Shop Manuel WA900-3

SEN02034-13
WHEEL LOADER WA800 -3E0

WA900 -3E0
WA800- 70001
SERIAL NUMBERS and up
WA900- 60001
SEN02036-13
WHEEL LOADER 1SHOP MANUAL
WA800-3E0,
WA900-3E0
Machine model Serial number

WA800-3E0 70001 and up
WA900-3E0 60001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2

Table of contents ............................................................................................................................................. 4
WA800-3E0, WA900-3E0 1
SEN02036-13 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN02034-13
00 Index and foreword SEN02035-13

Index SEN02036-13 q
Foreword and general information SEN02037-04
01 Specification SEN02038-02
Specification and technical data SEN02039-02
10 Structure, function and maintenance standard SEN02040-07

Engine and cooling system SEN02351-01
Power train, Part 1 SEN02352-01 q
Steering system SEN02353-01
Brake system SEN02354-01
Undercarriage and frame SEN02355-00
Hydraulic system, Part 1 SEN02356-00
Work equipment SEN02357-00
Cab and its attachments SEN02358-00
Electrical system, Part 1 SEN02359-00
Electrical system, Part 3 SEN02361-03 q
20 Standard value table SEN02041-02

Standard service value table SEN02154-02 q
30 Testing and adjusting SEN02042-06

Testing and adjusting, Part 1 SEN02155-04
Testing and adjusting, Part 2 SEN02156-03 q
40 Troubleshooting SEN02043-06
Failure code table, fuse and relay locations SEN02142-04
General information on troubleshooting SEN02143-02
Troubleshooting by failure code (Display of code), Part 1 SEN02144-01
2 WA800-3E0, WA900-3E0

Troubleshooting by failure code (Display of code), Part 6 SEN02268-01 q
Troubleshooting of electrical system (E-mode) SEN02149-01
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02150-01
Troubleshooting of engine (S-mode) SEN02151-01
Troubleshooting of machine monitor system (M-mode) SEN02152-00
Troubleshooting of maintenance monitor system (K-mode) SEN02153-02
Troubleshooting of remote boom positioner controller system (if equipped) (W-mode) SEN04494-00
50 Disassembly and assembly SEN02044-08

General information on disassembly and assembly SEN02739-02
Engine and cooling system, Part 1 SEN02740-01
Power train, Part 2 SEN02743-01
Brake system SEN02745-03 q
Hydraulic system SEN02747-03 q
Cab and its attachments SEN02749-02 q
Electrical system SEN02750-00
90 Diagrams and drawings SEN02045-02

Hydraulic diagrams and drawings SEN02046-00
Electrical diagrams and drawings SEN02047-02 q
WA800-3E0, WA900-3E0 3
Table of contents 1
00 Index and foreword
Index SEN02036-13
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN02037-04

Safety notice ............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code................................................................................................. 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN02039-02
General assembly drawing.......................................................................................................... 2
Specifications .............................................................................................................................. 4
Weight table ................................................................................................................................ 7
Table of fuel, coolant and lubricants ............................................................................................ 10
10 Structure, function and maintenance standard

Engine and cooling system SEN02351-01
Engine mount .............................................................................................................................. 2
Transmission mount .................................................................................................................... 3
Damper........................................................................................................................................ 4
Radiator, oil cooler, aftercooler .................................................................................................... 6
Fuel system ................................................................................................................................. 9
Power train .................................................................................................................................. 2
Power train system...................................................................................................................... 4
Torque converter ......................................................................................................................... 6
Torque converter regulator valve................................................................................................. 14
Transmission ............................................................................................................................... 16
Transfer ....................................................................................................................................... 28
Transmission control valve .......................................................................................................... 31
Torque converter oil cooler .......................................................................................................... 2
Drive shaft ................................................................................................................................... 4
Center support............................................................................................................................. 6
Axle ............................................................................................................................................. 8
Differential ................................................................................................................................... 10
Final drive.................................................................................................................................... 16
Steering system SEN02353-01
Steering piping............................................................................................................................. 2
AJSS lever linkage ...................................................................................................................... 4
EPC valve.................................................................................................................................... 5
Steering column........................................................................................................................... 6
Rotary valve ................................................................................................................................ 7
Steering control valve .................................................................................................................. 10
Steering unit (orbit-roll valve)....................................................................................................... 22
4 WA800-3E0, WA900-3E0
Steering pump ............................................................................................................................. 25

Steering cylinder.......................................................................................................................... 27
Slow return valve......................................................................................................................... 29
Emergency steering piping.......................................................................................................... 30
Diverter valve .............................................................................................................................. 31
Emergency steering pump .......................................................................................................... 37
Brake piping ................................................................................................................................ 2
Brake........................................................................................................................................... 3
Brake valve ................................................................................................................................. 6
Accumulator charge valve........................................................................................................... 14
PPC relief valve........................................................................................................................... 18
Accumulator (for brake)............................................................................................................... 20
Slack adjuster.............................................................................................................................. 21
Parking brake .............................................................................................................................. 23
Parking brake caliper .................................................................................................................. 25
Spring cylinder............................................................................................................................. 26
Parking brake solenoid................................................................................................................ 27
Brake cooling system (if equipped) ............................................................................................. 28
Brake cooling system (55°C specification) (If equipped)............................................................. 36
Axle mount .................................................................................................................................. 2
Center hinge pin.......................................................................................................................... 5
Tire and wheel............................................................................................................................. 7
Jack up point ............................................................................................................................... 8
Hydraulic piping........................................................................................................................... 2
Work equipment lever linkage ..................................................................................................... 3
Hydraulic tank ............................................................................................................................. 4
Torque converter charging, PPC and brake pump ...................................................................... 8
Main control valve ....................................................................................................................... 2
Accumulator (For PPC valve)...................................................................................................... 17
Main piston pump........................................................................................................................ 18
Main piston pump cut-off solenoid valve ..................................................................................... 29
PPC valve ................................................................................................................................... 30
PPC relief valve........................................................................................................................... 35
Switch pump................................................................................................................................ 36
Control pump............................................................................................................................... 45
Work equipment linkage.............................................................................................................. 2
Bucket positioner and lift arm kick-out ........................................................................................ 6
Remote lift arm positioner ........................................................................................................... 8
Auto greasing system.................................................................................................................. 9
Hydraulic cylinder........................................................................................................................ 10
ROPS cab ................................................................................................................................... 2
Air conditioner ............................................................................................................................. 3
Machine monitor system ............................................................................................................. 2
Main monitor ............................................................................................................................... 4
Maintenance monitor................................................................................................................... 8
Work equipment control system .................................................................................................. 2
Remote position, joystick steering controller............................................................................... 5
Active power maximizing electrical circuit ................................................................................... 6
Automatic transmission system (ATM) ........................................................................................ 13
WA800-3E0, WA900-3E0 5

Engine starting/stopping circuit ................................................................................................... 2
Parking brake circuit.................................................................................................................... 4
Preheating circuit......................................................................................................................... 10
Emergency engine stop............................................................................................................... 12
Hydraulic oil level sensor............................................................................................................. 14
Battery and starting motor disconnector switch and starting aid connector ................................ 16
Sensor ......................................................................................................................................... 18
20 Standard value table

Standard service value table SEN02154-02
Standard value table for engine................................................................................................... 2
Standard value table for chassis ................................................................................................. 3
Standard value table for electrical system................................................................................... 7
30 Testing and adjusting

Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Measuring engine speed ............................................................................................................. 8
Measuring intake air (boost) pressure......................................................................................... 10
Measuring exhaust gas color ...................................................................................................... 11
Measuring exhaust temperature.................................................................................................. 12
Adjusting valve clearance............................................................................................................ 14
Measuring compression pressure ............................................................................................... 15
Measuring blow-by pressure ....................................................................................................... 17
Measuring engine oil pressure .................................................................................................... 19
Handling fuel system equipment ................................................................................................. 20
Releasing residual pressure in fuel system................................................................................. 20
Testing fuel pressure ................................................................................................................... 21
Measuring fuel return rate and leakage....................................................................................... 22
Bleeding air from fuel circuit ........................................................................................................ 25
Testing leakage in fuel system .................................................................................................... 27
Handling reduced cylinder mode operation................................................................................. 28
Handling no-injection cranking operation .................................................................................... 28
Handling controller voltage circuit ............................................................................................... 29
Adjusting speed sensor ............................................................................................................... 29
Testing and adjusting alternator belt tension ............................................................................... 30
Testing and adjusting belt tension for air conditioner compressor............................................... 31
Testing and adjusting power train oil pressure ............................................................................ 32
Procedure for operating emergency steering spool when transmission valve fails..................... 37
Measuring operating effort of AJSS lever (AJSS specification) .................................................. 3
Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification) .. 4
Testing and adjusting steering stopper bolt (AJSS specification)................................................ 6
Testing and adjusting steering stop valve.................................................................................... 8
Measuring steering oil pressure .................................................................................................. 9
Testing and adjusting emergency steering oil pressure .............................................................. 10
Bleeding air from steering circuit ................................................................................................. 12
Measuring brake pedal................................................................................................................ 13
Measuring brake performance .................................................................................................... 14
Testing and adjusting accumulator charge pressure ................................................................... 15
Measuring wheel brake oil pressure reduction............................................................................ 17
Measuring wear of wheel brake disc ........................................................................................... 19
Bleeding air from wheel brake circuit .......................................................................................... 20
Releasing residual pressure in brake accumulator circuit ........................................................... 21
Testing parking brake performance ............................................................................................. 22
Measuring parking brake solenoid oil pressure........................................................................... 23
6 WA800-3E0, WA900-3E0
Testing and adjusting wear of parking brake pad ........................................................................ 24

Testing and adjusting PPC oil pressure ...................................................................................... 25
Adjusting PPC valve linkage ....................................................................................................... 27
Testing and adjusting work equipment oil pressure .................................................................... 28
Bleeding air from piston pump .................................................................................................... 30
Bleeding air from work equipment circuit .................................................................................... 31
Adjusting work equipment lever linkage...................................................................................... 32
Releasing remaining pressure in hydraulic circuit....................................................................... 34
Testing and adjusting bucket proximity switch ............................................................................ 35
Testing and adjusting bucket positioner and tilt limiter ................................................................ 36
Testing and adjusting lift arm proximity switch ............................................................................ 38
Testing and adjusting active working proximity switch ................................................................ 39
Checking proximity switch operation pilot lamp .......................................................................... 40
Testing and adjusting lift arm position detection lever ................................................................. 41
Adjusting speedometer module of main monitor......................................................................... 42
Special function of engine service monitor.................................................................................. 2
VHMS controller initial setting procedure .................................................................................... 26
Precautions for replacing VHMS controller ................................................................................. 48
Pm-clinic inspection table............................................................................................................ 54
40 Troubleshooting
Failure code table, fuse and relay locations SEN02142-04
Failure code table........................................................................................................................ 2
Method of displaying action code and failure code on machine monitor..................................... 9
Transmission & AJSS controller LED display.............................................................................. 11
Transmission control system....................................................................................................... 12
AJSS (Advanced Joystick Steering System) control system....................................................... 13
Location of fuse........................................................................................................................... 14
Location of relay.......................................................................................................................... 18
General information on troubleshooting SEN02143-02
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Testing before troubleshooting .................................................................................................... 4
Classification and procedures of troubleshooting ....................................................................... 5
Contents of troubleshooting table................................................................................................ 6
Connection table for connector pin numbers .............................................................................. 8
T- branch box and T- branch adapter table ................................................................................. 44
Failure code [15B0NX] (Transmission oil filter: Clogging)........................................................... 4
Failure code [AA1ANX] (Air cleaner L.H: Clogged)..................................................................... 6
Failure code [AA1BNX] (Air cleaner R.H: Clogged) .................................................................... 9
Failure code [AB00L4] (Alternator: Failure on battery charge circuit
(R terminal signal is present and engine is stopped)........................................................... 12
(R terminal signal is present and engine is stopped)........................................................... 14
Failure code [AB00MA] (Alternator: Failure on battery charge circuit
(Absence of R terminal signal and detection error) ............................................................. 16
Failure code [AB00MB] (Alternator: Failure on battery charge circuit
Failure code [AB00MC] (Alternator: Failure on battery charge circuit
Failure code [B@BAZK] (Engine oil: Oil level low)...................................................................... 22
Failure code [B@BAZG] (Engine oil: Low oil pressure) .............................................................. 24
Failure code [B@BCZK] and [b@BCZK] (Radiator coolant: Low coolant level) ......................... 28
Failure code [B@BDNS] (Engine: Overheating) ......................................................................... 30
Failure code [B@C6NS] (Front brake oil temperature: Overheating) ......................................... 32
Failure code [B@CENS] (Torque converter oil temperature overheating) .................................. 34
WA800-3E0, WA900-3E0 7
Failure code [B@JFZG] (Brake oil: Low oil pressure) ................................................................. 36

Failure code [CA111] Engine controller (Left bank): Internal abnormality ................................... 4
Failure code [CB111] Engine controller (Right bank): Internal abnormality ................................. 6
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank):
Abnormal speed sensor signal ............................................................................................ 8
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank):
Abnormal speed sensor signal ............................................................................................ 9
Failure code [CA122] Charge pressure sensor too high (At left bank only):
Excessively high voltage detected ....................................................................................... 10
Failure code [CA123] Charge pressure sensor too low (At left bank only):
Excessively low voltage detected ........................................................................................ 12
Failure code [CA131] Throttle sensor abnormally high level (Only left bank):
High voltage detection ......................................................................................................... 13
Failure code [CA132] Throttle sensor too low (At left bank only):
Failure code [CA135] Oil pressure sensor too high (At left bank only):
Failure code [CA141] Oil pressure sensor too low (At left bank only):
Failure code [CA144] Coolant temperature sensor too high:
Failure code [CA145] Coolant temperature sensor too low (At left bank only):
Failure code [CA153] Charge temperature sensor too high (At left bank only):
Failure code [CA154] Charge temperature sensor too low (At left bank only):
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank):
Low voltage detection .......................................................................................................... 28
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank):
Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank):
Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank):
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only):
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only):
Failure code [CA227] Sensor power source (2) too high (At left bank):
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank):
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed ............... 40
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only):
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only):
Failure code [CA263] Fuel temperature sensor too high (At left bank):
Failure code [CB263] Fuel temperature sensor too high (At right bank):
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank):
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank):
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit.............................................. 50
8 WA800-3E0, WA900-3E0
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit ........................................... 51
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection ...................................... 52
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection.................................... 53
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit ............................................. 54
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit ........................................... 55
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection ...................................... 56
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection.................................... 57
Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or
short circuit (At left bank): Disconnection, short circuit ........................................................ 4
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch........................... 16
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch ........................ 17
Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit ................. 18
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality .......... 20
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank):
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank):
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank):
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank):
Failure code [CA431] Trouble in idle validation switch................................................................ 28
Failure code [CA432] Idle validation action error ........................................................................ 30
Failure code [CA441] Power supply voltage abnormally low level (Left bank):
Failure code [CB441] Power supply voltage abnormally low level (Right bank):
Failure code [CA442] Power supply voltage abnormally high level (Left bank):
Failure code [CB442] Power supply voltage abnormally high level (Right bank):
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank):
Abnormally high pressure occurrence ................................................................................. 33
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank):
Abnormally high pressure occurrence ................................................................................. 33
Failure code [CA451] Common rail pressure sensor too high (At left bank):
Excessively high voltage detected....................................................................................... 34
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank):
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank):
Abnormally low voltage detection ........................................................................................ 38
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank):
Abnormally low voltage detection ........................................................................................ 38
Failure code [CA553] Common rail pressure too high (1) (At left bank):
Excessively high pressure detected .................................................................................... 39
Failure code [CB553] Common rail pressure too high (1) (At right bank):
Excessively high pressure detected .................................................................................... 40
WA800-3E0, WA900-3E0 9
Failure code [CA554] In-range error in common rail pressure sensor (At left bank):
In-range error ....................................................................................................................... 41
Failure code [CB554] In-range error in common rail pressure sensor (At right bank):
In-range error ....................................................................................................................... 41
Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank):
Loss of pressure feed detected ........................................................................................... 42
Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank):
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal ......... 50
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal....... 52
Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank):
Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank):
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank):
Abnormal phase................................................................................................................... 57
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank):
Abnormal phase................................................................................................................... 57
Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data .............. 3
Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data ............ 3
Failure code [CA778] Engine Bkup speed sensor abnormality (At left bank):
Bkup signal error.................................................................................................................. 4
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank):
Bkup signal error.................................................................................................................. 6
Failure code [CA781] Inter-multicontroller communication error (Left bank):
Communication error ........................................................................................................... 8
Failure code [CB781] Inter-multicontroller communication error (Right bank):
Communication error ........................................................................................................... 10
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank):
Distinction error.................................................................................................................... 11
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank):
Distinction error.................................................................................................................... 12
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank):
Disconnection/Short circuit .................................................................................................. 14
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error ....................... 26
Failure code [CA2185] Throttle sensor power supply abnormally high level (Only left bank):
Failure code [CA2186] Throttle sensor power source too low (At left bank only):
Failure code [CA2555] Intake heater relay voltage low error (Left bank only)............................. 32
Failure code [CA2556] Intake heater relay voltage high error (Left bank only) ........................... 34
Failure code [D160KZ] (or TM & AJSS controller LED display [10], abnormality in
backup lamp relay system: Disconnection, short circuit or hot short circuit......................... 36
10 WA800-3E0, WA900-3E0
Failure code [D180KA] (Preheating relay output system: Disconnection) .................................. 38

Failure code [D180KB] (Preheating relay output system: Grounding fault) ................................ 39
Failure code [D180KY] (Preheating relay output system: Hot short circuit) ................................ 40
Failure code [D19AKB] (or TM & AJSS controller LED display [56], abnormality in
joystick caution relay output system: Disconnection or short circuit)................................... 42
Failure code [D19BKZ] (or TM & AJSS controller LED display [62], abnormality in
joystick neutral interlock relay output system: Disconnection or short circuit) ..................... 44
Failure code [D1EFKA] (Pre-lubrication start relay output system: Disconnection) .................... 46
Failure code [D1EFKB] (Pre-lubrication start relay output system: Grounding fault) .................. 48
Failure code [D1EFKY] (Pre-lubrication start relay output system: Hot short circuit).................. 50
Failure code [D1EHKA] (Engine start relay output system: Disconnection)................................ 52
Failure code [D1EHKB] (Engine start relay output system: Grounding fault).............................. 54
Failure code [D1EHKY] (Engine start relay output system: Hot short circuit) ............................. 56
Failure code [D5ZHL6] (Starting switch terminal C signal: Error)................................................ 58
Failure code [D5ZSKA] (Machine monitor communication output: Disconnection)..................... 60
Failure code [D5ZSKB] (Machine monitor communication output: Grounding fault)................... 61
Failure code [D5ZSKY] (Machine monitor communication output: Hot short circuit) .................. 62
Failure code [DB2RKR] (Engine controller CAN-NET communication:
Disconnection and grounding fault) ..................................................................................... 3
Failure code [DBB0KK] (or VHMS LED display: "n9" o "01", VHMS controller:
Low supply voltage) ............................................................................................................. 6
Failure code [DBB0KQ] (or VHMS LED display: "nF" o "11", VHMS controller model selection:
Disagreement of model selection signals) ........................................................................... 8
Failure code [DBB3KK] (or VHMS LED display: "n9" o "05", VHMS controller:
Low direct supply voltage) ................................................................................................... 10
Failure code [DBB5KP] (or VHMS LED display: "n9" o "04", VHMS controller sensor power
supply (5 V): Low output voltage) ........................................................................................ 12
Failure code [DBB6KP] (or VHMS LED display: "n9" o "02", VHMS controller sensor power
supply (24 V): Low output voltage) ...................................................................................... 14
Failure code [DBBQKR] (or VHMS LED display: "n8" o "02", VHMS controller
CAN communication abnormality) ....................................................................................... 16
Failure code [DBG2KK] (Solenoid power supply: Low voltage) .................................................. 18
Failure code [DBG3KK] (Battery direct power supply: Low voltage) ........................................... 20
Failure code [DBG9KQ] (Model selection signal: Abnormal) ...................................................... 22
Failure code [DBGRKR] (Pre-lubrication controller CAN-NET communication:
Disconnection or grounding fault) ........................................................................................ 23
Failure code [DBL0KR] (Power ladder controller CAN-NET communication:
Disconnection or grounding fault) ....................................................................................... 26
Failure code [DDE2KB] (Engine oil pressure switch error: Grounding fault)............................... 28
Failure code [DDE2L6] (Engine oil pressure switch error: Disconnection or hot short circuit) .... 30
Failure code [DDK3KZ] (or TM & AJSS controller LED display [20], abnormality in
joystick forward-reverse switch system: Disconnection or hot short circuit) ........................ 32
Failure code [DDK5KZ] (or TM & AJSS controller LED display: “21”, Abnormality in
shifting up/down switch system: Disconnection, short circuit or hot short circuit)................ 35
Failure code [DDP5KZ] (Abnormality in steering lock switch system:
Disconnection or short circuit) ............................................................................................. 38
Failure code [DGE5KX] (Atmospheric temperature sensor: Out of input signal range (short))... 40
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range (short)) ... 42
Failure code [DGR4KX] (Front brake oil temperature sensor:
Out of input signal range (short)) ......................................................................................... 44
Failure code [DGT5KA] (or VHMS LED display: "n3" o "12", L.H. bank exhaust gas
temperature sensor system (Front): Disconnection or short circuit) .................................... 3
Failure code [dGT5KA] (or VHMS LED display: "n3" o "22", L.H. bank exhaust gas
temperature sensor system (Rear): Disconnection or short circuit) .................................... 6
Failure code [DGT5KB] (or VHMS LED display: "n3" o "11", L.H. bank exhaust gas
temperature sensor system (Front): Hot short circuit) ......................................................... 10
WA800-3E0, WA900-3E0 11
Failure code [dGT5KB] (or VHMS LED display: "n3" o "21", L.H. bank exhaust gas
temperature sensor system (Rear): Hot short circuit) .......................................................... 12
Failure code [DGT6KA] (or VHMS LED display: "n3" o "24", R.H. bank exhaust gas
temperature sensor system (Front): Disconnection or short circuit) .................................... 14
Failure code [dGT6KA] (or VHMS LED display: "n3" o "26", R.H. exhaust gas
temperature sensor system (Rear): Disconnection or short circuit)..................................... 17
Failure code [DGT6KB] (or VHMS LED display "n3" o "23", R.H. bank exhaust gas
temperature sensor system (front): Hot short circuit) .......................................................... 20
Failure code [dGT6KB] (or VHMS LED display "n3" o "25", R.H. bank exhaust gas
temperature sensor system (rear): Hot short circuit) ........................................................... 22
Failure code [DHE5KB] (or VHMS_LED display: "n3" o "32",
Blow-by pressure sensor system: Short circuit)................................................................... 24
Failure code [DHE5KY] (or VHMS LED display: "n3" o "31",
Blow-by pressure sensor system: Hot short circuit)............................................................. 26
Failure code [DHP2KX] (Main pump oil pressure sensor error: Disconnection or short circuit) .. 28
Failure code [DHT3KX] (or VHMS LED display: "n6" o "14", Transmission oil pressure
sensor system: Out of input signal range) ........................................................................... 30
Failure code [DHT8KX] (Steering pump oil pressure sensor error):
Failure code [DHU2KX] (Front brake oil pressure sensor error:
Failure code [DHU3KX] (Rear brake oil pressure sensor error: Disconnection or short circuit).. 36
Failure code [DK00L8] (or TM & AJSS controller LED display [58],
steering and frame angle displacement).............................................................................. 38
Failure code [DK30KX] (or TM & AJSS controller LED display [57],
abnormality in steering angle potentiometer system): Disconnection or short circuit) ......... 40
Failure code [DKD0KX] (or TM & AJSS controller LED display [59],
abnormality in frame angle potentiometer system: Disconnection or short circuit).............. 42
Failure code [DLE4KA] (or TM & AJSS controller LED display [23], abnormality in
engine speed sensor system: Disconnection, short circuit or hot short circuit) ................... 44
Failure code [DLT4KA] (or TM & AJSS controller LED display [22],
abnormality in speed sensor system: Disconnection, short circuit or hot short circuit)........ 46
Failure code [DUM7KY] (Pre-lubrication operation lamp output abnormality: Hot short circuit).. 48
Failure code [DUM7KZ] (Pre-lubrication operation lamp output abnormality:
Disconnection or grounding fault) ........................................................................................ 49
Failure code [DXF0KZ] (or TM & AJSS controller LED display [63], abnormality in joystick
EPC solenoid system: Disconnection, short circuit or hot short circuit) ............................... 51
Failure code [DXH4KZ] (or TM & AJSS controller LED display [14],
abnormality in 1st solenoid system: Disconnection, short circuit or hot short circuit) .......... 52
abnormality in 2nd solenoid system: Disconnection, short circuit or hot short circuit) ......... 54
abnormality in 3rd solenoid system: Disconnection, short circuit or hot short circuit).......... 56
abnormality in R solenoid system: Disconnection, short circuit or hot short circuit) ............ 58
abnormality in F solenoid system: Disconnection, short circuit or hot short circuit)............. 60
Failure code [F@BBZL] (or VHMS LED display: "n3" o "38",
Blow-by pressure sensor system: High pressure error)....................................................... 62
Failure code [F@BYNR] (or VHMS LED display: "n3" o "62", L.H. front exhaust gas
temperature sensor (2): Abnormal rise of exhaust gas temperature) .................................. 63
Failure code [f@BYNR] (or VHMS LED display: "n3" o "72", L.H. rear exhaust gas
Failure code [F@BYNS] (or VHMS LED display: "n3" o "61", L.H. front exhaust gas
Failure code [f@BYNS] (or VHMS LED display: "n3" o "71", L.H. rear exhaust gas
12 WA800-3E0, WA900-3E0
Failure code [F@BZNR] (or VHMS LED display: "n3" o "82", R.H. front exhaust gas
temperature sensor (2): Abnormal rise of exhaust gas temperature) ................................. 65
Failure code [f@BZNR] (or VHMS LED display: "n3" o "92", R.H. rear exhaust gas
Failure code [F@BZNS] (or VHMS LED display: "n3" o "38", R.H. front exhaust gas
Failure code [f@BZNS] (or VHMS LED display: "n3" o "39", R.H. rear exhaust gas
Troubleshooting of electrical system (E-mode) SEN02149-01
E-1 Engine does not start............................................................................................................ 4
E-2 Abnormality in preheating system ........................................................................................ 10
E-3 Transmission and AJSS controller does not work ................................................................ 16
E-4 Transmission and AJSS controller model selection error ..................................................... 18
E-5 Parking brake does not work (as the emergency brake) ...................................................... 20
E-6 Parking brake is applied while machine is traveling ............................................................. 24
E-7 Parking brake is released as starting switch is turned ON ................................................... 26
E-8 Setting to the neutral position becomes unavailable while the parking brake is in
operation (parking brake operates normally) ....................................................................... 28
E-9 Parking brake remains in the neutral and not removable to other position
(when parking brake is not applied)..................................................................................... 30
E-10 Defective kick-down switch................................................................................................. 32
E-11 Defective hold switch .......................................................................................................... 36
E-12 Lift arm (boom) kick-out is unavailable ............................................................................... 40
E-13 Bucket positioner functional error ....................................................................................... 42
E-14 Active working functional error ........................................................................................... 44
E-15 Turn signal or hazard display do not flash .......................................................................... 50
E-16 Small lamp does not light up .............................................................................................. 56
E-17 Head lamp does not light up............................................................................................... 59
E-18 Abnormality in lighting up of front working lamp ................................................................. 62
E-19 Abnormality in lighting up of rear working lamp.................................................................. 62
E-20 Abnormality in transmission cut-off..................................................................................... 62
E-21 Abnormality in low idle selection......................................................................................... 62
E-22 Abnormality in parking brake dragging warning ................................................................. 62
E-23 Abnormality in buzzer ......................................................................................................... 62
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02150-01
Method of using troubleshooting chart ........................................................................................ 3
H-1 Machine does not move ....................................................................................................... 5
H-2 Machine lacks power or speed (every speed range)............................................................ 6
H-3 Excessive time lag when starting machine or shifting gear .................................................. 7
H-4 Torque converter oil temperature is high .............................................................................. 8
H-5 Steering does not turn .......................................................................................................... 9
H-6 Turning, response of steering is poor ................................................................................... 10
H-7 Joystick lever is heavy.......................................................................................................... 11
H-8 Steering wheel shakes or jerks............................................................................................. 12
H-9 Minimum turning radii to right and left are different .............................................................. 13
H-10 Wheel brakes do not work or braking effect is poor ........................................................... 14
H-11 Wheel brakes are not released or brakes drag .................................................................. 15
H-12 Lift arm does not rise .......................................................................................................... 16
H-13 Lift arm moves slowly or does not have sufficient lifting power .......................................... 17
H-14 When raising lift arm, becomes slow at certain height ....................................................... 18
H-15 Lift arm cylinder cannot hold down bucket ......................................................................... 18
H-16 Lift arm has large amount of hydraulic drift ........................................................................ 18
H-17 Lift arm fluctuates while working ........................................................................................ 19
H-18 Lift arm drops momentarily when lever is operated from HOLD to RAISE......................... 19
H-19 Bucket does not tilt back .................................................................................................... 20
H-20 Bucket moves slowly or has insufficient tilt back power ..................................................... 21
H-21 Bucket movement becomes slow during tilt back............................................................... 22
H-22 Bucket cylinder cannot hold down bucket .......................................................................... 22
WA800-3E0, WA900-3E0 13
H-23 Bucket has large amount of hydraulic drift ......................................................................... 22

H-24 Bucket fluctuates while traveling under load (work equipment valve "HOLD")................... 23
H-25 Bucket dumps momentarily when lever is operated from HOLD to TILT............................ 23
H-26 Lift arm and bucket levers do not move smoothly .............................................................. 24
Troubleshooting of engine (S-mode) SEN02151-01
Method of using troubleshooting chart ........................................................................................ 3
S-1 Starting performance is poor................................................................................................. 6
S-2 Engine does not start............................................................................................................ 7
S-3 Engine does not pick up smoothly ........................................................................................ 10
S-4 Engine stops during operations ............................................................................................ 11
S-5 Engine does not rotate smoothly .......................................................................................... 12
S-6 Engine lacks output (or lacks power).................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion) ................................................................ 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 16
S-9 Oil becomes contaminated quickly ....................................................................................... 17
S-10 Fuel consumption is excessive ........................................................................................... 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................. 19
S-12 Oil pressure drops .............................................................................................................. 20
S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... 21
S-14 Coolant temperature becomes too high (overheating) ....................................................... 22
S-15 Abnormal noise is made ..................................................................................................... 23
S-16 Vibration is excessive ......................................................................................................... 24
Troubleshooting of machine monitor system (M-mode) SEN02152-00
Machine monitor system ............................................................................................................. 3
M-1 Machine monitor does not work ........................................................................................... 4
M-2 Engine starts immediately after (within 3 sec of) turning starting switch ON,
but all the machine monitors remain lit ................................................................................ 6
M-3 Speedometer display does not work .................................................................................... 7
M-4 Shift indicator error............................................................................................................... 9
M-5 Monitor turn signal (hazard) indicator does not light up ....................................................... 20
M-6 Parking indication error ........................................................................................................ 22
M-7 Abnormality in preheating system ........................................................................................ 23
M-8 Night lamp does not light up................................................................................................. 28
M-9 Front work lamp error........................................................................................................... 30
M-10 Rear work lamp error ......................................................................................................... 34
M-11 Abnormality in transmission cut-off switch.......................................................................... 38
M-12 Abnormality in low idle selection ........................................................................................ 42
M-13 Emergency steering indication error .................................................................................. 44
M-14 Parking brake dragging warning error................................................................................ 46
M-15 Buzzer and caution lamp error upon parking brake dragging warning outputting .............. 47
M-16 Buzzer error ....................................................................................................................... 50
M-17 Switching state of machine monitor is not stored............................................................... 56
M-18 Failure indication mode error ............................................................................................. 58
M-19 Machine monitor does not indicate failure code................................................................. 60
M-20 Abnormality in auto grease system .................................................................................... 62
Troubleshooting of maintenance monitor system (K-mode) SEN02153-02
Maintenance monitor system ...................................................................................................... 3
K-1 Maintenance monitor does not work..................................................................................... 4
K-2 Immediately after turning starting switch ON (within 3 sec.), engine starts but
the maintenance monitor remains fully lit up ....................................................................... 6
K-3 Work check item flashes upon turning starting switch ON (engine not running)................... 8
K-4 Caution item flashes upon turning starting switch ON (engine running) ............................... 12
K-5 The warning buzzer does not sound while caution item indicator flashes ............................ 28
K-6 The warning buzzer sounds while monitor indicates no error............................................... 30
K-7 The warning lamps (check lamp and caution lamp) do not flash while
caution item indicator flashes .............................................................................................. 31
K-8 Warning lamps (check and caution lamps) lights up while the maintenance monitor
indicates no error ................................................................................................................. 33
14 WA800-3E0, WA900-3E0
K-9 Night lamp does not light up ................................................................................................. 36

K-10 Night lamp remains lit up .................................................................................................... 38
K-11 Service meter does not work .............................................................................................. 40
K-12 Service meter keeps on working (when engine stops) ....................................................... 42
K-13 Gauge items (fuel, engine coolant temperature and torque converter oil temperature) error 44
Troubleshooting of remote boom positioner controller system (if equipped) (W-mode) SEN04494-00
W-1 Short circuit, disconnection in dumping solenoid system .................................................... 4
W-2 Short circuit in power source at hot end of dumping solenoid ............................................. 5
W-3 Short circuit in power source at return end of dumping solenoid......................................... 6
W-4 Boom kick-out function trouble ............................................................................................ 8
W-5 Disconnection in boom RAISE, LOWER detection pressure switch.................................... 10
W-6 Short circuit, disconnection in boom angle potentiometer system....................................... 12
W-7 Sensor cannot be adjusted .................................................................................................. 14
W-8 Abnormality in engine speed signal system ........................................................................ 15
W-9 Remote positioner RAISE, LOWER LEDs do not light up ................................................... 16
W-10 Remote positioner RAISE set LED does not flash ............................................................ 18
W-11 Remote positioner LOWER set LED does not flash .......................................................... 20
W-12 Buzzer for switch operation does not sound...................................................................... 22
W-13 Shock when stopping boom .............................................................................................. 23
W-14 Short circuit in boom RAISE, LOWER pressure detection switch ..................................... 24
50 Disassembly and assembly

General information on disassembly and assembly SEN02739-02
How to read this manual ............................................................................................................. 2
Coating materials list................................................................................................................... 4
Special tools list........................................................................................................................... 7
Sketches of special tools............................................................................................................. 13
Removal and installation of engine assembly ............................................................................. 2
Removal and installation of radiator assembly............................................................................ 7
Removal and installation of damper assembly............................................................................ 10
Disassembly and assembly of damper assembly ....................................................................... 11
Removal and installation of fuel tank assembly .......................................................................... 15
Removal and installation of right bank fuel supply pump assembly ............................................ 2
Removal and installation of left bank fuel supply pump assembly .............................................. 6
Removal and installation of cylinder head assembly .................................................................. 10
Removal and installation of fuel injector assembly ..................................................................... 20
Removal and installation of engine front oil seal ......................................................................... 25
Removal and installation of engine rear oil seal.......................................................................... 28
Disassembly and assembly of transfer assembly ....................................................................... 2
Disassembly and assembly of PTO assembly ............................................................................ 16
Removal and installation of parking brake calipers assembly..................................................... 20
Disassembly and assembly of parking brake calipers assembly ................................................ 21
Removal and installation of parking brake pad ........................................................................... 23
Removal and installation of parking brake spring cylinder .......................................................... 24
Removal and installation of torque converter and transmission assembly ................................. 25
Disassembly and assembly of torque converter assembly ......................................................... 2
Disassembly and assembly of transmission assembly ............................................................... 10
Removal and installation of front axle assembly ......................................................................... 2
Removal and installation of rear axle assembly .......................................................................... 4
Removal and installation of center support assembly ................................................................. 10
Disassembly and assembly of center support assembly ............................................................ 12
Removal and installation of differential assembly ....................................................................... 16
WA800-3E0, WA900-3E0 15
Disassembly and assembly of differential assembly ................................................................... 18

Disassembly and assembly of final drive assembly .................................................................... 27
Removal and installation of brake assembly ............................................................................... 2
Disassembly and assembly of brake assembly........................................................................... 3
Removal and installation of left brake valve assembly ................................................................ 8
Removal and installation of right brake valve assembly.............................................................. 9
Disassembly and assembly of accumulator charge valve........................................................... 10
Disassembly and assembly of slack adjuster.............................................................................. 12
Removal and installation of center hinge pin............................................................................... 2
Removal and installation of counterweight assembly.................................................................. 14
Hydraulic system SEN02747-03
Removal and installation of hydraulic tank and filter case assembly........................................... 2
Removal and installation of hydraulic pump assembly................................................................ 4
Removal and installation of work equipment control valve assembly ......................................... 7
Disassembly and assembly of work equipment control valve assembly ..................................... 9
Disassembly and assembly of PPC valve assembly................................................................... 12
Removal and installation of steering valve assembly .................................................................. 13
Removal and installation of diverter valve assembly................................................................... 15
Disassembly and assembly of diverter valve assembly .............................................................. 16
Removal and installation of Orbit-roll assembly .......................................................................... 18
Removal of steering stop valve ................................................................................................... 20
Disassembly and assembly of hydraulic cylinder assembly........................................................ 21
Removal and installation of work equipment assembly............................................................... 2
Replacement of boom front bushing ........................................................................................... 7
Removal and installation of operator cab assembly.................................................................... 2
Removal and installation of floor frame assembly....................................................................... 4
Disassembly and assembly of operator’s seat assembly............................................................ 7
Removal and installation of AJSS lever switch assembly ........................................................... 40
Electrical system SEN02750-00
Removal and installation of engine controller assembly ............................................................. 2
Removal and installation of transmission and steering controller assembly ............................... 3
Removal and installation of main monitor assembly ................................................................... 4
Removal and installation of air conditioner unit assembly........................................................... 6
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN02046-00
Power train hydraulic circuit diagram .......................................................................................... 2
Brake hydraulic circuit diagram ................................................................................................... 3
Work equipment hydraulic circuit diagram .................................................................................. 5
Electrical diagrams and drawings SEN02047-02
Electrical circuit diagram (1/8) ..................................................................................................... 3
Electrical circuit diagram of emergency engine stop ................................................................... 21
Electrical circuit diagram of hydraulic oil level sensor ................................................................. 23
Electrical circuit diagram of battery and starting motor disconnector switch and starting aid connector
.................................................................................................................................................... 29
Connector arrangement diagram ................................................................................................ 31
16 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 17
SEN02036-13
WA800, 900-3E0 Wheel loader

Form No. SEN02036-13
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 03-17 (01)
18
SEN02037-04
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
WA800-3E0, WA900-3E0 1
Safety notice 1
Important safety notice
Proper service and repair are 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 dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
q Always wear safety glasses when hit- Wearing protective goggles
7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
2 WA800-3E0, WA900-3E0
2. Preparations for work

1) Before adding oil or making any repairs,
park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
3) When disassembling or assembling, sup-
port the machine with blocks, jacks, or
stands before starting work. 5) When raising a heavy component (heavier
4) Remove all mud and oil from the steps or than 25 kg), use a hoist or crane. Before
other places used to get on and off the starting work, check that the slings (wire
machine. Always use the handrails, lad- ropes, chains, and hooks) are free from
ders or steps when getting on or off the damage. Always use slings which have
m a c h i n e . N e v e r j u m p o n o r o ff t h e ample capacity and install them to proper
machine. If it is impossible to use the places. Operate the hoist or crane slowly
handrails, ladders or steps, use a stand to to prevent the component from hitting any
provide safe footing. other part. Do not work with any part still
raised by the hoist or crane.
3. Precautions during work 6) When removing a cover which is under
1) Before disconnecting or removing compo- internal pressure or under pressure from a
nents of the oil, water, or air circuits, first spring, always leave 2 bolts in diagonal
release the pressure completely from the positions. Loosen those bolts gradually
circuit. When removing the oil filler cap, a and alternately to release the pressure,
drain plug, or an oil pressure pickup plug, and then remove the cover.
loosen it slowly to prevent the oil from 7) When removing components, be careful
spurting out. not to break or damage the electrical wir-
2) The coolant and oil in the circuits are hot ing. Damaged wiring may cause electrical
when the engine is stopped, so be careful fires.
not to get scalded. Wait for the oil and 8) When removing piping, stop the fuel or oil
coolant to cool before carrying out any from spilling out. If any fuel or oil drips
work on the oil or water circuits. onto the floor, wipe it up immediately. Fuel
3) Before starting work, stop the engine. or oil on the floor can cause you to slip
When working on or around a rotating and can even start fires.
part, in particular, stop the engine. When 9) As a general rule, do not use gasoline to
checking the machine without stopping wash parts. Do not use it to clean electri-
the engine (measuring oil pressure, cal parts, in particular.
revolving speed, temperature, etc.), take 10) Be sure to assemble all parts again in their
extreme care not to get rolled or caught in original places. Replace any damaged
rotating parts or moving parts. parts and parts which must not be reused
4) For the machine equipped with a bat- with new parts. When installing hoses and
tery disconnct switch, turn the battery wires, be sure that they will not be dam-
disconnect switch to the OFF (O) posi- aged by contact with other parts when the
tion, before starting the work. For machine is operated.
machines without a battery disconnct 11) When installing high pressure hoses,
switch, remove the cable from the battery, make sure that they are not twisted. Dam-
before starting the work. Always remove aged tubes are dangerous, so be
the cable from the negative (-) terminal extremely careful when installing tubes for
first. high pressure circuits. In addition, check
t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
installed.
WA800-3E0, WA900-3E0 3
12) When assembling or installing parts, 7) Limit the hanging angle to 60°, as a rule.
always tighten them to the specified Do not sling a heavy load with ropes form-
torques. When installing protective parts ing a wide hanging angle from the hook.
such as guards, or parts which vibrate vio- When hoisting a load with 2 or more
lently or rotate at high speed, be particu- ropes, the force subjected to each rope
l ar l y c a r e f u l t o c h e c k t h a t t h e y a r e will increase with the hanging angle. The
installed correctly. table below shows the variation of allow-
13) When aligning 2 holes, never insert your able load in kN {kg} when hoisting is made
fingers or hand. Be careful not to get your with 2 ropes, each of which is allowed to
fingers caught in a hole. sling up to 9.8 kN {1,000 kg} vertically, at
14) When measuring hydraulic pressure, various hanging angles. When the 2 ropes
check that the measuring tools are cor- sling a load vertically, up to 19.6 kN {2,000
rectly assembled. kg} of total weight can be suspended.
15) Take care when removing or installing the This weight is reduced to 9.8 kN {1,000
tracks of track-type machines. When kg} when the 2 ropes make a hanging
removing the track, the track separates angle of 120°. If the 2 ropes sling a 19.6
suddenly, so never let anyone stand at kN {2,000 kg} load at a lifting angle of
either end of the track. 150°, each of them is subjected to a force
16) If the engine is operated for a long time in as large as 39.2 kN {4,000 kg}.
a place which is not ventilated well, you
may suffer from gas poisoning. Accord-
ingly, open the windows and doors to ven-
tilate well.
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
8) When installing wire ropes to an angular
load and guide the operator safely.
load, apply pads to protect the wire ropes.
q Do not stand under the load.
If the load is slippery, apply proper mate-
q Do not step on the load.
rial to prevent the wire rope from slipping.
2) Check the slings before starting sling
9) Use the specified eyebolts and fix wire
work.
ropes, chains, etc. to them with shackles,
3) Keep putting on gloves during sling work.
etc.
(Put on leather gloves, if available.)
10) Apply wire ropes to the middle portion of
4) Measure the weight of the load by the eye
the hook.
and check its center of gravity.
q Slinging near the tip of the hook may
5) Use proper sling according to the weight
cause the rope to slip off the hook
of the load and method of slinging. If too
during hoisting. The hook has the
thick wire ropes are used to sling a light
maximum strength at the middle por-
load, the load may slip and fall.
tion.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
4 WA800-3E0, WA900-3E0
6. Precautions for using overhead hoist crane

k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disas-
sembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock preven-
tion earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
11) Do not use twisted or kinked wire ropes.
of the control buttons without fail.
12) When lifting up a load, observe the follow-
5) Do not sling a load slantingly. Do not move
ing.
the crane while the slung load is swinging.
q Wind in the crane slowly until wire
6) Do not raise or lower a load while the
ropes are stretched. When settling
crane is moving longitudinally or laterally.
the wire ropes with the hand, do not
7) Do not drag a sling.
grasp them but press them from
8) When lifting up a load, stop it just after it
above. If you grasp them, your fingers
leaves the ground and check safety, and
may be caught.
then lift it up.
q After the wire ropes are stretched,
9) Consider the travel route in advance and
stop the crane and check the condi-
lift up a load to a safe height.
tion of the slung load, wire ropes, and
10) Place the control switch on a position
pads.
where it will not be an obstacle to work
q If the load is unstable or the wire rope
and passage.
or chains are twisted, lower the load
11) After operating the hoist, do not swing the
and lift it up again.
control switch.
q Do not lift up the load slantingly.
12) Remember the position of the main switch
13) When lifting down a load, observe the fol-
so that you can turn off the power immedi-
lowing.
ately in an emergency.
q When lifting down a load, stop it tem-
13) If the hoist stops because of a power fail-
porarily at 30 cm above the floor, and
ure, turn the power switch OFF. When
then lower it slowly.
turning on a switch which was turned OFF
q Check that the load is stable, and
by the electric shock prevention earth
then remove the sling.
leakage breaker, check that the devices
q Remove kinks and dirt from the wire
related to that switch are not in operation
ropes and chains used for the sling
state.
work, and put them in the specified
14) If you find an obstacle around the hoist,
place.
stop the operation.
15) After finishing the work, stop the hoist at
5. Precautions for using mobile crane
the specified position and raise the hook
a Read the Operation and Maintenance
to at least 2 m above the floor. Do not
Manual of the crane carefully in advance
leave the sling installed to the hook.
and operate the crane safely.
WA800-3E0, WA900-3E0 5
7. Selecting wire ropes 2) Connection

1) Select adequate ropes depending on the 1] When installing the air conditioner cir-
weight of parts to be hoisted, referring to cuit hoses and tubes, take care that
the table below. dirt, dust, water, etc. will not enter
them.
Wire ropes 2] When connecting the air conditioner
(Standard “Z” twist ropes without galvanizing) hoses and tubes, check that O-rings
(JIS G3525, No. 6, Type 6X37-A) (1) are fitted to their joints.
Nominal 3] Check that each O-ring is not dam-
Allowable load
diameter of rope aged or deteriorated.
mm kN ton 4] When connecting the refrigerant pip-
10 8.8 0.9 ing, apply compressor oil for refriger-
12 12.7 1.3 ant (R134a) (DENSO: ND-OIL8,
14 17.3 1.7 VA L E O T H E R M A L S Y S T E M S :
16 22.6 2.3 ZXL100PG (equivalent to PAG46))
18 28.6 2.9 to its O-rings.
20 35.3 3.6
a Example of O-ring (Fitted to every joint of
25 55.3 5.6
hoses and tubes)
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
a The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the a For tightening torque, see the precautions for
refrigerant (air conditioner gas: installation in each section of "Disassembly
R134a) which has fewer factors of and assembly".
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
6 WA800-3E0, WA900-3E0
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
WA800-3E0, WA900-3E0 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 WA800-3E0, WA900-3E0
Explanation of terms for maintenance standard 1

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
WA800-3E0, WA900-3E0 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 WA800-3E0, WA900-3E0
Handling of electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
WA800-3E0, WA900-3E0 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 WA800-3E0, WA900-3E0
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
WA800-3E0, WA900-3E0 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 WA800-3E0, WA900-3E0
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
WA800-3E0, WA900-3E0 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the com-
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 WA800-3E0, WA900-3E0
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
WA800-3E0, WA900-3E0 17
Points to remember when handling hydraulic equipment

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

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

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 WA800-3E0, WA900-3E0
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
WA800-3E0, WA900-3E0 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 WA800-3E0, WA900-3E0
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
WA800-3E0, WA900-3E0 21
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 WA800-3E0, WA900-3E0
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-

General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
WA800-3E0, WA900-3E0 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 WA800-3E0, WA900-3E0
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
WA800-3E0, WA900-3E0 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 WA800-3E0, WA900-3E0
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
WA800-3E0, WA900-3E0 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 WA800-3E0, WA900-3E0
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the 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.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
WA800-3E0, WA900-3E0 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 WA800-3E0, WA900-3E0
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
WA800-3E0, WA900-3E0 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

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 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 WA800-3E0, WA900-3E0
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

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

Nominal 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 connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 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} 127.4 {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}
WA800-3E0, WA900-3E0 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(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 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 WA800-3E0, WA900-3E0
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
WA800-3E0, WA900-3E0 35
Conversion table 1
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), and then draw a hori-
zontal 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 2 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 it 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.
Millimeters to inches (B)

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)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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
36 WA800-3E0, WA900-3E0
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
Liters to U.S. Gallons

1 l = 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
WA800-3E0, WA900-3E0 37
Liters to U.K. Gallons

1 l = 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 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
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
38 WA800-3E0, WA900-3E0
kg/cm2 to lb/in2
1 kg/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 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
WA800-3E0, WA900-3E0 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade 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 81 177.8
–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 60 140.0 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
40 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 41
SEN02037-04

© 2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12
42
SEN02039-02
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
01 Specification 1
Specification and technical data
General assembly drawing ............................................................................................................................. 2
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................... 7
Table of fuel, coolant and lubricants.............................................................................................................. 10
WA800, WA900-3E0 1
SEN02039-02 01 Specification
General assembly drawing 1

WA800-3E0 1
2 WA800, WA900-3E0
WA900-3E0 1
WA800, WA900-3E0 3
Specifications 1
Machine model WA800-3E0 WA900-3E0
Serial number 70001 and up 60001 and up
Weight
Operating weight kg 102,200 107,500

Distribution (front) kg 59,140 60,000
Distribution (rear) kg 43,060 47,500
Bucket capacity (piled) m3 11.0 13.0
Rated load mm 19,800 23,400
Travel speed Forward 1st km/h 7.0 7.0
Forward 2nd km/h 12.3 12.3
Forward 3rd km/h 28.0 28.0
Performance
Reverse 1st km/h 7.1 7.1

Reverse 2nd km/h 12.4 12.4
Reverse 3rd km/h 28.3 28.3
Max. rimpull kN {kg} 588.4 {60,000} 588.4 {60,000}
Gradeability deg 25 25
Min. turning radius
Center of outside wheel mm 9,200 9,200
Outside portion of chassis mm 10,900 11,000
Over length mm 13,960 14,490
Over weight (chassis) mm 4,585 4,585
Bucket width mm 4,810 (Cutting edge) 4,810 (Cutting edge)

5,045 (Tire guard) 5,045 (Tire guard)
Overall height (top of ROPS cab) mm 5,275 5,275
(Bucket raised) mm 9,300 9,680
Dimensions
Wheelbase mm 5,450 5,450

Tread mm 3,350 3,350
Min. ground clearance mm 550 550
Height of bucket hinge pin mm 6,785 6,960
Dumping clearance (tip of edge) mm 4,630 (5,010) 4,640 (5,020)
Dumping reach (tip of edge) mm 2,385 (2,150) 2,450 (2,215)
Bucket dump angle deg 50 (Max. height) 47 (Max. height)
Bucket tilt angle (SAE carrying position) deg 60 (Max. height) 60 (Max. height)
Digging depth (10°dump) (tip of edge) mm 430 (604) 470 (645)
4 WA800, WA900-3E0

Model Komatsu SAA12V140E-3
4-cycle, water-cooled, V type,

Type 12-cylinder direct injection, with
2-turbocharger, aftercooler
No. of cylinder – bore × stroke mm 12–140×165
Piston displacement l (cc) 30.48 {30,480}
Hosepower
Gross [SAE J1995] kW({HP}/rpm 636 {853}/2,000 671 {900}/2,050

Engine
ISO 14396 kW({HP}/rpm 636 {853}/2,000 671 {900}/2,050
Net [ISO 9249/SAE J1349] kW({HP}/rpm 603 {808}/2,000 638 {856}/2,050
Maximum torque kW/rpm{HP/rpm} 3,727 {380}/(1,400 rpm) 4,089 {417}/(1,300 rpm)
Fuel consumption ratio g/kWh{HPh} 200.2 {149.3} 200.4 {149.5}

High idle speed rpm 650 650
Low idle speed rpm 2,200 2,200
Starting motor 24V, 7.5 kW×2
Alternator 24V, 90 A×2
Battery 12V, 200 Ah×4
3-element, 1-stage, single-phase
Torque converter
(TCA51-1A)
Power train
Transmission Planetary gear, multiple-disc

Hydraulically actuated, modulation type
Reduction gear Spiral bevel gear
Differential Straight bevel gear
Final drive Planetary gear, single reduction, oil bath
Drive type Front/rear-wheel drive
Front axle Fixed-frame, full-floating
Axle, wheel
Rear axle Center pin support type, full-floating

Tire 45/65-45-46PR(L-5) 45/65-45-58PR(L-5)
Wheel rim 36.00 × 45WTB
2
Inflation pressure kPa{kg/cm } 515 {5.25} 667 {6.8}
Main brake Front/rear wheel braking,
separate front/rear wheel, wet disc,
Brake
hydraulically actuated
Parking brake Mounted on front axle input shaft, dry disc,
hydraulically release spring apply
WA800, WA900-3E0 5

Steering
Type Articulated type

system
Structure Fully hydraulically power steering
Torque converter, l/min 421 432

transmission pump (Gear type (Gear type
SAR(4)112+SAR(3)100) SAR(4)112+SAR(3)100)
Steering pump l/min 307 315

(Fixed capacity piston (Fixed capacity piston
pump HPF76+71) pump HPF76+71)
Switch pump l/min 405 415

(Variable capacity piston (Variable capacity piston
Hydraulic pump pump HPV90+90) pump HPV90+90)
delivery
PPC pump l/min 68 70

(Gear type ASR(1)-32) (Gear type ASR(1)-32)
Brake pump l/min 29 30

(Gear type SAR(1)-14) (Gear type SAR(1)-14)
Hydraulic system
Work equipment pump l/min 405 415

(Variable capacity piston (Variable capacity piston
pump HPV90+90) pump HPV90+90)
Transmission valve MPa {kg/cm2} 2.5 {25} (Spool type, electrical control)
Steering control valve MPa {kg/cm2} 31.4 {320} (Spool type)

Control valve set
pressure PPC valve MPa {kg/cm2} 3.7 {38} (2-lever type)
31.4 {320} 34.5 {350}

Main control valve MPa {kg/cm2}
(2-spool type) (2-spool type)
Steering cylinder mm Reciprocating piston 2 – 160 × 503
No. – bore × stroke
Lift arm cylinder mm Reciprocating piston 2 – 260 × 1,368

Cylinder
Bucket cylinder mm Reciprocating piston 1 – 300 × 906

equipment
Link type Single Z bar link

Work
Bucket edge type Spade nose bucket with teeth
6 WA800, WA900-3E0
Weight table 1
Unit: kg
Engine (dry) 3,690 3,690
Radiator (dry) 880 880
Torque converter (dry) 590 590
Transmission (dry) 2,300 2,300
Damper 178 178
Upper drive shaft 58 58
Center drive shaft 184 184
Front drive shaft 171 171
Rear drive shaft 184 184
Center support 165 165
Front axle 8,190 8,190
Rear axle 7,700 7,700
Front differential assembly (not including parking
1,226 1,226
brake)
Rear differential assembly 1,256 1,256
Planetary carrier assembly (each) 238 238
Wheel hub (each) 600 600
Axle pivot (rear axle) 286 286
Wheel (each) 874 874
Tire (each) 2,630 2,720
Steering control valve 66 66
Steering cylinder (each) 206 206
Hydraulic tank (dry) 824 824
Work equipment pump 150 150
Parking brake assembly 185 185
Torque converter charging + PPC +brake pump 49 49
Switch pump 157 157
Steering pump 145 145
Fender and guard assembly 1,393 1,393
PPC valve 4 4
Main control valve (each) 95 95
Hydraulic oil cooler 400 400
Lift arm cylinder (each) 998 998
Bucket cylinder 1,210 1,210
88(Top) 88(Top)
Engine hood
28 (Side) (each) 28 (Side) (each)
Front frame 7,342 7,891
Rear frame 9,168 9,644
Bucket link (including bushing) 593 566
Bellcrank (including bushing) 1,850 1,850
Lift arm (including bushing) 8,495 8,690
Bucket (with teeth) 11,430 12,320
Counterweight 2,200 2,200 + 2,600
Fuel tank 806 806
Battery (each) 64 64
Cab 447 447
Air conditioner unit 55 55
WA800, WA900-3E0 7
Unit: kg
Operator’s seat 50 50
Floor plate 419 419
ROPS support assembly 1,387 1,387
8 WA800, WA900-3E0
WA800, WA900-3E0 9
Table of fuel, coolant and lubricants 1

a For details of the notes (e.g., Note. 1, Note.2...) in the table, see the Operation and Maintenance Man-
ual.
10 WA800, WA900-3E0
Reservoir
Transmission Hydraulic Front axle
Engine oil pan Brake oil tank
case system (each)
Capacity
Liters 140 164 1,065 42 360
Specified
US gal 36.96 43.3 281.16 11.09 95.0
Liters 130 140 725 31 360
Refill
US gal 34.35 36.96 191.4 8.18 95.0
Reservoir
Rear axle Pins Fuel tank Cooling system
Capacity
Liters 360 — 1,555 337
Specified
US gal 95.0 — 410.83 89.0
Liters 360 — — —
Refill
US gal 95.0 — — —
WA800, WA900-3E0 11
SEN02039-02

© 2012 KOMATSU
All Rights Reserved
12
SEN02351-01
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine mount.................................................................................................................................................. 2
Transmission mount........................................................................................................................................ 3
Damper ........................................................................................................................................................... 4
Radiator, oil cooler, aftercooler ....................................................................................................................... 6
Fuel system..................................................................................................................................................... 9
WA800-3E0, WA900-3E0 1
SEN02351-01 10 Structure, function and maintenance standard
Engine mount 1
2 WA800-3E0, WA900-3E0
Transmission mount 1
unit: mm
No. Check item Criteria Remedy
1.5 (Paraleism of center pin and matching surface of transmis-
1 Mount standard shim thickness Adjust
sion yoke should be less than 0.15)
WA800-3E0, WA900-3E0 3
Damper 1
1. Breather Function
2. Cover q The damper reduces the torsional vibration
3. Outer body caused by the vibration caused by changes in
4. Rubber cushion engine torque, and acts to protect the engine
5. Inner body and other parts from such torsional vibration.
6. Shaft
7. Breather Operation
q The engine power is transmitted to the fly-
wheel and outer body (3) and rubber cushion
(4) absorbs the torsional vibration of the
engine. The engine power is then transmitted
through inner body (5) to shaft (6). From here,
the engine power is transmitted through the
coupling to the torque converter and drive
shaft.
4 WA800-3E0, WA900-3E0
Unit: mm
Standard Tolerance Standard Clearance
Clearance between bearing and size Shaft Hole clearance limit
8
shaft +0.015 –0.008 –0.035
95 0.025 Replace
+0.003 –0.020 –0.003
Clearance between bearing and –0.008 –0.008 –0.033
9 170 0.018
housing –0.025 –0.033 –0.017
Standard size Tolerance Clearance limit
Wear of oil seal contact surface
10 –0.008
of shaft 115 –0.018 Repair or
–0.087
replace
Wear of oil seal contact surface –0.1
11 140 –0.012
of sleeve –0.1
WA800-3E0, WA900-3E0 5
Radiator, oil cooler, aftercooler 1
6 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 7
1. Radiator upper tank

2. Hydraulic oil cooler
3. Radiator core
4. Aftercooler
5. Radiator lower tank
6. Torque converter oil cooler
7. Coolant reservoir tank
A: Aftercooler inlet
B: Coolant inlet
C: Torque converter oil cooler inlet
D: Torque converter oil cooler outlet
E: Aftercooler outlet
F: Coolant outlet
Specifications
Torque converter oil
Radiator Hydraulic oil cooler Aftercooler
cooler
Core type
Type Core type PF2-7 Core type PF4-6 Shell and tube
Triangle street fin
Pitch of fin (mm) 4.0/2p 3.0p 6.0/2p —
Total radiation surface
226.44 156.27 29.33 × 2 9.63
(m2)
Water passage area
301.50 — — 72.3
(cm2)
Pressure valve opening 70 ± 15
— — —
pressure (kPa {kg/cm2}) {0.7 ± 0.15}
Vacuum valve opening 0–5
— — —
pressure (kPa {kg/cm2}) {0 – 0.05}
8 WA800-3E0, WA900-3E0
Fuel system 1
1. Fuel tank
2. Fuel cut-off valve
3. Injector
4. Common rail
5. Supply pump
6. Feed pump
7. Fuel filter
8. Right branch block
9. Fuel pre-filter
10. Priming pump
11. Left branch block
WA800-3E0, WA900-3E0 9
SEN02351-01

© 2009 KOMATSU
All Rights Reserved
10
SEN02352-01
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Power train, Part 1
Power train...................................................................................................................................................... 2
Power train system ......................................................................................................................................... 4
Torque converter ............................................................................................................................................. 6
Torque converter regulator valve .................................................................................................................. 14
Transmission................................................................................................................................................. 16
Transfer......................................................................................................................................................... 28
Transmission control valve............................................................................................................................ 31
WA800, WA900-3E0 1
Power train 1
1. Center drive shaft Outline

2. Transfer q Power from engine (7) is transmitted through
3. Transmission the flywheel of engine to damper (6). The
4. Torque converter damper output shaft is connected to pump of
5. Upper drive shaft torque converter (4) via drive shaft. The turbine
6. Damper of the torque converter is connected to input
7. Engine shaft of transmission (3).
8. Rear axle q The transmission has 5 hydraulic clutches to
9. Rear drive shaft set itself to 4 forward gear speeds and 3
10. Parking blake reverse gear speeds, which is operated
11. Front drive shaft through selection of one of them using AJSS
12. Front axle lever switch.
q The output shaft of the transmission is con-
nected to gear of transfer (2) and the power is
transmitted to the output shaft. The power from
the transfer output shaft is transmitted through
the center drive shaft (1), center support (10),
front drive shaft (11) and rear drive shaft (9) to
front axle (12) and rear axle (8), and then
transmitted through the wheels to the tires.
2 WA800, WA900-3E0
WA800, WA900-3E0 3
Power train system 1
4 WA800, WA900-3E0
1. Front differential
2. Front brake
3. Front final differential
4. Front wheel
5. Front axle
6. Front drive shaft
7. Center drive shaft
8. Emergency steering pump
9. Transfer
10. Transmission
11. Torque converter
12. Steering pump
13. Main pump
14. Upper drive shaft
15. Damper
16. Engine
17. Switch pump
18. Torque converter charging pump (×2) + PPC pump + brake pump
19. Rear final drive
20. Rear wheel
21. Rear axle
22. Rear differential
23. Rear brake
24. Rear drive shaft
25. Center support
26. Parking blake
WA800, WA900-3E0 5
Torque converter 1
6 WA800, WA900-3E0
A: From main relief valve

B: To transfer case
C: To power train oil cooler
P1: Torque converter inlet port oil pressure pickup-
port
1. Torque converter regulator valve

2. Torque converter outlet port oil temperature
sensor mounting port
3. Switch pump mounting port
4. Work equipment pump mounting port
5. Steering pump mounting port
6. Power train, PPC, brake pump mounting port
Specifications
Type 3-element, 1-stage, 1-phase
Stall torque ratio 2.84
WA800, WA900-3E0 7
1. Flange 9. Retainer
2. Torque converter input shaft 10. Sleeve
3. Boss 11. Stator shaft
4. Turbine 12. Transmission input shaft
5. Drive case 13. PTO drive gear (Number of teeth: 86)
6. Stator 14. PTO gear (Number of teeth: 81)
7. Pump 15. PTO gear shaft
8. Guide
8 WA800, WA900-3E0
WA800, WA900-3E0 9
10 WA800, WA900-3E0
Unit: mm

Standard size Tolerance Repair limit
Outside diameter of flange oil
1 0
seal contact surface 110 109.8
–0.087 Repair by hard
Inside diameter of retainer seal +0.040 chromium-plat-
2 170 170.5 ing or replace
ring contact surface 0
Inside diameter of sleeve seal +0.035
3 85 85.1
ring contact surface 0
Backlash between PTO drive
4 0.20 – 0.52
gear and PTO gear
Tolerance
Standard size
Shaft Hole
Tolerance for fit-
5a ness of PTO gear Outside 0 +0.012
180
bearing (rear) diameter –0.025 –0.028
Inside +0.030 0
75
diameter –0.011 –0.015
Replace
Outside 0 +0.012
Tolerance for fit- 125
diameter –0.018 –0.028
5b ness of PTO gear
bearing (rear) Inside +0.030 0
70
diameter –0.011 –0.015
Outside 0 +0.010
diameter –0.015 –0.025
6 ness of PTO gear
bearing (front) Inside +0.030 0
65
diameter –0.011 –0.015
WA800, WA900-3E0 11
Power transmitting route Oil flow
The power from engine q The oil flows through the main relief valve and
O its pressure is reduced to below the set pres-
Damper sure by the torque converter relief valve, and
O then it flows through the oil passage of housing
Drive shaft (1) (1), inlet port (A), stator shaft (2), retainer (3)
O and the oil passage of guide (4) to pump (5).
Flange (2) q The oil is given a centrifugal force by pump (5),
O and then it enters turbine (6) to transmit its
Torque converter input shaft (3), PTO drive gear energy to turbine (6).
(4), drive case (6) and pump (7) rotate together q The oil from turbine (6) is sent to stator (7), and
O then returned to pump (5). A part of this oil is
Oil is used as medium sent from stator (7) through the oil passage of
O stator shaft (2), outlet port (B), oil passage of
Turbine (8) and boss (9) housing (1) and torque converter regulator
O valve to the oil cooler.
Transmission input shaft (10)
q The power being transmitted to PTO drive gear

(4) is then transmitted through PTO gear (5)
and then used as the pump driving power.
12 WA800, WA900-3E0
WA800, WA900-3E0 13
Torque converter regulator valve 1
Unit: mm

size Shaft Hole clearance limit
1
Clearance between spool and –0.035 +0.016 0.035 –
40 0.081
valve body –0.045 0 0.061
Replace
Standard size Repair limit
Free length Installed length Installed load Free length Installed load
2
341 N 325 N
Valve spring 157 84 152
{34.8 kg} {33.1 kg}
3. Valve body Outline

4. Spool q This valve is provided at the torque converter
5. Poppet outlet circuit in order to secure an optimum
performance of the torque converter by adjust-
A: From torque converter ing its set oil pressure.
B: To oil cooler Set pressure: 0.49 – 0.69 MPa {5 – 7 kg/cm2}
C: Drain
D: Drain
P2: Torque converter outlet port oil pressure pickup
port
14 WA800, WA900-3E0
Operation
q The oil from the torque converter is conducted

to chamber (E) through port (A) and orifice (a).
q When the oil pressure force generated in
chamber (E) is smaller than the tension of
spring (1), spool (2) is pressed rightward, clos-
ing port (A) and port (B).
q If the oil pressure force generated in chamber

(E) becomes larger than the tension of spring
(1), spool (2) is pressed leftward, opening port
(A) and port (B).
WA800, WA900-3E0 15
Transmission 1
(Transmission and transfer)
a For section (B-B), see "Transfer".
16 WA800, WA900-3E0
A: To torque converter
B: From torque converter
C: To power train pump
D: From oil filter
E: To power train oil cooler
F: From power train oil cooler
1. Transmission
2. Transmission control valve
3. Transfer
4. Drain valve
5. Drain plug
6. Speed sensor mounting port
7. Oil filler
8. Emergency steering pump mounting port
9. Oil filler tube
WA800, WA900-3E0 17
18 WA800, WA900-3E0
1. Transmission input shaft Outline

2. R ring gear (hub) q The transmission employed consists of the
3. Tie bolt united planetary gear mechanism and disc
4. R planetary pinion (Number of teeth: 30) clutch that provides "3 forward gear speeds
5. R ring gear (Number of inside teeth: 86) and 3 reverse gear speeds".
6. F planetary pinion (Number of teeth: 26) q The transmission selects a single rotating
7. F ring gear (Number of inside teeth: 90) direction and a single speed by fixing the plan-
8. Planetary pinion (Number of teeth: 26) etary gear mechanism and 2 of 5 disc clutches
9. 2nd ring gear (Number of inside teeth: 89) by use of transmission control valve.
10. 2nd planetary pinion (Number of teeth: 31) q The transmission transmits the power being
11. 1st ring gear (Number of inside teeth: 89) transmitted to the transmission input shaft to
12. 1st planetary pinion (Number of teeth: 31) the output shaft after selecting a single speed
13. Intermediate shaft from the 1st to 3rd speeds both in the forward
14. Transmission output shaft and reverse travel. In this case, the gear speed
15. Clutch disc change is done by F and R clutches plus com-
16. Clutch plate binations of 3 speed clutches.
17. 3rd hub
18. 1st sun gear (Number of teeth: 27) Number of plates and discs used
19. 1st carrier
Clutch No. Number of plates Number of discs
20. Housing
21. 2nd sun gear (Number of teeth: 27) F clutch 5 6
22. 2nd carrier R clutch 5 6
23. 1st clutch housing 1st clutch 4 5
24. 2nd clutch housing
2nd clutch 3 4
25. Ring gear (Number of inside teeth: 90)
26. Housing 3rd clutch 5 6
27. F clutch housing
28. Sun gear (Number of teeth: 38)
29. F carrier Combinations of clutches at respective gear
30. F sun gear (Number of teeth: 38) speeds and reduction ratio
31. R clutch housing
Gear speed Clutch used Reduction ratio
32. R carrier
33. Housing Forward 1st F × 1st 5.907
34. R sun gear (Number of teeth: 26) Forward 2nd F × 2nd 3.343
Forward 3rd F × 3rd 1.375
Neutral – –
Reverse 1st R × 1st 5.801
Reverse 2nd R × 2nd 3.282
Reverse 3rd R × 3rd 1.350
WA800, WA900-3E0 19
20 WA800, WA900-3E0
Unit: mm

1 R clutch spring (12 springs)
115 N 97.6 N
91 78 85.5
{11.7 kg} {9.95 kg}
139 N 119 N
2 F clutch spring (12 springs) 108.5 92 102
{14.2 kg} {12.1 kg}
123 N 104 N
3 2nd clutch spring (12 springs) 91 77 85.5
{12.5 kg} {10.6 kg}
194 N 165 N
4 1st clutch spring (12 springs) 91 69 85.5
{19.8 kg} {16.8 kg}
Total assembled thickness of 6 Standard size Tolerance Repair limit
5
discs and 5 plates for R clutch 61.4 ± 0.33 58.2
Total assembled thickness of 6
6 61.4 ± 0.33 58.2
discs and 5 plates for F clutch
7 discs and 3 plates for 2nd 39.0 ± 0.26 36.9
clutch
8 discs and 4 plates for 1st 50.2 ± 0.30 47.5
clutch
9 discs and 5 plates for 3rd 61.4 ± 0.43 58.2
clutch
Thickness of F, R, 1st, 2nd 5.4 ±0.1 4.9
10
clutch disc 3rd 5.4 ±0.15 4.9
Replace
Thickness of F, R, 1st, 2nd 5.8 ±0.1 5.2
11
clutch plate 3rd 5.8 ±0.1 5.2
–0.01
Wear of input shaft Width 3.0
–0.03
2.7
12
seal ring (large)
Thickness 3.5 ±0.1 3.35
–0.01
Wear of input shaft Width 2.5
–0.03
2.25
13
seal ring (small)
Thickness 1.7 ±0.1 1.55
–0.01
Wear of collar seal Width 3.0
–0.03
2.7
14
ring (6 places)
Thickness 4.0 ±0.12 3.85
–0.01
Wear of 2nd clutch Width 4.0
–0.04
3.6
15
housing seal ring
Thickness 5.0 ±0.15 4.85
–0.01
Wear of 2nd car- Width 4.0 3.6
16 –0.03
rier seal ring
Thickness 5.0 ±0.15 4.85
–0.01
Wear of Intermedi- Width 2.5
–0.03
2.25
17
ate shaft seal ring
Thickness 1.7 ±0.1 1.55
Backlash between sun gear
18 0.15 – 0.40
and planetary pinion
Backlash between R, 1st, 2nd 0.15 – 0.39
19 planetary pinion F, Interme-
and ring gear 0.15 – 0.40
diate
WA800, WA900-3E0 21
Disc clutch
Structure Operation
When clutch is "engaged" (fixed)
q Disc clutch is used for fixing ring gear (1). It

consists of piston (2), plate (3), disc (4), pin (5), q The oil from transmission control valve is sent
return spring (6) and washer spring (8). with pressure to the rear side of piston (2)
q Inside teeth of disc (4) are engaged with out- through the oil passage of clutch housing (7)
side teeth of ring gear (1). and pushes piston (2) leftward.
q Plate (3) is assembled to clutch housing (7) q Piston (2) contacts plate (3) closely against
with pin (5). disc (4) to stop rotation of disc (4) by use of the
friction force generated between them.
q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.
When clutch is "disengaged" (released)
q As the oil from transmission control valve is

stopped, piston (2) is pushed back rightward
by return spring (6).
q Plate (3) and disc (4) are released from the
frictional force and ring gear (1), as the result,
is also released.
q Washer spring (8) is installed between plate
(3). This spring quickens return of piston (2) as
the clutch is disengaged by providing smooth
separation of plate (3) and disc (4). At the
same time, it is used for preventing the drag-
ging.
22 WA800, WA900-3E0
Power transmitting route
Forward 1st gear speed
F ring gear (4) of F clutch and 1st ring gear (17) of

1st clutch are fixed hydraulically.
The power from torque converter

O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F carrier (10)
O
Planetary pinion (11)
O
Sun gear (12)
O
Intermediate shaft (13)
O
1st sun gear (14)
O
1st planetary pinion (15)
O
1st carrier (16)
O
Output shaft (23)
WA800, WA900-3E0 23
Forward 2nd gear speed
F ring gear (4) of F clutch and 2nd ring gear (20) of 2nd clutch are fixed hydraulically.

O
Input shaft (1)
O
F sun gear (2)
O
O
F carrier (10)
O
O
Sun gear (12)
O
O
2nd sun gear (18) 1st sun gear (14)
O
2nd planetary pinion (19)
O
2nd carrier (21)
O
1st ring gear (17)
O
O
1st carrier (16)
O
Output shaft (23)
24 WA800, WA900-3E0
Forward 3rd gear speed
F ring gear (4) of F clutch and 3rd hub (22) of 3rd

clutch are fixed hydraulically.

O
Input shaft (1)
O
F sun gear (2)
O
O
F carrier (10)
O
O
Sun gear (12)
O
O
3rd hub (22)
O
3rd clutch
O
Output shaft (23)
WA800, WA900-3E0 25
Reverse 1st gear speed
R ring gear (7) of R clutch and 1st ring gear (17) of

1st clutch are fixed hydraulically.

O
Input shaft (1)
O
R sun gear (5)
O
R planetary pinion (6)
O
R ring gear (9)
(R carrier (8) is fixed with R ring gear (7) = R ring
gear (9) rotation direction is opposite to input shaft
(1))
O
F carrier (10)
O
O
Sun gear (12)
O
O
1st sun gear (14)
O
O
1st carrier (16)
O
Output shaft (23)
26 WA800, WA900-3E0
WA800, WA900-3E0 27
Transfer 1
1. Transmission output shaft
2. Transfer input gear (Number of teeth: 32)
3. Transfer idler gear A (Number of teeth: 33)
4. Transfer idler gear B (Number of teeth: 34)
5. Transfer output gear (Number of teeth: 44)
6. Front coupling
7. Output shaft
8. Strainer
9. Rear coupling
Outline
q The transfer is installed in the output side of
the transmission and fixed to the transmission
case with the bolt.
28 WA800, WA900-3E0
Unit: mm
Outside diameter of coupling
10 0 Repair by hard
oil seal contact surface (front) 170 169.8
–0.100 chromium-plat-
Outside diameter of coupling 0 ing or replace
11 170 169.8
oil seal contact surface (rear) –0.100
–0.01
Width 3.0 2.8
Wear of bushing –0.03
12
seal ring Thick-
4.3 ±0.12 4.15
ness
Backlash between input gear
13 0.23 – 0.59
and idler gear A
Backlash between idler gear A
14 0.23 – 0.59
and idler gear B
Backlash between idler gear B
15 0.23 – 0.59
and output gear
Tolerance
Standard size
Shaft Hole
Tolerance for fit-
Outside 0 +0.004
16 ness of input shaft 180
diameter –0.025 –0.021
bearing (front)
Inside +0.059 0
100
diameter +0.037 -0.020
Outside 0 –0.040
diameter –0.030 –0.086
17 ness of input shaft
Inside +0.072 0
bearing (rear) 120
diameter +0.050 –0.020
Outside 0 –0.012
diameter –0.025 –0.052
18 ness of idler gear A Replace
Inside +0.053 0
bearing (front) 80
diameter +0.040 –0.015
Outside 0 –0.012
diameter –0.025 –0.052
19 ness of idler gear A
Inside +0.053 0
bearing (rear) 80
diameter +0.040 –0.015
Outside 0 –0.012
diameter –0.025 –0.052
20 ness of idler gear B
Inside +0.053 0
bearing (front) 80
diameter +0.040 –0.015
Outside 0 –0.012
diameter –0.025 –0.052
21 ness of idler gear B
Inside +0.053 0
bearing (rear) 80
diameter +0.040 –0.015
Outside 0 –0.014
diameter –0.030 –0.060
22 ness of front cou-
Inside +0.052 0
pling bearing 140
diameter +0.027 -0.025
Outside 0 –0.022
diameter –0.030 –0.051
23 ness of rear cou-
Inside +0.052 0
pling bearing 140
diameter +0.027 –0.025
Standard clearance Clearance limit
Clearance between cage and
24 –0.05 – +0.05 Adjust shim
case (after shim insertion) –
(Standard shim thickness: 1.0)
Tightening torque of front cou- 2,060 – 2,350 Nm
25
pling mounting bolt {210 – 240 kgm}
Retighten
Tightening torque of rear cou- 2,060 – 2,350 Nm
26
pling mounting bolt {210 – 240 kgm}
WA800, WA900-3E0 29
Operation
Power transmitting route
Transmission output shaft (1)

O
Transfer input gear (2)
O
Transfer idler gear A (3)
O
Transfer idler gear B (4)
O
Transfer output gear (5)
O
Output shaft (6)
O
Front coupling (7) Rear coupling (8)
O
Center drive shaft
O
Center support
O
Front drive shaft Rear drive shaft
O
Front axle Rear axle
30 WA800, WA900-3E0
Transmission control valve 1
A: From oil filter Outline

B: To power train oil cooler q The oil from the pump flows through the oil fil-
P0: Main relief oil pressure pickup port ter into the transmission control valve and then
P2: Modulating oil pressure pickup port (after quick is divided into the main relief circuit, clutch
return valve) actuation circuit and pilot circuit.
P3: Reducing oil pressure pickup port q The priority valve sends the oil to the pilot cir-
P5: Pilot oil pressure pickup port cuit first.
P8: Load piston oil pressure pickup port q The oil sent to the pilot valve is used as pilot
P9: Lubricating oil pressure pickup port pressure to actuate each clutch valve.
P10:Torque converter inlet port oil pressure pickup q The oil flowing through the priority valve to the
port modulating valve and quick return valve is
used to actuate the clutch.
1. Pilot oil filter q The lubrication relief valve keeps the transmis-
2. Solenoid valve sion lubricating circuit pressure below the set
3. Lower valve pressure.
4. Upper valve q If the directional lever or gear shift lever is
5. Breather operated, the solenoid valve of each clutch
operates to control the clutch valve.
WA800, WA900-3E0 31
Upper valve
1. Pilot valve
2. Priority valve
3. Modulating valve
4. Load piston
5. Quick return valve
6. Reducing valve
7. Lubrication relief valve
32 WA800, WA900-3E0
Unit: mm

Clearance between pilot valve size Shaft Hole clearance limit
8
and valve body –0.035 +0.013 0.035 –
28 0.078
–0.045 0 0.058
Clearance between priority –0.035 +0.013 0.035 –
9 28 0.078
valve and valve body –0.045 0 0.058
Clearance between modulating –0.035 +0.016 0.035 –
10 35 0.081
Clearance between quick –0.035 +0.013 0.035 –
11 19 0.078
return valve and valve body –0.045 0 0.058
Clearance between reducing –0.035 +0.013 0.035 –
12 28 0.078
Clearance between lubrication –0.035 +0.013 0.035 –
13 28 0.078
relief valve and valve body –0.045 0 0.058
14 Pilot valve spring Replace
164 N 156 N
68.7 54 66.6
{16.7 kg} {15.9 kg}
165 N 157 N
15 Priority valve spring (outside) 41.5 31 40.3
{16.8 kg} {16.0 kg}
130 N 124 N
16 Priority valve spring (inside) 35 31 34.0
{13.3 kg} {12.6 kg}
Modulating valve spring (out- 688 N 654 N
17 100 76 97.0
side) {70.2 kg} {66.7 kg}
Modulating valve spring 346 N 329 N
18 80 69 77.6
(inside) {35.3 kg} {33.5 kg}
320 N 304 N
19 Reducing valve spring 86 54 83.4
{32.6 kg} {31.0 kg}
172 N 163 N
20 Lubrication relief valve spring 78 48 75.7
{17.5 kg} {16.6 kg}
Standard shim thickness of 0
21
pilot valve Change of oil pressure per shim (0.5 mm): 31.4 kPa {0.32 kg/cm2}
Standard shim thickness of pri- 3.0
22
ority valve Change of oil pressure per shim (0.5 mm): 136 kPa {1.39 kg/cm2}
2.0 each on front and rear sides
Standard shim thick- Large
Change of oil pressure per shim (0.5 mm): 37.3 kPa {0.38 kg/cm2}
23 ness of modulating Adjust shim
valve 5.0
Small
Change of oil pressure per shim (0.5 mm): 41.2 kPa {0.42 kg/cm2}
24
reducing valve Change of oil pressure per shim (0.5 mm): 28.4 kPa {0.29 kg/cm2}
25
lubrication relief valve Change of oil pressure per shim (0.5 mm): 3.92 kPa {0.04 kg/cm2}
WA800, WA900-3E0 33
Lower valve
1. Main relief valve

2. Torque converter relief valve
3. F clutch valve
4. R clutch valve
5. 1st clutch valve
6. 2nd clutch valve
7. 3rd clutch valve
34 WA800, WA900-3E0
Unit: mm

Clearance between main relief size Shaft Hole clearance limit
8
valve and valve body –0.035 +0.016 0.035 –
45 0.081
–0.045 0 0.061
Clearance between torque
–0.035 +0.016 0.035 –
9 converter relief valve and valve 45 0.081
–0.045 0 0.061
body
Clearance between F clutch –0.035 +0.013 0.035 –
10 22 0.078
Clearance between R clutch –0.035 +0.013 0.035 –
11 22 0.078
Clearance between 1st clutch –0.035 +0.013 0.035 –
12 28 0.078
Clearance between 2nd clutch –0.035 +0.013 0.035 – Replace
13 22 0.078
Clearance between 3rd clutch –0.035 +0.013 0.035 –
14 22 0.078
Main relief valve spring (out- Free length Installed length Installed load Free length Installed load
15
side) 927 N 881 N
160 97 155
{94.5 kg} {89.8 kg}
682 N 647 N
16 Main relief valve spring (inside) 185 138 180
{69.5 kg} {66.0 kg}
Torque converter relief valve 518 N 492 N
17 206.5 143 200
spring {52.8 kg} {50.2 kg}
114 N 108 N
18 Clutch valve spring 78 45 75.7
{11.6 kg} {11.0 kg}
Standard shim thickness of 6.0
19
main relief valve Change of oil pressure per shim (0.5 mm): 11.8 kPa {0.12 kg/cm2}
Adjust shim
Standard shim thickness of 1.0
20
torque converter relief valve Change of oil pressure per shim (0.5 mm): 6.86 kPa {0.07 kg/cm2}
WA800, WA900-3E0 35
Solenoid valve
1. R clutch solenoid valve Operation table of solenoid valve

2. F clutch solenoid valve
Solenoid valve
3. Connector F R 1st 2nd 3rd
4. 2nd clutch solenoid valve Gear speed
5. 1st clutch solenoid valve
F1 Q Q
6. 3rd clutch solenoid valve
7. Emergency manual spool F2 Q Q
F3 Q Q
N
R1 Q Q
R2 Q Q
R3 Q Q
36 WA800, WA900-3E0
Main relief valve
Outline
q The main relief valve regulates the pressure in
the power train hydraulic circuit to the set pres-
sure.
Set pressure: 2.75 MPa {28 kg/cm2}
(At rated engine speed)
Operation
q The oil from the pump flows through the filter, q If the oil pressure in the circuit exceeds the set
port (A) and orifice (a) of main relief valve (1) to pressure, the oil in chamber (C) pushes piston
chamber (C). (2).
q When the oil pressure in port (A) is below the q The reaction to piston (2) moves main relief
set pressure, the oil flows through port (D) to valve (1) to the left and connects port (A) to
the priority valve. port (E).
q The oil from the pump flows through port (E) to
the torque converter.
WA800, WA900-3E0 37
Torque converter relief valve
Outline
q The torque converter valve regulates the
torque converter inlet circuit pressure below
the set pressure to protect the torque converter
from abnormally high pressure.
(Cracking pressure)
Operation
q The oil from main relief valve (1) flows through q If the oil pressure applied to the torque con-
port (E) to the torque converter. It also flows verter exceeds the set pressure, the oil in
through orifice (b) of torque converter relief chamber (F) pushes piston (4).
valve (3) to chamber (F). q The reaction to piston (4) moves torque con-
verter relief valve (3) to the left and connects
port (A) to port (B).
q The oil in port (A) is sent through port (B) to the
oil cooler.
38 WA800, WA900-3E0
Pilot valve
Outline
q The pilot valve sets the oil pressure in the
clutch actuating circuit.
Set pressure: 1.03 MPa {10.5 kg/cm2}
Operation
q The oil from the pump flows through the pilot q If the oil in clutch valve (3) exceeds the set
oil filter to port (A). pressure, the oil in chamber (D) pushes piston
q The oil flows through port (B) and orifice (b) of (2).
clutch valve (3) to chamber (C). It also flows q The reaction to piston (2) moves pilot valve (1)
through orifice (a) of pilot valve (1) to chamber to the left.
(D). q Port (B) is disconnected from port (A) and the
oil pressure applied to clutch valve (3) is kept
at the set pressure.
WA800, WA900-3E0 39
Priority valve
Outline
q The priority valve is installed between the
pump and modulating valve. When the gear
speed is changed, even if the oil pressure in
the clutch actuating circuit lowers sharply, the
priority valve disconnects the pilot circuit and
clutch actuating circuit to keep supplying the oil
to the pilot circuit and secure the oil pressure.
Operation
q The oil from the pump flows through port (A) q If the gear change switch is operated, the oil
and orifice (a) of priority valve (1) to chamber pressure after port (C) is lowered sharply to
(B). near 0 MPa {0 kg/cm2} by the function of the
q If the oil pressure in port (A) exceeds the set solenoid valve.
pressure, the oil in chamber (B) pushes piston q The oil pressure in port (A) is also lowered, but
(2). valve (1) is moved to the right by the reaction
q The reaction to piston (2) moves priority valve force of spring (3).
(1) to the left and connect port (A) to port (C) to q Port (C) is disconnected from port (A) and the
supply the oil to modulating valve (4). oil pressure in port (D), or in the pilot circuit, is
secured.
40 WA800, WA900-3E0
Modulating valve and quick return valve
Outline Operation
q The modulating valve and quick return valve
act together to raise the pressure applied to Immediately after shifting gear (Range A in chart)
the clutch piston gradually to the set pressure
to engage the clutch smoothly. This reduces
the gear shift shocks and prevents generation
of peak torque. Accordingly, the operator is
l e s s fa t i g u e d , t he o p e r at i n g c om f o r t i s
improved, and the durability of the power train
is increased.
A. Feeling range
B. Modulating range
C. Oil pressure rise completion range
q If the gear change switch is operated, the oil

passage from the pump to the clutch cylinder is
opened and the oil flows to the clutch cylinder.
At the same time, quick return valve (1) moves
to the right and port (D) is connected to port (E)
and the back pressure oil supplied to load pis-
ton (3) is drained.
q Modulating valve (2) is moved to the right by
the reaction forces of springs (4) and (5) and
load piston (3) moves to the left.
WA800, WA900-3E0 41
Start of oil pressure rise (Range B in chart)
q If the oil from the pump fills the circuit from port q The oil flows through orifice (b) of modulating
(A) to the clutch cylinder, the oil pressure starts valve (2) to chamber (B) and pushes piston (6).
to rise. q The reaction to piston (6) moves modulating
q The oil flowing through orifice (a) of quick valve (2) to the left and throttles the oil pas-
return valve (1) moves quick return valve (1) to sage between ports (A) and (C).
the left and disconnects port (E) from port (D). q The oil flows through orifice (c) of quick return
valve (1), orifice (d) and port (D) and applies
back pressure to load piston (3) to move load
piston to the right.
42 WA800, WA900-3E0
Completion of oil pressure rise (Range C in chart)
q As the oil pressure in the clutch cylinder circuit q If the oil pressure in the clutch cylinder circuit
rises, the back pressure applied to load piston rises to the set pressure, load piston (3)
(3) rises and piston (3) moves to the right. As a touches the stopper of modulating valve (2)
result, port (A) is connected to port (C). In addi- and does not move any more.
tion, as the oil pressure pushing piston (6) q Modulating valve (2) stops in a position where
rises, the reaction to piston (6) moves modulat- port (C) is disconnected from port (A) and the
ing valve (2) to the left and throttles the oil pas- oil pressure rise is completed.
sage between ports (A) and (C).
The above operation is repeated intermittently
to increase the oil pressure in the clutch cylin-
der circuit gradually.
WA800, WA900-3E0 43
Reducing valve
Outline
q The reducing valve is installed between the
quick return valve and the 3rd clutch valve. It
reduces the oil pressure applied to the 3rd
clutch to protect the 3rd clutch.
q The oil from quick return valve (1) flows q If the 3rd clutch cylinder is filled with the oil, the
through ports (A) and (B) to the 3rd clutch cyl- oil flowing through orifice (a) to chamber (C)
inder to fix 3rd clutch (4). pushes piston (3).
q The reaction to piston (3) moves reducing
valve (2) to the right. As a result, port (B) is dis-
connected from port (A) to protect 3rd clutch
(4).
44 WA800, WA900-3E0
Lubrication relief valve
Outline
q The lubrication relief valve keeps the transmis-
sion lubricating circuit pressure below the set
pressure to protect the transmission from
abnormally high pressure.
Operation
q The oil from the torque converter relief valve q If abnormally high pressure is generated in the
and oil cooler flows through ports (A) and (B) lubricating circuit, the oil in chamber (C) moves
and lubricates the transmission. It also flows lubrication relief valve (1) to the left to connect
through orifice (a) of lubrication relief valve (1) port (D) to port (A). As a result, the oil in port
to chamber (C). (A) is relieved to port (D) to protect the lubricat-
ing circuit.
WA800, WA900-3E0 45
Solenoid valve
Outline
q There is 1 solenoid valve installed for each
clutch valve. If the directional lever or gear shift
lever is operated, the solenoid valve is oper-
ated to control each clutch valve.
Operation
When solenoid is "de-energized" When solenoid is "energized"
q The oil from clutch valve (1) flows to port (A). q If the directional lever or gear shift lever is
Since solenoid valve (2) is deenergized at this operated, solenoid valve (2) is energized.
time, however, port (B) is disconnected from q Port (A) is connected to port (B) and the oil
port (A) and clutch valve (1) does not move. from clutch valve (1) is drained. Accordingly,
the oil pressure in port (C) becomes higher
than that in port (A).
q Clutch valve (1) moves to the left to send the
oil from the quick return valve to the clutch cyl-
inder.
46 WA800, WA900-3E0
Emergency manual spool
Outline Position to turn "OFF" (disengage) clutch

q When the solenoid valve does not operate
because of a trouble in the electrical system,
the operator can drive the machine temporarily
by operating the emergency manual spool.
The emergency manual spool is installed to
each clutch valve.
a The emergency manual spool is a device to
drive the machine to a place for repair. Take
care extremely when operating it.
Operation
Normal operation
q If emergency manual spool (3) is tightened to
the right about 10 mm, the oil flowing in port
(A) shuts port (B) to disengage the clutch,
regardless of the operation of solenoid valve
(2).
Position to turn "ON" (engage) clutch
q While the solenoid valve is operating normally,

emergency manual spool (3) is kept at the cen-
ter.
q The oil flowing through clutch valve (1) to port
(A) controls clutch valve (1) according to the
operation of solenoid valve (2).
q If emergency manual spool (3) is loosened to

the left about 10 mm, the oil flowing in port (A)
opens port (B) to engage the clutch, regardless
of the operation of solenoid valve (2).
WA800, WA900-3E0 47
SEN02352-01

© 2017 KOMATSU
All Rights Reserved
48
SEN02470-02
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Power train, Part 2
Torque converter oil cooler.............................................................................................................................. 2
Drive shaft....................................................................................................................................................... 4
Center support ................................................................................................................................................ 6
Axle ................................................................................................................................................................. 8
Differential ..................................................................................................................................................... 10
Final drive ..................................................................................................................................................... 16
WA800-3E0, WA900-3E0 1
Torque converter oil cooler 1
1. Torque converter oil cooler Outline

q The oil which comes out from the torque con-
A. Oil inlet port verter outlet port is at a high temperature
(From torque converter regulator valve) because of the energy used in transmitting the
B. Oil outlet port (To transmission lubricating) motive force. This torque converter oil passes
C. Water inlet port (From water pump) through oil inlet port (A) and enters the oil
D. Water outlet port (To engine block) cooler. Here it is cooled by the engine cooling
water. The oil then flows out from oil outlet port
(B), lubricates the transmission and returns to
transfer case.
2 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 3
Drive shaft 1
1. Front drive shaft 4. Rear drive shaft

2. Center support 5. Upper drive shaft
3. Center drive shaft
Outline
q The motive force from the engine passes When the machine is articulated, or when
trough the damper, upper drive shaft (5), there is shock from the road surface during
torque converter, transmission and transfer. traveling, or when there is shock during opera-
Part of this motive force passes through rear tions, the axle in front and behind the engine
drive shaft (4) and goes to the rear axle, the and transmission change position.
rest of motive force passes through center To allow the motive force to be transmitted
drive shaft (3), center support (2) and front without damage to parts of the machine when
drive shaft (1) and is sent to the front axle. there is shock or when the components move
q In addition to transmit the motive force, the position, the drive shafts have a universal joint
drive shafts have the following purposes. and a sliding joint. This allows them to handle
changes in angle and length.
4 WA800-3E0, WA900-3E0
Front drive shaft
Center drive shaft

Rear drive shaft
Upper drive shaft
WA800-3E0, WA900-3E0 5
Center support 1
1. Front coupling Function

2. Case q The center support is installed to the front
3. Grease nipple frame between the center drive shaft and front
4. Rear coupling drive shaft.
q With the articulating frame, this part is con-
stantly twisting from side to side, so there is lia-
ble to be large stress on the drive shaft.
Therefore, the center support is used to trans-
mit the power smoothly, to reduce the stress
on the drive shafts, and in this way improve the
durability of drive shafts.
6 WA800-3E0, WA900-3E0
Unit: mm
Standerd Torerance Standerd Clearance
Clearance between case and size Shaft Hole clearance limit
5
bearing –0.030 –0.022 –0.051 –
230 0.011
–0.030 –0.051 0.008
Clearance between case and –0.030 –0.022 –0.051 – Replace
6 215 0.011
bearing –0.030 –0.051 0.008
Clearance between case and +0.052 –0.030 –0.007 –
7 130 –0.024
bearing +0.027 –0.025 –0.027
Clearance between coupling +0.045 –0.030 –0.065 –
8 120 –0.020
shaft and bearing +0.023 –0.020 –0.023
Standerd size Tolerance Repair limit
9 Wear of oil seal surface –0.100 Repair chrome
160 –0.20
–0.100 plating or
–0.100 replace
10 Wear of oil seal surface 160 –0.20
–0.100
11 End play of coupling shaft End play 0.05 – 0.15 Replace
WA800-3E0, WA900-3E0 7
Axle 1
Front axle
1. Front axle
2. Final drive
3. Brake
4. Front differential
5. Drain plug
6. Parking brake
7. Spring cylinder
8 WA800-3E0, WA900-3E0
Rear axle
1. Rear differential
2. Rear axle
3. Brake
4. Final drive
5. Drain plug
WA800-3E0, WA900-3E0 9
Differential 1
Front differential
1. Bevel gear (No. of teeth: 39)

2. Differential housing
3. Differential side gear (No. of teeth: 28)
4. Differential pinion gear (No. of teeth: 22)
5. Shaft
6. Bevel pinion (No. of teeth: 10)
10 WA800-3E0, WA900-3E0
Rear differential
1. Bevel pinion (No. of teeth: 10)

2. Bevel gear (No. of teeth: 39)
3. Shaft
4. Differential pinion gear (No. of teeth: 22)
5. Differential side gear (No. of teeth: 28)
6. Differential housing
7. Coupling
WA800-3E0, WA900-3E0 11
Unit: mm
Standard size Tolerance Clearance limit
1 Thickness of side gear washer
9.0 — 8.5
Thickness of pinion gear Replace
2 10.75 — 10.25
washer
–0.100
3 Wear of oil seal surface 150 —
–0.100
12 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 13
Unit: mm
Clearance of bearing outer race size Shaft Hole clearance limit
1
in differential gear assembly –0.035 +0.036 –0.016 –
280 —
–0.035 –0.016 0.071
Clearance of bearing inner race +0.074 0.025 –0.049 –
2 180 —
in differential gear assembly +0.049 0.025 –0.099
Clearance of outer race of –0.035 –0.035 –0.046 –
3 215 —
pinion shaft bearing –0.030 –0.046 0.030
Clearance of inner race of –0.035 –0.035 –0.020 –
4 120 —
Clearance of outer race of –0.035 –0.035 –0.052 –
5 290 —
Clearance of inner race of +0.040 –0.035 –0.015 –
6 160 —
pinion shaft bearing +0.015 –0.025 –0.065
Clearance of differential pinion –0.035 –0.028 –0.003 –
7 160 —
gear outer race bearing –0.025 –0.068 –0.068
Clearance of differential pinion +0.013 –0.035 –0.028 –
8 90 –
gear inner race bearing –0.009 –0.015 0.009
Clearance of differential pinion –0.035 –0.028 –0.010 –
9 140 —
gear outer race bearing –0.018 –0.068 –0.068 Replace
Clearance of differential pinion +0.013 –0.035 –0.028 –
10 90 —
gear inner race bearing –0.009 –0.015 0.009
Clearance between differential –0.035 +0.057
11 330 0 – 0.114 —
carrier and cage –0.057 +0.057
Clearance between spider and –0.035 +0.030
12 70 0 – 0.060 —
differential pinion bushing –0.030 +0.057
13 Backlash of bevel gear 0.43 – 0.61
14 Backlash of differential gear 0.31 – 0.40
Free rotating torque of pinion
22.6 Nm {2.3 kgm}
15 gear
Preload of pinion bearing 21 kN {2,140 kg}
Free rotation torque of bevel
22.5 Nm {2.6 kgm}
16 gear
Preload of side bearing 28 kN {2,860 kg}
17 Rear face runout of bevel gear 0.13
Standard thickness of shims for
18 Clearance “a” + (0.1±0.05)
stop shaft
Standard thickness of shims for
19 2.0
differential cage
14 WA800-3E0, WA900-3E0
Outline When turning

q The motive force from the drive shaft passes q When turning, the rotating speed of the left and
through bevel pinion (1) and transmitted to right wheels is different, so pinion gear (4) and
bevel gear (5). side gear (3) inside the differential assembly
q The bevel gear changes the direction of the rotate in accordance with the difference
motive force by 90°, and at the same time between the rotating speed of the left and right
reduces the speed. It then transmits the motive wheels. The motive force of carrier (6) is then
force through differential to axle shaft (2). transmitted to axle shafts (2).
When driving straight forward

q When the machine is driven straight forward,
the rotating speed of the left and right wheels is
the same, so pinion gear (4) inside carrier (6)
is sent through pinion gear (4) and side gear
(3) and is transmitted equally to the left and
right axle shafts (2).
WA800-3E0, WA900-3E0 15
Final drive 1
1. Axle shaft Outline

2. Brake q To gain larger drive force, the final drive uses a
3. Planetary gear (No. of teeth 39) planetary gear system to reduce the speed
4. Ring gear (No. of teeth 99) and send drive force to the tires.
5. Drain plug
6. Housing Operation
7. Sun gear (No. of teeth 18) q The motive force transmitted from the differen-
8. Wheel tial through axle shaft (1) to sun gear (7) is
transmitted to planetary gear (3). The plane-
tary gear rotates around the inside of fixed ring
gear (4) and in this way transmits rotation at a
reduced speed to planetary carrier. This motive
for ce is then sent wheels (8) which ar e
installed to planetary carriers.
16 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 17
Unit: mm
Clearance between planetary size Shaft Hole clearance limit
9
shaft and bearing +0.018 –0.020 –0.038 –
100 —
+0.013 –0.020 –0.003
Clearance between planetary –0.020 –0.028 –0.003 –
10 180 —
gear and bearing –0.025 –0.068 –0.068
Clearance between axle –0.017 –0.020 –0.018 –
11 300 —
housing and bearing –0.069 –0.035 0.069
Clearance between wheel hub –0.020 –0.045
12 460 –0.108 – 0 —
and bearing –0.045 –0.108
Clearance between axle –0.018 –0.020 –0.022 –
13 320 — Replace
housing and bearing –0.075 –0.040 0.075
Clearance between wheel hub –0.020 –0.045
14 480 –0.108 – 0 —
and bearing –0.045 –0.108
Thickness of retainer at ring Standard size Tolerance Repair limit
15
gear hub mount 30 ±0.1 29.6
Backlash between planetary Standard size Repair limit
16
gear and sun gear 0.26 – 0.58 1.0
Backlash between planetary
17 0.30 – 0.78 1.2
gear and ring gear
Thickness of standard shim for
18 2.0
wheel hub
18 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 19
SEN02470-02

© 2017 KOMATSU
All Rights Reserved
20
SEN02353-01
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Steering system
Steering piping ................................................................................................................................................ 2
AJSS lever linkage.......................................................................................................................................... 4
EPC valve ....................................................................................................................................................... 5
Steering column .............................................................................................................................................. 6
Rotary valve .................................................................................................................................................... 7
Steering control valve.................................................................................................................................... 10
Steering unit (orbit-roll valve) ........................................................................................................................ 22
Steering pump............................................................................................................................................... 25
Steering cylinder ........................................................................................................................................... 27
Slow return valve .......................................................................................................................................... 29
Emergency steering piping ........................................................................................................................... 30
Diverter valve ................................................................................................................................................ 31
Emergency steering pump ............................................................................................................................ 37
WA800-3E0, WA900-3E0 1
Steering piping 1
AJSS specification
1. Steering valve
2. Steering lock valve
3. Rotary valve
4. EPC valve
5. Steering cylinder (Right)
6. Steering cylinder (Left)
7. Steering pump
2 WA800-3E0, WA900-3E0
Steering piping 1
Steering wheel specification
1. Steering valve
2. Steering unit (Orbit-roll valve)
3. Stop valve (Right)
4. Stop valve (Left)
5. Steering cylinder (Right)
6. Steering cylinder (Left)
7. Steering pump
WA800-3E0, WA900-3E0 3
AJSS lever linkage 1
1. AJSS lever (Steering lever) 8. Potentiometer (Frame angle)

2. Potentiometer (Lever control angle) 9. Front frame
3. Upper joint 10. Bracket
4. Universal joint 11. Rod (Frame angle potentiometer)
5. Lower joint 12. Universal joint
6. Steering lock valve 13. Rod (Steering lock valve)
7. Rotary valve 14. Steering lock lever
4 WA800-3E0, WA900-3E0
EPC valve 1
AJSS specification
1. Minimum pressure assurance pressure reducing Function

valve q The EPC valve controls the oil flow to the rotary
2. Electromagnetic proportional valve valve with the electromagnetic proportional valve
(2) controlled with the command current from the
P1. From PPC pump transmission and AJSS controller.
P2. From diverter valve q Even if the electromagnetic proportional valve
C. To rotary valve (2) does not work because of a controller trou-
D. To hydraulic valve ble, the minimum pressure assurance pres-
sure reducing valve (1) supplies the minimum
oil pressure to the rotary valve.
WA800-3E0, WA900-3E0 5
Steering column 1
1. Steering wheel
2. Steering column
3. Joint
4. Orbit-roll valve
6 WA800-3E0, WA900-3E0
Rotary valve 1
AJSS specification
1. Neutral position spring T: To hydraulic tank

2. Valve body L: To port Pb of steering control valve
3. Check valve R: To port Pa of steering control valve
4. Spool P: From PPC pump
5. Sleeve
6. Feedback spool
7. Feedback sleeve
8. Loose spring
9. Drive shaft
10. Center pin
11. Body
WA800-3E0, WA900-3E0 7
Outline Structure
q With steering lever connected on the top, the q Spool (4) connects to sleeve (5) through center
rotary valve switches the flow of oil supplied pin (10) (which is out of contact with the spool
from the EPC pump through the EPC valve to when the steering lever is in “neutral”) and
move the spool of the steering control valve. neutral position spring (1).
This movement of the 3-spool operates the q The top and bottom of drive shaft (9) are
steering cylinder to steer the machine. engaged with center pin (10) and combined
q On the other hand, the link installed on the with sleeve (5) and feedback sleeve (7) in one
front frame is connected to the underside of body.
the rotary valve, which feeds back the steering q Feedback spool (6) is connected to feedback
angle of the machine. sleeve (7) through center pin (10) (which is not
This mechanism ensures that the position of in contact with the spool while the steering
the steering lever always matches the steering lever is in “neutral”) and loose spring (8).
position of the machine. q Valve body (2) has 4 ports, which are con-
nected to the pump circuit, tank circuit and the
pilot circuit of the steering control valve respec-
tively.
8 WA800-3E0, WA900-3E0
Operation
At turning
q Operating the steering lever causes spool (4) to overcome neutral position spring (1) and turn relative to
sleeve (5).
This turning causes spool (4) fall on the port of sleeve (5), creating a passage for oil to allow oil to flow
toward the steering control valve, then machine turns.
At neutral
q When application of the operating effort on the steering lever is stopped, the return force of neutral posi-
tion spring (1) returns spool (4) and sleeve (5) to the neutral position, so the oil passage is shut off and
the oil stops flowing.
q When the steering lever is held at a certain angle and the machine is steered to the angle equivalent to
the operating angle of the steering lever (since sleeve (5) turns according to the steering angle of the
machine), spool (4) and sleeve (5) are also returned to the neutral position, and the oil stops flowing.
WA800-3E0, WA900-3E0 9
Steering control valve 1
1. Overload relief valve

2. Main relief valve
3. Steering spool
4. Control spool
5. Surge cut relief valve
A. To steering cylinder
B. To steering cylinder
P1. From steering pump
P2. From switch pump
PB. To main control valve
T. To hydraulic tank (through hydraulic oil cooler)
10 WA800-3E0, WA900-3E0
Unit: mm
Instllation Instllation
Free length Free length Load limit
6 Steering spool return spring length load
74.5 N 58.8 N
41.8 38.0 —
{7.6 kg} {6 kg}
8.8 N 7.0 N
7 Load check valve spring 20.9 13.2 —
{0.9 kg} {0.71 kg}
410 N 328 N
8 Control spool return spring 90.8 83.0 —
{41.8 kg} {33.8 kg} Replace
182.4 N 145.1 N
9 Main relief valve spring 24.0 22.19 —
{18.6 kg} {14.8 kg}
182.4 N 145.1 N
10 Surge cut relief valve spring 24.0 22.19 —
{18.6 kg} {14.8 kg}
590 N 471 N
11 Overload relief valve spring 39.5 35.7 —
{60.2 kg} {40.8 kg}
8.8 N 7.0 N
12 Check valve return spring 20.9 13.2 —
{0.9 kg} {0.71 kg}
WA800-3E0, WA900-3E0 11
Overload relief valve q When the pressure at port (A) reaches the set
pressure of the relief valve, pilot poppet (4)
opens and the oil goes around pilot poppet (4)
and flows to port (B).
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet q When pilot poppet (4) opens, the pressure at
5. Spring the rear poppet (1) drops, poppet (1) moves to
the right, and it is seated with pilot poppet (4).
Function
q The overload relief valve is installed in the cyl-
inder circuit of steering control valve. When the
steering control valve is at neutral and any
impact is applied to the steering cylinder and
abnormal pressure is generated, this valve
functions as a safety valve to relieve the circuit
to prevent breakage of the cylinder or hydraulic
piping.
Operation
1. Operation of relief valve
q Port (A) is connected to the cylinder circuit and
port (B) is connected to the drain circuit. The
oil passes through the hole in poppet (1) and
q Compared with the pressure at port (A), the
acts on the area of diameters (d1) and (d2).
pressure on the inside is low, so relief valve
Check valve poppet (3) and relief valve poppet
poppet (2) opens and the oil flows from port (A)
(2) are securely seated.
to port (B) to prevent any abnormal pressure.
12 WA800-3E0, WA900-3E0
2. Operation of suction valve

q Negative pressure is generated at port (A), the
difference in the area of diameters (d3) and
(d4) opens check valve poppet (3), and oil
flows from port (B) to port (A) to prevent a vac-
uum from forming in the circuit.
WA800-3E0, WA900-3E0 13
Main relief valve
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
q The main relief valve of the steering control
valve is inside the valve and sets the maximum
pressure in the steering circuit when it is oper-
ated. In other words, when the valve is being
operated and the steering circuit goes above
the set pressure of this valve, it relieves the oil
and actuates the flow control spool of the
steering control valve to drain the oil to the
steering circuit.
14 WA800-3E0, WA900-3E0
Operation of steering relief valve
q When the pressure in the circuit rises and q When flow control spool (4) moves, the oil from
reaches set by spring (2) and adjustment the steering pump is drained and the oil from
screw (1), pilot poppet (3) opens and drains the switch pump is relieved to the main control
the oil. valve, so the steering circuit pressure is pre-
q When this happens, the balance of the pres- vented from going above the set value.
sure in pressure receiving chamber (I) and
pressure receiving chamber (II) is lost, and
flow control spool (4) moves to the left.
WA800-3E0, WA900-3E0 15
Operation of steering control valve
When steering spool is at neutral
q The oil from the steering pump enters port (A) q When the pressure in pressure receiving
and the oil from the switch pump enters port chamber (I) reaches a certain value (set by
(B). spring (3)), notch (f) opens and the oil from the
q When steering spool (2) is at the neutral posi- steering pump goes to the drain circuit. Notch
tion, pressure receiving pressure chamber (II) (g) is closed, so the oil from the switch pump
is connected to the drain circuit through orifice all flows to the main control valve.
(b), and notch (c) is closed.
q Notch (c) is closed, so the pressure of the oil at
port (A) and port (B) rises. This pressure
passes through orifice (a), goes to pressure
receiving chamber (I) and moves control spool
(1) to the left.
16 WA800-3E0, WA900-3E0
When the steering spool is operated
q Engine running at low speed
q When the steering is operated, oil flows from q The merged oil passes through notches (c)
the rotary valve to steering spool (2) and and (d), pushes load check valve (5), and flows
pushes steering spool (2) to the right. The cir- to the cylinder. The return oil from the cylinder
cuit between pressure receiving camber (II) passes through notch (e) and flows to the drain
and the drain circuit is shut off, and at the circuit.
same time, notch (c) opens. q When this happens, the pressure before passing
q As a result, the pressure in pressure receiving through notch (c) is set to pressure receiving
chamber (II) rises, and control spool (1) moves chamber (I) and the pressure after passing
to the right unit notch (h) closes. through notch (c) is sent to pressure receiving
q The passage from port (B) to the main control chamber (II). Control spool (1) is actuated so that
valve is shut off, so the oil from the switch the difference in pressure on both sides of notch
pump pushes up pump merge-divider check (c) is kept constant. There fore, an oil flow corre-
valve (4) and merges with the oil from the sponding to the opening of notch (c) is supplied
steering pump port (A). to the cylinder port. These pressure differences
(control pressure) are set by spring (3).
WA800-3E0, WA900-3E0 17
q Engine running at high speed
q There is no need for supply of extra oil from the q The oil from the steering pump passes through
switch pump, so the steering pump pressure notches (c) and (d), pushes load check valve
rises until notch (g) closes and shuts off the (5), and flows to the cylinder. The return oil
merge passage from port (B). from the cylinder passes through notch (e) and
q The pressure difference on both sides of notch flows to the drain circuit.
(c) is controlled only by notch (f), and the q Notch (g) is closed, so the oil from the switch
excess oil from the steering pump is drained pump all flows from port (B) and is sent to the
from notch (f) to the drain circuit. (At this point, main control valve.
notch (g) is completely closed.)
18 WA800-3E0, WA900-3E0
Operation of steering valve
Neutral
q The steering is not operated, so steering spool

(2) dose not move.
q The oil from the steering pump enters port (A).
The oil from the switch pump enters port (B).
q When the pressure at ports (A) and (B) rises,
control spool (1) moves to the left, so the oil
from the steering pump passes through port
(C) of the spool and is drained.
The oil from the switch pump passes through
port (D) and all flows to the main control valve.
WA800-3E0, WA900-3E0 19
Turning right
q When the steering is operated to the right, the

rotary valve is operated and steering spool (2)
moves to the left.
The oil from the steering pump enters port (A),
then flows to steering spool (2) through control
spool (1). The oil pushes open load check
valve (6) 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.
The oil from the left and right cylinders passes
through load check valve (5) of the steering
spool and is drained. The oil from the switch
pump enters port (B), goes through control
spool (1), pushes open check valve (4), and is
merged with the oil from the steering pump.
20 WA800-3E0, WA900-3E0
Turning left
q When the steering is operated to the left, the The oil from the left and right cylinders passes
rotary valve is operated and steering spool (2) through load check valve (6) of the steering
moves to the right. spool and is drained. The oil from the switch
The oil from the steering pump enters port (A), pump enters port (B), goes through control
then flows to steering spool (2) through control spool (1), pushes open check valve (4), and is
spool (1). The oil pushes open load check merged with the oil from the steering pump.
valve (5) 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.
WA800-3E0, WA900-3E0 21
Steering unit (orbit-roll valve) 1

1. Neutral position spring a. To hydraulic tank

2. Valve body b. To steering cylinder (demand valve port Pb)
3. Check valve c. To steering cylinder (demand valve port Pa)
4. Spool d. From PPC pump
5. Sleeve
6. Gear rim
7. Gear
8. Cover
9. Drive shaft
10. Center pin
22 WA800-3E0, WA900-3E0
Outline
q The steering unit is directly connected to the

shaft of the steering wheel. The oil from the
PPC pump passes through the steering
demand valve, and is switched to the left and
right steering cylinders to determine the direc-
tion of travel of the machine.
q The steering unit can be broadly divided into
the following: spool (4) and sleeve (5), which
have a rotor type direction selection function,
and the gear set (combination of gear (7) and
gear rim (6)), which acts as a hydraulic motor
when the steering is operated.
Structure
q Spool (4) is interconnected with the drive shaft

of the steering wheel and is connected to
sleeve (5) by neutral position spring (1) and
center pin (10) (when the steering wheel is at
neutral, it does not contact the spool).
q The top of drive shaft (9) is meshed with center
pin (10) and forms one unit with sleeve (5).
The bottom is meshed with the spline of gear
(7) of the gear set.
q Valve body (2) has four ports. These are con-
nected respectively to the pump circuit, tank
circuit, and pilot circuit of the steering demand
valve.
In addition, the port at the pump end and the
port at the tank end are connected by check
valve (3) inside the housing. lf there is any fail-
ure in the PPC pump, oil is sucked in directly
from the tank end by the check valve.
WA800-3E0, WA900-3E0 23
Operation 1
When turning
q When the steering wheel is turned, spool (4) q When the steering wheel is turned, the oil
overcomes neutral position spring (1) and inside gear (7) flows, passes inside sleeve (5)
turns slightly in relation to sleeve (5). Because and spool (4), operates the spool of the steer-
of this rotation, the ports of sleeve (5) and ing demand valve, and actuates the steering
spool (4) overlap, so a passage is formed for cylinders.
the oil to flow, and the oil flows to gear (7).
At neutral
q When the turning of the steering wheel is q When the non-reaction type steering valve is at
stopped (the rotation of the spool is stopped), the neutral position, the steering cylinder and
the return force of neutral position spring (1) spool (4) and sleeve (5) are bfocked, so the
returns spool (4) and sleeve (5) to the neutral reaction from the machine is not transmitted to
position, so the oil passage is shut off and the the steering wheel.
oil stops flowing.
24 WA800-3E0, WA900-3E0
Steering pump 1
Type: HPV95+95
Specification Outline
Items Steering pump q This pump consists of 2 fixed-displacement
swash plate-type piston pumps and 1 impeller
Type HPV95+95
pump between them.
Rated discharge pressure 31.4 MPa {320 kg/cm2} q The front pump and rear pump are originally of
Rated rpm 2150 rpm the variable displacement type, but their dis-
placement is fixed since inserted collars (16)
Theoretical delivery (front) 76.2 cc/rev
and (17) disable servo piston (15) and fix
Theoretical delivery (rear) 71.5 cc/rev rocker cam (4).
Max. delivery 161.6 + 151.6 l/min q For explanation of the operation, see the sec-
tion of the work equipment pump. The work
equipment pump is of the variable displace-
ment type, however, since its rocker cam (4)
can move.
WA800-3E0, WA900-3E0 25
1. Shaft (front) 12. Case (rear)

2. Cradle (front) 13. End cap (rear)
3. Case (front) 14. End cap (front)
4. Rocker cam 15. Servo piston
5. Shoe 16. Collar
6. Piston 17. Collar
7. Cylinder block
8. Valve plate PA1 : Front pump delivery port
9. Impeller PA2 : Rear pump delivery port
10. Cradle (rear) PS : Pump suction port
11. Shaft (rear)
26 WA800-3E0, WA900-3E0
Steering cylinder 1
Steering cylinder mount
Unit: mm
Clearance between mounting size clearance limit
Shaft Hole
1 and bushing connection of
steering cylinder rod and frame –0.036 +0.307 0.256 –
110 0.7
–0.090 +0.220 0.397
Clearance between mounting
and bushing connection of –0.036 +0.020 0.036 –
2 110 0.7
steering cylinder bottom and –0.090 +0.020 0.310
frame
Standard Replace
Width of Width of clearance
Width of hinge
Connection of steering cylinder bushing spacer (Clearance
3
and front frame a+b)
90 +0
–0.2
10.5 116 2
Standard clearance
Width of boss Width of hinge
Connection of steering cylinder (Clearance a+b)
4
and rear frame +0.8 Max 0.5
110 –0.2 116±1.5
after adjusting shim
WA800-3E0, WA900-3E0 27
Unit: mm
Clearance between piston rod size Shaft Hole clearance limit
1
and bushing –0.036 +0.265 0.085 –
100 —
–0.090 +0.049 0.355
Clearance between piston rod –0.036 +0.307 0.256 – Replace bushing
2 100 —
mounting pin and bushing –0.090 +0.220 0.397
Clearance between cylinder
–0.036 +0.020 0.036 –
3 bottom mounting pin and 110 —
–0.090 +0.020 0.110
bushing
4 Cylinder bore +0.3 Replace
160 —
+0.3
28 WA800-3E0, WA900-3E0
Slow return valve 1 Operation

q When the oil is flowing to arrow o, it pushes
spring (2) and flows through the orifice, and
between poppet (1) and the poppet seat.
q When the oil is flowing to arrow i, the oil flows

only from orifice (a) inside poppet (1), so the
flow is controlled.
1. Poppet
2. Spring
3. Body
Function
q To reduce the shock caused by the inertia of
the machine when the steering is operated, an
orifice is installed in the oil line of the return cir-
cuit from the cylinder. This applies pressure to
the returning oil, and regulates the movement
of the cylinder piston.
WA800-3E0, WA900-3E0 29
Emergency steering piping 1
1. Emergency steering pump

2. Transmission
3. Diverter valve
4. Hydraulic tank
30 WA800-3E0, WA900-3E0
Diverter valve 1
1. Emergency steering pump Function

2. Transmission q The diverter valve is selector valve which
3. Diverter valve senses the pilot pressure from the steering
4. Hydraulic tank pump and if there is no abnormality in the
steering circuit, it drains the oil from the emer-
A. To emergency pump gency pump to the tank. If no pilot pressure
B. Sensor mounting port from the steering pump reaches the diverter
C. To hydraulic oil tank valve, the oil from the emergency pump is
D. To steering valve switched to the steering circuit and flows to
E. From hydraulic tank enable the machine to be steered.
F. From steering circuit
WA800-3E0, WA900-3E0 31
Emergency steering relief valve Operation

q Port (A) is connected to the pump circuit, and
port (C) is connected to the drain circuit. The
oil passes through the orifice in main valve (1)
and fills port (B). Pilot poppet (3) is in contact
with valve seat (2).
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
q When the pressure inside ports (A) and (B)
Function reaches the pressure set by the poppet spring
q Compared to the steering valve relief pressure (set pressure), pilot poppet (3) opens and the
of 31.4 MPa {320 kg/cm2}, the rated pressure of hydraulic pressure at port (B) escapes from
the emergency steering pump and diverter valve port (D) to port (C). This lowers the pressure at
are both 20.6 MPa {210 kg/cm2}. Therefore, to port (B).
protect the emergency steering pump and q When the pressure at port (B) drops, the orifice
diverter valve, there is a relief valve in the piping of main valve (1) generates a difference in
from the diverter valve to the steering valve. pressure between port (A) and port (B). Main
When the emergency steering is being oper- valve (1) is opened by the pressure at port (A)
ated, and the hydraulic pressure generated by and the oil at port (A) is relieved.
the steering exceeds 20.6 MPa {210 kg/cm2} ,
the relief valve is actuated.
32 WA800-3E0, WA900-3E0
q Pump, engine working normally
a. Sensor
b. Relief valve
c. From steering cylinder
d. To steering cylinder
e. To main control valve
f. Hydraulic tank
g. Oil cooler
h. Oil filter
j. From rotary valve
P1. Emergency steering pump

P2. Main pump
P3. Steering pump
P4. Switch pump
WA800-3E0, WA900-3E0 33
When the steering pump and engine are working

normally, the main pump, steering pump, and
switch pump are rotated by the engine.
Therefor, oil is sent to the steering valve, and the
machine can be steered. In addition, the emer-
gency pump is rotated by the transmission, so oil
from port (A) of the diverter valve pushes open
check valve (2) and enters port (B).
Pressure oil from the steering pump is flowing to
port (D), so it pushes spool (3) in direction of the
arrow.
As a result, the oil from port (B) flows to port (C)
and is drained to hydraulic tank.
34 WA800-3E0, WA900-3E0
q Failure in pump or engine when machine is traveling
a. Sensor
b. Relief valve
c. From steering cylinder
d. To steering cylinder
e. To main control valve
f. Hydraulic tank
g. Oil cooler
h. Oil filter
j. From rotary valve
P1. Emergency steering pump

P2. Main pump
P3. Steering pump
P4. Switch pump
WA800-3E0, WA900-3E0 35
If there is a failure in pump or engine when the

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

that it can rotate to both directions.
36 WA800-3E0, WA900-3E0
Emergency steering pump 1
Unit: mm
Clearance between gear case Standard size Tolerance Standard clearance
1
and side plate gear SAM (3)-100 0.10 – 0.15 0.19
Clearance between inside
2 diameter of plain bearing out- SAM (3)-100 0.020 – 0.043 0.075 Replace
side diameter of gear shaft
Type Standard size Tolerance Repair limit
3 Insertion depth of pin –0.5
SAM (3)-100 14 —
–0.5
4 Rotating torque of spline shaft 6.86 – 11.8 Nm {0.7 – 1.2 kgm}
Standard Repair limit
Revolution Pressure
Discharge Type discharge discharge
(rpm) 2
(MPa{kg/cm }) —
— Oil: EO10-CD (l/min) (l/min)
Temperature: 40 – 55°C SAM (3)- 20.6
2,500 214 189
100 {210}
WA800-3E0, WA900-3E0 37
SEN02353-01

© 2010 KOMATSU
All Rights Reserved
38
SEN02354-01
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Brake system
Brake piping .................................................................................................................................................... 2
Brake............................................................................................................................................................... 3
Brake valve ..................................................................................................................................................... 6
Accumulator charge valve............................................................................................................................. 14
PPC relief valve ............................................................................................................................................ 18
Accumulator (for brake) ................................................................................................................................ 20
Slack adjuster ............................................................................................................................................... 21
Parking brake................................................................................................................................................ 23
Parking brake caliper .................................................................................................................................... 25
Spring cylinder .............................................................................................................................................. 26
Parking brake solenoid ................................................................................................................................. 27
Brake cooling system (if equipped)............................................................................................................... 28
Brake cooling system (55°C specification) (If equipped) .............................................................................. 38
WA800-3E0, WA900-3E0 1
Brake piping 1
1. Accumulator charge valve

2. Slack adjuster (Front)
3. Slack adjuster (Rear)
4. Brake oil tank
5. Accumulator
6. Parking brake solenoid valve
7. Brake valve (Right)
8. Brake valve (Left)
2 WA800-3E0, WA900-3E0
Brake 1
1. Guide pin
2. Return spring
3. Cylinder
4. Brake piston
5. Outer gear
6. Hub gear
7. Plate
8. Disc
WA800-3E0, WA900-3E0 3
Unit: mm
Installed Installed Installed
Free length Free length
9 Return spring length load load
998 N 949 N
114 98.8 111.7
{101.9 kg} {96.8 kg}
10 Thickness of plate
2.4 — 2.15
11 Thickness of plate 5.1 — 4.6
Assembled thickness of plate
12 107.4 — 101.1
disc
Replace
–0.155
13 Wear of seal contact surface 108.4 —
–0.155
Wear of piston seal contact +0.097
14 107.4 —
surface +0.097
Wear of piston seal contact +0.097
15 107.4 —
surface +0.097
Strain of plate and disc contact Standerd strain Repair limit
16
surface 0.5 0.7
Backlash of outer gear and
17 0.21 – 0.64
plate
18 Backlash of inner gear and disc 0.21 – 0.64
4 WA800-3E0, WA900-3E0
Function
q All the 4 wheels are equipped with a main
brake, which is wet-type multi-disc brake.
q When the brake pedal is pressed down, pres-

sure oil from the slack adjuster moves brake
piston (4) in the direction shown by an arrow
mark to press disc (8) to contact plate (7). This
generates friction force between the disc and
the plate. While the wheel is rotating with the
disc, this friction causes the machine to slow
down and stop.
q When the brake pedal is released, back pres-

sure on brake piston (4) is released and force
of return spring (2) moves the piston in the
direction shown by an arrow mark to release
the brake.
WA800-3E0, WA900-3E0 5
Brake valve 1
Brake valve (Left)
1. Brake pedals
2. Rod
3. Spool
4. Cylinder
A: Brake port
P: Accumulator port
T: Drain port
6 WA800-3E0, WA900-3E0
Unit: mm
Clearance between pedal size Shaft Hole clearance limit
5
mounting hole and pin –0.01 +0.022 0.112 –
ø10 0.25
–0.09 +0.022 0.01
Clearance between roller and –0.01 +0.022 0.112 –
6 ø10 0.25
pin –0.09 +0.022 0.01
7 Outside diameter of roller
30 ±0.1 29.2
Replace
8 Control spring length load load
3.82 N
34 33.5 33 —
{0.39 kg}
12.8 N
9 Control spring 46.3 46 45 —
{1.3 kg}
60.8 N
10 Return spring 86.2 58 78 —
{6.2 kg}
16.7 N
11 Return spring 31.5 19.5 28 —
{1.70 kg}
WA800-3E0, WA900-3E0 7
Brake valve (Right)
1. Brake pedals A: To rear brake

2. Rod B: To front brake
3. Piston and pilot PA: From accumulator charge valve
4. Spool PB: From accumulator charge valve
5. Cylinder, upper PP: From pilot port
6. Spool T: Drain port
7. Cylinder, lower
8 WA800-3E0, WA900-3E0
Unit: mm
Clearance between pedal size Shaft Hole clearance limit
8
mounting hole and pin –0.025 +0.1 0.0252 –
ø10 0.25
–0.075 +0.1 0.175
Clearance between roller and –0.025 +0.1 0.0252 –
9 ø10 0.25
pin –0.075 +0.1 0.175
10 Outside diameter of roller –0.5
30 29.2
–0.5
Installed Installed Installed Replace
11 Control spring length load load
7.662 N
34 30.0 33 —
{0.781 kg}
0N
12 Control spring 46 46 45 —
{0 kg}
60.8 N
13 Return spring 86.2 58 78 —
{6.2 kg}
16.7 N
14 Return spring 31.5 19.5 28 —
{1.70 kg}
17.7 N
15 Return spring 17 16.5 — —
{1.8 kg}
WA800-3E0, WA900-3E0 9
Outline
q There are two brake valves installed in parallel
under the front of the operator’s cab, and these
are actuated by depressing the pedal.
q When the right pedal is depressed, oil is sent
to the brake cylinder to apply the brakes.
q When the left pedal is depressed, oil is sent to
the right pedal to apply the brakes in the same
way as when the right pedal is depressed.
In addition, the left brake pedal operates the
transmission cut-off switch to actuate the
transmission solenoid valve electrically and set
the transmission to neutral.
10 WA800-3E0, WA900-3E0
Operation Brake applied (left brake pedal)

Brake applied (right brake valve) q When pedal (7) is depressed, spool (10) is
Upper portion pushed up by rod (8) and spring (9), and drain
q When brake pedal (1) is depressed, the oper- port (c) is closed. The oil from the pump and
ating force is transmitted to spool (3) through accumulator flows from port (E) to port (F).
rod (2) and spring (4). When spool (3) goes q Port (F) of the left brake valve and port (PP) of
down, drain port (a) is closed, and the oil from the right brake valve are connected by a hose,
the pump and accumulator flows from port (A) so the oil flowing to port (F) flows to pilot port
to port (C) and actuates the front brake cylin- (PP) of the right brake valve.
ders. q The oil entering pilot port (PP) enters port (G)
from orifice (d), and pushes pilot piston (11).
Lower portion The spring pushes spool (3) down, so the
operation is same as when the right brake
q When brake pedal (1) is depressed, the oper-
valve is depressed.
ating force is transmitted to spool (3) through
rod (2) and spring (4). When spool (3) goes
down, spool (5) is also pushed down by
plunger (6). When this happens, drain port (b)
is closed, and oil from the pump and accumu-
lator flows from port (B) to port (D) and actu-
ates the rear brake cylinders.
WA800-3E0, WA900-3E0 11
Applying brake when upper valve fails Lower portion

(right brake valve) q When spool (3) in the upper portion moves up
q Even if there is leakage of oil in the upper pip- and the circuit between port (A) and port (C) is
ing, spool (5) is moved down mechanically shut off, oil also fills the rear brake cylinder at
when pedal (1) is depressed, and the low por- the same time, so the pressure in the circuit
tion is actuated normally. The upper brake is between port (B) and port (D) rises. The oil
not actuated. entering port (J) from orifice (f) of spool (5)
pushes up spool (5) by the same amount that
Applying brake when lower valve fails spool (3) moves, and shut off port (B) and port
(right brake valve) (D). Drain port (b) is closed, so the oil entering
the brake cylinder is held, and the brake is
q Even if there is leakage of oil in the lower pip-
applied.
ing, the upper portion is actuated normally.
q The pressure in the space in the upper portion
is balanced with the operating force of the
pedal, and the pressure in the space in the
lower portion is balanced with the pressure in
the space in the upper portion. When spools
(3) and (5) move to end of their stroke, the cir-
cuits between ports (A) and (C) and between
ports (B) and (D) are fully opened, so the pres-
sure in the space in the upper and lower por-
tions and the pressure in the left and right
brake cylinders is the same as the pressure
from pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of the
brake can be adjusted by the amount that the
pedal is depressed.
When actuation is balanced

Upper portion
q When oil fills the front brake cylinder and the
pressure between port (A) and port (C)
becomes high, the oil entering port (H) from
orifice (e) of spool (3) pushes against spring
(4). It pushes up spool (3) and shuts off the cir-
cuit between port (A) and port (C). When this
happens, drain port (a) stays closed, so the oil
entering the brake cylinder is held and the
brake remains applied.
12 WA800-3E0, WA900-3E0
Brake released (right brake valve)

Upper portion
q When pedal (1) is released and the operating
force is removed from the top of the spool, the
back pressure from the brake cylinder and the
force of spool return spring move spool (3) up.
Drain port (a) is opened and the oil from the
brake cylinder flows to the hydraulic tank
return circuit to release the front brake.
Lower portion
q When pedal is released, spool (3) in the upper
portion move up. At the same time, the back
pressure from the brake cylinder and the force
of spool return spring move spool (5) up. Drain
port (b) is opened and the oil from the brake
cylinder flows to the hydraulic tank return cir-
cuit to release the rear brake.
WA800-3E0, WA900-3E0 13
Accumulator charge valve 1
A: To brake oil tank Function

ACC: Plug q The accumulator charge valve is actuated to
PP: To brake valve maintain the oil pressure from the pump at the
P: From pump specified pressure and to store it in the accu-
T: Drain mulator.
q 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.
14 WA800-3E0, WA900-3E0
1. Valve body
2. Main relief valve (R3)
3. Relief valve (R1)
4. PPC relief valve (R2)
5. Relief valve (H1)
6. Filter
WA800-3E0, WA900-3E0 15
Operation 2. When oil is supplied to accumulator

1. When no oil being supplied to accumulator 1) Cut-in condition
(cut-off condition) q When the pressure at port (B) is lower
q The pressure at port (B) is higher than the set than the set pressure of the relief valve
pressure of the relief valve (R1), so piston (8) (R1), piston (8) is pushed back down by
is forcibly pushed up by the oil pressure at port spring (5). Valve seat (7) and poppet (6)
(B). Poppet (6) is opened, so port (C) and port are brought into tight contact, and port (C)
(T) are short circuited. and port (T) are shut off.
q The spring chamber at the right end of spool q The spring chamber at the right end of
(15) is connected to port (C) of the relief valve spool (15) is also shut off from port (T), so
(R1), so pressure becomes the brake oil tank the pressure rises, and the pressure at
pressure. The oil from the pump enters port port (P) also rises in the same way.
(P), pushes spool (15) to the right at a low q When the pressure at port (P) goes above
pressure equivalent to the load on spring (14), the pressure at port (B) (accumulator
and flows from port (A) to brake oil tank. At the pressure), the supply of oil to the accumu-
same time, it also passes through orifices (17), lator starts immediately. In this case, it is
(18), and (16), and flows to the brake oil tank. decided by the size (area) of orifice (17)
and the pressure difference (equivalent to
the load on spring (14)) generated on both
sides of the orifice. A fixed amount is sup-
plied regardless of the engine speed, and
the remaining oil flows to port (A).
16 WA800-3E0, WA900-3E0
2) When cut-out pressure is reached 3. Safety relief valve (R3)

q When the pressure at port (B) (accumula- q If the pressure at port (P) (pump pressure)
tor pressure) reaches the set pressure of goes above the set pressure of the relief valve
the relief valve (R1), poppet (6) separates (R3), the oil from the pump pushes spring (3).
from valve seat (7), so an oil flow is gener- Ball (11) is pushed up and the oil flows to the
ated and the circuit is relieved. brake oil tank circuit, so this sets the maximum
q When the circuit is relieved, a pressure pressure in the brake circuit and protects the
difference is generated above and blow circuit.
piston (8), so piston (8) moves up, poppet
(6) is forcibly opened, and port (C) and
port (T) are short circuited.
q The spring chamber at the right end of
spool (15) is connected to port (C) of the
relief valve (R1), so the pressure becomes
the brake oil tank pressure.
q The pressure at port (P) drops in the same
way to a pressure equivalent to the load
on spring (14), so the supply of oil to port
(B) is stopped.
WA800-3E0, WA900-3E0 17
PPC relief valve 1
1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw
Function
q The PPC relief valve is located between the
brake pump and brake circuit. When any
abnormal pressure has occurred in the brake
circuit, oil from the pump is relieved from this
valve in order to protect the pump and the cir-
cuit from damage.
18 WA800-3E0, WA900-3E0
Operation q When pressure at port (B) drops, the orifice of

q The relief valve is installed on the accumulator main valve (1) functions so as to allow pres-
charge valve. Port (A) is connected to the sure differential to occur at ports (A) and (B),
pump circuit, and port (C) to the drain circuit. causing main valve (1) to open due to pressure
Oil runs through the orifice of main valve (1) from port (A) and oil in port (A) is drained to
and fills port (B). Pilot poppet (4) is seated on port (C) for relief.
the valve seat (3).
q When pressure at ports (A) and (B) reaches
the set pressure, pilot poppet (4) opens and oil
pressure at port (B) is carried from port (D) to
port (C), causing pressure at port (B) to drop.
WA800-3E0, WA900-3E0 19
Accumulator (for brake) 1
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function Specifications
q Accumulator is installed between the accumu- Gas used: Nitrogen gas
lator charge valve and brake valve. The space Amount of gas: 6,000cc
between cylinder (3) and free piston (4) is filled Charge pressure: 3.43 ± 0.20 MPa {35 ± 2.0 kg/cm2}
with nitrogen gas. The nitrogen gas absorbs (at 50°C)
the hydraulic pulses generated by hydraulic
pump and secures the braking force and oper-
ability when the engine stops by utilizing its
compressibility.
20 WA800-3E0, WA900-3E0
Slack adjuster 1
1. Cylinder
2. Check valve
3. Piston
4. Spring
5. Bleeder
Function
q The slack adjuster is installed on the brake oil
line leading to the brake piston from the brake
valve, and functions to keep the time lag during
brake operation at a fixed level.
Unit: mm
Clearance between body and size Shaft Hole clearance limit
6
piston –0.030 +0.074 0.030 –
80 0.25
–0.076 +0.074 0.150
Replace
length load load
7 Slack adjuster spring
49 N
198 90 — —
{5.0 kg}
WA800-3E0, WA900-3E0 21
Operation q As the brake valve is kept pressed down fur-

1. When the brake pedal is pressed down ther, oil pressure from the brake valve exceeds
q Before the brake is pressed down, piston (4) is the specified to open check valve (3) and oil
restored as much as amount of stroke (S) (a flows through port (D) to port (C). This gives
full stroke). When the brake pedal is pressed the braking force. Thus, the time lag when the
down, oil discharged from the brake valve brake is in operation is maintained the same.
flows in from port (P) of the slack adjuster.
From port (P) the oil is divided and sent to left
and right cylinders (2) and moves piston (4) a
distance of stroke (S) to the right or left.
2. When the brake is released

q When the brake is released, return spring (8)
of the brake restores piston (4) as much as the
amount of oil of stroke (S) and the brake
q Because of this, an amount of oil correspond- returns to its released state. In the other words,
ing to stroke (S) flows from port (C) to brake return stroke of brake piston (7) depends on
cylinder (7). When this happens, the clearance the amount of oil of stroke (S) and the braking
between the brake piston and disc becomes 0, time lag stays the regardless of the amount of
so no braking force is generated. wear of the brake disc.
22 WA800-3E0, WA900-3E0
Parking brake 1
1. Spring cylinder Outline

2. Caliper q The parking brake is a disc type and is
3. Caliper installed on the front axle.
4. Spring cylinder q The force of the spring inside spring cylinder is
5. Differential case used to apply the brake mechanically, it is
6. Spring released by oil pressure.
7. Disc q The parking brake caliper is fixed to the front
differential case. The disc is installed to the dif-
ferential yoke and rotates together with cou-
pling.
WA800-3E0, WA900-3E0 23
Unit: mm
Standard backlash Repair limit Repair or
8 Face runout of disc
0.4 0.8 replace
Rebuild
(Thickness of
Min. 20
9 Thickness of disc 25 disc must not be
under 20 mm)
Max. 20
Thickness of pad (including Replace
10 21.5 11.5
thickness of plate
Standard
Standerd Allowable
dimention of Tolerance
clearance clearance
blade
–0.3
22.3
–0.3
Clearance between plate and Correct or
11 Standard
brake assembly replace
dimention of
Tolerance 1.0 ± 0.4 1.5
brake
assembly
+0.4
23
–0.1
24 WA800-3E0, WA900-3E0
Parking brake caliper 1
1. Adjuster Outline
2. Piston q A piston guide is installed to caliper (5). Piston
3. Piston shaft (2) and piston shaft (3) are inserted, and the
4. Pad rotation of piston shaft (3) moves piston (2) in
5. Caliper the axial direction to bring pad (4) into tight
contact.
q The adjuster (1) is joined by a spline to the
spline side of piston shaft (3). Pad (4) is
inserted together with caliper (5) into the cali-
per mounting plate and is held in position.
WA800-3E0, WA900-3E0 25
Spring cylinder 1
1. Outer spring Outline

2. Inner spring q The oil pressure from the parking brake sole-
3. Piston noid valve pushes the spring and releases the
4. Cylinder parking brake. When the engine is stopped,
5. Boot the parking brake is applied by springs (1) and
6. Rod (2), so the machine is prevented from moving.
26 WA800-3E0, WA900-3E0
Parking brake solenoid 1
1. Solenoid valve assembly Function

2. Block q The parking brake solenoid valve is installed
on the right inner side of front frame. When the
B: Outlet port parking brake switch is turned “ON”, the sole-
B1: Port for parking brake pilot lamp switch noid valve is energized. This sends the brake
P: Inlet port oil to the parking brake spring cylinder and sets
T: Drain port the parking brake to TRAVEL position. When
the parking brake is turned “OFF”, the solenoid
valve id de-energized, and the brake oil pres-
sure is removed from the parking brake spring
cylinder to set the machine to the PARKING
condition.
q Parking brake solenoid valve
Energized : TRAVEL
De-energized: PARKED
WA800-3E0, WA900-3E0 27
Brake cooling system (if equipped) 1

Brake cooling piping
1. Brake cooling pump (Front) (SBL(1)24) 7. Cooling fan motor

2. Brake cooling pump (Rear) (SBR(1)24) 8. Oil cooler (Front)
3. Brake cooling oil temperature caution switch 9. Oil cooler (Rear)
(Rear) 10. Rear axle
4. Brake cooling oil temperature caution switch 11. Front axle
(Front) 12. Relief valve
5. Oil filter (Front) 13. Magnet box (Rear)
6. Oil filter (Rear) 14. Magnet box (Front)
28 WA800-3E0, WA900-3E0
A. Front axle oil inlet (From oil cooler) F. Oil cooler (Front) oil outlet (To front axle)
B. Front axle oil outlet (To pump) G. Oil cooler (Rear) oil inlet (From oil filter)
C. Rear axle oil inlet (From oil cooler) H. Oil cooler (Rear) oil outlet (To rear axle)
D. Rear axle oil outlet (To pump) J. Oil filter inlet (From pump)
E. Oil cooler (Front) oil inlet (From oil filter) K. Oil filter outlet (To oil cooler)
WA800-3E0, WA900-3E0 29
Fan drive piping

WA800-3E0 Serial No.: 70001 - 70021
WA900-3E0 Serial No.: 60001 - 60030
30 WA800-3E0, WA900-3E0
1. Flow priority valve

2. Flow divider
3. PPC pump
4. Fan drive motor
5. Shaft
6. Fan
WA800-3E0, WA900-3E0 31
WA800-3E0 Serial No.: 70022 and up

32 WA800-3E0, WA900-3E0
1. Flow priority valve

2. Flow divider
3. PPC pump
4. Fan drive motor
5. Shaft
6. Fan
WA800-3E0, WA900-3E0 33
Hydraulic circuit diagram of brake cooling system

WA800-3E0 Serial No.: 70001 - 70021
WA900-3E0 Serial No.: 60001 - 60030
34 WA800-3E0, WA900-3E0

WA800-3E0, WA900-3E0 35
1. Torque converter charging pump (x 2) + PPC OUTLINE

pump + brake pump q The oil from the PPC pump is divided by flow
2. Flow divider divider (2) for the PPC circuit and cooling fan
3. Flow priority valve drive circuit. Then, it flows through flow priority
4. Fan drive motor valve (3) to fan drive motor (4) and drives the
5. Hydraulic tank fan to cool the brake cooling oil (axle oil).
6. Hydraulic oil filter q The front and rear brake cooling oil circuits are
7. Brake cooling pump (Front) independent from each other.
8. Brake cooling pump (Rear) q The oil discharged by brake cooling pumps (7)
9. Oil filter (Front) and (8) is sent through oil filters (9) and (10) to
10. Oil filter (Rear) oil coolers (11) and (12), where it is cooled.
11. Oil cooler (Front) Then, it flows to axles (15) and (16) to cool the
12. Oil cooler (Rear) brakes.
13. Relief valve (Front) After cooling the brakes, the oil is sucked in the
14. Relief valve (Rear) pumps again and circulated in the brake cool-
15. Front axle ing circuits.
16. Rear axle q Brake cooling oil temperature caution switches
17. Magnet box (Front) (19) and (20) are installed to the front and rear
18. Magnet box (Rear) brake cooling circuits. They flash the caution
19. Brake cooling oil temperature caution switch lamp when the oil temperature rises to about
(Front) 105°C.
20. Brake cooling oil temperature caution switch
(Rear)
36 WA800-3E0, WA900-3E0
Electric circuit diagram of brake cooling system
WA800-3E0, WA900-3E0 37
Brake cooling system (55°C specification) (If equipped) 1

WA900-3E0 Serial No.: 60001 - 60030
38 WA800-3E0, WA900-3E0
1. Additional hydraulic oil cooler A. To additional hydraulic oil cooler (From main
2. Additional torque converter oil cooler control valve)
3. Flow priority valve B. Hydraulic oil inlet
4. Flow divider C. Hydraulic oil outlet
5. PPC pump D. To hydraulic tank (From additional hydraulic oil
6. Orifice plate cooler)
7. Fan drive motor E. Torque converter oil outlet (To additional torque
8. Shaft converter oil cooler)
9. Fan F. Torque converter oil inlet
10. Orifice plate G. Torque converter oil outlet
WA800-3E0, WA900-3E0 39

40 WA800-3E0, WA900-3E0
1. Additional hydraulic oil cooler A. To additional hydraulic oil cooler (From main
2. Additional torque converter oil cooler control valve)
3. Flow priority valve B. Hydraulic oil inlet
4. Flow divider C. Hydraulic oil outlet
5. PPC pump D. To hydraulic tank (From additional hydraulic oil
6. Orifice plate cooler)
7. Fan drive motor E. Torque converter oil outlet (To additional torque
8. Shaft converter oil cooler)
9. Fan F. Torque converter oil inlet
10. Orifice plate G. Torque converter oil outlet
WA800-3E0, WA900-3E0 41
Hydraulic circuit diagram of brake cooling system

WA900-3E0 Serial No.: 60001 - 60030
1. Torque converter charging (x 2) + PPC pump + 8. Hydraulic tank

brake pump 9. Hydraulic oil cooler
2. Flow divider 10. Torque converter
3. Flow priority valve 11. Orifice
4. Fan drive motor 12. Additional torque converter oil cooler
5. Orifice 13. Torque converter oil cooler
6. Additional hydraulic oil cooler 14. Transmission lubrication
7. Hydraulic oil filter 15. Transmission case
42 WA800-3E0, WA900-3E0
1. Torque converter charging (x 2) + PPC pump + 8. Hydraulic tank

brake pump 9. Hydraulic oil cooler
2. Flow divider 10. Torque converter
3. Flow priority valve 11. Orifice
4. Fan drive motor 12. Additional torque converter oil cooler
5. Orifice 13. Torque converter oil cooler
6. Additional hydraulic oil cooler 14. Transmission lubrication
7. Hydraulic oil filter 15. Transmission case
WA800-3E0, WA900-3E0 43
Outline
q The oil from the PPC pump is divided by flow
divider (2) for the PPC circuit and cooling fan
drive circuit. Then, it flows through flow priority
valve (3) to fan drive motor (4) and drives the
cooling fan to cool the hydraulic oil and torque
converter oil.
q The oil returning from the main control valve
flows into additional hydraulic oil cooler (6),
where it is cooled, and then it returns to
hydraulic tank (8).
q The oil from the torque converter outlet port
flows through additional torque converter oil
cooler (12), where it is cooled. It is further
cooled in torque converter oil cooler (water-
cooled) (13), and then it lubricates the trans-
mission and returns to the transmission case.
a For the flow divider and flow priority valve, see

BRAKE COOLING SYSTEM.
44 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 45
SEN02354-01

© 2011 KOMATSU
All Rights Reserved
46
SEN02355-00
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Undercarriage and frame
Axle mount ...................................................................................................................................................... 2
Center hinge pin.............................................................................................................................................. 5
Tire and wheel................................................................................................................................................. 7
Jack up point................................................................................................................................................... 8
WA800-3E0, WA900-3E0 1
Axle mount 1
2 WA800-3E0, WA900-3E0
1. Front frame Front axle

2. Rear frame q Front axle (4) receives the force directly during
3. Rear axle operations, so it is fixed directly to front frame
4. Front axle (1) by axle mounting bolts.
5. ROPS support
Rear axle
q Rear axle (3) has a structure which allows the
center of the rear axle to float, so that all tires
can be in contact with the ground when travel-
ing over soft ground.
WA800-3E0, WA900-3E0 3
Unit: mm
Clearance of shaft and hole size clearance limit
Shaft Hole
6 (Front support side)
(Before press-fit bushing) +4.800 +0.155 –4.80 –
470.2 —
+0.800 +0.155 –0.645
Clearance of shaft and hole
–0.068 +1.021 0.323 –
7 (Front support side) 460 1.6
–0.165 +0.255 1.186
(After press-fit bushing)
+4.800 +0.155 –4.80 –
8 (Rear support side) 470.2 —
+0.800 +0.155 –0.645
(Before press-fit bushing) Replace
–0.068 +1.021 0.323 –
9 (Rear support side) 460 1.6
–0.165 +0.255 1.186
(After press-fit bushing)
Standerd clearance Clearance limit
10 Thickness of thrust washer
8 ±0.2
–0.21
11 Thickness of thrust plate 37
–0.35
12 Thickness of rear bushing 5 ±0.1
13 Thickness of front bushing 5 ±0.1
4 WA800-3E0, WA900-3E0
Center hinge pin 1
1. Front frame Outline

2. Rear frame q The front frame and rear frame are joined by
3. Rear axle center hinge pin through a bearing. The steer-
4. Front axle ing cylinders adjust the angle of curvature to
5. Upper hinge pin the left and right of the front and rear frame (in
6. Lower hinge pin other words, they adjust the turning radius).
WA800-3E0, WA900-3E0 5
Unit: mm
Clearance between lower hinge size Shaft Hole clearance limit
7
pin and bushing –0.043 +0.070 0.043 –
146.05 —
–0.068 +0.070 0.138
Clearance between lower hinge –0.043 +0.063 0.043 –
8 146.05 1.0
pin and spacer (small) –0.068 +0.063 0.131
9 146.05 —
pin and bearing –0.068 +0.070 0.093
10 146.05 1.0
pin and spacer (large) –0.068 +0.070 0.131
11 206.0 —
spacer (large) and bushing –0.122 +0.077 0.199
Clearance between front frame +0.025 –0.067 –0.138 –
12 234.95 —
and upper hinge bearing +0.025 –0.113 –0.067
Clearance between upper hinge –0.043 +0.063 0.043 –
13 127 —
pin and rear frame –0.068 +0.063 0.131
Clearance between upper hinge –0.043 +0.025 0.043 –
14 127 —
pin and bearing –0.068 +0.063 0.093
Replace
Clearance between front frame +0.025 –0.078 –0.155 –
15 304.8 —
and lower hinge bearing +0.025 –0.130 –0.078
Clearance between rear frame –0.043 +0.063 0.043 –
16 170 —
and bushing –0.068 +0.063 0.131
Clearance at press-fitted part of +0.310 +0.063 –0.310 –
17 146.05 —
seal of upper hinge pin +0.210 +0.063 –0.147
Clearance at press-fitted part of +0.260 +0.072 –0.260 –
18 210 —
seal of lower hinge pin +0.160 +0.072 –0.088
Clearance between lower hinge +0.186 +0.063 –0.186 –
19 161.0 —
bushing and frame (upper) +0.146 +0.063 –0.083
Clearance between lower hinge +0.242 +0.072 –0.242 –
20 226 —
bushing and frame (lower) +0.196 +0.063 –0.124
Height of lower hinge spacer Standard size Tolerance Repair limit
21
(small) 73 ±0.1 —
Height of lower hinge spacer
22 155.5 ±0.1 —
(large)
Thickness for lower hinge and
23 32 ±0.8 —
retainer
Shim thickness for lower hinge
24 1.93
and retainer
Shim thickness for lower hinge
25 2.20 Adjust
and retainer
Shim thickness for upper hinge
26 2.31
and retainer
6 WA800-3E0, WA900-3E0
Tire and wheel 1
1. Tire Outline
2. Rim q The tires act to absorb the shock that the
3. Valve machine receives the road surface, and at the
4. Lock ring same time, provide drive force by rotating in
5. Side ring contact with the ground.
q Depending on the purpose of use, there are
various type of tire available, so it is important
to select the correct tire to match the type of
work and bucket capacity.
Specifications
Tire type: 45/65-45-58PR
TRA code: L5
Normal wheel: 36.00 × 45 WTB
Normal inflation pressure: 667 kPa {6.8 kg/cm2}
WA800-3E0, WA900-3E0 7
Jack up point 1
1. Front frame (Lift arm cylinder installed under part, right)

2. Front frame (Lift arm cylinder installed under part, left)
3. Rear part of rear frame (The space during battery box and fuel tank, right)
4. Rear part of rear frame (The space during battery box and fuel tank, left)
Outline
q When jacking up the machine for replacement of a tire, etc, set the jack under the front frame (under the
lift arm cylinder mounting port).
q The jack up point is not indicated in Operation and Maintenance Manual since it is dangerous to jack up
the machine unnecessarily.
8 WA800-3E0, WA900-3E0
SEN02355-00

© 2006 KOMATSU
All Rights Reserved
10
SEN02356-00
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Hydraulic system, Part 1
Hydraulic piping .............................................................................................................................................. 2
Work equipment lever linkage......................................................................................................................... 3
Hydraulic tank ................................................................................................................................................. 4
Torque conbverter charging, PPC and brake pump........................................................................................ 8
WA800-3E0, WA900-3E0 1
Hydraulic piping 1
1. Hydraulic tank 7. Main control valve

2. Shuttle valve 8. Lift cylinder
3. Hydraulic oil cooler 9. Switch pump
4. Accumulator 10. Main piston pump
5. PPC valve 11. Steering pump
6. Bucket cylinder
2 WA800-3E0, WA900-3E0
Work equipment lever linkage 1
1. Kick-down switch 5. Lock lever

2. Lift arm lever 6. Solenoid valve for bucket lever
3. Hold switch 7. Solenoid valve for lift arm lever
4. Bucket lever 8. PPC valve
WA800-3E0, WA900-3E0 3
Hydraulic tank 1
1. Filter bypass valve Outline

2. Hydraulic filter q The oil from the hydraulic tank is sent from the
3. Strainer pump through the control valve to the cylin-
4. Drain valve ders. In the return circuit, the oil from various
5. Strainer parts merges. A part of oil is cooled in the oil
6. Breather cooler, passes through hydraulic filter (2) and
7. Oil filter returns to the tank.
q Hydraulic filter (2) filters all the oil in the circuit.
A. Oil cooler return port If hydraulic filter (2) becomes clogged, bypass
B. Main return port valve (1) acts to allow the oil to return directly
C. Gear pump suction to the tank. This prevents damage to filter (2).
D. Main piston pump suction port Bypass valve (1) is also actuated when nega-
E. Emergency pump suction tive pressure is generated in the circuit.
F. Emergency pump return port
4 WA800-3E0, WA900-3E0
Operation of oil filter bypass valve

q When the filter is clogged q When negative pressure is formed in the
Bypass valve (1) opens and the oil returns return circuit
directly to the tank without passing through the Valve (2) moves up and acts a check valve.
filter. Check valve set pressure:
Bypass valve set pressure: 0.0255 MPa {0.26 kg/cm2}
0.125 MPa {1.27 kg/cm2}
WA800-3E0, WA900-3E0 5
Breather
1. Body
2. Filter element
3. Poppet
4. Sleeve
Function
q Preventing negative pressure inside the
tank
The tank is pressurized, sealed type, so nega-
tive pressure is formed inside the hydraulic
tank when the oil level drops during operations.
When this happens, the difference in pressure
between the tank and outside atmospheric
pressure opens poppet (3), and air from the
outside is led into the tank to prevent negative
pressure.
q Preventing rise in pressure inside the tank

When the hydraulic cylinders are being used,
the oil level in the hydraulic circuit changes and
the temperature rises. If the hydraulic pressure
rises above the set pressure, sleeve (4) is
actuated to release the hydraulic pressure
inside the tank.
6 WA800-3E0, WA900-3E0
Torque conbverter charging, PPC and brake pump 1
8 WA800-3E0, WA900-3E0
Unit: mm
No. Check Item Criteria Remedy

Model Standard clearance Clearance limit
SAR4-112 0.11 – 0.16 0.19
Clearance between gear case
1 SAR3-100 0.13 – 0.18 0.22
and side plate, gear
SAR1-32 0.10 – 0.15 0.19
SAR1-14 0.10 – 0.15 0.19
SAR4-112 0.06 – 0.140 0.20
Clearance between inside SAR3-100 0.06 – 0.149 0.20
2 diameter of plain bearing and Replace
outside diameter of gear shaft SAR1-32 0.06 – 0.119 0.20
SAR1-14 0.06 – 0.149 0.20
–0
SAR4-112 21–0.5
–0
SAR3-100 14–0.5
3 Insertion depth of pin
–0
SAR1-32 10–0.5
–0
SAR1-14 10–0.5
4 Rotating torque of spline shaft 20.6 – 36.3 Nm {2.1 – 3.7 kgm} —
Revolution Discharge
Model discharge discharge
(rpm) pressure
(l/min) (l/min)
2.9 MPa
SAR4-112 2200 242 222
{30 kg/cm2}
Discharge
2.9 MPa
— Oil: EO10-CD SAR3-100 2200 210 183 —
{30 kg/cm2}
Temperature: 45 – 55°C
2.9 MPa
SAR1-32 2200 68 57
{30 kg/cm2}
9.8 MPa
SAR1-14 2200 {100 kg/ 29 24
cm2}
WA800-3E0, WA900-3E0 9
SEN02356-00

© 2006 KOMATSU
All Rights Reserved
10
SEN02471-00
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Hydraulic system, Part 2
Main control valve ........................................................................................................................................... 2
Accumulator (For PPC valve) ....................................................................................................................... 17
Main piston pump.......................................................................................................................................... 18
Main piston pump cut-off solenoid valve ....................................................................................................... 29
PPC valve ..................................................................................................................................................... 30
PPC relief valve ............................................................................................................................................ 35
Switch pump ................................................................................................................................................. 36
Control pump ................................................................................................................................................ 45
WA800, WA900-3E0 1
Main control valve 1
1. Main relief valve PA1 : From PA1 of PPC valve

2. Lift arm spool PA2 : From PB2 of PPC valve
3. Bucket spool PB1 : From PB1 of PPC valve
4. Body PB2 : From PA2 of PPC valve
5. Suction valve A1 : To bucket cylinder bottom side
6. Unloader valve A2 : To lift arm cylinder bottom side
7. Float selector valve B1 : To bucket cylinder rod side
8. Safety-suction valve B2 : To lift arm cylinder rod side
P : Pump port
P1 : From PA2 of PPC valve
P2 : From PB2 of PPC valve
T : Drain port (to hydraulic tank)
2 WA800, WA900-3E0
Outline
q The two main control valves control the actua- q There are two safety valves (with suction
tion of the lift arm and the bucket in the hydrau- valves) (8) to protect the circuit if abnormal
lic system. It has a tandem circuit which gives pressure is generated in the bucket circuit. If
priority to the bucket circuit. one of the two safety valves is acting as a relief
q The oil from the pump enters port (P). The valve, the other valve acts as a suction valve to
maximum pressure is set by main relief valve make up any lack of oil.
(1). The oil passes through the bypass circuit
of bucket spool (3) and lift arm spool (2). It then
flows from port (T) to the drain circuit, passes
through the filter and returns to the tank. If the
bucket and lift arm spools are actuated, the oil
flows to the bucket and lift arm cylinders.
However, the circuit gives priority to the
bucket, so when the bucket spool is being
operated, even if the lift arm spool is operated,
the lift arm will not move.
WA800, WA900-3E0 3
Unit: mm
Free length ×
Installed Installation Installation
Outside Free length
9 Spool return spring length load load
diameter
431N 345N
69.9 × 57 63 —
{44 kg} {35.2 kg}
608N 486N
10 Spool return spring 77 × 39 71.5 —
{62 kg} {49.6 kg} If damaged or
217N 173N deformed,
11 Spool return spring 79.7 × 38 75.5 —
{22.1 kg} {17.7 kg} replace
18.8N 15.1N spring.
12 Check valve spring 78.2 × 26.6 52 —
{1.92 kg} {1.51 kg}
6.9N 5.49N
13 Suction valve spring 27.9 × 13 18 —
{0.7 kg} {0.56 kg}
162N 129N
14 Float selector valve spring 53.0 × 11.2 40.1 —
{16.5 kg} {13.2 kg}
49N 39.2N
15 Unload valve spring 82.7 × 18.6 47 —
{5.0 kg} {4.0 kg}
4 WA800, WA900-3E0
Relief valve Operation

q Ports (A) and (B) are connected to the pump
circuit and drain circuit respectively. The oil
pressure in port (A) is applied through the hole
of piston (3) to port (C).
q When the oil pressure is below the set relief
pressure, poppet (4) is in contact with the seat
of plug (6) and the oil does not flow from cham-
ber (C) into the drain circuit. Accordingly, the
oil pressure in port (A) is equal to that in cham-
ber (C).
q Since d2 < d3, main valve (2) is in contact with
the left side. The sectional areas are set in the
following order; d5 > d4 > d1 > d3 > d2.
1. Main valve
2. Piston
3. Piston spring
4. Poppet
5. Poppet spring
6. Plug with valve seat
7. Sleeve
8. Adjustment screw
9. Locknut
10. Orifice
WA800-3E0
Cracking pressure: 27.5 MPa {280 kg/cm2}
Relief pressure: 31.4 MPa {320 kg/cm2} q If the pump pressure is raised by spring (5) to
WA900-3E0 the relief pressure poppet (4) opens and the oil
Cracking pressure: 30.4 MPa {310 kg/cm2} in chamber (C) is drained through chamber
Relief pressure: 34.3 MPa {350 kg/cm2} (D).
q If poppet (4) opens, the oil flows from (A)
through (C) to (D).
Function
q The relief valve is installed at the inlet of the
work equipment valve. When the oil pressure
rises above the specified level, this valve
drains the oil into the hydraulic tank to limit the
maximum pressure of the work equipment cir-
cuit and protect the circuit.
WA800, WA900-3E0 5
q As the oil flows from (A) to (C) [hole through Safety-suction valve
piston (2)], its pressure lowers. As a result, the
pressure in chamber (C) is lower than that in 1 2 3 4 5 6
port (A), thus main valve (1) moves to the right.
q Then, the oil flows from port (A) to port (B) and
limits the maximum pressure to protect the cir-
cuit.
SEW00166
1. Suction valve
2. Main valve
3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body
Function
q The safety valve (with suction valve) is in the
bucket cylinder circuit in the main valve. If
shock causes any abnormally high pressure in
the cylinder when the main valve is at neutral,
the safety valve (with suction valve) releases
the abnormal pressure and protects the cylin-
der from damage.
q This valve prevents generation of negative
pressure in the circuit.
6 WA800, WA900-3E0
Operation As a suction valve

As a safety valve q If negative pressure is generated in port (A),
q Port (A) is the cylinder circuit and port (B) is the port (D) also has negative pressure, because
drain circuit. ports (D) and (A) are connected with each
The pressure oil in port (A) flows to port (D) other. The tank pressure in port (B) is applied
through a hole in pilot piston (4). It also flows to to port (E).
port (C) through an orifice consisting of the Hydraulic pressure (a) equivalent to the area
main valve and pilot piston (4). difference between (d2) and (d1) is applied to
Pilot piston (4) is secured to the suction valve the safety valve because of the tank pressure
by locknut. The diameter of the cross section in port (E). Therefore, hydraulic pressure (e)
(cross sectional area) gives a relationship of acts to open the valve and hydraulic pressure
d2 > d1 > d3 > d4. (a) acts to close suction valve (1).
q If the pressure in port (A) drops, (approaching
negative pressure) hydraulic pressure (a)
A B C 2 4 D becomes smaller than oil pressure (e).
q When oil pressure (e) becomes larger than oil
pressure (a) + valve spring (5) force, suction
valve (1) opens, causing the oil to flow from
port (B) into port (A). This prevents negative
pressure from building up in port (A).
d1 d3 d4 d2
SEW00167
q If abnormally high oil pressure occurs in port

(A), suction valve (1) is not actuated because
of the relationship d2 > d1.
However, because of the relationship d3 > d4
in ports (A) and (C), the hydraulic pressure on
main valve (2) is equivalent to the area differ-
ence between d3 and d4. If this pressure goes
up to the main valve spring force (set pres-
sure), main valve (2) is actuated, and the oil in
port (A) flows into port (B).
A B 1 2 3 D
SEW00168
WA800, WA900-3E0 7
Suction valve
1 2 3
SEW00170
1. Main poppet
2. Sleeve
3. Spring
Operation
q If negative pressure is generated in port (A) (lift
arm cylinder rod end) (if the pressure is lower
than in port (B) in the tank circuit), main poppet
(1) opens because oil then flows from port (B)
at the tank end to port (A) at the cylinder port
end.
8 WA800, WA900-3E0
Float selector valve and unload valve 2. FLOAT position

Function When the lift arm control lever is pushed for-
q The float selector valve (2) and the unloader ward from the LOWER position, it enters the
valve (3) are inside the main control valve. FLOAT position.
When the lift arm control lever is moved to the Lift arm spool (1) of the main control valve is in
float position, the float selector valve (2) the same condition as at the LOWER position.
detects this. When it is actuated, it actuates the The hydraulic pressure at port (A) is higher
unloader valve (3) and sets the lift arm in the than at the LOWER position, so float selector
FLOAT position. valve (2) moves in the direction of the right-
ward. The back pressure of unloader valve (3)
Operation is drained, so unloader valve (3) opens to give
1. LOWER position the FLOAT condition.
This shows the condition with the lift arm con-
trol lever in the LOWER position.
WA800, WA900-3E0 9
3. FLOAT position (pushed up) 4. FLOAT position (lowering under own weight)
If the machine moves in reverse and the lift When the machine is moving in reverse and
arm is pushed up, the pressure at the cylinder the lift arm comes down under its own weight,
rod end becomes high. It passes through port the pressure at the cylinder bottom end is high,
(B) and is drained through unloader valve (3). and it is drained from port (C).
A vacuum is formed at the cylinder bottom end, A vacuum is formed at the cylinder rod end, so
so oil flows in from port (C). oil flows in from port (B).
10 WA800, WA900-3E0
Operation of hydraulic circuit

Lift arm and bucket spools in "HOLD"
Operation
q The oil enters port (A) from the steering valve, q The oil from the PPC pump passes through
and the maximum pressure is set by relief check valve (13), and enters port L of the PPC
valve (11). valve. However, the lift arm and bucket levers
q Bucket spool (1) is at the HOLD position, so are at the HOLD position, so the oil returns to
the bypass circuit is open and the oil at port (A) the hydraulic tank from PPC relief valve (12).
passes around the spool and flows to port (B).
Lift arm spool (2) is also at HOLD, so the
bypass circuit is open and the oil at port (B)
passes around the spool, enters port (C) of the
drain circuit, passes through the filter in the
hydraulic tank, and returns to the tank.
WA800, WA900-3E0 11
Lift arm spool in "RAISE"
Operation
q When lift arm lever (3) is pulled, the oil flows q At the same time, the oil at the cylinder rod end
from port (L) of the PPC valve to port (N) and enters drain port (C) from port (K) and returns
port (T). In addition, the oil at port (S) passes to the tank. Therefore, the lift arm rises.
through port (M) and flows to the drain circuit.
The oil pressure at port (T) pushes lift arm
spool (2) and moves it to the RAISE position.
q The oil from the steering valve passes through
the bypass circuit of the bucket spool (1) and
flows to the bypass circuit of lift arm spool (2).
The bypass circuit is closed by the spool, so
the oil pushes open check valve (10). The oil
flows from port (H) to port (I), and flows to the
cylinder bottom.
12 WA800, WA900-3E0
Lift arm spool in "LOWER"
Operation
q When lift arm lever (3) is pushed, the oil flows q At the same time, the oil at the cylinder bottom
from port (L) of the PPC valve to port (M) and enters drain port (C) from port (I) and returns to
port (S). In addition, the oil at port (T) flows to the tank. Therefore, the lift arm goes down.
the drain circuit.
The oil pressure at port (S) pushes lift arm
spool (2) and moves it to the LOWER position.
q The oil from the steering valve passes through
the bypass circuit of the bucket spool (1) and
flows to the bypass circuit of lift arm spool (2).
The bypass circuit is closed by the spool, so
the oil pushes open check valve (10). The oil
flows from port (J) to port (K), and flows to the
cylinder rod end.
WA800, WA900-3E0 13
Lift arm spool in "FLOAT"
Operation
q When lift arm lever (3) is pushed to the FLOAT q If a difference in pressure greater than the
position, the PPC valve spool moves beyond specified pressure is generated at port (W) and
the LOWER position to the FLOAT position. port (X), valve (7) moves to the right, opens
The pressure oil at port (L) flows to port (M), port (C1) and port (C), and connects to the
and at the same time, it also flows to port (S) drain circuit. When port (C1) is connected to
and port (W). In addition, the pressurized oil at the drain circuit, unload valve (8) moves up
port (T) flows to port (N). and the oil from the pump flows to the drain cir-
q The pressurized oil at port (S) pushes lift arm cuit.
spool (2) to the LOWER position. q Therefore, the oil at the cylinder rod end
passes from port (K) through unload valve (8)
and flows to the drain circuit. The oil at the cyl-
inder bottom flows from port (I) to port (C), and
then flows to the drain circuit. Therefore, the lift
arm is set to the FLOAT condition.
14 WA800, WA900-3E0
Bucket spool in "DUMP"
Operation
q When bucket lever (4) is pushed, the pressure
oil at port (L) of the PPC valve flows from port
(Q) to port (V). In addition, the oil at port (R)
flows to the drain circuit. The pressure oil at
port (V) moves bucket spool (1) to the DUMP
position.
q The bypass circuit is closed by bucket spool
(1), so the oil from port (A) pushes open check
valve (10). The oil from check valve (10) flows
from port (F) to port (G), and then flows to the
cylinder rod end.
q At the same time, the oil at the cylinder bottom
flows from port (D) to drain port (C), and
returns to the tank, so the bucket is dumped.
WA800, WA900-3E0 15
Bucket spool in "TILT BACK"
Operation
q When bucket lever (4) is pulled, the pressure
oil at port (L) of the PPC valve flows from port
(P) to port (R). In addition, the oil at port (V)
flows to the drain circuit. The pressure oil at
port (R) moves bucket spool (1) to the TILT
position.
q The bypass circuit is closed by bucket spool
(1), so the oil from port (A) pushes open check
valve (10). The oil from check valve (10) flows
from port (E) to port (D), and then flows to the
cylinder bottom.
q At the same time, the oil at the cylinder rod end
flows from port (G) to drain port (C), and
returns to the tank, so the bucket is tilted.
16 WA800, WA900-3E0
Accumulator (For PPC valve) 1

Operation
q After the engine stops, when the PPC valve is
at NEUTRAL, chamber (A) (volume of nitrogen
gas: 3000 cc) inside the bladder is com-
pressed by chamber (B).
q When the PPC valve is operated, the pressure
in chamber (B) drops below 2.9 MPa {30 kg/
cm 2} and the pressure of the nitrogen gas in
chamber (A) makes the bladder expand. The
actuating pressure is 1.2 to 2.9 MPa {12 to 30
kg/cm2}.
1. Cap
2. Nut
3. Body
4. Bladder
5. Oil port
6. Nut
Specifications
Type of gas: Nitrogen gas
Gas amount: 3,000 cc
Max. actuation pressure:2.9 MPa {30 kg/cm2}
Min. actuation pressure: 1.2 MPa {12 kg/cm2}
Function
q The accumulator is installed between the
hydraulic pump and PPC valve. An inflatable
bladder is filled with nitrogen gas, and the com-
pressibility is used to store the pressure of the
oil. As a result, the lift arm and bucket can be
lowered under their own weight even after the
engine has been stopped.
WA800, WA900-3E0 17
Main piston pump 1

Type: HPV95+95
1. ES valve (Engine sensing) Outline

2. Front servo valve q These pump assemblies consist of two vari-
3. Rear servo valve able displacement swash-plate type pumps,
4. Front main pump two servo valve units, and impeller pump (built
5. Rear main pump in between the front main pump and the rear
6. Control pump (BAR025) main pump), a control pump and a relief valve.
7. Relief valve
8. Pump sub-assembly
9. Front servo valve assembly
10. Rear servo valve assembly
11. Impeller pump
18 WA800, WA900-3E0
Piston pump
Specification
1. Shaft (front) 9. Impeller
Model : HPV95 + 95
2. Cradle (front) 10. Cradle (rear)
Rated discharge pressure: 34.3 MPa {350 kg/cm2}
3. Case (front) 11. Shaft (rear) Rated rpm : 2100 rpm
4. Rocker cam 12. Case (rear) Theoretical delivery : front 97.4 cm3/rev
5. Shoe 13. End cap (rear) rear 97.4 cm3/rev
Max. delivery : 204.5 + 204.5 l/min
6. Piston 14. End cap (front)
7. Cylinder block 15. Servo piston
8. Valve plate
WA800, WA900-3E0 19
20 WA800, WA900-3E0
Function
q The engine rotation and torque transmitted to
the pump shaft is converted into hydraulic
energy, and pressurized oil is discharged
according to the load.
q It is possible to change the delivery amount by
changing the swash plate angle.
Structure
q Cylinder block (7) is supported to shaft (1) by a q Cylinder block (7) seals the pressure oil to
spline, and shaft (1) is supported by the front valve plate (8) and carries out relative rotation.
and rear bearings. This surface is designed so that the oil pres-
q The tip of piston (6) is spherical, and shoe (5) sure balance is maintained at a suitable level.
is caulked to it to form one unit. Piston (6) and The oil inside each cylinder chamber of cylin-
shoe (5) form a spherical bearing. der block (7) is sucked in and discharged
q Rocker cam (4) has plane surface (A), and through valve plate (8).
shoe (5) is always pressed against this surface q Impeller (9) is connected to shaft (1) through
while sliding in a circular movement. Rocker the spline boss (10) and rotates together with
cam (4) brings high pressure oil at cylindrical the shaft. The oil sucked in through the suction
surface (B) with cradle (2), which is secured to port is sent to the cylinder chamber by centrifu-
the case, and forms a static pressure bearing gal force to make suction easier.
when it slides.
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
WA800, WA900-3E0 21
Operation 2) If center line (X) of rocker cam (4) is in line

1. Operation of pump with the axial direction of cylinder block (7)
q Cylinder block (7) rotates together with shaft (swash plate angle = 0), the difference
(1), and shoe (5) slides on flat surface (A). between volumes (E’) and (F’) inside cylin-
When this happens, rocker cam (4) moves der block (7) becomes 0, so the pump
along cylindrical surface (B), so angle (a) does not carry out any suction or dis-
between center line (X) of rocker cam (4) and charge of oil.
th e axia l d ir ection of cylinde r bloc k ( 7)
changes. (Angle (a) is called the swash plate
angle.)
2. Control of discharge amount

If swash plate angle (a) becomes larger, the
difference in volumes (E) and (F) becomes
1) Center line (X) of rocker cam (4) maintains larger and the discharge volume increases.
swash plate angle (a) in relation to the Swash plate angle (a) is changed by servo pis-
axial direction of cylinder block (7), and ton (15). Servo piston (15) moves in a recipro-
flat surface (A) moves as a cam in relation cal movement ( ) in accordance with the
to shoe (5). In this way, piston (6) slides on command from the servo valve. This straight
the inside of cylinder block (7), so a differ- line movement is transmitted through the rod
ence between volumes (E) and (F) is cre- of rocker cam (4) to rocker cam (4), and rocker
ated inside cylinder block (7). The suction cam (4), which is supported by the cylindrical
and discharge is equal to this difference surface to cradle (10), slides in an oscillating
(E) – (F). movement in direction ( ) along the cylindri-
In other words, when cylinder block (7) cal surface.
rotates and the volume of chamber (E)
becomes smaller, the oil is discharged
during that stroke. On the other hand, the
volume of chamber (F) becomes larger,
and as the volume becomes bigger, the oil
is sucked in.
22 WA800, WA900-3E0
Relief valve q If the pressure in chamber (B) reaches the pilot

valve spring force (set pressure), the pilot
valve moves, allowing the oil in chamber (B) to
flow into chamber (C). In addition, the oil flows
from chambers (A) to (B) through orifices.
1. Adjustment screw
2. Locknut
3. Pilot valve spring
4. Pilot valve
5. Main valve spring q If the oil flows through the orifice of valve (6), a
6. Main valve differential pressure occurs between the cham-
bers (A) and (B), moving valve (6) to the left.
Set pressure: 2.9 MPa {30 kg/cm2} This allows the oil in chamber (A) to flow into
(at 50 l/min) chamber (C).
Function
The relief valve is built in the body of control pump.
It relieves the oil delivered from the pump.
Flow of the oil

q Chamber (A) forms a pump circuit and cham-
ber (C) forms a tank drain circuit. The oil flows
into chamber (B) through the main relief valve
orifice to keep the chamber filled.
Pilot valve is set in the valve seat.
WA800, WA900-3E0 23
ES valve (Engine Sensing valve)
1. Plug Function
2. Valve body q This valve acts to control the delivery amount
3. Shaft of the hydraulic pump to match the changes in
4. Plug the engine speed.
5. Plug
6. Spool
7. Spool
8. Plug
9. Plug
24 WA800, WA900-3E0
Function When the pilot pressure difference is below

q A variable displacement piston pump is used point (a)
for the hydraulic pump to save energy by
reducing the consumption of hydraulic pres-
sure when the engine is running at low speed.
At the same time, it is also used to increase the
engine acceleration from low speed.
For this reason, a pressure difference valve is
used to detect the engine speed by using a
pressure difference system. The delivery
(delivery per rotation) is then adjusted to match
the engine speed.
When the pilot pressure difference is above

point (b)
Operation
q Oil from the PPC pump passes through pres-
sure difference valve (1) and is sent to the PPC
valve. Pilot pressure from the inlet and outlet
ports (ports (A) and (B)) of the pressure differ-
ential valve is supplied to the ES valve (2).
The difference in pilot pressure becomes
larger as the flow from the PPC pump
increases (in other words, as the engine speed
increases).
When the pilot pressure difference reaches
point (a) (0.12 MPa {1.24 kg/cm 2 }), the ES
valve starts to operate, and actuates the servo
valve and servo cylinder to change the swash
plate angle of the pump.
When the swash plate angle is changed, the
piston stroke also changes to change the deliv-
ery of the pump (delivery per rotation).
Until the difference in pilot pressure reaches
0.31 MPa {3.2 kg/cm 2 }, the pump delivery
(delivery per rotation) increases in proportion
with the increase in the difference in pilot pres-
sure (in other words, the increase in the engine
speed).
When the difference in pressure reaches 0.31
MPa {3.2 kg/cm2}, the pump delivery (delivery
per rotation) reaches the maximum.
WA800, WA900-3E0 25
Servo valve
1. Sleeve
2. Body
3. Spool
4. Arm
5. Plug
6. Sleeve
7. Spool
8. Plug
26 WA800, WA900-3E0
Operation
1. Increasing of delivery amount (swash plate angle changes to the right)
q Input signal pressure (Pi) acts on chamber (E) q With the movement of guide spool (12), port
in the control piston from port (D). Pressure (B) and port (A) connect to each other, allowing
(Pc) in the charging pump is guided into port oil pressure (Pc), in the control pump to act on
(B). chamber (F) in servo piston (11). Servo piston
q If input signal pressure (Pi) is raised a little, the (11) is then pushed rightward, increasing the
oil pressure acting on chamber (E) will swash plate angle of the main piston pump.
increase accordingly. Control piston (9) there- Thus, the pump discharge is increased.
fore moves to a position (rightward) where the q Since arm (4) turns counterclockwise on pin
force of spring (10) is in balance with the oil (13), guide spool (12) moves leftward, causing
pressure in chamber (E), thus allowing arm (4) port (B), port (C) and drain port (A) to close.
to swing rightward with servo piston (11) serv- The pump discharge, therefore, increases with
ing as the supporting point. As a result, guide the change in input signal pressure (Pi).
spool (12) moves to the right.
WA800, WA900-3E0 27
2. Decreasing of delivery amount (swash plate angle changes to the left)
q Next, let’s examine the case where servo pis- q Since arm (4) rotates clockwise on pin (13),
ton (11) is moved leftward. Assume that the guide spool (12) moves rightward, shutting off
servo piston is in a balanced position at a cer- port (B), port (C) and port (A). The pump dis-
tain location. If (Pi) is decreased, control piston charge, therefore, decreases with the change
(9) moves to a position where the oil pressure in input signal pressure (Pi).
in chamber (E) balances with the force of
spring (10). Then, arm (4) swings leftward,
using servo piston (11) as a support point, and
cause, guide spool (12) to move leftward.
q With the movement of guide spool (12), port
(B) and port (A) are shut off and port (A)
becomes open to the drain.
On the other hand, port (B) and port (C) are
connected to each other, allowing the oil to
flow into chamber (H) in the servo cylinder.
Servo piston (11) is then pushed leftward by
the force of spring (14), decreasing the swash
plate angle of the main piston pump. Thus, the
pump discharge is decreased.
28 WA800, WA900-3E0
Main piston pump cut-off solenoid valve 1
1. Solenoid valve A. A port (To main piston pump)

2. Spool P. P port (From Differential pressure regulating valve)
3. Body T. T port (From Differential pressure regulating valve)
4. Spring
Outline
Solenoid valve is installed between the differential
pressure regulating valve and main piston pump,
and change the main piston pump delivery by work
condition.
Operation
If solenoid valve (1) is operated by the current from
the active power maximizing circuit, spool (2) in the
valve moves to connect ports (P) and (A) and close
port (T).
As a result, the pressure of the high-pressure oil
flowing in the work equipment pump ES valve is
reduced and the delivery of the work equipment
pump is minimized.
WA800, WA900-3E0 29
PPC valve 1
30 WA800, WA900-3E0
WA800, WA900-3E0 31
P : From pump
T : To tank (drain)
P1 : To lift arm cylinder (RAISE)
P2 : To bucket cylinder (DUMP)
P3 : To lift arm cylinder (LOWER)
P4 : To bucket cylinder (TILT)
1. Bolt
2. Piston
3. Plate
4. Collar
5. Retainer
6. Valve
7. Body
Unit: mm
Free length ×
Installed Installation Installation
Outside Free length
8 Centering spring length load load
diameter
5.39 N 4.31 N If damaged or
39.9 × 12.2 34.5 —
{0.55 kg} {0.44 kg} deformed,
19.6 N 15.7 N replace
9 Centering spring 56.5 × 12.2 36 — spring.
{2 kg} {1.6 kg}
33.3 N 26.7 N
10 Metering spring 33.5 × 7.4 29.4 —
{3.4 kg} {2.72 kg}
14.7 N 11.8 N
11 Spool return spring 27.1 × 11.5 17.5 —
{1.5 kg} {1.2 kg}
32 WA800, WA900-3E0
Operation Therefore, spring (9) is compressed in propor-

1. Control lever at “neutral” (Fig. 1): tion to the travel of the control lever, so the
Ports (PA1), (P2), (PB1) and (P4) are con- pressure at port (P2) also rises in proportion to
nected to drain chamber (D) through fine con- the travel of the control lever. The spool of the
trol hole (f) in spool (10). control valve moves to a position where the
pressure of port (PA1) (same as pressure at
port (P2)) and the force of the return spring of
the control valve are balanced.
(Fig. 1)
2. Control lever operated slightly (fine con-

trol) (Fig. 2): (Fig. 2)
When piston (4) starts to be pushed by plate
(2), retainer (7) is pushed. Valve (10) is also
pushed by spring (9) and moves down.
When this happens, fine control hole (f) is shut
off from drain chamber (D). At almost the same
time it is connected to pump pressure chamber
(PP), and the pilot pressure of the control valve
is sent through fine control hole (f) to port (P2)
and (PA1). When the pressure at port (P2)
rises, valve (10) is pushed back. Fine control
hole (f) is shut off from pump pressure cham-
ber (PP). At almost the same time it is con-
nected to drain chamber (D), so the pressure
at port (P2) escapes to drain chamber (D).
Valve (10) moves up and down until the force

of spring (9) is balanced with the pressure of
port (P2).
The position of valve (10) and body (11) (when
fine control hole (f) is midway between drain
chamber (D) and pump pressure chamber
(PP)) does not change until the head of valve
(10) contacts the bottom of piston (4).
WA800, WA900-3E0 33
3. Control lever moved back from slightly 4. Control lever operated to end of travel
operated position to neutral (Fine control) (Fig. 4):
(Fig. 3): Plate (2) pushes piston (4) down, and piston
When plate (2) starts to be pushed back, pis- (4) forcibly pushes in valve (10).
ton (4) is pushed up by a force corresponding Fine control hole (f) is shut off from drain
to the force of centering spring (8) and the chamber (D), and is connected to pump pres-
pressure at port (P2). sure chamber (PP).
At the same time, fine control hole (f) of valve Therefore, pressure oil from the charging
(10) is connected to drain chamber (D), so the pump passes through fine control hole (f), and
oil at port (P2) escapes. flows from port (P2) to chamber (PA1) to push
If the pressure at port (P2) drops too far, valve the spool of the control valve.
(10) is pushed down by spring (9). Fine control The oil returning from chamber (A2) flows from
hole (f) is shut off from drain chamber (D), and port (PB1) through fine control hole (f’) to drain
at almost the same time it is connected to chamber (D).
pump pressure chamber (PP). The pump pres-
sure is supplied until the pressure at port (P2)
returns to a pressure equivalent to the position
of the lever.
When the spool of the control valve returns,
the oil in drain chamber (D) flows in from fine
control hole (f’) of the valve which has not
moved. The extra oil then flows through port
(P4) to chamber (PB1).
(Fig. 4)
(Fig. 3)
34 WA800, WA900-3E0
PPC relief valve 1 q If the pressure at ports (A) and (B) reach the
pressure set by the poppet spring, pilot poppet
(3) opens and the pressure oil at port (B) flows
through port (D) to port (C). As a result, the
pressure at port (B) drops.
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring q If the pressure at port (B) drops, a pressure dif-
5. Adjustment screw ference is generated between ports (A) and (B)
due to the orifice in main valve (1). Main valve
Set pressure: 2.9 MPa {30 kg/cm2} (1) is pushed open by the pressure at ports
(A), and the oil at port (A) is relieved.
Function
q The PPC relief valve is between the PPC
pump and the PPC valve. When the PPC valve
is not being actuated, or when abnormal pres-
sure is generated, the oil sent from the pump is
relieved through this valve to protect the pump
and circuit from damage. (Sets maximum pres-
sure in the circuit).
Operation
q Port (A) is connected to the pump circuit, and
port (C) is connected to the drain circuit. The
oil passes through the orifice of main valve (1)
and fills port (B). Pilot poppet (3) is in close
contact with valve seat (2).
WA800, WA900-3E0 35
Switch pump 1
Type: HPV95 + 95
Outline Specification
q This pump consists of 2 variable-displacement Switch pump
swash plate-type piston pumps, 1 impeller
Type HPV95 + 95
pump (installed between the front pump and
rear pump), and 1 control pump. For explana- Rated discharge pressure 34.3 MPa {350 kg/cm2}
tion of the operations of the switch pump, con- Rated rpm 2120 rpm
trol pump, relief valve, ES valve, and servo
Theoretical delivery (front) 97.4 cm3/rev
valve, see the section of the work equipment
pump. Theoretical delivery (rear) 97.4 cm3/rev
Max. delivery 206.5 + 206.5 l/min
36 WA800, WA900-3E0
1. Front servo valve

2. ES valve
3. CO valve, NC valve
4. Rear servo valve
5. Relief valve
6. Control pump
7. Rear pump
8. Front pump
9. Pump sub-assembly
10. Front servo valve assembly
11. Rear servo valve assembly
12. Impeller pump
WA800, WA900-3E0 37
Piston pump
1. Shaft (front) 9. Impeller

2. Cradle (front) 10. Cradle (rear)
3. Case (front) 11. Shaft (rear)
4. Swash plate 12. Case (rear)
5. Shoe 13. End cap (rear)
6. Piston 14. End cap (front)
7. Cylinder block 15. Servo piston
8. Valve plate
38 WA800, WA900-3E0
WA800, WA900-3E0 39
CO + NC valve
40 WA800, WA900-3E0
PD: Jet sensor downstream IN port

PT: Jet sensor upstream IN port
P1: Pump pressure IN port
PE: TVC valve output pressure F-R intercon-
nection port
PDR: CO + NC valve drain OUT port
PECN: CO + NC valve output pressure OUT port
CO valve
1. Plug
2. Piston
3. Spring
4. Spool
5. Piston
6. Plug
NC valve
7. Plug
8. Sleeve
9. Piston
10. Spool
11. Spring
12. Plug
WA800, WA900-3E0 41
CO valve
1) When the switch pump discharge pressure is
less than the relief pressure
Function Operation
q During operation, CO valve carries out the cut- q Spool (1) is pushed downward to the stroke
off function; when the load is increased, switch end by spring (2). As a result, port (a) and port
pump discharge pressure is increased and (b) are fully opened, and control pump output
approaches to the relief pressure, pump deliv- pressure (PSV) equals to CO valve output
ery is decreased and relief loss is reduced. pressure (Pec). Therefore the CO valve output
q The CO valve is controlled by the balance pressure (Pec) becomes maximum and the
between switch pump discharge pressure switch pump delivery becomes maximum.
(PA2) + CO valve output pressure (Pec) and
the spring force.
42 WA800, WA900-3E0
2) When the switch pump discharge pressure

approaches to the relief pressure
q When the load is increased and switch pump

discharge pressure (PA2) approaches to the
relief pressure, switch pump discharge pres-
sure (PA2) pushes piston (3). At the same
time, CO valve output pressure (Pec) pushes
piston (3), and spool (1) moves upward. As a
result, because the flow from port (a) to port (b)
is throttled, the opening area of port (b) and
port (c) (drain port) are increased. This causes
CO valve output pressure (Pec) to lower, and
the pump delivery is minimized.
WA800, WA900-3E0 43
NC valve
Operation
q Function of NC valve is canceled.
q Because (Pt) and (Pd) are always intercon-
nected by a hose, opening area of port (c) and
port (b) become maximum (always opened).
Therefore, NC valve output pressure (Pecn)
always equals to CO valve output pressure
(Pec).
44 WA800, WA900-3E0
Control pump 1
Type: BAR025
1. Collar Specification
2. Body
Type : BAR 25
3. Housing
4. Drive gear Theoretical delivery : 25 cm3/rev.
5. Driven gear Max. discharge pressure : 2.9 MPa {30 kg/cm2}
WA800, WA900-3E0 45
Unit: mm

1 Top clearance of gear
0.090 – 0.130 0.145
2 Side clearance of gear 0.055 – 0.075 0.105 Replace
Clearance between gear shaft
3 0.045 – 0.076 0.13
and bushing
Pump Revolution
Discharge Pressure discharge discharge
model (rpm)
– Oil: EO10-CD (l/min) (l/min) –
Temperature: 45 – 55°C 2.9 MPa
BAR25 3,200 72 68
{30 kg/cm2}
Tightening torque for housing
– 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm} Tighten
case mounting bolt
46 WA800, WA900-3E0
SEN02471-00

© 2006 KOMATSU
All Rights Reserved
48
SEN02357-00
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Work equipment
Work equipment linkage ................................................................................................................................. 2
Bucket positioner and lift arm kick-out ............................................................................................................ 6
Remote lift arm positioner ............................................................................................................................... 8
Auto greasing system ..................................................................................................................................... 9
Hydraulic cylinder.......................................................................................................................................... 10
WA800-3E0, WA900-3E0 1
Work equipment linkage 1
1. Bucket
2. Bellcrank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
7. Bucket hinge pin
8. Bucket hinge pin
9. Bellcrank pin
10. Cord ring
2 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 3
4 WA800-3E0, WA900-3E0
Unit: mm
Clearance between pin and size clearance limit
Shaft Hole
1 bushing at joint of lift arm and
frame –0.050 +0.435 0.370 –
200 1.0
–0.122 +0.320 0.557
Clearance between pin and
–0.043 +0.395 0.339 –
2 bushing at joint of bucket 180 1.0
–0.106 +0.295 0.501
cylinder bottom and bellcrank
–0.043 +0.395 0.339 –
3 bushing at joint of lift cylinder 180 1.0
–0.106 +0.295 0.501
rod and lift arm
–0.043 +0.395 0.339 –
4 bushing at joint of lift cylinder 180 1.0
–0.106 +0.295 0.501 Replace
bottom and frame
–0.050 +0.435 0.370 –
5 bushing at joint of bellcrank and 200 1.0
–0.122 +0.320 0.557
lift arm
–0.043 +0.434 0.390 –
6 bushing at joint of bucket link 180 1.0
–0.106 +0.347 0.540
and bellcrank
–0.043 +0.434 0.390 –
7 bushing at joint of bucket and 180 1.0
–0.106 +0.347 0.540
bucket link
–0.043 +0.434 0.390 –
8 bushing at joint of lift arm and 180 1.0
–0.106 +0.347 0.540
bucket
Width between Standard clearance
Widh of hinge
9 Joint of lift arm and frame bosses (Clearance a+b)
214 ± 0.8 210 ± 2.9 0.3 – 7.7
Joint of bucket cylinder and
10 213 ± 0.8 210 +0.8
+0.8 2.2 – 4.0
frame
11 Joint of lift arm and lift cylinder 213 ± 1.5 210 +0.8
+0.8 0.7 – 4.5 Insert shims on
both sides.
12 Joint of lift cylinder and frame 214 ± 0.8 210 +0.8
+0.8 2.4 – 4.8 Clearance on
Joint of bucket cylinder and both left and
13 213 +0.1
+0.8 210 +0.8
+0.8 1.4 – 3.8 right sides less
bellcrank
than 1.5mm
14 Joint of bellcrank and lift arm 358 ± 0.5 355 ± 0.5 2.0 – 4.0
Joint of bellcrank and bucket
15 213 +0.1
+0.8 250 +1
–3 2.0 – 5.0
link
16 Joint of bucket link and bucket 259 +1.5
+0.8 250 ± 3 2.0 – 5.0
17 Joint of lift arm and bucket 259 +1.5
+0.8 254 ± 4.9 0.1 – 11.4
WA800-3E0, WA900-3E0 5
Bucket positioner and lift arm kick-out 1
Unit: mm
Clearance of bucket position
1 3–5
switch
Clearance of lift arm position
2 3–5 Adjust
detect switch
Clearance of lift arm kick-out
3 3–5
sensor
6 WA800-3E0, WA900-3E0
Bucket positioner Lift arm kick-out

q The bucket positioner is an electrically actu- q The lift arm kick-out is electrically operated and
ated system which is used to set the bucket to acts to stop the lift arm. When the lift arm
the desired angle when the bucket is moved reaches the desired position before the maxi-
from the DUMP position to the TILT position. mum height, the lift arm is returned to neutral.
When the bucket reaches the desired position, q Plate (4) is secured to the lift arm. A proximity
the bucket lever is returned from the TILT posi- switch (3) is fixed to the frame. When the lift
tion to the HOLD position, and the bucket is arm is moved from the LOWER position to the
automatically set to the suitable angle. RAISE position, the lift arm rises. When it
q Bar (2) is secured to bucket cylinder rod (5) by reaches the desired position, the proximity
bolts. In addition, proximity switch (1) is fixed to switch (3) and plate (4) come into contact and
the cylinder by bolts. the lift arm lever is returned to neutral.
q When the bucket is moved from the DUMP
position to TILT position, the bucket cylinder
rod (5) moves to the left, and at the same time,
bar (2) also moves to the left. Bar (2) separates
from proximity switch (1) at the desired posi-
tion, and the bucket lever is returned to neutral.
WA800-3E0, WA900-3E0 7
Remote lift arm positioner 1
Unit: mm
Clearance of bucket position
1 3–5
switch
Adjust
Clearance of lift arm position
2 3–5
detect sensor
8 WA800-3E0, WA900-3E0
Auto greasing system 1
Outline
q When set the starting switch to START posi-
tion, the auto greasing system starts automati-
cally. Greasing is set by the timer of greasing
interval and greasing is done by specified
operating time of pump.
Greasing interval: 11.25 minutes

Operating time of pump: 60 seconds
WA800-3E0, WA900-3E0 9
Hydraulic cylinder 1
Unit: mm

Name of Standard Tolerance Standard Clearance
cylinder size Shaft Hole clearance limit
Clearance between piston rod –0.043 +0.216 0.091 –
1 Bucket 180 0.622
and bushing –0.106 +0.048 0.322
–0.043 +0.228 0.091 –
Lift arm 160 0.634
–0.106 +0.048 0.334
–0.043 +0.395 0.338 – Replace
Bucket 180 1.0 bushing
Clearance between piston rod –0.106 +0.295 0.501
2
pin and bushing –0.043 +0.395 0.338 –
Lift arm 180 1.0
–0.106 +0.295 0.501
–0.043 +0.395 0.338 –
Clearance between cylinder Bucket 180 1.0
–0.106 +0.295 0.501
3 bottom mounting pin and bush-
ing –0.043 +0.395 0.338 –
Lift arm 180 1.0
–0.106 +0.295 0.501
Steering Standard size Tolerance Repair limit
+0.2
Bucket 300 –
4 Cylinder bore 0 Replace
+0.2
Lift arm 260 –
0
10 WA800-3E0, WA900-3E0

© 2006 KOMATSU
All Rights Reserved
12 WA800-3E0, WA900-3E0
SEN02358-00
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Cab and its attachments
ROPS cab ....................................................................................................................................................... 2
Air conditioner ................................................................................................................................................. 3
WA800-3E0, WA900-3E0 1
ROPS cab 1
1. Door
2. Front glass
3. Front wiper
4. ROPS
5. Antenna
6. Rear wiper
2 WA800-3E0, WA900-3E0
Air conditioner 1
Air conditioner piping
1. Refrigerant piping (to air conditioner unit)

2. Refrigerant piping (from air conditioner unit)
3. Air conditioner unit
4. Condenser
5. Receiver dryer
6. Hot water take-out port
7. Hot water return port
8. Compressor
WA800-3E0, WA900-3E0 3
Condenser
1. Electric wiring
2. Fan
3. Refrigerant gas inlet port
4. Refrigerant gas outlet port
Compressor
1. Refrigerant gas inlet port Specifications

2. Refrigerant gas outlet port Type: Piston pump
3. Suction side charge port Used refrigerant: R134a
4. Clutch
5. Relief valve
4 WA800-3E0, WA900-3E0
Dry receiver
1. Body
2. Dryer
WA800-3E0, WA900-3E0 5
SEN02358-00

© 2006 KOMATSU
All Rights Reserved
6
SEN02359-00
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Electrical system, Part 1
Machine monitor system ................................................................................................................................. 2
Main monitor ................................................................................................................................................... 4
Maintenance monitor ...................................................................................................................................... 8
WA800-3E0, WA900-3E0 1
Machine monitor system 1
2 WA800-3E0, WA900-3E0
Outline
q The machine monitor system uses the sensors
and other devices installed to various parts of
the machine to observe the condition of the
machine. It processes this information swiftly
and displays it on the monitor panel to inform
the operator of the condition of the machine.
q The machine monitor system consists of the
main monitor, maintenance monitor, sensors,
switches, relays, alarm buzzer, and power
source.
q The displays can be broadly divided into the
following: Cautions displayed on the monitors
(abnormalities in the machine where an alarm
is given) and normal conditions which are
always displayed on the instrument panel (pilot
lamps and readings for the gauges, speedom-
eter, and service meter).
q There are also various switches built into the
monitor panel which function to operate the
machine.
a The main monitor uses the network wiring to

send signals to the controller, and functions to
display the following information.
1) Shift indicator: 1st – 3rd, N, F, R.
2) HOLD (if equipped)
3) Failure action code, failure code, time
elapsed since failure (failure data display
mode)
WA800-3E0, WA900-3E0 3
Main monitor 1
4 WA800-3E0, WA900-3E0
Machine monitor display function

Display
Display item Display range Display method
category
Display flashes (for details, see
When there is abnormality dis-
Check Check Maintenance monitor display
play on maintenance monitor
function)
Emergency steering actuated
(when equipped with emergency When actuated Display flashes
steering)
Parking brake actuated, trans- Display flashes and buzzer
Caution
mission not at neutral sounds
Caution Display flashes (buzzer may also
When there is abnormality dis-
sound) (for details, see Mainte-
play on maintenance monitor
nance monitor display function)
Turn signal (left, right) When operated Display lights up
Display lights up
Buzzer sounds when parking
Parking brake When operated
brake is applied and shift lever is
not at N
Emergency steering normal
When normal (oil is flowing in
(when equipped with emergency Display lights up
hydraulic circuit)
steering)
Pilot
Lights up
Lighting up time changes
according to engine coolant tem-
Preheating When preheating
perature when starting switch is
turned ON (for details, see Pre-
heating circuit)
Shift hold (Machine equipped
When shift is held Display lights up
with auto shift)
Digital display (display switches
Speed-
Travel speed 0 – 99 km/h between tachometer and speed-
ometer
ometer)
Shift
Shift indicator 1–3N Digital display
indicator
When controller detects failure
Digital display
Failure and action by operator is
Buzzer sounds (For details of the
action Failure action code needed, CALL is displayed, or
travel data display mode, see
code CALL and E TT (action code)
Trouble data display mode)
are displayed in turn
Shift F, R, display (when equipped
F, R Digital display
indicator with joystick steering)
WA800-3E0, WA900-3E0 5
Machine monitor switch function

Item Function Display Actuation
Lights up (goes out Auto-greasing control actuated
momentarily when (automatic greasing carried out at
switch is turned ON) fixed internal)
Forced greasing is carried out
Auto-greasing while switch is being pressed when Flashes (slowly) Grease empty
display is lighted up Abnormality in auto-greasing con-
Flashes (rapidly)
troller system
Goes out Auto-greasing controller not installed
Low idle speed set to approx. 850
Engine low idle speed is changed Lights up
Engine low rpm
between two stages each time
idle Low idle speed set to approx. 650
switch is pressed Goes out
rpm
Front working lamp lights up or Lights up Front working lamp lights up
Working lamp goes out each time switch is
(front) pressed when side lamps are
lighted up Goes out Front working lamp goes out
Rear working lamp lights up or Lights up Rear working lamp lights up

Working lamp goes out each time switch is
(rear) pressed when side lamps are
lighted up Goes out Rear working lamp goes out
Transmission cut-off function is Lights up Cut-off function actuated

Transmission
actuated or stopped each time
cut-off
switch is pressed Goes out Cut-off function stopped
Auto shift mode switches to man- Lights up Manual mode

Manual
ual mode when switch is pressed Goes out Auto shift mode
6 WA800-3E0, WA900-3E0
Trouble data display mode

Item Switch operation Actuation
All switch displays (LEDs) go out, and failure
code is displayed on speedometer display
and time elapsed since failure is displayed
on failure action code display.
(1)Failure code is a two-digit display given in
numbers or letters. The display for the
With engine stopped and starting switch
failure now occurring flashes and the dis-
turned ON, press 2nd switch from top on left
Method of switching to play for past failures lights up. If there is
side of main monitor (switch below emer-
trouble data display no failure, CC is displayed (000 is dis-
gency steering display) and working lamp
mode played for time elapsed since failure)
(front) switch simultaneously for at least 5
(2)The time elapsed since failure is dis-
seconds.
played as a three-digit number to show
how long ago the failure occurred (the
oldest failure time is displayed. Any time
greater than 999H is displayed as 999H).
(3)A maximum of 9 items are stored in
memory for the failure code.
Method of sending Failure code and time elapsed since failure
Press working lamp (front) switch
failure code change to next item.
Failure code and time elapsed since failure
Press working lamp (rear) switch for at least being displayed are cleared. Failure code
Clearing failure code
2 seconds for problem now occurring (flashing display)
cannot be cleared.
Press 2nd switch from top on left side of
main monitor (switch below emergency
Resetting from travel
steering display) and working lamp (front) Changes to normal display
data display mode
switch simultaneously for at least 5 sec-
onds, or start the engine.
WA800-3E0, WA900-3E0 7
Maintenance monitor 1
1. Check items (Checks before starting) 3. Gauge items

1A. Engine coolant level 3A. Fuel level
1B. Engine oil level 3B. Engine coolant temperature
2. Caution items (warning items) 3C. Torque converter oil temperature
2A. Engine oil pressure 4. Service meter
2B. Brake oil pressure 4A. Service meter numeric display
2C. Battery charge 4B. Service meter RUN pilot lamp
2D. Air cleaner (L.H.) 5. Monitor module
2E. Air cleaner (R.H.) 6. Switch module
2F. Transmission oil filter
Outline
q The maintenance monitor has a display func-
tion for the caution items and gauges.
q The maintenance monitor consists of the moni-
tor module, switch module, service meter,
case, and other mechanisms.
q The monitor module has a built-in CPU (Cen-
tral Processing Unit). It processes the signal
from the sensors, and carries out the display
and output.
q A liquid crystal display and LEDs are used for
the display portions. The switches are
embossed sheet switches.
8 WA800-3E0, WA900-3E0
Maintenance monitor display function

Display
Display item Display range Display method
category
Engine coolant level Below low level Displays when engine is stopped and starting
switch is ON
Display when normal: OFF
Engine oil level Below low level Display when abnormal: Flashes
Check CHECK lamp flashes
Displays when engine is running
Above specified differential
Transmission oil filter Display when normal: OFF
pressure
Display when abnormal: Flashes
Engine coolant level Below low level Displays when engine is running
Engine oil pressure Below specified pressure Display when normal: OFF
Brake oil pressure Below specified pressure CAUTION lamp flashes
Buzzer sounds
Engine coolant temperature Above 102°C Buzzer sounds if above 105°C
Torque converter oil tem-
Above 120°C Buzzer sounds if above 130°C
perature
Caution
Displays when engine is running
Fuel level Below low level
CAUTION lamp flashes
Battery charge When charge is defective Displays when engine is running
Above specified negative Display when abnormal: Flashes
Air cleaner
pressure CAUTION lamp flashes
Actuated when charge is normal
Service Service meter 0 – 9999.9h
Advances 1 for every hour
meter
Service meter indicator Lights up when service meter is running
All lamps light up below applicable level
Fuel level Display by 7 segments
Flashes when level is 1
One place lights up to show applicable level
Gauges Engine coolant temperature Display by 7 segments
Flashes when level is 6 or 7
Torque converter oil tem- One place lights up to show applicable level
Display by 7 segments
perature Flashes when level is 6 or 7
WA800-3E0, WA900-3E0 9
10 WA800-3E0, WA900-3E0
Outline of engine service monitor system 1. Item displayed always

Display of “KOMATSU”
Outline
q Each controller on the network monitors and
controls the machine condition with the sen-
sors etc. installed to various parts of the
machine.
The engine service monitor system transmits
the information from the controllers as network
information to the monitor, and then the engine
service monitor displays that information to
notify the operator and service person of the
machine information.
When an error occurs, the engine service mon-
itor notifies it to the main monitor, which turns
the alarm ON, and lights/blinks the engine
warning lamp to notify the operator of the error.
2. Item displayed when error occurs
q The engine service monitor itself, engine con- Action code (If the machine monitor mode
troller, VHMS controller (only when it is set to selector switch (>) is pressed while an action
ADD in the option select mode) and pre-lubri- code is displayed, failure code (6-digit) is dis-
cation controller (only when it is set to ADD in played)
the option select mode) are applicable to the
operation that the engine service monitor noti- 3. And so on
fies an error to the main monitor or lights/blinks The engine service monitor has the service
the engine warning lamp and records the error. mode function for the ease of troubleshooting
(Note) Not all the controllers are applicable to for the controllers (including the engine service
the above operation. For example, the monitor itself) on the network. The main items
transmission controller sends informa- of this function are as follows.
tion to the main monitor directly. 1) SERVICE METER screen
The service meter of the engine service
q The engine service monitor system is installed monitor is for recording of failures and
under the lunch box tray on the right rear in the integrates the operating hours indepen-
operator's cab. You can access it by removing dently from the service meter for the oper-
the lunch box. ator (mechanical service meter).
Accordingly, the value of the service meter
q The engine service monitor displays the ordi- for the operator may become different
nary screen (“KOMATSU” is displayed) or the from that of the service meter of the
service mode. engine service monitor after years. The
service meter of the engine service moni-
q The screen displayed in the ordinary state tor is used as an auxiliary one for record-
(other than the service mode) is the ordinary i n g o f f a i l u r e s , h o w e v e r, a n d t h e
screen. The main displayed items are as fol- mechanical service meter for the operator
lows. is the main one.
2) ELECTRIC FAULT screen
Occurrence of electrical failures of each
controller to be saved in the engine ser-
vice monitor is displayed. This information
can be deleted.
3) MACHINE FAULT screen
Occurrence of mechanical failures of each
controller to be saved in the machine
monitor is displayed.
4) REAL-TIME MONITOR screen
Output values and calculated values rec-
ognized by each controller on the network
are displayed in real time.
WA800-3E0, WA900-3E0 11
5) CYLINDER CUT-OUT screen Engine service monitor

This function is used to specify a cylinder q The engine service monitor is installed under
which has combustion trouble by cutting the lunch box in the cab and normally out of
off the fuel for the fuel injector of each cyl- the operator's sight.
inder in order. q When the engine controller, engine service
6) NO INJECTION screen monitor itself or pre-lubrication controller (if
This function is used to lubricate the inside equipped) has an error, the engine service
of the engine without injecting fuel when monitor notifies the operator of that error.
starting the engine after a long downtime. When any error occurs, the engine service
7) OPERATION INFO screen monitor lights the external engine warning
Fuel consumption per operating hour is lamp (yellow) to notify the error.
displayed. When an error equivalent to E03 (E02) occurs,
8) MANUAL SNAP SHOT screen the engine service monitor notifies the main
Directions to take in snap shot data is monitor of that error by diagnosis signals to
given to the VHMS. turn the error alarm ON, in addition the above.
9) OPTIONAL SELECT screen (The main monitor turns the caution lamp and
This function is used to select the informa- alarm buzzer ON.)
tion of the controllers to be used and the [Front view]
options.
10) INITIALIZE screen
This function is used to set the engine ser-
vice monitor when the machine is deliv-
ered.
[Rear view]
12 WA800-3E0, WA900-3E0
Displayed item list

Brightness
Input circuit
control Operation in Condition for display or
LED color
Item Symbol self-check specification of
(When lighted) Direct input of
Installed: q (when key is ON) operation
signal or CAN
Not installed: —
Character display for ser-
Upper line: vice person (Not installed
KOMATSU is Since input cir- in operator's sight)
LCD displayed at center. cuit depends on
Character Letter: Black each displayed Display unit to display
— —
display Background: Back light is turned item, see specifi- error codes of engine
Green ON for 2 seconds cations of each controller, engine service
and OFF for item. monitor and pre-lubrica-
1 second. tion controller and ser-
vice functions
Lights up when error sig-
nal is output (Installed in
operator's sight sepa-
rately from main unit)
(When this lamp blinks,
error should be assumed
to be E03 or equivalent,
even if main monitor does
not turn caution lamp and
CAN (Engine alarm buzzer ON)
Engine
2 seconds: ON controller and
warning LED Yellow —
1 second: OFF pre-lubrication Reason: This lamp lights
lamp
controller) when error that main
monitor turns caution
lamp and alarm buzzer
ON occurs. When cau-
tion lamp and alarm
buzzer have trouble and
do not operate, this lamp
blinks to prevent operator
from continuing normal
operation.
WA800-3E0, WA900-3E0 13
Engine service monitor character display function
The engine service monitor system is installed under the lunch box tray on the right side in the operator's
cab. You can access it by removing the lunch box.
Using the character display function, you can use the service function.
(*1) Once you pass on the ID input screen, you can directly move to the function selection screen without
displaying this screen until the starting switch is turned OFF.
14 WA800-3E0, WA900-3E0
Self-check function
Self-check
The self-check function operates 3 seconds after
the key is turned ON.
After the key ON, it automatically starts and ends
the self-check function operation.
After 3 seconds, you are brought to the ordinary
screen automatically.
In self-check mode, the mode switch is disabled.
Normal screen (1st layer)

After the self-check, the following screen is auto-
matically displayed.
a This display is written in English, regardless of

setting of language.
WA800-3E0, WA900-3E0 15
Failure code display screen (1st layer)
q Pressing the > switch while the alarm screen is

displayed changes to the failure code display
screen.
q Pressing the > switch again displays the
“KOMATSU” display screen (ordinary screen)
for 10 seconds, and automatically returns to
the alarm screen.
q If you do not perform any switch input for 30
seconds with the failure code display screen
displayed or a new error occurs, you are
returned to the alarm screen.
q When multiple errors occur, every pressing of
the > switch displays items in descending
order of priority. Items of the same priority is
displayed in reverse chronological order of
occurrence.
q Example of failure code display screen (When

1380MW, DW73KZ, BQJANS occur simulta-
neously))
The upper column displays failure code (6-digits) so
that the ECM CODE and space are sandwiched.
The lower column displays the message 2.
For information on the failure code (6-digits), ECM

CODE, and message 2, see the failure code list.
In 10 seconds, you are automatically brought to the

alarm screen.
16 WA800-3E0, WA900-3E0
Engine service monitor outline service mode 1) How to input ID

1] Press the < or > switch. Then, the
The engine service monitor has the service mode value at the cursor position increases
function for the ease of troubleshooting for the con- or decreases at the cursor position.
trollers (including the engine service monitor itself) Select a desired value using the U
on the network. When setting options, etc., use the switch.
service mode of the engine service monitor, too. 2] Completing operations equivalent to 4
digits (1) brings you to the ELECTRIC
1. How to set engine service monitor in service FAULT screen.
mode a If you input an incorrect value,
Turn the starting switch of the machine ON and press t switch to return the cur-
then turn the engine service monitor ON. sor to the highest-order digit, and
While the character display of the engine ser- re-enter values from there.
vice monitor is displaying the ordinary service a If you press the t switch while
meter screen or the alarm screen, hold down the cursor is at the highest-order
engine service monitor mode selector switch 1 digit, the normal service meter
( t ) and mode selector switch 2 (<) simulta- screen or alarm screen is
neously for 5 seconds, and the screen returned.
changes to the service ID input screen. a If any switch operation is done at
least 60 seconds during the ID
input, the normal service meter
screen or alarm screen is
returned.
ID to enter the service mode is

“6491”.
Remarks: If the starting switch is

turned OFF in the service mode, the
normal service meter screen or alarm
screen is returned at the next starting
switch ON.
WA800-3E0, WA900-3E0 17
2. Service mode menu
For the operation after selecting each menu, Outline

see the related menu item. (Select each menu The service meter of the engine service moni-
with the U switch.) tor is for recording of failures and integrates
(*1) If the VHMS is not set to “ADD” in the the operating hours independently from the
option select mode, the menus are not dis- service meter for the operator (mechanical ser-
played. vice meter).
a The service mode menu shows a different Accordingly, the value of the service meter for
screen by operating the < or >switch. Select a the operator may become different from that of
target operation menu screen with the switch. the service meter of the engine service monitor
a If you press the U switch when the following after years. The service meter of the engine
screen (selection screen) is displayed, the service monitor is used as an auxiliary one for
menu screen/operation screen of each func- recordin g of failures, however, and the
tion appears. mechanical service meter for the operator is
a If you press the t switch when the following the main one.
screen (selection screen) is displayed, the nor-
mal service meter screen or alarm screen is
returned at the next starting switch ON.
1) SERVICE METER screen
18 WA800-3E0, WA900-3E0
2) ELECTRIC FAULT screen 4) REAL-TIME MONITOR screen
[ ] field displays number of the failure his- Outline

tory currently recorded (up to 20 cases). This function is used to check the input and
output signals, etc. recognized by each con-
Outline troller on the network.
This function is used to check the electrical
system failure history of each controller saved 5) CYLINDER CUT-OUT screen
in the machine monitor. For the failure codes
displayed in the electrical system failure his-
tory, see “Troubleshooting”. After each failure
is repaired and the normal operation is con-
firmed, delete the failure history.
3) MACHINE FAULT screen
Outline
This function is used to stop fuel injection by
cylinder and specify the cylinder having defec-
tive combustion by shutting off fuel injected
from the fuel injector.
For the method of checking using this function,
see Testing and adjusting: “Operating engine
[ ] field displays number of the failure his- in reduced cylinder mode”.
tory currently recorded (up to 20 cases).
Outline
This function is used to check the mechanical
system failure history of each controller saved
in the machine monitor. For the failure codes
displayed in the mechanical system failure his-
tory, see “Troubleshooting”.
WA800-3E0, WA900-3E0 19
6) NO INJECTION screen 8) MANUAL SNAP SHOT screen
Outline Outline
This function is used when lubricating the The direction to take in the snap shot data is
engine with the engine stopped when restart- given to the VHMS.
ing it after a long time of non-operation. This function is used only when the VHMS is
For the starting method of engine using this installed.
function, see Testing and adjusting: “No injec- For inspection with this function, see Testing
tion cranking operation of engine”. and adjusting, “Inspection with VHMS”.
9) OPTIONAL SELECT screen

7) OPERATION INFO screen
Outline
Outline With this function, you can display installation
Fuel consumption per operating hours is dis- of an optional device and change the setting of
played. that device. Use this function after any optional
device is installed or removed. For the method
of setting and changing this function, see Test-
ing and adjusting: “Adjustment performed on
the monitor”.
20 WA800-3E0, WA900-3E0
10) INITIALIZE screen
Outline
This function is used only in the factory. Do not
use it.
WA800-3E0, WA900-3E0 21
Function of displaying electrical system failure history
1) Display of electrical system failure history and selection of clearing entirely the electrical system failure
history
The items are displayed in the sequential order by the latest occurrence time from the latest one.
The items which have not been reset are displayed before the items which have been reset.
Pressing the > switch scrolls the items from the newer ones to the older ones.
Pressing the < switch scrolls the items from the newer ones to the older ones.
After the oldest saved item, the “Electrical system failure history all clear selected” screen is displayed.
Pressing the t switch changes the screen to the “Electrical system failure history selected” screen.
Pressing the U switch changes the screen to the “Electrical system failure history individual cleared” screen
or the “Electrical system failure history all cleared” screen.
2) Selection of electrical system failure history (1st layer)

Pressing the < switch changes the screen to the “Select initialization” screen.
Pressing the > switch changes the screen to the “Select display of mechanical system failure history” screen.
Pressing the t switch changes the screen to the normal screen or alarm screen.
Pressing the U switch changes the screen to the “Display electrical system failure history” screen.
22 WA800-3E0, WA900-3E0
3) Display of electrical system failure history and the electrical system failure history all clear selected (2nd
layer)
Pressing the t switch changes the screen to the “Display electrical system failure history” screen.
Pressing the U switch changes the screen to the “Display electrical system failure history” screen.
q If there is only 1 history, the current screen does not change to the “Electrical system failure history all
clear” screen (Only the “Electrical system failure history individual clear” screen is displayed).
q If the number of the histories exceeds 20, they are deleted in order from the oldest one.
4) Electrical system failure history individual clear and Electrical system failure history all clear (3rd layer)
Select “YES” or “NO” with the < or > switch.
The cursor “_” blinks on the selected item. If “YES” is selected and the t switch is pressed, clearing is exe-
cuted. If “NO” is selected and the t switch is pressed, clearing is cancelled and the display changes as
shown below.
q If clearing is cancelled (NO), the current screen returns to the “Display electrical system failure history”
screen of the corresponding failure.
(Returns to the screen before the “Electrical system failure history individual clear” (Electrical system
failure history all clear) screen).)
q If clearing is executed (YES), the current screen returns to the “Display electrical system failure history”
screen of the corresponding next failure.
After all the failure histories are cleared, the current screen returns to the “Select electrical system fail-
ure history” screen.
By default, the cursor is on NO (cancel) to prevent resetting by an error.
You cannot delete a failure which has not been reset. At this time, the operation cancel peep (for 1 sec) is
heard.
If any failure history is cleared, the operation acceptance peeps (“ON” for 0.1 sec, “OFF” for 0.1 sec, “ON” for
0.1 sec) are heard.
When clearing of all the histories is selected, if there is any history to be cleared, clearing is assumed to be
completed.
WA800-3E0, WA900-3E0 23
Function of displaying mechanical system failure history
1) Display of mechanical system failure history

Pressing the t switch changes the screen to the “Mechanical system failure history selected” screen.
q The mechanical system fault histories cannot be deleted.
2) Selection of mechanical system failure history (1st layer)

Pressing the > switch changes the screen to the “Select real-time monitor” screen.
Pressing the < switch changes the screen to the “Select display of electrical system failure history” screen.
Pressing the t switch changes the screen to the normal screen or alarm screen.
Pressing the U switch changes the screen to the “Mechanical system failure history selected” screen.
24 WA800-3E0, WA900-3E0
3) Display of mechanical system failure history (2nd layer)

Pressing the > switch scrolls the items from the older ones to the newer ones.
Pressing the t switch changes the screen to the “Mechanical system failure history selected” screen.
WA800-3E0, WA900-3E0 25
Function of real-time monitor
The real-time monitor function displays the information saved in the controllers mounted on the machine in
real time.
This function is used for testing, adjusting, or troubleshooting the machine.
This function classifies the items and data by the controllers having them, and then displays the results. It
has 2 display modes of the normal display mode and the 2-item display mode for displaying 2 data simulta-
neously.
Operating procedure
1. Hold the t switch and < switch simultaneously for at least 5 seconds to change the screen to the ID
inputting screen.
2. Input the ID with the < and > switches, and then press the U switch to enter the screen for the service
mode.
3. Using the < and > switches, display “Real-time monitor selection” screen, and then press the U switch.
26 WA800-3E0, WA900-3E0
4. Press the U switch, and the “Monitor panel information display select screen”.
Pressing the “<” and “>” switches selects transmission controller information, engine controller informa-
tion, work equipment controller information and 2 item display function in order.
WA800-3E0, WA900-3E0 27
5. Press the U switch while each selection In display of 2 items mode, input the ID of nec-
screen is displayed, and then the “Display 1 essary information and press the U switch to
item” screen or “Select 2 items display infor- display 2 items simultaneously.
mation” screen appears. The ID displayed is the same as the ID number
displayed on the “Display 1 item” screen.
6. Items displayed on the “Display 1 item” screen

change in order by pressing < and > switches,
displaying information held by the controller.
Display of “------” means that the input value is

out of the display range.
***: item name

%%%%%: Data and unit (Unit: SI unit)
$$$$: ID number
Items displayed on the “Display 1 item” screen

change in order by pressing < and > switches,
displaying information held by the controller.
How to input ID
“00000” is displayed during screen transition.
Input a value between 0 and 9 at the cursor (_)
position.
First, the cursor appears at the highest-order
digit. Each time the > or < switch is pressed,
the digit changes by 1 between 0 and 9.
Select a desired digit and press the U switch.
The cursor moves to the 2nd position. Select
the digits for the all positions in the same man-
ner as the previous steps.
Input a value at the lowest-order digit and
press the U switch to move to the screen to
select the display of 2nd item.
If you press the t switch during the process-
ing, the screen returns to the “Select 2 items
display information” screen.
28 WA800-3E0, WA900-3E0
The state of the input and output signals of the controller can be checked with the real-time monitor
function of the monitor.
The items displayed by the real-time monitor and related to the engine service monitor and the contents
of display in the normal state are as follows.
No. Item ID No. Display of item Unit Contents of display data Display contents in normal operation Remarks
1 Part No. 20727 PART NUMBER --- 1234567 As per part No.
2 Serial No. 20402 SERIAL NUMBER --- 12345 As per serial No.
Monitor software
3 20200 VERSION --- As per software No.
No.
Application ver-
4 20221 VERSION (APP) --- 01000000 As per software version No.
sion No.
5 Data version No. 20222 VERSION (DATE) --- 00010001 As per data version No.
0.0 – 30.0
6 Charge level 04302 ALTERNATOR R V 0.0 – 30.0 V
---(Other than above)
10000000 (Starting motor C = ON) D-IN-0: Starting motor = C
01000000 (Headlamp = ON) D-IN-1: Headlamp
00000000 (Unused) D-IN-2: Unused
Input signal 00010000 (For service = ON) D-IN-3: For service
7 40291 D-IN--0------7 --- 01010101
D_IN_0-7 00001000 (For service = ON) D-IN-4: For service
00000100 (Feedback signal = ON) D-IN-5: Feedback signal
00000001 (Monitor mode switch (<) = ON) D-IN-7: Monitor mode switch (<)
10000000 (Monitor mode switch (<) = ON) D-IN-8: Monitor mode switch (<)
01000000 (Monitor mode switch (U) = ON) D-IN-9: Monitor mode switch (U)
00000000 (Monitor mode switch (t) = ON) D-IN-10: Monitor mode switch (t)
Input signal 00010000 (Unused) D-IN-11: Unused
8 40922 D-IN-8-10 --- 01000000
D_IN_8-10 00001000 (Unused) D-IN-12: Unused
1000 (Main monitor communication = ON) D-OUT-0: Maintenance monitor communication
Input signal 0100 (Engine maintenance lamp = ON) D-OUT-1: Engine maintenance lamp
9 40925 D-OUT-0-1 --- 01000000
D_OUT_0-1 0000 (Unused) D-OUT-2: Unused
0000 (Unused) D-OUT-3: Unused
WA800-3E0, WA900-3E0 29
Engine service monitor service mode; Cylinder 3. Using the < and > switches, display “Reduced
cut-out function cylinder mode selection (CYLINDER CUT-
OUT)” screen, and then press the U switch.
q For the testing method with this function, see
Testing and adjusting, “Reduced cylinder mode
operation of engine”.
Only the operating method is described in this
section.
Engine reduced-cylinder function

1. Hold the t switch and < switch simultaneously
for at least 5 seconds to change the screen to
the ID inputting screen.
2. Input the ID with the < and > switches, and

then press the U switch to enter the screen for
the service mode.
30 WA800-3E0, WA900-3E0
For change of the screen with the <, > and t switches, see “Functions for service person 1, Change diagram
of screen on 2nd layer”.
(*1): If the U switch is pressed on this screen, the screen changes to the left bank cylinder cut-out command
operation screen. (The right bank operates normally.)
(*2): If the U switch is pressed on this screen, the screen changes to the right bank cylinder cut-out com-
mand operation screen. (The left bank operates normally.)
(*3): If the U switch is pressed on this screen, the screen changes to the left bank cylinder cut-out command
operation screen. At this time, all the right bank cylinders stop.)
(*4): If the U switch is pressed on this screen, the screen changes to the right bank cylinder cut-out com-
mand operation screen. At this time, all the left bank cylinders stop.)
a If the screen returns from the individual bank control screen to the previous screen, the <,> switch
blinks and operation is prohibited for 5 seconds. This prohibition time is set so that injection of all the cyl-
inders will be stabilized before the next menu operation is started.
a While either bank is stopped (for about 8 seconds), the <,> and U switches blink and operation is pro-
hibited.
WA800-3E0, WA900-3E0 31
Right bank or left bank cut-off command operation

Each time the > switch is pressed, the cursor moves to the right (Select a cylinder to which the cylinder cut-
off command will be output).
Each time the < switch is pressed, the cursor moves to the left (Select a cylinder to which the cylinder cut-off
command will be output).
Turn ON/OFF the monitor cylinder cut-off command operation with the U switch. Each time the U switch is
pressed, the command is output or reset.
If the t switch is pressed, the screen returns to the previous screen and all the cylinder cut-out commands
from the monitor are reset.
Example of operation: When 3rd cylinder cut-out command is output
It displays the engine speed [rpm] in upper column and the last injection volume command [mg] in lower col-
umn at the same time.
32 WA800-3E0, WA900-3E0
No injection cranking
For the starting method of engine using this function, see “Testing and adjusting: No injection cranking oper-
ation of engine”.
This section describes only the operating method.
WA800-3E0, WA900-3E0 33
(*1) The upper column does not display. Note: Other than the reset operation above, you
The lower column displays the average fuel can reset data by initializing the monitor panel
consumption [L/h] from the last resetting. or specifying optional setting to OFF.
The counting is stopped at 99999.9, the upper
limit.
(*2) The upper column displays the cumulative fuel

consumption [L] from the last resetting.
The counting is stopped at 9999999.9, the
upper limit.
The lower column displays the elapsed time [h]
from the last resetting.
The counting is stopped at 9999999.9, the
upper limit.
(*1 – *2)
Calculation is done only for the duration in
which the engine is run.
(*3) Using the U switch, clear data of (*1), and (*2),
to return to the previous screen.
Using the t switch, return to the previous
screen without resetting.
34 WA800-3E0, WA900-3E0
Receiving fuel consumption [L]

q The monitor panel calculates the integrated
fuel consumption [L] from the momentary fuel
consumption [L/h] received from the engine
controller.
q The integrated fuel consumption [L] is cor-
rected with the fuel adjustment function (FUEL
ADJUST) in the service mode.
q The momentary fuel consumption [L/h]
received from the engine controller is corrected
according to the following table.
[Value corrected by table] = [Momentary fuel con-

sumption received from engine controller] x [Cor-
rection value (a)]
Model Correction value (a)
WA800-3E0 1
WA900-3E0 1
(*4) Set the gain correction value.

1) When the screen changes, the current set
value is displayed and the cursor is set to
the symbol (+/–).
2) While the cursor is at the symbol, each
time > or < switch is pressed, “+”, and
“–” are displayed alternately.
3) Settle the symbol with the U switch, and
the cursor moves to the leftmost place.
4) First, while the cursor is at the leftmost
place, each time the >/< switch is pressed,
the digit increases/decreases between 0
and 9. (The digit at the leftmost place
changes between 0 and 2.)
5) When a desired digit is input, press the U
switch to confirm that number.
6) The cursor moves to the right place. Input
a digit similarly to 4).
7) Input a digit to the rightmost place and
press the U switch. (If the digit is con-
firmed, the screen returns to the previous
screen.)
8) If the t switch is pressed while a value is
being input, the current value is not
changed and the cursor moves to the
symbol. If the t switch is pressed again,
the screen returns to the previous screen.
9) When the rightmost place digit is con-
firmed, if the value is out of the range from
–50.0 to +50.0, the current value is not
changed and the cursor moves to the
symbol as if the t switch is pressed.
Processing with monitor panel:

q Default: 0.0%
q The integrated fuel consumption [L] is cor-
rected by this set value in the range of
[–50.0 to +50.0%].
WA800-3E0, WA900-3E0 35
Snap shot function

For this function, see the section of “Testing and adjusting: Manual snapshot function”.
36 WA800-3E0, WA900-3E0
Function of selecting optional device Troubleshooting

For setting with this function, see Testing and The engine service monitor always monitors the
adjusting, “Adjustment with monitor”. state of the input and output signals and the system
uses them for its self-diagnosis. If the system
detects abnormality by the self-diagnosis, it trans-
mits the abnormality occurrence information
through the network to the engine service monitor.
If abnormality occurs, the operator can check it with
the engine service monitor (fault history display)/
VHMS.
The engine service monitor notifies the operator of
E01, E02, E03 and other errors by lighting the
engine warning lamp. When error E03 (including
E02) occurs, in particular, the engine service moni-
tor notifies it to the main monitor by the diagnosis
signal and then the main monitor notifies the error
(Display of 90 CALL + Buzzer).
If the communication circuit between the engine
service monitor and main monitor has an error, the
engine service monitor cannot notify the error when
another error equivalent to E03 occurs. Accord-
ingly, the error must be repaired immediately (E03).
Since the main monitor cannot output an alarm,
however, the engine maintenance lamp blinks spe-
cially to notify the error in this case.
When engine warning lamp lights: E01, E02, E03
(When E02 or E03 occurs, however, main monitor
displays “90 CALL” and sounds the buzzer)
When engine warning lamp blinks: E03 (Only when
communication between engine service monitor
and main monitor has an error)
WA800-3E0, WA900-3E0 37
Engine service monitor signal table by connector
CN1 (070-20-pole)
Pin No. Specifications I/O Form of use Signal name Remarks
1 SW power supply (+24 V) I Power supply +24 V SW power supply (+24 V)
2 SW power supply (+24 V) I Power supply +24 V SW power supply (+24 V)
3 GND I GND GND
4 GND I GND GND
5 NSW power supply (+24 V) I Unswitched +24 V NSW power supply (+24 V)
6 NSW power supply (+24 V) I Unswitched +24 V NSW power supply (+24 V)
7 D_IN_0 (24 V, 5 mA) I D/I +24 V Key SW C signal
8 (NC) I (NC)
9 (NC) — (NC)
10 D_IN_3 (24 V/GND, 5 mA) I D/I GND (NC)
11 D_IN_4 (24 V/GND, 5 mA) I D/I GND (NC)
Feedback signal of
12 D_IN_5 (24 V/GND, 5 mA) I D/I GND Feedback signal main monitor commu-
nication
13 (NC) — (NC)
14 D_IN_7 (24 V/GND, 5 mA) I D/I GND Mode selector SW2 (<)
15 D_IN_8 (24 V/GND, 5 mA) I D/I GND Mode selector SW2 (>)
16 D_IN_9 (NSW24 V/GND, 5 mA) I D/I +24 V Mode selector SW1 (U)
17 D_IN_10 (24 V/GND, 5 mA) I D/I +24 V Mode selector SW1 (t)
18 D_OUT_0 (+24 V, sink 200 mA) O D/O sink Main monitor communication
19 D_OUT_1 (+24 V, sink 200 mA) O D/O sink Engine maintenance lamp
20 — I — WAKE UP signal
CN2 (070-12-pole)
Pin No. Specifications I/O Form of use Signal name Remarks
1 CAN+ I/O CAN+ CAN+
2 (NC) — (NC)
3 CAN– O CAN– CAN–
4 (NC) — (NC)
5 (NC) — (NC)
6 CAN TERM I/O CAN TERM CAN built in terminator
7 (NC) — (NC)
8 (NC) — (NC)
9 A_IN_0 (0 – 30 V) I A/I Alternator R
10 (NC) I (NC)
11 (NC) — (NC)
12 (NC) — (NC)
38 WA800-3E0, WA900-3E0
Pre-lubrication system
Electrical circuit diagram of pre-lubrication system
WA800-3E0, WA900-3E0 39
1. Outline
The pre-lubrication controller receives the engine oil pressure switch signal and the signals of the sensors
installed to various parts of the engine for each controller through the network and drives the pump with the
motor to lubricate the engine parts before the engine is started. Consequently, wear is reduced, seizure is
prevented, and unlubricated operation is prevented after a periodic inspection or a long downtime.
2. Flow of pre-lubrication system

The flow of the pre-lubrication controller system is shown below.
40 WA800-3E0, WA900-3E0
3. Pre-lubrication function When the engine oil temperature is below

The pre-lubrication function starts when the 45°C, if pre-lubrication is continued for 60
key switch of the machine is turned to the seconds without satisfying the condition
START position and its operating time varies for completion, it stops to protect the
with the state of the engine oil pressure switch motor. Pre-lubrication is not completed at
and engine oil temperature. this time but it is still required.
1) Judgment of sate of engine oil pressure
switch 4) Permission to start engine
The pre-lubrication controller judges After the condition for completion of pre-
necessity of pre-lubrication by the engine lubrication is satisfied and pre-lubrication
oil pressure switch signal. is stopped, the pre-lubrication controller
keeps outputting the engine start permis-
Oil pressure Threshold value Judgment of sion signal for 70 seconds. If the operator
switch of pressure state turns the key switch to the START position
again, the engine is cranked.
Pressure is
Below 29.4 kPa Pre-lubrication Even if the key switch is turned to the
applied
{0.3 kg/cm2} is necessary S TA R T p o s i t i o n , t h e e n g i n e i s n o t
(CLOSE)
cranked, or started, as long as the engine
29.4 kPa Pre-lubrication
Pressure is start permission signal is not output.
{0.3 kg/cm2} is stopped
applied (OPEN) If the engine is not started for 70 seconds
or above (unnecessary)
after pre-lubrication is completed, pre-
lubrication is required again to start the
engine.
2) Judgment of operating time
The maximum operating time of the pre-
5) Display of operation
lubricator is decided according to the
The state of the pre-lubrication function is
engine oil temperature sensor signal
displayed by the special operation lamp.
obtained through the network. When the
The main contents of the display are as
oil temperature is below 45°C, the maxi-
follows.
mum operating time is 60 seconds. When
the former is 45°C or above, the latter is Opera-
10 seconds. State Operating condition
tion lamp
After key switch is
Ready for
Engine oil temperature Maximum operating time Blink turned ON until pre-
pre-lubrication
lubrication starts
Below 45°C 60 sec
During pre-
45°C or above 10 sec ON During pre-lubrication
lubrication
Completion of Completion of pre-
OFF
3) Condition for completion pre-lubrication lubrication
When the given conditions are satisfied,
pre-lubrication is judged to be completed
and pre-lubrication is stopped. The main
conditions are as follows.
1] When the engine oil pressure switch
signal becomes “Pressure is applied
(OPEN)” after pre-lubrica tion is
started, regardless of the remaining
operating time
2] When pre-lubrication is continued for
10 seconds while the engine oil tem-
perature is 45°C or above
3] When pre-lubrication is continued for
10 seconds and the network has an
error while the engine oil temperature
is below 45°C
WA800-3E0, WA900-3E0 41
6) Skipping pre-lubrication function

When the engine cannot be started because of a trouble in the pre-lubrication system, the operator
can start it by changing the connection of the emergency connector to skip the pre-lubrication func-
tion.
For the change of the emergency connector to skip the pre-lubrication function, see the Operation
and Maintenance Manual.
The electric circuit related to the emergency connector is shown below.
42 WA800-3E0, WA900-3E0
4. Preheating function
If the pre-lubrication controller is installed, it controls the preheating function, as well as the pre-lubrica-
tion function, instead of the engine controller.
As a result, the time to start preheating changes from the time when “the key switch is turned ON” to the
time when “the condition for completion of pre-lubrication is satisfied”.
The preheating time varies with the engine coolant temperature. The preheating time map is shown
below.
WA800-3E0, WA900-3E0 43
List of display contents of the real-time monitor of pre-lubrication controller

The state of the controller input and output signals can be checked using the real-time monitor function of the
engine service monitor.
The following table shows the display items and display contents in normal operation of the real-time monitor
in relation to the pre-lubrication controller:
No. Item ID No. Display of item Unit Contents of display data Display contents in normal operation Remarks
[3 – 10 digits of part No.
are displayed]
1 Assembly No. 20412 PART NUMBER --- Depends on assembly No.
Example: “3146R110” is
displayed for 7831-46-R11.
123456 (Display of 6 dig-
2 Serial No. 20410 SERIAL NUMBER --- Depends on serial No.
its)
[3 – 10 digits of part No.
Software part are displayed]
3 20248 VERSION --- Depends on Software part number
number Example: “3146R110” is
displayed for 7831-46-R11.
4 Application version 20246 VERSION (APP) --- 01000000 Depends on Application version
5 Data version 20247 VERSION (DATA) --- 00010001 Depends on Data version
0.0 – 30.0 (Resolution: 0.1
6 Charge level 04305 ALTERNATOR R V V) 0.0 – 30.0 V
---[Other than above]
00000000 (Unused)
D-IN-0: Unused
01000000 (Engine oil pressure switch = ON) No
D-IN-1: Engine oil pressure switch
pressure: Engine starts.
D-IN-2: Unused
01010101 00000000 (Unused)
Input signal D-IN-3: Starting motor C
7 40973 D-IN--0------7 --- Input signal state of D-IN-0 00010000 (Starting motor C = ON)
D_IN_0-7 D-IN-4: Model selection signal 1
– 7 is displayed. 00001000 (Model selection signal 1 is kept at “1”)
D-IN-5: Model selection signal 2
00000000 (Model selection signal 2 is kept at “0”)
D-IN-6: Model selection signal 3
00000000 (Model selection signal 3 is kept at “0”)
D-IN-7: Unused
00000000 (Unused)
D-OUT-0: Preheater relay operates
10000000 (Preheater relay operates) D-OUT-1: Pre-lubrication relay oper-
01000000 (Pre-lubrication relay operates) ates
01000000 00100000 (Engine start permission relay operates) D-OUT-2: Engine start permission
Output signal ON/OFF output state of 00000000 (Unused) relay operates
8 40974 D-OUT-0------7 ---
D_OUT_0-7 SOL-OUT-0 – 2 is dis- 00000000 (Unused) D-OUT-3: Unused
played to D-OUT-0 – 2. 00000000 (Unused) D-OUT-4: Unused
D-OUT-7: Unused
D-OUT-8: Unused
00000000 (Unused)
D-OUT-9: Unused
00000000 (Unused)
D-OUT-10: Unused
00000001 00000000 (Unused)
D-OUT-11: Unused
Output signal ON/OFF output state of 00000000 (Unused)
9 40975 D-OUT-8-----15 --- D-OUT-12: Unused
D_OUT_8-15 SIG-OUT-0 – 1 is dis- 00000000 (Unused)
D-OUT-13: Unused
played to D-OUT-14 – 15. 00000000 (Unused)
D-OUT-14: Unused
00000000 (Unused)
D-OUT-15: Pre-lubrication opera-
00000001 (Pre-lubrication operation lamp = ON)
tion lamp ON
01010000
ON/OFF output state of
Output signal No using item in this data.
10 40976 D-OUT-16----23 --- SIG-OUT-2 – 3, HSW- No using item in this data.
D_OUT_16-23 Constantly set to 00000000
OUT-0 – 1 is displayed to
D-OUT-16 – 19.
Troubleshooting function
The pre-lubrication controller always monitors the
state of the input and output signals and the system
uses them for its self-diagnosis. If the system
detects abnormality by the self-diagnosis, it trans-
mits the abnormality occurrence information
through the network to the engine service monitor.
If abnormality occurs, the operator can check it with
the engine service monitor (fault history display)/
VHMS.
44 WA800-3E0, WA900-3E0
Pin assignment
CN pin Specification Signal name i/o Function Remarks
CN1–1 VB (Controller PWR) VB (Controller PWR) i 24/12 V
Special for key switch
CN1–2 KEY_SIG KEY_SIG i
contact input
CN1–3 WAKE_UP WAKE_UP i
CN1–4 A_IN_3 ··· i 4.7k PU A/D input
CN1–5 D_IN_1 E/G OIL PRESS SW i Lo side ON/OFF input
AC pulse input for elec-
CN1–6 PLS_AC_IN0 ··· i
tromagnetic pickup
SIG_OUT_0/
CN1–7 ··· o ···
PLS_OUT_0
CN1–8 DA_0 ··· o D/A output
CN1–9 SOL_OUT_0 PREHEAT RELAY o Hi side ON/OFF output ON/OFF priority
CN1–10 HSW_OUT_0 ··· o ···
CN1–11 VB (Controller PWR) VB (Controller PWR) i 24/12 V
Special for key switch
CN1–12 KEY_SIG KEY_SIG i
contact input
Cannot be used
Power supply R terminal
CN1–13 A_IN_0/AIN6 ALTERNATOR R i when A IN 6 is
input
used
CN1–15 D_IN_2 ··· i Hi side ON/OFF input
AC pulse input for elec-
CN1–16 PLS_AC_IN1 ··· i
tromagnetic pickup
SIG_OUT_1/ PRELUBE LAMP
CN1–17 o ON/OFF output
PLS_OUT_1 (LED)
CN1–18 S_NET ··· i/o
CN1–19 SOL_OUT_1 PRELUBE RELAY o Hi side ON/OFF output ON/OFF priority
CN1–20 HSW_OUT_1 ··· o ···
CN1–21 GND (Controller GND) GND (Controller GND) i
CN1–22 POT_PWR ··· o 5 V 80 mA (max.)
Cannot be used
CN1–24 A_IN_5 ··· i 150 PU A/D input when A IN 0 is
used
CN1–25 D_IN_3 KEY SW C i Hi side ON/OFF input
CN1–26 D_IN_5 MACHINE SELECT 2 i Lo side ON/OFF input
SIG_OUT_2/
CN1–27 ··· o ···
PLS_OUT_2
CN1–28 CAN0_H CAN0_H i/o KOM NET/c
E/G START SAFETY
CN1–29 SOL_OUT_2 o Hi side ON/OFF output ON/OFF priority
RELAY
CN1–30 VIS (Solenoid PWR) VIS (Solenoid PWR) i
CN1–31 GND (Controller GND) GND (Controller GND) i
CN1–32 A_GND/PLS_GND ···
CN1–34 D_IN_0 ··· i Lo side ON/OFF input
WA800-3E0, WA900-3E0 45
CN pin Specification Signal name i/o Function Remarks

Cannot be used
SIG_OUT_3/
CN1–37 ··· — ··· when D_IN_7 is
PLS_OUT_3/DIN7
used
CN1–38 CAN0_L CAN0_L i/o KOM MET/c
CN1–39 CAN0_SH ··· CAN shield
SOL COM (Solenoid SOL COM (Solenoid
CN1–40 i
common GND) common GND)
46 WA800-3E0, WA900-3E0
SEN02359-00

© 2006 KOMATSU
All Rights Reserved
48
SEN02360-02
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Work equipment control system...................................................................................................................... 2
Remote position, joystick steering controller................................................................................................... 5
Active power maximizing electrical circuit....................................................................................................... 6
Automatic transmission system (ATM).......................................................................................................... 13
WA800-3E0, WA900-3E0 1
Work equipment control system 1

System structure diagram
Control functions
Remote positioner function

Lift arm LOWER, RAISE position stop
Lift arm LOWER, RAISE stop position set
Sensor adjustment function
Model selection function
Outline
q With the remote positioner control, the opera-
tor can set the lift arm stop (lever kickout) to
the desired position. This ensures smooth
movement of the lift arm when it starts and
stops moving, and makes it safer and easier to
carry out operations when traveling in reverse,
digging, or approaching dump trucks.
2 WA800-3E0, WA900-3E0
Work equipment control circuit structure
WA800-3E0, WA900-3E0 3
Remote positioner function 2. Remote positioner set RAISE stop position

1. Lift arm raise/lower position stop setting
q The controller is always able to detect the When the RAISE lamp is ON, the stop position
direction of operation of the lever from the can be set as desired.
pressure switch installed to the lift arm PPC The set position is retained even when the key
valve and the angle (position) of the lift arm is turned OFF.
from the lift arm angle potentiometer. 1) Setting stop position
1) RAISE kickout (when RAISE lamp is ON) i) Operate the lift arm lever to the deter-
When the lift arm lever enters the RAISE mined position (above horizontal),
detent and the lift arm goes up to the set then return the lever to HOLD.
position, the lift arm slows down and stops. ii) Push the raise set switch
At the same time, the detent is released iii) The RAISE lamp will go out and the
and the operator can raise the lift arm to a raise set lamp will flash at the same
position beyond the RAISE detent. time. (For 2.5 sec)
2) LOWER lift arm stop (when the LOWER iv) When the raise set lamp goes out and
lamp is ON) the RAISE lamp lights up, the raise
When the lift arm lever is placed at the stop position is written to memory.
FLOAT or MAX LOWER position, and the
lift arm goes down to the set position, the 3. Remote positioner set lower stop position
lift arm slows down and stops. If the lever setting
is held in position, the lift arm remains When the LOWER lamp is ON, the stop posi-
stopped. If the lever is returned slightly, tion can be set as desired.
the lift arm will go down further. The set position is retained even when the key
The operator can set the raise and lower is turned OFF.
stop positions as desired. 1) Setting stop position
i) Operate the lift arm lever to the deter-
Table 1 mined position (below horizontal),
Stop position then return the lever to HOLD.
Raise Lower ii) Push the lower set switch.
Mode iii) The LOWER lamp will go out and the
lower set lamp will flash at the same
WA800-3E0
0° – 43° 0 – –41° time. (For 2.5 sec)
WA900-3E0
iv) When the lower set lamp goes out
The controls can be set by pressing the remote and the LOWER lamp lights up, the
position raise/lower selector switch to change lower stop position is written to mem-
in the order given below. When the lamp is ory.
lighted up, the lift arm will automatically stop at
that position. Sensor adjustment function
q This function offsets the error when the potenti-
ometer is installed and makes it possible to
detect the correct position data for the work
equipment.
Always carry out adjustment of the sensor
when the controller, potentiometer, or work
equipment are replaced.
(For details, see Testing and adjusting.)
q The controller always observes to check that
the electronic equipment forming the solenoid
valves receiving the output signals are func-
tioning correctly.
q If any of these devices has abnormality, the
work equipment controller detects and displays
that abnormality on its display section.
(See the troubleshooting for the remote boom
positioner controller system)
4 WA800-3E0, WA900-3E0
Remote position, joystick steering controller 1
Connector signals
CN RB-1 CN RB-2 CN RB-3
1 — 1 Engine selection 1 1 —
2 — 2 Remote positioner upper set switch 2 —
3 — 3 Remote positioner lower set switch 3 —
4 — 4 Positioner selector switch 4 Engine speed signal (+)
5 Dumping sol (+) 5 Lift arm RAISE pressure switch 5 —
6 — 6 Lift arm LOWER pressure switch 6 Remote positioner upper stop LED
7 — 7 Engine selection 7 Remote positioner lower stop LED
8 Power source input 24 V 8 Lift arm lever detent switch 8 —
9 GND 9 Signal GND output 9 —
10 Remote positioner upper set display 10 Potentiometer power source +5 V 10 —
11 — 11 — 11 —
12 NETWORK signal 12 — 12 —
13 — 13 — 13 —
14 — 14 — 14 Remote positioner lower stop display
15 Dumping sol (–) 15 — 15 —
16 — 16 — 16 Buzzer output
17 Sol power source input (+24 V) 17 —
18 Power source input (+24 V) 18 —
19 GND 19 Lift arm angle positioner
20 Lift arm lever kickout 20 —
21 —
WA800-3E0, WA900-3E0 5
Active power maximizing electrical circuit 1
Outline Powerful Loading:

q When the machine is used for light digging When the machine is used for digging, the
work and much oil flow is not necessary to the work equipment pump delivery is reduced.
work equipment, the active power maximizing During digging operation, the drive force is
system minimizes the delivery of either pump large and working speed is low.
(variable-displacement piston pump) to reduce
the hydraulic load on the engine and increase Normal Loading:
the drive force. The work equipment pump delivery is not
q If the active working switch is set in the “Pow- reduced during digging operation. The working
erful Loading” position, when the lift arm is in speed is high.
the digging position (height) and the lift arm
cylinder bottom oil pressure increases, the
solenoid valve is operated to change the oil
pressure on the work equipment pump servo
valve to minimize the pump delivery.
6 WA800-3E0, WA900-3E0
When directional selector switch is N
q When the starting switch is turned ON, a cur-

rent flows in the active working switch and neu-
tral 1 relay terminal (3).
q While the directional selector switch is in the
“N” (Neutral) position, the neutral signal (+24
V) flows in neutral 1 relay terminal (1) to
“close” contacts (3) and (5).
Then, the current flows from neutral relay 1 ter-
minal (3) through (5), neutral 2 relay terminals
(1) and (2) to the ground and neutral 2 relay
contacts (3) and (6) are “opened”.
q Accordingly, even if the active working switch
is set in the “Powerful Loading” position, the
current from the active working switch is cut off
by the neutral 2 relay and the active power
maximizing system does not operate.
WA800-3E0, WA900-3E0 7
Powerful Loading mode (Start of digging)
q When the directional selector switch is set in q Since the lift arm cylinder bottom oil pressure
the forward position, the neutral signal does is not high at the start of digging, the oil pres-
not flow and neutral 1 relay contacts (3) and (5) sure switch is turned OFF.
are “opened”. Accordingly, no current flows to the lift arm cyl-
Accordingly, no current flows to the neutral 2 inder bottom pressure relay coil and contacts
relay coil and contacts (3) and (6) are “closed”. (3) and (6) are “closed” and a current flows
Then, the power is supplied from the active from neutral 2 relay terminal (6) through lift arm
working switch through neutral 2 relay termi- bottom pressure relay terminals (3) and (6) to
nals (3) and (6) to the lift arm position proximity timer 1 terminal (14).
switch and lift arm cylinder bottom oil pressure q If the current continues flowing from timer 1
switch. terminal (14) through (13) to the ground for the
q If the lift arm is lowered and the lift arm position set time, contacts (8) and (12) are “closed”.
proximity switch is turned ON, the ground side Then, the current flows from timer 1 terminal
(terminal (6)) of the pump cut-off relay coil is (12) through no-load relay terminals (1) and (2)
connected through the proximity switch to the to the ground and contacts (3) and (5) are
ground. “closed”. Since the current continues flowing
from relay terminal (5) through (1) to the
ground, no-load relay terminals (3) and (5) are
kept “closed”.
8 WA800-3E0, WA900-3E0
Powerful Loading mode (During digging)
Operation ground and contacts (3) and (5) are “closed”.

q When the machine digs and the lift arm cylin- Accordingly, the current flows from terminal (5)
der bottom oil pressure rises and the oil pres- through the load relay coil to the ground and
sure switch is turned ON, the current stops load relay terminals (3) and (5) are “closed”.
flowing to the lift arm cylinder bottom pressure q Then, the current flows from neutral 2 relay ter-
relay coil and the current to timer 1 terminal minal (6) through no-load relay terminals (3)
(14) is turned OFF. and (5), load relay terminals (5) and (3), timer
Timer 1 contacts (8) and (12) are “closed” and 2 terminals (4) and (12), pump cut-off relay
the current flowing from timer 1 terminal (12) to coil, and proximity switch to the ground. As a
the no-load relay coil is turned OFF. Since the result, pump cut-off relay contacts (3) and (4)
current flows from no-load relay terminal (5) to are “closed” and the circuit from the active
the coil, however, no-load relay contracts (3) working switch through the neutral 2 relay,
and (5) are kept “closed”. pump cut-off relay and solenoid valve to the
q At the same time, the current flows from lift arm ground is formed and the solenoid valve oper-
cylinder bottom pressure relay terminal (1) ates to minimize the work equipment pump
through (2) and oil pressure switch to the delivery.
WA800-3E0, WA900-3E0 9
Powerful Loading mode (Finish of digging)
Operation q Then, the current flowing from timer 2 to the

q When the machine finishes digging and the lift pump cut-off relay coil is turned OFF and relay
arm cylinder bottom oil pressure lowers and contacts (3) and (4) are “opened” and the cur-
the oil pressure switch is turned OFF, the current flowing to the solenoid valve is turned
rent flowing to the lift arm cylinder bottom pres- OFF.
sure relay coil is turned OFF and contacts (3) Accordingly, the work equipment pump deliv-
and (5) are “opened” and the current flowing to ery is returned to the normal level.
the load coil is turned OFF. q After digging is finished, when the lift arm rises
Load relay contacts (3) and (6) are “closed” to a position (height) at which the proximity
and a current flows from terminal (6) to timer 2 switch is turned OFF, the circuit from pump cut-
terminal (14). off relay terminal (6) through proximity switch
q If the current continues flowing from terminal to the ground is broken. Accordingly, contacts
(14) through (13) to the ground for the set time, (3) and (4) of the pump cut-off relay are
timer 2 “opens” contacts (4) and (12). “opened” and the current flowing to the sole-
noid valve is turned OFF.
10 WA800-3E0, WA900-3E0
q After digging is finished and the directional

lever is set in the “N” (Neutral) position, the
neutral 1 relay coil is energized and a current
flows from neutral 1 relay to neutral 2 relay coil
and contacts (3) and (6) are “opened”.
Then, the current flowing from neutral 2 relay
terminal (6) is turned OFF and the relays and
timers are set in the initial state.
WA800-3E0, WA900-3E0 11
Normal Loading mode
q In the Normal Loading mode, no current flows

from the active working switch to the neutral 2
relay. Accordingly, no current flows to the sole-
noid valve and the work equipment pump
delivery is kept at the normal level.
12 WA800-3E0, WA900-3E0
Automatic transmission system (ATM) 1
q The automatic transmission system consists of

the transmission controller, directional selector
switch, shift-up/down switch, engine speed
sensor, travel speed sensor and directional/
gear speed solenoid.
q The transmission controller shifts the transmis-
sion to the proper gear speeds according to
the shift-up/down switch signal, travel speed
signal and engine speed signal.
q The safety function prevents the machine from
starting when the engine is started and pro-
tects the transmission when the travel direction
is changed. With this function, the transmission
and clutch are protected and their durability is
heightened.
q The self-diagnosis system monitors the input
and output conditions constantly and displays
them on the 2 “7-segment LED's” of the trans-
mission controller. If it detects any failure, it
displays the failure code, and displays the
“remedy code” on the main monitor and
flashes the caution lamp for higher safety,
depending on the degree of the failure.
q The transmission controller has a communicat-
ing function and transmits the information of
the travel direction (“F”, “N”, “R”) and gear
speed (1st, 2nd, 3rd) to the main monitor,
which displays it.
WA800-3E0, WA900-3E0 13
Outline 5) Skip shift

1. Auto gear shift function If the accelerator pedal is pressed while
When the engine speed is 1,450 rpm or higher, the machine is coasting in the 3rd gear
shifting up and shifting down operations of the speed at speed below 8 km/h (with the
transmission are controlled with the signals of engine speed below 1,450 rpm), the 2nd
the directional switch, shift-up/down switch, gear speed is selected immediately so
and travel speed sensor, according to the that the machine can be accelerated eas-
“Automatic gear shift change points table” ily. If the travel speed is 8 km/h or higher,
(Table 1) saved in the transmission controller. however, the present gear speed is main-
1) Shift-up/down switch tained.
The highest gear speed (gear shift range) 6) No-shift time
for the auto gear shift is limited. A certain period to keep each gear speed
The highest gear speed is displayed in the after gear shifting operation is set to pre-
“1st, 2nd, 3rd indicator” installed to the vent gear s hi ft hunting. This per iod
dashboard. depends on the gear shifting pattern. See
Highest gear speed 3: Between 2nd and “Table 1 Automatic gear shift change
3rd gear speeds points table”.
Highest gear speed 2: Only 2nd gear speed 7) Hold function
Highest gear speed 1: Only 1st gear speed The gear speed when the hold switch is
2) When directional switch is in “N” position pressed is held as the optimum gear
If the directional switch is in the neutral speed. In this case, even if the travel
position, only the gear speed clutch of the speed lowers, the transmission is not
transmission is operated. shifted down. If the travel direction is
3) When directional switch is in “F” position changed, however, the transmission is
If the directional switch is set from the N usually shifted down to the 2nd, then
position to the F position, the solenoids of shifted up to the set hold gear speed
the F and 2nd of the transmission are according to the gear shift travel speed
turned ON (F2). (Auto 2nd start) condition. (This function prevents unnec-
1] When the gear is shifted up (when essary gear shift-down operation while the
highest gear speed is “3rd”) machine is traveling on finished or down-
When the accelerator pedal is hill ground.)
pressed to accelerate the machine 8) Kick-down function
and the travel speed reaches about If the operation (the operation of turning
5.4 km/h, the 2nd solenoid is turned “ON” the kick-down switch) by the opera-
“ON” and the 1st is turned “OFF”. tor satisfies the conditions in “Table 1
(The transmission is set in the F2.) Automatic gear shift change points table,
If the travel speed reaches about 10.9 Item 5. Kick-down”, the transmission is
km/h, the 3rd solenoid is turned “ON” shifted down to the 1st gear forcibly,
and the 2nd is turned “OFF”. (The regardless of the auto shift function.
transmission is set in the F3.) This function is reset when the travel
2] When the gear is shifted down (when speed rises or the travel direction is
highest gear speed is “3rd”) changed. In this case, the transmission is
If the accelerator pedal is released set in the 2nd gear speed. This function is
and the travel speed lowers to about kept effective while the gear speed is held
10.3 km/h while traveling in the 3rd (Hold function, with engine speed below
gear speed, the 2nd solenoid is 1,450 rpm).
turned “ON” and the 3rd is turned
“OFF”. (The transmission is set in the
F2 position.)
4) When directional selector switch is in “R”
position
Similarly to the operation in the F position,
the 2nd or 3rd gear speed (when the gear
shift range is 3) is selected automatically
according to the travel speed when the
modulated clutch outlet speed is 1,450
rpm or higher.
14 WA800-3E0, WA900-3E0
2. Manual gear shift function

The auto gear shift mode can be stopped by
selecting the manual gear shift mode.
In the manual gear shift mode, the gear speed
is changed according to the shift-up and shift-
down switches.
1) Shift-up/down switch
Each time the shift-up switch is pressed,
the transmission is shifted up from the 1st
to 2nd and 3rd gear speed. Each time the
shift-down switch is pressed, the transmis-
sion is shifted down from the 3rd to 2nd
and 1st gear speed. In the manual gear
shift mode, all of the “1st, 2nd and 3rd
indicators” are turned OFF.
2) When directional selector switch is in “N”
position
If the directional selector switch is in the
neutral position, only the gear speed
clutch of the transmission operates.
3) When directional selector switch is in “F”
or “R” position
If the directional selector switch is set in
the “F” or “R” position, the forward sole-
noid or reverse solenoid operates.
4) Kick-down function
Only when the operator applies the kick-
down function (turns the kick-down switch
“ON”) during travel in the forward 2nd (F2)
gear speed, the transmission is shifted
down to the 1st gear speed. If the travel
direction is changed or the gear is shifted
up, the kick-down function is reset.
5) Selection of auto-shift mode or manual
shift mode
1] Gear speed output when auto-shift
mode is changed to manual shift
mode
The gear speed before the mode
changing operation is kept.
2] Gear speed output when manual shift
mode is changed to auto-shift mode
The transmission is set to a proper
gear speed according to the travel
speed before the mode changing
operation and using “Table 1 Auto-
matic gear shift change points table,
Item 7. Data of selection of F and R”.
WA800-3E0, WA900-3E0 15
3. Transmission cut-off function

This function set the transmission in neutral by sensing the brake pilot pressure with the pressure sen-
sor when the left brake pedal is pressed.
This function makes it possible to cut off the transmission at any point by saving the brake pedal position
to set the transmission in neutral as the brake pilot pressure.
1) Contents of transmission cut-off control
When the transmission cut-off switch is ON and the pressure of the left brake
pressure sensor signal exceeds the set pressure, forward or reverse clutch of
the transmission is disengaged to set the transmission in neutral. (When the
condition for transmission cut-off operation is satisfied)
Outline
When the condition of resetting the cut-off operation is satisfied while the
Transmission cut-off transmission is cut off (When the left brake pressure lowers below the reset
control pressure or transmission cut-off switch is turned OFF), forward or reverse
clutch is engaged.
Condition for The transmission cut-off switch is ON and the brake pilot pressure > the cut-off
operation IN pressure.
Condition for {Transmission cut-off switch is OFF} or {Transmission cut-off pressure < Cut-
resetting off OUT pressure}
Condition for
permission of The transmission cut-off switch is ON.
setting
(1) Press the left brake to a position to set (Cut-off point can be set even if the
brake is not pressed).
(2) Press the transmission cut-off set switch.
(3) If the pressure when the switch is pressed is in the settable range, the
Setting transmission controller saves that pressure temporarily. If the pressure is
method out of the settable range, the controller saves the upper limit or lower limit
Setting of transmission
temporarily and sounds the setting completion buzzer twice (Pip, pip).
cut-off point
(4) After 2.5 seconds, the transmission controller saves the setting (The set-
ting mode finishes). (The setting is kept even after the key switch is turned
OFF.)
(1) Press the transmission cut-off switch again during the 2.5 seconds in set-
ting step (4) above.
Resetting (2) Set the cut-off point to the default of the left brake pressure.
method The setting cancel buzzer sounds (Peep).
(3) Save the set (default) value (The setting mode finishes.)
(The setting is kept even after the key switch is turned OFF.)
2) Settable range of transmission cut-off The cut-off OUT pressure is (Cut-off set
point pressure – 0.30 [MPa] {3 [kg/cm2]}).
Give hysteresis of 0.30 [MPa] {3 [kg/cm2]}
[Settable range]
to the cut-off IN pressure (to set in neutral)
0.49 – 4.81 [MPa] and cut-off OUT pressure (to reset).
{5 – 49 [kg/cm2]} Example) When the cut-off point is set to
0.98 {MPa] {10 [kg/cm2]} of the
pressure sensor
Note) If the cut-off point is set to pressure Cut-off IN pressure =
below 0.49 [MPa] {5 [kg/cm2]}, it is 0.98 [MPa] {10 [kg/cm2])
actually set to 0.49 [MPa] {5 [kg/ Cut-off OUT pressure =
cm2]}. 0.68 [MPa] {7 [kg/cm2])
Note) If the cut-off point is set to pressure
of 4.81 [MPa] {49 [k g/cm 2 ]} or
above, it is actually set to 4.8 [MPa]
{49 [kg/cm2]}.
The default value is 1.47 [MPa] {15 [kg/
cm2]} (same with WA-3 pressure switch).
16 WA800-3E0, WA900-3E0
4. Transmission controller travel mode and functions list
WA800-3E0, WA900-3E0 17
18 WA800-3E0, WA900-3E0
5. Safety functions 4) Manual gear shift mode

1) Neutral safety I f t h e t r a v e l s p e e d d a ta c a n n o t b e
When the engine is started, if the direc- obtained because of a travel speed sensor
tional switch is not in the “N” position, the trouble, the transmission is set in the man-
transmission controller keeps the trans- ual gear shift mode automatically.
mission in neutral and the machine does 5) Resetting detent when engine stops
not start. This function is reset if the “N” While the starting switch is in the “ON”
signal is input once after the engine is position and the engine speed is below
started. The machine circuit is so com- 500 rpm, the kick-out solenoid relay is
posed that the engine cannot be started operated so that the work equipment con-
when the transmission is not in neutral. trol lever cannot be set in the detent hold
2) Neutralizer state. With this mechanism, the work
When the parking brake is applied (the equipment does not rise or lower suddenly
neutralizer relay signal is input), the “F” just after the engine is started.
and “R” solenoids are released to set the
transmission in neutral so that the
machine will not start and the parking
brake will not burn while the parking brake
is working.
3) Transmission protect
If the travel direction is changed or the
gear is shifted down while the machine is
traveling, the gear speed is controlled and
warning buzzer is turned on to protect the
transmission.
1] Gear speed control
When the engine speed and travel
speed are under a certain condition,
the transmission is shifted down to
the 2nd gear speed.
the transmission is kept at the current
gear speed but shifted down to the
2nd gear speed as the travel speed
lowers.
(See Fig. Control at shift down, Fig.
Gear speed before F R changing,
Table 1 Automatic gear shift change
points table, Item 5. Shift-down when
kick-down is ON, and Item 6. F-R
change.)
2] Warning with caution buzzer
the caution buzzer sounds for warn-
ing.
(See Fig. Control at shift down, Fig.
Gear speed before F R changing,
Table 1 Automatic gear shift change
points table, Item 5. Shift-down when
kick-down is ON, and Item 6. F-R
change.)
WA800-3E0, WA900-3E0 19
Table 1 Automatic gear shift change points table

I
Travel speed
Item Gear speed No-shift time (sec)
(km/h)
1. Basic gear shift change 1o2 Min 5.4 (5.6)* 2

2o3 Min 10.9 (11.4)* 2
3o2 Below 10.4 (9.9)* 2
2. Engine speed (Below 1,450 rpm) 3o2 Below 1.0 0
3. Engine speed (Below 1,450 rpm o 1,450 rpm or above) 3o2 Below 8.0 2
4. When hold is ON 1o2 5.4 0
Shift-up 2o3 10.9 0
5. When kick-down is ON
5
Shift-down (See Fig. Control at shift down)
6. F–R change (See Fig. Gear speed before F R changing)
(F o) N o R 2
(R o) N o F
7. F–R change
FoNoF o3 Min 10.9 0
RoNoR o2 Below 10.9
* In ( ) show limit travel speed.
20 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 21
6. AJSS control
Function
AJSS is a turn control system with a joystick, which senses articulation angle and faithfully bends the
machine in accordance with the tilting angle of AJSS lever, by adopting pilot oil pressure method with
feedback mechanism.
1) AJSS system
q In AJSS, when the joystick steering lever and the frame are connected with link through the
rotary valve, and deviation occurs between the operating angle of the lever and the machine
frame turning angle, the pilot oil pressure is applied to the steering valve from the rotary valve,
and the machine turns in the direction of lever operation until the operating angle of the lever
and the machine frame turning angle match and the rotary valve closes.
22 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 23
2) AJSS neutral interlock

q In AJSS, since there is a possibility that the machine operates and turns immediately after the
engine is started, if the joystick steering lever is in a position other than neutral (there is devia-
tion between the operating angle of the lever and the machine frame angle), the engine start
signal is cut, and starting the engine is prohibited by turning the neutral safety relay on.
q If the steering lock lever is locked, and the joystick steering lever is in a position other than neu-
tral while the engine is operating, there is a possibility that the machine turns immediately after
the lever is unlocked, the caution buzzer is sounded in order to call attention of the operator.
q Since the machine does not turn with the steering locked, operation of FR is prohibited with the
transmission controller. Therefore, if the forward-reverse switch of the joystick steering knob is
set to a position other than neutral while the steering is locked, because there is a possibility
that forward-reverse operation occurs immediately after unlocked, the caution buzzer is
sounded in order to call attention of the operator.
Conditions Reference Neutral safety control
Steering pilot Reference
Joystick Steering Engine start
Engine pressure Machine state Transmission
steering lever lock lever neutral safety
NET signal neutral safety
Neutral The key is on,
Without pressure
position Locked the engine is
(switch = OPEN)
deviation stopped
angle less Without pressure
than 6° Unlocked
(switch = OPEN)
Stopped
(below Starting the
500 rpm) Operation engine is not pos-
Without pressure
position Locked sible when the
(switch = OPEN)
deviation joystick steering
angle more lever is operated
than 6° Without pressure
Unlocked
(switch = OPEN)
Transmission
Neutral shift is not possi-
Without pressure
position Locked Lever locked ble when the
(switch = OPEN)
deviation steering is locked
angle less (N maintenance).
Operat- than 6° With pressure Normally
Unlocked
ing (500 (switch = CLOSE) operating
rpm or Transmission
above) Operation The lever is shift is not possi-
Without pressure The caution
position Locked operated while it ble when the
(switch = OPEN) buzzer sounds
deviation is locked steering is locked
angle more (N maintenance)
than 6° With pressure Normally
Unlocked
(switch = CLOSE) operating
24 WA800-3E0, WA900-3E0
3) Speed-sensing steering
q In AJSS, the steering characteristics is changed in accordance with travel speed, by controlling
the pilot basic pressure of the rotary valve with EPC.
q When travel speed is 7 km/h or less, it is controlled to turn speedily when the lever operating
stroke is large, prioritizing V shape work efficiency.
q When travel speed is higher, the turning speed is reduced from the neutral range of lever oper-
ating stroke, limiting sudden turning operation in rapid lever operation.
q It has three changeable tables.
a For the adjustment method and the characteristics of each table, refer to “Testing and adjust-
ing: Modification of AJSS oil pressure command table pattern”.
AJSS characteristics
WA800-3E0, WA900-3E0 25
4) 0 point adjustment procedure for AJSS steering and frame angle sensors
This function reads the offset angles of the AJSS steering lever angle and frame angle sensors and
corrects them automatically. Adjust the 0 points of those sensors according to the following proce-
dure.
1] Set the machine and AJSS lever in the straight travel position.
2] Stop the engine (Set the starting switch in the OFF position) and set the steering lock lever in
the LOCK position.
3] Pull out neutral position adjustment connector (1) (CN JL3) in the right console.
4] Turn the starting switch to the START position and start the engine.
5] Connect neutral position adjustment connector (1) (CN JL3).
6] Set the joystick steering lock lever to FREE position.
7] The buzzer sounds “pip, pip, pip” 1 second after, and the adjustment is finished.
Note) Do not move the AJSS lever during steps 4] – 7].
If the adjustment is not finished normally, check that the output voltages of the AJSS
lever sensor and frame angle sensor are 2.40 – 2.60 V and then repeat the adjustment
from step 1].
[
26 WA800-3E0, WA900-3E0
7. Selecting function Fine control priority (Table 1):

This signal is an ON/OFF digital signal, which This is a fine control priority level. If this
is used to judge the function when the starting level is selected, the maximum turning
switch is set in the ON position. speed is set lower than the default for
1) Model selecting function operators who have been operating the
Model selecting function signal table CAT machines with joystick specification.
Model CN3B-22 CN3B-30 CN3B-23 The operability of the AJSS is kept and
WA800-3E0 OPEN GND OPEN less shocks are made when the AJSS
lever is operated sharply. The difference
WA900-3E0 GND GND GND
between the high-speed work range and
the low-speed work range is reduced.
2) Selection of AJSS options
Option selecting table The table can be changed by reconnecting
Selection of connector (1) (CN JL4) in the left console. The
Model CNC5-9 CNC5-17 CNC5-16
option changed table becomes effective when the
STD starting switch is turned from the OFF position
WA800-3E0 GND OPEN GND
(Table 2) to the ON position after the connector is recon-
Response nected.
WA800-3E0 priority GND GND GND
(Table 3) STD (Table 2): Connect CN NORMAL to con-
Fine control nector (1) (CN JL4) (Condition at delivery).
WA800-3E0 priority OPEN GND GND Response priority (Table 3): Connect CN
(Table 1) QUICK to connector (1) (CN JL4).
Fine control priority (Table 1): Connect CN
q Selection of option is set to STD SLOW to connector (1) (CN JL4).
(Table 2) when machine is delivered.
This function changes the stopping shock and

response of the AJSS by changing the data of
the EPC output current for the AJSS lever
stroke.
STD (Table 2):

This is the default level of Komatsu and a
recommended level in which the machine
performance and steering performance
are balanced well.
Response priority (Table 3):

This is a response priority level. If this
level is selected, the tur ning speed
reaches the maximum before the AJSS
lever reaches the stroke end in the low-
speed work range to reduce the catch-up
feeling. On the other hand, if the AJSS
lever is operated sharply, large shocks are
made. This is a V-shape loading priority
mode.
a Since the maximum turning speed
cannot be obtained in table No. 1,
measure it with table No. 2 or 3.
WA800-3E0, WA900-3E0 27
28 WA800-3E0, WA900-3E0
8. Communicating function 9. Power source of transmission controller

The transmission controller has a communicat- When the starting switch is turned “ON” and
ing function through “S-NET” and keeps com- the source voltage is 20 V or higher and a volt-
municating with the main monitor. If any age of +20 V or higher is applied to the trans-
trouble occurs, the transmission controller dis- mission controller solenoid, drive of each
plays the remedy code on the main monitor to solenoid valve can be controlled.
notify the operator for higher safety, depending If the source voltage lowers below 19 V, all the
on the degree of the trouble. outputs are turned “OFF” and each solenoid
The failure code saved in the main monitor can cannot be controlled. (The machine cannot
be checked in the failure history mode of the travel.)
main monitor. For the method of operating the
main monitor, see Main Monitor.
WA800-3E0, WA900-3E0 29
10. Self-diagnosis function

The transmission controller constantly moni-
tors the input and output signals of the auto-
matic transmission system, executes self-
diagnosis, and displays the result with the LED
of the transmission controller.
The transmission controller also transmits the
following data to the main monitor.
1) Ordinary display: The output gear speed is
displayed with the LED of the transmission
controller.
2) Display of failure code: If any trouble is
detected, its contents are displayed by the
code. For the failure codes, see Table 3
Failure code table.
Table 3 Failure code table

1) Auto/Manual transmission control system
System Main monitor
Code Item Remarks
Short circuit Disconnection Remedy code
10 Backup lamp relay Q Q Not set
11 Not set — — — —
12 F solenoid Q Q CALL
13 R solenoid Q Q CALL
14 1st solenoid Q Q CALL
15 2nd solenoid Q Q CALL
16 3rd solenoid Q Q CALL
17 Not set — — — —
18 Not set — — — —
19 AJSS directional switch Q Q E00
20 Directional switch signal Q Q CALL
21 Gear shift signal Q Q Not set
22 Travel speed sensor X Q E00
23 Engine speed sensor X Q E00
2) AJSS control system
System
Code Item Main monitor remedy code
Short circuit Disconnection
55 Travel speed sensor Q Q E00
56 Joystick caution buzzer relay Q Q None
57 Joystick lever angle sensor Q Q E01 + CALL
Shifting of potentiometer signals of
58 AJSS lever angle sensor and frame — — E01 + CALL
angle sensor
59 Frame angle sensor Q Q E01 + CALL
60 AJSS lever lock switch Q Q E01 + CALL
62 Joystick neutral interlock relay Q Q E00
Joystick basic pressure control EPC
63 Q Q E01 + CALL
solenoid
30 WA800-3E0, WA900-3E0
Controller connector input and output signals

CN C1
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 8 BACK LAMP RELAY Output
2 T/M F SOL. Output 9 T/M R SOL. Output
3 T/M 1 SOL. Output 10 T/M 2 SOL. Output
4 ENGINE REVOLUTION OUTPUT Output 11 KICK OUT SOL RELAY OUTPUT Output
5 T/M 3 SOL. Output 12 GND Input
6 GND Input 13 +24 V Input
7 +24 V Input
CN C2
signal signal
1 Sol. Power Supply (+24) Input 12 Sol. Power Supply (+24) Input
2 Auto 1 RANGE LED (+) Output 13
5 16
6 17 AJSS EPC SOL. (–) Output
7 AJSS EPC SOL. (+) Output 18
8 J/S LEVER NEUTRAL SAFETY RELAY (+) Output 19 J/S CAUTION BUZZER RELAY (–)
9 J/S CAUTION BUZZER RELAY (+) Output 20
10 CAUTION (MONITOR) (+) Output 21 GND Input
11 GND Input
CN C3A
signal signal
1 Input 11
2 Output 12
3 S/T LEVER POTENTIO SENSOR Input 13 FRAME ANGLE POTENTIO SENSOR Input
4 LH BRAKE PRESS SENSOR Input 14
5 15
S/T POTENTIO SENSOR/GND (for pressure
6 Pressure sensor power supply (+24 V) Output 16 Output
sensor)
7 Potentio power supply (+5 V) Output 17
8 18
9 19 AJSS neutral adjust Input
10 20
CN C3B
signal signal
1 9 S/T LEVER LOCK PRESSURE SWITCH Input
2 MACHINE SELECT.1 Input 10 MACHINE SELECT.2 Input
3 MACHINE SELECT.3 Input 11
4 S-NET+ Input 12 S-NET+ Input
5 DIRECTION F Input 13 DIRECTION N Input
6 DIRECTION R Input 14 NEUTRALIZER RELAY Input
7 SHIFT UP SWITCH (N.O.) Input 15 SHIFT UP SWITCH (N.C.) Input
8 SHIFT DOWN SWITCH (N.O.) Input 16 SHIFT DOWN SWITCH (N.C.) Input
CN C4
Pin No. Signal name Input/Output Pin No. Signal name Input/Output
signal signal
1 7
2 ENGINE SPEED SENSOR (+) Input 8
3 9 GND (for engine speed sensor) Output
4 10
5 11
6 12
WA800-3E0, WA900-3E0 31
CN C5
signal signal
1 GND (PULS) Output 10 GND (for speed sensor) Output
2 SPEED SENSOR (+) Input 11
3 GND Output 12
4 GND Output 13 HOLD SWITCH Input
5 KICK DOWN SWITCH Input 14 AUTO/MANUAL SWITCH Input
6 T/M CUT OFF SWITCH Input 15
7 T/M CUT OFF SET SWITCH Input 16 AJSS CHANGE TRIG Input
8 17 AJSS SELECT 2 Input
9 AJSS SELECT 1 Input
32 WA800-3E0, WA900-3E0
11. LED display

When the engine is started, the LED is set in
1). “Program part No. display mode”, then 2).
“Output gear speed display mode”. If any trou-
ble is detected, however, the LED is set in the
“Troubleshooting display mode” immediately.
1) Program part No. display mode
2) Output gear speed display mode

LED display ‘X ° Y..’ (Dots of both are
turned off.)
X: Drive condition of directional solenoid
Forward “F”: ‘F’, Reverse “R”: ‘A’, Neutral:
‘0’
Y: Drive condition of gear speed solenoid
3) Troubleshooting display mode (Trouble

currently detected)
“E– (2 sec)” and “Code (2 sec)” are
repeated as 1 routine.
WA800-3E0, WA900-3E0 33
SEN02360-02

© 2010 KOMATSU
All Rights Reserved
34
SEN02361-03
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Engine starting/stopping circuit ....................................................................................................................... 2
Parking brake circuit ....................................................................................................................................... 4
Preheating circuit .......................................................................................................................................... 10
Emergency engine stop ................................................................................................................................ 12
Hydraulic oil level sensor .............................................................................................................................. 14
Battery and starting motor disconnector switch and starting aid connector .................................................. 16
Sensor........................................................................................................................................................... 18
WA800-3E0, WA900-3E0 1
Engine starting/stopping circuit 1
Function
1. The neutral safety circuit is employed to
secure safety when the engine is started.
q The engine can not be started while the
directional selector switch is not in N
(Neutral).
q When the AJSS lever is in a position other
than neutral, the engine can not be
started.
2 WA800-3E0, WA900-3E0
Operation 5. When starting switch is turned to “Start” position

1. When starting switch is turned to “ON” position q If the starting switch is turned to the “Start”
q If the starting switch is turned to the “ON” position, terminals B and C of the starting
position, terminals B and BR of the start- switch are closed and the current flows
ing switch are closed and the current flows from the neutral safety relay through the
from the battery through the starting AJSS neutral safety relay to the starting
switch and battery relay coil to the ground motor, and the engine starts rotating.
and the contacts of the battery relay are When the engine starts rotating, fuel injec-
closed. As a result, the power is supplied tion starts to each cylinder with the rota-
to each circuit of the vehicle. tion signal from the engine rotation sensor
Also, the operation signal is provided from connected to the engine controller, and
the terminal ACC of the starting switch into then the engine starts.
the engine controller, and the engine is 6. Engine stopped
ready to start. q If the starting switch is set in the “OFF”
2. Neutral maintaining circuit position, the current of terminal ACC of
q The engine does not start until transmis- the starting switch is cut out and the ACC
sion controller outputs the start prohibition signal to the engine controller is cut out
signal once. This prevents the engine from accordingly, and the engine controller
starting before the transmission controller stops fuel injection.
is started. The self-holding circuit is q When fuel injection stops, the engine
employed to prevent the starting motor slows down the rotation and stops. When
from hunting when the voltage drops and the alternator stops generating electricity,
the transmission controller stops output- voltage supply from R terminal stops, and
ting signals during the starting operation. the current from BR terminal of the starting
3. Neutral safety circuit switch is cut out, the contact of the battery
q When the directional lever is set in the “N” relay opens, and the power supply pro-
position, current flows from the N contact vided to various parts of the machine is
of the directional switch to the coil of the cut out.
neutral safety relay, and by conducting the
three terminals of the neutral safety relay
with the five terminals, the engine
becomes ready to be started.
4. AJSS neutral safety circuit
q When the engine is started in a condition
other than steering neutral condition, in
which the lever angle of AJSS and the
machine frame angle are the same, the
machine can begin turning immediately
after it is started, which can be a cause of
danger. Therefore, if the deviation of the
lever angle and the frame angle, sensed
by the work equipment controller, is 6° or
more, starting the engine is prohibited by
energizing the AJSS neutral safety relay
coil by the work equipment controller, and
opening the three and six terminals of the
relay.
WA800-3E0, WA900-3E0 3
Parking brake circuit 1

Operation
1. Starting switch OFF
q When the starting switch is turned OFF, the

battery relay is opened, so electricity does not
flow to the parking brake circuit. For this rea-
son, if the starting switch is at the OFF posi-
tion, no electric current flows to the parking
brake solenoid valve, regardless of whether
the parking brake switch is ON (applied) or
OFF (released), so the parking brake is actu-
ated.
4 WA800-3E0, WA900-3E0
2. Starting switch ON
2-1 When parking brake switch is ON (actuated) before starting switch is turned ON
q The electric current flows in circuit (1) from the

battery o starting switch o battery relay coil o
ground, so the battery relay is closed. When
this happens, electric current flows in circuit (2)
from the battery o battery relay o parking
brake switch terminal 1 – 3 o parking brake
safety relay terminal 1 – 2 o ground. In this
way, the parking safety relay is actuated and
safety relay terminals 3 – 5 are closed.
q When this happens, circuit (3) is formed from
the battery o battery relay o parking safety
relay terminal 5 – 3 o parking safety relay ter-
minal 1 – 2 o ground. From this point, the
parking safety relay is in the condition of circuit
(3) until the starting switch is turned OFF.
q In this condition, electric current does not flow
to the parking brake solenoid valve, so the
parking brake is actuated.
q In addition, in this condition, the transmission
is shifted to neutral by transmission controller.
WA800-3E0, WA900-3E0 5
2-2 When parking brake switch is OFF (released) before starting switch is turned ON
q Electric current flows in circuit (1) from the bat-

tery o starting switch o battery relay coil o
ground, so the battery relay is closed. How-
ever, in this case, the parking brake switch is
OFF (released), so the parking safety relay is
not actuated.
For this reason, the electric current does not
flow to the parking brake solenoid valve, so
after the automatic parking brake is applied,
the parking brake is not released automatically
even when the starting switch is turned ON.
q In addition, the electric current does not flow to
the transmission controller, so the machine
does not move.
6 WA800-3E0, WA900-3E0
3. Parking brake switch OFF (Released)

When the parking brake switch is turned from ON to OFF after the starting switch is turned ON
q If the parking brake switch is turned from ON

(actuated) to OFF (released), the circuit for ter-
minals 2 and 3 of the parking brake switch is
connected, and the parking brake safety relay
is also actuated. For this reason, electric cur-
rent flows in circuit (1) from the battery (+) o
battery relay o parking brake safety relay o
parking brake switch, and then flows to circuit
(2).
(2) This circuit is formed from the emergency
brake switch o parking brake solenoid valve
o ground, and the parking brake is released.
q In addition, a signal is sent at the same time
from terminal 3 of the neutralizer relay to the
transmission controller to make it possible to
travel.
WA800-3E0, WA900-3E0 7
4. Parking brake switch ON (actuated)
q If the parking brake switch is turned ON

(applied) after carrying out operations with the
parking brake switch OFF (released), the cir-
cuit in the diagram above is formed.
q Electric current does not flow to the parking
brake solenoid valve, so the oil pressure from
the accumulator to the spring cylinder is shut
off. At the same time, the oil pressure inside
the spring cylinder passes through the parking
brake valve and is drained, so the parking
brake is applied by the force of the spring.
q In addition, at the same time, the neutralizer
relay is reset, so the circuit between terminals
3 and 5 is opened, and no electricity flows to
the transmission directional circuit, so the
transmission is shifted to neutral.
As a result, the signal from terminal 3 to the
transmission controller is cut and the transmis-
sion is shifted to neutral.
In this way, the transmission is shifted to neu-
tral when the parking brake is applied. This
makes it impossible for the machine to travel
with the parking brake applied, and prevents
the parking brake from seizing.
8 WA800-3E0, WA900-3E0
5. When main brake oil pressure drops (emergency brake actuated)
Operation
q If the accumulator pressure drops, the emer-
gency brake switch installed to the accumula-
tor is opened.
For this reason, the electric current stops flow-
ing to the parking brake solenoid valve, so the
oil pressure inside the spring cylinder is
drained and the parking brake is applied.
However, in this case, the condition is different
from the case where the parking brake switch
is ON (applied), because there is electric cur-
rent flowing to the neutralizer relay coil.
q For this reason, a signal is sent to the trans-
mission controller, and it is possible to engage
the transmission clutch. In this way, it is possi-
ble to use the engine brake when the emer-
gency brake is applied, so the braking distance
becomes shorter. At the same time, if the
emergency brake has been applied and it is
necessary to move the machine (for example,
if the emergency brake is applied when the
machine is on a railway crossing), it is possible
to move the machine by operating the trans-
mission lever.
WA800-3E0, WA900-3E0 9
Preheating circuit 1
(Automatic preheating system)
Outline Operation
q To improve the ease of starting in cold areas, q When the starting switch is turned to the ON
an automatic preheating system is installed. (ACC) position, a circuit is formed from engine
This system helps to reduce the preheating controller o preheating output o ground.
time and also automatically sets the preheating The preheating relay coil is excited, so the pre-
time to match the engine coolant temperature heating relay is actuated to actuate the heater
when the starting switch is operated. relay.
q When the starting switch is turned to the ON q Current flow from the battery o battery relay o
(ACC) position, the preheating pilot lamp on heater relay o electrical intake air heater to
the main monitor lights up and preheating is carry out preheating. When the preheating
carried out on the intake air for the electrical completion signal is sent from the controller,
intake air heater. the preheating relay and heater relay are
The engine coolant temperature is detected by turned OFF and the preheating is completed.
the coolant temperature sensor, and the pre-
heating time is set by the engine controller.
q While the pilot lamp is lighted up, preheating is
being carried out, so the starting switch must
be kept at the ON position. If the starting
switch is turned to the START position while
the pilot lamp is ON, the preheating is can-
celed.
10 WA800-3E0, WA900-3E0
When equipped the prelube system
Outline q While the pilot lamp is lighted up, preheating is

q To improve the ease of starting in cold areas, being carried out, so the starting switch must
an automatic preheating system is installed. be kept at the ON position. If the starting
This system helps to reduce the preheating switch is turned to the START position while
time and also automatically sets the preheating the pilot lamp is ON, the preheating is can-
time to match the engine coolant temperature celed.
when the starting switch is operated.
q When prelube operation is completed automat- Operation
ically, the preheating pilot lamp on the main q When prelube operation is completed automat-
monitor lights up and preheating is carried out ically, prelube controller o controller inside
on the intake air for the electrical intake air main monitor’ preheating output o ground.
heater. The preheating relay coil is excited, so the pre-
The engine coolant temperature is detected by heating relay is actuated to actuate the heater
the coolant temperature sensor, and the pre- relay.
heating time is set by the prelube controller, q Current flow from the battery o battery relay o
receiving a signal via network. heater relay o electrical intake air heater to
q When equipped with the prelube system, pre- carry out preheating. When the preheating out-
heating time is controlled by prelube controller, put is stopped from the controller, the preheat-
not by engine controller. ing relay and heater relay are turned OFF and
the preheating is completed.
WA800-3E0, WA900-3E0 11
Emergency engine stop 1

WA900-3E0 (RIO TINTO specification)
12 WA800-3E0, WA900-3E0
1. Emergency engine stop switch

(Left rear of machine)
2. Emergency engine stop switch
(Right rear of machine)
3. Emergency engine stop switch (In cab)
Function
q The emergency engine stop switch is installed
to 3 places, 1 in the cab and 2 on the outside of
the machine. If any one of them is pressed,
the engine stops.
q Use the emergency engine stop switch only in
an emergency. Usually, stop the engine with
the starting switch.
q If the engine is to be kept stopped for a long
time after it is stopped with the emergency
engine stop switch, turn the starting switch
OFF. If lights are lighting when the engine is
stopped with the emergency engine stop
switch, they keep lighting and the battery may
die.
q If the engine cannot be stopped with the emer-
gency engine stop switch, stop it with the
engine shutdown switch on the left side of the
rear frame (above the frame lock bar).
WA800-3E0, WA900-3E0 13
Hydraulic oil level sensor 1

14 WA800-3E0, WA900-3E0
1. Hydraulic oil level caution lamp

2. Level switch
3. Timer
4. Relay
5. Fuse
Function
q If the oil level in the hydraulic tank lowers
while the machine is operating, the hydraulic
oil level caution lamp on the maintenance
monitor lights up, the centralized warning lamp
(CAUTION) on the main monitor blinks, and
the alarm buzzer sounds.
WA800-3E0, WA900-3E0 15
Battery and starting motor disconnector switch and starting aid

connector 1
WA800/900-3E0 (Option)
WA900-3E0 (For NA, KAL)
1. Battery disconnector switch (For NA, KAL, option) *

2. Starting motor disconnector switch (For NA, KAL) *
3. Starting aid connector (For KAL)
* : The shape of disconnect switch for KAL is different.
16 WA800-3E0, WA900-3E0
Function
1. Battery disconnector switch (For NA, KAL, 3. Starting aid connector (For KAL)
option) q This machine is optionally equipped with a
q If the battery disconnector switch is turned start aid connector in compliance with
OFF, the electrical system of the machine SAE J1283.
does not work at all under the same condi- q For usage and precautions of the start aid
tion as if the battery is not connected. connector, refer to Operation Manual.
q Usually, use the battery disconnector
switch when storing the machine for a
long time (1 month or more), repairing the
electrical system, performing arc welding
on the machine, inspecting or handling the
battery, or when replacing a fuse or a slow
blow fuse.
q The clock of the monitor/radio and recep-
tion preset memory of radio will be lost,
and need to be set again when using
them.
q Just after the starting switch is turned
OFF, the VHMS saves the data. When
turning the battery disconnector switch
OFF, check that the VHMS operation indi-
cators in the component box on the left
side of the rear frame and on the side of
the battery disconnector switch are turned
OFF.
a Do not turn the battery disconnector
switch OFF while the engine is running or
just after the engine is stopped. If it is
turned OFF under such conditions, the
electrical system may be damaged seri-
ously.
a Before testing or maintaining the machine,
turn the battery disconnector switch OFF
and check that the engine does not start
even if the starting switch is operated.
2. Starting motor disconnector switch (For

NA, KAL)
q If the starting motor disconnector switch is
turned OFF, the power supply (24V) circuit
for the starting motor is turned OFF.
q Use the starting motor disconnector switch
when repairing the electrical system, per-
forming arc welding on the machine,
inspecting or handling the battery, or
replacing a fuse or a slow blow fuse.
a Do not turn the starting motor disconnec-
tor switch OFF while the engine is running
or just after the engine is stopped. If it is
turned OFF under such conditions, the
electrical system may be damaged seri-
ously.
a Before testing or maintaining the machine,
turn the starting motor disconnector switch
OFF and check that the engine does not
start even if the starting switch is oper-
ated.
WA800-3E0, WA900-3E0 17
Sensor 1
Engine rotation sensor
Transmission rotation sensor
1. Magnet 3. Harness
2. Locknut 4. Connector
Function
q The transmission rotation sensor senses the
pulse signal of the transmission output gear
and the transmission controller coverts it into a
speed signal. This speed signal is converted
into the travel speed and then displayed.
q The engine rotation sensor senses the pulse
signal of the ring gear of the flywheel and the
engine controller coverts it into a speed signal.
This speed signal is displayed as the engine
speed.
18 WA800-3E0, WA900-3E0
Modulation clutch pressure sensor
1. Sensor
2. Lead wire
3. Connector
Function
q Installed to the modulation clutch, this sensor
detects pressure of the clutch to be used for
calculating thermal load to the clutch.
WA800-3E0, WA900-3E0 19
Transmission oil temperature sensor

Engine coolant temperature sensor
Hydraulic oil temperature sensor
Brake oil temperature sensor
1. Thermistor
2. Plug
3. Harness
4. Connector
Function
q The signal of the transmission oil temperature
sensor is sensed by the machine monitor and
indicated by gauge. If it becomes high, the
caution signal is output.
q The signal of the engine coolant temperature
sensor is sensed by the machine monitor and
indicated by gauge. If it becomes high, the
caution signal is output.
q The hydraulic oil temperature sensor is
installed to sense the hydraulic oil temperature
when the VHMS specification is employed.
q The brake oil temperature sensor is installed to
sense the brake oil temperature when the
VHMS specification is employed.
20 WA800-3E0, WA900-3E0
Kick-down, hold switch

AJSS specification
1. Kick-down switch
2. Spring
3. Spring
4. Hold switch
5. Wiring harness
Kick-down switch Hold switch

Operation q The hold switch is installed to the lift arm lever,
q The kick-down (shifting down from 2nd o 1st) and when the hold switch is pressed, the
is actuated only when traveling in F2. speed range displayed on the main monitor
q When traveling in F2, if it is desired to shift transmission indicator is held (when equipped
down to 1st without operating the AJSS lever, with auto shift).
operate the kick-down switch on the lift arm q Press the hold switch again to cancel (when
lever to ON to shift down to F1. equipped with auto shift).
After this, even if the kick-down switch is
pressed, the transmission is kept at F1.
Cancellation (or not actuated)

q When directional selector switch of AJSS lever
is at N
q When directional selector switch of AJSS lever
is at R
q When gear speed is not at 2nd
q When starting switch is OFF
WA800-3E0, WA900-3E0 21
1. Kick-down switch
2. Spring
3. Spring
4. Hold switch
5. Wiring harness
Kick-down switch Hold switch

Operation q The hold switch is installed to the lift arm lever,
q The kick-down (shifting down from 2nd o 1st) and when the hold switch is pressed, the
is actuated only when traveling in F2. speed range displayed on the main monitor
q When traveling in F2, if it is desired to shift transmission indicator is held (when equipped
down to 1st without operating the speed lever, with auto shift).
operate the kick-down switch on the lift arm q Press the hold switch again to cancel (when
lever to ON to shift down to F1. equipped with auto shift).
q After this, even if the kick-down switch is
pressed, the transmission is kept at F1.
Cancellation (or not actuated)

q When directional selector switch is at N
q When directional selector switch is at R
q When gear speed is not at 2nd
q When starting switch is OFF
22 WA800-3E0, WA900-3E0
AJSS steering lock switch
Function
q When AJSS steering lock lever is operated,
steering pilot pressure circuit is cut off, lower-
ing the pilot pressure and opening the switch
accordingly.
q When the steering lock lever is OFF, the pilot
pressure is lowered while the engine is not run-
ning. As the result, AJSS does not operate
same as when the steering lock lever is ON.
WA800-3E0, WA900-3E0 23
AJSS knob
1. Horn switch: horn sounding switch Function

2. Shift down switch: Selects a gear speed (shift q Directional switch is held at a selected posi-
down) tion. Transmission controller shifts gear
3. Shift up switch: Selects a gear speed (shift up) according to the signal from the directional
4. Directional switch: Selects the travel direction switch.
and neutral. q Shift-up and -down switches select circuit only
while the switch is being depressed, and the
transmission controller uses this signal for gear
shifting operation accordingly.
q Horn switch operates the relay and sounds the
horn while it is being depressed.
24 WA800-3E0, WA900-3E0
Lift arm angle sensor

AJSS frame angle sensor
AJSS lever angle sensor
1. Connector 5. Bearing
2. Case 6. Contact
3. Shaft 7. Mold
4. Element
Function
q Lever angle sensor is installed to AJSS lever in
the L.H. console, and frame angle sensor is to
the follow-up linkage of the machine rear
frame. Data from these sensors are converted
to the lever angle and swing angle respectively
inside the work equipment controller.
q Lift arm angle sensor is installed on front
frame. According to the movement of lift arm,
sensor shaft is rotated by the lever attached to
sensor.
Output voltage of sensor are converted to lift
arm angle inside the work equipment control-
ler.
WA800-3E0, WA900-3E0 25
Work equipment pressure sensor

Steering pressure sensor
Rear brake pressure sensor (VHMS (if equipped))
Front brake pressure sensor (VHMS (if equipped))
1. Sensor
2. Connector
Function Operation
q These sensors convert pump discharge pres- q When oil pressure led from the pressure input
sure to voltage and transmit to the governor port applies pressure to the diaphragm of oil
pump controller. pressure sensor, the diaphragm is deformed
from deflection.
q Gauge layer is installed to the opposite of the
diaphragm. Deflection of the diaphragm is con-
verted into output voltage by the resistance of
the gauge layer and is sent to the amplifier.
q After amplifying the voltage, the amplifier
transmits the voltage to the governor controller.
q Relational expression of pressure P (MPa {kg/
cm2}) and output voltage (V)
V = 0.08 {0.008} × P + 0.5
26 WA800-3E0, WA900-3E0
Fuel level sensor
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
q The fuel level sensor is installed to the side of
the fuel tank. The float moves up and down
according to the fuel level.
The float moves the variable resistor through
the arm. The voltage signal is sent to the
machine monitor to indicate the fuel level.
Also, when the machine monitor indicator
reaches a specified position, caution lamp is lit.
WA800-3E0, WA900-3E0 27
Brake pressure switch
1. Case 3. Connector
2. Tube
Function
q When the brake is depressed, oil pressure
operates the pressure switch to turn on the
brake lamp on the rear of the machine.
28 WA800-3E0, WA900-3E0
Parking brake pressure switch

Emergency brake pressure switch
2. Tube
Function
q When the parking brake is released, oil pres-
sure is fed to the brake piston. The oil pressure
operates the pressure switch to turn out the
parking brake pilot lamp on the machine moni-
tor.
WA800-3E0, WA900-3E0 29
Air cleaner clogging sensor
1. Indicator 3. Adapter
2. Spring
Function
q The air cleaner clogging sensor is installed to
the air cleaner outlet. If the air cleaner is
clogged and the pressure reaches the speci-
fied level (negative pressure), caution lamp on
the machine monitor lights up to output a warn-
ing.
30 WA800-3E0, WA900-3E0
Transmission clogging sensor
1. Body Function
2. Tube q The clogging sensor is installed to the filter
3. Connector section. If the filter is clogged and the pressure
difference between the lower and higher sides
A: Take-out port on low pressure side reaches a specified level, the switch turns
B: Take-out port on high pressure side OFF, and the maintenance caution lamp lights
up. At the same time, a message appears to
the character display on the engine service
monitor to warn on abnormal situation.
Operating pressure: 275 kPa {2.8 kg/cm2}
Principle of switching: Differential pressure slid-

ing piston type
WA800-3E0, WA900-3E0 31
Engine oil level sensor
1. Stopper 4. Plug
2. Float 5. Tube
3. Sensor 6. Connector
Function
q The engine oil level sensor is installed to the
side of the oil pan. If the oil level lowers below
the specified level, the float lowers and the
switch is turned “OFF”.
32 WA800-3E0, WA900-3E0
Coolant level sensor
1. Stopper 4. Plug
2. Float 5. Tube
Function
q This sensor is installed to the radiator upper
tank, and if the coolant level goes below the
specified level, the float goes down and the
switch goes “OFF”.
WA800-3E0, WA900-3E0 33
Brake accumulator pressure switch (Rear and front)
2. Tube
Function
q If the brake accumulator oil pressure lowers,
the contact becomes OPEN, and the caution
lamp lights up on the machine monitor to warn
of abnormality.
34 WA800-3E0, WA900-3E0
Atmospheric temperature sensor
Specifications
1. Power consumption: Max. 0.5 mW
2. Withstand pressure: 0.98 MPa {10 kg/cm2}
3. Temperature detection range (ambient): –30°C
to 120°C
4. Temperature conservation range: –50°C to
140°C
5. Performance table
Detected
tempera-
–20 –10 0 10 20 50
ture
(°C)
Resis-
tance 30.32 18.58 11.74 7.623 5.077 1.712
(kz)
a: Sensor heat sensitizing portion mount diame-

ter 16 × 1.5
Function
This sensor inputs the atmospheric temperature to
the VHMS controller as a variation of the thermistor
resistance.
WA800-3E0, WA900-3E0 35
Transmission oil pressure sensor
2. Lead wire
Specifications
1. Accuracy: ±3% (–20 – 110°C)
2. Consumption current: Max. 20 mA
3. Overload pressure: 9.81 MPa {110 kg/cm2}
a: Sensor mount diameter: PT 1/8
Function
q Converts the oil pressure of transmission into
voltage and inputs the data to the VHMS con-
troller as transmission oil pressure value.
36 WA800-3E0, WA900-3E0
Exhaust temperature sensor and amplifier
Specifications
1. Rated output: DC 24 V
2. Temperature detection range:
100 to 1000°C
300 to 800°C (guaranteed accuracy ±10°C)
3. Output voltage characteristics: as per perfor-
mance table below
4. Range of operating temperature: –40 to 110°C
5. Current consumption: Max. 30 mA
a: Sensor heat sensitizing portion mount diame-

ter R1/8
b: Amplifier
c: Connector (power supply side)
c: Connector (sensor side)
Output voltage characteristics

(ambient temperature: 20°C)…Reference value
Detected
tempera-
50 100 400 700 800
ture
(°C)
Output
voltage 1.191 1.397 2.626 3.899 4.316
(V)
Function
A thermocouple type temperature sensor installed
to the inlet port of turbocharger. It outputs the
exhaust temperature data to the VHMS controller.
WA800-3E0, WA900-3E0 37
Blow-by pressure sensor
Specifications
1. Supply voltage: DC 5 V
2. Output voltage: 0.5 V (when engine stops) and
up
3. Size: Mount (portion “a”) R1/4
Outside diameter of pressure-receiving
seat 37
Cable length 1,110 mm
Function
Converts the internal pressure of engine crankcase
into voltage and inputs the data to the VHMS con-
troller as a blow-by pressure value.
38 WA800-3E0, WA900-3E0
Communication (ORBCOMM) controller and antenna
Controller a: Communication antenna mount
Specifications
1. Operating power supply voltage: DC 12 V to
DC 30 V
2. Size: W306 × D177.5 × H50 (mm)
Installed position
Installed to under the auxiliary seat.
Connector section
CN1A(ORB-A): AMP070-14
CN1B(ORB-B): SMP070-10
CN2: Communication antenna cable connector
Installed position
Installed on top of a pole erected on the front R.H.
side of the machine body.
Function
Transmits data collected and stored by the VHMS
controller to the computer center via communica-
tions satellites.
Antenna
Specifications
1. Type: helical whip antenna (1)
2. Impedance: 50 z
3. Input terminal: M-P type
4. Length: 165 ± 20 mm
WA800-3E0, WA900-3E0 39
Accelerator pedal sensor
1. Pedal
2. Connector
3. Sensor
Function
q This sensor is installed on the surface of the Output characteristics
floor. It outputs the accelerator signal or idle
validation signal depending on the accelerator
pressing angle.
Accelerator signal
q Magnitude of the accelerator pedal displace-
ment being detected by the potentiometer
inside the sensor is output in variable voltage
from No. 2 pin.
Idle validation signal

q The switch inside the sensor detects the accel-
erator pedal operation. As the accelerator
pedal is released, it outputs the signal being
entered to No. 5 pin from No. 4 pin. And as the
accelerator pedal is pressed, it outputs the sig-
nal being entered to No. 6 pin from No. 4 pin.
40 WA800-3E0, WA900-3E0
Stop lamp pressure switch
2. Tube
Function
q When the foot brake is stepped on and the brake operating pressure is generated, the pressure switch
contact is closed, the relay is operated and stop lamp lights up.
Emergency brake pressure switch (rear)

Emergency brake pressure switch (front)
2. Tube
Function
q When the brake accumulator pressure lowers, the switch contact opens. Circuit between the parking
brake switch and parking brake solenoid is cut off, and the parking brake is tripped to operate.
WA800-3E0, WA900-3E0 41
SEN02361-03

© 2017 KOMATSU
All Rights Reserved
42
SEN02154-02
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
20 Standard value table 1

Standard service value table
Standard value table for engine ...................................................................................................................... 2
Standard value table for chassis ..................................................................................................................... 3
Standard value table for electrical system ...................................................................................................... 8
WA800-3E0, WA900-3E0 1
SEN02154-02 20 Standard value table
Standard value table for engine 1

Engine SAA12V140E-3 SAA12V140E-3
Standard Standard
value for Service limit value for Service limit
Item Measurement conditions Unit
new value new value
machine machine
• Engine coolant High idle +20 +20 +20 +20
2,200 –30 2,200 –30 2,200 –30 2,200 –30
temperature:
Engine speed rpm
Within operating +60 +60 +60 +60
range Low idle 650 –30 650 –30 850 –30 850 –30
• All revolution ranges

Exhaust temperature °C Max. 680 750 Max. 700 Max. 750
• Atmospheric temperature: 20°C
Air supply pressure kPa Min. 126.66 Min. 132.3
• At rated output — —
(boost pressure) {mmHg} {Min. 950} {Min. 1,000}
At sudden acceler-
Max. 4.5 5.5 Max. 4.5 5.5
• Engine coolant ation
Bosch
Exhaust color temperature: within
Rated output index Max. 1.0 2.0 Max. 1.0 2.0
operating range
At high idle Max. 1.0 2.0 Max. 1.0 2.0
• Normal tempera- Intake valve 0.35 ± 0.02 — 0.35 ± 0.02 —

Valve clearance mm
ture Exhaust valve 0.57 ± 0.02 — 0.57 ± 0.02 —
• At rated output kPa Max. 2.94 5.88 Max. 2.94 5.88
Blow-by pressure
• Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {600} {Max. 300} {600}
0.29 – 0.44 0.2 0.29 – 0.44 0.2

• Engine oil tempera- Rated output {3.0 – 4.5} {2.0} {3.0 – 4.5} {2.0}
MPa
Oil pressure ture: Min. 80°C
{kg/cm2} Min. 0.08 0.07 Min. 0.08 0.07
• SAE30 oil At low idle
{Min. 0.8} {0.7} {Min. 0.8} {0.7}
Oil temperature • Whole speed range (oil pan) °C 80 – 110 120 80 – 110 120
Deflection of one belt when pressed with
Alternator belt tension finger force of approx. 98 N mm 20 20 20 20
(approx. 10 kg)
2 WA800-3E0, WA900-3E0
Standard value table for chassis

(*1):AJSS specification
(*2):Steering wheel specification
(*3):Shows the value before detent
Machine model WA800, WA900-3E0
Category
Standard value for

Item Measurement conditions Unit Service limit value
new machine
N o FORWARD, • Engine stopped 8.4 ± 1.0 8.4 ± 4.0

Transmission
REVERSE • Measure at end of switch {0.86 ± 0.1} {0.86 ± 0.4}

switch (*1)
5.0 ± 1.0 5.0 ± 2.0

Operating effort Upshift N {kg}
• Engine stopped {0.5 ± 0.1} {0.5 ± 0.2}
• Measure at center of lever knob 5.0 ± 1.0 5.0 ± 2.0
Downshift
{0.5 ± 0.1} {0.5 ± 0.2}
N o FORWARD, 5.9 (+4.9/–2.9) Max. 16.7
Directional
lever (*2)
Operating effort N {kg}

REVERSE • Engine stopped {0.6 (+0.5/–0.3)} {Max. 1.7}
N o FORWARD, • Measure at center of lever knob
Stroke mm 35 ± 10 35 ± 10
REVERSE
5.9 (+4.9/–2.9) Max. 16.7
1st o 2nd
{0.6 (+0.5/–0.3)} {Max. 1.7}
Gearshift lever (*2)
5.9 (+4.9/–2.9) Max. 16.7

Operating effort 2nd o 3rd N {kg}
{0.6 (+0.5/–0.3)} {Max. 1.7}
• Engine stopped 5.9 (+4.9/–2.9) Max. 16.7
3rd o 4th • Measure at center of lever knob {0.6 (+0.5/–0.3)} {Max. 1.7}
1st o 2nd 35 ± 10 35 ± 20
Stroke 2nd o 3rd mm 35 ± 10 35 ± 20
3rd o 4th 35 ± 10 35 ± 20
HOLD o RAISE Max. 23.5 Max. 35.28
(*3) {Max. 2.4} {Max. 3.6}
Max. 15.68 Max. 23.52
RAISE o HOLD
{Max. 1.6} {Max. 2.4}
HOLD o LOWER Max. 24.5 Max. 37.24
Lift arm (*3) {Max. 2.5} {Max. 3.8}
LOWER o HOLD • Engine speed: Low idle — —
Operating effort
• Hydraulic oil temperature: Within oper-

Max. 34.5 Max. 51.94
LOWER o FLOAT ating range
Work equipment control lever
N {kg} {Max. 3.5} {Max. 5.3}

• Hook push-pull scale to center of lever
knob and measure. Max. 14.7 Max. 22.54
FLOAT o HOLD
• Measure maximum value. {Max. 1.5} {Max. 2.3}
Max. 23.52 Max. 35.28
HOLD o DUMP
{Max. 2.4} {Max. 3.6}
Max. 23.52 Max. 35.28
Bucket HOLD o TILT (*3)
{Max. 2.4} {Max. 3.6}
Max. 14.7 Max. 22.54
TILT o HOLD
{Max. 1.5} {Max. 2.3}
HOLD o RAISE
67 ± 15 67 ± 30
(*3) • Engine speed: Low idle
Lift arm HOLD o LOWER • Hydraulic oil temperature: Within oper-
53 ± 15 53 ± 30
Stroke
(*3) ating range

mm
• Hook push-pull scale to center of lever
HOLD o FLOAT 67 ± 15 67 ± 30
knob and measure.
HOLD o DUMP • Measure maximum value. 60 ± 15 60 ± 30
Bucket
HOLD o TILT (*3) 60 ± 15 60 ± 30
WA800-3E0, WA900-3E0 3
Machine model WA800, WA900-3E0

Category
Standard value for

Item Measurement conditions Unit Service limit value
new machine
• Engine started
Operating effort • Measure the operating effort at the N {kg} 54.2 {5.5} Max. 83.9 {8.5}
Accelerator pedal
point 150 mm from the pedal fulcrum.

a For measuring posture, see Fig A at
Neutral (a1) end of this section 57 —
Operating
• Engine speed: Low idle deg.
angle
Max. (a3) • Hydraulic oil temperature: Within oper- 40 —
ating range
294 ± 29.4 Max. 421.4
Operating effort N {kg}
{30 ± 3} {Max. 43}
a For measuring posture, see Fig. B at
Brake pedal
end of this section Right: 45

Neutral (a1) —
Operating • Engine speed: Low idle Left: 53
deg.
angle • Hydraulic oil temperature: Within oper- Right: 15
Max. (a2) ating range —
Left: 16.9
Play mm 5 ± 0.5 —
A a For measuring posture, see Fig. C at Max. 2.5 —
Fitting of wheel lock ring end of this section
Tire
B mm Max. 4.0 —
• Tire inflation pressure: Specified pres-
Clearance of wheel lock ring C sure 20 – 35 —
4 WA800-3E0, WA900-3E0

Standard Standard
Category

new value new value
machine machine
Torque converter stall • Engine coolant temperature: 2,040 ± 100 2,040 ± 200 2,120 ± 100 2,120 ± 200
Within operating range
Engine speed
Hydraulic stall 2,080 ± 100 2,080 ± 200 2,150 ± 100 2,150 ± 200
• Torque converter oil temperature:
Within operating range rpm Normal Normal Normal Normal
Torque converter stall + • Hydraulic oil temperature: 1,600 ± 100 1,600 ± 200 1,640 ± 100 1,640 ± 200
hydraulic stall (full stall) Within operating range Active Active Active Active
• Speed control: F3 1,870 ± 100 1,870 ± 200 1,900 ± 100 1,900 ± 200
• Engine stopped
Play deg. Max. 8 Max. 10 Max. 8 Max. 10
• Machine facing straight to front
• Flat, level, straight, dry, and paved 13.7 ± 4.9 13.7 ± 4.9
Operating effort N {kg} 23.5 {2.4} 23.5 {2.4}
AJSS lever
road {1.4 ± 0.5} {1.4 ± 0.5}

• Engine speed: High idle
Operating angle deg. 86 ± 5 Max. 95 86 ± 5 Max. 95
• Left lock – right lock
Low idle • Engine started Max. 9.6 Max. 10.6 Max. 9.6 Max. 10.6
Operating • Hydraulic oil temperature: Within
High idle sec.
time operating range Max. 5 Max. 6 Max. 5 Max. 6
(P-mode) • Left lock – right lock
+0.29 +0.29 +0.29 +0.29
Transmission main relief 2.75 –0 2.75 –0 2.75 –0 2.75 –0
valve pressure +3 +3 +3 +3
{28 –0 } {28 –0 } {28 –0 } {28 –0 }
1.03 ± 0.10 1.03 ± 0.10 1.03 ± 0.10 1.03 ± 0.10
Transmission, torque converter
Pilot reducing pressure

{10.5 ± 1.0} {10.5 ± 1.0} {10.5 ± 1.0} {10.5 ± 1.0}
+0.29 +0.29 +0.29 +0.29
Modulate pressure 2.45 –0 2.45 –0 2.45 –0 2.45 –0
MPa
(excluding F3, R3) • Engine: High idle
+3 +3 +3 +3
{kg/cm2} {25.0 –0 } {25.0 –0 } {25.0 –0 } {25.0 –0 }
• Torque converter oil temperature:
Torque converter inlet 0.79 – 0.94 0.59 – 0.94 0.79 – 0.94 0.59 – 0.94
port pressure {8.0 – 9.5} {6.0 – 9.5} {8.0 – 9.5} {6.0 – 9.5}
Torque converter outlet 0.59 ± 0.10 0.59 ± 0.10 0.59 ± 0.10 0.59 ± 0.10
port pressure {6.0 ± 1.0} {6.0 ± 1.0} {6.0 ± 1.0} {6.0 ± 1.0}
Lubrication valve 0.14 ± 0.06 0.14 ± 0.06 0.14 ± 0.06 0.14 ± 0.06
pressure {1.4 ± 0.6} {1.4 ± 0.6} {1.4 ± 0.6} {1.4 ± 0.6}
Reducing valve pressure 1.96 ± 0.10 1.96 ± 0.10 1.96 ± 0.10 1.96 ± 0.10
(for F3, R3) {20 ± 1.0} {20 ± 1.0} {20 ± 1.0} {20 ± 1.0}
• Hydraulic oil temperature:
+0.97 +0.97 +0.49 +0.97
Within operating range 31.36 –0.78 31.36 –0.78 31.36 –0.39 31.36 –0.78
Steering relief pressure
• Engine full +10 +10 +5.0 +10
{320 –8.0} {320 –8.0 } {320 –4.0} {320 –8.0 }
• Steering is relieved.
• Hydraulic oil temperature: 45 –
55°C
Steering
MPa 2.45 ± 0.1 2.45 ± 0.2 2.45 ± 0.1 2.45 ± 0.2

AJSS EPC pressure • Engine speed: High idle (P-mode)
{kg/cm2} {25 ± 1} {25 ± 2} {25 ± 1} {25 ± 2}
• Operating AJSS fully
• Frame lock bar: Lock position
Emergency steering relief Within operating range 20.58 ± 0.49 20.58 ± 0.98 20.58 ± 0.49 20.58 ± 0.98
pressure • Engine started {210 ± 5.0} {210 ± 10} {210 ± 5.0} {210 ± 10}
• Machine speed: 24 km/h
WA800-3E0, WA900-3E0 5

Standard Standard
Category

new value new value
machine machine
• Brake oil pres-
+0.49 +0.98 +0.49 +0.98
• Engine speed: sure warning 5.88 –0 5.88 –0.49 5.88 –0 5.88 –0.49
Charge cut-in pressure
Accumulator
Low idle lamp: +5.0 +15 +5.0 +15

{60 –0 } {100 –5.0 } {60 –0 } {100 –5.0 }
• Hydraulic oil When goes out MPa
temperature: 2
• When oil pres- {kg/cm }
+0.98 +1.47 +0.98 +1.47
Within operat- sure turns from 9.8 –0 9.8 –0.49 9.8 –0 9.8 –0.49
Charge cut-out pressure ing range increasing to +10 +15 +10 +15
{100 –0 } {100 –5.0 } {100 –0 } {100 –5.0 }
decreasing
PPC valve source pres-
• Hydraulic oil temperature: Within +0.2 +0.2 +0.2 +0.2
sure 3.72 –0 3.72 –0.2 3.72 –0 3.72 –0.2
operating range
(Orbit-roll source pres- +2.0 +2.0 +2.0 +2.0
• Engine speed: High idle {38 –0 } {38 –2.0 } {38 –0 } {38 –2.0 }
sure)
Lift arm
MPa
PPC
RAISE, • Hydraulic oil temperature: Within {kg/cm2} 3.72 +0.2 +0.2 +0.2 +0.2
–0 3.72 –0 3.72 –0 3.72 –0
PPC valve FLOAT, operating range +2.0 +2.0 +2.0 +2.0
output pres- bucket • Engine speed: High idle {38 –0 } {38 –0 } {38 –0 } {38 –0 }
sure DUMP, TILT • Work equipment control lever: Full
Lift arm operating 2.54 ± 0.05 2.54 ± 0.05 2.54 ± 0.05 2.54 ± 0.05
LOWER {26 ± 0.5} {26 ± 0.5} {26 ± 0.5} {26 ± 0.5}
• Tire inflation pressure:
Specified pressure
• Flat, horizontal, straight, dry
paved road surface
• Speed when applying brake:
Performance 20 km/h, braking delay: m Max. 7.5 — Max. 7.5 —
Wheel brake
0.1 second
• Brake pedal operating effort:
Specified operating effort
(294 ± 29.4 N {30 ± 3 kg})
• Measure stopping distance.
• Engine stopped
• Compress by pump to 4.2 – 5.2
MPa Max. 0.49 Max. 0.49
Drop in brake pressure MPa {43 – 53 kg/cm2} — —
{kg/cm2} {Max. 5.0} {Max. 5.0}
• Measure drop in brake pressure
after 5 minutes
• Tire inflation pressure:
Specified pressure
• Flat dry paved road with 1/
Parking brake
Performance 5(11°20’) grade Stopped — Stopped —

• Machine at operating condition
—
a For measuring posture, see Fig. D
and E at end of this section
Pad thickness • Including back metal 31.7 12.7 31.7 12.7
Pad clearance • Total of each end 1.06 ± 0.18 Max. 2.1 1.06 ± 0.18 Max. 2.1
+0.98 +0.98 +0.98 +0.98
Lift arm relief 31.4 –1.27 31.4 –1.27 34.3 –1.27 34.3 –1.27
Oil pressure
pressure • High idle +10 +10 +10 +10

• Hydraulic oil temperature: Within MPa {320 –13 } {320 –13 } {350 –13 } {350 –13 }
operating range {kg/cm2} +0.98 +0.98 +0.98 +0.98
Work equipment
Bucket relief 31.4 –1.27 31.4 –1.27 34.3 –1.27 34.3 –1.27
• Relieve only measuring circuit
pressure +10 +10 +10 +10
{320 –13 } {320 –13 } {350 –13 } {350 –13 }
Clearance between
bucket positioner and 3–5 3–5 3–5 3–5
proximity switch • Hydraulic oil temperature: Within
mm
Clearance between boom operating range
kick-out and proximity 3–5 3–5 3–5 3–5
switch
6 WA800-3E0, WA900-3E0
Machine model WA800-3E0

Category
Standard value
Service limit
Item Measurement conditions Unit for new
value
machine
RAISE
• Hydraulic oil temperature: 10.4 ± 0.5 Max. 13.3
• High idle
Lift arm speed
• No load
LOWER a For measuring posture, see Fig F at end of
4.8 ± 0.5 Max. 6.4
this section
At full stroke
DUMP
2.5 ± 0.3 Max. 3.7

Work equipment speed
Work equipment
sec.
At full stroke

Bucket • Engine coolant temperature:
sec. 3.8 ± 0.3 Max. 4.9
speed Within operating range
• No load
a For measuring posture, see Fig
G at end of this section
TILT
When bucket horizontal
2.0 ± 0.3 Max. 2.9
Retraction of lift arm cyl- • Hydraulic oil temperature: 45 - 55°C

Work equipment
Max. 40 Max. 40
Hydraulic drift
inder rod • Stop engine, leave for 5 minutes, then mea-

sure for next 15 minutes.
mm
• Bucket empty, boom, bucket horizontal
Retraction of bucket cyl- a For measuring posture, see Fig. H at end of
this section Max. 20 Max. 20
inder rod
• Engine stopped
Play deg. Max. 8 Max. 10
• Machine facing straight to front
14.7 ± 2.0
Operating effort • Flat, level, straight, dry, and paved road N {kg} 24.5 {2.5}
{1.4 ± 0.5}
AJSS lever

Operating angle deg. 80 ± 5 Max. 89
• Left lock – right lock
• Engine started
Low idle Max. 6.6 Max. 7.6
• Hydraulic oil temperature: Within operating
Operating time range sec.
High idle • Left lock – right lock Max. 3.5 Max. 4.5
• Mode 2 (standard)
WA800-3E0, WA900-3E0 7
Standard value table for electrical system

AJSS (Advanced Joystick Steering System) specification
k When testing, make sure that there are no persons around the testing site.
Sys- Name of Connector Inspection Measurement
Judgement table
tem component No. method conditions
If the condition is as shown in the table below, it is normal.
Measure voltage
Between C1(7), (13) – chassis 1) Turn starting
switch OFF.
C1 Between C2(1), (12) – chassis
Power supply 20 – 30 V 2) Insert T-adapter.
C2 3) Turn starting
Between C1(7), (13) – (6), (12)
switch ON.
Between C2(1), (23) – (11), (21)
If the condition is as shown in the table below, it is normal. 1) Turn starting

Measure voltage
switch OFF.
Between (6) – (17)
Power supply 20 – 30 V 2) Insert T-adapter.
C3A Between (6) – chassis 3) Turn starting
(for signal)
switch ON.
4) Turn parking
brake switch ON
Measure
switch OFF.
voltage
Parking Between (6) – (17)

L01 20 – 30 V 2) Insert T-adapter.
brake switch
Between (6) – chassis 3) Turn starting
switch ON.
Transmission & Joystick steering controller

switch OFF.
resistance
Measure
Solenoid TR1 Between (2) – (6) 50 – 70 z

2) Disconnect
(1st) (male) Between (2), (6) – chassis Min. 1 Mz connectors.
3) Connect
T-adapter.
switch OFF.
resistance
Measure

2) Disconnect
(2nd) (male) Between (3), (6) – chassis Min. 1 Mz connectors.
3) Connect
T-adapter.
switch OFF.
resistance
Measure

2) Disconnect
(3rd) (male) Between (3), (6) – chassis Min. 1 Mz connectors.
3) Connect
T-adapter.
switch OFF.
resistance
Measure

2) Disconnect
(F) (male) Between (4), (6) – chassis Min. 1 Mz connectors.
3) Connect
T-adapter.
switch OFF.
resistance
Measure

2) Disconnect
(R) (male) Between (5), (6) – chassis Min. 1 Mz connectors.
3) Connect
T-adapter.
switch OFF.
resistance
Measure
Engine speed E03 Between (1) – (2) 500 – 1000 z

2) Disconnect
sensor (male) Between (1), (2) – chassis Min. 1 Mz connectors.
3) Connect
T-adapter.
8 WA800-3E0, WA900-3E0
Judgement table
Measure in AC range 1) Turn starting
Controller
Measure
voltage
Engine speed switch OFF.
C4 Between (2) – (9) Min. 0.5 V
sensor 2) Insert T-adapter.
3) Start engine.
1) Screw in the engine speed sensor until it contacts the
Adjust
Engine speed
— ring gear, then turn it back 1 turn. —
sensor
2) It works normally by adjustment above.
switch OFF.
resistance
BC01 Measure Between (1) – (2) 500 – 1000 z
2) Disconnect con-
Speed sensor
(male) Between (1), (2) – chassis Min. 1 Mz nectors.
3) Connect
T-adapter.
1) Screw in until the tip of sensor contacts gear, then turn

Adjust
Speed sensor — back 3/4 – 1 turn. —

2) Sensor should work normally when adjusted as above.
System network If the condition is as shown in the table below, it is normal.
(S-NET) 1) Turn starting
Controller
Between (4), (12) – chassis 4–8V

Measure
switch OFF.
voltage
(Between
C3B 2) Insert T-adapter.
transmission 3) Turn starting
controller and switch ON.
main monitor)
switch OFF.
resistance
Measure
Kick-down switch Kick-down switch at ON Between Max. 1 z 2) Disconnect

and shift-down (1) – (2)
Kick-down switch at ON Min. 1 Mz connectors.
switch 3) Connect
L15 T-adapter.
(male) If the condition is as shown in the table below, it is normal. 1) Turn starting
switch OFF.
resistance
Measure
Shift-up switch at ON Between Max. 1 z

2) Disconnect
Shift-up switch (3) – (4)
Shift-up switch at OFF Min. 1 Mz connectors.
3) Connect
T-adapter.
1) Turn starting
Measure
Cut-off switch at OFF Between 17 – 30 V switch OFF.

voltage
Transmission
C5 (6) – 2) Insert T-adapter.
cut-off switch Cut-off switch at ON Max. 1 V
chassis 3) Turn starting
switch ON.
WA800-3E0, WA900-3E0 9
Judgement table
1) Turn starting
Measure
Manual switch at ON Between Max. 1 V switch OFF.
voltage
Manual
C5 (14) – 2) Insert T-adapter.
switch Manual switch at OFF 20 – 30 V 3) Turn starting
chassis
switch ON.
Normal ranges are as follows.

When joystick FNR switch is 1) Turn starting
17 – 30 V
Measure
Joystick voltage
in “F” Between switch OFF.
FNR switch (5) – 2) Insert T-adapter.
“F” When joystick FNR switch is chassis 3) Turn starting
Max. 1 V
not in “F” switch ON.

17 – 30 V
Measure
Joystick Between switch OFF.

voltage
in “N”

“N” When joystick FNR switch is chassis 3) Turn starting
Max. 1 V
not in “N” switch ON.

Controller

Measure
Joystick Between 17 – 30 V switch OFF.

voltage
in “R”
“R” When joystick FNR switch is chassis 3) Turn starting
Max. 1 V switch ON.
not in “R”
C3B
Normal ranges are as follows. 1) Turn starting

Measure
Between switch OFF.

voltage
Neutralizer Parking brake released 17 – 30 V

(14) – 2) Insert T-adapter.
relay signal 3) Turn starting
Parking brake applied chassis Max. 1 V
switch ON.

When joystick shift-up 1) Turn starting
Measure
Joystick shift- Between 17 – 30 V switch OFF.

voltage
switch is “ON”
up switch (7) – 2) Insert T-adapter.
(N.O) When joystick shift-up chassis 3) Turn starting
Max. 1 V switch ON.
switch is “OFF”

When joystick shift-down 1) Turn starting
Measure

voltage
switch is “ON”
down switch (8) – 2) Insert T-adapter.
(N.O) When joystick shift-down chassis 3) Turn starting
Max. 1 V switch ON.
switch is “OFF”
10 WA800-3E0, WA900-3E0
Judgement table
When joystick shift-up 1) Turn starting
Measure
voltage
switch is “ON”
up switch (15) – 2) Insert T-adapter.
(N.C) When joystick shift-up chassis 3) Turn starting
Max. 1 V switch ON.
switch is “OFF”

When joystick shift-down 1) Turn starting
Joystick shift- Measure Between 17 – 30 V switch OFF.
voltage
switch is “ON”
down switch C3B (16) – 2) Insert T-adapter.
(N.C) When joystick shift-down chassis 3) Turn starting
Max. 1 V switch ON.
switch is “OFF”

When steering lock lever is 1) Turn starting
Measure
Between 17 – 30 V switch OFF.

voltage
Steering in “LOCK”
lock signal When steering lock lever is 3) Turn starting
chassis Max. 1 V
in “FREE” switch ON.
Controller

When steering angle is switch OFF.
Measure
3.5 – 4.5 V 2) Insert T-adapter.

voltage
Steering lever RIGHT. Between 3) Start engine.

angle sensor (3) – (16)
When steering angle is 4) Move joystick to
0.5 – 1.5 V
LEFT. left or right stoke
end.
C3A
switch OFF.
When frame angle is
Measure
0.5 – 1.5 V 2) Insert T-adapter.

voltage
Frame angle RIGHT. Between

3) Start engine.
sensor (13) – (16)
When frame angle is LEFT. 3.5 – 4.5 V 4) Move joystick to
left or right stoke
end.
1) Turn starting
When joystick steering lever switch OFF.
Measure
Joystick lever Between Max. 1 V

voltage
is in neutral 2) Insert T-adapter.

neutral inter- C2 (8) – 3) Turn starting
lock relay When joystick steering lever chassis 17 – 30 V switch ON.
is not in neutral
WA800-3E0, WA900-3E0 11
Judgement table
1) Turn starting
When steering lever angle is switch OFF.
3.5 – 4.5 V
Measure
2) Insert T-adapter.
voltage
RIGHT. Between
3) Start engine.
When steering lever angle is (1) – (3) 4) Move joystick to
0.5 – 1.5 V
LEFT. left or right stoke
Steering lever end.
JS2
angle sensor
switch OFF.
resistance
Measure
Between (1) – (2) 0 – 5 kz

2) Disconnect
Between (3), (2) – chassis 4 – 5 kz connector.
3) Connect
T-adapter.
switch OFF.
When frame angle is RIGHT. Between 0.5 – 1.5 V
Measure
2) Insert T-adapter.
voltage
When frame angle is LEFT. (1) – (3) 3.5 – 4.5 V 3) Start engine.
4) Move joystick to
left or right stoke
Frame angle end.
L27
sensor
switch OFF.
resistance
Measure
Between (1) – (2) 0 – 5 kz

2) Disconnect con-
Between (3), (2) – chassis 4 – 5 kz nector.
3) Connect
T-adapter.
switch OFF.
Measure
Left brake released 0.9 – 1.1 V

voltage
Left brake 2) Connect

C3A
pressure sensor Left brake being pressed 1.1 – 5.1 V T-adapter.
3) Turn starting
switch ON.
switch OFF.
Measure
Cut-off switch at OFF 17 – 30 V

voltage
Cut-off position 2) Connect

C5
set switch Cut-off switch at ON Max. 1 V T-adapter.
3) Turn starting
switch ON.
Pre-lubrication controller
Engine: Stopped Between Max. 1 z 1) Turn starting

(E02) and switch OFF.
resistance
Measure
Engine oil pres- machine 2) Connect

E02 Engine started Min. 1 Mz
sure switch body T-adapter.
3) Turn starting
switch ON.
12 WA800-3E0, WA900-3E0
Judgement table
Measure
switch OFF.
voltage
Between (1), (2) – chassis
Power supply L05 20 – 30 V 2) Insert T-adapter.
Between (3), (2) – chassis 3) Turn starting
switch ON.

Engine running
28 ± 2 V
Measure
Between 1) Turn starting
voltage
Charge (At above 1/2 throttle)
L05 (5) – (3) switch OFF.
(Alternator) Starting switch ON Max 1 V 2) Insert T-adapter.
* If the battery is old, or after starting in cold areas, the
voltage may not rise for some time.
Measure
switch OFF.
voltage
Directional Directional lever at N Between 20 – 30 V

L05 2) Insert T-adapter.
switch (N) Directional lever not at N (8) – (3) Max 1 V 3) Turn starting
switch ON.
Measure
Starting switch START Between 20 – 30 V 1) Turn starting

voltage
Starting switch L09

(3) – switch OFF.
C terminal (male) Starting switch OFF or ON Max 1 V 2) Insert T-adapter.
Chassis

Main monitor
Measure
1) Turn starting
voltage
Starting switch C Start engine Between 20 – 30 V

switch OFF.
terminal Starting switch OFF or ON (4) – (3) Max. 1 V 2) Insert T-adapter.

L05
*20 – 30 V
Starting switch ON Between o1V
Measure
1) Turn starting
voltage
Preheating switch (19) – (3)

Starting switch OFF Max. 1 V switch OFF.
ON 2) Insert T-adapter.
* Voltage changes only when water temperature is below
0°C, and time taken to change differs according to water
temperature.
Measure
Starting switch ON Between 20 – 30 V 1) Turn starting

voltage
Starting switch BR L09

(2) – switch OFF.
terminal (male) Starting switch OFF Max. 1 V
chassis 2) Insert T-adapter.

Measure
1) Turn starting
voltage
Starting switch BR Starting switch ON Between 20 – 30 V

L07 switch OFF.
terminal Starting switch OFF (10) – (12) Max. 1 V 2) Insert T-adapter.

switch OFF.
resistance
Measure
Parking brake F12 Parking brake switch ON Between Max. 1 z

2) Disconnect con-
indicator switch (male) Parking brake switch OFF (10) – (12) Min. 1 Mz nectors.
3) Connect
T-adapter.
WA800-3E0, WA900-3E0 13
Judgement table
1) Turn starting
Measure
Directional lever at F Between 20 – 30 V switch OFF.
voltage
Directional switch
(F) Directional lever not at F Max. 1 V 3) Turn starting
chassis
switch ON.
L08
Measure 1) Turn starting
voltage Directional lever at R Between 20 – 30 V switch OFF.
Directional switch
(R) Directional lever not at R Max. 1 V
chassis 3) Turn starting
switch ON.

switch OFF.
Measure
Between (1), (2) – chassis

voltage
20 – 30 V 2) Disconnect con-
Power supply L18
Between (1), (2) – (3) nectors.
3) Connect
T-adapter.
1) Turn starting
Approx. switch OFF.
resistance
Normal temperature (25°C)

Measure
Engine coolant E04 Between 40 kz 2) Disconnect con-

temperature sensor (male) (1) – (2) Approx. nectors.
130°C 3) Connect
1.7 kz
T-adapter.

1) Turn starting
Main monitor
Approx. switch OFF.

resistance
Normal temperature (25°C)

Measure
Torque converter 40 kz
T02 Between 2) Disconnect con-
oil temperature
(male) (1) – (2) Approx. nectors.
sensor 130°C 3) Connect
1.7 kz
T-adapter.

switch OFF.
a See Fig. J at end of this section Approx.
2) Disconnect con-
resistance
Float raised to stopper 4z

Measure
nectors.
R08
Fuel level sensor a See Fig. K at end of this section Approx. 3) Drain fuel.
(male) 4) Remove fuel
Float lowered to stopper 85 z
level sensor.
5) Connect
T-adapter.
switch OFF.
resistance
Measure
Radiator coolant G06 Coolant level normal Between Max. 1 z

2) Disconnect con-
level sensor (male) Coolant level low (1) – (2) Min. 1 Mz nectors.
3) Connect T-
adapter.
Engine oil pressure when
engine running:
Min. 1 Mz
above 0.07 MPa 1) Turn starting
resistance
Measure
{0.7 kg/cm2} switch OFF.

Engine oil Between
E09 2) Disconnect ter-
pressure sensor Engine oil pressure when (1) – (2) minal.
starting switch ON: 3) Start engine.
Max. 1 z
above 0.03 MPa
{0.3 kg/cm2}
14 WA800-3E0, WA900-3E0
Judgement table
BC04 Accumulator pressure:
(male) Min. 5.39 ± 0.49 MPa Min. 1 Mz 1) Turn starting
BC05 switch OFF.
resistance
{55 ± 5 kg/cm2}
Measure
Brake accumulator
(male) Between 2) Disconnect con-
low pressure Depress brake and lower
BC06 (1) – (2) nectors.
switch accumulator pressure to 3) Connect
(male) Max. 1 z
BC07 below 4.41 ± 0.49 MPa T-adapter.
(male) {45 ± 5 kg/cm2}

Engine running 1) Turn starting
Measure
Voltage
Charge Between 28 ± 2 V switch OFF.

L18 (above half throttle)
(Alternator) (12) – (3) 2) Insert T-adapter.
Starting switch ON Max. 1 V 3) Start engine.

1) Turn starting
resistance
Measure
Engine oil level normal Between Max. 1 z

Engine oil level E05 switch OFF.
(1) –
sensor (male) 2) Disconnect ter-
Engine oil level abnormal chassis Min. 1 Mz
minal.
B08
R.H.
1) Turn starting
Main monitor
continuity
(male) Air cleaner normal 20 – 30 V

Check
Between switch OFF.

Dust indicator
Air cleaner clogged (1) – (2) Max. 5 V 2) Insert T-adapter.
B06
L.H.
3) Start engine.
(male)
If the condition is as shown in the table below, monitor panel is normal.
Table 1 (CHECK lamp & CAUTION lamp)
Connector Monitor item Sensor

Measurement Display
No. (input connector) signal input
Engine coolant level Engine stopped Flashing 15 – 20 V

((8) – (3)) Starting switch ON Lighted off Max. 1 V
Engine oil level Engine stopped Flashing 15 – 20 V

((13) – (3)) Starting switch ON Lighted off Max. 1 V
CHECK lamp
Engine oil pressure Flashing 15 – 20 V 1) Connect
and Engine start
((10) – (3)) Lighted off Max. 1 V
T-adapter.
CAUTION lamp
Brake oil pressure Flashing 15 – 20 V
L18 (male) Engine start
Transmission oil filter Flashing 15 – 20 V

Engine start
Battery charge Flashing Max. 10 V

Engine start
((12) – (3)) Lighted off Min. 12 V
Air cleaner Flashing 15 – 20 V

Engine start
((14), (15) – (3)) Lighted off Max. 1 V
WA800-3E0, WA900-3E0 15
Judgement table
Table 2 (Gauge)
Display level resistance
Gauge display position (monitor panel input
resistance)
Starting switch ON Starting switch OFF
Fuel level Min. Green 6 0 - 15.7
Green 1
Green 2
Green 3
Green 4
Green 5
Green 6
gauge Green 5 12.6 - 24.0
Red Green 4 20.5 - 30.6
L18 (male)
Green 3 26.7 - 39.6
Measure Green 2 35.2 - 51.6
resistance E F
Max. Green 1 46.5 - 80.6
between (6) – Red Green (kz) Red 73.8 -
(3) Flash
i-ng ON
1) Turn starting
67 102 130°C switch OFF, then
Min. Red 2 0.24 - 3.47
Engine cool- insert dummy
Red 1 3.13 - 3.75
ant tempera- resistance or
Green 1
Green 2
Green 3
Green 4
Green 4 3.39 - 4.26

Gauge measure resis-
Red 1
Red 2
White
ture gauge Green 3 3.85 - 5.14

tance of sensor.
L18 (male) Green 2 4.65 - 6.94
Main monitor
2) Turn starting
Measure Max. Green 1 6.27 - 10.26
switch ON and
resistance E F (kz) White 9.19 -
check display.
between (4) – White Green Red
(3) ON Flashing
(1 place) (1 place)
Torque con- 50 120 130°C Min. Red 2 0.24 - 1.90

verter oil tem- Red 1 1.68 - 2.40
Green 1
Green 2
Green 3
Green 4
Green 5
perature Green 5 2.15 - 3.05

Red 1
Red 2
gauge L18 Green 4 2.74 - 5.14

Green 3 4.65 - 9.39
(male)
Max. Green 2 8.43 - 18.18
Measure E F (kz) Green 1 15.88 -
resistance
White Green Red
between (4) –
ON Flashing
(3) (1 place) (1 place)

1) Turn starting
Transmission oil filter switch OFF.
resistance
Max. 1 z
Measure
Transmission oil BC02 (male) normal Between 2) Disconnect con-

filter sensor BC02 (male) (1) – (2) nectors.
Transmission oil filter
Min. 1 Mz 3) Connect
clogged T-adapter.
16 WA800-3E0, WA900-3E0
Judgement table
BC08 Accumulator pressure: Between
Measure resistance
(male) Min. 3.92 ± 0.49 MPa BC08 Min. 1 Mz
1) Turn starting
BC09 {40 ± 5 kg/cm2} (1) – (2),
switch OFF.
Emergency brake (male) BC09 2) Disconnect con-
switch BC10 Depress brake and lower (1) – (2), nectors.
(male) accumulator pressure to BC10 3) Connect
(1) – (2), Max. 1 z T-adapter.
BC11 below 3.63 ± 0.49 MPa
(male) {37 ± 5 kg/cm2} BC11
(1) – (2)

Accumulator pressure:
Measure voltage
Min. 3.92 ± 0.49 MPa {40 ± 20 – 30 V 1) Turn starting

5 kg/cm2} switch OFF.
Emergency brake Between
CBL1 2) Insert T-adapter.
switch Depress brake and lower (3) – (4) 3) Turn starting
accumulator pressure to switch ON.
Max. 1 V
below 3.63 ± 0.49 MPa
{37 ± 5 kg/cm2}

Main monitor
Between (1) – (3) 20 – 30 V

1) Turn starting
Measure
switch OFF.
voltage
Bucket positioner Between

F05 Bucket fully dumped Max. 1 V 2) Insert T-adapter.
proximity switch (2) – (3)
3) Turn starting
Between switch ON.
Bucket fully tilted 20 – 30 V
(2) – (3)

Between (1) – (3) 20 – 30 V
1) Turn starting
Measure
switch OFF.
voltage
Lift arm kick-out Between

F06 Bucket fully dumped Max. 1 V 2) Insert T-adapter.
proximity switch (2) – (3)
3) Turn starting
Between switch ON.
Bucket fully tilted 20 – 30 V
(2) – (3)

switch OFF.
resistance
Measure
Lift arm kick-out Between (1) – (2) 19 – 23 z

2) Disconnect con-
L16
solenoid Between (1), (2) – chassis Min. 1 Mz nectors.
3) Connect
T-adapter.
switch OFF.
resistance
Measure
Bucket positioner Between (1) – (2) 19 – 23 z

2) Disconnect con-
L17
solenoid Between (1), (2) – chassis Min. 1 Mz nectors.
3) Connect
T-adapter.
WA800-3E0, WA900-3E0 17
Judgement table
Constant Between B – C 4.85 – 5.15 V 1) Starting switch
Measure voltage
OFF
Constant Between C – A 0.50 – 4.50 V 2) T-adapter
Steering pressure
V26 When steering is at neutral inserted
sensor Between C – A 0.50 – 0.90 V
position 3) Starting switch
ON
When steering is relieved Between C – A 4) Engine started

Measure voltage
OFF
Brake pressure
V23 When brake pressure not inserted
sensor Between C – A 0.50 – 0.90 V 3) Starting switch
present
ON
Between C – A 4) Engine started

Measure voltage
OFF
Front brake pres-
V22 When brake pressure not inserted
sure sensor Between C – A 0.50 – 0.90 V 3) Starting switch
present
ON
Between C – A 4) Engine started
1) Starting switch
Measure voltage
Constant Between B – C 4.85 – 5.15 V OFF

Main pump
V27 inserted
pressure sensor When engine is stopped Between C – A 0.50 – 0.90 V 3) Starting switch
VHMS
Between C – A ON
4) Engine started
1) Starting switch
Measure voltage

Transmission Constant Between C – A 0.50 – 4.50 V 2) T-adapter
pressure V28 inserted
sensor When engine is stopped Between C – A 0.50 – 0.90 V 3) Starting switch
Between C – A ON
4) Engine started
1) Starting switch
Measure voltage

Blow-by pressure
V32 inserted
sensor Between C – A 0.50 – 0.90 V 3) Starting switch
Between C – A ON
4) Engine started
1) Starting switch
Measure voltage
50 – 100°C Between 1 – 2 1.0 – 3.5 mV OFF

Exhaust gas tem- 300 – 400°C Between 1 – 2 11.2 – 15.6 mV 2) Connector
perature sensor V39 disconnected
(Front right) 500 – 600°C Between 1 – 2 19.7 – 24.2 mV 3) T-adapter
700 – 800°C Between 1 – 2 28.1 – 32.6 mV connected
1) Starting switch
Measure voltage
50 – 100°C Between 1 – 2 1.0 – 3.5 mV OFF

(Front left) 500 – 600°C Between 1 – 2 19.7 – 24.2 mV 3) T-adapter
18 WA800-3E0, WA900-3E0
Judgement table
1) Starting switch
Measure voltage
50 – 100°C Between 1 – 2 1.0 – 3.5 mV OFF
(Rear right) 500 – 600°C Between 1 – 2 19.7 – 24.2 mV 3) T-adapter
1) Starting switch
Measure voltage
50 – 100°C Between 1 – 2 1.0 – 3.5 mV OFF
Exhaust gas tem- 300 – 400°C Between 1 – 2 11.2 – 15.6 mV 2) T-adapter con-
perature sensor V45 nected
(Rear left) 500 – 600°C Between 1 – 2 19.7 – 24.2 mV 3) Starting switch
700 – 800°C Between 1 – 2 28.1 – 32.6 mV ON
Constant Between A – C 20 – 30 V 1) Starting switch

Measure voltage
Exhaust gas tem- OFF

50 – 100°C Between B – C 1.0 – 1.6 V
2) T-adapter con-
perature sensor
V35 300 – 400°C Between B – C 2.1 – 2.7 V nected
amplifier (Front 3) Starting switch
right) 500 – 600°C Between B – C 2.9 – 3.6 V ON
700 – 800°C Between B – C 3.8 – 4.4 V
Constant Between A – C 20 – 30 V
Measure voltage
1) Starting switch
Exhaust gas tem- 50 – 100°C Between B – C 1.0 – 1.6 V OFF
perature sensor 2) T-adapter con-
V34 300 – 400°C Between B – C 2.1 – 2.7 V
amplifier nected
(Front left) 500 – 600°C Between B – C 2.9 – 3.6 V 3) Starting switch
VHMS
ON
700 – 800°C Between B – C 3.8 – 4.4 V
Measure voltage
1) Starting switch
V42 300 – 400°C Between B – C 2.1 – 2.7 V
amplifier nected
(Rear right) 500 – 600°C Between B – C 2.9 – 3.6 V 3) Starting switch
ON
700 – 800°C Between B – C 3.8 – 4.4 V
Measure voltage
1) Starting switch
V41 300 – 400°C Between B – C 2.1 – 2.7 V
amplifier nected
(Rear left) 500 – 600°C Between B – C 2.9 – 3.6 V 3) Starting switch
ON
700 – 800°C Between B – C 3.8 – 4.4 V
1) Starting switch
Measure resis- Measure resis-
Normal temperature OFF

Hydraulic oil tem- Between 1 – 2 35 – 50 kz
tance
(approx. 25°C) 2) Connector

V24
perature sensor disconnected
Approx. 100°C Between 1 – 2 3.1 – 4.5 kz 3) T-adapter
connected
1) Starting switch
Normal temperature OFF
Brake oil tempera- Between 1 – 2 35 – 50 kz
tance
(approx. 25°C) 2) Connector

F25
ture sensor disconnected
Approx. 100°C Between 1 – 2 3.1 – 4.5 kz 3) T-adapter
connected
WA800-3E0, WA900-3E0 19
Judgement table
Normal temperature 1) Starting switch

Between A – B 4.7 – 3.6 kz OFF
resistance
Measure
(approx. 25°C)
Atmospheric tem- 2) Connector
V20
perature sensor Approx. 0°C Between A – B 13.4 – 10.2 kz disconnected
3) T-adapter
Approx. 40°C Between A – B 2.6 – 2.1 kz connected
Constant Between A – C 4.85 – 5.15 V

1) Starting switch
Constant Between B – A 0.70 – 4.50 V OFF
Measure
voltage
Lift arm angle When lift arm cylinder is 2) Connector

FB4 Between B – A 4.00 – 4.50 V
sensor extended to maximum disconnected
3) T-adapter
When lift arm cylinder is most connected
Between B – A 0.70 – 1.30 V
contracted
1) Starting switch
Between 1 – 2 15 – 25 z OFF
resistance
Measure
2) Connector
Dumping solenoid FB5 Between 1 – 2 Min. 1 Mz
disconnected
VHMS
3) T-adapter
connected
1) Starting switch
When lift arm is raised Between 1 – 2 Min. 1 Mz OFF
resistance
Measure
Lift arm raising 2) Connector

FB1 Other than above Between 1 – 2 Max. 1 z
pressure switch disconnected
3) T-adapter
connected
1) Starting switch
When lift arm is raised Between 1 – 2 Min. 1 Mz OFF
resistance
Measure
Lift arm raising 2) Connector

FB2 Other than above Between 1 – 2 Max. 1 z
pressure switch disconnected
3) T-adapter
connected
When lift arm raising detent 1) Starting switch

Between 1 – 2 Min. 1 Mz
operation is turned on OFF
resistance
Measure
Lift arm detent 2) Connector

FB3 When lift arm lowering detent
pressure switch Between 1 – 2 Min. 1 Mz disconnected
operation is turned on 3) T-adapter
Other than above Between 1 – 2 Max. 1 z connected
1) Starting switch
Constant Between 1 – 3 4.75 – 5.25 V OFF
Measure
voltage
Accelerator pedal 2) T-adapter

Pedal at low idle Between 1 – 3 0.50 – 0.80 V
sensor connected
Pedal at full throttle Between 1 – 3 3.70 – 4.00 V 3) Starting switch
ON
Others
Pedal at low idle Between 4 – 5 Max. 0.50 V

1) Starting switch
Pedal at low idle Between 4 – 6 5.75 – 6.25 V OFF
Measure
voltage
Accelerator pedal 2) T-adapter

Pedal at full throttle Between 4 – 5 5.75 – 6.25 V
IVS switch connected
Pedal at full throttle Between 4 – 6 Max. 0.50 V 3) Starting switch
ON
Constant Between 1 – 2 5.75 – 6.25 V
20 WA800-3E0, WA900-3E0
Machine posture and procedure for performance measurement
a Fig. A a Fig. D
a Fig. B a Fig. E
a Fig. C a Fig. F
WA800-3E0, WA900-3E0 21
a Fig. G a Fig. K
a Fig. H
a Fig. J
22 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 23
SEN02154-02

© 2017 KOMATSU
All Rights Reserved
24
SEN02155-04
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Measuring engine speed................................................................................................................................. 8
Measuring intake air (boost) pressure .......................................................................................................... 10
Measuring exhaust gas color .........................................................................................................................11
Measuring exhaust temperature ................................................................................................................... 12
Adjusting valve clearance ............................................................................................................................. 14
Measuring compression pressure................................................................................................................. 15
Measuring blow-by pressure......................................................................................................................... 17
Measuring engine oil pressure...................................................................................................................... 19
Handling fuel system equipment................................................................................................................... 20
Releasing residual pressure in fuel system .................................................................................................. 20
Testing fuel pressure..................................................................................................................................... 21
Measuring fuel return rate and leakage ........................................................................................................ 22
Bleeding air from fuel circuit.......................................................................................................................... 25
Testing leakage in fuel system ...................................................................................................................... 27
Handling reduced cylinder mode operation .................................................................................................. 28
WA800-3E0, WA900-3E0 1
SEN02155-04 30 Testing and adjusting
Handling no-injection cranking operation ...................................................................................................... 28

Handling controller voltage circuit ................................................................................................................. 29
Adjusting speed sensor................................................................................................................................. 29
Testing and adjusting alternator belt tension................................................................................................. 30
Testing and adjusting belt tension for air conditioner compressor ................................................................ 31
Testing and adjusting power train oil pressure .............................................................................................. 32
Procedure for operating emergency steering spool when transmission valve fails....................................... 37
2 WA800-3E0, WA900-3E0
Tools for testing, adjusting, and troubleshooting 1
Sym-
Testing/Adjusting item Part No. Part name Q'ty Remarks
bol
1 799-201-9001 Handy smoke checker 1 Bosch index: 0 – 9
Testing exhaust gas
A Commercially
color 2 Smoke meter 1
available
Measuring exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
temperature
Adjusting valve Commercially Intake: 0.35 mm
C Clearance gauge 1
clearance available Exhaust: 0.57 mm
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
Measuring compression
D 795-471-1330 Adapter 1
pressure 2 For 140E-3, 5
6261-71-6150 Gasket 1
1 799-201-1590 Gauge 1 0 – 10 kPa {0 – 1,000 mmH2O}
799-201-1504 Blow-by checker 2
Measuring blow-by
E 2 799-201-1450 • Adapter 2
pressure
3 799-201-1151 • Nozzle 2
4 799-201-1571 • Tube 1
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
Measuring engine oil 1 799-101-5160 • Nipple 1 PT1/8
F
pressure 790-301-1210 • Joint 1 14 × 1.5 (male) – PT1/8 (female)
or
Nipple 1 Size: 14 × 1.5 mm
799-101-5230
07002-11423 • O-ring 1
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
Measuring intake air 799-201-2202 Boost gauge kit 1 –101 – 200kPa {–760 – 1,500 mmHg}
G
pressure 799-401-2220 Hose 1 I-coupler type (if necessary)
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1 Pressure gauge: 60 MPa
{600 kg/cm2}
Measuring fuel pressure H
799-101-5160 • Nipple 1 PT1/8
2 Under setting Adapter 1 8 × 1.25 (male) – PT1/8 (female)
3 07002-10823 • O-ring 1
4 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 6151-51-8490 Spacer 1 φ14
2 6141-71-1710 Joint 1 φ10
Commercially
3 Hose 1 Inside diameter: Approx. 11 mm
available
Measuring pressure Commercially
4 Hose 1 Inside diameter: Approx. 17 mm
limiter leakage and J available
injector return rate Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
7 07376-70315 Plug 1 Size: 03
WA800-3E0, WA900-3E0 3
Sym-
bol
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
Measuring power train 1 Pressure gauge: 60 MPa
K 790-261-1204 Digital hydraulic tester 1
oil pressure {600 kg/cm2}
799-401-2320 Gauge 1
{10 kg/cm2}
2 799-101-5160 • Nipple 1 PT1/8
Measuring AJSS lever
L 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
operating effort
Pressure gauge:
Testing and adjusting 1 {25, 60, 400, 600 kg/cm2}
M
steering oil pressure Pressure gauge: 60 MPa
{600 kg/cm2}
2 799-101-5160 • Nipple 1 PT1/8
1 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
Measuring brake pedal N Commercially
2 Angle meter 1
available
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting
accumulator charge P Pressure gauge: 60 MPa
pressure {600 kg/cm2}
2 799-101-5160 • Nipple 1 PT1/8
3 799-401-3100 Adapter 1 Size: 02
1 793-605-1001 Brake tester kit 1
Measuring wheel brake
Q 2 790-101-1430 • Coupler 1
oil pressure
3 790-101-1102 Pump 1
Measuring wear of Commercially
R Slide calipers 1
wheel brake disc available
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Measuring parking
brake solenoid output S Pressure gauge: 60 MPa
pressure {600 kg/cm2}
2 799-101-5160 • Nipple 1 PT1/8
3 799-401-3300 Adapter 1 Size: 04
Commercially
1 Slide calipers 1
Measuring wear of available
T
parking brake pad Commercially
2 Thickness gauge 1
available
Pressure gauge:
U
PPC oil pressure Pressure gauge: 60 MPa
{600 kg/cm2}
2 799-101-5160 • Nipple 1 PT1/8
4 WA800-3E0, WA900-3E0
Sym-
bol
Pressure gauge:
work equipment oil V
pressure 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
2 799-101-5160 • Nipple 1 PT1/8
1 799-608-3101 Service kit 1
2 799-608-3211 • Diskette 1
3 799-608-3220 • Harness 1
Initialization of VHMS
W Commercially Note type personal com-
controller 4 1 OS: Windows 98/2000/Me/XP/Vista
available puter
Commercially RS232C-USB conversion
5 1
available cable
799-601-4100
or T-adapter assembly 1
799-601-4200
799-601-4130 • T-adapter 1 Ne sensor
799-601-4330 • Socket 1 For G (Bkup) sensor
799-601-4240 • Socket 1 For ambient pressure sensor
799-601-4250 • Socket 1 For boost pressure sensor
For common rail pressure sensor
799-601-9420 • T-adapter 1 (included in 799-601-9000 and 799-
601-9200, too)
799-601-4150 • T-adapter 1 For oil pressure sensor
799-601-9430 • Socket 1 For supply pump PCV
799-601-9020 • T-adapter 1 For injector
799-601-4260 • T-adapter 1 For controller (4-pole)
Troubleshooting for For controller (50-pole)
engine controller/ X 799-601-4211 • T-adapter 1
(Only 799-601-4100)
sensors/actuators
For controller (60-pole)
799-601-4220 • T-adapter 1
(Only 799-601-4100)
799-601-4350 • T-adapter 1 60-pole (Only 799-601-4100)
799-601-9000
or
799-601-9100 T-adapter assembly 1
or
799-601-9300
799-601-9320 • T-adapter 1 24-pole
799-601-9310 • Plate 1
For boost temperature sensor
795-799-5540 Socket 1
For intake air temperature
For coolant temperature sensor
795-799-5530 Socket 1 For fuel temperature sensor
For oil temperature sensor
WA800-3E0, WA900-3E0 5
Sym-
bol
799-601-2500
or
799-601-2700
or
799-601-2800
799-601-7100
or
799-601-7400
or
799-601-8000
For Econo
799-601-2600 • T-adapter box 1
(Does not include 799-601-2700)
For MIC-13P (Does not include 799-
799-601-2720 • MIC adapter 1
601-2800 and 799-601-7100)
799-601-2730 • MIC adapter 1 For MIC-17P
799-601-2740 • MIC adapter 1 For MIC-21P
799-601-4100
or
799-601-4200
799-601-9000
or
799-601-9200
799-601-4211 • DRC adapter 1 For DRC50 (Only 799-601-4100)
799-601-9020 • DT adapter 1 For DT2P
Troubleshooting for For DT3P (Does not include 799-
chassis sensors/wiring Y 799-601-9030 • DT adapter 1
601-4100 and 799-601-4200)
harnesses
799-601-9040 • DT adapter 1 For DT4P
For DT6P (Does not include 799-
799-601-9050 • DT adapter 1
601-4100 and 799-601-4200)
799-601-9060 • DT adapter 1
601-4100 and 799-601-4200)
799-601-9110 • DT adapter 1
601-4100 and 799-601-4200)
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
For X1P (Does not include 799-601-
799-601-7010 • X adapter 1
7000 and 799-601-7100)
799-601-7020 • X adapter 1 For X2P
799-601-7030 • X adapter 1 For X3P
For SW6P
799-601-7050 • SWP adapter 1
For SW8P
799-601-7060 • SWP adapter 1
799-601-7090 • M adapter 1 For M2P
799-601-7120 • M adapter 1 For M4P
799-601-7130 • M adapter 1 For M6P
6 WA800-3E0, WA900-3E0
Sym-
bol
799-601-7140 • S adapter 1 For S8P
799-601-7150 • S adapter (White) 1 For S10P
For S12P
799-601-7160 • S adapter (Blue) 1
799-601-7180 • AMP040 adapter 1 For A8P (Only 799-601-7400)
For A12P (Does not include 799-
799-601-7190 • AMP040 adapter 1
601-7000 and 799-601-7100)
799-601-7210 • AMP040 adapter 1 For A16P
799-601-7220 • AMP040 adapter 1 For A20P
Troubleshooting for 799-601-7360 Relay adapter 1 For REL-5P
chassis sensors/wiring Y 799-601-7370 Relay adapter 1 For REL-6P
harnesses
799-601-7510 • 070 adapter 1 For 07-10P
799-601-7520 • 070 adapter 1 For 07-12P
799-601-7530 • 070 adapter 1 For 07-14P
799-601-7540 • 070 adapter 1 For 07-18P
799-601-7550 • 070 adapter 1 For 07-20P
799-601-9350 • DRC adapter 1 For DRC-40
799-601-9360 • DRC adapter 1 For DRC-24
Measuring coolant
temperature and oil 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
pressure
—
Measuring operating 79A-264-0021 Push-pull scale 1
effort and pressing
force 79A-264-0091 Push-pull scale 1
Measuring stroke and Commercially
— Ruler 1
hydraulic drift available
Measuring work Commercially
— Stopwatch 1
equipment speed available
Measuring voltage and Commercially
— Circuit tester 1
resistance available
WA800-3E0, WA900-3E0 7
Measuring engine speed 1 2. Measuring torque converter stall speed
k
1) Referring to Troubleshooting, “Special func-
Lock the tires with chocks.
k
tion of main monitor”, select the real-time
When measuring, check that there are no monitoring function in the service mode.
persons around the machine. 2) Select and display “ENG SPEED” from the
a Measure the engine speed under the following monitoring items of the engine controller.
condition. a Monitoring item: ENG SPEED
q Engine coolant temperature: Within oper- Code No. 01002: ENG SPEED
ating range (Engine speed)
q Hydraulic oil temperature: Within operat-
ing range
q Torque converter oil temperature: Within
operating range
1. Measuring engine speed (low idle and high

idle)
1) Referring to Testing and adjusting, “Spe-
cial function of engine service monitor”,
select the real-time monitoring function in
the service mode.
2) Select and display “ENG SPEED” from the
monitoring items of the engine controller.
a Monitoring item: ENG SPEED
Code No. 01002: ENG SPEED
(Engine speed) 3) Start the engine.
4) Turn the transmission cut-off selector
switch OFF and press the left brake pedal
securely. (Check that the transmission cut-
off pilot lamp is turned OFF.)
5) Set the gear shift lever in the “F3” or “R3”
position.
6) Release the parking brake.
k Keep pressing the brake pedal securely.
7) Press the accelerator pedal gradually to

the high idle. While running the engine at
high idle, stall the torque converter and
measure the engine speed.
a Measure the stall speed 2 – 3 times.
3) Start the engine, set it in the measuring a Do not keep stalling the torque con-
condition, and measure the engine speed. verter for more than 20 seconds.
Take care that the torque converter oil
temperature will not exceed 120°C.
8 WA800-3E0, WA900-3E0
3. Measuring hydraulic stall speed 4. Measuring torque converter stall and

1) Referring to Testing and adjusting, “Special hydraulic stall (full stall) speed
function of engine maintenance monitor”, 1) Referring to Testing and adjusting, Part 3,
select the real-time monitoring function in “Special function of engine maintenance
the service mode. monitor”, select the real-time monitoring
2) Select and display “ENG SPEED” from the function in the service mode.
monitoring items of the engine controller. 2) Select and display “ENG SPEED” from the
a Monitoring item: ENG SPEED monitoring items of the engine controller.
Code No. 01002: ENG SPEED a Monitoring item: ENG SPEED
(Engine speed) Code No. 01002: ENG SPEED
(Engine speed)
3) Run the engine at high idle.

4) Relieve the lift arm cylinder or bucket cyl- 3) Start the engine.
inder on the extraction side and measure 4) Turn the transmission cut-off selector switch
the engine speed. OFF and press the left brake pedal securely.
(Check that the transmission cut-off pilot
lamp is turned OFF.)
5) Set the gear shift lever in the “F3” or
“R3”position.
k Keep pressing the brake pedal securely.
7) While running the engine at high idle, stall

the torque converter and relieve the lift arm
cylinder or bucket cylinder on the extraction
side and measure the engine speed.
a Do not keep stalling the torque con-
verter for more than 20 seconds.
Take care that the torque converter oil
temperature will not exceed 120°C.
WA800-3E0, WA900-3E0 9
Measuring intake air (boost) 3. Start the engine.

pressure 1
4. Press the left brake securely.
a Measuring tools for intake air (boost) pressure
Symbol Part No. Part name 5. Turn the transmission cut-off selector switch
OFF and press the left brake pedal securely.
799-201-2202 Boost gauge kit
G (Check that the transmission cut-off pilot lamp
790-401-2220 Hose is turned OFF.)
k When installing and removing the measur- 6. Operate the directional switch and transmis-
ing tools, take care not to touch a hot part sion auto/manual shift selector switch to select
of the engine. the manual shift and set the transmission in
a Measure the intake air pressure (boost pres- “F3” or “R3” with the gear shift up/down switch.
sure) under the following condition.
q Engine coolant temperature: Within oper- 7. Release the parking brake.
ating range While running the engine at high idle, stall the
q Hydraulic oil temperature: Within operat- torque converter and measure the engine speed.
ing range k Keep pressing the brake pedal securely.
operating range 8. Press the accelerator pedal gradually to the
high idle. While running the engine at high idle,
1. Remove the intake air pressure pickup plug stall the torque converter and measure the
((L1) on the left bank or (R1) on the right bank) intake air pressure.
at the air intake connector bottom. a Measure the stall speed 2 – 3 times.
a Do not keep stalling the torque converter
for more than 20 seconds. Take care that
the torque converter oil temperature will
not exceed 120°C.
2. Install nipple [1] of boost gauge kit G and con-

nect it to pressure gauge.
a Example of left bank (L1)
10 WA800-3E0, WA900-3E0
Measuring exhaust gas color 1

a Measuring instruments for exhaust gas color
Symbol Part No. Part name
1 799-201-9001 Handy smoke checker
A Commercially
2 Smoke meter
available
k When installing and removing the measuring

instruments, take care not to touch a hot part.
a If an air source and an electric power source
are not available in the field, use handy smoke
checker A1. When recording official data, use
smoke meter A2. 2) Connect the probe hose, receptacle of the
a Measure the exhaust gas color under the fol- accelerator switch, and air hose to smoke
lowing condition. meter A2.
q Engine coolant temperature: Within oper- a Keep the pressure of the supplied
ating range compressed air at 1.5 MPa {15 kg/
cm2} or below.
1. Measuring with handy smoke checker A1 3) Connect the power cable to a 100 V AC
1) Stick a sheet of filter paper to smoke receptacle.
checker A1. a Confirm that the smoke meter power
2) Insert the exhaust gas intake pipe in the switch is in the OFF position, before con-
muffler (exhaust pipe). necting the power cable to an outlet.
3) Start the engine and heighten the engine 4) Loosen the cap nut of the suction pump
coolant temperature to the operating range. and fit the filter paper.
4) Accelerate the engine suddenly or run it at a Fit the filter paper securely so that the
high idle and operate the handle of smoke exhaust gas will not leak.
checker A1 so that the filter paper will 5) Turn on the power switch of smoke meter A2.
absorb the exhaust gas.
5) Take out the filtering paper and compare it 6) Start the engine and keep it running until
with the attached scale for judgement. the engine coolant temperature rises to
6) Remove the measurement tool after the the operating range.
measurement, and make sure that the 7) Accelerate the engine suddenly or run it at
machine is back to normal condition. high idle and press the accelerator pedal
of smoke meter A2 and collect the
2. Measuring with smoke meter A2 exhaust gas into the filter paper.
1) Insert the probe of smoke meter A2 in the 8) Put the polluted filtering paper on non-pol-
outlet of the muffler (exhaust pipe) and fix luted filtering paper (more than 10 sheets)
it to the exhaust pipe with a clip. in the filtering paper holder, and read the
indicated value.
9) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
WA800-3E0, WA900-3E0 11
Measuring exhaust temperature 1 a If exhaust temperature sensors are installed

to the engine, connect thermometer [2] to
a Measuring tool for exhaust temperature one of those sensors.
B 799-101-1502 Digital thermometer
k Install and remove the measuring tool after

the exhaust manifold is cooled.
a Measure the exhaust temperature under the
following condition.
q Engine coolant temperature:
q Hydraulic oil temperature:
operating range
1. Remove 1 exhaust temperature pickup plug (1)

3. Procedure for measuring exhaust tempera-
from the measuring point on the exhaust mani-
ture periodically for preventive maintenance
fold.
a To prevent the torque converter from over-
a There are 4 measuring points at the left
heating, increase the exhaust temperature
front, left rear, right front and right rear.
temporarily by full-stall operation (torque
converter stall + hydraulic stall), and then
measure the exhaust temperature while
only the torque converter is stalled.
1) Start the engine.
2) Press the left brake securely.
3) Turn the transmission cut-off selector switch
OFF and press the left brake pedal securely.
(Check that the transmission cut-off pilot
lamp is turned OFF.)
4) Operate the directional switch and trans-
mission auto/manual shift selector switch
to select the manual shift and set the
transmission in “F3” or “R3” with the gear
shift up/down switch.
2. Install sensor [1] of digital thermometer B and
k
connect them to thermometer [2].
Keep pressing the brake pedal securely.
a Example of installation to right rear (RR)
6) Press the accelerator pedal gradually to the
high idle. While running the engine at high
idle, stall the torque converter and relieve
the lift arm cylinder or bucket cylinder on the
extraction side (Full stall operation).
Increase the exhaust temperature to about
650°C (to condition (a) in the figure).
Do not keep stalling the torque converter
not exceed 120°C.
12 WA800-3E0, WA900-3E0
7) As the exhaust temperature reached

about 650°C, release the hydraulic relief
and then decrease the exhaust tempera-
ture by stalling torque converter alone.
(the state of (b) in the figure)
a The exhaust temperature starts low-
ering from the level of the full-stall
operation. Measure the exhaust tem-
perature as it stabilized. (the state of
(c) in the figure)
a If the exhaust temperature rises in
stead of going down, set a higher full
stall temperature than the current one
(650°C).
4. Procedure for measuring the maximum

exhaust temperature
Operate the machine actually and measure the
maximum exhaust temperature.
a Use the PEAK mode of the thermometer
(in which the maximum value can be
saved).
a The exhaust temperature largely depends
on the outside air temperature (intake air
temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it
by the following calculation.
a Corrected value [°C] = Measured value +
2 × (20 – Outside air temperature)
5. Remove the measurement tool after the mea-

surement, and make sure that the machine is
back to normal condition.
WA800-3E0, WA900-3E0 13
Adjusting valve clearance 1 3. Loosen locknut (6) of adjustment screw (5) of

the right No. 1 cylinder and insert clearance
a Adjusting tool for valve clearance gauge C of the specified thickness between
Symbol Part No. Part name crosshead (4) and rocker arm (3) and adjust
the adjustment screw so that the thickness
Commercially
C Clearance gauge gauge will barely move.
available
a Valve clearance
Air intake valve: 0.35 mm,
Adjustment method for valve clearance Exhaust valve: 0.57 mm
1. Remove the cylinder head cover.
2. Rotate the crankshaft forward and bring the

right No. 1 cylinder to the compression top
dead center, while watching the movement of
the air intake valve of the right No. 6 cylinder,
and set stamped line of “R1.6TOP” on vibration
damper (1) to pointer (2).
a Use barring tool (B) installed to the right
front side of the flywheel housing to rotate
the crankshaft.
a The air intake valve of the right No. 6 cyl-
inder moves (is open) when the right No. 1
cylinder is around the compression top
dead center.
4. Tighten the locknut under this condition to fix
the adjustment screw.
3 Locknut:
52.9 – 64.7 Nm {5.4 – 6.6 kgm}
a After tightening the locknut, check the
valve clearance again.
5. Rotate the crankshaft to set the stamped line

of the damper to the pointer for the next cylin-
der and adjust the valve clearance. Then,
adjust the valve clearances of the other cylin-
ders similarly according to the firing order.
a Firing order
R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6 –
R2 – L2 – R4 – L4
6. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
14.7 – 34.3 Nm {1.5 – 3.5 kgm}
14 WA800-3E0, WA900-3E0
Measuring compression pressure1

a Measuring tools for compression pressure
1 795-502-1590 Compression gauge
D 795-471-1330 Adapter
2
6261-71-6150 Gasket
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold or muffler or get caught
in a rotating part.
a Measure the compression pressure after the
engine is warmed up.
(Engine oil temperature: 40 – 60°C) 4. Install adapter D2 to the mounting hole of the
injector and connect compression gauge D1.
1. Remove cylinder head cover (1) of the cylinder a Fit the gasket to the injector end without fail.
to measure the compression pressure. a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
a If a small amount of engine oil is applied to
the joint of the adapter and gauge, air
does not easily leak.
5. Install rocker arm assembly (2) and adjust the

valve clearance.
3 Rocker arm assembly mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
a See “Adjusting valve clearance”.
2. Set the cylinder to be measured to the com-

pression top dead center and remove rocker
arm assembly (2).
a See “Adjusting valve clearance”.
3. Disconnect fuel high-pressure tube (3) and

injector wiring harness and remove injector (4).
a Disconnect the terminal from the injector
and disconnect the bracket from the
rocker housing to remove the injector wir-
ing harness from the injector (Loosen the
2 terminal nuts alternately). 6. Referring to “Special function of engine mainte-
a Pass a wire under the fuel passage pro- nance monitor”, set the engine in the no-injec-
jected sideway and pull it up to remove the tion cranking operation.
injector (Do not pry up the injector top).
WA800-3E0, WA900-3E0 15
7. Rotate the engine with the starting motor and a Install the injector wiring harness accord-
measure the compression pressure. ing to the following procedure
a Read the pressure gauge pointer when it 1) Install the injector wiring harness to the
is stabilized. cylinder head and fix the connector side
with the plate. Install O-ring (16).
8. After finishing testing, remove the testing tools 2) Install cap (17) with clip on the injector
and return the removed parts. side of wiring harness.
a Install the injector and fuel high-pressure Press wiring harness (18) between the
tube according to the following procedure. injector top and cap to the injector main
1) Push in injector (11) with the hand to body without slack.
assemble holder (12) temporarily. 3) Tighten nut (19) on the injector side.
2) Tighten bolt (13) and washer (14) tempo- 3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
rarily.
2 Spherical part of washer: Engine oil
3) Tighten sleeve nut (15) of the fuel high-
pressure tube temporarily.
4) Tighten bolt (13) permanently.
3 Bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
5) Tighten sleeve nut (15) permanently.
3 Sleeve nut:
39.2 – 49.0 Nm {4 – 5 kgm}
4) Tighten the clamp and spacer with the bolt.

5) Install rocker arm assembly.
93 – 103 Nm {9.5 – 10.5 kgm}
a Adjust the valve clearance. For details, see
“Adjusting valve clearance”.
6) Install head cover.
3 Cylinder head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
16 WA800-3E0, WA900-3E0
Measuring blow-by pressure 1 3. Start the engine and increase the engine cool-
ant temperature to the operating range.
a Measuring tools for blow-by pressure
Symbol Part No. Part name 4. Press the left brake securely.
799-201-1590 Gauge
1 5. Turn the transmission cut-off selector switch
799-201-1504 Blow-by checker OFF and press the left brake pedal securely.
E 2 799-201-1450 • Adapter (Check that the transmission cut-off pilot lamp
3 799-201-1151 • Nozzle is turned OFF.)
4 799-201-1571 • Tube
6. Operate the directional switch and transmis-
a Measure the blow-by pressure under the fol- sion auto/manual shift selector switch to select
lowing condition. the manual shift and set the transmission in
q Engine coolant temperature: Within oper- “F3” or “R3” with the gear shift up/down switch.
ating range
q Hydraulic oil temperature: Within operat- 7. Release the parking brake.
ing range While running the engine at high idle, stall the
q Torque converter oil temperature: Within torque converter and measure the engine
operating range speed.
a
k
The right and left banks have their respective
Keep pressing the brake pedal securely.
breathers. Measure the blow-by pressure on
either bank.
8. Press the accelerator pedal gradually to the
high idle. While running the engine at high idle,
1. Install adapters [2] and nozzles [3] to the right
stall the torque converter and measure the
and left breathers respectively.
blow-by pressure.
a Do not keep stalling the torque converter
2. Connect tube [4] and gauge [1] to either noz-
zle. Stop the tube joint of the other nozzle with
a short tube etc.
not exceed 120°C.
a Normally, the blow-by pressure should be
measured while the engine is operated at
the rated output. In the field, however, an
approximate value can be obtained by
stalling the torque converter.
a If it is impossible to run the engine at the
rated output or stall the torque converter,
measure while the engine is running at
high idle. The value obtained in this case
is about 80% of the blow-by pressure at
the rated output.
a Precaution for measuring blow-by pressure
The blow-by pressure may vary largely
with the engine condition. If the measured
value is judged abnormal, check for
increase of oil consumption, bad exhaust
gas color, deterioration of oil, high deterio-
ration speed of oil, etc. which are related
to the abnormal blow-by pressure.
WA800-3E0, WA900-3E0 17
9. After finishing measurement, remove the mea-

suring tools and return the removed parts.
18 WA800-3E0, WA900-3E0
Measuring engine oil pressure 1 2. Install nipples [1] and [2] of hydraulic tester F1
and connect them to hydraulic tester F2.
a Measuring tools for engine oil pressure a Since the thread size of the sensor mount-
Symbol Part No. Part name ing part is 14 × P1.5, nipple (799-101-
5230) can be used.
799-101-5002 Hydraulic tester
799-261-1204 Digital hydraulic tester
799-101-5160 • Nipple
1
F 790-301-1210 • Joint
or 799-101-5230 Nipple
07002-11423 • O-ring
2 799-401-2320 Gauge
a Measure the engine oil pressure under the fol-

lowing condition.
q Engine coolant temperature: Within oper-
ating range
1. Remove oil temperature sensor (1) on the left

side of the cylinder block. Connect the connec- 3. Run the engine at rated output and low idle and
tors of the removed oil temperature sensor and measure the oil pressure in each operation.
wiring harness. a When measuring while the engine is
a If the oil pressure sensor is removed from mounted on the machine, measure under
the block, the engine controller detects the conditions written in the Shop manual
abnormally low oil pressure. Accordingly, for the machine.
do not remove it.

WA800-3E0, WA900-3E0 19
Handling fuel system equipment 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel system 1
fuel system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacement of fuel filter stopped.
cartridge a Before the fuel circuit is tested and its parts are
The fuel filter cartridge used must be a genuine removed, the residual pressure in the fuel cir-
Komatsu part. cuit must be released completely. Accordingly,
The fuel injection pump and nozzle of the com- observe the following.
mon rail type fuel injection system (CRI) are k Before testing the fuel system or removing
consisted of more precision parts than those its parts, wait at least 30 seconds after stop-
used for the current pumps and nozzles. This ping the engine until the residual pressure
system, therefore, employs a special filter with in the fuel circuit is released. (Do not start
highly efficient filtering performance to prevent the work just after stopping the engine
mixing of foreign substances. Thus, substitut- since there is residual pressure.)
ing it with a non-genuine filter could cause
troubles in the fuel system. It is strictly prohib-
ited to use such part.
20 WA800-3E0, WA900-3E0
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
799-101-5160 • Nipple {1.5 – 3 kg/cm2}
H
2 (Setting) Adapter
3 07002-10823 • O-ring 4. Since the fuel circuits on the LH and RH banks
after the priming pump are independent, test
4 799-401-2320 Gauge
each circuit.
a Test only the fuel pressure in the low-pressure
circuit from the feed pump through the engine 5. After finishing testing, remove the testing tools
controller cooler and fuel filter to the supply and return the removed parts.
pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Remove air bleeder plug (1) on the top of fuel

filter.
2. Install adapter H2 and connect to gauge H4.
WA800-3E0, WA900-3E0 21
Measuring fuel return rate and 3) Insert spacer J2 on common rail (1) side
leakage 1 and tighten the removed joint bolt again.
Be sure to fit the gaskets to both ends of
a Measuring tools for fuel return rate and leakage the spacer.
Symbol Part No. Part name 4) Connect test hose J3 to the end of joint
J2.
1 6151-51-8490 Spacer
a Bind the connecting part of the test
2 6141-71-1770 Joint hose with a wire etc. to prevent it from
Commercially coming off.
3 Hose a The above is the preparation work for
available
measuring the leakage from the pres-
Commercially
4 Hose sure limiter.
J available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
7 07376-70315 Plug
a Prepare an oil (receiving) pan of about 20 l to

receive the fuel flowing out during measurement.
1. Preparation work
1) Remove tube (3) between common rail (1)
and block (2).
2) Insert spacer J1 on block (2) side and
tighten the removed joint bolt again.
a Connect the return piping to the fuel
tank again.
a Be sure to fit the gaskets to both ends
of the spacer.
22 WA800-3E0, WA900-3E0
2. Measuring leakage from pressure limiter 3. Testing return rate from injector
1) Lay test hose J3 so that it will not slacken a Keep the hose on the pressure limiter side
and put its end in the oil pan. connected and keep its end in the oil pan
2) Referring to “Special functions of engine while measuring the return rate from the
maintenance monitor”, set the monitor so injector.
that it can check the engine speed with the 1) Disconnect return hose (2) of return block
real-time monitoring function. (1) and connect test hose J4.
3) Start the engine and keep its speed to a Stop the return hose with plug J7 etc.
1,600 rpm with no load. and fix it to the fuel tank.
4) After the engine speed is stabilized, mea- a Bind the connecting part of the test
sure the leakage in 1 minute with measur- hose with a wire etc. to prevent it from
ing cylinder J5. coming off.
a You may measure the leakage for 20 2) Lay test hose J4 so that it will not slacken
seconds and judge by multiplying the and put its end in the oil pan.
result by 3.
a If the leakage from the pressure limiter
is in the following range, it is normal.
Measurement condition Leakage (cc/min)
Stall or relief Max. 10
3) Referring to “Special functions of engine

maintenance monitor”, set the monitor so
that it can check the engine speed with the
real-time monitoring function.
5) After finishing measurement, stop the engine.
WA800-3E0, WA900-3E0 23
4) Run the engine at the rated output.

5) After the engine speed is stabilized, test
the return rate in 1 minute with measuring
cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injector
is in the following range, it is normal.
Rated output speed Limit of return rate (spill)
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
6) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
5. Check the RH bank following the identical pro-

cedure.
24 WA800-3E0, WA900-3E0
Bleeding air from fuel circuit 1

a If fuel is used up or if a fuel circuit part is
removed and installed, bleed air from the fuel
circuit according to the following procedure.
1. Remove fuel pre-filters (6) and fill it with fuel.

a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the fuel pre-filters (6), and
then add fuel through part (b) (holes
around the central hole).
a After filling the fuel pre-filters (6) with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not 2. Install fuel pre-filters (6) to the pre-filter head.
remove the filter but fill it with the fuel by a Apply engine oil thinly over the packing on
operating priming pump (3). the fuel pre-filter side.
a Don't fill fuel directly after removing main a After the packing of the fuel pre-filter
filters (1). touches the sealing face of the filter head,
tighten the fuel filter 1/2 – 3/4 turns.
3. Loosen air bleed plugs (2) and (4) of the fuel

main filter and operate priming pump (3).
a Operate the priming pump until the fuel
flows out of the hole of plug (2). When
bubbles stop coming out, tighten plug (2).
3 Air bleeding plug:
2.0 – 3.9 Nm {0.2 – 0.4 kgm}
4. Continue priming pump operation until fuel flows

out of the hole of plug (4). When bubbles stop
coming out, tighten plug (4).
3 Air bleeding plug:
2.0 – 3.9 Nm {0.2 – 0.4 kgm}
5. Loosen air bleeder (5) of the fuel supply pump

and operate priming pump (3) 90 – 100 times.
flows out of the air bleeder and tighten the
air bleeder. Then, operate the priming pump
several times more until it becomes heavy.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
WA800-3E0, WA900-3E0 25
6. Move over to the RH side of the engine.

Loosen the air bleeder (8) of the fuel supply
pump and operate priming pump (3).
flows out of the air bleeder and the fuel is
checked. Further operate the priming
pump until it becomes heavy.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
7. Crank the engine with the starting motor to

start engine.
a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 3.
26 WA800-3E0, WA900-3E0
Testing leakage in fuel system 1 9. Inspect the fuel piping and devices for fuel
k
leakage.
Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If fuel leakage is recognized, repeat the
After testing the fuel system or removing procedure from step 1 after repairing the
its parts, test it for fuel leakage according leakage.
to the following procedure. a If no fuel leakage is detected, check is
a Clean and degrease the engine and the parts completed.
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If fuel leakage is recognized, repeat the
procedure from step 1 after repairing the
leakage.
4. Run the engine at low idle.

leakage.
for fuel leakage.
leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
leakage.
8. Run the engine at high idle and load it.

a When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.
WA800-3E0, WA900-3E0 27
Handling reduced cylinder mode Handling no-injection cranking

operation 1 operation 1
a Reduced cylinder mode operation means to run a No-injection cranking means to crank the
the engine with the fuel injectors of 1 or more cyl- engine with the starting motor while all the
inders disabled electrically to reduce the number injections are stopped electrically. The purpose
of effective cylinders. The purposes and effects and effect of this operation are as follows.
of this operation are as follows. q When a machine or engine has been stored for
a long time, implementing the no-injection
1. This operation is used to find out a cylinder cranking before starting the engine lubricates
which does not output power normally (or, the engine parts and thus prevents its seizure.
combustion in it is abnormal). a The no-injection cranking operation is set from
the service mode of the machine monitor. For
2. When a cylinder is selected for the reduced details, see Special functions of machine monitor.
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects. The possible defects
are as follows.
q Leakage through cylinder head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system

controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a Set the reduced cylinder mode operation
in the service mode of the engine service
monitor.
For details, see “Special functions of
engine service monitor”.
28 WA800-3E0, WA900-3E0
Handling controller voltage circuit 1 Adjusting speed sensor 1

1. Disconnection or connection of the connector a The G (Bkup) speed sensor and Ne speed
between the engine controller and engine must sensor for the common rail fuel injection sys-
be done after turning off the starting switch. tem cannot be adjusted.
a Adjust speed sensor (1), which detects the sig-
2. It is prohibited to start the engine when T- nal of the flywheel ring gear to use it for the
adapter is inserted or connected, for trouble- electronic system on the machine side, accord-
shooting purpose, to the connector between ing to the following procedure.
the engine controller and engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
1. Remove speed sensor (1) and check that its tip

is free from steel chips and flaws, and then
install it again temporarily.
2 Threads: Gasket sealant (LG-6)
2. Screw in sensor (1) until its tip touches the

tooth tip of flywheel ring gear (2).
3. Return sensor (1) by 3/4 – 1 turn.

a Clearance (a) of 1.1 – 1.5 mm will be made
between the sensor tip and gear tooth tip.
4. While fixing sensor (1), tighten nut (3).

3 Nut: 49 – 68.6 Nm {5 – 7 kgm}
WA800-3E0, WA900-3E0 29
Testing and adjusting alternator

belt tension 1
Testing
Press the intermediate point of the belt between
alternator pulley and drive pulley with a finger and
measure deflection (a) of the belt.
a Pressing force: Approx. 59 Nm {Approx. 6 kg}
a Deflection (a): approx. 20 mm (1 piece)
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
1. Loosen nut (B) and bolt (2) alternately.
2. Adjust belt tension using nut (A).
3. Tighten bolt (2) to have adjust bolt (1) and

plate (3) made orthogonal to each other.
4. Tighten nut (B) to fix plate (3).

a After adjusting, test the belt tension again.
30 WA800-3E0, WA900-3E0
Testing and adjusting belt tension Adjusting

for air conditioner compressor 1 1. Loosen mounting bolts and nuts (1), (2), (3),
locknut (4).
Testing 2. Turn adjustment nut (5) to adjust the tension of

q Measure deflection (b) of the belt when it is air conditioner compressor belt (6).
pushed with a force of approx. 98 N {approx. 10
kg} at a point midway between the drive pulley 3. When the position of the air conditioner com-
and the air conditioner compressor pulley. pressor is correct, tighten locknut (4), mounting
a Deflection (b) of belt (standard value): bolts and nuts (1), (2), (3) to secure it in posi-
9 – 12.5 mm tion.
4. After adjusting the belt tension, repeat the test-

ing procedure above to check that the deflec-
tion is adjusted within the standard range.
WA800-3E0, WA900-3E0 31
Testing and adjusting power train 1. Open the transmission top cover.
oil pressure 1
2. Turn the transmission cut-off selector switch
oil pressure measurement points and measure- OFF and press the left brake pedal securely.
ment gauges (Check that the transmission cut-off pilot lamp
Measuring gauge Sym-
is turned OFF.)
No. Oil pressure to be measured
MPa {kg/cm2} bol
1 Transmission min relief pressure 6 {60} P0
2 Modulating oil pressure 6 {60} P2
3 Torque converter inlet pressure 2.5 {25} P1
4 Torque converter outlet pressure 2.5 {25} P11
5 Lubricating valve pressure 1 {10} P9
6 Reducing valve pressure 2.5 {25} P3
7 Pilot reducing valve pressure 2.5 {25} P5
a Testing and adjusting tools for power train oil

pressure
1 790-261-1204 Digital hydraulic tester
K
799-401-2320 Gauge
2 799-101-5160 • Nipple
k Lock the tires with chocks.

a Measure the power train oil pressure under
the following condition.
q Coolant temperature:
q Torque converter oil temperature:
32 WA800-3E0, WA900-3E0
Measuring 2. Measuring modulating pressure

1. Measuring transmission main relief pressure 1) Remove modulating pressure pickup plug
1) Remove transmission main relief pressure (P2) (PT1/8).
pickup plug (P0) (PT1/8).
2) Connect nipple K2 (PT1/8) and oil pres-

sure gauge [1] of hydraulic tester K1 to the
2) Connect nipple K2 (PT1/8) and oil pres-
measuring port.
a Use the oil pressure gauge of 6 MPa
measuring port.
{60 kg/cm2}.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.
3) Run the engine at engine full and put the

directional switch in neutral, and measure
3) Start the engine and keep the directional
the pressure when the shift down or shift
switch in the “N (Neutral)” position.
up switch is operated.
4) Measure the transmission main relief pres-
a Measure pressure except F3 and R3.
sure at low idle and high idle.
Standard value for modulating oil pres-
Standard value for transmission main relief
sure: 2.45 - 2.74 MPa (25 - 28 kg/
pressure: 2.75 - 3.0 MPa (28 - 31 kg/cm2)
cm2)
5) After finishing measurement, remove the
measuring tools and return the removed
parts.
parts.
WA800-3E0, WA900-3E0 33
3. Measuring torque converter inlet pressure 4. Measuring torque converter outlet pressure
1) Remove torque converter inlet pressure 1) Remove torque converter outlet pressure
pickup plug (P1) (PT1/8). pickup plug (P11) (PT1/8).
2) Connect nipple K2 (PT1/8) and oil pres- 2) Connect nipple K2 (PT1/8) and oil pres-
sure gauge [1] of hydraulic tester K1 to the sure gauge [1] of hydraulic tester K1 to the
measuring port. measuring port.
a Use the oil pressure gauge of 2.5 a Use the oil pressure gauge of 2.5
MPa {25 kg/cm2}. MPa {25 kg/cm2}.
3) Start the engine and keep the directional 3) Start the engine and keep the directional
switch in the “N (Neutral)” position. switch in the “N (Neutral)” position.
4) Measure the torque converter inlet pres- 4) Measure the torque converter outlet pres-
sure at low idle and high idle. sure at low idle and high idle.
Standard value for torque converter inlet Standard value for torque converter outlet
pressure: pressure: 0.59 ± 0.10 MPa (6.0 ± 1.0 kg/
New machine 0.79 - 0.94 MPa (8.0 - 9.5 cm2)
kg/cm2) 5) After finishing measurement, remove the
Field machine 0.59 - 0.94 MPa (6.0 - 9.5 measuring tools and return the removed
kg/cm2) parts.
parts.
34 WA800-3E0, WA900-3E0
5. Measuring lubrication valve pressure Standard value for reducing valve pres-
1) Remove oil pressure pickup plug (P9) sure: 1.96 ± 0.10 MPa (20 ± 1.0 kg/cm2)
(PT1/8) of the transmission valve. 5) After finishing measurement, remove the
2) Connect nipple K2 (PT1/8) and oil pres- measuring tools and return the removed parts.
measuring port. 7. Measurement of pilot reducing oil pressure
a Use the oil pressure gauge of 1 MPa 1) Remove pilot reducing oil pressure pickup
{10 kg/cm2}. plug (P5) (PT1/8).
2) Connect nipple K2 (PT1/8) and pressure

3) Start the engine and keep the directional gauge [1] in hydraulic tester K1 to the
switch in the “N (Neutral)” position. pickup port.
4) Measure the lubrication valve pressure at Use pressure gauge of 2.5 MPa {25 kg/
high idle. cm2}.
Standard value for lubricating valve pres- 3) Start the engine and keep the directional
sure: 0.14 ± 0.06 MPa (1.4 ± 0.6 kg/cm2) switch at NEUTRAL position.
5) After finishing measurement, remove the mea- 4) With engine at high idle, measure the oil
suring tools and return the removed parts. pressure at gear shift operation.
Standard value for pilot reducing oil
6. Measuring pressure reducing valve pressure pressure: 1.03 ± 0.10 MPa (10.5 ±
1) Remove oil pressure pickup plug (P3) 1.0 kg/cm2)
(PT1/8) of the transmission valve. 5) After finishing measurement, remove the
2) Connect nipple K2 (PT1/8) and oil pres- measuring tools and return the removed
sure gauge [1] of hydraulic tester K1 to the parts to their original position.
measuring port.
a Use the oil pressure gauge of 2.5
MPa {25 kg/cm2}.
3) Start the engine and keep the directional

switch in the “N (Neutral)” position.
4) Measure the pressure reducing valve
pressure at high idle.
WA800-3E0, WA900-3E0 35
Adjusting
1. Adjusting transmission main relief valve
k Measure the transmission main relief
valve while the engine is stopped.
a If the transmission main relief pressure is
out of the standard, adjust it according to
the following procedure.
1) Loosen cap (1) and lower the spring ten-
sion.
2) Remove cover (2), pull out plunger (3),
and increase or decrease the number of
shims (4) to adjust the oil pressure.
a Standard shim thickness: 6.0 mm
a Adjustment pressure/shim (t = 0.5 mm):
Approx. 11.8 kPa {0.12 kg/cm2}
a If the number of the shims is increased
(decreased), the set pressure is height-
ened (lowered).
36 WA800-3E0, WA900-3E0
Procedure for operating

emergency steering spool when
transmission valve fails 1
Outline
a The transmission valve is controlled electrically.
Therefore, the emergency manual spool is
installed to enable the machine to be moved if
there is any failure in the electrical system, or
in the solenoid valve and spool.
k The emergency manual spool is for use
when failure in the transmission control
prevents the machine from being moved. It
allows the machine to be moved from a
dangerous place to a place where repairs 3. Decide the direction to move the machine (for-
can be carried out safety. ward or in reverse), then move the emergency
The emergency manual spool must never manual spool to the operating position.
be used except when the transmission con- FORWARD: Rotate FORWARD clutch spool
trol has broken down. and 1st spool counterclockwise,
k When operating the emergency manual and pull out approx. 10 mm to the
spool, follow the correct order of operation operating position.
exactly, and pay full attention to safety REVERSE: Rotate REVERSE clutch spool
when moving the machine. and 1st spool counterclockwise,
k To prevent the machine from moving, lower and pull out approx. 10 mm to the
the bucket to the ground, apply the parking operating position.
brake, and block the wheels.
k Always stop the engine before operating
spool.
Operation
1. Open cover on upper side of transmission.
2. Remove lock plate (2) of emergency manual

spool (1) of the transmission valve.
a Simply loosen the mounting bolts to
remove the lock plate (2).
WA800-3E0, WA900-3E0 37
4. Check that the area around the machine is safe,

remove the blocks from under the wheels.
5. Sit in the operator’s seat, and depress the left

brake pedal fully.
6. Start the engine, release the parking brake,

then release the brake pedal gradually to start
the machine.
k When the engine is started, the transmis-

sion is engaged and the machine will start.
Therefore, before starting the engine,
always check that the direction of travel is
safe, and always keep the brake pedal
depressed. If the machine does not start,
turn the 2nd spool and 3rd spool clockwise,
and screw in approx. 10 mm to the OFF
position.
7. After moving the machine, stop the engine,

apply the parking brake, and block the wheels.
8. Return the emergency manual spool to the

neutral position, and install the lock plate.
38 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 39
SEN02155-04

© 2011 KOMATSU
All Rights Reserved
40
SEN02156-03
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Measuring operating effort of AJSS lever (AJSS specification) ...................................................................... 3
Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification)...................... 4
Testing and adjusting steering stopper bolt (AJSS specification) ................................................................... 6
Testing and adjusting steering stop valve ....................................................................................................... 8
Measuring steering oil pressure...................................................................................................................... 9
Testing and adjusting emergency steering oil pressure ................................................................................ 10
Bleeding air from steering circuit................................................................................................................... 12
Measuring brake pedal ................................................................................................................................. 13
Measuring brake performance ...................................................................................................................... 14
Testing and adjusting accumulator charge pressure..................................................................................... 15
Measuring wheel brake oil pressure reduction ............................................................................................. 17
Measuring wear of wheel brake disc............................................................................................................. 19
Bleeding air from wheel brake circuit ............................................................................................................ 20
Releasing residual pressure in brake accumulator circuit............................................................................. 21
Testing parking brake performance............................................................................................................... 22
Measuring parking brake solenoid oil pressure ............................................................................................ 23
WA800-3E0, WA900-3E0 1
Testing and adjusting wear of parking brake pad .......................................................................................... 24

Testing and adjusting PPC oil pressure ........................................................................................................ 25
Adjusting PPC valve linkage ......................................................................................................................... 27
Testing and adjusting work equipment oil pressure ...................................................................................... 28
Bleeding air from piston pump ...................................................................................................................... 30
Bleeding air from work equipment circuit ...................................................................................................... 31
Adjusting work equipment lever linkage........................................................................................................ 32
Releasing remaining pressure in hydraulic circuit......................................................................................... 34
Testing and adjusting bucket proximity switch .............................................................................................. 35
Testing and adjusting bucket positioner and tilt limiter .................................................................................. 36
Testing and adjusting lift arm proximity switch .............................................................................................. 38
Testing and adjusting active working proximity switch .................................................................................. 39
Checking proximity switch operation pilot lamp ............................................................................................ 40
Testing and adjusting lift arm position detection lever................................................................................... 41
Adjusting speedometer module of main monitor........................................................................................... 42
2 WA800-3E0, WA900-3E0
Measuring operating effort of AJSS lever (AJSS specification) 1
a Measuring instruments for AJSS lever operat-

ing effort
L 79A-264-0021 Push-pull scale
a Measure the operating effort of AJSS lever

under the following condition.
q Hydraulic oil temperature: Within operating range
q Engine speed: Low idle
1. Install and fix push-pull scale L at operating

point (a) of AJSS lever (1).
2. Measure operating effort of AJSS lever (1) by

pulling the lever in the right and left using
push-pull scale L.
a Operate the work equipment control lever
at the ordinary operating speed and mea-
sure the minimum necessary effort to
operate the AJSS lever.
WA800-3E0, WA900-3E0 3
Testing and adjusting AJSS lever angle sensor and frame angle sensor
(AJSS specification) 1
4 WA800-3E0, WA900-3E0
Testing Adjusting
1. Start the engine and set steering lock lever (1) a If the buzzer was not sounded, adjust it
to Free position. according to the following procedure.
2. Operate AJSS lever (2) with the engine at low 1. Loosen the mounting bolt of steering lever
idle to set the steering to neutral (straight for- angle sensor (4) or frame angle sensor (5) to
ward position). adjust the mounting position.
a Neutral position (straight forward) is where a Standard installation position (Refer-
the front frame lock is available with the ence): The position where the bolt comes
frame lock lever. to the center of the slot.
a After the adjustment, check the alarm buzzer
3. Set steering lock lever (1) to the lock position operation again using the above testing proce-
and maintain the engine at low idle. dure.
a Don't allow AJSS lever to move as long as
steps 3 to 5 are implemented.
4. Slide left arm rest (3) to the storage position

(rear end).
a As it is moved up to this position, the con-
sole switch for inspection is turned ON.
5. Set steering lock lever (1) to the free position

and check the alarm buzzer for its operation.
a The alarm buzzer is normal if it sounds in
one second from operating the steering
lock lever.
WA800-3E0, WA900-3E0 5
Testing and adjusting steering stopper bolt (AJSS specification) 1
6 WA800-3E0, WA900-3E0
Testing Adjusting
1. Start the engine and set steering lock lever (1) a If clearance (a) is not normal, adjust it accord-
to Free position. ing to the following procedure.
2. Move AJSS lever (2) to the right or left stroke 1. Set steering lock lever to free position and
end with the engine running at low idle. Main- return the steering to the center position.
tain the steering at that position.
k Operate the steering slowly. Use care 2. Set steering lock lever (1) to lock position.
in this operation so that your body or
arm may not be caught between the 3. Adjust protrusion dimension (b) nonconforming
front and rear frames. side adjustment bolt (5).
a Protrusion dimension (b):
3. Set steering lock lever (1) to lock position. Increasing its length increases clearance (a)
Decreasing it decreases clearance (a)
4. Make sure that clearance (a) between front a Standard protrusion dimension (b) (Refer-
frame (3) and rear frame (4) is normal. ence): 15 mm
a Clearance (a): 20 – 30 mm 3 Locknut: 8.8 – 10.8 Nm {0.9 – 1.1 kgm}
a Check the left steering and right steering
separately. a After the adjustment, check clearance (a)
again using the above testing procedure.
WA800-3E0, WA900-3E0 7
Testing and adjusting steering

stop valve 1
STEERING WHEEL SPECIFICATION
TESTING
1. Set the front frame and rear frame facing
straight.
2. Check that locknut (2) of stopper bolt (1) is not
loose.
3. Start the engine, and check that there is a
clearance between the front frame stopper and
rear frame stopper when the steering is turned
to the right or left.
k Measure the clearance with the engine
stopped.
4. Before adjusting stopper bolt, check front
frame stopper does not come into contact with
rear frame stopper at steering end. If they
come into contact, adjust as shown below.
a If they do not come into contact because
of lack of stopper, repair and then check
above for each steering end.
ADJUSTING
a If the clearance between the front frame and
rear frame is not within the standard value,
adjust as follows.
1. Loosen locknut (2), tighten stopper bolt (1),
and make sure that there is no contact with the
steering stop valve (3).
2. Start the engine, run at engine slow, then turn
the steering wheel slowly to bring the front
frame and rear frame into contact.
k When turning, be extremely careful not
to get your arm or any other part of
your body caught between the front
frame and rear frame.
3. Stop the engine, then loosen the stopper bolt
until it contacts the steering stop valve contact
surface.
4. Start the engine and run it at engine solw.
Return the steering wheel slowly. When dis-
tance b between stop valve (3) and head of
stopper bolt (1) becomes about 20 – 30 mm,
stop the engine.
5. Loosen stopper bolt (1) 8.5 – 9 turns (length c:
14.9 – 15.8 mm), then tighten locknut (2).
a Carry out the procedure in Steps 1 – 5 to
adjust both the left and right sides.
6. Start the engine, turn the machine, and check
that clearance between the front frame and
rear frame is within the standard value for both
the left and right and that the steering stopper
valve and stopper bolt come into contact and
the steering is stopped.
8 WA800-3E0, WA900-3E0
Measuring steering oil pressure 1 1. Steering relief pressure

1) Remove steering circuit oil pressure pickup
a Measuring tools for steering oil pressure plug (2) (PT1/8) of the right steering cylinder
Symbol Part No. Part name (1).
1
M 790-261-1204 Digital hydraulic tester
2 799-101-5160 • Nipple
a Measure the steering oil pressure under the

q Coolant temperature:
Measuring
k Loosen the oil filler cap to release the resid-
ual pressure in the hydraulic tank, then 2) Install nipple M2 and connect oil pressure
operate the steering wheel 2 – 3 times to gauge of hydraulic tester M1.
release the residual pressure in the piping. a Use the oil pressure gauge of 40 MPa
k Apply frame lock lever (1). {400 kg/cm2}.
3) While running the engine at high idle, turn

the steering wheel to the left and measure
the oil pressure when the steering relief
valve operates.
If the oil pressure gauge is connected to
the steering circuit oil pressure pickup
plug of the left steering cylinder, turn the
steering wheel to the right.
parts.
WA800-3E0, WA900-3E0 9
Testing and adjusting emergency 3. Disconnect hose (3) to pilot port of diverter
steering oil pressure 1 valve, replace elbow (4) by oil passage shut off
elbow (for details, see next page), then con-
Measuring nect hose (3).
a Measure the emergency steering oil pressure (As a result of this, oil pressure to pilot port of
under the following condition. diverter valve is shut off, emergency steering is
q Coolant temperature: operating.)
k Loosen the oil filler cap to release the resid-

ual pressure in the hydraulic tank.
k Apply frame lock lever (1).
1. Disconnect center support shaft (1) from the

transmission.
2. Disconnect drive shaft (2) between the trans-

mission and rear axle from the transmission.
4. Remove plug (5) (PT 1/8) between diverter valve

and steering valve, and install nipple C2 and
hydraulic tester C1 (40 MPa {400 kg/cm2}).
5. Start engine, shift transmission gear shift lever

to F3 or R3, raise speedometer until 24 km/h.
Turn the steering wheel to the right or left and
measure the pressure when the relief valve is
actuated.
10 WA800-3E0, WA900-3E0
Adjusting
k Always stop the engine before adjusting
the hydraulic pressure.
1. Remove capnut (6) of the relief valve.
2. Loosen locknut (7), then turn adjustment screw

(8) to adjust.
a Amount of adjustment for 1 turn of adjust-
ment screw.
1 turn: Approx. 3.5 MPa {35.7 kg/cm2}
a Adjust the set pressure as follows.
To INCREASE pressure, TIGHTEN screw.
To DECREASE pressure, LOOSEN screw.
a If it is impossible to measure relief pres-
sure accurately, do not try to adjust the
pressure.
a Preparation of oil passage blocking elbow

Prepare elbow (02736-10210) and drive
pin (9) 5 mm in diameter into the drilled
hole and weld part (a) to block the oil pas-
sage.
WA800-3E0, WA900-3E0 11
Bleeding air from steering circuit1

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

minutes.
2. Run the engine at low idle and turn 4 – 5 times

to the left and right in turn.
a Operate the piston rod to approx. 100 mm
before the end of its stroke. Be careful not
to relieve the circuit.
3. Repeat Step 2 with the engine at full throttle.
4. Run the engine at low idle and operate the pis-

ton to the end of its stroke to relieve the circuit.
12 WA800-3E0, WA900-3E0
Measuring brake pedal 1

a Measurement condition
q Engine speed: Low idle
Measuring pressing angle of pedal

1. Install push gauge [1] to the foot of the mea-
surer.
a Set the push gauge in a position 150 mm
from the fulcrum of the pedal.
2. While running the engine at low idle, measure

pedal pressing angle (a1).
3. Apply angle gauge [2] to the brake pedal and

measure pressing angle (a3) from pressing
angle (a1) to pressing angle (a2) (a3 = a1 – a2).
q (a3): Pressing angle at pressing effort of
294 ± 29.4 N {30 ± 3 kg}
WA800-3E0, WA900-3E0 13
Measuring brake performance 1
a Measure the brake performance under the fol- Measuring method

lowing condition. 1. Start the engine and drive the machine.
q Road: Flat, level, paved, and dry road
q Braking initial speed: 20 km/h 2. Set the gear shift lever or gear speed selector
q Tire inflation pressure: switch in the 3rd position and run up.
0.67 MPa {6.8 kg/cm2}: WA900-3E0
0.51 MPa {5.25 kg/cm2}:WA800-3E0 3. When the travel speed becomes the braking
q Tire size: initial speed of 20 km/h, press the left brake
45/65 – 45 – 58PR (L-5): WA900-3E0 pedal with the specified force.
45/65 – 45 – 46PR (L-5): WA800-3E0 a Decide the approach course and braking
q Brake pedal pressing force: point in advance and apply the brake at
Specified pressing force that braking point.
294 ± 29.4 N {30 ± 3 kg} a When measuring, turn the transmission
q Pressing time lag: 0.1 sec cut-off switch ON.
4. Measure the distance from the braking point to

the stopping point.
a Perform the above measurement 3 times
and obtain the average.
14 WA800-3E0, WA900-3E0
Testing and adjusting 3. Install adapter P3 and nipple P2 and connect

accumulator charge pressure 1 oil pressure gauge (1) of hydraulic tester P1.
a Use the oil pressure gauge of 39.2 MPa
a Testing and adjusting tools for accumulator {400 kg/cm2}.
charge pressure
1
P
2 799-101-5160 • Nipple
3 799-401-3100 Adapter
a Measure the accumulator charge pressure

ating range
q Hydraulic oil temperature: Within operat-
ing range
k Lock the tires with chocks securely.
4. Measure the accumulator charge cut-in pres-
k While the engine is stopped, press the
sure. While running the engine at low idle,
brake pedal at least 100 times to release measure the oil pressure when the brake oil
the pressure from the accumulator circuit. pressure caution lamp on the monitor panel
goes off.
Measuring a Cut-in pressure:
5.88 (+0.49/0) MPa {60 (+5/0) kg/cm2}
1. Remove the brake oil tank side cover (on the
front side of the machine).
5. Measure the accumulator charge cut-out pres-
sure. After the accumulator charge cut-in
2. Disconnect hose (2) (port PP) from accumula-
operation, the rising oil pressure gauge lowers
tor distribution tube (3) side of accumulator
suddenly. Measure the oil pressure at this
charge valve (1).
time.
a After finishing measurement, remove the mea-

WA800-3E0, WA900-3E0 15
Adjusting
a If the accumulator charge cut-out pressure is
adjusted, the cut-in pressure changes accord-
ing to the valve area ratio.
1. Loosen locknut (5) of cut-out valve (4) and turn

adjustment screw (6) to adjust the pressure.
a If the adjustment screw is

q turned to the right, the pressure rises.
q turned to the left, the pressure lowers.
a Quantity of adjustment per turn of adjustment

screw: 5.59 MPa {57 kg/cm2}
3 Locknut: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}
a After finishing adjustment, check the accumu-

lator charge cut-in and cut-out pressures again
according to the above measurement proce-
dure.
16 WA800-3E0, WA900-3E0
Measuring wheel brake oil

pressure reduction 1
a Measuring tools for wheel brake oil pressure
1 793-605-1001 Brake tester kit
Q 2 790-101-1102 Coupler
3 799-401-3100 Pump
k High-pressure oil in the accumulator may

spout out because of a trouble in a brake
component, even if the brake pedal is not
pressed. Accordingly, while the engine is
stopped, press the brake pedal at least 100 3. Set brake tester kit Q1 and connect coupler Q2
times to release the pressure from the and pump Q3.
accumulator circuit.
k Apply the parking brake and lock the tires
with chocks securely.
a Measure the oil pressure of the front
brakes (right and left) and rear brakes
(right and left) similarly.
a Measure the wheel brake oil pressure
Measuring
4. Loosen bleeder (4) and operate the pump to
1. Remove brake hose cover (1).
bleed air, and then tighten bleeder (4).
2. Remove hose (2) and nipple (3) on the mea- 5. Operate the pump until the oil pressure rises to
sured side. the specified level and then close the stop valve.
a Specified oil pressure:
k When the hose is disconnected, if the brake 4.2 – 5.2 MPa {43 – 53 kg/cm2}
pedal is pressed, high-pressure oil spouts
out. Accordingly, never press the brake 6. Leave the brake circuit under this condition for 5
pedal. minutes and then check reduction of the pressure.
a If the hose is moved while the pressure is
mea s ur ed , t he pr e ss u re f lu ct uat es .
Accordingly, do not move the hose.
a After measuring the pressure, operate the
pump to release the pressure, and then
remove the brake tester kit.
WA800-3E0, WA900-3E0 17
18 WA800-3E0, WA900-3E0
Measuring wear of wheel brake

disc 1
Commercially
R 1 Slide calipers
available
k Stop the machine on a level place and lock

the tires with chocks.
1. Remove plug (1).
q Wear limit: (a) = 46.3 mm

(Reference: (a) of new machine = 40.7 ± 1.4 mm)
a If the wear is near the limit, check it fre-
quently, regardless of the maintenance
interval.
2. Lightly press the brake pedal to the stroke end.
3. Using slide calipers R, measure depth (a) from

the housing end to the spring guide.
a Keep pressing the brake pedal during
measurement.
4. After measuring, return plug (1).

3 Plug (1): 29.4 – 39.2 Nm {3.0 – 4.0 kgm}
WA800-3E0, WA900-3E0 19
Bleeding air from wheel brake circuit1

k Stop the machine on a level place and lock
the tires with chocks.
a If a brake circuit part is removed and installed,
bleed air from the brake circuit according to the
a Bleed air from the front brake circuit and rear
brake circuit similarly (2 places each).
1. Run the engine and increase the pressure in

the accumulator and then stop the engine.
k While the engine is running, the drive shaft
is rotating. Accordingly, never bleed air
from the slack adjuster.
2. Put either end of vinyl hoses [1] in bleeders (2)

of slack adjuster (1) and put the other end in a
container.
3. Press the brake pedal and loosen bleeder

screws (2) to bleed air.
a After tightening the bleeder screws,
release the brake pedal slowly.
a Use the left brake pedal.
4. Repeat this operation until no bubbles are con-

tained in the oil flowing in hose [1], and then
press the brake pedal fully and tighten bleeder
screw (2) while the oil is flowing.
5. Bleed air from the slack adjuster on the oppo-

site side and bleeder (3) of each wheel accord-
ing to the above procedure.
20 WA800-3E0, WA900-3E0
Releasing residual pressure in

brake accumulator circuit 1
k Before disconnecting any of the following
brake accumulator circuits, release resid-
ual pressure in that brake circuits.
q Piping between accumulator charge valve and

brake accumulator
q Piping between accumulator charge valve and
parking brake emergency release valve
q Piping between brake accumulator and brake
valve on both sides
1. Stop the engine.
2. Press the brake pedal at least 100 times to

release the pressure from the brake accumula-
tor circuit.
WA800-3E0, WA900-3E0 21
Testing parking brake performance1

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

directional lever in the N position, and stop the
engine.
3. Turn the parking brake switch ON (to park),

and then release the brake gradually. At this
time, the machine must not move.
a When the engine is stopped, the parking
brake is turned ON (to park) automatically.
a Measure the parking brake performance
on an uphill and a downhill.
22 WA800-3E0, WA900-3E0
Measuring parking brake solenoid 4. Install adapter S3 and connect nipple S2 and
oil pressure 1 oil pressure gauge [1] of hydraulic tester S1.
a Use the oil pressure gauge of 39.2 MPa
a Measuring tools for parking brake oil pressure {400 kg/cm2}.
1
S
2 799-101-5160 • Nipple
3 799-401-3300 Adapter
k Lock the tires with chocks securely.

k Install and remove the measuring tools
after the oil temperature decreases fully.
a Measure the parking brake oil pressure under
the following condition.
q Coolant temperature: Within operating range
q Power train oil temperature: Within operating
range 5. Run the engine and increase the pressure in
the accumulator and then turn parking brake
k While the engine is stopped, press the switch ON.
brake pedal at least 100 times to release the
pressure from the accumulator circuit. 6. While running the engine at low idle, measure
the oil pressure.
1. Turn the starting switch ON and turn the park-
k After measuring parking brake oil pressure,
ing brake switch OFF to release the brake.
stop the engine and press the brake pedal
2. Remove the front frame right side cover. at least 100 times to release the pressure
from the accumulator circuit and then turn
3. Disconnect parking brake spring cylinder out- parking brake switch OFF and remove the
put hose (1). oil pressure measuring tools.

WA800-3E0, WA900-3E0 23
Testing and adjusting wear of

parking brake pad 1
Measuring tools
Commercially
1 Slide calipers
available
T
Commercially
2 Clearance gauge
available
a If the parking brake does not work perfectly,

check the parking brake for wear according to
the following procedure.
k Lower the work equipment fully and lock
the tires with chocks. Adjusting
a If the clearance is out of the standard data,
Measuring
adjust it according to the following procedure.
1. Turn the starting switch ON and turn the park-
ing brake switch OFF to release the brake. 1. Turn the starting switch ON and turn the park-
ing brake switch OFF to release the brake.
2. Using slide calipers T1, measure the thickness
k
of the parking brake pad. If the starting switch is turned OFF, the
parking brake operates. Take care.
k If the starting switch is turned OFF, the
parking brake operates. Take care. 2. Turn adjustment bolt (4) of parking brake slack
adjuster (3) to bring parking brake pad (2) in
a Measure the 4 parking brake pads. light contact with disc (1).
a If any pad is out of the standard, replace it a If the adjustment bolt is tightened until
and its mating one. parking brake pad (2) is pressed against
a For the method of removing the parking disc (1), the brake will squeak and the disc
brake pad, see Disassembly and assem- will be heated. Take care extremely.
bly, “Removal of parking brake pad”.
3. Insert clearance gauge T2 between disc (1)

and pad (2) to measure the clearance between
them.
3. Return adjustment bolt (4) counterclockwise

180° ± 30° (3 notches). By this work, the total
of the right and left clearances ((a) + (b))
between pad (2) and disc (1) is adjusted to
1.06 ± 0.18 mm.
a The parking brake pad clearance is the a After the above adjustment, measure the
total of the measured values on both sides brake performance again and check that it
((a) and (b)). is within the standard range.
24 WA800-3E0, WA900-3E0
Testing and adjusting PPC oil 2. Measuring PPC valve output pressure
pressure 1 1) Remove the work equipment valve cover.
2) Remove oil pressure pickup plug (PT1/8)
a Testing and adjusting tools for PPC oil pressure (2) of the tilt dump circuit and install nipple
Symbol Part No. Part name U2 and oil pressure gauge [1] of hydraulic
tester U1.
1
U 790-261-1204 Digital hydraulic tester
a Use the oil pressure gauge of 5.9 MPa {60
2 799-101-5160 • Nipple kg/cm2}.
a Test and adjust the PPC oil pressure under the
3) Start the engine and raise the lift arm and
then dump the bucket at full throttle and
q Engine coolant temperature: Within operating range
measure the oil pressure when the relief
q Hydraulic oil temperature: Within operating range
valve operates.
k Loosen the oil filler cap of the hydraulic
tank gradually to release the pressure in
the hydraulic tank
k Operate the work equipment control lever 2 –
3 times to release the pressure in the PPC
Measuring
1. Measuring PPC relief pressure
1) Remove oil pressure pickup plug (PT1/8)
of the port (P) from the underside of the
PPC valve assembly.
2) Install nipple U2 and oil pressure gauge
[1] of hydraulic tester U1.
3) Run the engine at full throttle and mea-
sure the oil pressure.
a Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}.

WA800-3E0, WA900-3E0 25
Adjusting
1. Adjusting PPC relief valve
k Adjust the hydraulic pressure while the
engine is stopped.
k Gradually loosen the oil filler cap of the
hydraulic tank to release the pressure from
the tank.
k Operate the work equipment control lever 2 –
3 times to release the pressure from the accu-
mulator circuit for PPC.
1) Remove the upper cover of the transmis-
sion.
2) Remove cap nut (3) of the PPC relief
valve beside the accumulator charge
valve for PPC.
3) Loosen locknut (4) and turn adjustment
screw (5) to adjust the pressure.
a Quantity of adjustment per turn of adjust-
ment screw: 0.96 MPa {9.8 kg/cm2}
26 WA800-3E0, WA900-3E0
Adjusting PPC valve linkage 1

1. Remove cover at the bottom of the work equip-
ment control lever.
2. Adjust dimension (a) from nut (1) of the PPC

valve linkage to the top surface of the floor.
q Dimension (a) (target value): 54 mm
3. Loosen nuts (2) and (3), then adjust the

installed height of trunnion (5) so that there is
no play in lever (4).
4. After adjusting, tighten nuts (2) and (3).
WA800-3E0, WA900-3E0 27
Testing and adjusting work

equipment oil pressure 1
a Testing and adjusting tools for work equipment
oil pressure
1
V 790-261-1204 Digital hydraulic tester
2 799-101-5160 • Nipple
a Test and adjust the work equipment oil pres-

sure under the following condition.
ating range 3) Remove oil pressure pickup plug (PT1/8)
q Hydraulic oil temperature: Within operat- (1) of the tilt-dump circuit and install nipple
ing range V2 and oil pressure gauge [1] of hydraulic
k Loosen the oil filler cap of the hydraulic tester V1.
tank gradually to release the pressure in a Use the oil pressure gauge of 39.2 MPa
the hydraulic tank {400 kg/cm2}.
Measuring
1. Measuring work equipment relief pressure
1) Lower part (b) of the bucket to the ground
with part (a) raised by 30 – 50 mm.
2) After stopping the engine, operate the
work equipment control lever and check
that the bottom of the bucket (both parts
(a) and (b)) is in contact with the ground.
a After lowering the bucket to the ground,
operate the work equipment control lever
2 – 3 times to release the pressure in the
piping.
4) Start the engine and raise the lift arm and

then tilt-dump the bucket at high idle and
measure the oil pressure when the relief
valve operates.

28 WA800-3E0, WA900-3E0
Adjusting
1. Adjusting work equipment relief valve
k When adjusting the oil pressure, stop
the engine.
Loosen locknut (3) of work equipment relief
valve (2) and turn adjustment screw (4) to
adjust the pressure.
a Quantity of adjustment per turn of adjust-
ment screw: 12.6 MPa {128 kg/cm2}
a After finishing adjustment, measure the work

equipment relief pressure again according to
the above measurement procedure.
WA800-3E0, WA900-3E0 29
Bleeding air from piston pump 1 3. When oil overflows from plugs (1), (2) and (3)
in turn, and tighten plugs under air is bled com-
a When replacing oil inside hydraulic tank or pletely. After that, in order to fill the inside of
removing piston pump or hydraulic pipings of the pump with the hydraulic oil, leave it for 10
piston pump, bleed air from piston pump to minutes.
prevent pump inner parts seizing as follows.
a Since the oil level in the hydraulic tank is
1. Check that the hydraulic tank is filled with higher than positions (1), (2) and (3) above, air
hydraulic oil. is bled easily.
a The cap of the hydraulic tank remains
removing, until the air bleeding of the pis- 4. Loosen the mouthpiece of the case drain hose
ton pump finishes. (4), starting an engine at the condition of low
idle. Tighten the mouthpiece, confirming that
2. Loosen plug (1), (2) and (3) of piston pump hydraulic oil flows from the mouthpiece.
suction tube.
30 WA800-3E0, WA900-3E0
Bleeding air from work equipment

circuit 1
a After removing and installing the work equip-
ment control valve or work equipment cylinder,
bleed air from the work equipment circuit
according to the following procedure.
1. Start the engine and run it at low idle for about

5 minutes.
2. While running the engine at low idle, raise and

lower the lift arm 4 – 5 times.
a Move the piston rod to about 100 mm
before each stroke end and never relieve
the circuit.
3. While running the engine at high idle, perform

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

piston rod to each stroke end and relieve the
circuit.
5. Perform the operations in 2 and 3 for the

bucket cylinder.
WA800-3E0, WA900-3E0 31
Adjusting work equipment lever

linkage 1
If the operating effort or stroke of the work equip-
ment control lever is out of the standard or if the
work equipment control lever, PPC valve assembly,
or lift arm-bucket solenoid is removed, perform the
following adjustment.
k When adjusting, stop the engine.

a Check that the operating effort of the work
equipment control lever is in the standard
range.
1. Remove the work equipment lever side cover.
2. Operate lift arm control lever (1) and adjust rod

(4) so that lift arm control lever cam follower (2)
will be evenly inserted in the detents at both ends
of cam (3) and clearance (a) will be 0 – 1 mm.
a Distance (b) between pins of rod (4):
337 mm (Reference value)
3. Operate bucket control lever (5) and adjust rod

(8) so that bucket control lever cam follower (6)
will be evenly inserted in the detents at both ends
of cam (7) and clearance (c) will be 0 – 1 mm.
a Distance (c) between pins of rod (8):
337 mm (Reference value)
32 WA800-3E0, WA900-3E0
4. Set lift arm kick-out solenoid (9) and bucket posi- 6. Move the solenoid so that clearance (e) between
tioner solenoid (10) in the pull (ON) state accord- bucket control lever cam (7) and cam follower (6)
ing to the following procedure. will be 0 – 0.5 mm when bucket positioner sole-
1) Disconnect wiring connectors (F05) (11) noid (10) is in the pull state.
and (F06) (12). a Set the bucket control lever in neutral
a F05 (11): Bucket positioner proximity when performing the above adjustment.
switch
F06 (12): Lift arm kick-out proximity switch 7. If the lift arm control lever resetting effort is not
2) Insert a T-adapter to short terminals A and 19.6 N {2 kgm} or bucket control lever resetting
B. effort is not 9.8 N {1 kgm}, adjust it by changing
a Check that the solenoid is pulling by 12 mm. the mounting hole of spring (13) (There are 4
mounting holes).
a The spring is installed to the 2nd hole from
the top when the machine is delivered.
5. Move the solenoid so that clearance (d) between

lift arm control lever cam (3) and cam follower (2)
will be 0 – 0.5 mm when lift arm kick-out solenoid
(9) is in the pull state 8. After adjusting, operate the bucket control lever
a Set the lift arm control lever in neutral and lift arm control lever and check that they are
when performing the above adjustment. held at the tilt, dump, and raise and float posi-
tions.
WA800-3E0, WA900-3E0 33
Releasing remaining pressure in

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

accumulator circuit
a If the piping between the accumulator and
accumulator check valve, and between
the accumulator and brake valve is to be
disconnected, release the remaining pres-
sure from the circuit as follows.
1) Stop the engine.
2) Depress the brake pedal at least 100
times to release the pressure inside the
brake accumulator circuit.
3. Releasing remaining pressure PPC accu-

mulator circuit
a If the piping between the PPC accumula-
tor and PPC valve is to be disconnected,
release the remaining pressure from the
circuit as follows.
q Operate the control lever 2 – 3 times to
release all the remaining pressure.
34 WA800-3E0, WA900-3E0
Testing and adjusting bucket 3. Adjust and fix nut (4) of switch so that the
proximity switch 1 clearance (a) between the proximity switch
sensing surface and the angle is within the
a If the bucket tilt limiter is equipped, perform standard value.
check and adjustment of "Bucket positioner q Standard clearance (a) : 3 – 5 mm
and tilt limiter". 3 Mounting nut of proximity switch:
Testing 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
1. With the engine stopped, check that the clear- a After adjusting, operate the bucket control
ance between switch (1) and angle (2) is within lever and check that the proximity switch
the standard value. operates at a desired position.
2. Start the engine, run at high idle and check the

actuating position. (Measure 3 times and take
the average.)
Adjusting
1. Lower the bucket to the ground and set it at a
desired digging angle and then return the con-
trol lever to the hold position and stop the
engine.
2. Fix support (3) to the bucket cylinder bracket

so that the tip of angle (2) align the center of
the proximity switch (1).
WA800-3E0, WA900-3E0 35
Testing and adjusting bucket positioner and tilt limiter 1
1. Bucket cylinder Inspection

2. Proximity switch (bucket positioner) 1. With the engine stopped, check that the clear-
3. Protector ance between proximity switch (2) and detec-
4. Detection bar tion bar is 3 to 5 mm.
5. Plate 2. Start and run the engine at high idle, and check
6. Proximity switch (tilt limiter) through the cylinder stroke. (Check 3 times
7. Plate and take the average.)
Adjusting
CB: Tilt back position 1. Bucket positioner
H: Bucket at level position 1) Lower the bucket to the ground, and set it
level. (Work on a level ground)
a: Bucket at level position on ground 2) Adjusting and fix so that sensor face (F) of
Standard lift cylinder: 1291 mm proximity switch (2) is 0.5 to 1.0 mm back
High lift cylinder: 1300 mm from end (E) of protector (3) as shown in
the figure. (See enlarged view "P")
b: Tilt stop position sensor detection position 3 Proximity switch mounting nut:
Standard lift cylinder: 484 mm 14.7 to 19.6 Nm {1.5 to 2.0 kgm}
High lift cylinder: 481 mm 3) Since detection bar (4) moves sideways
above proximity switch sensor surface (F),
c: adjust detection bar (4) so that the clear-
q When bucket is level on ground ance between detection bar (4) and sen-
Standard lift cylinder: 2472 mm sor surface (F) of proximity switch (2) is 3
High lift cylinder: 2765 mm to 5 mm through the cylinder stroke. (See
q When bucket is at tilt stop position from bucket enlarged "View Z")
at level position on ground 4) While running the engine at medium
Standard lift cylinder: 2831 mm speed (1500 rpm), move the bucket posi-
High lift cylinder: 3127 mm tioner by dumping the bucket from the tilt
position. Check that the bucket is directed
d: Tilt stop detection position down by 0 to 1° from the level position
Standard lift cylinder: 943 mm when it is lowered to the ground.
High lift cylinder: 1232 mm a If the bucket is not positioned so, see
"a", "b", and "c" in the general view, and
set plate (5) to the standard position.
36 WA800-3E0, WA900-3E0
5) Perform the above operation 3 times, and 3) Since detection bar (4) moves sideways
check the position of proximity switch above proximity switch sensor surface
mounting plate (5), then adjust again if (F'), adjust detection bar (4) so that the
necessary. clearance between detection bar (4) and
sensor surface (F') of proximity switch (6)
is 3 to 5 mm through the cylinder stroke.
(See enlarged "View Z")
4) While running the engine at medium
speed (1500 rpm), operate the tilt limiter
by tilting the bucket from the level position
(bucket pin height above ground: 360
mm).
5) At this time, adjust the position of proxim-
ity switch mounting plate (7) so that the
clearance between bucket stopper (8) and
boom stopper (9) is 50 mm as shown in
the figure.
a If the clearance does not become so,

see "a", "b", and "c" in the general
view, and set plate (7) to the standard
position.
6) Perform the above operation 3 times, and
check the position of proximity switch
mounting plate (7), then adjust again if
necessary.
2. Tilt limiter (For enlarged view "P" and "View Z",

see "1. Bucket positioner")
a Perform the following after adjusting the
"1. bucket positioner".
1) Lower the bucket to the ground, and after
setting the bucket level, tilt it slowly.
2) As in step 2) of 1, adjust and fix proximity
switch (6) so that sensor face (F') of prox-
imity switch (6) is 0.5 to 1.0 mm back from
protector end (E') similarly to the bucket
positioner. (See enlarged view "P")
3 Proximity switch mounting nut:
14.7 to 19.6 Nm {1.5 to 2.0 kgm}
WA800-3E0, WA900-3E0 37
Testing and adjusting lift arm Adjusting

proximity switch 1 1. Raise the lift arm to a desired position, stop the
engine, and lock the work equipment control
Testing lever.
1. While the engine is stopped, check that clear-
ance (b) between switch (1) and plate (2) is in 2. Loosen the mounting bolt, adjust the plate so
the standard range. that distance (a) between the center of proxim-
ity switch (1) and top of plate (2) will be in the
1 standard range, and tighten the mounting bolt.
q Standard distance (a): 0 – 5 mm
a
3. Loosen nut (3) of proximity switch (1) and
adjust clearance (b) between the sensitive sur-
face of proximity switch (1) and plate (2) to 3 –
5 mm and then tighten nut (4).
q Standard clearance (b): 3 – 5 mm
2 3 Proximity switch mounting nut (3):
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
B 3 W1 2 6 4 2 a After adjusting, operate the lift arm control

lever and check that the proximity switch oper-
ates at a desired position.
2. Start the engine and check the operating point

at high idle. (Check 3 times and obtain the
average.)
38 WA800-3E0, WA900-3E0
Testing and adjusting active Adjusting

working proximity switch 1 1. If distance (a) is out of the standard, adjust it
by moving plate (2).
Testing
1. Start the engine, lower the bucket to the 2. If clearance (b) is out of the standard, adjust it
ground with its bottom on the horizontal, and with proximity switch mounting nut (3).
stop the engine. 3 Mounting nut:
17.15 ± 2.45 Nm {1.75 ± 0.25 kgm}
2. Measure distance (a) between the center of
proximity switch (1) and bottom of plate (2). a After adjusting, operate the lift arm control
a Standard distance (a): 115 mm lever and check that the proximity switch
operates normally.
3. Measure clearance (b) between the sensitive

surface of the proximity switch and plate (2).
a Standard clearance (b): 3 – 5 mm
WA800-3E0, WA900-3E0 39
Checking proximity switch operation pilot lamp 1

Proximity switch operation pilot lamp (Red)
The proximity switch has a pilot lamp to indicate its
operating condition. Use this pilot lamp when
adjusting the proximity switch.
q A: Operation pilot lamp (Red)
Positional relationship
Proximity switch between proximity switch Operation pilot lamp Remarks
sensitive surface and object
Bucket positioner Near ON
Lift arm kick-out Operates when center of switch is near.
Active working Far OFF
40 WA800-3E0, WA900-3E0
Testing and adjusting lift arm

position detection lever 1
Testing
1. Make sure that clearance (a) between lift arm
angle sensor (1) and detection lever (2) is
within the standard value.
q Clearance (a): 0.5 – 1 mm
Adjusting
a If clearance (a) does not conform to the stan-
dard value, adjust it according to the following
procedure.
1. Loosen bolt (3).
2. Adjust position of detection bar (2) so that

clearance (a) between lift arm angle sensor (1)
and detection lever (2) to the standard value.
Then tighten bolt (3).
WA800-3E0, WA900-3E0 41
Adjusting speedometer module of

main monitor 1
q The speedometer on the main monitor is a
common part for all machines, and the input
signal for the travel speed differs according to
the machine, so it is necessary to adjust the
monitor for use with the particular model.
Adjustment procedure
q Turn off the power, then remove the machine
monitor and adjust the switches at the back of
the speedometer.
3) After completing adjustment, fit the rubber
1. Setting machine model
caps securely and install the main monitor.
1) Remove the rubber caps from dipswitches
1, 2 and 3 at the back of the speedometer.
Correction amount of switch 2 (for reference)
Switch position 0 1 2 3 4 5 6 7
Correction
+14 +12 +10 +8 +6 +4 +2 0
amount (%)
Switch position 8 9 A B C D E F
Correction
0 –2 –4 –6 –8 –10 –12 –14
amount (%)
a DIP switch 4 is set as shown in the figure

below when delivered. If it is changed, the
machine will not function normally. Accordingly,
do not change it. When the main monitor is
2) When the rubber cap is removed, a rotary replaced, check the setting of DIP switch 4.
switch can be seen inside. Using a flat-
DIP switch 4
headed screwdriver, turn this switch to Specification
adjust it to the settings in the table below. 1 2 3 4
With auto
Switch 1 Switch 2 Switch 3 ON ON OFF OFF
shift system
Tire size (speedo- (tacho-
(model
meter cor- meter input
selection)
rection) selection)
45/65-45-46PR
0 7 0
(WA800-3E0)
45/65-45-58PR
1 7 0
(WA900-3E0)
42 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 43
SEN02156-03

© 2017 KOMATSU
All Rights Reserved
44
SEN02157-04
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Special function of engine service monitor...................................................................................................... 2
VHMS controller initial setting procedure...................................................................................................... 26
Precautions for replacing VHMS controller ................................................................................................... 48
Pm-clinic inspection table ............................................................................................................................. 54
WA800-3E0, WA900-3E0 1
Special function of engine service monitor
Normal functions and special functions of engine service monitor

The engine service monitor is equipped with the normal functions and special functions. Various items of
data are displayed on the character display situated at the center of the service monitor.
Depending on the internal setting of the engine service monitor, the display items are divided into automatic
display items and items displayed when the engine service monitor switches are operated.
1) Normal functions: Operator mode

Functions for which the content is normally displayed or which can be displayed and operated by the
operator operating the switches.
2) Special functions: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspec-
tion, maintenance, and troubleshooting.
Operator mode Service mode

1 Normal screen (KOMATSU display) 1 Service meter display (*1)
2 Remedy code display function 2 Electrical system fault history data display function
3 Failure code display function 3 Mechanical system fault history display function
4 Real-time monitor function
5 Engine reduced-cylinder function
6 No injection cranking function
Operating information display function
7
(relevant to fuel consumption)
8 Manual snapshot function (if equipped)
9 Optional device selecting function
10 Initialize function
(*1) Display of service meter

The service meter of the engine service monitor is for recording of failures and integrates the operating
hours independently from the service meter for the operator (mechanical service meter).
Accordingly, the value of the service meter for the operator may become different from that of the ser-
vice meter of the engine service monitor after years. The service meter of the engine service monitor is
used as an auxiliary one for recording of failures, however, and the mechanical service meter for the
operator is the main one.
2 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 3
4 WA800-3E0, WA900-3E0
Operator mode 3. Remedy code display function

a Following overviews the operator mode. If a trouble that requires changing the operat-
a See “Structure, function and maintenance ing method or implementing testing and adjust-
standard” or “Operation and maintenance ment emerges, this function displays a remedy
manual” for details of the operator mode. code E01, E02 or E03 on the character display,
alerting to take appropriate actions.
1. Normal screen
Turning on the starting switch displays the nor-
mal screen “KOMATSU”.
2. Operator mode self-check function

The self-check is started 3 seconds after the
starting key is turned on. The self-check func-
tion is automatically turned on after the starting
switch is turned on, and the system automati-
cally proceeds to the 1st layer 3 seconds after
the self-check function is completed. The
mode switch operation is not accepted as long
as the self-check is continued. (The monitor-
on-board lamps and LCDs remain turned off
during this operation except the character dis-
play.)
WA800-3E0, WA900-3E0 5
a Remedy codes and actions alerted to operator

Remedy codes Actions recommended to operator
E01 • Do necessary testing and/or adjustment as the current work is over or at shift of the operator.
• When an overrun-related item is displayed, slow down the engine or machine speed.
E02 • When an overrun-related item is displayed, stop the machine and run the engine at mid speed
with no load.
E03 • Stop the engine and machine immediately and contact a service man.
4. Failure code display function a The service code display function displays the
While the failure code is displayed on the char- following information.
acter display, press the upper side [>] of the A: Failure code (Location code + Problem
service mode selector switch 2. The user code code)
is switched to the failure code. B Controller code
a The failure codes detected in the past are MON: Engine maintenance monitor
divided into failures of the electrical system ENG: Engine controller
and the mechanical system and are recorded VHMS: VHMS controller
as fault history. (For details, see Service ELP: Pre-lubrication controller (if equipped)
Mode.) C: The system where failure occurred
a When two or more failures are involved, press
the [>] switch to display another code.
a After displaying every involved failure code by
pressing the [>] switch, pressing this switch
again returns the KOMATSU screen for the
normal display. Pressing the [>] switch one
more time displays the failure codes from the
first. If the [>] switch is not touched for 30 sec-
onds, the user code display screen automati-
cally appears.
a For details of a displayed failure code, see

Failure code list.
a If no switch is operated for 30 seconds or more
on the failure code display screen, the user
code display screen is automatically turned on.
6 WA800-3E0, WA900-3E0
Monitoring codes list

MONITOR PANEL [Engine maintenance monitor system]
Monitoring
No. Monitoring items (*1) Display item (*2) Data display range (*3) Unit (*4)
code
1 20227 Part number PART NUMBER Arabic numerals Status display
2 20402 Serial number SERIAL NUMBER Arabic numerals Status display
3 20200 Monitor ROM part number VERSION Arabic numerals Status display
4 20221 Application version VERSION (APP) Arabic numerals Status display
5 20222 Data version VERSION (DATA) Arabic numerals Status display
6 04302 Charge level ALTERNATOR R 0.00 – 30.00 V
7 40921 Input signal D_IN_0-7 D-IN--0------7 See attached table Status display
8 40922 Input signal D_IN_8-10 D-IN--8-10 See attached table Status display
9 40925 Output signal D_OUT_0-1 D-OUT-01 See attached table Status display
*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated forms are used since the number of displayed letters is limited.
*3: If a value is below (or above) the display range, the lowest (highest) value of the display range is dis-
played.
*4: If a displayed item has a unit, only the SI units are used.
*5: An item that does not allow monitoring is indicated as “Not used” though its code and item name may be
displayed on the machine monitor.
WA800-3E0, WA900-3E0 7

ENG [Engine controller system]
Monitoring
code
1 20400 Hardware serial number ECM S/N Arabic numerals Status display
2 03200 Battery voltage POWER SUPPLY 0.0 – 480.0 V
3 01002 Engine Speed ENG SPEED 0 – 4000 rpm
4 04104 Engine coolant temperature COOLANT TEMP -40 – 210 °C
Engine coolant temperature sensor
5 04105 COOLANT TEMP 0.00 – 5.00 V
voltage
6 37200 Oil pressure sensor ENG OIL PRESS -99.9 – 999.9 kPa
7 37201 Oil pressure sensor voltage ENG OIL PRESS 0.00 – 5.00 V
8 42700 Engine oil temperature ENG OIL TEMP -40 – 210 °C
9 42702 Engine oil temperature sensor voltage ENG OIL TEMP 0.00 – 5.00 V
10 36400 Common rail pressure RAIL PRESS 0 – 400 MPa
11 36402 Common rail pressure sensor voltage RAIL PRESS 0.00 – 5.00 V
12 37400 Atmospheric pressure AMBIENT PRESS -99.9 – 999.9 kPa
13 37402 Atmospheric pressure sensor voltage AMBIENT PRESS 0.00 – 5.00 V
14 18400 Air intake temperature INTAKE TEMP -50 – 200 °C
15 18401 Air intake temperature sensor voltage INTAKE TEMP 0.00 – 5.00 V
16 04204 Fuel temperature FUEL TEMP -40 – 210 °C
17 14201 Fuel temperature sensor voltage FUEL TEMP 0.00 – 5.00 V
18 18500 Boost temperature CHG TEMP -50 – 200 °C
19 18501 Boost temperature sensor voltage CHG TEMP 0.00 – 5.00 V
20 36500 Boost pressure CHG PRESS-A -99.9 – 999.9 kPa
21 36502 Boost pressure sensor voltage CHG PRESS-A 0.00 – 5.00 V
22 18700 Engine output torque OUTPUT TORQUE -24000 – 24000 Nm
23 36700 Equivalent torque TORQUE RATIO 0 – 100 %
24 31706 Final accelerator position FINAL THROTTLE 0 – 100 %
25 37300 Momentary fuel consumption FUEL RATE 0.0 – 999.9 L/h
Final injection volume command INJECT
26 18600 0 – 1000 mg
(in weight) COMMAND
27 36300 Final injection timing command TFIN INJECT TIMING -180.0 – 180.0 CA
28 31701 Accelerator pedal position THROTTLE POS 0 – 100 %
29 31707 Accelerator pedal sensor voltage THROTTLE POS 0.00 – 5.00 V
30 18300 Idle validation signal IVS 1 ON/OFF Status display
31 18301 Idle validation signal IVS 2 ON/OFF Status display
32 18900 Engine controller internal temperature ECM IN TEMP -40 – 210 °C
Final common rail pressure command PRESS
33 36200 0 – 400 MPa
PFIN COMMAND
PCV valve close timing
34 17201 PCV TIMING -180.0 – 180.0 CA
(BTDC standard)
35 17500 Selection of engine mode POWER MODE 0–4 Status display
8 WA800-3E0, WA900-3E0

MONITOR PANEL [Engine maintenance monitor system]
Monitoring
code
Incoming value is displayed as is
Name of selected model
36 00400 MACHINE ID (H) (Upper 8 characters out of 16 Status display
(upper 8 digits)
ASCII characters)
Name of selected model
37 00401 MACHINE ID (L) (Upper 8 characters out of 16 Status display
(lower 8 digits)
ASCII characters)
38 20216 Build version BUILD VER (Upper 8 characters out of 16 Status display
ASCII characters)
39 20217 Calibration Data version CAL VER Status display
(8 ASCII characters)
40 20401 Hardware SIN (R) R-ECM S/N 0 – 49999999 Status display
R-POWER
41 03205 Battery voltage (R) 0.0 – 480.00 V
SUPPLY
42 36403 Common rail pressure (R) R-RAIL PRESS 0 – 400 MPa
Common rail pressure sensor
43 36404 R-RAIL PRESS 0.00 – 5.00 V
voltage (R)
44 04205 Fuel temperature (R) R-FUEL TEMP -40 – 210 °C
Fuel temperature sensor
45 14202 R-FUEL TEMP 0.00 – 5.00 V
voltage (R)
Controller internal R-ECM IN
46 18901 -40 – 210 °C
temperature (R) TEMP
PCV valve close timing
47 17202 R-PCV TIMING -180.0 – 180.0 CA
(BTDC standard) (R)
48 20218 Calibration Data version (R) R-CAL VER Status display
(8 ASCII characters)
model or option.
*2: Abbreviated forms are employed since the number of displayed letters is limited.
played.
WA800-3E0, WA900-3E0 9

VHMS [VHMS controller system]
Monitoring
code
1 37501 Atmospheric temperature AIR TEMP -30 – +100 °C
2 42800 Blow-by pressure BLOWBY PRESS 0.0 – 20.0 kPa
Exhaust gas tempera-
3 42600 EXHAUST TMP FR 200 – 950 °C
ture (Front right)
4 42601 EXHAUST TMP FL 200 – 950 °C
ture (Front left)
5 42608 EXHAUST TMP RR 200 – 950 °C
ture (Rear right)
6 42609 EXHAUST TMP RL 200 – 950 °C
ture (Rear left)
Transmission pump oil
7 43000 TM PUMP PRESS 0.00 – 50.00 MPa
pressure
Work equipment pump oil
8 01136 LO PUMP PRESS 0.00 – 50.00 MPa
pressure
Steering pump oil
9 29700 ST PUMP PRESS 0.00 – 50.00 MPa
pressure
Torque converter oil
10 30103 T/C OIL TEMP 0 – 160 °C
temperature
11 04407 Hydraulic oil temperature HYD TEMP 24 – 131 °C
12 91904 Brake oil pressure (Front) BRAKE PRESS F 0.00 – 50.00 MPa
13 91905 Brake oil pressure (Rear) BRAKE PRESS R 0.00 – 50.00 MPa
14 30213 Brake oil temperature BRAKE OIL TEMP 24 – 131 °C
15 04304 Alternator R ALTERNATOR R 0.0 – 30.0 V
01010101 [1 and 0 are indicated below the
applicable display (Number)] [1] represents Status
16 40944 Input signal D_IN_0-7 D-IN--0------7
input signal is ON, and [0] represents input display
signal is OFF or not used portion.
17 40945 Input signal D_IN_8-115 D-IN--8-----115
010 [1 and 0 are indicated below the appli-
cable display (Number)] [1] represents Status
18 40972 Input signal D_IN_16-18 D-IN--16-18
19 40946 Output signal D_OUT-7 D-OUT-0--7
output signal is ON, and [0] represents out- display
put signal is OFF or not used portion.
20 40947 SEL signal 0-3 D-SEL-0--3
output signal is ON, and [0] represents out- display
put signal is OFF or not used portion.
model or option.
played.
10 WA800-3E0, WA900-3E0

EPL [Pre-lubrication controller system]
Monitoring
code
20248 ROM part number VERSION Arabic numerals Status display
20246 Application version VERSION(APP) Arabic numerals Status display
20247 Data version VERSION(DATA) Arabic numerals Status display
04305 Charge level ALTERNATOR R 0.00 – 30.00 V
40973 Input signal D_IN_0-7 D-IN--0------7 See attached table Status display
40974 Output signal D_OUT-7 D-OUT-0------7 See attached table Status display
40975 Output signal D_OUT_8-15 D-OUT-8-----15 See attached table Status display
40976 Output signal D_OUT_16-23 D-OUT-16----23 See attached table Status display
model or option.
played.
WA800-3E0, WA900-3E0 11
Service mode (*1): When the cursor is located at the left-

1. Procedure for switching to Service mode most position, pressing the switch
and screen display restores the normal screen (Operator
When using Service mode, carry out the fol- mode).
lowing special operation to switch the screen When the cursor is at a location other
display. than the leftmost position, pressing
1-1. Confirmation of screen display the switch returns the cursor to the
Make sure that the engine service monitor is leftmost position.
set to the operator mode and any of the If any switch operation is not done for
KOMATSU, User code or Failure code is dis- 60 seconds or more from ID input
played on the screen. screen, the normal screen is automat-
1-2. Displaying ID input initial screen ically turned on.
Hold down [t] switch and [<] switch simultane-
ously for 5 seconds minimum to open ID input
initial screen.
a Holding down the two switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the buttons.
1-4. Displaying menu initial screen

a After settling 4-digit ID, turn on the menu
initial screen of Service mode.
a Once entered and settled, an ID remains
effective until the starting switch is turned
off.
1-3. Inputting and confirming ID

Operate the buttons to input the ID.
q ID: 6491
1) Cursor (C) is positioned at the highest-
order digit. Pressing [<] and [>] switches
changes the value of this digit in the range
of 0 – 9.
2) Press [U] switch when the intended value
appeared to specify it.
a The cursor moves to the 2nd digit.
3) Set the value in the same order and then
press [U] switch.
a When you have entered a wrong value to
a position except the highest-order digit,
move to the highest-order digit using [t]
switch to repeat the procedure from the
first. In this case, values that had been
entered remain as they are until modified.
When the cursor is at the highest-order
digit, it can move to the higher layer using
[t] switch.(*1).
12 WA800-3E0, WA900-3E0
1-5. Selecting service mode menu 2. Electrical system fault history display func-
a Pressing [<] and [>] switches from the tion (ELECTRIC FAULT)
menu screen displays Service mode The machine monitor records the past failures
menus endlessly in the following order. in the electrical system as the failure codes.
a The menus are displayed in the field indi- The failure codes are displayed from the fol-
cated with [*] mark. lowing operations.
[1] 39699.0 h: Service meter display 2-1. Selecting the menu
[2] ELECTRIC FAULT: Electrical system Select the ELECTRIC FAULT from the menu
fault history display function screen of Service mode.
[3] MACHINE FAULT: Mechanical sys- a [**] field displays total number of the fault
tem fault history display function history currently recorded (up to 20
[4] REAL-TIME MONITOR: Real-time cases).
monitoring function
[5] CYLINDER CUT-OUT: Engine
reduced-cylinder function
[6] NO INJECTION: No injection crank-
ing function
[7] OPERATION INFO: Operating infor-
mation display function
[8] SNAPSHOT: Manual snapshot
[9] OPTIONAL SELECT: Optional device
selecting function
[10] INITIALIZE: Initialize function (Func-
tion specialized for plant)
1-6. Completion of mode and function
Either of the following procedures ends a
mode or function independent of the function
being selected and the layer in which it is used. 2-2. Displaying fault history
1) When the operation is to be continued Press [U] button while the menu is selected to
using another mode or function: Press [t] display the recorded fault history.
switch to return to the mode screen or
menu screen to be used next.
a Note, however, that [t] switch functions
as an execution key on [YES/NO] screen.
a When the normal screen (Operator mode)
was inadvertently turned on, repeat above
steps from 1) (input of the ID is not neces-
sary).
2) When ending an operation completely:
Turn the starting switch off from the cur-
rent state.
2-3. Displayed fault history

The electrical system fault history display func-
tion displays the following information.
A: Record number
B: Failure code (Location code in four digits +
Problem code in two digits)
C: Number of occurrences (number of occur-
rences of same code in past)
D: Elapsed time 1 (Elapsed time on service
meter from the first occurrence)
E: Elapsed time 2 (Elapsed time on service
meter from the last occurrence)
WA800-3E0, WA900-3E0 13
a The code of a failure currently occurring is

indicated in flashing.
“Failure code list” of the failure code dis-
play function.
a Note that part of the information displayed
from the electrical system fault history dis-
play function and the failure code display
function is not identical.
a When the requested fault history is not
recorded, [-] is indicated in the display
space.
2-6. Deleting all fault history

1) Press [<] or [>] switch while the fault his-
tory is on the screen to display the ALL
CLEAR menu screen.
2-4. Switching fault history display

Pressing [<] or [>] switch while a set of fault
history is on the screen displays another set of
recorded fault history.
2-5. Deleting individual fault history
1) Press [U] switch while the target fault his-
tory of deletion is on the screen to turn on
CLEAR screen. 2) Press [U] switch to display the ALL
2) Select “YES” or “NO” using [<] or [>] CLEAR screen.
switch. 3) Select “YES” or “NO” using [<] or [>]
a The selected cursor will start flashing. If switch.
“YES” is selected and [ t ] sw itc h is a The selected cursor will start flashing. If
pressed, the information will be deleted. If “YES” is selected and [ t ] switch is
“NO” is selected and [t] switch is pressed, pressed, the information will be deleted. If
deletion is cancelled and the “Electrical “NO” is selected and t switch is pressed,
system fault history selection” screen is deletion is cancelled and the “Electrical
restored. system fault history selection” screen is
a By default, the cursor is set to NO (cancel) restored.
to prevent resetting error. a By default, the cursor is set to NO (cancel)
a Information of the currently occurring fail- to prevent resetting error.
ure is not deletable. a Information of the currently occurring fail-
ure is not deletable.
14 WA800-3E0, WA900-3E0
3. Mechanical system fault history display 3-3. Displayed fault history

function (MACHINE FAULT) The mechanical system fault history display
The machine monitor records the past failures function displays the following information.
in the mechanical system as the failure codes.
The failure codes are displayed from the fol- A: Record number
lowing operations. B: Failure code (Location code in four digits +
3-1. Selecting the menu Problem code in two digits)
a Select MACHINE FAULT from the menu C: Number of occurrences (number of occur-
screen of Service mode. rences of same code in past)
a [**] field displays total number of the fault D: Elapsed time 1 (Elapsed time on service
history currently recorded. meter from the first occurrence)
E: Elapsed time 2 (Elapsed time on service
meter from the last occurrence)
a The code of a failure currently occurring is
indicated in flashing.
“Failure code list” of the failure code dis-
play function.
a Note that part of the information displayed
from the mechanical system fault history
display function and the failure code dis-
play function is not identical.
a When the requested fault history is not
recorded, [-] is indicated in the display
space.
3-2. Displaying fault history

Press [U] switch while the menu is selected to
display the recorded fault history.
3-4. Switching fault history display

Pressing [<] or [>] switch while a set of fault
history is on the screen displays another set of
recorded fault history.
3-5. Deleting fault history (Not available)
The fault history of the mechanical system is
not deletable.
WA800-3E0, WA900-3E0 15
4. Real-time monitoring function 4-3. Selecting sub menu

(REAL-TIME MONITOR) a Press [<] or [>] switch from the sub menu
The machine monitor checks state of the screen to display the sub menus endlessly
machine on real-time basis referencing signals in the following order.
of the sensors being installed in various parts a The sub menus are displayed in the field
of the machine. indicated with [*] mark.
The real-time monitoring functions displays fol- [1] MONITOR PANEL: Machine monitor
lowing two types of information. system
q 1 item independent display [2] ENGINE: Engine controller system
(for each controller) [3] ENGIN SUB: Engine controller (Child)
q 2 items simultaneous display system
(code input) [4] VHMS: VHMS controller system
4-1. Selecting the menu [5] PRELUBE: Pre-lubrication controller
Select REAL-TIME MONITOR from the menu system
screen of Service mode. [6] 2 ITEMS: 2 items display
4-2. Displaying sub menu 4-4. Setting the 1 item individual monitoring
Press [U] switch while the menu is selected to 1) Select the target controller system of mon-
display the sub menu initial screen. itoring from the sub menu screen.
16 WA800-3E0, WA900-3E0
2) Press [U] switch while the sub menu is 4-5. Setting 2 items simultaneous monitoring
selected to display the MONITOR PANEL 1) Select 2 ITEMS from the sub menu
screen. screen.
3) Press [<] or [>] switch to select a monitor- 2) Press [U] switch while the sub menu is
ing item. selected to display the monitoring code
a The monitoring items are scrolled accord- input screen.
ing to the internally set order.
a Holding down [U] switch turns on high-
speed scrolling.
a Holding and cancelling the monitoring
data: Pressing [U] switch while the moni-
toring is in progress holds the monitoring
data and [U] mark starts flashing.Press-
ing [U] switch again restores the active
state.
1] This cursor (C) is located at the high-

est-order digit. Pressing [<] or [>]
switch changes the value of this digit
in the range of 0 – 9.
2] Press [U] switch when the intended
value appeared to specify it as the set
value.
a The cursor moves to the 2nd position.
3] Set the value in the same order and
then press [U] switch.
4) Display data for 1 item individual monitor- a When you have entered a wrong
ing value to a position except the highest-
The 1 item individual monitoring screen order digit, the cursor can move to the
displays the following information. highest-order digit using [ t ] switch
A: Item display and repeat the procedure from the
B: Monitoring codes (5 digits) first. In this case, values that had
1: Monitoring data been entered remain as they are until
(including the unit used) modified. When the cursor is at the
a See the “Monitoring code list” for highest-order digit, it can move to the
details. higher layer using [t] switch.
WA800-3E0, WA900-3E0 17
3) As both monitoring codes are settled, the 5. Engine reduced-cylinder function

2 ITEMS screen will be turned on. The engine reduced-cylinder function denotes
a Holding and cancelling the monitoring setting the injector of a single cylinder or two or
data: more cylinders to electrically no injection state
Pressing [U] switch while the monitoring and turns on the operation on reduced-cylinder
is in progress holds the monitoring data condition. When any cylinders of the engine
and [U] mark starts flashing.Pressing [U] were suspected for abnormal output (combus-
switch again restores the active state. tion), this approach is used to single out the
failed cylinder.
1) Selecting the menu
Display the CYLINDER CUT-OUT screen
from the menu screen of Service mode.
4) Display data for 2 items simultaneous

monitoring
a The 2 items simultaneous monitoring
screen displays the following information.
A: Monitoring code 1
1: Monitoring data 1 (including the unit 2) Displaying sub menu
used) Press [U] switch while the menu is
B: Monitoring code 2 selected to display the sub menu.
2: Monitoring data 2 (including the unit
used)
a See the “Monitoring code list” for details.
18 WA800-3E0, WA900-3E0
3) Selection between activation and non-acti- 4) Selecting a cylinder to be reduced

vation on a bank basis Using [<] or [>] switch, select a cylinder to
From the activation/non-activation selec- be reduced from No. 1 – No. 6 cylinders
tion screen on a bank basis, select the and then settle the selected cylinder using
activation or non-activation of the right or [U] switch.
l e ft b a n k u s i n g t h e [ > ] , [ < ] a n d [ t ] a The cylinder to be reduced is selectable
switches. while the engine is running.
q [>]: Switches the selection screen. a Any number of cylinders can be reduced –
q [<]: Switches the selection screen. a single unit or two or more units.
q [t]: Returns to the reduced cylinder q [>] switch: Advances the cursor right-
mode display screen. ward
q [U]: Proceeds to the reduced cylinder q [<] switch: Advances the cursor left-
operation screen. ward
a To switch the screen, it shall be operated q [U] switch: Settles the cylinder to be
with an 8-second minimum time interval reduced (the cursor starts flashing
since it may take time in some cases to after the settlement)
bring one of the banks to the all stop. q [t] switch: Restores the CYLINDER
q When setting the right bank side to the all CUT-OUT screen
active in confirming the left bank side
a As the reduced-cylinder command is

q When setting the right bank side to the all stop issued from the engine controller to the
in confirming the left bank side cylinder to be reduced, the bottom of the
stopped cylinder number turns to black.
5) Cancelling a reduced cylinder

Using [<] or [>] switch, select the currently
stopped cylinder and then press [U]
switch to cancel the reduced-cylinder
command from the engine controller. The
black display will disappear.
WA800-3E0, WA900-3E0 19
6. No injection cranking function

The machine monitor is equipped with the
function capable of lubricating the engine
through no injection cranking. When a machine
has been stored for a long time, this function is
used to lubricate the engine prior to its restart
in order to prevent its wear or damages out of
oil.
The no injection cranking must be set up while
the engine is stopped.
1) Selecting menu
Display the NO INJECTION screen from
menu screen of Service mode.
2) Pressing [U] switch sets up the no injec-

tion cranking.
a If this screen does not appear as [U]
switch is hit, a communication error should
be suspected.
a If the no injection cranking is selected as

the engine is running, the engine stop
instruction screen will appear.
a In such case, stop the engine once and
then do the set up again.
20 WA800-3E0, WA900-3E0
7. Operating information display function

It is a fuel consumption-related function and
displays the following information.
q Fuel consumption ratio and average fuel
consumption
q Cumulative fuel consumption and travel
distance
q Cumulative fuel consumption and elapsed
time
q Loaded volume and loading frequency
(This display is available only when the
load meter is installed.)
1) Selecting menu
Display the OPERATION INFO screen
from the menu screen of Service mode.
2] Cumulative fuel consumption and
elapsed time
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
q The counting is stopped at 99999.9,
the upper limit.
a The lower column displays the
elapsed time [h] from the last reset-
ting.
the upper limit.
a Calculation is done only for the dura-
tion in which the engine is running.
2) Press [U] switch to display the fuel con-

sumption ratio and average fuel consump-
tion screen.
3) Using [<] or [>] switch, select the item to
be displayed from 1] – 2] on the fuel con-
sumption ratio and average fuel consump-
tion screen.
1] Fuel consumption ratio and average
fuel consumption screen
a The upper column is blank.
the upper limit.
a The lower column displays the aver-
age fuel consumption [L/h] from the
last resetting.
the upper limit.
a Calculation is done only for the dura-
tion in which the engine is running.
WA800-3E0, WA900-3E0 21
4) Deleting display data 7] Press [U] switch when the intended

a Select a desired item and then delete it value appeared to specify it as the set
using [U] switch. value.
a Use [t] switch when canceling deletion of a The cursor moves to the 2nd digit.
data. 8] Set the values up to the lowest digit in
the same order as above and then
press [U] switch to settle.
a As the selection is settled, the pre-
ceding screen is restored.
a If [t] switch is pressed before finish-
ing entering, the cursor moves to the
[+] and [–] position. In this case, the
value remains unchanged. Pressing
[t] switch again restores the preced-
ing screen.
a If the value is not in the –50 – +50
range, pressing [U] switch at the low-
est digit just moves the cursor the [+]
and [–] position and the value
remains as it is.
5) Setting gain correction
a Gain correction denotes the function of
correcting cumulative fuel consumption.
a Gain correction is available only from the
fuel consumption ratio and average fuel
consumption screen.
1] After deleting data (RESET screen),
press [<] or [>] switch to display the
current set value.
2] Pressing [U] switch displays the cor-

rection screen.
a Default value: 0.0%
a This setting allows correcting the
cumulative fuel consumption in the
range of –50.0 to +50.0.
3] Move the cursor to [+] or [–].
4] Pressing [<] or [>] switch alternately
displays [+] and [–].
5] Press [U] switch to settle [+] or [–].
a The cursor moves to the highest-
order digit of the set value.
6] Pressing [<] or [>] switch changes the
value of this digit in the range of 0 – 9.
22 WA800-3E0, WA900-3E0
8. Manual snapshot function 3) Press [U] switch to start the snapshot.

a The manual snapshot function stores 7 min- a The upper column displays the
utes and 30 seconds worth data to be used for elapsed time.
Pm clinic or testing/adjustment to VHMS con- a [–] sign in the leftmost position of the
troller. lower column is replaced with [*] and
a When collecting data at a regular interval for it starts flashing.
Pm clinic, it is required to observe the machine a For every 30 seconds, [–] is replaced
operating procedure specified for the quick with [*] starting with the leftmost one.
Pm. As for the data collection for the testing or When two or more [*] signs are dis-
adjustment purpose, however, no specified played, the rightmost one flashes.
machine operating procedure is stipulated. a Pressing [t] switch while the snap-
a When using the data being stored with the shot is taking place stops the snap-
manual snapshot function, a PC must be con- shot.
nected. For the connecting as well as operat-
ing procedure, refer to VHMS controller initial
setting procedure. (Connection of a PC may be
done before or after the snapshot.)
a For detail of operation of the snapshot function,
see the Quick Pm implementation procedure.
1) Display the SNAPSHOT screen from the
menu screen of Service mode.
4) Refer to the Pm clinic implementation pro-

cedure for the machine operation.
a After 10th [*] is displayed (5 minutes
elapsed from the start), [#] will be dis-
played for 11th through 15th posi-
tions.
q *: Indicates the data sampling interval
is once every 10 seconds.
2) Pressing [U] switch to turn on the ready q #: Data sampling interval is once
(READY) screen. every 1 second.
a The lower column displays 15 pieces of
[–] sign. 5) As 7 minutes and 30 seconds elapsed
from start of the snapshot, following
screen appears and then the initial screen
is restored in 5 seconds later.
(End of snapshot)
WA800-3E0, WA900-3E0 23
9. Optional device selecting function

a When enabling an optional setting, turn the starting switch off once after changing the current set-
ting, and turn on the starting switch again after respective in-vehicle controller power supplies have
been completely turned off (it takes approx. 10 seconds).
a List of installed optional devices and their setting
Check item Display in English Default Description of selection

VHMS controller VHMS Provided Selects Yes or No to installation of VHMS controller
Pre-lubrication
PRELUBE Not provided Selects Yes or No to installation of pre-lubrication controller
controller
Power ladder
LADDER Provided Selects Yes or No to installation of power ladder controller
controller
24 WA800-3E0, WA900-3E0
1) Display the “OPTIONAL SELECT” screen a Pressing [U] switch alternately displays
from the Service Mode menu screen. “1:VHMS NO ADD” or “1:VHMS ADD”
screen.
10. Initializing function

This function is prepared exclusively for the
plant use and not used for service purpose.
2) Hold down [U] switch for 5 seconds or

longer.
9-1. Option setting/not setting selection

a Among the items included in the list of
installed optional devices and their setting,
modify the target item of the option set-
ting/not setting in the following manner.
a If the options are not selected, “1:VHMS
NO ADD” screen appears.
a If the options are selected, “1:VHMS ADD”

screen is displayed.
WA800-3E0, WA900-3E0 25
VHMS controller initial setting 1. Confirmation of machine information,

procedure 1 engine information, transmission controller
information and controller information
a Equipment used for VHMS controller initial set- a This confirmation procedure is targeted at
ting the entire machine.
Confirm and record the machine informa-
Symbol Part No. Part name tion, engine information, VHMS controller
1 799-608-3101 Service kit information and ORBCOMM terminal
information.
2 799-608-3211 • Diskette
3 799-608-3220 • Harness
No. Information to be confirmed
W Note type PC
Commercially 1 Model name
4 (Windows 98/2000/Me/XP/
available 2 Machine serial No.
Vista)
Commercially 3 Current service meter hour
5 RS232C-USB conversion cable
available 4 Engine serial No.
5 Transmission serial No.
a Initial setting of VHMS controller shall be done
according to the following procedure. This 6 VHMS controller serial No.
operation is needed prior to a full-scale opera- 7
ORBCOMM terminal serial No.
tion of a machine being delivered and assem- [Only for machines equipped with ORBCOMM]
bled in the field, or prior to resumption of its
operation after a long time of storage. a VHMS controller (1) and ORBCOMM ter-
a Machine data collected with VHMS controller minal (2) are installed at the bottom of the
are stored and managed on WebCARE data- operator seat.
base. In order to endure smooth data process-
ing on WebCARE, consistency must be
provided among the settings done on VHMS
controller. Inconsistencies in the settings
obstruct loading of data to WebCARE, ham-
pering appropriate use of VHMS data. The ini-
tial setting, therefore, is a must.
a For the installation procedure of the VHMS ini-
tial setting program to a PC, refer to the “Oper-
ation and maintenance manual” being bundled
with the service kit W1.
a In the procedure, service menus of the monitor
panel are used. Thus, it is advisable to refer-
ence the information contained in the “Special
functions of monitor panel” to understand their
procedure beforehand.
a The initial setting procedure is described in the
ORBCOMM installation specification and the
ORBCOMM-less specification. When using the
ORBCOMM-less installation specification,
implement the procedures needed for VHMS
alone, bypassing those prepared only for ORB-
COMM installation specification.
a Check each step of the setting work referencing
the “VHMS initial setting work check sheet”.
a Information such as models shown in the fig-
ures may not be identical with actual ones.
26 WA800-3E0, WA900-3E0
2. Connecting a PC 3. Confirming VHMS controller operation and

a This work is done inside the cab. confirming satellite capturing state
1) Make sure the starting switch is at OFF a This work is done inside the cab.
position. a Confirmation of capturing of the satellite is
k Before connecting or disconnect- done for [ORBCOMM installation specifi-
ing a PC, be sure to turn off the cation].
starting switch. 1) Turn the starting switch ON.
2) With personal computer W4 switched ON, 2) Check the controller for normal operation
connect it to download connector DPC7 referencing 7-segment LED of VHMS con-
by wiring harness W3. troller.
a Connect RS232C terminal of the PC. a VHMS controller is fed with switch
a If the personal computer does not power supply. Thus, its operation is
have the connection port for RS232C judged normal if its 7-segment LED
terminal, connect by using RS232C- starts flashing while rotating as the
USB conversion cable W5. starting switch is turned on and then if
(To use the USB conversion cable, its the controller starts counting in the
driver must be installed to the personal ascending order.
computer.)
3) Among the 7-segment LED situated in the

a Download connector DLF is installed right side of VHMS controller, refer to the
in the front side of the bottom of oper- one that represents the decimal point to
ator seat. check whether or not ORBCOMM control-
ler has captured the communication satel-
lite. [ORBCOMM installation specification]
a Check whether or not ORBCOMM
controller is capturing the communi-
cation satellite from VHMS controller.
a It is successfully capturing the satel-
lite when the LED representing the
decimal point in the right side 7-seg-
ment LED is flashing.
WA800-3E0, WA900-3E0 27
4. Starting the VHMS initial setting tool 5. Initial setting of VHMS controller (Ver. 3. 5. 2. 1
a This work is done inside the cab (from PC). or older version)
1) Operating [VHMS initial setting tool] icon on a This work is done inside the cab (from
the PC, start up the VHMS initial setting tool. PC).
a It is prohibited in the initial setting to mod-
Important ify the data of service meter [SMR].
a Appearance of the setup screen of [Machine Information]
the VHMS setting tool depends its 1) Open [Machine Information] tab.
tool. a [Data clear and Set up] menu displays
a When using Ver.3.5.2.1 or older ver- [Machine Information] tab first.
sion (CD-ROM), the setting proce- 2) Check every data for correctness.
dure shall conform to that described
in Section 5.
a When using an update version
(Ver.3.5.2.1 or after), the procedure in
Section 6 shall be used.
a It is recommended to download the
latest VHMS version from WebCARE
to update the currently used version.
(Related material: Service mate SMP-623)
2) Enter the 10-digit service ID to [Service ID].
a Service ID: 7826144000
3) Select [Data clear and Set up] from
[Select Function] item.
4) Click [OK] button to proceed to the setup
screen.
3) When [Date/Time] information is not appro-

priate, correct it in the following manner.
1] Press [Edit] button in the lower right
side of [Date/Time] box to display the
correction screen.
2] After correcting it to the correct infor-
mation, press [OK] button.
28 WA800-3E0, WA900-3E0
4) When [Machine Information] information is [Communication Setting] [ORBCOMM installation

not appropriate, correct it in the following specification only]
manner. a This setting shall be implemented after the
1] Press [Edit] button in the lower right request for station opening has been made
side of [Machine Information] dialog and station of ORBCOMM has been opened.
box to display the correction screen. 6) Open [Communication Setting] tab.
2] After correcting it to the correct infor- 7) Check every data for correctness.
mation, press [OK] button.
5) As every data in [Machine Information]

has been checked and corrected, press
[Apply] button to settle the setting.
a As [Apply] button is pressed, a mes-
sage confirming above setting will
appear on the screen. Check the set- 8) When modifying the setting of [SHORT
ting again and, if the setting is correct, FAULT HISTRY], employ the following
press [OK] button. procedure.
a ORBCOMM installation specification 1] Select [SHORT FAULT HISTRY] from
requires the settlement operation after the screen and then press [Edit] button
[Communication Setting] is completed. in the lower left side of [File Transfer
Setting] block to display the setup
screen.
2] Correct the setting and, as it is com-
pleted, press [OK] button.
a In the initial setting, select [Occur-
rence] from [Timing] item and then
set the function to ON.
WA800-3E0, WA900-3E0 29
9) When modifying the setting of [SHORT 11) As every data in [Communication Setting]
TREND ANALYSIS], employ the following has been checked and corrected, press
procedure. [Apply] button to settle the setting.
1] Select [SHORT TREND ANALYSIS] a As [Apply] button is pressed, a mes-
from the screen and then press [Edit] sage confirming above setting will
button in the lower left side of [File appear on the screen. Check the set-
Transfer Setting] block to display the ting again and, if the setting is correct,
setup screen. press [OK] button.
2] Correct the setting and, as it is com-
pleted, press [OK] button.
a In the initial setting, enter [20h] to
[SMR] and then set the function to
ON.
10) When modifying the setting of [Satellite 12) As every data in [Machine Information]
Setting], employ the following procedure. and [Communication Setting] has been
1] Press [Edit] button in the [Satellite checked and corrected, press [Exit] button
Setting] block to display the correc- to end [VHMS initial setting tool].
tion screen.
2] Set the GCC code to the region
applied and, as setting is completed,
press [OK] button.
GCC Code Area Remarks

N.America (*1) *1: Except U.S. Territories
1 C.S.Americas in Micronesia and Midway
Faroe Islands Island
Europe (*2)
Middle East
Asia(*3) *2: Except Faroe Islands
120
Africa *3: Except Japan
Oceania
CIS
130 Japan
30 WA800-3E0, WA900-3E0
6. Initial setting of VHMS controller (Ver. 3. 5. 2. 1 3) Confirm the machine information and, if
or later version) they are correct, press [Next] button.
a This work is done inside the cab (from PC).
a It is prohibited in the initial setting to mod-
ify the data of service meter [SMR].
1) Select [VHMS Setting] and then press
[Next] button.
a When VHMS has been installed later,

it is required to enter the information
such as [Serial No.].
2) Select [Set up & All clear] and press [Next]

button.
WA800-3E0, WA900-3E0 31
4) Select the time zone. 8) If there is no problem in the setting dis-

5) Enter the local time. played last, press [Apply] button.
6) When DST (Daylight Saving Time) (or
summer time) is currently used, press
[Next] button.
a Selecting DST advances the clock by
an hour. Thus, correction of the time
is needed again.
9) A screen message will confirm whether or

not the data before the setting is to be
saved. If the data is not necessary, select
[NO].
7) Set the GCC code to the target region of

application and, as setting is completed,
press [Next] button.
GCC Code Area Remarks

N.America (*1) *1: Except U.S. Territories
1 C.S.Americas in Micronesia and Midway
Faroe Islands Island
Europe (*2)
Middle East
Asia(*3) *2: Except Faroe Islands
120
Africa *3: Except Japan
Oceania
CIS
130 Japan
10) As correction of the first setting is com-

pleted, press [OK] button to end the pro-
gram.
32 WA800-3E0, WA900-3E0
11) Turn the starting switch OFF.

Check that the 7-segment LED of the
VHMS controller keeps displaying for sev-
eral seconds and then goes off securely.
12) Opening station request of ORBCOMM

terminal
Fill in the necessary matters in the paper
of “VHMS request of ORBCOMM termi-
nal” and send KOMTRAX Support Center,
Komatsu Ltd. by fax or mail.
WA800-3E0, WA900-3E0 33
To: KOMTRAX Support Center, Komatsu Ltd.

Phone +81-463-22-8780 Important
Fax +81-463-22-8448
Address 3-25-1 Shinomiya, Hiratsuka-shi, Kanagawa 254-8555, Japan
E-mail cs_kom@komatsu.co.jp
For VHMS equipped machine;

DO NOT connect ORBCOMM antenna and turn the
machine key switch ON prior to terminal activation.
If ORBCOMM antenna is connected and the

machine key switch is turned on prior to terminal
activation,
ORBCOMM Inc (USA) send command signal
automatically to disable the ORBCOMM terminal.
After 24 hours from disable, Orbcomm terminal

(part number 7826-12-2302 or up) will be
reactivated automatically.
Older ORBCOMM terminal is not re-activated
automatically.
VHMS Request for ORBCOMM Terminal

To activate ORBCOMM terminal, please fill in the below form and send by fax or e-mail to
KOMTRAX Support Center, Komatsu Ltd.
Terminal Info.
Terminal Part Number P/S (Please fill in terminal P/S & S/N or put on enclosed sticker
here)
Terminal S/N S/N
Terminal Activation Date (YY/MM/DD) / /

Country to use
Machine Info. Model-Type-#S/N – #
With GPS Antenna Yes / No
DB Info.
DB’s Contact Address
DB’s Name
Phone Number (Country-Area-Local-Local) – – –
Fax Number (Country-Area-Local-Local) – – –
E-mail Address
Name (Please print) First Middle Family
Subsidiary Info.
Subsidiary’s Contact Address
Subsidiary’s Name
Phone Number (Country-Area-Local-Local) – – –
Fax Number (Country-Area-Local-Local) – – –
E-mail Address
Name (Please print) First Middle Family
Signature
Notes)
It will take one or two weeks to activate after being received this sheet.
ORBCOMM terminal is unable to communicate before activation being completed.
34 WA800-3E0, WA900-3E0
7. Executing quick Pm 6) Press the mode switch 1 [U] to start the

a Quick Pm denotes the Pm click done by snapshot.
use of the manual snapshot function of the a As the snapshot is started, the upper
machine monitor. column starts displaying the elapsed
a It stores 7 minutes and 30 seconds worth time.
of data to VHMS controller. a [–] in the leftmost position of the lower
k Park the machine in a flat place. column is replaced with [*] for every
30 seconds. When two or more [*]
1) Start the engine. signs are displayed, the rightmost
2) Switch the engine service monitor to Ser- one flashes.
vice Menu. a When stopping the snapshot currently
a For the procedure of opening Service taking place, press the mode switch 1
Menu, see the Special functions of [t].
engine service monitor.
3) Display the manual snapshot function
screen from the menu screen of Service
mode.
7) After the snapshot is started, operate the

machine according to the following table.
a Make sure the engine coolant tem-
perature and torque converter oil tem-
4) Press the mode switch 1 [U]. perature are within the operating
5) [READY] will be displayed on the screen, range.
turning on the standby mode. a After 10th [*] is displayed (5 minutes
a The lower column displays 15 pieces elapsed from the start), [#] will be dis-
of [–] sign. played for 11th through 15th posi-
tions.
q *: Indicates the data sampling interval
is once every 10 seconds.
q #: Indicates the data sampling interval
is once every 1 second.
WA800-3E0, WA900-3E0 35
a Machine operation for snapshot
Machine operation
No. Start End
Machine status Power mode Work equipment
1 0:00 1:00 Low idle OFF —
2 1:00 1:30 Hi idle OFF —
3 1:30 2:00 Hi idle ON —
4 2:00 2:30 Low idle ON Right steering
5 2:30 3:00 Hi idle ON Right steering
6 3:00 3:30 Low idle ON Left steering
7 3:30 4:00 Hi idle ON Left steering
8 4:00 4:30 Low idle ON Bucket relief
9 4:30 5:00 Hi idle ON Bucket relief
10 5:00 5:30 T/C stall (Note 1) ON —
11 5:30 6:00 Hi idle ON —
12 6:00 6:30 T/C stall (Note 1) ON Bucket relief
13 6:30 7:00 Hi idle ON Foot brake operation (Note 2)
14 7:00 7:30 Low idle ON Foot brake operation (Note 2)
(Note 1): 1) Set the auto-shift and manual selector switch to the manual.
2) Press the brake pedal fully, set the lever to F3 (forward at 3rd) and set the engine to high idle.
(Note 2): Repeat pumping of the foot brake 20 times.
36 WA800-3E0, WA900-3E0
8) As 7 minutes and 30 seconds elapsed

from start of the snapshot, following
screen appears and then the initial screen
is restored in 5 seconds. (End of snap-
shot)
WA800-3E0, WA900-3E0 37
Important 10) Open the quick Pm data to draw a graph.

Data of quick Pm are recorded only once. a Select time for X-axis and select the
Thus, if another quick PM is repeated, the cur- following for Y-axis.
rent data will be overwritten with the last one. q Engine speed
In order to avoid above trouble, be sure to q Fuel Inject (fuel injection)
download data of every completed quick Pm to q Blowby Press (Blow-by pressure)
PC. For the procedure, see “8. Download of q RH F Exhaust Temp (Exhaust tempera-
setting data”. ture 1, 2 and 3 cylinders)
q RH R Exhaust Temp (Exhaust tem-
9) Read the quick PM data by use of the perature 4, 5 and 6 cylinders)
analysis tool. q LH F Exhaust Temp (Exhaust tempera-
a For detailed usage of the analysis ture 1, 2 and 3 cylinders)
tool, see the “Operation and mainte- q LH R Exhaust Temp (Exhaust temper-
nance manual”. ature 4, 5 and 6 cylinders)
q Engine Oil Temp (Engine oil tempera-
ture)
q Engine Oil Press (Engine oil pres-
sure)
q Coolant Temp (Engine coolant tem-
perature)
q Boost Press (Boost pressure)
q Accelerator Pos (Accelerator angle)
q Ambient Temp (Ambient temperature)
q Loader Pump P (Work equipment oil
pressure)
q ST Pump Press (Steering oil pressure)
q Hyd Oil Temp (Hydraulic oil tempera-
ture)
q Shift Indicator (Shift position)
q T/C Oil Temp (Torque converter oil
temperature)
q Transmission Pump P (Transmission
pump pressure)
q Brake (F.R) Charge P (Front and rear
brake pressure)
q Brake Oil Temp (Brake oil tempera-
ture)
38 WA800-3E0, WA900-3E0
11) Apply a check mark to the Display graph

value at clicked position.
WA800-3E0, WA900-3E0 39
12) Clicking the graph shows, below the

graph, the X-axis value of respective mea-
surement items. (An example of a graph
displayed – Not an actual one)
40 WA800-3E0, WA900-3E0
13) Record above values in the Pm clinic inspection sheet.

a Following shows the relation between the data needed for Pm clinic and the measuring condi-
tions.
Measurement items
Transmission PUMP pressure

Exhaust gas temperature
Rear brake temperature

Steering pump pressure
Loader pump pressure
Front brake pressure

Engine oil pressure
Blow-by pressure
Boost pressure
Engine speed
E/P
Machine operation
mode
Low idle E-mode Q Q Q
Hi idle E-mode Q Q
Hi idle P-mode Q Q
Right steering + low idle P-mode Q
Right steering + high idle P-mode Q
Left steering + low idle P-mode Q
Left steering + high idle P-mode Q
Bucket relief + low idle P-mode Q
Bucket relief + high idle P-mode Q Q
Torque converter stall (Note 1) P-mode Q Q Q Q
Hi idle P-mode
Torque converter stall + bucket relief P-mode Q Q Q Q
Foot brake operation (Note 2) + high idle P-mode Q Q
Foot brake operation (Note 2) + low idle P-mode Q Q
WA800-3E0, WA900-3E0 41
8. Download of setting data

1) Using harness [1] of service kit W1, con-
nect PC W4 to download connector DLF
in the cab or download connector VDL on
the ground.
2) When using download connector DLF in

the cab, set the starting switch to ON posi-
tion.
3) When using download connector VDL on
the ground, set switch (4) to ON position.
a Download connector DLF in the cab a The green LED will come on.
is installed in the front side of the bot-
tom of operator seat.
4) Operating [VHMS analysis tool] on PC,

start up the VHMS analysis tool.
a Download-to-ground connector VDL
is provided under cover (3) in the
accumulator installation position,
which is located on the left side of the
machine body.
42 WA800-3E0, WA900-3E0
a Enter [User Name] and [Password]. 9. Confirmation of download data

a For the operating procedure, see the 1) Check the setting data using [View] function.
VHMS analysis tool operation and a For the operating procedure, see the
maintenance manual. VHMS analysis tool operation and
maintenance manual.
a Make sure that [MFA0] code, which
was used in the quick snapshot, is
indicated in [Fault History].
a Make sure the snap shot data are
recorded.
5) Using [Download] function, download the

data currently recorded on VHMS to PC.
a For the operating procedure, see the
VHMS analysis tool operation and
maintenance manual. 2) As check of the setting data is finished,
a After making sure the download is end [VHMS analysis tool].
complete, proceed to the next step.
WA800-3E0, WA900-3E0 43
10. Disconnecting the PC

1) Make sure the starting switch is at OFF
position.
k Before connecting or disconnect-
ing a PC, be sure to turn off the
starting switch.
2) End the OS of PC W4 and then turn off the
PC power.
11. Report to Komatsu

As steps 1 – 9 are completed, send VHMS/
WebCARE setting report to VHMS/WebCARE
Support Center in Komatsu Headquarters.
a This report is a must since setting on the
receiving end in the satellite communica-
tion must be done by Komatsu.
a In this case, send VHMS data via Notes
3) When the data was download into the cab, (LAN) or E-mail (WAN).
disconnect harness [1] of service kit W1 Komatsu VHMS/WebCARE Support Center
from download connector DLF.
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: webcare@komatsu.co.jp
4) When the data was download to the

ground, disconnect harness [1] of service
kit W1 from download connector VDL
44 WA800-3E0, WA900-3E0
[For storage] Date of setting:

DB/branch
VHMS Initial Setting Work Check Sheet office name
Data entered by:
Setup step Check item Result
Model name
Serial No.
Confirmation of machine body and
1 Engine serial No.
component nameplates
Transmission controller serial No.
VHMS controller serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
Is “Data Clear and Set up” selected for the setting tool
4 Starting of VHMS initial setting tool yes no
mode?
Initial setting of VHMS controller Is model name identical with machine body? yes no
Is machine body serial No. correctly entered? yes no
(Setting of machine body informa- Is engine serial No. correctly entered? yes no
5 tion)
In this step, basic machine body Is today's date entered? yes no
information are set on VHMS con- Is current time entered? yes no
troller
Is SMR correctly entered? yes no
6 Saving of settings Is LED (7-segment) turned off? yes no
7 Confirmation of VHMS function Is LED operation normal? yes no
Is service mode “SNAPSHOT” turned on and is the

8 Execution of quick Pm yes no
switch hit?
9 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
10 Download Is LED operation normal? yes no
Are all files downloaded? yes no

Hour, min-
The time downloaded (Reference wrist watch)
ute:
[Confirmation of data]
11 Confirmation of download data
Is [MFA0] error present in Fault History? yes no
Are SMR and time in Fault History consistent with set-
yes no
tings?
Is any data missing in Snap Shot0? yes no
12 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
WA800-3E0, WA900-3E0 45
[For storage] Date of setting:

DB/branch
ORBCOMM Station Opening Work office name
Check Sheet Data entered by:
Setup step Check item Result
Model name
Serial No.
Confirmation of machine body and Engine serial No.
1
component nameplates Transmission serial No.
VHMS controller serial No.
ORBCOMM terminal serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
4 Starting of VHMS initial setting tool Is “Set up” selected for the setting tool mode? yes no
Entry of setting to S.Fault History

Initial setting of VHMS controller Presence/absence of communication On Off
1. Setting of communication
(Setting of machine body infor- Number of cases (Default is 8 cases)
mation and PLM are completed) Entry of setting of S.Trend Analysis setting
Presence/absence of communication On Off
Interval (Default is 20H)
5
Entry of setting of S.Payload data
Presence/absence of communication On Off
Tabulation start time
Interval of tabulation (in days) day
2. Setting for start of communica-
Is GCC code set? (130 for Japan) yes no
tion
6 Saving of settings Is LED (7-segment) turned off after data was stored? yes no
How is decimal point display in VHMS monitor

ORBCOMM controller performance
7 (7-segment)? yes no
check
(OFF, ON, long/short flashing)
46 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 47
Precautions for replacing VHMS 2. Confirmation, saving and loading of VHMS

controller 1 controller setting information (Ver. 3. 5. 2. 1 or
older version)
a Care should be paid to the following equipment a This work is done inside the cab (from PC).
when replacing VHMS controller a Setting information is saved from the
VHMS controller to be replaced to the PC
Symbol Part No. Part name and the saved information is loaded to the
799-608-3101 Service kit new VHMS controller after the replace-
ment.
1 799-608-3210 • Diskette
2-1. Confirmation and saving of VHMS controller
W 799-608-3220 • Wiring harness setting information prior to replacement
Commercially Note type PC 1) Connect the PC and start the VHMS initial
2
available (Windows 98/2000/Me/XP) setting tool.
a See the “VHMS controller initial set-
a When it is required to replace a VHMS control- ting procedure” for this operation.
ler, setup of the replacing VHMS controller 2) Select [Save/Load] and press [OK] button.
shall be conducted before and after the
replacement according to the following proce-
dure.
a Machine data collected with VHMS controller
are stored and managed on WebCARE data-
base. In order to endure smooth data process-
ing on WebCARE, consistency must be
provided among the settings done on VHMS
controller. Inconsistencies in the settings
obstruct loading of data to WebCARE, ham-
pering appropriate use of VHMS data. Setting
work after replacement, therefore, is a must.
a Check each step of the setting work referenc-
ing the “VHMS initial setting work check
sheet”.
a Information such as models shown in the fig-
ures may not be identical with actual ones.
[Operations needed prior to replacement of

VHMS controller]
1. Download of the remaining data
a This work is done inside the cab (from PC).
a Using [Download] function, download the 3) Confirm every information before the
currently recorded and remained data on replacement.
VHMS to PC. 4) Select [Save] from [File] of the menu.
a For the operating procedure, refer to “8.
Download of setting data” in “VHMS con-
troller initial setting procedure”.
48 WA800-3E0, WA900-3E0
2-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
initial setting tool.
ting procedure” for this operation.
2) Select [Save/Load] and press [OK] button.
5) Reconfirm the information and then press

[OK] button to save the information.
3) Select [Load] from [File] of the menu.
6) Select [Exit] from [File] of the menu to end

the VHMS setting tool.
7) Disconnect the PC.
a Refer to “10. Disconnecting the PC” in
“VHMS controller initial setting proce-
dure”.
8) Turn the PC power off.
9) Proceed to replacement of VHMS control-
lers.
WA800-3E0, WA900-3E0 49
4) Currently saved information will be dis- 7) After adjusting time, press [OK] button.
played. Press [OK] button.
8) Press [Apply] button to display contents of

the setting. Check the setting again and, if
it is acceptable, press [OK] button.
5) Display the saved information on another

screen.
6) Press [Edit] button and adjust the time.
50 WA800-3E0, WA900-3E0
9) The confirmation screen will ask whether 3. Confirmation, saving and loading of VHMS
or not the data before the above setup is controller setting information (Ver. 3. 5. 2. 1
to be saved. Press [NO] button. or later version)
a It is not necessary to save the data before a This work is done inside the cab (from PC).
the setting. a Setting information is saved from the VHMS
controller to be replaced to the PC and the
saved information is loaded to the new
VHMS controller after the replacement.
3-1. Confirmation of VHMS controller setting infor-
mation prior to replacement
1) Connect the PC and start the VHMS initial
setting tool.
2) Select [When VHMS needs to be replaced]
and then press [Next] button.
10) The setup result is displayed. Confirm the

contents and press [Close] button.
3) Select [Save current setting before

replacement of VHMS controller] and
press [Next] button.
11) Select [Exit] from [File] of the menu to end

the VHMS initial setting tool.
WA800-3E0, WA900-3E0 51
4) Confirm every information before the 3) Select [Use previous setting after replace-
replacement and then press [Save] but- ment of VHMS controller] and press [Next]
ton. button.
5) Select [Exit] from [File] of the menu to end 4) Currently saved information will be dis-
the VHMS initial setting tool. played. Press [Next] button.
6) Disconnect the PC.
a Refer to “10. Disconnecting the PC” in
“VHMS controller initial setting proce-
dure”.
7) Turns the PC power off.
8) Proceed to replacement of VHMS control-
lers.
3-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
initial setting tool.
2) Select [When VHMS needs to be
replaced] and then press [Next] button.
5) Adjust the time and press [Apply] button.
52 WA800-3E0, WA900-3E0
6) The confirmation screen will ask whether [Operations needed after replacement of VHMS
or not the data before the above setup is controller]
to be saved. Press [NO] button. a Execute the quick Pm referring “7. Executing
a It is not necessary to save the data quick Pm” in “VHMS controller initial setting
before the setting. procedure”.
a Download the data referring “8. Download of
setting data” in “VHMS controller initial setting
procedure”.
a After the replacement, send VHMS/WebCARE
setting report sheet to VHMS/WebCARE Sup-
port Center in Komatsu Headquarters.
a Also send two sets of data, the downloaded
before and after the VHMS replacement, via
Notes (LAN) or E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: webcare@komatsu.co.jp
7) The above completes modification of the

setting. Press [OK] button to end the
VHMS initial setting tool.
WA800-3E0, WA900-3E0 53
Pm-clinic inspection table 1

WA800-3E0 Serial No. 70001 and up
Machine serial No. #
Engine serial No.

hour inspection SAA12V140E-3
Work instruction No. Date of execution Service meter Inspector

Year: Month: Day: hours
Interview with operator and walk-around check

Is there abnormality before starting inspection? Outside temperature
Max. °C
Min. °C
Altitude m
Maximum coolant temperature (overheated)? Maximum torque converter oil temperature

(During operation) (overheated)? (During operation)
a If machine is cold, warm it up.

a Working mode: P-mode
Standard
Service limit Measure-
Item Condition Unit value for new Good Bad
value ment result
machine
WA800-3E0 +60 +60
650 –30 650 –30
Engine at low idle
WA900-3E0 +60 +60
850 –30 850 –30
Engine at high idle +20 +20
2,200 –30 2,200 –30
Engine at high idle WA800-3E0 2,040 ± 100 2,040 ± 200
and torque con-
verter stalled WA900-3E0 2,120 ± 100 2,120 ± 200
Engine at high idle WA800-3E0 2,080 ± 100 2,040 ± 200
Engine speed and work equipment rpm
relieved WA900-3E0 2,150 ± 100 2,150 ± 200
Normal Normal
1,600 ± 100 1,600 ± 200
WA800-3E0
Active Active
Torque converter 1,870 ± 100 1,870 ± 200
Engine
stalled + Work equip-

ment relieved Normal Normal
1,640 ± 100 1,640 ± 200
WA900-3E0
Active Active
1,900 ± 100 1,900 ± 200
Engine at high idle and torque converter kPa Max. 2.94 Max. 2.94
Blow-by pressure
stalled {mmH2O} {Max. 300} {Max. 300}
0.29 – 0.44 0.2
Engine at high idle
Lubricating oil MPa {3.0 – 4.5} {2.0}
SAE15W-40
pressure {kg/cm2} Min. 0.08 0.07
Engine at low idle
{Min. 0.8} {0.7}
Engine at high idle and torque converter kPa Min. 126.66
Boost pressure —
stalled {mmHg} {Min. 950}
Engine at high idle and torque converter
Exhaust
stalled °C Max. 680 750
temperature
Outside temperature: 20°C
Torque converter
0.79 – 0.94 0.59 – 0.94

Inlet pressure
{8.0 – 9.5} {6.0 – 9.5}
Engine at high idle
MPa
Torque converter oil temperature: Within
Outlet {kg/cm2} 0.59 ± 0.10 0.59 ± 0.10
operating range
pressure {6.0 ± 1.0} {6.0 ± 1.0}
54 WA800-3E0, WA900-3E0
a When the transmission position is at the speed range, apply the brake securely. Good Bad
Engine: 2,000 rpm 2.75 2.75
Main relief
Transmission: Neutral (+0.29/0) (+0.29/0)
pressure
Oil temperature: Within operating range {28 (+3/0)} {28 (+3/0)}
Directional lever:
Reduced pilot Neutral 0.93 – 1.13 0.93 – 1.13
pressure Gear shift lever: {9.5 – 11.5} {9.5 – 11.5}
1st to 2nd speed
Directional lever:
Transmission
Modulation pres- Neutral

2.45 – 2.74 2.45 – 2.74
sure Neutral and MPa
Gear shift lever: {25 – 28} {25 – 28}
1st speed {kg/cm2}
2nd to 1st speed Oil temperature when
engine is at high idle:
Directional lever: Within operating range
Modulation pres- Neutral
2.45 – 2.74 2.45 – 2.74
sure Neutral and
Gear shift lever: {25 – 28} {25 – 28}
2nd speed
1st to 2nd speed
Pressure reduc- Directional lever:
ing valve pres- Neutral 1.86 – 2.06 1.86 – 2.06
sure Neutral and Gear shift lever: {19 – 21} {19 – 21}
3rd speed 2nd to 3rd speed
WA800-3E0, WA900-3E0 55
Pm-clinic inspection table

Standard
value for Service limit Measure-
Item Condition Unit Good Bad
new value ment result
machine
Secure frame with safety bar.
Steering
Steering relief 30.6 – 31.9 30.6 – 32.4

Engine at high idle
pressure MPa {312 – 325} {312 – 330}
Engine at low idle {kg/cm2}
AJSS EPC pressure
Steering in neutral
Tire inflation pressure: Specified pressure
Parking brake Test on flat and dry paved slope of 1/5
— Stopped Stopped
performance (11° 20').
Set machine in operating state.
Pad thickness 31.7 12.7
Parking brake mm
Clearance between pad and disc 0.88 – 0.24 2.1
Measure when
Charge cut-in brake oil pres- 5.9 – 6.4 5.4 – 6.9
pressure Hydraulic oil tempera- sure warning {60 – 65} {55 – 70}
ture: Within operating lamp goes off. MPa
range Measure when {kg/cm2}
Charge cut-out Engine at low idle brake oil pres- 9.8 – 10.8 9.3 – 11.3
pressure sure starts low- {100 – 110} {95 – 115}
Brake
ering after rising.

Engine: Stopped
Lowering of brake kPa Max. 0.49 Max. 0.49
Measure lowering of oil pressure from 4.9
oil pressure 2 {kg/cm2} {Max. 5.0} {Max. 5.0}
MPa {50 kg/cm } in 5 minutes.
Tire inflation pressure: Specified pressure
Test on flat, level, straight, and dry paved
road.
Wheel brake Braking initial speed: 20km/h,
m Max. 7.5 Max. 7.5
performance Delay in pressing pedal: Max 0.1 sec
Brake pedal pressing force:
Specified force, 294 ± 29.4 Nm {30 ± 3 kg}
Measure braking distance.
Wear of wheel
Measure with disc wear indicator. mm 4.5 – 11.5 Max. 13.6
brake disc
30.6 – 32.34 30.6 – 32.34
WA800-3E0
{312 – 330} {312 – 330}
Work equipment MPa
33.03 – 33.03 –
valve relief pressure N-mode {kg/cm2}
Hydraulic oil tem- WA900-3E0 35.28 35.28
Work equipment
perature: Within {337 – 360} {337 – 360}

operating range Rising time 9.9 – 10.9 Max. 13.3
Lift arm speed
Engine at high idle Lowering time 4.3 – 5.3 Max. 6.4
sec
Dump 2.2 – 2.8 Max. 3.7
Bucket speed
Tilt back 3.5 – 4.1 Max. 4.9
Hydraulic oil tem-
Bucket cylinder Max. 20 Max. 20
Hydraulic drift of perature: Within mm/
work equipment operating range 15 min.
Lift cylinder Max. 40 Max. 40
Engine: Stopped
Visual check of Front axle There must not be
Axle
—
differential drain plug Rear axle excessive metal powder.
Memo
56 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 57
SEN02157-04

© 2011 KOMATSU
All Rights Reserved
58
SEN02142-04
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
40 Troubleshooting 1
Failure code table, fuse and relay locations
Failure code table ........................................................................................................................................... 2
Method of displaying action code and failure code on machine monitor ........................................................ 9
Transmission & AJSS controller LED display ................................................................................................11
Transmission control system......................................................................................................................... 12
AJSS (Advanced Joystick Steering System) control system ........................................................................ 13
Location of fuse............................................................................................................................................. 14
Location of relay............................................................................................................................................ 18
WA800-3E0, WA900-3E0 1
SEN02142-04 40 Troubleshooting
Failure code table 1

1. Failure code by engine service monitor
Failure Applicable Action History Reference
Failure contents
codes equipment code classification manual
15B0NX Transmission oil filter: Clogging VH, MT — Electrical system
AA1ANX Air cleaner L.H: Clogged VH, MT — Electrical system
AA1BNX Air cleaner R.H: Clogged VH, MT — Electrical system

Alternator: Failure on battery charge circuit (R terminal signal is
AB00L4 PLC E01 Electrical system
present and engine is stopped)
Alternator: Failure on battery charge circuit (R terminal signal is
AB00L6 ESM E03 Electrical system
present and engine is stopped)
Alternator: Failure on battery charge circuit (Absence of R termi-
AB00MA ESM E03 Electrical system
nal signal and detection error)
Troubleshoot-
AB00MB PLC E01 Electrical system ing by failure
nal signal and detection error)
code (Display
AB00MC VH, MT — — of code)
nal signal and detection error
(Part 1)
B@BAZK Engine oil: Oil level low VH, MT — — SEN02144-01
B@BAZG Engine oil: Low oil pressure VH, MT — —

B@BCZK
Radiator coolant: Low coolant level VH, MT — —
b@BCZK
B@BDNS Engine: Overheating VH, MT — —
B@C6NS Front brake oil temperature: Overheating VH, MT — —
B@CENS Torque converter oil temperature overheating VH, MT — —
B@JFZG Brake oil: Low oil pressure VH, MT — —
CA111 Engine controller (Left bank) ENG E03 Electrical system
CB111 Engine controller (Right bank) ENG E03 Electrical system
CA115 Engine NE/Bkup speed sensor abnormality (Left bank) ENG E03 Electrical system
CB115 Engine NE/Bkup speed sensor abnormality (Right bank) ENG E03 Electrical system
CA122 Charge pressure sensor abnormally high level (Only left bank) ENG E03 Electrical system
CA123 Charge pressure sensor abnormally low level (Only left bank) ENG E03 Electrical system
CA131 Throttle sensor high error (Only left bank) ENG E03 Electrical system
CA132 Throttle sensor low error (Only left bank) ENG E03 Electrical system
Troubleshoot-
CA135 Oil pressure sensor abnormally high level (Only left bank) ENG E01 Electrical system ing by failure
CA141 Oil pressure sensor abnormally low level (Only left bank) ENG E01 Electrical system code (Display
of code)
Coolant temperature sensor abnormally high level (Only left
CA144 ENG E02 Electrical system (Part 2)
bank) SEN02145-01
Coolant temperature sensor abnormally low level (Only left
CA145 ENG E01 Electrical system
bank)
Charge temperature sensor abnormally high level (Only left
bank)
Charge temperature sensor abnormally low level (Only left
bank)
CA187 Sensor power supply (2) abnormally low level (Left bank) ENG E03 Electrical system
CB187 Sensor power supply (2) abnormally low level (Right bank) ENG E03 Electrical system
Engine oil temperature sensor abnormally high level (Only left
bank)
Engine oil temperature sensor abnormally low level (Only left
bank)
2 WA800-3E0, WA900-3E0

Failure contents
Ambient temperature sensor abnormally high level (Only left
bank)
Ambient temperature sensor abnormally low level (Only left
bank)
CA227 Sensor power supply (2) abnormally high level (Left bank) ENG E03 Electrical system
CB227 Sensor power supply (2) abnormally high level (Right bank) ENG E03 Electrical system
CA234 Engine overspeed (Only left bank) ENG E02 Electrical system
CA238 Ne speed sensor power supply abnormality (Left bank) ENG E03 Electrical system
CB238 Ne speed sensor power supply abnormality (Right bank) ENG E03 Electrical system
CA263 Fuel temperature sensor abnormally high level (Left bank) ENG E01 Electrical system
Troubleshoot-
CB263 Fuel temperature sensor abnormally high level (Right bank) ENG E01 Electrical system ing by failure
code (Display
CA265 Fuel temperature sensor abnormally low level (Left bank) ENG E01 Electrical system of code)
(Part 2)
CB265 Fuel temperature sensor abnormally low level (Right bank) ENG E01 Electrical system
SEN02145-01
CA271 PCV1 short circuit (Left bank) ENG E03 Electrical system
CB271 PCV1 short circuit (Right bank) ENG E03 Electrical system
CA272 PCV1 disconnection (Left bank) ENG E03 Electrical system
CB272 PCV1 disconnection (Right bank) ENG E03 Electrical system
CA273 PCV2 short circuit (Left bank) ENG E03 Electrical system
CB273 PCV2 short circuit (Right bank) ENG E03 Electrical system
CA274 PCV2 disconnection (Left bank) ENG E03 Electrical system
CB274 PCV2 disconnection (Right bank) ENG E03 Electrical system

Injector #1 (L/B#1) system disconnection/short circuit (Left
bank)
bank)
bank)
bank)
bank)
bank)
CA342 Engine controller data mismatch (Left bank) ENG E03 Electrical system
CB342 Engine controller data mismatch (Right bank) ENG E03 Electrical system Troubleshoot-
Injector drive circuit abnormality ing by failure
CA351 ENG E03 Electrical system code (Display
(Left bank)
of code)
CB351 Injector drive circuit abnormality (Right bank) ENG E03 Electrical system (Part 3)
SEN02146-01
CA352 Sensor power supply (1) abnormally low level (Left bank) ENG E03 Electrical system
CB352 Sensor power supply (1) abnormally low level (Right bank) ENG E03 Electrical system
CA386 Sensor power supply (1) abnormally high level (Left bank) ENG E03 Electrical system
CB386 Sensor power supply (1) abnormally high level (Right bank) ENG E03 Electrical system
CA431 Throttle in idle validation switch ENG E01 Electrical system
CA432 Idle validation action error ENG E03 Electrical system
CA441 Power supply voltage abnormally low level (Left bank) ENG E03 Electrical system
CB441 Power supply voltage abnormally low level (Right bank) ENG E03 Electrical system
CA442 Power supply voltage abnormally high level (Left bank) ENG E01 Electrical system
WA800-3E0, WA900-3E0 3

Failure contents
CB442 Power supply voltage abnormally high level (Right bank) ENG E03 Electrical system
CA449 Common rail abnormally high pressure (2) (Left bank) ENG E03 Electrical system
CB449 Common rail abnormally high pressure (2) (Right bank) ENG E03 Electrical system
CA451 Common rail pressure sensor abnormally high level (Left bank) ENG E03 Electrical system
CB451 Common rail pressure sensor abnormally high level (Right bank) ENG E03 Electrical system
CA452 Common rail pressure sensor abnormally low level (Left bank) ENG E03 Electrical system
CB452 Common rail pressure sensor abnormally low level (Right bank) ENG E03 Electrical system
CA553 Common rail abnormally high pressure (1) (Left bank) ENG E03 Electrical system
CB553 Common rail abnormally high pressure (1) (Right bank) ENG E03 Electrical system Troubleshoot-
ing by failure
CA554 Common rail pressure sensor in-range error (Left bank) ENG E03 Electrical system code (Display
of code)
CB554 Common rail pressure sensor in-range error (Right bank) ENG E03 Electrical system
(Part 3)
Supply pump low pressure (1)
CA559 ENG E03 Electrical system SEN02146-01
(Left bank)
CB559 ENG E03 Electrical system
(Right bank)
CA689 Engine Ne speed sensor abnormality (Left bank) ENG E03 Electrical system
CB689 Engine Ne speed sensor abnormality (Right bank) ENG E03 Electrical system
Intake air temperature sensor abnormally high level (Only left
bank)
Intake air temperature sensor abnormally low level (Only left
bank)
CA731 Engine Bkup speed sensor abnormal phase (Left bank) ENG E03 Electrical system
CB731 Engine Bkup speed sensor abnormal phase (Right bank) ENG E03 Electrical system
Engine controller all data loss
(Left bank)
Engine controller all data loss
(Right bank)
CA778 Engine Bkup speed sensor abnormality (Left bank) ENG E03 Electrical system
CB778 Engine Bkup speed sensor abnormality (Right bank) ENG E03 Electrical system
CA781 Inter-multicontroller communication error (Left bank) ENG E03 Electrical system
CB781 Inter-multicontroller communication error (Right bank) ENG E03 Electrical system
CA1257 Multicontroller distinction wiring harness key error (Left bank) ENG E03 Electrical system
CB1257 Multicontroller distinction wiring harness key error (Right bank) ENG E03 Electrical system Troubleshoot-
Injector #7 (R/B#1) system disconnection/short circuit (Right ing by failure
CB1548 ENG E03 Electrical system code (Display
bank)
Injector #8 (R/B#2) system disconnection/short circuit (Right of code)
CB1549 ENG E03 Electrical system (Part 4)
bank)
Injector #10 (R/B#4) system disconnection/short circuit (Right SEN02147-02
bank)
Injector #11 (R/B#5) system disconnection/short circuit (Right
bank)
bank)
bank)
CA1633 KOMNET abnormality (Left bank) ENG E03 Electrical system
Decelerator pedal sensor power supply abnormally high level
(Only left bank)
Decelerator pedal sensor power supply abnormally low level
(Only left bank)
4 WA800-3E0, WA900-3E0

Failure contents
(Left bank)
(Right bank)
CA2555 Intake heater relay voltage low error (At left bank) ENG E03 Electrical system
CA2556 Intake heater relay voltage high error (At left bank) ENG E03 Electrical system
D160KZ Abnormality in backup lamp relay system: Disconnection, short
TM — Electrical system
[10] TM* circuit or hot short circuit
D180KA Preheating relay output system: Disconnection PLC E01 Electrical system
D180KB Preheating relay output system: Grounding fault PLC E01 Electrical system
D180KY Preheating relay output system: Hot short circuit PLC E01 Electrical system
D19AKB Abnormality in joystick caution relay output system: Disconnec-
TM — Electrical system Troubleshoot-
[56] TM* tion or short curcuit ing by failure
D19BKZ Abnormality in joystick neutral interlock relay output system: Dis
TM E00 Electrical system code (Display
[62] TM* connection or short circuit of code)
D1EFKA Pre-lubrication start relay output system: Disconnection PLC E01 Electrical system (Part 4)
SEN02147-02
D1EFKB Pre-lubrication start relay output system: Grounding fault PLC E01 Electrical system
D1EFKY Pre-lubrication start relay output system: Hot short circuit PLC E01 Electrical system
D1EHKA Engine start relay output system: Disconnection PLC E01 Electrical system
D1EHKB Engine start relay output system: Grounding fault PLC E01 Electrical system
D1EHKY Engine start relay output system: Hot short circuit PLC E01 Electrical system
D5ZHL6 Staring switch terminal C signal: Error ESM E03 Electrical system
D5ZSKA Machine monitor communication output: Disconnection ESM E03 Electrical system
D5ZSKB Machine monitor communication output: Grounding fault ESM E03 Electrical system
D5ZSKY Machine monitor communication output: Hot short circuit ESM E03 Electrical system
Engine controller CAN-NET communication: Disconnection and
DB2RKR ESM E03 Electrical system
grounding fault
DBB0KK VHMS controller: Low supply voltage
VHMS — —
"n9" o "01" i VHMS LED display
DBB0KQ VHMS controller model selection: Disagreement of model selec-
tion signals VHMS — —
"nF" o "11" i VHMS LED display
DBB3KK VHMS controller: Low direct supply voltage
VHMS — —
DBB5KP VHMS controller sensor power supply (5V): Low output voltage
VHMS — —
DBB6KP VHMS controller sensor power supply (24V): Low output voltage
VHMS — —
"n9" o "02" i VHMS LED display Troubleshoot-
DBBQKR VHMS controller CAN communication abnormality ing by failure
VHMS — —
"n8" o "02" i VHMS LED display code (Display
of code)
DBG2KK Solenoid power supply: Low voltage PLC E03 Electrical system
(Part 5)
DBG3KK Battery direct power supply: Low voltage PLC E03 Electrical system SEN02148-02
DBG9KQ Model selection signal: Abnormal PLC E01 Electrical system

Pre-lubrication controller CAN-NET communication: Disconnec-
DBGRKR ESM E01 Electrical system
tion or grounding fault
Power ladder controller CAN-NET communication: Disconnec-
DBL0KR ESM E01 Electrical system
DDE2KB Engine oil pressure switch error: Grounding fault PLC E01 Electrical system
Engine oil pressure switch error: Disconnection or hot short cir-
DDE2L6 PLC E01 Electrical system
cuit
DDK3KZ Abnormality in joystick forward-reverse switch system: Discon-
TM CALL Electrical system
[20]TM* nection or hot short circuit
WA800-3E0, WA900-3E0 5

Failure contents
DDK5KZ Abnormality in shifting up/down switch system: Disconnection,
TM — Electrical system
[21]TM* short circuit or hot short circuit
DDP5KZ Abnormality in steering lock switch system: Disconnection or Troubleshoot-
TM E00 Electrical system
[60]TM* short circuit ing by failure
Atmospheric temperature sensor: Out of input signal range code (Display
DGE5KX VHMS — —
(short) of code)
Hydraulic oil temperature sensor: Out of input signal (Part 5)
DGH2KX VHMS — —
range(short) SEN02148-02
Front brake oil temperature sensor: Out of input signal range
DGR4KX VHMS — —
(short)
DGT5KA L.H. bank exhaust gas temperature sensor system (Front):
Disconnection or Resistance VHMS — —
dGT5KA L.H. bank exhaust gas temperature sensor system (Rear):
Disconnection or short circuit VHMS — —
DGT5KB L.H. bank exhaust gas temperature sensor system (Front):
Hot short circuit VHMS — —
dGT5KB L.H. bank exhaust gas temperature sensor system (Rear):
DGT6KA R.H. bank exhaust gas temperature sensor system (Front):
Disconnection or short circuit VHMS — —
dGT6KA R.H. exhaust gas temperature sensor system (Rear):
Disconnection or short circuit) VHMS — —
DGT6KB R.H. bank exhaust gas temperature sensor system (front):
dGT6KB R.H. bank exhaust gas temperature sensor system (front):
DHE5KB Blow-by pressure sensor system: Short circuit
VHMS — Electrical system
"n3" o "32" i VHMS_LED display Troubleshoot-
DHE5KY Blow-by pressure sensor system: Hot short circuit ing by failure
VHMS — Electrical system
Main pump oil pressure sensor error: Disconnection or short cir- of code)
DHP2KX VHMS — Electrical system
cuit (Part 6)
DHT3KX Transmission oil pressure sensor system: Out of input signal SEN02268-00
range VHMS — Electrical system
Steering pump oil pressure sensor error: Disconnection or short
DHT8KX VHMS — Electrical system
circuit
Front brake oil pressure sensor error: Disconnection or short cir-
DHU2KX VHMS — Electrical system
cuit
Rear brake oil pressure sensor error: Disconnection or short cir-
DHU3KX VHMS — Electrical system
cuit
DK00L8
Steering and frame angle displacement TM E00 Electrical system
[58]TM*
DK30KX Abnormality in steering angle potentiometer system: Disconnec-
[57]TM* tion or short circuit
DKD0KX Abnormality in frame angle potentiometer system: Disconnec-
[59]TM* tion or short circuit
DLE4KA Abnormality in engine speed sensor system: Disconnection,
DLT4KA Abnormality in speed sensor system: Disconnection, short cir-
[22]TM* cuit or hot short circuit
Pre-lubrication operation lamp output abnormality: Hot short cir-
DUM7KY PLC E01 Electrical system
cuit
Pre-lubrication operation lamp output abnormality: Disconnec-
DUM7KZ PLC E01 Electrical system
DXF0KZ Abnormality in joystick EPC solenoid system: Disconnection,
6 WA800-3E0, WA900-3E0

Failure contents
DXH4KZ Abnormality in 1st solenoid system: Disconnection, short circuit
[14]TM* or hot short circuit
DXH5KZ Abnormality in 2nd solenoid system: Disconnection, short circuit
DXH6KZ Abnormality in 3rd solenoid system: Disconnection, short circuit
DXH7KZ Abnormality in R solenoid system: Disconnection, short circuit or
[13]TM* hot short circuit
DXH8KZ Abnormality in F solenoid system: Disconnection, short circuit or
[12]TM* hot short circuit
F@BBZL Blow-by pressure sensor system: High pressure error
VHMS — —
F@BYNR L.H. front exhaust gas temperature sensor (2): Abnormal rise of
exhaust gas temperature VHMS — —
L.H. rear exhaust gas temperature sensor (2): Abnormal rise of Troubleshoot-
f@BYNR
exhaust gas temperature VHMS — — ing by failure
F@BYNS L.H. front exhaust gas temperature sensor (1): Abnormal rise of of code)
exhaust gas temperature VHMS — — (Part 6)
"n3" o "61" i VHMS LED display SEN02268-00
f@BYNS L.H. rear exhaust gas temperature sensor (1): Abnormal rise of
F@BZNR R.H. front exhaust gas temperature sensor (2): Abnormal rise of
f@BZNR R.H. rear exhaust gas temperature sensor (2): Abnormal rise of
F@BZNS R.H. front exhaust gas temperature sensor (1): Abnormal rise of
f@BZNS R.H. rear exhaust gas temperature sensor (1): Abnormal rise of
a Failure code:
Failure codes are arranged in ascending order from younger number and alphabetical order.
TM* represents LED indicator on transmission & AJSS controller and machine monitor.
a Associated component:
Associated component indicates the controller system where a failure has occurred.
ESM: Engine service monitor system
ENG: Engine controller system
TM: Transmission & AJSS (Advanced joystick steering system) controller system
PLC: Pre-lubrication controller system)
MTM: Maintenance monitoring system
VHMS: VHMS controller system
VH, MT: VHMS controller system and maintenance monitor system
a Action code:
Action code refers to data indicated on the operator mode when detecting failure code.
a Category of history:
The category of failure history shows which of the failure history indication function, electrical system or
mechanical system, should be used for recording a given failure code.
Note) This table includes items for optional equipment.
a Method of checking failure code displayed on engine service monitor is described in Structure and oper-
ation, "Engeins service monitor", "Service mode functions".
WA800-3E0, WA900-3E0 7
2. Failure code table by machine monitor
a Machine monitor can display the failure code and action code of transmission & AJSS (Advanced Joy-
stick Steering System) controller.
q Codes table of transmission & AJSS (Advanced Joystick Steering System) controller
Abnormal Reproducing
Action phenomenon operation Refer-
Failure Caution
code Abnormal system Saving ence
code Short Discon- Short Discon- buzzer
*1 code
circuit nection circuit nection
— 10 Backup lamp relay Q Q t a Q × D160KZ
12 F solenoid Q Q t a Q Q DXH8KZ
13 R solenoid Q Q t a Q Q DXH7KZ
14 1st solenoid Q Q t a Q Q DXH4KZ
CALL
15 2nd solenoid Q Q t a Q Q DXH5KZ
16 3rd solenoid Q Q t a Q Q DXH6KZ
20 Joystick forward-reverse switch Q Q a a Q Q DDK3KZ
— 21 Joystick shift-up/down switch Q Q a a Q Q DDK5KZ
22 Speed sensor × Q × a Q Q DLT4KA
E00
23 Engine speed sensor × Q × a Q × DLE4KA
— 56 Caution buzzer relay output Q × a t Q × D19AKB
57 Steering lever angle sensor Q Q a a Q Q DK30KX
Shifting of steering lever angle
58 Q Q a a Q Q DK00L8
sensor or frame angle sensor
59 Frame angle sensor Q Q a a Q Q DKD0KX
E00
60 Steering lock pressure switch Q Q a t Q Q DDP5KZ
62 Joystick neutral interlock relay Q × t a × Q D19BKZ
Steering basic pressure control
63 Q Q a a Q Q DXF0KZ
EPC solenoid
q When the starting switch is turned to the OFF position after a failure occurs, if the failure code disap-
pears, the failure can be reproduced by performing the reproducing operation shown in the table.
(a: Turn starting switch ON (Do not start engine), T: Start engine, t: Operate related actuator.)
a If any abnormality is detected, the joystick caution system operates.
a When failure code [56] is displayed, disconnection cannot be judged, since the related circuit is output-
ting signals constantly.
*1 Action code table
Action Transmission control system only Alarm

Action by operator
code Problem system Action of machine buzzer
Automatic gearshifting not
Disconnection in travel speed Normal operation possible
carried out (changes to man-
sensor system at manual
E00 ual gearshifting) No
Disconnection in engine Gearshifting not carried out in Normal operation possible
speed sensor system Auto mode. at manual
Shift lever system disconnec- Become neutral and cannot
tion, short circuit with GND, travel (Judges controller input
short circuit as N) Stop travelling
F, R solenoid signal system immediately,
Become neutral and cannot
CALL disconnection, short circuit Yes Turn starting switch OFF,
travel (Solenoid output off)
with GND, short circuit Call service after action
1st, 2nd, 3rd solenoid system above.
Become neutral and cannot
disconnection, short circuit
travel (Solenoid output off)
with GND, short circuit
8 WA800-3E0, WA900-3E0
Method of displaying action code Note: If the engine is not stopped, it is impossi-
and failure code on machine monitor1 ble to switch to the trouble data display
mode, so the codes for failures which
a Refer to “Testing and adjusting” for method of can only be detected when the engine is
displaying failure code on the engine service operating light up.
monitor.
a Main monitor is the same as machine monitor.
1. Outline
The speedometer display on the main monitor
is used to display the troubleshooting for each
control system. The nature of the troubleshoot-
ing is displayed as the action code, failure
code, and the time elapsed since failure.
The signals between the main monitor and
each controller are transmitted in serial
through the network circuit.
2. Display of action code

This code informs the operator directly of the
abnormality, and takes action, such as stop- 4. Saving failure code
ping the machine immediately. The transmission and joystick steering control-
There are three types of action code: E00, E01 ler writes the failure codes to memory.
+ CALL (E01 and CALL are displayed alter- 1) A total of 9 failure codes can be saved in
nately), and CALL. If a failure occurs suddenly, memory.
one of these codes is shown on the speedom- 2) The data that is saved to memory is as fol-
eter display. lows:
(1) Failure code
(2) Time elapsed since failure
(up to 1000 hours)
3) The failures are saved in the order that
they occur. If a failure code already exists
in the memory, the repeat failure code is
not saved.
4) If there are already 9 items in memory,
and a 10th failure occurs, the oldest item
is deleted and the new item is saved.
a It is possible to display the failure code
and time elapsed since failure for items
saved in memory by operating the main
monitor set switch.
3. Failure code and time elapsed since failure

The failures detected by each controller are
changed to a code and displayed. It is possible
to tell from this code which system in which
controller has failed, so carry out troubleshoot-
ing for the applicable controller.
For failure that have occurred and been reset,
the failure code and the time elapsed since fail-
ure are displayed to make it easy to check fail-
ures that are not occurring at present.
The failure codes for failures that are now
occurring flash, and the codes for failures that
are not occurring light up.
For details of the method of operating and
transferring data to the trouble data display
mode, see “Structure and function” for the
main monitor.
WA800-3E0, WA900-3E0 9
5. Switch operation procedure and actuation

Switch operation Actuation
Trouble data memory
mode display
1) Stop engine. • The failure code is dis-
2) Turn starting switch played on the speed-
ON. ometer display and the
3) Push operation mode time elapsed since fail-
switch (1) and head ure is displayed on the
lamp switch (2) simul- action code display.
taneously and keep • If there is no failure,
pressed for at least 5 the speedometer dis-
seconds. play shows [CC] and
the action code display
shows [0000].
Going to next failure
code
4) Press head lamp • The failure code and
switch (2). time elapsed since fail-
ure are displayed in
turn (when this is
done, the failure code
for the latest failure is
displayed first).
• If the failure still exists,
the display flashes; if
the failure has been
restored, the display
lights up.
Clearing failure code
5) Keep rear lamp switch • The failure code and
(3) pressed for at least elapsed time on the
2 seconds. display are cleared.
• If the failure still exists,
the failure code is not
cleared.
Quitting trouble data

memory display mode
6) Push operation mode • The display returns to
switch (1) and head the normal display.
lamp switch (2) simul-
taneously and keep
pressed for at least 5
seconds. Or start the
engine.
10 WA800-3E0, WA900-3E0
Transmission & AJSS controller LED display 1

The transmission & AJSS controller uses two 7-segment LEDs to display the internal condition of the control-
ler and input/output errors. The display shows two characters at the same time, and changes these in turn to
give the display.
a When the engine is started, “Program part No. display mode” appears, follwed by “Output speed range
display mode”. If there is any abnormality in the controller, it changes to “Troubleshooting mode”.
a The failure mode is saved to memory by the main monitor.
Table 1 (Output speed range display mode)

Display Content Display Content
0. 1. Neutral, 1st F. 3. FORWARD, 3rd
0. 2. Neutral, 2nd A. 1. REVERSE, 1st
0. 3. Neutral, 3rd A. 2. REVERSE, 2nd
F. 1. FORWARD, 1st Neutral safety condition or
E. 0.
F. 2. FORWARD, 2nd abnormality in selection signal
WA800-3E0, WA900-3E0 11
Transmission control system 1

12 WA800-3E0, WA900-3E0
AJSS (Advanced Joystick Steering System) control system 1

WA800-3E0, WA900-3E0 13
Location of fuse 1
a When carrying out troubleshooting related to the electrical system, you should check the breakers and
fuses links to see if the power is supplied normally.
Connection table and location of circuit breakers (30 A and 20 A) and fuse
a This connection table shows the devices to which each power supply of the circuit breaker and fuse box
supplies power (A switch power supply is a device which supplies power while the starting switch is in
the ON position and a constant power supply is a device which supplies power while the starting switch
is in the OFF and ON positions).
Types of power supply Breaker No. Breaker capacity Destination of power
CBF1 30 A Fuse box 1 (12) – (15) *1
Constant power supply
CBF2 20 A Engine controller L-bank (EM3)
(Battery output)
CBF3 20 A Engine controller R-bank (EM4)
Fuse box 1 (1) – (3) and (8) – (11) *1
Switch power supply 80 A
SBF1 Fuse box 2 (1) – (14) *1
(Battery relay output)
120 A Alternator B terminal
*1 For fuse boxes 1 and 2, see the next page and on.
14 WA800-3E0, WA900-3E0
Types of power supply Fuse No. Capacity of fuse Destination of power

Switch power supply Upper (E14) 350 A Heater relay (R.H.) (Engine)
(Battery relay output) Lower (E15) 350 A Heater relay (L.H.) (Engine)
WA800-3E0, WA900-3E0 15
Location and connection table for fuse box 1
a Numbers in the circle indicate the corresponding fuse numbers shown in the circuit diagram of respec-
tive failure codes.
q Fuse box 1
Breaker and
Type of power supply Fuse No. Capacity of fuse Destination of circuit
fuse output
(1) 20 A Main lamp circuit
(2) 20 A Rear lamp and brake lamp
(3) 10 A Turn signal lamp
(4) 10 A Right headlamp *2
(5) 10 A Left headlamp *2
Switch power supply SBF1 (80 A) (6) 10 A Right clearance lamp *2
(7) 10 A Left clearance lamp *2
(8) 10 A Parking brake
(9) 10 A Rotary lamp (if equipped)
(10) 10 A Instrument panel
(11) 10 A Work equipment positioner
(12) 20 A Starting switch
(13) 20 A Hazard lamp
Constant power supply CBF1 (30 A)
(14) 10 A Spare (if equipped)
(15) 10 A Auto grease A (if equipped)
*2 Power is supplied through fuse (1) and then conducted through the fuse again.
16 WA800-3E0, WA900-3E0
Location and connection table for fuse box 2
a Numbers in the circle indicate the corresponding fuse numbers shown in the circuit diagram of respec-
tive failure codes.
q Fuse box 2
Breaker and
Type of power supply Fuse No. Capacity of fuse Destination of circuit
fuse output
(16) 20 A Front working lamp
(17) 20 A Rear working lamp
(18) 30 A Air conditioner A (Condenser)
(19) 20 A Air conditioner B (Blower)
(20) 20 A Wiper and washer
(21) 10 A Transmission controller
(22) 10 A Cigarette lighter and radio
(23) 30 A Rear heat-resistant glass
Switch power supply SBF1 (80 A)
(24) 20 A Side working lamp
(25) 10 A Auto grease B (if equipped)
(26) 20 A Power window L.H.
(27) 20 A Power window R.H.
Air suspension seat and active
(28) 10 A
working
(29) 10 A Spare 1 DC converter (if equipped)
(30) 5A Engine controller
WA800-3E0, WA900-3E0 17
Location of relay 1
Location and connection table for relay (For AJSS spec)
q Relay (For AJSS spec)

Relay No. Relay name Remarks
L64 Engine oil pressure
L80 Dust indicator right
L79 Dust indicator left
L61 Rear working light
L68 Turn signal light
L57 Neutral
L58 Neutralizer
L59 Parking brake safety
L60 Front working light
L90 Front axle working light
L52 Hazard
L53 Brake light
L54 Backup light
L66 Head light
L73 Pre heated
L48 Bucket positioner
L49 Boom kick out
L65 A.J.S.S. caution
L67 Side marker light
L55 Horn
SL3 Step light
SL4 Step light timer
IL11 Led brightness
U04 Working system - 4
L95 S/T N interlock
L72 Grass heater
L51 Side working light
18 WA800-3E0, WA900-3E0
Location and connection table for relay (For steering wheel spec)
q Relay (For steering wheel spec)

L64 Engine oil pressure
L80 Dust indicator right
L79 Dust indicator left
L61 Rear working light
L68 Turn signal light
L57 Neutral
L58 Neutralizer
L59 Parking brake safety
L60 Front working light
L90 Front axle working light
L52 Hazard
L53 Brake light
L54 Backup light
L66 Head light
L73 Pre heated
L48 Bucket positioner
L49 Boom kick out
L65 Caution Option
L67 Side marker light
L55 Horn
SL3 Step light
SL4 Step light timer
L96 Start neutral hold
L72 Grass heater
L51 Side working light
WA800-3E0, WA900-3E0 19
Location and connection table for air conditioer relay
q Relay (For air conditioer)

A10 Blower
A11 Blower
A13 Blower
A16 Magnetic clutch
A19 Blower
A12 Condenser
A14 Condenser LH
A15 Condenser RH
20 WA800-3E0, WA900-3E0
Location and connection table for power window and prelube relay
q Relay (For power window and prelube)

L71 Power window relay
PRE5 Prelube start
PRE4 Engin start
PRE7 Lever safety
L29 Prelube set on
WA800-3E0, WA900-3E0 21
SEN02142-04

© 2011 KOMATSU
All Rights Reserved
22
SEN02143-02
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting ........................................................................................................... 3
Testing before troubleshooting........................................................................................................................ 4
Classification and procedures of troubleshooting ........................................................................................... 5
Contents of troubleshooting table ................................................................................................................... 6
Connection table for connector pin numbers .................................................................................................. 8
T- branch box and T- branch adapter table ................................................................................................... 44
WA800-3E0, WA900-3E0 1
Points to remember when troubleshooting 1

k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately after any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to
carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro-
cedure.
2. Points to ask user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Are abnormal symptoms detected in the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a
problem of handling, operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part
exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is repaired, the same failure may occur again, unless the root cause
of the failure is repaired. To prevent this, always investigate why the cause of the failure
occurred. Then, remove the root cause.
2 WA800-3E0, WA900-3E0
Sequence of events in troubleshooting 1
WA800-3E0, WA900-3E0 3
Testing before troubleshooting 1
Item Criteria Remedy

1. Check of level and type of fuel — Add fuel
2. Check for foreign matter in fuel — Clean or drain
3. Check of level and type of oil in engine oil pan Between H and L Add oil
Between FULL and
4. Check of coolant level Add coolant
LOW
5. Check of air cleaner for clogging No red Clean or replace
6. Check of level and type of hydraulic oil Between H and L Add oil
Lubricating oil
In upper range of site
and coolant 7. Check of level and type of transmission oil Add oil
gauge
8. Check of level and type of differential oil — Add oil
9. Check of level and type of brake oil — Add oil
10. Check of fuel filter for clogging — Replace
11. Check of engine oil filter for clogging — Replace
12. Check of hydraulic oil filter for clogging — Replace
13. Check of transmission oil filter for clogging — Replace
1. Check of battery terminal cables for looseness
— Retighten or replace
and corrosion
2. Check of alternator terminal cables for
Electrical — Retighten or replace
looseness and corrosion
parts
3. Check of starting motor terminal cables for
— Retighten or replace
looseness and corrosion
4. Check of operation of instruments — Repair or replace
1. Check for abnormal noise and smell — Repair
Hydraulic and 2. Check for oil leakage — Repair
mechanical
equipment 3. Bleeding air — Bleed air
4. Check of effect of brake — Repair or adjust
1. Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace
2. Check of battery electrolyte level Between U.L and L.L Add or replace
3. Check wires for discoloration, burn, and removal
— Replace
of cover
4. Check for removed wire clamp and drooping
— Repair
wire
Electrical 5. Check wiring for wetting with water

Disconnect and dry
equipment (Check connectors and terminals for wetting —
connectors
with water, in particular)
6. Check of slow-blow fuses and fuses for
— Replace
disconnection and corrosion
7. Check of alternator voltage After several-minute
Repair or replace
(with engine at medium speed or higher) operation: 27.5 – 29.5 V
8. Check of operating sound of battery relay
— Replace
(Starting switch OFF ⇔ ON)
4 WA800-3E0, WA900-3E0
Classification and procedures of troubleshooting 1

Classification of troubleshooting
Mode Contents
Display of
Troubleshooting by [electrical system] or [mechanical system] failure code
code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
M-mode Troubleshooting of machine monitor system
K-mode Troubleshooting of maintenance monitor system
W-mode Troubleshooting of remote boom positioner controller system (if equipped)
Troubleshooting procedures
If a problem occurs on the machine, or if it is felt that there is a problem, carry out troubleshooting as follows.
1. When engine service monitor or machine monitor displays failure code

If a failure code is displayed on the engine service monitor or machine monitor at the same time as the
problem occurs, check the content of the display, then go to the applicable troubleshooting chart for the
failure code.
2. When engine service monitor or machine monitor does not display failure code, but failure his-
tory is recorded
If a problem occurs but the failure code display cannot be checked on the engine service monitor or
machine monitor, use the failure history display function in the machine monitor service mode to check
for a failure code.
If a failure code is recorded, there is a high probability that this is the cause, so go to the applicable trou-
bleshooting chart.
3. When a failure code is not displayed and failure history is not recorded either
If a problem occurs but the failure code display cannot be checked on the engine service monitor or
machine monitor, and also the problem is not recorded by the failure history display function in the
machine monitor, the problem of the electrical, hydraulic or mechanical system that cannot be detected
by a controller may have occurred.
In this case, check the symptom of the trouble and then carry out troubleshooting related to that phe-
nomenon in the “E-mode”, “H-mode”, “S-mode”, “M-mode” or “K-mode”.
WA800-3E0, WA900-3E0 5
Contents of troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
a Monitor means the engine service monitor or machine monitor.
Action code Failure code

Failure
Display of Trouble that appears in the machine
Display of monitor symptom
monitor
Failure content State where the monitor or controller detects the trouble
Controller's Action to be taken to protect the system and equipment when the monitor or controller detects
action a trouble
Symptoms that
Problem that appears as an abnormality in the main unit by the action taken by the monitor or
appears
controller (above)
on machine
General
Information related to troubles occurred or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value in normal state required to judge the
assumed cause (good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or wiring harness is
disconnected.
• Ground fault
A harness not connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes
into contact with the power (24 V) circuit.
• Short circuit
Possible causes Causes by which a trouble A harness of an independent circuit abnormally comes into
and standard is assumed to be defected contact with one of another circuit.
value in normal (The order number indi-
state cates a serial number, not <Notes on troubleshooting>
a priority sequence.) (1) Method of indicating connector numbers and handling of T-
adapter
For troubleshooting, insert or connect T-adapter shown
3 below unless especially specified.
• When “male” or “female” is not indicated for a connector
number, disconnect the connector, and insert the T-
adapters in both the male and female.
• When “male” or “female” is indicated for a connector
number, disconnect connector, and insert the T-adapter
in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
4 leads as shown below unless especially specified.
• Connect the plus (+) lead to a pin or harness indicated in
the front.
• Connect the minus (–) lead to a pin or harness indicated
in the rear.
6 WA800-3E0, WA900-3E0
Related circuit diagram
This is the excerpted circuit diagram related to troubleshooting.

• Connector No.: Indicates (model – number of pins) (color)
• Arrow (io): Indicates the approximate mounting place on machine
WA800-3E0, WA900-3E0 7
Connection table for connector pin numbers (Rev. 2008.09)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
8 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 9
10 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 11
12 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 13
14 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 15
16 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 17
18 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 19
20 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 21
22 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 23
24 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 25
26 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 27
28 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 29
30 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 31
32 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 33
34 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 35
36 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 37
38 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 39
40 WA800-3E0, WA900-3E0
(Rev. 2006.11)
WA800-3E0, WA900-3E0 41
42 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 43
T- branch box and T- branch adapter table 1

(Rev. 2008.02)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
44 WA800-3E0, WA900-3E0
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
WA800-3E0, WA900-3E0 45
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280 Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
46 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 47
SEN02143-02

© 2009 KOMATSU
All Rights Reserved
48
SEN02144-01
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
Troubleshooting by failure code
(Display of code), Part 1
Failure code [15B0NX] (Transmission oil filter: Clogging)............................................................................... 4
Failure code [AA1ANX] (Air cleaner L.H: Clogged) ........................................................................................ 6
Failure code [AA1BNX] (Air cleaner R.H: Clogged)........................................................................................ 9
(R terminal signal is present and engine is stopped) ................................................................................ 12
(R terminal signal is present and engine is stopped) ................................................................................ 14
(Absence of R terminal signal and detection error)................................................................................... 16
Failure code [B@BAZK] (Engine oil: Oil level low) ....................................................................................... 22
WA800-3E0, WA900-3E0 1
Failure code [B@BAZG] (Engine oil: Low oil pressure) ................................................................................ 24

Failure code [B@BCZK] and [b@BCZK] (Radiator coolant: Low coolant level) ........................................... 28
Failure code [B@BDNS] (Engine: Overheating) ........................................................................................... 30
Failure code [B@C6NS] (Front brake oil temperature: Overheating) ........................................................... 32
Failure code [B@CENS] (Torque converter oil temperature overheating) .................................................... 34
Failure code [B@JFZG] (Brake oil: Low oil pressure)................................................................................... 36
2 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 3
Troubleshooting by failure code (Display of code), Part 1 1

Failure code [15B0NX] (Transmission oil filter: Clogging) 1
Action code Failure code Transmission oil filter: Clogging
Trouble
— 15B0NX (VHMS controller system and maintenance monitor system)
Contents of • When the torque converter oil temperature circuit reached 50°C or above, the signal circuit of trans-
trouble mission clogging sensor was opened (disconnected from the ground wire).
Action of
• None in particular.
controller
Problem that
appears on • If the machine is used as it is, dirt and dust may be entered into the transmission circuit.
machine
Related • Presence of clogging can be checked with D-IN-5 of monitoring code: 40944 (Normal: 0, Clogged: 1)
information • VHMS controller will send the failure code to the engine service monitor.
Causes Standard value in normal state/Remarks on troubleshooting

1 Transmission filter clogging • Clean it or replace.
2) Disconnect connector BC02 and BC03.
3) Connect T-branch.
Defective transmission filter
2 Resis-
clogging sensor Between BC02 Filter is normal Max. 1 z
tance
(male) (1) – (2), and
BC03 (male) (1) – (2) Filter is clogged Resis-
Min. 1 Mz
tance
1) Turn starting switch ON.
2) Disconnect D16, then carry out troubleshooting with D16 being
turned OFF (measurement in the diode range).
3 Defective diode Between D16 (male) Forward direction: Continue
Continuity
(3) (+) – (2) (–) Reverse direction: No continuity
Between D16 (male) Forward direction: Continue
Possible causes Continuity
and standard
value in normal
2) Disconnect D16, VC04 and L18, then carry out troubleshooting
state
with their connection being turned OFF.
Disconnection in wiring Between VC04 (female) (11) – Resis-
Max. 1 z
harness D16 (female) (3) tance
4
(Disconnection or defective Max. 1 z
contact in connector) Between D16 (female) (2) and Resis-
When filter sensor is
chassis ground tance
normal
Between L18 (female) (16) – D16 Resis-
Max. 1 z
(female) (1) tance
2) Disconnect connector VC04.
4) Connect connector.
5 Defective VHMS controller 5) Turn starting switch on.
Between VC04 Filter is normal Voltage Max. 1 V
(female) (11) and
chassis ground Filter is clogged Voltage 20 – 30 V
4 WA800-3E0, WA900-3E0
Related electrical circuit diagram
WA800-3E0, WA900-3E0 5
Failure code [AA1ANX] (Air cleaner L.H: Clogged) 1

Action code Failure code Air cleaner L.H: Clogged
Trouble
— AA1ANX (VHMS controller system and maintenance monitor system)
Contents of
• Air cleaner clogging signal circuit is opened (disconnected from ground wire).
trouble
Action of
• Turns on the maintenance caution lamp.
controller
Problem that
appears on • If machine is operated as it is, the engine air intake performance may be deteriorated.
machine
• VHMS controller will send the failure code to the engine service monitor.
• Troubleshooting for air cleaner R.H clogging is carried out with failure code [AA1BNX]. When
[AA1BNX] is not indicated, replace, for instance, the relay, diode and air cleaner connector with that
Related of the air cleaner R.H circuit one by one. If, as the result, failure code [AA1ANX] is replaced with
information [AA1BNX], you can judge this replaced parts is the cause.
• Fuse (10) of fuse box 1 is not broken since failure code [AA1ANX] is indicated.
• When air cleaner L.H is normal, VC05 (1) is connected to chassis ground. When clogged: OPEN
• Clogging is checked with D-IN-7 of monitoring code: 40972 (Normal: 0, Clogged: 1)

Dust indicator is not lit in red Air cleaner is normal
1 Clogging on air cleaner
Dust indicator is lit in red Clogging on air cleaner
2) Replace L79 with a normal one.
Relay
Normal state is not
(L79) is
Confirm whether the normal state recovered normal
is recovered after L79 was
replaced. Defective
Normal state is
relay
recovered
Defective dust indicator relay (L79)
2
(L79) 1) Turn the starting switch OFF.
Possible causes 2) Disconnect connector L79.
and standard 3) Independent part check
value in normal Resis-
state Between L79 (male) (1) – (2) 260 – 320 z
tance
Resis-
Between L79 (male) (3) – (5) Min. 1M z
tance
Resis-
Between L79 (male) (3) – (6) Max. 1 z
tance
2) Disconnect connector B06.
3
Defective air cleaner a Since inside is consisted of electronic circuit, measurement of
clogging sensor resistance is not available.
Air cleaner is normal Voltage 20 – 30 V
Between B06 (1) – (2) Clogging on air
Voltage Max. 10 V
cleaner
6 WA800-3E0, WA900-3E0

Forward direction: The diode has
Between D21 (male) conductivity.
Continuity
4 Defective diode (3) (+) – (2) (–) Reverse direction: The diode
does not have conductivity.
Continuity
(1) (+) – (2) (–) Reverse direction: The diode
2) Disconnect D21, B06, VC05 and L18, then carry out trouble-
shooting with their connection being turned OFF.
Between VC05 (female) (1) – D21 (female) Resis-
Max. 1 z
(3) tance
Resis-
Disconnection in wiring Between D21 (female) (2) – L79 (female) (3) Max. 1 z
tance
harness
5 Resis-
(Disconnection or defective Between FS2 (female) (9) – L79 (female) (1) Max. 1 z
tance
Possible causes contact in connector)
Resis-
and standard Between B06 (female) (1) – L79 (female) (2) Max. 1 z
value in normal tance
state Between B06 (female) (2) and Resis-
Max. 1 z
Between L18 (female) (15) – D21 (female) Resis-
Max. 1 z
(1) tance
Wiring harness between VC05 (female) (1) – Resis-
Max. 1 z
Grounding fault in wiring D21 (female) (3) and chassis ground tance
6 harness (Short circuit with Wiring harness between D21 (female) (2) – Resis-
Max. 1 z
ground circuit) L79 (female) (3) and chassis ground tance
Wiring harness B06 (female) (1) – L79 Resis-
Max. 1 z
(female) (2) and chassis ground tance
Wiring harness between L18 (female) (15) – Resis-
Max. 1 z
D21 (female) (1) and chassis ground tance
2) Connect T-branch to connector VC05.
7 Defective VHMS controller
Air cleaner is normal Voltage Max. 1 V
Between VC05 (1)
and chassis ground Clogging on air
Voltage 20 – 30 V
cleaner
WA800-3E0, WA900-3E0 7
8 WA800-3E0, WA900-3E0
Failure code [AA1BNX] (Air cleaner R.H: Clogged) 1

Action code Failure code Air cleaner R.H: Clogged
Trouble
— AA1BNX (VHMS controller system and maintenance monitor system)
Contents of
• Air cleaner clogging signal circuit is opened (disconnected from ground wire).
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, the engine air intake performance may be deteriorated.
machine
• Troubleshooting for air cleaner L.H clogging is carried out with failure code [AA1ANX]. When
[AA1ANX] is not indicated, replace, for instance, the relay, diode and air cleaner connector with that
Related of the air cleaner L.H circuit one by one. If, as the result, failure code [AA1BNX] is replaced with
information [AA1ANX], you can judge this replaced parts is the cause.
• Fuse (10) of fuse box 1 is not broken since failure code [AA1BNX] is indicated.
• When air cleaner R.H is normal, VC05 (2) is connected to chassis ground. When clogged: OPEN
• Clogging is checked with D-IN-15 of monitoring code: 40945 (Normal: 0, Clogged: 1).

1 Clogging on air cleaner
Dust indicator is lit in red Clogging on air cleaner
Relay
Normal state is not
(L80) is
replaced. Relay
Normal state is
(L80) is
recovered
Defective dust indicator relay defective
2
(L80) 1) Turn the starting switch OFF.
Possible causes 2) Disconnect connector L80.
and standard 3) Independent part check
state Between L80 (male) (1) – (2) 260 – 320 z
tance
Resis-
Between L80 (male) (3) – (5) Min. 1 Mz
tance
Resis-
tance
3
Defective air cleaner a Since inside is consisted of electronic circuit, measurement of
clogging sensor resistance is not available.
Between B08 (1) – (2) Clogging on air
Voltage Max. 10V
cleaner
WA800-3E0, WA900-3E0 9

4 Defective diode Between D22 (male) Forward direction: Continue.
Continuity
(3) (+) – (2) (–) Reverse direction: No continuity.
Between D22 (male) Forward direction: Continue.
Continuity
Max. 1 z
(3) tance
Resis-
tance
harness
5 Resis-
tance
contact in connector)
Resis-
Between B08 (female) (1) – L80 (female) (2) Max. 1 z
Possible causes tance
and standard Between B08 (female) (2) and chassis Resis-
Max. 1 z
value in normal ground tance
state Between L18 (female) (14) – D22 (female) Resis-
Max. 1 z
(1) tance
Max. 1 z
Grounding fault in wiring D22 (female) (3) and chassis ground tance
6 harness (Short circuit with Wiring harness between D22 (female) (2) – Resis-
Max. 1 z
ground circuit) L80 (female) (3) and chassis ground tance
Max. 1 z
Max. 1 z
2) Connect T-branch to connector VC05.
Air cleaner is normal Voltage Max. 1 V
Between VC05 (2)
and chassis ground Clogging on air
Voltage 20 – 30 V
cleaner
10 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 11
Failure code [AB00L4] (Alternator: Failure on battery charge circuit (R

terminal signal is present and engine is stopped) 1
Action code Failure code Alternator: Failure on battery charge circuit (R terminal signal is
Trouble present and engine is stopped)
E01 AB00L4 (Pre-lubrication controller system)
• Engine is not operated normally (500 rpm or lower), due to the CAN communication data with the
Contents of
engine controller. However, the system is judged that charging voltage (12 V or above) from the alter-
trouble
nator R terminal is present.
Action of
• None in particular
controller
Problem that
appears on
machine
• Starting signal of starting switch: This failure code disappears if the voltage (24 V) is supplied from C
terminal.
• This failure code does not appear if the CAN communication from the engine controller is not possi-
ble.
• The engine service monitor carried out troubleshooting in [AB00L6] for a similar error.
Related • Judgment of controller pin 13:
information Charging voltage from alternator (R terminal) is normal: Min. 12 V
Charging voltage from alternator (R terminal) is not normal: Hysteresis of Max. 5 V
• The R terminal voltage supplied to the pre-lubrication controller is checked with monitoring code:
04305(V).
• The R terminal voltage supplied to the engine service monitor is checked with monitoring code:
04302(V).

2) Disconnect alternator R terminal (E21).
3) Turn the starting switch ON (without starting the engine) and
1 Defective alternator carry out troubleshooting.
Between alternator terminal R
Voltage Max. 5 V
and chassis ground
Possible causes 3) Turn the starting switch ON (without starting the engine) and
and standard carry out troubleshooting.
value in normal
state Between wiring harness terminal
Hot short in wiring harness Voltage Max. 1 V
R (E21) and chassis ground
2 (Short circuit with supply
voltage) 1) Turn the starting switch OFF.
2) Disconnect alternator PRE6.
carry out troubleshooting.
Between PRE6 (female) (13) and
Voltage Max. 1 V
chassis ground
Defective pre-lubrication If causes 1 – 2 are not detected, engine controller may be defective.
3
controller (Since trouble is in system, troubleshooting cannot be carried out.)
12 WA800-3E0, WA900-3E0
a Prelube controller is the same as pre-lubrication controller.
WA800-3E0, WA900-3E0 13
Failure code [AB00L6] (Alternator: Failure on battery charge circuit (R

terminal signal is present and engine is stopped) 1
Action code Failure code Alternator: Failure on battery charge circuit (R terminal signal is
Trouble present and engine is stopped)
E03 AB00L6 (Engine service monitor system)
When engine is stopped, alternator terminal R voltage is above 12 V.
All of the following 1, 2 and 3 were recognized.
1) The starting switch has not been turned ON (input of voltage from starting switch C terminal is not
Contents of
recorded).
trouble
2) Charging voltage (Min. 12 V) is supplied from alternator R terminal.
3) Engine is not operated normally (500 rpm or less), due to the CAN communication data with the
engine controller.
Action of
controller
Problem that
appears on
machine
• If the CAN communication with the engine controller is not possible, failure code [DB2RKR] is output.
• Starting signal of starting switch: Once this failure code is generated, it remains being stored even if
voltage (24 V) is supplied from C terminal.
• The pre-lubrication controller carried out troubleshooting in [AB00L4] for a similar error.
• Controller 13 pin monitored the charging voltage from the alternator (R terminal).
Related
Charging voltage from alternator (R terminal) is normal: Min. 12 V
information
Charging voltage from alternator (R terminal) is not normal: Hysteresis of Max. 5 V
• State of R terminal voltage supplied to the pre-lubrication controller is checked with monitoring code:
04305 (V).
• State of the R terminal voltage supplied to the engine service monitor is checked with monitoring
code: 04302 (V).

1 Defective alternator carry out troubleshooting.
Voltage Max. 5 V
and chassis ground
Possible causes 3) Turn the starting switch ON (without starting the engine) and
and standard carry out troubleshooting.
value in normal Between wiring harness terminal
state Hot short in wiring harness Voltage Max. 1 V
R (E21) and chassis ground
2 (Short circuit with supply
voltage) 1) Turn the starting switch OFF.
2) Disconnect alternator EM2.
Between EM2 (female) (9) and
Voltage Max. 1 V
chassis ground
If causes 1 – 2 are not defected, engine service monitor may be
Defective engine service
3 defective. (Since trouble is in system, troubleshooting cannot be
monitor
carried out.)
14 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 15

(Absence of R terminal signal and detection error) 1
Action code Failure code Alternator: Failure on battery charge circuit (Absence of R terminal
Trouble signal and detection error)
E03 AB00MA (Engine service monitor system)
While the engine is running, R terminal voltage was below 5 V.
All of the following 1, 2, 3 and 4 were recognized.
1 The starting switch has not been turned ON (input of voltage from starting switch C terminal is not
Contents of recorded).
trouble 2 Engine is not operated normally (500 rpm or more), due to the CAN communication data with the
engine controller.
3 Charging voltage from alternator R terminal is 5 V or less.
4 The starting switch is not currently turned ON (no input of voltage from starting switch C terminal)
Action of
controller
Problem that
appears on • Lowe battery charge
machine
• The pre-lubrication controller carried out troubleshooting in [AB00MB] for a similar error.
• Controller 13 pin monitored the charging voltage from the alternator (R terminal). Hysteresis of:
Charging voltage from alternator (R terminal) is normal: Min. 12 V
Charging voltage from alternator (R terminal) is not normal: Max. 5 V
Related • The starting switch C terminal signal being entered to the engine service monitor is checked with
information monitoring code: 40921 “D-IN-0” (ON: 1, OFF: 0).
04305 (V).
code: 04302 (V).

2) Start the engine and carry out troubleshooting.
1 Defective alternator
Voltage Min. 12 V
and chassis ground
Disconnection in wiring 2) Disconnect alternator R terminal (E21).
harness 3) Disconnect connector EM2, then carry out troubleshooting with
2 the connector being disconnected.
Possible causes (Disconnection or defective
and standard contact in connector) Between wiring harness terminal Resis-
value in normal Max. 1 z
(E21) – EM2 (female) (9) tance
state
Grounding fault in wiring 3) Disconnect connector EM2, then carry out troubleshooting with
3 harness (Short circuit with the connector being disconnected.
ground circuit)
Between EM (female) (9) and Resis-
Min. 1 Mz
If causes 1 – 3 are not detected, engine service monitor may be
monitor
carried out.)
16 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 17

E01 AB00MB (Pre-lubrication controller system)
• Engine is not operated normally (500 rpm or more), due to the CAN communication data with the
Contents of
engine controller. However, the system is judged that charging voltage (5 V or less) from the alterna-
trouble
tor R terminal is present.
Action of
controller
Problem that
appears on
machine
• Starting signal of starting switch: C terminal is irrelevant to this failure code.
• This failure code does not appear if the CAN communication from the engine controller is not possible.
• The engine service monitor diagnoses [AB00MA] for a similar error.
• Controller 13 pin monitored the charging voltage from the alternator (R terminal). Hysteresis of :
Related Charging voltage from alternator (R terminal) is normal: Min. 12 V
information Charging voltage from alternator (R terminal) is not normal: Max. 5 V
04305 (V).
code: 04302 (V).

Voltage Min. 12 V
and chassis ground
harness 3) Disconnect connector PRE6, then carry out troubleshooting with
2 the connector being disconnected.
Possible causes (Disconnection or defective
and standard contact in connector) Between wiring harness termi- Resis-
nals (E21) – PRE6 (female) (13) tance
state
Grounding fault in wiring 3) Disconnect connector PRE6, then carry out troubleshooting with
ground circuit)
Between PRE6 (female) (13) and Resis-
Min. 1 Mz
If causes 1 – 3 are not detected, pre-lubrication controller may be
Defective pre-lubrication
controller
carried out.)
18 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 19

— AB00MC (VHMS controller system and maintenance monitor system)
Contents of • Engine is run (500 rpm or above) but the system judged that charging voltage from the alternator R
trouble terminal is absent (open).
Action of
controller
Problem that
appears on
machine
• The engine speed signal is obtained not from the engine controller but from another sensor (Engine
speed signal: See failure code [DLE4KA]).
• For similar error, troubleshooting was carried out by engine service monitor in [AB00MA] and by pre-
Related lubrication controller in [AB00MB] respectively.
information • VHMS controller: VC02(4) pin monitored charging voltage from alternator (R terminal) (monitoring
code: 04304(V)).
a Charging voltage from alternator (R terminal) hysteresis of: Normal if 12 V or above and abnormal if
5 V or below

Voltage Min. 12 V
and chassis ground
harness 3) Disconnect connector VC02, then carry out troubleshooting with
Possible causes 2 the connector being disconnected.
(Disconnection or defective
and standard
contact in connector) Between wiring harness termi- Resis-
state nals (E21) – VC02 (female) (4) tance
Grounding fault in wiring 3) Disconnect connector VC02, then carry out troubleshooting with
ground circuit)
Between VC02 (female) (4) and Resis-
Min. 1 Mz
If causes 1 – 3 are not detected, VHMS controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
20 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 21
Failure code [B@BAZK] (Engine oil: Oil level low) 1

Action code Failure code Engine oil: Oil level low
Trouble
— B@BAZK (VHMS controller system and maintenance monitor system)
Contents of
• The engine oil level switch signal circuit was opened (disconnected from ground wire).
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, engine may be seized.
machine
• Detection is unavailable when the engine coolant temperature is 60°C or above.
Related • The error is reset when engine is started.
information • VHMS controller will send the failure code to the engine service monitor.
• Low engine oil level is checked with “D-IN-9” of monitoring code: 40945 (Low oil level: 1, Normal: 0).

• Engine oil level is normal
1 Low engine oil level a If engine oil level is low, check surroundings of the engine for
leakage of oil before adding oil.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective engine oil level Engine oil level is Resis-
2 Max. 1 z
switch Between E05 (male) normal tance
(1) – (2) Resis-
Engine oil level is low Min. 1 Mz
tance
Between D18 Forward direction: The diode has
3 Defective diode (female) (3) (+) – (2) Continuity conductivity.
(–) Reverse direction: Not conducted
Possible causes
and standard Between D18 Forward direction: Conducted
value in normal (female) (1) (+) – (2) Continuity Reverse direction: The diode
state (–) does not have conductivity.
1) Prepare with starting switch OFF, then carry out troubleshooting
2) Disconnect D18, E05, VC05 and L18, then carry out trouble-
harness Max. 1 z
4 D18 (female) (3) tance
contact in connector) Max. 1 z
Between D18 (female) (2) and Resis-
When engine oil level
is normal
Max. 1 z
(female) (1) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
5 Defective VHMS controller Engine oil level is
Between VC05 (5) Voltage Max. 1 V
normal
and chassis ground
Engine oil level is low Voltage 20 – 30 V
22 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 23
Failure code [B@BAZG] (Engine oil: Low oil pressure) 1

Action code Failure code Engine oil: Low oil pressure
Trouble
— B@BAZG (VHMS controller system and maintenance monitor system)
Contents of
• The engine oil pressure switch was shorted (connected to ground wire) while the engine was run.
trouble
Action of
controller
Problem that
appears on • Engine may be seized.
machine
• Fuse (10) of fuse box 1 is normal since the failure code is generated.
• Engine oil pressure switch while the engine is run: OPEN
Related o Relay 64: OFF
information o Engine pressure switch pin of the controller: Connected to ground wire
• State of the engine oil pressure switch is checked with “D-IN-1” of monitoring code: 40973.
(1: ON··Engine is not started (pressure is not present), 0: OPEN··Engine is started (pressure is
present))

1 Troubleshooting for engine unit: See S-12.
2) Disconnect E09, then carry out troubleshooting with E09 being
turned OFF.
Between E09 (sensor side termi- Resis-
Max. 1 z
2 Defective oil pressure switch nal) and chassis ground tance
2) Disconnect E09.
Possible causes 3) Start the engine and carry out troubleshooting.
and standard a This failure code will not appear.
value in normal 1) Turn the starting switch OFF.
state 2) Disconnect L64 and replace it with a new one.
3 Defective relay 3) Turn starting switch ON and carry out troubleshooting.
a This failure code will not appear.
turned OFF. (Measure in the diode range.)
4 Defective diode Between D20 (male) Forward direction: Continue.
Continuity
Between D20 (male) Forward direction: Continue.
Continuity
24 WA800-3E0, WA900-3E0

2) Disconnect D20, VC05, L18 and L64, then carry out troubleshoot-
ing with their connection being turned OFF.
Between VC05 (female) (4) – Resis-
Max. 1 z
D20 (female) (3) tance
Between D20 (female) (2) – L64 Resis-
Max. 1 z
(female) (3) tance
Disconnection in wiring
Between L64 (female) (6) and Resis-
harness Max. 1 z
5 chassis ground tance
Between L64 (female) (2) and Resis- When the engine oil
chassis ground tance pressure switch is
normal
Max. 1 z
fuse box 1 fuse (10) tance
Max. 1 z
Possible causes (1) tance
and standard 1) Turn the starting switch OFF.
value in normal 2) Disconnect D20, E09, VC05, L18 and L64, then carry out trouble-
state shooting with their connection being turned OFF.
Between VC05 (female) (4) –
Resis-
D20 (female) (3) and chassis Min. 1 Mz
tance
ground
Grounding fault in wiring Wiring harness between D20
Resis-
6 harness (Short circuit with (female) (2) – L64 (female) (3) Min. 1 Mz
tance
ground circuit) and chassis ground
Wiring harness between L64
Resis-
(female) (2) – E09 and chassis Min. 1 Mz
tance
ground
Resis-
(female) (10) – D20 (1) and Min. 1 Mz
tance
chassis ground
2) Disconnect VC05 and connect T-branch.
7 Defective VHMS controller 3) Start the engine and carry out troubleshooting.
Between VC05 (female) (4) and
Voltage Max. 1 V
chassis ground
WA800-3E0, WA900-3E0 25
26 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 27
Failure code [B@BCZK] and [b@BCZK] (Radiator coolant: Low coolant level)1
Action code Failure code Radiator coolant: Low coolant level
Trouble
— B@BCZK, b@BCZK (VHMS controller system and maintenance monitor system)
Contents of
• The radiator level switch signal circuit was opened (disconnected from ground wire).
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, engine may be seized.
machine
Related
• Low coolant level is checked with “D-IN-7” of monitoring code: 40944
information
(Low coolant level: 1, Normal: 0).

• Radiator coolant level is normal
Lowering of radiator coolant
1
level a If radiator coolant level is low, check surroundings of the engine
for leakage of oil before adding.
2) Disconnect connector GC06, then carry out troubleshooting with
the connector being disconnected.
Defective radiator coolant
2 Radiator coolant level Resis-
level switch Max. 1 z
Between G06 (male) is normal tance
(1) – (2) Radiator coolant level Resis-
Min. 1 Mz
is low tance
Possible causes 2) Disconnect D19, then carry out troubleshooting with D19 being
and standard turned OFF. (Measure in the diode range.)
value in normal 3 Defective diode Between D19 (male) Forward direction: Continue
state Continuity
Continuity
2) Disconnect D19, G06, VC05 and L18, then carry out trouble-
Max. 1 z
4
When radiator cool-
ant level is normal
Max. 1 z
(female) (1) tance
28 WA800-3E0, WA900-3E0

Possible causes 3) Connect T-branch.
and standard 4) Turn starting switch ON.
value in normal 5 Defective VHMS controller
state Radiator coolant level
Voltage Max. 1 V
Between VC04 (10) – is normal
(17) Lowering of radiator
Voltage 20 – 30 V
coolant level
WA800-3E0, WA900-3E0 29
Failure code [B@BDNS] (Engine: Overheating) 1

Action code Failure code Engine overheating
Trouble
— B@BDNS (VHMS controller system and maintenance monitor system)
Contents of
• Engine coolant temperature is 105°C or above.
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, engine may overheat.
machine
Related
information

Defective coolant sensor without turning starting switch ON.
1
(Internal defect) E04 (male) Coolant temperature Resistance
Between (1) – (2) 25 – 130°C 48 – 1.6 kz
Disconnection in wiring Between VC03 (female) (5) – E04 (female) Resis-
Max. 1 z
harness (1) tance
2
(Disconnection or defective Resis-
contact in connector) Between L18 (female) (4) – E04 (female) (1) Max. 1 z
tance
Possible causes Between E04 (female) (2) and chassis Resis-
and standard Max. 1 z
ground tance
value in normal
state a Prepare with starting switch OFF, then carry out troubleshooting
VC03 (female) Coolant temperature Resistance
Between (5) – (9) 25 – 130°C 48 – 1.6 kz
2) Disconnect E04.
3 Defective VHMS controller 3) Chang resistance sequentially between 1.6 kz or less and 10 kz
or above, then connect the shorting connector between E04
(female) (1) and (2).
When 1.6 kz or less is connected: This failure code appears.
When 10 kz or above is connected: This failure code will not
appear.
30 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 31
Failure code [B@C6NS] (Front brake oil temperature: Overheating) 1

Action code Failure code Front brake oil temperature: Overheating
Trouble
— B@C6NS (VHMS controller system)
Contents of • The system detected overheating (130°C or above) referencing the signal from the front brake oil
trouble temperature sensor.
Action of
controller
Problem that
appears on • Brake (front) does not work.
machine
Related
• Input signal from the oil pressure sensor is checked with monitoring code: 30213 (°C).
information

Possible causes Hydraulic system (pump, relief valve and piping) may be failed.
1 Defective hydraulic system
and standard Check and remove cause if pressure is dropped.
value in normal If cause 1 is not defected, front brake oil temperature sensor system
state Defective front brake oil
2 may be defective. Carry out troubleshooting for failure code
temperature sensor system
[DGR4KX].
32 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 33
Failure code [B@CENS] (Torque converter oil temperature

overheating) 1
Action code Failure code Torque converter oil temperature overheating
Trouble
— B@CENS (VHMS controller system and maintenance monitor system)
Contents of • While engine was running, signal circuit from the torque converter oil temperature sensor detected
trouble overheating of oil temperature (130°C or above).
Action of
controller
Problem that
appears on • If machine is operated as it is, power train components may be damaged.
machine
Related • VHMS controller will send the failure code to the engine service monitor.
information • Torque converter oil temperature is checked with monitoring code: 30103 (°C).

Overheating of power train
Power train oil may be overheating. Check it and remove cause if it
1 oil temperature (When the
is overheating.
system is normal)
2) Disconnect connector T02, then carry out troubleshooting with
the connector being disconnected.
Defective oil temperature
2 T02 (male) Oil temperature Resistance
sensor
Between (1) – (2) 25 – 130°C 48 k – 1.6 kz
Between (1) – (2) Min. 130°C Max. 1.6 kz
Possible causes 2) Disconnect VC03 and L18, then carry out troubleshooting with
and standard their connection being turned OFF.
value in normal 48 k – 1.6 kz
harness Between VC03 (female) (4) and Resis-
state 3 Resistance of oil
(Disconnection or defective chassis ground tance
pressure sensor
48 k – 1.6 kz
Resistance of oil
pressure sensor
2) Disconnect T02, VC04 and L18, then carry out troubleshooting
Grounding fault in wiring with their connection being turned OFF.
4 harness (Short circuit with
ground circuit) Wiring harness between VC03
Resis-
(female) (4) – L18 (female) (5) – Min. 1 Mz
tance
T02 (1) and chassis ground
If causes 1 – 4 are not detected, VHMS controller may be defective.
34 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 35
Failure code [B@JFZG] (Brake oil: Low oil pressure) 1

Action code Failure code Brake oil: Low oil pressure
Trouble
— B@JFZG (VHMS controller system and maintenance monitor system)
Contents of
• The brake accumulator pressure switch was opened while the engine was running.
trouble
Action of
controller
Problem that
appears on • Brake does not work.
machine
Related
• Brake accumulator pressure switch while engine is running: Closed (When normal)
information
o Brake accumulator pressure switch pin of controller: Connected to ground wire (When normal)

1 Troubleshooting of hydraulic and mechanical system: See H-10.
Continuity
2 Defective diode (3) (+) – (2) (–) Reverse direction: The diode
Possible causes Between D17 (male) conductivity.
Continuity
and standard (1) (+) – (2) (–) Reverse direction: The diode
value in normal does not have conductivity.
state 1) Turn the starting switch OFF.
2) Disconnect BC04, BC05, BC06 and BC07.
SW1: Between BC04 (male) (1) – Resis-
Max. 1 z
(2) tance
Defective oil pressure
3 SW2: Between BC05 (male) (1) – Resis-
switches (SW1 – SW4) Max. 1 z
(2) tance
Max. 1 z
(2) tance
Max. 1 z
(2) tance
36 WA800-3E0, WA900-3E0

2) Disconnect D17, VC05, L18, BC04, BC06 and BC07, then carry
out troubleshooting with their connection being turned OFF.
Max. 1 z
Between D17 (female) (2) – Resis-
Max. 1 z
BC04 (female) (1) tance
Disconnection in wiring Between BC04 (female) (2) – Resis-
harness Max. 1 z
4 BC05 (female) (1) tance
Between BC05 (female) (2) – Resis-
Between BC06 (female) (2) – Resis-
Max. 1 z
Between BC07 (female) (2) and Resis-
Max. 1 z
Max. 1 z
Possible causes (female) (1) tance
and standard 1) Turn the starting switch OFF.
value in normal 2) Disconnect D17, VC05, L18, BC04, BC06 and BC07, then carry
state out troubleshooting with their connection being turned OFF.
Between VC05 (female) (8) –
Resis-
D17 (female) (3) and chassis Min. 1 Mz
tance
ground
Wiring harness between D17
Grounding fault in wiring Resis-
(female) (2) – BC04 (female) (1) Min. 1 Mz
5 harness (Short circuit with tance
and chassis ground
ground circuit)
Wiring harness between BC07
(female) (1), BC06 (female) (1) – Resis-
Min. 1 Mz
BC05 (female) (1) and chassis tance
ground
Resis-
(female) (11) – D17 (1) and chas- Min. 1 Mz
tance
sis ground
2) Disconnect VC05 and connect T-branch.
6 Defective VHMS controller 3) Start the engine and carry out troubleshooting.
Between VC05 (female) (8) and
Voltage Max. 1 V
chassis ground
WA800-3E0, WA900-3E0 37
38 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 39
SEN02144-01

© 2010 KOMATSU
All Rights Reserved
40
SEN02145-01
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
Failure code [CA111] Engine controller (Left bank): Internal abnormality.......................................................... 4
Failure code [CB111] Engine controller (Right bank): Internal abnormality ....................................................... 6
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank):
Abnormal speed sensor signal....................................................................................................................... 8
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank):
Abnormal speed sensor signal....................................................................................................................... 9
Failure code [CA122] Charge pressure sensor too high (At left bank only):
Excessively high voltage detected ............................................................................................................... 10
Failure code [CA123] Charge pressure sensor too low (At left bank only):
Excessively low voltage detected ................................................................................................................ 12
Failure code [CA131] Throttle sensor abnormally high level (Only left bank): High voltage detection ............ 13
Failure code [CA132] Throttle sensor too low (At left bank only): Excessively low voltage detected.............. 15
Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected.... 16
Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected....... 18
WA800-3E0, WA900-3E0 1
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected....................20
Failure code [CA145] Coolant temperature sensor too low (At left bank only):
Excessively low voltage detected.................................................................................................................22
Failure code [CA153] Charge temperature sensor too high (At left bank only):
Excessively high voltage detected ...............................................................................................................24
Failure code [CA154] Charge temperature sensor too low (At left bank only):
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection.......28
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection ....29
Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank):
High voltage detection ..................................................................................................................................30
Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank):
Low voltage detection...................................................................................................................................32
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only):
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only):
Failure code [CA227] Sensor power source (2) too high (At left bank): Excessively high voltage detected ...36
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection ..38
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed....................................40
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only):
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only):
Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected....46
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection ......49
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection ....49
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit ..................................................................50
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit ................................................................51
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection ...........................................................52
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection.........................................................53
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit ..................................................................54
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit ................................................................55
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection ...........................................................56
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection.........................................................57
2 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 3
Failure code [CA111] Engine controller (Left bank): Internal

abnormality 1
Action code Failure code Symptom Engine controller (Left bank): Internal abnormality
E03 CA111 of failure (Engine controller system)
Failure content • Controller has abnormality in it.
Controller's
• Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
• Machine continues operation normally but may stop suddenly or may not able to start again once it
appear on
stops.
machine
General • The power supply voltage of engine controller (left bank) can be checked with monitoring function.
information (Code: 03200 (V))
Cause Standard values when normal and remarks for troubleshooting

Defective circuit breaker Circuit breaker may be defective. Check it directly. (If circuit
1
CBF2 breaker is turned OFF, circuit probably has ground fault.)
1) Starting switch OFF.
2) Disconnect battery earth and EM3, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness (Disconnection in
2 Wiring harness between EM3 (female) (4) – Resis-
wiring or defective contact in Max. 1 z
Possible battery LH (+) tance
connector)
causes and the Wiring harness between EM3 (female) (1) – Resis-
Max. 1 z
standard values ground tance
when normal a Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring without turning starting switch ON.
3 harness (Contact with GND
Between ground and wiring harness
circuit) Voltage 20 – 30 V
between EM3 (female) (4) – battery LH (+)
and carry out troubleshooting.
4 Defective engine controller
EM3 (female) Voltage
Between (4) – (1) 20 – 30 V
4 WA800-3E0, WA900-3E0
Circuit diagram related to engine controller power supply
WA800-3E0, WA900-3E0 5
Failure code [CB111] Engine controller (Right bank): Internal abnormality1

Action code Failure code Symptom Engine controller (Right bank): Internal abnormality
E03 CB111 of failure (Engine controller system)
Failure content • Controller has abnormality in it.
Controller's
action
Symptoms that
• Machine continues operation normally but may stop suddenly or may not able to start again once it
appear on
stops.
machine
General • The power supply voltage of engine controller (right bank) can be checked with monitoring function.
information (Code: 03205 (V))

Defective circuit breaker Circuit breaker may be defective. Check it directly. (If circuit
1
CBF3 breaker is turned OFF, circuit probably has ground fault.)
Disconnection in wiring har- without turning starting switch ON.
ness (Disconnection in wiring
or defective Max. 1 z
Possible battery LH (+) tance
Max. 1 z
standard values ground tance
Ground fault in wiring har- without turning starting switch ON.
3 ness (Contact with GND cir-
cuit) Voltage 20 – 30 V
between EM4 (female) (4) – battery LH (+)
Defective engine and carry out troubleshooting.
4
controller EM4 (female) Voltage
Between (4) – (1) 20 – 30 V
6 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 7
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At
left bank): Abnormal speed sensor signal 1
Action code Failure code Symptom Abnormal engine Ne and Bkup speed sensors (At left bank): Abnor-
E03 CA115 of failure mal speed sensor signal (Engine controller system)
• Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor cir-
Failure content
cuit.
Controller's
• Flashes warning lamp and turns on alarm buzzer.
action
Symptoms that
• Engine does not start (during engine stop).
appear on
• Engine stops (during engine running).
machine
General
information

Defective Ne speed sensor
1 Carry out troubleshooting of [CA689].
circuit
Defective Bkup speed
2 Carry out troubleshooting of [CA778].
sensor circuit
Since a mounting section of Ne speed sensor can be suspected to
Possible 3 be defective, directly check the mounting section. (Defective instal-
mounting section
causes and the lation of sensor itself, internal defect of flywheel, etc.)
standard values Since a mounting section of Bkup speed sensor can be suspected
when normal Bkup speed sensor mounting
4 to be defective, directly check the mounting section. (Defective
section
installation of sensor itself, internal defect of supply pump, etc.)
Defective connection of The defective (wrong) connections of Ne speed sensor and Bkup
5
sensor (wrong connection) speed sensor can be suspected. Directly check them.
Engine controller can be suspected to be defective if no problem is
6 Defective engine controller found in causes 1 – 5 (since this is an internal defect, it cannot be
diagnosed).
8 WA800-3E0, WA900-3E0
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At
right bank): Abnormal speed sensor signal 1
Action code Failure code Symptom Abnormal engine Ne and Bkup speed sensors (At right bank):
E03 CB115 of failure Abnormal speed sensor signal (Engine controller system)
• Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor cir-
Failure content
cuit.
Controller's
action
Symptoms that
• Engine does not start (during engine stop).
appear on
• Engine stops (during engine running).
machine
General
information

1 Carry out troubleshooting of [CB689].
circuit
Defective Bkup speed
2 Carry out troubleshooting of [CB778].
sensor circuit
Since a mounting section of Ne speed sensor can be suspected to
Possible 3 be defective, directly check the mounting section. (Defective instal-
mounting section
causes and the lation of sensor itself, internal defect of flywheel, etc.)
standard values Since a mounting section of Bkup speed sensor can be suspected
when normal Bkup speed sensor mounting
4 to be defective, directly check the mounting section. (Defective
section
installation of sensor itself, internal defect of supply pump, etc.)
Defective connection of The defective (wrong) connections of Ne speed sensor and Bkup
5
sensor (wrong connection) speed sensor can be suspected. Directly check them.
diagnosed).
WA800-3E0, WA900-3E0 9
Failure code [CA122] Charge pressure sensor too high (At left bank
only): Excessively high voltage detected 1
Action code Failure code Symptom Charge pressure sensor too high (At left bank only): Excessively
E03 CA122 of failure high voltage detected (Engine controller system)
Failure content • Excessively high voltage is detected at circuit of charge pressure (boost pressure) sensor.
Controller's • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Acceleration performance of engine deteriorates.
machine
• The signal of the charge pressure (boost pressure) can be checked with the monitoring function.
General
(Code: 36500 (kPa) (absolute pressure), 36502 (V))
information
• Duplication of failure code: turn ON the starting switch.

Defective sensor power If failure code [CA227] is displayed at the same time, carry out trou-
1
source circuit bleshooting for it first.
a Prepare with starting switch OFF, and diagnose with starting
switch ON or with engine started.
PIM Voltage
Defective charge pressure
2 (boost pressure) Between (1) – (2) Power source 4.75 – 5.25 V
sensor (internal defect) Since the sensor voltage is measured with the harness being con-
nected, if the voltage is abnormal, first check the harness and the
controller to make it sure if there is no other cause of the trouble,
and then judge the sensor is defective.
a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
Possible Disconnection in wiring Wiring harness between ENG (female) (37) Resis-
causes and the Max. 1 z
harness – PIM (female) (1) tance
standard values 3
(disconnection or defective Wiring harness between ENG (female) (44) Resis-
when normal contact of connectors) Max. 1 z
– PIM (female) (2) tance
Wiring harness between ENG (female) (47) Resis-
Max. 1 z
– PIM (female) (3) tance
switch still OFF.
Resis-
between ENG (female) (37) – PIM (female) Min. 1 Mz
tance
Defective harness grounding (1)
4 (contact with ground Between ground and wiring harness
circuit) Resis-
tance
(2)
Resis-
tance
(3)
10 WA800-3E0, WA900-3E0

switch still OFF.
Between wiring harness from ENG (female)
Resis-
(37) to PIM (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (44) to PIM (female) (2)
Harness short
Possible 5 Between wiring harness from ENG (female)
(Harness internal short) Resis-
causes and the (37) to PIM (female) (1) and wiring harness Min. 1 Mz
tance
standard values from ENG (female) (47) to PIM (female) (3)
when normal Between wiring harness from ENG (female)
Resis-
(44) to PIM (female) (2) and wiring harness Min. 1 Mz
tance
from ENG (female) (47) to PIM (female) (3)
Defective engine switch ON or with engine started.
6
controller ENG Voltage
Between (37) – (47) Power source 4.75 – 5.25 V
Circuit diagram related to charge pressure sensor
WA800-3E0, WA900-3E0 11
Failure code [CA123] Charge pressure sensor too low (At left bank
only): Excessively low voltage detected 1
Action code Failure code Symptom Charge pressure sensor too low (At left bank only): Excessively low
E03 CA123 of failure voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected at circuit of charge pressure (boost pressure) sensor.
Controller's • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
Symptoms that
appear on • Acceleration performance of engine deteriorates.
machine
• The signal of the charge pressure (boost pressure) can be checked with the monitoring function.
General
(Code: 36500 (kPa) (absolute pressure), 36502 (V))
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values 1
when normal
12 WA800-3E0, WA900-3E0
Failure code [CA131] Throttle sensor abnormally high level (Only left
bank): High voltage detection 1
Action code Failure code Symptom of Throttle sensor abnormally high level (Only left bank): High voltage
E03 CA131 failure detection (Engine controller system)
Failure content • Throttle sensor circuit is abnormally high (Min. 4.5 V)
Controller's • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 38% when it is
action ON.
Symptoms that
• Even if the accelerator pedal is depressed, the engine speed does not increase above medium
appear on
speed.
machine
• The throttle sensor signal (position and voltage of accelerator pedal) can be checked with the
General
monitoring function (Code: 31701 (%), 31707 (V)).
information
• Method of reproducing failure code: Turn the starting switch ON.

Defective throttle sensor If failure code [CA2185] or [CA2186] is also indicated, carry out trou-
1
power supply system bleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting
L25 Accelerator pedal Voltage
All range
Between (1) and (3) 4.75 – 5.25V
(Power supply)
Defective accelerator
2 When released 0.5 V*
pedal (Internal defect) Between (2) and (3)
When pressed 4.5 V*
Since the sensor voltage is measured with the harness being con-
nected, if the voltage is abnormal, first check the harness and the con-
troller to make it sure if there is no other cause of the trouble, and then
judge the sensor (accelerator pedal) is defective.
Disconnection in wiring Wiring harness between EM1 (female) (22) – Resis-
Possible Max. 1 z
harness L25 (female) (1) tance
causes and the 3
(Disconnection or defec- Wiring harness between EM1 (female) (9) – Resis-
standard values
tive contact of connector) L25 (female) (2) Max. 1 z
tance
when normal
Wiring harness between EM1 (female) (23) – Resis-
Max. 1 z
L25 (female) (3) tance
Grounding fault in wiring Wiring harness between EM1 (female) (22) – Resis-
Min. 1 Mz
harness L25 (female) (1) tance
4
(Contact with ground cir- Wiring harness between EM1 (female) (9) – Resis-
Min. 1 Mz
cuit) L25 (female) (2) tance
Min. 1 Mz
EM1 Accelerator pedal Voltage
Defective engine control-
5 All range
ler Between (22) and (23) 4.75 – 5.25 V
(Power supply)
When released 0.5 V*
Between (9) and (23)
When pressed 4.5 V*
* Refer to Fig. 1
WA800-3E0, WA900-3E0 13
Circuit diagram related
Fig. 1
Signal voltage of throttle sensor
Output voltage (V): Signal name SIG ··· pin (2) of L25
Lo: Switch circuit is closed
Hi: Switch circuit is open
Switch gap: Hysterical area of IVS1 and IVS2
14 WA800-3E0, WA900-3E0
Failure code [CA132] Throttle sensor too low (At left bank only):
Excessively low voltage detected 1
Action code Failure code Symptom of Throttle sensor too low: excessively low voltage detected (At left bank
E03 CA132 failure only) (Engine controller system)
Failure content • Throttle sensor circuit is abnormally high (Min. 4.5 V)
Controller's • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 38% when it is
action ON.
Symptoms that
• Even if the accelerator pedal is depressed, the engine speed does not increase above medium
appear on
speed.
machine
General
information
causes and the
standard values Carry out troubleshooting of failure code [CA131]
when normal
WA800-3E0, WA900-3E0 15
Failure code [CA135] Oil pressure sensor too high (At left bank only):
Excessively high voltage detected 1
Action code Failure code Symptom of Oil pressure sensor too high (At left bank only): Excessively high volt-
E01 CA135 failure age detected (Engine controller system)
Failure content • Excessively high voltage is detected at oil pressure sensor circuit.
Controller's • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
Symptoms that
appear on
machine
• The signal of engine oil pressure sensor can be checked in monitoring function.
General
(Code: 37200 (kPa), 32701 (V))
information

Defective sensor power If failure code [CA187] or [CA227] is displayed at the same time, carry
1
source circuit out troubleshooting for it first.
a Prepare with starting switch OFF, and diagnose with starting switch
ON or with engine started.
POIL Voltage
2 sensor Between (1) – (2) Power source 4.75 – 5.25 V
(internal defect) Since the sensor voltage is measured with the harness being con-
judge the sensor is defective.
a Prepare with starting switch OFF and diagnose with starting switch
still OFF.
Wiring harness between ENG (female) (37) – Resis-
harness Max. 1 z
POIL (female) (1) tance
3 (disconnection or defec-
tive contact of connec- Max. 1 z
tors)
Max. 1 z
Possible a Prepare with starting switch OFF and diagnose with starting switch
causes and the still OFF.
standard values Defective harness Between ground and wiring harness between Resis-
when normal Min. 1 Mz
grounding ENG (female) (37) – POIL (female) (1) tance
4
(contact with ground cir- Between ground and wiring harness between Resis-
Min. 1 Mz
cuit) ENG (female) (47) – POIL (female) (2) tance
Between ground and wiring harness between Resis-
Min. 1 Mz
ENG (female) (13) – POIL (female) (3) tance
still OFF.
Resis-
(37) to POIL (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (47) to POIL (female) (2)
Harness short
5
(Harness internal short) Between wiring harness from ENG (female) Resis-
tance
Resis-
tance
a Prepare with starting switch OFF, and diagnose with starting switch
Defective engine control- ON or with engine started.
6
ler ENG Voltage
Between (37) – (47) Power source 4.75 – 5.25 V
16 WA800-3E0, WA900-3E0
Circuit diagram related to oil pressure sensor
WA800-3E0, WA900-3E0 17
Failure code [CA141] Oil pressure sensor too low (At left bank only):
Excessively low voltage detected 1
Action code Failure code Symptom of Oil pressure sensor too low (At left bank only): Excessively low volt-
E01 CA141 failure age detected (At left bank only) (Engine controller system)
Failure content • Excessively low voltage is detected at oil pressure sensor circuit.
Controller's • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
Symptoms that
appear on
machine
• The signal of engine oil pressure sensor can be checked in monitoring function.
General
(Code: 37200 (kPa), 32701 (V))
information
causes and the
standard values 1
when normal
18 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 19
Failure code [CA144] Coolant temperature sensor too high: Excessively

high voltage detected 1
Action code Failure code Symptom of Coolant temperature sensor too high: Excessively high voltage
E01 CA144 failure detected (Engine controller system)
Failure content • Excessively high voltage is detected at signal circuit of coolant temperature sensor.
Controller's • Operates with a fixed coolant temperature (90°C).
Symptoms that
appear on • Engine does not start easily at low temperature.
machine
• The signal of coolant temperature sensor can be checked in monitoring function.
General
(Code: 04104 (°C), 04105 (V))
information

Defective coolant still OFF.
1 temperature sensor
TWTR (male) Coolant temperature Resistance
(Internal defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
Disconnection in wiring still OFF.
harness
2 (disconnection or Max. 1 z
TWTR (female) (A) tance
defective contact of
Wiring harness among ENG (female) (38) – Resis-
connectors) Max. 1 z
JB – TWTR (female) (B) tance
Possible still OFF.
Harness short
causes and the 3 Between ENG (female) (15) – all pins of ENG
standard values (female) (with all connectors in the harness Min. 1 Mz
tance
when normal disconnected)
Since the connections among coolant temperature sensor – engine
harness – engine controller are suspected to be defective, check for a
defective connection.
Defective wiring harness
4 • Connector is loose, lock is broken, seal is broken
connector
• Pin is corroded, bent, broken, pushed in, expanded.
• Moisture in connector, entry of dirt or sand, etc., and insufficient
insulation
Defect in other locations still OFF.
5
than engine controller ENG (female) Coolant temperature Resistance
Between (15) – (38) 10 – 100°C 0.6 – 20 kz
Defective engine Engine controller is possibly defective if no problem is found in causes
6
controller 1 – 5. (Since this is an internal defect, it cannot be diagnosed.)
20 WA800-3E0, WA900-3E0
Circuit diagram related to coolant temperature sensor
WA800-3E0, WA900-3E0 21
Failure code [CA145] Coolant temperature sensor too low (At left bank
Action code Failure code Symptom of Coolant temperature sensor too low (At left bank only): Excessively
E01 CA145 failure low voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected at signal circuit of coolant temperature sensor.
Controller's • Operates with a fixed coolant temperature (90°C).
Symptoms that
machine
• The signal of coolant temperature sensor can be checked in monitoring function.
General
(Code: 04104 (°C), 04105 (V))
information

Defective coolant still OFF.
1 temperature sensor
TWTR (male) Coolant temperature Resistance
(Internal defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
Defective harness still OFF.
2 grounding (contact with
ground circuit) Min. 1 Mz
ENG (female) (15) – TWTR (female) (A) tance
still OFF.
Harness short
Possible 3 Between ENG (female) (15) – all pins of ENG
causes and the (female) (with all connectors in the harness Min. 1 Mz
tance
standard values disconnected)
when normal Since the connections among coolant temperature sensor – engine
harness – engine controller are suspected to be defective, check for a
defective connection.
connector
insulation
5
than engine controller ENG (female) Coolant temperature Resistance
Between (15) – (38) 10 – 100°C 0.6 – 20 kz
6
22 WA800-3E0, WA900-3E0
Circuit diagram related to coolant temperature sensor
WA800-3E0, WA900-3E0 23
Failure code [CA153] Charge temperature sensor too high (At left bank
only): Excessively high voltage detected 1
Action code Failure code Symptom of Charge temperature sensor too high (At left bank only): Excessively
E01 CA153 failure high voltage detected. (Engine controller system)
• Excessively high voltage is detected at signal circuit of charge temperature (boost temperature)
Failure content
sensor.
Controller's
• Operates with a fixed charge temperature (boost temperature) (70°C).
action
Symptoms that
machine
• The signal of the charge temperature (boost temperature) sensor can be checked with the moni-
General
toring function. (Code: 18500 (°C), 18501 (V))
information
• Duplication of failure code: turn ON the Starting switch.

Defective charge temper- still OFF.
1 ature (boost temperature) TIM (male) Air boost temperature Resistance
sensor (internal defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) – ground In all range Min. 1 Mz
harness (disconnection Wiring harness between ENG (female) (23) – Resis-
2 Max. 1 z
or defective contact of TIM (female) (A) tance
connectors) Wiring harness between ENG (female) (47) – Resis-
Max. 1 z
JB – TIM (female) (B) tance
Possible still OFF.
causes and the Harness short
3 Between ENG (female) (23) – all pins of ENG
standard values (Harness internal short) Resis-
(female) (with all connectors in the harness Min. 1 Mz
when normal tance
disconnected)
Since the connections among charge temperature (boost tempera-
ture) sensor – engine harness – engine controller are suspected to be
defective, check for a defective connection.
connector
insulation
5
than engine controller ENG (female) Air boost temperature Resistance
Between (23) – (47) 10 – 100°C 0.5 – 20 kz
6
24 WA800-3E0, WA900-3E0
Circuit diagram related to charge temperature sensor
WA800-3E0, WA900-3E0 25
Failure code [CA154] Charge temperature sensor too low (At left bank
Action code Failure code Symptom of Charge temperature sensor too low (At left bank only): Excessively
• Excessively low voltage is detected at signal circuit of charge temperature (boost temperature)
Failure content
sensor.
Controller's
• Operates with a fixed charge temperature (boost temperature) (70°C).
action
Symptoms that
machine
• The signal of the charge temperature (boost temperature) sensor can be checked with the moni-
General
toring function. (Code: 18500 (°C), 18501 (V))
information

Defective charge temper- still OFF.
1 ature (boost temperature) TIM (male) Air boost temperature Resistance
sensor (internal defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) – ground In all range Min. 1 Mz
ENG (female) (23) – TIM (female) (A) tance
still OFF.
Harness short
Possible 3 Between ENG (female) (23) – all pins of ENG
causes and the (female) (with all connectors in the harness Min. 1 Mz
tance
standard values disconnected)
when normal Since the connections among charge temperature (boost tempera-
ture) sensor – engine harness – engine controller are suspected to be
defective, check for a defective connection.
connector
insulation
still OFF.
Defect in other locations
5 ENG (female) Air boost temperature Resistance
than engine controller
Between (23) – (47) 10 – 100°C 0.5 – 20 kz
Between (23) – ground In all range Min. 1 Mz
6
26 WA800-3E0, WA900-3E0
Circuit diagram related to charge temperature sensor
WA800-3E0, WA900-3E0 27
Failure code [CA187] Sensor power supply (2) abnormally low level
(Left bank): Low voltage detection 1
Action code Failure code Symptom of Sensor power supply (2) abnormally low level (Left bank): Low voltage
Failure content • Low voltage was detected in sensor power supply (2) (5 V) circuit.
• Ambient pressure sensor sets ambient temperature to default value (52.44 kPa {0.5 kg/cm2}) and
continues operation.
• Oil pressure sensor sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues opera-
Controller's
tion.
action
• Charge pressure sensor fixes charge pressure to (400 kPa {4.1 kg/cm2}) and continues operation.
• Bkup sensor operates with Ne speed sensor signal.
Symptoms that
appear on • Output lowers.
machine
General
information
causes and the
standard values Carry out troubleshooting for failure code [CA227].
when normal
28 WA800-3E0, WA900-3E0
Failure code [CB187] Sensor power supply (2) abnormally low level
(Right bank): Low voltage detection 1
Action code Failure code Symptom of Sensor power supply (2) abnormally low level (Right bank): Low volt-
E03 CA187 failure age detection (Engine controller system)
Controller's • Bkup sensor operates with Ne speed sensor signal.
action • Blinks warning lamp and sounds alarm buzzer.
Symptoms that
machine
General
information
causes and the
standard values Carry out troubleshooting for failure code [CB227].
when normal
WA800-3E0, WA900-3E0 29
Failure code [CA212] Engine oil temperature sensor abnormally high

level (Only left bank): High voltage detection 1
Action code Failure code Symptom of Engine oil temperature sensor abnormally high level (Only left bank):
E01 CA212 failure High voltage detection (Engine controller system)
Failure content • High voltage was detected in engine oil temperature sensor circuit.
Controller's
• Sets oil temperature to default value (100°C) and continues operation.
action
Symptoms that
appear on
machine
General • The signal of the engine oil temperature sensor can be checked with the monitoring function.
information (Code: 42700 (°C), 42702 (V))

Defective oil temperature without turning starting switch ON.
1
sensor (Internal defect) TOIL (male) Oil temperature Resistance
Between (A) – (B) 0 – 100°C 0.5 – 36 kz
harness (Disconnection Wiring harness between ENG (female) (17) – Resis-
Possible 2 Max. 1 z
in wiring or defective con- TOIL (female) (A) tance
causes and the
tact in connector) Wiring harness between ENG (female) (47) – Resis-
standard values Max. 1 z
when normal TOIL (female) (B) tance
3 harness (Contact with
GND circuit) Min. 1 Mz
TOIL (female) (A) tance
Defective engine control- without turning starting switch ON.
4
ler ENG Oil temperature Resistance
(17) – (47) 0 – 100°C 0.5 – 36 kz
30 WA800-3E0, WA900-3E0
Circuit diagram related to engine oil temperature sensor
WA800-3E0, WA900-3E0 31
Failure code [CA213] Engine oil temperature sensor abnormally low

level (Only left bank): Low voltage detection 1
Action code Failure code Symptom of Engine oil temperature sensor abnormally low level (Only left bank):
E01 CA213 failure Low voltage detection (Engine controller system)
Failure content • Low voltage was detected in engine oil temperature sensor circuit.
Controller's
• Sets oil temperature to default value (100°C) and continues operation.
action
Symptoms that
appear on
machine
General • The signal of the engine oil temperature sensor can be checked with the monitoring function.
causes and the
when normal
32 WA800-3E0, WA900-3E0
Failure code [CA221] Atmospheric pressure sensor too high (At left
bank only): Excessively high voltage detected 1
Action code Failure code Symptom of Atmospheric pressure sensor too high (At left bank only): Excessively
E01 CA221 failure high voltage detected (Engine controller system)
Failure content • Excessively high voltage is detected at signal circuit of atmospheric pressure sensor.
Controller's • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
Symptoms that
appear on • Output decreases.
machine
• The signal of the atmospheric pressure sensor can be checked in monitoring mode.
General
(Code: 37400 (kPa) (Absolute pressure), 37402 (V))
information

Defective sensor power If failure code [CA352] or [CA386] is displayed at the same time, carry
1
source circuit out troubleshooting for it first.
ON.
PAMB Voltage
Defective atmospheric Between (1) – (3) Power source 4.75 – 5.25 V
2 pressure sensor Between (2) – (3) Signal 0.5 – 4.5 V
judge the sensor is defective.
still OFF.
Disconnection in wiring Wiring harness between ENG (female) (37) – Resis-
Max. 1 z
harness (disconnection PAMB (female) (1) tance
3
or defective contact of Wiring harness between ENG (female) (3) – Resis-
connectors) Max. 1 z
PAMB (female) (2) tance
Possible
standard values PAMB (female) (3) tance
when normal a Prepare with starting switch OFF and diagnose with starting switch
still OFF.
Defective harness Min. 1 Mz
ENG (female) (37) – PAMB (female) (1) tance
ground circuit) Between ground and wiring harness between Resis-
Min. 1 Mz
Min. 1 Mz
still OFF.
Resis-
(37) to PAMB (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (3) to PAMB (female) (2)
Harness short
5 Between wiring harness from ENG (female)
tance
Resis-
tance
WA800-3E0, WA900-3E0 33

Possible a Prepare with starting switch OFF, and diagnose with starting switch
causes and the ON or with engine started.
standard values Defective engine
6 ENG Voltage
when normal controller
Between (37) – (38) 4.75 – 5.25 V
Between (3) – (38) 0.5 – 4.5 V
Circuit diagram related to atmospheric pressure sensor
34 WA800-3E0, WA900-3E0
Failure code [CA222] Atmospheric pressure sensor too low (At left bank
Action code Failure code Symptom of Atmospheric pressure sensor too low (At left bank only): Excessively
Failure content • Excessively low voltage is detected at signal circuit of atmospheric pressure sensor.
Controller's • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
Symptoms that
machine
• The signal of the atmospheric pressure sensor can be checked in monitoring mode.
General
(Code: 37400 (kPa) (Absolute pressure), 37402 (V))
information
causes and the
standard values Carry out troubleshooting of failure code [CA221].
when normal
WA800-3E0, WA900-3E0 35
Failure code [CA227] Sensor power source (2) too high (At left bank):
Action code Failure code Symptom of Sensor power source (2) too high (At left bank): Excessively high volt-
Failure content • Excessively high voltage is detected in sensor power source (2) (5V) circuit.
• Operates using Ne speed sensor signal instead of Bkup speed sensor signal.
• Operate oil pressure sensor with oil pressure at default value (250 kPa {2.5 kg/cm2})
Controller's
• Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.5 kg/cm2})
action
• Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm2}).
Symptoms that
machine
General
information

Check the codes that are displayed at the same time. If any other
1 Defective related circuits
codes are displayed, carry out troubleshooting for those codes.
ON.
Bkup speed sensor G connector
Disconnect the right Engine oil pressure
Defective sensor POIL connector
2 devices one by one. sensor
(internal defect)
If the code disap- Atmospheric pressure
pears, that device is PAMB connector
sensor
internally defective. Charge pressure sen-
PIM connector
sor
harness
3 (disconnection or defec- Max. 1 z
Possible each sensor (female) tance
tive contact of connec-
causes and the Wiring harness between ENG (female) (47) – Resis-
standard values
tors) Max. 1 z
each sensor (female) tance
when normal a Prepare with starting switch OFF and diagnose with starting switch
grounding Between ground and wiring harness between Resis-
4 Min. 1 Mz
(contact with ground cir- ENG (female) (37) – each sensor (female) tance
cuit) Between ground and wiring harness between Resis-
Min. 1 Mz
ENG (female) (47) – each sensor (female) tance
still OFF.
Harness short Between wiring harness from ENG (female)
5
(Harness internal short) (37) to each sensor (female) and wiring har- Resis-
Min. 1 Mz
ness from ENG (female) (47) to each sensor tance
(female)
Defective engine control- ON.
6
ler ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
36 WA800-3E0, WA900-3E0
Circuit diagram related to sensor power source (2) (5V)
WA800-3E0, WA900-3E0 37
Failure code [CB227] Sensor power supply (2) abnormally high level
(Right bank): High voltage detection 1
Action code Failure code Symptom of Sensor power supply (2) abnormally high level (Right bank): High volt-
E03 CB227 failure age detection (Engine controller system)
Failure content • High voltage was detected in sensor power supply (2) (5 V) circuit.
Controller's
• Bkup speed sensor operates with Ne speed sensor signal.
action
Symptoms that
machine
General
information

1 Related defective system If another code is also displayed, carry out troubleshooting for it.
Defective sensor (Inter- When device at right
2 is disconnected, if
nal defect) G (Bkup) speed
error code disappears, G connector
sensor
that device has defect
in it.
3 Max. 1 z
in wiring or defective con- each sensor (female) tance
tact in connector) Wiring harness between ENG (female) (47) – Resis-
Possible Max. 1 z
causes and the
standard values
when normal Ground fault in wiring
4 harness (Contact with Min. 1 Mz
GND circuit)
Min. 1 Mz
Short circuit in wiring har-
5 ness (with another wiring Between wiring harness from ENG (female)
harness) (37) to each sensor (female) and wiring har- Resis-
Min. 1 Mz
ness from ENG (female) (47) to each sensor tance
(female)
Defective engine control- carry out troubleshooting.
6
ler ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
38 WA800-3E0, WA900-3E0
Circuit diagram related to sensor power source (2) (At right bank)
WA800-3E0, WA900-3E0 39
Failure code [CA234] Engine over speed (At left bank only): Excessively
high speed 1
Action code Failure code Symptom of Engine over speed (At left bank only): Excessively high speed
E02 CA234 failure (Engine controller system)
Failure content • The engine speed exceeds upper control limit speed.
Controller's • Stops operation of injector until the engine speed drops to the normal speed.
Symptoms that
appear on • Engine speed fluctuates.
machine
• The engine speed can be checked in monitoring function.
General
(Code: 01002 (rpm))
information
• Duplication of failure code: Start engine and operate at high idle.

Possible codes are displayed, carry out troubleshooting for those codes.
causes and the The improper usage of equipped machine can be suspected. Instruct
2 Improper usage
standard values the proper usage.
when normal Engine controller can be suspected to be defective if no problem is
Defective engine
3 found in causes 1 – 2 (since this is an internal defect, it cannot be
controller
diagnosed).
40 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 41
Failure code [CA238] Abnormal power source for Ne speed sensor (At
left bank only): Excessively low voltage detected 1
Action code Failure code Symptom of Abnormal power source for Ne speed sensor (At left bank only):
E03 CA238 failure Excessively low voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
Controller's • Controls using Bkup speed sensor signal.
Symptoms that
• Engine stops during operation (when Bkup speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
machine
General
information

still OFF.
Defective Ne speed sen- Disconnect a device
1 sor shown on the right.
(internal defect) If the failure code dis- Ne speed sensor Ne connector
appears, that device is
internally defective.
harness
Wiring harness between left bank ENG Resis-
(female) (16) – Ne (female) (1) tance
tors) Max. 1 z
Possible (female) (48) – Ne (female) (2) tance
causes and the a Prepare with starting switch OFF and diagnose with starting switch
standard values Defective harness still OFF.
when normal grounding Between ground and wiring harness between Resis-
3 Min. 1 Mz
(contact with ground cir- left bank ENG (female) (16) – Ne (female) (1) tance
cuit) Between ground and wiring harness between Resis-
Min. 1 Mz
left bank ENG (female) (48) – Ne (female) (2) tance
still OFF.
Harness short Between wiring harness from left bank ENG
4
(Harness internal short) (female) (16) to Ne (female) (1) and wiring Resis-
Min. 1 Mz
harness from left bank ENG (female) (48) to tance
Ne (female) (2)
5
ler Left bank ENG Voltage
Between (16) – (48) 4.75 – 5.25 V
42 WA800-3E0, WA900-3E0
Circuit diagram related to Ne speed sensor power source
WA800-3E0, WA900-3E0 43
Failure code [CB238] Abnormal power source for Ne speed sensor (At
right bank only): Excessively low voltage detected 1
Action code Failure code Symptom of Abnormal power source for Ne speed sensor (At right bank only):
E03 CB238 failure Excessively low voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
Controller's • Controls using Bkup speed sensor signal.
Symptoms that
appear on
machine
General
information

still OFF.
Defective Ne speed sen- Disconnect a device
1 sor shown on the right.
(internal defect) If the failure code dis- Ne speed sensor Ne connector
appears, that device is
internally defective.
harness
Wiring harness between right bank ENG Resis-
tors) Max. 1 z
Possible
causes and the
still OFF.
standard values Defective harness
when normal Between ground and wiring harness between Resis-
grounding Min. 1 Mz
3 left bank ENG (female) (16) – Ne (female) (1) tance
(contact with ground cir-
cuit) Between ground and wiring harness between
Resis-
right bank ENG (female) (48) – Ne (female) Min. 1 Mz
tance
(2)
still OFF.
Harness short Between wiring harness from left bank ENG
4
(Harness internal short) (female) (16) to Ne (female) (1) and wiring Resis-
Min. 1 Mz
harness from right bank ENG (female) (48) to tance
Ne (female) (2)
5
ler Between left bank ENG (16) – Voltage
right bank ENG (48) 4.75 – 5.25 V
44 WA800-3E0, WA900-3E0
Circuit diagram related to Ne speed sensor power source
WA800-3E0, WA900-3E0 45
Failure code [CA263] Fuel temperature sensor too high (At left bank):
Action code Failure code Symptom of Fuel temperature sensor too high (At left bank): Excessively high volt-
Failure content • Excessively high voltage is detected at fuel temperature sensor circuit.
Controller's • Substitutes coolant temperature sensor.
action • If coolant temperature sensor is also abnormal, operates with a fixed fuel temperature (95°C).
Symptoms that
appear on
machine
General • The signal voltage of engine fuel temperature sensor can be checked in monitoring function.

Defective fuel tempera- still OFF.
1 ture sensor (internal
TFUEL (male) Fuel temperature Resistance
defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
harness
Possible 2 (disconnection or defec- Max. 1 z
TFUEL (female) (A) tance
causes and the tive contact of connec-
standard values tors) Max. 1 z
when normal TFUEL (female) (B) tance
3 Min. 1 Mz
(contact with ground cir- ENG (female) (30) – TFUEL (female) (A) tance
cuit) a Prepare with starting switch OFF and diagnose with starting switch
still OFF.
Defective engine control- ENG (female) Fuel temperature Resistance
4
ler Between (30) – (47) 10 – 100°C 0.6 – 20 kz
46 WA800-3E0, WA900-3E0
Circuit diagram related to fuel temperature sensor
WA800-3E0, WA900-3E0 47
Action code Failure code Symptom of Fuel temperature sensor too high (At right bank): Excessively high
E01 CB263 failure voltage detected (Engine controller system)
Failure content • Excessively high voltage is detected at fuel temperature sensor circuit.
• Substitutes coolant temperature sensor.
Controller's
• If coolant temperature sensor is also abnormal, sets fuel temperature to default value (95°C) and
action
Symptoms that
appear on
machine
General • The signal of engine fuel temperature sensor (right bank) can be checked in monitoring function.

Defective fuel tempera- still OFF.
1 ture sensor (internal
TFUEL (male) Fuel temperature Resistance
defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
still OFF.
harness
Possible 2 (disconnection or defec- Max. 1 z
TFUEL (female) (A) tance
causes and the tive contact of connec-
standard values tors) Max. 1 z
TFUEL (female) (B) tance
when normal
3 Min. 1 Mz
(contact with ground cir- ENG (female) (30) – TFUEL (female) (A) tance
cuit) a Prepare with starting switch OFF and diagnose with starting switch
still OFF.
Defective engine control- ENG (female) Fuel temperature Resistance
4
ler Between (30) – (47) 10 – 100°C 0.6 – 20 kz
Circuit diagram related to fuel temperature sensor
48 WA800-3E0, WA900-3E0
Failure code [CA265] Fuel temperature sensor abnormally low level

Action code Failure code Symptom of Fuel temperature sensor abnormally low level (Left bank): Low volt-
Failure content • Low voltage was detected in fuel temperature sensor circuit.
Controller's
action
Symptoms that
appear on
machine
General • The signal of engine fuel temperature sensor can be checked in monitoring function.
causes and the
when normal
Failure code [CB265] Fuel temperature sensor abnormally low level

Action code Failure code Symptom of Fuel temperature sensor abnormally low level (Right bank): Low volt-
Failure content • Low voltage was detected in fuel temperature sensor circuit.
Controller's
action
Symptoms that
appear on
machine
General • The signal of engine fuel temperature sensor (right bank) can be checked in monitoring function.
causes and the
when normal
WA800-3E0, WA900-3E0 49
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit 1
Action code Failure code Symptom of PCV1 short circuit (Left bank): Short circuit
Failure content • Short circuit occurred in supply pump PCV1 circuit.
Controller's
action
Symptoms that
appear on
machine
General • While engine is running, normally pulse voltage of approx. 24 V is supplied to PCV1 (1), but the
information voltage cannot be measured with a tester because of pulse voltage.

Defective supply pump without turning starting switch ON.
1 PCV1 PCV1 (male) Resistance
(Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) – ground Min. 1 Mz
Ground fault in wiring
PCV1 (female) (1) tance
Possible GND circuit)
causes and the Min. 1 Mz
standard values
when normal a Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Contact with
Wiring harness between ENG (female) (4) –
3 24V circuit) in wiring Voltage Max. 1 V
PCV1 (female) (1)
harness
Voltage Max. 1 V
PCV1 (female) (2)
Defective engine
4 ENG (female) Resistance
controller
Between (4) – (5) 2.3 – 5.3 z
Circuit diagram related to supply pump PCV1
50 WA800-3E0, WA900-3E0
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit 1
Action code Failure code Symptom of PCV1 short circuit (Right bank): Short circuit
E03 CB271 failure (Engine controller system)
Controller's
action
Symptoms that
appear on
machine

standard values
PCV1 (female) (1)
harness
Voltage Max. 1 V
PCV1 (female) (2)
Defective engine
controller
Between (4) – (5) 2.3 – 5.3 z
WA800-3E0, WA900-3E0 51
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection 1

Action code Failure code Symptom of PCV1 disconnection (Left bank): Disconnection
Failure content • Disconnection occurred in supply pump PCV1 circuit.
Controller's
action
Symptoms that
appear on
machine

(Internal disconnection) Between (1) – (2) 2.3 – 5.3 z
2 Max. 1 z
in wiring or defective PCV1 (female) (1) tance
Possible contact in connector) Wiring harness between ENG (female) (5) – Resis-
standard values
GND circuit)
Min. 1 Mz
Defective engine
controller
Between (4) – (5) 2.3 – 5.3 z
52 WA800-3E0, WA900-3E0
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection1

Action code Failure code Symptom of PCV1 disconnection (Right bank): Disconnection
Controller's
action
Symptoms that
appear on
machine

(Internal disconnection) Between (1) – (2) 2.3 – 5.3 z
2 Max. 1 z
in wiring or defective PCV1 (female) (1) tance
Possible contact in connector) Wiring harness between ENG (female) (5) – Resis-
standard values
GND circuit)
Min. 1 Mz
Defective engine
controller
Between (4) – (5) 2.3 – 5.3 z
WA800-3E0, WA900-3E0 53
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit 1
Action code Failure code Symptom of PCV2 short circuit (Left bank): Short circuit
Controller's
action
Symptoms that
appear on
machine

standard values
PCV2 (female) (1)
harness
Voltage Max. 1 V
PCV2 (female) (2)
Defective engine
controller
Between (9) – (10) 2.3 – 5.3 z
54 WA800-3E0, WA900-3E0
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit 1
Action code Failure code Symptom of PCV2 short circuit (Right bank): Short circuit
Controller's
action
Symptoms that
appear on
machine

standard values
PCV2 (female) (1)
harness
Voltage Max. 1 V
PCV2 (female) (2)
Defective engine
controller
Between (9) – (10) 2.3 – 5.3 z
WA800-3E0, WA900-3E0 55
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection 1

Action code Failure code Symptom of PCV2 disconnection (Left bank): Disconnection
Controller's
action
Symptoms that
appear on
machine

1 PCV2 (Internal discon-
PCV2 (male) Resistance
nection)
Between (1) – (2) 2.3 – 5.3 z
2 Max. 1 z
in wiring or defective con- PCV2 (female) (1) tance
Possible tact in connector) Wiring harness between ENG (female) (10) – Resis-
Max. 1 z
causes and the PCV2 (female) (2) tance
standard values a Prepare with starting switch OFF, then carry out troubleshooting
when normal without turning starting switch ON.
GND circuit)
Min. 1 Mz
ler
Between (9) – (10) 2.3 – 5.3 z
56 WA800-3E0, WA900-3E0
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection1

Action code Failure code Symptom of PCV2 disconnection (Right bank): Disconnection
Controller's
action
Symptoms that
appear on
machine

1 PCV2 (Internal discon-
PCV2 (male) Resistance
nection)
Between (1) – (2) 2.3 – 5.3 z
2 Max. 1 z
in wiring or defective con- PCV2 (female) (1) tance
Possible tact in connector) Wiring harness between ENG (female) (10) – Resis-
Max. 1 z
causes and the PCV2 (female) (2) tance
standard values a Prepare with starting switch OFF, then carry out troubleshooting
when normal without turning starting switch ON.
GND circuit)
Min. 1 Mz
ler
Between (9) – (10) 2.3 – 5.3 z
WA800-3E0, WA900-3E0 57
SEN02145-01
D475A, D475ASD-5E0 Bulldozer

© 2009 KOMATSU
All Rights Reserved
58
SEN02146-01
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or short circuit (At left bank):
Disconnection, short circuit ............................................................................................................................ 4
Disconnection, short circuit .......................................................................................................................... 10
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch ............................................... 16
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch............................................. 17
WA800-3E0, WA900-3E0 1
Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit ......................................18
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality ...............................20
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection.......22
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection ....23
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection ....24
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection ..26
Failure code [CA431] Trouble in idle validation switch.....................................................................................28
Failure code [CA432] Idle validation action error .............................................................................................30
Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection............31
Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection .........31
Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection .........32
Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection .......32
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank):
Abnormally high pressure occurrence..........................................................................................................33
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank):
Abnormally high pressure occurrence..........................................................................................................33
Failure code [CA451] Common rail pressure sensor too high (At left bank):
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank):
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank):
Abnormally low voltage detection.................................................................................................................38
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank):
Abnormally low voltage detection.................................................................................................................38
Excessively high pressure detected .............................................................................................................39
Excessively high pressure detected .............................................................................................................40
Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error................41
Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error .............41
Loss of pressure feed detected ....................................................................................................................42
Loss of pressure feed detected ....................................................................................................................48
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal..............................50
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal ...........................52
Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank):
Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank):
Low voltage detection...................................................................................................................................56
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase...............57
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase ............57
2 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 3

short circuit (At left bank): Disconnection, short circuit 1
Action code Failure code Symptom of Injector No. 1 (L/B No.1) system disconnection or short circuit (At left
E03 CA322 failure bank): Disconnection, short circuit (Engine controller system)
Failure content • A disconnection or short circuit has occurred in injector No. 1 circuit.
Controller's
action
Symptoms that
• Output decreases.
appear on
• Speed is not stable.
machine
General • While engine is running, normally pulse voltage of approx. 70 V is supplied to the positive (+) side
information of the injector, but the voltage cannot be measured with a tester because of pulse voltage.

switch still OFF.
Defective injector No. 1
1 CN1 (male) Resistance
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
Between (1), (2) and ground Min. 1 Mz
Disconnection in wiring switch still OFF.
harness Wiring harness between ENG (female) (45) – Resis-
2 Max. 1 z
(disconnection or defective CN1 (female) (1) tance
contact of connectors) Wiring harness between ENG (female) (53) – Resis-
Possible Max. 1 z
CN1 (female) (2) tance
causes and the
standard values a Prepare with starting switch OFF and diagnose with starting
when normal switch still OFF.
Defective harness
3 grounding (contact with Min. 1 Mz
ENG (female) (45) – CN1 (female) (1) tance
ground circuit)
Min. 1 Mz
Defective another cylinder If multiple failure codes are displayed for injector malfunction, carry
4
injector or wiring harness out troubleshooting for them, too.
switch still OFF.
5 Defective engine controller ENG (female) Resistance
Between (45) – (53) 0.4 – 1.1 z
4 WA800-3E0, WA900-3E0
Circuit diagram related to injector No. 1
WA800-3E0, WA900-3E0 5

Controller's
action
Symptoms that
appear on
machine

switch still OFF.
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Possible Max. 1 z
causes and the
Defective harness
3 grounding (contact with Min. 1 Mz
ground circuit)
Min. 1 Mz
4
switch still OFF.
Between (46) – (60) 0.4 – 1.1 z
6 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 7

Controller's
action
Symptoms that
appear on
machine

switch still OFF.
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Possible Max. 1 z
causes and the
Defective harness ground-
3 ing (contact with ground Min. 1 Mz
circuit)
Min. 1 Mz
4
switch still OFF.
Between (55) – (52) 0.4 – 1.1 z
8 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 9

Controller's
action
Symptoms that
appear on
machine

switch still OFF.
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Possible Max. 1 z
causes and the
circuit)
Min. 1 Mz
4
switch still OFF.
Between (57) – (59) 0.4 – 1.1 z
10 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 11

Controller's
action
Symptoms that
appear on
machine

switch still OFF.
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Possible Max. 1 z
causes and the
circuit)
Min. 1 Mz
4
switch still OFF.
Between (54) – (51) 0.4 – 1.1 z
12 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 13

Controller's
action
Symptoms that
appear on
machine

switch still OFF.
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Possible Max. 1 z
causes and the
circuit)
Min. 1 Mz
4
switch still OFF.
Between (56) – (58) 0.4 – 1.1 z
14 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 15
Failure code [CA342] Engine controller data mismatch (Left bank):

Mismatch 1
Action code Failure code Symptom of Engine controller data mismatch (Left bank): Mismatch
Failure content • Data mismatch occurred in engine controller.
Controller's
action
Symptoms that
appear on • Engine cannot be started or operated.
machine
General
information
causes and the
when normal
16 WA800-3E0, WA900-3E0
Failure code [CB342] Engine controller data mismatch (Right bank):

Mismatch 1
Action code Failure code Symptom of Engine controller data mismatch (Right bank): Mismatch
Failure content • Data mismatch occurred in engine controller.
Controller's
action
Symptoms that
appear on • Engine cannot be started or operated.
machine
General
information
causes and the
when normal
WA800-3E0, WA900-3E0 17
Failure code [CA351] Abnormal injector drive circuit (At left bank):
Abnormal circuit 1
Action code Failure code Symptom of Abnormal injector drive circuit (At left bank): Abnormal circuit
Failure content • Abnormality has occurred in injector drive circuit.
Controller's • Operates with limited output. (Limits common rail pressure.)
Symptoms that
machine
General
information

Check the failure codes (codes for injector system trouble) that are
1 Defective related circuits displayed at the same time. If any other codes are displayed, carry
out troubleshooting for those codes.
Since a circuit breaker of equipped machine side can be suspected
Defective circuit breaker to be defective, directly check them.
2
CBF2 (If circuit breaker is shut off, it is highly possible that a defective
grounding, etc. has occurred in the circuit.)
Possible Disconnection in wiring without turning starting switch ON.
causes and the harness
standard values (disconnection or defective Max. 1 z
battery LH (+) tance
when normal contact of connectors)
Max. 1 z
ground tance
Defective harness without turning starting switch ON.
Between ground and wiring harness between
ground circuit) Voltage 20 – 30 V
EM3 (female) (4) – battery LH (+)
Between (4) – (1) 20 – 30 V
18 WA800-3E0, WA900-3E0
Circuit diagram related to controller power source
WA800-3E0, WA900-3E0 19
Failure code [CB351] Injector drive circuit abnormality (Right bank):

Circuit abnormality 1
Action code Failure code Symptom of Injector drive circuit abnormality (Right bank): Circuit abnormality
Failure content • Abnormality occurred in injector drive circuit.
Controller's • Limits output and continues operation (Limits common rail pressure).
Symptoms that
machine
General
information

If another code (code of injector system abnormality) is also dis-
1 Related defective system
played, carry out troubleshooting for it.
Since a circuit breaker of equipped machine side can be suspected
Defective circuit breaker to be defective, directly check them.
2
CBF3 (If circuit breaker is shut off, it is highly possible that a defective
grounding, etc. has occurred in the circuit.)
Possible harness (Disconnection in
causes and the 3 Wiring harness between EM4 (female) (4) – Resis-
wiring or defective contact Max. 1 z
standard values battery LH (+) tance
in connector)
when normal Wiring harness between EM4 (female) (1) – Resis-
Max. 1 z
ground tance
Between ground and wiring harness between
GND circuit) Voltage 20 – 30 V
EM4 (female) (4) – battery LH (+)
Between (4) – (1) 20 – 30 V
20 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 21
Failure code [CA352] Sensor power supply (1) abnormally low level
Action code Failure code Symptom of Sensor power supply (1) abnormally low level (Left bank): Low volt-
Controller's • Common rail pressure sensor limits output and continues operation (Limits common rail pressure).
Symptoms that
machine
General
information
causes and the
when normal
22 WA800-3E0, WA900-3E0
Failure code [CB352] Sensor power supply (1) abnormally low level
Action code Failure code Sensor power supply (1) abnormally low level (Right bank): Low volt-
Symptom of
age detection
E03 CB352 failure
(Engine controller system)
Symptoms that
machine
General
information
causes and the
when normal
WA800-3E0, WA900-3E0 23
Failure code [CA386] Sensor power supply (1) abnormally high level
(Left bank): High voltage detection 1
Action code Failure code Symptom of Sensor power supply (1) abnormally high level (Left bank): High volt-
Symptoms that
machine
General
information

Defective sensor When device at right
(Internal defect) Left common rail
error code disap- PFUEL connector
pressure sensor
pears, that device has
defect in it.
Max. 1 z
harness (Disconnection in PFUEL (female) (1) tance
3
wiring or defective contact Wiring harness between ENG (female) (25) – Resis-
in connector) Max. 1 z
PFUEL (female) (2) tance
Max. 1 z
Possible Ground fault in wiring Min. 1 Mz
causes and the 4 harness (Contact with
standard values GND circuit) Wiring harness between ENG (female) (25) – Resis-
Min. 1 Mz
when normal PFUEL (female) (2) tance
Min. 1 Mz
Between wiring harness between ENG
(female) (33) – PFUEL (female) (1) and wir- Resis-
Min. 1 Mz
ing harness between ENG (female) (25) – tance
PFUEL (female) (2)
Short circuit in wiring
5 harness (with another
wiring harness) Min. 1 Mz
PFUEL (female) (3)
Min. 1 Mz
PFUEL (female) (3)
ENG Voltage
Between (33) – (47) 4.75 – 5.25 V
24 WA800-3E0, WA900-3E0
Circuit diagram related to sensor power supply 1 (5V)
WA800-3E0, WA900-3E0 25
Failure code [CB386] Sensor power supply (1) abnormally high level
(Right bank): High voltage detection 1
Action code Failure code Sensor power supply (1) abnormally high level (Right bank): High
Symptom of
voltage detection
E03 CB386 failure
(Engine controller system)
Symptoms that
machine
General
information

Defective sensor When device at right
(Internal defect) Right common rail
error code disap- PFUEL connector
pressure sensor
pears, that device has
defect in it.
Max. 1 z
3
in connector) Max. 1 z
Max. 1 z
Possible Ground fault in wiring har- Min. 1 Mz
causes and the 4 ness (Contact with GND
standard values circuit) Wiring harness between ENG (female) (25) – Resis-
Min. 1 Mz
when normal PFUEL (female) (2) tance
Min. 1 Mz
Min. 1 Mz
PFUEL (female) (2)
5 ness (with another wiring
harness) Min. 1 Mz
PFUEL (female) (3)
Min. 1 Mz
PFUEL (female) (3)
ENG Voltage
Between (33) – (47) 4.75 – 5.25 V
26 WA800-3E0, WA900-3E0
Circuit diagram related to sensor power supply (1) (5V)
WA800-3E0, WA900-3E0 27
Failure code [CA431] Trouble in idle validation switch 1

Action code Failure code Symptom of Trouble in idle validation switch
Failure content • Both of signals 1 and 2 of idle validation switch are open or there is trouble in ground circuit.
Controller's
• Operates normally according to throttle sensor (E01 Testing and maintenance)
action
Symptoms that
appear on • None in particular.
machine
• The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring
function (Code: 18300).
General
information

L25 Signal name Voltage
Defective accelerator Between (5) – (4) IVS 1
1 See Fig. 1
pedal (Internal defect) Between (6) – (4) IVS 2
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller, too,
for another cause of trouble, and then judge.
Max. 1 z
Max. 1 z
Disconnection in wiring Wiring harness between EM1 (female) (32) – Resis-
Max. 1 z
harness (Disconnection in L25 (female) (4) tance
2
wiring or defective contact Wiring harness between EM1 (female) (11) – Resis-
Max. 1 z
in connector) L25 (female) (5) tance
Max. 1 z
Possible L25 (female) (6) tance
Max. 1 z
with starting switch ON.
Grounding fault in wiring Min. 1 Mz
3 harness (Short circuit with
Min. 1 Mz
2) Disconnect L25
3) Turn starting switch ON and carry out troubleshooting.
Hot short (Short circuit Wiring harness between EM1 (female) (32) –
Voltage Max. 1 V
4 with 24V circuit) in wiring L25 (female) (4)
harness Wiring harness between EM1 (female) (11) –
Voltage Max. 1 V
L25 (female) (5)
Wiring harness between EM1 (female) (1) –
Voltage Max. 1 V
L25 (female) (6)
Defective engine controller 4.75 –
5 Between EM2 (male) (22) – (23) Voltage
R bank 5.25 V
28 WA800-3E0, WA900-3E0

Possible
EM1 Between
causes and the Signal name IVS 1
Defective engine controller (11) – (32)
standard values 6 Voltage See Fig. 1
L bank EM1 Between
when normal Signal name IVS 2
(1) – (32)
4.75 –
Between EM1 (22) – (33) Voltage
5.25 V
Circuit diagram related
Fig. 1
Signal voltage of throttle sensor Output voltage (V): Signal name SIG ··· pin (2) of L25
Lo: Switch circuit is closed
Hi: Switch circuit is open
Switch gap: Hysterical area of IVS1 and IVS2
WA800-3E0, WA900-3E0 29
Failure code [CA432] Idle validation action error 1

Action code Failure code Symptom of Idle validation action error
Failure content • Action error was detected in idle validation switch circuit.
Controller's • Operates at position of throttle of accelerator pedal (throttle sensor).
action • Turns the centralized warning lamp and alarm buzzer ON.
Symptoms that
appear on •
machine
General
information
causes and the
when normal
30 WA800-3E0, WA900-3E0
Failure code [CA441] Power supply voltage abnormally low level (Left
bank): Low voltage detection 1
Action code Failure code Symptom of Power supply voltage abnormally low level (Left bank): Low voltage
Failure content • Low voltage was detected in power supply voltage circuit.
Controller's
action
Symptoms that
• Machine continues operation normally but may stop suddenly or may not able to start again once
appear on
it stops.
machine
General
information
causes and the
when normal
Failure code [CB441] Power supply voltage abnormally low level (Right
bank): Low voltage detection 1
Action code Failure code Symptom of Power supply voltage abnormally low level (Right bank): Low voltage
E03 CB441 failure detection (Engine controller system)
Failure content • Low voltage was detected in power supply voltage circuit.
Controller's
action
Symptoms that
appear on
it stops.
machine
General
information
causes and the
when normal
WA800-3E0, WA900-3E0 31
Failure code [CA442] Power supply voltage abnormally high level (Left
Action code Failure code Symptom of Power supply voltage abnormally high level (Left bank): High voltage
Failure content • High voltage was detected in power supply voltage circuit.
Controller's
action
Symptoms that
appear on
it stops.
machine
General
information
causes and the
when normal
Failure code [CB442] Power supply voltage abnormally high level (Right
Action code Failure code Symptom of Power supply voltage abnormally high level (Right bank): High volt-
Failure content • High voltage was detected in power supply voltage circuit.
Controller's
action
Symptoms that
appear on
it stops.
machine
General
information
causes and the
when normal
32 WA800-3E0, WA900-3E0
Failure code [CA449] Common rail abnormally high pressure (2) (Left
bank): Abnormally high pressure occurrence 1
Action code Failure code Symptom of Common rail abnormally high pressure (2) (Left bank): Abnormally
E03 CA449 failure high pressure occurrence (Engine controller system)
Failure content • Common rail pressure sensor circuit detected abnormally high pressure (Level 2).
Symptoms that
machine
General
information
causes and the
when normal
Failure code [CB449] Common rail abnormally high pressure (2) (Right
bank): Abnormally high pressure occurrence 1
Action code Failure code Symptom of Common rail abnormally high pressure (2) (Right bank): Abnormally
E03 CB449 failure high pressure occurrence (Engine controller system)
Failure content • Common rail pressure sensor circuit detected abnormally high pressure (Level 2).
Symptoms that
machine
General
information
causes and the
when normal
WA800-3E0, WA900-3E0 33
Failure code [CA451] Common rail pressure sensor too high (At left
bank): Excessively high voltage detected 1
Action code Failure code Symptom of Common rail pressure sensor too high (At left bank): Excessively
E03 CA451 failure high voltage detected (Engine controller system)
Failure content • Excessively high voltage has occurred in the common rail pressure sensor circuit.
Controller's • Operates with limited output.(Limits common rail pressure.)
Symptoms that
machine
General • The signal of the common rail pressure sensor (left bank) can be checked with the monitoring
information function. (Code: 36400 (MPa), 36402 (V))

Defective sensor power If failure code [CA352] or [CA386] is displayed, carry out trouble-
1
source circuit shooting for it first.
switch ON or with engine started.
PFUEL Voltage
Defective common rail Between (1) – (3) Power source 4.75 – 5.25 V
2 pressure sensor Between (2) – (3) Signal 0.25 – 4.6 V
nected, if the voltage is abnormal, first check the harness and the
controller to make it sure if there is no other cause of the trouble, and
then judge the sensor voltage.
switch still OFF.
Max. 1 z
harness (disconnection or PFUEL (female) (1) tance
3
defective contact of con- Wiring harness between ENG (female) (25) – Resis-
nectors) Max. 1 z
Possible Max. 1 z
causes and the a Prepare with starting switch OFF and diagnose with starting
standard values switch still OFF.
when normal
Defective harness ground- Min. 1 Mz
ENG (female) (33) – PFUEL (female) (1) tance
4 ing (contact with ground
circuit) Between ground and wiring harness between Resis-
Min. 1 Mz
Min. 1 Mz
switch still OFF.
(33) to PFUEL (female) (1) and wiring har- Resis-
Min. 1 Mz
ness from ENG (female) (25) to PFUEL tance
(female) (2)
Harness short Between wiring harness from ENG (female)
5
(Harness internal short) (33) to PFUEL (female) (1) and wiring har- Resis-
Min. 1 Mz
(female) (3)
(25) to PFUEL (female) (2) and wiring har- Resis-
Min. 1 Mz
(female) (3)
34 WA800-3E0, WA900-3E0

Possible a Prepare with starting switch OFF, and diagnose with starting
causes and the switch ON or with engine started.
standard values 6 Defective engine controller ENG Voltage
when normal Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
WA800-3E0, WA900-3E0 35
Failure code [CB451] Common rail pressure sensor abnormally high

level (Right bank): High voltage detection 1
Action code Failure code Symptom of Common rail pressure sensor abnormally high level (Right bank):
E03 CB451 failure High voltage detection (Engine controller system)
Failure content • High voltage was detected in common rail pressure sensor circuit.
Symptoms that
machine
General • Signal of common rail pressure sensor (right bank) can be checked with monitoring function
information (Code: 36403 (MPa), 36404 (V)).

Defective sensor power If code [CB352] or [CB386] is displayed, carry out troubleshooting
1
supply system for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
PFUEL Voltage
Defective common rail
Between (1) – (3) Power supply 4.75 – 5.25 V
2 pressure sensor
(Internal defect) Between (2) – (3) Signal 0.25 – 4.6 V
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller, too,
for another cause of trouble, and then judge.
Max. 1 z
3
Max. 1 z
in connector) PFUEL (female) (2) tance
Max. 1 z
Possible PFUEL (female) (3) tance
causes and the a Prepare with starting switch OFF, then carry out troubleshooting
standard values without turning starting switch ON.
when normal Wiring harness between ENG (female) (33) – Resis-
Ground fault in wiring har- Min. 1 Mz
4 ness (Contact with GND
circuit) Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
PFUEL (female) (2)
5 ness (with another wiring Between wiring harness between ENG
harness) (female) (33) – PFUEL (female) (1) and wir- Resis-
Min. 1 Mz
PFUEL (female) (3)
Min. 1 Mz
PFUEL (female) (3)
36 WA800-3E0, WA900-3E0

Possible a Prepare with starting switch OFF, then turn starting switch ON and
causes and the carry out troubleshooting.
standard values 6 Defective engine controller ENG Voltage
when normal Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
WA800-3E0, WA900-3E0 37
Failure code [CA452] Common rail pressure sensor abnormally low

level (Left bank): Abnormally low voltage detection 1
Action code Failure code Symptom of Common rail pressure sensor abnormally low level (Left bank):
E03 CA452 failure Abnormally low voltage detection (Engine controller system)
Failure content • Low voltage was detected in common rail pressure sensor circuit.
Symptoms that
machine
General • Signal of common rail pressure sensor (left bank) can be checked with monitoring function
information (Code: 36400 (MPa), 36402 (V))
causes and the
when normal
Failure code [CB452] Common rail pressure sensor abnormally low

level (Right bank): Abnormally low voltage detection 1
Action code Failure code Symptom of Common rail pressure sensor abnormally low level (Right bank):
E03 CB452 failure Abnormally low voltage detection (Engine controller system)
Failure content • Low voltage was detected in common rail pressure sensor circuit.
Symptoms that
machine
General • Signal of common rail pressure sensor (right bank) can be checked with monitoring function
causes and the
when normal
38 WA800-3E0, WA900-3E0
Excessively high pressure detected 1
Action code Failure code Symptom of Common rail pressure high trouble (1) (At left bank): Excessively
E03 CA553 failure high pressure trouble occurred (Engine controller system)
• Excessively high pressure has been detected in the common rail pressure sensor circuit.
Failure content
(Pressure kept higher than set level beyond expectation for 10 seconds.)
Controller's
action
Symptoms that
machine
General • Signal of common rail pressure (left bank) can be checked with the monitoring function.

Improper fuel has been Since the use of improper fuel can be suspected, check the fuel.
2
used. (Viscosity is too high)
Defective electrical system Since an electrical defect of common rail pressure sensor is sus-
3 of common rail pressure pected, carry out troubleshooting for the following code.
Possible
sensor [CA451]
causes and the
standard values Defective mechanical sys-
Since a mechanical defect of common rail pressure sensor is sus-
when normal 4 tem of common rail pres-
pected, directly check the sensor.
sure sensor
Since a damage of spring, wear of seat or sticking of ball is sus-
5 Defective overflow valve
pected, directly check them.
Since an overflow piping is suspected to be clogged, directly check
6 Clogged overflow piping
it.
Since a mechanical defect of pressure limiter is suspected, directly
7 Defective pressure limiter
check the limiter.
WA800-3E0, WA900-3E0 39
Excessively high pressure detected 1
Action code Failure code Symptom of Common rail pressure high trouble (1) (At right bank): Excessively
E03 CB553 failure high pressure trouble occurred (Engine controller system)
• Excessively high pressure has been detected in the common rail pressure sensor circuit.
Failure content
(Pressure kept higher than set level beyond expectation for 10 seconds.)
Controller's
action
Symptoms that
machine
General • Signal of common rail pressure (right bank) can be checked with the monitoring function.

Improper fuel has been Since the use of improper fuel can be suspected, check the fuel.
2
used. (Viscosity is too high)
Defective electrical system Since an electrical defect of common rail pressure sensor is sus-
3 of common rail pressure pected, carry out troubleshooting for the following code.
Possible
sensor [CB451]
causes and the
standard values Defective mechanical sys-
Since a mechanical defect of common rail pressure sensor is sus-
when normal 4 tem of common rail pres-
pected, directly check the sensor.
sure sensor
Since a damage of spring, wear of seat or sticking of ball is sus-
5 Defective overflow valve
pected, directly check them.
Since an overflow piping is suspected to be clogged, directly check
6 Clogged overflow piping
it.
Since a mechanical defect of pressure limiter is suspected, directly
7 Defective pressure limiter
check the limiter.
40 WA800-3E0, WA900-3E0
Failure code [CA554] In-range error in common rail pressure sensor (At
left bank): In-range error 1
Action code Failure code Symptom of In-range error in common rail pressure sensor (At left bank): In-
E03 CA554 failure range error occurred (Engine controller system)
Failure content • In-range error has occurred in common rail pressure sensor circuit.
Symptoms that
machine
General
information
causes and the
standard values Carry out troubleshooting of [CA451].
when normal
Failure code [CB554] In-range error in common rail pressure sensor (At
right bank): In-range error 1
Action code Failure code Symptom of In-range error in common rail pressure sensor (At right bank): In-
E03 CB554 failure range error occurred (Engine controller system)
Failure content • In-range error has occurred in common rail pressure sensor circuit.
Symptoms that
machine
General
information
causes and the
standard values Carry out troubleshooting of [CB451].
when normal
WA800-3E0, WA900-3E0 41
Failure code [CA559] Loss of pressure feed from supply pump (1) (At
left bank): Loss of pressure feed detected 1
Action code Failure code Symptom of Loss of pressure feed from supply pump (1) (At left bank): Loss of
E03 CA559 failure pressure feed detected (Engine controller system)
Failure content • Loss of pressure feed (level 1) from supply pump has occurred.
Controller's
• Limits common rail pressure.
action
Symptoms that
appear on
machine
General
information

Improper fuel has been
2 Since the use of improper fuel is suspected, directly check the fuel.
used.
a See “Note 1” for the contents of diagnosis. See Testing and
adjusting “Testing fuel pressure” for the pressure inspection of the
fuel low pressure circuit.
Defective low pressure
3 Pressure in fuel low pressure
circuit device
circuit Min. 0.15 MPa
(At high idle or under the load {Min. 1.5 kg/cm2}
equivalent to rating (stalling))
4 Clogged filter or strainer a See “Note 2” for the contents of diagnosis.
Since an electrical defect of supply pump PCV is suspected, carry
Defective electrical system
5 out troubleshooting for the following codes.
of supply pump PCV
[CA271], [CA272], [CA273], and [CA274]
Possible Defective common rail Since a defect of common rail pressure sensor is suspected, check
causes and the 6
pressure sensor for a damage in harnesses.
standard values
a As for testing an amount of pressure limiter leak, see testing and
when normal
adjusting “Testing fuel return and leak amount”.
7 Defective pressure limiter Max. 10 cc/min.
Pressure limiter leak amount [Equivalent to rated operation
(stalling)]
a As for the test relating to return (spill) limit amount of injector, see
Testing and adjusting “Testing fuel return and leak amount”.
Speed under the conditions which
are equivalent to rated operation Injector return (spill) limit amount
(stalling)
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
Supply pump can be suspected to be defective if no problem is
9 Defective supply pump
found in causes 1 – 8.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no-
pressure feed”.
42 WA800-3E0, WA900-3E0
Note 1: When low-pressure circuit equipment is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
WA800-3E0, WA900-3E0 43
Check sheet for no-pressure feed
Model WA800-3E0 Operation No.

Model and serial No. # Date inspected / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual inspections Pass Fail

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) Pass Fail
3 Checking failure codes / / / /
Checking monitoring information
Standard value
Code Display item Condition for inspection Unit Measured value Pass Fail
(reference value)
Low idle rpm 620 – 700
*1 Engine speed High idle rpm 2,100 – 2,175
Equivalent to rating rpm 2,000
Low idle % 0
*2 Throttle speed
High idle % 100
Command for fuel injec-
*3 Equivalent to rating mm3 — — —
tion rate
Command for common
*4 Equivalent to rating MPa
4 rail pressure
Fuel pressure in
common rail
Low idle CA — — —
Command for
*6 High idle CA — — —
fuel injection timing
Equivalent to rating CA — — —
*7 Boost pressure Equivalent to rating kPa — — —
Coolant temperature
*8 Low idle °C — — —
(high temperature)
Coolant temperature
(low temperature)
*10 Fuel temperature Low idle °C — — —
Checking reduced cylinder mode operation (engine speed)
Func- Standard value
Cut-out cylinder Condition for inspection Unit Measured value Pass Fail
tion (reference value)
Cylinder No. 1 Low idle rpm — — —
5 Cylinder No. 2 Low idle rpm — — —

*11
Standard value
C. Inspection of pressure in fuel circuit Condition for inspection Unit Measured value Pass Fail
(reference value)
Pressure in fuel low pressure cir- At high idle or under the load equiva- MPa Min. 0.15
6
cuit lent to rating (stalling) {kg/cm2} {Min. 1.5}
44 WA800-3E0, WA900-3E0
D. Inspection of strainer and filter Pass Fail

7 Visual inspection of strainer
8 Visual inspection of gauze filter
9 Visual inspection of fuel filter
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return Standard value

Condition for inspection Unit Measured value Pass Fail
amount (reference value)
Pressure limiter Under the load equivalent to rating
11 cc/min Max 10
leak amount (stalling)
Equivalent to rating: 1,600 rpm cc/min 960
Equivalent to rating: 1,700 rpm cc/min 1,020 Rotation speed:
12 Injector return amount Equivalent to rating: 1,800 rpm cc/min 1,080
Equivalent to rating: 1,900 rpm cc/min 1,140 Return amount:
Equivalent to rating: 2,000 rpm cc/min 1,200
Inspection items *1 – *10 of B-4:

When inspecting with the monitoring function, see “Monitoring code table”.
Inspection items *11 of B-5:
When inspecting with the monitoring function, see “Adjustment mode table”.
Equivalent to rating: 1) Engine at full throttle, 2) Relieve pressure in each work equipment cylinder
WA800-3E0, WA900-3E0 45
Check sheet for no-pressure feed
Model WA900-3E0 Operation No.

Model and serial No. # Date inspected / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual inspections Pass Fail

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) Pass Fail
3 Checking failure codes / / / /
Checking monitoring information
Standard value
Code Display item Condition for inspection Unit Measured value Pass Fail
(reference value)
Low idle rpm 680 – 730
*1 Engine speed High idle rpm 2,180 – 2,210
Equivalent to rating rpm 2,050
Low idle % 0
*2 Throttle speed
High idle % 100
Command for fuel injec-
*3 Equivalent to rating mm3 — — —
tion rate
Command for common
4 rail pressure
Fuel pressure in
common rail
Low idle CA — — —
Command for
*6 High idle CA — — —
fuel injection timing
Equivalent to rating CA — — —
*7 Boost pressure Equivalent to rating kPa — — —
Coolant temperature
(high temperature)
Coolant temperature
(low temperature)
*10 Fuel temperature Low idle °C — — —
Checking reduced cylinder mode operation (engine speed)
Func- Standard value
Cut-out cylinder Condition for inspection Unit Measured value Pass Fail
tion (reference value)
5 Cylinder No. 2 Low idle rpm — — —

*11
Standard value
C. Inspection of pressure in fuel circuit Condition for inspection Unit Measured value Pass Fail
(reference value)
Pressure in fuel low pressure cir- At high idle or under the load equiva- MPa Min. 0.15
6
cuit lent to rating (stalling) {kg/cm2} {Min. 1.5}
46 WA800-3E0, WA900-3E0
D. Inspection of strainer and filter Pass Fail

7 Visual inspection of strainer
8 Visual inspection of gauze filter
9 Visual inspection of fuel filter
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return Standard value

Condition for inspection Unit Measured value Pass Fail
amount (reference value)
Pressure limiter Under the load equivalent to rating
11 cc/min Max 10
leak amount (stalling)
Equivalent to rating: 1,600 rpm cc/min 960
Equivalent to rating: 1,700 rpm cc/min 1,020 Rotation speed:
12 Injector return amount Equivalent to rating: 1,800 rpm cc/min 1,080
Equivalent to rating: 1,900 rpm cc/min 1,140 Return amount:
Equivalent to rating: 2,000 rpm cc/min 1,200
Inspection items *1 – *10 of B-4:

When inspecting with the monitoring function, see “Monitoring code table”.
Inspection items *11 of B-5:
When inspecting with the monitoring function, see “Adjustment mode table”.
Equivalent to rating: 1) Engine at full throttle, 2) Relieve pressure in each work equipment cylinder
WA800-3E0, WA900-3E0 47
Failure code [CB559] Loss of pressure feed from supply pump (1) (At
right bank): Loss of pressure feed detected 1
Action code Failure code Symptom of Loss of pressure feed from supply pump (1) (At right bank): Loss of
E03 CB559 failure pressure feed detected (Engine controller system)
Failure content • Loss of pressure feed (level 1) from supply pump has occurred.
Controller's
• Limits common rail pressure.
action
Symptoms that
appear on
machine
General
information

Improper fuel has been
2 Since the use of improper fuel is suspected, directly check the fuel.
used.
See failure code [CA559].
Defective low pressure
3 a See Testing and adjusting “Testing fuel pressure” for the pressure
circuit device
inspection of the fuel low pressure circuit.
4 Clogged filter or strainer See failure code [CA559].
Since an electrical defect of supply pump PCV is suspected, carry
Defective electrical system
5 out troubleshooting for the following codes.
of supply pump PCV
[CB271], [CB272], [CB273], and [CB274]
Defective common rail Since a defect of common rail pressure sensor is suspected, check
6
pressure sensor for a damage in harnesses.
Possible a As for testing an amount of pressure limiter leak, see testing and
causes and the adjusting “Testing fuel return and leak amount”.
standard values
7 Defective pressure limiter Max. 10 cc/min.
when normal
Pressure limiter leak amount [Equivalent to rated operation
(stalling)]
a As for the test relating to return (spill) limit amount of injector, see
Testing and adjusting “Testing fuel return and leak amount”.
Speed under the conditions which
are equivalent to rated operation Injector return (spill) limit amount
(stalling)
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
Supply pump can be suspected to be defective if no problem is
9 Defective supply pump
found in causes 1 – 8.
a Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for
no-pressure feed” (See failure code [CA559]).
48 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 49
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank):
Abnormal signal 1
Action code Failure code Symptom of Abnormal engine Ne speed sensor (At left bank): Abnormal signal
Failure content • Abnormal signal of the engine Ne speed sensor has been detected.
Controller's • Operates using Bkup speed sensor signal.
Symptoms that
appear on
machine
General
information
Causes Standard values when normal and remarks for troubleshooting

1
switch still OFF.
Disconnection in wiring Wiring harness between left ENG (female) Resis-
Max. 1 z
harness (16) – NE (female) (1) tance
2
(disconnection or defective Wiring harness between left ENG (female) Resis-
contact of connectors) Max. 1 z
(48) – NE (female) (2) tance
Wiring harness between left ENG (female) Resis-
Max. 1 z
switch still OFF.
Defective harness ground- Between ground and wiring harness between Resis-
Min. 1 Mz
ing left ENG (female) (16) – NE (female) (1) tance
3
cuit) Min. 1 Mz
left ENG (female) (48) – NE (female) (2) tance
Min. 1 Mz
left ENG (female) (27) – NE (female) (3) tance
Possible a Prepare with starting switch OFF and diagnose with starting
causes and the switch still OFF.
standard values
Between wiring harness from left ENG
when normal
(female) (16) to NE (female) (1) and wiring Resis-
Min. 1 Mz
harness from left ENG (female) (48) to NE tance
(female) (2)
Harness short Between wiring harness from left ENG
4
(Harness internal short) (female) (16) to NE (female) (1) and wiring Resis-
Min. 1 Mz
(female) (3)
Min. 1 Mz
(female) (3)
Defective mounting of sen- Since defective mounting of Ne speed sensor (improper gap) or
5 sor or defective parts for defective parts for speed detection (flywheel) can be suspected,
speed detection directly check it.
Engine Ne speed sensor can be suspected to be defective if no
Defective engine Ne
6 problem is found in causes 1 – 5 (since this is an internal defect, it
speed sensor
cannot be diagnosed).
diagnosed).
50 WA800-3E0, WA900-3E0
Circuit diagram related to engine Ne speed sensor
WA800-3E0, WA900-3E0 51
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank):
Abnormal signal 1
Action code Failure code Symptom of Abnormal engine Ne speed sensor (At right bank): Abnormal signal
Failure content • Abnormal signal of the engine Ne speed sensor has been detected.
Controller's • Operates using Bkup speed sensor signal.
Symptoms that
appear on
machine
General
information
Causes Standard values when normal and remarks for troubleshooting

Defective sensor power If failure code [CB238] is displayed at the same time, carry out trou-
1
switch still OFF.
Max. 1 z
harness (16) – NE (female) (1) tance
2
(disconnection or defective Wiring harness between right ENG (female) Resis-
contact of connectors) Max. 1 z
Wiring harness between right ENG (female) Resis-
Max. 1 z
switch still OFF.
Defective harness ground- Between ground and wiring harness between Resis-
Min. 1 Mz
ing left ENG (female) (16) – NE (female) (1) tance
3
cuit) Min. 1 Mz
right ENG (female) (48) – NE (female) (2) tance
Min. 1 Mz
right ENG (female) (27) – NE (female) (3) tance
Possible a Prepare with starting switch OFF and diagnose with starting
causes and the switch still OFF.
standard values
when normal
Min. 1 Mz
harness from right ENG (female) (48) to NE tance
(female) (2)
4
(Harness internal short) (female) (16) to NE (female) (1) and wiring Resis-
Min. 1 Mz
(female) (3)
Between wiring harness from right ENG
Min. 1 Mz
(female) (3)
Defective mounting of sen- Since defective mounting of Ne speed sensor (improper gap) or
5 sor or defective parts for defective parts for speed detection (flywheel) can be suspected,
speed detection directly check it.
Engine Ne speed sensor can be suspected to be defective if no
Defective engine Ne
speed sensor
diagnosed).
52 WA800-3E0, WA900-3E0
Circuit diagram related to engine Ne speed sensor
WA800-3E0, WA900-3E0 53
Failure code [CA691] Intake air temperature sensor abnormally high

Action code Failure code Symptom of Intake air temperature sensor abnormally high level (Only left bank):
E01 CA691 failure High voltage detection (Engine controller system)
Failure content • Intake air temperature sensor circuit detected high voltage.
Controller's
• Fixes intake air temperature (25°C) and continues operation.
action
Symptoms that
appear on
machine
General Signal of intake air temperature sensor can be checked with the monitoring function.
information (Code:18400 (°C), 18401 (V))

Defective charge tempera- without turning starting switch ON.
1 ture sensor (Internal TAMB Intake air temperature Resistance
defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) – ground All range Min. 1 Mz
Possible harness (Disconnection in Wiring harness between ENG (female) (43) – Resis-
2 Max. 1z
causes and the wiring or defective contact TAMB (female) (A) tance
standard values in connector) Wiring harness between ENG (female) (47) – Resis-
when normal Max. 1z
TAMB (female) (B) tance
circuit) Min. 1 Mz
TAMB (female) (A) tance
ENG (female) Intake air temperature Resistance
Between (43) – (47) 10 – 100°C 0.5 – 20 kz
54 WA800-3E0, WA900-3E0
Circuit diagram related to intake air temperature sensor
WA800-3E0, WA900-3E0 55
Failure code [CA692] Intake air temperature sensor abnormally low level
(Only left bank): Low voltage detection 1
Action code Failure code Symptom of Intake air temperature sensor abnormally low level (Only left bank):
E01 CA692 failure Low voltage detection (Engine controller system)
Failure content • Intake air temperature sensor circuit detected low voltage.
Controller's
• Fixes intake air temperature (25°C) and continues operation.
action
Symptoms that
appear on
machine
General Signal of intake air temperature sensor can be checked with the monitoring function.
information (Code:18400 (°C), 18401 (V))
causes and the
when normal
56 WA800-3E0, WA900-3E0
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At
left bank): Abnormal phase 1
Action code Failure code Symptom of Abnormal engine Bkup speed sensor phase (At left bank): Abnormal
E03 CA731 failure phase (Engine controller system)
• Abnormal phase has been detected in the engine Bkup sensor circuit.
Failure content
Phase not matching compared with the signal received from Ne speed sensor (left bank)
Controller's • Operates using engine Ne speed sensor signal.
Symptoms that
• Engine stops during operation (when Ne speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
machine
General If Bkup speed sensor needs to be replaced, fuel supply pump must be replaced. (See "Disassembly
information and assembly".)

Since a defect of engine Ne speed sensor can be suspected, carry
Possible Defective engine Ne
1 out troubleshooting for the following code.
causes and the speed sensor circuit
[CA689]
standard values
when normal Since a defect of engine Bkup speed sensor can be suspected, carry
Defective engine Bkup
speed sensor system
[CA778]
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At
right bank): Abnormal phase 1
Action code Failure code Symptom of Abnormal engine Bkup speed sensor phase (At right bank): Abnor-
E03 CB731 failure mal phase (Engine controller system)
• Abnormal phase has been detected in the engine Bkup sensor circuit.
Failure content
Phase not matching compared with the signal received from Ne speed sensor (right bank)
Controller's • Operates using engine Ne speed sensor signal.
Symptoms that
appear on
machine

Since a defect of engine Ne speed sensor can be suspected, carry
Possible Defective engine Ne
causes and the speed sensor circuit
[CB689]
standard values
when normal Since a defect of engine Bkup speed sensor can be suspected, carry
Defective engine Bkup
speed sensor system
[CB778]
WA800-3E0, WA900-3E0 57
SEN02146-01

© 2009 KOMATSU
All Rights Reserved
58
SEN02147-02
WA800-3E0
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data .................................. 3
Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data................................ 3
Failure code [CA778] Engine Bkup speed sensor abnormality (At left bank): Bkup signal error .................... 4
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error..................... 6
Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error ............... 8
Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error .......... 10
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank):
Distinction error..........................................................................................................................................11
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank):
Distinction error......................................................................................................................................... 12
Disconnection/Short circuit ....................................................................................................................... 14
WA800, WA900-3E0 1
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error......................................... 26
Failure code [CA2185] Throttle sensor power supply abnormally high level
(Only left bank): High voltage detection .................................................................................................... 28
Failure code [CA2186] Throttle sensor power source too low (At left bank only):
Excessively low voltage detected.............................................................................................................. 30
Loss of pressure feed detected................................................................................................................. 31
Loss of pressure feed detected................................................................................................................. 31
Failure code [CA2555] Intake heater relay voltage low error (Left bank only) .............................................. 32
Failure code [CA2556] Intake heater relay voltage high error (Left bank only) ............................................. 34
Failure code [D160KZ] (or TM & AJSS controller LED display [10],
abnormality in backup lamp relay system: Disconnection, short circuit or hot short circuit....................... 36
Failure code [D180KA] (Preheating relay output system: Disconnection) .................................................... 38
Failure code [D180KB] (Preheating relay output system: Grounding fault) .................................................. 39
Failure code [D180KY] (Preheating relay output system: Hot short circuit) .................................................. 40
Failure code [D19AKB] (or TM & AJSS controller LED display [56],
abnormality in joystick caution relay output system: Disconnection or short circuit)................................. 42
Failure code [D19BKZ] (or TM & AJSS controller LED display [62],
abnormality in joystick neutral interlock relay output system: Disconnection or short circuit) ................... 44
Failure code [D1EFKA] (Pre-lubrication start relay output system: Disconnection) ...................................... 46
Failure code [D1EFKB] (Pre-lubrication start relay output system: Grounding fault) .................................... 48
Failure code [D1EFKY] (Pre-lubrication start relay output system: Hot short circuit).................................... 50
Failure code [D1EHKA] (Engine start relay output system: Disconnection).................................................. 52
Failure code [D1EHKB] (Engine start relay output system: Grounding fault)................................................ 54
Failure code [D1EHKY] (Engine start relay output system: Hot short circuit) ............................................... 56
Failure code [D5ZHL6] (Starting switch terminal C signal: Error).................................................................. 58
Failure code [D5ZSKA] (Machine monitor communication output: Disconnection)....................................... 60
Failure code [D5ZSKB] (Machine monitor communication output: Grounding fault)..................................... 61
Failure code [D5ZSKY] (Machine monitor communication output: Hot short circuit) .................................... 62
2 WA800, WA900-3E0
Failure code [CA757] Loss of all engine controller data (At left bank):
Loss of all data 1
Action code Failure code Symptom of Loss of all engine controller data (At left bank): Loss of all data
Failure content • Loss of all data in engine controller has been detected.
Controller's
action
Symptoms that
appear on • The engine cannot be started, or cannot be operated.
machine
General
information
causes and the
standard values Carry out troubleshooting of [CA111].
when normal
Failure code [CB757] Loss of all engine controller data (At right bank):
Loss of all data 1
Action code Failure code Symptom of Loss of all engine controller data (At right bank): Loss of all data
Failure content • Loss of all data in engine controller has been detected.
Controller's
action
Symptoms that
appear on • The engine cannot be started, or cannot be operated.
machine
General
information
causes and the
standard values Carry out troubleshooting of [CB111].
when normal
WA800, WA900-3E0 3
Failure code [CA778] Engine Bkup speed sensor abnormality (At left
bank): Bkup signal error 1
Action code Failure code Symptom of Engine Bkup speed sensor abnormality (At left bank): Bkup signal
E03 CA778 failure error (Engine controller system)
Failure content • Abnormal engine Bkup speed sensor signal has been detected.
Controller's • Operates using Ne speed sensor signal.
Symptoms that
appear on
machine

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
source circuit shooting for it first.
switch still OFF.
2 Defective pull up resistor
Resis-
Between RES1 (male) (1) – (2) 620 z
tance
switch still OFF.
Max. 1 z
(37) – left G (female) (1) tance
Max. 1 z
harness (37) – RES1 (female) (1) tance
3
(disconnection or defective Wiring harness between left ENG (female) Resis-
Max. 1 z
contact of connectors) (47) – left G (female) (2) tance
Max. 1 z
(26) – left G (female) (3) tance
Max. 1 z
(26) – RES1 (female) (2) tance
Possible
causes and the a Prepare with starting switch OFF and diagnose with starting
standard values switch still OFF.
when normal Between ground and wiring harness between Resis-
Defective harness Min. 1 Mz
left ENG (female) (37) – left G (female) (1) tance
Min. 1 Mz
Min. 1 Mz
switch still OFF.
(female) (37) to left G (female) (1) and wiring Resis-
Min. 1 Mz
harness from left ENG (female) (47) to left G tance
(female) (2)
5
(Harness internal short) (female) (37) to left G (female) (1) and wiring Resis-
Min. 1 Mz
(female) (3)
(female) (47) to left G (female) (2) and wiring Resis-
Min. 1 Mz
(female) (3)
4 WA800, WA900-3E0

Defective mounting of sen- Since defective mounting of Bkup speed sensor (improper gap) or
6 sor or defective parts for defective parts for speed detection (in supply pump) can be sus-
Possible speed detection pected, directly check it.
causes and the Engine Bkup speed sensor can be suspected to be defective if no
standard values Defective engine Bkup
when normal speed sensor
diagnosed).
Circuit diagram related to engine Bkup speed sensor
WA800, WA900-3E0 5
Failure code [CB778] Engine Bkup speed sensor abnormality (Right

bank): Bkup signal error 1
Action code Failure code Symptom of Engine Bkup speed sensor abnormality (Right bank): Bkup signal
E03 CB778 failure error (Engine controller system)
Failure content • Engine Bkup speed sensor signal detected abnormality.
Controller's • Operates with Ne speed sensor signal
Symptoms that
• If engine has been running, it stops (when Ne speed sensor is also defective).
appear on
• If engine has been stopped, it cannot start (when Ne speed sensor is also defective).
machine

Defective sensor power If failure code [CB187] or [CB227] is displayed, carry out trouble-
1
supply system shooting for it first.
switch still OFF.
2 Defective pull up resistor
Resis-
Between RES (male) (1) – (2) 620 z
tance
Max. 1 z
(37) – right G (female) (1) tance
Disconnection in wiring Wiring harness between right ENG (female) Resis-
Max. 1 z
harness (Disconnection in (37) – RES (female) (1) tance
3
wiring or defective contact Wiring harness between right ENG (female) Resis-
Max. 1 z
in connector) (47) – right G (female) (2) tance
Max. 1 z
Max. 1 z
(26) – RES (female) (2) tance
Possible
when normal Wiring harness between right ENG (female) Resis-
Ground fault in wiring har- (37) – right G (female) (1) Min. 1 Mz
tance
circuit) Wiring harness between right ENG (female) Resis-
Min. 1 Mz
Min. 1 Mz
Between wiring harness between right ENG
(female) (37) – right G (female) (1) and wiring Resis-
Min. 1 Mz
harness between right ENG (female) (47) – tance
right G (female) (2)
5 ness (with another wiring Between wiring harness between right ENG
harness) (female) (37) – right G (female) (1) and wiring Resis-
Min. 1 Mz
Between wiring harness between right ENG
(female) (47) – right G (female) (2) and wiring Resis-
Min. 1 Mz
6 WA800, WA900-3E0

Defective sensor installa- Bkup speed sensor may be installed defectively (improper clear-
6 tion or defective speed ance) or speed sensing part (in supply pump) may be defective.
Possible
sensing part Check them directly.
causes and the
If causes 1 – 6 are not detected, engine Bkup speed sensor may be
standard values Defective engine Bkup
when normal 7 defective. (Since trouble is in system, troubleshooting cannot be
speed sensor
carried out.)
If causes 1 – 7 are not detected, engine controller may be defective.
Circuit diagram related to engine Bkup speed sensor
WA800, WA900-3E0 7
Failure code [CA781] Inter-multicontroller communication error (Left

bank): Communication error 1
Action code Failure code Symptom of Inter-multicontroller communication error (Left bank): Communica-
E03 CA781 failure tion error (Engine controller system)
Failure content • Communication error occurred between engine controllers (Left bank).
Controller's
action
Symptoms that
• During operation: Engine continues operation with 1 bank.
appear on
• When key is ON: Engine cannot be started.
machine
General
information

Defective terminate Resis-
1 Between RES2 (male) (A) – (B) 120 ± 12 z
resistor tance
Resis-
Between RES3 (male) (A) – (B) 120 ± 12 z
tance
Max. 1 z
(8) – right ENG (female) (8) tance
Max. 1 z
harness (Disconnection in (8) – RES2 (male) (A), RES3 (Male) (A) tance
2
wiring or defective contact Wiring harness between left ENG (female) Resis-
Possible Max. 1 z
in connector) (6) – right ENG (female) (6) tance
causes and the
(6) – RES2 (male) (B), RES3 (Male) (B) tance
when normal
Max. 1 z
(7) – right ENG (female) (7) and ground. tance
Wiring harness between left ENG (female) (8) Resis-
– right ENG (female) (8) tance
GND circuit)
Wiring harness between left ENG (female) (6) Resis-
Min. 1 Mz
– right ENG (female) (6) tance
2) Disconnect left ENG and right ENG, and carry out troubleshooting
4 Defective engine controller Left ENG (female) Resistance
Between (8) – (6) 54 – 66 z
8 WA800, WA900-3E0
Circuit diagram related to communication between multiple controller
WA800, WA900-3E0 9
Failure code [CB781] Inter-multicontroller communication error (Right

bank): Communication error 1
Action code Failure code Symptom of Inter-multicontroller communication error (Right bank): Communica-
E03 CB781 failure tion error (Engine controller system)
Failure content • Communication error occurred between engine controllers (Right bank).
Controller's
action
Symptoms that
• During operation: Engine continues operation with 1 bank.
appear on
• When key is ON: Engine cannot be started.
machine
General
information
causes and the
when normal
10 WA800, WA900-3E0
Failure code [CA1257] Multicontroller distinction wiring harness key

error (Left bank): Distinction error 1
Action code Failure code Symptom of Multicontroller distinction wiring harness key error (Left bank): Dis-
E03 CA1257 failure tinction error (Engine controller system)
Failure content • Controller of each bank disagrees with distinction wiring harness (Left bank).
Controller's • Stops operation.
Symptoms that
appear on • When key is ON: Engine cannot be started.
machine
General
Pin (34) of EM1 is connected to the ground in the controller.
information

Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness (Disconnection in without turning starting switch ON.
1
Max. 1 z
in connector) EM1 (female) (34) tance
Possible
causes and the Resis-
circuit) Between EM1 (female) (8) – ground Min. 1 Mz
standard values tance
when normal Connection error of wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
Connection error of con- Wiring harness between EM1 (female) (8) – Resis-
Min. 1 Mz
nector (34) tance
4 Defective engine controller found in causes 1 – 3 (Since this is an internal defective, it cannot be
diagnosed.)
Circuit diagram related to multicontroller distinction wiring harness key
WA800, WA900-3E0 11
Failure code [CB1257] Multicontroller distinction wiring harness key

error (Right bank): Distinction error 1
Action code Failure code Symptom of Multicontroller distinction wiring harness key error (Right bank): Dis-
E03 CB1257 failure tinction error (Engine controller system)
Failure content • Controller of each bank disagrees with distinction wiring harness (Right bank).
Controller's • Stops operation.
Symptoms that
appear on • When key is ON: Engine cannot be started.
machine
General
Pin (34) of EM2 is connected to the ground in the controller.
information

Connection error of wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
1
Connection error of con- Wiring harness between EM2 (female) (7) – Resis-
Min. 1 Mz
nector EM2 (female) (34) tance
Possible
causes and the Resis-
circuit) Between EM2 (female) (7) – ground Min. 1 Mz
standard values tance
when normal Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness (Disconnection in without turning starting switch ON.
3
Max. 1 z
in connector) (34) tance
4 Defective engine controller found in causes 1 – 3 (Since this is an internal defective, it cannot be
diagnosed.)
Circuit diagram related to multicontroller distinction wiring harness key
12 WA800, WA900-3E0
WA800, WA900-3E0 13
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short

circuit (Right bank): Disconnection/Short circuit 1
Action code Failure code Symptom of Injector #7 (R/B #1) system disconnection/short circuit (Right bank):
E03 CB1548 failure Disconnection/Short circuit (Engine controller system)
Failure content • Disconnection or short circuit occurred in injector #7 circuit.
Controller's
action
Symptoms that
• Output lowers.
appear on
• Engine speed is unstable.
machine

Defective injector #7 CN1 (male) Resistance
1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
harness (Disconnection in Wiring harness between ENG (female) (45) – Resis-
2 Max. 1 z
wiring or defective contact CN1 (female) (1) tance
in connector) Wiring harness between ENG (female) (53) – Resis-
Max. 1 z
Possible CN1 (female) (2) tance
when normal Ground fault in wiring har-
3 ness (Contact with GND Min. 1 Mz
circuit)
Min. 1 Mz
Defective injector of
If failure codes of 1 or more injectors are displayed, carry out trou-
4 another cylinder or defec-
bleshooting for them.
tive wiring harness
Between (45) – (53) 0.4 – 1.1 z
14 WA800, WA900-3E0
Circuit diagram related to injector #7 (R/B #1)
WA800, WA900-3E0 15

Controller's
action
Symptoms that
• Output lowers.
appear on
machine

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (54) – (51) 0.4 – 1.1 z
16 WA800, WA900-3E0
WA800, WA900-3E0 17

Action code Failure code Symptom of Injector #10 (R/B #4) system disconnection/short circuit (Right
E03 CB1551 failure bank): Disconnection/Short circuit (Engine controller system)
Controller's
action
Symptoms that
• Output lowers.
appear on
machine

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (56) – (58) 0.4 – 1.1 z
18 WA800, WA900-3E0
WA800, WA900-3E0 19

Controller's
action
Symptoms that
• Output lowers.
appear on
machine

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (46) – (60) 0.4 – 1.1 z
20 WA800, WA900-3E0
WA800, WA900-3E0 21

Action code Failure code Symptom of Injector #12 (R/B #6) system disconnection/short circuit (Right
E03 CB1553 failure bank): Disconnection/Short circuit (Engine controller system)
Controller's
action
Symptoms that
• Output lowers.
appear on
machine

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (57) – (59) 0.4 – 1.1 z
22 WA800, WA900-3E0
WA800, WA900-3E0 23

Controller's
action
Symptoms that
• Output lowers.
appear on
machine

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (55) – (52) 0.4 – 1.1 z
24 WA800, WA900-3E0
WA800, WA900-3E0 25
Failure code [CA1633] KOMNET abnormality (Left bank):

Communication error 1
Action code Failure code Symptom of KOMNET abnormality (Left bank): Communication error
Failure content • Abnormality occurred in KOMNET communication circuit to engine controller (Left bank).
Controller's • Continues normal control (Communication function cannot be used).
Symptoms that
• Information may not be transmitted or received normally through KOMNET communication system
appear on
and machine may not operate normally.
machine
General
information

Resis-
1 Defective terminal resistor Between EM5 (male) (A) – (B) 120 ± 12 z
tance
Resis-
Between EM6 (male) (A) – (B) 120 ± 12 z
tance
2) Disconnect engine service monitor EM2, VC06, PRE6, engine
controller EM1 and EM2, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring Wiring harness between EM1 (female) (46) –
Resis-
harness (Disconnection in engine controller EM2 (female) (46) – engine Max. 1 z
2 tance
wiring or defective contact service monitor EM2 (female) (1)
in connector) Wiring harness between EM1 (female) (47) –
Resis-
engine controller EM2 (female) (47) – engine Max. 1 z
Possible tance
service monitor EM2 (female) (3)
causes and the
standard values 54 – 66 z
when normal EM1 (female) (47) tance
Ground fault in wiring har- turning starting switch ON.
circuit) Min. 1 Mz
EM2 (female) (46) tance
Min. 1 Mz
turning starting switch ON.
54 – 66 z
EM1(female) (47) tance
54 – 66 z
26 WA800, WA900-3E0
Circuit diagram related to KOMNET
WA800, WA900-3E0 27
Failure code [CA2185] Throttle sensor power supply abnormally high

Action code Failure code Symptom of Throttle sensor power supply abnormally high level (Only left bank):
E03 CA2185 failure High voltage detection
Failure content • High voltage (above 5.25 V) was detected in decelerator pedal sensor power supply circuit.
Controller's
• Runs the engine at position of throttle 0% when accelerator pedal is OFF and 38% when it is ON.
action
Symptoms that
appear on • When accelerator pedal is pressed fully, engine speed does not rise above medium level.
machine
General
information

When device at right
Defective decelerator sen-
sor (Internal defect)
code disappears, that Accelerator pedal L25 connector
device has trouble in
it.
harness (Disconnection in Wiring harness between EM1 (female) (22) – Resis-
2 Max. 1 z
wiring or defective contact L25 (female) (1) tance
in connector) Wiring harness between EM1 (female) (23) – Resis-
Max. 1 z
Possible L25 (female) (3) tance
Ground fault in wiring har-
circuit)
Min. 1 Mz
Between wiring harness between EM1
4 ness (with another wiring
harness) (female) (22) – L25 (female) (1) and wiring Resis- 108 –
harness between EM1 (female) (23) – L25 tance 132 z
(female) (3)
EM1 Voltage
Between (22) – (23) 4.75 – 5.25 V
28 WA800, WA900-3E0
Circuit diagram related to throttle sensor power supply
WA800, WA900-3E0 29
Failure code [CA2186] Throttle sensor power source too low (At left
bank only): Excessively low voltage detected 1
Action code Failure code Symptom of Throttle sensor power source too low (At left bank only): Excessively
Failure content • Excessively low voltage is detected in the decelerator pedal sensor (5V) power source circuit.
Controller's
• Runs the engine at position of throttle 0% when accelerator pedal is OFF and 38% when it is ON.
action
Symptoms that
appear on • When accelerator pedal is pressed fully, engine speed does not rise above medium level.
machine
General
information
causes and the
standard values 1 Carry out troubleshooting for failure code [CA2185].
when normal
30 WA800, WA900-3E0
Failure code [CA2249] Loss of pressure feed from supply pump (2) (At
left bank): Loss of pressure feed detected 1
Action code Failure code Symptom of Loss of pressure feed from supply pump (2) (At left bank): Loss of
E03 CA2249 failure pressure feed detected (Engine controller system)
Failure content • Loss of pressure feed (level 2) occurred in the common rail circuit.
Controller's • Operates with limited output.
Symptoms that • Engine is hard to start.
appear on • Exhaust gas color becomes black.
machine • Output decreases.
General • Common rail pressure can be checked with the monitoring function.
information (Code: 36400 (MPa), 36402 (V) Common rail pressure (left bank)))
causes and the
standard values 1 Carry out troubleshooting of [CA559].
when normal
Failure code [CB2249] Loss of pressure feed from supply pump (2) (At
right bank): Loss of pressure feed detected 1
Action code Failure code Symptom of Loss of pressure feed from supply pump (2) (At right bank): Loss of
E03 CB2249 failure pressure feed detected (Engine controller system)
Failure content • Loss of pressure feed (level 2) occurred in the common rail circuit.
Controller's • Operates with limited output.
Symptoms that • Engine is hard to start.
appear on • Exhaust gas color becomes black.
machine • Output decreases.
General • Common rail pressure can be checked with the monitoring function.
information (Code: 36403 (MPa), 36404 (V) Common rail pressure (right bank))
causes and the
standard values 1 Carry out troubleshooting of [CB559].
when normal
WA800, WA900-3E0 31
Failure code [CA2555] Intake heater relay voltage low error (Left bank
only) 1
Action code Failure code Intake heater relay voltage low error (Left bank only)
Trouble
E01 CA2555 (Engine controller system)
Contents of
• Disconnection error was detected in intake air heater relay circuit.
trouble
Action of
• Automatic preheating (to be started when engine coolant temperature is below -5°C) is not started.
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related
• Only when the pre-lubrication controller is not equipped, the engine controller drives the preheater
information
relay L73.
Possible causes Cause Standard values when normal and remarks for troubleshooting
and standard
value in normal Carry out troubleshooting for failure code [CA2556].
state
32 WA800, WA900-3E0
WA800, WA900-3E0 33
Failure code [CA2556] Intake heater relay voltage high error (Left bank only)1
Action code Failure code Intake heater relay voltage high error (Left bank only)
Trouble
E01 CA2556 (Engine controller system)
Contents of
• Short circuit was detected in intake heater relay circuit.
trouble
Action of
• Automatic preheating (to be started when engine coolant temperature is below -5°C) is not started.
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related
• Only when the pre-lubrication controller is not equipped, the engine controller drives the preheater
information
relay L73.

Defective intake heater without turning starting switch ON.
1
relay (Internal defect) L73 (male) Resistance
Between (1) and (2) 200 – 400 z
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness (Disconnection or without turning starting switch ON.
2
Possible causes defective contact of Wiring harness between EM1 (female) (40) – Resis- 200 –
and standard connector) L73 – EM1 (female) (42) (coil resistance) tance 400 z
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Ground fault in wiring
Min. 1 Mz
EM1 (female) (40) – L73 – EM1 (female) (42) tance
4 Defective engine controller EM1 Heater relay Voltage
Between Operating condition 20 – 30 V
(40) and (42) Stop condition Max. 1 V
34 WA800, WA900-3E0
Circuit diagram related to preheater relay for intake heater
WA800, WA900-3E0 35
Failure code [D160KZ] (or TM & AJSS controller LED display [10],
abnormality in backup lamp relay system: Disconnection, short circuit
or hot short circuit 1
Action code Failure code Abnormality in backup lamp relay system: Disconnection, short cir-
Trouble cuit or hot short circuit
– D160KZ (Transmission & AJSS controller system)
Contents of • Backup lamp relay system on the primary side is abnormal: Disconnection, short circuit or hot short
trouble circuit
Action of
• Neutral (F, R, 1st, 2nd, 3rd speed solenoid output: OFF)
controller
Problem that
appears on • During reverse travel, backup lamp does not light up or remains lit.
machine
Related • Transmission & AJSS controller system LED display: "10"
information • Failure code is sent to engine service monitor via VHMS controller.

2) Disconnect backup lamp relay (L54) and carry out troubleshoot-
Defective backup lamp relay ing with starting switch OFF.
1
(L54)
Resis- 290 z
Between backup relay (L54) (male) (1) – (2)
tance ± 10%
2) Disconnect C1.
290 z
harness
2 Resis- ± 10%
(Disconnection or defective Between C1 (female) (8) – (6)
tance (L54 coil
resistor)
Possible Between C1 (female) (6) – (12) and chassis Resis-
Max. 1 z
causes and ground tance
standard value 1) Turn the starting switch OFF.
in normal state Ground fault in wiring harness 2) Disconnect C1 and L54.
3 (Short circuit with ground 3) Turn starting switch ON and carry out troubleshooting.
circuit) Resis-
Between C1 (female) (8) – (6) Min. 1 Mz
tance
Defective wiring harness 2) Disconnect C1 and L54.
4 (Contact with power supply 3) Turn the starting switch ON (without starting the engine) and
circuit) carry out troubleshooting.
Between C1 (female) (8) and chassis ground Voltage Max. 1 V
2) Disconnect C1 and connect T-branch.
5 Defective engine controller 3) Turn the starting switch ON (without starting the engine) and
Between C1 (female) (8) and chassis ground Voltage Max. 1 V
36 WA800, WA900-3E0
WA800, WA900-3E0 37
Failure code [D180KA] (Preheating relay output system: Disconnection) 1
Action code Failure code Preheating relay output system: Disconnection

Trouble
E01 D180KA (Pre-lubrication controller system)
• When preheating engine, pre-lubrication controller first turns the preheating relay ON.
Contents of
However, the controller failed to turn the preheat relay ON, and it was judged as disconnection.
trouble
(Preheat relay (L73) primary coil side: Disconnection)
Action of
• Turns the preheat relay output OFF.
controller
Problem that
appears on • Preheating disabled
machine
Related • The output state of the preheating relay controller can be checked with the monitoring code:
information 40974 "D-OUT-0" (1: ON, 0: OFF).

Defective preheating relay 2) Disconnect preheating relay (L73) and carry out troubleshooting.
1
(L73) Between preheating relay (L73) (male) (1) – Resis- 290 z
Possible (2) tance ± 10%
causes and Disconnection in wiring har- 1) Turn the starting switch OFF.
standard value ness 2) Disconnect connector PRE6 and carry out troubleshooting.
in normal state 2
(Disconnection or defective Resis- 290 z
contact in connector) Between PRE6 (female) (9) – (40)
tance ± 10%
controller
carried out.)
38 WA800, WA900-3E0
Failure code [D180KB] (Preheating relay output system: Grounding fault)1

Action code Failure code Preheating relay output system: Grounding fault
Trouble
E01 D180KB (Pre-lubrication controller system)
Contents of
However, the controller failed to turn the preheat relay ON, and it was judged as grounding fault.
trouble
(Preheat relay (L73) primary coil side: Grounding fault)
Action of
• Turns the preheating relay output OFF.
controller
Problem that
appears on • Preheating disabled
machine
Related • The output state of the preheating relay controller can be checked with the monitoring code:
information 40974 "D-OUT-0" (1: ON, 0: OFF).

1
(L73) Between preheating relay (L73) (male) (1) – Resis- 290 z
(2) tance ± 10%
Possible
causes and 1) Turn the starting switch OFF.
standard value Grounding fault in wiring har- 2) Disconnect connector PRE6 and L73, then carry out trouble-
in normal state 2 ness shooting.
(Contact with ground circuit) Between PRE6 (female) (9) and chassis Resis-
Min. 1 Mz
ground tance
controller
carried out.)
WA800, WA900-3E0 39
Failure code [D180KY] (Preheating relay output system: Hot short circuit) 1
Action code Failure code Preheating relay: Hot short circuit

Trouble
E01 D180KY (Pre-lubrication controller system)
Contents of
However, the controller failed to turn the preheat relay ON, and it was judged as hot short circuit.
trouble
(Preheat relay (L73) primary coil side: Hot short circuit)
Action of
• Turns the preheating relay output OFF.
controller
Problem that
appears on • Preheating constantly in operation.
machine
• The output state of the preheating relay controller can be checked with the monitoring code:
Related
40974 "D-OUT-0" (1: ON, 0: OFF).
information
• Heater coil may be burnt out due to overheated preheating coil.

1
(L73) Between preheating relay (L73) (male) (1) – Resis-
Min. 1 Mz
(3) tance
2) Disconnect connector PRE6 and carry out troubleshooting.
Resis-
Between PRE6 (female) (9) – (1) Min. 1 Mz
tance
Resis-
Possible Between PRE6 (female) (9) – (2) Min. 1 Mz
tance
causes and
Grounding fault in wiring Resis-
standard value Between PRE6 (female) (9) – (30) Min. 1 Mz
2 harness tance
in normal state
(Contact with ground circuit) 1) Turn the starting switch OFF.
2) Disconnect PRE6 and connect T-branch.
a When preheating in cold weather, turn the starting switch ON and
wait for a while, then check the preheating relay.
Between PRE6 (female) (9) and chassis
Voltage Max. 1 V
ground
controller
carried out.)
40 WA800, WA900-3E0
WA800, WA900-3E0 41
Failure code [D19AKB] (or TM & AJSS controller LED display [56],
abnormality in joystick caution relay output system: Disconnection or
short circuit) 1
Action code Failure code Abnormality in joystick caution relay output system: Disconnection
Trouble or short circuit
– D19AKB (Transmission & AJSS controller system)
Contents of
• Joystick caution relay primary side is abnormal: Disconnection or short circuit
trouble
Action of
controller
Problem that
appears on • Caution buzzer does not sound or keeps sounding.
machine
Related • Transmission & AJSS controller LED display: "56"

2) Disconnect relay (L65) (male) and carry out troubleshooting.
1 Defective relay (L65)
Resis- 200 –
Between relay (L65) (male) (1) – (2)
tance 400 z
2) Disconnect C2.
Disconnection in wiring 3) Turn starting switch ON and carry out troubleshooting.
harness
2 200 –
contact in connector) Resis- 400 z
Between C2 (female) (9) – (19)
tance (L65 coil
resistor)
Possible 2) Disconnect C2.
Ground fault in wiring harness 3) Turn starting switch ON and carry out troubleshooting.
causes and 3
(Contact with ground circuit)
standard value Between C2 (female) (9) – (19) and chassis Resis-
in normal state Min. 1 Mz
ground tance
2) Disconnect L65.
Reference 3) Turn the starting switch ON (without starting the engine) and
Hot short circuit in wiring carry out troubleshooting.
4
harness (Contact with power Wiring harness between L65 (female) (1)
Voltage Max. 1 V
supply circuit) and chassis ground
Wiring harness between L65 (female) (2)
Voltage Max. 1 V
and chassis ground
Defective transmission & 3) Turn the starting switch ON (without starting the engine) and
5
AJSS controller carry out troubleshooting.
Between C2 (9) – (19) Voltage 20 – 30 V
42 WA800, WA900-3E0
WA800, WA900-3E0 43
Failure code [D19BKZ] (or TM & AJSS controller LED display [62],
abnormality in joystick neutral interlock relay output system:
Disconnection or short circuit) 1
Action code Failure code Abnormality in joystick neutral interlock relay output system: Discon-
Trouble nection or short circuit)
E00 D19BKZ (Transmission & AJSS controller system)
Contents of
• Joystick neutral interlock relay primary side is abnormal: Disconnection or short circuit
trouble
Action of
controller
Problem that • Engine can be started while operating the steering lever.
appears on • After starting engine, steering suddenly becomes effective.
machine • The engine does not start.
Related • Transmission & AJSS controller LED display: "62"

2) Disconnect relay (L95) and carry out troubleshooting.
1 Defective relay (L95)
Resis- 200 –
Between relay (L95) (male) (1) and (2)
tance 400 z
Disconnection in wiring 2) Disconnect C2 and carry out troubleshooting.
harness 200 –
2
contact in connector) Between C2 (female) (8) and chassis ground
tance (L95 coil
resistor)
Possible
causes and
standard value Ground fault in wiring harness 2) Disconnect C2 and L95.
3
in normal state (Contact with ground circuit) Wiring harness between C2 (female) (8) – Resis-
Min. 1 Mz
L95 (1) and chassis ground tance
Defective transmission & Steering lever posi-
4 Measuring point Voltage
AJSS controller tion
Between C2 (8) and
Neutral Max. 1 V
chassis ground
Between C2 (8) and
F or R 20 – 30 V
chassis ground
44 WA800, WA900-3E0
WA800, WA900-3E0 45
Failure code [D1EFKA] (Pre-lubrication start relay output system:

Disconnection) 1
Action code Failure code Pre-lubrication start relay output system: Disconnection
Trouble
E03 D1EFKA (Pre-lubrication controller system)
• When pre-lubricating engine, pre-lubrication controller first turns the pre-lubrication start relay ON.
Contents of
However, the controller failed to turn the pre-lubrication start relay ON, and it was judged as discon-
trouble
nection (Pre-lubrication start relay (connector PRE5) primary (coil) side: Disconnection).
• Turns the pre-lubrication relay output OFF.
Action of • Turns the preheating relay output OFF.
controller • Turns the engine start relay OFF.
• After detecting error, the relay will not reset itself unless starting switch is turned OFF once.
Problem that • Pre-lubrication disabled
appears on • The engine does not start.
machine • Preheating disabled
• Engine can be started by bypassing pre-lubrication controller.
1) Disconnect connectors PRE2 and PRE1 from near pre-lubrication controller (in the vicinity of lower
Related front cover of right console).
information 2) Connect PRE1 female connector and PRE2 male connector.
• The output state (ON/OFF) of the pre-lubrication start relay can be checked with the monitoring code:
40974, "D-OUT-1" (1: ON, 0: OFF).

2) Disconnect pre-lubrication start relay (PRE5) and carry out trou-
Defective pre-lubrication start bleshooting.
1
relay
Between pre-lubrication start relay PRE5 Resis- 290 z
Possible (male) (1) – (2) tance ± 10%
causes and
standard value Disconnection in wiring 1) Turn the starting switch OFF.
in normal state harness 2) Disconnect connector PRE6 and carry out troubleshooting.
2
tance ± 10%
controller
carried out.)
46 WA800, WA900-3E0
WA800, WA900-3E0 47
Failure code [D1EFKB] (Pre-lubrication start relay output system:

Grounding fault) 1
Action code Failure code Pre-lubrication start relay output system: Grounding fault
Trouble
E03 D1EFKB (Pre-lubrication controller system)
Contents of
However, the controller failed to turn the pre-lubrication start relay ON, and it was judged as ground-
trouble
ing fault (Pre-lubrication start relay (connector PRE5) primary (coil) side: Grounding fault).
Problem that • Pre-lubrication disabled
1 Disconnect connectors PRE2 and PRE1 from near pre-lubrication controller (in the vicinity of lower
information 2 Connect PRE1 female connector and PRE2 male connector.
• The output state of the pre-lubrication start relay output can be checked with the monitoring code:
40974, "D-OUT-1" (1: ON, 0: OFF).

1
relay
Between pre-lubrication start relay PRE5 Resis- 290 z
Possible (male) (1) – (2) tance ± 10%
standard value 2) Disconnect connectors PRE6 and PRE5 and carry out trouble-
in normal state Ground fault in wiring harness shooting.
2
Between PRE6 (female) (19) and chassis Resis-
Min. 1 Mz
ground tance
controller
carried out.)
48 WA800, WA900-3E0
WA800, WA900-3E0 49
Failure code [D1EFKY] (Pre-lubrication start relay output system: Hot

short circuit) 1
Action code Failure code Pre-lubrication start relay output system: Hot short circuit
Trouble
E03 D1EFKY (Pre-lubrication controller system)
Contents of
However, the controller failed to turn the pre-lubrication start relay ON, and it was judged as hot short
trouble
circuit (Pre-lubrication start relay (connector PRE5) primary (coil) side: Hot short circuit).
Problem that • Pre-lubrication does not stop
• The output state of the pre-lubrication start relay output can be checked with the monitoring code:
40974, "D-OUT-1" (1: ON, 0: OFF).

1
relay
Between pre-lubrication start relay PRE5 Resis-
Min. 1 Mz
(male) (1) – (3) tance
Resis-
tance
Possible
causes and Resis-
standard value tance
Hot short in wiring harness
in normal state 2 (Contact with power supply Resis-
circuit) tance
1) Starting switch OFF
Voltage Max. 1 V
ground
controller
carried out.)
50 WA800, WA900-3E0
WA800, WA900-3E0 51
Failure code [D1EHKA] (Engine start relay output system:

Disconnection) 1
Action code Failure code Engine start relay output system: Disconnection
Trouble
E03 D1EHKA (Pre-lubrication controller system)
• When pre-lubricating engine, pre-lubrication controller turns the engine start relay ON. However, the
Contents of
controller failed to turn the engine start relay ON, and it was judged as disconnection (Engine start
trouble
relay (connector PRE4) primary (coil) side: Disconnection).
Problem that
machine
• The output state of the engine start relay can be checked with the monitoring code: 40974, "D-OUT-
2" (1: ON, 0: OFF).

2) Disconnect engine start relay (PRE4) and carry out troubleshoot-
1 Defective engine start relay ing.
Between engine start relay PRE4 (male) (1) Resis- 290 z
Possible – (2) tance ± 10%
causes and
standard value Disconnection in wiring 1) Turn the starting switch OFF.
in normal state harness 2) Disconnect connector PRE6 and carry out troubleshooting.
2
tance ± 10%
controller
carried out.)
52 WA800, WA900-3E0
WA800, WA900-3E0 53
Failure code [D1EHKB] (Engine start relay output system: Grounding

fault) 1
Action code Failure code Engine start relay output system: Grounding fault
Trouble
E03 D1EHKB (Pre-lubrication controller system)
Contents of
controller failed to turn the engine start relay ON, and it was judged as grounding fault (Engine start
trouble
relay (connector PRE4) primary (coil) side: Grounding fault).
Problem that
machine
2" (1: ON, 0: OFF).

2) Disconnect engine start relay (PRE4) and carry out troubleshoot-
1 Defective engine start relay ing.
Between engine start relay PRE4 (male) (1) Resis- 290 z
Possible – (2) tance ± 10%
standard value Grounding fault in wiring 2) Disconnect connectors PRE6 and PRE4 and carry out trouble-
in normal state 2 harness shooting.
(Contact with ground circuit) Between PRE6 (female) (29) and chassis Resis-
Min. 1 Mz
ground tance
controller
carried out.)
54 WA800, WA900-3E0
WA800, WA900-3E0 55
Failure code [D1EHKY] (Engine start relay output system: Hot short
circuit) 1
Action code Failure code Engine start relay output system: Hot short circuit
Trouble
E03 D1EHKY (Pre-lubrication controller system)
Contents of
controller failed to turn the engine start relay ON, and it was judged as hot short circuit (Engine start
trouble
relay (connector PRE4) primary (coil) side: Hot short circuit).
Problem that
appears on • Engine starts without pre-lubrication and preheating.
machine
2" (1: ON, 0: OFF).

2) Disconnect engine start relay PRE4 (male) (PRE4) and carry out
1 Defective engine start relay troubleshooting.
Between engine start relay PRE4 (male) (1) Resis-
Min. 1 Mz
– (3) tance
Resis-
tance
Possible
causes and Resis-
standard value tance
Grounding fault in wiring
in normal state 2 harness Resis-
(Contact with ground circuit) tance
Voltage Max. 1 V
ground
controller
carried out.)
56 WA800, WA900-3E0
WA800, WA900-3E0 57
Failure code [D5ZHL6] (Starting switch terminal C signal: Error) 1
Action code Failure code Starting switch terminal C signal input: Error
Trouble
E01 D5ZHL6 (Engine service monitor system)
All of the following 1), 2) and 3) were recognized.
1) The starting switch has not been turned ON (input of voltage from starting switch C terminal is not
recorded).
Contents of
2) Charging voltage (Min. 12 V) is supplied from alternator R terminal.
trouble
3) Engine is running normally (500 rpm or above) based on CAN communication data received from
engine controller. However if engine speed of 250 rpm or above is detected within 3 seconds after
starting switch is turned ON (voltage input from starting switch terminal C), no error is detected.
Action of
controller
Problem that
appears on
machine
• Since engine is started, starting switch terminal C and relay circuit are normal.
Related
• Starting switch terminal C signal of engine service monitor can be checked with the monitoring code:
information
40921, "D-IN-0" (1: ON, 0: OFF).

Disconnection in wiring 2) Disconnect connector L95.
harness 3) Disconnect connector EM1 and carry out troubleshooting with
1 starting switch OFF.
Possible contact in connector) Wiring harness between L95 (female) (3) – Resis-
Max. 1 z
causes and EM1 (female) (7) tance
in normal state Grounding fault in wiring 2) Disconnect connector EM1 and carry out troubleshooting.
2 harness
(Contact with ground circuit) Between EM1 (female) (7) and chassis Resis-
Min. 1 Mz
ground tance
monitor system
carried out.)
58 WA800, WA900-3E0
WA800, WA900-3E0 59
Failure code [D5ZSKA] (Machine monitor communication output:

Disconnection) 1
Action code Failure code Machine monitor communication output: Disconnection

Trouble
E03 D5ZSKA (Engine service monitor system)
Contents of • Communication was disabled between engine service monitor and machine monitor, and it was
trouble judged as disconnection.
Action of
• Flashes engine caution (warning) lamp.
controller
Problem that
appears on • Engine service monitor information cannot be displayed on machine monitor.
machine
• When E03 and E02 occur among the engine controller, pre-lubrication controller and engine service
monitor errors, engine service monitor sends pulse signal for 12 seconds ON (0 V) and 6 seconds
Related OFF (24 V) in repetition from connector EM1 (18).
information • Engine service monitor and machine monitor have feedback signals and they detect the warning sig-
nal when it fails to match (detection in 3 sec) their feedback signals.
(Engine service monitor feedback signal: EM1 (12): 24 V pullup)

Disconnection in wiring 2) Disconnect connector EM1 and carry out troubleshooting with
Possible
harness starting switch OFF.
causes and 1
standard value Resis-
in normal state
contact in connector) Between connector EM1 (female) (12) – (18) Max. 1 z
tance
Defective engine service If cause 1 is not detected, engine service monitor may be defective.
2
monitor (Since trouble is in system, troubleshooting cannot be carried out.)
60 WA800, WA900-3E0
Failure code [D5ZSKB] (Machine monitor communication output:

Grounding fault) 1
Action code Failure code Machine monitor communication output: Grounding fault
Trouble
E03 D5ZSKB (Engine service monitor system)
trouble judged as grounding fault.
Action of
controller
Problem that
machine
• When E03 and E02 occur among the engine controller, pre-lubrication controller and engine service
monitor errors, engine service monitor sends pulse signal for 12 seconds ON (0 V) and 6 seconds
Related OFF (24 V) in repetition from connector EM1 (18).
information • Engine service monitor and machine monitor have feedback signals and they detect the warning sig-
nal when it fails to match (detection in 3 sec) their feedback signals.
(Engine service monitor feedback signal: EM1 (12): 24 V pullup)

Possible
Ground fault in wiring harness 2) Disconnect connector EM1 and carry out troubleshooting.
causes and 1
(Contact with ground circuit) Between EM1 (female) (12) and chassis Resis-
standard value Min. 1 Mz
in normal state ground tance
2
WA800, WA900-3E0 61
Failure code [D5ZSKY] (Machine monitor communication output: Hot

short circuit) 1
Action code Failure code Machine monitor communication output: Hot short circuit
Trouble
E03 D5ZSKY (Engine service monitor system)
trouble judged as hot short circuit.
Action of
controller
Problem that
machine
Related
• Engine service monitor troubleshoots hot short circuit within itself.
information

Possible Hot short in wiring harness 2) Disconnect connector EM1 and L07.
causes and 1 (Contact with power supply 3) Turn starting switch ON.
standard value circuit) Wiring harness between EM1 (female) (12)
in normal state Voltage Max. 1 V
and chassis ground
2
62 WA800, WA900-3E0
WA800, WA900-3E0 63
SEN02147-02
WA800, WA900-3E0 Wheel loader

© 2010 KOMATSU
All Rights Reserved
64
SEN02148-02
WA800-3E0
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
Failure code [DB2RKR] (Engine controller CAN-NET communication: Disconnection and grounding fault) .... 3
Failure code [DBB0KK] (or VHMS LED display: "n9" o "01", VHMS controller: Low supply voltage) .............. 6
Failure code [DBB0KQ] (or VHMS LED display: "nF" o "11",
VHMS controller model selection: Disagreement of model selection signals)............................................... 8
Failure code [DBB3KK] (or VHMS LED display: "n9" o "05", VHMS controller: Low direct supply voltage) .. 10
Failure code [DBB5KP] (or VHMS LED display: "n9" o "04",
VHMS controller sensor power supply (5 V): Low output voltage) .............................................................. 12
Failure code [DBB6KP] (or VHMS LED display: "n9" o "02",
VHMS controller sensor power supply (24 V): Low output voltage) ............................................................ 14
Failure code [DBBQKR] (or VHMS LED display: "n8" o "02",
VHMS controller CAN communication abnormality) .................................................................................... 16
Failure code [DBG2KK] (Solenoid power supply: Low voltage)....................................................................... 18
Failure code [DBG3KK] (Battery direct power supply: Low voltage) ............................................................... 20
Failure code [DBG9KQ] (Model selection signal: Abnormal) ........................................................................... 22
WA800, WA900-3E0 1
Failure code [DBGRKR] (Pre-lubrication controller CAN-NET communication: Disconnection or grounding

fault) .......................................................................................................................................................... 23
Failure code [DBL0KR] (Power ladder controller CAN-NET communication: Disconnection or grounding
fault) .......................................................................................................................................................... 26
Failure code [DDE2KB] (Engine oil pressure switch error: Grounding fault) ...................................................28
Failure code [DDE2L6] (Engine oil pressure switch error: Disconnection or hot short circuit).........................30
Failure code [DDK3KZ] (or TM & AJSS controller LED display [20], abnormality in joystick forward-reverse
switch system: Disconnection or hot short circuit) .......................................................................................32
Failure code [DDK5KZ] (or TM & AJSS controller LED display: “21”, Abnormality in shifting up/down switch
system: Disconnection, short circuit or hot short circuit) ..............................................................................35
Failure code [DDP5KZ] (Abnormality in steering lock switch system: Disconnection or short circuit) .......... 38
Failure code [DGE5KX] (Atmospheric temperature sensor: Out of input signal range (short)) .......................40
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range (short))........................42
Failure code [DGR4KX] (Front brake oil temperature sensor: Out of input signal range (short)) ....................44
2 WA800, WA900-3E0
Failure code [DB2RKR] (Engine controller CAN-NET communication:

Disconnection and grounding fault) 1
Action code Failure code Engine controller CAN-NET communication: Disconnection and
Trouble grounding fault)
E03 DB2RKR (Engine service monitor system)
Contents of
• Engine service monitor cannot recognize engine controller in the CAN communication circuit.
trouble
Action of
controller
Problem that
appears on • Engine controller error cannot be notified to operator.
machine
Related
information

1) Turn starting switch OFF.
2) Disconnect connectors of engine service monitor EM2, engine
controllers EM1 and EM2, then carry out troubleshooting.
Between engine service monitor EM2
Resis-
(female) (1) – engine controller EM1 (female) Max. 1 z
tance
(46), – engine controller EM2 (female) (46)
Between engine service monitor EM2
Resis-
Disconnection in wiring (female) (3) – engine controller EM1 (female) Max. 1 z
tance
harness (Disconnection or (47), – engine controller EM2 (female) (47)
1
defective contact in Between engine service monitor EM2 Resis-
connector) Max. 1 z
(female) (1) – (6) tance
a Key ACC signal disconnection
2) Disconnect connectors of CBL1, engine controllers EM1 and
EM2, then carry out troubleshooting.
Between CBL1 (male) (2) – engine controller
Resis-
EM1 (female) (39), – engine controller EM2 Max. 1 z
tance
(female) (39)
Possible causes
and standard
2) Disconnect connectors of VC06, PRE6, engine service monitor
value in normal
EM2, engine controllers EM1 and EM2, then carry out trouble-
state
shooting.
Between engine service monitor EM2 Resis-
Min. 1 M z
Grounding fault in wiring Between engine service monitor EM2 Resis-
Min. 1 M z
2 harness (Contact with (female) (3) and chassis ground tance
ground circuit) a Key ACC signal grounding fault
2) Disconnect connectors of engine controllers EM1 and EM2, then
Between engine controller EM1 (female) (39)
Resis-
and engine controller EM2 (female) (39) and Min. 1 M z
tance
chassis ground
2) Insert T-branch to engine service monitor EM2
3 Between engine service monitor EM2 (1) and
(Contact with 24 V circuit) Voltage Max. 1 V
chassis ground
Between engine service monitor EM2 (3) and
Voltage Max. 1 V
chassis ground
WA800, WA900-3E0 3

Defective CAN terminal 2) Disconnect engine connectors EM5 and EM6, then carry out trou-
resistance (Internal bleshooting.
4
disconnection or short
EM5, AEM6 (male) Resistance
circuit)
Between (A) and (B) 120 ±12 z
5 Fuse disconnection Fuse box 2 (15) has conductivity.
Defective engine controller Carry out troubleshooting for defective engine controller power sup-
6
Possible causes power source ply [CA441] and [CB441].
and standard 1) Turn starting switch OFF.
value in normal 2) Disconnect connectors of engine service monitor EM2, then carry
state out troubleshooting.
Defective engine service Between engine service monitor EM2 (male) Resis-
7 120 ±12 z
monitor (6) – (3) tance
defective. (Troubleshooting cannot be carried out for internal defects
other than the above.)
If causes 1 – 7 are not detected, engine controller may be defective.
8 Defective engine controller (Troubleshooting cannot be carried out for internal defects other than
the above.)
4 WA800, WA900-3E0
WA800, WA900-3E0 5
Failure code [DBB0KK] (or VHMS LED display: "n9" o "01", VHMS
controller: Low supply voltage) 1
Action code Failure code VHMS controller: Low supply voltage
Trouble
– DBB0KK (VHMS controller system)
Contents of
• Switch supply voltage: VC01 (8) and (9) is below 19.5 V.
trouble
Action of
controller
Problem that
appears on • The system may not work properly.
machine
Related
• The LED of the VHMS controller displays "n9" o "01".
information

Defective VHMS controller 2) Disconnect VC01 and connect T-branch.
1 (When power supply pin 3) Start the engine and carry out troubleshooting.
voltage is normal)
Between VC01 (8), (9) – (11), (12), (19), (20) Voltage 20 – 30 V
Fuse box 1: Fuse (10) Continuity Yes
2 Fuse disconnection Between SBF1 (R03) – (R04) Continuity Yes
Between SBF1 (R03) – (R05) Continuity Yes
If failure codes [AB00MA] and [AB00MB] are displayed, carry out
Possible causes troubleshooting for them first.
value in normal 2) Disconnect VC01 and carry out troubleshooting.
state Between VC01 (female) (8), (9) – alternator Resis-
Disconnection in wiring Max. 1 z
harness (Disconnection or terminal B tance
4
defective contact in Battery relay BTR2 (R02) – alternator termi- Resis-
Max. 1 z
connector) nal B tance
Between VC01 (female) (11), (12), (19), (20) Resis-
Max. 1 z
and chassis ground tance
Ground fault in wiring har- 2) Disconnect VC01 and carry out troubleshooting.
5 ness (Contact with ground
Between VC01 (female) (8), (9) and chassis Resis-
circuit) Min. 1 M z
ground tance
6 WA800, WA900-3E0
WA800, WA900-3E0 7
Failure code [DBB0KQ] (or VHMS LED display: "nF" o "11", VHMS
controller model selection: Disagreement of model selection signals) 1
Action code Failure code VHMS controller model selection: Disagreement of model selection
Trouble signals
– DBB0KQ (VHMS controller system)
Contents of
• Improperly connected connectors were detected.
trouble
Action of
controller
Problem that
machine
Related
• The LED of the VHMS controller displays "nF" o "11".
information

Connector connection in
Check connection between VC02 and VC04 connectors, and VC03
1 VHMS controller
and VC05 connectors for abnormality. Repair if abnormal.
(When system is normal)
Possible causes harness (Disconnection or Between VC03 (female) (9), (12) and chassis Resis-
2 Max. 1 z
and standard defective contact in ground tance
value in normal connector) Between VC04 (female) (9), (17) and chassis Resis-
state Max. 1 z
ground tance
Between VC03 (female) (9), (12) and chassis
3 Defective VHMS controller Voltage Max. 1 V
ground
Between VC04 (female) (9), (17) and chassis
Voltage Max. 1 V
ground
8 WA800, WA900-3E0
WA800, WA900-3E0 9
Failure code [DBB3KK] (or VHMS LED display: "n9" o "05", VHMS
controller: Low direct supply voltage)
Action code Failure code VHMS controller: Low direct supply voltage
Trouble
– DBB3KK (VHMS controller system)
Contents of
• Direct supply voltage VC01:(6) and (7) are below 12.0 V
trouble
Action of
controller
Problem that
machine
Related
information

1 Fuse disconnection Fuse box 1: Fuse (13) Continuity Yes
Defective circuit breaker Directly check circuit breaker (CBF1). (If the circuit breaker is shut
2
(CBF1) down, the circuit probably has a grounding fault, etc.)
Disconnection in wiring 2) Disconnect VC01 and carry out troubleshooting.
Possible causes harness (Disconnection or
and standard Between VC01 (female) (6) or (7) and chas-
3 defective connector Voltage 20 – 30 V
value in normal sis ground
contact), defective VHMS
state Between L63 (female) (11), (12), (19), (20) Resis-
controller Max. 1 z
Ground fault in wiring 2) Disconnect battery ground and VC01 and carry on troubleshoot-
4 harness (Contact with ing.
ground circuit) Between VC01 (female) (6), (7) and chassis Resis-
Min. 1 M z
ground tance
10 WA800, WA900-3E0
WA800, WA900-3E0 11
Failure code [DBB5KP] (or VHMS LED display: "n9" o "04", VHMS
controller sensor power supply (5 V): Low output voltage)
Action code Failure code VHMS sensor power supply (5 V): Low output voltage
Trouble
– DBB5KP (VHMS controller system)
Contents of
• The sensor supply voltage (5 V) is out of the normal range (4.5 – 5.5 V).
trouble
Action of
controller
Problem that
machine
Related
information

2) Disconnect connectors VC01, V22, V23 and V32, then carry out
troubleshooting.
Between VC01 (female) (4) – V22 (female) Resis-
Max. 1 z
(B) tance
Resis-
Disconnection in wiring Between V22 (female) (B) – V23 (female) (B) Max. 1 z
tance
harness (Disconnection or
1 Resis-
defective contact in Between V22 (female) (A) – V23 (female) (A) Max. 1 z
tance
connector)
Between V22 (female) (A) and chassis Resis-
Max. 1 z
ground tance
Max. 1 z
(B) tance
Max. 1 z
ground tance
2) Disconnect connectors VC01, V22, V23 and V32, then carry out
Possible causes troubleshooting.
and standard
2 harness (Contact with Resis-
value in normal Between VC01 (female) (4) – (11) Min. 1 Mz
ground circuit) tance
state
Resis-
Between VC01 (female) (5) – (11) Min. 1 Mz
tance
2) Disconnect connector V22.
Defective brake oil 3) Turn starting switch ON and carry out troubleshooting.
pressure sensor (Internal This failure code will not appear.
3
disconnection or short 1) Turn starting switch OFF.
circuit) 2) Disconnect connector V23.
This failure code will not appear.
Defective blow-by pres- 1) Turn starting switch OFF.
sure sensor (Internal 2) Disconnect connector V32.
4
disconnection or short 3) Turn starting switch ON and carry out troubleshooting.
circuit) This failure code will not appear.
2) Disconnect connector VC01 and connect T-branch.
5 Defective VHMS controller 3) Turn starting switch ON and carry out troubleshooting.
Between VC01 (female) (4), (5) – (11) Voltage 4.5 – 5.5 V
12 WA800, WA900-3E0
WA800, WA900-3E0 13
Failure code [DBB6KP] (or VHMS LED display: "n9" o "02", VHMS
controller sensor power supply (24 V): Low output voltage)
Action code Failure code VHMS sensor power supply (24 V): Low output voltage
Trouble
– DBB6KP (VHMS controller system)
Contents of
• The sensor supply voltage (24 V) is out of the normal range (20 – 30 V).
trouble
Action of
controller
Problem that
machine
Related
information

2) Disconnect connectors VC01, V34, V35, V41 and V42, then carry
out troubleshooting.
Max. 1 z
(A) tance
Between V34 (female) (A) – V35, V41, V42 Resis-
harness (Disconnection or Max. 1 z
1 (female) (A) tance
defective contact in
connector) Max. 1 z
(C) tance
Between V34 (female) (C) – V35, V41, V42 Resis-
Max. 1 z
(female) (C) tance
Between V42 (female) (C) and chassis Resis-
Max. 1 z
ground tance
Ground fault in wiring 2) Disconnect connectors VC01, V34, V35, V41 and V42, then carry
2 harness (Contact with out troubleshooting.
ground circuit) Resis-
Between VC01 (female) (2) – (11) Min. 1 Mz
tance
Possible causes
and standard
value in normal
state This failure code will not appear.
Defective sensor amplifier 3) Turn starting switch ON and carry out troubleshooting.
and exhaust gas tempera-
3 ture sensor (Internal
disconnection or short 1) Turn starting switch OFF.
circuit) 2) Disconnect connector V41.
Defective exhaust gas
temperature sensor (Inter-
4 Refer to failure code [DGT5KA] – [DGT6KB].
nal disconnection or short
circuit)
Defective transmission 2) Disconnect connector V28.
5 3) Turn starting switch ON and carry out troubleshooting.
pressure sensor
14 WA800, WA900-3E0

Possible causes
and standard
2) Disconnect connector VC01 and connect T-branch.
value in normal 6 Defective VHMS controller 3) Turn starting switch ON and carry out troubleshooting.
state
Between VC01 (2) – (11) Voltage 20 – 30 V
WA800, WA900-3E0 15
Failure code [DBBQKR] (or VHMS LED display: "n8" o "02", VHMS
controller CAN communication abnormality)
Action code Failure code VHMS CAN communication abnormality
Trouble
– DBBQKR (VHMS controller system)
Contents of
• Communication (CAN) information from each controller cannot be received.
trouble
Action of
controller
Problem that
machine
Related • The LED of the VHMS controller displays "n8" o "02".
information • Related failure codes: [DB2RKR], [DBBQKR] and [CA1633]

2) Disconnect connectors of VC06, engine service monitors EM2
and PRE6, then carry out troubleshooting.
Between VC06 (4) – engine service monitor Resis-
harness (Disconnection or Max. 1 z
1 EM2 (female) (1) – PRE6 (female) (28) tance
Between VC06 (12) – engine service monitor Resis-
connector) Max. 1 z
EM2 (female) (3) – PRE6 (female) (38) tance
Between engine service monitors EM2 Resis-
Max. 1 z
(female) (1) – (6) tance
2) Disconnect connectors of VC06, engine service monitors EM2
and PRE6, engine controllers EM1 and EM2, then carry out trou-
Ground fault in wiring bleshooting.
Possible causes Resis-
ground circuit) Between VC06 (4) and chassis ground Min. 1 Mz
and standard tance
Between VC06 (12) and chassis ground Min. 1 Mz
state tance
Hot short circuit in wiring 2) Insert T-branch to VC06
3 harness (Contact with 3) Turn starting switch ON and carry out troubleshooting.
24 V circuit) Between VC06 (4) and chassis ground Voltage Max. 1 V
Between VC06 (12) and chassis ground Voltage Max. 1 V
Defective CAN terminal 2) Disconnect connectors EM5 and EM6 from engine and carry out
resistance (Internal troubleshooting.
4
EM5, EM6 (male) Resistance
circuit)
Between (A) – (B) 120 ± 12 z
If any of [DB2RKR], [DBBQKR] or [CA1633] does not appear and
causes 1 – 4 are not detected, VHMS controller may be defective.
(Troubleshooting cannot be carried out for internal defects other than
the above.)
16 WA800, WA900-3E0
WA800, WA900-3E0 17
Failure code [DBG2KK] (Solenoid power supply: Low voltage)

Action code Failure code Solenoid power supply: Low voltage
Trouble
E03 DBG2KK (Pre-lubrication controller system)
Contents of
• During starting switch is ON, solenoid supply voltage below 18 V is detected.
trouble
• Turns pre-lubrication relay output OFF.
Action of
• Turns pre-heating relay output OFF.
controller
• Turns engine start relay output OFF.
Problem that • The engine does not start.
appears on • No pre-lubrication effected
machine • No pre-heating effected
1) Disconnect connectors PRE2 and PRE1 from near pre-lubrication controller (in the vicinity of
Related lower front cover of right console).
• The output state (ON/OFF) of the pre-lubrication start relay can be checked with the monitoring
code: 40974, "D-OUT-1" (1: ON, 0: OFF).

Defective pre-lubrication 1) Turn starting switch OFF.
controller (When power 2) Disconnect PRE6 and connect T-branch.
1
supply pin voltage is 3) Start the engine and carry out troubleshooting.
normal) Between PRE6 (30) – (31) Voltage 20 – 30 V
Possible causes Between SBF1 (R03) – (R05) Continuity Yes
value in normal Disconnection in wiring 2) Disconnect PRE6 and R04 and carry out troubleshooting.
state harness (Disconnection or Resis-
3 Between PRE6 (female) (30) – R04 Max. 1 z
defective contact in tance
connector) Between PRE6 (female) (21), (31) and chas- Resis-
Max. 1 z
sis ground tance
Ground fault in wiring 2) Disconnect PRE6 and R04 and carry out troubleshooting.
ground tance
18 WA800, WA900-3E0
WA800, WA900-3E0 19
Failure code [DBG3KK] (Battery direct power supply: Low voltage)

Action code Failure code Battery direct power supply: Low voltage
Trouble
E03 DBG3KK (Pre-lubrication controller system)
Contents of
• Supply voltage of controller is low.
trouble
Action of
• Stops judging other errors caused by low voltage
controller
Problem that
appears on • Engine may not be able to start.
machine
1) Disconnect connectors PRE2 and PRE1 from near pre-lubrication controller (in the vicinity of
Related lower front cover of right console).
• The output state (ON/OFF) of the pre-lubrication start relay can be checked with the monitoring
code: 40974, "D-OUT-1" (1: ON, 0: OFF).

Defective pre-lubrication 1) Turn starting switch OFF.
controller (When power 2) Disconnect PRE6 and connect T-branch.
supply pin voltage is 3) Start the engine and carry out troubleshooting.
normal)
1
a Check which path Between PRE6 (1) and (11) – (31) Voltage 20 – 30 V
poses problem since
each pin 1 and pin 2 Between PRE6 (2) and (12) – (31) Voltage 20 – 30 V
have different path.
2 Fuse disconnection
Defective circuit breaker Directly check circuit breaker (CBF1). (If the circuit breaker is shut
3
(CBF1) down, the circuit probably has a grounding fault, etc.)
2) Disconnect L09.
4 Defective starting switch 3) Turn starting switch ON and carry out troubleshooting.
Between L09 (male) (1) – (4) Continuity Yes
Possible causes 2) Disconnect CBL1.
Defective engine 3) Turn engine shut-down switch OFF, then carry out troubleshoot-
and standard 5
shut-down switch ing.
value in normal
state Between CBL1 (female) (1) – (2) Continuity Yes
2) Disconnect PRE6.
Between PRE6 (female) (1), (11) and chassis
Disconnection in wiring Voltage 20 – 30 V
ground
6 Between PRE6 (female) (2), (12) and chassis
defective contact in Voltage 20 – 30 V
ground
connector)
2) Disconnect PRE6.
Between PRE6 (female) (21), (31) and chas- Resis-
Max. 1 z
sis ground tance
2) Disconnect battery ground and PRE6.
Ground fault in wiring 3) Turn starting switch ON and carry out troubleshooting.
7 harness (Contact with Between PRE6 (female) (1), (11) and chassis Resis-
Min. 1 Mz
ground circuit) ground tance
Between PRE6 (female) (2), (12) and chassis Resis-
Min. 1 Mz
ground tance
20 WA800, WA900-3E0
WA800, WA900-3E0 21
Failure code [DBG9KQ] (Model selection signal: Abnormal)

Action code Failure code Model selection signal: Abnormal
Trouble
E01 DBG9KQ (Pre-lubrication controller system)
Contents of • Because pre-lubrication controller model selection signal is not specified as GND, the system
trouble judged the signal as for different model.
Action of
• Pre-lubrication controller operates under the program for a different model.
controller
Problem that
appears on
machine
• Input state of model selection signal can be checked with monitoring code: 40973 (1: 24 V, 0:
GND)
Related
[D-IN-4]: PRE6 (35)=Machine select1
information
[D-IN-5]: PRE6 (26)=Machine select2 (NC: Internal pull-up)
[D-IN-6]: PRE6 (36)=Machine select3 (NC: Internal pull-up)

2) Disconnect PRE6 and carry out troubleshooting.
Between connectors PRE6 (female) (26) –
Resis-
Disconnection in wiring (31) Min. 1 Mz
tance
Possible causes harness (Disconnection or a Pin (26): No connection
1
and standard defective contact in Between connectors PRE6 (female) (36) –
value in normal connector) Resis-
(31) Min. 1 Mz
tance
state a Pin (36): No connection
Between connectors PRE6 (female) (31) – Resis-
Max. 1 z
(35) tance
If cause 1 is not detected, the pre-lubrication controller may be
2 defective. (Since trouble is in system, troubleshooting cannot be car-
controller
ried out.)
22 WA800, WA900-3E0
Failure code [DBGRKR] (Pre-lubrication controller CAN-NET

communication: Disconnection or grounding fault)
Action code Failure code Pre-lubrication controller CAN-NET communication: Disconnection
Trouble or grounding fault
E01 DBGRKR (Engine service monitor system)
Contents of • Engine service monitor cannot recognize pre-lubrication controller in the CAN communication cir-
trouble cuit.
Action of
controller
Problem that
appears on
machine
Related
information

2) Disconnect connectors of PRE6 and engine service monitor EM2,
then carry out troubleshooting.
Max. 1 z
(female) (1) – PRE6 (female) (28) tance
(female) (3) – PRE6 (female) (38) tance
1 Between engine service monitors EM2 Resis-
defective contact in Max. 1 z
connector) (female) (1) – (6) tance
a Key ACC signal disconnection
2) Disconnect connectors CBL1 and PRE6, then carry out trouble-
shooting.
Between CBL1 (male) (2) – PRE6 (female) Resis-
Max. 1 z
(2), and (12) tance
Possible causes
2) Disconnect connectors of VC06, PRE6, engine service monitor
and standard
EM2, engine controllers EM1 and EM2, then carry out trouble-
value in normal
shooting.
state
Min. 1 Mz
ground circuit)
a Key ACC signal grounding fault
2) Disconnect connectors CBL1 and PRE6, then carry out trouble-
shooting.
Min. 1 Mz
ground tance
2) Insert T-branch to engine service monitor EM2
Hot short circuit in wiring 3) Carry out troubleshooting with starting switch ON.
3 harness (Contact with Between engine service monitor EM2 (1) and
Voltage Max. 1 V
24 V circuit) chassis ground
Between engine service monitor EM2 (3) and
Voltage Max. 1 V
chassis ground
WA800, WA900-3E0 23

Defective CAN terminal 2) Disconnect engine connectors EM5 and EM6, then carry out trou-
resistance (Internal bleshooting.
4
EM5, EM6 (male) Resistance
circuit)
Between (A) – (B) 120 ± 12 z
Defective power supply to
5 Carry out troubleshooting for failure code [DBG3KK].
pre-lubrication controller
Possible causes
value in normal 2) Disconnect connectors of engine service monitors EM1 and EM2,
state then carry out troubleshooting.
Defective engine service Between engine service monitors EM2 Resis-
6 120 ± 12 z
monitor (male) (6) – (3) tance
defective. (Troubleshooting cannot be carried out for internal defects
other than the above.)
If causes 1 – 6 are not detected, the pre-lubrication controller may
7 be defective. (Troubleshooting cannot be carried out for internal
controller
defects other than the above.)
24 WA800, WA900-3E0
WA800, WA900-3E0 25
Failure code [DBL0KR] (Power ladder controller CAN-NET

communication: Disconnection or grounding fault)
Action code Failure code Power ladder controller CAN-NET communication: Disconnection or
Trouble grounding fault
E01 DBL0KR (Engine service monitor system)
• Installation of power ladder controller is selected in option setting of engine service monitor.
Contents of
If power ladder controller is installed, perform troubleshooting according to the separate Shop
trouble
Manual.
Action of
• (None in particular)
controller
Problem that
appears on • Error alarm appears and item related to power ladder is displayed on service monitor.
machine
Related • If power ladder controller is not installed, non-installation of power ladder controller must be
information selected in option setting of engine service monitor.

a Check installation of options in service mode. (See Testing and
Adjusting)
Installation of power lad-
Non-installation of
Possible causes der controller is selected in
1 Option setting Display power ladder control-
and standard option setting of service
ler
value in normal monitor.
state a If power ladder controller is installed, perform troubleshooting
according to the separate Shop Manual.
If no failure is found by check on cause 1, power ladder controller
Defective power ladder
2 may be defective (Since this is an internal defect, troubleshooting
controller
cannot be performed.)
26 WA800, WA900-3E0
WA800, WA900-3E0 27
Failure code [DDE2KB] (Engine oil pressure switch error: Grounding

fault)
Action code Failure code Engine oil pressure switch: Grounding fault
Trouble
E03 DDE2KB (Pre-lubrication controller system)
Contents of • Engine oil pressure switch detected low oil pressure (switch closed) when engine speed is Min.
trouble 500 rpm and engine oil pressure is over 100 kPa (communication from engine controller).
Action of
controller
Problem that
appears on
machine
• Engine speed: 01002 (rpm)
Related
• Engine oil pressure: 37200 (kPa)
information
• State of the engine oil pressure switch can be monitored with 40973 "D-IN-1" (ON: 1, OFF: 0).

Ground fault in wiring 2) Disconnect connector PRE6 and terminal E02, then carry out
1 harness (Contact with troubleshooting.
ground circuit) Between terminal E02 (harness side) and Resis-
Min. 1 Mz
Possible causes 2) Disconnect terminal E02.
and standard 3) Start the engine and carry out troubleshooting.
value in normal Between terminal E02 (oil pressure switch Resis-
state Defective engine oil Min. 1 Mz
2 side) and chassis ground tance
pressure switch
2) Disconnect terminal E02 and carry on troubleshooting.
Between terminal E02 (oil pressure switch Resis-
Max. 1 z
side) and chassis ground tance
controller
ried out.)
28 WA800, WA900-3E0
WA800, WA900-3E0 29
Failure code [DDE2L6] (Engine oil pressure switch error: Disconnection

or hot short circuit)
Action code Failure code Engine oil pressure switch error: Disconnection or hot short circuit
Trouble
E01 DDE2L6 (Pre-lubrication controller system)
• After starting switch is ON, no terminal C signal is input and engine oil pressure switch detected
Contents of
"OPEN" state although the engine speed is under 500 rpm (communication from engine control-
trouble
ler).
Action of
controller
Problem that
appears on
machine
• Engine speed: 01002 (rpm)
Related • Engine oil pressure switch: 40973 "D-IN-1" (ON: 1, OFF: 0).
information • Oil pressure can be monitored with engine starting switch terminal C signal: 40973 "D-IN-3" (ON:
1, OFF: 0).

Disconnection in wiring 2) Disconnect connector PRE6 and terminal E02, then carry out
harness (Disconnection or troubleshooting.
1
Resis-
connector) Between connector PRE6 (5) – terminal E02 Max. 1 z
tance
2) Disconnect connector PRE6 and terminal E02.
Hot short circuit in wiring
3) Connect T-branch to connector PRE6 (female).
power supply circuit)
Voltage Max. 1 V
Possible causes ground
value in normal 2) Disconnect terminal E02.
state 3) Start the engine and carry out troubleshooting.
Engine starting.
Resis-
Between terminal E02 (oil pressure switch Min. 1 Mz
Defective engine oil tance
3 side) and chassis ground
pressure switch
2) Disconnect terminal E02 and carry out troubleshooting.
While engine is starting
Resis-
Between terminal E02 (oil pressure switch Max. 1 z
tance
side) and chassis ground
controller
ried out.)
30 WA800, WA900-3E0
WA800, WA900-3E0 31
Failure code [DDK3KZ] (or TM & AJSS controller LED display [20],
abnormality in joystick forward-reverse switch system: Disconnection
or hot short circuit)
Action code Failure code Abnormality in joystick directional switch system: Disconnection,
Trouble short circuit or hot short circuit
CALL DDK3KZ (Transmission & AJSS controller system)
Contents of
• Abnormal signal from joystick forward-reverse switch
trouble
Action of • Immediately shifts to neutral at hot short circuit.
controller • Holds the immediately preceding range for 2 seconds at disconnection.
Problem that
appears on • Travel disabled
machine
• LED indication on transmission & AJSS controller: "20"
• Failure code [DDK3KZ] or transmission & AJSS controller LED displays "20", which means fuse
Related
box 2 (6) is connected (to the transmission AJSS controller power supply).
information
• Method of reproducing failure code: Turn starting switch ON.
• Failure code is sent to engine service monitor via VHMS controller.

2) Disconnect S31, and carry out troubleshooting by operating the
joystick forward-reverse switch.
Joystick forward-
reverse switch S31 (male) Resistance
position
Between (1) – (2) Max. 1 z
Defective forward-reverse F Between (1) – (3) Min. 1 Mz
1
switch Between (1) – (4) Min. 1 Mz
Between (1) – (2) Min. 1 Mz
N Between (1) – (3) Max. 1 z
Possible causes
and standard
value in normal R Between (1) – (3) Min. 1 Mz
state Between (1) – (4) Max. 1 z
2) Disconnect S31 and connect T-branch.
Between S31 (1) and chassis ground Voltage 20 – 30 V
2) Disconnect engine controllers C3B and S31, then carry out trou-
2 bleshooting.
Resis-
connector) Between C3B (female) (5) -S31 (female) (2) Max. 1 z
tance
Resis-
Between C3B (female) (6) -S31 (female) (4) Max. 1 z
tance
Between C3B (female) (13) – S31 (female) Resis-
Max. 1 z
(3) tance
32 WA800, WA900-3E0

2) Disconnect C3B, S31 and FS5, then carry out troubleshooting.
Between S31 (female) (1) and chassis Resis-
Min. 1 Mz
Reference ground tance
Ground fault in wiring Between S31 (female) (2) and chassis Resis-
Min. 1 Mz
harness (Contact with ground tance
3
ground circuit) Between S31 (female) (3) and chassis Resis-
(Fuse (6) in fuse box 2 is Min. 1 Mz
ground tance
disconnected.) Between S31 (female) (4) and chassis Resis-
Min. 1 Mz
ground tance
Resis-
Between S31 (male) (1) and chassis ground Min. 1 Mz
tance
2) Disconnect S31.
3) Turn the starting switch ON (without starting the engine) and carry
Between S31 (female) (2) and chassis
4 harness (Contact with Voltage Max. 1 V
ground
power supply circuit)
Voltage Max. 1 V
ground
Voltage Max. 1 V
value in normal 2) Disconnect C3B.
state 3) Turn the starting switch ON (without starting the engine) and carry
Joystick forward and
reverse travel switch Measuring point Voltage
position
Between C3B (5) and
20 – 30 V
chassis ground
Between C3B (6) and
F Max. 1 V
chassis ground
Between C3B (13)
Defective transmission & Max. 1 V
5 and chassis ground
AJSS controller
Between C3B (5) and
Max. 1 V
chassis ground
Between C3B (6) and
N Max. 1 V
chassis ground
Between C3B (13)
20 – 30 V
and chassis ground
Between C3B (5) and
Max. 1 V
chassis ground
Between C3B (6) and
R 20 – 30 V
chassis ground
Between C3B (13)
Max. 1 V
and chassis ground
WA800, WA900-3E0 33
34 WA800, WA900-3E0
Failure code [DDK5KZ] (or TM & AJSS controller LED display: “21”,
Abnormality in shifting up/down switch system: Disconnection, short
circuit or hot short circuit)
Action code Failure code Abnormality in shifting up/down switch system: Disconnection, short
Trouble circuit or hot short circuit)
– DDK5KZ (Transmission & AJSS controller system)
Contents of
• Abnormal signal from joystick shift switch
trouble
Action of
• Holds the immediately preceding range at disconnection.
controller
Problem that
machine
• LED indication on transmission & AJSS controller: "21"
• Failure code [DDK3KZ] or transmission & AJSS controller LED displays "21", which means fuse
Related
box 2 (6) is connected (to the transmission AJSS controller power supply).
information

shift switch.
Shift switch state S31 (male) Resistance
Not press switch
Defective directional Between (1) – (8) Min. 1 Mz
1
switch Between (1) – (5) Min. 1 Mz
Press shifting down Between (1) – (6) Max. 1 z
switch Between (1) – (7) Max. 1 z
Possible causes Between (1) – (5) Max. 1 z
and standard Press shifting up Between (1) – (6) Min. 1 Mz
value in normal switch Between (1) – (7) Min. 1 Mz
state Between (1) – (8) Max. 1 z
2) Disconnect S31 and correct T-branch.
Disconnection in wiring 2) Disconnect C3B and S31, then carry out troubleshooting.
harness (Disconnection or Resis-
2 Between C3B (female) (7) – S31 (female) (8) Max. 1 z
defective contact in tance
connector) Resis-
Between C3B (female) (8) – S31 (female) (6) Max. 1 z
tance
Max. 1 z
(7) tance
Max. 1 z
(5) tance
WA800, WA900-3E0 35

Between S31 (female) (1) and chassis Resis-
Min. 1 Mz
ground tance
Reference Between S31 (female) (5) and chassis Resis-
Min. 1 Mz
Ground fault in wiring ground tance
harness (Contact with Between S31 (female) (6) and chassis Resis-
3 Min. 1 Mz
(Fuse (6) in fuse box 2 is Between S31 (female) (7) and chassis Resis-
disconnected.) Min. 1 Mz
ground tance
Resis-
tance
Resis-
tance
2) Disconnect S31.
3) Turn the starting switch ON (without starting the engine) and carry
Hot short circuit in wiring Voltage Max. 1 V
ground
power supply circuit) Voltage Max. 1 V
ground
Voltage Max. 1 V
ground
Voltage Max. 1 V
value in normal 2) Disconnect C3B.
state 3) Turn the starting switch ON (without starting the engine) and carry
Shift switch state Measuring point Voltage
Between C3B (7) and
Max. 1 V
chassis ground
Between C3B (8) and
Max. 1 V
chassis ground
Not press switch
Between C3B (15)
20 – 30 V
and chassis ground
Between C3B (16)
20 – 30 V
and chassis ground
Between C3B (7) and
Defective transmission & Max. 1 V
5 chassis ground
AJSS controller
Between C3B (8) and
20 – 30 V
Press shifting down chassis ground
switch Between C3B (15)
20 – 30 V
and chassis ground
Between C3B (16) –
Max. 1 V
chassis ground
Between C3B (7) and
20 – 30 V
chassis ground
Between C3B (8) and
Max. 1 V
Press shifting up chassis ground
Max. 1 V
and chassis ground
Between C3B (16)
20 – 30 V
and chassis ground
36 WA800, WA900-3E0
WA800, WA900-3E0 37
Failure code [DDP5KZ] (Abnormality in steering lock switch system:

Disconnection or short circuit)
Action code Failure code Abnormality in steering lock switch system: Disconnection or short
Trouble circuit
– DDP5KZ (Transmission & AJSS controller system)
Contents of
• Signal from steering lock switch cannot be acquired
trouble
Action of
• Sounds the caution buzzer
controller
• In the case of disconnection
Transmission is stuck in Neutral.
Problem that
(Steering can be operated normally)
appears on
• In the case of grounding fault
machine
1) Travel enabled with steering in locked state.
2) Shift lever enters either "F" or "R".
Related • LED indication on transmission & AJSS controller: "60"

1) Start engine.
2) Steering lock lever position operation
3) Stop engine and turn starting switch OFF.
4) Disconnect L39 and carry out troubleshooting.
Defective steering lock 5) Start engine again and operate at the steering lock lever position.
1 6) Turn starting switch OFF, and carry out troubleshooting similarly.
switch
Steering lock lever
L39 Resistance
position
Lock Between (1) – (2) Min. 1 Mz
Release locking Between (1) – (2) Max. 1 z
2) Disconnect C3B and L39.
Disconnection in wiring 3) Turn starting switch OFF and carry out troubleshooting.
2 Resis-
defective contact in Between C3B (female) (9) – L39 (female) (1) Max. 1 z
tance
connector)
Possible causes Between L39 (female) (2) and grounding ter- Resis-
and standard Max. 1 z
minal (R11) tance
value in normal 1) Turn starting switch OFF.
state Ground fault in wiring 2) Disconnect C3B and L39.
3 harness (Contact with 3) Turn starting switch OFF and carry out troubleshooting.
ground circuit) Between C3B (female) (9) – L39 (female) (1) Resis-
Min. 1 Mz
2) Disconnect C3B and connect T-branch.
3) Start engine.
4) Steering lock lever position operation
5) Stop engine and carry on troubleshooting with starting switch ON.
6) Start engine again and operate at the steering lock lever position.
Defective transmission & 7) Stop engine and carry on troubleshooting with starting switch ON.
4
AJSS controller
Steering lock lever
Measuring point Voltage
position
Between C3B (9) and
Lock 20 – 30 V
chassis ground
Between C3B (9) and
Release locking Max. 1 V
chassis ground
38 WA800, WA900-3E0
WA800, WA900-3E0 39
Failure code [DGE5KX] (Atmospheric temperature sensor: Out of input

signal range (short))
Action code Failure code Atmospheric temperature sensor: Out of input signal range (short)
Trouble
– DGE5KX (VHMS controller system)
Contents of
• Atmospheric temperature sensor signal is out of normal range.
trouble
Action of
controller
Problem that
appears on
machine
Related • Atmospheric temperature can be checked with monitoring code: 37501 (°C).
information • Method of reproducing failure code: Turn the starting switch ON or start engine.

Defective atmospheric without turning starting switch ON.
temperature sensor
1 V21 (male) Resistance
(Internal disconnection or
short circuit) Between (A) – (B) 0.35 k – 57 kz (100 – -30°C)
Between (A) and chassis ground Min. 1 Mz
Disconnection in wiring 2) Disconnect VC02 and V21 and carry out troubleshooting.
Possible causes Wiring harness between VC02 (female) (10) Resis-
2 defective contact in Max. 1 z
and standard – V21 (female) (A) tance
connector)
value in normal Wiring harness between VC02 (female) (12) Resis-
state
(Reference) Max. 1 z
– V21 (female) (B) tance
Ground fault in wiring 2) Disconnect VC02 and V21 and carry out troubleshooting.
Wiring harness between VC02 (female) (10) Resis-
– V21 (female) (A) and chassis ground tance
VC02 (female) Resistance
Between (10) – (12) 0.35 k – 57 kz (100 – -30°C)
40 WA800, WA900-3E0
WA800, WA900-3E0 41
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input

signal range (short))
Action code Failure code Hydraulic oil temperature sensor: Out of input signal range (short)
Trouble
– DGH2KX (VHMS controller system)
Contents of
• Hydraulic oil temperature sensor signal is out of normal range.
trouble
Action of
controller
Problem that
appears on • Monitor panel hydraulic oil temperature meter may not display data normally.
machine
Related • State of hydraulic oil temperature can be checked with monitoring code: 04407 (°C).
information • Method of reproducing failure code: Turn the starting switch ON or start engine.

1 V24 (male) Resistance
connector) Between (1) – (2) 1.6 k – 48 kz (130 – 25°C)
Between (1) and chassis ground Min. 1 Mz
Disconnection in wiring 2) Disconnect VC02 and V24 and carry out troubleshooting.
Possible causes Wiring harness between VC02 (female) (11) Resis-
and standard – V24 (female) (1) tance
connector)
state
– V24 (female) (2) tance
Ground fault in wiring 2) Disconnect VC02 and V24 and carry out troubleshooting.
– V24 (female) (1) and chassis ground tance
Between (11) – (12) 1.6 k – 48 kz (130 – 25°C)
42 WA800, WA900-3E0
WA800, WA900-3E0 43
Failure code [DGR4KX] (Front brake oil temperature sensor: Out of

input signal range (short))
Action code Failure code Front brake oil temperature sensor: Out of input signal range (short))
Trouble
– DGR4KX (VHMS controller system)
Contents of
• Front brake oil temperature sensor signal is out of normal range.
trouble
Action of
controller
Problem that
appears on
machine
Related • Front brake oil temperature can be checked with monitoring code: 30213 (°C).
information • Method of reproducing failure code: Turn starting switch ON or start engine.

Defective front brake oil
F25 (male) Resistance
pressure sensor (Internal
1 1.6 k – 48 kz (130 – 25°C)
circuit) Between (1) – (2) a Overheat (Min. 120°C):
Max. 2.1 kz
Between (1) and chassis ground Min. 1 Mz
Disconnection in wiring 2) Disconnect VC02 and F25 and carry out troubleshooting.
Possible causes Wiring harness between VC02 (female) (2) – Resis-
and standard F25 (female) (1) tance
connector)
state
– F25 (female) (2) tance
Grounding fault in wiring 2) Disconnect VC02 and F25 and carry out troubleshooting.
F25 (female) (1) and chassis ground tance
1.6 k – 48 kz (130 – 25°C)
Between (2) – (12) a Overheat (Min. 120°C):
Max. 2.1 kz
44 WA800, WA900-3E0
WA800, WA900-3E0 45
SEN02148-02

© 2011 KOMATSU
All Rights Reserved
46
SEN02268-01
WA800-3E0
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
Failure code [DGT5KA] (or VHMS LED display: "n3" o "12",
L.H. bank exhaust gas temperature sensor system (Front): Disconnection or short circuit) ...................... 3
Failure code [dGT5KA] (or VHMS LED display: "n3" o "22",
L.H. bank exhaust gas temperature sensor system (Rear): Disconnection or short circuit) ....................... 6
Failure code [DGT5KB] (or VHMS LED display: "n3" o "11",
L.H. bank exhaust gas temperature sensor system (Front): Hot short circuit).......................................... 10
Failure code [dGT5KB] (or VHMS LED display: "n3" o "21",
L.H. bank exhaust gas temperature sensor system (Rear): Hot short circuit) .......................................... 12
Failure code [DGT6KA] (or VHMS LED display: "n3" o "24",
R.H. bank exhaust gas temperature sensor system (Front): Disconnection or short circuit).................... 14
Failure code [dGT6KA] (or VHMS LED display: "n3" o "26",
R.H. exhaust gas temperature sensor system (Rear): Disconnection or short circuit) ............................. 17
Failure code [DGT6KB] (or VHMS LED display "n3" o "23",
R.H. bank exhaust gas temperature sensor system (front): Hot short circuit) .......................................... 20
WA800, WA900-3E0 1
Troubleshooting by failure code (Display of code), Part 6
SEN02268-01
Failure code [dGT6KB] (or VHMS LED display "n3" o "25",

R.H. bank exhaust gas temperature sensor system (rear): Hot short circuit) ........................................... 22
Failure code [DHE5KB] (or VHMS_LED display: "n3" o "32",
Blow-by pressure sensor system: Short circuit) ........................................................................................ 24
Failure code [DHE5KY] (or VHMS LED display: "n3" o "31",
Blow-by pressure sensor system: Hot short circuit) .................................................................................. 26
Failure code [DHP2KX] (Main pump oil pressure sensor error: Disconnection or short circuit).................... 28
Failure code [DHT3KX] (or VHMS LED display: "n6" o "14"
Transmission oil pressure sensor system: Out of input signal range)....................................................... 30
Failure code [DHT8KX] (Steering pump oil pressure sensor error): Disconnection or short circuit) ............. 32
Failure code [DHU2KX] (Front brake oil pressure sensor error: Disconnection or short circuit)................... 34
Failure code [DHU3KX] (Rear brake oil pressure sensor error: Disconnection or short circuit) ................... 36
Steering and frame angle displacement) .................................................................................................. 38
abnormality in steering angle potentiometer system): Disconnection or short circuit) .............................. 40
abnormality in frame angle potentiometer system: Disconnection or short circuit) ................................... 42
Failure code [DLE4KA] (or TM & AJSS controller LED display [23],
abnormality in engine speed sensor system: Disconnection, short circuit or hot short circuit) ................. 44
Failure code [DLT4KA] (or TM AJSS controller LED display [22],
abnormality in speed sensor system: Disconnection, short circuit or hot short circuit) ............................. 46
Failure code [DUM7KY] (Pre-lubrication operation lamp output abnormality: Hot short circuit) ................... 48
Failure code [DUM7KZ] (Pre-lubrication operation lamp output abnormality:
Disconnection or grounding fault) ............................................................................................................. 49
Failure code [DXF0KZ] (or TM & AJSS controller LED display [63],
abnormality in joystick EPC solenoid system: Disconnection, short circuit or hot short circuit) ................ 51
abnormality in 1st solenoid system: Disconnection, short circuit or hot short circuit) ............................... 52
abnormality in 2nd solenoid system: Disconnection, short circuit or hot short circuit) .............................. 54
abnormality in 3rd solenoid system: Disconnection, short circuit or hot short circuit) ............................... 56
abnormality in R solenoid system: Disconnection, short circuit or hot short circuit).................................. 58
abnormality in F solenoid system: Disconnection, short circuit or hot short circuit) .................................. 60
Failure code [F@BBZL] (or VHMS LED display: "n3" o "38",
Blow-by pressure sensor system: High pressure error) ............................................................................ 62
Failure code [F@BYNR] (or VHMS LED display: "n3" o "62",
L.H. front exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature) ................... 63
Failure code [f@BYNR] (or VHMS LED display: "n3" o "72",
L.H. rear exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature) .................... 63
Failure code [F@BYNS] (or VHMS LED display: "n3" o "61",
L.H. front exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature) ................... 64
Failure code [f@BYNS] (or VHMS LED display: "n3" o "71",
L.H. rear exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature) .................... 64
Failure code [F@BZNR] (or VHMS LED display: "n3" o "82",
R.H. front exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature)................... 65
Failure code [f@BZNR] (or VHMS LED display: "n3" o "92",
R.H. rear exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature) ................... 65
Failure code [F@BZNS] (or VHMS LED display: "n3" o "38",
R.H. front exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature)................... 66
Failure code [f@BZNS] (or VHMS LED display: "n3" o "39",
R.H. rear exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature) ................... 66
2 WA800, WA900-3E0
Failure code [DGT5KA] (or VHMS LED display: "n3" o "12", L.H. bank SEN02268-01
Failure code [DGT5KA] (or VHMS LED display: "n3" o "12", L.H. bank
exhaust gas temperature sensor system (Front): Disconnection or short
circuit) 1
Action code Failure code L.H. bank exhaust gas temperature sensor system (front): Discon-
Trouble nection or short circuit
– DGT5KA (VHMS controller system)
Contents of
• L.H. bank exhaust gas temperature sensor signal voltage is 0.5 V or lower.
trouble
Action of
controller
Problem that
appears on • Monitoring function cannot monitor the L.H. bank exhaust gas temperature.
machine
information • 24 V power supply, GND: Refer to failure code [DBB6KP].

L.H. bank exhaust gas
temperature abnormally
1 Check the engine for abnormality. Correct, if any.
high (when the system is
normal)
L.H. bank exhaust gas temperature sensor
Defective L.H. bank Exhaust gas tempera-
(front) is replaced but condition does not
2 exhaust gas temperature ture sensor is normal.
become normal.
sensor
After L.H. bank exhaust gas temperature Defective exhaust
sensor (front) is replaced, condition becomes gas temperature sen-
normal. sor
2) Insert T-branch to V34.
Defective L.H. bank 4) Start engine and carry out troubleshooting.
Possible causes
and standard 3 exhaust gas temperature Between V34 (A) – (C) Voltage 20 – 30 V
value in normal sensor amplifier Before starting About
Between 20°C Voltage
state engine. 0.9 – 1.2 V
V34
About
(B) – (C) Start engine (no load) 500°C Voltage
2.6 – 3.5 V
Max. 1 z
(A) tance
Max. 1 z
(B) tance
4 harness (Disconnection or Max. 1 z
(C) tance
defective contact)
Resis-
Between V36 (male) (1) – V38 (female) (1) Max. 1 z
tance
Resis-
tance
Between VC01 (female) (11) – VC02 Resis-
Max. 1 z
(female) (12) tance
WA800, WA900-3E0 3
SEN02268-01 Failure code [DGT5KA] (or VHMS LED display: "n3" o "12", L.H. bank ex-

Min. 1 Mz
V34 (female) (A) and chassis ground tance
V34 (female) (B) and chassis ground tance
ground circuit)
Wiring harness between V36 (male) (1) – Resis-
Min. 1 Mz
V38 (female) (1) and chassis ground tance
Possible causes Wiring harness between V36 (male) (2) – Resis-
Min. 1 Mz
and standard V38 (female) (2) and chassis ground tance
value in normal a Prepare with starting switch OFF, then turn starting switch ON and
state carry out troubleshooting
2) Insert T-branch to VC02.
4) Start engine and carry out troubleshooting.
VC02 Exhaust temperature Voltage
Before starting
Between 20°C About 0.9 – 1.2 V
engine.
(7) – (12)
Start engine (no load) 500°C About 2.6 – 3.5 V
4 WA800, WA900-3E0
Failure code [DGT5KA] (or VHMS LED display: "n3" o "12", L.H. bank SEN02268-01
WA800, WA900-3E0 5
SEN02268-01 Failure code [dGT5KA] (or VHMS LED display: "n3" o "22", L.H. bank ex-
Failure code [dGT5KA] (or VHMS LED display: "n3" o "22", L.H. bank
exhaust gas temperature sensor system (Rear): Disconnection or short
circuit) 1
Action code Failure code L.H. bank exhaust gas temperature sensor system (rear): Discon-
– dGT5KA (VHMS controller system)
Contents of
• L.H. bank exhaust gas temperature sensor signal voltage is 0.5 V or lower.
trouble
Action of
controller
Problem that
machine

L.H. bank exhaust gas
normal)
L.H. bank exhaust gas temperature sensor
(rear) is replaced but condition does not
become normal.
sensor
After L.H. bank exhaust gas temperature Defective exhaust
sensor (rear) is replaced, condition becomes gas temperature sen-
normal. sor
Defective L.H. bank 4) Start the engine and carry out troubleshooting.
Possible causes
and standard 3 exhaust gas temperature Between V41 (A) – (C) Voltage 20 – 30 V
value in normal sensor amplifier Before starting About
state engine. 0.9 – 1.2 V
V41
About
2.6 – 3.5 V
Max. 1 z
(A) tance
Max. 1 z
(B) tance
4 harness (Disconnection or Max. 1 z
(C) tance
defective contact)
Resis-
tance
Resis-
tance
Between VC01 (female) (11) – VC02 Resis-
Max. 1 z
(female) (12) tance
6 WA800, WA900-3E0
Failure code [dGT5KA] (or VHMS LED display: "n3" o "22", L.H. bank SEN02268-01

Min. 1 Mz
– V41 (female) (B) and chassis ground tance
ground circuit)
Min. 1 Mz
Min. 1 Mz
state carry out troubleshooting.
Before starting
engine.
(16) – (12)
WA800, WA900-3E0 7
SEN02268-01 Failure code [dGT5KA] (or VHMS LED display: "n3" o "22", L.H. bank ex-
8 WA800, WA900-3E0
Failure code [dGT5KA] (or VHMS LED display: "n3" o "22", L.H. bank SEN02268-01
WA800, WA900-3E0 9
SEN02268-01 Failure code [DGT5KB] (or VHMS LED display: "n3" o "11", L.H. bank ex-
Failure code [DGT5KB] (or VHMS LED display: "n3" o "11", L.H. bank
exhaust gas temperature sensor system (Front): Hot short circuit) 1
Action code Failure code L.H. bank exhaust gas temperature sensor system (front): Hot short
Trouble circuit
– DGT5KB
(VHMS controller system)
Contents of
• L.H. bank exhaust gas temperature sensor signal voltage is 4.9 V or higher.
trouble
Action of
controller
Problem that
machine

L.H. bank exhaust gas temperature sensor is Exhaust gas tempera-
Defective L.H. bank
replaced but condition does not become nor- ture sensor
1 exhaust gas temperature
mal. Normal
sensor
When L.H. bank exhaust gas temperature Exhaust gas tempera-
sensor is replaced, condition becomes nor- ture sensor
mal. Defective
Defective L.H. bank 4) Start the engine and carry out troubleshooting.
2 exhaust gas temperature Between V34 (A) – (C) Voltage 20 – 30 V
sensor amplifier Before starting About
Possible causes Between 20°C Voltage
engine. 0.9 – 1.2 V
and standard V34
About
value in normal (B) – (C) Start engine (no load) 500°C Voltage
2.6 – 3.5 V
state
24 V circuit) Min. 1 Mz
V34 (female) (B) and V34 (female) (A) tance
VC02 Exhaust temperature 20 – 30 V
Before starting
engine.
(7) – (12)
10 WA800, WA900-3E0
Failure code [DGT5KB] (or VHMS LED display: "n3" o "11", L.H. bank SEN02268-01
WA800, WA900-3E0 11
SEN02268-01 Failure code [dGT5KB] (or VHMS LED display: "n3" o "21", L.H. bank ex-
Failure code [dGT5KB] (or VHMS LED display: "n3" o "21", L.H. bank
exhaust gas temperature sensor system (Rear): Hot short circuit) 1
Action code Failure code L.H. bank exhaust gas temperature sensor system (rear): Hot short
Trouble circuit
– dGT5KB
Contents of
• L.H. bank exhaust gas temperature sensor signal voltage is 4.9 V or higher.
trouble
Action of
controller
Problem that
machine

L.H. bank exhaust gas temperature sensor is
replaced but condition does not become nor-
mal.
sensor
When L.H. bank exhaust gas temperature Exhaust gas tempera-
sensor is replaced, condition becomes nor- ture sensor is abnor-
mal. mal.
Defective amplifier for L.H. 4) Start engine and carry out troubleshooting.
2 bank exhaust gas temper- Between V41 (A) – (C) Voltage 20 – 30 V
ature sensor Before starting About
engine. 0.9 – 1.2 V
and standard V41
About
2.6 – 3.5 V
state
– V41 (female) (B) and V41 (female) (A) tance
Before starting
engine.
(16) – (12)
12 WA800, WA900-3E0
Failure code [dGT5KB] (or VHMS LED display: "n3" o "21", L.H. bank SEN02268-01
WA800, WA900-3E0 13
SEN02268-01 Failure code [DGT6KA] (or VHMS LED display: "n3" o "24", R.H. bank ex-
Failure code [DGT6KA] (or VHMS LED display: "n3" o "24", R.H. bank
exhaust gas temperature sensor system (Front): Disconnection or short
circuit) 1
Action code Failure code R.H. bank exhaust gas temperature sensor system (front): Discon-
– DGT6KA (VHMS controller system)
Contents of
• R.H. bank exhaust gas temperature sensor signal voltage is 0.5 V or lower.
trouble
Action of
controller
Problem that
appears on • Monitoring function cannot monitor the R.H. bank exhaust gas temperature.
machine

R.H. bank exhaust gas
normal)
R.H. bank exhaust gas temperature sensor
Defective R.H. bank Exhaust gas tempera-
become normal.
sensor
After R.H. bank exhaust gas temperature Exhaust gas tempera-
sensor (front) is replaced, condition becomes ture sensor is defec-
normal. tive.
Possible causes 3) Turn starting switch ON and carry out troubleshooting.
and standard Defective R.H. bank 4) Start engine and carry out troubleshooting.
value in normal 3 exhaust gas temperature Between V35 (A) – (C) Voltage 20 – 30 V
state sensor amplifier Before starting About
engine. 0.9 – 1.2 V
V35
About
2.6 – 3.5 V
Max. 1 z
V35 (female) (A) tance
V35 (female) (B) tance
4 harness (Disconnection or
defective contact) Max. 1 z
– V35 (female) (C) tance
Max. 1 z
V39 (female) (1) tance
Max. 1 z
14 WA800, WA900-3E0
Failure code [DGT6KA] (or VHMS LED display: "n3" o "24", R.H. bank SEN02268-01

Min. 1 Mz
ground circuit)
Min. 1 Mz
Min. 1 Mz
Before starting
engine.
(5) – (12)
WA800, WA900-3E0 15
SEN02268-01 Failure code [DGT6KA] (or VHMS LED display: "n3" o "24", R.H. bank ex-
16 WA800, WA900-3E0
Failure code [dGT6KA] (or VHMS LED display: "n3" o "26", R.H. ex- SEN02268-01
Failure code [dGT6KA] (or VHMS LED display: "n3" o "26", R.H.
exhaust gas temperature sensor system (Rear): Disconnection or short
circuit) 1
Action code Failure code R.H. bank exhaust gas temperature sensor system (rear): Discon-
– dGT6KA (VHMS controller system)
Contents of
• R.H. bank exhaust gas temperature sensor signal voltage is 0.5 V or lower.
trouble
Action of
controller
Problem that
machine

R.H. bank exhaust gas
normal)
become normal.
sensor
sensor (rear) is replaced, condition becomes ture sensor is defec-
normal. tive.
Possible causes 3) Turn starting switch ON and carry out troubleshooting.
and standard Defective R.H. bank 4) Start engine and carry on troubleshooting.
value in normal 3 exhaust gas temperature Between V42 (A) – (C) Voltage 20 – 30 V
state sensor amplifier Before starting About
engine. 0.9 – 1.2 V
V42
About
2.6 – 3.5 V
Max. 1 z
V42 (female) (A) tance
– V42 (female) (C) tance
Max. 1 z
Max. 1 z
WA800, WA900-3E0 17
SEN02268-01 Failure code [dGT6KA] (or VHMS LED display: "n3" o "26", R.H. exhaust gas

Min. 1 Mz
ground circuit)
Min. 1 Mz
Min. 1 Mz
4) Start engine and carry on troubleshooting.
Before starting
engine.
(6) – (12)
18 WA800, WA900-3E0
Failure code [dGT6KA] (or VHMS LED display: "n3" o "26", R.H. ex- SEN02268-01
WA800, WA900-3E0 19
SEN02268-01 Failure code [DGT6KB] (or VHMS LED display "n3" o "23", R.H. bank ex-
Failure code [DGT6KB] (or VHMS LED display "n3" o "23", R.H. bank
exhaust gas temperature sensor system (front): Hot short circuit) 1
Action code Failure code R.H. bank exhaust gas temperature sensor system (front): Hot short
Trouble circuit
– DGT6KB
Contents of
• R.H. bank exhaust gas temperature sensor signal voltage is 4.9 V or higher.
trouble
Action of
controller
Problem that
machine

become normal.
sensor
sensor (front) is replaced, condition becomes ture sensor is defec-
normal. tive.
Defective R.H. bank 4) Start engine and carry on troubleshooting.
engine. 0.9 – 1.2 V
and standard V35
About
2.6 – 3.5 V
state
Before starting
engine.
(5) – (12)
20 WA800, WA900-3E0
Failure code [DGT6KB] (or VHMS LED display "n3" o "23", R.H. bank SEN02268-01
WA800, WA900-3E0 21
SEN02268-01 Failure code [dGT6KB] (or VHMS LED display "n3" o "25", R.H. bank ex-
Failure code [dGT6KB] (or VHMS LED display "n3" o "25", R.H. bank
exhaust gas temperature sensor system (rear): Hot short circuit) 1
Action code Failure code R.H. bank exhaust gas temperature sensor system (rear): Hot short
Trouble circuit
– dGT6KB
Contents of
• R.H. bank exhaust gas temperature sensor signal voltage is 4.9 V or rear.
trouble
Action of
controller
Problem that
machine

become normal.
sensor
sensor (rear) is replaced, condition becomes ture sensor is defec-
normal. tive.
Defective R.H. bank 4) Start engine and carry on troubleshooting.
engine. 0.9 – 1.2 V
and standard V42
About
2.6 – 3.5 V
state
4) Start engine and carry on troubleshooting.
Before starting
engine.
(6) – (12)
22 WA800, WA900-3E0
Failure code [dGT6KB] (or VHMS LED display "n3" o "25", R.H. bank SEN02268-01
WA800, WA900-3E0 23
SEN02268-01 Failure code [DHE5KB] (or VHMS_LED display: "n3" o "32", Blow-by pres-
Failure code [DHE5KB] (or VHMS_LED display: "n3" o "32", Blow-by

pressure sensor system: Short circuit) 1
Action code Failure code Blow-by pressure sensor system: Short circuit
Trouble
– DHE5KB (VHMS controller system)
Contents of
• Signal voltage from blow-by pressure sensor is under 0.1 V or lower.
trouble
Action of
controller
Problem that
appears on • Monitoring function cannot monitor the blow-by pressure.
machine

Defective 5 V power sup- Check for failure code [DBB5KP] display. If displayed, carry out the
1
ply circuit troubleshooting as stated.
Defective blow-by 2) Insert T-branch to V32.
pressure sensor, 3) Turn starting switch ON and carry out troubleshooting.
2
defective VHMS controller
Between V32 (B) – (A) Voltage 4.5 – 5.5 V ... P
or defective harness
Between V32 (C) – (A) Voltage 0.3 – 0.7 V ... Q
a If P is true but Q is not in cause 2, modify T-branch (by cutting the
sensor signal line on the T-branch) and check to determine which
causes the sensor error, blow-by pressure sensor, VHMS control-
ler or harness.
1) Cut the terminal C wiring of T-branch between the center connec-
Defective blow-by
3 tor and VHMS side connector.
Possible causes pressure sensor
and standard 3) Insert T-branch to V32.
value in normal 4) Turn starting switch ON and carry out troubleshooting.
state Between the terminal C side (wiring on the
Voltage 0.3 – 0.7 V
sensor side) of the cut T-branch – V32 (A)
(B) tance
(C) tance
Resis-
Between V32 (A) and chassis ground Max. 1 z
tance
a Prepare with starting switch OFF, then turn it ON and carry out
troubleshooting.
Between VC01 (female) (5) – (11) Voltage 4.5 – 5.5 V
24 WA800, WA900-3E0
Failure code [DHE5KB] (or VHMS_LED display: "n3" o "32", Blow-by SEN02268-01
WA800, WA900-3E0 25
SEN02268-01 Failure code [DHE5KY] (or VHMS LED display: "n3" o "31", Blow-by pres-
Failure code [DHE5KY] (or VHMS LED display: "n3" o "31", Blow-by
pressure sensor system: Hot short circuit) 1
Action code Failure code Blow-by pressure sensor system: Hot short circuit
Trouble
– DHE5KY (VHMS controller system)
Contents of
• Input signal voltage from the blow-by pressure sensor is 4.7 V or higher.
trouble
Action of
controller
Problem that
appears on • Monitoring function cannot monitor the blow-by pressure.
machine

Defective 5 V power Check for failure code [DBB5KP] display. If displayed, carry out the
1
supply circuit troubleshooting as stated.
Defective blow-by 2) Insert T-branch to V32.
pressure sensor, 3) Turn starting switch ON and carry out troubleshooting.
2
defective VHMS controller
or defective harness
causes the sensor error, blow-by pressure sensor, VHMS control-
ler or harness.
Possible causes 1) Cut the terminal C wiring of T-branch between the center connec-
and standard Defective blow-by
value in normal pressure sensor
state 3) Insert T-branch to V32.
Between the terminal C side (wiring on the
Wiring harness between VC02 (female) (18)
24 V circuit) Voltage Max. 1 V
– V32 (female) (C) and chassis ground
troubleshooting.
26 WA800, WA900-3E0
Failure code [DHE5KY] (or VHMS LED display: "n3" o "31", Blow-by SEN02268-01
WA800, WA900-3E0 27
SEN02268-01 Failure code [DHP2KX] (Main pump oil pressure sensor error: Disconnection
Failure code [DHP2KX] (Main pump oil pressure sensor error:

Action code Failure code Main pump oil pressure sensor error: Disconnection or short circuit)
Trouble
– DHP2KX (VHMS controller system)
Contents of
• Main pump oil pressure signal cannot be acquired.
trouble
Action of
controller
Problem that
machine
Related • 5 V power supply, GND: Refer to failure code [DBB5KP].
information • Main pump oil pressure can be checked with monitoring code 01136 (MPa).

1
Defective oil pressure 2) Insert T-branch to V27.
sensor, defective VHMS 3) Turn starting switch ON and carry out troubleshooting.
2
controller or defective har-
ness
Between V27(C) – (A) Voltage 0.5 – 4.5 V ... Q
causes the sensor error, oil pressure sensor, VHMS controller or
harness.
sensor
3) Insert modified T-branch to V27.
4) Carry out troubleshooting with starting switch ON.
Possible causes Between the terminal C side (wiring on the
and standard sensor side) of the cut T-branch – V27 (A)
state 2) Disconnect VC01, VC02 and V27, then carry on troubleshooting.
Disconnection in wiring Resis-
Between VC01 (female) (4) – V27 (B) Max. 1 z
harness (Disconnection or tance
4
defective contact in Resis-
Between VC02 (female) (15) – V27 (C) Max. 1 z
connector) tance
Resis-
tance
2) Disconnect VC01, VC02 and V27, then carry out troubleshooting
Ground fault in wiring with starting switch OFF.
5 harness (Contact with Between VC01 (female) (4) and chassis Resis-
Min. 1 Mz
Between VC02 (female) (15) and chassis Resis-
Min. 1 Mz
ground tance
2) Disconnect VC02 and insert T-branch.
6 Defective VHMS controller 3) Carry out troubleshooting with starting switch ON.
Between VC02 (15) – (12) Voltage 0.5 – 4.5 V
28 WA800, WA900-3E0
Failure code [DHP2KX] (Main pump oil pressure sensor error: Discon- SEN02268-01
WA800, WA900-3E0 29
SEN02268-01 Failure code [DHT3KX] (or VHMS LED display: "n6" o "14", Transmission oil
Failure code [DHT3KX] (or VHMS LED display: "n6" o "14",

Transmission oil pressure sensor system: Out of input signal range) 1
Action code Failure code Transmission oil pressure sensor system: Out of input signal range
Trouble
– DHT3KX (VHMS controller system)
Contents of
• Transmission oil pressure signal cannot be acquired.
trouble
Action of
controller
Problem that
machine
• Transmission oil pressure can be checked with monitoring code 43000 (MPa)
Related
information
• 24 V power supply, GND: Refer to failure code [DBB6KP].

Defective 24 V power If failure code [DBB6KP] is displayed, carry out the troubleshooting
1
supply circuit as stated.
2
controller or defective
Between V28 (B) – (A) Voltage 20 – 30 V ... P
harness
Between V28(C) – (A) Voltage 1 – 5 V ... Q
harness.
sensor 2) Turn starting switch OFF.
Voltage 1–5V
Possible causes
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Wiring harness between VC01 (female) (2) – Resis-
defective contact) Wiring harness between VC03 (female) (1) – Resis-
Max. 1 z
V28 (female) (C) tance
Max. 1 z
ground tance
ground circuit)
Min. 1 Mz
V28 (female) (C) and chassis ground tance
troubleshooting.
24 V circuit) Wiring harness between VC03 (female) (1) –
Voltage Max. 1 V
V28 (female) (C) and chassis ground
7 Defective VHMS controller troubleshooting.
Between VC03 (1) – (9) Voltage 1–5V
30 WA800, WA900-3E0
Failure code [DHT3KX] (or VHMS LED display: "n6" o "14", Transmis- SEN02268-01
WA800, WA900-3E0 31
SEN02268-01 Failure code [DHT8KX] (Steering pump oil pressure sensor error): Discon-
Failure code [DHT8KX] (Steering pump oil pressure sensor error):

Action code Failure code Steering pump oil pressure sensor error: Disconnection or short cir-
Trouble cuit)
– DHT8KX
Contents of
• Steering pump oil pressure signal cannot be acquired.
trouble
Action of
controller
Problem that
machine
Related • 5 V power supply, GND: Refer to failure code [DBB5KP].
information • Steering pump oil pressure can be checked with monitoring code 29700 (MPa).

1
2
harness
harness.
sensor
Possible causes Between the terminal C side (wiring on the
and standard Voltage 0.5 – 4.5 V
state
2) Disconnect VC01, VC02 and V26, then carry on troubleshooting.
Between VC01 (female) (4) – V26 (B) Max. 1 z
harness (Disconnection or tance
4
defective contact in Resis-
connector) tance
Resis-
tance
2) Disconnect VC01, VC02 and V26, then carry on troubleshooting.
ground tance
ground circuit)
Min. 1 Mz
ground tance
32 WA800, WA900-3E0
Failure code [DHT8KX] (Steering pump oil pressure sensor error): Dis- SEN02268-01
WA800, WA900-3E0 33
SEN02268-01 Failure code [DHU2KX] (Front brake oil pressure sensor error: Disconnec-
Failure code [DHU2KX] (Front brake oil pressure sensor error:

Action code Failure code Front brake oil pressure sensor error: Disconnection or short circuit
Trouble
– DHU2KX (VHMS controller system)
Contents of
• Front brake oil pressure signal cannot be acquired.
trouble
Action of
controller
Problem that
machine
• 5 V power supply: Refer to failure code [DBB5KP].
Related
• Front brake oil pressure can be checked with monitoring code 91904 (MPa).
information
• Failure code for rear brake oil pressure sensor error: [DHU3KX]

1
2
harness
harness.
Possible causes Voltage 0.5 – 4.5 V
and standard
value in normal
state with starting switch OFF.
Resis-
harness (Disconnection or Between VC01 (female) (4) – V22 (B) Max. 1 z
4 tance
connector) Resis-
tance
Resis-
tance
Min. 1 Mz
Min. 1 Mz
ground tance
34 WA800, WA900-3E0
Failure code [DHU2KX] (Front brake oil pressure sensor error: Discon- SEN02268-01
WA800, WA900-3E0 35
SEN02268-01 Failure code [DHU3KX] (Rear brake oil pressure sensor error: Disconnection
Failure code [DHU3KX] (Rear brake oil pressure sensor error:

Action code Failure code Rear brake oil pressure sensor error: Disconnection or short circuit
Trouble
– DHU3KX (VHMS controller system)
Contents of
• Rear brake oil pressure signal cannot be acquired.
trouble
Action of
controller
Problem that
machine
• 5 V power supply: Refer to failure code [DBB5KP].
Related
• Rear brake oil pressure can be checked with monitoring code 91905 (MPa).
information
• Failure code for front brake oil pressure sensor error: [DHU2KX]

1
2
harness
harness.
Possible causes Voltage 0.5 – 4.5 V
and standard
value in normal
state with starting switch OFF.
Resis-
harness (Disconnection or Between VC01 (female) (4) – V23 (B) Max. 1 z
4 tance
connector) Resis-
tance
Resis-
tance
Min. 1 Mz
Min. 1 Mz
ground tance
36 WA800, WA900-3E0
Failure code [DHU3KX] (Rear brake oil pressure sensor error: Discon- SEN02268-01
WA800, WA900-3E0 37
SEN02268-01 Failure code [DK00L8] (or TM & AJSS controller LED display [58], steering
steering and frame angle displacement) 1
Action code Failure code Steering and frame angle displacement
Trouble
E00 DK00L8 (Transmission & AJSS controller system)
Contents of • Signal from steering angle potentiometer (lever angle sensor) and frame angle potentiometer
trouble (frame angle sensor) are abnormal.
Action of
• Turns steering basic pressure control EPC solenoid output OFF.
controller
Problem that
appears on • Effective steering speed is different to the left and right.
machine
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure codes [DK30KX] and [DKD0KX].
state
38 WA800, WA900-3E0
Failure code [DK00L8] (or TM & AJSS controller LED display [58], SEN02268-01
WA800, WA900-3E0 39
SEN02268-01 Failure code [DK30KX] (or TM & AJSS controller LED display [57], abnormal-
abnormality in steering angle potentiometer system): Disconnection or
short circuit) 1
Action code Failure code Abnormality in steering angle potentiometer system: Disconnection
Trouble or short circuit
E00 DK30KX (Transmission & AJSS controller system)
Contents of
• Steering angle potentiometer (lever angle sensor) is abnormal: Disconnection or short circuit
trouble
Action of • Turns steering basic pressure control EPC solenoid output OFF.
controller • Controls on the frame angle sensor signal voltage as the input voltage.
Problem that
machine

When mounting position is corrected, the failure code disappears
(center misalignment).
1) Start engine.
2) Turn the steering wheel fully to the left end and stop engine.
Defective steering angle
4) Disconnect S30 and carry out troubleshooting.
1 potentiometer (lever angle
5) Similarly, turn the steering fully to the right and carry out trouble-
sensor) shooting.
Between (A) and (B) of potentiometer (lever Resis- 0 – 5 kz
angle sensor) S30 (male) tance variation
Between (B) and (C) of potentiometer (lever Resis-
5 kz
angle sensor) S30 (male) tance
2) Disconnect C3A and L27.
2 Resis-
defective contact in Between C3A (female) (7) – (16) 5 kz
tance
connector)
Resis-
Between C3A (female) (3) – (16) 0 – 5 kz
value in normal Ground fault in wiring 2) Disconnect C3A.
state 3 harness (Contact with 3) Turn starting switch ON and carry out troubleshooting.
ground circuit) Between C3A (female) (3) and chassis Resis-
Min. 1 Mz
ground tance
2) Disconnect S30.
Reference 3) Turn the starting switch ON (without starting the engine) and carry
Hot short circuit in wiring out troubleshooting.
4
harness (Contact with Between S30 (female) (A) and chassis
Voltage Max. 1 V
power supply circuit) ground
Between S30 (female) (C) and chassis
Voltage Max. 1 V
ground
2) Disconnect C3A and insert T-branch.
3) Start engine.
4) Turn the steering wheel fully to the left end.
Defective transmission &
5 5) Stop engine and carry on troubleshooting with starting switch ON.
AJSS controller
shooting.
0.5 – 4.5 V
Between C3A (3) – (16) Voltage
variation
40 WA800, WA900-3E0
Failure code [DK30KX] (or TM & AJSS controller LED display [57], ab- SEN02268-01
WA800, WA900-3E0 41
SEN02268-01 Failure code [DKD0KX] (or TM & AJSS controller LED display [59], abnormal-
abnormality in frame angle potentiometer system: Disconnection or
short circuit) 1
Action code Failure code Abnormality in frame angle potentiometer system: Disconnection or
Trouble short circuit
E00 DKD0KX (Transmission & AJSS controller system)
Contents of
• Frame angle potentiometer (frame angle sensor) is abnormal: Disconnection or short circuit
trouble
Action of • Turns steering basic pressure control EPC solenoid output OFF.
controller • Controls on the steering angle sensor signal voltage as the input voltage.
Problem that
machine
information • Failure code is transmitted to engine service monitor via VHMS controller.

When mounting position is corrected, the failure code disappears
(center misalignment).
1) Start engine.
2) Turn the steering wheel fully to the left end and stop engine.
Defective frame angle
1 potentiometer (frame
angle sensor) shooting.
Between (A) and (B) of potentiometer (frame Resis- 0 – 5 kz
angle sensor) L27 (male) tance variation
Between (B) and (C) of potentiometer (frame Resis-
5 kz
angle sensor) L27 (male) tance
2) Disconnect C3A and S30.
2 Resis-
defective contact in Between C3A (female) (7) – (16) 5 kz
tance
connector)
Resis-
Between C3A (female) (13) – (16) 0 – 5 kz
value in normal Ground fault in wiring 2) Disconnect C3A.
state 3 harness (Contact with 3) Turn starting switch ON and carry out troubleshooting.
ground circuit) Between C3A (female) (13) and chassis Resis-
Min. 1 Mz
ground tance
2) Disconnect L27.
Reference 3) Turn the starting switch ON (without starting the engine) and carry
Hot short circuit in wiring out troubleshooting.
4
harness (Contact with Between L27 (female) (A) and chassis
Voltage Max. 1 V
Between L27 (female) (C) and chassis
Voltage Max. 1 V
ground
2) Disconnect C3A and insert T-branch.
3) Start engine.
4) Turn the steering wheel fully to the left end.
5 5) Stop engine and carry on troubleshooting with starting switch ON.
AJSS controller
shooting.
0.5 – 4.5 V
Between C3A (13) – (16) Voltage
variation
42 WA800, WA900-3E0
Failure code [DKD0KX] (or TM & AJSS controller LED display [59], ab- SEN02268-01
WA800, WA900-3E0 43
SEN02268-01 Failure code [DLE4KA] (or TM & AJSS controller LED display [23], abnormal-
Failure code [DLE4KA] (or TM & AJSS controller LED display [23],
abnormality in engine speed sensor system: Disconnection, short
circuit or hot short circuit) 1
Action code Failure code Abnormality in engine speed sensor system: Disconnection, short
Trouble circuit or hot short circuit
E00 DLE4KA (Transmission & AJSS controller system)
Contents of
• Auto shift is disabled.
trouble
Action of
• Selects the manual shift mode.
controller
Problem that
appears on • Gear shift by shift lever operation
machine

Defective engine speed 2) Disconnect E03 and carry out troubleshooting.
1
sensor Resis- 100 – 500 z
Between E03 (female) (1) – (2)
tance (Coil resistance)
2) Disconnect C4.
harness (Disconnection or 3) Turn starting switch ON and carry out troubleshooting.
2
connector) Resis- 100 – 500 z
2) Disconnect C4, C5, L07, E03 and BC01.
Ground fault in wiring 3) Turn starting switch OFF and carry out troubleshooting.
3 harness (Contact with Between C4 (female) (2) – E03 (1) and chas- Resis-
Min. 1 Mz
Possible causes ground circuit) sis ground tance
and standard Between C4 (female) (9) – E03 (2) and chas- Resis-
value in normal Min. 1 Mz
sis ground tance
state 1) Turn starting switch OFF.
2) Disconnect E03 and BC01.
Hot short circuit in wiring 3) Turn starting switch ON and carry out troubleshooting.
4 harness (Contact with Between C4 (female) (2) – E03 (1) and chas-
Voltage Max. 1 V
power supply circuit) sis ground
Between C4 (female) (9) – E03 (2) and chas-
Voltage Max. 1 V
sis ground
2) Disconnect C4 and insert T-branch.
3) Start engine.
Defective transmission & 4) Change idling speed and carry out troubleshooting.
5
AJSS controller Min. 0.5 V
variation
Between C4 (2) – (9) Voltage
with idle
speed
44 WA800, WA900-3E0
Failure code [DLE4KA] (or TM & AJSS controller LED display [23], ab- SEN02268-01
WA800, WA900-3E0 45
SEN02268-01 Failure code [DLT4KA] (or TM & AJSS controller LED display [22], abnormal-
Failure code [DLT4KA] (or TM & AJSS controller LED display [22],
abnormality in speed sensor system: Disconnection, short circuit or hot
short circuit) 1
Action code Failure code Abnormality in speed sensor system: Disconnection, short circuit or
Trouble hot short circuit)
E00 DLT4KA (Transmission & AJSS controller system)
Contents of
• Auto shift is disabled.
trouble
Action of
• Selects the manual shift mode.
controller
Problem that
appears on • Gear shift by shift lever operation
machine

2) Disconnect BC01 and carry out troubleshooting.
1 Defective speed sensor
Resis- 100 – 500 z
Between BC01 (male) (1) – (2)
2) Disconnect C5.
harness (Disconnection or 3) Turn starting switch ON and carry out troubleshooting.
2
connector) Resis- 100 – 500 z
2) Disconnect C4, C5, L07, E03 and BC01.
Ground fault in wiring 3) Turn starting switch OFF and carry out troubleshooting.
Possible causes 3 harness (Contact with Between C5 (female) (1) – BC01 (2) and Resis-
Min. 1 Mz
and standard ground circuit) chassis ground tance
value in normal Between C5 (female) (2) – BC01 (1) and Resis-
state Min. 1 Mz
4 harness (Contact with Between C5 (female) (1) – BC01 (2) and
Voltage Max. 1 V
power supply circuit) chassis ground
Between C5 (female) (2) – BC01 (1) and
Voltage Max. 1 V
chassis ground
Defective transmission & 3) Start engine.
5
AJSS controller 4) Drive machine and carry out troubleshooting.
a Caution – collision
Between C5 (2) – (1) Voltage Min. 0.5 V
46 WA800, WA900-3E0
Failure code [DLT4KA] (or TM & AJSS controller LED display [22], ab- SEN02268-01
WA800, WA900-3E0 47
SEN02268-01 Failure code [DUM7KY] (Pre-lubrication operation lamp output abnormality:
Failure code [DUM7KY] (Pre-lubrication operation lamp output

abnormality: Hot short circuit) 1
Action code Failure code Pre-lubrication operation lamp output abnormality: Hot short circuit
Trouble
E01 DUM7KY (Pre-lubrication controller system)
Contents of • Pre-lubrication controller shows abnormality at operation lamp output: Hot short circuit is detected.
trouble (PRE6 (17) pin voltage: Min. 5.7 V)
Action of
• Pre-lubrication controller stops output to operation lamp.
controller
Problem that
appears on • Pre-lubrication operation lamp does not light up.
machine
Related • The output state of the pre-lubrication operation lamp can be checked with the monitoring code
information 40975, "D-00T-15" (1: ON, 0: OFF).

2) Disconnect PRE4 and PRE5, then carry out troubleshooting.
a Measure in diode range.
1 Between connectors PRE4 (male) (+) and
lamp Continuity Yes
PRE5 (male) (–)
Between connectors PRE5 (male) (+) and
Continuity None
PRE4 (male) (–)
Possible causes
and standard
value in normal Between connectors PRE6 (female) (17) – Resis-
Min. 1 Mz
state (30) tance
Hot short circuit of wiring
2 harness (Contact with 1) Turn starting switch OFF.
power supply circuit) 2) Disconnect connector PRE4.
3) Connect T-branch to connector PRE6 (female).
Voltage Max. 1 V
ground
controller
ried out.)
48 WA800, WA900-3E0
Failure code [DUM7KZ] (Pre-lubrication operation lamp output abnor- SEN02268-01
Failure code [DUM7KZ] (Pre-lubrication operation lamp output

abnormality: Disconnection or grounding fault) 1
Action code Failure code Pre-lubrication operation lamp output abnormality: Disconnection or
Trouble grounding fault)
E01 DUM7KZ
(Pre-lubrication controller system)
• Pre-lubrication controller shows abnormality when the operation lamp does not output: Disconnec-
Contents of
tion and/or grounding fault is detected.
trouble
(PRE6 (17) pin voltage: Max. 5.7 V for 3 seconds)
Action of
• Pre-lubrication controller stops output to operation lamp.
controller
Problem that
appears on • Pre-lubrication operation lamp does not light up or remains lit.
machine
Related • The output state of the pre-lubrication operation lamp can be checked with the monitoring code
information 40975, "D-00T-15" (1: ON, 0: OFF).

a Measure in diode range.
1 Between connectors PRE4 (male) (+) and
lamp Continuity Yes
PRE5 (male) (–)
Between connectors PRE5 (male) (+) and
Continuity None
PRE4 (male) (–)
Disconnection in wiring 1) Turn starting switch OFF.
Possible causes harness (Disconnection or 2) Disconnect PRE6 and PRE5, then carry out troubleshooting.
2
and standard defective contact in Between connectors PRE6 (female) (17) – Resis-
Max. 1 z
value in normal connector) PRE5 tance
state 1) Turn starting switch OFF.
2) Disconnect PRE4, PRE5 and PRE6, then carry out troubleshoot-
Grounding fault in wiring ing.
3 harness (Contact with Between PRE6 (female) (17) and chassis Resis-
Min. 1 Mz
Resis-
Between PRE5 (male) and chassis ground Min. 1 Mz
tance
controller
ried out.)
WA800, WA900-3E0 49
SEN02268-01 Failure code [DUM7KZ] (Pre-lubrication operation lamp output abnormality:
50 WA800, WA900-3E0
Failure code [DXF0KZ] (or TM & AJSS controller LED display [63], ab- SEN02268-01
Failure code [DXF0KZ] (or TM & AJSS controller LED display [63],
abnormality in joystick EPC solenoid system: Disconnection, short
circuit or hot short circuit) 1
Action code Failure code Abnormality in joystick EPC solenoid system: Disconnection, short
Trouble circuit or hot short circuit)
E00 DXF0KZ (Transmission & AJSS controller system)
Contents of
• Joystick EPC solenoid cannot be controlled.
trouble
Action of
• Turns output from joystick EPC solenoid OFF.
controller
Problem that
• Steering lever response becomes dull or sensitive.
appears on
• Steering speed becomes slower or quicker.
machine

2) Disconnect L26.
Defective joystick EPC 3) Turn starting switch OFF and carry out troubleshooting.
1
solenoid
Resis-
Between L26 (female) (1) – (2) About 12 z
tance
Disconnection in wiring 2) Disconnect C2.
2 3) Turn starting switch OFF and carry out troubleshooting.
Resis- About 12 z
connector) Between C2 (female) (7) – (17)
tance (solenoid resistance)
Possible causes 1) Turn starting switch OFF.
and standard Ground fault in wiring 2) Disconnect C2.
value in normal 3 harness (Contact with 3) Turn starting switch OFF and carry out troubleshooting.
state ground circuit) Between C2 (female) (7) – (17) and chassis Resis-
Min. 1 Mz
ground tance
2) Disconnect L26.
4 harness (Contact with Between L26 (female) (1) and chassis
Voltage Max. 1 V
Between L26 (female) (2) and chassis
Voltage Max. 1 V
ground
If causes 1-4 are not detected, the transmission & AJSS controller
5 may be defective. (Since trouble is in system, troubleshooting can-
AJSS controller
not be carried out.)
WA800, WA900-3E0 51
SEN02268-01 Failure code [DXH4KZ] (or TM & AJSS controller LED display [14], abnormal-
abnormality in 1st solenoid system: Disconnection, short circuit or hot
short circuit) 1
Action code Failure code Abnormality in 1st solenoid system: Disconnection, short circuit or
Trouble hot short circuit
CALL DXH4KZ (Transmission & AJSS controller system)
Contents of
• 1st solenoid is abnormal (disabled to turn ON or OFF).
trouble
Action of
• Neutral (F, R, 1, 2, 3 speed solenoid output: OFF)
controller
Problem that
machine

2) Disconnect T01 and carry out troubleshooting.
1 Defective 1st solenoid
Resis- 50 – 70 z
Between T01 (H) – (B)
2) Disconnect C1.
2 Resis- 50 – 70 z
defective contact in Between C1 (female) (3) – (6)
connector)
Between C1 (female) (6), (12) Resis-
Max. 1 z
and chassis ground (R11) tance
Possible causes
Ground fault in wiring 2) Disconnect C1 and T01.
value in normal
state 3 harness (Contact with 3) Turn starting switch OFF and carry out troubleshooting.
tance
Hot short circuit in wiring 2) Disconnect C1 and T01.
4 harness (Contact with 3) Turn the starting switch ON (without starting the engine) and carry
power supply circuit) out troubleshooting.
Between C1 (female) (3) – (6) Voltage Max. 1 V
Defective transmission & 3) Turn the starting switch ON (without starting the engine) and carry
5
AJSS controller
Between C1 (3) – (6) Voltage Max. 1 V
52 WA800, WA900-3E0
Failure code [DXH4KZ] (or TM & AJSS controller LED display [14], ab- SEN02268-01
WA800, WA900-3E0 53
abnormality in 2nd solenoid system: Disconnection, short circuit or hot
short circuit) 1
Action code Failure code Abnormality in 2nd solenoid system: Disconnection, short circuit or
Trouble hot short circuit)
Contents of
• 2nd solenoid is abnormal (disabled to turn ON or OFF).
trouble
Action of
controller
Problem that
machine

1 Defective 2nd solenoid
Resis- 50 – 70 z
Between T01 (G) – (B)
2) Disconnect C1.
2 Resis- 50 – 70 z
connector)
Max. 1 z
Possible causes
value in normal
tance
5
AJSS controller
54 WA800, WA900-3E0
WA800, WA900-3E0 55
abnormality in 3rd solenoid system: Disconnection, short circuit or hot
short circuit) 1
Action code Failure code Abnormality in 3rd solenoid system: Disconnection, short circuit or
Trouble hot short circuit
Contents of
• 3rd solenoid is abnormal (disabled to turn ON or OFF).
trouble
Action of
controller
Problem that
machine

1 Defective 3rd solenoid
Resis- 50 – 70 z
Between T01 (F) – (B)
2) Disconnect C1.
2 Resis- 550 – 70 z
connector)
Max. 1 z
Possible causes
value in normal
tance
5
AJSS controller
56 WA800, WA900-3E0
WA800, WA900-3E0 57
abnormality in R solenoid system: Disconnection, short circuit or hot
short circuit) 1
Action code Failure code Abnormality in R solenoid system error: Disconnection, short circuit
Trouble or hot short circuit
Contents of
• R solenoid is abnormal (disabled to turn ON or OFF).
trouble
Action of
controller
Problem that
machine

1 Defective R solenoid
Resis- 50 – 70 z
Between T01 (C) – (A)
2) Disconnect C1.
2 Resis- 50 – 70 z
connector)
Max. 1 z
Possible causes
value in normal
tance
5
AJSS controller
58 WA800, WA900-3E0
WA800, WA900-3E0 59
abnormality in F solenoid system: Disconnection, short circuit or hot
short circuit) 1
Action code Failure code Abnormality in F solenoid system: Disconnection, short circuit or hot
Trouble short circuit
Contents of
• F solenoid is abnormal (disabled to turn ON or OFF).
trouble
Action of
controller
Problem that
machine

1 Defective F solenoid
Resis- 50 – 70 z
Between T01 (D) – (A)
2) Disconnect C1.
2 Resis- 50 – 70 z
connector)
Max. 1 z
Possible causes
value in normal
tance
5
AJSS controller
60 WA800, WA900-3E0
WA800, WA900-3E0 61
SEN02268-01 Failure code [F@BBZL] (or VHMS LED display: "n3" o "38", Blow-by pres-
Failure code [F@BBZL] (or VHMS LED display: "n3" o "38", Blow-by
pressure sensor system: High pressure error) 1
Action code Failure code Blow-by pressure sensor system: High pressure error
Trouble
– F@BBZL (VHMS controller system)
Contents of
• Blow-by pressure sensor signal circuit detects pressure of 7.07 kPa.
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
Related • Blow-by pressure can be checked with monitoring code 42800 (kPa).
information • The LED of the VHMS controller displays "n3" o "38".

Abnormal rise of blow-by
Possible causes
1 pressure (when the Check the engine for abnormality. Correct, if any.
and standard system is normal)
value in normal
state Defective blow-by
2 Carry out troubleshooting for failure codes [DHE5KB] and
pressure sensor system
[DHE5KY].
62 WA800, WA900-3E0
Failure code [F@BYNR] (or VHMS LED display: "n3" o "62", L.H. front SEN02268-01
Failure code [F@BYNR] (or VHMS LED display: "n3" o "62", L.H. front
exhaust gas temperature sensor (2): Abnormal rise of exhaust gas
temperature) 1
Action code Failure code L.H. front exhaust gas temperature sensor (2): Abnormal rise of
Trouble exhaust gas temperature
– F@BYNR (VHMS controller system)
• Signal circuit of the L.H. front exhaust gas temperature sensor detects exhaust gas temperature
Contents of rise beyond the limit line 2 for 10 seconds.
trouble (Exhaust gas temperature limit line 2: Straight line between 750°C at rated output speed at mini-
mum and 800°C at max. torque speed at maximum)
Action of
controller
Problem that
machine
Related • L.H. front exhaust gas temperature can be checked with monitoring code: 42601 (°C).

Abnormal rise of L.H. front
exhaust gas temperature
Possible causes 1 Check the engine for abnormality. Correct, if any.
(when the system is
and standard normal)
value in normal
state Defective L.H. front
2 exhaust gas temperature Carry out troubleshooting for failure codes [DGT5KA] and
sensor system [DGT5KB].
Failure code [f@BYNR] (or VHMS LED display: "n3" o "72", L.H. rear
temperature) 1
Action code Failure code L.H. rear exhaust gas temperature sensor (2): Abnormal rise of
– f@BYNR (VHMS controller system)
• Signal circuit of the L.H. rear exhaust gas temperature sensor detects exhaust gas temperature
Action of
controller
Problem that
machine
Related • L.H. rear exhaust gas temperature can be checked with monitoring code: 42609 (°C).

Abnormal rise of L.H. rear
(when the system is
and standard
normal)
value in normal
Defective L.H. rear
state
2 exhaust gas temperature Carry out troubleshooting for failure codes [dGT5KA] and
sensor system [dGT5KB].
WA800, WA900-3E0 63
SEN02268-01 Failure code [F@BYNS] (or VHMS LED display: "n3" o "61", L.H. front ex-
Failure code [F@BYNS] (or VHMS LED display: "n3" o "61", L.H. front
temperature) 1
Action code Failure code L.H. front exhaust gas temperature sensor (1): Abnormal rise of
– F@BYNS (VHMS controller system)
• Signal circuit of the L.H. front exhaust gas temperature sensor detects exhaust gas temperature
Action of
controller
Problem that
machine
Related • L.H. front exhaust gas temperature can be checked with monitoring code: 42601 (°C).

Abnormal rise of L.H. front
Possible causes 1 exhaust gas temperature Check the engine for abnormality. Correct, if any.
and standard (when system is normal)
value in normal Defective L.H. front
state 2 exhaust gas temperature Carry out troubleshooting for failure codes [DGT5KA] and
Failure code [f@BYNS] (or VHMS LED display: "n3" o "71", L.H. rear
temperature) 1
Action code Failure code L.H. rear exhaust gas temperature sensor (1): Abnormal rise of
– f@BYNS
• Signal circuit of the L.H. rear exhaust gas temperature sensor detects exhaust gas temperature
Action of
controller
Problem that
machine
Related • L.H. rear exhaust gas temperature can be checked with monitoring code: 42609 (°C).

Abnormal rise of L.H. rear
value in normal Defective L.H. rear
state 2 exhaust gas temperature Carry out troubleshooting for failure codes [dGT5KA] and
64 WA800, WA900-3E0
Failure code [F@BZNR] (or VHMS LED display: "n3" o "82", R.H. front SEN02268-01
Failure code [F@BZNR] (or VHMS LED display: "n3" o "82", R.H. front
temperature) 1
Action code Failure code R.H. front exhaust gas temperature sensor (2): Abnormal rise of
– F@BZNR (VHMS controller system)
• Signal circuit of the R.H. front exhaust gas temperature sensor detects exhaust gas temperature
Action of
controller
Problem that
machine
Related • R.H. front exhaust gas temperature can be checked with monitoring code: 42600 (°C).

Abnormal rise of R.H. front
(when the system is
value in normal
state Defective R.H. front
Failure code [f@BZNR] (or VHMS LED display: "n3" o "92", R.H. rear
temperature) 1
Action code Failure code R.H. rear exhaust gas temperature sensor (2): Abnormal rise of
– f@BZNR (VHMS controller system)
• Signal circuit of the R.H. rear exhaust gas temperature sensor detects exhaust gas temperature
Action of
controller
Problem that
machine
Related • R.H. rear exhaust gas temperature can be checked with monitoring code: 42608 (°C).

Abnormal rise of R.H. rear
value in normal Defective R.H. rear
WA800, WA900-3E0 65
SEN02268-01 Failure code [F@BZNS] (or VHMS LED display: "n3" o "38", R.H. front ex-
Failure code [F@BZNS] (or VHMS LED display: "n3" o "38", R.H. front
temperature) 1
Action code Failure code R.H. front exhaust gas temperature sensor (1): Abnormal rise of
– F@BZNS (VHMS controller system)
• Signal circuit of the R.H. front exhaust gas temperature sensor detects exhaust gas temperature
Action of
controller
Problem that
machine
Related • R.H. front exhaust gas temperature can be checked with monitoring code: 42600 (°C).

Abnormal rise of R.H. front
(when the system is
value in normal
state Defective R.H. front
Failure code [f@BZNS] (or VHMS LED display: "n3" o "39", R.H. rear
temperature) 1
Action code Failure code R.H. rear exhaust gas temperature sensor (1): Abnormal rise of
– f@BZNS (VHMS controller system)
• Signal circuit of the R.H. rear exhaust gas temperature sensor detects exhaust gas temperature
Action of
controller
Problem that
machine
Related • R.H. rear exhaust gas temperature can be checked with monitoring code: 42608 (°C).

Abnormal rise of R.H. rear
value in normal Defective R.H. rear
66 WA800, WA900-3E0
Failure code [f@BZNS] (or VHMS LED display: "n3" o "39", R.H. rear SEN02268-01
WA800, WA900-3E0 67
SEN02268-01

© 2017 KOMATSU
All Rights Reserved
68
SEN02149-01
WA800-3E0
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
Troubleshooting of electrical system
(E-mode)
E-1 Engine does not start ............................................................................................................................... 4
E-2 Abnormality in preheating system .......................................................................................................... 10
E-3 Transmission and AJSS controller does not work .................................................................................. 16
E-4 Transmission and AJSS controller model selection error....................................................................... 18
E-5 Parking brake does not work (as the emergency brake)........................................................................ 20
E-6 Parking brake is applied while machine is traveling ............................................................................... 24
E-7 Parking brake is released as starting switch is turned ON ..................................................................... 26
E-8 Setting to the neutral position becomes unavailable while the parking brake is in operation
(parking brake operates normally) .......................................................................................................... 28
E-9 Parking brake remains in the neutral and not removable to other position
(when parking brake is not applied)........................................................................................................ 30
E-10 Defective kick-down switch .................................................................................................................. 32
E-11 Defective hold switch ............................................................................................................................ 36
E-12 Lift arm (boom) kick-out is unavailable ................................................................................................. 40
WA800, WA900-3E0 1
E-13 Bucket positioner functional error ......................................................................................................... 42

E-14 Active working functional error ............................................................................................................. 44
E-15 Turn signal or hazard display do not flash ............................................................................................ 50
E-16 Small lamp does not light up ................................................................................................................ 56
E-17 Head lamp does not light up................................................................................................................. 59
E-18 Abnormality in lighting up of front working lamp ................................................................................... 62
E-19 Abnormality in lighting up of rear working lamp.................................................................................... 62
E-20 Abnormality in transmission cut-off....................................................................................................... 62
E-21 Abnormality in low idle selection........................................................................................................... 62
E-22 Abnormality in parking brake dragging warning ................................................................................... 62
E-23 Abnormality in buzzer ........................................................................................................................... 62
2 WA800, WA900-3E0
WA800, WA900-3E0 3
E-1 Engine does not start 1

Contents of
The engine does not start. 1) Starting motor does not run
trouble
• The engine does not start, because the starting motor does not run due to troubles in starting motor
system and starting switch terminal C signal system.
• Check that the joystick lever and forward-reverse travel switch are in "N" position.
• Input state (ON/OFF) from starting switch terminal C to the engine service monitor can be checked
with the monitoring code : 40921, D-IN-0 (1: ON, 0: OFF).
• If failure code: D5ZHL6, DDK3KZ, DDK5KZ, DBG2KK, DBG3KK or D1EHKa is displayed, carry
out troubleshooting for it first.
• Confirm the sounds of battery relay as it is turned on and off, and identify whether the given trouble
lies on and beyond the starting switch BR terminal (battery relay system) or on and beyond the start-
Related ing switch C terminal.
information • Check that the pre-lubrication lamp lights up (if the lamp lights up, the starting motor C terminal signal
has been entered to the pre-lubrication controller through relays L57 and L95.)
(Mechanism is the same as the system without pre-lubrication controller.)
front cover of right console).
2) Connect PRE2 (female) to PRE1 (male).
(Connect the output from relay L95 pin 3 directly to pin 2 of diodes D11 – D14
Refer to the last of cause 18: Circuit diagram: Connection is established between PRE1 (male) (A)
and PRE2 (female) (A).

Specific gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
When circuit breaker CBF1, CBF2 or CBF3 is blocked, slow blow
Defective circuit breaker or
2 fuse (SBF1) or fuse of fuse box 1 (10), (12), (13) or fuse box 2 (6) is
fuse
burnt, the circuit probably has a grounding fault.
Possible
standard value 2) Turn the engine shutdown switch OFF.
in normal state Defective engine shutdown 3) Disconnect CBL1 and carry out troubleshooting with starting
3 switch OFF.
switch
Resis-
Between CBL1 (female) (1) – (2) Max. 1 z
tance
Defective battery relay Turn the starting switch ON-OFF, and if operating sound is heard
4 (Internal disconnection or from battery relay it is normal (on both sides).
short circuit) • Starting switch operation: OFF o ON o OFF
4 WA800, WA900-3E0

2) Disconnect E06 and E07, then connect T-branch.
Starting motor Voltage
Between terminals B
Power supply input 20 – 30 V
and E
Between R terminal
E06 (male) (2) – Battery input Max. 1 V
E terminal
Defective starting motor Between C terminal
5
(Internal defect) E06 (male) (1) – Starting input 20 – 30 V
E terminal
Between R terminal
E07 (male) (2) – Battery input Max. 1 V
E terminal
Between C terminal
E07 (male) (1) – Starting input 20 – 30 V
E terminal
If the starting motor does not run even if power supply input, battery
input and starting input is normal, the starting motor is defective.
2) Disconnect E06 and E07
Defective alternator 3) Set starting switch to ON, OFF and START and carry out trouble-
6 shooting.
(Internal short circuit)
Between alternator R terminal and chassis
Possible Voltage Max. 1 V
ground
causes and
in normal state 2) Disconnect the battery grounding cable and L09
3) Set starting switch to ON, OFF and START and carry out trouble-
shooting.
L09 (male) Position of switch Resistance
7 Defective starting switch
Between (1) – (2) OFF Min. 1 Mz
(between B – BR) ON Max. 1 z
(between (C) – (B)) START Max. 1 z
2) Disconnect D11 – D14
a Carry out troubleshooting in the diode range.
Between (1) (+)
Continuity No
– (2) (–)
D11 – D14 (male)
Between (2) (+)
Continuity Yes
– (1) (–)
2) Disconnect D15 and carry out troubleshooting.
8 Defective diode a Measure in the diode range.
Between D15 (male) (1) (–) Reverse direction:
Continuity
– (2) (+) No continuity
Between D15 (male) (1) (+) Forward direction:
Continuity
– (2) (–) Continue
Between D15 (male) (3) (–) Reverse direction:
Continuity
– (2) (+) No continuity
Between D15 (male) (3) (+) Forward direction:
Continuity
– (2) (–) Continue
WA800, WA900-3E0 5

Defective FNR (directional) a Check whether failure code [DDK3KZ] or transmission and AJSS
9 switch (Internal disconnection controller LED display "20" is displayed. If displayed, carry out
or short circuit) troubleshooting of failure code [DDK3KZ] first.
Defective shift up/down switch a Check whether failure code [DDK5KZ] or transmission and AJSS
10 (Internal disconnection or controller LED display "21" is displayed. If displayed, carry out
short circuit) troubleshooting of failure code [DDK5KZ] first.
L57 (Male) Resistance
Defective neutral safety relay Between (1) – (2) 200 – 400 z
11 (L57) a Prepare with starting switch OFF, then turn starting switch to
(Internal defect) START and carry out troubleshooting.
When neutral safety relay (L57) is replaced with a relay of the same
type, if the condition becomes normal, the neutral safety relay is
defective.
L95 (Male) Resistance
Defective steering lever neu- Between (1) – (2) 200 – 400 z
12 tral safety relay (L95) a Prepare with starting switch OFF, then turn starting switch to
(Internal defect) START and carry out troubleshooting.
When steering lever neutral safety relay (L95) is replaced with a
relay of the same type, if the condition becomes normal, the steer-
Possible ing lever neutral safety relay is defective.
causes and
standard value
in normal state
PER4 (male) Resistance
Defective engine start (PRE4)
Between (1) – (2) 200 – 400 z
(Internal defect)
13 a
a Only when pre-lubrication Prepare with starting switch OFF, then turn starting switch to
controller is equipped START and carry out troubleshooting.
When engine start relay (PRE4) is replaced with a relay of the same
type, if the condition becomes normal, the engine start relay is
defective.
Defective transmission and
Carry out troubleshooting referring to "E-3 transmission and AJSS
14 AJSS controller (power
controller power source system".
source)
Defective pre-lubrication con-
15 Carry out troubleshooting referring to [DBG2KK] and [DBG3KK].
troller (power source)
1) Turn the starting switch off
4) Check that the joystick lever is in the "N" position.
Between C2 (8) and chassis
Voltage Max. 1 V
ground
16 1) Turn the starting switch OFF.
AJSS controller
4) Check that the forward-reverse travel switch is in the "N" position
Between C3B (13) and chassis
Voltage 20 – 30 V
ground
6 WA800, WA900-3E0

4) Set the starting switch to the START position and carry out trou-
Defective pre-lubrication bleshooting
17
controller Input
Between PRE6 (25) – (21) 20 – 30 V
voltage
20 – 30 V
Output
Between PRE6 (29) – (21) (After the pre-lubrica-
voltage
tion lamp is goes out)
2) Disconnect battery grounding cable, battery relay and starting
motor B terminal E06, E07, C2, C3B, D11 – D16, L09, PRE6, L57
and L95.
Between battery RH (+) – battery relay BTR1 Resis-
Max. 1 z
(AR03) terminal – L09 (female) (1) tance
Between battery relay (AR02), (AL02) termi- Resis-
Max. 1 z
nals and chassis ground tance
Between D15 (female) (2) – battery relay Resis-
Max. 1 z
(AR01), (AL01) terminals tance
Between PRE6 (30) – starting motor A and B Resis-
Max. 1 z
(B terminal) tance
Between D15 (female) (3) – alternator R ter- Resis-
Max. 1 z
minal – E06 (female) (2) – E07 (female) (2) tance
Possible
causes and Between D11 (female) (1), D12 (female) (1) Resis-
Max. 1 z
standard value – E07 (female) (1) tance
in normal state Between D13 (female) (1), D14 (female) (1) Resis-
Max. 1 z
– E06 (female) (1) tance
Resis-
Disconnection in wiring Between D15 (female) (1) – L09 (2) Max. 1 z
tance
harness
18 Resis-
(Disconnection or defective Between L09 (3) – L57 (female) (5) Max. 1 z
contact in connector) tance
Resis-
Between L57 (female) (3) – L95 (female) (6) Max. 1 z
tance
Between L57 (female) (2), L95 (female) (2) – Resis-
Max. 1 z
chassis ground (R10) tance
Between L57 (female) (1) – C3B (female) Resis-
Max. 1 z
(13) tance
Resis-
Between L95 (female) (1) – C2 (female) (8) Max. 1 z
tance
Between L95 (female) (3) – PRE6 (female) Resis-
Max. 1 z
(25) – PRE4 (3) tance
Resis-
Between PRE4 (5) – D11 (female) (2) Max. 1 z
tance
Between D11 (female) (2) – D12 (female) (2) Resis-
Max. 1 z
– D13 (female) (2) – D14 (female) (2) tance
Between L95 (female) (3) – D11 (female) (2)
a When pre-lubrication controller is not pro-
Resis-
vided. Max. 1 z
tance
(PRE2 (female) is connected to PRE1
(male).)
WA800, WA900-3E0 7
8 WA800, WA900-3E0
WA800, WA900-3E0 9
E-2 Abnormality in preheating system 1

Contents of • Abnormality in preheating sys- 1) System does not operate preheating nor monitor preheating indi-
trouble tem cation does not light up.
• No preheating when engine coolant temperature is 5°C or above.
• Engine coolant temperature can be checked by monitoring code: 04104 (°C).
• For engine coolant temperature sensor, see failure code [CA144].
Related • Preheating system starts operation when preheat relay L73 is turned ON.
information • Controller that turns preheat relay L73 ON differs by the system type.
1) Without pre-lubrication controller: Engine controller (L bank)
• M-mode: See "M-7 Preheating system error"
2) With pre-lubrication controller: Pre-lubrication controller

Fuse box 1: Fuse (10) and (12) Continuity Yes
2) Disconnect L73 and connect T-branch.
a For primary coil side of the heater relay type L73 with pre-lubrica-
Defective pre-lubrication con- tion controller, see failure codes [D180KA], [D180KB] and
troller, defective engine con- [D180KY].
2
troller L bank or defective 20 – 30 V
harness (preheat-
ing time;
Between L73 (1) – (2) Voltage
several
tens of
seconds)
Defective preheating relay When replace preheat relay L73 with other relay and if the system
3
L73 returns to normal state, preheating relay is defective.
Possible 2) Disconnect L73, FS5 and heater relay terminal E10 and E12,
causes and then carry out troubleshooting.
standard value Disconnection in wiring Wiring harness between FS5 (female) (6) – Resis-
in normal state harness Max. 1 z
4 L73 (female) (3) tance
Resis-
contact in connector) Between L05 (female) (19) – E10 – E12 Max. 1 z
tance
Resis-
Between starting motor B terminal – E11 – E13 Max. 1 z
tance
2) Disconnect L73 and heater relay terminal E10 and E12 and carry
Ground fault in wiring harness out troubleshooting.
5
Min. 1 Mz
E10 – E12 tance
20 – 30 V
6 Defective machine monitor (preheat-
ing time;
Between L05 (female) (19) – (3) Voltage
several
tens of
seconds)
10 WA800, WA900-3E0
Contents of • Abnormality in preheating

2) Monitor display alone comes on.
trouble system
• Engine coolant temperature can be checked with monitoring code: 04104 (°C).
• For engine coolant temperature sensor, refer to failure code [CA144].
• Preheating system starts operation when preheat relay L73 is turned ON.
Related
• Controller that turns preheat relay L73 ON differs by the system type, but the L73 secondary coil side
information
is shared.
• M mode: Refer to "M-7 preheating system error"
1) The preheating lamp of the monitor alone does not light up
2) Preheating is kept operated.)

Heater fuse:
1 Fuse disconnection Continuity Yes
Upper and lower (350A)
Disconnection in wiring Between heater relay terminals
Voltage 20 – 30 V
harness E11, E13 and chassis ground
2
(Disconnection or defective 20 – 30 V
contact in connector) Between heater relay terminals (Preheating duration
Voltage
E10, E12 and chassis ground is few dozens of
Possible
seconds)
causes and
standard value a Prepare with starting switch OFF, then turn starting switch ON
in normal state and carry out troubleshooting.
20 – 30 V
Between electrical intake air
(Preheating duration
heater terminal and chassis Voltage
Defective electrical intake air is few dozens of
3 ground (R side)
heater seconds)
20 – 30 V
Between electrical intake air
(Preheating duration
heater terminal and chassis Voltage
is few dozens of
ground (L side)
seconds)
Defective heater relays LH
4 a When cause 2 is normal but cause 3 is abnormal
and RH
WA800, WA900-3E0 11
Related electrical circuit diagram (with pre-lubrication controller)
12 WA800, WA900-3E0
WA800, WA900-3E0 13
Related electrical circuit diagram (without pre-lubrication controller)
14 WA800, WA900-3E0
WA800, WA900-3E0 15
E-3 Transmission and AJSS controller does not work 1

Contents of
• Transmission and AJSS controller does not work.
trouble
Related • Since maintenance monitor shares the power supply system up to the entrance of the operator's cab,
information check if the machine monitor is working.

2) Disconnect C1 and C2, then connect T-branch.
Defective transmission and 3) Turn starting switch ON and carry out troubleshooting.
AJSS controller
1 Between C1 (female) (7) and
(When power supply pin volt- Voltage 20 – 30 V
(13) – (6)
age is normal)
Between C2 (female) (1) and
Voltage 20 – 30 V
(12) – (11)
Fuse box (2): Fuse (6) Continuity Yes
2 Disconnection of fuse Between SBF1 (R03) – (R04) Continuity Yes
Turn the starting switch ON-OFF, and if operating sound is heard
3 Defective battery relay
Possible from battery relay it is normal.
standard value 2) Disconnect C1 and C2, then carry out troubleshooting.
in normal state
Between C1 (female) (7) – bat- Resis-
Max. 1 z
Disconnection in wiring tery relay BTR2 (R02) tance
harness Between C1 (female) (7), (13) – Resis-
4 Max. 1 z
(Disconnection or defective C2 (female) (1), (12) tance
contact in connector) Between C1 (female) (6), (12) – Resis-
Max. 1 z
C2 (female) (11), (21) tance
Between C1 (female) (6) and Resis-
Max. 1 z
Ground fault in wiring harness 2) Disconnect C1 and C2, then carry out troubleshooting.
5 (Short circuit with ground Between C1 (female) (7), (13) –
circuit) Resis-
C2 (female) (1), (12) – chassis Min. 1 Mz
tance
ground
16 WA800, WA900-3E0
WA800, WA900-3E0 17
E-4 Transmission and AJSS controller model selection error 1

Contents of
• Transmission and AJSS controller model selection error
trouble
Related
information

Disconnection in wiring 1) Turn the starting switch OFF.
Possible harness 2) Disconnect C1 and C3B, then carry out troubleshooting.
1
causes and (Disconnection or defective Between C1 (female) (6), (12) – C3B (2), (3), Resis-
standard value contact in connector) Max. 1 z
(10) tance
in normal state
If cause 1 is not detected, transmission and AJSS controller may be
AJSS controller
carried out.)
18 WA800, WA900-3E0
WA800, WA900-3E0 19
E-5 Parking brake does not work (as the emergency brake) 1
Contents of 1) Parking brake does not work by turning the parking brake switch
• Parking brake does not work.
trouble ON.
Related
• The parking brake can work when the voltage (24 V) is not applied to the parking brake solenoid.
information

2) Disconnect L01.
3) Start the engine to charge the accumulator and carry out trouble-
1 Defective parking brake switch shooting
If the parking brake works in this state, the parking brake switch is
defective.
Possible 1) Turn the starting switch OFF.
causes and 2) Disconnect F11.
standard value Defective parking brake 3) Start the engine and carry out troubleshooting.
2
in normal state (solenoid)
If the parking brake does not work in this state, the parking brake
(solenoid) is defective.
2) Disconnect L01.
Hot short circuit in wiring 3) Start the engine to charge the accumulator and carry out trouble-
3 harness (Contact with power shooting
supply circuit)
Between L01 (female) (C) – FL1 (17) – F11
Voltage Max. 1 V
(1) and chassis ground
20 WA800, WA900-3E0
WA800, WA900-3E0 21
Contents of 2) If the brake pressure (accumulator pressure) goes low, the park-
• Parking brake does not work.
trouble ing brake does not work as the emergency brake.
Related • Relay L59 is turned on during travel, thereby applying the voltage (24 V) to C pin of L01.
information • If any of the emergency brake switches (SW1 – 4) is turned off due to low oil pressure, the parking
brake starts working.

2) Disconnect CBL1 and connect T-branch.
Short circuit between wiring 3) Disconnect BC8, BC9, BC10 and C11, then carry out trouble-
1 shooting.
harnesses
Resis-
Between CBL1 (female) (3) – (4) Min. 1 Mz
tance
causes and 2) Disconnect CBL1 and connect T-branch.
standard value Defective emergency brake 3) Step the brake pedal more than 30 times to drain the oil charged
in normal state 2 in accumulator, and carry out troubleshooting.
switch (all of 4 switches)
Resis-
Between CBL1 (3) – (4) Min. 1 Mz
tance
2) Disconnect F11.
Defective parking brake 3) Start the engine and carry out troubleshooting.
3
(solenoid)
If the parking brake does not work in this state, the parking brake
(solenoid) is defective.
22 WA800, WA900-3E0
WA800, WA900-3E0 23
E-6 Parking brake is applied while machine is traveling 1

Contents of
• Parking brake is applied while machine is traveling.
trouble
Related
• Relay L59 is turned on during travel, thereby applying the voltage (24 V) to C pin of L01 –1 pin of F11
information
(when normal).

2) Disconnect L01, turn on and off the parking brake switch and
Resis-
ON Between L01 (male) (A) – (B) Max. 1 z
tance
1 Defective parking brake switch Resis-
ON Between L01 (male) (B) – (C) Min. 1 Mz
tance
Resis-
OFF Between L01 (male) (A) – (B) Min. 1 Mz
tance
Resis-
OFF Between L01 (male) (B) – (C) Max. 1 z
tance
When replace parking brake safety relay L59 with other relay and if
Defective parking brake safety
2 the system returns to normal state, parking brake safety relay is
relay L59
defective.
2) Disconnect BC8, BC9, BC10 and BC11, then connect the short
Defective emergency brake connector to each of above (in place of emergency brake switch).
3 switch 3) Start the engine to charge the accumulator and carry out trouble-
(Any of 4 switches) shooting.
If system becomes normal, emergency brake switch is defective.

causes and Defective parking brake (sole- 2) Disconnect F11 and connect T-branch.
4 3) Start the engine and carry out troubleshooting.
standard value noid)
in normal state Between F11 (1) – (2) Voltage 20 – 30 V
2) Disconnect L01, L59, L58, F11, BC8, BC9, BC10, BC11 and FS2,
then carry out troubleshooting.
Between F11 (female) (2) and chassis Resis-
Max. 1 z
ground (F10) tance
Between F11 (female) (1) – BC08 (female) Resis-
Max. 1 z
(1) tance
Between BC08 (female) (2) – BC09 (female) Resis-
Max. 1 z
(1) tance
Disconnection in wiring Between BC09 (female) (2) – BC10 (female) Resis-
harness Max. 1 z
5 (1) tance
(1) tance
Between BC11 (female) (2) – L01 (female) Resis-
Max. 1 z
(C) tance
Between L01 (female) (B) – L59 (female) (1), Resis-
Max. 1 z
(3) tance
Between L59 (female) (5) – L01 (A) – FS2 Resis-
Max. 1 z
(7) tance
Between L59 (female) (2) and chassis Resis-
Max. 1 z
ground (R10) tance
24 WA800, WA900-3E0
WA800, WA900-3E0 25
E-7 Parking brake is released as starting switch is turned ON 1

Contents of
• Parking brake is released as starting switch is turned ON.
trouble
Related
• Since the parking brake switch is turned off during travel, the voltage (24 V) is applied to C pin of L01
information
–1 pin of F11 (when normal).

2) Disconnect L01.
3) Start the engine to charge the accumulator and carry out trouble-
1 Defective parking brake switch shooting.
If the parking brake works in this state, the parking brake switch is
Possible defective.
causes and When replace parking brake safety relay L59 with other relay and if
standard value Defective parking brake safety
2 the system returns to normal state, parking brake safety relay is
in normal state relay L59
defective.
2) Disconnect L01.
Hot short circuit in wiring 3) Start the engine to charge the accumulator and carry out trouble-
3 harness (Contact with power shooting.
supply circuit)
Between L01 (female) (C) – FL1 (17) – F11
Voltage Max. 1 V
26 WA800, WA900-3E0
WA800, WA900-3E0 27
E-8 Setting to the neutral position becomes unavailable while the

parking brake is in operation (parking brake operates normally) 1
Contents of • Setting to the neutral position is unavailable.
trouble (However, parking brake works normally.)
Related
• The parking brake is turned on during travel, thereby applying the voltage (24 V) to C pin of L01 – 1
information
pin of F11 (when normal).

Defective neutralizer relay If system returns to normal state when neutralizer L58 is removed,
1
(L58) the neutralizer relay is defective.
Possible
Hot short circuit in wiring 2) Disconnect L58.
causes and
2 harness (Contact with power 3) Turn starting switch ON and carry out troubleshooting.
standard value
in normal state supply circuit) Between L58 (female) (3) – (2) (chassis
Voltage Max. 1 V
ground)
If causes 1 and 2 are not detected, transmission and AJSS control-
3 ler may be defective. (Since trouble is in system, troubleshooting
AJSS controller
cannot be carried out.)
28 WA800, WA900-3E0
WA800, WA900-3E0 29
E-9 Parking brake remains in the neutral and not removable to other
position (when parking brake is not applied) 1
Contents of • Parking brake remains in the neutral and not removable to other position (when parking brake is not
trouble applied).
• The parking brake can be released when the voltage (24 V) is applied to the parking brake solenoid.
• When the parking brake is released, the voltage (24 V) is applied across L01 C pin – 1 pin of F11
Related
(when normal state). By the ON state of relay L58 at this time 14 pin of C3B becomes 24V (when nor-
information
mal state).
• For the forward-reverse travel switch, refer to failure code [DDK3KZ].

Defective neutralizer relay When replace neutralizer relay L58 with other relay and if the sys-
1
(L58) tem returns to normal state, neutralizer relay is defective.
2) Disconnect C3A and connect T-branch.
Between C3A (6) and chassis ground Voltage 20 – 30 V
Defective transmission and 1) Turn the starting switch OFF.

2 2) Disconnect C3B and connect T-branch.
AJSS controller
3) For the safety's sake, disconnect F11 so that the parking brake
may not be electrically released.
Possible 4) Start the engine to charge the accumulator.
causes and 5) Turn the parking switch OFF and carry out troubleshooting.
standard value
Between C3B (14) and chassis ground Voltage 20 – 30 V
in normal state
2) Disconnect L58, L01, C3A and C3B, then carry out troubleshoot-
ing.
ground (R10) tance
harness
3 Resis-
(Disconnection or defective Between L58 (female) (1) – L01 (female) (C) Max. 1 z
tance
Between L58 (female) (3) – C3B (female) Resis-
Max. 1 z
(14) tance
Resis-
Between L58 (female) (5) – C3A (female) (6) Max. 1 z
tance
30 WA800, WA900-3E0
WA800, WA900-3E0 31
E-10 Defective kick-down switch 1

Contents of
• Defective kick-down switch 1) Defective operation
trouble
Related • For an error in AJSS shift up/down switch, refer to failure code [DDK5KZ].
information • For an error in forward-reverse travel switch, refer to failure code [DDK3KZ].

2) Disconnect L15, turn on and off the kick down switch and carry
1 Defective kick-down switch Resis-
ON Between L15 (male) (1) – (2) Max. 1 z
tance
Resis-
OFF Between L15 (male) (1) – (2) Min. 1 Mz
tance
2 Defective machine monitor
Between L08 (male) (2), (4) and chassis Resis-
Possible Max. 1 z
ground tance
causes and
in normal state 2) Disconnect C5, turn on and off the kick down switch and carry out
troubleshooting.
3 Between C5 (female) (5) and Resis-
AJSS controller ON Max. 1 z
OFF Min. 1 Mz
Disconnection in wiring 2) Disconnect L08, C5 and L15, then carry out troubleshooting.
harness Resis-
4 Between C5 (female) (5) – L15 (female) (1) Max. 1 z
(Disconnection or defective tance
contact in connector) Between L08 (female) (2), (4) – L15 (female) Resis-
Max. 1 z
(2) tance
32 WA800, WA900-3E0
WA800, WA900-3E0 33
Contents of
• Malfunctioning of kick-down switch 2) Releasing operation is unavailable.
trouble

2) Disconnect L15, turn on and off the kick down switch and carry
1 Defective kick-down switch Resis-
ON Between 15 (male) (1) – (2) Max. 1 z
tance
Resis-
tance
Max. 1 z
ground tance
Possible
causes and
2) Disconnect C5, turn on and off the kick down switch and carry out
standard value
troubleshooting.
in normal state Defective transmission and
OFF Min. 1 Mz
Ground fault in wiring harness 2) Disconnect L08, C5 and L15, then carry out troubleshooting.
4 (Short circuit with ground
circuit) Wiring harness between C5 (female) (5) – Resis-
Min. 1 Mz
L15 (female) (1) and chassis ground tance
Short circuit between wiring 2) Disconnect L08, C5 and L15, then carry out troubleshooting.
5
harnesses Resis-
Between L15 (female) (1) – (2) Min. 1 Mz
tance
34 WA800, WA900-3E0
WA800, WA900-3E0 35
E-11 Defective hold switch 1

Contents of
• Defective hold switch 1) Defective operation
trouble

2) Disconnect L15, turn on and off the hold switch and carry out
troubleshooting.
1 Defective hold switch Resis-
tance
Resis-
tance
Possible Max. 1 z
ground tance
causes and
in normal state 2) Disconnect C5, turn on and off the hold switch and carry out trou-
bleshooting.
OFF Min. 1 Mz
Disconnection in wiring 2) Disconnect L08, C5 and L15, then carry out troubleshooting.
harness Resis-
4 Between C5 (female) (13) – L15 (female) (3) Max. 1 z
contact in connector) Between L08 (female) (2), (4) – L15 (female) Resis-
Max. 1 z
(4) tance
36 WA800, WA900-3E0
WA800, WA900-3E0 37
Contents of
• Malfunctioning of hold switch 2) Releasing operation is unavailable.
trouble

2) Disconnect L15, turn on and off the hold switch and carry out
troubleshooting.
1 Defective hold switch Resis-
tance
Resis-
tance
Max. 1 z
ground tance
Possible
causes and
2) Disconnect C5, turn on and off the hold switch and carry out trou-
standard value
bleshooting.
in normal state Defective transmission and
OFF Min. 1 Mz
Ground fault in wiring harness 2) Disconnect L08, C5 and L15, then carry out troubleshooting.
4 (Short circuit with ground
circuit) Wiring harness between C5 (female) (13) – Resis-
Min. 1 Mz
Short circuit between wiring 2) Disconnect L08, C5 and L15, then carry out troubleshooting.
5
harnesses Resis-
tance
38 WA800, WA900-3E0
WA800, WA900-3E0 39
E-12 Lift arm (boom) kick-out is unavailable 1

Contents of
• Lift arm (boom) kick-out is unavailable.
trouble
Related • Check if the bucket positioner function is normal (the power supply system for the boom kick-out is
information the same as that for the bucket positioner function).
a Boom is the same as lift arm.
1 Fuse disconnection Fuse box (1): Fuse (11) Continuity Yes
Defective boom horn relay When replace boom relay L49 with other relay and if the system
2
L49 returns to normal state, boom relay is defective.
2) Disconnect F06 and connect T-branch.
Defective proximity switch for Between F06 (A) – (C) Voltage 20 – 30 V
3
boom Bring the screwdriver
F06 (B) – (C) Voltage Max. 3 V
near to the switch.
Keep the screwdriver
F06 (B) – (C) Voltage 20 – 30 V
away from the switch.
Defective boom kick out 2) Disconnect L16 and carry out troubleshooting.
4
Possible solenoid L16 Resis-
causes and Between L16 (male) (1) – (2) 19 – 23 z
tance
standard value
in normal state
Between F06 (female) (C) and Resis-
Max. 1 z
Resis- 200 – 400 z
Between F06 (female) (B) – (C)
tance L49 coil resistance
harness 2) Disconnect L06, FS2, L49 and L16, then carry out troubleshoot-
5
(Disconnection or defective ing.
contact in connector) Between F06 (female) (A) – FS2 Resis-
Max. 1 z
(10) tance
Between L49 (female) (3) – FS2 Resis-
Max. 1 z
(10) tance
19 – 23 z
Boom kick out
solenoid resistance
40 WA800, WA900-3E0
WA800, WA900-3E0 41
E-13 Bucket positioner functional error 1

Contents of
• Bucket positioner functional error
trouble
Related • Check if the boom kick out function is normal (the power supply system for the bucket positioner is
information the same as that for the boom kick-out function.)
1 Fuse disconnection Fuse box (1): Fuse (11) Continuity Yes
When replace bucket relay L48 with other relay and if the system
2 Defective bucket relay L48
returns to normal state, bucket relay is defective.
Defective proximity switch for Between F05 (A) – (C) Voltage 20 – 30 V
3
bucket Bring the screwdriver
F05 (B) – (C) Voltage Max. 3 V
near to the switch.
Keep the screwdriver
F05 (B) – (C) Voltage 20 – 30 V
away from the switch.
Defective bucket positioner 2) Disconnect L17 and carry out troubleshooting.
4
Possible solenoid L17 Resis-
causes and Between L17 (male) (1) – (2) 19 – 23 z
tance
standard value
in normal state
2) Disconnect L05 and FS2, then carry out troubleshooting.
Between F05 (female) (C) and Resis-
Max. 1 z
Between F05 (female) (B) – FS2 Resis- 200 – 400 z
(10) tance L48 coil resistance
harness 2) Disconnect L05, FS2, L48 and L17, then carry out troubleshoot-
5
(Disconnection or defective ing.
contact in connector) Between F05 (female) (A) – FS2 Resis-
Max. 1 z
(10) tance
Between L48 (female) (3) – FS2 Resis-
Max. 1 z
(10) tance
19 – 23 z
Bucket positioner
solenoid resistance
42 WA800, WA900-3E0
WA800, WA900-3E0 43
E-14 Active working functional error 1

Contents of
• Active working functional error
trouble
• RY5 (neutral 1 relay) is irrelevant to the operation. It is reserved.
• For description of the operation, refer to "Structure, function and maintenance standard."
• Phenomenon when active working does not work (discharge amount of work equipment pump
remains at high level): Necessary driving force is not available in the digging work (makes the digging
work difficult): AW1
• Phenomenon when active working keeps working (switching the discharge amount from low to high
level is not available): Slow boom raising speed (Quick raising is unavailable): AW2
Related
• Timer 1 is relevant to phenomenon AW1 (inoperable) and timer 2 is relevant to phenomenon 2
information
(unchangeable from operating state).
• If interchanging timers 1 and 2 reverses the observable phenomenon, timer 1 or timer 2 is defective
(if both are defective, no change occurs on phenomenon AW1 (inoperable).
• If timer (1 or 2) failed, check whether diode U08 is normal referring to cause 11.
• If phenomenon AW2 (switching from the operating state is unavailable) was observed, set neutral
once before raising the boom (active working circuit is reset). If this operation eliminates phenome-
non AW2 (unchangeable from the operating state), timer 2 is defective.
Fuse box (1): Fuse (11) Continuity Yes
Fuse box (2): Fuses (6) and (13) Continuity Yes
Defective joystick directional If [DDK3KZ] is displayed, carry out troubleshooting of [DDK3KZ]
2
switch first.
Defective neutral 2 relay RY0
When replace neutral 2 relay RY0 with other relay and if the system
3 (Performance check: Refer to
returns to normal state, neutral 2 relay RY0 is defective.
cause 13)
Defective boom bottom pres-
When replace boom bottom pressure RY1 with other relay and if the
sure relay RY1
4 system returns to normal state, boom bottom pressure RY1 is
(Performance check: Refer to
defective.
causes 14 and 15)
Defective no-load relay RY2
When replace no-load relay RY2 with other relay and if the system
Possible 5 (Performance check: Refer to
returns to normal state, no-load relay RY2 is defective.
causes and cause 14)
standard value Defective load relay RY3
in normal state When replace load relay RY3 with other relay and if the system
6 (Performance check: Refer to
returns to normal state, load relay RY3 is defective.
cause 15)
Defective pump cutoff relay
When replace pump cutoff relay RY4 with other relay and if the sys-
7 RY4 (Performance check:
tem returns to normal state, pump cutoff relay RY4 is defective.
Refer to cause 15)
Defective boom proximity Between F14 (A) – (C) Voltage 20 – 30 V
switch F14
8 Between F14 (B) – (C) Voltage Max. 1 V
(Relevant information: Refer
to cause 15) 1) Turn the starting switch OFF.
3) Start the engine, raise the boom and curry out troubleshooting.
Between F14 (B) – (C) Voltage 20 – 30 V
44 WA800, WA900-3E0

4) Directional switch position: Set it to F and carry out troubleshoot-
ing.
a Work carefully.
Between F13 (A) – (C) Voltage 20 – 30 V
Defective hydraulic switch F13 Between F13 (B) – (C) Voltage 20 – 30 V
9 (Relevant information: Refer 1) Turn the starting switch OFF.
to cause 15) 2) Disconnect F13 and connect T-branch.
3) Start engine.
4) Directional switch position: F
5) Start digging work to increase the boom cylinder bottom oil pres-
sure enough and carry out troubleshooting.
a Work carefully.
a Boom cylinder bottom pressure: Min. 12.7 MPa {130 kg/cm2}
Between F13 (B) – (C) Voltage Max. 1 V
Defective 2-stage solenoid 2) Disconnect R16 and carry out troubleshooting.
10
R16 Resis-
Between R16 (male) (1) – (2) 19 – 23 z
tance
Possible 2) Disconnect R17 and U08, then carry out troubleshooting with
causes and starting switch OFF.
standard value a Measure in the diode range.
in normal state Between R17 (male) (2) (+) – Forward direction:
Continuity
(1) (–) Continue
Between R17 (male) (1) (+) – Reverse direction:
Continuity
(2) (–) No continuity
11 Defective diode
Between U08 (male) (2) (+) – Forward direction:
Continuity
(1) (–) Continue
Between U08 (male) (1) (+) – Reverse direction:
Continuity
Between U08 (male) (2) (+) – Forward direction:
Continuity
(3) (–) Continue
Between U08 (male) (1) (+) – Reverse direction:
Continuity
12 Defective timers 1 and 2 For how to carry out troubleshooting, refer to related information.
2) Disconnect RY0 and connect T-branch.
Between RY0 (3) – (2) Voltage 20 – 30 V
13 Defective neutral 2 relay RY0 Forward-reverse

Between
travel switch Voltage Max. 1 V
RY0 (6) – (2)
position: N
Forward-reverse
Between
travel lever Voltage 20 – 30 V
RY0 (6) – (2)
position: F
WA800, WA900-3E0 45

2) Disconnect RY2 and U06, then insert T-branch to RY2 and U06.
ing
a Set the directional switch to F and wait for 3 seconds or more
(specified timer 1 operating duration).
Between RY2 (3) – (2)
Timer 1: Does not pass through Voltage 20 – 30 V --- A
U06
Between RY2 (1) and (5) – (2)
Voltage 20 – 30 V --- B
Timer 1: Passes through U06
a If B is true, troubleshooting of following C – E is not necessary.
Possible No-load relay RY2, boom bot- Between U06 (1) – (2)
causes and tom pressure relay RY1, timer Passes through boom bottom Voltage 20 – 30 V --- C
standard value 14 1: Defective U06 and defec-
pressure relay RY1
in normal state tive wiring harness (the first
half) Between U06 (3) – (2)
Voltage 20 – 30 V --- D
Timer 1: Input
Between U06 (4) – (2)
Voltage 20 – 30 V --- E
Timer 1: Output
a Depending on true or false in A – E, following defect is suspected.
True False Defective items
Defective neutral 2 relay RY0 (fixed to ON)
A
or wiring harness
Defective boom bottom pressure relay RY1
A C (fixed to ON), hydraulic switch (fixed to ON)
or wiring harness
A, C D Defective wiring harness
A, C, D E Timer 1: Defective U06
46 WA800, WA900-3E0

2) Insert T-branch to RY3.
ing
a Set the directional switch to F and wait for 3 seconds or more
(specified timer 1 operating duration).
Between RY3 (5) – (2) Voltage 20 – 30 V --- F
a Confirm above F first and proceed to the following.
2) Disconnect RY1, RY3, RY4 and U07, then insert T-branch to
RY1, RY3, RY4 and U07.
3) Start engine.
4) Forward-reverse travel switch position: F
5) Start digging work to increase the boom cylinder bottom oil pres-
sure enough and carry out troubleshooting.
a Work carefully.
a Boom cylinder bottom pressure: Min. 12.7 MPa {130 kg/cm2}
Between RY4 (4) and chassis
Voltage 20 – 30 V --- G
ground
a If above G is true, no need to carry out troubleshooting for the fol-
lowing H – N (relay, timer and switch circuits are normal).
Between RY1 (1) – (2) 20 – 30 V --- H
(Is hydraulic switch F13 turned Voltage Hydraulic switch F13:
Possible Load relay RY3, boom bottom
ON?) ON
causes and pressure relay RY1, pump cut-
Between RY1 (5) and chassis
standard value 15 off relay RY4, hydraulic switch Voltage 20 – 30 V --- J
F13, boom proximity switch ground
in normal state
F14, timer 2: Defective U07 or Between RY3 (3) – (2) Voltage 20 – 30 V --- K
wiring harness (the latter half)
Between U07 (3) – (2) Voltage 20 – 30 V --- L
Between U07 (4) – (2)
Voltage 20 – 30 V --- M
Timer 2: Output
Between RY4 (5) – (6) 20 – 30 V --- N
(Is the boom proximity switch Voltage Boom proximity
F14 turned ON?) switch F14: ON
a Depending on true or false in B and F – N, following defect is sus-
pected.
True False Defective items
B F Defective wiring harness
F H (coil disconnected), hydraulic switch (does
not turn ON) or wiring harness
H J
(fixed to OFF)
Defective load relay RY3 (does not turn on)
J K
or wiring harness
K L Defective wiring harness
L M Timer 2: Defective U07
Defective pump cutoff relay RY4 (coil discon-
M N nected), boom proximity switch (does not
turn on) or wiring harness
WA800, WA900-3E0 47

2) Disconnect FS2, FS7, S31, F13, F14, R16, R17, RY0 – 4, U06
and U07, then carry out troubleshooting.
Between S31 (female) (3) – RY0 (female) (1) Resis-
Max. 1 z
– RY5 (female) (5) tance
Resis-
Between FS7 (female) (3) – RY0 (female) (3) Max. 1 z
tance
Between RY0 (female) (2) – RY2 (female)
Resis-
(2) – RY3 (female) (2) and chassis ground Max. 1 z
tance
(R10)
Between RY0 (female) (6) – RY1 (female)
Resis-
(1) and (3) – RY2 (female) (3) – RY4 Max. 1 z
tance
(female) (3) – U06 (female) (3)
Between RY0 (2) – RY2 (2) – RY3 (2) – U06
Resis-
(female) (2) – U07 (female) (2) – U08 Max. 1 z
tance
(female) (2) and chassis ground
Between RY1 (female) (5) – RY3 (female) Resis-
Max. 1 z
(1) tance
Possible Between RY2 (1) and (5) – RY3 (5) – RY4 Resis-
causes and Disconnection in wiring Max. 1 z
(1) – U06 (female) (4) tance
standard value 16 harness
(Disconnection or defective Between RY3 (3) – RY4 (2) – U07 (female) Resis-
in normal state Max. 1 z
contact in connector) (3) tance
Between RY3 (6) – U08 (3) – U07 (female) Resis-
Max. 1 z
(1) tance
Between RY1 (6) – U08 (1) – U06 (female) Resis-
Max. 1 z
(1) tance
Resis-
Between RY4 (5) – U07 (female) (4) Max. 1 z
tance
Resis-
Between RY1 (2) – F13 (female) (B) Max. 1 z
tance
Between F13 (female) (C) – F14 (female) (C) Resis-
Max. 1 z
Between FS2 (female) (10) – F13 (female) Resis-
Max. 1 z
(A) – F14 (female) (A) tance
Resis-
Between RY4 (6) – F14 (female) (B) Max. 1 z
tance
Between RY4 (4) – R16 (female) (1) – R17 Resis-
Max. 1 z
(female) (1) tance
Between R16 (female) (2) – R17 (female) (2) Resis-
Max. 1 z
48 WA800, WA900-3E0
WA800, WA900-3E0 49
E-15 Turn signal or hazard display do not flash 1

Contents of
• Turn signal or hazard display does not flash 1) Both turn signal and hazard displays do not flash.
trouble
Related
• M-5: Refer to turn signal (or hazard lamp) display does not flash (lamp flashes)
information

1 Fuse disconnection Fuse box 1: Fuses (3) and (12) Continuity Yes
Disconnection in wiring 2) Disconnect L46 and connect T-branch.
harness 3) Turn starting switch ON and carry out troubleshooting.
2
contact in connector) Between L46 (3) – (1) (Power
Voltage 20 – 30 V
supply input)
3 Defective flasher L46 3) Turn starting switch ON and carry out troubleshooting.
Possible
Repetition of 0 V and
causes and Between L46 (4) – (1) Voltage
20 – 30 V
standard value
in normal state 1) Turn the starting switch OFF.
2) Disconnect L46, L52, L68 and TSW, then carry out troubleshoot-
ing.
harness
4 Between L46 (female) (4) – L68 Resis-
(female) (2) and (4) – TSW (5) tance
Between F68 (female) (1) and
Continuity Yes
chassis ground (F10 and R10)
Continuity Yes
50 WA800, WA900-3E0
WA800, WA900-3E0 51
Contents of
• Turn signal or hazard display does not flash 2) Turn signal does not flash (hazard flashes).
trouble
Related
information

2) Disconnect the TSW, set turn switch to L, R and OFF and carry
Resis-
Between TSW (male) (5) – (4) Min. 1 Mz
tance
OFF
Resis-
tance
2 Defective turn switch Resis-
Between TSW (male) (5) – (4) Max. 1 z
tance
Possible R
Resis-
causes and Between TSW (male) (5) – (6) Min. 1 Mz
tance
standard value
in normal state Resis-
tance
L
Resis-
Between TSW (male) (5) – (6) Max. 1 z
tance
2) Disconnect L46 and TSW, then carry out troubleshooting.
Disconnection in wiring Between L46 (female) (4) – TSW Resis-
Max. 1 z
harness (female) (5) tance
3
(Disconnection or defective Between TSW (female) (4) and
contact in connector) Continuity Yes
Between TSW (female) (6) and
Continuity Yes
52 WA800, WA900-3E0
WA800, WA900-3E0 53
Contents of
• Turn signal or hazard display does not flash 3) Hazard does not flash (turn signal flashes).
trouble
Related
information

Defective turn/hazard relay When replace turn/hazard relay L68 with other relay and if the sys-
2
L68 tem returns to normal state, turn/hazard relay L68 is defective.
When replace hazard relay L52 with other relay and if the system
3 Defective hazard relay L52 returns to normal state, hazard relay L52 is defective (hazard starts
flashing when starting switch and hazard switch are turned ON).
2) Disconnect L03, turn on and off the hazard switch and carry out
troubleshooting.
4 Defective hazard switch Resis-
tance
Resis-
Possible ON Between L03 (male) (1) – (2) Max. 1 z
tance
causes and
in normal state 2) Disconnect L46, L52, 68, L03 and FS3, then carry out trouble-
shooting.
Max. 1 z
Between FS3 (female) (5) – L68 Resis-
(5) – L52 (female) (1) and (5) tance
harness
5 Between L03 (female) (1) – L68 Resis-
(female) (6) – L52 (female) (2) tance
Between L46 (female) (4) – L68 Resis-
Max. 1 z
(female) (2) and (4) tance
Continuity Yes
Continuity Yes
54 WA800, WA900-3E0
WA800, WA900-3E0 55
E-16 Small lamp does not light up 1

Contents of
• Small lamp does not light up.
trouble
Related
• M mode: See "M-8 Night lamp does not light up."
information

Fuse box 1:
1 Fuse disconnection Continuity Yes
Fuses (1), (6) and (7)
Defective small lamp relay When replace small lamp relay L67 with other relay and if the sys-
2
L67 tem returns to normal state, small lamp relay is defective.
2) Disconnect L02, turn on and off the light switch and carry out
troubleshooting.
3 Defective light switch Resis-
tance
ON Resis-
(I and II) tance
causes and 2) Disconnect L67, FS2, FS3 and L02, then carry out troubleshooting.
standard value Between FS2 (male) (4) – (5) – Resis-
in normal state Max. 1 z
(6) tance
Between FS2 (female) (5) and
Continuity Yes
Disconnection in wiring Between FS2 (female) (6) and
Continuity Yes
harness chassis ground (F10 and R10)
4
(Disconnection or defective Between L02 (female) (3) – L67 Resis-
(female) (1) tance
Max. 1 z
Max. 1 z
(female) (3) tance
Max. 1 z
56 WA800, WA900-3E0

2) Disconnect L67, FS2, FS3 and L02, then carry out troubleshoot-
ing.
Resis-
(female) (3) – L67 (female) (1) Min. 1 Mz
tance
and chassis ground
Wiring harness between FS2
Resis-
tance
and chassis ground
Wiring harness between FS3 (1)
Resis-
– L67 (female) (5) – L02 (female) Min. 1 Mz
tance
Possible
causes and Grounding fault in wiring 1) Turn the starting switch OFF.
standard value harness 2) Disconnect F02, F03, GR21, L05 and L21, then carry out trouble-
5
in normal state (Short circuit with ground cir- shooting.
cuit)
Resis-
Between F02 (female) (B) – (C) Min. 1 Mz
tance
Between F02 (male) (B) and Resis-
Min. 1 Mz
Resis-
Between F03 (female) (B) – (C) Min. 1 Mz
tance
Between F03 (male) (B) and Resis-
Min. 1 Mz
Between GR1 (male) (5), (6) – Resis-
Min. 1 Mz
(12) tance
Between GR1 (female) (5), (6) Resis-
Min. 1 Mz
WA800, WA900-3E0 57
58 WA800, WA900-3E0
E-17 Head lamp does not light up 1

Contents of
• Head lamp does not light up.
trouble
Related
• Fuse box 1: If fuse (1) blows, both head lamp and small lamp do not light up.
information

Fuse box 1:
1 Disconnection of fuse Continuity Yes
Fuses (1), (4) and (5)
When replace head lamp relay L66 with other relay and if the sys-
2 Defective head lamp relay L66
tem returns to normal state, head lamp relay is defective.
2) Disconnect L02, turn on and off the light switch and carry out
troubleshooting.
3 Defective light switch Resis-
tance
Resis-
ON(II) Between L02 (male) (2) – (4) Max. 1 z
tance
Possible ing.
causes and
Between FS3 (female) (1) – FS2 Resis-
standard value Max. 1 z
in normal state
Between FS2 (male) (1) – (2) – Resis-
Max. 1 z
(3) tance
(4) tance
harness
4 Between FS2 (female) (3) – L66 Resis-
(2) tance
Between L02 (female) (2) – L66 Resis-
Max. 1 z
(female) (5) tance
Max. 1 z
Between L66 (female) (1) and
Continuity Yes
chassis ground (R10)
Between L66 (female) (3) and
Continuity Yes
chassis ground (R10)
WA800, WA900-3E0 59

ing.
Between FS3 (female) (1) – FS2
Resis-
tance
and chassis ground
Resis-
(male) (1) – (2) – (3) and chassis Min. 1 Mz
tance
ground
Resis-
tance
and chassis ground
Possible Wiring harness between FS2
causes and Grounding fault in wiring Resis-
harness (female) (3) – L66 (female) (2) Max. 1 z
standard value 5 tance
(Short circuit with ground cir- and chassis ground
in normal state
cuit) Wiring harness between L02
Resis-
(female) (2) – L66 (female) (5) Max. 1 z
tance
and chassis ground
2) Disconnect F01 and F04, then carry out troubleshooting.
Resis-
Between F01 (female) (2) – (3) Min. 1 Mz
tance
Between F01 (male) (3) and Resis-
Min. 1 Mz
Resis-
Between F04 (female) (2) – (3) Min. 1 Mz
tance
Between F04 (male) (3) and Resis-
Min. 1 Mz
60 WA800, WA900-3E0
WA800, WA900-3E0 61
E-18 Abnormality in lighting up of front working lamp 1

a Go to Troubleshooting M-9.
E-19 Abnormality in lighting up of rear working lamp 1

E-20 Abnormality in transmission cut-off 1

E-21 Abnormality in low idle selection 1

E-22 Abnormality in parking brake dragging warning 1

E-23 Abnormality in buzzer 1

62 WA800, WA900-3E0
WA800, WA900-3E0 63
SEN02149-01

© 2009 KOMATSU
All Rights Reserved
64
SEN02150-01
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
Method of using troubleshooting chart............................................................................................................ 3
H-1 Machine does not move ........................................................................................................................... 5
H-2 Machine lacks power or speed (every speed range) ............................................................................... 6
H-3 Excessive time lag when starting machine or shifting gear...................................................................... 7
H-4 Torque converter oil temperature is high.................................................................................................. 8
H-5 Steering does not turn .............................................................................................................................. 9
H-6 Turning, response of steering is poor..................................................................................................... 10
H-7 Joystick lever is heavy ............................................................................................................................11
H-8 Steering wheel shakes or jerks .............................................................................................................. 12
H-9 Minimum turning radii to right and left are different ................................................................................ 13
H-10 Wheel brakes do not work or braking effect is poor ............................................................................. 14
H-11 Wheel brakes are not released or brakes drag .................................................................................... 15
H-12 Lift arm does not rise............................................................................................................................ 16
H-13 Lift arm moves slowly or does not have sufficient lifting power............................................................ 17
WA800-3E0, WA900-3E0 1
H-14 When raising lift arm, becomes slow at certain height ......................................................................... 18
H-15 Lift arm cylinder cannot hold down bucket ........................................................................................... 18
H-16 Lift arm has large amount of hydraulic drift .......................................................................................... 18
H-17 Lift arm fluctuates while working .......................................................................................................... 19
H-18 Lift arm drops momentarily when lever is operated from HOLD to RAISE........................................... 19
H-19 Bucket does not tilt back ...................................................................................................................... 20
H-20 Bucket moves slowly or has insufficient tilt back power ....................................................................... 21
H-21 Bucket movement becomes slow during tilt back................................................................................. 22
H-22 Bucket cylinder cannot hold down bucket ............................................................................................ 22
H-23 Bucket has large amount of hydraulic drift ........................................................................................... 22
H-24 Bucket fluctuates while traveling under load (work equipment valve "HOLD") .................................... 23
H-25 Bucket dumps momentarily when lever is operated from HOLD to TILT.............................................. 23
H-26 Lift arm and bucket levers do not move smoothly ................................................................................ 24
2 WA800-3E0, WA900-3E0
Method of using troubleshooting chart 1

This troubleshooting chart determines the location from the problem occurring on the machine and catego-
rizes the problem under one of the main components, such as the steering system or work equipment
hydraulic system. Use the following procedure to carry out accurate troubleshooting swiftly.
Step 1. Ask operator questions Step 3. Method of reading matrix

q The questions to ask the operator are given 1. Operate the machine when carrying out trou-
under the problem. If the answer to the ques- bleshooting of the items in the Diagnosis col-
tion matches the content given, the cause umn. If any problems occur as the result of the
given after the arrow is the probable troubleshooting, put a check against the item.
cause.Keeping the content of the questions in a When carrying out the troubleshooting,
mind, read the matrix and proceed with Step 2 check the easier items first. It is not neces-
and Step 3 to pinpoint the correct cause. sary to follow the number order.
[Example]
Example: Steering does not turn
Ask the operator and check the following points. Remedys
No.
q Did the problem suddenly start? Diagnosis
o Related equipment broken Steering does not turn in both directions (left
1
q Was the steering wheel heavy before? and right)
o Wear of related parts, defective seal Steering turns only in one direction (left or
2
right)
Step 2. Checks before troubleshooting Steering is heavy when turned in both direc-
q Before measuring the oil pressure or starting 3
tions (left and right)
the troubleshooting, confirm the checks before Steering wheel is heavy in one direction (left
starting items, check for leakage of oil, or for 4
or right)
loose bolts. This will prevent wasting time
5 Work equipment moves
when troubleshooting. The items given under
“Checks before troubleshooting” are checks
that are particularly important to make about
the condition of the machine before starting the
actual troubleshooting.
Example: Checks before starting troubleshoot-

ing
q Is oil level and type of oil in hydraulic tank cor-
rect?
q Is there any oil leakage from steering valve or
demand valve?
q Is steering linkage adjusted properly?
WA800-3E0, WA900-3E0 3
2. Find the matching cause in the Cause column. 5. Narrow down the causes.
In the same way as in Step 2), if a problem is Of the causes found in Step 2) and Step 4),
found, the Q marks on the same line for the there are common items (Q marks on the line
troubleshooting item are the causes. (In Diag- for each Diagnosis item and in the same
nosis item 2 in the same diagram below the Cause column as each other) that have
cause is (c) or (e).) causes common with the problem items found
When there is one Q mark: in the troubleshooting in Step 1) and Step 3).
Carry out troubleshooting for the other items a The items that are not common (items that
marked with Q in the same Cause column to do not have Q marks in the same cause
check if the problem occurs, then make common as each other) are probably not
repairs. the cause, so they can be eliminated. (The
When there are two Q marks: causes for Diagnosis item 2 in the dia-
Go to Step 3) to narrow down the cause. gram below are (c) or (e), and the causes
in Diagnosis item 5 are (b) or (e), so
Cause (e) is the common cause.)
3. Operate the machine and carry out trouble-

shooting of the items not checked in Step 1.
Operate the machine in the same way as in 6. Repeat the operation in Steps 3, 4, and 5 until
Step 1, and if any problem occurs, put a check the cause is narrowed down to 1 item (1 com-
against the item. (In Troubleshooting item 5 in mon item).
the diagram below, the problem was re- a If cause items are 2 or more, continue until
enacted.) number of items becomes minimum.
4. Find the matching cause in the Cause column. 7. Remedy

In the same way as in Step 2), if a problem is After narrowing down the common causes,
found, the Q marks on the same line for the take the action given in the remedy line.
troubleshooting item are the causes. (In Diag- Marks and remedies in remedy line
nosis item 5 in the diagram below the cause is ×: Replace E: Repair A: Adjust C: Clean
(b) or (e).)
4 WA800-3E0, WA900-3E0
H-1 Machine does not move 1

Ask the operator the following points Causes
q Did the machine suddenly stop moving? Torque Torque
con-
Yes = Component seized or damaged verter
Transmission con-
q Was there any abnormal noise when the machine pump verter
stopped moving? a b c d e f g h i j k l m n o
Yes = Component broken.
Operation of torque converter regulator valve defective, valve spring deteriorated

Operation of torque converter relief valve defective, valve spring deteriorated
Checks before troubleshooting
q Is oil level in transmission case correct?
Operation of control valve spool defective (biting or dirt caught inside)

q Is monitor display normal?
Pilot reducing valve spring deteriorated, operation of spool defective

q Is drive shaft broken?
Air sucking up at suction side of torque converter pump
Shaft seal ring in rotating clutch for 3rd circuit defective

Rotating clutch for 3rd defective (oil sealing defective)
Operation of transmission main relief valve defective
Seal ring, groove of transmission clutch defective

Operation of modulating valve spool defective
Operation of modulating relief valve defective
Damage to internal part of transmission

Operation of solenoid valve defective
Torque converter pump defective
Transmission clutch seized
E x A E E E x x x x x x E E E
Remedy
No. E
Problems
x x x x x x x
1 Abnormal noise between pump and filter. Q Q
2 Machine does not move in any speed range. (Item 1 normal) Q Q Q Q Q Q Q
3 Machine moves normally in certain speed ranges. Q Q Q Q Q Q Q Q Q
4 Machine will not move when torque converter oil temperature rises. Q Q Q Q
5 Transmission main relief pressure too low. Q
6 Low at every speed range. Q Q Q Q
Transmission modulating
7 Low at certain speed ranges. Q Q Q
pressure too low.
8 Indicator fluctuates violently. Q
9 Pilot pressure defective. Q Q
10 Troupe converter relief valve pressure too low. Q
11 Troupe converter regulator valve pressure too low. Q
Note 1: If the solenoid valve and hydraulic pressure are normal, the "m" in the Causes column indicates
that the valve spool does not work.
Note 2: If the transmission clutch pressure is low, but the cause cannot be found in the above table, a pos-
sible cause is cracks in the valve or transmission.
WA800-3E0, WA900-3E0 5
H-2 Machine lacks power or speed (every speed range) 1

Checks before troubleshooting Causes
q Is oil level in transmission case correct? Torque
con- Engine Transmis- Torque
q Is there any leakage of oil from joints of piping or valves? verter sion converter
q Is parking brake or wheel brake dragged? pump
a b c d e f g h i j
Checking for abnormalities
Operation of torque converter regulator valve defective, valve spring deteriorated

q Engine high idle speed
q Torque converter stall speed
Operation of torque converter relief valve defective, or spring deteriorated

q Machine travel speed
q Transmission clutch pressure (both high pressure and low pres-
Damage to internal part of torque converter (turbine rivet defective)

Oil leaking inside torque converter (seal ring defective, plug loose)
sure)
q Pressure at outlet port of torque converter pump
q Pilot reducing pressure
Modulating valve spring deteriorated, operation defective

Operation of transmission main relief valve defective
Operation of pilot reducing valve defective

Drop in engine performance
E x E A E x E E E x
Remedy
No. E
Problems
x x x x x
1 Abnormal noise from between pump and filter. Q Q
2 Torque converter stall speed too high. Q Q Q Q Q Q
3 Torque converter stall speed too low. Q Q Q Q
4 Transmission main relief valve pressure too low. Q
5 Transmission modulating pres- Low at every speed range (Item 2 abnormal) Q Q
6 sure too low. Indicator fluctuates violently. Q
7 Pilot reducing pressure too low (Items 5 and 6 normal) Q
8 Relief pressure at torque converter too low (Items 5 – 7 normal) Q
9 Torque converter regulator valve pressure (outlet port pressure) too low. Q
10 Iron or aluminum particles stuck to strainer of transmission case. Q
11 Modulating pressure drops when oil temperature rises. Q
6 WA800-3E0, WA900-3E0
H-3 Excessive time lag when starting machine or shifting gear 1

q Is oil level in transmission case correct? Torque
con-
q Is there any leakage of oil from joints of piping or valves? verter
Transmission
pump
a b c d e f g h
Modulating valve spring deteriorated, operation of spool defective

Seal ring, groove of transmission clutch defective
Shaft seal ring in rotating clutch circuit defective

Rotating clutch defective (oil sealing defective)
Throttle hole of quick return valve clogged
Operation of quick return valve defective
E x E E E x x x
Remedy
No.
Problems
x x
1 Abnormal noise between pump and filter. Q
2 Excessive time lag in every speed range. Q Q Q Q Q
3 Machine moves normally in certain speed ranges. Q Q Q
4 Transmission modulating pressure too low in every speed range. Q Q Q Q
5 As in Items 4; indicator fluctuates violently. Q
6 Torque converter oil temperature is above operating range. Q Q
WA800-3E0, WA900-3E0 7
H-4 Torque converter oil temperature is high 1

q Does torque converter oil temperature go up during torque converter Torque
con- Torque
stall, and down when the torque converter is not installed? verter converter
Yes = Normal (incorrect selection of gear speed) pump
a b c d e
Leakage of oil inside torque converter (seal ring defective), plug loose, pump (turbine cracked)
q Is oil level in transmission case correct?
q Is transmission filter clogged?
Checking for abnormalities

a If the oil temperature is normal but the oil temperature gauge is out-
side the operating range, the oil temperature gauge is defective.
Operation of torque converter regulator valve defective

Operation of torque converter relief valve defective
E x E A E
Remedy
No. E
Problems
x x x x
1 Pump makes abnormal noise when oil temperature is low. Q
2 High idle and low idle speeds are too low. Q Q
3 Hydraulic pressure at inlet port of torque converter too low. Q
4 Transmission modulating pressure too low. Q Q
8 WA800-3E0, WA900-3E0
H-5 Steering does not turn 1

q Did the problem suddenly start? Hydrau- Rotary Steering Cylin-
lic
Yes = Related equipment broken pump valve valve der
q Was there any abnormal noise when this happened?
a b c d e f g
Where did the noise come from?
Defective actuation of demand spool
Defective actuation of steering spool

Defective steering and switch pump
Defective safety-suction valve

q Is the oil level in the hydraulic tank correct?
Is the type of oil correct?
q Is the steering shaft broken?
Defective rotary valve

Defective PPC pump
Defective piston seal

q Has the lock bar been removed from the frame?
q Is steering valve open?
E x E E E x x
Remedy
No.
Problems
x x x x
1 Steering wheel does not turn in both directions (left and right) Q Q Q Q Q Q
2 Steering wheel turns only in one direction (left or right) Q
3 Joystick lever is heavy in both directions (left and right) Q Q Q
4 Work equipment moves Q Q Q Q
5 Work equipment does not move Q Q
6 Abnormal noise comes from around PTO Q Q
7 Abnormal noise comes from around PPC pump or hydraulic tank Q
Oil pressure is low or there is no pressure in
8 Q Q Q Q Q Q
When steering relief pres- both directions (left and right)
sure is measured Oil pressure is low or there is no pressure in
9 Q
one direction (left or right)
When rotary valve output pressure is measured, oil pressure is found to be
10 Q Q Q
low or there is no oil pressure
11 When PPC valve (rotary Oil pressure is low Q Q
valve) basic pressure is mea-
12 sured There is no oil pressure Q Q
a There is a close connection between the steering circuit and the work equipment circuit, so if any abnor-
mality is felt in the steering, check the operation of the work equipment also.
WA800-3E0, WA900-3E0 9
H-6 Turning, response of steering is poor 1

q Did the problem suddenly start? Hydraulic pump
Rotary
Steering valve
Cylin-
Yes = Related equipment broken valve der
q Was there any abnormal noise when this happened? a b c d e f g h i j k

Air sucked in at suction end of pump
q Was there previously any symptom, such as difficulty in
steering?

Yes = Wear of related equipments, defective seal
Defective main relief valve

Defective Steering pump
Defective switch pump

Defective PPC pump

Defective PTO
E E x x x E E E E x E
Remedy
No.
Problems
x x x x x x
1 Turning, response of steering is poor in both directions (left and right) Q Q Q Q Q Q Q Q Q Q
2 Turning, response of steering is poor in one direction (left or right) Q Q
3 Joystick lever is heavy in both directions Q Q
4 Joystick lever is heavy in one direction (left or right)
5 Work equipment moves Q Q Q Q Q
6 Work equipment speed also is slow Q Q Q Q
7 Abnormal noise comes from around PTO Q
8 Abnormal noise comes from around steering pump or hydraulic tank Q Q
9 Abnormal noise comes from around switch pump or hydraulic tank Q Q
Oil pressure is low or there is no pressure in
10 Q Q Q Q Q Q Q Q Q
When steering relief pres- both directions (left and right)
sure is measured Oil pressure is low or there is no pressure in
11 Q
one direction (left or right)
12 Q Q
low
When PPC valve (rotary valve) basic pressure is measured, oil pressure is
13 Q
found to be low
a There is a close connection between the steering circuit and the work equipment circuit, so if any abnor-
mality is felt in the steering, check the operation of the work equipment also.
10 WA800-3E0, WA900-3E0
H-7 Joystick lever is heavy 1

Checking for abnormalities Causes
q Is the steering difficult to turn? Rotary Steering
Others
Yes = Go to H-6 valve valve
q Measure the operating effort and turning speed, and a b c
check the “Standard value table” to see if they are abnor-
mal.
Ask the operator the following points
Interference of joystick lever or steering shaft

q Did the heavy steering suddenly start? And did you hear
strange noise at the time? In what area did you hear the
noise?

Yes = Related equipment broken
q Was there previously any symptom, such as heavy steer-
ing?
Yes = Wear of related equipment, defective seal

q Is the tire inflation pressure correct?
E E E
Remedy
No.
Problems
x x x
1 Joystick lever is heavy when turned in both directions (left and right) Q Q Q
2 Joystick lever is heavy when turned in one direction (left or right) Q
Joystick lever is heavy even when joint between steering shaft and rotary
3 Q
valve is disconnected
Oil pressure is low in both directions (left
4 Q Q
When steering relief pres- and right)
sure is measured Oil pressure is low in one direction (left or
5 Q
right)
6 Q Q
low
WA800-3E0, WA900-3E0 11
H-8 Steering wheel shakes or jerks 1

q Is the steering difficult to turn? Rotary Hydraulic
AJSS
Steering valve Cylinder EPC sole-
Yes = Go to H-6 valve pump
noid valve
q Is there any abnormal noise from around the steering
a b c d e f g h
equipment?
Defective actuation of EPC solenoid valve


q Is the joystick lever play correct?
q Is there any abnormality in the connection between the

steering shaft and the steering pilot valve?
Defective main relief valve

q Is the tire inflation pressure correct?
Defective EPC pump

q Did you bleed air of steering cylinder?
q Did you align the neutral (calibration) of joystick lever?
E E E E x E E x
Remedy
No.
Problems
x x x x x x
1 Steering wheel shakes or jerks in both directions (left and right) Q Q Q Q Q
2 Steering wheel shakes or jerks in one directions (left or right) Q
During operations or when traveling (when steering is neutral), steering
3 Q Q
wheel shakes or jerks in both directions (left and right)
During operations or when traveling (when steering is neutral), steering
4 Q
wheel shakes or jerks in one direction (left or right)
Steering wheel jerks or there is excessive shock when steering is operated
5 Q Q
to end of its stroke
6 Work equipment also jerks Q
Oil pressure is unstable in both directions
7 Q Q Q Q Q
When steering relief pres- (left and right)
sure is measured Oil pressure is unstable in one direction (left
8 Q
or right)
Oil pressure is unstable in both directions
9 Q
When rotary valve output (left and right)
pressure is measured Oil pressure is unstable in one direction (left
10 Q Q Q
or right)
When PPC valve (rotary valve) basic pressure is measured, oil pressure is
11 Q Q Q
found to be unstable
12 WA800-3E0, WA900-3E0
H-9 Minimum turning radii to right and left are different 1
Cause and remedy

q Defective adjustment of steering stopper bolt (E)
WA800-3E0, WA900-3E0 13
H-10 Wheel brakes do not work or braking effect is poor 1

Slack adjuster
q Measure the actual brake performance, and check if
Charge valve
Accumulator
there is actually an abnormality or whether it is just the
Others
Brake Brake
feeling of the operator. For details, see Testing and Wheel brake
pump valve
adjusting, “Measuring brake performance”.
a b c d e f g h i j k l m n
Defective piston seal or defective bleeding of gas from accumulator

q Did the problem suddenly start?
Yes = Related equipment broken
q Was there any abnormal noise when this happened?
q Did the problem gradually appear?
Yes = Wear of related equipments, defective seal

Air sucked in at suction end of pump
Defective accumulator charge valve

Defective actuation of brake piston

q Is the brake pedal play correct?
q Is there any leakage of oil from the brake tube?
Defective brake piston seal
Air is mixed in brake circuit

Defective right brake valve
Defective left brake valve
Is there any deformation of the tube?
Defective slack adjuster
Breakage inside brake

q Is the tire inflation pressure and tread pattern correct? Defective brake pump
Wear of brake disc
Defective axle oil

Defective PTO
E E E E x E E E E E E E E x
Remedy
No.
Problems
x x x x x x x x x x
1 Brake has no effect only when left brake pedal is depressed Q
2 Left brake pedal is light when it is depressed Q Q Q Q Q Q Q Q
3 Right brake pedal is light when it is depressed Q Q Q Q Q Q Q
4 Left brake pedal is heavy when it is depressed Q
5 Right brake pedal is heavy when it is depressed Q
Abnormally large operating force is needed to obtain specified braking
6 Q Q Q Q Q
force
7 Abnormal noise is heard from brake when brake is applied Q Q Q
8 Work equipment, steering also do not work Q Q
9 Movement of work equipment, steering is slow Q Q Q
10 Abnormal noise comes from around PTO Q
11 Abnormal noise comes from around brake pump or hydraulic tank Q Q
12 Many metal particles are found in oil drained from axle case Q
When accumulator charge pressure is measured, oil pressure is found
13 Q Q Q
to be low
14 Brake stops having effect immediately when engine is stopped Q
15 There is a time lag before brake takes effect Q Q
16 When brake oil pressure is measured, it is found to be low Q
When drop in brake piston pressure is measured, it is found to be
17 Q Q
excessive
18 When wear of brake disc is measured, it is found to be excessive Q Q
19 When air is bled from brake line, air comes out Q
14 WA800-3E0, WA900-3E0
H-11 Wheel brakes are not released or brakes drag 1

q Did the problem suddenly start? Brake Slack Wheel
Yes = Related equipment broken valve adjuster brake
q Was there any abnormal noise when this hap- a b c d e
pened? Where did the noise come from?
Defective actuation of slack adjuster
Defective actuation of brake piston

Defective right brake valve

q Does the brake pedal come back fully?
Defective left brake valve
Seized brake disc, plate

q Is the parking brake still applied (ON)?
E E E E x
Remedy
No.
Problems
x x x x
1 Machine cannot travel at all Q Q
2 Machine can travel a small amount Q Q Q
When remaining pressure is released from brake accumulator cir-
3 Q
cuit with left brake pedal only, brake is released
When remaining pressure is released from brake accumulator cir-
4 Q
cuit with right brake pedal only, brake is released
When air bleed plug in wheel portion is loosened, oil flows out and
5 Q
brake is released
6 When air bleed plug is loosened, a large amount of oil flows out Q Q
When brake disc wear is measured and brake pedal is released,
7 Q
piston returns
When brake disc wear is measured and brake pedal is released,
8 Q Q
piston does not return
WA800-3E0, WA900-3E0 15
H-12 Lift arm does not rise 1

q Did the problem suddenly fail to rise? Steer-
PPC
Work
Cylin-
o Seizure or damage to various units. Tank-pump ing
valve
equipment
der
valve control valve
q Was unusual noise produced? (Where did it ema-
nate from?) a b c d e f g h i j
q Were there previous signs of the lift arm slowing
Blockage in suction port of pump or excessive amount of air contained in oil

down?
o Wear of parts of flattening of spring.

q Is oil level in hydraulic tank correct?
q Is travel of lift arm control lever and spool correct?
Defective actuation of main relief valve
Internal damage valve body (lift spool)
Damaged lift arm cylinder piston seal

Faulty hydraulic and switch pump
Defective actuation of relief valve

Pump PTO is not being driven
Defective actuation of spool

Faulty PPC pump
C E E E x E E E x x
Remedy
No.
Problems
E x x x x x x
1 Bucket cannot be operated and lift arm is unable to rise. Q Q Q Q Q Q Q Q
The machine body can be lifted up by the lift arm however, the lift
2 arm is unable to rise. Or, the bucket operates but the lift arm is Q Q Q
unable to rise.
3 The lift arm can rise under no load but cannot rise under load. Q Q Q
4 The hydraulic pump produces an abnormal noise. Q Q Q
5 Lift arm cylinder has large amount of hydraulic drift. Q Q
When the engine is at full, steering action is light and excessively
6 Q
fast.
7 When the engine is at full, steering action is heavy and slow. Q Q
16 WA800-3E0, WA900-3E0
H-13 Lift arm moves slowly or does not have sufficient lifting power 1
q Is the travel of the lift arm control lever and also the Steer-
PPC
Work
Cylin-
Tank –
spool of the work equipment control valve correct? ing equipment
pump valve der
valve control valve
q Seizure of work equipment linkage bushing.
(Does emits abnormal noise) a b c d e f g h
Blockage of suction port of pump or excessive amount of air contained in oil

Fault check
Defective actuation of main relief valve and faulty improperly adjusted

q There is a strong relationship between faults
involving lifting force and lifting speed. Such faults
appear initially in the form of insufficient lifting
speed. Measure the lifting speed of the lift arm
when loaded and refer to the “Standard value
table” to determine whether or not there is a fault.
Damaged lift arm cylinder piston seal

Internal damage or worn valve body

Faulty hydraulic and switch pump

C E E E E A x E
Remedy
No.
Problems
E x x x x x x
Bucket tilt back force and speed are abnormal and lift arm lifting
1 Q Q Q Q
speed is low.
Bucket tilt back force and speed are normal but lift arm lifting
2 Q Q Q
speed is slow.
Some as Item 1 except that lift arm lifting speed becomes particu-
3 Q
larly low when oil temperature rises.
4 Hydraulic pump emits abnormal noise. Q Q
When the engine is at full, steering action is light and excessively
5 Q
fast.
6 When the engine is at full, steering action is heavy and slow. Q
7 Cylinder has a large amount of hydraulic drift. Q Q
8 The relief pressure of relief valve of work equipment control valve. Q Q Q Q
WA800-3E0, WA900-3E0 17
H-14 When raising lift arm, becomes slow at certain height 1

q External deformation of lift arm cylinder.
Cause
q Swollen or internally damaged lift arm cylinder tube.
a Regarding other faults occurring during lift arm rise, refer to item "H-13 Lift arm moves slowly or does
not have sufficient lifting power".
H-15 Lift arm cylinder cannot hold down bucket 1
Refer to item "H-13 Lift arm moves slowly or does not have sufficient lifting power".

q Is travel of lift arm spool of work equipment control valve correct?
Cause
q Defective lift arm cylinder rod side suction valve seat of work equipment control valve
q Oil leakage from lift arm cylinder piston seal
H-16 Lift arm has large amount of hydraulic drift 1

q Did the hydraulic drift suddenly become large?
o Dirt lodged in valve or damaged parts.
q Did the hydraulic drift gradually become large?
o Worn parts.

q Is the lift arm spool in the hold position?
o Seized ring bushing, defective spool detent.
Troubleshooting and cause

q When measuring hydraulic drift, internal leakage of lift arm cylinder makes oil leakage noise.
o Damaged cylinder packing.
q When measuring hydraulic drift, lift arm cylinder does not make oil leakage noise.
o Defective oil sealing of lift arm spool.
o Defective check valve between pipings.
18 WA800-3E0, WA900-3E0
H-17 Lift arm fluctuates while working 1
During excavation or ground leveling when the lift arm control lever is in the "HOLD" position, the bucket and
lift arm move up and down in accordance with the terrain.
Troubleshooting and cause

Check the amount of hydraulic drift and whether or not the machine body can be lifted up by the lift arm cyl-
inder.
1. If the amount of hydraulic drift is greater than the standard value, refer to item "H-16 Lift arm has large
amount of hydraulic drift".
2. If the machine body can not be lifted up by the lift arm cylinder, refer to item "H-15 Lift arm cylinder can-
not hold down bucket".
3. If the amount of hydraulic drift is normal and the machine body can be lifted up by the lift arm cylinder
after the lift arm is moved several times to cause the lift arm cylinder to move through its entire stroke o
the trouble is due to the generation of a vacuum in the cylinder.
a If a vacuum is generated frequently o defective suction valve on lift arm cylinder rod side.
H-18 Lift arm drops momentarily when lever is operated from HOLD to
RAISE 1
The lift arm drops momentarily under its own weight when the lift arm control lever is gradually shifted from
the "HOLD" position to the "RAISE" position while the engine is at low idle. When the control lever is put
completely into the "RAISE" position, the lift arm moves normally.
Cause
q Defective seating of work equipment control valve or lift arm spool check valve.
WA800-3E0, WA900-3E0 19
H-19 Bucket does not tilt back 1

q Did the bucket suddenly cease to move? Steer-
PPC
Work
Cylin-
o Seized or damaged equipment. Tank – pump ing
valve
equipment
der
valve control valve
q Was any abnormal noise emitted (where did it
emanate from?) a b c d e f g h i j
q Was there previous signs of the bucket slowing

down?
o Worn parts or flattening of spring.

q Is the travel of the bucket control lever and spool
correct?
Internal damaged valve body (dump spool)

Defective actuation of main relief valve
Defective hydraulic and steering pump
Damaged bucket cylinder piston seal


Pump PTO is not being driven
Defective PPC pump
Defective spool
C E E E x E E A x x
Remedy
No.
Problems
E x x x x x x
1 Lift arm cannot be operated and bucket is unable to tilt back. Q Q Q Q Q Q Q
The machine can be lifted up by the bucket but the bucket cannot
2 Q Q Q
tilt back. Or, the lift arm operates but the bucket cannot tilt back.
The bucket can tilt back under no load but cannot excavate or
3 Q Q
scoop.
4 The hydraulic pump produces an abnormal noise. Q Q Q
5 Bucket cylinder has large hydraulic drift. Q Q
Steering action is light and excessively fast when the engine is at
6 Q
full.
7 Steering action is heavy and slow when the engine is at full. Q
20 WA800-3E0, WA900-3E0
H-20 Bucket moves slowly or has insufficient tilt back power 1

q Is the travel of the bucket control lever and the Steer-
PPC Main con- Cylin-
Tank –
work equipment control valve spool correct? ing
pump valve trol valve der
valve
q Seizure of bushing in bucket linkage?
(Does emit abnormal noise?) a b c d e f g h i
Defective actuation of safety valve (with suction valve) on rod side of the bucket cylinder
Fault checks
q Check deficient tilt back force by performing actual
work.

q Measure the operating speed of the bucket and
check it against the “Standard value table” to deter-
mine whether or not it is normal.
Defective actuation of main relief valve and incorrectly adjusted
Internally worn or damaged valve body (bucket spool)
Damaged bucket cylinder piston seal

Defective hydraulic and switch pump

C E E E x A E x x
Remedy
No. E
Problems
E x x x x x
Lift arm lifting force and lifting speed are abnormal and also bucket
1 Q Q Q Q Q
tilt force and tilt speed are abnormal.
Lift arm lifting force and lifting speed are normal but bucket tilt
2 Q Q Q Q
force and tilt speed are abnormal.
Phenomena of item 1 become particularly bad when the oil tem-
3 Q
perature increases.
4 The hydraulic pump emits an abnormal noise. Q Q
Steering action is light and excessively fast when the engine is at
5 Q
full.
6 Steering action is heavy and slow when the engine is at full. Q
7 The bucket cylinder has a large amount of hydraulic drift. Q Q Q
The relief pressure of relief valve of work equipment control valve
8 Q Q Q Q
is also low.
9 The discharge volume of the hydraulic pump is low. Q
WA800-3E0, WA900-3E0 21
H-21 Bucket movement becomes slow during tilt back 1

q External deformation of bucket cylinder.
Cause
q Swollen or internally damaged bucket cylinder tube.
q As to other faults which occur when operating bucket, refer to item "H-20 Bucket moves slowly or has
insufficient tilt back power".
H-22 Bucket cylinder cannot hold down bucket 1
Refer to item "H-20 Bucket moves slowly or has insufficient tilt back power".

q Is the travel of bucket spool of work equipment control valve correct?
Cause
q Defective seat of safety valve (with suction valve) of the rod side of bucket cylinder of work equipment
valve.
q Oil leakage from seal of bucket cylinder piston.
H-23 Bucket has large amount of hydraulic drift 1

q Did the hydraulic drift suddenly become large?
o Dirt lodged in valve or damaged parts.
q Did the hydraulic drift gradually become large?
o Worn parts.

q Is the bucket spool in the hold position?
o Seized ring bushing, faulty spool detent.
Fault check
q Use the “Standard value table” to check whether or not the hydraulic drift of the bucket is actually large.
Cause
q Oil leakage in bucket cylinder
q Defective seating of safety valve (with suction valve) at bottom side.
q Defective oil sealing of bucket spool.
q Defective check valve between pipings.
22 WA800-3E0, WA900-3E0
H-24 Bucket fluctuates while traveling under load (work equipment

valve "HOLD") 1

q Excessive play in pin and bushing of work equipment linkage. (Was an abnormal noise produced?)
Cause
q Defective piston seal of bucket cylinder.
q Defective safety valve (with suction valve) for the head side of bucket cylinder.
If the above symptoms occur together, refer to the troubleshooting items corresponding to each fault.
H-25 Bucket dumps momentarily when lever is operated from HOLD to

TILT 1
The bucket dumps momentarily under its own weight when the bucket control lever is gradually shifted from
the "HOLD" position to the "TILT" position while the engine is at low idle.
When the control lever is put completely into the "TILT" position, the bucket moves normally.
Cause
q Defective seating of bucket spool check valve of work equipment valve.
WA800-3E0, WA900-3E0 23
H-26 Lift arm and bucket levers do not move smoothly 1

Fault check Causes
q Using the “Standard value table”, check whether or Lever PPC valve
Work equipment
not the operating effort of the lever is large. control valve
a b c d e f g h i j k
Distortion of valve body due to non-uniform tightening of valve mounting bolts
Incorrect clearance between work equipment control valve body and spool
Poor roundness of work equipment control valve body and spool
Foreign matter lodged in work equipment control valve spool
Sticking of detent of work equipment control valve spool
Incorrect clearance between PPC valve body and spool
Seizure of control lever of rotating parts of link
Poor roundness of PPC valve body and spool
Bent work equipment control valve spool

Foreign matter lodged in PPC valve
Bent PPC valve spool
E x E E C E x E x x C
Remedy
No.
Problems
x x x E x x E
Movement of lift arm and bucket levers becomes sluggish when
1 Q Q Q Q Q
load is applied and oil pressure increase.
Movement of lift arm and bucket levers becomes sluggish along
2 Q Q Q Q Q
with change in oil temperature.
Movement of lift arm and bucket levers becomes partially sluggish
3 Q
irrespective of oil pressure and temperature.
Movement of lift arm and bucket levers becomes generally slug-
4 Q Q Q Q Q Q
gish irrespective of oil pressure and temperature.
Movement of lift arm and bucket levers does not become light
5 even when the link of the control lever is disconnected at the valve Q
connection part and the lever operated.
24 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 25
SEN02150-01

© 2009 KOMATSU
All Rights Reserved
26
SEN02151-01
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 3
S-1 Starting performance is poor .................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations ...............................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power) ..................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 16
S-9 Oil becomes contaminated quickly ......................................................................................................... 17
S-10 Fuel consumption is excessive............................................................................................................. 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 19
S-12 Oil pressure drops ................................................................................................................................ 20
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 21
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 22
S-15 Abnormal noise is made....................................................................................................................... 23
WA800-3E0, WA900-3E0 1
S-16 Vibration is excessive ........................................................................................................................... 24
2 WA800-3E0, WA900-3E0
Method of using troubleshooting chart 1

The troubleshooting chart consists of “questions”, “check items”, “causes”, and “troubleshooting” blocks.
The “questions” and “check items” narrow down the causes to highly probable “causes” by simple inspection
or from symptoms without using a diagnostic tool.
Then, the final verifications of “causes” are carried out by checking the narrowed down “causes” in the order
of their probability with diagnostic tools or by direct inspection following the “troubleshooting” procedure.
Questions:
Information to be obtained by questioning the user
or operator, and which corresponds to the sections
A and B in the right chart.
Section A includes basic information, and section B
contains items which can be obtained depending
on the level of the user or operator.
Check items:
Items checked by the serviceman in order to nar-
row down the causes, section C of the right chart is
corresponding to them.
Causes:
Items to be narrowed down by the questions and
check items.
The serviceman narrows down the causes to highly
probable causes according to the information from
A, B and C.
Troubleshooting:
Items to be verified at the end in order to check if
the narrowed down causes are the true factors
causing the failure. The verification is carried out
by applying diagnostic tools or implementing direct
inspection in the order of probability.
This troubleshooting chart marks the content of the

questions and check items with E, Q or w accord-
ing to their closer relationship with the causes.
E : A cause that can be referred to in relation to
the question or check item.
Q : A cause that is related the question or check
item.
w : A cause particularly probable among those
marked with Q above.
a Count the priority level of each marking as w >
Q when determining the cause.
Don't count E when determining the cause.
The item with this marking may be counted,
however, if no difference is present than this
and the cause cannot be determined.
WA800-3E0, WA900-3E0 3
<Example of troubleshooting> Exhaust smoke is black

Let us assume that [Clogged air cleaner element] is taken to be the cause of black exhaust gas. Three symp-
toms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was
lost gradually], and [Air cleaner clogging caution lamp is flashing].
4 WA800-3E0, WA900-3E0
If we look for the linkage of these three phenomena to possible causes, we find that they have causal rela-
tionship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
WA800-3E0, WA900-3E0 5
S-1 Starting performance is poor 1

General causes for poor starting performance are Causes
q Defective electrical system
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
Defective alternator (generator section)

q Insufficient supply of fuel
Defective alternator (regulator section)

Clogged fuel filter element or strainer
Stuck or seized supply pump plunger

q Insufficient intake of air
Defective intake air heater system

q Improper selection of fuel (particularly during winter)
Defective or deteriorated battery

Clogged feed pump gauze filter
Worn piston ring and cylinder
q Coolant in exhaust pipe
Clogged air cleaner element

a The common rail fuel injection system (CRI) recognizes
the fuel injection timing electrically. Accordingly, even if
the starting operation is carried out, the engine may not
Defective injector
start until the crankshaft revolves 2 turns at maximum.
This phenomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of
machine operation
Operated for long period E E E E
Starting perfor- Became worse gradually Q w w Q Q
mance Engine starts easily when warm w
Questions
Non-specified fuel is being used Q Q Q Q

Replacement of filters not carried out according to Operation and Maintenance
Manual w w w Q Q
Engine oil replenished more frequently w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed) w
During operation, charge level monitor indicates abnormal charge (if monitor is
installed) w w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
When priming pump is operated, it makes no reaction or it is heavy E w Q Q
Starting motor cranks engine slowly w
Fuel does not flow out if air bleeding plug of fuel filter is
While engine is removed w w
cranked with start-
If spill hose from injector is disconnected,
ing motor, Q w
Check items
little fuel spills

When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
There is hunting from engine (rotation is irregular) Q Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter and strainer directly q
Inspect feed pump gauze filter directly q
Troubleshooting
Carry out troubleshooting of the failure code for "No-pressure feed by supply pump
(*1)" q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change on some cylinders q
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q
engine at low idle? None q
When specific gravity of electrolyte and voltage of battery are measured, they are
low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
6 WA800-3E0, WA900-3E0
S-2 Engine does not start 1

a) Engine does not turn Causes
General causes why engine does not turn
Defective starting motor (safety relay section)

q Engine seized inside
Defective connection of battery terminal
Defective starting motor (motor section)

o See "S-4 Engine stops during operations".
q Water hammer caused by coolant which entered cylinder

q Defective electrical system
Defective steering circuit wiring

q Malfunction of hydraulic pump
Broken flywheel ring gear
Defective starting switch

Defective battery relay
Questions
Degree of machine opera-

tion
Operated for long period E E
Condition of horn when Horn does not sound Q Q
starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q
Check items
Speed of rotation is low w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages w
Makes rattling noise and does not turn Q Q
Inspect flywheel ring gear directly q
Carry out troubleshooting

When specific gravity of electrolyte and voltage of battery are measured, they are low q
Troubleshooting
There is not voltage (20 - 30 V) between battery relay terminal B and

terminal E q
When terminal B and terminal C of starting switch are connected,
Turn starting switch OFF,
engine starts q
connect cord, turn the
in E-mode
switch ON and carry out When terminal B and terminal C at safety relay outlet are connected,
troubleshooting engine starts q
When terminal B and terminal C at safety relay outlet are connected,
engine does not start q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
WA800-3E0, WA900-3E0 7
b) Engine turns but no exhaust smoke comes out Causes

General causes why engine turns but no exhaust smoke
Defective operation of overflow valve (Does not close)

comes out
q Fuel is not being supplied
Leaking, clogging and entry of air to fuel piping

q Supply of fuel is extremely small

q Improper selection of fuel (particularly in winter)
Wrong connection of supply pump PCV

Seized, abnormally worn feed pump
Defective operation of flow damper

Broken supply pump shaft spline
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Use of improper fuel
Defective injector
Degree of
Operated for long period E E E
Questions
machine operation
Exhaust smoke suddenly stopped coming out (when starting again) w w Q w w w E E
Non-specified fuel is being used w
w w E E Q
Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is no fuel in it w Q w
w
Check items
Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy w Q Q
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q Q Q w Q
cranked with out
starting motor, If spill hose from injector is disconnected, little fuel spills Q w w w w Q

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting of failure code for "No-pressure feed by supply pump
q q q
error (*1)"
Carry out troubleshooting of failure code for "Abnormality in PCV1 (*2) or Abnor-
q
mality in PCV2 (*3)"
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Remedy
Add
8 WA800-3E0, WA900-3E0
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Defective coolant temperature sensor and/or wiring harness

General causes why exhaust smoke comes out but engine
Worn dynamic valve system (Valve, rocker lever, etc.)

does not start
q Lack of rotating force due to defective electrical system
Leaking, clogging of fuel system, and entry of air

Stuck and/or seized supply pump plunger

Clogged injector and/or defective spray
q Improper selection of fuel
Worn piston ring and/or cylinder liner
Defective intake air heater system

Clogged fuel filter and/or strainer

Use of improper fuel

Degree of machine
operation Operated for long period E E E E
Suddenly failed to start w w Q
Questions

Manual w w w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed) w
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w w
When fuel filter is removed, there is no fuel in it w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
Fuel does not flow out if air bleeding plug of fuel filter is
While engine is
removed Q Q w w
cranked with start-
ing motor, If spill hose from injector is disconnected, little fuel spills Q Q w
some cylinders is low w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
q
Troubleshooting
Inspect fuel filter, strainer directly

Carry out troubleshooting of failure code for "No-pressure feed by supply pump error
(*1)" q
When injector unit is tested, spray condition is bad q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Coolant temperature gauge does not indicate normally (if coolant temperature
gauge is installed) q
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Remedy
WA800-3E0, WA900-3E0 9
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Defective operation of flow damper (Maximum leakage from injector)

q Defective spray condition of fuel
q Controller is controlling in derate mode
Seized turbocharger or interference of turbocharger

(limiting injection rate (output) because of an error in electri-
cal system)
Leaking, clogging of or entry of air to fuel piping

Clogged injector and/or defective spray


Improper valve clearance

Degree of
machine operation Operated for long period E E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w w
Replacement of filters not carried out according to Operation and Maintenance Manual w w w
some cylinders is low Q w
Color of exhaust Blue under light load w

Check items
gas is Black w Q w w
When engine is cranked, interference sound is emitted from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q

Inspect valve clearance directly q
Troubleshooting
When turbocharger is rotated by hand, it is found to be heavy q

Inspect feed pump gauze filter directly
Carry out troubleshooting of failure code for "No-pressure feed by supply pump error
(*1)" q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change on some cylinders q q
Adjusting
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
10 WA800-3E0, WA900-3E0
S-4 Engine stops during operations 1

General causes why engine stops during opera- Causes
tions
Broken auxiliary equipment (pump, compressor, etc.)

q Seized parts inside engine
Broken or seized piston and/or connecting rod

q There is overheating

q Malfunction of hydraulic pump
Defective starting switch wiring harness

Broken or seized crankshaft bearing
Leaking and/or clogged fuel piping

Broken supply pump shaft spline

Malfunction of hydraulic pump

Broken dynamic valve system
Defective power supply wiring

Broken or seized feed pump
harness of engine controller

Broken or seized gear train
(valve, rocker arm, etc.)

Degree of machine
operation
Operated for long period EE
Abnormal noise was heard and engine
stopped suddenly w w w w Q w Q w w
Questions
Condition when Engine overheated and stopped w Q Q

engine stopped
Engine stopped slowly w Q Q Q Q
Engine stopped after hunting w Q Q Q Q Q Q
Replacement of filters not carried out according to Operation and
Maintenance Manual w w
Fuel level monitor indicates low level (if monitor is installed) w
Metal particles are found when oil pan is drained w w Q Q
Check items
Does not turn at all w w

When engine is Turns in opposite direction w
cranked by hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Inspect piston and connecting rod directly q
Carry out troubleshooting in H-mode
Inspect crankshaft bearing directly q

Inspect gear train directly q
Troubleshooting

Inspect feed pump directly q
Carry out troubleshooting of failure code for "No-pressure feed by
supply pump error (*1)" q q
Engine rotates when pump auxiliary equipment (pump, compressor,
etc.) is removed q
Inspect power supply wiring harness of controller q
Inspect starting switch wiring harness q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
*1: Failure code [CA559], [CB559] and failure

Clean
Clean
Clean
Remedy
Add
code [CA2249], [CB2249]
WA800-3E0, WA900-3E0 11
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
q Air in fuel system
Defective operation of flow damper (Maximum leakage from injector)

q Defective speed sensor (Error at degree that it is not indicated)
Clogged injector and/or defective spray (dirt in injector)
Defective G (Bkup) speed sensor or wiring harness

Defective Ne speed sensor and/or wiring harness
Leaking or clogging or entry of air to fuel piping

Low setting of low idle speed
Clogged fuel filter or strainer

Degree of machine
operation Operated for long period E E
Questions
Occurs at a certain speed range Q Q Q

Occurs at low idle w Q Q Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w Q Q
Replacement of filters not carried out according to Operation and Maintenance Manual w w
Check items
Rust and water are found when fuel tank is drained Q Q


Troubleshooting

Carry out troubleshooting of failure code for "Abnormality in engine Ne speed sensor (*1)" q
Carry out troubleshooting of failure code for "Abnormality in engine Bkup speed sensor (*2)" q
Replace,
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Remedy
Add
*1: Failure code [CA689] and failure [CB689]

*2: Failure code [CA778] and failure [CB778]
12 WA800-3E0, WA900-3E0
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Causes
Defective installation of boost pressure sensor (air leakage)
Defective fuel temperature sensor and/or wiring harness

Defective boost pressure sensor and/or wiring harness

Clogged injector or defective spray (dirt in injector)

Defective drive of injector (signal and/or solenoid)
q Overheat
o See "S-14 Coolant temperature becomes

too high (Overheating)"

Air leakage from air intake piping

Leaking or clogged fuel piping
(limiting injection rate (output) because of an

error in electrical system)

Degree of machine
operation Operated for long period E E E E E
Q Q Q Q
Questions
Suddenly
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters not carried out according to Operation and Main-
tenance Manual w Q
Engine oil replenished more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Color of exhaust Black w w
gas Blue under light load w
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low w
w
Check items
When engine is cranked, interference sound is emitted from around turbocharger

High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops
when load is applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w Q
There is hunting from engine (rotation is irregular) Q Q Q Q
Blow-by gas is excessive w w

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting

Carry out troubleshooting of failure code for "No-pressure feed by supply
pump error (*1)" q
When a cylinder is cut out for reduced cylinder mode operation, engine
speed does not change on some cylinders q q
Inspect boost pressure sensor mount directly q
Carry out troubleshooting of failure code for "Abnormality in charge pres-
sure sensor (*2)" q
Carry out troubleshooting of failure code for "Abnormality in fuel temper-
ature sensor (*3)" q
Adjusting
Replace,
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
WA800-3E0, WA900-3E0 13
*2: Failure code [CA122] and failure code[CA123]
14 WA800-3E0, WA900-3E0
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and cylinder head
Defective coolant temperature sensor or wiring harness

q Excessive injection of fuel

Clogged fuel spill piping (on cylinder head side)

q Overheat

o See "S-14 Coolant temperature becomes too high

(Overheating)"
Improper fuel injection pressure

(limiting injection rate (output) because of an error in
Crushed or clogged muffler
Clogged or seized injector

electrical system)
Abnormally worn injector
Improper injection timing

Degree of
machine operation
Suddenly became black w Q Q Q
Questions
Color of exhaust Gradually became black

gas w Q Q
Blue under light load w
Non-specified fuel is being used Q Q
Oil replenished more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, and clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low Q w
Check items

Torque converter stall speed or pump relief speed is high
(Fuel is injected excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w

When turbocharger is rotated by hand, it is fount to be heavy q
q
Troubleshooting
Inspect valve clearance directly

When muffler is removed, exhaust sound improves q
Carry out troubleshooting of failure code for "No-pressure feed by supply pump
error (*1)" q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change on some cylinder q
Inspect fuel spill piping (on cylinder head side) directly q q
Carry out troubleshooting of failure code for "Abnormality in coolant temperature
sensor error (*2)"
Adjusting
Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
WA800-3E0, WA900-3E0 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal combustion of oil
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

Worn or damaged valve (stem, guide, seal)
q Long-time operation of engine at low idle or high idle
(Do not run engine continuously at idle without load for

more than 20 minutes)
Clogged breather or breather hose

Dust sucked in from intake system
q External leakage of oil
Worn seal at turbocharger end
Worn or damaged rear oil seal
Oil leakage from oil drain plug

q Wear of parts in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of machine oper- Operated for long period
E E E E
Questions
ation
Oil consumption suddenly increased w Q
Oil replenished more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is contaminated with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is contaminated with oil w
Inside of turbocharger exhaust outlet pipe is contaminated with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is increasing w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found contaminated abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
16 WA800-3E0, WA900-3E0
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
Clogged breather and/or breather hose

q Use of improper fuel

q Use of improper oil
q Operation under excessive load
Worn valve and/or valve guide
Defective oil filter safety valve
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Degree of machine operation Operated for long period E E E
Questions
Non-specified oil is being used Q

Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is
installed) w Q
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is contaminated with oil w
Engine oil temperature rises quickly w
Blue under light load w
Check items
Color of exhaust gas

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

q q
Troubleshooting
When compression pressure is measured, it is found to be low

Inspect breather and breather hose directly q
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
—
Remedy
WA800-3E0, WA900-3E0 17
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
q Leakage of fuel
Defective coolant temperature sensor or wiring harness

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail fuel pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector

Degree of
E E E
Questions
Operated for long period

machine operation
More than other machines of same model Q Q Q Q
Condition of fuel
consumption
Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some cylin-
ders is low w
Check items
Low idle speed is high Q

Torque converter stall speed or hydraulic pump relief speed is high Q
Color of exhaust Black Q Q Q Q
gas White Q
Remove and inspect head cover directly q

Inspect feed pump oil seal directly q
Troubleshooting
Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
change on some cylinders q
If spill hose from injector is disconnected and measured, much fuel spills q
Carry out troubleshooting of failure code for "Abnormality in coolant temperature sensor (*2)" q
Confirm with monitoring function of machine monitor q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
18 WA800-3E0, WA900-3E0
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is mixed in coolant Causes
q Internal leakage in lubrication system
Damaged cylinder liner O-ring and/or hole caused by pitting

q Internal leakage in cooling system
Broken hydraulic cooler or power train oil cooler

Broken cylinder head and/or head gasket
Insufficient protrusion of cylinder liner

Broken oil cooler core and/or O-ring
Cracks inside cylinder block
Degree of machine
Operated for long period E E
Questions
operation
Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w w
Check items
Hydraulic oil or power train oil on applicable machine side is cloudy white. w
When hydraulic oil or power train oil on applicable machine side is drained, water is discharged w
Pressure-tightness test of cylinder head shows there is leakage q
on applicable machine side

Troubleshooting
Inspect cylinder block and liner directly q q
Inspect cylinder liner directly q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy
WA800-3E0, WA900-3E0 19
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage, clogging, and/or wear of lubrication system
Defective oil pressure sensor and/or defective wiring harness

q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the Opera-
tion and Maintenance Manual is not observed.
q Deterioration of oil due to overheating
Defective oil level sensor and/or wiring harness

Leaking, crushed, clogged hydraulic piping
Clogged and/or broken pipe in oil pan
Defective oil pump relief valve

Coolant and fuel mixing in oil
Clogged strainer in oil pan
Worn journal of bearing
Lack of oil in oil pan
Defective oil pump
Clogged oil filter

Degree of
E E E
Questions
machine operation Operated for long period

Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters not carried according to Operation and Maintenance Manual w
Indicates pressure drop at low idling time w Q
Oil pressure Indicates pressure drop at low and high idling times Q w w w Q
monitor
(if installed) Indicates pressure drop on slopes w
Indicates pressure drop occasionally w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking or crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q
Metal particles are found in oil filter q

q q
Troubleshooting
Inspect oil pan strainer and pipe directly

See S-13
Oil pump rotation is heavy, there is play in oil pump q

Valve and spring of oil pump relief valve are fatigued and damaged q
Inspect oil filter directly q
Carry out troubleshooting of failure code for "Abnormality in oil pressure sensor (*1)" q
If oil level sensor is replaced, oil level monitor indicates normally q
Adjusting
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
—
Remedy
Add
20 WA800-3E0, WA900-3E0
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Causes
q Coolant in oil (milky)
Clogged water pump drain hole (breather hole) and/or defective seal
q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in cool-

ant".
Defective seal of auxiliary equipment (pump, compressor)

Broken oil cooler core and/or O-ring

Fuel leakage inside head cover
Worn or damaged rear oil seal

Cracks inside cylinder block
Defective thermostat seat

Defects in supply pump
Questions
Degree of
machine operation
Fuel consumption increasing w w
Coolant replenished more frequently Q w
There is oil mixed in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q w
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles
appears, or coolant spurts back w Q
Check items
Exhaust smoke is white Q Q

Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, coolant comes out w
Oil level in damper chamber of machine is low w
Oil level in hydraulic tank is low w

Remove and inspect head cover directly q
q q
Troubleshooting
Inspect cylinder block and/or liner directly

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect water pump directly q
Remove and inspect thermostat cover directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
WA800-3E0, WA900-3E0 21
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too high Causes
q Lack of cooling air (deformation, and/or damages of fan)
Rise in power train oil temperature on applicable machine side

q Drop in heat dissipation efficiency
q Problem in coolant circulation system
q Oil temperature of power train is rising
Slipping fan belt and/or worn fan pulley

Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Defective operation of thermostat
Clogged or crushed radiator fins
Clogged or broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Degree of
machine operation
Questions
Sudden overheated Q w Q
Condition for
Persistent overheating Q w w Q
Coolant tempera- Rises quickly Q w
ture gauge
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator and coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud, inside of underguard on applicable machine side are clogged with
dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature gauge enters red range faster than engine coolant tem-
perature gauge (if oil temperature gauge and coolant temperature gauge are w
installed) on the installed machine side

Inspect cylinder liner directly q
q
Inspect oil cooler directly

Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

When operation of thermostat is tested, it does not open at cracking temperature q
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
in H-mode
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt and pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
22 WA800-3E0, WA900-3E0
S-15 Abnormal noise is made 1

General causes why abnormal noise is emitted Causes
q Abnormality due to defective parts
Improper fuel injection timing (abnormality in coolant temperature sensor)

q Abnormal combustion
q Air leakage from air intake system
Deformed cooling fan and/or looseness or interference of fan belt

a Judge if the noise is an internal noise or an external noise
before starting troubleshooting.
a While the engine is not sufficiently warmed up, it is operated
Defective inside of muffler (dividing board out of position)

Broken dynamic valve system (valve and/or rocker lever)
Leakage of air between turbocharger and cylinder head
in the low-temperature mode. Accordingly, the engine sound
rises slightly higher. This is no abnormality, however.
Excessive wear of piston ring and/or cylinder liner

a When the engine is accelerated, the engine sound rises
slightly for approx. 3 seconds maximum. This is no abnor-
mality, however.
Interference or seizure of turbocharger
Removed or seized gear train bushing

Improper gear train backlash
Clogged or seized injector

Dirt caught in injector

Degree of
Operated for long period E
Questions
machine operation
Condition of Gradually increased Q Q
abnormal noise Suddenly increased Q Q Q
Non-specified fuel is being used Q
Oil replenished more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is emitted around muffler w
Check items

some cylinders is low w Q
Color of exhaust Blue under light load w
gas Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is fount to be heavy q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
Abnormal noise is heard only when engine is started q
Confirm with monitoring function of machine monitor q
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
WA800-3E0, WA900-3E0 23
S-16 Vibration is excessive 1

General causes why vibration occurs Causes
q Defective parts (abnormal wear, breakage, etc.)
Broken output shaft and/or parts in damper on installed machine side

Misalignment between engine and devices on installed machine side
q Misalignment between installed machine
q Abnormal combustion
a If abnormal noise vibration occur, carry out troubleshooting for "S-15
Abnormal noise is emitted", too.
Stuck dynamic valve system (valve, rocker lever, etc.)
Loose engine mounting bolts and/or broken cushions

Worn main bearing and/or connecting rod bearing
Worn front support spigot joint portion

Improper gear train backlash

Worn camshaft bushing
Degree of
E E E E
Questions
Operated for long period

machine operation
Condition of vibra- Suddenly increased Q Q
tion Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
q
Troubleshooting
Inspect gear train directly

Inspect camshaft bushing directly q
Confirm with monitoring function of machine monitor q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect front support spigot joint portion directly q
Inspect output shaft or inside of damper directly q
Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
24 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 25
SEN02151-01

© 2009 KOMATSU
All Rights Reserved
26
SEN02152-00
WA800-3E0
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
Troubleshooting of machine monitor
system (M-mode)
Machine monitor system ................................................................................................................................. 3
M-1 Machine monitor does not work............................................................................................................... 4
M-2 Engine starts immediately after (within 3 sec of) turning starting switch ON,
but all the machine monitors remain lit .................................................................................................... 6
M-3 Speedometer display does not work........................................................................................................ 7
M-4 Shift indicator error .................................................................................................................................. 9
M-5 Monitor turn signal (hazard) indicator does not light up......................................................................... 20
M-6 Parking indication error.......................................................................................................................... 22
M-7 Abnormality in preheating system.......................................................................................................... 23
M-8 Night lamp does not light up .................................................................................................................. 28
M-9 Front work lamp error ............................................................................................................................ 30
M-10 Rear work lamp error ........................................................................................................................... 34
M-11 Abnormality in transmission cut-off switch ........................................................................................... 38
M-12 Abnormality in low idle selection.......................................................................................................... 42
WA800, WA900-3E0 1
M-13 Emergency steering indication error .................................................................................................... 44

M-14 Parking brake dragging warning error.................................................................................................. 46
M-15 Buzzer and caution lamp error upon parking brake dragging warning outputting................................ 47
M-16 Buzzer error ......................................................................................................................................... 50
M-17 Switching state of machine monitor is not stored................................................................................. 56
M-18 Failure indication mode error ............................................................................................................... 58
M-19 Machine monitor does not indicate failure code................................................................................... 60
M-20 Abnormality in auto grease system...................................................................................................... 62
2 WA800, WA900-3E0
Machine monitor system 1

Machine monitor system
WA800, WA900-3E0 3
M-1 Machine monitor does not work 1

Contents of
• Machine monitor does not work.
trouble
Related • Since machine monitor shares the power supply system with maintenance monitor, check if the main-
information tenance monitor is working.

Defective machine monitor 2) Disconnect L05 and connect T-branch.
1 (When power supply pin 3) Turn starting switch ON and carry out troubleshooting.
voltage is normal)
Between L05 (1) and (2) – (3) Voltage 20 – 30 V
2 Disconnection of fuse Between SBF1 (R03) – (R04) Continuity Yes
standard value 2) Disconnect L05, L06 and L07, then carry out troubleshooting.
in normal state
Disconnection in wiring Wiring harness between L05 (female) (1) – Resis-
Max. 1 z
harness (2) – battery relay BTR2 (R02) tance
4
(Disconnection or defective Between L05 (female) (3) – L06 (female) Resis-
(16) – L07 (female) (12) tance
Max. 1 z
ground (R11) tance
Ground fault in wiring harness 2) Disconnect L05 and carry out troubleshooting.
5
(Contact with ground circuit) Between L05 (female) (1) – (2) and chassis Resis-
Min. 1 Mz
ground tance
4 WA800, WA900-3E0
WA800, WA900-3E0 5
M-2 Engine starts immediately after (within 3 sec of) turning starting
switch ON, but all the machine monitors remain lit 1
Contents of • Engine starts immediately after (within 3 sec of) turning starting switch ON, but all the machine moni-
trouble tors remain lit.
Related • Troubleshooting of maintenance monitor system: Refer to "K-3".
information • If engine does not start, refer to "Troubleshooting of electrical system", E-1

1 Defective machine monitor 3) Turn starting switch ON.
4) Turn starting switch START and carry out troubleshooting.
Possible
causes and Between L05 (4) – (3) Voltage 20 – 30 V
in normal state 2) Disconnect relay L95 and L05, then carry out troubleshooting.
harness Resis-
2 Between L05 (female) (4) – L95 (female) (3) Max. 1 z
contact in connector) Between L05 (female) (3) and chassis Resis-
Max. 1 z
ground (R11) tance
6 WA800, WA900-3E0
M-3 Speedometer display does not work 1

Contents of
• Speedometer display does not work normally.
trouble
• If error is in the speed sensor system, failure code [DLT4KA], transmission & AJSS controller LED:
Related
"22" will be displayed.
information

2) Disconnect BC01 and carry out troubleshooting.
100 –
1 Defective speed sensor 500 z
Resis-
Between BC01 (male) (1) – (2) (Coil
tance
resis-
tance)
2) Disconnect L07.
harness
2 100 –
contact in connector) Resis- 500 z
Between L07 (female) (1) – (2)
tance (resis-
tance)
Possible 2) Disconnect C4, C5, L07, E03 and BC01.
causes and 3) Turn starting switch OFF and carry out troubleshooting.
Ground fault in wiring harness
standard value 3 Wiring harness between L07 (female) (2) – Resis-
(Contact with ground circuit) Min. 1 Mz
in normal state BC01 (2) and chassis ground tance
Min. 1 Mz
BC01 (1) and chassis ground tance
Hot short in wiring harness 3) Turn starting switch ON and carry out troubleshooting.
4 (Contact with power supply Wiring harness between L07 (female) (2) –
Voltage Max. 1 V
circuit) BC01 (2) and chassis ground
Wiring harness between L07 (female) (1) –
Voltage Max. 1 V
BC01 (1) and chassis ground
3) Start engine.
5 Defective machine monitor 4) Drive machine and carry out troubleshooting.
a Caution – collision
Voltage
Min. 0.5 V
WA800, WA900-3E0 7
8 WA800, WA900-3E0
M-4 Shift indicator error 1

Contents of 1) Even when FNR switch is set to "F" or "R" position, shift indicator
• Shift indicator error
trouble remains indicating N.
• If error is in the joystick forward-reverse travel switch system, failure code [DDK3KZ], transmission &
AJSS controller LED: "20" will be displayed.
• Failure code [DDK3KZ] or transmission & AJSS controller LED displays "20", which means fuse box
Related
2 (6) is connected (to the transmission AJSS controller power supply).
information
• FNR switch position data ("F, N, R") is received from transmission & AJSS controller on S-Net.

2) Disconnect S31 and carry out troubleshooting by operating joy-
stick forward-reverse travel switch.
Joystick forward-
reverse travel switch S31 (male) Resistance
position
Defective forward-reverse F Between (1) – (3) Min. 1 Mz
1
travel switch Between (1) – (4) Min. 1 Mz
N Between (1) – (3) Max. 1 z
R Between (1) – (3) Min. 1 Mz
Possible
causes and
Disconnection in wiring 2) Disconnect C3B, S31, L05 and L08, then carry out troubleshoot-
in normal state
harness ing.
2
Resis-
contact in connector) Between L08 (female) (7) – S31 (female) (2) Max. 1 z
tance
Resis-
Between L08 (female) (8) – S31 (female) (4) Max. 1 z
tance
Resis-
Between L05 (female) (8) – S31 (female) (3) Max. 1 z
tance
2) Disconnect C3B, S31, FS5, L05 and L08, then carry out trouble-
shooting.
Wiring harness between S31 (female) (1) Resis-
Min. 1 Mz
Reference
Ground fault in wiring harness Wiring harness between S31 (female) (2) Resis-
Min. 1 Mz
3 (Contact with ground circuit) and chassis ground tance
(Fuse (6) in fuse box 2 is Wiring harness between S31 (female) (3) Resis-
broken.) Min. 1 Mz
Min. 1 Mz
Wiring harness between S31 (male) (1) and Resis-
Min. 1 Mz
WA800, WA900-3E0 9

2) Disconnect L05 and L08.
Joystick directional
Measuring point Voltage
switch position
Between L08 (7) and
20 – 30 V
chassis ground
Between L08 (8) and
F Max. 1 V
chassis ground
Between L05 (8) and
Possible Max. 1 V
Defective transmission & chassis ground
causes and 4
AJSS controller Between L08 (7) and
standard value Max. 1 V
chassis ground
in normal state
Between L08 (8) and
N Max. 1 V
chassis ground
Between L05 (8) and
20 – 30 V
chassis ground
Between L08 (7) and
Max. 1 V
chassis ground
Between L08 (8) and
R 20 – 30 V
chassis ground
Between L05 (8) and
Max. 1 V
chassis ground
Defective communication of
5 See "M-19".
S-NET
10 WA800, WA900-3E0
WA800, WA900-3E0 11
Contents of 2) Even when FNR switch is set to "N" position, "N" is not indicated.
• Shift indicator error
trouble (Indicating either one of 1st, 2nd or 3rd clutch)
Related
• (See contents of trouble 1.)
information

Defective forward-reverse
1 (See contents of trouble 1))
travel switch
2) Disconnect S31.
Possible Hot short in wiring harness Wiring harness between S31 (female) (2)
causes and 2 (Contact with power supply Voltage Max. 1 V
and chassis ground
standard value circuit)
in normal state Wiring harness between S31 (female) (3)
Voltage Max. 1 V
and chassis ground
Wiring harness between S31 (female) (4)
Voltage Max. 1 V
and chassis ground
3 (See cause 4, contents of trouble 1))
AJSS controller
Defective communication of
4 See "M-19".
S-NET
12 WA800, WA900-3E0
WA800, WA900-3E0 13
Contents of
• Shift indicator error 3) Gear speed is not indicated.
trouble
• If error is in the shift up-down switch system, failure code [DDK5KZ], transmission & AJSS controller
LED: "21" will be displayed.
Related • If failure code [DDK5KZ] or transmission & AJSS controller LED displays "21" is displayed, fuse box
information 2 (6) is not broken, which is connected to the transmission AJSS controller power supply.

shift switch.
State of shift switch S31 (male) Resistance
Not press switch
Defective forward-reverse
1 Between (1) – (5) Min. 1 Mz
travel switch
Press shift down Between (1) – (6) Max. 1 z
switch Between (1) – (7) Max. 1 z
Possible Between (1) – (8) Min. 1 Mz
causes and
standard value Between (1) – (5) Max. 1 z
in normal state Between (1) – (6) Min. 1 Mz
Press shift up switch
5 – 15 z
Resis-
Between T01 (H) – (B) (1st solenoid) (Coil resis-
tance
tance)
2 Defective solenoid 5 – 15 z
Resis-
Between T01 (G) – (B) (2nd solenoid) (Coil resis-
tance
tance)
5 – 15 z
Resis-
Between T01 (F) – (B) (3rd solenoid) (Coil resis-
tance
tance)
14 WA800, WA900-3E0

2) Disconnect engine controllers C3B and S31, then carry out trou-
bleshooting.
Wiring harness between C3B (female) (7) – Resis-
Max. 1 z
S31 (female) (8) tance
Max. 1 z
Max. 1 z
Max. 1 z
Disconnection in wiring S31 (female) (5) tance
harness 1) Turn the starting switch OFF.
3
(Disconnection or defective 2) Disconnect C1 and L05, then carry out troubleshooting.
5 – 15 z
Between L05 (female) (12) – (3) Resis-
(Coil resis-
(1st solenoid) tance
tance)
5 – 15 z
Possible Between L05 (female) (13) – (3) Resis-
(Coil resis-
causes and (2nd solenoid) tance
tance)
standard value
in normal state 5 – 15 z
Between L05 (female) (14) – (3) Resis-
(Coil resis-
(3rd solenoid) tance
tance)
Max. 1 z
ground (R11) tance
Between T01 (female) (B) and chassis Resis-
Max. 1 z
ground (R10) tance
Min. 1 Mz
Reference Min. 1 Mz
4 (Contact with ground circuit) Min. 1 Mz
(Fuse (6) in fuse box 2 is
disconnected.) Wiring harness between S31 (female) (7) Resis-
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
WA800, WA900-3E0 15

2) Disconnect C1, T01 and L05.
3) Turn starting switch OFF and carry out troubleshooting.
Ground fault in wiring harness Between L05 (female) (12) – (3) Resis-
Min. 1 Mz
5 (Disconnection or defective tance
contact in connector) Resis-
tance
Resis-
tance
2) Disconnect S31.
Possible carry out troubleshooting.
causes and Wiring harness between S31 (female) (5)
standard value Voltage Max. 1 V
and chassis ground
in normal state
Wiring harness between S31 (female) (6)
Voltage Max. 1 V
and chassis ground
Hot short in wiring harness Wiring harness between S31 (female) (7)
Voltage Max. 1 V
6 (Contact with power supply and chassis ground
circuit) Wiring harness between S31 (female) (8)
Voltage Max. 1 V
and chassis ground
2) Disconnect L05.
Between L05 (female) (12) – (3) Voltage Max. 1 V
16 WA800, WA900-3E0

State of shift switch Measuring point Voltage
Between C3B (7) and
Max. 1 V
chassis ground
Between C3B (8) and
Max. 1 V
chassis ground
Not press switch
Between C3B (15)
20 – 30 V
and chassis ground
Between C3B (16)
20 – 30 V
and chassis ground
Between C3B (7) and
Max. 1 V
chassis ground
Between C3B (8) and
Possible 20 – 30 V
Press shifting down chassis ground
causes and switch
Defective transmission & Between C3B (15)
standard value 7 20 – 30 V
AJSS controller and chassis ground
in normal state
Between C3B (16)
Max. 1 V
and chassis ground
Between C3B (7) and
20 – 30 V
chassis ground
Between C3B (8) and
Max. 1 V
Press shifting up chassis ground
Max. 1 V
and chassis ground
Between C3B (16)
20 – 30 V
and chassis ground
Between L05 (12) – (3) Voltage Max. 1 V
WA800, WA900-3E0 17
18 WA800, WA900-3E0
M-5 Monitor turn signal (hazard) indicator does not light up 1

Contents of
• Monitor turn signal (hazard) indicator does not light up (lamp itself lights up).
trouble
Related
• For troubleshooting of turn signal (hazard) circuit in general, see "E-mode."
information

Broken monitor turn signal
1 After replacing turn signal lamp, it lights up.
lamp bulb
2) Disconnect L06.
4) Set the turn signal switch to the left and carry out troubleshooting.
Possible
Disconnection in wiring Repetition of 0 V and
causes and Between L06 (female) (14) – (16) Voltage
harness 20 – 30 V
standard value 2
in normal state (Disconnection or defective 1) Turn the starting switch OFF.
contact in connector) 2) Disconnect L06.
4) Set the turn signal switch to the right and carry out troubleshooting.
Repetition of 0 V and
20 – 30 V
If causes 1 – 2 are not detected, machine monitor may be defective
(Since trouble is in system, troubleshooting cannot be carried out.).
20 WA800, WA900-3E0
WA800, WA900-3E0 21
M-6 Parking indication error 1

Contents of
• Parking indicator does not light up or remains lit.
trouble
Related
• Parking brake indicator switch opens with parking brake OFF and short-circuits with ON.
information

2) Disconnect F12.
4) Turn the parking brake switch OFF and carry out troubleshooting.
Resis-
Between F12 (male) (1) – (2) Min. 1 Mz
Defective parking brake tance
1
indicator switch 1) Turn the starting switch OFF.
2) Disconnect F12.
4) Turn the parking brake switch ON and carry out troubleshooting.
Possible Resis-
causes and Between F12 (male) (1) – (2) Max. 1 z
tance
standard value
in normal state
Disconnection in wiring 2) Disconnect F12 and L06, then carry out troubleshooting.
harness Wiring harness between L06 (female) (11) – Resis-
2 Max. 1 z
(Disconnection or defective F12 (female) (1) tance
contact in connector) Between F12 (female) (2) and chassis Resis-
Max. 1 z
ground (F10) tance
Ground fault in wiring harness 2) Disconnect F12 and L06, then carry out troubleshooting.
3
(Contact with ground circuit) Wiring harness between L06 (female) (11) – Resis-
Min. 1 Mz
F12 (female) (1) and chassis ground tance
22 WA800, WA900-3E0
M-7 Abnormality in preheating system 1

Contents of • Abnormality in preheating sys- 1) System does not operate preheating or only monitor preheating
trouble tem indication does not light up.
• Engine coolant temperature can be checked by monitoring code: 04104 (°C).
• For engine coolant temperature sensor, see failure code [CA144].
Related • Preheating system starts operation when preheat relay L73 is turned ON.
information • Controller that turns preheat relay L73 ON differs by the system type.
1) Without pre-lubrication controller: Engine controller (L bank)
2) With pre-lubrication controller: Pre-lubrication controller
• E-mode: See "E-2 Preheating system error"

Fuse box 1: Fuse (10) and (12) Continuity Yes
Heater relay fuse: Upper, Lower (350A) Continuity Yes
a For primary coil side of heater relay type L73 without pre-lubrica-
tion controller, see "E-2 Preheating system error."
Defective pre-lubrication con- a For primary coil side of the heater relay type L73 without pre-
troller, defective engine con- lubrication controller, see failure codes [D180KA], [D180KB] and
2 [D180KY].
troller L bank or defective
harness 20 – 30 V
(preheat-
ing time;
several
tens of
seconds)
Possible Defective preheating relay When replace preheat relay L73 with other relay and if the system
causes and 3
L73 returns to normal state, preheating relay is defective.
standard value
Disconnection in wiring 2) Disconnect L05, L73 and FS5, then carry out troubleshooting.
harness Resis-
4 Between L05 (female) (19) – L73 (5) Max. 1 z
contact in connector) Wiring harness between FS5 (female) (6) – Resis-
Max. 1 z
5
(Contact with ground circuit) Resis-
tance
20 – 30 V
6 Defective machine monitor (preheat-
ing time;
several
tens of
seconds)
WA800, WA900-3E0 23
24 WA800, WA900-3E0
WA800, WA900-3E0 25
Contents of • Abnormality in preheating sys-

2) Preheating system remains operating.
trouble tem
• Preheating system starts operation when preheat relay L73 is turned ON.
Related • Controller that turns preheat relay L73 ON differs by the system type, but the L73 secondary coil side
information is same.
• E-mode: See "E-2 Preheating system error"

Defective preheating relay 2) Disconnect L73.
L73
a If preheating ends, preheating relay is defective.
Hot short in wiring harness a If preheating does not end in the above cause 1
2 (Contact with power supply Wiring harness between L73 (female) (5) – L05 (19) – heater relays
Possible circuit) E10, E12
causes and
in normal state 2) Disconnect L05 and connect T-branch.
Voltage
3 Defective machine monitor 20 – 30 V
(preheat-
Between L05 (female) (19) – (3) Voltage ing time;
several
tens of
seconds)

See 1), M-7
26 WA800, WA900-3E0
M-8 Night lamp does not light up 1

Contents of
• Night lamp does not light up.
trouble
Related • For troubleshooting of small lamp circuit in general, see "E-mode."
information • Check if the night lamp for maintenance monitor lights up.

1 Disconnection of fuse Fuse box 1: Fuse (1) and (6) Continuity Yes
2
L67 tem returns to normal state, small lamp relay is defective.
harness 2) Disconnect L05 and FS2, then carry out troubleshooting.
3
(Disconnection or defective Wiring harness between L05 (female) (16) – Resis-
Possible contact in connector) Max. 1 z
FS2 (5) tance
causes and
in normal state Ground fault in wiring harness 2) Disconnect L05 and carry out troubleshooting.
4
tance
Turn the starting switch OFF.
Disconnect L05 and connect T-branch.
5 Defective machine monitor Turn starting switch ON.
Turn small lamp switch ON and carry out troubleshooting.
Between L05 (female) (16) – (3) Voltage 20 – 30 V
28 WA800, WA900-3E0
WA800, WA900-3E0 29
M-9 Front work lamp error 1

Contents of 1) None of machine monitor display, front work lamp and front axle
• Front work lamp error
trouble work lamp lights up.
• Check that machine monitor lamp lights up.
Related
• When machine monitor output, L06 (1) is grounded, front work lamp and front axle work lamp light up.
information
• ON operation of front work lamp relay L60 is independent from that of front axle work lamp relay L90.

1 Disconnection of fuse Fuse box 2: Fuse (1) Continuity Yes
Defective front work lamp When replace front work lamp relay L60 with other relay and if the
2
relay L60 system returns to normal state, front work lamp relay is defective.
When replace front axle work lamp relay L90 with other relay and if
Defective front axle work lamp
3 the system returns to normal state, front axle work lamp relay is
relay L90
defective.
2) Disconnect L05, FS5, L60 and L90, then carry out troubleshoot-
Disconnection in wiring ing.
harness
4 Resis-
(Disconnection or defective Between L06 (female) (1) – L60 (6) – L90 (6) Max. 1 z
tance
Wiring harness between FS5 (female) (1) – Resis-
Max. 1 z
L60 (2), (4), (5) – L90 (2), (5) tance
Possible
standard value 2) Disconnect L06, FS5, L60 and L90, then carry out troubleshoot-
in normal state ing.
Ground fault in wiring harness Resis-
5 Between L06 (female) (1) – (16) Min. 1 Mz
(Contact with ground circuit) tance
Wiring harness between FS5 (female) (1) –
Resis-
L60 (2), (4) or (5) – L90 (2), (5) and chassis Min. 1 Mz
tance
ground
Hot short in wiring harness 2) Disconnect L06, L60 and L90.
6 (Contact with power supply 3) Turn starting switch ON and carry out troubleshooting.
circuit)
4) Turn front work lamp switch ON and carry out troubleshooting.
30 WA800, WA900-3E0
WA800, WA900-3E0 31
Contents of 2) Any one of machine monitor display, front work lamp and front
• Front work lamp error
trouble axle work lamp does not light up.
Related
• Machine monitor output: When L06 (1) is grounded, front work lamp and front axle work lamp light up.
information
• ON operation of front work lamp relay L60 is independent from that of front axle work lamp relay L90.

Defective front work lamp When replace front work lamp relay L60 with other relay and if the
1
relay L60 system returns to normal state, front work lamp relay is defective.
When replace front axle work lamp relay L90 with other relay and if
Defective front axle work lamp
2 the system returns to normal state, front axle work lamp relay is
relay L90
defective.
2) Disconnect L05, L60 and L90, then carry out troubleshooting.
Between L05 (female) (17) – L60 (female) Resis-
Max. 1 z
Disconnection in wiring (1) tance
harness Between L60 (female) (1) and chassis
3 Continuity Yes
(Disconnection or defective ground
contact in connector) Between L60 (female) (3) and chassis
Continuity Yes
Possible ground
causes and Between L90 (female) (1) and chassis
standard value Continuity Yes
ground
in normal state
2) Disconnect Work Left, Right, L05, L60, L90, C03, C04, FAR and
FAL, then carry out troubleshooting.
Resis-
Ground fault in wiring harness Between L05 (female) (17) – (3) tance
Min. 1 Mz
4
Wiring harness between L60 (3) – Work Left Resis-
Min. 1 Mz
and Right (1) and chassis ground tance
Wiring harness between L90 (1) – FAR (1) – Resis-
Min. 1 Mz
FAL (1) and chassis ground tance
4) Turn front work lamp switch ON and carry out troubleshooting.
32 WA800, WA900-3E0
WA800, WA900-3E0 33
M-10 Rear work lamp error 1

Contents of 1) None of machine monitor display, rear work lamp and side work
• Rear work lamp error
trouble lamp lights up.
Related
• When machine monitor output, L06 (2) is grounded, front work lamp and front axle work lamp light up.
information
• Unless rear work lamp relay L61 turns ON, side work lamp relay L51 does not turn ON.

1 Disconnection of fuse Fuse box 2: Fuse (2) Continuity Yes
Defective rear work lamp relay When replace rear work lamp relay L61 with other relay and if the
2
L61 system returns to normal state, rear work lamp relay is defective.
Disconnection in wiring 2) Disconnect L06, FS5 and L61, then carry out troubleshooting.
harness Resis-
3 Between L06 (female) (2) – L61 (6) Max. 1 z
contact in connector) Wiring harness between FS5 (female) (2) – Resis-
Max. 1 z
L61 (2), (4), (5) tance
Possible
2) Disconnect L06, FS5 and L61, then carry out troubleshooting.
causes and
standard value Ground fault in wiring harness Resis-
4 Between L06 (female) (2) – (3) Min. 1 Mz
in normal state (Contact with ground circuit) tance
Between FS5 (female) (2) – L61 (female) (2), Resis-
Min. 1 Mz
(4), (5) and chassis ground tance
Hot short in wiring harness 2) Disconnect L06 and L61.
circuit)
4) Turn rear work lamp switch ON and carry out troubleshooting.
34 WA800, WA900-3E0
WA800, WA900-3E0 35
Contents of 2) Any one of machine monitor display, rear work lamp and side
• Rear work lamp error
trouble work lamp does not light up.
Related
• When machine monitor output, L06 (2) is grounded, rear work lamp and side work lamp light up.
information
• Unless rear work lamp relay L61 turns ON, side work lamp relay L51 does not turn ON.

Defective side work lamp relay When replace side work lamp relay L51 with other relay and if the
1
L51 system returns to normal state, side work lamp relay is defective.
2) Disconnect L05 and L61, then carry out troubleshooting.
Resis-
Between L05 (female) (18) – L61 (1) Max. 1 z
tance
Disconnection in wiring Between L61 (1) and chassis ground Continuity Yes
harness
2 Between L61 (1) – L51 (5) Continuity Yes
Between L51 (6) and chassis ground Max. 1 z
tance
Wiring harness between FS6 (female) (3) – Resis-
Max. 1 z
L51 (2) tance
Possible Between L51 (1) and chassis ground Continuity Yes
causes and
standard value
2) Disconnect FS6, L05, L51, L61, C16, C17, G03, G07, G02 (if
in normal state
equipped) and G08 (if equipped), then carry out troubleshooting.
Resis-
tance
3 Wiring harness between L61 (3) – G02 (1) – Resis-
G08 (1) and chassis ground (if equipped) tance
Between FS6 (3) – L51 (2) and chassis Resis-
Min. 1 Mz
ground tance
Wiring harness between L51 (1) – C16 (1) – Resis-
Min. 1 Mz
C17 (1) and chassis ground tance
4) Turn rear work lamp switch ON and carry out troubleshooting.
36 WA800, WA900-3E0
WA800, WA900-3E0 37
M-11 Abnormality in transmission cut-off switch 1

Contents of • Abnormality in transmission 1) Machine monitor display lights up but cut-off function does not
trouble cut-off switch work.
Related • If machine monitor display does not light up and cut-off function does not work even when transmis-
information sion cut-off switch is pressed, machine monitor is defective.

2) Disconnect L34.
Defective transmission cut-off 3) Turn starting switch ON, transmission cut-off switch ON and carry
1
switch out troubleshooting.
2) Disconnect L06, C5 and L34, then carry out troubleshooting.
Between L06 (female) (3) – C5 (6) Max. 1 z
harness tance
2
contact in connector) Between C5 (female) (7) – L34 (6) Max. 1 z
tance
Resis-
Between L34 (5) and chassis ground (R10) Max. 1 z
tance
Ground fault in wiring harness 2) Disconnect L06 and C5, then carry out troubleshooting.
3
Possible (Contact with ground circuit) Wiring harness between L06 (female) (3) – Resis-
causes and Min. 1 Mz
C5 (female) (6) and chassis ground tance
standard value
in normal state Hot short in wiring harness 2) Disconnect L34.
circuit)
Between L34 (male) (6) – (5) Voltage Max. 1 V
2) Disconnect C5.
5) Turn transmission cut-off switch ON and carry out troubleshoot-
ing.
Between L06 (male) (3) – (16) Voltage 20 – 30 V
Defective transmission & 4) Turn transmission cut-off switch ON and carry out troubleshoot-
6
AJSS controller ing.
38 WA800, WA900-3E0
WA800, WA900-3E0 39
Contents of • Abnormality in transmission 2) Cut-off function works irrespective of transmission cut-off switch
trouble cut-off switch being ON or OFF.
Related • If machine monitor display does not light up and cut-off function does not work even when transmis-
information sion cut-off switch is pressed, machine monitor is defective.

Defective transmission cut-off 2) Disconnect L34.
switch
If cut-off function works, transmission cut-off switch is defective.
Disconnection in wiring har- 1) Turn the starting switch OFF.
ness 2) Disconnect L06 and C5, then carry out troubleshooting.
2
contact in connector) Between L06 (female) (3) – C5 (6) Max. 1 z
tance
Ground fault in wiring harness 2) Disconnect C5 and L34, then carry out troubleshooting.
3
(Contact with ground circuit) Wiring harness between C5 (female) (7) – Resis-
Possible Min. 1 Mz
causes and L34 (6) and chassis ground tance
in normal state 2) Disconnect C5.
5) Turn transmission cut-off switch OFF and carry out troubleshoot-
ing.
Defective transmission & 4) Turn transmission cut-off switch OFF and carry out troubleshoot-
5
AJSS controller ing.
40 WA800, WA900-3E0
WA800, WA900-3E0 41
M-12 Abnormality in low idle selection 1

Contents of 1) Even when low idle select switch is turned ON, low idle speed
• Low idle selection error
trouble does not rise nor lamp is lit.
Related
information
Possible Cause Standard value in normal state/Remarks on troubleshooting

causes and 1) Turn starting switch ON and carry out troubleshooting.
standard value 1 Defective machine monitor 2) Turn low idle select switch ON.
in normal state Low idle speed rises and the lamp lights up.
Contents of 2) When low idle select switch is turned ON, the lamp lights up but
• Abnormality in low idle selection
trouble low idle speed does not rise.
Related
• Related circuit diagram: See contents of trouble 3).
information

harness 2) Disconnect L06 and EM1, then carry out troubleshooting.
1
contact in connector) Between L06 (female) (7) – EM1 (4) Max. 1 z
tance
Ground fault in wiring harness 2) Disconnect L06 and EM1, then carry out troubleshooting.
2
(Contact with ground circuit) Between L06 (female) (7) – EM1 (4) and Resis-
Possible Min. 1 Mz
causes and
in normal state 2) Disconnect L06 and connect T-branch (keep L06 disconnected).
4) Turn low idle select switch ON and carry out troubleshooting.
2) Disconnect EM1 and connect T-branch.
Defective engine controller 3) Turn starting switch ON.
4
(L bank) 4) Turn low idle select switch ON and carry out troubleshooting.
Between EM1 (4) and chassis ground Voltage 20 – 30 V
42 WA800, WA900-3E0
Contents of 3) When low idle select switch is turned OFF, the lamp goes out but
• Abnormality in low idle selection
trouble low idle speed does not drop.
Related
information

Hot short in wiring harness 2) Disconnect L06 and EM1.
circuit)
Between L06 (female) (7) – (female) (16) Voltage Max. 1 V
Possible
2) Disconnect L06 and connect T-branch (keep L06 disconnected).
causes and
standard value
4) Turn low idle select switch OFF and carry out troubleshooting.
in normal state
Between L06 (female) (7) – (female) (16) Voltage Max. 1 V
2) Disconnect EM1 and connect T-branch.
Defective engine controller 3) Turn starting switch ON.
3
(L bank) 4) Turn low idle select switch OFF and carry out troubleshooting.
Between EM1 (4) and chassis ground Voltage Max. 1 V
WA800, WA900-3E0 43
M-13 Emergency steering indication error 1

Contents of • Emergency steering indication 1) Emergency steering normal indication does not light up.
trouble error
Related
Related circuit diagram: See contents of trouble 3).
information

Possible Disconnection in wiring 1) Turn the starting switch OFF.
causes and harness 2) Disconnect L05 and carry out troubleshooting.
1
standard value (Disconnection or defective Between L05 (female) (10) and chassis Resis-
in normal state contact in connector) Max. 1 z
ground (R10) tance
2 Defective machine monitor a When cause 1 is not detected
Contents of • Emergency steering indication

2) Emergency steering lamp does not light up normally.
trouble error
Related • Related circuit diagram: See contents of trouble 3).
information • Emergency steering indicator switch is turned OFF while emergency steering is in operation.

Defective emergency steering 2) Disconnect R01.
indicator switch
Emergency steering lamp lights up normally.
Disconnection in wiring har- 1) Turn the starting switch OFF.
Possible 2) Disconnect L05 and R01, then carry out troubleshooting.
ness
causes and 2
(Disconnection or defective Between L05 (female) (11) – R01 (female) Resis-
standard value
in normal state (1) tance
Ground fault in wiring harness 2) Disconnect L05 and R01, then carry out troubleshooting.
3
(Contact with ground circuit) Wiring harness between L05 (female) (11) – Resis-
Min. 1 Mz
R01 (female) (1) and chassis ground tance
44 WA800, WA900-3E0
Contents of • Emergency steering indication 3) Emergency steering lamp remains lit up.
trouble error
Related
• Emergency steering indicator switch is turned OFF while emergency steering is in operation.
information

2) Disconnect R01.
Defective emergency steering 3) Start the engine and carry out troubleshooting.
1
indicator switch
Resis-
Between R01 (male) (1) – (2) Max. 1 z
Possible tance
standard value Disconnection in wiring har- 2) Disconnect L05 and R01, then carry out troubleshooting.
in normal state ness Between L05 (female) (11) – R01 (female) Resis-
2 Max. 1 z
(Disconnection or defective (1) tance
contact in connector) Between R01 (female) (2) and chassis Resis-
Max. 1 z
ground (R10) tance
WA800, WA900-3E0 45
M-14 Parking brake dragging warning error 1

Contents of • Parking brake dragging warning 1) When parking brake is applied, buzzer will sound even if forward-
trouble error reverse travel switch is set to "N" position, and caution lamp flashes.
• For forward-reverse travel switch position failure, see failure code [DDK3KZ] (transmission & AJSS
Related
controller LED indication "20").
information
• Forward-reverse travel switch position data ("F, N, R") is received from transmission & AJSS controller on S-Net.

Defective forward-reverse Check if failure code [DDK3KZ] (Transmission & AJSS controller
Possible 1
travel switch LED display: "20") appears. If appears, see failure code [DDK3KZ].
causes and
standard value Defective communication of
2 See "M-19".
in normal state S-NET
Contents of • Parking brake dragging warning 2) When parking brake is applied, buzzer and caution lamp do not
trouble error work even if FNR switch is set to other than "N" position.
• For forward-reverse travel switch position failure, see failure code [DDK3KZ] (transmission & AJSS
Related
controller LED indication "20").
information
• Forward-reverse travel switch position data ("F, N, R") is received from transmission & AJSS controller on S-Net.

1 Defective parking brake switch If parking brake indicator lamp does not light up, see "M-6".
Possible Defective forward-reverse Check if failure code [DDK3KZ] (Transmission & AJSS controller
2
causes and travel switch LED display: "20") appears. If appears, see failure code [DDK3KZ].
standard value Defective communication of
in normal state 3 See "M-19".
S-NET
46 WA800, WA900-3E0
M-15 Buzzer and caution lamp error upon parking brake dragging
warning outputting 1
• When parking brake dragging
Contents of
warning is output, buzzer and 1) Buzzer and caution lamp work continually.
trouble
caution lamp error occurs.
Related
• Buzzer and caution lamp work when L07 is open (24 V).
information

1 Defective machine monitor Repeti-
tion of
0 V and
20 – 30 V
harness 2) Disconnect L07 and L19, then carry out troubleshooting.
Possible 2
causes and contact in connector) Between L07 (female) (6) – L19 (female) (5) Max. 1 z
tance
standard value
Hot short in wiring harness 2) Disconnect L07 and L19.
circuit)
2) Disconnect L07 and L19, then connect T-branch to L19.
Defective maintenance
4 Repeti-
monitor
tion of
0 V and
20 – 30 V
WA800, WA900-3E0 47
• Buzzer and caution lamp error

Contents of
upon parking brake dragging 2) Buzzer and caution lamp do not work.
trouble
warning outputting
Related
• Buzzer and caution lamp work when L07 (6) is 24 V or L07 is open (24 V).
information

1 Defective machine monitor Repeti-
tion of
0 V and
20 – 30 V
Possible
causes and
standard value Ground fault in wiring harness 2) Disconnect L07 and L19, then carry out troubleshooting.
2
in normal state (Contact with ground circuit) Resis-
tance
2) Disconnect L07 and L19, then connect insert T-branch to L19.
3 Repeti-
monitor
tion of
0 V and
20 – 30 V
48 WA800, WA900-3E0
M-16 Buzzer error 1

Contents of 1) When the starting switch is ON, the self-check buzzer does not
• Buzzer error
trouble sound for 3 seconds.
• Buzzer output pin is connected with wired OR, so buzzer sounds when either machine monitor, main-
Related
tenance monitor or relay L65 connects the buzzer negative (–) side to ground.
information
• If fuse 1 (10) is broken, neither machine monitor nor maintenance monitor can be turned ON.

harness Wiring harness between FS2 (female) (9) – Resis-
1 Max. 1 z
(Disconnection or defective L42 (female) (1) tance
tance
2 Defective buzzer 4) Connect Pin 2 (buzzer wiring: black) of T-branch connector to the
Possible
causes and chassis ground and carry out troubleshooting.
standard value Feed current between L42 (1)(+) – (2)(–). Buzzer sounds.
in normal state
Hot short in wiring harness 2) Disconnect L06, L19 and L42.
circuit)
2) Disconnect L06 and connect T-branch to L06 (male).
4 Defective machine monitor Between L06 (male) (8) – (16)
a When the starting switch is ON, buzzer
Voltage Max. 1 V
error for 3 seconds (during self-check pro-
cess)
50 WA800, WA900-3E0
WA800, WA900-3E0 51
Contents of
• Buzzer error 2) Transmission & AJSS controller sounds no buzzer.
trouble
• Transmission & AJSS controller sounds buzzer through two paths via machine monitor or relay L65.
1 When sounding buzzer via relay L65 path
1) AJSS lever operation during steering lock: Peep
2) During error to steering lock system (disconnection or short circuit): Peep
a For defective relay L65 primary coil side or defective transmission & AJSS controller, see fail-
ure code [D19AKB].
2 When sounding buzzer via machine monitor path
1) Immediately after key ON (buzzer sounds 2 sec. and 3 sec. after key ON): Pip, Pip
Related 2) FR changeover caution sounding (for 3 sec. Pip, Pip, Pip, Pip)
information 3) Shift down protection caution (Pip, Pip, Pip, Pip, until the condition is off)
4) Forward-reverse travel (FNR) switch is set to "F" or "R" while shift steering lever is being locked.
(Pip, Pip, Ppip keeps on sounding until the condition is off (lever is set to "N")
5) AJSS angle sensor neutral adjustment is completed
(Sounds 3 times upon completion: Pip, Pip, Pip).
6) When cut-off point is set up (Sounds 2 times upon setting is completed: Pip, Pip)
7) When cut-off point is reset (Pip upon reset)
tenance monitor or relay L65 connects the buzzer negative side (–) to ground.

2) Replace L65 with other relay.
1 Defective relay L65 3) Turn starting switch ON.
Buzzer sounds.
2) Disconnect L65, L42, C2 and L08, then carry out troubleshooting.
harness tance
2
contact in connector) Between C2 (female) (10) – L08 (female) (6) Max. 1 z
tance
Resis-
tance
Possible 2) Disconnect L08 and C2.
causes and 3) Turn starting switch ON and carry out troubleshooting.
3 (Contact with power supply
standard value
circuit) Wiring harness between L08 (female) (6) –
in normal state Voltage Max. 1 V
C2 (10) and chassis ground
2) Disconnect C2.
4 Defective machine monitor 4) Connect C2 (female) (10) to (female) (11) (GND) and carry out
troubleshooting.
The caution buzzer sounds
Defective transmission & 4) Set steering lock lever and set the forward-reverse travel (FNR)
5 switch to "F" (See related information 2).
AJSS controller
Pulse of
Voltage 0 V and
C2 (10) and chassis ground
24 V
52 WA800, WA900-3E0
WA800, WA900-3E0 53
Contents of
• Buzzer error 3) Buzzer sounds constantly.
trouble
• Buzzer output pin is connected with wired OR, and buzzer sounds when either maintenance monitor
Related or relay L65 connects the buzzer negative side (–) to ground.
information • For defective relay L65 primary coil side or defective transmission & AJSS controller, see failure code
[D19AKB].

Defective relay L65 or defec- 2) Disconnect L65.
1 tive transmission & AJSS con- 3) Turn starting switch ON and carry out troubleshooting.
troller
Buzzer does not sound.
Defective transmission & 2) Disconnect C2.
AJSS controller
2) Disconnect L06.
3 Defective machine monitor 3) Turn starting switch ON and carry out troubleshooting.
Possible
causes and
standard value Defective maintenance moni- 2) Disconnect L19.
in normal state tor
2) Disconnect L06, L19 and L42, then carry out troubleshooting.
Resis-
Grounding fault in wiring Between L06 (female) (8) – (16) Min. 1 Mz
tance
5 harness (Contact with ground
circuit) 1) Turn the starting switch OFF.
2) Disconnect L08 and C2, then carry out troubleshooting.
Min. 1 Mz
2) Disconnect L42.
6 Defective buzzer 3) Turn starting switch ON.
Between L42 (female) (1) (+) – (2) (–) Voltage Max. 1 V
54 WA800, WA900-3E0
WA800, WA900-3E0 55
M-17 Switching state of machine monitor is not stored 1

Contents of
• Switching state of machine monitor is not stored.
trouble
Related • If D15 is defective, battery relay does not turn ON (see "E-1", the troubleshooting for electrical sys-
information tem).

Possible 1
causes and contact in connector) Max. 1 z
(2) tance
standard value
2 Defective machine monitor 3) Turn starting switch ON and carry out troubleshooting.
Between L07 (10) – (12) Voltage 20 – 30 V
56 WA800, WA900-3E0
M-18 Failure indication mode error 1

Contents of
• Failure indication mode error 1) Machine monitor does not enter failure indication mode.
trouble
Related
• For failure of alternator, see Failure code [AB00**].
information

a Since failure code [AB00**] for alternator will appear, see the fail-
ure code appeared.
Possible
causes and Hot short in wiring harness 2) Disconnect L05 and connect T-branch.
standard value 2 (Contact with power supply 3) Turn starting switch ON and carry out troubleshooting.
in normal state circuit)
If causes 1 – 2 are not detected, machine monitor may be defective.
Contents of
• Failure indication mode error 2) Failure time in the failure indication mode does not gain.
trouble
Related
• For failure of alternator, see Failure code [AB00**].
information

a Since failure code [AB00**] for alternator will appear, see the fail-
ure code appeared.
Possible
causes and
harness 2) Disconnect L05 and carry out troubleshooting.
standard value 2
in normal state (Disconnection or defective Wiring harness between L05 (5) – alternator Resis-
(terminal R) tance
58 WA800, WA900-3E0
WA800, WA900-3E0 59
M-19 Machine monitor does not indicate failure code 1

Contents of
• Machine monitor does not indicate failure code.
trouble
• If VHMS controller is installed, engine service monitor indicates converted failure codes (see the list
Related
of failure codes), too.
information
• When replacing machine monitor, set dip switch 3 on the back of the machine monitor to "F."

a Tester can not be applicable since pulse width is less than 1 ms.
Repeti-
tion of
0 V and
12 V
2) Disconnect VC04.
Possible
causes and Machine monitor indicates failure code.
standard value
in normal state
Disconnection in wiring 2) Disconnect C3B, L08 and VC04, then carry out troubleshooting.
harness Wring harness between C3B (female) (4) – Resis-
3 Max. 1 z
(Disconnection or defective L08 (female) (1), (3) – VC04 (female) (18) tance
contact in connector) Between L08 (female) (2), (4) – VC04 Resis-
Max. 1 z
(female) (17) tance
Ground fault in wiring harness 2) Disconnect C3B, L08 and VC04, then carry out troubleshooting.
4
tance
Defective transmission & If causes 1 – 4 are not detected, machine monitor may be defective.
5
AJSS controller (Since trouble is in system, troubleshooting cannot be carried out.)
60 WA800, WA900-3E0
WA800, WA900-3E0 61
M-20 Abnormality in auto grease system 1

Contents of • Abnormality in auto grease sys-
1) Forced greasing disabled
trouble tem
• Related circuit diagram: See contents of trouble 2).
Related
• See the operation and maintenance manual, "Handling Auto Grease System."
information
• Machine monitor L06 Pin 5: L output for forced greasing

2) Disconnect GRE, insert T-branch and connect the auto grease
system.
Defective auto grease system 3) Turn starting switch ON.
1 4) Turn auto grease switch ON and carry out troubleshooting.
or faulty handling
a See the operation and maintenance manual, "Handling of Auto
Grease System."
Between GRE (1) and chassis ground Voltage Max. 3 V
2) Disconnect L06 and GRE, then carry out troubleshooting.
Between L06 (female) (5) – GRE (female) Resis-
Max. 1 z
(1) tance
Between GRE (female) (5) and chassis Resis-
Possible ground (R10) tance
harness
causes and 2 1) Turn the starting switch OFF.
standard value contact in connector) 2) Disconnect GRE and connect T-branch.
in normal state (Do not connect auto grease system.)
a Check for power supply input.
Between GRE (4) – (5) Voltage 20 – 30 V
Between GRE (6) – (5) Voltage 20 – 30 V
Ground fault in wiring harness 2) Disconnect L06 and GRE, then carry out troubleshooting.
3
Between L06 (5) – (16) Min. 1 Mz
tance
2) Disconnect L08 and insert T-branch to L08.
(Do not connect auto grease system.)
4) Turn auto grease switch ON and carry out troubleshooting.
62 WA800, WA900-3E0

2) Machine monitor lamp flashes rapidly (two times/sec.)
trouble tem
• Machine monitor lamp flashes rapidly (two times/sec.) (Abnormal): Machine monitor L07 Pin 11 and
Related
L08 Pin 5 are both input to L.
information
• Machine monitor indication is lit (Normal): Machine monitor L07 Pin 11 is input to L, and L08 Pin 5 to H.
a Machine monitor L08 Pin 5: H input poses problem during normal state.

3) Disconnect GRE and connect auto grease system.
Between L08 (5) and chassis ground Voltage 20 – 30 V
causes and 2) Disconnect L08 and GRE, then carry out troubleshooting.
harness
standard value 2
(Disconnection or defective Between L08 (female) (5) – GRE (female) Resis-
in normal state
(3) tance
3
(Contact with ground circuit) Between L08 (female) (5) and chassis Resis-
Min. 1 Mz
ground tance
Defective auto grease system a See the operation and maintenance manual, "Handling Auto
4
or faulty handling Grease System", if cause 1 – 3 are not detected.
WA800, WA900-3E0 63
Contents of • Abnormality in auto grease sys- 3) Machine monitor lamp flashes rapidly (two times/sec.) when
trouble tem grease capacity is zero.
• Related circuit diagram: See contents of trouble 2.
Related
• Machine monitor lamp flashes slowly (once/sec.) when grease capacity is zero under normal state.
information
: Machine monitor L07 Pin 11 is input to H, and L08 Pin 5 to L.

Between L07 (11) – (12) Voltage 20 – 30 V
causes and 2) Disconnect L07 and GRE, then carry out troubleshooting.
harness
standard value 2
(Disconnection or defective Between L07 (female) (11) – GRE (female) Resis-
in normal state
(2) tance
3
(Contact with ground circuit) Between L07 (female) (11) and chassis Resis-
Min. 1 Mz
ground tance
4
Table 1 (Relationship between input signal and indication)

L07 (11) L08 (5) Indication (meaning on normal state)
L L Rapid flashing (two times/sec.) (Error)
H L Slow flashing (once/sec.) (Grease is zero)
H H Lamp turned out (not operating)
L H Lamp is lit (normal)
64 WA800, WA900-3E0

4) Machine monitor indication turns out.
trouble tem
• Machine monitor indication turns out (not operating):
Related Machine monitor L07 Pin 11 and L08 Pin 5 are both input to H.
information • Machine monitor indication is lit (Normal):
Machine monitor L07 Pin 11 is input to L, and L08 Pin 5 to H.

Possible
causes and L07 (11) – (12) Voltage Max. 3 V
in normal state Hot short in wiring harness 2) Disconnect GRE.
2 (Contact with power supply 3) Turn starting switch ON.
circuit) Between L07 (11) – GRE (female) (2) and
Voltage Max. 1 V
GRE (female) (5)
3
WA800, WA900-3E0 65

© 2006 KOMATSU
All Rights Reserved
66 WA800, WA900-3E0
SEN02153-02
WA800-3E0
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
Troubleshooting of maintenance
monitor system (K-mode)
Maintenance monitor system .......................................................................................................................... 3
K-1 Maintenance monitor does not work ........................................................................................................ 4
K-2 Immediately after turning starting switch ON (within 3 sec.),
engine starts but the maintenance monitor remains fully lit up................................................................. 6
K-3 Work check item flashes upon turning starting switch ON (engine not running) ...................................... 8
K-4 Caution item flashes upon turning starting switch ON (engine running) ................................................ 12
K-5 The warning buzzer does not sound while caution item indicator flashes.............................................. 28
K-6 The warning buzzer sounds while monitor indicates no error ................................................................ 30
K-7 The warning lamps (check lamp and caution lamp) do not flash while caution item indicator flashes ... 31
K-8 Warning lamps (check and caution lamps) lights up while the maintenance monitor indicates no error 33
K-9 Night lamp does not light up................................................................................................................... 36
K-10 Night lamp remains lit up...................................................................................................................... 38
K-11 Service meter does not work ................................................................................................................ 40
WA800, WA900-3E0 1
K-12 Service meter keeps on working (when engine stops) ......................................................................... 42

K-13 Gauge items (fuel, engine coolant temperature and torque converter oil temperature) error .............. 44
2 WA800, WA900-3E0
Maintenance monitor system 1

Maintenance monitor system
a Main monitor may mean machine monitor in other section.
WA800, WA900-3E0 3
K-1 Maintenance monitor does not work 1

Contents of 1) Maintenance monitor does not fully light up for 3 sec-
• Maintenance monitor does not work.
trouble onds upon turning starting switch ON.
Related • Since maintenance monitor shares the power supply system with machine monitor, check if machine
information monitor is working.

Defective maintenance 1) Turn the starting switch OFF.
monitor 2) Disconnect L18 and connect T-branch.
(When power supply pin
voltage is normal) Between L18 (1), (2) – (3), (9) Voltage 20 – 30 V
causes and 1) Turn starting switch OFF.
standard value 2) Disconnect L18 and L19, then carry out troubleshooting.
in normal state
Disconnection in wiring Wiring harness between L18 (female) (1), (2) Resis-
Max. 1 z
harness – battery relay BTR2 (R02) tance
4
(Disconnection or defective Between L18 (female) (3), (9) – L19 (female) Resis-
(8) tance
Max. 1 z
ground (R11) tance
5
Between L18 (female) (1), (2) – (3) and (9) Min. 1 Mz
tance
Contents of 2) Maintenance monitor partly does not light up for 3

• Maintenance monitor does not work.
trouble seconds upon turning starting switch ON.
Related
information
Possible
Defective maintenance monitor
cause
3) When turning starting switch ON, maintenance moni-

Contents of
• Maintenance monitor does not work. tor remains lit up and does not go out for 3 seconds
trouble
and longer.
Related
information
Possible
Defective maintenance monitor
cause
4 WA800, WA900-3E0
WA800, WA900-3E0 5
K-2 Immediately after turning starting switch ON (within 3 sec.), engine

starts but the maintenance monitor remains fully lit up 1
Contents of • Immediately after turning starting switch ON (within 3 sec.), engine starts but the maintenance moni-
trouble tor remains fully lit up.
Related • Troubleshooting of machine monitor system: Refer to "M-2."
information • If engine does not start, refer to troubleshooting "E-1" for electrical system.

4) Turn starting switch START and carry out troubleshooting.
Possible
causes and Between L19 (1) – (8) Voltage 20 – 30 V
standard value 1) Turn starting switch OFF.
in normal state 2) Disconnect L95 and L19, then carry out troubleshooting.
harness Resis-
2 Between L19 (female) (1) – L95 (female) (3) Max. 1 z
contact in connector) Between L19 (female) (8) and chassis Resis-
Max. 1 z
ground (R11) tance
6 WA800, WA900-3E0
WA800, WA900-3E0 7
K-3 Work check item flashes upon turning starting switch ON (engine
not running) 1
Contents of
1) Engine oil level indicator flashes.
trouble
• Detection is unavailable when the engine coolant temperature is 60°C or above.
• The error is reset when engine is started.
• Refer to failure code [B@BAZK].
Related
• Low engine oil level can be checked with monitoring code: 40945 "D-IN-9."
information
(1: Low oil level, 0: Normal)
• Engine oil level indicator flashes: The engine oil level switch signal circuit was opened (disconnected
from ground wire).

• Engine oil level is normal
1 Low engine oil level a If engine oil level is low, check surroundings of the engine for
leakage of oil before adding oil.
Defective engine oil level Engine oil level is Resis-
2 Max. 1 z
switch Between E05 (male) normal tance
(1) – (2) Resis-
Engine oil level is low Min. 1 Mz
tance
2) Disconnect D18 and carry out troubleshooting with starting switch
OFF. (Measure in the diode range.)
Continuity
Possible
causes and Between D18 (male) Forward direction: Continue
Continuity
standard value (1) (+) – (2) (–) Reverse direction: No continuity
in normal state 1) Prepare with starting switch OFF, then carry out troubleshooting
with starting switch OFF.
2) Disconnect D18, E05, VC05 and L18, then carry out trouble-
shooting with starting switch OFF.
harness Max. 1 z
4 D18 (female) (3) tance
Between D18 (female) (2) and Resis-
when engine oil level
is normal
Max. 1 z
(female) (1) tance
5 Engine oil level is
monitor Between L18 (13) – Voltage Max. 1 V
normal
(3)
Engine oil level is low Voltage 20 – 30 V
8 WA800, WA900-3E0
WA800, WA900-3E0 9
Contents of
2) Engine coolant level indicator flashes.
trouble
• Refer to failure codes [B@BCZK] and [b@BCZK].
Related • Low coolant level can be checked with monitoring code: 40944 "D-IN-7" (1: low level, 0: normal)
information • Engine coolant level indicator flashes: Radiator level switch signal circuit is opened (disconnected
from ground wire).

• Radiator coolant level is normal.
Lowering of radiator coolant
1
level a If radiator coolant level is low, check surroundings of the engine
for leakage of oil before adding.
2) Disconnect connector G06 and carry out troubleshooting.
Defective radiator coolant Radiator coolant level Resis-
2 Max. 1 z
level switch Between G06 (male) is normal tance
(1) – (2) Low radiator coolant Resis-
Min. 1 Mz
level tance
2) Disconnect D19 and carry out troubleshooting.
(Measure in the diode range.)
Continuity
Possible Between D19 (male) Forward direction: Continue

Continuity
causes and (1) (+) – (2) (–) Reverse direction: No continuity
in normal state 2) Disconnect D19, G06, VC04 and L18, then carry out trouble-
Max. 1 z
4
when radiator cool-
ant level is normal
Max. 1 z
(female) (1) tance
Defective maintenance 4) Turn starting switch ON.
5
monitor Radiator coolant level
Voltage Max. 1 V
is normal
Between L18 (8) – (3)
Low radiator coolant
Voltage 20 – 30 V
level
10 WA800, WA900-3E0
WA800, WA900-3E0 11
K-4 Caution item flashes upon turning starting switch ON (engine

running) 1
Contents of
1) Engine oil pressure indicator flashes.
trouble
• Refer to failure code [B@BAZG].
• Fuse (10) in fuse box 1 is normal since engine oil pressure indicator flashes.
• Engine oil pressure switch while the engine is run: OPEN
o Relay 64: OFF
Related o Engine pressure switch pin of the maintenance monitor: Connected to ground wire
information • The engine oil pressure indicator flashes: Engine oil pressure switch is short-circuited (connected to
ground circuit) while the engine is running.
• State of engine oil pressure switch can be checked with monitoring code: 40973 "D-IN-1".
(1: ON; Engine is not started (pressure is not present), 0: OPEN; Engine is started (pressure is
present))

1 Refer to S-12 Troubleshooting for engine unit.
2) Disconnect E09 and carry out troubleshooting with starting switch
OFF.
Between E09 (sensor side terminal) and Resis-
Max. 1 z
2 Defective oil pressure switch chassis ground tance
2) Disconnect E09.
a Engine oil pressure indicator stops flashing.
2) Disconnect L64 and replace it with a new one.
3 Defective relay 3) Turn starting switch ON and carry out troubleshooting.
a Engine oil pressure indicator stops flashing.
Possible
causes and 4 Defective diode Between D20 (male) Forward direction: Continue
Continuity
standard value (3) (+) – (2) (–) Reverse direction: No continuity
in normal state Between D20 (male) Forward direction: Continue
Continuity
(1) (+) – (2)(–) Reverse direction: No continuity
2) Disconnect D20, VC05, L18 and L64, then carry out troubleshoot-
ing with starting switch OFF.
Max. 1 z
Between D20 (female) (2) – L64 Resis-
Max. 1 z
(female) (3) tance
harness Max. 1 z
5 chassis ground tance
Between L64 (female) (2) and Resis- When the engine oil
chassis ground tance pressure switch is
normal
Between L64 (female) (1) – fuse Resis-
Max. 1 z
box 1 fuse (10) tance
Max. 1 z
(1) tance
12 WA800, WA900-3E0

2) Disconnect D20, E09, VC05, L18 and L64, then carry out trouble-
Min. 1 Mz
(3) and chassis ground tance
Possible 6 Wiring harness between D20 (female) (2) – Resis-
causes and L64 (female) (3) and chassis ground tance
standard value Wiring harness between L64 (female) (2) – Resis-
E09 and chassis ground tance
Min. 1 Mz
D20 (1) and chassis ground tance
Defective maintenance 2) Disconnect L18 and connect T-branch.
monitor
WA800, WA900-3E0 13
14 WA800, WA900-3E0
Contents of
2) Charge indicator flashes.
trouble
• For similar error, troubleshooting was carried out by engine service monitor in [AB00MA], by pre-
lubrication controller in [AB00MB] and by VHMS controller in [AB00MC] respectively.
a Charging voltage from alternator (R terminal): Normal if 12 V or above and abnormal if hysteresis of 5
Related
V or below
information
• VHMS controller: VC02 (4) pin alternator (R terminal) charging voltage can be checked with monitor-
ing code: 04304 (V).
• Flashing charge indicator: Charging voltage is not supplied from alternator R terminal (OPEN).

Between alternator terminal R and chassis
Voltage Min. 12 V
ground
harness 3) Disconnect connector L18 and carry out troubleshooting.
Possible 2
causes and Between wiring harness terminals (E21) – Resis-
standard value
in normal state
Ground fault in wiring harness 3) Disconnect connector L18 and carry out troubleshooting.
3
Min. 1 Mz
ground tance
If causes 1 – 3 are not detected, maintenance monitor may be
monitor
carried out.)
WA800, WA900-3E0 15
16 WA800, WA900-3E0
Contents of
3) Brake oil pressure indicator flashes.
trouble
• Refer to failure code [B@JFZG].
• Brake accumulator pressure switch while engine is running: Closed (When normal)
Related
o Brake accumulator pressure switch pin of controller: Connected to ground wire (when normal)
information
• The brake oil pressure indicator flashes: Brake accumulator pressure switch is opened while the
engine is running.

1 Refer to troubleshooting of hydraulic and mechanical system: H-10.
OFF (measurement in the diode range)
Continuity
Continuity
2) Disconnect BC04, BC05, BC06 and BC07.
Resis-
SW1: Between BC04 (male) (1) – (2) Max. 1 z
tance
3 Resis-
switches (SW1 – SW4) SW2: Between BC05 (male) (1) – (2) Max. 1 z
tance
Resis-
Possible SW3: Between BC06 (male) (1) – (2) Max. 1 z
tance
causes and
Resis-
standard value SW4: Between BC07 (male) (1) – (2) Max. 1 z
in normal state tance
2) Disconnect D17, VC05, L18, BC04, BC05, BC06 and BC07, then
carry out troubleshooting with starting switch OFF.
Max. 1 z
(3) tance
Between D17 (female) (2) – BC04 (female) Resis-
Max. 1 z
(1) tance
Disconnection in wiring Between BC04 (female) (2) – BC05 (female) Resis-
harness Max. 1 z
4 (1) tance
Between BC05 (male) (2) – BC06 (female) Resis-
(1) tance
Max. 1 z
(1) tance
Between BC07 (female) (2) and chassis Resis-
Max. 1 z
ground tance
Between L18 (female) (11) – D17 (female) Resis-
Max. 1 z
(1) tance
WA800, WA900-3E0 17

2) Disconnect D17, VC05, L18, BC04, BC05, BC06 and BC07, then
carry out troubleshooting with starting switch OFF.
Min. 1 Mz
(3) and chassis ground tance
Possible 5 Wiring harness between D17 (female) (2) – Resis-
causes and BC04 (female) (1) and chassis ground tance
standard value Between BC07 (female) (1), BC06 (female) Resis-
(1), BC05 (female) (1) and chassis ground tance
Min. 1 Mz
D17 (1) and chassis ground tance
Defective maintenance 2) Disconnect L18 and connect T-branch.
monitor
18 WA800, WA900-3E0
WA800, WA900-3E0 19
Contents of
4) Air cleaner (R.H.) indicator flashes.
trouble
• Refer to failure code [AA1BNX].
• Troubleshooting for air cleaner L.H. clogging is carried out with failure code [AA1ANX]. When
[AA1ANX] is not indicated, replace, for instance, the relay, diode and air cleaner connector with that
of the air cleaner L.H. circuit one by one. If, as the result, failure code [AA1BNX] is replaced with
Related [AA1ANX], you can judge this replaced parts are the cause.
information • Fuse (10) of fuse box 1 is not broken since air cleaner (R.H.) indicator flashes.
• When air cleaner R.H. is normal, L18 (14) is connected to ground wire. When clogged: OPEN
• Clogging can be checked with monitoring code 40945 "D-IN-15" (1: normal, 0: clogged)
• L18 (14) air cleaner (R.H.) indicator flashes: Air cleaner clogging signal circuit is opened (discon-
nected from ground wire).

1 Air cleaner clogging
Dust indicator is lit in red Air cleaner clogging
Relay
Normal state is not
(L80) is
replaced. Relay
Normal state is recov-
(L80) is
ered
2
(L80) 1) Turn starting switch OFF.
2) Disconnect connector L80.
3) Independent part check
Resis- 260 –
Between L80 (male) (1) – (2)
Possible tance 320 z
causes and Resis-
standard value Between L80 (male) (3) – (5) Min. 1 Mz
tance
in normal state
Resis-
tance
Defective air cleaner clogging 4) Turn starting switch ON.
3
sensor a Since inside is consisted of electronic circuit, it is not impossible
to judge by measurement of resistance.
Between B08 (1) – (2)
Air cleaner clogging Voltage Max. 10 V
Continuity
(3) (+) – (2)(-) Reverse direction: No continuity
Continuity
20 WA800, WA900-3E0

Max. 1 z
(3) tance
Resis-
tance
harness
5 Resis-
tance
Resis-
tance
Between B08 (female) (2) and chassis Resis-
Max. 1 z
ground tance
Possible Between L18 (female) (14) – D22 (female) Resis-
Max. 1 z
causes and (1) tance
in normal state 2) Disconnect D22, E08, VC05 and L18, then carry out trouble-
Max. 1 z
6 Wiring harness between D22 (female) (2) – Resis-
(Contact with ground circuit) Max. 1 z
Wiring harness between B08 (female) (1) – Resis-
Max. 1 z
Max. 1 z
2) Connect T-branch to connector L18.
7
monitor
Between L18 (14) – Air cleaner is normal Voltage Max. 1 V
(3) Air cleaner clogging Voltage 20 – 30 V
WA800, WA900-3E0 21
22 WA800, WA900-3E0
Contents of
5) Air cleaner (L.H.) indicator flashes.
trouble
• Refer to failure code [AA1ANX].
• Troubleshooting for air cleaner R.H. clogging is carried out with failure code [AA1BNX]. When
[AA1BNX] is not indicated, replace, for instance, the relay, diode and air cleaner connector with that
of the air cleaner R.H. circuit one by one. If, as the result, failure code [AA1ANX] is replaced with
Related [AA1BNX], you can judge this replaced parts are the cause.
information • Fuse (10) of fuse box 1 is not broken since air cleaner (L.H.) indicator flashes.
• When air cleaner (L.H.) is normal, L18 (15) is connected to ground wire. When clogged: OPEN
• Clogging can be checked with monitoring code 40972 "D-IN-17" (1: clogged, 0: normal)
• Air cleaner (L.H.) indicator flashes: Air cleaner clogging signal circuit is opened (disconnected from
ground wire).

1 Air cleaner clogging
Dust indicator is lit in red Air cleaner clogging
Relay
Normal state is not
(L79) is
replaced. Relay
Normal state is recov-
(L79) is
ered
2
(L79) 1) Turn starting switch OFF.
3) Independent part check
Resis- 260 –
Possible tance 320 z
causes and Resis-
standard value Between L79 (male) (3) – (5) Min. 1 Mz
tance
in normal state
Resis-
tance
Defective air cleaner clogging 4) Turn starting switch ON.
3
sensor a Since inside is consisted of electronic circuit, it is impossible to
judge by measurement of resistance.
Between B06 (1) – (2)
Air cleaner clogging Voltage Max. 10 V
Continuity
Continuity
WA800, WA900-3E0 23

shooting with turning starting switch OFF.
Max. 1 z
(3) tance
Resis-
tance
harness
5 Resis-
tance
Resis-
tance
Between B06 (female) (2) and chassis Resis-
Max. 1 z
ground tance
Possible Between L18 (female) (15) – D21 (female) Resis-
Max. 1 z
causes and (1) tance
in normal state 2) Disconnect D18, B06, VC05 and L18, then carry out trouble-
shooting with turning starting switch OFF.
Max. 1 z
6 Wiring harness between D21 (female) (2) – Resis-
(Contact with ground circuit) Max. 1 z
Max. 1 z
Max. 1 z
2) Connect T-branch to connector L18.
7
monitor
Between L18 (15) – Air cleaner is normal Voltage Max. 1 V
(3) Air cleaner clogging Voltage 20 – 30 V
24 WA800, WA900-3E0
WA800, WA900-3E0 25
Contents of
6) Transmission oil filter indicator flashes.
trouble
• Clogging can be checked with monitoring code 40944 "D-IN-5" (1: clogged, 0: normal)
• Refer to failure code [15B0NX].
Related
• Transmission oil filter indicator flashes: When the torque converter oil temperature circuit reached
information
50°C or above, signal circuit of transmission clogging sensor was opened (disconnected from the
ground wire).

1 Transmission filter clogging • Clean it or replace.
2) Disconnect connector TMF1.
Defective transmission filter
2 Resis-
clogging sensor Filter is normal Max. 1 z
Between BC02, BC03 tance
(male) (1) – (2) Resis-
Filter is clogged Min. 1 Mz
tance
Continuity
Possible Continuity
causes and
in normal state 2) Disconnect D16, VC04 and L18, then carry out troubleshooting
with their connection being turned OFF.
Max. 1 z
4
Filter sensor is
normal
Max. 1 z
(female) (1) tance
Defective maintenance 4) Connect connector.
5
monitor 5) Turn starting switch ON.
Between L18 Filter is normal Voltage Max. 1 V
(female) (16) – (3) Filter is clogged Voltage 20 – 30 V
26 WA800, WA900-3E0
WA800, WA900-3E0 27
K-5 The warning buzzer does not sound while caution item indicator
flashes 1
Contents of
• The warning buzzer does not sound while caution item indicator flashes.
trouble
Related
tenance monitor or relay L65 connects the buzzer negative side (–) to ground.
information
• If fuse 1 (10) is broken, neither machine monitor nor maintenance monitor can be turned ON.

harness Resis-
1 Between FS2 (female) (9) – L42 (female) (1) Max. 1 z
tance
2 Defective buzzer 4) Connect Pin 2 of T-branch connector (buzzer wiring in black) to
Possible
causes and chassis ground and carry out troubleshooting.
standard value Feed current between L42 (1) (+) – (2) (–). Buzzer sounds.
in normal state
Hot short circuit in wiring 1) Turn starting switch OFF.
harness 2) Disconnect L06, L19 and L42.
(Contact with power supply
circuit) Between L19 (female) (4) – (8) Voltage Max. 1 V
4 Pulse
monitor
Between L19 (4) – (8) voltage of
Voltage
a When caution item indicator flashes 0 V and
20 – 30 V
28 WA800, WA900-3E0
WA800, WA900-3E0 29
K-6 The warning buzzer sounds while monitor indicates no error 1

a Refer to "M-16 3) Buzzer sounds constantly".
30 WA800, WA900-3E0
K-7 The warning lamps (check lamp and caution lamp) do not flash
while caution item indicator flashes 1
Contents of • The warning lamps (check lamp and caution lamp) do
1) Check lamp does not flash.
trouble not flash while caution lamp flashes.
Related a Check lamp for burnt-out.
information • When normal: Pin 2 of L19 is L and check lamp lights up.

2) Disconnect L19 and connect T-branch to L19 (male) (L19
remains disconnected)
1 4) Make short-circuit between L19 (2) and (8), then carry out trou-
monitor
bleshooting.
(Connect L19 (2) to ground wire.)
If check lamp lights up, the maintenance monitor is normal.
2) Disconnect L06 and connect T-branch to L06 (female) (L06
Possible remains disconnected)
causes and 3) Turn starting switch ON.
standard value 2 Defective machine monitor 4) Make short-circuit between L06 (female) (10) and chassis
in normal state ground, then carry out troubleshooting. (What happens if instead
of machine monitor, you connect check lamp output to chassis
ground?)
a If check lamp lights up, machine monitor is defective.
3
(10) tance
harness 2) Disconnect L06 and L19.
circuit) Between L19 (2) – (8) Voltage Max. 1 V
WA800, WA900-3E0 31
Contents of • Warning lamps (check lamp and caution lamp) do not

2) Caution lamp does not flash.
trouble flash while caution lamp flashes.
Related a Check lamp for burnt-out.
information • When normal: Pin 3 of L19 is L and caution lamp lights up.

2) Disconnect L19 and connect T-branch to L19 (male) (L19
remains disconnected).
1
monitor 4) Make short-circuit between L19 (3) and (8), then carry out trou-
bleshooting. (Connect L19 (3) to ground wire.)
If caution lamp lights up, the maintenance monitor is normal.
2) Disconnect L06 and connect T-branch to L06 (female) (L06
remains disconnected).
Possible 3) Turn starting switch ON.
causes and 2 Defective machine monitor 4) Make short-circuit between L06 (female) (9) and chassis ground,
standard value then carry out troubleshooting. (What happens if instead of
in normal state machine monitor, you connect caution lamp output to chassis
ground?)
a If caution lamp lights up, machine monitor is defective.
3
contact in connector) Between L19 (female) (3) – L06 (female) (9) Max. 1 z
tance
harness 2) Disconnect L06 and L19.
32 WA800, WA900-3E0
K-8 Warning lamps (check and caution lamps) lights up while the
maintenance monitor indicates no error 1
Contents of • Warning lamps (check and caution lamps) lights up
1) Check lamp flashes.
trouble while the maintenance monitor indicates no error.
Related
• When normal: Pin 2 of L19 is L and check lamp lights up.
information

Defective maintenance 2) Disconnect L19.
monitor
If check lamp goes out, the maintenance monitor is normal.
Possible
causes and
2) Disconnect L06.
standard value 2 Defective machine monitor 3) Turn starting switch ON and carry out troubleshooting.
in normal state
a If check lamp goes out, machine monitor is defective.
3
tance
WA800, WA900-3E0 33
Contents of • Warning lamps (check and caution lamps) lights up

2) Caution lamp flashes.
trouble while the maintenance monitor indicates no error.
Related
• When normal: Pin 3 of L19 is L and caution lamp lights up.
information

Defective maintenance 2) Disconnect L19.
monitor
If caution lamp goes out, maintenance monitor is normal.
Possible
causes and
2) Disconnect L06.
standard value 2 Defective machine monitor 3) Turn starting switch ON and carry out troubleshooting.
in normal state
a If caution lamp goes out, machine monitor is defective.
3
tance
34 WA800, WA900-3E0
WA800, WA900-3E0 35
K-9 Night lamp does not light up 1

Contents of
• Night lamp does not light up.
trouble
Related • For troubleshooting of small lamp circuit in general, refer to "E-mode."
information • Check if the night lamp for machine monitor lights up.

1 Fuse disconnection Fuse box 1: Fuse (1) and (6) Continuity Yes
2
(L67) tem returns to normal state, small lamp relay is defective.
harness 2) Disconnect L05 and FS2, then carry out troubleshooting.
3
Possible contact in connector) Between L05 (female) (16) – FS2 (5) Max. 1 z
tance
causes and
in normal state Ground fault in wiring harness 2) Disconnect L05 and carry out troubleshooting.
4
tance
5
monitor 4) Turn small lamp switch ON and carry out troubleshooting.
36 WA800, WA900-3E0
WA800, WA900-3E0 37
K-10 Night lamp remains lit up 1

Contents of
• Night lamp remains lit up.
trouble
Related • Check if the night lamp for machine monitor remains lit up.
information • Check if small lamp remains lit up.

1) Starting switch OFF and Light switch OFF.
1 Defective light switch
Resis-
Between L02 (male) (3) – (4) Min. 1 Mz
tance
2
Possible L67 tem returns to normal state, small lamp relay is defective.
causes and 1) Starting switch OFF and Light switch OFF.
standard value Hot short circuit in wiring 2) Disconnect L21.
in normal state 3 harness 3) Turn starting switch ON and carry out troubleshooting.
(Contact with 24 V circuit) Between L21 (female) (1) – L05 (16) – FS2
Voltage Max. 1 V
(5) – each small lamp and chassis ground
1) Starting switch OFF and Light switch OFF.
Defective maintenance 2) Disconnect L21 and connect T-branch to the (female) side.
monitor
38 WA800, WA900-3E0
WA800, WA900-3E0 39
K-11 Service meter does not work 1

Contents of
• Service meter does not work.
trouble
• For alternator error (on R terminal) (shortage of charging voltage though engine is running), trouble-
shooting is carried out by engine service monitor in [AB00MA], by pre-lubrication controller in
[AB00MB] and by VHMS controller in [AB00MC] respectively.
Related
• Charging voltage of alternator (R terminal) can be checked with monitoring code: 04304 (V) (with the
information voltage of VC02 (4) pin of VHMS controller).
a Charging voltage from alternator (R terminal) is hysteresis of : Normal if 12 V or
above and abnormal if 5 V or below

Between alternator terminal R and chassis
Voltage Min. 12V
ground
Defective maintenance 2) Disconnect L22 and connect T-branch to the female side.
2 3) Start engine and carry out troubleshooting.
monitor
Between L22 (female) (2) – (1) Voltage Min. 12V
Possible
causes and 1) Turn starting switch OFF.
standard value 2) Disconnect alternator R terminal (E21).
Disconnection in wiring 3) Disconnect connector L22 and carry out troubleshooting.
in normal state
harness
3 Between wiring harness terminals (E21) – Resis-
Max. 1 z
ground tance
Ground fault in wiring harness 3) Disconnect connector L22 and carry out troubleshooting.
4
Resis-
tance
40 WA800, WA900-3E0
WA800, WA900-3E0 41
K-12 Service meter keeps on working (when engine stops) 1

Contents of
• Service meter keeps on working (when engine stops).
trouble
• For alternator error (on R terminal) (charging voltage is present though engine is not running), trou-
bleshooting is carried out by engine service monitor in [AB00L6] and by pre-lubrication controller in
[AB00L4] respectively.
Related
• Charging voltage of alternator (R terminal) can be checked with monitoring code: 04304 (V).
information (Voltage of VC02 (4) pin of VHMS controller)
a Charging voltage from alternator (R terminal) is hysteresis of: Normal if 12 V or
above and abnormal if 5 V or below

1 Defective alternator Between alternator terminal R and chassis
Voltage Max. 3 V
ground
Possible 1) Turn starting switch OFF.
causes and Defective maintenance 2) Disconnect L22 and connect T-branch to the female side.
standard value 2 3) Turn starting switch ON and carry out troubleshooting.
monitor
in normal state Between L22 (female) (2) – (1) Voltage Max. 3 V
harness 2) Disconnect alternator R terminal (E21) and connector L22.
42 WA800, WA900-3E0
WA800, WA900-3E0 43
K-13 Gauge items (fuel, engine coolant temperature and torque

converter oil temperature) error 1
Contents of
1) Fuel gauge error -1) Display area displays nothing or lesser items.
trouble
Related
a Recheck if fuel is supplied to appropriate level.
information

2) Disconnect R08 and connect short circuit connector to the male
side.
1 Defective fuel sensor 3) Turn starting switch ON and carry out troubleshooting.
a If short circuit connector is unavailable, make short-circuit
between R08 (female) (1) and (2).
Fuel gauge indicates "FULL".
Possible 2) Disconnect L18 and R08, then carry out troubleshooting.
causes and
harness Resis-
standard value 2 Between L18 (female) (6) – R08 (male) (1) Max. 1 z
in normal state
contact in connector) Between R08 (female) (2) and chassis Resis-
Max. 1 z
ground tance
harness 2) Disconnect L18.
monitoring
carried out.)
44 WA800, WA900-3E0
Contents of
1) Fuel gauge error -2) Fuel gauge keeps on indicating "FULL" and does not work.
trouble
Related
• Recheck if fuel is supplied to appropriate level.
information

2) Disconnect R08.
1 Defective fuel sensor 3) Turn starting switch ON and carry out troubleshooting.
a R08 remains "OPEN."
Possible Display area for fuel gauge goes out completely.
causes and
in normal state Ground fault in wiring harness 2) Disconnect L18 and R08, then carry out troubleshooting.
2
tance
monitor
carried out.)
WA800, WA900-3E0 45
Contents of 2) Engine coolant temperature

-1) Display area displays nothing.
trouble gauge error
Related • Refer to failure codes [B@BDNS] "Engine overheat".
information • Engine coolant temperature sensor resistance: 1.6 – 48 kz (coolant temperature 130 – 25°C)

2) Disconnect E04.
Defective engine coolant tem- 3) Turn starting switch ON and carry out troubleshooting.
1
perature sensor a E04 remains "OPEN."
Engine coolant temperature gauge indicates the lowest level.
Ground fault in wiring harness 2) Disconnect L18 and E04, then carry out troubleshooting.
Possible 2
causes and Between L18 (female) (4) – (3) Min. 1 Mz
tance
standard value
in normal state 1) Turn starting switch OFF.
2) Disconnect L18 and VC03.
3) Connect T-branch to L18 (female) side and carry out trouble-
shooting.
Defective maintenance 1.6 –
3
monitor 48 kz
Between L18 (female) (4) – (3) Resis- (Coolant
(Coolant temperature resistance) tance tempera-
ture 130 –
25°C)
46 WA800, WA900-3E0
Contents of 2) Engine coolant temperature -2) Engine coolant temperature gauge keeps on indicating lowest
trouble gauge error level and does not work.
Related
• Refer to failure codes [B@BDNS] "Engine overheat".
information

2) Disconnect E04 and connect short circuit connector to the female
side.
between E04 (female) (1) and (2).
Defective engine coolant tem-
1 Display area of engine coolant temperature rises step by step, then
perature sensor
goes out.
with starting switch OFF.
E04 (male) Coolant temperature Resistance
Between (1) – (2) 25 – 130°C 48 – 1.6 kz
Disconnection in wiring 2) Disconnect L18 and E04, then carry out troubleshooting.
Possible
causes and harness Resis-
2 Between L18 (female) (4) – E04 (female) (1) Max. 1 z
standard value (Disconnection or defective tance
in normal state contact in connector) Between E04 (female) (2) and chassis Resis-
Max. 1 z
ground tance
shooting.
Defective maintenance 1.6 –
4
monitor 48 kz
Resis- (Coolant
(3)
tance tempera-
(Resistance of coolant temperature sensor)
ture 130 –
25°C)
WA800, WA900-3E0 47
48 WA800, WA900-3E0
Contents of 3) Torque converter oil tempera-

-1) Display area displays nothing.
trouble ture gauge error
Related • Refer to failure code [B@CENS] "Torque converter oil temperature overheating".
information • Torque converter oil temperature sensor resistance: 1.6 – 48 kz (oil temperature 130 – 25°C

2) Disconnect T02.
Defective torque converter oil 3) Turn starting switch ON and carry out troubleshooting.
1
temperature sensor a T02 remains "OPEN."
Torque converter oil temperature gauge indicates the lowest level.
Ground fault in wiring harness 1) Disconnect L18 and T02, then carry out troubleshooting.
Possible 2
causes and Between L18 (female) (5) – (3) Min. 1 Mz
tance
standard value
in normal state 1) Turn starting switch OFF.
shooting.
Defective maintenance moni- 1.6 –
3
tor 48 kz
Resis- (Coolant
(3)
tance tempera-
(Resistance of coolant temperature sensor)
ture 130 –
25°C)
WA800, WA900-3E0 49
Contents of 3) Torque converter oil tempera- -2) Torque connector oil temperature gauge keeps on indicating low-
trouble ture gauge error est level and does not work.
Related
• Refer to failure code [B@CENS] "Torque converter oil temperature overheating".
information

2) Disconnect E04 and connect short circuit connector to the female
side.
between E04 (female) (1) and (2).
Defective torque converter oil
1 Display area of torque converter oil temperature rises step by step,
temperature sensor
then goes out.
T02 (male) Oil temperature Resistance
Between (1) – (2) 25 – 130°C 48 – 1.6 kz
Disconnection in wiring 2) Disconnect L18 and T02, then carry out troubleshooting.
Possible
causes and harness Wiring harness between L18 (female) (5) – Resis-
2 Max. 1 z
standard value (Disconnection or defective T02 (female) (1) tance
in normal state contact in connector) Between T02 (female) (2) and chassis Resis-
Max. 1 z
ground tance
shooting.
Defective maintenance moni- 1.6 –
4
tor 48 kz
Resis- (Oil tem-
(3)
tance perature
(Resistance of oil temperature sensor)
130 –
25°C)
50 WA800, WA900-3E0
WA800, WA900-3E0 51
SEN02153-02

© 2010 KOMATSU
All Rights Reserved
52
SEN04494-00
WA800-3E0
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
Troubleshooting of remote boom
positioner controller system (if equipped)
(W-mode)
W-1 Short circuit, disconnection in dumping solenoid system ........................................................................ 4
W-2 Short circuit in power source at hot end of dumping solenoid ................................................................. 5
W-3 Short circuit in power source at return end of dumping solenoid............................................................. 6
W-4 Boom kick-out function trouble ................................................................................................................ 8
W-5 Disconnection in boom RAISE, LOWER detection pressure switch...................................................... 10
W-6 Short circuit, disconnection in boom angle potentiometer system......................................................... 12
W-7 Sensor cannot be adjusted.................................................................................................................... 14
W-8 Abnormality in engine speed signal system .......................................................................................... 15
W-9 Remote positioner RAISE, LOWER LEDs do not light up ..................................................................... 16
W-10 Remote positioner RAISE set LED does not flash .............................................................................. 18
W-11 Remote positioner LOWER set LED does not flash ............................................................................ 20
W-12 Buzzer for switch operation does not sound ....................................................................................... 22
WA800, WA900-3E0 1
W-13 Shock when stopping boom ................................................................................................................ 23

W-14 Short circuit in boom RAISE, LOWER pressure detection switch ....................................................... 24
2 WA800, WA900-3E0
WA800, WA900-3E0 3
W-1 Short circuit, disconnection in dumping solenoid system 1

User code Failure code
Trouble Short circuit, disconnection in dumping solenoid system
— 43
Contents of
• Dumping solenoid system is abnormal.
trouble
Action of
• Turns dumping solenoid output OFF.
controller
Problem that
appears on • Shock is generated when boom stops in remote positioner mode.
machine
Related
information

1 Defective dumping solenoid
Resis-
Between FB5 (male) (1) – (2) 10 – 20 z
tance
ness Wiring harness between RB-1 (female) (5) – Resis-
2 Max. 1 z
(Disconnection or defective FB5 (female) (1) tance
contact in connector) Wiring harness between RB-1 (female) (15) Resis-
Max. 1 z
– FB5 (female) (2) tance
Possible causes
Grounding fault in wiring har- without turning starting switch ON.
value in normal 3 ness
state (Contact with ground circuit) Between wiring harness RB-1 (female) (5) – Resis-
Min. 1 Mz
FB5 (1) and ground tance
There may be defect in connections between solenoid, machine wir-
ing harness and work equipment controller. Check those connec-
Defective wiring harness tions directly.
4
connector • Loosened connector, broken lock, or broken seal
• Corroded, bent, broken, pressed-in, or expanded pin
• Dampness, dirt and sand, or defecting insulation in connector
Defective work equipment and carry out troubleshooting.
5
controller RB-1 Voltage
Between (5) – (15) 20 – 30 V
4 WA800, WA900-3E0
W-2 Short circuit in power source at hot end of dumping solenoid 1

Trouble Short circuit in power source at hot end of dumping solenoid
— 44
Contents of
trouble
Action of
controller
Problem that
appears on • Boom lowers.
machine
Related
information

Resis-
Between FB5 (male) (1) – (2) 10 – 20 z
tance
2 Max. 1 z
Max. 1 z
Hot short (contact with 24V and carry out troubleshooting.
Possible causes 3
circuit) in wiring harness. Between wiring harness RB-1 (female) (5) –
and standard Voltage Max. 1 V
value in normal FB5 (1) and ground
4 ness
(Contact with ground circuit) Between wiring harness RB-1 (female) (5) – Resis-
Min. 1 Mz
5
6
Between (5) – (15) 20 – 30 V
WA800, WA900-3E0 5
W-3 Short circuit in power source at return end of dumping solenoid 1

Trouble Short circuit in power source at return end of dumping solenoid
— 45
Contents of
trouble
Action of
controller
Problem that
appears on • Shock is generated when boom stops in remote positioner mode.
machine
Related • If this trouble occurs, short circuit is made in controller and controller may break down or fuse of
information shorted power supply line may be broken.

Resis-
Between FB5 (male) (1) – (2) 10 – 20 z
tance
2 Max. 1 z
Max. 1 z
Possible causes 3
circuit) in wiring harness. Between RB-1 (female) (15) –- chassis
value in normal ground
4 ness
(Contact with ground circuit) Between wiring harness RB-1 (female) (5) – Resis-
Min. 1 Mz
5
6
Between (5) – (15) 20 – 30 V
6 WA800, WA900-3E0
WA800, WA900-3E0 7
W-4 Boom kick-out function trouble 1

Trouble Boom kick-out function trouble
— 49
Contents of
• Boom kick-out relay system is abnormal.
trouble
Action of
• Turns boom lever kick-out output OFF.
controller
Problem that
• Boom does not stop at desired position in remote positioner mode (Boom lever detent is not reset or
appears on
boom lever is not set in detent).
machine
Related • If this trouble occurs, short circuit is made in controller and controller may break down or fuse of
information shorted power supply line may be broken.

Defective boom kick-out without turning starting switch ON.
1 relay (Internal disconnection
or short circuit) Resis- 200 –
tance 400 z
ness Wiring harness between RB-1 (female) (20) Resis-
2 Max. 1 z
(Disconnection or defective – L49 (female) (1) tance
contact in connector) Wiring harness between L49 (female) (2) – Resis-
Max. 1 z
LR2 (male) (W) tance
Possible causes 3
circuit) in wiring harness. Between RB-1 (female) (20) –- chassis
value in normal ground
4 ness
(Contact with ground circuit) Wiring harness between RB-1 (female) (20) Resis-
Min. 1 Mz
– L49 (female) (1) and chassis ground tance
There may be defect in connections between relay, machine wiring
harness and work equipment controller. Check those connections
Defective wiring harness directly.
5
Defective work equipment without turning starting switch ON.
6
controller RB-1 (female) Resistance
Between (20) – LR2 (male) (W) 200 – 400 z
8 WA800, WA900-3E0
WA800, WA900-3E0 9
W-5 Disconnection in boom RAISE, LOWER detection pressure switch1

Trouble Disconnection in boom RAISE, LOWER detection pressure switch
— 51
Contents of
• Boom RAISE/LOWER sensing pressure switch system is abnormal.
trouble
Action of
• Dumping solenoid does not operate.
controller
Problem that
• Boom lever is not set in detent.
appears on
• Boom lever detent is not reset.
machine
Related infor-
mation

Resis-
1 Defective pressure switch Between FB1 (male) (1) – (2) Max. 1 z
tance
Resis-
Between FB2 (male) (1) – (2) Max. 1 z
tance
Disconnection in wiring har- Wiring harness between RB-2 (female) (5) – Resis-
Max. 1 z
ness (Disconnection in wiring FB1 (female) (1) tance
2
or defective contact in con- Wiring harness between RB-2 (female) (6) – Resis-
nector) Max. 1 z
FB2 (female) (1) tance
Wiring harness between RB-2 (female) (9) – Resis-
Max. 1 z
Possible causes FB1, FB2 (female) (2) tance
state Ground fault in wiring har-
3 ness (Contact with GND cir- Min. 1 Mz
FB1 (female) (1) and chassis ground tance
cuit)
Min. 1 Mz
There may be defect in connections between pressure switch,
machine wiring harness and work equipment controller. Check
Defective wiring harness those connections directly.
4
Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment RB-2 Resistance
5
controller
(5) – (9) Max. 1 z
(6) – (9) Max. 1 z
10 WA800, WA900-3E0
WA800, WA900-3E0 11
W-6 Short circuit, disconnection in boom angle potentiometer system 1

Trouble Short circuit, disconnection in boom angle potentiometer system
E14 52
Contents of
• There is short circuit or disconnection in boom angle potentiometer system.
trouble
Action of • Remote positioner function is turned OFF.
controller • Upper and lower stop lamps go off.
Problem that
appears on • Remote positioner does not function.
machine
Related infor-
mation

Resis-
1 Defective potentiometer Between FB-4 (male) (A) – (B) 0.2 – 5 kz
tance
Resis-
Between FB-4 (male) (B) – (C) 4 – 5 kz
tance
Disconnection in wiring har- Wiring harness between RB-2 (female) (19) Resis-
Max. 1 z
ness (Disconnection in wiring – FB4 (female) (A) tance
2
or defective contact in con- Wiring harness between RB-2 (female) (10) Resis-
nector) Max. 1 z
– FB4 (female) (C) tance
Max. 1 z
FB4 (female) (B) tance
Possible causes without turning starting switch ON.
and standard Hot short (Short circuit with Wiring harness between RB-2 (female) (19)
3 24 V circuit) in wiring har- – FB4 (female) (A), RB2 (female) (10) – FB4 Min. 1 Mz
state tance
ness (C)
Wiring harness between RB-2 (female) (19) Resis-
Min. 1 Mz
– FB4 (A), RB2 (female) (9) – FB4 (B) tance
cuit) Wiring harness between RB-2 (female) (19) Resis-
Min. 1 Mz
– FB4 (female) (A) and chassis ground tance
There may be defect in connections between potentiometer,
5
Prepare with starting switch OFF, then turn starting switch ON and
Defective work equipment carry out troubleshooting.
6
(10) – (9) 4.75 – 5.25 V
12 WA800, WA900-3E0
WA800, WA900-3E0 13
W-7 Sensor cannot be adjusted 1

Trouble Remote positioner RAISE/LOWER set LED does not light or blink
— —
Contents of
• Remote positioner RAISE/LOWER set switch or LED system is abnormal.
trouble
Action of
controller
Problem that
appears on • Remote positioner RAISE/LOWER set LED does not light or blink
machine
Related infor- • See Troubleshooting W-10.
mation • If the LED blinks in set mode, check installation of boom angle potentiometer.

Possible causes Defective remote positioner
When remote positioner RAISE/LOWER set switch is turned ON, if
and standard 1 RAISE/LOWER set switch or
LED lights or blinks, switch and LED are normal.
value in normal LED system.
state Defective work equipment Since trouble is in system, troubleshooting cannot be carried out (If
2
controller above cause is not detected, controller is judged defective.)
14 WA800, WA900-3E0
W-8 Abnormality in engine speed signal system 1

Trouble Abnormality in engine speed signal system
— —
Contents of
• Short circuit or disconnection in engine speed signal system
trouble
Action of
controller
Problem that
appears on • Remote boom positioner does not operate.
machine
Related infor-
mation

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness (Disconnection in wiring without turning starting switch ON.
1
nector) Max. 1 z
C1 (female) (4) tance
Possible causes 2 ness (Contact with GND cir-
cuit) Wiring harness between RB-3 (female) (4) – Resis-
and standard Min. 1 Mz
value in normal
state There may be defect in connections between transmission control-
ler, machine wiring harness and work equipment controller. Check
3
If causes 1 – 3 are not detected, work equipment controller may be
Defective work equipment
controller
carried out.)
WA800, WA900-3E0 15
W-9 Remote positioner RAISE, LOWER LEDs do not light up 1

Trouble Remote positioner RAISE, LOWER LEDs do not light up
— —
Contents of
• Remote positioner RAISE/LOWER set switch or LED system is abnormal.
trouble
Action of
controller
Problem that
appears on • Remote positioner RAISE, LOWER LEDs do not light up.
machine
Related infor-
mation

Defective positioner selector RB-4 (male) Switch Resistance
1
switch
Between (7) – (16) ON Max. 1 z
Disconnection in wiring har- Wiring harness between RB-2 (female) (4) – Resis-
Max. 1 z
ness (Disconnection in wiring RB-4 (female) (7) tance
2
nector) Max. 1 z
RB-4 (female) (12) tance
Max. 1 z
Possible causes – RB-4 (female) (13) tance
state
Ground fault in wiring har- Min. 1 Mz
RB-4 (female) (7) and chassis ground tance
cuit) Wiring harness between RB-3 (female) (6) – Resis-
Min. 1 Mz
Min. 1 Mz
– RB-4 (female) (13) and chassis ground tance
There may be defect in connections between selector switch,
4
controller
carried out.)
16 WA800, WA900-3E0
WA800, WA900-3E0 17
W-10 Remote positioner RAISE set LED does not flash 1

Trouble Remote positioner RAISE set LED does not flash
— —
Contents of
• Remote positioner RAISE set switch or LED system is abnormal.
trouble
Action of
controller
Problem that
appears on • Remote positioner RAISE set LED does not flash.
machine
Related infor-
mation

Defective remote positioner RB-4 (male) Switch Resistance
1
RAISE set switch
ness (Disconnection in wiring Wiring harness between RB-1 (female) (10) Resis-
2 Max. 1 z
or defective contact in con- – RB-4 (female) (10) tance
nector) Wiring harness between RB-2 (female) (2) – Resis-
Max. 1 z
Possible causes RB-4 (female) (5) tance
– RB-4 (female) (10) and chassis ground tance
cuit)
Min. 1 Mz
There may be defect in connections between set switch, machine
wiring harness and work equipment controller. Check those con-
Defective wiring harness nections directly.
4
controller
carried out.)
18 WA800, WA900-3E0
WA800, WA900-3E0 19
W-11 Remote positioner LOWER set LED does not flash 1

Trouble Remote positioner LOWER set LED does not flash
— —
Contents of
• Remote positioner LOWER set switch or LED system is abnormal.
trouble
Action of
controller
Problem that
appears on • Remote positioner LOWER set LED does not flash.
machine
Related infor-
mation

Defective remote positioner RB-4 (male) Switch Resistance
1
LOWER set switch
ness (Disconnection in wiring Wiring harness between RB-2 (female) (3) – Resis-
2 Max. 1 z
or defective contact in con- RB-4 (female) (4) tance
Max. 1 z
Possible causes RB-4 (female) (9) tance
cuit)
Min. 1 Mz
There may be defect in connections between set switch, machine
wiring harness and work equipment controller. Check those con-
Defective wiring harness nections directly.
4
controller
carried out.)
20 WA800, WA900-3E0
WA800, WA900-3E0 21
W-12 Buzzer for switch operation does not sound 1

Trouble Buzzer for switch operation does not sound
— —
Contents of
• Short circuit or disconnection in buzzer system.
trouble
Action of
controller
Problem that
appears on • Buzzer for switch operation does not sound.
machine
Related infor-
• Check that main monitor and alarm buzzer operate normally, in advance.
mation

ness (Disconnection in wiring Wiring harness between RB-3 (female) (16) Resis-
1 Max. 1 z
or defective contact in con- – L08 (female) (6) tance
nector) Wiring harness between C2 (female) (10) – Resis-
Max. 1 z
Possible causes Ground fault in wiring har-
Wiring harness between FB-3 (female) (16) Resis-
and standard 2 ness (Contact with GND cir- Min. 1 Mz
– L08 (female) (6) and chassis ground tance
value in normal cuit)
state Wiring harness between C2 (female) (10) – Resis-
Min. 1 Mz
There may be defect in connections between set main monitor,
3
controller
carried out.)
22 WA800, WA900-3E0
W-13 Shock when stopping boom 1

Trouble Shock when stopping boom
— —
Contents of
• Boom lever detent swich system is abnormal.
trouble
Action of
controller
Problem that
appears on • Shock when stopping boom.
machine
Related infor-
• Check that failure code [49] is not displayed.
mation

1 Defective detent switch
Resis-
FB3 (male) (1) – (2) (Boom lever in NEUTRAL) Max. 1 z
tance
ness (Disconnection in wiring Wiring harness between RB-2 (female) (8) – Resis-
2 Max. 1 z
or defective contact in con- FB3 (female) (1) tance
Max. 1 z
FB3 (female) (2) tance
Possible causes
and standard Ground fault in wiring har-
value in normal Wiring harness between RB-2 (female) (8) – Resis-
state FB3 (female) (1) and chassis ground tance
cuit)
Min. 1 Mz
There may be defect in connections between detent switch,
4
Defective work equipment without turning starting switch ON.
5
controller RB-2 (female) Resistance
(8) – (9) Max. 1 z
WA800, WA900-3E0 23
W-14 Short circuit in boom RAISE, LOWER pressure detection switch 1

Trouble Short circuit in boom RAISE, LOWER pressure detection switch
— —
Contents of
• Short circuit in boom RAISE, LOWER pressure detection switch system.
trouble
Action of
controller
Problem that
• Detent is not reset and boom moves to upper or lower end
appears on
(Remote boom positioner does not operate).
machine
Related infor-
mation

Resis-
1 Defective pressure switch FB1 (male) (1) – (2) Max. 1 z
tance
Resis-
FB2 (male) (1) – (2) Max. 1 z
tance
Wiring harness between RB-2 (female) (5) –
Resis-
FB1 (female) (1), RB-2 (female) (6) – FB2 Max. 1 z
tance
(female) (1).
2 Wiring harness between RB-2 (female) (5) –
ness Resis-
FB1 (female) (1), RB-2 (female) (9) – FB1, Max. 1 z
tance
FB2 (female) (2).
Wiring harness between RB-2 (female) (6) –
Possible causes Resis-
FB2 (female) (1), RB-2 (female) (9) – FB1, Max. 1 z
and standard tance
FB2 (female) (2).
value in normal
Ground fault in wiring har-
cuit)
Min. 1 Mz
There may be defect in connections between pressure switch,
4
Defective work equipment RB-2 (female) Resistance
5
controller
(5) – (9) Max. 1 z
(6) – (9) Max. 1 z
24 WA800, WA900-3E0
WA800, WA900-3E0 25
SEN04494-00

© 2008 KOMATSU
All Rights Reserved
26
SEN02739-02
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tools list .............................................................................................................................................. 7
Sketches of special tools .............................................................................................................................. 13
WA800-3E0, WA900-3E0 1
SEN02739-02 50 Disassembly and assembly
How to read this manual 1

(Rev. 2009.1)
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In “Removal” section, the work procedures,
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2]••• etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in “Removal” section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this “Installation” section.
model. They have a new part num- 6 : Amount of oil or coolant to be drained
4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
Installation
developed for other models. Each
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
79 T- - : for the following.
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
2 WA800-3E0, WA900-3E0
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In “Disassembly” section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used. sembly” section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
2) Distinction of new and existing special 6 : Amount of oil or coolant drained
tools
N: Tools newly developed for this
model. They have a new part num- Assembly
ber respectively. q In “Assembly” section, the work procedures,
R: Tools made available by redesign- precautions and know-how to do the work, and
ing the existing tools which were the amount of oil and coolant to be replenished
developed for other models. Each are described.
of them has a new part number q Common tools that are necessary for assem-
assigned by setting forward the bly are described as [1], [2]••• etc. and their
part number of the existing tool. part numbers, part names and quantities are
Blank : Tools already available for other not described.
models. They can be used without q The meanings of the symbols used in “Assem-
any modification. bly” section are as follows.
3) Circle mark Q in sketch column:
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of “Sketches of a : Guidance or precautions for the work
2 : Type of coating material
special tools”.
3 : Tightening torque
q Part No. of special tools starting with
5
79 T- - :
* *** ****
means that they are not available
: Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
WA800-3E0, WA900-3E0 3
Coating materials list 1

(Rev. 2009.02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
4 WA800-3E0, WA900-3E0
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
compound
prevention
Seizure
pound with metallic super-fine-grain, etc.

LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
Grease
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
WA800-3E0, WA900-3E0 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease
• Used for oil seals of the transmission, etc.

• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 WA800-3E0, WA900-3E0
Special tools list 1
a Tools with part number 79 T- - means that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
* *** ****
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
“Sketches of special tools”).
New/remodeled
Necessity
Sketch
Sym-
Q’ty
Component Part No. Part Name Nature of work, remarks
bol
Removal, installation of cylin-

1 790-331-1110 Wrench q 1
der head
Removal of front and rear
2 795-931-1100 Seal puller t 1
seal
795T-621-1430 Plate t 1 Q Press fitting of engine front
795T-621-1441 Push tool t 1 Q seal
Disassembly,
A 3 01050-32280 • Bolt t 3
assembly of engine
01582-02218 • Nut t 3
01640-22232 • Washer t 3
795T-621-1531 Push tool t 1 Q Press fitting of rear seal
4 01050-32050 • Bolt t 5
01640-02032 • Washer t 5
790-101-5401 Push tool KIT (C) t 1 Press fitting of bearing in
790-101-5521 • Plate 1 cover
1
790-101-5421 • Grip 1
Disassembly, 01010-51240 • Bolt 1
assembly of B
damper 793T-812-1110 Plate t 1 N Q Press fitting of oil seal in
2 790-101-5421 • Grip t 1 cover
01010-51240 • Bolt t 1
3 790-101-7190 Push tool t 1 Press fitting of shaft
790-501-5200 Unit repair stand t 1
1 790-901-5110 Bracket t 1
Disassembly,
790-901-5120 Plate t 1
assembly of torque C
converter Removal, installation of round
2 791-381-1011 Wrench t 1
nut
3 790-201-2870 Spacer t 1 Press fitting of shaft bearing
WA800-3E0, WA900-3E0 7
New/remodeled
Necessity
Sketch
Sym-
Q’ty
bol
4 790-201-2760 Spacer t 1 Press fitting of turbine bearing

790-201-2250 Plate t 1 Press fitting of shaft bearing
5 inner race
790-201-2760 Spacer t 1
790-101-5401 Push tool KIT (C) t 1 Press fitting of housing bear-
790-101-5481 • Plate 1 ing outer race
6
790-101-5421 • Grip 1
01010-51240 • Bolt 1
Disassembly, 790-101-5401 Push tool KIT (C) t 1 Press fitting of retainer oil seal
assembly of torque C 790-101-5461 • Plate 1
converter 7
790-101-5421 • Grip 1
01010-51240 • Bolt 1
Press fitting of pump shaft
8 790-201-2740 Spacer t 1
collar, bearing
790-101-5401 Push tool KIT (C) t 1 Press fitting of front housing
790-101-5431 • Plate 1 bearing outer race
9
790-101-5421 • Grip 1
01010-51240 • Bolt 1
1 799-301-1600 Oil leak tester KIT t 1 Check of operation of clutch
793T-815-1110 Push tool t 1 N Q Press fitting of clutch shaft
2 main bearing, sub bearing
790-210-2760 Spacer t 1
790-101-5401 Push tool KIT (C) t 1 Press fitting of bushing in
790-101-5461 • Plate 1 cover
3
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-101-5621 Plate t 1 Press fitting of main bearing
4 790-101-5421 • Grip t 1 outer race in cage
01010-51240 • Bolt t 1
790-101-5201 Push tool KIT (B) t 1 Press fitting of transfer gear
790-101-5321 • Plate 1 bearing inner race
Disassembly, 5
assembly of D 790-101-5221 • Grip 1
transmission 01010-51225 • Bolt 1
790-101-5401 Push tool KIT (C) t 1 Press fitting of bearing outer
790-101-5521 • Plate 1 race in cage
6
790-101-5421 • Grip 1
01010-51240 • Bolt 1
793T-815-1120 Plate t 1 N Q Press fitting of bearing outer
7 790-101-5421 Grip t 1 race in transfer output shaft
cage
01010-51240 Bolt t 1
790-101-5401 Push tool KIT (C) t 1 Press fitting of oil seal in
790-101-5491 • Plate 1 output shaft cage
8
790-101-5421 • Grip 1
01010-51240 • Bolt 1
8 WA800-3E0, WA900-3E0
New/remodeled
Necessity
Sketch
Sym-
Q’ty
bol
790-101-5401 Push tool KIT (C) t 1 Press fitting of oil seal in

790-101-5561 • Plate 1 transfer output shaft cage
9
790-101-5421 • Grip 1
assembly of D
transmission 790-101-7200 Centering tool t 1 Centering of transmission and
790-101-7230 • Shaft 1 support
10
790-101-7240 • Guide 1
01010-51230 • Bolt 1
790-101-7180 Push tool t 1 Press fitting of center support
1 790-101-5421 Grip t 1 bearing
01010-51240 Bolt t 1
790-101-7140 Push tool t 1 Press fitting of bearing
2 790-101-5421 Grip t 1
Disassembly, 01010-51240 Bolt t 1
assembly of center E
support 792-715-1300 Push tool t 1 Press fitting of main bearing
3 790-101-5421 Grip t 1 outer race
01010-81235 Bolt t 1
790-101-5621 Plate t 1 Press fitting of sub bearing
4 790-101-5421 Grip t 1 outer race
01010-51240 Bolt t 1
790-501-2000 Engine repair stand t 1 Disassembly, assembly of dif-
1 ferential
790-901-5110 Bracket t 1
790-101-2300 Push tool q 1 Removal of pinion shaft
790-101-2310 • Block 1 bearing
790-101-2350 • Leg 2
790-101-2360 • Plate 4
2
790-101-2430 • Adapter 2
02215-11622 • Nut 2
790-101-2102 Puller (30 tons) q 1
790-101-1102 Hydraulic pump q 1
Disassembly, 793T-822-1130 Push tool t 1 N Q Press fitting of pinion bearing
assembly of H 3
differential 793T-822-1140 Push tool t 1 N Q inner race
4 793T-822-1150 Push tool t 1 N Q Press fitting of bearing in sleeve
793T-822-1110 Plate t 1 N Q Press fitting of oil seal, dust
793T-822-1120 Spacer t 1 N Q seal in cage
5
790-101-5421 • Grip t 1
01010-51240 • Bolt t 1
792-340-1120 Nut, wrench t 1 Removal, installation of
6 sleeve round nut
796-550-1310 Wrench t 1
792-525-3000 Micrometer t 1 Adjusting preload of side
7 790-425-1670 Adapter t 1 bearing
790-425-1660 Wrench t 1
WA800-3E0, WA900-3E0 9
New/remodeled
Necessity
Sketch
Sym-
Q’ty
bol
792-633-1300 Fixture t 4 Removal, installation of brake

1 01010-81430 Bolt t 4
01641-21423 Washer t 4
791-585-1510 Installer t 1 Installation of floating seal
792-530-1700 Push tool t 1
791-580-1610 • Plate 1
791-580-1620 • Arm 4
792-530-1630 • Stud 4
2
791-580-1640 • Plate 1
791-585-1650 • Plate 4
assembly of brake
J 01640-21426 • Washer 4
and final drive
assembly 01541-21670 • Nut 4
793T-833-1110 Plate t 1 N Q Press fitting of oil seal in hub
3 790-101-5421 • Grip t 1
01010-51240 • Bolt t 1
790-438-1060 Nipple t 1 Check for brake oil leakage
4
793-520-1805 Brake tester t 1
790-101-5401 Push tool KIT (C) t 1 Press fitting of bearing and
790-101-5541 • Plate 1 carrier spacer in planetary
gear
5 790-101-5451 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-101-2501 Push puller t 1 Press fitting of upper center
790-101-2510 • Block 1 hinge bearing
790-101-2520 • Screw 1
791-112-1180 • Nut 1
790-101-2540 • Washer 1
790-101-2610 • Leg 2
790-101-2570 • Plate 4
1
Disassembly, 790-101-2740 • Adapter 2
assembly of center K 790-101-2560 • Nut 2
hinge 790-101-7340 Push tool t 1
790-101-7350 Guide t 1
790-201-1310 Spacer t 1
790-101-2102 Puller (30 tons) t 1
790-101-1102 Hydraulic pump t 1
790-201-1970 Plate t 1 Press fitting of upper retainer
2 790-101-5021 • Grip t 1 dust seal
01010-50816 • Bolt t 1
10 WA800-3E0, WA900-3E0
New/remodeled
Necessity
Sketch
Sym-
Q’ty
bol
790-101-2300 Push tool t 1 Press fitting of lower center

790-101-2310 • Plate 1 hinge bearing
790-101-2320 • Screw 1
790-101-2330 • Nut 1
790-101-2340 • Washer 1
790-101-2390 • Leg 2
790-101-2360 • Plate 4
3
02215-11622 • Nut 2
Disassembly, 790-101-7330 Adapter t 2
assembly of center K 790-201-1310 Spacer t 1
hinge
790-101-7310 Push tool t 1
790-101-7320 Grip t 1
790-101-2102 Puller (30 tons) t 1
790-101-1102 • Hydraulic pump t 1
793T-846-1110 Plate t 1 N Q Press fitting of lower retainer
4 790-101-5221 • Grip t 1 dust seal
01010-51225 • Bolt t 1
Removal, installation of cen-
5 790-450-1110 Adapter t 1
ter hinge shaft
1 790-502-1003 Cylinder repair stand q 1 Repair of hydraulic cylinder
790-720-1000 Expander t 1 Installation of piston rings of
2 796-720-1680 Ring t 1 all cylinders
07281-01589 Clamp t 1
796-720-1710 Ring t 1 Installation of piston rings of
3 lift cylinder
07281-02709 Clamp t 1
796-720-1730 Ring t 1 Installation of piston rings of
4 dump cylinder
07281-03209 Clamp t 1
790-201-1500 Push tool KIT t 1 Press fitting of dust seal of
790-201-1660 • Plate 1 steering cylinder
Removal, 5
installation of U 790-101-5021 • Grip 1
hydraulic cylinder 01010-50816 • Bolt 1
792-103-3601 Push tool t 1 Press fitting of dust seal of lift
6 cylinder
792-103-0400 Grip t 1
791-863-1140 Push tool t 1 Press fitting of dust seal of
7 790-101-5221 • Grip t 1 dump cylinder
01010-51225 • Bolt t 1
790-201-1702 Push tool KIT t 1 Press fitting of roll bushing of
790-201-1851 • Push tool 1 steering cylinder
8
790-101-5021 • Grip 1
01010-50816 • Bolt 1
WA800-3E0, WA900-3E0 11
New/remodeled
Necessity
Sketch
Sym-
Q’ty
bol
792-103-4102 Push tool t 1 Press fitting of roll bushing of

9 790-101-5421 • Grip t 1 lift cylinder
Removal, 01010-81235 • Bolt t 1
installation of U
hydraulic cylinder 792-625-1300 Push tool t 1 Press fitting of roll bushing of
10 790-101-5421 • Grip t 1 dump cylinder
01010-81235 • Bolt t 1
793T-870-1110 Sleeve t 1 N Q Removal of bucket hinge pin
793T-870-1120 Plate t 1 N Q and bucket link pin
791-745-2110 Adapter t 1
790-438-1110 Screw t 1
790-101-2540 Washer t 1
1
02215-11622 Nut t 1
01010-81655 Bolt t 3
01640-21626 Washer t 3
Removal of work
equipment pin and 790-101-2102 Puller t 1
removal, V 790-101-1102 Hydraulic pump t 1
installation of 793T-870-1130 Sleeve t 1 N Q Removal, installation of
bushing
793T-870-1140 Plate t 1 N Q bushing of lift arm end
(bucket hinge)
793T-870-1150 Plate t 1 N Q
01580-13024 Nut t 2
2 01643-33080 Washer t 2
791-650-1240 Spacer t 2
791-650-1230 Bolt t 1
790-314-1000 Puller (80 tons) t 1
790-101-1102 Hydraulic pump t 1
12 WA800-3E0, WA900-3E0
Sketches of special tools 1
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A3 Plate
A3 Push tool
WA800-3E0, WA900-3E0 13
A4 Push tool
B2 Plate
14 WA800-3E0, WA900-3E0
D2 Push tool
D7 Plate
WA800-3E0, WA900-3E0 15
H5 Spacer
H3 Push tool
16 WA800-3E0, WA900-3E0
H3 Push tool
H4 Push tool
WA800-3E0, WA900-3E0 17
J3 Plate
K4 Plate
18 WA800-3E0, WA900-3E0
V1 Sleeve
V1 Plate
WA800-3E0, WA900-3E0 19
V2 Sleeve
V2 Plate
20 WA800-3E0, WA900-3E0
V2 Plate
WA800-3E0, WA900-3E0 21
SEN02739-02

© 2011 KOMATSU
All Rights Reserved
22
SEN02740-01
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Engine and cooling system, Part 1
Removal and installation of engine assembly ................................................................................................. 2
Removal and installation of radiator assembly ............................................................................................... 7
Removal and installation of damper assembly ............................................................................................. 10
Disassembly and assembly of damper assembly ..........................................................................................11
Removal and installation of fuel tank assembly ............................................................................................ 15
WA800-3E0, WA900-3E0 1
Removal and installation of 7. Remove L.H. and R.H. brackets (6) and (7).
engine assembly 1
Removal
k Lower the work equipment to the ground
and stop the engine. Apply the parking
brake and put the blocks under the wheels.
k Disconnect the cable from the negative (–)
terminal of the battery.
k Collect the air conditioner refrigerant
(R134a) from the air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere. 8. Disconnect air conditioner hose (8). [*1]
k If the refrigerant gas (R134a) gets in your
eyes, you may lose your sight. Accord- 9. Disconnect heater hose clamps (9) from the
ingly, put on protective goggles while you bulkhead.
are collecting the refrigerant (R134a) or fill-
ing the air conditioner circuit with the
refrigerant (R134a). Collecting and filling
work must be conducted by a qualified per-
son.
1. Drain the coolant.

6 Coolant: 337 l
2. Remove L.H. and R.H. doors (1) and cover (2).
3. Remove handrail (3).
4. Remove muffler (4).

10. Disconnect air conditioner hose (10). [*2]
5. Disconnect the hood and the air cleaner joint
bracket. 11. Disconnect transmission breather (11).
6. Lift and remove hood and side hood assembly 12. Temporarily lift drive shaft (12) and remove the
(5). mounting bolts to disconnect the drive shaft. [*3]
4 Hood and side hood assembly: 300 kg a After disconnecting the drive shaft, lift it
with rope.
2 WA800-3E0, WA900-3E0
13. Disconnect harness connector BR1 (13).
14. Disconnect harness connectors V34, V35, V41

and V42 (14).
20. Open the grille and disconnect harness con-

nectors GR1 (19).
15. Loosen the clamps between the turbocharger

and air cleaner, and remove 2 hoses (15).
16. Disconnect komaclone tube intermediate hose

(16).
21. Remove the grille.

4 Grille: 30 kg
22. Temporarily lift radiator guard (20) and remove

the mounting bolts to disconnect the radiator
guard.
17. Remove step cover (17). 4 Radiator guard: 230 kg
18. Disconnect washer tank hose and harness

connector.
19. Temporarily lift air cleaner and bulkhead

assembly (18) and remove the mounting bolts
to disconnect the air cleaner and the bulkhead
assembly.
WA800-3E0, WA900-3E0 3
23. Disconnect air conditioner hoses (21). [*4] 28. Temporarily lift fan (28) and remove the mount-
ing bolts to shift the fan toward the radiator.
a Take care not to damage the radiator core
with the fan.
24. Loosen the hose clamps and remove L.H. and

R.H. air tubes (22) and (23).
25. Loosen the hose clamps and remove 2 radia- 29. Disconnect fuel return hoses (29) and (30).
tor inlet port tubes (24).
30. Disconnect heater hose (31).
26. Disconnect 2 aeration hoses (25).
31. Disconnect water pump inlet port tube (32).

27. Remove fan pulley cover (26) and remove fan
guard (27). 32. Disconnect water pump outlet port tube (33).
4 WA800-3E0, WA900-3E0
33. Disconnect hoses (34) and (35). 38. Disconnect the harness clamps at 3 locations,
remove the cover and disconnect harness con-
nectors V33 (43), V39 (44), V45 (45) and V46
(46).
34. Disconnect fuel return hoses (36) and (37).
35. Disconnect the heater hose.

39. Disconnect starting motor cables (47) and (48).
40. Disconnect battery relay harness (49).
41. Disconnect grounding (50).
36. Disconnect prefilter fuel inlet port hoses (38)

and (39).
37. Remove the cover and disconnect harness

connectors ER1 (40), ER2 (41), E14 (42) and
E15 (43). 42. Temporarily lift the engine and remove the L.H.
and R.H. front mounting bolt (51), L.H. and
R.H. rear mounting bolt (52). [*5]
WA800-3E0, WA900-3E0 5
43. Lift and remove engine assembly (53). Installation

a When removing, be careful not to allow
each section to interfere with one another. q Carry out installation in reverse order of
a Before removing, make sure every hose removal.
and harness is disconnected.
4
[*1], [*2], [*4]
Engine assembly: 3,500 kg
a Care must be exercised in the installation so
that dusts, dirt or water may not enter the hose
of the air conditioner circuit.
a Make sure that O-ring is installed to the air
conditioner hose piping joints before tighten-
ing.
a Check the O-ring for scratches or degradation.
a Apply the compressor oil (Denso: ND-OIL8,
Zexel: ZXL100PG (equivalent to PAG46)) for
the new refrigerant (R134a) to the coolant pip-
ing O-ring.
[*3]
3 Drive shaft mounting bolt:
156.9 – 196.1 Nm {16 – 20 kg}
[*5]
3 Engine mount mounting bolt (for both front
and rear)
768.3 – 1029 Nm {78.4 – 105 kg}
q Charging the air conditioner gas

Fill the air conditioner circuit with the refriger-
ant (R134a).
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
6 WA800-3E0, WA900-3E0
Removal and installation of 5. Remove radiator grille.

radiator assembly 1 4 Grille: 30 kg
Removal
k Stop the machine on level ground and 6. Disconnect connector GR1 (7).
install the lock bar to the frame. Lower the a After disconnecting the radiator coolant
work equipment to the ground and stop the level sensor wiring connector G06, move
engine. Then apply the parking brake and the connector towards the radiator.
put blocks under the wheels to prevent the
1. Draining coolant
Loosen drain valve (1) and drain coolant.
a If the coolant contains antifreeze, dispose
of it correctly.
6 Coolant: Approx. 337 l
7. Sling radiator guard (8) temporarily, remove

mounting bolts, then lift off.
4 Radiator guard: 230 kg
2. Remove exhaust assembly (2) and then

remove handrails (3), (4).
3. Remove side cover (5).
4. Remove engine hood (6).

4 Exhaust assembly: 45 kg (2 pieces)
4 Engine hood: 90 kg
WA800-3E0, WA900-3E0 7
8. Disconnect coolant drain hose (9) from radia- 16. Remove fan pulley cover and fan guard (17)
tor. from radiator.
9. Loosen clamp of lower hose (10). 17. Remove radiator supports (18) of both sides.
[*1]
10. Disconnect hose (11).
18. Sling radiator (19) temporarily, remove mount-

11. Loosen hose clamp and disconnect 2 radiator ing bolts, then lift off. [*2]
inlet tubes (12). a Raise the radiator slightly and check that
the lower and upper hoses have come
12. Loosen hose clamp and disconnect air tubes out, then lift off the radiator.
(13) from both sides. a Be careful not to let the fan hit the radiator
core.
4
13. Loosen hose clamp and disconnect air tubes
Radiator: 750 kg
(14) from both sides.
14. Disconnect 2 aeration hoses (15).
15. Remove plate (16) of both sides.
8 WA800-3E0, WA900-3E0
Installation
q Carry out installation in the reverse order to

removal.
[*1]
3 Support mounting bolt:
490 – 608 Nm {50.0 – 62.0 kgm}
[*2]
3 Radiator mounting bolt:
490 – 608 Nm {50.0 – 62.0 kgm}
q Refilling with coolant

a Tighten drain valve (1), then add engine
coolant through the coolant filler of the
radiator to the specified level.
5 Engine coolant: 337 l
a Run the engine to circulate the coolant
through the system. Then, check the cool-
ant level again.
WA800-3E0, WA900-3E0 9
Removal and installation of Installation

damper assembly 1
Removal removal.
k Stop the machine on level ground and
lower the work equipment completely to the [*1]
ground, then put blocks under the wheels 3 Drive shaft mounting bolt:
to prevent the machine from moving. 157 – 196 Nm {16.0 – 20.0 kgm}
[*2]
1. Remove the engine hood and bulkhead. For 3 Cover mounting bolt:
details, see "Removal and installation of 98 – 123 Nm {10.0 – 12.5 kgm}
engine." [*3]
3 Damper mounting bolt:
2. Disconnect drive shaft (1). [*1] 245 – 309 Nm {25.0 – 31.5 kgm}
4 Drive shaft: 60 kg
3. Remove mounting bolts (2), then remove cover

(3). [*2]
4 Cover: 120 kg
4. Loosen the upper 2 bolts of damper (5), then

sling temporarily and remove mounting bolts
(4). [*3]
5. Slowly sling and lift off damper (5).

4 Damper assembly: 230 kg
10 WA800-3E0, WA900-3E0
Disassembly and assembly of

damper assembly 1
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-101-5401 Push tool KIT (C) t 1
790-101-5521 • Plate 1
1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
B 4) Face cover (1) in the opposite direction,
793T-812-1110 Plate t 1 N Q
and remove bearing (6) and spacer (7).
2 790-101-5421 • Grip t 1 a Bearing (6) cannot be used again
01010-51240 • Bolt t 1 after it has been removed. Always
3 790-101-7190 Push tool t 1 replace it in the same way as oil seals
(2) and (8).
Disassembly
1. Cover
1) Remove oil seal (2) from cover (1).
2) Remove stopper snap rings (4) and (5) of
shaft (3).
2. Damper
1) Remove mounting bolts (9), and using
forcing screws, remove flange (10).
a Tighten the 3 forcing screws evenly.
3) Pull out shaft (3) from cover (1).

a After pulling out shaft (3), remove oil
seal (8).
WA800-3E0, WA900-3E0 11
a Do not remove spacer (11) unless Assembly

necessary. 1. Damper
1) Install flange (15) under outer body (13),
then install inner body (14).
a Align the bolt mounting holes of the
bottom flange and outer body.
2 Contact surface of flange and outer
body: Gasket sealant (LG-4)
2) Remove rubber (12).
2) Assemble rubber (12) between inner body

(14) and outer body (13).
2 Whole surface of rubber:
Grease (G2-LI)
2 Outside circumference of inner
body:
Grease (G2-LI)
2 Inside circumference of outer body:
Grease (G2-LI)
3) Remove inner body (14) and flange (15) 2 Between inner body and rubber:
from outer body (13). Grease (G2-LI)
a Screw in the mounting bolts, tap with
a hammer and remove.
12 WA800-3E0, WA900-3E0
a Fill clearance (a) evenly at 6 places

with 70 cc grease.
2) Using tool B2, press fit oil seal (8) in cover

(1).
3) Install flange (10), and tighten mounting a Press fit the oil seal so that the lip sur-
bolts (9). face is on the bearing side.
2 Contact surface of flange and outer a Fill clearance (a) between oil seal (8)
body: Gasket sealant (LG-4) and the bearing with grease.
3 Mounting bolt: 2 Clearance (a) between oil seal and
278 ± 31 Nm {28.3 ± 3.2 kgm} bearing: ENS grease
Amount of grease: 80 g
2 Lip of oil seal: ENS grease
2. Cover
1) Using tool B1, press fit bearing (6) and
spacer (7) in cover (1).
a When press fitting the bearing, check
that the inside diameter of the spacer
and the inside diameter of the bearing
are aligned.
2 Outside circumference of bearing
outer race:
Coat with adhesive (LT-2)
2 Bearing: ENS grease
WA800-3E0, WA900-3E0 13
3) Install stopper snap ring (5) of bearing (6) a Fill clearance (b) between oil seal (2)
to cover (1). and the bearing with grease.
4) Using tool B1, press fit oil seal (2) in cover 2 Clearance (b) between oil seal and
(1). bearing: ENS grease
a Press fit the oil seal so that the lip sur- Amount of grease: 160 g
face is on the bearing side. 2 Lip of oil seal: ENS grease
7) Remove plug (16), then fill with grease
through plug hole.
2 Grease area (d) between bearings:
ENS grease
Amount of grease: 700 ± 30 g
3 Plug:
7.4 ± 2.5 Nm {0.75 ± 0.25 kgm}
2 Shaft spline portion (portion (e)):
Molybdenum disulphide
dry lubricant (LM-P)
(Leave to dry naturally for 2 – 3 min-
utes after coating, then install.)
8) Fill portion (f) with grease.
2 Portion (f): ENS grease
5) Using tool B3, press fit shaft (3) in cover Amount of grease: 30 g
(1). a Always keep to the specified amount
2 Inside of inner race of bearing (6): for grease in the grease areas ((a),
Adhesive (LT-2) (b), (d), (f)).
a Always remove all other grease com-
pletely before using ENS grease. Do
not mix it with any other grease.
Use a different grease gun for each
type of grease.
a ENS grease Part No.: 427-12-11871
(2 kg can)
6) Assemble snap ring (4) to shaft (3).
14 WA800-3E0, WA900-3E0
Removal and installation of fuel 8. Disconnect fuel hose (11), left and right blowby
tank assembly 1 hoses (12) and fuel return hoses (12a).
a Disconnect the clamps of fuel hose, left
Removal and right engine blowby hoses, fuel return
k Stop the machine on level ground and hoses and engine blowby drain hose.
lower the work equipment completely to the
ground, then put blocks under the wheels
to prevent the machine from moving.
1. Drain the fuel.

6 Fuel: 1,555 l (Full)
2. Remove step (1) and covers (2) and (3).
3. Disconnect engine oil drain valve (4), torque

converter cooling water drain valve (5) and
cooling water drain valve (6) from the fuel tank.
9. Disconnect fuel gauge connector R08 (13).

a This connector is just above the drain
valve.
4. Remove side cover (7).
6. Remove fuel cut valve cover (9). 10. Remove cover (14) installed between the fuel
tank and counterweight.
7. Remove step (10).
WA800-3E0, WA900-3E0 15
11. Temporarily sling fuel tank (15), then remove Installation

mounting bolts (16). [*1]
4
Fuel tank assembly: 800 kg
removal.
[*1]
3 Fuel tank mounting bolt:
1,520 – 1,910 Nm {155.0 – 195.0 kgm}
q Bleeding air
Bleed air from the fuel line. For details, see
testing and adjusting, "Bleeding air from each
portion".
12. Set block [1] under the fuel tank.
13. Slowly lower fuel tank (15).

a Pull the fuel tank out of under the machine
body.
16 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 17
SEN02740-01

© 2009 KOMATSU
All Rights Reserved
18
SEN02741-03
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Engine and cooling system, Part 2
Removal and installation of right bank fuel supply pump assembly................................................................ 2
Removal and installation of left bank fuel supply pump assembly .................................................................. 6
Removal and installation of cylinder head assembly .................................................................................... 10
Removal and installation of fuel injector assembly ....................................................................................... 20
Removal and installation of engine front oil seal........................................................................................... 25
Removal and installation of engine rear oil seal ........................................................................................... 28
WA800-3E0, WA900-3E0 1
Removal and installation of right 7. Remove the clamps and disconnect fuel hoses
bank fuel supply pump assembly1 (8) and (9).
Removal 8. Remove priming pump (10).

completely and stop the engine. Apply the 9. Disconnect fuel tubes (11), (12) and (13). [*1]
parking brake and put the blocks under the
wheels.
1. Remove door (1) and cover (2).
10. Disconnect harness connectors G (14), PCV1

(15) and PCV2 (16).
2. Remove 3 oil filters (3).
3. Remove bracket (4).
4. Remove oil filler tube (5).
5. Remove oil level gauge (6).
6. Disconnect fuel hose (7).
2 WA800-3E0, WA900-3E0
11. Remove clamps (17), (18) and (19). [*2] Installation

12. Remove bracket (20). q Carry out installation in reverse order of
removal.
13. Remove the pin and remove fuel spray preven-
tion cap (21) and (22). [*3]
[*1]
3 Tubes (11), (12) and (13) joint bolts:
14. Remove high-pressure pipes (23) and (24).
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
[*4]
15. Remove fuel tube (25). [*5] [*2], [*3], [*4], [*5], [*6], [*7]
k When handling the high-pressure pipe and
16. Remove oil tube (26). [*6] clamp, pay attention to the following.
q It is strictly prohibited to bend the high-
pressure piping to use it again or using it
in other locations.
q Install the specified clamp securely in the
specified position with the specified
torque.
q Don't apply lubricant and the like to the
high-pressure piping sleeve nut and the
threaded portion of the mating side.
a Axial force in the tightening can be exces-
sive, potentially damaging the high-pres-
sure piping.
k Before installing the high-pressure piping,
check it for the following defects. If there is
17. Remove bracket (27). any of these defects, it can cause fuel leak-
age. Accordingly, replace the high-pres-
18. Remove 4 mounting bolts (28), and remove sure piping.
supply pump assembly (29). [*7] q Check the taper seal of the connecting
part (Part (a): Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
q Check part (d) (end of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
19. If necessary, remove nut (30), coupling (31)

and key (32) from supply pump assembly (29).
WA800-3E0, WA900-3E0 3
1) Install key (32) and coupling (31) to supply

pump assembly (29), then tighten with nut
(30).
a Be careful not to forget the key (23)
when installing the coapling (22).
3 Nut: 176 – 196 Nm {18 – 20 kgm}
3) After installing high-pressure pipes (23)

and (24) to supply pump (29) and com-
mon rail (3) temporarily, tighten the sleeve
nut with the specified torque.
a Control the torque by using a spanner
type torque wrench (commercially
2) Install supply pump assembly (29) tempo- available part) for the tightening.
3 High-pressure
rarily. pipe sleeve nut
a Align and insert the unequal spline (supply pump side):
portion of the supply pump side to 39.2 – 49 Nm {4 – 5 kgm}
3 High-pressure
unequal spline portion (A) of the sup- pipe sleeve nut
ply pump drive case side. (common rail side):
a When it is difficult to insert the supply 39.2 – 58.8 Nm {4 – 6 kgm}
pump, turn the crankshaft to change 4) Tighten supply pump assembly mounting
position of unequal spline portion (A). bolt (28).
5) Tighten the mounting bolt across the sup-
ply pump assembly bottom face and
bracket.
3 Supply pump mounting bolt (Bot-
tom side):
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
6) Install oil tube (26).
3 Oil tube joint bolt (on the block
side):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Oil tube joint bolt (on the supply
pump side):
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
a Tighten mounting bolt (28) with the
specified torque after tightening the
sleeve nut of the high-pressure pipe
(between supply pump and common
rail).
2 Supply pump assembly mounting
bolt: Adhesive (LT-2)
4 WA800-3E0, WA900-3E0
7) Install fuel tube (25). 9) Install the fuel spray prevention cap to the
3 Fuel tube joint bolt (supply pump sleeve nut on the high-pressure pipe.
side): k Direct the slit downward when
14.8 – 19.6 Nm {1.5 – 2.0 kgm} installing the fuel spray prevention
3 Fuel tube joint bolt (common rail cap.
side): q Supply pump side (22): Bottom
17.7 – 22.6 Nm {1.8 – 2.3 kgm} q Common rail side (21): Facing
inward (Opposed)
8) Install high-pressure pipe clamps (17),

(18) and (19) according to the following k Check that the high-pressure pipe is sepa-
procedure. rated from the surrounding harnesses by
1] Manually tighten and install tempo- 10 mm and over. If less than 10 mm, adjust
rarily the stay and top and bottom the harness position to retain necessary
clamps of the high-pressure pipe space.
clamp.
2] Tighten the top and bottom clamps q Bleed air from the fuel circuit, referring to
permanently. "Bleeding air from fuel circuit" in "Testing and
a Before tightening the stay perma- adjusting."
nently, deflect the rubber first.
a Use care in the tightening so that
e x c e s s i v e f o r c e ma y n o t be
applied to the supply pump side
install position.
3 Top and bottom clamp bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
3] Tighten respective stays permanently.
WA800-3E0, WA900-3E0 5
Removal and installation of left 4. Disconnect fuel hose (6).

bank fuel supply pump assembly1
5. Disconnect fuel tubes (7), (8) and (9). [*1]
Removal
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
1. Open door (1) and apply hook.
2. Remove cover (2).
6. Remove clamps (10), (11) and (12). [*2]
8. Remove the pin and remove fuel spray preven-

tion cap (14) and (15). [*3]
9. Remove high-pressure pipes (16) and (17).

[*4]
10. Disconnect fuel hose (18).

3. Disconnect harness connectors G (3), PCV1
(4) and PCV2 (5). 11. Remove oil tube (19). [*5]
6 WA800-3E0, WA900-3E0
12. Remove bracket (20). Installation
13. Remove 4 mounting bolts (21), and remove q Carry out installation in reverse order of
supply pump assembly (22). [*6] removal.
[*1]
3 Tubes (7), (8) and (9) joint bolts:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
[*2], [*3], [*4], [*5], [*6]

k When handing the to high-pressure pipe
and clamp, pay attention to the following.
q It is strictly prohibited to bend the high-
pressure piping to use it again or using it
in other locations.
q Install the specified clamp securely in the
specified position with the specified
torque.
14. If necessary, remove nut (23), coupling (24) q Don't apply lubricant and the like to the
and key (25) from supply pump assembly (22). high-pressure piping sleeve nut and the
threaded portion of the mating side.
a Axial force in the tightening can be exces-
sive, potentially damaging the high-pres-
sure piping.
k Before installing the high-pressure piping,
any of these defects, it can cause fuel leak-
age. Accordingly, replace the high-pres-
sure piping.
q Check the taper seal of the connecting
WA800-3E0, WA900-3E0 7
1) Install key (25), coupling (24) to supply

pump assembly (22), then tighten with nut
(23).
a Be careful not to forget the key (25)
when installing the coupling (24).
3 Nut: 176 – 196 Nm {18 –20 kgm}
3) After installing high-pressure pipes (16)

and (17) to supply pump (22) and com-
mon rail (23) temporarily, tighten the
sleeve nut with the specified torque.
2) Install supply pump assembly (22) tempo- available part) for the tightening.
rarily. 3 High-pressure pipe sleeve nut
a Align and insert the unequal spline (supply pump side):
portion of the supply pump side to 39.2 – 49 Nm {4 – 5 kgm}
unequal spline portion (A) of the sup- 3 High-pressure pipe sleeve nut
ply pump drive case side. (common rail side):
a When it is difficult to insert the supply 39.2 – 58.8 Nm {4 – 6 kgm}
pump, turn the crankshaft to change 4) Tighten supply pump assembly mounting
position of unequal spline portion (A). bolt (21).
5) Tighten the mounting bolt across the sup-
ply pump assembly bottom face and
bracket.
3 Supply pump mounting bolt (Bot-
tom side):
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
6) Install oil tube (19).
3 Oil tube joint bolt (on the block
side):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Oil tube joint bolt (on the supply
pump side):
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
a Tighten mounting bolt (21) with the

specified torque after tightening the
sleeve nut of the high-pressure pipe
(between supply pump and common
rail).
2 Supply pump assembly mounting
bolt: Adhesive (LT-2)
8 WA800-3E0, WA900-3E0
7) Install fuel tube (25). 9) Install the fuel spray prevention cap to the
3 Fuel tube joint bolt (supply pump sleeve nut on the high-pressure pipe.
side): k Direct the slit downward when
14.8 – 19.6 Nm {1.5 – 2.0 kgm} installing the fuel spray prevention
3 Fuel tube joint bolt (common rail cap.
side): q Supply pump side (14): Bottom
17.7 – 22.6 Nm {1.8 – 2.3 kgm} q Common rail side (15): Facing
inward (Opposed)
8) Install high-pressure pipe clamps (10),

(11) and (12) according to the following k Check that the high-pressure pipe is sepa-
procedure. rated from the surrounding harnesses by
1] Manually tighten and install tempo- 10 mm and over. If less than 10 mm, adjust
rarily the stay and top and bottom the harness position to retain necessary
clamps of the high-pressure pipe space.
clamp.
2] Tighten the top and bottom clamps q Bleed air from the fuel circuit, referring to
permanently. "Bleeding air from fuel circuit" in "Testing and
a Before tightening the stay perma- adjusting."
a Use care in the tightening so that
e x c e s s i v e f o r c e ma y n o t be
applied to the supply pump side
install position.
9.8 ± 1 Nm {1 ± 0.1 kgm}
3] Tighten respective stays permanently.
WA800-3E0, WA900-3E0 9
Removal and installation of 6. Loosen the hose clamps and remove L.H. and
cylinder head assembly 1 R.H. tubes (6), (7), (8) and (9).
Special tool
New/Remodel
Necessity
Sym
Part No. Part name
Sketch
bol
Q'ty
A 1 790-331-1110 Wrench (Angle) t 1
Removal
brake and put the blocks under the wheels.
k Disconnect the cable from the negative (–) 7. Disconnect the engine harness connector from
terminal of the battery. the intake temperature sensor installed to the
a This document describes the removal and turbocharger intake pipe.
installation procedures of the right bank cylin-
der head assembly. 8. Loosen the clamps between the turbocharger
and air cleaner, and remove 2 hoses (10).
1. Drain the coolant.
6 Coolant : 337 l 9. Remove the muffler drain tube.
2. Remove L.H. and R.H. doors (1) and cover (2). 10. Disconnect Komaclone tube intermediate hose
(11).
11. Remove muffler assembly (12).
5. Lift and remove hood and side hood assembly

(5).
4 Hood and side hood assembly : 300 kg
10 WA800-3E0, WA900-3E0
12. Remove harness cover (67), and then remove 15. Remove U-bolt [17] and remove air inlet pipe
harness bracket (68). (18). [*1]
16. Remove bracket (19). [*2]
13. Remove harness connectors at 6 locations and

disconnect harness (13).
17. Remove connector (20) and electrical intake
air heater (21). [*3]
14. Remove oil tubes (14) and (15), and remove oil
filter head assembly (16).
18. Remove spill pipe (23). [*4]
WA800-3E0, WA900-3E0 11
19. Remove cover (24). [*5] 24. Remove exhaust connectors (30) and (31).
20. Remove bracket (25). 25. Remove bracket (38).
21. Remove 5 clamps (26). [*6]
26. Disconnect water pipe (32) and hose (33). [*9]
22. Remove 6 clamps (27) and remove bracket 27. Disconnect turbocharger oil filler hose (34).
(28). [*7]
28. Disconnect turbocharger drain tube (35).
23. Temporarily lift air intake manifold assembly

(29) and remove the mounting bolts to remove 29. Temporarily lift turbocharger assembly (36)
the assembly. [*8] and remove the mounting bolts to remove the
4
assembly. [*10]
Air intake manifold assembly : 45 kg
12 WA800-3E0, WA900-3E0
30. Remove heat insulation plate (37). 33. Remove fuel tube (43). [*13]
31. Temporarily lift exhaust manifold assembly (39) 34. Remove cover (44).
and remove the mounting bolts to remove the
assembly. [*11] 35. Remove air vent tube (45). [*14]
4 Exhaust manifold assembly : 25 kg
36. Remove head cover (46). [*15]
32. Remove rubber covers (40) and (41), and 37. Loosen locknuts (47) and then loosen adjust-
remove high-pressure pipe (42). [*12] ment screws (48) fully. [*16]
a Remove the high-pressure pipe con- a Make sure that the valve tension is not
nected to the cylinder head to be applied to the rocker arm and thus it is
removed. free to move.
38. Remove rocker arm assembly (49). [*17]

a Record the parts installation positions
using a tag to avoid confusion in the later
assembly.
WA800-3E0, WA900-3E0 13
39. Remove push rod (50). [*18] 43. Insert a small L-bar [1] under the fuel connec-
tor and pry out fuel injector (56) slowly.
a Do not grip the solenoid valve at the top of
the injector to pull off the injector.
40. Remove injector terminal mounting nut (51)

and clamp mounting bolt (52). [*19]
41. Remove plate (53) fixing the connector, push 44. Remove crosshead (57). [*21]
connector into the cylinder head and remove
injector harness (54).
45. Lift off cylinder head assembly (58). [*22]

4 Cylinder head assembly: 25 kg
42. Remove holder mounting bolt (55). [*20]
a When removing the cylinder head assem-
bly without removing the fuel injector, be
sure to prevent its interference with the
floor surface since the injector tip pro-
trudes through the bottom of the cylinder
head.
14 WA800-3E0, WA900-3E0
46. Remove the cylinder head gasket (59). Installation
q Carry out installation in reverse order of

removal.
[*1]
3 Air inlet pipe locknut:
14.7 – 44.1 Nm {1.5 – 4.5 kgm}
[*2]
3 Bracket mounting bolt (connector and
bracket): 29.4 – 44.1 Nm {3.0 – 4.5 kgm}
3 Bracket mounting bolt (air intake manifold
and bracket):
49.0 – 68.6 Nm {5.0 – 7.0 kgm}
[*3]
3 Connector mounting bolt:
49.0 – 68.6 Nm {5.0 – 7.0 kgm}
[*4]
3 Spill pipe joint bolt:
(Inner side) 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
(Outer side) 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*5]
3 Cover mounting bolt:
30.5 – 34 Nm {3.1 – 3.5 kgm}
[*8]
a Tighten the mounting bolts in order as shown
in the diagram.
3 Air intake manifold mounting assembly
mounting bolts:
58.8 – 73.5 Nm {6 – 7.5 kgm}
WA800-3E0, WA900-3E0 15
[*9] [*6], [*7], [*12]

3 Water connector (Block side): a Install high-pressure pipe according to the fol-
78.5 – 103 Nm {8 – 10.5 kgm} lowing instructions.
3 Water pipe flare nut (Water connector side): k Install the high-pressure pipe and clamp
24.5 – 59 Nm {2.5 – 6 kgm} paying attention to the following points.
3 Water pipe joint bolt (Turbocharger side): q It is strictly prohibited to reuse a high-pres-
24.5 – 34.3 Nm {2.5 – 3.5 kgm} sure pipe by modifying its bend or using
3 Water connector (Turbocharger side): the pipe in an unintended location.
29.4 – 39.2 Nm {3 – 4 kgm} q The clamp used must be a legitimate one.
3 Water pipe flare nut (Water connector side): And it must be installed in the specified
29.4 – 39.2 Nm {3 – 4 kgm} position with the specified torque.
q After installing the high-pressure pipe and
[*10] clamp, make sure that 10 mm minimum
a Tighten the turbocharger assembly mounting clearance is provided between the high-
bolt after temporarily tightening and positioning pressure pipe and adjacent harness. If the
of respective connections. clearance is less than 10 mm, adjust the
4
harness position to secure the space.
k Before installing the high-pressure pipe,
Turbocharger assembly: 35 kg
2 Turbocharger assembly mounting bolt and
nut:
Molybdenum disulfide lubricant (LM-P)
3
age. Accordingly, replace the high-pressure
Turbocharger assembly mounting bolt:
pipe.
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
[*11]
a Install the gasket so that the face stamped with
"OUT" on the surface comes to the side of the
exhaust manifold.
a Tighten the mounting bolts in the following
order.
a Tighten it once and then tighten again with the
same torque.
2 Exhaust manifold assembly mounting bolt:
3 Exhaust manifold assembly mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
1) After installing fuel injector (54) and com-

mon rail temporarily to high-pressure pipe
(41), tighten the sleeve nut with the speci-
fied torque.
available) for the tightening.
3 High-pressure pipe sleeve nut
(injector side):
39.2 – 49 Nm {4 – 5 kgm}
3 High-pressure pipe sleeve nut
(common rail side):
39.2 – 49 Nm {4 – 5 kgm}
a After the tightening, make sure the O-
ring is not projecting from the sleeve
nut.
16 WA800-3E0, WA900-3E0
9) Install the rubber cover to the sleeve nut

on the high-pressure pipe.
a Direct the slit downward when install-
ing the rubber cover.
q Injector side (41): Bottom
q Common rail side (40): Cylinder
block side
2) Manually tighten and install temporarily

the stay and top and bottom clamps of
high-pressure pipe clamp (26) and (27).
3) Tighten the top and bottom clamps perma-
nently.
a Before tightening the stay perma-
3 Top and bottom clamp bolt: [*13]
9.8 ± 1 Nm {1 ± 0.1 kgm} 3 Fuel tube joint bolt:
4) Tighten the stay permanently. 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
the stay and top and bottom clamps of the [*14]
high-pressure pipe. 3 Air vent tube
6) Install the high-pressure pipe clamp and 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
gate type frame temporarily.
a First tighten the high-pressure pipe [*15]
clamp permanently, and then tighten 3 Head cover mounting bolt:
the gate type frame permanently to 14.7 – 34.3 Nm {1.5 – 3.5 kgm}
the common rail mounting bolt.
3 Gate type frame mounting bolt: [*16], [*17]
9.8 ± 1 Nm {1 ± 0.1 kgm} 1) Install rocker arm assembly (49) according to
7) Tighten the high-pressure pipe clamp per- the following procedure.
manently. a Make sure that the ball of adjustment screw
3 High pressure pipe clamp bolt: (48) is securely fitted to the push rod socket.
9.8 ± 1 Nm {1 ± 0.1 kgm} a When tightening the mounting bolt, make sure
8) Tighten the clamp stay permanently. adjustment screw (48) is not pushing the push
a Tighten the clamp of the air intake rod.
manifold after installing the manifold. 2 Rocker arm: Engine oil (EO30-DH)
93 – 103 Nm {9.5 – 10.5 kgm}
a Tighten locknut (47) after adjustment of the
valve clearance is completed.
2) Adjust the valve clearance, referring to "Adjust-
ing valve clearance" in "Testing and adjusting."
[*18]
a Make sure that the push rod end is securely fit-
ted to the cam follower socket.
2 Both ends of push rod:
Engine oil (EO30-DH)
WA800-3E0, WA900-3E0 17
[*19] [*21]
3 Injector terminal mounting nut: 2 Crosshead sliding portion:
2 ± 0.2 Nm {0.2 ± 0.02 kgm} Engine oil (EO30)
a After tighten the injector terminal mounting nut, 1) Adjust the crosshead according to the fol-
push the harness against the injector body to lowing procedure.
eliminate sagging. 1] Loosen locknut (64) and then loosen
adjustment screw (65) to a position
[*20] where it does not contact against
a Install the fuel injector according to the follow- valve stem (66).
ing procedure. 2] Maintain the contact with valve stem
a Check that the inside of the injector sleeve is (66) on the push rod side by pressing
free from dirt. the contact face against the rocker
1) Install O-rings (60) and (61) and gasket (62) to arm using a finger.
the fuel injector. 3] Tighten adjustment screw (65) to con-
2 O-ring: Engine oil (EO30-DH) firm the position where adjustment
screw (65) is contacted against valve
stem (66).
4] Drive in adjustment screw (65) further
by 20° from the contacting position
against valve stem (66).
5] Tighten locknut (64) while suppress-
ing move of adjustment screw (65).
3 Locknut:
58.8 ± 5.9 Nm {6.0 ± 0.6 kgm}
2) Insert fuel injector to the cylinder head along

with holder.
3) Install spherical washer (63) and then tighten
holder mounting bolt (55) temporarily.
2 Special washer: Engine oil (EO30-DH)
4) Tighten holder mounting bolt (55) with the
specified torque.
58.8 – 73.5 Nm {6 – 7.5 kgm}
18 WA800-3E0, WA900-3E0
[*22] 4) After the tightening, stamp punch mark (a) to

a Tighten the mounting bolts according to the fol- the head of mounting bolts (No. 1 – 6).
lowing procedure.
1) Tighten mounting bolts (No. 1 – 7) temporarily.
2) Tighten the mounting bolts (No. 1 – 6) in 3
steps according to the order indicated in the
figure.
a When a bolt with 5 punch marks, which
indicates the tightening frequency up to
today, in its head is found, replace it with a
new one.
2 Cylinder head assembly mounting bolt:
3 Cylinder head assembly mounting bolt
(No. 1 – 6)
1st time: 137 – 157 Nm {14 – 16 kgm}
2nd time: 284 – 294 Nm {29 – 30 kgm} q Bleeding air
3rd time: 90 (+30/0)° Bleed air from the fuel circuit, referring to
"Bleeding air from fuel circuit" in "Testing and
adjusting."
a When tool A1 is not used in tightening of the

3rd time, check the rotating angle after apply-
ing marking to the cylinder head and bolt head
using paint.
3) Tighten the mounting bolt (No. 7) with the fol-

lowing torque.
2 Cylinder head assembly mounting bolt:
3 Cylinder head assembly mounting bolt
(No. 7):
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
WA800-3E0, WA900-3E0 19
Removal and installation of fuel 8. Remove high-pressure pipe clamp bolts (8)
injector assembly 1 and remove cover (9). [*1]
Removal 9. Remove high-pressure pipe clamps (10) and

k Lower the work equipment to the ground (11). [*2]
brake and put the blocks under the wheels. 10. Remove rubber cover. [*3]
terminal of the battery. 11. Remove high-pressure pipe (12). [*4]
1. Remove L.H. and R.H. doors (1) and cover (2).
4. Lift and remove hood and side hood assembly

(5).
4 Hood and side hood assembly: 300 kg
5. Remove the muffler drain tube.
6. Disconnect Komaclone tube intermediate hose

(6). 12. Remove head cover (13). [*5]
7. Remove muffler assembly (7) together with the

bracket.
20 WA800-3E0, WA900-3E0
13. Loosen locknut (14) and turn adjustment screw 16. Remove holder mounting bolts (18). [*9]
(15) to the limit. [*6]
a Check that no valve tension applies to the 17. Insert a small L-shaped bar to the bottom of
rocker arm and the arm is in free state. the fuel connector, and pull out fuel injector
(19) slowly using the leverage. [*10]
14. Remove rocker arm assembly (16). [*7] a Do not pull out the fuel solenoid valve sec-
tion at the top of injector, using a tool such
as pliers.
15. Loosen injector terminal mounting nut (17). [*8]
WA800-3E0, WA900-3E0 21
Installation 3 High-pressure pipe sleeve nut

(common rail side):
q Carry out installation in reverse order of 39.2 – 49 Nm {4 – 5 kgm}
removal. a After the tightening, make sure the O-
ring is not projecting from the sleeve
[*1], [*2], [*3], [*4] nut.
High-pressure pipe (between common rail – fuel
injector)
k Install the high-pressure pipe and clamp
paying attention to the following points.
q It is strictly prohibited to reuse a high-pres-
sure pipe by modifying its bend or using
the pipe in an unintended location.
q The clamp used must be a legitimate one.
And it must be installed in the specified
position with the specified torque.
q After installing the high-pressure pipe and
clamp, make sure that 10 mm minimum
clearance is provided between the high-
pressure pipe and adjacent harness. If the
clearance is less than 10 mm, adjust the
harness position to secure the space.
k Before installing the high-pressure pipe,
age. Accordingly, replace the high-pressure
pipe.
the stay and top and bottom clamps of
high-pressure pipe clamps (10) and (11).
3) Tighten the top and bottom clamps perma-
nently.
a Before tightening the stay perma-
9.8 ± 1 Nm {1 ± 0.1 kgm}
4) Tighten the stay permanently.
the stay and top and bottom clamps of the
high-pressure pipe.
6) Install the high-pressure pipe clamp and
1) After installing fuel injector (19) and com- gate type frame temporarily.
mon rail (20) temporarily to high-pressure a First tighten the high-pressure pipe
pipe (12), tighten the sleeve nut with the clamp permanently, and then tighten
specified torque. the gate type frame permanently to
a Control the torque by using a spanner the common rail mounting bolt.
type torque wrench (commercially 3 Gate type frame mounting bolt:
available) for the tightening. 9.8 ± 1 Nm {1 ± 0.1 kgm}

3 High-pressure pipe sleeve nut 7) Tighten the high-pressure pipe clamp per-
(injector side): manently.
39.2 – 49 Nm {4 – 5 kgm} 3 High pressure pipe clamp bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
22 WA800-3E0, WA900-3E0
8) Tighten the clamp stay permanently.

a Tighten the clamp of the air intake
manifold after installing the manifold.
2) Adjust the valve clearance, referring to "Adjust-

ing valve clearance" in the "Testing and adjust-
ing."
9) Install the rubber cover to the sleeve nut 3) Tighten locknut (14).
on the high-pressure pipe. 3 Locknut tightening torque:
a Direct the slit downward when install- 52.9 – 64.7 Nm {5.4 – 6.6 kgm}
ing the rubber cover.
q Injector side (22): Bottom [*8]
q Common rail side (21): Cylinder 3 Injector terminal mounting nut:
block side 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a After tightening the injector terminal mounting
nut, press the harness to the injector main
body to prevent slackening.
[*9], [10]
Fuel injector
a Check that the inside of the injector sleeve is
free from dirt.
1) Install O-rings (23) and (24) and gasket (25) to
the fuel injector.
2 O-ring: Engine oil (EO30-DH)
[*5]
3 Head cover mounting bolt:
14.7 – 34.3 Nm {1.5 – 3.5 kgm}
[*6], [*7]
1) Install rocker arm assembly (16).
a Check that the ball of adjustment screw
(15) is securely placed in the socket of the
push rod.
a When tightening the mounting bolts, make
sure that adjustment screw (15) does not
press the push rod.
2 Rocker arm: Engine oil (EO30)
3 Rocker arm assembly mounting bolts:
93 – 103 m {9.5 – 10.5 kgm}
a Tighten locknut (14) after adjusting the
valve clearance.
WA800-3E0, WA900-3E0 23
2) Insert fuel injector (19) to the cylinder head

along with holder (18).
3) Install spherical washer (26) and then tighten

holder mounting bolt (18) temporarily.
2 Special washer: Engine oil (EO30-DH)
4) Tighten sleeve nut (27) of the high-pressure
pipe temporarily.
a Also tighten the sleeve nut on the com-
mon rail side temporarily to proceed with
the positioning.
a See "High-pressure pipe" for precautions
on this operation.
5) Tighten holder mounting bolt (18) with the
specified torque.
58.8 – 73.5 Nm {6 – 7.5 kgm}
a Leave sleeve nut (27) being tightened
temporarily in above operation as is. This
nut is to be tightened with the specified
torque similar to the sleeve nut on the
common rail side.
q Bleeding air
Bleed air from the fuel circuit, referring to
"Bleeding air from fuel circuit" in "Testing and
adjusting."
24 WA800-3E0, WA900-3E0
Removal and installation of 1) Change the end of tool A2 to the hook

engine front oil seal 1 type.
2) Hook the hook on the metal ring of front
Special tools seal (1).
3) Remove the seal with the impact of a slide
New/Remodel
hammer (SH).
Symbol
Necessity
Part No. Part name
q Tool A2
Sketch
Q'ty
Seal puller assem-
2 795-931-1100 t 1
bly
795T-621-1430 Plate t 1 Q
A 795T-621-1441 Push tool t 1 Q

3 01050-32280 • Bolt t 3
01582-02218 • Nut t 3
01640-22232 • Washer t 3
Removal
k Lower the work equipment completely to
the ground and stop the engine.
k Disconnect the cable from the negative (–) a CS: Crankshaft
1. Remove the radiator assembly, referring to

"Removal and installation of radiator assem-
bly."
2. Remove the damper and crankshaft pulley. [*1]

4 Damper and crankshaft pulley assembly:
75 kg
3. Remove front oil seal (1) according to the fol-

lowing procedure.
WA800-3E0, WA900-3E0 25
Installation 3) Tighten nuts [1] using tool A3 (push tool),

press oil seal (1) in the front case until it
1. Clean, degrease and then dry the contact sur- becomes the dimension (a) as shown in
face between the front cover and front seal. the figure.
a Oil seal press fit dimensions
2. Using a clean cloth, remove foreign matter (a): 17 mm (from crank shaft end sur-
deposited the crankshaft flange. face)
a Clean foreign matter deposited on the seal (b): 25.1 mm (from front cover end
lip surface (surface around the crankshaft) surface)
and then degrease and dry the surface.
a Check the crankshaft end face corner and
lip siding surface for scratches due to the
housing, burrs or rusts.
3. Install front oil seal (1) according to the follow-

ing procedure.
a Before installing the seal, check that the
end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and
rust of the housing.
a When installing the seal, do not apply oil
or grease to the shaft and seal lip. Wipe
off the oil from the shaft.
1) The surface having the parts number (PN) q Carry out the following installation in the
marking must face to the outside of reverse order of removal.
engine.
[*1]
Installation of damper and crankshaft pulley assem-
bly
1) Install the damper and crankshaft pulley
assembly by aligning it to the crankshaft
dowel pin.
2) Tighten each mounting bolt 3 times in the
procedure shown in the figure.
2 Damper and crankshaft pulley
a s s e m b l y m o u n t i n g b o l ts a n d
washers: Engine oil (EO30-DH)
3 Damper and crankshaft pulley
assembly mounting bolts
1st time: 73.5 ± 19.6 Nm {7.5 ± 2.0 kgm}
2) Tighten nuts [1] using the tool A3 (plate), 2nd time: 245 ± 19.6 Nm {25 ± 2.0 kgm}
and press oil seal (1) to the crank shaft 3rd time: 744.8 ± 19.6 Nm {76 ± 2.0 kgm}
end surface.
26 WA800-3E0, WA900-3E0
a When the damper and crankshaft pul-

ley have been disassembled, reas-
semble them by tightening their
mounting bolts in the procedure
shown in the figure.
2 Damper mounting bolts and wash-
ers: Engine oil (EO30-DH)
3 Damper mounting bolts:
98 – 122 Nm {10.0 – 12.5 kgm}
WA800-3E0, WA900-3E0 27
Removal and installation of 3. Remove rear seal (2) according to the follow-
engine rear oil seal 1 ing procedure.
a Be careful not to damage the seal-
Special tools mounted section of the flywheel housing
and the crankshaft seal contact surface.
New/Remodel
a Strike on the seal lightly to unbind adhe-
Symbol
sion once before removing.
Necessity
Part No. Part name
1) Change the end of tool A2 to the hook
Sketch
type.
Q'ty
2) Hook the hook on the metal ring of rear
Seal puller assem-
2 795-931-1100 t 1 seal (2).
bly
3) Remove the seal with the impact of a slide
A 795T-621-1531 Push tool t 1 Q hammer (SH).
4 01050-32050 • Bolt t 5 q Tool A2
01640-02032 • Washer t 5
Removal
the ground and stop the engine.
1. Remove the torque converter and transmission

assembly, referring to "Removal and installa-
tion of torque converter and transmission
assembly."
2. Remove flywheel (1). [*1]

4
q CS: Crankshaft
Flywheel assembly: 130 kg
28 WA800-3E0, WA900-3E0
Installation 3) Use tool A4 (push tool) to press rear oil

seal (2) to the flywheel housing (FWH) so
1. Clean, degrease and dry the contact surface that the dimension (a) of rear oil seal
with the flywheel housing. becomes as shown in the diagram.
a Oil seal press fit dimension
2. Remove attached substances from the crank- (a): 5 mm (from the end face of the
shaft flange with a clean cloth. flywheel housing)
a Clean, degrease and dry the seal lip sur-
faces (peripheral surfaces of crankshaft).
a Check the edge-corner of the crank shaft
and lip sliding surface for any housing
flaws, burrs, sharp edges, rust, etc.
3. Assemble rear oil seal (2) (end face seal)

a Check the edge-corner of the crank shaft
and lip sliding surface for any housing
flaws, burrs, sharp edges, rust, etc.,
before assembling the seal.
a When assembling the seal, do not apply
oil or grease to the shaft and the seal lip.
Thoroughly remove extra oil from the q For the rest of the installation work, carry out
shaft. the installation in the reverse order of removal.
2 Rear oil seal inner peripheral surface:
Gasket sealant (LG-7 equivalent) [*1]
1) Apply thin layer of gasket sealant evenly a Install the flywheel assembly by aligning it to
on the inner peripheral surface of the rear the crankshaft dowel pin.
oil seal. a After having tightened the mounting bolts,
2) Set the side stamped "IN" toward the mount plate [1] between the flywheel and the
inside of engine and the side stamped flywheel housing so that the crankshaft does
"OUT" toward the outside. not rotate.
WA800-3E0, WA900-3E0 29
a Tighten the mounting bolts in the procedure

shown in the figure.
2 Flywheel assembly mounting bolts:
Engine oil (EO30)
3 Flywheel assembly mounting bolts
1st time: 98 ± 19.6 Nm {10 ± 2 kgm}
2nd time: 294 ± 19.6 Nm {30 ± 2 kgm}
3rd time: 539 ± 19.6 Nm {55 ± 2 kgm}
a After having installed the flywheel assembly,

check for its facial runout and radial runout
using dial gauge [2].
Standard value for facial runout: Max. 0.25 mm
Standard value for radial runout: Max. 0.25 mm
30 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 31
SEN02741-03

© 2011 KOMATSU
All Rights Reserved
32
SEN02742-03
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Power train, Part 1
Disassembly and assembly of transfer assembly ........................................................................................... 2
Disassembly and assembly of PTO assembly .............................................................................................. 16
Removal and installation of parking brake calipers assembly....................................................................... 20
Disassembly and assembly of parking brake calipers assembly .................................................................. 21
Removal and installation of parking brake pad ............................................................................................. 23
Removal and installation of parking brake spring cylinder ............................................................................ 24
Removal and installation of torque converter and transmission assembly ................................................... 25
WA800-3E0, WA900-3E0 1
Disassembly and assembly of 3. Transfer input gear and related parts

transfer assembly 1 1) Cage
1] Remove mounting bolts (1).
Special tools 2] Using forcing screws [1] (Dia. = 12
mm, Pitch = 1.75 mm), remove cage
New/Remodel
assembly (2).
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-101-5401 Push tool KIT (C) t 1
790-101-5521 • Plate 1
6
790-101-5421 • Grip 1
01010-51240 • Bolt 1
793T-815-1120 Plate t 1 N Q
7 790-101-5421 Grip t 1
01010-51240 Bolt t 1
D 790-101-5401 Push tool KIT (C) t 1
790-101-5491 • Plate 1
8 3] Remove snap ring (3), then remove
790-101-5421 • Grip 1 outer race (5) from cage (4).
01010-51240 • Bolt 1
790-101-5401 Push tool KIT (C) t 1
790-101-5561 • Plate 1
9
790-101-5421 • Grip 1
01010-51240 • Bolt 1
Disassembly
a Clean all parts and repair any burrs.
1. Transmission assembly
Disassemble transmission assembly.
For details, see "Disassembly and assembly of
transmission assembly."
2) Transfer input gear
2. Invert and set the transfer assembly horizon- Using eyebolts [2] (Dia. = 12 mm, Pitch =
tally, after separating the rotating clutch. 1.75 mm), lift off gear (6).
4 Gear: 40 kg
2 WA800-3E0, WA900-3E0
3) Cage, bearing 2] Using eyebolt [2] (Dia. = 12 mm, Pitch

1] Using push tool [3] (outside diameter: = 1.75 mm), lift off cage assembly
162 mm), remove bearing (8) from (11).
cage. a The cage is thick, so raise it verti-
2] Remove the bolts (11 pieces). Then, cally.
4
using eyebolts (2 pieces) (Dia. = 12
Cage assembly: 40 kg
mm, Pitch = 1.75 mm), remove the
cage assembly (9). 3] Remove bearing (13) from cage (12).
4. Transfer idle gear B and related parts 2) Transfer gear B

1) Cage assembly 1] Using eyebolts [2] (Dia. = 12 mm,
1] Remove mounting bolts (10), then Pitch = 1.75 mm), lift off gear assem-
screw in forcing screws [1] (Dia. = 12 bly (14).
4
mm, Pitch = 1.75 mm) and remove fit-
Gear assembly: 50 kg
ting portion of cage.
WA800-3E0, WA900-3E0 3
2] Remove bearing inner race (16) from 3) Screw in forcing screws [1] (Dia. = 12 mm,
gear (15). Pitch = 1.75 mm) and remove fitting por-
3] Remove bearing inner race (17) from tion of cage.
gear (15). a Check the number and thickness of
shims (20), and keep in a safe place.
4) Using eyebolts [2] (Dia. = 12 mm, Pitch =
1.75 mm), lift off coupling and cage
assembly (21).
4 Coupling, cage assembly: 55 kg
5) Disassemble coupling and cage assembly

as follows.
1] Set in press, then using push tool D8
(outside diameter: 135 mm), remove
coupling (23) from cage (22).
5. Rear coupling, cage assembly

1) Remove mounting bolt (18), then remove
holder (19).
a Width across flats of mounting bolt:
55 mm
2) Remove coupling cage mounting bolts
(64).
a Make match marks on the spline of
the shaft and the coupling.
4 WA800-3E0, WA900-3E0
2] Remove oil seal (24) from cage (22). 3) Remove strainer assembly (29).
3] Remove bearing (25) from cage (22).
7. Transfer idle gear A and related parts

6) Remove collar (26). 1) Cage assembly
1] Turn over and set transfer holizon-
tally.
4 Transfer: 770 kg
2] Remove mounting bolts (30).
3] Screw in forcing screws [1] (Dia. = 12
6. Strainer assembly
1) Remove cover (27).
2) Remove spring (28).
4] Using eyebolts [2] (Dia. = 12 mm,

Pitch = 1.75 mm), lift off cage assem-
bly (31).
4 Cage assembly: 30 kg
WA800-3E0, WA900-3E0 5
5] Remove bearing (33) from cage (32). 3) Bearing

Remove bearing (38).
2) Transfer idle gear A

1] Using eyebolts (Dia. = 12 mm, Pitch = 8. Cage assembly of the transfer idle gear A
1.75 mm), lift off gear assembly (34). side
4
1) Remove mounting bolts (39).
Gear assembly: 50 kg
2) Using forcing screws [1] (Dia. = 12 mm,
Pitch = 1.75 mm), remove cage assembly
(40).
2] Remove bearing inner races (36) and

(37) from gear (35).
3) Remove bearing (42) from cage (41).
4) Remove cover (43) from cage (41).
6 WA800-3E0, WA900-3E0
9. Transfer output gear and related parts

1) Coupling assembly
1] Remove mounting bolts (44), then
remove holder (45).
a Width across flats of mounting
bolt: 55 mm
2] Lift off coupling assembly (46).
a Support the block under the
shaft.
3] Remove oil seal (52) from cage (51).

4] Remove snap ring (53) from cage
(51), then remove bearing (54).
3] Remove inner race (48) from coupling

(47).
3) Transfer output gear, shaft assembly

1] Using holder (45) and mounting bolts
(44), lift off transfer output gear and
shaft assembly (55).
4 Transfer output gear, shaft
assembly: 90 kg
2) Cage assembly
screw in forcing screws (Dia. = 12
2] Using eyebolts [2] (Dia. = 12 mm,
Pitch = 1.75 mm), lift off cage assem-
bly (50).
4 Cage assembly: 45 kg
WA800-3E0, WA900-3E0 7
2] Lift off gear (57) from shaft (56). Assembly

4 Gear: 60 kg
3] Remove spacer (58) from shaft (56). 1) No. 4 gear, shaft assembly
1] Install spacer (58) to shaft (56).
2] Raise gear (57) and install to shaft
(56).
3] Using holder (45) and mounting bolts

(44), raise No. 4 gear, shaft assembly
(55) and install.
a Support the block under the
shaft.
8 WA800-3E0, WA900-3E0
2) Cage assembly
1] Set the cage (51) and bearing (54) to
press.
2] Using tool D6 (outside diameter: 245
mm), press fit bearing (54) to cage
(51).
3] Install snap ring (53) to cage (51).
3) Coupling assembly
(inside diameter: 135 mm), press fit
inner race (48) in coupling (47).
4] Using push tool (outside diameter:

195 mm), press fit oil seal (52) in
cage (51).
2 Oil seal: Grease (G2-LI)
a Apply gasket sealant to the oil
seal fitting face. Spread it thinly
to the inside of the housing hole
and wipe off the projected part.
2] Raise coupling assembly (46) and

install.
3] Fit O-ring and holder (45), and tighten
with mounting bolts (44).
3 Mounting bolt:
2,059 – 2,354 Nm {210 – 240 kgm}
5] Fit O-ring, then using eyebolts [2]

(Dia. = 12 mm, Pitch = 1.75 mm),
raise cage assembly (50) and install.
6] Tighten with mounting bolts (49).
WA800-3E0, WA900-3E0 9
2. Cage assembly of tansfer idle gear B side 3. Transfer idle gear A and related parts
1) Fit O-ring and install cover (43) to cage 1) Bearing
(41). Using push tool D6 (outside diameter: 165
mm), press fit bearing (38).
2) Using push tool D6 (outside diameter: 165

mm), press fit bearing (42) in cage (41). 2) Transfer idle gear A assembly
inner race (37) in gear (35).
2 Inner race: Adhesive (LT-2)
a After press fitting, wipe off the
projected adhesive.
3) Fit cage assembly (40) and tighten with

mounting bolts (39).
10 WA800-3E0, WA900-3E0
a After press fitting, when the inner 2] Fit O-ring, then using eyebolts [2]
races (36) and (37) are at the (Dia. = 12 mm, Pitch = 1.75 mm),
room temperature, check that the raise cage assembly (31) and install.
clearance between the gear (35)
and inner race is 0.04 mm or less
at 2 places.
a Clearances (c) and (d):
Max. 0.04 mm
3] Tighten with mounting bolts (30).
3] Using eyebolts (Dia. = 12 mm, Pitch =

1.75 mm), raise gear assembly (34)
and install.
4. Strainer assembly
1) Turn over and set transfer horizontally.
4 Transfer: 700 kg
2) Install strainer assembly (29).
3) Cage assembly
(outside diameter: 165 mm), press fit
bearing (33) in cage (32).
WA800-3E0, WA900-3E0 11
3) Install spring (28). ii] Using push tool D8 (outside

a Insert the spring securely in the diameter: 195 mm), install oil
groove at the top of the strainer. seal (24) in cage (22).
4) Fit O-ring and install cover (27). 2 Oil seal: Grease (G2-LI)
a Apply gasket sealant to the
oil seal fitting face.
Spread it thinly to the inside
of the housing and wipe off
the projected part.

1) Coupling, cage assembly
1] Install collar (26).
iii] Set in press, then using push tool

D8 (outside diameter: 160 mm),
press fit coupling (23) in cage
(22).
2] Assemble coupling and cage assem-

bly as follows.
i] Set in press, then using push tool
D8 (outside diameter: 220 mm),
press fit bearing (25) in cage
(22).
12 WA800-3E0, WA900-3E0
2) Adjusting coupling, cage assembly

1] Fit O-ring, then using eyebolts [2]
(Dia. = 12 mm, pitch = 1.75 mm),
raise coupling and cage assembly
(21) and install.
a Install the front and rear cou-
plings of the output shaft to the
splines so that the phase differ-
ence will be 10° or less when the
output shaft is assembled.
6. Transfer idle gear B and related parts

1) No. 3 gear
2] Using forcing screw [1] (Dia. = 12

mm, Pitch = 1.75 mm), insert shim
(20) with thickness of measured
clearance + (0 ± 0.05) mm.

inner race (16) to gear (15).
3] Tighten coupling cage mounting bolt

(64).
4] Fit holder (19) and tighten with
mounting bolt (18).
3 Mounting bolt:
2,059 – 2,354 Nm {210 – 240 kgm}
WA800-3E0, WA900-3E0 13
3] After press fitting, when the inner 2] Fit O-ring, then using eyebolts [2]
races (16) and (17) are at the room (Dia. = 12 mm, Pitch = 1.75 mm),
temperature, check clearances raise cage assembly (11) and install.
between the gear (15) and inner race. 3] Tighten with mounting bolts (10).
a Clearances (a) and (b):
Max. 0.44 mm.
2 Inner race: Adhesive (LT-2)
a After press fitting, wipe off the
projected adhesive.
7. Transfer input gear and related parts

1) Bearing, transfer input gear
1] Turn over the transfer.
4 Transfer: 700 kg
4] Using eyebolts [2] (Dia. = 12 mm, 2] Install bearing (9) to the cage by
Pitch = 1.75 mm), raise gear assem- expansion fit.
bly (14) and install. 3] After installing the bearing, tighten the
bolts (11 pieces).
2) Cage assembly
1] Set in press, then using push tool D6 4] Using eyebolts [2] (Dia. = 12 mm,
(outside diameter: 165 mm), press fit Pitch = 1.75 mm), raise transfer input
bearing (13) in cage (12). gear (6) and install.
14 WA800-3E0, WA900-3E0
2) Cage assembly 9. Adjusting speedometer sensor

1] Set in press, then using push tool D6 1) Screw in sensor (68) until it contacts out-
(outside diameter: 210 mm), press fit side surface of gear (69).
outer race (5) in cage (4). a Before installing the sensor, check
that the gear is at the outside surface
compared with the mounting surface.
2) After sensor (68) contacts gear (69), turn it
back 3/4 – 1 turn and secure with locknut
(70).
a Be careful that the outlet direction of
the sensor harness is not the oppo-
site direction to the sensor connector
clamp.
2 Sensor thread: Adhesive (LT-2)
3 Sensor locknut:
39.2 ± 9.8 Nm {4 ± 1 kgm}
2] Install snap ring (3).

3] Fit cage assembly (2) and tighten with
mounting bolts (1).
8. Transmission assembly
Assemble transmission assembly.
transmission assembly."
WA800-3E0, WA900-3E0 15
Disassembly and assembly of 2. Snap ring

PTO assembly 1 Remove snap ring (3).
Disassembly
Preparatory work
q Remove PTO. For details, see "Disassembly
and assembly of torque converter assembly".
a The procedure for disassembly and assembly

of the gear and shaft assemblies is the same,
but for gear and shaft assemblies I, II, III and
IV, the shaft and bearing are different.
3. Bearing
1) Turn over PTO case assembly (4).
2) Remove outer race (5).
1. Retainer
1) Remove bolts (1a).
2) Using forcing screws [1] (Dia. = 10 mm,
Pitch = 1.25 mm), remove retainer (1).
3) Remove oil seal (2).
4) Remove dust seal (2a).
4. Shaft assembly
1) Remove snap ring (6).
2) Using push tool [2] (outside diameter: 60
mm), tap shaft assembly and remove.
16 WA800-3E0, WA900-3E0
3) Remove snap ring (7). 7. Snap ring, bearing

4) Remove spacer (7a). 1) Turn over case.
5) Set shaft assembly in position, then using 2) Remove snap ring (13).
push tool [3], pull out bearing (8) from 3) Turn over case again, and remove bearing
shaft (9). (14).
a Push tool [3]
Unit: mm
Gear, shaft assembly Push tool outside
No. diameter
I, II, III 70
IV 65
5. Inner race
Remove inner race (10).
6. Spacer, gear
1) Lift up gear (11) and remove.
2) Remove spacer (12).
a Gear (11) must be installed facing in
the correct direction, so remember
the direction.
WA800-3E0, WA900-3E0 17
Assembly 2. Spacer, gear

Preparatory work 1) Install spacer (12).
q Clean all parts, and check for dirt or damage. 2) Set gear (11) in position.
Coat the sliding surfaces of all parts with a Be careful to install gear (11) facing in
engine oil before installing. the correct direction.
a The procedure for disassembly and assembly

of the gear and shaft assemblies is the same,
but for gear and shaft assemblies I, II, III and
IV, the shaft and bearing are different.
3. Shaft assembly
1) Using push tool [5], press fit bearing (8) in
shaft.
a Push tool [5]
Unit: mm
1. Bearing, snap ring
1) Using push tool [4] (outside diameter =
No. diameter
115 mm), press fit bearing (14).
I, II, III 80
IV 75
2) Install spacer (7a).

3) Install snap ring (7).
4) Using push tool [6], press fit shaft assem-

bly (9).
a Push tool [6]
Unit: mm
No. diameter
I, II, III 155
IV 120
18 WA800-3E0, WA900-3E0
4. Snap ring 7. Inner race

Install snap ring (3). 1) Turn over PTO case assembly (4).
2) Set bottom of shaft on stand [7].
a Set the PTO case assembly so that
there is no play.
5. Bearing
Using push tool [9] (outside diameter: 145
mm), press fit bearing (5) in case.
3) Using push tool [8] (inside diameter: 70
mm), press fit inner race (15).
6. Retainer
1) Press fit dust seal (2a) to retainer.
2) Press fit oil seal (2) to retainer. 4) Install snap ring (6).
2 Oil seal press-fitting surface: a Check that the gear rotates smoothly.
Gasket sealant (LG-4)
3) Fit O-ring, then using guide bolts [10] (Dia.
= 10 mm, Pitch = 1.25 mm), install retainer
(1).
2 Lip of oil seal: Grease (G2-LI)
WA800-3E0, WA900-3E0 19
Removal and installation of 6. Remove plate (8). [*1]

parking brake calipers assembly 1 a Remove cover (9). [*2]
a After removing the plate, remove pad (10).
Removal a Sling the calipers so that they will not fall.
lower the work equipment completely to the 7. Remove parking brake calipers (11).
ground, then put blocks under the wheels a The parking brake calipers must be
to prevent the machine from moving. removed by two workers.
k
4
See Testing and adjusting, "Releasing Parking brake caliper assembly: 40 kg
residual pressure in brake accumulator cir-
cuit", and release residual pressure in
1. Release the parking brake and turn adjustment

bolt (1) counterclockwise to set the yoke free.
2. Pull out pin (3), then disconnect the yoke from

adjuster (4).
4. Apply the parking brake, then disconnect hose

(6).
a Before disconnecting the hose, check that
any pressure is not remaining in the brake
cylinder. Installation
5. Remove the mounting bolt, then remove spring q Carry out installation in the reverse order to
cylinder (7). removal.
[*1]
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
820 – 1,030 Nm {84 – 105 kgm}
[*2]
3 Mounting bolt: 490 – 608 Nm {50 – 62 kgm}
20 WA800-3E0, WA900-3E0
Disassembly and assembly of 4. Remove piston shaft (8) and thrust bearing (9)
parking brake calipers assembly 1 from piston.
Disassembly
1. Remove snap ring (1), then pull out adjuster

(2).
5. Remove piston (11) and piston seal (12) from

calipers (10).
2. Remove washers (3) and (4), and seal (5).
3. Remove bolt, then remove cap (6) and gasket

(7).
WA800-3E0, WA900-3E0 21
Assembly 4. Install seal (5) and washers (3) and (4).

a Fit the seal securely in the groove.
1. Assemble piston seal (12) in calipers (10), and 2 Seal: Grease (G2-LI)
insert piston (11).
a Piston, piston seal: Grease (G2-LI)
5. Assemble adjuster (2) and secure with snap

ring (1).
2. Screw piston shaft (8) into piston, and install
thrust bearing (9).
a Be careful to install the thrust bearing fac-
ing in the correct direction.
2 Thrust bearing: Grease (G2-LI)
3. Fit gasket (7) and install cap (6).

3 Mounting bolt:
177 ± 20 Nm {18 ± 2 kgm}
22 WA800-3E0, WA900-3E0

parking brake pad 1
Removal removal.
install the lock bar on the frame. Lower the [*1]
work equipment to the ground and stop the 2 Mounting bolt: Adhesive (LT-2)
engine. Then put blocks under the wheels 3 Mounting bolt:
to prevent the machine from moving. 490 – 608 Nm {50 – 62 kgm}
a Turn the main switch ON, and release the
parking brake. [*2]
1. Turn adjustment bolt (1) in counterclockwise 3 Mounting bolt:
direction to increase clearance between pad 820 – 1,030 Nm {84 – 105 kgm}
and disc.
2. Remove cover (2). [*1]
3. Loosen mounting bolts of plate (3). [*2]

a Sling to prevent calipers (4) from falling.
4. Move plate to side carefully so that pad does

not fall, then remove pad (5).
a When removing the front pad, first remove
the rear pad and move the calipers to the
front, then remove the front pad.
a Remove the pad of the parking brake cali-
pers on the right side in the same way.
WA800-3E0, WA900-3E0 23

parking brake spring cylinder 1
Removal removal.
k See Testing and adjusting, "Releasing
1. Release the parking brake and turn adjustment

bolt (1) counterclockwise to set the yoke (2)
free.
2. Pull out pin (3), then disconnect yoke (2) from

adjuster (4).
3. Apply the parking brake, then disconnect hose

(5).
a Check that no pressure is remaining in the
brake cylinder.
a After removing the hose, cover the hole to
prevent dust from entering.
4. Remove the mounting bolt (6), then remove

parking brake spring cylinder (7).
24 WA800-3E0, WA900-3E0
Removal and installation of

torque converter and
transmission assembly 1
Special tools
New/Remodel
Necessity
Sketch
Q'ty
790-101-7200 Centering tool t 1
1 790-101-7230 • Shaft 1
D 10
2 790-101-7240 • Guide 1
3. Disconnect assembly drain hoses (3) of the
3 01010-51230 • Bolt 1
L.H. and R.H. brake valves.
k Stop the machine on level ground and 4. Disconnect hoses (4) and (5) between the
lower the work equipment completely to the accumulator and right-hand brake valve.
to prevent the machine from moving. 5. Disconnect hose (6) between the accumulator
k Loosen the oil filler cap of the hydraulic and left-hand brake valve.
tank gradually to release the pressure in
the hydraulic tank 6. Disconnect hoses (7) and (8) between the
k Operate the work equipment control lever 2 – right-hand brake valve and slack adjuster, then
3 times to release the pressure in the PPC remove clamp (9).
k Release residual pressure in brake acccu-
mulator circuits. For detail, see Testing and
adjusting "Releasing residual pressure in
brake accumulator circuit".
advance.
atmosphere.
eyes, you may lose your sight. Accord-
ingly, put on protective goggles while you
son.
1. Remove front, rear, right and left side covers

(1) under the cab.
2. Remove cab (2). For details, see "Removal

and installation of cab."
3 Cab assembly: 400 kg
WA800-3E0, WA900-3E0 25
7. Disconnect hose (10) between the accumula- 15. Disconnect ground cable (21).
tor and Orbit-roll.
16. Disconnect the frame side clamp of air condi-
8. Disconnect hose (11) between the Orbit-roll tioner drain hose (22).
and right-hand stopper valve.
9. Disconnect drain hose (12) of the Orbit-roll.
10. Disconnect hose (13) between the Orbit-roll

and left-hand stopper valve.
11. Disconnect hose clamp (14).

a Close the hot water outlet valve on the
engine side.
18. Disconnect air conditioner hose (24). [*1]

a Since the adapter is brittle, apply 2 span-
ners to it to disconnect each hose.
12. Disconnect hoses (15) (Raise lift arm), (16)

(Dump), (17) (Lower lift arm) and (18) (Tilt)
between the PPC valve and control valve.
13. Disconnect hose (19) between the PPC valve

and PPC pump.
14. Disconnect PPC valve drain hose (20).
26 WA800-3E0, WA900-3E0
19. Disconnect connector (25), then remove wire 24. Disconnect the suction tubes of the pumps for
clamps (26), (27) and (28) and move them torque converter, transmission (45), PPC (46)
toward the body. and brake (47).
a Connector: CN-CBLI, LR1, LR2, V20 and FL1.
20. Disconnect washer hose (29) at the joint.
25. Disconnect steering pump suction tube (48).
26. Disconnect steering pump drain hose (49).

21. Remove 4 mounting nuts (40) of the floor frame
mount. [*2]
22. Sling the floor frame (41) and lift off.

a While slinging the floor frame slowly,
check that all the clamps and harnesses
are disconnected.
27. Disconnect outlet tubes of the pumps for brake

(50), PPC (51), torque converter, transmission
(52) and (53).
23. Remove transmission top cover (42), then

remove bracket (43).
WA800-3E0, WA900-3E0 27
28. Disconnect switch pump suction tube (54).
29. Disconnect loader pump suction tube (55).
37. Disconnect emergency steering pump drain

hose (64).
30. Disconnect switch pump outlet hose (56). 38. Disconnect emergency steering pump outlet
hose (65) and suction hose (66).
31. Disconnect loader pump outlet hose (57).
40. Remove the mounting bolts, then remove
33. Disconnect control pump suction tubes (59) emergency steering pump (68).
4
and (60).
Emergency steering pump: 50 kg
34. Disconnect steering pump outlet tube (61).
35. Disconnect switch pump drain hose (62) and

loader pump drain hose (63).
41. Remove hoses (69) and (70) of the sight

gauge.
a Remove the drain hose of the engine con-
trol servo cylinder from the oil feed tube.
36. Sling upper drive shaft (63) temporarily and
remove the mounting bolts, then lift off the
shaft. [*3]
a Make match marks on the couplings.
4 Upper drive shaft: 60 kg
28 WA800-3E0, WA900-3E0
42. Remove hose (71) of the torque converter 46. Remove transmission solenoid valve wiring
cooler. (77) from the connectors.
a Disconnect speedometer sensor connec- a When removing the connector, be careful
tor (72) (CM-BC01). not to damage the case of the threaded
parts.
43. Remove hose (73) between the transmission

and torque converter cooler. 47. Sling rear drive shaft (78) temporarily and
remove the mounting bolts, then lift off the
44. Remove hose (74) between the torque con- shaft. [*4]
verter filter and transmission. a When slinging the drive shaft, install suffi-
ciently long slings on left and right sides of
the transmission.
4 Rear drive shaft: 190 kg
45. Remove tube (75) between the torque con-

verter and torque converter cooler.
a Disconnect torque converter oil tempera-
ture sensor wiring (76) from the connector.
WA800-3E0, WA900-3E0 29
48. Sling center drive shaft (79) temporarily and 50. Remove the mounting bolts of the trunnion
remove the mounting bolts, then lift off the (81). [*6]
shaft. [*5] a Secure the trunnion to the torque con-
4
verter with wires.
Center drive shaft: 186 kg
a If shims are installed between the frame
and trunnion, check its quantity and thick-
ness.
a Disconnect trunnion greasing hose (82)
from the trunnion.
49. Sling transmission and torque converter

assembly (80) temporarily.
a Set the slings as short as possible.
51. Remove mount bracket (83) and mounting bolt

(84) on the front side. [*8]
a Keep mount bracket (83) on the front side
removed.
a Be careful not to lose the pin between the
transmission and bracket.
52. Moving the transmission and torque converter

(80) toward the engine, sling and lift it off
slowly.
4 Transmission and torque converter
assembly: 2,900 kg
30 WA800-3E0, WA900-3E0
Installation 3) Insert the shim in the mount.

4) Position the transmission and tighten the
q Carry out installation in the reverse order to mounting bolts.
removal.
[*1]
a When connecting each hose, do not twist it.
a Be careful not to let dirt, dust, water, etc. in
each hose.
a Fill the air conditioner circuit with the refriger-
ant (R134a).
[*2]
3 Mounting nut:
245 – 309 Nm {25.0 – 31.5 kgm}
[*3]
3 Upper drive shaft:
157 – 196 Nm {16.0 – 20.0 kgm}
[*4]
3 Rear drive shaft:
342 – 427 Nm {35.0 – 43.5 kgm}
[*5]
3 Center drive shaft:
342 – 427 Nm {35.0 – 43.5 kgm}
[*6]
3 Trunnion mounting bolt:
490 – 608 Nm {50.0 – 62.0 kgm}
a Check the parallelism and adjust the shims. [*7]
3
Parallelism: 0.15 mm max. Bracket mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
1) Set the transmission to the frame, then

tighten the front and rear mounting bolts
temporarily.
2) Install tools D10-1, D10-2 and D10-3 to
the upper and lower center hinge pins,
then install dial gauge [1] to the coupling
on the transmission side to measure the
parallelism of the coupling and shaft D10-
1.
WA800-3E0, WA900-3E0 31
SEN02742-03

© 2017 KOMATSU
All Rights Reserved
32
SEN02743-01
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Power train, Part 2
Disassembly and assembly of torque converter assembly ............................................................................. 2
Disassembly and assembly of transmission assembly ................................................................................. 10
WA800-3E0, WA900-3E0 1
Disassembly and assembly of

torque converter assembly 1
Special tools
New/Remodel
Necessity
Sym
Part No. Part name
Sketch
bol
Q'ty
790-501-5200 Unit repair stand t 1
1 790-901-5110 Bracket t 1
790-901-5120 Plate t 1
2 791-381-1011 Wrench t 1
1. Valve
3 790-201-2870 Spacer t 1
1) Remove tubes (2) and (3), and block (4).
4 790-201-2760 Spacer t 1 2) Remove valve assembly (5).
790-201-2250 Plate t 1 3) Remove tube (6) and block (7).
5
790-201-2760 Spacer t 1
790-101-5401 Push tool KIT (C) t 1
790-101-5481 • Plate 1
6
C 790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-101-5401 Push tool KIT (C) t 1
790-101-5461 • Plate 1
7
790-101-5421 • Grip 1
01010-51240 • Bolt 1
8 790-201-2740 Spacer t 1
790-101-5401 Push tool KIT (C) t 1
790-101-5431 • Plate 1 2. PTO assembly
9
790-101-5421 • Grip 1 1) Remove holder (8) and coupling (9).
01010-51240 • Bolt 1
Disassembly
Preparatory work
q Remove torque converter and PTO assembly.
transmission assembly".
q Set torque converter and PTO assembly (1) on
tool C1.
4 Torque converter, PTO assembly:
650 kg
2 WA800-3E0, WA900-3E0

2.0 mm), sling PTO assembly temporarily.
3) Screw in forcing screws [2], and lift off
PTO assembly (10).
3] Using 2 forcing screws [4] (Dia. = 10

mm, Pitch = 1.25 mm) remove turbine
(18).
a Use the forcing screws to push
3. Turbine and case assembly the inner race of the bearing.
1) Remove plug (11), and drain oil inside
drive case.
2) Leave 2 bolts on opposite sides, and
remove all remaining pump mounting bolts
(12).
3) Set case side at top, and remove 2
remaining mounting bolts.
2.0 mm), lift off turbine and case assembly
(13).
4] Remove bearing (20) from case (19).

5] Remove bearing (21) from input
shaft.
5) Disassemble turbine and case assembly

as follows.
1] Remove mounting bolts, then remove
input shaft (14) and gear (15).
2] Remove snap ring (16) and plate
(17).
WA800-3E0, WA900-3E0 3
4. Stator 4) Remove bolts, then remove collar (27),

1) Remove snap ring (22). pump (28) and guide (30).
2) Remove stator (23). 5) Remove bearing (29) from guide (30).
5. Pump assembly 6. Stator shaft

1) Using tool C2, loosen nut (24). 1) Remove 8 mounting bolts (31).
a Leave the nut in position to prevent
the bearing and pump from flying off.
2) Remove stator shaft (32) from rear hous-

ing (33).
2) Remove 2 plugs (25) at stator shaft end.
3) Remove inner race of bearing from hole
where plug was removed, then remove
pump assembly (26).
4 WA800-3E0, WA900-3E0
3) Remove seal ring (34). Assembly

4) Remove sleeve (35). Preparatory work
q Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with
engine oil before installing.
q Set torque converter rear housing (33) on tool
C1.
1. Stator shaft
1) Expand fit sleeve (35) to stator shaft.
2) Install seal ring (34) to stator shaft.
a Make the protrusion of the seal ring
from the shaft uniform.
3) Operate repair stand, rotate torque con-

verter case 90°, install stator shaft (32),
then tighten 8 mounting bolts (31) from
opposite side.
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
WA800-3E0, WA900-3E0 5
2. Pump assembly 4) Set pump assembly (26) in position, be

1) Using push tool C8 (outside diameter: 195 careful not to damage the seal ring.
mm), press fit bearing (29) in guide. a Coat the seal ring with grease (G2-
LI), make the amount of protrusion
from the shaft uniform, and fix in posi-
tion.
5) Using push tool C5, press fit inner race
(36) to stator shaft.
a Be careful to install the inner race fac-
ing in the correct direction.
6) Set pump. Be careful not to damage the
seal ring while setting pump.
a Coat the seal ring with grease (G2-
LI), make the amount of protrusion
from the shaft uniform, and fix in posi-
tion.
2) Install guide (30) and retainer (27) to (36) to stator shaft.
pump (28). a Be careful to install inner race facing
2 Mounting bolt: Adhesive (LT-2) in the correct direction.
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}

(36) to stator shaft.
6 WA800-3E0, WA900-3E0
8) Using tool C2, install nut (24) to stator 2) Set turbine (18) in push tool C3 (outside
shaft. diameter: 105 mm, height: 165 mm).
2 Nut: Adhesive (LT-2) 3) Using push tool C4 (inside diameter: 110
3 Nut: 588 – 637 Nm {60 – 65 kgm} mm), press fit case (19) to turbine (18).
3. Stator 4) Fit plate (17) and install snap ring (16).

1) Align spline, and install stator (23). 5) Using push tool C9 (inside diameter: 90
2) Install snap ring (22). mm), press fit bearing (21) in pilot.
4. Turbine case assembly 6) Install gear (15).

1) Using push tool C5, press fit bearing (20) 7) Install pilot (14).
in case (19). 2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
WA800-3E0, WA900-3E0 7
8) Using eyebolts [3] (Dia. = 16 mm, Pitch = 5. PTO assembly

2.0 mm), raise turbine case assembly 1) Fit O-ring, then using eyebolts [1] (Dia. =
(13), align oil groove of case with drain 16 mm, Pitch = 2.0 mm), install PTO
hole of pump (2 places), then install. assembly (10).
9) Tighten pump mounting bolts temporarily. a Be careful not to damage the oil seal
2 Mounting bolt: Adhesive (LT-2) when installing.
a Mount PTO assembly after adjusting
mounting position. If move PTO
assembly after mounting, O-ring will
be twisted and gone out of groove.
10) Rotate repair stand 90° and tighten

3 Mounting bolt:
49 – 58.8 Nm {5 – 6 kgm}
11) Tighten drain plug (11). 2) Install coupling (9).
12) Tighten 2 plugs (25). 3) Fit O-ring and install holder (8).
3 Plug: 2 Mounting bolt: Adhesive (LT-2)
9.8 – 12.7 Nm {1 – 1.3 kgm} 3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
8 WA800-3E0, WA900-3E0
6. Valve assembly
1) Fit O-ring and install block (7) and tube
(6).
2) Fit O-ring and install valve assembly (5).
3) Fit block (4) and install tubes (3) and (2).
3 Valve assembly mounting bolt:
44 – 54 Nm {4.5 – 5.5 kgm}
WA800-3E0, WA900-3E0 9
Disassembly and assembly of 2. Control valve assembly

transmission assembly 1 1) Remove 11 mounting bolts.
a The length of the bolts is different, so
Special tools check before removing.
a Remove only 10 bolts marked q in
New/Remodel
the diagram.
Necessity
Sym
Part No. Part name
Sketch
bol
Q'ty
1 790-301-1600 Oil leak tester KIT t 1
793T-815-1110 Push tool t 1 N Q
2
790-201-2760 Spacer t 1
790-101-5401 Push tool KIT (C) t 1
790-101-5461 • Plate 1
3
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-101-5621 Plate t
4 790-101-5421 • Grip t
D 2) Using eyebolts [1] (Dia. = 10 mm, Pitch =
01010-51240 • Bolt t 1.5 mm), lift off control valve assembly (3).
4
790-101-5201 Push tool KIT (C) t 1
Control valve assembly: 110 kg
790-101-5321 • Plate 1
5
790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5401 Push tool KIT (C) t 1
790-101-5521 • Plate 1
6
790-101-5421 • Grip 1
01010-51240 • Bolt 1
Disassembly
1. Torque converter assembly

Using eyebolts, remove torque converter
assembly (1) from transmission assembly (2).
4 Torque converter assembly: 650 kg 3. Sleeve
Remove sleeve (4).
10 WA800-3E0, WA900-3E0
4. Transmission case 2) Remove tie bolts (16).

1) Raise transfer and transmission assembly,
and put transfer (14) at bottom.
4 Transfer, transmission assembly:
2,200 kg
6. Plate
Using eyebolts [3] (Dia. = 12 mm, Pitch = 1.75
mm), lift off plate (17).
4 Plate: 30 kg
2.0 mm), lift off transmission case (15).
4 Transmission case: 130 kg
7. Spring
Remove spring (18).
a This spring is different from the other
springs, so keep it separately in a safe
5. Tie bolts
place.
1) Using tool D1, check the operation of the
piston before disassembling.
WA800-3E0, WA900-3E0 11
8. Spring, disc, plate 2) Disassemble shaft and No. 1 carrier

Remove spring (19), disc (20), and plate (21). assembly as follows.
a There are springs between each plate. 1] Remove snap ring (24).
2] Remove gear (25).
9. No. 1 ring gear

Remove ring gear (22). 3] Remove collar (27) from shaft and
carrier assembly (26).
10. Shaft, No. 1 carrier assembly

1) Using eyebolts [4] (Dia. = 12 mm, Pitch = 4] Remove snap ring (28), then remove
1.75 mm), lift off shaft and No. 1 carrier shaft assembly (29) from carrier
assembly (23). assembly (30).
12 WA800-3E0, WA900-3E0
5] Remove bearing (31). 10] Remove pin, then remove thrust

washer (36), planetary gear (37),
needle bearing (38), and spacer (39).
a When removing the pin, be care-
ful not to lose the ball.
6] Remove sun gear (32).

7] Remove bearing (33).
11. No. 2 ring gear

1) Remove mounting bolts (40), then remove
plate (41).
2) Remove ring gear (42).

9] Remove snap ring (35).
12. No. 1 piston, housing

1.75 mm), lift off piston and housing (43).
4 Piston, housing: 65 kg
2) Remove piston (45) from housing (44).
WA800-3E0, WA900-3E0 13
13. Spring 17. No. 2 piston, housing

Remove spring (46). 1) Using eyebolts [6] (Dia. = 12 mm, Pitch =
a This spring is different from the other 1.75 mm), lift off piston and housing (52).
4
Piston, housing: 65 kg
place.
14. Spring, disc, plate

Remove spring (47), disc (48), and plate (49). 18. No. 2, 3 carrier assembly
a There are springs between each plate. 1) Remove snap ring (55).
2) Using puller, pull out bearing press-fit por-
tion of No. 2 and 3 carrier assembly (56).
1.75 mm), lift off carrier assembly (56).
4 Carrier assembly: 90 kg
15. Guide pin

Remove guide pin (50).
16. Ring gear

Remove ring gear (51).
14 WA800-3E0, WA900-3E0
4) Disassemble No. 2 and 3 carrier assembly 19. Ring gear, plate

as follows. 1) Remove ring gear (64).
1] Remove sun gear (57). 2) Using eyebolts (Dia. = 12 mm, Pitch =
2] Remove mounting bolts (58), then 1.75 mm), lift off plate (65).
remove retainer (59).

3] Remove pin, then remove thrust 1) Remove collar (66).
washer (60), planetary gear (61), and
needle bearing (62).
ful not to lose the ball.

1.75 mm), lift off piston and housing (67).
4 Piston, housing: 65 kg
4] Remove bearing (63). 3) Remove piston (69) from housing (68).
WA800-3E0, WA900-3E0 15
21. Spring 24. No. 4 piston, housing

Remove spring (70). 1) Using eyebolts [9] (Dia. = 12 mm, Pitch =
a This spring is different from the other 1.75 mm), lift off piston and housing (75).
4
Piston, housing: 65 kg
place.

Remove spring (71), disc (72), and plate (73). 25. Spring
a There are springs between each plate. Remove spring (78).
place.
23. No. 3 ring gear

Remove ring gear (74).
16 WA800-3E0, WA900-3E0
26. Spring, disc, plate 2) Remove snap ring (85).

Remove spring (79), disc (80), and plate (81). 3) Set in press, then using push tool D4
a There are springs between each plate. (Inside diameter: 80 mm, Length: 400
mm), remove bearing (86).
27. Guide pin
Remove guide pin (82).
30. No. 4 ring gear, carrier assembly

28. Plate 1.75 mm), lift off ring gear and carrier
Remove plate (83). assembly (87).
4 Ring gear, carrier assembly: 80 kg
29. Shaft assembly

1) Remove shaft assembly (84).
2) Disassemble No. 4 ring gear and carrier
assembly as follows.
1] Remove bearing assembly (88) from
ring gear and carrier assembly (87).
WA800-3E0, WA900-3E0 17
2] Remove collar (91) from bearing (90). 31. Sun gear

Remove sun gear (99).

remove retainer (93). 32. Cover assembly
4] Remove snap ring (94), then remove 1) Turn over transfer assembly.
4
ring gear (95).
Transfer assembly: 1,100 kg
2) Remove mounting bolts (5), then using
forcing screws [11] (Dia. = 12 mm, Pitch =
1.75 mm), remove cover assembly (6).
5] Remove pin, then remove thrust

washer (96), planetary gear (97), and
needle bearing (98).
ful not to lose the ball. 3) Remove snap ring (8) from cover (7), then
remove bushing (9).
18 WA800-3E0, WA900-3E0
33. Collar assembly 35. Rotating clutch assembly

1) Remove snap ring (10). 1) Raise transfer assembly (122), and disas-
2) Using puller [12], remove collar assembly semble rotating clutch assembly.
4
(11).
a When using the puller, remove the
outside seal ring (1 piece). 2) Remove flange (100) of bearing.
34. Inner race

Using puller [13], pull out rotating clutch
assembly (120), then remove inner race (121).
a When pulling out the rotating clutch
assembly, fit a block under the rotating
clutch to prevent it from falling.
WA800-3E0, WA900-3E0 19
q Fine disassembly of rotating clutch assem- 4] Remove pin (106), then remove
bly thrust washer (107), planetary gear
(108), and needle bearing (109).
36. No. 5 carrier assembly a When removing the pin, be care-
1) Remove mounting bolts (101). ful not to lose the ball.
1.75 mm), sling carrier assembly (102),
then using forcing screws (Dia. = 12 mm,
Pitch = 1.75 mm), lift off carrier assembly.
4 Carrier assembly: 65 kg
37. Sun gear, No. 5 ring gear

1) Remove sun gear (110).
2) Remove ring gear (111).
3) Disassemble carrier assembly as follows.

1] Remove snap ring (103).
2] Remove collar (104).

Remove spring (112), disc (113), and plate
(114).
a There are springs between each plate.
20 WA800-3E0, WA900-3E0
39. Retainer, pressure plate Assembly

1) Remove mounting bolts (115), then
remove retainer (116). a Precautions when assembling
2) Remove pressure plate (117). q Coat the rotating and sliding surfaces of
all parts with engine oil (SAE10W) before
installing.
q Coat the seal rings and roller bearings
with grease (G2-LI), then install them,
making sure that they are not off center.
q Align the notches on the discs when
installing.
q Check that the snap rings are fitted
securely.
a Clean all parts, and repair any damage.
q Fine assembly of rotating clutch assembly

a Before assembling, coat plug (121) with
adhensive (LT-2) and tighten it into shaft
40. Bearing (120) until its head is flush with the end of
Using puller [15], remove bearing (118). shaft (120) and then bend 2 parts (parts
(a)) and install pin (122).
41. Bearing
Remove bearing (119).
1. Bearing
Heat bearing (119) and install it by shrink fit.
a Do not heat bearing (119) higher than
120°C.
2. Bearing
1) Install 2 seal rings to drum (123).
a Install the seal rings so that the
grooves face the direction of the fig-
urfe.
2) Press fit bearing (118).
WA800-3E0, WA900-3E0 21

Install spring (112), disc (113), and plate (114).
a Number of discs: 6
Number of plates: 5
3. Pressure plate, retainer

1) Fit seal ring to pressure plate (117), then
install to drum.
a Install the seal rings so that the
grooves face the direction of the fig-
urfe. 5. No. 5 ring gear, sun gear
2) Fit retainer (116) and tighten mounting 1) Install ring gear (111).
bolts (115). 2) Install sun gear (110).
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
22 WA800-3E0, WA900-3E0
6. No. 5 carrier assembly

1) Assemble carrier assembly as follows.
1] Install needle bearing (109), planetary
gear (108), and thrust washer (107),
then knock in pin (106).
a Be careful not to forget the ball
when installing.
7. Rotating clutch assembly

1) Install flange (100) of bearing.
2) Raise transfer assembly (122), and con-
nect rotating clutch assembly.
2] Heat bearing (105) and install it by

shrink fit.
a Do not heat bearing (105) higher
than 120°C.
3] Fit 2 seal rings to collar (104) and
install.
8. Inner race
Using push tool D5 (inside diameter: 103 mm,
length: 70 mm), press fit inner race (121) to
rotating clutch (120).

1.75 mm), raise carrier assembly (102)
and install.
3) Tighten mounting bolts (101).
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
WA800-3E0, WA900-3E0 23
8A. Collar assembly 10. Sun gear

1) Install 2 seal rings to collar. 1) Turn over transfer assembly.
4
2) Using push tool D6 (inside diameter: 83
mm), press fit collar assembly (11).
a Align the collar assembly exactly with 2) Install sun gear (99).
the position of the dowel pin and
press fit gradually.
11. No. 4 ring gear, carrier assembly

1) Assemble No. 4 ring gear and carrier
assembly as follows.
9. Cover assembly 1] Assemble needle bearing (98) in
1) Set in press, then using push tool D3 (out- planetary gear (97), fit thrust washers
side diameter: 135 mm), press fit bushing (96) to both ends and set to carrier.
(9) in cover (7).
2] Fit ball (120) and push in pin (121).

3) Fit O-ring and install cover assembly (6), when installing to the shaft.
then tighten mounting bolts (5).
24 WA800-3E0, WA900-3E0
3] Fit snap ring (94) to ring gear (95), 6] Cool the outer race of bearing (88)
and install ring gear. and fit bearing (88) to ring gear and
4] Fit retainer (93) and tighten with carrier assembly (87) by expansion
mounting bolts (92). fit.
a Check that the snap ring installed a Install seal rings to the ring gear
to the ring gear is set securely and carrier assembly.
between the retainer and the car-
rier.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
2) Cool only the outer race of bearing (105).

Then, using eyebolts [10] (Dia. = 12 mm,
Pitch = 1.75 mm), sling and install ring
gear and carrier assembly (87) to bearing
(105) by expansion fit.
5] Heat bearing (90) and install it to col-

lar (91) by shrink fit.
a Do not heat the bearing higher
than 120°C.
a Install a seal ring on the collar.
12. Plate
Align with dowel pin, and install plate (83).
WA800-3E0, WA900-3E0 25
13. Shaft assembly 16. Spring

1) Install snap ring (85). Install spring (78).
2) Heat bearing (86) and install it to the shaft a This spring is different from the other
by shrink fit. springs, so be careful to distinguish it
a Do not heat bearing (86) higher than when installing.
120°C. a Free height of spring: 91 mm
3) Tap shaft assembly (84), and press fit 17. No. 4 piston, housing
bearing. 1) Fit seal ring, then install piston (77) in
housing (76).
a Install the seal ring with the groove
(a) facing the housing as shown in the
diagram.
1.75 mm), align with dowel pin, raise pis-
ton and housing (75), and install.
a When installing, check through the
clearance between the piston and the
transfer that spring (78) has not fallen
over.
14. Guide pin

Install guide pin (82).
15. Disc, spring, plate

Install disc (80), spring (79), and plate (81).
Number of plates: 4
26 WA800-3E0, WA900-3E0
18. No. 3 sun gear 21. No. 3 piston, housing

Install ring gear (74). 1) Fit seal ring, then install piston (69) in
housing (68).
facing the housing as shown in the
diagram.

Number of plates: 3 2) Using eyebolts (Dia. = 12 mm, Pitch =
clearance between the piston and the
housing that spring (70) has not fallen
over.
3) Install collar (66).
20. Spring
Install spring (70).
springs, so be careful to distinguish it
when installing.
a Free height of spring: 91 mm
22. Plate, ring gear

1) Using eyebolts (Dia. = 12 mm, Pitch =
1.75 mm), align with dowel pin, then raise
plate (65) and install.
2) Install ring gear (64).
WA800-3E0, WA900-3E0 27
4] Fit retainer (59) and tighten with

2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
5] Cool only the outer race of bearing
(63). Then, using eyebolts [7] (Dia. =
12 mm, Pitch = 1.75 mm), sling and
install carrier assembly (56) to bear-
ing (63).
23. No. 2, 3 carrier assembly

1) Assemble No. 2 and 3 carrier assembly as
follows.
shrink fit.
than 120°C.
6] Insert seal ring in collar, then assem-

ble to shaft.
a When the seal ring (c) is assem-
bled to the collar, install so that
the narrow width (d) of the seal
ring and collar is at the bottom.
2] Assemble needle bearing (62) in

planetary gear (61), and fit thrust
washers (60) to both ends, then set in
carrier.
when installing the shaft.
7] Install sun gear (57).

28 WA800-3E0, WA900-3E0

Number of plates: 5

1) Fit seal ring, then install piston (54) in
housing (53).
(d) facing the housing as shown in the
diagram. 28. Spring
2) Using eyebolts [6] (Dia. = 12 mm, Pitch = Install spring (46).
1.75 mm), align with dowel pin, raise pis- a This spring is different from the other
ton and housing (52), and install. springs, so be careful to distinguish it
when installing.
a Free height of spring: 108.5 mm
25. Ring gear

Install ring gear (51).
26. Guide pin 1) Fit seal ring, then install piston (45) in
Install guide pin (50). housing (44).
(e) facing the housing as shown in the
diagram.
clearance between the housing and
the piston that spring (46) has not
fallen over.
WA800-3E0, WA900-3E0 29
31. Shaft, No. 1 carrier assembly

1) Assemble shaft and No. 1 carrier assem-
bly as follows.
1] Assemble needle bearing (38) and
spacer (39) in planetary gear (37), fit
thrust washers (36) to both ends and
set to carrier.
when installing to the shaft.
30. No. 2 ring gear

1) Fit snap ring (42A) to ring gear (42), and
install ring gear.

shrink fit.
than 120°C.
2) Fit plate (41), and tighten with mounting

bolts (40).
a Check that the snap ring installed to
the ring gear is set securely between
the plate and the carrier.
3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
30 WA800-3E0, WA900-3E0
5] Heat bearing (33) and install it by 9] Fit seal ring and install collar (27) to
shrink fit. shaft and carrier assembly (26).
than 120°C.
6] Install sun gear (32).
10] Install gear (25).

7] Heat bearing (31) and install it to the

shaft by shrink fit.
than 120°C.
2) Cool only the outer race of bearing (33).

Then, using eyebolts [4] (Dia. = 12 mm,
Pitch = 1.75 mm), sling and install shaft
and No. 1 carrier assembly (23).
8] Cool only the outer race of bearing

(31). Then, press fit shaft assembly
(29) to the carrier assembly (30) and
install snap ring (28).
WA800-3E0, WA900-3E0 31
32. No. 1 ring gear 35. Plate

Install ring gear (22). Using eyebolts [3] (Dia. = 12 mm, Pitch = 1.75
mm), raise plate (17) and install.
a When installing, check through the clear-
ance between the plate and the piston that
spring (18) has not fallen over.

Number of plates: 5 36. Tie bolts
Install 17 tie bolts (16).
3 Tie bolt: 353 – 392 Nm {36 – 40 kgm}
34. Spring
Install spring (18).
a This spring is different from the other 37. Piston operation check
springs, so be careful to distinguish it Using tool D1, check stroke of each piston.
when installing. a Air pressure:
a Free height of spring: 108.5 mm 0.3 – 0.5 MPa {3 – 5 kg/cm2}
Unit: mm
Piston Standard stroke
No. 1 7.6
No. 2 8.6
No. 3 7.0
No. 4 7.8
32 WA800-3E0, WA900-3E0
40. Control valve assembly

1) Fit gasket, then using eyebolts [1] (Dia. =
10 mm, Pitch = 1.5 mm), install control
valve assembly (3).
a Align the hole position of the gasket
at the mating surface.
38. Transmission case

1) Fit O-ring, then using eyebolts [2] (Dia. =
12 mm, Pitch = 1.75 mm), raise transmis-
sion case (15) and install.
2) Tighten 10 mounting bolts.

a Tighten the mounting bolts uniformly
in turn so that there is no deformation
of the valve.
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
39. Sleeve
1) Raise transfer and transmission assem-
bly and set in upright position.
4 Transfer, transmission assembly:
2,200 kg
2) Fit O-ring and install sleeve (4).
41. Torque converter assembly

Using eyebolts, install torque converter assem-
bly (1) to transmission assembly (2).
WA800-3E0, WA900-3E0 33
SEN02743-01

© 2009 KOMATSU
All Rights Reserved
34
SEN02744-02
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Power train, Part 3
Removal and installation of front axle assembly ............................................................................................. 2
Removal and installation of rear axle assembly.............................................................................................. 4
Removal and installation of center support assembly................................................................................... 10
Disassembly and assembly of center support assembly .............................................................................. 12
Removal and installation of differential assembly ......................................................................................... 16
Disassembly and assembly of differential assembly..................................................................................... 18
Disassembly and assembly of final drive assembly...................................................................................... 27
WA800-3E0, WA900-3E0 1
Removal and installation of front 1. Tires, wheels

axle assembly 1 Sling left and right tires and wheels (3) tempo-
rarily, remove mounting nuts, then lift off.
4
Removal Tire, wheel: 3,600 kg
install the lock bar on the frame. Lower the
work equipment to the ground and stop the
engine. Then apply the parking brake and
q Block the rear tires and apply the parking

brake securely.
q Insert blocks [1] between the top face (1) of the
rear axle housing and frame (2). (both left and
right)
2. Drive shaft
Lift off front drive shaft (4). [*1]
a Make match marks on the drive shaft cou-
pling to act as a guide when assembling.
a Move the drive shaft towards the front dif-
ferential, then move the center support
end to the side and remove the pilot por-
tion at the differential end.
4 Front drive shaft: 180 kg
q Jack up the machine and set blocks [2] under

the front frame on the left and right.
2 WA800-3E0, WA900-3E0
3. Brake hoses 5. Front axle

Disconnect brake hoses (5) and (6) from con- 1) Sling axle (8) temporarily, remove mount-
nection of tube. ing bolts, then use hoist and jack to main-
a Fit covers after disconnecting the piping. tain balance, and lower on top of roller.[*3]
4 Front axle: 8,200 kg
a Fix chains around the axle as shown
in the figure.
4. Parking brake hose

Disconnect hose (7) from parking brake cylin-
der. [*2]
a Check that the parking brake is actuated.
a Disconnect the air hoses from the left and 2) Pull out front axle (8) from chassis.
right parking brake cylinder. a Reference diagram of roller
Installation

removal.
[*1]
3 Front drive shaft:
343 – 427 Nm {35.0 – 43.5 kgm}
[*2]
q Bleeding air
Bleed air from the front brake circuits. For
details, see Testing and adjusting, "Bleeding
air from wheel brake circuit".
[*3]
3 Front axle mounting bolt:
3,170 – 3,870 Nm {323 – 395 kgm}
WA800-3E0, WA900-3E0 3
Removal and installation of rear 3. Fuel tank

axle assembly 1 1) Loosen drain valve and drain fuel.
6 Fuel : 1,555 l (Full)
Removal
k Stop the machine on level ground and 2) Remove engine oil drain valve (14), cool-
install the lock bar on the frame. Lower the ing water drain valve (15) of torque con-
work equipment to the ground and stop the verter cooler, and cooling water drain
engine. Then apply the parking brake and valve (16) from fuel tank.
q Put blocks under the front wheels to prevent

the machine from moving, and apply the park-
ing brake securely.
1. Remove left and right steps (1), and covers (2)

and handrail (3).
3) Disconnect fuel hose (17) left and right

blowby hoses (18), left and right fuel
return hoses (18a).
a Remove the clamps of the fuel hoses,
left and right engine blowby hoses,
fuel return hoses and engine blowby
water drain hoses.
2. Remove under cover (4). [*1]
4 WA800-3E0, WA900-3E0
4) Disconnect wiring harness connector CN- 4. Frame support

R08 (19) for fuel unit. Jack up rear frame and set stand under frame.
a Insert blocks [1] between the top face of
the rear axle housing and frame (both left
and right).
a For safety, put bracket [3] and steel sheet
[4] under support [2].
5) Sling fuel tank (20) temporarily, remove

mounting bolts, then lift off. [*2]
a Fix the lifting tool to the lifting hooks,
be careful to maintain the balance,
and lift off slowly.
a Check that all the fuel has been 5. Tire, wheel
drained. Sling left and right rear tire and wheel (21) tem-
a Lay a pallet under the tank, set blocks porarily, remove mounting nuts, then lift off. [*3]
4
in position in line with the fuel tank,
Tire, wheel : 3,600 kg
then pull out the fuel tank from the
chassis.
a For details, see "Removal and instal-
lation of fuel tank assembly".
4 Fuel tank : 800 kg
WA800-3E0, WA900-3E0 5
6. Drive shaft 8. Rear axle, support

Sling rear drive shaft (22) temporarily, remove 1) Remove mounting bolts, then remove
mounting bolts, then lift off. [*4] thrust cover (26). [*6]
a Use a lifting tool of ample length for the
4 Thrust cover : 120 kg
drive shaft, and lift up from both ends of
the transmission. a Remove grease tube.
4 Rear drive shaft : 190 kg
a Thrust cover (26) is heavy, so handle

it as follows and use fixed signals
7. Brake piping when removing.
1) Remove cover (23). [*5] q Leave one bolt in position at the
2) Disconnect tube (24) from slack adjuster. bottom, and use this bolt as a
3) Remove support lubrication tube (25). pivot to rotate the cover carefully.
q Hold the cover with a pallet,
remove the 1 remaining bolt,
then remove the cover carefully.
6 WA800-3E0, WA900-3E0
2) Remove thrust washer (27), thrust plate 5) Move rear axle approx. 250 mm to front,
(28) and thrust washer (29). remove from rear support, then using hoist
4
and jack to maintain balance, lower rear
Thrust plate : 80 kg
axle.
4 Rear axle and support : 8,000 kg
a Lay steel sheets under the part being
lowered, and lower one end of the
axle on to the roller.
6) Pull out rear axle and support (31) from
the body.
3) Sling rear axle temporarily.

a Fit a chain around the axle and be
careful to maintain the balance.
4) Secure front support (30) to rear axle with

wire, and remove front support mounting
bolts. [*7]
WA800-3E0, WA900-3E0 7
9. Front support 10. Rear support

1) Remove front support (32) from rear axle. Remove O-ring (or seal) (36) and bushing (37)
a Be careful not to damage the O-ring from rear support.
(or seal). a For machines where the bushing and sup-
4
port are stuck together, remove bushing
Front support : 290 kg
(37) in the procedure for Step 10.
2) Remove retainer (33), O-ring (or seal) 11. Procedure for removing bushing
(34), and bushing (35) from front support 1) Insert tip of a knife between bushing and
(32). support, separate bushing and support
a For machines where the bushing and around whole circumference, then remove
support are stuck together, remove bushing.
bushing (35) in the procedure for Step a If the adhesive is hard, and it is diffi-
10. cult to separate the bushing and sup-
port, heat the bushing to 100°C with
boiling water or with a small torch,
then try again to separate the bushing
and support.
2) Coat adhesion portion (where it is held to
the support) with adhesive removing liq-
uid, wait for 2 – 3 minutes, then remove
adhesive.
2 Portion with hardened adhesive :
Adhesive removing liquid
(part No. 427-46-11890)
8 WA800-3E0, WA900-3E0
Installation

removal.
[*1]
3 Undercover mounting bolt:
490 – 608 Nm {50 – 62 kgm}
[*2]
3 Fuel tank mounting bolt:
1,510 – 1,910 Nm {155 – 195 kgm}
[*3]
3 Hub nut: 736 – 912 Nm {75 – 93 kgm}
[*4]
3 Rear drive shaft:
343 – 427 Nm {35.0 – 43.5 kgm}
[*5]
a Bleed air from the rear brake circuit. For
details, see Testing and adjusting, "Bleeding
air from wheel brake circuit".
[*6]
2 Thrust washer: Lubricant (G2-LI)
3 Thrust washer mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
3 Thrust cover:
824 – 1,030 Nm {84 – 105 kgm}
[*7]
2 Bushing: Lubricant (G2-LI)
3 Retainer mounting bolt:
157 – 196 Nm {16 – 20 kgm}
3 Front support mounting bolt:
3,170 – 3,870 Nm {323 – 395 kgm}
WA800-3E0, WA900-3E0 9
Removal and installation of center 2) Lift off front drive shaft (2). [*2]
support assembly 1 a Move the drive shaft towards the front
differential, move the center support
Special tools end to the side and remove the pilot
portion at the differential end.
New/Remodel
4 Front drive shaft: 180 kg
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
790-101-7200 Centering tool t 1

1 790-101-7230 • Shaft 1
D 10
2 790-101-7240 • Guide 1
3 01010-51230 • Bolt 1
Removal
k Stop the machine on level ground and turn
the steering wheel fully to the left lock.
Lower the work equipment to the ground
and stop the engine. Then apply the park-
2. Center support
ing brake and put blocks under the wheels.
Sling center support (3) temporarily, remove
mounting bolts, then lift off. [*3]
1. Drive shaft
a If there are shims inserted between the
1) Lift off center drive shaft (1). [*1]
center support and frame, check the num-
4 Center drive shaft: 190 kg ber of shims and use as a guide when
assembling.
a When lifting off, be careful not to damage
the steering cylinder rod.
4 Center support: 170 kg
10 WA800-3E0, WA900-3E0
Installation
removal.
[*1]
3 Center drive shaft:
342 – 427 Nm {35.0 – 43.5 kgm}
[*2]
3 Front drive shaft:
342 – 427 Nm {35.0 – 43.5 kgm}
[*3]
3 Center support mounting bolt:
820 – 1,030 Nm {84 – 105 kgm}
a Check the parallelism and adjust the shims.
Parallelism: 0.15 mm max.
1) Set the center support (3) to the frame,
then tighten the mounting bolts temporar-
ily.
2) Install tools D10-1, D10-2 and D10-3 to
the upper and lower center hinge pins,
then install dial gauge [1] to the coupling
on the center support side to measure the
parallelism of the coupling and shaft D10-
1.
3) Adjust the shims on the center support
mounting face.
4) Position the center support and tighten the
mounting bolts.
3 Center support mounting bolt:
820 – 1,030 Nm {84 – 105 kgm}
WA800-3E0, WA900-3E0 11
Disassembly and assembly of 2. Coupling

center support assembly 1 Remove center bolt (3), then remove holder
(4), O-ring and coupling (5).
Special tools a Check the number and thickness of the
shims between the holder and shaft.
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
795-101-7180 Push tool t 1

1 790-101-5421 Grip t 1
01010-51240 Bolt t 1
790-101-7140 Push tool t 1
2 790-101-5421 Grip t 1
01010-51240 Bolt t 1
E
792-715-1300 Push tool t 1
3 790-101-5421 Grip t 1
01010-81235 Bolt t 1
790-101-5621 Push tool t 1 3. Retainer
4 790-101-5421 Grip t 1 Remove mounting bolts, then remove retainer
01010-51240 Bolt t 1 (6).
a Remove the O-ring at the mating face of
retainer (6) and case (7).
Disassembly
1. Retainer
Remove mounting bolts (2) of retainer (1).
a Rotate the coupling and remove all mount-
ing bolts.
a Turn over the center support.
4. Shaft
1) Set shaft and case assembly (8) on press
stand.
2) Remove shaft (9) with press.
a Be extremely careful as the shaft will
drop out suddenly.
12 WA800-3E0, WA900-3E0
3) Remove bearing cone (10) and retainer Assembly

(1) from shaft. 1. Bearing cup
a Remove O-ring (11) from retainer. Install bearing cup (13) to the case.
5. Oil seal 2. Oil seal

Remove oil seal (12) from retainers (1) and (6). Install oil seals (12) to retainers (1) and (6) with
tool E1.
2 Outside of oil seal: Grease (G2-LI)
6. Case
Remove bearing cup (13) from case.
WA800-3E0, WA900-3E0 13
3. Bearing cone 5. Retainer

1) Install retainer (1) to the shaft, then press 1) Secure retainer (6) to case (7).
fit bearing cone (10) with tools E2. a Be careful not to get the O-ring
a After installing the bearing, check that caught.
there is not a clearance at the shaft end. 3 Mounting bolt:
2 Lip of seal: Grease (G2-LI) 98 – 123 Nm {10 – 12.5 kgm}
2 Inner circumference of bearing:
Grease (G2-LI)
2) Install O-ring (11) to the retainer.
4. Case
1) Install case (7) to the shaft.
2) Press fit bearing cone (14) with tool E2,
then install O-ring (15).
a Fill the inner circumference of the
case with grease.
a When press fitting bearing (14), be
careful not to apply excessive force.
2) Tighten retainer (1) with mounting bolts

(2).
a Be careful not to get the O-ring
caught.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
14 WA800-3E0, WA900-3E0
6. Coupling a Align the spline of the shaft and cou-

1) Select shim as follows. pling (5) so that match marks (b) are
q Rotate case (7) and tighten bolt (3) aligned.
until starting torque is (7.9 – 11.8 Nm
{0.8 – 1.2 kgm}).
q Measure clearance (a) between
holder (4) and shaft (9) at holes in
holder at 3 places, take the average
clearance, and select shims of a
thickness equal to the average clear-
ance + 0.1 to 0.15 mm.
a To measure the clearance, first
measure the thickness of the
holder.
7. End play
Check that end play is within specified range.
a End play: 0.05 – 0.15 mm
a Carry out greasing after installing the cen-
ter support to the chassis.
2) Assemble coupling (5), install O-ring (16),

shim (17) selected above, and holder (9),
then tighten bolt (3).
a Rotate the case and tighten the bolts
to the specified torque.
3 Mounting bolt:
2,452 – 3,040 Nm {250 – 310 kgm}
(width across flats: 55 mm)
WA800-3E0, WA900-3E0 15
Removal and installation of 4. Remove snap ring, then remove sun gear (3).
differential assembly 1 a When removing the sun gear, pull out the
torque shaft slightly to remove.
Removal
1. Remove axle assembly and set on block [1].
For details, see "Removal and installation of
axle assembly".
4 Front axle assembly: 8,200 kg
4 Rear axle assembly: 7,700 kg
5. Raise torque shaft (4), and pull out from spline

of differential assembly.
a Remove the torque shaft on the opposite
side in the same way.
2. Remove drain plug of final case and drain plug

at bottom of differential case, and drain oil from
final drive case.
a There is a large amount of oil drained, and
the oil spurts out suddenly, so be careful
when draining.
6 Final drive case: 360 l
3. Remove final drive case cover (2).

6. When removing front differential assembly,
remove parking brake assembly as follows.
1) Loosen the adjustment bolt, and remove
the plate.
2) Pull out pin, and remove cylinder assem-
bly (7).
3) Remove brake pad assembly (8).
4) Remove cover (9) and disc (10), then
remove bracket. [*1]
7. Remove holder, then remove coupling (11).[*2]

a Check the number and thickness of the
shims assembled inside the holder, and
keep in a safe place.
4 Coupling: 40 kg
16 WA800-3E0, WA900-3E0
Installation

removal.
[*1]
2 Disc mounting bolt: Adhesive (LT-2)
3 Disc mounting bolt:
490 – 608 Nm {50 – 62 kgm}
[*2]
2 Holder mounting bolt: Adhesive (LT-2)
2,452 – 3,040 Nm {250 – 310 kgm}
[*3]
Adjustment of shim of shaft
a Adjust the shim of the shaft when the differen-
tial or axle housing is replaced.
1) Install shaft and tighten the mounting bolts
evenly, then measure the clearance
between the axle housing and shaft.
a Do not assemble shims.
3 Mounting bolt:
3.9 ± 1.0 Nm {0.4 ± 0.1 kgm}
2) Prepare shim having thickness of mea-
sured clearance (a) + 0.1 ± 0.05 mm, then
insert it.
8. Remove mounting bolts, pull out differential a Thickness of shim:
assembly (11) slightly, then using lifting hooks Clearance (a) + (0.1 ± 0.05 mm)
[2] adjust balance with bar and remove differ- 3 Mounting bolt:
ential assembly. [*3] 245 – 309 Nm {25 – 31 kgm}
4 Differential assembly: 1,250 kg [*4]
k When pulling out the differential

assembly, support the bottom of the
differential assembly with a garage
jack.
[*4]
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
WA800-3E0, WA900-3E0 17
Disassembly and assembly of 1. Remove case (2).

differential assembly 1 4 Case: (Front) 45 kg
Special tools (Rear) 70 kg
New/Remodel
2. Remove oil seal (3) from case.
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
790-501-2000 Engine repair stand t 1

1
790-901-5110 Bracket t 1
790-101-2300 Push tool q 1
790-101-2310 • Block 1
790-101-2350 • Leg 2
790-101-2360 • Plate 4
2
790-101-2430 • Adapter 4
02215-11622 • Nut 2
790-101-2102 Puller (30 tons) q 1
790-101-1102 Hydraulic pump q 1
793T-822-1130 Push tool t 1 N Q 3. Fit the coupling (4) temporarily, and remove
H 3 pinion and cage assembly (5).
793T-822-1140 Push tool t 1 N Q
4 793T-822-1150 Push tool t 1 N Q 4 Coupling, pinion, cage assembly:
793T-822-1110 Plate t 1 N Q
180 kg
793T-822-1120 Spacer t 1 N Q
5 a Check the number and thickness of the
790-101-5421 • Grip t 1
shims, and keep in a safe place.
01010-51240 • Bolt t 1
792-340-1120 Nut, wrench t 1
6
796-550-1310 Wrench t 1
792-525-3000 Micrometer t 1
7 790-425-1670 Adapter t 1
790-425-1660 Wrench t 1
a The internal structure of front and rear differen-

tial is identical, excluding the shape in appear-
ance.
Disassembly
q Preparatory work
Set differential assembly (1) to tools H1.
4 Differential assembly: 1,250 kg
18 WA800-3E0, WA900-3E0
4. Disassemble pinion and cage assembly as fol- 6. Remove mounting bolts (13), then remove cap
lows. (14).
1) Remove coupling, and sling cage (6) tem-
porarily, then using tools H2 and [1], pull
out bearing (7), and remove cage.
a If tools H2 and [1] are not used, sup-
port the flange surface of the cage,
push the pinion shaft with a press to
disassemble.
7. Remove differential gear case assembly (15).

4 Differential gear case assembly:
1,250 kg
2) Remove outer race (8).

3) Remove bearing (11) from pinion shaft
(10).
8. Disassemble differential gear case assembly

as follows.
1) Remove mounting bolts (16), then remove
case (17).
4 Case: 85 kg
5. Remove left and right locks, then loosen the
nut (12) with a bar to a point where it can be
turned by hand.
WA800-3E0, WA900-3E0 19
2) Remove bearing (18), washer (33) and 3) Remove collar (26).

dowel pin (34) from case (17). 4) Remove bearing (27) from shaft.
3) Remove bevel gear (19). 5) Remove outer race (28) from pinion gear.
4) Remove pinion gear assembly (20)
together with cross shaft (21).
4 Pinion gear, cross shaft: 110 kg
6) Remove collar (29).

7) Remove outer race (30) from pinion gear.
a Disassemble pinion gear assembly as follows.

1) Raise lock plate, hold pinion gear assem-
bly (20) with press, then using wrench H6,
loosen lock nut (22) and remove.
2) Push shaft (23) with press, and remove
pinion gear (24) and bearing (25).
20 WA800-3E0, WA900-3E0
9. Remove bevel gear (31). Assembly

a Coat the rotating surfaces of the bearing roller,
10. Remove thrust washer (32). inner race and outer race rollers with engine oil
before installing.
11. Remove mounting bolts, and using eyebolts
(Dia. = 24 mm, Pitch = 3.0 mm), remove bevel 1. Using the eyebolts (Dia. = 24 mm, Pitch = 3.0
gear. mm), install the bevel gear.
4 Bevel gear: 320 kg
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
2. Install thrust washer (32).

a Align the thrust washer with the dowel pin
when installing.
3. Install bevel gear (31).
a Assemble pinion gear as follows.

1) Press fit outer race (30) to pinion gear,
install collar (29), and press fit outer race
(28).
2) Press fit bearing (27) in shaft.
WA800-3E0, WA900-3E0 21
2) Install bevel gear (19).

a Move the bevel gear and check that
the pinion gear assembly rotates
smoothly.
3) Install pinion gear (24) and collar (26), and

then press fit bearing (25) in shaft.
4) Fit lock plate and tighten lock nut (22) with
wrench H6.
a Bend the lock plate securely. 3) Install dowel pin (34), washer (33) and
3 Lock nut: bearing (18) to case (17).
882 – 1,080 Nm {90 – 110 kgm} a Align the washer (33) with the dowel
pin (34) when installing.
a Assemble differential gear case assembly as

follows. 4) Install case, and tighten mounting bolts.
1) Assemble pinion gear assembly (20) in 2 Mounting bolt: Adhesive (LT-2)
cross shaft (21), and install to case. 3 Mounting bolt:
a Align the notch in the pinion gear with 824 – 1,030 Nm {84 – 105 kgm}
the cross shaft dowel pin when install-
ing. 4. Tighten nut (12) temporarily, and put differen-
tial gear case assembly (15) in differential
case.
a Align the nut with the groove in the differ-
ential case, then check that it rotates
smoothly by hand.
22 WA800-3E0, WA900-3E0
a If the increase deflection is greater

than the standard distance, return to
the position before adjusting with the
adjustment nut.
When returning the adjustment nut,
rotate the bevel gear, and tap the
bearing cap and bevel gear with a
plastic hammer to check that there is
no clearance at (b). Then adjust
again.
5. Install cap (14) and tighten mounting bolts (13).

3 Mounting bolt:
1,520 – 1,912 Nm {155 – 195 kgm}
a Check the match mark on the bearing cap
when installing.
a When tightening the bolts, rotate the bevel
gear 20 – 30 times to settle the bearing
before tightening.
a Assemble pinion and cage assembly as fol-

lows.
1) Press fit bearing (11) to pinion shaft (10).
a Check that there is no clearance
between the bearing inner race and
the pinion.
2) Press fit outer race (8) to cage.
a Adjust the preload of the bevel gear as follows.

1) Using tool D7, measure distance (D).
2) Adjust with the nut (12) so that the
increase in distance (D) is 0.39 ± 0.15 mm.
a The increase becomes the amount of
deflection of the case from before giv-
ing preload to after giving preload.
WA800-3E0, WA900-3E0 23
3) Install pinion shaft to cage (6). a Rotate the cage 20 – 30 times, then using
4) Press fit bearing (7). push-pull scale [3], check the starting torque.
a Starting torque: 22.6 ± 6.9 Nm {2.3 ± 0.7
kgm}
5) Install coupling (4), and tighten holder (33)

with mounting bolt to 304 – 344 Nm {31 –
35 kgm} temporarily, then measure clear- a Check that the bearing roller big end and
ance (a) between holder and pinion with inner race lip are in contact.
depth gauge [2]. a There must be no clearance in (b).
a Add 0.11 mm to the measured value for
clearance (a) to decide the shim thick-
ness.
6. Fit O-ring and assemble shim, then install pin-

ion and cage assembly (5) to differential case.
a If the shim was disassembled, assemble
6) Insert shim and rotate cage while tighten- the same number and thickness of shims
ing holder mounting bolts to specified that was removed.
tightening torque. 2 Mounting bolt: Adhesive (LT-2)
2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt:
3 Mounting bolt: 490 – 608 Nm {50 – 62 kgm}
2,450 – 3,040 Nm {250 – 310 kgm}
24 WA800-3E0, WA900-3E0
7. Adjusting tooth contact, backlash a Adjust tooth contact as follows.

a Adjust backlash as follows. 1] Adjust the position of the bevel pinion by
1) Move bevel gear with adjustment nut. changing the shims between the differen-
When adjusting the bevel gear, do not tial case and bearing cage.
change the preload of the bearing. 2] Adjust tooth contact between pinion gear
Always turn the adjustment nuts at both and bevel gear.
ends the same amount in the same direc- For details, see Adjusting tooth contact.
tion. 3] If the bevel gear is excessively close to
2) Put dial gauge H7 at right angles in con- the bevel pinion, the contact mark will be
tact with the face of the tooth at the out- as shown in the following figure. Make
side of the bevel gear. correction according to the following pro-
Turn the adjustment nut and adjust until cedure:
the movement of the gauge indicator is q Decrease the number of shims of the
0.43 – 0.61 mm. cage assembly (on the bevel pinion
a Adjust at 3 or 4 places. Keep the pin- side) and shift it in the direction of (C).
ion gear locked when measuring. q Adjust the bearing adjustment nut
and shift the bevel gear in the direc-
tion of (D) away from the bevel pinion.
4] If the bevel gear is excessively away from

the bevel pinion, the contact mark will be
as shown in the following figure. Make
correction according to the following pro-
cedure:
q Increase the number of shims of the
cage assembly (on the bevel pinion
side) and shift it in the direction of (E).
q Adjust the bearing adjustment nut
and shift the bevel gear in the direc-
tion of (F) closer to the bevel pinion.
WA800-3E0, WA900-3E0 25
3) Testing of tooth contact 2] If the bevel pinion is excessively away

Apply thin layer of red lead on the tooth from the bevel gear, the contact mark
surface of the bevel gear. Turn the bevel will be as shown in the following fig-
gear in the forward and backward direc- ure. Make correction according to the
tions and check the contact mark left on following procedure:
the bevel gear. q Reduce the number of shims of
a Proper tooth contact the cage assembly (on the bevel
Fifty percent of the total length of a pinion side) and shift it in the
tooth is in contact centering around direction of (C).
the pitch line toward the heel with q Adjust the bearing adjustment
approx. 5 mm of the toe side remain- nut and shift the bevel gear in the
ing unmarked or not in contact. direction of (D) away from the
bevel pinion.
4) Adjusting of tooth contact

1] If proper tooth contact mark was not 3] If the bevel pinion is excessively close
obtained upon checking, proceed to a to the bevel gear, the contact mark
tooth adjustment. will be as shown in the following fig-
a Make adjustment by shifting the ure. Make correction according to the
bevel gear and increasing/ following procedure:
decreasing the number of shims q Increase the number of shims of
(shifting of bevel pinion gear) of the cage assembly (on the bevel
the cage assembly. pinion side) and shift it in the
a After adjustment, check the direction of (E).
backlash again. q Adjust the bearing adjustment
a When making adjustment by nut and shift the bevel gear in the
shifting the bevel gear, don't direction of (F) closer to the bevel
change pre-load given the bear- pinion.
ing. Accordingly, turn the respec-
tive left and right adjustment nuts
by the same quantity (check with
the shifting of the notch) and in
the same direction.
a Shim thickness: 0.05, 0.2, 0.3
and 1.0 mm
8. After adjusting tooth contact and backlash,

install left and right locks.
26 WA800-3E0, WA900-3E0
Disassembly and assembly of 3. Remove final drive case cover (2).

final drive assembly 1
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
792-633-1300 Fixture t 4
J 1 01010-81430 Bolt t 4
01641-21423 Washer t 4
4. Remove snap ring (3), then remove sun gear

Disassembly (3A).
k Stop the machine on level ground and a Pull out the torque shaft approx. 150 mm,
install the lock bar on the frame. then push in the sun gear approx. 10 mm,
Lower the work equipment to the ground and and remove the snap ring.
stop the engine. Then apply the parking brake
and put blocks under the wheels to prevent the
1. Loosen wheel nut, jack up machine with work

equipment, insert stand under axle, then sling
wheel assembly temporarily, remove wheel
nut, and lift off wheel assembly (1).
4 Wheel assembly: 3,600 kg
5. Remove torque shaft (4).

4 Torque shaft: 110 kg
a Remove retainer (5).
2. Remove drain plug of final drive case, and

drain oil from final drive case.
a There is a large amount of oil drained, and
the oil spurts out suddenly, so be careful
when draining.
WA800-3E0, WA900-3E0 27
6. Remove 3 hexagonal bolts, then using eye- 3) Remove the bearing from pinion gear,
bolts [1] (Dia. = 12 mm, Pitch = 1.75 mm), lift then remove outer race (11), spacer
off carrier case assembly (6). (12), and snap ring (13).
a When pulling out the carrier case assem- a Keep the bearing and outer race as
bly, insert a bar in the casting hole at the set.
bottom of the case, and adjust the balance
when pulling out.
4 Carrier case assembly: 390 kg
7. Using tool J1, secure wheel hub (14) and float-

ing seal case (15).
a Secure tool J1 at 4 places on opposite
sides to prevent uneven contact of the
a Disassemble carrier case assembly as fol- floating seal.
lows.
1) Remove mounting bolts (7), then
remove retainer (8).
2) Using a copper hammer, knock out
shaft, then remove pinion gear (9)
and bearing from carrier case.
8. Remove retainer (16), then remove shim (17).

a Check the number and thickness of the
shims, and keep in a safe place.
28 WA800-3E0, WA900-3E0
9. Lift off ring gear assembly (18).

a When pulling out the ring gear assembly,
insert a bar in the casting hole at the bot-
tom of the case, and adjust the balance
when pulling out.
4 Ring gear assembly: 240 kg
10. Remove lock plate, then remove ring gear (20)

from ring gear hub (19).
4 Ring gear hub: 95 kg
4 Ring gear: 150 kg
11. Replace wheel hub stud bolts

a If any stud bolts are damaged or elon-
gated, replace all of them.
Remove stud bolts (double nut)
q Remove stud bolts (1) (53 pieces) from
wheel hub (2) according to the following
procedure.
1) Check that the threaded holes of wheel
hub (2) are free from damage.
2) Install 2 nuts to each stud bolt.
3) Tighten the 2 nuts so that they are
pressed to each other (Turn the bottom
one counterclockwise and the top one
clockwise).
4) Remove the stud bolt by turning only the
bottom nut in the loosening direction.
WA800-3E0, WA900-3E0 29
Assembly 3. Adjust wheel bearing as follows.

1) Align ring gear assembly (18) with spline
1. Install stud bolts of axle shaft.
q Install stud bolts (1) (53 pieces) to wheel 2) Install retainer (16) without shim, and
hub (2) according to the following proce- tighten it with 4 bolts temporarily.
dure, while preventing scuffing. a Measure thickness of the retainer (b)
1) Check that the nut side is with identifica- before installing.
tion mark "E" or is stepped. 2 Retainer mounting bolt:
a When tighting, do not coat grease or 181 – 191 Nm {18.5 – 19.5 kgm}
oil on the screw portion. 3) Remove tool J1, rotate the hub 20 – 30
2) Install 2 nuts to the nut side of each stud bolt. times, then tighten the mounting bolts uni-
3) Tighten the 2 nuts so that they are formly to the specified torque.
pressed to each other (Turn the bottom 3 Retainer mounting bolt:
one counterclockwise and the top one 824 – 1,030 Nm {84 – 105 kgm}
clockwise).
4) Install the stud bolt by turning only the top
nut in the tightening direction.
5) Tighten the stud bolt to the incomplete
thread portion.
q Tightening (protrusion) distance: 98 – 100
mm
3 Stud bolt:
238 – 335Nm {24.3 – 34.2 kgm}
4) Using calipers [2] or depth micrometer

through measuring hole of retainer, mea-
sure distance (a) from retainer to end face
of axle shaft.
a Measure at 2 places and take the
average.
a Difference (C) between measured
values = (a) – (b) + 0.3 mm (Round
the measurement up to the nearest
0.1 mm).
2. Install ring gear (20) to ring gear hub (19), and a Select the combination of shims to
secure with lock plate. give the required thickness with the
minimum number of shims.
3 Mounting bolt:
78.5 – 98 Nm {8 – 10 kgm}
a Clean all the grease and oil from the bolt
thread and mounting hole.
30 WA800-3E0, WA900-3E0
5) Using tool J1, secure wheel hub (14) and 4. Assemble planetary carrier as follows.
floating seal case (15). 1) Install snap ring (13) and spacer (12) to
a Secure tool J1 at 4 places on oppo- pinion gear.
site sides to prevent uneven contact 2) Press fit outer race (11), and assemble the
of the floating seal. bearing.
6) Remove 3 mounting bolts. 3) Set pinion gear (9) and bearing in carrier
7) Fit selected shim (17) and retainer, then case, assemble shaft, then press fit shaft
tighten mounting bolts. with copper hammer.
a Remove tool J1, rotate the hub 5 – 6 4) Tighten retainer (8) with mounting bolts
times, then tighten the mounting bolts (7).
uniformly to the specified torque. 2 Mounting bolt: Adhesive (LT-2)
2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt:
3 Mounting bolt: 275 ± 29 Nm {28 ± 3 kgm}
824 – 1,030 Nm {84 – 105 kgm}
a After tightening the bolts, rotate the hub
and check for any abnormality in the rota-
tion of the bearing rollers.
WA800-3E0, WA900-3E0 31
5. Fit O-ring, then using eyebolts [1] (Dia. = 12

mm, Pitch = 1.75 mm), raise carrier case
assembly (6), align tooth faces of planetary
gear and ring gear, then set in mounting posi-
tion and tighten 3 hexagonal bolts.
a When installing the carrier case assembly,
insert a bar in the casting hole at the bot-
tom of the case to adjust the balance
when installing.
10. Raise wheel assembly (1), install to wheel hub,

then temporarily tighten nuts.
Jack up machine with work equipment, remove
stand from under axle, then lower machine.
11. Tighten wheel nuts fully.

3 Wheel nut:
736 – 912 Nm {75 – 93 kgm}
6. Raise torque shaft (4) and set in mounting

position temporarily.
7. Align spline and push torque shaft (4) in

mounting position of differential assembly.
a Leave the torque shaft protruding approx.
150 mm, install the snap ring to the sun
gear, then push in completely.
8. Install retainer (5) and sun gear (3A), and

secure with snap ring (3).
a When aligning the tooth faces of the sun
gear and carrier gear, raise the torque
shaft slightly to align. 12. Tighten drain plug of final case, and add oil
until it flows out from level plug.
9. Fit O-ring and install final case cover (2).
32 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 33
SEN02744-02

© 2017 KOMATSU
All Rights Reserved
34
SEN02745-03
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Brake system
Removal and installation of brake assembly................................................................................................... 2
Disassembly and assembly of brake assembly .............................................................................................. 3
Removal and installation of left brake valve assembly.................................................................................... 8
Removal and installation of right brake valve assembly ................................................................................. 9
Disassembly and assembly of accumulator charge valve ............................................................................ 10
Disassembly and assembly of slack adjuster ............................................................................................... 12
WA800-3E0, WA900-3E0 1
Removal and installation of brake 3. Sling wheel hub (2) temporarily, remove
assembly 1 mounting nut, then remove wheel hub. [*1]
a Bearing (3) will fall out, so remove the
Special tools bearing while removing the wheel hub.
3 Bearing: 45 kg
3 Wheel hub: 600 kg
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
792-633-1300 Fixture t 4
J 1 01010-81430 Bolt t 4
01641-21423 Washer t 4
Removal
1. Remove ring gear.

For details see “Disassembly and assembly of
final drive assembly”.
2. Disconnect brake tube (1).
4. Sling brake (4) temporarily, and remove

mounting bolts, then remove brake. [*2]
a Bearing (5) will fall out, so remove the
bearing while removing the brake.
3 Bearing: 45 kg
3 Brake: 380 kg
2 WA800-3E0, WA900-3E0
Installation Disassembly and assembly of

brake assembly 1
removal. Special tools
New/Remodel
[*1]
Necessity
2
Symbol
Sketch
Mounting nut: Adhesive (LT-2)
Q'ty
3
Part No. Part name
Mounting nut: 490 – 608 Nm {50 – 62 kgm}
[*2]
2
792-633-1300 Fixture t 4
Mounting bolt: Adhesive (LT-2)
3 Mounting bolt: 1 01010-81430 Bolt t 4
824 – 1,030 Nm {84 – 105 kgm} 01641-21423 Washer t 4
791-585-1510 Installer t 1
q Bleeding air 792-530-1700 Push tool t 1
Bleed air from the brake circuit. For details, 791-580-1610 • Plate 1
see Testing and adjusting, "Bleeding air from J 791-580-1620 • Arm 4
wheel brake circuit". 792-530-1630 • Stud 4
2
791-580-1640 • Plate 1
791-585-1650 • Plate 4
01010-51425 • Bolt 8
01640-21426 • Washer 4
01541-21670 • Nut 4
Disassembly
1. Remove mounting bolts, and install eyebolts
[1] (Dia. = 16 mm, Pitch = 2.0 mm), then lift off
cylinder assembly (1).
4 Cylinder assembly: 140 kg
WA800-3E0, WA900-3E0 3
a Disassemble cylinder as follows. 2) Remove disc (7).

1) Install eyebolts [1] (Dia. = 16 mm, Pitch =
2.0 mm), push in spring with bar [2], then
pull out pin (2).
k When lift back the bar [2] after
removing the pin, take care bar [2]
coming out from the shaft.
2) Remove spring (3), shaft (4), and washer.
3. Remove tool J1.
3) Remove piston (5).
4. Install eyebolts [1] (Dia. = 16 mm, Pitch = 2.0

mm), then lift off outer drum (8).
4 Outer drum: 240 kg
2. Removal of plate and disc

1) Remove stopper bolt, then remove plate
(6).
4 WA800-3E0, WA900-3E0
5. Knock out retainer (10) through removal hole Assembly

in inner gear (9), then remove together with 1. Using tools J2, install floating seal (14) to hub.
floating seal (11). a When assembling the floating seal, clean
the surface of the O-ring with alcohol and
assemble without twisting.
a Use a new part for the O-ring.
6. Remove mounting bolts, then remove hub (12)

from outer drum.
7. Remove oil seal (13). 2. Install oil seal (13).

a Tap the oil seal with a plastic hammer to
8. Remove floating seal (14). install uniformly.
2 Lip of oil seal: Grease (G2-LI)
3. Fit O-ring and install hub (12) to outer drum.

3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
WA800-3E0, WA900-3E0 5
4. Using tools J2, install floating seal (11) to

retainer (10).
a When assembling the floating seal, clean
the surface of the O-ring with alcohol and
assemble without twisting.
7. Using tool J1, fix inner gear and outer gear.

a Center the inner gear and outer gear, and
tighten with tool J1.
5. Fit O-ring to inner gear (9), align with dowel pin

and install retainer (10) together with floating
seal (11).
a When installing the retainer to the inner
gear, tap the end of face of the retainer
with a copper hammer to install.
8. Assemble disc (7) and plate (6).

a Align the notched teeth at 6 places around
the circumference of the disc (7) and plate
(6) when assembling.
9. Fit O-ring and tighten stopper bolts of disc and

plate.
6. Using eyebolts [1] (Dia. = 16 mm, Pitch = 2.0

mm), install outer drum (8) to inner gear.
a Coat the sliding surface of the floating seal
thinly with engine oil, and be careful not to
damage the floating seal when installing
the outer drum.
a Center the inner gear and outer gear.
6 WA800-3E0, WA900-3E0
a Use pads to prevent damage to the

side face of the piston.
a When installing plugs (16) and (17),
coat the thread with gasket sealant,
the install.
2 Plug thread: Gasket sealant
(LG-5)
a Assemble cylinder as follows.

1) Assemble seal rings to cylinder (15) and
piston (5), and set piston (5) at bottom.
a Coat to each seal ring with engine oil.
4) Assemble washer, shaft (4), and spring (3)

to piston from cylinder end.
5) Screw in eyebolts [1] (Dia. = 16 mm, Pitch
= 2.0 mm), compress spring with bar [2],
then install pin (2) in shaft.
2) Align return spring guide shaft hole of pis-

ton (5) and cylinder (15), then press fit pis-
ton (5).
a Assemble so that casting holes A’
(bleeder side) and B’ (plug side) of
the piston are in the positions shown
in the figure on the right.
a When press fitting the piston, tap with 10. Fit O-ring, then screw in eyebolts [1] (Dia. = 16
a plastic hammer. Do not hit with a mm, Pitch = 2.0 mm), install cylinder assembly
steel or copper hammer. (1).
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
3) Turn over cylinder (15), and set so that

piston (5) is facing down.
WA800-3E0, WA900-3E0 7
Removal and installation of left

brake valve assembly 1
Removal
1. Disconnect drain tube (1).

7. Remove 4 bolts (13), then remove brake valve
2. Disconnect elbow (2) between the left brake (14).
valve and right brake valve. a This work must be done by two workers.
Remove the valve under the floor frame.
3. Disconnect hose (3) between the left brake
valve and accumulator.
Installation
4. Pull out snap pin (9), then pull out pins (7) and
(8). q Carry out installation in the reverse order to
a Be careful not to lose L-pin (10). removal.
5. Remove pedal (11). q Bleeding air

Bleed air from the brake circuit. For details,
6. Remove boot (12). see Testing and adjusting, “Bleeding air from
wheel brake circuit”.
8 WA800-3E0, WA900-3E0
Removal and installation of right

brake valve assembly 1
Removal
1. Disconnect drain hose (1).
2. Disconnect hose (2) between the right brake 8. Remove 4 bolts (13), then remove brake valve
valve and left brake valve. (14).
a This work must be done by two workers.
3. Disconnect hoses (3) and (4) between the right Remove the valve under the floor frame.
brake valve and slack adjuster.
4. Disconnect hoses (5) and (6) between the right

brake valve and accumulator.
Installation

5. Pull out snap pin (9), then pull out pins (7) and removal.
(8).
a Be careful not to lose L-pin (10). q Bleeding air
6. Remove pedal (11). see Testing and adjusting, "Bleeding air from
wheel brake circuit".
7. Remove boot (12).
WA800-3E0, WA900-3E0 9
Disassembly and assembly of 7. Remove locknut (14) from valve body (1), then
accumulator charge valve 1 remove adjustment screw (15).
Disassembly 8. Remove retainer (16), spring (17), shim (18)

1. Remove PPC relief valve (2) from valve body and O-ring (19) from adjustment screw (15).
(1).
9. Remove plug (20) from valve body (1), then
2. Remove O-rings (3), (5) and 2 backup rings (4) remove retainer (21), piston (22) and valve
from the PPC relief valve. seat (23).
3. Remove plug (6) from valve body (1), then 10. Remove O-ring (24) from plug (20).
remove spring (7) and spool (8).
11. Remove locknut (14) from valve body (1), then
4. Remove the O-ring (9) from plug (6). remove adjustment screw (15).
5. Remove bushing (10) from valve body (1). 12. Remove ball (25), spring (26), shim (18) and
O-ring (19) from adjustment screw (15).
6. Remove snap ring (11), filter (12) and O-ring
(13) from bushing (10). 13. Remove plug (27) from valve body (1), then
remove orifice (28).
14. Remove snap ring (29) from valve body (1),

then remove filter (30).
10 WA800-3E0, WA900-3E0
Assembly 9. Insert filter (12) in bushing (10), then install

1. Insert filter (30) in valve body (1), then install snap ring (11).
snap ring (29). a When replacing the snap ring (11) or the
filter (12) or the bushing (10) with new
2. Install orifice (28) to valve body (1). one, replace them at once.
2 Orifice: Loctite (#241) (The snap ring (11) or the filter (12) cannot
3 Orifice: be supplied as an indivisual part.)
3.14 – 3.9 Nm {0.32 – 0.40 kgm}
10. Install O-ring (13) to bushing (10), then install
3. Install plug (27). them to valve body (1).
2 Plug: ThreeBond (#1305) 3 Bushing:
29.4 – 39.2 Nm {3.0 – 4.0 kgm}
4. Install O-ring (19) to adjustment screw (15),
then set shim (18), spring (26) and ball (25), 11. Assemble spring (7) to spool (8), then insert
and install them to valve body (1). them in valve body (1).
5. Install locknut (14) to adjustment screw (15). 12. Install O-ring (9) to plug (6), then install them to
3 Locknut: 9.8 – 11.8 Nm {1.0 – 1.2 kgm} valve body (1).
3 Plug: 53.9 – 68.6 Nm {5.5 – 7.0 kgm}
6. Install valve seat (23), piston (22) and retainer
(21) to valve body (1). Install O-ring (24) to 13. Install O-ring (5), backup ring (4) and ring (3) to
plug (20), then install them. PPC relief valve (2), then install them to valve
2 Plug: 30.4 – 37.3 Nm {3.1 – 3.8 kgm} body (1).
3 PPC relief valve:
7. Assemble O-ring (19) to adjustment screw 79 – 88 Nm {8 – 9 kgm}
(15). Set shim (18) and spring (17) and retainer
(16), then install them to valve body (1).
8. Install locknut (14) to adjustment screw (15).

3 Locknut: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}
WA800-3E0, WA900-3E0 11
Disassembly and assembly of 3. Piston

slack adjuster 1 1) Remove spring (5) and O-ring (6).
2) Push out piston (7) and remove O-ring.
Disassembly a Gently push out the piston with a rod
1. Bleeder (diameter 10 mm) when remove it.
Remove bleeder (2) from body (1). a Pay attention not to give damage to
screw portion with the rod.
2. Cylinder
Remove mounting bolts, then disconnect body 4. Poppet
(1) and bracket (3) from cylinder (4). a Do not disassemble poppet unless neces-
k Cylinder has spring tension inside. sary.
Carefully remove them holding 2 parts If disassembled, replace poppet and cylin-
together. der as assembly.
1) Remove cover (8) from cylinder (4), then
remove plug (9), spring (10) and poppet
(11).
a Remove the poppet by air blowing
through the oil hole of the cylinder.
a Hold the oil port of the cylinder by
hand and pay attention not to blow air
hard.
a If replace poppet (11) or cylinder (4),
replace them as a set.
2) Remove O-ring (12) from the poppet.
12 WA800-3E0, WA900-3E0
Assembly 3. Cylinder
1. Poppet 1) Install O-ring (6) and spring (5) to cylinder.
1) Fit O-ring (12) to poppet (11).
2) Install poppet (11), spring (10), plug (9)
and cover (8), then assemble into the cyl-
inder (4).
2) Install cylinder (4) and bracket (3) to body

(1).
2 Mounting bolt:
157 – 186 Nm {16 – 19 kgm}
2. Piston
1) Fit O-ring (13) to piston (7). 4. Bleeder
2) Insert piston (7) into cylinder (4). Install bleeder (2).
a Confirm that the piston moves
smoothly.
WA800-3E0, WA900-3E0 13
SEN02745-03

© 2017 KOMATSU
All Rights Reserved
14
SEN02746-03
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Undercarriage and frame
Removal and installation of center hinge pin .................................................................................................. 2
Removal and installation of counterweight assembly ................................................................................... 14
WA800-3E0, WA900-3E0 1
Removal and installation of center Removal

hinge pin 1
a Before starting the work, remove the bucket.
Special tools k Stop the machine on level ground and
install the lock bar to the frame. Lower the
New/Remodel
engine and apply the parking brake, then
Necessity
Sym
Part No. Part name
Sketch
bol put blocks under the wheels to prevent the
Q'ty
k Loosen the oil filler cap to release the pres-
790-101-2501 Push puller t 1 sure from the hydraulic tank, then operate
790-101-2510 • Block 1 the work equipment control lever over TILT
790-101-2520 • Screw 1 and NEUTRAL at least 40 times to release
the pressure from the accumulator and pip-
790-112-1180 • Nut 1
ing.
k
790-101-2540 • Washer 1 Disconnect the cable from the negative (–)
790-101-2610 • Leg 2 terminal of the battery.
790-101-2570 • Plate 4 k Collect the air conditioner refrigerant
1 (R134a) from the air conditioner circuit in
790-101-2740 • Adapter 2
advance.
790-101-2560 • Nut 2 a Ask professional traders for collecting and fill-
790-101-7340 Push tool t 1 ing operation of refrigerant (R134a).
790-101-7350 Guide t 1 a Never release the refrigerant (R134a) to the
atmosphere.
t 1
k
790-201-1310 Spacer
If the refrigerant gas (R134a) gets in your
790-101-2102 • Puller (30 tons) t 1 eyes, you may lose your sight. Accord-
790-101-1102 • Hydraulic pump t 1 ingly, put on protective goggles while you
790-201-1970 Plate t 1 are collecting the refrigerant (R134a) or fill-
2 790-101-5021 • Grip t 1
01010-50816 • Bolt t 1 work must be conducted by a qualified per-
K 790-101-2300 Push tool t 1 son.
790-101-2310 • Plate 1
1. Floor frame
790-101-2320 • Screw 1
Remove the floor frame. For details, see
790-101-2330 • Nut 1 “Removal and installation of floor frame”.
790-101-2340 • Washer 1
790-101-2390 • Leg 2 2. Steering cylinder pin
Remove lock plates (1) of the right-hand and
790-101-2360 • Plate 4
3 left-hand steering cylinder pins, then pull out
02215-11622 • Nut 2 the pins (2) downward. [*1]
790-101-7330 Adapter t 2 a Remove the bushings.
790-201-1310 Spacer t 1
790-101-7310 Push tool t 1
790-101-7320 Grip t 1
790-101-2102 Puller (30 tons) t 1
790-101-1102 • Hydraulic pump t 1
793T-846-1110 Plate t 1 N Q
4 790-101-5221 • Grip t 1
01010-51225 • Bolt t 1
5 790-450-1110 Adapter t 1
2 WA800-3E0, WA900-3E0
3. Hydraulic piping 5. PPC piping, brake piping

Disconnect the following hoses from the joints Disconnect the following hoses from the tubes.
on the rear frame side. 1) Hoses (10) (Raise lift arm), (11) (Lower lift
1) Hose (3) between switch pump and frame arm), (12) (Dump) and (13) (Tilt) between
2) Hose (4) between loader pump and work PPC valve and control valve
equipment valve 2) Hoses (14) and (15) between brake valve
3) Hose (5) between steering pump and and slack adjuster
steering valve 3) Parking brake solenoid valve drain hose
4) Hose (6) between oil cooler and steering (16), and hose (17) between parking
valve brake solenoid valve and accumulator
5) Hose (7) between work equipment valve charge valve
and hydraulic tank 4) Hoses (18) (right side) and (19) (left side)
6) Hose (8) between diverter valve and between stop valve and steering valve
steering valve a Attach a tag to each hose for identification.
a Disconnect the clamps of each hose.
4. Drive shaft
Sling and remove center drive shaft (9). [*2] 6. Supporting of frame
4
1) Adjust the height of the rear frame with
Center drive shaft: 190 kg
hydraulic jacks, and place blocks [1].
a Apply the hydraulic jacks and place
the blocks on left and right sides of
the frame.
2) Place blocks [2] under the front frame by
using jacks.
WA800-3E0, WA900-3E0 3
3) Place blocks [3] under the counterweight. 3) Remove spacer (23).

4) Move the hydraulic hoses to the right side
of the machine by using lever blocks.
8. Upper hinge pin

1) Remove mounting bolts (24) and (25),
7. Lower hinge pin then remove retainer (26). [*4]
1) Remove the mounting bolts, then remove
retainer (20). [*3]
a Check the quantity and thickness of
the shim s inserted between the
retainer and frame.
2) Install eyebolts K5 to upper hinge pin (27),

and lift off.
4 Upper hinge pin: 40 kg
2) Install eyebolts to lower hinge pin (21),

then lift off pin.
4 Lower hinge pin: 70 kg
a Remove bolt (22) of the hinge pin,
and install the eyebolt.
4 WA800-3E0, WA900-3E0
9. Disconnecting frame 2) Remove dust seal (30) from retainer.

Remove lock bar, pull out front frame to front
and disconnect frames.
a Be careful not to let the spacer at the
upper of the lower hinge bite into the rear
frame.
a Be careful to maintain the balance when
carrying out the operation.
a Move the frame about 100 mm at a time.
a Remove spacer (28) from the rear frame.
3) Remove spacer (31) from front frame.
10. Lower hinge

1) Remove mounting bolt, then remove
retainer (29). [*5]
a There are shims between the retainer
and the frame, so check the number
and thickness of the shims, and keep
in a safe place. 4) Remove plate (32) from front frame, then
remove dust seal (33).
WA800-3E0, WA900-3E0 5
5) Remove bearing (34). 3) Remove plate (37) from front frame, then
remove dust seal (38).
11. Upper hinge

1) Remove retainer (35). [*6] 4) Remove bearing (39).
a There are shims between the retainer
and the frame, so check the number
and thickness of the shims, and keep
in a safe place.
2) Remove dust seal (36) from retainer.
6 WA800-3E0, WA900-3E0
Installation 2. Tightening of the upper bolt

a Check "4. Precautions" in advance.
q Carry out installation in the reverse order to 1) Tighten bolts (1), (2) and (3) by using
removal. ratchet wrench.
3 Bolt (1), (2), (3):
[*1] 39 Nm {4 kgm}
a Adjust clearance (d) to the specification values a Tightening torque of 39 Nm {4 kgm}:
with shims. Tighten to the operating effort of 20
Clearance (d): 3.0 mm max. kg by using ratchet wrench of L =
k When aligning the position of the pin hole, 200.
use a bar. Never put your fingers on the pin Then, tighten them at 3 places clockwise
hole. in the order of (1), (2), (3), (1), (2), (3) by
using ratchet wrench.
3 Bolt (1), (2), (3):
39 Nm {4 kgm}
2) Tighten bolts once clockwise in the order

of (1), (2), (3) by using torque wrench.
3 Bolt (1), (2), (3):
98 Nm {10 kgm}
3) Hit any position of (A) or (B) or (C) twice

by using plastic hammer so that the clear-
ance between taper collet and frame (part
Y of the figure) becomes even, and taper
collet does not slant.
a Assemble the steering cylinder pin according Hit each part of (A), (B), (C) twice by using
to the following procedure. plastic hammer. Perform this for 2 times.
1. After tightening the upper taper collet and the 4) Tighten bolts clockwise in the order of (1),
(2), (3). Perform this for 3 times.
3 Bolt (1), (2), (3):
steering cylinder pin, tighten the lower taper
collet and the steering cylinder pin.
98 Nm {10 kgm}
5) Tighten bolts clockwise in the order of (1),

3 Bolt (1), (2), (3):
147 Nm {15 kgm}

3 Bolt (1), (2), (3):
177 Nm {18 kgm}

3 Bolt (1), (2), (3):
196 Nm {20 kgm}
WA800-3E0, WA900-3E0 7
8) Loosen bolt (1) temporarily, apply adhe-

sive to it, and tighten it.
Loosen bolt (2) temporarily, apply adhe-
2 Bolt (1), (2), (3):
Adhesive (LOCTITE #262)
3 Bolt (1), (2), (3):
177 Nm {18 kgm}

3 Bolt (1), (2), (3):
Upper right rear
177 Nm {18 kgm}
Upper left front
Upper right front
Upper left rear
8 WA800-3E0, WA900-3E0
3. Tightening of the lower bolt 9) Tighten bolts clockwise in the order of (1),
a Check "4. Precautions" in advance. (2), (3). Perform this for 3 times.
1) Tighten bolts (1), (2) and (3) by using 3 Bolt (1), (2), (3):
ratchet wrench. 177 Nm {18 kgm}
3 Bolt (1), (2), (3):
39 Nm {4 kgm}
a Tightening torque of 39 Nm {4 kgm}:
Tighten to the operating effort of 20
kg by using ratchet wrench of L =
200.
Then, tighten them at 3 places clockwise
in the order of (1), (2), (3), (1), (2), (3) by
using ratchet wrench.
3 Bolt (1), (2), (3):
39 Nm {4 kgm}
2) Tighten bolts once clockwise in the order

of (1), (2), (3) by using torque wrench. Lower left front
3 Bolt (1), (2), (3):
98 Nm {10 kgm}
3) Hit each part of (E), (F), (G) twice by using

plastic hammer. Perform this for 2 times.

3 Bolt (1), (2), (3):
98 Nm {10 kgm}

(2), (3). Perform this for 3 times. Lower right front
3 Bolt (1), (2), (3):
147 Nm {15 kgm}

3 Bolt (1), (2), (3):
177 Nm {18 kgm}

3 Bolt (1), (2), (3):
196 Nm {20 kgm}
8) Loosen bolt (1) temporarily, apply adhe- Lower left rear

2 Bolt (1), (2), (3):
Adhesive (LOCTITE #262)
3 Bolt (1), (2), (3):
177 Nm {18 kgm}
Lower right rear
WA800-3E0, WA900-3E0 9
4. Precautions
1) Install taper collet (4) so that its slit (part B) 5) The height to start hitting the plastic ham-
faces inside of machine. mer (dimension H) is 150 mm.
2) Note that there is no clearance or slant 6) Degrease the bolts and holes before start-
between the frame and the collet (part Y) ing the work.
when they are assembled temporarily
before tightening. 7) Apply LM-P to the inner surface of bush-
ing on cylinder side and to the dust seal lip
3) The above mentioned clearance or slant before installing the pin. (Part a)
must not be found both during and after 2 Part a:
tightening. Lubricant (LM-P)
Install dust seal (5) with its lip out. (View
4) Use plastic hammer [1] of the following P)
size.
q Dimension 8) Do not allow adhesion of lubricant as
L: 320 mm grease, etc. to the pin and the taper face
D: 38mm of the collet. (Part b)
10 WA800-3E0, WA900-3E0
[*2] a Do not allow any lubricant to attach to taper

3 Drive shaft mounting bolt: surface (f) of upper hinge pin (1).
343 – 427 Nm {35.0 – 43.5 kgm} a Tighten bolts (4) lightly.
a Tighten each bolt (4) once in the order of (A),
[*3] (B), (C), (D), (E), and (F).
2 Outer circumference of lower hinge pin: Then, tighten each of it three times in the order
Lubricant (LM-P) of (A), (C), (E), (B), (D), and (F).
a Install the retainer to the lower hinge pin with- 2 Adhesive: (LT-2)
out using shims, then tighten it to the specified 3 Mounting bolt:
torque. 98.1 ± 9.8 Nm {10.0 ± 1.0 kgm}
a Jack up the front frame until the spacer a Furthermore, tighten each bolt (4) once in the
reaches the rear frame hinge. order of (A), (B), (C), (D), (E), and (F).
a Tap the lower hinge pin head with a copper Then, tighten each of it in the order of (A), (C),
hammer so that the mounting bolt will be tight- (E), (B), (D), and (F) until all of the bolts cannot
ened to the specified torque, then tighten the be turned.
bolt to the specified torque. 3 Mounting bolt:
a Before installing the retainer, measure its thick- 549.0 ± 59.0 Nm {56.0 ± 6.0 kgm}
ness to select shims. a Check that the clearance (g) between the
3 Mounting bolt: retainer and the bushing is within 3 to 7 mm. If
(Shaft side) 1,520 – 1,910 Nm {155 – 195 kgm} the clearance (g) is 3 mm or less, remove the
(Frame side) 824 – 1,030 Nm {84 – 105 kgm} grease because it may have attached to taper
a Remove the all outside mounting bolts and surface (f) of the upper hinge pin (1), and
measure clearance (c) between the retainer tighten bolts (4) again.
and frame at 3 holes, then calculate the aver- If the clearance (g) is 7 mm or more, loosen
age. bolts (4) because they may have been tight-
Select shims so that the average clearance will ened insufficiently, and tighten them again.
be 0.08 – 0.18 mm.
a The thickness of the shims must not exceed

the clearance measured at the 3 places.
a Remove the grease from the mounting bolts
and mounting holes completely.
3 Mounting bolt:
927 ± 103 Nm {94.5 ± 10.5 kgm}
[*4]
a Install the retainer (2) to the upper hinge pin (1)
with bolts (3).
2 Adhesive: (LT-2)
3 Mounting bolt:
549.0 ± 59.0 Nm {56.0 ± 6.0 kgm}
a Apply lubricant to the outer circumference (e)
of upper hinge pin (1) and install the pin.
2 Outside of hinge pin: Lubricant (G2-LI)
WA800-3E0, WA900-3E0 11
a Tighten the 10 mounting bolts of the retainer,

and measure clearance (b) between the
retainer and hinge at 4 places. Then, select
shims so that clearance (b) will be 0.08 –
0.18 mm less than the measured value.
[*5]
a Press fit the bearing and spacer to the front
frame with tool K3.
a Be careful that the bearing is not at an angle.
a Fill inside of the bearing with grease suffi-
ciently.
a When installing the bearing, be sure to remem-
ber to install the spacer.
a The clearance of the bearing is adjusted, so do
not change the combination of bearing and the
spacer. When replacing, replace as a set.
a Press fit so that the lip of the dust seal is facing
outside.
2 Dust seal lip face: Lubricant (G2-LI)
12 WA800-3E0, WA900-3E0
a The thickness of the shims must not exceed a Tighten the 6 mounting bolts of the retainer,
the clearance measured at the 4 places. and measure clearance (a) between the
a After selecting shims, tighten the retainer to the retainer and hinge at 4 places. Then, select
specified torque. shims so that clearance (a) will be 0.08 –
3 Mounting bolt (For adjusting shims): 0.18mm less than the measured value.
245 ± 25 Nm {25.0 ± 2.5 kgm}
4 Mounting bolt:
804 – 1,030 Nm {84 – 105 kgm}
a Press fit so that the lip of the dust seal is facing
outside.
2 Dust seal lip face: Lubricant (G2-LI)
a Install the spacer with the more chamfered
side on the bearing side.
2 Inside of spacer: Lubricant (G2-LI)
[*6]
a Install tool K1 to the top of the front frame
upper hinge, then set the bearing. Press fit the
bearing to the press fit part from above.
a Be careful that the bearing is at an angle. a The thickness of the shims must not exceed
a Fill inside of the bearing with grease suffi- the clearance measured at the 4 places.
ciently. a After selecting shims, tighten the retainer to the
a When installing the bearing, be sure to remem- specified torque.
ber to install the spacer. 3 Mounting bolt (For adjusting shims):
a The clearance of bearing is adjusted, so do not 78 ± 7.8 Nm {8.0 ± 0.8 kgm}

change the combination of it and the spacer. 3 Mounting bolt:
When replacing, replace as a set. 490 – 608 Nm {50 – 62 kgm}

a Press fit so that the lip of the dust seal is facing a Press fit so that the lip of he dust seal is facing
outside. outside.
2 Dust seal lip face: Lubricant (G2-LI) 2 Dust seal lip face: Lubricant (G2-LI)
q Refilling with oil

Add oil through the oil filler of the hydraulic
tank to the specified level.
a Before starting the engine, bleed air from
the piston pump circuit. For details, see
Testing and adjusting.
a After bleeding air, run the engine to circu-
late the hydraulic oil through the system.
Then, check the oil level again.
q Bleeding air
Bleed air from the brake system.
a For the air bleeding procedure, see Test-
ing and adjusting.
q Filling with refrigerant (R134a)

a Fill the air conditioner circuit with the
refrigerant (R134a).
WA800-3E0, WA900-3E0 13

counterweight assembly 1
Removal
k Stop the machine on level ground, install
the lock bar on the frame, and put blocks
under the wheels to prevent the machine
from moving.
1. Sling counterweight (1), then remove mounting

bolts, and lift off.
a When lifting off the counterweight, be
careful to maintain the balance.
4 Counterweight:
2,200 kg (WA800-3E0)
2,200 + 2,600 kg (WA900-3E0)
Installation

removal.
[*1]
3 Counterweight mounting bolt:
1,510 – 1,910 Nm {155 – 195 kgm}
14 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 15
SEN02746-03

© 2013 KOMATSU
All Rights Reserved
16
SEN02747-03
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Hydraulic system
Removal and installation of hydraulic tank and filter case assembly .............................................................. 2
Removal and installation of hydraulic pump assembly ................................................................................... 4
Removal and installation of work equipment control valve assembly ............................................................. 7
Disassembly and assembly of work equipment control valve assembly......................................................... 9
Disassembly and assembly of PPC valve assembly .................................................................................... 12
Removal and installation of steering valve assembly ................................................................................... 13
Removal and installation of diverter valve assembly .................................................................................... 15
Disassembly and assembly of diverter valve assembly................................................................................ 16
Removal and installation of Orbit-roll assembly ............................................................................................ 18
Removal of steering stop valve..................................................................................................................... 20
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 21
WA800-3E0, WA900-3E0 1
Removal and installation of 2. Remove step (3) on the top of the hydraulic
hydraulic tank and filter case tank.
assembly 1 4 Step: 150 kg
Removal
k Stop the machine on level ground and 3. Remove ladder (4) from hydraulic tank.
lower the work equipment completely to the 4 Ladder: 45 kg
a Observe the following points to protect the

hydraulic equipment when disassembling and
assembling it.
q Before disassembling any part, clean the
machine body, particularly around that
part.
q When disassembling and assembling the
hydraulic equipment, do not let dust in the
hydraulic circuit.
q Perfectly clean the parts, particularly the
circuits and parts in the trouble section.
q Before disassembling or after cleaning the
hydraulic equipment, mask the all open- 4. Disconnect tube (5) between the hydraulic tank
ings of the piping and hydraulic parts. and hydraulic pump from the hydraulic tank.
k Loosen the oil filler cap to release the pres- 5. Disconnect tube (6) between the hydraulic tank
sure from the hydraulic tank, then operate and PPC pump from the hydraulic tank.
the steering wheel and work equipment
control lever 2 – 3 times to release the pres-
sure from the piping.
1. Draining oil
Remove plug (1), then loosen plug (2) and
drain hydraulic oil.
6 Hydraulic tank: 725 l
6. Disconnect tubes (7) and (8) between the

hydraulic tank and diverter valve from the
hydraulic tank.
2 WA800-3E0, WA900-3E0
7. Disconnect return tube (9) between the work Installation

equipment valve and hydraulic tank from the
hydraulic tank. q Carry out installation in the reverse order to
removal.
[*1]
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
q Refilling with oil (Hydraulic tank)

1) Add hydraulic oil to the specified level.
2) Before starting the engine, bleed air from
the steering pump, switch pump and
loader pump. (For details, see Testing and
adjusting, "Bleeding air from piston
pump".)
3) Run the engine to circulate the oil through
8. Disconnect return tube (10) between the oil the system. Then, check the oil level
cooler and hydraulic tank from the hydraulic again.
5
tank. Hydraulic tank: 725 l
9. Temporarily sling hydraulic tank and filter case

assembly (11).
10. Remove mounting bolts (12) and (13), then

remove hydraulic tank and filter case assembly
(11). [*1]
4 Hydraulic tank and filter case assembly:
900 kg
WA800-3E0, WA900-3E0 3
Removal and installation of 4. Loader pump

hydraulic pump assembly 1 1) Disconnect suction tube (2).
2) Disconnect 2 hoses (3) between the
Removal switching pump E.S. valve and loader
k Stop the machine on level ground and pump E.S. valve.
1. Drain oil from the hydraulic tank.

6 Hydraulic tank: 725 l
2. Remove step (1) from the rear of the cab.
3) Remove bracket (4), then disconnect con-

trol pump discharge tube (5).
4) Disconnect clamp (6).
5) Disconnect 2 discharge hoses (7).
6) Disconnect drain hose (8).
7) Disconnect 2 hoses between the active
power max. solenoid valves.
8) Sling loader pump (9) and lift it off.
4 Loader pump: 160 kg
3. For the location of each PTO pump, see the
figure below.
q (a): Switch pump
q (b): Loader pump
q (c): Torque converter, transmission, and
PPC pump
q (d): Steering pump
4 WA800-3E0, WA900-3E0
5. Switching pump 6. 4-unit (Torque converter, transmission,

1) Disconnect 2 discharge hoses (10). PPC, brake) pump assembly
2) Disconnect control pump discharge tube a Remove the switching pump in advance.
(11). 1) Disconnect suction tubes (16) and (17) of
the torque converter and transmission
pump.
2) Disconnect suction tube (18) of the PPC
pump.
3) Disconnect suction tube (19) of the brake
pump.
3) Disconnect suction tube (12).

4) Disconnect drain hose (13).
5) Disconnect 2 hoses (14) of the loader
pump E.S. valve.
6) Disconnect 2 hoses between the active
power max. solenoid valves.
7) Sling switching pump (15) and lift it off. 4) Disconnect tube (20) of the accumulator
4
charge valve.
Switching pump: 160 kg
5) Disconnect tube (21) of the PPC.
6) Disconnect tubes (22) and (23) of the
torque converter and transmission.
7) Sling 4-unit pump assembly (24) and lift it
off.
4 4-unit pump assembly: 60 kg
WA800-3E0, WA900-3E0 5
7. Steering pump assembly Installation

a Remove the loader pump in advance.
1) Disconnect drain hose (25). q Carry out installation in the reverse order to
2) Disconnect 2 discharge tubes (26). removal.
q Refilling with oil (hydraulic tank)

Refill hydraulic oil through the oil filler port to
the specified level. Let the oil circulate in the
piping by starting the engine. Then check the
oil level again.
q Bleeding air
Bleed air from each part. For details, see Test-
ing and adjusting, "Bleeding air from piston
pump".
3) Remove bracket (27).

4) Disconnect suction tube (28).
5) Sling steering pump (29) and lift it off.
4 Steering pump: 150 kg
6 WA800-3E0, WA900-3E0
Removal and installation of work 2. Hydraulic piping

equipment control valve Disconnect the following hydraulic piping from
work equipment control valve.
assembly 1 1) Hoses (1A) and (2) between steering
Removal demand valve and work equipment control
k Stop the machine on level ground and valve. Disconnect them on the side of the
install the lock bar on the frame. Lower the work equipment control valve.
work equipment to the ground and stop the 2) Hoses (3) and (4) between work equip-
engine. Then apply the parking brake and ment control valve and bucket cylinder.
put blocks under the wheels to prevent the Disconnect them on the side of the work
machine from moving. equipment control valve.
3) Tubes (7) between work equipment con-
a To keep the hydraulic circuits clean and to pro- trol valve and the hydraulic oil tank. Dis-
tect the hydraulic equipment, be careful of the connect them on the side of the work
following points when disassembling or assem- equipment control valve.
bling. a Remove the clamp before removing
q Before disassembling, wash the machine. the tube.
Be particularly careful to completely clean 4) Tubes (5) and (6) between work equip-
the area that is to be disassembled. ment control valve and the lift cylinder.
q Do not let dirt or dust get into the hydraulic Disconnect them on the side of the work
circuits when disassembling or assem- equipment control valve.
bling. a Remove the clamp before removing
q Carry out thorough flushing of the parts, the tube.
and be particularly careful to do this thor- a Cover pipings disconnected with blind
oughly for the circuits or parts that have plugs to prevent dust in them.
failed.
q When disassembling or after flushing,
always mask the openings of the piping or
hydraulic equipment completely.
k Loosen the oil filler cap to release the pres-

sure from the hydraulic tank, then operate
the steering wheel and work equipment
sure from the piping.
1. Cover
Remove cover (1) from the front frame.
WA800-3E0, WA900-3E0 7
3. PPC piping 4. Work equipment control valves

Disconnect the following PPC pipings from the Screw eyebolts into work equipment control
work equipment control valve. valves, remove mounting bolts, then raise work
1) Tubes (8) and (9) between PPC valve and equipment control valves (13) and (14) and
the dump spool piston remove to outside of frame.
4
2) Tubes (10) and (11) between PPC valve
Work equipment control valve:
and the lift spool piston
90 kg (1 piece)
a Cover pipings disconnected with blind
a When raising the valve, be careful not to
plugs to prevent dust in them.
hit the valve against the frame. Also be
a Attach tag plate and others to tubes
careful not to get your fingers caught.
disconnected to distinguish attaching
positions.
Installation

a Before starting the engine, bleed air from
the piston pump circuit. For details, see
Testing and adjusting.
a After bleeding air, run the engine to circu-
late the hydraulic oil through the system.
Then, check the oil level again.
q Bleeding air
Bleed air from the brake system.
a For the air bleeding procedure, see Test-
ing and adjusting.
8 WA800-3E0, WA900-3E0
Disassembly and assembly of 6. Remove plate (12) from valve body (1), then
work equipment control valve remove spring (13) and check valve (14).
assembly 1 7. Remove flange (15) from valve body (1), then
Disassembly remove spring (16), seal (17) and valve (18).
1. Remove hose (2), T-piece (3) and valve (4)
from valve body (1).
2. Remove hose (5), T-piece (6) and joint (7) from

valve body (1).
3. Remove suction valve (8) and 2 safety valves

(9) having the suction tube from valve body (1).
a Since the safety valve cannot be adjusted
actually, do not disassemble it.
4. Remove plug (10) from the valve body.
5. Remove main relief valve (11) from valve body

(1). 8. Remove elbows (19) and (20) from cases (21)
and (26).
9. Remove case (21) from valve body (1), then

remove springs (22) and (23), retainer (24) and
spool (25).
10. Remove case (26) from valve body (1), then

remove springs (27) and (28) and retainer (29).
11. Remove plug (30) from valve body (1).
WA800-3E0, WA900-3E0 9
12. Loosen nut (33) of main relief valve (11), then Assembly
divide it into holder (31A) and sleeve (32A).
1. Assembly of sleeve (32A)
13. Remove nut (33) from holder (31A). 1) Install backup ring (44), spring (43) and
valve (42) to sleeve (32), then secure
14. Remove nut (34) from holder (31A), then them with snap ring (41).
remove screw (35), retainer (36), spring (37) 2) Install the O-ring to seat (39), then install
and poppet (38). them and backup ring (40) together to
sleeve (32).
2. Assembly of holder (31A)

1) Install the O-ring and poppet (38), spring
(37), retainer (36) and screw (35) to holder
(31).
2) Install nut (33) to holder (31A).
15. Remove seat (39) and backup ring (40) from

sleeve (32A).
16. Remove snap ring (41) from sleeve (32A), then

remove valve (42), spring (43) and backup ring
(44).
a If sleeve (32) or valve (42) has any trou- 3. Install holder (31A) to sleeve (32A).
ble, replace as a set, since those parts are
not supplied independently.
10 WA800-3E0, WA900-3E0
4. Insert retainer (29), springs (28) and (27) in 12. Install safety valve (9) having the suction tube
valve body (1). Install the O-ring to case (26), to valve body (1).
then install them to the valve body. 3 Safety valve (9) having suction tube:
186 ± 10 Nm {19 ± 1 kgm}
5. Insert spool (25), retainer (24) and springs (23)
and (22). Install the O-ring to case (21), then 13. Install suction valve (8) to valve body (1).
install them to the valve body (1). 3 Suction valve (8):
186 ± 10 Nm {19 ± 1 kgm}
6. Install elbows (19) and (20) to cases (21) and
(26). 14. Install joint (7) and T-piece (6) to valve body
3 Elbows (19), (20): (1), then connect hose (5) between elbow (20)
90.7 ± 12.3 Nm {9.25 ± 1.25 kgm} and T-piece (6).
a When clamping the hose, be careful not to
7. Install plug (30) to valve body (1). twist it.
3 Plug (30):
152 ± 24 Nm {15.5 ± 2.5 kgm} 15. Install valve (4) and T-piece (3) to valve body
(1), then connect hose (2) between elbow (19)
and T-piece (3).
3 Valve (4):
68.7 ± 9.8 Nm {7.0 ± 1.0 kgm}
3 T-pieces (3), (6):
34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}
3 Hoses (2), (5):
49.0 ± 19.0 Nm {5.0 ± 2.0 kgm}
3 Joint (7):
34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}
8. Insert valve (18), seal (17) and spring (16) in

valve body (1), then install the O-ring to flange
(15).
9. Insert check valve (14) and spring (13) in valve

body (1), then install the O-ring to plate (12).
10. Install main relief valve (11) to valve body (1).

3 Main relief valve (11):
324 ± 44 Nm {33.0 ± 4.5 kgm}
11. Install plug (10) to valve body (1).

3 Plug (10):
68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
WA800-3E0, WA900-3E0 11
Disassembly and assembly of Assembly

PPC valve assembly 1 1. Assembly of piston
Assemble the following parts to piston (12).
Disassembly 1) Assemble shim (11), spring (10), and main
1. Remove bolt (1), then remove plate (2). spring (9).
2) Push down retainer (8), and install collar
2. Remove seal (3), then remove collar (4). (7).
3. Remove piston (5). 2. Assemble valve (16), spring (15), and retainer
(14) to body (17).
4. Disassembly of piston
Remove the following parts from piston assem- 3. Install snap ring (13).
bly (6).
1) Push down retainers (8), and remove col- 4. Assemble piston assembly (6).
lar (7).
2) Remove retainers (8), main spring (9), 5. Install piston (5), then install collar (4) and seal
spring (10), shim (11), and piston (12). (3).
5. Remove snap ring (13). 6. Align with dowel pin, and install plate (2), then
install bolt (1).
6. Remove retainer (14), spring (15), and valve 3 Bolt: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
(16) from body (17).
12 WA800-3E0, WA900-3E0

steering valve assembly 1
Removal
k Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
Then operate the steering wheel and the
control levers 2 – 3 times to release the
remaining pressure in the hydraulic piping. 6) Remove tube (8) between steering valve
(T port) and return port of hydraulic oil
1. Step tank.
Remove step (1) on cab front. 7) Remove tubes (9) and (10) between orbit-
roll and steering valve pilot circuit.
a Remove the tube clamp in advance.
2. Hydraulic piping
Disconnect the following tubes from steering
valve. 3. Steering valve
1) Remove tube (2) between steering valve Sling steering valve temporarily, remove
(P2 port) and switch pump. mounting bolts (11), then remove steering
2) Remove tube (3) between steering valve valve (12).
(P1 port) and steering pump.
4 Steering valve: 70 kg
3) Remove tube (4) between steering valve
(P, B port) and work equipment valve.
4. Bracket
a Remove the bolts of bracket (5) for
Remove bracket (13) from steering valve (12).
fixing tube (4) in advance.
(A port) and steering cylinder.
(B port) and steering cylinder.
WA800-3E0, WA900-3E0 13
Installation

removal.

q Bleeding air
Before starting the engine, bleed air from the
steering pump, switch pump and work equip-
ment pump.
a See Testing and adjusting.
a Run the engine to circulate the oil through
the system. Then, check the oil level
again.
14 WA800-3E0, WA900-3E0

diverter valve assembly 1 q Carry out installation in the reverse order to
removal.
Removal
the ground, then put blocks under the
wheels to prevent the machine from mov-
ing.
k Gradually loosen the cap of the hydraulic
tank to release the pressure from the tank.
1. Disconnect hose (1) of the hydraulic tank.
2. Disconnect tube (2) of the steering valve.
3. Disconnect hoses (3) and (4) of the emergency

steering pump.
4. Disconnect tube (5) of the hydraulic tank.
5. Disconnect connector (6) (R01).
6. Disconnect hose (7) of the steering pump.
7. Disconnect hose (8) of the hydraulic tank.
8. Remove the mounting bolt, then remove

diverter valve (9).
4 Diverter valve: 70 kg
WA800-3E0, WA900-3E0 15
Disassembly and assembly of 4) Remove cover (11) from valve body (2),
diverter valve assembly 1 then remove spring (12) and check valve
(13).
Disassembly 5) Remove O-ring (14) from cover (11), then
1. Remove mounting bolt (1), then disconnect remove backup ring (15).
selector valve (3) from check valve (2).
3. Disassembly of selector valve

2. Disassembly of check valve 1) Remove cover (16) from valve body (3),
1) Remove spring (5) and check valve (4) then remove O-ring (17) and spool (18)
from valve body (2). from valve body (3).
2) Remove cover (6) from valve body (2), 2) Remove cover (19) from valve body (3),
then remove spring (7) and check valve then remove spring (20) and retainer (21).
(8). 3) Remove O-ring (22) from cover (19).
3) Remove O-ring (9) and backup ring (10)
from cover (6).
16 WA800-3E0, WA900-3E0
Assembly
1. Assembly of check valve
1) Assemble check valve (8) and spring (7)
to valve body (2).
2) Install backup ring (10) and O-ring (9) to
cover (6), then install them to valve body
(2).
2. Assembly of selector valve

1) Install spool (17) to valve body (3).
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
2) Install O-ring (18) to valve body (3), then
install cover (16).
3) Assemble check valve (13) and spring

(12) to valve body (2).
cover (11), then install them to valve body
(2).
3) Assemble retainer (21) and spring (20) to

valve body (3).
4) Install O-ring (22) to cover (19), then
install them to valve body (3).
3 Mounting bolt:
58.8 – 73.6 Nm {6.0 – 7.5 kgm}
5) Assemble check valve (4) and spring (5)
to valve body (2).
6) Install the O-ring to selector valve body
(3), then install bolt (1) to check valve (2).
3 Mounting bolt: 98.1 Nm {10 kgm}
WA800-3E0, WA900-3E0 17
Removal and installation of Orbit- 4. Disconnect hose (4) of the accumulator.

roll assembly 1
(Steering wheel specification) 5. Disconnect hose (5) of the right-hand stop
valve.
Removal
k Stop the machine on level ground and 6. Disconnect hose (6) of the left-hand stop
lower the work equipment completely to the valve.
to prevent the machine from moving. 7. Disconnect drain hose (7).
terminal of the battery. 8. Remove mounting bolt (8), then remove Orbit-
1. Remove cover (1) from the steering column. roll (9) and bracket together. [*2]
2. Loosen joint lock bolt (2). [*1] 9. Loosen lock bolt (10), then remove joint (11).
10. Remove bolt (12), then remove bracket (13)

from Orbit-roll (9).
3. Remove cover (3) under the cab.
18 WA800-3E0, WA900-3E0
Installation

removal.
[*1]
3 Joint lock bolt:
55.9 ± 7.8 Nm {5.7 ± 0.8 kgm}
[*1]
3 Bracket mounting bolt:
51.9 ± 7.8 Nm {5.3 ± 0.8 kgm}
q Bleeding air
Bleed air from the steering circuit. For details,
see Testing and adjusting, "Bleeding air from
each portion".
WA800-3E0, WA900-3E0 19
Removal of steering stop valve 1
k stop the machine on level ground and

1. Disconnect hose (1) of the steering valve.
2. Disconnect hose (2) of the orbit-roll.
3. Disconnect drain hose (3).
4. Remove mounting bolt (4), then remove steer-

ing stop valve (5).
Installtion of steering stop valve 1

removaI.
a Check the stop valve. For details, see TEST-

ING AND ADJUSTING, Adjustment of stop
valve.
20 WA800-3E0, WA900-3E0
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1 1. Cylinder assembly
1) Set cylinder assembly (1) on Tool U1.
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
Cylinder repair
1 790-502-1003 stand q 1
790-720-1000 Expander t 1
2 796-720-1680 Ring t 1
07281-01589 Clamp t 1
796-720-1710 Ring t 1
3
07281-02709 Clamp t 1
2) Remove mounting bolts (2) of head cover.
796-720-1730 Ring t 1
4
07281-03209 Clamp t 1
790-201-1500 Push tool KIT t 1
790-201-1660 • Plate 1
5
790-101-5021 • Grip 1
01010-50816 • Bolt 1
792-103-3601 Push tool t 1
U 6 792-103-0400 • Grip t 1
791-863-1140 Push tool t 1
7 790-101-5221 • Grip t 1
01010-51225 • Bolt t 1
790-201-1702 Push tool KIT t 1
3) Pull out piston rod (3) from cylinder.
790-201-1851 • Push tool 1
8 a When pulling out the rod, the oil
790-101-5021 • Grip 1 remaining inside the cylinder will
01010-50816 • Bolt 1 come out, so catch it in a container.
792-103-4102 Push tool t 1 a If the piston rod cannot be pulled
smoothly out of the cylinder, rotate
9 790-101-5421 • Grip t 1
the piston rod slightly when pulling
01010-81235 • Bolt t 1 out.
4
792-625-1300 Push tool t 1
Steering cylinder piston rod assem-
10 790-101-5421 • Grip t 1 bly: 90 kg
4
01010-81235 • Bolt t 1
Dump cylinder piston rod assem-
bly: 520 kg
4 Lift cylinder piston rod assembly:
450 kg
a Remove the cylinder from tool U1.
WA800-3E0, WA900-3E0 21
4. Head cover
1) Remove O-ring (12) and backup ring (13).
2) Remove snap ring (14), then pull out dust
seal (15), rod packing (16), backup ring
(17), and bushing (18) from head cover
(19).
2. Piston rod
1) Remove spacer mounting bolts (4), then
remove spacer (5).
2) Pull out piston (6) and head cover (19).
3) Remove O-ring (8) and backup rings (7)
and (9) from piston rod (3).
3. Piston
1) Remove wear ring (10) from piston (6).
2) Remove piston ring (11).
22 WA800-3E0, WA900-3E0
Assembly 2) Remove piston ring (11) from tool, and

a Coat the sliding surfaces of all parts with install on piston (6).
hydraulic oil before installing. Be careful not to 3) Using tool U3, tighten piston ring (11).
damage U-packings, dust seals or O-rings
when installing.
1. Head cover
1) Press fit bushing (18) in head cover (19),
and install backup ring (17), rod packing
(16), dust seal (15), and snap ring (14).
a Be careful not to deform the bushing
when press fitting.
head cover (19).
a Do not try to force the backup ring
into position. Warm it in warm water
(50 to 60°C) before fitting it.
4) Install wear rings (10) to piston (6).
2. Piston
1) Set piston ring (11) on tool U2 and expand
it.
a Set the piston ring on the expander
and turn the handle 8 – 10 times to
expand the ring.
WA800-3E0, WA900-3E0 23
3. Piston rod 3) Tighten head cover mounting bolts (2).

1) Install head cover (19) to cylinder rod (3). a Coat the O-ring and backup ring on
2) Install O-ring (8) and backup rings (7) and the cover side with grease.
(9) to rod. 3 Steering cylinder mounting bolt:
a Coat the backup ring with grease to 461 ± 14 Nm {47.0 ± 1.45 kgm}
prevent it from protruding, and (width across flats: 30 mm)
assemble it carefully. 3 Dump cylinder mounting bolt:
2 Backup ring, O-ring: 2,450 ± 250 Nm {250 ± 25 kgm}
Grease (G2-LI) (width across flats: 55 mm)
3) Install piston (6). 3 Lift cylinder mounting bolt:
4) Set spacer (5) in position, and tighten 1,550 ± 170 Nm {157.5 ± 17.5 kgm}
spacer mounting bolts (4). (width across flats: 46 mm)
a Remove all oil and grease from the 4) Remove cylinder assembly (1) from tool
mounting bolts and mounting holes. U1.
2 Mounting bolt:
Adhesive (Locktite 262)
3 Mounting bolt:
110 ± 12 Nm {11.25 ± 1.25 kgm}
(Steering cylinder)
3 Mounting bolt:
277 ± 32 Nm {28.25 ± 3.25 kgm}
(Lift, dump cylinder)
4. Cylinder assembly
1) Set cylinder in tool U1.
2) Assemble piston rod (3) in cylinder.
24 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 25
SEN02747-03

© 2017 KOMATSU
All Rights Reserved
26
SEN02748-01
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Work equipment
Removal and installation of work equipment assembly .................................................................................. 2
Replacement of boom front bushing ............................................................................................................... 7
WA800-3E0, WA900-3E0 1
Removal and installation of work

equipment assembly 1
Special tools
New/Remodel
Necessity
Sym
Part No. Part name
Sketch
bol
Q'ty
793T-870-1110 Sleeve t 1 N Q
793T-870-1120 Plate t 1 N Q
791-745-2110 Adapter t 1
790-438-1110 Screw t 1
790-101-2540 Washer t 1
V 1
02215-11622 Nut t 1
01010-81655 Bolt t 3
01640-21626 Washer t 3
790-101-2102 Puller t 1
790-101-1102 Pump (30 tons) t 1
Removal
put blocks under the wheels to prevent the 2. Bucket
k
1) Move cord ring (6) toward the bucket.
Loosen the oil filler cap to release the pres- 2) Remove lock bolts (7) of the pins on left
sure from the hydraulic tank, then operate and right sides, then slowly pull out
the steering wheel and work equipment mounting pins (8). [*2]
sure from the piping. 4 Mounting pin: 75 kg
a Check the quantity of shims (9)
1. Bucket link between the bucket and lift arm, and
1) Move cord ring (1) toward the bucket. use it as the standard value for
2) Temporarily sling bucket link (4) and assembly.
remove lock bolt (3). Then, slowly pull 3) Move the machine in reverse to discon-
mounting pin (2) out of the bucket link, and nect the bucket.
disconnect bucket link. [*1]
4 Mounting pin: 90 kg
a Check the quantity of shims (5)
between the bucket link and bucket,
and use it as the standard value for
assembly.
2 WA800-3E0, WA900-3E0
3. Bucket link 2) Temporarily sling dump cylinder (11) and

Temporarily sling bucket link (4) and slowly pull slowly pull out mounting pin (12), then dis-
out the mounting pin, then lift out the bucket connect the cylinder rod and bell crank.
link from the bell crank. a Disconnect grease hose (13) from the
a Remove the cord ring from the joint in pin.
advance. a Do not pull out the pin completely.
a Insert mounting pin (10) in the pinhole of After disconnecting the dump cylin-
the bell crank and tighten the lock bolt der, insert the pin in the bell crank
lightly. mounting portion, then install the lock
4
bolt.
Bucket link: 450 kg
3) Raise the dump cylinder and lock it with

4. Dump cylinder the lever block.
1) Put block [1] between the bell crank and a Be sure to lock the cylinder for safety.
lift arm to lock the bell crank.
a When the dump cylinder pin is
removed, the bell crank falls down
toward the machine. Accordingly, be
sure to lock the bell crank.
WA800-3E0, WA900-3E0 3
5. Lift cylinder pin 6. Lift arm and bell crank

1) Raise the lift arm until pin (14) exceeds 1) Remove boom kick-out switch (18).
the height of the fender, then temporarily a Remove the cover, then remove the
sling the lift arm and bell crank. switch.
2) Disconnect grease tube (15) from the
mounting pin.
4 Lift arm and bell crank: 9,600 kg
2) Remove stays for the lights on left and

right sides.
a Disconnect connectors (19) (CN-F01,
02, 03, 04) on left and right sides in
3) Support lift cylinder (16) on the lever block
advance.
at the rear and remove the lock bolt, then
3) Disconnect both grease tubes (20) from
slowly pull the pin out of the cylinder.
mounting pins, then remove grease nipple
a After removing the lift cylinder, insert
(21).
both mounting pins (17) in the lift arm
pinholes and tighten the lock bolts
lightly.
4) Slowly pull out left and right mounting pins

(22), then sling and remove lift arm and
bell crank (23).
a If shims are installed between the
front frame and lift arm, check its
quantity.
a Sling right and left mounting pins and
lift them off.
4 WA800-3E0, WA900-3E0
2) Pull dust seal (31) and bushing (32) out of

bell crank (24).
7. Bell crank
Slowly pull out the mounting pin, then sling the
bell crank (24) from lift arm and lift it off. 3) Remove dust seal (33) and bushing (34)
a Do not pull out mounting pin (25) com- from bucket link (4).
pletely. After removing the bell crank, sling a Remove dust seal (35) and bushing
and lift off the mounting pin. (36) from the joint of the bell crank
4
and ring.
Bell crank: 1,800 kg
a If the pin cannot be pulled out easily

because of its wear after long use,
make and use tool V1.
8. Dust seal and bushing
1) Pull dust seal (27) and bushing (28) out of
lift arm (26).
a Remove dust seal (29) and bushing
(30) from the joint of the lift arm and
frame.
WA800-3E0, WA900-3E0 5
Installation

removal.
k When aligning the position of the pin hole,

use a bar. Never put your fingers on the pin
hole.
a When installing the pins and bushings,
apply grease to them.
2 Pin, bushing: Lubricant (G2-LI)
[*1]
a Assemble shims evenly in (a) and (b).
a Reduce the clearance to below 1.5 mm.
[*2]
a Assemble shims evenly in (a) and (b).
a Reduce the clearance to below 1.5 mm.
q Supplying grease
Supply grease to each mounting portion.
6 WA800-3E0, WA900-3E0
Replacement of boom front 3) Set tool V2.

bushing 1 4) Pull out bushing (2) by operating the
puller.
Special tools 5) After bushing (2) comes out by the stroke,
tighten the puller piston and add the
New/Remodel
spacer, then tighten the nut.
a Stroke of puller: 15 mm
Necessity
Sym
Part No. Part name
Sketch
bol
Q'ty
793T-870-1130 Sleeve t 1 N Q
793T-870-1140 Plate t 1 N Q
793T-870-1150 Plate t 1 N Q
01580-13024 Nut t 2
V 2 01643-33080 Washer t 2
791-650-1240 Spacer t 2
791-650-1230 Bolt t 1
790-314-1000 Puller (80 tons) t 1
790-101-1102 Pump (30 tons) t 1
2. Press fitting of bushing
1. Pulling out bushing
1) Set tool V2.
1) Clean the lift arm end.
2) Press fit bushing (2) by operating the
2) Remove dust seal (1).
puller.
a Check that bushing (2) is press fitted
evenly while operating the puller.
3) After bushing (2) is press fitted by the
stroke, tighten the puller piston and add
the spacer, then tighten the nut.
4) Install dust seal (1).
WA800-3E0, WA900-3E0 7
SEN02748-01

© 2009 KOMATSU
All Rights Reserved
8
SEN02749-02
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Cab and its attachments
Removal and installation of operator cab assembly ....................................................................................... 2
Removal and installation of floor frame assembly .......................................................................................... 4
Disassembly and assembly of operator’s seat assembly ............................................................................... 7
Removal and installation of AJSS lever switch assembly ............................................................................. 40
WA800-3E0, WA900-3E0 1
Removal and installation of 4. DIsconnect window washer hose (4) at the

operator cab assembly 1 joint.
Removal
k Stop the machine on level ground, install
the lock bar on the frame, and put blocks
under the wheels to prevent the machine
from moving.
1. Remove covers (1) at bottom of floor frame.
5. Remove 2 steering post lock bolts (5).
2. Remove right cover (2) inside cab.
6. Remove plastic mounting bolts and pull up rub-

ber boot (6) at bottom of steering post.
3. Disconnect electric wiring connectors (3).

Connectors: CN-CL1, CL2, CL3, CL4, CL5,
CL8, SL1, GND1.
2 WA800-3E0, WA900-3E0
7. Remove 4 bolts (7), then tip steering post over 9. Raise cab assembly (10) slowly and keep hori-
fully towards operator's seat. zontal when lifting off. [*1]
a At the same time, set the column tilt lever a Be careful that there is no interference
to the unlock position and tip the steering with the electric wiring at the rear right of
column over fully towards the operator's the floor frame.
seat. a Cover the steering post and plastic cover
with a sheet to prevent any damage.
4 Cab: 400 kg
8. Remove 2 cab mounting bolts (8) and 4 mount-

ing bolts each at intermediate position and
rear.
Installation

removal.
[*1]
q When installing the cab assembly, do not for-
get to install the seal.
a Coat the seal uniformly with adhesive.
2 Seal: Adhesive (Cemedyne 366E)
WA800-3E0, WA900-3E0 3
Removal and installation of floor 3. Disconnect assembly drain hoses (3) of the
frame assembly 1 right and left brake valves.
Removal 4. Disconnect hoses (4) and (5) between the

k Stop the machine on level ground and accumulator and right-hand brake valve.
ground, then put blocks under the wheels 5. Disconnect hose (6) between the accumulator
to prevent the machine from moving. and left-hand brake valve.
k Loosen the oil filler cap of the hydraulic
tank gradually to release the pressure in 6. Disconnect hoses (7) and (8) between the
the hydraulic tank right-hand brake valve and slack adjuster, then
k Operate the work equipment control lever 2 – remove clamp (9).
3 times to release the pressure in the PPC
k Release residual pressure in brake acccu-
mulator circuits. For detail, see Testing and
adjusting "Releasing residual pressure in
brake accumulator circuit".
advance.
atmosphere. 7. Disconnect hose (10) between the accumula-
k If the refrigerant gas (R134a) gets in your tor and Orbit-roll.
ingly, put on protective goggles while you 8. Disconnect hose (11) between the Orbit-roll
are collecting the refrigerant (R134a) or fill- and right-hand stopper valve.
refrigerant (R134a). Collecting and filling 9. Disconnect drain hose (12) of the Orbit-roll.
son. 10. Disconnect hose (13) between the Orbit-roll
and left-hand stopper valve.
1. Remove front, rear, right and left side covers
(1) under the cab. 11. Disconnect hose clamp (14).
2. Remove cab (2). For details, see “Removal

and installation of cab assembly”.
4 Cab assembly: 400 kg
4 WA800-3E0, WA900-3E0
12. Disconnect hoses (15) (Raise lift arm), (16) 18. Disconnect air conditioner hose (24). [*1]
(Dump), (17) (Lower lift arm) and (18) (Tilt) a Since the adapter is brittle, apply 2 span-
between the PPC valve and control valve. ners to it to disconnect each hose.
13. Disconnect hose (19) between the PPC valve

and PPC pump.
14. Disconnect PPC valve drain hose (20).
19. Disconnect connector (25), then remove wire

clamps (26), (27), (28) and move them toward
the body.
a Connector: CN-CBL1, LR1, LR2, V20,
FL1.
15. Disconnect ground cable (21). 20. Disconnect washer hose (29) at the joint.
16. Disconnect the frame side clamp of air condi-

tioner hose (22).
21. Remove 4 mounting nuts (30) of the floor

frame mount. [*2]
22. Sling and lift off floor frame (31).

a While slinging the floor frame slowly,
a Close the hot water outlet valve on the
check that all the clamps and harnesses
engine side.
are disconnected.
4 Floor frame: 240 kg
WA800-3E0, WA900-3E0 5
Installation
removal.
[*1]
a When connecting each hose, do not twist it.
a Be careful not to let dirt, dust, water, etc. get
into hoses.
a Fill the air conditioner circuit with the refriger-
ant (R134a).
[*2]
3 Mounting nut:
245 – 309 Nm {25.0 – 31.5 kgm}
q Bleeding air
see Testing and adjusting, "Bleeding air from
wheel brake circuit".
6 WA800-3E0, WA900-3E0
Disassembly and assembly of 2. Removal and installation of seat pad and

operator’s seat assembly 1 backrest upholstery
[ Manufactured by GRAMMER ]
a Although the machine of the joystick steering

specification is not equipped with the left arm-
rest, its operator's seat assembly are also dis-
assembled and assembled according to the
I. Upper seat
1. Removal and installation of storage box
Removal
1) Remove the storage box by referring to “1.
Removal and installation of storage box”.
2) Undo the 4 screws (1), and remove the
backrest upholstery (2).
3) Undo the 5 screws (4), and remove the
seat pad (5).
4) Disconnect the connectors (3) and (6).
Installation
1) Connect the connectors (3) and (6).
2) Install the seat pad (5), and fix it with the 5
Removal screws (4).
1) Open the storage box (1). 3) Install the backrest upholstery (2), and fix
2) Remove the hook (3). it with the 4 screws (1).
3) Undo the screws (2) and remove the stor- 4) Install the storage box by referring to “1.
age box (1). Removal and installation of storage box”.
Installation
1) Set the storage box (1) and fix it with the
screws (2).
2) Install the hook (3).
WA800-3E0, WA900-3E0 7
3. Removal and installation of mechanical 4. Removal and installation of armrests

lumbar support (If equipped)
Removal Removal
1) Remove the storage box by referring to “1. 1) Remove the cover (1).
Removal and installation of storage box”. 2) Unscrew the hexagon nuts (2) and
2) Remove the backrest upholstery by refer- remove the nuts and washers (3).
ring to “2. Removal and installation of seat 3) Remove the armrests (4).
pad and backrest upholstery".
3) Drill off the rivets (1), loosen the spring
steel sheets (2) from the L-bars (3) and Installation
remove them. 1) Set the armrests (4).
4) Unhook the L-bars (3) from the catch ele- 2) Put the washers (3) and tighten hexagon
ment (4). nuts (2).
5) Undo the hexagon socket screw (5) and 3 Hexagon nuts: 25 Nm {2.6 kgm}
remove the adjusting knob (6) with the 3) Install the cover (1).
toothed wheel (7).
6) Drill off the rivet (8), remove the wrap
spring brake element (9) and the catch
element (4).
Installation
1) Install the wrap spring brake element (9)
and the catch element (4), and fix them
with the rivets (8).
2) Install the adjusting knob (6) and the
toothed wheel (7), and tighten the hexa-
gon socket screw (5).
3) Install the catch element (4) to the L-bars
(3) and fix with the rivets (1).
4) Install the 2 spring steel sheets (2) to the
L-bar (3), and fix with the rivets (1).
5) Install the backrest upholstery by referring
to “2. Removal and installation of seat pad
and backrest upholstery”.
6) Install the storage box by referring to “1.
8 WA800-3E0, WA900-3E0
5. Disassembly and assembly of backrest
Removal a Insert the bearing (B/8) into the upper

1) Detach the storage box by referring to “1. hole on the backrest support on the
Removal and installation of storage box”. right side (figure B/4).
2) Remove the backrest upholstery by refer- 2) Press the backrest (1) slightly to the left
ring to “2. Removal and installation of seat and install it.
pad and backrest upholstery”. a The big cylindrical stamping on the
3) Remove the armrests by referring to “4. backrest adjustment (figure C/2) must
Removal and installation of armrests”. (If engage into the big positional bore
equipped) hole on the backrest support on the
4) Disassemble the backrest adjustment by left side (figure C/3).
referring to “6. Disassembly and assembly a The integral catch on the backrest
of backrest adjustment”. (figure A/1) must engage into the tor-
5) Unscrew the hexagon nut (5) and remove sion spring (figure A/9).
the washers (6) and (7). 3) Put the washer (10) and tighten the hexa-
6) Remove the hexagon bolt (11) and the gon bolt (11).
washer (10). 4) Put the washers (6) and (7), and tighten
7) Press the backrest (1) slightly to the left the hexagon nut.
and take it off upwards. 3 Hexagon nuts: 25 Nm {2.6 kgm}
8) Remove the bearing (8) and the torsion 5) Assemble the backrest adjustment by
spring (9) from the backrest (1). referring to “6. Disassembly and assembly
of backrest adjustment”.
Installation 6) Install the armrests by referring to “4.
1) Install the bearing (8) and the torsion Removal and installation of armrests”. (If
spring (9) to the backrest (1). equipped)
a Oil the bearing point (Q) on the back-
rest (1) for the bearing (8) with acid-
free multiple-purpose lubricant.
WA800-3E0, WA900-3E0 9
7) Install the backrest upholstery by referring 7. Disassembly and assembly of seat angle
to í2. Removal and installation of seat pad and seat depth adjuster
6. Disassembly and assembly of backrest

adjustment
Disassembly
1) Remove the storage box by referring to “1.
2) Remove the backrest upholstery by refer-
ring to “2. Removal and installation of seat
pad and backrest upholstery”.
3) Remove the armrests by referring to “4.
Removal and installation of armrests”. (If
equipped)
Disassembly
4) Fold the backrest (1) forwards.
1) Remove the seat pad by referring to “2.
5) Unscrew 3 flat-headed screws (2), remove
Removal and installation of seat pad and
the adaptor plate (3) and the flat-headed
backrest upholstery”.
screw (4).
2) Remove the switch by the following proce-
6) Remove the lever (5) and handle (6).
dure. (If equipped)
1] Disconnect the spring (1).
Assembly 2] Tilt the switch-plate (2) forwards and
1) Fold the backrest(1) forwards. remove it.
2) Install the handle (6) and the lever (5). 3] Drill off the rivet (3) and remove the
3) Tighten the 3 flat-headed screws (4), seat switch (4).
install the adaptor plate (3) and then
tighten the flat-headed screw (2).
a The lifter of the flat-headed screw (4)
must engage into the nut of the adap-
tor plate (3).
3 Flat-headed screw:
12 Nm {1.2 kgm}
4) Install the armrests by referring to “4.
Removal and installation of armrests”. (If
equipped)
5) Install the backrest upholstery by referring
to “2. Removal and installation of seat pad
10 WA800-3E0, WA900-3E0
3) Remove the flexible support plate (7) by 1] Turn the lever (14) clockwise until it
the following procedure. snaps-in, install the plate (15).
1] Press the spring plate (5) (“P” posi- 2] Install the spring (13) to hook (a) of
tion) inwards (arrow), operate the the lever (14) and hook (b) of the
lever for seat angle adjustment (6). plate (15).
2] Pull the flexible support plate (7) to 3] Install the cover (9), the levers for
backwards and remove it. seat angle and seat depth adjustment
4) Remove the plate (15) by the following (6), (10), the linkage rod (11) and the
procedure. locking lever (12), then tighten the
1] Drill off the rivet and remove the hexagon socket screws (8).
spring steel sheet (5). 4] Install the spring steel sheet (5) and
2] Unscrew the hexagon socket screws fix it with the rivet.
(8), remove the cover (9), the levers 6) Install the flexible support plate by the fol-
for seat angle and seat depth adjust- lowing procedure.
ment (6), (10), the linkage rod (11) 1] Press the spring plate (5) (“P” posi-
and the locking lever (12). tion) inwards (arrow), operate the
3] Remove the spring (13). lever for seat angle adjustment (6).
4] Turn the lever (14) clockwise until it 2] Swivel the flexible support plate (7)
snaps-in, pull the plate (15) to the upwards and install it.
very front and remove it. 3] Install the end hook of the linkage rod
5) Remove the covers on the right and left (11) to the position (c) of the lever
side by referring to “8. Removal and instal- (10), and the other side of hook of the
lation of covers”. linkage rod (11) to the port (d) of the
6) Unscrew the nut (16), remove the lever lever (14).
(14) and the screw (17).
7) Drill off the rivet (18) and remove the
spring steel sheets (19).
8) Drill off the rivet (20) and remove the
locating element (21).
Assembly
1) Install the locating element (21) and fix it
with the rivet (20).
2) Install the spring steel sheets (19) and fix
it with the rivet (18).
3) Set the lever (14) and the screw (17), and
fix with nut (16).
4) Install the covers on the right and left side
by referring to “8. Removal and installation
of covers”.
5) Assemble the plate (15) by the following
procedure.
WA800-3E0, WA900-3E0 11
Removal
1) Remove the seat pad by referring to "2.
backrest upholstery".
2) Remove spring(1) and switch-plate (2). (If
equipped)
3) Remove the flexible support plate by fol-
lowing procedure.
1] Press the spring sheet inwards
(arrow), operate the lever for seat
angle adjustment (3).
2] Pull the flexible support plate (4) to
backwards and remove it.
4) Remove the spring (5).
7) Install the switch (4) by the following pro- 5) Turn the lever (6) clockwise until it snaps-
cedure. (If equipped) in, pull the plate (7) to the very front and
1] Install the seat switch (4) and fix it remove it.
with the rivet (3). 6) Drill off the rivet (8) and remove the wash-
2] Tilt the switch-plate (2) forwards and ers (9).
install it. 7) Unhook the covers (10) by pulling them
3] Install the spring (1). forwards and remove them in an upward
8) Install the seat pad by referring to “2. direction.
Installation
8. Removal and installation of covers 1) Install the covers (10) of right and left.
2) Install the washers (9) and fix it with the
rivet (8).
3) Turn the lever (6) clockwise until it snaps-
in, then install the plate (7).
4) Remove the spring (5) (see 7. Disassem-
bly and assembly of seat angle and seat
depth adjuster).
5) Install the flexible support plate (4) (see 7.
Disassembly and assembly of seat angle
and seat depth adjuster).
6) Install spring (1) and switch-plate (2) (see
7. Disassembly and assembly of seat
angle and seat depth adjuster). (If
equipped)
7) Install the seat pad by referring to “2.
12 WA800-3E0, WA900-3E0
9. Removal and installation of slide rails Installation

1) Install the slide rails (10).
2) Put the nuts (9) and tighten the hexagon
socket screws (8).
a Replace the hexagon socket screws
(8) with new ones.
3 Hexagon socket screws:
25 Nm {2.6 kgm}
3) Install the bellows to the upper part of the
suspension system.
4) Put the washers (7) and install the seat
top assembly (1) and remove.
5) Put the washers (5) and nuts (6), then
tighten the hexagon socket screws (4).
(4) with new ones.
25 Nm {2.6 kgm}
6) Push the seat top assembly (1) as far for-
ward as possible.
7) Put the nuts (3) and tighten the hexagon
socket screws (2).
(2) with new ones.
25 Nm {2.6 kgm}
8) Push the seat top assembly (1) as far
back as possible.
9) Install the seat pad by referring to “2.
Removal
1) Remove the seat pad by referring to “2.
2) Push the seat top assembly (1) as far
back as possible.
3) Unscrew the hexagon socket screws (2)
and remove the nuts (3).
4) Push the seat top assembly (1) as far for-
ward as possible.
5) Unscrew the hexagon socket screws (4),
remove the washers (5) and nuts (6).
6) Remove the seat top assembly (1) and
remove the washers (7).
7) Disconnect the bellows from the upper
part of the suspension system and lay it
down.
8) Unscrew the hexagon socket screws (8)
and remove the nuts (9).
9) Remove the slide rails (10).
WA800-3E0, WA900-3E0 13
II. Suspension 2. Removal and installation of front cover
1. Removal and installation of top cover
Removal
1) Remove the upper part of the seat by
Removal referring to “I. Upper seat”.
1) Remove the upper part of the seat by 2) Remove the top cover by referring to “1.
referring to “I. Upper seat”. Removal and installation of top cover”.
2) Pull the connecting cable (3) inwards 3) Bore out 2 rivet heads and drive out blind
through the upper cover (2). rivets (1), remove the front cover (2).
3) Remove the 2 bellows pins (1) and take
the upper cover (2) off.
Installation
1) Install the front cover (2) and fix it with the
Installation 2 rivets (1).
1) Install the connecting cable (3) inwards 2) Install the top cover by referring to “1.
through the upper cover (2). Removal and installation of top cover".
2) Install the upper cover (2) and fix it with 3) Install the upper part of the seat by refer-
the 2 bellows pins (1). ring to "I. Upper seat”.
3) Install the upper part of the seat by refer-
ring to “I. Upper seat”.
14 WA800-3E0, WA900-3E0
3. Removal and installation of bellows
Installation
Removal 6) Install the wire insert (5) to the bellows (2).
1) Remove the upper part of the seat by 7) Install the bellows (2).
referring to “I. Upper seat”. 8) Fix the bellows (2) with pins (3) to the
2) Remove the bellows (2) from the upper lower part of the suspension (6) in the
part of the suspension (1) by following reverse order of their removal.
procedure. 9) Fix the connecting cable with the cable tie
1] Take bellows pins (4) off on the front. (10). (If equipped)
2] Take bellows pins (3) off on the left 10) Fix the bellows (2) with pins (3) to the
side of the top. upper part of the suspension (1) in the
3] Remove 2 bellows pins (4) on the reverse order of their removal.
back and take 2 bellows pins (3) off 11) Install the upper part of the seat by refer-
the upper part of the suspension sys- ring to “I. Upper seat”.
tem (1).
4] Take 3 bellows pins (3) on the right
side off the upper part of the suspen-
sion (1) and pull the bellows (2) over
the handle for vertical shock absorber
adjustment (9).
3) Remove the bellows (2) from the lower
part of the suspension (6) by the following
procedure.
1] Take 3 bellows pins (3) on the front
side off the lower part of the suspen-
sion (6).
2] Release 2 bellows pins (3) on the left
side from the lower part of the sus-
pension (6).
3] Release 4 bellows pins (3) on the
back side from the lower part of the
suspension (6).
4] Remove a cable tie (10) on the right
side from the connecting cable, and
take 2 bellows pins (3) off the lower
part of the suspension (6). (If
equipped)
4) Lift the bellows (2) over the lower part of
the suspension (6) and remove the bel-
lows (2) in a downward direction.
5) Remove the wire insert (5) from the bel-
lows (2).
WA800-3E0, WA900-3E0 15
4. Removal and installation of Bowden pull

wire and handle for vertical shock absorber
adjustment
Removal 10) Mark the points where the Bowden pull

1) Remove the upper part of the seat by wire (5) is fastened with the swinging
referring to “I. Upper seat”. structure (14) with the cable tie (8) and
2) Remove the top cover by referring to “1. take the cable tie (8) off.
Removal and installation of top cover”. 11) Pull the fixation (12) off the vertical shock
3) Take the bellows off by referring to “3. absorber (13).
Removal and installation of bellows”. 12) Take the Bowden pull wire (5) off the bear-
4) Move the suspension system to the high- ing (9).
est position. 13) Remove the fixation (12) from the fork
k Risk of crushing! Secure the sus- (11).
pension between the swinging 14) Take the Bowden pull wire (5) off the fork
structure and lower part of the sus- (11), remove the fork (11) and compres-
pension system with suitable spac- sion spring (10).
ers. 15) Mark the location of the mounting hole for
5) Screw out Torx screw (2). the Bowden pull wire (5) in the upper part
6) Pull the handle for vertical shock absorber of the suspension (4), pull the Bowden pull
adjustment (1) off the upper part of the wire (5) out of the upper part of the sus-
suspension (4). pension (4) and then remove it.
7) Remove the Bowden pull wire (5) from the
handle for vertical shock absorber adjust-
ment (1).
8) Push the Bowden pull wire (5) off the
bearing for Bowden pull wire (6).
9) Bore out the rivet head and drive out the
blind rivet (7), and remove the bearing for
Bowden pull wire (6).
16 WA800-3E0, WA900-3E0
Installation
1) Move the suspension system to the high-
est position.
k Risk of crushing! Secure the sus-
pension between the swinging
structure and lower part of the sus-
pension system with suitable spac-
ers.
2) Put the Bowden pull wire (5) to the upper
part of the suspension (4) through the
location of the mounting hole marked
before removing the Bowden pull wire (5).
3) Install the fork (11) and compression
spring (10), and take the Bowden pull wire
(5) to the fork (11).
4) Install the fixation (12) to the fork (11).
5) Take the Bowden pull wire (5) to the bear-
ing (9).
6) Put the fixation (12) to the vertical shock
absorber (13).
7) Install the Bowden pull wire (5) and fix it
with the cable tie (8) at the marked points.
a Install the Bowden pull wire according
to the marking.
8) Install the bearing for Bowden pull wire (6)
and fix it with the rivet (7).
9) Install the Bowden pull wire (5) to the
bearing for Bowden pull wire (6).
10) Install the Bowden pull wire (5) to the han-
dle for vertical shock absorber adjustment
(1).
11) Install the handle for vertical shock
absorber adjustment (1) to the upper part
of the suspension (4).
12) Tighten Torx screw (2).
3 Torx screw: 2.25 Nm {0.23 kgm}
13) Install the bellows off by referring to “3.
Removal and installation of bellows”.
14) Install the top cover by referring to “1.
Removal and installation of top cover”.
WA800-3E0, WA900-3E0 17
5. Removal and installation of vertical shock Installation

absorber 1) Move the suspension system to the high-
est position.
ers.
2) Install the vertical shock absorber (4).
a When re-installing the vertical shock
absorber (4), make sure the labeling
is on top.
3) Assemble the vertical shock absorber (4)
to the swinging structure (7) and put the
stud (3).
4) Install circlip (5) to the stud (3).
a Apply acid-free multi-purpose lubri-
cant to the entire external surface (F)
of the stud (3).
5) Install the fixation (2) and bearing (1) to
the vertical shock absorber (4).
6) Assemble the vertical shock absorber (4)
to the swinging structure (7) and put the
stud (6).
cant to the entire external surface (F)
of the stud (6).
7) Install the circlip (8) to the stud (6).
Removal
1) Remove the upper part of the seat by
referring to “I. Upper seat”.
2) Remove the top cover by referring to “1.
3) Take the bellows off by referring to “3.
est position.
ers.
5) Remove circlip (8) from stud (6).
6) Pull the stud (6) out of swinging structure
(7) and vertical shock absorber (4).
7) Take the fixation (2) and bearing (1) off the
vertical shock absorber (4).
8) Remove circlip (5) from stud (3).
9) Pull the stud (3) out of the swinging struc-
ture (7) and the vertical shock absorber
(4).
10) Remove the vertical shock absorber (4) in
an upward direction.
18 WA800-3E0, WA900-3E0
6. Removal and installation of compressor
Removal 11) Pull the compressed-air hose (7) off the

1) Remove the upper part of the seat by compressor (3).
referring to “I. Upper seat”. a Do not use a screwdriver to lift the
2) Remove the top cover by referring to “1. compressed-air hose (7) off the spike
Removal and installation of top cover”. of the compressor (3).
3) Take the bellows off by referring to “3. a Heat the compressed-air hose (7) at
Removal and installation of bellows”. the head of compressor (3) (e.g.
4) Move the suspension system to the high- using a hot-air blower) and then, pull
est position. it off in one move.
k Risk of crushing! Secure the sus- 12) Pull out the compressor cable (5) in a
pension between the swinging downward direction and remove compres-
structure and lower part of the sus- sor (3) to the front.
pension system with suitable spac- 13) Remove the support (9) from the lower
ers. part of the suspension (2).
5) Mark the points where the compressor
cable (5) is fastened with the 6 cable ties
(6) and remove the cable ties (6).
6) Disconnect the right-angle plug (10) from
the height level control unit (1).
7) Disconnect the electric connector of the
flat plug (11).
8) Mark the points where the compressed-air
hose (7) is fastened with the cable tie (12)
and remove the cable tie (12).
9) Mark the points where the compressor (3)
is fastened with the 2 cable ties (4) and
remove the cable ties (4).
10) Pull the fitting (8) out of the spike of the
compressor (3) and push it backwards off
the compressed-air hose (7).
WA800-3E0, WA900-3E0 19
Installation
est position.
ers.
2) Install the support (9) to the lower part of
the suspension (2).
3) Install the compressor (3) to the support
(9).
4) Install the compressed-air hose (7) and fix
it with cable tie (4) at the marked points.
a Loosely apply the cable tie (4) until
the locking head of the cable tie (4) is
located slightly over the front curve of
compressor (3) and while the com-
pressor (3) can be still moved.
a Align the compressor (3) and use the
pliers to tighten the locking head of
the cable tie (4) to 310 Nm{31.6 kgm}
in the direction shown (arrow).
5) Put the fitting (8) to the compressed-air
hose (7).
6) Install them to the spike of the compressor
(3).
7) Fix the compressor (3) with the cable ties
(4) at marked points.
a Fix the cable tie according to the
marking.
8) Fix the compressed-air hose (7) with cable
tie (12) at the marked points.
9) Connect the electric connector of the flat
plug (11).
10) Connect the right-angle plug (10) to the
height level control unit (1).
11) Install the compressor cable (5) and fix it
with cable tie (6) at the marked points.
a Tie back any excess length of the
compressor cable (5).
20 WA800-3E0, WA900-3E0
7. Removal and installation of height level

controller
Removal 9) Pull the air input hoses (10) and (11) off
1) Remove the upper part of the seat by the pneumatic spring (see “8. Removal
referring to “I. Upper seat”. and installation of air hose”).
2) Remove the top cover by referring to “1. 10) Mark the place where the cable is fas-
Removal and installation of top cover”. tened with the right-angle plugs (13) and
3) Take the bellows off by referring to “3. (14) and the cable tie and then remove the
Removal and installation of bellows”. cable tie.
4) Move the suspension system to the high- 11) Mark the place where the Bowden pull
est position. wire (19) is fastened with the cable tie and
k Risk of crushing! Secure the sus- remove the cable tie.
pension between the swinging 12) Unhook the Bowden pull wires (3) and
structure and lower part of the sus- (19) from the height level control (1).
pension system with suitable spac- 13) Mark and then disconnect the right-angle
ers. plugs (13) and (14) from the height level
5) Loosen up the 2 circlips (17) from the stud control unit (1).
(18) and then remove them. 14) Remove the 2 hexagon nuts (4) from the
6) Knock out the stud (18) from the lower thread of the height level control (1).
part of the suspension (15) and then 15) Remove the plate (7), loop of the webbing
remove it. (5) and the edge protection strip (6).
a Firmly hold the webbing (5) and let it 16) Remove the height level control (1) from
carefully roll back to the rewinder on the upper part of the suspension (8).
the height level controller (1). 17) Undo the Torx screw (9) and take the
7) Remove the 2 buffers (16) from the loop of attachment for Bowden pull wire (2) off the
the webbing (5). height level valve (1).
8) Mark the points where the air input hoses a To do this, first release the 2 catchers
(10) and (11) are fastened with 5 cable on the backside of the attachment for
ties (12) and remove the cable ties (12). Bowden pull wire (2) and take the
attachment for Bowden pull wire (2)
off the height level valve (1).
WA800-3E0, WA900-3E0 21
18) Pull the Bowden pull wire (3) out of the

attachment for Bowden pull wire (2).
19) Remove the height level controller in an
upward direction.
Installation
est position.
ers.
2) Install the height level controller.
3) Install the Bowden pull wire (3) to the
attachment for Bowden pull wire (2).
4) Install the attachment for Bowden pull wire
(2) to the height level controller (1).
5) Tighten the Torx screw (9) to height level
controller (1).
a Finger-tighten the Torx screw (9).
6) Install the height level control (1) to the
upper part of the suspension (8).
7) Install the plate (7), loop of the webbing
(5) and the edge protection strip (6).
8) Install the 2 hexagon nuts (4) to the thread
of the height level controller (1).
9) Connect the right-angle plugs (13) and
(14) to the height level controller (1) at the
marked point.
10) Install the Bowden pull wires (3) and (19)
to the height level controller (1).
11) Install the Bowden pull wire (19) and fix it
with the cable tie at the marked points.
12) Install the right-angle plugs (13) and (14)
and fix them with the cable tie at the
marked points.
13) Install the air input hoses (10) and (11) to
the pneumatic spring (see “8. Removal
and installation of air hose”).
14) Fix the air input hoses (10) and (11) with
the 5 cable ties (12) at the marked points.
15) Install the 2 buffers (16) to the loop of the
webbing (5).
16) Install the stud (18) to the lower part of the
suspension (15).
17) Install the 2 circlips (17) to the stud (18)
and then remove them.
22 WA800-3E0, WA900-3E0
Adjustment 7) Adjust the output level (2) as follows.

1) Remove the upper part of the seat by Adjust the clearance between valve lever
referring to “I. Upper seat”. (6) and cam disc (7) by turning the cross-
2) Remove the top cover by referring to “1. head screw (10).
Removal and installation of top cover”. q Specified value: The valve lever (6)
3) Take the bellows off by referring to “3. must seat on the cam disc without
Removal and installation of bellows”. pressure (7).
4) Move the suspension system to the high- q Turn the cross-head screw (10) to the
est position. left, the valve lever (6) is moving
k Risk of crushing! Secure the sus- towards the cam disc (7). This
pension between the swinging increases the pressure on the valve
structure and lower part of the sus- tappets (4) at the output valve (2) and
pension system with suitable spac- the air escapes the output valve (2)
ers.
earlier.
5) Loosen the self-tapping screw (9) a half
q Turn the cross-head screw (10) to the
turn.
right, the valve lever (6) is moving
6) Adjust the micro-switch (3) as follows.
away from the cam disc (7). This
Adjust the clearance between cam switch
decreases the pressure on the valve
(5) and cam disc (7) by turning the cross-
tappets (4) at the output valve (2) and
head screw (8).
the air escapes the output valve (2)
q Specified clearance (A) = 0.5 mm.
q Turn the cross-head screw (8) to the later.
left, the cam switch (5) is moving 8) Tighten the self-tapping screw (9) after the
towards the cam disc (7). adjustment has been completed.
q Turn the cross-head screw (8) to the 9) Install the bellows off by referring to “3.
right, the cam switch (5) is moving Removal and installation of bellows”.
away from the cam disc (7). 10) Install the top cover by referring to “1.
q When the cam switch (5) seats on the Removal and installation of top cover”.
cam disc (7) under pressure, the 11) Install the upper part of the seat by refer-
compressor (11) turns too early and ring to “I. Upper seat”.
runs already during the compression
and expansion of the seat suspen-
sion.
WA800-3E0, WA900-3E0 23
8. Removal and installation of compressed-air

hoses
a Disconnect the hose not more than 1 to 2 7) Pull the compressed-air hose (11) off the
times. Check the hose for damage before con- compressor (5) and remove it. (Refer to
necting it. “6. Removal and installation of compres-
sor”)
8) Pull the compressed-air hose with angle
Removal (8) off the pneumatic spring (9) and then
1) Remove the upper part of the seat by off the air tank (10).
referring to “I. Upper seat”. a When pulling the hoses out, the
2) Remove the top cover by referring to “1. retaining ring of the quick coupling
Removal and installation of top cover”. (13) must first be completely pressed
3) Take the bellows off by referring to “3. back (e.g. using a flat pliers) to avoid
Removal and installation of bellows”. marks.
4) Move the suspension system to the high- 9) Mark the points where the compressed-air
est position. hose with angle (8) is fastened with cable
k Risk of crushing! Secure the sus- ties (6), (7) and (12) and then remove the
pension between the swinging cable ties (6), (7) and (12).
structure and lower part of the sus- 10) Remove the air hose with angle (8).
pension system with suitable spac- 11) Mark the points where the air input hoses
ers. (3) and (4) are fastened with the cable ties
5) Mark the points where the compressed-air (2) and (6) and remove the cable ties (2)
hose (11) is fastened with the cable tie and (6).
(12) and remove the cable tie (12). 12) Pull the air input hoses (3) and (4) out of
6) Pull the compressed-air hose (11) off the the pneumatic spring (9).
pneumatic spring (9). 13) Remove the height level controller (1) with
a When pulling the hoses out, the air input hoses (3) and (4).
retaining ring of the quick coupling a To ensure the tightness, the air input
(13) must first be completely pressed hoses (3) and (4) cannot be removed
back (e.g. using a flat pliers) to avoid from the height level control (1).
marks.
24 WA800-3E0, WA900-3E0
Installation a Apply pressure to insert the air hose

a Always replace a damaged (marks) hose with with angle (8) into the pneumatic
a new one. It is possible to cut the damaged spring (9) and air tank (10) up to the
part off (about 12 mm) using special tools (14) blue marking.
only once. After the cut off, the blue marking 6) Fix the compressed air hose with angle (8)
should be (arrow) set back by the length of the with cable ties (6), (7) and (12) at the
cut off piece. marked points.
a Do not fix the cable tie (12) at the
1) Move the suspension system to the high- angle.
est position. 7) Install the compressed-air hose (11) to the
k Risk of crushing! Secure the sus- compressor (5). (Refer to “6. Removal and
pension between the swinging installation of compressor”)
structure and lower part of the sus- 8) Install the compressed-air hose (11) to the
pension system with suitable spac- pneumatic spring (9).
ers. 9) Fix the compressed-air hose with the
2) Install the height level controller (1) with cable tie (12) at the marked points.
air input hoses (3) and (4). 10) Install the bellows off by referring to “3.
a Cut the air input hose (3) or (4) off at Removal and installation of bellows”.
the leaky area and connect the new 11) Install the top cover by referring to “1.
air input hose (3) or (4) to an appro- Removal and installation of top cover”.
priate adapter. Subsequently, cut the 12) Install the upper part of the seat by refer-
excess length off. ring to “I. Upper seat”.
3) Install the air input hoses (3) and (4) to the
pneumatic spring (9). Hydrostatic test
4) Fix the air input hoses (3) and (4) with the a After the installation of a compressed-air hose,
cable ties (2) and (6) at the marked points. the hydraulic test of the suspension should be
5) Install the compressed-air hose with angle performed.
(8) to the pneumatic spring (9) and then q Apply 60 kg load to the suspension for 24
off the air tank (10). hours.
a To avoid kinking, always install the q The lowering within this time may not
compressed-air hose with angle (8) exceed 15 mm.
first on the pneumatic spring (9). a The compressed-air hoses are locked after
they have been connected.
WA800-3E0, WA900-3E0 25
9. Removal and installation of Bowden pull 8) Undo the 3 cross-head screws (7).
wires and handle for height adjustment 9) Take the Bowden pull wires (1) and (6) off
the holder for Bowden pull wire (4), and
then pull them out of the upper part of the
suspension (2).
10) Remove the holder (4) for Bowden pull
wire.
11) Replace the handle (5), if required.
a The handle (5) and holder for Bowden
pull wire (4) are wedged into the 2
latching noses (arrow) at the lower
part of the holder for Bowden pull wire
(4). Carefully separate the parts.
a To remove the handle, use a screw-
driver to bend open the handle (5)
between the handle (5) and holder for
Bowden pull wire (4) so that the 2
latching noses are released from the
handle (5).
a Take the handle (5) off the holder for
Bowden pull wire (4).
Installation
1) Install the handle (5) to holder (4), if
removed.
a When the handle (5) is deformed,
replace it.
2) Install the Bowden pull wires (1) and (6) to
the holder for Bowden wire (4).
a Adjust the new Bowden pull wire to
Removal the length of the old one (excess
1) Remove the upper part of the seat by length of the wire).
referring to “I. Upper seat”. 3) Install the holder (4) to the upper part of
2) Remove the top cover by referring to “1. the suspension (2) and tighten the 3
Removal and installation of top cover”. cross-head screws (7).
3) Take the bellows off by referring to “3. 4) Install the Bowden pull wire (6) to the
Removal and installation of bellows”. height level controller. (See “7. Removal
4) Mark the points where the Bowden pull and installation of height level controller”.)
wire (1) is fastened with the 2 cable ties 5) Install the Bowden pull wire (1) to the
(3), and then remove the cable ties (3). height level controller (See “7. Removal
5) Mark the points where the Bowden pull and installation of height level controller”.)
wire (6) is fastened with the 2 cable ties 6) Fix the Bowden pull wire (6) with the 2
(8), and then remove the cable ties (8). cable ties (8) at the marked points.
6) Take the Bowden pull wire (1) off the a Loosely fix the Bowden pull wire with
height level controller and pull it out of the the cable ties at the marked points
holder for Bowden pull wire (See “7. and make sure it is not distorted.
Removal and installation of height level 7) Fix the Bowden pull wire (1) with the 2
controller”.) cable ties (3) at the marked points.
a To release the tension of the Bowden a Loosely fix the Bowden pull wire with
pull wire (1), press the handle for the cable ties at the marked points
height adjustment (5) upwards. and make sure it is not distorted.
7) Take the Bowden pull wire (6) off the 8) Install the bellows off by referring to “3.
height level controller. (See “7. Removal Removal and installation of bellows”.
and installation of height level controller”) 9) Install the top cover by referring to “1.
a To release the tension of the Bowden Removal and installation of top cover”.
pull wire (6), press the handle for 10) Install the upper part of the seat by refer-
height adjustment (5) upwards. ring to “I. Upper seat”.
26 WA800-3E0, WA900-3E0
Checking and adjustment 5) Check the clearance between the Bowden

a When checking and adjustment is performed wire lever (10) and holder for Bowden wire
through removal and installation, pass proce- end cap (9).
dures 1) and 2) of “Checking”. q Specified value: Distance (A)
(Checking) between 1 and 3.5 mm with the han-
1) Remove the upper part of the seat by dle for height adjustment (2) in the up
referring to “I. Upper seat”. position.
2) Remove the top cover by referring to “1. q When the specified value exceeds
Removal and installation of top cover”. 3.5 mm, the suspension cannot be
3) Operate the handle for height adjustment lifted above the middle position.
(2) several times in both directions and
check the following: (Adjustment)
q Bowden pull wires (1) and (3) for 1) Adjustment of the Bowden pull wire (3):
easy-running. 1] Loosen the counternut (6) and adjust
q Bowden wire lever (10), valve lever the clearance between the Bowden
(14) and valve tappets (13) at the out- wire lever (10) and holder for Bowden
put valve (12) for smoothness of run- wire end cap (9) using the locknut (5).
ning. q Turn the locknut (5) inwards, the
4) Check the neutral position of the handle Bowden pull wire gets longer.
for seat height adjustment (2) and the ten- q Turn the locknut (5) outwards,
sile force of the retracting spring (11) on the Bowden pull wire gets
the height level valve (4): shorter.
q The retracting spring (11) must fix the q Specified value: Clearance (A)
handle for seat height adjustment (2) between 1 and 3.5 mm.
in neutral position. 2] Secure the locknut (5) with the coun-
q The retracting spring (11) must tightly ternut (6) and make sure not to distort
pull the Bowden pull wires (1 and 3) the Bowden pull wire (3).
and keep the Bowden wire lever (10) 3] Operate the handle for seat height
in neutral position. adjustment (2) several times and
check the specified value, repeat the
adjustment if necessary.
WA800-3E0, WA900-3E0 27
2) Adjustment of the Bowden pull wire (1):

1] Loosen the counternut (7) and adjust
the tension of the Bowden pull wire
(1) on the height valve (4) using the
locknut (8).
q Turn the locknut (8) inwards, the
Bowden pull wire gets longer.
q Turn the locknut (8) outwards,
the Bowden pull wire gets
shorter.
q Specified value: The Bowden
wire (8) must be tightened, but
not distorted on the suspension
device on the height level valve
(4).
2] Secure the locknut (8) with the coun-
ternut (7) and make sure not to distort
the Bowden pull wire (1).
3] Operate the handle for seat height
adjustment (2) several times and
check the specified value, repeat the
adjustment if necessary.
28 WA800-3E0, WA900-3E0
10. Removal and installation of pneumatic

spring
Removal Installation
1) Remove the upper part of the seat by 1) Move the suspension system to the high-
referring to “I. Upper seat”. est position.
2) Remove the top cover by referring to “1. k Risk of crushing! Secure the sus-
Removal and installation of top cover”. pension between the swinging
3) Take the bellows off by referring to “3. structure and lower part of the sus-
Removal and installation of bellows”. pension system with suitable spac-
4) Remove the 2 air input hoses, com- ers.
pressed-air hose and air input hose with 2) Turn the spring system by 180° and place
angle from the pneumatic spring (6) by it onto the upper part (1).
referring to “8. Removal and installation of 3) Slightly compress the pneumatic spring
compressed-air hoses”.
(6) and install the pneumatic spring (6) to
5) Undo the counter sunk screw (3) from the
the swinging structure (5) and lower part
pneuma ti c spr ing (6) and rem ove it
of the suspension (2).
together with the washer (4).
6) Move the suspension system to the high- 4) Tighten the counter sunk screw (7) to the
est position. pneumatic spring (6).
3 Counter sunk screw (6):
pension between the swinging 6 Nm {0.61 kgm}
structure and lower part of the sus- 5) Turn the spring system by 180° and place
pension system with suitable spac- it onto the upper part (1).
ers. 6) Put the washer (4) to the pneumatic spring
7) Turn the spring system by 180° and place (6) and tighten the counter sunk screw (3).
3 Counter sunk screw (3):
it onto the upper part (1).
8) Undo the counter sunk screw (7) from the 6 Nm {0.61 kgm}
pneumatic spring (6).
9) Slightly compress the pneumatic spring
(6) and remove it from the swinging struc-
ture (5) and lower part of the suspension
(2).
WA800-3E0, WA900-3E0 29
7) Install the 2 air input hoses, compressed-

air hose and air input hose with angle to
the pneumatic spring (6) by referring to “8.
Removal and installation of compressed-
air hoses”.
30 WA800-3E0, WA900-3E0
11. Removal and installation of air tank for

additional air supply
2) Remove the top cover by referring to “1. k Risk of crushing! Secure the sus-
4) Move the suspension system to the high- ers.
est position. 2) Install the clamp (5) to the bracket (6), if
k Risk of crushing! Secure the sus- removed.
pension between the swinging a Replace the clamp with new one, if
structure and lower part of the sus- required.
pension system with suitable spac- 3) Install the air tank (3) to bracket (2) and
ers. clamp (5).
5) Remove the air hose with angle (4) from 4) Install the air hose with angle (4) to the air
the air tank (3) by referring to “8. Removal tank (3) by referring to “8. Removal and
and installation of compressed-air hoses”. installation of compressed-air hoses”.
6) Remove the air tank (3) from bracket (2) 5) Install the bellows off by referring to “3.
and clamp (5). Removal and installation of bellows”.
7) Take the clamp (5) off the bracket (6) in a 6) Install the top cover by referring to “1.
downward direction, if required. Removal and installation of top cover”.
a To do this, use a screwdriver to press 7) Install the upper part of the seat by refer-
through the hole (arrow) in the ring to “I. Upper seat”.
bracket against the catchers (arrow)
of the clamp (5) and pull the clamp (5)
out in a downward direction.
WA800-3E0, WA900-3E0 31
12. Removal and installation of cable harness
2) Remove the top cover referring to “1. k Risk of crushing! Secure the sus-
4) Move the suspension system to the high- ers.
est position. 2) Connect the right-angle plug (6) to the
height level control unit (1).
pension between the swinging 3) Connect the electric connection (flat plug)
structure and lower part of the sus- of the compressor cable (4) to the cable
pension system with suitable spac- harness of the connector plug (2) and
ers. cable harness of the machine power con-
5) Mark the points where the cable of the nector (3).
machine power connector (3) is fastened 4) Fix the cable harness of the connector
with the cable tie (8) on the upper part of plug (2) and cable harness of the machine
the suspension (7) and remove the cable power connector (3) with the cable ties (5)
tie (8). at the marked points.
6) Mark places where the cable harness of a Run the cable harnesses (2) and (3)
the connector plug (2) and cable harness and fix them with the cable ties (5) so
of the machine power connector (3) are that they are neither squeezed nor
fastened with the cable ties (5) and otherwise damaged.
remove the cable ties (5). 5) Fix the cable of the machine power con-
7) Disconnect the electric connection (flat nector (3) with the cable tie (8) on the
plug) of the compressor cable (4) to the upper part of the suspension (7) at the
cable harness of the connector plug (2) marked points.
and cable harness of the machine power
connector (3).
8) Disconnect the right-angle plug (6) from
the height level control unit (1).
32 WA800-3E0, WA900-3E0

WA800-3E0, WA900-3E0 33
13. Disassembly and assembly of upper part of

the suspension system
Disassembly 8) Move the suspension system to the high-

1) Remove the upper part of the seat by est position.
referring to “I. Upper seat”. k Risk of crushing! Secure the sus-
2) Remove the top cover referring to “1. pension between the swinging
Removal and installation of top cover”. structure (7) and lower part of the
3) Take the bellows off by referring to “3. suspension system with suitable
Removal and installation of bellows”. spacers.
4) Take the Bowden pull wire and handle off 9) Bore out 2 rivet heads and drive out blind
the upper part of the suspension (1) by rivets (10), remove the stops (9).
referring to “4. Removal and installation of 10) Push the upper part of the suspension (1)
Bowden pull wires and handle for vertical forwards until the cut-outs (arrow) on the
shock absorber”. left and right sides at the guiding rails (2)
a The Bowden pull wire does not need are located at the same height with the
to be taken off the vertical shock front rollers (8) of the swinging structure
absorber. (7).
5) Remove the vertical shock absorber from 11) Remove the upper part of the suspension
the upper part of the suspension (1) by (1) on the front side over the rollers (8)
referring to “5. Removal and installation of and the back rollers (6) of the swinging
vertical shock absorber”. structure (7).
6) Remove the height level controller from
the upper part of the suspension (1) by
referring to “7. Removal and installation of
height level controller”.
a Air input hoses do not need to be
taken off the pneumatic spring.
7) Remove Bowden pull wires and handle for
height adjustment by referring to “9.
Removal and installation of Bowden pull
wires and handle for height adjustment”.
34 WA800-3E0, WA900-3E0
Assembly
est position.
ers.
2) Push the upper part of the suspension (1)
forwards until the cut-outs (arrow) on the
left and right sides at the guiding rails (2)
are located at the same height with the
front rollers (8) of the swinging structure
(7).
3) Install the upper part of the suspension (1)
on the back rollers (6) and the front rollers
(8) of the swinging structure (7).
cant to the side surfaces (F) of the 2
guiding rails (2) of the rollers (6).
4) Install the stops (9) and fix with the 2 rivets
(10).
5) Install Bowden pull wires and handle for
height adjustment by referring to “9.
wires and handle for height adjustment”.
6) Install the height level controller to the
upper part of the suspension (1) by refer-
ring to “7. Removal and installation of
height level controller”.
7) Install the vertical shock absorber to the
upper part of the suspension (1) by refer-
ring to “5. Removal and installation of ver-
tical shock absorber”.
8) Install the Bowden pull wire and handle to
the upper part of the suspension (1) by
referring to “4. Removal and installation of
Bowden pull wires and handle for vertical
shock absorber”.
WA800-3E0, WA900-3E0 35
14. Lower part of the suspension system
Removal 8) Unscrew the 2 hexagon nuts (11), remove

1) Remove the upper part of the seat by washers (10) and counter sunk screws
referring to “I. Upper seat”. (9).
2) Remove the top cover by referring to “1. 9) Undo the 2 corrugated-head screws (5)
Removal and installation of top cover”. and take the U-shaped profiles (6) off the
3) Take the bellows off by referring to “3. guiding rail (8).
Removal and installation of bellows”. 10) Push the upper part of suspension (1) with
4) Remove compressor from the lower part the swinging structure (3) backwards until
of the suspension (7) by referring to “6. the 2 fixed bearings (4) on the swinging
Removal and installation of compressor”. structure (3) can be taken out through the
a Compressor cable and compressed- cut-outs (arrows) of the guiding rails (8) on
air hose do not need to be removed. the upper part of suspension (1).
a Protect the compressor against 11) Lift the upper part of the suspension (1)
shocks (impacts) by fixing it on the with the swinging structure (3) out and pull
swinging structure with adhesive it out together with the 2 rollers (2) from
tape. the guiding rails (8) by turning sideways.
5) Remove the webbing from the lower part
of the suspension (7) by referring to “7.
Removal and installation of height level Installation
controller”. 1) Install the upper part of the suspension (1)
6) Undo the counter sunk screw from the with the swinging structure (3) together
pneumatic spring by referring to “10. with the 2 rollers (2) to the guiding rails
Removal and installation of pneumatic (8).
spring”. a Apply acid-free multi-purpose lubri-
7) Remove the 2 cable ties for the vehicle cant to the bearing surface at the side
power connector cable on the lower part (F) of the 2 guiding rails (8) of the roll-
of suspension(7) by referring to “12. ers (2).
Removal and installation of cable har- 2) Install the U-shaped profile (6) to the guid-
ness”. ing rail (8) and tighten the 2 corrugated-
head screws (5).
36 WA800-3E0, WA900-3E0
3) Put the counter sunk screws (9) and the

washers (10), and tighten the 2 hexagon
nuts (11).
4) Install the 2 cable ties for the machine
power connector cable on the lower part
of suspension(7) by referring to “12.
Removal and installation of cable har-
ness”.
5) Tighten the counter sunk screw to the
pneumatic spring by referring to “10.
Removal and installation of pneumatic
spring”.
6) Install the webbing to the lower part of the
suspension (7) by referring to “7. Removal
and installation of height level controller”.
7) Install compressor to the lower part of the
suspension (7) by referring to “6. Removal
and installation of compressor”.
WA800-3E0, WA900-3E0 37
15. Swinging structure
Removal 9) Take the Bowden pull wires for height

1) Remove the upper part of the seat by level adjustment off the height level valve
referring to “I. Upper seat”. by referring to “9. Removal and installation
2) Remove the top cover by referring to “1. of Bowden pull wire and handle for height
Removal and installation of top cover”. adjustment”.
3) Take the bellows off by referring to “3. 10) Remove the pneumatic spring by referring
Removal and installation of bellows”. to “10. Removal and installation of pneu-
4) Take the Bowden pull wire for vertical matic spring”.
11) Remove the air tank for additional air sup-
shock absorber adjustment off the vertical
ply by referring to “11. Removal and instal-
shock absorber by referring to “4.
lation of air tank for additional air supply”.
12) Remove the cable harness by referring to
wire and handle for vertival shock
“12. Removal and installation of cable har-
absorber adjustment”. ness”.
5) Take the vertical shock absorber off the 13) Take the upper part of the suspension off
swinging structure by referring to “5. the swinging structure by referring to “13.
Removal and installation of vertical shock Removal and installation of upper part of
absorber”. the suspension”.
6) Remove the compressor by referring to “6. 14) Take the lower part of the suspension off
Removal and installation of compressor”. the swinging structure by referring to “14.
7) Take the webbing off the lower part of the Removal and installation of lower part of
suspension by referring to “7. Removal the suspension”.
and installation of height level controller”. 15) Take 4 rollers (5), 2 rollers (6), 2 fixed
8) Remove the cable tie for the air input bearings (9) and 4 felt rings (4) off the
hoses of the height level control and pull swinging structure (1).
the air input hoses off the pneumatic 16) Pull the tube piece (8) out of the fixed
spring by referring to “8. Removal and bearing (9).
installation of compressed-air hoses”. 17) Remove the 2 buffers (7) from the swing-
ing structure (1).
18) Remove the edge protection strip (2) from
the swinging structure (1).
38 WA800-3E0, WA900-3E0
Installation 12) Install the Bowden pull wires for height

1) Check: maximum clearance (A) or (B) level adjustment to the height level valve
between the rollers (5) and guiding rails of by referring to "9. Removal and installation
the lower part of the suspension (11) or of Bowden pull wire and handle for height
upper part of the suspension (10) over the adjustment".
complete adjustment length. 13) Install the cable tie for the air input hoses
2) Place the washer compensating for clear- of the height level controller and pull the
ance (2) between the roller (5 or 6) and air input hoses to the pneumatic spring by
axle of the swinging structure (1), if neces- referring to “8. Removal and installation of
sary. compressed-air hoses”.
a Clearance spacers (with thickness of 14) Install the webbing to the lower part of the
0.2 mm and 0.5 mm) are included in suspension by referring to “7. Removal
the wear parts set. and installation of height level controller”.
3) Install the edge protection strip (2) to the 15) Install the compressor by referring to “6.
swinging structure (1). Removal and installation of compressor”.
4) Install the 2 buffers (7) to the swinging 16) Install the vertical shock absorber to the
structure (1). swinging structure by referring to “5.
5) Put the tube piece (8) to the fixed bearing Removal and installation of vertical shock
(9). absorber”.
6) Install 4 rollers (5), 2 rollers (6), 2 fixed 17) Install the Bowden pull wire for vertical
bearings (9) and 4 felt rings (4) to the shock absorber adjustment to the vertical
swinging structure (1). shock absorber by referring to “4.
7) Install the lower part of the suspension to Removal and installation of Bowden pull
the swinging structure by referring to “14. wire and handle for vertival shock
Removal and installation of lower part of absorber adjustment”.
the suspension”. 18) Install the bellows off by referring to “3.
8) Install the upper part of the suspension to Removal and installation of bellows”.
the swinging structure by referring to “13. 19) Install the top cover by referring to “1.
Removal and installation of upper part of Removal and installation of top cover”.
the suspension”. 20) Install the upper part of the seat by refer-
9) Install the cable harness by referring to ring to “I. Upper seat”.
“12. Removal and installation of cable har-
ness”.
10) Install the air tank for additional air supply
by referring to “11. Removal and installa-
tion of air tank for additional air supply”.
11) Install the pneumatic spring by referring to
“10. Removal and installation of pneu-
matic spring”.
WA800-3E0, WA900-3E0 39
Removal and installation of AJSS 3. Remove screws (5) (4 pieces) and washers (6)
lever switch assembly 1 (4 pieces).
Removal
k Before starting the removal work, be sure to
perform the works described in "Section 00,
Safety notice", "2. Preparation work" and "3.
Precautions during work".
k Disconnect the cable from the negative (-) ter-
minal of the battery. (If the machine is equipped
with the battery disconnect switch, turn it to
OFF position.)
1. Remove screws (1) (5 pieces) and washers (2)

(5 pieces).
5. Remove bolt (9), and remove clamp (9a) which
2. Move cover (3) to a place where it is not a
is fixing wiring harness (8).
hindrance to work.
a Pass the cover (3) to AJSS lever shaft (4)
and fix it with tape, etc. as shown in the figure
below.
6. Remove screws (11) (2 pieces) and collars (12)

(2 pieces) at portion (a) on the back of knob (10).
40 WA800-3E0, WA900-3E0
7. Push up wiring harness (8) passed through shaft

(4) toward knob (b).
8. Disconnect connectors (15) and (16), and
remove AJSS lever cover (17) and switch
assembly together.
Installation
1. Install AJSS lever switch assembly (22)

9. Remove screw (18), and disconnect relay unit

(19). 2. Install upshift switch (23) and downshift switch
10. Remove directional selector switch (20) and (24) of switch assembly (22) to AJSS lever cover
hooks (c) (3 pieces) of horn switch (21), and (17).
remove AJSS lever switch assembly (22). a Color of upshift switch cable:
Blue/black, green/yellow
a Color of downshift switch cable:
Green/black, brown/white
3. Install relay unit (19) with screw (18).

a Confirm that the relay unit does not catch the
harness.
3 Screw (18):
0.7 to 0.9 Nm {0.07 to 0.09 kgm}
a Install upshift switch (23) and downshift
switch (24) to the center of mounting hole.
a Check that rubber boot (27) is not tensed or
deformed.
WA800-3E0, WA900-3E0 41
a The shape of the directional switch differs ac-

cording to the machine serial number.
5. Install horn switch (26) to AJSS lever cover (17).

a Check that hook (f) of horn switch (26) is in-
stalled securely.
4. Install directional selector switch (20) to AJSS

lever cover (17).
a Check that hooks (d) (2 pieces) of directional
selector switch (20) are installed securely.
a Check that height (e) of rubber boot (25)
above cover (17) is even all around the pe-
riphery. If it is not, even it out by moving di-
rectional selector switch (20) back and forth
2 to 3 times to fit.
Height (e) of rubber boot (25): 1.5 mm 6. Connect wiring harness (8) which is passing
through shaft (4) to connectors (16) and (15).
a Connect connector (16) (4-pole) first, then
connect connector (15) (6-pole).
a Check that locks (g) of connectors (16)
and (15) are set normally.
42 WA800-3E0, WA900-3E0
9. Install clamp (9a) with bolt (9), and fix wiring

harness (8).
7. Install collars (12) (2 pieces) to back (a) of knob

(10).
a Install the collar (12) with the small diame- 10. Install cover (7) with screws (5) (4 pieces) and
ter end first. washers (6) (4 pieces).
8. Install cover (17) with screws (11) (2 pieces).
a Install horn switch (21) to the center of the
mounting hole and eliminate clearance
around it.
3 Screw (11)
0.8 ± 0.1 Nm {0.08 ± 0.01 kgm}
11. Install cover (3) with screws (1) (5 pieces) and

washers (2) (5 pieces).
WA800-3E0, WA900-3E0 43
Check of operation
1. Connect the negative (-) terminal of the battery.
(If the machine is equipped with the battery
disconnect switch, turn it to ON position.)
2. Start the engine, operate AJSS lever and each
switch as follows, and check their operations.
Steering operation
q Operate AJSS lever to the right and left, and
check that the machine turns in the operating
direction of AJSS lever.
Directional operation
q Set directional selector switch (20) to each
position (N, F, R), and check that the travel
direction changes according to the operation
of directional selector switch.
Upshift and downshift operations
q Operate upshift switch (23) and downshift
switch (24), and check that gear is shifted ac-
cording to the switch operation.
Horn switch operation
q Operate horn switch (21), and check that the
horn sounds according to the horn switch op-
eration.
44 WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 45
SEN02749-02

© 2017 KOMATSU
All Rights Reserved
46
SEN02750-00
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up

Electrical system
Removal and installation of engine controller assembly ................................................................................. 2
Removal and installation of transmission and steering controller assembly ................................................... 3
Removal and installation of main monitor assembly ....................................................................................... 4
Removal and installation of air conditioner unit assembly .............................................................................. 6
WA800-3E0, WA900-3E0 1

engine controller assembly 1
q Carry out installation in reverse order of
Removal removal.
and stop the engine. Apply the parking [*1], [*2]
brake and put the blocks under the wheels. a Make sure inside of the controller connector is
k Disconnect the cable from the negative (–) free from sands, dusts or water. If such foreign
terminal of the battery. substances are present, clean them com-
pletely with the air blow. (Sands, dusts or water
1. Remove right and left engine side covers (1). can cause defect contact or allow commingling
of water.)
2. Removal of the right bank engine controller

assembly
1) Remove the controller cover.
2) Disconnect harness connectors EM2 (2)
and EM4 (3). [*1]
3) Remove 4 nuts and remove engine con-
troller assembly (4).
3. Removal of the left bank engine controller

assembly
1) Remove the controller cover.
2) Disconnect harness connectors EM1 (5)
and EM3 (6). [*2]
3) Remove 4 nuts and remove engine con-
troller assembly (7).
2 WA800-3E0, WA900-3E0

transmission and steering
controller assembly 1 removal.
Removal
1. Open the right-hand door of the cab, then

remove the cover out of the control stand case.
2. Disconnect connectors (1), (2), (3), (4), (5) and

(6).
(1) = C1, (2) = C3B, (3) = C3A, (4) = C4, (5) =
C2, (6) = C5
3. Remove mounting bolts (7), then remove

transmission and steering controller (8).
WA800-3E0, WA900-3E0 3
Removal and installation of main 5) Remove steering post cover (8) and
monitor assembly 1 mounting bolt cap, then remove mounting
bolt (9).
Removal a Turn down the steering post cover
k Stop the machine on level ground and forward.
1. Removal of surrounding steering column

1) Remove dashboards (1) and (2).
2) Remove steering post covers (3) and (4).
2. Remove bracket (10) on the back side of the

main monitor.
3) Remove steering post cover (5).

4) Remove steering post cover (6) and
mounting bolt cap (7), then remove the
bolt.
3. Remove main monitor (11) and 8 mounting

bolts (12).
a When removing the main monitor, be
careful not to give a large shock to it.
4 WA800-3E0, WA900-3E0
4. Disconnect connectors (13), (14), (15) and (16) Installation

from the main monitor (11), then remove the
main monitor. [*1] q Carry out installation in the reverse order to
(13) = CN-L06 removal.
(14) = CN-L07
(15) = CN-L05 [*1]
(16) = CN-L08 a Apply the locks of the connectors securely.
WA800-3E0, WA900-3E0 5
Removal and installation of air 3. Remove operator’s seat (2).

conditioner unit assembly 1 4 Operator’s seat: 40 kg
Removal
advance.
atmosphere.
ingly, put on protective goggles while you
5. Remove air conditioner unit cover (3), console
box cover (4) and box (5).
son.
1. Remove the cab. For details, see “Removal

and installation of cab assembly”.
2. Connect refrigerant collector to adapter (1) of

the air conditioner compressor hose, then col-
lect the refrigerant (R134a).
6. Remove fuse box (6) from the air conditioner

unit, then move it toward the right-hand con-
sole box.
7. Disconnect connectors (7) (LC3) and (8)

(LC2).
8. Disconnect 2 refrigerant tubes (9).
6 WA800-3E0, WA900-3E0
9. Disconnect 2 heater hoses (10). Installation

a Be careful, since the tube on the unit side
is soft. q Carry out installation in the reverse order to
removal.
q Filling with refrigerant (R134a)

Fill the air conditioner circuit with the refriger-
ant (R134a).
10. Remove mounting bolt (11), then remove air

conditioner unit (12).
a Remove the air conditioner unit by pulling
it out to the left.
WA800-3E0, WA900-3E0 7
SEN02750-00

© 2007 KOMATSU
All Rights Reserved
8
SEN02046-00
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Power train hydraulic circuit diagram .............................................................................................................. 2
Brake hydraulic circuit diagram....................................................................................................................... 3
Work equipment hydraulic circuit diagram ...................................................................................................... 5
WA800, WA900-3E0 1
SEN02046-00 90 Diagrams and drawings
Power train hydraulic circuit diagram 1
2 WA800, WA900-3E0
Brake hydraulic circuit diagram 1
WA800, WA900-3E0 3
Work equipment hydraulic circuit diagram Work equipment hydraulic circuit diagram
WA800, WA900-3E0
WA800, WA900-3E0 5
SEN02046-00

© 2006 KOMATSU
All Rights Reserved
8
SEN02047-02
WA800-3E0,
WA900-3E0

WA800-3E0 70001 and up
WA900-3E0 60001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram (1/8)......................................................................................................................... 3
Electrical circuit diagram (5/8) (STD) .............................................................................................................11
Electrical circuit diagram (5/8) (NA specification) ......................................................................................... 13
Electrical circuit diagram (6/8)....................................................................................................................... 15
Electrical circuit diagram of emergency engine stop..................................................................................... 21
Electrical circuit diagram of hydraulic oil level sensor................................................................................... 23
Electrical circuit diagram for KAL (1/2).......................................................................................................... 25
Electrical circuit diagram for KAL (2/2).......................................................................................................... 27
Electrical circuit diagram of battery and starting motor disconnector switch and starting aid connector ...... 29
Electrical circuit diagram for bucket tilt limitter (If equipped) ......................................................................... 30
Connector arrangement diagram .................................................................................................................. 31
WA800-3E0, WA900-3E0 1
2 WA800-3E0, WA900-3E0
Electrical circuit diagram (1/8)
Electrical circuit diagram (1/8) WA800, WA900-3E0
1
SEN02047-02
WA800, WA900-3E0 3
1
SEN02047-02
WA800, WA900-3E0 5
1
SEN02047-02
WA800, WA900-3E0 7
1
SEN02047-02
WA800, WA900-3E0 9
1
STD 1
SEN02047-02
WA800, WA900-3E0 11
1
NA specification 1
SEN02047-02
WA800, WA900-3E0 13
1
SEN02047-02
WA800, WA900-3E0 15
1
SEN02047-02
WA800, WA900-3E0 17
1
SEN02047-02
WA800, WA900-3E0 19
Electrical circuit diagram of emergency
Electrical circuit diagram of emergency engine stop engine stop
1
WA800, WA900-3E0
SEN02047-02
WA800, WA900-3E0 21
Electrical circuit diagram of hydraulic oil level sensor Electrical circuit diagram of hydraulic oil level sensor
WA900-3E0 (RIO TINTO specification) WA800-3E0, WA900-3E0
WA800-3E0, WA900-3E0 23
Electrical circuit diagram for KAL (1/2)
Electrical circuit diagram for KAL (1/2) WA800-3E0, WA900-3E0
SEN02047-02
WA800-3E0, WA900-3E0 25
Electrical circuit diagram for KAL (2/2)
Electrical circuit diagram for KAL (2/2) WA800-3E0, WA900-3E0
SEN02047-02
WA800-3E0, WA900-3E0 27
Electrical circuit diagram of battery and starting motor disconnector

switch and starting aid connector 1
WA800-3E0, WA900-3E0 29
Electrical circuit diagram for bucket tilt limitter (If equipped) 1

WA800/900-3E0
30 WA800-3E0, WA900-3E0
Connector arrangement diagram
WA800-3E0, WA900-3E0
Connector arrangement diagram
Connector Number Address of Connector Number Address of Connector Number Address of Connector Number Address of
Model Component name Model Component name Model Component name Model Component name
No. of pins stereogram No. of pins stereogram No. of pins stereogram No. of pins stereogram
A10 YAZAKI 4 Air conditioner Blower relay (HI) AA-4 E06 — 2 Starting motor A AN-2 JF4 — 6 ES-cap RA1 — 2 Battery relay RH N-9
A11 YAZAKI 4 Air conditioner Blower relay (M2) AA-5 E07 — 2 Starting motor B AN-2 JG1 — 6 ES-cap RA2 — 2 Battery relay LH N-7
A12 YAZAKI 4 Air conditioner condenser relay AA-3 E08 — 1 Freon compressor magnet clutch JG2 — 6 ES-cap RA3 — 1 Battery relay RH N-9
A13 YAZAKI 4 Air conditioner blower relay (M1) AA-5 E09 Terminal 1 Engine oil pressure switch JG3 — 6 ES-cap RA4 — 1 Battery relay LH M-7
A14 YAZAKI 4 Air conditioner condenser HI (1) relay AA-3 E10 Terminal 1 Right heater relay AN-5 JL1 DTM 12 Intermediate connector AH-3 RB-1 — 21 Work equipment controller
A15 YAZAKI 4 Air conditioner condenser HI (2) relay Z-2 E11 Terminal 1 Right heater relay AN-3 JL2 DT2 2 Intermediate connector AH-3 RB-2 — 20 Work equipment controller
A16 AMP 12 Air conditioner control amp AA-3 E12 Terminal 1 Left heater relay AL-9 JL3 — 2 — RB-3 — 16 Work equipment controller
A16 YAZAKI 4 Air conditioner magnetic clutch relay U-1 E13 Terminal 1 Left heater relay AL-6 JL4 DT2 6 AJSS mode select RB4 — 16 Sub monitor V-9
A17 AMP 16 Air conditioner control amp U-1 E14 Terminal 1 Fuse holder JR1 — 4 ES-cap S30 DT2 3 Potentiometer AH-7
A18 SWP 8 Air conditioner left air flow servomotor V-1 E15 Terminal 1 Fuse holder JR2 — 3 ES-cap S31 DTM 12 AJSS Lever switch AH-8
A19 SWP 8 Air conditioner right air flow servomotor R-5 E16 Terminal 1 GND JR3 — 6 ES-cap SEL 1 M 4 —
A21 X 2 Air conditioner pressure switch AA-7 E17 Diode 2 Diode JR4 — 6 ES-cap SL1 M 4 Intermediate connector (cab)
A22 — 2 Air conditioner pressure switch AA-8 E18 Diode 2 Diode JR5 — 6 ES-cap SL2 KES 2 Rear step light switch AA-7
A4 X 2 Air conditioner REC&FRE air servomotor X-9 E19 Diode 2 Diode JV6 — 6 RS232C GND SL3 Relay 5 — Z-8
A5 M 2 Air conditioner thermistor AA-7 E20 Terminal 1 Alternator AM-9 L01 DT2 3 Parking brake switch AC-6 SL4 M 6 — Z-8
A6 SWP 6 Air conditioner air mix servo motor AA-6 E21 Terminal 1 Alternator AM-9 L02 SWP 4 Light switch AC-6 SL5 DT2 2 Step lamp
A7 M 6 Air conditioner blower motor & resistor AA-6 E22 Terminal 1 Alternator L03 DT2 2 Hazard switch AC-6 SV1 — 4 Hydraulic pump assembly
A8A S 10 Intermediate connector AA-6 E30 Terminal 1 Prelube relay L04 DT2 6 Intermediate connector AE-8 SW1 One-pin connector 1 Normal open pressure switch
A8B S 8 Intermediate connector AA-5 E30 Terminal 1 Fuse holder AM-1 L05 AMP 040 20 Main monitor R-5 SW2 One-pin connector 1 Normal open pressure switch
A9 YAZAKI 4 Air conditioner blower relay (MAIN) AA-3 E31 Terminal 1 Fuse holder AM-1 L06 AMP 040 16 Main monitor R-2 T01 — 10 Solenoid J-2
AL01 Terminal 1 Battery relay LH N-5 E99 Terminal 1 Starting motor L07 AMP 040 12 Main monitor R-4 T02 DT2 2 Torque convertor oil temperature sensor K-2
AL02 Terminal 1 Battery relay LH N-6 EM1 DRC26 50 Engine controller (L Bank) AN-4 L08 AMP 040 8 Main monitor R-2 T03 — 50 GND
AL03 Terminal 1 Battery relay LH N-6 EM1 20 Engine service monitor W-9 L09 M 4 Starting switch R-2 TIM — 10 Auto grease controller
AR01 Terminal 1 Battery relay RH M-9 EM2 DRC26 50 Engine controller (R Bank) AJ-5 L10 S 10 Wiper switch S-2 TR1 DT2A 8 Intermediate connector G-9
AR02 Terminal 1 Battery relay RH M-9 EM2 — 12 Engine service monitor W-9 L12 — 3 Transmission cut off press sensor U-1 TSW SWP 6 Turn signal
AR03 Terminal 1 Battery relay RH M-9 EM3 DT06 4 Engine controller (L Bank) AN-4 L15 M 4 Kickdown switch & shift-up switch TURN DT2 3 Front combination lamp RH C-6
ASS AMP 2 Air suspension seat AA-8 EM3 SWP 6 Panel mode switch 2 V-9 L16 — 2 Lift arm kick out solenoid R-6 TURN DT2 3 Front combination lamp LH E-1
B02 KES 2 Front window washer H-9 EM4 DT06 4 Engine controller (R Bank) AI-6 L17 — 2 Bucket positioner solenoid R-5 U00 Relay 5 Relay S-8
B03 KES 2 Diode EM4 SWP 6 Panel mode switch 1 V-9 L18 AMP 040 16 Sub monitor T-8 U01 Relay 5 Relay R-9
B04 KES 2 Rear window washer H-9 EM5 — 1 Engine caution lamp AC-4 L19 AMP 040 8 Sub monitor U-8 U02 Relay 5 Relay R-9
B05 KES 2 Diode EM5 — 3 Service connector L21 KES 2 Sub monitor U-8 U03 Relay 5 Relay R-9
B06 DT2 2 Left dust indicator I-9 EM6 — 1 Engine caution lamp AC-4 L22 KES 2 Sub monitor U-9 U04 Relay 6 Relay R-9
B08 DT2 2 Right dust indicator I-9 EM6 — 3 Terminator L24 — 2 Idle/throttle validation switch S-2 U05 Relay 5 Relay S-7
B10 X 2 Air conditioner left condenser L-6 EM7 DT2A 12 KOM-NET service connector L25 — 6 Idle/throttle validation switch S-2 U06 KES 6 —
B11 X 1 Air conditioner left condenser L-6 ER1 — 31 Intermediate connector AN-1 L26 DT2 2 J/S EPC solenoid AF-1 U07 KES 6 —
B12 X 2 Air conditioner right condenser L-4 ER2 — 9 Intermediate connector AN-1 L27 DT2 3 Frame angle potentiometer AF-1 U08 — 3 —
B13 X 1 Air conditioner right condenser L-5 F01 DT4 4 Intermediate connector B-6 L29 Relay 6 Lever safety relay U16 KES 4 Active mode switch
BC01 DT2 2 Speed sensor F-1 F02 DT3 3 Intermediate connector B-5 L31 — 1 Intermediate connector AD-8 V09 DRC26 40 Orbcomm (RX.unit) X-1
BC02 DT2 2 Torque convertor oil filter sensor I-1 F03 DT3 3 Intermediate connector B-2 L32 — 1 Intermediate connector AD-8 V1 DT2A 12 Intermediate connector (VHMS) T-1
BC03 DT2 2 Torque convertor oil filter sensor I-1 F04 DT4 4 Intermediate connector B-2 L33 — 1 Intermediate connector AC-7 V10 — 5 Personal computer T-1
BC04 DT2 2 Brake accumulator low pressure switch 1 L-2 F05 DT3 3 Proximity switch for bucket positioner B-3 L34 SWP 6 Transmission cut off switch T-7 V2 DT2B 12 Intermediate connector (VHMS) V-1
BC05 DT2 2 Brake accumulator low pressure switch 2 L-1 F06 DT3 3 Proximity switch for lift arm positioner B-3 L35 M 4 DC converter AA-8 V20 DRC12 24 Intermediate connector (VHMS) F-9
BC06 DT2 2 Brake accumulator low pressure switch 3 M-3 F07 YZK 090 2 Horn RH B-5 L36 YAZAKI 2 — V21 DT3 3 Ambient air pressure sensor H-1
BC07 DT2 2 Brake accumulator low pressure switch 4 N-2 F08 YZK 090 2 Horn LH E-1 L39 DT2 2 Steering lock switch AF-2 V22 DT3 3 Brake oil pressure sensor (Front) N-3
BC08 DT2 2 Emergency brake switch 1 L-2 F09 DT2B 12 Intermediate connector B-5 L40 7P 7 Right power window switch T-8 V23 DT3 3 Brake oil pressure sensor (Rear) L-2
BC09 DT2 2 Emergency brake switch 2 L-1 F10 Terminal 1 GND B-6 L41 7P 7 Left power window switch T-8 V24 DT2 2 Hydraulic oil temperature sensor F-1
BC10 DT2 2 Emergency brake switch 3 M-3 F11 DT2 2 Parking brake solenoid B-1 L42 M 2 Caution buzzer W-9 V26 DT3 3 Steering oil pressure sensor F-1
BC11 DT2 2 Emergency brake switch 4 N-2 F12 DT2 2 Parking brake indicate switch B-1 L44 Relay 6 Wiper switch relay X-9 V27 DT3 3 Work equipment pump pressure sensor G-9
BC12 Terminal 1 Engine shutdown switch H-1 F13 DT3 3 Active working hydraulic system B-1 L46 — 4 Flasher unit W-9 V28 DT3 3 Transmission oil pressure I-1
BC13 Terminal 1 Engine shutdown switch H-1 F14 DT2 3 Active working hydraulic system B-5 L48 Relay 5 Bucket F relay P-7 V3 DT2C 12 Intermediate connector (VHMS) V-1
BR1 DT2A 8 Intermediate connector L-3 F15 DT2 2 Intermediate connector C-1 L49 Relay 5 Lift arm relay P-7 V32 — 3 Blowby pressure sensor AJ-4
C01 M 6 Front wiper motor D-7 F16 DT2 2 Intermediate connector L51 Relay 6 Side work lamp relay S-9 V34 DT3 3 Exhaust gas temperature sensor amplifier B-7
C02 YAZAKI PA 9 AM/FM radio D-7 F25 DT2 2 Front brake oil temperature sensor B-1 L52 Relay 5 Hazard relay O-7 V35 DT3 3 Exhaust gas temperature sensor amplifier B-7
C03 DT2 2 Right front work lamp E-8 FA1 DT2 2 Intermediate connector B-3 L53 Relay 5 Stop lamp relay O-7 V36 — 2 Intermediate connector A-7
C04 DT2 2 Left front work lamp E-8 FAL DT2 2 Front frame axle lights LH D-1 L54 Relay 5 Back lamp relay O-8 V37 — 2 Intermediate connector A-7
C05 KYOURITU ES 4 Warning lamp (beacon) switch E-8 FAR DT2 2 Front frame axle lights RH C-1 L55 Relay 6 Horn relay R-7 V38 — 2 Exhaust gas temperature sensor (F.L) AN-3
C06 KES 2 Room lamp G-9 FB1 DT2 2 If equipped B-4 L57 Relay 5 Neutral O-7 V39 — 2 Exhaust gas temperature sensor (F.R) AN-3
C07 M 4 Rear wiper motor G-9 FB2 DT2 2 If equipped B-3 L58 Relay 5 Neutralizer O-8 V4 DT2 6 Intermediate connector (VHMS) T-1
C08 One-pin connector 1 Cigarette lighter D-7 FB3 DT2 2 — B-3 L59 Relay 5 Parking brake safety relay O-9 V40 — 8 Down load harness L-2
C09 KES 1 Cigarette lighter E-8 FB4 DT3 3 Lift arm angle sensor B-6 L60 Relay 6 F work lamp relay P-9 V41 DT3 3 Exhaust gas temperature sensor amplifier B-8
C1 MIC 13 Transmission & joystick steering controller S-7 FB5 DT2 2 — B-4 L61 Relay 6 R work lamp relay P-9 V42 DT3 3 Exhaust gas temperature sensor amplifier B-8
C10 — 1 — D-7 FB6 6 ES-cap L64 Relay 5 Engine oil pressure relay O-8 V43 — 2 Intermediate connector A-8
C11 — 1 Right room lamp door switch F-8 FG3L DT2 2 Fog lamp LH L65 Relay 5 Caution. J/T relay Q-7 V44 — 2 Intermediate connector A-8
C12 — 1 Left room lamp door switch H-9 FG3R DT2 2 Fog lamp RH L66 Relay 6 Head lamp relay V45 — 2 Exhaust gas temperature sensor (R.L) AN-3
C13 KES 2 Left speaker H-9 FL1 DRC12 40 Intermediate connector Y-2 L67 Relay 5 Small lamp relay Q-7 V46 — 2 Exhaust gas temperature sensor (R.R) AN-3
C14 KES 2 Right speaker G-9 FS1 L 2 Fuse box 1 Z-8 L68 Relay 6 Turn/hazard relay P-9 VC01 AMP 070 20 VHMS controller P-1
C15 DT2 2 Warning lamp (beacon) E-8 FS2 S(BLUE) 12 Fuse box 1 Z-9 L71 Relay 11 Power window relay R-7 VC02 AMP 070 18 VHMS controller P-1
C16 DT2 2 Left side work lamp G-9 FS3 M 6 Fuse box 1 Y-9 L72 Relay 5 Heater glass relay R-9 VC03 AMP 070 12 VHMS controller Q-1
C17 DT2 2 Right side work lamp F-8 FS4 L 2 Fuse box 2 Y-9 L73 Relay 5 Pre heat relay Q-9 VC04 AMP 070 18 VHMS controller P-3
C18 KYOURITU ES 4 Fog lamp switch (if equipped) FS5 M 6 Fuse box 2 Y-9 L79 Relay 5 Left dust indicator relay O-9 VC05 AMP 070 12 VHMS controller P-3
C19 M 2 Maruteki (if equipped) FS6 M 4 Fuse box 2 Y-9 L80 Relay 5 Right dust indicator relay O-8 VC06 AMP 070 14 VHMS controller Q-3
C2 MIC 21 Transmission & joystick steering controller R-6 FS7 M 6 Fuse box 2 X-9 L81 — 2 Stop lamp switch T-1 VC07 AMP 070 10 VHMS controller P-3
C3A AMP 040 20 Transmission & joystick steering controller S-7 G01 DT6 6 Rear combination lamp (RH) J-9 L88 Diode 3 AJSS N hold relay WORK DT2 2 Work lamp RH C-7
C3B AMP 040 16 Transmission & joystick steering controller S-7 G02 DT2 2 Rear work lamp RH (ADD) J-9 L89 Relay 6 AJSS N safety relay WORK DT2 2 Work lamp LH D-1
C4 AMP 040 12 Transmission & joystick steering controller R-6 G03 DT2 2 Rear work lamp RH (ADD) J-9 L90 Relay 6 Axle work lamp relay Q-9 CM850.L Terminal 1 Left bank engine AI-7
C40 KES 4 Glass heater switch G04 DT2 2 Back up alarm L-8 L95 Relay 5 Neutral safety relay R-9 CM850.R Terminal 1 Right bank engine AI-5
C41 — 1 Rear glass heater G06 DT2 2 Coolant level sensor K-9 LR1 DRC12 70 Intermediate connector F-9 ENGL RRC26 60 Engine controller (L bank) AN-4
C42 — 1 Rear glass heater G07 DT2 2 Rear work lamp LH (ADD) L-8 LR2 HD34-24 9 Intermediate connector F-8 ENGR RRC26 60 Engine controller (R bank) AJ-5
C5 MIC 17 Transmission & joystick steering controller R-6 G08 DT2 2 Rear work lamp LH (ADD) L-7 LR6 — 24 Intermediate connector G — 3 Left bank engine AL-1
CBL1 DT2A 12 Intermediate connector (Compo. box) J-2 G09 DT6 6 Rear combination lamp (LH) L-7 MMS DT2A 12 MMS SPEC W-1 G — 3 Right bank engine AM-6
CL1 S (BLUE) 12 Intermediate connector (cab) R-4 G1 Relay 5 Relay NSW — 1 AUX. AA-8 GND.L Terminal 1 Left bank engine AM-1
CL18 — 1 Power window regulator LH G2 Relay 5 Relay OP1 — 1 AUX. X-9 GND.R Terminal 1 Right bank engine AK-5
CL19 — 1 Power window regulator LH G3 Diode 2 Diode PRE1 DT2 3 Intermediate connector J1939 — 4 CAN data link (L.H.) AI-6
CL2 S 10 Intermediate connector (A/C controller) R-3 G4 Diode 2 Diode PRE2 DT2 3 Intermediate connector J1939 — 4 CAN data link (R.H.) AI-6
CL20 — 1 Power window regulator RH G5 Diode 2 Diode PRE3 DT2A 12 Intermediate connector LS — 14 Injector output (L.H.) AI-9
CL21 — 1 Power window regulator RH G6 DT2 4 Intermediate connector PRE4 Relay 5 Engine start relay NE — 3 Engine speed sensor (L.H.) AI-6
CL3 M 6 Intermediate connector (A/C controller) R-3 GFL — 2 — PRE4 — 1 Prelube lamp AC-5 NE — 2 Engine speed sensor (R.H.) AJ-5
CL4 M 6 Intermediate connector (cab) R-3 GND 1 — 1 AUX. PRE5 Relay 5 Prelube start relay PAMB — 3 Ambient air pressure sensor AI-8
CL5 M 4 Intermediate connector (cab) GR1 DT2A 12 Intermediate connector K-9 PRE5 — 1 Prelube lamp AC-5 PCV1 — 2 Supply pump 1 (+) L.H. AL-1
CL8 M 4 Intermediate connector (cab) GRE DT2 6 Intermediate connector X-1 PRE7 Relay 5 Prelube set ON relay PCV1 — 2 Supply pump 1 (+) R.H. AM-6
CLB M 4 Intermediate connector GRE DT2 6 Auto grease PRF6 DRCA 40 Prelube controller PCV2 — 2 Supply pump 1 (–) L.H. AM-1
D07 — 2 WD900 HEAD DT2 2 Head lamp RH C-7 PSW — 2 Normal open pressure switch PCV2 — 2 Supply pump 1 (–) R.H. AM-6
D11 — 2 — HEAD DT2 2 Head lamp LH E-1 R01 DT2 2 Short connector H-1 PFUEL — 3 Fuel pressure (L.H.) AN-2
D12 — 2 — IL1 LED 1 Shift indicator LED AJSS AD-2 R02 Terminal 1 Battery relay LH PFUEL — 3 Fuel pressure (R.H.) AL-5
D13 — 2 — IL10 — 2 — R03 Terminal 1 Fuse holder E-9 PIM — 3 Boost pressure AI-8
D14 — 2 — IL11 Relay 5 LED brightness control Q-9 R04 Terminal 1 Fuse holder E-9 POIL — 3 Oil pressure AN-1
D15 Diode 3 Battery relay IL2 One-pin connector 1 Shift indicator LED AJSS AD-2 R05 Terminal 1 Fuse holder E-9 RES — 2 Right bank engine
D16 — 3 Torque converter oil filter IL3 One-pin connector 1 Shift indicator LED AJSS AC-3 R06 Terminal 1 Circuit breaker C-9 RES 1 — 2 Left bank engine
D17 — 3 Brake oil pressure LD. IL4 One-pin connector 1 Shift indicator LED AJSS AC-3 R07 Terminal 1 Circuit breaker C-9 RES 2 — 3 CAN data link
D18 Diode 3 — IL5 One-pin connector 1 Shift indicator LED AJSS AC-3 R08 DT2 2 Fuel level sensor L-4 RES 3 — 3 CAN data link
D19 Diode 3 — IL6 One-pin connector 1 Shift indicator LED AJSS AD-2 R09 DT2 2 Step light switch M-7 R.P — 14 Injector output (R.H.) AK-5
D20 Diode 3 Eng. oil pressure IL7 Diode 3 — R10 Terminal 1 GND L-7 TAMB — 2 Inlet air temperature AJ-9
D21 Diode 3 Left dust indicator IL8 — 2 — R11 Terminal 1 GND (For battery) TFUEL — 2 Fuel temperature (L.H.) AL-1
D22 Diode 3 Right dust indicator JB1 — 6 ES-cap R12 Terminal 1 Circuit breaker C-9 TFUEL — 2 Fuel temperature (R.H.) AM-8
E00 Terminal 1 GND JB2 — 6 ES-cap R13 Terminal 1 Circuit breaker C-9 TIM — 2 Boost temperature AI-9
E01 Terminal 1 Prelube relay JE1 — 6 ES-cap R14 Terminal 1 Circuit breaker C-8 TOIL — 2 Engine oil temperature AN-2
E02 Terminal 1 Prelube oil pressure switch JE2 — 6 ES-cap R15 Terminal 1 Circuit breaker C-8 TWTR — 2 Coolant temperature input AK-1
E03 — 2 Engine speed sensor JF1 — 6 ES-cap R16 DT2 2 2 Stage solenoid
E04 — 2 Engine coolant temperature sensor (For monitor) AJ-4 JF2 — 6 ES-cap R17 Diode 2 —
E05 — 2 Engine oil level sensor AK-5 JF3 — 6 ES-cap R85 M 2 Remote positioner
SEN02047-02
WA800-3E0, WA900-3E0 31
WA800-3E0, WA900-3E0 33
SEN02047-02

© 2017 KOMATSU
All Rights Reserved
34

Shop Manuel WA900-3

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SEN02034-13

WHEEL LOADER WA800 -3E0

WHEEL LOADER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual .......................................................................................................................... 2

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN02034-13

00 Index and foreword SEN02035-13

10 Structure, function and maintenance standard SEN02040-07

20 Standard value table SEN02041-02

30 Testing and adjusting SEN02042-06

Troubleshooting by failure code (Display of code), Part 2 SEN02145-01

50 Disassembly and assembly SEN02044-08

90 Diagrams and drawings SEN02045-02

Foreword and general information SEN02037-04

10 Structure, function and maintenance standard

Steering pump ............................................................................................................................. 25

Electrical system, Part 3 SEN02361-03

20 Standard value table

30 Testing and adjusting

Testing and adjusting wear of parking brake pad ........................................................................ 24

Failure code [B@JFZG] (Brake oil: Low oil pressure) ................................................................. 36

Failure code [D180KA] (Preheating relay output system: Disconnection) .................................. 38

H-23 Bucket has large amount of hydraulic drift ......................................................................... 22

K-9 Night lamp does not light up ................................................................................................. 36

50 Disassembly and assembly

Disassembly and assembly of differential assembly ................................................................... 18

90 Diagrams and drawings

WA800, 900-3E0 Wheel loader

WHEEL LOADER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work

4. Precautions for sling work and making

6. Precautions for using overhead hoist crane

7. Selecting wire ropes 2) Connection

a The allowable load is one-sixth of the

8. Precautions for disconnecting and con-

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-