SEBM024710

Machine model Serial number

WA380-5 60001 and up

• This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.

• WA380-5 mounts the SAA6D114E-2 engine.

For details of the engine, see the 114 Series Engine Shop Manual.

© 2005
All Rights Reserved 00-1
Printed in Japan 07-05 (03) (10)
 00

CONTENTS

No. of page
01 GENERAL ......................................................................................... 01-1

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1

20 TESTING AND ADJUSTING ............................................................. 20-1

30 DISASSEMBLY AND ASSEMBLY ................................................... 30-1

90 OTHERS ............................................................................................ 90-1

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q 30-126 (10) 90- 19 (8)
30-127 (9) 90- 21 (4)
q 30-128 (10) 90- 23 (4)
q 30-129 (10) 90- 25 (4)
30-130 (9) 90- 27 (8)
30-131 (9) 90- 29 (4)
30-132 (9) 90- 31 (4)
30-133 (9) 90- 33 (4)
q 30-134 (10) 90- 35 (4)
30-135 (9) 90- 37 (4)
30-136 (9) 90- 39 (4)
30-137 (9)
30-138 (9)
30-139 (9)
q 30-140 (10)
q 30-141 (10)
q 30-142 (10)
q 30-143 (10)
q 30-144 (10)
q 30-145 (10)
q 30-146 (10)
30-147 (9)
30-148 (9)
q 30-149 (10)
q 30-150 (10)
q 30-151 (10)
q 30-152 (10)
q 30-153 (10)
q 30-154 (10)
30-155 (9)
q 30-156 (10)
q 30-157 (10)
30-158 (9)
q 30-159 (10)
q 30-160 (10)
q 30-161 (10)
30-162 (9)
q 30-163 (10)
q 30-164 (10)
30-165 (9)
30-166 (9)
30-167 (9)
30-168 (9)
q 30-169 (10)
q 30-170 (10)
q 30-171 (10)
q 30-172 (10)
q 30-173 (10)

WA380-5 00-2-5
(10)
SAFETY SAFETY NOTICE

SAFETY
SAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.

To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.

00-3
SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.

00-4
FOREWORD GENERAL

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.

STRUCTURE AND FUNCTION

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

TESTING AND ADJUSTING

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

DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.

MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.

00-5
FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:

Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.

SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):

2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204

00-6
FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

HOISTING

Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4

• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.

★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.

2) Sling wire ropes from the middle portion of the

hook.

00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.

k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.

Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.

2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).

3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)

4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.

Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.

00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly

3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.

• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection

00-9
FOREWORD COATING MATERIALS

COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.

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

00-10
FOREWORD COATING MATERIALS

Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to
LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass

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

00-11
FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

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

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147
30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370

Tightening torque
Thread diameter Width across
of bolt flats

mm mm Nm kgm

6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483

Thread diameter Width across flat Tightening torque

mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5
18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5

00-12
FOREWORD STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

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

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

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

00-13
FOREWORD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22

2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51

3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.20
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.

Tightening torque (Nm {kgm}) Taper seal Face seal type

type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target (mm) - Threads per
inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –

00-14
FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE

Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication

Code W B B R Y G L
1 Pri-
mary
Color White Black Black Red Yellow Green Blue

Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White

Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow

Code WL — BR RY YG GY LY
Auxi-
4 liary
Color White & Blue — Black & Red Red & Yellow Yellow & Green & Blue & Yellow
Green Yellow

Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black

Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n

00-15
FOREWORD CONVERSION TABLE

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.

EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

(B)

Millimeters to inches

1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

00-16
FOREWORD CONVERSION TABLE

Millimeters to Inches
1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound
1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-17
FOREWORD CONVERSION TABLE

Liter to U.S. Gallon

1l = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Liter to U.K. Gallon

1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

00-18
FOREWORD CONVERSION TABLE

kgm to ft. lb
1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-19
FOREWORD CONVERSION TABLE

kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

00-20
FOREWORD CONVERSION TABLE

Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F

°C °F °C °F °C °F °C °F

–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

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

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

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

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

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

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

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

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

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

–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

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

00-21
FOREWORD UNITS

UNITS

In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.

Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}

00-22 04-05
 01 GENERAL

General assembly drawing . . . . . . . . . . . . . . . . . .01-2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
Weight table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
List of lubricants and coolant . . . . . . . . . . . . . . . . 01-9

WA380-5 01-1
GENERAL GENERAL ASSEMBLY DRAWING

GENERAL ASSEMBLY DRAWING

Item Unit WA380-5

A Overall length mm 8,235

B Overall height mm 3,315
C Overall height when bucket is raised mm 5,565
D Overall width mm 2,695
E Min. ground clearance mm 390
F Bucket width mm 2,905
G Dumping clearance (tip of BOC) mm 2,885/2,800
H Dumping reach (tip of BOC) mm 1,165/1,210
I Bucket dump angle deg. 45

BOC: Bolt-on cutting edge.

01-2 WA380-5
(8)
GENERAL SPECIFICATIONS

SPECIFICATIONS

Machine model WA380-5

Serial No. 60001 and up

Operating weight kg 16,150

Weight

Distribution (front) SAE travel posture kg 7,785

Distribution (rear) SAE travel posture kg 8,365
Bucket capacity (piled) m³ 3.3
Rated load KN {kg} 51.8 {5,280}
N mode P mode
Travel speed FORWARD 1st km/h 4.8 6.3
FORWARD 2nd km/h 8.5 11.4
FORWARD 3rd km/h 15.3 20.2
FORWARD 4th km/h 24.7 31.5
Performance

REVERSE 1st km/h 5.2 6.7

REVERSE 2nd km/h 9.1 11.8
REVERSE 3rd km/h 16.2 21.0
REVERSE 4th km/h 25.5 32.5
Max. rimpull FORWARD kN {kg} 130 {13,240} 168 {17,170}
REVERSE kN {kg} 122 {12,400} 158 {16,075}
Gradeability deg 25
Min. turning (Center of outside
radius wheel) mm 5,620

SAE travel posture (tip of BOC) mm 6,540/6,580

Overall length (with BOC) mm 8,235
Overall width (chassis) mm 2,695
Bucket width (with BOC) mm 2,905
Overall height (top of cab) mm 3, 315
Overall height (Bucket approx. raised
to max.) mm 5,565

Wheel base mm 3,300

Dimensions

Tread mm 2,160
Min. ground clearance mm 390
Max. height of bucket hinge pin mm 4,030
Dumping clearance (tip of BOC) mm 2,885 / 2,800
Dumping reach (tip of BOC) mm 1,165 / 1,210
Steering angle deg 40
Bucket tilt angle (travel posture) deg 50
Bucket tilt angle (max. height) deg 65
Bucket dump angle (max. height) deg 49
Digging depth (10° dump) (tip of BOC) mm 310/360

BOC: Bolt-on cutting edge.

WA380-5 01-3
(8)
GENERAL SPECIFICATIONS

SPECIFICATIONS

Machine model WA380-5

Serial No. 60001 and up

Model SAA6D114E-2
4-cycle, water-cooled, serial 6-cylinder,
Type direct injection type with supercharger and air cooling
aftercooler
No. of cylinders - bore x stroke mm 6 - 114 x 135
Piston displacement l {cc} 8.27 {8,270}
N mode P mode
Flywheel horsepower kW {HP}/rpm 136/1,730 140/2,000
Engine

{182/1,730} {187/2,000}
Maximum torque Nm {kgm}/rpm 882/1,400 882/1,400
{90/1,400} {90/1,400}
Min. fuel consumption ratio g/kWh {g/HPh} 219{163} 219{163}
High idle speed rpm 1,900 ± 50 2,210 ± 50
Low idle speed rpm 900 (+50/0) 900 (+50/0)
Starting motor 24 V 7.5 kW
Alternator 24 V 35 A
Battery (*1) 24 V 136 Ah x 2 pcs. (165G51)
3-element, 1-stage, 1-phase
Torque converter 3-element, 1-stage, 2-phase (with lockup clutch)
Multple-shaft power shift, helical gear and spur gear,
Power train

Transmission constant-mesh type

Multiple plate disc type, hydrualically actuated, modula-
tion type
Reduction gear Spiral bevel gear, splash lubrication type
Differential Straight bevel gear type
Final drive Planetary gear 1-stage, splash lubrication type
Drive type Front and rear wheel drive
Axle

Front axle Fixed to frame, semi-floating type

Rear axle Center pin support, semi-floating type
Tire size 20.5-25-16PR
Rim size 17.00x25-1.7
Tire

Inflation pressure Front tire kPa {kg/cm²} 343.2 {3.5}

Rear tire kPa {kg/cm²} 343.2 {3.5}

Braking system 4 wheel braking, Front and rear wheel independent sys-
tem control
Main brake Brake type Sealed wet-type disc brake
Operation method Hydraulically controlled
Brakes

Control method Hydraulic power servo assisted brake

Braking system Speed change gear output shaft braking
Parking brake Operation method Wet type disc brake
Control method Hydraulically released spring type

*1:Battery capacity (Ah) shows the rate of 5 hours.

01-4 WA380-5
(9)
GENERAL SPECIFICATIONS

Machine model WA380-5

Serial No. 60001 and up

Steering

Type Articulated steering

control

Control Hydraulic control

Torque converter pump

• Type Gear type
• Delivery l /min 181
Steering pump
• Type Gear type
• Delivery l /min 94
Hydraulic pump
Hydraulic pump

• Type Gear type

• Delivery l /min 212
Switching pump
• Type Gear type
• Delivery l /min 94
Pilot control pump
• Type Gear type

l /min
Hydraulic system

• Delivery 48
Cooling fan pump
• Type Variable displacement piston type
Type Reciprocating piston type
Steering cylinder

Cylinder inner diameter mm 80

Piston rod diameter mm 45
Stroke mm 442
Max. length between pins mm 1,209
Min. length between pins mm 767
Type Reciprocating piston type
Cylinder inner diameter mm 160
Lift cylinder
Cylinder

Piston rod diameter mm 90

Stroke mm 713
Max. length between pins mm 2,050
Min. length between pins mm 1,337
Type Reciprocating piston type
Bucket cylinder

Cylinder inner diameter mm 180

Piston rod diameter mm 90
Stroke mm 535
Max. length between pins mm 1,690
Min. length between pins mm 1,155

WA380-5 01-5
(10)
GENERAL SPECIFICATIONS

Machine model WA380-5

Serial No. 60001 and up

Work equipment control valve

• Type 2-spool type
Control valve
Hydraulic system

• Set pressure MPa {kg/cm²} 20.6 {210}

Steering valve
• Type Spool type
• Set pressure MPa {kg/cm²} 15.7 {160}
Cooling fan motor
Motor

• Type Fixed displacement piston type

equipment

Link type Single link

Work

Bucket edge type Flat blade with top BOC

BOC: Bolt-on cutting edge.

01-6 WA380-5
(8)
GENERAL WEIGHT TABLE

WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WA380-5

Serial No. 60001 and up

Engine (without coolant and oil) 870

Radiator (without coolant) 77
Transmission (including torque converter) 767
Transmission (including torque converter, with lockup clutch) 803
Center drive shaft 25
Front drive shaft 22
Rear drive shaft 9.8
Front axle 911
Rear axle 892
Axle pivot (rear axle) 102
Wheel (each) 110
Tire (each) 207
Steering valve 24
Steering cylinder assembly (each) 28
Orbit roll 5.7
Emergency steering pump (If equipped) 2.6
Emergency steering motor (If equipped) 13
Brake valve (R.H.) 8.5
Brake valve (L.H.) 5.3
Hydraulic tank (without hydraulic oil) 171
Torque converter, work equipment, pilot control pump (3 tandem pump) 35
Steering, switching pump (2 tandem pump) 29
Work equipment PPC valve 3
Work equipment control valve 72
Lift cylinder assembly (each) 158
Bucket cylinder assembly 172
Engine hood 160
Front frame 1,439
Rear frame 1,275
Bucket link 55
Bell crank 316
Lift arm (including bushing) 1,074
Bucket (width: 2,905 mm, with BOC) 1,618
Counterweight 1,200
Fuel tank (without fuel) 180

BOC: Bolt-on cutting edge.

WA380-5 01-7
(10)
GENERAL WEIGHT TABLE

Unit: kg
Machine model WA380-5

Serial No. 60001 and up

Battery (each) 36
Operator’s Cab (If equipped) 700
Operator’s seat 36
Air conditioner unit (If equipped) 12.5
Floor board 313
Oil cooler 3.5
Torque convertor oil cooler 21
Cooling fan drive pump 25
Cooling fan drive motor 13

01-8 WA380-5
(10)
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANT

TABLE OF FUEL, COOLANT AND LUBRICANT

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

★ As engine oil for the engine oil pan, SAE10W30 (API CH-4, CI-4) may be used instead of SAE10W30DH,

Unit: l
and SAE15W40 (API CH-4, CI-4) may be used instead of SAE15W40DH.

WA380-5
CAPACITY
Specified Refill
Engine oil pan 37 32
Transmission case 62 54
Hydraulic system 186 129
Axle (each) 38 38
Fuel tank 300 —
Cooling system 36 —
WA380-5 01-9
4
(10)
 10 STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD

Cooling system............................................... 10-2 Bucket ..........................................................10-183

Engine mount, transmission mount ............. 10-3 Bucket positioner, boom kick-out ..............10-184
Power train ..................................................... 10-4 Work equipment cylinder ...........................10-190
Power train system diagram ......................... 10-5 Cab ...............................................................10-191
Drive shaft (propeller shaft) .......................... 10-8 Air conditioner (If equipped) ......................10-192
Torque converter, transmission piping ........ 10-9 Machine monitoring system ......................10-193
Torque converter.......................................... 10-10 Machine monitor.........................................10-200
Transmission ................................................ 10-18 Transmission control system.....................10-260
Transmission control valve ......................... 10-34 Transmission controller..............................10-284
Axle ............................................................... 10-48 Work equipment control system
Differential .................................................... 10-50 (If equipped)..........................................10-286
Final drive ..................................................... 10-59 Work equipment controller ........................10-302
Axle mounting, center hinge pin ................ 10-62 Electric transmission control......................10-304
Steering piping ............................................. 10-66 Kick down, hold switch...............................10-308
Steering column, orbit-roll .......................... 10-67 Engine starting circuit.................................10-309
Steering valve............................................... 10-68 Engine stop circuit ......................................10-311
Orbit-roll valve.............................................. 10-83 Preheating circuit ........................................10-312
Stop valve ..................................................... 10-87 Engine power mode selector circuit..........10-313
Steering pump, switch pump...................... 10-88 Parking brake circuit ...................................10-314
Emergency steering pump (If equipped).... 10-90 Sensors ........................................................10-318
Emergency steering motor (If equipped) ... 10-91
Steering cylinder .......................................... 10-92
Joystick steering lever (If equipped)........... 10-94
Steering lever (If equipped)......................... 10-95
Steering switch valve (If equipped) ............ 10-97
Brake piping.................................................. 10-98
Brake valve ................................................. 10-100
Charge valve ............................................... 10-107
Accumulator (for brake)............................. 10-111
Brake ........................................................... 10-113
Parking brake control ................................. 10-118
Parking brake .............................................. 10-119
Parking brake solenoid valve .................... 10-121
Parking brake emergency release valve... 10-123
Hydraulic piping ......................................... 10-124
Work equipment control lever .................. 10-127
Hydraulic tank............................................. 10-129
Torque converter charging, work equipment,
and pilot control pumps..................... 10-131
PPC relief valve........................................... 10-133
E.C.S.S. valve (If equipped) ....................... 10-135
Work equipment control valve.................. 10-137
Work equipment PPC valve ....................... 10-154
PPC valve
(for multi function mono lever) ....... 10-159-1
EPC solenoid valve (If equipped) ............. 10-160
Shut off valve (If equipped) ....................... 10-163
Attachment PPC valve (If equipped) ......... 10-164
Cooling fan motor ...................................... 10-168
Cooling fan motor drive pump.................. 10-173
Work equipment linkage ........................... 10-181

WA380-5 10-1
(8)
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING SYSTEM

COOLING SYSTEM

1. Radiator 5. Reservoir tank

2. After cooler 6. Cooling fan
3. Oil cooler 7. Cooling fan motor
4. Torque converter oil cooler

Specifications
Torque converter oil
Radiator Oil cooler After cooler cooler
Core type CF19-4 CF40-1 AL-CFT PTO-OL

Fin pitch (mm) 4.0/2 4.5/2 4.0/2

*1
100 X 558 X 12 Step
Total heat radiating area (m²) 60.08 2.90 17.55 1.291
Pressure valve opening pressure 68.6
(kPa {kg/cm²}) {0.7} — — —

Vacuum valve opening pressure 0 - 4.9

(kPa {kg/cm²}) {0 - 0.05} — — —

* 1: Shows the element size.

10-2 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ENGINE MOUNT, TRANSMISSION MOUNT

ENGINE MOUNT, TRANSMISSION MOUNT

Unit: mm

No. Check item Criteria Remedy

Clearance between transmis-

1 sion mount bracket and adjust- 1 - 1.5 Adjust
ment bolt

WA380-5 10-3
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD POWER TRAIN

POWER TRAIN

1. Transmission 4. Rear axle 7. Front drive shaft

2. Torque converter 5. Rear drive shaft 8. Front axle
3. Engine 6. Center drive shaft

Outline

• The power from engine (3) is transmitted • The power from the transmission output shaft
through the engine flywheel to torque con- passes through center drive shaft (6), front
verter (2). The turbine in the torque converter is drive shaft (7) and rear drive shaft (5), and is
connected to the input shaft of transmission (1). transmitted to front axle (8) and rear axle (4) to
• The transmission has 6 hydraulically operated drive the wheels.
clutches. These provide 4 FORWARD and
REVERSE speeds.

10-4 WA380-5
4
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM

POWER TRAIN SYSTEM DIAGRAM

Without torque converter lock-up clutch

WA380-5 10-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM

With torque converter lock-up clutch

10-6 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM

Outline
1. Front axle
2. Differential • The power from engine (15) is transmitted
3. Wet-type multiple-disc brake through the flywheel to torque converter (16).
4. Final drive The torque converter uses oil as a medium to
5. Front drive shaft vary the transmission torque according to the
6. Center drive shaft. change in the load. It transmits the power to
7. Parking brake (wet-type multiple-disc) the transmission input shaft.
8. Transmission (multiple-shaft) The power from the engine passes through
9. Rear drive shaft the torque converter pump drive gear and is
10. Rear tire transmitted to steering pump (20), switch pump
11. Final drive (21), cooling fan drive pump (22), transmission
12. Wet-type multiple-disc brake and torque converter charging pump (17), work
13. Differential equipment hydraulic pump (18), and PPC
14. Rear axle pump (19) to drive these pumps.
15. Engine • Transmission (8) operates the directional valves
16. Torque converter and speed valves in the transmission to actuate
17. Torque converter charging pump the 6 hydraulically operated clutches and select
18. Work equipment hydraulic pump one of the 4 FORWARD or REVERSE speeds.
19. Pilot pump
• Parking brake (7) is applied by an electromag-
20. Steering pump
netic valve that is actuated when the parking
21. Switch pump
brake switch is operated. It is a wet-type multi-
22. Cooling fan drive pump
ple-disc brake installed to the front of the out-
23. Flange bearing
put shaft to stop the machine.
24. Front tire
25. Torque converter lock-up clutch • The power from the output shaft of transmis-
sion (8) is transmitted to the front and rear
axles. At the front, the power is transmitted to
front axle (1) through center drive shaft (6),
flange bearing (23), and front drive shaft (5).
At the rear, it is transmitted to rear axle (14)
through rear drive shaft (9).
• The power transmitted to front axle (1) and rear
axle (14) is reduced by the pinion gear in differ-
entials (2) and (13), and is transmitted through
the differential mechanism to the sun gear
shaft.
• The power from the sun gear is further reduced
by planetary-type final drive (11) and is trans-
mitted to the wheels through the axle shaft.

WA380-5 10-7
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DRIVE SHAFT (PROPELLER SHAFT)

DRIVE SHAFT (PROPELLER SHAFT)

1. Front drive shaft Outline

2. Flange bearing
3. Center drive shaft • The power from the transmission output shaft
4. Rear drive shaft passes through center drive shaft (3), front
drive shaft (1), and rear drive shaft (4), and is
transmitted to the front axle and rear axle.
• When the body is articulated, or when the
machine is traveling and there is shock from
the ground surface, or when there is shock dur-
ing operations, the position of the transmis-
sion and the front and rear axles changes. The
transmission is designed so that even if the
position of the components changes as a
result of such shock, power can be transmitted
without damage to any parts. With this design,
the drive shafts have universal joints and flange
bearings that enable them to handle any
changes in the angle and length.

10-8 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER, TRANSMISSION PIPING

TORQUE CONVERTER, TRANSMISSION PIPING

1. Hydraulic oil tank 6. Last chance filter

2. Steering, switch pump 7. Transmission converter oil cooler
3. Torque converter charging, work equipment, 8. Transmission
pilot control pumps 9. Oil filter
4. Torque converter 10. Oil feeder pipe
5. Torque converter control valve

WA380-5 10-9
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER

TORQUE CONVERTER
Without lock-up clutch

1. Flywheel 6. Pump
2. Drive case (Number of teeth: 72) 7. PTO drive gear (Number of teeth: 97)
3. Boss 8. Stator shaft
4. Turbine 9. Transmission input shaft
5. Stator

Specifications
Type 3-element, 1-stage, 1-phase
Stall torque ratio 3.27

10-10 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER

Unit: mm
No. Check item Criteria Remedy

Standard size Tolerance Repair limit

1 -0.010
Outside diameter of pilot 52 -0.040 51.75 Repair hard chrome
plating or replace
2 Inside diameter of PTO gear seal 110 +0.035 110.5
ring sliding portion +0.035

Width 3 -0.00 2.7

Wear of stator shaft -0.10
3 seal ring
Thickness 4.3 ±0.1 3.9 Replace

4 Backlash of PTO drive gear and 0.17-0.45

drive gear

WA380-5 10-11
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER

Path of power transmission

Flow of power Flow of oil

• The torque converter is installed between the • The oil passes through the main relief valve and
engine and transmission. its pressure is adjusted by the torque con-
The power from the engine goes from flywheel verter relief valve so that it is less than the set
(1) and enters drive case (2). pressure. It then enters inlet port A, passes
Drive case (2), pump (3), and PTO gear (4) are through the passage in stator shaft (1), and
each fixed by bolts and are rotated directly by flows to pump (2).
the rotation of the engine. The oil is given centrifugal force by pump (2).
The power from pump (3) uses oil as a medium It then enters turbine (3) and transmits the
to rotate turbine (5) and transmit the power to energy of the oil to the turbine.
transmission input shaft (7) through the boss The oil from turbine (3) is sent to stator (4),
(6). and enters the pump (2) again. However, part
The power from drive case (2) passes through of the oil is sent from stator (4) through outlet
PTO gear (4) and is used as the power to drive port B to the cooler.
the gear pump.

10-12 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER

With lock-up clutch

1. Flywheel 9. Stator shaft

2. Clutch housing (Number of teeth: 72) 10. Guide
3. Boss (Number of teeth: 90) 11. Transmission input shaft
4. Turbine 12. One way clutch
5. Drive case 13. Race
6. Stator 14. Disc
7. Pump 15. Piston
8. PTO drive gear (Number of teeth: 97)

Specifications
Type 3-element, 1-stage, 2-phase
Stall torque ratio 2.98

WA380-5 10-13
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER

10-14 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER

Unit: mm
No. Check item Criteria Remedy

Standard size Tolerance Repair limit

1 -0.010
Outside diameter of pilot 52 -0.040 51.75

2 Outside diameter of input shaft 35 +0.025 35.5

seal ring sliding portion +0.035
Repair hard chrome
3 Inside diameter of clutch housing 340 +0.089 340.1 plating or replace
seal ring sliding portion +0.035

4 Inside diameter of clutch piston 260 +0.081 260.1

seal ring sliding portion +0.035

5 Inside diameter of PTO gear seal 120 +0.035 120.5

ring sliding portion +0.035

Width 5 -0.01 4.5

Wear of clutch housing -0.04
6 seal ring
Thickness 6 ±0.15 5.85

Width 3.95 -0.00 3.55

Wear of stator shaft -0.1
7 seal ring
Thickness 4.6 ±0.1 4.14

8 Inside diameter of outer race one- 91.661 ±0.008 91.691

way clutch rolling surface
Replace
9 Outside diameter of outer race 72.661 +0.008 72.631
one-way clutch rolling surface -0.005

10 Inside diameter of bushing sliding 72.775 +0.015 72.855

portion +0.035

11 Thickness of bushing sliding por- 5 -0.00 4.5

tion -0.1

12 Thickness of clutch disc 5 ±0.1 4.4

13 Backlash of input shaft and PTO 0.17-0.45

gear

WA380-5 10-15
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER

Path of power transmission

Flow of power
Lock-up clutch disengaged Lock-up clutch engaged

• When the lock-up clutch is disengaged, the con- • When the lock-up clutch is engaged, drive case
nection of drive case (3) and turbine (6) is dis- (3) and turbine (6) are connected and form one
connected, and the torque converter functions unit. Stator (9) is rotated by the rotation of
as normal. pump (4) and turbine (6).
The power generated by the engine is transmit- The power generated by the engine is transmit-
ted from flywheel (1) to clutch housing (2), and ted from flywheel (1) to clutch housing (2), and
rotates drive case (3) and pump (4) as one unit. rotates drive case (3) and pump (4) as one unit.
The power from pump (4) uses oil as a medium In addition, drive case (3) and turbine (6) are
to rotate turbine (6) and transmits the power connected by the lock-up clutch, so the power
from turbine (6) to transmission input shaft (8) is transmitted directly from turbine (6) to
through boss (7). transmission input shaft (8) without using oil
The power from drive case (3) passes through as a medium.
PTO gear (5) and is used as the power to drive The power from drive case (3) passes through
the gear pump. PTO gear (5) and is used as the power to drive
the gear pump.

10-16 WA380-5
4
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER

Flow of oil

• The oil passes through the main relief valve and

its pressure is adjusted by the torque converter
relief valve so that it is less than the set pres-
sure. It then enters inlet port A, passes through
the passage in stator shaft (1) and guide (2), and
flows to pump (3).
The oil is given centrifugal force by pump (3). It
then enters turbine (4) and transmits the energy
of the oil to turbine (4).
The oil from turbine (4) is sent to stator (5), and
enters pump (3) again. However, part of the oil
is fed to the torque converter oil cooler from the
stator (5) passing through the outlet port B.

WA380-5 10-17
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

TRANSMISSION

1. Steering, switch, 5. Main relief,

cooling fan pump mounting section torque converter relief valve
2. Torque converter oil pressure, work equipment 6. Transmission case (Front)
oil pressure, pilot control pump mounting section 7. Transmission oil filter
3. Transmission case (Rear) 8. Oil level gauge
4. Transmission control valve 9. Flow valve

10-18 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

1. PTO driven gear (Number of teeth: 89) 9. Output shaft

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

WA380-5 10-19
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

10-20 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

Unit: mm
No. Check item Criteria Remedy
Tolerance Standard Clearance
Standard size clearance limit
Clearance between PTO driven Shaft Hole
1 gear shaft and bearing (F)
55 +0.030 0. 00 -0.045 - —
+0.011 -0.015 -0.011
Clearance between PTO driven 0. 00 +0.030
2 gear bearing and housing (R) 100 -0.015 +0.035 0 - 0.045 —

Clearance between PTO driven +0.025 0. 00 -0.037 -

3 gear shaft and bearing (R) 45 +0.009 -0.012 -0.009 —

Clearance between PTO driven 0. 00 +0.030

4 gear bearing and housing (R) 85 -0.015 +0.035 0 - 0.045 —

Clearance between the input shaft 0. 00 +0.030

5 bearing and the housing (R) 110 -0.015 +0.035 0 - 0.045 —

Clearance between the input shaft 0. 00 +0.030

6 bearing and the housing (F) 110 -0.015 +0.035 0 - 0.045 —

Clearance between the upper 0. 00 +0.030

7 shaft bearing and the housing (R) 110 -0.015 +0.035 0 - 0.045 —

Clearance between the upper 0.00 +0.030

8 shaft bearing and the housing (F) 120 -0.015 +0.035 0 - 0.045 —

Clearance between the lower 0.00 0. 00 -0.035 -

9 shaft bearing and the housing (R) 100 -0.018 -0.035 0.018 —

Clearance between the lower 0.00 0. 00 -0.035 -

10 shaft bearing and the housing (F) 120 -0.018 -0.035 0.018 —

Clearance between the output 0.00 -0.018 -0.058 -

11 shaft bearing and the housing (R) 130
-0.020 -0.058 0.002
—

Clearance between the output +0.030 0. 00 -0.045 -

12 shaft and the bearing (R) 75 +0.011 -0.015 -0.011 —

Clearance between the output 0.00 -0.018 -0.058 -

13 shaft bearing and the housing (F) 130 -0.020 -0.058 0.002 — Replace
Clearance between the output +0.035 0. 00 -0.055 -
14 shaft and the bearing (F) 85 +0.013 -0.020 -0.013 —

Standard size Tolerance Clearance limit

Inner diameter of the seal ring
contact surface 60 +0.050 60.1
+0.035

15 Width of the seal ring groove 3.2 +0.076 3.5

+0.035
Width of the seal ring 3.1 ±0.05 2.8

Thickness of the seal ring 2.29 0.00 2.1

-0.100
Inner diameter of the seal ring
50 +0.050 50.1
contact surface +0.035

Width of the seal ring groove 3.2 +0.076 3.5

16 +0.035
Width of the seal ring 3.1 ±0.05 2.8

Thickness of the seal ring 2.29 0.00 2.1

-0.100
Inner diameter of the oil seal slid- 0.00
17 ing surface of the coupling (R) 95 -0.087 94.8

Inner diameter of the oil seal slid- 0.00

18 ing surface of the coupling (F) 95 -0.087 94.8

Standard clearance Clearance limit

Clearance between the retainer
19 and the housing 0.85 - 1.65
(Standard shim thickness: 1.10) —

Clearance between the cage and 1.18 - 1.94

20 the case Standard shim thickness: 1.15) —

WA380-5 10-21
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

1. PTO driven gear (Number of teeth: 79)

2. R idler gear (Number of teeth: 28)
3. Spacer
4. Strainer
Unit: mm
No. Check item Criteria Remedy

Tolerance Standard Clearance

Clearance between PTO Standard size clearance limit
5 driven gear shaft and bearing Shaft Hole
(F) +0.030 0. 00 -0.045 -
65 +0.011 -0.015 -0.011 —

Clearance between PTO 0. 00 +0.030

6 driven gear bearing and hous- 120 -0.015 +0.035 0 - 0.045 —
ing (F)
Clearance between PTO +0.020 0. 00 -0.032 -
7 driven gear shaft and bearing 50 — Replace
(R) +0.009 -0.012 -0.009

Clearance between PTO 0. 00 +0.030

8 driven gear bearing and hous- 90 -0.015 +0.035 0 - 0.045 —
ing (R)

9 Clearance between R idler 50 +0.027 0. 00 -0.039 - —

gear bearing and case +0.002 -0.012 -0.002

10 Clearance between R idler 80 0. 00 -0.021 -0.051 - —

gear bearing and R idler gear -0.016 -0.051 -0.005

Outline
Table of the combination of the clutch and reduc-
• The transmission shall be installed after the tion gear ratio
torque converter and the power from the
Speed step Using clutch Reduction gear ratio
torque converter shall enter into the transmis-
F1 F X 1st 4.095
sion passing through the transmission input
shaft. F2 F X 2nd 2.311
F3 F X 3rd 1.265
• The transmission shall transfer the power of the
transmission input shaft to the output shaft F4 F X 4th 0.706
after changing the speed into forward 1 speed R1 R X 1st 3.834
through 4 speed and into reverse 1 speed R2 R X 2nd 2.163
through 4 speed by combination of the F • R R3 R X 3rd 1.185
clutch and 4 pcs. of the speed clutch. R4 R X 4th 0.661

10-22 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

F and R clutches (Without a lock-up clutch)

A: R clutch oil port C: Lubricating oil port

B: F clutch oil port

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

Unit: mm
No. Check item Criteria Remedy

Tolerance Standard Clearance

Standard size clearance limit
11 Clearance at bearing press fit Shaft Hole
part of shaft (F)
+0.039 0. 00 -0.054 -
60 +0.020 -0.015 -0.020 —

12 Clearance at bearing press fit 60 +0.030 0. 00 -0.045 - —

part of shaft (R) +0.011 -0.015 -0.011
Standard size Tolerance Clearance limit

13 Thickness 1.7 ±0.05 1.5

Separator plate
Distortion — 0.1 0.15
Replace
Thickness 2.2 ±0.08 1.6
14 Friction plate
Distortion — 0.1 0.25

15 Load of wave spring 1,010 N ±101 N 859 N

(Height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
16 Warp of spring plate 1.4 ±0.2 1.2

17 Thickness of thrust washer of 3 ±0.1 2.7

F and R clutches
18 End play of R gear 0.30 - 0.70

19 End play of F gear 0.24 - 0.76

WA380-5 10-23
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

F and R clutches (With a lock-up clutch)

A: R clutch oil port C: Lubricating oil port

B: F clutch oil port D: Lock-up clutch oil port

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

Unit: mm
No. Check item Criteria Remedy

Tolerance Standard Clearance

Standard size clearance limit
11 Clearance at bearing press fit Shaft Hole
part of shaft (F)
60 +0.039 0. 00 -0.054 - —
+0.020 -0.015 -0.020

12 Clearance at bearing press fit 60 +0.030 0. 00 -0.045 - —

part of shaft (R) +0.011 -0.015 -0.011
Standard size Tolerance Clearance limit

13 Thickness 1.7 ±0.05 1.5

Separator plate
Distortion — 0.1 0.15
Replace
Thickness 2.2 ±0.08 1.6
14 Friction plate
Distortion — 0.1 0.25

15 Load of wave spring 1,010 N ±101 N 859 N

(Height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
16 Warp of spring plate 1.4 ±0.2 1.2

17 Thickness of thrust washer of 3 ±0.1 2.7

F and R clutches
18 End play of R gear 0.30 - 0.70

19 End play of F gear 0.24 - 0.76

10-24 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

1st•4th Clutch

A: 1st clutch oil port C: Lubricating oil port

B: 4th clutch oil port

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

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

Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance at bearing press fit size Shaft Hole clearance limit
11
part of shaft (F)
55 +0.035 0. 00 -0.050 - —
+0.025 -0.015 -0.025

12 Clearance at bearing press fit 60 +0.039 0. 00 -0.054 - —

part of shaft (R) +0.020 -0.015 -0.020
Standard size Tolerance Repair limit

13 Thickness 1.7 ±0.05 1.5

Separator plate
Distortion — 0.1 0.15

Thickness 2.2 ±0.08 1.6 Replace

14 Friction plate
Distortion — 0.10 0.25

15 Load of wave spring 1,010 N ±101N 859 N

(height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}

16 Thickness of 1st • 4th clutch 3 ±0.1 2.7

thrust washer

17 Thickness of 1st clutch thrust 3 ±0.1 2.7

washer
18 End play of 1st gear 0.26 - 0.74

19 End play of 4th gear 0.28 - 0.72

WA380-5 10-25
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

2nd•3rd Clutch

A: 2nd clutch oil port C: Lubricating oil port

B: 3rd clutch oil port

1. Output gear (Number of teeth: 49) 6. 3rd clutch

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

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance at bearing press fit size Shaft Hole clearance limit
11
part of shaft (F) +0.050 0. 00 -0.065 -
55 +0.040 -0.015 -0.040 —

12 Clearance at bearing press fit 55 +0.039 0. 00 -0.054 - —

part of shaft (R) +0.020 -0.015 -0.020
Standard size Tolerance Repair limit

13 Thickness 1.7 ±0.05 1.5

Separator plate
Distortion — 0.05 0.15
Replace
Thickness 2.2 ±0.08 1.6
14 Friction plate
Distortion — 0.10 0.25

15 Load of wave spring 1,010 N ±101N 859 N

(height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}

16 Thickness of 2nd•3rd clutch 3 ±0.1 2.7

thrust washer
17 End play of 2nd gear 0.28 - 0.72

18 End play of 3rd gear 0.28 - 0.72

10-26 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

Operation of clutch
Clutch engaged Clutch disengaged

• The oil sent from the transmission valve passes • The oil sent from the transmission valve is shut
through the passage inside shaft (1), goes to off, so the pressure of the oil acting on the back
the back face of piston (6), and actuates piston face of piston (6) drops.
(6). • Piston (6) is returned to its original position by
• When piston (6) is actuated, separator plate (2) wave spring (7), and shaft (1) and clutch gear (4)
and friction plate (3) are pressed together, so are separated.
shaft (1) and clutch gear (4) form one unit, and • When the clutch is disengaged, the oil at the
transmit the power. back face of the piston is drained through oil
When this happens, the oil is drained from oil drain hole (5) by centrifugal force to prevent the
drain hole (5), but the amount of oil drained is clutch from remaining partially engaged.
less than the amount of oil supplied, so there is
no influence on the operation of the clutch.

★ Oil drain hole (5) is provided only in the 1st,

2nd, 3rd, and 4th clutches.

WA380-5 10-27
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

FORWARD 1ST

Operation

• In the case of FORWARD 1st, F clutch (3) and 1st • 1st clutch (9) is engaged, so the power trans-
clutch (9) are engaged. The power transmitted mitted to 1st•4th cylinder gear (7) goes through
from the torque converter to input shaft (1) is 1st clutch (9) and is transmitted from 1st gear
transmitted to output shaft (22). (10) to 2nd•3rd cylinder gear (16). From here, it
• The clutch discs of F clutch (3) and 1st clutch (9) passes through lower shaft (20), output gear
are fixed by the hydraulic pressure applied to (19), and output gear (21), and is transmitted to
the clutch piston. output shaft (22).
• The power from the torque converter goes from
input shaft (1) through F clutch (3) to F gear (2),
and is transmitted to 1st•4th cylinder gear (7).

10-28 WA380-5
4
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

FORWARD 2ND

Operation

• In the case of FORWARD 2nd, F clutch (3) and • 2nd clutch (17) is engaged, so the power trans-
2nd clutch (17) are engaged. The power trans- mitted to 2nd gear (18) goes through 2nd clutch
mitted from the torque converter to input shaft (17) and is transmitted to 2nd•3rd cylinder gear
(1) is transmitted to output shaft (22). (16). From here, it passes through lower shaft
• The clutch discs of F clutch (3) and 2nd clutch (20), output gear (19), and output gear (21), and
(17) are fixed by the hydraulic pressure applied is transmitted to output shaft (22).
to the clutch piston.
• The power from the torque converter goes from
input shaft (1) through F clutch (3) to F gear (2),
and is transmitted through 1st•4th cylinder gear
(7), upper shaft (12), and idler gear (11) to 2nd
gear (18).

WA380-5 10-29
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

FORWARD 3RD

Operation

• In the case of FORWARD 3rd, F clutch (3) and • 3rd clutch (15) is engaged, so the power trans-
3rd clutch (15) are engaged. The power trans- mitted to 3rd gear (14) goes through 3rd clutch
mitted from the torque converter to input shaft (15) and is transmitted to 2nd•3rd cylinder gear
(1) is transmitted to output shaft (22). (16). From here, it passes through lower shaft
• The clutch discs of F clutch (3) and 3rd clutch (20), output gear (19), and output gear (21), and
(15) are fixed by the hydraulic pressure applied is transmitted to output shaft (22).
to the clutch piston.
• The power from the torque converter goes from
input shaft (1) through F clutch (3) to F gear (2),
and is transmitted through 1st•4th cylinder gear
(7) to 3rd gear (14).

10-30 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

FORWARD 4TH

Operation

• In the case of FORWARD 4th, F clutch (3) and • 4th clutch (8) is engaged, so the power trans-
4th clutch (8) are engaged. The power transmit- mitted to 1st•4th cylinder gear (7) goes through
ted from the torque converter to input shaft (1) 4th clutch (8) and is transmitted from 4th gear
is transmitted to output shaft (22). (6) to 4th gear (13). From here, it passes
• The clutch discs of F clutch (3) and 4th clutch (8) through lower shaft (20), output gear (19), and
are fixed by the hydraulic pressure applied to output gear (21), and is transmitted to output
the clutch piston. shaft (22).
• The power from the torque converter goes from
input shaft (1) through F clutch (3) to F gear (2),
and is transmitted to 1st•4th cylinder gear (7).

WA380-5 10-31
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION

REVERSE 1ST

Operation

• In the case of REVERSE 1st, R clutch (4) and 1st • 1st clutch (9) is engaged, so the power trans-
clutch (9) are engaged. The power transmitted mitted to 1st•4th cylinder gear (7) goes through
from the torque converter to input shaft (1) is 1st clutch (9) and is transmitted from 1st gear
transmitted to output shaft (22). (10) to 2nd•3rd cylinder gear (16). From here, it
• The clutch discs of R clutch (4) and 1st clutch (9) passes through lower shaft (20), output gear
are fixed by the hydraulic pressure applied to (19), and output gear (21), and is transmitted to
the clutch piston. output shaft (22).
• The power from the torque converter goes from
input shaft (1) through R clutch (4) to R gear (5).
The direction of rotation is reversed by idler
gear (23), and is transmitted through idler gear
(11) and upper shaft (12) to 1st•4th cylinder gear
(7).

10-32 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

TRANSMISSION CONTROL VALVE

Without lock-up clutch
Serial No.: 60001 – (Transmission No. 110643)

A: 2nd clutch oil pressure detection port

B: 3rd clutch oil pressure detection port 1. ECMV (for 2nd clutch)
C: 1st clutch oil pressure detection port 2. ECMV (for 3rd clutch)
D: 4th clutch oil pressure detection port 3. ECMV (for 1st clutch)
E: R clutch oil pressure detection port 4. ECMV (for 4th clutch)
F: F clutch oil pressure detection port 5. ECMV (for R clutch)
G: Main relief oil pressure detection port 6. ECMV (for F clutch)
H: Torque converter relief oil pressure detection port 7. Parking brake solenoid valve
J: Parking brake oil pressure detection port 8. Main relief, torque converter
relief valve
9. Last-chance filter

10-34 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

Serial No.: (Transmission No. 110644) and up

A: 2nd clutch oil pressure detection port 1. ECMV (for 2nd clutch)
B: 3rd clutch oil pressure detection port 2. ECMV (for 3rd clutch)
C: 1st clutch oil pressure detection port 3. ECMV (for 1st clutch)
D: 4th clutch oil pressure detection port 4. ECMV (for 4th clutch)
E: R clutch oil pressure detection port 5. ECMV (for R clutch)
F: F clutch oil pressure detection port 6. ECMV (for F clutch)
G: Main relief oil pressure detection port 7. Parking brake solenoid valve
H: Torque converter relief oil pressure detection port 8. Main relief, torque converter
J: Parking brake oil pressure detection port relief valve
9. Last-chance filter

WA380-5 10-34-1
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

ECMV actuation table

ECMV
F R 1st 2nd 3rd 4th
Gear
speed range
F1 c c
F2 c c
F3 c c
F4 c c
R1 c c
R2 c c
R3 c c
R4 c c

Outline

• The oil from the pump passes through the flow

valve, is filtered by the oil filter, enters the
transmission control valve, and is separated
into the main relief circuit and clutch actuation
circuit.
• The oil pressure adjusted by the main relief
valve and flowing to the clutch actuation circuit
passes through the last-chance filter and actu-
ates the clutch and parking brake. The oil
relieved by the main relief valve is supplied to
the torque converter.
• When the transmission shifts gear, the ECMV
uses the command current from the transmis-
sion controller to raise the clutch oil pressure
smoothly in order to reduce the transmission
shock. In addition, it keeps the clutch pressure
constant when the machine is traveling.
• By switching the F, R, and 1st-4th ECMVs, the
adjusted oil pressure is supplied to the selected
clutch to provide the necessary speed range.

WA380-5 10-35
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

With lock-up clutch

Serial No.: 60001 – (Transmission No. 110643)

A: 2nd clutch oil pressure detection port 1. ECMV (for 2nd clutch)
B: 3rd clutch oil pressure detection port 2. ECMV (for 3rd clutch)
C: 1st clutch oil pressure detection port 3. ECMV (for 1st clutch)
D: 4th clutch oil pressure detection port 4. ECMV (for 4th clutch)
E: R clutch oil pressure detection port 5. ECMV (for R clutch)
F: F clutch oil pressure detection port 6. ECMV (for F clutch)
G: Lock-up clutch oil pressure detection port 7. ECMV (for lock-up clutch)
H: Main relief oil pressure detection port 8. Parking brake solenoid valve
J: Torque converter relief oil pressure detection port 9. Main relief, torque converter
K: Parking brake oil pressure detection port relief valve
10. Last-chance filteR

10-36 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

Serial No.: (Transmission No. 110644) and up

A: 2nd clutch oil pressure detection port 1. ECMV (for 2nd clutch)
B: 3rd clutch oil pressure detection port 2. ECMV (for 3rd clutch)
C: 1st clutch oil pressure detection port 3. ECMV (for 1st clutch)
D: 4th clutch oil pressure detection port 4. ECMV (for 4th clutch)
E: R clutch oil pressure detection port 5. ECMV (for R clutch)
F: F clutch oil pressure detection port 6. ECMV (for F clutch)
G: Lock-up clutch oil pressure detection port 7. ECMV (for lock-up clutch)
H: Main relief oil pressure detection port 8. Parking brake solenoid valve
J: Torque converter relief oil pressure detection port 9. Main relief, torque converter
K: Parking brake oil pressure detection port relief valve
10. Last-chance filteR

WA380-5 10-36-1
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

ECMV actuation table (with lock-up clutch)

ECMV
F R 1st 2nd 3rd 4th Lock
up
Gear
speed range
F1 c c
F2 c c
F3 c c c
F4 c c c
R1 c c
R2 c c
R3 c c c
R4 c c c

Outline

• The oil from the pump passes through the flow

valve, is filtered by the oil filter, enters the
transmission control valve, and is separated
into the main relief circuit and clutch actuation
circuit.
• The oil pressure adjusted by the main relief
valve and flowing to the clutch actuation circuit
passes through the last-chance filter and actu-
ates the clutch and parking brake. The oil
relieved by the main relief valve is supplied to
the torque converter.
• When the transmission shifts gear, the ECMV
uses the command current from the transmis-
sion controller to raise the clutch oil pressure
smoothly in order to reduce the transmission
shock. In addition, it keeps the clutch pressure
constant when the machine is traveling.
• By switching the F, R, and 1st-4th ECMVs, the
adjusted oil pressure is supplied to the selected
clutch to provide the necessary speed range.
• When traveling in 3rd or 4th, the lock-up ECMV
is actuated at a speed greater than the set
speed of the transmission controller.

WA380-5 10-37
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

ECMV (Electronic Control Modulation Valve)

A : To clutch 1. Connector for fill switch

P : From pump 2. Connector for proportional solenoid
T : Drain 3. Oil pressure detection valve
Dr : Drain 4. Fill switch
P1 : Clutch oil pressure detection port 5. Proportional solenoid
P2 : Pilot oil pressure detection port 6. Pressure control valve

10-38 WA380-5
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

ECMV for speed clutch

Outline of ECMV
ECMV and proportional solenoid
• The ECMV consists of two components: the
pressure control valve and the fill switch. • There is one proportional solenoid installed to
• Pressure control valve each ECMV.
The proportional solenoid receives the flow of It generates propulsion force as shown in the
electricity sent from the transmission controller, diagram below according to the command cur-
and the pressure control valve converts this rent from the controller.
into hydraulic pressure.
• Fill switch The propulsion force generated by the propor-
The fill switch detects when the clutch is filled tional solenoid acts on the pressure control
with oil. It has the following functions. valve spool and generates oil pressure as
1) When the clutch is filled with oil, it sends a shown in the diagram below. In this way, the
signal (fill signal) at the same time to the command current flow is controlled and the
controller to inform the controller that the propulsion force varies to actuate the pressure
filling is completed. control valve and control the oil flow and oil
2) While oil pressure is applied to the clutch, it pressure.
outputs a signal (fill signal) to the controller Characteristics of proportional solenoid
to inform the controller of the existence of
the oil pressure. current - propulsion force
Range A: Before shifting gear
(when draining)
Range B: During filling
Range C: Pressure adjustment
Range D: During filling (during trigger)
Range E: Fill started
Range F: Fill completed

Characteristics of propotional solenoid

propulsion - oil pressure

ECMV and fill switch

• There is one fill switch installed to each ECMV.

When the filling of the clutch is completed, the
fill switch is turned on by the clutch pressure.
★ The logic is so designed that the controller will With this signal, the oil pressure starts the
not recognize completion of filling even if the build-up.
fill switch is turned ON in the triggering range
(range D).

WA380-5 10-39
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

Actuation of ECMV

• The ECMV is controlled by the command cur- 1. Before shifting gear (when draining) (range A in
rent from the controller to the proportional graph)
solenoid and the fill switch output signal. When no current is flowing to proportional
The relationship between ECMV proportional solenoid (1), pressure control valve spool (3)
solenoid command current and the clutch input drains the oil at clutch port A through drain
pressure and fill switch output signal is as port T.
shown in the diagram below. When this happens, there is no hydraulic force
Range A: Before shifting gear acting on oil pressure detection valve spool (4),
(when draining) so fill switch (6) goes OFF.
Range B: During filling
Range C: Pressure adjustment
Range D: During filling (during trigger)
Range E: Fill started
Range F: Fill completed

★ The logic is so designed that the controller will

not recognize completion of filling even if the
fill switch is turned ON in the triggering range
(range D).

10-40 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

2. Start of fill (ranges B in graph) 3. Adjusting pressure (range C in graph)

When there is no oil inside the clutch, if current When electric current flows to proportional
is applied to proportional solenoid (1), oil pres- solenoid (1), the solenoid generates a propul-
sure is applied in chamber B to balance with sion force proportional to the current. The total
the force of the solenoid, and pressure control of this propulsion force of the solenoid and the
valve (3) is pushed to the left. As a result, pump propulsion force of the oil pressure at the clutch
port P and clutch port A open, and oil starts to port and the reaction force of pressure control
fill the clutch. When the clutch is filled with oil, valve spring (2) is adjusted so that it is bal-
oil pressure detection switch (4) is actuated, anced.
and fill switch (6) comes ON.

WA380-5 10-41
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

ECMV for lock-up clutch Operation

Outline When traveling in torque converter drive
• This ECMV sets the lock-up clutch hydraulic • When the machine is traveling in torque con-
pressure to the specified pressure, and also verter drive, no electric current is flowing to
switches the lock-up clutch. proportional solenoid (1).
It has a modulation wave pattern, which Pressure control valve (3) drains the oil from
engages the lock-up clutch smoothly, and clutch port A through drain port T, and the lock-
reduces the shock when shifting gear. Further- up clutch is released.
more, it prevents the generation of peak torque At the same time, there is no hydraulic force
in the power train. As a result, the machine acting on oil pressure detection valve (4), so fill
gives a good ride, and the durability of the switch (6) goes OFF.
power train is greatly increased.

10-42 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

When traveling in direct drive

(Changing from torque converter drive €
direct drive)

1. During filling 2. Adjusting pressure

When the transmission shifts to direct drive When electric current flows to proportional
(lock-up), if current is applied to proportional solenoid (1), the solenoid generates a propul-
solenoid (1) by an electric signal, oil pressure is sion force proportional to the current. The total
applied in chamber B to balance with the force of this propulsion force of the solenoid and the
of the solenoid, and pressure control valve (3) is propulsion force of the oil pressure at the clutch
pushed to the left. As a result, pump port P port and the reaction force of pressure control
and clutch port A open, and oil starts to fill the valve spring (2) is adjusted so that it is bal-
clutch. When the clutch is filled with oil, oil anced.
pressure detection switch (4) is actuated, and
fill switch (6) comes ON.

WA380-5 10-43
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE

A : Drain (torque converter relief) 1. Body

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

Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between main relief size Shaft Hole clearance limit
6 valve and valve body
28 -0.035 +0.013 0.035 - 0.078
-0.045 0 0.058
Clearance between torque con- -0.035 +0.013 0.035 -
7 verter relief valve and valve 22 -0.045 0 0.058 0.078
body

Standard size Repair limit Replace

Free Installed Installed Free Installed
8 Main relief valve spring (outer) length length load length load

122 83.5 371 N 118.3 352 N

{37.8 kg} {35.9 kg}

9 Main relief valve spring (inner) 108 83.5 301 N 104.8 286 N
{30.7 kg} {29.2 kg}
Torque converter relief valve 134 N 128 N
10 spring 50 43 {13.7 kg} 48.5 {13.0 kg}

10-44 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

Main relief valve

Outline
• The oil from the hydraulic pump passes
Torque converter relief valve through the filter, enters port A of the main
The torque converter relief valve is installed in the relief valve, and then passes through orifice a in
torque converter inlet port circuit. It acts to keep spool (6) and enters chamber B.
the oil pressure in the torque converter inlet port When the oil from the pump fills the circuit, the
circuit at or below the set pressure and protects the oil pressure starts to rise.
torque converter from abnormally high pressure.
Set pressure: 0.84 MPa {8.55 kg/cm²}
(cracking pressure)

Main relief valve

The main relief valve maintains the oil pressure in
the transmission and parking brake at the set pres-
sure.
Set pressure: 2.86 MPa {29.2 kg/cm²}
(engine at rated speed)

Operation

Torque converter relief valve

• The oil relieved from the main relief valve flows • When the oil pressure in the circuit rises, the oil
from port C into the torque converter, and at entering port B pushes piston (4). The reaction
the same time, passes through orifice b of compresses valve spring (7) and moves spool
spool (2) and enters port D. (6) to the left to open port A and port C.
When the oil fills the circuit to the torque con- When this happens, the oil from the pump is
verter, the oil pressure starts to rise. relieved from port A to port C, and flows from
port C into the torque converter.
• When the oil pressure in the circuit to the
The oil pressure at port A at this point is 2.86
torque converter rises, the oil entering port D
MPa {29.2 kg/cm} (engine at rated speed).
pushes piston (9). The reaction compresses
valve spring (3), and moves spool (2) to the
right to open port C and port E.
When this happens, the oil from port C is
relieved to port E and is drained to the oil tank.
The oil pressure at port C at this point is 0.84
MPa {8.55 kg/cm²} (cracking pressure)

WA380-5 10-45
4
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

FLOW VALVE

A : To transmission valve circuit

B : From pump
C : To transmission lubrication circuit

1. Valve body
2. Valve spool
Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between flow con- size Shaft Hole clearance limit
3 trol valve and body
25 -0.020 +0.013 0.020 - 0.06
-0.030 0 0.043

Standard size Repair limit Replace

Free Installed Installed Free Installed

4 Flow control valve spring length length load length load

63.8 47 79.5 N 61.9 75.5 N

{8.11 kg} {7.7 kg}

Operation

• The oil from the pump flows to the transmis-

sion valve circuit, but if it goes above the speci-
fied amount, the flow valve acts to send it to the
transmission lubrication circuit.
• If the flow of oil from the pump goes above the
specified amount, valve spool (2) moves and
sends part of the oil from the pump to the trans-
mission lubrication circuit.

10-46 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE

AXLE
FRONT AXLE

1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler port/level plug
8. Drain plug

10-48 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE

REAR AXLE

1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler port/level plug
8. Drain plug

WA380-5 10-49
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL

DIFFERENTIAL
FRONT DIFFERENTIAL

1. Pinion gear (Number of teeth: 12)

2. Shaft
3. Bevel gear (Number of teeth: 41)
4. Sun gear shaft
5. Bevel pinion (Number of teeth: 10)
6. Side gear (Number of teeth: 24)

10-50 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL

REAR DIFFERENTIAL

1. Pinion gear (Number of teeth: 12)

2. Shaft
3. Bevel gear (Number of teeth: 41)
4. Sun gear shaft
5. Bevel pinion (Number of teeth: 10)
6. Side gear (Number of teeth: 24)

WA380-5 10-51
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL

Unit: mm
No. Check item Criteria Remedy

7 Backlash of differential gear 0.13 - 0.18

Adjust
8 Starting torque of bevel gear 13.7 - 37.2 Nm {1.4 - 3.8 kgm}(At outside surface of bevel gear)

Standard size Tolerance Repair limit

9 Pinion gear washer thickness
3 ±0.08 2.8 Replace

10 Side gear washer thickness 4 ±0.05 3.8

11 Thickness of shim at differential 0.3 - 1.25

side bearing carrier

12 Backlash of bevel gear 0.25 - 0.33

Adjust
13 End play of pinion gear 0.182

14 Thickness of shim at differential 1.05 ± 0.35

housing and gauge assembly

10-52 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL

Outline When turning

• The power from the engine passes through the
• When turning, the rotating speed of the left and
torque converter, transmission, and drive
right wheels is different, so pinion gear (4) and
shafts, and is transmitted to the front and rear
side gear (3) inside the differential transmit the
axles.
power of carrier (6) to sun gear shaft (2) while
• Inside the axle, the power is transmitted from
rotating in accordance with the difference
bevel pinion (1) to bevel gear (5) and the
between the left and right rotating speeds.
direction is changed 90°. It is also reduced and
passes through pinion gear (4) and is transmit-
ted to sun gear shaft (2).
• The power of the sun gear is further reduced by
the planetary gear type final drive and is trans-
mitted to the axle shaft and wheels.

When traveling in a straight line

• When traveling in a straight line, the rotating

speed of the left and right wheels is the same,
so pinion gear (4) inside the differential assem-
bly does not rotate. The power of carrier (6)
passes through pinion gear (4) and side gear
(3), and is transmitted equally to the left and
right sun gear shafts (2).

WA380-5 10-53
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL

LIMITED SLIP DIFFERENTIAL

1. Plate
2. Disc
3. Pinion
4. Washer
5. Side gear
6. Bevel pinion
7. Shaft
8. Pressure ring
9. Case

10-54 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL

WA380-5 10-55
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL

Unit: mm
No. Check item Criteria Remedy

Standard size Tolerance Repair limit

1 Washer thickness 2
±0.03 1.8
2.1

3
2 Plate thickness ±0.02 2.9
3.1

3 Disc thickness 3 +0.04 2.95

-0.03
Standard Shaft Hole Standard Clearance
Clearance between spider and size Clearance limit
4 differential pinion gear
30 -0.110 +0.050 0.110 - 0.3
-0.160 +0 0.210
Piston assembly portion of dif- -0.110 +0.079 0.110 -
5 ferential housing (housing, pis- 290.5 -0.191 +0 0.270 —
ton)

6 Piston assembly portion of 311 -0.111 +0.081 0.111 - —

bearing carrier (piston, carrier) -0.190 +0 0.271
Replace
Outer race 150 -0 -0.045 -0.085 - —
Clearance at differ- -0.016 -0.085 -0.029
7 ential side bearing
Inner race 100 +0.059 -0 -0.079 - —
+0.037 -0.020 -0.037

Outer race 150 -0 -0.050 -0.075 - —

Clearance of bear- -0.020 -0.075 -0.030
8 ing at pinion shaft
gear end Inner race 70 +0.039 -0 -0.054 - —
+0.020 -0.015 -0.020

Outer race 140 -0 -0.048 -0.088 - —

Clearance of bear- -0.018 -0.088 -0.030
9 ing at pinion shaft
coupling end Inner race 65 +0.039 -0 -0.054 - —
+0.020 -0.015 -0.020

10 Backlash between case and 0 - 0.4

plate

11 Clearance between disc and 0.2 - 0.6

plate

12 Backlash between side gear and 0.13 - 0.36

disc

13 End play (one end) of side gear 0.15 - 0.35

in axial direction

10-56 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL

Operation of limited slip differential When traveling in a straight line

The power transmitted from the transmission is
1. When there is no imbalance between drive
transmitted from bevel gear (6) to case (9), pres-
force of left and right wheels [Road surface
sure ring (8), shaft (7), pinion (3), and gear (5), and
condition (friction coefficient) and load for left and
is divided to the left and right shafts.
right wheels are uniform and load on bucket is cen-
The brake system, consisting of discs (2) and plates
tered exactly]
(1) is installed at the rear face of side gear (5). A
The power from the transmission is divided
brake torque is generated that is proportional
equally to the left and right by the differential gear.
to the torque transmitted from pressure ring (8) to
In this case, the wheel slip limit of the left and right
shaft (7).
wheels is the same, so even if the power from the
This brake torque acts to limit the rotation in rela-
transmission exceeds the wheel slip limit, both
tion to side gear (5) and case (9), so it is difficult
wheels will slip and the differential will not be actu-
for left and right side gears (5) to rotate mutually
ated.
and the operation of the differential is limited.
There is no load on the brake at the rear face of the
side gears.
Brake torque generation mechanism of left
and right side gears (5).
Shaft (7) is supported at the cam surface cut into
the facing surfaces of left and right pressure rings
(8).
The power (torque) transmitted from pressure rings
(8) to shaft (7) is transmitted at the cam surface,
but force Fa separating left and right pressure
rings (8) is generated in proportion to the torque
transmitted according to the angle of this cam sur-
face.
This separation load Fa acts on the brake at the rear
face of left and right side gears (5) and generates
the brake torque.

WA380-5 10-57
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL

2. When there is imbalance between drive Difference in wheel drive force for each type of dif-
force of left and right wheels [Road surface ferential when wheel on one side slips
condition (friction coefficient) and load for left and Wheel drive force
right wheels are not uniform and it is easier for (when one wheel is slipping)
wheel on one side to slip] Slipping Locked Total
Example 1. When digging, and wheel on one side is wheel wheel (ratio)
on soft surface Limited slip differ- 3.64
Example 2. When clearing snow, and wheel on one 1 2.64
ential (1.82)
side is on snow and wheel on other side is on
Normal differential 1 1 2 (1)
asphalt
Example 3. When traveling on slope, and there is
imbalance between load on left and right wheels On road surfaces where the wheel on one side is
The power from the transmission is divided likely to slip, the limited slip differential increases
equally to the left and right by the differential gear. the drive force by 1.82 times more than the nor-
However, when the drive force exceeds the wheel mal differential.
slip limit on the side where the wheel is slipping,
the amount of the force exceeding the wheel slip
limit passes through the brake and case at the rear When turning
face of the side gear and is transmitted to the brake
The differential gears built into a limited slip differ-
on the opposite side (locked side) and is sent to
ential are the same as the gears used in a normal
the wheel on the locked side.
differential, so the difference in rotation between
If this excess portion of the drive force becomes
the inside and outside wheels when turning the
greater than the braking force, the differential
machine can be generated smoothly.
starts to work.

10-58 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD FINAL DRIVE

FINAL DRIVE

1. Planet gear (No. of teeth: 26)

2. Planetary carrier
3. Axle shaft
4. Ring gear (No. of teeth: 69)
5. Sun gear shaft (No. of teeth: 15)

WA380-5 10-59
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD FINAL DRIVE

Unit: mm
No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between pinion gear size Clearance limit
6 Shaft Hole
bearing and shaft
Replace
40 +0.013 -0 -0.025 - —
+0.002 -0.012 -0.002

7 Clearance between axle hous- 358 +0.100 +0.100 -0.100 - —

ing and ring gear +0.030 +0 0.070

8 Clearance between oil seal and Max. 0.2 Adjust

housing

Housing 215 +0.500 -0.072 -0.050 - —

Press-fitting por- +0.300 -0 -0.372
9 tion of axle shaft
seal Shaft 180 -0 -0.300 -0.500 - —
-0.063 -0.500 -0.237
Clearance at press- Outer race 180 -0 -0.045 -0.085- —
fitting portion of -0.025 -0.085 -0.020
10 axle housing bear- Replace
Inner race 120 +0.045 -0 -0.065 - —
ing +0.023 -0.020 -0.023
Clearance at press- Outer race 157.162 +0.025 -0.012 -0.077 - —
fitting portion of +0 -0.052 -0.012
11 axle housing bear-
Inner race 98.425 +0.059 +0.025 -0.059 - —
ing +0.037 +0 -0.012

12 End play of axle shaft 0 - 0.1 Adjust

13 Clearance of guide pin 12 +0.025 +0.207 0.120 - — Replace

+0.007 +0.145 0.200

10-60 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD FINAL DRIVE

Outline

• The final drive reduces the speed of the power

from the engine and increases the drive force.
• Ring gear (4) is press fitted to the axle housing
and is fixed in position by a pin.
• The power transmitted from the differential and
passing through sun gear shaft (5) has its
speed reduced by the planetary gear mecha-
nism and the drive force increased.
The increased drive force passes through plan-
etary carrier (2) and axle shaft (3) and is trans-
mitted to the wheels.

WA380-5 10-61
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN

AXLE MOUNTING, CENTER HINGE PIN

1. Front axle
2. Front frame Outline
3. Rear axle
4. Rear frame • The front frame and rear frame are joined
through a bearing by the center hinge pin. In
addition, the left and right steering cylinders
are connected to the front and rear frames,
and the articulation angle of the frame (the
steering radius) is adjusted by the movement of
the cylinder.

10-62 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN

Unit: mm
No. Check item Criteria Remedy

Standard size Tolerance Repair limit

1 Thickness of thrust plate
22 ±0.5 —

2 Thickness of wave plate 5 +0.3 —

-0.1
Tolerance Replace
Standard Standard Clearance
Clearance between hole and size Shaft Hole clearance limit
3 shaft at front support end
190 -0.050 +0.472 0.050 - —
-0.122 +0 0.594
Clearance between hole and -0.005 +0.522 0.055 -
4 170 —
shaft at rear support end -0.124 +0.050 0.646

WA380-5 10-63
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN

10-64 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN

Unit: mm
No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between upper hinge size Clearance limit
1 Shaft Hole
pin and rear frame

80 -0.030 +0.071 0.066 - —

-0.049 +0.036 0.120

2 Clearance between upper hinge 80 -0.030 +0.060 0.060 - —

pin and spacer (small) -0.049 +0.030 0.109

3 Clearance between upper hinge 80 -0.030 -0 0.015 - —

pin and bearing -0.049 -0.015 0.049

4 Clearance between upper hinge 80 -0.030 +0.030 0.030 - —

pin and spacer (large) -0.049 +0 0.079

5 Clearance between rear frame 95 -0.036 +0.071 0.072 - —

and spacer (large) -0.071 +0.036 0.142

6 Clearance between front frame 130 -0 -0.048 -0.088 - —

and upper hinge bearing -0.025 -0.088 -0.023
Replace
7 Clearance between lower hinge 80 -0.030 +0.067 0.057 - —
pin and rear frame bushing -0.076 +0.027 0.143

8 Clearance between lower hinge 80 -0.030 -0 0.015 - —

pin and bearing -0.076 -0.015 0.076

9 Clearance between front frame 130 -0 -0.048 -0.088 - —

and lower hinge bearing -0.025 -0.088 -0.023

10 Clearance between rear frame 95 +0.089 +0.054 -0.089 - —

and bushing +0.054 +0 0

11 Clearance at seal press-fitting 105 +0.17 +0.054 -0.17 - —

portion of lower hinge pin +0.08 +0 -0.026

Standard size Tolerance Repair limit

12 Height of upper hinge spacer
(small)
25.5 ±0.1 —

13 Height of upper hinge spacer 56 ±0.1 —

(large)

Standard size
14 Shim value for upper hinge and
retainer
2.5

15 Shim value for upper hinge and 2.5

retainer

16 Shim value for lower hinge and 2

retainer
Adjust
20±2 Nm {2±0.2kgm} (When adjusting shim)
17 Tightening torque for upper
hinge retainer mounting bolt
98 - 123 Nm {10 - 12.5 kgm} (Final value)

20±2 Nm {2±0.2kgm} (When adjusting shim)

18 Tightening torque for lower
hinge retainer mounting bolt
98 - 123 Nm {10 - 12.5 kgm} (Final value)

WA380-5 10-65
b
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING PIPING

STEERING PIPING

1. Work equipment valve 7. Switch pump

2. Steering valve 8. Steering pump
3. Steering cylinder (right) 9. Steering cylinder (left)
4. Hydraulic oil tank 10. Orbit-roll
5. Emergency steering pump 11. Stop valve (right)
6. Emergency steering motor 12. Stop valve (left)
13. PPC accumulator

10-66 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING COLUMN, ORBIT-ROLL

STEERING COLUMN, ORBIT-ROLL

1. Steering wheel 4. Joint

2. Steering column 5. Orbit-roll
3. Tilt lever
Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between steering size Shaft Hole Clearance limit
6 shaft and column bearing Replace
19 -0 +0.15 0.05 - 0.23 0.4
-0.08 -0.05

WA380-5 10-67
b
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

STEERING VALVE

10-68 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

1. Overload safety valve

2. Check valve
3. Steering spool
4. Flow control spool
5. Main relief valve

A : To steering cylinder
B : To steering cylinder
Pa : From orbit-roll
Pb : To orbit-roll
P1 : From steering pump
P2 : From switch pump
PB : To work equipment circuit
T : To tank

Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit

Free Installed Installed load Free Installed

6 Steering spool return spring length length length load

37.2 32.0 56.9N — 47.1 N

{5.8 kg} {4.8 kg}

7 Poppet spring 20.9 13.2 9.3±4.9 N — 7.85 N

{0.95±0.5 kg} {0.8 kg} Replace

8 Demand spool return spring 75.1 68.5 136.1 N — 114.7 N

{13.88 kg} {11.7 kg}

9 Relief valve spring 24.0 22.19 182 kN — 145 kN

{18.6 kg} {14.8 kg}

10 Check valve return spring 21.6 17.0 2.26 N — 1.77 N

{0.23 kg} {0.18 kg}

WA380-5 10-69
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

OVERLOAD RELIEF VALVE

Operation
Functioning as relief valve

• Port A is connected to the cylinder circuit and

port B is connected to the drain circuit. Oil
passes through the center of the hole in poppet
(1) and acts on diameters d1 and d2, which
have different areas. Check valve poppet (3)
and relief valve poppet (2) are seated securely.

• When the pressure at port A reaches the set

pressure of the relief valve, pilot poppet (4)
opens, and the oil flows around pilot poppet
(4), passes through the drill hole, and flows to
1. Poppet port B.
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring

Function
• The overload relief valve is installed to the
steering valve. If the cylinder is subjected to
impact when the steering valve is at neutral
and abnormal pressure is generated, this valve
functions as a safety valve and relieves the
circuit to prevent the damage to the cylinder
or hydraulic piping. If negative pressure forms
at the cylinder end, it functions as a suction
valve to prevent the formation of any vacuum.

10-70 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

Functioning as suction valve

• When pilot poppet (4) opens, the pressure • If negative pressure forms at port A, check
behind poppet (1) drops, so poppet (1) moves valve poppet (3) opens because of the differ-
and seats pilot poppet (4). ence in area between diameters d3 and d4.
When this happens, the oil flows from port B
to port A to prevent any vacuum from forming.

• The pressure on the inside is lower than the

pressure at port A, so relief valve poppet (2)
opens. When this happens, the oil flows from
port A to port B to prevent any abnormal pres-
sure.

WA380-5 10-71
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

STEERING RELIEF VALVE

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

Function
• The steering relief valve is inside the steering
valve. It sets the maximum pressure in the
steering circuit when the steering valve is
being operated. In other words, when the
steering valve is operated, if the pressure in
the steering circuit goes above the set pressure
of this valve, it relieves the oil from the valve,
and by relieving the oil, actuates the flow con-
trol spool of the demand valve and drains the
oil going to the steering circuit.

10-72 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

Operation of steering relief valve

• When the pressure in the circuit rises and • When flow control spool (6) moves, the oil
reaches the pressure set by adjustment screw from the steering pump is drained and the oil
(1) and spring (2), pilot poppet (4) opens and from the switch pump is relieved to the main
drains the oil. control valve to prevent the pressure in the
• When this happens, the balance between the steering circuit from going above the set pres-
pressures in pressure-receiving chamber (I) and sure.
the pressure-receiving chamber (II) is lost and
flow control spool (6) moves to the left in the
direction of the arrow (").

WA380-5 10-73
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

Operation of demand valve

When steering spool is at neutral

• The oil from the steering pump enters port A; • When the pressure in the pressure-receiving
the oil from the switch pump enters port B. chamber (I) reaches a certain value (set by
• When steering spool (2) is at neutral, pressure- spring (5)), notch f opens and the oil from the
receiving chamber (II) is connected to the drain steering pump is relieved to the drain circuit;
circuit through orifice b; in addition, notch c is in addition, notch g closes, so all the flow of oil
closed. from the switch pump goes to the main control
• Because notch c is closed, the pressure of the valve.
oil at port A and port B rises, and this pres-
sure passes through orifice a, is taken to pres-
sure-receiving chamber (I) and moves flow
control spool (1) to the left in the direction of
the arrow (").

10-74 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

When steering spool is operated

• Engine running at low speed

• When steering spool (2) is pushed (operated), • The merged oil passes through notches c and
pressure-receiving chamber (II) and the drain d, pushes up load check valve (4), and flows to
circuit are shut off, and at the same time, notch the cylinder. The return oil from the cylinder
c opens. passes through notch e and enters the drain cir-
• As a result, the pressure in pressure-receiving cuit.
chamber (II) rises, and flow control spool (1) is • When this happens, the pressure before pass-
moved to the right in the direction of the arrow ing through notch c goes to pressure-receiv-
(!) until notch h closes. ing chamber (I) and the pressure after passing
through notch c goes to pressure-receiving
• The passage from port B to the main control chamber (II). Flow control spool (1) is actuated
valve is shut off, so the oil from the switch so that the difference in pressure on both sides
pump pushes up merge check valve (3) and the of notch c is maintained at a constant value.
oil is merged with the oil from the steering • Therefore, an oil flow matching the degree of
pump at port A. opening of notch c is discharged from the cyl-
inder port. These pressure differences (control
pressure) are set by spring (5).

WA380-5 10-75
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

• Engine running at high speed

• No extra oil is needed from the switch pump, • The oil from the steering pump passes through
so the pressure of the steering pump rises notches c and d, pushes up load check valve
until notch g closes and shuts off the merge (4), and flows to the cylinder. The return oil
passage at port B. from the cylinder passes through notch e and
• The difference in pressure on both sides of enters the drain circuit.
notch c is controlled only by notch f. The • Notch g is closed, so the oil from the switch
excess oil from the steering pump is drained to pump is sent from port B to the main control
the drain circuit from notch f. (When this hap- valve.
pens, notch g is completely closed.)

10-76 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

FLOW AMP

1. Steering spool 5. Cap A : From Orbit-roll valve

2. Valve housing (body) 6. Capscrew B : From Orbit-roll valve
3. Spring seat 7. Orifice C : Passage (inside housing)
4. Return spring
• Operation of flow amp
1. Spool at neutral (Orbit-roll valve not actuated)

• When the Orbit-roll valve is not actuated, both

pilot port PiA and pilot port PiB are connected
through the Orbit-roll to the drain (return) cir-
cuit, so steering spool (1) is kept at neutral by
return spring (4).

WA380-5 10-77
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

2. Spool actuated (oil flows to port PiA)

• When the oil flows to port PiA, the pressure • Port PiB is connected to the drain circuit
inside the cap at end A rises and moves steer- through the Orbit-roll valve, so the oil flowing
ing spool (1) in the direction of the arrow. to end B is drained.
• The oil entering for port PiA passes through • The pressure generated at port PiA is propor-
the hole in spring seat (3), through orifice (7) in tional to the amount of oil flowing in, so steer-
steering spool (1), and then flows to the oppo- ing spool (1) moves to a position where the
site end (B end). opening of the flow amp notch balances the
pressure generated with the force of return
spring (4).

10-78 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

3. Spool returning (steering wheel stopped)

• When the steering wheel (Orbit-roll valve) is

stopped, ports PiA and PiB are both connected
to the drain circuit through the Orbit-roll valve.
For this reason, steering spool (1) is returned to
the neutral position by return spring (4).

WA380-5 10-79
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

Operation of steering valve

Neutral

• The steering wheel is not being operated, so • When the pressures at ports A and B rise, flow
steering spool (1) does not move. control spool (4) is moved to the left in the
• The oil from the steering pump enters port A. direction of the arrow (!), and the oil from the
The oil from the switch pump enters port B. steering pump passes through port C of the
spool and is drained.
The oil from the switch pump passes through
port D and all flows to the main control valve.

10-80 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

Turning right

• When the steering wheel is turned to the right, • The oil at the opposite ends of the left and
the control linkage is actuated and steering right cylinders passes through load check
spool (1) moves to the left in the direction of valve (3) of the steering spool and is drained.
the arrow ("). • The oil from the switch pump enters port B,
• The oil from the steering pump enters port A, goes through flow control spool (2), pushes
goes through flow control spool (2) and flows open check valve (5), and merges with the oil
to steering spool (1). It then pushes open load from the steering pump.
check valve (4) of the spool, and flows to the
bottom end of the left cylinder and the rod end
of the right cylinder to turn the machine to the
right.

WA380-5 10-81
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE

Turning left

• When the steering wheel is turned to the left, • The oil at the opposite ends of the left and
the control linkage is actuated and steering right cylinders passes through load check
spool (1) moves to the right in the direction of valve (4) of the steering spool and is drained.
the arrow (!). • The oil from the switch pump enters port B,
• The oil from the steering pump enters port A, goes through flow control spool (2), pushes
goes through flow control spool (2) and flows open check valve (5), and merges with the oil
to steering spool (1). It then pushes open load from the steering pump.
check valve (3) of the spool, and flows to the
rod end of the left cylinder and the bottom end
of the right cylinder to turn the machine to the
left.

10-82 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ORBIT-ROLL VALVE

ORBIT-ROLL VALVE

1. Needle bearing 5. Rotor 9. Spool

2. Center spring 6. Cover 10. Stator
3. Drive shaft 7. Center pin 11. Lower cover
4. Valve body 8. Sleeve

WA380-5 10-83
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ORBIT-ROLL VALVE

Outline

• The steering valve is connected directly to the

shaft of the steering wheel. It switches the flow
of oil from the steering pump to the left and
right steering cylinders to determine the direc-
tion of travel of the machine.
• The orbit-roll valve, broadly speaking, consists
of the following components: rotary type spool
(9) and sleeve (8), which have the function of
selecting the direction, and the Girotor set (a
combination of rotor (5) and stator (10)), which
acts as a hydraulic motor during normal steer-
ing operations, and as a hand pump (in fact, the
operating force of the steering wheel is too
high, so it cannot be operated) when the steer-
ing pump or engine have failed and the supply
of oil has stopped.
Structure

• Spool (9) is directly connected to the drive shaft

of the steering wheel, and is connected to
sleeve (8) by center pin (7) (it does not contact
the spool when the steering wheel is at neutral)
and centering spring (2).
• The top of drive shaft (3) is meshed with center
pin (7), and forms one unit with sleeve (8),
while the bottom of the drive shaft is meshed
with the spline of rotor (5) of the Girotor.
• There are four ports in valve body (4), and they
are connected to the pump circuit, tank circuit,
and the circuits at the head end and bottom end
of the steering cylinders. The pump port and
tank port are connected by the check valve
inside the body. If the pump or engine fail, the
oil can be sucked in directly from the tank by
this check valve.

10-84 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ORBIT-ROLL VALVE

CONNECTION BETWEEN HAND PUMP AND SLEEVE

• The diagrams above show the connections with

the sleeve ports used to connect the suction
and discharge ports of the Girotor.
• If the steering wheel has been turned to the
right, ports a, c, e, g, i and k are connected by
the vertical grooves in the spool to the pump
side. At the same time, ports b, d, f, h, j, and l
are connected to the head end of the left steer-
ing cylinder in the same way.
In the condition in Fig.1, ports 1, 2, and 3 are
the discharge ports of the Girotor set. They are
connected to ports l, b, and d, so the oil is sent
to the cylinder.
Ports 5, 6, and 7 are connected and the oil
flows in from the pump.
If steering wheel is turned 90°, the condition
changes to the condition shown in Fig. 2. In this
case, ports 1, 2, and 3 are the suction ports,
and are connected to ports i, k, and c. Ports 5,
6, and 7 are the discharge ports, and are con-
nected to ports d, f, and h.

WA380-5 10-85
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ORBIT-ROLL VALVE

• In this way, the ports of the Girotor acting as

delivery ports are connected to ports which are
connected to the end of the steering valve
spool. The ports acting as suction ports are con-
nected to the pump circuit.
• Adjusting delivery in accordance with angle of
steering wheel:
For every 1/7 turn of the steering wheel, the
inner teeth of the Girotor gear advance one
position so the oil flow from the pump is
adjusted by this movement. In this way, the oil
delivered from the pump is directly propor-
tional to the amount the steering wheel is
turned.

FUNCTION OF CENTER SPRING

• Centering spring (2) consists of four layers of

leaf springs crossed to form an X shape. The
springs are assembled in spool (9) and sleeve
(8) as shown in the diagram on the right.
When the steering wheel is turned, the spring is
compressed and a difference in rotation (angle
variation) arises between the spool and the
sleeve.
Because of this, the ports in the spool and
sleeve are connected and oil is sent to the cylin-
der. When the turning of the steering wheel is
stopped, the Girotor also stops turning, so no
more oil is sent to the cylinder and the oil pres-
sure rises.
To prevent this, when the turning of the steer-
ing wheel is stopped, the action of the centering
spring only allows it to turn by an amount equal
to the difference in angle of rotation (angle vari-
ation) of the sleeve and spool, so the steering
wheel returns to the NEUTRAL position.

10-86 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STOP VALVE

STOP VALVE

1. Boot A : From orbit-roll

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

WA380-5 10-87
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING PUMP, SWITCH PUMP

STEERING PUMP, SWITCH PUMP

SAL (3) 45+45

1. Steering pump Outline

2. Switch pump • The steering pump and switch pump are
installed to the PTO shaft of the torque con-
verter. When the shaft rotates, the pumps are
driven and supply pressure oil to the steering
circuit.
• The pressure of the oil supplied from the switch
pump is adjusted by the steering valve, and
when the pressure in the steering circuit is suf-
ficient to meet the demand, the oil from the
switch pump is diverted to the work equip-
ment hydraulic circuit.

10-88 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING PUMP, SWITCH PUMP

Unit: mm
No. Check item Criteria Remedy

Model Standard clearance Clearance limit

3 Side clearance SAL(3)45

0.10 - 0.15 0.19
SAL(3)45

Clearance between inside SAL(3)45

4 diameter of plain bearing and 0.06 - 0.149 0.20 Replace
outside diameter of gear shaft SAL(3)45

Model Standard size Tolerance Repair

limit

5 Driving depth of pin SAL(3)45

14 -0 —
-0.5
SAL(3)45

6 Spline rotating torque 13.8 - 23.6 Nm {1.4 - 2.4 kgm}

Standard Discharge
Speed Discharge discharge amount
Model (rpm) pressure amount limit
(MPa {kg/cm²} (l/min) (l/min) —
Discharge amount
— Oil: SAE 10WCD
Oil temperature: 45 - 55°C SAL(3)45 101 96
2,500 20.6
{210}
SAL(3)45 101 96

WA380-5 10-89
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EMERGENCY
EMERGENCY STEERING
STEERING PUMP (IF(If
PUMP equipped)
EQUIPPED)

EMERGENCY STEERING PUMP (If equipped)

SBL (1)21

Function
• The emergency steering pump is installed to
the transmission together with the emergency
steering motor. If the engine stops or if the oil
pressure in the steering circuit drops below
the set pressure, it supplies oil to the steering
circuit.
Unit: mm
No. Check item Criteria Remedy

Standard clearance Clearance limit

1 Side clearance
0.10 - 0.15 0.19

Clearance between inside

2 diameter of plain bearing and 0.060 - 0.119 0.20 Replace
outside diameter of gear shaft

Standard size Tolerance Repair limit

3 Driving depth of pin -0
10 —
-0.5

4 Spline rotating torque 2.0 - 4.9 Nm {0.2 -0.5 kgm}

Standard
Discharge Discharge
Speed discharge
amount limit
Discharge amount (rpm) pressure amount —
— Oil: SAE 10WCD (MPa {kg/cm²} (l/min)
(l/min)
Oil temperature: 45 - 55°C
20.6
3,500 {210} 67.6 62.4

10-90 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EMERGENCY
EMERGENCY STEERING
STEERING MOTOR(IF(IfEQUIPPED)
MOTOR equipped)

EMERGENCY STEERING MOTOR (If equipped)

1.Terminal E
2.Terminal M

Function
• If there is an abnormal drop in the oil pressure
in the steering circuit, the emergency steering
motor receives a signal from the transmission
controller and drives the emergency pump.

Specifications
Type Direct current motor

Rated voltage 24V

Rated output 0.9kW

WA380-5 10-91
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING CYLINDER

STEERING CYLINDER

Unit: mm
No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between mounting size Clearance limit
1 pin and bushing at connection Shaft Hole
of frame and cylinder rod
50 -0 +0.142 0.080 - —
-0.025 +0.080 0.167
Clearance between mounting -0 +0.142 0.080 -
2 pin and bushing at connection 50 -0.025 +0.080 0.167 — Replace
of frame and cylinder bottom

Width of boss Width of hinge Standard clearance

Connection of steering cylinder (a + b)
3 and front frame
60 66 Max. 0.5
(after adjusting shim)

4 Connection of steering cylinder 60 63 Max. 0.5

and rear frame (after adjusting shim)

10-92 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING CYLINDER

Unit: mm
No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between piston rod size Clearance limit
1 Shaft Hole
and bushing
+0.025 +0.141 0.021 -
45 +0.064 -0.004 0.205
0.505 Replace pin,
bushing
2 Clearance between piston rod 50 -0 +0.142 0.080 - 1.0
support shaft and bushing -0.025 +0.080 0.167
Clearance between cylinder
3 bottom support shaft and bush- 50 -0 +0.142 0.080 - 1.0
-0.025 +0.080 0.167
ing

4 Tightening torque of cylinder 677 ± 67.5 Nm {69 ± 6.9 kgm}

head
Tightening torque of cylinder
5 1.25 ± 0.13 kNm {127 ± 12.7 kgm} (Width across flats: 50 mm) Tighten
piston
Tightening torque of nipple
6 plug on cylinder head side 9.8 - 12.74 Nm {1.0 - 1.3 kgm}

WA380-5 10-93
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD JOYSTICK
JOYSTICK STEERING
STEERING LEVER
LEVER (IF(IfEQUIPPED)
equipped)

JOYSTICK STEERING LEVER (If equipped)

1. Shift UP switch 9. Console lock lever

2. Shift DOWN switch 10. Height adjustment lock lever
3. F-N-R switch 11. Angle/Position adjustment lock lever
4. Joystick steering lever 12. Console
5. Joystick ON/OFF switch 13. Block
6. Hi/Lo switch 14. Solenoid valve
7. Horn switch 15. Orbit-roll
8. Steering electrical lever

10-94 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING
STEERING LEVER
LEVER (IF(IfEQUIPPED)
equipped)

STEERING LEVER (If equipped)

(FOR JOYSTICK STEERING LEVER)

1. Body 5. Retainer
2. Piston 6. Lever
3. Lever 7. Potentiometer
4. Disc 8. Connector

Function

• The steering potentiometer is installed to the

left side part of the floor, and is interconnected
by a link to the steering end of the monolever.
When the monolever is operated in the steering
direction, disc (4) is rotated through the link,
pushes piston (2) down, and rotates potentiom-
eter (7).
• Steering lever potentiometers sense lever angle
and output angle signal to HSS controller.
• Two potentiometers are attached to the steer-
ing lever and they output a signal as shown in
the diagram.

WA380-5 10-95
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING
STEERING LEVER
LEVER (IF(If equipped)
EQUIPPED)

Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit

1 Spring Free length Installed Installed Free Installed Replace

length load length load spring if
5.88 N 4.71 N damaged of
49 x 7.0 25 — deformed
{0.6 kg} {0.48 kg}
2 Spring 45.8 x 15.5 32 73.5 N — 58.8 N
{7.5 kg} {6.0 kg}

10-96 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING
STEERING SWITCH
SWITCH VALVE
VALVE (IF(IfEQUIPPED)
equipped)

STEERING SWITCH VALVE (If equipped)

(FOR JOYSTICK STEERING LEVER)

Operation

• Steering switch valve switches oil circuit from

R.H. steering cylinder circuit to L.H. steering cyl-
inder circuit or in reverse according to the oper-
ated direction of steering lever.
• According to the angle of steering lever, steer-
ing switch valve controls the oil flow amount.

WA380-5 10-97
b
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE PIPING

BRAKE PIPING

10-98 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE PIPING

1. Brake valve (L.H.)

2. Brake valve (R.H.)
3. Hydraulic oil tank
4. Accumulator (for the front side)
5. Accumulator (for the rear side)
6. Accumulator (for the rear side)
7. Accumulator (for the front side)
8. Charge valve
9. Parking brake emergency release valve
10. Pilot control pump
11. Rear brake
12. Transmission control valve
13. Parking brake solenoid valve
14. Parking brake
15. Front brake

WA380-5 10-99
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE

BRAKE VALVE
BRAKE VALVE (LEFT)

T : Drain port 1. Brake pedal

A : To the R.H. brake valve PP 2. Rod
P : From the charge valve ACC2 3. Spool
4. Cylinder

10-100 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE

Unit: mm
No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between pedal size clearance limit
5 Shaft Hole
mount hole and pin

10 -0.025 +0.1 0.025 - 0.25

-0.075 0 0.175

6 Clearance between roller and 10 -0.025 +0.1 0.025 - 0.25

pin -0.075 0 0.175

Standard size Tolerance Repair limit

7 Outside diameter of roller
30 -0 29.2
-0.5
Replace
Standard size Repair limit

Free length Installed Installed Free length Installed

8 Control spring length load load

34.7 34.7 0 Nm 33.7 —

{0 kg}

9 Control spring 51.8 49.7 40.3 Nm 50.8 —

{4.12 kg}
116.4 Nm
10 Return spring 197.8 58 {11.88 kg} 178 —

11 Return spring 31.5 19.5 16.7 Nm 28 —

{1.7 kg}

WA380-5 10-101
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE

BRAKE VALVE (RIGHT)

T : Drain port 1. Brake pedal

A : To the rear brake 2. Rod
B : To the front brake 3. Piston (Pilot)
PA : From the charge valve ACC1 4. Spool
PB : From the charge valve ACC2 5. Cylinder (Upper)
PP : From the L.H. brake valve A 6. Spool
7. Cylinder (Lower)

10-102 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE

Unit: mm
No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between pedal size clearance limit
8 Shaft Hole
mount hole and pin

10 -0.025 +0.1 0.025 - 0.25

-0.075 0 0.175

9 Clearance between roller and 10 -0.025 +0.1 0.025 - 0.25

pin -0.075 0 0.175

Standard size Tolerance Repair limit

10 Outside diameter of roller
30 -0 29.2
-0.5

Standard size Repair limit Replace

Free Installed Installed Free Installed
11 Control spring length length load length load

34.7 34.7 0 Nm 33.7 —

{0 kg}

12 Control spring 51.8 49.7 40.3 Nm 50.8 —

{4.12 kg}

13 Return spring 197.8 58 116.4 Nm 178 —

{11.88 kg}

14 Return spring 31.5 19.5 16.7 Nm 28 —

{1.7 kg}

15 Return spring 17 16.5 17.7 Nm — —

{1.8 kg}

WA380-5 10-103
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE

Outline
• There are two brake valves installed in parallel When brake is applied (left brake valve)
at the bottom front of the operator's compart-
ment. They are actuated when the pedal is • When pedal (7) is depressed, spool (10) is
depressed. pushed up by rod (8) and spring (9), and closes
drain port c. The oil from the pump and accu-
• When the right pedal is depressed, oil is sent to
mulator flows from port E to port F.
the brake cylinder and the brake is applied.
• Port F of the left brake valve and port PP of the
• When the left pedal is depressed, oil is sent to right brake valve are connected by a hose, so
the right pedal and the brake is applied in the the oil flowing into port F flows to pilot port PP
same way as when the right pedal is depressed. of the right brake valve.
• In addition, when the left brake pedal is
• The oil entering pilot port PP passes through
depressed, the transmission cut-off switch actu-
orifice d and enters port G, pushes piston (11)
ates the transmission solenoid valve electrically
and the spring pushes spool (3) down to apply
to set the transmission to neutral.
the brake in the same way as when the right
brake valve is depressed.
Operation
When brake is applied (right brake valve)

Upper portion
• When pedal (1) is depressed, the operating
effort is transmitted through rod (2) and spring
(4) to spool (3). When spool (3) goes down,
drain port a is closed and the oil from the
pump and accumulator flows from port A to
port C to actuate the rear brake cylinder.

Lower portion
• When pedal (1) is depressed, the operating
effort is transmitted through rod (2) and spring
(4) to spool (3). When spool (3) goes down,
plunger (6) moves spool (5) down. When this
happens, drain port b is closed and the oil from
the pump and accumulator flows from port B to
port D to actuate the front brake cylinder.

10-104 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE

Applying brake (right brake valve) when there Balanced operation

is failure in upper valve Upper portion
• When the oil fills the rear brake cylinder and the
• Even if there is leakage of oil from the upper oil pressure between port A and port C
piping, when pedal (1) is depressed, spool (5) becomes high, the oil entering port H through
is moved down mechanically, so the lower orifice e of spool (3) pushes against spring (4)
portion is actuated normally. and pushes spool (3) up to shut off port A and
The brake for the upper portion is not actuated. port C. When this happens, drain port a
Applying brake (right brake valve) when there remains closed and the oil entering the brake
is failure in lower valve cylinder is maintained, so the brake remains
applied.
• Even if there is leakage of oil from the lower Lower portion
piping, when pedal (1) is depressed, the lower • Spool (a) in the upper portion moves up, and at
portion is actuated normally. the same time as port A and port C are shut
off, the front brake cylinder is also filled with oil
and the oil pressure between port B and port D
becomes high. The oil entering port J through
orifice f of spool (5) pushes up the spool by the
same amount that spool (3) moves and shuts
off port B and port D.
Drain port b is closed, so the oil entering the
brake cylinder is maintained and the brake is
applied.
• The pressure in the space in the upper portion
is balanced with the operating effort of the
pedal, and the pressure in the space in the
lower portion is balanced with the pressure in
the space in the upper portion. Spools (3) and
(5) move the full stroke, and ports A - C and
ports B - D are opened completely, so the oil
pressure in the space in the lower portion and
the left and right brake cylinders becomes the
same as the oil pressure from the pump.
Therefore, the amount that the brake is applied
can be adjusted by the amount that the pedal
is depressed, up to the point where the piston
is operated fully.

WA380-5 10-105
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE

Brake released (right brake valve)

Upper portion
• When pedal (1) is let back and the operating
effort on the top of the spool is removed, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (3)
up, drain port a is opened, the oil from the
brake cylinder flows to the hydraulic tank return
circuit, and the rear brake is released.

Lower portion
• When the pedal is let back, at the same time as
spool (3) in the upper portion moves up, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (5),
drain port b is opened, the oil from the brake
cylinder flows to the tank return circuit, and the
front brake is released.

10-106 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CHARGE VALVE

CHARGE VALVE

A1 : To the PPC (*EPC) valve

A2 : Plug
ACC1: To the R.H. brake valve PA
ACC2: To the R.H. brake valve PB
To the L.H. brake valve P
P : From the pump
PP : To the accumulator
T : Drain

* EPC valves are optional parts.

WA380-5 10-107
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CHARGE VALVE

1. Valve body
2. Main relief valve (R3)
3. Relief valve (R1)
4. PPC (EPC*) relief valve (R2)
5. Relief valve (H1)

*EPC valves are optional parts.

Function
• The charge valve acts to maintain the oil from
the pump at the specified pressure and to
charge the accumulator.
• When the oil pressure reaches the specified
pressure, the oil from the pump is connected
to the drain circuit to reduce the load on the
pump.

10-108 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CHARGE VALVE

Operation

1. When oil is not being supplied to accumu- 2. When oil is being supplied to accumulator
lator (cut-out condition)
1) Cut-in condition
• The pressure at port B is higher than the set
• When the pressure at port B goes below the
pressure of relief valve R1, so piston (2) is
set pressure of relief valve R1, piston (2) is
forcibly pushed up by the oil pressure at
pushed back down by spring (8), valve seat
port B and poppet (1) opens, and port C
(9) and poppet (1) are put in tight contact,
and port T are connected.
and port C and port T are shut off.
• The spring chamber at the right end of • The spring chamber at the right end of
spool (6) is connected to port C of relief spool (6) is also shut off from port T, so the
valve R1, so it is the tank pressure. pressure rises. The pressure at port P also
• The oil from the pump enters port P and a rises in the same way.
low pressure equivalent to the load of • At the moment the pressure at port P goes
spring (5) pushes spool (6) to the right, then above the pressure of port B (accumulator
flows from port A to the PPC valve, orbit- pressure), the supply of oil to the accumula-
roll and fan pump. tor starts. In this case, it is determined by
At the same time, it also passes through the size (area) of orifice (7) and the pres-
orifices (7), (4), and (3), and returns to the sure difference generated on both sides of
tank. the orifice (equivalent to the load of spring
(5)). A fixed amount is supplied, regardless
of the speed of the engine, and the
remaining oil flows to port A.

WA380-5 10-109
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CHARGE VALVE

2) When cut-out pressure is reached

• When the pressure at port B (accumulator
pressure) reaches the set pressure of relief
valve R1, poppet (1) separates from valve
seat (9), the oil flows, and the relief is actu-
ated.
• A difference in pressure at the top and bot-
tom of piston (2) is created by the relief
action, so piston (2) moves up or down,
forcibly opens poppet (1), and port C and
port T are connected.
• The spring chamber at the right end of
spool (6) is connected to port C of relief
valve R1, so it is the tank pressure.
• The pressure at port P goes down in the
same way to a pressure equivalent to the
load of spring (5), and the supply of oil to
port B is also stopped.

3. Safety relief valve (R3)

• When the pressure at port P (pump pressure)
goes above the set pressure of relief valve R3,
the oil from the pump pushes against spring
(10), pushes up ball (11), and sends the oil to
the tank circuit to set the maximum pressure in
the brake circuit and protect the circuit.

10-110 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ACCUMULATOR (FOR BRAKE)

ACCUMULATOR (FOR BRAKE)

1. Valve
2. Top cover
3. Cylinder
4. Piston

Function
Specifications
• The accumulator is installed between the Gas used : Nitrogen gas
charge valve and brake valve. Amount of gas : 2,850 cc
The area between cylinder (3) and free piston Charge pressure: 3.43 ± 0.1 MPa {35 ± 1.0 kg/cm²}
(4) is charged with nitrogen gas. The compres- (at 20°C)
sion ability of this gas is used to absorb the
pulse of the hydraulic pump and to ensure
that there is power to carry out braking and
operate the machine if the engine stops.

WA380-5 10-111
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ACCUMULATOR (FOR BRAKE)

1. Top cover
2. Piston
3. Cylinder
4. End cover
5. Core

Function
Specifications
• This is installed between the brake valve and Gas used : Nitrogen gas
the brake cylinder. The area between cylinder Amount of gas : 46 cc
(3) and free piston (2) is charged with nitrogen Charge pressure: 0.29 ± 0.05 MPa {3 ± 0.5 kg/cm²}
gas. The compression ability of this gas is used (at 50°C)
to ensure that there is power to carry out brak-
ing and operate the machine.

10-112 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE

BRAKE
FRONT
★ Figure shows brake with limited slip differential.

1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Discs (x3)

WA380-5 10-113
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE

Unit: mm
No. Check item Criteria Remedy

Standard size Tolerance Repair limit

10 Thickness of inner ring
6 ±0.1 5.5

Thickness of brake disc 6.5 ±0.15 5.7

11 Depth of lining groove 0.8 (Min.) — 0.4

Thickness of lining 1.0 0.9 (Min.) — Replace

12 Wear of brake outer ring disc 23.3 ±0.1 0.3

contact surface

Standard size Repair limit

13 Spring load Installed height Installed load Installed load

6.5 460 N {47 kg} 372 N {38 kg}

Outline
• The front brake has a wet-type multiple-disc
structure, and consists of piston (3), inner ring
(5), discs (9), outer ring (8), and spring (4).
• The brake cylinder consists of differential hous-
ing (1) and bearing carrier (2), and piston (3) is
assembled in it.
Inner ring (5) and outer ring (8) are joined to
the spline portion of axle housing (7).
• Discs (9) have a lining adhered to both sides.
They are assembled between inner ring (5) and
outer ring (8), and are joined by the spline of
sun gear shaft (6).

10-114 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE

REAR
★ Figure shows brake with limited slip differential.

1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Discs (x3)

WA380-5 10-115
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE

Unit: mm
No. Check item Criteria Remedy

Standard size Tolerance Repair limit

10 Thickness of inner ring
6 ±0.1 5.5

Thickness of brake disc 6.5 ±0.15 5.7

11 Depth of lining groove 0.8 (Min.) — 0.4

Thickness of lining 1.0 0.9 (Min.) — Replace

12 Wear of brake outer ring disc 23.3 ±0.1 0.3

contact surface

Standard size Repair limit

13 Spring load Installed height Installed load Installed load

6.5 460 N {47 kg} 372 N {38 kg}

Outline
• The rear brake has a wet-type single-disc struc-
ture, and consists of piston (3), inner ring (5),
disc (9), outer ring (8), and spring (4).
• The brake cylinder consists of differential hous-
ing (1) and bearing carrier (2), and piston (3) is
assembled in it.
Inner ring (5) and outer ring (8) are joined to
the spline portion of axle housing (7).
• Disc (9) has a lining stuck to both sides. It is
assembled between inner ring (5) and outer
ring (8), and is joined by the spline of sun gear
shaft (6).

10-116 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE

Outline
When brake is applied When brake is released

• When the brake pedal is depressed, pressure oil • When the oil pressure is released, piston (2) is
P goes from the hydraulic tank through the returned to its original position by the force of
pump and brake charge valve. It acts on the spring (8), a gap is formed between inner ring
piston inside the brake cylinder and the piston (3) and outer ring (5), and discs (4) become free.
slides. Lattice shape grooves are cut into the lining
Therefore, piston (2) stops the rotation of discs stuck to disc (4), and when disc (4) is rotating,
(4) fitted between inner ring (3) and outer ring oil flows in the grooves and carries out cooling
(5), and applies the brake to the machine. of the lining.

WA380-5 10-117
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE CONTROL

PARKING BRAKE CONTROL

1. Parking brake switch

2. Parking brake emergency release valve
3. Transmission control valve
4. Parking brake solenoid valve
5. Parking brake

Outline
• The parking brake is a wet-type multiple disc • While the parking brake is being applied (when
brake built into the transmission. It is installed the solenoid is OFF), the signal from the trans-
to the bearing portion of the output shaft. It is mission controller to the transmission solenoid
applied mechanically by the pushing force of a valve is cut by the neutralizer signal, and the
spring, and is released by hydraulic power. transmission is held at neutral.
• When the parking brake switch (1) in the opera- • Parking brake emergency release valve (2) is
tor's compartment is turned ON, the hydraulic installed to release the parking brake if it is
pressure is shut off by parking brake solenoid necessary to move the machine when trouble
valve (4) installed to transmission control has occurred in the engine or drive system
valve (3), and the parking brake is applied. and the machine remains stopped (the parking
When the parking brake switch is turned OFF, brake remains applied).
the parking brake is released by the hydraulic
pressure of the cylinder.

10-118 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE

PARKING BRAKE

1. Output shaft Outline

2. Spring
3. Spring • The parking brake is a wet-type multiple-disc
4. Piston brake and is applied mechanically by a spring
5. Parking brake oil port to apply braking force to transmission output
6. Plate shaft (1).
7. Disc • The tension of spring (3) uses piston (4) to push
8. Wave spring discs (7) and plates (6) together and stop output
shaft (1).
• When the brake is released, oil pressure from
parking brake oil port (5) actuates piston (4) to
release the force pushing discs (7) and plates
(6) together.

WA380-5 10-119
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE

Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit

Free Installed Installed Free Installed

9 Parking brake spring (outer) length length load length load

94 75.2 1,113 N 91.2 1,058 N

{113.5 kg} {107.8 kg}

10 Parking brake spring (inner) 94 75.2 583 N 91.2 553 N

{59.4 kg} {56.4 kg}

Standard size Tolerance Repair limit Replace

Thickness
11 Separate plate 4.0 ±0.05 3.9

Distortion — 0.05 0.25

12 Brake disc Thickness 3.2 ±0.08 2.97

13 Wave spring load 1,106 N {112.8 kg} ±57 N 940 N {95.9 kg}
(Height: 3.2 mm) {±5.8 kg}

10-120 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE SOLENOID VALVE

PARKING BRAKE SOLENOID VALVE

Serial No.: 60001 – (Transmission No. 110643)

Serial No.: (Transmission No. 110644) and up

1. Movable iron core

2. Coil
3. Bushing pin
4. Spring
5. Spool
6. Valve seat
7. Check valve

WA380-5 10-121
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE SOLENOID VALVE

Operation
Parking brake applied (solenoid OFF) Parking brake released (solenoid ON)

• When the parking brake switch in the operator's • When the parking brake switch is turned OFF,
compartment is turned ON, the solenoid is the solenoid is turned ON and spool (5) moves
turned OFF and spool (5) is pushed to the left by to the right. When this happens, the pressure
spring (4). When this happens, the circuit oil from the pump goes from port P through
between pump port P and parking brake port A the inside of spool (5) and flows from port A to
is closed and the pressure oil from the pump the parking brake. At the same time, port T is
does not flow to the parking brake. closed and the oil is not drained. As a result,
• At the same time, the oil from the parking brake the spring inside the parking brake is pushed
flows from port A to port T, and is drained. back by the hydraulic force and the parking
As a result, the discs inside the parking brake brake is released.
are pushed by the spring and the parking brake
is applied.

10-122 WA380-5
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE EMERGENCY RELEASE VALVE

PARKING BRAKE EMERGENCY RELEASE VALVE

1. Grip
2. Valve

A : From accumulator
B : To parking brake solenoid

Outline
• The parking brake emergency release valve is
installed between the brake circuit accumula-
tor and the parking brake solenoid. It is possi-
ble to open this valve manually if no pressure
oil can be supplied from the transmission
pump because of engine failure or other fail-
ure. This makes it possible to supply pressure
from the brake circuit accumulator to the park-
ing brake cylinder.

WA380-5 10-123
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC PIPING

HYDRAULIC PIPING

10-124 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC PIPING

WA380-5 10-125
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC PIPING

Outline
1. Work equipment valve
2. Bucket cylinder • The hydraulic system consists of the work
3. Steering valve equipment circuit and steering circuit. The
4. Hydraulic oil tank work equipment circuit controls the operation
5. Breather of the bucket and attachments.
6. PPC valve • The oil from hydraulic tank (4) is sent by work
7. Cooling fan pump equipment pump (11) to work equipment valve
8. Steering switch pump (1). If the bucket and lift arm spools of the work
9. Oil cooler equipment valve are in the HOLD position, the
10. Torque converter oil cooler oil is sent through the drain circuit of the work
11. Torque converter oil pressure • work equipment equipment valve, filtered by the filter in the
oil pressure • pilot control pump hydraulic tank, and returned to the tank.
12. PPC accumulator • If the work equipment control lever is operated,
13. Charge valve the bucket or lift arm spool of the PPC valve (6)
14. E.C.S.S. valve moves to operate each spool of the work equip-
15. Steering cylinder ment valve (1) hydraulically. Then, the oil flows
16. E.C.S.S. accumulator from the work equipment valve to lift cylinder
17. Lift cylinder (17) or bucket cylinder (2) to move the lift arm
18. Emergency steering pump or bucket.
19. Emergency steering motor • The maximum pressure in the hydraulic circuit
20. Cooling fan motor is controlled with the relief valve in the work
equipment valve. The bucket cylinder circuit is
equipped with the safety-suction valve for pro-
Note: If EPC valve is installed, change "PPC valve" tection of the circuit.
to "EPC valve" when reading. • PPC accumulator (12) is installed to the PPC
pilot circuit so that the lift arm can be lowered
to the ground even while the engine is stopped.
• Hydraulic tank is pressurized, enclosed, and
equipped with breather (5) having the relief
valve. Certain pressure is applied to this tank to
prevent generation of negative pressure in the
tank and cavitation in the pump.
• If the vehicle cannot be steered normally
because of a stall of the engine, a trouble in the
steering pump, oil leakage from the piping, etc.,
emergency steering motor (19) drives emer-
gency steering pump (18) so that the vehicle
can be steered.
• Fan motor (20) installed to the radiator is driven
hydraulically and variably with fan motor drive
pump (7).

10-126 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL LEVER

WORK EQUIPMENT CONTROL LEVER

For PPC valve

1. Lift arm control lever

2. Bucket control lever
3. Kick down switch
4. Holding switch
5. Canceling switch
(When equipped with load meter)
6. Sub-totaling switch
(When equipped with load meter)
7. Wrist rest
8. Wrist rest height adjusting lever
9. Lever stand angle adjusting lever
10. Work equipment PPC valve
11. Work equipment lock lever

WA380-5 10-127
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL LEVER

For EPC valve (If equipped)

1. Lift arm control lever 7. Wrist rest

2. Bucket control lever 8. Wrist rest adjusting lever
3. Kick-down switch 9. Lever stand tilt adjusting lever
4. Hold switch 10. EPC valve
5. Cancel switch 11. Work equipment lock lever
(When equipped with load meter) 12. Travel direction selector switch
6. Sub-totaling switch
(When equipped with load meter)

10-128 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC TANK

HYDRAULIC TANK

1. Oil filler port

2. Breather Specifications
3. Hydraulic oil tank Tank capacity (l) 195
4. Sight gauge Oil quantity inside the tank (l) 129
5. Bypass valve
Bypass valve setting pressure 0.125
6. Oil filter (MPa{kg/cm²}) {1.27}

WA380-5 10-129
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC TANK

Breather

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

Prevention of negative pressure in tank

• Since the tank is pressurized and enclosed, if

the hydraulic oil level in it lowers, negative
pressure is generated. At this time, sleeve (4) is
opened by the differential pressure between the
tank pressure and the atmospheric pressure to
prevent generation of the negative pressure.
(Set pressure of suction valve: 2.0 ± 0.3 kPa
{0.02 ± 0.003 kg/cm²})
Prevention of pressure rise in tank

• While the hydraulic circuit is in operation, the

hydraulic oil level in the tank varies as the
hydraulic cylinders operate and the tempera-
ture rises. Consequently, the pressure in the
tank varies, too. If the pressure in the tank rises
above the set level, poppet (3) operates to
release the pressure from the tank.
(Set pressure of exhaust valve: 0.1 ± 0.015 MPa
{1.0 ± 0.15 kg/cm²})

10-130 WA380-5
(8)
STRUCTURE AND FUNCTION, TORQUE CONVERTER CHARGING, WORK
MAINTENANCE STANDARD EQUIPMENT, AND PILOT CONTROL PUMPS

TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND

PILOT CONTROL PUMPS
SAL (3) 80 + 90 + (1)22

1. Torque converter charging pump

2. Work equipment pump Outline
3. Pilot control pump
• The torque converter charging, work equip-
ment, and pilot control pumps are installed to
the PTO shaft of the torque converter and
driven by shafts to supply oil to the transmis-
sion, work equipment, and PPC circuit.

WA380-5 10-131
STRUCTURE AND FUNCTION, TORQUE CONVERTER CHARGING, WORK
MAINTENANCE STANDARD EQUIPMENT, AND PILOT CONTROL PUMPS

Unit: mm
No. Check item Criteria Remedy

Model Standard clearance Clearance limit

SAL(3)80
4 Side clearance 0.10 - 0.15
SAL(3)90 0.19

SAL(1)20 0.08 - 0.13

SAL(3)80
Clearance between inside 0.069 - 0.149
5 diameter of plain bearing and SAL(3)90 0.20 Replace
outside diameter of gear shaft
SAL(1)20 0.06 - 0.119

Model Standard size Tolerance Repair

limit

SAL(3)80
6 Driving depth of pin 14
SAL(3)90 -0 —
-0.5

SAL(1)20 10

7 Spline rotating torque 17.7 - 33.3 Nm {1.8 -3.4 kgm}

Discharge Standard Discharge

Model Speed pressure discharge amount
(rpm) (MPa {kg/cm²} amount limit
(l/min) (l/min)
Discharge amount —
— Oil: SAE10WCD SAL(3)80 20.6 {210} 184 170
Oil temperature: 45 - 55°C
SAL(3)90 2,500 20.6 {210} 208 192

SAL(1)20 2.9 {30} 47 42

10-132 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC RELIEF VALVE

PPC RELIEF VALVE

1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw

Outline
• The PPC relief valve is installed in the charge
valve between the PPC pump and PPC valve.
While the PPC valve is not in operation or when
abnormal pressure is generated in the PPC cir-
cuit, the PPC relief valve relieves the oil sent
from the pump to protect the pumps and cir-
cuits.

Note: If EPC valve is installed, change "PPC valve"

to "EPC valve" when reading.

WA380-5 10-133
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC RELIEF VALVE

Operation

• The relief valve is installed to the charge valve • If the pressure in port B lowers, a pressure dif-
and ports A and C are connected to the pump ference is made between ports A and B
circuit and drain circuit respectively. because of the orifice of main valve (1). As a
The oil flows through the orifice of main valve result, main valve (1) is opened by the pressure
(1) and fills port B. in port A and the oil in port A is drained and
Pilot poppet (4) is seated at valve seat (3). relieved into port C.
• If the pressure in ports A and B reaches the set
level, pilot poppet (4) opens and the pressure in
port B is released through port D into port C,
and the pressure in port B lowers consequently.

10-134 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD E.C.S.S.
E.C.S.S. (IF(IfEQUIPPED)
VALVE
VALVE equipped)

E.C.S.S. VALVE (If equipped)

★ E.C.S.S.: Abbreviation for – Electronically Controlled Suspension System

A : From lift cylinder bottom

B : From lift cylinder head
P : From work equipment pump
SP : To E.C.S.S. accumulator
T : To tank

WA380-5 10-135
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD E.C.S.S.
E.C.S.S. VALVE
VALVE (IF(If equipped)
EQUIPPED)

1. Main spool
2. Solenoid valve
3. Flow control valve
4. Shuttle valve
5. Charge valve

10-136 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

WORK EQUIPMENT CONTROL VALVE

1. 2-spool valve

T : Drain port (To the tank) P2 : From the switch pump (steering valve)
A1: To the bucket cylinder head P1A : From the P1 port of the PPC valve
A2: To the lift cylinder head P1B : From the P2 port of the PPC valve
B1: To the bucket cylinder bottom P2A : From the P3 port of the PPC valve
B2: To the lift cylinder bottom P2B : From the P4 port of the PPC valve
P1: From the work equipment pump

1. Solenoid valve

WA380-5 10-137
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

1. Cutoff valve assembly 7. Cutoff relief valve

2. Unload valve 8. Screen
3. Bucket spool 9. Safety valve with suction valve
4. Lift arm spool 10. Check valve
5. Check valve 11. Main relief valve
6. Suction valve

10-138 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit

Spool return spring Free length Installed Installed Free length Installed
12 (For bucket) length load load

54.8 53.5 125 N — —

{12.7 kg}

13 Spool return spring 54.8 52.2 235 N — —

(For bucket and lift arm) {24 kg}

14 Spool return spring 30.7 26.8 235 N — —

(For bucket and lift arm) {24 kg}
If spring is
15 Spool return spring 55.3 40.0 233 N — — damaged or
(For lift arm) {23.8 kg} deformed,
replace it
16 Spool return spring 86.8 83.5 208 N — —
(For lift arm) {21.2 kg}

17 Main valve spring of main 39.5 23.2 33.3 N — —

relief valve {3.4 kg}

18 Poppet spring of relief valve 49.3 41.9 259 N 47.8 208 N

{26.4 kg} {21.2 kg}

19 Check valve spring 32.6 24.5 44.1 N — —

{4.5 kg}

20 Suction valve spring 27.9 19.0 6.86 N — —

{0.7 kg}

WA380-5 10-139
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

2. 3-spool valve

T : Drain port (To the tank) P2 : From the switch pump (Steering valve)
A1: To the attachment cylinder P1A : From the attachment PPC valve
A2: To the bucket cylinder head P1B : From the attachment PPC valve
A3: To the lift cylinder head P2A : From the P1 port of the PPC valve
B1: To the attachment cylinder P2B : From the P3 port of the PPC valve
B2: To the bucket cylinder bottom P3A : From the P2 port of the PPC valve
B3: To the lift cylinder bottom P3B : From the P4 port of the PPC valve
P1: From the work equipment pump

1. Solenoid valve

10-140 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

1. Cutoff valve assembly 7. Suction valve

2. Unload valve 8. Cutoff relief valve
3. Attachment spool 9. Screen
4. Bucket spool 10. Safety valve with the suction valve
5. Lift arm spool 11. Check valve
6. Check valve 12. Main relief valve

WA380-5 10-141
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit

Spool return spring Free Installed Installed Free Installed

13 (For bucket and attachment) length length load length load

54.8 53.5 125 N — —

{12.7 kg}

14 Spool return spring 54.8 52.2 235 N — —

(For bucket and lift arm) {24 kg}

15 Spool return spring 30.7 26.8 235 N — —

(For bucket and lift arm) {24 kg}
If spring is
16 Spool return spring 55.3 40.0 233 N — — damaged or
(For lift arm) {23.8 kg} deformed,
replace it
17 Spool return spring 86.8 83.5 208 N — —
(For lift arm) {21.2 kg}

18 Main valve spring of main 39.5 23.2 33.3 N — —

relief valve {3.4 kg}

19 Poppet spring of relief valve 49.3 41.9 259 N 47.8 208 N

{26.4 kg} {21.2 kg}

20 Check valve spring 32.6 24.5 44.1 N — —

{4.5 kg}

21 Suction valve spring 27.9 19.0 6.86 N — —

{0.7 kg}

10-142 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

3. Relief valve

• When the hydraulic pressure inside the port A

and the port B reaches the set pressure of the
pilot poppet spring (4), the pilot poppet (3)
opens to let the hydraulic pressure of the port B
flow from the port D to the port C and the pres-
sure of the port B drops.

1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjusting screw

• When the pressure at the port B drops, pres-

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

WA380-5 10-143
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

4. Safety-suction valve

1. Suction valve • When abnormal pressure is generated in port

2. Main valve A, suction valve (1) does not operate since d2 >
3. Main valve spring d1. Main valve (2) receives the oil pressure cor-
4. Pilot piston responding to the area difference between d3
5. Suction valve spring and d4 of ports A and C, however, since d3 >
6. Valve body d4.
• If the oil pressure applied to main valve (2)
reaches the set pressure of main valve spring
(3), main valve (2) operates and the oil flows
Function
from port A to port B.
• The safety-suction valve is in the bucket cylin-
der circuit in the work equipment valve. When
the work equipment valve is in neutral, if any
impact is applied to the cylinder and abnormal
pressure is generated, that pressure is released
through this valve to protect the cylinder.
• If negative pressure is generated in the cylinder
circuit, this valve works as a suction valve.

Operation

(1) Operation as safety valve

• Ports A and B are connected to the cylinder cir-
cuit and drain circuit respectively.
• The oil pressure in port A is applied through
the hole of pilot piston (4) to port D. It is also
applied through the orifice consisting of main
valve (2) and pilot piston (4) to port C.
• Pilot piston (4) is fixed to the safety valve and
the diameters (sectional areas) are set in the fol-
lowing order; d2 > d1 > d3 > d4.

10-144 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

5. Suction valve
(2) Operation as suction valve
• If negative pressure is generated in port A, the
pressure in port D becomes negative since
those ports are connected to each other.
• Since the tank pressure of port B is applied to
port E, the safety valve receives oil pressure e
corresponding to the area difference between
d2 and d1.
• Accordingly, oil pressure is applied in the open-
ing direction of the valve and oil pressure a is
applied in the closing direction of suction valve
(1).
• If the pressure in port A lowers to near 0, it is
lower than oil pressure e.
• When oil pressure e becomes larger than the 1. Main poppet
total of oil pressure a and the force of valve 2. Sleeve
spring (5), suction valve (1) opens and the oil 3. Spring
flows from port B to port A to prevent genera-
tion of negative pressure in port A.
Function

• The suction valve prevents generation of nega-

tive pressure in the circuit.

Operation

• If negative pressure is generated in port A (lift

cylinder head) (If pressure lower than the pres-
sure in tank circuit port B is generated), main
poppet (1) opens because of the area difference
between d1 and d2, then the oil flows from
tank port B to cylinder port A.

WA380-5 10-145
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

6. Cut-off valve

Function

• The cut-off valve is installed between the

switching pump and work equipment valve. It
sends the oil from the switching pump to the
work equipment valve or drains it to control the
work equipment speed according to the work-
ing condition.
• The cut-off valve is operated with the hydraulic
system and the electronic governor controller.
• Operating condition of cut-off valve
c Cuts off (Drains oil)
± Does not operate (Sends oil to work
equipment valve)
Above Below When kick-
Mode 15.7 MPa 15.7 MPa down switch
{160 kg/cm²} {160 kg/cm²} is "ON"
Standard Hi c ± ±
specifica-
tion vehi- S c ± c
cle Lo c c c

Operation

(1) When work equipment valve is held

(When solenoid valve of hyper-specification
vehicle is turned OFF)
• The oil of the switching pump (The oil from the
steering valve) pushes up check valve (1) and
merges with the oil from the work equipment
pump and then flows into the work equipment
valve.
(2) When work equipment valve is operated
(When solenoid valve of hyper-specification
vehicle is turned OFF)

1) When work equipment pump pressure is lower

than cut-off pressure
• Similarly to the state where the work equip-
ment valve is held, the oil of the switching
pump (the oil from the steering valve) pushes
up check valve (1) and merges with the oil from
the work equipment pump and then flows into
the work equipment valve.

10-146 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

2) When work equipment pump pressure is (3) When solenoid valve is turned ON
higher than cut-off pressure • Since port SP is connected to the drain circuit,
• If the work equipment pump pressure reaches the pilot oil flows along the arrows.
the cut-off pressure, cut-off valve (2) is opened • Then, differential pressure is generated in
by the oil pressure in chamber a and then the unload valve (3) and it opens unload valve (3).
oil in chamber b of unload valve (3) is drained • Accordingly, the oil from switching pump (the
through chamber c of cut-off valve (2). oil from the steering valve) is always drained,
• Since the oil in chamber d of unload valve (3) regardless of the level of the work equipment
flows through orifices e and f to chamber b, the port pressure.
oil pressure in chamber d lowers and unload
valve (3) opens.
• Accordingly, the oil from the switching pump is
drained.

WA380-5 10-147
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

7. Operation of the work equipment control valve

(1) Neutral position of the lift arm and bucket spools

Operation

• The oil goes into the port A from the pump and • Although the oil coming from the PPC pump
the maximum pressure is being stipulated by goes into the port L of the PPC valve, as the lift
the relief valve (1). arm lever and the bucket lever are being set to
• As for the bucket spool (2), a bypass circuit is the holding position, the oil return to the
being opened for holding purpose and the oil hydraulic oil tank through the PPC relief valve.
coming from the port A passes around the
spool to flow into the port B.
• As for the lift arm spool (3) also, a bypass circuit
is being opened to make the neutral state and
the oil coming from the port B passes around
the spool to return to the tank through the drain
circuit.

10-148 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

(2) RAISE position of the lift arm spool

Operation
• When the lift arm lever (4) is pulled, the oil • After that, oil flow to the port D and further to
flows from the port L to the port N of the PPC the cylinder bottom.
valve and, from there, it goes into the port S of • The oil from the PPC valve flows through check
the work equipment control valve. valve (13) into port L of the PPC valve. Since
• Also, oil of the port T flow into the drain circuit the lift arm and bucket control levers are in the
passing through the port M. The pressurized hold position, however, the oil returns through
oil of the port S pushes the lift arm spool (3) to PPC relief valve (12) to the hydraulic tank.
the UP position.
• The oil coming from the pump passes through
the bypass circuit of the bucket spool (2) to flow
to the bypass circuit of the spool (3).
• Since the bypass circuit is being closed by the
spool (3), the oil pushes open the check valve
(5).

WA380-5 10-149
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

(3) LOWER position of the lift arm spool

Operation

• When the lift arm lever (4) is pushed, the oil • After that, oil flow to the port E and further to
flows from the port L to the port M of the PPC the cylinder head.
valve and, from there, it goes into the port T of • On the other hand, the oil in the cylinder bot-
the work equipment control valve. tom goes into the drain port F through the port
• Also, oil of the port S flow into the drain circuit. D to return to the tank. As the result, the lift
The pressurized oil of the port T pushes the lift arm goes down.
arm spool (3) to the LOWER position.
• The oil coming from the pump passes through
the bypass circuit of the bucket spool (2) to flow
to the bypass circuit of the spool (3).
• Since the bypass circuit is being closed by the
spool (3), the oil pushes open the check valve
(5).

10-150 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

(4) FLOAT position of the lift arm spool

Operation

• When the lift arm lever is pushed to the FLOAT • As the result, while the bucket is contacting the
position, the lift arm spool (3) further moves ground surface, the bucket can move up and
from the LOWER position to the FLOAT posi- down when the ground surface is uneven.
tion.
• The oil coming from the pump passes through
the bypass circuit of the bucket spool (2) to flow
to the bypass circuit of the lift arm spool (3).
• Because of the spool (3), the oil in the bypass
circuit flows into the drain circuit and the oil
cannot push-open the check valve.
• Also, since both of the lift cylinder RAISE circuit
D and the LOWER circuit E are being connected
to the drain circuit, the lift arm comes down by
its own weight.

WA380-5 10-151
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

(5) DUMP position of the bucket spool

Operation
• When the bucket lever (6) is pushed, the pres-
surized oil form the port L of the PPC valve • On the other hand, the oil in the bucket cylinder
flows into the port V of the work equipment bottom flow into the drain port F through the
control valve through the port Q. port G to return to the tank. As the result, the
bucket dumps.
• Also, the oil from the port R flows to the drain
circuit.
The pressurized oil from the port V moves the
bucket spool (2) to the DUMP position.
• Since the oil coming from the pump is being
closed by the spool (2), the oil from the port A
pushes the check valve (7) to let it open.
• The oil coming from the check valve (7) flows
into the bucket cylinder head through the port
H.

10-152 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

(6) TILT position of the bucket spool

Operation

• When the bucket lever (6) is pulled, the pressur- • The oil coming from the check valve (7) flows
ized oil form the port L of the PPC valve flows into the bucket cylinder bottom through the
into the port R of the work equipment control port G.
valve through the port P. • On the other hand, the oil in the bucket cylinder
• Also, the oil from the port V flows to the drain head flow into the drain port F through the port
circuit. H to return to the tank. As the result, the
The pressurized oil from the port R moves the bucket tilts.
bucket spool (2) to the TILT position.
• Since the oil coming from the pump is being
closed by the spool (2), the oil from the port A
pushes the check valve (7) to let it open.

WA380-5 10-153
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

WORK EQUIPMENT PPC VALVE

P : From HST charging pump

T : To hydraulic tank
P1 : To bucket TILT valve
P2 : To bucket DUMP valve
P3 : To lift arm RAISE valve
P4 : To lift arm LOWER (FLOAT) valve

10-154 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

1. Spool 9. Ring
2. Metering spring 10. Plate
3. Centering spring 11. Retainer
4. Spring 12. Piston
5. Retainer 13. Body
6. Solenoid 14. Ball
7. Rod 15. Detent spring
8. Lever 16. Retainer

WA380-5 10-155
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

Operation

1. When in NEUTRAL

(1) PPC valve for bucket (2) PPC valve for lift arm

• Ports PA and PB of the bucket control valve • Ports PA and PB of the lift arm control valve
and ports P1 and P2 of the PPC valve are con- and ports P3 and P4 of the PPC valve are con-
nected through fine control hole f of spool (1) nected through fine control hole f of spool (1)
to the drain chamber D. to the drain chamber D.

10-156 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

2. When in fine control

(NEUTRAL € Fine control)

• If rod (7) and piston (12) are pushed by lever (8),

retainer (11) is pushed and spool (1) is also
pushed down through metering spring (2).
• Accordingly, fine control hole f is disconnected
from drain chamber D and connected to pump
pressure chamber PP almost simultaneously,
and then the pilot oil of the main pump flows
from port P1 to port PB.
• If the pressure in port P1 rises, spool (1) is
pushed back and fine control hole f is discon-
nected from pump pressure chamber PP and
connected to drain chamber D almost simulta-
neously to release the pressure in port P1.
• As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port P1.
The positional relationship between spool (1)
and body (13) (where fine control hole f is
between drain chamber D and pump pressure
chamber PP) does not change until retainer
(11) comes in contact with spool (1).
• Since metering spring (2) is compressed in pro-
portion to the stroke of the control lever, the
pressure in port P1 rises in proportion to the
stroke of the control lever.
• Accordingly, the control valve spool moves to a
position at which the pressure in the chamber
PB (equal to the pressure in port P1) is bal-
anced with the force of the control valve spool
return spring.

WA380-5 10-157
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

3. When in fine control 4. When lever is operated to stroke end

(When control lever is returned)

• If lever (8) begins to return, the force of center- • If lever (8) and rod (7) push down piston (12)
ing spring (3) and the pressure in port P1 push and retainer (11) pushes down spool (1), fine
up spool (1). control hole f is disconnected from drain cham-
• As a result, fine control hole f is connected to ber D and connected to pump pressure cham-
drain chamber D and the oil in port P1 is ber PP.
released. • Accordingly, the pilot oil from the main pump
• If the pressure in port P1 lowers too much, flows through fine control hole f and port P1
spool (1) is pushed down by metering spring (2) into chamber PB and pushes the control valve
and fine control hole f is disconnected from spool.
drain chamber D and connected to pump pres- • The oil returning from chamber PA flows
sure chamber PP almost simultaneously. Then, through port P2 and fine control f' into drain
the pump pressure is applied until the pressure chamber D.
in port P1 is restored to the level corresponding
to the position of the lever.
• When the control valve spool returns, the oil in
drain chamber D flows in through fine control
hole f of the valve which is not in operation and
then flows through port P2 into chamber PA.

10-158 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

5. When lift arm is FLOATED 6. When FLOAT state of lift arm is reset

• If rod (7) and piston (12) on the LOWER side of • Lever (8) is returned from the FLOAT position
port P3 are pushed down by lever (8), ball (14) by pushing it down with a force greater than
touches projection a of rod (7) in the middle of the attractive force of solenoid (6) and retainer
the stroke (The detent starts to operate). (5).
• If rod (7) is pushed in further, ball (14) pushes • The FLOAT state also can be reset and the lever
up retainer (16) supported on detent spring (15) can be returned to the neutral position by turn-
and escapes out to go over projection a of the ing off the current in solenoid (6) (demagnetiz-
piston. ing the solenoid).
• At this time, rod (7) on the opposite side is • The lift arm RAISE and bucket TILT operations
pushed up by spring (4) through retainer (11). are carried out similarly to the above.
• If rod (7') is pushed up and the current is flow-
ing in solenoid (6), retainer (5) is attracted by
solenoid (6).
• Accordingly, rod (7') is kept pushed up and the
FLOAT state is kept even if the lever is released.
• At the same time, the control valve is also
moved to the FLOAT position and kept at that
position.

WA380-5 10-159
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE

PPC VALVE (FOR MULTI FUNCTION MONO LEVER)

P : From PPC accumulator

T : To hydraulic tank
P1 : To bucket TILT valve
P2 : To bucket DUMP valve
P3 : To lift arm RAISE valve
P4 : To lift arm LOWER (FLOAT) valve

10-159-1 WA380-5
1
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE

1. Spool 9. Plate
2. Metering spring 10. Retainer
3. Centering spring 11. Piston
4. Spring 12. Body
5. Retainer 13. Ball
6. Solenoid 14. Detent spring
7. Rod 15. Retainer
8. Disc

WA380-5 10-159-2
b
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE

OPERATION
1. At NEUTRAL
(1) PPC Valve for Bucket (2) PPC Valve for Lift arm

• PA and PB ports of the control valve for bucket • PA and PB ports of the control valve for lift arm
and P1 and P2 ports of the PPC valve lead to and P3 and P4 ports of the PPC valve lead to
the drain chamber D through the fine control the drain chamber D through the fine control
hole f of the spool (1). hole f of the spool (1).

10-159-3 WA380-5
b
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE

2. At Fine Control
(Neutral ­ Fine Control)
• When the rod (7) and the piston (11) are pressed
with the disc (8), the retainer (10) is also
pressed, and the spool (1) is pressed with the
metering spring (2) and moves downward.
• When the fine control hole f is interrupted from
the drain chamber D as a result of the down-
ward movement, it leads to the pump pressure
chamber PP almost at the same time. Then,
pilot pressure oil of the main pump is sent from
the P4 port to the PB port through the fine con-
trol hole f.
• When the pressure is increased at the port P4,
the spool (1) is pushed back, and when the fine
control hole f is interrupted from the pump
pressure chamber PP, it leads to the drain
chamber D almost at the same time, and the
pressure is released from the P4 port.
• Therefore, the spool (1) rises and falls so that
pressure at the P4 port balances with force of
the metering spring.
The positional relations between the retainer
(10) and the body (12) (the fine control hole f is
at the intermediate position between the drain
chamber D and the pump pressure chamber
PP) do not change until the retainer (10) gets to
the spool (1).
• Since the metering spring (2) is tightened in
proportion to control lever stroke, pressure at
the P4 port rises in proportion to the control
lever stroke.
• Therefore, the control valve spool moves to the
position where pressure of the PB chamber (the
same as pressure at the P4 port) balances with
force of the return spring of the control valve
spool.

WA380-5 10-159-4
b
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE

3. At Fine Control 4. At Full Stroke

(When the control valve is returned)
• As the disc (8) begins to be returned, the spool (1) • When the disc (8) and the rod (7) push the pis-
is pushed upward by the force of the centering ton (11) down and the retainer (10) pushes the
spring (3) and by the pressure at the P4 port. spool (1) down, the fine control hole f is inter-
• Therefore, the fine control hole f leads to the rupted from the drain chamber D and leads to
drain chamber D and pressured oil is released the pump pressure chamber PP. Therefore, the
from the P4 port. pilot pressure oil from the main pump passes
• When pressure at the P4 port drops too much, through the fine control hole f and is led to the
the spool (1) is pushed downward with the PB chamber from the P4 port to push the con-
metering spring (2) and the fine control hole f is trol valve spool.
interrupted from the drain chamber D and leads • The return oil from the PA chamber flows to the
to the pump pressure chamber PP almost at the drain chamber D through the P3 port and the
same time. And the pump pressure is supplied fine control hole f.
through the fine control hole f until the pres-
sure at the P4 port rises to the pressure accord-
ing to the lever position.
• When the control valve spool returns, oil flows
in through the fine control hole f’ of the valve
on the non-moving side from the drain cham-
ber D and is led to the PA chamber through the
P3 port for replenishment.

10-159-5 WA380-5
b
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE

5. At FLOAT 6. When FLOAT is released

• When the rod (7) and the piston (11) on the P4 • To return the disc from the FLOAT position,
port LOWER side are pushed downward with press it down with a force more than the
the disc (8), the ball (13) touches the rod (7) pro- adsorbing force between the solenoid (6) and
trusion a halfway in the stroke (the start of retainer (5).
detent operation). • Or demagnetize the solenoid (6), and the FLOAT
• When the rod (7) is pushed down more, the ball position is released and the lever returns to the
pushes the retainer (15) being held with the neutral position.
detent spring (14) upward and escapes outside • To raise the lift arm or to tilt the bucket, take the
and then rides over the piston protrusion a. same procedures.
• At this time, the rod (7') on the opposite side is
pushed up with the spring (4) through the
retainer (11').
• Also, the rod (7') is pushed up further, and
when the solenoid (6) is energized, the retainer
(5) is adsorbed to the solenoid (6).
• Therefore, the rod (7') remains pushed up and
keeps FLOAT even if the lever is no longer sup-
ported by hand.
• At the same time, the control valve also strokes
to the FLOAT position and comes to remain
floated.

WA380-5 10-159-6
b
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EPC
EPC SOLENOID
SOLENOID VALVE (IF(If
VALVE equipped)
EQUIPPED)

EPC SOLENOID VALVE (If equipped)

P : From control pump C2: Bucket DUMP

T : To tank C3: Lift arm RAISE
C1: Bucket TILT C4: Lift arm LOWER

1. Bucket TILT EPC 7. Spool

2. Bucket DUMP EPC 8. Spring
3. Lift arm RAISE EPC 9. Push pin
4. Lift arm LOWER EPC 10. Coil
5. Block 11. Plunger
6. Body 12. Connector

WA380-5
10-160 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EPC
EPC SOLENOID
SOLENOID VALVE (IF(If
VALVE equipped)
EQUIPPED)

Function Operation

• The EPC valve consists of the proportional sole- 1. When the signal current is 0 (Coil is de-
noid section and the hydraulic valve section. magnetized)
• On the receiving signal current from the pump • While the signal current from the controller is
controller, the EPC valve generates an EPC out- not flowing in coil (10), coil (10) is demagne-
put pressure in proportion to the signal current tized.
and applies it to the control valve. • Accordingly, spool (7) is pressed by spring (8)
to the right.
• Port P is closed and the hydraulic oil from the
control pump does not flow in the control valve.
• The oil from the work equipment control valve
is drained through parts C and T.

WA380-5 10-161
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EPC
EPC SOLENOID
SOLENOID VALVE (IF(If
VALVE equipped)
EQUIPPED)

2. When signal current is small (Coil is mag- 3. When signal current is maximum (Coil is
netized in fine control mode) magnetized in full operation.
• If a small signal current flows in coil (10), coil • If the signal current flows in coil (10), coil (10) is
(10) is magnetized and a thrust to the left is gen- magnetized.
erated in plunger (11). Since the signal current is at maximum, the
• Push pin (9) pushes spool (7) to the left and the thrust in plunger (11) becomes maximum.
hydraulic oil from port P flows in port C. • Accordingly, push pin (9) presses spool (7) to
• The pressure in port C rises. If the total of the the left.
force applied to face a of spool (7) and the load • As a result, the maximum hydraulic oil flows
of spring (8) exceeds the thrust of plunger (11), from port P to port C and the pressure in the
spool (7) is pushed to the right. circuit between the EPC valve and control valve
• Ports P and C are disconnected from each other becomes highest.
and port C and port T are connected to each • At this time, port T is closed and the oil does
other simultaneously. not flow in the tank.
• As a result, spool (7) moves to the right or left
until the thrust of plunger (11) is balanced with
the total of the pressure in port c and the load
of spring (8).
• Accordingly, the pressure in the circuit between
the EPC valve and control valve is controlled in
proportion to the signal current.
a Control valve

10-162 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SHUT
SHUT OFF
OFF VALVE (IF(If
VALVE equipped)
EQUIPPED)

SHUT OFF VALVE (If equipped)

Function
A : To EPC valve • If the signal from the controller is turned on, the
P : From pilot circuit pump (Pump from EPC) shut-off valve is turned on to connect the oil
T : To hydraulic tank path from the pilot circuit pump to the EPC
valve.

WA380-5 10-163
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ATTACHMENT
ATTACHMENT PPC
PPC VALVE
VALVE (IF(If equipped)
EQUIPPED)

ATTACHMENT PPC VALVE (If equipped)

T : To the tank P1: To the service valve

P : From the main pump P2: To the service valve

1. Spool 6. Plate
2. Metering spring 7. Retainer
3. Centering spring 8. Body
4. Piston 9. Filter
5. Lever

10-164 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ATTACHMENT
ATTACHMENT PPC
PPC VALVE
VALVE (IF(IfEQUIPPED)
equipped)

Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit

Free length Installed Installed Free Installed
10 Center ring spring x If spring is
Outside diameter length load length load damaged or
deformed,
41.1 X 15.5 28.4 38.0 N — 30.4 N replace it
{3.88 kg} {3.1 kg}

11 Metering spring 22.7 X 8.10 22.0 16.7 N — 13.3 N

{1.70 kg} {1.36 kg}

WA380-5 10-165
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ATTACHMENT
ATTACHMENT PPC
PPC VALVE
VALVE (IF(IfEQUIPPED)
equipped)

Operation

1. At the neutral position

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

2. At the fine control position

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

10-166 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ATTACHMENT
ATTACHMENT PPC
PPC VALVE
VALVE (IF(IfEQUIPPED)
equipped)

3. At the fine control position (When the 4. At full stroke

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

WA380-5 10-167
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR

COOLING FAN MOTOR

Model: LMF28

P : From fan pump

T : From cooler to tank
TC: To tank

Specifications
Model : LMF28
Capacity : 28.0 cc/rev
Rated speed : 1,400 rpm
Rated flow : 40 l/min
Cracking pressure of check valve : 0.044 MPa {0.45 kg/cm²}

10-168 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR

1. Output shaft 8. End cover

2. Case 9. Center spring
3. Thrust plate 10. Check valve spring
4. Shoe 11. Check valve
5. Piston 12. Pilot valve
6. Cylinder block 13. Changeover spool
7. Valve plate 14. Changeover spool spring

Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit

Free length Installed Installed Free Installed If spring is
10 Check valve spring x length load length load damaged or
Outside diameter deformed,
3.43 N 2.55 N replace it
13.0 x 6.5 7.0 {0.35 kg} — {0.26 kg}

WA380-5 10-169
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR

1. HYDRAULIC MOTOR
Function
• This hydraulic motor is a swash plate-type axial
piston motor, which converts the pressure of
the hydraulic oil sent from the hydraulic pump
into revolution.

Principle of operation

• The oil sent from the hydraulic port flows

through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the Y-Y line
connecting the top dead center and bottom
dead center of the stroke of piston (4).
• The oil sent to one side of cylinder block (5)
presses pistons (4) (2 or 3 pieces) and generates
force F1 (F1 kg = P kg/cm² x π/4 D2 cm²).
• This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of Eo
degrees to the output shaft (1), the force is
divided into components F2 and F3.
• The radial component F3 generates torque
against the Y-Y line connecting the top dead
center and bottom dead center (T = F3 x ri).
• The resultant of this torque [T = Σ(F3 x ri)]
rotates the cylinder block (5) through the piston.
• Since the cylinder block (5) is coupled with the
output shaft by means of spline, the output
shaft revolves to transmit the torque.

10-170 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR

2. SUCTION VALVE
(2) When pump is stopped
Function
• If the engine is stopped and the input revolution
• If the fan pump stops, the hydraulic oil does not of the fan pump lowers to 0 rpm, the hydraulic
flow into the motor. Since the motor continues oil from the pump is not supplied to port P any
revolution because of the force of inertia, how- more. As the hydraulic oil is not supplied to the
ever, the pressure on the outlet side of the MA side of the motor, the motor speed lowers
motor rises. gradually to stop.
• When the oil stops flowing in from inlet port P, • If the motor shaft is revolved by the force of
the suction valve sucks in the oil on the outlet inertia while the oil flow in the port P is reduc-
side and supplies it to the port MA where there ing, the oil in port T on the outlet side is sent by
is not sufficient oil to prevent cavitation. the suction valve to the MA side to prevent cav-
itation.
Operation

(1) When pump is started

• If the hydraulic oil from the pump is supplied to

port P and the pressure on the MA side rises
and starting torque is generated in the motor,
the motor starts revolution. The oil on the out-
let MB side of the motor returns through port T
to the tank.

WA380-5 10-171
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR

3. OPERATION OF REVOLUTION
DIRECTION CHANGEOVER
VALVE
(1) When ON-OFF solenoid for changeover (2) When ON-OFF solenoid for changeover
valve is turned OFF valve is turned ON

• If ON-OFF solenoid (1) for changeover valve is • If ON-OFF solenoid (1) for changeover valve is
turned "OFF", the hydraulic oil from the pump is turned "ON", ON-OFF changeover valve (2)
blocked by ON-OFF changeover valve (2) and changes to let the hydraulic oil from the pump
port C is connected to the tank circuit. flow through port C into spool chamber D.
• Accordingly, changeover spool (3) is pushed by • The hydraulic oil in chamber D pushes
changeover spool spring (4) to the right to open changeover spool (3) against changeover spool
motor port MA and then the hydraulic oil flows spring (4). As a result, motor port MB opens
in to revolve the motor forward (clockwise). and the hydraulic oil flows in to revolve the
motor in reverse (counterclockwise).

10-172 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP

COOLING FAN MOTOR DRIVE PUMP

Model: LPV30

P : EPC valve main pressure TO : Drain

PS: Suction port of pump PHO: Discharge port of pump

1. Bleeder

WA380-5 10-173
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE 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

10-174 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP

Function

• This pump converts the revolution and torque • The oil in each cylinder of cylinder block (7) can
of the engine transmitted from its shaft into be drawn and discharged through valve plate
hydraulic energy and discharges hydraulic oil (8).
according to the load.
• The discharge amount can be changed by
changing the swash plate angle.

Structure

• Cylinder block (7) is supported on shaft (1)

through spline a. Shaft (1) is supported on the
front and rear bearings.
• The end of piston (6) has a concave sphere,
which holds shoe (5) as a spherical bearing.
• Rocker cam (4) has plane A. Shoe (5) is kept
pressed against plane A and slide circularly.
Rocker cam (4) slides around ball (11).
• Piston (6) moves axially and relatively in each
cylinder of cylinder block (7).
• Cylinder block (7) revolves relatively against
valve plate (8), sealing the hydraulic oil. The
hydraulic pressure on the revolving surface of
the cylinder block is balanced properly.

WA380-5 10-175
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP

Operation

1. Operation of pump

• Shaft (1) and cylinder block (7) revolve together • If center line X of rocker cam (4) is in the direc-
and shoe (5) slides on plane A. As rocker cam tion of the axis of cylinder block (7) (Swash
(4) slants around ball (11) at this time, angle α plate angle = 0), the difference between vol-
between the center line X of rocker cam (4) and umes E and F in cylinder block (7) is 0 and oil is
axis of cylinder block (7) changes. Angle α is not sucked or discharged (The swash plate
called the swash plate angle. angle is not reduced to 0 actually, however).
• If the angle between the center line X of rocker • In short, swash plate angle α is in proportion to
cam (4) and the axis of cylinder block (7) is α, the discharge of the pump.
plane A works as a cam for shoe (5).
• Accordingly, each piston (6) slides inside cylin-
der block (7) and makes difference between vol-
umes E and F in cylinder block (7) and the oil is
drawn and discharged by the difference.
• In short, if cylinder block (7) revolves and vol-
ume of chamber E is reduced, the oil is dis-
charged. On the other hand, the volume of
chamber F is increased and the oil is sucked.
(The figure shows the end of suction process of
chamber F and the end of discharge process of
chamber E.)

10-176 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP

2. Control of discharge

• If swash plate angle α is increased, the differ-

ence between volumes E and F, or discharge Q,
is increased. Swash plate angle Eo is changed
with servo piston (10).
• Servo piston (10) is reciprocated linearly by the
signal pressure of the servo valve. This linear
motion is transmitted to rocker cam (4). Rocker
cam (4) supported on ball (11) rocks around ball
(11).

WA380-5 10-177
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP

SERVO VALVE

P : EPC valve main pressure

T : Drain
PE: Control piston pressure
PH: Pump discharge pressure

1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve

10-178 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP

Function • Then, the cut of spool (5) connects the land of

the piston pressure path to the pump discharge
• The servo valve controls the relationship pressure path and then the discharge oil is sent
between the current input to the EPC valve and to the servo piston.
the swash plate angle as shown below. • The servo piston is pushed up by the rocker
cam. Then, position feedback is applied and the
lever moves in the direction to compress the
spring.
• If spool (5) is pushed back, the pump discharge
circuit is disconnected from the servo piston
circuit and the pressure in the servo piston
chamber lowers and then the rocker cam
returns toward the maximum swash plate
angle.
• These processes are repeated to fix the swash
plate to the position at which the EPC output
pressure is balanced with the spring force.
• Accordingly, as the EPC output pressure is
• The output oil of the EPC valve flows in the pis- increased or decreased, the swash plate angle
ton chamber to push piston (6). Piston (6) is narrowed or widened.
pushes spool (5) until it is balanced with the
spring.

WA380-5 10-179
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP

SAFETY VALVE

Function

• The discharge pressure of the fan pump rises

when the engine is started and when the fan is
reversed to stop.
• The safety valve is installed to protect the fan
system circuit at these times.
• If the discharge pressure rises above the crack-
ing pressure of the safety valve, the seat of the
safety valve opens to release the oil into the
drain path to prevent generation of abnormally
high pressure in the discharge port.

10-180 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE

WORK EQUIPMENT LINKAGE

WA380-5 10-181
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE

1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
Unit: mm
No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between bushing size clearance limit
7 and pin at each end of bucket Shaft Hole
link
85 -0.036 +0.207 0.156 - 1.0
-0.090 +0.120 0.297
Clearance between bushing -0.036 +0.207 0.156 -
8 and pin of joint of lift arm and 85 -0.090 +0.120 0.297 1.0
bucket
Clearance between bushing -0.036 +0.207 0.156 -
9 and pin of joint of lift arm and 95 -0.090 +0.120 0.297 1.0
frame
Clearance between bushing Replace
10 and pin of joint of bucket cylin- 110 -0.036 +0.207 0.156 - 1.0 (Replace if pin
der bottom and frame -0.090 +0.120 0.297 has scuff mark)
Clearance between bushing -0.036 +0.207 0.156 -
11 and pin of joint of bucket cylin- 110 -0.090 +0.120 0.297 1.0
der rod and lever
Clearance between bushing
12 and pin of joint of bell crank 120 -0.036 +0.245 0.181 - 1.0
and lift arm -0.090 +0.145 0.335

Clearance between bushing -0.036 +0.207 0.156 -

13 and pin of joint of lift cylinder 95 1.0
rod and lift arm -0.090 +0.120 0.297

Clearance between bushing -0.036 +0.207 0.156 -

14 and pin of joint of lift cylinder 95 -0.090 +0.120 0.297 1.0
bottom and frame

Width of boss Width of hinge

Standard
Joint of bucket cylinder and Standard Standard clearance
15 size Tolerance size Tolerance
frame

110 -0 114 ±1.5 2.5-6.0

-0.5 Replace (Insert
shims on both
16 Joint of lift arm and frame 122 — 129 +3 7.0-10.0 sides so that
+0 clearance will be
1.5 mm or less
17 Joint of lift arm and bucket 106 — 108 +1.5 2.0-3.5 on each side)
0

18 Joint of bucket link and bucket 112.5 +2.8 116 +1.5 0.7-5.5
-0.5 0

19 Joint of lift cylinder and frame 90 -0 93.5 +3 3.5-7.0

-0.5 +0

20 Joint of bell crank and bucket 112.5 +2.8 117 ±1.5 1.7-6.5
link -0.5
Replace
+2
21 Joint of bell crank and lift arm 220 +0 223 ±0.5 0.5-3.5

Joint of bucket cylinder and -0 Adjust clearance

22 bell crank 110 -0.5 117 ±1.5 5.5-9.0 on each side to
1.5 mm or less
Adjust clearance
23 Joint of lift arm and lift cylinder 100 — 106 ±1.5 4.5-7.5 on each side to
2.0 mm or less

10-182 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET

BUCKET

1. Bucket
2. Bolt-on cutting edge
3. Bucket tooth

Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit

4 Wear of bucket tooth Replace
50 18.5

5 Clearance of fitting part of Max. 0.5 — Adjust or

bucket tooth replace

6 Wear or cutting edge 93 — Turn over or

replace

WA380-5 10-183
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, BOOM KICK-OUT

BUCKET POSITIONER, BOOM KICK-OUT

1. Proximity switch
2. Bucket cylinder rod
3. Lever
4. Plate

Unit: mm
No. Check item Criteria Remedy

5 Clearance of bucket positioner 3-5

switch
Adjust
6 Clearance of boom kick-out 3-5
switch

10-184 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, BOOM KICK-OUT

Bucket positioner Boom kick-out

• The bucket positioner is operated electrically • The boom kick-out is operated electrically and
and used to return the bucket control lever from used to return the lift arm control lever to the
the TILT position to the HOLD position to obtain hold position to stop the lift arm when the lift
proper digging angle automatically when the arm moves to any position before the maxi-
bucket is moved from the DUMP position to any mum position.
bucket angle before the TILT position. • Plate (4) is fixed to the lift arm and proximity
• Lever (3) is bolted to bucket cylinder rod (2) and switch (1) is fixed to the frame.
proximity switch (1) is bolted to the cylinder. If the lift arm control lever is moved from the
• If the bucket control lever is moved from the lower position to the raise position, the lift arm
DUMP position toward the TILT position, the is raised. When the proximity switch and plate
bucket cylinder rod moves to the front side of come near each other at any point, the switch
the vehicle body and lever (3) moves forward, operates to return the lift arm control lever to
too. When proximity switch (1) leaves lever (3) the hold position.
at any point, the switch operates to return the
bucket control lever to the neutral position.

WA380-5 10-185
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, BOOM KICK-OUT

Operation of proximity switch

When lift arm is raised

• When lift arm (3) is lower than the set position • If lift arm control lever (7) is moved to the raise
of the boom kick-out, plate (2) is not on the position, lift arm spool (8) is moved to the posi-
detection plane of proximity switch (1). Boom tion of the arrow and held at that position by
kick-out relay (4) is turned off and the current the coil turned on by detent solenoid (6). As a
flows in detent solenoid (6) of PPC valve (5) and result, lift arm control lever (7) is held at the
the coil is turned on. RAISE position and lift arm (3) is raised.

10-186 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, BOOM KICK-OUT

• If lift arm (3) is raised to the set position of the

kick-out, or if plate (2) reaches the detection
plane of proximity switch (1), proximity switch
(1) lights up and boom kick-out relay (4) is
turned on. As a result, the circuit of detent sole-
noid (6) of PPC valve (5) is turned off and the
coil is turned off. Accordingly, held lift arm
spool (8) receives the reaction force of spring
(9) and returns lift arm control lever (7) to the
neutral position.

Operation of proximity switch

When part to be detected is apart from detection

plane of proximity switch
Pilot lamp of proximity switch OFF

Boom kick-out relay switch circuit OFF

PPC valve detent solenoid circuit ON

PPC valve detent solenoid ON

When part to be detected is on detection plane of

proximity switch
Pilot lamp of proximity switch ON

Boom kick-out relay switch circuit ON

PPC valve detent solenoid circuit OFF

PPC valve detent solenoid OFF

WA380-5 10-187
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, BOOM KICK-OUT

When bucket is tilted

• When the bucket is tilted more than the set • If bucket control lever (7) is moved to the TILT
position of the bucket leveler, lever (2) is on the position, DUMP spool (8) is moved to the posi-
detection plane of proximity switch (1) and tion of the arrow and held at that position by
proximity switch (1) lights up. At this time, the coil turned on by detent solenoid (6). As a
bucket positioner relay (4) is turned on and the result, bucket control lever (7) is held at the TILT
current flows in detent solenoid (6) of PPC valve position and the bucket is tilted.
(5) and the coil is turned on.

10-188 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, BOOM KICK-OUT

• If the bucket is tilted to the set position of the

bucket leveler, or if lever (2) leaves the detec-
tion plane of proximity switch (1), the lamp of
proximity switch (1) goes off and lift arm kick-
out relay (4) is turned off. As a result, the circuit
of detent solenoid (6) of PPC valve (5) is turned
off and the coil is turned off.
Held dump spool (8) receives the reaction force
of spring (9) and returns bucket control lever (7)
to the NEUTRAL position.

Operation of proximity switch

When part to be detected is apart from detection

plane of proximity switch
Pilot lamp of proximity switch ON

Bucket positioner relay switch cir-

cuit ON

PPC valve detent solenoid circuit ON

PPC valve detent solenoid ON

When part to be detected is on detection plane of

proximity switch
Pilot lamp of proximity switch OFF

Bucket positioner relay switch circuit OFF

PPC valve detent solenoid circuit OFF

PPC valve detent solenoid OFF

WA380-5 10-189
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER

WORK EQUIPMENT CYLINDER

LIFT CYLINDER

BUCKET CYLINDER

Unit: mm
No. Check item Criteria Remedy

Tolerance
Name of Standard Standard Clearance
cylinder size clearance limit
Clearance between Shaft Hole
1 piston rod and Replace
bushing -0.036 +0.257 0.084 - bushing
Lift 90 -0.090 +0.048 0.347 0.647

Bucket 90 -0.036 +0.257 0.084 - 0.647

-0.090 +0.048 0.347

Lift 95 -0.036 +0.35 0.236 - 1.0

Clearance between -0.090 +0.20 0.440
2 piston rod support
shaft and bushing Bucket 110 -0.036 +0.207 0.156 -
1.0
-0.090 +0.120 0.297 Replace pin
-0.036 +0.207 0.156 - and bushing
Clearance between Lift 95 1.0
cylinder bottom -0.090 +0.120 0.297
3 support shaft and
Bucket 110 -0.036 +0.207 0.156 - 1.0
bushing -0.090 +0.120 0.297

Tightening torque Lift 250±24.5 Nm {25.5±2.5 kgm}

4 of cylinder head Bucket 343±34.3 Nm {35±3.5 kgm}

Tightening torque Lift 294±29.4 Nm {30±3.0 kgm}

5 of cylinder piston Retighten
Bucket 294±29.4 Nm {30±3.0 kgm}
Tightening torque Lift 58.9–73.6 Nm {6.0–7.5 kgm}
6 of fixed screw of
cylinder piston Bucket 58.9–73.6 Nm {6.0–7.5 kgm}

10-190 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CAB

CAB

1. Front glass
2. Front windshield wiper
3. Rear windshield wiper
4. Door
5. Air conditioner filter (If equipped)
6. Antenna (If equipped)

WA380-5 10-191
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AIR
AIR CONDITIONER
CONDITIONER (IF(If equipped)
EQUIPPED)

AIR CONDITIONER (If equipped)

AIR CONDITIONER PIPING

1. Air outlet duct 7. Air compressor

2. Fresh air suction duct 8. Hot water return piping
3. Inside air suction filter 9. Refrigerant piping
4. Inside-Fresh air changeover damper 10. Hot water take-off piping
5. Receiver tank 11. Air conditioner unit
6. Air conditioner condenser 12. Floor duct

10-192 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

MACHINE MONITORING SYSTEM

Outline
• The machine monitor system uses the sensors • Normal mode indications are those which are
and other devices installed to various parts of usually being made for ordinary use by the
the machine to observe the condition of the machine operators. The description below
machine. It processes this information swiftly applies to the contents of the main indications.
and displays it on the monitor panel to inform
the operator of the condition of the machine. 1. Items which are always indicated
• The machine monitor is available in two differ- • Meters (Travel speedometer or engine
ent specifications, the standard specification tachometer)
and the load meter specification. As to the load • Gauges (Engine coolant temperature gauge,
meter specification, machine monitor functions torque converter oil temperature gauge,
are being supplemented to carry out the neces- hydraulic oil temperature gauge and fuel
sary load meter calculations and relevant indi- level gauge)
cations, with an optional printer for printing out • Pilot indications
of the calculated data of the load meter. • Service meter
• The indications of the machine monitor will be
made under the normal mode and under the 1) Load meter specification items which are
always indicated
service mode.
(Items which are indicated in addition to the
• The machine monitor has ON/OFF output func- standard spec. indications)
tion of automatic preheating which assists with • Weight calculated by the load meter
the starting of the engine. • Time
2. Items which will be indicated only when some
abnormality occurs
• Cautions
• Action code indications (When the machine
monitor mode changeover switch (>) is
depressed and released while the action
code is being indicated, the failure code (6
digits) will be indicated.)

3. When the time comes to change the filter or oil,

necessary items for the filter change or oil
change will be indicated on the character dis-
play. (Maintenance monitoring functions)

4. In addition to the above, this system is

equipped with the functions to indicate the
travel distance integrating meter (odometer), to
reset the filter • oil changing time, to select the
telephone number inputting language and to
adjust the illuminance of the night time illumi-
nation for the machine monitor, by use of the
character display and its operation switch, the
machine monitor mode changeover switch.
1) Other functions under the load meter speci-
fication
With the load meter specification system,
functions necessary to make changeovers
of the load meter indication mode, to make
changeovers of the printer output mode, to
execute calibration of the load meter, and to
adjust the clock time are being supple-
mented in addition to the standard specifi-
cation functions.

WA380-5 10-193
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

• This machine monitoring system is equipped • The machine monitoring system consists of the
with the service mode function to facilitate the machine monitor proper, buzzer, and switches
troubleshooting work for respective controllers that are used for inputting data to the machine
(including the machine monitor itself) on the monitor proper, sensors, respective controller
network. The description below applies to the on the network, and relevant switches and sen-
contents of the main functions. sors.

1. Electric fault history

This function will indicate the electric fault his-
tory data of respective controllers being memo-
rized by the machine monitor. Also, it can be
used to delete the aforementioned data.

2. Machine fault history

This function will indicate the machine fault his-
tory and machine fault history data of respec-
tive controllers being memorized by the
machine monitor.

3. Real time monitor

This function will make real time indications of
the inputting data and outputting data being
recognized by respective controllers on the net-
work.

4. Tuning
This function is to be used for compensation
and adjustment of the installation errors and
dispersions in the manufacturing processes of
individual parts of sensors, proportional elec-
tromagnetic valves.

5. Revising the filter • oil changing time

This function is to be used for revisions of the
preset filter and oil changing time. (Revision of
the time for the maintenance monitor opera-
tion)

6. Controller initializing function

This function is being used to effect the settings
of this machine monitor before shipment from
our factory.

10-194 WA380-5
(9)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

Individual circuit diagrams of the machine monitor

Starting and lighting functions

Load meter

WA380-5 10-195
(9)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

Sensing functions

10-196 WA380-5
(9)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

Power supply and network

WA380-5 10-197
(9)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

Automatic preheating function

10-198 WA380-5
(9)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

S-net input S-net signal using items

Machine monitor Transmission controller Work equipment

S-net output controller
Hydraulic oil temperature Fan pump control
Coolant temperature Fan pump control
Torque converter temperature Fan pump control
Emergency steering self-
Emergency steering operation signal checks
Sensor adjusting mode signal Compensation Compensation
Machine monitor

Monitor mode switch

signal Compensation Compensation

Emergency steering self-

Automatic pre-heating start signal checks
Transmission trigger resetting signal Learning control
Machine model Machine model Machine model
selection selection selection
Tire selection Tire selection Tire selection
Tire compensation Tire compensation Tire compensation
Communication Communication
Controller specification
selection selection
Option specification Option selection Option selection
FNR lever or seesaw switch signal FNR indications

FNR solenoid output signal Actual speed stage indica-

tions
1, 2, 3 and 4 lever position signals 1 2 3 4 lever positions

1, 2, 3 and 4 solenoid output signal Actual speed stage indica-

tions
FNR seesaw switch selection signal Indicator
Transmission hold signal Indicator
Transmission controller

Auto-shifting selection signal Indicator

Lock up selection signal Indicator
E.C.S.S. signal Indicator
Fan reversing signal Indicator
Power mode signal Indicator
Trigger learned signal Hearing control
Transmission failure code Character inductance
Engine revolution signal Engine tachometer
Travel speed signal Travel speedometer
Kick down switch signal Semi-auto digging
Kick down mode signal Semi-auto digging
Buzzer signal Operation buzzer
I/O state signals Real time monitor
Semi-auto digging signal Indicator
equipment
controller
Work

Joystick neutral signal Neutral cut

Buzzer signal Operation buzzer
I/O status signal Real time monitor

WA380-5 10-199
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR

MACHINE MONITOR
SPEEDMETER SPECIFICATIONS

1. Torque converter oil temperature gauge 22. Maintenance caution lamp

2. Torque converter oil temperature caution lamp 23. Battery electrolyte level caution lamp
3. Engine coolant temperature gauge 24. Battery charge circuit caution lamp
4. Engine coolant temperature caution lamp 25. Steering oil pressure caution lamp
5. Speedometer or engine tachometer 26. Emergency steering pilot lamp
6. Turn signal pilot lamp (left) 27. Character display
7. Headlamp high beam pilot lamp 28. Output mode pilot lamp
8. Turn signal pilot lamp (right) 29. Semi auto digging pilot lamp
9. Hydraulic oil temperature caution lamp 30. Preheating pilot lamp
10. Hydraulic oil temperature gauge 31. Auto greasing pilot lamp
11. Fuel level caution lamp 32. Joystick pilot lamp
12. Fuel gauge 33. Directional selector pilot lamp
13. Central warning lamp 34. Shift indicator
14. Brake oil pressure caution lamp 35. Auto-shift pilot lamp
15. Engine oil pressure caution lamp 36. Lockup pilot lamp
16. Engine oil level caution lamp 37. Shift hold pilot lamp
17. Radiator coolant level caution lamp 38. Shift lever position pilot lamp
18. Air cleaner clogging caution lamp 39. Brake oil level caution lamp
19. Parking brake pilot lamp 40. Transmission oil filter clogging caution lamp
20. Axle oil temperature caution lamp
21. Cooling fan reverse rotation pilot lamp

10-200 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR

LOAD METER SPECIFICATION (If equipped)

1. Torque converter oil temperature gauge 23. Battery electrolyte level caution lamp
2. Torque converter oil temperature caution lamp 24. Battery charge circuit caution lamp
3. Engine coolant temperature gauge 25. Steering oil pressure caution lamp
4. Engine coolant temperature caution lamp 26. Emergency steering pilot lamp
5. Speedometer or engine tachometer 27. Character display
6. Turn signal pilot lamp (left) 28. Output mode pilot lamp
7. Headlamp high beam pilot lamp 29. Semi auto digging pilot lamp
8. Turn signal pilot lamp (right) 30. Preheating pilot lamp
9. Hydraulic oil temperature caution lamp 31. Auto greasing pilot lamp
10. Hydraulic oil temperature gauge 32. Joystick pilot lamp
11. Fuel level caution lamp 33. Directional selector pilot lamp
12. Fuel gauge 34. Shift indicator
13. Central warning lamp 35. Auto-shift pilot lamp
14. Brake oil pressure caution lamp 36. Lockup pilot lamp
15. Engine oil pressure caution lamp 37. Shift hold pilot lamp
16. Engine oil level caution lamp 38. Shift lever position pilot lamp
17. Radiator coolant level caution lamp 39. Brake oil level caution lamp
18. Air cleaner clogging caution lamp 40. Transmission oil filter clogging caution lamp
19. Parking brake pilot lamp 41. Bucket load indication
20. Axle oil temperature caution lamp 42. Work indication
21. Cooling fan reverse rotation pilot lamp 43. Addition mode: Gross load indication
22. Maintenance caution lamp Subtraction mode: Residual amount indica-
tion

WA380-5 10-201
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STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR

TABLE OF MONITOR INDICATION ITEMS

Determination conditions if the engine is in operation: c: Turns on.
The engine is to be deemed in operation when 2 of the : Flashes. (1.6sec 50% Duty)
following 3 conditions are being established.
1. Charge is normal. ✩: Intermittent (Cycle 240msec. ON 80msec. OFF
2. Engine oil pressure is normal. 160msec.)
3. History of occurrence of IGN_C = 24V when the starting U: According to separately set conditions.
key was turned is being registered.

Operation status
Engine in
Engine stopped operation

Indication color
Concentrated warning

Concentrated warning
Night time

Individual indications

Individual indications
Message indication

Message indication
dimming

Warning buzzer

Warning buzzer
Category No. Items Device Operating conditions Remarks
c: Occurs.
—: Does
not occur.

To be turned on by
Concen- respective controllers
trated Concentrated
When an error occurs U U U U U U U U Red and message will be
warning 13 warning lamp
LED c indicated simulta-
neously.
lamp
Other cases than above — — — — — — —

When the small lamp is

Back light — Back light LED c turning ON — — — — — — Orange

The status will be main-

Engine revolution Pointer: tained until the starting
(Speedmeter — — — — — — — — key is turned OFF when
specification) Movement a communication error
is occurring.
5
(Can be
Travel speed switched over "0" will be indicated in
(Speedmeter between the — — — — — — — case of communication
specification) engine revo- error.
lution.)

Pointer: Other cases than below — — — — — — —

11
12
Fuel quantity Movement c
Indicator: LED 80 Ω or more — c — — c — Red

Other cases than below — — — — — — —

Pointer: White range:
10 Hydraulic oil tem- Movement
c Warning: 110°C or more  c c B@HANS  c c B@HANS Red 50 - 110°C
9 perature Indicator: LED Red range:
Gauge 110 - 135°C
When abnormality is
Meter detected — — — DGH2KX — — — DGH2KX —

Other cases than below — — — — — — —

Warning: 102°C or more — c — — c — Red White range:
3 Engine coolant Pointer: 50 - 102°C
Movement c
4 temperature
Indicator: LED Warning: 105°C or more  c c B@BCNS  c c B@BCNS Red Red range:
102 - 135°C
When abnormality is
detected — — — DGE2KX — — — DGE2KX —

Other cases than below — — — — — — —

Warning: 120°C or more — c — — c — Red White range:
1 Pointer:
Torque converter Movement 50 - 120°C
c
2 oil temperature Indicator: LED Warning: 130°C or more  c c B@BCNS  c c B@BCNS Red Red range:
120 - 135°C
When an abnormality is
detected — — — DGE2KX — — — DGE2KX —

Turns on when the engine

revolution is selected
— Engine speed LED c under the service mode — — — — — — Green X r/min
optional select
Unit
To be set to by use of the
rotary switch on the moni-
— Travel speed LED c tor while engine revolu- — — — — — — Green km/h or MPH
tion is not being selected

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Operation status
Engine in
Engine stopped operation

Indication color
Concentrated warning

Concentrated warning
Night time

Individual indications

Individual indications
Message indication

Message indication
dimming

Warning buzzer

Warning buzzer
Category No. Items Device c: Occurs. Operating conditions Remarks
—: Does
not occur.

Upper digits: F, N, R
Lower digits: Speed
stages
Actual gear shift 9 segment Indication will be main- Speed stage indication
34 stage LCD — tained until the starting — — — — — — — will not be made while
at the "N" stage.
key is turned OFF when a
combination error has
occurred.

"F" is being selected

F LED c (Neutral safety indication ✩ c c — c — Green
when engine is stopped)

N LED c "N" is being selected — c — — c — Orange

"R" is being selected

R LED c (Neutral safety indication ✩ c c — c — Green
Indication will be main-
when engine is stopped)
Shift lever tained until the starting
38 When the 4th speed is key is turned OFF when
positions 4 LED c being selected — c — — c — Green a combination error has
occurred.
When the 3rd speed is
3 LED c being selected — c — — c — Green

When the 2nd speed is

Speed 2 LED c being selected — c — — c — Green
shifting
When the 1st speed is
opera- 1 LED c being selected — c — — c — Green
tions
When auto-shift is being
selected — c — — c — Green Indication will be main-
tained until the starting
35 Auto-shift LED c key is turned OFF when
a combination error has
Other cases than above — — — — — — — occurred.

When auto-shift and shift Indication will be main-

hold is being selected — c — — c — Green tained until the starting
37 Shift hold LED c key is turned OFF when
Other cases than above — — — — — — — aoccurred.
combination error has

When the lock up function Green The LED will not turn on
is in operation — — — — c — in case of machines
Torque converter without lock up mecha-
nism. Indication will be
36 lockup LED c maintained until the
(Optional) starting key is turned
OFF when a combina-
Other cases than above — — — — — — — tion error has occurred.

Interlocked with the

When blinker switch is
being turned ON blinker switch
6 Green ((Hazard
lamp) will also
8
Turn signal LED c (including the time when — c — — c — be turned ON when the
the starting key is turned
OFF) starting key is turned
OFF.)

When high beam is being

turned ON
(When the headlamp is
7 High beam LED c turned ON and, also, when — c — — c — Blue
the high beam is turned
ON)

Normal voltage — — — — — — —
When the abnormality
was detected while the
Other 24 Battery charge LED c Charging trouble  c c AB00AMA Red engine is stopped, the
symbols alarm will continue after
starting the engine also.
When an abnormality is
detected  c c AB00L6 — — — Red

Normal oil level (CLOSE) — — — — — — — Low oil level alarm is

sounded when the start-
ing key is turned ON,
16 Engine oil level LED c and the alarm continues
B@BAZK after the engine is
Oil level is low (OPEN) — c — — — — Red started.

Normal coolant level

(CLOSE) — — — — — — —
Engine coolant
17 level
LED c
Coolant level is low
(OPEN) — c — B@BCZK — c — B@BCZK Red

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Operation status
Engine in
Engine stopped operation

Indication color
Concentrated warning

Concentrated warning
Night time

Individual indications

Individual indications
Message indication

Message indication
dimming

Warning buzzer

Warning buzzer
Category No. Items Device c: Occurs. Operating conditions Remarks
—: Does
not occur.

Normal pressure (OPEN) — — — — — — —

Less than specified pres-

sure (CLOSE) When the abnormality
Engine oil pres- & when the engine revolu- was detected while the
15 sure
LED c tion is 500rpm or more — — —  c c B@BAZG Red engine is stopped, the
& when 15 sec. or more alarm will continue after
has passed after starting starting the engine also.
the engine
When an abnormality is
detected — — — DHE4L6 — — — —

Normal pressure (CLOSE) — — — — — — —

Less than specified pres-

sure (F) (OPEN)
& when the engine is
started (when detecting
time continues) & when 50 — — —  c c 2G42ZG Red
sec. has passed after start-
ing the engine (without
detecting time)

Less than specified pres-

sure (R) (OPEN)
& when the engine is
started (when detecting
time continues) & when 50 — — —  c c 2G43ZG Red
Brake oil sec. has passed after start-
pressure ing the engine (without The alarm will be
14 Accumulator oil
LED c detecting time) changed over, not being
pressure cancelled by the
Less than specified pres- changeover at 50 sec.
sure (F) (OPEN) after starting the engine.
& when the engine is
started (when detecting
time continues) & during — c —  c c Red
50 sec. after starting the
engine (without detecting
time)

Less than specified pres-

sure (F) (OPEN)
& when the engine is
Other
started (when detecting
time continues) & during — c —  c c Red
symbols 50 sec. after starting the
engine (without detecting
time)

Normal (CLOSE) — — — — — — —
When the abnormality
When sensor 1 is being was detected while the
18 Air cleaner LED c blinded (OPEN) — — — — c — AA1ANX Red engine is stopped, the
clogging
alarm will continue after
When an abnormality is starting the engine also.
detected with sensor 1 — — — DHA4KA — — — —

When the steering oil

pressure is normal (OPEN) — — — — — — —

When emergency steer-

ing signal is being input
Emergency steer- while the engine is
ing function is in
operation stopped, the system
determines that self-
25 (when the steer- LED c When the steering oil checking of emergency
ing oil pressure is
normal)
pressure dropped (CLOSE)
& when the engine revolu- — —  c c DDS5L6 Red steering is in progress
and when the steering
(Optional) tion is 500rpm or more oil pressure is found too
low during self-check-
ing of emergency steer-
ing, the indicator will be
turned ON.
When the pump operates
(for 1 min. or more)  c c DY30N1  c c DY30N1 Green
Emergency steer- (OPEN)
ing is normal
(Emergency When the pump operates
26 steering pump is
LED c (for less than 1 min.) — c — — c — Green
in operation) (OPEN)
(Optional)
When the pump stops
(CLOSE) — — — — — — —

Normal — — — — — — —
2V or less — c — — c — D61AZK Red
Battery electro-
23 lyte level LED c When this option is not
(Optional) installed — — — — — — —

When an abnormality is
detected — — — DJBAKX — — — DJBAKX —

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Operation status
Engine in
Engine stopped operation

Indication color
Concentrated warning

Concentrated warning
Night time

Individual indications

Individual indications
Message indication

Message indication
dimming

Warning buzzer

Warning buzzer
Category No. Items Device c: Occurs. Operating conditions Remarks
—: Does
not occur.

When the parking brake is Turns ON as the contact

in operation — c — — c — Red goes OPEN when the
(OPEN) parking brake is oper-
ated.
19 Parking brake LED c This indicator will be
When the parking brake is
commonly used with the
released — — — — — — — parking brake dragging
(CLOSE)
prevention LED.

Not in operation/Not
installed — — — — — — —

In operation — c — — c — Green
Auto greasing
31 (Optional)
LED c  
The tank is empty — — — — Green
1Hz 1Hz

Abnormal —  — —  — Green
2Hz 2Hz

When pre-heating and

Other cases than below — — — — — — — after heating are not
made due to occurrence
of some abnormality,
Preheating When pre-heating is being the (including output
30 (Auto pre-heat- LED c made — c — — c — Red section failure) alarm
ing) will not turn on.

The indication will not

When a communication be made when a com-
error has occurred — — — — — — — munication error has
occurred.

When this option is not

installed — — — — — — —

When the wheel steering

is in operation — — — — — — —

When the Joystick is being

Joystick operated — c — — c — Green
32 changeover LED c
(Optional)
"Priority to the FNR lever"
caution ✩  c ✩  c Green

The indication will not

When a communication be made when a com-
error has occurred — — — — — — — munication error has
Other occurred.
symbols When this option is not
installed — — — — — — —

When this function is not

in operation — — — — — — —
Semi auto dig-
29 ging LED c When the automatic dig-
— c — — c — Green
(Optional) ging is operation

The indication will not

When a communication be made when a com-
error has occurred — — — — — — — munication error has
occurred.

Normal — — — — — — —

22 Maintenance
LED c
Less than 30 hours after
maintenance —  — U —  — U — Simultaneously, the
message display will
monitor indicate the content.
Less than 30 hours before The indicator will light
maintenance for 30 sec. only after the
or maintenance time has — c — U — c — U Red starting key is turned
come ON.

When this option is not

installed — — — — — — —

When column shift is

being used — — — — — — —

When the R.H. FNR switch

is being used
When seasaw switch — c — — c — Green
Right directional mode
33 selector switch LED c
(Optional) As for the "priority to the
FNR lever" caution,
"Priority to the FNR lever"
caution ✩  c ✩  c Green when the optional Joy-
stick is being employed,
the Joystick indicator
will flash.

The indication will not

When a communication be made when a com-
error has occurred — — — — — — — munication error has
occurred.

WA380-5 10-205
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Operation status
Engine in
Engine stopped operation

Indication color
Concentrated warning

Concentrated warning
Night time

Individual indications

Individual indications
Message indication

Message indication
dimming

Warning buzzer

Warning buzzer
Category No. Items Device c: Occurs. Operating conditions Remarks
—: Does
not occur.

Power mode = P — c — — c — Green Will indicate the state

28 Power mode LED c where the power mode
Other cases than above — — — — — — — is being selected.
Cooling fan forward rota-
tion — — — — — — —

Cooling fan Cooling fan reverse rota- As indi- As indi- Will indicate the state
21 reverse LED c tion — c — cated at — c — cated at Orange
where the fan is in for-
right right
rotation ward/reverse rotation.
As indi- As indi-
Fan switch and solenoid
are not in conformity —  — cated at —  — cated at Orange
Other right right
symbols When the load meter indi-
5 Load meter
cation is being made U U U U U U U U —
41 (Load meter Calculation results will
42 specification)
LCD c be shown in figures.
When the load meter indi-
cation is not being made — — — — — — —
43 (Optional)

Other cases than below — — — — — — —

Axle oil tempera-

20 ture
LED c When the temperature
rises (Rear)  c c B@C7NS  c c B@C7NS Red

When an abnormality is
detected (Rear) — — — DGR2KA — — — DGR2KA —

Priority degrees of the buzzer sound: Repetitive () > Intermittent (✩) > Cancellation of operation > Confirmation of receiving the operation

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SETTING OF THE MACHINE MONITOR

1. Machine model selecting rotary switch [SW1]

2. Spare rotary switch [SW2]
3. Speedometer/Tachometer indication changeover and tire size selecting rotary switch [SW3]
4. Engine controller installation setting dip switch [SW5-1]
5. Work equipment/joystick controller installation setting dip switch [SW5-2]
6. Spare dip switch [SW5-3]
7. Spare dip switch [SW5-4]
8. Spare dip switch [SW6-1]
9. Spare dip switch [SW6-2]
10. Spare dip switch [SW6-3]
11. Spare dip switch [SW6-4]

Check the settings or change the settings of the rotary switches, dip switches and check or change the
option setting in the following cases:
In case it becomes necessary to remove the machine monitor once and when reinstalling it
In case the machine monitor has been replaced with a new monitor
In case the tire size has been changed (speed compensation settings)
In case the optional equipment is being installed or being removed

Setting statuses of respective switches can be checked on the real time monitor under the service mode.
Refer to the "Real time monitoring function".

WA380-5 10-207
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When making settings, turn off the power supply and remove the machine monitor in advance. Refer to
the Chapter "Disassembly and Assembly" when removing the machine monitor.
Make settings of respective switches (SW1, 2, 3, 5 and 6) according to the instructions.
When turning the rotary switches, turn them gently using a precision plus head type screwdriver, etc.
With the rotary switches, the triangular projection is the arrow mark for setting.
When changing the settings of the dip switches, move them gently using a precision minus head type
screwdriver, etc.
When inserting a tool inside the grommeted hole, be careful not to touch any other parts than the targeted
switch.
As for the option setting, the settings can be changed or checked using the "Optional Select" under the ser-
vice mode. (Refer to the Section "Initial Setting/Adjustment". page10-241 and above)
Depending on the type of the option, it becomes necessary to make the initial state setting. (Refer to the
Section "Initial Setting/Adjustment".)
As for the initial stage adjustment, the adjustment can be made by the "Tuning" under the service mode.
(Refer to the Section "Initial Setting/Adjustment".)

1. Precautions
When making settings, observe the instructions.
When moving the switches, move them gently using a precision screwdriver, etc.
When inserting a tool inside the grommeted hole, be careful not to touch any other parts than the tar-
geted switch.
Be careful not to let dust and any other foreign substance enter into the equipment.
After finishing the setting work, be sure to insert the grommets back to their original positions securely.

2. When making the machine model selection settings (Setting of the rotary switch [SW1])
Since a single type of machine monitor is being applied to many machine models, it is necessary make
the setting for the machine model to which the machine monitor has been installed.
When the machine monitor has been replaced, it becomes necessary to make machine model selection
setting by the rotary switch [SW1] to let the system make proper controls for the machine model to
which the machine monitor has been installed.

Adjustment procedures
Make the setting indicated in the following Table to fit to the machine model to which the machine
monitor has been installed.

Machine model SW1 Remarks

WA380-5 0

3. When making the setting of the rotary switch

[SW2]
Make the setting as follows and do not change
it.
Setting position of the SW2: "0"

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4. When making the speedometer/tachometer indication changeover setting and tire size selection setting
(Setting of the rotary switch [SW3])
Since the machine monitor is being set to the tire size of standard tires for speed calculations, when the
tire size has been changed, it becomes necessary to adjust to the new tire size by the rotary switch
[SW3] for compensation of the speed indications.

Adjustment procedures
Make the setting according to the following Table to fit to the tire size.
Meter indication SW3 Tire size Remarks
changeover
km/h indication 0 Small diameter tire

MPH indication 1 Small diameter tire Usable in non-SI-unit

employing countries only
rpm indication 2 Small diameter tire
km/h indication 3 Large diameter tire

MPH indication 4 Large diameter tire Usable in non-SI-unit

employing countries only
rpm indication 5 Large diameter tire

Tire size WA380-5

20.5-25 small Standard
23.5-25 large If equipped

Making the speedometer/tachometer indication changeover setting means to change the indication content
of the speedmeter located in the central section of the monitor.
Changeover from the speedometer to (engine) tachometer can also be made using the "Optional Select".
After the above setting is made, the indication unit of the travel distance integrating meter (odometer) will
become according to the setting made as above.
Since the MPH indication is only for the countries employing the non-SI-unit only, do not make the MPH
indication setting for machines being used in countries employing the SI-unit.
In case other tires than the above or when the speed indications deviate from the actual speed by wears of
the tires, it is possible to make tire compensations using the "Optional Select".

5. When making necessary setting when the engine controller is installed (Setting of the dip switch [SW5-
1])
Make the setting as follows and do not change it.
Setting position of the SW5-1 in case of machines not equipped with the KOMATSU Common Rail
engine (WA380-5 ): "OFF"

6. When making necessary setting for the work equipment/joystick controller (Setting of the dip switch
[SW5-2])
When the work equipment/joystick controller is newly installed or removed, make the setting as fol-
lows.
Setting position of the SW5-2 in case the controller has been removed: "OFF"
Setting position of the SW5-2 in case the controller has been newly installed: "ON"

7. When making the setting of the dip switch [SW5-3]

Make the setting as follows and do not change it.
Setting position of the SW5-3: "OFF"

WA380-5 10-209
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8. Serial No.: 60001 - 60219

When making the setting of the dip switch [SW5-4]
Make the setting as follows and do not change it.
Setting position of the SW5-4: "OFF"

Serial No.: 60220 and up

When making the setting of a machine equipped with the joystick lever (When making the setting of the
dip switch [SW5-4]

Setting position of the SW5-4 in the case the use of the 3rd gear speed lockup, 4th gear speed, and 4th
gear speed lockup is prohibited: "OFF"

Setting position of the SW5-4 in the case the use of the 3rd gear speed lockup, 4th gear speed, and 4th
gear speed lockup is permitted: "ON"

9. When making the setting of the dip switch [SW6-1]

Make the setting as follows and do not change it.
Setting position of the SW6-1: "OFF"

10. When making the setting of the dip switch [SW6-2]

Make the setting as follows and do not change it.
Setting position of the SW6-2: "OFF"

11. When making the setting of the dip switch [SW6-3]

Make the setting as follows and do not change it.
Setting position of the SW6-3: "OFF"

12. When making the setting of the dip switch [SW6-4]

Make the setting as follows and do not change it.
Setting position of the SW6-4: "OFF"

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Service mode functions

1. Outline
1) Electric fault history
Use this function to check the electric fault history of respective controllers being memorized by the
machine monitor. Regarding the failure code being used in the electric fault history, refer to the
Chapter "Troubleshooting". When the fault is repaired and after checking and confirming that nor-
mal operation has been restored, delete the fault history.
The electric fault history indications on the character display are as follows.

***: Indicates which sequence number of fault history counting from the top.
######: Indicates the failure code.
$$$: Indicates the number of times of occurrence of the subject failure code
%%%%%: Indicates the elapsed time from the initial occurrence of the same electric fault (the value
deducting the service meter value when the electric fault initially occurred from the current service
meter value).
@@@@@: Indicates the elapsed time from last occurrence of the same electric fault (the value
deducting the service meter value when the electric fault last occurred from the current service
meter value).
When the indication is showing the currently occurring electric fault, the failure code flashes. Up to
max. 20 failure codes can be memorized.
2) Machine fault history
Use this function to check the machine fault history of respective controllers being memorized by
the machine monitor. Regarding the failure code being used in the machine fault history, refer to
the Chapter "Troubleshooting".
The machine fault history indications on the character display are as follows.

***: Indicates which sequence number of fault history counting from the top.
######: Indicates the failure code.
$$$: Indicates the number of times of occurrence of the subject failure code.
%%%%%: Indicates the service meter value at the time of initial occurrence of the same machine
fault.
@@@@@: Indicates the service meter value at the time of last occurrence of the same machine
fault.
When the indication is showing the currently occurring machine fault, the failure code flashes. As for
the failure codes of the machine fault, up to several failure codes can be memorized.

WA380-5 10-211
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3) Real time monitor

Use this function to check the inputting and outputting signals being recognized by respective con-
trollers on the network.
The real time monitor indications on the character display are as follows.

***: Indicates the item name.

#####: Indicates the ID number allocated to each item.
%%%* Indicates the data. When a unit is being used, the unit will be shown on the right-hand side
of the data.
By designating the ID number allocated to each item, it is also possible to have optional 2 items
indicated at the same time.
The indications on the character display when optional 2 items are indicated at the same time are as fol-
lows.

***: Indicates the designated ID numbers

%%%* Indicates the data. When a unit is being used, the unit will be shown on the right-hand side
of the data.
4) Tuning
Use this function to make initial adjustments of the sensors, etc. which are being installed to the
machine.
Use this function when sensors, EPC valves or controllers have been replaced or supplemented.
5) Changing the filter and oil changing time
This function is being explained in the section "Filter and oil changing time indication on the charac-
ter display" in the Chapter "Handling" in the Operation and Maintenance Manual. Use this function
when revising the changing time.
6) Settings of the optional equipment and functions
Use this function to indicate the installation status of the optional equipment and to change the set-
tings.
Use this function when optional equipment is installed or removed.

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7) Settings of the serial number of the machine

Use this function to indicate the serial number of the machine and to make new settings.
Use this function for the purposes of machine controls, etc.
8) Controller initialization
Since this function is for factory use only, do not touch it.

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2. Operation methods

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Items Related to the Fault History of Electric System

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

2) Selection of displaying the fault history of electric system (first layer)

Pressing the > switch changes the screen to the [Select the initializing function] screen.
Pressing the < switch changes the screen to the [Select displaying the fault history of vehicle sys-
tem] screen.
Pressing the „ switch changes the screen to the ordinary or alert screen.
Pressing the ‘ switch changes the screen to the [Display abnormalities in electric system] screen.

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3) Selection of displaying the fault history of electric system and clearing the entire fault history of
electric system (second layer)
A current fault is displayed prior to the restored ones.
Pressing the > switch displays the next older fault.
Pressing the < switch displays the next newer fault.
After the oldest fault in memory was displayed, a screen is displayed allowing to select clearing the
entire fault history of electric system of the relevant controller.
Pressing the switch changes the screen to the [Select displaying abnormalities in electric system]
screen on the first layer.
Pressing the switch changes the screen to the [Clear individually the fault history of electric sys-
tem] or [Clear the fault history of electric system] screen.
* If the history consisted of one fault, pressing the switch does not change the screen to that for all-
out clearing (but change the screen to that for individual clearing).

4) Clearing individually the fault history of electric system, and clearing the entire fault history of elec-
tric system (the third layer)
Select YES or NO with the < or > switch.
Cursor (_) blinks on the selected item. Pressing the switch changes the display as follows, with
the history reset if YES was selected, or not if NO was selected:
1 If No (cancel) was selected, the display returns to the [Display the fault history of electric
system] screen of the relevant fault (i.e., the screen before entering the [Clearing individually
(entirely) the fault history of electric system] screen).
2 If YES (clear ) was selected, the display returns to the [Display the fault history of electric
system] screen of a fault next to the relevant fault. If the fault history to be shown exhausts, the
screen returns to the [Select displaying the fault history of electric system] screen.
By default, the cursor is on NO (no reset) to prevent resetting by error.
A current fault cannot be cleared. If it was selected, a peep sounds for one second to notify that the
operation is cancelled.
If a fault was cleared, peeps sound (on for 0.1 sec. - off for 0.1 sec. - on for0.1 sec.) to notify that the
operation has been accepted.
If the entire history was cleared, it is considered to have been cleared even if it consisted of only
one fault .

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Items Related to the Fault History of Machine System

1) Display of the fault history of vehicle system
A current fault is displayed prior to the restored ones.
Pressing the > switch displays the next older fault.
Pressing the < switch displays the next newer fault.
After the oldest fault in memory was displayed, a screen is displayed allowing to select clearing the
entire fault history of electric system of the relevant controller.
Pressing the switch changes the screen to the [Select displaying abnormalities in machine sys-
tem] screen on the first layer.

2) Selection of displaying the fault history of machine system (first layer)

Pressing the > switch changes the screen to the [Select the real-time monitor functions] screen.
Pressing the < switch changes the screen to the [Select displaying the fault history of machine sys-
tem] screen.
Pressing the switch changes the screen to the ordinary or alert screen.
Pressing the switch changes the screen to the [Display abnormalities in electric system] screen.

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3) Display of the fault history of vehicle system (second layer)

The fault history is displayed in the order of occurrence with the newest fault first.
A current fault is displayed prior to the restored ones.
The fault history is displayed in the order of occurrence with the newest fault first.
Pressing the > switch displays the next newer fault.
Pressing the < switch displays the next older fault.
Pressing the switch changes the screen to the [Select displaying abnormalities in vehicle system]
screen.

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Items Related to Maintenance Monitor

1) Selection/display of the maintenance monitor items
Each time the > switch is pressed, an item is shown from No.1 in the ascending order.
Each time the < switch is pressed, an item is shown from No.13 in the descending order.
Pressing the switch changes the screen to the [Select the maintenance monitor functions] screen.
Pressing the switch changes the screen to the [Maintenance interval timer reset] screen.

2) Selection/display of the maintenance monitor (first layer)

Pressing the > switch changes the screen to the [Select the optional functions] screen.
Pressing the < switch changes the screen to the [Select the cylinder cut-out function] screen.
Pressing the switch changes the screen to the ordinary or alert screen.
Pressing the switch changes the screen to the [Select the maintenance monitor items] screen.

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3) Selection of the maintenance items (second layer)

The display is the same as that on the maintenance monitor which is included in the functions open
to operators, except that the maintenance caution lamp is turned off.
Pressing the switch changes the screen to the [Select the maintenance monitor functions] screen.
Pressing the switch changes the screen to the [Change the maintenance monitor interval time]
screen.

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4) Changing the maintenance interval time (third layer)

The change of the maintenance interval time can be set to any value within a range 0-9999h.
Pressing the switch causes the change of the time skipped, and changes the screen to the [Select
the maintenance items] screen. In this case, a peep sounds for one second to notify that the opera-
tion is cancelled.

How to Enter Interval Time

1
b Enter a number from 0-9 in the cursor position.
2
c The cursor is at the highest digit first. Each time the < or > switch was pressed, the number
changes by 1 within a range 0-9.
3
d If the desired number was entered, press the switch to apply it.
4
e The cursor moves to the second highest digit. Repeat the procedures mentioned in 2 and 3
until the last number is filled in the lowest digit.
5
f After the lowest digit was entered, press the switch.
6
g -1 If the entered value represents the time which can be set, the screen changes to the confir-
mation screen.
6 -2 Otherwise, the screen does not change to the confirmation screen but to the [Select the
maintenance items] screen. In this case, a peep sounds for one second to notify that the
operation is cancelled.
7
h If a wrong number was entered, return to the [Maintenance items] screen with the switch, and do
the procedure from the beginning again.

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5) Confirming the changed maintenance interval time (fourth layer)

Select YES or NO with the < or > SW.
Cursor (_) blinks on the selected item. Pressing the „SW returns the display to the [Select the
maintenance items] screen, with the change applied if YES was selected, or not if NO was selected:
The default of the cursor is on NO (no change) to prevent resetting by error.
A current fault cannot be cleared. If it was selected, a peep sounds for one second to notify that the
operation is cancelled.
If the change of the time-setting was completed, peeps sound (on for 0.1 sec. € off for 0.1 sec. € on
for 0.1 sec.) to notify that the operation has been accepted.

The maintenance interval time is set when the machine is shipped as in the following table:
Interval for
Items replacement (h) Items shown ID numbers

Engine oil 500 ENG OIL 01

Engine oil filter 500 ENG FILT 02
Fuel filter 500 FUEL FILT 03
Corrosion resister 1,000 CORR RES 06
Transmission oil 1,000 TM OIL 12
Transmission oil filter 1,000 TM FILT 13
Hydraulic fluid filter 2,000 HYD FILT 04
Hydraulic oil tank breather element 2,000 HYD BREATH 05
Axle oil 2,000 AXLE OIL 15
Hydraulic fluid 2,000 HYD OIL 10

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Real-time Monitoring Function

The real-time monitor shows real-time the information which the controller mounted on the vehicle has.
This function is used for checking and adjustment, diagnosis of faults of the vehicle and other purposes.
The real-time monitor shows the items and their data, classified by the controllers which have information.
It shows them in two ways: the ordinary display, and the 2-item display where two data items are shown
simultaneously.

Operation

1. Press the switch and < switch for more than five seconds to go to the [ID Entry] screen.

2. Enter ID with the < and > switch, and press the switch to go to the screen for service persons.

3. Press the < and > switch to display the [Select the real-time monitor] screen, then press the switch to
fix the screen.

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4. Press the switch, and the [Select the information displayed on monitor panel] screen appears. Press-
ing the < or > switch display the screens [Select the information of the transmission controller], [Select
the information of the engine controller], [Select the information of the working machine controller],
and [Select the 2-item display] in order.

5. Pressing the switch, while each selection screen is shown, displays the [One-item display] screen or
the [Select information on 2-item display] screen.

***: Shows items.

%%%%%: Shows data and unit (SI system)
$$$$: Shows ID.

In the case of 1-item display, pressing the < and > switch changes the items shown in turn, displaying the
information each controller has.

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How to Enter an ID
After the screen was changed from another, “00000” is shown.
Enter a number 0-9 in the cursor position.
The cursor is at the highest digit first. Each time the < or > switch was pressed, the number changes by 1
within a range 0-9.
If the desired number was entered, press the switch.
The cursor moves to the second highest digit. Repeat the procedures mentioned above until the last num-
ber is filled in the lowest digit.
If the lowest digit was entered, press the switch, and the screen changes to that for displaying/selecting
the second item. Alternately, pressing the switch returns the screen to that for displaying/selecting two
items.

In the case of 2-item display, enter the IDs of the information to be displayed, and the two items are shown
simultaneously. The IDs shown are the same as those on the 1-item display screen.

6. In the case of 1-item display, pressing the < and > switch changes the items shown in turn, displaying
the information each controller has.

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Real-time Monitoring Items

Displayed Component Terminal
Item ID Real-time monitoring item Item displayed Display unit Remarks
range detected No.
A value out
SI unit sys- of the range
All the items are shown even
if some of them are not Abridged due to tem so long displayed is
limitation of num- as the val- shown as the
equipped depending on mod- ber of letters. ues have lowest (high-
els and options.
units est) value in
the range.
Monitor panel controller
Shows the part
20200 Part No. of monitor’s ROM MONITOR ROM — — Monitor — No. of monitor-
panel’s ROM
01001 Engine speed ENG SPEED 1rpm 0-3000 Transmission L62-10
40000 Travel speed SPEED km/h 0-50 Transmission L62-20
04202 Fuel level FUEL SENSOR 1% 0-100 Monitor L55-1
Any temperature
04401 Hydraulic oil temperature HYD TEMP 1°C 24-131 Monitor L55-7 lower than 24°C is
displayed as 24°C
Any temperature
04103 Coolant temperature COOLANT TEMP 1°C 24-131 Monitor L55-8 lower than 24°C is
displayed as 24°C
Any temperature
lower than -31°C
04104 Coolant temperature (low) COOLANT Lo 1°C -31-91 Monitor L55-3
is displayed as
-31°C
Any temperature
40100 Torque converter oil temperature TC OIL TEMP 1°C 24-131 Monitor L55-2 lower than 24°C is
displayed as 24°C
04302 Charging level of alternator ALTERNATOR R 0.1V 0.0-30.0 Monitor L52-18
40200 Voltage of small lamps SMALL LAMP 0.1V 0.0-30.0 Monitor L53-12
40300 Battery electrolyte level A BATTERY A2V 0.1V 0.0-30.0 Monitor L55-5
40301 Battery electrolyte level B BATTERY B2V 0.1V 0.0-30.0 Monitor L55-12
06001 Lift arm angle BOOM ANG 1° -41-46 Monitor L55-10
40400 Lift arm bottom pressure BTM PRESS 0.01MPa 0.00-50.00 Monitor L55-9
40500 Lift arm rod pressure ROD PRESS 0.01MPa 0.00-50.00 Monitor L55-4
Calculated
40600 Calibration pressure CAL PRESS 0.01MPa 0.00-50.00 Monitor
value

40700 Calculated pressure MES PRESS 0.01MPa 0.00-50.00 Monitor Calculated

value
Calculated
40800 Calculated load weight MES LOAD 0.01t 0.00-50.00 Monitor
value
Switch on
30802 Rotary switch position SW1,SW2,SW3 — 0-F Monitor the rear
Switch on
30904 Dip switch position SW5-1,SW5-2 — OFF.ON Monitor
the rear

30905 Dip switch position SW5-3,SW5-4 OFF.ON Monitor Switch on

the rear
Switch on
30906 Dip switch position SW6-1,SW6-2 OFF.ON Monitor the rear
Switch on
30907 Dip switch position SW6-3,SW6-4 OFF.ON Monitor the rear

40900 Input signal D_IN_0-7 D-IN--0-----7 — 10101010 Monitor See separate

sheet
See separate
40901 Input signal D_IN_8-15 D-IN--8-----15 — 10101010 Monitor sheet
See separate
40902 Input signal D_IN_16-23 D-IN-16-----23 — 10101010 Monitor
sheet

40903 Input signal D_IN_24-31 D-IN-24-----31 — 10101010 Monitor See separate

sheet
See separate
40904 Input signal D_IN_32-39 D-IN-32-----39 — 10101010 Monitor
sheet
Transmission controller
Part No. of Transmission control- Shows part No. of
20201 TRANSM ROM — — Transmission —
ler’s ROM ROM

41000 Target speed of fan pump FAN PUMP 1rpm 0-3000 Transmission Calculated
value

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Displayed Component Terminal

Item ID Real-time monitoring item Item displayed Display unit range detected No. Remarks

A value out
SI unit sys- of the range
All the items are shown even Abridged due to tem so long displayed is
if some of them are not
equipped depending on mod- limitation of num- as the val- shown as the
ber of letters. ues have lowest (high-
els and options. units est) value in
the range.
Transmission controller
41100 Pressure of left-hand brake L.H. BRAKE 0.1MPa 0.00-50.00 Transmission L61-19
Calculated
41200 Transmission cut-off pressure CUT OFF 0.01MPa 0.00-50.00 Transmission
value
Calculated
41300 Number of times of kick-down K/D TIMES — — Transmission value

41400 Average cycle time CYCLE TIME 1 SEC — Transmission Calculated

value

31608 F ECMV current ECMV F 1mA 0-1000 Transmission L63-5

31606 R ECMV current ECMV R 1mA 0-1000 Transmission L63-15

31602 1st-clutch ECMV current ECMV 1 1mA 0-1000 Transmission L63-25

31603 2nd-clutch ECMV current ECMV 2 1mA 0-1000 Transmission L63-6

31604 3rd-clutch ECMV current ECMV 3 1mA 0-1000 Transmission L63-16

31605 4th-clutch ECMV current ECMV 4 1mA 0-1000 Transmission L63-26

31609 L/C ECMV current ECMV LU 1mA 0-1000 Transmission L63-35

41400 Fan pump EPC current FAN EPC 1mA 0-1000 Transmission L63-36

41500 Transmission oil temperature ECMV OIL TEMP 1°C 24-131 Transmission L61-9

41600 Selection of engine mode ENGINE MODE — P/N Transmission L61-6

Calculated
41700 Selection of shift mode SHIFT MODE — H/M/L Transmission
value

41808 F fill time FILL TIME F 10msec 0-2550 Transmission Calculated

value
Calculated
41806 R fill time FILL TIME R 10msec 0-2550 Transmission value

41802 1st-clutch fill time FILL TIME 1 10msec 0-2550 Transmission Calculated
value

41803 2nd-clutch fill time FILL TIME 2 10msec 0-2550 Transmission Calculated
value
Calculated
41804 3rd-clutch fill time FILL TIME 3 10msec 0-2550 Transmission value
Calculated
41805 4th-clutch fill time FILL TIME 4 10msec 0-2550 Transmission value

31508 F fill time FILL SW(F) — 0/1 (Normal/ Transmission Calculated

abnormal) value
0/1 (Normal/ Calculated
31506 R fill time FILL SW(R) — abnormal) Transmission value
0/1 (Normal/ Calculated
31502 1st-clutch fill time FILL SW(1) — abnormal) Transmission value

31503 2nd-clutch fill time FILL SW(2) — 0/1 (Normal/ Transmission Calculated
abnormal) value
0/1 (Normal/ Calculated
31504 3rd-clutch fill time FILL SW(3) — Transmission
abnormal) value
0/1 (Normal/ Calculated
31505 4th-clutch fill time FILL SW(4) — abnormal) Transmission value

40905 Input signal D_IN_0-7 D-IN--0------7 — 10101010 Transmission See separate

sheet
See separate
40906 Input signal D_IN_8-15 D-IN--8-----15 — 10101010 Transmission sheet
See separate
40907 Input signal D_IN_16-23 D-IN-16-----23 — 10101010 Transmission
sheet

40908 Input signal D_IN_24-31 D-IN-24-----31 — 10101010 Transmission See separate

sheet
30202 Rear brake oil temperature R BRAKE OIL 1°C 24-131 Transmission L61-20

40915 Output signal D_OUT_0-6 D-OUT-0------6 — 101010 Transmission See separate

sheet

40914 Output signal D_OUT_0-5 D-OUT-0------5 — 101010 Transmission See separate

sheet

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Displayed Component Terminal

Item ID Real-time monitoring item Item displayed Display unit range detected No. Remarks

A value out
SI unit sys- of the range
All the items are shown even Abridged due to tem so long displayed is
if some of them are not
equipped depending on mod- limitation of num- as the val- shown as the
ber of letters. ues have lowest (high-
els and options. units est) value in
the range.
Work equipment controller
Part No. of work equipment con- Work Shows part No. of
20202 troller’s ROM BOOM ROM — — equipment — ROM
Work
41900 Lift arm-raising EPC current RAISE EPC 1mA 0-1000 L73-6
equipment
Work
41901 Lift arm-lowering EPC current LOWER EPC 1mA 0-1000 equipment L73-16

41902 Bucket tilt EPC current TILT EPC 1mA 0-1000 Work L73-5
equipment

41903 Bucket dump EPC current DUMP EPC 1mA 0-1000 Work L73-15
equipment
Work
41904 R.H. Joystick EPC current R.H. J/S EPC 1mA 0-1000 equipment L73-26

Work
41905 L.H. Joystick EPC current L.H. J/S EPC 1mA 0-1000 equipment L73-36

Work
41906 3rd valve 1 EPC current 3RD EPC1 1mA 0-1000 L73-25
equipment
Work
41907 3rd valve 2 EPC current 3RD EPC2 1mA 0-1000 L73-35
equipment

42000 Lever potentiometer-voltage lift BOOM POT1 0.01V 0.00-5.00 Work L71-19
arm 1 equipment
Lever potentiometer-voltage lift Work
42001 BOOM POT2 0.01V 0.00-5.00 L71-13
arm 2 equipment
Lever potentiometer-voltage Work
42002 bucket 1 BUCKET POT1 0.01V 0.00-5.00 equipment L71-7

Lever potentiometer-voltage Work

42003 BUCKET POT2 0.01V 0.00-5.00 L71-1
bucket 2 equipment
Lever potentiometer-voltage Joy- Work
42004 stick 1 J/S POT1 0.01V 0.00-5.00 equipment L71-9

Lever potentiometer-voltage Joy- Work

42005 J/S POT2 0.01V 0.00-5.00 L71-3
stick 2 equipment
Lever potentiometer-voltage 3rd Work
42006 3RD POT1 0.01V 0.00-5.00 L71-20
valve 1 equipment
Lever potentiometer-voltage 3rd Work
42007 3RD POT2 0.01V 0.00-5.00 L71-14
valve 2 equipment
Work
06002 Lift arm angle BOOM ANG 1° -41-46 L71-8
equipment

40401 Lift arm bottom pressure BTM PRESS 0.01MPa 0.00-50.00 Work — No function
equipment
0-256000
Number of times of lift arm lever Work Calculated
42100 operation BOOM LVR 1000 (incremental equipment value
step=1000)
0-256000
42101 Number of times of bucket lever BUCKET LVR 1000 (incremental Work Calculated
operation equipment value
step=1000)
0-256000
42102 Number of times of 3rd lever oper- 3RD LVR 1000 (incremental Work Calculated
ation equipment value
step=1000)
Work
01003 Engine speed ENG SPEED 1rpm 0-3000 L72-10
equipment
Work
40001 Travel speed SPEED 1km/h 0-50 equipment L72-20

40910 Input signal D_IN_0-7 D-IN--0------7 — 10101010 Work See separate

equipment sheet
Work See separate
40911 Input signal D_IN_8-15 D-IN--8-----15 — 10101010 equipment sheet
Work See separate
40912 Input signal D_IN_16-23 D-IN-16-----23 — 10101010 equipment sheet

40913 Input signal D_IN_24-31 D-IN-24-----31 — 10101010 Work See separate

equipment sheet
Work See separate
40917 Output signal D_IN_0-6 D-OUT-0------6 — 1010101
equipment sheet

40916 Output signal SOL/0-0-5 SOL/0-0------5 — 101010 Work See separate

equipment sheet

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How to read input signals (D-IN--0------7) How to read output signals (D-OUT-0------7)
The signal input into controller by ON/OFF switch is The signal output from controller by ON/OFF switch
shown as [D-IN-*] (* represents input No.). is shown as [D-OUT-*] (* represents output No.).
The display shows it as follows: The display shows it as follows:

***: Shows items. ***: Shows items.

%%%%%: Shows data and unit (SI system) %%%%%: Shows data and unit (SI system)
$$$$: Shows ID No. $$$$: Shows ID No.
If input status [0] or [1] is shown, Input OFF or ON is If output status [0] or [1] is shown, Output OFF or
displayed, respectively. ON is displayed, respectively.

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STRUCTURE AND FUNCTION,
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I/O signal Displayed item Connector Pin No. ON/OFF logic

No.
Machine Monitor
D-IN-0 Head lamp L52 1 Head lamp turned ON=(24V)/OFF (OPEN)
D-IN-1 No item L52 10 ON (24V)/OFF (OPEN)
D-IN-2 IGN_C L52 2 Starter activated=(24V)/OFF (OPEN)
D-IN-3 No item L52 11 ON (24V)/OFF (OPEN)
D-IN-4 Auto-grease A (If equipped) L52 3 Tank empty or abnormal=(24V)/OFF (OPEN)
D-IN-5 Auto-grease B (If equipped) L52 12 Operating or abnormal=(24V)/OFF (OPEN)
D-IN-6 No item L52 4 ON (24V)/OFF (OPEN)
D-IN-7 No item L52 13 ON (24V)/OFF (OPEN)
D-IN-8 No item L52 5 ON (24V)/OFF (OPEN)
D-IN-9 No item L52 14 ON (24V)/OFF (OPEN)
D-IN-10 No item L52 6 ON (24V)/OFF (OPEN)
D-IN-11 No item L52 15 ON (24V)/OFF (OPEN)
D-IN-12 Blinker R L52 7 Right blinker=ON (24V)/OFF (OPEN)
D-IN-13 Blinker L L52 16 Left blinker=ON (24V)/OFF (OPEN)
D-IN-14 Input from the ‘ switch L52 8 Switch pressed=ON (24V)/OFF (OPEN)
D-IN-15 Input from the „ switch L52 17 Switch pressed=ON (24V)/OFF (OPEN)
D-IN-16 Brake oil pressure (front) L53 1 Pressure normal=ON (GND)/OFF (OPEN)
D-IN-17 Brake oil pressure (rear) L53 7 Pressure normal=ON (GND)/OFF (OPEN)
D-IN-18 No item L53 2 ON (GND)/OFF (OPEN)
D-IN-19 No item L53 8 ON (GND)/OFF (OPEN)
D-IN-20 Clogged air cleaner L53 3 No clogging=ON (GND)/OFF (OPEN)
D-IN-21 No item L53 9 ON (GND)/OFF (OPEN)
D-IN-22 No item L53 4 ON (GND)/OFF (OPEN)
D-IN-23 No item L53 10 ON (GND)/OFF (OPEN)
D-IN-24 No item L53 5 ON (GND)/OFF (OPEN)
D-IN-25 No item L53 11 ON (GND)/OFF (OPEN)

D-IN-26 Parking brake L54 1 Parking brake in operation=ON (GND)/OFF

(OPEN)
D-IN-27 Coolant level L54 10 Coolant level normal=ON (GND)/OFF (OPEN)
D-IN-28 Engine oil pressure L54 2 Dropped pressure=ON (GND)/OFF (OPEN)
D-IN-29 Engine oil level L54 11 Oil level normal=ON (GND)/OFF (OPEN)

D-IN-30 (Emergency steering) motor L54 3 (Emergency steering) motor activated=ON

normal (If equipped) (GND)/OFF (OPEN)
D-IN-31 No item — — —

D-IN-32 Load meter subtotal switch (If L54 4 Switch pressed=ON (GND)/OFF (OPEN)
equipped)

D-IN-33 Load meter cancel switch (If L54 13 Switch pressed=ON (GND)/OFF (OPEN)
equipped)
D-IN-34 High-beam switch L54 5 High-beam=ON (GND)/OFF (OPEN)
D-IN-35 No item L54 14 ON (GND)/OFF (OPEN)
D-IN-36 Service function 2 L54 6 ON (GND)/OFF (OPEN)
D-IN-37 Input from the > switch L54 15 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-38 Input from the < switch L54 7 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-39 Dropped steering pressure L54 6 Oil pressure normal=ON (GND)/OFF (OPEN)

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I/O signal Displayed item Connector Pin No. ON/OFF logic

No.
Transmission Controller
D-IN-0 Steering pressure switch (N.O.) L61 23 Pressure normal=ON (GND)/OFF (OPEN)

D-IN-1 Steering pressure switch (N.C.) L61 17 Abnormal pressure (drop down)=ON (GND)/
OFF (OPEN)
D-IN-2 Transmission cut-off switch L61 11 Switched pressed=ON (GND)/OFF (OPEN)
D-IN-3 Transmission cut-off set switch L61 5 Switched pressed=ON (GND)/OFF (OPEN)

D-IN-4 E.C.S.S. change-over switch (If L61 24 Switched pressed=ON (GND)/OFF (OPEN)
equipped)

D-IN-5 Lock-up change-over switch (If L61 18 Switched pressed=ON (GND)/OFF (OPEN)
equipped)
D-IN-6 Kick-down switch L61 12 Switched pressed=ON (GND)/OFF (OPEN)
D-IN-7 Engine power mode E L61 6 P mode=ON (GND)/OFF (OPEN)
D-IN-8 Shift range 1st L63 10 1st gear=ON (24V)/OFF (OPEN)
D-IN-9 Shift range 2nd L63 20 2nd gear=ON (24V)/OFF (OPEN)
D-IN-10 Shift range 3rd L63 30 3rd gear=ON (24V)/OFF (OPEN)
D-IN-11 Shift range 4th L63 40 4th gear=ON (24V)/OFF (OPEN)
D-IN-12 Joystick shift up (If equipped) L63 9 Switch pressed=ON (24V)/OFF (OPEN)
D-IN-13 Joystick shift down (If equipped) L63 19 Switch pressed=ON (24V)/OFF (OPEN)

D-IN-14 Electric (emergency steering) man- L63 29 Switch pressed=ON (GND)/OFF (OPEN)
ual switch (If equipped)
D-IN-15 IGN_C (AFTER N SAFETY) L63 39 Starter activated=ON (24V)/OFF (OPEN)

D-IN-16 Right FNR (Joystick) change-over L62 35 Switch pressed=ON (24V)/OFF (OPEN)
switch (If equipped)

D-IN-17 Right seesaw & Joystick F (If L62 25 Forward=ON (24V)/OFF (OPEN)
equipped)

D-IN-18 Right seesaw & Joystick N (If L62 15 Neutral=ON (24V)/OFF (OPEN)
equipped)

D-IN-19 Right seesaw & Joystick R (If L62 5 Reverse=ON (24V)/OFF (OPEN)
equipped)
D-IN-20 Direction lever F L62 36 Forward=ON (24V)/OFF (OPEN)
D-IN-21 Direction lever N L62 26 Neutral=ON (24V)/OFF (OPEN)
D-IN-22 Direction lever R L62 16 Reverse=ON (24V)/OFF (OPEN)
D-IN-23 Neutralizer (Parking brake) signal L62 6 Parking switch ON=(24V)/OFF (OPEN)
D-IN-24 E-POC FILL F L62 37 Fill switch ON=(GND)/OFF (OPEN)
D-IN-25 E-POC FILL R L62 27 Fill switch ON=(GND)/OFF (OPEN)
D-IN-26 E-POC FILL 1st L62 17 Fill switch ON=(GND)/OFF (OPEN)
D-IN-27 E-POC FILL 2nd L62 7 Fill switch ON=(GND)/OFF (OPEN)
D-IN-28 E-POC FILL 3rd L62 13 Fill switch ON=(GND)/OFF (OPEN)
D-IN-29 E-POC FILL 4th L62 3 Fill switch ON=(GND)/OFF (OPEN)
D-IN-30 E-POC FILL lock-up L62 2 Fill switch ON=(GND)/OFF (OPEN)
D-IN-31 Shift hold switch L62 38 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-32 No item L62 28 ON (GND)/OFF (OPEN)
SOL/0-0 Electric (emergency steering) relay L63 7 Output ON (24V)/OFF (OPEN)
(If equipped)
SOL/0-1 E.C.S.S. relay L63 17 Output ON (24V)/OFF (OPEN)
SOL/0-2 Switch pump cut-off L63 27 Output ON (24V)/OFF (OPEN)
SOL/0-3 Neutral output L63 37 Output ON (24V)/OFF (OPEN)
SOL/0-4 Fan pump reverse solenoid L63 28 Output ON (24V)/OFF (OPEN)
SOL/0-5 Fan pump neutral solenoid L63 38 Output ON (24V)/OFF (OPEN)
D-OUT-0 Back lamp relay L63 4 Output ON (24V)/OFF (OPEN)
D-OUT-1 Transmission cut-off indicator L63 8 Output ON (24V)/OFF (OPEN)

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I/O signal Displayed item Connector Pin No. ON/OFF logic

No.
Work equipment controller (If equipped)

D-IN-0 Joystick ON/OFF change-over L71 23 Joystick (right FNR) selection=ON (24V)/OFF
switch (OPEN)

D-IN-1 Work equipment lock lever switch L71 17 Operating position=ON(24V)/

Obstruction position=OFF(OPEN)
D-IN-2 No item L71 11 ON (24V)/OFF (OPEN)
D-IN-3 No item L71 5 ON (24V)/OFF (OPEN)
D-IN-4 No item L71 24 ON (24V)/OFF (OPEN)
D-IN-5 No item L71 18 ON (24V)/OFF (OPEN)
D-IN-6 No item L71 12 ON (24V)/OFF (OPEN)
D-IN-7 No item L71 6 ON (24V)/OFF (OPEN)

D-IN-8 Joystick speed Hi/Lo change-over L73 10 Joystick Hi speed selection=ON (GND)/OFF
switch (OPEN)
D-IN-9 Bucket proximity switch (horizontal) L73 20 Horizontal position=ON (GND)/OFF (OPEN)
D-IN-10 Bucket full-stroke switch L73 30 Stroke end position=ON (GND)/OFF (OPEN)
D-IN-11 No item L73 40 ON (GND)/OFF (OPEN)
D-IN-12 Semi-auto digging hard switch L73 9 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-13 Semi-auto digging soft switch L73 19 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-14 No item L73 29 ON (GND)/OFF (OPEN)
D-IN-15 No item L73 39 ON (GND)/OFF (OPEN)
D-IN-16 No item L72 35 ON (GND)/OFF (OPEN)
D-IN-17 No item L72 25 ON (GND)/OFF (OPEN)
D-IN-18 No item L72 15 ON (GND)/OFF (OPEN)
D-IN-19 No item L72 5 ON (GND)/OFF (OPEN)
D-IN-20 No item L72 36 ON (GND)/OFF (OPEN)
D-IN-21 No item L72 26 ON (GND)/OFF (OPEN)
D-IN-22 No item L72 16 ON (GND)/OFF (OPEN)
D-IN-23 No item L72 6 ON (GND)/OFF (OPEN)
D-IN-24 No item L72 37 ON (GND)/OFF (OPEN)
D-IN-25 No item L72 27 ON (GND)/OFF (OPEN)
D-IN-26 No item L72 17 ON (GND)/OFF (OPEN)
D-IN-27 No item L72 7 ON (GND)/OFF (OPEN)
D-IN-28 Remote positioner raise set switch L72 13 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-29 Remote positioner lower set switch L72 3 Switch pressed=ON (GND)/OFF (OPEN)

D-IN-30 Remote positioner raise selection L72 2 Switch pressed=ON (GND)/OFF (OPEN)
switch

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I/O signal Displayed item Connector Pin No. ON/OFF logic

No.

D-IN-31 Remote positioner lower selection L72 38 Switch pressed=ON (GND)/OFF (OPEN)
switch
D-IN-32 No item L72 28 ON (GND)/OFF (OPEN)
SOL/0-0 Joystick EPC cut relay L73 7 Output ON (24V)/OFF (GND)
SOL/0-1 Detent lift arm RAISE L73 17 Output ON (24V)/OFF (GND)
SOL/0-2 Detent lift arm FLOATING L73 27 Output ON (24V)/OFF (GND)
SOL/0-3 Detent TILT L73 37 Output ON (24V)/OFF (GND)
SOL/0-4 Work equipment lock solenoid L73 28 Output ON (24V)/OFF (GND)
SOL/0-5 No item L73 38 Output ON (24V)/OFF (GND)
D-OUT-1 Remote positioner raise lamp L73 8 Output ON (24V)/OFF (GND)
D-OUT-2 Remote positioner lower lamp L73 18 Output ON (24V)/OFF (GND)

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(For Reference) Check Using the Real-Time Monitor

Example: Measurement of engine speed

Measure the engine speed under the following conditions:

Temperature of coolant: within operation range
Temperature of hydraulic oil: 45-55 °C
Temperature of power train oil: 70-90 °C

Use the real-time monitor first to check these conditions.

Conditions Real-time monitor item Component ID
Temperature of coolant COOLANT TEMP Machine monitor 04103
Temperature of hydraulic oil HYD TEMP Machine monitor 04401
Temperature of power train oil TC OIL TEMP Machine monitor 40100

After checking those conditions on the real-time monitor, check the engine speed
Conditions Real-time monitor item Component ID
Engine speed ENG SPEED Machine monitor 01001

(For Reference) Troubleshooting Using the Real-Time Monitor

Example: Cannot succeed in re-setting the Transmission cut-off position.

Possible causes of disabled cut-off of Transmission include the following:

Abnormal cut-off selection switch
Abnormal cut-off position set switch
Abnormal left brake pressure sensor
Abnormal Transmission controller

Check the Transmission controller first to see if any abnormality was found and to see if an error was
issued.
If no error was detected, check the status of input signals on the real-time monitor.
1. Check the cut-off selection switch
Item Real-time monitor item Pin position ID
D-IN-2 D-IN--0------7 L61-11 40905
40905:**0****
The third digit is [0] if the Transmission cut-off selection switch has recognized itself as not ON.
Item Real-time monitor item Pin position ID
D-IN-2 D-IN--0------7 L61-11 40905
40905:**1****
On the contrary, the digit is [1] if the switch has recognized itself as ON.
If [0] continues after you operated the switch, you can consider that the cut-off selection switch system
is abnormal.

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2. Check the cut-off set switch

Item Real-time monitor item Pin position ID
D-IN-3 D-IN--0------7 L61-11 40905
40905:***0***
The fourth digit is [0] if the Transmission cut-off set switch has recognized itself as not ON.
Item Real-time monitor item Pin position ID
D-IN-3 D-IN--0------7 L61-11 40905
40905:***1***
On the contrary, the digit is [1] if the switch has recognized itself as ON.
If [0] continues after you operated the switch, you can consider that the cut-off set switch is abnormal.

3. Check the left-hand brake pressure sensor

Check the left-hand brake pressure sensor with the engine kept operating.
Item Real-time monitor item Pin position ID
Left brake pressure L.H. BRAKE L61-19 41100
41100:*.**MPa
If the pressure does not change after you stepped on/released the cut-off brake, you can consider that
the sensor system is abnormal.
If you stepped on the left-hand brake fully, about 5.00Mpa {51kg/cm²} of pressure should be shown.
If you released the brake, a value less than 0.5Mpa {5kg/cm²} should be shown.
The pressure may change when you stepped on the brake even when the engine is stopped if some
pressure remains in accumulator; if no pressure remains in it, a value less than 0.5Mpa {5kg/cm²}
should be shown.

4. Check the cut-off pressure set value

Check the set value of the pressure at which Transmission is cut off.
1) Set the cut-off position at a desired pressure by stepping on the cut-off brake, with the left-hand
brake pressure sensor kept displaying.
Here, it is set at a pressure 1.5Mpa{15kg/cm²}.
Item Real-time monitor item Pin position ID
Left brake pressure L.H. BRAKE L61-19 41100
41100: 1.50MPa
Set the cut-off position ([1.50] was selected arbitrarily).
Setting cut-off causes the pressure taken into memory when the set switch being pressed was
released.
2) Check the cut-off pressure just set on the real-time monitor.
Item Real-time monitor item Pin position ID
Transmission cut-off pressure CUT OFF Calculated value 41200
41200: 1.50MPa
The result is accepted if the value is substantially the same with the value previously set.
Although, if the cut-off pressure has been set to less than 0.49Mpa{5kg/cm²}, 0.49Mpa{5kg/cm²}
shall be adopted as the set value; if the cut-off pressure has been set to more than 4.5Mpa{45kg/
cm²}, 4.5Mpa{45kg/cm²} shall be adopted as the set value.

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Load Meter Function (If equipped)

1. Outline
For the load meter, there are addition mode, subtraction mode, data display mode, calibration mode
and calculation stop mode, and each mode can be selected with the monitor panel mode selector
switch. If a printer (If equipped) is connected to the load meter, it is possible to print out measurement
data.

2. Operating Method

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3. Weight Calculation However, the real measured value (D) of lift arm
Since the pressure sensor (A) mounted on the pressure has characteristics shown in the figure
bottom side of the lift cylinder and the pressure below because operations of the tires and the
sensor (B) mounted on the head side detect work equipment cause spring effect to the
operating pressures (P) of the lift arm, and also machine.
the lift arm angle sensor (C) calculates positions
of the center of gravity, the load meter calcu-
lates weight (W) of load.

From the really measured value (D) in lift arm

lifting operation, value (B) is calculated accord-
ing to the calculation method below.
Weight is calculated from the differential pres- • The pressure fluctuates greatly and no fixed
sure (C) between the standard value (A) of lift value can be measured for 0.5 seconds after
arm pressure in unloaded state memorized the lift arm lifting start (E) due to the shift
(and corrected by calibration) and the calcu- from the static state to an dynamic state.
lated value (B) of lift arm pressure in the loaded So, the pressure cannot be used for calcula-
state. Also, it is designed for improving accu- tion.
racy that weights are detected and calculated
• Since the machine spring effect has peri-
while the boom is being lifted.
odic cycle of approximately one second, the
calculated value (B) is calculated as a mean
value of every second from the lift arm lift-
ing start to the stop.

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Judgment of Lift Arm Lifting Start

When all the following conditions are satisfied, the lift arm is judged to have started moving, and weight
calculation starts.

The lift arm angle ranges from -10° to -30°. (The range between below horizontal and above touching
Condition 1 the ground)
The lift arm angle increases more than 0.1° in 0.1 second. (The lift arm started moving upward at a
Condition 2 fixed speed.)

Judgment of Stop of Lift Arm Lifting

When any of the following conditions is satisfied, the lift arm is judged to have stopped, and a weight calcu-
lation ends.

The lift arm angle incseases less than 0.5° in 0.5 seconds. (The lift arm lifting speed reduced below
Condition 1 fixed value.)

Condition 2 The lift arm moves downward. (When lift arm lowering operation is done, the calculation is finished.)

Condition 3 The lift arm angle became up to +20° (The calculation stops at high position.)

The lift arm lifting speed changed suddenly. (The speed reduced below 70% in comparison with the
Condition 4 previous angular velocity.)

Condition 5 The calculation was carried out for 7 times.

Display of Calculated Weight

Calculated weight is displayed as the average value of each calculated values.

Calculation count Calculating time (sec.) Weight calculating and displaying methods
Weight is displayed by only one calculation. In this case, the weight
1 time only 1.5 - 2.5 display flashes to inform the operator that the calculating time is
short and the calculation accuracy is not enough.
2 times 2.5 - 3.5 Averaged weight of the two calculations is displayed.
3 times or more 3.5 - The averaged weight of the latest three calculations is displayed.

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4. Subtraction and Addition Modes

Addition Mode Subtraction Mode
At this mode, bucket load is added at each load- This mode is for reducing each bucket load
ing, and added value of loads is displayed, this from previously set target weight value, and is
mode is used to grasp total workloads. used for fixed total loading value works, etc.

• When the addition mode is selected, • When the subtraction mode is selected,
"TOTAL LOADED" (1) is displayed, and each "REMAINING TARGET"(1) is displayed, and
calculated bucket load (3) is added to the the calculated bucket load (3) is reduced
total load display (2). from the residual quantity display (2).
• Weights of any five kinds of object materi- • Weights of any five kinds of object materials
als can be independently accumulated and can be independently accumulated and dis-
displayed. For selection of object materi- played. For selection of object materials, the
als, the five kinds from A to E can be five kinds from A to E are selected and set
selected and set in the display of work in the display of work object materials (4).
object materials (4).
• Values up to 9999t are displayed in the total ★ For the detail of display and calculation
load display (2) unless data are cleared with methods of bucket load display (3) larger
the load meter sub-total switch. Values up than the residual quantity (2), see the para-
to 999.9t are displayed in units of 0.1t, and graph of "Operation of Load Meter" in the
when the value is over 1000t, the decimal Operation and Maintenance Manual.
point disappears and values are displayed
★ For the detail of residual quantity display,
in units of 1t.
see the paragraph of "Total Load Display
and Residual Quantity Display."
★ For the detail of total load display, see the
paragraph of "Total Load Display and Resid-
ual Quantity Display."

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Load Meter Cancel Switch

Total Load Display and Residual Quantity Display

Actual total load Total load Remarks

weight (t) display

- -99.5 -99.9 To be displayed with

decimal point
To be displayed with
-99.4 - -0.1 -**.* decimal point (round-
ing off the second
fractions)
To be displayed with
0 - 999.4 ***.* decimal point (round-
ing off the second
fractions)
To be displayed in • When this switch (1) is pressed during the
integers only (count- calculated weight display holding time (15
999.5 - 9999.4 **** ing factions of 0.5 and seconds after calculation), the bucket load
over as a unit and cut-
ting away the rest) is judged not to be loaded and the calcula-
tion is cancelled. The display of total load
To be displayed in
9999.5 - 9999 integers only. (or residual quantity) is also cancelled to be
increased (or decreased), and returns to the
previous value.
Unit of Calculated Weight
• All calculated weights are displayed in the SI
Load Meter Sub-total Switch
unit (metric ton). When "MPH" is selected to
display travel speed with the rotary switch
on the back of the monitor, however, it is
possible to change the unit to short ton by
setting the optional device in the service
mode. In this case, weights are printed out
in short ton as well.

k In countries where the SI unit is adopted,

the units of travel speed and load weight
should not be selected in any unit other
than the SI unit.

• To clear the total load display (in the addi-

tion mode), or to clear the residual quantity
display (in the subtraction mode), or to print
out displays, keep pressing this switch (1)
for more than 2 seconds.

Specification Operation after the switch is

pressed

Without printer The total load display (or residual

quantity display) is cleared.
The stored sub-total data are
With printer printed out. After being output, the
sub-total data are cleared.

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Automatic sub-total Function

1) When a printer (If equipped) is connected
Subtotal Data When a weight is calculated at the 501st
• After calculating weight, the following data are time, the data will be stored in the RAM 15
stored as a set: seconds later, and at the same time, data up
• Kind of object materials to 500 times will be printed out. After
• Each load weight being printed out, the sub-total data will be
cleared. After the 500th data is stored, the
• Total number of loading times
following messages will be displayed on
• Total load weight the character display: "LOAD DATA FULL"
Memory capacity: More than 500 loading times and "CLEAR DATA" But the measurement
can be continued.

2) When a printer (If equipped) is not connected

When a weight is calculated at the 501st
time, the data will be stored in the RAM 15
seconds later, and at the same time, weight
data of each bucket load up to 500 times
will be cleared. After the 500th data is
stored, the following messages will be dis-
played on the character display: "LOAD
DATA FULL." , "CLEAR DATA". But the
measurement can be continued.

Display on the Character Display after the 500th

Data is Stored.

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5. Cumulative Data Display Function

Data Display Data Reset

• Total load weight and total number of loading • Cumulative data of any of A to E or of all object
times are displayed in the addition mode or in materials are reset.
the subtraction mode. • "TOTAL DATA" is displayed on the character
• When "DATA" is selected on the load meter display. Press (>) or (<) on the monitor panel
function, then "TOTAL DATA" is displayed on mode selector switch 2, then, select any of A to
the character display. E or "turn on all" on the work object material
display, and press (<>) on the mode selector
switch.
• "RESET" and "YES <> NO" are displayed on the
character display for confirmation. Since the
cursor is located at the "NO" position right after
the screen changed, press (<) on the monitor
panel mode selector switch 2 to move it to the
"YES" position and press („) on the mode
selector switch.

★ The time based on the hour meter in which the

data were integrated is displayed on the lower
line (*****-*****h).
Example) If 12300-12450h is displayed, the data
integrated in 150 h from 12300 h to 12450 h are
displayed on the character display.
• Press (>) or (<) on the monitor panel mode
selector switch 2 and select any or all of A to E.
When any of A to E is selected, the cumulative
weight (2) for each kind and the number of • When the monitor begins to operate, the buzzer
loading times (3) will be displayed. When turn will sound "Pipi", and the service meter display
on all is selected, the total cumulative weight appears.
(2) of all object materials from A to E and the
total number of loading times (3) will be dis-
★ When more than 6 hours has elapsed after the
played.
battery is disconnected, cumulative date of the
load will be deleted from the memory. Keep
this in mind when using battery disconnection
switch.

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6. Printout (If equipped)

★ This function is available only when the printer (If equipped) is connected.
Output formats of the load meter can be selected from three (A, B and C) output modes. Output for-
mats of each mode are as follows:
★ For the output mode selection and output methods refer to the paragraph of "Operation of Load
Meter" in the Operation and Maintenance Manual.
Mode A (Total printout) Mode B (Sub-total printout) Mode C (Operation record printout)
• Machine Model, Serial number • Machine Model, Serial number • Machine Model, Serial number
• Printing time and date • Printing time and date • Record starting time and date, Service
• Sub-total data of loading (Kind, Num- • Loading data (Load weight) meter
ber of loading times, Load weight) • Loading sub-total data (Kind, Number • Record ending (printing) time and
• Total data of loading (Total number of of loading times, Load weight) data, Service meter
loading times, Total load weight) • Loading total data (Total number of • Subtotal data of loading (Kind, Num-
loading times, Total load weight) ber of loading times, Load weight)
• Total data of loading (Total number of
loading times, Total load weight)
• Maintenance time (Maintenance items,
remaining time)

Example of Printout in each Mode (In case of WA470-5)

Example of Printout in Mode A Example of Printout in Mode B Example of Printout in Mode C
WA470-5 #70001 WA470-5 #70001 WA470-5 #70001
25/OCT/2001 17:30 25/OCT/2001 17:30 Start time
25/OCT/2001 9:15
Material Times Total Load Material: A Service meter 00043.0h
A 1 2.62t 1: 2.62t End time
B 2 6.04t Total: 1 times 2.62t 25/OCT/2001 17:30
C 3 7.11t Service meter 00051.2h
D 4 9.04t Material: B
E 5 14.82t 1: 2.62t 2: 3.42t Material Times Total
Total 16 42.25t Total: 2 times 6.04t A 1 2.62t
B 2 6.04t
Material: C C 3 7.11t
1: 3.43t 2: 2.25t D 4 9.04t
3: 1.43t E 5 14.82t
Total: 3 times 7.11t Total 16 42.25t

Material: D Maintenance
1: 1.43t 2: 2.27t Engine oil 250h
3: 2.05t 4: 3.38t Transmission oil 1000h
Total: 4 times 9.04t Hydraulic oil 2000h
Axle oil 2000h
Material: E Engine oil filter 250h
1: 3.48t 2: 2.94t Transmission oil filter 500h
3: 3.64t 4: 1.97t Hydraulic oil filter 1000h
5: 2.79t Axle pivot pin 500h
Total: 5 times 14.82t Bobm pin 100h
Steering cylinder pin 250h
Center hinge pin 1000h

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7. Calibration Load Calibration

• There are two kinds of calibrations, i.e., the no- • This calibration is for compensating the stan-
load calibration for measuring pressure when dard pressure in a loaded state and is intended
the bucket is empty and the load calibration for to carry out the compensation (B) of an error
measuring pressure when a known weight is from the standard value (A) in the vicinity of
loaded. When the lift arm is raised while the load calibration (C) conducted as shown in the
bucket is fully tilted, the lift arm operating pres- figure below.
sure without load (0kg) or with a known load
weight is memorized.
• In general, accuracy can be fully secured only in
calibration without load. When the center of
gravity of a load is quite different from our pre-
set position due to modification of the lift arm
or the bucket, it is necessary to calibrate at the
load.
★ The memory of calibration data is not deleted
even while the battery is removed for a certain
time.

No-load Calibration ★ For the calibrating method, see the paragraph

• This calibration is for canceling such weight of Inspection and Adjustment of Load Meter in
difference peculiar to machine as work equip- the Volume of Inspection and Adjustment.
ment weight, etc. and is intended to compen-
sate offset error (B) from standard value (A) as
shown in the figure below. 8. Calculation Stop
This function stops the calculating function of
the load meter. During the calculation stop,
the load meter display disappears, and the
travel speed display or the engine speed dis-
play appears and the data is not added to the
total data. To resume the calculation, select
the Addition Mode or the Subtraction Mode.
★ For how to stop calculation, refer to the
paragraph of "Operation of Load Meter" in
the Operation and Maintenance Manual.

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Machine setting
Setting of machine serial number

1. Hold down the switch and < switch for 5 sec- 4. Enter the machine serial number.
onds or more, and change to the [ID entry
screen].

Entering ID
At transition to the screen, “50000” or “set
numeric value” is displayed on the screen.
2. Use the < and > switch to enter ID, and press Enter a numeric value 0 to 9 at the cursor posi-
the switch to enter the service person screen. tion.
The cursor appears on the highest-order posi-
tion, and 0 to 9 is displayed one by one each
time the > or < switch is pressed.
When a target numeric value is displayed, press
the switch.
The cursor moves to the second digit. Follow
the same procedure to enter up to the lowest-
order digit, and press the switch.
If a numeric value is changed, the operation
acceptance completion sound is output.
If an incorrect numeric value is entered, use the
switch to return to the [Select Setting] screen
once, and repeat the procedure from the begin-
ning.
3. Use the < and > switch to display the [machine
serial No. entry] screen, and press the switch
to decide the machine serial number.

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Setting necessary for option mounting

When one of the options below is added or replaced, initialize the sensors and solenoids using the machine
monitor.
Additional or changeable options Initial adjustment items
Transmission mainframe, Transmission controller, and ECMV Transmission initial learning
Lift arm angle sensor and work equipment controller Adjustment of work equipment lift arm angle
EPC lever, work equipment controller, and work equipment EPC Adjustment of work equipment EPC
valve
3 EPC levers, work equipment controller, and work equipment Adjustment of work machine EPC
EPC valve
Joystick lever, work equipment controller, Joystick EPC valve Adjustment of Joystick steering
Lift arm angle sensor and machine monitor Adjustment of load meter lift arm angle

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Optional device setting for machine monitor

When one of the options below is added or removed, change the machine monitor setting. If the machine
monitor is replaced, set the option mounting state of the machine.

Option set items

Item No. Option item English Remarks
Monitor panel controller
1 Auto grease AUTO GREASE
2 Battery electrolyte reduction sensor BAT LIQUID *4
3 Transmission clogging sensor TRANSM CLOG *4
4 Printer PRINTER
5 Lift arm high lift specifications HI LIFT
6 Speed/engine tachometer switch ENGINE RPM *1
7 Short ton switch SHORT TON *2
Transmission controller
1 Travel damper E.C.S.S
2 Torque converter lock-up LOCK UP
3 Emergency steering EMER STRG
4 Tire size TIRE SIZE *3
5 Spare switch AUTO RE FAN *4
6 Right FNR switch R.H. FNR SW
Work equipment controller
1 EPC lever EPC LEVER
2 Joystick lever JOY STICK
3 EPC 3rd levers EPC 3RD

* 1 : Setting of speed/engine tachometer indicator switch

When the rotary switch on the rear is km/h:the engine rotation is displayed at engine rotation option = ADD.
When the rotary switch on the rear is MPH:the engine rotation is displayed at engine rotation option = ADD.
When the rotary switch on the rear is rpm: the travel speed (km/h) is displayed engine rotation option = NO ADD.
* 2 : Setting of load meter short ton (US ton) indicator switch
When the DIP switches on the rear is MPH, the indicator is switched to short ton.
The MPH indicator is the domestic type using the non-SI unit (mile); so, do not change for SI unit countries.
* 3 : Adjustment of tire size
When the speed indicator does not match the actual value because an unspecified tire is used or a tire is abraded,
correct the tires so that the speed indicator matches the actual value.
When the normal tire size is changed, use the rotary switch 3 on the rear, not the adjustment function.
* 4 : No optional items are set for this machine.

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Operation method
1. Operate the monitor mode switch to select a 4. After a target controller is selected, press and
service mode optional select. release the monitor mode switch ( ). The set-
Pressing the monitor mode switch changes the ting state for each option appears as follows.
option setting as follows.

##: Displays an item number.

***: Displays an item name.
Upper row: Displayed when no option is set
2. Press and release the monitor panel mode
currently.
switch ( ).
Lower row: Displayed when option is set cur-
The screen changes to the monitor panel option
rently.
setting selectable display.
Pressing the switch changes ADD (set) or NO
ADD (not set), and the display is switched.
If the setting is changed, the operation accep-
tance completion sound (two short tones (0.1
sec. ON € 0.1 sec. OFF € 0.1 sec. ON)) is out-
put.
To adjust the tire size, the operation and display
sizes are as follows:

3. When the option setting controller is not the

monitor, use the monitor panel mode switch (<
or >) to switch to each controller.

Using the switches the 00% and @@%.

@@: Can be switched every 2% up to deflection
-12 to +12% for the setting of the DIP switches
on the rear.
+00€+02€+04€+06€+08€+10€+12€-02€-04
€-06€-08€-10€-12€+00… .
When the value is changed, the operation
acceptance completion sound (two short tones
(0.1 sec. ON € 0.1 sec. OFF € 0.1 sec. ON)) is
output.
Adjust the tire size only when an unspecified
tire is mounted.
5. Press and release the monitor panel mode
switch ( ); the menu returns to the preceding
screen.

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Transmission initial learning setting

Learning for correcting the solid difference of transmission

1. Learning data reset

Issue the learning data reset command to reset all learning data stored in the non-volatile memory.

Display of Transmission initial learning and procedure for resetting data

(1) Hold down the switch and < switch for 5 seconds or more at the same time, and change to
the ID entry screen. (Figure 1)
(2) Use the < and > switch to enter ID, and press the switch to enter the service person screen.
(3) Use the < and > switch to display the sensor initialization selection screen (Figure 2), and
press the switch to decide the value.
(4) Use the < and > switch to display the Transmission initial learning screen (Figure 3) of set
item 1.
(5) Depress the switch, and the transmission initial learning setting screen (Fig. 4-1 or Fig. 4-
2) appears.
(6)-1 If the initial learning has not been carried out, the initial learning incompletion (reset) screen
(Fig. 4-1) appears.
(6)-2 If the initial learning has been carried out, the initial learning completion screen (Fig. 4-2)
appears.
(7) To reset the initial learning, depress the switch to display the initial learning reset screen
(Fig. 5).
(8)-1 To reset the initial learning, select YEW with the < switch and depress the switch.
After the switch is depressed, if the initial learning incompletion (reset) screen (Fig. 4-1)
appears, the initial learning is reset.
(8)-2 If you do not need to reset the initial learning, select NO and depress the switch.
After the switch is depressed, the screen before the ž switch was depressed (Fig. 4-1 or
Fig. 4-2) appears and resetting is cancelled.

If the initial learning is necessary, carry out (1) - (5), and then carry out the resetting operation (up to (8)-1)
once while either the screen in (6)-1 or the screen in (6)-2 is displayed.

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2. Initial learning procedure

Preparation for machine

1. Start the engine.

2. Display the transmission oil temperature (Item ID: 41500, ECMV OIL TEMP) on the real-time monitor.
3. Operate the gear shift lever and directional lever, and circulate the oil inside the transmission.
Gear range N2 € F2 € F1 € F2 € F3 € F4 € F3 € F2 € N2 € R2 € N2
Holding time 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec
After holding each gear speed for the time specified or more, shift gears to the next range.
Operate the engine at low idling, place the shift mode switch in the MANUAL position and transmission cut- off switch in the OFF
position (the lockup switch in the OFF position).

4. Increase the oil temperature of transmission to 55 - 70°C.

Set the oil temperature to the specified temperature while learning operation.
Check that the machine is in normal conditions (no fault is detected).

Initial learning method

1. Carry out initial learning operation at the state of the machine mentioned above. (Do not stop the engine.)
2. Check that the oil temperature of transmission is in the range of 55 - 70°C on the real-time monitor.
If it is outside of the specified range, be sure to carry it out within the specified temperature range.
★ If the initial learning is carried out at the temperature outside of the specified range, it may cause
time lag and gear shift shock.
3. Shift the transmission by operating the gear shift lever and directional lever.
Gear range N2 € F2 € F1 € F2 € F3 € F4 € F3 € F2 € N2 € R2 € N2
Holding time 5 sec 5 sec 5 sec 3 sec 3 sec 3 sec 3 sec 3 sec 3 sec 3 sec 3 sec
After holding each gear speed for the time specified or more, shift gears to the next range.
Operate the engine at low idling, place the shift mode switch in the MANUAL position, and the transmission cut-off switch in the
OFF position (the lockup switch in the OFF position).
Carry out shifting operation while driving the machine actually or while depressing the brake pedal.

★ When setting to N2 initially, operate the directional lever by placing it in the N position following the
F2 or R2 position.
Even if the shift lever is changed to 2 after placing the directional lever in N, the gear will not
change. Therefore, operate the directional lever by placing it in the N position after setting the gear
shift lever to 2.
When the directional lever is placed in the N position at the shift lever in other than 2, place the
directional lever in the F or R position and then operate the directional lever in the N position fol-
lowing F2 or R2.
★ Hold the shift lever for the specified holding time or more for each speed of gear range.
If the gear shift lever is operated for the holding time or less, completion of initial learning (display
of TUNED) will not appear.
4. Check that completion of initial learning (display of TUNED) appears on the initial learning of transmis-
sion setting screen on the real-time monitor.

5. When the initial learning is not carried out (display of INITIAL STATUS), repeat operations mentioned in
3 and 4 until completion of initial learning (display of TUNED) appears.

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Adjustment of work equipment lift arm angle

(For electric work equipment lever) (If equipped)

1. Hold down the switch < switch for 5 seconds 4. Press the < and > switch to display the [Work
or more at the same time, and change to the [ID Equipment Lift Arm Angle Adjustment] screen
Entry] screen. of set item 2.

2. After the ID is entered using the < and > switch, 5. Press the switch here; the [Work Equipment
press the switch to enter the service person Lift Arm Angle Set] screen appears.
screen.

3. Press the < and > switch to display the [Sensor 6. Adjust the lift arm to the highest position with-
Initial Setting Selection] screen, and press the out load.
switch to decide the value.
7. Press the switch here: the lift arm angle sen-
sor value is read, and a difference between the
read result and reference value is stored as an
offset value.

8. Confirm that the buzzer sounds (two short

tones) twice and the menu returns to the [Lift
Arm Angle Adjustment] screen. The setting is
then completed.

9. Pressing the switch ends the lift arm angle

correction even if it is performed currently.

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Adjustment of work equipment EPC (If equipped)

Item setting
1. Hold down the < and > switch for 5 seconds or more at he same time, and change to the [ID Entry] screen.
2. Use the < and > switch to enter ID, and press the switch to enter the service person screen.
3. Use the < and > switch to display the [Sensor Initial Setting Selection] screen, and press the switch to
decide the value.
4. Use the < and > switch to display the [Work Equipment EPC Adjustment] screen on set items 4 to 7.
Lift arm up: No.4
Lift arm down: No.5
Bucket tilt: No.6
Bucket dump: No.7
3-valve extension: No.8
3-valve reduction: No.9
Set the value individually.
5. Press the switch here; the [Work Equipment EPC Setting] screen appears.

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Adjustment for each EPC

Lift arm RAISE
1. Dump the bucket to lower the lift arm, and lift the front tires. Lift the lift arm (lower the machine) by
degrees in the engine high idling state.
2. Return the lever by fine operation to stop the lift arm (tire floating). Then hold the lever at that position.
3. Press the switch here; the EPC command value is read, and a difference between the read value and
reference value is stored as an offset value.
4. The buzzer sounds twice (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
ment] screen. The setting is then completed.
5. When the switch is pressed as the lever stroke is in the down direction, the buzzer sounds for 1 sec-
ond, and the adjustment is canceled as the [Work Equipment EPC Setting] screen remains displayed.
6. When the switch is pressed as the lever is at the neutral position, the adjustment value is cleared,
and the buzzer sounds twice (two short tones). The menu then returns to the [Work Equipment EPC
Adjustment] screen.
7. Press the switch; the work equipment EPC dispersion correction is ended even if it is in progress of
processing.
Lift arm LOWER
1. Adjust the lift arm to the horizontal level without load, and lower the lift arm by degrees in the engine
high idling state.
2. Return the lever by fine operation to stop the lift arm, then hold the lever at that position.
3. Press the switch here; the EPC command value is read, and a difference between the read value and
reference value is stored as an offset value.
4. The buzzer sounds twice (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
ment] screen. The setting is then completed.
5. When the switch is pressed as the lever stroke is 40% or more in the down direction, the buzzer
sounds for 1 second, and the adjustment is canceled as the [Work Equipment EPC Setting] screen
remains displayed.
6. When the switch is pressed as the lever is at the neutral position, the adjustment value is cleared,
and the buzzer sounds twice (two short tones). The menu then returns to the [Work Equipment EPC
Adjustment] screen.

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Bucket tilt
1. Dump the bucket to lower the lift arm, and lift the front tires. Tilt the bucket by degrees in the engine
high idling state. (Lower the machine.)
2. Return the lever by fine operation to stop the bucket (tire floating), then hold the lever at that position.
3. Press the switch here; the EPC command value is read, and a difference between the read value and
reference value is stored as an offset value.
4. The buzzer sounds twice (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
ment] screen. The setting is then completed.
5. When the switch is pressed as the lever stroke is in the dump direction, the buzzer sounds for 1 sec-
ond, and the adjustment is canceled as the [Work Equipment EPC Setting] screen remains displayed.
6. When the switch is pressed as the lever is at the neutral position, the adjustment value is cleared,
and the buzzer sounds twice (two short tones). The menu then returns to the [Work Equipment EPC
Adjustment] screen.
7. When the switch is pressed, the work equipment EPC dispersion correction is ended even if it is in
progress of processing.

Bucket dump
1. Adjust the bucket to the horizontal level without load, and lower the bucket by degrees in the engine
high idling state.
2. Return the lever by fine operation to stop the lift arm, then hold the lever at that position.
3. Press the switch here; the EPC command value is read, and a difference between the read value and
reference value is stored as an offset value.
4. The buzzer sounds twice (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
ment] screen. The setting is then completed.
5. When the switch is pressed as the lever stroke is in the tilt direction, the buzzer sounds for 1 second,
and the adjustment is canceled as the [Work Equipment EPC Setting] screen remains displayed.
6. When the switch is pressed as the lever is at the neutral position, the adjustment value is cleared,
and the buzzer sounds twice (two short tones). The menu then returns to the [Work Equipment EPC
Adjustment] screen.

3-valve extension
1. Extend three valves by degrees in the engine high idling state.
2. Return the lever by fine operation. After the cylinder of three valves stops, hold the lever at that posi-
tion.
3. Press the switch here; the EPC command value is read, and a difference between the read value and
reference value is stored as an offset value.
4. The buzzer sounds twice, (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
ment] screen. The setting is then completed.
5. When the switch is pressed as the lever stroke is in the fastening direction, the buzzer sounds for 1
second, and the adjustment is canceled as the [Work Equipment EPC Setting] screen remains dis-
played.
6. When the switch is pressed as the lever is at the neutral position, the adjustment value is cleared,
and the buzzer sounds twice (two short tones). The menu then returns to the [Work Equipment EPC
Adjustment] screen.
7. When the switch is pressed, the work equipment EPC dispersion correction is ended even if it is in
progress of processing.

3-valve reduction
1. Reduce three valves by degrees in the engine high idling state.
2. Return the lever by fine operation. After the cylinder of three valves stops, hold the lever at that posi-
tion.
3. Press the switch here; the EPC command value is read, and a difference between the read value and
reference value is stored as an offset value.
4. The buzzer sounds twice, (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
ment] screen. The setting is then completed.
5. When the switch is pressed as the lever stroke is in the extension direction, the buzzer sounds for 1
second, and the adjustment is canceled as the [Work Equipment EPC Setting] screen remains dis-
played.
6. When the switch is pressed as the lever is at the neutral position, the adjustment value is cleared,
and the buzzer sounds twice (two short tones). The menu then returns to the [Work Equipment EPC
Adjustment] screen.
7. When the switch is pressed, the work equipment EPC dispersion correction is ended even if it is in
progress of processing.
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Correction of position of work equipment EPC lever detent

Procedure for correcting position of work equipment EPC lever

Perform the following procedure with the engine stopped

1. Push and hold the „ switch and > switch simul- 4. Display the screen for adjusting items No. 4 — 6
taneously for 5 seconds to go to the "Input ID" of the work equipment EPC with the < switch
screen. and > switch.

Screen for adjusting work equipment EPC

2. Input the ID with the < switch and > switch, then RAISE lift arm: No. 4
push the ‘ switch to go to the screen for the LOWER lift arm: No. 5
service person. Tilt bucket: No. 6
Set these items respectively.
Perform this correction procedure when the electric
work equipment control lever or work equipment
controller is replaced.
This correction procedure cannot be performed if
the ROM No. of the work equipment controller in
the real-time monitor is ****R200.

5. Push the ‘ switch and the screen for setting

the work equipment EPC appears.

3. Display the "Select initial setting of sensors"

screen with the < switch and > switch and enter
the setting.

Screen for setting work equipment EPC.

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< Adjustment of each EPC lever > [Adjustment of position of lift arm RAISE
[Adjustment of position of lift arm LOWER detent]
(FLOAT) detent] Perform the following procedure with the
1) -1. Lower the lift arm to the ground. engine stopped.
2) -1. Stop and hold the lift arm lever before the 1) -2. Lower the lift arm to the ground.
FLOAT detent position. 2) -2. Stop and hold the lift arm lever before the
3) -1. Push the switch at this time. The lever volt- RAISE detent position.
age is read and the standard value is changed 3) -2. Push the switch at this time. The lever volt-
and saved. age is read and the standard value is changed
4) -1. The buzzer sounds twice. The screen for and saved.
adjusting the work equipment EPC appears and 4) -2. The buzzer sounds twice. The screen for
the adjustment is completed. adjusting the work equipment EPC appears and
the adjustment is completed.
Screen for adjusting work equipment EPC 5) -2. At this time, if the switch is pushed while
the lever output voltage is below the standard
value (out of design range), the buzzer sounds for
1 second and the screen for setting work equip-
ment EPC does not change. The adjustment is
cancelled in this case.

The buzzer sounds twice and the screen for

adjusting work equipment EPC appears again.

6) Correction of the position of the work equipment

EPC lever detent can be stopped at any time by
pushing the switch.

5) -1. At this time, if the switch is pushed while

the lever output voltage is below the standard
value (out of the design range), the buzzer sounds
for 1 second and the screen for setting work
equipment EPC does not change. The adjustment
is cancelled in this case.
The buzzer sounds twice and the screen for
adjusting work equipment EPC appears again.
6) Correction of the position of the work equipment
EPC lever detent can be stopped at any time by
pushing the switch.

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[Adjustment of the position of the bucket TILT

detent]
Perform the following procedure with the
engine stopped.
1) -3. Lower the lift arm to the ground.
2) -3. Stop and hold the bucket lever before the TILT
detent position.
3) -3. Push the switch at this time. The lever volt-
age is read and the standard value is changed
and saved.
4) -3. The buzzer sounds twice. The screen for
adjusting the work equipment EPC appears and
the adjustment is completed.
5) -3. At this time, if the switch is pushed while
the lever output voltage is below the standard
value (out of the design range), the buzzer sounds
for 1 second. The screen for setting the work
equipment EPC does not change. The adjustment
is cancelled in this case.

The buzzer sounds twice and the screen for

adjusting work equipment EPC appears again.

6) Correction of the position of the work equipment

EPC lever detent can be stopped at an time by
pushing the switch.

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Adjustment of Joystick steering (If equipped)

1. Hold down the switch < switch for 5 seconds
or more at the same time, and change to the [ID
Entry] screen.

5. Press the switch here; the [Joystick Calibra-

tion Adjustment] screen appears. (Right or left)

2. Use the < and > switch to enter ID, and press
the switch to enter the service person screen.

Setting of starting point (Right or left)

6. Set the engine high idling state, and set the
switch speed High/Low switch to High.
(For this operation, use the stationary steering.)
3. Use the < and > switch to display the [Sensor
7. Start the steering by right or left steering fine-
Initialization Setting] screen, and press the
operation, and stop the steering. Then hold the
switch to decide the value.
lever at that position.
8. Press the switch here; the EPC command
value is read, and a difference between the read
value and reference value is stored as an offset
value.
9. The buzzer sounds twice (two short tones), and
the [Joystick Steering Calibration Adjustment]
screen returns. The setting is then completed.
10. When the switch is pressed as the lever is in
the reverse state, the buzzer sounds for 1 sec-
ond, and the adjustment is canceled as the
[Joystick Calibration Setting] screen remains
4. Use the < and > switch to display the [Joystick displayed.
Calibration Adjustment] screen of set item 11 or 11. When the switch is pressed as the lever is at
12. (Right or left) the neutral position, the adjustment value is
cleared to the initial value, and the buzzer
sounds twice (two short tones). The menu then
returns to the [Joystick Steering Calibration
Adjustment] screen.
12. When the switch is pressed, the Joystick cali-
bration is ended even if it is in progress of pro-
cessing.
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