05 –
ø 19 0.4
-0.08 +0.05 0.23
10-58 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PRIORITY VALVE
PRIORITY VALVE
P: From steering pump LS: From orbit-roll valve

CF: To orbit-roll valve T: To hydraulic tank
EF: To work equipment control valve
1. Relief valve body 7. Plug

2. Spring seat 8. Valve body
3. Spring 9. Spool
4. Poppet 10. Spring
5. Seat 11. Plug
6. Screen
Unit: mm
Standard size Repair limit
Free length Installed Installed Free length Installed

12 Control spring length load load
Replace
63.4 47.6 187 N 63.4 ± 1 187 ± 14.7 N
{19.1 kg} {19.1 ± 1.5 kg}
13 Relief spring 31 26.9 146 N – 146 ± 14.7 N

{14.9 kg} {14.9 ± 1.5 kg}
WA200-5 10-59
Outline Operation
• The priority valve is in the circuit between the
steering pump and the orbit-roll valve. It acts to 1. Steering wheel at neutral
divide the flow of oil from the steering pump and When the engine is stopped, spool (3) is
send it to the orbit-roll valve or oil cooler circuit. pushed fully to the left by the tension of spring
It also sets the oil pressure in the circuit from the (4). The circuit between ports M and N is fully
priority valve to the orbit-roll valve to 20.6 MPa open, while the circuit between ports M and Q is
{210 kg/cm2} to protect the circuit. fully closed.
In this condition, is the engine is started and the
steering pump is rotated, the oil from the pump
goes from the port M to port N, and then enters
port A to the orbit-roll valve.
When this happens, the oil passing through ori-
fice m in spool (3) enters port P. It then com-
presses spring (4), and moves spool (3) to the
right in the direction of the arrow.
This stabilizes the condition so that the circuit
between ports M and Q is almost fully open and
the circuit between ports M and N is almost fully
closed. Therefore, the oil from the pump almost
all flows to the work equipment circuit.
10-60 WA200-5
2. Steering wheel turned to left 3. Steering cylinder at end of stroke

When the steering wheel is turned to the left, an If the operator tries to turn the steering wheel
angle variation is generated between the spool further when the steering cylinder has reached
and sleeve of the orbit-roll valve, and the oil flow the end of its stroke, the circuit from port M
is switched. (For details, see ORBIT-ROLL through port N to port S is kept open and the
VALVE.) pressure rises.
The oil from the pump flows from port M to port When this pressure rises above requirement
N, and enters port A. The degree of opening of pressure relief valve (10) opens and the oil is
the sleeve (port A) and spool (port B) creates a relieved to the hydraulic tank. Because of this
difference between the pressure up to port A flow of oil, a differential pressure is created on
and the pressure beyond port B. Some of the oil both sides of orifice r. Therefore, the balance is
from port B flows to the Girotor, and then goes lost between the load of spring (4) and the pres-
to the front right cylinder. The remaining oil sure up to port A and the pressure beyond port
passes through orifice b, flows to port J, and B. As a result, the pressure up tp the port A
then enters port R. becomes relatively higher.
When this happens, spool (3) stabilizes at a For this reason, the pressure at port P moves
position where the differential pressure between spool (3) even further to the right from the con-
the circuit up to port A and circuit beyond port B dition in Item 2. It stabilizes the condition at a
(pressure of port P - pressure of port R) and the position where the circuit between ports M and
load of the spring (4) are balanced. It adjusts N is almost fully closed, and the circuit between
the degree of opening from port M to ports N ports M and Q is almost fully open.
and Q, and distributes the flow to both circuits.
The ratio of this distributed flow is determined
by the degree of opening of port A and port B,
in other words, the angle variation between the
sleeve and spool of the orbit-roll valve. This
degree the opening is adjusted steplessly by
the amount the steering is turned.
WA200-5 10-61
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ORBIT-ROLL VALVE
ORBIT-ROLL VALVE
P: From steering pump LS: To priority valve

L: To steering cylinder T: To hydraulic tank
R: To steering cylinder
1. Ground 8. Drive shaft

2. Valve body 9. Sleeve
3. Check valve 10. Spool
4. Gerotor 11. Center pin
5. Spacer 12. Centering spring
6. Cover 13. Anti-cavitation valve
7. Spacer 14. Over-load relief valve
10-62 WA200-5
Outline Structure
• The orbit-roll valve is connected directly to the • Top (A) of spool (3) is connected to the drive
shaft of the steering wheel. It switches the flow shaft of the steering column and further connect-
of oil from the steering pump to the left and right ed to sleeve (5) through center pin (4) (which is
steering cylinders to determine the direction of not in contact with the spool while the steering
travel of the machine. wheel is in neutral) and centering spring (12).
• The orbit-roll valve, broadly speaking, consists • Top (B) of drive shaft (6) is engaged with center
of the following components: rotary type spool pin (4) and combined with sleeve (5) in one
(3) and sleeve (5), which have the function of se- body, and the bottom is engaged with the spline
lecting the direction, and the Girotor set (a com- of rotor (8) of the gerotor set.
bination of rotor (8) and stator (9)), which acts as • Valve body (2) has 5 ports, which are connected
a hydraulic motor during normal steering opera- to the pump circuit, tank circuit, left steering cir-
tions, and as a hand pump (in fact, the operating cuit, right steering circuit, and LS circuit respec-
force of the steering wheel is too high, so it can- tively. The ports on the pump side and tank side
not be operated) when the steering pump or en- are connected by the check valve in the body. If
gine have failed and the supply of oil has the pump or engine fails, the oil can be sucked
stopped. through this check valve directly from the tank
side.
WA200-5 10-63
Operation
1. Steering wheel at neutral
10-64 WA200-5
• While the steering wheel is in neutral, spool (3)

and sleeve (5) are fixed at a place where center
pin (4) is set to the center of the oblong hole of
spool (3) by centering spring (12).
At this time, port A of sleeve (5) from the pump,
port E to gerotor, port F of the right steering cir-
cuit, port G of the left steering circuit, and verti-
cal grooves B, C, and D of spool (3) are shut
off.
Orifice b of port J to the priority valve is con-
nected to vertical groove B of spool (3).
Port K of sleeve (5) connects port L of spool (3)
to vertical groove M.
• As a result of above connection and disconnec-
tion of the ports and vertical grooves, the oil
which has been set to the pilot pressure of the
priority valve is drained through port J, orifice b,
vertical grooves M and K, and port L into the hy-
draulic tank.
WA200-5 10-65
2. Steering wheel turned (turning left)
10-66 WA200-5
• If the steering wheel is turned to the left, spool 3. Steering wheel stopped
(3) connected by the drive shaft of the steering When the oper ation of steering wheel is
column turns to the left. stopped, the difference in rotation between the
At this time, since spool (3) and sleeve (5) are spool (3) and sleeve (5) is returned to the neu-
connected by centering spring (12), spool (3) tral condition by the reaction of centering spring
compresses centering spring. (12).
Accordingly, an angular displacement is made
between spool (3) and sleeve (5) by the com-
pression of centering spring (12).
Then, port A is connected to vertical groove B
first. Next, vertical groove B is connected to
port E, and then port E is connected to vertical
groove C, and vertical groove C is connected to
port G of the left steering circuit at last.
Orifice b of port J to vertical B and priority valve
is kept connected, but port K of sleeve (5) dis-
connects vertical groove M and port L gradually.
When port A is connected to vertical groove B,
port F of the right steering circuit is connected to
vertical groove D.
• As a result of above connection and disconnec-
tion of the ports and vertical grooves, the oil from
the pump flows through port A to the vertical
groove B, and then flows to port E to rotate the
gerotor. The oil discharged from the gerotor
flows through port E, vertical groove C, and port
G to the head side of the left steering cylinder.
The hydraulic pressure in vertical groove M is
transmitted through orifice b to port J and used
as the pilot pressure of the priority valve.
The oil from the head side of the right steering
cylinder is drained through port F, vertical
groove D, and port H into the hydraulic tank.
WA200-5 10-67
CONNECTION BETWEEN HAND PUMP AND SLEEVE
• The diagrams above show the connections with Therefore, the amount of oil discharged is
the sleeve ports used to connect the suction and directly proportional to the amount the steering
discharge ports P of the Girotor. wheel is turned.
• 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 right steer-
ing cylinder in the same way.
In the condition in Fig. 1, ports 1, 2, and 3 are
the discharge ports of the Girotor set.
They are connected to port l, b, and d, so the oil
is sent to the steering cylinder.
Ports 5, 6, and 7 are connected and the oil
flows in from the pump.
If the steering wheel is turned 90°, the condition
changes to the condition shown in Fig. 2. In this
case, ports 2, 3, and 4, are the suction ports,
and are connected to ports k, a, and c. Ports 5,
6, and 7 are the discharge ports, and are con-
nected to ports d, f, and h.
• In this way, the ports acting as the discharge
ports of the Girotor are connected to the ports
going to the steering cylinder, while the ports
acting as the suction ports are connected to the
pump circuit.
• Adjustment of discharge according to amount
steering wheel is turned.
For each 1/7 turn of the steering wheel, the
inside teeth of the Girotor advance one tooth,
and the oil from the pump is discharged in an
amount that matches this movement.
10-68 WA200-5
Role of centering spring

• Center spring (12) is composed of 4 X-shaped
leaf springs and 2 flat leaf springs and installed
between spool (3) and sleeve (5) as shown in
the figure.
• If the steering wheel is turned, spool (3) com-
presses centering spring (12) and an angular
displacement is made between spool (3) and
sleeve (5).
As a result, the ports of spool (3) and sleeve (5)
are connected and the oil is sent to the steering
cylinder. When the steering wheel stops turn-
ing, the gerotor also stops turning. Then, the oil
is not sent to the steering cylinder and its pres-
sure rises. To prevent this, when the steering
wheel stops turning, it is returned by the reac-
tion force of centering spring (12) toward the
neutral position by the angular displacement of
spool (3) and sleeve (5).
WA200-5 10-69
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 2-WAY RESTRICTOR VALVE
2-WAY RESTRICTOR VALVE
1. Tube
2. Poppet
3. Body
Function
• An orifice is installed to the return circuit on the
cylinder side to give pressure to the return oil
and control the movement of the cylinder piston
for reduction of shocks caused by inertia of the
machine body when the machine is steered.
Operation
• When the oil flows to the left (to move the cylin-
der forward), it pushes poppet (3) open and
flows through orifice (a) of poppet (3) and notch
(b).
• When the oil flows to the right (to move the cyl-
inder backward), it flows through only orifice (a)
of poppet (3). Accordingly, the oil flow rate is re-
stricted.
10-70 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CUSHION VALVE
CUSHION VALVE
A: From left swing port of steering cylinder Outline

B: From right swing port of steering cylinder • When the oil pressure in the steering cylinder
rises or rebounds, the cushion valve instantane-
1. Valve seat ously lets the high-pressure oil escape to anoth-
2. Valve body er line to prevent a shock.
3. Spring
4. Poppet Function
5. Orifice • If high-pressure oil flows in port A suddenly, it
6. Plug compresses spring (3) and pushes poppet (4) of
7. Spring port A open and flows through the center groove
8. Spool of spool (8), and then pushes poppet (11) of port
9. Plug B open and flows in port B.
10.Spring • At the same time, this high-pressure oil flows
11. Poppet through orifice (5) of port A to the pressure
chamber of plug (6) and pushes back spool (8)
to the right against the pressure on port B side
and the tension of spring (7). As a result, the oil
flow from port A to port B is stopped.
• This temporary oil flow has a cushioning effect.
Since the cushion valve does not operate after
this, it does not affect the ordinary steering oper-
ation.
• When the pressure changes so slowly that the
cushioning effect is not necessary, spool (8)
stops the oil before poppet (4) is opened, thus
the cushion valve does not work as a cushion.
WA200-5 10-71
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CYLINDER
STEERING CYLINDER
Unit: mm
Tolerance
Clearance between mounting pin size Clearance limit
1 and bushing at connection of Shaft Hole
frame and cylinder rod
ø 40 -0 +0.180 0.042 – —
-0.025 +0.042 0.205
Clearance between mounting pin -0 +0.180 0.042 –
2 and bushing at connection of ø 40 -0.025 +0.042 0.205 — Replace
frame and cylinder bottom
Width of boss Width of hinge Standard clearance

(a + b)
3 Connection of steering cylinder
and front frame Max. 0.5
50 53
(after adjusting shim)
4 Connection of steering cylinder 50 53 Max. 0.5

and rear frame (after adjusting shim)
10-72 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CYLINDER
Unit: mm
Tolerance
Clearance between piston rod size Clearance limit
1 Shaft Hole
and bushing
ø 40 -0.025 +0.132 0.031 – 0.519 Replace pin,

-0.087 +0.006 0.219 bushing
2 Clearance between piston rod ø 40 -0 +0.180 0.042 – 1.0

support shaft and bushing -0.025 +0.042 0.205
3 Clearance between cylinder bot- ø 40 -0 +0.180 0.042 – 1.0

tom support shaft and bushing -0.025 +0.042 0.205
4 Tightening torque of cylinder head 539 ± 53.9 Nm {55 ± 5.5 kgm}
5 Tightening torque of cylinder pis- 785 ± 78.5 kNm {80 ± 8.0 kgm} (Width across flats: 46 mm)
ton Tighten
6 Tightening torque of nipple plug 9.8 – 12.74 Nm {1.0 – 1.3 kgm}

on cylinder head side
WA200-5 10-73
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EMERGENCY STEERING PIPING
EMERGENCY STEERING PIPING

(If equipped)
1. Orbit-roll valve
2. Priority valve
3. Pressure switch (for detecting drop of steering oil pressure)
4. Steering pump
5. HST motor 2
6. Emergency steering valve
7. Pressure switch (For detecting operation of emergency steering)
8. Check valve
10-74 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EMERGENCY STEERING VALVE
EMERGENCY STEERING VALVE

(If equipped)
PP: From steering pump 1. Check valve body

A: To port A of HST motor 2 2. Check valve
B: To port B of HST motor 2 3. Valve body
Y: To orbit-roll valve 4. Pressure reducing valve
S: To hydraulic tank 5. Selector valve
G: To pressure switch
WA200-5 10-75
Operation
When engine and steering pump are normal
• While the engine and steering pump are operat-

ing normally, the oil sent from the steering pump
flows into the orbit-roll valve to steer the ma-
chine.
• At this time, the oil from the steering pump flows
in port PP and pushes spool (1) to the left to shut
off the circuit from the HST motor to the orbit-roll
valve.
10-76 WA200-5
When engine or steering pump is abnormal
• If the engine or steering pump has a trouble and

the steering pump does not supply oil sufficiently
to the orbit-roll valve during travel, the discharge
pressure of the steering pump lowers and spool
(1) is pushed back to the right by the reaction
force of spring (2).
• At this time, the oil from the HST motor is set
high by check valves (3) and (4). Then, the oil is
reduced in pressure by pressure reducing valve
(5) to a proper level for the steering circuit and it
flows through spool (1) and port Y to the orbit-roll
valve. As a result, the machine can be steered.
• If the quantity of the oil in the HST circuit be-
comes insufficient because of oil leakage into
the steering circuit, etc., check valves (6) and (7)
add oil to the HST circuit.
a Check valves (3) and (4) work so that the emer-

gency steering system will operate regardless of
the travel direction.
WA200-5 10-77
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE PIPING
BRAKE PIPING
1. Hydraulic tank 7. Accumulator (for front)

2. Brake valve 8. Accumulator (for rear)
3. Brake and cooling fan pump 9. Charge valve
4. Slack adjuster (for right rear) 10. Strainer
5. Rear brake 11. Slack adjuster (for left front)
6. Slack adjuster (for left rear) 12. Front brake
13. Slack adjuster (for right front)
10-78 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
P1: From HST pump A: To rear brake

T1: To hydraulic tank PB: From accumulator (Front side)
T2: To steering pump (Suction side) B: To front brake
PA: From accumulator (Rear side)
1. Rod 5. Brake valve body (for rear)

2. Inching valve spool 6. Brake valve spool (for front)
3. Inching valve body 7. Brake valve body (for front)
4. Brake valve spool (for rear)
Unit: mm

Clearance between inching size Shaft Hole clearance limit
8
valve spool and body
-0.022 +0.033 0.020 –
ø 22.4 0.096
-0.053 +0 0.086
Clearance between inching -0.022 +0.033 0.020 –
9 ø 22.4 0.096
valve guide and body -0.053 +0 0.086
Clearance between inching -0.050 +0.050 0.050 –
10 ø 12 0.157
valve spool and guide -0.093 +0 0.143
Replace
Free Installed Installed Free Installed
11 Inching valve control spring length length load length load
24.5 N 20.8 N
34.7 16.7 –
{2.5 kg} {2.1 kg}
12 Brake valve control spring 35.6 24.0 113 N – 96 N

{11.5 kg} {9.8 kg}
13 Inching valve return spring 50.0 49.5 19.6 N – 16.7 N

{2.0 kg} {1.7 kg}
14 Brake valve return spring 114.9 52.4 147 N – 125 N

{15.0 kg} {12.7 kg}
WA200-5 10-79
Outline
• The brake valve is installed under the front of the
operator's seat. If either brake pedal is pressed,
oil flows to the brake piston to operate the brake.
• Both brake pedals are connected mechanically
to each other. If either of them is pressed, the
other moves, too.
• The brake valve has an inching valve in it to con-
trol the control pressure of the HST pump.
Operation
1. When brake pedal is pressed
• If brake pedal (1) is pressed, the pressing force When only either brake operates (When either
is transmitted through rod (2), spool (3), and brake fails)
spring (4) to spool (5). • Even if only either brake operates because of oil
• If spool (5) is pushed to the right, port Ta is leakage, etc. in the front or rear brake system,
closed and the oil from the pump flows through the pressing force of brake pedal (1) moves
the accumulator, port PA, and port A to the rear spools (5) and (6) mechanically to the right.
brake piston to operate the rear brake. Accordingly, the oil from the pump flows nor-
• At the time when spool (5) is pushed to the right, mally to the brake piston of the normal system
spool (6) is also pushed to the right to close port to operate the brake and stop the machine.
Pb. As a result, the oil from the pump flows With this mechanism, safety is heightened.
through the accumulator, port PB, and port B to
the front brake piston to operate the front brake.
10-80 WA200-5
2. When balanced
• If the rear brake piston is filled with oil and the oil • The oil pressure in the rear brake circuit (on port
pressure between ports PA and A rises, the oil A side) is balanced with the pressing force of the
flowing through orifice c of spool (5) into cham- brake pedal. The oil pressure in the front brake
ber E pushes back spool (5) to the left against circuit (on port B side) is balanced with the oil
spring (4) and close ports PA and A from. Since pressure in the rear brake circuit (on port A
port Ta is kept closed at this time, the oil which side).
flowed into the brake piston is held and the If spools (5) and (6) move to the right stroke
brake is kept operated. end, the passes between ports PA and A and
• At the time when spool (5) is pushed to the left, between ports PB and B are fully open and the
the front brake piston is filled with oil and the oil pressure in the rear and front brake circuits is
pressure between ports PB and B rises. As a re- equal to the oil pressure from the pump.
sult, the oil which flowed through orifice d of Accordingly, the operator can adjust the braking
spool (6) into chamber F pushes back spool (6) force with the brake pedal until spool (5) and (6)
to the left by the moving distance of spool (5) to move to the right stroke end.
close ports PB and B. Since port Tb is kept
closed, the oil which flowed into the brake piston
is held and the brake is kept operated.
WA200-5 10-81
3. When brake pedal is released
• If brake pedal (1) is released, the pedal pressing

force applied to spool (5) is lost.
• Spool (5) is pushed back to the left by the back
pressure of the rear brake piston and reaction
force of spring (7). Consequently, port PA is
closed and the oil in the rear brake piston flows
through ports A and port Ta into the hydraulic
tank and the rear brake is released.
• At the time when spool (5) moves to the left,
spool (6) is also pushed back to the left by the
back pressure of the front brake piston and reac-
tion force of spring (7). Consequently, port PB
is closed and the oil in the front brake piston
flows through ports B and Tb into the hydraulic
tank and the front brake is released.
10-82 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD INCHING VALVE
INCHING VALVE
P1: From port Y of HST pump Outline

T2: To steering pump (Suction side) • The inching valve is built in brake valve (2). It re-
duces the control oil pressure of the HST circuit
1. Brake pedal to reduce the capacity of the HST pump accord-
2. Brake valve ing to stroke (S) of spool (3).
3. Spool
4. Body
WA200-5 10-83
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CHARGE VALVE
CHARGE VALVE
10-84 WA200-5
P: From brake and cooling fan pump

T: To hydraulic tank
A: To cooling fan motor
ACC1: To accumulator (Rear side)
ACC2: To accumulator (Front side)
S: Brake operation sensor port
G: Gauge port
1. Valve body
2. Inverse shuttle valve
3. Plunger
4. Unload relief valve
5. Flow control valve
6. Unload valve
7. Relief valve
Unit: mm

Clearance between inverse size Shaft Hole clearance limit
8
shuttle valve spool and body
-0.006 +0.011 0.006 –
ø 12 0.029
-0.014 +0 0.025
Clearance between plunger -0.005 +0.009 0.005 –
9 ø8 0.024
and body -0.012 +0 0.021
Clearance between flow control
-0.006 +0.011 0.006 –
10 valve, unload valve spool and ø 18 0.032
-0.017 +0 0.028
body
Free Installed Installed Free Installed Replace
Inverse shuttle valve return
11 length length load length load
spring
9.8 N 8.3 N
21.6 18.3 –
{1.0 kg} {0.85 kg}
Unload relief valve return spring 188 N 160 N
12 35.9 30.0 –
(inside) {19.2 kg} {16.3 kg}
Unload relief valve return spring 137 N 116 N
13 (outside) 39.8 27.5 {14.0 kg} – {11.8 kg}
Flow control valve, unload 49 N 42 N
14 valve spool return spring 51.6 45.0 {5.0 kg} – {4.3 kg}
4.9 N 4.2 N
15 Check valve return spring 11.5 9.0 {0.5 kg} – {0.43 kg}
Function
• The charge valve keeps the oil pressure from
the pump to the set pressure and stores it in the
accumulator.
• If the oil pressure rises above the set pressure,
the oil from the pump is led to the drain circuit to
reduce the load on the pump.
WA200-5 10-85
Operation 2. When oil is supplied to accumulator

1. When oil is not supplied to accumulator 1) Cut-in state
(Cut-out state) • If the accumulator pressure lowers, the
• Plunger (1) is moved by the pressure of the pressure in port E lowers and plunger
accumulator to the left to keep unload relief (1) moves to the right and unload relief
valve (2) pushed open. valve (2) closes the drain circuit.
• The oil in the spring chamber of unload • Accordingly, the oil pressure in port F
valve (3) flows through port F, unload relief and the spring chamber of unload relief
valve (2), and port T into the hydraulic tank. valve (3) rises and unload relief valve
• Since the oil pressure in port F lowers, un- (3) moves to the right.
load valve (3) is moved by the oil pressure in • As a result, ports C and B are connect-
chamber B to the left. ed to each other and the oil from the
• Accordingly, ports C and D are connected to pump flows to port B.
each other and almost all the oil from the • If the oil pressure in port B exceeds the
pump flows through ports P, C, D and A to set pressure of check valve (4), it push-
the cooling fan motor. es check valve (4) open and flows to
port E to start heightening the pressure
in the accumulator. The supply pres-
sure for the accumulator is decided by
the set pressure of check valve (4).
• A set quantity of oil is supplied to the ac-
cumulator, regardless of the engine
speed, and the excessive oil flows
through port A to the cooling fan motor.
• The oil flowing to port E is supplied first
to the accumulator having the lowest
pressure by inverse shuttle valve (5).
10-86 WA200-5
2) Cut-out state 3. When input pressure to valve rises above set

• If the pressure in port F reaches the set pressure
pressure (cut-out pressure) of unload • If the oil pressure in chamber B reaches the
relief valve (2), the oil in the spring set pressure of relief valve (6), the oil flowing
chamber of unload valve (3) flows from the pump through port P to chamber B
through port F, unload relief valve (2), pushes relief valve (6) open and flows
and port T to the hydraulic tank. through port T into the hydraulic tank.
• Plunger (1) is moved to the left by the As a result, the maximum pressure in the
pressure of the accumulator to keep un- brake circuit is limited to protect the circuit.
load relief valve (2) pushed open.
• Since the oil pressure in port F lowers,
unload valve (3) is moved by the oil
pressure in chamber B to the left.
• Accordingly, ports C and D are connect-
ed to each other and almost all the oil
from the pump flows through ports P, C,
D and A to the cooling fan motor.
WA200-5 10-87
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR (FOR BRAKE)
ACCUMULATOR (FOR BRAKE)

1. Cylinder
2. Piston
Function
• The accumulator is installed between the charge
valve and brake valve. The space between its
cylinder (1) and free piston (2) is filled with nitro-
gen gas. The brake oil pressure is stored in this
space by utilizing the compressibility of the nitro-
gen gas and used as the pressure source to
drive the brake.
Specifications
Gas used: Nitrogen gas
Amount of gas: 500cc
Charge pressure: 3.43 ± 0.1 MPa {35 ± 1.0 kg/cm2}
(at 20°C)
10-88 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
A: From brake valve

B: To brake piston
1. Body
2. Check valve
3. Piston
Unit: mm

Clearance between piston and size Shaft Hole clearance limit
4
body
-0.065 +0.052 0.065 –
ø 30 0.163
-0.098 +0 0.150
Clearance between check -0.013 +0.015 0.013 –
5 ø 10 0.048
valve and body -0.028 +0 0.043
Replace
Free Installed Installed Free Installed
6 Piston return spring length length load length load
11.8 N 9.8 N
87.5 48.2 –
{1.2 kg} {1.0 kg}
53.9 N 46.1 N
7 Check valve return spring 21.7 19.25 {5.5 kg} – {4.7 kg}
WA200-5 10-89
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER
Function
• The slack adjuster is installed to the brake oil
line from the brake valve to the brake piston and
used to fix the time lag of operation of the brake.
Operation
When brake is applied When brake is released
• The oil from the brake valve flows to port A and • The oil kept between piston (1) and brake piston
moves piston (1) to the right. The oil kept be- pushes back piston (1) to the left. Oil of quantity
tween piston (1) and brake piston drives the equivalent to the moving distance of piston (1) is
brake. returned through port A to the brake valve and
• Since the oil kept between piston (1) and brake drained into the hydraulic tank.
piston drives the brake, the brake piston stroke
is fixed and the time lag of operation of the brake
is reduced.
• If the quantity of the oil between piston (1) and
brake piston becomes insufficient because of
wear of the brake disc, etc., check valve (2) is
pushed open and oil is added.
10-90 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE
BRAKE
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Discs (x2)
10-92 WA200-5
Unit: mm

10 Thickness of inner ring
6 ± 0.1 5.5
Thickness of brake disc 6.5 ± 0.15 5.7
11 Depth of lining groove 0.8 (Min.) — 0.4
Thickness of lining 1.0 0.8 (Min.) —

Replace
Standard size Tolerance Wear limit
Wear of brake outer ring disc
12 contact surface
19.0 ± 0.1 0.3
13 Spring load Installed height Installed load Installed load
6.5 2,253 N {230 kg} 1,800 N {184 kg}
Outline
• The rear brake has a wet-type multiple-disc
structure, and consists of piston (3), inner ring
(5), disc (9), outer ring (8), and spring (4).
• The brake cylinder consists of differential hous-
ing (1) and bearing carrier (2), and piston (3) is
assembled in it.
Inner ring (5) and outer ring (8) are joined to
the spline portion of differential housing (1).
• Disc (9) has a lining stuck to both sides. It is as-
sembled between inner ring (5) and outer ring
(8), and is joined by the spline of sun gear shaft
(6).
WA200-5 10-93
Outline
When brake is applied When brake is released
• When the brake pedal is depressed, pressure oil • When the oil pressure is released, piston (2) is
P goes from the hydraulic tank through the returned to its original position by the force of
pump and brake charge valve. It acts on the pis- spring (8), a gap is formed between inner ring
ton inside the brake cylinder and the piston (2) (3) and outer ring (5), and discs (4) become free.
slides. Lattice shape grooves are cut into the lining
Therefore, piston (2) stops the rotation of discs stuck to disc (4), and when disc (4) is rotating,
(4) fitted between inner ring (3) and outer ring oil flows in the grooves and carries out cooling of
(5), and applies the brake to the machine. the lining.
10-94 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE CONTROL
PARKING BRAKE CONTROL
1. Parking brake lever 4. Control cable

2. Lowest switch of parking brake lever 5. Transfer
3. Intermediate switch of parking brake lever 6. Multiple-disc brake lever
Outline
• The mechanical parking brake is built in transfer • If parking brake lever (1) is returned, multiple-
(5). If parking brake lever (1) is operated, multi- disc brake lever (6) connected by control cable
ple-disc brake lever (6) is operated to "apply" or (4) is pushed down and the parking brake is "re-
"release" the parking brake. leased"
• If parking brake lever (1) installed on the opera- • While the parking brake is "applied", the current
tor's seat is pulled, multiple-disc brake lever (6) to the forward-reverse solenoid valve of the HST
connected by control cable (4) is pulled up and pump is shut off and the swash plate of the HST
the parking brake is "applied". pump is kept in neutral.
WA200-5 10-95
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
1. Lever 5. Plate
2. Housing 6. Disc
3. Ball 7. Wave spring
4. Piston 8. Output shaft
Unit: mm

Thickness of plate
9 2.6 ± 0.06 2.5
Distortion of plate — 0.05 0.1

Replace
Thickness of brake disc 2.2 ± 0.08 2.05
10
Distortion of brake disc — 0.02 0.25
Load on wave spring 1,010 N ± 101N 858 N

11 (Height: 2.2 mm) {103 kg} {± 10.3 kg} {87.6 kg}
Outline
• The parking brake is a wet multiple-disc brake
which mechanically brakes transmission output
shaft (8).
• Lever (1) is connected to the control cable. If the
parking brake lever is pulled, ball (3) between
piston (4) connected to lever (1) and housing (2)
moves on the inclined surface of the piston
groove. As a result, piston (4) presses plates (5)
and discs (6) to brake output shaft (8).
10-96 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING
HYDRAULIC PIPING
WA200-5
10-98 WA200-5
(3)
1. Work equipment control valve Outline

2. Bucket cylinder • The hydraulic system consists of the HST, steer-
3. Hydraulic tank ing, work equipment, brake, cooling fan, and
4. Work equipment PPC valve transfer lubricating circuit. Work equipment cir-
5. Lock valve cuit controls the operation of the lift arm and
6. Oil cooler bucket.
7. Cold relief valve • The oil in hydraulic tank (3) is sent by the work
8. 4-gear pump unit equipment pump of 4-gear pump unit (8) to work
• Steering pump equipment control valve (1). If both spools of the
• Work equipment pump lift arm and bucket of work equipment control
• Brake and cooling fan pump valve (1) are held, the oil flows through the drain
• Transfer lubricating oil pump circuit of work equipment control valve (1) and is
9. Accumulator (for PPC circuit) filtrated by the return filter installed to hydraulic
10. Accumulator (for E.C.S.S.) (If equipped) tank (3) and returns to hydraulic tank (3).
11. Lift cylinder • If the work equipment control lever is operated,
12. E.C.S.S. valve (If equipped) the spool of the lift arm or bucket of work equip-
(E.C.S.S. : Electronical Controlled Suspension ment PPC valve (4) operates.
System) • The oil from the PPC valve hydraulically oper-
ates each spool of work equipment control valve
(1) and flows to lift cylinder (11) or bucket cylin-
der (2) to move the lift arm or bucket.
• The maximum pressure in the hydraulic circuit is
controlled by the relief valve in work equipment
control valve (1). The bucket cylinder circuit has
a safety valve (safety-suction valve) to protect it-
self.
• Accumulator (for PPC circuit) (9) is installed to
the PPC pilot circuit so that the work equipment
can be lowered to the ground even if the engine
stops.
• Hydraulic tank (3) is pressurized, enclosed, and
equipped with a breather which has a relief valve
and which is also used as an oil filler cap. The
breather pressurizes the tank and prevents gen-
eration of negative pressure and cavitation.
WA200-5 10-99
(3)
WA200PT-5
10-99-1 WA200-5
(3)
1. Work equipment control valve Outline

2. Bucket cylinder • The hydraulic system consists of the HST, steer-
3. Hydraulic tank ing, work equipment, brake, cooling fan, and
4. Attachment PPC valve transfer lubricating circuit. Work equipment cir-
5. Work equipment PPC valve cuit controls the operation of the lift arm, bucket,
6. Lock valve and attachment.
7. Check valve • The oil in hydraulic tank (3) is sent by the work
8. Oil cooler equipment pump of 4-gear pump unit (9) to work
9. 4-gear pump unit equipment control valve (1). If the all spools of
• Steering pump the lift arm, bucket, and attachment of work
• Work equipment pump equipment control valve (1) are held, the oil
• Brake and cooling fan pump flows through the drain circuit of work equipment
• Transfer lubricating oil pump control valve (1) and is filtrated by the return filter
10. Accumulator (for PPC circuit) installed to hydraulic tank (3) and returns to hy-
11. Accumulator (for E.C.S.S.) (If equipped) draulic tank (3).
12. Bypass valve (for bucket circuit) • If the work equipment control lever is operated,
13. Lift cylinder the spool of the lift arm or bucket of work equip-
14. E.C.S.S. valve (If equipped) ment PPC valve (5) operates. If the auxiliary le-
(E.C.S.S.: Electronically Controlled Suspension ver is operated, the spool of attachment PPC
System) valve (4) operates.
15. Coupler plunger The oil from the PPC valve hydraulically oper-
ates each spool of work equipment control
valve (1) and flows to lift cylinder (13), bucket
cylinder (2), or coupler plunger (15) to move the
lift arm, bucket, or attachment.
• The maximum pressure in the hydraulic circuit is
controlled by the relief valve in work equipment
control valve (1). The bucket cylinder circuit has
a safety valve (safety-suction valve) to protect it-
self.
• Accumulator (for PPC circuit) (10) is installed to
the PPC pilot circuit so that the work equipment
can be lowered to the ground even if the engine
stops.
• Hydraulic tank (3) is pressurized, enclosed, and
equipped with a breather which has a relief valve
and which is also used as an oil filler cap. The
breather pressurizes the tank and prevents gen-
eration of negative pressure and cavitation.
WA200-5 10-99-2
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT LEVER LINKAGE
WORK EQUIPMENT LEVER LINKAGE

WA200-5
Mono-lever type
1. Work equipment control lever

2. Wrist rest
3. Lock valve
4. Work equipment lock lever
5. Work equipment PPC valve
6. Wrist rest height adjustment lever
10-100 WA200-5
(3)
WA200-5
2-lever type
(If equipped)
1. Lift arm control lever

2. Bucket control lever
3. Wrist rest
4. Lock valve
WA200-5 10-100-1
(3)
WA200PT-5
Mono-lever type
1. Auxiliary control lever

2. Work equipment control lever
3. Wrist rest
4. Lock valve
7. Attachment PPC valve
10-100-2 WA200-5
(3)
WA200PT-5
2-lever type
(If equipped)
1. Lift arm control lever

2. Bucket control lever
3. Auxiliary control lever
4. Wrist rest
5. Lock valve
7. Attachment PPC valve
9. Wrist rest height control lever
WA200-5 10-100-3
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Oil filler cap / Breather Specifications

2. Return filter
3. Hydraulic tank Tank capacity (l) 83
4. Drain plug Oil quantity inside the tank (l) 58
5. Sight gauge
6. Return filter bypass valve Bypass valve setting pressure 0.2
(MPa{kg/cm2}) {2.04}
WA200-5 10-101
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
Breather
1. Oil filler cap

2. Case
3. Unlocking knob
4. Sleeve
5. Poppet
6. Filter element
Prevention of negative pressure in tank

• Since the hydraulic tank is pressurized and en-
closed, negative pressure can be generated
when the oil level in the tank lowers. At this time,
sleeve (4) is opened by the pressure difference
from the atmospheric pressure and the atmos-
phere flows in the tank to prevent generation of
negative pressure.
(Set pressure of air intake valve:
3.0 ± 0.3 kPa {0.03 ± 0.003 kg/cm2})
Prevention of rise of pressure in tank

• While the hydraulic circuit is in operation, the
pressure in the hydraulic tank rises when the oil
level in the hydraulic tank rises according to the
operation of the hydraulic cylinders and when
the temperature rises. If the pressure in the tank
rises above the set pressure, poppet (5) oper-
ates to release the pressure from the tank.
(Set pressure of exhaust valve:
0.1 ± 0.015 MPa {1.0 ± 0.15 kg/cm2})
10-102 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 4-GEAR PUMP UNIT
4-GEAR PUMP UNIT

(Steering / Work equipment / Brake and cooling fan / Transfer lubricating oil)
SAR(2)50 + (2)32 + SBR(1)10 + 12
1. Steering pump Outline

2. Work equipment pump • The 4-gear pump unit is installed to the HST
3. Brake and cooling fan pump pump and driven through its shaft to supply hy-
4. Transfer lubricating oil pump draulic oil to the steering, work equipment,
brake, cooling fan, and transfer.
10-104 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 4-GEAR PUMP UNIT
Unit: mm
Type Standard clearance Clearance limit

SAR(2)50
5 Side clearance SAR(2)32
0.10 – 0.15 0.19
SBR(1)10
SBR(1)12
SAR(2)50
0.06 – 0.125
Clearance between inside SAR(2)32
6 diameter of plain bearing and 0.20
SBR(1)10 Replace
outside diameter of gear shaft
0.068 – 0.115
SBR(1)12
Type Standard size Tolerance Repair limit
SAR(2)50
12 +0
SAR(2)32
7 Diving depth of pin -0.5
SBR(1)10 10 –
+0.5
SBR(1)12 7
+0
8 Spline rotating torque 9.8 – 23.5 Nm {1.0 – 2.4 kgm}
Discharge Standard Discharge
Speed pressure discharge amount
Type
(rpm) (MPa {kg/ amount limit
Discharge amount cm2} (l/min) (l/min.)
–
– Oil: SAE10W SAR(2)50 138 127
Oil temperature: 45 - 55°C
SAR(2)32 20.6 {210} 88 81
3,000
SBR(1)10 27 25
SBR(1)12 2.9 {30} 32 30
WA200-5 10-105
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR (FOR PPC CIRCUIT)
ACCUMULATOR (FOR PPC CIRCUIT)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Outline
• The accumulator is installed between the HST
charge pump and work equipment PPC valve.
Even if the engine stops with the work equip-
ment raised, the pressure of the compressed ni-
trogen gas in the accumulator sends the pilot oil
pressure to the work equipment control valve to
operate the valve so that the work equipment will
lower by its weight.
Specifications
Amount of gas: 300 cc
Charge pressure: 1.18 MPa {12 kg/cm2}) (at 80°C)
Max. using pressure: 6.86 MPa {70 kg/cm2}
10-106 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LOCK VALVE
LOCK VALVE
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
• The lock valve is installed between the HST
charge pump and work equipment PPC valve. If
the work equipment lock lever is set in the LOCK
position, the lock valve operates to shut off the
oil in the PPC circuit so that the work equipment
cannot be operated.
WA200-5 10-107
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BYPASS VALVE
BYPASS VALVE
WA200PT-5
PP: From port P2 of work equipment PPC valve 1. Bypass solenoid valve
P: From bucket cylinder head side 2. Connector
T: To bucket cylinder bottom side 3. Plug
C: Plug 4. Body
Dr: To hydraulic tank 5. Spool
6. Spool
7. Body
10-107-1 WA200-5
(3)
Operation
When bucket is "DUMP" in FAST mode (from tilt-back position to just before dump end)
• If the bucket is "DUMP" with the dump speed • The oil from the work equipment control valve
switch in the FAST mode position, the oil of the and the oil from the bucket cylinder head side
work equipment PPC valve operates the work merge together and flow to the bucket cylinder
equipment control valve and the oil from the bottom side, thus the bucket dump speed is
work equipment pump flows to the bucket cylin- heightened.
der bottom side.
• Since the tilt lever angle proximity switch does
not operate, bypass solenoid valve (1) is turned
ON and spool (2) moves to the left.
• At this time, the oil from the work equipment
PPC valve flows through port PP into chamber A
and pushes spool (3) to the right and opens
ports P and T.
• A part of the oil on the bucket cylinder head side
flows through the work equipment control valve
into the hydraulic tank, but most of the oil flows
through ports P and T to the bucket cylinder bot-
tom side.
WA200-5 10-107-2
(3)
When bucket is "DUMP" in FAST mode (from just before dump end to dump end)
• If the bucket is "DUMP" continuously to just be- a When the dump speed switch is set in the SLOW
fore the dump end with the dump speed switch mode position, the bucket is operated as ex-
in the FAST mode position, the tilt lever angle plained on this page regardless of the tilt lever
proximity switch operates. angle.
• Bypass solenoid valve (1) is turned OFF and
spool (2) is moved to the right and held in the
neutral position by the reaction force of spring
(4).
• At this time, port PP and chamber A are closed
and spool (3) is pushed back to the left by the re-
action force of spring (5) to close ports P and T.
• The oil on the bucket cylinder head side does
not flow through the bypass valve but all of it
flows through the work equipment control valve
into the hydraulic tank.
• Since only the oil from the work equipment con-
trol valve flows to the bucket cylinder bottom
side, the bucket dump speed is lowered.
10-107-3 WA200-5
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD QUICK COUPLER VALVE
QUICK COUPLER VALVE

WA200PT-5
Outline
• The coupler plunger is extracted or retracted by
operating the quick coupler valve lever to couple
and uncouple each attachment and the coupler.
Operation
When quick coupler valve lever is in position "A" When quick coupler valve lever is in position "B"
• If the auxiliary control lever is operated with • If the auxiliary control lever is operated with
quick coupler valve lever (1) in position "A", oil quick coupler valve lever (1) in position "B", oil
flows in coupler plunger (2) to extract or retract flows in attachment cylinder to extract or retract
coupler plunger (2) and couple or uncouple the attachment cylinder and operate the attach-
attachment and coupler. ment.
WA200-5 10-107-4
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD E.C.S.S. VALVE
E.C.S.S. VALVE
(If equipped)
(E.C.S.S.: Electronically Controlled Suspension System)
P: From work equipment hydraulic pump

A: From lift cylinder bottom side
B: From lift cylinder head side
SP: To accumulator (for E.C.S.S.)
10-108 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD E.C.S.S. VALVE
1. Main spool
2. Solenoid valve
3. Flow control valve
4. Shuttle valve
5. Charge valve
WA200-5 10-109
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR (FOR E.C.S.S.)
ACCUMULATOR (FOR E.C.S.S.)

(If equipped)
1. Valve
2. Top cover
3. Cylinder
4. Free piston
Function
• The accumulator is installed to the lift cylinder
bottom circuit. The space between its cylinder
(3) and free piston (4) is filled with nitrogen gas.
The nitrogen gas absorbs the oil pressure puls-
es generated on the lift cylinder bottom side dur-
ing travel for higher travel performance and
operating performance by utilizing its compress-
ibility.
Specifications
Amount of gas: 2,000 cc
Charge pressure: 1.67 ± 0.1 MPa {17 ± 1.0 kg/cm2}
(at 20°C)
10-110 WA200-5
HYDRAULIC PIPING OF
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING SYSTEM
HYDRAULIC PIPING OF COOLING SYSTEM
1. Cooling fan motor Outline

2. Brake and cooling fan pump • Cooing fan motor (1) installed to the radiator is
3. Hydraulic tank driven hydraulically by brake and cooling fan
4. Charge valve pump (2).
WA200-5 10-111
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING FAN MOTOR
COOLING FAN MOTOR
P1: From charge valve Specifications

P2: To hydraulic tank
Dr: To hydraulic tank Model MSF-12-10
Type Fixed displacement swash

1. Port block plate-type piston motor
2. Valve plate
3. Piston Theoretical capacity
9.9
4. Shoe (cc/rev)
5. Thrust plate Rated speed
6. Output shaft 1,350
(rpm)
7. Case
8. Cylinder block Rated capacity
13.4
9. Center spring (l/min)
10. Check valve
11. Check valve spring
10-112 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING FAN MOTOR
Function
• This hydraulic motor is a swash plate-type axial
piston motor, which converts the pressure of the
hydraulic oil sent from the hydraulic pump into
revolution.
Principle of operation
• The oil sent from the hydraulic port flows through
valve plate (7) into cylinder block (5).
This oil can flow on only one side of the Y-Y line
connecting the top dead center and bottom
dead center of the stroke of piston (4).
• The oil sent to one side of cylinder block (5)
pressed pistons (4) (2 or 3 pieces) and gener-
ates force F1 (F1 kg=P kg/cm2 x x/4 D2 cm2).
• This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of Eo de-
grees to the output shaft (1), the force is divided
into components F2 and F3.
• The radial components F3 generates torque
against the Y-Y line connecting the top dead
center and bottom dead center (T = F3 x ri).
• The resultant of this torque [T = (F3 x ri)] ro-
tates the cylinder block (5) throught the piston.
• Since the cylinder block (5) is coupled with the
output shaft by means of spline, the output shaft
(1) revolves to transmit the torque.
WA200-5 10-113
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
WORK EQUIPMENT CONTROL VALVE

1. 2-Spool valve
P: Pump B2: To lift cylinder bottom

T: Drain PA1: To work equipment PPC valve P2
A1: To bucket cylinder head PA2: To work equipment PPC valve P4
A2: To lift cylinder head PB1: To work equipment PPC valve P1
B1: To bucket cylinder bottom PB2: To work equipment PPC valve P3
10-114 WA200-5
1. Main relief valve 4. Check valve

2. Bucket spool 5. Suction valve
3. Lift arm spool 6. Safety-suction valve
Unit: mm

Free
length x Installed Installed Free Installed
Lift arm raise and bucket tilt
7 Outside length load length load
spool return spring
diameter
92.2 N 87.3 N Replace spring if
42.5 x 27.5 41 40.4 damaged or
{9.4 kg} {8.9 kg}
deformed
Lift arm lower spool return 55.9 N 53 N
8 58.9 x 26.3 57.3 56
spring {5.7 kg} {5.4 kg}
110.8 N 105 N
9 Lift arm float spool return spring 53.4 x 12 38.5 {11.3 kg} 50.7 {10.7 kg}
Bucket dump spool return 72.5 N 68.6 N
10 spring 42 x 27.5 41 {7.4 kg} 39.9 {7 kg}
WA200-5 10-115
2. 3-Spool valve
P: To pump B3: To lift cylinder bottom

T: To drain PA1: To service PPC valve P1
A1: To service cylinder PA2: To work equipment PPC valve P2
A2: To bucket cylinder head PA3: To work equipment PPC valve P4
A3: To lift cylinder head PB1: To service PPC valve P2
B1: To service cylinder PB2: To work equipment PPC valve P1
B2: To bucket cylinder bottom PB3: To work equipment PPC valve P3
10-116 WA200-5
1. Main relief valve 5. Check valve

2. Service spool 6. Suction valve
3. Bucket spool 7. Safety-suction valve
4. Lift arm spool
Unit: mm

Free
length x Installed Installed Free Installed
Lift arm raise and bucket tilt
8 Outside length load length load
spool return spring
diameter
92.2 N 87.3 N Replace spring if
42.5 x 27.5 41 40.4
{9.4 kg} {8.9 kg} damaged or
deformed
Lift arm lower spool return 55.9 N 53 N
9 58.9 x 26.3 57.3 56
spring {5.7 kg} {5.4 kg}
110.8 N 105 N
10 Lift arm float spool return spring 53.4 x 12 38.5 {11.3 kg} 50.7 {10.7 kg}
Bucket dump spool return 72.5 N 68.6 N
11 spring 42 x 27.5 41 {7.4 kg} 39.9 {7 kg}
WA200-5 10-117
3. Relief valve
• When the hydraulic pressure inside the port A
and the port B reaches the set pressure of the
pilot poppet spring (4), the pilot poppet (3) opens
to let the hydraulic pressure of the port B flow
from the port D to the port C and the pressure of
the port B drops.
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjusting screw
Function • When the pressure at the port B drops, pressure

• The relief valve is installed to the inlet of the work difference occurs between the port A and the
equipment valve. When the oil pressure rises port B by the orifice of the main valve (1) and the
above the specified level, this valve drains the oil main valve shall be pushed open to let the oil of
into the hydraulic tank to limit the maximum the port A to pass through the port C to flow into
pressure of the work equipment circuit and pro- the drain circuit, to release the abnormal pres-
tect the circuit. sure.
• The preset pressure can be changed by increas-
Operation ing or decreasing the tension of the pilot poppet
• The port A is connected to the pump circuit and spring (4).
the port C is connected to the drain circuit. The • To change the preset pressure, remove the cap
oil passes through the orifice of the main valve nut to loosen the lock nut. After that, screw-in the
(1) to fill the port B. The pilot poppet (3) is con- adjust screw (5) to raise the preset pressure and
tacting (seated) to the valve seat (2). loosen the adjust screw (5) to lower the preset
pressure.
10-118 WA200-5
4. Safety-suction valve
1. Piston • If abnormal pressure generated in port A reach-

2. Main valve es the set pressure of spring (6), poppet (5)
3. Piston spring opens and the hydraulic oil in port C is drained
4. Valve seat through port D and periphery a of suction valve
5. Poppet (7).
6. Poppet spring
7. Suction valve
8. Suction valve spring
9. Adjustment screw
Function
• The safety-suction valve is in the bucket cylinder
circuit in the work equipment valve. When the
work equipment valve is in neutral, if any impact
is applied to the cylinder and abnormal pressure
is generated, that pressure is released through
this valve to protect the cylinder.
• If negative pressure is generated in the cylinder
circuit, this valve works as a suction valve.
• If poppet (5) opens, the pressure in port C low-
Operation ers and piston (1) moves to the right. Piston (1)
(1) Operation as safety valve comes in contact with the tip of poppet (5) and
• Ports A and B are connected to the cylinder cir- the hydraulic oil is drained through throttle b and
cuit and drain circuit respectively. port D.
• The hydraulic oil in port A flows through the hole
of piston (1) to port C. Since d2 < d3, main valve
(2) is seated on the left side.
• The order of the diameters (areas) of the sec-
tions is d5 > d4 > d1 > d3 > d2.
WA200-5 10-119
5. Suction valve
• Since the pressure in port C is lower than that in
port A, main valve (2) moves to the right and the
hydraulic oil flows through port A to port B, thus
generation of abnormal pressure is prevented.
• Even if abnormal pressure is generated, suction
valve (7) having a large section diameter does
not operate since d1 < d4.
1. Main poppet
2. Sleeve
3. Spring
4. Spacer
Function
• The suction valve prevents generation of nega-
(2) Operation as suction valve tive pressure in the circuit.
• If negative pressure is generated in the cylinder
circuit, the pressure in ports A and C becomes Operation
negative since those ports are connected. The • If negative pressure is generated in port A (lift
hydraulic pressure equivalent to the area differ- cylinder head) (If the pressure in port A is lower
ence between d4 and d1 is applied to suction than the pressure in the tank circuit port B), main
valve (7). poppet (1) opens because of the area difference
• If the pressure difference between ports B and A between d1 and d2 and the oil flows from tank
increases above the set pressure, it moves suc- port B into cylinder port A.
tion valve (7) to the right. Accordingly, hydraulic
oil flows from port B to port A to prevent gener-
ation of negative pressure in port A.
10-120 WA200-5
6. Operation of the work equipment control valve
(1) Neutral position of the lift arm and bucket spools
Operation
• The hydraulic oil flows through pump (1) and pri-
ority valve to port A and its maximum pressure
is controlled by relief valve (2).
• The bypass circuit of bucket spool (3) is open
since bucket spool is in neutral.
• Since lift arm spool (4) is in neutral, its bypass
circuit is open. Accordingly, the hydraulic oil in
port B returns through the periphery of the spool,
port C of the drain circuit, and filter into the tank.
WA200-5 10-121
(2) RAISE position of the lift arm spool
Operation
• If the work equipment control lever is pulled, lift
arm spool (4) is pulled out to the RAISE position.
• The hydraulic oil flows through pump (1) and by-
pass circuit of bucket spool (3) to the bypass cir-
cuit of lift arm spool (4).
• Since the bypass circuit is closed by the spool,
the hydraulic oil from port B pushes check valve
(5) open.
• The hydraulic oil from port B flows through port
D to the cylinder bottom side.
• On the other hand, the hydraulic oil on the cylin-
der head side returns through port E and drain
port C into the tank. Accordingly, the lift arm ris-
es.
10-122 WA200-5
(3) LOWER position of the lift arm spool
Operation
• If the work equipment control lever is pushed, lift • On the other hand, the hydraulic oil on the cylin-
arm spool (4) is pushed in to the LOWER posi- der bottom side returns through port D and drain
tion. port C into the tank. Accordingly, the lift arm low-
• The hydraulic oil flows through pump (1) and by- ers.
the hydraulic oil from port B pushes check valve
(5) open.
• The hydraulic oil from port B flows through port
E to the cylinder rod side.
WA200-5 10-123
(4) FLOAT position of the lift arm spool
Operation
• If the work equipment control lever is pushed fur- • While the bucket is in contact with the ground, it
ther from the LOWER position, lift arm spool (4) can move up and down according to the uneven-
is pushed in to the FLOAT position. ness of the ground.
• The hydraulic oil flows through pump (1) and by-
• The hydraulic oil in the bypass circuit flows into
the drain circuit because of the spool and cannot
push check valve (5) open.
• Since both of RAISE circuit D and LOWER cir-
cuit E of the lift cylinder are connected to the
drain circuit, the lift arm is lowered by its weight.
10-124 WA200-5
(5) TILT position of the bucket spool
Operation
• If the work equipment control lever is pulled,
bucket arm spool (3) is pulled out to the TILT po-
sition.
the hydraulic oil from port A pushes check valve
(7) open.
• The hydraulic oil from port G flows to the cylinder
bottom side.
der rod side returns through port H and drain
port C into the tank. Accordingly, the bucket tilts.
WA200-5 10-125
(6) DUMP position of the bucket spool
Operation
• If the work equipment control lever is pushed,
bucket arm spool (3) is pushed in to the DUMP
position.
the hydraulic oil from port A pushes check valve
(7) open.
• The hydraulic oil from port H flows to the cylinder
rod side.
der bottom side returns through port G and drain
port C into the tank. Accordingly, the bucket
dumps.
10-126 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
WORK EQUIPMENT PPC VALVE

Mono-lever type
a Do not disassemble. If it is disassembled, its set pressure must be adjusted.
P: From HST charging pump

P1: To bucket TILT valve
P2: To bucket DUMP valve
P3: To lift arm RAISE valve
P4: To lift arm LOWER (FLOAT) valve
WA200-5 10-127
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Rod 10. Piston
5. Disc 11. Body
6. Nut (for connecting lever)
10-128 WA200-5
Operation
1. When in NEUTRAL
(1) PPC valve for bucket (2) PPC valve for lift arm
• Ports PA and PB of the bucket control valve and • Ports PA and PB of the lift arm control valve and
ports P1 and P2 of the PPC valve are connected ports P3 and P4 of the PPC valve are connected
through fine control hole f of spool (1) to the through fine control hole f of spool (1) to the
drain chamber D. drain chamber D.
WA200-5 10-129
2. When in fine control

(NEUTRAL o Fine control)
• If rod (7) and piston (13) are pushed by disc (8),

retainer (12) is pushed and spool (1) is also
pushed down through metering spring (2).
• Accordingly, fine control hole f is disconnected
from drain chamber D and connected to pump
pressure chamber PP almost simultaneously,
and then the pilot oil of the main pump flows
from port P1 to port PB.
• If the pressure in port P1 rises, spool (1) is
pushed back and fine control hole f is discon-
nected from pump pressure chamber PP and
connected to drain chamber D almost simultane-
ously to release the pressure in port P1.
• As a result, spool (1) moves up and down to bal-
ance the force of metering spring (2) with the
pressure in port P1.
The positional relationship between spool (1)
and body (14) (where fine control hole f is be-
tween drain chamber D and pump pressure
chamber PP) does not change until retainer (12)
comes in contact with spool (1).
• Since metering spring (2) is compressed in pro-
portion to the stroke of the control lever, the
pressure in port P1 rises in proportion to the
stroke of the control lever.
• Accordingly, the control valve spool moves to a
position at which the pressure in the chamber
PB (equal to the pressure in port P1) is balanced
with the force of the control valve spool return
spring.
10-130 WA200-5
3. When in fine control 4. When lever is operated to stroke end

(When control lever is returned)
• If disc (8) begins to return, the force of centering • If disc (8) and rod (7) push down piston (13) and
spring (3) and the pressure in port P1 push up retainer (12) pushes down spool (1), fine control
spool (1). hole f is disconnected from drain chamber D and
• As a result, fine control hole f is connected to connected to pump pressure chamber PP.
drain chamber D and the oil in port P1 is re- • Accordingly, the pilot oil from the main pump
leased. flows through fine control hole f and port P1 into
• If the pressure in port P1 lowers too much, spool chamber PB and pushes the control valve spool.
(1) is pushed down by metering spring (2) and • The oil returning from chamber PA flows through
fine control hole f is disconnected from drain port P2 and fine control f' into drain chamber D.
chamber D and connected to pump pressure
chamber PP almost simultaneously. Then, the
pump pressure is applied until the pressure in
port P1 is restored to the level corresponding to
the position of the lever.
• When the control valve spool returns, the oil in
drain chamber D flows in through fine control
hole f' of the valve which is not in operation and
then flows through port P2 into chamber PA.
WA200-5 10-131
5. When lift arm is FLOATED 6. When FLOAT state of lift arm is cancel
• If rod (4) and piston (9) on the LOWER side of • Disc (5) is returned from the FLOAT position by
port P4 are pushed down by disc (11), the inter- pushing it down with a force greater than the at-
nal mechanism of body (10) starts to operate the tractive force of solenoid.
detent in the middle of the stroke. • The FLOAT state also can be canceled and the
• If rod (4) is pushed up and the current flows into lever can be returned to the neutral position by
the solenoid in body (10), an attractive force is turning off the current in solenoid (6) (demagnet-
generated. izing the solenoid).
• Accordingly, rod (4') is kept pushed up and the
FLOAT state is kept even if the lever is released.
• At the same time, the control valve is also • The lift arm RAISE and bucket TILT operations
moved to the FLOAT position and kept at that are carried out similarly to the above.
position.
10-132 WA200-5
2-lever type (If equipped)

a Do not disassemble. If it is disassembled. If it is disassembled, its set pressure must be adjusted.
a Refer to the section “Mono-lever type” for operation of this valve.
P: From HST charge pump P3: To lift arm RAISE valve

T: To hydraulic tank P4: To bucket DUMP valve
P1: To bucket tilt valve
P2: To lift arm LOWER (FLOAT) valve
WA200-5 10-132-1
(3)
1. Spool
2. Metering spring
3. Centering spring
4. Rod
5. Disc
6. Nut (for connecting lever)
7. Joint
8. Plate
9. Retainer
10. Piston
10-132-2 WA200-5
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT PPC VALVE
ATTACHMENT PPC VALVE
T: To the tank P1: To attachment valve

P: From HST charge pump P2: To attachment valve
1. Spool 6. Plate
2. Metering spring 7. Retainer
3. Centering spring 8. Body
4. Piston 9. Filter
5. Lever
10-134 WA200-5
Unit: mm

Free length
x Installed Installed Free Installed
10 Center ring spring length load length load Replace spring
Outside diameter if damaged or
36.3 N 30.4 N deformed
41.1 X 15.5 29.0 {3.70 kg} — {3.1 kg}
16.7 N 13.3 N
11 Metering spring 22.7 X 8.10 22.0 {1.70 kg} — {1.36 kg}
WA200-5 10-135
Operation
1. At the neutral position

• The ports A and B of the control valve and • By the above structure, the spool (1) moves
the ports P1 and P2 of the PPC valve are up and down so that the power of the meter-
being connected to the drain chamber D ing spring (2) and the P1 port pressure may
through the fine control hole of the spool (1). balance.
• Until the retainer (7) hits the spool (1), the
positional relation between the spool (1) and
the body (8) (the fine control hole comes to
the intermediate potion between the drain
chamber D and the pressure chamber of the
pump) does not change.
• Therefore, since the metering spring (2) is
compressed in proportion to the control le-
ver stroke, the pressure at the P1 port also
rises in proportion to the control lever stroke.
• By the above, control valve spool moves to
the position where pressure of the chamber
A (same pressure to P1 port) balances to
the force of control valve spool return spring.
2. At the fine control position

(Neutral o fine control)
• When the piston (4) is pushed by the lever
(5), the retainer (7) is pushed and the spool
(1) also is pushed trough the metering
spring (2) to move to the lower side.
• When the fine control hole f is shut off from
the drain chamber D by the above, it con-
nects to the pressure chamber PP of the
pump almost simultaneously and the pilot
pressure oil of the main pump is led from the
P1 port to the A port through the fine control
hole f.
• When the pressure at the P1 port goes up,
the spool (1) is pushed back and, when the
fine control hole f is shut off from the pres-
sure chamber PP of the pump, it connects to
the drain chamber D almost simultaneously
to release the pressure at the P1 port.
10-136 WA200-5
3. At the fine control position (When the control 4. At full stroke

lever is returned) • When the lever (5) pushes down the piston
• When the lever (5) is started to be returned, (4) and when the retainer pushes down the
by the power of the centering spring (3) and spool (1), the fine control hole f is shut off
by the pressure of the P1 port, the spool (1) from the drain chamber D and, then, it con-
is pushed up. By the above, the fine control nects to the pressure chamber PP of the
hole f connects to the drain chamber D to re- pump.
lease the pressurized oil from the P1 port. • Therefore, the pilot pressure oil coming from
• In case the pressure of the P1 port drops ex- the main pump passes through the fine con-
cessively, the spool (1) is pushed down by trol hole f to be led to the A chamber through
the metering spring (2) and the fine control the P1 port to push the control valve spool.
hole f is shut off from the drain chamber D, • The return oil from the B chamber passes
connecting to the drain chamber D almost through the P2 port and the fine control hole
simultaneously to supply the pump pressure f' to flow into the drain chamber D.
PP until the pressure of the P1 port returns
to the pressure corresponding to the lever
position.
• When the control valve spool returns, the oil
in the drain chamber D flows through the
fine control hole f' of the valve which is not
moving to be led to the B chamber through
the P2 port to refill the oil.
WA200-5 10-137
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE

WA200-5
10-138 WA200-5
(3)
1. Bucket
2. Tilt lever
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
Unit: mm
Tolerance
Clearance between bushing and size clearance limit
7 pin at each end of joint of bucket Shaft Hole
link
ø 65 -0.030 +0.174 0.130 – 1.0
-0.076 +0.100 0.250
8 Clearance between bushing and ø 65 -0.030 +0.174 0.130 – 1.0

pin of joint of lift arm and bucket -0.076 +0.100 0.250

pin of joint of lift arm and frame -0.076 +0.100 0.250
Clearance between bushing and -0.030 +0.174 0.130 – Replace
10 pin of joint of bucket cylinder bot- ø 70 -0.076 +0.100 0.250 1.0 (Replace if pin
tom and frame has scuff mark)
Clearance between bushing and -0.030 +0.174 0.130 –
11 pin of joint of bucket cylinder rod ø 70 -0.076 +0.100 0.250 1.0
and tilt lever

pin of joint of tilt lever and lift arm -0.076 +0.100 0.250
13 pin of joint of lift cylinder rod and ø 65 -0.076 +0.100 0.250 1.0
lift arm
14 pin of joint of lift cylinder bottom ø 65 -0.076 +0.100 0.250 1.0
and frame
Width of boss Width of hinge

Standard
Joint of bucket cylinder and Standard Standard clearance
15 frame Tolerance Tolerance
size size
80 -0 83 ± 1.5 1.5 – 5.0

-0.5
Adjust clearance
16 Joint of lift arm and frame 85 — 89 ± 1.5 2.5 – 5.5 on each side to
1.5 mm or less
17 Joint of lift arm and bucket 85 — 88 +3.0 3.0 – 6.0
+0
18 Joint of bucket link and bucket 85 ± 1.0 88 +3.0 2.0 – 7.0

+0
19 Joint of lift cylinder and frame 85 -0 89 ± 1.5 2.5 – 6.0

-0.5
20 Joint of tilt lever and bucket link 85 ± 1.0 88 ± 1.5 0.5 – 5.5
Replace
21 Joint of tilt lever and lift arm 148 ± 0.5 151 ± 1.5 1.0 – 5.0
22 Joint of bucket cylinder and tilt 80 0 88 ± 1.5 6.5 – 10.0 Adjust clearance
lever -0.5 on each side to
23 Joint of lift arm and lift cylinder 85 — 89 ± 1.5 2.5 – 5.5 1.5 mm or less
WA200-5 10-139
WA200PT-5
10-139-1 WA200-5
(3)
1. Bucket
2. Bucket link
3. Tilt lever
4. Bucket cylinder
5. Lift cylinder
6. Lift arm
7. Coupler plunger
8. Quick coupler
Unit: mm
Tolerance
Clearance between bushing and size clearance limit
9 Shaft Hole
pin at each end of bucket link
-0.030 +0.174 0.130 –
ø 60 -0.076 +0.100 0.250 1.0
Clearance between bushing and

10 pin of joint of lift arm and quick ø 65 -0.030 +0.174 0.130 – 1.0
coupler -0.076 +0.100 0.250

11 pin of joint of lift arm and frame ø 75 -0.076 +0.100 0.250 1.0
Clearance between bushing and Replace

12 pin of joint of bucket cylinder bot- ø 95 -0.030 +0.174 0.130 – 1.0 (Replace if pin
tom and frame -0.076 +0.100 0.250 has scuff mark)
13 pin of joint of bucket cylinder rod ø 95 -0.030 +0.174 0.130 – 1.0
and tilt lever -0.076 +0.100 0.250

14 pin of joint of tilt lever and lift arm ø 65 -0.076 +0.100 0.250 1.0

15 pin of joint of lift cylinder rod and ø 65 -0.030 +0.174 0.130 – 1.0
lift arm -0.076 +0.100 0.250

16 pin of joint of lift cylinder bottom ø 65 -0.030 +0.174 0.130 – 1.0
and frame -0.076 +0.100 0.250
Width of boss Width of hinge

Standard
Standard Standard clearance
17 Joint of bucket cylinder and size Tolerance size Tolerance
frame
+0
90 -0.5 94 ± 1.5 2.5 – 6.0 Replace (Insert
shims on both
18 Joint of lift arm and frame 85 — 89 ± 1.5 2.5 – 5.5 sides so that
clearance will be
1.5 mm or less on
+1.5 each side)
19 Joint of lift arm and quick coupler 82 — 84 +0 2.0 – 3.5
Joint of bucket link and quick

20 coupler 90 ± 1.0 93 ± 1.5 0.5 – 5.5
+0
21 Joint of lift cylinder and frame 85 -0.5 89 ± 1.5 2.5 – 6.0
22 Joint of tilt lever and bucket link 90 ± 1.0 93 ± 1.5 0.5 – 5.5 Replace
Adjust clearance
23 Joint of tilt lever and lift arm 90 — 93 ± 1.5 1.5 – 4.5 on each side to
1.5 mm or less
24 Joint of bucket cylinder and tilt 90 -0 93 ± 1.5 1.5 – 5.0 Replace

lever -0.5
Adjust clearance
25 Joint of lift arm and lift cylinder 82 — 89 ± 1.5 0.5 – 3.5 on each side to
1.5 mm or less
WA200-5 10-139-2
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BUCKET
BUCKET
WA200-5
1. Bucket 3. Bucket tooth (If equipped)

2. Bolt-on cutting edge 4. Adapter (If equipped)
Unit: mm
5 Wear of cutting edge (Thickness) Turn over or
25.4 15 replace
6 Wear of cutting edge (Length) 62 5
Tooth 35 18
7 Wear of bucket tooth Replace
Tip tooth 42 30
Adjust or
8 Clearance of adapter mount Max. 0.5 — replace
10-140 WA200-5
(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BUCKET
WA200PT-5
1. Bucket 3. Bucket tooth (If equipped)

2. Bolt-on cutting edge 4. Adapter (If equipped)
Unit: mm
5 Wear of cutting edge (Thickness) Turn over or
24.5 15 replace
6 Wear of cutting edge (Length) 62 5
Tooth 35 18
7 Wear of bucket tooth Replace
Tip tooth 42 30
Adjust or
8 Clearance of adapter mount Max. 0.5 — replace
WA200-5 10-140-1
(4)
CONTROL OF BUCKET POSITIONER,
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM KICK-OUT, AND DUMP SPEED
CONTROL OF BUCKET POSITIONER, BOOM KICK-OUT, AND

DUMP SPEED
a The dump speed control is installed to only WA200PT-5.
WA200-5
1. Bucket positioner proximity switch 4. Bucket cylinder

2. Boom kick-out proximity switch (If equipped) 5. Boom
3. Plate 6. Plate (If equipped)
Unit: mm
Clearance of bucket positioner

7 proximity switch 3–5
Adjust
Clearance of boom kick-out prox-
8 imity switch 3–5
WA200-5 10-141
(3)
OUTLINE
Bucket positioner
• The bucket positioner is driven electrically.
When the bucket is returned to an angle from the
DUMP position toward the TILT position, the
bucket positioner returns the work equipment
(bucket) control lever from the TILT position to
the HOLD position to automatically stop the
bucket at a proper digging angle.
• Plate (3) is bolted to the rod of bucket cylinder
(4). Proximity switch (1) is bolted to the cylinder.
• If the work equipment (bucket) control lever is
moved from the DUMP position to the TILT posi-
tion, the rod of bucket cylinder (4) moves toward
the front of the machine. When plate (3) parts
from proximity switch (1) at a point, proximity
switch (1) operates to return the work equipment
(bucket) control lever to the HOLD position.
Boom kick-out
• The boom kick-out is driven electrically. When
the lift arm is raised to an angle before the max-
imum position, the boom kick-out returns the
work equipment (lift arm) control lever from the
RAISE position to the HOLD position to auto-
matically stop the lift arm at the current position.
• Plate (6) is fixed to lift arm (5). Proximity switch
(2) is fixed to the front frame.
• If the work equipment (lift arm) control lever is
moved from the LOWER position to the RAISE
position, lift arm (5) rises. When plate (6) parts
from proximity switch (2), proximity switch (2)
operates to return the work equipment (lift arm)
control lever to the HOLD position.
10-142 WA200-5
(3)
OPERATION OF PROXIMITY SWITCH
When bucket is tilted

• While the bucket is dumping more than the set • If the work equipment (bucket) control lever (7)
position of the bucket positioner, plate (2) is over is moved to the TILT position, bucket dump
the sensing face of proximity switch (1), the lamp spool (8) moves up and is held at that position by
of which is lighting up. the coil magnetized by detent solenoid (6). As a
At this time, bucket positioner relay (4) is turned result, work equipment (bucket) control lever (7)
on and a current flows in detent solenoid (6) of is held at TILT position and the bucket tilts.
work equipment PPC valve (5) to magnetize the
coil.
WA200-5 10-143
(3)
• If the bucket tilts and parts from the set position FUNCTION OF PROXIMITY SWITCH
of the bucket positioner, or if plate (2) parts from
over the sensing face of proximity switch (1), the When object of sensing is over sensing face of
lamp of proximity switch (1) goes off and bucket proximity switch
positioner relay (4) is turned off. Accordingly,
the circuit of detent solenoid (6) of work equip- Lamp of proximity switch ON
ment PPC valve (5) is turned off to demagnetize Bucket positioner relay switch circuit Made
the coil.
Bucket dump spool (8) held at the TILT position Work equipment PPC valve detent
Made
receives the reaction force of spring (9) and solenoid circuit
returns work equipment (bucket) control lever Work equipment PPC valve detent
(7) to the HOLD position. Magnetized
solenoid
When object of sensing is apart from over sens-

ing face of proximity switch
Lamp of proximity switch OFF
Bucket positioner relay switch circuit Broken
Work equipment PPC valve detent

Broken
solenoid circuit

Demagnetized
solenoid
10-144 WA200-5
(3)
When lift arm is raised • If the work equipment (lift arm) control lever (7)
• While the lift arm (3) is lower than the set posi- is moved to the RAISE position, boom lower
tion of the boom kick-out, plate (2) is over the spool (8) moves up and is held at that position by
sensing face of proximity switch (1), the lamp of the coil magnetized by detent solenoid (6). As a
which is lighting up. result, work equipment (lift arm) control lever (7)
At this time, boom kick-out relay (4) is turned on is held at RAISE position and the lift arm rises.
and a current flows in detent solenoid (6) of
coil.
WA200-5 10-145
(3)
• If the lift arm (3) rises and parts from the set po- FUNCTION OF PROXIMITY SWITCH
sition of the kick-out, or if plate (2) parts from
lamp of proximity switch (1) goes off and boom proximity switch
kick-out relay (4) is turned off. Accordingly, the
circuit of detent solenoid (6) of work equipment Lamp of proximity switch ON
PPC valve (5) is turned off to demagnetize the Boom kick-out relay switch circuit Made
coil.
Lift arm raise spool (8) held at the RAISE posi- Work equipment PPC valve detent
Made
tion receives the reaction force of spring (9) and solenoid circuit
returns work equipment (lift arm) control lever Work equipment PPC valve detent
solenoid

Boom kick-out relay switch circuit Broken

Broken
solenoid circuit

Demagnetized
solenoid
10-146 WA200-5
(3)
WA200PT-5
1. Fork positioner proximity switch 6. Lift arm

2. Bucket positioner proximity switch 7. Plate (If equipped)
3. Plate 8. Plate
4. Boom kick-out proximity switch (If equipped) 9. Tilt lever
5. Bucket cylinder 10. Dump speed control proximity switch
Unit: mm
Clearance of bucket positioner

11 3–5
proximity switch
Clearance of boom kick-out prox-

12 3–5 Adjust
imity switch
Clearance of dump speed control

13 3–5
proximity switch
WA200-5 10-146-1
(3)
OUTLINE
Bucket positioner or fork positioner The dump speed control

• The bucket positioner is driven electrically. • The dump speed control is driven electrically.
When the bucket or fork is returned to an angle When the bucket or fork approaches the dump
from the DUMP position toward the TILT posi- end, the dump speed controller lowers the dump
tion, the bucket positioner returns the work speed to reduce the shock made at the dump
equipment (bucket or fork) control lever from the end.
TILT position to the HOLD position to automati- • Plate (8) is fixed to tilt lever (9). Proximity switch
cally stop the bucket or fork at a proper digging (10) is fixed to lift arm (6).
angle or lift angle. • While the dump speed switch of the right-hand
• Plate (3) is bolted to the rod of bucket cylinder console is in the FAST position, if the work
(5). Proximity switches (1) and (2) are bolted to equipment (bucket or fork) control lever is
the cylinder. moved to the DUMP position, tilt lever (9) moves
• If the work equipment (bucket or fork) control le- toward the front of the machine. When plate (8)
ver is moved from the DUMP position to the TILT approaches proximity switch (10) at a point,
position, the rod of bucket cylinder (5) moves to- proximity switch (10) operates to lower the dump
ward the rear of the machine. When plate (3) speed.
approaches proximity switches (1) and (2) at a
point, proximity switch (1) or (2) operates to re-
turn the work equipment (bucket or fork) control
lever to the HOLD position.
• While the attachment selector switch of the right-
hand console is in the BUCKET position, prox-
imity switch (2) operates. While the former is in
the FORK position, proximity switch (1) oper-
ates.
Boom kick-out
• The lift arm kick-out is driven electrically. When
the lift arm is raised to an angle before the max-
imum position, the lift arm kick-out returns the
work equipment (lift arm) control lever from the
RAISE position to the HOLD position to auto-
matically stop the lift arm at the current position.
• Plate (7) is fixed to lift arm (6). Proximity switch
(4) is fixed to the front frame.
• If the work equipment (lift arm) control lever is
moved from the LOWER position to the RAISE
position, lift arm (6) rises. When plate (7) parts
from proximity switch (4), proximity switch (4)
operates to return the work equipment (lift arm)
control lever to the HOLD position.
10-146-2 WA200-5
(3)
OPERATION OF PROXIMITY SWITCH
When bucket is tilted

a The case when the attachment selector switch is
in the BUCKET position is shown below.
• While the bucket is dumping more than the set • If the work equipment (bucket) control lever (7)
position of the bucket positioner, plate (2) is not is moved to the TILT position, bucket dump
over the sensing face of proximity switch (1), the spool (8) moves up and is held at that position by
lamp of which is turned off. the coil magnetized by detent solenoid (6). As a
At this time, since relay (3) does not operate, result, work equipment (bucket) control lever (7)
bucket positioner relay (4) is turned on and a is held at TILT position and the bucket tilts.
current flows in detent solenoid (6) of work
equipment PPC valve (5) to magnetize the coil.
WA200-5 10-146-3
(3)
• If the bucket tilts to the set position of the bucket FUNCTION OF PROXIMITY SWITCH
positioner, or if plate (2) comes over the sensing
face of proximity switch (1), the lamp of proximity When object of sensing is over sensing face of
switch (1) lights up and relay (3) operates to turn proximity switch
bucket positioner relay (4) off. Accordingly, the
PPC valve (5) is turned off to demagnetize the Attachment selector switch relay ON
coil.
Bucket dump spool (8) held at the TILT position Bucket positioner relay switch circuit Broken
receives the reaction force of spring (9) and
returns work equipment (bucket) control lever Broken
solenoid circuit
(7) to the HOLD position.
Demagnetized
solenoid

Attachment selector switch relay OFF
Bucket positioner relay switch circuit Made

Made
solenoid circuit

Magnetized
solenoid
10-146-4 WA200-5
(3)
When lift arm is raised

• While the lift arm (3) is lower than the set posi- • If the work equipment (lift arm) control lever (7)
tion of the boom kick-out, plate (2) is over the is moved to the RAISE position, lift arm lower
sensing face of proximity switch (1), the lamp of spool (8) moves up and is held at that position by
which is lighting up. the coil magnetized by detent solenoid (6). As a
At this time, boom kick-out relay (4) is turned on result, work equipment (lift arm) control lever (7)
and a current flows in detent solenoid (6) of is held at RAISE position and the lift arm rises.
coil.
WA200-5 10-146-5
(3)
• If the lift arm (3) rises and parts from the set po- FUNCTION OF PROXIMITY SWITCH
sition of the kick-out, or if plate (2) parts from
lamp of proximity switch (1) goes off and boom proximity switch
kick-out relay (4) is turned off. Accordingly, the
PPC valve (5) is turned off to demagnetize the Boom kick-out relay switch circuit Made
coil.
Lift arm raise spool (8) held at the RAISE posi- Work equipment PPC valve detent
Made
tion receives the reaction force of spring (9) and solenoid circuit
returns work equipment (lift arm) control lever Work equipment PPC valve detent
solenoid

Boom kick-out relay switch circuit Broken

Broken
solenoid circuit

Demagnetized
solenoid
10-146-6 WA200-5
(3)
When bucket is dumped

a The case when the dump speed switch is in the
FAST position is shown below.
• While the tilt lever (3) is tilted more than the set • When the bucket approaches the dump end and
position of the bell crank angle sensor, plate (2) plate (2) comes over the sensing face of proxim-
is not over the sensing face of proximity switch ity switch (1), the lamp of which lights up and
(1), the lamp of which is turned off. dump speed relay (4) is turned on. As a result,
At this time, dump speed relay (4) is turned ON the circuit of bypass solenoid valve (5) is broken
and a current flows in the coil of bypass sole- and the coil is demagnetized.
noid valve (5) to merge the oils on the head side The oil on the head side of bucket dump cylin-
and bottom side of bucket cylinder (6) together, der (6) does not flow to the bottom side and the
thus the bucket dump speed is heightened. bucket dump speed is lowered.
WA200-5 10-146-7
(3)
a While the dump speed switch is in the SLOW

mode position, the dump speed is kept low re-
gardless of the bell crank angle.
FUNCTION OF PROXIMITY SWITCH
When object of sensing is over sensing face of

proximity switch
Lamp of proximity switch ON
Dump speed relay switch circuit Made
Bypass solenoid valve circuit Broken
Bypass solenoid Demagnetized

Lamp of proximity switch ON
Dump speed relay switch circuit Broken
Bypass solenoid valve circuit Made
Bypass solenoid Magnetized
10-146-8 WA200-5
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

WA200-5
LIFT CYLINDER
BUCKET CYLINDER
Unit: mm
Tolerance
Name of Standard Standard Clearance
cylinder size clearance limit
Clearance between Shaft Hole
1 piston rod and bush- Replace
-0.030 +0.262 0.097 – bushing
ing Lift ø 65 0.666
-0.104 +0.067 0.366
Bucket ø 65 -0.030 +0.262 0.097 – 0.666

-0.104 +0.067 0.366
Tightening torque of Lift 981 ± 98.1 Nm {100 ± 10.0 kgm}
2
cylinder head Bucket 1,030 ± 103 Nm {105 ± 10.5 kgm}
Lift 2,600 ± 260 Nm {265 ± 26.5 kgm} Retighten

Tightening torque of (Width across flats:70 mm)
3
cylinder piston nut 3,140 ± 310 Nm {320 ± 32.0 kgm}
Bucket
(Width across flats:75 mm)
WA200-5 10-147
(3)
WA200PT-5
LIFT CYLINDER
BUCKET CYLINDER
COUPLER PLUNGER
10-147-1 WA200-5
(3)
Unit: mm
Tolerance
Name of Standard Standard Clearance
cylinder size clearance limit
Shaft Hole
Clearance between
-0.030 +0.262 0.097 – Replace
1 piston rod and bush- Lift ø 65 -0.104 +0.067 0.366 0.666
bushing
ing
-0.030 +0.258 0.078 –
Bucket ø 80 -0.076 +0.048 0.334 0.634
Coupler -0.020 +0.081 0.011 –

plunger ø 20 -0.072 -0.009 0.153 0.453
Tightening torque of
cylinder head Lift 981 ± 98.1 Nm {100 ± 10.0 kgm}
2 cylinder head bolt Bucket 250 ± 24.5 Nm {25.5 ± 2.5 kgm}
Tightening torque of Coupler

cylinder head plunger 294 ± 29.4 Nm {30 ± 3.0 kgm}
Tightening torque of 2,600 ± 260 Nm {265 ± 26.5 kgm} Retighten

cylinder piston nut Lift (Width across flats: 70 mm)
3 cylinder piston Bucket 294 ± 29.4 Nm {30 ± 3.0 kgm}
Tightening torque of Coupler 78 ± 7.8 Nm {8 ± 0.8 kgm}

cylinder piston nut plunger (Width across flats: 22 mm)
4 cylinder piston screw Bucket 58.9 – 73.6 Nm {6 – 7.5 kgm}
WA200-5 10-147-2
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
(If equipped)
AIR CONDITIONER PIPING
1. Air outlet duct 8. Compressor

2. Fresh air inlet filter 9. Hot water return piping
3. Fresh air inlet duct 10. Hot water take-out piping
4. Recirculating air filter 11. Refrigerant piping
5. Recirculating / Fresh air selector damper 12. Air conditioner unit
6. Receiver tank 13. Floor duct
7. Condenser
10-148 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
MACHINE MONITORING SYSTEM

Outline
• The machine monitor system uses the sensors • Normal mode indications are those which are
and other devices installed to various parts of usually being made for ordinary use by the ma-
the machine to observe the condition of the machine operators. The description below applies
chine. It processes this information swiftly and to the contents of the main indications.
displays it on the monitor panel to inform the op-
erator of the condition of the machine. 1. Items which are always indicated
• The indications of the machine monitor will be • Meters (Travel speedometer)
made under the normal mode and under the • Gauges (Engine cooling water temperature
service mode. gauge, HST oil temperature gauge and fuel
• The machine monitor has ON/OFF output func- level gauge)
tion of automatic preheating which assists with • Pilot indications
the starting of the engine. • Service meter
• The machine monitor has the relay ON/OFF out-
put function to cut the output to the HST solenoid 2. Items which will be indicated only when some
when the HST controller has a trouble. abnormality occurs
• Cautions
• Action code indications (When the machine
monitor panel mode selector switch (>) is
depressed and released while the action
code is being indicated, the failure code (6
digits) will be indicated.)
3. When the time comes to change the filter or oil,

necessary items for the filter change or oil
change will be indicated on the character dis-
play. (Maintenance monitoring functions)
4. In addition to the above, this system is equipped

with the functions to indicate the travel distance
integrating meter (odometer), to reset the filter/
oil changing time, and to select the language by
use of the character display and the machine
monitor panel mode selector switch which is the
operation switch of the character display.
10-150 WA200-5
• This machine monitoring system is equipped • The machine monitoring system consists of the
with the service mode function to facilitate the machine monitor proper, buzzer, and switches
troubleshooting work for respective controllers that are used for inputting data to the machine
(including the machine monitor itself) on the net- monitor proper, sensors, respective controller
work. The description below applies to the con- on the network, and relevant switches and sen-
tents of the main functions. sors.
1. Electric fault history

This function will indicate the electric fault history
data of respective controllers being memorized
by the machine monitor. Also, it can be used to
delete the aforementioned data.
2. Machine fault history

This function will indicate the machine fault his-
tory and machine fault history data of respective
controllers being memorized by the machine
monitor.
3. Real time monitor

This function will make real time indications of
the inputting data and outputting data being rec-
ognized by respective controllers on the net-
work.
4. Maintenance monitor
This function is to be used for revisions of the
preset filter and oil changing time. (Revision of
the time for the maintenance monitor operation)
5. Selection of optional items

This function is used to set the machine model,
tier size, and optional equipment.
6. Controller initializing function

This function is being used to effect the settings
of this machine monitor before shipment from
our factory.
WA200-5 10-151
(6)
Individual circuit diagrams of the machine monitor
Starting and lighting
10-152 WA200-5
1. Starting switch Connection table of connector pins of machine mon-

2. Alternator itor
3. Emergency flasher switch
4. Flasher unit Symbol Connector pin No.
5. Turn signal lever a CNL23-3
6. Turn signal lamp (Left)
7. Turn signal lamp (Right) b CNL23-1
8. Head lamp relay
c CNL23-12
9. Lamp switch
10. Dimmer switch d CNL22-11
11. Head lamp (Lo)
e CNL23-17
12. Head lamp (Hi)
13. Clearance lamp, tail lamp relay f CNL21-12
14. Clearance lamp, tail lamp
15. License plate lamp g CNL22-12
16. Working lamp relay h CNL23-9
17. Tachograph lamp (If equipped)
WA200-5 10-153
Power supply and network
1. Monitor panel mode selector switch 1 "U" Connection table of connector pins of machine mon-
2. Monitor panel mode selector switch 1 "u" itor
3. Monitor panel mode selector switch 2 "<"
4. Monitor panel mode selector switch 2 ">" Symbol Connector pin No.
5. HST controller a CNL23-11
b CNL21-2
c CNL21-1
d CNL21-4
e CNL21-5
f CNL22-6
g CNL22-2
h CNL21-3
i CNL21-7
j CNL21-15
k CNL23-14
10-154 WA200-5
Sensing
1. Alarm buzzer Connection table of connector pins of machine mon-

2. HST filter clogging sensor itor
3. Steering oil pressure sensor (If equipped)
(Machines equipped with emergency steering) Symbol Connector pin No.
4. Emergency steering oil pressure sensor a CNL21-11
(Machines equipped with emergency steering)
(If equipped) b CNL23-6
5. Coolant level sensor
c CNL22-3
6. Brake oil pressure sensor
7. Engine oil pressure sensor d CNL22-5
8. Parking brake not applied signal
e CNL23-8
9. Parking brake indicator signal
10. Fuel level sensor f CNL23-19
11. HST oil temperature sensor
12. Coolant temperature sensor (for monitor) g CNL23-10
13. Axle oil temperature sensor h CNL21-13
i CNL23-18
j CNL23-13
k CNL21-14
l CNL21-16
m CNL21-8
WA200-5 10-155
HST safety control
1. Directional lever Connection table of connector pins of machine mon-

2. HST safety relay itor
3. Motor 1 solenoid valve
4. Clutch solenoid valve Symbol Connector pin No.
5. HST controller a CNL22-8
b CNL22-10
c CNL22-9
d CNL22-6
e CNL22-2
f CNL21-3
g CNL23-15
10-156 WA200-5
Autmatic preheating
1. Coolant temperature sensor (for preheating) Connection table of connector pins of machine mon-
2. Automatic preheater relay itor
3. Engine heater relay
4. Ribbon heater Symbol Connector pin No.
a CNL21-6
b CNL22-4
WA200-5 10-157
CAN input
Machine monitor HST controller
CAN output
Directional lever signal HST control
Machine monitor Model selection Model selection
HST function selection HST control
Travel speed pulse Travel speedometer
Gear speed signal Indication of 1, 2, 3, or 4

HST controller
Error Indication of characters
Input/Output state signal Real-time monitor
10-158 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITOR
MACHINE MONITOR
a Monitor lamps 17 and 18 do not operate on this machine.
1. HST oil temperature gauge 17. Engine oil level caution lamp
2. HST oil temperature caution lamp 18. Air cleaner clogging caution lamp
3. Engine water temperature gauge 19. Maintenance caution lamp
4. Engine water temperature caution lamp 20. Radiator water level caution lamp
5. Speedometer 21. HST oil filter clogging caution lamp
6. Turn signal pilot lamp (Left) 22. Engine oil pressure caution lamp
7. Head lamp beam pilot lamp 23. Battery charge circuit caution lamp
8. Turn signal pilot lamp (Right) 24. Character display
9. Meter indication pilot lamp 25. Steering oil pressure caution lamp
10. Fuel level caution lamp (Machine equipped with emergency steering)
11. Fuel level gauge 26. Emergency steering pilot lamp
12. Centralized warning lamp (Machine equipped with emergency steering)
13. Parking brake pilot lamp 27. Preheater pilot lamp
14. Brake oil pressure caution lamp 28. Gear speed selector switch position pilot lamp
15. Parking brake not applied caution lamp 29. Directional lever position pilot lamp
16. Axle oil temperature caution lamp
WA200-5 10-159
LIST OF ITEMS DISPLAYED
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ON MONITOR
LIST OF ITEMS DISPLAYED ON MONITOR

Condition for judging running of engine: When running judgment A or B is satisfied, it is judged that the engine
is running.
1. Input is given to alternator terminal R (24 V).
2. Engine oil pressure is normal (Open).
3. Signal of terminal C has been input at least once after IGN_BR, and then it has been turned OFF at least
once.
Judgment of operation
A: After 1 and 2 are established simultaneously, it is judged that the engine is running until IGN_BR is turned
OFF.
B: If 1 and 3 are established simultaneously or 2 and 3 are established simultaneously, it is judged that the
engine is running. If both signals of 1 and 2 are lost, however, it is judged that the engine is stopped even
if IGN_BR is turned ON.
Pri-
Lamp Period of lamp Buzzer Condition for operation Period of buzzer
ority
Warning for dangerous Period: 1,600 msec

w: ON and OFF condition ON: 800 msec
Q: ON – 1
continuously (When error indication OFF: 800 msec
or caution is turned on) (DUTY 50%)
Period: 1,600 msec Caution for wrong oper-

Period: 240 msec
ON: 800 msec ation, etc. (When abnor-
w: Flash A: Intermittent ON 1: 80 msec 2
OFF: 800 msec mal operation is
OFF: 160 msec
(DUTY 50%) performed)
Period: 240 msec Cancellation of calibra-

E: Cancellation
A: Intermittent ON 1: 80 msec tion, etc. (When opera- ON: 1,000 msec (Once) 3
sound
OFF: 160 msec tion is not accepted)
ON: 1,000 msec.

E: Condition is Completion of calibra-
e: Completion OFF: 160 msec.
set sepa- – tion, etc. (When com- 4
sound ON: 1,000 msec (Once)
rately pleted normally)
10-160 WA200-5
Operation
Engine is stopped Engine is running
Centralized warning
Centralized warning
Individual indication
Indication of failure
Warning buzzer
Warning buzzer
Condition for Indication
code message
code message
Division No. Item Device Remarks
operation color
When clear-
Backup Bulb for night
– Backup lamp ance lamp is – – – – – – – – Orange
lamp light
ON
km/h or MPH
Indication of
Unit 9 LED – Q – – – Q – – Green (Selected by setting
meter
monitor)
Conversion of If there is error in
Pointer: travel speed communication, con-
5 Travel speed – – – – – – – – –
Movement pulse into dition is held until key
travel speed is turned OFF.
Other than
– – – – – – – – –
below
HST oil tem- Pointer: Alarm: Above
1 perature/HST Movement w Q Q B@CRNS w Q Q B@CRNS Red White range: 50 - 110°C
110°C
2 oil tempera- Indicator: Red range: 110 - 135°C
ture caution LED HST oil tem-
perature: – – – DGH1KX – – – DGH1KX –
Above 150°C
Other than
– – – – – – – – –
below
Engine water Alarm: Above –
Pointer: 102°C Q – – – Q – – Red
temperature/
3 Movement White range: 50 - 102°C
Engine water Alarm: Above
4
temperature
Indicator: w Q Q B@BCNS w Q Q B@BCNS Red Red range: 102 - 135°C
Gauge/ LED 105°C
caution
Meter Engine water
temperature: – – – DGE2KX – – – DGE2KX –
Above 150°C
Pointer: Other than
Fuel level / below – – – – – – – – –
10 Fuel level Movement
11 Indicator: Above 110z
caution
LED – Q – – – Q – – Red
(Below 5%)
Conversion of
travel speed
Odometer pulse into – – – – – – – – –
travel dis-
tance
24 LCD Operates
when charge
is normal.
Service meter Corresponds – – – – – – – – –
to clock time
in 1:1.
Other than Lamp is turned ON by
– – – – – – – – –
below each controller and
Centralized message is indicated
12 Bulb
warning lamp When error is E E E on character display.
E E E E E Red Lamp is turned ON by
made
caution.
Oil pressure
is normal – – – – – – – – –
(GND) *1: For 30 sec just
Brake oil after key is turned ON
Oil pressure
14 pressure Bulb is abnormal – Q – – w Q Q – Red and engine is started
(Accumulator *2: 30 sec after
oil pressure) (OPEN) (*1) engine is started
Oil pressure (after *1)
is abnormal – – – – w Q Q 2G42ZG Red
(OPEN) (*2)
Caution Other than – – – – – – – – – Lamp lights up and
lamp below warning buzzer
Prevention of
When appli- sounds when engine
omitting to
15 Bulb cation of is stopped and park-
apply parking
brake parking brake A Q Q – – – – – Red ing brake is released
is omitted (or when key is turned
(24 V) OFF).
Oil tempera-
ture is normal – – – – – – – – –
*3: oil temperature
Oil tempera- above 120°C is
ture is abnor- w Q Q B@C7NS w Q Q B@C7NS Red detected for continu-
mal (*3) ous 5 seconds or oil
Axle oil tem-
16 perature Bulb temperature above
Brake oil tem- 115°C is detected for
perature: – – – DGR1KX – – – DGR1KX – continuous 5 seconds
Above 150°C and the travel speed
Detection of is above 35 km/h
– – – DGR1KB – – – DGR1KB –
error
WA200-5 10-161
Operation
Centralized warning
Centralized warning
Warning buzzer
Warning buzzer
code message
code message
operation color
Oil level is If error is detected

– – – – – – – – –
normal (GND) when IGN_C signal is
turned ON. Error is
not detected while
engine is running. (If
17 Engine oil Bulb abnormality is
temperature Oil level is
– Q – B@BAZK – – – – Red detected when key is
low (OPEN) turned ON, alarm is
kept turned ON until
normal oil level is
detected.)
Normal
– – – – – – – – – Error is detected only
Clogging of (OPEN)
18 Bulb while engine is run-
air cleaner Clogging
– Q – – – Q – AA1ANX Red ning.
(GND)
Mainte- Normal – – – – – – – – –
19 Bulb 30 h before
nance – Q – E – Q – E Red
maintenance
Water level is
– – – – – – – – – Error is judged when
Caution Radiator normal (GND)
lamp 20 Bulb it is detected for 30
water level Water level is
low (OPEN) – Q – B@BCZK – Q – B@BCZK Red sec.
Normal
– – – – – – – – – Error is judged when
Clogging of (OPEN)
21 Bulb HST oil temperature
HST oil filter Clogging
– Q – 15BONX – Q – 15BONX Red is above 50°C.
(GND)
Oil pressure
is normal – – – – – – – – –
(OPEN)
Oil pressure Error is detected 15
22 Engine oil Bulb is low (GND) – Q – – w Q Q B@BAZG Red sec after engine is
pressure
When abnor- started.
mality is – – – DHE4L6 – – – – Red
detected
(OPEN)
Normal volt-
w – Q AB00L6 – – – – Red
Battery age (24 V)
23 charge circuit Bulb
Defective
– Q – – w Q Q AB00MA Red
charge (0 V)
When turn
signal lever is Interlocked with turn
6 Turn signal signal lever. Oper-
turned ON
Bulb (while key is – Q – – – Q – – Green ates when hazard
8 lamp lamp switch is turned
turned OFF,
too) ON.
When beam
of head lamp
is turned ON Interlocked with lamp
Beam of head
7 lamp Bulb (When both – Q – – – Q – – Blue switch and dimmer
head lamp switch.
and beam are
turned ON)
Parking brake Lamp lights up when
is released – – – – – – – – – parking brake is
(OPEN) applied.
Parking Parking brake Operation of forward-
13 Bulb is applied – Q – – – Q – – Red reverse (F-R) lever is
Pilot lamp brake (GND) prohibited and warn-
Prevention of ing buzzer is turned
dragging of A Q Q – A Q Q – Red ON while parking
parking brake brake is applied.
Steering oil Oil pressure
is normal – – – – – – – – –
pressure (OPEN)
25 (Machines Bulb
equipped with Oil pressure
emergency is low (GND) – Q – – w Q Q DDS5L6 Red
steering)
Emergency Oil pressure
– – – – – – – – –
is lost (GND)
steering
26 (Machines Bulb Oil pressure
equipped with is normal – Q – – – Q – – Green
emergency (OPEN)
steering)
a Monitor lamps 17 and 18 do not operate on this machine.
10-162 WA200-5
Operation
Centralized warning
Centralized warning
Warning buzzer
Warning buzzer
code message
code message
operation color
Other than Lamp lights up when

– – – – – – – – –
below automatic preheater
is turned ON.
Automatic Output is turned OFF
27 Bulb When engine when IGN_C signal is
preheating is preheated – Q – – – Q – – Orange turned ON.
(postheated) Postheater is turned
ON after IGN_C sig-
nal is turned OFF.
When F is
Direc- F – Q – – – Q – – Green
selected
tional When N is
29 N LED – Q – – – Q – – Orange
lever selected
Pilot lamp When R is
position R – Q – – – Q – – Green
selected
When 1st
1 gear speed is – Q – – – Q – – Green
received Indicator lamp lights
Gear When 2nd up when CAN signal
2 gear speed is – Q – – – Q – – Green is received from HST
speed controller.
received
28 selector LED Indicator lamp does
When 3rd not light up when
switch 3 gear speed is – Q – – – Q – – Green CAN communication
position received is defective (All lamps
When 4th go off).
4 gear speed is – Q – – – Q – – Green
received
WA200-5 10-163
Service mode functions
1. Outline
1) Electrical equipment system failure history 2) Machine system failure history
This function is used to check the electrical This function is used to check the machine
equipment system failure history of each system failure history of each controller
controller saved in the machine monitor. saved in the machine monitor. For the fail-
For the failure codes displayed in the elec- ure codes displayed in the machine system
trical equipment system failure history, see failure history, see TROUBLESHOOTING.
TROUBLESHOOTING. After each failure is The contents of the machine system failure
repaired and the normal operation is con- history displayed on the character display
firmed, delete the failure history. are as follows.
The contents of the electrical equipment
system failure history displayed on the
character display are as follows.
*1: Displayed alternately every 3 seconds
***: The order in which the subject failure

*1: Displayed alternately every 3 seconds occurred
######: Failure code
***: The order in which the subject failure $$$: Frequency of occurrence of the sub-
occurred ject failure
######: Failure code %%%%%: The service meter value of the
$$$: Frequency of occurrence of the sub- first occurrence of the subject
ject failure failure
%%%%%: The time elapsed since the sub- @@@@@: The service meter value at the
ject failure occurrence for the occurrence of the latest failure
first time (it is determined by The failure code failure of a currently
subtracting the service meter detected failure flashes. Up to several
value of the first occurrence machine system failure codes are saved.
from the current service meter
value)
@@@@@: The time elapsed since occur-
rence of the latest failure (it is
determined by subtracting the
service meter value at the lat-
est occurrence from the current
service meter value)
The failure code failure of a currently
detected failure flashes. Up to 20 failure
codes are saved.
10-164 WA200-5
3) Real-time monitor Any 2 items can be displayed simultane-

This function is used to check the input and ously by specifying their ID Nos. In this
output signals, etc. recognized by each case, they are displayed on the character
controller on the network. display as shown below.
The contents of the real-time monitor dis-
played on the character display are as fol-
lows.
#####: Specified ID Nos.

*1: Changed after 3 seconds %%%: Data. If a unit is used, it is displayed
on the right of the data.
***: Item name
######: ID No. given to each item
%%%: Data. If a unit is used, it is displayed
on the right of the data.
WA200-5 10-165
4) Maintenance monitor
This function is explained in "Operation
manual, Operation, Character display, Dis-
play of replacement periods of filters and
oils". It is used to change the replacement
periods of the filters and oils.
5) Selection of options
With this function, you can display installa-
tion of an optional device and change the
setting of that device. Use this function
after any optional device is installed or
removed.
6) Initialize
This function is used only in the factory. Do
not use it.
10-166 WA200-5
(4)
2. Operating method
WA200-5 10-167
Items Related to the Fault History of Electric System

1) Selection of displaying and clearing the fault history of electric system
The fault history is displayed in the order of occurrence with the new fault first.
A current fault is displayed prior to the restored ones.
Pressing the > SW displays the next older fault.
Pressing the < SW displays the next newer fault.
After the oldest fault in memory was displayed, a screen is displayed allowing to select clearing the
entire fault history of electric system of the relevant controller.
Pressing the tSW changes the screen to the [Select displaying abnormalities in electric system]
screen on the first layer.
Pressing the USW changes the screen to the [Clear individually the fault history of electric system] or
[Clear the fault history of electric system] screen.
2) Selection of displaying the fault history of electric system (first layer)

Pressing the > SW changes the screen to the [Select the initializing function] screen.
Pressing the < SW changes the screen to the [Select displaying the fault history of vehicle system]
screen.
Pressing the tSW changes the screen to the ordinary or alert screen.
Pressing the USW changes the screen to the [Display abnormalities in electric system] screen.
10-168 WA200-5
3) Selection of displaying the fault history of electric system and clearing the entire fault history of electric
system (second layer)
A current fault is displayed piror to the restored ones.
Pressing the tSW changes the screen to the [Select displaying abnormalities in electric system]
Pressing the USW changes the screen to the [Clear individually the fault history of electric system] or
[Clear the fault history of electric system]screen.
* If the history consisted of one fault, pressing the switch does not change the screen to that for all-out
clearing (but change the screen to that for individual clearing).
1. [Display the electrical equipment system failure history] screen

2. [Display the electrical equipment system failure history] screen (When there is not history)
3. [Select clearing entirely the electrical equipment system failure history] screen
***: The order in which the subject failure occurred

######: Unified failure code (6 digits)
$$$: Frequency of occurrence of the subject failure
%%%%%: The time elapsed since the subject failure occurrence for the first time (it is determined by
subtracting the service meter value of the first occurrence from the current service meter
value)
@@@@@: The time elapsed since occurrence of the latest failure (it is determined by subtracting the
service meter value at the latest occurrence from the current service meter value)
WA200-5 10-169
4) Clearing individually the fault history of electric system, and clearing the entire fault history of electric
system (the third layer)
Select YES or NO with the < or > SW.
Cursor (_) blinks on the selected item. Pressing the tSW changes the display as follows, with the his-
tory reset if YES was selected, or not if NO was selected:
a. If No (cancel) was selected, the display returns to the [Display the fault history of electric
system] screen of the relevant fault (i.e., the screen before entering the [Clearing individually
(entirely) the fault history of electric system] screen).
b. If YES (clear ) was selected, the display returns to the [Display the fault history of electric
system] screen of a fault next to the relevant fault. If the fault history to be shown exhausts, the
screen returns to the [Select displaying the fault history of electric system] screen.
By default, the cursor is on NO (no reset) to prevent resetting by error.
A current fault cannot be cleared. If it was selected, a peep sounds for one second to notify that the
operation is cancelled.
If a fault was cleared, peeps sound (on for 0.1 sec. - off for 0.1 sec. - on for0.1 sec.) to notify that the
operation has been accepted.
If the entire history was cleared, it is considered to have been cleared even if it consisted of only one
fault .
1. [Clear individually the electrical equipment system failure history] screen

2. [Clear entirely the electrical equipment system failure history] screen
10-170 WA200-5
Items Related to the Fault History of Machine System

1) Display of the fault history of vehicle system
Pressing the tSW changes the screen to the [Select displaying abnormalities in machine system]
2) Selection of displaying the fault history of machine system (first layer)

Pressing the > SW changes the screen to the [Select the real-time monitor functions] screen.
Pressing the < SW changes the screen to the [Select displaying the fault history of machine system]
screen.
Pressing the tSW changes the screen to the ordinary or alert screen.
Pressing the USW changes the screen to the [Display abnormalities in electric system] screen.
WA200-5 10-171
3) Display of the fault history of vehicle system (second layer)

The fault history is displayed in the order of occurrence with the newest fault first.
The fault history is displayed in the order of occurrence with the newest fault first.
Pressing the > SW displays the next newer fault.
Pressing the < SW displays the next older fault.
Pressing the tSW changes the screen to the [Select displaying abnormalities in vehicle system]
screen.
1. [Display the machine system failure history] screen

2. [Display the machine system failure history] screen (When there is not history)
***: The order in which the subject failure occurred

######: Unified failure code (6 digits)
$$$: Frequency of occurrence of the subject failure
%%%%%: The service meter value of the first occurrence of the subject failure
@@@@@: The service meter value at the occurrence of the latest failure
10-172 WA200-5
Real-time monitor function
The real-time monitor function displays the information saved in the HST controller and machine monitor mount-
ed on the machine in real time.
This function is used for testing, adjusting, and troubleshooting in the normal display mode or 2-item display
mode for displaying 2 data simultaneously.
1) Selection/Display of real-time monitor item

Pressing the > SW changes the screen in the order of No. 1, No. 2, No. 3 --- Select display of 2 items.
Pressing the < SW changes the screen in the order of Select of display of 2 items, No. 13, No. 12, No.
11 ---.
Pressing the tSW changes the screen to the [Select real-time monitor function] screen.
In [Display of real-time monitor]: Pressing the USW holds the displayed data. Pressing it again
returns the displayed data into the active state.
In [Select display of 2 items]: Pressing the USW changes the screen to the [Select 2 items] screen.
2) Selection of real-time monitor function (first

layer)
Pressing the > SW changes the screen to
the [Select maintenance monitor function]
screen.
Pressing the < SW changes the screen to
the [Select display of machine system fail-
ure history] screen.
Pressing the tSW change the screen to
the normal screen or alarm screen.
Pressing the USW change the screen to
the [Display of real-time monitor] screen.
WA200-5 10-173
3) Display of real-time monitor and selection of display of 2 items (second layer)

Pressing the > SW displays the next data.
Pressing the < SW displays the previous data.
Pressing the tSW changes the screen to the [Select real-time monitor function] screen.
In [Display of real-time monitor]: Pressing the USW holds the displayed data. Pressing it again
returns the displayed data into the active state.
In [Select display of 2 items]: Pressing the USW changes the screen to the [Select 2 items] screen.
*1: Changed after 3 seconds
1. [Display of real-time monitor] screen

2. [Select display of 2 items] screen
***: Real-time monitor item name

$$$$$: ID of item
%%%: Data and unit (SI unit)
4) Selection of 2 items (third layer)

How to input ID
a. When the screen appears, the cursor (_)
is blinking at the highest position of
"00000".
b. Each time the > SW or the < SW is
pressed, the digit changes by 1 between
0 and 9.
c. Select a necessary digit and press the
USW.
d. The cursor moves to the 2nd position.
Select the digits for the all positions by
performing steps b. and c. above.
e. After selecting the digit for the lowest po-
sition, press the USW.
f. If the ID is entered, the screen changes
to the [Display 2 items] screen.
g-1. If you press the tSW before finishing
entering the ID, the cursor moves to the
highest position.
g-2. If you press the tSW while the cursor
is at the highest position, the screen re-
turns to the [Select display of 2 items]
screen.
10-174 WA200-5
5) Display of 2 items (fourth layer)

Pressing the tSW changes the screen to the [Select 2 items] screen.
Pressing the USW holds the displayed data. Pressing it again returns the displayed data into the
active state.
$$$$$: ID of item
%%%%: Data and unit (SI unit)
a The first item and second item are displayed alternately every 3 seconds
a If an item ID that cannot be displayed is selected on the [Select 2 items] screen, the data & unit
display box (%%%) is left blank.
Real-time Monitoring Items

Component Terminal
Item ID Real-time monitoring item Item displayed Display unit Displayed range Remarks
detected No.
All the items are shown A value out of the range
Abridged due to SI unit system so
even if some of them are displayed is shown as
limitation of long as the val-
not equipped depending the lowest (highest)
number of letters. ues have units
on models and options. value in the range.
20200 Monitor ROM No. MONITOR ROM --- --- Monitor ---
40000 Travel speed SPEED 1 km/h 0 – 50 HST L41-13
04202 Fuel level FUEL SENSOR 1% 0 – 100 Monitor L23-13
04101 Engine water temperature COOLANT TEMP 1 °C 24 – 131 Monitor L21-16
Engine water temperature
04103 COOLANT Lo 1 °C -31 – 91 Monitor L21-6
low
30100 HST oil temperature HST TEMP 1 °C 24 – 131 Monitor L21-14
30202 Axle oil temperature BRAKE TEMP 1 °C 24 – 131 Monitor L21-8
HST con-
01005 Engine speed ENG SPEED 1 rpm 0 – 3000 HST L42-4
troller CAN
HST con-
32600 HST oil pressure HST PRESS 0.1 MPa 0.0 – 100.0 HST L41-3
troller CAN
Motor 1 solenoid feed- HST con-
80000 MOTOR SOL 1 mA 0 – 1000 HST L41-6
back current troller CAN
Clutch solenoid feedback HST con-
80100 CLUTCH SOL 1 mA 0 – 1000 HST L41-14
current troller CAN
HST con-
50302 Potentiometer voltage SPEED POT 1% 0 – 100 HST L41-1
troller CAN
HST con-
80200 HST traction force TRACTION --- STD/LIMIT HST L42-3
troller CAN
WA200-5 10-175
(Reference) Inspection with real-time monitor
Example) Measurement of engine speed

Measure the engine speed under the following condition.
Cooling water temperature: Within operating range
HST oil temperature: 45 - 55°C
First, check this condition with the real-time monitor.
Condition Real-time monitor item Component ID
Cooling water temperature COOLANT TEMP Machine monitor 04101
HST oil temperature HST TEMP Machine monitor 30100
After checking the above items with the real-time monitor, check the engine speed.
Condition Real-time monitor item Component ID
Engine speed ENG SPEED HST controller 01005
10-176 WA200-5
Maintenance functions
1) Selection/Display of maintenance monitor item

Pressing the > SW changes the screen in the order of No. 1, No. 2, No. 3 ---.
Pressing the < SW changes the screen in the order of No. 13, No. 12, No. 11 ---.
Pressing the tSW changes the screen to the [Select maintenance monitor function] screen.
Pressing the USW changes the screen to the [Change maintenance interval time].
2) Selection of display of maintenance monitor function (first layer)

Pressing the > SW changes the screen to the [Select OPT function] screen.
Pressing the < SW changes the screen to the [Select real-time monitor function] screen.
Pressing the tSW change the screen to the normal screen or alarm screen.
Pressing the USW change the screen to the [Select maintenance monitor item] screen.
WA200-5 10-177
3) Selection of maintenance monitor (second layer)

The contents of this display are the same as those of the maintenance monitor of the function opened
to the operator. Maintenance caution lamp does not light up, however.
Pressing the tSW change the screen to the [Select maintenance monitor function] screen.
Pressing the USW change the screen to the [Change maintenance monitor interval time] screen.
1. [Select maintenance item] screen

2. Example) When the data is HST oil filter
##: ID No. of each maintenance item

***: Each maintenance item
10-178 WA200-5
4) Change of maintenance interval time (third layer)

The maintenance interval time can be set freely to 0 - 9999 h.
If you press the tSW, the time is not changed but the screen changes to the [Select maintenance
item] screen.
At this time, the operation cancel sound (1-second peep) is heard.
How to input interval

a. When the screen appears, the cursor (_) is blinking at the highest position.
b. Each time the > SW or the < SW is pressed, the digit changes by 1 between 0 and 9.
c. Select a necessary digit and press the USW.
d. The cursor moves to the 2nd position. Select the digits for the all positions by performing steps (b.)
and (c.) above.
e. After selecting the digit for the lowest position, press the USW.
f-1. If the input interval time is acceptable, the screen changes to the check screen.
f-2. If the input interval time is not acceptable, the time does not change but the screen changes to the
[Select maintenance item] screen. At this time, the operation cancel sound (1-second peep) is
heard.
g. If you have input a wrong value, press the tSW to return to the [Select maintenance item] screen
and repeat the above steps from the first.

***: Each maintenance item
%%%%: Current interval time (4 digits)
If there is not a digit in a position of the interval time, input "0". Example: "0012"
WA200-5 10-179
5) Check of change of maintenance interval time (fourth layer)

Select YES or NO with the < or > SW. The cursor (_) blinks on the selected item. Pressing the tSW
returns the screen to the [Select maintenance item] screen with the change done if YES was selected,
or not if NO was selected.
By default, the cursor is on NO (the change not done) to prevent resetting by error.
When the change of the set time is finished, the operation acceptance peeps (on for 0.1 sec o off for
0.1 sec o on for 0.1 sec) are heard.

%%%%: Interval time (4 digits) to be changed
The maintenance interval time is set as shown in the following table, when shipped.
Item Replacement interval time (h) Displayed item name ID No.
Engine oil 500 ENG OIL 01
Engine oil filter 500 ENG FILT 02
Fuel filter 500 FUEL FILT 03
Transfer oil 1,000 TRANSF OIL 25
HST oil filter 1,000 HST FILT 26
Hydraulic oil filter 2,000 HYD FILT 04
Hydraulic oil 2,000 HYD OIL 10
Axle oil 2,000 AXLE OIL 15
10-180 WA200-5
Setting required when optional device is installed
When any of the following optional devices is added or replaced, adjust the sensors, etc. to the initial values with
the machine monitor.
Added or replaced optional device Adjustment item
Tire size, machine monitor Model selection, tire size selection, tire deviation selection
Function of selecting optional device

1) Selection and display of optional item
Pressing the > SW or < SW changes the selected optional items in order.
Pressing the tSW changes the screen to the [Select function of selecting optional device]
In [Model selection item]: Pressing the USW changes the screen to the [Select model] screen.
In [Select each optional device]: Pressing the USW updates the items of each optional device.
2) Selection of function of selecting optional

device (fourth layer)
Pressing the > SW changes the screen to
the [Select initializing function] screen.
Pressing the < SW changes the screen to
the [Select maintenance monitor function]
screen
Pressing the tSW changes the screen to
the normal screen or alarm screen.
Pressing the USW changes the screen to
the [Model selection item] screen.
WA200-5 10-181
3) Model selection item and selection of optional device (second layer)

Pressing the > SW or < SW changes the selected optional items in order.
In [Model selection item]: Pressing the USW changes the screen to the [Select model] screen.
In [Select each optional device]: Pressing the USW updates the items of each optional device.
1. [Model selection item] screen

2. [Select tire deviation] screen
Selection of tire deviation

Pressing the USW selects deviation from the standard tire between -12% and +12% (at intervals of 2%). (@@
is the deviation selected when shipped.)
(+00/+02/+04/+06/+08/+10/+12/-02/-04/-06/-08/-10/-12)
When selection is finished, the operation acceptance peeps (on for 0.1 sec o off for 0.1 sec o on for 0.1 sec)
are heard.
4) Selection of model (third layer)

Pressing the >SW or <SW selects a model.
(100/150/200/250/320)
Pressing the tSW changes the screen to the [Model selection item] screen.
If you press the USW to finish selection, the operation acceptance peeps (on for 0.1 sec o off for 0.1
sec o on for 0.1 sec) are heard and the screen changes to the [Select tire size] screen.
a Select "200" for this machine.
10-182 WA200-5
5) Selection of tire size (fourth layer)

Pressing the > SW or < SW selects a tire size.
(13.0/14.0/15.5/16.9/17.5/18.4/20.5)
If you press the USW to finish selection, the operation acceptance peeps (on for 0.1 sec o off for 0.1
sec o on for 0.1 sec) are heard and the screen changes to the [Model selection item] screen.
a Since "200" was selected on the "Select model" screen, "15.5" "17.5" or "20.5" can be selected. (Other tire
sizes are not displayed.)
WA200-5 10-183
AMP040-16P [CN-L21]
Pin No. Specification I/O Type of use Signal name WA200/200PT-5 Remarks
SW for operating
1 D_IN (NSW +24V) I D/I+24V Service SW t SW input machine monitor
SW for operating
2 D_IN (+24V) I D/I+24V Service SW U SW input machine monitor
3 GND I GND CAN shield GND
SW for operating
4 D_IN (GND) I D/IGND Increment SW < SW input machine monitor
5 D_IN (GND) I D/IGND Decrement SW > SW input SW for operating

machine monitor
Engine water temperature Engine water temperature
6 A_IN I A/I sensor (For automatic pre- sensor (For automatic pre-
heating) heating)
7 GND I GND Sensor GND GND
Brake oil temperature sen- Brake oil temperature sen-
8 A_IN I A/I
sor sor
9 N.C. – – --- ---
10 N.C. – – --- ---
D_OUT Buzzer Buzzer
11 O D/O sink
(+24 V, sink: 200 mA) (Machine monitor) (Machine monitor)
Lamp switch Lamp switch
12 D_IN (+24V) I D/I+24V
(Clearance lamp) (Clearance lamp)
Parking brake omission pre- Parking brake omission pre-
13 D_IN (NSW +24V) I D/I+24V
vention vention
14 A_IN I A/I HST oil temperature sensor HST oil temperature sensor
15 GND I GND GND GND
Engine water temperature Engine water temperature
16 A_IN I A/I
sensor sensor
10-184 WA200-5
(3)
AMP040-12P [CN-L22]
1 N.C. – – --- ---
Machine monitor – HST con-
2 CAN- I/O CAN CAN-
troller
3 D_IN (GND) I D/IGND Emergency steering operation Emergency steering operation (If equipped)
4 D_OUT O D/O sink Automatic preheater relay Automatic preheater relay

(+24 V, sink: 200 mA)
5 D_IN (GND) I D/IGND Emergency steering normal Emergency steering normal (If equipped)
Machine monitor – HST con- CAN+
6 CAN+ I/O CAN
troller
7 N.C. – – --- ---
8 D_IN (+24V) I D/I+24V Direction R Direction R
9 D_IN (+24V) I D/I+24V Direction N Direction N
10 D_IN (+24V) I D/I+24V Direction F Direction F
11 D_IN (+24V) I D/I+24V Turn signal lamp left Turn signal lamp left
12 D_IN (GND) I D/IGND Dimmer switch Dimmer switch
AMP040-20P [CN-L23]
1 D_IN (NSW+24V) I D/I+24V IGN BR IGN BR
2 N.C. – – --- ---
3 D_IN (+24V) I D/I+24V IGN C IGN C
4 N.C. – – --- ---
5 N.C. – – --- ---
6 D_IN (GND) I D/IGND HST filter clogging HST filter clogging
7 D_IN (GND) I D/IGND (Air cleaner clogging) ---
8 D_IN (GND) I D/IGND Engine water level Engine water level
9 D_IN (+24V) I D/I+24V Lamp switch (Head lamp) Lamp switch (Head lamp)
10 D_IN (GND) I D/IGND Engine oil pressure Engine oil pressure
NSW power supply Power supply
11 (+24 V) I +24 V NSW power supply (+24 V) NSW power supply (+24 V)
12 D_IN (GND) I D/IGND Alternator R Alternator R

13 A_IN I A_I Fuel level sensor Fuel level sensor
14 GND I GND GND GND
D_OUT
15 O D/O sink HST solenoid cut-out relay HST solenoid cut-out relay
(+24 V, sink: 200 mA)
16 N.C. – – --- ---
17 D_IN (+24V) I D/I+24V Turn signal lamp right Turn signal lamp right
18 D_IN (+24V) I D/I+24V Parking brake Parking brake
19 D_IN (GND) I D/IGND Brake oil pressure Brake oil pressure
20 D_IN (GND) I D/IGND (Engine oil level) ---
WA200-5 10-185
(3)
ELECTRICAL SYSTEM
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD (HST CONTROLLER SYSTEM)
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)

System diagram
10-186 WA200-5
ELECTRICAL SYSTEM
Control function
1. Speed changing function
The HST controller calculates the maximum speed matched to the selected gear speed and controls the
HST according to the gear speed signal and travel speed adjustment signal.
1. HST controller a. CNL41-10: Travel speed adjustment potentiom-

2. Gear speed selector switch eter power supply (+5 V)
3. Travel speed adjustment dial b. CNL41-1: Travel speed adjustment signal
4. Shift control relay c. CNL41-2: Travel speed adjustment potentiome-
5. Traction control switch ter GND
d. CNL42-12: Gear speed signal
e. CNL42-3: Traction control signal
Travel speed
Travel speed Traction con-
Selected gear Traction Clutch sole- Motor 1 sole- Motor 2 sole- adjustment
range trol switch
speed control noid output noid output noid output signal input
(km/h) signal
voltage (V)
0 – 13 (Set
–
with travel
1st (Normally Unlimited ON MAX – MID MAX. fixed 1.0 – 4.0
speed adjust-
OFF)
ment signal)
Standard
Unlimited
(OFF)
2nd 0 – 13 ON MAX – MID MAX. fixed 1.0 – 4.0
Limited
Limited
(ON)
Standard
Unlimited
(OFF)
3rd 0 – 20 ON, OFF MAX – 0 MAX. fixed 0
Limited
Limited
(ON)
Standard
Unlimited
(OFF) MAX. fixed -
4th 0 – 34.5 ON, OFF MAX – 0 0
Limited Variable
Limited
(ON)
Note: The travel speed range shown above is for the tire size of 17.5-25.
2. Traction control function

The HST controller can limit the output torque
according to the traction control signals when
the selected gear speed is 2nd - 4th.
WA200-5 10-187
ELECTRICAL SYSTEM
3. Travel speed adjustment function (Variable shift control system)

If the gear speed selector switch is set to the 1st position, the maximum speed can be limited to 4 - 13 km/
h with the travel speed adjustment signal.
4. Motor 1 overrun prevention function

While the machine is traveling at high speed (15 km/h or higher) with the gear in the 3rd or 4th position, if
the gear is shifted to the 1st or 2nd position, the clutch is engaged at high speed and motor 1 speed
exceeds the allowable limit.
To prevent motor 1 from overrunning in this case, the HST controller prohibits shifting the gear from 3rd or
4th position to the 1st or 2nd position while the travel speed is above 10 km/h.
If the gear cannot be shifted, the action code (E00) is displayed on the machine monitor and the alarm
buzzer is turned ON.
The error condition is reset when the travel speed lowers below 9 km/h or the gear speed selector switch is
set in a gear speed position at which the gear can be shifted.
Gear shifting operation Action after gear shifting

Travel speed at
Switch position Switch position Actual gear speed Display of action
gear shifting Remarks
before gear shifting after gear shifting after gear shifting code
(km/h)
2nd 2nd Gear can be
1st 0– 3rd 3rd Not displayed shifted regardless
4th 4th of travel speed.
1st 1st Gear can be

2nd 0– 3rd 3rd Not displayed shifted regardless
4th 4th of travel speed.
1st 1st
0 – 10 2nd 2nd Not displayed Gear can be
4th 4th shifted to 1st or
3rd 2nd only when
1st 3rd travel speed is
Displayed (E00)
10 – 2nd 3rd below 9 km/h.
4th 4th Not displayed
1st 1st
0 –10 2nd 2nd Not displayed Gear can be
3rd 3rd shifted to 1st or
4th 2nd only when
1st 3rd travel speed is
Displayed (E00)
10 – 2nd 3rd below 9 km/h.
3rd 3rd Not displayed
10-188 WA200-5
ELECTRICAL SYSTEM
5. Travel speed limiting function

When the machine travels down a slope at high speed, the axle speed and engine speed exceed the
allowable limit, and the travel speed exceeds the allowable limit consequently.
To limit the travel speed in this case, the HST controller limits the output of motor 2 while the travel speed
is above 36 km/h.
If the travel speed is limited, the action code (E00) is displayed on the machine monitor and the alarm
buzzer is turned ON.
The error condition is reset when the travel speed lowers below 35.6 km/h.
WA200-5 10-189
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST CONTROLLER
HST CONTROLLER
Input and output signals
AMP 1-963217-1-16P [CN-L41]

Pin No. Signal name Input/Output signal Pin No. Signal name Input/Output signal
Travel speed adjustment potenti- 9 NC –
1 Input
ometer signal Travel speed adjustment potenti-
10 Output
Travel speed adjustment potentiometer (+5 V)
2 –
ometer GND 11 NC –
3 HST pressure sensor signal Input 12 HST pressure sensor (+5 V) Output
4 HST pressure sensor GND – 13 Travel speed signal A (Pulse) Input
5 Motor 2 solenoid Output 14 Clutch solenoid Output
6 Motor 1 solenoid Output 15 NC –
7 Power supply (+24 V) Input 16 GND –
8 Power supply (+24 V) Input
AMP 2-963217-1-16P [CN-L42]

Pin No. Signal name Input/Output signal Pin No. Signal name Input/Output signal
1 NC – 9 NC –
2 Checker H Input and output 10 NC –
3 Traction control signal Input 11 Engine speed sensor GND –
4 Engine speed signal Input 12 Gear speed signal Input
Travel speed signal B (Revolv- 13 NC –
5 Input
ing direction) 14 Checker D Input and output
6 NC – 15 Checker B Input and output
7 Checker C Input and output 16 CAN-H Input and output
8 CAN-L Input and output
10-190 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE START CIRCUIT
ENGINE START CIRCUIT
a For details of the directional lever relay, see Electrical circuit diagram.
1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to secure
3. Starting switch the safety when the engine is started.
4. Directional lever • The engine does not start if the directional
5. Neutral safety relay lever is not in the N (Neutral) position.
6. Starting motor safety relay
7. Starting motor
8. Alternator
9. Fuel cut-out solenoid
10. Fuel solenoid pull relay
11. Fuel cut-out solenoid timer
12. Machine monitor
13. Short connector
14. Directional lever relay
WA200-5 10-191
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE START CIRCUIT
Operation
1. When starting switch is ON 3. When starting switch is turned to START posi-
• If the starting switch is turned ON, terminals tion
B and BR of the starting switch are closed • If the starting switch is turned to the START
and the current flows from the battery position, terminals B and C of the starting
through the starting switch and battery relay switch are closed and the current flows from
coil to the ground and the contacts are short connector terminal 7 through terminal
closed. As a result, the power is supplied to 8 and neutral safety relay terminals 3 and 5
each circuit of the machine. to starting motor safety relay terminal S, and
At this time, if the signal from terminal ACC then the contacts are closed to start the
of the starting switch flows in the timer starting motor and engine.
relay, the relay contacts are closed for 3 • If the directional lever is not in the N (Neu-
seconds and the current flows into the coil tral) position, the neutral safety relay does
on the pull side of the fuel cut-out solenoid. not operate and the engine does not start.
The current from terminal ACC of the start-
ing switch flows into the coil on the hold
side of the fuel cut-out solenoid to hold the
solenoid so that the fuel will be supplied
even after the coil on the pull side is ener-
gized. The engine is now ready to start.
2. Neutral safety circuit

• If the directional lever is set in the N (Neu-
tral) position, the current flows from contact
N of the forward-reverse lever to the multi-
function selector relay circuit. At this time,
multi-function selector relay circuit supplies
a current as the N signal to the neutral safety
relay coil to connect neutral safety relay ter-
minals 3 and 5.
10-192 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT
Operation
1. Battery • The current from ACC terminal of starting switch
2. Battery relay to hold side coil of fuel cut solenoid is cutoff
3. Starting switch when starting is turned off. Fuel supply to engine
4. Directional lever is shut off.
5. Neutral safety relay When the fuel supply is stopped, the engine re-
6. Starting motor safety relay duces its speed and stops. Then, the power
7. Starting motor generation of the alternator stops to shut off volt-
8. Alternator age supply from the terminal L of the alternator.
9. Fuel cut-out solenoid In addition, the current from the terminal BR of
10. Fuel solenoid pull relay starting switch is shut off. Consequently, the
11. Fuel cut-out solenoid timer battery relay contact opens to shut down the
12. Machine monitor power supplied to every circuit of the machine.
13. Short connector
14. Directional lever relay
WA200-5 10-193
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PREHEATING CIRCUIT
PREHEATING CIRCUIT
(AUTOMATIC PREHEATING SYSTEM)
1. Battery Operation
2. Battery relay • When the starting switch is turned ON, the ma-
3. Starting switch chine monitor is started up. At this time, if the
4. Automatic preheating relay coolant temperature is 0°C or less, the machine
5. Engine heater relay monitor makes to contact the coil of the preheat-
6. Ribbon heater ing relay to the earth and the preheating relay
7. Machine monitor operates to let the engine heater relay operate to
8. Coolant temperature sensor (For preheating) start preheating by the electric intake air heater.
• The operating time of the preheating process is
Outline as shown below
• The automatic preheating system is being in-
stalled to improve the engine starting capability
in cold weather areas. This system is capable
of shortening the preheating time and, at the
same time, it is capable of making automatic set-
ting of the preheating time matching the current
coolant temperature, by merely turning the start-
ing switch.
• When the starting switch is turned ON, the pre-
heating pilot lamp on the machine monitor lights
and the electric intake air heater starts preheat-
ing the intake air.
As for the preheating time, the coolant tempera-
ture is detected by the coolant temperature sen-
sor and the controller being built into the
machine monitor carries out the preheating time
setting.
• While the pilot lamp is lighting, preheating is in
progress and keep the starting switch at the ON
state. If the starting switch is turned to the
START position, the preheating process is can-
celled.
10-194 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE CIRCUIT
PARKING BRAKE CIRCUIT
1. Parking brake lever intermediate switch 14. Directional lever relay

2. Parking brake lever bottom switch 15. Forward relay
3. Parking brake relay 16. Reverse relay
4. Parking brake selector connector (CNL20) 17. Neutral safety relay
5. Parking brake selector connector (CNL18) 18. HST pump forward solenoid valve
6. Parking brake pilot lamp relay 19. HST pump reverse solenoid valve
7. Parking brake drag prevention relay 20. Motor 1 solenoid valve
8. Machine monitor 21. Clutch solenoid valve
9. Alarm buzzer 22. Motor 2 solenoid valve
10. HST controller power hold relay 23. HST motor directional selector solenoid valve
11. HST controller
12. HST safety relay
13. Directional lever
WA200-5 10-195
Operation
1. When parking brake lever is returned (ON o OFF)
Position of starting switch OFF ON
State of engine Stopped Running
Position of parking brake

Lock Mid-Free Free Lock Mid-Free Free Lock Mid-Free Free
lever
Intermediate switch (1) Open Close Open Close Open Close
Bottom switch (2) Open Close Open Close Open Close
Parking brake ON ON
reminder caution lamp OFF (Reset) (Oper- OFF (Reset) (Oper- OFF (Reset)
(Alarm buzzer) ated) ated)
Parking brake pilot lamp OFF ON OFF ON OFF
1) When parking brake lever is in Lock posi- • The parking brake pilot lamp goes off re-
tion gardless of the state of the parking
• When the parking brake is applied, both brake. Parking brake reminder caution
intermediate switch (1) and bottom lamp lights up and the alarm buzzer
switch (2) are open. sounds only when the engine is
• The parking brake pilot lamp lights up stopped.
only while the starting switch is in the • Then, the HST controller power hold re-
ON position and goes off regardless of lay operates and the current flows in the
the state of the parking brake reminder HST controller to hold the operation of
caution lamp. the motor solenoid and clutch solenoid
• The parking brake is applied. and prevent the machine from moving
down on a slope, etc.
2) When parking brake lever is moved from • The parking brake is released.
Lock position to Mid position
• If the parking brake lever is returned a
little, intermediate switch (1) is closed
but the contacts of the parking brake re-
lay are kept open.
• The parking brake pilot lamp and park-
ing brake reminder caution lamp oper-
ate as in step 1).
• The parking brake is kept applied.
3) When parking brake is set in Free position

• If the parking brake lever is returned to
the end, bottom switch (2) is closed.
• At this time, the coil flows in the coil of
the parking brake relay to close the con-
tacts, and then the parking brake pilot
lamp relay operates.
• Since the current flows in the coil of the
parking brake drag prevention relay, the
forward-reverse solenoid circuit is
closed and the machine can travel for-
ward or in reverse and the parking brake
reminder caution signal is input to the
machine monitor.
10-196 WA200-5
2. When parking brake lever is pulled (OFF o ON)
Position of starting switch OFF ON
State of engine Stopped Running
Position of parking brake

Free Free-Mid Lock Free Free-Mid Lock Free Free-Mid Lock
lever
Intermediate switch (1) Close Open Close Open Close Open
Bottom switch (2) Close Open Close Open Close Open
Parking brake
OFF OFF
reminder caution lamp ON (Operated) ON (Operated) OFF (Reset)
(Reset) (Reset)
(Alarm buzzer)
Parking brake pilot lamp OFF OFF ON OFF ON
1) When parking brake is set in Free position

• When the parking brake is released, • Since the current to the coil of the park-
both intermediate switch (1) and bottom ing brake drag prevention relay is cut
switch (2) are closed. out, the forward-reverse solenoid circuit
• The parking brake pilot lamp goes off re- is opened. Accordingly, the machine
gardless of the state of the parking does not move forward or in reverse
brake. Parking brake reminder caution even if the directional lever or the direc-
lamp lights up and the alarm buzzer tional selector switch is operated.
sounds only when the engine is • The parking brake pilot lamp lights up
stopped. only while the starting switch is in the
• Then, the HST controller power hold re- ON position and goes off regardless of
lay operates and the current flows in the the state of the parking brake reminder
HST controller to hold the operation of caution lamp.
the motor solenoid and clutch solenoid • The parking brake is applied.
and prevent the machine from moving
down on a slope, etc.
• The parking brake is released.
2) When parking brake lever is moved from

Free position to Mid position
• If the parking brake lever is pulled a lit-
tle, bottom switch (2) is opened but the
contacts of the parking brake relay are
kept closed.
• The parking brake pilot lamp and park-
ing brake reminder caution lamp oper-
ate as in step 1).
• The parking brake is kept released.
3) When parking brake lever is in Lock posi-

tion
• If the parking brake lever is pulled to the
end, intermediate switch (1) is opened.
• At this time, the current to the coil of the
parking brake relay is cut out and the
contacts are opened and the parking
brake pilot lamp relay is turned OFF.
WA200-5 10-197
(3)
ELECTRONICALLY CONTROLLED
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSION SYSTEM
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM

Electronically Controlled Suspension System (Abbreviation: ECSS)
(If equipped)
1. ECSS controller
2. ECSS relay
3. ECSS switch
4. ECSS solenoid
5. Speed sensor
Function
• The controller controls the ECSS solenoid valve automatically to turn the accumulator charged with high-
pressure gas ON and OFF to damp the vertical movement of the work equipment and reduce the jolts of the
machine during high-speed travel. Consequently, the operator comfort is improved, the material spills less,
and the working efficiency is increased.
System operation table

Travel speed
ECSS switch ECSS solenoid output State of ECSS
(km/h)
OFF 0 – MAX OFF OFF
0–5 OFF OFF
Turn system ON
5 – MAX ON ON
ON (*1)
MAX – 4 ON ON
Turn system OFF
4–0 OFF OFF
*1: When the bucket of WA200PT-5 is tilted, the ECSS is not turned ON even if the travel speed is increased
above 5 km/h.
10-198 WA200-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS
SENSORS
Engine speed sensor
1. Wire 4. Housing
2. Magnet 5. Connector
3. Terminal
Function
• The engine speed sensor is installed to the ring
gear of the flywheel housing. As the gear re-
volves, the engine speed sensor generates a
pulse voltage.
Speed sensor
1. Connector 3. O-ring
2. Sensor 4. Bolt
Function
• The speed sensor is installed to the transfer
case. As the gear revolves, the speed sensor
generates a pulse voltage and a revolving direc-
tion signal (Counterclockwise: ON).
WA200-5 10-199
Engine oil pressure sensor
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Function
• This sensor is mounted to the engine block. The
diaphragm detects oil pressure, and when it
reaches below the specified value, the switch is
turned ON.
Fuel level sensor
1. Connector 3. Arm
2. Variable resistor 4. Froat
Function
• This sensor is mounted to the side surface of the
fuel tank. The float moves vertically depending
on the remaining quantity of the fuel.
The movement of the float operates the variable
resistor through the arm and sends a signal to
the machine monitor to indicate the remaining
quantity of the fuel.
10-200 WA200-5
Coolant temperature sensor (For monitor)

HST oil temperature sensor
1. Connector
2. Plug
3. Thermistor
Function
• The coolant temperature sensor (for monitor) is
installed to the engine cylinder block and the
HST oil temperature sensor is installed to the hy-
draulic piping of motor 2. They generate ther-
mistor resistance change signals as
temperature change signals.
Coolant temperature sensor (For preheating)
1. Connector
2. Plug
3. Thermistor
Function
• The coolant temperature sensor (for preheating)
is installed to the engine coolant piping. It gen-
erates thermistor resistance change signals as
temperature change signals.
WA200-5 10-201
Axle oil temperature sensor
1. Connector
2. Plug
3. Thermistor
Function
• The axle oil temperature sensor is installed to
the front axle. It generates thermistor resistance
change signals as temperature change signals.
HST oil pressure sensor
1. Sensor
2. Lead wires
3. Connector
Function
• The HST oil pressure sensor is installed to the
solenoid block of motor 2. It measures the oil
pressure in the HST circuit and generates sig-
nals of that pressure.
10-202 WA200-5
Steering oil pressure sensor

(If equipped)
Emergency steering oil pressure sensor
(If equipped)
1. Retainer 5. Case
2. Piston 6. Switch
3. Body 7. Connector
4. Push rod
Function
• The steering oil pressure sensor is installed to
the block of priority valve port P. It measures the
oil pressure in the steering circuit and generates
signals of that pressure.
• The emergency steering oil pressure sensor is
installed to the emergency steering valve. It
measures the oil pressure in the emergency
steering circuit and generates signals of that
pressure.
HST oil filter clogging sensor
1. Terminal
2. Plug
Function
• The HST oil filter clogging sensor is installed to
the HST oil filter. It senses the oil pressures be-
fore and after the filter. If the difference between
the measured pressures exceeds the set level,
the switch is turned ON.
WA200-5 10-203
(3)
Coolant level sensor
1. Float 3. Connector
2. Sensor 4. Sub-tank
Function
• This sensor is mounted to the sub-tank in the
bulkhead. The float lowers to turn off the switch
when the coolant level reaches below the spec-
ified level.
10-204 WA200-5
20 TESTING AND ADJUSTING
Standard value table

Standard value table for engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
Standard value table for chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
Testing and adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201
a Note the following when making judgements using the standard value tables for testing, adjusting, or trouble-
shooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation to
judge if there is a failure.
3. These standard values are not the standards used in dealing with claims
k
When carrying out testing, adjusting, or troubleshooting, stop the machine on level ground, insert the
safety pins, and use chocks to prevent the machine from moving.
k
When carrying out work together with other workers, always use signals and do not let unauthorized
people near the machine.
k
When checking the coolant level, always wait for the coolant to cool down. If the radiator cap is removed
when the coolant is still hot, the coolant will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
WA200-5 20-1
(4)..
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE
Machine Model WA200-5

Engine SAA6D102E-2
Item Measurement Conditions Unit Standard Value For Service Limit Value
New Machine
High idle 2,250 ± 50 -
Revolving Speed Low idle rpm 825 ± 50 -
Rated revolving speed 2,000 -
At sudden acceleration Max. 4.0 Min. 6.0
Exhaust gas color Bosch index
At high idle Max. 0.5 Max. 2.0
Air intake valve 0.25 -
Valve clearance Exhaust valve mm 0.51 -
(Normal temperature)
Oil temperature: 40 - 60°C MPa Min. 2.4 1.69
Compression (SAE15W-40 oil) {kg/cm2} {Min. 24.6} {17.2}
pressure
(Engine speed) (rpm) (250 - 280) (250 - 280)
At high idle
kPa Max. 0.49 Max. 0.98
Blow-by pressure (Coolant temperature: Min. 70°C) {mmH2O} {Max. 50} {Max. 100}
(SAE15W-40 oil)
(Oil temperature: Min. 80°C)
At high idle (SAE15W-40) 340 - 640 245

kPa
Oil pressure {3.5 - 6.5} {2.5}
{kg/cm2}
Min. 150 80
At low idle (SAE15W-40) {Min. 1.5} {0.8}
Oil temperature All revolution range (Inside oil pan) °C 90 -110 Min. 120
Fuel injection timing Before compression top dead center °(deg.) 11 ± 1 11 ± 1
Fan belt tension - - Auto-tensioner -
Air conditioner com- Deflection made by finger pressure of about mm 10 - 15 10 - 15
pressor belt tension 98.1N {about 10kg}
20-2 WA200-5
(4)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Machine model WA200-5

Measurement Standard Value
Category Item Unit Service Limit Value
Conditions For New Machine
• Engine running 61.7 +19.6
N 0
Pressing effort • Measure at 150 mm from ful- 132.4{13.5}
{kg}
crum of pedal {6.3 +20 }
Accelerator
pedal α1 • Engine stopped 50 -
Pressing angle a Detail drawing, See TEST- deg.
α2 ING AND ADJUSTING 31.5 +3
-2 -
Height of stopper L1 mm 52 -
5.9 +5.9
0
N-
13.7 {1.4}
FORWARD {0.6 +0.6
0 }
Operating effort N
{kg} 5.9 +5.9
N- • Engine stopped 0
Directional REVERSE • Measure at 10 mm from top 13.7 {1.4}
lever {0.6 +0.6
0 }
of lever
N-
FORWARD 45 ± 10 40 ± 20
Travel mm
N- 45 ± 10 40 ± 20
REVERSE
7.8 ± 4.9 15.7
F1 - F2 {0.8 ± 0.5} {1.6}
• Engine stopped
Operating effort • Measure at 10 mm from end N 7.8 ± 4.9 15.7
F2 - F3
{kg} {0.8 ± 0.5} {1.6}
of switch knob
Speed
switch (Dial 7.8 ± 4.9 15.7
F3 - F4 {0.8 ± 0.5} {1.6}
switch)
F1 - F2 30 ± 5 30 ± 10
Travel F2 - F3 • Engine stopped deg. 30 ± 5 30 ± 10
F3 - F4 30 ± 5 30 ± 10
• Flat, horizontal, straight, dry
paved road surface
• Engine speed: Low idle
(Bucket empty)
• Hydraulic oil temperature: N 9.8 ± 2.9 Max. 14.7
Operating effort
45 - 55°C {kg} {1.0 ± 0.3} {Max. 1.5}
• Engine coolant temperature:
Operating range
• Tire inflation pressure: Speci-
fied pressure

Steering paved road surface
wheel Low idle • Hydraulic oil temperature: 3.7 ± 0.4 Max. 4.8
45 - 55°C
• Engine coolant temperature:
Operating time Operating range Sec.
fied pressure
High idle • Machine stopped 3.7 ± 0.3 3.7 ± 1
• Steering wheel turning speed:
60rpm
• Engine stopped
Play • Machine facing straight to mm 30 ± 20 Max. 100
front
• α1: Pressing
effort at 0N • Engine coolant temperature: 50 -
Press- {0kg} Operating range
Brake pedal ing • Engine speed: Low idle deg.
angle • α2: Pressing • Detail drawing, See TEST-
effort at 196N ING AND ADJUSTING 35 ± 2 35 ± 4
{20kg}
WA200-5 20-3
(4)..d
12
14.7 +4.9
0
HOLDo 29.4
RAISE {1.5 +0.5 {3}
0 }
18.6 +4.9
0
RAISEo 35.3
HOLD {1.9 +0.5 {3.6}
0 }
12.3 +4.9
0
HOLDo 25.7
LOWER {1.25 +0.5 {2.6}
Lift arm 0 }
LOWERo - -
HOLD
18.6 +4.9
0
LOWERo 35.3
FLOAT N {3.6}
Operating effort
{kg} {1.9 +0.5
0 }
• Engine coolant 21.6 +4.9

0
FLOATo 39.7
temperature: HOLD {4.0}
Operating range {2.2 +0.5
0 }
Work equip- • Engine speed:
ment con- 16.7 +4.9
0
Low idle HOLDo 32.3
trol lever DUMP {3.3}
• Hydraulic oil {1.7 +0.5
0 }
temperature:
60 - 80°C 14.7 +4.9
0
Bucket HOLDo 29.4
TILT {1.5 +0.5 {3}
0 }
18.6 +4.9
0
TILTo 27.9
HOLD {1.9 +0.5 {2.9}
0 }
HOLDo
RAISE 46 ± 9 46 ± 12
Lift arm HOLDo 46 ± 9 46 ± 12

LOWER
Travel LOWERo mm 14 ± 9 14 ± 12
FLOAT
HOLDo
60 ± 9 60 ± 12
DUMP
Bucket
HOLDo
TILT 46 ± 9 46 ± 12
HST stall • Engine coolant temperature: 2,180 ± 100 2,180 ± 200

Hydraulic Operating range
2,070 ± 100 2,070 ± 200
stall • HST oil temperature:
Engine Engine speed rpm
Full stall 60 - 80°C
(HST stall + • Hydraulic oil temperature:
2,060 ± 200 2,060 ± 300
Hydraulic 45 - 55°C
stall)
20-4 WA200-5
(4)
12
• Engine speed: Full speed
• Hydraulic oil temperature:
High pres- 45 -55°C 45.6 ± 1.0 45.6 +1.0
-2.5
sure cut-off • Directional lever: FORWARD
pressure {465 ± 10} {465 +10
• Speed switch: 2ND speed -25 }
• Traction control switch: ON
Low pres-
sure relief • Engine speed: Full speed
pressure • Hydraulic oil temperature: 2.5 +0.2
0 2.5 +0.2
-0.1
(Work 45 -55°C +0.2 +2.0
equipment {25.5 0 } {25.5 -1.0 }
PPC circuit • Directional lever: N
pressure)
When 2.5 +0.2 2.5 +0.2
• Engine speed: brake 0 -1.0
Full speed pedal {25.5 +0.2 +0.2
HST oil • Hydraulic oil releasing 0 } {25.5 -1.0 }
pressure Servo pis-
ton control temperature:
When
oil pressure 45 - 55°C
brake
• Directional Max. 0.6 Max. 0.6
Power train pedal
lever: N {Max. 6} {Max. 6}
(HST) depress-
ing MPa
{kg/
• Hydraulic oil temperature: cm2}
45 - 55°C
• Gear speed selector switch:
1st
Servo pis- • Travel speed control dial: 2.5 +0.2
0 2.5 ± 0.2
ton drive oil "1" on min. side
{25.5 +2.0 {25.5 ± 2.0}
pressure • Directional lever: Measure in 0 }
both forward and reverse
position.
• Measure while driving at full
throttle (Max. speed: 4 km/h).
• Hydraulic oil temperature:

45 - 55°C
Clutch con- • Directional lever: FORWARD 2.5 +0.2
0 2.5 +0.2
-0.1
Transfer trol pres- • Speed switch: 3RD or 4TH
+2.0 +2.0
sure speed {25.5 0 } {25.5 -1.0 }
• Travel at a speed of at least
10km/h
• Engine speed: High idle

20.6 ± 0.7 20.6 ± 2.0
Steering Steering relief pressure • Hydraulic oil temperature:
45 - 55°C {210 ± 7} {210 ± 20}

paved road surface
• Speed when applying brake:
32km/h, braking delay: Within
0.1sec
Performance • Brake pedal operating effort: m Max.12 Max.12
313.8N{32kg}
Wheel • Tire inflation pressure: Speci-
brake fied pressure
• Measure braking distance
• Check by inserting gauge Gauge must not go Gauge must not go

(mounted on machine). - between piston and between piston and
Disc wear plate. plate.
• Thickness of lining mm 1 ± 0.1 Max.0.6
fied pressure
Parking • Flat paved road with 1/5
Performance (11°20') grade - Holds position Holds position
brake
• Machine at operating condi-
tion
Work equip- • Engine speed: High idle MPa 20.6 ± 0.4 20.6 ± 2.0
ment con- Relief pressure • Hydraulic oil temperature: {kg/ {210 ± 4} {210 ± 20}
trol valve 45 - 55°C cm2}
WA200-5 20-5
(4)..d
12
• Engine speed:
High idle
• Hydraulic oil
RAISE 5.5 ± 0.5 Max. 8.2
temperature:
45 - 55°C
• Steering valve:
Neutral
• Apply no load
• Time taken for
Lift arm
work equipment
to rise from
position with
bucket in con- LOWER 3.6 ± 0.5 Max. 4.7
tact with ground
(bottom of
bucket horizon-
tal) to max.
height of lift arm
• Engine speed:
High idle
• Hydraulic oil 2.3 ± 0.3 Max. 3.8
TILT
Speed temperature: Sec.
45 - 55°C
• Steering valve:
Neutral
• Apply no load
Work equip- • Time taken for DUMP 1.4 ± 0.3 Max. 2.5
ment bucket to move
from max. tilt to
max. dump
Bucket • Engine speed:
High idle
• Hydraulic oil
temperature:
45 - 55°C
• Steering valve:
Neutral TILT 1.4 ± 0.3 Max. 2
• Apply no load
• Time taken for
bucket to move
from horizontal
position to max.
tilt
• Bucket no load
• Position of work equip-
Lift arm cyl- ment: Lift arm and bucket
inder Max. 20 Max. 30
in level position
• Engine stopped
Hydraulic drift • Hydraulic oil temperature:
45 -55°C
Bucket cyl- • Stop engine and leave for 5 mm
Max. 20
inder minutes, then measure for Max. 17
15 minutes.
Clearance between bucket 3-5 -

Proximity positioner switch • Hydraulic oil temperature:
switch Clearance between lift arm 45 -55°C
3-5 -
positioner switch
Max. fan speed • Hydraulic oil temperature: rpm 1,350 ± 40 -
Oil pres- 45 -55°C
sure drive
fan MPa
• Hydraulic oil temperature: 15.7 ± 1.6 15.7 ± 2.5
Fan driving pressure {kg/ {160 ± 16} {160 ± 25}
45 -55°C cm2}
20-6 WA200-5
(4)
Tools for testing, adjusting, and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-102

Measuring engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-104
Measuring exhaust gas color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
Adjusting valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-107
Measuring compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-109
Measuring blow-by pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110
Testing and adjusting fuel injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111
Measuring engine oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112
Measuring, testing operating force of accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-113
Adjusting engine stop solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-115
Adjusting engine speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
Testing and adjusting air conditioner compressor belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
Measuring directional lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-117
Testing and adjusting HST oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-118
Measuring clutch control pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-123
Testing and adjusting steering wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-124
Testing and adjusting steering oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-126
Bleeding air from steering circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-128
Testing hydraulic fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-129
Measuring brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130
Testing and adjusting brake pedal linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-131
Measuring brake performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-132
Testing and adjusting accumulator charge pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-133
Measuring brake oil pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-134
Measuring wear of brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-136
Bleeding air from brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-137
Measuring parking brake performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-138
Testing and adjusting parking brake control cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-139
Measuring and adjusting work equipment control lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140
Testing and adjusting work equipment hydraulic pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-141
Testing and adjusting work equipment PPC oil pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-142
Bleeding air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-144
Releasing remaining pressure in hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-145
Testing and adjusting bucket positioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-146
Testing and adjusting of boom kick-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-147
Checking proximity switch actuation display lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-148
Procedure for checking diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-149
Method of connecting T-adapter for HST controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150
Special functions of machine monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-151
Flow of modes and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-152
Pm clinic inspection chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170
k When carrying out testing, adjusting, or troubleshooting, stop the machine on level ground, inset the
safety pins, and use chocks to prevent the machine from moving.
k When carrying out work together with other workers, always use signals and do not let unauthorized
people near the machine.
k When checking the coolant level, always wait for the coolant to cool down. If the radiator cap is removed
when the coolant is still hot, the coolant will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
WA200-5 20-101
(4)..
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or measurement item Symbol Part No. Part Name Q’ty Remarks
1 799-205-1100 Tachometer KIT 1 Digital indication : 6 – 99999.9rpm
Engine speed A
2 795-790-2500 Adapter assembly 1 For 102 engine series
1 799-201-9001 Handy smoke checker 1 Discoloration 0- 70%
Exhaust gas color B Commercially (With standard color)
2 available Smoke meter 1 (Discoloration x 1/10 C Bosch index)
1 795-799-1131 Gear (Cranking tool) 1 For 102 engine series

2 795-799-1950 Lock pin 1
Valve clearance Q
Commercially
4 Filler gauge 1 (Intake: 0.25mm, Exhaust: 0.51mm)
available
A 1 799-205-1100 Tachometer KIT 1 Digital indication : 6 – 99999.9rpm
Compression pressure 1 795-502-1590 Gauge assembly 1 0 – 6.9MPa {0 – 70kg/cm2}
D
2 795-502-1700 Adapter 1 For 102 engine series
Blow-by pressure E 799-201-1504 Blow-by checker 1 0 – 4.9MPa {0 – 500mmH2O}
1 795-799-1131 Gear (Cranking tool) 1 For 102 engine series
Fuel injection timing Q 2 795-799-1950 Lock pin 1
3 795-799-1900 Pin assembly 1
799-101-5002 Analog type hydraulic 1 Pressure gauge:2.5, 5.9, 39.2, 58.8MPa

tester {25, 60, 400, 600kg/cm2}
Engine oil pressure C 1
790-401-2320 Analog type hydraulic 1 Pressure gauge: 0.98MPa {10kg/cm2}
tester
Analog type hydraulic Pressure gauge:2.5, 5.9, 39.2, 58.8MPa
799-101-5002 1
tester {25, 60, 400, 600kg/cm2}
1
790-261-1204 Digital type hydraulic 1 Pressure gauge: 58.8MPa {600kg/cm2}
tester
HST oil pressure C 799-101-5220 Nipple 1 Size: 10 X 1.25 mm
3
07002-11023 O-ring 1
790-301-1730 Joint 1
7 For G 1/4
07000-12014 O-ring 1

tester {25, 60, 400, 600kg/cm2}
1
Clutch control pressure C Digital type hydraulic
790-261-1204 1 Pressure gauge: 58.8MPa {600kg/cm2}
tester
4 799-401-3100 Adapter 1 Size: 02
799-101-5002 1
tester {25, 60, 400, 600kg/cm2}
1
Digital type hydraulic
Steering oil pressure C 790-261-1204 1 Pressure gauge: 58.8MPa {600kg/cm2}
tester
799-101-5220 Nipple 1 Size: 10 X 1.25 mm
3
07002-11023 O-ring 1
A 1 799-205-1100 Tachometer KIT 1 Digital indication : 6 – 99999.9rpm

Hydraulic fan speed, tester {25, 60, 400, 600kg/cm2}
1
oil pressure C Digital type hydraulic
tester
6 799-401-3300 Adapter 3 Size: 04
799-101-5002 1
Accumulator charge tester {25, 60, 400, 600kg/cm2}
C 1
pressure Digital type hydraulic
tester
1 793-605-1001 Brake test KIT 1
2 790-101-1430 Coupler 1
Brake oil pressure K
3 790-101-1102 Pump 1
4 793-463-1100 Stopper 1
20-102 WA200-5
(4)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or measurement item Symbol Part No. Part Name Q’ty Remarks
Wear of brake disc J 799-203-8001 Gauge 1 Mounted on machine
Bleeding air from brake circuit K 4 793-463-1100 Stopper 1

tester {25, 60, 400, 600kg/cm2}
Work equipment hydraulic C 1
pressure 790-261-1204 1 Pressure gauge: 58.8MPa {600kg/cm2}
tester
K 4 793-463-1100 Stopper 1
799-101-5002 1
tester {25, 60, 400, 600kg/cm2}
Work equipment PPC oil C 1
pressure 790-261-1204 1 Pressure gauge: 58.8MPa {600kg/cm2}
tester
K 4 793-463-1100 Stopper 1
Bleeding air C 6 799-401-3300 Adapter 1 Size: 04
Coolant temperature, oil tem- P 799-101-1502 Digital thermometer 1 -99.9 – 1,299°C
perature
79A-264-0021 Push-pull scale 1 0 – 294N {0 – 30kg}
Operating effort H
79A-264-0091 Push-pull scale 1 0 – 490N {0 – 50kg}
Commercially
Stroke, hydraulic drift R available Scale 1
Work equipment speed S Commercially Stopwatch 1

available
Commercially
Voltage, resistance T available Tester 1
799-601-7400 T-adapter assembly 1

1
799-60-7330 Adapter 1 For S-16 (White)
Troubleshooting of sensor U
and wiring harness 2 799-601-9000 T-adapter assembly 1 For DT type connector
3 799-601-9710 T-adapter assembly 1 For HST controller
4 799-601-9720 T-adapter assembly 1 For HST controller
WA200-5 20-103
(4)..d
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

Special tools required
2. Install adapter A2 and connect multi-tachometer
Symbol Part No. Part Name A1.
1 799-205-1100 Tachometer KIT
A
2 795-790-2500 Adapter assembly
k
When installing or removing the measur-
ing equipment, be careful not to touch
any hot parts.
MEASURING HIGH IDLE AND LOW IDLE SPEEDS

a Measure the engine speed under the following
conditions.
• Coolant temperature: Within operating range.
• Hydraulic temperature: 45 - 55°C
3. Start engine, and then measure the engine
1. Remove cap (1) of speed pick-up port. speeds at high idle and low idle.
k
a You should remove water separator (1) for the
ease of work. After installing the adapter, how- When measuring the engine speed, be
ever, install water separator (1) again. careful not to touch any rotating parts or
hot parts.
20-104 WA200-5
(4)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING HST STALL SPEED
k
Dig the bucket into the stockpile to pre-
vent the machine from moving forward.
a Check that the low idle and high idle speeds are
the standard value.
a Check that the engine speed is within the stan-
dard value. If it is not within the standard value,
loosen the linkage and check that there is no
play.
1. Measure the engine speed when the HST is
stalled.
MEASURING HYDRAULIC SPEED

a Check that the low idle and high idle speeds are
the standard value.
a Check that the engine speed is within the stan-
dard value. If it is not within the standard value,
loosen the linkage and check that there is no
play.
1. Start the engine and run at low idle.
2. Operate the work equipment control lever and
operate the cylinder to the end of its stroke.
3. Relieve the cylinder at the end of its stroke and
measure the engine speed at this point.
MEASURING FULL STALL SPEED

• Measure the engine speed when the HST stall
and hydraulic stall (bucket dump end relief) are
carried out at the same time.
a Measure the full stall if the HST stall speed and
hydraulic stall speed are normal.
If either of them shows any abnormality, remove
the problem and carry out the measurement
again.
WA200-5 20-105
(4)..d
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR

Symbol Part No. Part Name

1 799-201-9001 Handy Smoke Checker
B
2 Commercially available Smoke meter
k
When installing or removing the measur-
ing equipment, be careful not to touch
any hot parts.
a When measuring in the field where there is no air

or power supply, use Handy Smoke Checker B1;
when recording official data, use Smoke meter
B2. 2) Connect the probe hose, accelerator switch
plug, and air hose to smoke meter B2.
1. Measuring with Handy Smoke Checker B1 a The pressure of the air supply should be
1) Fit filter paper in tool B1. less than 1.5 MPa {15 kg/cm2}.
2) Insert the exhaust gas intake port into the
3) Connect the power cord to the AC 100 V out-
exhaust pipe.
let.
3) Start the engine and raise the engine coolant
a Before connecting the cord, check that
temperature to the operating range.
the power switch of the smoke meter is
4) Accelerate the engine suddenly run it at high
OFF.
idle, and at the same time operate the han-
dle of Handy Smoke Checker B1 to catch the 4) Loosen the cap nut of the suction pump, then
exhaust gas on the filter paper. fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch of smoke meter B2
ON.
9JF00754
5) Remove the filter paper and compare it with

the scale provided to judge the condition.
6) After completing the measurement, remove
the measuring equipment and return to the
original condition. 6) Start the engine and raise the engine coolant
temperature to the operating range.
2. Measuring with Smoke Meter B2 7) Accelerate the engine suddenly, and at the
1) Insert probe of smoke meter B2 into the out- same time, depress the accelerator pedal to
let port of the exhaust pipe, then secure it to catch the exhaust gas color on the filter
the exhaust pipe with the clip. paper.
8) 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.
9) After completing the measurement, remove
the measuring equipment and return to the
original condition.
20-106 WA200-5
(4)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE


1 795-799-1131 Gear (Cranking tool)
Q 2 795-799-1950 Lock pin
4 Commercially available Filler gauge 9JF00757
1. Remove the air cleaner, then remove all cylinder

head covers (1).
a Remove the bracket above the No. 5 cylin-
der head, too.
3. In this position, adjust the valve clearance of the

valves marked q in the valve arrangement chart.
At the same time, make counter marks on the
crankshaft pulley and timing gear case, then
remove timing pin (3).
TDD00723
2. Remove cap (2), then use gear Q1 to rotate the
crankshaft in the normal direction until timing pin
(3) enters the hole in the gear.
a Push pin (3) lightly while cranking.
a The position where the pin enters is the top
dead center for No. 1 cylinder.
a If it is difficult to check with pin (3) installed to
the flywheel housing, use metallic pin Q2.
a At compression top dead center, the rocker
arm of the No. 1 cylinder moves by hand an
amount equal to the valve clearance.
WA200-5 20-107
(4)..d
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
4. Rotate the crankshaft one more turn in the nor-

mal direction, align the counter marks made in
Step 3, then adjust the valve clearance of the
remaining valves marked Q.
a When adjusting the valve clearance, loosen
locknut (7) of adjustment screw (6), insert
filler gauge Q4 between the valve stem (5)
and rocker arm (4), and adjust the clearance
so that it is a sliding fit. Then tighten the
locknut to hold the adjustment screw in posi-
tion.
3 Locknut: 24± 4 Nm {2.45± 0.41 kgm}
a After tightening the locknut, check the valve

clearance again.
a Firing order: 1 - 5 - 3 - 6 - 2 - 4 Valve clear-
ance
Intake: 0.25 mm
Exhaust: 0.51 mm
BWW10462
20-108 WA200-5
(1)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

Special tools required 5. Set tachometer KIT A1 in position.
a For details, see MEASUREMENT OF
Symbol Part No. Part Name ENGINE SPEED.
A 1 799-205-1100 Tachometer KIT 6. Disconnect fuel cut solenoid connectors (CN-
1 795-502-1590 Gauge assembly E23, E03, E24).
D
2 795-502-1700 Adapter 7. Disconnect the fuel control linkage, secure the
governor lever of the fuel pump at the NO
k
INJECTION position, then crank the engine with
When measuring the compression pres- the starting motor and measure the compression
sure, be careful not to burn yourself on pressure.
the exhaust manifold or muffler, or to get a Measure the compression pressure at the
your clothes caught in the fan, fan belt or point where the pressure gauge indicator
other rotating parts. remains steady.
a When measuring the compression pressure,
measure the engine speed to confirm that it
1. Adjust the valve clearance. is within the specified range.
For details, see ADJUSTING VALVE CLEAR-
a After measuring the compression pressure,
ANCE.
install the nozzle holder assembly.
2. Warm up the engine to make the oil temperature
40 - 60°C.
3. Remove nozzle holder assembly (1) from the cyl-
inder to be measured.
4. Install adapter D2 in the mount of the nozzle

holder, then connect compression gauge D1.
WA200-5 20-109
(4)..d
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

Special tools required Blow-by checker E

E 799-201-1504 Blow-by checker
1 • 799-201-1541 Gauge
2 • 795-201-1571 Tube AJF00336

E
3 • 799-201-1450 Adapter
4 • 795-790-1950 Nozzle
1. When measuring the blow-by, warm up the

engine thoroughly so that the coolant tempera-
ture is at least 70°C.
2. Stop the engine, then install blow-by checker E
to breather hose (1). 3. Run the engine at the rated output, and measure
the blow-by pressure.
a 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. In this case,
the blow-by value will be about 80% of the
value at rated output.
a Blow-by varies greatly according to the con-
dition of the engine. Therefore, if the blow-
by value is considered abnormal, check for
problems connected with defective blow-by,
such as excessive oil consumption, defective
exhaust gas color, and prematurely dirty or
deteriorated oil.
20-110 WA200-5
(4)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING


1 795-799-1131 Gear (Cranking tool)
Q 2 795-799-1950 Lock pin
3 795-799-1900 Pin assembly
1. Testing
1) Using cranking tool Q1, rotate the crankshaft
in the normal direction until timing pin (1)
enters the hole in the gear.
a Highly precise adjustment of the fuel
injection timing is needed, so always
lock the drive gear with the pin when
adjusting the injection timing. 2. Adjusting
a If it is difficult to check with the pin • If the timing pin does not mesh, adjust as fol-
installed to the flywheel housing, it is lows.
possible to use metal lock pin Q2. 1) Remove the fuel injection pump assembly.
For details, see REMOVAL OF FUEL
INJECTION PUMP ASSEMBLY.
2) Rotate the camshaft of the fuel injection
pump, push timing pin (3) and mesh with
timing pin pointer (4).
3) Install the fuel injection pump assembly.
a For details, see INSTALLATION OF
FUEL INJECTION PUMP ASSEMBLY.
a After completing the inspection, remove
the inspection equipment and return to
the original condition.
a After completing the adjustment, remove
the adjustment equipment and return to
2) Remove plug (2), then reverse timing pin (3)
k
and check that pin (3) meshes with timing
pointer (4) on the fuel injection pump. Before starting the engine, check again
a If it is possible to insert the timing pin that you have not forgotten to return tim-
smoothly, the injection timing is correct. ing pin (3) of the drive gear and the timing
a If it is impossible to insert the timing pin, pin of the fuel injection pump to the origi-
the injection timing is not correct, so nal condition.
adjust it.
a If it is difficult to check with the pin
installed to the fuel injection pump, it is
possible to use metal pin assembly Q3.
a After completing the inspection, remove
the inspection equipment and return to
k
Be careful not to forget to return timing
pin (3) of the drive gear and the timing pin
of the fuel injection pump to the original
condition.
WA200-5 20-111
(1)..d
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE


C 2 799-401-2320 Hydraulic tester
k
When measuring, be careful not to let
your clothes get caught in any rotating
part.
k
Always stop the engine before removing
or installing any oil pressure sensor or oil
pressure gauge.
a When measuring the oil pressure, always mea-

sure at the specified oil temperature.
1. Remove engine oil pressure sensor (1).
2. Install tool C2 (Gauge: 1MPa {10kg/cm2}).
3. Start the engine, and measure the engine oil

pressure.
20-112 WA200-5
(1)
TESTING AND ADJUSTING MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL
MEASURING, TESTING OPERATING FORCE OF ACCELERATOR

PEDAL

H 79A-264-0021 Push-pull scale
MEASURING, TESTING OPERATING FORCE OF AJF00341

ACCELERATOR PEDAL
1. Set tool H at a position 150 mm from pedal ful-

crum a.
a Put the center of tool H in contact with a
point 150 mm from the pedal fulcrum.
a Carry out the above inspection, and adjust or

replace parts if necessary. Then carry out
the measurement of the operating effort
AJF00340 again to check that it is within the standard
value.
2. Start the engine, then measure the maximum

value when the pedal is pushed in from the low
idling position to the end of its travel (high idling).
3. Stop the engine.
4. Disconnect cable (1) at the bottom of the accel-
erator pedal, and check that there is no stiffness
in plate (2) or ball joint (3) at the engine end.
WA200-5 20-113
(1)..d
TESTING AND ADJUSTING MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL
12
OPERATING ANGLE OF ACCELERATOR PEDAL
Measuring Adjusting
1. Open the inspection cover of the engine hood.
1. Stop the engine. 2. Set accelerator pedal (1) in the FREE position
2. Measure operating angle a when the pedal is (Bring lever (2) in contact with U-bolt).
operated from the low idling position to the high 3. Adjust cable (4) so that governor lever (3) will be
idling position. in the idling position, and then tighten nuts (5)
Put angle gauge (1) in contact with the accelera- and (6).
3
tor pedal, and measure operating angle α (α =
α1 - α2) when the pedal is operated from low Locknut (5), (6):
idling position α1 to high idling position α2. 44 - 59 Nm {4.5 - 6.0 kgm}
3 Locknut (7):
2.9 - 4.9 Nm {0.3 - 0.5 kgm}
3 Mounting nut (8):

11.8 - 14.7 Nm {1.2 - 1.5 kgm}
4. Adjust stopper bolt (9) so that governor lever (3)

is at the high idling position when accelerator
pedal (1) is depressed.
a Screw in ball joint (10) at least 8 mm.
20-114 WA200-5
(1)
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
ADJUSTING ENGINE STOP SOLENOID

1. Disconnect joint (1) of stop rod (3) from fuel
injection pump stop lever (2).
a Always turn the starting switch OFF before
doing this.
BEW00084
4. If the position of the pin hole is within the stan-

dard value, connect rod (3) and lever (2).
5. Start the engine, then turn the starting switch
OFF and check that the engine stops.
2. Turn the starting switch ON and actuate the sole-
noid.
3. Check that the relationship between the position
of the pin and pin hole is as follows when fuel
injection pump stop lever (2) is operated fully by
hand to the OPERATING position.
• Check that the center (portion A) of the pin
hole of stop rod joint (1) is 1 - 2 mm to the
right of the center (portion B) of the pin of
stop lever (2).
a If it is not within the above measurement,
adjust with rod (3).
C: Play from operating end
D: Stop lever operating end
E: Solenoid at hold position
k
If the above dimension is the oppo-
site, there is a possibility that the
engine stop solenoid has seized.
WA200-5 20-115
(1)..d
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED TESTING AND ADJUSTING

SENSOR AIR CONDITIONER
a If engine speed sensor (1) (CN-E12) or the fly-
COMPRESSOR BELT
wheel have been removed and installed, adjust TENSION
as follows.
Testing
Press a point midway between the fan pulley and the

compressor pulley with a thumb and, and check belt
deflection (a).
• Belt pressing force: 98.0 N {10 kg} or equivalent
• Deflection of belt (a): 10 - 15 mm
1. Open the engine right side cover.

2. Screw in until the tip of engine speed sensor (1)
contacts the tip of the teeth of flywheel ring gear
(2) lightly.
a Check that there are no metal particles or
scratches on the tip of the sensor before
installing.
2
Adjusting
Thread: Gasket sealant (LG-5) a If the deflection is not correct, adjust as follows.
3. Turn engine speed sensor (1) back 1/2 - 1 turns

1. Loosen the mounting bolts (top and bottom: 2
from that point.
each) of compressor bracket (1).
a Adjust clearance a between the tip of the 2. Loosen locknut (2), and use adjustment bolt (3)
sensor and the tip of the gear teeth to 0.75 - to move compressor bracket (1) and adjust the
1.00 mm. belt tension.
4. Hold engine speed sensor (1) in position and 3. Tighten locknut (2).
tighten locknut (2). 4. Tighten the mounting bolts (top and bottom: 2
each) of compressor bracket (1).
5. After adjusting the belt tension, check the belt

tension again.
20-116 WA200-5
(1)
TESTING AND ADJUSTING MEASURING DIRECTIONAL LEVER
MEASURING DIRECTIONAL LEVER


k
Apply the parking brake and put chocks
under the tires.
Operating effort of directional lever
1. Stop the engine.

2. Install push-pull scale H or a spring balance to a
point 10mm from the tip of the control lever, then
measure the operating effort when the lever is
pulled in the direction of actuation.
a Carry out the measurement in each speed
range.
AJF00402
Travel of directional lever
1. Stop the engine.

2. Make mark a on the center of the knob of the
control lever, then measure the travel when the
lever is operated in the direction of actuation.
AJF00403
WA200-5 20-117
(4)..d
TESTING AND ADJUSTING TESTING AND ADJUSTING HST OIL PRESSURE
TESTING AND ADJUSTING HST OIL PRESSURE


Analog type hydraulic
799-101-5002
tester
1
790-261-1204
tester
C Nipple
799-101-5220 (Size 10 X 1.25 mm)
3
07002-11023 O-ring
790-301-1730 Joint (for G 1/4)
7
07000-12014 O-ring
k
Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank. 3) Measure the high-pressure cut-off oil pres-
sure under the following conditions.
a HST oil temperature when measuring: Within i) Lower the bucket to near the ground,
operating range then drive the machine forward and
a The high-pressure relief pressure is the same as thrust the bucket into the stockpile of soil
the safety pressure of the main circuit, so it can- or rock (portion a).
not be measured. (Normally, the cut-off valve is a Set the directional lever in the FOR-
actuated first, so it does not rise to the safety WARD position and the speed
valve set pressure) switch in the 2ND speed position,
and turn the traction control switch
1. Measuring high-pressure cut-off oil pressure ON.
1) Open the engine hood side cover.
2) Install oil pressure gauge C1 (58.8 MPa {600
kg/cm2}) to pressure measurement nipple (1)
or (2).
• Nipple (1): For FORWARD circuit (port:
MA)
• Nipple (2): For REVERSE circuit (port:
MB)
ii) Run the engine at full throttle and push

in until the machine stops moving for-
ward.
k
Carry out the measurement on
hard ground where it is difficult
for the tires to slip.
iii) Keep the engine running at full throttle,

check that the tires are not turning, then
measure the oil pressure.
20-118 WA200-5
(4)
2. Measuring low-pressure relief pressure (basic 3. Measuring servo piston control pressure (DA
pressure of work equipment EPC circuit) pressure)
1) Remove low-pressure relief pressure mea- 1) Remove the floor frame cover (bottom left of
surement plug (4) (10mm, P=1.25mm) from operator's cab).
under the machine. 2) Remove servo piston control pressure mea-
a The oil pressure measurement plug is surement plug (DA pressure) (10mm,
installed near the bottom right of the P=1.25mm).
transfer on the right side of the rear
frame.
3) Install a nipple, then connect oil pressure

gauge C1 (5.9 MPa {60 kg/cm2}).
4) Place the directional lever at N, run the

engine at high idle, and measure the control
3) Place the directional lever at N, run the pressure when the wheel brake pedal is
engine at high idle, and measure the low- depressed and when it is released.
pressure relief pressure. a The brake pedal is connected to the
inching valve and controls the control
pressure.
WA200-5 20-119
(4)..d
4. Measuring servo piston actuating pressure

1) Remove servo piston actuation pressure
measurement plug (6) or (7) (G 1/4) (width
across flats for hexagonal head wrench: 8
mm).
• Plug (6): For FORWARD circuit (port:
X1)
• Plug (7): For REVERSE circuit (port: X2)

3) Measure the servo piston actuating pressure

under the following conditions.
i) Set the speed selector switch in the "1st"
position and set the travel speed control
dial in the "1" position on the lowest
speed side.
ii) Drive with the engine at full throttle
(about 4 km/h) and measure the oil pres-
sure.
a Do not press the brake pedal.
iii) Measure the oil pressure during reverse
travel similarly.
20-120 WA200-5
(4)
Adjusting 2. Adjusting low-pressure relief valve

a If the low-pressure relief pressure is not cor-
a The high-pressure relief pressure is also the rect, adjust the low-pressure relief valve as
safety pressure of the main circuit, so it cannot follows.
be measured. (Normally, the cut-off valve is 1) Remove the engine side cover.
actuated first, so it does not rise to the safety 2) Loosen locknut (12) of low-pressure relief
valve set pressure) valve (11), then turn adjustment screw (13)
1. Adjusting high-pressure cut-off valve to adjust.
a If the high-pressure cut-off pressure is not a Turn the adjustment screw to adjust as
correct, adjust high-pressure cut-off valve (8) follows.
as follows. • To INCREASE pressure, turn
1) Remove the engine side cover. CLOCKWISE.
2) Loosen locknut (9) of high-pressure cut-off • To DECREASE pressure, turn
valve (8), then turn adjustment screw (10) to COUNTERCLOCKWISE
adjust. a Amount of adjustment for one turn of
a Turn the adjustment screw to adjust as adjustment screw: 0.38 MPa {3.9 kg/
follows.
cm2}
• To INCREASE pressure, turn
3) After adjusting, tighten locknut (12).
3
CLOCKWISE.
• To DECREASE pressure, turn Locknut: 69.6 Nm {7.1 kgm}
COUNTERCLOCKWISE.
a Amount of adjustment for one turn of
adjustment screw: 9.1 MPa {93 kg/cm2}
3 Locknut: 37.2 Nm {3.8 kgm}
a After completion of adjustment, repeat

the measurement procedure to check
the low-pressure relief pressure again.
WA200-5 20-121
(1)..d
3. Adjusting DA valve
a If the servo piston control pressure is not correct,
adjust the DA valve as follows.
1) Remove the engine side cover.
2) Loosen locknut (15) of DA valve (14), then
turn adjustment screw (16) to adjust.
a Turn the adjustment screw to adjust as
follows.
• To DECREASE pressure, turn
CLOCKWISE.
• To INCREASE pressure, turn
COUNTERCLOCKWISE
a Amount of adjustment for one turn of
adjustment screw: 0.34 MPa {3.5 kg/
cm2}
3 Locknut: 64.7 Nm {6.6 kgm}
a After completion of adjustment, repeat

the measurement procedure to check
the control pressure again.
20-122 WA200-5
(1)
TESTING AND ADJUSTING MEASURING CLUTCH CONTROL PRESSURE
MEASURING CLUTCH CONTROL PRESSURE


799-101-5002
tester
1
C Digital type hydraulic
790-261-1204
tester
4 799-401-3100 Adapter
AJF00398
k
When removing the measurement plug
and disconnecting the hose, loosen the
oil filler cap slowly to release the pressure
inside the hydraulic tank.
3. Set the speed selector switch to 3rd or 4th, travel
at a speed of at least 10 km/h, and measure the
1. Remove the rear frame left side cover. clutch inlet pressure (clutch solenoid valve out-
2. Disconnect clutch solenoid valve output pressure put pressure).
(clutch inlet pressure) hose (1), then connect oil
pressure gauge C1 (5.9 MPa {60 kg/cm2}) and
C4 (hose size: for # 02).
WA200-5 20-123
(4)..d
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL
TESTING AND ADJUSTING STEERING WHEEL


MEASURING PLAY OF STEERING WHEEL
a 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 mecha-
nism is at the neutral position, then make mark
(A) on the outside frame of the machine monitor.
2. Turn the steering wheel to the right, and make
mark (B) at the position where the operating
effort starts to become heavy.
AJF00371
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 effort becomes heavy
(when the steering valve lever starts to move).
Then measure the distance in a straight line
between marks (B) and (C).
20-124 WA200-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL
MEASURING OPERATING FORCE OF STEERING MEASURING OPERATING TIME FOR STEERING

WHEEL WHEEL
a Measurement conditions a Measurement conditions

• Road surface : Flat, horizontal, dry paved • Road surface : Flat, horizontal, dry paved
surface surface
• Engine coolant : Within green range on • Engine coolant : Within green range on
temperature engine coolant temperature temperature engine coolant temperature
gauge gauge
• Hydraulic oil : 45 - 55°C • Hydraulic oil : 45 - 55°C
temperature temperature
• Tire inflation : Specified pressure • Tire inflation : Specified pressure
pressure pressure
• Engine speed : Low idle (bucket empty) • Engine speed : Low idle and high idle
Measurement method Measurement method
1. Install push-pull scale H to the steering wheel 1. Start the engine.

knob. a After starting the engine, raise the bucket
a Install push-port scale H to the center. approx. 400 mm and remove the safety bar.
2. Start the engine. 2. Operate the steering wheel to the end of its
a After starting the engine, raise the bucket stroke to turn the machine to the left or right.
approx. 400 mm and remove the safety bar. 3. Measure the time taken to operate the steering
3. Pull push-pull scale H in the tangential direction wheel to the end of the stroke to the right or left.
and measure the value when the steering wheel a Operate the steering wheel at about 60 turns
moves smoothly. per minute without using force.
a Stop measuring when the steering wheel a Carry out the measurements both at low idle
starts to move. and high idle, and to both the left and right.
AJF00372 AJF00373
WA200-5 20-125
(4)..d
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING OIL PRESSURE
TESTING AND ADJUSTING STEERING OIL PRESSURE

3. Install nipple C3 and pressure gauge C1 (39.2
Symbol Part No. Part Name MPa {400 kg/cm2}).
799-101-5002
tester
1
790-261-1204
C tester
Nipple
799-101-5220 (Size 10 X 12.5mm)
3
07002-11023 O-ring
a Measuring condition
• Hydraulic oil temperature:45 - 55°C
Method of measuring main relief pressure
1. Fit safety bar (1) to the frame.

4. Start the engine, run the engine at high idle, then
turn the steering wheel to the left or right and
measure the pressure when the relief valve is
actuated.
2. Remove steering circuit pressure pickup plug (2)

(10 mm, P = 1.25 mm).
20-126 WA200-5
(4)
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING OIL PRESSURE
Method of adjusting main relief pressure
1. Stop the engine.

2. Remove the rear frame right inspection cover
and disconnect hose (2) and fitting (3) connected
to port T of the priority valve.
3. Turn adjustment screw (4) to adjust.

a Turn the adjustment screw to adjust as fol-
lows.
• To INCREASE pressure, turn CLOCK-
WISE.
• To DECREASE pressure, turn COUN-
TERCLOCKWISE.
a Pressure adjustment for one turn of adjust-
ment screw: Approx. 6.9 MPa (70 kg/cm2)
a Tool for adjusting adjustment screw: Size 7/
32 inch, hexagonal
a Do not carry out any adjustment if the relief
pressure cannot be measured accurately.
3 Adjustment screw:
2.3 ± 6.8 Nm (0.23 ± 0.69 kgm)
WA200-5 20-127
(1)..d
TESTING AND ADJUSTING BLEEDING AIR FROM STEERING CIRCUIT
BLEEDING AIR FROM STEERING CIRCUIT

a Bleed the air from the circuit as follows if the
steering valve or steering cylinder have been
removed and installed again.
1. Start the engine and run at idling for approx. 5

minutes.
2. Run the engine at low idling and turn 4 - 5 times
to the left and right.
a Operate the piston rod to approx. 100 mm
before the end of its stroke. Be careful not to
relieve the circuit.
3. Repeat Step 2 with the engine at full throttle.
4. Run the engine at low idling and operate the pis-
ton to the end of its stroke to relieve the circuit.
20-128 WA200-5
(1)
TESTING AND ADJUSTING TESTING HYDRAULIC FAN
TESTING HYDRAULIC FAN

Special tools required Measuring oil pressure
1. Open the radiator grill.
A 1 799-205-1100 Tachometer KIT 2. Disconnect hose (1), then connect oil pressure
799-101-5002
Analog type hydraulic gauge C1 (39.2 MPa {400 kg/cm2}) and C6
tester
1 (hose size: for # 04).
C Digital type hydraulic
790-261-1204
tester
6 799-401-3300 Adapter
k
Set the bottom face of the bucket horizon-
tal, lower the bucket completely to the
ground, and put chocks under the tires.
k
When removing the measurement plug
and disconnecting the hose, loosen the
oil filler cap slowly to release the pressure
inside the hydraulic tank.
• Hydraulic oil temperature: 45 - 55°C
Measuring fan speed

1. Open the radiator grill.
2. Install stand [1], probe [2], and reflecting tape [3]
in the tachometer [4] kit, then connect the meter
itself.
Tachometer KIT A1
AJF00407
3. Run the engine at high idle and measure the fan

drive oil pressure.
3. Start the engine, run at high idle, and measure

the fan speed.
WA200-5 20-129
(4)..d
TESTING AND ADJUSTING MEASURING BRAKE PEDAL
MEASURING BRAKE PEDAL

• Engine coolant temperature: Within green range
on engine coolant temperature gauge
• Engine speed: Low idle
Operating effort of pedal
1. Install push gauge (1) to the operator's foot.

a Set the push gauge at a point 150 mm from
the fulcrum of the pedal.
2. Start the engine, and measure pedal angle a1
when running at low idle.
3. Next, put angle meter (2) in contact with the
brake pedal and measure operating angle a from
position α1 to position α2 (α = α1 - α2) when the
pedal is depressed.
• Operating force at α2: 196 N (20 kg).
20-130 WA200-5
(4)
TESTING AND ADJUSTING TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE

Testing
1. Check for play in linkage mounting pin (7), pin-

hole of lever (6), and lever bushing.
2. Measure length of link (a = 184 mm), and check
that it is within the standard value.
a Measure the length from the center of pin (1)
to the center of ball joint (3).
3. Measure the distance of movement of rod (8)
and check that clearance b is within the standard
value.
a When doing this, check that the brake pedal
is in contact with the stopper.
Adjusting
1. Adjusting link length (a)

1) Remove pin (5) and ball joint (3), then
remove rod (1).
2) Loosen locknut (4), then turn yoke (2) and
ball joint (3) to adjust the length.
3) After adjusting the length of link (a), connect
it to the brake pedal.
a Standard values
a = 184 mm
2. Adjusting rod length (b)

1) Loosen locknut (7), turn rod (8) so that the tip
of the rod contacts the booster cylinder pis-
ton, then turn rod (8) back 1/4 turn.
a Movement for 1/2 turn of rod: 0.75 mm
2) Tighten locknut (7) to hold in position.
a Standard values
b = 0 - 0.3 mm
WA200-5 20-131
(1)..d
TESTING AND ADJUSTING MEASURING BRAKE PERFORMANCE
MEASURING BRAKE PERFORMANCE
9JF01100
• Road surface : Flat, horizontal, dry paved
surface
• Travel speed : 35 km/h when brakes are
applied
• Tire inflation : Specified pressure
pressure
• Tire size : 17.5 - 25
• Delay in apply- : 0.1 sec
ing brakes
Measurement method
1. Start the engine and drive the machine.

2. Set the speed selector switch to 4th and drive the
machine.
3. When the travel speed reaches 35 km/h, depress
the left brake pedal with the specified operating
force.
a 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.
4. Measure the distance from the point where the
brakes were applied to the point where the
machine stopped.
a Repeat this measurement three times and
take the average.
20-132 WA200-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE

Special tools required Adjusting
Symbol Part No. Part Name a When the accumulator charge cut-out pressure
799-101-5002
Analog type hydraulic is adjusted, the cut-in pressure also changes in
tester proportion to the ratio of the valve area.
C 1
790-261-1204
tester
1. Loosen locknut (4) of unload relief valve (accu-
mulator charge cut-out valve) (3), then turn
Measuring
adjustment screw (5) to adjust.
a Turn the adjustment screw to adjust as fol-
lows.
k
Put chocks under the tires. • To RAISE pressure, turn CLOCKWISE
• To LOWER pressure, turn COUNTER-
k
CLOCKWISE
Stop the engine, then depress the brake a Pressure adjustment for one turn of adjust-
pedal at least 100 times to release the
ment screw: 1.45 MPa {14.8 kg/cm2}
3
pressure inside the accumulator circuit.
Locknut :
11.8 - 16.7 Nm {1.2 - 1.7 kgm}
1. Remove the rear frame left side cover.
2. Install oil pressure gauge C1 (39.2 MPa {400 kg/ 2. After adjusting, tighten locknut (4).
cm2}) to measurement nipple (1).
a After completion of adjustment, repeat the

3. Measure the accumulator charge cut-in pres- measurement procedure given above to
sure. Start the engine, run the engine at low idle, check the accumulator cut-in pressure and
and measure the oil pressure when the brake cutout pressure again.
pressure warning lamp on the monitor panel
goes out.
• Cut-in pressure:5.9 +0.2 +2
0 MPa {60 0 kg/cm }
2
4. Measure the accumulator charge cut-out pres-

sure. After the accumulator charge cut-in is actu-
ated, measure the oil pressure when the
indicator of the oil pressure gauge has risen and
suddenly starts to drop.
• Cut-out pressure:9.8 +0.98 +10 2
0 MPa {100 0 kg/cm }
WA200-5 20-133
(4)..d
TESTING AND ADJUSTING MEASURING BRAKE OIL PRESSURE
MEASURING BRAKE OIL PRESSURE


1 793-605-1001 Brake test KIT
2 790-101-1430 Coupler
K
3 790-101-1102 Pump
4 793-463-1100 Stopper
• Engine coolant temperature: Within green
range on engine coolant temperature gauge
• Brake pressure: 4.1 MPa (42 kg/cm2)
k
Apply the parking brake and put chocks 6. Tighten the bleeder screw, operate pump K3,
under the tires.
raise the pressure to 4.1 MPa (42 kg/cm2), then
close stop valve (1).
Measuring
1. Raise the lift arm, set support [1] or lift arm drop
prevention stopper K4 in position, then remove
front cover (1).
k
When leaving the operator's seat, apply
the safety lock lever to the work equip-
ment control levers securely.
7. After applying the pressure, leave for 5 minutes

and measure the drop in the pressure.
9JF00773 a If the hose is moved while measuring the
pressure, the pressure will change, so do not
move the hose.
a After testing, operate pump K3 to lower the
pressure of the brake circuit, then remove
brake test kit K1.
a After completing the inspection, install the
2. Stop the engine. brake tube, then bleed the air from the brake
3. Remove brake tube (2) on the side to be mea- circuit.
sured, then remove nipple (3).
4. Set brake test kit K1 in position, then connect
pump K3 with coupler K2.
5. Loosen bleeder screw (4) and bleed the air.
a Operate pump K3 to bleed the air.
20-134 WA200-5
(4)
TESTING AND ADJUSTING MEASURING BRAKE OIL PRESSURE
Brake test tool
WA200-5 20-135
(1)..d
TESTING AND ADJUSTING MEASURING WEAR OF BRAKE DISC
MEASURING WEAR OF BRAKE DISC

Special tool required

799-203-8001
J (Tool mounted on Gauge
vehicle)
k
Park the vehicle on level ground and lock
the tires with chocks.
1. Remove inspection plug (1).
2. Depress the brake pedal to the stroke end.
3. Insert gauge J between piston (2) and the claw of

plate (3) through the inspection hole.
a If gauge J go between the piston and plate,
the brake disc is worn more than the limit. In
this case, replace the brake disc.
a For the procedure for replacing the brake
disc, see DISASSEMBLY AND ASSEMBLY,
Disassembly, assembly of differential
assembly.
4. Tighten the inspection plug.
3 127 - 177 Nm {13 - 18 kgm}
20-136 WA200-5
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
BLEEDING AIR FROM BRAKE CIRCUIT

3. Depress the brake pedal, then loosen the
Symbol Part No. Part Name bleeder screw and bleed the air.
K 4 793-463-1100 Stopper a Tighten the bleeder screw, then release the
brake pedal slowly.
k
a Add brake oil when necessary during the
Stop the machine on horizontal ground operation to keep the brake oil tank full.
and put blocks under the tires. 4. Repeat this operation, and when no more bub-
bles come out with the fluid from the hose,
a If equipment in the brake circuit has been
depress the pedal fully and tighten the bleeder
removed and installed, bleed the air from the
screw while the oil is still flowing.
brake circuit as follows.
a Repeat the operation to bleed the air from
a Use the same procedure for both the front brake
the other cylinders, and after completing the
circuit and rear brake circuit (2 places each).
operation, check the level in the oil tank and
add more oil if necessary.
1. Raise the boom, set support [1] or boom drop
prevention stopper K4 in position, then remove a To bleed the air completely, bleed the air first
front cover (1). from the cylinder, which is farthest from the
brake pedal.
a After bleeding the air, carry out a brake per-
formance test, then bleed the air again and
check that there is no air in the circuit.
9JF00773
k
Always be sure to apply the safety lock to
the work equipment control lever.
2. Remove the cap, insert vinyl hose (1) into

bleeder screw (2), and insert the other end in a
container.
WA200-5 20-137
(1)..d
TESTING AND ADJUSTING MEASURING PARKING BRAKE PERFORMANCE
MEASURING PARKING BRAKE PERFORMANCE

• Tire inflation : Specified pressure
pressure
• Road surface : Flat, dry paved road surface
with slope of 1/5 grade
(11°20').
• Machine : Operating condition
Measurement method
1. Start the engine, set the machine facing in a

straight line, then drive the machine up a 1/5
grade slope with the bucket empty.
2. Depress the brake, stop the machine, set the
directional lever to the neutral position, then stop
the engine.
3. Set the parking brake lever to PARKING, then
gradually release the brake pedal and check that
the machine is held in position.
a Carry out the measurement in two ways:
Once with the machine facing uphill, and
once more with the machine facing downhill.
20-138 WA200-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE
TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE

Special tool required
5. Install clevis pin (3) and tighten locknut (2).
3
H 79A-264-0021 Push-pull scale Locknut:
5.9 - 9.8 Nm {0.6 - 1.0 kgm}
Testing
a After finishing the adjustment, pull the park-
k
Apply the parking brake and lock the tires ing brake lever with the force of 294 - 392 N
with chocks. {30 - 40 kg} again and check that it is pulled
by 7 teeth.
1. Install push-pull scale H in the range of (a) from

the end of parking brake lever (1) (excluding the
button) and pull the parking brake lever with the
force of 294 - 392 N {30 - 40 kg}.
• (a): 55 mm
2. If the parking brake lever is pulled by 8 teeth or

more, check the fixing parts of the parking brake
control cable (on both lever side and brake side)
for looseness. If the fixing parts are loosened,
tighten them, and then perform the following
adjustment.
Adjusting
1. Release the parking brake.

a Check that the pawl of the parking brake
lever is at the lowest position.
2. Loosen locknut (2) and remove clevis pin (3).
3. Pull parking brake lever (4) on the transfer side in

the release direction. (Add the play of the park-
ing brake lever to the upper side, however.)
4. Under the above condition, tighten clevis (5) to

match its hole to the hole of parking brake lever
(4).
WA200-5 20-139
(7)
(1)..d
TESTING AND ADJUSTING MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL

LEVER

a Measuring condition
• Engine coolant temperature: Operating range of
engine coolant thermometer
• Engine speed: Low idling
k
Install the safety bar to the frame.
Measurement
1. Operating effort of work equipment control lever 2. Travel of work equipment control lever
1) Install tool H to the work equipment control 1) Measure the travel at each position when
lever and secure it in position. operating the work equipment control lever.
a Install tool H to the center of the knob. a Mark the lever knob and use a scale to
a Operate the control lever at the same measure.
speed as for normal operations, and a If the stroke is not within the standard
measure the minimum value for the value, check for play in the linkage and
effort needed to operate the knob. wear of the bushing.
a The following photo shows an example a The following photo shows an example
of the mono type, which is measured of the mono type, which is measured
similarly. similarly.
20-140 WA200-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC

PRESSURE

799-101-5002
tester
C 1
790-261-1204 tester
K 4 793-463-1100 Stopper 9JF00773
Measuring condition
k
the pressure inside the hydraulic tank,
1. Remove cap nut (2) of relief valve (1).
then operate the control levers several
times to release the remaining pressure
2. Loosen locknut (3) of relief valve (1), then turn
in the hydraulic piping.
adjustment screw (4) to adjust.
a Turn the adjustment screw to adjust the set
Measuring pressure as follows.
• TIGHTEN to INCREASE pressure
1. Install tool C1 (39.2 MPa {400 kg/cm2}) to the oil • LOOSEN to DECREASE pressure
pressure measurement nipple. a Pressure adjustment for one turn of adjust-
ment screw: Approx. 2.43 MPa (Approx.
24.8 kg/cm2)
a Do not carry out any adjustment if the relief
pressure cannot be measured accurately.
2. Start the engine, raise the lift arm approx. 400

mm, run the engine at high idle, then operate the
control lever to tilt back the bucket, and measure
the pressure when the relief valve is actuated.
Adjusting
a Always stop the engine before adjusting the oil

pressure.
k
When carrying out the operation with the
lift arm raised, set support (1) or lift arm
drop prevention stopper K4 in position
before starting the operation.
WA200-5 20-141
(4)..d
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL

PRESSURE
Special tools required Measuring
Symbol Part No. Part Name 1. Measuring PPC valve basic pressure
Analog type hydraulic 1) Remove oil pressure pickup plug (3) (10 mm,
799-101-5002
tester P = 1.25) from the underside of the PPC
1
790-261-1204
Digital type hydraulic accumulator.
C tester a The PPC accumulator is installed near
799-101-5220 Nipple the right bottom of the transfer on the
3 (Size 10 X 1.25 mm)
right side of the rear frame.
07002-11023 O-ring
K 4 793-463-1100 Stopper
Measuring condition
k
the pressure inside the hydraulic tank.
Then operate the control levers several
times to release the pressure in the pip-
ing.
k
Except for measuring the oil pressure,
2) Fit a nipple C3, then install oil pressure
when carrying out preparatory operations
with the lift arm raised, set support [1] or gauge C1 (5.9 MPa {60 kg/cm2}).
lift arm drop prevention stopper K4 in
position before starting the operation.
9JF00773
3) Set the directional lever in the N (Neutral)

position, run the engine at high idle, and
measure the low relief pressure.
k
When leaving the operator's seat, apply
the safety lock lever to the work equip-
ment control levers securely.
20-142 WA200-5
(4)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE
2. Measuring PPC valve output pressure

1) Remove the inspection cover of the front
frame.
2) Remove PPC output pressure measure-
ment plug (4) of the circuit to be measured,
then install oil pressure gauge C1 (5.9 MPa
{60 kg/cm2}).
a A: Bucket TILT
B: Bucket DUMP
C: Boom RAISE
D: Boom LOWER
a The 3-spool valve having an additional
spool for the front attachment is used as
standard for the PT specification.
WA200-5 20-143
(1)..d
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
Special tools required 3. Bleeding air from cylinders
1) Start the engine and run at idling for approx.
Symbol Part No. Part Name 5 minutes.
C 6 799-401-3300 Adapter 2) Run the engine at low idling, then raise and
lower the lift arm 4 - 5 times in succession.
1. Bleeding air from fan motor circuit a Operate the piston rod to a point approx.
1) Open the radiator grill, then remove cover 100 mm before the end of its stroke. Do
(1). not relieve the circuit under any circum-
stances.
3) Run the engine at full throttle and repeat
Step 2). After that, run the engine at low
idling, and operate the piston rod to the end
of its stroke to relieve the circuit.
4) Repeat Steps 2) and 3) to bleed the air from
the bucket and steering cylinders.
a When the cylinder has been replaced,
bleed the air before connecting the pis-
ton rod.
2) Disconnect hose (2) at the inlet port of the

motor, then fit tool C6 and connect air bleed
hose [1].
3) Start the engine, and when oil comes out

from air bleed hose, stop the engine and
remove the air bleed hose.
2. Bleeding air from work equipment PPC circuit

1) Operate each work equipment lever fully and
hold it in position to relieve the circuit for
approx. 1 minute. Carry out this operation
once for each work equipment lever stroke
end.
20-144 WA200-5
(1)
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT

1. Releasing remaining pressure between each
hydraulic cylinder and control valve.
a If the piping between the hydraulic cylinder
and the control valve is to be disconnected,
release the remaining pressure from the cir-
cuit as follows.
1) Stop the engine.
2) Loosen the oil filler cap slowly to release the
pressure inside the tank.
3) Operate the control levers.
a When the levers are operated 2 - 3
times, the pressure stored in the PPC
accumulator is removed. Start the
engine, run at low idling for approx. 5
seconds to charge the accumulator, then
stop the engine and operate the control
levers.
a Repeat the above operation 2 - 3 times
to release all the remaining pressure.
2. Releasing remaining pressure in brake accumu-

lator circuit
a If the piping between the ACC charge valve
and brake accumulator, between the ACC
charge valve and parking brake valve, and
between the accumulator and brake valve is
to be disconnected, release the remaining
pressure from the circuit as follows.
1) Stop the engine.
2) Depress the brake pedal at least 100 times
to release the pressure inside the brake
accumulator circuit.
3. Releasing remaining pressure in PPC accumula-

tor circuit
a If the piping between the PPC accumulator
and PPC valve is to be disconnected,
release the remaining pressure from the cir-
cuit as follows.
1) Operate the control lever 2 - 3 times to
release all the remaining pressure from the
circuit.
WA200-5 20-145
(1)..d
TESTING AND ADJUSTING TESTING AND ADJUSTING BUCKET POSITIONER
TESTING AND ADJUSTING BUCKET POSITIONER

a Engine coolant temperature: Operating range of 2) Adjust and secure clearance a between the
engine coolant thermometer sensitive surface of proximity switch (1) and
a Hydraulic oil temperature: 45 - 55 °C sensing bar (2) to the standard range with
a The machine of the PT specification has the fork the shim and mounting bolt of the proximity
positioner at the side of the bucket positioner. switch bracket.
Test and adjust the fork positioner similarly to the a Clearance a: 3 - 5 mm
bucket positioner. a Adjust sensing bar (2) with the shim so that
clearance a will be in the standard range
Testing through the stroke of the sensing bar.
1. Stop the engine and check that clearance a 2. Adjusting installing position (stopping position).
between proximity switch (1) and sensing bar (2) 1) Lower the bucket to the ground and set it to a
is in the standard range. desired digging angle, then return the lever
a Clearance a: 3 - 5 mm to the holding position and stop the engine.
2) Loosen 2 mounting bolts (5) and adjust the
position of switch protector (3) so that the rear
end of sensing bar (2) will be at the center of
the sensitive surface of proximity switch (1),
and then tighten 2 mounting bolts (5).
3) Check again that clearance (a) between
proximity switch (1) and sensing bar (2) is
3 - 5 mm.
• The installing position may be checked
by checking the operation of the pilot
lamp of the proximity switch with the
starting switch at the ON position.
(When the pilot lamp goes off, the bucket
stops.)
2. Run the engine at low idling and check the oper-

ating point. (Measure 3 times and obtain the
average.)
Adjusting
1. Adjusting clearance.
1) Adjust and secure clearance b between the
tip of switch protector (3) and the sensitive
surface (1) of the switch to the standard
range with switch nuts (4).
a Standard clearance b: 0.5 - 1.0 mm
3 Mounting nut:
14.7 - 19.6 Nm {1.5 - 2.0 kgm}
a After adjusting, start the engine and operate

the bucket control lever to check that the
bucket positioner operates at the desired
position.
20-146 WA200-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING OF BOOM KICK-OUT
TESTING AND ADJUSTING OF BOOM KICK-OUT

Testing 3. Adjust the switch so that clearance b between
the sensing surface of the switch and plate (2) is
1. With the engine stopped, check that clearance a the standard value, then secure in position.
3
between switch (1) and plate (2) is the standard
value. Switch mounting nut:
a Clearance a: 3 - 5 mm 14.7 - 19.6 Nm {1.5 - 2.0 kgm}
a After adjusting, operate the work equipment

and check that the boom kickout is actuated
at the desired position.
a Standard clearance b: 3 - 5 mm
2. Start the engine, run at high idling, and check the

actuation point.
(Check three times and take the average.)
Adjusting
1. Raise the boom to a desired height.
k
Always be sure to apply the safety lock to
the work equipment control lever.
2. Loosen 2 bolts (3) and adjust the position of the

plate so that the center of switch (1) will be at the
lower end of plate (2), and then tighten bolts (3).
AJF00395
WA200-5 20-147
(1)..d
TESTING AND ADJUSTING CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP
CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP

Proximity switch actuation display lamp (red)
A display lamp is installed to the proximity switch to

show the actuation status, and so use this when
adjusting.
• A: Actuation display lamp (red)
Relative position
Proximity of detector and Actuation
switch detection sur- display Remarks
face of proximity lamp
switch
In contact ON Actuated
Bucket when center
positioner Separated OFF of switch
approaches
In contact ON Actuated
Boom when center
kick-out Separated OFF of switch sep-
arates
20-148 WA200-5
(1)
TESTING AND ADJUSTING PROCEDURE FOR CHECKING DIODE
PROCEDURE FOR CHECKING DIODE

a Use the following procedure to check the central-
ized diode (8-pin) and theindividual diode (2-pin).
a The direction of continuity of the individual diode
is marked on the surface of the diode as shown
in the diagram below.
9JF00635
2. When using analog tester

1) Set to the resistance range.
2) When doing the following, check the deflec-
tion of the indicator.
i) Put the red (+) end of the test pin in con-
tact with the anode (P) of the diode, and
the black (-) end in contact with the cath-
ode (N).
ii) Put the red (+) end in contact with the
cathode (N) and the black (-) end of the
test pin in contact with the anode (P) of
the diode.
3) Judge the condition of the diode from the
deflection of the indicator.
• If the indicator does not deflect in Step i),
but it deflects in Step ii): Normal (note
1. When using digital tester that the amount of the deflection (resis-
1) Switch to the diode range and check the distance value) differs according to the type
play value. of tester and the selection of the mea-
a With a normal tester, the internal battery surement range.)
voltage is displayed.
• If the indicator deflects in both Step i)
2) Put the red (+) end of the test pin in contact and Step ii): Defective (internal short cir-
with the anode (P) of the diode, and the cuit)
black (-) end in contact with the cathode (N),
• If the indicator does not deflect in either
and check the display.
Step i) or Step ii): Defective (internal dis-
3) Judge the condition of the diode from the dis-
connection)
play value.
• Display value does not change: No conti-
nuity (defective)
• Display value of changes: There is conti-
nuity (normal) (see a)
a In the case of silicon diodes, a value
between 460 and 600 is displayed.
WA200-5 20-149
(1)..d
TESTING AND ADJUSTING METHOD OF CONNECTING T-ADAPTER FOR HST CONTROLLER
METHOD OF CONNECTING T-ADAPTER FOR HST CONTROLLER

a T-adapter for HST controller

799-601-9710 T-adapter
U 3
799-601-9720 T-adapter
a When carrying out troubleshooting for the elec-

tric circuit of the HST controller, connect T-adapt-
ers according to the following procedure.
1. Remove cover (1).
2. Using hexagonal wrench [1], disconnect connec-

tor L80 of the KOMTRAX controller.
4. Connect T-adapters U3 to disconnected connec-
tors L41 and L42.
3. Disconnect connectors L41 and L42 from the

HST controller.
1) Insert a flat-head screwdriver in slide bar (a) 5. Connect connector L80 of the KOMTRAX con-
of connector L41 and slide the slide bar. troller and tighten the screw to the specified
torque.
3
a Slide the slide bar until it is locked.
a The slide bar is made of plastics. Take Screw: 2.82 Nm {0.288 kgm}
care not to damage it with an excessive
force.
2) Disconnect connector L41.
a Similarly, disconnect connector L42.
20-150 WA200-5
(1)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR
SPECIAL FUNCTIONS OF MACHINE MONITOR

Normal functions and special functions of machine monitor
The machine monitor is equipped with normal functions and special functions.
Various items of data are displayed on the character display in the middle of the machine monitor. Depending on
the internal setting of the machine monitor, the display items are divided into automatic display items and items dis-
played when the machine monitor switches are operated.
1. Normal functions: Operator mode

Functions for which the content is normally displayed or which can be used displayed and operated by the
operator operating the switches.
2. Special functions: Service Mode
Functions which the serviceman can display and operate with the special switches to carry out inspection,
maintenance, and troubleshooting.
o
Operator mode Service mode
i
1 Service meter, time display (Load meter specification) 8 Electrical system fault history display function
2 Odometer display function 9 Mechanical system fault history display function
3 Filter replacement, oil change interval display function 10 Machine data monitoring function
4 Language selection function 11 Filter replacement, oil change interval display function
5 HST selection function 12 Option selection function
6 Action code display function 13 Initialize function
7 Failure code display function
WA200-5 20-151
(4)..d
TESTING AND ADJUSTING FLOW OF MODES AND FUNCTIONS
FLOW OF MODES AND FUNCTIONS
9JF01244
20-152 WA200-5
(1)
9JF00815
WA200-5 20-153
(1)..d
9JF00816
20-154 WA200-5
(1)
Operator mode
a The display is given endlessly when the [>], [<], [U], or [t] switches are operated.
a If a failure occurs, the screen switches automatically to the [Action code display function], regardless of the
screen being displayed.
a If the switches are not operated for more than 30 seconds, the screen switches automatically as follows
regardless of the screen being displayed.
• If there is no failure, the display switches to the [Service meter (time display) function].
• If there is a failure, the display switches to the [Action code display function].
Service mode
a The switching of each function occurs endlessly when the [>], [<], [U], or [t] switches are operated.
a Once the ID is input, it remains effective until the starting switch is turned OFF.
Character display
Sixteen characters can be displayed on the character
display. A combination of numerals, letters, and
symbols can be used for the display.
1. Numerals: 1, 2, 3, . . .
AJF00355
2. Lower case letters: a, b, c, . . .
3. Upper case letters: A, B, C, . . .
4. Japanese katakana:
5. Symbols: @, Y, $, . . .
6. Special characters
Operator mode operation and displays
1. Service meter, time display function

When the starting switch is turned ON, the dis-
9JF00693 play shows the service meter.
9JA04377
Operating switches
The display operations on the machine monitor are
all carried out with machine monitor mode selector
switches (1) and (2).
The following functions are set for the button for each
switch.
1. [U]: Execute, select

2. [t]: Cancel, enter (YES/NO screen only)
3. [>]: Right, next
4. [<]: Left, back
WA200-5 20-155
(4)..d
2. Odometer display function

From the normal service meter display screen or
action code display, press the [U] switch to dis-
play the odometer.
9EA04420
9AJ04378
ii) When the [U] switch is pressed, each

item is displayed, then the change interval
is displayed in the center and the related
number of times of replacement is dis-
played in turn on the right side.
3. Filter replacement and oil change interval display iii) Use the [>] or [<] switch to select the item
function to be reset.
1) Filter replacement and oil change interval
display (automatic display)
When the starting switch is turned ON (after
completion of the system check), but display
is given for approx. 30 seconds for the filters
and oil that are near the time for replacement 9EA04421
or change. At the same time, the mainte-
nance warning lamp also flashes or lights up
to advise the operator to carry out mainte-
nance.
iv) When the [U] switch is pressed, the reset

item and item to be reset are displayed.
a When resetting the replacement
interval, use the [>] or [<] switch to
9EA04415 select YES, then press the [t]
switch. The item is reset and the
screen returns to the previous
screen. (If the item is not to be reset,
select NO, then press the [t] switch.
The screen returns to the previous
screen. )
2) Resetting change interval

If the maintenance for each filter or oil has
been completed, operate the switch to reset
the time.
i) Press the [U] switch to display the 9EA04422
odometer, then press the [>] or [<] switch
to display [Maintenance monitor].
v) When the resetting the time for other

items, repeat the procedure from Step ii).
a To complete the operation, press the
[t] switch twice or turn the starting
switch OFF.
20-156 WA200-5
(4)
4. Language selection function

1) Press the [< >] switch to display the odome- 4) After selecting the language, press the [U]
ter, then press the [>] or [<] switch to display switch.
[Language selection]. a To complete the operation, press the [t]
switch twice or turn the starting switch
OFF.
9EA04423
(The following explanation is for when the

display is in Japanese)
(For European languages, the language
table is deleted: see separate explana-
tion)
2) When the [U] switch is pressed, the present
language is displayed.
3) Use the [>] or [<] switch to select the lan-
guage.
9EA04424
• The available languages are English, and

Japanese, German, French, Italian, Spanish,
and Swedish.
WA200-5 20-157
(1)..d
5. HST selector function 6. Action display function

1) Press the [U] switch to display the odome- If an abnormality occurs on the machine, the
ter, then press the [>] or [<] switch to display action code is displayed automatically depending
[HST selection]. on the level of the abnormality to advise the
operator to carry out the applicable action.
a The sketch below shows an example of
action code [E03 CALL] and [Perform main-
tenance immediately] shown in turn.
9EA04425
9EA04409
2) When the [U] switch is pressed, the present

HST selection is displayed.
3) Use the [>] or [<] switch to select either A or
B.
4) After selecting, press the [t] switch. a Action codes and remedy recommended to oper-
The HST selection is set and the screen ator
returns to the previous screen.
Action CALL Content of advice to operator
code
• Return switches and levers for control
E00 No
switch to normal condition
• Carry out maintenance after completion

E01 No of operation or when operators change
shift
9JA04426
• When overrun related display is given,
reduce engine speed and machine
speed and continue operation
E02 No
• When overheat related display is given,
stop machine and run engine at a mid-
range speed under no load
• Start engine and machine immediately

E03 Yes
a To complete the operation, press the [t] and contact serviceman
switch twice or turn the starting switch
OFF.
20-158 WA200-5
(1)
7. Failure code display function

If an action code is being displayed, press the [>]
switch to display the failure code for the existing
failure.
a The failure codes detected in the past are
divided into failures of the electrical system
and the mechanical system, and are
recorded as fault history. (For details, see
Service mode)
a With the failure code display function, the fol-
lowing information is displayed.
"Failure code + Controller code (on right
side) which sensed failure code" and "Sys-
tem having trouble" are displayed alter-
nately.
Code on right side:
MON o Machine monitor
HST o HST controller
9JA04414
a When there are multiple failures, press the

[>] switch to display the other failure codes.
a After pressing the [>] switch to display or the
failure codes for existing failures, press the
[>] switch to return to the service meter dis-
play screen.
a For details of of the failure code is displayed,
see [Failure code list].
WA200-5 20-159
(4)..d
Failure code table
Failure Location of Failure Action

Code (Location, component with failure) Nature of Failure (Problem, nature of failure) Controller code
(HST controller related)
989F00 HST Motor protection caution Actuated (00) HST E00
DHH1KX HST oil pressure sensor Input signal outside range (KX) HST E03
Engine revolution sensor (Speed signal mis-
DLE2LC *See separate table (LC) HST E03
match) (LC)
DW26KZ Motor 2 solenoid system Disconnection or short circuit (KZ) HST E03
DX19KZ Motor 1 solenoid system Disconnection or short circuit (KZ) HST E03
DX20KZ Clutch solenoid system Disconnection or short circuit (KZ) HST E03
(Monitor related)
15B0NX HST oil filter Clogging (NX) MON E01
2G42ZG Brake pressure Drop in oil pressure (ZG) MON E03
989F00 HST motor protection caution Actuated (00) MON E00
989FN1 HST overrun Overrun (N1) MON E02
AA1ANX Unused on this machine
AB00L6 Battery charging circuit (Alternator terminal R *See separate table (L6) MON E03
signal detected when engine stopped)
Battery charging circuit (No signal from alterna-
AB00MA Function impossible (MA) MON E03
tor terminal R, Abnormal detection)
B@BAZG Engine oil pressure Drop in oil pressure ((ZG) MON E01
B@BAZK Unused on this machine
B@BCNS Engine coolant temperature Overheat (NS) MON E02
B@BCZK Radiator coolant level Drop in level (ZK) MON E01
B@C7NS Axle oil temperature Overheat (NS) MON E02
B@CRNS HST oil temperature Overheat (NS) MON E02
D5ZHL6 Starting switch "C" (IGN "C" abnormal input sig- *See separate table (L6) MON E01
nal)
DAF0KT Controller Abnormally inside controller (KT) MON E03
DAJ0KR HST controller (Communication shut-down) Defective communication (Abnormally in applica- MON E03
ble component system) (KR)
Monitor panel mode selector switch 1 [t] (Panel
DD15LD switch 1) input error *See separate table (LD) MON E01
Monitor panel mode selector switch 1 [U] (Panel

DD16LD switch 2) input error *See separate table (LD) MON E01
DD17LD Monitor panel mode selector switch 2 [<] (Panel *See separate table (LD) MON E01
switch 3) input error
DD18LD Monitor panel mode selector switch 2 [>] (Panel *See separate table (LD) MON E01
switch 4) input error
DDK3KB Deretional lever F and R signals same time input Short circuit (KB) MON E03
DDS5L6 Steering oil pressure drop *See separate table (L6) MON E03
DGE2KX Engine coolant temperature sensor (High tem- Input signal outside range (KX) MON E01
perature) system abnormal
Engine coolant temperature sensor (Low tem-
DGE3L6 *See separate table (L6) MON E01
perature) system abnormal
DGH1KX HST oil temperature sensor system abnormal Input signal outside range (KX) MON E01
DGR4KA Axle oil temperature sensor system abnormal Disconnection (KA) MON E01
DGR4KX Axle oil temperature sensor system abnormal Short circuit (KB) MON E01
DHE4L6 Engine oil pressure sensor disconnect *See separate table (L6) MON E01
20-160 WA200-5
(4)
*Separate table: Detailed phenomena of problem code (L*)
Problem code Nature

L0 Fill signal ON 2 or more channels for clutches not forming a set are input at same time
L1 Fill signal is ON when command current to ECMV is OFF
L2 Fuel pressure is greater than maximum specified value
L3 Corresponding component cannot be controlled
L4 ON/OFF signals for 2 systems do not match
L5 Potentiometer signal and switch signal do not match
L6 Engine speed signal, terminal C signal, signals for oil pressure switch, coolant temperature, etc. do not match operat-
ing condition or stopped condition of machine
L8 Analog signals for 2 systems do not match
LC Speed signals for 2 systems do not match
LD Switch has been kept pressed for abnormally long time
LH Fill signal is OFF when command current to ECMV is ON
WA200-5 20-161
(4)..d
Procedure for switching to Service Mode and

screen display
a When using Service Mode, carry out the follow-
ing special operation to switch the screen dis-
play.
1) Checking screen display 9JF00712

With the machine monitor in the operator mode,
check that the screen is one of the following dis-
plays: Service meter, action code, or failure
code.
2) Initial screen display for ID input

Press the following 2 buttons at the same time
for at least 5 seconds to display the initial screen
4) Displaying menu initial screen
display for the ID input.
After all four digits of the ID are confirmed, the
• [t] button and [<] button menu initial screen of Service Mode is displayed.
a If the buttons are held pressed for at least 5 a Once the ID has been input and confirmed, it
seconds, the whole screen will give no dis- remains effective until the starting switch is
play, so check that the screen gives no dis- turned OFF.
play, then release the buttons.
9JF00713
9JF00711
3) Inputting, confirming ID
Operate the buttons to input the ID.
a ID: 6491
• [>] button: Number at cursor goes up.
• [<] button: Number at cursor goes down.
• [U] button: Number at cursor is confirmed.
• [t] button: Returns to initial screen (see
Note).
Note: When the cursor is at the left edge, the
screen returns to the normal screen (oper-
ator mode).
If the cursor is not at the left edge, the cur-
sor returns to the left edge.
a If more than 60 seconds passes before the
switch on the ID input screen is operated, the
screen returns automatically to the normal
screen.
20-162 WA200-5
(4)
5) Menu selection in Service Mode 8. Electrical system fault history display function
Press the [>] or [<] buttons on the menu screen (ELECTRIC FAULT)
and the menus of Service Mode are displayed The monitor retains the data for problems that
endlessly in the following order. occurred in the electrical system in the past as
a The menu is displayed in the places marked failure codes. They can be displayed as follows.
with [*]. 1) Menu selection
• [>] button: Go on to the next menu Select the display function for ELECTRIC
FAULT fault history on the menu screen of
• [<] button: Go back to previous menu
Service Mode.
(1) ELECTRICAL FAULT: Fault history display
function for electrical system
(2) MACHINE FAULT: Fault history display func-
tion for mechanical system
(3) REAL-TIME MONITOR: Machine data moni-
toring function
(4) MAINTENANCE MONITOR: Filter, oil
replacement interval setting function 9JF00713
(5) OPTION SELECT: Option installation selec-
tion function
(6) INITIALIZE: Initialize function (exclusive
function for factory)
2) Fault history display

With the menu selected, press the [U] but-
ton and display the fault history recorded in
9JF00714 memory.
3) Displayed fault history
A. Record number
B. Failure code (4-digit location code + 2
digit problem code
C. Number of occurrences (number of
occurrences of same code in past)
D. Elapsed time 1 (time elapsed on service
meter since first occurrence)
6) Completion of mode, function E. Elapsed time 2 (time elapsed on service
When operating at any point in any function, it is meter since last occurrence)
possible to finish the mode or function by using a Failure codes for problems that are still
any of the following methods. existing are shown on a flashing display.
(1) When continuing operations in another mode
a For details of the failure codes displayed,
or function: Press the [t] button and return
see FAILURE CODE TABLE in the
to the mode screen to be used or menu
explanation for the failure code display
screen to be used.
function.
a Note that if the [t] button is pressed on
the YES/NO screen, the function will be a Note that with the fault history display
executed. function and failure code display function
for the electrical system, the displayed
a If you return to the normal screen (oper-
data are partially different.
ator mode) by mistake, repeat the proce-
dure from Step 1) above (there is no a If no fault history are recorded, [-] is dis-
need to input the ID again). played on the display portion.
(2) When completing all operations:
Turn the starting switch OFF.
WA200-5 20-163
(4)..d
6) Deleting all fault history

(1) Display the fault history, then press the
[>] button or [<] button to display the ALL
CLEAR menu (Fig. 5).
(2) Press the [U] button once to display the
ALL CLEAR screen (Fig. 6).
9JF00718 • [U] button: Run ALL CLEAR menu
(3) Operate the buttons according to the
explanation on the screen (Fig. 6).
• [<] button: Select YES
• [>] button: Select NO
• [t] button: Run
a The data for an existing problem (flash-
(*1): Displayed alternately at intervals of 3 seconds. ing display) cannot be deleted.
4) Switching fault history display

If the [>] button or [<] button is pressed dur-
ing the display of fault history, the display
switches to the other recorded fault history.
• [>] button: Go on to data for next record
number.
9JF00720
• [<] button: Go back to data for last record
number.
5) Deleting individual fault history

(1) Display the fault history to be deleted,
then press the [U] button once to dis-
play the individual item CLEAR screen
(Fig. 4). (*1): Displayed alternately at intervals of 3 seconds.
• [U] button: Display CLEAR screen
(2) Operate the buttons according to the
explanation on the screen (Fig. 4).
• [<] button: Select YES
• [>] button: Select NO
• [t] button: Run
a The data for an existing problem (flash-
ing display) cannot be deleted.
9JF00719
(*1): Displayed alternately at intervals of 3 seconds.
20-164 WA200-5
(4)
9. Mechanical system fault history display function

(MACHINE FAULT)
The machine monitor retains the data for prob-
lems that occurred in the mechanical system in
the past as failure codes. They can be displayed
as follows.
1) Menu selection 9JF00718
Select the display function for MACHINE
FAULT fault history on the menu screen of
Service Mode.
4) Switching fault history display

9JF00721
If the [>] button or [<] button is pressed dur-
ing the display of fault history, the display
switches to the other recorded fault history.
• [>] button: Go on to data for the next
record number
• [<] button: Go back to data for last record
number
2) Fault history display 5) Deleting fault history (not permitted)
With the menu selected, press the [U] but- a The fault history for the mechanical sys-
ton and display the fault history recorded in tem cannot be deleted.
memory.
3) Display fault history
A. Record number
B. Failure code (4-digit location code + 2-
digit problem code)
C. Number of occurrences (number of
occurrences of same code in past)
D. Elapsed time 1 (time elapsed on service
meter since first occurrence)
E. Elapsed time 2 (time elapsed on service
meter since last occurrence)
a Failure codes for problems that are still
existing are shown on a flashing display.
a For details of the failure code displayed,
see FAILURE CODE TALBLE in the
explanation for the failure code display
function.
a Note that with the fault history display
function and failure code display function
for the mechanical system, the displayed
data are partially different.
a If no fault history are recorded, [-] is dis-
played on the display portion.
WA200-5 20-165
(4)..d
10. Machine data monitoring function (REAL-TIME

MONITOR)
The machine monitor can monitor the condition
of the machine in real time through the signals
from the sensors installed to various parts of the
machine.
In the machine data monitoring function, the fol- 9JF00723
lowing 2 types of display can be shown.
• 1st item independent display (for each con-
troller)
• 2nd item simultaneous display (code input)
1) Menu selection
Select the machine data monitoring function
(REAL TIME MONITOR) on the menu
(*1): Displayed after 3 seconds.
screen of the Service Mode.
4) Setting 2nd item simultaneous monitoring
(1) Press the [U] button and display the
REAL TIME MONITOR screen.
(2) Press the [>] button or [<] button to
select the 2nd item select screen (The
14th of last).
• [>] button: Number at cursor goes up
• [<] button: Number at cursor goes
down
(3) Press the [U] button and display the
monitoring code input screen.
(4) Operate each button and input the moni-
toring code for the 2nd monitoring item
2) Setting 1st item individual monitoring directly.
(1) Press the [U] button and display the • [>] button: Number at cursor goes up
REAL TIME MONITOR screen. • [<] button: Number at cursor goes
• [U] button: Run sub menu down
(2) Press the [>] button or [<] button to • [U] button: Number at cursor is con-
select the item for monitoring. firmed
• [>] button: Go on to next item • [t] button: Returns to code input
• [<] button: Go back to last item screen
a Scroll the monitoring items to display
in the internally set order.
a If the button is kept pressed, the
items will scroll at high speed.
a To hold or cancel monitoring data:
If the [U] button is pressed during
monitoring, the monitor data is held.
9JF00724
If the [U] button is pressed again, it
becomes active again.
3) Display data for 1st item individual monitor-
ing
a On the 1st item individual monitoring
screen, the following data are displayed
(Fig. 6).
A. Item display (5) When both of the monitoring codes have
B. Monitoring data (5-digit) been confirmed, the screen switches to
1. Monitoring data (including unit) the 2nd item display screen.
a For details, see MONITORING CODE
TABLE.
20-166 WA200-5
(4)
a To hold or cancel monitoring data:

If the [U] button is pressed during moni-
toring, the monitor data are held and the
[U] mark flashes. If the [U] button is
pressed again, it becomes active again.
a Display data for 2nd item simultaneous
monitoring
On the 2nd item simultaneous monitor-
ing screen, the following data are dis-
played.
A. Monitoring code 1
1. Monitoring data 1 (including unit)
B. Monitoring code 2
2. Monitoring data 2 (including unit)
a For details, see MONITORING CODE
TABLE.
Real-time monitoring items

Item Detection
Real-time monitoring item Item display Display unit Display range compo- Terminal No. Remarks
ID nent
Values outside
Items for sensors not display range
installed depending on the Abbreviated due to Items with are displayed
limit on number of units all use
model and option are all with fixed dis-
displayed characters SI units play in display
range
20200 Monitor ROM part No. MONITOR ROOM - - Monitor -
40000 Travel speed SPEED 1 km/h 0 - 50 HST L41-13
04202 Fuel level FUEL SENSOR 1% 0 - 100 Monitor L23-13
04101 Engine coolant temperature COOLANT TEMP 1 °C 24 - 131 Monitor L21-16
Engine coolant temperature
04103 (Low temperature) COOLANT Lo 1 °C -31 - 91 Monitor L21-6
30100 HST oil temperature HST TEMP 1 °C 24 - 131 Monitor L21-14

30202 Axle oil temperature BRAKE TEMP 1 °C 24 - 131 Monitor L21-8
HST Controller
01005 Engine speed ENG SPEED 1 rpm 0 - 3000 HST L42-4
CAN
HST Controller
32600 HST oil pressure HST PRESS 0.1 MPa 0.0 - 100.0 HST L41-3 CAN
Motor 1 solenoid feed-back HST Controller
80000 MOTOR SOL 1 mA 0 - 1000 HST L41-6
current CAN
Clutch solenoid feed-back HST Controller
80100 CLUTCH SOL 1 mA 0 - 1000 HST L41-14
current CAN
HST Controller
50302 Potential voltage SPEED POT 1% 0 - 100 HST L41-1
CAN
HST Controller
80200 HST traction force TRACTION - STD/LIMIT HST L42-3
CAN
WA200-5 20-167
(4)..d
11. Maintenance monitor

The machine monitor can set the maintenance
interval for filters and oil. This forms the base for
the filter and oil replacement interval and display.
a For details, see STRUCTURE AND FUNC-
TION, Maintenance monitor function.
Table of filter and oil replacement interval set items (when shipping)
Interval for replacement

Items Items shown ID numbers
(h)
Engine oil 500 ENG OIL 01
Engine oil filter 500 ENG FILT 02
Fuel filter 500 FUEL FILT 03
Transfer oil 1,000 TRANSF OIL 25
HST oil filter 1,000 HST FILT 26
Hydraulic oil filter 2,000 HYD FILT 04
Hydraulic oil 2,000 HYD OIL 10
Axle oil 2,000 AXLE OIL 15
20-168 WA200-5
(4)
12. Option selection function

Select the display function for option selection
function on the menu screen of Service Mode.
• When adding or removing optional equip-
ment, change the setting on the machine
monitor.
• When the machine monitor has been
replaced, set the status of optional equip-
ment installed on the machine.
a For details, see STRUCTURE AND FUNCTION,
Option selection function.
Option set items
Adding and changing option Adjustment item

Model selection, Tire size
Tire size, Machine monitor selection, Tire deflection selec-
tion
13. Initialize function

a This function is a special function used only at
the factory, so it cannot be used when servicing
the machine.
9JF00726
WA200-5 20-169
(4)..d
TESTING AND ADJUSTING PM CLINIC INSPECTION CHART
PM CLINIC INSPECTION CHART WA200-5 Serial No. 65001 and up
Machine serial No.

Hours inspection Engine serial No. SAA6D102E-2#
Work order No. Rotate Service Meter Serviceman

h
Questions asked to operator, walk around nspection
Ambient temperature
Was there any abnormality before inspection tarted?
Max. °C
Min. °C
Altitude m
a If the machine is cold, warm it up fully. <>: Reference value

Standard value
Item Conditions Unit for new Service limit Measure-ment Pass Fail
value results
machine
Low idle 800 - 850 -
High idle 2,200 - 2,300 -
rpm
Engine speed HST stall 2,080 - 2,280 1,980 - 2,380
Hydraulic stall 1,970 - 2,170 1,870 - 2,270
Engine
Full stall (HST stall + hydraulic stall) 1,860 - 2,260 1,760 - 2,360
Blow-by High idle kPa Max. 0.49 0.98
pressure {mmH2O} {Max. 50} {100}
340 - 640 245
High idle {3.5 - 6.5} {2.5}
Oil pressure SAE15W-40 kPa
{kg/cm 2} Min. 150 80
Low idle
{Min. 1.5} {0.8}
a Before starting the inspection, check that the machine does not move when the directional lever is placed in position.
k When measuring the transfer clutch control pressure, carry out the measurement at a place where the machine can travel safety
at a speed of more than 10 km/h.
Directional lever: F
High-pressure Speed selector switch: 44.6 - 46.6 43.1 - 46.6
2nd
cut-off pressure {455 - 475} {440 - 475}
Traction control switch:
ON
Low-pressure
relief pressure
(work equip- Directional lever: N 2.5 - 2.7 2.4 - 2.7
ment PPC cir- {25.5 - 27.5} {24.5 - 27.5}
cuit basic • Engine: Full
pressure) throttle
• Hydraulic Directional lever: N 2.5 - 2.7 2.4 - 2.7
oil temp.: Brake: released {25.5 - 27.5} {24.5 - 27.5}
HST
Servo piston MPa

control pressure 45 - 55°C Directional lever: N {kg/cm 2} Max. 0.6 Max. 0.6
Brake: depressed {Max. 6} {Max. 6}
Directional lever: F/R
Speed selector switch:
Servo piston 1st
actuation pres- Travel speed control 2.5 - 2.7 2.3 - 2.7
dial: Min. side {25.5 - 27.5} {23.5 - 27.5}
sure
Measure oil pressure
while driving at max.
speed (4 km/h).
Hydraulic oil Directional lever: F
Transfer clutch temp.: Speed selector switch: 2.5 - 2.7 2.4 - 2.7
control pressure 45 - 55°C 3rd or 4th {25.5 - 27.5} {24.5 - 27.5}
20-170 WA200-5
(4)
TESTING AND ADJUSTING PM CLINIC INSPECTION CHART
WA200-5 Serial No. 65001 and up

<>: Reference value
Standard value Service limit Measure-ment
Item Conditions Unit for new Pass Fail
value results
machine
Steering wheel Engine low idle 3.3 - 4.1 Max. 4.8

sec
operating time
Steering
Engine high idle 3.4 - 4.0 2.7 - 4.7

Lock frame with safety bar
Steering relief MPa 19.9 - 21.3 18.6 - 22.6
Engine high idle
pressure {kg/cm 2} {203 - 217} {190 - 230}
Machine tool, Machine tool,

gauge cannot gauge cannot
Brake
Service brake Wear of brake disc lining. mm be inserted be inserted

between pis- between pis-
tion and plate. tion and plate.
MPa 20.2 - 21.0 18.6 - 22.6

Relief pressure Bucket relief
{kg/cm 2} {206 - 214} {190 - 230}
Work eouipment
Raising time 5.0 - 6.0 Max. 8.2

Lift arm speed Engine high idle Lowering time 3.1 - 4.1 Max. 4.7
sec
Dumping time 1.1 - 1.7 Max. 2.5
Bucket speed
Tilting-back time 2.0 - 2.6 Max. 3.8
Bucket cylinder Max. 17 Max. 20
Hydraulic drift Engine stopped mm/15 min
Lift cylinder Max. 20 Max. 30
Front axle
Axle
Check differential drain plug visu- - Must be no excessive metal par-

ally Rear axle ticles
MEMO
WA200-5 20-171
(4)..d
TROUBLESHOOTING
Points to remember when troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202

Sequence of events in troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203
Precautions when carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-204
Check before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-212
Categories, procedure, and method of using troubleshooting charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-213
Phenomena considered to be failures and troubleshooting no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-214
Connection table for connector pin numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-218
T-adapter table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-240
Connector types and mounting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-243
Connector layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250
Troubleshooting of HST controller system (HST mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-301
Troubleshooting of travel damper system (ECSS mode). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-351
Troubleshooting of monitor system (MON mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-401
Troubleshooting of electrical system (E mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501
Troubleshooting of hydraulic, mechanical system (H mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-601
Troubleshooting of engine (S mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-701
WA200-5 20-201
(4)..
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
k
Stop the machine in a level ground, and check that the safety pin, chocks, and parking brake are
securely fitted.
k
When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
k
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k
When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
k
When removing the plug or cap from a location which is under pressure from oil, water or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the machine.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of pos-
sible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 2) Check for any external leakage of oil from
to disassemble the components. If components the piping or hydraulic equipment.
are disassembled immediately after a failure 3) Check the travel of the control levers.
occurs: 4) Check the stroke of the control valve spool.
• Parts that have no connection with the failure 5) Other maintenance items can be checked
or other unnecessary parts will be disassem- externally, so check any item that is consid-
bled. ered to be necessary.
• It will become impossible to find the cause of 4. Confirming the failure.
the failure. Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or as a
It will also cause a waste of man hours, parts, or
problem with the method of operation, etc.
oil and grease. At the same time, it will also lose
the confidence of the user or operator. For this a When operating the machine to re-enact the
reason, when carrying out troubleshooting, it is troubleshooting symptoms, do not carry out
necessary to carry out thorough prior investiga- any investigation or measurement that may
tion and to carry out troubleshooting in accor- make the problem worse.
dance with the fixed procedure. 5. Troubleshooting
2. Points to ask the user or operator. Use the results of the investigation and inspec-
1) Have any other problems occurred apart tion in Steps 2 - 4 to narrow down the causes of
from the problem that has been reported? the failure, then use the troubleshooting flow-
2) Was there anything strange about the chart to locate the position of the failure exactly.
machine before the failure occurred? a The basic procedure for troubleshooting is
3) Did the failure occur suddenly, or were there as follows.
problems with the machine condition before 1) Start from the simple points.
this? 2) Start from the most likely points.
4) Under what conditions did the failure occur? 3) Investigate other related parts or infor-
5) Had any repairs been carried out before the mation.
failure? When were these repairs carried 6. Measures to remove root cause of failure.
out? Even if the failure is repaired, if the root cause of
6) Has the same kind of failure occurred the failure is not repaired, the same failure will
before? occur again.
To prevent this, always investigate why the prob-
3. Check before troubleshooting. lem occurred. Then, remove the root cause.
1) Check the oil level.
20-202 WA200-5
(4)
TESTING AND ADJUSTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
WA200-5 20-203
(1)..d
TESTING AND ADJUSTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
PRECAUTIONS 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 hydraulic oil).
1. PRECAUTIONS WHEN HANDLING ELECTRIC
EQUIPMENT
1) Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting one
component to another component, connectors
used for connecting and disconnecting one wire
from another wire, and protector 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 oxidation of the
contact surfaces.
(2) Defective compression or soldering of con-

nectors
The pins of the male and female connectors
are in contact at the compressed terminal or
soldered portion, but there is excessive force
on the wiring, and the plating peels to cause
improper connection or breakage.
20-204 WA200-5
(1)
12 (3) Disconnections in wiring

If the wiring is held and tugged and the con-
nectors 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 compression of the connectors to the
wire may be loosened, or the soldering may
be damaged, or the wiring may be broken.
(4) High pressure water entering a connector

The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on the
connector, water may enter the connector
depending on the direction of the water jet.
The connector is designed to prevent water
from entering, but if water does enter, it is diffi-
cult for it to be drained. Therefore, if water
should get into the connector, the pins will be
short-circuited by the water, so if any water
gets in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
(5) Oil, grease 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, and this will cause
a defective contact. If there is oil or grease or
dirt stuck to the connector, wipe it off with a
dry cloth or blow dry with air, and spray it with
a contact restorer.
a When wiping the mating portion of the
connector, be careful not to use excessive
force or deform the pins.
a If there is water or oil present, it will
increase the contamination of the points,
so clean with air until all water and oil has
been removed.
WA200-5 20-205
(1)..d
2) Removing, installing, and drying connectors and

wiring harnesses
• Disconnecting connectors
(1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For 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.
a Never try to pull apart with one hand.
(2) When removing the connectors from the clips,
pull the connector in a parallel direction to the
clip.
a If the connector is twisted to the left and
right or up and down, 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 connector portion.
a If the machine is left for a long time, it is
particularly easy for improper contact to
occur, so always cover the connector.
20-206 WA200-5
(1)
• Connecting connectors
(1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, faulty
contact, corrosion, or damage to the con-
nector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
a If there is any oil, water, or dirt stuck to the
connector, wipe it off with a dry cloth. If
any water has gotten 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.
a If there is any damage or breakage,
replace the connector.
(2) Assemble the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with a 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 or the boot. In addition, if the wiring
harness is misaligned, or the clamp is out of
position, adjust it to its correct position.
a When blowing with dry air, there is danger
that the oil in the air may cause improper
contact, so clean with properly filtered air.
12 (4) When the wiring harness clamp of the connec-

tor has been removed, always return it to its
original condition and check that there is no
looseness of the clamp.
• Connecting connectors (DT type connector)
Since the DT 8-pole and 12-pole DT type connec-
tors have 2 latches respectively, push them in until
they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal) : a, b, d
• Incomplete locking state (Diagonal) : c
WA200-5 20-207
(1)..d
• Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe
it off with a dry cloth. Avoid washing it in water or
using steam. If the connector must be washed in
water, do not use high pressure water or steam
directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows:
(1) Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is blown dry with air, there
is the risk that oil in the air may cause a
faulty contact, so avoid blowing with air.
(2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer
to dry the connector.
a Hot air from the dryer can be used, but be
careful not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connector.
(3) Carry out a continuity test on the connector.

After drying, leave the wiring harness discon-
nected and carry out a continuity test to check
for any short circuits between pins caused by
water.
a After completely drying the connector,
spray it with contact restorer and reas-
semble.
20-208 WA200-5
(1)
3) Handling control box

(1) The control box contains a microcomputer and
electronic control circuits.
This controls 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) 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 con-
nected to the control box. Fit an arc welding
ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
a If there is any change, there is probably defective contact in the circuit.
WA200-5 20-209
(1)..d
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of hydrau-

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

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

If disassembly or maintenance work is carried out
on hydraulic equipment in the field, there is danger
of dust entering the equipment. It is also difficult to
confirm the performance after repairs, so it is
desirable to use unit exchange. Disassembly and
maintenance of hydraulic equipment should be
carried out in a specially prepared dust proof
workshop, and the performance should be con-
firmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tape, or
vinyl bags to prevent any dirt or dust from enter-
ing. Never leave any openings opened or blocked
with a rag, this could cause particles or dirt to get
into the system.
Drain all oil into a container and not unto the
ground and be sure to follow the proper environ-
mental regulation for any disposal of oil.
4) Do not let any dirt, or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil filler
and the area around it clean, and also use clean
pumps and oil containers. If an oil cleaning device
is used, it is possible to filter out the dirt that has
collected during storage, so this is an even more
effective method.
20-210 WA200-5
(1)
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil, so it
is best to change the oil when it is still warm.
When changing the oil, as much as possible of the
old hydraulic oil must be drained out. (Do not drain
the oil from the hydraulic tank; but drain the oil
from the filter and from the drain plug in the cir-
cuit.) If any old oil is left, the contaminants and
sludge in it will mix with the new oil and will
shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil from
the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or con-
taminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultra fine (about 3µ) particles that the filter built
into the hydraulic equipment cannot remove, so it
is an extremely effective device.
WA200-5 20-211
(1)..d
TESTING AND ADJUSTING CHECK BEFORE TROUBLESHOOTING
CHECK BEFORE TROUBLESHOOTING

Item Judgement Value Action
1. Check fuel level - Add fuel
Lubricating oil, coolant
2. Check for impurities in fuel - Drain

3. Check oil level in hydraulic oil tank - Add oil
4. Check oil filter (Hydraulic, HST) - Replace
5. Check brake oil level - Add oil
6. Check engine oil level inside oil pan - Add oil
7. Check coolant level - Add coolant
8. Check dust indicator for clogging - Clean or replace
9. Check play of steering wheel Max. 80 mm Adjust
10. Check emergency steering - Repair
Air, Hydraulic, Mechanical equipment
11. Check tire inflation pressure and damage - Air charge or replace
Before Starting Checking Item
12. Check loosen of hub nut Tightening torque (See DISASSEN- Tighten
BLY AND ASSEMBLY)
13. Check effect of foot brake - Adjust
14. Check effect of parking brake - Adjust or repair
15. Check effect of emergency brake - Adjust or repair
16. Check operation of steering - Adjust or repair
17. Check direction of rear view mirror and under mirror - Adjust
18. Check effect of exhaust gas color and sound - Adjust or repair
19. Check effect retarder brake - Adjust or repair
20. Check effect body mounting rubber - Replace
21. Check sound of horn - Repair
22. Check flashing of lamps - Repair or replace
Electrical equipment
23. Check operation of gauge when during operation - Adjust or repair

24. Check operation of monitor panel - Adjust or repair
25. Check operation of machine monitor system - Adjust or repair
26. Check for missing central warning lamps - Repair or replace
27. Check for looseness, corrosion of battery terminal, wiring - Tighten or clean
28. Check for looseness, corrosion of alternator terminal, wiring - Tighten or clean
29. Check for looseness, corrosion of starting motor terminal, wiring - Tighten or clean
30. Check for abnormal noise, smell - Repair
31. Check for oil leakage - Repair
32. Carry out air bleeding - Bleed air
33. Check battery voltage (Engine stopped) 24 V Charge or replace
Others Checking Item
34. Check battery electrolyte level - Add

35. Check for discolored, burnt, exposed wiring - Replace
36. Check for missing wiring clamps, hanging wire - Repair
37. Check for water leakage on wiring (Pay particular attention to - Dry
water leaking on connectors or terminals)
38. Check for blown, corroded fuses - Replace
39. Check alternator voltage (Engine running at 1/2 throttle of After running for several minutes: Replace
above) 28.5 - 29.5V
40. Check sound of actuation of battery relay (When starting switch
- Replace
is turned ON, OFF)
20-212 WA200-5
(1)
CATEGORIES, PROCEDURE, AND METHOD OF USING
TROUBLESHOOTING TROUBLESHOOTING CHARTS
CATEGORIES, PROCEDURE, AND METHOD OF USING

TROUBLESHOOTING CHARTS
1. Categories of troubleshooting codes
a If the machine monitor displays a failure code, the name of the controller is also displayed at the same
time, so the troubleshooting codes are categorized according to the name of each controller. (This may
also includes some failure codes for the electrical system that are not displayed)
a Failures of the hydraulic and mechanical system that the machine monitor cannot display are categorized
as H mode.
Failure code System for troubleshooting
HST Troubleshooting of HST controller system
ECSS Troubleshooting of travel damper system (If equipped) (ECSS controller system)
MON Troubleshooting of machine monitor system
E Troubleshooting of electrical system
H Troubleshooting of hydraulic, mechanical system
S Troubleshooting of engine
2. Procedure for troubleshooting

a If a problem occurs on the machine, or if any problem is felt, carry out troubleshooting as follows.
1) When failure code is displayed on machine monitor
If a failure code is displayed on the machine monitor at the same time as the problem occurs, check the
content of the display, then go to the applicable troubleshooting for the failure code.
2) If no failure code is displayed on the machine monitor but the failure is recorded in memory
If it is impossible to check the failure code display on the machine monitor when a problem occurs, use the
troubleshooting history display function in the service mode of the machine monitor to check if there is a
failure code.
If a failure code is recorded, it is probable that it is the cause, so go to the applicable troubleshooting for
the failure code.
3) If no failure code is displayed and no failure history is recorded
If it is impossible to check the failure display on the machine monitor when a problem occurs, and there is
also no failure code recorded in the troubleshooting history display function in the service mode of the
machine monitor, it is probable that are problem has occurred in the hydraulic or mechanical system or in
the electrical system that the controller cannot detect.
In such a case, check the condition of the failure carefully, then go to the applicable troubleshooting for the
failure.
WA200-5 20-213
(4)..d
PHENOMENA CONSIDERED TO BE FAILURES AND
TROUBLESHOOTING TROUBLESHOOTING NO.

TROUBLESHOOTING NO.
aWith mark q go to troubleshooting No. on failure code display.
Troubleshooting
No. Phenomena considered to be failures Failure HST ECSS MON S mode
E mode H mode
code mode mode mode (Engine)
Failures related to failure code
Failure code is displayed on failure code display unit
1 q
(LED display unit)
Failures related to engine (S mode)
2 Starting performance is poor (starting always takes time) S-1
3 Engine does not rotate S-2a)
Engine rotates but no exhaust smoke
4 Engine does S-2b)
comes out
not start
Exhaust smoke comes out but engine does
5 S-2c)
not start
6 Engine does not pick up smoothly (follow-up is poor) S-3
7 Engine stops during operations S-4
8 Engine does not rotate smoothly (hunting) S-5
9 Engine lacks output (or lacks power) S-6
10 Exhaust smoke is black (incomplete combustion) S-7
11 Oil consumption is excessive (or exhaust smoke is blue) S-8
12 Oil becomes contaminated quickly S-9
13 Fuel consumption is excessive S-10
14 Oil in coolant (or coolant spurts back, or coolant level goes S-11
down)
15 Oil pressure warning lamp light ON (drop in oil pressure) S-12
16 Oil level rises (coolant, fuel in oil) S-13
17 Coolant temperature becomes too high (overheating) S-14
18 Abnormal noise is made S-15
19 Vibration is excessive S-16
Failures related to HST (HST mode)
20 Defective HST controller power source (HST controller HST-1

does not function)
21 Travel speed does not shifted HST-2
22 HST output cannot be controlled (traction control) HST-3
23 Travel speed limit cannot be changed when gear speed HST-4

selector switch is in "1st" position
24 Travel speed is not increased HST-5
Travel damper (If equipped)
25 Travel damper does not operate or is not reset ECSS-1
Failures related to monitor (MON mode)
26 The parking brake indicator lamp does not light ON MON-1
27 The brake oil pressure warning lamp does not light ON MON-2
The engine coolant temperature warning lamp does not
28 light ON or the engine coolant temperature gauge does not MON-3
rises when engine is started
The HST oil temperature warning lamp does not light ON
29 or the HST oil temperature gauge does not rises when MON-4
engine is started
30 The fuel level gauge does not rises or goes down MON-5
31 The radiator coolant temperature warning lamp does not MON-6

light
20-214 WA200-5
(4)
Troubleshooting
code mode mode mode E mode H mode (Engine)
Failures related to monitor (MON mode)
32 The steering oil pressure warning lamp does not light ON MON-7
33 The emergency steering oil pressure indicator lamp does MON-8

not light ON
Input fault in monitor panel mode switch 1 [t] (panel
34 MON-9
switch 1)
Input fault in monitor panel mode switch 1 [U] (panel
35 MON-10
switch 2)
Input fault in monitor panel mode switch 2 [<] (panel
36 switch 3) MON-11
37 Input fault in monitor panel mode switch 2 [>] (panel MON-12

switch 4)
38 The alarm buzzer does not sound or stop MON-13
39 The wiper does not function MON-14
40 The each lamps do not light ON MON-15
Failures related to electrical system (E mode)
41 The engine does not start E-1
42 The engine does not stop E-2
43 Preheating is impossible or constant E-3
44 The parking brake (mechanical type) does not function E-4
45 Defective boom kick-out function and cancellation E-5
46 Defective bucket positioner function and cancellation E-6
47 Defective lift arm FLOATING holding function and E-7

cancellation
48 Travel direction is not changed normally E-8
49 The wiper does not function E-9
50 The window washer does not function E-10
51 Lamps do not work properly E-11
52 The horn does not sound E-12
53 Defective air conditioner E-13
Failures related to hydraulic and mechanical system (H mode)
54 The machine does not start H-1
55 The travel speed is slow H-2
56 The thrusting force is weak H-3
Engine stalls when traveling or engine speed drops
57 excessively H-4
58 Travel speed (gear) does not shifted H-5

59 The steering wheel dose not turn H-6
60 Steering is heavy H-7
61 The steering wheel shakes or jerks H-8
WA200-5 20-215
(4)..d
Troubleshooting
E mode H mode (Engine)
code mode mode mode
Failures related to hydraulic and mechanical system (H mode)
62 Machine deviates naturally to one side when traveling H-9
63 The brake does not work or does not work well H-10
64 The brake is not released or is dragged H-11
65 The lift arm does not rise or lower H-12
The lift arm moves slowly or the lift arm rising force is
66 H-13
insufficient
When rising, the lift arm comes to move slowly at specific
67 H-14
height
The lift arm cylinder cannot hold down the bucket (The
68 bucket rises in the air) H-15
69 Hydraulic drifts of the lift arm occur often H-16

70 The lift arm wobbles during operation H-17
When the control lever is switched from "HOLD" to
71 H-18
"RAISE", the lift arm falls temporarily
72 The bucket does not tilt back H-19
The bucket moves slowly or the tilting-back force is
73 insufficient H-20
74 The bucket comes to operate slowly in the midst of tilting- H-21

back
75 The bucket cylinder cannot hold down the bucket H-22
76 Hydraulic drifts of the bucket occur often H-23
The bucket wobbles during travel with cargo (The work
77 equipment valve is set to "HOLD") H-24
78 When the control lever is switched from "HOLD" to "TILT", H-25

the bucket falls temporarily
79 The control levers of lift arm and bucket do not move H-26
smoothly and heavy
80 The travel damper does not operate and machine pitches H-27
and bounces
20-216 WA200-5
(4)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
a Deuscht connector has marks of pin numbers on the wiring harness side.
X Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
BWP04702
2 799-601-7020
Part number: 08055-00282 Part number: 08055-00292
BWP04703
3 BWP04704 799-601-7030
BWP04705
4 BWP04706 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: black • Grommet: black
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410
— —
• Grommet: red • Grommet: red
20-218 WA200-5
(1)
SWP Type Connector

Number of
Pins T-adapter Part
Number
BWP04708
BWP04707
6 799-601-7050
BWP04710
BWP04709
8 799-601-7060
BWP04711
BWP04712
12 799-601-7310
BWP04713 BWP04714
14 799-601-7070
WA200-5 20-219
(1)..d
SWP Type Connector

Number of
Pins T-adapter Part
Number
BWP04715
16 BWP04716 799-601-7320

Terminal part number: Terminal part number:
— —
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
— —
• Grommet: red • Grommet: red
20-220 WA200-5
(1)
M Type Connector
Number of
Pins T-adapter Part
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
BWP04718
2 BWP04717 799-601-7090
BWP04719 BWP04720
3 799-601-7110
4 BWP04721 BWP04722 799-601-7120
BWP04723 BWP04724
6 799-601-7130
8 BWP04725 BWP04726 799-601-7340
WA200-5 20-221
(1)..d
S Type Connector
Number of
Pins T-adapter Part
Number
BWP04728
8 BWP04727 799-601-7140
10 (white) BWP04729 BWP04730 799-601-7150
BWP04731 BWP04732
12 (white) 799-601-7350
BWP04733 BWP04734
16 (white) 799-601-7330
20-222 WA200-5
(1)
S Type Connector
Number of
Pins T-adapter Part
Number
BWP04736
BWP04735
10 (blue) —
— —
BWP04737 BWP04738
12 (blue) 799-601-7160
BWP04739 BWP04740
16 (blue) 799-601-7170
WA200-5 20-223
(1)..d
MIC Type Connector

Number of
Pins T-adapter Part
Number
Body part number: 79A-222-2640 Body part number: 79A-222-2630
7 (Quantity: 5 pieces) (Quantity: 5 pieces) —
11 Body part number: 79A-222-2680 Body part number: 79A-222-2670 —

(Quantity: 5 pieces) (Quantity: 5 pieces)
BWP04742
BWP04741
5 799-601-2710

BWP04743 BWP04744
9 799-601-2950

BWP04745 BWP04746
13 799-601-2720

20-224 WA200-5
(1)
MIC Type Connector

Number of
Pins T-adapter Part
Number
BWP04748
BWP04747
17 799-601-2730

BWP04749 BWP04750
21 799-601-2740

— Body part number: 79A-222-2770 Body part number: 79A-222-2760 —

WA200-5 20-225
(1)..d
AMP040 Type Connector

Number of
Pins T-adapter Part
Number
BWP04752
BWP04751
8 799-601-7180
Housing part number: 79A-222-3430

—
(Quantity: 5 pieces)
BWP04753 BWP047544
12 799-601-7190
— Housing part number: 79A-222-3440

BWP04755 BWP04756
16 799-601-7210

— (Quantity: 5 pieces)
BWP04757 BWP04758
20 799-601-7220

—
a Terminal part number: 79A-222-3470 (for all numbers of pins).
20-226 WA200-5
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
AMP070 Type Connector

Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
10 799-601-7510
— Part number: 7821-92-7330
12 BWP04761 BWP04762 799-601-7520
— Part number: 7821-92-7340
14 BWP04763 BWP04764 799-601-7530
— Part number: 7821-92-7350
18 BWP04765 BWP04766 799-601-7540
— Part number: 7821-92-7360
20 BWP04767 BWP04768 799-601-7550
— Part number: 7821-92-7370
WA200-5 20-227
(4)..d
L Type Connector
Number of
Pins T-adapter Part
BWP04770
2 BWP04769 —
— —
PA Type Connector
Number of
Pins T-adapter Part
BWP04772
9 BWP04771 —
— —
BENDIX (MS) Type Connector

Number of
Pins T-adapter Part
Number
BWP04774
10 BWP04773 799-601-3460
— —
20-228 WA200-5
(4)
KES1 Automobile Type Connector

Number of
Pins T-adapter Part
Number
BWP04776
BWP04775
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 BWP04777 BWP04778 —
BWP04779 BWP04780
4 —
08027-10420 (Black) 08027-10470 (Black)
BWP04781 BWP04782
6 —
08027-10620 (Black) 08027-10670 (Black)
WA200-5 20-229
(1)..d
KES1 Automobile Type Connector

Number of
Pins T-adapter Part
Number
BWP04784
BWP04783
8 —
08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket)

Number of
Pins T-adapter Part
Number
BWP04786
5 BWP04785 799-601-7360
— —
BWP04788
6 BWP04787 799-601-7370
— —
Type F Type Connector

(shell size T-adapter Part
code) Pin (Male terminal) Body (Female terminal)
Number
4 —
— —
20-230 WA200-5
(1)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

code) Body (plug) Body (receptacle) Number
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

08191-11205, 08191-11206 08191-14105, 08191-14106
18-8
(1) Pin (female terminal) Pin (male terminal)
799-601-9210

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
WA200-5 20-231
(1)..d

799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230

799-601-9240

799-601-9240
20-232 WA200-5
(1)

799-601-9250

799-601-9250

799-601-9260

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
WA200-5 20-233
(1)..d

799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
20-234 WA200-5
(1)

799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
WA200-5 20-235
(1)..d
DT Series connector
Number
Body (plug) Body (receptacle)
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
20-236 WA200-5
(1)
DT Series connector
Number
Number
8GR: 799-601-9060
8B: 799-601-9070
8 8G: 799-601-9080
8BR: 799-601-9080
Part number: 08192-1820 T (normal type) Part number: 08192-1810 T (normal type)
08192-2820 T (fine wire type) 08192-2810 T (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
12 12G: 799-601-9130
12BR: 799-601-9140
Part number: 08192-1920 T (normal type) Part number: 08192-1910 T (normal type)
08192-2920 T (fine wire type) 08192-2910 T (fine wire type)
WA200-5 20-237
(1)..d
DTM Series connector
Number
Number
2 799-601-9010
DTHD Series connector

Number
Number
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-238 WA200-5
(1)
DRC26 Series connector
Number
Body (plug) Body (receptacle) Number
24 799-601-9360
— Part No.: 7821-93-3110
40
799-601-9350
(A)
— Part No.: 7821-93-3120
40 799-601-9350
(B)
— Part No.: 7821-93-3130
WA200-5 20-239
(4)..d
TROUBLESHOOTING T-ADAPTER TABLE
T-ADAPTER TABLE
a The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring har-
ness checker assemblies are shown in the lines.
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
799-601-2600 For measuring box Econo-21P Q Q Q Q Q Q

799-601-3100 For measuring box MS-37P Q
799-601-3200 For measuring box MS-37P Q
799-601-3300 For measuring box Econo-24P Q
799-601-3360 Plate For MS box
799-601-3410 BENDIX(MS) 24P Q Q
799-601-3420 BENDIX(MS) 24P Q Q
799-601-3430 BENDIX(MS) 17P Q Q
799-601-3440 BENDIX(MS) 17P Q Q
799-601-3450 BENDIX(MS) 5P Q Q
799-601-3460 BENDIX(MS) 10P Q Q
799-601-3510 BENDIX(MS) 5P Q Q
799-601-3520 BENDIX(MS) 14P Q Q
799-601-3530 BENDIX(MS) 19P Q Q
799-601-2910 BENDIX(MS) 14P Q Q
799-601-3470 CASE Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Extension cable Q Q Q
799-601-2850 CASE Q
799-601-7010 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
20-240 WA200-5
(4)
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-7320 SWP 16P Q

799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Cace Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Blown Q Q
799-601-9110 DT 12P-Gray Q Q
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Blown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
WA200-5 20-241
(4)..d
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-9230 HD30 18-20 Q Q

799-601-9240 HD30 18-21 Q Q
799-601-9250 HD30 24-9 Q Q
799-601-9260 HD30 2-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 For measuring box For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC26 40P Q
799-601-9360 DRC26 24P Q
799-601-9410 For NE, G sensor 2P Q
799-601-9420 For boost pressure, 3P Q

fuel
799-601-9430 PVC socket 2P Q
AMP 2-963215-1
799-601-9710 AMP 2-963217-1 16P Q
for HST controller
AMP 1-963215-1
799-601-9720 AMP 1-963217-1 16P Q
for HST controller
AMP 2-1437285-2
799-601-9730 AMP 2-1437285-8 26P Q
for HST controller
20-242 WA200-5
(4)
TESTING AND ADJUSTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

a The address column of the table indicates each address of a connector placement diagram (diagram in three
dimensions) and an electrical circuit system diagram.
a Symbols of the circuit diagram address column of the table:
HST: HST System, MON: Monitoring system, E: Electrical system.
a The item enclosed by parentheses in the connector type column indicates the color of the connector body. (B:
Black, Br: Brown, G: Green, Gr: Gray, W: White)
Address
Connec- Connector Number
Installation Name Layout System Drawing
tor No. Type of pins
Drawing HST MON E
A01 M 6 Blower motor, resister V-7 F-8
A02 SWP 6 Air mixing servomotor V-6 F-8
A03 M 2 Thermistor V-7 F-8
A05 Sumitomo 4 Air conditioner pressure switch V-8 E-8
A07 SWP 8 L.H. side blower servomotor R-1 D-8
A08 SWP 8 R.H. side blower servomotor N-4 D-8
A09 Sumitomo 5 Blower relay (Main) U-8 B-1
A10 Sumitomo 5 Blower relay (HI) U-8 B-1
A11 Sumitomo 5 Blower relay (M2) T-9 B-1
A12 Sumitomo 5 COND relay T-9 A-1
A13 Sumitomo 5 Blower relay (M1) S-9 A-1
A15 Sumitomo 5 Magnet clutch relay T-9 A-1
Intermediate connector
AL1 S 16 T-9 C-3
(Air conditioner relay harness)
B01 M 2 Rear working lamp (Right side) I-9 Q-1
B02 M 2 Rear working lamp (Left side) J-8 Q-1
B03-1 Terminal 1 Back-up alarm L-7 R-1
B03-2 Terminal 1 Back-up alarm L-7 R-1
B04 DT-T 3 Condenser H-9 N-3
B05 X 2 Coolant level sensor G-9 N-2
B06 KES1 2 Rear window shield washer G-9 Q-3
B07 KES1 2 Front window shield washer G-9 Q-3
BL1 DT-T 6 Intermediate connector (Bulkhead harness) H-2, W-1 M-3 M-4
BR1 DT-T 4 Intermediate connector (Grill harness) J-8 Q-3 P-1
C03 AMP040 16 Air conditioner controller E-9 B-9
C04 AMP040 12 Air conditioner controller E-9 C-9
C05 M 2 Front working lamp (Right side) D-8 C-9
C06 M 2 Front working lamp (Left side) E-9 C-9
C07 KES1 2 Room lamp F-9
C08 M 1 Door switch (Left side) (Room lamp) F-9
C09 M 1 Door switch (Right side) (Room lamp) D-8
C10 Terminal 1 Ground D-9
C11 PA 9 AM/FM radio D-9
C12 M 2 Speaker (Left side) G-9
C13 M 2 Speaker (Right side) F-9
C14 VHC 8 Warning lamp (beacon) switch E-9
C15 M 1 Warning lamp connector E-9
C16 Plug 1 Warning lamp (beacon) C-8
C17 Terminal 1 Ground D-8
C18 Terminal 1 Ground E-9 C-8
C19 VCH 8 Defroster switch E-9
WA200-5 20-243
(1)..d
Address
tor No. Type of pins Installation Name Layout System Drawing
Drawing HST MON E
C20 Sumitomo 5 Defroster F-9
C21 Yazaki 1 Rear glass (Defroster) F-9
C22 Yazaki 1 Rear glass (Defroster) H-9
C23 Terminal 1 Ground C-8
CAN1 DT-T 3 CAN connector O-7 F-1 K-2
CAN2 DT-T 3 CAN connector N-3 F-1 K-2
CL1 S 16 Intermediate connector (Cab harness) A-6, N-3 B-8
CL2 S 12 Intermediate connector (Cab harness) A-6, N-3 C-8
D01 Yazaki 3 Diode (Forward and reverse solenoid) X-9 A-4 H-1
D03 Yazaki 2 Diode (Fuel-cut solenoid) X-9 M-9
D04 Yazaki 2 Diode (Fuel-cut solenoid) X-9
D05 Yazaki 3 Diode (ECSS solenoid, heater relay) X-7 J-1 M-9
D06 Yazaki 2 Diode (Magnet clutch) W-9 N-9
D07 Yazaki 3 Diode (Engine started) W-9 A-3 H-1 N-9
D08 Yazaki 2 Diode (Engine started) W-7 N-9
D09 Yazaki 4 Diode (Parking brake, HST motor 2 solenoid) X-8 A-3
D10 Yazaki 2 Diode (Washer motor [F]) W-8 O-9
D11 Yazaki 2 Diode (Hazard) O-1 O-9
D12 Yazaki 3 Diode (HST controller power source) W-9 A-3 I-1
D13 Yazaki 2 Diode (Washer motor [R]) W-8 O-9
D14 Yazaki 2 Diode (Hazard) P-1 P-9
D15 Yazaki 2 Diode (Engine started) W-8 P-9
D16 Yazaki 2 Diode (Forward) X-3 H-9 J-9 A-4
D17 Yazaki 2 Diode (Reverse) X-3 G-9 I-9 A-4
D18 Yazaki 2 Diode (Neutral) X-3 A-4
E01 DT-T 2 Safety relay AD-2 W-4 Q-6
E02 Sumitomo 3 Alternator K-8 Q-2 Q-6
E03 Terminal 1 Fuel-cut solenoid Z-5 R-5
E06 Terminal 1 Heater relay AB-8 T-1 R-5
E09 Terminal 1 Ribbon heater AB-6 T-2 R-4
E10 Terminal 1 Starting motor B terminal AC-1 X-4 R-6
E11 Terminal 1 Alternator B terminal L-8
E12 DT-T 2 Engine speed sensor AA-3 K-1
E13 DT-T 3 Engine water temperature sensor (Preheating) L-7 Q-1
E14 X 2 Engine water temperature sensor (Monitor) AA-5 W-3
E15 Terminal 1 Engine oil pressure switch AA-5
E16 DT-T 2 FREON compressor magnet clutch Y-7
E19 Terminal 1 Safety relay Z-3 W-4 R-6
E20 Terminal 1 Safety relay Z-3 W-4 R-6
E21 Terminal 1 Starting motor C terminal Y-3 X-4 R-6
E22 Terminal 1 Ground Y-7
E23 Terminal 1 Fuel-cut solenoid (HOLD) Z-5 R-5
20-244 WA200-5
(1)
Address
Connec- Connector Number Installation Name System Drawing
tor No. Type of pins Layout
Drawing HST MON E
E24 Terminal 1 Fuel-cut solenoid (GND) Z-5 R-5
E25 Terminal 1 Ground AA-3
ER1 DT 6 Intermediate connector (Engine harness) L-4, Q-4 Q-5

AD-2
L-3,
ER2 DT-T 12 Intermediate connector (Engine harness) I-1 Q-4 P-5
AC-2
K-2,
ER3 L 2 Intermediate connector (Engine harness) U-2 Q-5
AC-2
F01 Yazaki 2 Horn (HI) A-5 N-2
F02 Yazaki 2 Horn (LOW) A-4 N-2
F03 DT-T 3 Bucket positioner proximity switch A-4 N-3
F04 DT-T 3 Lift arm kick-out proximity switch A-4 N-2
F07 DT-T 2 ECSS solenoid D-1 Q-4
F10 Terminal 1 Ground E-1 P-7 O-1
F11 DT-T 3 Steering pump pressure switch (Low pressure) G-1 O-8
F12 DT-T 3 Emergency steering pressure switch B-7
F14 DT-T 2 Axle oil temperature sensor A-2 Q-8
F15 DT-T 2 Quick-coupler solenoid valve (PT specification)
F16 DT-T 2 Bypass solenoid valve (PT specification)
F17 DT-T 2 Diode (PT specification)
F18 DT-T 2 PPC pressure switch (PT specification)
F19 DT-T 3 Fork positioner proximity switch (PT specification)
F20 DT-T 3 Bucket positioner proximity switch (PT specification)
F21 DT-T 3 Bell-crank angle detection switch (PT specification)
FL1 S 10 Intermediate connector (Front harness) B-7, P-1 M-6 M-5
FL2 DT-T 6 Intermediate connector (Front harness) C-8, P-1 M-6 M-4
Intermediate connector (Emergency steering har-
FL3 DT-T 4 ness) C-8, Q-1 M-7
FL5 DT-T 4 Intermediate connector (PT specification)

FL6 DT-T 4 Intermediate connector (PT specification)
FS1 - - Fuse box S-9 A-2 K-9 L-3
FS2 - - Fuse box S-9 L-9 L-2
HEAD L SWP 6 Front combination lamp (Left side) F-1 P-8 N-1
HEAD R SWP 6 Front combination lamp (Right side) A-5 P-8 N-1
J01 J 20 Junction connector (Orange) Q-1 A-1 D-1
J02 J 20 Junction connector (Blue) N-4 B-1 B-1 E-1
J03 J 20 Junction connector (Blue) N-4 B-1 B-1 E-1
J04 J 20 Junction connector (Gray) S-9 B-1 C-1 F-1
J05 J 20 Junction connector (Brown) X-7 D-1 G-1
J06 J 20 Junction connector (Brown) W-6 C-1 D-1 G-1
J07 J 20 Junction connector (Green) P-8 D-1 H-1
J08 J 20 Junction connector (Orange) X-7 D-1 E-1 H-1
J09 J 20 Junction connector (Pink) X-6 E-1 E-1 I-1
J10 J 20 Junction connector (Blue) W-7 F-1 I-1
J11 J 20 Junction connector (Brown) P-8 E-1 G-1 J-1
J12 J 20 Junction connector (Orange) W-7 F-1 G-1 J-1
L02 DT 4 Starting switch P-8 A-8 K-2 A-6
L03 DT-T 4 Speed selector switch O-7 E-8
L04 SWP 8 Light combination switch N-2 E-8 A-8
WA200-5 20-245
(1)..d
Address
Drawing HST MON E
L05 S 10 Wiper switch (Front, rear) O-2 A-5
L06 VCH 8 Hazard switch O-1 I-8 L-1
L07 VCH 8 Front working lamp switch Q-1 K-1
L08 VCH 8 Rear working lamp switch Q-1 K-1
L09 VCH 8 ECSS switch Q-8 L-9
L10 VCH 8 Monitor mode switch 1 N-5 A-8
L11 VCH 8 Monitor mode switch 2 N-5 A-8
L12 Yazaki 2 Cigar lighter N-4
L13 DT-T 2 Steering horn switch O-1 A-5
L14 DT-T 4 Intermediate connector (ECSS controller) N-2 M-3
L15 DT-T 4 FNR switch O-1 F-8 D-8 A-8
L16 DT-T 2 Option connector N-6 D-1
L17 DT-T 2 Parking brake selection connector (Electrical type) V-5 G-8
Parking brake selection connector (Mechanical
L18 DT-T 2 V-6 G-8
type)
L19 VCH 8 Parking brake switch N-5
L20 DT-T 2 Parking brake selection connector (Selection) V-5 G-8
L21 AMP040 16 Monitor panel controller N-3 B-8 C-1
L22 AMP040 12 Monitor panel controller N-2 G-7 C-8 C-1
L23 AMP040 20 Monitor panel controller N-5 G-7 C-8 D-1
L34 DT-T 2 Stop lamp switch V-3 L-1
L35 DT-T 2 PPC valve, electrical detent (Liftarm float) Q-8 C-1
L36 DT-T 2 PPC valve, electrical detent (Liftarm raise) N-7 C-1
L37 DT-T 2 PPC valve, electrical detent (Bucket tilt) N-6 C-1
L38 M 2 Power supply (Battery) V-5
L39 M 2 Power supply (Key-ON) L-6, V-5
L40 Terminal 1 Ground (HST controller) O-7 H-1
AMP 1-
L41 963217-1 16 HST controller N-7 B-8 J-1
AMP 2-
L42 963217-1 16 HST controller O-7 C-8 J-1
L43 DT-T 4 Checker N-6 D-8

L44 M 4 For steering controller R-1
L45 SWP 6 Auto-grease N-5
L46 M 2 Caution buzzer N-7 F-8
L47 DT-T 2 Parking brake switch (Intermediate) V-4 H-8
L48 M 6 Interval wiper timer P-8 G-8
L49 KES1 4 Flasher unit R-1 F-8 L-8
L50 M 4 Power supply V-4
L51 X 2 Air servomotor S-9 D-8
L52 M 4 Rear wiper motor G-9, U-8 H-8
L53 DT-T 2 Parking brake switch (Bottom) V-4 H-8
L54 M 3 Travel speed control dial P-8 E-8
L55 DT-T 2 Air suspension seat V-8
L56 VCH 8 Traction control switch Q-8 F-8
L57 M 6 Front wiper motor A-7, N-2 G-8
L58 M 2 DC converter V-4
L70 M 2 Power supply (PT specification)
L71 VCH 8 Dump speed select switch (PT specification)
20-246 WA200-5
(1)
Address
Drawing HST MON E
L72 VCH 8 Quick-coupler attachment switch (PT specification)
L73 VCH 8 Attachment selection switch (PT specification)
L74 M 2 Intermediate connector (PT specification)

*Connect to L58 connector.
L75 R 5 Bell-crank angle detection relay (PT specification)
L76 R 5 Attachment selection relay (PT specification)
L77 DT-T 4 ECSS controller (PT specification)
L78 DT-T 4 Intermediate connector (PT specification) *Connect

to L14 connector.
L100 Terminal 1 Ground V-7 G-1 L-1 C-3
L101 R 5 Mechanical parking brake relay N-9 A-7
L102 R 5 HST controller power hold relay M-8 A-6 A-7
L103 R 5 Shift control relay N-8 A-6
L104 R 5 Parking brake indicator relay (Electrical type) N-9 A-6
L105 R 5 Parking brake safety relay N-8
L106 R 5 Neutral safety relay M-8 A-4 I-9
L107 R 6 Reverse relay M-8 A-5 A-4 K-9
L108 R 5 Forward relay N-7 A-5 A-4
L109 R 5 Back buzzer relay M-9 I-9
L110 R 5 ECSS relay N-9 L-9
L111 R 5 HST solenoid safety relay M-9 A-4
L112 R 5 Parking brake neutral safety relay M-9 A-3
L113 R 5 Boom kick-out relay N-9 H-9
L114 R 5 Bucket positioner relay N-8 H-9
L115 R 5 Auto preheating relay M-9 A-3 I-9
L116 R 5 Horn relay N-9 I-9
L117 R 5 Small lamp relay (Left side) U-9 A-6 J-9
L118 R 5 Small lamp relay (Right side) X-5 A-6 J-9
L119 R 5 Head lamp relay (Right side) W-4 A-5 K-9
L120 R 5 Head lamp relay (Left side) T-9 A-5 K-9
L121 R 5 Stop lamp relay U-8 K-9
L122 R 6 Working lamp relay U-8 J-9
L132 R 5 Multi relay 1 (M/T lever relay) W-4 A-3
L133 R 5 Multi relay 2 (FNR lever select relay) W-4 H-9 J-9 A-3
L134 R 5 Multi relay 3 (FNR lever select relay) W-4 B-3
L135 R 5 Multi relay 4 (FNR lever select relay) W-5 A-3
L136 R 5 Multi relay 5 (Reverse relay) X-5 I-9 J-9 B-3
L137 R 5 Multi relay 6 (Forward relay) X-5 I-9 K-9 B-3
LR1 DT 2 Intermediate connector (Rear harness) J-3, X-2 H-4 M-5 M-6
LR2 L 2 Intermediate connector (Rear harness) J-3, X-3 H-4 M-5 M-6
LR3 L 2 Intermediate connector (Rear harness) J-3, X-2 H-4 M-5 M-6
LR4 DT-T 12 Intermediate connector (Rear harness) I-3, W-3 H-3 M-4 M-6
LR5 DT-T 6 Intermediate connector (Rear harness) H-3, W-2 H-3 M-4 M-5
LR6 DT-T 6 Intermediate connector (Rear harness) I-3, W-2 M-4 M-5
LR7 DT-T 2 Intermediate connector (Rear harness) H-3, W-2 M-3 M-4
LT1 DT-T 12 Intermediate connector (HST harness) J-2, X-2 G-6 M-6 M-3
LT2 DT-T 4 Intermediate connector (HST harness) J-2, X-1 H-5 M-6 M-3
WA200-5 20-247
(1)..d
Address
Connec- Connector Number Installation Name System Drawing
tor No. Type of pins Layout
Drawing HST MON E
LT3 DT-T 4 Intermediate connector (HST harness) J-2, X-1 M-5
MF1 DT 12 Direction select switch N-6 D-8
MF2 VCH 8 Direction select switch function Q-8 E-8
MF3 DT-T 12 Intermediate connector (Multi-function harness) X-4 H-6 I-5 B-4
MF4 DT-T 2 Intermediate connector (Multi-function harness) X-4
R00 Terminal 1 Ground (Battery) J-9 X-5
R01 Terminal 1 Battery relay L-4, AD-2 L-2 X-6 R-7
R02 Terminal 1 Slow blow fuse (30A) J-2 L-4 X-7 R-8
R04 Terminal 1 Battery relay K-4 L-2 X-6 R-7
R07 Terminal 1 Slow blow fuse (120A) K-2 X-7 R-7
R08 DT-T 4 Fuel solenoid cut timer L-2 P-8
R09 Terminal 1 Fuel solenoid pull relay L-2 Q-9
R10 Terminal 1 Fuel solenoid pull relay L-2 Q-9
R11 Terminal 1 Slow blow fuse (30A) K-2 R-8
R12 Terminal 1 Slow blow fuse (30A) K-2 R-8
R13 DT-T 2 Fuel solenoid pull relay L-3 Q-8
R15 Terminal 1 Battery relay (+) K-2 L-3 X-6 R-7
R16 Terminal 1 Battery relay (-) K-2 L-3 X-6 R-7
R20 Terminal 1 Ground L-5 H-1 O-1 P-1
R21 X 2 Fuel level sensor L-7 U-8
R22 M 6 Rear combination lamp (Left side) L-6 P-2 Q-1
R23 M 6 Rear combination lamp (Right side) I-9 P-2 Q-2
R24 DT-T 2 License lamp J-9 O-1 Q-2
R25 Terminal 1 Ground (License lamp) G-9 O-1 R-2
R26 Terminal 1 Ground A-6 P-1
RR1 L 2 Intermediate connector (power supply harness) L-4 J-4 Q-5 O-6
RR2 DT-T 6 Intermediate connector (power supply harness) L-3 J-4 Q-5 O-6
T01 DT-T 4 F-R solenoid AA-1 K-2 W-1
T05 DT-T 2 Clutch control EPC solenoid J-2 K-7
T06 DT-T 2 HST motor 1 EPC solenoid H-1 K-8
HST motor 2 EPC solenoid and motor 2 overrun
T07 DT-T 4 H-1 K-8 R-8 Q-3
solenoid
T09 DT-T 4 Speedometer sensor B-7, G-3 K-9 Q-4
T10 X 2 HST oil temperature sensor H-3 R-8
T11 DT-T 3 HST oil pressure sensor H-1 K-5
T12 X 2 Brake oil pressure sensor I-1 S-8
T13 Terminal 1 HST filter clogging sensor I-1 T-6
T14 Terminal 1 Ground I-1 J-5 U-6 Q-3
TEL DT-T 12 Short connector H-6 M-7 G-8
20-248 WA200-5
(1)
TESTING AND ADJUSTING CONNECTOR LAYOUT DRAWING
CONNECTOR LAYOUT DRAWING
20-250 WA200-5
(1)
WA200-5 20-251
(1)..d
20-252 WA200-5
(1)
WA200-5 20-253
(1)..d
9JF00605
20-254 WA200-5
(1)
TROUBLESHOOTING OF HST CONTROLLER
SYSTEM (HST MODE)
HST controller system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-302

Before troubleshooting code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-304
Before troubleshooting electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-305
Information contained in troubuleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-306
Failure code [989F00] (HST motor protection caution (00)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-308
Failure code [DHH1KX](HST oil pressure sensor input signal outside range (KX)). . . . . . . . . . . . . . . . . . . . 20-309
Failure code [DLE2LC] (Engine revolution sensor revolution speed signal mismatch (LC)) . . . . . . . . . . . . . 20-311
Failure code [DW26KZ](Motor 2 solenoid system discontinuity or short-circuiting (KZ)) . . . . . . . . . . . . . . . . 20-312
Failure code [DX19KZ] (Motor 1 solenoid system discontinuity or short-circuiting (KZ)) . . . . . . . . . . . . . . . . 20-314
Failure code [DX20KZ] (Clutch solenoid system discontinuity or short-circuiting (KZ)) . . . . . . . . . . . . . . . . . 20-316
[HST-1] Defective HST controller power source (HST controller does not function) . . . . . . . . . . . . . . . . . . 20-318
[HST-2] Travel speed does not shifted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-320
[HST-3] HST Output Control (Traction control) cannot be controlled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-323
[HST-4] Travel speed limit cannot be changed when gear speed selector switch is in "1st" position . . . . . 20-325
[HST-5] Travel speed is not increased. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-327
WA200-5 20-301
(4)..
TROUBLESHOOTING HST CONTROLLER SYSTEM DIAGRAM
HST CONTROLLER SYSTEM DIAGRAM
9JF01139
20-302 WA200-5
(4)
TROUBLESHOOTING HST CONTROLLER SYSTEM DIAGRAM
9JF01140
WA200-5 20-303
(4)..d
(4)
monitor
code
Failure
989F00
989F00
AB00L6
989FN1
15B0NX
D5ZHL6
DHE4L6
DDS5L6
DLE2LC
DX20KZ
DX19KZ
DD18LD
DD17LD
DD16LD
DD15LD
DAJ0KR
DAF0KT
2G42ZG
DGE3L6
AB00MA
DDK3KB
DW26KZ
DHH1KX
DGR4KA
DGR1KX
DGH1KX
DGE2KX
20-304
HST controller
E03
E01
E01
E01
E01
E03
E03
E01
E03
E03
E01
B@CRNS E02
B@C7NS E02
B@BCZK E01
B@BCNS E02
B@BAZG E01
E03
E02
E00
E03
E01
E03
E03
E03
E03
E03
E00
E01
E01
E01
E01
E01
code
Failures related to
Failures related to
Action
Defective machine monitor
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Defective HST controller
q q
q
q q
q
q
q
q
q
TROUBLESHOOTING
Defective starting switch
q
Defective monitor panel mode switch 1 [t]
q
Defective monitor panel mode switch 1 [U]
q
Defective monitor panel mode switch 2 [<]
q
Defective monitor panel mode switch 2 [>]
q
Defective derectional lever
q
q
Battery is deteriorated
Defective battery relay
q q
Defective fuse, fusible link
Defective alternator
q
Defective engine revolution sensor
q
Defective HST motor 2 solenoid
q
FAILURE CODE AND POSSIBLE CAUSES TABLE
q
Defective clutch solenoid
q q
q
Engine oil pressure drops
Defective engine oil pressure sensor
q q
q
Engine coolant temperature overheating
Defective engine coolant temperature sensor (high temperature)
q q
q
Defective engine coolant temperature sensor (low temperature)
q
Possible Causes
Engine coolant level lacks

Defective coolant level sensor
q q
q Defective HST oil pressure sensor
HST oil filter clogging
BEFORE TROUBLESHOOTING CODE DISPLAY
Defective HST oil filter sensor
q q
HST oil temperature overheating
Defective HST oil temperature sensor
q q
q
Brake oil pressure drops
Defective brake oil pressure sensor
q q Axle oil temperature overheating
Defective axle oil temperature sensor
q q
q
q
Steering oil temperature overheating
Defective steering oil temperature sensor
q q
Defective relay
Wiring harness discontinuity
q
q q
q q
q q
q
q
q
q
q
Ground fault in wiring harness
q
q
q
q q
q
q q q
q q
q
q
q
q
q
q
q
q
q
Hot short in wiring harness
WA200-5
q
q
q q q
q q q q
q
q
q q
TROUBLESHOOTING BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM

FUSE BOX CONNECTION TABLE
a This connection chart shows the equipment that each fuse box power source supplies power directly to
("switch power source" means the power supplied when the starting switch is ON; "permanent power source"
means the power supplied when the starting switch is OFF).
Category Fuse No. Fuse capacity Power supply destination

1 20A Starting switch
2 10A Hazard lamp
3 10A HST control A
Permanent power source
4 10A Parking brake 1
(Fuse box 1)
5 10A Meter, panel
6 10A Car radio A, Room lamp
7 10A Spare power supply (battery +24 V)
8 10A Head lamp (left side)
9 10A Head lamp (right side)
10 10A Turn signal lamp
Switch power source 11 10A Back lamp, stop lamp

(Fuse box 1) 12 20A HST control B
13 10A Work equipment positioner
14 10A Wiper
15 10A Car radio B
1 20A Air conditioner A
2 20A Air conditioner B
3 10A Beacon lamp
4 10A -
5 10A Load-meter
6 20A Spare power supply (+24 V when key is ON)
7 10A DC converter
Switch power source
(Fuse box 2) 8 10A Parking brake 2
9 10A Horn
10 10A Side marker lamp (left side)
11 10A Side marker lamp (right side)
12 20A Front working lamp
13 20A Rear working lamp
14 10A (Spare 1)
15 10A (Spare 2)
WA200-5 20-305
(4)..d
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBULESHOOTING TABLE
INFORMATION CONTAINED IN TROUBULESHOOTING TABLE

a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their con-
tents fully before proceeding to actual troubleshooting work.
Controller
Action code Failure code
code Trouble Trouble displayed in fault history
Panel display Panel display Panel display
Contents of • Condition when machine monitor or controller detected trouble.
trouble
Action of
monitor panel • Action to take to protect system or equipment when machine monitor or controller detected trouble.
or controller
Problem that • Condition that appeared as problem on machine when action (given above) was taken by machine monitor or control-
appears on
machine ler.
Related • Information related to troubleshooting or error that occurred.

information
Causes Standard Value in Normal State and Remarks on Troubleshooting
<Data to fill in>

1 • Normal standard values used to judge probable cause
• Remarks regarding decision-making
<Condition when wiring harness is defective>

• Disconnection
There is defective connection of connector or disconnection in wiring harness
2 • Ground fault
Wiring harness not wired to ground (GND) circuit is in contact with ground (GND)
circuit
• Short circuit with power source (Hot short)
Wiring harness not wired to power supply (24 V) circuit is in contact with power
Possible Probable cause when
trouble occurred supply (24 V) circuit
causes and
standard value (the numbers are index
3 numbers and do not <Points to remember when troubleshooting>
in normal state
indicate the order of pri- 1) Method of displaying connector No. and handling T-adapter
ority) Unless there is special instruction, insert or connect the T-adapter as follows
• If there is no indication for the male or female terminal of the connector No.,
disconnect the connector and insert the T-adapter in both the male and
female terminals
• If there is indication for the male or female terminal of the connector No., dis-
4
connect the connector and connect the T-adapter to only the terminal indi-
cated (either the male terminal or female terminal)
<Points to remember when troubleshooting>
2) Given order for pin numbers and handling tester lead
Unless there is a special instruction, connect tester (+) lead and (-) lead as fol-
lows to carry out troubleshooting
• Connect the (+) lead to the wiring harness for the pin No. given first
5
• Connect the (-) lead to the wiring harness for the pin No. given last
20-306 WA200-5
(4)
Related circuit diagram
This is part of electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)
• Arrow: Roughly indicates the location in the machine where it is installed.
PHENOMENON CODE TABLE
a Regarding phenomenon code provided with instruction "Refer to table", check it against table below.
Phenomenon Details Disconnection Details
code
KA Disconnection L0 Fill signal ON 2 or more channels
KB Short circuit L1 Fill signal is ON when command current is OFF
KK Drop in power source voltage, input L2 Fuel pressure is higher than maximum set value
KQ Non match in model selection signal L3 Corresponding component cannot be controlled
KR Defective communication L4 ON/OFF signals for 2 systems do not match
Engine signals do not match operating condition or
KT Abnormality inside controller L6 stopped condition of machine
KX Input signal outside range L8 Analog signals for 2 systems do not match
KY Short circuit with power source (Hot short) LC Speed signals for 2 systems do not match
Switch has been kept pressed for abnormally long
KZ Disconnection or short circuit LD
time
MA Function impossible LH Fill signal is OFF when command current is ON
NS Overheat
ZG Drop in oil pressure
ZK Drop in level
WA200-5 20-307
(4)..d
TROUBLESHOOTING 989F00
Failure code [989F00] (HST motor protection caution (00))

Controller
code Trouble HST motor protection caution (00)
E00 989F00 HST
• Not considered to be a failure.
Contents of • The travel speed exceeds the allowable speed the HST motor on down shifting.
trouble
(When the travel speed is at 3rd or 4th speed (10 km/h), the display shows the speed shift down to 1st or 2nd speed.)
Action of
monitor panel • Activates an alarm.
or controller
Problem that
appears on • Shift down control cannot be applied.
machine
Related
information
20-308 WA200-5
(4)
TROUBLESHOOTING DHH1KX
Failure code [DHH1KX] (HST oil pressure sensor input signal

outside range (KX))
Controller
code Trouble HST oil pressure sensor input signal outside range (KX)
E03 DHH1KX HST
Contents of • There is disconnection, short circuit with ground, short circuit with power source (Hot short) in HST oil pressure sensor
trouble system, so HST oil pressure sensor signal is not input.
Action of • Error is sent to machine monitor through CAN communications, and machine monitor turns HST safety relay ON (cuts
monitor panel
motor 1, clutch solenoid circuit).
or controller
Problem that
appears on • Travels but drive power is low
machine
Related • The HST oil pressure can be checked in the monitoring function (Code: 32600).
information

1) Turn starting switch OFF. 2) Disconnect connector T11. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON
Defective HST oil pressure
1
sensor Between T11 (A) and (C) Voltage 0.5 - 4.5 V
Between T11 (A) and (B) Voltage 4-6V
1) Turn starting switch OFF. 2) Disconnect connectors L41 and T11. 3) Connect T-
adapter
Disconnection in wiring Wiring harness between L41 (Female) (3) and

T11 (Female) (C) Resistance Max. 1z
2 harness (Disconnection in
wiring or defective contact Wiring harness between L41 (Female) (4) and
in connector) Resistance Max. 1z
T11 (Female) (A)
Wiring harness between L41 (Female) (12) and
Resistance Max. 1z
T11 (Female) (B)
adapter
Wiring harness between L41 Resistance between L41
Possible Ground fault in wiring (Female) (3) and T11 (Female) (Female) (3), T11 (Female) (C) Min. 1Mz
causes and 3
harness (C) and chassis ground
standard value
in normal state Wiring harness between L41 Resistance between L41
(Female) (12) and T11 (Female) (12), T11 (Female) Min. 1Mz
(Female) (B) (B) and chassis ground
adapter. 4) Turn starting switch ON
Wiring harness between L41 Voltage between L41 (Female)
(Female) (3) and T11 (Female) (3), T11 (Female) (C) and chas- Max. 1V
(C) sis ground
4 Hot short in wiring harness Wiring harness between L41 Voltage between L41 (Female)
(Female) (4) and T11 (Female) (4), T11 (Female) (A) and chas- Max. 1V
(A) sis ground
(Female) (12) and T11 (12), T11 (Female) (B) and Max. 1V
(Female) (B) chassis ground
1) Turn starting switch OFF. 2) Disconnect connector L41. 3) Insert T-adapter.
5 Defective HST controller Between L41 (3) and (4) Voltage 0.5 - 4.5 V
Between L41 (12) and (4) Voltage 4-6V
WA200-5 20-309
(4)..d
TROUBLESHOOTING DHH1KX
9JF00512
20-310 WA200-5
(4)
TROUBLESHOOTING DLE2LC
Failure code [DLE2LC] (Engine revolution sensor revolution speed

signal mismatch (LC))
Controller
code Trouble Engine revolution sensor revolution speed signal mismatch (LC)
E03 DLE2LC HST
• There is an abnormality in the speed calculated from the speed sensor signal and signal speed from the engine revo-
Contents of lution signal.
trouble
• Operates the HST safety relay to output failure codes DX19KZ and DX20KZ.
monitor panel motor 1, clutch solenoid circuit).
or controller
Problem that
machine
Related • The engine speed can be checked in the monitoring function (Code: 01005).
information

1) Turn starting switch OFF. 2) Disconnect connector E12. 3) Connect T-adapter
Defective engine revolu-
1 Between E12 (Male) (1) and (2) Resistance 500 - 1,000z
tion sensor
Between E12 (Male) (1), (2) and chassis ground Resistance Min. 1Mz
1) Turn starting switch OFF. 2) Disconnect Connectors L42, E12. 3) Connect T-
adapter
2 Ground fault in wiring
harness Wiring harness between L42 Resistance between L42
Possible (Female) (4) and E12 (Female) (Female) (4), E12 (Female) (1) Min. 1Mz
causes and (1) and chassis ground
standard value
in normal state 1) Turn starting switch OFF. 2) Disconnect Connectors L42, E12. 3) Insert T-adapter.
(Female) (4) and E12 (Female) (4), E12 (Female) (1) and chas- Max. 1V
(1) sis ground
4) Connect connector. 5) Turn starting switch ON 6) Start engine
4 Defective HST controller
Between L42 (Female) (4) and (11) Voltage Min. 0.5V
(AC range)
9JF00513
WA200-5 20-311
(4)..d
TROUBLESHOOTING DW26KZ
Failure code [DW26KZ] (Motor 2 solenoid system discontinuity or

short-circuiting (KZ))
Controller
code Trouble Motor 2 solenoid system discontinuity or short-circuiting (KZ)
E03 DW26KZ HST
• Excessive electricity flows when output to motor 2 solenoid circuit is ON; no electricity flows when output is ON or
Contents of electricity flows when output is ON.
trouble
• Operates the HST safety relay to output failure codes DX19KZ and DX20KZ.
monitor panel motor 1, clutch solenoid circuit).
or controller • Operates the HST safety relay to output failure codes DX19KZ and DX20KZ.
Problem that • Travel speed does not increase.

appears on
• Travel speed indicator on machine monitor stays at 0 km/h and does not move
machine
Related
information

1) Turn starting switch OFF. 2) Disconnect connector T07. 3) Connect T-adapter
Between T07 (Female) (1) and (2) Resistance 10 - 30z
1 Defective motor 2 solenoid Between T07 (Female) (3) and (4) Resistance 10 - 30z
Between T07 (Female) (1), (3) and chassis
Resistance Min. 1Mz
ground
1) Turn starting switch OFF. 2) Disconnect Connectors L41, T07 and fuse FS1 (12)
terminal. 3) Connect T-adapter
Disconnection in wiring
2 harness (Disconnection in Wiring harness between T07 (Female) (1) and
wiring or defective contact Resistance Max. 1z
L41 (Female) (5)
in connector)
Wiring harness between T07 (Female) (2) and Resistance Max. 1z
chassis ground
Possible 1) Turn starting switch OFF. 2) Disconnect Connectors L41 and fuse FS1 (12).
causes and 3) Connect T-adapter
standard value Ground fault in wiring
3 harness Wiring harness between T07 Resistance between T07
in normal state
(Female) (1) and L41 (Female) (Female) (1), L41 (Female) (5) Min. 1Mz
(5) and chassis ground
Turn travel speed selector
switch 1st Voltage 20 - 30 V

switch 2nd Voltage 20 - 30 V
4 Defective HST controller Between L41
(5) and chas- Turn travel speed selector
switch 3rd Voltage 20 - 30 V
sis ground
Turn travel speed selector Voltage 20 - 30 V
switch 4th (Max. 10km/h)
Voltage Max. 2V
switch 4th (10 - 38km/h)
20-312 WA200-5
(4)
TROUBLESHOOTING DW26KZ
WA200-5 20-313
(4)..d
TROUBLESHOOTING DX19KZ
Failure code [DX19KZ] (Motor 1 solenoid system discontinuity or

Controller
code Trouble Motor 1 solenoid system discontinuity or short-circuiting (KZ)
E03 DX19KZ HST
Contents of • Excessive electricity flows when output to motor 1 solenoid circuit is ON; no electricity flows when output is ON or
trouble electricity flows when output is ON.
monitor panel
or controller
Problem that
machine
Related • Motor 1 solenoid current can be checked in the monitoring function (Code:80000).
information

1 Defective motor 1 solenoid
Resistance Min. 1Mz
ground
1) Turn starting switch OFF. 2) Interchange relay (L111) with normal relay. 3) Turn
starting switch ON. 4) Operate FNR switch
The condition Relay (L111)
Does condition become normal when HST safety is abnormal is normal
relay (L111) is interchanged with normal relay? The condition Defective
is normal relay (L111)
Defective HST safety relay 1) Turn starting switch OFF. 2) Disconnect connector L111. 3) Solid part check
2
(L111) Between L111 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L111. 3) Solid part check.
4) Applies impressed voltage between L111 (Male) (1) - (2)
Applies 24V impressed voltage Resistance Max. 1z
Between L111 between L111 (Male) (1) - (2)
(Male) (3) and
(5) Does not apply voltage
Resistance Min. 1Mz
between L111 (Male) (1) - (2)
Possible 1) Turn starting switch OFF. 2) Disconnect Connectors L23, L41, L111, T06 and fuse
causes and FS1 (12). 3) Connect T-adapter
standard value
in normal state Wiring harness between T06 (Female) (1) and
L41 (Female) (6) Resistance Max. 1z
Disconnection in wiring Wiring harness between T06 (Female) (2) and Resistance Max. 1z
harness (Disconnection in L111 (Female) (5)
3
chassis ground
Wiring harness between L111 (Female) (2) and Resistance Max. 1z
L23 (Female) (15)
Wiring harness between fuse FS1 (12) and L111
Resistance Max. 1z
(Female) (1)
1) Turn starting switch OFF. 2) Disconnect Connectors L23, L41, L111, T06 and fuse
FS1 (12). 3) Connect T-adapter
Wiring harness between T06 Resistance between T06
Ground fault in wiring Wiring harness between T06 Resistance between T06
4 harness (Female) (2) and L111 (Female) (Female) (2), L111 (Female) (5) Min. 1Mz
Wiring harness between fuse Resistance between fuse FS1
FS1 (12) and L111 (Female) (12), L111 (Female) (1) and Min. 1Mz
(1) * chassis ground
In the above case of marked mark (*), the fuse is blown.
20-314 WA200-5
(4)

Voltage 2 - 20V
switch 1st
Possible
causes and Turn travel speed selector
switch 2nd Voltage 2 - 20V
standard value 5 Defective HST controller
in normal state Between L41
(6) and chas- Turn travel speed selector
sis ground switch 3rd and 4th Voltage 2 - 20V
(Max. 10km/h)
switch 3rd and 4th Voltage Max. 3V
(Min. 10km/h)
9JF00521
WA200-5 20-315
(4)..d
Failure code [DX20KZ] (Clutch solenoid system discontinuity or

Controller
code Trouble Clutch solenoid system discontinuity or short-circuiting (KZ)
E03 DX20KZ HST
Contents of • Excessive electricity flows when output to clutch solenoid circuit is ON; no electricity flows when output is ON or elec-
trouble tricity flows when output is ON.
monitor panel
or controller
Problem that
appears on • Travel speed does not switch.
machine
Related • The clutch solenoid current can be checked in the monitoring function (Code:80100).
information

1 Defective clutch solenoid
Resistance Min. 1Mz
ground
Does condition become normal when HST safety is abnormal is normal
Defective HST safety relay 1) Turn starting switch OFF. 2) Disconnect connector L111. 3) Solid part check
2
(L111) Between L111 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L111. 3) Solid part check,
Between L111 between L111 (Male) (1) - (2)
(Male) (3) and
between L111 (Male) (1) - (2) Resistance Min. 1Mz
Possible 1) Turn starting switch OFF. 2) Disconnect Connectors L23, L41, L111, T05 and fuse
causes and FS1 (12). 3) Connect T-adapter
standard value
in normal state Wiring harness between T05 (Female) (1) and Resistance Max. 1z
L41 (Female) (14)
Disconnection in wiring Wiring harness between T05 (Female) (2) and

Resistance Max. 1z
3
in connector) chassis ground Resistance Max. 1z

L23 (Female) (15)
Wiring harness between fuse FS1 (12) and L111 Resistance Max. 1z
(Female) (1)
1) Turn starting switch OFF. 2) Disconnect Con-
nectors L23, L41, L111, T05 and fuse FS1 (12). Resistance Max. 1z
3) Connect T-adapter
Ground fault in wiring
4 Wiring harness between T05 Resistance between T05
harness
In the above case of marked mark (*), the fuse is blown.
20-316 WA200-5
(4)

Voltage 3 - 15V
switch 1st
Possible
causes and Turn travel speed selector
switch 2nd Voltage 3 - 15V
standard value 5 Defective HST controller Between L41
in normal state (14) and Turn travel speed selector
chassis switch 3rd and 4th Voltage 3 - 15V
ground (Max. 10km/h)
switch 3rd and 4th Voltage Max. 4V
(Min. 10km/h)
9JF00522
WA200-5 20-317
(4)..d
TROUBLESHOOTING HST-1
[HST-1] (Defective HST controller power source (HST controller

does not function))
Controller
Action code Failure code Defective HST controller power source (HST controller does not func-
code Trouble
tion)
Not set Not set Not set
Contents of • HST controller power source system is defective, so HST controller does not work.
trouble
Action of
monitor panel • None in particular
or controller
Problem that • Travels but drive power is low
appears on • Machine monitor announces failure code DAJOKR for defective HST controller communications
machine
Related
information

1) Turn starting switch OFF. 2) Disconnect Connectors L41, L102 and fuse FS1 ter-
minal. 3) Connect T-adapter
L102 (Female) (5)
Disconnection in wiring Wiring harness between fuse FS1 (3) and L102
Resistance Max. 1z
harness (Disconnection in (Female) (3)
1
wiring or defective contact Wiring harness between fuse FS1 (12) and L102
(Female) (1)
chassis ground
chassis ground
Does condition become normal The condition Relay (L102) is normal

when HST safety relay (L102) is abnormal
is interchanged with normal The condition
relay? is normal Defective relay (L102)
Defective HST power 1) Turn starting switch OFF. 2) Disconnect connector L102. 3) Solid part check
Possible 2
causes and source safety relay (L102) Between L102 (Male) (1) and (2) Resistance 200 - 400z
standard value
in normal state 1) Turn starting switch OFF. 2) Disconnect connector L102. 3) Solid part check.
Applies 24V impressed voltage
Between between L102 (Male) (1) - (2) Resistance Max. 1z
L102 (Male)
(3) and (5) Does not apply voltage Resistance Min. 1Mz
1) Turn starting switch OFF. 2) Replace diode (D12) to correct diode. 3) Turn starting
switch START
The condition is abnormal Diode (D12) is normal
The condition is normal Defective diode (D12)
Measure at diode range
D12 (Male) (1) - (2) Continuity
3 Defective diode (D12) D12 (Male) (3) - (2) Continuity
D12 (Male) (1) - (3) Discontinuity
a Connect the (+) pole of the tester to the left side of D12 ( ) - ( ).
20-318 WA200-5
(4)

1) Turn starting switch OFF. 2) Disconnect Connectors L41, L102 and fuse FS1 ter-
minal. 3) Connect T-adapter
(Female) (8) and L102 (Female) (8), L102 (Female) (5) Min. 1Mz
(Female) (5) and chassis ground
Ground fault in wiring Resistance between fuse FS1

Possible 4 Wiring harness between fuse (3), L102 (Female) (3) and Min. 1Mz
causes and harness FS1 (3) and L102 (Female) (3)
chassis ground
standard value
in normal state Wiring harness between fuse Resistance between fuse FS1
(1) chassis ground
a In the above case, the all fuses are blown.

5 Defective HST controller 4) Connect connector. 5) Turn starting switch ON
Between L41 (8) and (16) Voltage 20 - 30V
9JF00531
WA200-5 20-319
(4)..d
[HST-2] (Travel speed does not shifted)

Controller
code Trouble Travel speed does not shifted
Contents of • The speed selector switch system is defective, so the travel speed cannot be changed.
trouble
Action of
or controller
Problem that
appears on • Travel speed does not shifted
machine
Related
information

1) Turn starting switch OFF. 2) Disconnect connector L03. 3) Connect T-adapter
2nd Resistance Max. 1z
Between L03 (Female) (1) and
(2) Other than
Resistance Min. 1Mz
the above
1st Resistance Min. 1Mz
Between L03 (Female) (1) and 2nd Resistance Min. 1Mz

(3) 3rd Resistance Max. 1z
1 Defective travel speed
4th Resistance Max. 1z
selector switch
(4) Other than Resistance Min. 1Mz
the above
1st Resistance Max. 1z
Possible 2nd Resistance Min. 1Mz
causes and Between L03 (Female) (3) and
standard value (4) 3rd Resistance Min. 1Mz
in normal state
Does condition become normal when shift control is abnormal is normal
Defective shift control relay 1) Turn starting switch OFF. 2) Disconnect connector L103. 3) Solid part check
2 (L103) Between L103 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L103. 3) Solid part check,
Between Resistance Max. 1z
L103 (Male)
(3) and (5) Does not apply voltage
Resistance Min. 1Mz
20-320 WA200-5
(4)

Defective travel speed Between L54 (Female) (1) and (3) Resistance 4 - 6 kz
3
potentiometer Between L54 (Female) (1) and (2) Resistance 0.25 - 5 kz
Between L54 (Female) (2) and (3) Resistance 0.25 - 5 kz
1) Turn starting switch OFF. 2) Disconnect Connectors L42, L103, J07 and fuse FS1
terminal. 3) Connect T-adapter
L103 (Female) (5)
Resistance Max. 1z
(Female) (3)
harness (Disconnection in Wiring harness between fuse FS1 (12) and L103
4 Resistance Max. 1z
wiring or defective contact (Female) (1)
in connector)

J07 (Female) (1)
Resistance Max. 1z
J07 (Female) (18)
Possible
causes and 1) Turn starting switch OFF. 2) Disconnect Connectors L42, L103 and fuse FS1 ter-
standard value minal. 3) Connect T-adapter
in normal state
(Female) (12) and L103 (Female) (12), L103 (Female) Min. 1Mz
(Female) (5) (5) and chassis ground
Ground fault in wiring Wiring harness between fuse Resistance between fuse FS1
5 FS1 (12) and L103 (Female) (12), L103 (Female) (3) and Min. 1Mz
harness
(3) chassis ground
(1) chassis ground
1) Turn starting switch OFF. 2) Disconnect Connectors L42, L103. 3) Insert T-

adapter.
4) Turn starting switch ON
6 Hot short in wiring harness
(Female) (12) and L103 (12), L103 (Female) (5) and Max. 1V
(Female) (5) chassis ground
7 Defective HST controller Between L42 Travel speed "1st", "4th" Voltage 20 - 30V
(12) and
selector
chassis "2nd", "3rd" Voltage Max. 1V
ground switch
WA200-5 20-321
(4)..d
9JF00532
20-322 WA200-5
(4)
[HST-3] HST Output Control (Traction control) cannot be controlled

Controller
code Trouble HST output control (Traction control) cannot be controlled
Contents of • The traction control switch system is defective, so the HST output control cannot be controlled.
trouble
Action of
or controller
Problem that
appears on • The HST output control (Traction control) cannot be controlled.
machine
Related • Traction control ON-OFF output signal can be checked in the monitoring function (Code: 80200).
information

1) Turn starting switch OFF. 2) Disconnect connector L56. 3) Connect T-adapter.
Defective traction control Between L56 Traction control switch ON Resistance Max. 1z
1
switch (Female) (3)
and (2) Traction control switch OFF Resistance Min. 1Mz
1) Turn starting switch OFF. 2) Disconnect Connectors L42, L56 and fuse FS1 termi-
nal. 3) Connect T-adapter.
harness (Disconnection in Wiring harness between L42 (Female) (3) and
2 wiring or defective contact Resistance Max. 1z
L56 (Female) (2)
in connector)
(Female) (3)
1) Turn starting switch OFF. 2) Disconnect Connectors L42, L56 and fuse FS1 termi-
Possible Wiring harness between L42 Resistance between L42
causes and (Female) (3) and L56 (Female) (Female) (3), L56 (Female) (2) Min. 1Mz
standard value Ground fault in wiring (3) and chassis ground
in normal state 3
harness
Resistance between fuse FS1
Wiring harness between fuse (12), L56 (Female) (3) and Min. 1Mz
FS1 (12) and L56 (Female) (3)
chassis ground
1) Turn starting switch OFF. 2) Disconnect connectors L41 and L56. 3) Connect T-
adapter. 4) Turn starting switch ON.
(Female) (3) and L56 (Female) (3), L56 (Female) (2) and chas- Max. 1V
(2) sis ground
1) Turn starting switch OFF. 2) Disconnect Connector L42. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.
5 Defective HST controller Between L42 Traction control switch ON Voltage 20 - 30V
(3) and chas-
sis ground Traction control switch OFF Voltage Max. 1V
WA200-5 20-323
(4)..d
9JF00533
20-324 WA200-5
(4)
[HST-4] (Travel speed limit cannot be changed when gear speed

selector switch is in "1st" position)
Controller
Action code Failure code Travel speed limit cannot be changed when gear speed selector switch
code Trouble
is in "1st" position
Contents of • There is disconnection, short circuit with ground, short circuit with power source (Hot short) in speed potentiometer
trouble system, so speed potentiometer signal is not input.
Action of
or controller
Problem that • Travel speed cannot be controlled when the travel speed selector switch is at 1st.
appears on
(Speed is fixed at 4 km/h or 13 km/h)
machine
Related • The speed potentiometer is displayed by real-time monitoring code 50302 {speed limit is taken as follows: max.
information (13 km/h = 100%)/min. (4 km/h = 0%)

Defective travel speed Between L54 (Female) (1) and (3) Resistance 4 - 6kz
1
potentiometer Between L54 (Female) (1) and (2) Resistance 0.25 - 5kz
Between L54 (Female) (2) and (3) Resistance 0.25 - 5kz
2nd Resistance Max. 1z
(2) Other than Resistance Min. 1Mz
the above
1st Resistance Min. 1Mz
Between L03 (Female) (1) and 2nd Resistance Min. 1Mz

(3) 3rd Resistance Max. 1z
2 Defective travel speed
selector switch 4th Resistance Max. 1z
(4) Other than
the above Resistance Min. 1Mz
1st Resistance Max. 1z

Possible
causes and Between L03 (Female) (3) and 2nd Resistance Min. 1Mz
standard value (4)
in normal state 3rd Resistance Min. 1Mz
1) Turn starting switch OFF. 2) Disconnect Connectors L41, L54, L03. 3) Connect T-
adapter
Disconnection in wiring Wiring harness between L41 (Female) (10) and Resistance Max. 1z
3
L54 (Female) (2)
Resistance Max. 1z
L54 (Female) (3)
1) Turn starting switch OFF. 2) Disconnect Connectors L41, L54, L03. 3) Connect T-
adapter
(Female) (10) and L54 (Female) (10) and chassis Min. 1Mz
(Female) (1) ground
4 Ground fault in wiring Wiring harness between L41
harness (Female) (1), L54 (Female) (2) Resistance between L41
(Female) (1) and chassis Min. 1Mz
and L03 (Female) (1)
30 ground

(Female) (2), L54 (Female) (3) (Female) (2) and chassis Min. 1Mz
and L03 (Female) (3) ground
WA200-5 20-325
(4)..d

1) Turn starting switch OFF. 2) Disconnect connector L41, L54 and L03.
3) Connect T-adapter. 4) Turn starting switch ON
(Female) (10) and L54 Max. 1V
(Female) (1)
5 Hot short in wiring harness Wiring harness between L41
Possible (Female) (1), L54 (Female) (2) Voltage between L41 (Female) Max. 1V
causes and (1) and chassis ground
and L03 (Female) (1)
standard value
in normal state Wiring harness between L41
Voltage between L41 (Female)
(Female) (2), L54 (Female) (3) Max. 1V
and L03 (Female) (3) (2) and chassis ground
1) Turn starting switch OFF. 2) Disconnect Connectors L41.

3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON
6) Travel speed selector switch 1ST
6 Defective HST controller
Between L41 (10) and (2) Voltage 4 - 6V
Between L41 (1) and (2) Voltage 0.5V - 5V
9JF00511
20-326 WA200-5
(4)
[HST-5] (Travel speed is not increased)

Action code Failure code Controller code
Trouble Travel speed is not increased (Abnormality in speed sensor system)
E03 DLT3KA HST
Contents of • The travel speed signal does not input due to disconnection or short-circuit with ground in travel speed sensor signal.
trouble
Action of
or controller
Problem that • Travel speed does not increase.
appears on
• Travel speed indicator on machine monitor stays at 0 km/h and does not move
machine
Related –
information

1) Turn starting switch OFF. 2) Disconnect Connectors L41, L42, L102 and T09.
Wiring harness between T09 (Female) (4) and L42
Resistance Max. 1z
(Female) (5)
Wiring harness between T09 (Female) (3) and L41
(Female) (13) Resistance Max. 1z

chassis ground
Disconnection in wiring har-
ness (Disconnection in wir- Wiring harness between T09 (Female) (1) and L41
1 (Female) (7), between L41 (Female) (8) and L102 Resistance Max. 1z
ing or defective contact in
connector) (Female) (5)
Resistance Max. 1z
fuse FS1 (3)
Resistance Max. 1z
chassis ground
D12 (Female) (2)
Wiring harness between D12 (Female) (3) and Resistance Max. 1z
fuse FS1 (12)
1) Turn starting switch OFF. 2) Disconnect Connectors L41, L42, L102 and T09.
Possible (13) and chassis ground
causes and
standard value Wiring harness between T09 Resistance between T09
in normal state (Female) (1), L41 (Female) (7)
(Female) (1) and L41 (Female)
and chassis ground, between Min. 1Mz
Ground fault in wiring (7), between L41 (Female) (8)
L41 (Female) (8), L102 (Female)
2 and L102 (Female) (5) *
harness (5) and chassis ground
Resistance between L102
Wiring harness between L102 (Female) (3) and fuse FS1 (3) Min. 1Mz
(Female) (3) and fuse FS1 (3) *
and chassis ground
(Female) (1) and D12 (Female) (Female) (1) and D12 (Female) Min. 1Mz
(2) * (2) and chassis ground
Resistance between D12
Wiring harness between D12 (Female) (3) and fuse FS1 (12) Min. 1Mz
(Female) (3) and fuse FS1 (12) *
and chassis ground
a In the above case of marked mark (*), the fuse is blown.
1) Turn starting switch OFF. 2) Disconnect connector T09. 3) Insert T-adapter. 4) Con-
nect connector. 5) Turn starting switch ON. 6) Move machine slightly and repeat fol-
lowing action: stop machine o measure voltage
Between T09 (1) and (2) Voltage 20 - 30V
Min. 5 V
Between T09 (3) and (2) Voltage (Pulse)
Defective travel speed sen-
3
sor a Measure the voltages according to the position where the machine is stopped.
Move machine forward in mea-
Voltage 20 - 30V
Between T09 surement condition
(4) and (2) Move machine in reverse in
measurement condition Voltage Min. 5 V
WARNING When moving the machine forward and in reverse when measuring the
voltage, be particularly careful to ensure safety.
WA200-5 20-327
(4)..d

4) Connect connector. 5) Turn starting switch ON. 6) Move machine slightly and
repeat following action: stop machine o measure voltage
Between L41 (7), (8) and chassis ground Voltage 20 - 30V
Possible Min. 5 V
Between L41 (13) and chassis ground Voltage
causes and (Pulse)
standard value
in normal state
4 Defective HST controller a Measure the voltages according to the position where the machine is stopped.
Move machine forward in mea-
Between L42 surement condition Voltage 20 - 30V
(5) and chas-
sis ground Move machine in reverse in
Voltage Min. 5 V
measurement condition
WARNING When moving the machine forward and in reverse when measuring the
voltage, be particularly careful to ensure safety.
9JF00519
20-328 WA200-5
(4)
TROUBLESHOOTING OF TRAVEL DAMPER
SYSTEM (ECSS MODE)
Related electrical circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-352

ECSS-1 Malfunction of travel damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-353
WA200-5 20-351
(4)..
TROUBLESHOOTING RELATED ELECTRICAL CIRCUIT DIAGRAM
RELATED ELECTRICAL CIRCUIT DIAGRAM

a For the connection table of the fuse box, see HST-mode, MON-mode, E-mode, etc.
a For how to read the troubleshooting table, see HST-mode, MON-mode, E-mode, etc.
a Before carrying out the troubleshooting, understand the contents of the related circuit diagram.
20-352 WA200-5
(4)
TROUBLESHOOTING ECSS-1
ECSS-1 MALFUNCTION OF TRAVEL DAMPER

a) Travel damper does not operate.
Action code Failure code Controller code Malfunction of travel damper
Trouble
Not set Not set Not set a) Travel damper does not operate
Contents of • The travel damper does not operate.

trouble
Action of monitor
panel or • None in particular.
controller
Problem that
appears on • The travel damper does not operate.
machine
Related • If the fuse is broken, check for ground fault.
information

1) Turn starting switch OFF
Defective travel damper 3) Connect T-adapter.
1
switch
Between L09 (male) Travel damper switch: ON Resistance Max. 1 z
(2) and (3) Travel damper switch: OFF Resistance Min. 1 Mz
1) Turn starting switch OFF.
2) Relay: Replace L110 with normal relay.
3) Turn starting switch ON.
4) Operate travel damper switch.
When relay L110 is No Relay L110 is normal.
replaced, does condition
become normal? Yes Relay L110 is defective.
2) Disconnect relay L110.
Defective travel damper 3) Check relay unit.
2
relay (L110)
Possible causes Between relay L110 (male) (1) and (2) Resistance 200 - 400z
and standard 1) Turn starting switch OFF..
value in normal 2) Disconnect relay L110.
state
3) Check relay unit.
4) Apply normal voltage between relay L110 (male) (1) and (2).
When 24 V is applied between
and (1) and (2) Resistance Max. 1 z
Between L110 (male)
(3) and (5) When normal voltage is not Resistance Min. 1 Mz
applied between and (1) and (2)
2) Replace travel damper solenoid (F07) with normal solenoid.
Travel damper solenoid is
When solenoid (F07) is No normal.
Defective travel damper replaced, does condition
3 become normal? Travel damper solenoid is
solenoid (F07) Yes
defective.
1) Turn starting switch OFF..
2) Disconnect connector F07.
3) Connect T-adapter.
Between F07 (male) (1) and (2) Resistance 21 - 24z
WA200-5 20-353
(4)..d
.
2) Replace diode (D05) with normal one.
Condition does not become normal. Diode (D05) is normal
Condition becomes normal. Diode (D05) is defective.
Check diode unit.
4 Defective diode (D05) Check continuity from (2) to (1) in diode range. There is continuity.
Check continuity from (2) to (3) in diode range. There is continuity.
Check continuity from (1) to (2) in diode range. There is not continuity.
Check continuity from (3) to (1) in diode range There is not continuity.
a Apply (+) pin of circuit tester to left line.
Defective travel damper
5 4) Turn starting switch ON.
controller
Between L14 (4) and Travel speed: 0 - 5 km/h Voltage Max. 1 V
chassis ground Travel speed: Above 6 km/h Voltage 20 - 30 V
Possible causes
and standard 2) Disconnect connectors L09, L110, L14, LT1, T09, D05, FL2, and F07 and fuse termi-
value in normal nal FS1
state 3) Connect T-adapter.
Wiring harness between fuse FS1 (13) and J05 (1), (6) and Resistance Max. 1 z
L14 (female) (1)
Wiring harness between fuse FS1 (13) and J05 (1), (7) and
Resistance Max. 1 z
L09 (female) (2)
Wiring harness between L09 (female) (3) and L110 (female) Resistance Max. 1 z
(3)
Wiring harness between L14 (female) (2) and chassis Resistance Max. 1 z
ground
Disconnection in wiring Wiring harness between L14 (female) (3) and LT1 (male) (2) Resistance Max. 1 z
harness (Disconnection in
6 Wiring harness between L14 (female) (4) and L110 (female) Resistance
wiring or defective Max. 1 z
contact in connector) (1)
Wiring harness between L110 (female) (2) and chassis
Resistance Max. 1 z
ground
Wiring harness between L110 (female) (5) and J08 (14), (15)
Resistance Max. 1 z
and D06 (female) (1)
Wiring harness between L110 (female) (5) and J08 (14), (16) Resistance
and FL2 (male) (4) Max. 1 z
Wiring harness between LT1 (female) (2) and T09 (female) Resistance Max. 1 z
(3)
Wiring harness between FL2 (female) (4) and F07 (female)
Resistance Max. 1 z
(1)
Wiring harness between F07 (female) (2) and chassis
Resistance Max. 1 z
ground
20-354 WA200-5
(4)

2) Disconnect connectors L09, L110, L14, LT1, T09, J08, D05, FL2, and F07 and fuse ter-
minal FS1
Between this
Wiring harness between fuse FS1 (13) and wiring harness
Resistance Min. 1 Mz
J05 (1), (6) and L14 (female) (1) and chassis
ground
Between this
Wiring harness between fuse FS1 (13) and wiring harness
J05 (1), (7) and L09 (female) (2) and chassis
ground
Between this
Wiring harness between L09 (female) (3) wiring harness
and L110 (female) (3) and chassis Resistance Min. 1 Mz
ground
Between this
Wiring harness between L14 (female) (3) wiring harness
and LT1 (male) (2) (A) and chassis Resistance Min. 1 Mz
Possible causes ground
and standard
value in normal Ground fault in wiring Between this
7 harness
state Wiring harness between L14 (female) (4) wiring harness Resistance Min. 1 Mz
and L110 (female) (1) and chassis
ground
Between this
Wiring harness between L110 (female) (5) wiring harness Resistance Min. 1 Mz
and J08 (14), (15) and D05 (female) (1) and chassis
ground
Between this
Wiring harness between L110 (female) (5) wiring harness Resistance Min. 1 Mz
and J08 (14), (16) and FL2 (male) (4) and chassis
ground
Between this
Wiring harness between LT1 (female) (2) wiring harness Resistance Min. 1 Mz
and T09 (female) (3) (A) and chassis
ground
Between this
Wiring harness between FL2 (female) (4) wiring harness Resistance Min. 1 Mz
and F07 (female) (1) and chassis
ground
a When ground fault occurs in a wiring harness other than the ones marked with (A),
the fuse is broken.
WA200-5 20-355
(4)..d
b) Travel damper is not reset

Action code Failure code Controller code Malfunction of travel damper
Trouble
Not set Not set Not set b) Travel damper is not reset
Contents of • The travel damper is not reset.

trouble
Action of monitor
panel or • None in particular.
controller
• The travel damper is not reset when the travel speed is above 6 km/h and the travel damper switch is turned OFF.
Problem that • The travel damper is not reset when the travel speed is below 5 km/h and the travel damper switch is turned ON.
appears on
machine • The travel damper is not reset when the travel speed is below 5 km/h and the travel damper switch is turned OFF.
(The travel damper is not reset under any condition.).
Related
–
information

Defective travel damper 3) Connect T-adapter.
1 switch
Between L09 (male) Travel damper switch: ON Resistance Max. 1 z
(2) and (3) Travel damper switch: OFF Resistance Min. 1 Mz
2) Relay: Replace L110 with normal relay.
4) Operate travel damper switch.
When relay L110 is No Relay L110 is normal.
become normal? Yes Relay L110 is defective.
Possible causes 2) Disconnect relay L110.
and standard Defective travel damper 3) Check relay unit.
2 relay (L110)
value in normal
state Between relay L110 (male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF..
2) Disconnect relay L110.
4) Apply normal voltage between relay L110 (male) (1) and (2).
Resistance Max. 1 z
Between L110 (male) and (1) and (2)
(3) and (5) When normal voltage is not
applied between and (1) and (2) Resistance Min. 1 Mz

2) Replace travel damper solenoid (F07) with normal solenoid.
3 solenoid (F07) (Not reset Travel damper solenoid is
under any condition) When solenoid (F07) is No normal.
become normal? Travel damper solenoid is
Yes defective.
20-356 WA200-5
(4)

2) Replace diode (D05) with normal one.
Condition does not become normal. Diode (D05) is normal
Condition becomes normal. Diode (D05) is defective.
Check diode unit.
4 Defective diode (D05) Check continuity from (2) to (1) in diode range. There is continuity.
Check continuity from (2) to (3) in diode range. There is continuity.
Check continuity from (3) to (1) in diode range There is not continuity.
a Apply (+) pin of circuit tester to left line.
5 4) Turn starting switch ON.
Possible causes controller
and standard Between L14 (4) and Travel speed: 0 - 5 km/h Voltage Max. 1 V
value in normal chassis ground
state Travel speed: Above 6 km/h Voltage 20 - 30 V
2) Disconnect connectors L09, L110, L14, J08, D05, FL2, and F07.
Wiring harness between Max. 1V

L09 (female) (3) and L110 Between this wiring harness and (Travel damper is not reset
(female) (3) chassis ground when speed is above 6 km/
h and switch is OFF)
Max. 1V
Wiring harness between
L14 (female) (4) and L110 Between this wiring harness and (Travel damper is not reset
(female) (1) chassis ground when speed is below 5 km/h
Hot short in wiring and switch is ON)
6
harness
L110 (female) (5) and J08 Between this wiring harness and Max. 1V
(14), (15) and D06 chassis ground (Travel damper is not reset
(female) (1) under any condition)
Wiring harness between Max. 1V

L110 (female) (5) and J08 Between this wiring harness and (Travel damper is not reset
(14), (16) and FL2 (male) chassis ground
under any condition)
(4)
Between this wiring harness and Max.
1V
FL2 (female) (4) and F07 chassis ground (Travel damper is not reset
(female) (1) under any condition)
WA200-5 20-357
(4)..d
TROUBLESHOOTING OF MONITOR
SYSTEM (MON MODE)
Monitor system circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402

Before troubleshooting code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406
Before troubleshooting electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-407
Information contained in troubuleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-408
Failure code [15B0NX] (HST oil filter clogged (NX)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410
Failure code [2G42ZG] (Decreased brake oil pressure (ZG)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-411
Failure code [989F00] (HST motor protection caution (00)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412
Failure code [989FN1] (HST overrunning (N1)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-413
Failure code [AB00L6] (Defective battery charging circuit (L6)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414
Failure code [AB00MA] (Defective battery charging circuit (MA)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-415
Failure code [B@BAZG] (Decreased engine oil pressure (ZG)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-416
Failure code [B@BCNS] (Engine coolant temperature overheating (NS)) . . . . . . . . . . . . . . . . . . . . . . . . . 20-417
Failure code [B@BCZK] (Alarm indicating low coolant level (ZK)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418
Failure code [B@C7NS] (Axle oil temperature overheating (NS)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-419
Failure code [B@CRNS] (HST oil temperature overheating (NS)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-420
Failure code [D5ZHL6] (Starting switch "C" (IGN "C") input failure (L6)) . . . . . . . . . . . . . . . . . . . . . . . . . 20-422
Failure code [DAF0KT] (Controller inside failure (KT)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-424
Failure code [DAJ0KR] (HST controller communication failure (KR)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-426
Failure code [DD15LD] (Monitor panel mode selector switch 1 [t] (Panel switch 1) input error (LD)) . . . 20-428
Failure code [DD16LD] (Monitor panel mode selector switch 1 [U] (Panel switch 2) input error (LD)) . . 20-429
Failure code [DD17LD] (Monitor panel mode selector switch 2 [<] (Panel switch 3) input error (LD)) . . . 20-430
Failure code [DD18LD] (Monitor panel mode selector switch 2 [>] (Panel switch 4) input error (LD)) . . . 20-431
Failure code [DDK3KB] (Multiple directional lever FR signal input (KB)). . . . . . . . . . . . . . . . . . . . . . . . . . 20-432
Failure code [DDS5L6] (Decreased steering oil pressure (L6)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-434
Failure code [DGE2KX] (Engine coolant temperature (High temperature) sensor system failure (KX)) . . 20-435
Failure code [DGE3L6] (Engine coolant temperature (Low temperature) sensor system failure (L6)) . . . 20-436
Failure code [DGH1KX] (HST oil temperature sensor system failure (KX)) . . . . . . . . . . . . . . . . . . . . . . . . 20-437
Failure code [DGR4KA] (Axle oil temperature sensor system discontinuity (KA)) . . . . . . . . . . . . . . . . . . . 20-438
Failure code [DGR4KX] (Axle oil temperature sensor system failure (KX)) . . . . . . . . . . . . . . . . . . . . . . . . 20-439
Failure code [DHE4L6] (Engine oil pressure sensor system discontinuity (L6)) . . . . . . . . . . . . . . . . . . . . 20-440
[MON-1] The parking brake indicator lamp does not light ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-442
[MON-2] The brake oil pressure warning lamp does not light ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-446
[MON-3] The engine coolant temperature warning lamp does not light ON, or after the engine starts,
the engine coolant temperature gauge does not rise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-447
[MON-4] The HST oil temperature warning lamp does not light ON, or after the engine starts,
the HST oil temperature gauge does not rise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-448
[MON-5] The fuel level gauge does not rise or decrease.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-449
[MON-6] The radiator coolant level warning lamp does not light ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-450
[MON-7] The steering oil pressure warning lamp does not light ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-451
[MON-8] The emergency steering oil pressure indicator lamp does not light ON . . . . . . . . . . . . . . . . . . . 20-452
[MON-9] Input failure in monitor panel mode selector switch 1 [t] (Panel switch 1) . . . . . . . . . . . . . . . . 20-453
[MON-10] Input failure in monitor panel mode selector switch 1 [U] (Panel switch 2) . . . . . . . . . . . . . . . . 20-454
[MON-11] Input failure in monitor panel mode selector switch 2 [<] (Panel switch 3) . . . . . . . . . . . . . . . . . 20-455
[MON-12] Input failure in monitor panel mode selector switch 2 [>] (Panel switch 4) . . . . . . . . . . . . . . . . . 20-456
[MON-13] The alarm buzzer does not sound or stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-457
[MON-14] The wiper does not function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458
[MON-15] The lamps do not work properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458
WA200-5 20-401
(4)..
TROUBLESHOOTING MONITOR SYSTEM CIRCUIT DIAGRAM
MONITOR SYSTEM CIRCUIT DIAGRAM
20-402 WA200-5
(4)
WA200-5 20-403
(4)..d
20-404 WA200-5
(4)
WA200-5 20-405
(4)..d
(4)
monitor
code
Failure
989F00
989F00
AB00L6
989FN1
15B0NX
D5ZHL6
DHE4L6
DDS5L6
DLE2LC
DX20KZ
DX19KZ
DD18LD
DD17LD
DD16LD
DD15LD
DAJ0KR
DAF0KT
2G42ZG
DGE3L6
AB00MA
DDK3KB
DW26KZ
DHH1KX
DGE2KX
DGR4KA
DGR1KX
DGH1KX
B@C7NS
B@BCZK
B@BAZG
20-406
HST controller
E00
E01
E03
E03
E03
E03
E03
E01
E02
E00
E03
E01
E01
E01
E01
E01
E01
E03
E03
E01
E01
E01
E01
E03
E01
E03
E03
B@CRNS E02
E02
B@BCNS E02
E01
E03
code
Failures related to
Failures related to
Action
Defective machine monitor
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Defective HST controller
q
q q
q
q
q
q
q
q q
TROUBLESHOOTING
Defective starting switch
q
Defective monitor panel mode switch 1 [t]
q
Defective monitor panel mode switch 1 [U]
q
Defective monitor panel mode switch 2 [<]
q
Defective monitor panel mode switch 2 [>]
q
Defective derectional lever
q
q
Battery is deteriorated
Defective battery relay
q q
Defective fuse, fusible link
Defective alternator
q
Defective engine revolution sensor
q
q
FAILURE CODE AND POSSIBLE CAUSES TABLE
q
Defective clutch solenoid
q q
Engine oil pressure drops
Defective engine oil pressure sensor
q
q q
Engine coolant temperature overheating
Defective engine coolant temperature sensor (high temperature)
q q
q
Defective engine coolant temperature sensor (low temperature)
q
Possible Causes
Engine coolant level lacks

Defective coolant level sensor
q q
q Defective HST oil pressure sensor
HST oil filter clogging
Defective HST oil filter sensor
q q
HST oil temperature overheating
Defective HST oil temperature sensor
q
q q
Brake oil pressure drops
Defective brake oil pressure sensor
q q Axle oil temperature overheating
Defective axle oil temperature sensor
q
q
q q
Steering oil temperature overheating
Defective steering oil temperature sensor
q q
Defective relay
q q
q
q
q
q q
q q
q
q
q
Ground fault in wiring harness
q
q
q q
q
q
q
q
q
q
q
q
q
q
q q
q
q q q
Hot short in wiring harness

q
q q
q
q
q
q q q
q q q q
WA200-5


2 10A Hazard lamp
3 10A HST control A
(Fuse box 1)
5 10A Meter, panel

14 10A Wiper
15 10A Car radio B
3 10A Beacon lamp
4 10A -
5 10A Load-meter
7 10A DC converter
Switch power source
9 10A Horn
14 10A (Spare 1)
15 10A (Spare 2)
WA200-5 20-407
(4)..d

Controller
trouble
Action of
or controller
appears on
machine ler.

information
<Data to fill in>


• Disconnection
2 • Ground fault
circuit
causes and
in normal state
female terminals
4
5
20-408 WA200-5
(4)
PHENOMENON CODE TABLE
a Regarding phenomenon code provided with instruction "Refer to table", check it against table below.
Phenomenon Details Disconnection Details
code
KA Disconnection L0 Fill signal ON 2 or more channels
KB Short circuit L1 Fill signal is ON when command current is OFF
KK Drop in power source voltage, input L2 Fuel pressure is higher than maximum set value
KQ Non match in model selection signal L3 Corresponding component cannot be controlled
KR Defective communication L4 ON/OFF signals for 2 systems do not match
Engine signals do not match operating condition or
KT Abnormality inside controller L6 stopped condition of machine
KX Input signal outside range L8 Analog signals for 2 systems do not match
KY Short circuit with power source (Hot short) LC Speed signals for 2 systems do not match
Switch has been kept pressed for abnormally long
KZ Disconnection or short circuit LD
time
MA Function impossible LH Fill signal is OFF when command current is ON
NS Overheat
ZG Drop in oil pressure
ZK Drop in level
WA200-5 20-409
(4)..d
TROUBLESHOOTING 15B0NX
Failure code [15B0NX] (HST oil filter clogged (NX))

Controller
code Trouble HST oil filter clogged (NX)
E01 15B0NX MON
Contents of • When HST oil temperature went above 50oC: signal circuit of HST oil filter clogging sensor changed to CLOSE (con-
trouble nected to GND)
Action of
or controller
Problem that
appears on • If it is used as it is, there is danger that dirt will circulated in the HST circuit
machine
Related
information
1 HST oil filter clogged • Clean or replace
1) Turn starting switch OFF. 2) Disconnect connector T13.

Defective HST oil filter Between T13 Filter is normal Resistance Min. 1Mz
2
clogging sensor and chassis
ground Filter clogged Resistance Max. 1z
Possible
causes and 1) Turn starting switch OFF. 2) Disconnect connector T13.
in normal state 3 Wiring harness between L23 Resistance between L23
harness (Female) (6), T13 and chassis Min. 1Mz
(Female) (6) and T13 ground
4 Defective machine monitor Filter is nor-
Voltage 20 - 30V
Between L23 (Female) (6) and mal
chassis ground
Filter clogged Voltage Max. 1V
20-410 WA200-5
(4)
TROUBLESHOOTING 2G42ZG
Failure code [2G42ZG] (Decreased brake oil pressure (ZG))

Controller
code Trouble Decreased brake oil pressure (ZG)
E03 2G42ZG MON
Contents of • When engine was running (continuously for more than 30 seconds), signal from accumulator oil pressure sensor went
trouble below 4.6 MPa {45 kg/cm2}.
Action of
or controller
Problem that
appears on • If it is used as it is, there is danger that the brake will have no effect.
machine
Related
information

Accumulator (Brake) oil pressure is normal
Decrease brake oil pres- a If the oil pressure is not normal, carry out troubleshooting for the hydraulic,
1
sure
mechanical system.
1) Turn starting switch OFF. 2) Disconnect connector T12. 3) Connect T-adapter.
Defective brake oil pres- Oil pressure is normal Resistance Max. 1z

2 Between T12 (5.88 MPa {60 kg/cm2})
sure sensor (Male) (1) and
(2) Oil pressure is low (3.92 MPa
Resistance Min. 1Mz
{40 kg/cm2})
Turn starting switch OFF. 2) Disconnect Connectors T12, T23. 3) Connect T-adapter.
Possible Wiring harness between T12 (Female) (1) and
3 harness (Disconnection in Resistance Max. 1z
causes and wiring or defective contact L23 (Female) (19)
standard value in connector) Wiring harness between T12 (Female) (2) and
in normal state chassis ground Resistance Max. 1z
1) Turn starting switch OFF. 2) Disconnect Connectors T12, L23. 3) Connect T-

adapter.
4 Wiring harness between L23 Resistance between L23
harness
(Female) (19) and T12 (Female) (19), T12 (Female) Min. 1Mz
5 Defective machine monitor Between L23 Oil pressure is normal Voltage Max. 1V
(Female) (19) (5.88MPa {60kg/cm2})
and chassis Oil pressure is low (3.92MPa
ground Voltage 20 - 30V
{40kg/cm2})
WA200-5 20-411
(4)..d
TROUBLESHOOTING 989F00
Failure code [989F00] (HST motor protection caution (00))

Controller
code Trouble Transmission protection caution (00)
E00 989F00 MON
• Not considered to be a failure.
Contents of • The travel speed exceeds the allowable speed of the HST motor on down shifting.
trouble
• The travel speed exceeds 36km/h.
Action of
or controller
Problem that
appears on • If travel speed exceeds 38 km/h, speed is automatically reduced.
machine
Related
information
20-412 WA200-5
(4)
TROUBLESHOOTING 989FN1
Failure code [989FN1] (HST overrunning (N1))

Controller
code Trouble HST overrunning (N1)
E02 989FN1 MON
Contents of • Travel speed exceeds 40 km/h.

trouble • Automatic speed reduction when travel speed exceeds 36 km/h does not work.
Action of
or controller
Problem that
appears on • If the machine is driven as it is, HST motor may be broken (seized).
machine
Related
information

2) Operate machine monitor
1 ---
Other code is displayed at Carry out troubleshooting for applicable code dis-
same time played
When machine was used in
Inspect and repair cause of problem and damage
Possible 2 Overrunning HST way that would cause HST to
causes and to HST.
overrun
standard value
in normal state 1) Start engine.
2) Operate machine monitor
3) Travel on flat ground.
3 Defective machine monitor Travel speed goes above 36 Carry out troubleshooting for HST controller sys-
km/h. tem failure codes DW26KZ and DX19KZ.
Travel speed does not go Inspect and repair cause of problem and damage
above 36 km/h. (Less than 36 to HST.
km/h)
WA200-5 20-413
(4)..d
TROUBLESHOOTING AB00L6
Failure code [AB00L6] (Defective battery charging circuit (L6))

Controller
Action code Failure code Defective battery charging circuit (L6)
code Trouble
(Alternator terminal R signal detected when engine stopped)
E03 AB00L6 MON
Contents of • The alternator terminal R signal input voltage is 12V or higher before the engine started.
trouble
Action of
or controller
Problem that • The engine cannot be started.
appears on
machine • The service meter increases simply by starting switch ON.
Related
information

Engine
started
Voltage 28 - 29V
Between alternator terminal R (Throttle 1/2
1 Defective alternator or more).
[E02 (1)] and chassis ground
Engine
Voltage Max. 1.5V
stopped.
Possible adapter. 4) Turn starting switch ON.
causes and 2 Hot short in wiring harness Wiring harness between L23 Voltage between L23 (Female)
standard value (Female) (12) and E02 (12), E02 (Female) (1) and Max. 1V
in normal state (Female) (1) chassis ground
Engine
started
3 Defective machine monitor Voltage 28 - 29V
Between L23 (Female) (12) (Throttle 1/2
and chassis ground or more).
Engine
stopped. Voltage Max. 1.5V
20-414 WA200-5
(4)
TROUBLESHOOTING AB00MA
Failure code [AB00MA] (Defective battery charging circuit (MA))

Controller Defective battery charging circuit (MA)
code Trouble (No signal from alternator terminal R when engine stopped, Abnormal
E03 AB00MA MON detection)
Contents of • During engine operation, the input voltage to the alternator terminal R signal is below 5V.
trouble
Action of
or controller
Problem that • The battery is deteriorated.

appears on • The engine cannot be started.
machine • The service meter does not work.
Related
information

1 Battery is deteriorated. ---
Engine
started
(Throttle 1/2 Voltage 28 - 29V
2 Defective alternator Between alternator terminal R
[E02 (1)] and chassis ground or more).
Engine
Voltage Max. 1.5V
stopped.
Disconnection in wiring 1) Turn starting switch OFF. 2) Disconnect Connectors L23, E02. 3) Connect T-
harness (Disconnection in adapter.
3 wiring or defective contact
Possible Wiring harness between L23 (Female) (12) and
in connector) E02 (Female) (1) Resistance Max. 1z
causes and
standard value 1) Turn starting switch OFF. 2) Disconnect Connectors L23, E02. 3) Connect T-
in normal state adapter.
4 harness Wiring harness between L23 Resistance between L23
(Female) (12) and E02 (Female) (12), E02 (Female) Min. 1Mz
Engine
5 Defective machine monitor started
(Throttle 1/2 Voltage 28 - 29V
Between L23 (Female) (12)
and chassis ground or more).
Engine Voltage Max. 1.5V
stopped.
WA200-5 20-415
(4)..d
TROUBLESHOOTING B@BAZG
Failure code [B@BAZG] (Decreased engine oil pressure (ZG))

Controller
code Trouble Decreased engine oil pressure (ZG)
E01 B@BAZG MON
Contents of • The engine oil pressure sensor circuit is always in the CLOSE state 15 minutes after the engine started.
trouble
Action of
or controller
Problem that
appears on • The engine oil pressure is low (The engine may be damaged).
machine
Related
information

Decreased engine oil pres-
1 ---
sure
1) Turn starting switch OFF. 2) Disconnect connector E15. 3) Connect T-adapter.
Engine
Defective engine oil pres- Between engine oil pressure Resistance Max. 1z
2 stopped.
sure sensor (switch) sensor terminal (E15) and
chassis ground Engine rotat-
Resistance Min. 1Mz
ing.
Possible
causes and 1) Turn starting switch OFF. 2) Disconnect Connectors L23, E15. 3) Connect T-
standard value adapter.
in normal state Ground fault in wiring
3 Resistance between L23
harness Wiring harness between L23
(Female) (10), E15 and chassis Min. 1Mz
(Female) (10) and E15 ground
Engine
4 Defective machine monitor stopped. Voltage Max. 1V
and chassis ground Engine rotat-
Voltage 20 - 30V
ing.
20-416 WA200-5
(4)
TROUBLESHOOTING B@BCNS
Failure code [B@BCNS] (Engine coolant temperature overheating

(NS))
Controller
code Trouble Engine coolant temperature overheating (NS)
E02 B@BCNS MON
Contents of • The engine coolant temperature is above 105°C
trouble
Action of • Activates an alarm (Turns the engine coolant temperature warning lamp ON at 102°C or above and issues this failure
monitor panel
code at 105°C or above).
or controller
Problem that
appears on • The engine coolant temperature overheat alarm is issued (The engine may be damaged if operation continues).
machine
Related
information

Overheating engine
1 ---
coolant temperature
Defective engine coolant Normal tem-
2 temperature sensor (high perature Resistance 35 - 50kz
temperature) Between E14 (Male) (1) and (2) (25°C).
When 100°C Resistance 3.1 - 4.5kz
Possible
causes and 1) Turn starting switch OFF. 2) Disconnect Connectors L21, E14. 3) Connect T-
in normal state 3 Ground fault in wiring
(Female) (16) and E14 (Female) (16), E14 (Female) Min. 1Mz
Normal tem-
4 Defective machine monitor
Between L21 (Female) (16) perature Resistance 35 - 50kz
and chassis ground (25°C).
When 100°C Resistance 3.1 - 4.5kz
WA200-5 20-417
(4)..d
TROUBLESHOOTING B@BCZK
Failure code [B@BCZK] (Alarm indicating low coolant level (ZK))

Controller
code Trouble Alarm indicating low coolant level (ZK)
E01 B@BCZK MON
Contents of • The coolant level sensor circuit is opened.
trouble
Action of
or controller
Problem that
appears on • The coolant level is low (The engine may be damaged).
machine
Related
information

1 Decrease coolant level. ---
1) Turn starting switch OFF. 2) Disconnect connector B05. 3) Connect T-adapter.
Reserve tank low level and
Defective coolant level sen- Between B Resistance Max. 1z
2 above (normal).
sor (Male) (1) and
(2) Reserve tank low level and
Resistance Min. 1Mz
below (abnormal).
1) Turn starting switch OFF. 2) Disconnect Connectors L23, B05. 3) Connect T-
Possible
causes and adapter.
standard value harness (Disconnection in Wiring harness between L23 (Female) (8) and
in normal state 3 wiring or defective contact Resistance Max. 1z
B05 (Female) (1)
in connector)
Wiring harness between B05 (Female) (2) and
Chassis ground Resistance Max. 1z

Between L23 Reserve tank low level and

4 Defective machine monitor Voltage Max. 1V
(Female) (8) above (normal).
and chassis Reserve tank low level and
ground below (abnormal). Voltage 20 - 30V
20-418 WA200-5
(4)
TROUBLESHOOTING B@C7NS
Failure code [B@C7NS] (Axle oil temperature overheating (NS))

Controller
code Trouble Axle oil temperature overheating (NS)
E02 B@C7NS MON
Contents of • The axle oil temperature is overheating.
trouble
Action of
or controller
Problem that
appears on • The brake may be damaged if operation continues.
machine
Related • This failure code is displayed if the probability of a failure in the electrical system is low.
information • The axle oil temperature is displayed by monitoring code 30202.

Overheating axle oil tem-
1 ---
perature.
1) Turn starting switch OFF. 2) Disconnect connector F14. 3) Connect T-adapter.
Possible 2 Defective axle oil tempera- Between F14 Normal temperature (25°C). Resistance 35 - 50kz
causes and ture sensor (Male) (1) and
standard value (2) When 100°C Resistance 3.1 - 4.5kz
in normal state
3 Defective machine monitor Between L21 Normal temperature (25°C). Resistance 35 - 50kz
(Female) (8)
and chassis When 100°C Resistance 3.1 - 4.5kz
ground
WA200-5 20-419
(4)..d
TROUBLESHOOTING B@CRNS
Failure code [B@CRNS] (HST oil temperature overheating (NS))

Controller
code Trouble HST oil temperature overheating (NS)
E02 B@CRNS MON
Contents of • The HST oil temperature is above 110°C.
trouble
Action of
or controller
Problem that
appears on • The HST may be damaged if operation continues.
machine
Related • This failure code is displayed if the probability of a failure in the electrical system is low.
information • The HST oil temperature is display by monitoring code 30100.

Overheating HST oil tem-
1 ---
perature.
Possible 2 Defective HST oil tempera- Between T10 Normal temperature (25°C). Resistance 35 - 50kz
causes and ture sensor (Male) (1) and
standard value (2) When 100°C Resistance 3.1 - 4.5kz
in normal state
(Female) (14)
ground
20-420 WA200-5
(4)
TROUBLESHOOTING D5ZHL6
Failure code [D5ZHL6] (Starting switch "C" (IGN "C") input failure
(L6))
Controller
code Trouble Starting switch "C" (IGN "C") input failure (L6)
E01 D5ZHL6 MON
Contents of • When engine was running, starting switch C (IGN C) terminal signal turned ON, or did not turn ON when starting
trouble switch was at START
Action of
or controller
Problem that
appears on • No reaction.
machine
Related
information

1) Turn starting switch OFF. 2) Disconnect starting switch terminals. 3) Connect T-
adapter.
1 Defective starting switch Between Starting switch START. Resistance Max. 1z
starting
switch termi- Other than the above. Resistance Min. 1Mz
nal B and C
2) Interchange relay (L106) with normal relay
Does condition become normal when neutral is abnormal. is normal.
safety relay (L106) is interchanged with normal
relay? The condition Defective
is normal. relay (L106)
Defective neutral safety 1) Turn starting switch OFF. 2) Disconnect connector L106. 3) Solid part check.
2
relay (L106) Between L106 (Male) (1) and (2) Resistance 200 - 400z
L106 (Male)
Possible between L106 (Male) (1) - (2)
causes and
standard value 1) Turn starting switch OFF. 2) Disconnect Connectors L02, L15, L23 and fuse L106.
in normal state 3) Connect T-adapter.
L106 (Female) (3)
wiring or defective contact L106 (Female) (5)
in connector)
Resistance Max. 1z
chassis ground
Resistance Max. 1z
L15 (Female) (3)
1) Turn starting switch OFF. 2) Disconnect Connectors L02, L15, L23 and L106.
(Female) (3) and L106 (Female) (3), L106 (Female) (3) Min. 1Mz
Ground fault in wiring Wiring harness between L23 Resistance between L23
4 (Female) (3) and L106 (Female) (3), L106 (Female) (5) Min. 1Mz
harness
a In the above case, the fuse is blown.
20-422 WA200-5
(4)
TROUBLESHOOTING D5ZHL6

1) Turn starting switch OFF. 2) Disconnect Connectors L23, L106. 3) Connect T-
adapter.
Possible (Female) (3) and L106 (3), L106 (Female) (5) and Max. 1V
causes and (Female) (5) chassis ground
standard value
in normal state 1) Turn starting switch OFF. 2) Disconnect connector L23. 3) Insert T-adapter.
6 Defective machine monitor Between L23 Starting switch START. Voltage 20 - 30V
(Female) (3)
and Chassis Other than the above. Voltage Max. 1V
ground
WA200-5 20-423
(4)..d
TROUBLESHOOTING DAF0KT
Failure code [DAF0KT] (Controller inside failure (KT))

Controller
code Trouble Controller inside failure (KT)
E03 DAF0KT MON
Contents of • Abnormality has occurred inside controller.
trouble
Action of
or controller
Problem that
appears on • Abnormality in data recorded inside monitor, monitor operation possible
machine
Related
information
Possible Causes Standard Value in Normal State and Remarks on Troubleshooting

causes and
standard value Abnormality inside machine monitor, so troubleshooting cannot be carried out.
1 Defective machine monitor
in normal state (Abnormality may be repaired by initializing machine monitor.)
20-424 WA200-5
(4)
TROUBLESHOOTING DAJ0KR
Failure code [DAJ0KR] (HST controller communication failure

(KR))
Controller
code Trouble HST controller communication failure (KR)
E03 DAJ0KR MON
Contents of • Communications (CAN) data cannot be received from HST controller.
trouble
Action of
or controller
Problem that • HST controller holds at condition before abnormality occurred.
appears on • HST controller actuates with mode that ignores CAN communications.
machine
• Movement of machine becomes abnormal.
Related • Speed range display does not switch.
information
• Speedometer always displays 0 km/h.

adapter.
Wiring harness between L22
(Female) (6) and L42 (Female) 40 - 80z
(Female) (2) and (6)
(16))
(Female) (2) and L42 (Female) 40 - 80z
(Female) (2) and (6)
(8)
1 Defective wiring harness
(Female) (6) and L42 (Female) (Female) (2) and chassis Min. 1Mz
(16) ground
(Female) (2) and L42 (Female) (Female) (2) and chassis Min. 1Mz
(8) ground
a Check that terminal resistances CAN1, CAN 2 are connected.
a Resistance value of terminal resistances CAN1, CAN 2: 120z
Possible 1) Turn starting switch OFF. 2) Replace HST controller. 3) Turn starting switch ON.
causes and
standard value HST control-
in normal state Communication is abnormal. ler is normal.
2 Defective HST controller When HST controller is
replaced, do communications Defective
become normal? Communication is normal. HST control-
ler
1) Turn starting switch OFF. 2) Disconnect Connectors CAN1, CAN2. 3) Connect T-
adapter.
Defective terminal resis-
3 tance Wiring harness between CAN1 (A) and (B) Resistance 100 - 130z
Wiring harness between CAN2 (A) and (B) Resistance 100 - 130z
1) Turn starting switch OFF. 2) Replace machine monitor. 3) Turn starting switch ON.
Machine
Communication is abnormal. monitor is
When machine monitor is normal.
replaced, do communications
4 Defective machine monitor become normal? Defective
Communication is normal. Machine
monitor
a When replacing the machine monitor, carry out adjustments.
For details, see TESTING AND ADJUSTING, Adjusting machine monitor.
20-426 WA200-5
(4)
TROUBLESHOOTING DAJ0KR
WA200-5 20-427
(4)..d
TROUBLESHOOTING DD15LD
Failure code [DD15LD] (Monitor panel mode selector switch 1 [t]

(Panel switch 1) input error (LD))
Controller
Action code Failure code Monitor panel mode selector switch 1 [t] (Panel switch 1) input error
code Trouble
(LD)
E01 DD15LD MON
Contents of • The monitor panel mode selector switch 1 [t] (Panel switch 1) input circuit is always in the CLOSE state for more
trouble thirty seconds.
Action of
or controller
Problem that
appears on • The monitor does not work.
machine
Related
information

Defective monitor panel When monitor panel mode

1 Between L10 selector switch 1 [t] is turned Resistance Max. 1z
mode selector switch 1 [t] (Female) (2) ON.
and (3)
Other than above. Resistance Min. 1Mz
Possible
causes and adapter. 4) Turn starting switch ON.
standard value 2 Hot short in wiring harness Wiring harness between L21 Voltage between L21 (Female)
in normal state (Female) (1) and L10 (Female) (1), L10 (Female) (3) and chas- Max. 1V
(3) sis ground
3 Defective machine monitor Between L21 When monitor panel mode

(Female) (1) selector switch 1 [t] is turned Voltage 20 - 30V
and chassis ON.
ground Other than above. Voltage Max. 1V
20-428 WA200-5
(4)
Failure code [DD16LD] (Monitor panel mode selector switch 1 [U]

Controller
Action code Failure code Monitor panel mode selector switch 1 [U] (Panel switch 2) input error
code Trouble
(LD)
E01 DD16LD MON
Contents of • The monitor panel mode selector switch 1 [U] (Panel switch 2) input circuit is always in the CLOSE state for more
trouble thirty seconds.
Action of
or controller
Problem that
machine
Related
information


1 Between L10 selector switch 1 [U] is turned Resistance Max. 1z
mode selector switch 1 [U] (Female) (2) ON.
and (1)
Possible
standard value 2 Hot short in wiring harness Wiring harness between L21 Voltage between L21 (Female)
in normal state (Female) (2) and L10 (Female) (2), L10 (Female) (1) and chas- Max. 1V
(1) sis ground

(Female) (2) selector switch 1 [U] is turned Voltage 20 - 30V
and chassis ON.
WA200-5 20-429
(4)..d
Failure code [DD17LD] (Monitor panel mode selector switch 2 [<]

Controller
Action code Failure code Monitor panel mode selector switch 2 [<] (Panel switch 3) input error
code Trouble
(LD)
E01 DD17LD MON
Contents of • The monitor panel mode selector switch 2 [<] (Panel switch 3) input circuit is always in the CLOSE state for more thirty
trouble seconds.
Action of
or controller
Problem that
machine
Related
information


1 Between L11 selector switch 2 [<] is turned Resistance Max. 1z
mode selector switch 2 [<] (Female) (2) ON.
and (3)
Possible
standard value harness Wiring harness between L21 Resistance between L21
in normal state (Female) (4) and L11 (Female) (Female) (4), L11 (Female) (3) Min. 1Mz

(Female) (4) selector switch 2 [<] is turned Voltage Max. 1V
and chassis ON.
ground Other than above. Voltage 20 - 30V
20-430 WA200-5
(4)
Failure code [DD18LD] (Monitor panel mode selector switch 2 [>]

Controller
Action code Failure code Monitor panel mode selector switch 2 [>] (Panel switch 4) input error
code Trouble
(LD)
E01 DD18LD MON
Contents of • The monitor panel mode selector switch 2 [>] (Panel switch 4) input circuit is always in the CLOSE state for more thirty
trouble seconds.
Action of
or controller
Problem that
machine
Related
information


1 Between L11 selector switch 2 [>] is turned Resistance Max. 1z
mode selector switch 2 [>]. (Female) (2) ON.
and (1)
Possible

(Female) (5) selector switch 2 [>] is turned Voltage Max. 1V
and chassis ON.
WA200-5 20-431
(4)..d
TROUBLESHOOTING DDK3KB
Failure code [DDK3KB] (Multiple directional lever FR signal input

(KB))
Controller
code Trouble Multiple directional lever FR signal input (KB)
E03 DDK3KB MON
Contents of • Multiple signals (F and R signal) are input due to short-circuited directional lever.
trouble
Action of • Input signal is displayed as it is (F and R light up at same time).

monitor panel • When engine is started, machine moves even when directional lever is at N position.
or controller • Activates an alarm.
Problem that • Does not travel.

appears on
• The power train may be damaged.
machine
Related
information

1 Hot short in wiring harness (Female) (10) and L15 (10), L15 (Female) (2) and Max. 1V
(Female) (2) chassis ground
(4) sis ground
Between L15 When directional lever is turned Resistance Max. 1z

Possible (Female) (1) F.
causes and and (2)
standard value 2 Defective directional lever Other than above. Resistance Min. 1Mz
in normal state When directional lever is turned
Between L15 Resistance Max. 1z
(Female) (1) R.
and (4) Other than above. Resistance Min. 1Mz
Between L15 When directional lever is turned

F. Voltage 20 - 30V
(Female) (1)
3 Defective machine monitor and (2) Other than above. Voltage Max. 1V

R. Voltage 20 - 30V
(Female) (1)
and (4) Other than above. Voltage Max. 1V
20-432 WA200-5
(4)
TROUBLESHOOTING DDK3KB
WA200-5 20-433
(4)..d
TROUBLESHOOTING DDS5L6
Failure code [DDS5L6] (Decreased steering oil pressure (L6))

Controller
code Trouble Decreased steering oil pressure (L6)
E03 DDS5L6 MON
Contents of • The steering oil pressure sensor signal circuit is always in the CLOSE state during the engine is revolved.
trouble
Action of
or controller
Problem that
appears on • The steering may be not worked if operation continues.
machine
Related • This warning is given only when the emergency steering is installed.
information

• Steering oil pressure is normal.
Decreased steering oil a If the oil pressure is not normal, carry out troubleshooting for the hydraulic,
1
pressure
mechanical system.

Steering oil pressure is low
2 Defective steering oil pres- Between F11 (Engine stopped). Resistance Max. 1z
sure sensor (switch) (Male) (A)
and (C) Steering oil pressure is normal Resistance Min. 1Mz
(Engine started).
Possible 1) Turn starting switch OFF. 2) Disconnect Connectors L22, F11. 3) Connect T-
causes and adapter.
in normal state 3 Wiring harness between L22 Resistance between L22
harness
(Female) (3) and F11 (Female) (Female) (3), F11 (Female) (C) Min. 1Mz
(C) and chassis ground
Steering oil pressure is normal.
[0.9 MPa {9.2 kg/cm 2}] and Voltage 20 - 30V
4 Defective machine monitor Between L22 above
(Female) (3)
and Chassis Steering oil pressure is abnor-
ground mal (low). Voltage Max. 1V
[0.5 MPa {5.1 kg/cm 2}] and
below
20-434 WA200-5
(4)
TROUBLESHOOTING DGE2KX
Failure code [DGE2KX] (Engine coolant temperature (High

temperature) sensor system failure (KX))
Controller
Action code Failure code Engine coolant temperature (High temperature) sensor system failure
code Trouble
(KX)
E01 DGE2KX MON
Contents of • The engine coolant temperature sensor input voltage is less 0.98V.
trouble
Action of
or controller
Problem that
appears on • The engine coolant temperature gauge is in the MAX position.
machine
Related • The engine coolant temperature is displayed by real-time monitoring code 04101.
information

Defective engine coolant
1 temperature (High temper- Between E14 Normal temperature (25°C). Resistance 35 - 50kz
ature) sensor (Male) (1) and
(2) When 100°C Resistance 3.1 - 4.5kz
Possible adapter.
causes and Ground fault in wiring
standard value
in normal state (Female) (16) and E14 (Female) (16), E14 (Female) Min. 1Mz
(Female) (16)
ground
WA200-5 20-435
(4)..d
TROUBLESHOOTING DGE3L6
Failure code [DGE3L6] (Engine coolant temperature (Low

temperature) sensor system failure (L6))
Controller
Action code Failure code Engine coolant temperature (Low temperature) sensor system failure
code Trouble
(L6)
E01 DGE3L6 MON
Contents of • After starting the engine, and running it for more than 30 minutes, engine coolant temperature (low temperature) sen-
trouble sor signal becomes abnormal 4.5V
Action of
monitor panel • The Activates an alarm.
or controller
Problem that
appears on • After starting switch is turned ON, system always carries out automatic preheating.
machine
Related • The engine coolant temperature (low temperature) is displayed by real-time monitoring code 04101.
information

1 temperature (Low tempera- Between E13 Normal temperature (25°C). Resistance 3.1 - 5.7kz
ture) sensor (Male) (A)
and (B) When 100°C Resistance 0.2 - 0.7kz
Possible Disconnection in wiring 1) Turn starting switch OFF. 2) Disconnect Connectors L21, E13. 3) Connect T-
causes and harness (Disconnection in adapter.
2
standard value wiring or defective contact Wiring harness between L21 (Female) (6) and
in normal state in connector) Resistance Min. 1Mz
E13 (Female) (A)
3 Defective machine monitor Between L21 Normal temperature (25°C). Resistance 3.1 - 5.7kz
(Female) (6)
ground
20-436 WA200-5
(4)
TROUBLESHOOTING DGH1KX
Failure code [DGH1KX] (HST oil temperature sensor system

failure (KX))
Controller
code Trouble HST oil temperature sensor system failure (KX)
E01 DGH1KX MON
Contents of • The HST oil temperature sensor input voltage is less 0.98V.
trouble
Action of
or controller
Problem that
appears on • The HST oil temperature gauge is in the MAX position.
machine
Related • The HST oil temperature is displayed by real-time monitoring code 30100.
information

Defective HST oil tempera- Between T10 Normal temperature (25°C). Resistance 35 - 50kz
1
ture sensor (Male) (1) and
1) Turn starting switch OFF. 2) Disconnect Connectors L21, T10. 3) Connect T-
Possible adapter.
standard value
in normal state (Female) (14) and T10 (Female) (14), T10 (Female) Min. 1Mz
(Female) (14)
ground
WA200-5 20-437
(4)..d
TROUBLESHOOTING DGR4KA
Failure code [DGR4KA] (Axle oil temperature sensor system

discontinuity (KA))
Controller
code Trouble Axle oil temperature sensor system discontinuity (KA)
E01 DGR4KA MON
Contents of • The axle oil temperature sensor signal is 4.5 V or above.
trouble
Action of
or controller
Problem that
appears on • The axle oil temperature is displayed by real-time monitoring code 30202.
machine
Related
information

Defective axle oil tempera- Between F14 Normal temperature (25°C). Resistance 35 - 50kz
1
Disconnection in wiring 1) Turn starting switch OFF. 2) Disconnect Connectors L21, F14. 3) Connect T-
Possible
2 wiring or defective contact
standard value Wiring harness between L21 (Female) (8) and
in normal state in connector) Resistance Max. 1z
F14 (Female) (1)
Defective machine monitor Between L21 Normal temperature (25°C). Resistance 35 - 50kz
3
(Female) (8)
ground
20-438 WA200-5
(4)
TROUBLESHOOTING DGR4KX
Failure code [DGR4KX] (Axle oil temperature sensor system

failure (KX))
Controller
code Trouble Axle oil temperature sensor system failure (KX)
E01 DGR4KX MON
Contents of • The brake oil temperature sensor input voltage is less 0.98V.
trouble
Action of
or controller
Problem that
appears on • The axle oil temperature is displayed by real-time monitoring code 30202.
machine
Related
information

Defective axle oil tempera- Between F14 Normal temperature (25°C). Resistance 35 - 50kz
1
1) Turn starting switch OFF. 2) Disconnect Connectors L21, F14. 3) Connect T-
Possible adapter.
causes and 2 Ground fault in wiring
in normal state (Female) (8) and F14 (Female) (Female) (8), F14 (Female) (1) Min. 1Mz
(Female) (8)
ground
WA200-5 20-439
(4)..d
TROUBLESHOOTING DHE4L6
Failure code [DHE4L6] (Engine oil pressure sensor system

discontinuity (L6))
Controller
code Trouble Engine oil pressure sensor system discontinuity (L6)
E01 DHE4L6 MON
Contents of • The engine oil pressure sensor circuit is always in the CLOSE state when the engine is stopped.
trouble
Action of
or controller
Problem that
appears on
machine
Related
information

Engine
Defective engine oil pres- Between engine oil pressure Resistance Max. 1z
1 sure sensor (switch) stopped.
sensor terminal E15 and chas-
sis ground Engine rotat-
ing. Resistance Min. 1Mz
Possible Disconnection in wiring 1) Turn starting switch OFF. 2) Disconnect Connectors L22, E15. 3) Connect T-
standard value 2
in normal state in connector) Resistance Max. 1z
E15 (Female) (C)
Engine
3 Defective machine monitor stopped. Voltage Max. 1V
and Chassis ground Engine rotat- Voltage 20 - 30V
ing.
20-440 WA200-5
(4)
TROUBLESHOOTING MON-1
[MON-1] (The parking brake indicator lamp does not light ON)
Controller
code Trouble The parking brake indicator lamp does not light ON
Contents of • The parking brake indicator lamp does not light ON when the parking brake lever is pulled.
trouble
Action of
or controller
Problem that
appears on • The parking brake indicator lamp does not light ON when the parking brake lever is pulled.
machine
Related • If the parking brake does not work normally, carry out troubleshooting after carrying out the applicable troubleshoot-
information ing.

starting switch ON. 4) Operate parking brake switch.
Does condition become normal Relay (L104)

The condition is abnormal.
when parking brake indicator is normal.
lamp relay (L104) is inter- Defective
changed with normal relay? The condition is normal.
relay (L104)
Defective parking brake 1) Turn starting switch OFF. 2) Disconnect connector L104. 3) Solid part check.
1
indicator lamp relay (L104) Between L104 (Male) (1) and (2) Resistance 200 - 400z
L104 (Male)

2) Replace L101 with normal relay.
4) Operate parking brake switch.
When mechanical parking No Relay (L101)

brake relay (L101) is replaced, is normal.
Possible does condition becomes nor-
causes and Relay (L101)
mal? Yes is defective.
standard value
in normal state 1) Turn starting switch OFF.
2 Defective mechanical park- 2) Disconnect connector L101.
ing brake relay (L101) 3) Check relay unit.
Between L101 (male) (1) and (2) Resistance 200 - 400z
4) Apply normal voltage between L101 (male) (1) and (2).
Between Apply 24 V between (1) and (2). Resistance Max. 1z

L101 (male) Do not apply 24 V between (1)
(3) and (4) and (2). Resistance Min. 1Mz

Defective parking brake
lever middle position detec- Parking brake lever is placed
3 Between L47 LOCK to MIDDLE. Resistance Max. 1z
tion switch (Mechanical (Male) (1) and
type) (2) Parking brake lever is placed
Resistance Min. 1Mz
MIDDLE to FREE.
Defective parking brake Set parking brake lever to bot-
lever lowest position detec- Resistance Max. 1z
Between L53 tom position.
4 tion switch (Mechanical (Male) (1) and Set parking brake lever to any
type) (2) position other than bottom posi- Resistance Min. 1Mz
tion.
20-442 WA200-5
(4)

1) Turn starting switch OFF. 2) Disconnect Connectors L23, L47, L53 and L104.
3) Connect T-adapter. 4) Check that connector L20 is connected to L18.
L104 (Female) (6)
chassis ground Resistance Max. 1z
Disconnection in wiring Wiring harness between L104 (Female) (2) and Resistance Max. 1z
harness (Disconnection in chassis ground
5
in connector) J12 (Female) (7) Resistance Max. 1z

J12 (Female) (5)
Wiring harness between J12 (Female) (6) and

fuse FS1 (4)
1) Turn starting switch OFF. 2) Disconnect connector L23, L53, L47, L104. 3) Con-
nect T-adapter.
Possible Wiring harness between L23 Resistance between L23

causes and (Female) (18) and L104 (Female) (18), L104 (Female) Min. 1Mz
standard value (Female) (5) * (5) and chassis ground
(Female) (1) and J12 (Female) (Female) (1) and chassis Min. 1Mz
(7) ground
Ground fault in wiring Wiring harness between J10 Resistance between L53
6 (Female) (19) and L53 (Female) (2) and chassis Min. 1Mz
harness
(Female) (2) ground
(Female) (1) and J12 (Female) (Female) (1) and chassis Min. 1Mz
(5), (6) and L47 (Female) (2) ground

(Female) (1) and fuse FS1 (4) (Female) (1) and chassis Min. 1Mz
ground
a In the above case (Other than marked mark (*)), the fuse is blown.
7 Defective junction connec- Carry out inspection, and if any abnormality is found, repair or replace.
tor (J10) and (J12)
Between L23 Parking brake lever is placed

(Female) (18) PARKING.
and chassis Parking brake lever is placed
ground other than FREE. Voltage 20 - 30V
WA200-5 20-443
(4)..d
20-444 WA200-5
(4)
WA200-5 20-445
(4)..d
[MON-2] (The brake oil pressure warning lamp does not light ON)
Controller
code Trouble The brake oil pressure warning lamp does not light ON
Contents of • The brake oil pressure sensor signal circuit is always in the CLOSE state.
trouble
Action of
or controller
Problem that
appears on • The brake oil pressure warning lamp does not light ON when accumulator oil pressure is decreased.
machine
Related
information

Brake oil pressure is normal
Defective brake oil pres- (When 5.88MPa {60kg/cm2} Resistance Max. 1z
1 Between T12 and above).
sure sensor (Male) (1) and
(2) Steering oil pressure is abnor-
mal (When 3.92MPa {40kg/ Resistance Min. 1Mz
cm 2} and below).
Possible adapter.
standard value 2 harness Wiring harness between L23 Resistance between L23
in normal state (Female) (19) and T12 (Female) (19), T12 (Female) Min. 1Mz
4) Connect connector. 5) Start engine.
Brake oil pressure is normal
3 Defective machine monitor Between L23 (When 5.88MPa {60kg/cm2} Voltage Max. 1V
(Female) (19) and above).
and Chassis Steering oil pressure is abnor-
ground mal (When 3.92MPa {40kg/ Voltage 20 - 30V
cm 2} and below).
20-446 WA200-5
(4)
[MON-3] (The engine coolant temperature warning lamp does not

light ON, or after the engine starts, the engine coolant temperature
gauge does not rise.)
Controller
Action code Failure code The engine coolant temperature warning lamp does not light ON, or after
code Trouble
the engine starts, the engine coolant temperature gauge does not rise.
Contents of • The engine coolant temperature sensor circuit is always in the OPEN state.
trouble
Action of
or controller
Problem that • The engine coolant temperature warning lamp does not light ON.
appears on
machine • After the engine starts, the engine coolant temperature gauge does not rise.
Related • The engine coolant temperature is displayed by real-time monitoring code 04101.
information

Defective engine coolant Between E14 Normal temperature (25°C) Resistance 35 - 50kz
1 temperature sensor (Male) (1) and
Possible adapter.
causes and harness (Disconnection in Wiring harness between L21 (Female) (16) and
standard value 2 wiring or defective contact Resistance Max. 1z
E14 (Female) (1)
in normal state in connector)
Wiring harness between E14 (Female) (2) and Resistance Max. 1z
chassis ground
Between L21 Normal temperature (25°C) Resistance 35 - 50kz
3 Defective machine monitor (Female) (16)
and Chassis When 100°C Resistance 3.1 - 4.5kz
ground
WA200-5 20-447
(4)..d
[MON-4] (The HST oil temperature warning lamp does not light ON,
or after the engine starts, the HST oil temperature gauge does not
rise.)
Controller
Action code Failure code The HST oil temperature warning lamp does not light ON, or after the
code Trouble
engine starts, the HST oil temperature gauge does not rise.
Contents of • The HST oil temperature sensor circuit is always in the OPEN state.
trouble
Action of
or controller
Problem that • The HST oil temperature warning lamp does not light ON.
appears on
machine • After the engine starts, the HST oil temperature gauge does not rise.
Related • The HST oil temperature is displayed by real-time monitoring code 30100.
information

Defective HST oil tempera- Between T10 Normal temperature (25°C). Resistance 35 - 50kz
1 ture sensor (Male) (1) and
Possible adapter.
causes and harness (Disconnection in Wiring harness between L21 (Female) (14) and
standard value 2 wiring or defective contact Resistance Max. 1z
T10 (Female) (1)
chassis ground
Between L21 Normal temperature (25°C). Resistance 35 - 50kz
3 Defective machine monitor (Female) (14)
and Chassis When 100°C Resistance 3.1 - 4.5kz
ground
20-448 WA200-5
(4)
[MON-5] (The fuel level gauge does not rise or decrease.)

Controller
code Trouble The fuel level gauge does not rise or decrease.
Contents of • An abnormality has occurred in the fuel level sensor circuit.
trouble
Action of
or controller
Problem that
appears on • The fuel level gauge does not rise or decrease.
machine
Related • The fuel level is displayed by real-time monitoring code 04202.
information

1) Turn starting switch OFF. 2) Disconnect connector R21. 3) Connect T-adapter.
FULL Resistance 1 - 5z
1 Defective fuel level sensor
Between R21 (Male) (1) and (2) 1/2 LEVEL Resistance 29 - 36z
EMPTY Resistance 103 - 117z
1) Turn starting switch OFF. 2) Disconnect Connectors L23, R21. 3) Connect T-
adapter.
2 harness (Disconnection in Wiring harness between L23 (Female) (13) and
Possible R21 (Female) (1)
causes and in connector)
Wiring harness between R21 (Female) (2) and
standard value chassis ground Resistance Max. 1z
in normal state
1) Turn starting switch OFF. 2) Disconnect Connectors L23, R21. 3) Connect T-
adapter.
(Female) (13) and R21 (Female) (13), R21 (Female) Min. 1Mz
FULL Resistance 1 - 5z
4 Defective machine monitor Between L23 (Female) (13)
1/2 LEVEL Resistance 29 - 36z
and Chassis ground
EMPTY Resistance 103 - 117z
WA200-5 20-449
(4)..d
[MON-6] (The radiator coolant level warning lamp does not light
ON)
Controller
code Trouble The radiator coolant level warning lamp does not light ON
Contents of • The radiator coolant level sensor signal circuit is always in the CLOSE state.
trouble
Action of
or controller
Problem that • The radiator coolant level warning lamp does not light ON, when the radiator coolant level (Coolant volume) is insuffi-
appears on cient.
machine
Related • The radiator coolant level warning lamp does not light up until the sensor circuit is kept OPEN for 30 seconds.
information

1) Turn starting switch OFF. 2) Disconnect connector B05. 3) Connect T-adapter.
Between B05 Reserve tank low level or more

1 Defective radiator coolant (Normal). Resistance Max. 1z
level sensor (Male) (1) and
chassis Reserve tank low level or less
ground Resistance Min. 1Mz
(Abnormal).
1) Turn starting switch OFF. 2) Disconnect Connectors L23, B05. 3) Connect T-
Possible adapter.
causes and
standard value Ground fault in wiring Wiring har-
2 ness between Resistance between L23
in normal state harness
L23 (Female) (Female) (8), B05 (Female) (1) Resistance Min. 1Mz
(8) and B05 and chassis ground
(Female) (1)
Between L23 Reserve tank low level or more

3 Defective machine monitor (Normal). Resistance Max. 1z
(Female) (8)
and Chassis Reserve tank low level or less
ground (Abnormal). Resistance Min. 1Mz
20-450 WA200-5
(4)
[MON-7] (The steering oil pressure warning lamp does not light
ON)
Controller
code Trouble The steering oil pressure warning lamp does not light ON
Contents of • The steering oil pressure sensor signal circuit is always in the CLOSE state during the engine is revolved.
trouble
Action of
or controller
Problem that
appears on • The steering may be not worked if operation continues.
machine
Related • This warning is given when the emergency steering (if equipped) is installed.
information

adapter.
Defective steering oil pres- Steering oil pressure is low
1 Between F11 Resistance Max. 1z
sure sensor (switch) (Engine stopped).
(Male) (A)
and (C) Steering oil pressure is normal
(Engine started). Resistance Min. 1Mz

Possible adapter.
causes and Disconnection in wiring
standard value 2 harness (Disconnection in Wiring harness between L22 (Female) (3) and
in normal state F11 (Female) (C)
in connector)
Wiring harness between F11 (Female) (A) and Resistance Max. 1z
chassis ground
Between L22 Steering oil pressure is low

(Female) (3) (Engine stopped).
and Chassis Steering oil pressure is normal
ground (Engine started). Voltage 20 - 30V
WA200-5 20-451
(4)..d
[MON-8] (The emergency steering oil pressure indicator lamp does

not light ON)
Controller
code Trouble The emergency steering oil pressure indicator lamp does not light ON
Contents of • The emergency steering oil pressure sensor circuit is always in the OPEN state during the engine is revolved.
trouble
Action of
or controller
Problem that • The emergency steering does not work, so if the machine continues to be used, there is danger that the steering itself
appears on will stop working.
machine
Related • This indicator lights up only when the emergency steering (if equipped) is installed.
information

adapter.
Defective steering oil pres- Steering oil pressure is low.
1 Between F12 Resistance Min. 1Mz
sure sensor (switch) (While engine is stopped)
(Male) (A)
and (B) Steering oil pressure is normal.
(While engine is running) Resistance Max. 1z

Possible adapter.
standard value 2 harness (Disconnection in Wiring harness between L22 (Female) (5) and
in normal state F12 (Female) (B)
in connector)
Wiring harness between F12 (Female) (A) and Resistance Max. 1z
chassis ground
Between L22 Steering oil pressure is low.

3 Defective machine monitor Voltage 20 - 30V
(Female) (5) (While engine is stopped)
and Chassis Steering oil pressure is normal.
ground (While engine is running) Voltage Max. 1V
20-452 WA200-5
(4)
[MON-9] (Input failure in monitor panel mode selector switch 1 [t]

(Panel switch 1))
Controller
code Trouble Input failure in monitor panel mode selector switch 1 [t] (Panel switch 1)
Contents of • The monitor panel mode selector switch 1 [t] (Panel switch 1) input circuit is always in the OPEN state.
trouble
Action of
or controller
Problem that
machine
Related
information


1 Between L10 selector switch 1 [t] is turned Resistance Max. 1z
mode selector switch 1 [t] (Female) (2) ON.
and (3)
1) Turn starting switch OFF. 2) Disconnect Connectors L21, L10, fuse FS1 (5).
in connector)
fuse FS1 (5)
Possible
causes and 1) Turn starting switch OFF. 2) Disconnect Connectors L21, L10, fuse FS1 (5). 3)
standard value Connect T-adapter.
Ground fault in wiring (3) and chassis ground
3
harness
Wiring harness between L10 (Female) (2), fuse FS1 (5) and Min. 1Mz
(Female) (2) and fuse FS1 (5)
chassis ground


(Female) (1) selector switch 1 [t] is turned Voltage 20 - 30V
and chassis ON.
WA200-5 20-453
(4)..d
[MON-10] (Input failure in monitor panel mode selector switch 1

[U] (Panel switch 2))
Controller
Action code Failure code Input failure in monitor panel mode selector switch 1 [U] (Panel switch
code Trouble
2)
Contents of • The monitor panel mode selector switch 1 [U] (Panel switch 2) input circuit is always in the OPEN state.
trouble
Action of
or controller
Problem that
machine
Related
information


1 Between L10 selector switch 1 [U] is turned Resistance Max. 1z
mode selector switch 1 [U] (Female) (2) ON.
and (1)
1) Turn starting switch OFF. 2) Disconnect Connectors L21, L10, fuse FS1 (5).
in connector)
fuse FS1 (5)
Possible
causes and 1) Turn starting switch OFF. 2) Disconnect Connectors L21, L10, fuse FS1 (5).
standard value 3) Connect T-adapter.
3
harness
Wiring harness between L10 (Female) (2), fuse FS1 (5) and Min. 1Mz
(Female) (2) and fuse FS1 (5)
chassis ground


(Female) (2) selector switch 1 [U] is turned Voltage 20 - 30V
and chassis ON.
20-454 WA200-5
(4)
[MON-11] (Input failure in monitor panel mode selector switch 2 [<]

(Panel switch 3))
Controller
code Trouble Input failure in monitor panel mode selector switch 2 [<] (Panel switch 3)
Contents of • The monitor panel mode selector switch 2 [<] (Panel switch 3) input circuit is always in the OPEN state.
trouble
Action of
or controller
Problem that
machine
Related
information

When monitor panel mode
Defective monitor panel Between L11
1 mode selector switch 2 [<] selector switch 2 [<] is turned Resistance Max. 1z
(Female) (2) ON.
and (3)
adapter.
L11 (Female) (3)
Possible in connector)
causes and Wiring harness between L11 (Female) (2) and Resistance Max. 1z
standard value chassis ground
in normal state
(3) sis ground
Between L21 When monitor panel mode

4 Defective machine monitor selector switch 2 [<] is turned Voltage Max. 1V
(Female) (4)
and chassis ON.
WA200-5 20-455
(4)..d
[MON-12] (Input failure in monitor panel mode selector switch 2 [>]

(Panel switch 4))
Controller
code Trouble Input failure in monitor panel mode selector switch 2 [>] (Panel switch 4)
Contents of • The monitor panel mode selector switch 2 [>] (Panel switch 4) input circuit is always in the OPEN state.
trouble
Action of
or controller
Problem that
machine
Related
information

When monitor panel mode
Defective monitor panel Between L11
1 mode selector switch 2 [>] selector switch 2 [>] is turned Resistance Max. 1z
(Female) (2) ON.
and (1)
adapter.
L11 (Female) (1)
Possible in connector)
causes and Wiring harness between L11 (Female) (2) and Resistance Max. 1z
in normal state
(1) sis ground
Between L21 When monitor panel mode

4 Defective machine monitor selector switch 2 [>] is turned Voltage Max. 1V
(Female) (5)
and chassis ON.
20-456 WA200-5
(4)
[MON-13] (The alarm buzzer does not sound or stop)

Controller
code Trouble The alarm buzzer does not sound or stop
Contents of • The alarm buzzer does not sound or stop.
trouble
Action of
or controller
Problem that
appears on • The alarm buzzer does not sound or stop.
machine
Related
information

Disconnection in wiring adapter.
L46 (Female) (2)
in connector)
Resistance Max. 1z
fuse FS1 (5)
1) Turn starting switch OFF. 2) Disconnect Connectors L46. 3) Connect T-adapter.

Ground fault in wiring (Female) (1), fuse FS1 (5) and Max. 1z
2 harness (Female) (1) and fuse FS1 (5) chassis ground

Possible
causes and 1) Turn starting switch OFF. 2) Disconnect connector L46. 3) Insert T-adapter.
standard value 4) Connect connector. 5) 5 seconds lapsed after the starting switch was turned ON.
in normal state Alarm buzzer
3 Defective alarm buzzer The alarm buzzer sounds. is normal.
chassis ground The alarm buzzer does not Defective
sound. alarm buzzer.
Turn starting switch ON. Voltage 20 - 30V
For 2 seconds after the starting
4 Defective machine monitor Between L21 switch was turned ON. (The Voltage 20 - 30V
(Female) (11) alarm buzzer sounds.)
and chassis
ground For 1 second after 2 seconds
lapsed after the starting switch Voltage Max. 1V
was turned ON. (The alarm
buzzer does not sound.)
WA200-5 20-457
(4)..d
TROUBLESHOOTING MON-14, MON-15
[MON-14] The wiper does not function

a Defects in the wiper system is given in the TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE), so
see the section for TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).
[MON-15] The lamps do not work properly

a Defects in the lamp system (lamps do not work properly) is given in the TROUBLESHOOTING OF ELECTRI-
CAL SYSTEM (E MODE), so see the section for TROUBLESHOOTING OF ELECTRICAL SYSTEM (E
MODE).
20-458 WA200-5
(4)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
Electrical system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-502

Parking brake related diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-506
Before troubleshooting electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-508
Information contained in troubuleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-510
[E-1] The engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
[E-2] The engine does not stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-518
[E-3] Preheating is impossible or constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-520
[E-4] The parking brake (Mechanical type) does not function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-524
[E-5] Defective boom kick-out function and cancellation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-531
[E-6] Defective bucket positioner function and cancellation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-534
[E-7] Defective lift arm FLOATING holding function and cancellation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-537
[E-8] Travel direction is not changed normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-538
[E-9] The wiper does not function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-544
[E-10] The window washer does not function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-550
[E-11] Lamps do not work properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-553
[E-12] The horn does not sound. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-564
[E-13] Defective air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-566
WA200-5 20-501
(4)..
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM
ELECTRICAL SYSTEM DIAGRAM
20-502 WA200-5
(4)
WA200-5 20-503
(4)..d
20-504 WA200-5
(4)
TROUBLESHOOTING PARKING BRAKE RELATED DIAGRAM
PARKING BRAKE RELATED DIAGRAM
20-506 WA200-5
(4)
TROUBLESHOOTING PARKING BRAKE RELATED DIAGRAM
WA200-5 20-507
(4)..d


2 10A Hazard lamp
3 10A HST control A
(Fuse box 1)
5 10A Meter, panel

14 10A Wiper
15 10A Car radio B
3 10A Beacon lamp
4 10A -
5 10A Load-meter
7 10A DC converter
Switch power source
9 10A Horn
14 10A (Spare 1)
15 10A (Spare 2)
20-508 WA200-5
(4)

Controller
trouble
Action of
or controller
appears on
machine ler.

information
<Data to fill in>


• Disconnection
2 • Ground fault
circuit
causes and
in normal state
female terminals
4
5
20-510 WA200-5
(4)
WA200-5 20-511
(4)..d
TROUBLESHOOTING E-1
[E-1] (The engine does not start)

a) - 1 Defective starting motor system (When direction selector actuation switch is turned OFF)
Controller
Action code Failure code The engine does not start
code Trouble
a) Defective starting motor system
Contents of • The engine does not start due to defective starting motor system.
trouble
Action of
or controller
Problem that
appears on • The engine does not start.
machine
• If the failure code D5ZHL6 for abnormality in starting switch C input is given, carry out troubleshooting first for the
Related applicable code.
information
• If the fuses are blown, check the wiring harness is short-circuited with the ground.

Specific gravity Min. 1.26V
1 Defective battery
Voltage Min. 24V
1) Turn starting switch OFF. 2) Replace battery relay with normal relay.
When battery relay is replaced, No Battery relay is normal.
does condition becomes nor-
mal? Yes Battery relay is defective.
1) Turn starting switch OFF. 2) Disconnect battery relay. 3) Check relay unit.
2 Defective battery relay Between battery relays R15 and R16 Resistance 30 - 70z
1) Turn starting switch OFF. 2) Disconnect battery relay. 3) Check relay unit.
4) Apply normal voltage between battery relays R15 and R16.
Apply 24 V between R15 and Resistance Max. 1z
Between bat- R16.
tery relays
R04 and R01 Do not apply 24 V between R15
and R16. Resistance Min. 1Mz
Possible
causes and 1) Turn starting switch OFF. 2) Interchange relay (L106) with normal relay. 3) Turn
standard value starting switch ON.
in normal state
Does condition become normal The condition is abnormal. Relay (L106)
when neutral safety relay is normal.
(L106) is interchanged with nor- Defective
mal relay? The condition is normal. relay (L106)
Defective neutral safety 1) Turn starting switch OFF. 2) Disconnect connector L106. 3) Solid part check.
3 relay (L106) Between L106 (Male) (1) and (2) Resistance 200 - 400z
L106 (Male)
Resistance Min. 1Mz
4 Defective directional lever Resistance Max. 1z
(Female) (1) N.
20-512 WA200-5
(4)
TROUBLESHOOTING E-1

1) Turn starting switch OFF. 2) Interchange relay (one of L133, L136, or L137) with
normal relay. 3) Turn starting switch ON.
Relay (L133,
Does condition become normal The condition is abnormal. L136, L137)
when neutral safety relay (one is normal.
of L133, L136, or L137) is inter- Defective
changed with normal relay? The condition is normal. relay (L133,
L136, L137)
1) Turn starting switch OFF. 2) Disconnect one of connectors L133, L136, or L137.
Defective multi-function 3) Solid part check.
5 related relay (L133, L136,
L137) Between (Male) (1) - (2) of one of L133, L136, or
L137 Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect one of connectors L133, L136, or L137.
3) Solid part check. 4) Applies impressed voltage between (Male) (1) - (2) of one of
L133, L136, or L137
Between Applies 24V impressed voltage
(Male) (3) - Resistance Max. 1z
(5) of one of
L133, L136, Does not apply voltage
or L137
1) Turn starting switch OFF. 2) Replace both diodes (D08, D15) with normal diodes.
3) Turn starting switch START.
Defective diode (D08, D15)
a Only when defect The condition is abnormal. Diode (D08, D15) is normal.
6
occurs in both at the The condition is normal. Defective diode (D08, D15)
same time Measure from (2) end with diode range Continuity
Measure from (1) end with diode range Discontinuity
1) Turn starting switch OFF. 2) Replace diode (D07) with normal diode. 3) Turn start-
ing switch START.
Possible The condition is abnormal. Diode (D07) is normal.
causes and
standard value The condition is normal. Defective diode (D07)
in normal state Measure between (1) o (2) with diode range Continuity
Measure between (3) o (2) with diode range Continuity
7 Defective diode (D07)
Measure between (2) o (3) with diode range Discontinuity
a Put (+) pole of tester in contact with left side.
1) Turn starting switch OFF. 2) Disconnect connector L106, D08, D15, terminal E01,
R01 and E10. 3) Connect T-adapter.
D08 (Female) (2)
Resistance Max. 1z
wiring or defective contact D15 (Female) (2)
8 in connector) Wiring harness between D08 (Female) (1) and
a Starting motor related E01 (Female) (1)
Resistance Max. 1z
harness
Wiring harness between D15 (Female) (1) and
Resistance Max. 1z
E01 (Female) (1)
Wiring harness between R01 and starting motor
terminal B (E10) Resistance Max. 1z
1) Turn starting switch OFF. 2) Disconnect connector D07, E02, terminal R16, R15,
R07, R04, R02 and R05. 3) Connect T-adapter.
Disconnection in wiring Wiring harness between R16 and chassis ground Resistance Max. 1z
harness (Disconnection in Wiring harness between R15 and D07 (Female) (2) Resistance Max. 1z
wiring or defective contact
9 in connector) Wiring harness between E02 (Female) (2) and Resistance Max. 1z
a Battery relay related R15
harness Wiring harness between R04 and R02 Resistance Max. 1z
Wiring harness between R01 and R05 Resistance Max. 1z
Wiring harness between battery and R04 Resistance Max. 1z
WA200-5 20-513
(4)..d
TROUBLESHOOTING E-1

1) Turn starting switch OFF. 2) Disconnect connector L02, D07, terminal R03 and
fuse FS1. 3) Connect T-adapter.
harness (Disconnection in Wiring harness between L02 (Female) (1), FS1 Resistance Max. 1z
wiring or defective contact (1) and R03
10 in connector) Wiring harness between L02 (Female) (2) and
a Starting switch related D07 (Female) (1)
Resistance Max. 1z
harness
Resistance Max. 1z
L23 (Female) (1)
1) Turn starting switch OFF. 2) Disconnect connector L15, terminal R06 and fuse
FS1. 3) Connect T-adapter.
harness (Disconnection in Wiring harness between L15 (Female) (1), FS1
(2) and R06 Resistance Max. 1z
11 in connector) Wiring harness between L15 (Female) (3) and
a Directional lever L106 (Female) (1)
Resistance Max. 1z
related harness
Resistance Max. 1z
Possible chassis ground
causes and 1) Turn starting switch OFF. 2) Disconnect connector E01, E02, D07. 3) Connect T-
standard value adapter. 4) Turn starting switch ON.
in normal state 12 Hot short in wiring harness Wiring harness between E01 Voltage between E01 (Female)
(Female) (2), E02 (Female) (1) (2), E02 (Female) (1) and chas- Max. 1V
and D07 (Female) (3) sis ground
1) Disconnect starting switch terminal. 2) Solid part check.
13 Defective starting switch
Turn starting switch START. Between terminal B and C Max. 1z
1) Solid part check.
14 Defective starting motor • If the check of the individual part shows that it is normal, the starting motor is
normal.
Between Engine started (Throttle 1/2 and
alternator ter- above) Voltage 26.5 - 29V
15 Defective alternator minal R [E02
(1)] and chas- Engine stopped Voltage Max. 1V
sis ground
1) Turn starting switch OFF. 2) Disconnect connector TEL. 3) Connect T-adapter.
16 Defective short connector
TEL Wiring harness between TEL (Female) (7) and Resistance Max. 1z
(8)
20-514 WA200-5
(4)
TROUBLESHOOTING E-1
a) - 2 Defective starting motor system (When the directional selector actuation switch is turned ON)
a Perform the inspection and troubleshooting in this section in addition to a) -1.
Controller
code Trouble
a) Defective starting motor system
Contents of • The engine does not start due to defective starting motor system.
trouble
Action of
or controller
Problem that
machine
applicable code.
Related • If the fuses are blown, check the wiring harness is short-circuited with the ground.
information
• When the directional selector actuation switch is operated, the directional lever must be in the "N" position and the
directional selector switch must be in the "N" position.

Specific gravity Min. 1.26V
1 Defective battery
Voltage Min. 24V
1) Turn starting switch OFF. 2) Interchange relay (L132, L133, L134) with normal
relay. 3) Turn starting switch ON.
Relay (L132,
Does condition become normal The condition is abnormal. L133, L134)
when neutral safety relay is normal.
(L132, L133, L134) is inter- Defective
changed with normal relay? The condition is normal. relay (L132,
L133, L134)
1) Turn starting switch OFF. 2) Disconnect connector L132, L133, L134. 3) Solid part
Defective neutral safety check.
2 relay (L132, L133, L134)
Between L132, L133, L134 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L132, L133, L134. 3) Solid part
Possible check. 4) Applies impressed voltage between L132, L133, L134 (Male) (1) - (2)
causes and
standard value Applies 24V impressed voltage
in normal state Between between L132, L133, L134 Resistance Max. 1z
L132, L133, (Male) (1) - (2)
L134 (Male) Does not apply voltage
(3) and (5) between L132, L133, L134 Resistance Min. 1Mz
(Male) (1) - (2)
1) Turn starting switch OFF. 2) Disconnect connector MF1. 3) Connect T-adapter.
Defective directional select Between MF1 When direction select switch is
switch (Female) (1) turned N.
1) Turn starting switch OFF. 2) Replace both diodes (D18) with normal diodes.
Defective diode (D18)
a Only when defect The condition is abnormal. Diode (D18) is normal.
4 occurs in both at the The condition is normal. Defective diode (D18)
same time Measure from (2) end with diode range Continuity
Measure from (1) end with diode range Discontinuity
WA200-5 20-515
(4)..d
TROUBLESHOOTING E-1
b) Defective fuel cut solenoid system

Controller
code Trouble
b) Defective fuel cut solenoid system
Contents of • The fuel cut solenoid system is defective, so the engine does not start.
trouble
Action of
or controller
Problem that
machine
Related applicable code.
information
• If the fuses are blown, check the wiring harness is short-circuited with the ground.

1) Turn starting switch OFF. 2) Interchange relay (R13) with normal relay. 3) Turn
starting switch ON.
Relay (R13)
Does condition become normal The condition is abnormal.
is normal.
when pull relay (R13) is inter-
changed with normal relay? The condition is normal. Defective
relay (R13)
Defective fuel cut solenoid 1) Turn starting switch OFF. 2) Disconnect connector L104. 3) Solid part check.
1 pull relay (R13) Between R13 (Male) (1) and (2) Resistance 50 - 90z
1) Turn starting switch OFF. 2) Disconnect connector R13. 3) Solid part check.
4) Applies impressed voltage between R13 (Male) (1) - (2)
Between R13 between R13 (Male) (1) - (2)
(Male) (3) and
between R13 (Male) (1) - (2) Resistance Min. 1Mz
1) Turn starting switch OFF. 2) Disconnect terminal E03, E23, E24. 3) Connect T-
adapter. 4) Solid part check.
2 Defective fuel cut solenoid Between E23 and E24 Resistance 43 - 53z
Between E03 and E24 Resistance 0.8 - 1.2z
1) Turn starting switch OFF. 2) Disconnect connector R08. 3) Insert T-adapter.
4) Connect connector.
Between R08 Turn starting switch ON. Voltage 20 - 30V
Defective fuel cut solenoid (1) and (2)
3 Turn starting switch OFF. Voltage Max. 1V
timer
2 - 4 sec after turning starting Voltage Min. 16V
Possible Between R08 switch ON
causes and (3) and (4)
standard value Other than above. Voltage Max. 1V
in normal state 1) Turn starting switch OFF. 2) Replace diode (D03 or D04) with a normal diode.
Defective diode
4 (D03 or D04) The condition is abnormal. Diode (D03 or D04) is normal.
The condition is normal. Defective diode (D03 or D04)
1) Turn starting switch OFF. 2) Disconnect connector L02, D03, D04, D08, D15, terminal
E01, E03, E11, E23, E24, R05, R08, R09, R10, R12 and R13. 3) Connect T-adapter.
Wiring harness between E24 and chassis ground Resistance Max. 1z
Wiring harness between D03 (Female) (2) and Resistance Max. 1z
chassis ground
Wiring harness between E03 and R09 Resistance Max. 1z
Wiring harness between D04 (Female) (2) and
Resistance Max. 1z
chassis ground
harness (Disconnection in Wiring harness between E23 and L02 (Female) (4) Resistance Max. 1z
5 wiring or defective contact Wiring harness between E23 and R08 (Female) (1) Resistance Max. 1z
in connector)
Wiring harness between R08 (Female) (2) and Resistance Max. 1z
chassis ground
Resistance Max. 1z
R13 (Female) (1)
R13 (Female) (2) Resistance Max. 1z

1) Disconnect starting switch terminal. 2) Solid part check.
6 Defective starting switch
Turn starting switch START. Between terminal B and ACC Max. 1z
20-516 WA200-5
(4)
TROUBLESHOOTING E-1
WA200-5 20-517
(4)..d
TROUBLESHOOTING E-2
[E-2] (The engine does not stop)

Controller
code Trouble The engine does not stop
Contents of • The engine does not stop.
trouble
Action of
or controller
Problem that
appears on • The engine does not stop.
machine
Related • If the failure code D5ZHL6 for abnormality in starting switch C input is given, carry out troubleshooting first for the
information applicable code.

1) Turn starting switch OFF. 2) Disconnect terminal E03, E23, E24. 3) Connect T-
adapter. 4) Solid part check.
1 Defective fuel cut solenoid
Between E23 and E24 Resistance 43 - 53z
Between E03 and E24 Resistance 0.8 - 1.2z
1) Turn starting switch OFF. 2) Disconnect connector R08. 3) Insert T-adapter.
Possible 4) Connect connector.
Defective fuel cut solenoid
causes and 2 timer Turn starting switch ON. Voltage 20 - 30V
standard value Between R08
in normal state (1) and (2) Turn starting switch OFF. Voltage Max. 1V
1) Turn starting switch OFF. 2) Disconnect connector L02, D03, D08, terminal E03,
E23 and R09. 3) Connect T-adapter. 4) Turn starting switch OFF.
Wiring harness between E03, Voltage between E03 (Harness Max. 1V
3 Hot short in wiring harness R09 and D03 (Female) (1) side) and chassis ground
Wiring harness between E23, Voltage between E23 (Harness
L02 (Female) (4) and R08 Max. 1V
side) and chassis ground
(Female) (1)
20-518 WA200-5
(4)
TROUBLESHOOTING E-2
WA200-5 20-519
(4)..d
TROUBLESHOOTING E-3
[E-3] (Preheating is impossible or constant)

a) Preheating is impossible
Controller
Action code Failure code Preheating is impossible or constant
code Trouble
a) Preheating is impossible
Contents of • Preheating is impossible. (The engine coolant temperature at 0°C and below.)
trouble
Action of
or controller
Problem that
appears on • Preheating is impossible.
machine
Related
information

1) Turn starting switch OFF. 2) Disconnect heater relay terminal E06, E07, E08.
Between E06 and chassis ground Resistance 19 - 25z
Defective electrical intake When relay is ON (impressed
1
air heater relay voltage 24V between E08 - Resistance Max. 1z
Between E07 chassis ground).
and E08
When the relay OFF (Other Resistance Min. 1Mz
than above).
Defective electrical intake 1) Turn starting switch OFF. 2) Disconnect heater terminal E09. 3) Solid part check.
2
air heater Between heater terminal E09 and chassis ground Resistance 0.17 - 0.27z
1) Turn starting switch OFF. 2)Replace relay L115 with normal relay 3) Turn starting
switch ON.
Condition is Relay L115 is
Does condition become normal when automatic abnormal. normal.
preheating relay L115 is replaced with normal
relay? Condition is Defective
normal. relay L115.
Defective auto-preheating 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
Possible 3
causes and relay (L115) Between L115 (Male) (1) and (2) Resistance 200 - 400z
standard value
in normal state 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
L115 (Male)
Resistance Min. 1Mz
1) Turn starting switch OFF. 2) Replace diode (D05) with normal diode. 3) Turn start-
ing switch ON.
Condition is abnormal. Diode (D05) is normal.
Condition is normal. Defective diode (D05)
Measure between (2) - (1) with diode range Continuity
Measure between (1) - (2) with diode range No continuity
a Put (+) pole of tester in contact with left side.
20-520 WA200-5
(4)
TROUBLESHOOTING E-3

1) Turn starting switch OFF. 2) Disconnect connector L115, L22, fuse FS2 (5), E06,
E07 and E08. 3) Connect T-adapter.
Wiring harness between E08 and E09 Resistance Max. 1z
Wiring harness between R07 and E07 Resistance Max. 1z
Disconnection in wiring Wiring harness between E06, J08 and L115
harness (Disconnection in (Female) (5) Resistance Max. 1z
5
in connector) Wiring harness between fuse FS2 (5) and L115 Resistance Max. 1z
(Female) (3)
Resistance Max. 1z
(Female) (1)
L22 (Female) (4)
1) Turn starting switch OFF. 2) Disconnect connector D05, L115, L22, fuse FS2 (5),
E06, E07 E08, E09 and R07. 3) Connect T-adapter.
Wiring harness between E08 Resistance between E08, E09
Min. 1Mz
and E09 * and chassis ground
Wiring harness between R07 Resistance between R07, E07
and E07 * and chassis ground Min. 1Mz
Wiring harness between E06, Resistance between E06, J08,

L115 (Female) (5) and chassis Min. 1Mz
J08 and L115 (Female) (5) *
ground
Possible
causes and Wiring harness between fuse Resistance between fuse FS2
standard value FS2 (5) and L115 (Female) (5), L115 (Female) (3) and Min. 1Mz
in normal state (3) * chassis ground
Ground fault in wiring Wiring harness between fuse Resistance between fuse FS2
6 harness FS2 (5) and L115 (Female) (5), L115 (Female) (1) and Min. 1Mz
Wiring harness between J08 Resistance between J08
(Female) (12) and D05 (Female) (12), D05 (Female) Min. 1Mz
(Female) (3) * (3) and chassis ground
a Item 6 above is wiring harness related to electrical intake air heater
a If it is marked * , the fuse is blown

(Female) (6), E13 (A) and Min. 1Mz
(Female) (6) and E13 (A) chassis ground
a The above is wiring harness related to the engine coolant temperature (low tem-
perature) sensor

7 temperature (Low tempera- Between E13 Normal temperature (25°C). Resistance 3.1 - 5.7kz
ture) sensor (Male) (A)
and (B) When 100°C Resistance 0.2 - 1.0kz
1) Turn starting switch OFF. 2) Replace junction connector (J06, J09, J11) with nor-
mal junction connector
8 Defective junction connec-
tor (J06, J09, J11) Condition is abnormal. Junction connector (J06, J09, J11) is normal.
Condition is normal. Defective junction connector (J06, J09, J11).
WA200-5 20-521
(4)..d
TROUBLESHOOTING E-3
b) Preheating is constant
Controller
Action code Failure code Preheating is impossible or constant
code Trouble
b) Preheating is constant
Contents of • Preheating is constant.
trouble
Action of
or controller
Problem that
appears on • Preheating is constant.
machine
• If the failure code DGE3L6 for abnormality in engine coolant temperature (low temperature) sensor related is given,
Related carry out troubleshooting first for the applicable code.
information
• The engine coolant temperature (low temperature) is displayed by real-time monitoring code 04103.

1) Turn starting switch OFF. 2) Disconnect heater relay terminal E06, E07, E08.
Between E06 and chassis ground Resistance 19 - 25z
Defective electrical intake When relay is ON (impressed
1
air heater relay voltage 24V between E08 - Resistance Max. 1z
Between E07 chassis ground).
and E08
When the relay OFF (Other Resistance Min. 1Mz
than above).
1) Turn starting switch OFF. 2) Replace relay L115 with normal relay. 3) Turn starting
switch ON.
Does condition become normal when automatic abnormal. normal.
preheating relay L115 is replaced with normal
relay? Condition is Defective
normal. relay L115.
Defective auto-preheating 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
2
Possible 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
causes and 4) Applies impressed voltage between L115 (Male) (1) - (2)
standard value
in normal state Applies 24V impressed voltage
L115 (Male)
1) Turn starting switch OFF. 2) Disconnect connector L115, L22, fuse FS2 (5), E06,
E07 and E08. 3) Connect T-adapter. 4) 1 minute after starting switch is turned ON.
Wiring harness between E08 Voltage between E08, E09 and
Max. 1V
3 Hot short in wiring harness and E09 chassis ground
Voltage between E06, J08,
Wiring harness between E06, L115 (Female) (5) and chassis Max. 1V
J06 and L115 (Female) (5)
ground
1) Turn starting switch OFF. 2) Disconnect connectors L22 and L115.
4 Wiring harness between L22 Resistance between L22
harness
(female) (4) and L115 (female) (female) (4), L115 (female) (2) Min. 1Mz
Defective mechanical mon- 4) Connect connector. 5) 1 minute after starting switch is turned ON.
5
itor
Voltage between L22 (4) and chassis ground Min. 16 V
20-522 WA200-5
(4)
TROUBLESHOOTING E-3
WA200-5 20-523
(4)..d
TROUBLESHOOTING E-4
[E-4] (The parking brake (Mechanical type) does not function)

a) Parking brake dragging prevention does not function (mechanical type)
Controller The parking brake (Mechanical type) does not function
code Trouble a) Parking brake dragging prevention does not function (mechanical
Not set Not set Not set type)
Contents of • Parking brake dragging prevention does not function

trouble
Action of
or controller
Problem that
appears on • Parking brake dragging prevention does not function
machine
Related
information

switch ON. 4) Operate parking brake switch.
Does condition become normal when parking abnormal. normal.
brake neutral safety relay L112 is replaced with
normal relay? Condition is Defective
normal. relay L112.
Defective parking brake 1) Turn starting switch OFF. 2) Disconnect connector L112. 3) Solid part check.
1 neutral safety relay (L112) Between L112 (Male) (1) and (2) Resistance 200 - 400z
L112 (Male)
Possible 1) Turn starting switch OFF. 2) Disconnect connector D01, L19, L112, T01. 3) Con-
causes and nect T-adapter.
standard value
2 Ground fault in wiring (Female) (5) and J08 (7), (9) (Female) (5), T01 (Female) (4) Min. 1Mz
harness and T01 (Female) (2), (4) and chassis ground
(Female) (5) and J08 (7), (8) (Female) (5), T01 (Female) (2) Min. 1Mz
and T01 (Female) (2) and chassis ground
1) Turn starting switch OFF. 2) Replace diode D01 with normal diode. 3) Turn start-
ing switch ON.
Condition is abnormal. Diode (D05) is normal.
Condition is normal. Defective diode (D01)
Measure between (1) - (2) with diode range Discontinuity
20-524 WA200-5
(4)
TROUBLESHOOTING E-4
b) Parking brake "non-applied" indicator does not light up (mechanical type)

Controller The parking brake (Mechanical type) does not function
code Trouble b) Parking brake "non-applied" indicator does not light up (mechanical
Not set Not set Not set type)
Contents of • Parking brake "non-applied" indicator does not light up

trouble
Action of
or controller
Problem that
appears on • Parking brake "non-applied" indicator does not light up
machine
Related
information

Defective parking brake Place parking brake lever

1 Between L53 LOCK. Resistance Min. 1Mz
lowest switch (Male) (3) and
(2) Place parking brake lever Resistance Max. 1z
FREE.
Defective parking brake Place parking brake lever Resistance Min. 1Mz
2 Between L47 LOCK to MIDDLE.
middle switch (Male) (3) and
(1) Place parking brake lever MID-
Resistance Max. 1z
DLE to FREE.
Possible
causes and 1) Turn starting switch OFF. 2) Replace relay L101 with normal relay. 3) Turn starting
standard value switch ON. 4) Operate parking brake switch.
in normal state Relay L101 is
Does condition become normal Condition is abnormal.
normal.
when parking brake relay L101
is replaced with normal relay? Condition is normal. Defective
relay L101.
Defective mechanical type 1) Turn starting switch OFF. 2) Disconnect connector L101. 3) Solid part check.
3
parking brake relay (L101) Between L101 (Male) (1) and (2) Resistance 200 - 400z
L101 (Male)
WA200-5 20-525
(4)..d
TROUBLESHOOTING E-4

1) Turn starting switch OFF. 2) Disconnect connector L47, L53, fuse FS1 terminal.

J12 (6), (7) and L53 (Female) (1)
Resistance Max. 1z
Disconnection in wiring J10 (19), (18) and L21 (Female) (13)
4
wiring or defective contact J10 (Female) (19), (20) and J05 (14), (16) and Resistance Max. 1z
in connector) L101 (Female) (1)
J10 (Female) (19), (20) and J05 (14), (17) and Resistance Max. 1z
L101 (Female) (5)

Resistance Max. 1z
Possible J12 (Female) (6), (4) and L101 (Female) (3)
causes and
standard value 1) Turn starting switch OFF. 2) Disconnect connector L101, L47, L53, both ends of
in normal state fuse FS1 terminal. 3) Connect T-adapter.
Wiring harness between fuse
FS1 (4) and L47 (Female) (1) (Female) (1) and chassis Min. 1Mz
ground
5 (Female) (2) and J12 (6), (5) (Female) (2), L53 (Female) (1) Min. 1Mz
harness
and L53 (Female) (1) and chassis ground
(Female) (2) and J12 (6), (4) (Female) (2), L101 (Female) (3) Min. 1Mz
and L101 (Female) (3) and chassis ground
Defective junction connec- • Carry out inspection, and if any abnormality is found, repair or replace.
6 tor (J05), (J10) and (J12)
4) Connect connector. 5) Turn starting switch
Between L21 Place parking brake lever

(13) and LOCK to MIDDLE.
chassis Place parking brake lever
FREE.
20-526 WA200-5
(4)
TROUBLESHOOTING E-4
20-528 WA200-5
(4)
TROUBLESHOOTING E-4
WA200-5 20-529
(4)..d
TROUBLESHOOTING E-5
[E-5] (Defective boom kick-out function and cancellation)

Controller
code Trouble Defective boom kick-out function and cancellation
Contents of • Boom kick-out does not function or cannot be cancelled due to defective boom kick-out proximity switch system, lift
trouble arm PPC detent system and lift arm detent relay system.
Action of
or controller
Problem that
appears on • Boom kick-out does not function or cannot be cancelled.
machine
Related
information

1) Turn starting switch OFF. 2) Disconnect connector L113. 3) Replace lift arm detent
relay (L113) with normal relay. 4) Operate boom kick-out.
Boom kick-out function is normal. Defective relay L113.
Boom kick-out does not function. Relay L113 is normal.
Defective lift arm detent Between L113 (Male) (1) and (2) Resistance 200 - 400z
1 relay (L113)
L113 (Male)
Defective lift arm PPC 1) Turn starting switch OFF. 2) Disconnect connector L37. 3) Connect T-adapter.
2 detent Between L37 (Male) (1) and (2) Resistance 30 - 50z
1) Turn starting switch OFF. 2) Disconnect connector F04. 3) Interchange lift arm
positioner proximity switch (F04) with bucket positioner proximity switch (F03). 4)
Operate boom kick-out.
Possible
causes and 3 Defective lift arm posi-
tioner proximity switch Boom kick-out function is normal. Defective boom kick-out prox-
standard value imity switch F04
in normal state
Boom kick-out proximity switch
Boom kick-out does not function.
F04 is normal.
1) Turn starting switch OFF. 2) Disconnect connector F04, L113, L36 and fuse FS1
terminal. 3) Connect T-adapter.
Wiring harness between F04 (Female) (A) and
Resistance Max. 1z
fuse FS1 (13)
Wiring harness between F04 (Female) (B) and
Resistance Max. 1z
L113 (Female) (2)
Wiring harness between F04 (Female) (C) and
Resistance Max. 1z
Disconnection in wiring chassis ground
wiring or defective contact fuse FS1 (13)
in connector)
fuse FS1 (13)

Resistance Max. 1z
chassis ground
a With all the above items, the boom kick-out does not function
WA200-5 20-531
(4)..d
TROUBLESHOOTING E-5

Wiring harness between F04 Resistance between F04
(Female) (B) and L113 (Female) (B), L113 (Female) Min. 1Mz
a In this case, the boom kick-out detent does not function (lever returns to neutral)
5 Resistance between F04
harness Wiring harness between F04
(Female) (A) and fuse FS1 (13) (Female) (A), FS1 (13) and Min. 1Mz
Possible chassis ground
causes and
standard value Resistance between L113
in normal state (Female) (1) and fuse FS1 (13) (Female) (1), fuse FS1 (13) and Min. 1Mz
chassis ground
(Female) (3), fuse FS1 (13) and Min. 1Mz
(Female) (3) and fuse FS1 (13) chassis ground
a In this case, the fuse is blown and no detents function (lever returns to neutral)
1) Turn starting switch OFF. 2) Disconnect connector L113, L36. 3) Connect T-

Wiring harness between L113 Voltage between L113
6 Hot short in wiring harness (Female) (5) and L36 (Female) (Female) (5), L36 (Female) (1) Max. 1V
a In this case, the boom kick-out does not function (lever does not return to neu-
tral)
20-532 WA200-5
(4)
TROUBLESHOOTING E-5
WA200-5 20-533
(4)..d
TROUBLESHOOTING E-6
[E-6] (Defective bucket positioner function and cancellation)

Controller
code Trouble Defective bucket positioner function and cancellation
Contents of • Bucket positioner does not function or cannot be cancelled due to defective bucket positioner proximity switch system,
trouble bucket PPC detent system and bucket detent relay system.
Action of
or controller
Problem that
appears on • Bucket positioner does not function or cannot be cancelled.
machine
Related
information

1) Turn starting switch OFF. 2) Disconnect connector L114. 3) Replace bucket detent
relay (L114) with normal relay. 4) Operate bucket positioner.
Bucket positioner function is normal. Defective relay L114.
Bucket positioner does not function. Relay L114 is normal.
Defective bucket detent Between L114 (Male) (1) and (2) Resistance 200 - 400z
1 relay (L114)
L114 (Male)
Defective bucket PPC 1) Turn starting switch OFF. 2) Disconnect connector L37. 3) Connect T-adapter.
2 detent Between L37 (Male) (1) and (2) Resistance 30 - 50z
1) Turn starting switch OFF. 2) Disconnect connector F03. 3) Interchange bucket
positioner proximity switch (F03) with lift arm positioner proximity switch (F04). 4)
Operate bucket positioner.
Possible
causes and 3 Defective bucket posi-
tioner proximity switch Bucket positioner function is normal. Defective bucket positioner
standard value proximity switch F03
in normal state
Bucket positioner proximity
Bucket positioner does not function.
switch F03 is normal.
Wiring harness between F03 (Female) (A) and
Resistance Max. 1z
fuse FS1 (13)
Wiring harness between F03 (Female) (B) and
Resistance Max. 1z
L114 (Female) (2)
Wiring harness between F03 (Female) (C) and
Resistance Max. 1z
Disconnection in wiring chassis ground
wiring or defective contact fuse FS1 (13)
in connector)
fuse FS1 (13)

Resistance Max. 1z
chassis ground
a With all the above items, the bucket positioner does not function
20-534 WA200-5
(4)
TROUBLESHOOTING E-6

Wiring harness between F03 Resistance between F03
(Female) (B) and L114 (Female) (B), L114 (Female) Min. 1Mz
a In this case, the bucket positioner detent does not function (lever does not return
to neutral)

5 Ground fault in wiring a In this case, the bucket positioner does not function (lever returns to neutral)
harness
Possible Resistance between F03

Wiring harness between F03 (Female) (A), FS1 (13) and Min. 1Mz
causes and (Female) (A) and fuse FS1 (13)
in normal state Resistance between L114
(Female) (1) and fuse FS1 (13) (Female) (1), fuse FS1 (13) and Min. 1Mz
chassis ground
(Female) (3), fuse FS1 (13) and Min. 1Mz
(Female) (3) and fuse FS1 (13) chassis ground
a In this case, the fuse is blown and no detents function (lever returns to neutral)
1) Turn starting switch OFF. 2) Disconnect connector L114, L37. 3) Connect T-

Wiring harness between L114 Voltage between L114
6 Hot short in wiring harness (Female) (5) and L37 (Female) (Female) (5), L37 (Female) (1) Max. 1V
a In this case, the bucket positioner does not function (lever does not return to
neutral)
WA200-5 20-535
(4)..d
TROUBLESHOOTING E-6
20-536 WA200-5
(4)
TROUBLESHOOTING E-7
[E-7] (Defective lift arm FLOATING holding function and

cancellation)
Controller
code Trouble Defective lift arm FLOATING holding function and cancellation
Contents of • Lift arm FLOATING holding does not function or cannot be cancelled due to defective lift arm FLOATING PPC detent
trouble system.
Action of
or controller
Problem that
appears on • Lift arm FLOATING holding does not function or cannot be cancelled.
machine
Related
information
Defective lift arm FLOAT- 1) Turn starting switch OFF. 2) Disconnect connector L35. 3) Connect T-adapter.
1 ING PPC detent Between L35 (Male) (1) and (2) Resistance 30 - 50z
Possible
causes and 1) Turn starting switch OFF. 2) Disconnect connector L35 and fuse FS1 terminal. 3)
standard value Connect T-adapter.
in normal state Disconnection in wiring
harness (Disconnection in Wiring harness between fuse FS1 (13) and L35
(Female) (1)
in connector)
chassis ground
WA200-5 20-537
(4)..d
TROUBLESHOOTING E-8
[E-8] (Travel direction is not changed normally)

a) When directional lever is set in "F", machine does not travel forward
Controller
Action code Failure code Travel direction is not changed normally
code Trouble
a) When directional lever is set in "F", machine does not travel forward
Contents of • The machine does not travel forward since the directional lever system, forward relay system, or forward solenoid
trouble valve system is defective.
Action of
or controller
Problem that
appears on • The machine does not travel forward.
machine
• If failure code "DDK3KB" is displayed to indicate simultaneous input of directional lever FR signals, carry out the trou-
bleshooting for it first.
Related • When the parking brake lever is pulled, if the parking brake omission warning lamp goes off and the parking brake
information
indicator lamp does not light up, carry out the troubleshooting for "MON-1 Parking brake indicator lamp does not light
up" before carry out the following troubleshooting.

When direc-
1 Defective directional lever tional lever is Resistance Max. 1 z
in "F".
Between L15 (female) (1) and (2)
When direc-
tional lever is Resistance Min. 1 Mz
not in "F".
1. Turn starting switch OFF.
2. Replace L112 with normal relay.
3. Turn starting switch ON.
4. Operate parking brake.
Possible Relay (L112)

causes and No is normal.
When parking brake neutral safety relay (L112) is
standard value replaced, does condition become normal?
in normal state Yes Relay (L112)
is defective.
2 Defective parking brake 3) Check relay unit.
neutral safety relay (L112)

Resistance Max. 1 z
Between and (1) and (2)
L112 (male) When normal voltage is not
(3) and (5) applied between and (1) and Resistance Min. 1 Mz
(2)
20-538 WA200-5
(4)
TROUBLESHOOTING E-8

Relay (L108)
No is normal.
When forward relay (L108) is replaced, does con-
dition become normal? Relay (L108)
Yes
is defective.
3 Defective forward relay
(L108) Between L108 (male) (1) and (2) Resistance 200 - 400z
2) Disconnect connector L108
When 24 V is applied between Resistance Max. 1 z

L108 (male) When normal voltage is not
(2)
2) Disconnect connector T01.
4 Defective forward solenoid
Between T01 (male) (1) and (2) Resistance 30 - 60z
Between T01 (male) (1), (2) and chassis ground Resistance Min. 1 Mz
Possible 2) Disconnect connectors T01, L15, L108, and L112 and fuse (FS1).
causes and 3) Connect T-adapter.
standard value
in normal state
Wiring harness between L15 (female) (2) and
L108 (female) (1) Resistance Max. 1 z
harness (Disconnection in Wiring harness between L108 (female) (2) and Resistance Max. 1 z
5 chassis ground
in connector) Wiring harness between fuse FS1 (12) and L108
(female) (3) Resistance Max. 1 z
Wiring harness between L108 (female) (5) and Resistance Max. 1 z

T01 (female) (1)
Wiring harness between T01 (female) (2) and Resistance Max. 1 z
L112 (female) (5)
2) Disconnect connectors T01, L15, L22, and L108

(female) (2) and L22 (female) (female) (2), L22 (female) (10) Min. 1 Mz
6
harness (female) (5) and D01 (female) (female) (5), D01 (female) (1) Min. 1 Mz
(female) (5) and T01 (female) (female) (5), T01 (female) (1) Min. 1 Mz
Resistance between fuse (FS1)
(12), L15 (female) (1), L108
(FS1) (12) and L15 (female) Min. 1 Mz
(1), L108 (female) (3) (female) (3) and chassis
ground
a In all of these cases, the fuse is broken.
WA200-5 20-539
(4)..d
TROUBLESHOOTING E-8
b) When directional lever is set in "R", machine does not travel in reverse
Controller
Action code Failure code Travel direction is not changed normally
code Trouble
b) When directional lever is set in "R", machine does not travel in reverse
Contents of • The machine does not travel in reverse since the directional lever system, reverse relay system, or reverse solenoid
trouble valve system is defective.
Action of
or controller
Problem that
appears on • The machine does not travel in reverse.
machine
• If failure code "DDK3KB" is displayed to indicate simultaneous input of directional lever FR signals, carry out the trou-
bleshooting for it first.
Related • When the parking brake lever is pulled, if the parking brake omission warning lamp goes off and the parking brake
information
indicator lamp does not light up, carry out the troubleshooting for "MON-1 Parking brake indicator lamp does not light
up" before carry out the following troubleshooting.

2) Disconnect connector F15.
1 Defective directional lever When direc-

tional lever is Resistance Max. 1 z
Between L15 (female) (1) and in "R".
(4) When direc-
tional lever is Resistance Min. 1 Mz
not in "R".
1. Turn starting switch OFF.
2. Replace L112 with normal relay.
3. Turn starting switch ON.
4. Operate parking brake.
Possible
causes and No Relay (L112)
standard value When parking brake neutral safety relay (L112) is is normal.
in normal state replaced, does condition become normal? Relay (L112)
Yes
is defective.
2 Defective parking brake 2) Disconnect connector L112.
neutral safety relay (L112) 3) Check relay unit.


Between Resistance Max. 1 z
(1) and (2)
L112 (male)
(3) and (5) When normal voltage is not
applied between (1) and (2)
20-540 WA200-5
(4)
TROUBLESHOOTING E-8

Relay (L107)
No is normal.
When forward relay (L107) is replaced, does con-
dition become normal? Relay (L107)
Yes is defective.
Defective reverse relay 1) Turn starting switch OFF.

3 (L107) 2) Disconnect connector L107

L107(male) When normal voltage is not
(6)
L107(male) When normal voltage is not
(6)
2) Disconnect connector T01.
4 Defective reverse solenoid
Possible Between T01 (male) (3) and (4) Resistance 30 - 60z
causes and
standard value Between T01 (male) (3), (4) and chassis ground Resistance Min. 1 Mz
in normal state
2) Disconnect connectors T01, L15, L107, and L112 and fuse (FS1).
Wiring harness between L15 (female) (4) and

harness (Disconnection in Wiring harness between L107 (female) (6) and Resistance Max. 1 z
5 chassis ground
in connector) Wiring harness between fuse FS1 (12) and L107
(female) (3) Resistance Max. 1 z
Wiring harness between L107 (female) (4) and Resistance Max. 1 z

T01 (female) (3)
Wiring harness between T01 (female) (4) and

2) Disconnect connectors T01, L15, L22, and L107

6 Ground fault in wiring (5) and chassis ground
harness
(female) (4) and D01 (female) (female) (4), D01 (female) (3) Min. 1 Mz
Resistance between fuse (FS1)
Wiring harness between fuse (12), L15 (female) (1), L107
(FS1) (12) and L15 (female) Min. 1 Mz
(female) (1) and chassis
(1), L107 (female) (1)
ground
a In all of these cases, the fuse is broken.
WA200-5 20-541
(4)..d
TROUBLESHOOTING E-8
20-542 WA200-5
(4)
TROUBLESHOOTING E-9
[E-9] (The wiper does not function)

a) The front wiper does not function
Controller
Action code Failure code The wiper does not function
code Trouble
a) The front wiper does not function
Contents of • The front wiper does not function due defective front wiper, switch, timer or wiring harness.
trouble
Action of
or controller
Problem that
appears on • The front wiper does not function.
machine
Related
information

Between L57 (6) and chassis ground Voltage 20 - 30V
Between L57 (2) and chassis Turn wiper
Voltage 20 - 30V
ground switch Lo.
1 Defective front wiper motor
Voltage 20 - 30V
ground switch Hi.
• When the wiper switch is turned OFF during running of the wiper, the voltage is
applied between the L57 (Female) (5) and chassis ground until the wiper motor
stops.

Between L48 (4) and chassis Turn wiper Voltage 20 - 30V
Possible ground switch INT
causes and 2 Defective wiper timer
standard value Turn wiper
Between L48 (2) and chassis switch Voltage 20 - 30V
in normal state ground WASHER
Between L48 (5) and chassis ground 20 - 30V to 0V
(The voltage is output intermittently by wiper Voltage 0V to 20 - 30V
switch INT) (Repeated)
Between L05 Turn wiper switch Lo. Resistance Max. 1z
(Male) (7) and
(5) Other than above. Resistance Min. 1Mz
Between L05 Turn wiper switch Hi. Resistance Max. 1z
3 Defective front wiper switch (Male) (7) and
Between L05 Turn wiper switch INT Resistance Max. 1z
(Male) (7) and
Between L05 Turn wiper switch INT Resistance Max. 1z
(Male) (3) and
20-544 WA200-5
(4)
TROUBLESHOOTING E-9

1) Turn starting switch OFF. 2) Disconnect connector L05, L48, L57 and fuse FS1
Resistance Max. 1z
L48 (Female) (4)

Resistance Max. 1z
L57 (Female) (2)
L57 (Female) (1)
in connector)
Resistance Max. 1z
L57 (Female) (5)

Resistance Max. 1z
(Female) (3)
Resistance Max. 1z
(Female) (6)
1) Turn starting switch OFF. 2) Disconnect connector L05, L48, L52, L57 and fuse
Possible FS1 terminal. 3) Connect T-adapter.
causes and
standard value Wiring harness between L05 Resistance between L05
Ground fault in wiring (Female) (4) and L57 (Female) (Female) (4), L57 (Female) (1) Min. 1Mz
5
harness (1) and chassis ground
Wiring harness between fuse Resistance between L05

ground
Wiring harness between fuse (Female) (3) and chassis Min. 1Mz
ground
FS1 (14) and L57 (Female) (6) ground
WA200-5 20-545
(4)..d
TROUBLESHOOTING E-9
20-546 WA200-5
(4)
TROUBLESHOOTING E-9
b) The rear wiper does not function

Controller
Action code Failure code The wiper does not function
code Trouble
b) The rear wiper does not function
Contents of • The rear wiper does not function due defective rear wiper, switch, timer or wiring harness.
trouble
Action of
or controller
Problem that
appears on • The rear wiper does not function.
machine
Related
information

1 Defective rear wiper motor Voltage 20 - 30V
ground switch Lo.
• When the wiper switch is turned OFF during running of the wiper, the voltage is
applied between the L52 (Female) (1) and chassis ground until the wiper motor
stops.

Between L05 Turn wiper switch Lo. Resistance Max. 1z
2 Defective rear wiper switch (Male) (7) and
Between L05 Turn wiper switch OFF. Resistance Max. 1z
(Male) (8) and
1) Turn starting switch OFF. 2) Disconnect connector L05, L52 and fuse FS1 termi-
Possible Wiring harness between L05 (Female) (8) and
causes and Resistance Max. 1z
L52 (Female) (1)
standard value Disconnection in wiring
in normal state harness (Disconnection in Wiring harness between L05 (Female) (9) and
L52 (Female) (2)
in connector)
(Female) (7)
1) Turn starting switch OFF. 2) Disconnect connector L05, L48, L52, L57 and fuse
FS1 terminal. 3) Connect T-adapter.
4
harness
ground
FS1 (14) and L52 (Female) (4) ground
a In the all above cases, the fuse is blown.
20-548 WA200-5
(4)
TROUBLESHOOTING E-9
WA200-5 20-549
(4)..d
TROUBLESHOOTING E-10
[E-10] (The window washer does not function)

Controller
code Trouble The window washer does not function
Contents of • The window washer does not function due defective window washer motor, switch, timer (Front only) or wiring har-
trouble ness.
Action of
or controller
Problem that
appears on • The window washer does not function.
machine
Related
information

1) Turn starting switch OFF. 2) Disconnect connector B07, B06. 3) Insert T-adapter.
• Front washer motor
Defective window washer
1 motor Between B07 (1) and chassis ground Voltage 20 - 30V
• Rear washer motor
Between B06 (1) and chassis ground Voltage 20 - 30V

• Common to front switch and rear switch.
Between L05 (Male) (7) and chassis ground Voltage 20 - 30V

• Front switch
Possible
causes and Between L05 Turn washer switch ON. Resistance Max. 1z
2 Defective wiper switch (Male) (7) and
standard value
in normal state (6) Turn washer switch OFF. Resistance Min. 1Mz
• Rear switch
Between L05 Turn washer switch ON. Resistance Max. 1z

(Male) (7) and
(10) Turn washer switch OFF. Resistance Min. 1Mz
Turn washer
Between L05 (Male) (7) and
(9), (10) and wiper low Resistance Max. 1z
switch ON.
Wiring harness between L48 (3) and chassis Voltage 20 - 30V
ground
Defective wiper timer Wiring harness between L48 Turn washer
3 Voltage 20 - 30V
(Relay) (2) and chassis ground switch ON.
Wiring harness between L48 (5) and chassis
(0.2 to 0.8 sec. after the washer switch was
turned ON)
20-550 WA200-5
(4)

1) Turn starting switch OFF. 2) Disconnect connector L05, L48, B06, B07 and fuse
• Front side

Resistance Max. 1z
B07 (Female) (1)
Resistance Max. 1z
L48 (Female) (2)
in connector)
• Rear side

B06 (Female) (1)
• Common to front and rear side.

Resistance Max. 1z
(Female) (7)
Possible 1) Turn starting switch OFF. 2) Disconnect connector L05, L48, L52, L57, D10, D13
causes and and fuse FS1 terminal. 3) Connect T-adapter.
standard value • Front side
in normal state
(Female) (6) and B07 (Female) (Female) (6), B07 (Female) (1) Min. 1Mz
5 (5) and chassis ground
harness
• Rear side

(Female) (10) and B06 (Female) (10), B06 (Female) Min. 1Mz
• Common to front and rear side.

ground
a In the all above cases, the fuse is blown.
WA200-5 20-551
(4)..d
20-552 WA200-5
(4)
[E-11] (Lamps do not work properly)

a) Neither high beam nor low beam of headlamp light up
Controller
Action code Failure code Lamps do not work properly
code Trouble
a) Neither high beam nor low beam of headlamp light up
Contents of • Head lamp (Hi beam and Lo beam) does not light ON due to defective switch, lamp or wiring harness (Ground fault) in
trouble the head lamp system.
Action of
or controller
Problem that
appears on • Head lamp (Hi beam and Lo beam) does not light ON when the lamp switch is turned STEP 2.
machine
• If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and relay,
Related between fuse and lamp)
information
• When circuits for other lamp systems are normal

1) Turn starting switch OFF. 2) Disconnect connector HEAD L, HEAD R. 3) Insert T-
adapter. 4) Connect connector. 5) Turn starting switch ON.
Between
HEAD L (3) Turn lamp switch STEP 2 and
and chassis dimmer switch Lo. Voltage 20 - 30V
ground
Between
HEAD L (3) Turn lamp switch STEP 2 and Voltage 20 - 30V
1 Defective head lamp and chassis dimmer switch Hi.
ground
Between
HEAD R (3) Turn lamp switch STEP 2 and Voltage 20 - 30V
and chassis dimmer switch Lo.
Possible ground
causes and
standard value Between
in normal state HEAD R (3) Turn lamp switch STEP 2 and Voltage 20 - 30V
and chassis dimmer switch Hi.
ground
Turn lamp switch OFF. Resistance Min. 1Mz
Between L04
(Male) (2) and Turn lamp switch 1 STEP. Resistance Min. 1Mz
(3)
Defective lamp switch and Turn lamp switch STEP 2. Resistance Max. 1z
2 dimmer switch
Between L04 Turn dimmer switch Lo. Resistance Max. 1z
(Male) (4) and
(3) Turn dimmer switch Hi. Resistance Min. 1Mz
Between L04 Turn dimmer switch Lo. Resistance Min. 1Mz
(Male) (5) and
(3) Turn dimmer switch Hi. Resistance Max. 1z
WA200-5 20-553
(4)..d

switch ON.
Does condition become normal Relay L120 is

Condition is abnormal.
when the headlamp relay (left) normal.
L120 is replaced with normal Defective
relay? Condition is normal.
relay L120.
Defective head lamp relay 1) Turn starting switch OFF. 2) Disconnect connector L120. 3) Solid part check.
3 (Left side) (L120) 4) Applies impressed voltage between L120 (Male) (1) - (2)
Between L120 (Male) (1) and (2) Resistance 200 - 400z
L120 (Male)
Resistance Min. 1Mz
switch ON.

when headlamp relay (right) normal.
relay? Condition is normal. relay L119.
Defective head lamp relay 1) Turn starting switch OFF. 2) Disconnect connector L119. 3) Solid part check.
4
(Right side) (L119) Between L119 (Male) (1) and (2) Resistance 200 - 400z
Possible 1) Turn starting switch OFF. 2) Disconnect connector L119. 3) Solid part check.
causes and 4) Applies impressed voltage between L119 (Male) (1) - (2)
standard value
in normal state Applies 24V impressed voltage
L119 (Male)
1) Turn starting switch OFF. 2) Disconnect connector L04, L120, L119, HEAD L,
HEAD R and fuse FS1 terminal (8), (9). 3) Connect T-adapter.
a When both sides are defective (in this case, clearance lamp also does not light
up)

chassis ground
a When left side is defective

HEAD L (Female) (3) Resistance Max. 1z
harness (Disconnection in Wiring harness between fuse FS1 terminal (8)
and L120 (Female) (1), (3)
in connector)
Resistance Max. 1z
L04 (Female) (2)
a When right side is defective

Resistance Max. 1z
HEAD R (Female) (3)
Wiring harness between fuse FS1 terminal (9)
Resistance Max. 1z
and L119 (Female) (1), (3)
Resistance Max. 1z
L04 (Female) (2)
20-554 WA200-5
(4)
WA200-5 20-555
(4)..d
b) Head lamp (Lo beam) does not light ON

Controller
Action code Failure code Each lamps does not function
code Trouble
b) Head lamp (Lo beam) does not light ON
Contents of • Head lamp (Lo beam) does not light ON due to defective switch, lamp or wiring harness (Ground fault) in the head
trouble lamp system.
Action of
or controller
Problem that
appears on • Head lamp (Lo beam) does not light ON when the lamp switch is turned STEP 2.
machine
Related • If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and lamp)
information • When circuits for other lamp systems are normal

Between
1 Defective head lamp
ground
Between
HEAD R (3) Turn lamp switch STEP 2 and
ground
Possible Turn lamp switch OFF. Resistance Min. 1Mz
causes and Between L04
standard value (Male) (2) and Turn lamp switch 1 STEP. Resistance Min. 1Mz
in normal state (3)
Defective lamp switch and Turn lamp switch STEP 2. Resistance Max. 1z
2
dimmer switch
(Male) (4) and
(Male) (5) and
1) Turn starting switch OFF. 2) Disconnect connector L04, HEAD L, HEAD R.
HEAD L (Female) (1)
in connector)
Resistance Max. 1z
HEAD R (Female) (1)

a See "TROUBLESHOOTING CODE [E-11.(a)]".
20-556 WA200-5
(4)
c) Head lamp (Hi beam) does not light ON

Controller
code Trouble
c) Head lamp (Hi beam) does not light ON
Contents of • Head lamp (Hi beam) does not light ON due to defective switch, lamp or wiring harness (Ground fault) in the head
trouble lamp system.
Action of
or controller
Problem that
appears on • Head lamp (Hi beam) does not light ON when the lamp switch is turned STEP 2.
machine

Between
Voltage 20 - 30V
1 Defective head lamp and chassis dimmer switch Hi.
ground
Between
HEAD R (3) Turn lamp switch STEP 2 and
Voltage 20 - 30V
and chassis dimmer switch Hi.
ground
Turn lamp switch OFF. Resistance Min. 1Mz
Between L04
Possible (Male) (2) and Turn lamp switch 1 STEP. Resistance Min. 1Mz
causes and (3)
standard value Defective lamp switch and Turn lamp switch STEP 2. Resistance Max. 1z
2
in normal state dimmer switch
(Male) (4) and
(Male) (5) and
1) Turn starting switch OFF. 2) Disconnect connector L04, HEAD L, HEAD R.
wiring or defective contact J03 (4), (2) and HEAD L (Female) (2)
in connector)

J03 (4), (2) and HEAD R (Female) (2)

WA200-5 20-557
(4)..d
d) Clearance lamp (Small lamp) does not light ON

Controller
code Trouble
d) Clearance lamp (Small lamp) does not light ON
Contents of • Clearance lamp (Small lamp) does not light ON due to defective switch, lamp or wiring harness (Ground fault) in the
trouble clearance lamp system.
Action of
or controller
Problem that
appears on • Clearance lamp (Small lamp) does not light ON when the lamp switch is turned STEP 1.
machine

Between
HEAD L (5)
and chassis Turn lamp switch STEP 1. Voltage 20 - 30V
1 Defective clearance lamp
ground
Between
HEAD R (5)
and chassis Turn lamp switch STEP 1. Voltage 20 - 30V
ground
2 Defective lamp switch Between L04 Turn lamp switch OFF. Resistance Min. 1Mz
Possible (Male) (2) and
causes and (3) Turn lamp switch STEP 1. Resistance Max. 1z
standard value
in normal state 1) Turn starting switch OFF. 2) Replace relay L117 with normal relay. 3) Turn starting
switch ON.

Condition is abnormal. normal.
when small lamp relay (left)
Defective small lamp relay
(Left side) (L117) 1) Turn starting switch OFF. 2) Disconnect connector L117. 3) Solid part check.
3
a When left side is defec- Between L117 (Male) (1) and (2) Resistance 200 - 400z
tive
Between between L117 (Male) (1) - (2)
L117 (Male)
20-558 WA200-5
(4)

switch ON.
Does condition become normal Condition is abnormal. Relay L118 is

when small lamp relay (right) normal.
Defective small lamp relay
(Right side) (L118) 1) Turn starting switch OFF. 2) Disconnect connector L118. 3) Solid part check.
4
a When right side is Between L118 (Male) (1) and (2) Resistance 200 - 400z
defective
L118 (Male)
Resistance Min. 1Mz
a When both sides are defective (in this case, headlamp also does not light up)
Possible
causes and Wiring harness between L04 (Female) (3) and
standard value Resistance Max. 1z
chassis ground
in normal state

Resistance Max. 1z
J10 (9), (10) and HEAD L (Female) (5)
(Female) (1), (3) Resistance Max. 1z
harness (Disconnection in Wiring harness between L117 (Female) (2) and Resistance Max. 1z
5 wiring or defective contact L04 (Female) (1)
in connector) Wiring harness between HEAD L (Female) (4) Resistance Max. 1z
and chassis ground

Resistance Max. 1z
HEAD R (Female) (5)
(Female) (1), (3) Resistance Max. 1z

L04 (Female) (1)
Wiring harness between HEAD R (Female) (4) Resistance Max. 1z
and chassis ground

WA200-5 20-559
(4)..d
e) Turn signal lamp does not blink

Controller
code Trouble
e) Turn signal lamp does not blink
Contents of • Turn signal lamp does not blink due to defective switch, lamp or wiring harness (Ground fault) in the turn signal lamp
trouble system.
Action of
or controller
Problem that
appears on • Turn signal lamp does not blink
machine

Between L04 Turn turn-signal switch RIGHT. Resistance Max. 1z
(Male) (6) and
1 Defective turn-signal switch Turn turn-signal switch LEFT. Resistance Min. 1Mz
(7)
Between L04 Turn turn-signal switch RIGHT. Resistance Max. 1z
(Male) (6) and
(8) Turn turn-signal switch LEFT. Resistance Min. 1Mz
Possible Between L06 Turn hazard switch OFF. Resistance Max. 1z
causes and (Male) (1) and
standard value (2) Turn hazard switch ON. Resistance Min. 1Mz
in normal state
Between L06 Turn hazard switch OFF. Resistance Max. 1z
(Male) (3) and
(2) Turn hazard switch ON. Resistance Min. 1Mz
2 Defective hazard switch a When hazard switch does not function

(Disconnection or defective Resistance Min. 1Mz
contact)
Between L06
(Male) (5) and 1) Turn starting switch OFF.
(6) 2) Disconnect connector L04,
L119, L120, HEAD L, HEAD R Resistance Max. 1z
and fuse FS1 terminal (8), (9).
20-560 WA200-5
(4)

a When both sides are defective (in this case, headlamp also does not light up)

Resistance Max. 1z
chassis ground

Resistance Max. 1z
J03 (10), (6) and HEAD L (Female) (6)
Wiring harness between HEAD L (Female) (4)
Resistance Max. 1z
and chassis ground
Resistance Max. 1z
J03 (10), (9) and R22 (Female) (1)
chassis ground
Resistance Max. 1z
D12 (2), (1) and J03 (7)

Resistance Max. 1z
J03 (20), (16) and HEAD R (Female) (6)
Wiring harness between HEAD R (Female) (4)
and chassis ground Resistance Max. 1z
Possible
standard value harness (Disconnection in Wiring harness between L04 (Female) (7) and Resistance Max. 1z
3 J03 (20), (19) and R23 (Female) (1)
in normal state wiring or defective contact
in connector)
chassis ground
Resistance Max. 1z
D11 (2), (1) and J03 (17)
a When both sides are defective
Wiring harness between fuse FS1 (10) and J10

(4), (1) and L06 (Female) (1) Resistance Max. 1z
(Female) (3)
Resistance Max. 1z
L49 (Female) (B)
Wiring harness between L49 (Female) (E) and
Resistance Max. 1z
chassis ground
Wiring harness between L49 (Female) (L) and
J01 (Female) (6) Resistance Max. 1z

J01 (Female) (4)
a When hazard switch does not function

Resistance Max. 1z
J01 (Female) (5)
Resistance Max. 1z
J01 (Female) (18)

WA200-5 20-561
(4)..d
f) Working lamp does not light ON

Controller
code Trouble
f) Working lamp does not light ON
Contents of • Working lamp does not light ON due to defective switch, lamp or wiring harness (Ground fault) in the clearance lamp
trouble system.
Action of
or controller
Problem that
appears on • Working lamp does not light ON.
machine
• If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and lamp)
Related • When circuits for other lamp systems are normal
information
• When side lamps do not light up, carry out troubleshooting first for side lamp system.

1) Turn starting switch OFF. 2) Disconnect connector C05, C06, B01 or B02.
3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON.
Turn front working lamp switch
Between C05 ON. Voltage 20 - 30V
(1) and chas-
sis ground Turn front working lamp switch Voltage Max. 1V
OFF.
Turn front working lamp switch Voltage 20 - 30V
Between C06 ON.
(1) and chas-
1 Defective working lamp sis ground Turn front working lamp switch Voltage Max. 1V
OFF.
Turn rear working lamp switch
Between B01 Voltage 20 - 30V
ON.
(1) and chas-
sis ground Turn rear working lamp switch Voltage Max. 1V
OFF.
Between B02 ON. Voltage 20 - 30V
(1) and chas-
sis ground Turn rear working lamp switch
Voltage Max. 1V
OFF.
1) Turn starting switch OFF. 2) Disconnect connector C05, C06, B01 or B02.
Possible 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON.
causes and
standard value Turn front working lamp switch Resistance Max. 1z
Between L07 ON.
in normal state (Male) (2) and
Defective working lamp (3) Turn front working lamp switch
2 switch Resistance Min. 1Mz
OFF.
Between L08 Resistance Max. 1z
ON.
(Male) (2) and
(3) Turn rear working lamp switch
OFF. Resistance Min. 1Mz
1) Turn starting switch OFF.2) Replace relay L122 with normal relay. 3) Turn starting
switch ON.
Condition is abnormal. Relay L122 is

Does condition become normal normal.
when working lamp relay L122
is replaced with normal relay? Defective
Condition is normal. relay L122.
Defective working lamp 1) Turn starting switch OFF. 2) Disconnect connector L122. 3) Solid part check.
3
L122 (Male)
Resistance Min. 1Mz
20-562 WA200-5
(4)

a When all lamps are defective

Resistance Max. 1z
L122 (Female) (1)
Resistance Max. 1z
chassis ground
a When front lamps are defective

Resistance Max. 1z
L07 (Female) (2)
Possible Wiring harness between fuse FS2 (12) and L122
causes and Disconnection in wiring Resistance Max. 1z
(Female) (1)
standard value harness (Disconnection in
4
in normal state wiring or defective contact Wiring harness between L07 (Female) (3) and
C05 (Female) (1), C06 (Female) (1)
Wiring harness between C05 (Female) (2), C06
Resistance Max. 1z
a When rear lamps are defective

Resistance Max. 1z
L08 (Female) (2)
Resistance Max. 1z
(Female) (3)
B01 (Female) (1), B02 (Female) (1)
Wiring harness between B01 (Female) (2), B02 Resistance Max. 1z

WA200-5 20-563
(4)..d
[E-12] (The horn does not sound)

Controller
code Trouble The horn does not sound
Contents of • Horn does not sound due to defective switch, relay, horn or wiring harness in the horn system.
trouble
Action of
or controller
Problem that
appears on • The horn does not sound.
machine
Related
information

1) Turn starting switch OFF. 2) Disconnect connector L13. 3) Connect connector.
Between L13 Push horn switch ON Resistance Max. 1z
1 Defective horn switch (Male) (1) and
chassis Horn switch OFF Resistance Min. 1Mz
ground
Between L116 (1), (3) and chassis ground Voltage 20 - 30V
Between L116 (2) and chassis ground Voltage Max. 1V
switch ON.
Relay L116 is
Possible Does condition become normal Condition is abnormal. normal.
causes and 2 Defective horn relay (L116) when horn and lamp relay L116
standard value is replaced with normal relay? Condition is normal. Defective
in normal state relay L116.
Between L116 (Male) (1) and (2) Resistance 200 - 400z
L116 (Male)
1) Turn starting switch OFF. 2) Disconnect connector F01, F02. 3) Insert T-adapter.
4) Connect T-adapter. 5) Turn starting switch ON.
Between F01 Push horn switch ON Voltage 20 - 30V
(Male) (1) and
3 Defective horn Horn switch OFF Voltage Max. 1V
(2)
Between F02 Push horn switch ON Voltage 20 - 30V
(Male) (1) and
(2) Horn switch OFF Voltage Max. 1V
20-564 WA200-5
(4)

1) Turn starting switch OFF. 2) Disconnect connector L13, L116 and fuse FS2 (9) ter-
minal. 3) Connect T-adapter.
(Female) (1), (3)
L13 (Female) (1)
in connector)
Resistance Max. 1z
F02 (Female) (1)
Wiring harness between F01 (Female) (2), F02
(Female) (2) and chassis ground Resistance Max. 1z
Possible
causes and 1) Turn starting switch OFF. 2) Disconnect connector L116, F01, F02 and fuse FS2
standard value (9) terminal. 3) Connect T-adapter.
in normal state
FS2 (9) and L116 (Female) (1), (9), L116 (Female) (1), (3) and Min. 1Mz
(3) *1 chassis ground
5 (1) *2 and chassis ground
harness
Wiring harness between L116 (Female) (5), F01 (Female) (1),
(Female) (5) and F01 (Female) Min. 1Mz
F02 (Female) (1) and chassis
(1), F02 (Female) (1) ground
a In case of *1 above, fuse is blown
a In case of *2 above, horn does not stop sounding
WA200-5 20-565
(4)..d
[E-13] (Defective air conditioner)

a) The air conditioner does not work
Controller
Action code Failure code Defective air conditioner
code Trouble
a) The air conditioner does not work
Contents of • The air conditioner does not work.
trouble
Action of
or controller
Problem that
appears on • The air conditioner does not work.
machine
Related • If fuse FS2 (2) is blown, check wiring harness between fuse FS2 (2) - C03 (Female) (8) for short circuit with ground.
information

1) Turn starting switch OFF. 2) Disconnect connector C03, fuse FS2 terminal.
Possible
causes and harness (Disconnection in Wiring harness between fuse FS2 (2) and C03
standard value (Female) (8)
Wiring harness between C03 (Female) (11) and
Resistance Max. 1z
chassis ground
Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
2
control panel
20-566 WA200-5
(4)
WA200-5 20-567
(4)..d
b) Air does not flow out or amount of air cannot be adjusted.

Controller
code Trouble
b) Air does not flow out or amount of air cannot be adjusted.
Contents of • Air does not flow out or amount of air cannot be adjusted.
trouble
Action of
or controller
Problem that
appears on • Air does not flow out or amount of air cannot be adjusted.
machine
Related
information

1) Turn starting switch OFF. 2) Disconnect connector A09, A10, A11, A13 and fuse
Wiring harness between fuse FS2 (2) and A09
Resistance Max. 1z
(Female) (1)
Disconnection in power Wiring harness between fuse FS2 (2) and A10
source wiring harness Resistance Max. 1z
(Female) (1)
1 (Disconnection in wiring or
defective contact in Wiring harness between fuse FS2 (2) and A11
connector)
Wiring harness between fuse FS2 (2) and A13
Resistance Max. 1z
(Female) (1)
Wiring harness between fuse FS2 (1) and A09 Resistance Max. 1z
(Female) (3)
1) Turn starting switch OFF. 2) Disconnect connector C03, A09, A10, A11, A12 and
fuse FS2 terminal. 3) Connect T-adapter.
A09 (Female) (2) Resistance Max. 1z
Wiring harness between C03 (Female) (4) and Resistance Max. 1z
A10 (Female) (2)
Wiring harness between A09 (Female) (4) and
ness (Disconnection in wir- Wiring harness between A10 (Female) (4) and
2 A01 (Female) (5) Resistance Max. 1z
ing or defective contact in
Possible connector) Wiring harness between A11 (Female) (4) and A01
causes and
standard value Wiring harness between A13 (Female) (4) and
in normal state A01 (Female) (3) Resistance Max. 1z
Resistance Max. 1z
chassis ground
Resistance Max. 1z
chassis ground
1) Turn starting switch OFF. 2) Disconnect connector A01, A05, A09, A10, A11, A13
and fuse FS2 terminal. 3) Connect T-adapter.
(2), A09 (Female) (1) and chas- Min. 1Mz
FS1 (2) and A09 (Female) (1) *
sis ground
Wiring harness between fuse (2), A10 (Female) (1) and chas- Min. 1Mz
sis ground
Ground fault in wiring (2) and A11 (Female) (1) and Min. 1Mz
3 FS1 (2) and A11 (Female) (1) * chassis ground
harness
sis ground
FS1 (2) and A12 (Female) (1) * sis ground
sis ground
20-568 WA200-5
(4)

sis ground
Wiring harness between C03 Resistance between C03
(Female) (7) and A09 (Female) (Female) (7), A09 (Female) (2) Min. 1Mz
Ground fault in wiring Wiring harness between A09 Resistance between A09
3
harness (Female) (4) and A01 (Female) (Female) (4), A01 (Female) (6) Min. 1Mz
Wiring harness between A10 Resistance between A10
(Female) (2) and C03 (Female) (Female) (2), C03 (Female) (3) Min. 1Mz
a If marked * above, fuse is blown
1) Turn starting switch OFF. 2) Replace relay A09 with normal relay. 3) Turn starting
Possible switch ON. 4) Start air conditioner
causes and Defective blower main relay Defective
standard value 4 Does condition become normal Condition is normal.
A09 relay.
in normal state when relay is replaced with nor-
mal relay? Condition is abnormal. Relay is
normal.
switch ON. 4) Start air conditioner
Defective blower Hi relay Condition is normal. Defective
5 A10 Does condition become normal relay.
when relay is replaced with nor-
mal relay? Relay is
Defective blower M2 relay Defective
6 Does condition become normal Condition is normal.
A11 relay.
mal relay? Condition is abnormal. Relay is
normal.
Defective blower M1 relay Defective
A13 relay.
mal relay? Relay is
1) Turn starting switch OFF. 2) Replace motor with normal motor. 3) Turn starting
Defective
8 Defective blower motor Does condition become normal Condition is normal.
motor.
when motor is replaced with nor-
mal motor? Relay is
motor.
1) Turn starting switch OFF. 2) Disconnect connector A01. 3) Solid part check.
Between A01 (Female) (1) and (3) Resistance 2.8z
9 Defective blower resister
10
control panel

WA200-5 20-569
(4)..d
c) Does not cool or temperature cannot be adjusted.
Controller
code Trouble
c) Does not cool or temperature cannot be adjusted.
Contents of • Does not cool or temperature cannot be adjusted.
trouble
Action of
or controller
Problem that
appears on • Does not cool or temperature cannot be adjusted.
machine
Related
information

1) Turn starting switch OFF. 2) Disconnect connector A12, A15 and fuse FS2 termi-
Disconnection in power nal. 3) Connect T-adapter.
source wiring harness (Dis- Wiring harness between fuse FS2 (2) and A12
1 connection in wiring or Resistance Max. 1z
(Female) (1), (4)
defective contact in con-
nector) Wiring harness between fuse FS2 (2) and A15
Resistance Max. 1z
(Female) (1), (4)
1) Turn starting switch OFF. 2) Disconnect connector A02, A03, A05, A07, A08, A12,
A15, B04, C03, C04 and J06. 3) Connect T-adapter.
Wiring harness between A05 (Female) (2) and Resistance Max. 1z

C03 (Female) (4)
B04 (Female) (2)
A12 (Female) (2), A15 (Female) (2)
B04 (Female) (1)
E16 (Female) (1)
Disconnection in wiring Wiring harness between B04 (Female) (3) and Resistance Max. 1z
harness (Disconnection in chassis ground
2
wiring or defective contact Wiring harness between compressor magnet
clutch (-) terminal and chassis ground
Possible
causes and Resistance Max. 1z
standard value A03 (Female) (2)
in normal state Wiring harness between A03 (Female) (1) and
Resistance Max. 1z
J06 (16), (15) and C03 (Female) (12)
Resistance Max. 1z
J06 (16), (15) and A02 (Female) (4)
Resistance Max. 1z
C03 (Female) (9)
C04 (Female) (4)
C03 (Female) (15)
Resistance Max. 1z
C04 (Female) (3)
1) Turn starting switch OFF. 2) Disconnect connector A02, A03, A05, A12, A15, B04,
C03, C04 and fuse FS2 terminal. 3) Connect T-adapter.
FS1 (2) and A12 (Female) (1), (2), A12 (Female) (1), (4) and Min. 1Mz
FS1 (2) and A15 (Female) (1), (2), A15 (Female) (1), (4) and Min. 1Mz
Ground fault in wiring (4) * chassis ground
3
harness
(2) * and chassis ground
Resistance between A05
Wiring harness between A05 (Female) (4), A12 (Female) (2),
(Female) (4) and A12 (Female) Min. 1Mz
(2), A15 (Female) (2) A15 (Female) (2) and chassis
ground
20-570 WA200-5
(4)

(Female) (3) and E16 (Female) (Female) (3), E16 (Female) (1) Min. 1Mz
(Female) (16) and A03 (Female) (16), A03 (Female) Min. 1Mz
(Female) (1) and J06 (16), (15) (Female) (1), C03 (Female) Min. 1Mz
and C03 (Female) (12) (12) and chassis ground
(Female) (1) and J06 (16), (15) (Female) (1), A02 (Female) (4) Min. 1Mz
Ground fault in wiring and A02 (Female) (4) and chassis ground
3 harness
(Female) (5) and C03 (Female) (Female) (5), C03 (Female) Min. 1Mz
(15) (15) and chassis ground
a If marked * above, fuse is blown
Defective compressor Defective
Possible 4 Does condition become normal Condition is normal.
clutch relay A15 relay.
causes and when relay is interchanged with
standard value normal relay? Condition is abnormal. Relay is
in normal state normal.
1) Turn starting switch OFF. 2) Disconnect connector A05. 3) Connect T-adapter.
5 Defective pressure switch Between A05 Turn air conditioner switch OFF. Resistance Min. 1Mz
(Male) (1) and When air conditioner switch is
(2) Resistance Max. 1z
ON and cooling is in operation
1) Turn starting switch OFF. 2) Disconnect connector ACTH. 3) Turn starting switch
ON. 4) Start air conditioner.
6 Defective thermister Temperature: 25°C 37 - 50kz
Between A03 (Male) (1) and (2)
Temperature: 100°C 3.5 - 4.0kz
1) Turn starting switch OFF. 2) Replace motor with normal motor. 3) Turn starting
Defective temperature con- Defective
trol servo motor motor.
when servo motor is inter-
changed with normal motor? Motor is
normal.
1) Turn starting switch OFF. 2) Replace compressor with normal compressor. 3) Turn
starting switch ON. 4) Start air conditioner
Defective air
Condition is normal. conditioner
Defective air conditioner Does condition become normal compressor.
8 compressor when air conditioner compres-
sor is replaced with normal Air condi-
compressor? tioner com-
pressor is
normal.
Turn starting switch OFF. 2) Replace diode D06 with normal diode.
Defective
Condition is normal. diode D06.
9 Defective diode (D06) Replace diode D06 with normal
diode Diode D06 is
10 control panel

WA200-5 20-571
(4)..d
d) Impossible to switch between recirculated air and fresh air
Controller
code Trouble
d) Impossible to switch between recirculated air and fresh air
Contents of • Air conditioner system is defective, so it is impossible to switch between recirculated air and fresh air
trouble
Action of
or controller
Problem that
appears on • Impossible to switch between recirculated air and fresh air
machine
Related
information

1) Turn starting switch OFF. 2) Disconnect connector C04, L51. 3) Connect T-
adapter.
harness (Disconnection in Wiring harness between C04 (Female) (1) and
in connector)
Wiring harness between C04 (Female) (2) and Resistance Max. 1z
L51 (Female) (1)
Possible
causes and 1) Turn starting switch OFF. 2) Disconnect connector C04, L51. 3) Connect T-
in normal state
2 harness (2) and chassis ground
3 control panel

20-572 WA200-5
(4)
e) Impossible to switch vents

Controller
code Trouble
e) Impossible to switch vents
Contents of • Impossible to switch vents
trouble
Action of
or controller
Problem that
appears on • Impossible to switch vents
machine
Related
information

1) Turn starting switch OFF. 2) Disconnect connector A03, A07, A08, C03, C04, J06.
Wiring harness between A07 (Female) (1) and C03 (Female) (1) Resistance Max. 1z
ness (Disconnection in wir- Wiring harness between A08 (Female) (1) and C04 (Female) (5) Resistance Max. 1z
1 ing or defective contact in
connector) Wiring harness between A08 (Female) (2) and C04 (Female) (6) Resistance Max. 1z
Wiring harness between A03 (Female) (1) and J06 (16), (14) and
Wiring harness between A03 (Female) (1) and J06 (16), (14) and
1) Turn starting switch OFF. 2) Disconnect connector ACP1, ACP2, ACM2. 3) Connect
T-adapter.

(Female) (1), C03 (Female) Min. 1Mz
(Female) (1) and C03 (Female) (1)

(Female) (2) and C03 (Female) (2) (Female) (2), C03 (Female) Min. 1Mz
Possible (2) and chassis ground
causes and
standard value Resistance between A07
Wiring harness between A07 (Female) (3), C03 (Female)
in normal state (Female) (3) and C03 (Female) (11) Min. 1Mz

Wiring harness between A08
2 harness
(Female) (2) and C04 (Female) (6) Min. 1Mz
(Female) (8) and C03 (Female) (14) Min. 1Mz

(Female) (1), J06 (16), (14),
(Female) (1) and J06 (16), (14) and Min. 1Mz
A07 (Female) (6) and chassis
A07 (Female) (6) ground
(Female) (1) and J06 (16), (14) and (Female) (1), J06 (16), (14),
A08 (Female) (6) and chassis Min. 1Mz
A08 (Female) (6)
ground
3 control panel

WA200-5 20-573
(4)..d
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)
Method of using troubleshooting chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-602

Failure code and cause table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-604
H-1 The machine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-606
H-2 The travel speed is slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-607
H-3 The thrusting force is weak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608
H-4 Engine stalls when traveling or engine speed drops excessively . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609
H-5 The gear is not shifted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-610
H-6 The steering wheel does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-611
H-7 The steering wheel is heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612
H-8 Steering wheel shakes or jerks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-613
H-9 Machine deviates naturally to one side when traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-613
H-10 The brake does not work or does not work well . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
H-11 The brake is not released or is dragged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615
H-12 The lift arm does not rise or lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-617
H-13 The lift arm moves slowly or the lift arm rising force is insufficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618
H-14 When rising, the lift arm comes to move slowly at specific height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-619
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air) . . . . . . . . . . . . . . . . . . 20-619
H-16 Hydraulic drifts of the lift arm occur often . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-619
H-17 The lift arm wobbles during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-619
H-18 When the control lever is switched from "HOLD" to "RAISE," the lift arm falls temporarily . . . . . . . . . . 20-620
H-19 The bucket does not tilt back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-621
H-20 The bucket moves slowly or the tilting-back force is insufficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622
H-21 The bucket comes to operate slowly in he midst of tilting-back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-623
H-22 The bucket cylinder cannot hold down the bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-623
H-23 Hydraulic drifts of the bucket occur often. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-623
H-24 The bucket wobbles during travel with cargo (The work equipment valve is set to "HOLD") . . . . . . . . 20-624
H-25 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily. . . . . . . . . . . . 20-624
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy . . . . . . . . . . . . . . . . . . 20-624
H-27 The travel damper does not operate and machine pitches and bounces . . . . . . . . . . . . . . . . . . . . . . . 20-625
WA200-5 20-601
(4)..
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
METHOD OF USING TROUBLESHOOTING CHART

This troubleshooting chart, like the other troubleshooting charts (YES/NO type), determines the location from the
problem of occurring on the machine and categorizes the problem under one of the main components, such as the
steering system or work equipment hydraulic system. Use the following procedure to carry out accurate trouble-
shooting swiftly.
Step 1. Ask operator questions 2) Find the matching cause in the Causes col-
The questions to ask the operator are given umn.
under the problem. If the answer to the question If a problem is found, the Q marks on the
matches the content given, the cause given after same line as the troubleshooting are the
the arrow is the probable cause. causes. (In Troubleshooting item 2 in the
Keeping the content of the questions in mind, same diagram on the right the cause is c or
read the matrix and proceed with Step 2 and e.)
Step 3 to pinpoint the correct cause. When there is one Q mark
Carry out troubleshooting for the other items
Example: Steering wheel will not turn marked with Q in the same Causes column
Ask the operator and check the following points. to check if the problem occurs, then make
• Did the problem suddenly start? repairs.
o Broken part in steering equipment When there are two Q marks
Go to Step 3) to narrow down the cause.
• Was the steering wheel heavy before?
o Internal wear, defective seal in steering 1. Steering wheel does not turn i Problem
related equipment (example)
Ask the operator the following questions.
Step 2. Checks before troubleshooting • Did the problem suddenly start?
Before measuring the oil pressure or starting the Yes = Equipment related to steering broken
troubleshooting, confirm the checks before start- • Was there previously any symptom, such as heaviness of
the steering wheel?
ing items, check for leakage of oil, or for loose Yes = Wear of equipment related to steering, defective seal
bolts.
This will prevent wasting time when trouble-
Checks before troubleshooting (example)
shooting.
• Is the oil level in the hydraulic tank correct? Is the type of oil
The items given under Checks before trouble-
correct?
shooting are checks that are particularly impor- • Is there any leakage of oil from the steering valve or Orbit-
tant to make about the condition of the machine roll?
before starting the actual troubleshooting. • Has the safety bar been removed from the frame?
Example: Checks before starting troubleshooting <Example 1>

• Is oil level and type of oil in hydraulic tank Remedy
correct? No.
Problems
• Is there any oil leakage from steering valve
Steering wheel does not turn in either direction (left and
or demand valve? 1
right)
• Is steering linkage adjusted properly? 2 In Item 1, movement of work equipment is abnormal
3 Steering wheel turns only in one direction (left or right)
Step 3. Method of reading matrix 4 Steering wheel is heavy and does not turn
1) Operate the machine when carrying out trou-
bleshooting of the items in the Troubleshoot-
<Example 2>
ing column. If any problems occur as the
Cause
result of the troubleshooting, put a check
against the item. a b c d e
a When carrying out the troubleshooting, Remedy E
X C A X
check the easier items first. It is not nec- Problems X
essary to follow the number order. 1 Q Q Q Q
2 q q
3 Q Q
4 Q Q
5 Q Q
20-602 WA200-5
(4)
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHART
3) Operate the machine and carry out trouble-

shooting of the items not checked in Step 1).
Operate the machine in the same way as in Cause
Step 1), and if any problem occurs, put a a b c d e
check against the item. (In Troubleshooting E
Remedy
item 5 in the diagram on the right, the prob- X C A X
lem was re-enacted.) Problems X
4) Find the matching cause in the cause col- 1 Q Q Q Q
umn. o 2 q q
In the same way as in Step 2), if a problem is 3 Q Q
found, the Q marks on the same line for the 4 Q Q
troubleshooting item are the causes. (In
o 5 q q
Troubleshooting item 5 in the diagram on the
right, the cause is b or e.) Applicable items found in Step 3)
Applicable items found in Step 1)
5) Narrow down the causes. Causes to eliminate Common causes

Of the causes found in Step 2) and Step 4),
there are common items (Q marks on the Cause
line for each troubleshooting item and in the a b c d e
same Cause column as each other) that Remedy E
have causes common with the problem X C A X
Problems X
items found in the troubleshooting in Step 1)
1 Q Q Q Q
and Step 3).
a The items that are not common (items o 2 q q
that do not have Q marks in the same 3 Q Q
cause common as each other) are prob- 4 Q Q
ably not the cause, so they can be elimi- o 5 q q
nated.
(The causes for Troubleshooting item 2 Nature of remedy
in the diagram on the right are c or e,
and the causes in Troubleshooting item Cause
5 are b or e, so Cause e is the common a b c d e
cause.)
Remedy E
6) Repeat the operation in Steps 3), 4), and 5) X C A X
until the cause is narrowed down to 1 item (1 Problems X
common item). 1 Q Q Q Q
a If cause items are 2 or more, continue o 2 q q
until number of items becomes mini- 3 Q Q
mum.
4 Q Q
o 5 Q q
7) Remedy
After narrowing down the common causes,
taken the action given in the remedy line.
X: Replace E: Repair A: Adjust C: Clean
WA200-5 20-603
(1)..d
TESTING AND ADJUSTING FAILURE CODE AND CAUSE TABLE
FAILURE CODE AND CAUSE TABLE
Damper
Inching valve
Inching valve linkage

Part causing problem HST HST
HST pump
motor 2 motor 1
Pump body (Charge pump end)
Low pressure relief valve (Charge relief valve)

High pressure cut-off valve
Motor body
Motor body
Pump body (Piston pump end)
DA valve
Forward and reverse solenoid valve

High pressure relief valve
Mode selector solenoid valve (SOL a)
Angle stopper solenoid valve (SOL b)
Angle stopper control solenoid valve

Failure Code
Does not travel forward or in reverse Q Q Q Q Q Q Q Q Q Q Q
Does not travel forward (reverse is normal) Q Q
The machine does not start at reverse (Forward is normal) Q Q
Speed is slow in both forward and reverse Q Q Q Q Q Q Q Q Q Q Q
HST related
The travel speed is slow at forward (Reverse is normal) Q Q

The travel speed is slow at reverse (Forward is normal) Q Q
Rimpull is weak in both forward and reverse Q Q Q Q Q Q
The thrusting force is weak at forward (Reverse is normal) Q
The thrusting force is weak at reverse (Forward is normal) Q
Engine stalls when traveling or engine speed drops excessively Q Q Q
The gear is not shifted Q Q
The steering wheel does not turn
Brake Steering wheel
The steering wheel is heavy

There is play in steering wheel or excessive shock
Machine deviates naturally to one side when traveling
The brake does not work or does not work well
The brake is not released or is dragged
The lift arm does not rise or lower Q Q
The lift arm moves slowly or the lift arm rising force is insufficient Q
When the lift arm rising, the lift arm comes to move slowly at
specific height
The lift arm cylinder cannot be hold down the bucket
(The bucket rises in the air)
Hydraulic drift of the lift arm occur often
Work equipment system
The lift arm wobbles during operation

When the control lever is switched from "HOLD" to "RAISE", the
lift arm falls temporarily
The bucket does not tilt back Q Q
The bucket moves slowly or the tilting-back force is insufficient Q
The bucket comes to operate slowly in he midst of tilting-back
The bucket cylinder cannot be hold down to bucket
Hydraulic drift of the bucket occur often
The bucket wobbles during travel with cargo
(The work equipment valve is set to "HOLD")
When the control lever is switched from "HOLD" to "TILT", the
bucket falls temporarily
The control levers of the lift arm and bucket do not move
smoothly and heavy
20-604 WA200-5
(1)
Q
Q
Q
Q
Clutch solenoid
Q
Q
Q
Q
Clutch
Q
Q
Transfer
WA200-5
Q
Traction controll switch
Q
Q
Q
Q
Q
Q
Q
Work equipment and steering pump
Q
Brake pump
Q
Q
Q
Orbit-roll
Q
Q
Q
Q
Q
Q
Q
Priority valve
Q
Q
Relief valve
Steering valve
Q
Safty valve
Q
Q
Q
Q
Steering cylinder
Q
Tire inflation pressure
Q
Accumulator charge valve
Q
Brake valve
Q
Q
Slack adjuster
Q
Q
Brake disc and plate
Axle
Q
Q
Brake piston
Q
Wheel brake linkage
Q
Q
Q
Q
Q
Q
Main relief valve
Q
Q
Q
Q
Lift arm spool
Q
Q
Q
Q
Q
Bucket spool
Q
Q
Q
Q
Suction and safety valve
control valve
Work equipment
Suction valve
Q
Q
Q
Q
Q
Lift arm cylinder
Q
Q
Q
Q
Q
Bucket cylinder
Q
Q
Q
Q
Lift arm PPC valve
Q
Q
Q
Q
Bucket PPC valve
Q
2-way restrictor valve
Q
Cushion valve
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
Work equipment system Brake Steering wheel HST related

FAILURE CODE AND CAUSE TABLE
20-605
(1)..d
TESTING AND ADJUSTING H-1
H-1 The machine does not start

Ask the operator about the following: Cause
• Has the machine come not start suddenly? HST HST
o Breakage of HST pump and motor related equipment HST pump Others
motor 2 motor 1
• Was there any problem of not traveling before? a b c d e f g h i j k l m n o
o Internal wear of HST pump and motor related equip-

Damper

Inching valve
Clutch solenoid
Transfer
DA valve
forward and reverse solenoid valve
Clutch
Motor body
Motor body
ment, defective seal
Inspection before diagnosis

• Are the oil level in the hydraulic tank and the oil type appro-
priate?
• Is inching valve linkage properly adjusted?
• Is the any external oil leak found around the hydraulic piping,
pump and motor?
Remedy E E E E E E E E E E E E E E E
No. Diagnosis X X X X X X X X X X X X X X X
A
1 Does not travel forward or in reverse Q Q Q Q Q Q Q Q Q Q Q Q Q Q
2 Does not travel forward (reverse is normal) Q Q
3 The machine does not start at reverse (Forward is normal) Q Q

Does not travel forward or in reverse, motor makes sound
4 Q Q Q
of rotation
20-606 WA200-5
(1)
H-2 The travel speed is slow

• Did the travel speed suddenly becomes slower? HST
o Breakage of HST pump and motor related equipment HST pump HST motor 2 motor 1 Others
• Was there any problem of travel speed becoming slower a b c d e f g h i j k l m n o
before?
Mode selector solenoid valve (SOL a)

Clutch solenoid
DA valve
forward and reverse solenoid valve
Angle stopper solenoid valve (SOL b)
Angle stopper control solenoid valve
Inching valve
Clutch
Motor body
Motor body
o Internal wear of HST pump and motor related equip-
ment, defective seal
priate?
• Is the inching valve linkage adjusting appropriate?
• Is inching valve linkage properly adjusted?
pump and motor?
Remedy E E E E E E E E E E E E E E E
No. Diagnosis X X X X X X X X X X X X X X X
A
1 Travel speed is slow in both forward and reverse Q Q Q Q Q Q Q Q Q Q Q Q Q
2 The travel speed is slow at forward (Reverse is normal) Q Q
3 The travel speed is slow at reverse (Forward is normal) Q Q

Maximum travel speed in both forward and reverse is
4 Q
approx. 4 km/h
Maximum travel speed in both forward and reverse is
5 Q
approx. 18 km/h
Abnormal sound comes from motor in both forward and
6 reverse when travel speed is 10 km/h or more Q Q
WA200-5 20-607
(1)..d
H-3 The thrusting force is weak

a When the travel speed is slow, carry out troubleshooting for Cause
H-2 first. HST HST HST
Others
pump motor 2 motor 1
a b c d e f g h i j k
Transfer
Motor body
Motor body
Inclination control solenoid valve
Inching valve
Clutch solenoid
Clutch
Traction controll switch

Remedy E E E E E E E E E E E
No. Diagnosis X X X X X X X X X X X
A
1 Rimpull is weak in both forward and reverse Q Q Q Q Q Q Q Q Q Q
2 The thrusting force is weak at forward (Reverse is normal) Q
3 The thrusting force is weak at reverse (Forward is normal) Q

Rimpull is weak in both forward and reverse, but maximum
4 Q Q Q Q
travel speed is reached the linee.
20-608 WA200-5
(1)
H-4 Engine stalls when traveling or engine speed drops excessively

• Was there any problem before? HST HST Others
o Dirt in HST pump, motor related equipment pump motor 2
a b c
DA valve

Inclination stopper solenoid valve (SOLb)
pump and motor?
Remedy E E E
No. Diagnosis X X X
Engine stalls when traveling or engine speed drops exces-

1 Q Q Q
sively
Machine moves when the direction the lever is at F or R
2 and engine is at Li Q
WA200-5 20-609
(1)..d
H-5 The gear is not shifted

a If the speed range switch and the monitor display do not Cause
match, check the electrical wiring. HST HST
Others
a When the travel speed is slow, carry out troubleshooting for motor 2 motor 1
H-2 first. a b c d
Clutch solenoid
Inclination stopper solenoid valve (SOLb)
Clutch
Remedy E E E E
No. Diagnosis X X X X
1 The gear is not shifted Q Q Q Q
20-610 WA200-5
(1)
H-6 The steering wheel does not turn

• Did the problem suddenly start? Hydraulic
o Breakage of steering related equipment Others
pump
• Was there previously any symptom, such as heavy steering? a b c d e f
o Internal wear of steering related equipment, defective
Obit-roll
Defective hydraulic pump or PTO
Priority valve
Emergency steering valve (*1)

Internal defective steering cylinder (Defective piston seal)
Steering pump and switch pump
2-way restrictor valve

seal
priate?
• Has the safety bar been removed from frame?
Relief valve
Steering
Spool
Remedy E E E E
No. Diagnosis X X X X X X X
Steering wheel does not turn in both directions (left and

1 Q Q Q Q Q Q
right)
In condition in Item 1, movement of work equipment is
2 abnormal Q
In condition in Item 1, movement of work equipment is nor-

3 mal Q
4 Steering wheel turns only in one direction (left or right) Q Q Q
5 Steering wheel is heavy and does not turn Q Q Q Q
6 Oil pressure of steering circuit is low or there is no pressure Q

Emergency steering does not function in both directions
7 Q
(left and right)
a There is a close connection between the steering circuit and work equipment circuit, so if any abnormality is
felt in the steering, check the operation of the work equipment also.
a If the steering pump is abnormal (broken), check the priority valve at the same time.
*1. This warning is given only when the emergency steering is installed.
WA200-5 20-611
(1)..d
H-7 The steering wheel is heavy

• Did the problem suddenly start? Hydraulic
o Breakage of steering related equipment Valve Others
pump
• Was there previously any symptom, such as heavy steering? a b c d e f
o Internal wear of steering related equipment, defective
Obit-roll internal defect

Priority valve
Clogging of oil cooler

Internal defective steering cylinder (Defective piston seal)
Clogging of hydraulic oil return filter, defective bypass valve

The steering pump is defective The hydraulic pump is defective
seal
priate?
• Is the connection of the orbit-roll and the serration of the
steering column normal?
valve and cylinder?
• Is there any gouging of center hinge pin bearing and steering
cylinder pin, bushing?
• Is the tire inflation pressure correct?
Check for abnormalities
Spool
Relief valve
• Measure operating effort of steering wheel and time taken to
turn steering, and check standard judgment value table to
see if there is any abnormality.
Remedy E E E E E E E
No. Diagnosis X X X X X X X
A C C
Steering wheel is heavy when turned in both directions (left
1 and right) Q Q Q Q Q
2 Steering wheel is heavy when turned in one direction (left Q Q

and right)
3 Steering wheel is heavy particularly when engine is running Q Q Q Q

at low speed
Lift arm lifting speed is slow when engine is running at full
4 speed Q Q
5 Steering wheel is heavy and there is jerking Q Q
6 Hydraulic oil overheats Q Q Q
7 Oil pressure of steering circuit is low or there is no pressure Q Q
8 Pressure rises in return piping of steering cylinder Q
20-612 WA200-5
(1)
TESTING AND ADJUSTING H-8, H-9
H-8
H-8 Steering wheel shakes or jerks

Checks before troubleshooting Cause
• Is the hydraulic oil level correct? Is the type of oil correct? Valves Cylinder Valves
• Is there any play in the center hinge pin bearing or steering
a b c d
cylinder pin or bushing?
Defect inside steering cylinder (inside surface of cylinder, piston seat, nut, bolt)
Defective cushion valve

Defect inside drbitrol
Defective 2-way restrictor valve
• Is there any variation in the tire inflation pressure?
• Is the steering wheel play correct?
Check for abnormalities

• Operate at a safe place and check how the steering wheel
shakes and under what conditions.
a In cases where the steering wheel is heavy but does not
shake, go to "H-7 The steering wheel is heavy".
Remedy E E E
1 Chassis shakes when traveling on rough road surface Q Q Q

Shakes when steering is suddenly turned during operation
2 or travel Q Q Q Q
3 Chassis shakes when accelerating during travel operations Q Q Q
4 Chassis shakes when engine is started Q
5 Excessive shock when steering wheel is turned back Q
H-9 Machine deviates naturally to one side when traveling

Causes: Defective steering
• Defective operation of safety valve
: Oil leakage inside steering cylinder
: Variation in tire inflation pressure
WA200-5 20-613
(1)..d
H-10 The brake does not work or does not work well
• Has the brake come not to work suddenly? a b c d e f g h i j k
o Breakage of brake equipment
Mixing of air in brake circuit

Wear or abnormality of brake lining in axle
Defective seal of accumulator piston, insufficient gas pressure

Defective slack adjuster
Metal contact due to complete wear of brake lining in axle
Defective brake pump (For charge)

Defective brake piston seal in axle
Defective operation of brake piston in axle
Brake linkage
Defect inside brake valve
Defective operation of accumulator charge valve

• Has the brake come not to work gradually?
o Wear of lining and disc, defective seal

• Is the oil level in the hydraulic tank appropriate?
• Is the play of brake pedal appropriate?
• Oil leak from brake tube and connector, deformation of tube.
• Tire air pressure and state of tire tread.
Check abnormality
• Measure the braking force and check referring to the stan-
dard value table if the brake does not work practically.
Remedy E E E E E E E
No. Diagnosis X X X X X X X X X
1 When the brake pedal is stepped on, only a little resistance Q Q Q Q Q

is felt
2 When the brake pedal is stepped on, a strong resistance is Q Q

felt
3 When the brake works, an abnormal noise occurs from the Q Q

axle brake
When the four wheels are jacked up, the axle is placed on a
4 table and the brake is applied at the first forward speed, Q Q Q Q
only a specific wheel rotates
5 An airflow is observed in bleeding air from brake circuit, and Q

the brake returns to normal after the bleeding
6 Brake oil leaks abnormally from the axle during inspection Q
7 Much metal powders are mixed in the axle oil Q
8 The brake pedal leg-power and stroke are normal, but the Q Q Q Q Q Q Q Q Q
brake does not work well
9 The brake does not work often when the engine is stopped Q Q Q Q Q Q
10 The accumulator is not charged, and a buzzer sounds Q Q Q
11 The brake works after some time lag Q Q Q
20-614 WA200-5
(1)
H-11 The brake is not released or is dragged

• Has the brake pedal returned completely? a b c d
• Is the parking brake released completely?
Defective slack adjuster

Defective brake piston seal in axle
Wear or abnormality of brake lining in axle

Defective operation of brake piston in axle
Check abnormality
• Abnormal heat of brake.
• Does the machine travel smoothly inertia on a level ground?
Remedy E E E E
1 The brake pedal is released, but the brake is still applied Q Q Q Q
When the brake pedal is released, oil is drained from the air
2 bleeder, the circuit oil pressure drops and the brake is Q Q
released
When the four wheels are jacked up, the axle is placed on a
3 table, the engine is stopped, the parking brake is released Q Q Q
and the tires are rotated by hand but a specific tire hardly
rotates
WA200-5 20-615
(1)..d
H-12 The lift arm does not rise or lower

• Has the lift arm come not to work suddenly? Priority HST PPC Work equip-
o Seizure or breakage of each equipment Tank to Pump Cylinder
valve pump valve ment valve
Did any abnormal noise occur at the time (And where)? a b c d e f g h i j
• Was there the phenomenon that the lift arm worked slowly?
Breakage inside valve body (Lift arm spool)
Damage of lift arm cylinder piston seal

Defective steering pump
Defective operation of main relief valve

Defective HST charge pump
Defective operation of spool
Defective low-pressure relief valve

Clogging of pump suction port or mixing of much air in oil
Defective work equipment pump

o Wear of parts or deformation of spring

• Is the oil level in the hydraulic tank appropriate?
• Is the stroke of the lift arm control lever appropriate?
• Is the engine speed appropriate?
Remedy C E E E E E E
No. Diagnosis E X X X X X X X X X
1 The bucket cannot operate and the lift arm cannot rise Q Q Q Q Q Q Q Q
2 The bucket operates but the lift arm cannot rise Q Q

The lift arm can rise without load but cannot rise when
3 Q Q Q Q
loaded
4 The hydraulic pump causes an abnormal noise Q Q Q Q
5 Large hydraulic drift of lift arm cylinder Q Q

When the engine is at full throttle, the steering operation is
6 heavy and slow Q Q
WA200-5 20-617
(1)..d
H-13 The lift arm moves slowly or the lift arm rising force is insufficient
Inspection before diagnosis Cause
• Is the stroke of the lift arm control lever appropriate? Tank to Priority HST PPC Work equipment Cylinder
Pump valve pump valve valve
Check of Abnormality
a b c d e f g h
• Rising force and speed problem are closely related, and this
problem occurs as insufficient rising speed at first. Measure
Damage of lift arm cylinder piston seal

Wear or breakage inside valve body (Lift arm spool)
Defective operation or improper adjustment of main relief valve

Defective work equipment pump and steering pump
Defective low-pressure relief valve

the lift arm rising speed when the lift arm is loaded and make
sure referring to the criterion table that the speed is abnor-
mal.
Remedy C E E E E A E
No. Diagnosis E X X X X X X X
The bucket tilting force and speed are abnormal, and the lift
1 arm rising speed is slow Q Q Q Q Q
The bucket tilting force and speed are normal, and the lift
2 Q Q Q
arm rising speed is slow
When the oil temperature rises in No. 1, the lift arm speed
3 Q Q
becomes very slow
4 The hydraulic pump causes an abnormal noise Q Q
5 Large hydraulic drift of lift arm cylinder Q Q

The relief oil pressure from the relief valve of the work
6 Q
equipment valves is low
7 Q
equipment valves is too high
20-618 WA200-5
(1)
H-14 When rising, the lift arm comes to move slowly at specific height

• Deformation of lift arm cylinder in appearance
Cause
• Expansion of lift arm cylinder tube or damage inside
a For other abnormal phenomena during lift arm rise, see "H-13. The lift arm moves slowly or the lift arm rising force is insufficient."
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)
See "H-13. The lift arm moves slowly or the lift arm rising force is insufficient."

• Is the stroke of the lift arm control lever appropriate?
Cause
• Defective seat of suction valve on the lift arm cylinder rod side of work equipment valve
• Oil leak from lift arm cylinder piston seal
H-16 Hydraulic drifts of the lift arm occur often
Ask the operator about the following:

• Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
• Have hydraulic drifts come to occur often gradually? o Wear of parts

• Is the lift arm spool at the neutral position? o The spool detent is defective
Diagnosis and Cause

• Does any leaking noise occur inside the lift arm cylinder when hydraulic drift is measured? o The cylinder packing is defective
H-17 The lift arm wobbles during operation
The bucket and the lift arm moves up and down as the topography goes in digging or leveling with the lift arm control lever in the "HOLD" posi-
tion.
Diagnosis and Cause

Check at first the hydraulic drift and if the lift arm cylinder can lift the machine
1. When the hydraulic drift is more than the standard value, see "H-15. Hydraulic drifts of the lift arm occur often."
2. When the lift arm cylinder cannot lift the machine, see "H-15. The lift arm cylinder cannot hold down the bucket."
3. When the lift arm cylinder comes to enable to lift the machine after the lift arm is operated several times with the normal hydraulic drift and
after the lift arm cylinder operates to full stroke o The cause is vacuum generated inside the cylinder
a Frequent hydraulic drifts o The suction valve on the lift arm cylinder rod side is defective
WA200-5 20-619
(1)..d
H-18 When the control lever is switched from "HOLD" to "RAISE," the lift arm falls temporarily
Check of Phenomenon
• When the control lever is switched from "HOLD" to "RAISE" gradually at low idling of the engine, the lift arm falls temporarily due to its own
weight. When the control lever is completely set to "RAISE," the lift arm returns to normal.
Cause
• Improper adhesion of lift arm spool check valve of the work equipment valve
20-620 WA200-5
(1)
H-19 The bucket does not tilt back

• Has the bucket come not to work suddenly o Seizure or Priority HST PPC Work Equipment Cylinder
breakage of each equipment Tank to Pump
Valve pump Valve Valve
• Did any abnormal noise occur at the time (And where)?
a b c d e f g h i j
• Was there the phenomenon that the bucket worked slowly?
o Wear of parts or deformation of spring
The low-pressure relief valve is defective

The HST charge pump (which is used as PPC pump, too) is defective
Breakage inside valve body (Bucket spool)

The hydraulic pump and the switch pump are defective
Damage of bucket cylinder piston seal

The steering pump is defective
The spool is defective
Defective operation of main relief valve

• Is the stroke of the bucket control lever appropriate?
Remedy C E E E E A
No. Diagnosis E X X X X X X X X
1 The lift arm cannot operate and the bucket cannot tilt back Q Q Q Q Q Q Q
The bucket can lift the machine but cannot tilt back, or the
2
lift arm operates but the lift arm cannot tilt back Q Q Q
The bucket can tilt back without load but cannot in digging Q
3 Q Q
or scooping up
4 The hydraulic pump causes an abnormal noise Q Q Q
5 Large hydraulic drift of bucket cylinder Q Q
6 When the engine is at full throttle, the steering operation is Q Q

heavy and slow
WA200-5 20-621
(1)..d
H-20 The bucket moves slowly or the tilting-back force is insufficient

Inspection before diagnosis Cause
• Is the stroke of the bucket control lever appropriate? Tank to Priority HST PPC
• Seizure of work equipment linkage bushing (Does any Work equipment valve Cylinder
Pump valve pump valve
abnormal noise occur?) a b c d e f g h i

Wear or breakage inside valve body (Bucket spool)
Damage of bucket cylinder piston seal

The hydraulic pump and the switch pump are defective
Defective operation or improper adjustment of main relief valve

Defective operation of low-pressure relief valve
Defective operation of safety valve (With suction valve) on bucket cylinder bottom side
• Make sure in an actual operation that the tilting-back force is
insufficient.
• Measure the operating speed of the bucket, and make sure
referring to the criterion value table that the speed is abnor-
mal
Remedy C E E E E A E
No. Diagnosis E X X X X X X X X
The lift arm rising force and speed are abnormal, and the
1 Q Q Q Q Q
bucket tilting force and speed are abnormal
The lift arm rising force and speed are normal, and the
2 bucket tilting force and speed are abnormal Q Q Q Q
When the oil temperature rises in No. 1, the bucket speed

3 becomes worse Q Q
4 The hydraulic pump is causing an abnormal noise Q Q
5 Large hydraulic drift of bucket cylinder Q Q Q

6 Q Q Q
equipment valves is low
7 equipment valves is too high Q
20-622 WA200-5
(1)
H-21 The bucket comes to operate slowly in he midst of tilting-back

• Deformation of bucket cylinder in appearance
Cause
• Expansion of bucket cylinder tube or damage inside
For other abnormal phenomena during bucket operation, see "H-20. The bucket moves slowly or the tilting-back force is insufficient."
H-22 The bucket cylinder cannot hold down the bucket
See "H-20. The bucket moves slowly or the tilting-back force is insufficient."

• Is the stroke of the bucket control lever appropriate?
Cause
• Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
• Oil leak from bucket cylinder piston seal
H-23 Hydraulic drifts of the bucket occur often
Ask the operator about the following:

• Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
• Have hydraulic drifts come to occur often gradually? o Wear of parts

• Is the bucket lever (PPC valve) at the neutral position? o Seizure of link bushing or the spool detent is defective
• Refer to the criterion value table and check if the hydraulic drift of the bucket occurs often practically
Cause
• Oil leak in bucket cylinder
• Improper adhesion of safety valve (With suction valve) on the bottom side
• Improper oil tight of bucket spool
WA200-5 20-623
(1)..d
H-24 The bucket wobbles during travel with cargo (The work equipment valve is set to "HOLD")

• Pin of work equipment linkage and "play of bushing" (Is any abnormal noise heard?)
Cause
• Defective seal of bucket cylinder piston
• Defective operation of safety valve (With suction valve) on bucket cylinder rod side. For other abnormal phenomena, refer to diagnoses for
relevant abnormal phenomena.
H-25 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily
Check of Phenomenon
• When the control lever is switched from "HOLD" to "RAISE" gradually at low idling of the engine, the bucket falls temporarily due to its own
weight. When the control lever is completely set to "TILT," the bucket returns to normal.
Cause
• Improper adhesion of bucket spool check valve of the work equipment valve
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy
Check of Abnormality Cause

• Refer to the criterion value table and check if the lever oper- PPC
ating efforts are large practically. valve
a
Defective operation of relief valve
Remedy C
No. Diagnosis E
Becomes heavy in some places during operation regard-

1 Q
less of oil pressure and oil temperature
2 Becomes heavy overall during operation regardless of oil Q

pressure and oil temperature
20-624 WA200-5
(1)
TROUBLESHOOTING H-27
H-27 The travel damper does not operate and machine pitches and bounces
Check the following points with the operator. Cause

• Did the machine starts pitching and bouncing suddenly? o Solenoid
Breakage of related device Accumulator Controller Sensor
valve
Did abnormal sound come out when the machine started a b c d
pitching and bouncing? From what part did the abnormal
Gas leakage from accumulator or defective seal

sound come out?
• Did the machine starts pitching and bouncing gradually? o
Wear of related device or defective seal
Check before troubleshooting

• Check that the hydraulic tank is filled with oil of a proper type
up to a proper level.
Defective travel speed sensor

Malfunction of solenoid valve
• Check that the travel damper switch is set properly.
Malfunction of controller
No. Remedy X X X
Troubleshooting X
Travel speed to start operation of travel damper (6 km/h) is

1 changes largely Q Q
2 Travel damper does not work while machine is loaded Q Q
3 Travel damper does not work while machine is empty Q Q

Lift arm lowers more than 30 cm at maximum when travel
4 damper operated while machine is loaded Q
5 Travel damper does not work at all Q Q Q Q
WA200-5 20-625
(4)..d
TROUBLESHOOTING OF ENGINE
(S MODE)
Method of using troubleshooting charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-702

S-1 Starting performance is poor (Starting always takes time) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-706
S-2 Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-708
(1) Engine does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-708
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) . . . . . . . . . . . . . . . . . . 20-709
(3) Exhaust smoke comes out but engine does not start(Fuel is being injected) . . . . . . . . . . . . . . . . . 20-710
S-3 Engine does not pick up smoothly (Follow-up is poor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-711
S-4 Engine stops during operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-712
S-5 Engine does not rotate smoothly (Hunting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-713
S-6 Engine lacks output (or lacks power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-714
S-7 Exhaust smoke is black (Incomplete combustion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-715
S-8 Oil consumption is excessive (or exhaust smoke is blue) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-716
S-9 Oil becomes contaminated quickly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-717
S-10 Fuel consumption is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-718
S-11 Oil is in engine coolant, or coolant spurts back, or coolant level goes down . . . . . . . . . . . . . . . . . . . . 20-719
S-12 Oil pressure warning lamp lights up (Drop in oil pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-720
S-13 Oil level rises (Water, fuel in oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-721
S-14 Engine coolant temperature becomes too high (Overheating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-722
S-15 Abnormal noise is made . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-723
S-16 Vibration is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-724
WA200-5 20-701
(4)..
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspection with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds 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 nar-
row down the causes. The items under (C) in the
chart on the right correspond to this.
The serviceman narrows down the causes from infor-
mation (A) that he has obtained from the user and
the results of (C) that he has obtained from his own Causes
inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been marked
as having the highest probability from information
gained from [Questions] and [Check items].
(b) (2) (3)
(a) w
Questions
(A) (b) w
(c) w
(d) Q
(B) (e) Q
Check items
(C)
i q
shooting
Trouble-
ii q
iii q
20-702 WA200-5
(4)
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
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 !, and these, causes that have a
high probability are marked with T.
Check each of [Questions] and [Check items] in turn, and marked the ! Causes
or T in the chart for items where the problem appeared. The vertical col-
umn (Causes) that has the highest number of points is the most probable
n)
cause, so start troubleshooting for that item to make final confirmation of
jectio
the causes.
ive in
*1. For [Confirm recent repair history] in the [Questions] Section, ask
e
the user, and mark the Cause column with # to use as reference
ce ss
renc
le
nozz
for locating the cause of the failure. However, do not use this
p ( ex
ent
terfe
when making calculations to narrow down the causes.
r
elem
tion
e
g
d
er, in
timin
pum
*2. Use the # in the Cause column as reference for [Degree of use
n
injec
, cyli
aner
(Operated for long period)] in the [Questions] section as refer-
harg
tion
io n
g
ized
ence. As a rule, do not use it when calculating the points for locat-
n rin
ir cle
t
injec
injec
rboc
e
ing the causes, but it can be included if necessary to determine
s
pisto
ged a
ed tu
ctive
ged,
oper
the order for troubleshooting.
Worn
Defe
Clog
Clog
Im p r
Seiz
*1 Confirm recent repair history
*2 Degree of use of machine Operated for long period EEE
w
WA200-5 20-703
(1)..d
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have
causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and
[Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air Causes
• Improper condition of fuel injection
valve nd head
ized)
• Excessive injection fuel
tion)
er se
injec
ray
seat
ra
e sp
lung
arge
e
leara (excessiv
ce
fectiv
ck, p
boch
eren
and
le, de
ent
p (ra
n tur
air cle er, interf
valve
nder
e
ler
elem
ing
p
c
m
pum
n
nozz
muff
e
n tim
n pu
e
li
g, cy
ct of
betw
aner
harg
tion
gged
Impro injection
Impro e injectio
lve c
jectio
conta
n rin
injec
of air
rboc
Legend
lo
a
per in
Q
c
pisto
per v
: Possible causes (judging from Questions and check items)
ed tu
ctive
ctive
hed,
w
age
ged
ged
: Most probable causes (judging from Questions and Check items)
ctiv
t : Possible causes due to length of use (used for a long period)
Worn
Leak
Crus
Defe
Defe
Defe
Clog
Clog
Seiz
q : Items to confirm the causes.
Confirm recent repair history

Degree of use Operated for long period EEE E
Suddenly became black w Q Q
Color of exhaust gas Gradually became black w Q Q
Questions
Black under light load w

Engine oil must be added more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Non-specified fuel is being used Q Q
Noise of interference is heard from around turbocharger w
Dust indicator lamp is red w
Blow-by gas excessive w
Engine pickup is poor and combustion is irregular Q w Q Q Q Q
When exhaust manifold is touched immediately after start- w Q
Check items
ing engine, temperature of some cylinders is low

Match marks on fuel injection pump are out of alignment w
Seal on injection pump has come off w
Clanging sound is heard from around cylinder head w
Exhaust noise is abnormal Q Q w
Muffler is crushed w
Leakage of air between turbocharger and head, loose clamp w
When turbocharger is rotated by hand, it is found to be heavy q

When air cleaner element is inspected directly, it is found to be clogged q
When compression pressure is measured, it is found to be low q q
Speed does not change when operation of certain cylin-
q
Troubleshooting
ders is stopped
When check is made using delivery method, injection tim- q
ing is found to be incorrect
Injection pump test shows that injection amount is incorrect q
When valve clearance is checked directly, it is found to be q
outside standard value
When muffler is removed, exhaust color returns to normal q
When control rack is pushed, it is found to be heavy, or q
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
20-704 WA200-5
(1)
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Causes items in the vertical
column.
Three symptoms
Step 2
Add up the total of Q and w marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect:
(1) Clogged air cleaner element: wQw
(2) Air leakage between turbocharger
and head QQ
(3) Clogged, seized injection nozzle: Q
(4) Defective contact of valve, valve seat: Q
(5) Worn position ring, cylinder: Q
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked q. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
WA200-5 20-705
(1)..d
TESTING AND ADJUSTING S-1
S-1 Starting performance is poor

(Starting always takes time)
General causes why exhaust smoke comes out but engine takes time
to start
• Defective electrical system
• Insufficient supply of fuel
• Insufficient intake of air Causes
• Improper selection of fuel
(At ambient temperature of -10°C or below, ASTM D975 No. 2 die-
sel fuel is used)
a Battery charging rate
at
e se
Charging rate
Ambient 100% 90% 80% 75% 70%
ter
leane alve, valv
temperature
ze fil
t
men
20°C 1.28 1.26 1.24 1.23 1.22
ater
aine
conta ylinder
p gau
r ele
0°C 1.29 1.27 1.25 1.24 1.23
ir he
v
r, str
ct o f
g, c
-10°C 1.30 1.28 1.26 1.25 1.24
pum
ke a
l filte
n rin
• The specific gravity should exceed the valve for the charging rate
feed
l inta
air c
fu e
pisto
of 70% in the above table.
ctive
trica
ged
ged
ged
• In cold areas the specific gravity must exceed the value for the
Worn
Defe
Clog
Clog
Clog
Elec
charging rate of 75% in the above table.
Degree of use of machine Operated for long period EEE
Gradually became worse w w Q Q Q
Ease of starting
Starts when warm w
Questions
Indicator lamp does not light up w

Replacement of filters has not been carried out according to operation Manual w w w
Non-specified fuel has being used Q Q
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular Q Q
Blow-by gas is excessive w
Check items
Timing lock on fuel injection pump does not match

Mud is stuck to fuel tank cap
When Engine is cranked with starting motor,
w w
1) Little fuel comes out even when injection pump piping sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular) Q Q
When fuel filter, strainer are inspected directly, they are found to be clogged q
When feed pump strainer is inspected directly, it is found to be clogged q
Troubleshooting
Heater mount does not become warm q

Is voltage 26 - 30V between alternator terminal B and termi- Yes
nal E with engine at low idling? No
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy or does not return
(check after removing fuel injection pump)
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
* Use a test stand
20-706 WA200-5
(1)
q
Replace Defe
ctive
q
w w
Replace Defe regu
lator
ctive
a
q
w
w
Replace
E
Defe ltern
ctive a to r
WA200-5
q
w
w
Q
Q
Replace Defe or de
t erior
ctive a te d
w
*Adjust Defe injec
t io batte
ctive n no
zzle ry
q
w
w
Q
Q
Replace Defe injec
tion t
ctive im
q
Q w
Correct Defe injec ing
ctive tion
pum
q
w Q
Q
Clean Clog Leak
age,
p (ra
ck, p
ged
w
clogg lunge
Replace Defe air b
re athe ing, r stu
ctive air in ck)
f e
w
Replace r hole fuel
Defe ed p in pipin
Causes
ctive
boos
ump fuel t
ank g
t com
pens
ator
ca n c
el
20-707
(1)..d
S-1
S-2 Engine does not start

(1) Engine does not turn
General causes why engine does not turn

Causes
• Internal parts of engine seized
a If internal parts of the engine are seized, carry
out troubleshooting for "Engine stops during
operations".
witch
• Defective electrical system
ion
nect
• Failure in power train
ircuit
fety s
ry
batte
l co n
ng c
or s a
oid
a
rated
witch
starti
otor
in
solen
lay
term
ctive fety relay
ing m
terio
ry re
ing s
g of
l cu t
ttery
ar
or de
b a tte
wirin
g ge
start
start
e
a
sa
u
b
f
en rin
ctive
ctive
ctive
ctive
ctive
ctive
ctive
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Brok
Questions
Degree of use of machine Operated for long period E E

Condition of horn when start- Horn sounds w Q Q
ing switch is turned ON Horn volume is low w
Speed of rotation is low w
When starting switch is Makes grating noise w w
turned to START, pinion
moves out, but Soon disengages pinion again w
Makes rattling noise and does not turn Q Q Q
When starting switch is turned to START, pinion does not move w Q Q
out
Check items
When starting switch is turned to ON, there is no clicking sound Q w

Battery terminal is loose w
When starting switch is turned ON, linkage is not actuated w
Troubleshooting of defective wiring in starting circuit
When battery is checked, battery electrolyte is found to be low w
Specific gravity of electrolyte, voltage of battery is low q

For the following conditions 1) - 5), turn the starting switch OFF,
connect the cord, and carry out troubleshooting
q
1) When terminal B and terminal C of starting switch are con-
nected, engine starts
2) When terminal B and terminal C of starting motor are con-
q
Troubleshooting
nected, engine starts

3) When terminal B and terminal C of starting safety relay are
q
connected, engine starts
4) When terminal of safety switch and terminal B of starting
motor are connected, engine starts q
5) There is no 24V between battery relay terminal b and termi- q

nal E
When ring gear is inspected directly, tooth surface is found to be
q
chipped
Cannot be moved by hand even when linkage of fuel cut solenoid
is disconnected q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy -
20-708 WA200-5
(1)
(2) Engine turns but no exhaust smoke comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust smoke

Causes
comes out
• Supply of fuel impossible
d)
• Supply of fuel is extremely small
seize
• Improper selection of fuel (particularly in winter)
nger
(rack t, key
a Standards for use of fuel
ank
, plu
shaf
fuel t
strain iston
AMBIENT TEMPERATURE
KIND OF
rive
-4 14 32 50 68°C
ainer
le in
FLUID
mp p
g
r
fuel u solenoid
pipin
-20 -10 0 10 20°F
e
mp d
um p
er ho
tr
u
leakin tank
s
p
fuel
p
n pu
ump
d
ASTM D975 No. 2
se d
reath
n
e
ilter,
in
t
jectio
fe
u
g
Diesel fuel
jectio
c
ed p
fuel
n
uel f
fuel
air b
roke
ASTM D975 No. 1
in
fe
t
en, in
n
f
ctive
ctive
oper
fficie
ed b
ged
ged
ged
ged
D e fe
Defe
Br ok
Clog
Clog
Clog
Clog
Im p r
Seiz
I n su
Questions
Degree of use of machine Operated for long period EE E

Exhaust smoke suddenly stops coming out (when starting again) w w w
Replacement of filters has not been carried out according to Oper-
w w
ation Manual
Fuel tank is found to be empty w
There is leakage from fuel piping w
Mud is stuck to fuel tank cap w
When starting switch is turned ON, linkage is not actuated w
When fuel filter is drained, fuel does not come out w
When engine is cranked with starting motor,
1) No fuel comes out even when fuel filter air bleed plug is w Q Q Q
Check items
loosened
2) No fuel spurts out even when injection pump piping sleeve w w w
nut is loosened
Rust and water are found when fuel tank is drained Q Q Q
Inspect injection pump directly q
When control rack is pushed, it is found to be heavy, or does not
q
return
Troubleshooting
Inspect feed pump directly q

When fuel filter, strainer are inspected directly, they are found to
q q
be clogged
When feed pump strainer is inspected directly, it is found to be
q
clogged
When fuel cap is inspected directly, it is found to be clogged q
Cannot be moved by hand even when linkage of fuel cut solenoid
q
is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
WA200-5 20-709
(1)..d
(3) Exhaust smoke comes out but engine does not start
(Fuel is being injected)
General causes why exhaust smoke comes out but

Causes
engine not start
.)
• lack of rotating force due to defective electrical sys-
er etc
tem
)
st u ck
er lev
k ca p
pray
, rock
nger
• Insufficient intake of air
reath zle, defec m

tive s
l tan
er
ste
, plu
valve
heat
• Improper selection of fuel and oil
y
el sy
in fue
atter
r
rack
e
tem (
ke air
n
t
leane rainer
m en
li
in fu
ted b
r
mp (
e
r
r hole
e sys
linde
strain
r ele
l inta
st
ir
riora
z
n pu
a
n no
n valv
g , cy
e
ump
ing,
se d
ctrica
lter,
Worn e injectio
Leak e or dete
jectio
ed p
clogg
n rin
fuel u
broke
fi
air b
air c
le
fuel
e
e
pisto
in
f
ctive
age,
ctive,
oper
ged
ged
ged
ged
ged
ctiv
ctiv
D e fe
D e fe
D e fe
Clog
Clog
Clog
Clog
Clog
Im p r
Defe

Degree of use of machine Operated for long period EEE E
Suddenly failed to start w w
When engine is cranked, abnormal noise is heard from around w
cylinder head
Questions

Replacement of filters has not been carried out according to Oper- w w w
ation Manual
Rust and water are found when fuel tank is drained w w
Indicator lamp does not light up w
Starting motor cranks engine slowly w
Mud is stuck to fuel tank cap Q
When fuel lever is placed at FULL position, it does not contact stopper Q
When engine is cranked with starting motor,
Check items
1) Little fuel comes out even when fuel filter air bleed plug is w
loosened
2) No fuel comes out even when fuel filter air bleed plug is w w Q
loosened
When exhaust manifold is touched immediately after starting w
engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out w
Remove head cover and check directly q
When control rack is pushed, it is found to be heavy, or does not q
return
When compression pressure is measured, it is found to be low q
When fuel filter, strainer are inspected directly, they are found to q q
Troubleshooting
be clogged
When feed pump strainer is inspected directly, it is found to be q
clogged
Heater mount does not become warm q
Either specific gravity of electrolyte or voltage of battery is low q
When feed pump is operated, there is no response, or operation q
is too heavy
Speed does not change when operation of certain cylinders is stopped q
When fuel tank cap is inspected directly, it is found to be clogged q
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
20-710 WA200-5
(1)
S-3 Engine does not pick up smoothly

(Follow-up is poor)
General causes why engine does not pick up smoothly

Causes
cap
pray
t
• Improper fuel used
e se a
l pipin uel tank
tive s
d valv
e fe c
er
nger
a ce
e an
n
ent
leakin er hole in
g
aine
li
zle, d
valve er, interf

er
p plu
r
reath nce
elem
f valv
train
d
p str
ed tu ring, cylin
a
ed in ction noz
pum
g fu e
clear
er, s
aner
a ct o
pum
rg
ocha
ction
t
air cle
il
co n t
uel f
feed
air b
inje
n
b
je
pisto
r
f
ctive
oper
ged,
ged
ged
ged
ged
ged
Worn
Defe
Clog
Clog
Clog
Clog
Clog
Clog
Impr
Seiz
Seiz
Degree of use of machine Operated for long period EEE E E
Questions
ation Manual
Non-specified fuel is being used w w w w
Engine pick-up suddenly became poor Q w Q Q
Rust and water are found when oil is drained w w
Blue under light load Q w
Color of exhaust gas
Black w w w Q
Check items

High idling speed under no load is normal, but speed suddenly w w Q
drops when load is applied
There is hunting from engine (rotation is irregular) Q w Q Q
When exhaust manifold is touched immediately after starting
w Q
When air cleaner element is inspected directly, it is found to be q
clogged
When fuel filter, strainer are inspected directly, they are found to q
be clogged
Troubleshooting
clogged
Speed does not change when operation of certain cylinders is q
stopped
When control rack is pushed, it is found to be heavy, or does not return q
When valve clearance is checked directly, it is found to be outside q
standard value
When feed pump is operated, operation is too light or too heavy q
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
WA200-5 20-711
(1)..d
S-4 Engine stops during operations
General causes why engine stop during operations

Causes
• Seized parts inside engine
tc.)
ver, e
ck)
• Overheating
r st u
ker le
a If there is overheating and the engine stops,
lunge
od
carry out troubleshooting for overheating.
k
e, roc
el tan
ting r
ring
t
ke y
• Failure in power train
c k, p
(valv
pisto
t bea
quipm
in fu
nnec
a If the engine stops because of a failure in the
haft,
p (ra
er
iping
stem
pump iner
p
strain
power train, carry out troubleshooting for the
le
shaf
n , co
train
pum
e
o
pum
e
fuel p
a
y
h
y
tank
p driv
chassis.
r
r
rank
r train
t
ther
ia
pisto
gear
fe e d
s
valve
auxil
ction
filter,
el in
aking
c
a
pum
powe
eized
ized
eized
eized
amic
r
je
um p
eed
air b
fu
fu e l
in
l
le
e
e
t
n dyn
n
en fu
f
en, s
en, s
en, s
en, s
ctive
re in
en p
ged,
fficie
ged
ged
ged
Broke
Failu
Defe
Brok
Brok
Brok
Brok
Brok
Clog
Brok
Clog
Clog
Clog
Insu
Degree of use of machine Operated for long period EE
Abnormal noise was heard and w w w w w w Q Q w
engine stopped suddenly
Condition when engine
Questions
Engine overheated and stopped w Q Q

stopped
Engine stopped slowly w Q Q
There was hunting and engine stopped w Q Q Q
Replacement of filters has not been carried out according to Oper-
w w
ation Manual
Non-specified fuel is being used Q Q Q Q
Fuel level lamp lights up w
When feed pump is operated, operation is too light or too heavy Q Q w
w
Check items
Engine rotates, but stops when power train is operated

Does not turn at all w w
When it is attempted to turn Turns in opposite direction w
by hand using barring tool Moves amount of backlash w w
Shaft does not turn w
Rust and water are found when tank is drained w w
Troubleshooting of chassis
Metal particles are found when oil is drained w w Q Q
Remove oil pan and inspect directly q q

Remove head cover and inspect directly q
When gear train is inspected, it does not turn q
Troubleshooting
Rotates when pump auxiliary equipment is removed q

be clogged
When feed pump strainer is inspected directly, it is found to be
q
clogged
Inspect feed pump directly q
When control rack is pushed, it is found to be heavy, or does not
q
return
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy -
Add
20-712 WA200-5
(1)
S-5 Engine does not rotate smoothly

(Hunting)
General causes why engine does not rotate smoothly

Causes
• Air in fuel system
um p
ozzle
• Defective governor mechanism
eed p nd feed p
and n
• Defective electric governor mechanism
(engine with electric governor)
ump
a If hunting stops when electric governor rod is dis-
ka
ank
el t an
k
connected, carry out troubleshooting for the
fuel t
r
c
erno
rol ra
rnor
chassis.
een fu
een f
v
le in
ed air ilter, stra er
adjus n of gove
co n t
low
o
iner
train
t of g
betw
it betw
er ho
o
k
n of
ficien eed is to
mp s
n
tmen
l in ta
ircuit
reath
Defe e operatio
io
circu
ed pu
a t
ir in c
oper
t fue
fuel f
air b
sp
in
e
idling
ged a
f
ctive
ctive
ged
ged
ged
ctiv
Clogg
Insuf
Defe
Defe
Clog
Clog
Clog
Clog
Low
Degree of use of machine Operated for long period EE
Occurs at a certain speed range w w w Q
Occurs at low idling Q w Q Q Q Q
Questions
Condition of hunting
Occurs even when speed is raised Q Q Q Q
Occurs on slopes w
Replacement of filters has not been carried out according to Oper- w w
ation Manual
Rust and water are found when tank is drained Q Q
Leakage from fuel piping w w
When feed pump is operated,
w
Check items
1) No response, light, return is quick

2) No response, light, return is normal w
Engine speed sometimes rises too far w w
Engine is sometimes difficult to stop w w
Seal on injection pump has come off w w
When governor level is moved it is found to be stiff q q
When injection pump is tested, governor is found to be improperly q
adjusted
Troubleshooting

return
When fuel tank cap is inspected directly, it is found to be clogged q q
clogged
be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
WA200-5 20-713
(1)..d
S-6 Engine lacks output

(or lacks power)
General causes why engine lacks output

Causes
ent
justm
ray
tive a eat
• Improper fuel used
agm
ve sp
es
(if non-specified fuel is used, output drops)
ank
iaphr
d
d valv
nce
t
• Lack of output due to overtaking
efecti
e l
tor d
in fu
m
er
rfere
a If there is overheating and lack of output, carry
aking ge, defec

e an
hrag
ent
lung
ainer
ing
jectio nozzle, d
e n sa
er
r
out troubleshooting for overheating.
le
n ce
e
elem
linde
el pip
f valv
strain
t
mp p
diap
o
er, in
p st r
h
a
omp
ther
r
g, c y
linka
aner
fu
a ct o
gate
n pu
pum
le
harg
lter,
o st c
c
brea
io
n rin
ir cle
valve
w e st
fi
lever
t
co n t
rboc
c
eed
fuel
je
o
ir
le
b
pisto
in
ged a
a
ged f
e d tu
ctive
ctive
ctive
ed in
oper
ged,
fu e l
ged
ged
ged
Worn
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Bent
Clog
Clog
Impr
Seiz
Seiz
Degree of use of machine Operated for long period E EEE E
Suddenly w w w
Questions
Power was lost

Gradually Q Q Q Q Q Q
ation Manual
Non-specified fuel is being used w w w w
Black w w
Blow-by gas excessive w Q
Check items
Engine pickup is poor and combustion is irregular w Q Q Q

High idling speed under no load is normal, but speed suddenly w w Q
drops when load is applied
When exhaust manifold is touched immediately after starting w Q
There is hunting from engines (rotation is irregular) Q Q Q Q
High idling speed of engine is low Q w
Leakage from fuel piping w
clogged
be clogged
Troubleshooting

clogged
stopped
return
standard value
When level is placed at FULL position, it does not contact stopper q
When feed pump is operated, operation is too light or too heavy q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
20-714 WA200-5
(1)
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black

Causes
head
)
eized
n)
• Excessive injection of fuel
jectio
r and
ay
, plun at
ger s
se
e sp r
ive in
arge
valve
ence
ectiv
cess
b o ch
(rack
and
, def
erfer
x
nt
n tur
leme
valve
tion n der
clogg arance
ffler
ing
ump
ump
ozzle
r, int
lin
tw e e
n tim
ner e
u
ion p
ed m
tion p
g, c y
ct of
arge
le
e
lve c
jectio
a
b
conta
t
n rin
rboch
ir cle
injec
injec
of air
injec
a
in
pisto
v
a
e d tu
ctive
ctive
ctive
hed,
oper
oper
age
ged
ged
Worn
Leak
Crus
Defe
Defe
Defe
Clog
Clog
Impr
Impr
Confirm recent repair history Seiz
Degree of use of machine Operated for long period EEE E
Suddenly became black w Q Q
Color of exhaust gas Gradually became black w Q Q
Questions

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Engine pickup is poor and combustion is irregular Q w Q Q Q Q
Check items

Timing lock on fuel injection pump does not match w
Exhaust noise is abnormal Q Q w
Muffler is crushed w
Leakage of air between turbocharger and head, loose clamp w
clogged
Troubleshooting

stopped
When check is made using delivery method, injection timing is q
found to be incorrect
standard value
When muffler is removed, exhaust color returns to normal q
return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
WA200-5 20-715
(1)..d
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
a Do not run the engine at idling for more than 20 min-

Causes
utes continuously. (Both low and high idling)
General causes why oil consumption is excessive
rger
• Abnormal combustion of oil
o ch a
e)
engin
• External leakage of oil
Turb
l
d
n se a
• Wear of lubrication system
r hea
face
less
h o se
st e m
r
coole
roke
linde
u
liner
s
ke sy
th e r
seal
e), b
g
r oil
der (
il coo pan or cy
lu
brea
nd
end
ain p
a
seal,
o
ing
, guid
in t
ged b ing, cylin
e
te r
il pip
e
er or
wer
from
oil dr
oil fil
in
ring
rear
(stem
Worn al at turb
r
oil
at blo
le
om o
reath
d in
iston
from
from
m
ke n
nr
valve
e
pisto
se a l
age f
age f
, bro
suck
en p
en o
age
age
se
Worn
Worn
Worn
Worn
Leak
Leak
Leak
Leak
Clog
Brok
Dust
Brok
Degree of use of machine Operated for long period E EE E
Oil consumption suddenly increased w Q
Engine oil must be added more frequently w Q
Questions
Engine oil becomes contaminated quickly Q w Q

Exhaust smoke is blue under light load w w
Excessive w w Q Q
Amount of blow-by gas
None w
Area around engine is dirty with oil w w w w
There is oil in engine cooling water w
When exhaust pipe is removed, inside is found to be dirty with oil w Q
Check items
When turbocharger air supply pipe is removed, inside is found to w

be dirty with oil
Oil level in clutch or TOROFLOW transmission damper chamber w
rises
Clamps for intake system are loose w
When breather element is inspected, it is found to be clogged with q
dirty oil
Troubleshooting
There is external leakage of oil from engine q q q q

Pressure-tightness test of oil cooler shows there is leakage q
Excessive play of turbocharger shaft q q
Inspect rear seal directly q
When intake manifold is removed, dust is found inside q
When intake manifold is removed, inside is found to be dirty with q
oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20-716 WA200-5
(1)
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly

Causes
• Entry of exhaust gas due to internal wear
• Clogging of lubrication passage
• Improper fuel
en d
• Improper oil used
rbine
• Operation under excessive load
tu b e
se
e r tu
r
drain
er ho
r line
harg
e a th
linde
er oil
e
rboc
lack
id
e gu
r
er, b
g, cy
harg
e is b
at tu
turbo r
le
, valv
er
il coo
eath
c
n rin
oil filt
se a l
mok
valve
r
pisto
b
ust s
ctive
ged
ged
ged
ged
Worn
Worn
E xh a
Defe
Clog
Clog
Clog
Clog
Degree of use of machine Operated for long period E E E
Questions

Non-specified fuel is being used Q
Black w
w Q Q Q
Carry out troubleshooting for "Exhaust smoke is black".

Excessive
Check items
Amount of blow-by gas

None w
When oil filter is inspected, metal particles are found Q w Q
When exhaust pipe is removed, inside is found to be dirty with oil w
Engine oil temperature rises quickly w

When breather element is inspected directly, hose is broken or is q
Troubleshooting
found to be clogged with dirty oil

When oil filter is inspected directly, it is found to be clogged q
When oil cooler is inspected directly, it is found to be clogged q
Turbocharger oil drain tube is clogged q
Excessive play of turbocharger shaft q
When safety valve is directly inspected, spring is found to be
catching or broken
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy -
WA200-5 20-717
(1)..d
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive

Causes
• Leakage of fuel
n)
• Excessive injection of fuel
jectio
ton)
kage
al ins ead cove el filter
p (pis
ive in
rol lin
u
ing, f
r
pum
ce ss
nger
co n t
el pip
y
eed
spra
p (ex
p plu
timin
fu e l
ide f
m fu
eh
nt of
lder
pum
m
n
u
jectio
insid
tion p
e fro
le ho
stme
tion
fuel in
a ka g
l
oil se
e
n o zz
injec
injec
adju
of fu
le
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Leak
Defe
Defe
Defe
Defe
Defe
Defe
Exte
More than for other machines of
Questions
w Q
Condition of fuel same model
consumption Gradually increased Q Q
Suddenly increased Q Q
Black w Q Q Q
Exhaust smoke color
White Q
There is irregular combustion w
Check items

Match mark on injection pump is misaligned w
There is external leakage of fuel from engine w
Engine oil level rises and smells of diesel fuel Q w w
Engine low idling and high idling speeds are high Q w
Injection pump measurement shows that injection amount is q
excessive
stopped
Troubleshooting

return
When check is made using delivery method, injection timing is q
found to be incorrect
Remove feed cover and inspect directly q
When engine speed is measured, low and high idling speeds are q
found to be high
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-718 WA200-5
(1)
TROUBLESHOOTING S-11
S-11 Oil is in engine coolant, or coolant spurts back,

or coolant level goes down
General causes why oil is in engine coolant

Causes
• Internal leakage in lubrication system
• Internal leakage in cooling system
coole sket
ck
a
g
ad g
r blo
r
O-rin
d, he
linde
ing
ore,
in oil
y pitt
r hea
in cy
ler c
r a
sed b
t
linde
racks
i l c oo
ower
y
s c au
nal c
en o
en p
en c
Brok
Brok
Brok
Hole
Inter
Questions
Degree of use of machine Operated for long period E E

Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Engine oil level has risen, oil is cloudy white w Q Q
Check items
Excessive air bubbles inside radiator spurts back w

Hydraulic oil, transmission oil is cloudy white w
When hydraulic oil transmission oil is drained, water is found w
Pressure-tightness test of oil cooler shows there is leakage q q

shooting
Trouble-
Pressure-tightness test of cylinder head shows there is leakage q

Remove oil pan and inspect directly q q
Replace
Replace
Replace
Replace
Replace
Remedy
WA200-5 20-719
(4)..d
S-12 Oil pressure warning lamp lights up

(Drop in oil pressure)
General causes why oil pressure lamp lights up

• Leakage, clogging, wear of lubricating system Causes
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
a Standards for engine oil selection
Selection of SAE No. according to
sens ing
Type of oil ambient temperature
ip
n
pan
i l pa
or
ulic p
g
-30 -20 -10 0 10 20 30 40°C
razin
e oil
ide o
nsor
f valv ve
hydra
l
SAE30CD
or va
ipe b
al
sure
id
e
s
journ
an
e ins
vel s
ner in
mp
oil
p
Defe e oil pres

Defe , crushed
SAE10WCD
Defe e regulat
ti o n p
er
oil pu
il
il pip
el in
Engine oil
oil le
o
relie
oil filt
ing,
strai
n
SAE10W-30CD
n t, fu
bear
o
u
of oil
ctive
ctive
ctive
en s
ged
ged
ged
ctiv
ctiv
ing
SAE15W-40CD
Coola
Worn
Leak
Lack
Defe
Defe
Clog
Clog
Clog
Brok
Questions
Replacement of filters has not been carried out according to Oper- w

ation Manual
Warning lamp lights up w Q
Lights up at low idle w Q
Condition when oil pressure Lights up at low, high idle w w w w Q Q Q
lamp lights up Lights up on slopes w
Sometimes lights up w w Q Q
Check items
There is crushing, leakage from hydraulic piping (external) w

Oil level sensor lamp lights up w w
When oil level in oil pan is inspected, it is found to be low w
Metal particles are found when oil is drained w
Metal particles are stuck to oil filter element w Q
Oil is cloudy white or smells of diesel oil w
When oil filter is inspected, it is found to be clogged q q

Carry out troubleshooting for
Remove oil pan and inspect directly q q q

Troubleshooting
Oil pump rotation is heavy, there is play q

There is catching of relief valve or regulator valve, spring or valve q q
"Oil level rises".
guide is broken
When oil level sensor is replaced, oil level sensor lamp goes out q
When oil pressure is measured, it is found to be within standard q
valve
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy -
Add
20-720 WA200-5
(4)
S-13 Oil level rises (Water, fuel in oil)
a If there is oil in the coolant, carry out troubleshooting

Causes
for "Oil is in engine coolant".
General causes why oil level rises
r
• Water in oil (milky white)
cove
• Fuel in oil (diluted, and smells of diesel fuel)
al
head
nt se
• Entry of oil from other component
p
t
pum
aske
ipme
ide in g inside
ce
surfa
d, he ve
le ho O-ring
ad g
ction
y equ
slee
lock
pipin
seal
der b
lder
j
ia
ore,
ks in by pitting
il
rear
s ta t
fr o m
r hea
u x
ler c
cylin
Leak e pump a
Defe e part ins

o
aged
m
f fu e l
nozz
linde
il coo
side
e
de
h
, dam
t
o
en cy
ctive
s ma
ctive
en o
age
ctiv
ctiv
Worn
D e fe
D e fe
D e fe
Brok
Brok
Crac
Hole
Questions
Degree of use of machine Operated for long period E EE E

There is oil in radiator coolant w Q Q Q Q
Fuel must be added more frequently w w w
Exhaust smoke is white w Q Q
When engine is first started, drops of water come from muffler w
Leave radiator cap open. When engine is run at idle, an abnormal w Q
Check items
number of bubbles appear, or coolant spurts back

Oil level goes down in clutch, TORQFLOW transmission, or w
damper chamber
Oil level goes down in hydraulic tank w
Engine oil smells of diesel fuel w w w
Coolant temperature is low w
Pressure-tightness test of oil cooler shows there is leakage q
Pressure-tightness test of cylinder head shows there is leakage q
Troubleshooting
Inspect rear seal directly q

When pump auxiliary equipment is removed, seal is found to be q
damaged
Remove injection pump and inspect directly q
Defective contact with thermostat seal valve q
Remove oil pan and check directly q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
WA200-5 20-721
(4)..d
S-14 Engine coolant temperature becomes too high

(Overheating)
General causes why engine coolant temperature

Causes
becomes too high
• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
e
ratur
• Rise in oil temperature in power train
re ga )
e
n
g
of co lant temp s not ope
t
u
aske
a Carry out troubleshooting for chassis.
mpe
il coo pulley
ns
ad g
oil te
eratu
to r fi
n
l er
e
d, he
valve
t (do
erter
orn f
adia
ore
ing
osta
r hea
p
ing, w
conv
r
sure
y pitt
to r c
en o
pum
hed
herm
lant
e
pres
adia
brok
crus
de b
rque
c oo
ylind
p
ater
p
o
li
t
belt s
r
en w
ctive
s ma
ctive
ctive
i n to
ged,
ged,
en c
ged
Defe
Lack
Defe
Clog
Defe
Brok
Clog
Clog
Brok
Hole
Rise
Fa n
Degree of use of machine Operated for long period EE EE
Suddenly overheated w Q Q
Questions
Condition of overheating
Always tends to overheat w w Q Q
Rise quickly w Q
Coolant temperature gauge
Does not go down from red range w
Radiator coolant level sensor lights up w
Fan belt whines under sudden load w
Cloudy white oil is floating on coolant w
Coolant flows out from overflow hose w
Excessive air bubbles inside radiator, coolant spurts back w
Engine oil level has risen, oil is cloudy white Q w
Check items
There is play when fan pulley is rotated w

Radiator shroud, inside of underguard are clogged with dirt or mud w w
When light bulb is held behind radiator, no light passes through w
Coolant is leaking because of cracks in hose or loose clamps w
When belt tension is inspected, it is found to be loose w
Power train oil temperature enters red range faster than engine w
coolant temperature
Temperature difference between top and bottom radiator tanks is q

Carry out troubleshooting for chassis.
excessive
Temperature difference between top and bottom radiator tanks is q
slight
Troubleshooting
When coolant filler port is inspected, core is found to be clogged q

When function test is carried out on thermostat, it does not open q
When coolant temperature is measured, it is found to be normal q
When oil cooler is inspected directly, it is found to be clogged q
When measurement is made with radiator cap tester, set pressure q
is found to be low
Remove oil pan and inspect directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy -
Add
20-722 WA200-5
(4)
S-15 Abnormal noise is made
a Judge if the noise is an internal noise or an external

Causes
noise.
.)
ad
ine)
ition)
er, etc
General causes why abnormal noise is made
er he
s eng
)
eized
f pos
tion)
• Abnormality due to defective parts
er lev
cylind
er les
• Abnormal combustion
injec
out o
ger s
m (va rance
, rock
r and
er (lin
• Air sucked in from intake system
sive
, plun
oard
e
a
e
renc
e n ce
harge
e cle
lv
ylind
ozzle
fan b p (exces
ing b
(rack
terfe
h
erfer
f valv
ing, c
c
cklas
n
ide m een turbo

(divid
syste
n
elt in
ump
r, int
g
io
ton r
um
ent o
in
a
c t
b
h
valve
d inje
tion p
p
uffler
s
arge
of pis
train
d bu
tion
tw
justm
air be
amic
boch
seize
injec
injec
fa n ,
gear
seize
wear
a d
n dyn
f
r
rmed
ct ins
age o
ed tu
ctive
ctive
ctive
ssive
oper
ged,
ing,
Broke
Defe
Defe
Defo
Defe
Defe
Miss
Clog
Impr
Leak
Exce
Seiz
Degree of use of machine Operated for long period E
Questions
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Black w Q Q
Metal particles found in oil filter w w
Check items
Engine pickup is poor and combustion is abnormal w

Abnormal noise is loud when accelerating engine Q Q Q Q Q Q
Clanging sound is heard from around cylinder head w w
Leakage of air between turbocharger and cylinder head, loose w
clamp
Vibrating noise is heard from around muffler w
Remove gear cover and inspect directly q q
Troubleshooting
stopped
return
Fan is deformed, belt is loose q
When valve clearance is checked, it is found to be outside q
standard value
Remove cylinder head cover and inspect directly q
When muffler is removed, abnormal noise disappears q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
WA200-5 20-723
(1)..d
S-16 Vibration is excessive
a If there are abnormal noise together with the vibra-

Causes
tion, carry out troubleshooting also for "Abnormal
ck)
)
noise is made".
ction
tc. stu
General causes why vibration is excessive
shion
l inje
d
ver, e
ligne
• Defective parts (abnormal wear, breakage)
per)
e n cu
e fue
ker le
misa
• Improper combustion
m
aring
e, roc
essiv
brok
a
• Abnormal combustion
aft (d
a in
(valv
in be
r
olts,
(exc
w er t
sh
u t sh
ackla
m
ting b
, ma
ump
syste
o
o u tp
d p
b
g rod
tion p
moun
alve
in
ing
a
side
ar tra
ngine
mic v
b u sh
ectin
injec
art in
gine
e
dyna
e
conn
g
ca m
ctive
e en
er of
en p
oper
ctive
Worn
Worn
Loos
Defe
Cent
Brok
Impr
Defe
Degree of use of machine Operated for long period EEE
Questions
Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Metal particles are found in oil filter w w
Metal particles are found when oil is drained w w
Oil pressure is low at low idling Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w Q
Remove oil pan and inspect directly q
Remove side cover and inspect directly q
Troubleshooting
Inspect directly for loose engine mounting bolts, broken cushion q

Inspect inside of output shaft (damper) directly q
When face runout and radial runout are inspected, they are found q
to be incorrect
Remove front cover and inspect directly q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-724 WA200-5
(1)
30 DISASSEMBLY AND ASSEMBLY 1
How to read this manual ...................................... 30-2 Disassembly and assembly of axle housing
Precautions when performing operation .............. 30-4 assembly ...................................................... 30-78
Special tool list ..................................................... 30-6 Disassembly and assembly of differential
Sketches of special tools...................................... 30-9 assembly ...................................................... 30-86
Removal and installation of fuel injection Removal and installation of HST pump
pump assembly............................................. 30-16 and 4-gear pump assembly......................... 30-111
Removal and installation of nozzle holder Removal and installation of HST motor 1
assembly ...................................................... 30-21 assembly .....................................................30-114
Removal and installation of cylinder head Removal and installation of HST motor 2
assembly ...................................................... 30-22 assembly .....................................................30-115
Removal and installation of engine .................... 30-30 Removal and installation of work equipment
Removal and installation of radiator assembly... 30-37 control valve assembly ................................30-117
Removal and installation of air aftercooler Removal and installation of travel damper
assembly ...................................................... 30-38 valve assembly............................................30-118
Removal and installation of hydraulic oil Removal and installation of hydraulic tank ...... 30-120
cooler assembly............................................ 30-40 Removal and installation of work equipment
Removal and installation of cooling fan and assembly .................................................... 30-121
fan motor assembly ...................................... 30-42 Disassembly and assembly of hydraulic
Removal and installation of fuel tank cylinder assembly....................................... 30-128
assembly ...................................................... 30-43 Removal and installation of operator's cab
Removal and installation of transfer assembly... 30-45 assembly .................................................... 30-136
Disassembly and assembly of transfer Removal and installation of operator's
assembly ...................................................... 30-48 cab glass (stuck glass) ............................... 30-141
Removal and installation of parking brake Removal and installation of center hinge pin ... 30-149
assembly ...................................................... 30-67 Removal and installation of counterweight ...... 30-156
Disassembly and assembly of parking brake Removal and installation of air conditioner
assembly ...................................................... 30-69 unit assembly ............................................. 30-158
Removal and installation of front axle Removal and installation of air conditioner
assembly ...................................................... 30-74 compressor assembly ................................ 30-161
Removal and installation of rear axle Removal and installation of monitor panel....... 30-162
assembly ...................................................... 30-75
WA200-5 30-1
(2)
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
HOW TO READ THIS MANUAL 1 INSTALLATION

• Except where otherwise instructed, install
1. REMOVAL AND INSTALLATION OF ASSEM- parts is the reverse order of removal.
BLY • Instructions and precautions for installing
parts are shown with [*1] mark in the INSTAL-
SPECIAL TOOLS LATION Section, identifying which step the
• Special tools that are deemed necessary for instructions are intended for.
removal or installation of parts are listed. • Marks shown in the INSTALLATION Section
stand for the following.
k
• List of the special tools contains the following
kind of information. : This mark indicates safety-related
1) Necessity precautions which must be followed
t: Special tools which cannot be substituted, when doing the work.
should always be used.
a : This mark gives guidance or pre-
q: Special tools which are very useful if avail-
2 : This mark stands for a specific
cautions when doing the procedure.
able, can be substituted with commercially
available tools.
3 : This mark indicates the specified

coating agent to be used.
2) New/remodel
N: Tools with new part numbers, newly devel-
5 : This mark indicates an amount of

oped for this model. torque.
R: Tools with upgraded part numbers, remod-
eled from already available tools for other oil or water to be added.
models.
Blanks: Tools already available for other mod-
els, used without any modification. SKETCHES OF SPECIAL TOOLS
3) Mark Q in sketch column: • Various special tools are illustrated for the
This mark means that a sketch of the special convenience of local manufacture.
tool is presented in the section of Sketches of
Special Tools.
a Part No. of special tools starting with 79*T
means that they are locally made parts and
as such not interchangeable with those made
by Komatsu in Japan e.g. 79*T--- xxx --- xxxx.
REMOVAL
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to
be drained.
• Various symbols used in the REMOVAL Sec-
tion are explained and listed below.
k : This mark indicates safety-related
precautions which must be followed
when doing the work.
cautions when doing the procedure.
[*1] : This mark shows that there are
instructions or precautions for install-
6 : This mark shows oil or water to be

ing parts.
4 : This mark shows the weight of a

drained
part or a device.
30-2 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
2. DISASSEMBLY AND ASSEMBLY OF ASSEM- ASSEMBLY

BLY • Section titled ASSEMBLY contain proce-
dures, precautions and the know-how for the
SPECIAL TOOLS work, as well as the amount of oil or water to
• Special tools which are deemed necessary be added.
for disassembly and assembly of parts are • Various symbols used in ASSEMBLY Section
listed. are explained and listed below.
k
• List of the special tools contains the following
: This mark indicates safety-related
kind of information.
precautions which must be fol-
1) Necessity
lowed when doing the work.
t: Special tools which cannot be substituted,
should always be used. a : This mark gives guidance or pre-
q: Special tools which are very useful if avail- cautions when doing the proce-
2 : This mark stands for a specific

able, can be substituted with commercially dure.
available tools.
3 : This mark indicates the specified

2) New/remodel coating agent to be used.
N: Tools with new part numbers, newly devel-
5 : This mark indicates an amount of

oped for this model. torque.
R: Tools with upgraded part numbers, remod-
eled from already available tools for other oil or water to be added.
models.
Blank: Tools already available for other mod-
els, used without any modification.
SKETCHES OF SPECIAL TOOLS
3) Circle mark Q in sketch column:
• Various special tools are illustrated for the
A circle mark means that a sketch of the spe- convenience of local manufacture.
ci al tool is presented in the sect ion of
Sketches of Special Tools.
a Part No. of special tools starting with 79*T
means that they are locally made parts and
as such not interchangeable with those made
by Komatsu in Japan e.g. 79*T--- xxx --- xxxx.
DISASSEMBLY
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or
water to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.
k
: This mark indicates safety-related
precautions which must be fol-
lowed when doing the work.
cautions when doing the proce-
6 : This mark shows oil or water to be

dure.
drained
WA200-5 30-3
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
PRECAUTIONS WHEN PERFORMING OPERATION 1

Be sure to follow the general precautions given below when performing removal or installation (disassembly or
assembly) of units.
1. PRECAUTIONS WHEN PERFORMING REMOVAL WORK
• If the engine coolant water contains antifreeze, dispose of it properly.
• After disconnecting hoses or tubes, cover them or install blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake during assembly.
• To avoid loosening any wire contacts, do not pull on the wires. In order to prevent excessive force to the wiring,
hold onto the connectors when disconnecting them.
• Fasten tags to wires and hoses to identify them and show their installation position. This helps prevent any
mistakes when re-installing.
• Count and check the number and thickness of the shims and keep them in a safe place.
• When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from enter-
ing after removal.
a Precautions when handling piping during disassembly
Install the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Nut (elbow end)
Number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes
Nominal
Flange (hose end) Sleeve head (tube end) Split flange
Number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used:
Nominal Dimensions (mm)

Part No.
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 22.5 22.5 34
30-4 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
2. PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with
2 - 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt
or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling the cylinders, pumps and other
hydraulic equipment removed for repair, bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the cylin-
der 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
a After doing this run the engine at normal speed. When using the machine for the first time after repair or long
storage, follow the same procedure.
3. PRECAUTIONS WHEN COMPLETING THE OPERATION

• 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 has been removed, always bleed the air from the system after reassem-
bling the parts. For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the connecting pins of work equip-
ment parts.
WA200-5 30-5
(2)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST 1

a Tools with part number 79QT-QQQ-QQQQcannot be supplied (they are items to be locally manufactured).
a Necessity : t ----Cannot be substituted, should always be installed (used)
: q ----Special tools which are very useful if available, can be substituted with commercially
available tools.
a New/remodel: N ----Tools with new part numbers, newly developed for this model
: R ----Tools with upgraded part numbers, remodeled from items already available for
other models
: Blank----Tools already available for other models, can be used without any modification
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools
(See SKETCHES OF SPECIAL TOOLS).
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
Removal, installation of
fuel injection pump 1 795-799-1390 Remover t 1 Disconnection of gear and shaft
assembly
Removal, installation of A Removal of nozzle holder
3 795-799-1171 Puller q 1
nozzle holder assembly assembly
4 790-331-1110 Wrench t 1 Tightening of cylinder head bolt
cylinder head assembly
1 790-201-2840 Spacer t 1 Press fitting of
2 793T-417-1110 Push tool t 1 Q output shaft bearing
790-101-5201 Push tool kit t 1
Disassembly, assembly of • 790-101-5311 • Plate 1 Press fitting of oil seal of parking
transfer assembly 3
• 790-101-5221 • Grip 1 brake case
D
• 01010-51225 • Bolt 1
Disassembly, assembly of
parking brake assembly 793T-417-1120 Push tool t 1 Q
Press fitting of dust seal of park-
4 790-101-5221 Grip t 1
ing brake case
01010-81225 Bolt t 1
5 799-301-1500 Oil leak tester t 1 Transfer clutch operating test
793T-623-1170 Push tool t 1 Q
793T-422-1230 Push tool t 1 Q Press fitting of
1
793T-423-1110 Push tool t 1 Q inner race of axle shaft bearing
792T-446-1150 Push tool t 1 Q
793T-422-1240 Seal support t 2 Q
Disassembly, assembly of 01010-80860 Bolt t 6 Supporting of
H 2
axle housing assembly 793T-423-1120 Seal support t 2 Q axle shaft oil seal
01010-80860 Bolt t 6
793T-659-1110 Push tool t 1 Q Press fitting of
3
790-201-2750 Spacer t 1 inner race of axle shaft bearing
Adjustment of shim of axle
4 793T-423-1150 Holder t 1 Q
shaft bearing
30-6 WA200-5
(2)
New/remodel
Necessity
Symbol
Sketch
Q'ty
Operation check of
5 799-301-1500 Oil leak tester t 1
clutch piston
6 797-101-1131 Wrench t 1
pinion shaft nut
No-load operating torque of lim-
7 793-615-1100 Wrench t 1
ited-slip differential
8 793T-422-1220 Push tool t 1 Q Press fitting of
H 9 797T-423-1320 Push tool t 1 Q pinion shaft bearing
differential assembly
Press fitting of oil seal
10 792T-423-1130 Push tool t 1 Q
pinion shaft cage
Installation of brake piston
11 793-520-2202 Installer q 3
Check for brake oil leakage
13 790-190-1500 Pump assembly t 1
14 799-101-5210 Nipple t 1 Check for brake oil leakage
15 793T-422-1611 Plate t 1 Q
790-502-1003 Repair stand t 1 Disassembly, assembly of
1
790-101-1102 Hydraulic pump t 1 hydraulic cylinder
Removal, installation of cylinder
2 790-382-3802 Wrench assembly t 1
head
790-102-1320 Socket (for lift arm) t 1
790-102-1330 Socket (Bucket)
Removal, installation of piston
3 or commercially (Width across flats t 1
nut
available tools 46 mm)
790-302-1280 Socket (Steering) t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
• Push tool (for lift arm Press fitting of cylinder head
hydraulic cylinder U 4 790-201-1791 1
and bucket) bushing
assembly
790-201-1811 • Push tool (Steering) 1
• Push tool
790-201-1831 1
(WA200PT-5 bucket)
790-101-1521 • Grip 1
01010-50816 • Bolt 1
• Plate
5 790-201-1610 (for lift arm and 1 Installation of dust seal
bucket)
790-201-1550 • Plate (Steering) 1
• Push tool
790-201-1640 1
(WA200PT-5 bucket)
WA200-5 30-7
(4)
New/remodel
Necessity
Symbol
Sketch
Q'ty
6 790-720-1000 Expander q 1
Ring
796-720-1670 q 1
(for lift arm and bucket)
Clamp
07281-01159 q 1
(for lift arm and bucket)
796-720-1740 Ring (Steering) q 1 Installation of piston ring
7
Disassembly, assembly 07281-00809 Clamp (Steering) q 1
of hydraulic cylinder U Ring
assembly 796-720-1680 q 1
(WA200PT-5 bucket)
Clamp
07281-01589 q 1
(WA200PT-5 bucket)
Wrench assembly
790-102-4300 t 1
(WA200PT-5 bucket)
8 Removal, installation of piston
Pin
790-102-4310 t 2
(WA200PT-5 bucket)
799-703-1200 Service tool kit t 2
operator's cab assembly
799-703-1100 Vacuum pump (100V) t 1
air conditioner unit
1 799-703-1111 Vacuum pump (220V) t 1 Supply of refrigerant
assembly
799-703-1121 Vacuum pump (240V) t 1
Removal, installation of X
air conditioner compres-
799-703-1401 Gas leak detector t 1
sor assembly
1 793-498-1120 Clear plate t 2
Adjustment of clearance of win-
Removal, installation of 2 2 793-498-1130 Plate t 2
dow glass
operator's cab glass 3 793-498-1110 Magnet t 2
(Stuck glass) Removal, installation of window
3 793-498-1210 Lifter (Suction cup) t 2
glass
30-8 WA200-5
(4)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS 1

Note: Komatsu will not be held responsible for special tools manufactured according to these sketches.
D2 PUSH TOOL
D4 PUSH TOOL
WA200-5 30-9
(2)
H1 PUSH TOOL
H1 PUSH TOOL
30-10 WA200-5
(2)
H1 PUSH TOOL
H1 PUSH TOOL
WA200-5 30-11
(2)
H2 SEAL SUPPORT
H2 SEAL SUPPORT
30-12 WA200-5
(2)
H3 PUSH TOOL
H4 HOLDER
WA200-5 30-13
(2)
H8 PUSH TOOL
H9 PUSH TOOL
30-14 WA200-5
(2)
H10 PUSH TOOL
H15 PLATE
WA200-5 30-15
(4)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL AND INSTALLATION OF

FUEL INJECTION PUMP
ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
A1 795-799-1390 Remover t 1
REMOVAL
k Lower the work equipment to the ground and stop
6. Remove 6 fuel injection tubes (6).[*2]
the engine.
k Disconnect the cable from the negative (–) termi-
nal of the battery.
1. Open the engine right side cover.
2. Disconnect fuel control cable (1) from the fuel

injection pump.
[*1]
7. Disconnect engine stop solenoid terminals PULL

(7), HOLD (8), and GND (9).
8. Remove cotter pin (10) and nut (11), and then

remove engine stop solenoid rod (12) from the
fuel injection pump.
9. Remove engine stop solenoid (13) and bracket

(14) together.
[*3]
3. Disconnect fuel supply hoses (2) and (3).
4. Disconnect fuel filter (4).
5. Disconnect fuel return hose (5).
30-16 WA200-5
(2)
13. Using timing pin (20), match the timing gear to the
fuel injection timing.
a For details, see TESTING AND ADJUSTING,
Testing and adjusting fuel injection timing.
10. Remove fuel tubes (15) and (16).

[*4]
14. Remove cap (21).
11. Remove lubrication tubes (17) and (18).
a Use a filter wrench, etc. to remove the cap.
12. Remove boost compensator tube (19).
15. Remove fuel injection pump nut (22) and washer
(23).
a Take care not to drop the nut and washer into
the case.
16. Using tool A1, disconnect the fuel injection pump

shaft and pump drive gear.
WA200-5 30-17
(2)
17. Remove fuel injection pump bracket (24). INSTALLATION

• Carry out installation in the reverse order to
removal.
[*1]
a Adjust the fuel control cable. For details, see
TESTING AND ADJUSTING, Measuring, testing
operating force of accelerator pedal.
[*2]
3 Fuel injection tube nut
(on injection pump side):
24 ± 4 Nm {2.45 ± 0.41 kgm}
Fuel injection tube nut
(on nozzle holder side):
30 ± 5 Nm {3.06 ± 0.51 kgm}
18. Remove 4 fuel injection pump mounting nuts (25)
and fuel injection pump assembly (26).
[*3]
3 Engine stop solenoid bracket mounting nut:
[*5]
14 – 21 Nm {1.4 – 2.1 kgm}

a Adjust the engine stop solenoid. For details, see
TESTING AND ADJUSTING, Adjusting engine
stop solenoid.
[*4]
3 Fuel tube joint bolt (on fuel filter side):
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*5]
a Install the fuel injection pump assembly according
to the following procedure.
1. Ensure that the drive gear is fixed to the fuel

injection timing using timing pin (20).
30-18 WA200-5
(2)
2. Remove plug (27) from the fuel injection pump, 4. Install fuel injection pump bracket (24).
3 Fuel injection pump bracket mounting
turn over timing pin (28), and re-install the plug
into the fuel injection pump.
bolt (Injection pump side):
a Ensure that the cut-out portion of the timing
22 ± 2 Nm {2.2 ± 0.2 kgm}
pin engages the protruding portion in the
pump.
a If you cannot insert the timing pin, injection
timing is not right. Make an adjustment.
(See TESTING AND ADJUSTING, Testing
and adjusting fuel injection timing.)
5. Install washer (23) and tighten fuel injection pump

nut (22) temporarily.
a When installing, be careful not to drop nuts or
washers in the case.
k Tighten the nut temporarily with the following
3. Install fuel injection pump assembly (26), and
tightening torque so that you do not damage
ensure it with 4 nuts (25).
3 Fuel injection pump mounting nuts:
the timing pin.
3 Fuel injection pump nut temporary tight-
9.8 ± 2 Nm {1.0 ± 0.2 kgm}
ening torque:
12.5 ± 2.5 Nm {1.27 ± 0.25 kgm}
WA200-5 30-19
(2)
6. Pull timing pin (20) on the timing gear side and • Bleeding air
restore it to its original position. Bleed air from the fuel system using the following
procedure.
1. Fill the fuel tank and bring the fuel gauge to FULL
position.
2. Loosen air bleeding plug (29).
3. Remove cap (30).
7. Tighten fuel injection pump nut (22) securely.

3 Fuel injection pump nut secure tightening
torque: 95 ± 10 Nm {9.7 ± 1.01 kgm}
k Before starting the engine, double-check that
you returned drive gear timing pin (20) and
fuel injection pump timing pin (28) to their
original position.
4. Loosen the knob of feed pump and move it up
and down, so that the fuel overflow until no more
bubbles come out from the air bleeding plug
mounting section.
a Wipe out fuel from the engine completely with

rag.
5. Tighten air bleeding plug (29).

3 Air bleeding plug:
7.8 – 11.8 Nm {0.8 – 1.2 kgm}
6. Push the feed pump knob and tighten it.
7. Start the engine, and check that there is no leak

from the fuel system.
30-20 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL AND INSTALLATION OF a Take care that dirt and foreign matter will not
enter the mounting part of the nozzle holder
NOZZLE HOLDER ASSEMBLY assembly
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
A 3 795-799-1171 Puller t 1
REMOVAL
k Lower the work equipment to the ground and stop
the engine.
1. Open the engine right and left side covers. a If the nozzle holder is difficult to remove, use
tool A3.
2. Remove fuel injection tubes (1).
[*1]
INSTALLATION
3. Remove spill tube (2). • Carry out installation in the reverse order to
[*2] removal.
[*1]
3 Fuel injection tube nut (on injection pump side):
24 ± 4 Nm {2.45 ± 0.41 kgm}
Fuel injection tube nut (on nozzle holder side):
30 ± 5 Nm {3.06 ± 0.51 kgm}
[*2]
3 Spill tube joint bolt: 9 Nm {0.9 kgm}
[*3]
3 Nozzle holder: 60 Nm {6.1 kgm}
4. Loosen and remove nozzle holder assembly (3). • Bleeding air

[*3] Bleed air from the fuel system. See Removal and
installation of fuel injection pump assembly.
WA200-5 30-21
(2)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

CYLINDER HEAD ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
3 795-799-1171 Puller t 1
A
4 790-331-1110 Wrench t 1
REMOVAL
k Stop the machine on a level place and set the
4. Disconnect the following wiring connectors and
terminals.
safety bar to the frame. a Disconnect the wiring harness clamps, too.
k Lower the work equipment to the ground, stop the (11): PULL
engine, apply the parking brake, and put chocks (12): HOLD
under the tires. (13): GND

(14): E14
nal of the battery.
1. Remove engine assembly. For details, see

Removal and Installation of engine assembly.
2. Drain the coolant.

6 Coolant: 17 l
3. Remove the air conditioner compressor accord-

ing to the following procedure.
1) Disconnect wiring connector E16 (1) and
ground terminal E22 (2).
2) Remove cover (3).
3) Loosen 2 mounting bolts (4) and 2 mounting (15): E09
bolts (5).
4) Loosen 2 locknuts (6) and 2 adjustment bolts 5. Remove the mounting bolts of heater relay (16).
(7).
5) Remove air conditioner compressor belt (8).
[*1]
6) Remove 2 mounting bolts (4), 2 mounting
bolts (5), and air conditioner compressor and
bracket assembly (10).
a Place the air conditioner piping by the
side of the engine without disconnecting
it.
30-22 WA200-5
(2)
6. Remove air hose (17) between the air cleaner 10. Remove the muffler according to the following
and turbocharger. procedure.
[*2] 1) Remove mounting bolts (21), 2 pieces on
each side.
2) Remove 1 mounting bolt (22).
3) Remove 4 mounting bolts from the inside of
rear side a.
4) Raise muffler (23) and disconnect drain tube
(24).
7. Disconnect radiator inlet hose (18).

[*3]
8. Disconnect aftercooler upper hose (19).

[*4]
9. Remove air cleaner and bracket assembly (20).
WA200-5 30-23
(2)
11. Remove the turbocharger and exhaust manifold 7) Lift off turbocharger and exhaust manifold
assembly according to the following procedure. assembly (32).
1) Disconnect turbocharger lubrication tubes [*6]
4 Turbocharger and exhaust manifold
(25) and (26).
[*5]
assembly: 40 kg
2) Remove bracket (27).
12. Remove 6 fuel injection tubes (33).

3) Remove bracket (28).
[*7]
4) Remove muffler drain tube mounting bolt
(29).
5) Remove exhaust manifold heat insulation
cover (30).
6) Remove muffler brackets (31).
30-24 WA200-5
(2)
13. Remove alternator belt cover (34). 18. Remove air conditioner compressor bracket (42).
14. Disconnect wiring connectors E02 (35) and termi-

nal E11 (36).
15. Remove mounting bolts (37), (38) and alternator

(39).
19. Remove engine stop solenoid bracket mounting

bolts and nuts (43).
[*9]
20. Disconnect air hose (44).

[*10]
16. Remove alternator bracket (40). 21. Remove air intake connector (45) and heater
(46).
17. Remove engine sling and thermostat housing
assembly (41).
[*8]
WA200-5 30-25
(2)
22. Remove boost compensator tube (47). 28. Remove 6 nozzle holders (54).
[*11]
23. Remove fuel tubes (48) and (49).
24. Remove fuel filter (50).
a If the nozzle holder is difficult to remove, use

tool A3.
25. Disconnect spill hose (51).
26. Disconnect heater hose (52).
29. Remove 6 cylinder head covers (55).

[*12]
27. Remove spill tube (53).
30-26 WA200-5
(2)
30. Remove rocker arm (56). INSTALLATION

[*13] • Carry out installation in the reverse order to
a Loosen the locknut, and then loosen adjust- removal.
ment screw by 2 – 3 turns.
[*1]
a Adjust the tension of the air conditioner compres-
s o r b e l t . F o r d e ta i l s , s ee T E S T I N G A N D
ADJUSTING, Testing and adjusting air condi-
tioner compressor belt tension.
[*2]
3 Air hose clamp:
9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
[*3]
2 Mating face of hose: Gasket sealant
(ThreeBond 1208E or equivalent)
3 Radiator hose clamp:
10.5 ± 0.5 Nm {107 ± 5 kgcm}
31. Remove push rods (57). [*4]
3 Aftercooler hose clamp:
[*14]
10.5 ± 0.5 Nm {107 ± 5 kgcm}
[*5]
3 Mounting nut of turbocharger lubrication tube
(25): 35 ± 5 Nm {3.57 ± 0.51 kgm}
Mounting bolt of turbocharger lubrication tube
(26): 24 ± 4 Nm {2.45 ± 0.41 kgm}
[*6]
a Tighten the exhaust manifold mounting bolts in 3
times according to the following procedure.
3 Exhaust manifold mounting bolt:
1st time: Tighten the bolts to 24 ± 4 Nm {2.45
± 0.41 kgm} in the order of 1 – 12.
2nd time: Tighten the bolts to 43 ± 6 Nm {4.38
32. Lift off cylinder head assembly (58). ± 0.61 kgm} in the order of 1 – 12.
[*15] 3rd time: Tighten the bolts to 43 ± 6 Nm {4.38
4 Cylinder head assembly: 55 kg

± 0.61 kgm} in the order of 1 – 4.
33. Remove cylinder head gasket (59).

[*16]
WA200-5 30-27
(2)
[*7] 3. Tighten the cylinder head bolts in 3 times in the

3 Fuel injection tube nut (on injection pump
order shown in the following figure.
side): 24 ± 4 Nm {2.45 ± 0.41 kgm} 5Threads and seat of mounting bolt: Engine oil
3 Cylinder head bolt:
Fuel injection tube nut (on nozzle holder
side): 30 ± 5 Nm {3.06 ± 0.51 kgm}
1st time: Tighten the bolts to 90 ± 5 Nm
{9.18 ± 0.51 kgm} in the order
[*8]
3 Thermostat housing mounting bolt:
of 1 - 26.
2nd time: Tighten the bolts to 120 ± 5 Nm
24 ± 4 Nm {2.45 ± 0.41 kgm} {12.24 ± 0.51 kgm} in the order
of 3, 6, 11, 14, 19, and 22.
[*9] 3rd time:
3 Engine stop solenoid bracket mounting nut:
• When using tool A4
Using angle tightening wrench A4,
14 – 21 Nm {1.4 – 2.1 kgm}
retighten them 90° ± 5°. (Angle tight-
ening)
[*10]
3 Air hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*11]
3 Nozzle holder: 60 Nm {6.1 kgm}
[*12]
3 Cylinder head cover mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
[*13][*14][*15][*16]
a Install the rocker arm assembly and cylinder head
assembly according to the following procedure.
a Check that there is not dirt or foreign matter on
the mounting face of the cylinder head or in the
cylinder.
1. Set cylinder head gasket (59) to the cylinder

block.
a Check that the gasket is matched to the hole
of the block.
2. Sling cylinder head assembly (58) and set it to the

cylinder block.
30-28 WA200-5
(2)
• When not using tool A4 6. Tighten rocker arm assembly mounting bolts (8
Make marks on bolts and cylinder mm diameter).
3 Rocker arm mounting bolt:
heads as shown in a, and retighten
them by the angle of b (90° ± 5 ° ).
24 ± 4 Nm {2.45 ± 0.41 kgm}
(Angle tightening)
4. Install push rod (57). 7. Adjust the engine stop solenoid. For details, see
a Lubricate the push rod section with engine TESTING AND ADJUSTING, Adjusting valve
oil. clearance.
• Refilling with water

Add water through the water filler to the specified
level. Run the engine to warm the water. Then,
check the water level again.
• Bleeding air
Bleed air from the fuel system. See Removal and
5. Install rocker arm assembly (56), and tighten the

mounting bolts with fingers.
a Ensure that the ball of the adjustment screw
is fitted to the socket of push rod (57).
a Lubricate the thread portion and seat surface
of bolts with 8 mm diameter and bolts with 12
mm diameter with engine oil.
WA200-5 30-29
(2)
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL AND INSTALLATION OF 5) Remove air hose (7) between the air cleaner
and turbocharger.
ENGINE a This is to obtain the place to secure the
air conditioner condenser.
REMOVAL
safety bar to the frame.
k Lower the work equipment to the ground, stop the
engine, apply the parking brake, and put chocks
under the tires.
nal of the battery.

6 Coolant: 17 l
2. Remove the engine hood assembly according to

the following procedure. 6) Disconnect wiring connector BL1 (8) and har-
1) Remove left and right fenders (1). ness clamp to the left rear of the operator
2) Remove covers (2), (3), and (4). cab.
3) Remove pre-cleaner (5). 7) Disconnect the 2 window washer hoses (9) at

[*1] the right front of the engine hood.
30-30 WA200-5
(2)
8) Disconnect wiring connector B04 (10) for air 12) Remove 4 mounting bolts (15) of cover (14).
conditioner condenser.
9) Remove 2 clamps (11) for the receiver tank
hose.
10) Remove 2 U-bolts (12).
a While removing the air conditioner con-
denser, fix the receiver tank to the side of
the engine along with the air conditioner
condenser with a rope or something.
13) Disconnect reservoir tank hose (16).
11) Remove air conditioner condenser mounting

bolts (13), 2 pieces on each side.
a With the air conditioner piping connected,
move the air conditioner condenser to the
engine and fix it with a rope or some-
thing.
14) Remove grille (17), and remove fan guard

(18).
WA200-5 30-31
(2)
15) Remove fuel tank air bleeding hose (19) from 18) Lift off engine hood assembly (22).
its clamp. a Carefully remove the air conditioner con-
denser so that you avoid damaging it.
16) Remove left and right covers (20).

3. Remove the air conditioner compressor accord-
1) Disconnect wiring connector E16 (23) and
ground terminal E22 (24).
3) Loosen 2 mounting bolts (26) and 2 mounting
bolts (27).
4) Loosen 2 locknuts (28) and 2 adjustment
bolts (29).
5) Remove air conditioner compressor belt (30).
[*2]
6) Remove 2 mounting bolts (26), 2 mounting
bolts (27), and air conditioner compressor
and bracket assembly (31).
a Place the air conditioner piping by the
17) Remove engine hood mounting bolts (21), 3 side of the engine without disconnecting
pieces on each side. it.
30-32 WA200-5
(2)
4. Disconnect the following wiring connectors and 5. Remove the mounting bolts for fuel filter (41).
terminals. a Tie the fuel filter to the engine with a rope or
(32): Engine grounding something.
(33): E13
(34): E10 6. Remove bars (42) (43), and cover (44).
(35): E02
(36): E11
7. Disconnect radiator inlet hose (45) and radiator

outlet hose (46).
(37): ER1 [*3]
(38): ER2
(39): ER3 8. Disconnect aftercooler upper hose (47).
[*4]
9. Disconnect heater hose (48).

a Disconnect 3 heater hose clamps.
(40): T01
WA200-5 30-33
(2)
10. Disconnect fuel supply hose (49) and fuel return 14. Disconnect spill hose (59).
hose (50).
15. Remove 3 fan motor hose clamps (60).

11. Remove mounting nut (52) for fuel control cable
(51), and remove the fuel control cable together 16. Remove air intake hose (61) and air intake tube
with bracket (53). (62) together.
[*5]
a Move the fuel control cable and the bracket
assembly to outside of the engene.
17. Put blocks [1] on the left and right side of the
frame, put pipe [2] on these blocks, and fix HST
pump assembly (63) to pipe [2] with lever blocks
12. Disconnect heater hose (54). [3].
13. Remove hose clamps (55) through (58).

a Move the air conditioner condenser and the
receiver tank to outside of the engine assem-
bly.
30-34 WA200-5
(2)
18. Remove all mounting bolts (64) for the damper 20. Move engine assembly (67) to the rear of the
cover. machine after pulling up a little, and separate it
[*6] from the HST pump assembly.
a Do not remove the HST pump section by [*8]
removing mounting bolts (65) for the HST
pump. 21. Remove engine assembly (67) by gradually pull-
If you disassemble the engine assembly at ing it up.
the HST pump mounting section, you may a Ensure that all the wiring and piping are dis-
damage the damper, because you cannot connected.
see the section where gears engage when a Carefully remove the radiator, aftercooler,
mounting the engine assembly. and the hydraulic oil cooler so that none of
them is damaged.
4 Engine assembly: 650 kg
19. Disconnect 4 engine mount bolts (66).

[*7]
WA200-5 30-35
(2)
INSTALLATION [*8]
• Carry out installation in the reverse order to a When installing the engine assembly, carefully
removal. align the positions and mate damper flange (68)
with HST pump boss (69) gear.
[*1] a Be careful not to damage flange (68).
3 Pre-cleaner clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*2]
sor belt. For details, see TESTING AND
[*3]
2 Mating face of radiator hose: Gasket sealant
10.5 ± 0.5 Nm {107 ± 5 kgcm}
[*4]
3 Aftercooler hose clamp:
10.5 ± 0.5 Nm {107 ± 5 kgcm}
[*5]
[*6]
2 Mating face of damper cover:
Gasket sealant (LG-6)
3 Damper cover mounting bolt: • Bleeding air
58.8 – 73.5 Nm {6 – 7.5 kgm} Bleed air from the fuel system. See Removal and
[*7]
3 Engine mounting bolts: • Refilling with water
610 – 765 Nm {62.5 – 78 kgm} Add water through the water filler to the specified
30-36 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL AND INSTALLATION OF 5. Disconnect radiator outlet hose (4).

[*2]
RADIATOR ASSEMBLY
REMOVAL
under the tires.

6 Coolant: 17 l
2. Remove air aftercooler (1) by referring to

"Removal and Installation of air aftercooler" sec- 6. Remove 2 upper mounting bolts (5) for the radia-
tion. tor assembly.
3. Disconnect reservoir tank hose (2).
7. Lift up radiator assembly (6), and remove by pull-

ing out toward the fan guard.
4. Disconnect radiator inlet hose (3). a Take care not to damage the core section.
[*1]
WA200-5 30-37
(2)
DISASSEMBLY AND ASSEMBLY AIR AFTERCOOLER
INSTALLATION REMOVAL AND INSTALLATION OF

removal.
AIR AFTERCOOLER ASSEMBLY
REMOVAL
[*1][*2]
2 Mating face of hose: Gasket sealant
10.5 ± 0.5 Nm {107 ± 5 kgcm} engine, apply the parking brake, and put chocks
under the tires.
Add water through the water filler to the specified 1. Remove grille (1), and remove fan guard (2).
2. Remove clamp (3), and then cover (4).
30-38 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY AIR AFTERCOOLER
3. Remove stays (5) and (6). 6. Remove 2 upper mounting bolts (11) for the air
aftercooler.
4. Disconnect upper air hose (7).

[*1] 7. Lift up air aftercooler assembly (12), and remove
by pulling out toward the right of the machine.
a Take care not to damage the core section.
5. Loosen clamps (8), (9), and remove air hose and

pipe assembly (10).
INSTALLATION
removal.
[*1]
3 Air hose clamp:
10.5 ± 0.5 Nm {107 ± 5 kgcm}
WA200-5 30-39
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
REMOVAL AND INSTALLATION OF 3. Remove stays (5) and (6).

HYDRAULIC OIL COOLER
ASSEMBLY
REMOVAL
under the tires.
k Slowly loosen the oil filler cap of the hydraulic
tank to release the residual pressure in the
hydraulic tank.
4. Disconnect upper hose (7) and lower hose (8) for
1. Remove grille (1), and remove fan guard (2). the hydraulic oil cooler.
a Oil will leak. Prepare an oil receiver and an oil
stopper.
2. Remove clamp (3), and then cover (4).
30-40 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
5. Remove 2 upper mounting bolts (9) and 2 lower INSTALLATION

mounting bolts (10) for the hydraulic oil cooler. • Carry out installation in the reverse order to
removal.
• Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
6. Remove hydraulic oil cooler assembly (11) by

pulling it out toward the right side of the machine.
a Take care not to damage the core section.
WA200-5 30-41
(2)
DISASSEMBLY AND ASSEMBLY COOLING FAN AND FAN MOTOR
REMOVAL AND INSTALLATION OF 3. Disconnect port P1 hose (4), port P2 hose (5),
and port Dr hose (6).
COOLING FAN AND FAN MOTOR a Oil will leak. Prepare an oil receiver and an oil
ASSEMBLY stopper.
REMOVAL
under the tires.
hydraulic tank.
1. Open the grille, and remove cover (2).
4. Remove 1 mounting bolt (7) for the fan, and

remove cooling fan (8).
[*1]
2. Open the fan guard assembly, and remove guard

(3).
30-42 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY FUEL TANK
5. Remove the 2 mounting bolts and fan motor REMOVAL AND INSTALLATION OF
assembly (9).
FUEL TANK ASSEMBLY
REMOVAL
under the tires.
nal of the battery.
1. Drain the fuel.

6 Fuel tank: 175 l (When filled)
2. Remove grille (1), and remove fan guard (2).

INSTALLATION
removal.
[*1]
3 Mounting bolt: 27 – 34 Nm {2.8 – 3.5 kgm}

3. Remove filler cap (3).
4. Remove the clamp for fuel tank air bleeding hose

(4).
WA200-5 30-43
(2)
DISASSEMBLY AND ASSEMBLY FUEL TANK
6. Open the engine left side cover and disconnect

wiring connector R21 (6) at the top left front of the
fuel tank.
7. Support the bottom of the fuel tank with transmis-

sion jack.
8. Remove mounting bolt (7) at the left and right

side and mounting bolt (8) at the back.
10. Lower transmission jack [1], and remove fuel tank

assembly (13).
[*1]
a Take extra care that the fuel tank does not
come off the transmission jack.
4 Fuel tank assembly: 80 kg (not including
fuel)
9. Lower the transmission jack gradually, and INSTALLATION

remove spill hose (9), fuel supply hose (10), and • Carry out installation in the reverse order to
fuel return hose (11) at the top right front of the removal.
fuel tank.
a Mark all the hoses and tubes with tags to pre- [*1]
3 Fuel tank mounting bolt:
vent mistakes in the mounting position when
installing.
245 – 309 Nm {25 – 31.5 kgm}
• Fueling (fuel tank)

Feed fuel through the fuel filler.
5Fuel tank: 175 l (When filled)
30-44 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY TRANSFER
REMOVAL AND INSTALLATION OF 5. Disconnect priority valve port P hose (4).

TRANSFER ASSEMBLY
REMOVAL
under the tires.
k Press the brake pedal at least 100 times to
release the residual pressure in the brake accu-
mulator circuit.
nal of the battery. 6. Disconnect port PA hose (5) and port PB hose (6)
from the brake valve.
1. Remove the operator's cab assembly. For details,
see Removal and installation of operator's cab
assembly.
2. Remove the HST pump and 4-gear pump assem-

bly. For details, see Removal and installation of
HST pump and 4-gear pump assembly.
3. Disconnect motor 2 drain hose (1) and motor 1

drain hose (3).
4. Disconnect accumulator charge valve drain hose

(2).
7. Disconnect hoses (9) and (10) from the accumu-

lator for PPC.
WA200-5 30-45
(2)
8. Disconnect transfer oil cooler hose (11). 12. Remove rear drive shaft (16).
[*2]
9. Disconnect 2 hydraulic oil cooler hose clamps

(12) and motor 2 drain hose clamp (13) from the 13. Sling the transfer assembly temporarily and
right inside of the frame. remove 2 transfer cushions (17) on both sides,
and then remove 2 transfer mounting bolts (18)
10. Disconnect wiring connector T09 (14). on both sides.
[*3]
a After removing the right cushion, remove
accumulator bracket assembly (19).
11. Disconnect front drive shaft (15) from the transfer

side.
[*1]
30-46 WA200-5
(2)
14. Lift off transfer assembly (20). INSTALLATION

a Check that all the wires and pipes are discon- • Carry out installation in the reverse order to
nected, and then sling the assembly slowly. removal.
4 Transfer and HSS motor assembly:
[*1][*2]
3 Drive shaft mounting bolt:
350 kg
59 – 74 Nm {6.0 – 7.5 kgm}

a When installing the drive shaft, check that the key
groove of the spider cap is fitted in the key groove
of the mating yoke, and then tighten the mounting
bolts.
a When installing the rear drive shaft, check that
the lateral runout of the rear axle and transfer
from each other is less than 3 mm. If the runout
is 3 mm or larger, shift the transfer cushion and
transfer mount to reduce the runout.
[*3]
3 Transfer cushion mounting bolt:
M10 bolt: 59 – 74 Nm {6.0 – 7.5 kgm}
M12 bolt: 98 – 123 Nm {10 – 12.5 kgm}
3 Transfer mount mounting bolt:

610 – 765 Nm {62.5 – 78 kgm}
WA200-5 30-47
(2)
DISASSEMBLY AND ASSEMBLY 3. Brake accumulator

1) Disconnect wiring connectors T06 (1), T07
OF TRANSFER ASSEMBLY (2), T10 (3), and T11 (4).
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
1 790-201-2840 Spacer t 1
2 793T-417-1110 Push tool t 1 Q
• 790-101-5311 • Plate 1
3
• 790-101-5221 • Grip 1
D
• 01010-51225 • Bolt 1
793T-417-1120 Push tool t 1 Q
4 790-101-5221 Grip t 1 2) Disconnect clutch port hose (5) and hose
01010-81225 Bolt t 1
clamp.
3) Remove the 6 mounting bolts, and then brake
accumulator and transfer oil filter bracket
assembly (6).
DISASSEMBLY
1. Draining transfer oil
6 Transfer case: 5.5 l
2. Speed sensor
Remove speed sensor (75).
4. HST motor
1) Disconnect hoses (7) through (10) from the
HST motors 1 and 2.
30-48 WA200-5
(2)
2) Remove the 4 mounting bolts each from HST 7. Parking brake assembly
motor 1 (11) and HST motor 2 (12), and lift 1) Set the transfer assembly to a block with the
them off. parking brake side up.
2) Remove coupling (14) on the parking brake
side.
5. Oil supply pipe

Remove oil supply pipe (13).
3) Remove the mounting bolts. Using forcing
screws [3], remove parking brake assembly
(15).
a For disassembly and assembly of the
parking brake assembly, see Disassem-
bl y and assem bly of parking brake
assembly.
6. Parking brake control cable

1) Disconnect hose (13a).
2) Remove parking brake control cable (13b)
along with bracket (13c).
WA200-5 30-49
(2)
8. Hub 2) Remove 4 belleville springs (19).

1) Remove snap ring (16). a Check the directions of the belleville
2) Remove hub (17). springs.
a The 1st and 4th belleville springs have
white marks.
a When any belleville spring needs to be
replaced, replace all of the 4 springs as a
set.
9. Belleville springs
1) Turn over the case and remove cage (18)
from the HST motor mounting section.
a Loosen the mounting bolts evenly and
gradually to release the belleville springs,
and then remove the cage. 10. Piston and spacer
• Free height of belleville springs (6- 1) Using 2 forcing screws [4], remove piston
piece set): 32.8 mm (20).
• Installed height of belleville springs
(4-piece set): 25.6 mm
• Installed load of belleville springs (4-
piece set): 21,500 N {2,190 kg}
2) Using 2 eyebolts [5], remove spacer (21).
30-50 WA200-5
(2)
11. Clutch discs, plates, and springs 13. Cage assembly

1) Remove 4 discs (22), 5 plates (23), and 4 1) Remove the mounting bolts. Using forcing
wave springs (24). screws [15], remove cage assembly (60).
2) Using bar [6], remove end plate (25). 2) Remove shims (61).
a Check the thickness and quantity of the
shims.
12. Coupling
1) Remove the mounting bolts and holder (58).
2) Remove coupling (59). 3) Remove dust seal (76) and oil seal (77) from
cage (78).
4) Remove outer race (79).
WA200-5 30-51
(2)
14. Spacer 17. Disassembly of HST motor 1 shaft and ring

1) Remove spacer (62). gear assembly
1) Using puller [8], remove bearing (27).
15. Front case

2) Remove snap ring (29) and sun gear (30).
screws [16] and bars [17], remove front case
(63).
3) Remove snap ring (31).
16. Removal of HST motor 1 shaft and ring gear

1) Remove HST motor 1 shaft and ring gear
assembly (28).
30-52 WA200-5
(2)
4) Supporting ring gear (32) and using push tool 19. Disassembly of carrier assembly
[10] and a press, push out HSS motor 1 shaft 1) Press shaft (39) and remove ball (40) and
(33). pinion shaft (39) from carrier (41).
a Keep the ball carefully.
2) Remove 2 thrust washers (42), planetary
gear (43), and bearing (44) (at 3 places).
5) Remove bearing (34) and spacer (35) from

ring gear (32).
6) Remove snap ring (36) and bearing (37).
20. Holder
1) Remove the mounting bolts and holder (45).
18. Removal of carrier assembly

1) Using tool [11], remove carrier assembly (38)
2) Remove seal rings (46) and (47) from holder
from the dowel pin of the HST motor 1 gear.
(45).
WA200-5 30-53
(2)
21. Removal of HST motor 2 gear and bearing 24. Disassembly of output shaft and gear assembly
assembly 1) Using puller [20], remove front bearing (69).
1) Remove HST motor 2 gear and bearing
assembly (64).
2) Remove snap ring (70) and output gear (71).

22. Disassembly of HST motor 2 gear and bearing
assembly
1) Using puller [18] and plate [19] remove 2
bearings (66) from HST motor 2 gear (65).
3) Using push tool [21] and the press, push rear

bearing (72) out of output shaft (73).
23. Removal of output shaft and gear assembly

1) Remove 2 mounting bolts of cover (67).
2) Remove output shaft and gear assembly (68)
and cover (67).
30-54 WA200-5
(2)
25. Removal of HST motor 1 gear and outer races 26. Disassembly of HST motor 1 gear and outer
a Do not remove the HST motor 1 gear shaft. (If races
it is removed forcibly and reused, it can cause 1) Using puller [14], remove 2 outer races (53)
a trouble.) f rom HST m otor 1 gear (52), and t hen
1) Using puller [31], remove bearing (50) and remove spacer (54).
HST motor 1 gear and outer races (51).
2) Remove seal ring (85) from HST motor 1

a If the claws of puller [31] are so thick that
gear (52).
they cannot be inserted between the gear
and case, screw 3 mounting bolts (M12 x
35 mm) [23] into the carrier mounting
holes of HST motor 1 gear (51) by 15 mm.
Then, using 3-claw puller [24], remove
bearing (50) and HST motor 1 gear and
outer races (51).
27. Bearing
1) Remove 2 plugs (48) from shaft (49).
WA200-5 30-55
(2)
2) Remove spacer (55). ASSEMBLY

3) Insert 2 push tools [32] in the plug holes and a Clean the all parts and check them for dirt or
hit them evenly to remove bearing (56) from damage. Coat their sliding surfaces with transfer
shaft (49). oil TO10 (EO10-CD) before installing.
a Do not remove shaft (49). a Before icing a bearing in dry ice for expansion fit,
drop about 6 cc of EO10-CD or EO-30CD onto it
and rotate it 10 turns.
1. Rear case
1) Press fit outer race (81) to rear case (80).
28. Rear case

1) Remove outer race (81) from rear case (80).
2. Assembly of output shaft and gear assembly

1) Using tool D1 and the press, press fit rear
bearing (72) to output shaft (73) until it stops.
a After press fitting the bearings, apply
transfer oil to them and rotate them.
29. Clutch housing

1) Using push tool [24], remove clutch housing
(26) and 3 pins (83).
2) Remove snap ring (86) from clutch housing
(26).
3) Remove snap ring (57).
30-56 WA200-5
(2)
2) Install output gear (71) and snap ring (70).

2 Spline of gear: Grease (LM-G)
4. Assembly of HST motor 2 gear and bearing

assembly
1) Using push tool [22], press fit 2 bearings (66)
3) Using tool D2 and the press, press fit front to HST motor 2 gear (65).
bearing (69). a After press fitting the bearings, apply
a After press fitting the bearings, apply transfer oil to them and rotate them.
transfer oil to them and rotate them.
5. Installation of HST motor 2 gear and bearing

3. Installation of output shaft and gear assembly assembly
1) Place cover (67) on the gear and install out- 1) Install HST motor 2 gear and bearing assem-
put shaft and gear assembly (68) to the rear bly (64).
case.
2) Install the mounting bolts of cover (67).
a Check that cover (67) does not interfere
with the inside surface of the gear.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
WA200-5 30-57
(2)
6. Assembly of HST motor 1 gear and outer 8. Bearing and HST motor 1 gear
races 1) Using push tool [26] and the press, press fit
1) Install seal ring (85) to HST motor 1 gear bearing (56).
(52).
2 Seal ring: Grease (G2-LI)
2) Install spacer (55).
2) Install spacer (54) to HST motor 1 gear (52).

3) Using push tool [25], press fit 2 outer races
(53) to HST motor 1 gear (52).
3) Install HST motor 1 gear and outer races

(51).
4) Using push tool [27] and the press, press fit
bearing (50).
• Projection of bearing from shaft:
7. Installation of motor 1 gear and outer races
1.71 – 3.35mm
1) Install O-ring (82) to shaft (49).
2 O-ring: Grease (G2-LI)
30-58 WA200-5
(2)
9. Holder 10. Assembly of carrier assembly

1) Install seal rings (46) and (47) to holder (45). 1) Set planetary gear (43), bearing (44), and 2
2 Seal ring and O-ring: Grease (G2-LI)
thrust washers (42) to carrier (41) (at 3
places).
2) Install pinion shaft (39) to carrier (41), match-
ing their ball holes to each other, and then
install ball (40).
2) Install holder (45) and tighten the mounting

bolts.
a Set the hole 2 mm in diameter g on the
top of the holder horizontally [Set it at 90°
11. Installation of carrier assembly
to the hole 4.5 mm in diameter h on shaft
1) Install carrier assembly (38), matching it to
(49)].
3 Mounting bolt:
the dowel pin of the HST motor 1 gear.
88.2 – 107.8 Nm {9 – 11 kgm}
12. Assembly of HST motor 1 shaft and ring gear

assembly
1) Install bearing (37) to ring gear (32), and then
install snap ring (36).
WA200-5 30-59
(2)
2) Set ring gear (32) to HST motor 1 shaft (33). 5) Install snap ring (31).
Using push tool [28] and the press, press fit
bearing (37).
6) Install sun gear (30) and snap ring (29).
3) Install spacer (35) and set bearing (34).
7) Using tool [33], press fit bearing (27) to HST

motor 1 shaft (33).
4) Using push tool [29] and the press, press fit
bearing (34).
30-60 WA200-5
(2)
13. Installation of HST motor 1 shaft and ring gear 2) Install front case (63).
3 Mounting bolt:
1) Install HST motor 1 shaft and ring gear assem-
bly (28).
98 – 123 Nm {10 – 12.5 kgm}
14. Front case

a Use the front case and rear case as an 15. Clutch housing
assembly. 1) Install snap ring (57) to the front case.
a When installing the cases, match the match 2) Install clutch housing (26) and 3 pins (83).
marks on their tops to each other.
1) Apply gasket sealant to the rear case accord-
a Apply the gasket sealant to forcing screw
contact part a, similarly to the dimensions
for a bolt hole.
a Apply the gasket sealant so that dimen-
sions b and c will be the same respec-
tively.
a Apply the gasket sealant so that dimen-
sion e x dimension f will be 2 – 5 mm.
2 Gasket sealant:
ThreeBond 1207B or equivalent
WA200-5 30-61
(2)
16. Clutch discs, plates, and springs 2) Install the O-ring and piston (20).
1) Install end plate (25).
2) Install 4 discs (22), 4 wave springs (24), and

18. Belleville springs
5 plates (23).
1) Set the 1st one of 4 belleville springs (19)
a Soak the discs in clean transfer oil for at
with the white mark side down.
least 2 minutes before installing them.
2) Set the 2nd and 3rd belleville springs in the
opposite direction to the 1st one.
(2nd and 3rd ones do not have mark.)
3) Set the 4th belleville spring with the white
mark side up.
a When any belleville spring needs to be
replaced, replace all of the 4 springs as a
set.
17. Spacer and piston

1) Install the O-ring and spacer (21).
30-62 WA200-5
(2)
19. Cage 21. Hub

1) Install cage (18). 1) Turn over the transfer assembly and install
a Tighten the mounting bolts evenly and hub (17).
gradually. 2) Install snap ring (16).
2 Spline of output shaft:
• Installed load of belleville springs
(4-piece set): 21,500 N {2,190 kg}
3 Mounting bolt:
Lubricant containing molybdenum
disulfide (LM-P)
230 – 289 Nm {23.5 – 29.5 kgm}
22. Parking brake assembly

20. Operation test of transfer clutch 1) Install 2 dowel pins (85) from the parking
1) Using tool D5, apply air pressure to transfer brake assembly.
clutch disengagement port m.
a When the air pressure is applied, if the
transfer clutch is disengaged, it is operat-
ing normally.
• Clutch disengaging air pressure:
1.52 MPa {15.5 kg/cm2}
2) Install parking brake assembly (15).

a After the all internal teeth of the disc are
meshed with the spline and the clearance
between the parking brake housing and
transfer case is eliminated, tighten the
mounting bolts.
a If the mounting bolts are tightened while
there is clearance between the parking
brake housing and transfer case and the
internal teeth of the disc are shifted from
t he spli ne, the disc wil l be broken.
Accordingly, remove the dowel pins and
check securely in advance that there is
not clearance.
a Do not reuse the basket but replace it.
WA200-5 30-63
(2)
a Install the coupling after ADJUSTING 24. Adjusting pre-load on output shaft taper roller
PRE-LOAD ON OUTPUT SHAFT TAPER bearing
ROLLER BEARING. 1) Install cage (78) without inserting any shim.
3 Mounting bolt: 3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm} 4.80 ± 0.98 Nm {0.5 ± 0.1 kgm}
2) Rotate the output shaft 20 turns and check
the tightening torque of the mounting bolts
tightened in step 1).
a If the tightening torque has changed,
repeat steps 1) and 2), and then check
again.
3) If the tightening torque has not changed,
measure the clearances at 3 places j of cage
(78) and obtain average k.
a To confirm that the bearing is not leaning,
check that the dispersion of clearances at
3 places j is 0.15 mm or less. If the dis-
persion i s l arge, the beari ng is not
installed normally or there is another
cause. In this case, eliminate the cause
23. Cage assembly and reduce the dispersion to 0.15 mm or
1) Press fit outer race (79) to cage (78). less.
2) Using tools D3 and D4, press fit oil seal (77)
and dust seal (76) to cage (78).
2 Lips and clearances of oil seal and
dust seal:
Silicon grease
(ThreeBond 1855 or equivalent).
30-64 WA200-5
(2)
4) Calculate shim thickness t. 2) Install holder (58) and tighten the mounting
• Shim thickness t = Average of clearance bolt.
k + 0.15 mm to 0.20 mm
5) Insert selected shims (61) between cage (78)
and the front case.
6) Tighten the cage mounting bolts.
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
3) Install coupling (14) on the parking brake

side.
2 Spline of coupling: Lubricant contain-
ing molybdenum disulfide (LM-G)
7) Install holder (58) and the holder mounting

bolt to the output shaft.
8) Set torque wrench [30] to the holder mount-
ing bolt and measure the rotating torque of
the output shaft.
a Measure the rotating torque without install-
ing the front and rear couplings.
• Rotating torque of output shaft:
3.9 – 5.9 Nm {0.4 – 0.6 kgm}
26. Parking brake control cable

1) Install parking brake control cable (13b) along
with bracket (13c).
2) Connect hose (13a).
25. Coupling
1) Install coupling (59) on the cage side.
2 Spline of coupling:
Lubricant containing
molybdenum disulfide (LM-G)
WA200-5 30-65
(2)
27. Oil supply pipe 3) Connect hoses (7) through (10) to the HST
Install oil supply pipe (13). motors 1 and 2.
28. HST motor 29. Brake accumulator

1) Sling and install HST motor 2 (12). 1) Install brake accumulator and transfer oil filter
2 Spline of HST motor 2: Lubricant
bracket assembly (6) with 6 mounting bolts.
2) Connect clutch port hose (5) and ensure it
containing molybdenum disulfide
with a clamp.
(LM-G)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
2) Sling and install HST motor 1 (11).
a Do not apply LM-G to the spline of HST
motor (1).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
3) Connect wiring connectors T06 (1), T07 (2),

T10 (3), and T11 (4).
30-66 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
30. Speed sensor REMOVAL AND INSTALLATION OF

1) Install speed sensor (75).
PARKING BRAKE ASSEMBLY
REMOVAL
under the tires.
1. Drain the transfer oil.

6 Transfer case: 5.5 l

31. Refilling with oil.
Feed oil into the transfer case. 3. Disconnect rear drive shaft (2).
5Transfer case: 5.5 l

[*1]
4. Disconnect hoses (3) and (4) at the top and the

bottom of the oil cooler.
5. Remove the 4 mounting bolts for the mount

bracket, and remove oil cooler bracket assembly
(5).
WA200-5 30-67
(2)
6. Release the parking brake. 10. Remove the parking brake mounting bolts. Using
a Make sure the claw of the parking brake lever forcing screws [1], remove parking brake assem-
is at the lowest position. bly (10).
[*3]
7. Remove cotter pin (6) and pin (7) of the parking
brake cylinder.
[*2]
8. Disconnect transfer lubricating oil pump suction

hose (8) from the parking brake.
INSTALLATION
removal.
9. Remove coupling (9). [*1]

3 Rear drive shaft mounting bolt:
a In case oil leaks, receive it with a pan.
59 – 74 Nm {6.0 – 7.5 kgm}
way of the spider cap is fitted in the key way of
the mating yoke, and then tighten the mounting
bolts.
a When installing the rear drive shaft, check that
the lateral runout of the rear axle and transfer
from each other is less than 3 mm. If the runout
is 3 mm or larger, shift the transfer cushion and
transfer mount to reduce the runout.
[*2]
a Insert cotter pin (6) in pin (7), and then open it to
both sides by 180°.
a Check the tension of the parking brake control
cable. For details, see TESTING AND ADJUST-
ING, Testing and adjusting parking brake control
cable.
[*3]
a Using the guide bolt, install the parking brake
assembly.
3 Parking brake mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
• Refilling with oil (Transfer case)

5Transfer case: 5.5 l
30-68 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY 2. Plates, disc, and springs

1) Remove 2 clamping bolts (3) and 2 spacers
OF PARKING BRAKE ASSEMBLY (4).
a Since the spring tension is applied,
SPECIAL TOOLS loosen the 2 clamping bolts evenly.
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name

• 790-101-5311 • Plate 1
3
• 790-101-5221 • Grip 1
D • 01010-51225 • Bolt 1
793T-417-1120 Push tool t 1 Q
4 790-101-5221 Grip t 1
01010-81225 Bolt t 1
DISASSEMBLY 2) Remove 5 plates (5), 4 wave springs (6), and

4 discs (7).
1. Strainer
3. Cam plate
1) Remove cam plate (8).
2) Remove strainer (2).
WA200-5 30-69
(2)
4. Balls 6. Pin
1) Remove 6 balls (9). 1) Remove pin (12).
7. Dust seal and oil seal

1) Remove dust seal (13) and oil seal (14).
5. Lever
1) Remove the mounting bolt and lever (10).
8. Oil seal and bearings

1) Remove oil seal (15).
2) Remove 2 bearings (16) from parking brake
case (17).
2) Remove lever (11).
30-70 WA200-5
(2)
ASSEMBLY
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with transfer
oil (EO10-CD) before installing.
a Do not reuse the gasket but remove it completely.
1. Oil seal and bearings

1) Install 2 bearings (16) to parking brake case
(17).
2) Install oil seal (15).
2 Oil seal: Grease (G2-LI)
(Perform the work with the gasket removed.)
3. Pin
1) Install pin (12).
a Install the pin with the grooved part out-
ward.
a Check that dirt is not sticking to the ball
groove and inside of the housing.
2. Oil seal and dust seal

1) Using tools D3 and D4, press fit oil seal (14)
and dust seal (13).
2 Lips and clearances of oil seal and
dust seal: Silicon grease
(ThreeBond 1855 or equivalent).
4. Lever
1) Install levers (11) and (10).
WA200-5 30-71
(2)
a When installing levers (11) and (10),

match their match marks a and b.
3 Mounting bolt:
27 – 34 Nm {2.8 – 3.5 kgm}
a Move cam plate (8) several times so that

balls (9) will be fitted to grooves c of cam
plate (8).
a Check that the cam plate does not hitch
on the housing.
5. Balls
1) Install 6 balls (9).
a Check that dirt is not sticking to the balls.
7. Plates, disc, and springs

1) Install 4 discs (7), 4 wave springs (6), and 5
plates (5).
a Soak the discs in clean transfer oil for at
least 2 minutes before installing them.
a Check that dirt is not sticking to the discs
6. Cam plate
and plates.
1) Install cam plate (8).
a Check that dirt is not sticking to the ball
grooves, inside of parking brake housing,
cam plate, discs, and plates.
30-72 WA200-5
(2)
2) Using push tool [1], press plate (5) lightly with 2) Install the O-ring and cover (1).
a press and install 2 spacers (4) and 2 clamp-
3 Mounting bolt:
ing bolts (3).
a Take care not to press plate (5) too much
and not to damage it. 98 – 122.5 Nm {10 – 12.5 kgm}
a Press plate (5) until it is flush with the
parking brake case.
a Move the lever and check that it returns
normally.
3 Clamping bolt: Adhesive (LT-2)
3 Clamping bolt:
19.6 – 27.4 Nm {2.0 – 2.8 kgm}
8. Strainer
1) Install strainer (2).
WA200-5 30-73
(4)
DISASSEMBLY AND ASSEMBLY FRONT AXLE
REMOVAL AND INSTALLATION OF 3. Remove work equipment valve upper cover (2).
FRONT AXLE ASSEMBLY
REMOVAL
k Stop the machine on a level ground and set the
under the tires.
k Release the residual pressure in the brake accu-
mulator circuit. For details, see RELEASING
REMAINING PRESSURE IN HYDRAULIC CIR-
CUIT.
4. Disconnect wiring connector F14 (3).

1. Raise the chassis with the work equipment and
set stands [1] under the frame in front of the front 5. Disconnect brake hose (4).
wheels to float the front of the chassis.
6. Disconnect front drive shaft (5).

2. Lift off the front wheel (1). [*2]
[*1]
a Lift off the front wheel on the other side simi-
larly.
4 Front wheel (1 side): 210 kg
30-74 WA200-5
(4)
DISASSEMBLY AND ASSEMBLY REAR AXLE
7. Sling front axle assembly (6) temporarily and sup- REMOVAL AND INSTALLATION OF
port it on jack [2]. Remove the 4 mounting bolts
on both sides and front axle assembly (6).
REAR AXLE ASSEMBLY
[*3]
4 Front axle assembly: 530 kg
REMOVAL
under the tires.
k Release the residual pressure in the brake accu-
mulator circuit. For details, see RELEASING
REMAINING PRESSURE IN HYDRAULIC CIR-
CUIT.
1. Raise the chassis with the work equipment and

set stands [1] under the frame in front of the rear
wheels to float the rear of the chassis.
2. Support the counterweight on jack [2].
INSTALLATION 3. Set blocks [3] between top of each side of the

• Carry out installation in the reverse order to rear axle and the rear frame.
removal.
[*1]
3 Front wheel mounting bolt:
785 – 980 Nm{80 – 100 kgm}
[*2]
groove of the spider cap is fitted to the key groove
bolts.
3 Front drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*3]
3 Front axle mounting bolt:
785 – 980 Nm{80 – 100 kgm}
• Bleeding air
Bleed air from the brake system. For details, see
TESTING AND ADJUSTING, Bleeding air from
brake circuit.
WA200-5 30-75
(2)
4. Lift off rear wheel (1). 7. Remove cover (3a).

[*1]
a Lift off the front wheel on the other side simi- 8. Remove rear drive shaft (4).
larly. [*2]
4 Rear wheel (1 side): 210 kg
9. Remove the bolts and coupling (5).

[*3]
5. Disconnect brake hose (2) from the left inside of
a If the coupling is not removed, dust seal (9) is
the frame.
damaged easily in step 12.
6. Disconnect grease supply tube (3).

10. Secure support (6) and both sides of the rear axle
with lever block [2].
11. Sling rear axle assembly (7) temporarily, support

it on jack [3], and remove the mounting bolts of
support (6).
[*4]
30-76 WA200-5
(2)
INSTALLATION
removal.
[*1]
3 Rear wheel mounting bolt:
785 – 980 Nm{80 – 100 kgm}
[*2]
a Check that the radial runout of the rear axle from
the transfer in lateral direction is not larger than 3
mm. If it is larger than 3 mm, reduce it by moving
the transfer mount.
groove of the spider cap is fitted to the key groove
12. Pull out the rear axle assembly toward the rear of
the chassis and disconnect it from the rear frame
bolts.
3 Rear drive shaft mounting bolt:
assembly.
a Take care not to damage dust seal (9) of rear
frame (8). 59 – 74 Nm {6.0 – 7.5 kgm}
[*3]
2 Coupling mounting bolt: Adhesive (LT-2)
3 Coupling mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
[*4]
3 Support mounting bolt:
785 – 980 Nm{80 – 100 kgm}
• Bleeding air
Bleed air from the brake system. For details, see
TESTING AND ADJUSTING, Bleeding air from
brake circuit.
13. Lower the crane and jack [3] simultaneously to
remove rear axle assembly (7).
4 Rear axle assembly: 500 kg
WA200-5 30-77
(2)
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
DISASSEMBLY AND ASSEMBLY 3. Axle housing assembly

1) Sling axle housing assembly (1) temporarily
OF AXLE HOUSING ASSEMBLY and remove the housing mounting bolts.
a When removing both axle housing
SPECIAL TOOLS assemblies, make match marks on the
housings and differential case so that the
New/remodel
Necessity
housing assemblies will not be mistaken.
Symbol
Sketch
Q'ty
Part No. Part Name 2) Remove axle housing assembly (1).
793T-623-1170 Push tool t 1 Q

793T-422-1230 Push tool t 1 Q
1
793T-423-1110 Push tool t 1 Q
792T-446-1150 Push tool t 1 Q
H 01010-80860 Bolt t 1
2
01010-80860 Bolt t 1
793T-659-1110 Push tool t 1 Q
3
790-201-2750 Spacer t 1
4 793T-423-1150 Holder t 1 Q
3) Set axle housing assembly (1) with the plane-
tary carrier side up.
DISASSEMBLY
a The following photos and illustrations show the
front axle housing as an example.
1. Oil drain
6 Axle (Each of front and rear axles): 18 l
2. Axle assembly
1) Set the axle assembly on block [1].
a Set block [1] so that the axle assembly
will not lean when the housing assembly
on one side is removed.
4. Planetary carrier assembly

1) Remove axle shaft mounting bolt (2).
30-78 WA200-5
(2)
2) Remove planetary carrier assembly (3). 2) Hit the end of axle shaft (6) with copper ham-
mer [2] to drive it out.
3) Remove shims (4).

a Check the thickness and quantity of the 6. Axle shaft bearing
shims. a Do not heat the bearing to remove it or cut it
with gas.
1) When removing bearing (7) from axle shaft
(6), evenly push in part a around the oil seal
and sleeve (8) with a screwdriver toward the
flange.
2) Make clearance b at the contact part of bear-
ing (7) and sleeve (8a) to hitch the claws of
the puller.
5. Axle shaft
1) Sling axle housing assembly (5) about 20
mm.
3) Install bearing puller [3] to the bottom of the

bearing and fix it securely.
4) Install bearing puller [3] to clearance b.
WA200-5 30-79
(2)
5) Tighten the bolts of bearing puller [3] to 8. Planetary carrier

remove bearing (7). 1) Using push tool [6], drive in roll pin (15) of
6) Remove oil seal (8). planetary carrier (14) until it is in the range of
shaft (16).
a Take care not to drive in the roll pin too
deep.
7. Axle housing
1) Using puller [4], pull up ring gear (9) and 3
pins (10) evenly to remove them from axle
housing (11).
a Install spacer [5] to the bolt end of puller
[4] to adjust the height.
a Take care that the claws of the puller will
not come off the ring gear.
2) Remove outer races (12) and (13) from axle
housing (11).
2) Using push tool [7], push out shaft (16) with a

press.
30-80 WA200-5
(2)
3) Pull out roll pin (15) from the removed shaft ASSEMBLY
(16). 1. Axle housing and axle shaft
1) Press fit bearing outer races (12) and (13) to
axle housing (11).
4) Remove pinion gear (17), bearings (18), and

spacer (19) from planetary carrier (14).
2) Using tool H1, press fit seal (8) and bearing
(7) to axle shaft (6) simultaneously.
a Press fit the seal and bearing until oil seal
sleeve (8a) is flush with shaft end c, and
then check that there is not clearance
between oil seal sleeve (8a) and bearing
(7).
3) Install tool H2 under oil seal (8).

a Adjust tool H2 so that the top of tool H2
will lightly touch oil seal (8) and the clear-
ance will be even.
WA200-5 30-81
(4)
2. Axle shaft bearing 3. Selecting shims

1) Stand axle shaft (6) on the block and fix it 1) After bearings (7) and (20) are fitted well,
securely. measure the turning force of hole (d) of axle
2) Sling axle housing (11) vertically, and then housing (11).
lower it slowly. • Turning force
a Install the front axle, matching it to the oil (Not static friction, but dynamic friction)
seal, and insert the axle housing by utiliz- (Common to front and rear)
ing its weight. (Including seal resistance)
2 Fitting part of oil seal and bearing
14.7 - 44.1 N {1.5 - 4.5 kg}
(front axle): Axle oil
a After installing the housing, leave tool H2
installed until step 4).
3) Using tool H3, press fit bearing (20) to axle
shaft (6).
a Press fit the bearing, turning the axle
housing with the hand.
2 Outside of bearing: Axle oil
4) Remove tool H2 horizontally.
a Check that oil seal (8) does not lean.
a Fit the end face of axle housing (11) to
the flange of oil seal (8) (Reduce the
clearance to below 0.2 mm.)
a If the turning force is below the standard

value, press fit the bearings again and
perform the work in step 1).
a If the turning force exceeds the standard
value, adjust it according to following
steps 2) - 4).
30-82 WA200-5
(4)
2) Hold 2 parts of axle shaft and housing assem-

bly (5) and sling it by 20 - 30 mm, as you
installed the axle housing.
3) Rotating axle shaft (6), hit the flange with a
copper hammer in the direction of the arrow
several times to drive out axle shaft (6).
4) Adjust the turning force to the standard value
according to step 1).
4. Planetary carrier
1) Install spacer (19) in planetary carrier (14).
a Insert the spacer from g side of planetary
carrier (14) before installing gear (17).
2) Raise spacer (19), then install gear (17) and

bearings (18).
5) Install planetary carrier (14) to the spline of

axle shaft (6) without the gear and place tool
H4.
a Just place tool H4 on planetary carrier
(14). Do not tighten the bolt.
6) Using a depth micrometer, measure distance
(e) from the end of tool H4 to the end of the
axle shaft.
a Subtract thickness (t) of tool H4 from dis-
tance (e), and let the result be (e – t).
• Shim thickness = (e – t) +0.05
+0
mm
7) After determining the shim thickness, remove
planetary carrier (14).
WA200-5 30-83
(4)
3) Using push tool [8], press fit shaft (16) to 5. Ring gear
planetary carrier (14). 1) Install ring gear (9) to axle housing (11) and
a When press fitting, match pin holes f. insert 3 pins (10).
2 Shaft: Axle oil
a Match the pin holes of the housing and
ring gear.
a Matching the holes of shaft (16) and roll

6. Planetary carrier assembly
pin (15), drive roll pin (15) so that it will be
1) Install shim (4) selected in steps 3.-8) to the
flush with planetary carrier (14).
end of the axle shaft.
4) Hit the end of shaft (16) and the differential

2) Sling and install planetary carrier assembly
side of gear (17) lightly to push back the
(3).
k When installing the planetary carrier, take
bearing and check that the gear rotates
smoothly.
care not to catch your fingers in the gear.
30-84 WA200-5
(2)
3) Tighten mounting bolt (2).

a Degrease and clean the bolt hole of the
axle shaft and mounting bolt.
3 Mounting bolt:
490 – 608Nm {50 – 62kgm}
a Clean the shaft end and planetary carrier
spline thoroughly before installing.
7. Axle housing assembly

1) Degrease and clean the mating faces of the
axle housing and differential housing and
apply gasket sealant all over them.
2 Mating faces of housings: Gasket
sealant (LOCTITE 515 or equiva-
lent)
2) Sling axle housing assembly (1) horizontally
and install it carefully, matching it to the spline
4) Install dial gauge [9] to axle housing (11) and
grooves of the sun gear shaft.
measure the end play of the planetary carrier.
• End play of planetary carrier: 0 – 0.1 mm
3) Tighten the axle housing mounting bolts in

the diagonal order.
3 Mounting bolt:
5) Rotate axle housing (11) 10 or more turns to
fit it. Then, using push-pull gauge [10], mea-
sure the starting torque at the mounting bolt 245 – 309 Nm {25.0 – 31.5 kgm}
hole of the axle housing assembly.
• Starting effort • Refilling with oil (Axle housing)
(Common to front and rear) Tighten the drain plug and add oil through the
(Including resistance of seal and plane- oil filler to the specified level, and then check
tary carrier) the oil level.
5Axle (Each of front and rear): 18 l
34.3 - 63.7 N {3.5 - 6.5 kgm}
a If the starting torque exceeds the above
range, adjust it again, referring to 3.
Adjusting end play above.
WA200-5 30-85
(4)
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY 2) Remove 2 thrust washers (5) and thrust plate
(6).
OF DIFFERENTIAL ASSEMBLY 3) Lift off rear axle support (7).
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name

6 797-101-1131 Wrench t 1
7 793-615-1100 Wrench t 1
8 793T-422-1220 Push tool t 1 Q
9 797T-423-1320 Push tool t 1 Q
H
10 792T-423-1130 Push tool t 1 Q
11 793-520-2202 Installer q 3
4) Remove packing (8) and bushing (9) from
13 790-190-1500 Pump assembly t 1 rear axle support (7).
14 799-101-5210 Nipple t 1
15 793T-422-1611 Plate t 1 Q
DISASSEMBLY
1. Oil drain
6 Axle (Each of front and rear axles): 18 l
2. Brake pipe
1) Remove brake tube and hose assembly (2).
3. Rear axle support (Only rear axle)

1) Remove grease tube (3).
a Check the thickness and quantity of the 5. Axle oil temperature sensor (Only front axle)
shims. 1) Remove cover (10).
2) Remove axle oil temperature sensor (11).
4. Axle housing (The shape of the cover in the figure is differ-
1) Remove both axle housings (1). For details, ent more or less from the shape of the actual
see DISASSEMBLY AND ASSEMBLY OF cover.)
AXLE HOUSING.
30-86 WA200-5
(4)
6. Differential assembly 2) Remove 2 inside hexagon bolts (15) and

1) Place and stabilize differential assemblies outer plate (16).
(12) and (13) on blocks.
a (12): Front differential
(13): Rear differential
3) Remove 2 discs (17), 1 plate (18), and 4

wave springs (19).
4) Using tool H5, supply air to the brake port to

7. Brake remove piston (20).
a Remove both brakes according to the follow-
ing procedure.
1) Remove sun gear shafts (14).
WA200-5 30-87
(2)
5) Remove seal (87) from piston (20). 11. Disassembly of long cage assembly (Only
front differential)
1) Remove oil seal (25).
8. Top cover
1) Remove the mounting bolts, and then remove
top cover (21), using forcing screws [2].
2) Using push tool [3], push shaft (26) with a
press to remove it from long cage (27).
9. Slack adjuster
1) Remove 2 slack adjusters (22).
3) Remove snap ring (28) and ring (29), and

then remove bearing (30) from long cage
10. Removal of long cage assembly
(27).
(Only front differential)
1) Remove coupling (23).
a Remove the coupling protector only when
it needs to be removed.
2) Remove long cage assembly (24).
30-88 WA200-5
(2)
12. Removal of front cage assembly 13. Removal of rear cage assembly
(For front differential) (For rear differential)
1) Using tool H6, loosen nut (31) before remov- 1) Before removing cage assembly, loosen the
ing the cage assembly. mounting bolts of coupling (41).
screw [5], remove rear cage assembly (42).
shims.

screw [4], remove front cage assembly (32).
shims.
14. Disassembly of front cage assembly
(For front differential)
1) Remove nut (31) and holder (33).
2) Using push tool [6], push out pinion gear

assembly (81) with a press.
WA200-5 30-89
(2)
3) Remove spacer (34) and bearing (35) from 2) Remove oil seal (82).
pinion gear (36).
3) For the further disassembly procedure for the

4) Remove bearing (37), outer races (38) and
rear cage assembly, see steps 2) - 4) in 14
(39) from cage (40).
Disassembly of front cage assembly shown
above.
16. Bearing carrier

1) Sling differential carrier assembly (43) tempo-
rarily.
15. Disassembly of rear cage assembly

(For rear differential)
1) Remove coupling (41).
a Remove the coupling protector only when
it needs to be removed.
2) Remove the mounting bolts and both bearing

carriers (44), using forcing screws [7].
a Identify the right and left bearing carriers
to avoid confusion.
shims.
30-90 WA200-5
(2)
18. Diassembly of standard differential carrier

assembly
a When keeping the parts on both sides, make
marks on them so that they will not be mis-
taken.
1) Remove 12 mounting bolts (46).
a Do not remove 4 mounting bolts (47) of
spider shaft a.
3) Remove seal (84) and ring (85) from each

bearing carrier (44).
4) Remove outer race (86).
2) Remove case and bearing assembly (48).

a Before disconnecting the case and bear-
ing assembly, make match marks on it
and the case.
17. Removal of differential carrier assembly

1) Lift off differential carrier assembly (43) from
differential housing (45).
a Take care that the sling will not come off.
a Do not damage the bearing of the differ-
ential carrier assembly by hitting it
against the differential case.
3) Using puller [8], remove bearing (49) from

case (50).
WA200-5 30-91
(2)
4) Remove washer (51) and side gear (52). 7) Remove side gear (57).
5) Remove pinion gear assembly (53). 8) Remove washer (58).
6) Remove 4 spherical washers (54) and 4 pin- 9) Remove 4 mounting bolts, and then remove
ion gears (55) from spider shaft (56). bevel gear and bearing assembly (59) from
case (60).
30-92 WA200-5
(2)
10) Using puller [9], remove bearing (61) from 2) Using push tool [10], remove bearing (64)
bevel gear (62). from bevel gear (65).
19. Disassembly of limited-slip differential assem- 3) Remove washer (66).

bly (If equipped)
a If the machine is equipped with the limited-
slip differential assembly, disassemble it
according to the following procedure.
a When keeping the parts on both sides, make
marks on them so that they will not be mis-
taken.
1) Remove the 16 mounting bolts and bevel
gear and bearing assembly (63)
a Before disconnecting the bevel gear and
bearing assembly, make match marks on
it and the case.
4) Remove 2 plates (67) and 2 discs (68).
WA200-5 30-93
(2)
5) Remove pressure ring (69). 8) Remove 4 pinion gears (72) from spider shaft
a Insert a finger in the hole on the side of (73).
the case to raise the pressure ring.
9) Remove side gear (74).

6) Remove side gear (70).
10) Remove pressure ring (75).

7) Remove pinion gear assembly (71).
30-94 WA200-5
(2)
11) Remove 2 plates (76) and 2 discs (77). ASSEMBLY

a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with axle oil
before installing.
1. Assembly of limited-slip differential assembly

(If equipped)
1) Install bearing (79) to case (80).
a Install the bearing by shrink fit at temper-
ature below 100°C or by using push tool
[12] and a press.
12) Remove washer (78).
2) Install washer (78).

a Install the washer with the dimpled side in
(up).
13) Using push tool [11], remove bearing (79)

from case (80).
WA200-5 30-95
(2)
3) Install 2 discs (77) and 2 plates (76). 6) Install 4 pinion gears (72) to spider shaft (73).
2 Before installing the discs and plates,
soak them in the following oils.
• Front differential (standard and limited-
slip differential) AXO80
• Rear differential
(Standard differential): AXO80 or AXO75
(Limited-slip differential): AXO80 or
FUCHS (TITAN HYDRA ZF 20W-40 MC)
7) Install pinion gear assembly (71).
4) Install pressure ring (75).
8) Install side gear (70).

a Referring to step 10) below, match the
cut of the inside of the disc to the oil
groove of the side gear.
30-96 WA200-5
(2)
9) Install pressure ring (69). 11) Selection of thickness of plate

i) Using depth gauge [12], measure dis-
tance d between case (80) and plate
(67).
a Distance d is the clearance between
the case and plate.
ii) Select the thickness of the plate so that
distance d will be 0.2 – 0.6 mm.
a Replace the plates on both sides so
that their thickness (total of 2 pieces)
will be the same and assemble them
according to the procedure 3) after
shown above.
• Varieties of plate thickness:
3.0 mm, 3.1 mm
10) Install 2 discs (68) and 2 plates (67).

a Match cut b of the inside of the disc to oil
groove c of the side gear.
2 Before installing the discs and plates,
soak them in the following oils.
• Front differential (standard and lim-
ited-slip differential) AXO80
• Rear differential
(Standard differential): AXO80 or
AXO75
(Limited-slip differential): AXO80 or
FUCHS (TITAN HYDRA ZF 20W-40
MC)
12) Install bearing (64) to bevel gear (65).
ature below 100°C or by using push tool
[12] and a press.
WA200-5 30-97
(2)
13) Install washer (66) to the back side of the 15) Adjust the clearance of the side gear in the
bevel gear. axial direction.
a Install the washer with the dimpled side i) Measure clearance e between the side
toward side gear. gear and washer through the shaft holes
a When installing the washer, apply grease on both sides of the limited-slip differen-
thinly to it so that it will stuck to the bevel tial.
gear. • Clearance e:
0.13 – 0.36 mm (on both sides)
a If the clearance is out of the standard
range, replace the washer with new one.
14) Install bevel gear and bearing assembly (63).

a Match the match marks made when the
assembly was removed.
16) Measure the no-load operation torque.
i) Install sun gear shafts (14) to both sides
3 Mounting bolt:
of limited-slip differential assembly (83).
ii) Fix the sun gear shaft on one side and
245 – 309 Nm {25 – 31.5 kgm}
install tool H7 to the sun gear shaft on the
other side.
iii) Install torque wrench (13) to tool H7 and
measure the no-load operation torque.
a When measuring, let the case rotate
freely.
• No-load operation torque:
Max. 10 Nm {Max. 1.0 kgm}
• If the no-load operation torque exceeds
the standard value, disassemble the lim-
ited-slip differential again and perform 11)
Selection of thickness of plate and 15)
Adjust the clearance of the side gear in
the axial direction.
30-98 WA200-5
(2)
2. Assembly of standard differential carrier 3) Install washer (58).

assembly a Install the washer with the dimpled side
1) Install bearing (61) to bevel gear (62). up (facing to side gear).
ature below 100 °C or by using push tool
[14] and a press.
2) Install bevel gear and bearing assembly (59)

to case (60) with the 4 mounting bolts.
a Install the mounting bolts to the 4 places
of the spider shaft.
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
5) Install 4 pinion gears (55) and 4 spherical

bushings (54) to spider shaft (56).
WA200-5 30-99
(2)
6) Install pinion gear assembly (53). 9) Install washer (51) to case and bearing
assembly (48).
a Install the washer with the dimpled side
up (toward the side gear).
a When installing the washer, apply grease
thinly to it so that it will stuck to the case.
10) Install case and bearing assembly (48).

a Turn over the assembly and tighten the
mounting bolts.
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
8) Install bearing (49) to case (50).

ature below 100°C or by using puller [15]
and a press.
30-100 WA200-5
(2)
3. Installation of differential assembly

1) Sling differential carrier assembly (43) and
set it to the mounting section of differential
case (45).
a Take care that the sling will not come off.
a Do not damage the bearing of the differ-
ential carrier assembly by hitting it
against the differential case.
4) Using push-pull gauge [17], measure the

starting torque of the bevel gear in the tan-
gential direction.
• Starting torque: 8.8 – 20.6 N {0.9 – 2.1 kg}
a If the starting torque is out of the standard
range, adjust it by increasing or decreas-
ing the shim thickness.
• Varieties of shim thickness:
4. Bearing carrier 0.05mm, 0.2 mm, 0.3mm, 0.8mm
1) Install outer race (86). a Limit the shim thickness after the adjust-
2) Install ring (85) and seal (84) to bearing car- ment to 0.5 – 1.35 mm on each side.
rier (44).
5. Assembly of front cage assembly

3) Using guide bolt [16], install shim (87) and (For front differential)
both bearing carriers (44). 1) Install outer races (39) and (38) to cage (40).
a Install the shims of the thickness and
quantity checked when disassembled to
each bearing carrier.
a Turning the bevel gear, tighten the
mounting bolts.
2 Bearing: Differential oil
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
WA200-5 30-101
(2)
2) Install bearing (35) to pinion gear (36).

ature below 100 °C or by using tool H8
and a press.
3) Install spacer (34) to pinion gear (36).
8) Apply axle oil to the bearing and rotate the

cage several turns to spread the axle oil to
every part of the bearing, and then measure
the following.
2 Bearing: Axle oil
4) Stand pinion gear assembly (81) and install
cage assembly (88). •End play: 0 - 0.162 mm
5) Install bearing (37) to pinion gear assembly •Starting torque at cage mounting hole A:
(81). 0 - 60.8 N {0 - 6.2 kg}
a Install the bearing by shrink fit at temper- a If the cage is heavy to rotate, replace the
ature below 100°C or by using tool H9 bearing, and then check the starting
and a press. torque again.
6. Assembly of rear cage assembly

1) Referring to 5 Assembly of front cage assem-
bly, Steps 1) - 5), assemble the rear cage
assembly.
2) Apply axle oil to the bearing and rotate the
cage several turns to spread the axle oil to
every part of the bearing.
2 Bearing: Axle oil
3) Install coupling (41).
2 Contact surfaces of coupling and
beari ng: Lu bri cant co ntai ni ng
molybdenum disulfide (LM-G or
LM-P)
3 Mounting bolt:
6) Install holder (33) and nut (31).
a Replace nut (31) with new one.
7) Using tool H6 (See 12. REMOVAL OF 245 - 309 Nm {25.0 - 31.5 kgm}
FRONT CAGE ASSEMBLY), tighten nut (31)
to the specified torque.
a Secure assembly by gripping the outside
of the pinion gear in a vise.
3 Mounting nut:
441 - 539 Nm {45 - 55 kgm}
30-102 WA200-5
(4)
4) Rotate the cage several turns to spread the

axle oil to every part of the bearing, and then
measure the following.
• End play: 0 - 0.162 mm
• Starting torque at cage mounting hole A:
0 - 60.8 N {0 - 6.2 kg}
a If the cage is heavy to rotate, replace the
bearing, and then check the starting
torque again.
5) Remove coupling (41). Using tool H10, press
fit oil seal (82).
2 Oil seal: Grease (G2-LI)
8. Installation of rear cage assembly

1) Install guide bolt [19] to the differential case
assembly, and then install shim (90), O-ring,
and rear cage assembly (42).
a For the adjustment of the shims and tight-
ening torque, see 7. Installation of front
cage assembly.
6) Install coupling (41).

3 Mounting bolt:
245 - 309 Nm {25.0 - 31.5 kgm}
7. Installation of front cage assembly (For front

differential)
1) Install guide bolt [19] to the differential case
assembly, and then install shim (89), O-ring, 9. Adjusting backlash
and front cage assembly (32). 1) Measure the backlash of the bevel gear with
a Install the shims of the thickness and dial gauge [20].
quantity checked when disassembled to • Reference value of backlash:
each bearing carrier. 0.20 – 0.33mm
a Install the shims with the thinnest one on a Measure the backlash at 3 places on the
the cage side. periphery of the bevel gear and check
• Adjustment allowance of shims: that the dispersion of the measured val-
0.50 – 1.23 mm ues is 0.1 mm or less.
0.05mm, 0.2 mm, 0.3mm, 0.6mm
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
WA200-5 30-103
(4)
10. Testing tooth contact

1) Apply red lead thinly to the surfaces of the
bevel gear teeth and turn the bevel gear in
the forward and reverse directions, then
check the tooth contact pattern on the bevel
gear.
a The center of the tooth contact must be
as follows.
• Middle of tooth height
• Point on tooth at which distance of x
from small end c is 22 ± 3 mm
a Width y of the tooth contact must be 28 ±
3 mm
a Check that there is not a strong contact at
tip A, bottom B, small end C, or large end
2) If the measured backlash is out of the stan- D.
dard range, adjust it by moving a part of the
shims on either side to the opposite side.
a Do not change the total thickness of the
shims on both sides.
a If the backlash is insufficient, move a part
of shims g to shims f. (Move the bevel
gear in direction A.)
a If the backlash is too large, move a part
of shims f to shims g. (Move the bevel
gear in direction B.)
11. Adjusting tooth contact

1) If the tooth contact pattern is not proper,
adjust the tooth contact.
a Adjust the tooth contact by increasing or
decreasing the shims on both sides of the
bearing carrier (to move the bevel gear)
and the shims of the cage assembly (to
move the bevel pinion).
a After adjusting the tooth contact, check
the backlash again.
2) If the bevel pinion is too far from the bevel
gear, the tooth contact pattern is as follows.
In this case, adjust the tooth contact accord-
• Decrease the shims of the cage assem-
bly (on the bevel pinion side) to move the
cage assembly in the direction C.
• Adjust the shims on both sides of the
bearing carrier to move bevel gear in the
direction of D far from the bevel pinion.
shims on both sides of the bearing car-
rier.
30-104 WA200-5
(2)
3) If the bevel pinion is too close to the bevel 5) If the bevel gear is too far from the bevel pin-
gear, the tooth contact pattern is as follows. ion, the tooth contact pattern is as follows.
In this case, adjust the tooth contact accord- In this case, adjust the tooth contact accord-
ing to the following procedure. ing to the following procedure.
• Increase the shims of the cage assembly • Increase the shims of the cage assembly
(on the bevel pinion side) to move the (on the bevel pinion side) to move the
cage assembly in the direction E. cage assembly in the direction E.
• Adjust the shims on both sides of the • Adjust the shims on both sides of the
bearing carrier to move bevel gear in the bearing carrier to move bevel gear in the
direction of F close to the bevel pinion. direction of F close to the bevel pinion.
a Do not change the total thickness of the a Do not change the total thickness of the
shims on both sides of the bearing car- shims on both sides of the bearing car-
rier. rier.
4) If the bevel gear is too close to the bevel pin-

ion, the tooth contact pattern is as follows.
In this case, adjust the tooth contact accord-
• Decrease the shims of the cage assem-
bly (on the bevel pinion side) to move the
cage assembly in the direction C.
• Adjust the shims on both sides of the
bearing carrier to move bevel gear in the
direction of D far from the bevel pinion.
shims on both sides of the bearing car-
rier.
WA200-5 30-105
(2)
12. Brake 3) Install 1 disc (17A), 1 disc (17B), 1 plate (18),

a Install both brakes according to the same pro- 2 wave springs (19A), and 2 wave springs
cedure. (19B).
1) Install seal (87) to piston (20). a Install these parts in order of (19A),
(17A), (18), (19B), and (17B).
a Pile up the 2 springs and match their cuts
to each other, and then install them so
that their cuts will be in the range marked
with a in the brake oil port.
2 Thinly apply differential oil to the pis-

ton and piston mounting section.
2) Using tool H11, press fit piston (20) evenly.
a Press fit the piston until it touches the
housing.
a Do not hit the piston with a plastic ham-
mer, etc. to press fit it. (If it is press fitted
so, it and its O-ring will be damaged.)
4) Install outer plate (16) and install 2 inside

hexagon bolts (15).
30-106 WA200-5
(4)
5) Install sun gear shaft (14).
3) Perform the low-pressure oil leakage test.

6) Install bleeder screw (13). a Operate pump H13 and heighten the
7) Install tool H15. pressure to 98 kPa {1 kg/cm2}.
a You may install tool H15 when checking a Leave the brake system for 5 minutes
for brake oil leakage. and check that the pressure does not
8) Set plate [28] (tool H11 or equivalent). lower at all from 98 kPa {1 kg/cm2}.
Using tool H5, supply air into the brake oil a If the oil leaks (the pressure lowers more
port so that the piston will move smoothly. than the specification), remove the brake
k If the air is supplied without setting the
piston and check the seals, etc. for dam-
age.
plate, the piston will jump out and will be
a If the hose is moved while the pressure is
dangerous.
meas ur ed, the press ure fluctuates.
Accordingly, do not move the hose.
4) Perform the high-pressure oil leakage test.
a If the low-pressure oil does not leak,
operate pump H13 and heighten the
pressure to 4,410 kPa {45 kg/cm2}.
a Turn the coupling and check that the
shaft on the test side does not turn.
a Leave the brake system for 5 minutes
and check that the pressure does not
lower more than 98 kPa {1 kg/cm2} from
4,410 kPa {45 kg/cm2}.
a If the oil leaks (the pressure lowers more
than the specification), remove the brake
piston and check the seals, etc. for dam-
age.
13. Check for brake oil leakage a If the hose is moved while the pressure is
1) Keep plate [28] (tool H11 or equivalent) set.
k If the brake oil is checked for leakage
meas ur ed, the press ure fluctuates.
Accordingly, do not move the hose.
without setting the plate, the piston will 5) Remove pump H13, nipple H14, tool H15,
jump out and will be dangerous. and plate [28] (tool H11 or equivalent), and
then perform the test on the opposite side.
2) Install tool H15, nipple H14, and pump H13 to
the brake port, and then bleed air from the
brake system through the bleeder.
a Bleed air by operating pump H13.
WA200-5 30-107
(4)
14. Slack adjuster 17. Disassembly of long cage assembly (Only

1) Install 2 slack adjusters (22). front differential)
a Take care that the O-rings will not come 1) Using push tool [21], press fit bearing (30) to
off. shaft (26) with a press.
3 Mounting bolt:
a Direct the shield side of the bearing
down.
98 - 122.5 Nm {10 - 12.5 kgm}
2) Using push tool [22], press fit shaft and bear-
ing assembly (91) to long cage (27).
15. Upper cover
1) Remove bleeder screw (13) temporarily and
install upper cover (21).
2 Cover mating face:
Adhesive (LOCTITE 515 or equivalent)
3 Mounting bolt:
98 - 122.5 Nm {10 - 12.5 kgm}
2) Install bleeder screw (13).
3) Install ring (29) and snap ring (28).
16. Axle oil temperature sensor (Only front axle)

1) Install axle oil temperature sensor (11).
2 Threads: Gasket sealant (LG-5)
3 Axle oil temperature sensor:
29.4 – 49 Nm{3 – 5 kgm}
2) Install cover (10).
3 Mounting bolt:
4) Using tool H10, press fit oil seal (25).
98 – 122.5 Nm {10 – 12.5 kgm} 2 Oil seal: Grease (G2-LI)
30-108 WA200-5
(4)
18. Installation of long cage assembly 20. Rear axle support

1) Sling and install long cage assembly (24). 1) Install bushing (9) and packing (8) to rear
3 Mounting bolt:
axle support (7).
a Install the bushing with the chamfered
98 – 123 Nm {10 – 12.5 kgm}
part on the axle side and the slit at the
2) Install coupling (23). side position.
2 Contact surfaces of coupling and
a Install the packing with the lip on the out-
side of the rear axle support (on the axle
bearing:
side).
Lubricant containing molybde-
num disulfide (LM-G) or (LM-P)
3 Mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
2) Sling and install rear axle support (7).

3) Install thrust plate (6) and 2 thrust washers
(5).
a Clean the mating faces of the thrust plate
and thrust washer thoroughly.
a Insert a feeler gauge all round the mating
19. Axle housing faces of the thrust plat e and thrust
1) Sling and install right and left axle housings washer to check that there is not a clear-
(1). For details, see Disassembly and ance.
2 Periphery of pivot mounting part:
assembly of axle housing.
Grease (G2-LI)
2 Mounting bolt:
Adhesive (LOCTITE 262)
3 Mounting bolt:
93.1 – 122.5 Nm {9.5 – 12.5 kgm}
2) Install the brake tube assembly.
WA200-5 30-109
(4)
21. Adjust the shim of cover (trunnion cap) (4). 2) Measure dimension m between rear axle
1) Measure dimension k of cover (4) with depth support (7) and thrust washer (5) with depth
micrometer [23] at 4 places on the diagonal micrometer [23] at 4 places on the diagonal
lines and obtain the average. lines and obtain the average.
a Clean the contact face of the depth a Clean the contact face of the depth
micrometer thoroughly. micrometer thoroughly.
• Standard average value k: • Standard average value m (Reference):
19.85 – 20.0 mm 19.65 – 20.0 mm
3) Calculate shim thickness t.

Shim thickness t = m – k
a Decide the number of the shims by the
calculated shim thickness and the follow-
ing table.
• Shim thickness (1 piece): 0.2 mm
Shim thickness (t) Number of shims
0 – 0.07 mm 1
0.08 – 0.27 mm 2
0.28 – 0.47 mm 3
30-110 WA200-5
(4)
4) Install selected shim (92), and then install

cover (4) again.
2 Cover: Grease (G2-LI)
3 Mounting bolt:
93.1 – 122.5 Nm {9.5 – 12.5 kgm}
22. Axle housing

1) Install both axle housings (1). For details, see
Disassembly and assembly of axle housing
assembly.
23. Grease tube and brake piping

1) Install grease tube (3).
2) Install brake tube and hose assembly (2).
• Refilling with oil (Axle housing)

Tighten the drain plug and add oil through the oil
filler to the specified level.
3 Drain plug:
127.4 – 176.4 Nm {13 – 18 kgm}
3 Oil filler plug:
93.1 – 122.5 Nm {9.5 – 12.5 kgm}
5Axle (Each of front and rear axles): 18 l
WA200-5 30-110-1
(4)
DISASSEMBLY AND ASSEMBLY HST PUMP AND 4-GEAR PUMP
REMOVAL AND INSTALLATION OF 5. Disconnect the following tubes and hoses.

• (3): Hose between accumulator charge valve
HST PUMP AND 4-GEAR PUMP port P and brake pump
ASSEMBLY • (4): Hose between accumulator charge valve
port A and fan motor
REMOVAL • (5): Hose between HST pump port Y and
steering pump
• (6): HST pump port T2 hose
• (7): HST pump port G hose
• (8): Brake valve return hose
under the tires.
hydraulic tank.
nal of the battery.
1. Drain the hydraulic oil.

6 Hydraulic tank: 58 l
2. Remove the operator's cab assembly. For details,

see Removal and installation of operator's cab
assembly. • (9): Transfer lubricating oil pump suction
hose
3. Remove rubber (1). • (10) (11): Work equipment suction hose
• (12): Clutch solenoid valve return hose
• (13): Steering pump suction tube
• (14): Steering pump hose
4. Disconnect wiring connectors T01 (2).
WA200-5 30-111
(2)
• (15): Brake and fan pump discharge hose • (22): HST pump port A discharge tube
• (16): Transfer lubricating hose • (23): HST pump port B discharge tube
[*1]
• (17): 4 HST pump discharge hoses

• (18): HST pump suction hose 6. Sling HST pump and 4-gear pump assembly (24)
• (19): HST pump port Fa hose temporarily, and then remove its 6 mounting bolts
• (20): HST pump port Fe hose and it.
Mounting bolt M12: 4, Mounting bolt M16: 2
[*2]
4 HST pump and 4-gear pump assembly:
110 kg
• (21): Work equipment pump discharge hose
30-112 WA200-5
(2)
INSTALLATION • Refilling with oil (Hydraulic tank)

• Carry out installation in the reverse order to Add oil through the oil filler to the specified level.
removal. Run the engine to circulate the oil through the
5Hydraulic tank: 58 l
[*1]
3 U-clamp of tube (12):
10 – 26 Nm {1.1 – 2.7 kgm}
[*2]
2 Mating face of pump: Gasket sealant (LG-6)
3 Mounting bolt:
M12 bolt: 98 – 123 Nm {10 – 12.5 kgm}
M16 bolt: 245 – 309 Nm {25.0 – 31.5 kgm}
1. If boss (25) was removed from the HST pump

assembly, install it according to the following pro-
cedure.
a Install boss (25) so that it will be flush with the
shaft end of pump (26).
• Level difference between boss and pump
shaft end: Max. 0.5 mm
2. Tighten mounting bolt (27) of boss (25).

3 Mounting bolt: 86 Nm {8.8 kgm}
WA200-5 30-113
(2)
DISASSEMBLY AND ASSEMBLY HST MOTOR 1
REMOVAL AND INSTALLATION OF 4. Disconnect port T1 hose (4) and port T2 hose (5).
HST MOTOR 1 ASSEMBLY 5. Disconnect port A hose (6) and port B hose (7).
REMOVAL
under the tires.
hydraulic tank.
nal of the battery.
6. Support motor 1 assembly (8) with block [2]

6
placed on transmission jack [1] and remove 4
Hydraulic tank: 58 l motor 1 mounting bolts.
[*2]
side. 7. Supporting motor 1 assembly (8) with the hand,
[*1] lower transmission jack [1] gradually to remove
motor 1 assembly (8).
4 Motor 1 assembly: 35 kg
3. Disconnect wiring connectors T06 (2) and T11 (3)

from motor 1.
30-114 WA200-5
(2)
INSTALLATION REMOVAL AND INSTALLATION OF

removal.
HST MOTOR 2 ASSEMBLY
REMOVAL
[*1]
59 – 74 Nm {6.0 – 7.5 kgm}
[*2] engine, apply the parking brake, and put chocks

3 Motor 1 assembly mounting bolt: under the tires.
98 – 123 Nm {10 – 12.5 kgm} k Slowly loosen the oil filler cap of the hydraulic
• Refilling with oil (Hydraulic tank) hydraulic tank.
system. Then, check the oil level again. nal of the battery.
5Hydraulic tank: 58 l
6 Hydraulic tank: 58 l

side.
[*1]
3. Disconnect wiring connectors T07 (2) and T10 (3)

from motor 2.
WA200-5 30-115
(2)
4. Disconnect port T1 hose (4) and port T2 hose (5). INSTALLATION

5. Disconnect port A hose (6) and port B hose (7). removal.
[*1]
59 – 74 Nm {6.0 – 7.5 kgm}
[*2]
3 Motor 2 assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}

6. Support motor 2 assembly (8) with block [2] 5Hydraulic tank: 58 l
placed on transmission jack [1] and remove 4
motor 1 mounting bolts.
[*2]
7. Supporting motor 2 assembly (8) with the hand,

lower transmission jack [1] gradually to remove
motor 2 assembly (8).
4 Motor 2 assembly: 35 kg
30-116 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CONTROL VALVE
REMOVAL AND INSTALLATION OF 3. Disconnect the following hoses and tubes.

[*1]
WORK EQUIPMENT CONTROL a Mark all the hoses and tubes with tags to pre-
VALVE ASSEMBLY vent mistakes in the mounting position when
installing.
REMOVAL a Since oil will leak through the disconnected
k Stop the machine on a level ground and, apply
hoses and tubes, prepare oil receivers.
• (2) (3): Port P hose
the parking brake, and put chocks under the tires.
• (4) (5): Port T hose
• (6): Port A1 hose
1. Bend the chassis to the left and raise the lift arm • (7): Port B1 hose
and dump the bucket. Then, support the lift arm • (8): Port A2 tube
with block [1] and hydraulic jack [2], setting them • (9): Port B2 tube
flush with each other. • (10): Bucket DUMP PPC hose
k Support the lift arm securely.
• (11): Bucket TILT PPC hose
k Stop the engine, and then slowly loosen the

• (12): Lift arm LOWER PPC hose
• (13): Lift arm RAISE PPC hose
oil filler cap of the hydraulic tank to release • (14): PULL PPC hose (WA200PT-5)
the residual pressure in the hydraulic tank. • (15): PUSH PPC hose (WA200PT-5)
k Operate the work equipment control lever 2 –
3 times to release the residual pressure in the
work equipment circuit.
2. Remove the work equipment valve upper cover

(1).
WA200-5 30-117
(4)
DISASSEMBLY AND ASSEMBLY TRAVEL DAMPER VALVE
4. Loosen 2 lower bracket mounting bolts (16) and REMOVAL AND INSTALLATION OF
remove 1 upper bracket mounting bolt (17).
a Just loosen 2 lower bracket mounting bolts
TRAVEL DAMPER VALVE
(16). Do not remove them. ASSEMBLY
5. Remove work equipment control valve assembly REMOVAL
k Stop the machine on a level ground and, apply
(18).
the parking brake, and put chocks under the tires.
nal of the battery.
1. Bend the chassis to the right and raise the lift arm
and dump the bucket. Then, support the lift arm
with block [1] and hydraulic jack [2], setting them
flush with each other.
k Support the lift arm securely.
k Stop the engine, and then slowly loosen the
oil filler cap of the hydraulic tank to release
the residual pressure in the hydraulic tank.
k Operate the work equipment control lever 2 –
3 times to release the residual pressure in the
INSTALLATION work equipment circuit.
removal.
[*1]
a Connect PPC hoses (10) – (15) according to their
band colors shown below.
• WA200-5
No. Connecting point Band color
(10) Bucket DUMP Blue
(11) Bucket TILT Red
(12) Lift arm LOWER Orange
(13) Lift arm RAISE Yellow
• WA200PT-5
2. Remove work equipment valve upper cover (1).
(14) PULL White and red
(15) PUSH Green

30-118 WA200-5
(4)
DISASSEMBLY AND ASSEMBLY TRAVEL DAMPER VALVE
3. Release the residual pressure in the travel 5. Disconnect the following hoses and tubes.
damper circuit. [*1]
1) Loosen locknut (2). a Mark all the hoses and tubes with tags to pre-
2) Loosen adjustment screw (3) by 1/2 – 1 turn vent mistakes in the mounting position when
to release the pressure in the accumulator installing.
circuit for the travel damper. a Since oil will leak through the disconnected
a Locknut (2) and adjustment screw (3) are hoses and tubes, prepare oil receivers.
painted red. • (5): Port P hose
3) After releasing the residual pressure, return • (6): Port T hose
adjustment screw (3) and tighten locknut (2) • (7): Port SP hose
securely. • (8): Port A hose
3 Mounting bolt:
• (9): Port B hose
12.7 ± 0.6 Nm {1.3 ± 0.06 kgm}
4. Disconnect wiring connector F07 (4).
6. Remove 3 bracket mounting bolts (10) and travel

damper valve assembly (11).
INSTALLATION
removal.

WA200-5 30-119
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL AND INSTALLATION OF 5. Disconnect 7 hoses (6), (7), (8), (9), (10), (11),
and (12) from the hydraulic tank.
HYDRAULIC TANK [*1]
REMOVAL
under the tires.
k Operate the work equipment control lever 2 – 3
times to release the residual pressure in the work
equipment circuit.
1. Remove hydraulic tank upper cover (1).

hydraulic tank.
2. Remove cab right undercover (2) and right fender
(2a).
6. Sling the hydraulic tank assembly temporarily and

remove 2 upper mounting bolts (13) and 1 lower
mounting bolt (14).
[*2]
3. Remove tube (3) from the hydraulic oil filter.
4. Remove hydraulic oil filter cover mounting bolts

(4) and move hydraulic oil filter cover assembly
(5) and its hoses to under the operator's cab.
30-120 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
7. Lift off hydraulic tank (15) and ladder together. REMOVAL AND INSTALLATION OF
4 Hydraulic tank and ladder assembly: WORK EQUIPMENT ASSEMBLY
160 kg (including hydraulic oil)
REMOVAL
under the tires.
nal of the battery.
1. Sling the bucket link temporarily and remove

bucket link pin (1).
[*1]
4 Bucket link: 25 kg
a Secure the bucket link to the tilt lever with
INSTALLATION wires, etc.
• Carry out installation in the reverse order to a Check the thickness and quantity of the
removal. shims.
[*1]
2 Inserting parts of hoses (6) and (7):
Gasket sealant (ThreeBond 1208D or
equivalent)
3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*2]
3 Hydraulic tank mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}

system. Then, check the oil level again. 2. Remove bucket hinge mounting pin (2).
[*2]
k Never insert your fingers in the pin holes.
shims.
WA200-5 30-121
(2)
3. Move the machine to the rear and disconnect the 6. Release the residual pressure in the hydraulic
bucket. piping. For details, see RELEASING REMAINING
PRESSURE IN HYDRAULIC CIRCUIT.
4. Sling bucket cylinder assembly (3) temporarily
and pull out rod-side pin (4) to disconnect the cyl- 7. Sling boom cylinder assembly (6) temporarily and
inder rod and tilt lever. remove rod-side pin (5).
[*3] [*4]
a Lift rod-side of cylinder, and install block [1] a Check the thickness and quantity of the
between the cylinder bottom and frame. shims.
a Check the thickness and quantity of the a When lowering the boom cylinder assembly,
shims. put a block on the axle.
4 Bucket cylinder assembly: 80 kg 4 Boom cylinder assembly (1 piece): 80 kg
8. Disconnect boom positioner proximity switch con-

nector F04 (7).
9. Remove boom kick-out switch (8).

[*5]
5. Install support stand [2] at the tip of the lift arm.
30-122 WA200-5
(2)
10. Sling lift arm and bell crank and bucket link 13. Sling bell crank assembly (14) temporarily and
assembly (10) temporarily and pull out mounting pull out mounting pin (15).
pin (11).
[*6] 14. Lift off bell crank assembly (14).
4 Bell crank assembly: 140 kg
shims.
11. Lift off lift arm and bell crank and bucket link
assembly (10).
4 Lift arm, bell crank, and bucket link
assembly: 750 kg
15. Pull dust seal (17) and bushing (18) out of lift arm
(16).
[*8]
12. Sling bucket link assembly (12) temporarily, pull

out mounting pin (13), and remove the bucket link
assembly from the bell crank assembly.
[*7]
4 Bucket link assembly: 25 kg
16. Pull dust seal (19) and bushing (20) out of bell
crank (14).
[*8]
WA200-5 30-123
(2)
17. Pull dust seal (21) and bushing (22) out of bucket INSTALLATION
link (12). • Carry out installation in the reverse order to
[*8] removal.
k When starting the engine, check that the forward-

reverse lever is in neutral and the parking brake is
applied.
k When aligning the pin holes, use a bar. Never
insert your fingers in the pin holes.
a Supply grease until it comes out of the joint.
a When you finish greasing every part, idle the
engine at low speed, and repeat 2 to 3 times the
operations of tilting and dumping of bucket as
well as raising and lowering of lift arm, to allow
grease to spread all over the pin.
[*1]
Procedure for installing bucket link pin
1. Apply lubricant or grease to the inside surface of
bushing of bucket link.
2 Inside of bushing:
disulfide (LM-P or its equivalent) or
Hyper White grease (G2-T)
2. Sling the bucket link and align the holes for

mounting pin (1).
3. Insert shims on both sides so that clearances a

on both sides will be the same.
• Clearance a (On each side): Max. 1.5 mm
• Varieties of shim thickness: Only 1.5 mm
4. Install mounting pin (1) and lock it with bolt (24).

a Take care not to damage the pin.
30-124 WA200-5
(2)
5. After installing the pin, supply grease. [*3]

2 Bucket link pin:
Procedure for installing bucket cylinder pin (on
rod side)
Grease containing molybdenum disul-
1. Apply lubricant or grease to the inside surface of
fide (LM-G) or Hyper White grease
bushing of bucket cylinder.
(G2-T)
[*2] Lubricant containing molybdenum

Procedure for installing bucket hinge pin disulfide (LM-P or its equivalent) or
1. Apply lubricant or grease to the inside surface of Hyper White grease (G2-T)
bushing of lift arm.
2. Align the holes for bucket cylinder pin (4) by oper-
ating work equipment lever.
k When starting the engine, check that the for-
Hyper White grease (G2-T) ward-reverse lever is in neutral and the park-
ing brake is applied.
2. Align the holes for mounting pin (2), by moving
the machine forward or backward using work
3. Insert shims on both sides so that clearances c
equipment lever.
• Clearance c (On each side): Max. 1.5 mm
ward-reverse lever is in neutral and the park- • Varieties of shim thickness: Only 3.0 mm
3. Insert shims on both sides so that clearances b k Never insert your fingers in the pin holes.
• Clearance b (On each side): Max. 1.5 mm
• Varieties of shim thickness: Only 1.5 mm

5. After installing the pin, supply grease.

2 Bucket cylinder pin (on rod side):
(G2-T)
5. After installing the pin, supply grease. 6. Adjust the bucket positioner. For details, see
2 Bucket hinge pin:
TESTING AND ADJUSTING, Testing and adjust-
ing bucket positioner.
(G2-T)
WA200-5 30-125
(2)
[*4] [*6]
Procedure for installing lift arm cylinder pin (on Procedure for installing lift arm pin (on frame
rod side) side)
1. Apply lubricant or grease to the inside surface of 1. Apply lubricant or grease to the inside surface of
bushing of lift arm cylinder. bushing of lift arm.
2 Inside of bushing: 2 Inside of bushing:
Lubricant containing molybdenum Lubricant containing molybdenum
disulfide (LM-P or its equivalent) or disulfide (LM-P or its equivalent) or
Hyper White grease (G2-T) Hyper White grease (G2-T)
2. Align the holes for lift arm cylinder pin (5) by oper- 2. Align holes of lift arm pin (11).
ating work equipment lever.
3. Insert shims on both sides so that clearances e
ward-reverse lever is in neutral and the park-
• Clearance e (On each side): Max. 1.5 mm
• Varieties of shim thickness: 1.5 mm, 3.0 mm
3. Insert shims on both sides so that clearances d 4. Install mounting pin (11) and lock it with bolt (29).
• Clearance d (On each side): Max. 1.5 mm
• Varieties of shim thickness: Only 1.5 mm a Take care not to damage the pin.


2 Lift arm pin (on frame side):
(G2-T)
2 Lift arm cylinder pin (on rod side):
(G2-T)
[*5]
a Adjust the boom kick-out. For details, see TEST-
ING AND ADJUSTING, Testing and adjusting of
boom kick-out.
30-126 WA200-5
(2)
[*7] [*8]
Procedure for installing bucket link pin a Press fit bushings (18), (20), and (22) to lift arm
1. Apply lubricant or grease to the inside surface of (16), bell crank (14), and bucket link (12) respec-
bushing of bucket link. tively with hydraulic cylinder [3], etc., and then
install the dust seals.
Lubricant containing molybdenum 2 Bushing: Grease (G2-LI)
a Apply grease to the seal so that the seal will not
Hyper White grease (G2-T)
be damaged.
2. Align the holes of bucket link mounting pin (13).

a Press fit the dust seals (17), (19), and (21) with
the lip out.
• Installed dimension g: 0.25 – 0.8 mm
• Installed dimension h: 2 – 3 mm

2 Bucket link pin:
(G2-T)
WA200-5 30-127
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEMBLY DISASSEMBLY

1. Cylinder assembly
OF HYDRAULIC CYLINDER Set cylinder assembly (1) for the tool U1.
ASSEMBLY
2. Cylinder head and piston rod assembly
SPECIAL TOOLS (Excluding WA200PT-5 bucket cylinder)
1) Using tool U2, remove cylinder head (2) from
New/remodel
the cylinder.
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
790-502-1003 Repair stand t 1

1
790-101-1102 Hydraulic pump t 1
Wrench assembly
2 790-382-3802 t 1
(For lift arm and bucket)
790-102-1320 Socket (for lift arm) t 1
790-102-1330
Socket (for bucket)
or its equiva-
3 (Width across flats 46 t 1
lent available
mm)
in the market
790-302-1280 Socket (For steering) t 1
790-101-5021 Grip 1 2) Pull cylinder head and piston rod assembly
01010-50816 Bolt 1 (3) out of cylinder (4).
a Since oil will flow out when the piston rod
• Push tool
4 790-201-1791 (Lift arm and bucket) 1 assembly is pulled out of the cylinder,
prepare an oil receiver.
• Push tool
790-201-1811 1
(Steering)
• Push tool
790-201-1831 1
(WA200PT-5 bucket)
U 790-101-1521 Grip 1
01010-50816 Bolt 1
5 790-201-1610 • Plate 1
(Lift arm and bucket)
790-201-1550 • Plate (Steering) 1
• Push tool
790-201-1640 1
(WA200PT-5 bucket)
6 790-720-1000 Expander q 1
Ring
796-720-1670 q 1
Clamp
07281-01159 q 1
796-720-1740 Ring (Steering) q 1
7
07281-00809 Clamp (Steering) q 1
Ring
796-720-1680 q 1
(WA200PT-5 bucket)
Clamp
07281-01589 q 1
(WA200PT-5 bucket)
Wrench assembly
790-102-4300 t 1
(WA200PT-5 bucket)
8
Pin
790-102-4310 t 2
(WA200PT-5 bucket)
30-128 WA200-5
(2)
3. Cylinder head and piston rod assembly 4. Piston cylinder head

(WA200PT-5 Bucket cylinder assembly) (Excluding WA200PT-5 bucket cylinder)
1) Remove the mounting bolt of cylinder head 1) Set the cylinder head and piston rod assem-
assembly (2). bly (3) for the tool U1.
• Width across flats of bolt: 24 mm 2) Using tool U3, remove nut (5).
• Width across flats of nut (Steering): 46 mm
(Lift arm): 70 mm
(Bucket): 75 mm
3) Remove piston assembly (6) and cylinder
head assembly (2).
2) Pull cylinder head and piston rod assembly

(3) out of cylinder (4).
a Since oil will flow out when the piston rod
assembly is pulled out of the cylinder,pre-
pare an oil receiver.
5. Piston and cylinder head
(WA200PT-5 bucket cylinder)
1) Set cylinder head and piston rod assembly
(3) to tool U1.
WA200-5 30-129
(2)
2) Remove lock screw (7) of the piston assem- 4) Remove cylinder head assembly (2) from the
bly. cylinder.
a Screw size: M12 x 1.75
6. Fine disassembly of piston rod assembly

a If screw (7) is so caulked that it cannot be Remove wear ring (9) and piston ring (10) from
removed, tighten it and apply tap (19) to piston (8).
its threads, and then removed it.
7. Disassembly of piston assembly

3) Using tool U8, remove piston assembly (6). (WA200PT-5 bucket cylinder)
a When not using tool U8, loosen the pis- 1) Remove wear ring (9) and piston ring (10)
ton assembly by using 2 holes [A]. from piston (8).
• Hole [A]: ø10 mm 2) Remove O-ring and backup ring (11) from
piston (8).
30-130 WA200-5
(2)
8. Fine disassembly of cylinder head assembly ASSEMBLY

(Excluding WA200PT-5 bucket cylinder) a Take care not to damage the packings, dust
1) Remove O-ring and backup ring (12). seals, O-rings, etc.
2) Remove snap ring (13) and dust seal (14). a Do not insert each backup ring forcibly, but warm
3) Remove rod packing (15). it in water at 50 – 60°C and then insert it.
4) Remove bushing (16).
5) Remove O-ring (17). 1. Fine assembly of cylinder head assembly
(Excluding WA200PT-5 bucket cylinder)
1) Using tool U4, press fit bushing (16).
9. Disassembly of cylinder head assembly

(WA200PT-5 bucket cylinder assembly)
1) Remove O-ring and backup ring (12). 2) Install rod packing (15).
2) Remove snap ring (13) and dust seal (14). 3) Using tool U5, install dust seal (14) and
3) Remove rod packings (15) and (15a). secure it with snap ring (13).
4) Remove bushing (16). 4) Install backup ring and O-ring (12).
5) Install O-ring (17).
WA200-5 30-131
(2)
2. Assembly of cylinder head assembly 3. Fine assembly of piston assembly

(WA200PT-5 bucket cylinder assembly) 1) Using tool U6, expand piston ring (10).
1) Using tool U4, press fit bushing (16). a Set the tool to the piston ring and turn its
handle by 8 – 10 turns to expand the pis-
ton ring.
2) Install rod packings (15) and (15a).

3) Using tool U5, install dust seal (14) and 2) Remove piston ring (10) from tool U6 and
secure it with snap ring (13). install it to piston (8).
4) Install backup ring and O-ring (12). 3) Using tool U7, shrink piston ring (10).
4) Install wear ring (9).
30-132 WA200-5
(2)
4. Assembly of cylinder and piston rod assem- • When reusing the rod and piston assem-
bly (Excluding WA200PT-5 bucket cylinder) bly, assemble them according to the fol-
1) Set cylinder head and piston rod assembly lowing procedure.
(3) for tool U1. a Clean the parts thoroughly and remove
2) Install cylinder head assembly (2) and piston metal chips and dirt.
assembly (6) to the piston rod. 3) Using tightening tool U8, tighten piston
3) Using tool U3, tighten nut (5) to the specified ass embly (6) until the scr ew holes are
torque. aligned.
• Width across flats of nut (Steering): 46 mm a Remove burrs and fins from the threads
(Lift arm): 70 mm with a file, etc.
(Bucket): 75 mm 4) Tighten screw (7).
2 Threads of piston rod: Liquid adhe- 2 Threads of screw:
sive (LOCTITE No. 262 or equiva- Adhesive (LOCTITE No. 262)
3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm}
lent)
3 Nut (Steering):
785 ± 78.5 Nm {80 ± 8.0 kgm}
3 Nut: (Lift arm):
2.60 ± 0.26 Nm {265 ± 26.5 kgm}
3 Nut (Bucket):
3.14 ± 0.31 Nm {320 ± 32.0 kgm}
5) Caulk 4 points of threaded parts b with a

punch.
5. Assembly of cylinder head and piston rod

assembly (WA200PT-5 bucket cylinder)
1) Set piston rod (19) to tool U1.
2) Install cylinder head assembly (2).
WA200-5 30-133
(4)
a Caulk the end of screw (7) by hollowing it 7) Make 1 screw hole to install screw (7).
at least 1 thread. a Make 1 hole horizontally with a drill at the
V-groove of the threaded parts of piston
(8) and rod (19).
• Threading dimensions (mm)
Diameter of Depth of tap Tap to be Tapping
tap drill hole drill hole used depth
10.3 27 12 x 1.75 20
8) After making the hole, remove the all chips

and dirt and clean thoroughly.
• When replacing either or both of the rod

and piston, assemble the new parts
6) Using tool U8, screw in piston assembly (6)

until it touches the end [part C] of rod (19),
and then tighten it to the specified torque.
9) Tighten screw (7).

2 Threads of screw:
Adhesive (LOCTITE No. 262)
3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm}
10) Caulk 4 points of the threaded part with a
punch.
6. Cylinder head
(Excluding WA200PT-5 bucket cylinder)
1) Set cylinder (4) to tool U1.
2) Sling cylinder head and piston rod assembly
(3) and install cylinder (4).
30-134 WA200-5
(4)
3) Using tool U2, install cylinder head assembly

(2) to the cylinder.
3 Cylinder head (Steering):
539 ± 54.0 Nm {55 ± 5.5 kgm}
3 Cylinder head (Lift arm):
981 ± 98.1 Nm {100 ± 10 kgm}
3 Cylinder head (Bucket):
1.03 ± 0.10 kNm {105 ± 10.5 kgm}
4) Remove cylinder assembly (1) from tool U1.
7. Cylinder head (WA200PT-5 bucket cylinder)

1) Set cylinder (4) to tool U1.
2) Sling cylinder head and piston rod assembly
(3) and install cylinder (4).
3) Install cylinder head assembly (2) to the cylin-
der.
3 Cylinder head mounting bolt:
250 ± 24.5 Nm {25.5 ± 2.5 kgm}
4) Remove cylinder assembly (1) from tool U1.
WA200-5 30-135
(4)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
REMOVAL AND INSTALLATION OF 2. Open the engine right cover.

OPERATOR'S CAB ASSEMBLY 3. Remove the mounting nut of ball joint (5) from the
fuel control cable.
SPECIAL TOOLS [*1]
New/remodel
Necessity
4. Remove the mounting bolt and disconnect fuel
Symbol
Sketch
Q'ty
Part No. Part Name control cable (6) from the engine.
[*2]

799-703-1100 Vacuum pump [100V] t 1
X 1 799-703-1111 Vacuum pump [220V] t 1
799-703-1121 Vacuum pump [240V] t 1
REMOVAL
under the tires. 5. Disconnect 2 windshield washer hoses (7) at the
k Operate the work equipment control lever 2 – 3 right-front side of engine hood.
times to release the residual pressure in the work
equipment circuit.
hydraulic tank.
k Connect tool to the air conditioner compressor
hose valve and collect the refrigerant (R134a).
nal of the battery.
a The operator's cab and the floor frame of this
machine are made as a single unit.
1. Remove left/right fenders (1) and covers (2) – (4).

6. Disconnect cab ground (8) from the right side of
the operator's cab.
30-136 WA200-5
(4)
7. Disconnect the following wiring connectors.

a Right side of operator's cab
• (9): FL1
• (10): FL2
9. Disconnect hoses (25) – (29) from the Orbit-roll

valve.
• (25): Port LS hose (Right)
• (26): Port P hose (Left lower)
a Left side of operator's cab • (27): Port R hose (Right lower)
• (11): LR2 • (28): Port T hose (Left upper)
• (12): LR1 • (29): Port L hose (Right upper)
• (13): LR3
• (14): LT1
• (15): LT2
• (16): LR4
• (17): LR6
• (18): LR5
• (19): LR7
• (20): BL1
10. Remove the locknut and disconnect brake valve

linkage (30).
[*3]
11. Remove the 4 mounting bolts, and place brake

valve (31) on the frame.
• (21): L34
8. Disconnect wire clamp (22) and hose clamps (23)

and (24).
WA200-5 30-137
(2)
12. Disconnect the PPC hoses. 13. Release the parking brake.
[*4]
a For details on how to disconnect hoses, see 14. Under the machine, remove pin (38) at the left-
P RECA UTIO NS W HEN PERFO RMI NG rear side of transfer, and remove parking brake
OPERATION, 3. How to disconnect/connect control cable (39) from bracket.
push-pull type coupler Type 1. [*5]
• WA200-5: (32) – (37)
• WA200PT-5: (32) – (37),(47),(48)
15. Disconnect 2 air conditioner hoses (40) and 2

heater hoses (41).
16. Remove cable clamp (42).
17. Remove left/right mount covers (43) at the opera-

tor's cab.
30-138 WA200-5
(2)
18. Remove the 4 mounting nuts of operator's cab INSTALLATION

(44). • Carry out installation in the reverse order to
[*6] removal.
[*1] [*2]
3 Mounting nut of ball joint:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3 Locknut: 44 – 59 Nm {4.5 – 6.0 kgm}
[*3]
a Adjust the brake linkage. For details, see TEST-
ING AND ADJUSTING, Testing and adjusting
brake pedal linkage.
19. Remove cover (45) because it interferes with the [*4]

sling. a For details on how to connect PPC hoses, see
PRECAUTIONS WHEN PERFORMING OPERA-
TION, 3. How to disconnect/connect push-pull
type coupler Type 1.
a Connect PPC hoses (32) – (37), (47), and (48)
according to their band colors as shown below.
a PPC hose band colors of WA200-5

(34) Port P Red/Blue
(37) Port T Blue/Black
20. Lift off operator's cab assembly (46).
a Check that all the wires and pipes are discon- a PPC hose band colors of WA200PT-5
nected.
4 Operator's cab assembly: 810 kg
(34) Port P Red/Blue
(37) Port T Blue/Black
(47) Port E Green
(48) Port F White/Red
[*5]
a Adjust the parking brake control cable. For
details, see TESTING AND ADJUSTING, Testing
and adjusting parking brake control cable.
[*6]
3 Operator's cab mounting nut:
824 – 1,030 Nm {84 – 105 kgm}
WA200-5 30-139
(2)

• Bleeding air from PPC circuit

Hold the work equipment control lever to a stroke
end to relieve the oil for about 1 minute. Perform
this operation once for each stroke end of the
work equipment control lever.

Add water through the water filler to the specified
• Charging air conditioner with refrigerant

Using Tool X1, charge the air conditioner circuit
with refrigerant (R134a).
30-140 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
REMOVAL AND INSTALLATION OF a If the glass is narrow, you may cut the adhe-
sive by the following method. Insert a fine
OPERATOR'S CAB GLASS (STUCK wire [2] (piano wire, etc.) in the adhesive and
GLASS) grip its both ends with priors [3], etc. (or hold
them by winding them onto something) and
SPECIAL TOOLS cut the adhesive with the wire.
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
1 793-498-1120 Clear plate t 2

2 2 793-498-1130 Plate t 2
X 3 793-498-1110 Magnet t 2
Lifter
3 793-498-1210 t 2
(Suction cup)
REMOVAL
a All sides of each glass of the operator's cab of
this machine are stuck. a The broken window glass may be removed
a Remove the window glass to be replaced accord- with knife [4] and a screwdriver. (If the screw-
ing to the following procedure. driver is applied directly to the normal window
glass, the glass will be broken.)
1. Using seal cutter [1], cut the adhesive between a When using knife [4], insert a screwdriver in
broken window glass (1) and operator's cab (2). the cut to widen it and move the knife for-
ward.
2. Remove the window glass.
WA200-5 30-141
(2)
INSTALLATION
1. Using scraper [5], remove the remaining adhe-
sive.
a Do not scratch the paint.
4. Stick both-sided adhesive tape (4) along the

inside edge of the glass sticking section.
Size of both-sided adhesive tape: 7 x 4.8mm
a When sticking the both-sided adhesive tape,
2. Remove oil, dust, dirt, etc. from the sticking sur- do not touch the cleaned surface as long as
faces of cab (2) and window glass (3) with white possible.
gasoline. a Do not remove the release tape of the both-
a If the sticking surfaces are not cleaned well, sided adhesive tape on the glass sticking side
the glass may not be stuck perfectly. before sticking the glass.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
a Take care the corner (part b) of both-sided

adhesive tape will not float.
3. When the adhesive was removed with the

scraper, if any paint was flaked off, coat the bare
part with paint.
a If the glass is installed without repairing the
bare part, that part will be rusted.
a Do not apply paint to a part which will be
coated with primer.
30-142 WA200-5
(2)
a When sticking the both-sided adhesive tape 3) Using Tool X3 (suction cups), place window
around a side or a rear window glass, start at glass (3) on Tool X2-1 (5 mm spacer) and
center of the top and make a clearance of match it to the operator's cab.
about 5 mm at end joint c.
4) Check the clearance between window glass

5. Position the replacement glass.
(3) and operator's cab (2) on both sides and
1) Stick X2-2 (thin steel sheet) to Tool X2-1
adjust it evenly.
(spacer) with adhesive.
5) Stick tape [6] between window glass (3) and
• Spacer thickness t: 5 mm
operator's cab (2) and draw positioning line a.
2) Match Tool X2-3 (magnet) to Tools X2-1 and
6) Cut the tape between window glass (3) and
X2-2 and set them to the 2 lower places of
operator's cab (2) with a knife, and then
the window glass sticking part of operator's
remove the window glass.
cab (2).
a Do not remove the tapes left on the win-
dow glass and operator's cab before
installing the window glass.
6. Apply primer.
a The usable period of primer (5) is 4 months
after the date of manufacture. Do not use
primer (5) after this period has been expired.
a Use the primer within 2 hours after unpacking
it.
a Even if the primer is packed again just after it
is unpacked, use it within 24 hours after it is
unpacked for the first time.
(Discard the primer if 24 hours have passed
after it has been unpacked.)
WA200-5 30-143
(2)
1) Stir the primers for paint and glass sufficiently

before using them.
a If the primer has been stored in a refriger-
ator, leave it at the room temperature for
at least half a day before stirring it.
(If the primer is unpacked just after taken
out of the refrigerator, water will be con-
densed. For this reason, leave the primer
at the room temperature for a sufficient
time.)
2) When reusing primer brush (6), wash it in
white gasoline.
a After washing the brush, check it again
for dirt and foreign matter.
a Prepare respective brushes for the paint
primer glass primer.
4) Evenly apply glass primer (8) to the black part

of window glass (3) to be stuck.
2 Glass primer: SUNSTAR GLASS
3) Evenly apply paint primer (7) to the parts on
the outside of both-sided adhesive tape on
operator's cab (2) which will be coated with PRIMER 580 SUPER
the adhesive.
2 Paint primer: SUNSTAR GLASS
a Do not apply the primer more than 2
times.
PRIMER 580 SUPER (If it is applied more than 2 times, its per-
a Do not apply the primer more than 2 formance will be lowered.)
times. a Parts to be coated with primer: On the
(If it is applied more than 2 times, its per- both-sided adhesive tape (4) and opera-
formance will be lowered.) tor's cab (2), apply the primer all over
a Parts to be coated with primer: Apply the dimension d at the position of the window
primer all over dimension d on the out- glass (3).
side of the both-sided adhesive tape. • Dimension to apply primer d: 23 mm
• Dimension to apply primer d: 23 mm a Do not apply the primer to the boarder
a After applying the primer, leave it for at about 5 mm wide between the black part
least 5 minutes (within 8 hours) to dry. and transparent part of the glass.
a If the glass primer is applied by mistake, a After applying the primer, leave it for at
wipe it off with white gasoline. least 5 minutes (within 8 hours) to dry.
(If wrong primer is applied, the glass will a If the paint primer is applied by mistake,
not be stuck.) wipe it off with white gasoline.
(If wrong primer is applied, the glass will
not be stuck.)
30-144 WA200-5
(2)
1) Break aluminum seal (10) of the outlet of

adhesive cartridge (9) and install the nozzle.
2) Cut the tip of adhesive nozzle (11) so that

dimensions f and g will be as follows.
• Dimension f: 10 mm
• Dimension g: 12 mm
7. Apply adhesive.
a Use either of the 2 types of the adhesive.
2 Adhesive (Summer): SUNSTAR PEN-
GUINE SEAL 580 SUPER "S"
2 Adhesive (Winter): SUNSTAR PEN-
GUINE SEAL 580 SUPER "W"
3) Set adhesive cartridge (9) to caulking gun [7].
a The using limit of the adhesive is 4 months a An electric caulking gun is more efficient.
after the date of manufacture. Do not use the
adhesive after this limit.
a Keep the adhesive in a dark place where the
temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the all
hardened part from the nozzle tip.
WA200-5 30-145
(2)
4) Remove adhesive tape (13) of the both-sided

adhesive tape on the glass side.
8. Install window glass (3).

a If the glass is positioned wrongly, the adhe-
sive must be removed and cleaned, and then
5) Apply adhesive (12) to the outside of both-
the primer and adhesive must be applied
sided adhesive tape (4) of the operator's cab.
again. Accordingly, position the glass care-
a Before applying the adhesive, check that
fully when sticking it.
the primer is applied to the surface to
1) Similarly to step 1, match Tools X2-1, X2-2,
which the adhesive will be applied.
and X2-3, and set them to the 2 lower places
of the window glass sticking part of operator's
cab (2).
a Apply adhesive (12) to dimensions h and

j of both-sided adhesive tape (4) of oper-
ator's cab (2).
• Dimension h: 10 mm
• Dimension j: 12 mm
a Apply adhesive (12) higher than both-
sided adhesive tape (4).
a Apply the adhesive evenly.
30-146 WA200-5
(2)
2) Using Tool X3, raise and place window glass 3) After sticking window glass (3), press it
(3) on Tool X2-1 (5 mm spacer) and stick it to evenly.
the operator's cab. a Press all over the window glass to the
a Match the lines of the match tapes stuck degree that the window glass will be
in step 1. stuck to the both-sided adhesive tape.
a Stick the glass within 10 minutes after a Do not press the window glass to
applying the adhesive. strongly.
a Before sticking the glass, check that the
primer is applied to the surface to which
the glass will be stuck.
9. Cure the stuck window glass for a certain time.

a Curing time before removing Tool X2-1 (5 mm
spacer) (at temperature of 20°C and humidity
a Check clearance k between the front side of 60%): 10 hours
of the front glass and each side and a Curing time before operating machine:
adjust it evenly. 24 hours (1 day)
• Clearance k: 5 mm
WA200-5 30-147
(2)
10. If the front glass and both front glasses are 3) Remove the caulking material projected from
replaced, seal them. the joint with cardboard [8], etc.
1) Stick masking tapes (14) along the parts to be
sealed shown in the figure.
a Stick the masking tapes to both inside
and outside of the operator's cab.
4) Remove the masking tapes from the window

glass.
11. Remove the primer and adhesive from the opera-

tor's cab and window glass.
a Using white gasoline, wipe off the adhesive
before it is dried up.
a When cleaning the glass, do not give an
impact to it.
2) Fill the joint of the glasses with caulking

material (15).
a The usable period of the following caulk-
ing material is 4 months after the date of
manufacture. Do not use the caulking
material after its usable period.
2 Caulking material: SUNSTAR PEN-
GUINE SEAL NO. 2505
30-148 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
REMOVAL AND INSTALLATION OF 3. Disconnect all wiring harness clamps (1) between
the front frame and rear frame from the rear
CENTER HINGE PIN frame.
REMOVAL
under the tires.
nal of the battery.
1. Place blocks [1] under both sides of the front

frame and rear frame, raise the counterweight
with hydraulic jack [2], and set stands [3].
2. Remove the operator's cab assembly. For details, side.
see Removal and installation of operator's cab [*1]
assembly.
5. Disconnect front brake hose (3) from the hose

bracket of the front frame.
[*2]
WA200-5 30-149
(2)
6. Remove 2 hose clamp bracket mounting bolts (4) 9. Remove pins (11) from the bottom side of both
from the front frame. steering cylinders.
[*4]
7. Disconnect the PPC hoses from the work equip-

ment valve. [*3] 10. Remove the lower hinge pin.
WA200-5: (5) – (8) [*5]
WA200PT-5: (5) – (8),(35),(36) 1) Remove lock bolt (12).
2) Remove lower hinge pin (13).
8. Disconnect port P hose (9) and port T hose (10).
a Since oil will leak through the disconnected
hoses and tubes, prepare oil receivers.
11. Remove the upper hinge pin.

[*6]
1) Remove mounting bolt (14).
2) Remove mounting nut (15).
30-150 WA200-5
(2)
3) Adjust the height of the front frame and rear 2) Using a tool such as a bar, raise front frame
frame with the hydraulic jack so that you can assembly (20) by 1 – 2 mm to move lower
pull out the pin easily, and then remove upper spacer (21) from rear frame assembly (22).
hinge pin (16) and shim (17). a You may raise the front frame assembly
[*7] by 1 – 2 mm with a large-sized crane, if
a Check the thickness and quantity of the available.
shims.
3) Turn the tires to move front frame assembly

(20) forward.
4) Remove upper spacer (18).
a The upper spacer may be removed after
the front frame is disconnected.
13. Disassemble the lower hinge of the front frame.

[*9]
1) Remove washer (23).
12. Disconnect the front frame and rear frame.
2) Remove snap ring (24), and use a tool (such
[*8]
as the push tool) to remove bearing (25).
1) Set hand lift truck [4] under bucket (19).
WA200-5 30-151
(2)
14. Disassemble the upper hinge of the front frame.

[*10]
1) Remove lower spacer (28).
2) Remove dust seal (29).
INSTALLATION
3) Remove retainer (30) and shim (31). removal.
shims. [*1]
4) Remove dust seal (32) from retainer (30). a When installing the drive shaft, check that the key
groove of the spider cap is fitted in the key groove
bolts.
3 Front drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*2]
a Bleed air from the brake. For details, see TEST-
ING AND ADJUSTING, Bleeding air from brake
circuit.
[*3]
a Connect PPC hoses (5) – (8), (35), and (36)
according to their band colors as shown below.
5) Remove bearing (33a) and spacer (33b).
a PPC hose band colors of WA200-5

(6) Bucket TILT Red
(8) Bucket RAISE Yellow
a PPC hose band colors of WA200PT-5

(6) Bucket TILT Red
15. Remove 2 bushings (34) from the lower hinge of (8) Lift arm RAISE Yellow
the rear frame. (35) PULL White/Red
[*11] (36) PUSH Green
30-152 WA200-5
(2)
[*4] 2) Press fit dust seal (29) to the front frame.

a Adjust the shim so that the total of the upper and a Press fit the dust seal with the lip out.
2 Lip of dust seal: Grease (G2-LI)
lower clearances between the frame and cylinder
will be less than 0.5 mm.
3) Install lower spacer (28).
• Varieties of shim thickness: 0.5 mm, 1 mm
2 Inside of bushing on cylinder side and dust
a Install the spacer with the chamfered part
on the bearing side.
2 Lower spacer:
seal:
Lubricant containing molybdenum disul-
Lubricant containing molybde-
fide (LM-P)
num disulfide (LM-P)
[*9][*10][*11]
a Assemble the upper hinge and lower hinge
1. Install 2 bushings (34) to the lower hinge of the
rear frame.
4) Press fit dust seal (32) to retainer (30).

a Press fit the dust seal with the lip out.
2 Lip of dust seal: Grease (G2-LI)
2. Assemble the upper hinge of the front frame.

1) Using push tool [5], press fit bearing (33a)
and spacer (33b) to the front frame.
a Since the clearance of bearing (33a) and
spacer (33b) is adjusted properly, do not
change their combination.
a Since bearing (33a) and spacer (33b) are
an assembly, always replace them as a
set.
a Press fit the bearing and frame securely
so that a clearance will not be made
between the bearing and frame.
2 Bearing: Grease (G2-LI)
WA200-5 30-153
(2)
5) Tighten evenly the mounting bolt of retainer

(30).
3 Retainer mounting bolt:
3.92 – 5.88 Nm {0.4 – 0.6 kgm}
6) Measure the clearance between retainer (30)
and the front frame with feeler gauge [6], and
then select shims so that the maximum clear-
ance will be 0.1 – 0.2 mm when the shims are
inserted.
• Standard shim thickness: 1.3 mm
0.1 mm, 0.5 mm
3) Install snap ring (24) and washer (23).
7) Insert selected shim (31) and tighten the

mounting bolts evenly.
3 Mounting bolt: [*5][*6][*7][*8]
59 – 74 Nm {6.0 – 7.5 kgm} a Install the upper hinge pin and lower hinge pin
1. Set hand lift truck under the bucket and turn the
tires to move the front frame assembly toward the
rear frame.
3. Assemble the lower hinge of the front frame.

1) Install snap ring (24).
2) Using push tool [7], press-fit bearing (25) into
the front frame.
a Press fit the bearing and frame securely
so that a clearance will not be made
between the bearing and frame.
2 Bearing: Grease (G2-LI)
30-154 WA200-5
(2)
2. Using a tool (such as a bar), raise front frame 5. Insert upper hinge pin (16) and lower hinge pin
assembly (20) by 1 – 2 mm to move spacer (21) (13) to the end.
to the spacer of rear frame assembly (22). a Do not insert the shim for the upper hinge pin.
a You may raise the front frame assembly by 1
– 2 mm with a large-sized crane, if available.
6. Tighten mounting nut (15) of upper hinge pin (16).

3. Align the upper and lower pin holes. 3 Mounting nut:
a Using a hydraulic jack, adjust the height of 510 – 607.6 Nm {52.0 – 62.0 kgm}
the front and rear frames and align the pin
holes. 7. Measure clearance a between upper hinge pin
k When aligning the pin holes, use a bar. Never
(16) and rear frame top with a feeler gauge, and
then select shims so that the maximum clearance
insert your fingers in the pin holes.
will be less than 0.4mm when the shims are
inserted.
4. Install upper spacer (18). • Standard shim thickness: 0.8 mm
a Install the spacer with the chamfered part on • Varieties of shim thickness: 0.4 mm
the bearing side.
2 Lower spacer:
disulfide (LM-P)
WA200-5 30-155
(2)
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
8. Insert selected shim (17) between upper hinge REMOVAL AND INSTALLATION OF
pin (16) and rear frame, and tighten the 4 mount-
ing bolts.
COUNTERWEIGHT
3 Mounting bolt: REMOVAL
98 – 123 Nm {10.0 – 12.5 kgm}

under the tires.
1. Disconnect battery negative (–) terminal (1) from

the right side, and then disconnect battery termi-
nal (2).
2. Disconnect wiring connectors R23 (3) and R24

(4).
9. Tighten lock bolt (12) of lower hinge pin (13).

3 Lock bolt: 98 – 123 Nm {10 – 12.5 kgm}
3. Disconnect battery terminals (5) and (6) from the

left side.
4. Disconnect wiring connector R22 (7).

30-156 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
5. Open the grille and sling it temporarily. 9. Sling counterweight (11) temporarily and remove
the mounting bolt, and then remove the counter-
6. Open the engine left side cover and disconnect weight.
wiring connector BR1 (8). [*1]
a When removing the counterweight, insert bar
[1] in its rear part to balance it.
4 Counterweight and batteries (left/right)
assembly: 1,250 kg
7. Disconnect both damper gas cylinders (9).
INSTALLATION
removal.
[*1]
3 Mounting bolt: 785 – 980 Nm {80 – 100 kgm}
8. Remove the 4 mounting bolts and lift off grille

(10).
WA200-5 30-157
(2)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL AND INSTALLATION OF 2. Remove covers (3) and (4).

AIR CONDITIONER UNIT
ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name

799-703-1100 Vacuum pump [100V] t 1
X 1 799-703-1111 Vacuum pump [220V] t 1
799-703-1121 Vacuum pump [240V] t 1
799-703-1401 Gas leak detector t 1 3. Remove bracket (5) and cover (6).
REMOVAL
under the tires.
nal of the battery.
4. Remove bracket (7), and disconnect defroster

1. Remove the operator's cab left undercover and hose (8).
disconnect 2 heater hoses (1) from tube (2).
a Disconnect the heater hoses from the air con-
ditioner unit.
30-158 WA200-5
(4)
5. Release the parking brake. 11. Disconnect wiring connectors L122 (16), L117
(17), L118 (18), L121 (19), L120 (20), L119 (21),
6. Disconnect wiring connectors L47 (9) and L53 and A8 (22).
(10).
7. Remove parking brake control cable (11) from the

lever and the bracket.
[*1]
8. Remove box (12).
12. Disconnect wiring connectors (23) – (25).
9. Remove covers (13) and (14).
10. Remove bracket (15).
13. Remove console box (26).
WA200-5 30-159
(2)
14. Remove wiring connector bracket (27). 19. Remove air conditioner unit assembly (35).
a When you remove it, lift up the drain hose at
15. Remove clamp (28). the bottom of the unit.
16. Disconnect wiring connectors A03 (29), A01 (30),

and A02 (31).
INSTALLATION
removal.
[*1]
a Adjust the parking brake control cable. For
details, see TESTING AND ADJUSTING, Testing
and adjusting parking brake control cable.
[*2]
2 O-ring:
Compressor oil for new refrigerant
(NO-OIL8)

17. Disconnect air conditioner pipes (32) and (33).
[*2]
18. Disconnect heater hose (34) from the tube.
a Do not remove the heater hose from the floor.
Removing it will make it difficult to insert into
the floor.
30-160 WA200-5
(2)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR

AIR CONDITIONER COMPRESSOR
ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name

799-703-1100 Vacuum pump [100V] t 1
X 1 799-703-1111 Vacuum pump [220V] t 1
799-703-1121 Vacuum pump [240V] t 1
REMOVAL
under the tires.
nal of the battery.
1. Open the right-side cover of the engine.
2. Disconnect wiring connector E16 (1) and ground INSTALLATION

terminal E22 (2). • Carry out installation in the reverse order to
removal.
3. Disconnect air conditioner pipes (3) and (4).
[*1] [*1]
2 O-ring:
4. Disconnect 2 air conditioner pipe clamps (5).
Compressor oil for new refrigerant (NO-
OIL8)
[*2]
6. Loosen 2 mounting bolts (7) and 2 mounting bolts
(8).
s o r b e l t . F o r d e ta i l s , s ee T E S T I N G A N D
7. Loosen 2 locknuts (9) and 2 adjustment bolts
(10).
8. Remove air conditioner compressor belt (11).
[*2]
9. Remove 2 mounting bolts (7), 2 mounting bolts
(8), and air conditioner compressor bracket
assembly (12).
WA200-5 30-161
(4)
DISASSEMBLY AND ASSEMBLY MONITOR PANEL
REMOVAL AND INSTALLATION OF 4. Using puller [1], remove steering wheel (4) from
the steering column.
MONITOR PANEL
REMOVAL
nal of the battery.
1. Remove pad (1) from the steering wheel.

[*2]
2. Remove contact assembly (2).
3. Remove steering wheel mounting nut (3).

[*1]
30-162 WA200-5
(2)
7. Remove the following wiring connectors. 8. Loosen hexagon socket head bolt (15) and
a Before disconnecting switch connectors (7) – remove light and FNR switch assembly (16).
(12) above the front panel cover, pull out the [*3]
switch upward.
• (7): L07
• (8): L08
• (9): L06
• (10): L19
• (11): L10
• (12): L11
• (13): L04
• (14): L15
9. Remove the front panel cover.

[*4]
1) Remove 8 mounting bolts (18) of front panel
cover (17).
2) Turn 2 clips (19) by 90° to remove them from

the front panel cover.
a Since 4 clips (20) on the operator's cab
glass side cannot be removed, discon-
nect from 2 clips (19).
WA200-5 30-163
(2)
3) Remove front panel cover (17). 12. Remove monitor panel (23) from bracket (24).
a Take care not to damage the painted sur- [*5]
face in the operator's cab.
10. Disconnect monitor panel wiring connectors L21

(21), L22 (22), and L23 (23) from the points on INSTALLATION
the back side of the monitor panel shown in the • Carry out installation in the reverse order to
figure. removal.
[*1]
3 Steering wheel mounting nut:
29 ± 2.9 Nm {3.0 ± 0.3 kgm}
[*2]
3 Cover mounting bolt (Fine thread):
1.97 – 2.45 Nm {0.2 – 0.25 kgm}
3 Cover mounting bolt (Coarse thread):
5.88 Nm {0.6 kgm}
[*3]
3 Hexagon socket head bolt:
11. Remove 4 bracket mounting bolts (21), and 14.7 – 34 Nm {1.5 – 3.5 kgm}
remove monitor panel and bracket assembly (22).
[*4]
3 Front panel cover mounting bolt:
3.44 – 4.4 Nm {0.35 – 0.45 kgm}
[*5]
3 Monitor panel mounting bolt:
2.75 – 3.53 Nm {0.28 – 0.30 kgm}
30-164 WA200-5
(2)
OTHERS
90 OTHERS
Hydraulic circuit diagram

WA200-5 ................................................................................................................................................ 90-3
Hydraulic circuit diagram
WA200PT-5 ........................................................................................................................................ 90-4-1
Electrical circuit diagram 1/4 (1/4)
(Machines equipped with ROPS cab) ..................................................................................................... 90-5
(Machines equipped with ROPS cab) ................................................................................................... 90-11
Electrical circuit diagram 2/4
(Machines equipped with ROPS canopy) ............................................................................................. 90-19
WA200-5 90-1
(3)
HYDRAULIC CIRCUIT DIAGRAM
WA200-5
WA200-5 90-3
(3)
HYDRAULIC CIRCUIT DIAGRAM
WA200PT-5
WA200-5 90-4-1
(3)
ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4)
(Machines equipped with ROPS cab)
WA200-5 90-5
WA200-5 90-7
WA200-5 90-9
WA200-5 90-11
ELECTRICAL CIRCUIT DIAGRAM 2/4
WA200-5 90-13
WA200-5 90-15
WA200-5 90-17
(3)
(Machines equipped with ROPS canopy)
WA200-5 90-19
WA200-5 90-21
WA200-5 90-23
WA200-5 90-25
WA200-5 90-27
WA200-5 90-29
WA200-5 90-31
(3)

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SEBM033307

MACHINE MODEL SERIAL NUMBER

WA200-5 65001 and up

• WA200, 200PT-5 mounts the SAA6D102E-2-A engine.

10 STRUCTURE, FUNCTION AND

20 TESTING AND ADJUSTING ...................................................................... 20-1

30 DISASSEMBLY AND ASSEMBLY .......................................................... 30-1

90 OTHERS .................................................................................................................... 90-1

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

30-137 (2) 90-19

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

k Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

k Slinging with one rope may cause turning

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

• Used as lubricant for sliding portion (to

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS