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SEN06006-02

WHEEL LOADER

WA470 -7
SERIAL NUMBERS

10001

and up

SHOP MANUAL

WHEEL LOADER
WA470-7
Model

Serial Number

WA470-7

10001 and up

00 Index and foreword


1 00 Index and foreword

WA470-7

00-1

00 Index and foreword


Index

Index

(ALL-0310-001-A-00-A)

00 Index and foreword ....................................................................................................................... 00-1


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

00-2

WA470-7

00 Index and foreword


Index

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


Steering valve.................................................................................................................. 10-129
Orbit-roll valve ................................................................................................................. 10-143
Stop valve ....................................................................................................................... 10-149
Emergency steering motor ................................................................................................ 10-150
Emergency steering pump ................................................................................................ 10-151
Brake system ......................................................................................................................... 10-152
Layout of brake parts........................................................................................................ 10-152
Charge valve ................................................................................................................... 10-154
Brake valve ..................................................................................................................... 10-160
Slack adjuster .................................................................................................................. 10-164
Accumulator (for brake) .................................................................................................... 10-167
Brake .............................................................................................................................. 10-168
Parking brake control ....................................................................................................... 10-171
Parking brake .................................................................................................................. 10-172
Parking brake solenoid valve ............................................................................................ 10-173
Parking brake emergency release valve............................................................................. 10-176
Undercarriage and frame......................................................................................................... 10-177
Axle mount and center hinge pin........................................................................................ 10-177
Tire ................................................................................................................................. 10-178
Hydraulic system .................................................................................................................... 10-180
Hydraulic component layout .............................................................................................. 10-180
Work equipment control .................................................................................................... 10-182
Hydraulic tank.................................................................................................................. 10-183
Double type gear pump .................................................................................................... 10-186
Work equipment pump...................................................................................................... 10-187
Control valve ................................................................................................................... 10-208
CLSS .............................................................................................................................. 10-217
Hydraulic circuit diagram and names of valves.................................................................... 10-221
Accumulator charge valve................................................................................................. 10-232
Work equipment lock solenoid valve .................................................................................. 10-236
Accumulator (for PPC circuit) ............................................................................................ 10-237
Accumulator (for ECSS) ................................................................................................... 10-238
Work equipment ..................................................................................................................... 10-239
Work equipment linkage ................................................................................................... 10-239
Bucket ............................................................................................................................ 10-240
Bucket positioner and boom positioner............................................................................... 10-241
Cab and its attachments .......................................................................................................... 10-242
ROPS cab ....................................................................................................................... 10-242
Electrical system .................................................................................................................... 10-243
Engine control system ...................................................................................................... 10-243
Preheating system ........................................................................................................... 10-245
Engine power mode selector circuit ................................................................................... 10-247
Engine output limit function ............................................................................................... 10-248
Automatic warm-up function.............................................................................................. 10-249
Parking brake control system ............................................................................................ 10-250
System operating lamp function......................................................................................... 10-252
Battery disconnect switch function ..................................................................................... 10-254
Transmission controller system ......................................................................................... 10-256
Work equipment control system......................................................................................... 10-277
Machine monitor system ................................................................................................... 10-293
Rear view monitor system................................................................................................. 10-317
KOMTRAX system ........................................................................................................... 10-320
System component parts .................................................................................................. 10-323
Sensor ............................................................................................................................ 10-350
20 Standard value tables.................................................................................................................... 20-1
Table of contents ........................................................................................................................ 20-2
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
WA470-7

00-3

00 Index and foreword


Index

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


Standard value table for electrical system............................................................................. 20-18
30 Testing and adjusting .................................................................................................................... 30-1
Table of contents ........................................................................................................................ 30-2
General information on testing and adjusting................................................................................. 30-4
Tools for testing and adjusting ............................................................................................... 30-4
Sketch of tools for testing and adjusting ................................................................................. 30-8
Engine and cooling system ........................................................................................................ 30-10
Testing engine speed ......................................................................................................... 30-10
Testing boost pressure ....................................................................................................... 30-12
Testing exhaust gas color ................................................................................................... 30-14
Testing and adjusting valve clearance .................................................................................. 30-16
Testing compression pressure............................................................................................. 30-18
Testing blowby pressure ..................................................................................................... 30-22
Testing engine oil pressure ................................................................................................. 30-24
Testing EGR valve and KVGT oil pressures .......................................................................... 30-25
Testing fuel pressure .......................................................................................................... 30-26
Testing fuel return rate and leakage ..................................................................................... 30-27
Bleeding air from fuel system .............................................................................................. 30-31
Testing fuel circuit for leakage ............................................................................................. 30-33
Handling cylinder cutout mode operation.............................................................................. 30-34
Handling no injection cranking operation .............................................................................. 30-35
Testing of KDPF and muffler stack for looseness and damage ............................................... 30-36
Testing of installed condition of cylinder head and manifolds .................................................. 30-37
Testing engine piping for damage and looseness .................................................................. 30-38
Testing and adjusting air conditioner compressor belt tension ................................................ 30-39
Testing and adjusting alternator belt tension ......................................................................... 30-41
Procedures for cleaning fuel doser....................................................................................... 30-43
Writing compensation values at replacement of injector and engine controller ......................... 30-46
Power train............................................................................................................................... 30-50
Adjusting transmission output speed sensor ......................................................................... 30-50
Adjusting transmission input speed sensor ........................................................................... 30-51
Flushing procedure for torque converter and transmission hydraulic circuit.............................. 30-52
Retrieval of disabled machine due to transmission valve failure.............................................. 30-54
Testing oil leakage from axle final drive ................................................................................ 30-56
Testing drive shaft for looseness, backlash, and damage....................................................... 30-57
Testing and adjusting power train oil pressure....................................................................... 30-58
Steering system........................................................................................................................ 30-73
Testing directional lever ...................................................................................................... 30-73
Testing steering wheel ........................................................................................................ 30-74
Testing work equipment control lever ................................................................................... 30-76
Testing and adjusting steering circuit oil pressure.................................................................. 30-78
Bleeding air from steering cylinder circuit.............................................................................. 30-81
Testing and adjusting steering stopper valve......................................................................... 30-82
Brake system ........................................................................................................................... 30-83
Testing brake pedal ............................................................................................................ 30-83
Testing and adjusting brake pedal linkage ............................................................................ 30-84
Testing braking performance ............................................................................................... 30-85
Testing and adjusting of accumulator charge pressure........................................................... 30-86
Testing of brake accumulator nitrogen gas pressure and procedure for charging brake
accumulator with nitrogen gas................................................................................ 30-88
Testing wheel brake oil pressure.......................................................................................... 30-92
Testing lowering of wheel brake pressure ............................................................................. 30-94
Testing wear of wheel brake disc ......................................................................................... 30-96
Bleeding air from wheel brake circuit.................................................................................... 30-97
Releasing remaining pressure in brake accumulator circuit .................................................... 30-99
Testing parking brake performance .................................................................................... 30-100
Testing parking brake oil pressure ..................................................................................... 30-101
Testing wear of parking brake disc ..................................................................................... 30-102

00-4

WA470-7

00 Index and foreword


Index

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


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

00-5

00 Index and foreword


Index

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


Failure code [15SHL1] Release Trouble of ECMV (4th) ....................................................... 40-154
Failure code [15SHLH] Malfunction of ECMV (4th) .............................................................. 40-156
Failure code [2F00MA] Failure of Parking Brake Circuit ....................................................... 40-158
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................. 40-162
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) .............................................. 40-164
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-166
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-167
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-168
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-169
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-170
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-171
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-172
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-173
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-174
Failure code [989A00] Engine Overrun Prevention Activated ............................................... 40-175
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-176
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-177
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-178
Failure code [A1U0N3] HC Desorb Request 1 .................................................................... 40-179
Failure code [A1U0N4] HC Desorb Request 2 .................................................................... 40-181
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-183
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-185
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-186
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-188
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-189
Failure code [B@CENS] T/C Oil Temp. Overheat................................................................ 40-191
Failure code [B@HANS] HYD Oil Temp. Overheat .............................................................. 40-192
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-193
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-194
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-196
Failure code [CA131] Throttle Sensor High Error................................................................. 40-198
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-200
Failure code [CA135] Eng Oil Press Sensor High Error........................................................ 40-202
Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................ 40-204
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-206
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-208
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-210
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-212
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-214
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-216
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-218
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-220
Failure code [CA234] Eng Overspeed ................................................................................ 40-221
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-222
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-223
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-224
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-225
Failure code [CA273] PCV2 Short Error ............................................................................. 40-226
Failure code [CA274] PCV2 Open Error ............................................................................. 40-227
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-228
Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................. 40-230
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-232
Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................. 40-234
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-236
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-238
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-240
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-241
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-242

00-6

WA470-7

00 Index and foreword


Index

Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-244
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-246
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-248
Failure code [CA431] Idle Validation Sw Error..................................................................... 40-249
Failure code [CA432] Idle Validation Process Error ............................................................. 40-252
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-255
Failure code [CA442] Battery Voltage High Error................................................................. 40-257
Failure code [CA449] Rail Press Very High Error................................................................. 40-258
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-259
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-261
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-263
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-265
Failure code [CA553] Rail Press High Error ........................................................................ 40-267
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-268
Failure code [CA556] Crankcase Press High Error 2 ........................................................... 40-269
Failure code [CA559] Rail Press Low Error......................................................................... 40-270
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-274
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-275
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-277
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-279
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-281
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-283
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-284
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-285
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-286
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-288
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-289
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-292
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-295
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-296
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-298
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-300
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-302
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-304
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-306
Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-309
Failure code [CA1922] KDPF Soot Load High Error 2.......................................................... 40-312
Failure code [CA1923] Dosing Fuel Valve 1 High Error ........................................................ 40-317
Failure code [CA1924] Dosing Fuel Valve 1 Low Error......................................................... 40-319
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ................................................. 40-322
Failure code [CA1927] Dosing Fuel Press Sens High Error .................................................. 40-324
Failure code [CA1928] Dosing Fuel Press Sens Low Error................................................... 40-326
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-328
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ...................................................... 40-329
Failure code [CA1977] Fuel Doser Open/Short Error ........................................................... 40-331
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-333
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-335
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-337
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-339
Failure code [CA2265] Fuel Feed Pump Open Error............................................................ 40-340
Failure code [CA2266] Fuel Feed Pump Short Error ............................................................ 40-342
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-344
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-346
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-348
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-350
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-352
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-353
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-355
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-357
WA470-7

00-7

00 Index and foreword


Index

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


Failure code [CA2387] KVGT Servo Error .......................................................................... 40-361
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-362
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-364
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-366
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-368
Failure code [CA2732] Dosing Fuel Valve 2 High Error ........................................................ 40-371
Failure code [CA2733] Dosing Fuel Valve 2 Low Error......................................................... 40-373
Failure code [CA2741] Dosing Fuel Valve Swap Error ......................................................... 40-375
Failure code [CA2765] Inj Trim Data Error .......................................................................... 40-377
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ...................................................... 40-378
Failure code [CA2881] Dosing Fuel Pressure Low Error 1.................................................... 40-381
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-386
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-388
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-390
Failure code [CA3167] Fuel Doser Degradation .................................................................. 40-393
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-396
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-399
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-402
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-405
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-409
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-412
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....................................................... 40-415
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-418
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-421
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-425
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-430
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-433
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-437
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-442
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-446
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-449
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-454
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-456
Failure code [D150KA] Disconnection of Emerg. Steering Relay .......................................... 40-458
Failure code [D150KB] Ground Fault of Emerg. Steering Relay ............................................ 40-460
Failure code [D150KY] Hot Short of Emergency Steering Relay ........................................... 40-462
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ................................... 40-464
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output..................................... 40-466
Failure code [D160KY] Hot Short of Backup Lamp Relay Output .......................................... 40-468
Failure code [D191KA] Disconnection of Neutral Output Relay............................................. 40-470
Failure code [D191KB] Ground Fault of Neutral Output Relay .............................................. 40-472
Failure code [D191KY] Hot Short of Neutral Output Relay.................................................... 40-474
Failure code [D192KA] Disconnection of ECSS Solenoid..................................................... 40-476
Failure code [D192KB] Ground Fault of ECSS Solenoid ...................................................... 40-478
Failure code [D192KY] Hot Short of ECSS Solenoid ........................................................... 40-479
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-480
Failure code [D1E6KA] Disconnection of Parking Brake Relay ............................................. 40-482
Failure code [D1E6KB] Ground Fault of Parking Brake Relay............................................... 40-484
Failure code [D1E6KY] Hot Short of Parking Brake Relay .................................................... 40-486
Failure code [D5ZHKA] Failure of Key SW C Signal ............................................................ 40-488
Failure code [D5ZHKB] Key SW C Signal Short Circuit........................................................ 40-490
Failure code [D5ZHKZ] Failure of Key SW C Signal ............................................................ 40-492
Failure code [D5ZHL6] Disconnection of Key SW C ............................................................ 40-494
Failure code [D811MC] KOMTRAX Error............................................................................ 40-496
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-497
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-498
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-500
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 .......................................................... 40-502

00-8

WA470-7

00 Index and foreword


Index

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


Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................... 40-505
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-506
Failure code [DAF0MC] Monitor Error ................................................................................ 40-507
Failure code [DAF3KK] Controller Power Source Low (MON)............................................... 40-508
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-510
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .......................................... 40-511
Failure code [DAFGMC] GPS Module Error........................................................................ 40-513
Failure code [DAFLKA] Operating Lamp Open Circuit (MON)............................................... 40-514
Failure code [DAFLKB] Operating Lamp Short Circuit (MON)............................................... 40-516
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-518
Failure code [DAQ0KK] Controller Power Source Low (T/M) ................................................ 40-519
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ....................................... 40-522
Failure code [DAQ0MC] T/M Con Error .............................................................................. 40-523
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .............................................. 40-524
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ................................................. 40-526
Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay .......................................... 40-529
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) .......................................... 40-531
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ................................................ 40-532
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ................................................ 40-534
Failure code [DAQQKR] CAN2 Discon (Transmission Con) ................................................. 40-536
Failure code [DAQRKR] CAN1 Discon (Transmission Con) ................................................. 40-537
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ......................................... 40-538
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-539
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-540
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-541
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-546
Failure code [DB90KK] Drop in BBC Controller Main Power Source ..................................... 40-551
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ...................................... 40-553
Failure code [DB90MC] BBC Error..................................................................................... 40-554
Failure code [DB91KA] Disconnection of Key SW ACC (BBC) ............................................. 40-555
Failure code [DB92KK] Solenoid Power Source Low (BBC) ................................................. 40-557
Failure code [DB95KX] Failure of 5 V Power Source 1......................................................... 40-559
Failure code [DB96KX] Failure of 5 V Power Source 2......................................................... 40-561
Failure code [DB99KQ] Inconsistency of Model Selection (BBC) .......................................... 40-563
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC)................................................ 40-564
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ................................................ 40-566
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) .................................................. 40-568
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) .................................................. 40-569
Failure code [DB9RMA] Inconsistency of Option Selection (BBC)......................................... 40-570
Failure code [DBE5KX] Failure of 5V Power Source............................................................ 40-571
Failure code [DBE6KX] Failure of 24 V Power Source ......................................................... 40-573
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ..................................... 40-575
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................................ 40-577
Failure code [DDB6L4] Neutral Signal Malfunction .............................................................. 40-579
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ........................................... 40-582
Failure code [DDK3KA] FNR SW Input Signal Disconnection............................................... 40-584
Failure code [DDK3KB] FNR SW Input Signal Short Circuit.................................................. 40-587
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ............................................ 40-589
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit............................................... 40-592
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW .......................................... 40-594
Failure code [DDT0L4] Failure of Shift Mode Select SW ...................................................... 40-596
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal...................................... 40-598
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal ........................................... 40-600
Failure code [DDW9LD] Ground Fault of Kickdown Switch................................................... 40-602
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW ................................................ 40-604
Failure code [DF10KA] Disconnection of Shift Lever Input ................................................... 40-606
Failure code [DF10KB] Ground Fault of Shift Lever Input ..................................................... 40-608
Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor........................................... 40-611
WA470-7

00-9

00 Index and foreword


Index

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

00-10

WA470-7

00 Index and foreword


Index

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

00-11

00 Index and foreword


Index

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


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

00-12

WA470-7

00 Index and foreword


Index

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

00-13

00 Index and foreword


Index

S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start
but does not) .................................................................................................... 40-1074
S-4 Engine startability is poor .......................................................................................... 40-1075
S-5 Engine does not pick-up smoothly ............................................................................. 40-1077
S-6 Engine stops during operation ................................................................................... 40-1079
S-7 Engine runs rough or is unstable ............................................................................... 40-1081
S-8 Engine lacks power .................................................................................................. 40-1082
S-9 KDPF gets clogged in a short time ............................................................................. 40-1084
S-10 Engine oil consumption is excessive ........................................................................ 40-1086
S-11 Engine oil becomes contaminated early.................................................................... 40-1087
S-12 Fuel consumption is excessive ................................................................................ 40-1088
S-13 Oil is in coolant (or coolant spurts or coolant level goes down).................................... 40-1089
S-14 Oil pressure drops .................................................................................................. 40-1090
S-15 Fuel mixes into engine oil........................................................................................ 40-1091
S-16 Water mixes into engine oil (milky) ........................................................................... 40-1092
S-17 Coolant temperature rises too high (overheating) ...................................................... 40-1093
S-18 Unusual noise is heard ........................................................................................... 40-1094
S-19 Vibration is excessive ............................................................................................. 40-1095
S-20 Air cannot be bled from fuel circuit ........................................................................... 40-1096
S-21 Active regeneration is executed frequently ............................................................... 40-1097
S-22 Active regeneration takes a long time....................................................................... 40-1098
S-23 White smoke is exhausted during active regeneration ............................................... 40-1099
50 Disassembly and assembly ........................................................................................................... 50-1
Table of contents ........................................................................................................................ 50-2
General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-17
Engine and cooling system ........................................................................................................ 50-47
Removal and installation of supply pump assembly............................................................... 50-47
Removal and installation of injector assembly....................................................................... 50-53
Removal and installation of fuel doser assembly ................................................................... 50-61
Removal and installation of cylinder head assembly.............................................................. 50-63
Removal and installation of engine hood assembly ............................................................... 50-77
Removal and installation of grille assembly .......................................................................... 50-79
Removal and installation of cooling system assembly............................................................ 50-82
Removal and installation of radiator core assembly ............................................................... 50-85
Removal and installation of aftercooler................................................................................. 50-87
Removal and installation of hydraulic oil cooler ..................................................................... 50-90
Removal and installation of power train oil cooler assembly ................................................... 50-92
Removal and installation of engine assembly ....................................................................... 50-96
Removal and installation of engine front oil seal .................................................................. 50-102
Removal and installation of engine rear oil seal................................................................... 50-105
Removal and installation of cooling fan and cooling fan motor assembly ............................... 50-110
Removal and installation of KDPF assembly....................................................................... 50-112
Disassembly and assembly of KDPF assembly .................................................................. 50-117
Removal and installation of KCCV assembly ...................................................................... 50-126
Removal and installation of KVGT assembly....................................................................... 50-128
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly...................... 50-133
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly..................... 50-134
Removal and installation of air cleaner assembly ................................................................ 50-136
Removal and installation of air conditioner compressor belt ................................................. 50-138
Removal and installation of alternator belt .......................................................................... 50-139
Removal and installation of fuel tank assembly ................................................................... 50-140
Power train............................................................................................................................. 50-143
Removal and installation of torque converter and transmission assembly.............................. 50-143
Disassembly and assembly of transmission assembly......................................................... 50-148
Disassembly and assembly of torque converter assembly ................................................... 50-178

00-14

WA470-7

00 Index and foreword


Index

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


Removal and installation of front axle assembly .................................................................. 50-208
Removal and installation of rear axle assembly................................................................... 50-210
Disassembly and assembly of axle housing assembly......................................................... 50-215
Disassembly and assembly of differential assembly ............................................................ 50-225
Steering system...................................................................................................................... 50-244
Removal and installation of steering valve assembly ........................................................... 50-244
Brake system ......................................................................................................................... 50-246
Removal and installation of brake charge valve assembly.................................................... 50-246
Removal and installation of parking brake disc and plate ..................................................... 50-247
Undercarriage and frame......................................................................................................... 50-250
Removal and installation of center hinge pin ....................................................................... 50-250
Removal and installation of counterweight assembly ........................................................... 50-258
Removal and installation of full-length fender assembly ....................................................... 50-260
Hydraulic system .................................................................................................................... 50-261
Removal and installation of hydraulic tank assembly ........................................................... 50-261
Removal and installation of control valve assembly ............................................................. 50-264
Removal and installation of steering pump and power train pump assembly .......................... 50-267
Removal and installation of work equipment pump and cooling fan pump assembly............... 50-269
Disassembly and assembly of hydraulic cylinder assembly.................................................. 50-271
Work equipment ..................................................................................................................... 50-278
Removal and installation of work equipment assembly ........................................................ 50-278
Cab and its attachments .......................................................................................................... 50-283
Removal and installation of operator's cab and floor frame assembly.................................... 50-283
Removal and installation of operator's cab glass (stuck window glass).................................. 50-287
Removal and installation of operator's seat assembly.......................................................... 50-295
Removal and installation of seat belt .................................................................................. 50-297
Removal and installation of air conditioner unit assembly..................................................... 50-298
Removal and installation of air conditioner compressor assembly......................................... 50-303
Removal and installation of air conditioner condenser assembly .......................................... 50-305
Electrical system .................................................................................................................... 50-307
Removal and installation of machine monitor assembly ....................................................... 50-307
Removal and installation of engine controller assembly ....................................................... 50-308
Removal and installation of work equipment controller assembly.......................................... 50-309
Removal and installation of transmission controller assembly .............................................. 50-311
Removal and installation of monitor controller assembly ...................................................... 50-312
Removal and installation of mass air flow and temperature sensor ....................................... 50-314
Removal and installation of KOMTRAX terminal assembly .................................................. 50-315
60 Maintenance standard................................................................................................................... 60-1
Table of contents ........................................................................................................................ 60-2
Engine and cooling system .......................................................................................................... 60-3
Engine related parts ............................................................................................................. 60-3
Cooling fan pump ................................................................................................................. 60-4
Cooling fan motor................................................................................................................. 60-7
Power train................................................................................................................................. 60-9
Drive shaft ........................................................................................................................... 60-9
Torque converter ................................................................................................................ 60-10
Transmission ..................................................................................................................... 60-12
Transmission control valve.................................................................................................. 60-21
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV .......................................... 60-23
3rd, 4th clutch ECMV.......................................................................................................... 60-24
Lockup clutch ECMV .......................................................................................................... 60-25
Main relief and torque converter relief valve.......................................................................... 60-26
Axle .................................................................................................................................. 60-27
Differential ......................................................................................................................... 60-29
Final drive ......................................................................................................................... 60-39
Steering system........................................................................................................................ 60-41
Steering column................................................................................................................. 60-41
Steering pump ................................................................................................................... 60-42
WA470-7

00-15

00 Index and foreword


Index

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


Steering cylinder ................................................................................................................ 60-48
Emergency steering pump .................................................................................................. 60-51
Brake system ........................................................................................................................... 60-52
Charge valve ..................................................................................................................... 60-52
Slack adjuster .................................................................................................................... 60-54
Brake ................................................................................................................................ 60-55
Parking brake .................................................................................................................... 60-57
Parking brake solenoid valve .............................................................................................. 60-58
Undercarriage and frame........................................................................................................... 60-59
Axle mount and center hinge pin.......................................................................................... 60-59
Hydraulic system ...................................................................................................................... 60-63
Hydraulic tank.................................................................................................................... 60-63
Double type gear pump ...................................................................................................... 60-64
Work equipment pump........................................................................................................ 60-65
Control valve ..................................................................................................................... 60-67
Work equipment ....................................................................................................................... 60-76
Work equipment linkage ..................................................................................................... 60-76
Bucket .............................................................................................................................. 60-80
Work equipment cylinder .................................................................................................... 60-81
80 Appendix...................................................................................................................................... 80-1
Table of contents ........................................................................................................................ 80-2
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-6
Outline of refrigeration cycle.................................................................................................. 80-7
Air conditioner unit ............................................................................................................... 80-9
Dual pressure switch .......................................................................................................... 80-14
Air conditioner controller ..................................................................................................... 80-15
Compressor....................................................................................................................... 80-16
Condenser ........................................................................................................................ 80-17
Receiver drier .................................................................................................................... 80-18
Sunlight sensor .................................................................................................................. 80-20
Outer temperature sensor (outside air temperature sensor) ................................................... 80-21
Procedure for testing and troubleshooting ............................................................................ 80-22
Circuit diagram and arrangement of connector pins............................................................... 80-24
System diagram................................................................................................................. 80-27
Parts and connectors layout................................................................................................ 80-30
Testing with self-diagnosis function ...................................................................................... 80-35
How to open the electrical system abnormality record screen in service mode of the machine
monitor ................................................................................................................ 80-36
Testing temperature control system ..................................................................................... 80-38
Testing vent (mode) changeover.......................................................................................... 80-40
Testing FRESH/RECIRC air changeover.............................................................................. 80-42
Check evaporator temperature sensor ................................................................................. 80-44
Testing relays .................................................................................................................... 80-46
Troubleshooting chart 1 ...................................................................................................... 80-48
Troubleshooting chart 2 ...................................................................................................... 80-49
Information in troubleshooting table ..................................................................................... 80-51
Failure code list related to air conditioner.............................................................................. 80-52
Failure code [879AKA] A/C Inner Sensor Open Circuit .......................................................... 80-53
Failure code [879AKB] A/C Inner Sensor Short Circuit........................................................... 80-55
Failure code [879BKA] A/C Outer Sensor Open Circuit.......................................................... 80-57
Failure code [879BKB] A/C Outer Sensor Short Circuit .......................................................... 80-59
Failure code [879CKA] Ventilating Sensor Open Circuit ......................................................... 80-61
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-63
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................................................ 80-65
Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-67

00-16

WA470-7

00 Index and foreword


Index

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


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

WA470-7

00-17

00 Index and foreword


Foreword, safety and general information

Foreword, safety and general information


Important safety notice

(ALL-0370-001-A-00-A)

(ALL-1120-012-A-01-A)

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

handling causes an extreme


danger. Read and understand what is
described in the operation and maintenance
manual before operating the machine. Read
and understand what is described in this
manual before starting the work.

Before performing any greasing or repairs, read


all the safety labels stuck to the machine. For
the locations of the safety labels and detailed
explanation of precautions, see the operation
and maintenance manual.
Locate a place in the repair workshop to keep
the tools and removed parts. Always keep the
tools and parts in their correct places. Always
keep the work area clean and make sure that
there is no dirt, water or oil on the floor. Smoke
only in the areas provided for smoking. Never
smoke while working.
When performing any work, always wear the
safety shoes and helmet. Do not wear loose
work cloths, or clothes with buttons missing.

1. Always wear the protective eyeglasses when


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

00-18

knowledge of welding perform the work. When


performing welding work, always wear welding
gloves, apron, shielding goggles, cap, etc.
Before starting work, warm up your body
thoroughly to start work under good condition.
Avoid continuing work for long hours and take
rests with proper intervals to keep your body in
good condition. Take a rest in a specified safe
place.
Safety points
1
2
3
4
5
6
7
8
9
10

Good arrangement
Correct work clothes
Observance of work standard
Practice of making and checking signals
Prohibition of operation and handling by
unlicensed workers
Safety check before starting work
Wearing protective goggles (for cleaning or
grinding work)
Wearing shielding goggles and protectors (for
welding work)
Good physical condition and preparation
Precautions against work which you are not
used to or you are used to too much

Preparation
Before adding oil or making any repairs, place
the machine on a firm and level ground, and
apply the parking brake and chock the wheels or
tracks to prevent the machine from moving.
Before starting work, lower the work equipment
(blade, ripper, bucket, etc.) to the ground. If it is
not possible to lower the equipment to the
ground, insert the lock pin or use blocks to
prevent the work equipment from falling. And be
sure to lock all the work equipment control levers
and hang a warning tag on them.
When performing the disassembling or
assembling work, support the machine securely
with blocks, jacks, or stands before starting the
work.
Remove all of mud and oil from the steps or
other places used to get on and off the machine
completely. Always use the handrails, ladders of
WA470-7

00 Index and foreword


Foreword, safety and general information

steps when getting on or off the machine. Never


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

WA470-7

When removing piping, prevent the fuel or oil


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

00-19

00 Index and foreword


Foreword, safety and general information

Keep putting on the gloves during sling work.


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

Use the specified eye bolts and fix wire ropes,


chains, etc. to them with shackles, etc.
Apply wire ropes to the middle portion of the
hook.
a Slinging near the tip of the hook may cause
the rope to slip off the hook during hoisting.
The hook has the maximum strength at the
middle part.

k Slinging

with one rope may cause turning


of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.

Hanging angle must be 60 degrees or smaller as


a rule.
When hanging a heavy load (25kg or heavier),
the hanging angle of the rope must be narrower
than that of the hook.
a When slinging a load with two ropes or more,
the larger the hanging angle is, the larger the
tension of each rope. The figure bellow
shows the variation of allowable load in kN
{kg} when hoisting is made with two ropes,
each of which is allowed to sling up to 9.8 kN
{1000kg} a load vertically, at various hanging
angles. When the two ropes sling a load
vertically, up to19.6 kN {2000 kg} of total
weight can be suspended. This weight is
reduced to 9.8 kN {1000 kg} when the two
ropes make a hanging angle of 120 degrees.
If the two ropes sling a 19.6 kN {2000 kg}
load at a hanging angle of 150 degrees, each
rope is subjected to a force as large as 39.2
kN {4000 kg}.

Do not use twisted or kinked wire ropes.


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

When installing wire ropes to an angular load,


apply pads to protect the wire ropes. If the load
is slippery, apply proper material to prevent the
wire rope from slipping.

00-20

WA470-7

00 Index and foreword


Foreword, safety and general information

Precautions for using overhead traveling crane


k The

hoist or crane must be used to sling the


components weighing 25 kg or heavier. A
part weighing 25 kg or heavier in
"disassembly and assembly" section is
indicated with the symbol of 4 .

Before starting work, check the wire ropes,


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

Allowable load
kN
8.8

ton
0.9

Nominal
diameter of rope
mm
12
14
16
18
20
25
30
40
50
60

Allowable load
kN
12.7
17.3
22.6
28.6
35.3
55.3
79.6
141.6
221.6
318.3

ton
1.3
1.7
2.3
2.9
3.6
5.6
8.1
14.4
22.6
32.4

a The allowable load is calculated as one sixth of


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

replacing the air conditioner unit, air


conditioner compressor, condenser or
receiver drier, etc., collect the refrigerant (air
conditioner gas: R134a) from the air
conditioner circuit before disconnecting the
air conditioner hoses.

a Ask a qualified person for collecting, adding and


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

refrigerant gas (air conditioner gas: R134a)


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

When loosening the nuts fixing air conditioner


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

00-21

00 Index and foreword


Foreword, safety and general information

Check that the O-ring is not damaged or


deteriorated.
Apply compressor oil for refrigerant (R134a) to
the O-ring.
a However, do not apply oil to the threaded
portion of a bolt, nut or union.
Manufacturer
DENSO
VALEO THERMAL
SYSTEMS
SANDEN

Part name
ND-OIL8
ZXL100PG (equivalent to
PAG46)
SP-10

When tightening nuts of the air conditioner


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

For tightening torques, see "Others",


"Precautions for disconnection and connection
of air conditioner piping".

00-22

WA470-7

00 Index and foreword


Foreword, safety and general information

Fire prevention
Action if fire occurs

(ALL-0000-001-K-27-A)
(ALL-0000-17A-K-01-A)

Turn the starting switch to the OFF position to


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

Prevent fire

(ALL-0000-17B-K-03-A)

Fire caused by fuel, oil, coolant or window


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

WA470-7

9 J D 0 1 7 2 0

9 J D 0 1 7 2 1

Fire caused by accumulation or attachment


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

00-23

00 Index and foreword


Foreword, safety and general information

KDPF is a system for purifying soot in exhaust


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

Dispose of waste materials

(ALL-0000-99A-K-02-A)

To prevent pollution, pay full attention to the way to


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

Some kinds of rubber and plastics may produce


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

00-24

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00 Index and foreword


Foreword, safety and general information

How to read the shop manual

(ALL-0320-010-A-01-A)

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

Item

Safety

Caution

Weight

Tightening
torque

WA470-7

Remarks
The special safety precautions required for performing work are
described.
The special technical precautions or other precautions for preserving
standards required when performing work are described
The weight of part or component and the cautions required when
selecting hoisting wire or when working posture is important are
described.
The tightening torques that require special attention during assembly
work are described.

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00 Index and foreword


Foreword, safety and general information

Symbol

Item

Coat

Oil, coolant

Drain

Remarks
The places to be coated with adhesives, etc. during assembling are
indicated.
The places to which oil is supplied and the quantity of the oil are
indicated.
The places from which oil is drained and quantity of the oil are indicated.

Unit
In this shop manual, the units are indicated with International System of units (SI).
For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.

00-26

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Foreword, safety and general information

Explanation of terms for maintenance standard

(ALL-0330-006-A-01-A)

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

Tolerance
-0.022
-0.126

120

The tolerance may be indicated in the text and a


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

Tolerance
Shaft
-0.030
-0.076

Hole
+0.046
0

Standard clearance and standard value


The clearance made when new parts are
assembled is called the standard clearance,
which is indicated by the range from the
minimum clearance to the maximum clearance.
When some parts are repaired, the clearance is
generally adjusted to the standard clearance.
The values indicating performance and function
of new products or equivalent are called the
"standard value", which is indicated by a range
or a target value.
When some parts are repaired, the value of
performance/function is set to the standard
value.

WA470-7

Standard interference
When the diameter of a hole of a part shown in
the given standard dimension and tolerance
table is smaller than that of the shaft to be
inserted, the difference between those
diameters is called the "interference".
Subtract the maximum dimension of the hole
from the minimum dimension of the shaft and
call it (A). Subtract the minimum dimension of
the hole from the maximum dimension of the
shaft and call it (B). The range between (A) and
(B) is the "standard interference".
After repairing or replacing some parts, measure
the dimension of their hole and shaft and check
that the interference is in the standard range.
Repair limit and allowable value or allowable
dimension
The dimensions of parts change because of the
wear or deformation while they are used. When
the dimension changes exceeding certain value,
the parts can not be used any longer. This value
is called "repair limit".
If a part is worn to the repair limit, it must be
replaced or repaired.

00-27

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Foreword, safety and general information

The performance and function of the products


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

00-28

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Foreword, safety and general information

Handling equipment of fuel system devices

(PC-AD00-2A4-K-00-A)

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

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Foreword, safety and general information

Handling of intake system parts

(PC220-A900-2A4-K-00-A)

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

00-30

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00 Index and foreword


Foreword, safety and general information

Handling of hydraulic equipment

(ALL-C000-2A4-P-01-A)

(Rev. 2012/01)
With the increase in pressure and precision of the hydraulic components, the most common cause of a
failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when
adding hydraulic oil,or when disassembling or assembling the hydraulic components.
Be careful of working environment
Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.
Disassembly and maintenance work in the field
When disassembly or maintenance work of the
hydraulic is performed in the field, there is
danger of dust entering the components. It is
also difficult to check the performance of the
components after repairs, so it is desirable to
use the component exchange service. The
disassembly and assembly of the hydraulic
components must be performed in the specially
arranged dustproof workshop and the
performance test of the components must be
performed with the special testing equipment.

Sealing openings
Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never leave the openings of the
pipes and hoses without being covered or
plugged with cloth as foreign material may enter
them or environment may be polluted by the oil
leaked. Do not discard the waste oil somewhere
or other. Hand it over to your customer for
disposal, or dispose it by yourself.

WA470-7

Preventing intrusion of foreign materials during


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

Replacing hydraulic oil while its temperature is


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

00-31

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Foreword, safety and general information

Flushing operations
After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.

Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil circuit.
The oil cleaning equipment can remove the ultra
fine (approximately 3 m) particles that the filter
built in the hydraulic equipment can not remove.
So, it is an extremely effective device.

00-32

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Foreword, safety and general information

Method of disconnecting and connecting of push-pull type coupler

(ALL-

C930-001-P-00-A)

(Rev. 2012/01)
k Loosen

the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the
hydraulic tank.

k Even

if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.

Type 1

(ALL-C930-925-P-01-A)

Disconnection
1. Hold adapter (1) and push hose joint (2) into
mating adapter (3). (Fig. 1)
a It can be pushed in by approximately 3.5mm.
a Do not hold rubber cap portion (4).
2. While pushing hose joint (2) into adapter (3),
push rubber cap (4) against adapter (3) until
"click" is heard. (Fig. 2)
3. Hold hose adapter (1) or hose (5) and pull it out.
(Fig. 3)
a Since some hydraulic oil flows out, prepare
an oil container.

WA470-7

Connection
1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3) aligning them with each other.
(Fig. 4)
a Do not hold rubber cap part (4).
2. After inserting the hose fitting in the adapter on
the other side perfectly, pull it back to check the
connecting condition. (Fig. 4)
a When the hose fitting is pulled back, the
rubber cap will move toward the hose,
however, it is not a problem.

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Foreword, safety and general information

Type 2

(ALL-C930-925-P-02-A)

Disconnection
1. While holding the fitting, push body (7) in straight
until sliding prevention ring (6) hits contact
surface (a) at the hexagonal part on the male
side. (Fig. 6)
2. While keeping the condition of Step 1, turn lever
(8) to the right (clockwise). (Fig. 7)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (7) to disconnect it. (Fig. 8)

00-34

Connection
1. While holding the fitting, push body (7) in straight
until sliding prevention ring (6) hits contact
surface (a) at the hexagonal part on the male
side to connect it. (Fig. 9)

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00 Index and foreword


Foreword, safety and general information

Type 3

(ALL-C930-925-P-03-A)

Disconnection
1. While holding the fitting, push body (9) in straight
until sliding prevention ring (8) hits contact
surface (b) at the hexagonal portion on the male
side. (Fig. 10)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface (b)
of the hexagonal portion on the male side. (Fig.
11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig. 12)

WA470-7

Connection
1. While holding the fitting, push body (9) in straight
until sliding prevention ring (8) hits contact
surface (a) at the hexagonal portion on the male
side to connect them. (Fig. 13)

00-35

00 Index and foreword


Foreword, safety and general information

Handling of electrical equipment

(ALL-E000-2A4-P-01-A)

(Rev. 2012/01)
To maintain the performance of the machine over a long period, and to prevent failures or troubles before
they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics components
and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in
"Handling of electrical equipment".
Precautions for handling electric equipment
Handling wiring harnesses and connectors
Wiring harnesses consist of wires connecting
one component to another component,
connectors used for connecting and
disconnecting one wire from another wire, and
protectors or tubes used for protecting the wires.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling the wiring harnesses.

Main failures occurring in wiring harness


Defective contact of connectors (defective
contact between male and female connectors)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,or
because one or both of connectors are
deformed or the position is not correctly aligned,
or because there is corrosion or oxidization of
the contact surfaces. The corroded or oxidized
contact surfaces may become shiny again (and
contact may become normal) by connecting and
disconnecting the connectors approximately ten
times.

00-36

Defective crimping or soldering of connectors


The pins of the male and female connectors are
attached to wires by crimping or soldering. If
excessive force is applied to the wire, the joining
area may become loose, which may result in a
defective connection or breakage.

Disconnections in wiring
If the wiring harness is pulled to disconnect the
connector, or the components are lifted with a
crane while the wiring harness is still connected,
or a heavy object hits the wiring harness, the
crimping of the connector may separate, or the
soldering may be damaged, or the wiring
harness may be broken.

WA470-7

00 Index and foreword


Foreword, safety and general information

blow it with compressed air and spray it with


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

High-pressure water entering connector


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

Removing, installing, and drying connectors


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

Entry of water, mud or dirt when disconnecting a


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

WA470-7

2. When removing from clips


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

00-37

00 Index and foreword


Foreword, safety and general information

Check that there is no oil, dirt or water stick


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

When removing a connector from a clip, pull


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

a If any oil, water or dirt is stuck to the


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

3. Action to take after removing connectors


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

3. Correct the protrusion of the boot and


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

Connecting connectors
1. Check the connector visually.

00-38

WA470-7

00 Index and foreword


Foreword, safety and general information

If the connector clamp is removed, be sure to


return it to its original position. And check
that it is securely installed.

If there is any oil or dirt on the wiring harness,


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

Deutsch connector (DT8-pin, DT12-pin)


Disconnection
1. While pressing locks (a) and (b) from each side
respectively, pull out female connector (2).

2. Dry the inside of the connector with a dryer.


If water gets inside the connector, use a dryer to
dry the connector.

Connection
1. Push in female connector (2) horizontally until
the lock clicks. (Arrow: x)
2. Since locks (a) and (b) may not be set
completely, push in female connector (2) with
curving movement until the locks are set
normally. (Arrow: x, y, and z)

a Hot air from the dryer can be used, but


regulate the time to use hot air in order to
prevent the connector or related parts from
becoming too hot, as it causes deformation
or damage to the connector.

a Lock (a) in the figure is pulled down (not set


completely), and lock (b) is set completely.

3. Perform a continuity test on the connector.


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

00 Index and foreword


Foreword, safety and general information

Handling of connectors used on engine

2. While pressing lock (L2), pull out connector (1).

Slide, lock type (Type 1) (FRAMATOME-3,


FRAMATOME-2)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a In the case that even if lock (L2) is pressed,
connector (1) cannot be pulled out toward
you unless part A floats, float part A with a
small flat-head screwdriver while pressing
lock (L2), and then pull out connector (1)
toward you.
a Lock (L2) is located in the back of connector
(1).

Connection
1. Insert the connector securely until a click is
heard.
Slide, lock type (Type 2) (FRAMATOME-24)
Disconnection
1. Slide down lock (red) (L1).

00-40

Connection
1. Insert the connector securely until a click is
heard.
Pull lock type (PACKARD-2)
Disconnection
1. Disconnect the connector (2) by pulling lock (B)
(on the wiring harness side) of connector (2)
outward.

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00 Index and foreword


Foreword, safety and general information

Connection
1. Insert the connector securely until a click is
heard.

Connection
1. Insert the connector securely until a click is
heard.

Push lock type (1) (BOSCH-3)


Disconnection

Push lock type (2) (SUMITOMO-4)


Disconnection

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


the direction of the arrow.
114 series

1. While pressing lock (C), pull out connector (4) in


the direction of the arrow.
Connection
1. Insert the connector securely until a click is
heard.

107 series
Push lock type (3) (AMP-3)
Disconnection
1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.
Example) Fuel pressure sensor in common rail:
PFUEL etc (AMP-3)

a If the lock is located on the underside, use


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

WA470-7

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Foreword, safety and general information

Example) Injection pressure control valve of


supply pump: PCV (SUMITOMO-2)

Example) Speed sensor of supply pump: G


(SUMITOMO-3)
a Pull the connector straight up.

Connection
1. Insert the connector securely until a click is
heard.
Turn-housing type (Round green connector)
(CANNON-4)
Disconnection

Connection
1. Insert the connector to the end while aligning its
grove to the other.
2. Turn housing (H1) in the direction of the arrow
until it "clicks".

Handling controller
The electronic circuits for control including the
microcomputers are assembled in the controller.
These electronic circuits in the controller must
be handled with care as they control the
machine.
Do not place objects on top of the controller.

1. Turn housing (H1) in the direction of the arrow.


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

Cover the control connectors with tape or a vinyl


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

00-42

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Foreword, safety and general information

temperature even for a short period of time.


(Place it on a suitable dry stand.)

Precautions when performing arc welding


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

WA470-7

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Foreword, safety and general information

How to read electric wire code

(ALL-E500-030-P-00-A)

(Rev. 2012/01)
In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by
symbols. The wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not
indicated on the diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.
Type, symbol, and material
AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular
compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of
the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV
and AVS in material of the coating.
(Table 1)
Type

Symbol

Low-voltage
wire for
AV
automobile
Thin-cover
low-voltage
wire for
AVS
automobile
(Type 1)
Thin-cover
low-voltage
wire for
CAVS
automobile
Type 2
Heatresistant lowvoltage wire AEX
for
automobile

00-44

Conductor
material

Insulator material

Temperature
range (C) in
use

Example of use
For large current wiring
(nominal No. 5 and above)

Soft polyvinyl chloride

-30 to +60

Annealed
copper for
electric
appliance

General wiring
(nominal No. 3 and lower)

For mid- to small-size


excavators
(nominal No. 1.25 and lower)

Heat-resistant cross
linked polyethylene

-50 to +110

(Safety factor:
Wiring at high-temperature
place

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Dimension
(Table 2)

Coating D

(0.5) 0.75f (0.85) 1.25f (1.25)


Nominal No.
0.5f
Number of
strands/
20/
30/
11/
50/
16/
7/0.32
Diameter of 0.18
0.18 0.32 0.18 0.32
strand
Conductor
Crosssectional
0.51 0.56 0.76 0.88 1.27 1.29
area (mm2)
d (approx.)
1.0
1.2
1.5
AVS Standard
2.0
2.2
2.5

AV
Standard
AEX

Standard

2.0

2.2

2.7

2f

3f

37/
0.26

26/
0.32

58/
0.26

41/
0.32

65/
0.32

1.96

2.09

3.08

3.30

5.23

1.9
2.9

1.9
2.9

2.3
3.5

2.4
3.6

3.0

4.6

3.0

3.1

3.8

4.6

Coating D

Nominal No.
8
15
20
30
40
Number of
strands/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of
strand
Conductor
Crosssectional
7.95
13.36
20.61
35.19
42.73
area (mm2)
d (approx.)
3.7
4.8
6.0
8.0
8.6

AVS Standard
AV
Standard
5.5
7.0
8.2
10.8
11.4
AEX

Standard

Coating D

Nominal No.
Number of
strands/
Diameter of
strand
Conductor
Crosssectional
area (mm2)
d (approx.)
CAVS

Standard

5.3

7.0

8.2

10.8

50

60

85

100

108/
0.80

127/
0.80

169/
0.80

217/
0.80

54.29

63.84

84.96

109.1

9.8

13.0

10.4

13.6

12.0

16.0

13.6

17.6

13.0

13.6

16.0

17.6

11.4

0.5f

0.5

0.75f

0.85

1.25f

1.25

7/round
compression

11/round
compression

16/round
compression

0.56

0.88

1.29

0.9

1.1

1.4

1.6

1.8

2.1

a "f" of nominal No. denotes "flexible".

WA470-7

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Foreword, safety and general information

Color codes table


(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR

Color of wire
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red

Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW

Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow & Green
Yellow & Blue
Yellow & Red
Yellow & White

a Remarks: In a color code consisting of two colors, the first color is the color of the background and the
second color is the color of the marking.
Examples)
GW means that the background is "Green" and marking is "White".
Types of circuits and color codes
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Appendix

00-46

R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch

WG

RB
YR
GW
LW
BrW
LgR

AVS, AV, CAVS

RY
RG
YB
YG
GR
GY
LR
LY
BrR
BrY
LgY
LgB

AEX

RL
YL
GB
LB
BrB
LgW

YW
GL

R
B
R
D
Y
G
L

Gr
Br

WA470-7

00 Index and foreword


Foreword, safety and general information

Precautions when performing operation

(ALL-1160-927-A-00-A)

(Rev. 2012/01)
When performing "removal or installation" and "disassembly or assembly" of the components, observe the
following general cautions.
Precautions for removal work
If the coolant contains antifreeze, dispose of it correctly as chemicals. Do not drain the coolant to the
sewage rashly.
After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
When draining oil, prepare a container with sufficient capacity.
Check the match marks which indicate the installing position, and put match marks on the places where
they seem necessary before removal of the components to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
Attach the tags to wires and hoses to show their installing positions to prevent any mistake when
installing.
Check the number and thickness of the shims, and keep them in a safe place.
When hoisting the components, prepare the slings with sufficient strength.
When using forcing screws to remove any component, tighten the forcing screws uniformly and
alternately.
Before removing any component, clean the surrounding area and cover the component to prevent any
foreign material from entering after removal.
a Precautions when handling piping during disassembly
Use the plugs indicated below for the pipes disconnected at the disassembly.
Face seal type hoses and tubes
Nominal No.
02
03
04
05
06

Plug (nut end)


07376-70210
07376-70315
07376-70422
07376-70522
07376-70628

Nut (elbow end)


02789-00210
02789-00315
02789-00422
02789-00522
02789-00628

Split flange type hoses and tubes


Nominal No.
04
05

WA470-7

Flange (hose end)


07379-00400
07379-00500

Sleeve head (tube end)


07378-10400
07378-10500

Split flange
07371-30400
07371-30500

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If the part is not under hydraulic pressure, the following corks can be used.
Nominal No.

Part No.

06
08
10
12
14
16
18
20
22
24
27

07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
07049-02734

D
6
8
10
12
14
16
18
20
22
24
27

Dimensions
d
5
6.5
8.5
10
11.5
13.5
15
17
18.5
20
22.5

L
8
11
12
15
18
20
22
25
28
30
34

Precautions for installation work


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

00-48

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Foreword, safety and general information

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

WA470-7

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Precautions at the time of completing work


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

00-50

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Foreword, safety and general information

Practical use of KOMTRAX

(ALL-Q210-13V-K-00-A)

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

WA470-7

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Foreword, safety and general information

Standard tightening torque table

(ALL-M140-03B-P-01-A)

(Rev. 2012/01)
Table of tightening torque for bolts and nuts
Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.
1. The following table applies to the bolts in Fig. A.
Thread
diameter
(mm)
6
8
10
12
14
16
18

Width
across flats
(mm)
10 (10)
13 (12)
17 (14)
19 (17)
22
24
27

(Nm)
11.8 to 14.7
27 to 34
59 to 74
98 to 123
157 to 196
245 to 309
343 to 427

(kgm)
1.2 to 1.5
2.8 to 3.5
6.0 to 7.5
10.0 to 12.5
16 to 20
25 to 31.5
35 to 43.5

20

30

490 to 608

50 to 62

22
24
27
30
33
36
39

32
36
41
46
50
55
60

662 to 829
824 to 1,030
1,180 to 1,470
1,520 to 1,910
1,960 to 2,450
2,450 to 3,040
2,890 to 3,630

67.5 to 84.5
84 to 105
120 to 150
155 to 195
200 to 250
250 to 310
295 to 370

Tightening torque

a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.
2. The following table applies to the bolts in Fig. B.
Thread
diameter
(mm)
6
8
10
12
Fig. A

Width
across flats
(mm)
10
12
14
17

Tightening torque
(Nm)
5.9 to 9.8
13.7 to 23.5
34.3 to 46.1
74.5 to 90.2

(kgm)
0.6 to 1.0
1.4 to 2.4
3.5 to 4.7
7.6 to 9.2
Fig. B

a Values with parentheses are applied to the width across flats of (*) marked bolts (flanged bolts)

00-52

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Foreword, safety and general information

Table of tightening torque for split flanged bolts


a Unless otherwise specified, tighten the split flange bolt to the torque shown in the table below.
Thread
diameter
(mm)
10
12
16

Width
across flats
(mm)
14
17
22

Tightening torque
(Nm)
59 to 74
98 to 123
245 to 309

(kgm)
6.0 to 7.5
10.0 to 12.5
25 to 31.5

Table of tightening torque for O-ring boss piping joints


a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.
Nominal No.
02

03, 04
05, 06
10, 12
14

Thread
diameter
(mm)
14
18
20
24
33
42

Width
across flats
mm
Varies
depending
on type of
connector.

Tightening torque (Nm {kgm})


Range
35 to 63 {3.5 to 6.5}
59 to 98 {6.0 to 10.0}
84 to 132 {8.5 to 13.5}
128 to 186 {13.0 to 19.0}
363 to 480 {37.0 to 49.0}
746 to 1,010 {76.0 to 103}

Target
44 {4.5}
78 {8.0}
103 {10.5}
157 {16.0}
422 {43.0}
883 {90.0}

Table of tightening torque for O-ring boss plugs


a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.
Nominal No.
08
10
12
14
16
18
20
24
30
33
36
42
52

WA470-7

Thread
diameter
(mm)
8
10
12
14
16
18
20
24
30
33
36
42
52

Width
across flats
mm
14
17
19
22
24
27
30
32
32

36

Tightening torque (Nm {kgm})


Range
5.88 to 8.82 {0.6 to 0.9}
9.8 to 12.74 {1.0 to 1.3}
14.7 to 19.6 {1.5 to 2.0}
19.6 to 24.5 {2.0 to 2.5}
24.5 to 34.3 {2.5 to 3.5}
34.3 to 44.1 {3.5 to 4.5}
44.1 to 53.9 {4.5 to 5.5}
58.8 to 78.4 {6.0 to 8.0}
93.1 to 122.5 {9.5 to 12.5}
107.8 to 147.0 {11.0 to 15.0}
127.4 to 176.4 {13.0 to 18.0}
181.3 to 240.1 {18.5 to 24.5}
274.4 to 367.5 {28.0 to 37.5}

Target
7.35 {0.75}
11.27 {1.15}
17.64 {1.8}
22.54 {2.3}
29.4 {3.0}
39.2 {4.0}
49.0 {5.0}
68.6 {7.0}
107.8 {11.0}
127.4 {13.0}
151.9 {15.5}
210.7 {21.5}
323.4 {33.0}

00-53

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Foreword, safety and general information

Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a The table is applied to the threads coated with engine oil (wet threads)
Nominal
No. of
hose

Width
across
flats
(mm)

02

19

03
04
05
06
(10)
(12)
(14)

22
24
27
32
36
41
46
55

Tightening torque (Nm {kgm})

Taper seal

Range

Target

34 to 54 {3.5 to 5.5}
34 to 63 {3.5 to 6.5}
54 to 93 {5.5 to 9.5}
59 to 98 {6.0 to 10.0}
84 to 132 {8.5 to 13.5}
128 to 186 {13.0 to 19.0}
177 to 245 {18.0 to 25.0}
177 to 245 {18.0 to 25.0}
197 to 294 {20.0 to 30.0}
246 to 343 {25.0 to 35.0}

44 {4.5}
44 {4.5}
74 {7.5}
78 {8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}

Face seal
Nominal No. - Thread root
Thread size threads per
diameter
inch, type of (reference)
(mm)
thread

9/16 -18UN
14.3

14

11/16 -16UN
17.5

18
22
13/16 -16UN
20.6
24
1 -14UNS
25.4
30
1-3/16 -12UN
30.2

33

36

42

Table of tightening torque for face seal joints


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

19
22
24 {27}
30 {32}
36

Tightening torque (Nm {kgm})


Range

Target

14 to 16 {1.4 to 1.6}
24 to 27 {2.4 to 2.7}
43 to 47 {4.4 to 4.8}
60 to 68 {6.1 to 6.8}
90 to 95 {9.2 to 9.7}

15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}

Face seal
Thread root
Nominal No. diameter
threads per inch,
type of thread
(Reference)
9/16 -18UN
11/16 -16UN
13/16 -16UN
1 -14UNS
1-3/16 -12UN

14.3
17.5
20.6
25.4
30.2

Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.

00-54

WA470-7

00 Index and foreword


Foreword, safety and general information

Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Thread diameter
(mm)
6
8
10
12
14

Tightening torque
(Nm)
10 2
24 4
43 6
77 12

(kgm)
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22

Tightening torque table for I-joints on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric I-joints used on the 102, 107 and 114 series engines to the
torque shown in the following table.
Thread diameter
(mm)
6
8
10
12
14

Tightening torque
(Nm)
82
10 2
12 2
24 4
36 5

(kgm)
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51

Tightening torque table for tapered screws on 102,107 and 114 series engines
a Unless otherwise specified, tighten the tapered inch thread screws used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Material
Thread diameter (inch)
1/16
1/8
1/4
3/8
1/2
3/4

WA470-7

In cast iron or steel


Tightening torque
(Nm)
(kgm)
15 2
1.53 0.20
20 2
2.04 0.20
25 3
2.55 0.31
35 4
3.57 0.41
55 6
5.61 0.61
75 8
7.65 0.82

In aluminum
Tightening torque
(Nm)
(kgm)
51
0.51 0.10
15 2
1.53 0.20
20 2
2.04 0.20
25 3
2.55 0.31
35 4
3.57 0.41
45 5
4.59 0.51

00-55

00 Index and foreword


Foreword, safety and general information

List of abbreviation

(ALL-0360-005-A-00-A)

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

Actual word spelled


out

Purpose of use (major


applicable machine (*), or
equipment/device)

Explanation

ABS

Anti-skid Brake
System

Travel and brake


(HD, HM)

Function with which when the tires skid


(wheels stop rotating), the brakes are
released, and when the wheels start to rotate,
the brakes are applied again.

AISS

Automatic Idling
Setting System

Engine

Automatic setting function of at idle speed

AJSS

ARAC

ARSC

ASR
ATT
BCV
CAN
CDR

CLSS

CRI

ECM

00-56

Function that a lever can perform the steering


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

Steering
(WA)

WA470-7

00 Index and foreword


Foreword, safety and general information

Abbreviation
ECMV

ECSS

ECU

EGR

EMMS

EPC
FOPS
F-N-R
GPS

HSS

Actual word spelled


out

Purpose of use (major


applicable machine (*), or
equipment/device)

Proportional electromagnetic valve that


gradually increases oil pressure to engage
clutch and reduces transmission shock.
System that ensures smooth high-speed
Electronically
Travel
travel by using hydraulic spring effect of
Controlled Suspension
accumulator to absorb vibration of machine
(WA)
System
during travel
Electronic control device that uses the signals
from the sensors on the machine to indicate
Electronic Control Unit Electronic control system the optimum actuation to the actuators .
(Same as ECM)
Function to recirculate part of exhaust gas to
Exhaust Gas
combustion chamber in order to reduce
Engine
Recirculation
combustion temperature and to control
emission of NOx.
System
that allows data (filter, oil replacement
Equipment
interval,
malfunctions on machine, failure
Management
Machine monitor
code,
and
failure history) from each sensor on
Monitoring System
the machine to be checked on monitor.
Electromagnetic proportional control
Electromagnetic
Oil pressure
Mechanism that actuator works in proportion
Proportional Control
to current
Structure that protects operator's head from
Falling Object
falling objects. (Structure to protect operator)
Cab and canopy
Protective Structure
Performance standardized in ISO 3449
Forward-NeutralOperation
Forward - NEUTRAL - REVERSE
Reverse
Communication
Global Positioning System Satellite
Global Positioning
positioning system that is used to determine
(KOMTRAX
KOMTRAX
System
the current location on the earth
Plus)
Steering function that uses a combination of
hydraulic motor and bevel shaft to control
Steering
Hydrostatic Steering
difference in travel speed of right and left
System
(D)
tracks to turn machine without using steering
Electronic Control
Modulation Valve

Transmission
(D, HD, WA, etc.)

Transmission
(D, WA)

HST

Hydro Static
Transmission

IMA

Inlet Metering Actuator Engine

IMV

Inlet Metering Valve

Engine

KCCV

Komatsu Closed
Engine
Crankcase Ventilation

KCSF

Komatsu Catalyzed
Soot Filter

Engine

KDOC

Komatsu Diesel
Oxidation Catalyst

Engine

KDPF

Komatsu Diesel
Particulate Filter

Engine

WA470-7

Explanation

clutch.
Hydraulic transmission system that uses a
combination of hydraulic pump and hydraulic
motor to shift gear steplessly without using
gears.
Valve that adjusts fuel intake amount at inlet
port of pump in order to control fuel discharge
amount of supply pump. Same meaning as
IMV
Valve adjusting fuel intake amount at inlet port
of pump in order to control fuel discharge
amount of supply pump. Described IMV (IMA)
This mechanism separates oil in blowby gas
and returns it to the intake side to afterburn it
there. It primarily consists of filters.
This filter is used to capture soot in exhaust
gas.
It is built in to KDPF.
The catalyst used for purifying exhaust gas.
This is built in KDPF or assembled with the
muffler.
This component with built-in KDOC (catalyst)
and KCSF (soot-capturing filter)
purifies exhaust gas.

00-57

00 Index and foreword


Foreword, safety and general information

Abbreviation

Actual word spelled


out

Purpose of use (major


applicable machine (*), or
equipment/device)

KTCS

Komatsu Traction
Control System

Travel and brake


(HM system)

KVGT

Komatsu Variable
Geometry
Turbocharger

Engine

LCD

Liquid Crystal Display

Machine monitor

LED

Light Emitting Diode

Electronic parts

LIN

Local Interconnect
Network

Communication and
electronic control

LS

Load Sensing

Oil pressure

LVDS

Low Voltage
Differential Signaling

Communication and
electronic control

MAF

Mass Air Flow

Engine

MMS

Multimedia Messaging
Communication
Service

NC

Normally Closed

Electric and hydraulic

NO

Normally Open

Electric and hydraulic

Open-center Load
Sensing System

Oil pressure

Pressure
Compensation

Oil pressure

OLSS
PC

PCCS

Palm command control Steering


system
(D)

PCV

Pre-stroke Control
Valve

PPC

Proportional Pressure Oil pressure


Control

PPM
PTO
PTP

00-58

Piston Pump and


Motor
Power Take Off
Power Tilt and power
Pitch dozer

Engine

Oil pressure
(D, PC, etc.)
Power transmission
Work equipment
(D)

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

00 Index and foreword


Foreword, safety and general information

Abbreviation

Actual word spelled


out

Purpose of use (major


applicable machine (*), or
equipment/device)

Roll-Over Protective
Structure

Cab and canopy

International unit
system

Unit

SOL

Solenoid

Electric

TWV

Two Way Valve

Hydraulic and electric

VFT

Variable Flow
Turbocharger

Engine

ROPS:

SI

Explanation
Structure that protects operator fastening seat
belt from being crushed when machine tips
over (Structure to protect operator when
machine tips over)
Performance standardized in ISO 3471
Abbreviation for "International system of units"
Unit system that is employed worldwide, and
"one unit against one factor"
Actuator that moves a part with a movable iron
core in the coil (solenoid), which is moved by
energizing the coil.
Solenoid valve that switches the direction of
flow.
Turbocharger variable in route of exhaust
passage.

*1: Code for applicable machine family


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

Actual word spelled out


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

00-59

00 Index and foreword


Foreword, safety and general information

Abbreviation
T/C
T/M

00-60

Actual word spelled out


Torque Converter
Transmission

WA470-7

00 Index and foreword


Foreword, safety and general information

Conversion table

(ALL-2150-931-A-00-A)

(Rev. 2012/01)
Method of using the conversion table
The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 55 mm into inches
1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).
3. Take the point where the two lines cross as (C). This point (C) gives the value when converting the unit
from millimeters to inches. Therefore, 55 mm = 2.165 in.
Conversion of 550 mm into inches
1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the
left) to get 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65
in.
Millimeters to inches
(B)

(A)

WA470-7

0
10
20
30
40

0
0
0.394
0.787
1.181
1.575

1
0.039
0.433
0.827
1.220
1.614

2
0.079
0.472
0.866
1.260
1.654

3
0.118
0.512
0.906
1.299
1.693

4
0.157
0.551
0.945
1.339
1.732

50
60
70
80
90

1.969
2.362
2.756
3.150
3.543

2.008
2.402
2.795
3.189
3.583

2.017
2.441
2.835
3.228
3.622

2.087
2.480
2.847
3.268
3.661

2.126
2.520
2.913
3.307
3.701

5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740

6
0.236
0.630
1.024
1.417
1.811

1 mm 0.03937 in
7
8
9
0.276 0.315 0.354
0.669 0.709 0.748
1.063 1.102 1.142
1.457 1.496 1.536
1.850 1.890 1.929

2.205
2.598
2.992
3.386
3.780

2.244
2.638
3.032
3.425
3.819

2.283
2.677
3.071
3.465
3.858

2.323
2.717
3.110
3.504
3.898

00-61

00 Index and foreword


Foreword, safety and general information

Millimeters to inches

0
10
20
30
40
50
60
70
80
90

0
0
0.394
0.787
1.181
1.575
1.969
2.362
2.756
3.150
3.543

2
0.079
0.472
0.866
1.260
1.654
2.047
2.441
2.835
3.228
3.622

3
0.118
0.512
0.906
1.299
1.693
2.087
2.480
2.847
3.268
3.661

4
0.157
0.551
0.945
1.339
1.732
2.126
2.520
2.913
3.307
3.701

5
0.197
0.591
0.984
1.378
1.772
2.165
2.559
2.953
3.346
3.740

6
0.236
0.630
1.024
1.417
1.811
2.205
2.598
2.992
3.386
3.780

7
0.276
0.669
1.063
1.457
1.850
2.244
2.638
3.032
3.425
3.819

1 mm 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.323
2.677
2.717
3.071
3.110
3.465
3.504
3.858
3.898

1
2.20
24.25
46.30
68.34
90.39
112.44
134.48
156.53
178.57
200.62

2
4.41
26.46
48.50
70.55
92.59
114.64
136.69
158.73
180.78
202.83

3
6.61
28.66
50.71
72.75
94.80
116.85
138.89
160.94
182.98
205.03

4
8.82
30.86
51.91
74.96
97.00
119.05
141.10
163.14
185.19
207.24

5
11.02
33.07
55.12
77.16
99.21
121.25
143.30
165.35
187.39
209.44

6
13.23
35.27
57.32
79.37
101.41
123.46
145.51
167.55
189.60
211.64

7
15.43
37.48
59.53
81.57
103.62
125.66
147.71
169.76
191.80
213.85

1 kg 2.2046 lb
8
9
17.64
19.84
39.68
41.89
61.73
63.93
83.78
85.98
105.82 108.03
127.87 130.07
149.91 152.12
171.96 174.17
194.01 196.21
216.05 218.26

1
0.264
2.906
5.548
8.189
10.831
13.473
16.115
18.756
21.398
24.040

2
0.528
3.170
5.812
8.454
11.095
13.737
16.379
19.020
21.662
24.304

3
0.793
3.434
6.076
8.718
11.359
14.001
16.643
19.285
21.926
24.568

4
1.057
3.698
6.340
8.982
11.624
14.265
16.907
19.549
22.190
24.832

5
1.321
3.963
6.604
9.246
11.888
14.529
17.171
19.813
22.455
25.096

6
1.585
4.227
6.869
9.510
12.152
14.795
17.435
20.077
22.719
25.361

1 l 0.2642 U.S.Gal
7
8
9
1.849
2.113
2.378
4.491
4.755
5.019
7.133
7.397
7.661
9.774
10.039 10.303
12.416 12.680 12.944
15.058 15.322 15.586
17.700 17.964 18.228
20.341 20.605 20.870
22.983 23.247 23.511
25.625 25.889 26.153

1
0.039
0.433
0.827
1.220
1.614
2.008
2.402
2.795
3.189
3.583

Kilograms to pounds

0
10
20
30
40
50
60
70
80
90

0
0
22.05
44.09
66.14
88.18
110.23
132.28
154.32
176.37
198.42

l to U.S. Gallons

0
10
20
30
40
50
60
70
80
90

00-62

0
0
2.642
5.283
7.925
10.567
13.209
15.850
18.492
21.134
23.775

WA470-7

00 Index and foreword


Foreword, safety and general information

l to U.K. Gallons

0
10
20
30
40
50
60
70
80
90

0
0
2.200
4.399
6.599
8.799
10.998
13.198
15.398
17.598
19.797

1
0.220
2.420
4.619
6.819
9.019
11.281
13.418
15.618
17.818
20.017

2
0.440
2.640
4.839
7.039
9.239
11.438
13.638
15.838
18.037
20.237

3
0.660
2.860
5.059
7.259
9.459
11.658
13.858
16.058
18.257
20.457

4
0.880
3.080
5.279
7.479
9.679
11.878
14.078
16.278
18.477
20.677

5
1.100
3.300
5.499
7.699
9.899
12.098
14.298
16.498
18.697
20.897

6
1.320
3.520
5.719
7.919
10.119
12.318
14.518
16.718
18.917
21.117

1 l 0.21997 U.S.Gal
7
8
9
1.540
1.760
1.980
3.740
3.950
4.179
5.939
6.159
6.379
8.139
8.359
8.579
10.339 10.559 10.778
12.528 12.758 12.978
14.738 14.958 15.178
16.938 17.158 17.378
19.137 19.357 19.577
21.337 21.557 21.777

1
7.2
79.6
151.9
224.2
296.6
368.9
441.2
513.5
585.9
658.2
730.5
802.9
875.2
947.5
1019.9
1092.2
1164.5
1236.8
1309.2
1381.5

2
14.5
86.8
159.1
231.5
303.8
376.1
448.5
520.8
593.1
665.4
737.8
810.1
882.4
954.8
1027.1
1099.4
1171.7
1244.1
1316.4
1388.7

3
21.7
94.0
166.4
238.7
311.0
383.4
455.7
528.0
600.3
672.7
745.0
817.3
889.7
962.0
1034.3
1106.6
1179.0
1251.3
1323.6
1396.0

4
28.9
101.3
173.6
245.9
318.3
390.6
462.9
535.2
607.6
679.9
752.2
824.6
896.9
969.2
1041.5
1113.9
1186.2
1258.5
1330.9
1403.2

5
36.2
108.5
180.8
253.2
325.5
397.8
470.2
542.5
614.8
687.1
759.5
831.8
904.1
976.5
1048.8
1121.1
1193.4
1265.8
1338.1
1410.4

6
43.4
115.7
188.1
260.4
332.7
405.1
477.4
549.7
622.0
694.4
766.7
839.0
911.4
983.7
1056.0
1128.3
1200.7
1273.0
1345.3
1417.7

7
50.6
123.0
195.3
267.6
340.0
412.3
484.6
556.9
629.3
701.6
773.9
846.3
918.6
990.9
1063.2
1135.6
1207.9
1280.1
1352.6
1424.9

kgm to ft.lb

0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190

WA470-7

0
0
72.3
144.7
217.0
289.3
361.7
434.0
506.3
578.6
651.0
723.3
795.6
868.0
940.3
1012.6
1084.9
1157.3
1129.6
1301.9
1374.3

1 kgm 7.233 ft.lb


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

00-63

00 Index and foreword


Foreword, safety and general information

kg/cm2 to lb/in2

0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240

00-64

0
0
142.2
284.5
426.7
568.9
711.2
853.4
995.6
1,138
1,280
1,422
1,565
1,707
1,849
1,991
2,134
2,276
2,418
2,560
2,702
2,845
2,987
3,129
3,271
3,414

1
14.2
156.5
298.7
440.9
583.2
725.4
867.6
1,010
1,152
1,294
1,437
1,579
1,721
1,863
2,005
2,148
2,290
2,432
2,574
2,717
2,859
3,001
3,143
3,286
3,428

2
28.4
170.7
312.9
455.1
597.4
739.6
881.8
1,024
1,166
1,309
1,451
1,593
1,735
1,877
2,020
2,162
2,304
2,446
2,589
2,731
2,873
3,015
3,158
3,300
3,442

3
42.7
184.9
327.1
469.4
611.6
753.8
896.1
1,038
1,181
1,323
1,465
1,607
1,749
1,892
2,034
2,176
2,318
2,460
2,603
2,745
2,887
3,030
3,172
3,314
3,456

4
56.9
199.1
341.4
483.6
625.8
768.1
910.3
1,053
1,195
1,337
1,479
1,621
1,764
1,906
2,048
2,190
2,333
2,475
2,617
2,759
2,901
3,044
3,186
3,328
3,470

5
71.1
213.4
355.6
497.8
640.1
782.3
924.5
1,067
1,209
1,351
1,493
1,636
1,778
1,920
2,062
2,205
2,347
2,489
2,631
2,773
2,916
3,058
3,200
3,343
3,485

6
85.3
227.6
369.8
512.0
654.3
796.5
938.7
1,081
1,223
1,365
1,508
1,650
1,792
1,934
2,077
2,219
2,361
2,503
2,646
2,788
2,930
3,072
3,214
3,357
3,499

1 kg/cm2 14.2233 lb/in2


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

WA470-7

00 Index and foreword


Foreword, safety and general information

Temperature
Conversion of Fahrenheit to Celsius
A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice
versa is to see the number in the center column of the following table. The figures on the following table
show the temperatures in both Fahrenheit and Celsius.
When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
C
-40.4
-37.2
-34.4
-31.7
-28.9
-28.3
-27.8
-27.2
-26.7
-26.1
-25.6
-25.0
-24.4
-23.9
-23.3
-22.8
-22.2
-21.7
-21.1
-20.6
-20.0
-19.4
-18.9
-18.3
-17.8
-17.2
-16.7
-16.1
-15.6
-15.0
-14.4
-13.9
-13.3
-12.8
-12.2

WA470-7

-40
-35
-30
-25
-20
-19
-18
-17
-16
-15
-14
-13
-12
-11
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
9
10

F
-40.0
-31.0
-22.0
-13.0
-4.0
-2.2
-0.4
1.4
3.2
5.0
6.8
8.6
10.4
12.2
14.0
15.8
17.6
19.4
21.2
23.0
24.8
26.6
28.4
30.2
32.0
33.8
35.6
37.4
39.2
41.0
42.8
44.6
46.4
48.2
50.0

C
-11.7
-11.1
-10.6
-10.0
-9.4
-8.9
-8.3
-7.8
-7.2
-6.7
-6.1
-5.6
-5.0
-4.4
-3.9
-3.3
-2.8
-2.2
-1.7
-1.1
-0.6
0
0.6
1.1
1.7
2.2
2.8
3.3
3.9
4.4
5.0
5.6
6.1
6.7
7.2

11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

F
51.8
53.6
55.4
57.2
59.0
60.8
62.6
64.4
66.2
68.0
69.8
71.6
73.4
75.2
77.0
78.8
80.6
82.4
84.2
86.0
87.8
89.6
91.4
93.2
95.0
96.8
98.6
100.4
102.2
104.0
105.8
107.6
109.4
111.2
113.0

C
7.8
8.3
8.9
9.4
10.0
10.6
11.1
11.7
12.2
12.8
13.3
13.9
14.4
15.0
15.6
16.1
16.7
17.2
17.8
18.3
18.9
19.4
20.0
20.6
21.1
21.7
22.2
22.8
23.3
23.9
24.4
25.0
25.6
26.1
26.7

46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80

F
114.8
116.6
118.4
120.2
122.0
123.8
125.6
127.4
129.2
131.0
132.8
134.6
136.4
138.2
140.0
141.8
143.6
145.4
147.2
149.0
150.8
152.6
154.4
156.2
158.0
159.8
161.6
163.4
165.2
167.0
168.8
170.6
172.4
174.2
176.0

C
27.2
27.8
28.3
28.9
29.4
30.0
30.6
31.1
31.7
32.2
32.8
33.3
33.9
34.4
35.0
35.6
36.1
36.7
37.2
37.8
40.6
43.3
46.1
48.9
51.7
54.4
57.2
60.0
62.7
65.6
68.3
71.1
73.9
76.7
79.4

1C 33.8F
F
81
177.8
82
179.6
83
181.4
84
183.2
85
185.0
86
186.8
87
188.6
88
190.4
89
192.2
90
194.0
91
195.8
92
197.6
93
199.4
94
201.2
95
203.0
96
204.8
97
206.6
98
208.4
99
210.2
100
212.0
105
221.0
110
230.0
115
239.0
120
248.0
125
257.0
130
266.0
135
275.0
140
284.0
145
293.0
150
302.0
155
311.0
160
320.0
165
329.0
170
338.0
175
347.0

00-65

00 Index and foreword


Foreword, safety and general information

00-66

WA470-7

SHOP MANUAL

WHEEL LOADER
WA470-7
Model

Serial Number

WA470-7

10001 and up

01 Specification
2 01 Specification

WA470-7

01-1

01 Specification
Table of contents

Table of contents

(ALL-0310-002-A-00-A)

01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Specifications ...................................................................................................................... 01-5
Weight table ...................................................................................................................... 01-11
Table of fuel, coolant, and lubricants .................................................................................... 01-13

01-2

WA470-7

01 Specification
Specification drawing

Specifications

(ALL-2111-001-A-00-A)

Specification drawing

(WA470_7-2110-931-A-00-A)

Item

A
B
C
D
E
F
G
H
I

Machine weight (with BOC)


Operating load
Bucket capacity (heaped, with BOC)
Engine model
Rated horsepower
SAE J1995 [Gross] (*1)
ISO 14396
ISO 9249/ SAE J1349 [Net] (*2)
Overall length (with BOC, additional weight)
Overall height
Overall height with bucket at max. height
Overall width
Min. ground clearance
Bucket width
Dumping clearance (*3) Bucket tip / BOC tip
Dumping reach (*3)
Bucket tip / BOC tip
Dumping angle
Bucket tip / BOC tip
Min. turning radius
Center of outside tire
Allowable towing load
1st (forward/reverse)
2nd (forward/reverse)
locked up travel speed
(P mode)
3rd (forward/reverse)
4th (forward/reverse)

Unit
kg
kg
m3

WA470-7
(in P mode)
23,510
6,720
4.2
Komatsu SAA6D125E-6 diesel engine

kW {HP} /
min-1 {rpm}
mm
mm
mm
mm
mm
mm
mm
mm
deg.
mm
mm
kN {kg}
km/h

204 {273}/ 2,000 {2,000}


204 {273}/ 2,000 {2,000}
203 {272}/ 2,000 {2,000}
8,825
3,500
5,960
3,010
525
3,170
3,270/3,185
1,190/1,235
45
7,615/7,650
6,630
171 {17,400}
7.6/7.9
13.2/13.7
23.6/24.3
38.3/39.0

*1: Indicates the value of the basic engine (without cooling fan).
*2: Indicates the value at the minimum cooling fan speed.
*3: Indicates the value when the tilt down angle of bucket is 45 degrees.

WA470-7

01-3

01 Specification
Specification drawing

a The engine rated horsepower is indicated in the net value and gross value. The gross denotes the
flywheel horsepower measured on the basic engine unit, while the net denotes the value measured of an
engine under the condition essentially the same as that when it is installed on a machine.
a Following shows the rated horsepower (net) at the maximum cooling fan speed.
194 kW {260 HP}/ 2,000 min-1 {2,000 rpm}
a BOC: Abbreviation for Bolt On Cutting edge

01-4

WA470-7

01 Specification
Specifications

Specifications

(WA470_7-2111-931-A-00-A)

Machine model
Serial No.
Machine weight
Machine weight (front wheel) in SAE
travel posture
Machine weight (rear wheel) in SAE
travel posture

kg

WA470-7
10001 and up
23,510

kg

10,600

kg

12,910

m3
kg

WA470-7
10001 and up
4.2
6,720

Performance

When traveling in torque converter drive mode


When traveling with torque converter locked up

Travel speed

Machine model
Serial No.
Bucket capacity (heaped)
Operating load

E mode
6.6
11.4
19.6
30.8
6.8
11.7
20.2

P mode
7.6
13.1
22.9
36.2
7.9
13.5
23.6

Reverse 4th

31.7

37.3

Forward 1st
Forward 2nd
Forward 3rd
Forward 4th
Reverse 1st
Reverse 2nd
Reverse 3rd
Reverse 4th

6.6
11.5
20.4
33.1
6.8
11.8
21.1

7.6
13.2
23.6
38.3
7.9
13.7
24.3

34.2

39.0

170 {17,300}
160 {16,300}

192 {19,600}
181 {18,500}

Forward 1st
Forward 2nd
Forward 3rd
Forward 4th
Reverse 1st
Reverse 2nd
Reverse 3rd

km/h

Maximum rim pull


Forward
Reverse
Gradeability
WA470-7

km/h

km/h

km/h

kN {kg}
deg.

25

01-5

01 Specification
Specifications

Machine model
Serial No.
Minimum turning radius (center of
outside tire)
Turning radius (cutting edge tip/BOC tip)
in SAE travel posture

WA470-7
10001 and up
mm

6,630

mm

7,615/7,650

a BOC: Abbreviation for Bolt On Cutting edge

01-6

WA470-7

01 Specification
Specifications

Dimension
Machine model
Serial No.
Overall length (with BOC)
Overall width (machine body)
Bucket width (with BOC)
Overall height (top of cab)
Overall height with bucket at max.
height
Wheelbase
Tread
Min. ground clearance
Max. hinge pin height
Dumping clearance (*1)
(cutting edge tip/BOC tip)
Dumping reach (*1)
(cutting edge tip/BOC tip)
Steering angle
Tilt back angle of bucket (travel posture/
max. height)
Tilt down angle of bucket (max. height)
Digging depth, 10 deg. (cutting edge tip/
BOC end)

mm
mm
mm
mm

WA470-7
10001 and up
8,825
3,010
3,170
3,500

mm

5,960

mm
mm
mm
mm

3,450
2,300
525
4,360

mm

3,270/3,185

mm

1,190/1,235

deg.

35

deg.

50/65

deg.

45

mm

265/315

*1: Indicates the value when the tilt down angle of bucket is 45 degrees.
a BOC: Abbreviation for Bolt On Cutting edge

WA470-7

01-7

01 Specification
Specifications

Engine
Machine model
Serial No.
Model
Type

Performance (In P mode)

mm
No. of cylinders bore x stroke
Total piston displacement
l {cc}
Rated horsepower
SAE J1995 [Gross] (*1)
kW {HP}/min1 {rpm}
ISO 14396
ISO 9249/ SAE J1349 [Net] (*2)
Nm {kgm}/
Max. torque (*1)
min-1 {rpm}
g/kWh
Fuel consumption rate at rated
horsepower
{g/HPh}
Max. speed with no load
min-1 {rpm}
min-1 {rpm}
Min. speed with no load

WA470-7
10001 and up
SAA6D125E-6
4-cycle, water-cooled, in-line vertical, direct injection,
with turbocharger, air-cooled aftercooler, and watercooled EGR
6 - 125 x 150
11.04 {11,040}
204 {273}/ 2,000 {2,000}
204 {273}/2,000 {2,000}
203 {272}/ 2,000 {2,000}
1,307 {133}/ 1,450 {1,450}
224 {165}
2,170 50
800 (+ 50/0)

Starting motor
Alternator
Battery (*3)

24 V, 7.5 kW
24 V, 50 A
12 V, 140 Ah, 2 pieces

*1: Indicates the value of the basic engine (without cooling fan).
*2: Indicates the value at the minimum cooling fan speed.
*3: The battery capacity (Ah) is indicated in the 5-hour rate.
a The engine rated horsepower is indicated in the net value and gross value. The gross denotes the
flywheel horsepower measured on the basic engine unit, while the net denotes the value measured of an
engine under the condition essentially the same as that when it is installed on a machine.
a Following shows the rated horsepower (net) at the maximum cooling fan speed.
194 kW {260 HP}/ 2,000 min-1 {2,000 rpm}
Power train
Machine model
Serial No.
Torque converter
Transmission
Reduction gear system
Differential
Final drive

WA470-7
10001 and up
3-element, 1-stage, 2-phase
Counter-shaft, power shift, helical and spur gear,
constant mesh type
Multiple disc, hydraulically actuated, modulation
Spiral bevel gear, oil bath lubrication type
Straight bevel gear type
Planetary gear single reduction type, oil bath
lubrication type

Axle
Machine model
Serial No.
Drive wheel
Front axle
Rear axle

01-8

WA470-7
10001 and up
Front and rear wheel drive
Fixed to frame, semi-float type
Center pin support, semi-float type

WA470-7

01 Specification
Specifications

Tire
Machine model
Serial No.
Size
Rim size
Inflation pressure
Front wheel
Rear wheel

WA470-7
10001 and up
26.5R25 AA L - 3
22.00 - 25WTB
kPa
{kg/cm2}

450 {4.5}
350 {3.5}

Brake
Machine model
Serial No.

WA470-7
10001 and up
4-wheel braking, braking with independent front and
rear wheel systems
Sealed, wet disc type
Hydraulically operated type
With hydraulic booster
Transmission output shaft braking
Wet disc type
Actuation with spring, hydraulic release

Parking

Main

Braking method
Brake type
Operation type
Operating method
Braking method
Brake type
Actuating method

Steering
Machine model
Serial No.

WA470-7
10001 and up
Articulation type
Hydraulic operation type

Steering method
Actuating method

Hydraulic pump

Hydraulic system
Machine model
Serial No.
Power train pump
Type
Discharge
Steering pump
Type
Discharge
Work equipment pump
Type
Discharge
Cooling fan pump
Type
Discharge
Emergency steering pump
Type
Discharge

WA470-7

WA470-7
10001 and up

cm3/rev

Gear type
80+32

cm3/rev

Variable displacement swash plate piston type


90

cm3/rev

Variable displacement swash plate piston type


120

cm3/rev

Variable displacement swash plate piston type


30

cm3/rev

Gear type
21

01-9

01 Specification
Specifications

Hydraulic system

Type
Cylinder bore
Piston rod outside diameter
Stroke
Max. distance between pins

mm
mm
mm
mm

WA470-7
10001 and up
Double-acting piston type
90
50
441
1,296

Min. distance between pins

mm

855

Lift cylinder

Type
Cylinder bore
Piston rod outside diameter
Stroke
Max. distance between pins
Min. distance between pins
Type
Cylinder bore
Piston rod outside diameter
Stroke
Max. distance between pins
Min. distance between pins
Work equipment control valve
Type

Control valve

Bucket cylinder

Cylinder

Steering cylinder

Machine model
Serial No.

Set pressure

mm
mm
mm
mm
mm

2-spool type
MPa {kg/
cm2}

Steering valve
Type

34.3 {350}
Spool type

Set pressure
Motor

mm
mm
mm
mm
mm

Double-acting piston type


140
95
764
2,167
1,403
Double-acting piston type
160
100
575
1,795
1,220

Cooling fan motor


Type
Motor capacity

MPa {kg/
cm2}

cm3/rev

24.5 {250}
Fixed displacement, swash plate, piston type
28

Work equipment
Machine model
Serial No.
Link type
Shape of bucket cutting edge

WA470-7
10001 and up
Z-bar link
Straight cutting edge with BOC

a BOC: Abbreviation for Bolt On Cutting edge

01-10

WA470-7

01 Specification
Weight table

Weight table
k This

(WA470_7-2120-931-A-00-A)

weight table is prepared for your reference when handling or transporting the components.
Unit: kg

Machine model
Serial No.
Engine (excluding coolant and oil)
Cooling assembly (including fan, frame, and air conditioner condenser)
(excluding coolant and oil)
Cooling sub assembly (excluding fan, cooling fan motor, frame, coolant,
and oil)
Radiator (1 piece)
Aftercooler
Oil cooler
Air conditioner condenser
Cooling fan motor
Torque converter oil cooler
Cooling fan pump
Transmission (including torque converter)
Without lockup clutch
With lockup clutch
Front drive shaft
Center drive shaft
Rear drive shaft
Front axle
With conventional differential
With limited slip differential
Rear axle
with conventional differential
With limited slip differential
Axle pivot (rear axle)
Tire and rim assembly (26.5 - R25 AA L - 3) (1 piece)
Tire (26.5R25 AA L - 3) (1 piece)
Rim (22.00-25WTB) (1 piece)
Power train pump
Work equipment pump
Steering pump
Work equipment control valve
Work equipment EPC valve
Brake valve
Steering valve
Emergency steering motor
Emergency steering pump
Steering cylinder assembly (1 piece)
Lift cylinder assembly (1 piece)
Bucket cylinder assembly
Front frame
Rear frame
Counterweight
Additional weight

WA470-7

WA470-7
10001 and up
1,486
369
204
33
25
7
3
14
25
25
1,148
1,193
33
40
20
1,238
1,250
1,168
1,180
144
655
415
240
20
103
40
108
4
7
24
13
3
37
185
206
1,852
1,735
1,595
385

01-11

01 Specification
Weight table

Unit: kg
Machine model
Serial No.
Engine hood assembly (including hydraulic tank, hydraulic tank mounting
bracket, hood, grille assembly, and upper portion of bulkhead)
Food body (excluding hydraulic tank hydraulic tank mounting bracket)
Hood
Side door (1 piece)
Grille
Mask
Hydraulic tank (excluding hydraulic oil)
Hydraulic tank mounting bracket
Fuel tank (excluding fuel)
Boom (including bushings)
Bucket link
Bell crank
Bucket (3,170 mm wide, including BOC side guard)
Operator's cab (including floor assembly)
Operator's seat
Air conditioner unit
Battery (1 piece)

WA470-7
10001 and up
690
428
38
47
87
25
168
68
194
1,470
89
390
2,023
1,078
50
5
45

a BOC: Abbreviation for Bolt On Cutting edge

01-12

WA470-7

01 Specification
Table of fuel, coolant, and lubricants

Table of fuel, coolant, and lubricants

(WA470_7-RA19-05A-K-00-A)

a For details of notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.

WA470-7

01-13

01 Specification
Table of fuel, coolant, and lubricants

Unit: l
Refill point
Engine oil pan
Transmission case
Hydraulic oil system
Axle (front / rear)
Cooling system
Fuel tank

01-14

Specified capacity
47
76
270
57/56
80
380

Refill capacity
38
65
173
57/56

WA470-7

SHOP MANUAL

WHEEL LOADER
WA470-7
Model

Serial Number

WA470-7

10001 and up

10 Structure and function


3 10 Structure and function

WA470-7

10-1

10 Structure and function


Table of contents

Table of contents

(ALL-0310-002-A-00-A)

10 Structure and function ................................................................................................................... 10-1


Table of contents ........................................................................................................................ 10-2
Engine and cooling system .......................................................................................................... 10-4
Engine related parts ............................................................................................................. 10-4
KVGT.................................................................................................................................. 10-6
EGR system piping drawing ................................................................................................ 10-12
EGR system circuit diagram ................................................................................................ 10-14
EGR valve......................................................................................................................... 10-15
EGR cooler........................................................................................................................ 10-17
KCCV layout drawing ......................................................................................................... 10-19
KCCV ventilator ................................................................................................................. 10-21
KDPF................................................................................................................................ 10-23
Cooling system .................................................................................................................. 10-27
Cooling fan pump ............................................................................................................... 10-30
Cooling fan motor............................................................................................................... 10-39
Power train............................................................................................................................... 10-46
Power train system............................................................................................................. 10-46
Drive shaft ......................................................................................................................... 10-49
Power train piping drawing .................................................................................................. 10-50
Transmission control .......................................................................................................... 10-51
Torque converter ................................................................................................................ 10-54
Transmission ..................................................................................................................... 10-59
Transmission control valve.................................................................................................. 10-78
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV .......................................... 10-81
3rd, 4th clutch ECMV.......................................................................................................... 10-88
Lockup clutch ECMV .......................................................................................................... 10-95
Main relief and torque converter relief valve.......................................................................... 10-99
Axle ................................................................................................................................ 10-101
Differential ....................................................................................................................... 10-103
Final drive ....................................................................................................................... 10-113
Steering system...................................................................................................................... 10-115
Layout of steering parts .................................................................................................... 10-115
Steering column............................................................................................................... 10-116
Steering pump ................................................................................................................. 10-117
Steering valve.................................................................................................................. 10-129
Orbit-roll valve ................................................................................................................. 10-143
Stop valve ....................................................................................................................... 10-149
Emergency steering motor ................................................................................................ 10-150
Emergency steering pump ................................................................................................ 10-151
Brake system ......................................................................................................................... 10-152
Layout of brake parts........................................................................................................ 10-152
Charge valve ................................................................................................................... 10-154
Brake valve ..................................................................................................................... 10-160
Slack adjuster .................................................................................................................. 10-164
Accumulator (for brake) .................................................................................................... 10-167
Brake .............................................................................................................................. 10-168
Parking brake control ....................................................................................................... 10-171
Parking brake .................................................................................................................. 10-172
Parking brake solenoid valve ............................................................................................ 10-173
Parking brake emergency release valve............................................................................. 10-176
Undercarriage and frame......................................................................................................... 10-177
Axle mount and center hinge pin........................................................................................ 10-177
Tire ................................................................................................................................. 10-178
Hydraulic system .................................................................................................................... 10-180
Hydraulic component layout .............................................................................................. 10-180
Work equipment control .................................................................................................... 10-182
Hydraulic tank.................................................................................................................. 10-183

10-2

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10 Structure and function


Table of contents

Double type gear pump .................................................................................................... 10-186


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

WA470-7

10-3

10 Structure and function


Engine related parts

Engine and cooling system


Engine related parts

(ALL-R401-001-K-00-A)

(WA470-A001-041-K-00-A)

1. Air cleaner

10-4

WA470-7

10 Structure and function


Engine related parts

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

WA470-7

10-5

10 Structure and function


KVGT

KVGT

(ENG125-AA10-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger and denotes the variable displacement
turbocharger.
a The shape is subject to machine models.

10-6

WA470-7

10 Structure and function


KVGT

1. Blower housing
2. KVGT speed sensor
3. Hydraulic actuator
4. Turbine housing
5. Plate
6. Vane
7. Nozzle ring
8. Push rod
9. Shaft
10. Blower impeller
11. Turbine impeller
12. Piston
A: Air intake inlet
B: Air intake outlet
C: Exhaust inlet
D: Exhaust outlet

Operation

(ENG125-AA10-044-K-00-A)

1. Air cleaner
2. KVGT
3. KDPF
4. EGR cooler
5. EGR valve
C: Blower impeller
T: Turbine impeller
The new exhaust gas regulation not only requires to control emissions at high engine speed but also at
low engine speed. To meet the requirements, the EGR ratio is increased. (EGR ratio = volume of EGR/
intake air flow)
To obtain a high EGR ratio especially at low engine speed, the turbine inlet pressure (P3) must be higher
than the boost pressure (P2). A variable displacement turbocharger (KVGT), in which the exhaust gas
pressure hitting the turbine impeller (T) can be adjusted, is introduced.
The charged pressure rises faster, also contributing to suppress the generation of PM (particles) due to
insufficient oxygen at low engine speed.
The turbine impeller (T) drives the blower impeller (C) via a shaft to send a large amount of air to the
cylinders for combustion. When the air flow from KVGT (2) increases, more fuel can be injected, and the
engine output increases.
Since the density of the air and the amount of oxygen increases when the air is cooled, more fuel can be
injected, and the engine output increases.

WA470-7

10-7

10 Structure and function


KVGT

a Adequate amount of clean high quality oil is required to maintain the KVGT performance. Be sure to use
Komatsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when
replacing oil or oil filter.

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

10-8

WA470-7

10 Structure and function


KVGT

When nozzle ring is open


At high engine speed, exhaust gas inlet passage (P) is widened (L2).
As the engine speed and the turbine inlet pressure (exhaust gas pressure) increases, exhaust gas inlet
passage (P) widens (L2) to effectively apply the exhaust gas pressure to turbine impeller (11).

a Nozzle ring (7), vane (6) and rod (8) are integrated and slide together but do not rotate.
a KVGT position sensor is installed to hydraulic actuator (3). The KVGT position sensor is calibrated
together with the variable mechanism in the KVGT, and values are stored in the memory inside the KVGT
position sensor. If any of the hydraulic actuator (3), KVGT position sensor, or KVGT body fails, replace the
whole KVGT.
Hydraulic actuator operation
Hydraulic actuator (6) is moved by the oil pressure controlled by EPC valve (8) installed to the front cover.
The force for the movement is the oil pressure supplied from boost pump (12).
a The shape is subject to machine models.

WA470-7

10-9

10 Structure and function


KVGT

Position of hydraulic actuator (6) is sensed by KVGT position sensor (5) and the signals are fed back to
engine controller (7).

1. Air cleaner
2. Mass air flow and temperature sensor

10-10

WA470-7

10 Structure and function


KVGT

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

WA470-7

10-11

10 Structure and function


EGR system piping drawing

EGR system piping drawing

(ENG125-A9J0-04D-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation


a The shape is subject to machine models.

1. KVGT
2. EGR valve
3. Air intake connector
4. Intake manifold
5. Exhaust manifold
6. EGR cooler
7. Mixing connector

Function

(ENG107-A9J0-042-K-00-A)

EGR valve (driven hydraulically)


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

10-12

WA470-7

10 Structure and function


EGR system piping drawing

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

WA470-7

10-13

10 Structure and function


EGR system circuit diagram

EGR system circuit diagram

(ENG125-A9J0-052-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation

1. Air cleaner
2. KDPF
3. Ambient pressure sensor
4. Aftercooler
5. EGR cooler
6. EGR valve
7. Hydraulic actuator (power piston)
8. EPC valve (for EGR valve)
9. EGR valve lift sensor
10. Exhaust manifold
11. Boost pump
12. Intake manifold
13. Charge (boost) pressure and temperature sensors
14. Engine controller
15. Mixing connector
C: Blower impeller
T: Turbine impeller

Operation

(ENG125-A9J0-044-K-00-A)

The engine controller outputs signals for opening EGR valve (6) most properly according to the load on
the engine to attain both clean exhaust gas and low fuel consumption.
When EGR valve (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (10)
through EGR piping to EGR cooler (5).
The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6) and mixes with the intake air in
mixing connector (15), and then flows into intake manifold (12).

10-14

WA470-7

10 Structure and function


EGR valve

EGR valve

(ENG125-A9K1-041-K-00-A)

a The shape is subject to machine models.

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

WA470-7

10-15

10 Structure and function


EGR valve

Operation

(ENG107-A9K1-044-K-00-A)

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

10-16

WA470-7

10 Structure and function


EGR cooler

EGR cooler

(ENG125-A9L0-041-K-00-A)

a The shape is subject to machine models.

1. Header plate
4. Shell
A: EGR gas inlet
B: EGR gas outlet (to EGR valve)
C: Coolant inlet
D: Coolant outlet
E: Air vent
F: Air vent

2. Flat tube
3. Inner fin

Operation

(ENG125-A9L0-044-K-00-A)

The EGR gas enters from (A) and flows through 9 flat tubes (2).
WA470-7

10-17

10 Structure and function


EGR cooler

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

10-18

WA470-7

10 Structure and function


KCCV layout drawing

KCCV layout drawing

(ENG125-A180-04D-K-00-A)

KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation


a The shape is subject to machine models.

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

WA470-7

10-19

10 Structure and function


KCCV layout drawing

Operation

(ENG125-A180-044-K-00-A)

a The figure on the left shows the traditional flow of blowby gas that has been discharged to the atmosphere.
The figure on the right shows the flow of blowby gas recirculated to the intake system by the KCCV
ventilator.

1. Air cleaner
2. KVGT
3. Aftercooler
4. Cylinder block (crankcase)
5. Breather
6. KCCV ventilator
7. Oil pan
Engine oil is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and
then the cleaned gas (B) is recirculated to the intake side of the KVGT.
Separated engine oil (C) flows through a check valve and falls to the oil pan.

10-20

WA470-7

10 Structure and function


KCCV ventilator

KCCV ventilator

(ENG125-A18H-041-K-00-A)

a The shape is subject to machine models.

1. Case
2. CDR valve
3. Crankcase pressure sensor
4. Relief valve
5. Impactor
6. Filter
7. Heater tube
A: Blowby gas inlet (engine breather)
B: Blowby gas outlet (to KVGT intake side)
C: Oil drain port (to oil pan)
D: Coolant inlet
E: Coolant outlets

Function

(ENG125-A18H-042-K-00-A)

When blowby gas is recirculated to the intake side of the KVGT, the pressure inside the crankcase
becomes negative, and dust may be sucked in through the crankshaft seals. Therefore, CDR valve
(regulator valve) controls the pressure inside the crankcase.
If the filter in the KCCV ventilator clogs, pressure inside the crankcase increases and oil may leak, so clog
of filter is detected by crankcase pressure sensor.
There are two types of filters that differ by the filter replacement method; the top load type (removed
upward) and the bottom load type (removed downward).
Warmed engine coolant is conducted to the locations that pose potential problem of freezing to prevent it
from happening.

WA470-7

10-21

10 Structure and function


KCCV ventilator

Operation

(ENG107-A18H-044-K-00-A)

Blowby gas enters from (A). The larger drops of oil mist are removed from the blowby gas when it flows
through the impactor (5) holes in filter (6).
Smaller drops of oil mist are removed by filter (6).
Removed oil flows down along the case wall to oil drain port (C) and then flows to the oil pan.
The CDR valve operates when the pressure inside the crankcase becomes negative, to prevent excessive
negative pressure in the crankcase.
Crankcase pressure sensor (3) senses the blowby gas pressure (crankcase pressure).
When the engine controller determines that the filter is clogged from crankcase pressure sensor (3)
signals, failure code CA555 is issued. If the pressure increases further, failure code CA556 is issued.
Relief valve (4) is installed in case (1). It operates to protect the KCCV ventilator and engine when filter (6)
is blocked.

CDR valve

(ENG107-A18A-041-K-00-A)

CDR: Abbreviation for Crankcase Depression Regulator

1. Diaphragm
2. Spring
A: Crankcase side
B: KVGT side (intake side)
The CDR valve is a regulator valve which prevents excessive negative crankcase pressure (P1).
Normally, diaphragm (1) is pushed up by spring (2) and blowby gas flows from crankcase side (A) to
KVGT side (intake side) (B).
When intake air flow at KVGT side (intake side) (B) increases and crankcase pressure (P1) decreases,
force of spring (2) yields to ambient pressure (P2). The diaphragm shuts the passage and temporarily
blocks the flow.
Then, when blowby gas accumulates in the crankcase and pressure (P1) recovers, the diaphragm is
pushed up again and blowby gas starts to flow again.

10-22

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10 Structure and function


KDPF

KDPF

(ENG125-A9H0-041-K-00-A)

KDPF: Abbreviation for KOMATSU Diesel Particulate Filter


a The shape is subject to machine models.

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

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10-23

10 Structure and function


KDPF

KDOC unit (11) consists of a ceramic honeycomb coated with oxidation catalyst material. By using this
ceramic honeycomb, it regenerates (*1) NO (nitrogen monoxide) to NO2 (nitrogen dioxide) in exhaust gas.
The ceramic honeycomb is guarded by a mat made of special fiber to prevent damage caused by engine
and machine vibrations.
The mat also prevents overheating of the KDPF outer periphery by insulating the heat generated at the
ceramic honeycomb during operation.
The KCSF unit (4) also consists of a ceramic honeycomb coated with oxidation catalyst material, like the
KDOC unit (11). This ceramic honeycomb collects soot.
Three temperature sensors and one differential pressure sensor (an integrated KDPF differential pressure
and KDPF outlet pressure sensor) are installed to the KDPF.
Temperature signals from these three temperature sensors are used in combination to monitor the KDOC
and KCSF operations and to perform various troubleshootings.
The differential pressure sensor detects the amount of soot deposited in the KCSF by sensing the
pressure difference across the KCSF. Like the temperature sensors, this sensor is also used for various
troubleshootings.
*1: Denotes to purification (oxidation) processing of soot.
k While

engine is running and for some time after engine is stopped, the surface of KDPF and
nearby piping are extremely hot. Be careful not to get burned when working near the KDPF.

Function

(ENG125-A9H0-042-K-00-A)

A: Flow of exhaust gas


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

10-24

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10 Structure and function


KDPF

Inside the KCSF (2), there are many cells partitioned by ceramic walls. Cells plugged at the inlet side and
cells plugged at the outlet side are alternately arranged.
The soot deposited in KCSF (2) are naturally oxidized and burned away by the effect of KDOC (1)
(oxidation catalyzer), in operating conditions with relatively high exhaust gas temperatures. (This is
referred to as "passive regeneration".)
On the other hand, when the exhaust temperature is relatively low, in conditions such as continued low
load operations, the deposit of soot in KCSF (2) increases.
The engine controller continuously monitors the amount of deposited soot by estimating from the
operating conditions and calculating based on the KCSF (2) differential pressure sensor signals.
When the soot deposit exceeds a certain level, and the engine is operated with the exhaust gas
temperature exceeding a certain level, the engine controller executes "automatic regeneration" to burn
(oxidize) the soot.
During automatic regeneration, the engine controller automatically controls the fuel injection timing and
the KVGT to raise the exhaust temperature. (This operation is called "exhaust temperature-raising
control")
As the exhaust temperature increases, the engine controller automatically performs calculations based on
the exhaust temperature at the KDOC inlet and flow of the exhaust gas, so that KCSF (2) can efficiently
burn (oxidize) the soot.
Fuel is injected from (fuel doser) installed to the outlet portion of turbocharger. (Fuel dosing) Fuel that is
injected into this piping mixes with exhaust gas and combusts (oxidizes) soot by the action of KDOC (1).
Automatic regeneration is not performed when regeneration is executed from the machine monitor, or
when the outside air temperature is extremely low, and when the exhaust gas temperature is not high
enough to burn soot because the engine has been operated at low loads for a while. Thus, soot deposit in
the KCSF (2) will increase.
If the soot deposit in the KCSF (2) exceeds a certain level, it will be necessary to perform "manual
stationary regeneration" to burn away (oxidize) the soot in the KCSF (2).
If the soot deposit exceeds the acceptable level, the exhaust gas flow will be restricted. This can increase
fuel consumption, degrade engine combustion, or cause other problems.
If the soot deposit exceeds the limit to safely perform "manual stationary regeneration", the KDPF fails and
replacement becomes unavoidable. Make sure to follow the procedures in the Operation and
Maintenance Manual when performing "manual stationary regeneration"

Displaying KDPF regeneration

(HM400-A9H0-042-K-00-A)

a Regeneration refers to a new function used for purifying (oxidizing) soot accumulated in the soot collection
filter (KCSF) inside the KDPF.
1. Passive regeneration
When the engine exhaust temperature is relatively high, the catalyst effect of the KDOC to oxidize soot will
be stronger and the soot deposit in the KCSF will be naturally burned away.
2. Active regeneration (increase of engine exhaust temperature + fuel dosing)
1) Automatic regeneration
This is the regeneration process started automatically when the soot deposit exceeds a certain level.
At this time, the engine controller performs the exhaust temperature-raising control mode (*1) and fuel
dosing (*2). Another type of automatic regeneration is performed by the engine controller at certain
intervals, regardless of the amount of soot deposited in the KCSF.
*1: The fuel injection timing and the KVGTare controlled to raise the exhaust temperature.
*2: Fuel is injected to increase the exhaust temperature and accelerate the regeneration process.
2) Manual stationary regeneration
When the exhaust temperature does not reach a certain level due to the machine operating condition,
or when regeneration is disabled by the operator, automatic regeneration will not be performed and the
soot deposit in the KCSF may increase. In such conditions, the machine monitor displays a manual
stationary regeneration request, on the screen. The operator must perform regeneration by operating
the machine monitor on its screen. A regeneration feature is also provided for the technician who
should use this feature from the machine monitor menu after engine controller replacement, KDPF
replacement, and KCSF ash cleaning. (= Regeneration for service)
A KDPF drying feature is provided to prevent excessive accumulation of unburned fuel in the KDPF
when the machine is operated for a long time with low exhaust temperature.

WA470-7

10-25

10 Structure and function


KDPF

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

10-26

100 to 250C

KDOC_Out
(KDOC outlet
temperature sensor)
100 to 250C

KDPF_Out
(KDPF outlet
temperature sensor)

400 to 550C

WA470-7

10 Structure and function


Cooling system

Cooling system

(WA470-B000-041-K-00-A)

1. Accumulator charge valve


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

10-27

10 Structure and function


Cooling system

4. Aftercooler outlet hose


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

10-28

WA470-7

10 Structure and function


Cooling system

Specifications

(WA470-B000-030-K-00-A)

Core type
Fin pitch (mm)
Total heat dissipation
area (m2)
Pressure valve cracking
pressure
(kPa {kg/cm2})
Vacuum valve cracking
pressure
(kPa {kg/cm2})

Power train oil


cooler
PTO-OL
100 x 558 x 20
layers
(*1)

Radiator

Oil cooler

Aftercooler

AL WAVE-5

AL WAVE

AL WAVE

6.0/2

6.0/2

6.0/2

84.28 x 2

8.16

25.24

2.152

88.3 14.7
{0.9 0.15}

0 to 4.9
{0 to 0.05}

1: Indicates the element size.

WA470-7

10-29

10 Structure and function


Cooling fan pump

Cooling fan pump

(WA500-B450-041-K-00-A)

P1: Pump discharge port


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

10-30

WA470-7

10 Structure and function


Cooling fan pump

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

WA470-7

10-31

10 Structure and function


Cooling fan pump

Structure
Cylinder block (7) is supported on shaft (1) by spline (a).
Shaft (1) is supported by each bearing at the front and rear.
The tip of piston (6) is shaped as a concave sphere and crimped together with shoe (5).
Piston (6) and shoe (5) form a spherical bearing.
Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
Rocker cam (4) pivot on ball retainer (11).
Piston (6) moves relatively in the axial direction in each cylinder chamber of cylinder block (7).
Cylinder block (7) rotates relatively to valve plate (8) while blocking the pressurized oil.
This plane is designed so that the oil pressure is balanced correctly.
The pressurized oil can be sucked in and discharged from each cylinder chamber in cylinder block (7)
through valve plate (8).

Specifications

(WA470-B450-030-K-00-A)

Model
Type
Theoretical discharge (cm3/rev)
Fan drive pressure (MPa {kg/cm2})
Rated speed (rpm)

Function

LPV30
Variable displacement swash plate type piston pump
30
10.9 {111}
2,282

(WA380-B450-042-K-00-A)

The engine rotation and torque transmitted to the pump shaft is converted into the hydraulic energy and
the pressurized oil corresponding to the load is discharged.
It is possible to change the delivery by changing the swash plate angle.

10-32

WA470-7

10 Structure and function


Cooling fan pump

Operation

(WA380-B450-044-K-00-A)

Operation of pump

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

WA470-7

10-33

10 Structure and function


Cooling fan pump

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

10-34

WA470-7

10 Structure and function


Cooling fan pump

Control of delivery

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

WA470-7

10-35

10 Structure and function


Cooling fan pump

Servo valve

(WA470-B4H0-041-K-00-A)

P: EPC valve source pressure port


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

10-36

WA470-7

10 Structure and function


Cooling fan pump

Function

(PC400-B4H0-042-K-00-A)

The servo valve controls the pump so that the input current (i) to the EPC valve relates to pump delivery
(Q) as shown in the figure below.

Operation

(PC400-B4H0-044-K-00-A)

The output pressure of the EPC valve enters piston chamber (C) and pushes piston (6).
Piston (6) pushes spool (5) and moves to a position where it is balanced with the spring.
Land (PE) of the servo piston pressure passage is connected to pump delivery pressure passage (PH)
through the notch of spool (5), so the pump delivery pressure is transmitted to servo piston (10).
Rocker cam (9) is pushed up by servo piston (10), and then its position is fed back and lever (2) moves to
compress spring (8).
WA470-7

10-37

10 Structure and function


Cooling fan pump

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

10-38

WA470-7

10 Structure and function


Cooling fan motor

Cooling fan motor

(WA380-B5L0-041-K-00-A)

P: From fan pump


T: To oil cooler
TC: To hydraulic tank

WA470-7

10-39

10 Structure and function


Cooling fan motor

1. Output shaft
2. Case
3. Thrust plate
4. Piston assembly
5. Cylinder block
6. Valve plate
7. End cover
8. Center spring
9. Check valve
10. Pilot valve
11. Reversible valve spool
12. Safety valve
13. Cooling fan speed sensor

Specifications

(WA470-B5L0-030-K-00-A)

Model
Capacity (cc/rev)
Rated speed (rpm)
Rated flow rate (l/min)
Check valve cracking pressure (MPa {kg/
cm2})

10-40

LMF28
28.0
1,300
36.4
0.044 {0.45}

WA470-7

10 Structure and function


Cooling fan motor

Hydraulic motor

(WA380-B5N0-042-K-00-A)

This hydraulic motor is called a swash plate axial piston motor. It converts the energy of the pressurized oil
sent from the hydraulic pump into rotary motion.
This fan motor is installed within the blade width as shown in the figure.

Principle of operation

(HM300-B5N0-04B-K-00-A)

The pressurized oil sent from the pump flows through valve plate (3) into cylinder block (5).
This oil can flow to only one side of the (Y - Y) line connecting the top dead center and bottom dead center
of the stroke of piston (4).
The pressurized oil sent to one side of cylinder block (5) pushes each piston (4) (two or three pistons).
A single piston generates force F1 [F1 (kg) = P (kg/cm2) x xD2 / 4 (cm2)].
This force acts on thrust plate (2).
Since thrust plate (2) is fixed at specific angle (a) to output shaft (1), the force is divided into components
(F2) and (F3).
Of those components, radial component (F3) generates torque (T = F3 x ri) against the (Y - Y) line
connecting the top dead center and bottom dead center.
The total of these torque [T = s (F3 x ri)] rotates cylinder block (5) through piston (4).
Cylinder block (5) is connected to output shaft (1) with spline.
Output shaft (1) rotates to transmit the torque.

WA470-7

10-41

10 Structure and function


Cooling fan motor

10-42

WA470-7

10 Structure and function


Cooling fan motor

Suction valve
Function

(HM300-B6D0-001-K-00-A)

(HM300-B6D0-042-K-00-A)

When the pump stops, the pressurized oil does not flow into the motor any more.
Since the motor continues to rotate with the force of inertia, the pressure on the outlet side of the motor
increases.
When the oil stops flowing in from inlet port (P), suction valve (1) sucks in the oil on the outlet side and
supplies it to port (MA), compensating for the lack of oil on that side to prevent cavitation.

Operation

(WA500-B6D0-044-K-00-A)

When pump is started

The pressurized oil from the pump is supplied to port (P), increasing the (MA) side pressure.
The starting torque is generated in the motor, and the motor starts rotating.
The pressurized oil on the motor outlet (MB) side returns to the tank through port (T).

WA470-7

10-43

10 Structure and function


Cooling fan motor

When pump is stopped

When the engine stops, the pump input speed becomes 0 rpm.
The pressurized oil from the pump is not supplied to port (P).
As the pressurized oil is not supplied to (MA) side of the motor, the motor speed decreases gradually to
stop.
When the motor shaft is rotated by the force of inertia while the oil flow in port (P) is decreasing, the oil in
port (T) on the outlet side is sent by suction safety valve (1) to the (MA) side to prevent cavitation.

Reversible valve

(WA500-B6E0-041-K-00-A)

The rotating direction of the fan motor changes from the normal rotation to the reverse rotation, or from the
reverse rotation to the normal rotation corresponding to the current data which controls the pilot valve.
When changing from the normal rotation to the reverse rotation:

The solenoid valve controls the spool position according to the command current which is output from
controller in proportion to the set rate. While the command current passes the neutral range area, the fan
becomes neutral and the fan speed decreases sufficiently. As a result, the direction of the fan changes to
reverse rotation smoothly.
The fan rotation changes similarly from reverse to normal.

10-44

WA470-7

10 Structure and function


Cooling fan motor

Safety valve
Function

(ALL-B6G0-001-K-00-A)

(PC400-B6G0-042-K-00-A)

When the engine is started, the pressure in port (P) of the fan motor is increased in some cases.
Safety valve (1) is provided in order to protect the fan system circuit.

Operation

(WA500-B6G0-044-K-00-A)

If the pressure in port (P) rises above the cracking pressure of safety valve (1), valve (2) of safety valve (1)
opens to release the pressurized oil into port (T).
This operation prevents the generation of the abnormally high pressure in port (P).

WA470-7

10-45

10 Structure and function


Power train system

Power train

(ALL-C100-001-K-00-A)

Power train system

(WA470-C100-041-K-00-A)

1. Transmission
2. Torque converter
3. Engine
4. Rear axle
5. Rear drive shaft
6. Center drive shaft
7. Front drive shaft
8. Front axle

10-46

WA470-7

10 Structure and function


Power train system

Power train system

1. Front axle
2. Differential
3. Wet-type multiple-disc brake
WA470-7

10-47

10 Structure and function


Power train system

4. Final drive
5. Front drive shaft
6. Center drive shaft
7. Parking brake (wet-type multiple-disc)
8. Transmission (counter-shaft type)
9. Rear drive shaft
10. Rear tire
11. Final drive
12. Wet-type multiple-disc brake
13. Differential
14. Rear axle
15. Engine
16. Torque converter
17. Steering pump
18. Power train pump
19. Work equipment pump
20. Cooling fan pump
21. Flange bearing
22. Front tire

Function

(WA470-C100-042-K-00-A)

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

10-48

WA470-7

10 Structure and function


Drive shaft

Drive shaft

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

1. Front drive shaft


2. Flange bearing
3. Center drive shaft
4. Rear drive shaft

Function

(WA380-D510-042-K-00-A)

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

WA470-7

10-49

10 Structure and function


Power train piping drawing

Power train piping drawing

(WA470-C150-041-K-00-A)

1. Power train pump


2. Hydraulic tank
3. Power train oil cooler
4. Last chance filter
5. Transmission ECMV
6. Power train mount
7. Oil filler pipe
8. Oil filter
9. Transmission assembly

10-50

WA470-7

10 Structure and function


Transmission control

Transmission control

WA470-7

(WA470-CN20-041-K-00-A)

10-51

10 Structure and function


Transmission control

1. Machine monitor
2. Parking brake switch
3. Kickdown switch
4. Hold switch
5. Transmission cut-off and transmission cut-off set switch
6. Monitor controller
7. Transmission controller
8. Relay
9. Fuse box
10. Transmission cut oil pressure sensor
11. Brake valve
12. Directional lever and gear speed switch
13. Transmission ECMV
14. Transmission output speed sensor

Function
No.

(WA380-CN20-042-K-00-A)

Function
Selection of FORWARD,
REVERSE or NEUTRAL
Selection of gear speed

Kickdown

Hold

10-52

Operation
The travel direction can be selected with the directional lever.
The gear speed can be selected with the gear speed switch.
The gear speed can be shifted down by pushing the kickdown switch
without operating the gear shift lever. In the manual shift mode, only the
forward 2nd is shifted down. In the automatic shift mode, the gear speed is
shifted down according to the gear speed and travel speed before the
switch is operated.
If the hold switch is pushed in the automatic shift mode, the current gear
speed is maintained and is not shifted up even if the travel speed
increases. Even if the travel speed decreases, the gear speed is not
shifted down.
WA470-7

10 Structure and function


Transmission control

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


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

Transmission cut-off

WA470-7

10-53

10 Structure and function


Torque converter

Torque converter

(WA470-CD00-041-K-00-A)

1. Pilot
2. Flywheel
3. Lockup clutch housing
4. Boss
5. Turbine
6. Drive case
7. Stator
8. Pump
9. PTO gear
10. PTO drive gear (number of teeth: 97)
11. Stator shaft
12. Guide
13. Input shaft

10-54

WA470-7

10 Structure and function


Torque converter

14. Free wheel


15. Race
16. Lockup clutch disc
17. Lockup clutch piston

Specifications
Type
Stall torque ratio

WA470-7

(WA470-CD00-030-K-00-A)

3-element, 1-stage, 2-phase


2.14

10-55

10 Structure and function


Torque converter

Power transmitting route

(WA470-CD00-052-K-00-A)

When lockup clutch is "disengaged"

Drive case (3), boss (9) and turbine (8) are separated and the torque converter works as an ordinary torque
converter.
Power from engine
O
Flywheel (1)
O
Clutch housing (2)
O
Drive case (3), pump (5), and PTO drive gear (6) rotate as one unit
O
Oil is used as a medium
O
Turbine (8) and boss (9)
O
Transmission input shaft (10)
The power transmitted to PTO drive gear (6) is then transmitted through PTO gear (7) to drive the pump.

10-56

WA470-7

10 Structure and function


Torque converter

When lockup clutch is "engaged"

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

WA470-7

10-57

10 Structure and function


Torque converter

Oil flow

(WA470-CD00-044-K-00-A)

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

10-58

WA470-7

10 Structure and function


Transmission

Transmission

WA470-7

(WA470-CF00-041-K-00-A)

10-59

10 Structure and function


Transmission

A: From power train pump (for torque converter)


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

10-60

WA470-7

10 Structure and function


Transmission

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

10-61

10 Structure and function


Transmission

16. Transfer gear 1


17. 2nd clutch
18. Upper shaft
19. 1st clutch

1. PTO gear A(number of teeth: 85)


2. PTO gear B(number of teeth: 85)
3. Strainer

10-62

WA470-7

10 Structure and function


Transmission

F, 1st clutch

(WA470-CF82-041-K-00-A)

A: F clutch oil port


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

WA470-7

10-63

10 Structure and function


Transmission

R, 2nd clutch

(WA470-CFJ1-041-K-00-A)

A: R clutch oil port


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

10-64

WA470-7

10 Structure and function


Transmission

3rd, 4th clutch

(WA470-CFK1-041-K-00-A)

A: 3rd clutch oil port


B: 4th clutch oil port
C: Lubricating oil port
1. Lower shaft
2. 3rd cylinder
3. 3rd clutch
4. 3rd gear (number of teeth: 48)
5. 4th gear (number of teeth: 36)
6. 4th clutch
7. 4th cylinder

Structure

(WA470-CF60-041-K-00-A)

The transmission employs the counter-shaft, constant mesh type gear mechanism and the disc clutches
and has "forward 4-speeds and reverse 4-speeds".
The transmission selects one rotating direction and one gear speed by fixing two of the six disc clutches
hydraulically by the operation of the ECMV in the counter-shaft type constant mesh gear mechanism.
The transmission transmits the power received by the transmission input shaft to the output shaft by
changing the gear speed (forward 1st to 4th or reverse 1st to 4th) with any combination of the forward or
reverse clutch, and one of four speed clutches.
Number of plates and discs used
Clutch name
F clutch
R clutch
1st clutch
2nd clutch
3rd clutch
4th clutch

Number of plates
15
15
13
13
10
13

Number of discs
14
14
12
12
9
12

Combinations of clutches for each gear speed and reduction ratios


Gear speed
Forward 1st
Forward 2nd
Forward 3rd
WA470-7

Clutches to be used
F x 1st
F x 2nd
F x 3rd

Reduction ratio
3.886
2.196
1.218

10-65

10 Structure and function


Transmission

Gear speed
Forward 4th
Neutral
Reverse 1st
Reverse 2nd
Reverse 3rd
Reverse 4th

10-66

Clutches to be used
F x 4th
R x 1st
R x 2nd
R x 3rd
R x 4th

Reduction ratio
0.737
3.760
2.125
1.179
0.713

WA470-7

10 Structure and function


Transmission

Disc clutch
Operation

(HM300-CF60-001-K-00-A)

(WA470-CF60-044-K-00-A)

When clutch is "engaged" (locked)

The oil sent from the ECMV is supplied with pressure through the oil passage of shaft (1) to the back of
piston (2), and pushes piston (2) to the right.
Piston (2) presses plates (3) against discs (4) to stop rotation of discs (4) with the friction force between
them.
As the internal teeth of discs (4) are meshed with clutch gear (5), shaft (1) and clutch gear (5) transmit the
power in one piece.
The oil is drained through oil drain hole (6), but it does not affect the operation of the clutch since its
quantity is far less than the quantity of the supplied oil.
When clutch is "disengaged" (released)

When the oil sent from the ECMV is shut off, the oil pressure applied to the back of piston (2) decreases.
Piston (2) is pushed back to the left by the reactive force of wave spring (7).
The friction force between plates (3) and discs (4) is lost and shaft (1) and clutch gear (5) are released.
When the clutch is disengaged, the oil on the back of the piston is drained by the centrifugal force through
oil drain hole (6) to prevent partial engagement of the clutch.

a Oil drain hole (6) is provided only in the 3rd and 4th clutches.

WA470-7

10-67

10 Structure and function


Transmission

Power transmitting route


Forward 1st

10-68

(HM300-CF60-001-K-01-A)

(WA470-CF60-044-K-01-A)

WA470-7

10 Structure and function


Transmission

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


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

WA470-7

o (from bottom left)


O
1st clutch (9)
O
1st clutch gear (10)
O
Transfer shaft 1 (13)
O
Transfer gear 1 (14)
O
Transfer gear 2 (23)
O
(to top right) o

o (from bottom center)


O
Output gear (24)
O
Output shaft (25)

10-69

10 Structure and function


Transmission

Forward 2nd

10-70

(WA470-CF60-044-K-02-A)

WA470-7

10 Structure and function


Transmission

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


Power from torque converter
O
Input shaft (1)
O
Input gear (2)
O
F gear (3)
O
F clutch (5)
O
F/1st cylinder (7)
O
R/2nd cylinder (8)
O
(to top center)o

WA470-7

o (from bottom left)


O
2nd clutch (11)
O
2nd hub (12)
O
Transfer shaft 1 (13)
O
Transfer gear 1 (14)
O
Transfer gear 2 (23)
O
Output gear (24)
O
(to top right) o

o (from bottom center)


O
Output shaft (25)

10-71

10 Structure and function


Transmission

Forward 3rd

10-72

(WA470-CF60-044-K-03-A)

WA470-7

10 Structure and function


Transmission

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


Power from torque converter

o (from bottom left)

o (from bottom center)

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

O
3rd gear (15)
O
3rd clutch (16)
O
3rd cylinder (17)
O
Lower shaft (21)
O
Transfer shaft 2 (22)
O
Transfer gear 2 (23)
O
(to top right) o

O
Output gear (24)
O
Output shaft (25)

WA470-7

10-73

10 Structure and function


Transmission

Forward 4th

10-74

(WA470-CF60-044-K-04-A)

WA470-7

10 Structure and function


Transmission

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


Power from torque converter

o (from bottom left)

o (from bottom center)

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

O
4th gear (18)
O
4th clutch (19)
O
4th cylinder (20)
O
Lower shaft (21)
O
Transfer shaft 2 (22)
O
Transfer gear 2 (23)
O
(to top right) o

O
Output gear (24)
O
Output shaft (25)

WA470-7

10-75

10 Structure and function


Transmission

Reverse 1st

10-76

(WA470-CF60-044-K-05-A)

WA470-7

10 Structure and function


Transmission

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


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

WA470-7

o (from bottom left)


O
R/2nd cylinder (8)
O
F/1st cylinder (7)
O
1st clutch (9)
O
1st gear (10)
O
Transfer shaft 1 (13)
O
Transfer gear 1 (14)
O
(to top right) o

o (from bottom center)


O
Transfer gear 2 (23)
O
Output gear (24)
O
Output shaft (25)

10-77

10 Structure and function


Transmission control valve

Transmission control valve

(WA470-CJA0-041-K-00-A)

Left valve assembly

A: R clutch oil pressure pickup port


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

10-78

WA470-7

10 Structure and function


Transmission control valve

Right valve assembly

A: Lockup clutch oil pressure pickup port


B: F clutch oil pressure pickup port
C: 1st clutch oil pressure pickup port
D: 4th clutch oil pressure pickup port
1. Lockup clutch ECMV
2. F clutch ECMV
3. 1st clutch ECMV
4. 4th clutch ECMV

WA470-7

10-79

10 Structure and function


Transmission control valve

Function

(WA470-CJA0-042-K-00-A)

The oil from the pump flows through the oil filter into the transmission control valve assembly and then is
divided into the main relief circuit and clutch actuation circuit.
The oil regulated its pressure by the main relief valve and flowed into the clutch operating circuit goes
through the last chance filter, then operates the clutch and parking brake. The oil relieved from the main
relief valve is supplied to the torque converter.
When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according to
the command current from the transmission controller to reduce the gear shifting shocks. The ECMV also
keeps the clutch pressure constant during travel.
If the F or R, and one of the 1st to 4th clutch ECMVs are selected, the regulated oil pressure is supplied to
the selected clutches and the desired gear speed is obtained.
The lockup ECMV is actuated when the machine travels in the 2nd, 3rd, or 4th gear speed and its travel
speed exceeds the travel speed set by the transmission controller.
This machine uses three types of the ECMVs, which have the following identifications and differences.
Stamp on name plate
(A)

Identification
color
(B)

Mark
(C)

Flow detection valve

L*******

Not installed

Q*******

Pink

Installed

K*******
L/U: Indicates lockup clutch ECMV.

Fill switch
(operating pressure:
MPa {kg/cm2})
Installed
(0.20 {2.0})
Installed
(0.24 {2.45})
Not installed

Not installed

Clutches to
be used
F, R, 1st,
2nd
3rd, 4th
L/U

Table of ECMV
operation
ECMV

Gear speed

F
F1

F2

F3

F4

1st

2nd

3rd

4th

L/U

Q
Q

Q
Q

Q
Q

R1

R2

R3

R4

Q
Q

Q
Q

Q
Q

L/U: Indicates lockup clutch ECMV.

10-80

WA470-7

10 Structure and function


Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV

Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV

(WA470-CJJ0-

041-K-00-A)

a ECMV: Abbreviation for Electronic Control Modulation Valve


a Do not disassemble this since it needs to be adjusted for maintaining the performance after reassembly.

A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
1. Fill switch connector
2. Proportional solenoid connector
3. Oil pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate

Function

(HM300-CJJ0-042-K-00-A)

The ECMV consists of a pressure control valve and a fill switch.


Pressure control valve
WA470-7

10-81

10 Structure and function


Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV

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

Range A: Before shifting gear (oil is drained)


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

10-82

WA470-7

10 Structure and function


Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV

Proportional solenoid current - thrust characteristics

Proportional solenoid thrust - oil pressure characteristics

ECMV and fill switch


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

WA470-7

10-83

10 Structure and function


Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV

Operation of ECMV

(HM300-CJJ0-044-K-00-A)

ECMV is controlled by the command current sent from the controller to the proportional solenoid and the
fill switch output signal.
The relationship among the proportional solenoid command current for ECMV, clutch input pressure, and
fill switch output signal is shown below.

Range A: Before shifting gear (oil is drained)


Range B: Clutch is being filled
Range C: Pressure is being adjusted
Range D: Clutch is being filled (triggering period)
Point E: Filling is started
Point F: Filling is finished
a The logic is designed so that the controller does not recognize completion of filling even if the fill switch is
turned "ON" during the triggering period (Range D).

10-84

WA470-7

10 Structure and function


Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV

Before shifting gear [when oil is drained] (range A in chart)

While no current is flowing to the proportional solenoid (1), pressure control valve (3) drains the oil from
clutch port (A) through drain port (T).
Fill switch (5) is turned OFF at this time since the oil pressure is not applied to pressure sensing valve (4).

WA470-7

10-85

10 Structure and function


Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV

Filling phase (range B in chart)

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

10-86

WA470-7

10 Structure and function


Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV

Pressure build-up (range C in chart)

When a current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current.
The pressure builds up until the thrust of the solenoid is balanced with the sum of the thrust generated by
the oil pressure in clutch port and the reaction force of pressure control valve spring (2).

WA470-7

10-87

10 Structure and function


3rd, 4th clutch ECMV

3rd, 4th clutch ECMV

(WA470-CJJ0-041-K-01-A)

a Do not disassemble this since it needs to be adjusted for maintaining the performance after reassembly.

A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
1. Fill switch connector
2. Proportional solenoid connector
3. Flow detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate

Function

(WA470-CJJ0-042-K-00-A)

The ECMV consists of a pressure control valve and a fill switch.


Pressure control valve
The proportional solenoid receives the current from the transmission controller, and this valve converts it
into oil pressure.
Fill switch

10-88

WA470-7

10 Structure and function


3rd, 4th clutch ECMV

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

Range A: Before shifting gear (oil is drained)


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

WA470-7

10-89

10 Structure and function


3rd, 4th clutch ECMV

Proportional solenoid current thrust characteristics

Proportional solenoid thrust hydraulic pressure characteristics

ECMV and fill switch


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

Operation of ECMV

(WA470-CJJ0-044-K-00-A)

ECMV is controlled by the command current sent from the controller to the proportional solenoid and the
fill switch output signal.
The relation between the proportional solenoid command current for ECMV, clutch input pressure, and fill
switch output signal is shown below.

10-90

WA470-7

10 Structure and function


3rd, 4th clutch ECMV

Range A: Before shifting gear (oil is drained)


Range B: Clutch is being filled
Range C: Pressure is being adjusted
Range D: Clutch is being filled (triggering period)
Point E: Filling is started
Point F: Filling is finished
a The logic is designed so that the controller does not recognize completion of filling even if the fill switch is
turned "ON" during the triggering period (Range D).

WA470-7

10-91

10 Structure and function


3rd, 4th clutch ECMV

Before shifting gear [when oil is drained] (range A in chart)

While no current is flowing to the proportional solenoid (1), pressure control valve (3) drains the oil from
clutch port (A) through drain port (T).
Fill switch (5) is turned OFF at this time since the oil pressure is not applied to pressure sensing valve (4).

10-92

WA470-7

10 Structure and function


3rd, 4th clutch ECMV

Filling phase (range B in chart)

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

WA470-7

10-93

10 Structure and function


3rd, 4th clutch ECMV

Pressure build-up (range C in chart)

When a current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current.
The pressure builds up until the thrust of the solenoid is balanced with the sum of the thrust generated by
the oil pressure in clutch port and the reaction force of pressure control valve spring (2).

10-94

WA470-7

10 Structure and function


Lockup clutch ECMV

Lockup clutch ECMV

(HM300-CDT8-041-K-00-A)

a ECMV: Abbreviation for Electronic Control Modulation Valve


a Do not disassemble this ECMV since it needs to be adjusted for maintaining the performance after
assembly.

A: To clutch
P: From pump
T: Drain
Dr: Drain
P1: Clutch oil pressure pickup port
1.
2.
3.
4.
5.

Proportional solenoid connector


Sleeve
Proportional solenoid
Pressure control valve
Name plate

Function

(WA470-CDT8-042-K-00-A)

This valve is used for adjusting the clutch oil pressure to the set pressure and selecting a clutch.
Since the modulation waveform is used for the pressure application characteristics to the clutch, the
lockup clutch is engaged smoothly and the gear shift shocks are reduced. In addition, generation of a
peak torque in the power train is prevented. As a result, the operator comfort improves and the power train
durability increases.
WA470-7

10-95

10 Structure and function


Lockup clutch ECMV

When torque converter drive mode changes to direct drive mode

When gear is shifted (traveling in direct drive mode)

10-96

WA470-7

10 Structure and function


Lockup clutch ECMV

Operation

(WA380-CDT8-044-K-00-A)

When clutch is "disengaged" (released)

While no current is flowing to the proportional solenoid (1), pressure control valve (3) drains the oil from
clutch port (A) through drain port (T).

WA470-7

10-97

10 Structure and function


Lockup clutch ECMV

When clutch is "engaged" (locked)

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

10-98

WA470-7

10 Structure and function


Main relief and torque converter relief valve

Main relief and torque converter relief valve

(WA380-C156-041-K-00-A)

1. Body
2. Piston
3. Torque converter relief valve
4. Piston
5. Main relief valve
A: Drain (torque converter relief)
B: Drain
C: From pump
D: Drain
E: To torque converter
P1: Main relief oil pressure pickup port
P2: Torque converter relief oil pressure pickup port

Function

(WA470-CJ10-042-K-00-A)

Main relief valve


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

WA470-7

10-99

10 Structure and function


Main relief and torque converter relief valve

Operation

(WA380-CJ10-044-K-00-A)

Operation of main relief valve

The oil from the hydraulic pump flows to port (C) through the filter. Then it flows to chamber (F) through
orifice (a) in main relief valve (1).

When the oil pressure in the circuit exceeds the set pressure, the oil in chamber (F) pushes piston (2) and
the reaction force pushes main relief valve (1) leftward. This connects ports (C) and (E).
Then, the oil from the pump flows through port (E) into the torque converter.
Operation of torque converter relief valve

The oil relieved through the main relief valve flows through port (E) into the torque converter. It also flows
through orifice (b) in torque converter relief valve (3) into chamber (G).
When the oil pressure to the torque converter exceeds the set pressure, the oil in chamber (G) pushes
piston (4) and the reaction force of the piston pushes torque converter relief valve (3) rightward to connect
ports (E) and (A).
Then, the oil in port (E) is drained through port (A).

10-100

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10 Structure and function


Axle

Axle

(HM300-DA00-001-K-00-A)

Front axle

(WA470-DA20-041-K-00-A)

1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler pipe and level plug
8. Brake oil port
9. breather
10. Brake wear gauge
11. Drain plug
12. Air bleeder

WA470-7

10-101

10 Structure and function


Axle

Rear axle

(WA470-DAC0-041-K-00-A)

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. Brake oil port
9. breather
10. Brake wear gauge
11. Drain plug
12. Air bleeder

10-102

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10 Structure and function


Differential

Differential

(HM300-DC10-001-K-00-A)

Front conventional differential

(WA470-DC70-041-K-00-A)

1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear

WA470-7

10-103

10 Structure and function


Differential

Rear conventional differential

(WA470-DCD0-041-K-00-A)

1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear

10-104

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10 Structure and function


Differential

Operation

(WA380-DC10-044-K-00-A)

The power from the engine is transmitted to the front and rear axles through the torque converter,
transmission, and drive shafts.
The power to be transmitted is changed in direction 90 degrees and in transmitting speed by bevel pinion
(1) and bevel gear (5) in the axle housing, and then transmitted to sun gear shaft (2) through pinion (4).
The power of the sun gear is further reduced in transmitting speed by the planetary gear type final drives,
and then transmitted to the axle shaft and wheels.
When machine is traveling straight

When the machine is traveling straight, the right and left wheels rotate at the same speed. Accordingly,
pinions (4) in the differential assembly do not rotate and the power of carrier (6) is transmitted through
pinions (4) and side gears (3) to the right and left sun gear shafts (2) evenly.

WA470-7

10-105

10 Structure and function


Differential

When machine is turning

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

10-106

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10 Structure and function


Differential

Front limited slip differential

(WA470-DCH3-041-K-00-A)

(if equipped)

1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear

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Differential

Rear limited slip differential

(WA470-DCH4-041-K-00-A)

(if equipped)

1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear

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Differential

Operation

(WA470-DCH2-042-K-00-A)

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

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Differential

<Mechanism of generating braking torque to right and left side gears (6)>

Shaft (7) is supported on the cam surfaces made on the surfaces of pressure rings (4) that are facing each
other. The power (= torque) from pressure rings (4) is transmitted to shaft (7) through the cam surfaces. Force
Fa to separate right and left pressure rings (4) is generated by inclination of the cam surfaces in proportion to
the transmitted torque.
This separating force (Fa) acts on the brakes on the back of right and left side gears (6) to generate braking
torque.
<When machine is traveling straight>
When the driving forces of the right and left wheels are balanced

[When road conditions (friction coefficient) under the right and left wheels and the loads on wheels are even
and the center of load on the bucket is not shifted]
The power from the transmission is distributed evenly by the differential gear to the right and left. Since the
tire slip limits on the right and left sides are the same under this condition, both tires slip and the differential
does not operate even if the power from the transmission exceeds the tire slip limit.
No load is applied to the brake on the back of each side gear.

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Differential

When the driving forces of the right and left wheels are unbalanced

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

Limited Slip Differential


Conventional differential

Wheel driving force (slipping wheel is set as 1)


Slipping wheel
Total (ratio)
Locked wheel
3.64 (1.82)
1
2.64
1

2 (1)

On a road surface where either wheel slips easily, the Limited Slip Differential increases the driving force by
1.82 times compared to the conventional differential.

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Differential

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

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Final drive

Final drive

(WA470-DF10-041-K-00-A)

a The figure shows the front axle.

1. Planetary gear
2. Planetary carrier
3. Axle shaft
4. Ring gear
5. Sun gear shaft

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Final drive

Operation

(WA380-DF10-044-K-00-A)

a The figure shows the front axle.

The final drive finally reduces the speed to transmit the power from the engine and increases in drive
power.
Ring gear (4) is press-fitted to the axle housing and fixed with the pin.
The power transmitted from the differential through sun gear shaft (5) is reduced in speed and increased
in drive power by the planetary gear mechanism.
The increased drive power is transmitted through planetary carrier (2) and axle shaft (3) to the wheels.

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Layout of steering parts

Steering system

(ALL-F000-001-K-00-A)

Layout of steering parts

(WA470-DT00-04D-K-00-A)

1. Steering cylinder (R.H.)


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

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Steering column

Steering column

(WA380-F171-041-K-00-A)

1. Steering wheel
2. Steering column
3. Steering tilt lock lever
4. Short column
5. Orbit-roll valve

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Steering pump

Steering pump

(WA470-F220-041-K-00-A)

P1: Pump discharge port


PD: Drain port
PS: Pump suction port
P1L: Pump pressure input port
PD2: Drain plug
PEN: Control pressure pickup plug
PLS: Load pressure input port
POP: External pilot pressure input port
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Steering pump

PEPC: EPC source pressure input port


1. Pump body
2. Servo valve
3. Air bleeder
Pump body

PA: Control source pressure output port


PD4: Drain port
PD5: Drain port
PE: Control pressure input port
PEPC: EPC source pressure input port

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Steering pump

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

10. Shoe retainer


11. Servo piston
12. Spring
13. Oil seal
14. Ball retainer

Structure
Cylinder block (6) is supported by spline (a) on shaft (1).
Shaft (1) is supported by each bearing at the front and rear.
The tip of piston (5) shapes a spherical concave and integrates with shoe (4) by gripping it.
Piston (5) and shoe (4) form a spherical bearing.
Rocker cam (3) is supported by case (2) and ball retainer (9) and has flat surface (A), and shoe (4) is
always pressed against this surface while sliding in a circular pattern.
Shoe (4) leads high-pressure oil to form a static pressure bearing for its sliding.
Piston (5) moves relatively in the axial direction in each cylinder chamber of cylinder block (6).
Cylinder block (6) rotates relatively to valve plate (7) while sealing the pressurized oil.
This plane is designed so that the oil pressure is balanced correctly.
The pressurized oil can be sucked in and discharged from each cylinder chamber in cylinder block (6)
through valve plate (7).

Specifications

(WA470-F220-030-K-00-A)

Model
Type
Theoretical delivery (cm3/rev)
Rated delivery pressure: (MPa {kg/
cm2})
Rated speed (rpm)

Function

LPV90
Variable displacement swash plate type piston pump
90
24.5 {250}
2,280

(WA380-F220-042-K-00-A)

The engine rotation and torque transmitted to the pump shaft is converted into the hydraulic energy and
the pressurized oil corresponding to the load is discharged.

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Steering pump

It is possible to change the delivery by changing the swash plate angle.

Operation

(WA470-F220-044-K-00-A)

Operation of pump

Cylinder block (6) rotates together with shaft (1) and shoe (4) slides on plane (A).
Rocker cam (3) pivots on ball retainer (9), and accordingly angle (a) between center line (X) of rocker cam
(3) and the axis of cylinder block (6) changes.
Angle (a) is called the swash plate angle.

While angle (a) is made between center line (X) of rocker cam (3) and the axis of cylinder block (6), plane
(A) works as a cam for shoe (4).
Piston (5) reciprocates inside cylinder block (6) and a difference is made between volumes (E) and (F) of
the cylinder chamber in cylinder block (6).
Oil in amount of (F) minus (E) is sucked in and discharged from piston (5).
Oil is discharged while cylinder block (6) rotates and the volume of chamber (E) decreases.
Oil is sucked in when the volume of chamber (F) increases.
In the figure, chamber (F) is at the end of the suction stroke and chamber (E) is at the end of the discharge
stroke.

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Steering pump

When center line (X) of rocker cam (3) matches the axis of cylinder block (6) (the swash plate angle is
zero), the difference between volumes (E) and (F) inside cylinder block (6) is zero.
Suction and discharge of pressurized oil is not performed in this stage. Namely pumping action is not
performed. (Actually, however, a zero swash plate angle never occurs.)
The pump delivery is in proportion to swash plate angle (a).
Control of delivery

When swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, then
delivery (Q) is increased.
Swash plate angle (a) is changed by servo piston (11).
Servo piston (11) reciprocates linearly according to the signal pressure from the PC valve and LS valve.
This linear motion is transmitted to rocker cam (3).
Being supported by ball retainer (9) on case (2), rocker cam (3) slides in the direction of rotary movement.

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Steering pump

Servo valve

(WA380-F2J0-041-K-00-A)

P1: Pump delivery pressure port


PE: Control pressure output port
T: Drain port
PEPC: EPC source pressure input port

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Steering pump

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

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Steering pump

PA: Pump pressure input


PE: Control piston pressure
PLS: LS pressure input
PPL: PC valve output pressure
PPLS: LS pump pressure input
10. Nut
11. Plate
12. Plug
13. Spring
14. Seat
15. Spool
16. Plug

LS valve

(WA380-F2R0-001-K-00-A)

Function (WA380-F2R0-042-K-00-A)
The LS valve controls the pump delivery according to the travel of the control lever, or the flow demanded
by the actuator.
The LS valve detects the flow rate demanded by the actuator from differential pressure (dPLS) between
inlet pressure (PPLS) and outlet pressure (PLS) of the control valve and controls pump delivery (Q) of the
main pump. [(PPLS) is called the LS pump pressure, (PLS) the LS pressure, and (dPLS) the LS
differential pressure.]
In other words, pressure loss [= LS differential pressure (dPLS)], which occurs when oil flows through the
passage in control valve spool, is detected, and pump delivery (Q) is controlled to maintain the pressure
loss at a constant level. Through this operation, pump can deliver the proper volume of oil as demanded
by the actuator.
Main pump delivery pressure (PP), LS pump pressure (PPLS) and LS pressure (PLS) are transmitted into
the LS valve. Pump delivery (Q) changes as shown in the following figure according to the LS differential
pressure (dPLS).

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Steering pump

PC valve

(WA380-F2S0-001-K-00-A)

Function (WA380-F2S0-042-K-00-A)
The PC valve limits the oil flow to a certain level (depending on the delivery pressure) even if the travel of
the control valve is increased extremely so that the horsepower absorbed by the pump does not exceed
the engine horsepower, when pump delivery pressure (PA) is high.
In other words, the PC valve decreases the pump delivery when the actuator load is increased and the
pump delivery pressure rises, and increases it when the pump delivery pressure lowers.
If command current (X) sent to EPC valve increases further, the relationship between pump pressure (PP)
and pump delivery (Q) is shifted parallel in proportion to the thrust of EPC valve solenoid.
That is, since the thrust of the EPC valve solenoid is added to the left-hand thrust caused by the pump
pressure applied to spool (6), the relationship between pump pressure (PA) and (Q) is shifted from [1] to
[2] as (X) increases.

Operation

(WA380-F2S0-044-K-00-A)

Action of spring
The spring force of spring (3) in the PC valve is determined by the angle of the swash plate.
When servo piston (9) moves to the right, spring (3) is compressed through lever (2) and the spring force
changes.
When pump pressure (PA) is low
The pressing force of piston (10) is decreased and spool (6) is a little closer to the right (Fig. 1). At this time,
port (C) is connected to port (D) and the pressure transmitted to the LS valve becomes drain pressure
(PT).
When port (F) is connected to port (G) of the LS valve, the pressure in port (J) becomes drain pressure
(PT) and servo piston (9) moves to the left.
Consequently, the pump delivery is increased.
As servo piston (9) moves, lever (2) moves to the left and spring (3) expands and the spring force is
decreased. Consequently, spool (6) moves to the left and port (C) is disconnected from port (D) and
connected to pump discharge port (B).
As a result, the pressure in port (C) rises and the piston pressure is increased and servo piston (9) stops
moving to the left.
When pump pressure (PA) is high
The pressing force of piston (10) is increased and spool (6) is a little closer to the left (Fig. 2). At this time,
port (C) is connected to port (B) and the pressure transmitted to the LS valve becomes pump pressure
(PA).
When port (F) is connected to port (G) of the LS valve, the pressure in port (J) becomes pump pressure
(PA) and servo piston (9) moves to the right.
Consequently, the pump delivery is decreased.
As servo piston (9) moves, lever (2) moves to the right and spring (3) is compressed and spring force is
increased. Consequently, spool (6) moves to the right and port (C) is disconnected from port (B) and
connected to drain pressure port (D).
As a result, the pressure in port (C) lowers and the piston pressure is decreased and servo piston (9)
stops moving to the right.

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Steering pump

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

When load is heavy


(Fig. 2)

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Steering pump

When servo valve is balanced


(Fig. 3)

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Steering valve

Steering valve

(WA380-F570-041-K-00-A)

P: From steering pump


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

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Steering valve

1. Relief valve
2. Flow control spool
3. Steering relief valve
4. Steering spool
5. Overload relief valve

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Steering valve

Operation

(WA380-F570-044-K-00-A)

Operation of flow amplifier


When spool is in neutral (When orbit-roll valve is not operating)

Since ports (Pa) and (Pb) are connected to the drain circuit through the orbit-roll valve, steering spool (1)
is held in the neutral position by right and left return springs (2).
When spool operates (When oil flows in port (Pa))

The pressure in port (Pa) increases and steering spool (1) compresses left return spring (2) and moves to
the left.
The oil in port (Pa) flows through the hole of spring seat (3) and orifice (a) of steering spool (1) to port (Pb).
Since port (Pb) is connected to the drain circuit through the orbit-roll valve, the oil in port (Pb) is drained.
Since the pressure generated in port (Pa) is in proportion to the oil flow, steering spool (1) moves to a
position in which the oil pressure reduced by orifice (a) is balanced with the reaction force of return spring
(2).
When spool returns (When steering wheel operation is stopped)

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Steering valve

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

The oil from the steering pump flows in port (P).


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

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Steering valve

When steering spool operates

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

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Steering valve

If the open area of notch (e) changes, the steering pump delivers oil according to the open area of notch
(e) to keep the oil pressure in port (Pr) constant.
Operation of steering valve
When in neutral

Since the steering wheel is not operated, steering spool (1) does not move.
The oil from the steering pump flows in port (P).
When the oil pressure in port (P) increases, flow control spool (2) moves to the left to drain the oil from the
steering pump through notch (a) and port (T1).

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Steering valve

When machine turns to left

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

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Steering valve

When machine turns to right

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

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Steering valve

Steering relief valve

(WA380-F590-041-K-00-A)

1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat

Function

(WA380-F590-042-K-00-A)

The steering relief valve is installed to the steering valve and maintains the oil pressure in the steering
circuit at the set pressure during steering operation.

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Steering valve

Operation

(WA380-F590-044-K-00-A)

If the oil pressure in the steering circuit increases to the pressure set with adjustment screw (1) and spring
(2), pilot poppet (3) opens to drain the oil through port (T1).
Pressure receiving chambers (X) and (Y) are unbalanced in pressure and flow control spool (4) moves to
the left.
Flow control spool (4) operates to drain the oil from the steering pump and maintain the steering circuit
pressure below the set value.

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Steering valve

Overload relief valve

(WA380-F5B0-041-K-00-A)

1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring

Function

(WA380-F5B0-042-K-00-A)

The overload relief valve is installed to the steering valve and protects the cylinder circuit from abnormally
high pressure generated by impacts applied to the cylinder for some reason while the steering valve is in
neutral.
If abnormally high pressure is generated on the cylinder side, this valve works as a safety valve to prevent
breakage of the cylinder and hydraulic piping.
If negative pressure is generated on the cylinder side, this valve works as a suction valve to prevent a
vacuum in the circuit.

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Steering valve

Operation

(WA380-F5B0-044-K-00-A)

Operation as relief valve

Port (A) is connected to the cylinder circuit and port (B) is connected to the drain circuit.
The oil flows through the hole of poppet (1) to the inside of relief valve poppet (2).
Check valve poppet (3) and relief valve poppet (2) are securely seated because of the area difference
between diameters (d1) and (d2).

If the oil pressure in port (A) exceeds the set pressure of the relief valve, pilot poppet (4) is moved open to
the right.
The oil flows through pilot poppet (4) and drill hole to port (B).

Since pilot poppet (4) opens, the oil pressure inside poppet (1) lowers.
Poppet (1) moves to the right to seat pilot poppet (4).

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Steering valve

The oil pressure inside relief valve poppet (2) is lower than the oil pressure in port (A).
Since the oil pushes open relief valve poppet (2) to the right and flows from port (A) to port (B), the circuit
is protected from abnormally high pressure.
Operation as suction valve

If negative pressure is generated in port (A), it acts on the area difference between diameters (d3) and
(d4) and pushes check valve poppet (3) to the right.
The oil flows from port (B) to port (A) to prevent a vacuum.

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Steering valve

Relief valve

(WA380-F530-041-K-00-A)

1. Plug
2. Spring
3. Valve
4. Valve seat

Function

(WA380-F530-042-K-00-A)

The relief valve is installed to the steering valve and relieves the oil when the oil pressure in port (Pr)
exceeds the set pressure to protect the LS circuit of the steering pump from abnormally high pressure.

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Orbit-roll valve

Orbit-roll valve

(WA380-F550-041-K-00-A)

P: From charge valve


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

10. Spacer
11. End cap
Outline

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

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Orbit-roll valve

Structure

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

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Orbit-roll valve

Connection of hand pump and sleeve

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

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Orbit-roll valve

Role of centering spring

Centering spring (2) is composed of layers of two flat leaf springs and four X-shaped leaf springs and
installed between spool (9) and sleeve (8) as shown in the figure.

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Orbit-roll valve

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

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Stop valve

Stop valve

(WA380-F5U0-041-K-00-A)

A: From orbit-roll valve


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

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Emergency steering motor

Emergency steering motor

(WA380-F9R0-041-K-00-A)

(if equipped)

1. Terminal E
2. Terminal M

Function

(WA380-F9R0-042-K-00-A)

The emergency steering motor drives the emergency steering pump according to the signals from the
transmission controller when the steering circuit pressure decreases abnormally.

Specification
Name
Rated voltage (V)
Rated output (KW)

10-150

(WA380-F9R0-030-K-00-A)

DC motor
24
0.9

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Emergency steering pump

Emergency steering pump

(WA380-F940-041-K-00-A)

(if equipped)

Specification

(WA380-F940-030-K-00-A)

Model
Rotating speed (rpm)
Delivery pressure (MPa {kg/cm2})
Standard delivery (l/min)
Allowable delivery (l/min)

Function

SBL (1) 21
3,500
20.6 {210}
67.6
62.4

(WA380-F940-042-K-00-A)

The emergency steering pump is installed together with the emergency steering motor to the right side of
the transmission. It supplies oil to the steering circuit if the engine stops or the steering circuit pressure
decreases below the specified value.

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Layout of brake parts

Brake system

(ALL-G000-001-K-00-A)

Layout of brake parts

(WA470-G000-04D-K-00-A)

1. Slack adjuster (front)


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

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Layout of brake parts

13. Accumulator charge valve


14. Brake accumulator (for rear)
15. Parking brake emergency release valve
16. Rear brake oil pressure switch
17. Front brake oil pressure switch
18. Parking brake solenoid valve
19. Parking brake oil pressure switch

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Charge valve

Charge valve

(WA470-G2H0-041-K-00-A)

P: From pump
A: To cooling fan motor
PPC: To Orbitrol valve or work equipment valve or EPC valve of each pump
ACC1: To brake valve port PA
ACC2: To brake valve port PB
T: Drain
G: Accumulator charge pressure pickup port

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Charge valve

1. Valve body
2. Sequence valve (H1)
3. Relief valve (R2)
4. Shuttle valve (S1)
5. Priority valve
6. PPC relief valve (R3)
7. Main relief valve (R1)

Function

(WA380-G2H0-042-K-00-A)

The charge valve maintains the oil pressure from the pump at the set pressure and saves the pressure in
the accumulator.
When the pressure is saved in the accumulator, the circuit to the cooling fan motor opens to output the
pressurized oil from the pump to drive the cooling fan motor.
When the oil pressure rises above the specified pressure, the oil from the pump is led to the drain circuit to
reduce the load on the pump.
The charge valve reduces the oil from the pump in pressure and outputs the source pressure for the pilot
circuit.
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Charge valve

Operation

(WA380-G2H0-044-K-00-A)

When oil is not supplied to accumulator (cut-out condition)

Since the pressure in oil passage (B) is higher than the set pressure of relief valve (1), piston (2) is pushed
forcibly to the right by the pressurized oil from oil passage (B).
Relief valve (1) opens, and oil passage (C) and port (T) are interconnected.
The pressurized oil from the pump flows through orifices (a) and (b) and oil passage (C) to port (T).
Since the pressure drops when it passes orifice (a), pressure difference is generated between pressure
receiving chambers (D) and (E).
When the pressure in pressure receiving chamber (D) exceeds the set pressure of priority valve (5),
priority valve (5) compresses spring (6) and moves to the right.
The open areas of port (P) and orifice (c) are narrowed and port (P) starts to be interconnected to port (A).
The pressurized oil from the pump flows through port (P), sequence valve (7), and port (A) to the cooling
fan motor.
When oil is supplied to accumulator (Cut-in condition)

When the pressure in oil passage (B) decreases below the set pressure of relief valve (1), relief valve (1)
is returned to the left by the reaction forces of springs (3) and (4).

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Charge valve

Relief valve (1) closes, and oil passage (C) and port (T) are disconnected.
Since oil passage (C) and port (T) are disconnected, the pressure drops less when it passes orifice (a)
and the pressure difference between pressure receiving chambers (D) and (E) decreases.
Priority valve (5) is moved to the left by the reaction force of spring (6).
The open areas of port (P) and orifice (c) are increased and port (P) starts to be disconnected from port
(A).
When the oil pressure from the pump exceeds the pressure of ports (ACC1) and (ACC2), it pushes up
check valve (8) and pressure starts being saved in the accumulator through ports (ACC1) and (ACC2).
A certain quantity of oil decided by the size (area) of orifice (c) and the pressure difference over orifice (c)
(equivalent to force of spring (6)) is supplied through ports (ACC1) and (ACC2) to the accumulator. The
excess oil flows to ports (A) and (PPC).
When pressure reaches cut-off pressure

When the pressure in oil passage (C) reaches the set pressure of relief valve (1), relief valve (1) is pushed
to the right by the oil pressure from oil passage (C).
Relief valve (1) opens, and oil passage (C) and port (T) are interconnected.
Pressure difference is generated between the right and left sides of piston (2), and then piston (2) moves
to the right to open relief valve (1) forcibly.
Since pressure receiving chamber (E) of priority valve (5) is also connected to oil passage (C), the
pressure in pressure receiving chamber (E) becomes the drain pressure.
Since the pressure in pressure receiving chamber (D) decreases to the level for the force of spring (6), oil
supply to oil passage (B) stops.
Main relief valve (R1)

When the pressure in port (P) (pump pressure) exceeds the set pressure, it compresses spring (1) and
moves ball (2) to the left.
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Charge valve

The pressurized oil from the pump reduces in pressure when it passes through orifice (a). As a result, the
pressure difference compresses spring (3) and moves valve (4) to the left largely.
Since ports (P) and (T) are connected to drain the pump pressure, the maximum pressure of the charge
circuit is limited to protect the circuit.
PPC relief valve (R3)

When the pressure in port (PPC) (pilot pressure) exceeds the set pressure, the pressurized oil from the
pump compresses spring (1) and moves ball (2) to the left.
The pressurized oil from the pump reduces in pressure when it passes through orifice (a). As a result, the
pressure difference compresses spring (3) and moves valve (4) to the left.
The open area between ports (PPC) and (P) decreases and causes pressure drop. As a result, the
pressure in port (P) does not decrease to the set pressure of the PPC relief valve but is maintained.
The pressure in port (PPC) is maintained at a certain value of pressure by adjusting the open area
between ports (PPC) and (P) and supplied as the source pressure of the pilot pressure.
When the pressure in port (PPC) becomes abnormal, port (PPC) and port (T) are interconnected to
release the abnormal pressure and protect the pilot circuit.
Sequence valve (H1)

The pressure of port (P) (pump pressure) is applied to the left end of sequence valve (1) and the drain
pressure is applied to the right end.
When the pump pressure exceeds the set pressure of spring (2), sequence valve (1) moves to the right to
interconnect ports (P) and (A).
The pressurized oil from the pump flows through priority valve (3) and port (A) to the cooling fan motor to
drive the motor.
Even when the driving pressure of the cooling fan motor is low, the sequence valve maintains the pump
pressure above the set pressure of spring (2) and prevents the accumulator charge pressure and the
source pressure of the pilot circuit from decreasing.

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Charge valve

Shuttle valve (S1)

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

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Brake valve

Brake valve

(WA380-G2B0-041-K-00-A)

PA: From charge valve ACC1 port


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

Function

(WA380-G2B0-042-K-00-A)

The brake valve is installed to the front lower part of the operator's seat. When the brake pedal is
depressed, the oil flows to the brake piston to operate the brake.
The right and left brake pedals are connected mechanically. When either of them is depressed, the other
one is operated, as well.
If the brake pedal is depressed, the transmission cut-off oil pressure sensor operates and supplies signals
to the transmission controller to set the transmission in neutral electrically.

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Brake valve

Operation

(WA380-G2B0-044-K-00-A)

When brake pedal is depressed

When brake pedal (1) is depressed, the depressing force is transmitted to spool (5) through rod (2), piston
(3), and spring (4).
When spool (5) is pushed to the right, port (TA) is closed and the oil from the pump flows through the
accumulator to port (PA) and further flows through port (A) to the rear brake piston to operate the rear
brake.
At the same time when spool (5) is moved to the right, spool (6) is also moved to the right to close port
(TB). Then, the oil from the pump flows through the accumulator to port (PB) and further flows through port
(B) to the front brake piston to operate the front brake.
When only either brake operates
(When either brake has trouble)

Even if the front or rear brake system has trouble such as oil leakage and only either of them operates, the
depressing force of brake pedal (1) moves spools (5) and (6) to the right mechanically.
Accordingly, the oil from the pump flows to the normal brake piston to apply the brake as usual, thus the
machine can be stopped and the safety is kept high.
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Brake valve

Balancing operation

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

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Brake valve

When brake pedal is released

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

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Slack adjuster

Slack adjuster

(WA500-G310-041-K-00-A)

A: Inlet port
B: Outlet port
1. Cylinder
2. Check valve
3. Piston
4. Spring
5. Bleeder

Specifications

(WA470-G310-030-K-00-A)

Piston operating pressure (MPa {kg/cm2})


Cracking pressure of check valve (MPa {kg/cm2})
Closing pressure of check valve (MPa {kg/cm2})

Function

0.01 to 0.02 {0.1 to 0.2}


0.93 0.05 {9.5 0.5}
0.60 0.05 {6.0 0.5}

(WA470-G310-042-K-00-A)

The slack adjuster is installed in the brake oil line going to the brake piston from the brake valve, and
keeps the time lag in braking operation at a constant value.

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Slack adjuster

Operation

(WA470-G310-044-K-00-A)

1. When brake pedal is depressed

Before the brake pedal is depressed, pistons (4) are returned by stroke (S) (full stroke). When the brake
pedal is depressed, the oil from the brake valve is divided at slack adjuster port (P) and flows to the right
and left cylinders (2) to move pistons (4) rightward and leftward by stroke (S).

As a result, brake piston (6) moves by stroke (S). At this time, the clearance between brake piston (6) and
disc becomes zero, but no braking force is generated.

When the brake pedal is depressed further and the oil pressure from the brake valve exceeds the
specified pressure, check valve (3) opens and pressure is applied to port (C) to generate braking force.
Thus, the time lag when the brake is applied is maintained constant.

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Slack adjuster

2. When brake pedal is released

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

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Accumulator (for brake)

Accumulator (for brake)

(WA380-G2G0-041-K-00-A)

1. Plug
2. Gas valve
3. Top cover
4. Cylinder
5. Free piston
6. End cover

Specifications

(WA380-G2G0-030-K-00-A)

Gas to be used
Gas capacity (cc)
Charged pressure
(MPa {kg/cm2})
Max. pressure used
(MPa {kg/cm2})

Function

Nitrogen gas
2,850
3.43 0.1 {35 1.0}
(At 20C)
20.6 {210}

(WA380-G2G0-042-K-00-A)

The accumulator is installed between the charge valve and brake valve. The space between cylinder (4)
and free piston (5) is filled with nitrogen gas. The nitrogen gas absorbs the hydraulic pulsation generated
by the hydraulic pump by utilizing its compressibility, and secures the braking force and operability when
the engine is stopped.

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Brake

Brake
Front

(HM300-G160-001-K-00-A)
(WA470-G16H-041-K-00-A)

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

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Brake

Rear

(WA470-G16K-041-K-00-A)

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

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Brake

Operation

(WA380-G160-044-K-00-A)

When brake is applied

When the brake pedal is depressed, pressurized oil (P) supplied from the hydraulic tank through the pump
and brake charge valve flows through the oil passage in the brake cylinder to pushes piston (2) to the left.
Accordingly, discs (4) held between piston (2), plates (3), and end plate (5) are locked and the machine is
braked.
When brake is released

When the oil pressure is released, piston (2) is returned by the reaction force of spring (8). As a result,
clearance is made between plate (3) and end plate (5), and the brake is released.
The linings stuck to discs (4) are grooved in a check pattern, and oil flows in the grooves to cool the linings
while discs (4) are turning.

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Parking brake control

Parking brake control

(WA470-GJ00-041-K-00-A)

1. Parking brake switch


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

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Parking brake

Parking brake

(WA470-GJ20-041-K-00-A)

1. Output shaft
2. Spring (outside)
3. Spring (inside)
4. Parking brake oil port
5. Piston
6. Plate
7. Disc
8. Wave spring
Structure
The parking brake is a wet-type multiple-disc brake, which is operated mechanically by springs (2) and (3)
to brake output shaft (1).

Operation

(WA380-GJ20-044-K-00-A)

When the brake is applied, piston (5) presses plates (6) and discs (7) against each other with the tension
of springs (2) and (3) to lock output shaft (1).
When the brake is released, the oil pressure from parking brake oil port (4) moves piston (5) to release the
pressing force on discs (7) and plates (6).

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Parking brake solenoid valve

Parking brake solenoid valve

(WA470-GJD0-041-K-00-A)

1. Transmission control valve assembly (L.H. valve assembly)


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

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Parking brake solenoid valve

Operation

(WA380-GJD0-044-K-00-A)

When parking brake is applied (solenoid is de-energized)

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

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Parking brake solenoid valve

When parking brake is released (solenoid is energized)

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

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Parking brake emergency release valve

Parking brake emergency release valve

(WA470-GJG0-041-K-00-A)

A: From accumulator
B: To parking brake solenoid valve
1. Grip
2. Valve

Function

(WA380-GJG0-042-K-00-A)

The parking brake emergency relief valve is installed between the accumulator of the brake circuit and
parking brake solenoid. When the oil pressure from the power train pump cannot be supplied because of
an engine trouble etc., the accumulator charge pressure of the brake circuit can be supplied to the parking
brake cylinder by opening this valve manually.

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Axle mount and center hinge pin

Undercarriage and frame

(ALL-DT00-001-K-00-A)

Axle mount and center hinge pin

(WA470-H1K0-041-K-00-A)

1. Front axle
2. Front frame
3. Rear axle
4. Rear frame

Function

(WA380-H1K0-042-K-00-A)

Front frame (2) and rear frame (4) are connected by the center hinge pin with the bearing between them.
The right and left steering cylinders connecting front frame (2) and rear frame (4) adjust the articulate
angle of the frames, or the turning radius, by extending and retracting their piston rods.

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Tire

Tire

(WA470-DW60-041-K-00-A)

This machine has the following features by employing radial tires.

High grip
High operator comfort
Low puncture rate
Less uneven wear
Less fuel consumption
Long life
Less damage on machine
Less heat generation

Comparison of structures and characteristics of tires


Radial tire

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

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Tire

Bias tire

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

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Hydraulic component layout

Hydraulic system

(D65-PM10-001-K-00-A)

Hydraulic component layout

(WA470-PM10-04D-K-00-A)

1. Lift cylinder (R.H.)

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Hydraulic component layout

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

Work equipment control


3-lever type

(WA380-PK00-001-K-00-A)

(WA380-PK3A-041-K-00-A)

a The figure shows the machine with the auxiliary control lever.

1. Work equipment lock switch


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

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Hydraulic tank

Hydraulic tank

(WA470-PM30-041-K-00-A)

Oil filler cap with relief valve


2. Breather (for air intake)
3. Hydraulic tank
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Hydraulic tank

4. Drain plug
5. Strainer
6. Filter element
7. Bypass valve
8. Suction strainer
9. Sight gauge

Specifications

(WA470-PM30-030-K-00-A)

Hydraulic tank capacity (l)


Hydraulic oil in tank (l)
Bypass valve set pressure (MPa {kg/cm2})

Oil filler cap with relief valve

255
173
0.15 0.03 {1.53 0.31}

(WA470-PM37-041-K-00-A)

1. Bottom plate
2. Gasket
Prevention of pressure rise in tank
While the hydraulic circuit is in operation, the pressure in the hydraulic tank increases as the oil level and
the temperature in the hydraulic tank rise according to the operation of the hydraulic cylinders.
If the pressure in the tank exceeds the set pressure, bottom plate (1) is pushed up to release the pressure
in the tank and prevent pressure rise.
(Set pressure of air bleeding valve: 75 15 kPa {0.76 0.15 kg/cm 2})

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Hydraulic tank

Breather

(WA500-PM38-041-K-00-A)

1. Body
2. Filter element
3. Poppet
4. Sleeve

Function

(WA470-PM38-042-K-00-A)

Prevention of negative pressure in tank


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

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Double type gear pump

Double type gear pump

(WA470-RA1S-041-K-00-A)

Power train charge pump and power train lubrication pump

1. Power train charge pump (SAL (3) 80)


2. Power train lubrication pump (SAL (1) 32)

Specifications

(WA470-RA1S-030-K-00-A)

Model
Rotating speed (rpm)
Discharge pressure (MPa {kg/cm2})
Standard discharge (l/min)
Allowable discharge (l/min)

Function

SAL (3) 80
2,500
2.9 {30}
192
176

SAL (1) 32
2,500
2.9 {30}
78
70

(WA380-RA1S-042-K-00-A)

The double type gear pump consists of the power train charge pump and the power train lubrication pump.
It is installed to the PTO shaft of the torque converter and driven by the PTO shaft to supply oil pressure to
the torque converter and transmission circuits.

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Work equipment pump

Work equipment pump

(WA470-C200-041-K-00-A)

IM: PC mode selector current


PA: Pump discharge port
PB: Pump pressure inlet port
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Work equipment pump

PC: Cooling port


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

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Work equipment pump

1. Shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Servo piston
11. PC valve

Structure
Cylinder block (7) is supported to shaft (1) by spline (12).
Shaft (1) is supported by each bearing (13) at the front and rear.
The tip of piston (6) is shaped as a concave sphere and crimped together with shoe (5).
Piston (6) and shoe (5) form a spherical bearing.
Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
Rocker cam (4) rocks on cylindrical surface (B) of cradle (2) fixed to the case. High-pressure oil is supplied
between them to form a static pressure bearing.
Piston (6) moves relatively in the axial direction in each cylinder chamber of cylinder block (7).
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Work equipment pump

Cylinder block (7) rotates relatively to valve plate (8) while sealing the pressurized oil.
The oil pressure is balanced properly on the sealing surface of cylinder block (7) and valve plate (8).
The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).

Specifications

(WA470-C200-030-K-00-A)

Model
Type
Theoretical delivery (cm3/rev)
Rated delivery pressure: (MPa {kg/
cm2})
Rated speed (rpm) (*1)

HPV140
Variable displacement swash plate type piston pump
120 1
34.3 {350}
2,282

*1: It shows the value when engine speed is at rated speed of 2,000 rpm.

Function

(WA500-C200-042-K-00-A)

This pump converts the rotation and torque of the engine transmitted to its shaft into hydraulic pressure
and discharges pressurized oil according to the load.
It is possible to change the discharge by changing the swash plate angle.

Operation

(WA470-C200-044-K-00-A)

Operation of pump

Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
Rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (7) changes.
Angle (a) is called the swash plate angle.

While angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane
(A) works as a cam for shoe (5).
Piston (6) slides inside cylinder block (7) and a difference is made between volumes (E) and (F) in cylinder
block (7).
Oil in amount of (F) minus (E) is sucked in and discharged from each piston (6).

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Work equipment pump

Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
Oil is sucked in when the volume of chamber (F) increases.

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

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Work equipment pump

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

LS valve

10-192

(WA470-C2J0-041-K-00-A)

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10 Structure and function


Work equipment pump

PA: Pump port


PDP: Drain port
PLP: LS control pressure output port
PLS: LS pressure input port
PP: Pump port
PPL: Control pressure input port
PSIG: Drain port
1. Sleeve
2. Piston
3. Spool
4. Spring
5. Seat
6. Sleeve
7. Plug
8. Lock nut

Function

(WA470-C2J0-042-K-00-A)

The LS (load sensing) valve detects the load of the actuator and controls the pump discharge.
The LS valve controls pump discharge (Q) according to differential pressure (dPLS) [ = (PP - PLS)] (called
LS differential pressure) between pump discharge pressure (PP) and control valve outlet port pressure
(PLS).
The LS valve receives main pump pressure (PP) and pressure (PLS) (called the LS pressure) coming
from the control valve output.

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Work equipment pump

Operation

(WA500-C2J0-044-K-00-A)

When control valve is in neutral

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

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Work equipment pump

Operation in direction to increase pump discharge

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

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Work equipment pump

The pressure at the large end of servo piston (12) becomes drain pressure (PT) and pump pressure (PP)
is constantly transmitted to port (J) at the small end. Accordingly, servo piston (12) is pushed to the left
and moves the swash plate in the direction to increase the discharge.
Operation in direction to increase pump discharge

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

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Work equipment pump

When servo piston is balanced

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

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10 Structure and function


Work equipment pump

PC valve

(WA470-C2K0-041-K-00-A)

PA: Pump port


PDP: Drain port
PM: Mode selector pressure pilot port
PPL: Control pressure output port (to LS valve)
1. Plug
2. Servo piston assembly
3. Pin
4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring

Function

(WA470-C2K0-042-K-00-A)

The PC valve limits the oil flow to a certain level (depends on the discharge pressure) even if the stroke of
the control valve is increased extremely when pump discharge pressure (PP) is high.
If the pump discharge pressure increases due to increased load during operation, this valve decreases the
pump discharge.
If the pump discharge pressure decreases, this valve increases the pump discharge.
The relation between the pump discharge pressure (PP) and pump discharge (Q) is as shown in the
following figure, as a parameter for each current (X) value applied to the PC-EPC valve solenoid.
The controller continues counting the actual engine speed.
During low speed, command current (X) flows from the controller to PC-EPC valve solenoid according to
the engine speed to reduce the pump discharge.

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Work equipment pump

Operation

(WA470-C2K0-044-K-00-A)

When actuator load is small and pump discharge pressure (PP) is low

Action of PC-EPC valve solenoid (1)


Command current (X) from the work equipment controller flows to the PC-EPC valve solenoid (1).
This command current (X) acts on the PC-EPC valve to generate signal pressure to vary the force pushing
piston (2).
Spool (3) stops at a position where the combined force exerted by spring (4) is equalized to the force
exerted by pump pressure (PP) acting on spool (3).

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Work equipment pump

Depending on the position where spool stops, the pressure output from the PC valve [port (C) pressure]
varies.
The amperage of the command current (X) depends on the type of work (lever operation), working mode
selection, engine speed setting, and the actual engine speed.

Action of spring
The spring force of spring (4) in the PC valve depends on the position of the swash plate.
When servo piston (9) compresses or decompresses spring (4), the spring force varies.
When the command current (X) input to PC-EPC valve solenoid (1) varies, the thrust pushing piston (2)
varies.
The spring force of spring (4) is also varied by the PC-EPC valve solenoid command current (X).
Port (C) on the PC valve is connected to port (E) on the LS valve.
Pump pressure (PP) is transmitted to the small diameter end of servo piston (9), port (A), and port (B).
When pressures (PP) is low, spool (3) is at the left.
Port (C) and port (D) are connected, and the pressure entering the LS valve will be drain pressure (PT).
When port (E) of the LS valve is connected to port (G), the pressure from port (J) entering the large
diameter side of the piston becomes drain pressure (PT), and servo piston (9) moves to the left.
The pump discharge goes to increase.
The movement of servo piston (9) lets spring (4) to expand, and the spring force decreases.
When the spring force decreases, spool (3) moves to the right. Ports (C) and (D) are blocked, while pump
discharge pressure port (B) is connected to port (C).
Since the pressure in port (C) and the pressure at the large diameter side of the piston increase, servo
piston (9) stops moving to the left.

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10 Structure and function


Work equipment pump

Stop position of servo piston (9) (= pump discharge) is determined by a position where the press force
generated by pressure (PP) on spool (3) and the thrust by PC-EPC valve solenoid and the force of spring
(4) are balanced.
When actuator load is large and pump discharge pressure is high

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

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Work equipment pump

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

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Work equipment pump

PC-EPC valve

(WA500-C2N0-041-K-00-A)

C: To PC valve
P: From pilot lamp
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger

Function

(WA500-C2N0-042-K-00-A)

The EPC valve consists of the proportional solenoid and the hydraulic valve.

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Work equipment pump

When signal current (i) from the controller is received, an EPC output pressure proportional to the
amperage of current is generated and output to the PC valve.

Operation

(WA500-C2N0-044-K-00-A)

When signal current is zero (coil de-energized)


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

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Work equipment pump

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10 Structure and function


Work equipment pump

When signal current is minute (coil is energized)


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

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Work equipment pump

When signal current is maximum (coil is energized)


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

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Control valve

Control valve

(WA470-R404-041-K-00-A)

a In this section, the 4-spool valve (with ECSS control valve) is described.

A1: To bucket cylinder bottom


A2: To lift cylinder bottom

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10 Structure and function


Control valve

A3: To attachment port


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

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10 Structure and function


Control valve

1. Load check valve (bucket bottom)


2. Load check valve (boom bottom)
3. Pressure compensation valve (boom head)
4. Pressure compensation valve (bucket head)
5. Pressure compensation valve (attachment)
6. Pressure compensation valve (attachment)

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10 Structure and function


Control valve

1. Spool (ECSS control)


2. Spool (boom)
3. Spool (bucket)
4. Spool (attachment)

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Control valve

1. Suction safety valve (bucket bottom)


2. Suction safety valve (bucket head)
3. Suction safety valve (boom bottom)
4. Suction safety valve (boom head)
5. Suction safety valve (attachment)
6. Suction safety valve (attachment)

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Control valve

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

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

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Control valve

9. Suction safety valve (raise)


ECSS valve
10. ECSS spool
11. EPC valve (ECSS ON - OFF)
12. Accumulator charge valve

Attachment valve
1. EPC valve
2. Load check valve
3. LS shuttle valve
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Control valve

4. Load check valve


5. EPC valve
6. Suction safety valve
7. Attachment spool
8. Suction safety valve
9. Unload valve
10. Main relief valve
11. LS bypass valve

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CLSS

CLSS

(ALL-PNJ1-001-K-00-A)

CLSS: Abbreviation for Closed center Load Sensing System

Structure of CLSS

(WA470-PNJ1-041-K-00-A)

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

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CLSS

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

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CLSS

LS differential pressure (d
d PLS) and pump swash plate angle

a For details of the operation, see "Work equipment pump".


Pressure compensation control

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CLSS

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

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Hydraulic circuit diagram and names of valves

Hydraulic circuit diagram and names of valves

(WA470-PM10-054-K-00-A)

1. Bucket valve
2. Boom valve
3. ECSS valve
4. Attachment valve
5. Bucket spool
6. Boom spool
7. ECSS spool
8. Attachment spool
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9. Pressure compensation valve


10. Suction valve
11. Load check valve
12. Accumulator charge valve
13. Main relief valve
Relief pressure: 34.3 MPa {350 kg/cm2}
14. Unload valve
Cracking pressure: 1.9 MPa {19.5 kg/cm2}
15. Suction safety valve
Cracking pressure: 32.4 MPa {330 kg/cm2}
16. Safety valve
Cracking pressure: 38.2 MPa {390 kg/cm2}
17. Safety valve
Cracking pressure: 45.1 MPa {460 kg/cm2}
18. Safety valve
Cracking pressure: 22.6 MPa {230 kg/cm2}

Unload valve

(WA470-PQD0-040-K-00-A)

When the unload valve is actuating

a: Orifice
b: Port
c: Port
P: Pump circuit
PLS: LS circuit
T: Tank circuit
1. Spring

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

Pressure of pump circuit (P) is received by the end of valve (2).


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

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Hydraulic circuit diagram and names of valves

Pressure compensation valve

(WA470-C790-040-P-00-A)

(installed to cylinder head side of boom valve)


When high load is applied to the boom.

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

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


Piston (4) is pushed to the left by spring (5).
Valve (2) is also pushed to the left by piston (4) to close pump outlet circuit (A) and prevent reverse flow
from actuator circuit (B) to pump outlet circuit (A).
During combined operation (lowering boom and tilting bucket)

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

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Hydraulic circuit diagram and names of valves

Shuttle valve in pressure compensation valve

(WA470-C7C0-041-P-00-A)

When holding pressure in port (B) LS pressure in spring chamber (C)

1. Hydraulic pump
2. Load check valve
3. Shuttle valve
4. Piston

Function

(WA500-C7C0-042-P-00-A)

Shuttle valve (3) is pushed to the right by the port (B) pressure to disconnect the port (B) from port (D).
The holding pressure of port (B) is transmitted to spring chamber (C) to push piston (4) to the left so that
piston (4) and load check valve (2) do not separate from each other.

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Surface area ratio of pressure compensation valve

(WA470-C790-042-P-00-A)

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

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Hydraulic circuit diagram and names of valves

Introduction of LS pressure
LS shuttle valve

(ALL-C2A4-001-K-01-A)

(WA470-L1P0-041-K-00-A)

1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. Load check valve
5. Check valve
6. LS circuit
7. LS shuttle valve

Function (WA500-L1P0-042-K-00-A)
LS pressure (PLS) is the actuator load pressure on the outlet side of the control valve.
The upstream pressure (spool meter-in downstream pressure) of pressure compensation valve (3) is
transmitted through main spool (2) to LS shuttle valve (7).
The LS pressure is connected through valve (5) to port (B) of the actuator, and then it the actuator load
pressure.
Inlet hole (a) in main spool (2) is small in diameter and has a throttling function.
Operation (WA500-L1P0-044-K-00-A)
When main spool (2) is operated, the discharged oil from pump flows into actuator circuit (B).
Pump discharge pressure (PPS) is transmitted through inlet hole (a) of main spool (2) to LS circuit (PLS).
Pump discharge pressure (PPS) increases to the necessary pressure for actuator circuit (B).
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Check valve (5) in main spool (2) opens and the high pressure oil of LS circuit (PLS) flows into actuator
circuit (B).
The pressure in LS circuit (PLS) becomes almost the same as that in actuator circuit (B).

LS bypass plug

(WA470-PNSH-041-K-00-A)

1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass plug
6. LS circuit

Function

(WA500-PQH2-042-K-00-A)

This valve releases the remaining pressure in LS pressure circuit (6) through orifices (a) and (b).
This valve decreases the rising speed of the LS pressure to prevent a sudden change of the oil pressure.
Since the oil flows through LS valve (5), pressure loss is made by the circuit resistance between throttle
(c) of main spool (2) and LS shuttle valve (4).
The effective LS differential pressure decreases to improve the dynamic stability of the actuator.

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Hydraulic circuit diagram and names of valves

ECSS control valve

(WA500-L320-041-K-00-A)

1. Spool
2. Solenoid valve
3. Plug
4. Nut
5. Check valve

Function

(WA500-L320-042-K-00-A)

The controller automatically turns ON/OFF the accumulator charged with the high-pressure gas according
to the travel condition of the machine.
This valve gives elasticity to the vertical movement of the work equipment to restrict the machine body
from rocking, improve the operator comfort, and prevent the load from spilling during high-speed travel.

Operation

(WA500-L320-044-K-00-A)

When the travel speed exceeds 5 km/h, the signal enters solenoid valve (2) and the pressure is
transmitted to (a).
Spool (1) moves to the left.
When spool (1) moves, the passage of (PR) accumulator (ACC) closes and the passage of (A2)
accumulator (ACC), (B2) (T) opens, and ECSS is turned ON.
When the travel speed is 4 km/h or below, no signal enters solenoid valve (2) and spool (1) is kept in
neutral position. At this time, the passage of (PR) accumulator (ACC) opens and accumulator (ACC) is
charged.

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

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Accumulator charge valve

Accumulator charge valve

(WA500-G2H0-040-K-00-A)

CR: Accumulator charge pressure pickup port


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

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Accumulator charge valve

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Accumulator charge valve

When in neutral and (P) is low

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

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Accumulator charge valve

When load pressure (P) is high

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

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Work equipment lock solenoid valve

Work equipment lock solenoid valve

(WA380-PK1K-041-K-00-A)

P: From charge valve


A: To work equipment EPC valve port P
T: Drain

Function

(WA380-PK1K-042-K-00-A)

This valve is installed between the charge valve and work equipment EPC valve. Upon receiving the
operation signal from the work equipment controller, the solenoid is "energized" to block the oil to the work
equipment EPC valve and disables the operation of the work equipment.

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Accumulator (for PPC circuit)

Accumulator (for PPC circuit)

(WA380-PL40-041-K-00-A)

1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port

Specification

(WA380-PL40-030-K-00-A)

Gas to be used
Gas capacity (cc)
Charged pressure (MPa {kg/cm2
})
Max. allowable working pressure
(MPa {kg/cm2 })

Function

Nitrogen gas
500
1.18 {12} (at 80C)
3.92 {40}

(WA380-PL40-042-K-00-A)

This accumulator is installed between the charge valve and work equipment PPC valve. Even if the
engine is stopped while the work equipment is raised, pilot oil pressure can be supplied to the work
equipment control valve with the pressure of the compressed nitrogen gas in the accumulator to lower the
work equipment by its own weight.

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Accumulator (for ECSS)

Accumulator (for ECSS)

(WA470-L370-041-K-00-A)

1. Valve
2. Top cover
3. Cylinder
4. Free piston

Specifications

(WA470-L370-030-K-00-A)

Gas to be used
Gas capacity (cc)
Charged pressure (MPa {kg/cm2
})
Max. operating pressure (MPa
{kg/cm2 })

Function

Nitrogen gas
4,000
2.94 {30} (at 20C)
40 {408}

(WA380-L370-042-K-00-A)

This accumulator is installed in the lift cylinder bottom circuit. The space between cylinder (3) and free
piston (4) is filled with nitrogen gas. The nitrogen gas absorbs the hydraulic pulsation generated on the lift
cylinder bottom side to improve the travel performance and workability during travel by utilizing its
compressibility.

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Work equipment linkage

Work equipment

(ALL-L000-001-K-00-A)

Work equipment linkage

(WA470-LB31-041-K-00-A)

1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Boom
6. Bucket link

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Bucket

Bucket

(WA470-LB00-041-K-00-A)

1. Bucket
2. Wear plate
3. Bolt-on cutting edge
4. Bucket tooth (if equipped)

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Bucket positioner and boom positioner

Bucket positioner and boom positioner

(WA470-LEE0-041-K-00-A)

1. Bell crank
2. Boom
3. Bucket potentiometer
4. Bucket potentiometer lever
5. Boom potentiometer
6. Front frame
7. Boom potentiometer lever

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ROPS cab

Cab and its attachments


ROPS cab

(ALL-K000-001-K-00-A)

(WA380-K211-041-K-00-A)

The appearance differs corresponding to the destination.


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

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Engine control system

Electrical system

(ALL-RA1D-001-K-00-A)

Engine control system

(WA470-AK60-042-K-00-A)

1. Battery disconnect switch


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

18. Neutral safety relay


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

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Preheating system

Preheating system

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

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Slow-blow fuse
5. Starting switch
6. Engine controller
7. Machine monitor
8. Fuse box 2
9. Electric heater
10. Preheater relay
11. Electric heater relay

Automatic preheating system

(WA470-AM40-042-K-00-A)

Function
The automatic preheating system is installed to improve the engine startability in a cold district.
When the starting switch is turned to the "ON" position, the automatic preheating system shortens the
preheating time and sets the preheating time automatically according to the intake air temperature.
When the starting switch is turned to the "ON" position, the preheater pilot lamp on the machine monitor
lights up and the electric heater preheats the intake air
The engine controller sets the preheating time according to the engine coolant temperature sensed.
Keep the starting switch in the "ON" position while the pilot lamp is lit since the engine is being preheated
during this period. In this period, if the starting switch is turned to the "START" position, preheating is
canceled.

Operation

(WA470-AM40-044-K-00-A)

When the starting switch is turned to the "ON" position, the engine controller starts.
When the intake air temperature is -5C or below, the engine controller drives the preheater relay just after
the starting switch is turned to the "ON" position, and then the electric heater relay operates and the
electric heater start preheating the engine.
The operating time of the preheater is shown below.

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Preheating system

Manual preheating system

(WA380-AM40-042-K-01-A)

Function
When the engine is started in the cold season, the preheating time can be lengthened more than the time
with the auto preheating by turning the starting switch to the "Manual preheat" position.
If the starting switch is turned to the "Manual preheat" position, the preheater pilot lamp on the machine
monitor lights up and the electric heater preheats the intake air.
When the starting switch is turned to the "OFF" position, the pilot lamp goes off and the manual preheating
function is canceled.

Operation

(WA380-AM40-044-K-01-A)

If the starting switch is turned to the "Manual preheating" position, the electric heater relay operates and
the electric heater starts preheating.

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Engine power mode selector circuit

Engine power mode selector circuit

(WA380-AP11-051-K-00-A)

1. Power mode selector switch


2. Transmission controller
3. Machine monitor
4. Engine controller
5. Work equipment controller

Function

(WA380-AP11-042-K-00-A)

The engine output can be maximized by turning the power mode selector switch to the "P mode" position.
The fuel consumption during work can be reduced by setting the power mode selector switch to the "E
mode".
The switch signal is input to the work equipment controller. The work equipment controller sends the
signal to the transmission controller, which selects a proper gear speed and travel speed matched to the
power mode in the auto-shift mode.

Operation

(WA380-AP11-044-K-00-A)

When the power mode selector switch is turned to the "P mode" position, the switch signal is input to the
work equipment controller and the CAN signal is sent to the transmission controller.
The transmission controller determines the final engine mode and sends the CAN signal to the engine
controller, and the engine torque performance curve changes to the "P-mode".
When the engine mode is set to the "P mode" with the one-touch power maximizing function, the
transmission controller also sends the CAN signal to the engine controller, and the engine torque
performance curve changes to the "P-mode".
The transmission controller sends the engine output mode pilot lamp lighting signal to the machine
monitor with the CAN signal .

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Engine output limit function

Engine output limit function

(WA380-AP12-042-K-00-A)

If the engine controller recognizes a failure, it limits the engine torque or engine speed to protect the
engine.
The engine torque performance when the torque is limited is shown in the following figure.

A: 30% cut of maximum torque point


B: Approximately 50% of rated output point
The engine torque performance when the engine speed is limited is shown in the following figure.

A: Cut up to about engine speed at maximum torque point

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Automatic warm-up function

Automatic warm-up function

(WA470-AP13-042-K-00-A)

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

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Parking brake control system

Parking brake control system

(WA380-GP10-051-K-00-A)

1. Parking brake relay


2. Parking brake switch
3. Parking brake solenoid valve
4. Transmission controller
5. Auto idle stop parking brake relay

Operation

(WA470-GP10-044-K-00-A)

When starting switch is in "OFF" position


When the starting switch is turned to the "OFF" position, the contacts of parking brake relay (1) open, thus
no current flows in the parking brake circuit and the parking brake is applied.
While starting switch is in the "OFF" position, no current flows in parking brake solenoid valve (3) and the
parking brake keeps applied, regardless of the operating condition of parking brake switch (2).
When starting switch is in "ON" position
When parking brake switch is turned "ON" (operating) before starting switch is turned "ON"

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

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Parking brake control system

When parking brake switch (2) is turned "OFF" (release), no current flows in parking brake relay (1) and
the relay contacts are open.
Even if starting switch is turned "ON", no current flows to parking brake solenoid valve (3). Accordingly, the
parking brake is not released automatically.
When auto-idle stop operates

If parking brake switch (2) is turned "OFF" (release) while the starting switch is turned "ON", the current
from the battery relay flows through parking brake relay (1), parking brake switch (2), and auto idle stop
parking brake relay (5) to parking brake solenoid valve (3), thus the parking brake is kept released.

When the auto idle stop operates, transmission controller (4) outputs a current to auto idle stop parking
brake relay (5).
The current flows in the coil of auto idle stop parking brake relay (5) and the contacts open.
No current flows in parking brake solenoid valve (3), and the parking brake is applied.
When the auto-idle stop operates, the parking brake also operates automatically and keeps operating
during restarting operation.

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System operating lamp function

System operating lamp function

(WA380-AW1Q-051-K-00-A)

1. Battery disconnect switch


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

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System operating lamp function

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

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Battery disconnect switch function

Battery disconnect switch function

(WA470-AW1P-041-K-00-A)

1. System operating lamp


2. Battery disconnect switch

O: OFF
I: ON

Function

(WA380-AW1P-042-K-00-A)

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

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Battery disconnect switch function

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

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Transmission controller system

Transmission controller system

(WA380-CN20-001-K-00-A)

a The display of the travel speed explained in this section is for the tires of size 26.5-25, unless otherwise
specified.

Transmission controller system diagram

10-256

(WA470-CN20-051-K-00-A)

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10 Structure and function


Transmission controller system

WA470-7

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Transmission controller system

Transmission gear shift control function


Electronic modulation function

(WA380-CN11-042-K-00-A)

(WA380-CN12-042-K-00-A)

1. Engine
2. Torque converter
3. Transmission
4. Axle
5. Transmission controller
6. Combination switch
7. Accelerator pedal
8. Transmission ECMV
9. Engine speed sensor
10. Transmission input speed sensor
11. Transmission output speed sensor

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Transmission controller system

Input/output signal
a. Directional signals
b. Shift range signal
c. Accelerator signal
d. Transmission output speed signal
e. ECMV operation signal
f. Fill switch signal
g. Transmission input speed signal
h. Engine speed signal
The modulation control system controls the clutch pressure so that the transmission is shifted properly to
all the gear speeds (including the lockup clutch) and less shocks are generated at gear shifting
(engagement of the clutch) according to the engine speed, transmission oil temperature, transmission
input and output speeds, and gear shift pattern.
The clutch pressure is so controlled that the difference between the input and output speeds will follow the
target value corresponding to the engine speed and accelerator pedal position to prevent sharp
engagement.
After the clutch is disengaged, the disengagement pressure is kept low to prevent loss of torque until
engagement of the clutch starts.
If abnormal gear shift time lag occurs, the learning function corrects the modulation automatically.

Gear shift display function

(WA380-CN13-042-K-00-A)

The transmission controller sends the input signal condition related to gear shift via the network to the
machine monitor to display it.
1. Travel direction indicator
The shift lever position pilot lamps of the machine monitor indicate the directional lever condition input
from the transmission controller.
If the directional lever is in neutral and no signal is input to the transmission controller, all the shift lever
position pilot lamps of the machine monitor go off.
If two signals are input to the transmission controller because of a failure, two shift lever position pilot
lamps of the machine monitor may light up simultaneously.
While the directional lever is in the "R (Reverse)" position, the controller operates the backup lamp relay to
turn on the backup lamp and backup alarm buzzer.
2. Gear speed indicator
The shift lever position pilot lamps of the machine monitor indicate the gear shift lever condition input from
the transmission controller.
If the gear shift lever is in neutral and no signal is input to the transmission controller, all the shift lever
position pilot lamps of the machine monitor go off.
If two signals are input to the transmission controller because of a failure, a shift lever position pilot lamp
which is different from the gear shift lever position may light up since the higher gear speed is given priority.
3. Display of actual gear speed
The shift indicator of the machine monitor indicates the travel direction and gear speed output by the
transmission controller.
If the directional lever is in the "N (Neutral)" position, "N" is displayed. If the directional lever is in the "F
(Forward)" or "R (Reverse)" position, "F" or "R" and the gear speed are displayed simultaneously.
While the parking brake is in operation, "N" is always displayed since no gear speed signal is output.
While the transmission cut-off function is in operation and the transmission is in neutral, "N" is always
displayed as well.

Automatic gear shift function

(WA380-CN14-042-K-00-A)

The transmission gear is shifted in the automatic shift mode where the gear speed is selected
automatically according to the travel speed or is shifted in the manual shift mode where the gear speed is
selected with the gear shift lever.
The shift mode is changed with the transmission shift mode selector switch. If the auto-shift is selected,
the auto shift pilot lamp on the machine monitor lights up.
In the auto-shift mode, upshift/downshift operations and ON/OFF of the lockup clutch are controlled
according to the condition of the power mode.

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

Transmission shift mode selector switch


H
L
Auto-shift H mode
Auto-shift L mode
Auto-shift L mode
Auto-shift L mode

MANUAL
Manual shift mode
Manual shift mode

In the auto-shift mode, the upshift/downshift operations are controlled, corresponding to the directional
lever, gear shift lever, travel speed, accelerator pedal position, and engine speed.

a1: Upshift (Other than hunting prevention)


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

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Transmission controller system

Shift hold function

(WA380-CP11-042-K-00-A)

If the auto-shift is selected and the hold switch is pushed, the shift hold function maintains the current gear
speed and does not upshift the gear even when the travel speed increases. When the travel speed
decreases, this function does not downshift the gear.
The shift hold pilot lamp on the machine monitor keeps lighting while the shift hold function is in operation.
The shift hold function is canceled and the pilot lamp is turned OFF by pressing the hold switch again.
When the directional lever, gear shift lever, or kickdown switch is operated, the shift hold function is
canceled automatically. The operating condition of the torque converter lockup is not maintained.

Kickdown function

(WA470-CP12-042-K-00-A)

1. In manual shift mode


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

Transmission output speed when kickdown switch is pressed


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

Gear speed after


kickdown
1st T/C
1st T/C
2nd T/C
1st T/C
3rd T/C
1st T/C
1st T/C
3rd T/C (*1)
1st T/C
4th T/C (*1)

T/C: Indicates travel through torque converter


L/U: Indicates travel through direct drive (lockup operation)
*1: When the lockup function is canceled by pressing the kickdown switch, it is not turned on again until
the following conditions are met.
After the torque converter lockup switch is returned to the "OFF" position, it is turned to the "ON"
position again.
The travel speed becomes the faster speed at which the lockup operates.
3. In forward 1st
If the kickdown switch is pressed while the power mode is in "E mode" and the transmission is in the
forward 1st, the power mode changes to "P mode" temporarily. (One-push power max. function)
The change of the power mode occurs only when the transmission is in the forward 1st, regardless of the
auto-shift / manual shift, and canceled when the actual gear speed is changed to another position from the
1st or the directional lever is changed to another position from the forward.

Auto-kickdown function

(WA380-CP13-042-K-00-A)

When the machine is set in the digging condition in the auto-shift mode, if the travel speed reaches the
specified speed, the gear speed is changed to the 1st gear automatically.
The digging condition means the condition in which the travel speed decreases, the boom is near the
ground, the bucket is not tilted, and the brake pedal is not depressed.
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Transmission controller system

Torque converter lockup function

(WA500-CDR8-042-K-00-A)

The torque converter lockup function automatically controls the lockup operation while the torque
converter lockup switch is turned "ON", regardless of the shift mode.
The torque converter lockup pilot lamp on the machine monitor keeps lighting while the lockup is in
operation.
The lockup operates in the gear speeds shown in the following table.
Transmission shift
mode selector
switch
H
L
MANUAL

Gear speed for lockup operation (Lockup operates: Q)


F1

F2

F3

F4

Q
Q
Q

Q
Q
Q

Q
Q
Q

R1

R2

R3

R4

Q
Q
Q

Q
Q
Q

Q
Q
Q

1. Travel speed for lock up operation


The travel speed at which the lockup operates is determined by the directional lever, the gear shift lever,
the travel speed, and the accelerator pedal position. When the manual shift is selected, the lockup
operates at the same travel speed as in the auto-shift H mode.
2. Lockup protection function
The lockup operates only when the machine travel direction matches to the directional lever position.
3. Condition for disabling lockup
The lockup does not operate in the following cases.
Machine is digging (lockup protection)
Boom is being raised (boom raise operation priority)
When the accelerator is operated and the engine speed is low.

Hunting prevention function

(WA500-CN15-042-K-00-A)

The transmission controller detects and prevents hunting that occurs when the gear speed is shifted from
the 2nd to the 3rd and from the 3rd to the 2nd in the auto-shift mode.
If the gear is shifted continuously in the order of the 2nd o 3rd o 2nd o 3rd (3rd o 2nd o 3rd o 2nd), the
transmission controller judges that hunting occurs and changes the upshift point temporarily.
The hunting prevention function is canceled at the next gear shift operation (including the directional
change operation and kickdown operation). After the hunting prevention function is canceled, the normal
auto-shift point is applied.
When the 2nd lockup is turned ON/OFF continuously, the lockup is canceled. (This is also applied to the
3rd lockup.) Then the travel speed at which the lockup operates is changed temporarily.
The hunting prevention function related to the lockup operates when the controller recognizes hunting
even in the manual shift mode.

Adjustment of transmission initial learning and ECMV current

(WA380-CN16-042-K-00-A)

Dispersion of the transmission itself and ECMV can be corrected by adjusting the items of "ECMV
automatic correction" and "T/M initial learning" with the adjustment function of the machine monitor.
If the above items are not adjusted, gear shift shocks or time lag may occur.
a For the adjustment procedure, see Testing and adjusting, "Special functions of machine monitor".

Change of shift point

(WA380-CN17-042-K-00-A)

The transmission controller has the function to adjust gear shift point of forward travel in the auto-shift "L
mode".
Hunting occurs under a certain condition of jobsite, the travel speed at which the gear speed is
downshifted/upshifted can be adjusted by adjusting the items of "T/M gear shift point" with the adjustment
function of the machine monitor.
a For the adjustment procedure, see Testing and adjusting, "Special functions of machine monitor".

4th gear speed limit function

(WA380-CN18-042-K-00-A)

Operation in the 4th gear can be limited by setting "4th Gear Prohibition" to "ADD" with the "Option Select
function" of the machine monitor.
a For the setting procedure, see Testing and adjusting, "Special functions of machine monitor".

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Transmission protection function

(WA380-CV31-001-K-00-A)

Protection function when travel direction is changed

(WA470-CV32-042-K-00-A)

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

Transmission output shaft speed [rpm]


(Reference: Actual travel speed [km/h])

Engine speed [rpm]

960 {13}

1,700

1,034 {14}

1,900

1,181 {16}

Downshift protection function

(WA470-CV33-042-K-00-A)

If the travel speed is above the set speed in downshift operation, downshift is not accepted for protection
of the engine and pump.
The alarm buzzer sounds while the downshift protection function is in operation.
The alarm buzzer keeps sounding until the gear speed position of the gear shift lever matches with the
actual gear speed. Accordingly, the alarm buzzer stops sounding if the gear is upshifted even if the travel
speed does not decrease.
The downshift protection is effective even in the kickdown operation. If the kickdown switch is pressed
when the travel speed is higher than the protection condition, it is not accepted but the alarm buzzer
sounds for 3 seconds.
The downshift protection is effective even when the auto kickdown is applied, but the alarm buzzer does
not sound in this case.
The downshift protection operates under the following condition.
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Transmission output shaft speed [rpm]


(Reference: Actual travel speed [km/h])
Protection cancelation condition
Protection condition
Min. 2,227 (30.2)
Below 2,005 (27.2)
Min. 1,470 (19.9)
Below 1,322 (17.9)
Min. 1,061 (14.4)
Below 951 (12.9)

Downshift
target gear
speed
To 3rd speed
To 2nd speed
To 1st speed

Engine overrun prevention function

(WA380-CV34-042-K-00-A)

If the engine speed rises above 2,425 rpm, the alarm buzzer sounds for notice of operation of engine
overrun prevention function. The alarm buzzer stops when the engine speed lowers below 2,325 rpm.
If the engine speed rises above 2,500 rpm, the lockup is cancelled automatically to prevent overrun of the
engine.
The alarm buzzer sounds while the engine overrun prevention function is in operation.
Once the lockup is cancelled, the lockup condition is maintained for 5 seconds. When the transmission
output shaft speed decreases to a level corresponding to below 2,350 rpm of the engine speed after 5 or
more seconds, the lockup is applied again.
While the lockup is not in operation, the buzzer sounds for notice or warning at the above engine speeds,
but no special remedy is performed.

Speed limiting function

(WA470-CV35-042-K-00-A)

If the travel speed exceeds the specified maximum travel speed, the alarm buzzer sounds.
Unit: km/h
Model
Alarm activation specified value (actual travel speed)
Alarm cancellation specified value (actual travel speed)

WA470-7
40.0
39.5

If the travel speed exceeds the threshold value in the 4th lockup mode, the upper limit of the accelerator
pedal position is restricted to limit the maximum travel speed.
Unit: km/h
Model
Shift range
Actual travel speed (B)
Actual travel speed (C)

Neutralizer function

WA470-7
F4

R4
37.0
38.0

(WA380-CV36-042-K-00-A)

While the parking brake switch is turned "ON", the transmission is kept in neutral to prevent dragging of
the parking brake, regardless of the positions of the directional lever and gear shift lever.
Since the parking brake circuit employs the safety mechanism, the parking brake is kept applied even if
the starting switch is turned from the "OFF" position to the "ON" position. Accordingly, when the starting
switch is turned to the "ON" position, the transmission is always set in neutral, regardless of the positions
of the directional lever and gear shift lever.

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Transmission controller system

Engine control function

(WA380-CN19-001-K-00-A)

Power mode selection control

(WA380-CN1A-042-K-00-A)

When the power mode selector switch is set to the "P mode" position, the torque curve information in the P
mode is sent to the engine controller. At the same time, the information of the power mode is sent to the
machine monitor to change the output mode pilot lamp.
The output mode pilot lamp also changes when the "P mode" is selected with the one-touch power
maximizing function.

Engine stop prevention function

(WA500-CN1B-042-K-00-A)

When the travel direction is changed during high-speed travel, if the engine speed is low, the engine
receives counter-torque from the tires and may stall.
To prevent the engine from stalling, the throttle (accelerator pedal) position lower limit value is sent to the
engine controller when the travel direction is changed.

Overheat prevention function of transmission controller

(WA500-CV3C-042-K-00-A)

When the torque converter oil temperature exceeds 120C, the accelerator pedal position is controlled to
prevent overheat.
When the coolant temperature exceeds 100C, the engine output torque is limited to prevent overheat.

Brake load reduction control

(WA500-CV3D-042-K-00-A)

When the 2nd gear is selected in P mode, the upper limit of the accelerator pedal position is restricted to
limit the rim pull and reduce the load when the brake is dragged, according to the transmission output
shaft speed and the brake oil pressure.
a The larger one between the accelerator pedal position judged by the transmission output speed and that
judged by the brake oil pressure is selected.
Judgment by transmission output speed

A: Upper limit of accelerator pedal position


Judgment by brake oil pressure

B: Upper limit of accelerator pedal position


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Driving force cut control

(WA470-CV3E-042-K-00-A)

In the digging work, the upper limit of the accelerator pedal position is restricted to reduce the driving force
and priority is given to the "raising" operation of the boom, according to the load on the work equipment.
When conditions 1 to 4 are satisfied, the rim pull is judged too large and the upper limit of the accelerator
pedal position matched to the target rim pull is sent to the engine controller.
This function becomes effective when Lift up mode in Option select function of the machine monitor is
set to ADD.
a For the setting procedure of the Lift up mode, see Testing and adjusting, Special functions of machine
monitor.
Operating condition
Condition 1
Condition 2
Condition 3
Condition 4

Machine is digging
Machine is not scraping up
The traction force is high comparing to the lifting force. Or, boom stalls in boom RAISE
operation.
"Lift up mode" is set to ADD in Option Select

Engine torque control function (WA380-CV3H-042-K-00-A)


Engine torque control by phase of work
The engine output torque is controlled so that it is sufficient for each phase of the work by judging each phase
from the engine speed, travel speed, pump discharge pressure, travel direction, work equipment condition,
etc.

Cooling fan control function

(WA470-B711-042-K-00-A)

The hydraulic cooling fan is employed and the swash plate angle of the hydraulic pump is controlled to
reduce the horsepower loss and noise at low temperature.
The transmission controller receives the engine speed and coolant temperature received by the engine
controller via the network. The transmission controller also directly receives the information on the
hydraulic oil temperature and torque converter oil temperature.
The transmission controller sends the signal current to the swash plate angle control EPC valve of the
cooling fan pump on the basis of the received information and sets the fan speed corresponding to each
temperature and engine speed by controlling the swash plate angle.

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


g. Torque converter oil temperature signal
h. Cooling fan reverse signal
j. Cooling fan pump swash plate angle control signal
k. Cooling fan reverse pilot lamp signal
l. Front brake accumulator pressure drop signal
m. Rear brake accumulator pressure drop signal
Fan speed and temperature

*1: The target fan speed is decided by the highest temperature information among the coolant temperature,
hydraulic oil temperature, and torque converter oil temperature. However, when the coolant temperature is
low, the torque converter oil temperature is not used.
*2: In this range, the fan speed corresponds to the coolant temperature, hydraulic oil temperature, and torque
converter oil temperature.
*3: When the air conditioner is in operation, the minimum speed becomes 600 rpm.

Control function when engine is started

(WA470-B714-042-K-00-A)

When the engine is started, control different from the ordinary control by temperature is performed.

Range A: Engine speed Z 500 rpm (Engine "stopped" to "being cranked")


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

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The ordinary fan control based on "Fan speed set by temperature" is performed.

Control function when brake accumulator is charged

(WA380-B71B-042-K-00-A)

The fan pump is used for charging the brake accumulator as well.
While the brake accumulator is being charged, the charge time is shortened and the control is performed
differently from the normal control by temperature to prevent the fan from stopping during the charge.
For 10 seconds after the brake accumulator pressure drop signal is turned OFF, the minimum fan speed is
set to 750 rpm.
If the brake accumulator pressure is turned OFF, the minimum fan speed is 750 rpm for 10 seconds after
the control at the start of the engine is finished.

Fan reverse function

(WA470-B715-042-K-00-A)

When the manual fan reverse mode is operated through the machine monitor to clean the radiator core,
the cooling fan reverse rotation solenoid valve of the cooling fan motor operates to reverse the fan
rotation.
Fan rotation auto reverse function
1. Fan rotation manual reverse function
The operator can change the fan rotation direction freely by setting the manual fan reverse mode to the
Reverse or Default position.
While the fan rotation direction is being changed, the pilot lamp indicating the change is displayed on
the standard screen to notify the operator of the operating condition. If the changing condition is not
satisfied because of high temperature of the coolant or oil, changeover condition waiting pilot lamp
lights up.
On the standard screen, the cooling fan reverse pilot lamp indicates the fan reverse rotation condition.
When all the conditions are satisfied, the fan rotation direction is changed from Default to Reverse.
Condition 1 The manual fan reverse rotation mode is set to "Reverse".
The coolant temperature is below 102C.
Condition 2
[for prevention of overheat]
The hydraulic oil temperature is below 97C.
Condition 3
[for prevention of overheat]
The torque converter oil temperature is below 120C.
Condition 4
[for prevention of overheat]
At least 10 seconds elapse after the brake accumulator pressure drop signal is turned OFF.
Even if the accumulator pressure drop signal turns OFF, at least 10 seconds elapse after the
Condition 5 engine is started.
[For securing oil quantity to be added to the brake accumulator]
Condition 6 There is no error in the fan speed sensor or engine speed sensor.
When any of the conditions is satisfied, the fan rotation direction is changed from Reverse to Default.
The manual fan reverse rotation mode is set to the "Default" position while the fan is rotating in
reverse.
Condition 2 10 minutes elapse with the fan rotating in reverse.
Condition 3 An error is detected in the fan reverse solenoid or fan pump EPC solenoid.
Condition 4 The engine stops.
Condition 1

2. Fan rotation auto reverse function


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

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Condition 1
Condition 2
Condition 3
Condition 4

Condition 5
Condition 6
Condition 7

The fan reverse rotation switch is set to AUTO.


The auto-fan reverse rotation mode is set to any position of A to D.
The coolant temperature is below 102C.
[for prevention of overheat]
The hydraulic oil temperature is below 97C.
[for prevention of overheat]
The torque converter oil temperature is below 120C.
[for prevention of overheat]
At least 10 seconds elapse after the brake accumulator pressure drop signal is turned OFF.
Even if the accumulator pressure drop signal turns OFF, at least 10 seconds elapse after the
engine is started.
[For securing oil quantity to be added to the brake accumulator]
The fan rotation direction change cycle has passed.
There is no error in the fan speed sensor or engine speed sensor.

When any of the conditions is satisfied, the fan rotation direction is changed from Reverse to Default.
The auto-fan reverse rotation mode is turned OFF while the fan is rotating in reverse.
Condition 1 Or, it is set to a mode of fan reverse rotation time which is shorter than the fan reverse rotation
elapsed time.
Condition 2 The fan reverse rotation time has passed.
Condition 3 An error is detected in the fan reverse solenoid or fan pump EPC solenoid.
Condition 4 The engine stops.
3. Adjustment of fan reverse rotation changing cycle and duration
Three defaults, A to C, for fan reverse rotation cycle and duration are prepared. The fan reverse rotation
cycle and duration can be adjusted freely by adjusting the "Fan reverse rotation cycle" and "Fan reverse
rotation duration" with the adjustment function of the machine monitor. The set value is displayed as mode
D.
a For the adjustment procedure, see Testing and Adjusting, "Special functions of machine monitor".
4. Overheat prevention function
When the coolant, hydraulic oil, or torque converter oil overheats (the thermometer caution lamp on the
machine monitor lights up) while the fan is rotating in reverse, the reverse rotation is stopped and changed
to the forward rotation forcibly to increase the air flow to the radiator.
5. Fan speed in reverse rotation mode
The fan speed in the reverse rotation mode depends on the engine speed.
Engine speed [rpm]
Fan target speed [rpm]

850
900

Fan 100% setting function

1,750
1,300

2,050
1,300

(WA380-B71D-042-K-00-A)

The cooling fan speed can be set to 100% forcibly, independent from the hydraulic oil temperature or
coolant temperature.
The cooling fan speed can be set to 100% by setting the "Fan 100% adjustment" with the adjustment
function of the machine monitor.
The fan speed becomes the lower one of 1) or 2) below.
1) Max. target fan speed
2) Target fan speed decided by engine speed
a For the setting procedure, see Testing and Adjusting, "Special functions of machine monitor".

Protection function

(WA470-B713-042-K-00-A)

If the engine speed increases to 2,300 rpm or above, the swash plate angle of the cooling fan pump is
minimized to prevent overrun of the cooling fan motor.
If the transmission controller cannot recognize the engine speed or each temperature data because of a
network communication trouble etc., it sets those items as follows.
1) Engine speed: Assumes as 2,170 rpm.

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10 Structure and function


Transmission controller system

2) Engine coolant temperature: Ignored. The value obtained from the remaining normal sensors are used.
However, if neither of the hydraulic oil temperature and torque converter oil temperature is recognized, the
engine coolant temperature is assumed to be 90 C.
3) Hydraulic oil temperature: Ignored. The value obtained from the remaining normal sensors are used.
4) Torque converter oil temperature: Ignored. The value obtained from the remaining normal sensors are
used.

Transmission cut-off function

(WA380-CP30-042-K-00-A)

The transmission cut-off oil pressure sensor detects the brake pilot pressure when the right and left brake
pedals are depressed and the transmission is set in neutral.
The transmission can be cut off at any position by saving the brake pilot pressure at the brake pedal
position where the transmission comes in neutral.
1. Contents of control
If the transmission cut-off operating condition is met, the transmission is set in
neutral.
Outline
If the transmission cut-off cancellation condition is met, the cut-off is canceled
and the transmission gear is shifted by modulation.
<Operating condition in 1st or 2nd gear>
The transmission cut-off pilot lamp is turned "ON" and the brake pilot pressure
Transmisexceeds the cut-off-IN pressure.
sion cut- Operating <Operating condition in 3rd or 4th gear>
off control condition The transmission cut-off pilot lamp is turned "ON" and the accelerator pedal
depression is larger than 30% and the brake pilot pressure exceeds the IN
pressure of the cut-off circuit.
Condition The cut-off is canceled when any of the following conditions is met.
for
cancella- The transmission cut-off pilot lamp is turned "OFF".
The brake pilot pressure is below the OUT pressure of the cut-off circuit.
tion
Condition
possible to The transmission cut-off pilot lamp is turned "ON".
be set
1) The brake pedal is depressed to a set position. (Setting is possible even if the
brake pedal is not depressed)
2) The transmission cut-off set switch is pressed.
3) The brake pilot pressure when the switch is pressed is recognized.
<In case of within settable range>
The brake pilot pressure when the switch is pressed is saved temporarily.
<In case of out of settable range>
Setting
method
The upper or lower limit of the brake pilot pressure in the settable range is saved
Setting of
temporarily.
transmisThe setting completion buzzer (pip, pip) sounds.
sion cut4) The transmission cut-off switch built-in pilot lamp flashes for 2.5 seconds.
off point
5) The set value is saved. (Setting mode is finished)

Resetting
method

a The set condition is maintained even after the starting switch is turned to the
"OFF" position.
1) Under the condition of setting method Step 4) (the pilot lamp built in the
transmission cut-off switch flashes for 2.5 seconds), press the transmission cut-off
set switch again.
2) The pilot lamp stops flashing and the cut-off point is set to the brake pilot pressure
in default. The setting cancel buzzer (peep) sounds.
3) The set (default) value is saved. (Setting mode is finished)
a The set condition is maintained even after the starting switch is turned to the
"OFF" position.

2. Outputting condition

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Transmission controller system

Pilot lamp built-in


transmission cut-off
switch

Outputting condition

Transmission cut-off pilot lamp is turned "ON". Lights up


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

Flashes
(For 2.5 seconds or
until resetting)

Transmission cut-off pilot lamp lamp is turned


"ON" and transmission cut-off pressure sensor Keeps turned OFF
is abnormal.

Transmission cut-off pilot lamp is turned "ON" Lights up


and transmission cut-off set switch is abnormal

Transmission cut-off pilot lamp is turned "ON"


and transmission cut-off set switch is turned
"ON".
Reset during 2.5 seconds

Lights up

Transmission cut-off pilot lamp is turned "OFF" Goes out

Buzzer
command
Cut-off point
(Communication
output)
Controlled by
None
previously saved
value
When set switch
is pressed,
Brake pilot pressure
setting
when set switch is
completion
pressed is saved.
buzzer sounds
(pip, pip).
None
(Error is
displayed on
machine
monitor)
None
(Error is
displayed on
machine
monitor)
When set switch
is pressed,
setting
cancelltion
buzzer sounds
(peep).
None

Control is not made.


Saved value is not
changed.
Controlled by
position where error
occurred. Saved
value is not
changed.
Default value for
brake pilot oil
pressure is saved.
Control is not made.

a While the transmission is cut off, "N" is displayed on the shift indicator of the machine monitor. (Travel
direction output signal "N")
a If the transmission is cut off after the kickdown switch is pressed to set the gear speed to the 1st, it is
reset to the 1st, regardless of the shift mode.
a When the lockup is in operation, the cut-off operates after the lockup is released.
3. Settable range of transmission cut-off point
Settable range
0.49 to 4.41 MPa {5 to 45 kg/cm2}
Note 1: When the cut-off point is set 0.49 MPa {5 kg/cm2} or less, it is actually set to 0.49 MPa {5 kg/cm2}.
Note 2: When the cut-off point is set 4.41 MPa {45 kg/cm2} or more, it is actually set to 4.41 MPa {45 kg/
cm2}. The default value is 1.47 MPa {15 kg/cm2}.
Set a hysteresis of 0.20 MPa {2 kg/cm2} between cut-off-IN (neutralizing) pressure and cut-off-OUT
(restoration) pressure.
Example) When pressure sensor is set to a position of 0.98 MPa {10 kg/cm2}
Cut-off-IN pressure = 0.98 MPa {10 kg/cm2}
Cut-off-OUT pressure = 0.78 MPa {8 kg/cm2}

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Transmission controller system

E.C.S.S. function

(WA500-L3B0-051-K-00-A)

E.C.S.S.: Electronically Controlled Suspension System

1. Transmission controller
2. Gear shift lever
3. Speed sensor
4. E.C.S.S. switch
5. 1st clutch ECMV
6. 2nd clutch ECMV
7. 3rd clutch ECMV
8. 4th clutch ECMV
9. E.C.S.S. solenoid valve
Input/output signal
a. Gear shift lever "1st" signal
b. Gear shift lever "2nd" signal
c. Gear shift lever "3rd" signal
d. Gear shift lever "4th" signal
e. Travel speed signal
f. Pulse GND
g. E.C.S.S. switch "ON" signal
h. 1st clutch ECMV operation signal
i. 2nd clutch ECMV operation signal
j. 3rd clutch ECMV operation signal
k. 4th clutch ECMV operation signal
l. ECMV GND
m. ECMV GND
n. E.C.S.S. operation signal

Function

(WA380-L3B0-042-K-00-A)

The ECSS gives elasticity to the vertical movement of the work equipment to restrict rocking of the
machine body, improve the operator comfort, prevents the load from spilling, and improves the working
efficiency during high-speed travel by using the buffering effect of the accumulator charged with highpressure gas and automatically controlling the relief pressure of the lift cylinder for the traveling condition.
Setting method
The ECSS does not function unless ECSS Operating Speed is set to "ADD" with the "Option selection
function" of the machine monitor.
a For the setting procedure, see Testing and adjusting, "Special functions of machine monitor".

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Transmission controller system

Operation

(WA500-L3B0-044-K-00-A)

The operating condition of the ECSS is as per the following table.


ECSS switch

Gear speed

Travel speed [km/h]

OFF

All gear speeds


All gear speeds
1st

0 to Max.
0 to Max.
0 to Max.
(*3) Max. 4
(*2) Min. 5

ON

2nd to 4th

Boom lever
condition (*1)
ON/OFF
OFF
ON/OFF
ON/OFF
ON

E.C.S.S. operation
signal
OFF
OFF
OFF
OFF
ON

*1. Boom lever condition ON: Boom lever stroke > -80%

E.C.S.S. selection point


Travel speed [km/h]

A
(*3)
4

B
(*2)
5

*2: ECSS selection point (A) is the value obtained by subtracting 1 km/h from ECSS selection point (B) (4 to
15 km/h).
*3: The travel speed of ECSS selection point (B) can be set freely in the range from 5 to 15 km/h by adjusting
ECSS Operating Speed in the adjustment function of the machine monitor.
a For the adjustment procedure, see Testing and Adjusting, "Special functions of machine monitor".

Directional switch control function

(WA380-CV3F-042-K-00-A)

The switch to select the travel direction is installed on the side of the work equipment control lever
independently from the standard directional lever so that the operator can select the travel direction with
his/her right hand.
1. Selection of directional selector switch
When only the directional lever is used, the directional lever input signal leads to recognition of
travel direction. Since the switch to select the travel direction is added, a selector switch is installed
to select the additional switch or the directional lever.
a The operation with the directional selector switch is selected only when the directional selector
switch actuation switch is turned ON. However, the directional lever (standard directional lever) is
given the priority for the operation.
The condition for operating with the directional selector switch is that the standard directional lever
is in N (Neutral), the directional selector switch is in N (Neutral), and the directional selector switch
actuation switch is turned ON.
a When travel direction can be changed with the directional selector switch, the directional selector
pilot lamp of the machine monitor lights up in green.
a If the directional selector switch actuation switch is turned ON/OFF while either is not in N (Neutral),
the directional selector pilot lamp of the machine monitor lights up in yellow and the caution lamp
lights up.
Even if the directional selector switch is effective, if the standard directional lever is set in a position
other than N (F or R), the travel direction is set according to the operation of the directional lever.

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Transmission controller system

Since the directional operation is not selected normally, the directional selector pilot lamp of the
machine monitor lights up in yellow and the caution lamp lights up.
a If the alarm operates and the directional selector pilot lamp lights up in yellow, the alarm is not
turned OFF and the directional selector switch does not work until both of the standard directional
lever and the directional selector switch are set in N (Neutral).
The above description is shown in the table below.
Mode

Condition

Directional lever: [F or N or R]
Directional selector switch: [N]
Directional selector switch
actuation switch: [OFF]
Directional lever: [N]
Directional selector
Directional selector switch: [F
switch enable switch
or N or R]
(normal [directional
Directional selector switch
selector switch])
actuation switch: [ON]
Directional lever: [F or R]
Directional lever priority Directional selector switch: [F
or N or R]
(emergency operation)
Directional selector switch
actuation switch: [ON]
Directional lever: [F or N or R]
Directional lever,
Directional selector switch: [F
directional switch error or R]
(wrong operation)
Directional selector switch
actuation switch: [OFF]
Directional lever: [other than
N]
<e> Selection error
Directional selector switch:
[other than N]
(wrong operation)
Directional selector switch
actuation switch: [OFFio
Directional lever
(normal)

FNR recognition

Right
FNR
enabled/
disabled

Monitoring
operation
(Reference)

Subject to directional
lever

OFF
(disabled)

Pilot lamp
Goes out
Buzzer stops

Subject to directional
selector switch

ON
(enabled)

Pilot lamp
Lights up in
green
Buzzer stops

Subject to directional
lever

OFF
(disabled)

Pilot lamp
Lights up in
yellow
Buzzer stops

Subject to directional
lever
(Directional selector
switch is ignored)

OFF
(disabled)

Pilot lamp
Lights up in
yellow
Buzzer stops

Subject to directional
lever

OFF
(disabled)

Pilot lamp
Lights up in
yellow
Buzzer stops

2. Interlock when engine is started (Prohibition of starting of engine)


When the directional selector switch actuation switch is in the ON position and the directional selector
switch is not in the N (Neutral) position, the transmission controller operates the neutral safety function
to cut the starting motor C terminal signal to prevent the machine from moving just after the engine is
started.
3. Setting of directional selector switch
The directional selector switch does not perform control, unless the option setting of the directional
selector switch is set effective by the option setting of the machine monitor. This switch cannot be
installed together with joystick steering.
a For the method of setting the option, see Testing and Adjusting, "Special functions of machine
monitor".

Auto idle stop function

(WA380-AF87-042-K-00-A)

When the operating condition is satisfied, the engine is stopped after a set period.
After the engine is stopped, if the parking brake switch is in OFF position, the parking brake is applied.
After the engine is stopped, if the work equipment lever lock is released, the work equipment lever lock is
operated.
This function works when conditions 1 to 4 are satisfied at the same time.
a For the adjustment procedure of the set time, see Testing and Adjusting, "Special functions of machine
monitor".
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10 Structure and function


Transmission controller system

Operating condition
Condition 1
Condition 2
Condition 3
Condition 4

Accelerator pedal is released


Directional lever is in neutral
Machine is stopped
KDPF is not in regeneration

Action for restarting engine


To restart the engine, turn the starting switch from the ON position to the START position.

Real-time monitoring function of transmission controller

(WA380-CV3G-042-K-00-A)

The conditions of the input and output signals of the controller can be checked with the monitoring function of
the machine monitor.
a For the monitoring procedure, see Testing and adjusting, "Special functions of machine monitor".

Transmission controller self-diagnosis function

(WA380-CN1G-042-K-00-A)

The transmission controller constantly monitors the input and output conditions and performs selfdiagnosis of the system.
If any failure is detected by the self-diagnosis, its information is sent to the machine monitor through the
network.
If any failure occurs, it can be checked with the machine monitor / KOMTRAX.

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Work equipment control system

Work equipment control system

(WA380-PK01-001-K-00-A)

Work equipment control system diagram

WA470-7

(WA470-PK01-051-K-00-A)

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Work equipment control system

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Work equipment control system

Work equipment control function

(WA380-PK01-042-K-00-A)

Neutral position and work equipment speed

(WA500-PK11-042-K-00-A)

Function
The work equipment control lever has a play of 5% of the lever travel in the neutral position. The work
equipment starts moving when the lever moves over the play.
The work equipment speed for the lever travel can be changed by the setting of the controller.
The boom has five changeable tables and the bucket has three.
a For the adjustment method and the features of each table, see Testing and adjusting "Changing boom
lever pattern" and "Changing bucket lever pattern".
Boom lever stroke vs. speed table

Bucket lever stroke vs. speed table

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Work equipment control system

Work equipment neutral lock function

(WA380-PTLD-051-K-00-A)

1. Transmission controller
2. Work equipment lock switch
3. Work equipment controller
4. Monitor controller
5. Machine monitor
6. Work equipment neutral lock valve

Function (WA380-PTLD-042-K-00-A)
When the work equipment lock switch is operated, the controller turns OFF the output of the work
equipment EPC to stop the operation of the work equipment.
When the ECSS switch is turned OFF, the work equipment neutral lock valve is turned ON. Then, the EPC
pilot source pressure is cut and the operation of the work equipment is stopped.
When the lever is operated while the work equipment is locked even if the operator tries to unlock the work
equipment, the work equipment is not unlocked but kept locked for safety.
Work
Controller
equipment
control
lever
condiOperator's
tion
intention in
when
operation of work
work
Recogniequipment lock
equipzes
switch
ment
lock
switch
is
operated

In locking (no
switch operation)

10-280

In locking

Operation
of ECSS

Movement
of machine

Controller output
Work equipment
lock
indicator

ECSS
switch
Work
signal
equip(Transmis- ment lock
sion
solenoid
controller
valve
input)

ECSS
switch =
OFF

ON
(24 V)

ECSS SW
= ON

OFF
(OPEN)

Switch

ON
(Lights
up)

Monitor

ON
(Lights
up)

Work
equipment
EPC,
work
equipment
detent

Hydraulic

Cut (Work
equipment
OFF (No and ECSS
stop)
output)
Only ECSS
operates

WA470-7

10 Structure and function


Work equipment control system

Lock o Unlock
(Switch
operation)

Lock o Unlock
(Switch
operation)

In unlocking (no
switch operation)

Unlock o Lock
(Switch
operation)

Work
equipment
control In locking
lever is
not in
neutral
Work
equipment
In
control
unlocked
lever is
in
neutral

In
unlocked

In locking

ECSS
switch =
OFF

ON
(24 V)

ECSS SW
= ON

OFF
(OPEN)

Cut (Work
equipment
and ECSS
stop)

ON
(Lights
up)

ON
(Lights
up)

OFF (No
output)

OFF
(OPEN)

OFF
(Lights
out)

OFF
(Lights
out)

Outputs
according
to lever
operation

Operates

OFF
(OPEN)

OFF
(Lights
out)

OFF
(Lights
out)

Outputs
according
to lever
operation

Operates

ECSS
switch =
OFF

ON
(24 V)

ECSS SW
= ON

OFF
(OPEN)

ON
(Lights
up)

ON
(Lights
up)

* Popup

Cut (Work
equipment
OFF (No and ECSS
stop)
output)
Only ECSS
operates

Only ECSS
operates

* If the work equipment is locked with the switch operation by the operator, popup display appears on the
machine monitor.

Operation of work equipment control lever

(WA500-PK11-042-K-01-A)

Function
The work equipment controller detects the quantity of RAISE/LOWER and TILT/DUMP operations through
the signals of the work equipment control lever potentiometers, controls the operation of each EPC valve
with current, and operates the main spool with the EPC pressure to operate the work equipment.
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Work equipment control system

The work equipment control lever has detent notches and the system is adjusted so that the work
equipment operates at the maximum speed just before each detent.
The range beyond the LOWER detent is the "Boom float" position, where the boom is moved by external
forces.

Bucket priority control

(WA500-PTL3-042-K-00-A)

Function
Since this machine employs the CLSS, it can operate the bucket and boom simultaneously. However, it
can prevent the boom from rising to improve the digging work efficiency when the bucket operation
frequency is large.
This is realized by limiting the maximum boom rising speed for the bucket speed (Table below).

Boom stop modulation

(WA500-PTL4-042-K-00-A)

Function
When the operator performs boom stop operation faster than a certain speed, the work equipment
controller operates the modulation to reduce the stopping shocks of the boom raise/lower operation.
The operation of this stop modulation function can be changed by the setting of the controller.

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a For the changing method and precautions, see Testing and adjusting, "Boom stop modulation".

Case A: Modulation 0
When lever command flow > modulation command flow
Output matched to lever command flow
Case B: Modulation 20
When lever command flow < modulation command flow
Output matched to modulation command flow
a: Modulation 10 (when shipped)
b: Modulation starting position

Adjustment of lever detent position and work equipment starting current

(WA380-PLT5-042-K-00-A)

Function
The work equipment controller has the adjustment function of correcting dispersion.
The controller saves the lever potentiometer voltage in the detent position and adjusts the detent position
to perform the control before and after the detent securely. If the adjustment is not performed, "the
positioner may not operate normally before and after the detent" or "the lever position for floating the boom
may be abnormal".
If the work equipment starting current is not adjusted, "the dead zone of neutral may be wide" or "the work
equipment may generate large shocks when it starts/stops".
a For the adjustment procedure, see Testing and adjusting, "Boom raise adjustment", "Bucket tilt
adjustment", or "Bucket dump adjustment".

Swash plate control function of work equipment pump and steering


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

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Work equipment control system

A: Small electric current


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

A: Small electric current


B: Large electric current

Pickup assistance control function when engine speed is low

(WA500-PTL7-042-K-00-A)

When the work equipment and steering are operated simultaneously while the engine speed is low, the
pump absorption torque is larger for the torque generated by the engine and the engine does not pick up
well.
To help the engine picking up, when the accelerator pedal is depressed while the engine speed is low, a
command current matched to the work equipment pump pressure or travel speed is sent to the swash
plate angle control EPC valves of the work equipment pump to control the pump swash plate angles and
reduce the load is reduced.

Overheat prevention function of work equipment controller

(WA470-PLT8-042-K-00-A)

The work equipment controller controls the work equipment pump discharge in accordance with the
hydraulic oil temperature to prevent overheat.
It sends a command current to the swash plate angle control EPC valve of the work equipment pump to
control the pump swash plate angle.

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Work equipment control system

Remote positioner function


Remote bucket positioner

(WA380-PTL9-001-K-00-A)

(WA470-PTL9-042-K-01-A)

Function
When the bucket is at the flat position or below, if the tilt lever is set in the detent position, the bucket stops
slowly at a set position.
1. Setting stop position
The bucket stop position when the positioner is operated is changed with the bucket positioner
position set switch.
Condition for
enabling

Bucket lever is in Neutral and bucket is within 5.5 degrees of setting angle.
(1)

Setting method
(2)
(1)
Cancellation
method

(2)
(3)

Set the bucket to a desired position and push the bucket positioner switch. (less than
1 second)
The current bucket cylinder length is saved for the saved set position, and the setting
completion buzzer sounds and the value is displayed on the monitor for 3 seconds.
(The set position is maintained even after the key is turned to the OFF position.)
To cancel the saved position (returned it to the default), hold down the bucket
positioner switch for 1 second or more.
If within the set range, the position is set temporarily. However, the setting
cancellation buzzer sounds 1 second after and the stop position is set to the default.
The monitor displays the saved value (default: 0) for 3 seconds.

a The value displayed on the monitor is indication of a level and does not match to the actual bucket
angle.
a The bucket-equivalent angle means a calculated bucket angle. It does not always match to the
actual angle because of the shape of the bucket.
2. Cancellation of tilt detent
When the bucket lever is in the tilt detent position, if the cylinder reaches the detent cancellation
position, the detent is canceled and the bucket stops slowly.
3. Stopping tilting (slowly)
Tilting (slow) stop function decreases the speed of tilting within the range of 100 to 7 mm before the
target stop position by feeding back the cylinder length, corresponding to the stopping angle.
After the tilt detent is canceled, if the bucket lever is held in the tilt detent position, tilting is not
stopped (slowly) but accelerated from the time when the lever is judged to be held, in the return
modulation at the target flow set with the lever.

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Accordingly, if the detent is held with the bucket positioner operated and the bucket is operated
over the stop position, the bucket tilting is decelerated temporarily and then accelerated.
4. Detent operation while engine is stopped
While the engine is stopped, the detent is kept OFF, thus the lever is not held in the detent position
while the engine is stopped.
5. Adjustment of bucket angle
The work equipment controller has a function to correct the cylinder length when the bucket is in
the flat position.
As for the flat position of the bucket, one of the three positions A, B, and C can be saved according
to the attachment.
a For details of adjustment procedure, see "Bucket flat level adjustment" of "Explanation of components",
"Operation" in the Operation and maintenance manual.

Remote boom positioner

(WA500-PTL9-042-K-01-A)

Function
Raising kick-out (When pilot lamp lights up to indicate that only raising is effective or both raising and lowering
are effective)
If the boom lever is set in the "Raising detent" position, the boom starts deceleration before the set
position, cancels the raising detent, and controls stopping (slowly).
When the boom is not in the "Raising detent" position, it is raised by the operator's operation.
If raising is not selected, only the raising detent operates.
If the detent is turned ON, the remote positioner does not operated and only the kick-out function operates
(the boom stops at the top).
Stopping boom lowering (When pilot lamp lights up to indicate that only lowering is effective or both raising
and lowering are effective)
If the boom lever is set in the "Floating detent" position, the boom starts deceleration before the set
position, cancels the floating detent, and controls stopping (slowly).
If the boom lever is kept as it is, the boom starts lowering again.
If lowering is not selected, only the floating detent operates.
If the detent is turned ON when the boom angle is flat or below, the remote positioner does not operate
and only the floating detent function operates (the boom does not stop automatically).
a If the detent is turned ON when the boom is flat or below, the lowering remote positioner does not function
as the positioner and does not stop the boom, for distinction from the floating operation in the grading
work.

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a The floating detent does not operate at around the setting stop position. However, the floating detent
operates when the boom angle is below -37 degrees for the grading work.
1. Setting stop position
The boom stop position when the positioner is operated is changed with the boom positioner switch.
Setting and cancelation of raising stop position
Condition for
enabling

Boom lever travel: Neutral and boom position is flat or above

(1) Raise the boom to a position to set.


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

Method of setting
lowering stop

Boom lever stroke: Neutral and boom position is flat or below


(1) Lower the boom to a position to set.
(2) Press the remote positioner lowering position set switch. (less than 1 second)
(3) If the position in which the switch is pressed is within the set range, the boom angle
is saved, the setting completion buzzer (pip, pip) sounds, and the pilot lamp on the
monitor lights up.
(4) If the position is out of the range (boom angle is out of the range between -37
degrees and 0 degrees ) or the sensor has an error, setting is not performed again.
(The buzzer does not sound and set position is not changed)
(5) If the setting switch is operated less than 1 second, the set position is always
changed.
(The set position is maintained even after the key is turned to the OFF position.)
(1) Press the remote positioner lowering position set switch for 1 second or more.
(2) If the position is within the set range when the switch is pressed, it is set temporarily.
If the switch is held down for 1 second or more in (3) above, the setting cancel buzzer
sounds (peep) when 1 second elapses and the lowering selection is canceled and the
pilot lamp of the monitor goes off.

Method of
canceling setting of
lowering stop
a The setting can be canceled when the boom is in the range below the flat position.
(3) Leave the remote positioner lowering stop control unexecuted.
Perform only the float detent control.
(4) In this operation, the lowering stop setting is not canceled.
Remote positioner stop position settable range
[Raising/Lowering stop position settable range]

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Stop position
Range
0 degrees: Boom horizontal position

"Raising"
Min. 0 degrees

"Lowering"
0 to -37 degrees

2. Cancelation of boom raising detent


When the remote positioner is operated, the detent is turned OFF if the boom reaches the detent
cancelation position.
Once the boom raising detent is turned OFF automatically by the operation of the stop (slow) function, the
boom raising/lowering detent is kept OFF for 1 second.
3. Raising stop (slow)
Boom raising (slow) stop function decreases boom speed according to the stopping angle by feeding back
the boom angle.
After the boom raising detent is canceled, if the boom lever is held in the raising detent position, boom
raising (slow) stop function does not work and the boom raising is accelerated again.
Accordingly, if the detent is held with the boom raising remote positioner operated and the boom is
operated over the target stop angle, the boom raising is decelerated temporarily o accelerated.
4. Boom kick-out function
When the stop position of the remote positioner is not set or the boom raising detent is turned ON above
the stop position, the boom performs the kick-out operation and stops slowly before the travel end to
reduce the stopping shocks at the travel end.
5. Cancelation of boom lowering detent
When the remote positioner is operated, the detent is turned OFF if the boom reaches the detent
cancelation position.
Once the boom lowering detent is turned OFF automatically by the operation of the stop (slow) function,
the boom raising/lowering detent is kept OFF for 1 second.
6. Boom lowering stop (slow)
Boom lowering (slow) stop function decreases boom speed according to the stopping angle by feeding
back the boom angle.
After the boom lowering detent is canceled, the system checks for 0.05 seconds if the boom is held in the
raising detent. If the boom is held in the detent, the system does not perform the stopping (slow) operation
but accelerates the boom lowering again.
Accordingly, if the detent is held with the boom lowering remote positioner operated and the boom is
operated over the target stop angle, the boom lowering is decelerated temporarily o accelerated.
When the boom angle reaches -37 degrees, the system stops acceleration and performs the floating
operation even if during acceleration.
7. Detent operation while engine is stopped
While the engine is stopped, the detent is kept OFF, thus the lever is not held in the detent position while
the engine is stopped.
8. Adjustment of boom angle
The work equipment controller has function to correct the installation error of the boom potentiometer.
The controller saves the boom potentiometer voltage at the boom top and operates the remote boom
positioner function.
If the adjustment is not performed, the kick-out position may be "too much near this side" or "the boom
may not kick out and shocks may be generated at travel end".

Semi auto-digging function

(WA380-PTLA-042-K-00-A)

The semi auto-digging function uses only the kickdown switch and boom raising operation for the ease of
digging work. With this function, even an unskilled operator can improve the working efficiency. This
function has two modes of LOOSE and ROCK, either of which is selected according to the properties of
the objective material.

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A bucket automatic operation pattern matched to the working cycle and load is selected.
Mode selection
No.
1
2

Objective material
Gravel/Sand
Quarry/Blasted rocks

Mode
LOOSE mode
ROCK mode

1. Condition for starting semi auto-digging

Condition 1

Condition 2

WA470-7

The semi auto-digging is ready when following (1) to (4) are satisfied.
(1) Semi auto-digging is set in "ROCK" or "LOOSE" mode.
(2) Machine is traveling forward (There is F signal)
(3) Boom angle is less than -30 (almost on ground)
(4) Kickdown switch is operated
a Even during work in 1st gear speed, semi auto-digging does not start if kickdown
switch is not operated.
Semi auto-digging (auto tilt) starts when following (1) and (2) are satisfied.
(1) Boom is raised after condition 1 is satisfied.

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Work equipment control system

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


2. Condition for finishing semi auto-digging

Condition

Semi auto-tilt finishes when one of the following conditions is satisfied.


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

3. Tilt operation in digging mode


1) Operation in "LOOSE" mode

2) Operation in "ROCK" mode

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Electric emergency steering function

(WA470-F910-042-K-00-A)

1. Emergency steering switch


2. Transmission controller
3. Work equipment controller
4. Fuse box
5. Slow-blow fuse
6. Battery relay
7. Battery
8. Battery disconnect switch
9. Emergency steering switch relay
10. Emergency steering relay
11. Emergency steering pump oil pressure sensor
12. Steering pump
13. Steering pump oil pressure sensor
14. Steering valve
15. Emergency steering pump
16. Emergency steering motor
Input/output signal
a. CAN signal
b. Emergency steering manual operation signal
c. Steering pump oil pressure signal
d. Emergency steering relay signal
e. Emergency steering pump oil pressure signal
f. Sensor power supply
Function
The condition of the oil pressure sensors in the steering circuit is constantly monitored. When the steering
oil pressure decreases and the transmission output shaft speed (travel speed) increases above the
emergency steering "ON" value in the following figure, the emergency steering operation signal is output
to the emergency steering switch relay to operate the emergency steering.
The emergency steering motor can be operated by operating the emergency steering switch, regardless
of the steering oil pressure or transmission output shaft speed (travel speed).
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a The continuous operation time with the emergency steering switch must be limited within 60 seconds.
a The travel speed must be kept 5 km/h or below while the emergency steering is operated.

Emergency steering selection point


Travel speed [km/h]

A
1.9

B
2.0

The emergency steering does not function if "Emergency steering" is not set to "ADD" with the "Option
select function" of the machine monitor.
a For the setting procedure, see Testing and Adjusting, "Special functions of machine monitor".
Self-check function for emergency steering
The emergency steering performs the self-check of its operation automatically 3 seconds after the starting
switch is turned to the "ON" position (after the self-check of the machine monitor is finished).
However, the self-check is not performed in the following cases.
1. The starting motor is started by turning the starting switch to the "START" position
2. The engine is running already.
(Engine speed of 500 rpm or higher is detected)
3. Steering pressure is detected
4. The automatic preheating function operates
5. An error related to the emergency steering is detected by the self-check of the machine monitor
6. The engine is not started for 10 seconds or more after the previous self-check
(Engine speed of 500 rpm is not detected for 10 seconds or more)
During the self-check of the emergency steering, the emergency steering operation signal is output for up
to 3 seconds.
When the machine monitor detects the emergency steering operating pressure within 3 seconds, the
emergency steering system receives the emergency steering operation sensing signal through the
network from the machine monitor and finishes its self-check.
If the machine monitor does not detect the emergency steering operating pressure in 3 seconds, the
emergency steering system does not receive the emergency steering operation signal from the machine
monitor, thus it gives an error alarm.

Real-time monitoring function of work equipment controller

(WA380-PTLB-042-K-00-A)

The conditions of the input and output signals of the controller can be checked with the monitoring function of
the machine monitor.
a For the monitoring procedure, see Testing and adjusting, Special functions of machine monitor.

Self-diagnosis function of work equipment controller

(WA380-PTLC-042-K-00-A)

The work equipment controller constantly monitors the input and output conditions and performs selfdiagnosis of the system.
If any failure is detected by the self-diagnosis, its information is sent to the machine monitor via the
network.
If any failure occurs, it can be checked with the machine monitor / KOMTRAX.

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Machine monitor system

Machine monitor system

Function

(WA470-Q170-041-K-00-A)

(WA380-Q170-042-K-00-A)

The machine monitor system mainly consists of the machine monitor, monitor controller, and switch panel.
1. Machine monitor
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Machine monitor system

Displays the machine condition to the operator.


a The machine monitor has two display modes; One is the operator mode and the other is the service
mode.
2. Monitor controller
Obtains the condition data of various sections of the machine monitored with sensors and switches and
processes them. Communicates the network information with each controller.
a For details, see "Monitor controller".
3. Switch panel
Accepts operations of the operator.
a For details, see "Switch panel".

Details of monitor controller network signals

(WA470-Q180-03C-K-00-A)

Data sent
Updated every 10 msec (RTCDB/r)
No.
1
2
3
4
5
6
7

Item
Fan reverse set condition (reverse time)
Fan reverse set condition (interval time)
Fan manual selection (forward/reverse) enabled/disabled
Air conditioner Compressor Status
Attachment flow mode
Attachment flow level
Attachment set switch information

Updated every 100 msec (RTCDB/r)


No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Item
Service meter reading
Semi-auto digging mode setting
Auto-deceleration enabled/disabled setting
Parking brake operation
Adjustment ID
Adjustment switch information
Data for adjustment
Auto-kickdown enabled/disabled
Machine model data
Option data
Brake oil pressure (front)
Brake oil pressure (rear)
Idle stop set time
In-idle stop service mode flag
Idle stop set entry signal
Preheat condition
Engine speed fixing control command
Bucket flat level adjustment selection information
Bucket flat level adjustment initialization command
Recirculation air temperature
Set temperature
Air conditioner setting

Data received
Updated every 10 msec (RTCDB/r)
No.
1
2

10-294

Item
Engine speed
Final injection rate
WA470-7

10 Structure and function


Machine monitor system

No.
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
WA470-7

Item
1st throttle position (accelerator pedal)
Engine condition
Key switch ACC terminal (engine controller)
Throttle correction value
Throttle upper limit value
Throttle lower limit value
Dynamic torque request
Torque curve selection
Droop type selection
Droop switch selection
ABS droop trim
Automatic warm-up cancel flag
Machine safety state 1
Machine safety state 2
Engine speed control flag
Travel speed (tire diameter and correction counted in)
Actual gear speed display (F)
Actual gear speed display (N)
Actual gear speed display (R)
Actual gear speed display (1st)
Actual gear speed display (2nd)
Actual gear speed display (3rd)
Actual gear speed display (4th)
Directional lever display (F)
Directional lever display (N)
Directional lever display (R)
Shift range display (1st)
Shift range display (2nd)
Shift range display (3rd)
Shift range display (4th)
Transmission controller recognition lever direction
Working situation discrimination status
ECSS switch condition
Rim pull
Engine output mode
Engine output mode (Engine output mode condition in transmission controller)
Engine output mode selection
Throttle lock (RPM set) lower limit command value
Engine start permission flag
Boom lever condition
Bucket lever condition
Working condition check
Target rim pull
Scrape-up flag
Digging flag
Loader pump neutral flag
Steering pump neutral flag
Boom angle
Boom bottom pressure
Boom head pressure
Bell crank angle
Key SIG condition (ACC)

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No.
55
56

Item
Auto-kickdown work equipment posture sensing information
Depressing right brake pedal

Updated every 100 msec (RTCDB/r)


No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38

10-296

Item
Engine coolant temperature
Overrun condition
Grid heater control condition
Instantaneous fuel consumption
Soot accumulation level
KDPF regeneration mode
Manual regeneration permission condition
Thermal management auxiliary request
HC desorb flag
Hydraulic oil temperature
Torque converter oil temperature
AJSS indicator or FNR switch
Auto shift condition
Shift hold condition
Lockup operation condition
Fan reverse pilot lamp
Kickdown switch condition
Kickdown information
Transmission cut-off point setting buzzer operation
Lockup function switch
Left brake pressure
Idle stop remaining time
Idle stop condition
Cut-off switch built-in indicator condition
Semi-auto digging condition
Multicoulper operation condition
Throttle lock (RPM set) operation condition
Boom positioner operation condition
Positioner setting buzzer operation
Emergency steering motor operation condition
All work equipment lever neutral flag
Work equipment pump relief flag
AJSS warning
ATT (PCS) detent condition
ATT (PCS) mode (flow mode) condition
ATT (PCS) flow rate level
Bucket selection information
Work equipment lock indicator

WA470-7

10 Structure and function


Machine monitor system

Machine monitor

(HM300-Q180-042-K-00-A)

Precautions on the machine monitor display


If there is trouble in the machine monitor, monitor controller, another controller, or network wiring, the
machine monitor does not display normally.
One of the features of the liquid crystal unit is that there may be black spots (spots that do not light up) or
white spots (spots that stay lighting up) on the screen.
When there are fewer than 10 black or white spots, this is not a failure or a defect.
When the emergency steering self check is performed or the engine is started, the battery voltage may
drop suddenly, depending on the ambient temperature and the condition of the battery.
In this case, the machine monitor may go out for a moment or may be restarted. However, this
phenomenon is not a trouble.

Input and output signals of machine monitor

(WA380-Q180-03C-K-01-A)

JAE-8P [ CN-MDM1] (for LC unit)


Pin No.
1
2
3
4
5
6
WA470-7

Signal name
LC unit LVDS +
LC unit LVDS LC unit power supply return GND
LC unit backlight adjustment
LC unit power supply
LC unit ON/OFF control

Input/Output
Signal
Input
Input

Input
Input
Input

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Machine monitor system

Signal name

Pin No.
7
8

LC unit backlight ON/OFF control


LC unit temperature sensor

Input/Output
Signal
Input
Input

AMP-6P [ CN-MDM2] (for LED unit)


Signal name

Pin No.
1
2
3
4
5
6

LED unit power supply (+12 V)


LED unit power supply return GND
LIN
LED unit power supply (+5 V)
(*1)
GND

Input/Output
Signal
Input

Input/Output
Input

AMP-8P [ CN-MDM3] (for meter unit)


Pin No.
1
2
3
4
5
6
7
8

Signal name
Meter unit power supply (battery direct 24 V)
Key switch ACC terminal
CAN (+)
Meter unit power supply return GND
Monitor brightness selector switch (night mode signal)
(*1)
CAN2 terminating resistor
CAN (-)

Input/Output
Signal
Input
Input
Input/Output

Input
Input
Input/Output

*1: Never connect these pins. Malfunctions or failures may occur.

10-298

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10 Structure and function


Machine monitor system

Display

WA470-7

(WA470-Q1LA-042-K-00-A)

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10 Structure and function


Machine monitor system

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

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10 Structure and function


Machine monitor system

4. Parking brake pilot lamp


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

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Meters and gauges


Monitor
display

Item
displayed

(WA470-Q1LB-043-K-00-A)

Display
color

CharacSpeedomters:
eter
black

Engine
tachometer

10-302

Display range: 0 to 99 km/h

Graduations:
green,
red
Pointer:
red

D1
D2
D3
D4

Coolant
temperature (C)
135
102
88
74
59
50
Oil
temperature (C)
135
120
97
73
50
Oil
temperature (C)
125
100
83
67
50
Fuel
level (l)
226
190
114
42

D5

41

Point
Display range:
50 to 135 C
(red zone: 102
C and above)

A1
A2
A3
A4
A5
A6
Point

Display range:
50 to 135 C
(red zone: 120
C and above)

B1
B2
B3
B4
B5
Point

GraduaHydraulic tions:
green,
oil
tempera- red
ture gauge Pointer:
red

Display range:
50 to 125 C
(red zone: 100
C and above)

Graduations:
green,
red
Pointer:
red

Display range:
EMPTY to
FULL (red
zone: 42l or
less)

Fuel level
gauge

Remarks

Characters:
white
Display range: 0 to 3,500 rpm (red
Gradua- zone: 2,500 rpm and above)
tions:
white, red

Graduations:
Engine
white,
coolant
green,
temperared
ture gauge
Pointer:
red

Torque
converter
oil
temperature gauge

Contents

C1
C2
C3
C4
C5
Point

If communication error
occurs between monitor
controller and transmission
controller, "0" is displayed.
If communication error
occurs between monitor
controller and meter unit,
"00" is displayed.
If engine speed increases
above specified level,
engine overrun caution
lights up. (For details, see
engine overrun caution.)
If communication error
occurs, gauge pointer reads
0.
If temperature exceeds 102
C, engine coolant overheat
caution lights up. (For
details, see engine overrun
caution.)
If communication error
occurs, gauge pointer
disappears.

If temperature exceeds 120


C, torque converter oil
overheat caution lights up.
If communication error
occurs, gauge pointer
disappears.

If temperature exceeds 100


C, hydraulic oil caution
lights up.
If communication error
occurs, gauge pointer
disappears.

42 l or below, fuel level


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

WA470-7

10 Structure and function


Machine monitor system

Monitor
display

Item
displayed

ECO
gauge

Display
color

Green,
orange

Air
Characconditioner
ters:
display
white
area

Clock

Characters:
white

CharacService
meter (*1) ters:
white

Travel
odometer
(*1)

Characters:
white

CharacClock (*1) ters:


white

Fuel
consump- Charaction gauge ters:
white
(*1)

Contents

Remarks

Display range: 0 to 48.75 l/h


(Orange zone: 39 l/h or above)

Indicates instantaneous fuel


consumption (average of
fuel consumption per 3
seconds) in 10 steps.
Display/Non display of ECO
gauge can be set by using
user menu as follows; "ECO
Guidance" o "Display
Setting" o "ECO Gauge
Display".
Display/Non display of ECO
gauge can be set by using
user menu as follows; "ECO
Guidance" o "Display
Setting" o "ECO Gauge
Display".
If communication error
occurs, gauge reads 0.

Set temperature
Air blow rate
Vent

For details, see Operation &


Maintenance Manual.

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

When engine operating


Display range: 0 to 999999.9 h
hours exceeds 999999.9 h,
meter reading stops at
999999.9 h.
Indicates accumulated travel
distance.
When travel distance
Display range: 0 to 3999999.9 km
exceeds 3,999,999.9 km,
meter reading stops at
3,999,999.9 km.
Displays time.
12-hour/24-hour system
display can be switched by
12-hour system display (AM/PM)
using user menu as follows;
24-hour system display
"Monitor Setting" o "Clock
Adjustment".
Indicates average fuel
consumption.
1 Day/Split can be switched
1 Day display
by using user menu as
Split display
follows; "ECO Guidance" o
"Display Setting" o "Fuel
Consumption Gauge
Display".

*1: These items indicated to R.H. and L. H. meter display can be selected with user menu "Monitor Setting" o
"Select Meter Display" as follows.
L.H. meter display: Service meter, odometer, clock
R.H. meter display: Service meter, odometer, clock, fuel consumption gauge

WA470-7

10-303

10 Structure and function


Machine monitor system

Alarm monitor
Monitor
display

(WA470-Q1LA-043-K-00-A)

Item
displayed

Action
level

Centralized
warning
lamp

Brake oil
pressure
caution

Engine
coolant
temperature

Action
level

Centralized
warning
lamp

L04

L03

L02

Yellow

L01

Red
(LED)

See
remarks.

Q
(intermittent)

L03

L02

Q
(intermittent)

L02

Q
(intermittent)

Display
color

Red

Red
(LED)

Red

Alarm
buzzer
Q
(continuous)
Q
(intermittent)
Q
(intermittent)

Q
(intermittent)
Q
(intermittent)

Appears when trouble is


detected in machine.

Lights up for 2 seconds, then


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

Torque
converter
oil
temperature

Red

Hydraulic
oil
temperature

Red

L02

Q
(intermittent)

Appears when hydraulic oil


temperature is 100C or
above.

Fuel level

Red

Lights up when fuel level is


42 l or below.

Red

Yellow

Maintenance time
warning

10-304

Remarks

Lights up for 30 seconds after


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

10 Structure and function


Machine monitor system

Monitor
display

Item
displayed

Display
color

Action
level

Centralized
warning
lamp

Alarm
buzzer

Remarks
Notice time can be changed
in service menu
"Mmaintenance Mode
Setting" o "Maintenance
ModeChange" o
"Maintenance Notice Time
Setting".

Seat belt

Engine
system
error

Red

KDPF soot
accumulation
caution
icon
Engine
overrun

Engine oil
pressure

Transmission
system
error
Fan
control
system
error
Radiator
coolant
level

WA470-7

L04

Red

Yellow

Defective
KDPF
system

L03

L01

L04

Red
L03

Yellow

L01

Red

L03

Yellow

L01

L02

L03

L04

Red

Red

Red

Q
(continuous)
Q
(intermittent)

Q
(continuous)
Q
(intermittent)

Q
(intermittent)

Q
(intermittent)
Q
(intermittent)
Q
(intermittent)
Q
(continuous)
Q
(intermittent)

Q
(intermittent)

L03

Yellow

L01

Red

L03

Yellow

L01

Yellow

L01

Lights up when seat belt is


not fastened.

Appears when error is


detected in engine system.

Appears when error is


detected in KDPF system.

Appears when much soot is


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

Appears when error is


detected in transmission
system.

Appears when error is


detected in fan control
system.

Lights up when radiator


coolant level is low.

10-305

10 Structure and function


Machine monitor system

Monitor
display

Item
displayed

Display
color

Action
level

Centralized
warning
lamp

Alarm
buzzer

Engine oil
level

Yellow

L01

Lights up when engine oil


level is low.

Air cleaner
clogging

Yellow

L01

Lights up when air cleaner is


clogged.

Yellow

L01

Appears when error is


detected in steering system.

L03

Q
(intermittent)

Steering
system
error
caution
icon
Emergency steering
system
error
caution
icon (if
equipped)
Directional
switch

Brake oil
temperature
Work
equipment
system

Steering
oil
pressure

Emergency steering
motor (if
equipped)
System
error
caution
icon
Air
conditioner
system
error
caution
icon

10-306

Red

Remarks

Appears when error is


detected in emergency
steering system.

Yellow

L01

Red

Q
(intermittent)

Lights up when directional


switch or directional lever is
operated wrongly.
Lights up when brake oil
temperature is kept at 140C
or above for 900 seconds, or
at 150C or above for 20
seconds.

Yellow

Red

L03

Q
(continuous)

Yellow

L01

L03

L02

Red

L03

Q
(intermittent)

Yellow

L01

Yellow

L01

Red

Red

Q
(intermittent)
Q
(intermittent)
Q
(intermittent)

Appears when trouble is


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

WA470-7

10 Structure and function


Machine monitor system

a If three or more cautions are occurring, the icons displayed are changed two by two every 2 seconds.

WA470-7

10-307

10 Structure and function


Machine monitor system

Pilot lamp
Monitor
display

(WA470-C7K6-043-K-00-A)

Item
displayed

Contents

Parking
brake

Red
(LED)

Lights up when parking brake is


applied.

Turn signal
(left)

Green
(LED)

Lights up when left turn signal is


turned on.

Headlamp
(high
beam)

Blue
(LED)

Lights up when headlamp (high


beam) is turned on.

Turn signal
(right)

Green
(LED)

Lights up when right turn signal is


turned on.

Clearance
lamp

Green
(LED)

Lights up when clearance lamp is


turned on.

Shift
indicator

Remarks

Charac- Indicates actual gear speed (F1, F2,


ters:
F3, F4, N, R1, R2, R3, or R4).
White

Shift lever
position

Characters:
HighlighCurrent shift lever position (1, 2, 3,
ted in
4, N, R, N, or F) is highlighted.
white
(other
than N)

Message
(Unread)

Back- Lights up when there is unread


ground: message.
Green

Message
(read but
unreturned)

Back- Lights up when there is message


ground: read but not returned yet.
Black

Semi-auto
Digging

10-308

Display
color

Green

When starting switch is


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

Goes out when answer is


sent or validity of message
expires.

Lights up while machine is digging in


semi-auto mode.

WA470-7

10 Structure and function


Machine monitor system

Monitor
display

Item
displayed
Multicoupler
lock
release (if
equipped)
Directional
selection

Display
color

Contents

Red

Lights up when multi-coupler lock is


released.

Green
Yellow

Remarks

Lights up when directional switch is


effective.
Lights up when wrong operation is
made.

E.C.S.S.

Green

Lights up when ECSS is effective.

2-stage
low idle (if
equipped)

Green

Lights up when 2-stage low idle is


effective.

Lights up when raise stop is set.

Remote
positioner

Green

Lights up when lower stop is set.

Lights up when raise and lower


stops are set.

Work
equipment
lock

Red

Lights up when work equipment is


locked.

Auto-shift

Green

Lights up when auto-shift operates.

Green

Lights up when transmission cutoff operates.


Flashes when resetting is
acceptable.

Green

Pops up for only 3 seconds when


bucket positioner switch is
turned ON.
Displays set angle in range of 5
levels.

Transmission cut-off

Bucket
positioner

Lights up during KDPF regeneration.


KDPF
regeneration

WA470-7

Yellow
Lights up when KDPF regeneration
is stopped.

KDPF soot accumulation


caution icon lights up when
manual stationary
regeneration is required.

10-309

10 Structure and function


Machine monitor system

Monitor
display

Item
displayed

Display
color

Contents

Emergency steering
(if
equipped)

Green

Lights up when emergency steering


operates.

Remarks

Lights up when P mode is selected


with power mode selector switch.

P mode
Green

Lights up when E mode is selected


with power mode selector switch.

E mode

Shift hold

Green

Lights up when shift hold operates.

Lockup

Green

Lights up when lockup is engaged.

Yellow

Lights up when fan rotates in


reverse.
Flashes while rotation direction
is being changed.

Red

Lights up while rotation direction


change condition is being waited to
meet.

Fan
reverse
rotation

Preheating

ECO
guidance

10-310

Yellow

Background:
Green
Characters:
White

Lights up when engine electric


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

WA470-7

10 Structure and function


Machine monitor system

Guidance icon
Monitor
display

(WA380-Q1L3-043-K-00-A)

Item

User menu
selection

Display of
occurred error list

Move between
items (upper)

Move between
items (lower)

Return

Enter

Move between
tabs (right)

WA470-7

Function (Action that starts when


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

Move between
pages (upper)

Moves to upper page


(Moves to bottom page from top
page)

Move between
pages (lower)

Moves to lower item


(Moves to top page from bottom
page)

Start split fuel


consumption
measurement

Starts measurement of split fuel


consumption

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

Standard screen (when failure


occurs)

Overall user menu


Overall service menu

Overall user menu


Overall service menu

Overall user menu


Overall service menu

Overall user menu


Overall service menu

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

10-311

10 Structure and function


Machine monitor system

Monitor
display

Item

Stop split fuel


consumption
measurement

Stops measurement of split fuel


consumption

Display location
a Displayed when setting of
"Average fuel consumption
display" is split
User menu "ECO guidance"
"Operation record", "ECO
guidance record"
a Displayed when setting of
"Average fuel consumption
display" is split

Clear average fuel Clears average fuel consumption


consumption logs logs

User menu "ECO guidance"


"Average fuel consumption logs"

Select average
fuel consumption
log

Selects 1-hour/1-day average fuel


consumption log

User menu "ECO guidance"


"Average fuel consumption logs"

Initialize screen
brightness

Returns to monitor screen brightness User menu "Monitor setting"


"Screen adjustment"
to initial level

Store monitoring
item

Stores monitoring item

Service menu "Monitoring"

Clear saved
monitoring item

Clears monitoring item

Service menu "Monitoring"

Hold monitoring
value

Holds value of monitoring item

Cancel held
monitoring value

Cancels held value of monitoring


item

Clear

<Electrical system abnormality


record>
Clears electrical system abnormality
record
<Phone number entry>
Clears phone number
<Adjusting>
Clears input value

Move between
items (right)

10-312

Function (Action that starts when


corresponding switch is pressed)

Moves to right item

Service menu "Monitoring / Predefined"


Service menu "Monitoring"
Service menu "Testing"
"Cylinder cut-out operation"
Service menu "Adjusting"
Service menu "Monitoring / Predefined"
Service menu "Monitoring"
Service menu "Testing"
"Cylinder cut-out operation"
Service menu "Adjusting"
Service menu "Abnormality
record" "Electrical system
abnormality record"

a For method of clearing


abnormality record, see
Testing and adjusting
Service menu "Phone number
entry"
Service menu "Adjusting"
Service menu "Phone number
entry"
Service menu "Testing"
"Cylinder cut-out operation"
Other items (Adjusting screen)

WA470-7

10 Structure and function


Machine monitor system

Monitor
display

Item

Function (Action that starts when


corresponding switch is pressed)

Service menu "Phone number


entry"
Service menu "Testing"
"Cylinder cut-out operation"
Other items (Adjusting screen)

Move between
items (left)

Moves to left item

Change between
plus and minus

Changes plus or minus of input value Service menu "Adjusting"

Input decimal point Inputs decimal point

WA470-7

Display location

Service menu "Adjusting"

10-313

10 Structure and function


Machine monitor system

Operator mode functions

(WA470-Q193-042-K-00-A)

The functions which the operator can display or set by operating switches in normally displayed screen.
Display and setting of some functions require special operation of the switch.
Items available in the operator mode are as follows:
Category
(*1)

Item
Display of KOMATSU logo
Password input screen
Display of standard screen
Display of end screen
Display of the operation screen for engine shutdown secondary switch
Operation of air conditioner
Displaying and setting user menu
ECO Guidance
Machine Setting / Information
KDPF Regeneration
Maintenance
Monitor Setting
User Message (including KOMTRAX messages for user)
Display of ECO guidance
Display of warning (caution and action level)
Display of maintenance due time over
Display of KDPF regeneration
Checking function by LCD (Liquid Crystal Display)
Function of checking service meter and odometer
Function of setting usage limitation/ changing password

*1: The items available in the operator mode are categorized as shown below.
A: Displays that appear since starting switch is turned to ON position until the standard screen appears, and
the displays that appear after starting switch is turned to OFF position.
B: Displays that appear when the switch on the machine monitor is operated.
C: Displays when a certain condition is satisfied.
D: Displays that require special switch operations.
a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Operator
mode (Outline)" section in Testing and adjusting.
a For the operating method of the engine start lock function, see "Password setting and canceling manual".
a For how to operate the function of changing the ID key registration, see the Operation and Maintenance
Manual.

10-314

WA470-7

10 Structure and function


Machine monitor system

Service mode functions

(WA470-Q194-042-K-00-A)

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

WA470-7

10-315

10 Structure and function


Machine monitor system

Switch panel

(HM300-Q1C0-042-K-00-A)

Input/output signals of switch panel

(WA380-Q1A1-03C-K-00-A)

AMP-6P [ CN-MOM1]
Pin No.
1
2
3
4
5
6

10-316

Signal name
Switch panel power supply (+12 V)
GND (Switch panel power supply)
LIN
Switch panel continuous power supply (+5.6 V)
External starting signal (for switch panel)
Switch panel built-in buzzer

Input/output signal
Input

Input/Output
Input
Output
Input

WA470-7

10 Structure and function


Rear view monitor system

Rear view monitor system

Function

(HM300-Q162-041-K-00-A)

(HM300-Q162-042-K-00-A)

The rear view monitor system mainly consists of the rear view monitor, rear view camera, and monitor
controller.
1. Rearview monitor
Displays the rear view camera image to the operator according to the setting of the rear view monitor
controller (guide lines, display of reverse-interlock, luminance, etc.)
2. Rear view camera
Transmits the taken images to the rear view monitor.
3. Monitor controller
Sends the contents of change of the rear view monitor setting to the monitor.

WA470-7

10-317

10 Structure and function


Rear view monitor system

Rear view monitor

(HM300-Q16D-042-K-00-A)

Precautions for using rear view monitor


The reference lines must be re-adjusted in the following cases.
1. When the machine dimensions are changed because of replacement of tires, installation of optional
attachment, etc.
2. When the rear view camera is removed or its direction is changed because of damage etc.

Rear view monitor input/output signals

(WA380-Q16D-03C-K-00-A)

AMP-12P [ CN-RVM1]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12

Signal name
Continuous power supply (24 V)
GND (continuous power supply)
Service connector external start signal
(*1)
Rear view monitor brightness adjustment switch +
Rear view monitor brightness adjustment switch Shift lever R signal
Monitor brightness selector switch
(Night mode signal)
LIN
(*1)
(*1)
Key switch ACC signal

Input/output signal
Input

Input

Input
Input
Input
Input
Input/Output

Input

*1: Never connect these pins. Malfunctions or failures may occur.


AMP-8P [ CN-RVM2]
Signal name
Pin No.
Rear view camera power supply output
1

10-318

Input/output signal
Output
WA470-7

10 Structure and function


Rear view monitor system

2
3
4
5
6
7
8

Rear view camera NTSC signal


(*1)
(*1)
GND (rear view camera power supply)
(*1)
(*1)
GND (rear view camera shield)

Input

*1: Never connect these pins. Malfunctions or failures may occur.

Rear view camera

(HM300-Q162-042-K-01-A)

Rear view camera input/output signals

(WA380-Q162-03C-K-00-A)

DT-T-8P [ CN-RVC_1]
Pin No.
1
2
3
4

Signal name
Rear view camera power supply
Rear view camera NTSC signal output
(*1)
GND (rear view camera power supply)

Input/output signal
Input
Output

*1: Never connect these pins. Malfunctions or failures may occur.

WA470-7

10-319

10 Structure and function


KOMTRAX system

KOMTRAX system

(HM300-Q210-042-K-00-A)

The KOMTRAX system consists of the KOMTRAX terminal, communication antenna, and GPS antenna.
This system transmits various machine information by use of the radio communication. KOMTRAX
operator can refer this information and provide various services to the customers.
Following information can be transmitted from the KOMTRAX system.
1.
2.
3.
4.
5.
6.

Position information
Operation information (service meter, odometer, etc.)
Alarm and failure information
Fuel consumption information
Maintenance information
Machine working condition information

a To provide the services, you need to establish radio station for KOMTRAX separately.

KOMTRAX terminal

(HM300-Q220-042-K-00-A)

Model: TC330

1. LED lamp display


2. GPS antenna connection port

10-320

WA470-7

10 Structure and function


KOMTRAX system

3. Machine wiring harness connection port (CN1A)


4. Machine wiring harness connection port (CN1B)
5. Communication antenna connection port

Input and output signals of KOMTRAX terminal

(HM300-Q220-03C-K-00-A)

CN1A[CN-KOM1]
Signal name

Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
CAN2_H
CAN2_L
(*1)
(*1)
External starting signal
System operating lamp
(*1)
(*1)
(*1)

Input/output
signal

Input/Output
Input/Output

Input/Output
Output

*1: Never connect these pins. Malfunctions or failures may occur.


CN1B[CN-KOM2]
Signal name

Pin No.
1
2
3
4
5
6
7
8
9
10
11
12

GND (continuous power supply)


GND (continuous power supply)
Starting switch ACC signal
Alternator R signal
(*1)
Continuous power supply (24 V)
Continuous power supply (24 V)
(*1)
(*1)
(*1)
Starting switch C signal
(*1)

Input/output
signal

Input
Input

Input
Input

Input

*1: Never connect these pins. Malfunctions or failures may occur.

Function

(D65-Q220-042-K-01-A)

This terminal utilizes satellite communications technology.


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

10-321

10 Structure and function


KOMTRAX system

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

10-322

WA470-7

10 Structure and function


System component parts

System component parts


Engine controller

(ALL-RA1C-001-K-00-A)

(PC220-AP70-041-K-00-A)

Engine controller input and output signals

(PC400-AP70-03C-K-00-A)

The following is the list of the symbols used for signal classification in the input/output signal table.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
DRC26-60P(1)[ECM J1(CN-CE01)]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
WA470-7

Signal name
(*1)
Engine oil pressure sensor
Crankcase pressure sensor
(*1)
Charge temperature sensor
Intake temperature MAF sensor
CAN_C(+)
CAN_B(+)(KOMNET/r)
Bkup (camshaft) speed sensor (+)
(*1)
(*1)
(*1)
GND
Coolant temperature sensor
Charge pressure sensor
Ambient pressure sensor

Signal category

B
B

B
B
E
E
B

C
B
B
B

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10 Structure and function


System component parts

Pin No.
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60

Signal name
CAN_C(-)
CAN_B(-)(KOMNET/r)
(*1)
(*1)
Sensor power supply (12 V)
GND
Mass air flow sensor
(*1)
(*1)
Ne (crankshaft) speed sensor (+)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
Sensor power supply (5 V)
NE (crankshaft) speed sensor (-)
(*1)
(*1)
(*1)
(*1)
(*1)
Injector #4 (+)
Injector #5 (+)
Injector #6 (+)
Injector #3 (+)
Injector #2 (+)
Injector #1 (+)
(*1)
(*1)
(*1)
(*1)
Injector #4 ()
Injector #5 ()
Injector #6 ()
Injector #3 ()
Injector #2 ()
Injector #1 ()
GND
Sensor power supply (5 V)

Signal category
E
E

A
C
B

A
C

D
D
D
D
D
D

C
C
C
C
C
C
C
A

*1: Never connect these pins. Malfunctions or failures may occur.


DRC26-60P(2)[ECM J2(CN-CE02)]
Pin No.
1
2
3
4

10-324

Signal name
Supply pump #2 ()
Supply pump #2 (+)
(*1)
Supply pump #1 ()

Input/output
C
D

C
WA470-7

10 Structure and function


System component parts

Pin No.
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
WA470-7

Signal name
Supply pump #1 (+)
EGR actuator (+)
(*1)
Fuel dozer solenoid valve #2 (+)
Fuel dozer solenoid valve #1 (+)
KVGT actuator (+)
(*1)
(*1)
(*1)
(*1)
(*1)
EGR actuator (-)
(*1)
GND
(*1)
KVGT actuator (-)
GND
(*1)
(*1)
CAN_B(+)
CAN_B(-)
(*1)
(*1)
(*1)
(*1)
Power supply of dosing fuel pressure sensor (5 V)
Power supply of common rail pressure sensor (5 V)
KVGT speed sensor (+)
KVGT speed sensor (-)
(*1)
(*1)
Dosing fuel pressure sensor
(*1)
KVGT position sensor
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)

Input/output
D
D

D
D
D

C
C

E
E

A
A
B
C

(*1)

(*1)
GND
(*1)
(*1)
HC dozing solenoid (+)
(*1)
(*1)
(*1)
(*1)
Common rail pressure sensor
(*1)

10-325

10 Structure and function


System component parts

Pin No.
57
58
59
60

Signal name
(*1)
(*1)
EGR valve lift sensor
HC dozing solenoid (-)

Input/output

B
C

*1: Never connect these pins. Malfunctions or failures may occur.


DRC26-60P(3)[CN-CE03]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

10-326

Signal name
Electric power supply (24 V)
Electric power supply (24 V)
Starting switch ACC signal
Electrical intake air heater relay (+)
(*1)
(*1)
(*1)
(*1)
System operating lamp (in-use signal)
(*1)
Unswitched power supply (24 V)
Unswitched power supply (24 V)
(*1)
Dozing pump relay drive
(*1)
(*1)
CAN_A(+)(KOMNET/c)
CAN_A(-)(KOMNET/c)
Sensor GND
(*1)
GND (return from power supply)
GND (return from power supply)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
GND (return from power supply)
GND (return from power supply)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
Fuel control dial GND
Fuel control dial power supply (5 V)
KDPF pressure sensor GND
(*1)

Input/output
A
A
B
D

A
A

E
E
C

C
C

C
C

C
A
C

WA470-7

10 Structure and function


System component parts

Pin No.
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60

Signal name
KDOC inlet temperature sensor
(*1)
(*1)
KDOC outlet temperature sensor
(*1)
(*1)
Fuel control dial
KDPF pressure sensor power supply (5 V)
(*1)
KDPF outlet temperature sensor
KDPF differential pressure sensor
(*1)
(*1)
KDPF outlet pressure sensor
(*1)
(*1)

Input/output
B

B
A

B
B

*1: Never connect these pins. Malfunctions or failures may occur.

Work equipment controller

(WA380-PT10-041-K-00-A)

Input and output signals of work equipment controller

(WA380-PT10-03C-K-00-A)

DEUTSCH-24P [CN-L71]
Pin No.
1
2
3
4
5
WA470-7

Signal name
Joystick lever position B
Boom lever B
Steering pump oil pressure sensor
Signal GND
(*1)

Input/output signal
Input
Input
Input

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10 Structure and function


System component parts

Pin No.
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Signal name
(*1)
Joystick lever potentiometer A
Boom lever A
Oil pressure sensor of work equipment pump
(*1)
(*1)
Emergency steering pump oil pressure sensor
(*1)
Bucket lever B
(*1)
(*1)
(*1)
(*1)
(*1)
Bucket lever A
(*1)
Potentiometer power supply (5 V)
(*1)
2-stage low idle switch

Input/output signal

Input
Input
Input

Input

Input

Input

Output

Input

*1: Never connect these pins. Malfunctions or failures may occur.


DEUTSCH-40P (1) [CN-L72]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

10-328

Signal name
Potentiometer power supply (5 V)
(*1)
Remote positioner switch (boom)
(*1)
4th lever B
Lift cylinder bottom oil pressure sensor
(*1)
Emergency steering relay
Bucket tilt detent
(*1)
(*1)
Remote positioner switch (bucket)
(*1)
(*1)
4th lever A
Lift cylinder head oil pressure sensor
(*1)
Boom raise detent
Work equipment lock solenoid
(*1)
(*1)
CAN-L (KOMNET/c)
CAN-L (KOMNET/r)
External starting signal
3rd lever B
Boom potentiometer
Joystick steering HI/LO selector switch
Work equipment lock pilot monitor
(*1)

Input/output signal
Output

Input

Input
Input

Output
Output

Input

Input
Input

Output
Output

Input/Output
Input/Output
Input
Input
Input
Input
Output

WA470-7

10 Structure and function


System component parts

Pin No.
30
31
32
33
34
35
36
37
38
39
40

Signal name
(*1)
(*1)
CAN-H (KOMNET/c)
CAN-H (KOMNET/r)
(*1)
3rd lever A
Bucket potentiometer
Power mode selector switch (E)
(*1)
(*1)
(*1)

Input/output signal

Input/Output
Input/Output

Input
Input
Input

*1: Never connect these pins. Malfunctions or failures may occur.

WA470-7

10-329

10 Structure and function


System component parts

DEUTSCH-40P (2) [CN-L73]


Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Signal name
Continuous power supply (24 V)
Power supply (24 V)
GND (solenoid)
(*1)
4th valve retraction EPC
Boom RAISE EPC
Joystick lever left EPC
(*1)
Multicoulper release
Starting switch C signal
Continuous power supply (24 V)
Power supply (24 V)
GND (solenoid)
Starting switch ACC signal
4th valve extension EPC
Boom LOWER EPC
Joystick lever right EPC
(*1)
Battery relay
Work equipment lock switch
GND (controller)
Power supply (24 V)
GND (solenoid)
Starting switch ACC signal
Steering pump EPC
3rd valve retraction EPC
Bucket DUMP EPC
Joystick EPC cut relay
(*1)
Emergency steering switch
GND (controller)
GND (controller)
GND (controller)
System operating lamp
Work equipment pump EPC
3rd valve extension EPC
Bucket TILT EPC
(*1)
(*1)
Multicoupler release switch failure

Input/output signal
Input
Input

Output
Output
Output

Input
Input
Input
Input

Input
Output
Output
Output

Input
Input

Input

Input
Output
Output
Output
Output

Input

Input
Output
Output
Output

Input

*1: Never connect these pins. Malfunctions or failures may occur.

10-330

WA470-7

10 Structure and function


System component parts

Transmission controller

(WA380-CV10-041-K-00-A)

Transmission controller input and output signals

(WA380-CV10-03C-K-00-A)

DEUTSCH-24P [CN-L61]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

WA470-7

Signal name
Torque converter outlet pressure sensor
(*1)
Torque converter oil temperature sensor
Signal GND
Gear speed switch 4th
Joystick downshift switch
Torque converter inlet pressure sensor
Directional lever position (analogue)
Transmission oil temperature sensor
(*1)
Gear speed switch 3rd
Joystick upshift switch
Transmission cut-off oil pressure sensor
(*1)
(*1)
Sensor power supply (24 V)
Gear speed switch 2nd
Shift mode manual
(*1)
Hydraulic oil temperature sensor
Analog GND
Directional lever power supply (5 V)

Input/output signal
Input

Input

Input
Input
Input
Input
Input

Input
Input
Input

Output
Input
Input

Input

Output

10-331

10 Structure and function


System component parts

Pin No.
23
24

Signal name
Gear speed switch 1st
Shift mode H

Input/output signal
Input
Input

*1: Never connect these pins. Malfunctions or failures may occur.


DEUTSCH-40P (1) [CN-L62]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Signal name
(*1)
ECMV fill switch R
ECMV fill switch 4th
(*1)
Directional selector switch (F)
Parking brake switch
ECMV fill switch 2nd
(*1)
(*1)
(*1)
(*1)
ECMV fill switch F
ECMV fill switch 3rd
(*1)
Directional lever (R)
Starting switch C signal
ECMV fill switch 1st
(*1)
Backup lamp relay
Transmission output shaft speed sensor
(*1)
CAN-L (KOMNET/c)
CAN-L (KOMNET/r)
External starting signal
Directional lever (N)
Directional selector switch (R)
Directional selector switch enable switch
Transmission cut-off switch built-in indicator
Pulse GND
Cooling fan speed sensor
(*1)
CAN-H (KOMNET/c)
CAN-H (KOMNET/r)
(*1)
Directional lever (F)
Directional selector switch (N)
E.C.S.S. switch
Torque converter lockup switch
Pulse GND
Transmission input speed sensor

Input/output signal

Input
Input

Input
Input
Input

Input
Input

Input
Input
Input

Output
Input

Input/Output
Input/Output
Input
Input
Input
Input
Input

Input

Input/Output
Input/Output

Input
Input
Input
Input

Input

*1: Never connect these pins. Malfunctions or failures may occur.

10-332

WA470-7

10 Structure and function


System component parts

DEUTSCH-40P (2) [CN-L63]


Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Signal name
Continuous power supply (24 V)
Power supply (24 V)
GND (solenoid)
Battery relay
ECMV R
ECMV 3rd
(*1)
Neutral safety relay
Kickdown switch
(*1)
Continuous power supply (24 V)
Power supply (24 V)
GND (solenoid)
Starting switch ACC signal
E.C.S.S. solenoid
ECMV 4th
(*1)
Parking brake relay
Shift hold switch
Transmission cut-off switch
GND (controller)
Power supply (24 V)
GND (solenoid)
Starting switch ACC signal
Cooling fan EPC
ECMV F
ECMV 1st
(*1)
(*1)
Transmission cut-off set switch
GND (controller)
GND (controller)
GND (controller)
System operating lamp
Cooling fan reverse rotation solenoid
ECMV L/U
ECMV 2nd
(*1)
(*1)
(*1)

Input/output signal
Input
Input

Output
Output
Output

Output
Input

Input
Input

Input
Output
Output

Output
Input
Input

Input

Input
Output
Output
Output

Input

Input
Output
Output
Output

*1: Never connect these pins. Malfunctions or failures may occur.

WA470-7

10-333

10 Structure and function


System component parts

Monitor controller

(HM300-Q180-041-K-00-A)

Monitor controller input and output signals

(WA380-Q180-03C-K-02-A)

AMP-81P [CN-MCM1 A]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

10-334

Signal name
Continuous power supply (24 V)
GND (controller)
GND (controller)
Continuous power supply (24 V)
(*1)
Alternator R signal
(*1)
Fuel level sensor
Signal GND
Auto grease A
Starting switch C signal
Preheating
Signal GND
Right headlamp
Left turn signal lamp
Right turn signal lamp
Signal GND
Engine speed signal (pulse)
Personal lock relay
Alarm buzzer
(*1)
(*1)
(*1)

Input/output signal
Input

Input

Input

Input

Input
Input
Input

Input
Input
Input

Output
Output
Output

WA470-7

10 Structure and function


System component parts

Pin No.
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
WA470-7

Signal name
Starting switch ACC signal
(*1)
(*1)
Brake oil temperature sensor
(*1)
Seat belt
Unit selection
Engine shutdown secondary switch
(*1)
Monitor brightness selector switch
Clearance lamp switch
Auto grease B
Signal GND
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
Starting switch ACC signal
(*1)
(*1)
Battery electrolyte level sensor
(*1)
Coolant level sensor
Headlamp high beam
(*1)
(*1)
(*1)
Air cleaner clogging sensor
(*1)
(*1)
Travel speed signal (pulse)
System operating lamp
Tachograph power supply
(*1)
(*1)
(*1)
External starting signal
(*1)
(*1)
(*1)
(*1)
Load meter subtotal switch
Load meter sub cancel switch
Engine oil level sensor
(*1)
Parking brake oil pressure switch
Rear brake oil pressure switch
Front brake oil pressure switch
(*1)
(*1)

Input/output signal
Input

Output

Input
Input
Input

Input
Input
Input

Input

Input

Input
Input

Input

Output
Output
Output

Input

Input
Input
Input

Input
Input
Input

10-335

10 Structure and function


System component parts

Pin No.
76
77
78
79
80
81

Signal name
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)

Input/output signal

*1: Never connect these pins. Malfunctions or failures may occur.


AMP-40P [CN-MCM1 B]
Pin No.
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121

Signal name
Switch panel built-in buzzer
(*1)
(*1)
(*1)
Load meter printer BUSY
(*1)
(*1)
CAN-L (KOMNET/c)
(*1)
Caution LED power supply
(*1)
(*1)
Load meter printer GND
(*1)
(*1)
CAN-H (KOMNET/c)
Continuous power supply (5.6 V)
GND
(*1)
(*1)
Load meter printer TX
(*1)
(*1)
CAN-L (KOMNET/r)
External starting signal
Power supply (12 V)
LIN
(*1)
(*1)
(*1)
CAN-H (KOMNET/r)
CAN-H (KOMNET/r)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)

Input/output signal
Output

Input

Input/Output

Output

Input/Output
Output

Output

Input/Output
Input
Output
Input/Output

Input/Output
Input/Output

*1: Never connect these pins. Malfunctions or failures may occur.


JAE-8P [CN-MCM2]

10-336

WA470-7

10 Structure and function


System component parts

Pin No.
1
2
3
4
5
6
7
8

Signal name
LC unit LVDS (+)
LC unit LVDS (-)
LC unit GND (power supply return)
LC unit backlight adjustment
LC unit power supply
LC unit ON/OFF control
LC unit backlight ON/OFF control
LC unit temperature sensor

Input/output signal
Output
Output

Output
Output
Output
Output
Output

*1: Never connect these pins. Malfunctions or failures may occur.

Work equipment electric lever

(WA380-PK11-041-K-00-A)

a Do not disassemble this lever since it needs to be adjusted for maintaining the performance after
reassembly.

1. Boot
2. Sensor
WA470-7

10-337

10 Structure and function


System component parts

3. Detent solenoid
4. Connector

Function

10-338

(WA380-PK11-042-K-02-A)

WA470-7

10 Structure and function


System component parts

Operating effort characteristics


"Boom LOWER", "Boom RAISE", and "Bucket TILT" operations

The control lever is held at the three operation stroke ends of "Boom LOWER", "Boom RAISE", and
"Bucket TILT". (Electric detent)
"Bucket DUMP" operation

Free return
Output voltage characteristics
The operating angle (stroke) of the control lever is detected with the sensor and signal voltages are output
to the controller.
Each sensor outputs two signal voltages which are opposite to each other as shown in the figure.

WA470-7

10-339

10 Structure and function


System component parts

10-340

WA470-7

10 Structure and function


System component parts

Throttle position sensor

(WA380-AG22-041-K-00-A)

1. Pedal
2. Connector
3. Sensor

Function

(WA470-AG22-042-K-00-A)

This sensor, installed to the floor top, outputs accelerator signals and idle validation signals according to
the depressing angle of the accelerator pedal.
Accelerator signal
The potentiometer in the sensor detects displacement of the accelerator pedal and outputs the variable
voltage through pin No. 2.
Idle validation signal
The switch in the sensor detects the operating condition of the accelerator pedal. It outputs the signal input
to pin No. 5 from pin No. 4 while the accelerator pedal is released, and outputs the signal input to pin No. 6
from pin No. 4 while the accelerator pedal is depressed.

WA470-7

10-341

10 Structure and function


System component parts

Output characteristics

10-342

WA470-7

10 Structure and function


System component parts

Combination switch

(WA380-CX10-041-K-00-A)

Structure
The directional lever has three positions and the gear speed switch has four positions. The switch itself
does not have a detent mechanism, which is in the combination switch. Each switch is positioned with
pins at two places and fixed to the body with three screws. When each lever is operated to a desired
position, the switch connected with the shaft moves to supply the current to only its circuit.

Function

(WA380-CX10-042-K-00-A)

No.
Name
1 Gear speed switch
2 Directional lever
3

Self-cancel

4
5
6

Turn signal lever


Dimmer switch
Lamp switch

WA470-7

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

10-343

10 Structure and function


System component parts

Operation

(WA380-CX10-044-K-00-A)

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

10-344

WA470-7

10 Structure and function


System component parts

Kickdown switch
2-lever type

1.
2.
3.
4.

(WA380-CP22-001-K-00-A)

(WA380-CP22-041-K-00-A)

Switch A (white harness)


Switch B (yellow harness)
Spring
Harness

Function (WA380-CP22-042-K-00-A)
Switch A (1) installed to the boom control lever knob operates as a kickdown switch to downshift the gear.
Switch A (1) is a momentary type switch, namely, its contacts are closed only while it is pressed.

Hold switch
2-lever type

1.
2.
3.
4.

(WA380-CP25-001-K-00-A)

(WA380-CP25-041-K-00-A)

Switch A (white harness)


Switch B (yellow harness)
Spring
Harness

WA470-7

10-345

10 Structure and function


System component parts

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

10-346

WA470-7

10 Structure and function


System component parts

CAN terminating resistor

(PC220-Q2V1-041-K-00-A)

CAN: Abbreviation for Controller Area Network

1. Connector (with built-in resistor)

Specifications

(PC220-Q2V1-030-K-00-A)

Resistance: 120 z

Function

(PC220-Q2V1-042-K-00-A)

This resistance controls the reflection of the high-frequency signals at the end of CAN communication line
not to generate noise on the CAN communication signals sending and receiving between controllers.
a If this resistance is missing, an error occurs on CAN communication and the machine cannot be
operated.

Front brake oil pressure switch

(WA380-G41C-041-K-00-A)

1. Switch
2. Connector

Specification

(WA380-G41C-030-K-00-A)

Contact type: Normally open


Operating (ON) pressure: 5.39 0.49 MPa {55 5 kg/cm2}
Resetting (OFF) pressure: 4.41 0.49 MPa {45 5 kg/cm2}

Function

(WA380-G41C-042-K-00-A)

This sensor, installed to the inlet port of the front brake accumulator, senses the charge pressure in the
front brake circuit and turns the switch "ON" when the pressure exceeds the specified level.

WA470-7

10-347

10 Structure and function


System component parts

Rear brake oil pressure switch

(WA380-G41E-041-K-00-A)

1. Switch
2. Connector

Specification

(WA380-G41E-030-K-00-A)

Contact type: Normally open


Operating (ON) pressure: 5.39 0.49 MPa {55 5 kg/cm2}
Resetting (OFF) pressure: 4.41 0.49 MPa {45 5 kg/cm2}

Function

(WA380-G41E-042-K-00-A)

This sensor, installed to the inlet port of the rear brake accumulator, senses the charge pressure in the
rear brake circuit and turns the switch "ON" when the pressure exceeds the specified level.

Stop lamp oil pressure switch

(WA380-G7B4-041-K-00-A)

1. Switch
2. Connector

Specification

(WA380-G7B4-030-K-00-A)

Contact type: Normally open


Operating (ON) pressure: 0.59 0.098 MPa {6 1.0kg/cm 2}
Resetting (OFF) pressure: 0.39 0.049 MPa {4 0.5 kg/cm2}

Function

(WA380-G7B4-042-K-00-A)

This sensor, installed to the brake valve, senses the actuating pressure in the brake circuit and turns the
switch "ON" when the pressure exceeds the specified level.

10-348

WA470-7

10 Structure and function


System component parts

Parking brake oil pressure switch

(WA380-GP2F-041-K-00-A)

1. Switch
2. Connector

Specification

(WA380-GP2F-030-K-00-A)

Contact type: Normally open


Operating (ON) pressure: 0.59 0.049 MPa {6 0.5 kg/cm 2}
Resetting (OFF) pressure: 0.39 0.049 MPa {4 0.5 kg/cm2}

Function

(WA380-GP2F-042-K-00-A)

This sensor, installed to the parking solenoid valve of the transmission control valve, senses the actuating
pressure in the parking brake circuit and turns the switch "ON" when the pressure exceeds the specified
level.

WA470-7

10-349

10 Structure and function


Sensor

Sensor

(ALL-E700-001-P-00-A)

Ambient pressure sensor

(ENG-AAP2-041-K-00-A)

1. Connector
2. Sensor

Function

(ENG-AAP2-042-K-00-A)

This sensor, installed to the air intake cover at the engine top side, detects the ambient pressure to output
the corresponding variable voltage.
Output characteristics

10-350

WA470-7

10 Structure and function


Sensor

Engine oil pressure sensor

(PC400-ABK5-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Function

(PC400-ABK5-042-K-00-A)

This oil pressure sensor, installed in the cylinder block, It detects engine oil pressure to output variable
voltage.

Charge (Boost) pressure sensor

(PC400-AAM3-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function

(PC400-AAM3-042-K-00-A)

This sensor is installed to the engine intake manifold. It detects the engine boost pressure to output
signals as a variable voltage.
a a "Chargepressure" is the turbocharged pressure of a turbocharged engine. It is also referred to as a
"boost pressure".

WA470-7

10-351

10 Structure and function


Sensor

Charge (Boost) temperature sensor

Function

(D155-AAM4-041-K-00-A)

(D155-AAM4-042-K-00-A)

The charge (boost) temperature sensor detects the intake air temperature (boost temperature) and sends
it to the engine controller.
The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine
controller applies voltage to the thermistor and detects the temperature by the voltage divided by the
resistance in the computer and the resistance of the thermistor.

Coolant temperature sensor

(ENG-BA87-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Function

(WA470-BA87-042-K-00-A)

This sensor, installed on the cylinder block of the engine, converts the temperature variation into the
resistance variation, and outputs the corresponding signals.

10-352

WA470-7

10 Structure and function


Sensor

Ne (crankshaft) speed sensor

(ENG-AG42-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function

(WA470-AG42-042-K-00-A)

This sensor, installed to the flywheel housing, outputs the pulse voltage according to the rotation of the
gear.

WA470-7

10-353

10 Structure and function


Sensor

Bkup (camshaft) speed sensor

Function

(ENG125-AG62-041-K-00-A)

(ENG125-AG62-042-K-00-A)

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

Common rail pressure sensor

(ENG-AE28-041-K-00-A)

1. Connector
2. Sensor

10-354

WA470-7

10 Structure and function


Sensor

Function

(ENG-AE28-042-K-00-A)

This sensor, installed to the common rail in the engine, detects the fuel pressure to output the
corresponding variable voltage.

EGR valve lift sensor

(ENG125-A9S2-041-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation

1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector

Function

(ENG125-A9S2-042-K-00-A)

The sensor, installed to EGR valve on the engine, detects the EGR valve opening to output the
corresponding variable voltage.
Output characteristics
The relation between stroke and output voltage is as shown in the following graph.

WA470-7

10-355

10 Structure and function


Sensor

KVGT speed sensor

(ENG125-AAQ4-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger

1. Sensor
2. O-ring
3. Connector

Function

(ENG125-AAQ4-042-K-00-A)

This sensor, installed to KVGT in the engine, outputs the pulse voltage by means of the rotation of KVGT
turbine.

10-356

WA470-7

10 Structure and function


Sensor

KVGT position sensor

(ENG-AAQ3-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger

1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector

Function

(ENG-AAQ3-042-K-00-A)

This sensor, installed to KVGT in the engine, detects the location of the nozzle ring which is built in KVGT
to output the corresponding variable voltage.
Output characteristics
The relation between stroke and output voltage is as shown in the following graph.

WA470-7

10-357

10 Structure and function


Sensor

Mass air flow and temperature sensor

(ENG-A96H-041-K-00-A)

1. Connector
2. O-ring
3. Sensor

Function

(ENG-A96H-042-K-00-A)

This sensor is installed to the outlet side of air cleaner, converts the variations of intake air flow and
temperature into the resistance variation, and outputs the corresponding signals.
a The MAF (Mass Air Flow) means the intake air flow.

10-358

WA470-7

10 Structure and function


Sensor

KDPF differential pressure and outlet pressure sensor

(ENG-A9HL-041-K-00-A)

KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

1. High-pressure port
2. Low-pressure port
3. Connector
4. Sensor

Function

(ENG-A9HL-042-K-00-A)

This sensor, installed to KDPF, detects the inlet pressure and outlet pressure of KDPF to output the
corresponding variable voltage.
The output pressure difference is the difference between the KDPF inlet pressure which is detected at
high-pressure port (1) and the KDPF outlet pressure which is detected at low-pressure port (2).
The KDPF outlet pressure is output as a pressure which is detected at low-pressure port (2).

WA470-7

10-359

10 Structure and function


Sensor

KDOC inlet temperature sensor

(ENG-A9HG-041-K-00-A)

KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst

1. Sensor
2. Connector

Function

(ENG-A9HG-042-K-00-A)

This sensor, installed to the inlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.

KDOC outlet temperature sensor

(ENG-A9HH-041-K-00-A)

KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst

1. Sensor
2. Connector

Function

(ENG-A9HH-042-K-00-A)

This sensor, installed to the outlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.

10-360

WA470-7

10 Structure and function


Sensor

KDPF outlet temperature sensor

(ENG-A9HJ-041-K-00-A)

KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

1. Sensor
2. Connector

Function

(ENG-A9HJ-042-K-00-A)

This sensor, installed to the outlet side of KDPF, converts the temperature variation into the resistance
variation, and outputs the corresponding signals.

Crankcase pressure sensor

(ENG-A18C-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Function

(ENG-A18C-042-K-00-A)

This sensor, installed to the inlet side of KCCV head portion, detects the crankcase pressure (blowby
pressure) to output the corresponding variable voltage.

WA470-7

10-361

10 Structure and function


Sensor

Engine oil level sensor

(ENG-AB45-041-K-00-A)

1. Connector
2. Bracket
3. Float
4. Switch

Function

(ENG-AB45-042-K-00-A)

This sensor, installed on the side face of the oil pan, turns OFF by the lowered float, if the oil level
becomes lower than specified.

Dosing fuel pressure sensor

(PC400-A9JC-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function

(PC400-A9JC-042-K-00-A)

This sensor, which is installed to the dosing fuel solenoid valve assembly, detects the pressure of the fuel
supplied to output the corresponding variable voltage.

10-362

WA470-7

10 Structure and function


Sensor

Transmission input speed sensor

1.
2.
3.
4.

(WA470-CNB1-041-K-00-A)

Wire
Magnet
Housing
Connector

Function

(WA470-CNB1-042-K-00-A)

This sensor, installed to the left side of the transmission rear case, outputs the pulse voltage according to
the rotation of the gear.

WA470-7

10-363

10 Structure and function


Sensor

Transmission output shaft speed sensor

1.
2.
3.
4.
5.

(WA380-CNA1-041-K-00-A)

Wire
Magnet
Terminal
Housing
Connector

Function

(WA470-CNA1-042-K-00-A)

This sensor, installed to the right side of the transmission front case, outputs the pulse voltage according
to the rotation of the gear.

Cooling fan speed sensor

(D65-B750-041-K-00-A)

1. Sensor
2. Connector

Function

(D65-B750-042-K-00-A)

This sensor is installed to the cooling fan motor.


This sensor detects the gear speed and outputs corresponding pulse signals.

10-364

WA470-7

10 Structure and function


Sensor

Torque converter oil temperature sensor

(WA380-CDK4-041-K-00-A)

1. Connector
2. Plug
3. Thermistor

Function

(WA380-CDK4-042-K-00-A)

This sensor is installed to the block on the right side of the transmission rear case. It outputs a resistance
change signal of the thermistor for the temperature change.

Transmission oil temperature sensor

(WA380-CH18-041-K-00-A)

1. Connector
2. Plug
3. Thermistor

Function

(WA470-CH18-042-K-00-A)

This sensor, installed to the transmission rear case, outputs a resistance change signal of the thermistor
for the temperature change.

WA470-7

10-365

10 Structure and function


Sensor

Hydraulic oil temperature sensor

(PC-PMT1-041-K-00-A)

1. Connector
2. Plug
3. Thermistor

Function

(WA380-PMT1-042-K-00-A)

This sensor is installed to the block of the hydraulic tank return line. It outputs a resistance change signal
of the thermistor for the temperature change.

Brake oil temperature sensor

(WA380-GGD1-041-K-00-A)

1. Connector
2. Plug
3. Thermistor

Function

(WA380-GGD1-042-K-00-A)

This sensor is installed to the rear axle. It outputs a resistance change signal of the thermistor for the
temperature change.

10-366

WA470-7

10 Structure and function


Sensor

Torque converter inlet pressure sensor

(WA470-CDL5-041-K-00-A)

1. Sensor
2. Lead wire
3. Connector

Function

(WA470-CDL5-042-K-00-A)

This sensor, installed to the block on the left side of the transmission rear case, detects the torque
converter in let pressure and outputs it as a variable voltage.
Output characteristics

WA470-7

10-367

10 Structure and function


Sensor

Torque converter outlet pressure sensor

(WA470-CDL6-041-K-00-A)

1. Sensor
2. Lead wire
3. Connector

Function

(WA470-CDL6-042-K-00-A)

This sensor, installed to the block on the right side of the transmission rear case, detects the torque
converter outlet pressure and outputs it as a variable voltage.
Output characteristics

10-368

WA470-7

10 Structure and function


Sensor

Oil pressure sensor of work equipment pump

(WA380-PPD1-041-K-00-A)

1. Plug
2. Sensor
3. Connector

Function

(WA380-PPD1-042-K-00-A)

This sensor is installed to the work equipment control valve. It senses the pump delivery pressure and
outputs a variable voltage for it.
Output characteristics

WA470-7

10-369

10 Structure and function


Sensor

Steering pump oil pressure sensor

(WA380-F7C1-041-K-00-A)

1. Plug
2. Sensor
3. Connector

Function

(WA380-F7C1-042-K-00-A)

This sensor is installed to the block of the steering pump delivery line. It senses the pump delivery
pressure and outputs a variable voltage for it.
Output characteristics

10-370

WA470-7

10 Structure and function


Sensor

Emergency steering pump pressure sensor

(WA380-F9SA-041-K-00-A)

1. Plug
2. Sensor
3. Connector

Function

(WA380-F9SA-042-K-00-A)

This sensor, installed to the block of the emergency steering pump discharge port, detects the pump
discharge pressure and outputs a variable voltage for it.
Output characteristics

WA470-7

10-371

10 Structure and function


Sensor

Lift cylinder bottom oil pressure sensor

(WA380-L261-041-K-00-A)

1. Plug
2. Sensor
3. Connector

Function

(WA380-L261-042-K-00-A)

This sensor is installed to the line piping of the lift cylinder bottom. It senses the oil pressure in the cylinder
bottom and outputs a variable voltage for it.
Output characteristics

10-372

WA470-7

10 Structure and function


Sensor

Transmission cut-off oil pressure sensor

(WA380-CP61-041-K-00-A)

1. Sensor
2. Lead wire
3. Connector

Function

(WA380-CP61-042-K-00-A)

This sensor is installed to the front brake circuit tube under the floor. It senses the brake actuating
pressure and outputs a variable voltage.
Output characteristics

WA470-7

10-373

10 Structure and function


Sensor

Coolant level sensor

(WA380-B252-041-K-00-A)

1. Reservoir tank
2. Float
3. Sensor
4. Connector

Function

(WA380-B252-042-K-00-A)

This sensor is installed to the ladder on the right side of the machine. When the coolant level lowers below
the specified level, the float of this sensor lowers and turns the switch "OFF".

10-374

WA470-7

10 Structure and function


Sensor

Fuel level sensor

1.
2.
3.
4.
5.
6.
7.

(WA380-AD41-041-K-00-A)

Connector
Float
Arm
Body
Spring
Contact
Spacer

Function

(WA380-AD41-042-K-00-A)

This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level. The movement of the float moves the variable resistor through the arm and the resistance
change is converted into the change of the power supply voltage, which is output as a signal voltage.

WA470-7

10-375

10 Structure and function


Sensor

Air cleaner clogging sensor

(WA380-A968-041-K-00-A)

1. Boss
2. Switch
3. Conduit
4. Wire
5. Connector

Function

(PC-A968-042-K-00-A)

This sensor is installed on the air cleaner outlet side. The switch is turned to ON position, if the air
cleaner is clogged and the pressure level drops to the specified level (negative pressure).

10-376

WA470-7

10 Structure and function


Sensor

Boom potentiometer

(WA380-L6W6-041-K-00-A)

1. Shaft
2. Housing
3. Bearing
4. Brush
5. Variable resistor
6. Connector

Function

(WA380-L6W6-042-K-00-A)

This potentiometer is installed to the front frame. The movement of the boom moves the variable resistor
through the link installed to the boom and the resistance change is converted into the change of the power
supply voltage, which is output as a signal voltage.
Output characteristics

WA470-7

10-377

10 Structure and function


Sensor

Bucket potentiometer sensor

(WA380-LENB-041-K-00-A)

1. Shaft
2. Housing
3. Bearing
4. Brush
5. Variable resistor
6. Connector

Function

(WA380-LENB-042-K-00-A)

This potentiometer is installed to the pin connecting bell crank and boom. The movement of the bucket
moves the variable resistor through the link installed to the bell crank and the resistance change is
converted into the change of the power supply voltage, which is output as a signal voltage.
Output characteristics

10-378

WA470-7

SHOP MANUAL

WHEEL LOADER
WA470-7
Model

Serial Number

WA470-7

10001 and up

20 Standard value tables


4 20 Standard value tables

WA470-7

20-1

20 Standard value tables


Table of contents

Table of contents

(ALL-0310-002-A-00-A)

20 Standard value tables.................................................................................................................... 20-1


Table of contents ........................................................................................................................ 20-2
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
Standard value table for electrical system............................................................................. 20-18

20-2

WA470-7

20 Standard value tables


Standard value table for engine

Standard service value table


Standard value table for engine

(ALL-A000-001-K-00-A)
(WA470_7-A000-033-K-00-A)

Engine

Classification

Machine model
Engine

Item

WA470-7
SAA6D125E-6

Measurement condition

Coolant temperature: 60 to High idle


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

High idle
Low idle

Whole speed range (inside oil pan)

Between crankshaft pulley and alternator


pulley
Alternator belt
Deflection when pressed with finger at 59
tension
N {6 kg}

WA470-7

Unit

Standard value
for new
machine

Repair limit

rpm
rpm
rpm

2,170 50
800 (+ 50/-0)
2,000

kPa
{mmHg}

Min. 153
{Min. 1,150}

127
{950}

Bosch
index

Max. 1.0

Bosch
index

Max. 1.5

Max. 0.5

Max. 0.5

0.33
0.71

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

kPa
{mmH2O}

Max. 1.96
{Max. 200}

3.92
{400}

MPa
{kg/cm2}

0.29 to 0.69
{3.0 to 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

MPa
{kg/cm2}
MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}
Min. 1.18
{Min. 12.0}

1.43
{14.6}
1.18
{12.0}

90 to 110

120

mm

13 to 16

13 to 16

Bosch
index
Bosch
index
mm
mm

20-3

20 Standard value tables


Standard value table for engine

Classification

Machine model
Engine

Item

Air
conditioner
compressor
belt tension

WA470-7
SAA6D125E-6

Measurement condition

Unit

Standard value
for new
machine

Repair limit

Between compressor pulley and fan pulley


Deflection when pressed with finger at 98
N {10 kg}

mm

25 to 26

25 to 26

Others

Classification

Machine model
Engine

Item

Unit

MPa
Coolant temperature: 60 to 102C
Engine at high idle
{kg/cm2}
Engine speed:
1,600 rpm
Engine speed:
1,700 rpm
Fuel return
Coolant temperature: 60 to Engine speed:
rate from
cc/min
1,800 rpm
102C
injector
Engine speed:
1,900 rpm
Engine speed:
2,000 rpm
Coolant temperature: 60 to 102C
Leakage from Torque converter oil temperature: 60 to 80
cc/min
pressure
C
limitter
Torque converter stall
compression
pressure

Engine

Measurement condition

WA470-7
SAA6D125E-6

20-4

Standard value
for new
machine

Repair limit

0.15 to 0.3
{1.5 to 3.0}

0.15 to 0.3
{1.5 to 3.0}

Max. 960

Max. 1,020

Max. 1,080

Max. 1,140

Max. 1,200

Max. 10

WA470-7

20 Standard value tables


Standard value table for machine

Standard value table for machine

(WA470_7-0000-033-K-00-A)

Directional lever
Machine model
Item
Operating
effort

Stroke

Measurement condition

NEUTRAL o Engine stopped


FORWARD/ Measure at center of lever
REVERSE
knob stem.
Measure at 10 mm from lever
top.
NEUTRAL o
FORWARD/ Tilt angle of steering column:
Deepest position (monitor
REVERSE
side)

WA470-7
Standard value
Repair limit
Unit
for new machine
9.0 1.0
9.0 1.7
N {kg}
{0.92 0.1}
{0.92 0.17}

mm

39 6

39 12

Gear speed switch


Machine model
Item

Measurement condition
1st o 2nd

Operating
effort

2nd o 3rd
3rd o 4th

Rotation
angle

WA470-7

1st io 2nd
2nd io 3rd
3rd io 4th

Engine stopped

WA470-7
Standard value
Repair limit
Unit
for new machine
0.39 0.03
0.36 0.12
{4 0.3}
{3.7 1.2}
0.39 0.03
0.36 0.12
N {kg}
{4 0.3}
{3.7 1.2}
0.39 0.03
0.36 0.12
{4 0.3}
{3.7 1.2}
20 2
20 4
deg
20 2
20 4
20 2
20 4

20-5

20 Standard value tables


Standard value table for machine

Work equipment control lever


Machine model
Item

Measurement condition

Unit

HOLD o
RAISE (*1)
RAISE (*2) o
HOLD
HOLD o
LOWER (*1)
LOWER o
HOLD
LOWER o
FLOAT

Operating effort

Boom

Engine speed: Low idle

N {kg}

FLOAT (*2) o
HOLD
HOLD o
DUMP
HOLD o TILT
(*1)

Bucket

TILT (*2) o
HOLD
HOLD io
RAISE (*2)
HOLD io
LOWER (*1)
HOLD io Engine speed: Low idle
FLOAT
HOLD o
DUMP
HOLD o TILT
(*2)

Stroke

Boom

Bucket

WA470-7
Standard value
Repair limit
for new machine
6.5 to 11.4
Max. 17.1 {1.74}
{0.66 to 1.16}
9.8 to 20.6
4.9 to 30.5
{1.0 to 2.10}
{0.5 to 3.11}
6.5 to 11.4
Max. 17.1 {1.74}
{0.66 to 1.16}

mm

11.4 to 20.2
{1.16 to 2.06}
9.8 to 20.6
{1.0 to 2.0}
7.5 to 17.7
{0.76 to 1.80}
6.5 to 11.4
{0.66 to 1.16}
9.8 to 20.6
{1.0 to 2.10}

Max. 30.3 {3.09}


4.9 to 30.5
{0.5 to 3.11}
Max. 26.6 {2.7}
Max. 17.1 {1.74}
4.9 to 30.5
{0.5 to 3.11}

44.5 2.2

44.5 4.4

31.2 to 37.9

Min. 31.2

44.5 2.2

44.5 4.4

44.5 2.2

44.5 4.4

44.5 2.2

44.5 4.4

*1: Position before detent


*2: Position of detent
Steering wheel
Machine model
Item
Play

Operating effort
No. of turns (not including
play)
Low idle
Operating
High idle
time

20-6

Measurement condition
Engine stopped
Machine facing straight to
front
Flat, level, straight, and dry
paved road
Engine speed: Low idle
(bucket empty)
Engine speed: High idle
Left lock to right lock
Start engine.
Hydraulic oil temperature: 45
to 55C
Left lock to right lock

Unit

WA470-7
Standard value
Repair limit
for new machine

mm

Max. 20

Max. 40

N {kg}

9.4 to 15.6
{0.96 to 1.6}

9.4 to 15.6
{0.96 to 1.6}

times

3.5 0.4

3.5 0.4

4.1 0.4

4.1 0.4

3.5 0.4

3.5 0.4

sec.

WA470-7

20 Standard value tables


Standard value table for machine

Accelerator pedal
Machine model
Item

Measurement condition
Start engine.
Measure at 150 mm away
from pedal fulcrum

Depressing effort
NEUTRAL
(a1)

Depressing
angle

Max. (a2)

a For details, see Fig. A at end


of this section
Start engine.

Unit
N {kg}

deg.

WA470-7
Standard value
Repair limit
for new machine
45.5 to 58.8
{4.64 to 6.00}

45 2

17 2

Brake pedal
Machine model
Item

Measurement condition

Depressing effort
NEUTRAL
(a1)
Max. (a2)

Depressing
angle
Play

a For details, see Fig. B at the


end of this section
Engine speed: Low idle
Hydraulic oil temperature: 45
to 55C

WA470-7
Standard value
Repair limit
Unit
for new machine
323 30
Min. 264
N {kg}
{32.9 3.0}
{Min. 26.9}
deg.

53

15 (+1 / 0)
51

Tire
Machine model
Item
Fitting of wheel lock ring
Clearance of wheel lock
ring

Measurement condition
A
a For details, see Fig. C at end
B
of this section.
C Tire inflation pressure:
Specified pressure

Unit

mm

WA470-7
Standard value
Repair limit
for new machine
Max. 2.5
Max. 4.0
2 to 10

Engine speed
Machine model
Item
Torque converter stall
Hydraulic stall
Bucket CURL relief
Torque converter stall and
hydraulic relief speed
Bucket CURL relief

WA470-7

Measurement condition
Hydraulic oil
temperature: 60 to
102C
Torque converter
oil temperature: 60
to 80C
Hydraulic oil
temperature: 45 to
55C

E mode
P mode
E mode
P mode
E mode
P mode

Unit

rpm

WA470-7
Standard value
Repair limit
for new machine
1,710 50
1,710 100
1,785 50
1,785 100
1,825 100
1,825 200
2,110 100
2,110 200
1,555 100
1,555 200
1,645 100

1,645 200

20-7

20 Standard value tables


Standard value table for machine

Transmission and torque converter


Machine model
Item

Measurement condition

Unit

Low idle
Main relief oil pressure

Torque converter relief (inlet)


pressure
Torque converter outlet
pressure

Torque
converter oil
temperature: 60
to 80C

Lubricating oil pressure

Engine
speed:
2,000 rpm
Engine
speed:
2,000 rpm
Engine
speed:
2,000 rpm
Engine
speed:
2,000 rpm

MPa
{kg/
cm2}

1st, 2nd
ECMV output
(clutch)
Oil pressure

3rd, 4th
Forward,
Reverse

Torque converter oil


temperature: 60 to 80C
Engine speed: 2,000 rpm
Manual switch: ON

Lockup

WA470-7
Standard value
Repair limit
for new machine
2.32 0.2
2.32 0.2
{23.5 2.0}
{23.5 2.0}
2.55 0.2
{26.0 2.0}

2.55 0.2
{26.0 2.0}

0.1 to 0.88
{1.0 to 9.0}

0.1 to 0.88
{1.0 to 9.0}

0.06 to 0.71
{0.6 to 7.1}

0.06 to 0.71
{0.6 to 7.1}

0.175 0.075
{1.75 0.75}

0.175 0.075
{1.75 0.75}

2.35 0.15
{24 1.5}
2.30 0.15
{23.5 1.5}
2.06 0.15
{21.0 1.5}
1.66 0.15
{17.0 1.5}

2.35 0.15
{24 1.5}
2.30 0.15
{23.5 1.5}
2.06 0.15
{21.0 1.5}
1.66 0.15
{17.0 1.5}

Steering
Machine model
Item
Steering relief pressure

Steering control pressure

20-8

Measurement condition
Hydraulic oil temperature: 45
to 55C
Engine speed: High idle
Hydraulic oil temperature: 45
to 55C
Engine speed: Low idle
Steering wheel: Free

Unit

MPa
{kg/
cm2}

WA470-7
Standard value
Repair limit
for new machine
24.5 (+1.23 /
24.5 1.23
-2.45)
{250 12.5}
{250 (+12.5 /
-25)}
1.25 to 1.45
{12.7 to 14.8}

1.15 to 1.55
{11.7 to 15.3}

WA470-7

20 Standard value tables


Standard value table for machine

Accumulator
Machine model
Item

Charge cut-in pressure

Charge cut-out pressure

WA470-7

Measurement condition
Checking to
be
performed
when the
Engine
brake oil
speed: Low
pressure
idle
warning
Hydraulic
lamp goes
oil
off
tempera Measure
ture: 45 to
when brake
55C
oil pressure
starts
lowering
after rising.

Unit

WA470-7
Standard value
Repair limit
for new machine

5.9 (+0.5 / 0)
{60 (+5 / 0)}

5.9 (+0.98 /
-0.5)
{60 (+10 / -5)}

9.8 (+0.98 / 0)
{100 (+10 / 0)}

9.8 (+1.5 / -0.5)


{100 (+15 / -5)}

MPa
{kg/
cm2}

20-9

20 Standard value tables


Standard value table for machine

Power train
Machine model
Item

Measurement condition

P mode

Forward

E mode
Travel speed
(bucket empty)
(Lockup clutch: OFF)
P mode

Reverse

E mode

P mode

Forward

E mode
Travel speed
(bucket empty)
(Lockup clutch: ON)
P mode

Reverse

E mode

20-10

1st speed
2nd
speed
3rd
speed
4th speed
1st speed
2nd
speed
3rd
speed
4th speed
1st speed
2nd
speed
3rd
speed
4th speed
1st speed
2nd
speed
3rd
speed
4th speed
1st speed
2nd
speed
3rd
speed
4th speed
1st speed
2nd
speed
3rd
speed
4th speed
1st speed
2nd
speed
3rd
speed
4th speed
1st speed
2nd
speed
3rd
speed
4th speed

Unit

km/h

km/h

WA470-7
Standard value
Repair limit
for new machine
7.6 0.4
7.6 0.5
13.1 0.7

13.1 0.9

22.9 1.1

22.9 1.6

36.2 1.8
6.6 0.3

36.2 2.5
6.6 0.5

11.4 0.6

11.4 0.8

19.6 1.0

19.6 1.4

30.8 1.5
7.9 0.4

30.8 2.2
7.9 0.6

13.5 0.7

13.5 0.9

23.6 1.2

23.6 1.7

37.3 1.9
6.8 0.3

37.3 2.6
6.8 0.5

11.7 0.6

11.7 0.8

20.2 1.0

20.2 1.4

31.7 1.6
7.6 0.4

31.7 2.2
7.6 0.5

13.2 0.7

13.2 0.9

23.6 1.2

23.6 1.7

38.3 1.9
6.6 0.3

38.3 2.7
6.6 0.5

11.5 0.6

11.5 0.9

20.4 1.0

20.4 1.5

33.1 1.7
7.9 0.4

33.1 2.4
7.9 0.6

13.7 0.7

13.7 0.9

24.3 1.2

24.3 1.7

39.0 2.0
6.8 0.3

39.0 2.8
6.8 0.5

11.8 0.6

11.8 0.9

21.1 1.1

21.1 1.6

34.2 1.7

34.2 2.4

WA470-7

20 Standard value tables


Standard value table for machine

Wheel brake
Machine model
Item
Brake oil pressure

Drop of brake oil pressure

Performance

Measurement condition
Hydraulic oil temperature: 45
to 55C
Engine stopped
Measure lowering of oil
pressure after depressing
brake pedal for 5 min with 4.9
MPa {50 kg/cm2}
Tire inflation pressure:
Specified pressure
Flat, level, straight, and dry
paved road
Travel speed at beginning of
brake application 20 km/h:
Delay in applying brakes
Max. 0.1sec.
Brake pedal depressing
force:
Specified depressing effort
323 30 N {32.9 3 kg}
Measure braking distance.
Oil pressure: 4.9 MPa {50 kg/
cm2}
Pedal depressed completely

Wear of disc

Unit

MPa
{kg/
cm2}

WA470-7
Standard value
Repair limit
for new machine
4.8 0.4
Min. 4.2
{48.9 4.1}
{Min. 42.7}
Max. 0.49
Max. {5.0}

Max. 0.49
Max. {5.0}

Max. 5

Max. 5

mm

Protrusion of
shaft
0

Shaft protrusion
reaches wear
limit position
[Max. 2.4 mm]

Parking brake
Machine model
Item
Parking brake oil pressure
Parking brake solenoid valve
basic pressure

Performance

Measurement condition
Torque converter oil
temperature: 60 to 80C
Engine speed: Low idle
Parking brake: OFF
Tire inflation pressure:
Specified pressure
Flat paved road with a slope
of 1/5 (11 degrees 20') and
dry surface
Set machine in operating
condition.

Unit
MPa
{kg/
cm2}

WA470-7
Standard value
Repair limit
for new machine
Min. 2.32
Min. 2.32
{Min. 23.5}
{Min. 23.5}
Min. 2.32
Min. 2.32
{Min. 23.5}
{Min. 23.5}

Stopped

Stopped

mm

3.2 0.08

2.97

a For measuring posture, see


Figs. D and E at the end of
this section
Disc thickness

WA470-7

20-11

20 Standard value tables


Standard value table for machine

Work equipment EPC


Machine model
Item
Work equipment EPC valve
source pressure

Measurement condition

Unit

Hydraulic oil temperature: 45


to 55C
Engine speed: High idle

Boom RAISE
Work
equipment
EPC valve
output
pressure

Boom FLOAT

Hydraulic oil temperature: 45


to 55C
Boom LOWER Engine speed: High idle
Work equipment control lever
full operation
Bucket DUMP
Bucket TILT

20-12

MPa
{kg/
cm2}

WA470-7
Standard value
Repair limit
for new machine
3.72 (+0.2 /
3.72 (+0.2 / 0)
-0.2)
{38 (+2 / 0)}
{38 (+2 / -2)}
2.94 0.16
2.94 0.16
{30.0 1.6}
{30.0 1.6}
3.37 0.17
3.37 0.17
{34.4 1.7}
{34.4 1.7}
1.99 0.14
1.99 0.14
{20.3 1.4}
{20.3 1.4}
2.75 0.14
2.75 0.14
{28.0 1.4}
{28.0 1.4}
3.1 0.17
3.1 0.17
{31.5 1.7}
{31.5 1.7}

WA470-7

20 Standard value tables


Standard value table for machine

Work equipment
Machine model
Item

Measurement condition

Work equipment relief


pressure

Unload pressure

LS differential pressure

Work equipment speed

Boom RAISE

Boom LOWER

Bucket full
stroke

Bucket from
level position

Dump
Tilt back

Tilt back

Hydraulic drift

Retraction of lift cylinder


rod

Retraction of bucket
cylinder rod

Hydraulic oil temperature: 45


to 55C
Engine speed: High idle
Hydraulic oil temperature: 45
to 55C
Engine speed: High idle
Work equipment control
lever: NEUTRAL
Hydraulic oil temperature: 45
to 55C
Engine speed: High idle
Boom control lever: In
halfway
Hydraulic oil
E mode
temperature: 45 to P mode
55C
E mode
Engine speed:
High idle
Apply no load
a For measuring
posture, see Figs.
F and G at end of
this section
Hydraulic oil
temperature: 45 to
55C
Engine speed:
High idle
Apply no load

Unit

MPa
{kg/
cm2}

P mode

E mode
P mode
E mode
P mode
E mode

a For measuring
posture, see Figs. P mode
H and J at the end
of this section
Hydraulic oil temperature: 45
to 55C
Stop the engine and leave it
for 5 minutes, then take
measurement for 15 minutes.
Apply no load to bucket and
set boom and bucket in level
position.

sec.

WA470-7
Standard value
Repair limit
for new machine
34.3 (+1.8 /
34.3 1.77
-4.4)
{350 18}
{350 (+18 / -45)}
1.72 to 3.43
{17.5 to 35}

1.72 to 3.43
{17.5 to 35}

1.37 0.1
{14 1}

1.37 0.2
{14 2}

6.3 0.5
5.9 0.5
3.1 0.5

Max. 8.4
Max. 7.7
Max. 4.4

3.1 0.5

Max. 4.0

1.8 0.3
1.6 0.3
2.6 0.3
2.4 0.3
1.6 0.3

Max. 2.4
Max. 2.1
Max. 3.5
Max. 3.2
Max. 2.1

1.5 0.3

Max. 2.0

Max. 30

Max. 36

Max. 20

Max. 24

mm

a For measuring posture, see


Fig. K at the end of this
section

WA470-7

20-13

20 Standard value tables


Standard value table for machine

Hydraulic fan
Machine model
Item

Cooling fan maximum speed

Cooling fan minimum speed

Cooling fan drive pressure

Cooling fan reverse solenoid


output pressure

Measurement condition
Engine high idle
Coolant temperature: Min.
95C
Hydraulic oil temperature:
Min. 95C
Torque converter oil
temperature: Min. 105C
Engine low idle
Coolant temperature: Max.
70C
Hydraulic oil temperature:
Max. 70C
Torque converter oil
temperature: Max. 80C
Air conditioner: OFF
Engine high idle
Fan 100% mode (*)
Hydraulic oil temperature:
50C
When cooling fan is reversed
Engine high idle
Hydraulic oil temperature:
50C

Unit

rpm

MPa
{kg/
cm2}

WA470-7
Standard value
Repair limit
for new machine

1,300 100

1,300 200

Air conditioner:
OFF
175 50
Air conditioner:
ON
727 50

Air conditioner:
OFF
175 100
Air conditioner:
ON
727 100

14.3 1.4
{146 15}

14.3 2.1
{146 22}

2.51 0.35
{25.6 3.6}

2.51 0.53
{25.6 5.4}

*: Fan speed becomes 100% when it is set to reverse mode.

20-14

WA470-7

20 Standard value tables


Standard value table for machine

Machine posture and procedure for measuring performance

(WA380_7-0000-321-K-00-A)

a Fig. A

a Fig. B

a Fig. C

WA470-7

20-15

20 Standard value tables


Standard value table for machine

a Fig. D

a Fig. E

a Fig. F

a Fig. G

20-16

WA470-7

20 Standard value tables


Standard value table for machine

a Fig. H

a Fig. J

a Fig. K

WA470-7

20-17

20 Standard value tables


Standard value table for electrical system

Standard value table for electrical system


Controller

(WA470-RA1E-033-K-00-A)

Equipment name

Engine
controller

Continuous
power
supply
voltage

Continuous
power
supply
voltage
Work
equipment
controller
Solenoid
power
supply
voltage

Continuous
power
supply
voltage
Transmission
controller
Solenoid
power
supply
voltage

Monitor
controller

(D155-E000-001-P-00-A)

Continuous
power
supply
voltage

Procedure, measuring location, criteria and remarks


1. Turn starting switch to the OFF position, and set battery disconnect switch to
the OFF position.
2. Insert T-adapter into EC3.
3. Set battery disconnect switch to ON position.
4. Measure voltage with starting switch at OFF position and when starting
engine.
Between EC3 (1) and (21)
20 to 30 V
Between EC3 (2) and (22)
20 to 30 V
Voltage
Between EC3 (11) and (31)
20 to 30 V
Between EC3 (12) and (32)
20 to 30 V
1.
2.
3.
4.
5.

1.
2.
3.
4.
5.

1.
2.
3.
4.
5.

1.
2.
3.
4.
5.

1.
2.
3.
4.
5.

Turn starting switch to OFF position.


Turn the battery disconnect switch to OFF position.
Insert T-adapter into connector L73.
Turn battery disconnect switch to ON position.
Turn starting switch to ON position.
Between L73 (1) and each of (21), (31), (32),
Voltage
and (33), and between L73 (11) and each of
(21), (31), (32), and (33)
Turn starting switch to OFF position.
Turn the battery disconnect switch to OFF position.
Insert T-adapter into connector L73.
Turn battery disconnect switch to ON position.
Turn starting switch to ON position.
Between L73 (2) and (21)
Between L73 (12) and (31)
Voltage
Between L73 (22) and (32), and between L73
(22) and (33)
Turn starting switch to OFF position.
Turn the battery disconnect switch to OFF position.
Insert T-adapter into connector L63.
Turn battery disconnect switch to ON position.
Turn starting switch to ON position.
Between L63 (1) and each of (21), (31), (32),
Voltage
and (33), and between L63 (11) and each of
(21), (31), (32), and (33)
Turn starting switch to OFF position.
Turn the battery disconnect switch to OFF position.
Insert T-adapter into connector L63.
Turn battery disconnect switch to ON position.
Turn starting switch to ON position.
Between L63 (2) and (21)
Between L63 (12) and (31)
Voltage
Between L63 (22) and (33), and between L63
(32) and (33)

20 to 30 V

20 to 30 V
20 to 30 V
20 to 30 V

20 to 30 V

20 to 30 V
20 to 30 V
20 to 30 V

Turn starting switch to OFF position.


Turn the battery disconnect switch to OFF position.
Disconnect connector MCM1 A, and connect T-adapter to female side.
Turn battery disconnect switch to ON position.
Turn starting switch to ON position.
Between MCM1 A (female) (1) and (2)
20 to 30 V
Voltage
Between MCM1 A (female) (4) and (3)
20 to 30 V

1. Check that system operating lamp does not light up, and then set battery
disconnect switch to OFF position.

20-18

WA470-7

20 Standard value tables


Standard value table for electrical system

Equipment name
2.
3.
4.
5.

Procedure, measuring location, criteria and remarks


Turn starting switch to OFF position.
Disconnect connector MCM1 A, and connect T-adapter to female side.
Turn battery disconnect switch to ON position.
Turn starting switch to ON position.

a Check that engine shutdown secondary switch is at lower (OFF) position.


Between MCM1 A (female) (43) and (2)
20 to 30 V
Voltage
Between MCM1 A (female) (31) and (2)
20 to 30 V
Between MCM1 A (female) (24) and (3)
20 to 30 V

WA470-7

20-19

20 Standard value tables


Standard value table for electrical system

Engine control

(WA470-AG10-033-K-00-A)

Equipment name

Procedure, measuring location, criteria and remarks

EGR valve solenoid

1. Turn starting switch to OFF position.


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

KVGT solenoid

1. Turn starting switch to OFF position.


2. Disconnect connector VGT-SOL and connect T-adapter to male side.
Resistance Between VGT-SOL (male) (1) and (2)
5 to 10 z
1. Turn starting switch to OFF position.
2. Disconnect connector TWTR, and connect to socket to male side.

Coolant temperature
sensor

a Regard coolant temperature sensor as normal if its resistance is 700 z to 37


kz when coolant temperature is min. 0C.
0C
30 to 37 kz
Between TWTR (male) (A) and
25C
9.3
to 10.7 kz
(B)
50C
3.2 to 3.8 kz
a Coolant temperature80C
1.0 to 1.3 kz
Resistance
Resistance characteristics
95C
700 to 800 z
Whole coolant
Between TWTR (male) (B) and
temperature
Min. 1 Mz
ground
range
1. Turn starting switch to OFF position.
2. Disconnect connector TIM and connect socket to male side.

Charge temperature
sensor

a Regard charge temperature sensor as normal if its resistance is 280 z to


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

Intake air temperature


sensor

1. Turn starting switch to OFF position.


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

KDOC inlet temperature


sensor

1. Turn starting switch to OFF position.


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

KDOC outlet temperature


sensor

1. Turn starting switch to OFF position.


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

20-20

WA470-7

20 Standard value tables


Standard value table for electrical system

Equipment name

Procedure, measuring location, criteria and remarks


50C
7.8 to 12.2 kz
100C
3.2 to 4.5 kz
a Temperature-Resistance
400C
200 to 240 z
characteristics
700C
64 to 69 z
Between TEMP2 (female) (1) and ground
Min. 1 Mz

KDPF outlet temperature


sensor

1. Turn starting switch to OFF position.


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

Charge (Boost) pressure


sensor

1. Turn starting switch to OFF position.


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

Engine oil pressure


sensor

Ambient pressure sensor

Common rail pressure


sensor

Crankcase pressure
sensor

KDPF differential
pressure sensor

Dosing fuel pressure


sensor

KDPF outlet pressure


sensor

Turbocharger speed
sensor

WA470-7

Sensor output

0.3 to 4.7 V

Sensor output

0.3 to 4.7 V

Sensor output

0.3 to 4.7 V

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector PFUEL or J2.
3. Turn starting switch to ON position.
Between PFUEL (2) and (3) or
Voltage
Sensor output
J2 (55) and (21)

0.2 to 4.6 V

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector PCCV.
3. Turn starting switch to ON position.
Voltage
Between PCCV (3) and (2)

0.3 to 4.7 V

1. Turn starting switch to OFF position.


2. Insert T-adapters into connector J1 or POIL.
3. Turn starting switch to ON position.
Between J1 (2) and (59) or
Voltage
between POIL (3) and (2)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J1 or PAMB.
3. Turn starting switch to ON position.
Between J1 (16) and (59) or
Voltage
between PAMB (3) and (2)

Sensor output

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector E25.
3. Turn starting switch to ON position.
Voltage
Between E25 (2) and (1)

0.5 to 4.5 V

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector PDOSER.
3. Turn starting switch to ON position.
Voltage
Between PDOSER (3) and (2)

0.5 to 4.5 V

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector E25.
3. Turn starting switch to ON position.
Voltage
Between E25 (3) and (1)

0.5 to 4.5 V

1. Turn starting switch to OFF position.


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

20-21

20 Standard value tables


Standard value table for electrical system

Equipment name

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.


Accelerator pedal (throttle 2. Insert T-adapter into connector PD.
sensor)
3. Turn starting switch to ON position.
Voltage
Between PD (2) and (1)

EGR valve lift sensor

KVGT position sensor

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector J2 or SEGR.
3. Turn starting switch to ON position.
Between J2 (59) and (47), or between SEGR (3)
Voltage
and (2)

1.0 to 4.0 V

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector J2 or SVGT.
3. Turn starting switch to ON position.
Between J2 (38) and (47), or between SVGT (C)
Voltage
and (B)

1.0 to 4.0 V

1.
2.
3.
4.

Emergency steering pump


pressure sensor

20-22

3.7 to 4.0 V

Turn starting switch to OFF position.


Insert T-adapter into connector R37.
Start engine.
Turn emergency steering ON and operate steering.
Continuous
When
emergency
steering is
stopped
Voltage
Between R37 (2) and (1)
When
emergency
steering is
turned ON and
steering is
operated

0.50 to 4.5 V
0.50 to 0.90 V

0.50 to 3.05 V

WA470-7

20 Standard value tables


Standard value table for electrical system

Machine control

(WA470-E000-033-P-00-A)

Equipment name

Procedure, measuring location, criteria and remarks

E.C.S.S. solenoid

1. Turn starting switch to OFF position.


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

Boom RAISE EPC


solenoid

1. Turn starting switch to OFF position.


2. Disconnect connector F23, and connect T-adapter to male side.
Between F23 (male) (1) and (2)
5 to 15 z
Resistance Between ground and each of F23 (male) (1) and
Min. 1 Mz
(2)

Boom LOWER EPC


solenoid

1. Turn starting switch to OFF position.


2. Disconnect connector F24 and connect T-adapter to male side.
Between F24 (male) (1) and (2)
5 to 15 z
Resistance Between ground and each of F24 (male) (1) and
Min. 1 Mz
(2)

1. Turn starting switch to OFF position.


2. Disconnect connector F21 and connect T-adapter to male side.
Bucket TILT EPC solenoid
Between F21 (male) (1) and (2)
5 to 15 z
Resistance Between ground and each of F21 (male) (1) and
Min. 1 Mz
(2)
Bucket DUMP EPC
solenoid

1. Turn starting switch to OFF position.


2. Disconnect connector F22, and connect T-adapter to male side.
Between F22 (male) (1) and (2)
5 to 15 z
Resistance Between ground and each of F22 (male) (1) and
Min. 1 Mz
(2)

Radiator fan reverse


solenoid

1. Turn starting switch to OFF position.


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

Neutral lock solenoid

1. Turn starting switch to OFF position.


2. Disconnect connector F31, and connect T-adapter to male side.
Between F31 (male) (1) and (2)
35 to 45 z
Resistance Between ground and each of F31 (male) (1) and
Min. 1 Mz
(2)

Boom detent solenoid

1. Turn starting switch to OFF position.


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

Bucket detent solenoid

1. Turn starting switch to OFF position.


2. Disconnect connector L29B, and connect T-adapter to male side.
Between L29B (male) (1) and (2)
100 to 123 z
Resistance
Between L29B (male) (1) and ground
Min. 1 Mz

Fan pump EPC solenoid

1. Turn starting switch to OFF position.


2. Disconnect connector R29, and connect T-adapter to male side.
Between R29 (male) (1) and (2)
5 to 10 z
Resistance Between chassis ground and each of R29
Min. 1 Mz
(male) (1) and (2)

Loader pump EPC


solenoid

1. Turn starting switch to OFF position.


2. Disconnect connector R71, and connect T-adapter to male side.
Resistance Between R71 (male) (1) and (2)
5 to 15 z

WA470-7

20-23

20 Standard value tables


Standard value table for electrical system

Equipment name

Lockup clutch ECMV


solenoid

Procedure, measuring location, criteria and remarks


Between ground and each of R71 (male) (1) and
Min. 1 Mz
(2)
1. Turn starting switch to OFF position.
2. Disconnect connector LC.PS, and connect T-adapter to male side.
Between LC.PS (male) (1) and (2)
5 to 15 z
Resistance
Between ground and LC.PS (male) (1) or (2)
Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector 1.PS, and connect T-adapter to male side.
1st clutch ECMV solenoid
Between 1.PS (male) (1) and (2)
5 to 15 z
Resistance
Between ground and 1.PS (male) (1) or (2)
Min. 1 Mz
2nd clutch ECMV
solenoid

1. Turn starting switch to OFF position.


2. Disconnect connector 2.PS, and connect T-adapter to male side.
Between 2.PS (male) (1) and (2)
5 to 15 z
Resistance
Between ground and 2.PS (male) (1) or (2)
Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector 3.PS, and connect T-adapter to male side.
3rd clutch ECMV solenoid
Between 3.PS (male) (1) and (2)
5 to 15 z
Resistance
Between ground and 3.PS (male) (1) or (2)
Min. 1 Mz
R clutch ECMV solenoid

1. Turn starting switch to OFF position.


2. Disconnect connector R.PS and connect T-adapter to male side.
Between R.PS (male) (1) and (2)
5 to 15 z
Resistance
Between ground and R.PS (male) (1) or (2)
Min. 1 Mz

F clutch ECMV solenoid

1. Turn starting switch to OFF position.


2. Disconnect connector F.PS, and connect T-adapter to male side.
Between F.PS (male) (1) and (2)
5 to 15 z
Resistance
Between ground and F.PS (male) (1) or (2)
Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector 4.PS, and connect T-adapter to male side.
4th clutch ECMV solenoid
Between 4.PS (male) (1) and (2)
5 to 15 z
Resistance
Between ground and 4.PS (male) (1) or (2)
Min. 1 Mz
3rd valve (attachment)
EXTEND EPC solenoid

1. Turn starting switch to OFF position.


2. Disconnect connector F25, and connect T-adapter to male side.
Between F25 (male) (1) and (2)
5 to 15 z
Resistance Between ground and each of F25 (male) (1) and
Min. 1 Mz
(2)

3rd valve (attachment)


RETRACT EPC solenoid

1. Turn starting switch to OFF position.


2. Disconnect connector F26, and connect T-adapter to male side.
Between F26 (male) (1) and (2)
5 to 15 z
Resistance Between ground and each of F26 (male) (1) and
Min. 1 Mz
(2)

Transmission oil
temperature sensor

1. Turn starting switch to OFF position.


2. Disconnect connector TM.T and connect T-adapter to male side.
Oil temperature: 25C
35 to 50 kz
Between TM.T
(normal temperature)
Resistance (male) (1) and (2)
Oil temperature: 100C
3.1 to 4.5 kz

Hydraulic oil temperature


sensor

1. Turn starting switch to OFF position.


2. Disconnect connector R47 and connect T-adapter to male side.
Oil temperature: 25C
35 to 50 kz
Between R47 (male) (normal temperature)
Resistance (1) and (2)
Oil temperature: 100C
3.1 to 4.5 kz

Brake oil temperature


sensor (rear)

1. Turn starting switch to OFF position.


2. Disconnect connector R60, and connect T-adapter to male side.

20-24

WA470-7

20 Standard value tables


Standard value table for electrical system

Equipment name

Torque converter oil


temperature sensor

Loader pump pressure


sensor

Boom cylinder bottom


pressure sensor

Boom cylinder head


pressure sensor

Pilot pressure sensor of


main flow selector
solenoid

Transmission cut-off
pressure sensor

Torque converter input


pressure sensor

WA470-7

Procedure, measuring location, criteria and remarks


Rear brake oil
temperature: 25C
Rear brake oil
temperature: 30C
Between R60 (male) Rear brake oil
Resistance (1) and (2)
temperature: 80C
Rear brake oil
temperature: 90C
Rear brake oil
temperature: 100C

42.7 kz
35.13 kz
6.556 kz
4.925 kz
3.75 kz

1. Turn starting switch to OFF position.


2. Disconnect connector TC.T and connect T-adapter to male side.
Torque converter oil
temperature: 25C
35 to 50 kz
Between TC.T
(normal temperature)
Resistance (male) (1) and (2)
Torque converter oil
3.1 to 4.5 kz
temperature: 100C
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector F10.
3. Start engine.
Loader pump pressure:
0.50 to 4.4 V
Continuous
Between F10 (C)
Loader pump pressure: At
Voltage
0.50 to 0.90 V
and (A)
NEUTRAL
Loader pump pressure: At
2.97 to 3.39 V
bucket tilt relief
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector F12.
3. Start engine, and move lever to boom RAISE to perform troubleshooting.
Always
0.50 to 4.4 V
Between F12 (C)
Boom: At NEUTRAL
0.50 to 0.90 V
Voltage
and (A)
Boom cylinder bottom:
2.97 to 3.39 V
Hydraulic relief
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector F13.
3. Start engine, and troubleshoot by lowering boom.
Always
Between F13 (C)
Boom: At NEUTRAL
Voltage
and (A)
Boom cylinder head:
Hydraulic relief

0.50 to 4.4 V
0.50 to 0.90 V
2.97 to 3.39 V

1. Turn starting switch to OFF position.


2. Disconnect connector FLOW.P, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Voltage
Between FLOW.P (female) (2) and (1)
0.3 to 4.7 V
1.
2.
3.
4.

Turn starting switch to OFF position.


Insert T-adapter into connector R73.
Start engine.
Turn transmission cut-off switch ON.
When brake is released
When brake pedal is
Between R73 (C)
depressed (both right and
Voltage
and (A)
left)
Always

0.9 to 1.1 V
1.1 to 5.1 V
0.9 to 5.1 V

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector TCIN.P.
3. Turn starting switch to ON position.

20-25

20 Standard value tables


Standard value table for electrical system

Equipment name

Procedure, measuring location, criteria and remarks


Sensor output
Between TCIN.P (C) and (A)
0.9 to 5.1 V
voltage

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector R91.
Torque converter outlet oil
3. Turn starting switch to ON position.
pressure sensor
Sensor output
Between R91 (C) and (A)
voltage

0.9 to 5.1 V

Steering pump pressure


sensor

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector R86.
3. Start engine and operate steering.
Always
Between R86 (2)
Voltage
Steering: At NEUTRAL
and (1)
Steering: At Relief

Transmission input shaft


speed sensor

1. Turn starting switch to OFF position.


2. Disconnect connector REV IN, and connect T-adapter to male side.
Between REV IN (male) (1) and (2)
500 to 1,000 z
Resistance Between ground and each of REV IN (male) (1)
Min. 1 Mz
and (2)

Radiator fan speed


sensor

1. Turn starting switch to OFF position.


2. Disconnect connector R89 and connect T-adapter to male side.
1,000 to 4,000
Between R89 (male) (1) and (2)
z
Resistance Between ground and each of R89 (male) (1) and
Min. 1 Mz
(2)

0.50 to 4.5 V
0.50 to 0.90 V
3.02 to 3.42 V

1. Turn starting switch to OFF position.


2. Disconnect connector REV OUT, and connect T-adapter to male side.
Transmission output shaft
Between REV OUT (male) (1) and (2)
500 to 1,000 z
speed sensor
Resistance Between ground and each of REV OUT (male)
Min. 1 Mz
(1) and (2)
1.
2.
3.
4.
Analog signal system of
FNR lever

1.
2.
3.
4.
5.
Boom lever potentiometer

Bucket lever
potentiometer

20-26

Turn starting switch to OFF position.


Insert T-adapter into connector L02.
Turn starting switch to ON position.
Move FNR lever to perform troubleshooting.
FNR (directional) lever: F
(FORWARD)
FNR (directional) lever: N
Between L02 (11)
Voltage
(NEUTRAL)
and (12)
FNR (directional) lever: R
(REVERSE)
Turn starting switch to OFF position.
Insert T-adapter into connector L28A.
Set work equipment lock switch to LOCK position.
Turn starting switch to ON position.
Operate boom lever to perform troubleshooting.
Boom lever: NEUTRAL
Boom lever: RAISE (to
short of detent position)
Boom lever: RAISE (at
Between L28A (3)
Voltage
detent position)
and (2)
Boom lever: RAISE (at
detent position)
Boom lever: FLOAT

1.2 to 1.8 V
1.7 to 3.3 V
3.2 to 3.8 V

2.38 to 2.62 V
3.38 to 4.04 V
3.90 to 4.40 V
0.96 to 1.62 V
0.60 to 1.10 V

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector L29A.
3. Turn work equipment lock switch to LOCK position.
WA470-7

20 Standard value tables


Standard value table for electrical system

Equipment name

Procedure, measuring location, criteria and remarks


4. Turn starting switch to ON position.
5. Operate bucket lever to perform troubleshooting.
Bucket lever: NEUTRAL
2.38 to 2.62 V
Bucket lever: TILT (to
3.38 to 4.04 V
short of detent position)
Between L29A (3)
Voltage
and (2)
Bucket lever: TILT (at
3.90 to 4.40 V
detent position)
Bucket lever: Full DUMP
0.60 to 1.10 V
1.
2.
3.
4.
5.

3rd (attachment) lever


potentiometer

Boom angle sensor

Bucket angle sensor

1.
2.
3.
4.

1.
2.
3.
4.

Turn starting switch to OFF position.


Insert T-adapter into connector L30.
Turn work equipment lock switch to LOCK position.
Turn starting switch to ON position.
Operate 3rd (attachment) lever to perform troubleshooting.
3rd (attachment) lever:
NEUTRAL
3rd (attachment) lever:
Between L30 (3) and Operated to extend
Voltage
cylinder fully
(2)
3rd (attachment) lever:
Operated to retract
cylinder fully

2.38 to 2.62 V
3.90 to 4.40 V

0.60 to 1.10 V

Turn starting switch to OFF position.


Insert T-adapter into connector F11.
Turn starting switch to ON position.
Operate boom lever to perform troubleshooting.
Always
Between F11 (B)
Voltage
RAISE stroke end
and (A)
LOWER stroke end

1.13 to 4.02 V
3.52 to 4.02 V
1.13 to 1.63 V

Turn starting switch to OFF position.


Insert T-adapter into connector F32.
Turn starting switch to ON position.
Operate bucket lever to perform troubleshooting.
Always
Between F32 (B)
Voltage
Full TILT
and (A)
Full DUMP

2.15 to 4.45 V
3.95 to 4.45 V
2.15 to 2.65 V

Air cleaner clogging


sensor

1. Turn starting switch to OFF position.


2. Disconnect connector E45 and connect T-adapters to male side.
3. Turn starting switch to ON position.
When air cleaner is
Max. 1 z
Between E45 (male) normal
Resistance (1) and (2)
When air cleaner is
Min. 1 Mz
clogged

Fuel level sensor

1. Turn starting switch to OFF position.


2. Disconnect connector R33, and connect T-adapters to male side.
Between R33 (male) Fuel level: Full
Max. 12 z
Resistance (1) and (2)
Fuel level: Empty
80 to 100 z

Starting switch

1. Turn starting switch to OFF position.


2. Disconnect connector S40 and connect T-adapter to male side.
3. Troubleshoot by turning starting switch to ON, OFF, START, and HEAT
positions.
Starting switch: START
Max. 1 z
Between S40 (male)
Starting switch: OFF and
(1) and (3)
Min. 1 Mz
Resistance
ON
Between terminal B Starting switch: HEAT
Max. 1 z
and terminal R1

Transmission cut-off
switch

1. Turn starting switch to OFF position.

WA470-7

20-27

20 Standard value tables


Standard value table for electrical system

Equipment name

Remote positioner set


switch (boom)

Throttle lock set/


acceleration switch

Defective throttle lock


resume/deceleration
switch

Engine shutdown
secondary switch

Procedure, measuring location, criteria and remarks


2. Disconnect connector S_RH1 and connect T-adapter to male side.
Engine power mode
Max. 1 z
Between S_RH1
selection switch: ON
(male) (5) and (6)
Engine power mode
Min. 1 Mz
selection switch: OFF
Resistance
Between ground and
each of S_RH1
Always
Min. 1 Mz
(male) (5) and (6)
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH6, and connect T-adapters to male side.
Remote positioner set
Max. 1 z
switch: Boom set ON
Between S_RH6
Remote positioner set
(male) (5) and (6)
switch: Other than boom
Min. 1 Mz
Resistance
set ON
Between ground and each of S_RH6 (male) (5)
Min. 1 Mz
and (6)
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH7, and connect T-adapter to male side.
Throttle lock set/
acceleration switch: Other
Min. 1 Mz
Between S_RH7
than ON
Resistance (male) (5) and (6)
Throttle lock set/
Max. 1 z
acceleration switch: ON
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH7, and connect T-adapter to male side
Throttle Lock Resume/
Deceleration Switch:
Min. 1 Mz
Between S_RH7
Other than ON
Resistance (male) (4) and (5)
Throttle Lock Resume/
Max. 1 z
Deceleration Switch: ON
1. Turn starting switch to OFF position.
2. Disconnect connector S_FS and connect T-adapter to male side.
Between S_FS
Min. 1 Mz
(male) (3) and (2)
Engine shutdown
secondary switch: ON
Between S_FS
Min. 1 Mz
(male) (6) and (5)
Resistance
Between S_FS
Max. 1 z
(male) (1) and (2)
Engine shutdown
secondary switch: OFF
Between S_FS
Max. 1 z
(male) (4) and (5)

Parking brake indicator


switch

1. Turn starting switch to OFF position.


2. Disconnect connector PB.SW, and connect T-adapter to male side.
Parking brake pressure:
When parking brake is
Max. 1 z
released, Min. 0.61 MPa
2
{Min. 6.2 kg/cm }
Between PB.SW
Resistance (male) (1) and (2)
Parking brake pressure:
When parking brake is
Min. 1 Mz
applied, Max. 0.34 MPa
{Min. 3.5 kg/cm2}

Remote positioner set


switch (bucket)

1. Turn starting switch to OFF position.


2. Disconnect connector S_RH6, and connect T-adapters to male side.
Remote positioner set
Between S_RH6
Resistance (male) (5) and (6)
switch: Bucket angle set
Max. 1 z
ON

20-28

WA470-7

20 Standard value tables


Standard value table for electrical system

Equipment name

Right FNR (directional)


switch

Work equipment lock


switch

Transmission auto/
manual shift mode
selector switch

Procedure, measuring location, criteria and remarks


Remote positioner set
switch: Other than bucket
Min. 1 Mz
angle set ON
Between ground and each of S_RH6 (male) (5)
Min. 1 Mz
and (6)
1. Turn starting switch to OFF position.
2. Disconnect connector S_RHB, and connect T-adapter to male side.
Right FNR (directional)
Max. 1 z
switch: F (FORWARD)
Between S_RHB
(male) (1) and (2)
Right FNR (directional)
Min. 1 Mz
switch: Other than F
Right FNR (directional)
Max. 1 z
switch: N (NEUTRAL)
Between S_RHB
(male) (1) and (3)
Right FNR (directional)
Min. 1 Mz
switch: Other than N
Resistance
Right FNR (directional)
Max. 1 z
switch: R (REVERSE)
Between S_RHB
(male) (1) and (4)
Right FNR (directional)
Min. 1 Mz
switch: Other than R
Between S_RHB (1)
Always
or (2),(3),(4) and
Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector S_RHC, and connect T-adapter to male side.
Work equipment lock
Min. 1 Mz
Between S_RHC
switch: OFF
Resistance (male) (5) and (6)
Work equipment lock
Max. 1 z
switch: ON
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH3 and connect T-adapter to male side.
Shift mode: Manual shift
Max. 1 z
Between S_RH3
Shift mode: Auto shift (L)
Min.
1 Mz
(male) (4) and (5)
Shift mode: Auto shift (H)
Min. 1 Mz
Resistance
Shift mode: Manual shift
Min. 1 Mz
Between S_RH3
Shift mode: Auto shift (L)
Min. 1 Mz
(male) (5) and (6)
Shift mode: Auto shift (H)
Max. 1 z

Transmission cut-off
switch

1. Turn starting switch to OFF position.


2. Disconnect connector S_RH1, and connect T-adapters to male side.
Transmission cut-off set
Max. 1 z
Between S_RH1
switch: ON
(male) (5) and (6)
Transmission cut-off set
Min. 1 Mz
switch: OFF
Resistance
Between ground and
each of S_RH1
Always
Min. 1 Mz
(male) (5) and (6)

Kickdown switch

1. Turn starting switch to OFF position.


2. Disconnect connector L14 and connect T-adapter to male side.
Between L14 (male) Kickdown switch: ON
Max. 1 z
(1) and (2)
Kickdown switch: OFF
Min. 1 Mz
Resistance Between ground and
each of L14 (male) Always
Min. 1 Mz
(1) and (2)

Hold switch

1. Turn starting switch to OFF position.


2. Disconnect connector L14 and connect T-adapter to male side.
Between L14 (male) Kickdown switch: ON
Max. 1 z
Resistance (3) and (4)
Kickdown switch: OFF
Min. 1 Mz

WA470-7

20-29

20 Standard value tables


Standard value table for electrical system

Equipment name

20-30

Procedure, measuring location, criteria and remarks


Between ground and
each of L14 (male) Always
Min. 1 Mz
(3) and (4)

WA470-7

20 Standard value tables


Standard value table for electrical system

Machine monitor
Equipment name

LCD unit of
machine
monitor

Continuous
power
supply
voltage

(WA470-Q170-033-K-00-A)

Procedure, measuring location, criteria and remarks


1. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MCM2, and connect harness checker to female side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between harness checker (1) and (3)
Min. 0.3 V
Between harness checker (2) and (3)
Min. 0.3 V
Between harness checker (4) and (3)
Voltage
Min. 0.3 V
Between harness checker (5) and (3)
6.2 to 9.1 V
Between harness checker (7) and (3)
6.2 to 9.1 V

a When using T-adapters for connector MDM3 (070-8)


1. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MDM3, and connect T-adapters to female side.
Continuous 4. Turn battery disconnect switch to ON position.
Meter unit of power
5. Turn starting switch to ON position.
machine
6. Lighting up of clearance lamp
supply
monitor
voltage
Between MDM3 (female) (1) and (4)
20 to 30 V
Between MDM3 (female) (2) and (4)
20 to 30 V
Between
MDM3
Night lighting switch:
Voltage
Max. 0.2 V
(female) (5) and (4)
OFF
Between MDM3
Night lighting switch:
20 to 30 V
(female) (5) and (4)
ON

LED unit of
machine
monitor

a When using T-adapter for connector MDM2 (070-6)


1. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
Continuous 3. Disconnect connector MDM2, and connect T-adapters to female side.
power
4. Turn battery disconnect switch to ON position.
supply
5. Turn starting switch to ON position.
voltage
Between MDM2 (female) (1) and (2)
9.3 to 14.1 V
a 12 V power supply
Voltage
Between MDM2 (female) (4) and (2)
4 to 6.1 V
a 5 V power supply

Switch
panel of
machine
monitor

a When using T-adapter for connector MOM1 (070-6)


1. Check that system operating lamp does not light up, and then set battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
Continuous 3. Disconnect connector MOM1, and connect T-adapters to female side.
power
4. Turn battery disconnect switch to ON position.
supply
5. Turn starting switch to ON position.
voltage
Between MOM1 (female) (1) and (2)
9.3 to 14.1 V
a 12 V power supply
Voltage
Between MOM1 (female) (4) and (2)
4 to 6.1 V
a 5 V power supply

WA470-7

20-31

20 Standard value tables


Standard value table for electrical system

20-32

WA470-7

SHOP MANUAL

WHEEL LOADER
WA470-7
Model

Serial Number

WA470-7

10001 and up

30 Testing and adjusting


5 30 Testing and adjusting

WA470-7

30-1

30 Testing and adjusting


Table of contents

Table of contents

(ALL-0310-002-A-00-A)

30 Testing and adjusting .................................................................................................................... 30-1


Table of contents ........................................................................................................................ 30-2
General information on testing and adjusting................................................................................. 30-4
Tools for testing and adjusting ............................................................................................... 30-4
Sketch of tools for testing and adjusting ................................................................................. 30-8
Engine and cooling system ........................................................................................................ 30-10
Testing engine speed ......................................................................................................... 30-10
Testing boost pressure ....................................................................................................... 30-12
Testing exhaust gas color ................................................................................................... 30-14
Testing and adjusting valve clearance .................................................................................. 30-16
Testing compression pressure............................................................................................. 30-18
Testing blowby pressure ..................................................................................................... 30-22
Testing engine oil pressure ................................................................................................. 30-24
Testing EGR valve and KVGT oil pressures .......................................................................... 30-25
Testing fuel pressure .......................................................................................................... 30-26
Testing fuel return rate and leakage ..................................................................................... 30-27
Bleeding air from fuel system .............................................................................................. 30-31
Testing fuel circuit for leakage ............................................................................................. 30-33
Handling cylinder cutout mode operation.............................................................................. 30-34
Handling no injection cranking operation .............................................................................. 30-35
Testing of KDPF and muffler stack for looseness and damage ............................................... 30-36
Testing of installed condition of cylinder head and manifolds .................................................. 30-37
Testing engine piping for damage and looseness .................................................................. 30-38
Testing and adjusting air conditioner compressor belt tension ................................................ 30-39
Testing and adjusting alternator belt tension ......................................................................... 30-41
Procedures for cleaning fuel doser....................................................................................... 30-43
Writing compensation values at replacement of injector and engine controller ......................... 30-46
Power train............................................................................................................................... 30-50
Adjusting transmission output speed sensor ......................................................................... 30-50
Adjusting transmission input speed sensor ........................................................................... 30-51
Flushing procedure for torque converter and transmission hydraulic circuit.............................. 30-52
Retrieval of disabled machine due to transmission valve failure.............................................. 30-54
Testing oil leakage from axle final drive ................................................................................ 30-56
Testing drive shaft for looseness, backlash, and damage....................................................... 30-57
Testing and adjusting power train oil pressure....................................................................... 30-58
Steering system........................................................................................................................ 30-73
Testing directional lever ...................................................................................................... 30-73
Testing steering wheel ........................................................................................................ 30-74
Testing work equipment control lever ................................................................................... 30-76
Testing and adjusting steering circuit oil pressure.................................................................. 30-78
Bleeding air from steering cylinder circuit.............................................................................. 30-81
Testing and adjusting steering stopper valve......................................................................... 30-82
Brake system ........................................................................................................................... 30-83
Testing brake pedal ............................................................................................................ 30-83
Testing and adjusting brake pedal linkage ............................................................................ 30-84
Testing braking performance ............................................................................................... 30-85
Testing and adjusting of accumulator charge pressure........................................................... 30-86
Testing of brake accumulator nitrogen gas pressure and procedure for charging brake
accumulator with nitrogen gas................................................................................ 30-88
Testing wheel brake oil pressure.......................................................................................... 30-92
Testing lowering of wheel brake pressure ............................................................................. 30-94
Testing wear of wheel brake disc ......................................................................................... 30-96
Bleeding air from wheel brake circuit.................................................................................... 30-97
Releasing remaining pressure in brake accumulator circuit .................................................... 30-99
Testing parking brake performance .................................................................................... 30-100
Testing parking brake oil pressure ..................................................................................... 30-101
Testing wear of parking brake disc ..................................................................................... 30-102

30-2

WA470-7

30 Testing and adjusting


Table of contents

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


Hydraulic system .................................................................................................................... 30-105
Testing fan speed............................................................................................................. 30-105
Testing fan pump circuit oil pressure .................................................................................. 30-106
Bleeding air from hydraulic fan circuit ................................................................................. 30-108
Testing and adjusting work equipment EPC oil pressure ...................................................... 30-110
Testing and adjusting work equipment oil pressure.............................................................. 30-113
Bleeding air from work equipment circuit ............................................................................ 30-117
Releasing remaining pressure from work equipment circuit .................................................. 30-118
Testing of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator
with nitrogen gas ................................................................................................ 30-119
Work equipment ..................................................................................................................... 30-123
Testing and adjusting bucket position detection lever........................................................... 30-123
Testing and adjusting boom position detection lever ............................................................ 30-124
Electrical system .................................................................................................................... 30-125
Adjusting replaced, reassembled or added sensor, controller, etc. with machine
monitor .............................................................................................................. 30-125
Special functions of machine monitor ................................................................................. 30-127
Adjusting rearview camera angle ....................................................................................... 30-216
Handling voltage circuit of engine controller........................................................................ 30-217
Handling battery disconnect switch .................................................................................... 30-218
Testing diodes ................................................................................................................. 30-219
Pm clinic ................................................................................................................................ 30-220
Pm Clinic service ............................................................................................................. 30-220
Check sheet .................................................................................................................... 30-221

WA470-7

30-3

30 Testing and adjusting


General information on testing and adjusting

General information on testing and adjusting


Testing and
adjusting item
Testing boost
pressure

Symbol

Part No.

Feeler gauge

1 795-502-1590
795-471-1420
2
6217-71-6112
Commercially
3
available
1 799-201-1504
2 799T-201-3210
3 799T-201-3220

Gauge assembly
Adapter
Gasket

1
1
1

1 799-101-5002

Hydraulic tester

2 790-261-1204

Digital hydraulic tester

3 799-401-2320

Gauge

1 799-201-9002
Commercially
2
available

Testing and
adjusting valve
clearance

Testing engine oil


pressure

Testing fuel
pressure

Testing fuel
discharge, return
and leakage

30-4

Commercially
available

Boost gauge kit


Handy smoke checker

2 799-101-5002

Hydraulic tester

3 790-261-1204

Digital hydraulic tester

1 799-101-5002

Hydraulic tester

2 790-261-1204

Digital hydraulic tester

795-790-5120
3 07005-01412
790-301-1530
4 799-401-2320
1 6151-51-8490
2 6206-71-1770
Commercially
3
available
Commercially
4
available
Commercially
5
available
Commercially
6
available

Screw
Gasket
Elbow
Gauge
Spacer
Joint

Inner diameter 14 mm, length


1 approx. 2 m
1 0 to 10 kPa {0 to 1,000 mmH2O}
1 Hose inside diameter: 24 mm
2 Pipe outside diameter: 25.4 mm
Pressure gauge: 2.5, 6.0, 40, 60
1 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
1 kg/cm2}
Pressure gauge: 1.0 MPa {10
1 kg/cm2}
1
1
Pressure gauge: 2.5, 6.0, 40, 60
1 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
1 kg/cm2}
Pressure gauge: 2.5, 6.0, 40, 60
1 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
1 kg/cm2}
1 M14 x 1.5 o Rc1/8
1
1 Rc1/8 x Rc1/8
1 1 MPa
1
1

Hose

1 Inside diameter: approx. 6 mm

Hose

1 Inside diameter: approx. 16 mm

Measuring cylinder

Stopwatch

1
Testing EGR valve
and KVGT oil
pressure

Remarks

Smoke meter

799-201-2202

Testing exhaust gas


color

Testing blowby
pressure

Part name

-101 to 200 kPa {-760 to 1,500


1 mmHg}
1
Bosch index: 0 to 9
1

Testing compression
E
pressure

(WA470-5320-304-A-00-A)

Q'ty

Tools for testing and adjusting

(ALL-3831-001-A-00-A)

Hose
Blowby checker
Plug
Cap

795T-401-1310 Plug
02896-21018 O-ring

WA470-7

30 Testing and adjusting

Testing and
adjusting item

Symbol

Part name

Q'ty

General information on testing and adjusting

Developer for dye


penetrant (color
checker)

Part No.

Testing fuel circuit


for leakage

Commercially
available

Testing directional
lever

79A-264-0021 Push-pull scale

Testing and
adjusting power
train oil pressure

Hydraulic tester

2 790-261-1204

Digital hydraulic tester

3 799-401-2320

Gauge

799-101-5220
07002-11023

Nipple
O-ring

1
1

794-423-1190

Plug

79A-264-0021 Push-pull scale

4
Retrieval of disabled
machine due to
transmission valve
failure
Testing steering
wheel

Testing and
adjusting steering oil Q
pressure

Bleeding air from


hydraulic fan circuit

Testing and
adjusting of
accumulator charge
pressure

Testing lowering of
wheel brake
pressure

Testing wear of
wheel brake disc

Hydraulic tester

2 790-261-1204

Digital hydraulic tester

1 799-101-5002

Hydraulic tester

2 790-261-1204

Digital hydraulic tester

3 790-261-1130

Coupling

1 799-101-5002

Hydraulic tester

2 790-261-1204

Digital hydraulic tester

1
2
3
4
5
6
7

Brake test kit


Coupler
Pump
Adapter
Nipple
Hose
Coupling
Vernier calipers

2 790-261-1204

Digital hydraulic tester

WA470-7

799-101-5220
07002-11023

Nipple
O-ring

1 799-101-5002

1 799-101-5002

Pressure gauge: 2.5, 6.0, 40, 60


MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
kg/cm2}
Pressure gauge: 1.0 MPa {10
kg/cm2}
10 x 1.25 mm

Pressure gauge: 2.5, 6.0, 40, 60


1 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
1 kg/cm2}
1 10 x 1.25 mm
1
Pressure gauge: 2.5, 6.0, 40, 60
1 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
1 kg/cm2}
Pressure gauge: 2.5, 6.0, 40, 60
1 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 40 MPa {400
1 kg/cm2}
1
Pressure gauge: 2.5, 6.0, 40, 60
1 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
1 kg/cm2}
1
1
1
1 10 x 1.25 mm o R1/8
1
1 Length: 5 m
1

Hydraulic tester

3
Testing oil pressure
in cooling fan pump
circuit

1 799-101-5002

Remarks

793-605-1001
790-101-1430
790-101-1102
790-301-1720
799-101-5160
799-401-2220
790-261-1130
Commercially
available

30-5

30 Testing and adjusting

Testing and
adjusting item

Symbol

Part No.

Testing wear of
parking brake disc
Testing work
equipment control
lever

Ruler

Hydraulic tester

2 790-261-1204

Digital hydraulic tester

ZA

799-101-5220
07002-11023

Nipple
O-ring

1 799-101-5002

Hydraulic tester

2 790-261-1204

Digital hydraulic tester

799-101-5220
07002-11023

4 799-401-2701
1 401-799-2930

Nipple
O-ring
Differential pressure
gauge
Adapter

Pressure gauge: 2.5, 6.0, 40, 60


1 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
1 kg/cm2}
1 10 x 1.25 mm
1
Pressure gauge: 2.5, 6.0, 40, 60
1 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
1 kg/cm2}
1 10 x 1.25 mm
1

3 790-261-1204

Digital hydraulic tester

Commercially
available
Cu3886388
795-799-5730
Commercially
available
or
795-799-5740
795-799-5720
799-601-4510
Commercially
available
Commercially
available

Lap top type personal


computer
INSITE ver. 7.4
INLINE 5 Kit

Pressure gauge: 2.5, 6.0, 40, 60


1 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
1 kg/cm2}
Windows XP SP2/VISTA/
1
Windows 7
1
1

Cable (USB)
Cable (RS232)

Cable (9P)
Cable (12P)

1
1

Gas charge tool

Pressure reducing valve

Commercially
available

Charging hose

Testing wheel brake


2 799-101-5002
ZB
oil pressure

1
2
3
ZC
4
5
6

30-6

Push-pull scale

1 799-101-5002

Testing ECSS
accumulator
nitrogen gas
pressure and
procedure for
charging
accumulator with
nitrogen gas.

Digital hydraulic tester

793T-615-1820
07002-11023
Commercially
X
available
1 79A-264-0021
Y
Commercially
2
available

Writing
compensation
values at
replacement of
injector and engine
controller

Vernier calipers

790-261-1204
2

Testing and
adjusting work
equipment oil
pressure

Adapter
O-ring

799-101-5002
1
W

Remarks

Pressure gauge: 2.5, 6.0, 40, 60


1 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
1 kg/cm2}
1 10 x 1.25 mm
1

Hydraulic tester

Testing parking
brake oil pressure

Testing and
adjusting work
equipment EPC oil
pressure

Part name

Q'ty

General information on testing and adjusting

1
2
ZD
3

Hydraulic tester

WA470-7

30 Testing and adjusting

Testing and
adjusting item

SymPart No.
bol
1 792-610-1702
792-610-1310

Testing brake
accumulator
nitrogen gas
pressure and
procedure for
charging
accumulator with
nitrogen gas.

Removal and
installation of
coolant temperature
sensor

WA470-7

792-610-1320
ZE

792-610-1330

Part name
Gas charge tool
Nipple
(for Russia)
Nipple
(for US)
Nipple
(for US)

792-610-1350

Nipple
(for German)

792-610-1360

Nipple
(for UK)

795T-981-1010 Socket

Q'ty

General information on testing and adjusting

Remarks

1
1 GOST
1 CGA No. 351
1 ASA B-571-1965
DIN 477-7963
1 NEN 3268-1966
SIS-SMS 2235/2238
BS 341
1
Part1-1962
1

30-7

30 Testing and adjusting


General information on testing and adjusting

Sketch of tools for testing and adjusting

(WA470-3531-061-A-00-A)

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
H1: Plug

-:Socket

30-8

WA470-7

30 Testing and adjusting


General information on testing and adjusting

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
W: Adapter

WA470-7

30-9

30 Testing and adjusting


Engine and cooling system

Engine and cooling system


Testing engine speed

(ALL-R401-001-K-00-A)

(WA470-A000-360-K-01-A)

k Place

the machine on a level ground and


lower the work equipment to the ground.

a Measure the engine speed under the following


conditions.
Coolant temperature: 60 to 102C
Hydraulic oil temperature: 45 to 55C
Torque converter oil temperature: 60 to 80C

Testing

(WA470-A000-388-K-00-A)

a Check the engine speed with Monitoring/Predefined or Monitoring/Custom function of the


machine monitor.
Preparation
Operate machine monitor to display Fan 100%
Mode.
a For the machine monitor operating method, see
the section of "Adjustment (Fan 100% Mode)".

a Bucket does not move even when the bucket


lever is operated, since work equipment lock
switch is in ON (LOCK) position.
Measuring torque converter stall speed
1. Start the engine.
2. Set transmission cut-off switch to "OFF" position
and depress left brake pedal securely.
3. Set the torque converter lockup switch (if
equipped) to OFF position.
4. Set transmission shift mode selector switch to
the MANUAL position.
5. While keeping the directional lever or directional
selector switch in N (neutral) position, set the
gearshift lever to the 4th speed.
6. Release parking brake.
7. While depressing brake pedal, set directional
lever or directional selector switch to "F
(forward)" or "R (reverse)" position.
k Keep

brake pedal firmly depressed.

8. Depress the accelerator pedal gradually to run


the engine at full speed and stall the torque
converter to measure the engine speed.
a Measure the stall speed 2 to 3 times.
a Do not keep stalling torque converter for
more than 20 seconds. Take care that torque
converter oil temperature does not exceed
120C.

Measuring engine speed (low idle)


Start the engine, set it in the measuring condition,
and measure the engine speed.
Measuring engine speed (high idle)
1. Start the engine.
2. Set the work equipment mode to P, and work
equipment lock switch to OFF (released)
position.
3. Set boom at the lowest position. (Boom angle:
Max. -35.5 degrees)
a Bottom of the bucket is approx. 100 mm off
the ground while the bucket is level, and the
boom angle is Max. -35.5 degrees.
4. Set work equipment lock switch to ON (LOCK)
position.
5. Depress the accelerator pedal gradually while
operating bucket lever tilting. Measure the
engine speed at high idle.

30-10

a Measure the torque converter stall speed


respectively when the power mode and
economy mode are selected.
Measuring hydraulic stall speed
1. Start the engine and run it at high idle.
2. Set the work equipment lock switch to OFF
(released) position.
3. Set boom at the lowest position. (Boom angle:
Max. -35.5 degrees)
4. Relieve the bucket cylinder on the extension
side (bucket digging relief), and measure the
engine speed.
a Measure the hydraulic stall speed
respectively when the power mode and
economy mode are selected.
Measuring engine speed at torque converter
stall and hydraulic stall (full stall)
1. Start the engine.
2. Set transmission cut-off switch to "OFF" position
and depress left brake pedal securely.
3. Set the torque converter lockup switch (if
equipped) to OFF position.

WA470-7

30 Testing and adjusting


Engine and cooling system

4. Set transmission shift mode selector switch to


the MANUAL position.
5. While keeping the directional lever in N (neutral)
position, set the gear speed switch to the 4th
speed.
6. Release parking brake.
7. While depressing the brake pedal, set the
directional lever to the "F (forward)" or "R
(reverse)" position.
k Keep

brake pedal firmly depressed.

8. Run the engine at high idle with the torque


converter stalled, and relieve the bucket cylinder
on the extension side (bucket digging relief), and
measure the engine speed at this time.
a Do not keep stalling torque converter for
more than 20 seconds. Take care that torque
converter oil temperature does not exceed
120C.
a Measure the full stall speed when the power
mode is selected.

WA470-7

30-11

30 Testing and adjusting


Engine and cooling system

Testing boost pressure

(WA470-A900-360-K-01-A)

a Testing tools
Symbol
A

Part No.

Part name

799-201-2202 Boost gauge kit

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k When

installing and removing testing tools,


be careful not to touch a hot part of the
engine.

2. Install nipple [1] of boost gauge kit A, and


connect it to gauge [2].

a Testing of the boost pressure is to be performed


under the following conditions.

3 Nipple [1]:
15 2 Nm {1.53 0.2 kgm}

Coolant temperature: 60 to 102C


Torque converter oil temperature: 60 to 80C
With torque converter stalled

Testing with machine monitor

(WA380-

A900-362-K-00-A)

Check the boost pressure with Monitoring/Predefined or Monitoring/Custom of the machine


monitor.
a For the machine monitor operating method, see
the section of "Special functions of machine
monitor".
a Monitoring code: 36500 Charge Pressure-A

3. Start the engine and increase the coolant


temperature to the operating range.
4. Run the engine at medium or higher speed to
drain the oil in the hose.
a Repeat opening the self-sealing portion on
the hose by inserting approximately half of
the connection part of the gauge into the
hose to drain oil.
a When Pm kit (A) is available, you can use air
bleeding coupling (790-261-1130) in the kit.

Testing by use of testing tools

5.
(WA470-

A900-362-K-00-A)

1. Open side cover on the right of engine, and


remove boost pressure pickup port plug (1).

6.
7.
8.

9.

30-12

a If oil is left in the hose, the gauge does not


work. Accordingly, be sure to drain the oil.
Set the transmission cut-off switch to OFF
position and depress the left brake pedal
securely.
Set the torque converter lockup switch to OFF
position.
Set transmission shift mode selector switch to
the MANUAL position.
While keeping the directional lever or directional
selector switch in N (neutral) position, set the
gearshift switch to the 4th speed.
Release parking brake.

WA470-7

30 Testing and adjusting


Engine and cooling system

10.While depressing the brake pedal, set the


directional lever to the "F (forward)" or "R
(reverse)" position.
k Keep

brake pedal firmly depressed.

11.Depress the accelerator pedal gradually to run


the engine at high idle and stall the torque
converter, then measure the boost pressure.
a Do not keep stalling torque converter for
more than 20 seconds. Be careful that torque
converter oil temperature does not exceed
120C.
3 Pickup port plug (1):
15 2 Nm {1.53 0.2 kgm}
Boost pressure

Min. 93 kPa {min. 700 mmHg}

12.After finishing test, remove the testing tools and


restore the machine.

WA470-7

30-13

30 Testing and adjusting


Engine and cooling system

Testing exhaust gas color

(WA470-A900-360-K-00-A)

a Testing tools
Symbol
1
C
2

Part No.

Part name

799-201-9002 Handy smoke checker


Commercially
Smoke meter
available

3 Plug:
42.1 to 70.6 Nm {4.3 to 7.2 kgm}
2 Plug:
Seizure prevention compound (LC-G)

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k Be

careful not to touch any hot part when


installing or removing the testing tools.

k When

KDPF regeneration is started, the


high-temperature exhaust gas spurts from
the inspection port, that may cause burn
injury. Therefore, you must stop KDPF
regeneration through the machine monitor
before starting the inspection.
(For the stopping procedure for KDPF
regeneration, see the Operation and
Maintenance Manual.)

a Measure the exhaust gas color under the


following conditions.

Coolant temperature: 60 to 102C


Torque converter oil temperature: 60 to 80C
With torque converter stalled
Hold in stationary state for 5 seconds, then
collect the exhaust gas.

3. Measuring by using handy smoke checker C1


1) Fit a sheet of filter paper to handy smoke
checker C1.
2) Insert the exhaust gas intake pipe into plug
hole (6).
a Set the probe end so that it is in parallel
with the direction of the pipe at its center.
3) Start the engine, and operate the handle of
handy smoke checker C1 under the torque
converter stalled condition so that the filter
paper will absorb the exhaust gas.
a Suction time: 1.4 0.2 second

a If an air source and a electric power source are


not available in the field, use handy smoke
checker C1. When recording official data, etc.,
use smoke meter C2.

Testing

(WA470-A900-385-K-00-A)

1. Open the engine left side cover and remove


cover (4).

4) Remove the filter paper and compare it with


the attached scale for judgment.
5) After finishing the test, remove the testing
tools and restore the machine.
4. Testing with smoke meter C2
1) Connect the probe hose, accelerator switch
outlet and air hose to smoke meter C2.

2. Remove plug (5).

30-14

a The supplied air pressure must be 1.5


MPa {15 kg/cm2} or below.
2) Connect the power cable to an AC 100 V
receptacle.

WA470-7

30 Testing and adjusting


Engine and cooling system

a Before connecting the power cable, make


sure that the power switch of the smoke
meter is turned OFF.
3) Insert probe [1] of the smoke meter C2 into
port (6) for the removed plug.
a Set the probe end so that it is in parallel
with the direction of the pipe at its center.

4) Loosen the cap nut of the suction pump and


place the filter paper.
a Place the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch of smoke meter C2
ON.

6) Start the engine, put the torque converter in


the stalled condition, and then depress the
accelerator pedal of smoke meter C2 to
collect the exhaust gas impurities on the filter
paper.
7) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
8) After finishing the test, remove the testing
tools and restore the machine.

WA470-7

30-15

30 Testing and adjusting


Engine and cooling system

Testing and adjusting valve clearance


a Testing tools
Symbol
D

Part No.

Part name

Commercially Feeler gauge


available

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

(WA470-A700-360-K-00-A)

a The rocker arm of No.1 cylinder with the


piston at the compression top dead center
can be moved by hand by the distance
equivalent to the valve clearance. If the
rocker arm cannot be moved, the No.1
cylinder is not at its compression top dead
center. In that case, rotate the crankshaft one
more turn.

k Turn

the battery disconnect switch to OFF


position, and remove the key.

a Test and adjust the valve clearance under the


following conditions.
When engine is cold

Testing

(WA470-A700-361-K-00-A)

1. Remove cylinder head cover (1). For details, see


Disassembly and assembly, removal and
installation of cylinder head assembly.

2. Remove rubber cover (2) on the front side of


damper

3. Rotate the crankshaft in the normal direction to


set No.1 cylinder to the compression top dead
center by matching "1.6 TOP" stamping mark (a)
of the damper to pointer (4).

4. While No.1 cylinder is at the compression top


dead center, check the valve clearance of the
valves marked with q in the following figure.
5. Rotate the crankshaft in the normal direction by
one turn and check the valve clearance of the
remaining valves marked with Q.

a Stamp marks are "1.6 TOP", "2.5 TOP" and


"3.4 TOP".

30-16

WA470-7

30 Testing and adjusting


Engine and cooling system

a You may check the valve clearance of No.1


cylinder while No.1 cylinder is at the
compression top dead center and then turn
the crankshaft in the normal direction by 120
degrees and check the valve clearance of
each cylinder in the firing order.

4. After finishing the adjustment, remove the


adjusting tools and restore the machine.
3 Cylinder head cover (1) mounting
bolt:
9.8 1 Nm {1.0 0.1 kgm}

a Firing order: 1-5-3-6-2-4


a The valve clearance is normal if it is within
the range of the standard value. For standard
values, see "Standard value table",
"Standard value table related to engine".
6. After finishing the test, remove the testing tools
and restore the machine.

Adjusting

(WA470-A700-27D-K-00-A)

After testing, adjust the valve clearance according


to the following procedure if necessary.
a After setting the No.1 cylinder at the
compression top dead center, adjust valve
clearance of No.1 cylinder.
1. While fixing adjustment screw (6), loosen lock
nut (7).
2. Insert feeler gauge D into the clearance between
rocker arm (8) and crosshead (9), and adjust the
valve clearance with adjustment screw (6).
a With feeler gauge D inserted, turn the
adjustment screw (6) until the feeler gauge D
can move lightly.
a For standard values, see "Standard value
table", "Standard value table related to
engine".
3. With adjustment screw (6) fixed, tighten lock nut
(7).
3 Lock nut (7):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a After tightening lock nut (7), check the valve
clearance again.
a The following figure shows adjustment of air
intake side of No.4 cylinder.

WA470-7

30-17

30 Testing and adjusting


Engine and cooling system

Testing compression pressure

(WA470-A000-360-K-00-A)

a Testing tools
Symbol
1
2
E
3

Part No.

Part name

795-502-1590 Gauge assembly


795-471-1420 Adapter
6217-71-6112 Gasket
Hose (inside diameter 14
Commercially mm, length approximately
available
2 m)

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k Turn

the battery disconnect switch to OFF


position and remove the key.

k When

testing the compression pressure, be


careful not to burn yourself by touching the
exhaust manifold or KDPF, or get caught in a
rotating part.

a Measure the compression pressure under the


following conditions.
Engine oil temperature: 40 to 60C

Testing

(WA470-A000-36B-K-00-A)

1. Remove engine hood, air cleaner assembly, and


KDPF assembly according to "Removal and
installation of cylinder head assembly" in
"Disassembly and assembly".
2. Remove tubes (1) and (2) of KCCB, and
harness (3).

3. Remove spill tube (8).


a This helps the sleep nut to be removed
easily.

a Remove all connectors and clamps of supply


pump (4), EGR Valve (5), air conditioner
compressor (6), and dosing valve (7) for
wiring harness (3) to be released.

4. Remove the cylinder head cover (9), and set the


cylinder to be tested to the compression top
dead center. For details, see "Testing and
adjusting valve clearance".

30-18

WA470-7

30 Testing and adjusting


Engine and cooling system

a Check that both the intake rocker arm and


exhaust rocker arm at the compression top
dead center are movable by hand by the
distance equivalent to the valve clearance.
5. Replace the filter cartridge (10).

8. Pull high-pressure tube (12), and remove the


injector (16).

9. Install adapter E2 to the injector mounting hole.


a Be sure to install the gasket to the top of the
adapter E2.
6. Remove cover (11) of the common rail, then
remove high-pressure fuel tube (12) to be
checked.

a Fix the adapter E2 with the injector holder


(17).
3 Holder mounting bolt (18):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
10.Install rocker arm assembly (13).
3 Rocker arm assembly mounting bolt
(19):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
11.Adjust the valve clearance.
See "Testing and adjusting valve clearance".

7. Remove rocker arm assembly (13), and


disconnect injector wiring harness (14).
a Disconnect the injector wiring harness (14)
from the terminals on the injector side, and
pull it to the outside of the rocker housing.
(Loosen 2 pieces of terminal nuts
alternately).
a QR code tab (15) is attached to the top of the
injector. Do not remove or damage it.

WA470-7

12.Install spill tube, filter cartridge, wiring harness,


and air cleaner assembly.
13.Connect compression gauge E1 to adapter E2.

30-19

30 Testing and adjusting


Engine and cooling system

a Apply a small amount of engine oil to the


connecting portion of the adapter E2 and
compression gauge to prevent air leakage.

14.Install a fuel drain hose (E3) at where the tube is


disconnected of the common rail, and let
injected fuel drain to a container.

16.Rotate the crankshaft by the starting motor and


measure the compression pressure.
17.After finishing the test, remove the testing tools
and restore the machine to its original condition.
a Install the injector, injector wiring harness
and high-pressure fuel tube according to the
following procedure.
1) Install 2 O-rings (20) and (21) and gasket
(22) to injector (16).
a Do not fit O-ring (20) into spill groove in
the center, but fit it into O-ring groove.
Insert injector into cylinder head after
applying engine oil to O-ring.
2) Assemble holder (17) and injector (16), then
install them to the cylinder head temporarily.
3) Set spherical washer (23) to mounting bolt
(18) and tighten the bolts to the cylinder
head.

15.Select the "No-Injection cranking" operation by


operating the machine monitor.
a Turn the battery disconnect switch to ON
position, then turn the starting switch to ON
position.
a For the "No-Injection cranking" setup
procedure, see the section of "Special
functions of machine monitor".
k If

the engine is not set to the "No-Injection


cranking", it may start during
measurement and cause personal injury.
Accordingly, be sure to set the engine in
this mode.

30-20

2 Spherical part of spherical washer


(23):
Engine oil (SAE30DH)
3 Mounting bolt (18):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
4) Tighten 2 nuts at the tip of wiring harness
(14) alternately to injector (16).
3 Nut:
2.0 to 2.4 Nm {0.2 to 0.24 kgm}
5) Tighten tube (12) to injector (16).
3 Sleeve nut:
39.2 to 44.1 Nm {4 to 4.5 kgm}
6) Tighten the clamp bolt for the fuel piping.

WA470-7

30 Testing and adjusting


Engine and cooling system

3 Clamp bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}

3 Rocker arm assembly mounting


bolt (19):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a Adjust the valve clearance. For details of
the procedure, see "Adjusting valve
clearance".
3 Cylinder head cover mounting
bolt:
9.8 1 Nm {1.0 0.1 kgm}

WA470-7

30-21

30 Testing and adjusting


Engine and cooling system

Testing blowby pressure

(WA470-A000-360-K-02-A)

a Testing tools
Symbol
1
F

Part No.

Part name

799-201-1504 Blowby checker


Plug (hose inside
2 799T-201-3210 diameter: 24 mm)
Cap (pipe outside
3 799T-201-3220 diameter: 25.4 mm)

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

a Measure the blowby pressure under the


following conditions.
Coolant temperature: 60 to 102C
Torque converter oil temperature: 60 to 80C
Perform when the regeneration is stopped.

Testing

(WA470-A000-36C-K-00-A)

1. Open the side cover on the right side of engine.


2. Disconnect KCCV gas outlet side hose (1) and
KCCV gas inlet side hose (2).

4. Start the engine to increase temperature of the


engine coolant to the operating range.
5. Set the transmission cut-off selector switch to
OFF position, and depress the left brake pedal
securely.
6. Set the torque converter lockup switch to OFF
position.
7. Set transmission shift mode selector switch to
MANUAL position.
8. While keeping the directional lever or directional
selector switch in N (neutral) position, set the
gearshift lever to 4th speed.
9. Release parking brake.
10.While depressing brake pedal, set directional
lever or directional selector switch to "F
(forward)" or "R (reverse)" position.
k Keep

brake pedal firmly depressed.

11.Depress the accelerator pedal gradually to run


the engine at full speed and stall the torque
converter to measure the blowby pressure.
a Do not keep stalling the torque converter for
more than 20 seconds. Be careful that the
torque converter oil temperature will not
exceed 120C.
3 Clamp:
4.4 0.49 Nm {0.45 0.05 kgm}
3. Plug pipe (3) on KCCV gas outlet side with plug
F2, and install cap F3 to KCCV gas inlet pipe (4)
and outlet pipe (5). Install tool and adapter [1] of
blowby checker F1 to KCCV gas inlet hose (6),
and connect gauge [3].

30-22

a Normally, the blowby pressure should be


measured while the engine is operated at the
rated output. In the field, however, an
approximate value can be obtained by
stalling the torque converter.
a Precaution for measuring blowby pressure
The blowby pressure may vary largely with
the engine condition. If the measured value
is judged unusual, make a check for increase
of oil consumption, bad exhaust gas color,
early deterioration or contamination of oil, etc.
which are related to the unusual blowby
pressure.

WA470-7

30 Testing and adjusting


Engine and cooling system

12.After finishing test, remove the testing tools and


restore the machine.

WA470-7

30-23

30 Testing and adjusting


Engine and cooling system

Testing engine oil pressure

(WA470-AB00-360-K-00-A)

a Testing tools
Symbol
1
G 2
3

Part No.

Part name

799-101-5002 Hydraulic tester


790-261-1204 Digital hydraulic tester
799-401-2320 Gauge

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

a Measure the engine oil pressure under the


following condition.
Coolant temperature: 60 to 102C

Testing

(WA470-AB00-362-K-00-A)

a Check the engine oil pressure with Monitoring/


Pre-defined or Monitoring/Custom of the
machine monitor.

3. Start the engine to increase the cooling


temperature to the operating range.
4. Measure the oil pressure with the engine at low
idle and high idle.
a The engine oil pressure is normal if it is within
the range of the following standard values.
At high idle
At low idle

See standard value table


See standard value table

a Monitoring code: 37200 Engine Oil Pressure


1. Open side cover on the left of engine, and
remove oil pressure pickup port plug (1) from the
engine oil filter.

5. After finishing the test, remove the testing tools


and restore the machine.
3 Oil pressure pickup plug:
2. Install nipple [1] and hose [2] of hydraulic tester
G1 and connect them to gauge G3.

20 2 Nm {2.04 to 0.2 kgm}

3 Nipple:
20 2 Nm {2.04 to 0.2 kgm}
a The nipple and hose for digital hydraulic
tester G2 can also be used.

30-24

WA470-7

30 Testing and adjusting


Engine and cooling system

Testing EGR valve and KVGT oil pressures


a Testing tools
Symbol
H

Part No.

795T-401-1310
1
02896-21015
2 799-101-5002
3 790-261-1204

Part name
Plug
O-ring
Hydraulic tester
Digital hydraulic tester

(WA470-A9K1-360-K-00-A)

a The nipple and hose of digital hydraulic tester


H3 can also be used.
3 Plug H1:
34.3 to 44.1 Nm {3.5 to 4.5 kgm}

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

Coolant temperature: 60 to 102C


a The standard values for the EGR valve drive oil
pressure and the KVGT drive oil pressure are
the same, because they share the same circuit.

Testing

(WA470-A9K1-362-K-00-A)

1. Open side cover (1) on the left of engine

5. Start the engine and measure the oil pressure at


low idle and high idle.
a When the EGR valve and KVGT driving oil
pressure is in the following standard range, it
is normal.
At low idle
At high idle

See standard value table


See standard value table

2. Remove clamp (2), and lower dosing fuel hose


(4).
3. Remove plug (3) (driving oil pressure).
6. After finishing the test, remove the testing tools
and restore the machine.
3 When installing plug (3), install new Orings H1(2 pieces).
3 Joint plug (3):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}

4. Install plug H1, and install nipple and hose of


hydraulic tester H2, and then connect them to
gauge [3].
a Be sure to fit the O-ring to plug H1.
a Use gauge [3] of 2.5 MPa {25 kg/cm2}.
WA470-7

30-25

30 Testing and adjusting


Engine and cooling system

Testing fuel pressure

(WA470-AE20-360-K-00-A)

a Testing tools
Symbol
1
2
J

3
4

Part No.
799-101-5002
790-261-1204
795-790-5120
07005-01412
790-301-1530
799-401-2320

Part name
Hydraulic tester
Digital hydraulic tester
Screw
Gasket
Elbow
Gauge

k When

removing or installing testing tools for


the fuel system, stop the engine and wait for
at least 30 seconds until the remaining
pressure is released from the fuel circuit. (Do
not start the work immediately after the
engine is stopped since remaining pressure
is still in the circuit.)

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

5. Start the engine and measure the fuel pressure


at engine high idle.
a The fuel pressure is normal when it is within
the following standard value range.
Engine speed
High idle

Fuel pressure
See standard value table

k Since

the pressure in the high-pressure


circuit from the supply pump through the
common rail to the injector is very high and
dangerous, do not measure it.

Testing

(WA470-AE20-362-K-00-A)

1. Open the side cover on the right side of engine.


2. Remove fuel tube mounting bolt (3) on the upper
side of fuel filter.

6. After finishing the test, remove the testing tools


and restore the machine.
3 Fuel pressure pickup plug (3):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}

3. Install screw and elbow J3.


a Be sure to fit the gasket.
4. Install nipple and hose [2] of hydraulic tester J1
to screw and elbow J3, and then connect them
to gauge J4.
a The nipple and hose of digital hydraulic tester
J2 can also be used.

30-26

WA470-7

30 Testing and adjusting


Engine and cooling system

Testing fuel return rate and leakage

(WA500-AE20-360-K-00-A)

a Testing tools
Symbol
1
2
3
K

4
5
6

Part No.
6151-51-8490
6206-71-1770
Commercially
available
Commercially
available
Commercially
available
Commercially
available

Part name
Spacer
Joint
Hose (inside diameter:
approximately 6 mm)
Hose (inside diameter:
approximately 16 mm)
Measuring cylinder
Stopwatch

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

a Since some fuel flows out during test, prepare a


container of approximately 20 l.
k When

removing or installing testing tools for


the fuel system, stop the engine and wait for
at least 30 seconds until the remaining
pressure is released from the fuel circuit. (Do
not start the work immediately after the
engine is stopped since remaining pressure
is still in the circuit.)

WA470-7

30-27

30 Testing and adjusting


Engine and cooling system

A: Measuring position of leakage from pressure limiter


B: Measuring position of return rate from injector

30-28

WA470-7

30 Testing and adjusting


Engine and cooling system

Testing

(WA470-AE20-363-K-00-A)

Testing leakage from pressure limiter


1. Open engine right side cover (1) and (2).

a Be sure to install the gasket to the both ends


of the joint.
5. Connect test hose K3 to the end of joint K2.
a Bind the connected part of the test hose with
a wire, etc. to prevent it from coming off.
a Arrange the route of the test hose so that it
does not sag, and put its end in a container.

2. Remove tube (5) between pressure limiter (3)


and return block (4).

6. Start the engine, and stall the torque converter.


a For the torque converter stalling procedure,
see "Testing engine speed".
7. After the engine speed is stabilized, measure
the leakage for 1 minute by using measuring
cylinder K5.

3. Insert spacer K1 into the return block (4) side,


and tighten the removed joint bolt again.
3 Joint bolt:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
a Be sure to install the gasket to the both ends
of the spacer.

4. Insert joint K2 into the common rail (6) side and


tighten the removed joint bolt again.
3 Joint bolt:
17.7 to 22.6 Nm {1.8 to 2.3 kgm}

WA470-7

a Measuring duration can be 20 seconds if the


leaked amount is multiplied by 3 after the
measurement.
a Leakage from the pressure limiter is normal
when it is within the following standard value
range.
Measurement condition

Leakage
(cc/min)

With torque converter


stalled

See standard value table

8. Stop the engine after the measurement is over.


Testing fuel return rate from injector

30-29

30 Testing and adjusting


Engine and cooling system

a While measuring the fuel return rate from the


injector, keep the hose on the pressure limiter
side connected and insert the hose end in the
container.
1. Disconnect fuel return hose (7) of return block
(4).
a Plug the fuel hose by using a plug.
Plug part number: 07376-70315

a Return (spill) rate from the injector is normal


if it is within the following standard value
range.
Engine speed
(rpm)

Limit return (spill) rate


(cc/min)

1,600

See standard value table

1,700
1,800
1,900
2,000

See standard value table


See standard value table
See standard value table
See standard value table

2. Connect test hose K4 to the return block (4)


side.
a Bind the connected part of the test hose with
a wire, etc. to prevent it from coming off.
a Arrange the route of the test hose so that it
does not sag, and put its end in a container.

5. After finishing the test, stop the engine, remove


the testing tools and restore the machine.
3 Joint bolt on block side:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Joint bolt on common rail side:
17.7 to 22.6 Nm {1.8 to 2.3 kgm}

3. Start the engine, and stall the torque converter.


a For the torque converter stalling procedure,
see "Testing engine speed".
4. After the engine speed is stabilized, measure
the return rate for 1 minute by using measuring
cylinder K5.
a Measuring duration can be 20 seconds if the
leaked amount is multiplied by 3 after the
measurement.
a If the error of no-pressure feed occurs on the
supply pump, there is a case that the engine
speed does not increase. In such case,
record the engine speed during testing, as
well.

30-30

WA470-7

30 Testing and adjusting


Engine and cooling system

Bleeding air from fuel system

(PC400-AD00-001-K-00-A)

Low-pressure fuel circuit

1. Fuel tank
2. Fuel connector
3. Pre-filter
4. Fuel feed pump
5. Doser
6. Supply pump
7. Feed pump

a In the following cases, bleed air according to this


procedure.
When a fuel filter is replaced
When run out of fuel occurs
When starting the engine for the first time
after replacing fuel piping or supply pump
k Place

the machine on a level ground, and


lower the work equipment to the ground.

8. Cooling plate
9. Main fuel filter
10. Common rail pressure
11. Injector
12. Pressure limiter valve
WA470-7

k While

the fuel feed pump is in operation,


pressure is applied to the fuel circuit. Do not
loosen the air bleeding plug at this time,
since the fuel may spout out.

30-31

30 Testing and adjusting


Engine and cooling system

Bleeding air

(WA470-AD00-231-K-00-A)

1. Supply fuel to the fuel tank.


a Continue the supply of fuel until the fuel
gauge monitor turns to blue.
(Check the fuel level with monitor after
turning the starting switch to ON position.)
2. Open side cover (1) on the right of engine.

4. After the specified time (approximately 6


minutes and 30 seconds), lamp (3) automatically
goes off and the fuel feed pump stops.

3. Tilt switch (2) for the fuel feed pump in the


engine room to ON position.
a The fuel feed pump operates and lamp (3)
flashes.

a When only the fuel filter is replaced, air


bleeding work is completed at this point.
5. When fuel in the fuel circuit is lost in the cases
as fuel is run out or the fuel piping or supply
pump is replaced, set switch (2) to ON position
again immediately after the fuel feed pump stops
automatically.
6. Air bleeding is complete when lamp (3) goes off.
7. Start the engine.
k Make

sure that no person is found around


the engine before starting the engine.

a Do not turn the starting motor continuously


for more than 20 seconds.
a The air in the high-pressure circuit is bled
automatically by cranking the engine.
a After the engine is started, run it at low idle
for approximately 5 minutes to bleed air
completely from the fuel circuit.
a The timer built in this switch automatically
starts up and stops the fuel feed pump (see
the figure).
a Operation of the fuel feed pump stops while
the lamp is flashing. It is, however, not a
failure.
a If you set the switch to OFF position while the
lamp is lighted, the lamp goes out and the
fuel feed pump stops.

30-32

WA470-7

30 Testing and adjusting


Engine and cooling system

Testing fuel circuit for leakage

(WA380-AD00-001-K-01-A)

a Testing tools
Symbol
L

Part No.

Part name
Developer
Commercially for dye penetrant
available
check (color
checker)

k Very

high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it presents
a serious danger that could result in a fire.
After testing the fuel system and removing or
installing the tools for the test, test it for fuel
leakage according to the following procedure.

a To apply a load to the engine installed on the


machine, perform the torque converter stall
operation or hydraulic relief of the hydraulic
pump.
9. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
checker L is sprayed.
a If any fuel leakage is detected, repair it and
perform the checks from Step 1 again.
a If no fuel leakage is detected, check is
completed.

k Park

the machine on a level ground and


lower the work equipment to the ground.

a Clean and degrease the engine and the parts


around it in advance so that you can check it
easily for fuel leakage.

Testing

(WA380-AD00-364-K-00-A)

1. Spray color checker (developer) L to the fuel


supply pump, common rail, fuel injectors, and
joints of the high-pressure fuel piping.
2. Start the engine, keep its speed at 1,000 rpm or
below, and stop it when its speed is stabilized.
3. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
checker L is sprayed.
a If any fuel leakage is detected, repair it and
perform the checks from Step 1 again.
4. Start the engine and keep it running at low idle.
5. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
checker L is sprayed.
a If any fuel leakage is detected, repair it and
perform the checks from Step 1 again.
6. Start the engine and keep it running at high idle.
7. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
checker L is sprayed.
a If any fuel leakage is detected, repair it and
perform the checks from Step 2 again.
8. Start the engine and keep it running at high idle,
then apply a load to the engine.

WA470-7

30-33

30 Testing and adjusting


Engine and cooling system

Handling cylinder cutout mode operation

(PC-AD00-34F-K-00-A)

a The cylinder cut-out test mode operation means


to run the engine with the fuel injectors of one or
more cylinders disabled electrically to reduce the
number of active cylinders. The purposes and
effects of this operation are as follows.
1. This mode is used to find out a cylinder which
does not output power properly (or, combustion
in it is abnormal).
2. When a cylinder is selected for the Cylinder Cutout Mode operation, if the engine speed and
output do not change from the normal operation
(all-cylinder operation), that cylinder has one or
more defects.
The following problems can be considered:
Compression leak from cylinder head gasket
Defective injection from injector
Defective piston or piston ring
Defective valve mechanism (valve operating
system)
Defective electrical system
3. The injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, so the cylinder cut-out test can
be performed easily by the simple operations of
the switches compared with the mechanical fuel
injection system. This allows to find out a
defective cylinder easily.

30-34

WA470-7

30 Testing and adjusting


Engine and cooling system

Handling no injection cranking operation

(PC-A000-25L-K-00-A)

a No-injection cranking means to crank the engine


by using the starting motor while all the
injections are stopped electrically. The purpose
and effect of this operation are as follows.
Before the engine is started after it or the
machine has been stored for a long period, the
no-injection cranking is performed to lubricate
the engine parts and protect them from seizure.

WA470-7

30-35

30 Testing and adjusting


Engine and cooling system

Testing of KDPF and muffler stack for looseness and damage

(WA380-A9H0-280-K-

00-A)

1. Visually check KDPF and muffler stack for


cracking and damage. If any part is damaged,
replace it.
2. Check the mounting bolts of the KDPF and
muffler stack for looseness. If any part is
loosened, retighten it.

30-36

WA470-7

30 Testing and adjusting


Engine and cooling system

Testing of installed condition of cylinder head and manifolds

(WA380-A100-280-K-00-

A)

Check the cylinder head and intake and exhaust


manifold mountings for looseness. If any part is
loosened, retighten it.
a For the tightening torques, see the "Disassembly
and assembly".

WA470-7

30-37

30 Testing and adjusting


Engine and cooling system

Testing engine piping for damage and looseness

(WA380-A000-280-K-00-A)

Air intake and exhaust systems: Check the piping


for damage, the mounting bolts and nuts for
looseness, and the joints for air suction and exhaust
gas leakage. If any part is loosened or damaged,
retighten or repair it.
Cooling system: Check the piping for damage, the
mounting bolts and nuts for looseness, and the
joints for water leakage. If any part is loosened or
damaged, retighten or repair it.
Fuel system: Check the piping for damage, the
mounting bolts and nuts for looseness, and the
joints for fuel leakage. If any part is loosened or
damaged, retighten or repair it.

30-38

WA470-7

30 Testing and adjusting


Engine and cooling system

Testing and adjusting air conditioner compressor belt tension

(WA380-K5A0-001-K-

00-A)
k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

Testing

(WA470-K5A0-285-K-00-A)

1. Open the side cover on the right side of engine.


2. Before checking, insert the starting switch key
into lock (1) to release it, and open cover (2).

2. Loosen bolts (4) and (5).


3. Tighten bolt (9) after loosening nut (8) installed
to bracket (7), compressor (6) shifts in direction
A, and the compressor belt can be stretched.

3. Press the intermediate point of the belt between


air conditioner compressor pulley and crankshaft
pulley with a finger and measure deflection (a).
Belt pressing force: Approx. 98 N {Approx.
10 kg}
Deflection (a): 25 to 26 mm

4. After measurement, close cover (2), and lock it


with the starting switch key.

Adjusting

(WA470-K5A0-27C-K-00-A)

a If the belt deflection is abnormal, adjust it


according to the following procedure.
1. Before adjusting, insert the starting switch key
into lock (1) to release it, and open covers (2)
and (3).

4. After adjusting the belt tension properly, tighten


nut (8) until it touches boss (10) and tighten it
further in direction B so that it is not loosened.
3 Tightening torque:
157 to 196 Nm {16 to 20 kgm}
5. Tighten bolts (4) and (5) to fix bracket (7).
3 Tightening torque
Bolt (4): 157 to 196 Nm {16 to 20 kgm}
Bolt (5): 98 to 123 Nm {10 to 12.5 kgm}

WA470-7

30-39

30 Testing and adjusting


Engine and cooling system

6. After adjusting, close covers (2) and (3), and


lock it with the starting switch key.
a Check each pulley for damage, wear of the Vgroove, and the wear of the V-belt. In particular,
be sure to check that the V-belt does not touch
the bottom of the V-groove.
a Replace the belt with a new one if the belt is
stretched and has no allowance for adjustment,
or has slipping sound or squeak because of cuts
or cracks of the belt.
a If the V-belt is replaced, adjust its tension again
after one hour of operation.

30-40

WA470-7

30 Testing and adjusting


Engine and cooling system

Testing and adjusting alternator belt tension


Testing

(WA470-AKM4-923-K-00-A)

1. Open side cover on the left of engine.


2. Insert the starting switch key into lock (1) to
release it, and open cover (2).

3. Press the belt at the intermediate point between


the alternator pulley and crank pulley with your
finger and measure deflection (a).
Depressing force: Approximately 59 N {6 kg}
Deflection (a): Approximately 13 to 16 mm

(WA470-AKM4-360-K-00-A)

2. After loosening bolts (5) and (6), loosen locknut


(7).
3. Alternator (8) moves to the direction (A) by
rotating adjustment nut (9), and tension can be
applied to alternator drive belt.
4. When the belt tension becomes appropriate,
tighten locknut (7) until it comes to contact with
boss (10).
5. Tighten bolts (5) and (6) to fix alternator (8).
Bolt (5): 28.4 to 38.2 Nm {2.9 to 3.9 kgm}
Bolt (6): 107.8 to 147 Nm {11 to 15 kgm}
6. After adjusting, install cover (3) and handrail (4),
close cover (2), and lock it with the starting
switch key.
a Check each pulley for damage, wear of the Vgroove, and the wear of the V-belt. In particular,
be sure to check that the V-belt does not touch
the bottom of the V-groove.
a Replace the belt with a new one if the belt is
stretched and has no allowance for adjustment,
or has slipping sound or squeaks because of
cuts or cracks of the belt.
a If the V-belt is replaced, adjust its tension again
after one hour of operation.

4. After measurement, close cover (2), and lock it


with the starting switch key.

Adjusting

(WA470-AKM4-285-K-01-A)

1. Insert the starting switch key into lock (1) to


release it, open cover (2), then remove cover (3)
and handrail (4).
WA470-7

30-41

30 Testing and adjusting


Engine and cooling system

30-42

WA470-7

30 Testing and adjusting


Engine and cooling system

Procedures for cleaning fuel doser

(WA500-A9H6-360-K-00-A)

a The procedure given below is applicable when


you perform the engine troubleshooting "S-22
Active regeneration is operated for long" due to
malfunctioning of KDPF device or clean the fuel
doser in 4,500-hour periodic maintenance.
k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k Install

and remove the fuel doser after


making sure that the temperature of the
exhaust manifold and exhaust piping has
lowered.

Removal

Cleaning

(HM300-A9H6-255-K-00-A)

1. Eliminate soot (14) adhered to fuel doser (8).

(WA470-A9H6-520-K-00-A)

1. Open full-length fender (1), and side cover (2).

2.
3.
4.
5.
6.

Disconnect connector DOSER (3).


Remove clamps (4) (3 pieces).
Disconnect fuel hose (5). [*1]
Disconnect coolant hose (6). [*2]
Remove bolts (7) (2 pieces) (8 mm of width
across flats), and remove fuel doser assembly
(8).

2. Soak cloth (15) with sufficient volume of diesel


fuel, and press it against the accumulated soot
in the tip of the fuel doser injection port for the
diesel oil to permeate into the soot.

3. After the diesel fuel permeates into the


accumulated soot, clean it with cloth (15).

WA470-7

30-43

30 Testing and adjusting


Engine and cooling system

4. Eliminate soot in the injection port by scrubbing


the tip of the port by using nylon brush (16).
Eliminate soot completely from the injection
port by using nylon brush (16) and cloth (15).
a Use a nylon brush for the cleaning since a
wire brush can damage the injection port.
a Use diesel fuel for the cleaning agent without
using other solvents.

Installation

(HM300-A9H6-720-K-00-A)

1. Install heat insulator (10) to fuel doser (8).


2. Insert bolt (11) into fuel doser (8), install gasket
(9) to the fuel doser, then install them to the
exhaust connector.
3 Bolt (11) (width across flats 8 mm):
8.5 to 9.5 Nm {0.87 to 0.97 kgm}
a Bolt (11), gasket (9) and heat insulator (10) to
be used must be new ones.

a Tip of injection port after cleaning


Cleaning complete (A: Tip of injection port is
free from remaining soot)
Cleaning incomplete (B: Tip of injection port
has remaining soot)

30-44

a Install gasket (9) so that its stepped portion


becomes convex against the exhaust
connector.

WA470-7

30 Testing and adjusting


Engine and cooling system

a When installing gasket (9) and heat insulator


(10), be careful for them not to fall.
3. Install the bracket, fuel hose clamp and wiring
harness clamp in the reverse order of removal.
4. After installing the fuel doser, run the engine at
low idle for approximately three minutes. Then
stop the engine and check the fuel doser for
water and fuel circuits for leakage.

WA470-7

30-45

30 Testing and adjusting


Engine and cooling system

Writing compensation values at replacement of injector and engine


controller (WA500-AP70-360-K-00-A)
a Equipment for writing compensation values
Symbol

Part No.

1
2
3
ZC
4
5
6

Part name

a Service connector (1) (CN-SV) is installed to


rear left of the operator's seat.

Notebook computer:
Commercially
Windows XP SP2/VISTA/
available
Windows 7
Cu3886388 INSITE ver 7.4
795-799-5730 INLINE 5 Kit
Commercially
Cable (USB)
available
Cable (RS232)
or
795-799-5740
795-799-5720 Cable (9P)
799-601-4510 Cable (12P)

a To install INSITE to a PC, insert DVD-ROM


software and operate the PC according to the
displayed menus.
a Use INSITE ver 7.4 Feature Pack 1 or later
version for the writing.
a Since a failure (shutdown or disconnection) on a
PC or cable can induce a serious error to the
engine controller, sufficient care must be taken
for the cable connection.

Start INSITE
1. Boot the PC.
2. Turn the starting switch to the ON position and
supply power from the battery to the engine
controller.
3. Double-click the icon on the PC shown below.

a When connecting INSITE to the engine


controller, make sure not to stop supply of power
from the battery to the engine controller.
Stopping the power supply loses the connection
with INSITE.

Adjusting

(WA500-AP70-270-K-00-A)

Connecting PC
1. Check that the starting switch is turned to the
OFF position.
k The

starting switch must be turned to the


OFF position when a PC is connected or
disconnected.

2. Install personal computer ZC1, data link adapter


ZC3, and cables ZC4, ZC5, and ZC6, and then
connect them to service connector (1) (CN-SV).

4. Establish communication with the engine


controller.
1) Select "Connect to ECM".
Section A: Make sure that "INLINE 5 USB
(J1939) Connection" is indicated.

2) Select "Connect".
Section B: Confirm that "None" is
displayed.

30-46

WA470-7

30 Testing and adjusting


Engine and cooling system

a C: Connection-in-process screen
D: Screen after the connection is
completed (illustration does not move)
E: Communication status is displayed
(illustration moves during communication)

3) Input the new data to "New Barcode"


column.
a Replacement of the injector and engine
controller is performed.
1] Replace injector.
When the injector is replaced, write
the injector compensation value
written on the new injector in the
engine controller.
If the compensation value is not
correctly written, an engine trouble
can result.
The character string on the injector
top face is read from left to right.

5. Execute the injector trim function and data


writing.
1) Select "Advanced ECM Data".
Section F: Make sure that "Advanced
ECM Data" is indicated.

2) Select "High Pressure Common Rail Injector


Setup".
Section G: Make sure that "High
Pressure Common Rail Injector Setup" is
indicated.

WA470-7

2] Replacing engine controller


When the engine controller is
replaced, write the injector
compensation value written on the old

30-47

30 Testing and adjusting


Engine and cooling system

engine controller to the new engine


controller.
If the compensation value is not
correctly written, an engine trouble
can result.
Compensation value information
provided on the back of engine
controller
a: String of characters
b: QR code

Section K: Select "OK."

Screen while data processing is


continued (wait for 30 seconds)

Section H: "New Barcode" column

6) After data processing is over, turn the


starting switch to the ON position and select
"OK".
Section L: Select "OK."

4) Execute writing to the engine controller.


After entering the injector data, select "Apply".
I: Entry of data of the target injector.
Examples)
Enter data of No.1 cylinder injector
corresponding to "Cylinder1".
Section J: Select "Apply."

7) Screen that indicates data writing is over.


Select "OK".
Section M: Select "OK."

5) After writing data, turn the starting switch to


the OFF position and select "OK".

30-48

WA470-7

30 Testing and adjusting


Engine and cooling system

8) Screen that appears when data writing ends


successfully. "Success" is displayed on the
screen.
Section N: Make sure that "success" is
indicated.

7. Turn the starting switch to the OFF position, then


boot the PC again (turn the starting switch to the
ON position) to make sure that an error is not
present on the monitor.
a Failure code:
CA2765: Inj Trim Data Error
8. When replacing the injector, clear the values on
the compensation values sheet on the back of
the engine controller.
a Clear the data of the replaced injector on the
compensation values sheet that is provided
on the back of the engine controller.

a Screen that appears for faulty data writing


Section P: Indicates that writing is
faulty.
If the following screen appears in
stead of the screen of item 8) after the
operation of Step 7), it is suspected
that the entered new data is
inappropriate.
(Check the data again and repeat its
entry.)

a Record the data of the replaced injector in


the maintenance register.
9. When the engine controller is replaced,
inconsistency may result between the data
recorded on the sheet on the back of the engine
controller and that recorded in the register when
replacement of an injector or engine controller
was done before. In such case, you must use
the compensation character strings contained in
the maintenance record information or import
the compensation value information described
on the top face of every injector installed on the
cylinders, in the same way as you did in the
above when you replaced the injector.

6. Disconnect and end the communication with the


engine controller.
Section Q: Select "Disconnect from ECM."

WA470-7

30-49

30 Testing and adjusting


Power train

Power train

(ALL-C100-001-K-00-A)

Adjusting transmission output speed sensor


Adjusting

(WA380-CNA1-001-K-00-A)

(WA470-CNA1-270-K-00-A)

1. Remove cover on the right side of the rear


frame.
2. Disconnect connector REV OUT (1).

3. Loosen locknut (3), and screw in until tip of


sensor (4) touches a tooth tip of gear (5).
a Check that the sensor tip is free from iron
dust and flaws before installing.
a Apply the liquid gasket between the case and
threaded part of the sensor.
2 Thread portion: Liquid gasket (LG-5)

4. Unscrew sensor (4) from the current position by


a half to one turn.
a Adjust clearance (a) between the sensor tip
and gear (5) tooth tip to 0.75 to 1.5 mm.
5. Secure sensor (4) with lock nut (3).
3 Nut: 49.0 to 68.6 Nm (5.0 to 7.0 kgm)

30-50

WA470-7

30 Testing and adjusting


Power train

Adjusting transmission input speed sensor


Adjusting

(WA380-CNB1-001-K-00-A)

(WA470-CNB1-270-K-00-A)

1. Remove cover (1) on the left side of the rear


frame.

2. Disconnect connector REV IN (2).


3. Loosen locknut (3), and screw in sensor (4) until
its tip hits a tooth tip of gear(5) lightly.
a Check that the sensor tip is free from iron
dust and flaws before installing.
a Apply the liquid gasket between the case and
threaded part of the sensor.
2 Thread portion: Liquid gasket (LG-5)

4. Secure sensor (4) with lock nut (3).


3 Nut: 24.5 to 34.3 Nm (2.5 to 3.5 kgm)

WA470-7

30-51

30 Testing and adjusting


Power train

Flushing procedure for torque converter and transmission hydraulic


circuit (WA380-C151-001-K-00-A)
a Dust such as metal powder in the hydraulic
circuits of the torque converter and transmission
shortens the life of the torque converter and
transmission and causes internal breakage. To
remove dust in the hydraulic circuit, perform
flushing in the following cases.
1. When metal powder flows into the circuit
because of damage to the torque converter,
transmission and hydraulic components.
2. When the torque converter and transmission
are overhauled or modified.

Flushing procedures

(WA470-C151-256-K-00-A)

1. Install a new filter cartridge.


1) Remove inspection cover (1) on the left side
of the rear frame.

2. Supply oil to the transmission case.


Add oil through oil filler (4) to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Transmission case:
65 l (refill capacity)

2) Loosen drain plug (2) and drain the oil in the


filter piping.

3. Flush the hydraulic circuit according to the


following procedure.
1) Start the engine and run it at low idle without
operating the gear shift lever and directional
lever for approximately 20 minutes.
a Increase the engine speed to
approximately 1,500 rpm sometimes.

3) Remove transmission oil filter cartridge (3)


and install cartridge (714-07-28713).

a If the engine coolant temperature gauge


does not rise to the operating range
because of low ambient temperature,
continue the warm-up operation further.
2) Operate or travel for at least 20 minutes.
a Use all the gear speeds (Forward,
reverse, and 1st to 4th).
3) Run the engine at low idle for approximately
20 minutes in the similar procedure to the
one described in 3-1).
4. Replace the filter cartridge.
1) Replace cartridge (1) used for flushing with a
new cartridge (714-07-28713) following the

30-52

WA470-7

30 Testing and adjusting


Power train

same procedure as the one described in the


step 1.
k Be

sure to replace the cartridge with a


new one because the cartridge used
for flushing for long hours causes
premature clogging.

a When installing the filter cartridge, tighten


it by 2/5 turns after the O-ring came in
touch with the filter head.
2) Add oil and check the oil level again.

WA470-7

30-53

30 Testing and adjusting


Power train

Retrieval of disabled machine due to transmission valve failure

(WA470-CJA0-360-

K-00-A)

a Locations of ECMV units

Testing tools
Symbol
O

Part No.

k Place

Part name

794-423-1190 Plug

a If the machine cannot move due to failure of any


part of transmission valves (electrical system,
solenoid valve, spool, etc.), install plugs O. Then
the machine can move.

the machine on a level ground, and


lower the work equipment to the ground.

k Apply

the parking brake, and chock the


wheels.

k When

working while the oil temperature is


still high, be careful not to get burn injury.

k If

the machine cannot move in any gear


speed due to transmission control valve
failure, install the plugs L to ECMV. Then the
machine can move from a dangerous work
site to a safe place where repair can be
performed. Do not use this method for any
situations other than failure.

k When

moving the machine by this method,


observe the procedure and be careful for
safety.

30-54

WA470-7

30 Testing and adjusting


Power train

How to move

(WA470-CJA0-14A-K-00-A)

1. Remove side covers on the right and left of rear


frame.
2. Remove mud and dirt from around the ECMV.
3. Disconnect all connectors (1) from each ECMV.
(13 places)

5. Depress the brake pedal securely.


6. Start the engine, release the parking brake, and
then release the brake pedal gradually to start
and move the machine.
4. Remove 2nd ECMV and F or R ECMV solenoids
(2) (2 pieces), and then install plugs O as
referring to preceding position of each ECMV
installed.
Forward travel: F solenoid and 2nd solenoid
Reverse travel: R solenoid and 2nd solenoid
a If a wrong solenoid is removed, the
transmission may be broken. Care must be
taken.
a Install the plug with its projection facing the
ECMV. Check that the O-ring is fitted to the
mating face.
a Be careful that mud or dirt will not enter the
removed solenoids and valves.

a If the parking brake cannot be released


because of a failure in the electrical system,
release the parking brake referring to
"Method of releasing parking brake
manually".
k Remove

the chocks.

k If

the engine is started, the transmission


is engaged and the machine starts
immediately. Accordingly, when starting
the engine, check the moving direction of
the machine and secure safety around the
machine thoroughly and keep depressing
the brake pedal.

k Stop

the engine after moving the machine,


apply the parking brake, and chock the
wheels.

7. After finishing work, remove the testing tools and


restore the machine.

WA470-7

30-55

30 Testing and adjusting


Power train

Testing oil leakage from axle final drive

(WA470-DF10-280-K-00-A)

Check axle final drive (1) for oil leakage.


If oil leakage is found, the seal or the bearing may
be damaged. Check and repair as necessary.
a See "Disassembly and assembly".

30-56

WA470-7

30 Testing and adjusting


Power train

Testing drive shaft for looseness, backlash, and damage

(WA380-D510-280-K-00-A)

Check the drive shaft for damage, abnormal


backlash, and loosening of connecting bolts and
nuts. If any part is loosened or damaged, retighten
or repair it.
Move the cross member at the universal joint up
and down, right and left, and rotate in both
directions to check.
Push the sliding part of the front drive shaft upward
for several times, and rotate it both directions to
check.
a For the tightening torques, see the "Disassembly
and assembly".

WA470-7

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30 Testing and adjusting


Power train

Testing and adjusting power train oil pressure

(WA470-C100-360-K-00-A)

Pressure pickup plug for P1 (main relief pressure) and P2 (torque converter inlet pressure) is pressure
pickup port for torque converter valve itself. However, this machine is equipped with pressure pickup
nipple (No. 1 and 2) separately.

30-58

WA470-7

30 Testing and adjusting


Power train

WA470-7

30-59

30 Testing and adjusting


Power train

a Testing tools
Symbol
1
2
N 3
4

Part No.
799-101-5002
790-261-1204
799-401-2320
799-101-5220
07002-11023

Part name
Hydraulic tester
Digital hydraulic tester
Gauge
Nipple
O-ring

Oil pressure measuring point and measuring gauge

No.

Oil pressure to be measured

Main relief pressure


Torque converter relief pressure
Torque converter outlet
3 pressure
4 Lockup clutch pressure
5 Transmission F clutch pressure
6 Transmission R clutch pressure
Transmission 1st clutch
7 pressure
Transmission 2nd clutch
8 pressure
Transmission 3rd clutch
9 pressure
Transmission 4th clutch
10 pressure
11 Lubricating pressure
1
2

Measuring
gauge
MPa {kg/
cm2}
6 {60}
2.5 {25}
1 {10}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
1 {10}

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k If

the transmission gear speed must be


shifted while the tires are off ground or the
drive shaft is removed, be sure to lower the
engine speed 1,500 rpm or below, and then
operate the gear shift lever.
Also, be sure to shift only one speed at a
time and wait at least 5 seconds before
making the next shift. Never make multiple
shifts in short intervals or shift more than
one speed at once.

a Test the power train oil pressure under the


following conditions.
Torque converter oil temperature: 60 to 80C
Set the transmission cut-off switch to OFF
position, and use the left brake.
1. Remove side covers on the right and left side of
the transmission.

30-60

WA470-7

30 Testing and adjusting


Power train

Testing

(WA470-C100-362-K-00-A)

Testing transmission main relief pressure

3. While running the engine at low idle and at 2,000


rpm, measure the transmission main relief
pressure.

a Transmission main relief pressure pickup port


(1)

4. After finishing test, remove the testing tools and


restore the machine.
Testing torque converter relief pressure (inlet
pressure)
a Torque converter relief pressure (inlet pressure)
pickup port (nipple) (2)

1. Install hose [1] of hydraulic tester N1 to


transmission main relief pressure pickup nipple
(1). Connect gauge [2] to the hose.
a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.

2. Start the engine with power mode, and keep the


directional lever or directional selector switch in
N (NEUTRAL).

WA470-7

Testing by use of testing tools


1. Install hose [1] of the hydraulic tester N1 to
torque converter relief pressure (inlet pressure)
pickup nipple (2). Connect gauge [2] to the hose.
a The hose of digital hydraulic tester N2 can
also be used.

30-61

30 Testing and adjusting


Power train

a Use an oil pressure gauge of 2.5 MPa {25 kg/


cm2}.

2. Start the engine with power mode, and keep the


directional lever or directional selector switch in
N (NEUTRAL).
3. While running the engine at 2,000 rpm, measure
the torque converter relief pressure (inlet
pressure).

a Monitoring/Pre-defined (9/16) screen

1. Start the engine with power mode, and keep the


directional lever or directional selector switch in
N (NEUTRAL).
2. While running the engine at 2,000 rpm, measure
the torque converter relief pressure (inlet
pressure).
a When measuring torque converter inlet pressure
accurately for troubleshooting, etc, refer "testing
with testing tools".
Testing torque converter outlet pressure
a Torque converter outlet pressure pickup port (3)

4. After finishing test, remove the testing tools and


restore the machine.
Testing with machine monitor
Torque converter relief pressure (inlet pressure) can
be checked with Monitering/Pre-difined (9/16) or
Monitering (monitoring code: 32601) of the
machine monitor.
a For the machine monitor operating method, see
the section of "Special functions of machine
monitor".

Testing by use of testing tools


1. Remove torque converter outlet pressure pickup
port plug (3). Install nipple N4 and hose [1] of

30-62

WA470-7

30 Testing and adjusting


Power train

hydraulic tester N1 to it, and connect gauge N3


to the hose.

a Monitoring/Pre-defined (9/16) screen

3 Joint:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The elbow, nipple, and hose of digital
hydraulic tester N2 can also be used.
a Use an oil pressure gauge of 1 MPa {10 kg/
cm2}.

1. Start the engine with power mode, and keep the


directional lever or directional selector switch in
N (NEUTRAL).
2. While running the engine at 2,000 rpm, measure
torque converter outlet pressure.

2. Start the engine with power mode, and keep the


directional lever or directional selector switch in
N (NEUTRAL).
3. While running the engine at 2,000 rpm, measure
torque converter outlet pressure.

a When measuring torque converter outlet


pressure accurately for troubleshooting, etc,
refer "testing with testing tools".

4. After finishing test, remove the testing tools and


restore the machine.
3 Torque converter outlet pressure
pickup port plug (5):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
Testing with machine monitor
Torque converter outlet pressure can be measured
with Monitering/Pre-difined or Monitering
(monitoring code: 32603) of the machine monitor.
a For the machine monitor operating method, see
the section of "Special functions of machine
monitor".

WA470-7

30-63

30 Testing and adjusting


Power train

Testing lockup clutch pressure


k This

measurement is done in the traveling


condition. Therefore, care must be taken to
safety of surrounding area.

a Lockup clutch pressure pickup port (4)

3. Set the transmission shift mode selector switch


to AUTO.
4. Set working mode to the power mode, start the
engine, and set the parking brake switch to OFF
position.
5. Move the gear speed switch to the 3rd position.
6. Set the directional lever or directional selector
switch to the F (FORWARD) or R (REVERSE),
and then start traveling.
7. While traveling with the engine speed at 2,000
rpm, measure the lockup clutch oil pressure
when the lockup pilot lamp lights up.

8. After finishing test, remove the testing tools and


restore the machine.
3 Lockup clutch pressure pickup port
plug (3):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

1. Remove lockup clutch pressure pickup port plug


(4). Install nipple N4 and hose [1] of hydraulic
tester N1, and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.

2. Set the torque converter lockup switch to ON.

30-64

WA470-7

30 Testing and adjusting


Power train

Testing F (forward) clutch pressure


a F (forward) clutch pressure pickup port (5)

4. Set working mode to the power mode, start the


engine, and set the parking brake switch to OFF
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 4th (4th speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) position while depressing the
brake pedal.
k Keep

brake pedal firmly depressed. Take


extreme care for safety around the
machine since the machine may move.

7. While running the engine at 2,000 rpm, measure


the F (forward) clutch oil pressure.

1. Remove F (forward) clutch pressure pickup port


plug (4). Install nipple N4 and hose [1] of
hydraulic tester N1, and connect gauge [2] to the
hose.
3 Nipple:

8. After finishing test, remove the testing tools and


restore the machine.
3 F clutch pressure pickup port plug (4):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

9.8 to 12.7 Nm {1.0 to 1.3 kgm}


a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.

2. Set the transmission shift mode selector switch


to MANUAL.
3. Depress the brake pedal.

WA470-7

30-65

30 Testing and adjusting


Power train

Testing R (reverse) clutch pressure


a R (reverse) clutch pressure pickup port (6)

4. Set working mode to the power mode, start the


engine, and set the parking brake switch to OFF
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 4th (4th speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the R (REVERSE) position while depressing the
brake pedal.
k Keep

brake pedal firmly depressed. Take


extreme care for safety around the
machine since the machine may move.

7. While running the engine at 2,000 rpm, measure


the R (REVERSE) clutch oil pressure.

1. Remove R (reverse) clutch pressure pickup port


plug (5). Install nipple N4 and hose [1] of
hydraulic tester N1, and connect gauge [2] to the
hose.
3 Nipple:

8. After finishing test, remove the testing tools and


restore the machine.
3 R clutch pressure pickup port plug
(5):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

9.8 to 12.7 Nm {1.0 to 1.3 kgm}


a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.

2. Set the transmission shift mode selector switch


to MANUAL.
3. Depress the brake pedal.

30-66

WA470-7

30 Testing and adjusting


Power train

Testing 1st clutch pressure


a 1st clutch pressure pickup port (7)

4. Set working mode to the power mode, start the


engine, and set the parking brake switch to OFF
position.
5. While keeping the directional lever or right
directional selector switch in N (NEUTRAL), set
the gear speed switch to 1st (1st speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) or R (REVERSE) position
once while depressing the brake pedal, then
return it to the N (NEUTRAL) position.
k Keep

brake pedal firmly depressed. Take


extreme care for safety around the
machine since the machine may move.

a When the directional lever or directional


selector switch is in N (NEUTRAL), the gear
speed is not changed even if the gear speed
switch is moved. To avoid this, perform the
above operation.
7. While running the engine at 2,000 rpm, measure
the 1st clutch oil pressure.

1. Remove 1st clutch pressure pickup port plug (7).


Install nipple N4 and hose [1] of hydraulic tester
N1, and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.

8. After finishing test, remove the testing tools and


restore the machine.
3 1st clutch pressure pickup port plug
(9):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

2. Set the transmission shift mode selector switch


to MANUAL.
3. Depress the brake pedal.

WA470-7

30-67

30 Testing and adjusting


Power train

Testing 2nd clutch pressure


a 2nd clutch pressure pickup port (8)

4. Set working mode to the power mode, start the


engine, and set the parking brake switch to OFF
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 2nd (2nd speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) or R (REVERSE) position
once while depressing the brake pedal, then
return it to the N (NEUTRAL) position.
k Keep

brake pedal firmly depressed. Take


extreme care for safety around the
machine since the machine may move.

a When the directional lever or directional


selector switch is in N (NEUTRAL), the gear
speed is not changed even if the gear speed
switch is moved. To avoid this, perform the
above operation.
7. While running the engine at 2,000 rpm, measure
the 2nd clutch oil pressure.

1. Remove 2nd clutch pressure pickup port plug (8).


Install nipple N4 and hose [1] of hydraulic tester
N1, and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.

8. After finishing test, remove the testing tools and


restore the machine.
3 2nd clutch pressure pickup port plug
(8):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

2. Set the transmission shift mode selector switch


to MANUAL.
3. Depress the brake pedal.

30-68

WA470-7

30 Testing and adjusting


Power train

Testing 3rd clutch pressure


a 3rd clutch pressure pickup port (9)

4. Set working mode to the power mode, start the


engine, and set the parking brake switch to OFF
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 3rd (3rd speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) or R (REVERSE) position
once while depressing the brake pedal, then
return it to the N (NEUTRAL) position.
k Keep

brake pedal firmly depressed. Take


extreme care for safety around the
machine since the machine may move.

a When the directional lever or directional


selector switch is in N (NEUTRAL), the gear
speed is not changed even if the gear speed
switch is moved. To avoid this, perform the
above operation.
7. While running the engine at 2,000 rpm, measure
the 3rd clutch oil pressure.

1. Remove 3rd clutch pressure pickup port plug (9).


Install nipple N4, elbow (male: 10 x 1.25 and
female: PT1/8) of hydraulic tester N1, and nipple
hose [1], and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.

8. After finishing test, remove the testing tools and


restore the machine.
3 3rd clutch pressure pickup port plug
(9):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

2. Set the transmission shift mode selector switch


to MANUAL.
3. Depress the brake pedal.

WA470-7

30-69

30 Testing and adjusting


Power train

Testing 4th clutch pressure


a 4th clutch pressure pickup port (10)

4. Set working mode to the power mode, start the


engine, and set the parking brake switch to OFF
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 4th (4th speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) or R (REVERSE) position
once while depressing the brake pedal, then
return it to the N (NEUTRAL) position.
k Keep

brake pedal firmly depressed. Take


extreme care for safety around the
machine since the machine may move.

a When the directional lever or directional


selector switch is in N (NEUTRAL), the gear
speed is not changed even if the gear speed
switch is moved. To avoid this, perform the
above operation.
7. While running the engine at 2,000 rpm, measure
the 4th clutch oil pressure.

1. Remove 4th clutch pressure pickup port plug


(10). Install nipple N4 and hose [1] of hydraulic
tester N1, and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.

8. After finishing test, remove the testing tools and


restore the machine.
3 4th clutch pressure pickup port plug
(10):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

2. Set the transmission shift mode selector switch


to MANUAL.
3. Depress the brake pedal.

30-70

WA470-7

30 Testing and adjusting


Power train

Testing lubrication pressure


a Lubrication pressure pickup port (11)

3. While running the engine at 2,000 rpm, measure


the lubricating oil pressure.

4. After finishing test, remove the testing tools and


restore the machine.
3 Lubrication pressure pickup port plug
(13):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

1. Remove lubrication pressure pickup port plug


(11). Install nipple N4, install elbow [1], and hose
[1] of hydraulic tester N1, and connect gauge N3
to the hose.
3 Joint:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The elbow, nipple, and hose of digital
hydraulic tester N2 can also be used.
a Use an oil pressure gauge of 1 MPa {10 kg/
cm2}.

2. Start the engine with power mode, and keep the


directional lever or directional selector switch in
N (NEUTRAL).

WA470-7

30-71

30 Testing and adjusting


Power train

Adjusting

(WA470-C100-270-K-00-A)

Adjusting transmission main relief valve


k Stop

the engine before starting adjustment


of the transmission main relief valve.

a If the transmission main relief pressure is out of


the standard value, adjust it according to the
following procedure.
1. Remove plug (13) from transmission and torque
converter relief valve (12).

2. Remove outer spring (16) and inner spring (17).


3. Adjust by adding or removing shims (18).
a Standard shim thickness: 3.5 mm (0.5 x 7
pcs.)
a Amount of adjustment per shim:
0.04 MPa {0.4 kg/cm2}

30-72

WA470-7

30 Testing and adjusting


Steering system

Steering system

(ALL-F000-001-K-00-A)

Testing directional lever

(WA380-CX31-001-K-00-A)

a Testing tools
Symbol
M

Part No.

Part name

79A-264-0021 Push-pull scale

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

Testing

(WA470-CX31-384-K-00-A)

Operating effort of directional lever


Set push-pull scale M or a spring scale at the
point 12 mm from the tip of the directional lever
(1). Pull the push-pull scale M or the spring scale
in the operative direction of the lever to measure
the operating effort.

Travel of directional lever


Put a mark (a) at the center of the knob of the
directional lever (1). Move the knob in the
operating direction and measure its travel.

WA470-7

30-73

30 Testing and adjusting


Steering system

Testing steering wheel

(WA380-F151-001-K-00-A)

a Testing tools
Symbol
Part No.
Part name
P
79A-264-0021 Push-pull scale

Testing

(WA470-F151-384-K-00-A)

Measuring play of steering wheel


a Measure the play of the steering wheel under
the following conditions.
Engine speed: Stop
Posture of machine: Straight travel
Measuring method
1. Move the steering wheel lightly to the right and
left to find the neutral point in the steering
mechanism and put mark (A) on the outer frame
of the machine monitor.
2. Turn the steering wheel to the right until the
operating effort starts to become heavy. Put
mark (B) at the position right above mark (A).

Measuring operating effort of steering wheel


a Measure the operating effort of the steering
wheel under the following conditions.
Road surface: Flat, level, and dry paved
surface
Engine coolant temperature: 60 to 102C
Hydraulic oil temperature: 45 to 55 C
Tire inflation pressure: Specified pressure
Engine speed: Low idle
(bucket empty)
Measuring method
1. Install push-pull scale P to the steering wheel
knob.
a Install the push-pull scale P to the center of
the knob.
2. Start the engine.
a After starting the engine, raise the bucket
approximately 400 mm and remove the
frame lock bar.
3. Pull the push-pull scale N in the tangential
direction and read the value when the steering
wheel moves smoothly.
a Do not read the value indicated when the
steering wheel starts moving as the
operating effort.

3. Turn the steering wheel to the left (opposite to


step 2) until the operating effort starts to become
heavy. Put mark (C) at the position right above
mark (A), and measure the straight-line distance
between marks (B) and (C).

Measuring operating time of steering wheel


a Measure the operating time of the steering
wheel under the following conditions.

Road surface: Flat, level, dry paved surface


Engine coolant temperature: 60 to 102C
Hydraulic oil temperature: 45 to 55 C
Tire inflation pressure: Specified pressure
Engine speed: at low idle and high idle

Measuring method
1. Start the engine.
a After starting the engine, raise the bucket
approximately 400 mm and remove the
frame lock bar.

30-74

WA470-7

30 Testing and adjusting


Steering system

2. Turn the steering wheel in order to bring the


machine posture to the right or left turn with the
steering wheel at its travel end.
3. Turn the steering wheel in the reverse direction
of it described above, and measure the time
taken by the steering wheel to come to the end
of the travel.
a Do not turn the steering wheel forcibly but
turn it at the speed of 60 turns per minute.
a Measurement should be taken when the
machine is turning both to the right and left
with the engine running at low idle and high
idle.

WA470-7

30-75

30 Testing and adjusting


Steering system

Testing work equipment control lever


a Testing tools
Symbol
Part No.
Part name
1 79A-264-0021 Push-pull scale
Y
Commercially
Ruler
2
available
k Apply

(WA380-PK00-001-K-01-A)

Push the point, 42 mm (z) up the center (c) of


side screw (2), toward tangential direction of
lever movement (right and left direction).

the frame lock bar.

a Check the work equipment control lever under


the following condition.
Engine speed: Low idle

Testing

(WA380-PK00-384-K-00-A)

1. Measuring operating effort of work equipment


control lever
Install and fix tool Y1 to the work equipment
control lever.
3-lever type
a Install tool Y1 to the position 12 mm down
from the top of the knob.
a Operate the control lever at the same speed
as that for the normal operation, with the
minimum value for the effort needed to
operate the knob.

2. Measuring travel of work equipment control lever


Check the travel of the work equipment control
lever at each point.
3-lever type
a Put a mark on the lever knob at 12 mm down
from the top and use scale Y2 for the
measurement.
Multi-function mono-lever type
a Install tool Y1 to the following position.

a If the travel is out of the standard range,


replace the lever.

a Operate the control lever at the same speed


as that for the normal operation, with the
minimum value for the effort needed to
operate the knob.
1) RAISE
Push the lower end of kickdown switch (8
mm from center (a) of switch) horizontally
toward tangential direction of lever
movement.
2) LOWER
Push the point, 21 mm (y) under the lower
end (b) of cap (1), toward tangential direction
of lever movement.
3) TILT, DUMP

30-76

WA470-7

30 Testing and adjusting


Steering system

Multi-function mono-lever type


a Use scale Y2 for the measurement.
Mark and measure the positions as follows.
1) RAISE, LOWER
The position at 42 mm toward the lever top
end from the center (c) of side screw (2).
2) TILT, DUMP
The position at 21 mm down (y) from the
bottom (b) of cap (1).
a If the travel is out of the standard range,
replace the lever.

WA470-7

30-77

30 Testing and adjusting


Steering system

Testing and adjusting steering circuit oil pressure


a Tools for testing and adjusting
Symbol
1
Q
2

Part No.
799-261-5002
790-261-1204
799-401-3200
07002-12024

(WA470-F210-360-K-00-A)

a Monitoring/Pre-defined (14/16) screen


Part name

Hydraulic tester
Digital hydraulic tester
Adapter
O-ring

a Test the steering circuit pressure under the


following condition.
Hydraulic oil temperature: 45 to 55C
k Loosen

the oil filler cap of the hydraulic tank


to release the pressure inside the hydraulic
tank, then operate the steering wheel 2 or 3
turns to release the remaining pressure in
the piping.

k Set

frame lock bar (1) in position.

1. Start the engine, and run it at high idle, then turn


the steering wheel to the right or left. Measure
the oil pressure (maximum pressure at operating
steering) when the steering relief valve operates.
a When accurate measurement of steering circuit
oil pressure is required for the troubleshooting,
etc., refer "Testing by use of testing tools".
Testing by use of testing tools
1. Remove steering circuit pressure pickup plug (2)
on the left steering cylinder head side.

Testing

(WA470-F210-362-K-00-A)

Testing steering relief pressure


Testing with machine monitor
Steering circuit oil pressure can be measured with
Monitering/Pre-difined (14/16) or Monitering
(monitoring code: 95302) of the machine monitor.
a For the machine monitor operating method, see
the section of "Special functions of machine
monitor".

2. Install nipple Q3 and hose [1] of hydraulic tester


Q1, and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.74 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester Q2 can
also be used.
a Use the oil pressure gauge of 40 MPa {400
kg/cm2}.

30-78

WA470-7

30 Testing and adjusting


Steering system

2. Install adapter Q2, and connect hose (4) or (5)


(opposite side) to it.
3. Install hose [1] of hydraulic tester Q1and
connect gauge [2].
a Use the oil pressure gauge of 6 MPa {60 kg/
cm2}.

3. Start the engine, turn the steering wheel to the


left with engine running at high idle. Measure the
oil pressure (maximum pressure at operating
steering) when the steering relief valve operates.
a When the gauge is connected to the steering
circuit pressure pickup port plug on the right
side steering cylinder head, measure the
pressure by turning the steering wheel to the
right.

4. Start the engine, and measure the oil pressure


(maximum pressure at operating steering) when
turning the steering wheel with engine running at
high idle.
When measuring at hose (4): Turn the
steering wheel to the left.
When measuring at hose (5): Turn the
steering wheel to the right.

4. After finishing test, remove the testing tools and


restore the machine.
3 Steering circuit pressure pickup plug:
9.8 to 12.74 Nm {1.0 to 1.3 kgm}
Testing steering pilot circuit pressure
1. Remove steering control circuit hose (4) or (5)
(opposite side) of steering valve assembly (3)
through the clearance between the front side of
the operator's cab and front frame.

WA470-7

5. After finishing the measurement, remove the


measuring tools and restore the machine.
Testing steering control circuit pressure
1. Remove steering control circuit pressure pickup
port plug (6) of steering valve assembly (3)
through the clearance between the front side of
the operator's cab and front frame.

30-79

30 Testing and adjusting


Steering system

assembly (3) according to the following


procedure.

2. Install nipple Q3 and hose [1] of hydraulic tester


Q1, and connect gauge [2] to the hose.
a The hose of digital hydraulic tester Q2 can
also be used.
a Use the oil pressure gauge of 6 MPa {60 kg/
cm2}.

2. Loosen lock nut (6) and turn adjustment screw


(7) to adjust the pressure.
a When the adjustment screw is:
turned clockwise, the pressure is
increased.
turned counterclockwise, the pressure is
decreased.
a Quantity of adjustment per turn of adjustment
screw:
Per turn: 17.8 MPa {181.5 kg/cm2}
3 Lock nut:
27 to 31 Nm {2.8 to 3.2 kgm}

3. Start the engine, keep the steering wheel in


neutral, then measure the oil pressure with
engine at low idle.

Adjusting steering control circuit pressure


a Adjusting steering control circuit pressure is not
available.

4. After finishing test, remove the testing tools and


restore the machine.

Adjusting

(WA470-F210-27B-K-00-A)

k When

adjusting the oil pressure, be sure to


stop the engine.

Adjusting steering relief pressure


1. If the steering relief pressure is incorrect, adjust
steering relief valve (8) of steering valve

30-80

WA470-7

30 Testing and adjusting


Steering system

Bleeding air from steering cylinder circuit.


a Before bleeding air, check that the hydraulic oil
level is proper.
a If the steering valve or the steering cylinder is
removed and installed, bleed air from the
steering circuit according to the following
procedure.

Bleeding air

(WA470-F210-231-K-00-A)

Bleeding air from steering pump


1. Remove cover (1) located under the right side of
the hydraulic tank.

(WA380-F210-001-K-01-A)

3 Air bleeder:
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
4. Start the engine and run it at low idle for 5
minutes minimum.
Bleeding air from cylinder circuit.
1. Start engine, run engine at low idle for 5
minutes.
2. Run the engine at low idle, and turn the steering
wheel 4 to 5 times to the right and left.
a Stop the piston rod approximately 100 mm
before each stroke end and take care not to
relieve the circuit.
3. Run the engine at high idle and then, perform
the operation of Step 2.
4. Run the engine at low idle and operate the
piston rod to the end of its stroke to relieve the
circuit.

2. While the engine is stopped, loosen air bleeder


(2) of the steering pump and connect air bleeder
hose [1].

3. As oil containing no bubbles starts to flow out of


air bleeder(2), tighten air bleeder (2).

WA470-7

30-81

30 Testing and adjusting


Steering system

Testing and adjusting steering stopper valve


Testing

(WA470-F5U0-365-K-00-A)

1. Align the front frame and rear frame.


2. Check that lock nut (2) on stopper bolt (1) is not
loose.

(WA380-F5U0-001-K-00-A)

3. Stop the engine and then loosen stopper bolt (1)


until it touches the contact surface of steering
stop valve (3).
a Use care not to loosen the stopper bolt
excessively. Excessive loosening can result
in pushing the spool at the tip of steering stop
valve (3) .
4. Start and run the engine at low idle, and then
return the steering wheel slowly to set the
machine to the straight travel condition. Then
stop the engine.
5. Turn stopper bolt (1) in the loosening direction
by 8.5 turns (approx. 15 mm), then fix it by lock
nut (2) .
a Adjust both the right and left sides by
following the procedure from steps 1 to 5.

3. Start the engine and turn the steering wheel to


the right and left. Check that a clearance is
maintained between the front frame stopper and
rear frame stopper.
k Measure

the clearance while engine is

stopped.
a If the check can not be made because of
missing frame stopper and so on, do
necessary repair and then make sure that
the clearance is provided on both sides.

Adjustment

(WA380-F5U0-270-K-00-A)

a When the clearance between the front frame


and rear frame is out of the specified range,
adjust it in the following procedure.
1. Loosen lock nut (2) and then tighten stopper bolt
(1) to set distance (a) to the minimum.

6. Start the engine, turn the machine and then


check that there is a clearance between the front
frame and rear frame when the turning is
stopped due to the contact of steering stop valve
(3) and stopper bolt (1).

2. Run the engine at low idle and then bring the


front frame and rear frame into contact by
turning the steering wheel slowly.
k Use

care in this operation so that your


body or arm are not caught between the
front and rear frames.

30-82

WA470-7

30 Testing and adjusting


Brake system

Brake system

(ALL-G000-001-K-00-A)

Testing brake pedal

(WA470-G4A1-360-K-00-A)

a Test the brake pedal under the following


conditions.
Coolant temperature: 60 to 102C
Hydraulic oil temperature: 45 to 55C
Engine low idle

Testing

(WA380-G4A1-361-K-00-A)

1. Install push gauge [1] to the operator's foot.


a Set the push gauge at a point 150 mm from
the fulcrum of the pedal.
2. Start the engine and measure the pedal
depressing angle (a1) while running the engine
at low idle.
3. Apply angle gauge [2] to the brake pedal and
measure neutral angle a1 and maximum
depressing angle a2.
a2: Depressing angle at depressing effort of
32330 N {32.93.0 kg}

WA470-7

30-83

30 Testing and adjusting


Brake system

Testing and adjusting brake pedal linkage


Testing

(WA380-G4C0-001-K-00-A)

(WA380-G4C0-361-K-00-A)

1. Check linkage mounting pin (5), pinhole of lever


(6), and lever bushing for play. Make
adjustments as necessary.
2. Measure the length of the link (a 213 mm),
and check that it is within the standard value.
a Measure the length between the center of pin
(5) and the center of ball joint (3).
3. Measure the distance of movement of rod (8)
and check that clearance (b) is within the
standard value.
a When doing this, check that the brake pedal
hits the stopper.
4. Check bolts and nuts at each part and retighten
them if loosened.

Adjustment

(WA380-G4C0-270-K-00-A)

1. Adjusting link length (a)


1) Remove pin (5) and ball joint (3), then
remove rod (1).
2) Loosen lock nut (4), then turn yoke (2) and
ball joint (3) to adjust the length.
3) After adjusting the length of link (a), connect
it to the brake pedal.
a Standard length (a): 213 mm
2. Adjusting play of rod (b)
1) Loosen locknut (7), turn rod (8) so that the tip
of the rod contacts the booster cylinder
piston, then turn rod (8) back 1/4 turn.
a Moving distance in 1/2 turn of rod: 0.75
mm
2) Turn back by 1/4 turn and tighten lock nut (7).
a Standard value (b): 0 to 0.3 mm

30-84

WA470-7

30 Testing and adjusting


Brake system

Testing braking performance

(WA470-G000-360-K-00-A)

a Test the brake performance under the following


conditions.
Road surface: Flat, horizontal, dry paved
surface
Speed: Speed when applying brake: 20 km/h
Tire inflation pressure: Specified pressure
Tire size: 26.5 to 25
Brake pedal depressing force: Specified
depressing force
323 30 N {32.9 3 kg}
Delay in applying brakes: 0.1 sec

Testing

(WA380-G000-38E-K-00-A)

1. Start the engine and drive the machine.


2. Move the gear speed switch to the 4th position and give the machine a run-up.
3. When the travel speed reaches 20 km/h, depress the left brake pedal with the specified depressing force.
a Before performing this test, fix the run-up path and the point for applying the brakes, then apply the
brakes when the machine reaches that point.
4. Measure the distance between the point where the brake is applied and the point where the machine
stops.
a Repeat the preceding measurement three times and take the average.

WA470-7

30-85

30 Testing and adjusting


Brake system

Testing and adjusting of accumulator charge pressure

(WA470-G2H0-360-K-00-A)

a Tools for testing and adjusting


Symbol
T

Part No.

Part name

799-101-5002 Hydraulic tester


790-261-1204 Digital hydraulic tester

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k Stop

the engine, then depress the brake


pedal at least 100 times to release the
pressure inside the accumulator circuit.

a Measure the accumulator charge pressure


under the following conditions.
Coolant temperature: 60 to 102C
Hydraulic oil temperature: 45 to 55C

Testing

(WA470-G2H0-362-K-00-A)

1. Remove cover (1) and (2) on the right side of the


machine.
3. Measure the accumulator charge cut-in
pressure.
Start and run the engine at low idle, and then
measure the oil pressure when the brake
pressure caution lamp on the machine monitor
panel goes out.
4. Measure the accumulator charge cut-out
pressure.
After the accumulator charge cuts in, measure
the oil pressure when the rising indicator of the
gauge suddenly shifts to drop.
2. Install hose [1] of hydraulic tester T to
accumulator charge pressure pickup nipple (3)
of the accumulator charge valve, and connect
them to gauge [2].
a The hose for digital hydraulic tester T2 can
also be used.
a Use gauge of 40 MPa {400 kg/cm2}.

5. After finishing test, remove the testing tools and


restore the machine.

Adjusting

(WA470-G2H0-270-K-00-A)

a When the accumulator charge cut-out pressure


is adjusted, the cut-in pressure also changes in
proportion to the valve area ratio.

30-86

WA470-7

30 Testing and adjusting


Brake system

1. Loosen lock nut (6) of unload relief valve


(accumulator charge cut-out valve) (5), then turn
adjustment screw (7) to adjust.
a When the adjustment screw is:
turned clockwise, the pressure is
increased.
turned counterclockwise, the pressure is
decreased.
a Quantity of pressure adjustment per turn of
adjustment screw:
1.45 MPa {14.8 kg/cm2}
3 Lock nut (4):
11.8 to 16.7 Nm {1.2 to 1.7 kgm}

a After finishing measuring, check the


accumulator charge cut-in and cut-out
pressures again according to the above
measuring procedure.

WA470-7

30-87

30 Testing and adjusting


Brake system

Testing of brake accumulator nitrogen gas pressure and procedure for


charging brake accumulator with nitrogen gas (WA470-G2G0-001-K-00-A)
a Testing tools
Symbol

Part No.

Part name

Gas charge
tool
Nipple
792-610-1310
(for Russia)
Nipple
792-610-1320
(for US)
Nipple
792-610-1330
(for US)

1 792-610-1702

ZE
2

Nipple
792-610-1350 (for
Germany)
792-610-1360

Applicable
standard

Nipple
(for UK)

GOST
CGA No. 351
ASA B-5711965
DIN 477-1963
NEN 32681966
SIS-SMS
2235/2238
BS 341
Part1-1962

Testing nitrogen gas pressure in


accumulator (WA470-G2G0-280-K-00-A)
a The following testing procedure is applicable to
an independent accumulator as well.
Nitrogen gas cylinder (c) must be connected
even when the gas pressure only is measured.
1. Stop the engine and eliminate the pressure in
the brake circuit completely by depressing the
brake pedal until its reactive force disappears.
a Depressing the brake pedal roughly 30 times
eliminates its reactive force and no oil
pressure is left in the circuit.
2. Remove plug (2) and cap (3) from accumulator
(1).

k In

order to prevent leaked nitrogen gas from


contacting your skin and clothing, be sure to
wear the appropriate protective items (such
as goggles, leather gloves and protective
clothing) and do the work from the windward
side as much as possible.

k When

handling nitrogen in an ill-ventilated


location like in a room, you must improve
ventilation of the room and observe the local
regulation for labor safety and health to
prevent oxygen deficiency disease and other
hazards.

k The

accumulator is charged with highpressure nitrogen gas. Its inappropriate


handling can cause an explosion accident,
leading to serious personal injuries. The
following rules must be strictly observed
when handling the gas.
Do not bring any open flame near the
accumulator or expose it to fire.
Do not drill it, weld or fuse-cut it.
Do not give impacts to it by hitting or
rolling it.
Bleed the gas in it before disposing it.
Decrease the charged gas pressure to the
level of atmospheric pressure before
disassembling or removing it.
The gas to be charged must be nitrogen
gas.
Do not use explosive gases including
oxygen.
The accumulator must be handled strictly
following the procedure described in this
manual.

30-88

3. Connect gas charge tool ZE1 to valve (4) of


accumulator (1) according to the following
procedure.
1) Turn handle (a) of gas charge tool ZE1 fully
counterclockwise until it becomes
immovable.
2) Keep the valve and handle (b) of nitrogen
gas cylinder (c) closed.
3) After installing the attached extension of gas
charge tool ZE1 to gas valve (4) of
accumulator (1), connect the gas charge tool
to the accumulator.
4) Connect gas charge tool ZE1 and nitrogen
gas cylinder (c).
a Exercise care in the above operation
since the bending load applied to gas
valve (4) can damage it.
2 types of threads, w22-14 threads (male
thread A type) and w23-14 threads
(female thread B type), are available for
the nitrogen gas cylinder. When using a
cylinder with w23-14 threads (female
thread B type), connect the hose by using
the adapter.

WA470-7

30 Testing and adjusting


Brake system

(The adapter comes with gas charge tool


ZE1.) [Inside of Japan]
Depending on the given specification of
the nitrogen gas cylinder, nipple ZE2 is
used for connecting the hose.

4. Turn handle (a) of gas charge tool ZE1


clockwise gradually and read the gauge value.
k In

order to prevent damage of gas valve


(4), it is prohibited to rotate handle (a) 1.5
turns or more after the pressure of the
charged gas is displayed.

Check that no gas leakage is recognized.

a Since the pressure indication varies


depending on the ambient temperature at the
time of measurement, you must refer to the
following table when measuring the gas
pressure.
Ambient
temperature
C
15
16
17
18
19

MPa
3.37
3.39
3.40
3.41
3.42

kg/cm2
34.4
34.5
34.6
34.8
34.9

20

3.43

35.0

21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

3.44
3.46
3.47
3.48
3.49
3.50
3.52
3.53
3.54
3.55
3.56
3.57
3.58
3.60
3.61
3.63
3.64
3.65
3.67
3.68
3.69
3.70
3.71
3.72
3.73

35.1
35.2
35.4
35.5
35.6
35.7
35.8
36.0
36.1
36.2
36.4
36.6
36.7
36.8
36.9
37.0
37.2
37.3
37.4
37.5
37.6
37.7
37.8
37.9
38.0

Gas pressure

Remarks

Base gas
pressure

Displayed gas pressure = Base gas pressure


x ((273 + t) / (273 + 20))
(Every number in the formulas is represented
in C.)
5. If the indicated gas pressure is below or above
the targeted level, adjust it referring to "Charging
procedure of accumulator nitrogen gas".
a A certain amount of nitrogen gas is
discharged every time measurement is done
and the pressure decreases. Be sure to
replenish by the amount of the gas
discharged.

WA470-7

30-89

30 Testing and adjusting


Brake system

6. Turn handle (a) of gas charge tool ZE1 fully


counterclockwise until it becomes immovable.
7. Remove gas charge tool ZE1 from accumulator
(1) and restore it. See "Charging procedure of
accumulator nitrogen gas".

Procedure for charging accumulator


with nitrogen gas (WA470-G2G0-219-K-00-A)
a The following charging procedure is applicable
to an independent accumulator as well.
1. Stop the engine and eliminate the pressure in
the brake circuit completely by depressing the
brake pedal until its reactive force disappears.
a Depressing the brake pedal roughly 30 times
eliminates its reactive force and no oil
pressure is left in the circuit.
2. Remove plug (2) and cap (3) from accumulator
(1).

3. Connect gas charge tool ZE1 and nitrogen gas


cylinder (c) to valve (4) of accumulator (1)
according to the following procedure.
1) Turn handle (a) of gas charge tool ZE1 fully
counterclockwise until it becomes
immovable.
2) Turn handle (b) counterclockwise and leave
the valve open.
3) After installing the attached extension of gas
charge tool ZE1 to gas valve (4) of
accumulator (1), connect the gas charge tool
to the accumulator.
4) Connect gas charge tool ZE1 and nitrogen
gas cylinder (c).
2 types of threads, w22-14 threads (male
thread A type) and w23-14 threads
(female thread B type), are available for
the nitrogen gas cylinder. When using a
cylinder with w23-14 threads (female
thread B type), connect the hose by using
the adapter.
(The adapter comes with gas charge tool
ZE1.) [Inside of Japan]
Depending on the given specification of
the nitrogen gas cylinder, nipple ZE2 is
used for connecting the hose.

30-90

4. Open the valve of nitrogen gas cylinder (c)


slightly to discharge the gas with the pressure of
approximately 0.19 to 0.29 MPa {2 to 3 kg/cm2}.
5. Turn handle (b) clockwise to close the valve
when nitrogen gas starts to come out of handle
(b).
6. Turn handle (a) clockwise slowly to gradually
open valve (4) of accumulator (1).
a Exercise care in operating handle (a) since
excessive turning of handle (a) can damage
the accumulator valve core, inducing gas
leakage.
7. Open the valve of nitrogen gas cylinder (c)
further to charge the nitrogen gas to the
accumulator.
8. Close the valve of nitrogen gas cylinder (c) from
time to time during this operation to check the
nitrogen gas pressure in the accumulator.
a For the nitrogen gas pressure testing
procedure, see Item 4 of "Testing of
accumulator nitrogen gas pressure".
9. After the gas is charged up to the standard value,
close the valve of nitrogen gas cylinder (c).
When the charged gas volume is excessive,
discharge excessive gas by turning handle
(b) slowly counterclockwise while keep the
valve of nitrogen gas cylinder (c) being
closed.
10.Remove gas charge tool ZE1 from valve (4) of
accumulator (1) according to the following
procedure.
WA470-7

30 Testing and adjusting


Brake system

1) Turn handle (a) counterclockwise to close


the accumulator valve.
2) Turn handle (b) counterclockwise to open the
valve and discharge remaining nitrogen gas
in gas charge tool ZE1 and hose.
3) Remove gas charge tool ZE1 from valve (4)
of the accumulator.
11.Apply suds to valve (4) of the accumulator to
make sure there is not leakage of nitrogen gas.
12.Install plug (2) and cap (3) to accumulator (1).
3 Plug
73.5 to 98.0 Nm {7.5 to 10.0 kgm}

13.Within a week from charging nitrogen gas,


check the performance of the brake according to
the following procedure to check that no
pressure drop of nitrogen gas is found.
a Check the brake function within 5 minutes
from stop of the engine. (If more than 5
minutes elapse from stop of the engine,
correct measurement becomes unavailable
because oil pressure in the brake circuit
drops.)
1) Place the machine on a flat ground and turn
the parking brake switch to "PARKING"
position.
2) Start and run the engine at medium speed for
a minute, then stop the engine.
3) Turn the starting switch to ON position and
depress the brake pedal repeatedly to record
the depressing frequency required for the
brake oil pressure caution lamp to light up.
Depressing frequency is less than 5:
Accumulator gas pressure may be low
Depressing frequency is 5 or more:
Accumulator gas pressure is normal.

WA470-7

30-91

30 Testing and adjusting


Brake system

Testing wheel brake oil pressure

(WA470-G210-360-K-01-A)

a Tools for testing


Symbol
1
ZB 2
3

Part No.

Part name

401-799-2930 Adapter
799-101-5002 Hydraulic tester
790-261-1204 Digital hydraulic tester

k High

pressurized oil in the accumulator may


spout out because of a trouble in the brakerelated equipment even when the brake
pedal is not depressed. To prevent this,
depress the brake pedal at least 100 times
with the engine stopped to release the
accumulator circuit pressure.

a When accurate measurement of brake oil


pressure is required for troubleshooting, etc.,
refer "Testing by use of testing tools".
Testing by use of testing tools
1. Remove inspection cover (1) of the front frame
(front side).
Perform measurement at slack adjuster portion
on the left side of rear frame (rear side).
k When

removing the inspection cover with


the boom raised, place a stand under the
boom to support the boom securely.

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

a Perform measurement on both of front brake and


rear brake.
a Measure the wheel brake oil pressure under the
following condition.
Coolant temperature: 60 to 102

Testing

(WA470-G210-362-K-00-A)

Testing with machine monitor


Brake oil pressure (front brake only) can be
measured with Monitering/Pre-difined (12/16) or
Monitering (monitoring code: 41201) of the
machine monitor.

2. Remove hose (2). Install adapter ZB1, install


nipple [1] and hose [2] of hydraulic tester ZB2,
and then connect gauge [3] to the hose.
a The nipple and hose of digital hydraulic tester
ZB3 can also be used.
a Use gauge [3] of 6 MPa {60 kg/cm2}.
(Front side)

a For the machine monitor operating method, see


the section of "Special functions of machine
monitor".
a Monitoring/Pre-defined (12/16) screen

(Rear side)

1. Bleed air from the brake circuit. For details, see


Testing and adjusting "Bleeding air from wheel
brake circuit".
2. Start the engine and measure the wheel brake
oil pressure as the left brake pedal is depressed.

30-92

WA470-7

30 Testing and adjusting


Brake system

3. Bleed air from the brake circuit. For details, see


Testing and adjusting "Bleeding air from wheel
brake circuit".
4. Start the engine and measure the wheel brake
oil pressure as the left brake pedal is depressed.

5. After finishing test, remove the testing tools and


restore the machine.

WA470-7

30-93

30 Testing and adjusting


Brake system

Testing lowering of wheel brake pressure

(WA470-G210-360-K-00-A)

a Testing tools
Symbol
1
2
3
U 4
5
6
7

Part No.
793-605-1001
790-101-1430
790-101-1102
790-301-1720
799-101-5160
799-401-2220
790-261-1130

Part name
Brake test kit
Coupler
Pump
Adapter
Nipple
Hose
Coupling

k High

pressurized oil in the accumulator may


spout out because of a trouble in the brakerelated equipment even when the brake
pedal is not depressed. To prevent this,
depress the brake pedal at least 100 times
with the engine stopped to release the
accumulator circuit pressure.

3. Remove union, and install adapter U4, nipple U5


and hoseU6, and then install brake test kit U1.
a Use the O-ring fitted to the union.

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

a Measure the oil pressure of the front brakes


(right and left) and rear brakes (right and left)
similarly.
a Measure the wheel brake pressure lowering
under the following conditions.
Coolant temperature: 60 to 102C
Hydraulic oil temperature: 45 to 55C

Testing

(WA470-G210-38F-K-00-A)

1. Remove inspection cover (1) of the front frame.


k When

removing the inspection cover with


the boom raised, place a stand under the
boom to support the boom securely.

2. Remove brake tube (2) on the testing side.


4. Loosen bleeder screw (4) to bleed air.

30-94

WA470-7

30 Testing and adjusting


Brake system

a Bleed air by operating pump U3.

5. Tighten bleeder screw (4), operate pump U3 to


increase the pressure to 4.9 MPa {50 kg/cm2},
and close stop-valve [1].

6. Leave the brake circuit pressurized for 5 minutes


and check lowering of the pressure.
a If the hose is moved while the pressure is
measured, the pressure fluctuates.
Accordingly, do not move the hose.
a After testing the pressure, operate pump U3
to lower the pressure in brake test kit U1, and
then remove brake test kit U1.
a After finishing testing, install the brake tube
and bleed air from the brake circuit.
7. After finishing test, remove the testing tools and
restore the machine.
Brake test kit

WA470-7

30-95

30 Testing and adjusting


Brake system

Testing wear of wheel brake disc


a Testing tools
Symbol
V

Part No.
Part name
Commercially Vernier calipers
available

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

a There are inspection plugs on the right and left


sides of the front and rear axles. Perform the
check at all of the four plugs similarly.

Testing

(WA380-G167-001-K-00-A)

2. Depress the brake pedal to the travel end.


3. Push in shaft (2) and measure its projection (x)
(distance of wear) from end face (a) of guide (3)
with vernier calipers V.
a Keep depressing the brake pedal while
measuring the wear.
a If shaft (2) is projected from the end of guide
(3) to the groove, replace the disc.
Projection x from (a): Amount of wear
Projection y from (a): Wear limit (2.4 mm)
a If face (b) of the shaft is seen, the disc is
worn to the repair limit.

(WA470-G167-389-K-00-A)

1. Remove cap (1).

4. After finishing test, remove the testing tools and


restore the machine.
3 Cap (1):
29.4 to 39.2 Nm {3.0 to 4.0 kgm}

30-96

WA470-7

30 Testing and adjusting


Brake system

Bleeding air from wheel brake circuit

(WA470-G200-360-K-00-A)

k Place

the machine on a level ground, lower the work equipment to the ground, set the parking
brake switch and work equipment lock switch in LOCK position, stop the engine, and chock the
wheels.

a When brake circuit equipment is removed or installed, bleed air from the brake circuit according to the
following procedure.
a Take the similar procedure for the front brake circuit and rear brake circuit. (2 places each).
a Perform air bleeding in order of right side of rear axle o left side of rear axle o right side of front axle o
left side of front axle o slack adjuster.

Bleeding air

(WA470-G200-231-K-00-A)

1. Start the engine to accumulate pressure in the


accumulator, and then stop the engine.
2. Remove inspection cover (1) of the front frame.
k When

removing the inspection cover with


the boom raised, place a stand under the
boom to support the boom securely.

5. Connect hose [1] to bleeder screw (3) of wheel


brake, and place one end of hose [1] in the oil
container.
6. Depress the brake pedal and then loosen
bleeder screw (3) to bleed air.
a Release the brake pedal slowly after
tightening bleeder screw (3).
3. Connect hose [1] to bleeder screw (2) of slack
adjuster, and place one end of hose [1] in the oil
container.

4. Depress the brake pedal, and then loosen


bleeder screw (2) to bleed air.
a Release the brake pedal slowly after
tightening bleeder screw (2).

WA470-7

7. Repeat this operation until the oil flowing


through hose [1] becomes free from bubbles.
Then depress the pedal fully, and tighten
bleeder screw (2) and (3) while the oil is flowing.
8. Bleed air from other brake cylinders by using the
same procedure.
a When a complete bleeding is required, it is
advisable to start the operation from the
brake cylinder situated farthest from the
brake pedal.

30-97

30 Testing and adjusting


Brake system

a If the pressure in the accumulator is


decreased, start the engine to charge the
accumulator. Then stop the engine and
perform air bleeding following the same
procedure as described above.
a After finishing bleeding air, run the engine at
low idle, and check the oil level in the
hydraulic tank. If the level is low, refill with oil
to the specified level.
Bleeding method after removal and installation
of cab
a Perform the following if removing cab for work.
1. Remove hoses (1) to (5) (5 pieces) from brake
valve.
2. Remove hoses of front brake (1), rear brake (2),
accumulator (4) and (5), and hydraulic tank (3).
3. Perform air blowing through inlet of hoses
removed from brake valve side. (Blow the air in)
4. Install hoses (1) to (5) removed.
5. Perform air bleeding according to procedure for
air bleeding.

30-98

WA470-7

30 Testing and adjusting


Brake system

Releasing remaining pressure in brake accumulator circuit

(WA380-G2F0-001-K-00-A)

k Before

disconnecting any of the following


brake accumulator circuits, release
remaining pressure in the brake circuit.

Releasing remaining pressure

(WA380-

G2F0-22A-K-00-A)

Between accumulator charge valve and brake


accumulator
Between accumulator charge valve and parking
brake solenoid valve
Between brake accumulator and brake valve
1. Stop the engine.
2. Depress the brake pedal at least 100 times to
release the pressure in the brake accumulator
circuit.

WA470-7

30-99

30 Testing and adjusting


Brake system

Testing parking brake performance

(WA380-GJ20-001-K-00-A)

a Testing conditions
Tire inflation pressure: Specified pressure
Road surface: Flat, dry, paved road with (11
deg. 20') grade
Machine: Operating condition

Testing

(WA380-GJ20-38E-K-00-A)

1. Start the engine and set the machine in the


straight travel position, and then drive up a slope
of 1/5 gradient with no load in the bucket.
2. Depress the brake pedal to stop the machine,
set the directional lever in the" N (neutral)"
position, and stop the engine.
3. Turn the parking brake switch ON (to park), and
then release the brake pedal gradually. At this
time, the machine must not move.
a When the engine is stopped, the parking
brake is turned ON (to park) automatically.
a Test the parking brake performance on an
uphill and a downhill.

30-100

WA470-7

30 Testing and adjusting


Brake system

Testing parking brake oil pressure


a Testing tools
Symbol
1
W
2

(WA470-GJB0-360-K-00-A)

a Use gauge of 6 MPa {60 kg/cm2}.

Part No.

Part name

799-101-5002 Hydraulic tester


790-261-1204 Digital hydraulic tester
793T-615-1730 Adapter
07002-11023

O-ring

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

a Measure the parking brake oil pressure under


the following condition.
Torque converter oil temperature: 80 to 100C

Testing

(WA470-GJB0-362-K-00-A)

1. Remove side cover (1) on left of rear frame.


2. Remove parking brake oil pressure pickup plug
(1).

4. Start the engine, and run it at low idle, and


measure the parking brake oil pressure.
k Keep

depressing the brake pedal for


safety.

a Measure the oil pressure at when the parking


brake switch is turned OFF.

5. After finishing test, remove the testing tools and


restore the machine.
3 Parking brake pressure pickup port
plug (1):
9.8 to 12.74 Nm {1.0 to 1.3 kgm}

3. Install adapter W2 and hose [1] of hydraulic


tester W1, and connect them to gauge [2].
3 Adapter:
9.8 to 12.74 Nm {1.0 to 1.3 kgm}
a The hose for digital hydraulic tester W2 can
also be used.
WA470-7

30-101

30 Testing and adjusting


Brake system

Testing wear of parking brake disc


a Testing tools
Symbol
X

Part No.

Part name

Commercially Vernier calipers


available

(WA380-GJ72-001-K-00-A)

and assembly, "Removal of parking brake discs


and plates".
Judgement criteria of thickness(W): 2.97 mm
a If the parking brake disc thickness is below
the service limit, replace the disc.

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

a If the parking brake does not work effectively,


check the parking brake disc for wear according
to the following procedure.

Testing

(WA470-GJ72-389-K-00-A)

1. Drain the oil from the transmission case.


6 Transmission case: 65 l (refill
capacity)
2. Remove one of 2 bolts (1).
a Prepare an oil container to receive oil flew
from the bolt mounting holes.

Refilling of oil (transmission case)


Refill with oil to the specified level through
the oil filler port. Run the engine to circulate
the oil through the system. Then check the
oil level again.

3. Measure depth (a) from the end of cage (2) to


piston (3) by using vernier calipers X.
Clearance (a): Max. 38.3 mm

4. If depth (a) is above the standard, remove


parking brake disc (4), and measure its
thickness (W) of disc, referring to Disassembly

30-102

WA470-7

30 Testing and adjusting


Brake system

Method of releasing parking brake manually

(WA380-GJ20-001-K-01-A)

k Releasing

the parking brake manually is a


means to move the machine from a
dangerous job site to a safe place. Apply this
means only in an emergency.

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

a The parking brake is controlled hydraulically. If


you cannot release the parking brake because
of a failure in the transmission, emergency
release solenoid valve, etc., you can move the
machine by releasing the parking brake
manually.

How to release

(WA470-GJ20-141-K-00-A)

Releasing method by using the parking brake


emergency release valve
1. Remove inspection cover (1) on the right side of
the machine.

3. Turn the starting switch to ON position, turn the


parking brake switch to ON position and then to
OFF position.
a The parking brake is released by the above
procedure.
Mechanical releasing method
1. Drain the oil from the transmission case.
2. Loosen lock nut (3) and grip (4) of parking brake
emergency release valve (2) and open the
release valve.
3 Lock nut (3):
19.6 4.9 Nm {2.0 0.5 kgm}

6 Transmission case: 65 l (refill


capacity)
2. Remove 2 bolts (1). (Right and left)
a Prepare an oil container to receive oil flew
from the plug mounting holes.

3 Grip (4):
19.6 4.9 Nm {2.0 0.5 kgm}

3. Remove mounting bolts (2) (2 pieces), and


tighten them alternately into mounting part of
bolt (1).

WA470-7

30-103

30 Testing and adjusting


Brake system

a Remove bolts (2) (2 pieces) on the diagonal


positions.
a Piston (3) is pulled back by tightening bolts
(2), then the parking brake is released.
a Tighten the bolts (2 pieces) gradually and
evenly. (Tighten the bolts approximately 3
turns after it contacts the seat surface.)

4. After finishing the work, restore the machine.


Refilling of oil (transmission case)
After releasing the parking brake manually, refill
with oil to the specified level through the oil filler
port. Run the engine to circulate the oil through
the system. Then check the oil level again.

30-104

WA470-7

30 Testing and adjusting


Hydraulic system

Hydraulic system
Testing fan speed

(D65-PM10-001-K-00-A)
(WA380-B400-001-K-00-A)

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

a Test the cooling fan motor speed under the


following conditions.
Cooling fan maximum speed
Engine at high idle
Coolant temperature: Min. 95C
Hydraulic oil temperature: Min. 95C
Torque converter oil temperature: Min. 105C
Cooling fan minimum speed

Engine at low idle


Coolant temperature: Max. 75C
Hydraulic oil temperature: Max. 75C
Torque converter oil temperature: Max. 85C
Air conditioner: OFF

Testing

(WA470-B400-388-K-00-A)

1. Start the engine, and switch the machine


monitor to 01 Monitoring/Pre-defined display of
the service mode.
a For the operating method, see "Special
functions of machine monitor".
a Monitoring/Pre-defined (15/16)

2. While running the engine at low idle and high


idle, measure the cooling fan speed.
Cooling fan
speed

Engine speed

Standard value

Max. speed

High idle

See standard
value table

Min. speed

WA470-7

Low idle

Air
conditioner:
OFF
Air
conditioner:
ON

See standard
value table
See standard
value table

30-105

30 Testing and adjusting


Hydraulic system

Testing fan pump circuit oil pressure

(WA380-B441-001-K-00-A)

a Testing tools
Symbol
1
R
2

Part No.

Part name

799-101-5002 Hydraulic tester


790-261-1204 Digital hydraulic tester

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k Loosen

the cap of the hydraulic tank


gradually to release the pressure in the tank.

3. Remove cover (2).

a Measure the cooling fan pump circuit pressure


under the following conditions.
Engine high idle
Fan 100% mode
Hydraulic oil temperature: 50C

Testing

(WA470-B441-362-K-00-A)

Testing fan drive pressure


1. Start the engine, and switch machine monitor to
Fan 100% Mode display of "Adjustment"
function in the service mode.
a For the operating method, see "Special
functions of machine monitor".
a If this mode is displayed, the fan speed is
kept at 100% speed in accordance with the
engine speed, regardless of the condition of
the machine.

4. Connect oil pressure gauge [2] of hydraulic


tester R to oil pressure pickup nipple (3).
a Use the oil pressure gauge of 40 MPa {400
kg/cm2}.

5. Run the engine at high idle and measure the


cooling fan pump circuit oil pressure.
2. Open radiator grille (1).

30-106

Cooling fan pump circuit


See standard value table
oil pressure

WA470-7

30 Testing and adjusting


Hydraulic system

6. After finishing test, remove the testing tools and


restore the machine.
Testing cooling fan reverse solenoid output
pressure
1. Open radiator grille (1).

4. Select "Manual Fan Reverse Mode" by


operating the machine monitor.
a For the selection procedure, see the
Operation and Maintenance Manual.
5. Run the engine at high idle and measure the
cooling fan reverse solenoid output pressure.
a Measure the pressure in both fan reverse
mode and fan normal rotation mode and
confirm that the solenoid operates and the
specified oil pressure is generated in the fan
reverse mode.
Cooling fan reverse
solenoid output pressure See standard value table

2. Remove cover (2).

6. After finishing the measurement, remove the


testing tools and restore the machine.
3 Pickup port plug (4):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3. Remove pickup port plug (4) and connect oil
pressure gauge [2] of hydraulic tester R to it.
a Use the oil pressure gauge of 6 MPa {60 kg/
cm2}.

WA470-7

30-107

30 Testing and adjusting


Hydraulic system

Bleeding air from hydraulic fan circuit

(WA380-B441-001-K-01-A)

a Testing tools
Symbol
1
S 2
3

Part No.

Part name

799-101-5002 Hydraulic tester


790-261-1204 Digital hydraulic tester
790-261-1130 Coupling

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

a Before bleeding air, check that the hydraulic oil


level is proper.

Bleeding air

2. Remove cover (2).

(WA470-B441-231-K-00-A)

Bleeding air from cooling fan pump


1. Remove cover (1) at the lower right of the
operator's cab.

3. Install hose [1] in hydraulic tester S1 to the fan


pump circuit pressure pickup port nipple (3), and
also connect air bleeder coupling S3 to the
outlet end of the hose.
a Put the outlet end of the hose in the oil
container.
2. Connect air bleeder hose [1], and loosen air
bleeder (2) of the cooling fan pump.

a The hose for digital hydraulic tester S2 can


also be used.

3. As oil containing no bubbles starts to flow out of


air bleeder(2), tighten air bleeder (2).
3 Air bleeder (2):
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
4. Start the engine, and run it at low idle for 5
minutes minimum.
Bleeding air from cooling fan motor circuit
1. Open radiator grille (1).

30-108

WA470-7

30 Testing and adjusting


Hydraulic system

4. Start the engine, then stop it when the oil flows


out of the outlet end of the hose.
5. After finishing bleeding the air, remove the
testing tools and restore the machine.

WA470-7

30-109

30 Testing and adjusting


Hydraulic system

Testing and adjusting work equipment EPC oil pressure

(WA470-PL70-360-K-00-A)

a Testing tools
Symbol
1
2
Z
3

Part No.
799-101-5002
790-261-1204
799-101-5220
07002-11023

Part name
Hydraulic tester
Digital hydraulic tester
Nipple
O-ring

k Loosen

the oil filler cap slowly to release the


pressure inside the hydraulic tank.

k Turn

the starting switch to ON position,


release the work equipment lock switch, and
then operate the work equipment control
lever 2 to 3 times to release the pressure in
the PPC accumulator circuit.

a Measure the work equipment PPC oil pressure


under the following condition.

4. Start and run the engine at high idle, and then


operate the work equipment control lever and
measure the EPC valve source pressure.
EPC valve source
pressure

3.72 (+0.2/-0.2) MPa


{38 (+2/-2) kg/cm2}

Hydraulic oil temperature: 45 to 55C

Testing

(WA470-PL70-362-K-00-A)

EPC valve source pressure


1. Remove side cover (1) on the right of rear frame.

5. After finishing test, remove the testing tools and


restore the machine.
Testing EPC oil pressure (shut off valve output
pressure)
1. Remove inspection cover (1) of the front frame.
2. Remove oil pressure pickup port plug (3).
k When

removing the inspection cover with


the boom raised, place a stand under the
boom to support the boom securely.

3. Install nipple Z3 and hose [1] of hydraulic tester


Z1 and connect them to gauge [2].
a The hose for digital hydraulic tester Z2 can
also be used.
a Use gauge of 6 MPa {60 kg/cm2}.

30-110

WA470-7

30 Testing and adjusting


Hydraulic system

8. After finishing the test, remove the testing tools


and restore the machine.
Measuring EPC valve output pressure
1. Remove inspection cover (4) of the front frame.
k When

removing the inspection cover with


the boom raised, place a stand under the
boom to support the boom securely.

2. Disconnect EPC circuit hose (2) to be


measured.

2. Remove oil pressure pickup port plug (5) of EPC


valve output circuit to be measured.
a A: Attachment

3. Connect nipple and O-ring Z3.

B: Attachment
C: ECSS
D: Boom RAISE
E: Boom LOWER and boom FLOAT
F: Bucket TILT
G: Bucket DUMP

4. Install nipple and hose of hydraulic tester Z1,


and connect them to gauge G3.
a Use gauge of 6 MPa {60 kg/cm2}.
5. Start the engine.
6. Operate the work equipment lock switch to
release the lock of work equipment.
7. Run the engine at high idle, and measure EPC
valve source pressure (oil pressure) (shut off
valve output pressure).
k Do

not operate the work equipment


control lever.
Work equipment EPC
valve oil pressure
See standard value table
(Shut off valve outlet
pressure)
WA470-7

30-111

30 Testing and adjusting


Hydraulic system

3. Install nipple Z3 and hose [1] of hydraulic tester


Z1 and connect them to gauge [2].
a The hose for digital hydraulic tester Z2 can
also be used.
a Use gauge of 6 MPa {60 kg/cm2}.

4. Start the engine, run it at high idle, and move the


work equipment lever to measure the EPC valve
output pressure.

5. After finishing test, remove the testing tools and


restore the machine.

Adjusting

(WA470-PL70-270-K-00-A)

a The EPC relief valve is not adjustable.


1. Remove EPC relief valve cartridge assembly,
and replace it.
3 EPC relief valve cartridge assembly:
25 to 33.9 Nm {2.6 to 3.5 kgm}
3 Lock nut:
11.8 to 16.7 Nm {1.2 to 1.7 kgm}
a After the replacement, measure the EPC oil
pressure again.

30-112

WA470-7

30 Testing and adjusting


Hydraulic system

Testing and adjusting work equipment oil pressure


a Tools for testing and adjusting
Symbol
1
2
ZA 3
4

Part No.

(WA470-PM10-360-K-00-A)

k When

Part name

removing the inspection cover with


the boom raised, place a stand under the
boom to support the boom securely.

Hydraulic tester
Digital hydraulic tester
Nipple
O-ring
Differential pressure
799-401-2701 gauge

799-101-5002
790-261-1204
799-101-5220
07002-11023

a Measure the work equipment oil pressure under


the following condition.
Hydraulic oil temperature: 45 to 55C

Preparation

(WA470-PM10-330-K-00-A)

Combination of actuator and valve


a Note that the valve which relieves the oil
pressure depends on the actuator.
a The number of each actuator in the following
table shows the order from the top, when the
control valve is seen from the front of the
machine. (As for the service actuator, an
example of a single attachment installation is
shown.)
No.
1

Actuator
Service
Tilt
DUMP
Boom
(Lift cylinder)

Bucket

Valve to be relieved
Safety valve
Safety valve
Main relief valve

Testing

(WA470-PM10-362-K-00-A)

Testing work equipment relief pressure


Testing with machine monitor
Work equipment oil pressure can be measured with
Monitering/Pre-difined (9/16) or Monitering
(monitoring code: 94700) of the machine monitor.
a For the machine monitor operating method, see
the section of "Special functions of machine
monitor".
a Monitoring/Pre-defined (9/16) screen

Main relief valve

1. Lower section (b) to the ground keeping bucket


(a) 30 to 50 mm off the ground.
2. Stop the engine and operate the work
equipment control lever to check that both parts
(a) and (b) of the bucket touch the ground.
a After lowering the bucket to the ground,
operate the work equipment control lever 2 to
3 times to release the remaining pressure in
the piping.
1. Start the engine, and raise the boom, and keep it
level. Then, measure the oil pressure with the
bucket dumped while running the engine at high
idle.
a When accurate measurement of work equipment
relief pressure is required for troubleshooting,
etc., refer "Testing by use of testing tools".
Testing by use of testing tools
1. Remove pump pressure pickup port plug (2)
from the work equipment control valve.

3. Remove inspection cover (1) of the front frame.

WA470-7

30-113

30 Testing and adjusting


Hydraulic system

a For the machine monitor operating method, see


the section of "Special functions of machine
monitor".
a Monitoring/Pre-defined (9/16) screen

2. Install nipple ZA3 and hose [1] of hydraulic tester


ZA1 and connect them to gauge [2].
a The hose for digital hydraulic tester ZA2 can
also be used.
a Use the oil pressure gauge of 40 MPa {400
kg/cm2}.

1. Start the engine and raise the boom


approximately 400 mm. Then, measure the oil
pressure when all the levers are in NEUTRAL
position with the engine running at high idle.
a When accurate measurement of unload oil
pressure is required for troubleshooting, etc.,
refer "Testing by use of testing tools".
Testing by use of testing tools
1. Remove pump pressure pickup port plug (2)
from the work equipment control valve.

3. Start the engine, and raise the boom, and keep it


level. Then, measure the oil pressure with the
bucket dumped while running the engine at high
idle.

2. Install nipple ZA3 and hose [1] of hydraulic tester


ZA1, and connect them to gauge [2].
a The hose for digital hydraulic tester ZA2 can
also be used.
a Use the oil pressure gauge of 6 MPa {60 kg/
cm2}.
4. After finishing test, remove the testing tools and
restore the machine.
Testing unload oil pressure
Testing with machine monitor
Unload oil pressure can be measured with
Monitering/Pre-difined or Monitering (monitoring
code: 94700) of the machine monitor.

30-114

WA470-7

30 Testing and adjusting


Hydraulic system

2. Install nipple ZA3 and hose [1] of hydraulic tester


ZA1 and connect them to gauge [2] or
differential pressure gauge ZA4.
a When using the differential pressure gauge,
connect its high-pressure side to the pump
pressure side, and connect its low-pressure
side to the LS pressure side. The differential
pressure gauge requires 12 V power supply.
Thus, connect a battery.
a Use the gauge of 40 MPa {400 kg/cm2}.
3. Start the engine, and raise the boom
approximately 400 mm. Then, measure the oil
pressure when all the levers are in neutral
position with the engine running at high idle.

4. After finishing test, remove the testing tools and


restore the machine.
Testing LS differential pressure
a Before measuring the LS control circuit oil
pressure, check that the work equipment relief
oil pressure and work equipment EPC oil
pressure are normal.
a To obtain the LS differential pressure, measure
the pump discharge pressure and LS pressure
(actuator load pressure) simultaneously and
calculate the difference.
1. Remove pump pressure pickup port plug (2) and
LS pressure pickup port plug (3) from the work
equipment control valve.

Since the differential pressure is 1.5 MPa {15


kg/cm2} at maximum, use the gauge whose
accuracy is the same throughout the
measurement.

3. Start the engine and raise the boom


approximately 400 mm.
4. Run the engine at high idle and then, under the
following condition, measure the pump
discharge pressure and LS pressure (actuator
load pressure) simultaneously.
When all of control levers are in NEUTRAL
and when boom lever is moved halfway
a While measuring, take care not to move the
lift cylinder to the stroke end.
a Calculation of LS differential pressure:
LS differential pressure = pump discharge
pressure - LS pressure
a When the LS differential pressure is as
follows, it is normal.
Operation of lever
All control levers in
NEUTRAL
Boom control lever in
halfway

WA470-7

LS differential pressure
Unload pressure (see
the standard values
table)
Specified LS differential
pressure (see the
standard values table)

30-115

30 Testing and adjusting


Hydraulic system

a After finishing adjusting, measure the work


equipment relief valve pressure according to
the above measurement procedure.
Adjusting LS differential pressure
a LS differential pressure cannot be adjusted.

5. After finishing test, remove the testing tools and


restore the machine.
Adjusting work equipment relief pressure
1. Adjust main relief valve (5) of work equipment
control valve (4).

2. Loosen lock nut (6) and turn adjustment screw


(7) to adjust.
a When the adjustment screw is:
turned clockwise, the pressure is
increased.
turned counterclockwise, the pressure is
decreased.
a Quantity of adjustment per turn of adjusting
screw:
12.6 MPa {128 kg/cm2}
3 Lock nut:
29.4 to 39.2 Nm {3 to 4 kgm}

30-116

WA470-7

30 Testing and adjusting


Hydraulic system

Bleeding air from work equipment circuit

(WA470-PM10-231-K-00-A)

Bleeding air from cylinder


1. Start the engine and run it at idle for
approximately 5 minutes.
2. Run the engine at low idle and then, raise and
lower the boom 4 to 5 times.
a Stop the piston rod approximately 100 mm
before each stroke end and take care not to
relieve the circuit.
3. Run the engine at high idle and then, perform
operation of Step 2. Then, retract the piston rod
to the stroke end at low speed to relieve the
circuit.
4. Perform the same operation as the one in Steps
2 and 3 for the bucket and steering cylinders as
well.
a When a cylinder is replaced, perform this
operation before connecting the piston rod.

WA470-7

30-117

30 Testing and adjusting


Hydraulic system

Releasing remaining pressure from work equipment circuit

(WA470-PM10-22A-K-00-A)

Releasing remaining pressure between each


hydraulic cylinder and control valve
a If the piping between the hydraulic cylinder and
the control valve is to be disconnected, release
the remaining pressure in the circuit according to
the following procedure.
1. Stop the engine.
2. Loosen the oil filler cap slowly to release the
pressure inside the tank.
3. Turn the starting switch to ON position.
4. Set the work equipment lock switch to OFF
position.
5. Release the remaining pressure by operating
the work equipment control lever.
Releasing remaining pressure in ECSS circuit
k When

disconnecting the piping of ECSS


circuit (between the accumulator for ECSS
and work equipment control valve), release
the pressure of the accumulator for ECSS
according to the following procedure.

1. Remove inspection cover (1) of the front frame.


k When

removing the inspection cover with


the boom raised, place a stand under the
boom to support the boom securely.

4. After releasing the remaining pressure, tighten


plug (5)and lock nut (4) securely in this order.
a Loosen lock nut (4) to the maximum before
tightening plug (5). After tightening plug (5),
tighten lock nut (4).
3 Plug (5):
19.6 to 27.5 Nm {2.0 to 2.8 kgm}
3 Lock nut (4):
19.6 to 27.5 Nm {2.0 to 2.8 kgm}

2. Loosen lock nut (2) of ECSS bleeder plug (5) on


work equipment control valve (4).
3. Loosen bleeder plug (5) 1/2 to 1 turn to release
the accumulator pressure.
a When the work equipment control valve is
seen from the front of the machine, plug (5)
is installed to the left side of the control valve.

30-118

WA470-7

30 Testing and adjusting


Hydraulic system

Testing of ECSS accumulator nitrogen gas pressure and procedure for


charging accumulator with nitrogen gas (WA470-L370-360-K-00-A)
a Testing tools
Symbol
1
Z2
D
3

Part No.

k Place

Part name

Commercially Gas charge tool


available
Commercially Pressure reducing valve
available
Commercially Charging hose
available

a For testing and adjusting HYDAC accumulators,


commercially available tools are used. Please
contact one of distributors in your area.

the machine on a level ground, lower


the work equipment to the ground, and
chock the wheels.

a The following testing procedure is applicable to


an independent accumulator as well.
1. Remove cap (2) from the filling port of
accumulator (1).
2. Loosen hexagonal socket head bolt (3)
counterclockwise ( approximately 1/2 turn)
slightly by using hexagonal wrench with 6mm
(SW6)

Model and type (reference)


FPU-1 250 F4.0 G6 A3 K
k In

order to prevent leaked nitrogen gas from


contacting your skin and clothing, be sure to
wear the appropriate protective items (such
as goggles, leather gloves and protective
clothing) and do the work from the windward
side as much as possible.

k When

handling nitrogen gas in an illventilated location like in a room, you must


improve ventilation of the room and observe
the rules stipulated in the Industrial Safety
and Health Act to prevent oxygen deficiency
disease and other hazards.

k The

accumulator is charged with highpressure nitrogen gas. Its inappropriate


handling can cause an explosion accident,
leading to serious personal injury or death.
The following rules must be strictly observed
when handling the gas.
Do not bring any open flame near the
accumulator or expose it to fire.
Do not drill it, weld or fuse-cut it.
Do not give impacts to it by hitting or
rolling it.
Bleed the gas in it before disposing it.

3. Turn handle (4) of gas charge tool ZD1 fully


counterclockwise until it becomes immovable.
4. Close pressure relief valve (5).
5. Screw cap nut (6) into filling port of accumulator
(1) with hands. Adjust it so that a pressure
gauge (7) of gas charge tool ZD1 can be easily
seen.
6. Slowly turn handle (4) counterclockwise to
loosen the hexagonal socked head bolt (3), and
open it.
7. When pressure gauge (7) indicator reaches the
maximum value, turn handle (4) clockwise to the
fully closed position.
The pressure shown at this time is the
charge pressure of the accumulator.

Testing nitrogen gas pressure in


accumulator (WA470-L370-280-K-00-A)
k Loosen

the oil filler cap slowly to release the


pressure inside the hydraulic tank.

k Cancel

the work equipment lock switch while


starting switch is ON.

k Operate

the work equipment control lever 2


to 3 times to release the pressure in the PPC
accumulator circuit.

WA470-7

30-119

30 Testing and adjusting


Hydraulic system

a Since the indicated value varies with the ambient


temperature, refer to the following table and
check the gas pressure.
Ambient
temperature
C
15
16
17
18
19

MPa
4.43
4.35
4.37
4.38
4.4

kg/cm2
44.2
44.4
44.5
44.7
44.8

20

4.41

45

21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

4.43
4.44
4.46
4.47
4.49
4.5
4.52
4.53
4.55
4.56
4.58
4.59
4.61
4.62
4.64
4.65
4.67
4.68
4.7
4.71
4.73
4.74
4.76
4.77
4.79

45.2
45.3
45.5
45.6
45.8
45.9
46.1
46.2
46.4
46.5
46.7
46.8
47
47.2
47.3
47.5
47.6
47.8
47.9
48.1
48.2
48.4
48.5
48.7
48.8

Gas pressure

Remarks

a The following charging procedure is applicable


to an independent accumulator as well.
1. Remove cap (2) from the filling port of
accumulator (1).
2. Loosen hexagonal socket head bolt (3)
counterclockwise ( approximately 1/2 turn)
slightly by using hexagonal wrench with 6 mm
(SW6).

Base gas
pressure

Procedure for charging accumulator


with nitrogen gas (WA470-L370-219-K-00-A)
k Loosen

the oil filler cap slowly to release the


pressure inside the hydraulic tank.

3. Turn handle (4) of gas charge tool ZD1 fully


counterclockwise until it becomes immovable.
4. Close pressure relief valve (5).
5. Screw cap nut (6) into filling port of accumulator
(1) with hands. Adjust it so that a pressure
gauge (7) of gas charge tool ZD1 can be easily
seen.

6. Connect gas charge tool ZD1 and nitrogen gas


cylinder according to the following procedure.
1) Connect cap nut (7) of pressure reducing
valve ZD2 to the nitrogen gas cylinder.

k Cancel

the work equipment lock switch while


starting switch is ON.

k Operate

the work equipment control lever 2


to 3 times to release the pressure in the PPC
accumulator circuit.

k Place

the machine on a level ground, lower


the work equipment to the ground, and
chock the wheels.

30-120

WA470-7

30 Testing and adjusting


Hydraulic system

5) Slowly turn handle (4) counterclockwise to


loosen the hexagonal socked head bolt (3),
and open it.

2 types of threads, W22-14 threads (male


thread A type) and W23-14 threads
(female thread B type), are available for
the nitrogen gas cylinder. When using a
cylinder with W23-14 threads (female
thread B type), connect the hose by using
the adapter.
Connect cap nut (8) of charging hose
ZD3 to pressure reducing valve ZD2.
2) Connect cap nut (9) of charging hose ZD3 to
pressure relief valve (5) of gas charging tool
ZD1.

3) Slightly open shut off valve (11) of nitrogen


gas cylinder (10), and set the filling pressure
of pressure reducing valve ZD2 not to
damage the gas charging tool ZD1.
4) Close shut off valve (11) of nitrogen gas
cylinder (10), and check the pressure on the
gauge.

WA470-7

6) Open shut off valve (11) of nitrogen gas


cylinder (10) further, to charge the
accumulator with nitrogen gas.
7) Repeat the above operations until it reaches
to the filling pressure.
8) If the pressure in the accumulator is higher
than the set pressure, open the pressure
relief valve (5) of gas charge tool ZD1 to
reduce the pressure.
9) During this operation, close shut off valve
(11) of nitrogen gas cylinder (10) from time to
time to check the nitrogen gas pressure in
the accumulator.
a For the procedure of testing nitrogen gas
pressure, see "Testing of accumulator
nitrogen gas pressure".
10)After it is charged up to the standard value,
close shut off valve (11) of nitrogen gas
cylinder (10).
When it is charged excessively, open the
pressure relief valve (5) of gas charge
tool ZD1 to reduce the pressure with shut
off valve (11) of nitrogen gas cylinder (10)
closed.
a Since the indicated value varies with the
ambient temperature, refer to the following
table and check the gas pressure.
Ambient
temperature
C
15
16
17
18
19

MPa
2.89
2.90
2.91
2.92
2.93

kg/cm2

20

2.94

30.0

21
22

2.95
2.96

30.1
30.2

Gas pressure

Remarks

29.5
29.6
29.7
29.8
29.9
Base gas
pressure

30-121

30 Testing and adjusting


Hydraulic system

Ambient
temperature
C
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

Gas pressure
MPa
2.97
2.98
2.99
3.00
3.01
3.03
3.04
3.05
3.06
3.07
3.08
3.09
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20

Remarks

kg/cm2
30.3
30.4
30.5
30.6
30.7
30.8
31.0
31.1
31.2
31.3
31.4
31.5
31.6
31.7
31.8
31.9
32.0
32.1
32.2
32.3
32.4
32.5
32.6

7. Remove gas charge tool ZD1 from the


accumulator according to the following
procedure.
1) Slowly turn handle (4) clockwise, and tighten
the hexagonal socked head bolt (3).
2) Open pressure relief valve (5), and discharge
nitrogen gas remaining in gas charge tool
ZD1 and hose.
3) Remove gas charge tool ZD1 from the filling
port of the accumulator.

10.Within a week from charging nitrogen gas,


check that no pressure drop of nitrogen gas is
found.
a Check the brake function within 5 minutes
from stop of the engine. (If more than 5
minutes elapse from stop of the engine,
correct measurement becomes unavailable
because oil pressure in the brake circuit
drops.)
1) Place the machine on a level ground and
turn the parking brake switch to the ON
position.
2) Start and run the engine at medium speed for
a minute, then stop the engine.
3) Turn the starting switch to ON position and
depress the brake pedal repeatedly to record
how many times depressing are required for
the brake oil pressure caution lamp to light
up.
Number of times of depressing is less than 5:
Accumulator gas pressure may be low
Number of times of depressing is 5 or more:
Accumulator gas pressure is normal.

8. Apply suds to the filling port of the accumulator


to make sure there is no leakage of nitrogen
gas.
9. Install hexagonal socket head bolt (3) and cap
(2) to accumulator (1).

30-122

WA470-7

30 Testing and adjusting


Work equipment

Work equipment

(ALL-L000-001-K-00-A)

Testing and adjusting bucket position detection lever

(WA380-LEE1-001-K-00-A)

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

Testing

(WA470-LEE1-365-K-00-A)

1. Remove bucket positioner covers (1) and (2).

2. Make sure that clearance (a) between bucket


angle sensor (3) and detection lever (4) is within
the standard value.
Clearance (a): 0.5 to 1 mm

Adjusting

(WA470-LEE1-270-K-00-A)

a If clearance (a) does not conform to the standard


value, adjust it according to the following
procedure.
1. Loosen bolt (5).
2. Adjust position of detection lever (4) so that
clearance (a) between bucket angle sensor (3)
and detection lever (4) becomes in the specified
range. Then tighten bolt (5).

WA470-7

30-123

30 Testing and adjusting


Work equipment

Testing and adjusting boom position detection lever

(WA380-L6WR-001-K-00-A)

k Place

the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

Testing

(WA470-L6WR-365-K-00-A)

1. Make sure that clearance (a) between boom


angle sensor (1) and detection lever (2) is within
the standard value.
Clearance (a): 0.5 to 1 mm

Adjusting

(WA470-L6WR-270-K-00-A)

a If clearance (a) does not conform to the standard


value, adjust it according to the following
procedure.
1. Loosen bolt (3).
2. Adjust position of detection lever (2) so that
clearance (a) between boom angle sensor (1)
and detection lever (2) becomes in the specified
range. Then tighten bolt (3).

30-124

WA470-7

30 Testing and adjusting


Electrical system

Electrical system

(ALL-RA1D-001-K-00-A)

Adjusting replaced, reassembled or added sensor, controller, etc. with


machine monitor (WA500-RA1D-270-K-00-A)
1. Items to be set when sensor or controller is
replaced, reassembled or added
a If any of the following components and parts
is replaced or reassembled, make an initial
adjustment of the sensors, solenoids, etc.
with the machine monitor.
a For details of adjustment items (A to O), see
"Adjustment items table".
Corresponding chart of device, parts and
adjustment item
Device/Optional items replaced,
disassembled, assembled or
added
Machine monitor
Transmission
Transmission controller
Transmission ECMV solenoid
Boom angle sensor
Work equipment control valve
Work equipment EPC solenoid
Work equipment electric lever
Work equipment controller
Work equipment bucket angle
sensor
Bucket
Boom
Addition or removal of optional
item
Rearview monitor
Rearview camera
Work equipment pump

Adjustment
Contents of work
item
Adjusting reference line
N
Adjusting work equipment pump swash
O
plate
*1 See "Bucket flat level adjustment"in the
Operation section of the Operation and
maintenance manual.
*2 For setting procedures, see "Service News".

Adjustment
item
(sequence)
A, L, B
D, C, E
A, B, D, C, E
D, C, E
F, I
H
H
G
A, B, F, G, H, I
F, I
I
F, I
B
M, N
N
O

Adjustment items table


Adjustment
Contents of work
item
A
Machine Model Select
Option Select
B
Adjusting transmission ECMV electric
C
current
T/M initial learning reset
D
T/M initial learning
E
Adjustment of work equipment controller
F
boom angle
Adjustment of work equipment EPC
G
lever detent position
Adjustment of work equipment EPC
H
starting current
Setting of bucket positioner (*1)
I
Setting of service meter and travel
L
odometer (