WA150-6 Werkstatthandbuch PDF

SEN04885-05
WHEEL LOADER WA150 -6

SERIAL NUMBERS 80001 and up
SEN05072-05
WHEEL LOADER
WA150-6
Machine model Serial number

WA150-6 80001 and up
00 Index and foreword 00
100 Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
WA150-6 00-100 1
100 Index
SEN05072-05 Composition of shop manual
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 Tab 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 ..................................................................... SEN04885-05
00 Index and foreword .................................................................................................................... SEN05064-05

100 Index .................................................................................................................................. SEN05072-05 q
200 Foreword and general information ..................................................................................... SEN05073-00
01 Specification ............................................................................................................................... SEN05065-00

100 Specification and technical data......................................................................................... SEN05074-00
10 Structure, function and maintenance standard........................................................................... SEN05066-00

100 Engine and cooling system ................................................................................................ SEN05075-00
200 Power train......................................................................................................................... SEN05076-00
300 Steering system ................................................................................................................. SEN05077-00
400 Brake system ..................................................................................................................... SEN05078-00
500 Undercarriage and frame ................................................................................................... SEN05079-00
600 Hydraulic system................................................................................................................ SEN05080-00
700 Work equipment................................................................................................................. SEN05081-00
800 Cab and its attachments .................................................................................................... SEN05082-00
901 Electrical system, Part 1 .................................................................................................... SEN05083-00
902 Electrical system, Part 2 .................................................................................................... SEN05084-00
20 Standard value table................................................................................................................... SEN05067-00

100 Standard service value table.............................................................................................. SEN05123-00
30 Testing and adjusting ................................................................................................................. SEN05068-02

101 Testing and adjusting, Part 1.............................................................................................. SEN05124-00
102 Testing and adjusting, Part 2.............................................................................................. SEN05125-00
103 Testing and adjusting, Part 3.............................................................................................. SEN05126-02 q
40 Troubleshooting.......................................................................................................................... SEN05069-01
100 Failure code table and fuse locations ................................................................................ SEN05127-00
200 General information on troubleshooting............................................................................. SEN05128-01
301 Troubleshooting by failure code (Display of code), Part 1 ................................................. SEN05129-00
00-100 2 WA150-6
100 Index
Composition of shop manual SEN05072-05
306 Troubleshooting by failure code (Display of code), Part 6..................................................SEN05134-00

307 Troubleshooting by failure code (Display of code), Part 7..................................................SEN05135-00
400 Troubleshooting of electrical system (E-mode) ..................................................................SEN05136-00
500 Troubleshooting of hydraulic and mechanical system (H-mode)........................................SEN05137-00
600 Troubleshooting of engine (S-mode) ..................................................................................SEN05138-00
50 Disassembly and assembly ........................................................................................................SEN05070-01

100 General information on disassembly and assembly...........................................................SEN05185-01
200 Engine and cooling system ................................................................................................SEN05186-00
300 Power train .........................................................................................................................SEN05187-01
400 Undercarriage and frame ...................................................................................................SEN05188-00
500 Hydraulic system ................................................................................................................SEN05189-00
600 Work equipment .................................................................................................................SEN05190-00
700 Cab and its attachments.....................................................................................................SEN05191-00
800 Electrical system ................................................................................................................SEN05192-00
80 Appendix.....................................................................................................................................SEN05139-00
100 Air conditioner ....................................................................................................................SEN05140-00
90 Diagrams and drawings ..............................................................................................................SEN05071-00

100 Hydraulic diagrams and drawings ......................................................................................SEN05085-00
200 Electrical diagrams and drawings.......................................................................................SEN05086-00
WA150-6 00-100 3
100 Index
SEN05072-05 Table of contents
Table of contents 1
00 Index and foreword

100 Index SEN05072-05
Composition of shop manual......................................................................................................................... 2
Table of contents ........................................................................................................................................... 4
200 Foreword and general information SEN05073-00
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
100 Specification and technical data SEN05074-00
Specification dimension drawing ................................................................................................................... 3
Specifications ................................................................................................................................................ 4
Weight table .................................................................................................................................................. 8
Table of fuel, coolant and lubricants.............................................................................................................. 10
10 Structure, function and maintenance standard

100 Engine and cooling system SEN05075-00
Engine mount and transfer mount................................................................................................................. 2
Damper ......................................................................................................................................................... 3
Cooling system.............................................................................................................................................. 4
Cooling system hydraulic piping diagram...................................................................................................... 5
Cooling fan motor.......................................................................................................................................... 7
200 Power train SEN05076-00
Power train .................................................................................................................................................... 3
Power train system diagram.......................................................................................................................... 4
Drive shaft ..................................................................................................................................................... 6
HST hydraulic piping diagram ....................................................................................................................... 7
HST pump ..................................................................................................................................................... 8
HST motor..................................................................................................................................................... 17
Transfer ......................................................................................................................................................... 24
Clutch solenoid valve .................................................................................................................................... 35
Axle ............................................................................................................................................................... 36
Differential ..................................................................................................................................................... 38
Torque proportioning differential.................................................................................................................... 43
Limited slip differential................................................................................................................................... 44
Final drive...................................................................................................................................................... 48
300 Steering system SEN05077-00
Steering piping diagram ................................................................................................................................ 3
Steering column ............................................................................................................................................ 4
Priority valve.................................................................................................................................................. 5
Orbit-roll valve ............................................................................................................................................... 8
Steering cylinder............................................................................................................................................ 16
400 Brake system SEN05078-00
Brake piping diagram .................................................................................................................................... 3
Charge valve ................................................................................................................................................. 4
Brake valve ................................................................................................................................................... 8
Inching valve ................................................................................................................................................. 12
00-100 4 WA150-6
100 Index
Table of contents SEN05072-05
Accumulator (for brake) ................................................................................................................................. 13

Slack adjuster ................................................................................................................................................ 14
Brake ............................................................................................................................................................. 16
Parking brake control..................................................................................................................................... 21
Parking brake ................................................................................................................................................ 22
500 Undercarriage and frame SEN05079-00
Axle mount and center hinge pin ................................................................................................................... 2
600 Hydraulic system SEN05080-00
Hydraulic component layout drawing............................................................................................................. 2
Work equipment control lever linkage ........................................................................................................... 4
Hydraulic tank................................................................................................................................................ 6
3-gear pump .................................................................................................................................................. 8
Work equipment control valve ....................................................................................................................... 11
Work equipment PPC valve........................................................................................................................... 51
Attachment PPC valve................................................................................................................................... 58
Lock valve...................................................................................................................................................... 60
2-way restrictor valve..................................................................................................................................... 61
Accumulator (for oil cooler circuit) ................................................................................................................. 62
Accumulator (for PPC circuit) ........................................................................................................................ 63
Accumulator (for ECSS) ................................................................................................................................ 64
700 Work equipment SEN05081-00
Work equipment linkage ................................................................................................................................ 2
Bucket............................................................................................................................................................ 4
Bucket positioner and boom kick-out............................................................................................................. 6
Work equipment cylinder ............................................................................................................................... 12
800 Cab and its attachments SEN05082-00
Cab ................................................................................................................................................................ 3
901 Electrical system, Part 1 SEN05083-00
Machine monitor system................................................................................................................................ 2
Machine monitor ............................................................................................................................................ 6
902 Electrical system, Part 2 SEN05084-00
Electrical system (HST controller system)..................................................................................................... 2
HST controller................................................................................................................................................ 18
ECSS system ................................................................................................................................................ 19
KOMTRAX system ........................................................................................................................................ 20
Engine starting circuit .................................................................................................................................... 22
Engine stopping circuit .................................................................................................................................. 24
Preheating circuit........................................................................................................................................... 25
Engine output derating function..................................................................................................................... 26
Automatic warm-up function .......................................................................................................................... 26
Parking brake circuit ...................................................................................................................................... 28
Multi-function knob ........................................................................................................................................ 30
Sensor ........................................................................................................................................................... 31
20 Standard value table

100 Standard service value table SEN05123-00
Standard service value table for engine ........................................................................................................ 2
Standard service value table for chassis ....................................................................................................... 3
30 Testing and adjusting

101 Testing and adjusting, Part 1 SEN05124-00
Tools for testing, adjusting, and troubleshooting ........................................................................................... 3
Testing engine speed..................................................................................................................................... 8
Testing exhaust gas color .............................................................................................................................. 10
Testing exhaust temperature ......................................................................................................................... 12
Adjusting valve clearance.............................................................................................................................. 13
WA150-6 00-100 5
100 Index
Testing compression pressure ...................................................................................................................... 15

Testing blow-by pressure .............................................................................................................................. 17
Testing engine oil pressure ........................................................................................................................... 18
Testing intake air (boost) pressure ................................................................................................................ 19
Handling fuel system equipment ................................................................................................................... 19
Releasing residual pressure in fuel system................................................................................................... 20
Testing fuel pressure ..................................................................................................................................... 21
Testing fuel return rate and leakage.............................................................................................................. 22
Bleeding air from fuel circuit.......................................................................................................................... 25
Checking leakage in fuel system................................................................................................................... 26
Handling cylinder cut-out mode operation..................................................................................................... 27
Handling no-injection cranking operation ...................................................................................................... 27
Handling controller voltage circuit ................................................................................................................. 28
Check of muffler and muffler stack for looseness and damage .................................................................... 28
Check of muffler function .............................................................................................................................. 29
Check of installed condition of cylinder head and manifolds......................................................................... 29
Check of engine piping for damage and looseness ...................................................................................... 30
Testing and adjusting air conditioner compressor belt tension...................................................................... 30
Testing and adjusting alternator belt tension................................................................................................. 31
Checking operating force of accelerator pedal.............................................................................................. 3
Checking directional lever ............................................................................................................................. 4
Testing and adjusting HST oil pressure......................................................................................................... 5
Testing clutch control pressure...................................................................................................................... 9
Testing and adjusting steering wheel ............................................................................................................ 10
Testing and adjusting steering oil pressure ................................................................................................... 12
Bleeding air from steering circuit................................................................................................................... 14
Testing hydraulic fan ..................................................................................................................................... 15
Testing brake pedal ....................................................................................................................................... 17
Testing and adjusting brake pedal linkage .................................................................................................... 18
Testing brake performance............................................................................................................................ 19
Testing and adjusting accumulator charge pressure..................................................................................... 20
Testing wheel brake oil pressure................................................................................................................... 22
Testing wear of brake disc............................................................................................................................. 25
Bleeding air from wheel brake circuit ............................................................................................................ 26
Releasing residual pressure in brake accumulator circuit............................................................................. 27
Testing parking brake performance............................................................................................................... 28
Testing and adjusting parking brake control cable ........................................................................................ 29
Testing and adjusting parking brake switch................................................................................................... 30
Testing and adjusting work equipment control lever ..................................................................................... 31
Testing and adjusting work equipment hydraulic pressure............................................................................ 32
Testing work equipment PPC oil pressure .................................................................................................... 34
Bleeding air from hydraulic circuit ................................................................................................................. 36
Releasing remaining pressure in hydraulic circuit......................................................................................... 36
Testing and adjusting bucket positioner ........................................................................................................ 37
Testing and adjusting boom kick-out switch .................................................................................................. 39
Checking proximity switch operation pilot lamp ............................................................................................ 40
Procedure for testing diodes ......................................................................................................................... 41
Preparation work for troubleshooting for electric system .............................................................................. 43
Starting KOMTRAX terminal operations........................................................................................................ 47
Indicator lamps of KOMTRAX terminal ......................................................................................................... 51
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor............................ 2
Special functions of machine monitor (EMMS) ............................................................................................. 4
Pm clinic inspection chart...................................................................................................................... 58
00-100 6 WA150-6
100 Index
40 Troubleshooting
100 Failure code table and fuse locations SEN05127-00
Failure codes table ........................................................................................................................................ 2
Fuse locations ............................................................................................................................................... 8
200 General information on troubleshooting SEN05128-01
Points to remember when troubleshooting .................................................................................................... 2
Sequence of events in troubleshooting ......................................................................................................... 3
Testing before troubleshooting ...................................................................................................................... 4
Classification and procedures of troubleshooting.......................................................................................... 5
Information contained in troubleshooting table .............................................................................................. 8
Connection table for connector pin numbers................................................................................................. 10
T- branch box and T- branch adapter table ................................................................................................... 46
301 Troubleshooting by failure code (Display of code), Part 1 SEN05129-00
Failure code [2G40ZG] Brake: Oil pressure reduction .................................................................................. 2
Failure code [6091NX] HST filter: Clogging................................................................................................... 4
Failure code [989FN1] Travel speed: Overrun alarm .................................................................................... 5
Failure code [AB00L6] Alternator R system: Hot short.................................................................................. 6
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage ................... 8
Failure code [B@BAZG] Engine: Oil pressure reduction............................................................................... 10
Failure code [B@BCNS] Engine: Overheat................................................................................................... 11
Failure code [B@BCZK] Engine: Low coolant level ...................................................................................... 12
Failure code [B@C6NS] Front brake: High oil temperature .......................................................................... 14
Failure code [B@CRNS] HST: High oil temperature ..................................................................................... 15
Failure code [CA111] Abnormality in engine controller .................................................................................. 3
Failure code [CA115] Engine Ne or Bkup speed sensor error....................................................................... 6
Failure code [CA122] Charge pressure sensor high error............................................................................. 8
Failure code [CA123] Charge pressure sensor low error .............................................................................. 10
Failure code [CA131] Throttle sensor high error ........................................................................................... 12
Failure code [CA132] Throttle sensor low error............................................................................................. 14
Failure code [CA144] Coolant sensor high error ........................................................................................... 16
Failure code [CA145] Coolant sensor low error............................................................................................. 18
Failure code [CA153] Charge temperature sensor high error ....................................................................... 20
Failure code [CA154] Charge temperature sensor low error......................................................................... 22
Failure code [CA187] Sensor power supply 2 low error ................................................................................ 23
Failure code [CA221] Atmospheric pressure sensor high error..................................................................... 24
Failure code [CA222] Atmospheric sensor low error ..................................................................................... 26
Failure code [CA227] Sensor power supply 2 high error............................................................................... 27
Failure code [CA234] Engine overspeed....................................................................................................... 29
Failure code [CA238] Ne speed sensor power supply error.......................................................................... 30
Failure code [CA271] IMV (IMA) Short circuit................................................................................................ 32
Failure code [CA272] IMV (IMA) Disconnection ............................................................................................ 34
Failure code [CA322] Injector #1 open/short error ........................................................................................ 36
Failure code [CA351] Injectors drive circuit error .......................................................................................... 44
Failure code [CA352] Sensor power supply 1 low error ................................................................................ 46
Failure code [CA386] Sensor power supply 1 high error............................................................................... 48
Failure code [CA431] Idle validation switch error .......................................................................................... 2
Failure code [CA432] Idle validation action error........................................................................................... 6
Failure code [CA435] Engine oil pressure switch error ................................................................................. 10
Failure code [CA441] Battery voltage low error............................................................................................. 11
Failure code [CA442] Battery voltage high error ........................................................................................... 12
Failure code [CA449] Common rail pressure high error 2 ............................................................................. 13
Failure code [CA451] Common rail pressure sensor high error .................................................................... 14
WA150-6 00-100 7
100 Index
Failure code [CA452] Common rail pressure sensor low error ..................................................................... 16
Failure code [CA553] Common rail pressure high error 1............................................................................. 17
Failure code [CA559] Supply pump pressure very low error......................................................................... 18
Failure code [CA689] Engine Ne speed sensor error ................................................................................... 22
Failure code [CA731] Engine Bkup speed sensor phase error ..................................................................... 24
Failure code [CA757] All continuous data lost error...................................................................................... 25
Failure code [CA778] Engine Bkup speed sensor error................................................................................ 26
Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 28
Failure code [CA2185] Throttle sensor supply voltage high error ................................................................. 30
Failure code [CA2186] Throttle sensor power supply low error .................................................................... 32
Failure code [CA2249] Supply pump pressure very low error 2.................................................................... 34
Failure code [CA2311] Abnormality in IMV (IMA) solenoid ........................................................................... 36
Failure code [CA2555] Intake heater relay disconnection error .................................................................... 38
Failure code [CA2556] Intake heater relay short circuit error........................................................................ 40
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short ........................................................... 2
Failure code [D192KY] ECSS solenoid relay: Hot short ............................................................................... 4
Failure code [D1B0KA] HST safety relay: Disconnection ............................................................................. 6
Failure code [D1B0KB] HST safety relay: Ground fault ................................................................................ 8
Failure code [D1B0KY] HST safety relay: Hot short ..................................................................................... 10
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ............................................................. 12
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection.................................................. 14
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection ................................................ 16
Failure code [DAJ0KK] HST controller power supply: Low voltage .............................................................. 18
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality .................................................... 20
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault ................................... 22
Failure code [DAJ1L6] HST controller main power line: Hot short................................................................ 24
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage ....................................................... 26
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness............. 28
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault ............ 30
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range......................................................... 32
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals............. 34
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection ..................................................... 35
Failure code [DAJRMA] HST controller: Disagreement in option selection .................................................. 40
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line....................................... 2
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality .................................................. 6
Failure code [DD1NLD] Fan reverse switch signal: Abnormality .................................................................. 8
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short ........................................ 10
Failure code [DDB6KB] Parking brake indicator signal: Ground fault ........................................................... 12
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch
(intermediate switch): Trouble ............................................................................................................... 14
Failure code [DDB6L0] Parking brake reminder signal: Ground fault ........................................................... 16
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short ......................................... 18
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault ................................. 20
Failure code [DDD7KY] Travel speed control dial signal: Hot short.............................................................. 22
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault .................................................................. 24
Failure code [DDK6KY] FNR lever: Hot short ............................................................................................... 28
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault ............................ 2
Failure code [DF10KB] Travel speed range selector switch: Hot short......................................................... 6
Failure code [DGH1KX] HST oil temperature sensor: Ground fault.............................................................. 8
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault............................................................ 9
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short ......................................... 10
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault............................................ 12
Failure code [DHH1KY] HST oil pressure sensor: Hot short......................................................................... 14
Failure code [DHTCL6] HST filter clogging sensor: Functional defect.......................................................... 16
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short.............................................................. 18
00-100 8 WA150-6
100 Index
Failure code [DLT3KX] Travel speed sensor B: Abnormality......................................................................... 20

Failure code [DLT4KX] Travel speed sensor A: Abnormality......................................................................... 24
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality .................................................................. 26
Failure code [DV00KY] Alarm buzzer: Hot short ........................................................................................... 28
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault ........................................................ 30
Failure code [DW26KY] Motor 2 solenoid: Hot short..................................................................................... 32
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short ................................................................... 34
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault ...................................... 36
Failure code [DX16KA] Fan EPC solenoid: Disconnection ........................................................................... 2
Failure code [DX16KB] Fan EPC solenoid: Ground fault .............................................................................. 3
Failure code [DX16KY] Fan EPC solenoid: Hot short ................................................................................... 4
Failure code [DX19KA] Motor 1 solenoid: Disconnection.............................................................................. 6
Failure code [DX19KB] Motor 1 solenoid: Ground fault................................................................................. 8
Failure code [DX19KY] Motor 1 solenoid: Hot short...................................................................................... 10
Failure code [DX20KA] Clutch EPC solenoid: Disconnection ....................................................................... 12
Failure code [DX20KB] Clutch EPC solenoid: Ground fault .......................................................................... 14
Failure code [DX20KY] Clutch EPC solenoid: Hot short ............................................................................... 16
Failure code [DXH7KB] Reverse solenoid: Ground fault............................................................................... 18
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short............................................................. 20
Failure code [DXH8KB] Forward solenoid: Ground fault ............................................................................... 22
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short............................................................. 24
Failure code [J141N1] Steering pump: Overrun alarm .................................................................................. 26
Failure code [M100N1] HST pump: Overrun alarm ....................................................................................... 26
Failure code [M400N1] Motor 1: Overrun alarm ............................................................................................ 27
400 Troubleshooting of electrical system (E-mode) SEN05136-00
E-1 Engine does not start .............................................................................................................................. 3
E-2 Preheater does not operate normally...................................................................................................... 10
E-3 Travel speed is low or high ..................................................................................................................... 14
E-4 ECSS does not operate .......................................................................................................................... 20
E-5 ECSS keeps operating............................................................................................................................ 23
E-6 Defective boom kick-out function and cancellation ................................................................................. 26
E-7 Defective bucket positioner function and cancellation ............................................................................ 30
E-8 Defective lift arm FLOATING holding function and cancellation ............................................................. 34
E-9 Travel direction selection system does not function................................................................................ 38
E-10 Fan does not reverse ............................................................................................................................ 42
E-11 Fan keeps rotating in reverse................................................................................................................ 46
E-12 Wiper does not operate......................................................................................................................... 48
E-13 Windshield washer does not operate.................................................................................................... 52
E-14 Headlamp, clearance lamp, tail lamp and license lamp do not light up or go off .................................. 56
E-15 Working lamp does not light up or go off............................................................................................... 64
E-16 Turn signal lamp and hazard lamp do not light up or go off .................................................................. 69
E-17 Brake lamp does not light or it keeps lighting up .......................................................................... 76
E-18 Backup lamp does not light or it keeps lighting up................................................................................ 78
E-19 Backup alarm does not sound or it keeps sounding ............................................................................. 81
E-20 Horn does not sound or it keeps sounding ........................................................................................... 84
E-21 Alarm buzzer does not sound or it keeps sounding .............................................................................. 86
E-22 The KOMTRAX system does not work properly ................................................................................... 88
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN05137-00
Method of using troubleshooting chart .......................................................................................................... 3
Failure code and cause table ........................................................................................................................ 6
H-1 The machine does not start .................................................................................................................... 8
H-2 The travel speed is slow ......................................................................................................................... 9
H-3 The traction force is weak....................................................................................................................... 10
H-4 Engine stalls when traveling or engine speed drops excessively ........................................................... 11
H-5 Speed range is not shifted ...................................................................................................................... 12
H-6 The steering wheel does not turn ........................................................................................................... 13
H-7 The steering wheel is heavy ................................................................................................................... 14
WA150-6 00-100 9
100 Index
H-8 Steering wheel shakes or jerks............................................................................................................... 15

H-9 Machine deviates naturally to one side when traveling .......................................................................... 15
H-10 The brake does not work or does not work well ................................................................................... 16
H-11 The brake is not released or is dragged ............................................................................................... 17
H-12 The lift arm does not rise or lower ........................................................................................................ 18
H-13 The lift arm moves slowly or the lift arm rising force is insufficient ....................................................... 19
H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 20
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises above the ground)............. 20
H-16 Hydraulic drifts of the lift arm occur often ............................................................................................. 20
H-17 The lift arm wobbles during operation .................................................................................................. 20
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily .................. 21
H-19 The bucket does not tilt back................................................................................................................ 22
H-20 The bucket moves slowly or the tilting-back force is insufficient .......................................................... 23
H-21 The bucket comes to operate slowly in the midst of tilting-back................................................... 24
H-22 The bucket cylinder cannot hold down the bucket ............................................................................... 24
H-23 Hydraulic drifts of the bucket occur often ............................................................................................. 24
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”) ................. 24
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily ...................... 25
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy................................... 25
H-27 The ECSS does not operate and machine pitches and bounces......................................................... 26
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) ................ 27
600 Troubleshooting of engine (S-mode) SEN05138-00
Method of using troubleshooting charts ........................................................................................................ 2
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).................................................................................. 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 15
S-9 Oil becomes contaminated quickly ......................................................................................................... 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 20
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 21
S-15 Abnormal noise is made ....................................................................................................................... 22
S-16 Vibration is excessive ................................................................................................................... 23
50 Disassembly and assembly

100 General information on disassembly and assembly SEN05185-01
How to read this manual ............................................................................................................................... 2
Coating materials list..................................................................................................................................... 4
Special tools list............................................................................................................................................. 7
Sketches of special tools............................................................................................................................... 10
200 Engine and cooling system SEN05186-00
Removal and installation of fuel supply pump assembly............................................................................... 2
Removal and installation of fuel injector assembly ....................................................................................... 6
Removal and installation of engine hood assembly ...................................................................................... 10
Removal and installation of cylinder head assembly .................................................................................... 12
Removal and installation of radiator.............................................................................................................. 22
Removal and installation of air aftercooler .................................................................................................... 25
Removal and installation of hydraulic oil cooler assembly ............................................................................ 27
Removal and installation of engine and HST pump and 3-gear pump assembly ......................................... 29
Removal and installation of engine front oil seal........................................................................................... 34
Removal and installation of engine rear oil seal............................................................................................ 37
00-100 10 WA150-6
100 Index
Removal and installation of cooling fan and fan motor assembly.................................................................. 40

Removal and installation of fuel tank assembly............................................................................................. 43
300 Power train SEN05187-01
Removal and installation of transfer and HST motor assembly..................................................................... 2
Disassembly and assembly of transfer assembly.......................................................................................... 5
Removal and installation of parking brake assembly..................................................................................... 25
Disassembly and assembly of parking brake assembly ................................................................................ 26
Removal and installation of front axle assembly ........................................................................................... 30
Removal and installation of rear axle assembly ............................................................................................ 32
Disassembly and assembly of axle housing assembly.................................................................................. 34
Disassembly and assembly of differential assembly ..................................................................................... 45
400 Undercarriage and frame SEN05188-00
Removal and installation of center hinge pin................................................................................................. 2
Removal and installation of counterweight .................................................................................................... 10
500 Hydraulic system SEN05189-00
Removal and installation of transfer and HST pump and 3-gear pump assembly ........................................ 2
Removal and installation of HST motor 1 assembly ...................................................................................... 6
Removal and installation of HST motor 2 assembly ...................................................................................... 9
Removal and installation of work equipment control valve assembly............................................................ 11
Removal and installation of hydraulic tank assembly .................................................................................... 14
Disassembly and assembly of hydraulic cylinder assembly .......................................................................... 16
600 Work equipment SEN05190-00
Removal and installation of work equipment assembly................................................................................. 2
700 Cab and its attachments SEN05191-00
Removal and installation of operator's cab and floor frame assembly .......................................................... 2
Removal and installation of operator's cab glass (Stuck glass)..................................................................... 7
Removal and installation of air conditioner unit ............................................................................................. 15
800 Electrical system SEN05192-00
Removal and installation of monitor panel..................................................................................................... 2
Removal and installation of engine controller assembly................................................................................ 4
Removal and installation of HST controller assembly ................................................................................... 6
Removal and installation of KOMTRAX terminal assembly........................................................................... 7
80 Appendix
100 Air conditioner SEN05140-00
Structure and function ....................................................................................................................................... 4
Air conditioner component............................................................................................................................. 4
Configuration and function of refrigerating cycle ........................................................................................... 6
Outline of refrigerating cycle.......................................................................................................................... 7
Air conditioner unit......................................................................................................................................... 10
Functions of major components in the air conditioner unit ............................................................................ 11
Blower and intake unit ................................................................................................................................... 12
Compressor ................................................................................................................................................... 13
Condenser ..................................................................................................................................................... 14
Receiver drier ................................................................................................................................................ 15
Air conditioner control panel .......................................................................................................................... 16
Testing, adjusting and troubleshooting.............................................................................................................. 18
Caution about refrigerant............................................................................................................................... 18
Troubleshooting procedure............................................................................................................................ 19
Block diagram and circuit diagram of control system .................................................................................... 20
Detail of air conditioner unit ........................................................................................................................... 23
Arrangement of connector pins ..................................................................................................................... 24
Part and connector locations ......................................................................................................................... 25
Testing with self-diagnosis function (indication on control panel) .................................................................. 27
Testing temperature control ........................................................................................................................... 28
Testing Recirc/Fresh changeover .................................................................................................................. 29
WA150-6 00-100 11
100 Index
Testing evaporator temperature sensor electrically....................................................................................... 31

Testing relays ................................................................................................................................................ 32
Troubleshooting chart 1................................................................................................................................. 33
Troubleshooting chart 2................................................................................................................................. 34
Troubleshooting for electrical system (E mode) ............................................................................................ 37
E-1 Power supply system (Air conditioner does not operate) .................................................................... 38
E-2 Compressor or refrigerant system (Air is not cooled) .......................................................................... 41
E-3 Blower motor system (No air comes out or air flow is abnormal) ........................................................ 44
E-4 Temperature cannot be controlled ....................................................................................................... 47
E-5 Recirc/Fresh cannot be changed over................................................................................................. 50
Troubleshooting with gauge pressure ........................................................................................................... 52
Connection of service tool............................................................................................................................. 54
Precautions for connecting air conditioner piping ......................................................................................... 55
Handling of compressor oil............................................................................................................................ 56
1. Control of compressor oil ..................................................................................................................... 56
2. Adding of compressor oil...................................................................................................................... 56
3. Compressor replacement ..................................................................................................................... 57
4. Applying compressor oil for O-ring ....................................................................................................... 57
90 Diagrams and drawings

100 Hydraulic diagrams and drawings SEN05085-00
Hydraulic circuit diagram............................................................................................................................... 5
200 Electrical diagrams and drawings SEN05086-00
Electrical circuit diagram ............................................................................................................................... 3
Connector list and stereogram ...................................................................................................................... 27
00-100 12 WA150-6
100 Index
WA150-6 00-100 13
SEN05072-05
WA150-6 Wheel loader

Form No. SEN05072-05
©2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11
00-100 14
SEN05073-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
00 Index and foreword 00
200 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
WA150-6 00-200 1
SEN05073-00 Safety notice
Safety notice (Rev. 2008/08)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 weld in g wo rk , al way s wear wel din g
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.
Wearing protective goggles
q Always wear safety glasses when hit- 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.
00-200 2 WA150-6
Safety notice SEN05073-00
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
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 parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, 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
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
WA150-6 00-200 3
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
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
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.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
00-200 4 WA150-6
Safety notice SEN05073-00
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
WA150-6 00-200 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
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 a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
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.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
00-200 6 WA150-6
How to read the shop manual SEN05073-00
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.
WA150-6 00-200 7
SEN05073-00 How to read the shop manual
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 { }.
00-200 8 WA150-6
Explanation of terms for maintenance standard SEN05073-00
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
WA150-6 00-200 9
SEN05073-00 Explanation of terms for maintenance standard
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.
00-200 10 WA150-6
Handling of electric equipment and hydraulic component SEN05073-00
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.
WA150-6 00-200 11
SEN05073-00 Handling of electric equipment and hydraulic component
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.
00-200 12 WA150-6
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.
WA150-6 00-200 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.
00-200 14 WA150-6
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
WA150-6 00-200 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
oi l a nd wa ter fr om t he c om -
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.
00-200 16 WA150-6
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.
WA150-6 00-200 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.
00-200 18 WA150-6
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.
WA150-6 00-200 19
SEN05073-00 Handling of connectors newly used for engines
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.
00-200 20 WA150-6
Handling of connectors newly used for engines SEN05073-00
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.
WA150-6 00-200 21
SEN05073-00 Handling of connectors newly used for engines
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.
00-200 22 WA150-6
How to read electric wire code SEN05073-00
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)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
tor tric appliance General wiring in extremely
tant low-volt-
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
WA150-6 00-200 23
SEN05073-00 How to read electric wire code
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”.
00-200 24 WA150-6
How to read electric wire code SEN05073-00
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 – – – – – – –
WA150-6 00-200 25
SEN05073-00 Precautions when carrying out operation
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
00-200 26 WA150-6
Precautions when carrying out operation SEN05073-00
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.
WA150-6 00-200 27
SEN05073-00 Precautions when carrying out operation
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”.
00-200 28 WA150-6
Method of disassembling and connecting push-pull type coupler SEN05073-00
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.
WA150-6 00-200 29
SEN05073-00 Method of disassembling and connecting push-pull type coupler
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-
00-200 30 WA150-6
Method of disassembling and connecting push-pull type coupler SEN05073-00
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-
WA150-6 00-200 31
SEN05073-00 Standard tightening torque table
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.)
00-200 32 WA150-6
Standard tightening torque table SEN05073-00
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}
WA150-6 00-200 33
SEN05073-00 Standard tightening torque table
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 — —
00-200 34 WA150-6
Standard tightening torque table SEN05073-00
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
WA150-6 00-200 35
SEN05073-00 Conversion table
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
00-200 36 WA150-6
Conversion table SEN05073-00
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
WA150-6 00-200 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
00-200 38 WA150-6
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
WA150-6 00-200 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
00-200 40 WA150-6
WA150-6 00-200 41
SEN05073-00

©2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (01)
00-200 42
SEN05074-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
01 Specification 1
100 Specification and technical data

Specification dimension drawing..................................................................................................................... 3
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................... 8
Table of fuel, coolant and lubricants.............................................................................................................. 10
WA150-6 01-100 1
SEN05074-00
01-100 2 WA150-6
Specification dimension drawing SEN05074-00
Specification dimension drawing 1
Item Unit WA150-6

Machine weight (with BOC) kg 7,625
Normal load kg 2,400
Bucket capacity (heaped, with BOC) m3 1.5
Engine model — Komatsu SAA4D95LE-5 Diesel engine
Engine rated output
• Net [ISO 9249/SAE J1349] (*1) kW{HP}/rpm 73 {98}/2,200
• Gross [SAE J1995] (*2) 74 {99}/2,200
A Overall length (with BOC) mm 6,310
B Overall height mm 3,035
C Overall height with bucket lifted up mm 4,630
D Overall width mm 2,250
E Minimum ground clearance mm 400
F Bucket width mm 2,390
G Dumping clearance (*3) Bucket tip/BOC tip mm 2,765/2,705
H Dumping reach (*3) Bucket tip/BOC tip mm 940/970
I Bucket dump angle (max. height) degree 46
Bucket tip/BOC tip mm 5,360/5,380
Min. turning radius
Center of outside tire mm 4,675
Permissible towing load kN {kg} 56.4 {5,750}
1st (forward/reverse) 5.3 – 13.0/5.3 – 13.0
2nd (forward/reverse) 13.0/13.0
Travel speed km/h
3rd (forward/reverse) 22.4/22.4
4th (forward/reverse) 36.2/36.2
*1:
Indicates the value at the lowest cooling fan speed.
*2:
Indicates the value of the engine alone (without cooling fan).
*3:
Indicates the value at the 45° bucket dump angle.
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of an
independent engine. While, net denotes the value measured of an engine under the condition essentially the same
as that when it is installed on machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
71 kW {95 HP}/2,200 rpm
a BOC: Abbreviation for Bolt-On Cutting edge
WA150-6 01-100 3
SEN05074-00 Specifications
Specifications 1
Machine model name WA150-6

Serial No. 80001 and up
Machine weight kg 7,625
Weight
Machine weight (front wheel) in

kg 3,045
SAE travel posture
Machine weight (rear wheel) in
kg 4,580
SAE travel posture
Bucket capacity (heaped) m3 1.5
Normal load kg 2,400
Travel speed
• Forward 1st 5.3 – 13.0
• Forward 2nd 13.0
km/h
• Forward 3rd 22.4
• Forward 4th 36.2
Performance
• Reverse 1st 5.3 – 13.0

• Reverse 2nd 13.0
km/h
• Reverse 3rd 22.4
• Reverse 4th 36.2
Max. traction force
• Forward 66 {6,730}
kN {kg}
• Reverse 66 {6,730}
Gradeability deg. 25
Min. turning radius
mm 4,675
(center of outside tire)
Turning radius (cutting edge/BOC tip),
mm 5,360/5,380
SAE travel posture
Overall length (with BOC) mm 6,310
Overall width (chassis) mm 2,250
Bucket width (with BOC) mm 2,390
Overall height (cab top) mm 3,035
Overall height with bucket lifted up mm 4,630
Wheelbase mm 2,600
Tread mm 1,780
Minimum ground clearance mm 400
Dimension
Max. hinge pin height mm 3,485

Dumping clearance (*1)
mm 2,765/2,705
(cutting edge/BOC tip)
Dumping reach (*1)
mm 940/970
Steering angle deg. 38 (frame stopper 40)
Bucket tilt angle
deg. 46/66
(operating posture/max. height)
Bucket dump angle
deg. 46
(max. height)
Digging depth, 10°
mm 220/255
*1: Indicates the value at the 45° bucket dump angle.
01-100 4 WA150-6
Specifications SEN05074-00

Model SAA4D95LE-5
4-cycle, water-cooled, in-line vertical, direct injection type
Type
with turbocharger and air-cooled aftercooler
No. of cylinders – bore x stroke mm 4 – 95 x 115
Total piston displacement l {cc} 3.26 {3,260}
Rated output
• Net [ISO 9249/SAE J1349] (*1) 73 {98}/2,200
kW{HP}/rpm
Performance
• Gross [SAE J1995] (*2) 74 {99}/2,200

Engine
Max. torque (*1) Nm{kgm}/rpm 375 {38.2}/1,600

g/kWh
Min. fuel consumption 232 {173}
{g/HPh}
Max. speed at no load rpm 2,400
Min. speed at no load rpm 980
Starting motor 24 V, 5.5 kW
Alternator 24 V, 60 A
Battery (*3) 12 V, 92 Ah x 2 pieces
HST pump
• Type Variable displacement swash plate type piston pump
• Pump capacity cc/rev 0 – 71
HST motor 1
• Type Variable displacement bent axis type piston motor
Power train
• Motor capacity cc/rev 0 – 54.8

HST motor 2
• Type Variable displacement bent axis type piston motor
• Motor capacity cc/rev 32.6 – 54.8
Counter-shaft double acting planetary type, spur gear
Transfer
constant-mesh type, switching between 2 power trains
Reduction gear unit Spiral bevel gear type, splash lubrication type
Differential Straight bevel gear type, torque proportioning
Final drive Planetary gear single reduction type, splash lubrication type
Drive wheel Front and rear wheel drive
Axle
Front axle Fixed frame, semi-float type

Rear axle Center pin support type, semi-float type
Size 16.9 – 24 – 10PR
Rim size 24 x W15L
Tire
Inflation pressure
• Front wheel kPa 235 {2.4}
• Rear wheel {kg/cm2} 235 {2.4}
*1:
Indicates the value at the lowest cooling fan speed.
*2:
Indicates the value of the engine alone (without cooling fan).
*3:
The battery capacity (Ah) is indicated in the 5-hour rate value.
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of an
independent engine. While, net denotes the value measured of an engine under the condition essentially the same
as that when it is installed on machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
71 kW {95 HP}/2,200 rpm
WA150-6 01-100 5
SEN05074-00 Specifications

Braking method 4-wheel brake, independent front and rear wheel brakes
Type of brake Enclosed wet multiple disc type
Main
Drive method Hydraulic drive

Brake
Operating method Foot-operated (with hydraulic booster)

Braking method Transmission output shaft brake
Parking
Type of brake Wet multiple disc type

Drive method Mechanical type
Operating method Manual lever type
Steering
Steering method Articulated chassis type
Drive method Hydraulic drive
Work equipment and steering pump

• Type Gear type
Hydraulic pump
• Delivery cm3/rev 56.0

Brake and cooling fan pump
• Type Gear type
Transfer lubrication pump
• Type Gear type
Type Double-acting piston type
Steering cylinder
Cylinder bore mm 55
Piston rod outside diameter mm 30
Stroke mm 375
Hydraulic equipment
Max. distance between centers

mm 1,020
of pins
Min. distance between centers
mm 645
of pins
Cylinder bore mm 110
Lift cylinder

Cylinder
Stroke mm 628
mm 1,659
of pins
mm 1,031
of pins
Cylinder bore mm 110
Bucket cylinder

Stroke mm 452
mm 1,367
of pins
mm 915
of pins
01-100 6 WA150-6
Specifications SEN05074-00

Work equipment control valve
Control valve
• Type 2-spool type

Hydraulic equipment
• Set pressure MPa{kg/cm } 2

20.6 {210}
Steering valve
• Type Orbit-roll type
• Set pressure MPa{kg/cm } 2
18.6 {190}
Cooling fan motor
Motor
Fixed displacement, swash plate, piston type

• Type
<with reversible valve and flow control valve>
• Motor capacity cm3/rev 10
equipment
Type of link Z-bar link

Work
Shape of bucket cutting edge Straight cutting edge with BOC
WA150-6 01-100 7
SEN05074-00 Weight table
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Engine (excluding coolant and oil) 346
Damper 3
Cooling assembly (excluding coolant and oil) 70
• Radiator 10
• Oil cooler 8
• Aftercooler 11
Cooling fan motor 13
HST pump 56
HST motor 1 26
HST motor 2 26
Transfer 151
Front drive shaft 14
Rear drive shaft 4
Front axle
• With torque proportioning differential 410
• With limited slip differential 414
Rear axle
• With torque proportioning differential 380
• With limited slip differential 383
Axle pivot (Rear axle) 66
Wheel [24 x W15L] (1 piece) 60
Tire [16.9–24–10 PR] (1 piece) 100
Hydraulic tank (excluding hydraulic oil) 57
3-gear pump 20
Work equipment control valve 19
Work equipment PPC valve 3
Priority valve 6
Orbit-roll valve 7
Charge valve 6
Brake valve 10
Steering cylinder assembly (1 piece) 13
Lift cylinder assembly (1 piece) 64
Bucket cylinder assembly 50
Front frame 595
Rear frame 576
Counterweight 660
Additional counterweight (1 piece) 98
Engine hood (including side panel) 152
Fuel tank (excluding fuel) 73
01-100 8 WA150-6
Weight table SEN05074-00
Unit: kg
Lift arm (including bushing) 447
Bucket link 17
Bell crank 108
Bucket (1.5 m3, including BOC) 595
Operator's cab
800
(including air conditioner and interior parts)
Operator seat 30
Air conditioner unit 5
Battery (1 piece) 30
WA150-6 01-100 9
SEN05074-00 Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants 1
a For details of notes (Notes 1 and 2…) in the table, see Operation and Maintenance Manual.
Unit: l
Reservoir Specified capacity Refill capacity
Engine oil pan 12.0 11.5
Transfer case 4.4 3.9
Hydraulic system 90 47
Axle (front/rear) 14.0/14.5 14.0/14.5
Cooling system 14.6 —
Fuel tank 133 —
01-100 10 WA150-6
Table of fuel, coolant and lubricants SEN05074-00
WA150-6 01-100 11
SEN05074-00

©2009 KOMATSU
All Rights Reserved
01-100 12
SEN05075-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
10 Structure, function and

maintenance standard 10
100 Engine and cooling system

Engine mount and transfer mount................................................................................................................... 2
Damper ........................................................................................................................................................... 3
Cooling system ............................................................................................................................................... 4
Cooling system hydraulic piping diagram ....................................................................................................... 5
Cooling fan motor............................................................................................................................................ 7
WA150-6 10-100 1
SEN05075-00 Engine mount and transfer mount
Engine mount and transfer mount 1
10-100 2 WA150-6
Damper SEN05075-00
Damper 1
Unit: mm
No. Check item Criteria Remedy
Distance between HST pump Standard size Repair limit
1 installation surface and hub front Adjust
end 61.2 ±0.8
2 Wear of flange and insert Repair limit: 1.0 Replace
3. Flange Outline
4. HST pump input shaft q The damper protects the drive systems on and
5. Hub after the engine from torsional vibrations by
6. Cover reducing the torsional vibrations of the engine
7. Flywheel due to the fluctuations in torque.
8. Insert q The power from the engine is transmitted to
flange (3) through flywheel (7), absorbing tor-
sional vibrations on flange (3). Then it is trans-
mitted to HST pump through hub (5).
WA150-6 10-100 3
SEN05075-00 Cooling system
Cooling system 1
1. Oil cooler 4. Reservoir tank

2. Radiator 5. Cooling fan
3. Aftercooler 6. Cooling fan motor
Specifications
Radiator Oil cooler Aftercooler
Core type AL WAVE-4 CF40-1 AL WAVE
Fin pitch (mm) 3.5/2 3.5/2 4.0/2

Total heat dissipation area
23.48 3.10 12.35
(m2)
Pressure valve cracking pressure 68.6
— —
(kPa {kg/cm2}) {0.7}
Vacuum valve cracking pressure 0 – 4.9
— —
(kPa {kg/cm2}) {0 – 0.05}
10-100 4 WA150-6
Cooling system hydraulic piping diagram SEN05075-00
Cooling system hydraulic piping diagram 1
1. Cooling fan motor Outline

2. Strainer q Cooling fan motor (1) installed in the machine
3. Hydraulic tank rear side is driven by oil pressure from brake
4. Brake and cooling fan pump and cooling fan pump (4).
5. Charge valve
WA150-6 10-100 5
SEN05075-00 Cooling system hydraulic piping diagram
10-100 6 WA150-6
Cooling fan motor SEN05075-00
Cooling fan motor 1
Model: LMF10
P: From pump through charge valve Specifications

T: To hydraulic tank through return filter Capacity (cc/rev) 10
TC: To hydraulic tank Rated speed (rpm) 1,520
Rated flow (l/min) 15.2
1. ER terminal
Check valve cracking pressure
2. EF terminal (MPa {kg/cm2})
0.013 {0.13}
3. Solenoid proportional pilot valve
4. ON/OFF pilot valve
WA150-6 10-100 7
SEN05075-00 Cooling fan motor
10-100 8 WA150-6
1. Output shaft
2. Case
3. Thrust plate
4. Shoe
5. Piston
6. Cylinder block
7. Valve plate
8. End cover
9. Bearing
10. Center spring
11. Retainer shoe
12. Retainer guide
13. Bearing
14. Oil seal
15. Flow control spool
16. Suction safety valve
17. Reversible spool
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Free length x Installed
Outside Installed load Free length Installed load
18 Spool return spring diameter
length If damaged or
deformed, replace
44.84 x 12 33 58.8 N — 47.1 N spring
{6 kg} {4.8 kg}
44.1 N 35.3 N
19 Spool return spring 35 x 8.5 34
{4.5 kg}
—
{3.6 kg}
WA150-6 10-100 9
Hydraulic motor portion 1
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The pressurized oil from the hydraulic pump
flows through valve plate (7) into cylinder block
(5).
q This pressurized oil flows to the only one side
of the (Y-Y) line connecting the top dead center
and bottom dead center of the stroke of piston
(4).
q The pressurized oil sent to one side of cylinder
block (5) pushes piston (4) (2 or 3 pistons).
q A single piston generates the force F1 [F1 (kg)
= P (kg/cm2) x xD2/4 (cm2)].
q This force works on thrust plate (2).
q Since thrust plate (2) is fixed to the specific
angle (a) to output shaft (1), the force is
divided into components (F2) and (F3).
q Among them, radial component (F3) respec-
tively generates torque (T = F3 x ri) against the
(Y-Y) line connecting the top dead center and
bottom dead center.
q The result of this torque [T = s (F3 x ri)] rotates
cylinder block (5) through piston (4).
q This cylinder block (5) is connected to output
shaft (1) with the spline.
q Output shaft (1) rotates to transmit the torque.
10-100 10 WA150-6
Suction safety valve 1
Suction function
Function When stopped
q If the fan pump stops, the pressurized oil does
not flow into the motor.
q Since the motor continues revolution because
of the force of inertia, however, the pressure on
the outlet side of the motor rises.
q When the pressurized oil stops flowing in from
inlet port (P), suction safety valve (1) sucks in
the pressurized oil on the outlet side and sup-
plies it to port (MA) where there is not sufficient
oil to prevent cavitation.
Operation
When started
q When the engine stops, the input revolution of

the pump becomes 0 rpm.
q The pressurized oil from the pump is not sup-
plied to port (P).
q As the pressurized oil is not supplied to (MA)
side of the motor, the motor speed lowers
gradually to stop.
q If the motor shaft is revolved by the force of
inertia while the oil flow in port (P) is reducing,
the oil in port (T) on the outlet side is sent by
suction safety valve (1) to (MA) side to prevent
cavitation.
q The pressurized oil from the pump is supplied

to port (P), increasing the (MA) side pressure.
q The starting torque is generated in the motor,
the motor starts revolution.
q The pressurized oil on motor outlet (MB) side
of the motor returns through port (T) to the
tank.
WA150-6 10-100 11
Safety function
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Suction safety valve (1) is installed to protect
the fan system circuit.
Operation
q If the pressure in port (P) rises above the

cracking pressure of suction safety valve (1),
valve (2) of suction safety valve (1) opens to
release the pressurized oil into port (T).
q In this way, the safety valve prevents genera-
tion of an abnormal pressure in port (P).
10-100 12 WA150-6
Reversible valve 1
When the ON/OFF solenoid is de-energized When the ON/OFF solenoid is energized
q When ON/OFF solenoid (1) is "de-energized", q When ON/OFF solenoid (1) is "energized",
the pressurized oil from the pump is shut off by valve (2) is switched.
valve (2). q The pressurized oil from the pump flows to
q Port (C) opens for the hydraulic tank circuit. spool chamber (D) through port (C).
q Spool (3) is pushed to the right by spring (4). q The pressurized oil in chamber (D) com-
q Port (MA) opens and pressurized oil flows in to presses spring (4).
revolve the motor in forward (clockwise). q Spool (3) moves to the left.
q Port (MB) opens and pressurized oil flows in to
rotate the motor in reverse (counterclockwise).
WA150-6 10-100 13
Flow control valve 1
(continuously-variable type)
Function
This valve supplies the necessary pump delivery to
the motor, and returns the excessive oil to the
hydraulic tank.
q The motor speed increases in proportion to the

increase of the incoming oil (Q) as shown in
Fig. 1.
q When the incoming flow rate is (Q1), motor
speed becomes (B) rpm.
q In order to reduce noise and loss of the motor,
this valve keeps the fan speed constant inde-
pendent of the flow rate to the motor.
q Even if the flow rate is increased from (Q0) to
(Q1), the valve maintains the motor speed con-
stant between points (A) and (C) rpm.
Operation
q For the flow control valve, the upstream pres-
sure of the orifice is conducted to the right side
of spool (1) and the downstream pressure of
the orifice is led to its left side.
q The differential pressure before and after ori-
fice (E) by the incoming flow rate to the motor
works on spring (2).
q In Fig. 1, when the flow rate (Q0) is increased
beyond, the differential pressure before and
after spool (1) becomes larger than the
installed load of spring (2).
q Spool (1) moves to the left and port (P) is con-
nected to port (T).
q The excessive oil in (Z) portion of Fig. 1 flows
to the hydraulic tank through the flow control
valve, and the motor speed is kept constant
from (A) to (C).
q This flow control valve is a continuously-vari-
able type.
q As shown in Fig. 2, it is possible to change the
flow control valve continuously while maintain-
ing the motor speed constant between (A') to
( C ') by c ha n g i n g t h e c o m m an d c u r r e n t
between the motor speed (A) and (C).
10-100 14 WA150-6
WA150-6 10-100 15
SEN05075-00

©2009 KOMATSU
All Rights Reserved
10-100 16
SEN05076-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

200 Power train

Power train...................................................................................................................................................... 3
Power train system diagram ........................................................................................................................... 4
Drive shaft....................................................................................................................................................... 6
HST hydraulic piping diagram......................................................................................................................... 7
HST pump....................................................................................................................................................... 8
HST motor..................................................................................................................................................... 17
Transfer......................................................................................................................................................... 24
Clutch solenoid valve .................................................................................................................................... 35
Axle ............................................................................................................................................................... 36
Differential ..................................................................................................................................................... 38
Torque proportioning differential ................................................................................................................... 43
Limited slip differential .................................................................................................................................. 44
Final drive ..................................................................................................................................................... 48
WA150-6 10-200 1
200 Power train
SEN05076-00
10-200 2 WA150-6
200 Power train
Power train SEN05076-00
Power train 1
1. Engine
2. Damper
3. HST pump
4. 3-gear pump
5. High-pressure hose
6. HST motor 1
7. HST motor 2
8. Transfer
9. Front drive shaft
10. Front axle
11. Rear drive shaft
12. Rear axle
WA150-6 10-200 3
200 Power train
SEN05076-00 Power train system diagram
Power train system diagram 1
10-200 4 WA150-6
200 Power train
Power train system diagram SEN05076-00
1. Engine Outline
2. Damper q The power from engine (1) is transmitted to
3. HST pump HST pump (3) after its torsional vibrations have
4. Work equipment and steering pump been reduced with damper (2) installed on the
5. Brake and cooling fan pump flywheel.
6. Transfer lubrication pump q The power from engine (1) is also transmitted
7. High-pressure hose to HST pump (3) and the HST charge pump
8. HST motor 1 being built in HST pump (3) as well as work
9. HST motor 2 equipment and steering pump (4), brake and
10. Transfer cooling fan pump (5) and transfer lubrication
11. Transfer clutch pump (6) being connected to HST pump (3).
12. Parking brake q The directional selector valve and servo piston
13. Front drive shaft installed on HST pump (3) continuously modify
14. Front axle the oil discharge direction and discharged
15. Differential amount responding to inclination of the swash
16. Wet multiple disc type brake plate.
17. Final drive q HST motors (8) and (9) are installed on trans-
18. Front tire fer (10) and connected to HST pump (3)
19. Rear drive shaft through high-pressure hose (7).
20. Rear axle q The hydraulic power from HST pump (3)
21. Differential changes the rotating direction and speed of
22. Wet multiple disc type brake HST motors (8) and (9) to control the machine
23. Final drive forward and reverse travel and travel speed.
24. Rear tire q The power from HST motor 1 (8) is transmitted
to the output shaft through transfer clutch (11)
in transfer (10).
The power from HST motor 2 (9) is transmitted
to the output shaft through the gear in transfer
(10).
q As the parking brake lever is operated, parking
brake (12) being contained in the rear side of
transfer (10) activates the wet multiple disc
type brake to stop the machine.
q The power to the front side is transmitted to
front axle (14) through front drive shaft (13).
The power to the rear side is transmitted to
rear axle (20) through rear drive shaft (19).
q Speed of the power transmitted to axles (14)
and (20) is reduced on the pinion gear of differ-
entials (15) and (21), then transmitted to the
sun gear through the sun gear shaft.
q Speed of the power transmitted to the sun gear
is reduced on the planetary mechanism of final
drives (17) and (23), then transmitted to tires
(18) and (24) through the axle shaft and wheel.
WA150-6 10-200 5
200 Power train
SEN05076-00 Drive shaft
Drive shaft 1
1. Front axle Outline

2. Front drive shaft q The power from the transfer output shaft is
3. Transfer transmitted to front axle (1) and rear axle (5)
4. Rear drive shaft through front drive shaft (2) and rear drive
5. Rear axle shaft (4).
q When the machine is articulated or when it
receives traveling impacts or working impacts,
the distances between the transfer and the
front and rear axles change. The drive shafts
absorb fluctuations in the angle and length with
the universal joints and slip joint so that the
power will be transmitted without damaging the
parts even when the machine is exposed to
above impacts or changes in the component
positions.
10-200 6 WA150-6
200 Power train
HST hydraulic piping diagram SEN05076-00
HST hydraulic piping diagram 1
1. Hydraulic tank
2. HST pump
3. Clutch solenoid valve
4. HST drain oil filter
5. HST oil filter
6. HST motor 1
7. HST motor 2
WA150-6 10-200 7
200 Power train
SEN05076-00 HST pump
HST pump 1
a HST: Abbreviation for HydroStatic Transmission
10-200 8 WA150-6
200 Power train
HST pump SEN05076-00
1. Directional selector solenoid valve

2. High-pressure cut-off valve
3. Speed-related valve (DA valve)
4. Charge pump
5. Low-pressure relief valve
6. Servo cylinder
7. High-pressure relief valve
8. Control plate
9. Cylinder block
10. Piston
11. Swash plate
Specifications
Model A4VG71DA
Variable displacement
Type swash plate type piston
pump
Theoretical delivery
0 – 71
(cc/rev)
High-pressure relief valve set
43.2 {440}
pressure (MPa {kg/cm2})
Effective differential
High-pressure cut-off valve set
pressure
40.2 {410}
Low-pressure relief valve set
2.5 {25}
WA150-6 10-200 9
200 Power train
Operation
Flow of power Oil flow
q The HST pump is installed on the damper of q Inclination of swash plate (11) starts reciprocat-
the engine flywheel. ing movement of piston (10). The pumping
q The power from the engine is transmitted to action initiated by this reciprocating movement
the HST pump through the flywheel and suctions or discharges the oil in cylinder block
damper. (9) continuously.
q The HST pump is equipped with directional q The pumping action directs the oil flow in a cer-
selector solenoid valve (1) and servo cylinder tain definite direction so that it may flow to the
(6). HST motor.
q Driving the machine forward or reverse acti- q Reversing the inclination of swash plate (11)
vates directional selector solenoid valve (1), reverses the suction and discharge ports and,
tilting swash plate (11) and, as a result, caus- as a result, reversing the oil discharging direc-
ing the switch between the oil suction and dis- tion, too.
charge ports. q Piston (10) does not stroke when swash plate
q The HST pump is built-in cylinder block (9) and (11) is at neutral, thus the oil is not discharged.
9 pistons (10), and they rotate along with drive q Increasing or decreasing the inclination (angle)
shaft (12). of swash plate (11) changes the stroke of pis-
q Tips of piston (10) slide on the swash plate sur- ton (10), allowing to control the travel speed.
face of swash plate (11) that does not rotate. q If the amount of the oil in the low-pressure cir-
cuit (the oil to be returned from the motor to the
pump) becomes insufficient due to leakage of
oil in the HST pump, HST motor and control
valve, the charge pump supplies the oil
through speed-related valve (3) and the check
valve on high-pressure relief valve (7).
10-200 10 WA150-6
200 Power train
High-pressure relief valve 1
1. Locknut Function
2. Poppet spring q This valve is installed on the HST pump. If the
3. Check spring oil pressure on the high pressure circuit side
4. Orifice across the HST pump and HST motor goes
5. Main piston beyond the set pressure, it drains the pressure
6. Valve seat to the low pressure circuit side.
7. Pilot poppet This valve sets the maximum pressure of the
8. Adjustment screw HST circuit in this manner to protect the circuit.
q If low level of the oil is detected in the circuit,
the valve conducts oil from the HST charge
pump in order to protect cavitation.
WA150-6 10-200 11
200 Power train
Operation
q Port (A) is connected to the high pressure cir- q As the oil pressure in chamber (B) goes lower,
cuit side of the HST pump, and ports (C) and the orifice of main piston (2) is activated and
(D) are connected to the low pressure circuit differential pressure is generated in port (A)
side of the pump. and chamber (B).
q Oil fills up chamber (B) after flowing through q The oil pressure in port (A) pushes main piston
the orifice (1). (2) in the left direction, relieving the abnormal
q Pilot poppet (5) is seated on valve seat (4). pressure generated in port (A) to port (D).
q If oil pressure in port (A) and chamber (B) goes q As the oil pressure in port (A) goes lower than
beyond the set pressure, pilot poppet (5) is that in port (D), check spring (3) pushes back
pushed in the left direction. As a result, the oil main piston (2) in the right direction.
pressure in chamber (B) is released to port (D) q The oil in port (D) is conducted to port (A)
through chamber (C) and the oil pressure in through chamber (C) so that the oil level in port
chamber (B) is decreased. (A) may not go low.
q Increasing or decreasing the repulsive force of
poppet spring (6) allows adjusting the set pres-
sure.
q When increasing the set pressure, loosen the
locknut and screw the adjustment screw. When
decreasing, loosen the adjustment screw.
10-200 12 WA150-6
200 Power train
Low-pressure relief valve 1
Operation
1. Locknut
2. Adjustment screw q Port (A) is connected to the HST pump charge
3. Piston circuit and port (B) is connected to the drain
4. Spring circuit.
q As long as port (A) is below the set pressure,
Function oil does not flow to port (B).
q This valve is installed on the HST pump. If the q If oil pressure in port (A) goes beyond the set
oil pressure on the low pressure circuit side pressure, piston (3) is pushed in the right direc-
across the HST pump and HST motor goes tion. As a result, the oil pressure in port (A) is
beyond the set pressure, it drains the oil to the released to port (B) and the oil pressure in port
hydraulic tank. (A) is decreased.
This valve sets the oil pressure of the HST q Increasing or decreasing the repulsive force of
pump charge circuit in this manner to protect spring (4) allows adjusting the set pressure.
the circuit. q When increasing the set pressure, loosen lock-
nut (1) and screw adjustment screw (2). When
decreasing, loosen the adjustment screw.
WA150-6 10-200 13
200 Power train
HST charge pump 1
1. Cover bolt Specifications

2. Pump gear Gear pump
3. Key Type
(inscription type)
4. Coupling Theoretical delivery
19.6
5. Drive shaft (cc/rev)
6. Plate
7. Charge pump cover
8. Crescent separator plate Function
q This pump is connected to the HST pump drive
Outline shaft (5) with coupling (4). Pumping action is
q This pump is installed on the HST pump. It, turned on as it is rotated.
working in conjunction with the HST pump, q It contains pump gear (2) and crescent separa-
supplies oil to the HST speed-related valve tor plate (8) to suction or discharge oil continu-
and the low-pressure relief valve on the HST ously in the direction shown in the figure.
pump.
10-200 14 WA150-6
200 Power train
Speed-related valve (DA valve) 1
1. Locknut
2. Adjustment screw
3. Poppet spring
4. Spring seat
5. Pilot poppet
Function
q This valve is installed on the HST pump. It
diverges the oil from the HST charge pump
into 2 parts. One part flows to the directional
selector solenoid valve and other part flows to
the low-pressure relief valve.
Operation
q Port (A), port (D) and port (C) are connected to
the HST pump charge circuit, low-pressure
relief valve circuit and directional selector sole-
noid valve circuit, respectively.
q The oil from the HST charge pump constantly
flows to the low-pressure relief valve circuit
through port (A), orifice of pilot poppet (5),
chamber (B) and port (D).
q Orifice of pilot poppet (5) applies to the oil
pressure from the HST charge pump. As the
result, the differential pressure is generated in
port (A) and chamber (B).
q Oil pressure in port (A) pushes pilot poppet (5)
in the left direction to flow the oil in chamber
(B) to the directional selector solenoid valve
circuit through port (C).
q A set of pilot poppet (5) is consisted of poppet
spring (3) and spring seat (4).
q When decreasing the set pressure, loosen
locknut (1) and screw adjustment screw (2).
When increasing, loosen the adjustment
screw.
WA150-6 10-200 15
200 Power train
High-pressure cut-off valve 1
1. Adjustment screw
2. Locknut
3. Spring
4. Spool
5. Piston
6. Barrel
7. Shuttle spool
8. Valve seat
Function
q This valve is installed on the HST pump. If the
oil pressure on the high pressure circuit side
across the HST pump and HST motor goes
beyond the set pressure, it drains the oil in the
servo cylinder circuit to the hydraulic tank.
This valve sets the maximum pressure of the
HST pump circuit in this manner to protect the
circuit.
Operation
q Port (A), port (B), port (Pc) and port (T) are
connected to the high pressure circuit in the
reverse travel, high pressure circuit in the for-
ward travel, speed-related valve circuit and
drain circuit, respectively.
q As oil pressure in (A) side goes high, shuttle
spool (7) is pushed down and closes the port
(B) side circuit.
q Oil pressure on port (A) side pushes up piston
(5) and, at the same time, pushes up spool (4),
too, by compressing spring (3).
q Port (Pc) and port (T) are opened, releasing
abnormal pressure generated in port (Pc) to
port (T).
q As oil pressure in port (Pc) goes low, the
swash plate angle of the HST pump is
reduced. As a result, the pump delivery is
reduced and the HST pump circuit is pro-
tected.
10-200 16 WA150-6
200 Power train
HST motor SEN05076-00
HST motor 1
a HST: Abbreviation for HydroStatic Transmission
HST motor 1
1. Drive shaft Specifications

2. Piston
Model A6VM55EP2
3. Cylinder block
4. Port plate Variable displacement
5. EP servo valve Type bent axis type piston
motor
0 – 54.8
(cc/rev)
43.2 {440}
Effective differential
High-pressure cut-off valve set
pressure
40.2 {410}
2.5 {25}
WA150-6 10-200 17
200 Power train
SEN05076-00 HST motor
HST motor 2
1. Drive shaft Specifications

2. Piston
3. Cylinder block Model A6VM55HA1R2
4. Port plate Variable displacement
5. HA servo valve Type bent axis type piston
6. Directional shuttle valve motor
32.6 – 54.8
(cc/rev)
pressure 43.2 {440}
(MPa {kg/cm2})
High-pressure cut-off valve set Effective differential
pressure pressure
(MPa {kg/cm2}) 40.2 {410}
pressure 2.5 {25}
(MPa {kg/cm2})
10-200 18 WA150-6
200 Power train
Principle Operation
q It is assumed that the shaft of the disc is sup- q Pressurized oil from the HST pump flows to the
ported to enable free rotation of the disc. Force back side of piston (2) through the HST motor
F being applied aslant to the disc is divided inlet port, and is activated by inclination of pis-
into force F1 orthogonal to the disc and force ton (2) and cylinder block (3) as the rotating
F2 that works in the circumferential direction of force of drive shaft (1).
the disc. Force F1 pushes the disc in the axial q As the HST motor is rotated forward or
direction and force F2 rotates the disc clock- reverse, the oil in the high pressure circuit side
wise. is conducted to the directional shuttle valve (6).
q Also when force F' works on the disc instead of q As a large load is applied to the motor being
force F, it is likewise divided into force F1' and connected to servo valve (5), the pressure dif-
F2'. Force F2' rotates the disc counterclock- ference is generated between the high pres-
wise. sure circuit side and directional shuttle valve
(6), allowing the servo cylinder to increase
inclination of cylinder block (3).
Structure
q 7 pistons (2) are installed on the disc portion of
drive shaft (1) like spherical joints. They are
housed in cylinder block (3) having a certain
angle to drive shaft (1).
q As external load to the HST motor is
increased, servo valve (5) and directional shut-
tle valve (6) work to increase inclination of cyl-
inder block (3) and piston (2), reducing the
revolving speed and increasing the torque.
WA150-6 10-200 19
200 Power train
EP servo valve 1
1. Motor 1 solenoid valve Operation

2. EP servo valve q Suction force F1 of motor 1 solenoid valve (1)
3. Spring and force F2 of spring (3) are applied to EP
4. Servo cylinder servo valve (2).
q When the current value given to motor 1 sole-
Function noid valve (1) is small (when F1 < F2), EP
q This valve is installed on the rear side of HST servo valve (2) conducts the oil pressure on
motor 1. It controls the motor displacement the motor high pressure side circuit to the
depending on the current value given to motor small diameter side (S) of servo cylinder (4)
1 solenoid valve (1). and releases the oil pressure on the large
diameter side (L) to the tank (motor housing).
As the result, the servo cylinder (4) is moved
toward the min side.
q When the current value given to motor 1 sole-
noid valve (1) is large (when F1 > F2), EP
servo valve (2) conducts the oil pressure to the
large diameter side (L) to move servo cylinder
(4) toward the max side using the difference in
area between the large diameter and small
diameter side (S).
q Magnitude of spring (3) force varies depending
on the position of servo cylinder (4) (motor dis-
placement).
q The current value given to motor 1 solenoid
valve (1) controls the motor displacement to
the position where suction power F1 and
spring force F2 balance.
10-200 20 WA150-6
200 Power train
HA servo valve 1
1. Motor 2 solenoid valve Operation

2. HA servo valve q If the load to the motor is small, HA servo valve
3. Servo cylinder (2) conducts oil pressure to the small diameter
side (S) through the directional shuttle valve
Function and releases the oil pressure on the large
q This valve is installed in the rear side of HST diameter side (L) to the tank (motor housing).
motor 2. In order to bring out the motor output Servo cylinder (3) moves toward the min side,
corresponding to the external load to the minimizing the motor displacement.
motor, it controls the motor displacement using q If a large load is applied to the motor during, for
the oil pressure of the circuit being selected instance, uphill travel, HA servo valve (2) is
from the directional shuttle valve. switched to conduct the oil pressure from the
directional shuttle valve to the large diameter
side (L). As a result, the difference in area
between the large diameter side (L) and small
diameter side (S) moves servo cylinder (3)
toward the max side. The motor displacement
becomes the maximum and generates large
torque.
q As motor 2 solenoid valve (1) is energized, HA
servo valve (2) conducts the oil pressure from
the directional shuttle valve to the large diame-
ter side (L) independent of the magnitude of
the load to the motor to set the motor displace-
ment to the maximum.
WA150-6 10-200 21
200 Power train
Directional shuttle valve 1
1. Directional selector solenoid valve

2. Directional shuttle valve
Function
q This valve is installed in the rear side of HST
motor 2. It controls the destination of the oil
pressure to work on the HA servo valve refer-
encing the incoming signal, which corresponds
to the directional signal of the directional selec-
tor solenoid valve on the HST pump.
Above process reduces the decelerating
impacts that results when the oil pressure is
switched.
Operation
q Directional selector solenoid valve (1) inter-
locks with the directional selector valve on the
HST pump, since it has received the signal that
is corresponding to the directional signal to be
sent to the directional selector solenoid valve
on the HST pump.
q Directional shuttle valve (2) is activated by
directional selector solenoid valve (1) and con-
trols the destination of the oil pressure to work
on the HA servo valve.
10-200 22 WA150-6
200 Power train
WA150-6 10-200 23
200 Power train
SEN05076-00 Transfer
Transfer 1
a: Clutch port
b: Lubrication inlet port
c: Lubrication suction port
1. HST motor 2 mounting section

2. HST motor 1 mounting section
3. Oil filler pipe
4. Transfer
5. Parking brake lever
6. Speed sensor
10-200 24 WA150-6
200 Power train
Transfer SEN05076-00
1. HST motor 1 9. Sun gear (number of teeth: 27)

2. Input shaft 10. Parking brake
3. Transfer clutch 11. Rear coupling
4. Carrier 12. Output gear (number of teeth: 50)
5. Ring gear (number of teeth: 66) 13. Spacer
6. Planetary pinion (number of teeth: 19) 14. Output shaft
7. Planetary shaft 15. Front coupling
8. Motor 1 gear (number of teeth: 43)
WA150-6 10-200 25
200 Power train
Input shaft
10-200 26 WA150-6
200 Power train
Unit: mm
Standard Tolerance Standard Clearance
Clearance between input shaft size Shaft Hole clearance limit
1 and bearing (front) +0.011 0 –0.023 –
45 —
–0.002 –0.012 0.002
Clearance between input shaft 0 +0.013 –0.006 –
2 bearing and cage (front)
75
–0.013 –0.006 0.026
—
3 Clearance between input shaft

and bearing (middle)
45
+0.011
–0.005
0
–0.012
–0.023 –
0.005
—

bearing and ring gear (middle)
75
0
–0.013
+0.013
–0.006
–0.006 –
0.026
—

and bearing (rear)
40
+0.011
–0.005
0
–0.012
–0.023 –
0.005
—

bearing and carrier (rear)
68
0
–0.013
+0.013
–0.006
–0.006 –
0.026
—
7 Clearance between press-fitting

shaft and bearing
40
+0.033
+0.017
0
–0.012
–0.045 –
–0.017
—
8 Clearance between press-fitting

shaft bearing and motor 1 gear
80
0
–0.016
–0.014
–0.033
–0.033 –
0.002
—
9 Clearance
spacer
between piston and
150
–0.085
–0.125
+0.040
0
0.085 –
0.165
—
10 Clearance
cage
between piston and
187
–0.550
–0.650
+0.046
0
0.550 –
0.696 —
11 Clearance between clutch

housing and front case 180
+0.055
+0.015
+0.040
0
–0.055 –
0.025 —
Standard size Tolerance Repair limit
Thickness of separator plate
12 1.8 ±0.06 1.6
Strain on separator plate — 0.05 0.15
Thickness of friction plate 3.0 +0.05 2.55

–0.10
13 Replace
Strain on friction plate — 0.07 0.25
14 Load of wave spring

(height: 3.0 mm)
902 N
{92 kg}
±90 N
{±9.2 kg}
765 N
{78 kg}
Inside diameter of seal ring 25 +0.021 25.1
contact surface 0
+0.15
Width of seal ring groove 2.5 2.8
+0.10
15
–0.01
Width of seal ring 2.5 2.3
–0.03
Thickness of seal ring 1.2 ±0.1 1.05
Inside diameter of seal ring 60 +0.030 60.1
contact surface 0
Width of seal ring groove 3.0 +0.15 3.3
+0.10
16
Width of seal ring 3.0 –0.01 2.7
–0.03
Inside diameter of seal ring +0.035
contact surface 95 0 95.5
+0.15
Width of seal ring groove 3.0 +0.10 3.3
17
0
Width of seal ring 3.0 –0.05 2.7
18 Backlash between motor 1 gear

and output gear
0.170 – 0.439
— Side clearance of planetary gear

(on both sides)
0.35 – 0.80
WA150-6 10-200 27
200 Power train
Output shaft
10-200 28 WA150-6
200 Power train
Unit: mm
Clearance between output shaft size Shaft Hole clearance limit
1 and bearing (front) +0.030 0 –0.045 –
60 +0.011 –0.015 –0.011 —
Clearance between output shaft 0 –0.015 –0.040 –
2 bearing and cage (front)
95
–0.018 –0.040 0.003
—
Clearance between output shaft +0.030 0 –0.045 –
3 and bearing (rear)
55
+0.011 –0.015 –0.011
—
Clearance between output shaft 0 –0.015 –0.040 –
4 bearing and rear case (rear)
100
–0.018 –0.040 0.003
—
Clearance between oil seal and +0.170 +0.054 –0.170 –
5 cage (front)
100
+0.080 0 –0.026
—
Clearance between dust seal and +0.400 +0.054 –0.400 – Replace
6 cage (front)
100
+0.200 0 –0.146
—
Clearance between oil seal and +0.170 +0.054 –0.170 –
7 cage (rear)
100
+0.080 0 –0.026
—
Clearance between dust seal and +0.400 +0.054 –0.400 –
8 cage (rear)
100
+0.200 0 –0.146
—
Clearance between output shaft 0 +0.030 0–
9 and spacer
60
–0.030 0 0.060
—
10 Outside diameter of coupling oil
seal contact surface (front) 0
75 –0.074 74.8
11 Outside diameter of coupling oil

seal contact surface (rear) 75
0
–0.074 74.8
Standard size Standard clearance Clearance limit
12 Clearance
front case
between cage and
0.9 0.35 – 1.45 —
Adjust with shims
(A): The rotating torque when bolt (a) is loosened
13 Difference in the output shaft
rotating torque (B) – (A)
(B): The rotating torque when bolt (a) is tightened
0.20 – 0.78 Nm {0.02 – 0.08 kgm}
WA150-6 10-200 29
200 Power train
10-200 30 WA150-6
200 Power train
1. HST motor 2
2. Motor 2 gear (number of teeth: 43)
3. Strainer
4. Drain plug
Unit: mm
Clearance between input shaft size Shaft Hole clearance limit
5 and bearing +0.025 0 –0.037 –
50 —
+0.009 –0.012 –0.009
Replace
Clearance between input shaft 0 +0.018 –0.012 –
6 bearing and cage
80
–0.013 –0.012 0.031
—
Backlash between motor 2 gear
7 and output gear
0.170 – 0.439
WA150-6 10-200 31
200 Power train
Outline Operation of clutch

q The transfer is equipped with 2 HST motors. It
selects a gear speed out of 1st – 4th speed When clutch is "ENGAGED" (fixed)
both in the forward and reverse travels and
transmits it to the output shaft. It changes the
gear speed by varying output and revolving
direction of the HST motors and combinations
of the transfer clutches.
Relation between transfer clutch and transfer

clutch pressure at respective speed ranges
Speed
Transfer clutch Transfer clutch pressure
range
1st Engaged OFF
2nd Engaged OFF
Travel Travel Travel Travel
speed speed speed speed
3rd 0 – A km/h A – 22.4 km/h 0 – A km/h A – 22.4 km/h q As the oil from the clutch solenoid valve is cut
Engaged Disengaged OFF ON off, piston (2) is pushed back in the right direc-
Travel Travel Travel Travel tion by the repulsive force of spring (1).
speed speed speed speed q Piston (2) compresses plates (3) and discs (4)
4th 0 – A km/h A – 36.2 km/h 0 – A km/h A – 36.2 km/h
and the rotation of discs (4) is stopped by the
Engaged Disengaged OFF ON
frictional force.
*1: The travel speeds listed above are the ones when the q As the internal teeth of disc (4) are meshed
tires of the size 16.9-24 are worn. And value A varies
depending on the opening ratio of the accelerator pedal. with the external teeth of ring gear (5), ring
gear (5) is fixed.
Relationship between accelerator pedal angle When clutch is "DISENGAGED" (released)

and travel speed (A) for starting transfer clutch
switching modulation
Accelerator pedal angle (%)
Transfer clutch
0 – 65 65 – 90 90 – 100
Engaged o 9 km/h 9 – 11 km/h 11 km/h
Disengaged (B)
Disengaged o 8 km/h 8 – 10 km/h 10 km/h
Engaged (C)
q The oil from the clutch solenoid valve is pres-

sure-fed to the back side of piston (2), and
pushes piston (2) in the left direction by com-
pressing spring (1).
q Plates (3) and discs (4) are released from the
frictional force, setting ring gear (5) to the neu-
tral position.
q Wave spring (6) is assembled between plates
(3) to accelerate return of piston (2) as the
clutches are released. And at the same time, it
helps smooth separation of plates (3) and
discs (4) in order to prevent drag turning.
10-200 32 WA150-6
200 Power train
Power transmitting route

Low speed mode
Transfer clutch (1) is fixed to transmit power of both HST motor 1 (2) and HST motor 2 (3).
Power of HST motor 1 (2) Power of HST motor 2 (3)
O O
Input shaft (4) O
O O
Sun gear (5) O
O O
Planetary pinion (6) O
O O
Carrier (7) O
O O
Motor 1 gear (8) Motor 2 gear (9)
O O
Output gear (10) i i
O
Output shaft (11)
WA150-6 10-200 33
200 Power train
High speed mode
Transfer clutch (1) is released and, since HST motor 1 (2) stops, it transmits power of HST motor 2 (3) alone.
Power of HST motor 2 (3)
O
Motor 2 gear (9)
O
Output gear (10)
O
Output shaft (11)
10-200 34 WA150-6
200 Power train
Clutch solenoid valve SEN05076-00
Clutch solenoid valve 1
P: From HST charge pump Operation

A: To transfer clutch q When the current value of input signal is large,
T: To drain the transfer clutch drains oil pressure.
q As the current value of input signal becomes
1. Clutch solenoid valve smaller, oil pressure of the transfer clutch goes
2. Plunger higher inversely proportional to the current
3. Coil value.
4. Push pin q If the current value of input signal is further
5. Spring lowered until the oil pressure of the transfer
6. Spool clutch reaches the oil pressure at which oil is
7. Body pressure-fed from the HST charge pump, the
oil pressure of the transfer clutch remains at
this level even if the current value may be fur-
ther decreased.
WA150-6 10-200 35
200 Power train
SEN05076-00 Axle
Axle 1
Front axle 1
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet multiple disc type brake
6. Coupling
7. Oil filler port and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
11. Oil temperature sensor
10-200 36 WA150-6
200 Power train
Axle SEN05076-00
Rear axle 1
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet multiple disc type brake
6. Coupling
7. Oil filler port and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
WA150-6 10-200 37
200 Power train
SEN05076-00 Differential
Differential 1
Front differential 1
1. Pinion (number of teeth: 9)

2. Shaft
3. Bevel gear (number of teeth: 41)
4. Sun gear shaft
5. Bevel pinion (number of teeth: 9)
6. Side gear (number of teeth: 12)
10-200 38 WA150-6
200 Power train
Differential SEN05076-00
Unit: mm
Rotation starting force of bevel
7 gear 8.8 – 27.5 Nm {0.9 – 2.8 kgm} (outside of bevel gear) Adjust

8 Thickness of pinion washer
3 ±0.08 2.8 Replace
9 Thickness of side gear washer 2 ±0.05 1.8
10 Thickness of shim in differential

side bearing carrier (one side)
0.50 – 1.35
Adjust
11 Backlash of bevel gear 0.18 – 0.28
12 End play of pinion

(or rotation starting force)
0 – 0.151
(0 – 51 N {0 – 5.2 kg} (at cage bolt hole))
Replace

housing and cage assembly
0.35 – 1.4 Adjust

size Shaft Hole clearance limit
Clearance of
14 differential side 0 –0.024 –0.059 –
Outer race 105 —
bearing –0.020 –0.059 –0.004
Inner race 65 +0.051 0 –0.066 – —
+0.032 –0.015 –0.032
Outer race 110 0 –0.041 –0.076 – —
Clearance of bearing –0.015 –0.076 –0.026
15 on pinion shaft gear
side Inner race 50 +0.039 0 –0.051 – —
+0.025 –0.012 –0.025
Outer race 110 0 –0.041 –0.076 – —
16 on pinion shaft
coupling side Inner race 50 +0.039 0 –0.051 – — Replace
+0.025 –0.012 –0.025
17 Clearance
spider
between pinion and 25.18 –0.13
–0.18
+0.02
–0.02
0.11 –
0.2
—
Clearance in installation position –0.100 +0.072 0.100 –

18 of differential housing piston 214 –0.172 0 0.244 —
(housing and piston)
19 of bearing carrier piston 194
–0.172 0 0.244
—
(piston and carrier)
0 0 –0.035 –
Clearance between Outer race 90 —
–0.015 –0.035 0.015
20 drive shaft and cage
bearing +0.018 0 –0.030 –
Inner race 40 —
+0.002 –0.012 –0.002
WA150-6 10-200 39
200 Power train
Rear differential 1

2. Shaft
4. Sun gear shaft
5. Bevel pinion (number of teeth: 9)
10-200 40 WA150-6
200 Power train
Differential SEN05076-00
Unit: mm
Rotation starting force of bevel
7 gear
8.8 – 27.5 Nm {0.9 – 2.8 kgm} (outside of bevel gear) Adjust

8 Thickness of pinion washer
3 ±0.08 2.8 Replace
9 Thickness of side gear washer 2 ±0.05 1.8

side bearing carrier (one side) 0.50 – 1.35
Adjust
11 Backlash of bevel gear 0.18- 0.28
12 End play of pinion

(or rotation starting force)
0 – 0.150
(0 – 50 N {0 – 5.1 kg} (at cage bolt hole))
Replace

housing and cage assembly
0.35 – 1.4 Adjust

size Shaft Hole clearance limit
Clearance of
14 differential side 0 –0.024 –0.059 –
Outer race 105 —
bearing –0.020 –0.059 –0.004
Inner race 65 +0.051 0 –0.066 – —
+0.032 –0.015 –0.032
Outer race 110 0 –0.041 –0.076 – —
15 on pinion shaft gear
side Inner race 50 +0.039 0 –0.051 – —
+0.025 –0.012 –0.025
Outer race 90 0 –0.038 –0.073 – — Replace
16 on pinion shaft
coupling side Inner race 40 +0.033 0 –0.045 – —
+0.017 –0.012 –0.017
17 Clearance
spider
between pinion and 25.18 –0.13
–0.18
+0.02
–0.02
0.11 –
0.2
—

18 of differential housing piston 214 –0.172 0 0.244 —
(housing and piston)
19 of bearing carrier piston 194 –0.172 0 0.244 —
(piston and carrier)
WA150-6 10-200 41
200 Power train
Outline While machine is traveling straight
q The power from the engine is transmitted to

the front and rear axles through the torque
converter, transmission and drive shaft.
q In each axle, the direction of the power is q While the machine is traveling straight, the
changed by 90° and the speed is reduced by right and left wheels rotate at the same speed.
bevel pinion (1) and bevel gear (5). Then, the Accordingly, pinion (4) in the differential
power is transmitted through pinion (4) to sun assembly does not rotate and the power of car-
gear shafts (2). rier (6) is transmitted through pinion (4) and
q Speed of the power transmitted to the sun gear side gear (3) to right and left sun gear shafts
is further reduced by the final drive of the plan- (2) evenly.
etary gear type, and then transmitted to the
axle shafts and wheels. While machine is turning
q While the machine is turning, the right and left

wheels rotate at different speeds. Accordingly,
pinion (4) and side gear (3) in the differential
rotate and transmit the power of carrier (6) to
sun gear shafts (2), depending on the differ-
ence in rotation speed between the right and
left wheels.
10-200 42 WA150-6
200 Power train
Torque proportioning differential SEN05076-00
Torque proportioning differential 1
Outline q When the road resistances under the both tires

are the same, distance (a) from pinion (4) to
the meshing point of left side gear (7) and dis-
tance (b) to the meshing point of right side
gear (3) are the same.
q Accordingly, left traction force (TL) and right
traction force (TR) are balanced.
Travel on soft ground (When the road resis-

tances under both tires are different)
q When the tires slip on soft ground, the side

gear of the tire on the less road resistance side
turns forward. As a result, the meshing points
of pinion (4) and the side gears change.
q If left side gear (7) turns forward a little, dis-
tance (a) from the pinion to the meshing point
q A 4-wheel-drive wheel loader, as a construction
of the left side gear becomes longer than dis-
machine, must naturally work on places where
tance (b) to the meshing point of the right side
the ground condition is bad. If its tires slip in
gear, and then (a) and (b) are balanced at a
such places, its function lowers and the lives of
point where (a) x (TL) = (b) x (TR). The ratio of
the tires are shortened. To solve this problem,
(a) : (b) changes up to 1 : 1.38, depending on
the torque proportioning differential is used.
the meshing condition.
q Pinion (4) of this differential has an odd number
q Accordingly, the pinion does not run idle and
of teeth. The meshing points of pinion (4) and
the drive force is transmitted to both side gears
side gears (3) change according to the differ-
and the tires do not slip until the ratio of (a) : (b)
ence of the road resistance. Consequently, the
becomes 1 : 1.38, or the difference between
traction forces of the tires on both sides change.
the road resistances under both tires becomes
38%.
Operation
q The lives of the tires are lengthened 20 – 30%
Straight travel (When the road resistances and the working capacity is increased by the
under both tires are the same) above effect.
WA150-6 10-200 43
200 Power train
SEN05076-00 Limited slip differential
Limited slip differential 1
(if equipped)
1. Plate
2. Disc
4. Washer
6. Bevel pinion
7. Shaft
8. Pressure ring
10. Case
10-200 44 WA150-6
200 Power train
Limited slip differential SEN05076-00
Unit: mm
11 Thickness of plate 3
±0.02 2.9
3.1
+0.04
12 Thickness of disc 2.5
–0.03
2.45
13 Thicknesses of washer 2 ±0.05 1.8
14 Clearance between disc and plate

(total clearance on both sides)
0.2 – 0.6
Replace
15 End play of side gear in axial
direction (one side)
0.13 – 0.36
16 Backlash of case and plate 0 – 0.5
17 Backlash of side gear and disc 0.13 – 0.32

size clearance limit
18 Clearance between spider and
differential pinion
Shaft Hole
–0.110 +0.05 0.110 –
22 –0.160 0 0.210 —
WA150-6 10-200 45
200 Power train
SEN05076-00 Limited slip differential
Operation of limited slip differential While machine is traveling straight

q The power from the HST motor is transmitted When the drive forces of the right and left
through bevel gear (9), case (10), pressure wheels are balanced
ring (8), shaft (7), pinion (3) and side gear (5), [When the road conditions (coefficient of friction)
and then distributed to the right and left shafts. under both wheels and the wheel loads are even,
q The brake unit consisting of disc (2) and plate and the center of load is at the center of the bucket]
(1) is installed to the back side of side gear (5).
It generates braking torque in proportion to the
torque transmitted from pressure ring (8) to
shaft (7).
q Since the brake torque restricts the rotation of
side gears (5) and case (10), right and left side
gears (5) cannot rotate freely. Thus, the opera-
tion of the differential is restricted.
Mechanism of generation of braking torque by

right and left side gears (5)
q Shaft (7) is supported on the cam surfaces

being provided on the surfaces of pressure
rings (8) that are facing each other.
q The power (= torque) transmitted from pres-
sure rings (8) to shaft (7) is transmitted on the q The power from the transfer is evenly divided
cam surfaces. Force (Fa) to separate pressure into the right and left by the differential gears.
rings (8) from each other is generated by incli- Under this condition, the slip limits of the right
nation of the cam surfaces in proportion to the and left wheels are the same. Accordingly,
transmitted torque. even if the power from the transfer may exceed
q Separating load (Fa) acts on the brake on the the slip limits, both wheels slip and the differ-
back side of each side gear (5) to generate ential does not work.
braking torque. No load is applied to the brake on the back
side of the side gear.
10-200 46 WA150-6
200 Power train
Limited slip differential SEN05076-00
When the drive forces of the right and left Difference in wheel drive force by type of differen-
wheels are unbalanced tials when either wheel slipped
[When the road conditions (coefficient of friction) Wheel drive force
under both wheels and the wheel loads are uneven, (drive force of slipping wheel is 1)
and either wheel slips more easily] Slipping wheel Locked wheel Total (ratio)
Example 1. When either wheel is on soft ground in Limited slip
differential 1 2.64 3.64 (1.53)
digging work (if equipped)
Example 2. When either wheel is on snow and the Torque
other one is on asphalt in snow remov- proportioning
1 1.38 2.38 (1)
ing work differential
(standard)
Example 3. When the right and left wheel loads are
Conventional
unbalanced in travel on a slope 1 1 2 (0.84)
differential
Torque proportioning differential

q On a road where either wheel slips easily, the
drive force of the limited slip differential
increases to 1.53 times of the torque propor-
tioning differential.
Conventional differential
(this is not applied with this machine.)
q On a road where either wheel slips easily, the
drive force of the limited slip differential
increases to 1.82 times of the conventional dif-
ferential.
While machine is turning
q The power from the transfer is evenly divided

into the right and left sides by the differential q The same gears as that for the conventional
gear. If, however, the divided driving force differential are employed for the limited slip dif-
exceeds the wheel slip limit of the slip side, ferential. Thus, they allow to smoothly gener-
surplus of the driving force is transmitted to the ate a difference in rotation speed between the
opposite side (lock side) brake through the outer and inner wheels that is necessary for
brake and case on the gear back side. Then tuning.
the power is distributed to the lock side wheel.
q The differential starts working only as the sur-
plus portion of the drive force has exceeded
the braking force.
WA150-6 10-200 47
200 Power train
SEN05076-00 Final drive
Final drive 1
Front final drive 1
1. Planetary gear (number of teeth: 26)

2. Planetary carrier
3. Axle shaft
4. Ring gear (number of teeth: 69)
5. Sun gear shaft (number of teeth: 15)
10-200 48 WA150-6
200 Power train
Final drive SEN05076-00
Rear final drive 1
1. Planetary gear (number of teeth: 26)

2. Planetary carrier
3. Axle shaft
4. Ring gear (number of teeth: 69)
5. Sun gear shaft (number of teeth: 15)
WA150-6 10-200 49
200 Power train
SEN05076-00 Final drive
Unit: mm
Clearance between planetary size Shaft Hole clearance limit
6 gear bearing and shaft +0.025 +0.013 –0.025 – Replace
33.338 —
+0.013 0 0
Clearance between axle housing +0.100 +0.100 –0.100 –
7 and ring gear
255
+0.030 0 +0.070
—
Clearance between oil seal and
8 housing
Max. 0.2 Adjust
+0.50 +0.063 –0.5 –
Housing 130 —
Press-fitting part of +0.25 0 –0.187
9 axle shaft seal 0 –0.25 –0.45 –
Shaft 93.5 —
–0.054 –0.45 –0.196
+0.025 –0.013 –0.076 –
Clearance at press- Outer race 127 —
0 –0.051 –0.013
10 fitting part of axle
housing bearing +0.063 +0.025 –0.063 –
Inner race 77.788 —
+0.038 0 –0.013
Replace
+0.025
112.713 —
0 –0.077 –
Outer race —
+0.038 –0.014
Clearance at press- 112.661 —
0
11 fitting part of axle
housing bearing 0
69.9 –0.025 —
Inner race
–0.05 – —
+0.013 –0.012
69.85 — 0
12 End play of axle shaft 0 – 0.098 Adjust
–0.080 –0.036 +0.080 –
13 Clearance at guide pin and hole 8
–0.116 0 +0.152
— Replace
a Starting force of axle housing, see "Disassembly and assembly of axle housing assembly" in Disassem-
bly and assembly.
10-200 50 WA150-6
200 Power train
Final drive SEN05076-00
Outline
a The figure shows the front axle.

q The final drive finally reduces speed of the
power from the engine to increase the drive
force.
q Ring gear (4) is press fitted to the axle housing
and fixed with the pin.
q Speed of the power being transmitted from the
differential through sun gear shaft (5) is
reduced by the planetary gear unit to increase
the drive force.
The increased drive force is transmitted
through planetary carrier (2) and axle shaft (3)
to the tire.
WA150-6 10-200 51
SEN05076-00

©2009 KOMATSU
All Rights Reserved
10-200 52
SEN05077-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

300 Steering system

Steering piping diagram .................................................................................................................................. 3
Steering column .............................................................................................................................................. 4
Priority valve ................................................................................................................................................... 5
Orbit-roll valve................................................................................................................................................. 8
Steering cylinder ........................................................................................................................................... 16
WA150-6 10-300 1
300 Steering system
SEN05077-00
10-300 2 WA150-6
300 Steering system
Steering piping diagram SEN05077-00
Steering piping diagram 1
1. Steering cylinder (right)

2. Orbit-roll valve
3. Hydraulic tank
4. Priority valve
5. Work equipment and steering pump
6. Steering cylinder (left)
WA150-6 10-300 3
300 Steering system
SEN05077-00 Steering column
Steering column 1
1. Steering wheel
2. Steering column
3. Orbit-roll valve
4. Steering tilt lock lever
Unit: mm
Clearance between steering shaft size Shaft Hole clearance limit
5 and column bushing Replace
0 +0.15 0.05 –
19 0.4
–0.08 +0.05 0.23
10-300 4 WA150-6
300 Steering system
Priority valve SEN05077-00
Priority valve 1
P: From work equipment and steering pump LS: From Orbit-roll valve
CF: To Orbit-roll valve T: To hydraulic tank
EF: To work equipment control valve
1. Relief valve body 7. Plug

2. Spring seat 8. Valve body
3. Spring 9. Spool
4. Poppet 10. Spring
5. Seat 11. Plug
6. Screen
Unit: mm
Installed Installed Installed
Free length Free length
12 Control spring length load load
187 N 187 ± 14.7 N Replace
63.4 47.6 63.4 ± 1 {19.1±1.5kg}
{19.1 kg}
83 N 83 ± 14.7 N
13 Relief spring 31 27.8
{8.5 kg}
— {8.5 ± 1.5 kg}
WA150-6 10-300 5
300 Steering system
SEN05077-00 Priority valve
Outline Operation
q The priority valve is installed between the work
equipment and steering pump and Orbit-roll When steering wheel is at "neutral" position
valve and work equipment control valve. It
diverges the oil from the work equipment and
steering pump to the steering circuit or work
equipment circuit. It is also used for controlling
the oil pressure from the priority valve to the
Orbit-roll valve in order to protect the circuit.
Set pressure: 18.6 MPa {190 kg/cm2}
q When the engine is stopped, spool (3) is

pushed in the left direction by the repulsive
force of spring (4). Thus, port (M) and port (N)
are fully opened and port (M) and port (Q) are
closed.
q Starting the engine starts the work equipment
and steering pump rotation, and the oil from
the pump flows to port (A) of the Orbit-roll
valve through port (M) and port (N).
q The oil that flew to chamber (P) through orifice
(m) of spool (3) pushes spool (3) in the right
direction by compressing spring (4).
q Port (M) and port (Q) are opened and port (M)
and port (N) are almost closed to stabilize
spool (3).
q Most of the oil from the pump flows to the work
equipment circuit through port (Q).
10-300 6 WA150-6
300 Steering system
Priority valve SEN05077-00
When steering wheel is "turned left" When steering cylinder is at stroke end
q Turning the steering wheel left changes the q Trying to continuously turn the steering wheel
angle between the sleeve and spool on the after the steering cylinder has reached the
Orbit-roll valve, switching flow of the oil. (see stroke end increases oil pressure in port (S).
"Orbit-roll valve".) q As the oil pressure in port (S) goes beyond the
q Part of the oil from the pump that has flown to set pressure of relief valve (10), the relief valve
port (A) is then conducted to the R.H. steering (10) releases the oil pressure in port (S) to the
cylinder through port (B) and Gerotor, and the hydraulic tank through port (T).
remaining portion of the oil flows to chamber q It generates differential pressure before and
(R) through orifice (b) and port (J). after orifice (r), breaking down the balance
q Change in the angle between the sleeve and between the difference pressure up to port (A)
spool on the Orbit-roll valve generates a differ- and after port (B) and the repulsive force of
ence pressure between the oil pressure up to spring (4). As a result, oil pressure up to port
port (A) and that after port (B). (A) becomes relatively higher.
q Spool (3) stabilizes at a position where the dif- q As port (A) oil pressure is increased, oil in
ference pressure between that of up to port (A) chamber (P) pushes spool (3) in the right direc-
and after port (B) [chamber (P) pressure – tion by compressing spring (4).
chamber (R) pressure] is balanced with the q Port (M) and port (N) are almost closed, and
repulsive force of spring (4). port (M) and port (N) are nearly fully opened to
q The ratio of diversion is determined by the dis- stabilize spool (3).
placement in angle between the spool and
sleeve on the Orbit-roll valve, namely the
opening ratio of port (A) and port (B). And
changing the operating distance of the steering
wheel enables its stepless adjustment.
WA150-6 10-300 7
300 Steering system
SEN05077-00 Orbit-roll valve
Orbit-roll valve 1
P: From work equipment and steering pump LS: To priority valve

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

2. Valve body 9. Sleeve
3. Check valve 10. Spool
4. Gerotor 11. Center pin
5. Spacer 12. Centering spring
6. Cover 13. Anti-cavitation valve
7. Spacer 14. Overload relief valve
10-300 8 WA150-6
300 Steering system
Orbit-roll valve SEN05077-00
Outline Structure
q The Orbit-roll valve is connected to the drive q Top (A) of spool (9) is connected to the drive
shaft of the steering column. It changes the oil shaft of the steering column and further con-
flow from the work equipment and steering nected to sleeve (8) through center pin (7)
pump to the right or left steering cylinder to (which is not in contact with spool (9) while the
decide the travel direction of the machine. steering wheel is at "neutral") and centering
q The Orbit-roll valve is roughly divided into spring (2).
spool (9) and sleeve (8) that have rotary type q Top (B) of drive shaft (3) is engaged with cen-
direction selecting function and Gerotor (5) ter pin (7) and united with sleeve (8) and the
(combination of rotor (5a) and stator (5b)) that bottom is engaged with the spline of rotor (5a)
operates as a hydraulic motor during the nor- of the Gerotor (5).
mal steering operation and as a hand pump q 4 ports are provided on valve body (4). Each
(the steering wheel's operating effort becomes port is respectively connected to the pump cir-
too high to operate it actually) when the oil is cuit, tank circuit, L.H. steering circuit and R.H.
not supplied because of a trouble of the work steering circuit. And the ports of the pump side
equipment and steering pump or engine. and tank side are connected by the check
valve in the body. If the pump or engine fails,
the oil can be sucked through this check valve
directly from the tank side.
WA150-6 10-300 9
300 Steering system
Operation
When steering wheel is at "neutral" position
10-300 10 WA150-6
300 Steering system
q When the steering wheel is at "neutral" posi-

tion, centering spring (12) sets center pin (4) to
the center of the oblong hole on spool (3) and
move of spool (3) and sleeve (5) is stopped.
q Port (A) from sleeve (5) pump, port (E) to the
Gerotor, port (F) to the R.H. steering circuit and
port (G) to the L.H. steering circuit cut off the
vertical grooves (B), (C) and (D) on spool (3).
q Orifice (b) of port (J) to the priority valve is con-
nected to vertical groove (B) on spool (3).
q Port (K) of sleeve (5) is connected to vertical
groove (M) and port (L) on spool (3).
q Due to connection and disconnection of the
ports and vertical grooves, the oil in the priority
valve being set to the pilot pressure is con-
ducted through port (J), orifice (b), vertical
groove (M) and port (K), then drained from port
(L) to the hydraulic tank.
WA150-6 10-300 11
300 Steering system
When steering wheel is "turned left"
10-300 12 WA150-6
300 Steering system
q As the steering wheel is "turned left", spool (3) When steering wheel is at "stop" position
being connected to the drive shaft of the steer- q As operation of the steering wheel is stopped,
ing column is rotated counterclockwise. angular displacement between spool (3) and
q Since spool (3) and sleeve (5) are connected sleeve (5) disappears and the steering system
by centering spring (12), spool (3) compresses is returned to the neutral position by the repul-
centering spring (12). sive force of centering spring (12).
q An angular displacement corresponding to the
amount of compression of centering spring
(12) is generated between spool (3) and
sleeve (5).
q Port (A) and vertical groove (B) are connected
first being followed by the connection between
vertical groove (B) and port (E), port (E) and
vertical groove (C), and vertical groove (C) and
port (G) to the L.H. steering circuit.
q Although the connection between vertical
groove (B) and orifice (b) of port (J) to the pri-
ority valve is maintained, port (K) of sleeve (5)
starts gradually closing vertical groove (M) and
port (L).
q Port (F) of the R.H. steering circuit is con-
nected to vertical groove (D) at the same time
as port (A) and vertical groove (B) are con-
nected.
q Due to connection and disconnection of the
ports and vertical grooves, the oil from the
pump flows from port (A) to vertical groove (B)
then flows to port (E), starting rotation of the
Gerotor. The oil discharged from the Gerotor
flows to the L.H. steering cylinder head side
through port (E), vertical groove (C) and port
(G).
q Oil pressure of vertical groove (M) is transmit-
ted to port (J) through orifice (b), then supplied
from port (J) as the pilot pressure of the priority
valve.
q The oil from the R.H. steering cylinder head is
drained to the hydraulic tank through port (F),
vertical groove (D) and port (H).
WA150-6 10-300 13
300 Steering system
Connection of hand pump and sleeve
q Above figure shows the suction and discharge q The internal gear of the Gerotor advances by 1
ports (P) of the Gerotor and connections with tooth with every 1/7 turn of the steering wheel
the sleeve ports. and discharges the oil from the pump accord-
q If the steering wheel is turned to the right, ports ing to the steering angle of the steering wheel.
(a), (c), (e), (g), (i), and (k) will be connected to Accordingly, the discharge amount varies in
the pump side by the vertical grooves of the proportion to the steering angle of the steering
spool. Likewise, ports (b), (d), (f), (h), (j), and (l) wheel.
are connected to the R.H. steering cylinder
head side.
Under the condition in Fig. 1, ports (1), (2) and
(3) are in the discharge state of the Gerotor
and connected to ports (l), (b), and (d) and the
oil is sent to the steering cylinder. Ports (5), (6),
and (7) are also connected and the oil from the
pump flows in them.
Fig. 2 shows the state that has resulted from
turning the steering wheel by 90° continued for
above condition. Under this state, ports (2), (3),
and (4) are in the suction state and connected
to ports (k), (a), and (c). Ports (5), (6), and (7)
are in the discharge state and connected to
ports (d), (f), and (h).
q As shown above, the ports in the discharge
state of the Gerotor are connected to the ports
being connected to the steering cylinder. The
ports in the suction state are connected to the
pump circuit.
10-300 14 WA150-6
300 Steering system
Role of centering spring
q Centering spring (2) is composed of 4 X-

shaped leaf springs and 2 flat leaf springs and
installed between spool (9) and sleeve (8) as
shown in the figure.
q If the steering wheel is turned, spool (9) com-
presses centering spring (2) and angular dis-
placement (a) is generated between spool (9)
and sleeve (8).
As a result, the ports of spool (9) and sleeve
(8) are connected and the oil is sent to the
steering cylinder. When the steering wheel
stops turning, the Gerotor also stops turning.
Then, the oil is not sent to the steering cylinder
any more and its pressure rises.
To prevent this, when the steering wheel
stopped turning, Gerotor is turned by the reac-
tion force of centering spring (2) by angular
displacement (a) of spool (9) and sleeve (8) to
return the steering wheel to the "neutral" posi-
tion.
WA150-6 10-300 15
300 Steering system
SEN05077-00 Steering cylinder
Steering cylinder 1
Unit: mm
Clearance between bushing and size clearance limit
Shaft Hole
1 mounting pin on cylinder rod
frame connecting part –0.020 +0.117 0.100 –
30 —
–0.053 +0.080 0.170
Clearance between bushing and
–0.020 +0.117 0.100 –
2 mounting pin on cylinder bottom 30
–0.053 +0.080 0.170
—
Replace
frame connecting part
Width of boss Width of hinge Standard (a+b) clearance
Connecting part of steering
3 cylinder and front frame 0 – 1.0
40 43
(after shim is adjusted)
Connecting part of steering 0 – 1.0
4 cylinder and rear frame 40 43 (after shim is adjusted)
10-300 16 WA150-6
300 Steering system
Steering cylinder SEN05077-00
Unit: mm
Clearance between piston rod size Shaft Hole clearance limit
1 and bushing –0.020 +0.133 0.013 –
30 0.505
–0.072 –0.007 0.205
Replace pin and
Clearance between piston rod –0.020 +0.117 0.100 – bushing
2 supporting shaft and bushing
30
–0.053 +0.080 0.170
1.0
Clearance between cylinder
–0.020 +0.117 0.100 –
3 bottom supporting shaft and 30 –0.053 +0.080 0.170 1.0
bushing
WA150-6 10-300 17
SEN05077-00

©2009 KOMATSU
All Rights Reserved
10-300 18
SEN05078-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

400 Brake system

Brake piping diagram ...................................................................................................................................... 3
Charge valve................................................................................................................................................... 4
Brake valve ..................................................................................................................................................... 8
Inching valve ................................................................................................................................................. 12
Accumulator (for brake) ................................................................................................................................ 13
Slack adjuster ............................................................................................................................................... 14
Brake............................................................................................................................................................. 16
Parking brake control .................................................................................................................................... 21
Parking brake................................................................................................................................................ 22
WA150-6 10-400 1
400 Brake system
SEN05078-00
10-400 2 WA150-6
400 Brake system
Brake piping diagram SEN05078-00
Brake piping diagram 1
1. Hydraulic tank 7. Charge valve

2. Brake valve 8. Slack adjuster (for front left side)
3. Brake and cooling fan pump 9. Front brake
4. Rear brake 10. Slack adjuster (for front right side)
5. Accumulator (for front side) 11. Slack adjuster (for rear right side)
6. Accumulator (for rear side) 12. Slack adjuster (for rear left side)
WA150-6 10-400 3
400 Brake system
SEN05078-00 Charge valve
Charge valve 1
10-400 4 WA150-6
400 Brake system
Charge valve SEN05078-00
P: From brake and cooling fan pump

T: To hydraulic tank
A: To cooling fan motor
ACC1: To accumulator (rear side)
ACC2: To accumulator (front side)
S: Brake operation sensor port
G: Gauge port
1. Valve body
2. Inverse shuttle valve
3. Plunger
4. Unload relief valve
5. Unload valve
6. Relief valve
Unit: mm
Clearance between inverse size Shaft Hole clearance limit
7 shuttle valve and body –0.006 +0.011 0.006 –
12 –0.014 0 0.025 0.029
Clearance between plunger and –0.005 +0.009 0.005 –
8 body 8 –0.012 0 0.021 0.024
Clearance between unload valve –0.006 +0.011 0.006 –
9 and body 18 –0.017 0 0.028 0.032
Installed Installed Installed
10 Inverse
spring
shuttle valve return Free length length load Free length load Replace
9.8 N 8.3 N
21.6 18.3 {1.0 kg} — {0.85 kg}
11 Unload
(inside)
relief valve return spring
35.9 30.0
188 N
{19.2 kg} —
160 N
{16.3 kg}
12 Unload relief valve return spring

(outside) 39.8 27.5
137 N
{14.0 kg} —
116 N
{11.8 kg}
49 N 42 N
13 Unload valve return spring 51.6 45.0 {5.0 kg} — {4.3 kg}
4.9 N 4.2 N
14 Check valve return spring 11.5 9.0 {0.5 kg} — {0.43 kg}
Function
q The charge valve maintains the oil pressure
from the pump to the set pressure and accu-
mulates it in the accumulator.
q If the oil pressure from the pump goes beyond
the relief valve s et pres sur e, this valve
releases the oil pressure to the drain circuit in
order to reduce the load to the pump.
WA150-6 10-400 5
400 Brake system
SEN05078-00 Charge valve
Operation
When oil is not supplied to accumulator When oil is supplied to accumulator
(cut-off state) 1. Cut-in state
q Plunger (1) is moved in the left direction by the q As the accumulator pressure goes low, pres-
accumulator pressure, and maintains unload sure on port (E) goes low, allowing plunger (1)
relief valve (2) being pushed open. to move in the right direction and unload relief
q The oil in the spring chamber of unload valve valve (2) to close the drain circuit.
(3) is drained to the hydraulic tank through port q Since the oil pressure in port (F) and the spring
(F), unload relief valve (2) and port (T). chamber of unload valve (3) increases, unload
q Since oil pressure in port (F) is decreased, valve (3) moves in the right direction.
unload valve (3) moves in the left direction q Port (C) and port (B) are opened, conducting
being subjected to the action of the oil from the oil from the pump to port (B).
chamber (B). q As oil pressure in port (B) increases beyond
q Port (C) and port (D) are opened, supplying the set pressure of check valve (4), check
most of the oil from the pump to the cooling fan valve opens, allowing the oil to be supplied to
motor through port (P), ports (C) and (D), and the accumulator through port (E). The pressure
port (A). for supplying oil to the accumulator depends
on the set pressure of check valve (4).
q Amount of oil supplied to the accumulator is
constant independent of the engine speed,
thus surplus of the oil flows to the cooling fan
motor through port (A).
q Inverse shuttle valve (5) supplies precedence
to the accumulator of lower pressure when
supplying oil.
10-400 6 WA150-6
400 Brake system
Charge valve SEN05078-00
When the oil pressure from the pump went

2. When pressure reaches cut-off pressure beyond the set pressure
q As pressure in port (F) reaches the set pres- q As oil pressure in chamber (B) reaches the set
sure (cut-off pressure) of unload relief valve pressure of relief valve (6), relief valve (6) is
(2), oil in the spring chamber of unload valve opened to drain the oil from the pump to the
(3) is drained to the hydraulic tank through port hydraulic tank through port (T).
(F), unload relief valve (2) and port (T). Above process protects the brake circuit by
q Plunger (1) is moved in the left direction by the restricting its maximum pressure.
accumulator pressure, and maintains unload
relief valve (2) being pushed open.
q Since oil pressure in port (F) is decreased,
unload valve (3) moves in the left direction
being subjected to the action of the oil from
chamber (B).
q Port (C) and port (D) are opened, supplying
most of the oil from the pump to the cooling fan
motor through port (P), ports (C) and (D), and
port (A).
WA150-6 10-400 7
400 Brake system
SEN05078-00 Brake valve
Brake valve 1
P1: From HST pump PA: From accumulator (rear side)

T1: To hydraulic tank A: To Rear brake
T2: To work equipment and steering pump PB: From accumulator (front side)
(suction side) B: To front brake
1. Rod 5. Brake valve body (for rear)

2. Inching valve spool 6. Brake valve spool (for front)
3. Inching valve body 7. Brake valve body (for front)
4. Brake valve spool (for rear)
Unit: mm
Clearance between inching valve size Shaft Hole clearance limit
8 spool and body –0.022 +0.033 0.020 –
22.4 0.096
–0.053 0 0.086
Clearance between inching valve –0.022 +0.033 0.020 –
9 guide and body
22.4
–0.053 0 0.086
0.096
Clearance between inching valve –0.050 +0.050 0.050 –

10 spool and guide
12
–0.093 0 0.143
0.157
Installed Installed Installed Replace
Free length Free length
11 Inching valve control spring length load load
24.5 N 20.8 N
34.7 16.7 {2.5 kg} — {2.1 kg}
113 N 96 N
12 Brake valve control spring 35.6 24.0
{11.5 kg}
—
{9.8 kg}
19.6 N 16.7 N
13 Inching valve return spring 50.0 49.5
{2.0 kg}
—
{1.7 kg}
147 N 125 N
14 Brake valve return spring 114.9 52.4
{15.0 kg}
—
{12.7 kg}
10-400 8 WA150-6
400 Brake system
Brake valve SEN05078-00
Outline
q The brake valve is installed in the lower front
side of the operator's seat. Pressing the brake
pedal conducts oil to the brake piston, operat-
ing the brake.
q The left side and right side brake pedals are
mechanically interlocked. Pressing one of the
pedals operates another pedal at the same
time.
q The brake valve contains the inching valve to
regulate the control pressure of the HST pump.
Operation
When the brake pedal is pressed down
q Brake pedal (1) pressing effort is transmitted to When brake of one side is operated
spool (5) through rod (2), spool (3) and spring (when the other brake failed)
(4). q Even when only one side of the brakes
q As spool (5) is pushed in the right direction, remains operable due to, for instance, oil leak
port (Ta) is closed and the oil from the pump on the front or rear brake system, brake pedal
activates the rear brake after being conducted (1) pressing effort moves in the right direction
through the accumulator, port (PA), port (A) after being transmitted mechanically through
and rear brake piston. spool (5) and spool (6).
q As spool (5) is pushed in the right direction, q Oil from the pump is conducted normally to the
spool (6) is also pushed in the right direction, brake piston of the healthy system to enable
closing port (Tb). The oil from the pump flows stopping the machine as needed in order to
through the accumulator, port (PB) and port (B) ensure safety.
to the front brake piston to activate the front
brake.
WA150-6 10-400 9
400 Brake system
SEN05078-00 Brake valve
Balancing operation
q As the rear brake piston is filled with oil and the

oil pressure rises between port (PA) and port
(A), the oil being conducted to chamber (E)
through orifice (c) of spool (5) pushes spool (5)
in the left direction resisting repulsive force of
spring (4). As the result, port (PA) and port (A)
are disconnected.
q Since port (Ta) remains closed, the oil con-
ducted to the brake piston is retained and the
brake remains operable.
q At the same time as spool (5) is moved to the
left, the front brake piston is filled up with oil,
increasing the oil pressure between port (PB)
and port (B). Thus, the oil conducted to cham-
ber (F) through orifice (d) of spool (6) pushes
back spool (6) leftwards by the move distance
of spool (5). As a result, port (PB) and port (B)
are disconnected.
q Since port (Tb) remains closed, the oil con-
ducted to the brake piston is retained and the
brake remains operable.
q The oil pressure of the rear brake circuit [port
(A) side] is balanced with the brake pedal
pressing effort, and the oil pressure of the front
brake circuit [port (B) side] is balanced with the
oil pressure of the rear brake circuit [port (A)
side].
q As spools (5) and (6) are moved in the right
direction to the stroke end, port (PA) and port
(A) as well as port (PB) and port (B) are fully
connected. As a result, oil pressure of the rear
brake cir cuit and the front br ake circuit
becomes equal to that from the pump.
q Braking force is adjustable by adjusting the
brake pedal pressing effort until spools (5) and
(6) are driven in the right direction to the stroke
end.
10-400 10 WA150-6
400 Brake system
Brake valve SEN05078-00
When brake pedal is released
q Releasing brake pedal (1) releases the pedal

pressing effort being applied to spool (5).
q Spool (5) is pushed back in the left direction by
the back pressure of the rear brake piston and
repulsive force of spring (7), and port (PA) and
port (A) are closed.
q At the same time, oil in the rear brake piston is
drained to the hydraulic tank through port (A)
and port (Ta), releasing the rear brake.
q At the same time as spool (5) is moved in the
left direction, spool (6) is also pushed back in
the left direction by the back pressure of the
front brake piston and repulsive force of spring
(7). As the result, port (PB) and port (B) are
closed.
q Oil in the front brake piston is drained to the
hydraulic tank through port (B) and port (Tb),
releasing the front brake.
WA150-6 10-400 11
400 Brake system
SEN05078-00 Inching valve
Inching valve 1
P1: From HST pump port (Y) Outline

T2: To work equipment and steering pump q The inching valve, which is contained in brake
(suction side) valve (2), reduces the control oil pressure of
the HST circuit responding to stroke (S) of
1. Brake pedal spool (3) in order to reduce the capacity of the
2. Brake valve HST pump.
3. Spool
4. Body
10-400 12 WA150-6
400 Brake system
Accumulator (for brake) SEN05078-00
Accumulator (for brake) 1
1. Cylinder
2. Free piston
Function
q The accumulator is installed between the
charge valve and brake valve. The space
between cylinder (1) and free piston (2) is filled
with nitrogen gas. The nitrogen gas absorbs
the hydraulic pulses generated by the hydrau-
lic pump and secures the braking force and
operability when the engine is stopped by uti-
lizing its compressibility.
Specifications
Gas used Nitrogen gas
Amount of gas (cc) 500
Charge pressure 3.5 ± 0.1 {35.7 ± 1}
(MPa {kg/cm2}) (at 20°C)
Max. pressure used
10 {102}
(MPa {kg/cm2})
WA150-6 10-400 13
400 Brake system
SEN05078-00 Slack adjuster
Slack adjuster 1
A: From brake valve

B: To brake piston
1. Body
2. Check valve
3. Piston
Unit: mm
Clearance between piston and size Shaft Hole clearance limit
4 body –0.065 +0.052 0.065 –
30 0.163
–0.098 0 0.150
Clearance between check valve –0.013 +0.015 0.013 –
5 and body
10
–0.028 0 0.043
0.048
Standard size Repair limit Replace
Free length Installed Installed Free length Installed

6 Piston return spring length load load
87.5 48.2 11.8 N — 9.8 N
{1.2 kg} {1.0 kg}
53.9 N 46.1 N
7 Check valve return spring 21.7 19.25
{5.5 kg}
—
{4.7 kg}
10-400 14 WA150-6
400 Brake system
Slack adjuster SEN05078-00
Function
q The slack adjuster is installed between the
brake valve and brake piston. It maintains the
time lag up to activation of the brake constant.
Operation
When brake is applied When brake is released
q The oil from the brake valve flows to port (A) q The oil being stopped between piston (1) and
and moves piston (1) in the right direction to brake piston pushes back piston (1) in the left
activate the brake using the oil being amassed direction, allowing the oil, equivalent in the vol-
between piston (1) and the brake piston. ume to piston (1) move distance, to return to
q The slack adjuster maintains the time lag up to the brake valve through port (A) then is drained
activation of the brake constant by operating to the hydraulic tank.
t he b r a k e u s i n g th e o i l b e i ng a m a s s e d
between piston (1) and the brake piston.
q If the oil between piston (1) and brake piston
goes low due to wear on the brake disc and
like, it pushes open check valve (2) to make up
the deficit.
WA150-6 10-400 15
400 Brake system
SEN05078-00 Brake
Brake 1
Front brake 1
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Disc (2 pieces)
10-400 16 WA150-6
400 Brake system
Brake SEN05078-00
Unit: mm
10 Thickness of plate
6 ±0.1 5.5
Thickness of brake disc 5.2 ±0.15 4.4
11 Depth of lining groove 0.8 (min.) — 0.4
Thickness of lining 1.0 0.8 (min.) — Replace

Standard size Tolerance Wear limit
12 Wear of disc contact surface of
brake outer ring 25 ±0.1 0.3
Installed height Installed load Installed load
13 Load of spring
6.0 1,225 N 980 N
{125 kg} {100 kg}
Outline
q The front brake is a wet multiple disc type
brake, which consists of piston (3), inner ring
(5), disc (9), outer ring (8), and spring (4).
q The brake cylinder consists of differential
housing (1) and bearing carrier (2). And piston
(3) is assembled to them.
Inner ring (5) and outer ring (8) are coupled
with the spline of differential housing (1).
q Disc (9) has linings stuck to its both sides and
is installed between inner ring (5) and outer
ring (8), and they are coupled together by the
spline of sun gear shaft (6).
WA150-6 10-400 17
400 Brake system
SEN05078-00 Brake
Rear brake 1
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Disc (2 pieces)
10-400 18 WA150-6
400 Brake system
Brake SEN05078-00
Unit: mm
10 Thickness of plate
6 ±0.1 5.5
11 Depth of lining groove 0.8 (min.) — 0.4
Thickness of lining 1.0 0.8 (min.) — Replace

Standard size Tolerance Wear limit
12 Wear of disc contact surface of
brake outer ring 25 ±0.1 0.3
Installed height Installed load Installed load
13 Load of spring
6.0 1,225 N 980 N
{125 kg} {100 kg}
Outline
q The rear brake is a wet multiple disc type
brake, which consists of piston (3), inner ring
(5), disc (9), outer ring (8), and spring (4).
q The brake cylinder consists of differential
housing (1) and bearing carrier (2). And piston
(3) is assembled to them.
Inner ring (5) and outer ring (8) are coupled
with the spline of differential housing (1).
q Disc (9) has linings stuck to its both sides and
is installed between inner ring (5) and outer
ring (8), and they are coupled together by the
spline of sun gear shaft (6).
WA150-6 10-400 19
400 Brake system
SEN05078-00 Brake
Operation
When brake is operated
q As the brake pedal is pressed, oil pressure (P)

being supplied through the hydraulic tank,
pump and brake charge valve to the brake cyl-
inder acts on piston (2) in the brake cylinder to
move the piston.
Accordingly, disc (4) between piston (2), inner
ring (3), and outer ring (5) is stopped and the
brake is applied to the machine.
When brake is "released"
q If the oil pressure is released, piston (2) is

returned to the original position by the return-
ing force of spring (8) and clearance is made
between inner ring (3) and outer ring (5), and
disc (4) becomes free.
The linings stuck to disc (4) have cross
grooves on them. While disc (4) is rotating, oil
flows in those grooves to cool the linings.
10-400 20 WA150-6
400 Brake system
Parking brake control SEN05078-00
Parking brake control 1
1. Parking brake lever 4. Control cable

2. Parking brake lever bottom switch 5. Transfer
3. Parking brake lever intermediate switch 6. Multi-disc brake lever
Outline
q The parking brake is built in transfer (5). On
this mechanical parking brake, operating the
multi-disc brake lever (6) from parking brake
lever (1) allows "applying" or "releasing" the
parking brake.
q Pulling parking brake lever (1) on the opera-
tor's seat pulls up the multi-disc brake lever
(6), which is connected with control cable (4),
"applying" the parking brake.
q Returning parking brake lever (1) to its original
position pushes down the multi-disc brake
lever (6), which is connected with control cable
(4), "releasing" the parking brake.
q As long as the parking brake is "applied", cur-
rent to the directional solenoid valve on the
HST pump is cut off and the swash plate of the
HST pump is maintained at the neutral posi-
tion.
WA150-6 10-400 21
400 Brake system
SEN05078-00 Parking brake
Parking brake 1
1. Lever 5. Plate
2. Housing 6. Disc
3. Ball 7. Wave spring
4. Piston 8. Output shaft
Unit: mm
Thickness of plate
9 2.6 ±0.06 2.5
Strain on plate — 0.05 0.6

Replace
10
Strain on brake disc — 0.07 0.25
11 Load of wave spring

(height: 4.7 mm)
229 N
{23.4 kg}
±23 N
{±2.3 kg}
195 N
{19.9 kg}
Outline
q This parking brake is a wet multiple disc type
brake being operated mechanically to apply
braking to output shaft (8).
q Lever (1) is connected to the control cable. Ball
(3) provided between piston (4) and housing
(2), that are connected to lever (1), moves on
the slope of the piston groove responding to
the pulling distance of the parking brake lever.
By this move of the ball, piston (4) compresses
plate (5) and disc (6) to each other, thereby
applying brake to output shaft (8).
10-400 22 WA150-6
400 Brake system
Parking brake SEN05078-00
WA150-6 10-400 23
SEN05078-00

©2009 KOMATSU
All Rights Reserved
10-400 24
SEN05079-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

500 Undercarriage and frame

Axle mount and center hinge pin .................................................................................................................... 2
WA150-6 10-500 1
SEN05079-00 Axle mount and center hinge pin
Axle mount and center hinge pin 1
10-500 2 WA150-6
Axle mount and center hinge pin SEN05079-00
1. Front axle Outline

2. Tension bolt q Front axle (1) receives the force during work
3. Rear axle directly. Thus, it is fixed directly to front fame
4. Frame lock bar (5) with tension bolt (2).
5. Front frame q Rear axle (3) is designed to sway at the center
6. Center hinge pin of rear frame (7) so that each tire may contact
7. Rear frame the ground surface even when the machine is
8. Additional counterweight (if equipped) traveling on soft ground.
9. Counterweight q Front frame (5) and rear frame (7) are coupled
by the center hinge pin (6) with the bearing
between them. The right and left steering cylin-
ders connect the front frame (5) and rear frame
(7). They adjust the bending angle or the turn-
ing radius of the frame according to move of
the cylinder.
WA150-6 10-500 3
10-500 4 WA150-6
Unit: mm
Clearance between upper hinge size Shaft Hole clearance limit
1 pin and rear frame (small) –0.038 +0.100 0.038 –
50 —
–0.068 0 0.168
Clearance between upper hinge –0.038 +0.25 0.038 –
2 pin and spacer
50
–0.068 0 0.318
—
3 Clearance between upper hinge

pin and bearing
50
–0.038
–0.068
0
–0.012
0.026 –
0.068
—
4 Clearance between upper hinge

pin and rear frame (large)
66
–0.073
–0.103
±0.05
0.023 –
0.153
—
5 Clearance
and spacer
between front frame
105
–0.20
–0.30
–0.02
–0.12
0.08 –
0.28
—
6 Clearance between front frame

and upper hinge bearing
105
0
–0.015
–0.02
–0.12
–0.120 –
–0.005
— Replace
7 Clearance of press-fitting part of

upper hinge pin seal
88.90
+0.17
+0.08
±0.05
–0.220 –
–0.030
—
8 Clearance between lower hinge

pin and rear frame bushing
69.85
–0.050
–0.060
+0.067
+0.027
0.077 –
0.127
—
9 Clearance between lower hinge

pin and bearing
69.85
–0.050
–0.060
+0.053
+0.028
0.078 –
0.113
—
10 Clearance between front frame

and lower hinge bearing 88.9
0
–0.020 ±0.05
–0.05 –
0.07 —
11 Clearance
and bushing
between rear frame
80
+0.084
+0.059
+0.054
0
–0.084 –
–0.005 —
12 Height of upper hinge spacer
23 ±0.1 —
13 Standard thickness of shim

between upper hinge and retainer 1.3
14 Standard thickness of shim

between upper hinge and retainer 0.8
Adjust
3.92 – 5.88 Nm{0.4 – 0.6 kgm} (when shim is adjusted)
15 Tightening torque of upper hinge
retainer mounting bolt
59 – 74 Nm {6.0 – 7.5 kgm} (final value)
WA150-6 10-500 5
Unit: mm
1 Thickness of thrust plate 0
10 –0.15 —
+0.3
2 Thickness of thrust washer 5 –0.1 —
Standard Tolerance Standard Clearance Replace

Clearance between shaft and hole size Shaft Hole clearance limit
3 on front support side –0.043 +0.550 0.093 –
150 —
–0.106 +0.050 0.656
Clearance between shaft and hole –0.043 +0.550 0.093 –
4 on rear support side
150
–0.106 +0.050 0.656
—
Standard thickness of shim in

5 thrust cap
0.2 —
10-500 6 WA150-6
WA150-6 10-500 7
SEN05079-00

©2009 KOMATSU
All Rights Reserved
10-500 8
SEN05080-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

600 Hydraulic system

Hydraulic component layout drawing .............................................................................................................. 2
Work equipment control lever linkage ............................................................................................................. 4
Hydraulic tank ................................................................................................................................................. 6
3-gear pump.................................................................................................................................................... 8
Work equipment control valve........................................................................................................................11
Work equipment PPC valve .......................................................................................................................... 51
Attachment PPC valve .................................................................................................................................. 58
Lock valve ..................................................................................................................................................... 60
2-way restrictor valve .................................................................................................................................... 61
Accumulator (for oil cooler circuit)................................................................................................................. 62
Accumulator (for PPC circuit)........................................................................................................................ 63
Accumulator (for ECSS)................................................................................................................................ 64
WA150-6 10-600 1
SEN05080-00 Hydraulic component layout drawing
Hydraulic component layout drawing 1
10-600 2 WA150-6
Hydraulic component layout drawing SEN05080-00
1. Bucket cylinder Outline

2. Work equipment control valve q The hydraulic system is consisted of the HST,
3. Hydraulic tank steering, work equipment, brake, cooling fan
4. Accumulator (for PPC circuit) and transfer lubrication circuit. The work equip-
5. Work equipment PPC valve ment circuit controls move of the lift arm and
6. Lock valve bucket.
7. Check valve q The oil in hydraulic tank (3) is supplied to work
8. Oil cooler equipment control valve (2) by work equipment
9. 3-gear pump pump of 3-gear pump (9). When each spool of
• Work equipment and steering pump the lift arm and bucket of work equipment con-
• Brake and cooling fan pump trol valve (2) is at the Hold position, the oil
• Transfer lubrication pump flows the drain circuit of work equipment con-
10. Clutch solenoid valve trol valve (2), is filtered on the return filter on
11. Accumulator (for ECSS) (if equipped) hydraulic tank (3), then is returned to hydraulic
12. Accumulator (for work equipment circuit) tank (3).
13. Lift cylinder q Operating the work equipment control lever
operates the lift arm spool or bucket spool of
work equipment PPC valve (5).
The oil from work equipment PPC valve (5)
operates respective spools of work equipment
control valve (2) with its oil pressure, then
sends the oil pressure to lift cylinder (13) or
bucket cylinder (1) to operate the lift arm or
bucket.
q The maximum pressure in the hydraulic circuit
is controlled with the relief valve in work equip-
ment control valve (2). The bucket cylinder cir-
cuit is equipped with the safety-suction valve
for protection of the circuit.
q Accumulator (for PPC circuit) (4) is installed on
the PPC pilot circuit so that the work equip-
ment can be lowered to the ground even while
the engine is stopped.
q Hydraulic tank (3) is pressurized, enclosed,
and equipped with the breather having the
relief valve, which doubles the oil filler cap
function. The breather applies pressure to the
tank and, at the same time, prevents genera-
tion of negative pressure in the tank to prevent
cavitation in the pump.
WA150-6 10-600 3
SEN05080-00 Work equipment control lever linkage
Work equipment control lever linkage 1
Mono-lever type
1. Work equipment control lever

2. Wrist rest
3. Lock valve
4. Work equipment lock lever
5. Work equipment PPC valve
6. Wrist rest height adjustment lock lever
10-600 4 WA150-6
Work equipment control lever linkage SEN05080-00
Mono-lever type
(Machine with auxiliary control lever)
1. Auxiliary control lever

2. Work equipment control lever
3. Wrist rest
4. Lock valve
5. Work equipment lock lever
6. Work equipment PPC valve
7. Attachment PPC valve
8. Wrist rest height adjustment lever
WA150-6 10-600 5
SEN05080-00 Hydraulic tank
Hydraulic tank 1
1. Oil filler cap and breather Specifications

2. Return filter
3. Drain plug Capacity of hydraulic tank (l) 65
4. Hydraulic tank
Quantity of oil in hydraulic tank (l) 47
5. Sight gauge
6. Return filter bypass valve Set pressure of bypass valve 0.2
7. Check valve (MPa {kg/cm2}) {2.04}
Cracking pressure of check valve 0.1 ± 0.02
(MPa {kg/cm2}) {0.98 ± 0.2}
10-600 6 WA150-6
Hydraulic tank SEN05080-00
Breather 1
1. Oil filler cap

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

q Since the tank is pressurized and enclosed, if
the oil level in it lowers, negative pressure is
generated.
At this time, sleeve (4) is opened by the differ-
ential pressure between the tank pressure and
the atmospheric pressure to prevent genera-
tion of the negative pressure.
(set pressure of air intake valve:
3.0 ± 0.3 kPa {0.03 ± 0.003 kg/cm2})
Prevention of pressure buildup in tank

q While the hydraulic circuit is in operation, the
oil level in the tank rises as the hydraulic cylin-
ders operate, and the temperature rises. Con-
sequently, the pressure in the tank rises, too.
If the pressure in the tank rises beyond the set
level, poppet (5) is activated to release the
pressure in the tank to prevent rise of pressure
in the tank.
(set pressure of exhaust valve:
0.1 ± 0.015 MPa {1.0 ± 0.15 kg/cm2})
WA150-6 10-600 7
SEN05080-00 3-gear pump
3-gear pump 1
(Work equipment, steering, brake, cooling fan and transfer lubrication)
Model name: SAR (3) 56+SB (1) 10+6
Outline
q The 3-gear pump is installed on the HST
pump. The axial rotation drives this pump to
supply oil pressure to the work equipment,
steering, brake, cooling fan and transfer.
10-600 8 WA150-6
3-gear pump SEN05080-00
Unit: mm
Type Standard clearance Clearance limit
SAR(3)56 0.10 – 0.15 0.19
1 Side clearance
SBR(1)10 0.10 – 0.15 0.19
SBR(1)6 0.10 – 0.15 0.19
Clearance between inside SAR(3)56 0.060 – 0.149 0.20
2 diameter of plain bearing and SBR(1)10 0.060 – 0.119 0.20
Replace
outside diameter of gear shaft SBR(1)6 0.060 – 0.119 0.20
Type Standard size Allowance Repair limit
SAR(3)56 14 0
3 Pin driven depth SBR(1)10 10 –0.5
—
+0.5
SBR(1)6 7 0
4 Rotating torque of spline shaft 10.9 – 21.6 Nm {1.1 – 2.2 kgm}
Discharge Standard Allowable

Type Speed pressure delivery delivery
(rpm) (MPa {kg/cm2})
Delivery (l/min) (l/min) —
— Oil: SAE10WCD SAR(3)56 129 119
Oil temperature: 45 – 55°C
SBR(1)10 2,500 20.6{210} 23 21
SBR(1)6 14 13
WA150-6 10-600 9
SEN05080-00 3-gear pump
10-600 10 WA150-6
Work equipment control valve SEN05080-00
Work equipment control valve 1
2-spool valve (without ECSS valve)
A1: To bucket cylinder head PA1: From bucket dump PPC valve
A2: To lift cylinder head PA2: From lift arm lower PPC valve
B1: To bucket cylinder bottom PB1: From bucket tilt PPC valve
B2: To lift cylinder bottom PB2: From lift arm raise PPC valve
P: From work equipment and steering pump T: To hydraulic tank
WA150-6 10-600 11
SEN05080-00 Work equipment control valve
10-600 12 WA150-6
1. Main relief valve

2. Bucket spool
3. Lift arm spool
5. Check valve
6. Suction valve
Unit: mm
Free length x
Outside Installed Installed load Free length Installed load
length
92.2 N 73.7 N
42.53 x 27.5 41 —
{9.4 kg} {7.52 kg}
55.9 N 44.7 N
8 Spool return spring 58.87 x 26.3 57.3
{5.7 kg}
—
{4.56 kg} If damaged or
deformed, replace
111 N 88.7 N spring
9 Spool return spring 53.35 x 12 38.5
{11.3 kg}
—
{9.04 kg}
72.6 N 58.1 N
{7.4 kg}
—
{5.92 kg}
29.4 N 23.5 N
11 Check valve spring 39.5 x 11.2 25 {3 kg} — {2.4 kg}
5.49 N 4.41 N
12 Suction valve spring 46.8 x 7.5 40.6 {0.56 kg} — {0.45 kg}
WA150-6 10-600 13
10-600 14 WA150-6
A1: To bucket cylinder head PA1: From bucket dump PPC valve
A2: To lift cylinder head PA2: From lift arm lower PPC valve
A3: To attachment actuator PA3: From attachment PPC valve
B1: To bucket cylinder bottom PB1: From bucket tilt PPC valve
B2: To lift cylinder bottom PB2: From lift arm raise PPC valve
B3: To attachment actuator PB3: From attachment PPC valve
P: From work equipment and steering pump T: To hydraulic tank
WA150-6 10-600 15
10-600 16 WA150-6

2. Service spool
3. Bucket spool
4. Lift arm spool
6. Check valve
7. Suction valve
Unit: mm
Free length x
Outside Installed Installed load Free length Installed load
length
92.2 N 73.7 N
42.53 x 27.5 41 —
{9.4 kg} {7.52 kg}
55.9 N 44.7 N
{5.7 kg}
—
deformed, replace
111 N 88.7 N spring
{11.3 kg}
—
{9.04 kg}
72.6 N 58.1 N
{7.4 kg}
—
{5.92 kg}
29.4 N 23.5 N
5.49 N 4.41 N
13 Suction valve spring 46.8 x 7.5 40.6 {0.56 kg} — {0.45 kg}
WA150-6 10-600 17
2-spool valve (with ECSS valve)
10-600 18 WA150-6
A1: To bucket cylinder head

A2: To lift cylinder head
ACC: To accumulator for ECSS
B1: To bucket cylinder bottom
B2: To lift cylinder bottom
P: From work equipment and steering pump
PA1: From bucket dump PPC valve
PA2: From lift arm lower PPC valve
PB1: From bucket tilt PPC valve
PB2: From lift arm raise PPC valve
PI: Accumulator charge pressure pick-up port
TS: To hydraulic tank
WA150-6 10-600 19
10-600 20 WA150-6

2. Bucket spool
3.ECSS spool
4. Lift arm spool
6. Check valve
7. Suction valve
8. EPC valve
9. Accumulator charge valve
Unit: mm
Free length x
Installed
length
72.6 N 58.1 N
42 x 27.5 41 —
{7.4 kg} {5.92 kg}
83.6 N 66.9 N
11 Spool return spring 61.3 x 28 45
{8.52 kg}
—
{6.82 kg}
92.2 N 73.8 N
12 Spool return spring 42.53 x 27.5 41 {9.4 kg} — {7.52 kg} If damaged or
deformed, replace
55.9 N 44.7 N spring
13 Spool return spring 58.87 x 26.3 57.3 {5.7 kg} — {4.56 kg}
111 N 88.7 N
14 Spool return spring 53.35 x 12 38.5 {11.3 kg} — {9.04 kg}
29.4 N 23.5 N
5.88 N 4.71 N
16 Check valve spring 41.5 x 8.5 31.5 {0.6 kg} — {0.48 kg}
19.6 N 15.7 N
17 Valve spring 19.15 x 7.2 16.05 {2.0 kg} — {1.6 kg}
WA150-6 10-600 21
10-600 22 WA150-6
A1: To service actuator

A2: To bucket cylinder head
A3: To lift cylinder head
ACC: To accumulator for ECSS
B1: To service actuator
B2: To bucket cylinder bottom
B3: To lift cylinder bottom
P: From work equipment and steering pump
PA1: From attachment PPC valve
PA2: From bucket dump PPC valve
PA3: From lift arm lower PPC valve
PB1: From attachment PPC valve
PB2: From bucket tilt PPC valve
PB3: From lift arm raise PPC valve
PI: Accumulator charge pressure pick-up port
TS: To hydraulic tank
WA150-6 10-600 23
10-600 24 WA150-6

2. Service spool
3. Bucket spool
4. ECSS spool
5. Lift arm spool
7. Check valve
8. Suction valve
9. EPC valve
10. Accumulator charge valve
Unit: mm
Free length x
Installed
length
42 x 27.5 41 72.6 N — 58.1 N

{7.4 kg} {5.92 kg}
83.6 N 66.9 N
12 Spool return spring 61.3 x 28 45
{8.52 kg}
—
{6.82 kg}
92.2 N 73.8 N
13 Spool return spring 42.53 x 27.5 41
{9.4 kg}
—
deformed, replace
{5.7 kg}
—
{4.56 kg}
111 N 88.7 N
{11.3 kg}
—
{9.04 kg}
29.4 N 23.5 N
16 Check valve spring 39.5 x 11.2 25
{3 kg}
—
{2.4 kg}
5.88 N 4.71 N
17 Check valve spring 41.5 x 8.5 31.5
{0.6 kg}
—
{0.48 kg}
19.6 N 15.7 N
18 Valve spring 19.15 x 7.2 16.05
{2.0 kg}
—
{1.6 kg}
WA150-6 10-600 25
Operation of work equipment control valve

When lift arm and bucket spool are at the "NEUTRAL" position
Operation
q The pressurized oil flows to port (A) through q The bypass circuit is open since lift arm spool
pump (1) and the priority valve. And the maxi- (4) is at the neutral position. Thus, the pressur-
mum pressure is regulated by relief valve (2). ized oil in port (B) enters port (C) of the drain
q The bypass circuit is open since bucket spool circuit passing through in vicinity of the spool,
(3) is at the neutral position. Thus, the pressur- and returns to the hydraulic tank through the
ized oil in port (A) flows to port (B) passing filter.
through in vicinity of the spool.
10-600 26 WA150-6
When lift arm spool is at "RAISE" position
Operation
q Pulling the work equipment control lever pulls
out lift arm spool (4) to set it to the raise posi-
tion.
q The pressurized oil from pump (1) flows to the
bypass circuit of lift arm spool (4) through the
bypass circuit of bucket spool (3).
q Since the bypass circuit is closed by the spool,
the pressurized oil from port (B) pushes open
check valve (5).
q The pressurized oil from port (B) flows to the
cylinder bottom through port (D).
q The pressurized oil on the cylinder head side
returns to the hydraulic tank through port (E)
and drain port (C). Thus, the lift arm is moved
upward.
WA150-6 10-600 27
When lift arm spool is at "LOWER" position
Operation
q Pushing the work equipment control lever
pushes in lift arm spool (4) to set it to the lower
position.
check valve (5).
cylinder rod side through port (E).
q The pressurized oil on the cylinder bottom side
returns to the hydraulic tank through port (D)
downward.
10-600 28 WA150-6
When lift arm spool is at "FLOAT" position
Operation
q Pushing the work equipment control lever fur- q As long as the bucket is contacting against the
ther from the lower position pushes in lift arm ground surface, the lift arm can be raised or
spool (4) to set it to the float position. lowered due to undulations on the ground sur-
q The pressurized oil from pump (1) flows to the face.
q Since the pressurized oil in the bypass circuit
flows to the drain circuit by the spool, check
valve (5) cannot be pushed open.
q In addition, the lift arm descends by its own
weight since both the raise circuit (D) and
lower circuit (E) of the lift cylinder are con-
nected to the drain circuit.
WA150-6 10-600 29
When bucket spool is at "TILT" position
Operation
out bucket spool (3) to set it to the tilt position.
the pressurized oil from port (A) pushes open
check valve (7).
q The pressurized oil from port (G) flows to the
cylinder bottom side.
q The pressurized oil on the cylinder rod side
returns to the hydraulic tank through port (H)
and drain port (C). Thus, the bucket tilts.
10-600 30 WA150-6
When bucket spool is at "DUMP" position
Operation
pushes in bucket spool (3) to set it to the dump
position.
check valve (7).
q The pressurized oil from port (H) flows to the
cylinder head side.
returns to the hydraulic tank through port (G)
and drain port (C). Thus, the bucket dumps.
WA150-6 10-600 31

When lift arm and bucket spool are at the "NEUTRAL" position
10-600 32 WA150-6
Operation
q The pressurized oil flows to port (A) through
pump (1) and the priority valve. And the maxi-
mum pressure is regulated by relief valve (2).
q The bypass circuit is open since bucket spool
(3) is at the neutral position. Thus, the pressur-
ized oil in port (A) flows to port (B) passing
through in vicinity of the spool.
q The bypass circuit is open since lift arm spool
(4) is at the neutral position. Thus, the pressur-
ized oil in port (B) enters port (C) of the drain
circuit passing through in vicinity of the spool,
and returns to the hydraulic tank through the
filter.
WA150-6 10-600 33
When lift arm spool is at "RAISE" position
10-600 34 WA150-6
Operation
out lift arm spool (4) to set it to the raise posi-
tion.
check valve (5).
cylinder bottom through port (D).
q The pressurized oil on the cylinder head side
returns to the hydraulic tank through port (E)
upward.
WA150-6 10-600 35
When lift arm spool is at "LOWER" position
10-600 36 WA150-6
Operation
pushes in lift arm spool (4) to set it to the lower
position.
check valve (5).
cylinder rod side through port (E).
returns to the hydraulic tank through port (D)
downward.
WA150-6 10-600 37
When lift arm spool is at "FLOAT" position
10-600 38 WA150-6
Operation
q Pushing the work equipment control lever fur-
ther from the lower position pushes in lift arm
spool (4) to set it to the float position.
q Since the pressurized oil in the bypass circuit
flows to the drain circuit by the spool, check
valve (5) cannot be pushed open.
q In addition, the lift arm descends by its own
weight since both the raise circuit (D) and
lower circuit (E) of the lift cylinder are con-
nected to the drain circuit.
q As long as the bucket is contacting against the
ground surface, the lift arm can be raised or
lowered due to undulations on the ground sur-
face.
WA150-6 10-600 39
When bucket spool is at "TILT" position
Operation
q Pulling the work equipment control lever pulls q The pressurized oil on the cylinder rod side
out bucket spool (3) to set it to the tilt position. returns to the hydraulic tank through port (H)
q Since the bypass circuit is closed by the spool, and drain port (C). Thus, the bucket tilts.
check valve (7).
q The pressurized oil from port (G) flows to the
cylinder bottom side.
10-600 40 WA150-6
When bucket spool is at "DUMP" position
Operation
q Pushing the work equipment control lever q The pressurized oil on the cylinder bottom side
pushes in bucket spool (3) to set it to the dump returns to the hydraulic tank through port (G)
position. and drain port (C). Thus, the bucket dumps.
check valve (7).
q The pressurized oil from port (H) flows to the
cylinder rod side.
WA150-6 10-600 41
ECSS valve 1
(with ECSS valve)

a ECSS: Abbreviation for Electronically Controlled Suspension System
10-600 42 WA150-6
Function
q The controller automatically turns ON and OFF
the accumulator charged with high-pressure
gas according to the travel condition of the
machine.
q The vertical movement of the machine is
dam ped a nd p itch ing of the mac hin e i s
reduced during high-speed travel to enhance
the operator comfort, prevent the load from
spilling, and improve the working efficiency.
Operation
q If the travel speed increases to 5 km/h or
higher, the signal flows to solenoid valve (2)
and the pressure is applied to (a).
q Spool (1) moves to the right.
q If spool (1) moves, the passage from (PR) to
accumulator (ACC) is closed and those from
(A2) to accumulator (ACC) and from (B2) to (T)
are opened and the ECSS is turned ON.
q While the travel speed is below 5 km/h, the sig-
nal is not sent to solenoid valve (2) and spool
(1) is in neutral. At this time, the line from (PR)
to accumulator (ACC) is opened and accumu-
lator (ACC) is charged.
q If accumulator (ACC) is charged to the set
pressure, check valve (5) is closed and the
accumulator (ACC) pressure does not
increase any more.
Accumulator pressure relief valve

q If the pressure in accumulator (ACC) needs to
be relieved for maintenance of the machine,
etc., loosen plug (3) and nut (4) to open circuits
(PR) and (TS) and relieve the pressure in
accumulator (ACC).
WA150-6 10-600 43
Accumulator charge valve 1
(with ECSS valve)

P: From main pump 1. Screw

PR1: To accumulator for ECSS 2. Poppet (safety valve)
PR2: To solenoid valve basic pressure 3. Spring (safety valve)
TS1: To hydraulic tank 4. Spring (main pressure reducing valve)
TS2: To hydraulic tank 5. Pressure reducing valve spool
TS3: To hydraulic tank 6. Poppet (check valve)
TS4: To hydraulic tank 7. Spring (check valve)
10-600 44 WA150-6
WA150-6 10-600 45
When in neutral or pressure (P) is low
Function
q This valve reduces the discharge pressure of
the main pump and supplies it as control pres-
sure for the solenoid valves, PPC valves, etc.
Operation
q Poppet (2) is pressed by spring (3) against the
seat and the line from port (P) to port (T) is
closed.
q Poppet (6) is pressed to the left and the line
from port (P) to port (PR2) is opened.
q Poppet (6) is moved to the right by pressure
(PR) and the line from (PR) to (ACC) is
opened. As (PR) < (ACC) results, poppet (6) is
pressed leftward by spring (7) and the opening
between (PR) to (ACC) is closed.
10-600 46 WA150-6
When load pressure (P) is high
Operation
q If pressure (PR) rises above the set pressure,
poppet (3) opens and the hydraulic oil flows
through port (P), hole (a) in spool (5), opening
of poppet (2), and tank port (T).
q Accordingly, differential pressure is made
before and after hole (a) in spool (5) and spool
(5) moves to close the opening between port
(P) and (PR). Pressure (P) is reduced to a cer-
tain pressure (the set pressure) by the open
area at this time and supplied as pressure
(PR).
WA150-6 10-600 47
Relief valve 1
q As the pressurized oil in ports (A) and (B)

reaches the set pressure of spring (4), pilot
poppet (3) opens, leading the pressurized oil in
port (B) to port (C) through port (D), and pres-
sure in port (B) is decreased.
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
q As the pressure in port (B) goes low, the orifice
Function of main valve (1) generates differential pres-
q This valve is installed in the inlet of the work sure between ports (A) and (B). As a result, the
equipment control valve. When the oil pressure main valve is pushed open, and pressurized oil
increases beyond the specified level, it drains in port (A) flows to the drain circuit through port
the oil to the hydraulic tank. Above process (C) to release the abnormal pressure.
protects the work equipment circuit by restrict- q Using the repulsive force of spring (4) can
ing the maximum pressure. increase or decrease the set pressure.
q When increasing the set pressure, remove the
Operation cap nut to loosen the locknut and screw the
q Port (A) and port (C) are connected to the adjustment screw (5). When decreasing,
pump circuit and the drain circuit, respectively. loosen the adjustment screw (5).
Pressurized oil fills up port (B) after flowing
through the orifice of main valve (1). Pilot pop-
pet (3) is contacted with valve seat (2).
10-600 48 WA150-6
Suction safety valve 1
q The relation between the size of cross sec-

tional diameters (cross section areas) can be
presented as (d5) > (d4) > (d1) > (d3) > (d2).
1. Piston
2. Main valve
3. Piston spring
4. Valve seat
5. Poppet q If abnormal pressure is generated in port (A)
6. Poppet spring and reaches the set pressure of spring (6),
7. Suction valve poppet (5) opens to drain the pressurized oil in
8. Suction valve spring port (C) through port (D) and outer circumfer-
9. Adjustment screw ence (a) of suction valve (7).
Function
q This valve is installed in the bucket cylinder cir-
cuit of the work equipment control valve. When
the bucket lever is set to the neutral position, if
abnor mal pr ess ure is gener ated due to
impacts to the cylinder, the abnormal pressure
is relieved through this valve to protect the
hydraulic equipment such as cylinder from
damage.
q And if negative pressure is generated in the
cylinder circuit, this valve works as a suction
valve.
Operation
q Opening of poppet (5) decreases the pressure
in port (C), and piston (1) moves to the right.
Operation as safety valve
Piston (1) contacts the tip of poppet (5) and the
q Port (A) and port (B) are connected to the cyl- pressurized oil is drained from port (D) through
inder circuit and drain circuit, respectively. orifice (b).
q Pressurized oil in port (A) is conducted to port
(C) through piston (1) hole. Main valve (2) is
contacted against the left side due to the rela-
tion (d2) < (d3).
WA150-6 10-600 49
q Since the pressure in port (C) is lower than that Suction valve 1
in port (A), main valve (2) moves to the right
and the pressurized oil is conducted from port
(A) to port (B) to prevent generation of abnor-
mal pressure.
q Even if abnormal pressure is generated, suc-
tion valve (7) with the large cross sectional
diameter remains not operated because of the
relation (d1) < (d4).
1. Main poppet
2. Sleeve
3. Spring
Function
q This valve prevents to generate negative pres-
sure on the circuit.
Operation
Operation as suction valve
q If negative pressure is generated in port (A) (lift
q If negative pressure is generated on the cylin- cylinder head) [if a pressure lower than that in
der circuit, negative pressure is set on both the tank circuit port (B) is generated], main
port (A) and port (C) because they are con- poppet (1) is opened by the difference in area
nected to each other. Suction valve ( 7) between (d1) and (d2), and the pressurized oil
receives the pressurized oil by the difference in flows to cylinder port (A) from tank port (B).
area between (d4) and (d1).
q When the differential pressure between port
(B) and port (A) increases beyond the set pres-
sure, suction valve (7) moves to the right. Thus
the pressurized oil flows from port (B) to port
(A) to prevent generation of negative pressure
in port (A).
10-600 50 WA150-6
Work equipment PPC valve SEN05080-00
Work equipment PPC valve 1
a PPC: Abbreviation for Proportional Pressure Control
Mono-lever type
P: From HST charge pump P3: To lift arm valve (raise)

P1: To bucket valve (tilt) P4: To lift arm valve (lower, float)
P2: To bucket valve (dump) T: To hydraulic tank
WA150-6 10-600 51
SEN05080-00 Work equipment PPC valve
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Piston
4. Rod 10. Retainer
5. Disc 11. Body
6. Nut (for connecting lever) 12. Filter
10-600 52 WA150-6
Operation
When in neutral
Bucket PPC valve Lift arm PPC valve
q Ports (PA) and (PB) of the control valve q Ports (PA) and (PB) of the control valve (lift
(bucket valve) and ports (P1) and (P2) of the arm valve) and ports (P3) and (P4) of the PPC
PPC valve are connected through fine control valve are connected through fine control hole
hole (f) of spool (1) to drain chamber (D). (f) of spool (1) to drain chamber (D).
WA150-6 10-600 53
When in fine control

(Neutral o fine control)
q If rod (4) and piston (9) are pushed by disc (5),
retainer (10) is pushed and spool (1) is also
pushed downward through metering spring (2).
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q The pilot pressurized oil from the HST charge
pump flows through fine control hole (f) and
port (P1) to port (PB).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced
with the pressure at port (P1).
q The positional relationship between spool (1)
and body (11) (where fine control hole (f) is
between drain chamber (D) and pump pres-
sure chamber (PP)) does not change until
retainer (10) comes in contact with spool (1).
q Metering spring (2) contracts in proportion to
the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
the stroke of the control lever.
q The control valve spool moves to a position
where the pressure in chamber (PB) (equal to
the pressure in port (P1)) is balanced with the
force of the control valve spool return spring.
10-600 54 WA150-6
When in fine control mode During full stroke

(when control lever is returned) q Disc (5) and rod (4) push down piston (9) and
q When disc (5) starts to be returned, spool (1) is retainer (10) pushes down spool (1).
pushed up by the force of centering spring (3) q Fine control hole (f) is shut off from drain
and the pressure at port (P1). chamber (D), and is interconnected to pump
q Because of this, fine control hole (f) is con- pressure chamber (PP).
nected to drain chamber (D), and the pressur- q The pilot pressure oil from the HST charge
ized oil at port (P1) is released. pump flows through fine control hole (f) and
q If the pressure of port (P1) is lowered exces- port (P1) into chamber (PB) to push the control
sively, spool (1) is pushed down by metering valve spool.
spring (2). q The oil returning from chamber (PA) flows
q Fine control hole (f) is shut off from drain through port (P2) and fine control hole (f') into
chamber (D), and it is almost simultaneously drain chamber (D).
interconnected to pump pressure chamber
(PP).
q The pump pressure is supplied until the pres-
sure in port (P1) recovers to a pressure equiv-
alent to the position of the lever.
q When the control valve spool returns, the pres-
surized oil in drain chamber (D) flows in
through fine control hole (f') of the valve which
is not in operation and flows through port (P2)
into chamber (PA).
WA150-6 10-600 55
When lift arm is "float"

q If disc (5) pushes down rod (4) and piston (9)
on port (P4) "lower" side, the detent starts
operation before the stroke end. (the operating
effort of the lever becomes heavy.)
q If rod (4) is pushed down further, the detent
operates to keep the lift arm in "float" state
even if the lever is released.
q At the same time, the control valve is also
moved to the "float" position to keep the lift arm
in float condition.
When "float" state of lift arm is reset

q When returning disc (5) from the "float" posi-
tion, the rod is pushed down with a force larger
than absorptive power of the solenoid.
q The "float" state also can be reset and the
lever can be returned to the "neutral" position
by turning off the current in the solenoid (de-
energizing the solenoid).
q The lift arm raise and bucket tilt operations are

carried out similarly to the above.
10-600 56 WA150-6
WA150-6 10-600 57
SEN05080-00 Attachment PPC valve
Attachment PPC valve 1
(if equipped)
a PPC: Abbreviation for Proportional Pressure Control
a For the details of operation, see the paragraph of "Work equipment PPC valve".
10-600 58 WA150-6
Attachment PPC valve SEN05080-00
P: From self pressure reducing valve

P1: To attachment valve
P2: To attachment valve
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. Filter
Unit: mm
Free length x Installed
8 Centering spring
diameter
length If damaged or
deformed, replace
41.1 x 15.5 29 —
{3.7 kg} {2.96 kg}
16.7 N 13.3 N
9 Metering spring 22.73 x 8.1 22
{1.7 kg}
—
{1.36 kg}
WA150-6 10-600 59
SEN05080-00 Lock valve
Lock valve 1
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
q The lock valve is installed between the HST
charge pump and work equipment PPC valve.
As the work equipment lock lever is set to the
"Lock" position, this valve, in conjunction with
the work equipment lock lever, cuts off the oil
of the PPC circuit to disable the work equip-
ment operation.
10-600 60 WA150-6
2-way restrictor valve SEN05080-00
2-way restrictor valve 1
Operation
1. Tube
2. Coupling q When flowing in the left direction (in the cylin-
3. Vent der's forward move direction), the oil pushes
3. Union open vent (3), and flows from orifice (a) and
notch (b) of vent (3).
Function
q In order to reduce the impacts resulting from
the momentum of the bucket in the bucket
dumping, an orifice installed in the cylinder bot-
tom circuit controls the move of the cylinder
piston by giving pressure to the return oil.
q When flowing in the right direction (to the cylin-

der's return direction), the oil conducted
through orifice (a) of vent (3) alone, thus the
flow rate is restricted.
WA150-6 10-600 61
SEN05080-00 Accumulator (for oil cooler circuit)
Accumulator (for oil cooler circuit) 1
1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port
Outline
q This accumulator is installed between the work
equipment control valve and oil cooler to pro-
tect the oil cooler by reducing the hydraulic
pulses that result from operation of the work
equipment.
Specifications
Charge pressure 0.7 ± 0.1 {7.1 ± 1}
Max. pressure used
3.92 {40}
(MPa {kg/cm2})
10-600 62 WA150-6
Accumulator (for PPC circuit) SEN05080-00
Accumulator (for PPC circuit) 1
1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port
Outline
q This accumulator is installed between the
charge valve and work equipment PPC valve.
Even if the engine stops with the work equip-
ment raised, the pressure of the compressed
nitrogen gas in the accumulator applies the
pilot oil pressure to the work equipment control
valve so that the work equipment will lower by
its weight.
Specifications
Charged pressure 1.18(+0.2/0) {12(+2/0)}
Max. pressure used
3.92 {40}
(MPa {kg/cm2})
WA150-6 10-600 63
SEN05080-00 Accumulator (for ECSS)
Accumulator (for ECSS) 1
(if equipped)
1. Valve
2. Top cover
3. Cylinder
4. Free piston
Function
q This accumulator is installed to the lift cylinder
bottom circuit. The space between cylinder (3)
and free piston (4) is filled with nitrogen gas.
The nitrogen gas absorbs the oil pressure
pulses generated on the lift cylinder bottom
side during travel for higher travel performance
and operating performance by utilizing its com-
pressibility.
Specifications
Gas Nitrogen gas
Amount of gas (cc) 2,000
Charged pressure 2.5 ± 0.1 {25 ± 1.0}
Max. pressure used
20.6 {210}
(MPa {kg/cm2})
10-600 64 WA150-6
Accumulator (for ECSS) SEN05080-00
WA150-6 10-600 65
SEN05080-00

©2009 KOMATSU
All Rights Reserved
10-600 66
SEN05081-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

700 Work equipment

Work equipment linkage ................................................................................................................................. 2
Bucket ............................................................................................................................................................. 4
Bucket positioner and boom kick-out .............................................................................................................. 6
Work equipment cylinder .............................................................................................................................. 12
WA150-6 10-700 1
700 Work equipment
SEN05081-00 Work equipment linkage
Work equipment linkage 1
10-700 2 WA150-6
700 Work equipment
Work equipment linkage SEN05081-00
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
Unit: mm
Clearance between bushing and size Shaft Hole clearance limit
7 pin at each end of bucket link –0.025 +0.142 0.105 –
50 1.0
–0.064 +0.080 0.206
Clearance between bushing and –0.025 +0.142 0.105 –
8 pin connecting lift arm and bucket
50
–0.064 +0.080 0.206
1.0
9 Clearance between bushing and

pin connecting lift arm and frame
60
–0.030
–0.076
+0.174
+0.100
0.130 –
0.250
1.0
Clearance between bushing and
–0.025 +0.142 0.105 –
10 pin connecting bucket cylinder 50 –0.064 +0.080 0.206 1.0 Replace
bottom and frame (replace pin when it
Clearance between bushing and has scuff marks,
–0.025 +0.142 0.105 – too.)
11 pin connecting bucket cylinder 50 –0.064 +0.080 0.206 1.0
rod and bell crank
12 pin connecting bell crank and lift 65 –0.076 +0.100 0.250 1.0
arm
13 pin connecting lift cylinder rod 55
–0.076 +0.080 0.218
1.0
and lift arm
14 pin connecting lift cylinder bottom 55
–0.076 +0.100 0.250
1.0
and frame
Width of boss Width of hinge
Standard
Standard Standard clearance
15 Connecting part of bucket
cylinder and frame
size Tolerance size Tolerance Using the shims,
adjust the right and
80 0 83 ±1.5 1.5 – 5.0 left side clearances
–0.5 to 1.5 mm max.
16 Connecting
frame
part of lift arm and 84 — 88 +3.0
0 4.0 – 7.0
17 Connecting
bucket
part of lift arm and
84 — 88
+3.0
0 4.0 – 7.0 Using the shims,
left side clearances
18 Connecting
and bucket
part of bucket link
83 — 88
+3.0
0 5.0 – 8.0 to 0.5 mm max.
Using the shims,
19 Connecting
and frame
part of lift cylinder
85
0
–0.5 88
+3.0
0 3.0 – 6.5
to 1.5 mm max.
20 Connecting
bucket link
part of bell crank and
83 — 88 ±1.5 3.5 – 6.5 Using the shims,
21 Connecting
lift arm
part of bell crank and
143 ±0.5 146 — 2.5 – 3.5 to 0.5 mm max.
22 Connecting part of bucket

cylinder and bell crank 85
0
–0.5 88 ±1.5 1.5 – 5.0 Using the shims,
23 Connecting
cylinder
part of lift arm and lift
84 — 89 ±0.8 4.2 – 5.8 to 1.5 mm max.
WA150-6 10-700 3
700 Work equipment
SEN05081-00 Bucket
Bucket 1
1. Bucket 3. Bucket teeth (if equipped)

2. Bolt-on cutting edge
Unit: mm
4 Wear of cutting edge (thickness)
22 15.5 Reverse or replace
5 Wear of cutting edge (length) 62 5
6 Wear of bucket teeth 29 15.5 Replace

Clearance in adapter mounting
7 parts
Max. 0.5 — Adjust or replace
10-700 4 WA150-6
700 Work equipment
Bucket SEN05081-00
WA150-6 10-700 5
700 Work equipment
SEN05081-00 Bucket positioner and boom kick-out
Bucket positioner and boom kick-out 1
1. Bucket positioner proximity switch 4. Bucket cylinder

2. Boom kick-out proximity switch (if equipped) 5. Lift arm
3. Bar 6. Plate (if equipped)
Unit: mm
Clearance on bucket positioner
7 proximity switch
3–5
Adjust
Clearance on boom kick-out
8 proximity switch
3–5
10-700 6 WA150-6
700 Work equipment
Bucket positioner and boom kick-out SEN05081-00
Outline
Bucket positioner
q The bucket positioner is driven electrically.
When the bucket is returned to an angle from
the "dump" position to the "tilt" position, the
bucket positioner returns the work equipment
(bucket) control lever from the "tilt" position to
the "hold" position to automatically stop the
bucket at a proper digging angle.
q Bar (3) is fixed to the rod side of bucket cylin-
der (4). And proximity switch (1) is fixed to the
cylinder side.
q Moving the work equipment (bucket) control
lever from "dump" position to "tilt" position
moves the rod of bucket cylinder (4) toward the
machine front side.
As bar (3) moves a specific distance, proximity
switch (1) detects that it is away from the sens-
ing face, and returns the work equipment
(bucket) control lever to "hold" position.
Boom kick-out
(if equipped)
q The boom kick-out is driven electrically. As the
lift arm is raised to an angle before reaching
the maximum height, the boom kick-out returns
the work equipment (lift arm) control lever from
the "raise" position to the "hold" position to
stop the lift arm automatically at a desired
height.
q Plate (6) is fixed to lift arm (5). And proximity
switch (2) is fixed to the front frame.
q Moving the work equipment (lift arm) control
lever from "lower" position to "raise" position
moves lift arm (5) upward.
As plate (6) moves a specific distance, proxim-
ity switch (2) detects that it is away from the
sensing face, and returns the work equipment
(lift arm) control lever to "hold" position.
WA150-6 10-700 7
700 Work equipment
Operation of proximity switch
When bucket is tilted
q While the bucket is dumped more than the q Shifting work equipment (bucket) control lever
position being set from the bucket positioner, (7) toward the "tilt" position moves spool (8) to
bar (2) moves on to the sensing face of prox- the position of the arrow. And spool is held
imity switch (1), turning on the proximity switch there by the energized coil of detent solenoid
(1) lamp. (6).
At this point, bucket positioner relay (4) is "ON" As a result, work equipment (bucket) control
and current flows to detent solenoid (6) of work lever (7) is held at "tilt" position and the bucket
equipment PPC valve (5) to energize the coil. tilts.
10-700 8 WA150-6
700 Work equipment
a The power supply for detent solenoid (6) oper-

ation is turned "ON" or "OFF" by alternator
relay (11).
Detent solenoid (6) circuit is turned off since L
signal from alternator (10) is not sent to alter-
nator relay (11) as long as the engine is
stopped.
As the result, the work equipment (bucket)
control lever (7) cannot be moved and held in
the "tilt" position as long as bar (2) is posi-
tioned in sensing face of proximity switch (1).
Function of proximity switch
When object of sensing is over sensing face of

proximity switch
Lamp of proximity switch Turned ON
Bucket positioner relay ON

Work equipment PPC valve detent
Power ON
solenoid circuit
Energized
solenoid
When object of sensing is apart from sensing

face of proximity switch
Lamp of proximity switch Turned OFF
Bucket positioner relay OFF

Power OFF
solenoid circuit
De-energized
solenoid
q As the bucket is tilted and moved away from

the position set by the positioner, in other
words, as bar (2) moves away from the sens-
ing face of proximity switch (1), the lamp of
proximity switch (1) goes off and bucket posi-
tioner relay (4) is set to "OFF" state.
Because of above, detent solenoid (6) circuit
on work equipment PPC valve (5) is cut off and
the coil is de-energized.
Held spool (8) receives the reaction force of
spring (9) and returns work equipment (bucket)
control lever (7) to "hold" position.
WA150-6 10-700 9
700 Work equipment
When lift arm is raised
q While lift arm (3) is dumped beyond the posi- q Shifting work equipment (lift arm) control lever
tion set from the boom kick-out, plate (2) (7) toward the "raise" position moves spool (8)
moves on to the sensing face of proximity to the position of the arrow. And spool is held
switch (1), turning on the proximity switch (1) there by the energized coil of detent solenoid
lamp. (6).
At this point, boom kick-out relay (4) is "ON" As a result, work equipment (lift arm) control
and current flows to detent solenoid (6) of work lever (7) is held at "raise" position and lift arm
equipment PPC valve (5) to energize the coil. (3) rises.
10-700 10 WA150-6
700 Work equipment
a The power supply for detent solenoid (6) oper-

ation is turned "ON" or "OFF" by alternator
relay (11).
Detent solenoid (6) circuit is cut off since L sig-
nal from alternator (10) is not sent to alternator
relay (11) as long as the engine is stopped.
As the result, the work equipment (lift arm)
control lever (7) cannot be moved and held in
the "raise" position as long as plate (2) is posi-
tioned in sensing face of proximity switch (1).
Function of proximity switch
When object of sensing is over sensing face of

proximity switch
Lamp of proximity switch Turned ON
Boom kick-out relay ON

Power ON
solenoid circuit
Energized
solenoid
When object of sensing is apart from sensing

face of proximity switch
Lamp of proximity switch Turned OFF
Boom kick-out relay OFF

Power OFF
solenoid circuit
De-energized
solenoid
q As lift arm (3) is raised and moved away from

the position set by the boom kick-out, namely
as plate (2) moves away from the sensing face
of proximity switch (1), the lamp of proximity
switch (1) goes off and boom kick-out relay (4)
is set to "OFF" state.
Because of above, detent solenoid (6) circuit
on work equipment PPC valve (5) is cut off and
the coil is de-energized.
Held lift arm spool (8) receives the reaction
force of spring (9) and returns work equipment
(lift arm) control lever (7) to the "hold" position.
WA150-6 10-700 11
700 Work equipment
SEN05081-00 Work equipment cylinder
Work equipment cylinder 1
Lift cylinder
Bucket cylinder
Unit: mm
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
Clearance between –0.030 +0.163 0.036 –
1 piston rod and bushing Lift 60 0.567 Replace bushing
–0.104 +0.006 0.267
–0.030 +0.163 0.036 –
Bucket 55 0.567
–0.104 +0.006 0.267
10-700 12 WA150-6
700 Work equipment
Work equipment cylinder SEN05081-00
WA150-6 10-700 13
SEN05081-00

©2009 KOMATSU
All Rights Reserved
10-700 14
SEN05082-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

800 Cab and its attachments

Cab ................................................................................................................................................................. 3
WA150-6 10-800 1
SEN05082-00
10-800 2 WA150-6
Cab SEN05082-00
Cab 1
1. Front working lamp

2. Radio antenna
3. Door (left)
4. Air conditioner external air filter
5. Front glass
6. Front wiper
7. KOMTRAX GPS antenna (if equipped)
8. KOMTRAX communication antenna (if equipped)
9. Door (right)
10. Rear wiper
WA150-6 10-800 3
SEN05082-00

©2009 KOMATSU
All Rights Reserved
10-800 4
SEN05083-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

901 Electrical system, Part 1

Machine monitor system ................................................................................................................................. 2
Machine monitor ............................................................................................................................................. 6
WA150-6 10-901 1
SEN05083-00 Machine monitor system
Machine monitor system 1
Outline
q In the machine monitor system, each controller 4. In addition to the above, the following display,
on the network monitors controls the machine setting and adjustment functions are provided
condition with the sensors installed to various using the character display and the machine
parts of the machine, and then sends the result monitor mode selector switch, which is the
as network information to the machine monitor, operation switch of the character display.
which displays the information to notify the 1) Switching of traction level
operator of the machine condition. 2) Switching of HST reverse travel gear shift-
ing pattern
q The machine monitor displays the information 3) Display the odometer
in the operator mode or service mode. 4) Resetting the filter or oil replacement time
5) Input the telephone number
q The operator mode is used to display the infor- 6) Selecting the language
mation to the operator normally. The major 7) Adjusting the illuminance of nighttime light
functions used in the service mode are as fol- 8) Travel speed/engine speed display select-
lows. ing function
9) Function for setting display/no-display of
1. Items always displayed travel speed or engine speed to the char-
q Meters (speedometer or engine tachome- acter display
ter)
q Gauges (engine coolant temperature
gauge, HST oil temperature gauge and
fuel gauge)
q Pilot indicators
q Service meter
The following items are displayed according to

the set state of the optional device selecting
function.
q Travel speed or engine speed indication
on the character display
2. Items displayed when abnormality is detected

q Caution lamps
q Action code (while an action code is dis-
played, if the machine monitor mode
selector switch (>) is pressed and
released, the failure code (6 digits) is dis-
played.)
3. At the replacement period of a filter or oil, the

character display displays that filter or oil.
(maintenance monitoring function)
10-901 2 WA150-6
Machine monitor system SEN05083-00
q The service mode function is provided for the 10. Machine serial number input function
ease of troubleshooting for the controllers on Enters the machine serial number to identify
the network (including the machine monitor the machine.
itself). The major functions used in this mode
are as follows. 11. Model selection function
Enters the information of applicable model.
1. Electrical system failure history display func-
tion 12. Initialize function
The electrical system failures of each controller Sets the machine monitor to the state set when
saved in the machine monitor are displayed. the machine is delivered.
The information of those failures is also
deleted with this function.
2. Mechanical system failure history display func-

tion
The mechanical system failures of each con-
troller saved in the machine monitor are dis-
played.
3. Real-time monitoring function

The input and output signals recognized by
each controller on the network are displayed in
real time.
4. Engine reduced-cylinder function

This function is used for the purpose of speci-
fying cylinder having defective combustion by
stopping fuel injection to each cylinder from the
fuel injector.
5. No injection cranking function

Before restarting engine after a long-term stor-
ing of the machine, this function is used to
lubricate the engine internally.
6. Adjustment function
Functions are provided to correct and adjust
the installation errors and manufacturing dis-
persion of the sensors, solenoid valves, etc.
Function for changing control characteristics is
provided on user request.
7. Maintenance monitoring function

Changes the filter or oil replacement time and
makes ON/OFF selection of the function.
8. Operating information display function

Displays fuel consumption per operating hour.
9. Optional device selecting function

Verifies the installation of optional devices or
changes their setting.
WA150-6 10-901 3
SEN05083-00 Machine monitor system
System circuit diagram 1
a Items marked with "*1" in drawing may or may not installed.
10-901 4 WA150-6
Machine monitor system SEN05083-00
WA150-6 10-901 5
SEN05083-00 Machine monitor
Machine monitor 1
1. HST oil temperature gauge 21. Quick coupler operation pilot lamp (*1)
2. HST oil temperature caution lamp 22. Cooling fan reverse rotation pilot lamp
3. Engine coolant temperature gauge 23. Maintenance caution lamp
4. Engine coolant temperature caution lamp 24. Parking brake reminder caution lamp
5. Speedometer or engine tachometer 25. Battery charge circuit caution lamp
6. Turn signal pilot lamp (left) 26. Steering oil pressure caution lamp (*1)
7. Head lamp high beam pilot lamp 27. Emergency steering pilot lamp (*1)
8. Turn signal pilot lamp (right) 28. Meter display pilot lamp
9. Fuel level caution lamp 29. Character display portion
10. Fuel gauge 30. Preheating pilot lamp
11. Central warning lamp 31. Directional selector switch actuation pilot lamp
12. Brake oil pressure caution lamp (*1)
13. Engine oil pressure caution lamp 32. Economy operation display lamp
14. Water separator caution lamp (*1) 33. Shift hold pilot lamp (*1)
15. Engine oil level caution lamp (*1) 34. S mode operation pilot lamp
16. Radiator coolant level caution lamp 35. Traction control operation pilot lamp
17. HST oil filter clogging caution lamp 36. Travel speed range selector switch position
18. Air cleaner clogging caution lamp (*1) pilot lamp
19. Parking brake pilot lamp 37. Directional lever position pilot lamp
20. Brake oil temperature caution lamp
*1: Not used by this model
10-901 6 WA150-6
Machine monitor SEN05083-00
List of items displayed on monitor 1
Condition for judging that the engine is running:

If 2 or more are met in the following 3 conditions, the engine is judged running when the abnormality in the
CAN communication occurs and the charge level exceeds the specified level.
1. Turning "ON" of the starting switch is recorded (IGN-C signal was entered)
2. Charge level exceeds the specified value (the voltage reached 12 V once and remains 5 V or above after that)
3. Engine speed is 500 rpm or above
Lamp Lamp period Alarm buzzer Operating condition Buzzer period Priority
Warning for dangerous Period: 1,600 msec.
Q: ON — w: Intermittent condition (error or caution ON: 800 msec. 1
sounds message is generated) OFF: 800 msec. (duty 50%)
Period: 1,300 msec.
Period: 1,600 msec.
w: Flashing ON: 800 msec.
A: Intermittent Caution for erroneous
operation (when an irregular
ON: 200 msec.
OFF: 50 msec. 2
sounds
OFF: 800 msec. (duty 50%) operation is done) ON: 200 msec.
OFF: 850 msec.
Period: 240 msec.
A: Intermittent ON: 80 msec.
E: Canceling Set cancellation such as
ON: 1,000 msec. (1 time) 3
sounds calibration (inoperative state)
OFF: 160 msec.
E: Separately set —
e: Completion Completion of setting such as
calibration (when normally
ON: 100 msec.
OFF: 100 msec. 4
conditions sounds
ended) ON: 100 msec. (1 time)
Detecting Operating condition

time
(sec.) Engine stopped Engine is running
Display color
warning lamp
warning lamp
Alarm buzzer
Alarm buzzer
Centralized
Centralized
Display of
Display of
Detection
Individual
Individual
message
message
Category No. Check item Device Operating condition display Remarks
display
Reset
Turned ON with errors (E03

and E02) of each controller,
When error occurs E E E E E E E E simultaneously displaying the
Centralized message on the character
Red
warning 11 Centraized LED display.
lamp warning
For other than above, see
"Operating condition,
— — — — — —
centralized warning lamp"
of other items.
White
When lamp switch is at a
Back light — Back light LED — — — — — —
position other than "OFF"
Other than below — — — — — — White range: 30 – 105°C

Pointer:
Red range: 105 – 135°C
Movement
w Q Q w Q Q
Red
1 HST oil
2 temperature Alarm: Min. 105°C 10 1 B@CRNS B@CRNS When sensor is grounded:
Caution Max
lamp: LED When an abnormality is When sensor is disconnected
detected 20 5 — — — DGH1KX — — — DGH1KX or hot short-circuited: Min
(out of input signal range)
Other than below — — — — — —
Alarm: Min. 102°C 3 0 — Q — — Q — White range: 50 – 102°C

Pointer:
Gauge meter Movement Red range: 102 – 135°C
Engine
w Q Q w Q Q
Red
3
coolant Alarm: Min. 105°C B@BCNS B@BCNS When sensor is grounded:
4
temperature Max
Caution
lamp: LED When an abnormality is When sensor is disconnected
detected — — — CA144 — — — CA144 or hot short-circuited: Min
(high temperature)
When an abnormality is
detected — — — CA145 — — — CA145
(low temperature)
When engine speed (Switching is available with
Engine speed — — — — — —
Pointer: display is selected the machine monitor setting)
5 Movement —
When travel speed display When a communication error
Travel speed — — — — — — is detected, "0" is displayed.
is selected

Pointer: Max: 10 z
Min: 85 z
Movement
Min. 61.3 z 10 1 — Q — — Q —
Red
9 Fuel level
Gauge meter 10 When sensor is grounded:
Caution When an abnormality is Full
lamp: LED detected When sensor is disconnected
(input voltage is 4 V or 10 2 — — — DJF1KA — — — DJF1KA or hot short-circuited: Empty
above and no incoming
IGN-C signal is detected)
WA150-6 10-901 7

time
Display color
warning lamp
warning lamp
Alarm buzzer
Alarm buzzer
Centralized
Centralized
Display of
Display of
Detection
Individual
Individual
message
message
Category No. Check item Device Operating condition Remarks
display
display
Reset
Operates when charging
Service meter normally at 1:1 to the clock — — — — — — Displays various codes and
Black
Character time items according to the
display 29 LCD machine condition and switch
Converts travel speed operation.
Odometer — — — — — —
pulse into travel distance
Green
x 100 r/min
Engine speed
When engine speed
display is selected
0 0 — Q — — Q — (switching is available with
the machine monitor setting)
Unit 28 LED km/h or MPH
Green
Travel speed
When travel speed display
is selected
0 0 — Q — — Q —
(switching value is available
with the machine monitor
setting)
When F is selected
Green Green Green Green Green Green Orange Green

F LED (neutral safety is displayed 1 0 A Q Q — Q —
as engine is stopped)
Directional
37 lever N LED When N is selected 0 0 — Q — — Q —
position
When R is selected
R LED (neutral safety is displayed 1 0 A Q Q — Q —
as engine is stopped)
When an error is detected in
Items related communication, display is
to gear 4 LED
When 4th gear speed is
selected
0 0 — Q — — Q — maintained until starting
shifting
switch is turned "OFF".
Travel
speed 3 LED
When 3rd gear speed is
selected
0 0 — Q — — Q —
36 range
selector
switch 2 LED
When 2nd gear speed is
selected
0 0 — Q — — Q —
position
1 LED
When 1st gear speed is
selected
0 0 — Q — — Q —
When turn signal lever and Hazard lamp is activated

6
8
Turn signal LED hazard lamp switch signal 0 0 — Q — — Q — when starting switch is turned
is input "OFF", too.
When head lamp is set to
high beam Blue
7
Head lamp
high beam
LED (when head lamp is "ON" 0 0 — Q — — Q —
and dimmer switch is
"ON")
Normal oil pressure
— — — — — —
(CLOSE)
Below set pressure
(OPEN) (detection time
continues) and 30 seconds 1 1 — Q — w Q Q
Red
12 Brake
oil after engine is started (no
LED
pressure detection time)
Below set pressure
(OPEN) (detection time
continues) and after 30
seconds elapsed since
5 1 — — — w Q Q 2G40ZG
engine was started (no
detection time)
Other
symbols Normal oil pressure
— — — — — —
(CLOSE)
Red
13 Engine
oil
LED
pressure
Low oil pressure (OPEN) w Q Q B@BAZG w Q Q B@BAZG
Normal coolant level

— — — — — —
(CLOSE)
Red
16 Radiator LED
coolant level
Low coolant level (OPEN) 30 1 — Q — B@BCZK — Q — B@BCZK
Normal (OPEN) — — — — — —
Clogging (CLOSE)
(HST oil temperature is
Q
Red
17 HST
oil filter 10 1 — — — — — 6091NX
LED 50°C or above and no
clogging abnormality is detected)
detected KEY
3 OFF — — — DHTCL6 — — — DHTCL6
(clogging is detected as
engine was stopped)
10-901 8 WA150-6

time
Display color
warning lamp
warning lamp
Alarm buzzer
Alarm buzzer
Centralized
Centralized
Display of
Display of
Detection
Individual
Individual
message
message
display
display
Reset
Operation (OPEN) — Q — — Q —
Red
19 Parking brake LED Released (CLOSE) — — — — — —
Engine is running, parking

brake is operated and the
directional lever is at any
0 0 — — — A Q Q
position other than "N"
Temperature rise (oil

temperature: Min. 120°C) 5 5 — Q — — Q —
(reminder alarm)
Temperature rise (1 or 2)
1. Oil temperature is
130°C or above To be released if the oil
w Q Q w Q Q
Red
20 Brake
oil 2. Oil temperature is 5 5 B@C6NS B@C6NS temperature is detected
LED
temperature 125°C or above and consecutively at lower than
travel speed is 35 km/h 125°C for 5 sec.
or above
detected — — — DGR2KB — — — DGR2KB
(ground fault)
detected
— — — DGR2KZ — — — DGR2KZ
(disconnection or hot
short-circuit)
Normal 0 0 — — — — — —
Error message is displayed
Orange
Cooling fan on the character display as
22 reverse LED Reverse 0 0 — Q — Remarks — Q — Remarks long as reverse rotation of fan
rotation is continued.
"COOLING FAN REVERSE"
Selecting reverse rotation 0 0 — w — — w —
Ordinary — — — — — —
Other Message is simultaneously
symbols 23 Maintenance LED Red displayed on the character
30 hours or less before display.
maintenance or — Q — E — w — E
maintenance time
Error message is displayed
on the character display as
long as parking brake is left
Other than below — — — — — — unapplied.
"APPLY PKG BRAKE"
The alarm continues as long
Red
24 Parking
brake as starting switch is turned
LED
reminder "OFF".
This function is enabled when
"MECHA" is selected for
When parking brake is left
unapplied (CLOSE)
0 0 w Q Q Remarks — — — "7: PKG BRAKE" from the
"Option device selecting
function" of the machine
monitor.
Normal voltage — — — — — —
If an abnormality is detected
Engine is running, when starting switch is turned
alternator voltage is below "ON", the alarm is continued
the specified level, and no 30 1 — — — w Q Q AB00MA
even after engine is started.
Red
25 Battery
charge
LED incoming ING-C is
circuit present. <Voltage hysteresis>
Judgment for abnormal o
When an abnormality is normal: Min. 12 V
detected Judgment for normal o
(inconsistency between 3 1 w Q Q AB00L6 — — — abnormal: 5 V or below
engine condition and
corresponding signal)

Red
30 Preheating LED
When preheater is turned
ON 0 0 — Q — — Q —
Other than below 0 0 — — — — — —

Green
32 Economy LED
operation
Economy mode operation 0 0 — Q — — Q —
WA150-6 10-901 9

time
Display color
warning lamp
warning lamp
Alarm buzzer
Alarm buzzer
Centralized
Centralized
Display of
Display of
Detection
Individual
Individual
message
message
display
display
Reset
Green
The lamp goes off when the
34 S mode LED traction control is canceled
operation
S mode operation is
selected
0 0 — Q — — Q — with the one-push traction
control switch.
Other
When traction control is reset
symbols
with max. traction switch, or
Other than below — — — — — — when directional lever
Traction
Green
35 control LED position is switched, the lamp
operation is lit again.
Traction control operation
is turned on
0 0 — Q — — Q —
10-901 10 WA150-6
Machine monitor operation switch 1
1. Machine monitor mode selector switch 1

2. Machine monitor mode selector switch 2
Troubleshooting function 1
q The machine monitor monitors the input and output signals constantly for troubleshooting for the sys-
tem.
q If each controller detects abnormality by the self-diagnosis, abnormality information is forwarded to the
machine monitor over the network.
q Abnormality information can be checked on the character display using the failure code display mode of
the machine monitor.
WA150-6 10-901 11
Character display function 1
q Machine monitor display and setting can be changed by using the character display.
q The range where operator is enabled to operate is within the portion of the "Operator mode" in the figure
below.
a For the operating method in the operator mode, see the Operation and maintenance manual.
*1: When an ID entered from the "ID entry" screen is once approved, display changes directly to the "Select
function" screen without displaying the "ID entry" screen until the starting switch is turned "OFF".
10-901 12 WA150-6
Operator mode functions 1
Self-check screen (0th layer)

q Self-check is conducted for 3 seconds automatically when starting switch is turned to "ON".
q During a self-check, entry through the machine monitor operating switch is not accepted.
q After ending the self-check, the self-check screen automatically moves to 1st layer.
Normal screen (1st layer)

q If the item of "13: RPM/SPEED" is set to "ADD" in the "Optional device selecting function" of machine
monitor and the menu of "Engine speed display / non-display setting" is set to "rpm OFFoON" in the
"Display of functions opened to the operator", engine speed is displayed to the character display when
the travel speed is displayed at the center of the monitor.
q When the engine speed is displayed at the center of the monitor, travel speed is displayed to the charac-
ter display.
q Pressing the "U" switch changes the screen to the 2nd layer.
1. Engine speed display

2. Travel speed display
A. In the case of "km/h" display
B. In the case "MPH" display
a When "SI unit specification" is selected for the "Factory mode" from the machine monitor, the character
display shows the engine speed in "rpm" and the monitor center display is fixed to the travel speed in
"km/h".
WA150-6 10-901 13
Failure code screen (1st layer)

q Pressing the ">" switch while the Warning screen is on display changes display to the Failure code
screen.
q If multiple failure codes are present, pressing of the ">" switch sequentially displays them from the item
of higher priority downward. If items have the same priority, the item that occurred most recently will be
displayed first.
Example of a failure code screen (simultaneously occurring errors: DX16KA, B@BCZK and CA431)
*1: The screen automatically returns to the Warning screen if the switch is not pressed more than 10 sec-
onds in the Normal screen display.
*2: The screen returns to the Warning screen if the switch is not pressed more than 30 seconds in the fail-
ure code screen or if a new alarm is turned ON.
*3: Pressing the ">" switch on the Normal screen before 10 seconds lapse changes display to the initial fail-
ure code screen.
10-901 14 WA150-6
Display of functions opened to the operator (2nd layer or below)

q Certain menus are not displayed unless the items in the "Optional device selecting function" of the
machine monitor are set.
q Pressing "U" switch allows selecting each menu.
q For the 2nd layer down, the screen automatically returns to the screen of the 1st layer if the switch is not
pressed more than 60 seconds in the screen display of each menu.
q The language will be displayed as set in the Language selection function.
a See the "Operation and maintenance manual" for details of each menu.
*1: These menus are displayed when "ADD" is selected for "13: RPM/SPEED" item from the "Optional
device selecting function" of the machine monitor.
*2: These menus are displayed when "ADD" is selected for "12: RPM OPT" item from the "Optional device
selecting function" of the machine monitor.
k It is prohibited to select "ADD" for "12: RPM OPT" from the "Optional device selecting function"
of the machine monitor in the regions where the applicable law requires to display the travel
speed.
WA150-6 10-901 15
Service mode functions 1
q The machine monitor is provided with service mode function for the ease of troubleshooting for the con-
trollers on the network (including the machine monitor itself).
q Initial setting of the sensors and optional setting can be made in the service mode of the machine moni-
tor.
Procedure for switching to Service Mode

1. Checking of the screen display 3. ID input and confirmation
Check that the character display is set to the Operate the machine monitor mode selector
1st layer screen in the operator mode. switches 1 and 2 and enter ID. (ID: 6491)
2. Display of ID input initial screen

Pressing "u" switch and "<" switch simulta-
neously for 5 seconds or more displays the ID
entry initial screen.
a Pressing down the 2 switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the switches.
1) The cursor (C) is located at the highest-

order digit. Pressing "<" or ">" switch
changes the value of this digit in the range
of "0" to "9".
2) Press "U" switch at the target value to
validate it.
a The cursor moves to the 2nd digit
position.
3) Confirm the values for the 2nd digit and
onward following the same procedure.
a If you have entered a wrong value to
a p os it io n whe n the c ur s or was
located at any position other than the
highest-order digit, press "t" switch
to move the cursor to the highest-
order digit to enable to input correct
value. In this case, the values already
entered remain on the screen
unchanged.
a Pressing "t" switch when the cursor
is located at the highest-order digit,
the screen returns to the "1st layer" of
the operator mode.
a If switch is not operated more than 60
seconds on the "ID entry" screen, it
automatically returns to the "1st layer"
screen of the operator mode.
4) If ID is acknowledged upon confirming the
4th digit, the screen changes to the "Elec-
trical system failure history" selector
screen.
10-901 16 WA150-6
Service mode menu
a Pressing "<" or ">" switch on the menu screen switches individual menus of the service mode sequen-
tially and endlessly.
a Pressing "U" switch on the target menu screen changes the screen to the detailed screen of the same
menu.
a Pressing "t" switch on the menu screen returns the screen to the 1st layer of the operator mode.
WA150-6 10-901 17
Electrical system failure history display Real-time monitoring function (REAL-TIME

function (ELECTRIC FAULT) MONITOR)
a "**" field displays total number of the failure q This function is used to check on the input/out-
history currently recorded. (max. 20 histories to put signals, etc. each controller on the network
be stored) recognizes.
a For the operating procedure of this function,
q The history is used to check on the electrical see "Special functions of machine monitor
system failures of each controller saved in the (EMMS)" in Testing and adjusting.
machine monitor. After repairing the failure
content and verifying normal function, the fail-
ure history may be erased.
see "Special functions of machine monitor Engine reduced-cylinder function (CYLINDER
(EMMS)" in Testing and adjusting. CUT-OUT)
Mechanical system failure history display

function (MACHINE FAULT)
q This function is used for the purpose of speci-

fying cylinder having defective combustion by
stopping fuel injection to each cylinder from the
a "**" field displays total number of the failure fuel injector.
history currently recorded. (max. 20 histories to a For the operating procedure of this function,
be stored) see "Special functions of machine monitor
(EMMS)" in Testing and adjusting.
q The history is used to check on the mechanical
system failures of each controller saved in the
machine monitor.
see "Special functions of machine monitor
10-901 18 WA150-6
No injection cranking function (NO INJECTION) Maintenance monitoring function

(MAINTENANCE MONITOR)
q Before restarting engine after a long-term stor-

ing of the machine, this function is used to q This function is used for changing the filter and
lubricate the engine internally. oil replacement timing and making ON/OFF
a For the operating procedure of this function, selection of this function.
see "Special functions of machine monitor a For the operating procedure of this function,
(EMMS)" in Testing and adjusting. see "Special functions of machine monitor
Operating information display function

Adjustment function (TUNING) (OPERATION INFO)
q This function is used for correcting and adjust- q This function is used for displaying fuel con-
ing the installation errors and manufacturing sumption per operating hour.
dispersion of the sensors, solenoid valves, etc. a For the operating procedure of this function,
Function for changing control characteristics is see "Special functions of machine monitor
provided on user request. (EMMS)" in Testing and adjusting.
These functions are also used when sensors,
valves and controllers are replaced or added.
WA150-6 10-901 19
Optional device selecting function (OPTIONAL Model selection function (MACHINE)

SELECT)
q This function is used for displaying or changing

q This function is used for verifying the installed the setting of model information (machine
state of optional devices or when changing name).
their setting. a For the operating procedure of this function,
This function is also used for installing or see "Special functions of machine monitor
removing optional devices. (EMMS)" in Testing and adjusting.
a For the operating procedure of this function, a The figure shows when "WA250" is selected.
Machine serial number input function (MACHINE

No. SET) Initialize function (INITIALIZE)
q This function is used for displaying or entering q This function is used to set the machine moni-
the serial number of machine. tor to the state set when delivered.
Serial number of the set machine is used for a Since this function is specially handled by the
controlling the machine. factory, no modification is allowed.
10-901 20 WA150-6
Input and output signals 1
AMP070-20P[CN-L24]
Pin No. Specifications I/O Group Form of use Signal name Remarks
1 (NC) — — — —
2 (NC) — — — —
3 (NC) — — — —
4 NSW power supply (+24 V) I — Constant power NSW power supply (+24 V)
supply (+24 V)
5 NSW power supply (+24 V) I — Constant power NSW power supply (+24 V)
supply (+24 V)
Power supply
6 SW power supply (+24 V) I — (+24 V) SW power supply (+24 V)
7 SW power supply (+24 V) I — Power supply SW power supply (+24 V)

(+24 V)
8 (NC) — — — —
9 GND I — GND GND
10 GND I — GND GND

D_OUT_3
11 O A D/O sink ECSS relay If equipped
(+24 V, sink 200 mA)
D_OUT_2
12 (+24 V, sink 200 mA) O A D/O sink Back-up lamp
13 (NC) — — — —
D_OUT_0
14 O A D/O sink Alarm buzzer
(+24 V, sink 200 mA)
15 (NC) — — — —
16 (NC) — — — —
WA150-6 10-901 21
AMP070-18P(1)[CN-L25]
1 D_IN_0 I B D/I (+24 V) Head lamp

(24 V, 5 mA)
D_IN_2
2 I B D/I (+24 V) Starting switch C signal
(24 V, 5 mA)
3 (NC) — — — —
D_IN_6
4 I B D/I (+24 V) Quick coupler If equipped
(24 V, 5 mA)
D_IN_8
5 I B D/I (+24 V) ECSS switch If equipped
(24 V, 5 mA)
6 (NC) — — — —
D_IN_12
7 (NSW24 V, 5 mA) I C D/I (+24 V) Turn signal lamp, right
D_IN_14
8 I C D/I (+24 V) U switch
(NSW24 V, 5 mA)
9 GND O — GND Signal GND
D_IN_1 Cooling fan automatic reverse
10 I B D/I (+24 V)
(24 V, 5 mA) rotation switch (manual)
11 (NC) — — — —
12 (NC) — — — —
13 (NC) — — — —
D_IN_9 Cooling fan automatic reverse
14 I B D/I (+24 V) If equipped
(24 V, 5 mA) rotation switch (automatic)
15 (NC) — — — —
D_IN_13
16 (NSW24 V, 5 mA) I C D/I (+24 V) Turn signal lamp, left
17 D_IN_15 I C D/I (+24 V) t switch

(NSW24 V, 5 mA)
A_IN_0
18 (0 – 30 V) I H A/I Alternator R(L) signal
AMP070-12P(1)[CN-L26]
D_IN_16
1 (24 V/GND, 5 mA) I D D/I (GND) Brake oil pressure
2 (NC) — — — —
3 D_IN_20 I D D/I (GND) (air cleaner clogging)

(24 V/GND, 5 mA)
D_IN_22
4 (24 V/GND, 5 mA) I D D/I (GND) Traction control switch (S mode)
D_IN_24
5 I E D/I (GND) HST oil filter clogging
(24 V/GND, 5 mA)
6 GND O — GND Sensor ground
D_IN_17
7 (24 V/GND, 5 mA) I D D/I (GND) ECSS cut off switch If equipped
D_IN_19
8 (24 V/GND, 5 mA) I D D/I (GND) (service mode 2 and 3)
D_IN_21
9 I D D/I (GND) ECSS cut off switch dummy If equipped
(24 V/GND, 5 mA)
10 (NC) — — — —
D_IN_25
11 (24 V/GND, 5 mA) I E D/I (GND) (optional switch)
A_IN_1
12 I H A/I Clearance lamp and tail lamp
(0 – 30 V)
10-901 22 WA150-6
AMP070-18P(2)[CN-L27]
D_IN_26
1 I E D/I (GND) Parking brake
(24 V/GND, 5 mA)
D_IN_28 Parking brake left-unapplied
2 I E D/I (GND)
(24 V/GND, 5 mA) prevention
D_IN_30
3 I E D/I (GND) (Normal emergency steering)
(24 V/GND, 5 mA)
4 (NC) — — — —
D_IN_34
5 I F D/I (GND) Dimmer switch
(24 V/GND, 5 mA)
D_IN_36
6 I G D/I (GND) Parking brake dummy
(24 V/GND, 5 mA)
D_IN_38
7 I G D/I (GND) < switch
(24 V/GND, 5 mA)
8 (NC) — — — —
9 GND O — GND GND
D_IN_27
10 I E D/I (GND) Coolant level
(24 V/GND, 5 mA)
D_IN_29
11 I E D/I (GND) (engine oil level)
(24 V/GND, 5 mA)
12 (NC) — — — —
13 (NC) — — — —
D_IN_35 Parking brake left-unapplied

14 I F D/I (GND)
(24 V/GND, 5 mA) prevention dummy
D_IN_37
15 I G D/I (GND) > switch
(24 V/GND, 5 mA)
D_IN_39
16 I G D/I (GND) (Operation of emergency steering)
(24 V/GND, 5 mA)
17 (NC) — — — —
18 (NC) — — — —
AMP070-12P(2)[CN-L28]
A_IN_2
1 I J A/I Fuel level sensor
(high-resistance input)
A_IN_4
2 I J A/I HST oil temperature sensor
3 (NC) — — — —
4 (NC) — — — —
5 (NC) — — — —
6 GND O — GND GND
A_IN_3
7 I J A/I Brake oil temperature sensor
8 (NC) — — — —
9 (NC) — — — —
10 (NC) — — — —
11 GND O — GND (GND)
12 (NC) — — — —
WA150-6 10-901 23
AMP070-12P(3)[CN-L29]
1 (NC) — — — —
2 (NC) — — — —
3 CAN (+) I/O P CAN CAN (+)
4 (NC) — — — —
5 (NC) — — — —
6 GND O — GND GND
7 (NC) — — — —
8 CAN (–) I/O P CAN CAN (–)
9 (NC) — — — —
10 (NC) — — — —
11 (NC) — — — —
12 (NC) — — — —
AMP070-14P[CN-L30]
1 (NC) — — — —
2 (NC) — — — —
3 (NC) — — — —
4 (NC) — — — —
5 (NC) — — — —
6 (NC) — — — —
7 (NC) — — — —
8 (NC) — — — —
9 (NC) — — — —
10 (NC) — — — —
11 (NC) — — — —
12 (NC) — — — —
13 (NC) — — — —
14 (NC) — — — —
10-901 24 WA150-6
AMP040-8P
Do not connect wiring
1 (NC) — — — — harness on machine
6 (NC) — — — —
harness on machine
WA150-6 10-901 25
SEN05083-00

©2009 KOMATSU
All Rights Reserved
10-901 26
SEN05084-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up


Electrical system (HST controller system) ...................................................................................................... 2
HST controller ............................................................................................................................................... 18
ECSS system................................................................................................................................................ 19
KOMTRAX system........................................................................................................................................ 20
Engine starting circuit.................................................................................................................................... 22
Engine stopping circuit.................................................................................................................................. 24
Preheating circuit .......................................................................................................................................... 25
Engine output derating function .................................................................................................................... 26
Automatic warm-up function ......................................................................................................................... 26
Parking brake circuit ..................................................................................................................................... 28
Multi-function knob........................................................................................................................................ 30
Sensor........................................................................................................................................................... 31
WA150-6 10-902 1
SEN05084-00 Electrical system (HST controller system)
Electrical system (HST controller system) 1
a Except where otherwise specified, the displayed travel speed in this document represents the one when
16.9-24 tire is worn.
Input and output signals diagram

Travel speed range selector switch Ao o A HST motor 1 solenoid
Operating switch input
Variable shift control dial Ao o D HST motor 2 solenoid relay

Do o A Clutch solenoid
Solenoid output
Traction control switch
Directional lever (F, N, R) Do o A Cooling fan motor flow rate control EPC valve
Parking brake lever intermediate switch Do o D Cooling fan motor reverse rotation solenoid relay
Parking brake lever bottom switch Do o D Directional solenoid (F, R)
Po o D HST controller power holding relay
Sensor input
Speed sensor A
Speed sensor B Po o D HST safety relay
HST oil pressure sensor Ao o C Throttle upper limit (Eng_con)

Engine speed (Eng_con) Co o C Throttle lower limit (Eng_con)
Accelerator pedal angle (Eng_con) Co o C Automatic warm-up cancel (Eng_con)
Coolant temperature (Eng_con) Co Monitor display information (Eng_con)
o C (Failure code, real-time monitor, pilot lamp,
Boost temperature (Eng_con) Co alarm buzzer, etc.)
HST controller
CAN output
Monitor display information (Eng_con) o C Travel speed (Mon)
(Failure code, real-time monitor, pilot lamp, Co
alarm buzzer, etc.) o C ECSS operation command (Mon)
HST oil temperature (Mon) Co o C Back-up lamp operation command (Mon)
Cooling fan manual reverse rotation (Mon) Co o C Failure code signal (Mon)
Cooling fan automatic reverse rotation (Mon) C o o C Real-time monitor signal (Mon)
CAN input
ECSS (Mon) Co o C Pilot lamp signal (Mon)

Traction control S mode (Mon) Co o C Load frequency information (KOMTRAX)
Model selection (Mon) Co
Option device selecting (Mon) Co
Automatic fan switching cycle to reverse
rotation (Mon) Co
Reverse rotation duration (Mon) Co

Traction control level (A, B, C) (Mon) Co
HST selector (A, B) (Mon) Co
Tire selection (Mon) Co
Service meter (Mon) Co
Eng_con: Engine controller

Mon: Machine monitor
KOMTRAX: KOMTRAX terminal (if equipped)
A: Analog signal
D: Digital signal
P: Pulse signal
C: CAN signal
10-902 2 WA150-6
Electrical system (HST controller system) SEN05084-00
HST controller gear shifting control function 1
Gear shifting function

q Receiving the travel speed range selector signal and the variable shift control signal, this function con-
trols HST motor 1, HST motor 2 and transfer clutch in such that the maximum travel speed suited for the
given state is produced.
Selected Travel speed range Clutch solenoid HST motor 1 HST motor 2 Variable shift control
speed (km/h) output solenoid output solenoid output signal input voltage
range (V)
0 – 13
1st (depends on the variable ON MAX – MID Fixed to MAX (ON) 0.9 – 4.1
shift control signal)
2nd 0 – 13 ON MAX – MID Fixed to MAX (ON) —
3rd 0 – 22.4 ON, OFF MAX – 0 Fixed to MAX (ON) —
4th 0 – 36.2 ON, OFF MAX – 0 Fixed to MAX – —

Free (ON, OFF)
Relationship between accelerator pedal angle

and travel speed (A) for starting transfer clutch
switching modulation
Transfer clutch
0 – 65 65 – 90 90 – 100
Engaged o
9 km/h 9 – 11 km/h 11 km/h
Disengaged (C)
Disengaged o
8 km/h 8 – 10 km/h 10 km/h
Engaged (B)
Relationship between accelerator pedal angle

and travel speed (A) for switching HST motor 2
capacity
HST motor 2 Accelerator pedal angle (%)
capacity 0 – 65 65 – 90 90 – 100
Free (C) 9 km/h 9 – 11 km/h 11 km/h
Max. fixed (D) 10 km/h 10 – 12 km/h 12 km/h
WA150-6 10-902 3
1. HST pump 5. Clutch solenoid valve

2. HST motor 1 6. HST motor 1 solenoid valve
3. HST motor 2 7. HST motor 2 solenoid valve
4. Transfer clutch 8. Transfer output shaft
Gear shifting display function

q The HST controller displays the state of input signals related to gear shift on the monitor by sending
them to the machine monitor via network.
1. Directional indicators
The directional lever position pilot lamps of the machine monitor indicate the state of the directional
lever based on the input data to the HST controller.
When the directional lever is at the neutral position and no input signal is sent to the HST controller, all
the directional lever position pilot lamps of the machine monitor go off.
If two independent signals were sent to the HST controller by accident, two directional lever position
pilot lamps of the machine monitor may turn on at the same time.
As the directional lever is set to "R (reverse)", the transmission controller activates the backup lamp
relay to light the backup lamp and sound the backup alarm.
2. Speed range indicator

The travel speed range selector switch position pilot lamp of the machine monitor displays the state of
the travel speed range selector switch being sent to the HST controller.
Variable shift control system

q When the travel speed range selector switch is set to the 1st speed, the variable shift control signal
allows adjusting the maximum speed in the range of 4 – 13 km.
10-902 4 WA150-6
Transfer clutch control function

q In order to reduce impacts resulting from connecting the transfer clutch or to prevent inadequate torque
due to delayed connection of the transfer clutch, this function adjusts the clutch oil pressure to an opti-
mum level for the machine state (travel speed, travel load, HST oil temperature, directional lever and
accelerator opening ratio) by referencing the modulation table of the HST controller.
q In order to reduce lack of the torque, this function maintains the modulation control when the clutch is
released.
Traction control function

q Receiving the traction control signal, this function derates the maximum capacity of HST motor 1 to con-
trol the traction force.
q "Traction level selecting function" of the machine monitor allows selecting a desired traction force out of
3 levels (A, B and C).
q The traction control operation pilot lamp remains turned on as long as the traction control operation is
continued.
a For the operating method of this function, see the "Operation and maintenance manual".
S mode function
q Receiving the S mode signal, this function reduces the maximum capacity of HST motor 1 and the upper
limit of the throttle opening ratio in order to secure an optimum drive force for the dozing work on very
slippery road surface (on the snow-covered road, sandy terrain, etc.).
q This function restricts sudden start in forward travel by reducing skidding of tires through control of the
drive force. And by securing smooth start of the machine, this function offers enhanced operating perfor-
mance.
q The S mode operation pilot lamp of the machine monitor remains lighted as long as the S mode opera-
tion is continued.
a The traction force control in the S mode is enabled when the directional lever is set to the "forward" posi-
tion and the machine is traveling forward or stopped.
a For the operating method of this function, see the "Operation and maintenance manual".
Features
Switch Pilot lamp Traction level Guideline
position Traction Material Road
condition
1
(OFF) OFF 1
Suitable for loading work. Improves work
2A efficiency and provides antislip by
Powerful Hard-packed Un-slippery selecting traction level depending on
I I I material and road conditions.
2 2 2B O O O
(ON) (ON) Soft Loose Slippery
Select when operating with the special
2C attachment which requires small traction
force.
Provides the best driving force on very Select when the machine tends to slip
3 3 3 slippery road surfaces covered by snow, when forwarding, such as on snow or
(S mode) (ON) sand, etc. Prevents the tires from sand covered road surface.
slipping to facilitate work.
WA150-6 10-902 5
The maximum traction force available when the

travel speed range selector switch is set to "1st"
and the traction control switch is set to "ON"
q When the travel speed range selector switch

(1) is set to "1st" and the variable shift control
switch (2) is turned fully to the left, setting the
traction control switch to the ON position does
not reduce the maximum traction force. In this
case, the maximum traction force remains at
the same level as when the traction control
switch is set to the "OFF" position.
q As clockwise turning of the variable shift con-
trol switch (2) is continued, the traction force
approaches the maximum traction force being
set from the "Traction level selecting function"
of the machine monitor.
q It is possible to obtain the maximum traction
force, which has been set from the traction
control switch and "Traction level selecting
function" of the machine monitor, by turning the
variable shift control switch (2) fully to the right.
10-902 6 WA150-6
Max. traction function

q Pressing the max. traction switch while the traction control is "ON" or the S mode is selected cancels the
traction control or the S mode temporarily to increase the maximum drawbar pull.
q If the directional lever or directional selector switch is operated, or the max. traction switch is pressed
again while the traction control or S mode is cancelled from the max. traction switch, the traction "ON"
state or S mode is restored.
q As long as the traction control or S mode is cancelled from the max. traction switch, the traction control
operation pilot lamp or S mode operation pilot lamp of the machine monitor remains turned off.
a Holding down the max. traction switch for a second or longer cancels the traction control or S mode as
long as it is held down. The traction control or S mode is restored at the moment the switch is released.
a If the traction control is sequentially turned "ON" and "OFF" in less than a second, the traction control or
S mode is cancelled temporarily just like the max. traction switch is held down for less than a second.
1. Traction control switch

2. Max. traction switch
3. HST controller
4. Machine monitor
a. Traction control switch signal

b. S mode signal
c. CAN signal
WA150-6 10-902 7
HST controller protection function 1
HST motor 1 overrun prevention function 1

q If the 1st or 2nd speed is selected while the machine is traveling at a high speed with the travel speed
range selector switch being set to the 3rd or 4th, the transfer clutch is engaged during the high speed
travel, preventing HST motor 1 to overrun beyond the allowable rotating speed.
q In order to prevent the overrun, this function disables the gear shift from the 3rd or 4th to the 2nd or 1st
when the transfer clutch is released.
q As above gear shift is disabled, this function generates "OVERRUN PROTECT" message on the
machine monitor character display and activates the alarm buzzer.
q This error status is reset as the transfer clutch is engaged or the travel speed range selector switch is
set to an allowable gear shift position.
a Above error message is not sent to KOMTRAX terminal.
Gear shift operation Behavior after gear shift
Switch position Switch Actual speed
State of transfer Display of
before gear position after range after Remarks
clutch after gear shift message
shift gear shift gear shift
2nd 2nd
Gear shift available independent
1st Connected 3rd 3rd Not displayed
of traveling speed
4th 4th
1st 1st
Gear shift available independent
2nd Connected 3rd 3rd Not displayed
of traveling speed
4th 4th
1st 1st
Connected 2nd 2nd Not displayed
4th 4th Gear shift to 1st or 2nd becomes
3rd available only when the clutch is
(*1) 1st 3rd engaged.
Displayed
Other than the 2nd 3rd
connected state 4th 4th Not displayed
1st 1st
Connected 2nd 2nd Not displayed
3rd 3rd Gear shift to 1st or 2nd becomes
4th available only when the clutch is
(*1) 1st 3rd engaged.
Displayed
Other than the 2nd 3rd
connected state 3rd 3rd Not displayed
*1: The clutch is released including the ongoing clutch connection modulation (*2) and clutch release modulation state.
*2: It indicates the period 1.2 seconds after the clutch connection modulation has been started while the machine is
traveling at 8 up to 10 km/h.
Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switch-
ing modulation
Transfer clutch
0 – 65 65 – 90 90 – 100
Engaged o
9 km/h 9 – 11 km/h 11 km/h
Disengaged (B)
Disengaged o
8 km/h 8 – 10 km/h 10 km/h
Engaged (C)
10-902 8 WA150-6
HST motor 1 overrun prevention function 2

q Downhill travel at 1st or 2nd gear speed tends to allow the machine to increase the travel speed. This
function prevents the rotational speed of HST motor 1 goes beyond the allowable rotating speed.
q In order to restrict the travel speed, the function controls the HST motor 1 capacity to the allowable max-
imum if the travel speed goes beyond 14 km/h.
Travel speed control function

q Downhill travel at a high speed tends to allow the machine to exceed the speed limit because the rota-
tional speed of HST motor 2, axle and engine goes beyond the allowable rotating speed.
q In order to restrict the travel speed, the function fixes the HST motor 2 capacity to the allowable maxi-
mum if the travel speed goes beyond 38.1 km/h.
q As the travel speed is controlled, this function generates "OVERRUN PROTECT" message on the
q This error state is reset as the travel speed goes below 37.9 km/h or less.
a Above error message is not sent to KOMTRAX terminal.
Engine overrun prevention function

q If the HST motor 2 capacity reaches its allowable rotating speed when the machine travels downhill at a
high speed, the HST pump and engine rotation becomes high speed. This function prevents the HST
motor 2 to overrun beyond the allowable rotating speed.
q This function prevents the HST motor 2 solenoid valve to be set to "ON" (fixed to MAX) when the travel
speed is more than 28.6 km/h and the engine speed is more than 3,050 rpm. If the HST motor 2 sole-
noid valve is already set to "ON", the solenoid valve is forcibly set to "OFF" to prevent the HST pump
and engine from overrun.
q This function is canceled when the engine speed goes below 2,950 rpm.
q As the travel speed is controlled, this function generates "OVERRUN PROTECT" message on the
Neutralizer function
q When the parking brake lever is pulled (the switch at the bottom of the parking brake lever is "OFF"), this
function maintains, independent of the directional lever position, the HST pump at the neutral in order to
prevent dragging of the parking brake.
Economy operation pilot lamp function 1
q In order to prompt the operator for the low fuel consumption operation, this function lights up the econ-
omy operation pilot lamp as long as the low fuel consumption operation is continued.
q The economy operation pilot lamp lights up as the opening ratio of the accelerator pedal is maintained at
less than 75% for 0.5 seconds or longer.
q The economy operation pilot lamp can be constantly turned off by selecting "NO ADD" for "4: ECO
LAMP" item from the "Optional device selecting function" of the machine monitor.
a For the setting procedure, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.
WA150-6 10-902 9
Cooling fan control function 1
1. HST controller Input and output signals

2. Machine monitor HST controller
3. Engine controller a. CAN signal
4. Cooling fan pump b. Cooling fan motor flow rate control signal
5. Cooling fan motor c. Cooling fan reverse rotation signal
5a. Cooling fan motor flow rate control EPC valve
5b. Cooling fan reverse rotation solenoid valve Machine monitor
6. Cooling fan reverse rotation switch d. Cooling fan automatic reverse rotation signal
7. Machine monitor mode selector switch 1 (if equipped)
8. Machine monitor mode selector switch 2 e. Cooling fan manual reverse rotation signal
9. Cooling fan reverse rotation solenoid valve relay f. CAN signal
10. HST oil temperature sensor g. "U" switch signal
11. Boost pressure and oil temperature sensor h. "t" switch signal
12. Coolant temperature sensor i. ">" switch signal
13. Engine speed sensor j. "<" switch signal
14. Engine k. HST oil temperature signal
15. Radiator
Engine controller
l. CAN signal
m. Boost pressure and temperature signal
n. Engine speed signal
o. Coolant temperature signal
10-902 10 WA150-6
Fan control
q Employment of the hydraulically driven cooling fan and the control of the flow rate of the hydraulic motor
allow reducing the horsepower loss and noises as well as cutting the warm-up operation time in a low
temperature environment.
q Engine speed, coolant temperature and boost air temperature received by the engine controller, and the
information of HST oil temperature received by the machine monitor are sent to the HST controller via
the network.
q Based on the received information, the HST controller sends the signal current to the cooling fan motor
flow rate control EPC valve in order to set the fan speed to a level suitable for the respective tempera-
ture levels and the engine speed.
Fan speed in accordance with temperature
*1: The target fan speed is determined based on the coolant temperature, HST oil temperature or boost air
temperature data, whichever is the highest.
*2: Within this range, the fan speed is set according to the coolant temperature, HST oil temperature and
boost air temperature.
*3: When the boost air temperature is at the lower limit or when the HST oil temperature is low, the fan
speed is decreased to increase the oil and coolant temperature (heater spurting out temperature) and
cut the warm-up operation time.
(the fan speed in this area is controlled based on the hysteresis of each temperature.)
WA150-6 10-902 11
Control at start of engine

q In order to protect the fan from being stopped by low oil temperature or settled snow or dusts, the fan
speed is temporarily increased immediately after the engine is started to aid start of the fan rotation.
q After the basic control is turned on, normal fan control is carried on based on the procedure described in
the section of "Fan speed in accordance with temperature".
a The fan control (derating of the minimum fan speed) at start of the engine is conducted only once after
the starting switch has been set to "ON". When, however, the starting switch was turned "OFF" once
and then turned "ON" again, the control is implemented one more time if the control starting conditions
are met.
The control (derating of the minimum fan speed) at start of engine is carried out if every condition in the fol-
lowing table is met.
Condition 1 Starting switch is turned "ON".
Condition 2 Engine speed is 700 rpm or above.

Engine is rotating forward.
Condition 3 [above, however, does not apply as a condition if the controller recognized that switching in the rotating
direction is taking place.]
Condition 4 After the starting switch is turned "ON", the control at start of engine has not been carried out yet.
*1: When the fan speed control conditions at low temperature are not applicable and the minimum boost air
temperature is 20°C or above.
Point A: Starting switch is turned "ON" (when engine is stopped)

Point B: Control starting conditions are met
Area C: Minimum fan speed is restricted
Area D: Basic control is turned on
10-902 12 WA150-6
Fan reverse rotation function

q As the fan reverse rotation switch is pressed for cleaning of the radiator core, the cooling fan reverse
rotation solenoid valve of the cooling fan motor is activated, reverse rotating the fan.
1. Fan manual reverse rotation function

The operator can select the desired fan rotation direction by pressing the fan reverse rotation switch to
"MANUAL" for 0.5 seconds or longer.
As long as switching of the fan rotation direction is taking place, the pilot lamp of the machine monitor
keeps blinking to inform the operator that the switching is underway. And when the fan rotation is
reversed responding to the high engine speed, high coolant or oil temperature, this lamp also keeps on
blinking until the preparation for switching is completed.
As the fan rotation switching condition is met, this function sends the accelerator opening ratio-restrict-
ing signal to the engine controller so that the engine speed may not reach 1,200 rpm or above while the
switching is underway. Above control, however, is not applicable when the HST oil temperature is 30°C
or above.
The pilot lamp of the machine monitor keeps on blinking as long as the reverse rotation of the fan is con-
tinued.
The fan rotation is switched from "forward" to "reverse" as every condition in the following table is met.
Condition 1 The fan reverse rotation switch was set to "MANUAL" for 0.5 seconds or longer.
Condition 2 Engine speed over 500 rpm and below 1,200 rpm.
(*1) [above is required to prevent generation of peak pressure in the process of switching the direction.]
Coolant temperature is below 102°C.
Condition 3
[above is required to prevent overheating.]
HST oil temperature is below 100°C.
Condition 4
Boost air temperature is below 80°C.
Condition 5
30 seconds minimum have elapsed since the engine is started (since the engine speed reached
Condition 6 500 rpm or above).
[above is required to secure the oil to be supplied to the brake accumulator.]
The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met.
Condition 1 While the fan is rotating reverse, the fan reverse rotation switch was again set to "MANUAL" and the
(*1) engine speed went to below 1,200 rpm.
Condition 2 After the fan rotated in the reverse direction for 10 minutes, the engine speed went to less than
(*1) 1,200 rpm.
Condition 3 The engine has stopped.
*1: The engine speed-related requirement (1,200 rpm) is exempted when the HST oil temperature is
30°C or above.
2. Overheat prevention function

If overheat in the coolant temperature, HST oil temperature or boost air temperature was recognized
while the fan was rotating reverse, the reverse rotation is forcibly stopped and the forward rotation is
turned on in order to increase the air flow to the radiator.
3. Fan speed during reverse rotation

While the reverse fan rotation is continued, this function sets the fan speed to the maximum by cutting
off the command current (sets the command current to 0 mA) to the fan motor flow rate control EPC
valve.
Setting the fan speed to the maximum increases air flow to the radiator core maximum, making the
cleaning work easier.
WA150-6 10-902 13
4. Fan automatic reverse rotation function

(if equipped)
Setting the fan reverse rotation switch to "AUTO" allows changing the fan rotation direction switching
cycle and the reverse rotation duration at a specific interval.
As long as switching of the fan rotation direction is taking place, the pilot lamp of the machine monitor
keeps blinking to inform the operator that the switching is underway. And when the fan rotation is
reversed responding to the high engine speed, high coolant or oil temperature, this lamp also keeps on
blinking until the preparation for switching is completed.
The pilot lamp of the machine monitor keeps on blinking as long as the reverse rotation of the fan is con-
tinued.
The fan rotation is switched from "forward" to "reverse" as every condition in the following table is met.
Condition 1 The fan reverse rotation switch is set to "AUTO".
Coolant temperature is below 102°C.
Condition 2
HST oil temperature over 13°C and below 100°C.
Condition 3
[the upper limit of 100°C is required to prevent overheating.]
Boost air temperature is below 80°C.
Condition 4
30 seconds minimum have elapsed since the engine is started (since the engine speed reached
Condition 5 500 rpm or above).
[above is required to secure the oil to be supplied to the brake accumulator.]
Condition 6 The fan rotation direction switching cycle has elapsed.
The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met.
The fan reverse rotation switch is set to any position other than "AUTO" during the reverse fan
Condition 1
rotation.
Condition 2 The specified reverse rotation duration has elapsed.
Condition 3 The engine has stopped.
5. Adjustment of the automatic fan switching cycle to reverse rotation and duration
(if equipped)
Any cycle is settable for the switching cycle of fan rotation direction and also any duration is settable for
the reverse rotation duration by adjusting the items "Adjustment of interval of fan automatic reverse rota-
tion operation" and "Adjustment of continuance of fan automatic reverse rotation operation" with the
adjusting function of the machine monitor.
a For the adjustment procedure, see "Special functions of machine monitor (EMMS)" in Testing and
adjusting.
10-902 14 WA150-6
WA150-6 10-902 15
System circuit diagram 1
a Items marked with "*1" in drawing may or may not installed.
10-902 16 WA150-6
WA150-6 10-902 17
SEN05084-00 HST controller
HST controller 1
Input and output signals

DEUTSCH-40P [CN-HST]
Pin Signal name Input/Output Pin Signal name Input/Output
No. signal No. signal
1 VB (controller power) Input 21 GND (controller GND) —
2 Starting switch ACC signal Input 22 HST sensor power 5V Output
3 Wake up Input 23 Travel speed adjusting dial Input
4 Directional selector switch F Input 24 Directional selector switch R Input
5 Directional lever N Input 25 Directional selector switch operating switch Input
6 Parking brake lever intermediate switch Input 26 Speed sensor A Input
7 HST controller power holding relay Output 27 HST motor 2 solenoid relay Output
8 NC — 28 CAN0_H Input/Output
9 Clutch solenoid Output 29 Cooling fan motor flow rate control EPC Output
10 HST pump F solenoid Output 30 VIS (solenoid power) Input
11 VB (controller power) Input 31 GND (controller GND) —
12 Starting switch ACC signal Input 32 GND (sensor GND) —
13 Alternator R(L) signal Input 33 HST oil pressure sensor Input
14 Directional selector switch N Input 34 Directional lever F Input
15 Directional lever R Input 35 Traction control switch Input
16 Parking brake lever bottom switch Input 36 Speed sensor B Input
17 HST safety relay Output 37 Cooling fan motor reverse rotation Output
18 NC — solenoid relay
19 HST motor 1 solenoid Output 38 CAN0_L Input/Output
20 HST pump R solenoid Output 39 Travel speed range selector switch Input
40 SOL_COM (solenoid common GND) —
10-902 18 WA150-6
ECSS system SEN05084-00
ECSS system 1
(if equipped)
1. HST controller Operation

2. Machine monitor q The operating condition of ECSS is as follows.
3. ECSS switch
ECSS
4. ECSS relay ECSS switch Travel speed [km/h]
operation signal
5. ECSS solenoid valve OFF 0 – Max.
(with the built-in work equipment control valve) OFF
(*2) Max. 4
6. Speed sensor ON
(*1) Min. 5 ON
HST controller
a. Travel speed signal A
b. Travel speed signal B
c. CAN signal
Machine monitor
d. CAN signal
e. ECSS switch "ON" signal
f. ECSS operation signal
Outline
q When the machine travels at high speed, the
damping effect of the accumulator charged
with high-pressure gas and the automatic con- ECSS switching point A B
trol of the lift cylinder circuit relief pressure
under each travel condition damp the vertical (*2) (*1)
Travel speed [km/h]
4 5
movement of the work equipment and reduce
rocking of the chassis. As a result, the operator *1. It is allowed to select any travel speed at the
comfort is improved, spillage of material is pre- ECSS switching point (B) in the range of 5 to 8
vented, and the working efficiency is improved. km/h by adjusting the items "Adjustment of
ECSS operation travel speed" with the adjust-
Setting method ing function of the machine monitor.
q The ECSS can be enabled only when "ADD" is *2. The travel speed available at ECSS switching
selected for "5: E.C.S.S." item from the point (A) is obtained by deducting 1 km/h from
"Optional device selecting function" of the that available at the switching point (B)
machine monitor. (namely, 4 – 7 km/h).
a For the setting procedure, see "Special func- a For the adjustment procedure, see "Special
tions of machine monitor (EMMS)" in Testing functions of machine monitor (EMMS)" in Test-
and adjusting. ing and adjusting.
WA150-6 10-902 19
SEN05084-00 KOMTRAX system
KOMTRAX system 1
(if equipped)
q KOMTRAX terminal wirelessly transmits various machine information. KOMTRAX operators refer to the
information in their offices and can provide customers with various services accordingly.
a To be provided with the KOMTRAX terminal service, it is necessary to sign up separately.
KOMTRAX terminal transmits the following information:

1. Operation map
2. Service meter
3. Location information
4. Error history
etc.
10-902 20 WA150-6
KOMTRAX system SEN05084-00
KOMTRAX terminal 1
Model: TC301
q The KOMTRAX system uses satellite communication technology.
1. Communication antenna connector

2. GPS antenna connector
3. Machine harness connector (DEUTSCH-40P)

DEUTSCH-40P [CN-L80]
Pin No. Signal name Input/Output Pin No. Signal name Input/Output
signal signal
1 NC — 21 Check mode 1 Input
2 NC — 22 Check mode 0 Input
3 NC — 23 NC —
4 NC — 24 NC —
5 NC — 25 NC —
6 NC — 26 NC —
7 CAN0_L Input/Output 27 Starting switch C signal Input
8 CAN0_H Input/Output 28 Alternator R signal Input
9 NC — 29 NC —
10 NC — 30 NC —
11 NC — 31 NC —
12 NC — 32 NC —
13 NC — 33 NC —
14 NC — 34 NC —
15 NC — 35 NC —
16 NC — 36 Starting switch ACC signal Input
17 NC — 37 Power supply GND —
18 NC — 38 Power supply GND —
19 NC — 39 Constant power supply (24 V) Input
20 Immobilize signal Output 40 Constant power supply (24 V) Input
Outline
q The KOMTRAX terminal can send information q Use of KOMTRAX terminal must be limited to
via wireless communication antenna, acquiring the countries where such communication is
various information of the machine from the allowed.
network signal in the machine and the input a A different part number is assigned to the
signal. Also, the controller incorporates CPU KOMTRAX terminal used inside and outside
(Central Processing Unit) and provides the Japan because a different telecom company is
wireless communication function and the GPS employed outside Japan.
(Global Positioning System) function. When using the system outside Japan, user
q There are the LED lamp and the 7-segment must install the KOMTRAX terminal designed
indicator lamp in the display area, and these for outside Japan use and apply for the permis-
lamps are used for the testing and the trouble- sion of use of the system to the applicable
shooting. country before starting its use.
WA150-6 10-902 21
SEN05084-00 Engine starting circuit
Engine starting circuit 1
1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to
3. Slow-blow fuse secure safety when the engine is started.
4. Fuse box 1 q The engine can not be started while the
5. Fuse box 2 directional lever is at any position other
6. Starting switch than N (neutral).
7. Directional lever
8. Neutral safety relay 2. The KOMTRAX engine cut-off circuit is
9. KOMTRAX engine cut-off relay (if equipped) employed to disable the engine from starting
10. HST controller power holding relay when the KOMTRAX terminal receives an
11. Starting motor safety relay engine cut-off command issued through exter-
12. Starting motor nal operation.
13. Alternator (if equipped)
14. HST controller
15. Engine controller
16. Machine monitor
17. KOMTRAX terminal (if equipped)
18. Engine controller cut-off relay
19. CAN resistor
10-902 22 WA150-6
Engine starting circuit SEN05084-00
Operation
1. When starting switch is turned "ON"
q As the starting switch is turned "ON", ter-
minals B and BR of the starting switch are
closed and the current flows from the bat-
tery through the starting switch and bat-
tery relay coil to the ground, thereby
closing the contact of the battery relay. As
a result, the power is supplied to each cir-
cuit of the machine.
At this time, the ACC signal is sent from
terminal ACC of the starting switch to the
engine controller, readying the engine for
startup.
2. Neutral safety circuit

q Setting the directional lever to "N (neu-
tral)" conducts the current from contact N
of the directional lever to the neutral safety
relay to activate it.
3. When starting switch is set to "START"

q As the starting switch is set to "START",
the current flows through the starting
switch terminal C, KOMTRAX engine cut-
off relay and neutral safety relay to the
starting motor safety relay to start the
engine.
q When the directional lever is set to any
position other than "N (neutral)", the neu-
tral safety relay is not activated and inter-
rupts the engine startup.
q As KOMTRAX terminal receives the exter-
nally applied engine cut-off command,
KOMTRAX engine cut-off relay is acti-
vated, shutting down the circuit from the
starting switch terminal C to the starting
motor safety relay. Thus, engine start-up
becomes unavailable.
(if equipped)
WA150-6 10-902 23
SEN05084-00 Engine stopping circuit
Engine stopping circuit 1
Operation
q Setting the starting switch to "OFF" cuts off
ACC signal from the starting switch terminal
ACC to the engine controller.
q Although ACC signal is cut off, the engine con-
troller keeps the engine controller cut-off relay
working to maintain the current flow to the
engine controller until its internal processing is
complete.
q As ACC signal is cut off, the engine lowers its
speed and stops. At the same time, the alter-
nator stops power generation, stopping supply
of the voltage from the alternator terminal L.
And the current from the starting switch termi-
nal BR is also stopped and the contacts of the
battery relay are opened. Consequently, the
power supplied to each circuit of the machine
is stopped.
10-902 24 WA150-6
Preheating circuit SEN05084-00
Preheating circuit 1
1. Battery
2. Battery relay
3. Slow-blow fuse
4. Fuse box 1
5. Starting switch
6. Engine controller
7. Machine monitor
8. Electrical intake air heater relay
9. Electrical intake air heater
10. Boost pressure and temperature sensor
Outline Operation
q The automatic preheating system is installed q Set the starting switch to "ON" to start the
so that the engine will start easily in a cold dis- engine controller. At this time, if intake air tem-
trict. perature is –4°C or below, the engine controller
q The automatic preheating system is capable of starts up the electrical intake air heater imme-
cutting the preheating time short as the starting diately after the starting switch is turned "ON"
switch is set to "ON". This system is also capa- to initiate preheating by the electrical intake air
ble of automatically setting the preheating heater.
duration referencing temperature of intake air. q The preheating time is set as shown below.
q Setting the starting switch to "ON" lights the
preheater pilot lamp of the machine monitor
and starts preheating of intake air with the
electrical intake air heater.
The engine controller sets the preheating dura-
tion referencing the intake air temperature
being sent from the boost pressure sensor and
temperature sensor.
q The pilot lamp remains turned on as long as
preheating is continued. Keep the starting
switch in the "ON" position during this time.
Setting the starting switch to "START" from this
state resets preheating.
WA150-6 10-902 25
SEN05084-00 Engine output derating function
Engine output derating function 1 Automatic warm-up function 1
q If the engine controller detects a failure, it pro- q When starting the engine in a cold district, this
tects the engine by derating the engine torque function warms it up by increasing the engine
or speed. low idle speed.
q If the coolant temperature is below 20°C at
q Following figure shows the engine torque per- starting of the engine, this function increases
formance when the torque was derated. the low idle speed to 1,200 rpm. The condi-
tions required for increasing the low idle speed
depend on the coolant temperature as shown
in the figure below.
q If the coolant temperature reaches 30°C or
above, the low idle speed returns to 980 rpm.
A: Derated to approximately 30% of the maximum

torque point
B: Derated to approximately 50% of the rated out-
put point
q Following figure shows the engine torque per- The automatic warm-up function is reset and the
formance when the engine speed was derated. engine speed returns to 980 rpm as any of the fol-
lowing conditions is met.
The coolant temperature reaches 30°C or
Condition 1 above while the automatic warm-up
function is enabled.
The accelerator pedal angle remains at
Condition 2
70% for 3 seconds or more.
The automatic warm-up function remains
Condition 3
being enabled for 30 minutes or more.
The directional lever or directional selector
switch is set to "Forward" or "Reverse"
while the automatic warm-up function is
enabled.
Condition 4
(When the directional lever and directional
selector switch are returned to "Neutral" to
stop the machine, the automatic warm-up
A: Derated near to the engine speed at maximum function restarts.)
torque point
10-902 26 WA150-6
Automatic warm-up function SEN05084-00
WA150-6 10-902 27
SEN05084-00 Parking brake circuit
Parking brake circuit 1
1. Parking brake lever intermediate switch

2. Parking brake lever bottom switch
3. HST controller
4. Machine monitor
5. Alarm buzzer
6. HST controller power holding relay
7. HST safety relay
8. Clutch solenoid valve
9. HST motor 1 solenoid valve
10. HST pump forward solenoid valve
11. HST pump reverse solenoid valve
10-902 28 WA150-6
Parking brake circuit SEN05084-00
Operation
Starting switch position OFF ON
State of engine Stopped Running
Parking brake lever area Free Mid Lock Free Mid Lock Free Mid Lock
Parking brake lever
intermediate switch (1) Close Open Close Open Close Open
Parking brake lever bottom
switch (2)
[for parking brake pilot lamp Close Open Close Open Close Open
operation]
Parking brake reminder [*1], [*2] OFF [*1] OFF OFF
caution lamp ON (Reset) ON (Reset) (Reset)
(Alarm buzzer) (Sounded) (Sounded)
Parking brake pilot lamp OFF OFF ON OFF ON
When the parking brake lever is set to "Mid"

position
q When the parking brake lever is set to the mid
position, the bottom switch (2) is open but
intermediate switch (1) is closed.
q The parking brake pilot lamp comes on only
when the starting switch is "ON".
q As bottom switch (2) opens, the output to the
forward and reverse solenoid valves of HST
pump is stopped to prevent dragging of the
parking brake. And, at the same time, the
directional lever and the directional selector
switch are disabled to turn on the machine
travel in both the forward and reverse direction.
When the parking brake lever is set to "Free" *1: When the starting switch is turned from "ON" to
position "OFF":
q When the parking brake lever is set to the free q The parking brake reminder caution lamp turns
position, the intermediate switch (1) and bot- on and the alarm buzzer sounds.
tom switch (2) are both closed. q The HST controller power holding relay
q The parking brake pilot lamp goes off indepen- remains turned on, conducting current to the
dent of the given state. HST controller and maintaining the HST motor
q The parking brake is released. 1 solenoid valve and clutch solenoid valve
*1: When the starting switch is turned from "ON" to being activated. Thus, the machine is pro-
"OFF": tected from slipping through a slope.
q The parking brake reminder caution lamp turns
on and the alarm buzzer sounds. When the parking brake lever is set to "Lock"
q The HST controller power holding relay position
remains turned on, conducting current to the q Pulling the parking brake lever fully opens both
HST controller and maintaining the HST motor the intermediate switch (1) and bottom switch
1 solenoid valve and clutch solenoid valve (2).
being activated. Thus, the machine is pro- q The parking brake pilot lamp comes on only
tected from slipping through a slope. when the starting switch is "ON".
*2: If the parking brake lever is set to any position q The parking brake reminder caution lamp goes
other than "Lock" when the starting switch is at off independent of the given state.
"OFF", the parking brake reminder caution q As bottom switch (2) opens, the output to the
lamp remains turned off and the alarm buzzer forward and reverse solenoid valves of HST
is also not activated. And HST motor 1 sole- pump is stopped to prevent dragging of the
noid valve and clutch solenoid valve remain parking brake. And, at the same time, the direc-
inactivated. tional lever and the directional selector switch
are disabled to turn on the machine travel in
both the forward and reverse direction.
q The parking brake is activated.
WA150-6 10-902 29
SEN05084-00 Multi-function knob
Multi-function knob 1
1. Directional selector switch Function

2. Max. traction switch q Directional selector switch (1) is an alternate
3. Option switch [Reserved] type. Its control signal sent to the HST control-
ler causes switching between the forward and
reverse travel.
q Max. traction switch (2) and option switch (3)
are momentary type. Max. traction switch (2)
control signal sent to the HST controller can-
cels the traction control temporarily.
10-902 30 WA150-6
Sensor SEN05084-00
Sensor 1
Speed sensor
1. Hall IC 5. Heat shrink tube

2. Circuit board 6. Protective tube
3. O-ring 7. Lead wire
4. Housing 8. Connector
Function
q This sensor is installed on the transfer case. It generates two different types of pulses depending on the
rotational direction and speed of the gear.
WA150-6 10-902 31
SEN05084-00 Sensor
HST oil temperature sensor

Brake oil temperature sensor
1. Connector 2. Plug 3. Thermistor
Function
q The HST oil temperature sensor and the brake oil temperature sensor are installed on the motor 2
hydraulic piping and front axle, respectively. They generate the signal for the change in temperature as
variation in the resistance of the thermistor.
HST oil pressure sensor
1. Sensor 2. Lead wire 3. Connector
Function
q This sensor is installed on the motor 2 solenoid block to measure the oil pressure in the HST circuit and
generate the corresponding signal.
10-902 32 WA150-6
Sensor SEN05084-00
HST oil filter clogging sensor
1. Terminal 2. Plug
Function
q This sensor is installed on the HST oil filter to monitor the oil pressure before and after the filter. If the
pressure goes beyond the specified level, the switch is set to "ON".
Coolant level sensor
1. Float 3. Connector
2. Sensor 4. Sub-tank
Function
q This sensor is installed in the bulkhead. As the coolant goes below the specified level, the float moves
down, and the switch is set to "OFF".
WA150-6 10-902 33
SEN05084-00 Sensor
Fuel level sensor
1. Connector 4. Body 7. Spacer

2. Float 5. Spring
3. Arm 6. Contact
Function
q This sensor is installed on the side face 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 resistance changes according to the operat-
ing angle and signal voltage is generated from the source voltage according to the change of the resis-
tance.
10-902 34 WA150-6
Sensor SEN05084-00
Accelerator pedal sensor
1. Pedal Output characteristics

2. Connector
3. Sensor
Function
q This sensor is installed on the surface of the
floor. It outputs the accelerator signal or idle
validation signal depending on the accelerator
pedal pressing angle.
Accelerator signal
q Magnitude of the accelerator pedal displace-
ment being detected by the sensor is output in
variable voltage from No. 2 pin.
Idle validation signal

q The sensor detects the accelerator pedal oper-
ation. 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 signal being entered to
No. 6 pin from No. 4 pin.
WA150-6 10-902 35
SEN05084-00 Sensor
Boom kick-out proximity switch

(if equipped)
Bucket positioner proximity switch
1. Switch 3. Operation indication lamp

2. Locknut 4. Connector
Function
q The boom kick-out proximity switch is installed in the lift arm left side connecting part of the front frame.
And the bucket positioner proximity switch is installed on the bucket cylinder. As long as the plate is
positioned on the detector plane, the switch lights up the operation indication lamp and turns itself "ON".
10-902 36 WA150-6
Sensor SEN05084-00
WA150-6 10-902 37
SEN05084-00

©2009 KOMATSU
All Rights Reserved
10-902 38
SEN05123-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
20 Standard value table 20
100 Standard service value table

Standard service value table for engine .......................................................................................................... 2
Standard service value table for chassis......................................................................................................... 3
WA150-6 20-100 1
SEN05123-00 Standard service value table for engine
Standard service value table for engine 1
Machine model WA150-6

Engine SAA4D95LE-5
Standard value for
Item Measurement conditions Unit Service limit value
new machine
High idle (*) 2,400 ± 50 2,400 ± 50
Engine speed rpm
Low idle 980 ± 25 980 ± 25
Exhaust temperature
All revolution ranges
(Turbocharger inlet tem- °C Max. 700 750
(Atmospheric temperature: 20°C)
perature)
Intake air pressure At aftercooler outlet side kPa Min. 96
—
(Boost pressure) At rated output {mmHg} {Min. 720}
Engine coolant tempera- At high idle Pollution Max. 10 20

Exhaust gas color
ture: Within operating range At sudden acceleration level % Max. 30 30
Intake valve 0.35 —
Valve clearance Normal temperature mm
Exhaust valve 0.5 —
At rated output
kPa Max. 0.98 1.47
Blow-by pressure Engine coolant temperature: Within operating
{mmH2O} {Max. 100} {150}
range
At high idle
SAE0W30EOS Min. 0.29 0.25
Engine coolant tempera-
{Min. 3.0} {2.5}
ture: Within operating range SAE5W40EOS MPa
Oil pressure SAE10W30DH
At low idle {kg/cm2}
SAE15W40DH Min. 0.15 0.13
Engine coolant tempera- SAE30DH {Min. 1.5} {1.3}
ture: Within operating range
Oil temperature All engine speed ranges (Inside oil pan) °C 80 – 115 120
Deflection under finger pres-
Alternator –
Alternator belt tension sure of approx. 58.8 N 6 – 10 11
fan pulley
{approx. 6 kg}
mm
Deflection under finger
Air conditioner Air conditioner com-
pressure of approx. 98 N 16 – 18 19 – 21
compressor belt tension pressor – fan pulley
{approx. 10 kg}
*: Value when mounted on machine (Different from value in Engine Shop Manual)
20-100 2 WA150-6
Standard service value table for chassis SEN05123-00
Standard service value table for chassis 1

Category
Standard value Service limit

Item Measurement conditions Unit
for new machine value
N– 5.9 (+5.9/0)
{0.6 (+0.6/0)} 13.7 {1.4}
FORWARD
Operating N
Directional lever
effort {kg} 5.9 (+5.9/0)

N–
{0.6 (+0.6/0)} 13.7 {1.4}
REVERSE • Engine stopped
• Measure at 10 mm from top of lever
N–
45 ± 10 45 ± 20
FORWARD
Travel mm
N–
45 ± 10 45 ± 20
REVERSE
7.8 ± 4.9 15.7
1st – 2nd
{0.8 ± 0.5} {1.6}
Speed switch (Dial switch)
Operating • Engine stopped N 7.8 ± 4.9 15.7

2nd – 3rd
effort • Measure at 10 mm from end of switch knob {kg} {0.8 ± 0.5} {1.6}
7.8 ± 4.9 15.7
3rd – 4th
{0.8 ± 0.5} {1.6}
1st – 2nd 30 ± 5 30 ± 10
Travel 2nd – 3rd • Engine stopped deg. 30 ± 5 30 ± 10
3rd – 4th 30 ± 5 30 ± 10
14.7 (+4.9/0) 29.4

HOLD o RAISE {1.5 (+0.5/0)} {3}
18.6 (+4.9/0) 35.3

RAISE o HOLD {1.9 (+0.5/0)} {3.6}
12.3 (+4.9/0) 25.7

HOLD o LOWER {1.25 (+0.5/0)}
Work equipment control lever
{2.6}
Lift arm
LOWER o HOLD — —
• Engine coolant tempera-
ture: Operating range 18.6 (+4.9/0) 35.3
Operating LOWER o FLOAT N
• Engine speed: Low idle {1.9 (+0.5/0)} {3.6}
effort {kg}
• Hydraulic oil temperature:
60 – 80°C 21.6 (+4.9/0) 39.7
FLOAT o HOLD {2.2 (+0.5/0)} {4.0}
16.7 (+4.9/0) 32.3

HOLD o DUMP {1.7 (+0.5/0)} {3.3}
14.7 (+4.9/0) 29.4

Bucket HOLD o TILT {1.5 (+0.5/0)} {3}
18.6 (+4.9/0) 27.9

TILT o HOLD {1.9 (+0.5/0)} {2.9}
HOLD o RAISE
Work equipment control lever
46 ± 9 46 ± 12
Lift arm HOLD o LOWER 46 ± 9 46 ± 12

• Engine coolant tempera-
ture: Operating range
Travel • Engine speed: Low idle LOWER o FLOAT mm 14 ± 9 14 ± 12
60 – 80°C
HOLD o DUMP 60 ± 9 60 ± 12
Bucket
HOLD o TILT 46 ± 9 46 ± 12
WA150-6 20-100 3
SEN05123-00 Standard service value table for chassis

Category

• Engine stopped
Play mm 60 ± 20 Max. 100
• Machine facing straight to front
• Flat, level, straight, dry, and paved road 10.3 ± 1.5 Max.14.7
Operating effort N {kg}
Steering wheel
• Engine speed: Low idle (Bucket empty) {1.05 ± 0.15} {Max. 1.5}
• Engine speed: High idle
Turns (Not including play) Turns 3.7 ± 0.4 4.1 ± 0.8
• Left lock – right lock
Low idle • Engine started 3.7 ± 0.4 Max. 4.8

Operating • Hydraulic oil temperature: Within operating
sec.
time range
High idle • Left lock – right lock 3.7 ± 0.3 3.7 ± 1
Beginning of 24.5 – 37.8

—
Operating depression • Engine started {2.5 – 3.9}
Accelerator pedal
N {kg}
effort • Measure at 150 mm from fulcrum of pedal. 45.5 – 58.8
Full open —
{4.6 – 6.0}
Neutral (α1) a For measuring posture, see Fig. A at end of 45 ± 2 —

Operating this section
deg.
angle • Engine started
Stroke (α) • α = α1 – α2 17 ± 2 —
• Operating angle: 20°

• Engine speed: Low idle 294 ± 30 Min. 238
Operating effort N {kg}
• Hydraulic oil temperature: Within operating {30 ± 3.0} {Min. 24.3}
range
Brake pedal
Neutral (α1) a For measuring posture, see Fig. B at end of 50 —

Operating this section
angle • Engine speed: Low idle
Max. (α) deg. 20 (+2/0) —
• Hydraulic oil temperature: Within operating
range
Play • α = α1 – α2 5±1 —
HST stall 2,350 ± 100 2,350 (+100/–200)

Engine speed
• Engine coolant temperature: Within operating

range
Hydraulic stall rpm 2,260 ± 100 2,260 (+190/–200)
• HST oil temperature: 60 – 80°C
• Hydraulic oil temperature: 45 – 55°C
HST stall + hydraulic stall 2,225 ± 200 2,225 (+225/–300)
1st 5.3 ± 0.3 5.3 ± 0.4

Power train (HST)
2nd 13.0 ± 0.7 13.0 ± 0.9

Travel speed
FORWARD km/h
(Bucket empty)
3rd 22.4 ± 1.1 22.4 ± 1.6
4th 36.2 ± 1.8 36.2 ± 2.5
20-100 4 WA150-6

Category

1st 5.3 ± 0.3 5.3 ± 0.4
2nd 13.0 ± 0.7 13.0 ± 0.9

Travel speed
REVERSE km/h
(Bucket empty)
3rd 22.4 ± 1.1 22.4 ± 1.6
4th 36.2 ± 1.8 36.2 ± 2.5
• Engine speed: Full speed

• Hydraulic oil temperature: 45 – 55°C 44.0 (+1.0/-2.5)
High pressure 44.0 ± 1.0
• Directional lever: FORWARD {450 (+10/-25)}
cut-off pressure {450 ± 10}
• Speed switch: 2nd speed
• Traction control switch: ON
Low pressure
• Engine speed: Full speed
relief pressure
Power train (HST)
• Hydraulic oil temperature: 2.5 (+0.2/0) 2.5 (+0.2/-0.1)

(Work equip- {25.5 (+2/0)} {25.5 (+2/-1)}
45 – 55°C
ment PPC cir-
• Directional lever: N
cuit pressure)
• Engine speed: 2.5 (+0.2/0) 2.5 (+0.2/-0.1)

HST oil Full speed When brake pedal releasing
pressure {25.5 (+2/0)} {25.5 (+2/-1)}
Servo piston • Hydraulic oil
control oil pres- temperature:
sure 45 – 55°C
When brake pedal depress- MPa Max. 0.6 Max. 0.6
• Directional
ing {kg/ {Max. 6} {Max. 6}
lever: N
cm2}
• Hydraulic oil temperature: 45 – 55°C
• Gear speed selector switch: 1st
Servo piston • Travel speed control dial: “1” on Min. side 2.5 (+0.2/0) 2.5 ± 0.2
operating pres- • Directional lever: Measure in both forward and {25.5 (+2/0)} {25.5 ± 2}
sure reverse position.
• Measure while driving at full throttle (Max.
speed: 5 km/h).
45 – 55°C 2.5 (+0.2/0) 2.5 (+0.2/-0.1)
Clutch control
Transfer • Directional lever: FORWARD {25.5 (+2/0)} {25.5 (+2/-1)}
pressure
• Speed switch: 3rd or 4th speed
• Travel at a speed of at least 10 km/h
Steering

18.6 (+0.7/-0.9) 18.6 ± 2.0
Steering relief pressure • Hydraulic oil temperature:
{190 (+7/-9)} {190 ± 20}
45 – 55°C
• Flat, horizontal, straight, dry paved road sur-
face
• Speed when applying brake: 35 km/h
Wheel brake
• Braking delay: Within 0.1 sec

Performance m Max. 12 Max. 12
• Brake pedal operating effort:
322 N {33 kg}
• Tire inflation pressure: Specified pressure
• Measure braking distance
Disc wear • Thickness of lining mm 1 ± 0.1 Max. 0.6
Parking brake
• Tire inflation pressure: Specified pressure

• Flat paved road with 1/5 (11°20') grade
Performance • Machine at operating condition — Holds position Holds position
a For measuring posture, see Fig. C and Fig. D
at the end of this section
WA150-6 20-100 5

Work equipment control valve Category

• Engine speed: High idle MPa

20.6 ± 0.4 20.6 ± 2.0
Relief pressure • Hydraulic oil temperature: {kg/
{210 ± 4} {210 ± 20}
45 – 55°C cm2}
• Engine speed: High idle RAISE 5.6 ± 0.5 Max. 8.2

Lift arm • Hydraulic oil temperature: *1
45 – 55°C LOWER 3.6 ± 0.5 Max. 4.7
• Steering valve: Neutral
Speed TILT Sec. 1.4 ± 0.3 Max. 2.0
• Apply no load *2
Bucket a For measuring posture, DUMP 1.1 ± 0.3 Max. 1.7
see Fig. E – Fig. H at the
Work equipment
end of this section TILT *3 0.9 ± 0.3 Max. 1.6
• Bucket no load
• Position of work equipment: Lift arm and
Lift arm cylin-
bucket in level position Max. 20 Max. 30
der
• Engine stopped
Hydraulic drift mm
45 – 55°C
• Stop engine and leave for 5 minutes, then
Bucket cylinder measure for 15 minutes. Max. 17 Max. 20
a For measuring posture, see Fig. J at the end of
this section

Hydraulic drive fan
• Engine coolant temperature: Min. 90°C

Max. fan speed rpm 1,570 ± 50 1,570 ± 100
• Boost temperature: Min. 70°C
• HST oil temperature: Min. 95°C
MPa
• Engine coolant temperature: Min. 90°C 16.2 ± 1.6 16.2 ± 2.5
Fan drive pressure {kg/
• Boost temperature: Min. 70°C {165 ± 16} {165 ± 25}
cm2}
Proximity switch
Clearance between bucket

3–5 —
positioner switch
mm
45 – 55°C
Clearance between boom kick-
3–5 —
out switch
*1: Time taken to raise bucket from contact with ground (bottom of bucket horizontal) to max. height of lift
arm.
*2: Time taken to move bucket from max. tilt to max. dump.
*3: Time taken to move bucket from horizontal position to max. tilt.
20-100 6 WA150-6
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
WA150-6 20-100 7
a Fig. G
a Fig. H
a Fig. J
20-100 8 WA150-6
WA150-6 20-100 9
SEN05123-00

©2009 KOMATSU
All Rights Reserved
20-100 10
SEN05124-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
30 Testing and adjusting 30
101 Testing and adjusting, Part 1

Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Testing engine speed ...................................................................................................................................... 8
Testing exhaust gas color ............................................................................................................................. 10
Testing exhaust temperature......................................................................................................................... 12
Adjusting valve clearance ............................................................................................................................. 13
Testing compression pressure ...................................................................................................................... 15
Testing blow-by pressure .............................................................................................................................. 17
Testing engine oil pressure ........................................................................................................................... 18
Testing intake air (boost) pressure ................................................................................................................ 19
Handling fuel system equipment................................................................................................................... 19
Releasing residual pressure in fuel system .................................................................................................. 20
Testing fuel pressure..................................................................................................................................... 21
Testing fuel return rate and leakage.............................................................................................................. 22
Bleeding air from fuel circuit.......................................................................................................................... 25
Checking leakage in fuel system .................................................................................................................. 26
Handling cylinder cut-out mode operation .................................................................................................... 27
Handling no-injection cranking operation...................................................................................................... 27
Handling controller voltage circuit ................................................................................................................. 28
Check of muffler and muffler stack for looseness and damage .................................................................... 28
Check of muffler function .............................................................................................................................. 29
Check of installed condition of cylinder head and manifolds ........................................................................ 29
Check of engine piping for damage and looseness ...................................................................................... 30
Testing and adjusting air conditioner compressor belt tension ..................................................................... 30
WA150-6 30-101 1
SEN05124-00
Testing and adjusting alternator belt tension................................................................................................. 31
30-101 2 WA150-6
Tools for testing, adjusting, and troubleshooting SEN05124-00
Tools for testing, adjusting, and troubleshooting 1
Testing and Sym-

Part No. Part Name Q'ty Remarks
adjusting item bol
1 799-201-9001 Handy smoke checker 1 Bosch index: Level 0 – 9
Testing exhaust gas
A Commercially
color 2 Smoke meter 1
available
Adjusting valve Commercially
B Clearance gauge 1
clearance available
1 795-502-1590 Gauge assembly 1 0 – 7 MPa {0 – 70 kg/cm2}
Testing compression
C 795-502-1370 Adapter 1
pressure 2 For 95E-5 engine
6271-11-3880 Gasket 1
Testing blow-by
D 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester
1 1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester Pressure gauge: 60 MPa {600 kg/cm2}
Testing engine oil pres-
E
sure 6832-81-3170 Adapter 1
2
07002-11023 O-ring 1
3 799-401-2320 Hydraulic tester 1
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing fuel 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
G
compression pressure 795-471-2010 Adapter 1 8 × 1.25 mm o R1/8
2
07005-00812 Seal washer 1
3 799-201-2202 Boost gauge kit 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter: 10 mm
3 07042-20108 Plug 1 R1/8
Commercially
4 Measuring cylinder 1
available
Testing fuel return rate
H Commercially
and leakage 5 Stopwatch 1
available
Commercially
6 Hose 1 Inside diameter: 5 mm
available
Commercially
7 Hose 1 Inside diameter: 15 mm
available
Testing accelerator
J 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
pedal
1 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
Testing directional lever K Commercially
2 Scale 1
available
799-101-5002 Analog hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting
L
HST oil pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 790-261-1231 Adapter 1
WA150-6 30-101 3
SEN05124-00 Tools for testing, adjusting, and troubleshooting
Testing and Sym- Q'ty

Part No. Part Name Remarks
adjusting item bol
1 {25, 60, 400, 600 kg/cm2}
Testing clutch control 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
M
pressure
799-101-5220 Adapter 1
2
07002-11023 O-ring 1
Testing steering wheel N 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
Testing and adjusting 799-101-5002 Analog hydraulic tester 1
P {25, 60, 400, 600 kg/cm2}
steering oil pressure
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
1 799-205-1100 Tachometer kit 1 Digital display: 6 – 99999.9 rpm
2 {25, 60, 400, 600 kg/cm2}
Testing hydraulic fan Q
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
799-401-3300 Adapter 1
3 For hose size #04
02896-11012 O-ring 1
Testing and adjusting Pressure gauge: 2.5, 6, 40, 60 MPa
accumulator charge R {25, 60, 400, 600 kg/cm2}
pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
1 793-605-1001 Brake test kit 1
2 790-101-1430 Coupler 1
3 790-101-1102 Pump 1
Testing wheel brake oil
S 4 790-301-1720 Adapter 1 20 × 1.5 mm o R1/8
pressure
5 799-101-5160 Nipple 1
6 799-401-2220 Hose 1 Length: 5 m
7 790-261-1130 Coupling 1
Holding work equip-
T 793-463-1100 Stopper 1
ment position
Testing wear of brake
U 418-98-31110 Testing gauge 1 Component part of tool kit
disc
parking brake control V 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
cable
1 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
Testing work equip-
W Commercially
ment lever 2 Scale 1
available
work equipment oil X {25, 60, 400, 600 kg/cm2}
pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
work equipment PPC Y {25, 60, 400, 600 kg/cm2}
oil pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
30-101 4 WA150-6

adjusting item bol
799-601-7400 T-adapter assembly 1 AMP040 Connector
799-601-7500 T-adapter assembly 1 AMP070 Connector
799-601-9000 T-adapter assembly 1 DT, HD30 Connector
799-601-9300 T-adapter assembly 1 DRC26-40 (5 pins)
799-601-7360 Adapter 1 REL-5P (5 pins)
799-601-7310 T-adapter 1 SWP (12 poles)
799-601-7070 T-adapter 1 SWP (16 poles)
799-601-4101 T-adapter assembly 1 Connected with engine
Diagnosis for engine
related controller, sen- 799-799-5530 • T-adapter 1 Engine coolant temperature
Z
sor actuator and har- 799-601-4310 • T-adapter 1 Boost temperature/pressure sensor
ness
799-601-4130 • T-adapter 1 Ne sensor, CAM sensor
799-601-4160 • T-adapter 1 Hydraulic pressure sensor
799-601-4211 • T-adapter 1 Controller (50 poles)
799-601-4140 • T-adapter 1 Atmospheric pressure sensor
799-601-4340 • T-adapter 1 Pump actuator
799-601-4190 • T-adapter 1 Common rail pressure sensor
799-601-2500
or
799-601-2700
or
799-601-2800
or
799-601-2900 T-adapter 1 799-601-2900 is not supplied
or
799-601-7100
or
799-601-4700
or
799-601-8000
799-601-2600 • T-adapter box 1 Econo (Excl. 799-601-2700)
799-601-2740 • Adapter for MIC 1 For MIC-5P
Diagnosis for chassis 799-601-4101 T-adapter assembly 1
related controller, sen-
Z 799-601-4211 • Adapter for DRC 1 For DRC50
sor actuator and har-
ness 799-601-9020 • Adapter for DT 1 For DT2P
799-601-9030 • Adapter for DT 1 For DT3P
799-601-7000
or
799-601-7100
or T-adapter assembly 1
799-601-7400
or
799-601-8000
799-601-7010 • Adapter for X 1 For X1P
799-601-7050 • Adapter for SWP 1 For SWP6P
WA150-6 30-101 5
SEN05124-00 Tools for testing, adjusting, and troubleshooting

adjusting item bol
799-601-7060 • Adapter for SWP 1 For SWP8P (Excl. 799-601-8000)
For M1P (Excl. 799-601-7000 and
799-601-7080 • Adapter for M 1
799-601-7100)
799-601-7090 • Adapter for M 1 For M2P
799-601-7150 • Adapter for S 1 For S10P
799-601-7180 • Adapter for AMP040 1 For A8P (799-601-7400 only)
For A12P (Excl. 799-601-7000 and
799-601-7190 • Adapter for AMP040 1
799-601-7100)
799-601-7330 • Adapter for S 1 For S16PW (799-601-8000 only)
799-601-7320 Adapter for SWP 1 For SW16P
799-601-7340 Adapter for M 1 For M8P
799-601-7360 Adapter for relay 1 For REL-5P
799-601-7370 Adapter for relay 1 For REL-6P
799-601-7500 T-adapter assembly 1
799-601-7520 • Adapter for 070 1 For 070-12P
799-601-7530 • Adapter for 070 1 For 070-14P
Diagnosis for chassis 799-601-7540 • Adapter for 070 1 For 070-18P
related controller, sen- 799-601-7550 • Adapter for 070 1 For 070-20P
Z
sor actuator and har-
ness 799-601-9000
or T-adapter assembly 1
799-601-9200
For DT2P (Incl. in 799-601-4101
799-601-9020 • Adapter for DT 1
and 799-601-4201)
For DT4P (Incl. in 799-601-4101
799-601-9040 • Adapter for DT 1
and 799-601-4201)
799-601-9060 • Adapter for DT (Gray) 1 For DT8PGR
799-601-9070 • Adapter for DT (Black) 1 For DT8PB
799-601-9080 • Adapter for DT (Green) 1 For DT8PG
799-601-9110 • Adapter for DT (Gray) 1 For DT12PGR
799-601-9120 • Adapter for DT (Black) 1 For DT12PB
799-601-9130 • Adapter for DT (Green) 1 For DT12PG
799-601-9140 • Adapter for DT (Brown) 1 For DT12P
799-601-9300 T-adapter assembly 1
799-601-9350 • Adapter for DRC 1 For DRC-40
799-601-9360 • Adapter for DRC 1 For DRC-24
• Multi-adapter for
799-601-9890 1 For DT2–4, DTM2
DT2–4, DTM2
Measuring coolant, oil
and exhaust tempera- ZA 799-101-1502 Digital thermometer 1
ture
Measuring time and Commercially
— Stopwatch 1
speed available
30-101 6 WA150-6

adjusting item bol
Measuring voltage and Commercially
— Tester 1
resistance available
Removal and installation
Commercially 3.26 mm TORX wrench
of boost pressure and — TORX wrench 1
available (KTC Q4T15 or equivalent)
temperature sensor
Removal and installation
19 mm deep socket
of engine coolant — 795T-981-1010 Deep socket 1
(For 6261-81-6901)
temperature sensor
WA150-6 30-101 7
SEN05124-00 Testing engine speed
Testing engine speed 1 2. Measuring HST stall speed

k
1) Referring to “Special function of machine
Put chocks under the tires securely.
k
monitor”, select the real time monitoring
When measuring, check that there are no function of the service mode.
persons around the machine. 2) Select the two-item simultaneous monitor-
ing (2 ITEMS) and then enter the following
a Measure the engine speed under the following code numbers directly.
condition. a Monitoring items
q Engine coolant temperature: [1] Code No.01001: ENG SPEED
Within operating range (Engine speed)
q Hydraulic oil temperature: [2] Code No.04408: HST OIL TEMP
Within operating range (HST oil temperature)
q HST oil temperature:
Within operating range
1. Measuring engine speed (low idle and high

idle)
1) Referring to “Special function of machine
monitor”, select the real time monitoring
function of the service mode.
2) Display “ENG SPEED” from the monitor-
ing items of the machine monitor.
a Monitoring item
Code No. 01001: ENG SPEED
(Engine speed)
3) Start the engine.

4) Lower the bucket to near the ground, then
drive the machine forward and thrust the
bucket into the stockpile of soil or rock
(portion a).
3) Start the engine, set it in the measuring

condition, and measure the engine speed.
5) While running the engine at high idle,

press the accelerator pedal gradually.
When the HST stalls, measure the engine
speed.
a Measure the stall speed 2 – 3 times.
a Do not keep stalling the HST for more
than 20 seconds. Take care that the
HST oil temperature will not exceed
120°C.
30-101 8 WA150-6
Testing engine speed SEN05124-00
3. Measuring hydraulic stall speed 4. Measuring HST stall and hydraulic stall (full
1) Referring to “Special function of machine stall) speed
monitor”, select the real time monitoring 1) Set the machine monitor as in “2. Measur-
function of the service mode. ing HST stall speed”.
2) Display “ENG SPEED” from the monitor- 2) Start the engine.
ing items of the machine monitor. 3) Lower the bucket to near the ground, then
a Monitoring item drive the machine forward and thrust the
Code No. 01001: ENG SPEED bucket into the stockpile of soil or rock
(Engine speed) (portion a).
3) Run the engine at high idle. 4) While running the engine at high idle, stall
4) Relieve the lift arm cylinder or bucket cyl- the HST and relieve the lift arm cylinder or
inder on the extraction side and measure bucket cylinder on the extraction side
the engine speed. simultaneously and measure the engine
a Finish measurement in a short time speed at this time.
so that the hydraulic oil temperature a Do not keep stalling the HST for more
will not exceed 120°C. than 20 seconds. Take care that the
HST oil temperature will not exceed
120°C.
WA150-6 30-101 9
SEN05124-00 Testing exhaust gas color
Testing exhaust gas color 1 2. Measuring with smoke meter A2

1) Insert the probe of smoke meter A2 in the
a Necessary tools outlet of the muffler (exhaust pipe) and fix
Symbol Part No. Part Name it to the exhaust pipe with a clip.
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.
a Measure the exhaust gas color under the fol-
lowing condition.
q Engine coolant temperature: Within oper-
ating range
2) Connect the probe hose, receptacle of the
1. Measuring with handy smoke checker A1 accelerator switch, and air hose to smoke
1) Stick a sheet of filter paper to smoke meter A2.
checker A1. a Keep the pressure of the supplied
2) Insert the exhaust gas intake pipe in the compressed air at 1.5 MPa {15 kg/
muffler (exhaust pipe). cm2} or below.
3) Start the engine and heighten the engine 3) Connect the power cable to a 100 V AC
coolant temperature to the operating range. receptacle.
4) Accelerate the engine suddenly and run it a Confirm that the smoke meter power
at high idle, and operate the handle of switch is in the OFF position, before con-
smoke checker A1 so that the filter paper necting the power cable to an outlet.
will absorb the exhaust gas. 4) Loosen the cap nut of the suction pump
and fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter A2.
5) Take out the filter paper and compare it

with the attached scale for judgement.
6) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
30-101 10 WA150-6
Testing exhaust gas color SEN05124-00
6) Start the engine and keep it running until

the engine coolant temperature rises to
the operating range.
7) Accelerate the engine suddenly or run it at
high idle and press the accelerator pedal
of smoke meter A2 and collect the
exhaust gas into the filter paper.
8) Put the polluted filter paper on non-pol-
luted filter paper (more than 10 sheets) in
the filter paper holder, and read the indi-
cated value.
9) After finishing work, remove the used
instruments and return the removed parts.
WA150-6 30-101 11
SEN05124-00 Testing exhaust temperature
Testing exhaust temperature 1 4. Run the engine and test the exhaust tempera-
ture in the whole speed range.
a Necessary tools
Symbol Part No. Part name

ZA 799-101-1502 Digital thermometer
k Remove and install the testing tools after

the exhaust manifold temperature has low-
ered.
a Measure the exhaust temperature under the
following condition.
q Coolant temperature: Within operating
range
q Hydraulic oil temperature: Within operat-
ing range
q Power train oil temperature: Within operat-
ing range 5. After finishing testing, remove the testing tools
and return the removed parts.
1. Open the left side cover of the engine. 3 Exhaust temperature pickup plug:
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
2. Remove exhaust temperature pickup plug (1)
from the side face of the center of the exhaust
manifold.
3. Install sensor [1] of digital thermometer ZA and

connect it to thermometer [2].
30-101 12 WA150-6
Adjusting valve clearance SEN05124-00
Adjusting valve clearance 1 4. Check the movement of the rocker arm of the
No . 1 c yl i nd er to j u dg e th e v al v e to b e
a Necessary tools adjusted.
Symbol Part No. Part Name a If you can move the rocker arms of air
intake valves (IN) with the hand by the
Commercially
B Clearance gauge valve clearance, adjust the valves marked
available
with Q in the valve arrangement drawing.
a Adjust the valve clearance under the following a If you can move the rocker arms of
condition. exhaust valves (EX) with the hand by the
q Engine coolant temperature: Normal tem- valve clearance, adjust the valves marked
perature with q in the valve arrangement drawing.
a Valve arrangement drawing
1. Remove the engine hood assembly. For detail,
see Disassembly and assembly, “Removal and
installation of engine hood assembly”.
2. Remove cylinder head cover (1). For detail,

Disassembly and assembly, “Removal and
installation of cylinder head assembly”.
5. Adjust the valve clearance according to the fol-

lowing procedure.
1) While fixing adjustment screw (5), loosen
locknut (6).
2) Insert clearance gauge B in the clearance
between rocker arm (7) and crosshead (8)
and adjust the valve clearance with
3. Rotate the crankshaft forward (clockwise seen adjustment screw (5).
from the front) and set wide notch (a) (Width: a With the clearance gauge inserted,
25 mm) of signal plate (2) at the rear of the turn the adjustment screw to a degree
c r a n k s h a ft p u l l e y t o e m b o s s e d l e t t e r s that you can move the clearance
“1.4TOP” (b) of front cover (3). gauge lightly.
Reference: All of the other notches of the sig- 3) While fixing adjustment screw (5), tighten
locknut (6).
3 Locknut:
nal plate are 5 mm in width.
a Rotate the crankshaft with the crankshaft
pulley bolt (4) (Width across flats: 27 mm). 39.2 – 49 Nm {4 – 5 kgm}
a Always rotate the crankshaft pulley bolt a After tightening the locknut, check the
forward to prevent it from being loosened. valve clearance again.
WA150-6 30-101 13
SEN05124-00 Adjusting valve clearance
6. Rotate the crankshaft forward by 1 turn and set

wide slit (b) to projection top (a) according to
step 3.
7. Adjust the other valve clearances according to

steps 4 and 5.
a If the valves marked with q in the valve
arrangement drawing were adjusted in
steps 4 and 5, adjust the valves marked
with Q.
a If the valves marked with Q in the valve
arrangement drawing were adjusted in
steps 4 and 5, adjust the valves marked
with q.
Reference: You may rotate the crankshaft pul-
ley by 180° and adjust the valve
clearance of the cylinder which is
set to the compression top dead
center at this time (Firing order: 1 –
2 – 4 – 3).
8. After finishing adjustment, remove the adjust-

ing tools and return the removed parts.
3 Cylinder head cover mounting nut:
8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}
30-101 14 WA150-6
Testing compression pressure SEN05124-00
Testing compression pressure 1 5) Remove holder (7) and injector (1).

a If injector is stuck and cannot be
a Necessary tools removed easily, pass a wire under the
Symbol Part No. Part Name fuel inlet and pull it up to remove the
injector.
1 795-502-1590 Gauge assembly
a Do not apply an external force to any
C 795-502-1370 Adapter part other than the injector top termi-
2
6271-11-3880 Gasket nal.
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)
1. Remove the engine hood assembly. For detail,

see Disassembly and assembly, “Removal and
installation of engine hood assembly”.
2. Install the air cleaner removed by the above

work.
5. Insert adapter C2 in the injector mounting hole
3. Remove cylinder head cover (1). For details, and fix it with holder (7).
see Disassembly and assembly, “Removal and a Fit the gasket to the adapter end.
installation of cylinder head assembly”. 3 Holder mounting bolt:
27 – 30 Nm {2.8 – 3.1 kgm}
4. Remove the injector of the cylinder to be mea- a Seat the fulcrum of the holder perfectly
sured. before tightening the mounting bolts.
a Testing procedure for No. 1 cylinder is
described below as an example.
1) Remove wiring harness connector (2)
from injector (1).
2) Remove fuel scatter prevention cover (3)
from the joint.
3) Remove clamp (4) and high-pressure pipe
(5).
4) Pull out spill hose connector (6) from
injector (1).
WA150-6 30-101 15
SEN05124-00 Testing compression pressure
6. Connect compression gauge C1 to adapter 2) Insert injector (1) in the cylinder head and
C2. fix it with holder (7).
3 Holder mounting bolt:
27 – 30 Nm {2.8 – 3.1 kgm}
a Seat the fulcrum of the holder per-
fectly before tightening the mounting
bolts.
7. Set it in the no-injection cranking mode.

For operating method, see “Special function of
monitor panel (EMMS)”.
k Since starting of engine is dangerous,
be sure to set the injectors so that they 3) Connect spill hose connector (6) to injec-
will not inject fuel before starting the tor (1).
check. 4) Install high-pressure pipe (5).
3 High-pressure pipe sleeve nut
8. Crank the engine with the starting motor and (Both ends):
measure the compression pressure. 25.5 – 29.4 Nm {2.6 – 3.0 kgm}
a Read the pressure when the gauge 5) Install fuel scatter prevention cover (3) to
pointer is stabilized. the joint of high-pressure pipe (5).
a Install fuel scatter prevention cover
9. After finishing measurement, remove the mea- (3) with the slit down (on both injector
suring instruments and return the removed side and common rail side).
parts according to the following procedure. 6) Install clamp (4) to high-pressure pipe (5).
1) Install O-ring (8) and gasket (9) to injector a Install the clamp to the position from
(1). which it was removed. (The mounting
a Do not install O-ring (8) to groove “a”. bolt goes through the clamp and
enters the bolt hole of the air intake
manifold. Accordingly, if the mounting
bolt is installed normally, the clamp is
installed to its original position.)
7) Connect wiring harness connector (2) to
injector (1).
30-101 16 WA150-6
Testing blow-by pressure SEN05124-00
Testing blow-by pressure 1 a If it is impossible to run the engine at the

rated output or HST stalling and hydraulic
a Necessary tools stalling, measure while the engine is run-
Symbol Part No. Part Name ning at high idle. The value obtained in
this case is about 80% of the blow-by
D 799-201-1504 Blow-by checker
pressure at the rated output.
a Measure the blow-by pressure under the fol- a Precaution for measuring blow-by pressure:
lowing condition. The blow-by pressure may vary largely
q Engine coolant temperature: with the engine condition. If the measured
Within operating range value is judged abnormal, check for
q Hydraulic oil temperature: increase of oil consumption, bad exhaust
Within operating range gas color, deterioration of oil, high deterio-
q HST oil temperature: ration speed of oil, etc. which are related
Within operating range to the abnormal blow-by pressure.
1. Stop the engine. Install nozzle [1] and hose [2]

of blow-by checker D to blow-by hose (1) and
connect them to gauge [3].
Blow-by hose (1) is near the right-hand step.
7. Remove the measurement tool after the mea-

surement, and make sure that the machine is
back to normal condition.
2. Start the engine and increase the engine cool-

ant temperature to the operating range.
3. Press the left brake pedal securely.
4. Release the parking brake.
5. While pressing the brake pedal, set the direc-

tional lever or switch to the F (forward) or R
(reverse) position.
k Keep pressing the brake pedal securely.
6. Press the accelerator pedal gradually to the

high idle. While running the engine at HST
stalling and hydraulic stalling, measure the
blow-by pressure.
a Do not keep stalling the HST for more
than 20 seconds. Take care that the HST
oil temperature will 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
HST stalling and hydraulic stalling.
WA150-6 30-101 17
SEN05124-00 Testing engine oil pressure
Testing engine oil pressure 1 4. Run the engine at high idle and low idle and
test the oil pressure.
a Necessary tools
Symbol Part No. Part Name
1
790-261-1204 Digital hydraulic tester
E 6732-81-3170 Adapter
2
07002-11023 O-ring
3 799-401-2320 Hydraulic tester
k Stop the machine on a level ground and

lower the work equipment to the ground,
and th en lo ck th e tires secu rely with
chocks.
a Measure the engine oil pressure under the fol-
lowing condition.
5. After finishing testing, remove the testing tools
q Engine coolant temperature:
and return the removed parts.
3 Plug (1): 20 – 22 Nm{2.0 – 2.2 kgm}
Within operating range
1. Open the side cover of the engine left side.
2. Remove 1 oil pressure pickup plug (1) from the

right side of the cylinder block.
a Remove any one of the 3 oil pressure
pickup plugs.
3. Install adapter E2 and connect it to hydraulic

tester E3 by using hose of hydraulic tester E1.
30-101 18 WA150-6
Testing intake air (boost) pressure SEN05124-00
Testing intake air (boost) pressure1 Handling fuel system equipment 1
k When installing and removing the measur- a Precautions for testing and maintaining fuel
ing instruments, take care not to touch a system
hot part of the engine. The common rail fuel injection system (CRI)
k Put chocks under the tires securely. consists of more precise parts than the con-
k When measuring, check that there are no ventional fuel injection pump and nozzle. If for-
persons around the machine. eign matter enters this system, it can cause a
a Measure the intake air pressure (boost pres- trouble.
sure) under the following condition. When testing and maintaining the fuel system,
q Engine coolant temperature: take care more than the past. If dust, etc. sticks
Within operating range to any part, wash that part thoroughly with
q Hydraulic oil temperature: clean fuel.
Within operating range a Precautions for replacement of fuel filter car-
q HST oil temperature: tridge
Within operating range The fuel filter cartridge used must be a genuine
Komatsu part.
1. Measurement with monitoring function The fuel injection pump and nozzle of the com-
1) Referring to “Special functions of machine mon rail type fuel injection system (CRI) con-
monitor (EMMS)”, select the real-time sist of more precision parts than those used for
monitoring function in the service mode. the current pumps and nozzles. This system,
2) Display “CHG PRESS-A” in the monitoring therefore, employs a special filter with highly
functions of the machine monitor. efficient filtering performance to prevent mixing
a Monitoring item of foreign substances. Thus, substituting it with
Code No. 36500: CHG PRESS-A (Boost a non-genuine filter could cause troubles in the
pressure) fuel system. It is strictly prohibited to use such
part.
3) Press the accelerator pedal gradually to

the high idle and measure the boost pres-
sure when HST stalling and hydraulic
stalling.
a Do not keep the HST stalled for more that
20 seconds so that the HST oil tempera-
ture will not exceed 120°C.
WA150-6 30-101 19
SEN05124-00 Releasing residual pressure in fuel system
Releasing residual pressure in

fuel system 1
a Pressure is generated in the low-pressure cir-

cuit and high-pressure circuit of the fuel sys-
tem while the engine is running.
Low-pressure circuit:
Feed pump – Fuel filter – Supply pump
High-pressure circuit:
Supply pump – Common rail – Injector
a The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
a Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel cir-
cuit must be released completely. Accordingly,
observe the following.
k Before testing the fuel system or removing
its parts, wait at least 30 seconds after stop-
ping the engine until the residual pressure
in the fuel circuit is released. (Do not start
the work just after stopping the engine
since there is residual pressure.)
30-101 20 WA150-6
Testing fuel pressure SEN05124-00
Testing fuel pressure 1 3) Install adapter G2 and nipple [1] of

hydraulic tester G1 and connect them to
a Necessary tools oil pressure gauge [3].
Symbol Part No. Part name a Use the oil pressure gauge of 2.5
MPa {25 kg/cm2}.
1
790-261-1204 Digital hydraulic tester
G 795-471-2010 Adapter
2
07005-00812 Seal washer
3 799-201-2202 Boost gauge kit
k Put chocks under the tires securely.

k When measuring, check that there are no
persons around the machine.
a Test only the fuel pressure in the low-pressure
circuit from the feed pump through the fuel
main filter to the supply pump and in the return
circuit between the supply pump/common rail/
injector and fuel tank.
k Since the pressure in the high-pressure cir- 4) Run the engine at high idle and measure the
cuit from the supply pump through the pressure in the fuel low-pressure circuit.
common rail to the fuel injector is very a If the pressure in the fuel low-pres-
high, it cannot be measured. sure circuit is in the following range, it
is normal.
1. Measuring pressure in fuel low-pressure Reference: A value is negative pres-
circuit sure.
1) Open the side cover of the engine right
Engine speed Fuel pressure
side.
2) Remove fuel pressure pickup plug (1) – 49 – 0 kPa
At high idle
{– 0.5 – 0 kg/cm2}
from the fuel main filter.
5) After finishing measurement, remove the

measuring tools and return the removed
parts.
3 Fuel pressure pickup plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
WA150-6 30-101 21
SEN05124-00 Testing fuel return rate and leakage
Testing fuel return rate and 3) Insert spacer H1 on return block (3) side
leakage 1
and tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
a Necessary tools of the spacer.
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
3 07042-20108 Plug
Commercially
4 Measuring cylinder
available
H Commercially
5 Stopwatch
available
Commercially Hose
6
available (Inside diameter: 14 mm)
Commercially
7 Hose (Inside diameter: 5 mm)
available
a Prepare receiving pan of about 20 l to receive 4) Insert joint H2 on common rail (1) side and
the fuel flowing out during measurement. tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
k Put chocks under the tires securely. of the joint.
k When measuring, check that there are no 5) Remove spill hose connector joint (5) and
persons around the machine. install plug H3.
3 Plug H3:
1. Preparation work 3.9 – 6.9 Nm {0.4 – 0.7 kgm}
1) Remove spill hose (2) between common
rail (1) and injector.
2) Remove tube (4) between common rail (1)
and return block (3).
30-101 22 WA150-6
Testing fuel return rate and leakage SEN05124-00
6) Connect test hose H6 to the end of joint 2. Testing leakage from pressure limiter
H2. 1) Lay test hose H6 so that it will not slacken
a Bind the connecting part of the test and put its end in the oil pan.
hose with a wire, etc. to prevent it 2) Set for measuring the engine speed.
from coming off. (For detail, see “Testing engine speed”.)
7) Connect test hose H7 to connector (6) 3) Run the engine at the rated output.
side of spill hose (2). 4) After the engine speed is stabilized, test
a Bind the connecting part of the test the leakage in 1 minute with measuring
hose with a wire, etc. to prevent it cylinder H4.
from coming off. a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Engine speed Leakage
(rpm) (cc/min)
At rated output Max. 20
Reference:
A limit value is the value mentioned
above, but a standard value in nor-
malcy is “0 cc/min. (no leak)”.
8) The above is the preparation work for test-

ing.
5) After finishing testing, stop the engine.
WA150-6 30-101 23
SEN05124-00 Testing fuel return rate and leakage
3. Testing return rate from injector

1) Lay test hose H7 so that it will not slacken
and put its end in the oil pan.
2) Set for measuring the engine speed.
(For detail, see “Testing engine speed”.)
3) Run the engine at the rated output.
4) After the engine speed is stabilized, test
the return rate in 1 minute with measuring
cylinder H4.
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 injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit
(rpm) (cc/min)
1,600 190
1,700 200
1,800 210
1,900 220
2,000 230
5) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
3 Joint (5): 3.9 – 6.9 Nm {0.4 – 0.7 kgm}
30-101 24 WA150-6
Bleeding air from fuel circuit SEN05124-00
Bleeding air from fuel circuit 1 4. Install pre-fuel filter (1) to the filter head.
a Apply engine oil thinly over the packing on
a If fuel is used up or if a fuel circuit part is the pre-fuel filter side.
removed and installed, bleed air from the fuel a After the packing of the pre-fuel filter
circuit according to the following procedure.
k
touches the sealing face of the filter head,
Put chocks under the tires securely.
k
tighten the fuel filter 3/4 turns.
When measuring, check that there are no
persons around the machine.
1. Fill the fuel tank with fuel.
2. Open the right side cover of the engine.
3. Remove fuel pre-fuel filter (1) and fill it with

fuel.
5. Loosen air bleeding plug (4) of the fuel main fil-

ter bracket and operate priming pump (2).
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 pre-fuel filter, and then
add fuel through part (b) (holes around the
central hole).
a After filling the pre-fuel filter with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not a Operate the priming pump until fuel flows
remove the pre-fuel filter but fill it with the out of the plug hole. After checking that
fuel by operating priming pump (2). fuel flows out, tighten the plug (4).
a Do not add fuel to fuel main filter exter- a Confirm that air does not coexist in fuel.
nally. 3 Air bleeding plug (4):
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
6. Push the knob of the priming pump, and fix it.
7. Start the engine with the starting motor.

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 5.
WA150-6 30-101 25
SEN05124-00 Checking leakage in fuel system
Checking 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, check 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 a 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. Start the engine and stall the HST or relieve

the hydraulic pump to apply some load on the
engine.
30-101 26 WA150-6
Handling cylinder cut-out mode operation SEN05124-00
Handling cylinder cut-out mode Handling no-injection cranking

operation 1 operation 1
a Cylinder cut-out mode operation means to run a No-injection cranking means to crank the
the engine with the fuel injectors of 1 or more engine with the starting motor while all the
cylinders disabled electrically to reduce the injections are stopped electrically. The purpose
number of effective cylinders. The purposes and effect of this operation are as follows.
and effects 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 cylinder details, see “Special functions of machine
cut-out mode operation, if the engine speed monitor (EMMS)”, “No-injection cranking func-
and output do not change from the normal tion”.
operation (all-cylinder operation), that cylinder
has 1 or more defects. The possible defects
are as follows.
q Compression 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 cylinder cut-
out mode operation easily with switches to find
out a defective cylinder.
a The cylinder cut-out mode operation is set
from the service mode of the machine
monitor.
For details, see “Special functions of
machine monitor (EMMS)”, “Cylinder cut-
out mode operation function”.
WA150-6 30-101 27
SEN05124-00 Handling controller voltage circuit
Handling controller voltage circuit Check of muffler and muffler

1. When disconnecting or connecting a connector stack for looseness and damage 1
between the engine controller and engine, be 1. Check the muffler and muffler stack visually for
sure to turn the starting switch OFF. a crack and damage. If any part is damaged,
replace it.
2. If a T-adapter is inserted in or connected to a
connector between the engine controller and 2. Check the mounting bolts and nuts of the muf-
engine for troubleshooting, do not start the fler and muffler stack for looseness. If they are
engine. loosened, retighten them.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
30-101 28 WA150-6
Check of muffler function SEN05124-00
Check of muffler function 1 Check of installed condition of

q Check the muffler for abnormal sound and dif- cylinder head and manifolds 1
ference in sound from a new machine. If it Check the installed condition of the cylinder head
makes abnormal sound, repair it, referring to and air intake manifold and exhaust manifold. If
the Troubleshooting Volume. they are loosened, retighten them.
a For the tightening torque, see the “Disassem-
bly and assembly” volume.
WA150-6 30-101 29
SEN05124-00 Check of engine piping for damage and looseness
Check of engine piping for Testing and adjusting air

damage and looseness 1 conditioner compressor
Air intake and exhaust systems: belt tension 1
Check the piping for damage, looseness of the

mounting bolts and nuts, and suction of air and Testing
leakage of exhaust gas through the joints. If it q Press the middle point between air conditioner
is loosened or damaged, retighten or repair. compressor pulley and drive pulley with a finger
and measure deflection (a) of the belt.
Cooling system: a Pressing force: Approx. 98 N {Approx. 10 kg}
Check the piping for damage, looseness of the a Standard deflection (a): 16 – 18 mm
mounting bolts and nuts, and leakage of water
through the joints. If it is loosened or dam-
aged, retighten or repair.
Fuel system:
Check the piping for damage, looseness of the
mounting bolts and nuts, and leakage of fuel
through the joints. If it is loosened or dam-
aged, retighten or repair.
Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure.
1. Loosen compressor bracket upper mounting

bolts (1) and lower fixing nut (2).
2. Loosen locknut (3) and adjust the belt tension

by turning adjustment bolt (4).
3. After the tension is adjusted to the reference

value, tighten locknut (3), fixing nut (2) and
compressor bracket mounting bolts (1).
30-101 30 WA150-6
Testing and adjusting alternator belt tension SEN05124-00
Testing and adjusting alternator Adjusting

belt tension 1 a If the deflection is out of the standard range,
k
adjust it according to the following procedure.
Stop the machine on a flat place and lower
the work equipment to the ground. 1. Open the right side cover of the engine.
Testing 2. Loosen fixing bolt (3), adjustment bolt (4) and

1. Open the right side cover of the engine. fixing nut (5) of the alternator.
a Check each pulley for breakage, check
the V-grooves for wear, and check for con-
tact between the V-belts and V-groove
bottoms.
a If any V-belt has lengthened and there is
not adjustment margin or it has a cut or a
crack, replace it with new one.
a If a V belt is replaced, test and adjust it
again after one-hour operation.
2. Press the intermediate point of the belt

between alternator pulley (1) and water pump
pulley (2) with a finger and measure deflection
(a) of the belt.
a Pressing force: Approx. 58.8 N {Approx. 6 kg}
a Deflection (a): 6 – 10 mm 3. Using a hammer shaft etc., move the alternator
to adjust the alternator belt tension.
4. After adjusting the belt tension, tighten alterna-

tor fixing bolt (3) and fixing nut (5).
5. Check again that the tension of alternator belt

is in the standard range.
6. After finishing adjustment, return the removed

parts.
WA150-6 30-101 31
SEN05124-00

©2009 KOMATSU
All Rights Reserved
30-101 32
SEN05125-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

Checking operating force of accelerator pedal ............................................................................................... 3
Checking directional lever............................................................................................................................... 4
Testing and adjusting HST oil pressure .......................................................................................................... 5
Testing clutch control pressure ....................................................................................................................... 9
Testing and adjusting steering wheel ............................................................................................................ 10
Testing and adjusting steering oil pressure................................................................................................... 12
Bleeding air from steering circuit................................................................................................................... 14
Testing hydraulic fan ..................................................................................................................................... 15
Testing brake pedal....................................................................................................................................... 17
Testing and adjusting brake pedal linkage .................................................................................................... 18
Testing brake performance ........................................................................................................................... 19
Testing and adjusting accumulator charge pressure..................................................................................... 20
Testing wheel brake oil pressure................................................................................................................... 22
Testing wear of brake disc ............................................................................................................................ 25
Bleeding air from wheel brake circuit ............................................................................................................ 26
Releasing residual pressure in brake accumulator circuit............................................................................. 27
Testing parking brake performance............................................................................................................... 28
Testing and adjusting parking brake control cable ........................................................................................ 29
Testing and adjusting parking brake switch .................................................................................................. 30
Testing and adjusting work equipment control lever ..................................................................................... 31
Testing and adjusting work equipment hydraulic pressure ........................................................................... 32
Testing work equipment PPC oil pressure .................................................................................................... 34
Bleeding air from hydraulic circuit ................................................................................................................. 36
WA150-6 30-102 1
SEN05125-00
Releasing remaining pressure in hydraulic circuit......................................................................................... 36

Testing and adjusting bucket positioner ........................................................................................................ 37
Testing and adjusting boom kick-out switch .................................................................................................. 39
Checking proximity switch operation pilot lamp ............................................................................................ 40
Procedure for testing diodes ......................................................................................................................... 41
Preparation work for troubleshooting for electric system .............................................................................. 43
Starting KOMTRAX terminal operations........................................................................................................ 47
Indicator lamps of KOMTRAX terminal ......................................................................................................... 51
30-102 2 WA150-6
Checking operating force of accelerator pedal SEN05125-00
Checking operating force of a After greasing, wipe off grease completely (No
accelerator pedal 1
grease is adhered on roller surface and roller
sliding surface).
Necessary tools
J 79A-264-0021 Push-pull scale
k Stop the machine on a level ground, lower

the work equipment to the ground, and set
chocks under the tire securely.
Testing accelerator pedal operating effort
1. Set push-pull scale J at a position 150 mm

from pedal fulcrum (a).
a Put the center of push-pull scale J in con-
tact with a point 150 mm from the pedal 5. After finishing the work, remove the measuring
fulcrum. instruments and return the removed parts.
Testing accelerator pedal operating angle
1. Start the engine.

2. Measure operating angle (α) when the pedal is
operated from the low idle position to the high
idle position.
3. Apply angle gauge [1] to accelerator pedal (1)
and measure pressing angle between low idle
angle α1 and high idle angle α2 (α = α1 – α2).
2. Start the engine, then measure the maximum

value when the pedal is pushed in from the low
idle position to the end of its travel (high idle).
3. Stop the engine.
4. If the squeak noise is heard from accelerator
pedal when checking, lubricate from grease
nipple (1) of roller shaft.
2 Roller shaft: Grease (G2-LI)
WA150-6 30-102 3
SEN05125-00 Checking directional lever
Checking directional lever 1
Necessary tools
1 79A-264-0021 Push-pull scale
K Commercially
2 Scale
available

Checking operating effort of directional lever
1. Stop the engine.

2. Install push-pull scale K1 or a spring balance
to a point 10 mm from the tip of the directional
lever, then measure the operating effort when
the lever is pulled in the direction of actuation.
a Carry out the measurement in each speed
range.
Checking travel of directional lever
1. Stop the engine.

2. Make mark (a) on the center of the knob of the
directional lever, then measure the travel with
scale K2 when the lever is operated in the
direction of actuation.
30-102 4 WA150-6
Testing and adjusting HST oil pressure SEN05125-00
Testing and adjusting HST oil q Pickup plug (4): For FORWARD cir-
pressure 1
cuit (port: MA)
q Pickup plug (5): For REVERSE circuit
Necessary tools (port: MB)
Symbol Part No. Part Name a Install the oil pressure gauge L1 to
pickup plug (4) of the forward circuit.
799-101-5002 Analog type hydraulic tester
1
L 790-261-1204 Digital type hydraulic tester
2 790-261-1231 Adapter
Preparation work
a Remove cover (1) of the center step on the
right side of the chassis.
k Loosen the oil filler cap (2) slowly to
release the pressure inside the hydraulic
tank. (At this time, loosen the cap while
pulling lock pin (3).)
a HST oil temperature when measuring: Within

operating range
a The high-pressure relief pressure is the same 3. Measure the high-pressure cut-off oil pressure
as the safety pressure of the main circuit, so it under the following conditions.
cannot be measured. (Normally, the cut-off 1) Lower the bucket to near the ground, then
valve is actuated first, so it does not rise to the drive the machine forward and thrust the
safety valve set pressure) bucket into the stockpile of soil or rock
(portion (a)).
Testing a Set the directional lever to FOR-
WARD and the speed selector switch
Testing high-pressure cut-off oil pressure to 2nd and traction control switch to
[Testing with monitoring function] ON.
1. Referring to “Special functions of machine
monitor (EMMS)”, select the real-time monitor-
ing function in the service mode.
2. Display “HST PRESS” among the monitoring
items of the machine monitor.
a Monitoring item
Code No. 32600: HST PRESS (HST oil
pressure)
[Testing with tools]
1. Open the engine hood side cover.
2. Remove oil pressure pickup plugs (4) and (5)
and install oil pressure gauge L1 [60 MPa {600
kg/cm2}].
WA150-6 30-102 5
SEN05125-00 Testing and adjusting HST oil pressure
2) Run the engine at full throttle and press 3. Place the directional lever at N, run the engine
the b uck et i nto p orti on ( a) un til the at high idle, and measure the low-pressure
machine does not move forward. relief pressure.
k Carry out the measurement on 4. After finishing the work, remove the measuring
hard ground where it is difficult for instruments and return the removed parts.
the tires to slip.
3) Keep the engine running at full throttle, Testing servo piston control pressure (DA pres-
check that the tires are not turning, then sure)
measure the oil pressure. 1. Remove floor frame cover (8) (bottom left of
4) After finishing the work, remove the mea- operator's cab).
suring instruments and return the
removed parts.
Testing low-pressure relief pressure (basic

pressure of work equipment PPC circuit)
[Testing with monitoring function]
See “Testing high-pressure cut-off oil pressure”.
[Testing with tools]
1. Remove low-pressure relief pressure mea-
surement plug (6) (10 mm, P =1.25 mm) from
under the machine.
a The oil pressure pickup plug is installed to
the accumulator bottom near the lower
right of the transfer on the right side of the
rear frame. 2. Remove servo piston control pressure mea-
surement plug (9) (DA pressure) (10 mm, P =
1.25 mm).
2. Install a nipple, then connect hydraulic tester

L1 (6 MPa {60 kg/cm2}).
3. Install adapter L2, then connect oil pressure
gauge L1 (6 MPa {60 kg/cm2}).
30-102 6 WA150-6
Testing and adjusting HST oil pressure SEN05125-00
4. Place the directional lever at N, run the engine Adjusting

at high idle, and measure the control pressure
when the brake pedal is depressed and when it a The high-pressure relief pressure is also the
is released. safety pressure of the main circuit, so it cannot
a The brake pedal is connected to the inch- be measured. (Normally, the cut-off valve is
ing valve and controls the control pres- actuated first, so it does not rise to the safety
sure. valve set pressure)
5. After finishing the work, remove the measuring
Adjusting high-pressure cut-off valve
a If the high-pressure cut-off pressure is not cor-
Testing servo piston actuating pressure rect, adjust high-pressure cut-off valve (12) as
follows.
1. Remove servo piston actuation pressure mea-
surement plug (10) or (11) (G 1/4) (width 1. Remove the engine hood.
across flats for hexagonal head wrench: 8 2. Loosen locknut (13) of high-pressure cut-off
mm). valve (12), then turn adjustment screw (14) to
q Plug (10): For FORWARD circuit (port: X1) adjust.
q Plug (11): For REVERSE circuit (port: X2) a Turn the adjustment screw to adjust as fol-
lows.
q To INCREASE pressure, turn
CLOCKWISE.
q To DECREASE pressure, turn
COUNTERCLOCKWISE.
a Amount of adjustment for one turn of
adjustment screw: 9.1 MPa {93 kg/cm2}
3. After adjusting, tighten locknut (13).
3 Locknut: 37.2 Nm {3.8 kgm}
2. Install a nipple L [3], then connect oil pressure

gauge L [1], L [2] (6 MPa {60 kg/cm2}).
3. Measure the servo piston actuating pressure

under the following conditions.
1) Set the gear speed selector switch in the
“1st” position and set the travel speed
control dial in the “1” position on the low-
est speed side.
2) Measure the oil pressure while driving for-
ward at full throttle (4 km/h). Similarly, a After completion of adjustment, repeat the
measure while driving in reverse. measurement procedure to check the
a Do not press the brake pedal. high-pressure cut-off oil pressure again.
WA150-6 30-102 7
SEN05125-00 Testing and adjusting HST oil pressure
Adjusting low-pressure relief valve Adjusting DA valve

a If the low-pressure relief pressure is not cor- a If the servo piston control pressure is not cor-
rect, adjust the low-pressure relief valve as fol- rect, adjust the DA valve as follows.
lows. 1. Remove the engine hood.
1. Remove the engine hood. 2. Loosen locknut (20) of DA valve (19), then turn
2. Remove the cap (16) of low-pressure relief adjustment screw (21) to adjust.
valve (15). a Turn the adjustment screw to adjust as fol-
3. Remove locknut (17) and rotate adjustment lows.
screw (18) to adjust the pressure. q To DECREASE pressure, turn
a Turn the adjustment screw to adjust as fol- CLOCKWISE.
lows. q To INCREASE pressure, turn
q To INCREASE pressure, turn COUNTERCLOCKWISE
CLOCKWISE. a Amount of adjustment for one turn of
q To DECREASE pressure, turn adjustment screw: 0.34 MPa {3.5 kg/cm2}
COUNTERCLOCKWISE 3. After adjusting, tighten locknut (20).
a Amount of adjustment for one turn of 3 Locknut: 64.7 Nm {6.6 kgm}
adjustment screw: 0.38 MPa {3.9 kg/cm2}
3 Locknut: 69.6 Nm {7.1 kgm}
a After completion of adjustment, repeat the

measurement procedure to check the con-
trol pressure again.
measurement procedure to check the low-
pressure relief pressure again.
30-102 8 WA150-6
Testing clutch control pressure SEN05125-00
Testing clutch control pressure 1
Necessary tools
1
790-261-1204 Digital type hydraulic tester
M
799-101-5220 Adapter
2
07002-11023 O-ring
k When removing the measurement plug and

disconnecting the hose, loosen the oil filler
cap slowly to release the pressure inside
the hydraulic tank.
1. Remove the bottom left side cover of opera-

tor’s cab.
2. Remove a cap of nipple (1) for measuring

clutch control pressure.
3. Install adapter M2 and hydraulic tester M1 (6

MPa {60 kg/cm2}).
4. Set the speed selector switch to 3rd or 4th,

travel at a speed of at least 10 km/h, and mea-
sure the clutch inlet pressure (clutch solenoid
valve output pressure).

WA150-6 30-102 9
SEN05125-00 Testing and adjusting steering wheel
Testing and adjusting steering Measuring operating effort of steering wheel

wheel 1
a Measurement conditions
Necessary tools q Road surface:
Symbol Part No. Part Name Flat, horizontal, dry paved surface
N 79A-264-0021 Push-pull scale
Within green range on engine coolant
temperature gauge
Measuring play of steering wheel q Hydraulic oil temperature:
45 – 55°C
a Measurement conditions q Tire inflation pressure:
q Engine speed: Stopped Specified pressure
q Machine posture: Facing straight forward q Engine speed:
Low idle (bucket empty)
1. Move the steering wheel (1) 2 or 3 times lightly
to the left and right, check that the steering 1. Install push-pull scale N to the steering wheel
mechanism is at the neutral position, then knob (2).
make mark (A) on the outside frame of the
machine monitor. 2. Start the engine.
2. Turn the steering wheel to the right, and make a After starting the engine, raise the bucket
mark (B) at the position where the operating approx. 400 mm and remove the frame
effort starts to become heavy. lock bar.
3. Pull push-pull scale N in the tangential direc-

tion and measure the value when the steering
wheel moves smoothly.
a Do not use the value when the steering
wheel starts to move.
3. Turn the steering wheel to the left in the oppo-

site direction from Step 2, and make mark (C)
a t th e p o i n t w h er e th e o p e r a t i n g e ff o r t
becomes heavy (when the steering valve lever
starts to move). Then measure the distance in
a straight line between marks (B) and (C).
30-102 10 WA150-6
Testing and adjusting steering wheel SEN05125-00
Measuring operating time for steering wheel
q Road surface:
Flat, horizontal, dry paved surface
Within green range on engine coolant
temperature gauge
q Hydraulic oil temperature:
45 – 55°C
q Tire inflation pressure:
Specified pressure
q Engine speed
Low idle and high idle

a After starting the engine, raise the bucket
approx. 400 mm and remove the frame
lock bar.
2. Operate the steering wheel to the end of its
stroke to turn the machine to the left or right.
3. Measure the time taken to operate the steering
wheel to the end of the stroke to the right or
left.
a Turn the steering wheel smoothly at a
speed of 60 rpm.
a Carry out the measurements both at low
idle and high idle, and to both the left and
right.
WA150-6 30-102 11
SEN05125-00 Testing and adjusting steering oil pressure
Testing and adjusting steering oil 3. Fit a nipple to the steering circuit pressure
pressure 1
measurement plug hole, then install hydraulic
tester P (40 MPa {400 kg/cm2}).
Necessary tools
P
a Measuring condition
q Hydraulic oil temperature: 45 – 55°C
q Engine speed: High idle
Measuring main relief pressure
1. Fit frame lock bar (1) between front frame and

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

steering cylinder circuit.
30-102 12 WA150-6
Testing and adjusting steering oil pressure SEN05125-00
Adjusting main relief pressure 4. Loosen lock screw (5), and then turn adjust-
ment screw (6) to adjust.
1. Stop the engine. a Turn the adjustment screw to adjust as fol-
2. Remove cover (1) at the lower right of the lows.
operator's cab. q To INCREASE pressure, turn
CLOCKWISE.
q To DECREASE pressure, turn
COUNTERCLOCKWISE.
a Pressure adjustment for one turn of
adjustment screw: Approx. 6.9 MPa {70
kg/cm2}
a Tool [1] for adjusting adjustment screw:
Size 7/32 inch, hexagonal
a Do not carry out any adjustment if the
relief pressure cannot be measured accu-
rately.
3 Adjustment screw (6):
2.3 – 6.8 Nm {0.23 – 0.69 kgm}
3 Lock screw (5):
3. Disconnect hose (3) and fitting (4) connected 14.7 ± 2 Nm {1.5 ± 0.2 kgm}
to port (T) of the priority valve (2).

WA150-6 30-102 13
SEN05125-00 Bleeding air from steering circuit
Bleeding air from steering circuit 1

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.
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.
30-102 14 WA150-6
Testing hydraulic fan SEN05125-00
Testing hydraulic fan 1 3. Connect the cable of probe [2] to tachometer

[4].
Necessary tools
Symbol Part No. Part Name Tachometer kit Q1
1 799-205-1100 Tachometer KIT
2
Q 790-261-1204 Digital type hydraulic tester
799-401-3300 Adapter
3
02896-11012 O-ring

k When removing the measurement plug and
disconnecting the hose, loosen the oil filler
cap slowly to release the pressure inside
the hydraulic tank.
a Measurement conditions 4. Start the engine, run at high idle, and measure
q Hydraulic oil temperature: 45 – 55°C the fan speed.
a Test the fan in a place where the fan blade and
probe will not be exposed to direct sunlight or 5. After finishing the work, remove the measuring
strong light. instruments and return the removed parts.
Testing fan speed
1. Open the radiator grille.
2. Install stand [1], probe [2], and reflecting tape

[3] in the tachometer kit Q1.
WA150-6 30-102 15
SEN05125-00 Testing hydraulic fan
Testing fan drive oil pressure
1. Open the radiator grille.

2. Disconnect hose (1), install hydraulic tester Q2
(40 MPa {400 kg/cm2}) and adapter Q3 (Hose
size: For #04), and connect hose (1) again.
3. Start the engine and measure the fan drive oil

pressure.

30-102 16 WA150-6
Testing brake pedal SEN05125-00
Testing brake pedal 1
q Engine coolant temperature: Within green
range on engine coolant temperature gauge
q Engine speed: Low idle
1. Install push gauge [1] to the operator's foot.

a Set the push gauge at a point 150 mm
from the fulcrum of the pedal.
2. Start the engine, and measure pedal angle

“α1” when running at low idle.
3. Apply angle gauge [2] to the brake pedal and

measure pressing angle (α) between pressing
angles (α1) and (α2) (α = α1 – α2).
q Operating effort at (α2): 196 N {20 kg}.
WA150-6 30-102 17
SEN05125-00 Testing and adjusting brake pedal linkage
Testing and adjusting brake pedal

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

hole of lever (6), and lever bushing.
2. Measure length of link (1), and check that it is

within the standard value.
Standard link length (a): 184 mm
a Measure the length from the center of pin
(5) to the center of ball joint (3).
3. Measure the distance of movement of rod (8)

and check that clearance (b) is within the stan-
dard value.
Standard clearance (b): 0 – 0.3 mm
a When doing this, check that the brake
pedal is in contact with the stopper.
Adjusting
Adjusting link length (a)

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

1. Loosen locknut (7), turn rod (8) so that the tip
of the rod contacts the booster cylinder piston,
then turn rod (8) back 1/4 turn.
2. Tighten locknut (7).
a Standard value (b): 0 – 0.3 mm
30-102 18 WA150-6
Testing brake performance SEN05125-00
Testing brake performance 1
9JF01100
q Road surface:
Flat, horizontal, dry paved surface
q Travel speed:
35 km/h when brakes are applied
q Tire inflation pressure:
Specified pressure
q Delay in applying brakes:
0.1 sec
q Specified operating effort:
322 N {33 kg}
Measurement method
1. Start the engine and drive the machine.
2. Set the speed selector switch to 4th and drive

the machine.
3. When the travel speed reaches “Measurement

condition speed”, depress the left brake pedal
with the specified operating effort.
a Before carrying out this operation, deter-
mine the run-up path and the point for
applying the brakes, then apply the brakes
when the machine reaches that point.
4. Measure the distance from the point where the

brakes were applied to the point where the
machine stopped.
a Repeat this measurement three times and
take the average.
WA150-6 30-102 19
SEN05125-00 Testing and adjusting accumulator charge pressure

accumulator charge pressure 1
Necessary tools
R

Measuring
4. Measure the accumulator charge cut-in pres-
q Hydraulic oil temperature: 45 – 55°C sure. Start the engine, run the engine at low
k Stop the engine, then depress the brake idle, and measure the oil pressure when the
pedal at least 100 times to release the pres- brake pressure caution lamp on the monitor
sure inside the accumulator circuit. panel goes out.
q Cut-in pressure:
1. Remove the rear frame left side cover (1). 5.9 +0.2 +2
0 MPa {60 0 kg/cm }
2
5. Measure the accumulator charge cut-out pres-

sure.
a After the accumulator charge cut-in is
actuated, measure the oil pressure when
the indicator of the oil pressure gauge has
risen and suddenly starts to drop.
q Cut-out pressure:
9.8 +0.98
0 MPa {100 +10
0 kg/cm }
2

2. Remove plug (2).
3. Install measurement nipple and hydraulic

tester R (40 MPa {400 kg/cm2}).
30-102 20 WA150-6
Testing and adjusting accumulator charge pressure SEN05125-00
Adjusting
a When the accumulator charge cut-out pres-

sure is adjusted, the cut-in pressure also
changes in proportion to the ratio of the valve
area.
1. Loosen locknut (4) of unload relief valve (accu-

mulator charge cut-out valve) (3), then turn
adjustment screw (5) to adjust.
a Turn the adjustment screw to adjust as fol-
lows.
q To RAISE pressure, turn CLOCK-
WISE
q To LOWER pressure, turn COUN-
TERCLOCKWISE
adjustment screw: 1.45 MPa {14.8 kg/cm2}

3 Locknut: 11.8 – 16.7 Nm {1.2 – 1.7 kgm}

measurement procedure given above to
check the accumulator cut-in pressure
and cutout pressure again.
WA150-6 30-102 21
SEN05125-00 Testing wheel brake oil pressure
Testing wheel brake oil pressure 1 2. Remove brake tube (2) of the measured side.
a The right side is shown as an example in
a Necessary tools the figure.
3. Remove brake tube (2) or (3) on the measuring
1 793-605-1001 Brake test kit
side and install adapter S4 and nipple S5.
2 790-101-1430 Coupler a Use the O-ring fitted to the union.
3 790-101-1102 Pump
S 4 790-301-1720 Adapter
5 799-101-5160 Nipple
6 799-401-2220 Hose
7 790-261-1130 Coupling
T 793-463-1100 Stopper

k Apply the parking brake and put chocks
under the tires securely.
a Measure the oil pressure of the front brakes
(right and left) and rear brakes (right and left)
similarly.
a Measuring condition.
q Engine coolant temperature: Within oper-
ating range
q Hydraulic oil temperature: Within operat-
ing range
1. Remove front frame inspection cover (1).

k When raising the lift arm to remove the
inspection cover, place a stand [1]
under it to support securely.
Instead, you may set stopper T to the
lift arm cylinder to prevent the work 4. Connect brake test kit S1 to nipple S5.
equipment from lowering. a For the composition and connection, see
the figure on the following page.
5. Connect hose [1] and loosen bleeder screw (4)

to bleed air.
a Operate tool S3 to bleed air.
30-102 22 WA150-6
Testing wheel brake oil pressure SEN05125-00
Composition and connection diagram of brake test kit S
WA150-6 30-102 23
SEN05125-00 Testing wheel brake oil pressure
6. Tighten bleeder screw (4), operate pump S3 to

increase the pressure to 4.1 MPa {42 kg/cm2},
and tighten stop valve [2] (a component part of
S1).
7. Leave the brake circuit pressurized for 5 min-

utes and check lowering of the pressure.
a If the hose is moved while the pressure is
me as ur ed , the p re s su r e flu c tua tes .
Accordingly, do not move the hose.
a After testing the pressure, operate pump
S3 to lower the pressure in brake test kit
S1, and then remove brake test kit S1.
a After finishing testing, install the brake
tube and bleed air from the brake circuit.

30-102 24 WA150-6
Testing wear of brake disc SEN05125-00
Testing wear of brake disc 1 2. While pressing the brake pedal, insert testing
gauge U in the inspection plug hole and pinch
Necessary tools the inspection projection around piston (2) and
Symbol Part No. Part name plate (3) with the inspection gauge tip.
U 418-98-31110 Testing gauge
Reference: Testing gauge U is component part
of tool kit.
a If you can pinch the inspection projection
k Stop the machine on a level ground, lower around piston (2) and plate (3) with the
the work equipment to the ground, and set inspection gauge tip, the brake disc is
chocks under the tire securely. worn more than the repair limit. In this
a There are inspection plugs on the right and left case, replace the brake disc.
sides of the front and rear axles. Check at all of
the 4 plugs similarly.
1. Remove inspection plugs (1) from the axle

housing.

3 Inspection plug (1):
127.4 – 176.4 Nm {13 – 18 kgm}
WA150-6 30-102 25
SEN05125-00 Bleeding air from wheel brake circuit
Bleeding air from wheel brake 3. Connect hose [1] to bleeder screws [2] and
circuit 1
place hose [1] in the oil receive pan.
a Work on the rear side similarly from under-
Necessary tools side of the machine.
T 793-463-1100 Stopper

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).
a When a complete bleeding is required, it is
advisable to start the operation from the brake
cylinder situated farthest from the brake pedal. 4. Press the brake pedal and then loosen bleeder
a The work on the front right side is shown as an screw [2] to bleed air.
example. Work on each brake cylinder simi- a Return the brake pedal slowly after tight-
larly. ening bleeder screws [2].
1. Start the engine to accumulate pressure in the 5. Repeat this operation until the oil flowing
accumulator and then stop the engine. through hose [1] becomes free from bubbles.
Then press the pedal fully and tighten bleeder
2. Remove front frame inspection cover (1). screws [2] while the oil is flowing.
k When raising the lift arm and removing a As accumulated pressure in the accumu-
the inspection cover, place support lator is decreased, start the engine to
stand [1] under the lift arm to support accumulate pressure in the accumulator.
the lift arm securely or set stopper T to Then bleed air using the same procedure
the lift arm cylinder to prevent the work as described above.
equipment from falling. a After finishing bleeding air, run the engine
at low idle and check the oil level in the
hydraulic tank. If the level is low, add oil up
to the specified level.

30-102 26 WA150-6
Releasing residual pressure in brake accumulator circuit SEN05125-00
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 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.
WA150-6 30-102 27
SEN05125-00 Testing parking brake performance
Testing parking brake

performance 1
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 pedal to stop the machine, set

the directional lever in the N position, and stop
the engine.
3. Pull the parking brake lever fully, release the

brake pedal gradually, and check that the
machine is kept stopped.
a Measure the parking brake performance
on an uphill and a downhill.
30-102 28 WA150-6
Testing and adjusting parking brake control cable SEN05125-00
Testing and adjusting parking Adjusting

brake control cable 1 1. Release the parking brake.
a Check that the pawl of the parking brake
Necessary tools lever is at the lowest position.
2. Loosen locknut (2) and remove clevis pin (3).
V 79A-264-0021 Push-pull scale
k
3. Pull parking brake lever (4) on the transfer side
Stop the machine on a level ground, lower in the release direction. (Add the play of the
the work equipment to the ground, and set parking brake lever to the upper side, how-
chocks under the tire securely. ever.)
Testing 4. Under the above condition, tighten clevis (5) to

1. Install push-pull scale V to a position at dimen- match its hole to the hole of parking brake
sion (a) from the end of parking brake lever (1) lever (4).
(excluding the button) and pull it with a force of
about 294 N {about 30 kg}. 5. Install clevis pin (3) and tighten locknut (2).
q Dimension (a): 55 mm 3 Locknut: 5.9 – 9.8 Nm {0.6 – 1.0 kgm}
a After finishing adjustment, pull parking
2. If the parking brake lever is pulled by 8 notches brake lever (1) again with a force of about
or more, check the fixing parts of the parking 294 N {about 30 kg} and check that it trav-
brake control cable (on both lever side and els 5 – 7 notches. (An aim at the 5th
brake side) for looseness. If the fixing parts are notch)
loosened, tighten them, and then perform the
following adjustment.
WA150-6 30-102 29
SEN05125-00 Testing and adjusting parking brake switch
Testing and adjusting parking 2. Adjust nuts (5) to become (b) dimension range,
brake switch 1
and adjust position of switch (4) when parking
brake lever is at the 4th notch position.
(b) = 5 ± 1 mm
Testing method
1. Check that the pilot lamp switch (4) is turned
ON and the stop lamp lights when parking
brake lever (1) is at the 5th notch. If the lamp
lights at a position other than the 5th notch,
adjust the switch.
3. Adjust the installed position (c) of pilot lamp

switch (2) so that the switch will be turned ON
or OFF when parking brake lever (1) is at the
5th notch.
(c) = 1 ± 1 mm (Reference value)
Adjusting method
1. Adjust nuts (3) to become (a) dimension range,
and adjust position of switch (2) when parking
brake lever is in release position (off position).
(a) = 5 ± 1 mm
30-102 30 WA150-6
Testing and adjusting work equipment control lever SEN05125-00
Testing and adjusting work Measuring travel of work equipment control

equipment control lever 1 lever
Measure the travel at each position when operating
Necessary tools
the work equipment control lever.
Symbol Part No. Part Name a Mark the lever knob and use a scale W2 to
1 79A-264-0021 Push-pull scale measure.
a If the stroke is not within the standard value,
W Commercially
2 Scale check for play in the work equipment PPC
available valve.
k Install the frame lock bar to the frame.

a Measuring condition
q Engine coolant temperature: Operating range
of engine coolant thermometer
q Engine speed: Low idle
Measuring operating effort of work equipment

control lever
Install tool W1 to the work equipment control lever
and secure it in position.
a Install tool W1 to the center of the knob.
a Operate the control lever at the same speed as
for normal operations, and measure the mini-
mum value for the effort needed to operate the
knob.
WA150-6 30-102 31
SEN05125-00 Testing and adjusting work equipment hydraulic pressure
Testing and adjusting work Adjusting

equipment hydraulic pressure 1
a Always stop the engine before adjusting the oil
Necessary tools pressure.
k When carrying out the operation with the
lift arm raised, set support [1] or lift arm
799-101-5002 Analog type hydraulic tester drop prevention stopper T in position
X
790-261-1204 Digital type hydraulic tester before starting the operation.
T 793-463-1100 Stopper
1. Remove front frame inspection cover (1).
k Loosen the oil filler cap slowly to release

the pressure inside the hydraulic tank, then
operate the control lever several times to
release the remaining pressure in the
hydraulic piping.
Measuring condition
Measuring
1. Remove the oil pressure pickup plug of the

bucket cylinder and install hydraulic tester X
[40 MPa {400 kg/cm 2 }] of the oil pressure
pickup nipple. 2. Remove cap nut (2) of relief valve (5).
2. Start the engine, raise the lift arm approx. 400

mm, run the engine at high idle, then operate
the control lever to tilt back the bucket, and
measure the pressure when the relief valve is
actuated.
30-102 32 WA150-6
Testing and adjusting work equipment hydraulic pressure SEN05125-00
3. Loosen locknut (3) of relief valve (5), then turn

adjustment screw (4) to adjust.
a Turn the adjustment screw to adjust the
set pressure as follows.
q TIGHTEN to INCREASE pressure
q LOOSEN to DECREASE pressure
adjustment screw: Approx. 2.43 MPa
{Approx. 24.8 kg/cm2}
a Do not carry out any adjustment if the
relief pressure cannot be measured accu-
rately.

WA150-6 30-102 33
SEN05125-00 Testing work equipment PPC oil pressure
Testing work equipment PPC oil

pressure 1
Necessary tools
Y
T 793-463-1100 Stopper

the pressure inside the hydraulic tank.
Then operate the control levers several
times to release the pressure in the piping.
Measuring condition
Checking PPC valve output pressure
k When leaving the operator's seat, apply the 1. Remove the inspection cover (1) of the front
work equipment lock lever securely. frame.
k Except for measuring the oil pressure,
Testing PPC valve basic pressure when carrying out preparatory operations
with the lift arm raised, set support [1] or
1. Remove low-pressure relief pressure mea-
lift arm drop prevention stopper T in posi-
surement plug (1) (10 mm, P =1.25 mm) from
tion before starting the operation.
under the machine.
a The oil pressure pickup plug is installed to
the accumulator bottom near the lower
right of the transfer on the right side of the
rear frame.
2. Remove PPC output pressure measurement

plug of the circuit to be measured, then install
oil pressure gauge Y (6 MPa {60 kg/cm2}).
3. Start the engine, then remove support [1] or
boom drop prevention stopper T.
2. Install a nipple, then install hydraulic tester Y (6
MPa {60 kg/cm2}).
4. Run the engine at high idle, then operate the
work equipment control lever and measure the
oil pressure.
30-102 34 WA150-6
Testing work equipment PPC oil pressure SEN05125-00
4. Operate the work equipment control lever at

high idle and measure the oil pressure.
(1) 2 Valves (Without ECSS)
(2) 2 Valves + ECSS (If equipped)
a A: Bucket TILT
B: Bucket DUMP
C: Lift arm RAISE
D: Lift arm LOWER

WA150-6 30-102 35
SEN05125-00 Bleeding air from hydraulic circuit
Bleeding air from hydraulic circuit1 Releasing remaining pressure in

hydraulic circuit 1
Bleeding air from work equipment PPC circuit Releasing remaining pressure between each
1. Operate each work equipment lever fully and hydraulic cylinder and control valve
hold it in position to relieve the circuit for a If the piping between the hydraulic cylinder and
approx. 1 minute. Carry out this operation once the control valve is to be disconnected, release
for each work equipment lever stroke end. the remaining pressure from the circuit as fol-
lows.
Bleeding air from cylinders 1. Lower the work equipment to the ground, and
1. Start the engine and run at idle for approx. 5 stop the engine.
minutes. 2. Loosen the oil filler cap slowly to release the
2. Run the engine at low idle, then raise and pressure inside the tank.
lower the lift arm 4 – 5 times in succession. 3. Operate the control lever.
a Operate the piston rod to a point approx. a When the lever is operated 5 – 6 times to
100 mm before the end of its stroke. Do release all the remaining pressure.
not relieve the circuit under any circum-
stances. Releasing remaining pressure in brake accumu-
3. Run the engine at full throttle and repeat Step lator circuit
2. After that, run the engine at low idling, and a If the piping between the ACC charge valve
operate the piston rod to the end of its stroke to and brake accumulator, between the ACC
relieve the circuit. charge valve and parking brake valve, and
4. Repeat Steps 2 and 3 to bleed the air from the between the accumulator and brake valve is to
bucket and steering cylinders. be disconnected, release the remaining pres-
a When the cylinder has been replaced, sure from the circuit as follows.
bleed the air before connecting the piston 1. Stop the engine.
rod. 2. Depress the brake pedal at least 100 times to
release the pressure inside the brake accumu-
lator circuit.
Releasing remaining pressure in PPC accumu-

lator circuit
a If the piping between the PPC accumulator
and PPC valve is to be disconnected, release
the remaining pressure from the circuit as fol-
lows.
1. Lower the work equipment to the ground, and
stop the engine.
2. Operate the control lever 5 – 6 times to release
all the remaining pressure from the circuit.
30-102 36 WA150-6
Testing and adjusting bucket positioner SEN05125-00
Testing and adjusting bucket Adjusting

1. Adjusting clearance.
positioner 1
1) Adjust and secure clearance (b) between
a Measuring condition the tip of switch protector c and the sensi-
q Engine coolant temperature: White range tive surface (1) of the switch to the stan-
of engine coolant thermometer dard range with switch nuts (4).
q Hydraulic oil temperature: 45 – 55°C a Standard clearance (b): 0.5 – 1.0 mm
3 Mounting nut:
Testing 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
1. Stop the engine and check that clearance (a)
between proximity switch (1) and detection bar
(2) is in the standard range.
a Standard clearance (a): 3 – 5 mm
2) Adjust and secure clearance (a) between

the sensitive surface of proximity switch
(1) and detection bar (2) to the standard
range with the shim and mounting bolt of
2. Run the engine at same as usual working the proximity switch bracket.
speed and check the operating point. (Mea- a Standard clearance (a): 3 – 5 mm
sure 3 times and obtain the average.) a Adjust detection bar (2) with the shim
so that clearance (a) will be in the
standard range through the stroke of
the detection bar (2).
WA150-6 30-102 37
SEN05125-00 Testing and adjusting bucket positioner
2. Adjusting installing position (stopping

position).
1) Lower the bucket to the ground and set it
to a desired digging angle, then return the
lever to the HOLD position and stop the
engine.
2) Loosen 2 mounting bolts (5) and adjust
the position of switch protector (3) so that
the rear end of detection bar (2) will be at
the center of the sensitive surface of prox-
imity switch (1), and then tighten 2 mount-
ing bolts (5).
3) Check again that clearance (a) between
proximity switch (1) and detection bar (2)
is 3 – 5 mm.
q The installing position may be
checked by checking the operation of
the pilot lamp of the proximity switch
with the starting switch at the ON
position. (When the pilot lamp goes
off, the bucket stops.)
a After adjusting, start the engine and oper-

ate the work equipment control lever to
check that the bucket positioner set the
bucket at the desired position.
30-102 38 WA150-6
Testing and adjusting boom kick-out switch SEN05125-00
Testing and adjusting boom kick- 4. Adjust the switch so that clearance (a)
out switch 1
between the sensing surface of the switch and
plate (2) is the standard value, then secure in
a This contents applies only the "boom kick-out position.
(If equipped)" installation specification model. 3 Switch mounting nut:
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
Testing q The installing position may be checked by
checking the operation of the pilot lamp of
1. With the engine stopped, check that clearance the proximity switch with the starting
(a) between detection surface of switch (1) and switch at the ON position.
plate (2) is the standard value. a For ON/OFF of the pilot lamp, see “Check-
a Standard clearance (a): 3 – 5 mm ing proximity switch working pilot lamp”.
a After adjusting, start the engine, operate
the work equipment control lever and
check that the boom kickout is actuated at
the desired position.
2. Start the engine, run at high idle, and check the

actuation point.
(Check three times and take the average.)
Adjusting
1. Raise the lift arm to the desired height, then

mark the lift arm to show the position where
the center of the switch is aligned with the bot-
tom of the plate.
k Always be sure to apply the work equipment
lock lever.
2. Lower the lift arm and stop the engine.

3. Align the marks and adjust the position of the
plate so that the center of switch (1) is at the
bottom of plate (2), then secure in position with
bolts (3).
WA150-6 30-102 39
SEN05125-00 Checking proximity switch operation pilot lamp
Checking proximity switch

operation pilot lamp 1
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 between sensitive surface

Proximity switch Operation pilot lamp Remarks
of proximity switch and sensing object
Near ON Operates when center of
Bucket positioner
Far OFF switch is near
Near ON Operates when center of
Boom kick-out (*)
Far OFF switch is far
*: If equipped
30-102 40 WA150-6
Procedure for testing diodes SEN05125-00
Procedure for testing diodes 1 1. When using digital type circuit tester
1) Switch the testing mode to diode range
a Check an assembled-type diode (8 pins) and and confirm the indicated value.
independent diode (2 pins) in the following a Voltage of the battery inside is dis-
manner. played with conventional circuit testers.
a The conductive directions of the assembled- 2) Put the red probe (+) of the test lead to the
type diode are indicated on the surface of the anode (P) and the black probe (–) to the
diode as shown in the following figure. cathode (N) of diode, and confirm the indi-
cated value.
3) Determine acceptability of the diode from
the indicated value.
q Indicated value remains unchanged:
Conduction is absent (Failure)
q The indicated value changes: The
diode has conductivity (Normal) (See
a below.)
a A value between 460 to 600 is indi-
cated for silicon diodes.
a The conductive directions of the single diode is

indicated on the surface of the diode as shown
in the following figure.
WA150-6 30-102 41
SEN05125-00 Procedure for testing diodes
2. When using analog type circuit tester

1) Switch the testing mode to resistance
range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
1] Put the red probe (+) of the test lead
to the anode (P) and the black probe
(–) to the cathode (N) of diode.
2] Apply the red (+) lead of the tester to
the cathode (N) side of the diode and
apply the black (–) lead to the anode
(P) side.
3) Determine if a specific diode is good or no
good by the way the pointer swings.
q With the connection 1] above, the
pointer is not moved. It swings, how-
ev er, whe n the conne ction 2] i s
employed. Normal (However, magni-
tude of the pointer's move (indicating
the resistance value) varies depend-
ing on the given tester model and the
measurement range selected).
q The pointer swings with both the con-
nections of 1] and 2]: Defective (Inter-
nal short circuit)
q The pointer does not swing with both
the connections of 1] and 2]: Defec-
tive (Internal breaking of wire)
30-102 42 WA150-6
Preparation work for troubleshooting for electric system SEN05125-00
Preparation work for

troubleshooting for electric
system 1
a When carrying out troubleshooting for an elec-

tric circuit related to the machine monitor,
transmission controller, work equipment con-
troller, or KOMTRAX terminal, expose the
related connectors according to the following
procedure.
a Disconnect and connect the connectors of spe-
cial lock types according to the following pro-
cedure.
1. Machine monitor 2) Remove cover (1).

1) Disconnect the following connectors from
cover (1).
q Connector L06: Hazard switch
q Connector L07:
Front working lamp switch
q Connector L08:
Rear working lamp switch
q Connector L09:
ECSS switch (If equipped)
q Connector L10:
Machine monitor mode selector
switch 1
q Connector L11:
Machine monitor mode selector
switch 2
3) Remove 3 bracket mounting bolts (3) of
a Pull the switch out of the cover and
machine monitor (2) and reverse the
disconnect each connector.
machine monitor.
a If you insert your hands from under
a Take care not to pull the wiring har-
the cover and disconnect a connector
ness forcibly.
forcibly, you many damage the con-
nector or switch. Take care.
WA150-6 30-102 43
SEN05125-00 Preparation work for troubleshooting for electric system
4) Connect diagnosis T-adapters to connec- 3. KOMTRAX terminal (If equipped)

tors L24 to L30 of machine monitor (2). 1) Open right door (1) and remove console
cover (2).
2. HST controller
1) Remove cover (1) from the rear of the cab. 2) Connect diagnosis T-adapter to connec-
tor L80 of KOMTRAX terminal (3).
a If the connector cannot be discon-
nected and connected easily, remove
the KOMTRAX terminal.
a Since the connector is secured with
screws, loosen those screws before
disconnecting.
a When connecting the connector again,
tighten its screws to the specified
torque.
3 Screw:
2.2 – 2.8 Nm {0.23 – 0.29 kgm}
2) Connect diagnosis T-adapters to HST

connector of HST controller (2).
30-102 44 WA150-6
Preparation work for troubleshooting for electric system SEN05125-00
4. Boost pressure and temperature sensor 6. Common rail pressure sensor (FUEL RAIL
(BOOST PRESS & IMT) PRESS)
a Disconnection and connection of connector a Disconnection and connection of connector
The connector of the boost pressure and The connector of the common rail pres-
temperature sensor has a special locking sure sensor has a special locking mecha-
mechanism. Disconnect it according to nism. Disconnect it according to steps (a)
steps (a) – (b) and connect it according to – (b) and connect it according to steps (c)
steps (c) – (d) as shown below. – (d) as shown below.
Disconnection: Disconnection:
(a) Unlock – (b) Disconnect connector. (a) Unlock – (b) Disconnect connector.
Connection: Connection:
(c) Connect connector – (d) Lock. (c) Connect connector – (d) Lock.
a Removal and installation of sensor a Precautions for disconnecting connector

A torque wrench is necessary for removal The direction of the lock of the connector
and installation of the boost pressure and varies with the tightened position of the
temperature sensor. See Testing adjust- sensor and the lock may be in a direction
ing, “Troubleshooting tools table”. in which it is difficult to reset (on the under-
side or engine side).
5. Supply pump IMV solenoid (FUEL REGU- In this case, pinch the lock in direction (a)
LATOR) with bent-nose nippers (commercially
a Disconnection and connection of connector available), and the lock is reset.
The connector of the supply pump IMV Since the lock clicks when it is reset, dis-
solenoid has a special locking mecha- connect the connector after a click is
nism. Disconnect it according to steps (a) heard.
– (b) and connect it according to steps (c)
– (d) as shown below.
Disconnection:
(a) Unlock – (b) Disconnect connector.
Connection:
(c) Connect connector – (d) Lock.
WA150-6 30-102 45
SEN05125-00 Preparation work for troubleshooting for electric system
a Precautions for connecting connector 8. Ambient pressure sensor (AMBAIR PRES-

Take care not to connect the connector SURE)
reversely. Engine Ne speed sensor (CRANK SENSOR)
Engage lock (e) on the wiring harness Engine Bkup speed sensor (CAM SENSOR)
side with triangular notch (f) on the sensor Engine oil pressure switch (OIL PRESSURE
side (Do not engage lock (e) with square SWITCH)
guide (g) on the opposite side of triangular a Disconnection and connection of connectors
notch (f)). The connectors of the ambient pressure
sensor, engine Ne speed sensor, engine
Bkup speed sensor, and engine oil pres-
sure switch have a special locking mecha-
nism. Disconnect them according to steps
(a) – (c) and connect them according to
steps (d) – (f) as shown below.
Disconnection: (a) Slide lever – (b) Unlock –
(c) Disconnect connector.
Connection: (d) Connect connector – (e)
Lock – (f) Slide lever.
7. Engine coolant temperature sensor (COOL-

ANT TEMP)
a Disconnection and connection of connector
The connector of the engine coolant tem-
perature sensor has a special locking
mechanism. Disconnect it according to
steps (a) – (b) and connect it according to
steps (c) – (d) as shown below.
Disconnection:
(a) Unlock – (b) Disconnect connector.
Connection: a Removal and installation of sensor
(c) Connect connector – (d) Lock. A deep socket is necessary for removal
and installation of the engine oil pressure
switch. See Testing adjusting, “Trouble-
shooting tools table”.
a Removal and installation of sensor

A deep socket is necessary for removal
and installation of the engine coolant tem-
perature sensor. See Testing and adjust-
ing, “Troubleshooting tools table”.
30-102 46 WA150-6
Starting KOMTRAX terminal operations SEN05125-00
Starting KOMTRAX terminal 3) When about 5 seconds elapsed after the

operations 1
starting switch was set to ACC, make sure
that the 7-segment indicator lamp
a This contents applies only the "KOMTRAX (If changes to hyphen “–” on the KOMTRAX
equipped)" installation specification model. terminal.
In the case where the KOMTRAX terminal has

already been installed at the plant before ship-
ment:
a Implement the following procedure in the case
where the KOMTRAX terminal has already
been installed at the plant before shipment (as
standard equipment).
1. Notification of model, part number and

serial number
Notify the KOMTRAX operations administrator
of model, part number and serial number.
2. Registration of machine
The KOMTRAX operations administrator shall
use a KOMTRAX client PC to register the
machine.
a Refer to “Manual for KOMTRAX opera-
tions administrator” for the procedure.
a Now the terminal is ready for use.
In the case where the KOMTRAX terminal is ret-

rofitted:
a When retrofitting the KOMTRAX terminal after
shipment (retro-fitted machine), follow the
steps below.
1. Station opening check in machine side

a Complete steps 3) to 5) within 60 sec- 4) Disconnect check connector 1, and wait
onds. If 60 seconds or above elapsed, for about 5 seconds as it is.
begin with step 1) again. a Ensure that the connector is discon-
1) Turn OFF the starting switch and then, nected.
a ft e r m a k i n g s u r e 5 s e c o n d s h a v e 5) Reconnect check connector 1, and wait
elapsed, proceed to the next step. for about 5 seconds as it is.
2) Visually check that two check connectors a If the KOMTRAX terminal detects that
are connected. the connector was disconnected and
q Check connector 1: CHK0 connected, the dot on the 7-segment
q Check connector 2: CHK1 indicator lamp blinks a few times.
WA150-6 30-102 47
SEN05125-00 Starting KOMTRAX terminal operations
6) Make sure that the 7-segment indicator a As [Normal] is indicated, proceed to

lamp is indicated normally on the the next step.
KOMTRAX terminal. a If “–” remains displayed, execute
a If so, the 7-segment indicator lamp will steps 1) to 5) again.
indicate characters “d”, “0”, and “–”
repeatedly for 30 seconds after step 5)
was ended.
a Those characters, even if displayed
normally, will change to a character
other than hyphen “–”after 30 sec-
onds or above elapsed.
The display may change to a charac-
ter other than “0” even within 30 sec-
onds.
7) Turn the starting switch to START position

for about 5 seconds, and make sure that
the engine does not start.
a If the engine starts, re-execute the
procedure above from step 1).
a Do not return the starting switch to
OFF position.
8) Turn the starting switch from ACC position
to START position again, and make sure
that the engine starts.
9) Make sure that the KOMTRAX terminal's
indicator lamps are normally turned on.
a Move on to the next step if you can
check that the display is [Normal]. (It
takes from 90 seconds to 15 minutes
before the display turns normal.)
a If [GPS position data detection trou-
ble] is indicated, check if there is any
abnormality on the GPS antenna or
cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [Reception trouble] is indicated,
check if there is any abnormality on
the appearance of the communication
antenna or cable. If there is any
abnormality, repair it then repeat from
procedure 1) again.
a If [GPS position data detection trouble
and reception trouble] is indicated,
check if there is any abnormality on
the GPS antenna/cable or communi-
cation antenna/cable. If there is any
abnormality, repair it and start from
procedure 1) again.
30-102 48 WA150-6
Starting KOMTRAX terminal operations SEN05125-00
a If [Network trouble] is indicated, 10) Turn the starting switch OFF.

check the display of [LED-C4] refer- 11) Make sure that the 7-segment indicator
ring to “Lamp display of KOMTRAX lamp is displayed normally after 5 seconds
terminal”. If the CAN is not recog- elapsed.
nized, check the CAN harness of the a When [Normal] appears, station
KOMTRAX terminal, and then if there opening check is completed.
is any abnormality, repair it and start a If [Abnormal] appears, station open-
from procedure 1) again. ing check does not end normally, so
[A]: Normal you should perform the procedure
[B]: GPS position data detection trou- above from step 1) again.
ble a If station opening check ends nor-
[C]: Reception trouble mally, it should not be rechecked.
[D]: GPS position data detection trou-
ble and reception trouble
[E]: Network trouble
12) When station opening check ended nor-

m a l l y, a c o m m u n i c a t i o n w i t h t h e
KOMTRAX server starts automatically,
and settings are stored in KOMTRAX.
(This requires about 25 minutes to 4
hours.)
a During this time, you may turn the
s tarti ng swi tch off and star t th e
engine.
a During the communication and check
above, you should park the machine
outside to enable a frequent commu-
nication with the ORBCOMM satellite.
The station opening check may not
be completed in doors that cause
radio waves from the satellite to be
intercepted.
WA150-6 30-102 49
SEN05125-00 Starting KOMTRAX terminal operations
2. Application for the start of use

a Application for the start of use should be
made only after the inspection is finished.
1) Notify the KOMTRAX operations adminis-
trator of the following information about
the machine that completed the station
opening check in the machine side.
1] Information (model, part number, and
serial number) about the machine
that completed the station opening
check in the machine side
2] Part number and serial number of
KOMTRAX terminal
3] Value of service meter when the
KOMTRAX terminal was installed (in
0.1 hours)
2) The KOMTRAX operations administrator

shall use a KOMTRAX client PC to regis-
ter the machine.
a Refer to “Manual for KOMTRAX oper-
ations administrator” for the proce-
dure.
a Now the terminal is ready for use.
30-102 50 WA150-6
Indicator lamps of KOMTRAX terminal SEN05125-00
Indicator lamps of KOMTRAX terminal 1
a This contents applies only the "KOMTRAX (If equipped)" installation specification model.
LED lamps for CPU 7-segment and dot displays for CPU
1. LED-C1 (State of R or ACC signal) 7. 7 segments (Number of unsent mails)
2. LED-C2 (Starting output state) 8. Dot (GPS positioning state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download write state)
WA150-6 30-102 51
SEN05125-00 Indicator lamps of KOMTRAX terminal
In the KOMTRAX system, various information and processing details are displayed on the LED on the upper
surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Before using the KOMTRAX system, make sure that the application for starting its use is completed as well
as the station opening check in the machine side.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable should not be broken and normally be connected to the KOMTRAX
terminal.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
Check of terminal LED displays

1. Meaning of CPU LED displays
a The LED displays should be checked with the starting switch ON, starting switch START, or with the
engine started.
Display
No. LED Name/function Description
(*1)
ON Starting switch ACC signal: ON, Alternator R signal: ON
States of starting switch Fast blink Starting switch ACC signal: OFF, Alternator R signal: ON
1 LED-C1 ACC signal and alternator R
signal Slow blink Starting switch ACC signal: ON, Alternator R signal: OFF
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF
ON Engine control signal: ON
2 LED-C2 State of engine control signal
OFF Engine control signal: OFF
ON S-NET: Connected, Starting switch C signal: OFF
States of S-NET connection Fast blink Starting switch C signal: ON
3 LED-C3
and starting switch C signal Slow blink (Not used)
OFF S-NET: Not connected, Starting switch C signal: OFF
ON CAN: Connected (without fuel sensor)
Fast blink CAN: Connected (with fuel sensor)
4 LED-C4 State of CAN connection
Slow blink CAN: Not connected (with fuel sensor)
OFF CAN: Not connected (without fuel sensor)
5 LED-C5 1-LED ON Download write mode (system administrator only function)

Download write state
2-LED
6 LED-C6 Normal operation mode
OFF
*1: Blink types and blink times

Fast blink: Blinks in about 1-second cycle
Slow blink: Blinks in about 4-second cycle
30-102 52 WA150-6
Indicator lamps of KOMTRAX terminal SEN05125-00
2. Contents of 7-segment and dot displays for CPU

a The LED display should be checked with the starting switch turned ON.
Display
No. LED Name/function Description
(*2)
The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by “9”.) Light-on indicates that the
Number of unsent displayed
machine is in process of capturing the satellite.
7 7 segments mails, satellite
capture state The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by “9”.) Fast blink indicates that the
fast blink
satellite is not captured.
GPS positioning was completed. (The position can be con-
ON
GPS positioning firmed. *3)
8 Dot
status GPS positioning was not completed. (The position cannot be
OFF
confirmed. *3)
*2: Blink types and blink times

Fast blink: Blinks in about 0.5-second cycle
Slow blink: Blinks in about 2.0-second cycle
*3: Supplementary explanation of GPS positioning status
One or more minute may be taken until GPS positioning is completed after the starting switch was
turned ON even in an outdoor service area.
GPS positioning will fail in a weak signal or non-service area.
WA150-6 30-102 53
SEN05125-00

©2009 KOMATSU
All Rights Reserved
30-102 54
SEN05126-02
WHEEL LOADER
WA150-6

WA150-6 80001 and up

Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor.............................. 2
Special functions of machine monitor (EMMS) ............................................................................................... 4
Pm clinic inspection chart ............................................................................................................................. 58
WA150-6 30-103 1
SEN05126-02 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
Adjusting replaced, reassembled or added sensor, controller, etc. with

machine monitor 1
1. Items to be set when sensor or controller is replaced, reassembled or added

a If any of the following components and parts is replaced or reassembled, initialize the sensors,
solenoids, etc. with the machine monitor.
a Adjust the items in alphabetical order (A –) with the machine monitor.
Replaced, reassembled, or added component or option Adjustment item
Machine monitor A, B, C
HST controller A, B
Change of tire size B
Addition or removal of option B
Adjustment item Contents of adjustment Description No.

A Selection of machine model 12 (*1)
B Selection of option 10 (*1)
C Inputting of machine serial No. 11 (*1)
*1: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)”
30-103 2 WA150-6
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor SEN05126-02
2. Adjustment for user's needs

If the user makes the following indications or requests, change or adjust the items shown below with the
machine monitor.
Contents of indication/request Adjustment item
Change indication unit of speedometer (*2) D
Turn ECO lamp OFF E
Change interval of fan automatic reverse operation (Automatic reverse fan specification) F
Change continuance of fan automatic reverse operation (Automatic reverse fan specification) G
Travel speed is indicated too quickly/slowly H
Turn engine speed/travel speed on character display OFF J
ECSS operates at high or low travel speed K
Change display of major indication in engine speed (*3) L
Adjustment item Contents of change/adjustment Description No. (*1)

D Setting of option/Selection of speed unit (*2) 10
E Setting of option/Selection of indication of ECO lamp 10
Adjustment of sensor/Adjustment of interval of fan automatic
F 7–1
reverse operation
Adjustment of sensor/Adjustment of continuance of fan automatic
G 7–2
reverse operation
H Setting of option/Change of tire size 10
Setting of option/Change of indication of engine speed or travel
J 10
speed on normal screen of character display
M Adjustment of ECSS operation travel speed 7–5
No. 10 of
L Travel speed/engine speed display/non-display select
"Operator mode"
*1: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)”
*2: Change of the indication unit of the speedometer of the specification for the SI unit countries cannot be
set.
*3: When selecting “NO ADD” in optional select, cannot change travel speed/engine speed.
WA150-6 30-103 3
SEN05126-02 Special functions of machine monitor (EMMS)
Special functions of machine monitor (EMMS) 1
a EMMS: Equipment Management Monitoring System
1. Machine monitor mode change switch 1

2. Machine monitor mode change switch 2
3. Character display
30-103 4 WA150-6
Special functions of machine monitor (EMMS) SEN05126-02
Normal functions and special functions of machine monitor

The machine monitor is equipped with the normal functions and special functions. Various items of data are
displayed on the character display in the middle of the machine monitor.
Depending on the internal setting of the machine monitor, the display items are divided into automatic dis-
play items and items displayed when the machine 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.
a See the Operation and maintenance manual for details of the operator mode.
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.
No. No.
Operator mode Service mode
(*1) (*1)
1 Service meter display function 2 Electrical system fault history display function
2 Traction level selection function 3 Mechanical system fault history display function
3 HST function selection function 4 Real-time monitoring function
4 Odometer display function 5 Engine cylinder cut-out function
5 Maintenance monitoring function 6 No injection cranking function
6 Telephone number input function 7 Adjustment function
⇔
7 Language selection function 8 Maintenance monitoring function
8 Monitor brightness adjustment function 9 Operating information display function
Travel speed/engine speed display selecting
9 10 Optional device selecting function
function (*2)
Function of turning ON/OFF travel speed/
10 11 Machine serial number input function
engine speed display on character display (*3)
11 Action code display function 12 Model selection function
12 Failure code display function 13 Initialize function
*1: No. shows an item number in this document.

*2: q Not displayed if “SI unit specification” is set when delivered.
q Not displayed if “RPM OPT” is turned NO ADD by selecting an optional device in the service mode.
*3: Not displayed if “Travel speed/Engine speed on character display” is turned NO ADD by selecting an optional device
in the service mode.
WA150-6 30-103 5
Functions and flow of service mode

Note: Some items may not be used, depending on the setting and specification, although they are displayed
on the monitor. (For details, see the text.)
30-103 6 WA150-6
WA150-6 30-103 7
30-103 8 WA150-6
Operator mode 3. HST function selection function

a The operator mode is outlined below. While the speed range selector switch is in the
a For details of the operator mode, see “Struc- 3rd or 4th gear speed position, the reverse
ture, function and maintenance standard” or speed range can be set to 2 levels.
“Operation and Maintenance Manual”. a For details, see Operation and Mainte-
nance Manual, Operation, “Other func-
1. Service meter display function tions of machine monitor”.
If the starting switch is turned ON, the service
meter is displayed on the above line and the
engine speed is displayed on the lower line.
a If the engine speed is displayed at the
center of the monitor, the travel speed is
displayed.
4. Odometer display function

The odometer is displayed.
a For details, see Operation and Mainte-
tions of machine monitor”.
2. Traction level selection function

Press [U] switch on the ordinary service meter
display screen, and the screen to set the trac-
tion level selection function is displayed.
a If the traction control is turned ON with the
traction control switch, the traction can be
set to 3 levels.
a For details, see Operation and Mainte-
tions of machine monitor”.
a For items 3 and after, display a desired

screen with [<] or [>] switch on the “Trac-
tion level selection function” screen.
a Each time [<] or [>] switch is pressed, the
screen changes in order. Repeat either
switch until a desired screen is displayed.
WA150-6 30-103 9
5. Maintenance monitoring function 7. Language selection function

1) Filter, oil replacement time display (auto- Switch operation allows selecting a display lan-
matic display) guage of the machine monitor.
As the filter or oil replacement time draws a Functions of the service mode are con-
close, the machine monitor automatically stantly displayed in English since they are
displays its information to alert operator's exempted from the display selection func-
attention. tion.
2) Resetting replacement time (selection a A desired language is selectable from
menu) English, Japanese, German, French, Ital-
As maintenance operation for a filter or oil ian, Spanish and Swedish.
is completed, the machine monitor allows a For details, see the “Other functions of
resetting the time interval through the machine monitor” of the Operation section
switch operation. in the Operation and maintenance man-
a For details, see the “Other functions ual.
of machine monitor” of the “Opera-
tion” section in the Operation and
maintenance manual.
6. Telephone number input function

Telephone numbers are entered through the
switch operation. And modification or cancella-
tion of the phone numbers in the machine
monitor is also available through the switch
operation.
a When action code [E03] is displayed, a
phone number is displayed along with
[CALL].
a For details, see the “Other functions of
machine monitor” of the Operation section
in the Operation and maintenance man-
ual.
30-103 10 WA150-6
8. Monitor brightness adjustment function 9. Travel speed/engine speed display select-

Brightness of the machine monitor is adjustable ing function
in seven levels through the switch operation. A unit to be used for the machine monitor
a Adjustment of brightness is available in speed display is selectable from km/h and
two approaches – adjustment of the moni- MPH. It is also possible to turn on or off the dis-
tor alone and separate adjustment of the play of the travel speed and engine speed.
monitor and liquid crystal. a For details, see the “Other functions of
a For details, see the “Other functions of machine monitor” of the Operation section
machine monitor” of the Operation section in the Operation and maintenance man-
in the Operation and maintenance manual. ual.
10. Travel speed/engine speed display/non-dis-

play selecting function
A unit for the machine monitor speed display is
selectable from km/h and MPH. It is also possi-
ble to turn on or off display of the travel speed
and engine speed.
a For details, see the “Other functions of
machine monitor” of the Operation section
in the Operation and maintenance man-
ual.
WA150-6 30-103 11
11. Action code display function

If a trouble occurs, the machine monitor dis-
plays an action code corresponding to the seri-
ousness of the trouble to alert the operator for
appropriate actions.
a The figure below shows an example of the
screen on which action code [E03] and
[CALL + Telephone number] are alter-
nately displayed.
a When action code [E01] or [E02] is dis-
played, [CALL + Telephone number] is not
displayed.
a Action codes and actions alerted to operator

CALL + Tele-
Action code Actions recommended to operator
phone number
• Do necessary testing and/or servicing as the current work is over or at
E01 Not displayed
shift of the operator.
• When an overrun-related item is displayed:
Slow down the engine or machine speed.
E02 Not displayed
• When an overheat-related item is displayed:
Stop the machine and run the engine at mid speed with no load.
E03 Displayed • Stop the engine and machine immediately and contact a serviceman.
30-103 12 WA150-6
12. Failure code display function a The service code display function displays
Pressing [>] switch once while an action is dis- the following information.
played on the machine monitor displays the A: Failure code
failure code corresponding to the failure cur- B: Controller code
rently warned. MON: Machine monitor
a The failure codes detected in the past are HST: HST controller
divided into failures of the electrical sys- ENG: Engine controller
tem and the mechanical system and are C: The system where failure occurred
recorded as fault history. (For details, see
“Service mode”.)
a When two or more failures are involved,
pressing [>] switch displays further codes.
a If [>] switch is pressed again after it was
pressed to display every involved failure
code, the service meter display screen will
be restored.
Pressing [>] switch one more time dis-
plays the failure codes from the first.
If [>] switch is not touched for 30 seconds,
the action code display screen is automat-
ically displayed.
a For details of a displayed failure code, see

“Failure code list”.
a If any switch operation is not done for 30
seconds or more on the failure code dis-
play screen, the action code display
screen is automatically turned on.
WA150-6 30-103 13
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
Reference: The service meter is displayed in mode).
English, regardless of language When the cursor is at a location other
selection in the operator mode. than the leftmost position, pressing
When using Service mode, carry out the fol- the switch returns the cursor to the
lowing special operation to switch the screen leftmost position.
display. If any switch operation is not done for
1-1. Checking screen display 60 seconds or more from ID input
Make sure that the machine monitor is set to screen, the normal screen is automat-
the operator mode and any of “Service meter”, ically turned on.
“Action code” or “Failure code” is displayed on
the screen.
1-2. Displaying ID input initial screen
Hold down [t] switch and [<] switch simulta-
neously 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).
30-103 14 WA150-6
1-5. Selecting service mode menu 1-6. Completion of mode and function
a Pressing [<] and [>] switches from the Either of the following procedures ends a
menu screen displays Service mode mode or function independent of the function
menus endlessly in the following order. being selected and the layer in which it is used.
a The menus are displayed in the field indi- 1) When the operation is to be continued
cated with [*] mark. using another mode or function: Press [t]
[1] ELECTRIC FAULT: Electrical system switch to return to the mode screen or
fault history display function menu screen to be used next.
[2] MACHINE FAULT: Mechanical sys- a Note, however, that [t] switch functions
tem fault history display function as an execution key on [YES/NO] screen.
[3] REAL-TIME MONITOR: Real-time a When the normal screen (Operator mode)
monitoring function was inadvertently turned on, repeat above
[4] CYLINDER CUT-OUT: Engine steps from 1) (input of the ID is not neces-
reduced-cylinder function sary).
[5] NO INJECTION: No injection crank- 2) When ending an operation completely:
ing function Turn the starting switch off from the cur-
[6] TUNING: Adjustment function rent state.
[7] MAINTENANCE MONITOR: Mainte-
nance monitoring function
[8] OPERATION INFO: Operating infor-
mation display function
[9] OPTIONAL SELECT: Optional device
selecting function
[10] MACHINE No. SET: Machine serial
number input function
[11] MACHINE: Model selection function
[12] INITIALIZE: Initialize function (Func-
tion specialized for plant)
a The menu is indicated in the parts of [*].
WA150-6 30-103 15
2. Electrical system fault history display func- 2-3. Displayed fault history
tion (ELECTRIC FAULT) The electric system fault history display func-
The machine monitor records the past failures tion displays the following information.
in the electric system as the failure codes. The A: Record number
failure codes are displayed from the following B: Failure code (Location code in four digits +
operations. Problem code in two digits)
2-1. Selecting the menu C: Number of occurrences (number of occur-
Select the ELECTRIC FAULT from the menu rences of same code in past)
screen of Service mode. D: Elapsed time 1 (time elapsed on service
a [**] field displays total number of the fault meter since first occurrence)
history currently recorded (up to 20 E: Elapsed time 2 (time elapsed on service
cases). meter since 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 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.
2-2. Displaying fault history

Press [U] button while the menu is selected to
display the recorded fault history.
30-103 16 WA150-6
2-4. Switching fault history display 2-6. Deleting all fault history
Pressing [<] or [>] switch while a set of fault 1) Press [<] or [>] switch while the fault his-
history is on the screen displays another set of tory is on the screen to display the ALL
recorded fault history. CLEAR menu screen.
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) Select “YES” or “NO” using [<] or [>] switch.
a The selected cursor will start flashing. If
“YES” is selected a nd [t] switch is
pressed, the information will be deleted. If
“NO” is selected and [t] switch is
pressed, deletion is cancelled and the
“Maintenance interval change item”
screen is restored.
a By default, the cursor is set to NO (cancel)
to prevent resetting error.
a Information of the currently occurring fail- 2) Press [U] switch to display the ALL
ure is not deletable. CLEAR screen.
3) Select “YES” or “NO” using [<] or [>]
switch.
“YES” is selected and [t] switch is
“Maintenance interval change item”
screen is restored.
a Information of the currently occurring fail-
ure is not deletable.
WA150-6 30-103 17
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: Occurrence time 1 (Time on service meter
history currently recorded. at the first occurrence)
E: Occurrence time 2 (Time on service meter
at the last occurrence)
a The code of a failure currently occurring is
indicated in flashing.
“Failure code list” of next page.
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.
30-103 18 WA150-6
Failure codes table

Failure Action Category of
Troubled part/item Trouble Controller
code code record
Mechanical
2G40ZG Brake Oil pressure reduction MON E03
system
Mechanical
6091NX HST filter Clogging MON E01
system
Mechanical
989FN1 Travel speed Overrun alarm MON E02
system
Electrical
AB00L6 Alternator R system Hot short MON E01
system
Ground fault/Disconnection/Low Electrical
AB00MA Alternator R system MON E03
charge level system
Mechanical
B@BAZG Engine Oil pressure reduction ENG E03
system
Mechanical
B@BCNS Engine Overheat ENG E02
system
Mechanical
B@BCZK Engine Low coolant level MON E01
system
Mechanical
B@C6NS Front brake High oil temperature MON E02
system
Mechanical
B@CRNS HST High oil temperature MON E02
system
Electrical
CA111 Engine controller Internal abnormality ENG E03
system
Electrical
CA115 Engine NE, Bkup speed sensor Abnormality ENG E03
system
Electrical
CA122 Charge pressure sensor Abnormally high level ENG E03
system
Electrical
CA123 Charge pressure sensor Abnormally low level ENG E03
system
Electrical
CA131 Throttle sensor Abnormally high level ENG E03
system
Electrical
CA132 Throttle sensor Abnormally low level ENG E03
system
Electrical
CA144 Coolant temperature sensor Abnormally high level ENG E01
system
Electrical
CA145 Coolant temperature sensor Abnormally low level ENG E01
system
Electrical
CA153 Charge temperature sensor Abnormally high level ENG E01
system
Electrical
CA154 Charge temperature sensor Abnormally low level ENG E01
system
Electrical
CA187 Sensor power supply 2 Abnormally low level ENG E03
system
Electrical
CA221 Ambient pressure sensor Abnormally high level ENG E01
system
Electrical
CA222 Ambient pressure sensor Abnormally low level ENG E01
system
Electrical
CA227 Sensor power supply 2 Abnormally high level ENG E03
system
Mechanical
CA234 Engine Overspeed ENG E02
system
WA150-6 30-103 19

code code record
Electrical
CA238 Ne speed sensor power supply Abnormality ENG E03
system
Electrical
CA271 IMV (IMA) Short circuit ENG E03
system
Electrical
CA272 IMV (IMA) Disconnection ENG E03
system
Electrical
CA322 Injector #1 system Disconnection/Short circuit ENG E03
system
Electrical
system
Electrical
system
Electrical
system
Electrical
CA351 Injector drive circuit Abnormality ENG E03
system
Electrical
system
Electrical
system
Electrical
CA431 Idle validation switch Abnormality ENG E01
system
Electrical
CA432 Idle validation switch Abnormal remedy ENG E03
system
Electrical
CA435 Engine oil pressure switch Abnormality ENG E01
system
Electrical
CA441 Power supply voltage Abnormally low level ENG E03
system
Electrical
CA442 Power supply voltage Abnormally high level ENG E03
system
Electrical
CA449 Common rail pressure Abnormally high pressure 2 ENG E03
system
Electrical
CA451 Common rail pressure sensor Abnormally high level ENG E03
system
Electrical
CA452 Common rail pressure sensor Abnormally low level ENG E03
system
Electrical
CA553 Common rail pressure Abnormally high pressure 1 ENG E03
system
Electrical
CA559 Supply pump Low rail pressure 1 ENG E03
system
Electrical
CA689 Engine Ne speed sensor Abnormality ENG E03
system
Electrical
CA731 Engine Bkup speed sensor Abnormal phase ENG E03
system
Electrical
CA757 Engine controller Loss of all data ENG E03
system
Electrical
CA778 Engine Bkup speed sensor Abnormality ENG E03
system
Electrical
CA1633 KOMNET Abnormality ENG E03
system
Electrical
CA2185 Throttle sensor power supply Abnormally high level ENG E03
system
30-103 20 WA150-6

code code record
Electrical
CA2186 Throttle sensor power supply Abnormally low level ENG E03
system
Electrical
system
Electrical
CA2311 IMV (IMA) solenoid Abnormality ENG E03
system
Electrical
CA2555 Intake air heater relay Disconnection ENG E01
system
Electrical
CA2556 Intake air heater relay Short circuit ENG E01
system
Electrical
D160KY Backup lamp/buzzer relay Hot short MON E01
system
Electrical
D192KY ECSS solenoid relay Hot short MON E01
system
Electrical
D1B0KA HST safety relay Disconnection HST E03
system
Electrical
D1B0KB HST safety relay Ground fault HST E01
system
Electrical
D1B0KY HST safety relay Hot short HST E03
system
Electrical
D5ZHL6 IGN C system Ground fault/Disconnection MON E01
system
Electrical
DAF3KK UNSW power supply Ground fault/Disconnection MON E01
system
Electrical
DAFRKR Monitor panel CAN-NET signal Disconnection HST E03
system
Electrical
DAJ0KK HST controller power supply Low voltage HST E03
system
HST controller memory Electrical
DAJ0KT Abnormality HST E01
(EEPROM) system
HST controller main power Electrical
DAJ1L4 Disconnection/Ground fault HST E01
supply line system
DAJ1L6 Hot short HST E01
supply line system
Electrical
DAJ2KK Controller solenoid power supply Low voltage HST E03
system
HST controller load power supply Electrical
holding line system
HST controller load power supply Electrical
DAJ2L4 Disconnection/Ground fault HST E01
holding line system
Electrical
DAJ5KX Sensor 5V power supply Out of input range HST E03
system
(DAJ9KQ) HST controller Disagreement in model selection MON E03 —
Electrical
DAJRKR HST controller CAN-NET Disconnection in signal line MON E03
system
(DAJRMA) HST controller Disagreement in option selection MON E03 —
Electrical
DB2RKR Engine controller CAN-NET Disconnection in signal line HST E03
system
Electrical
DD1NL4 Fan auto reverse switch signal Abnormality HST E01
system
WA150-6 30-103 21

code code record
Electrical
DD1NLD Fan reverse switch signal Abnormality HST E01
system
Electrical
DDB6KA Parking brake reminder signal Disconnection/Hot short HST E01
system
Electrical
DDB6KB Parking brake indicator signal Ground fault HST E01
system
Parking brake indicator signal or Electrical
DDB6KZ Trouble MON E03
parking brake reminder signal system
Electrical
DDB6L0 Parking brake reminder signal Ground fault HST E01
system
Electrical
DDB6L4 Parking brake indicator signal Disconnection/Hot short HST E03
system
Electrical
DDD7KX Travel speed control dial Disconnection/Ground fault HST E01
system
Electrical
DDD7KY Travel speed control dial Hot short HST E01
system
Electrical
DDK6KA FNR lever Disconnection/Ground fault HST E03
system
Electrical
DDK6KY FNR lever Hot short HST E03
system
Travel speed range selector Electrical
DF10KA Disconnection/Ground fault HST E01
switch system
Travel speed range selector Electrical
DF10KB Hot short HST E01
switch system
Electrical
DGH1KX HST oil temperature sensor Ground fault MON E01
system
Electrical
DGR2KB Brake oil temperature sensor Ground fault MON E01
system
Electrical
DGR2KZ Brake oil temperature sensor Disconnection/Hot short MON E01
system
Electrical
DHH1KX HST oil pressure sensor Disconnection/Ground fault HST E03
system
Electrical
DHH1KY HST oil pressure sensor Hot short HST E03
system
Electrical
DHTCL6 HST filter clogging sensor Functional defect MON E01
system
Electrical
DJF1KA Fuel level sensor Disconnection/Hot short MON E01
system
Electrical
DLT3KX Travel speed sensor B Abnormality HST E03
system
Electrical
DLT4KX Travel speed sensor A Abnormality HST E03
system
Electrical
DLT4LC Travel speed sensor A & B Abnormality HST E03
system
Electrical
DV00KY Alarm buzzer Hot short MON E01
system
Electrical
DW26KA Motor 2 solenoid Disconnection/Ground fault HST E01
system
Electrical
DW26KY Motor 2 solenoid Hot short HST E01
system
Electrical
DW7BKY Fan reverse solenoid circuit Hot short HST E01
system
30-103 22 WA150-6

code code record
Electrical
DW7BKZ Fan reverse solenoid circuit Disconnection/Ground fault HST E01
system
Electrical
DX16KA Fan EPC solenoid Disconnection HST E01
system
Electrical
DX16KB Fan EPC solenoid Ground fault HST E01
system
Electrical
DX16KY Fan EPC solenoid Hot short HST E01
system
Electrical
DX19KA Motor 1 solenoid Disconnection HST E03
system
Electrical
DX19KB Motor 1 solenoid Ground fault HST E03
system
Electrical
DX19KY Motor 1 solenoid Hot short HST E03
system
Electrical
DX20KA Clutch EPC solenoid Disconnection HST E03
system
Electrical
DX20KB Clutch EPC solenoid Ground fault HST E03
system
Electrical
DX20KY Clutch EPC solenoid Hot short HST E03
system
Electrical
DXH7KB Reverse solenoid Ground fault HST E03
system
Electrical
DXH7KZ Reverse solenoid Disconnection/Hot short HST E03
system
Electrical
DXH8KB Forward solenoid Ground fault HST E03
system
Electrical
DXH8KZ Forward solenoid Disconnection/Hot short HST E03
system
Mechanical
J141N1 Steering pump Overrun alarm HST E02
system
Mechanical
M100N1 HST pump Overrun alarm HST E02
system
Mechanical
M400N1 Motor 1 Overrun alarm HST E02
system
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable controller:
Applicable controller indicates in which controller system the failure has occurred.
MON : machine monitor system
ENG : Engine controller system
HST : HST controller system
a Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
a Note: Optional equipments are also included in the table.
WA150-6 30-103 23
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] HST: HST controller system
(for each controller) [3] ENGINE: Engine controller system
q 2 items simultaneous display [4] 2 ITEMS: 2 items display
(code input)
4-1. Selecting the menu
Select REAL-TIME MONITORING from the
menu screen of Service mode.
4-4. Setting the 1 item individual monitoring

1) Select the target controller system of mon-
itoring from the sub menu screen.
4-2. Displaying sub menu

Press [U] switch while the menu is selected to
display the sub menu initial screen.
2) Press [U] switch while the sub menu is

selected to display the MONITOR PANEL
screen.
30-103 24 WA150-6
3) Press [<] or [>] switch to select a monitor- 4-5. Setting 2 items simultaneous monitoring
ing item. 1) Select 2 ITEMS from the sub menu
a The monitoring items are scrolled accord- screen.
ing to the internally set order. 2) Press [U] switch while the sub menu is
a Holding down [U] switch turns on high- selected to display the monitoring code
speed scrolling. input screen.
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
4) Display data for 1 item individual monitor- value.
ing a The cursor moves to the 2nd position.
The 1 item individual monitoring screen 3] Set the value in the same order and
displays the following information. then press [U] switch.
A: Item display a When you have entered a wrong
B: Monitoring codes (5 digits) value to a position except the highest-
1: Monitoring data order digit, the cursor can move to the
(including the unit used) highest-order digit using [t] switch
a See the “Real-time monitoring code and repeat the procedure from the
list” for details. 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.
WA150-6 30-103 25
3) As both monitoring codes are settled, the

2 ITEMS screen will be turned on.
a Holding and cancelling the monitoring
data:
Pressing [U] switch while the monitoring
is in progress holds the monitoring data
and [U] mark starts flashing.Pressing [U]
switch again restores the active state.
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
used)
B: Monitoring code 2
2: Monitoring data 2 (including the unit
used)
a See the “Real-time monitoring code list”
for details.
30-103 26 WA150-6
WA150-6 30-103 27
Real-time monitoring codes table

a Use this page in next page and a spread.
MONITOR PANEL [Machine monitor system]
Monitoring item Displayed item Data display range

No. Monitoring code
(*1) (*2) (*3)
1 20200 Monitor software No. VERSION Alphanumerals
2 20221 Application version No. VERSION (APP) Numerals
3 20222 Data version No. VERSION (DATA) Numerals
4 01001 Engine speed ENG SPEED 0 – 4000
5 40012 Travel speed SPEED 0.0 – 50.0
6 04202 Fuel level FUEL SENSOR 0 – 100
7 04200 Fuel level FUEL SENSOR 0.00 – 5.00
8 04103 Coolant temperature COOLANT TEMP –40 – 210
9 04408 HST oil temperature HST OIL TEMP 24 – 131
10 04409 HST oil temperature HST OIL TEMP 0.00 – 5.00
11 30201 Front brake oil temperature F BRAKE OIL 24 – 131
12 30204 Front brake oil temperature F BRAKE OIL 0.00 – 5.00
13 04302 Charge level ALTERNATOR R 0.0 – 30.0
14 40200 Small lamp voltage SMALL LAMP 0.0 – 30.0
15 06001 Boom angle BOOM ANG -----
16 06003 Boom angle BOOM ANG -----
17 40400 Boom bottom pressure BOOM BTM PRESS -----
18 40402 Boom bottom pressure BOOM BTM PRESS -----
30-103 28 WA150-6
a Use this page in front page and spread.
Unit
Contents of display in normal state Remarks
(*4)
Condition
As per software No. 3rd – 10th digits from right of part No. are displayed.
display
Condition
As per software application version No.
display
Condition
As per software data version
display
Low idle : 955 – 1,005 rpm

rpm Data are obtained from HST controller.
High idle: 2,350 – 2,450 rpm
F1/R1: 5.3 – 8.8 km/h • Shown value is max. speed in each speed range.
F2/R2: 13.0 – 17.3 km/h • Value of F1/R1 is speed when travel speed
km/h
F3/R3: 22.4 – 27.7 km/h control dial is at min. speed position.
F4/R4: 36.2 – 42.9 km/h • Value when tires of size 16.9 are installed.
0 – 100% (Depends on fuel level) %
Gauge FULL (100%, 10 z): 0.31 V

Gauge 1/2 (50%, 32.0 z): 0.87 V When sensor is disconnected or has hot-short: Gauge
Gauge 1/4 (25%, 44.5 z): 1.15 V V EMPTY
Caution (61.3 z): 1.46 V When sensor has ground fault: Gauge FULL
Gauge EMPTY (0%, 85 z): 1.82 V
Engine coolant temperature: Max. 102°C

Depends on machine condition (°C) °C
Data are obtained from engine controller.
Depends on machine condition (°C) °C Overheat: 105°C
When sensor is disconnected or has hot-short: Gauge

Gauge enters red range(105°C): 2.07 V
V MIN
(80°C): 2.91 V
When sensor has ground fault: Gauge MAX
Depends on machine condition (°C) °C
(120°C): 1.62 V
V
1(80°C): 2.91 V
Depends on machine condition (0.0 – 30 V) V
Depends on machine condition (0.0 – 30 V) V
----- deg (°)
----- V
a No use these items.
----- MPa
----- V
WA150-6 30-103 29
Monitoring item Displayed item Data display range

No. Monitoring code
(*1) (*2) (*3)
19 40500 Boom head pressure BOOM HEAD PRES -----
20 40501 Boom head pressure BOOM HEAD PRES -----
21 40600 Calibration pressure CAL PRESS -----
22 40800 Weight calculated by load meter MES LOAD -----
23 30802 Rotary switch setting condition SW1, SW2, SW3 F, F, F
24 30904 DIP switch setting condition SW5-1, SW5-2 ON/OFF, ON/OFF
28 40900 Input signal D_IN_0-7 D-IN--0------7 See separate table.
37 40925 Output signal D_OUT_0-3 D-OUT-0--3 See separate table.
*1: All items, including ones for which sensors are not installed on some models and optional components,
are displayed.
*2: Abbreviated as number of characters is limited.
*3: A number out of the display range is displayed as “-----”.
*4: If a unit is necessary, the SI unit is used.
30-103 30 WA150-6
Unit
(*4)
----- MPa
----- V
a No use these items.
----- MPa
----- t
Condition
a Do not move from initial position.
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
WA150-6 30-103 31

Monitoring Input/Output
No. Displayed item Contents of ON/OFF switch
code signal
D-IN-0 Headlamp Headlamp lighting = ON (24 V)/OFF (OPEN)
D-IN-1 Cooling fan reverse switch Switch = ON (24 V)/OFF (OPEN)
D-IN-2 Starting switch C Starting motor operation = ON (24 V)/OFF (OPEN)
D-IN-3 — —
1 40900
D-IN-4 — —
D-IN-5 — —
D-IN-6 — —
D-IN-7 — —
ECSS switch
D-IN-8 ECSS switch = ON (24 V)/OFF (OPEN)
(Machine with optional ECSS spec.)
Cooling fan automatic reverse switch
Cooling fan automatic reverse setting = ON (24 V)/
D-IN-9 (Machine with optional automatic reverse
OFF (OPEN)
cooling fan spec.)
D-IN-10 — —
2 40901
D-IN-11 — —
D-IN-12 Right winker Right winker lighting = ON (GND)/OFF (OPEN)
D-IN-13 Left winker Left winker lighting = ON (GND)/OFF (OPEN)
D-IN-14 U switch Pressing switch = ON (24 V)/OFF (OPEN)
D-IN-15 t switch Pressing switch = ON (24 V)/OFF (OPEN)
D-IN-16 Brake oil pressure Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-17 (ECSS cut switch) a No use (Always “OFF”)
D-IN-18 — —
D-IN-19 — —
3 40902
D-IN-20 (Air cleaner clogging) a No use (Always “OFF”)
D-IN-21 (ECSS cut switch [dummy]) a No use (Always “OFF”)
D-IN-22 — —
D-IN-23 — —
D-IN-24 HST filter clogging Clogging detection = ON (GND)/OFF (OPEN)
D-IN-25 — —
D-IN-26 Parking brake Resetting parking brake = ON (GND)/OFF (OPEN)
D-IN-27 Engine coolant level Normal coolant level = ON (GND)/OFF (OPEN)
4 40903
D-IN-28 Omission of applying parking brake Resetting parking brake = ON (GND)/OFF (OPEN)
D-IN-29 (Engine oil level) a No use (Always “OFF”)
D-IN-30 — —
D-IN-31 — —
*: “1” is displayed when ON and “0” is displayed when OFF.
30-103 32 WA150-6

code signal
D-IN-32 — —
D-IN-33 — —
D-IN-34 High beam (Dimmer switch) High beam = ON (GND)/OFF (OPEN)
Omission of applying parking brake
D-IN-35 Resetting parking brake = ON (GND)/OFF (OPEN)
(dummy)
5 40904
D-IN-36 Parking brake (dummy) Resetting parking brake = ON (GND)/OFF (OPEN)
D-IN-37 [>] switch Pressing switch = ON (GND)/OFF (OPEN)
D-IN-38 [<] switch Pressing switch = ON (GND)/OFF (OPEN)
Low steering pressure (Machine with
D-IN-39 Oil pressure reduction = ON (GND)/OFF (OPEN)
optional emergency steering spec.)
D-OUT-0 Alarm buzzer Output ON = ON (24 V)/OFF (OPEN)
D-OUT-1 — —
6 40925 D-OUT-2 Backup alarm/lamp relay Output ON = ON (24 V)/OFF (OPEN)
ECSS solenoid relay
D-OUT-3 Output ON = ON (24 V)/OFF (OPEN)
(Machine with optional ECSS spec.)
*: “1” is displayed when ON and “0” is displayed when OFF.
WA150-6 30-103 33
HST [HST controller system]

Monitoring Real-time monitoring item Displayed item Data display range
No.
code (*1) (*2) (*3)
1 20201 Software No. VERSION
2 20223 Application version No. VERSION (APP)
3 20224 Data version No. VERSION (DATA)
5 40978 Output signal D_OUT_0-7 D-OUT-0------7 See separate table.
6 40979 Output signal D_OUT_8-15 D-OUT-8-----15 See separate table.
7 40980 Output signal D_OUT_16-23 D-OUT-16----23 See separate table.
8 41600 Engine mode ENGINE MODE 0/2
9 32600 HST oil pressure HST PRESS 0.0 – 500.0
10 32601 HST oil pressure HST PRESS 0.001 – 5.000
11 80000 Motor 1 output command value MOTOR SOL DIR 0 – 1000
12 80100 Clutch output command value CLUTCH SOL DIR 0 – 1000
13 41400 Fan output command value FAN EPC DIR 0 – 1000
14 93400 Fan reverse switch input FAN REVERSE SW 0/2/1
15 40013 Travel speed SPEED (HST) 0 – 50.00
16 31400 Output shaft speed T/M SPEED : OUT 0 – 32767
17 31404 Output shaft speed T/M SPEED : OUT2 0 – 32767
18 95400 Throttle correction command output THROTTLE MOD –100 – 100
19 44200 Throttle quantity upper limit value output THROT LIMIT UP 0.0 – 100.0
20 44201 Throttle quantity lower limit value output THROT LIMIT LO 0.0 – 100.0
21 43504 Automatic warm-up cancel flag WARM-UP CANCEL 0/1
30-103 34 WA150-6

Unit
(*4)
As per software No. Condition display
As per software application version No. Condition display
As per software data version Condition display
Condition display
Condition display
Condition display
Condition display
0 Condition display “0” is always displayed.
Low-pressure relief pressure: 2.4 – 2.7

MPa
High-pressure cutoff pressure: 41.5 – 45.0
Low-pressure relief pressure: 0.660 – 0.680
V
High-pressure cutoff pressure: 3.267 – 3.500
Above 11 km/h in 3rd or 4th gear speed: 0 mA
mA
Other than above: 100 – 600 mA (Depends on control)
When clutch is engaged: 670 mA
When clutch is disengaged (Above 11 km/h in 3rd or 4th mA
gear speed): 0 mA
0 – 1000 mA
• Fan rotation direction is being reversed: 800 mA mA
• Fan is rotating in reverse: 0 mA
Switch position, forward: 0
Switch position, automatic reverse: 2 Condition display
Manual reverse switch is being operated: 1
Depends on travel speed. km/h Not used
0 km/h = 0 min-1
10 km/h = 1110 min-1 When tires of size 16.9 are installed.
20 km/h = 2219 min-1 min-1 “min-1” is SI unit of rotation speed.
30 km/h = 3328 min-1 (1 min-1 = 1 rpm)
40 km/h = 4438 min-1
0% % “0%” is always displayed.
Ordinary: 100%
%
Forward travel in S mode: 50 – 100%
0 – 20% %
Directional lever in N, stopped: 0 (OFF)

Condition display
Other than above: 1 (ON)
WA150-6 30-103 35

Monitoring Real-time monitoring item Displayed item Data display range
No.
code (*1) (*2) (*3)
22 99100 Parking brake switch signal PARKING A/B 11/00/10/01
23 04302 Alternator R voltage signal ALTERNATOR 0.0 – 30.0
24 99200 Travel speed control dial SPEED POT 0.0 – 50.0
25 99201 Travel speed control dial SPEED POT 0.001 – 5.000
26 80200 Traction level setting TRACTION 0 – 100
27 99101 Forward-Reverse selector switch FNR signal MULTI FNR 100/010/001
28 99300 Machine status HST STATUS 0–6
29 99301 Clutch status CLUTCH STATUS 0–4
30 99302 Forward-Reverse recognition TRAVEL F/R F/R
30-103 36 WA150-6

Unit
(*4)
Parking brake position (High): 00
(Middle): 10 Condition display
(Low): 11
0 – 30 V V
5.3 – 13.0 km/h (Depends on travel speed control dial position) km/h
0.9 – 4.1 V (Depends on travel speed control dial position) V
Traction level setting (When stopped)

• When traction level A is set: 86% Display is as shown at left, regardless of
%
• When traction level B is set: 77% traction control switch position.
• When traction level C is set: 62%
100: F, 010: N, 001: R
Condition display
ON/OFF refers to each bit.
Stopped: 0
Forward travel (Directional lever in F): 1
Reverse travel (Directional lever in R): 2
Forward travel, lever in R: 3 Condition display
Reverse travel, lever in F: 4
Forward travel, lever in N: 5
Reverse travel, lever in N: 6
Clutch condition
• Engaged o Being prepared for disengaging: 0
• Disengaged (During high-speed travel in 3rd, 4th speed range): 1
• Disengaged o Engagement is being modulated Condition display
(During deceleration in 3, 4th speed range): 2
• Completion of engagement (During low-speed travel in 1st, 2nd
speed range or 3rd, 4th speed range)
• Being disengaged: 4
Forward travel: F Previous condition is displayed while

Condition display
Reverse travel: R machine is stopped
*1: All items, including ones for which sensors are not installed on some models and optional components,
are displayed.
*2: Abbreviated as number of characters is limited.
*4: If a unit is necessary, the SI unit is used.
WA150-6 30-103 37

codes signal
D-IN-0 FNR (Directional) lever F (Forward) F (Forward) = ON (24 V)/OFF (OPEN)
D-IN-1 FNR (Directional) lever N (Neutral) N (Neutral) = ON (24 V)/OFF (OPEN)
D-IN-2 FNR (Directional) lever R (Reverse) R (Reverse) = ON (24 V)/OFF (OPEN)
(Right FNR (directional) switch selector

D-IN-3 —
switch)
1 40977
D-IN-4 Traction control switch Pressing switch = ON (GND)/OFF (OPEN)
D-IN-5 — —
D-IN-6 — —
D-IN-7 — —
D-OUT-0 — —
D-OUT-1 — —
D-OUT-2 — —
D-OUT-3 — —
2 40978
D-OUT-4 — —
D-OUT-5 — —
D-OUT-6 — —
D-OUT-7 — —
D-OUT-8 — —
D-OUT-9 — —
D-OUT-10 — —
D-OUT-11 — —
3 40979
D-OUT-12 — —
D-OUT-13 — —
D-OUT-14 VIS Self-holding relay Output ON = ON (GND)/OFF (OPEN)
D-OUT-15 HST safety relay Output ON = ON (GND)/OFF (OPEN)
D-OUT-16 Motor 2 solenoid relay Output ON = ON (GND)/OFF (OPEN)
D-OUT-17 Fan reverse solenoid relay Output ON = ON (GND)/OFF (OPEN)
D-OUT-18 Fan reverse solenoid relay HST pump F solenoid = ON (24 V)/OFF (OPEN)
D-OUT-19 HST pump R solenoid (Reverse) HST pump R solenoid = ON (24 V)/OFF (OPEN)
4 40980
D-OUT-20 — —
D-OUT-21 — —
D-OUT-22 — —
D-OUT-23 — —
“1” is displayed when ON and “0” is displayed when OFF.
30-103 38 WA150-6
ENG [Engine controller system]

Monitoring Monitoring items Displayed items Data display range Unit
No. Remarks
code (*1) (*2) (*3) (*4)
Status
1 20400 Hardware serial No. ECM S/N Arabic numerals
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
5 04105 Engine coolant temperature sensor voltage COOLANT TEMP 0.00 – 5.00 V
6 36400 Common rail pressure RAIL PRESS 0 – 400 MPa
7 36402 Common rail pressure sensor voltage RAIL PRESS 0.00 – 5.00 V
8 37400 Atmospheric pressure AMBIENT PRESS –99.9 – 999.9 kPa
9 37402 Atmospheric pressure sensor voltage AMBIENT PRESS 0.00 – 5.00 V
10 18500 Boost temperature CHG TEMP –50 – 200 °C
11 18501 Boost temperature sensor voltage CHG TEMP 0.00 – 5.00 V
12 36500 Boost pressure CHG PRESS-A –99.9 – 999.9 kPa
13 36502 Boost pressure sensor voltage CHG PRESS-A 0.00 – 5.00 V
14 18700 Engine output torque OUTPUT TORQUE –24000 – 24000 Nm
15 36700 Equivalent torque TORQUE RATIO 0 – 100 %
16 31706 Final accelerator position FINAL THROTTLE 0 – 100 %
17 37300 Momentary fuel consumption FUEL RATE 0.0 – 999.9 1/h
18 18600 Final injection volume command (in weight) INJECT COMMAND 0 – 1000 mg
19 36300 Final injection timing command TFIN INJECT TIMING –180.0 – 180.0 CA
20 31701 Accelerator pedal position THROTTLE POS 0 – 100 %
21 31707 Accelerator pedal sensor voltage THROTTLE POS 0.00 – 5.00 V
Status
22 18300 Idle validation signal IVS 1 ON/OFF
display
Status
23 18301 Idle validation signal IVS 2 ON/OFF
display
24 18900 Engine controller internal temperature ECM IN TEMP –40 – 210 °C
Final common rail pressure command
25 36200 PRESS COMMAND 0 – 400 MPa
PFIN
Status
26 17500 Selection of engine mode POWER MODE 0–4
display
Status
27 18800 WIF sensor stats WATER IN FUEL ON/OFF
display
Incoming value is
displayed as is Status
28 00400 Name of selected model (upper 8 digits) MACHINE ID (H)
(Upper 8 digits of display
16 characters)
Incoming value is
displayed as is Status
29 00401 Name of selected model (lower 8 digits) MACHINE ID (L)
(Lower 8 digits of display
16 characters)
Incoming value is
Status
30 20216 Build version BUILD VER displayed as is
display
(8 characters)
Incoming value is
Status
31 20217 Calibration data version CAL VER displayed as is
display
(8 characters)
*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*4: SI units alone are employed whenever a unit is needed.
WA150-6 30-103 39
5. Engine cylinder cut-out function 3) Selecting a cylinder to be cut-out

The engine cylinder cut-out function denotes Using [<] or [>] switch, select a cylinder to
setting the injector of a single cylinder or two or be cut-out from No. 1 – No. 4 cylinders
more cylinders to electrically no injection state and then settle the selected cylinder using
and turns on the operation on cylinder cut-out [U] switch.
condition. When any cylinders of the engine a The cylinder to be cut-out is selectable
were suspected for abnormal output (combus- while the engine is run.
tion), this approach is used to single out the a Any number of cylinders can be cut-out –
failed cylinder. a single unit or two or more units.
1) Selecting the menu q [>] switch: Advances the cursor right-
Display the CYLINDER CUT-OUT screen ward
from the menu screen of Service mode. q [<] switch: Advances the cursor left-
ward
q [U] switch: Settles the cylinder to be
cut-out (the cursor starts flashing after
the settlement)
q [t] switch: Restores the CYLINDER
CUT-OUT screen
2) Displaying sub menu

Press [U] switch while the menu is
selected to display the sub menu.
a As the cylinder cut-out command is issued

from the engine controller to the cylinder
to be cut-out, the bottom of the stopped
cylinder number turns to black.
30-103 40 WA150-6
4) Cancelling a cylinder cut-out 2) Pressing [U] switch sets up the no injec-

Using [<] or [>] switch, select the currently tion cranking.
stopped cylinder and then press [U] a If this screen does not appear as [U]
switch to cancel the cylinder cut-out com- switch is hit, a communication error should
mand from the engine controller. The be suspected.
black display will disappear.
a If the no injection cranking is selected as

6. No injection cranking function the engine is running, the engine stop
The machine monitor is equipped with the instruction screen will appear.
function capable of lubricating the engine a In such case, stop the engine once and
through no injection cranking. When a machine then do the set up again.
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.
WA150-6 30-103 41
7. Adjustment function (TUNING) 7-1. Adjustment of interval of fan automatic

The machine monitor implements initial setting reverse operation (If equipped)
after disassembly or replacement of the trans- a This function is used to change the inter-
fer, or after replacement or addition of sensor, val of the forward and reverse operations
HST pump, HST motor and EPC valve or con- of the fan when the fan automatic reverse
troller. Through the initial setting, the machine operation is selected.
monitor corrects and adjusts the installation a The interval of the fan automatic reverse
error or manufacturing variations of individual operation is adjustable in the range from
parts. 0.1 h (6 minutes) to 200 h. It must be set
a Adjustment function to at least twice the continuance of the fan
Item Code automatic reverse operation, however,
Adjustment item and cannot be set shorter than twice.
No. No.
Adjustment of interval of fan a When the machine is delivered, the inter-
7-1 03 val of fan automatic reverse operation is
automatic reverse operation (*1)
Adjustment of continuance of fan set to 2.0 h.
7-2 04
automatic reverse operation (*1) a When the machine is delivered, the con-
Adjustment of lift arm angle sensor tinuance of the fan automatic reverse
7-3 05 operation is set to 2 minutes.
(upper) (for load meter) (*2)
Adjustment of lift arm angle sensor 1) On the service mode menu screen, dis-
7-4 06 play the TUNING screen.
(lower) (for load meter) (*2)
Adjustment of ECSS operation travel
7-5 07
speed (*1)
*1: If equipped
*2: This menu is displayed but it is not used.
a The items which prohibit use

The setting of following items (code: 01,
02) are not changed because of prohibi-
tion of use.
2) Hold down the [U] switch for at least 5

seconds to display the next screen.
a Do not use this item.
30-103 42 WA150-6
3) With the [<] and [>] switches, select 03: 7-2. Adjustment of continuance of fan automatic
FAN REV PD screen. reverse operation (If equipped)
a This function is used to change the contin-
uance of the reverse operation when the
fan automatic reverse operation is
selected.
a The continuance of the fan automatic
reverse operation is adjustable in the
range from 0.5 minutes to 10 minutes. It
must be set to below 1/2 of the interval of
the fan automatic reverse operation, how-
ever, and cannot be set longer than 1/2.
a When the machine is delivered, the con-
tinuance of fan automatic reverse opera-
tion is set to 2.0 minutes.
a When the machine is delivered, the inter-
4) Press the [U] switch to settle. val of the fan automatic reverse operation
a If the [U] switch is pressed, the screen is set to 2.0 h.
to adjust the interval of fan automatic 1) On the service mode menu screen, dis-
reverse operation is displayed. play the TUNING screen.
5) With the [<] and [>] switches, select an
interval in the range from “0.1” to “200”
(Unit: h).
6) Press the [t] switch to settle the setting.
a The selected interval of fan automatic
reverse operation is not changed to a
value less than twice the continuance
of the fan automatic reverse operation.

WA150-6 30-103 43
3) With the [<] and [>] switches, select 04: 7-5. Adjustment of ECSS operation travel speed
FAN REV PD screen. (if equipped)
a This function is used to adjust the ECSS
operation/reset travel speed.
a The initial ECSS operation travel speed is
5 km/h (3.1 MPH).
a The ECSS reset travel speed is the ECSS
operation travel speed minus 1 km/h (0.6
MPH).
Example: q If the ECSS operation travel
speed is 5 km/h (3.1 MPH),
the ECSS reset travel speed
is 4 km/h (2.5 MPH).
q If the ECSS operation travel
speed is 8 km/h (5.0 MPH),
the ECSS reset travel speed
4) Press the [U] switch to settle. is 7 km/h (4.4 MPH).
a If the [U] switch is pressed, the 1) Display the “TUNING” screen from the
screen to adjust the continuance of menu screen of Service mode.
fan automatic reverse operation is
displayed.
5) With the [<] and [>] switches, select a con-
tinuance in the range from “0.5” to “10”
(Unit: minute).
6) Press the [t] switch to settle the setting.
a The selected continuance of fan auto-
matic reverse operation is not
changed to a value longer than 1/2 of
the interval of the fan automatic
reverse operation.

7-3. Adjustment of lift arm angle sensor (upper)

(Load meter specification)
a This item is not used.
7-4. Adjustment of lift arm angle sensor (lower)

(Load meter specification)
a This item is not used.
30-103 44 WA150-6
3) Select “07: ECSS SPEED” with [<] or [>] 8. Maintenance monitoring function
switch. The maintenance function offers the following
capabilities in the maintenance of filters and
oils.
q Change of maintenance interval time
q Selection between enabling or disabling
timer by item
q Setting of a default value
q Selection between enabling or disabling
timer for items
8-1. Changing maintenance interval time
1) Display the MAINTENANCE MONITOR
screen from the menu screen of Service
mode.
4) Press [U] switch to settle.

a If the selection is settled, the ECSS
operation travel speed adjustment
screen appears.
2) Press [U] switch to display 01: ENG OIL

screen.
a The lower left side space indicates the
time remained up to the replacement.
a The lower right side space indicates the
cumulative replacement frequencies.
5) To increase the ECSS operation travel 3) Using [<] or [>] switch, select the item for
speed, press [>] switch. which the maintenance interval is to be
a The operation travel speed is changed from the following.
increased 1 km/h (0.6 MPH) by 1
operation of the switch.
a The operation travel speed can be
adjusted to a maximum of 8 km/h (5.0
MPH).
6) To decrease the ECSS operation travel
speed, press [<] switch.
a The operation travel speed is
decreased 1 km/h (0.6 MPH) by 1
operation of the switch.
a The operation travel speed can be
adjusted to a minimum of 5 km/h (3.1
MPH).
7) If the operation travel speed is set to a
desired value, press [t] switch to finish
setting.
WA150-6 30-103 45
List of maintenance items
Indication of items on the Replacement

Item ID No.
character display interval time (H)
Engine oil 01 ENG OIL 500
Engine oil filter 02 ENG FILT 500
Fuel pre-filter 41 FUEL P FILT 500
Fuel filter 03 FUEL FILT 1000
Corrosion resistor 06 CORR RES 1000
Transfer oil 25 TRANSF OIL 1000
HST oil filter 26 HST FILT 1000
Hydraulic oil filter 04 HYD FILT 2000
Hydraulic oil 10 HYD OIL 2000
Axle oil 15 AXLE OIL 2000
HST drain filter 43 HST DR FILT 2000
4) Settle the target items of interval change a When you have entered a wrong value to
by use of [U] switch. a position except the highest-order digit,
move to the highest-order digit using [t]
switch and repeat the procedure from the
first. In this case, the value that had been
entered remains as it is until modified.
When the cursor is at the highest-order
digit, move to the higher layer using [t]
switch.
5) Maintenance interval time change proce-

dure
1] This cursor is located at the highest-
order digit. Pressing [<] or [>] switch
changes the value of this digit in the
range of 0 – 9.
value.
3] Set the values up to the lowest-order
digit in the same order and then press
[U] switch.
q When the input interval time is within
the setting range: The screen
changes to the check screen.
q When the entered interval time is out
of the setting range: The entered
interval time does not replace the cur-
rent value and the input screen will be
restored.
a The shortest interval time value is 50 h.
30-103 46 WA150-6
6) Select “YES” or “NO” using [<] or [>] a When “Timer by item” is disabled, the
switch. order of display becomes OFF o ON.
a The selected cursor will start flashing. If a The default display is ON.
“YES” is selected a nd [t] switch is
maintenance interval change item screen
is restored.
a When an interval time is changed, the
timer remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
2) Press [U] switch from this state.
a If “Timer by item” is disabled, OFF will be
displayed in the upper column.
8-2. Selection between enabling or disabling timer

by item
1) Pressing [<] or [>] switch from 8-1-3) Inter-
val time change screen displays the a If “Timer by item” is enabled, ON will be
“Selection between enabling or disabling displayed in the upper column.
timer by item” screen.
a When “Timer by item” is enabled, the
order of display is ON o OFF.
WA150-6 30-103 47
3) Select “YES” or “NO” using [<] or [>] 3) Press [U] switch from this state.
switch. 4) Select “YES” or “NO” using [<] or [>] switch.
a The selected cursor will start flashing. If a The selected cursor will start flashing. If
“YES” is selecte d a nd [t] switch is “YES” is selected and [t] switch is
pressed, the information will be deleted. If pressed, the change will be enabled If
“NO” is selected and [t] switch is “NO” is selected and [t] switch is
pressed, deletion is cancelled and the pressed, the change will not be imple-
maintenance interval change item screen mented and the maintenance monitoring
is restored. screen will be restored.
a By default, the cursor is set to NO (cancel) a By default, the cursor is set to NO (cancel)
to prevent resetting error. to prevent resetting error.
a An interval time is changed, the timer
remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
8-3. Changing set default value.

1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
a If the default value setting is executed, all

the currently changed interval times are
returned to the default values. It is executed
on every item independent of whether or not
the function is enabled for a specific item.
a Timer remaining time shall be Default
value – Elapsed tim e since the last
replacement.
a Executing the default value setting does
not affect the reset frequency. Namely, it
remains the same as before this operation
was executed.
2) Using [<] or [>] switch, select the INITIALIZE a Set enable for enable or disable of individ-
screen from the following table. ual items.
8-4. Selection between timer stop for all items and

enable by item
1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
30-103 48 WA150-6
2) Using [<] or [>] switch, select the ALL 5) Press [U] switch from the ALL ITEMS o
ITEMS OFF OR ON screen from the fol- OFF screen or the ALL ITEMS o ON
lowing table. screen.
a When [U] switch is pressed from the ALL
ITEMS o OFF screen, OFF will be is dis-
played in the upper space.
3) Press [U] switch to display the ALL

ITEMS o OFF screen.
a When [U] switch is pressed from the ALL

ITEMS o ON screen, ON will be is dis-
played in the upper space.
6) Select “YES” or “NO” using [<] or [>]
switch.
“YES” is selected and [t] switch is
maintenance interval change item screen
is restored.
4) Press [<] or [>] switch when selecting the to prevent resetting error.
ALL ITEMS o ON.
WA150-6 30-103 49
7) As the timer stop for all items is executed: 9. Operating information display function
a The timer function for all items is stopped It is a fuel consumption-related function and
a n d t h e M A I N T E N A N C E M O N I TO R displays the following information.
screen is restored. q Fuel consumption ratio and average fuel
a Setting for individual items is also disabled. consumption
a If cancelled: The operation is cancelled q Cumulative fuel consumption and travel
a n d t h e M A I N T E N A N C E M O N I TO R distance
screen is restored. q Cumulative fuel consumption and elapsed
8) When timer enable for all items is executed: time
a Interval time being set for all items is exe- 1) Selecting menu
cuted to the set value before disabled Display the OPERATION INFO screen
independent of whether or not it is from the menu screen of Service mode.
enabled or disabled for a specific item.
a The timer remaining time is reset. (The
reset frequency remains the same as
before the resetting.)
a The MAINTENANCE MONITOR screen is
restored.
a Setting for individual items is also enabled.
a If cancelled: The operation is cancelled
a n d t h e M A I N T E N A N C E M O N I TO R
screen is restored.
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] – 4] 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 displays fuel con-
sumption [L/km or L/mile] per 1 km (or
1 mile) from the last resetting.
q Above value is computed from the
fuel consumption ratio and travel dis-
tance (odometer distance).
a The lower column displays the aver-
age fuel consumption [L/h] from the
last resetting.
a Calculation is done only for the dura-
tion in which the engine is run.
30-103 50 WA150-6
3] 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 run.
2] Cumulative fuel consumption and travel
distance
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
the upper limit.
a The lower column displays the travel
distance [km or mile] from the last
resetting.
q The unit km or mile shall be selected
depending on that used on the odom-
eter.
the upper limit. 4) Deleting display data
a Calculation is done only for the dura- a Data on screens 3) – 1] to 3] allow dele-
tion in which the engine is run. tion.
a Select a desired item and then delete it
using [U] switch.
a Use [t] switch when canceling deletion of
data.
WA150-6 30-103 51
5) Setting gain correction

a Gain correction denotes the function of
correcting gain of cumulative fuel con-
sumption.
a Gain correction is reflected 3) – 1] to 3].
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.
value.
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.
30-103 52 WA150-6
10. OPTIONAL SELECT function

a The procedure for setting an option is as follows; Set the option and turn the starting switch OFF. After
the power for each controller is turned OFF (about 15 seconds), turn the starting switch ON again, and
the option is effective.
a Before setting an option, check that the machine model has been selected. (Select the machine model
before setting the option.)
Optional device installation setting table
Display in Setting at
No. Item Contents of selection Remarks
English monitor delivery
Select type (size) of tires to be
1 Tire type TIRE TYPE 16.9
installed.
2 Emergency steering EMERG S/T NO ADD If equipped, select “ADD”.
Right FNR (directional)
3 FNR NO ADD If equipped, select “ADD”.
switch
• Keep to “ADD” normally.
• “NO ADD” is selected, ECO lamp
4 ECO lamp operation ECO LAMP ADD
in machine monitor is kept turned
OFF.
If not installed optionally, select “NO
5 ECSS E. C. S. S. ADD
ADD”.
If fan reverse function is not
6 Reverse fan REVERSE FAN ADD installed, select “NO ADD”.
Select “MECHA”. MECHA: Mechanical
7 Parking brake PKG BRAKE MECHA
(Do not select “ELEC”.) ELEC: Electric
• Keep to “0” normally.
• If number other than “0” is
selected, only travel speed
9 Tire size correction TIRE SIZE 0% display in machine monitor
increases or decreases
according to selected number.
• Can be changed in only non-SI MPH: Display in mile
11 Travel speed unit SPEED (UNIT) — specification. For contents of km/h: Display in
change, see “Remarks” column. kilometer
• Can be changed in only non-SI
specification. For contents of
change, see “Remarks” column.
NO ADD: (*1)
Selection of travel speed/ • To change travel speed display to ADD: (*2)
12 engine speed display on RPM OPT NO ADD engine speed display in operator
ADD o NO ADD: (*3)
main screen mode, select “ADD”.
NO ADD o ADD: (*4)
Note: Do not select “ADD” in region
where display of travel speed is
obliged by law.
Selection of engine • Keep to “ADD” normally. ADD: (*5)
speed/travel speed on
• If “NO ADD” is selected, “Engine NO ADD: (*6)
13 normal screen of RPM/SPEED ADD
speed or travel speed” are not ADD o NO ADD: (*7)
character display or non- displayed on character display. NO ADD o ADD: (*8)
display
Reference: Item Nos. 8 and 10 are missing.
*1: “Selection of speed/engine speed” is not displayed in operator mode.

*2: “Selection of speed/engine speed” is displayed in operator mode (Tachometer can be displayed as main
item).
*3: Fixed to speedometer.
*4: Setting at previous ADD or initial setting.
*5: “Travel speed/rpm on character display: Displayed/Not displayed” is displayed in operator mode.
*6: “Travel speed/rpm on character display: Displayed/Not displayed” is not displayed in operator mode.
*7: Not displayed.
*8: Setting at previous ADD or initial setting.
WA150-6 30-103 53
1) Display the OPTIONAL SELECT screen 10-1. Option setting/not setting selection
from the menu screen of Service mode. a Among the items included in the list of installed
optional devices and their setting, the option
setting/not setting selection applies to the fol-
lowing items.
a If the options are not selected, the option non-
selection screen (NO ADD) is displayed.
2) Hold down [U] switch for 5 seconds or

longer.
3) The 1: TIRE TYPE screen will appear.
a If the [t] switch is pressed, the
screen returns to the OPTIONAL
SELECT screen. a If the options are selected, the option selected
screen (ADD) is displayed.
a Be sure to start setting of each option

o n 1 : T I R E T Y P E s c r e e n . A ft e r a [U] switch allows alternately displaying the
changing or settling the option, set option non-selection screen and the option-
other items in order on the next 2: selected screen.
EMERG S/T screen and the following
screens. Reference: Details of the main items are shown
below.
30-103 54 WA150-6
10-2. Selection of optional tire type 10-4. Setting tire deflection option
a Select “1: TIRE TYPE” from “Optional device a Select 9: TIRE SIZE from the list of installed
installation setting table”. optional devices and their setting.
Reference: a Pressing [U] switch sequentially displays
q This screen appears first when the screen [@@]% in the following order.
is changed from the “OPTIONAL SELECT” a The display progresses from +00 through –10.
screen. Pressing [U] switch at this point returns the
q The default display is the tire size set at display to +00.
factory shipment.
Order No.1 No.2 No.3 No.4 No.5 No.6 No.7
a Each time [U] switch is pressed, the tire type
changes from small to large. @@ +00 +02 +04 +06 +08 +10 +12
Selectable size: 14.0, 15.5, 16.9, 17.5 and 18.4
Order No.8 No.9 No.10 No.11 No.12 No.13 No.14
a If the tire type is changed, the operation accep-
tance tone (peep) sounds. @@ –02 –4 –6 –8 –10 –12 +00
a As the display is switched, the sound (beep)

indicating acceptance of the operation will be
generated.
10-3. Selection of optional parking brake

a "MECHA" (Mechanical: Default) is displayed.
a Do not change this setting.
10-5. Selection of optional travel speed unit

a If the SI unit specification is selected when
delivered, this menu is not displayed. (Unit is
fixed to km/h.)
a Select “11: SPEED UNIT” from “Optional
device installation setting table”.
a Each time [U] switch is pressed, the speed
unit changes.
Selectable item: MPH (default), km/h
a If the unit is changed, the operation accep-
tance tone (peep) sounds.
WA150-6 30-103 55
10-6. Storing option selection 11. Machine serial number input function
1) When the option selection was changed, 1) Display the MACHINE No. SET screen
turn off the starting switch once to stop the from the menu screen of Service mode.
controller operation completely. (After turn-
ing off the starting switch, wait for 15 sec-
onds without doing any switch operation.)
2) The specified option selection is enabled
as the starting switch is turned on.
a Whenever an option selection is made, turn
off the starting switch once and then turn it
on again in approximately 15 seconds.
2) Press [U] switch to display the MACHINE

No. screen.
3) Enter the serial number according to the
a The cursor is positioned at the high-
est-order digit.
1] Pressing [<] or [>] switch increases or
decreases the value at the cursor
position. Select a desired value using
these switches.
2] Press [U] switch to settle the selec-
tion.
a The cursor moves to the digit situated
immediately on the right hand.
3] 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 imme-
diately preceding screen is restored.
a Pressing [t] switch while entry is taking
place will move the cursor the highest-
order digit. In this case, repeat entry
from the highest-order digit.
a If [t] switch is pressed while the cur-
sor is at the highest-order digit, the
immediately preceding screen will be
restored.
30-103 56 WA150-6
12. Machine model select function a Press [t] switch when stopping the model
(MACHINE WA***) selection.
a The setting of the machine model of the a As the operation is stopped, the sound
machine monitor can be changed with the (beep) indicating acceptance of the opera-
machine model select function. tion will be generated, restoring the
a If the machine monitor is initialized, perform MACHINE screen.
the machine model select operation first. 4) With the [U] switch, settle the changed
a If the machine model select operation is machine model and tire size.
performed, the setting of options is reset. a As the selection is settled, the sound
Accordingly, start with the option select (beep) indicating acceptance of the opera-
operation and select all the options. tion will be generated, restoring the
MACHINE screen.
12-1. Implementing the model change a Check that the desired machine model is
1) Display the MACHINE screen from the displayed on the machine model select
menu screen of Service mode. screen.
a The currently selected machine model is
displayed on the lower line. 12-2. Storing model change
1) When the model change was done, turn off
the starting switch once to stop the controller
operation completely. (After turning off the
starting switch, wait for 15 seconds without
doing any switch operation.)
2) The model being selected as the starting
switch is turned on is validated.
a Whenever a model change was done, turn
off the starting switch once and then turn it
on again in approximately 15 seconds.
13. Initialize function

This function is used only in the factory. It is,
therefore, not used for a service purpose.
2) Hold down [U] switch for 5 seconds to
display the model selection screen.
14. Item that refers to SERVICE NEWS

Refer to SERVICE NEWS for the following
3) With the [<] and [>] switches, select the items.
machine model. q Setting of Service meter when machine
a Selectable models monitor is exchanged.
q WA100 q Setting of odometer when machine moni-
q WA150 tor is exchanged.
q WA200
q WA250
q WA270
q WA320
a If wrong model and tire are set,
machine does not work correctly.
WA150-6 30-103 57
SEN05126-02 Pm clinic inspection chart
Pm clinic inspection chart 1 WA150-6 Serial No. 80001 and up
Machine serial No.

Hours inspection Engine serial No. SAA4D95LE-5 #
Work order No. Date of execution Service Meter Serviceman

Year: Month: Day: h
Questions asked to operator, walk around inspection
Ambient temperature
Was there any abnormality before inspection started?
Max. °C
Min. °C
Altitude m
Max. coolant temp. (During operation) Max. HST oil temp. (During operation)
Segment color W G G G G R R Segment color G G G G G R R
1 2 3 4 5 6 7 1 2 3 4 5 6 7
a If the machine is cold, warm it up fully. <>: Reference value

Standard
Service limit Measurement
Item Conditions Unit value for new value results Pass Fail
machine
Low idle 955 – 1005 955 – 1005
High idle 2,350 – 2,450 2,350 – 2,450
Engine speed HST stall rpm 2,250 – 2,450 2,150 – 2,450
Hydraulic stall 2,160 – 2,360 2,060 – 2,450
Engine
Full stall (HST stall + hydraulic stall) 2,025 – 2,425 1,925 – 2,450
Blow-by kPa Max. 0.98 1.47
pressure At rated output {mmH2O} {Max. 100} {150}
High idle Min. 0.29 0.25

MPa {Min. 3.0} {2.5}
Oil pressure SAE15W-40 {kg/cm2} Min. 0.15 0.13
Low idle
{Min. 1.5} {1.3}
a Before starting the inspection, check that the machine does not move when the directional lever is placed in position.
k When measuring the transfer clutch control pressure, carry out the measurement at a place where the machine can travel
safety at a speed of more than 10 km/h.
Directional lever: F
Speed selector
High-pressure switch: 2nd 43.0 – 45.0 41.5 – 45.0
cut-off pressure {440 – 460} {425 – 460}
Traction control
switch: ON
Low-pressure
relief pressure
(work equip- 2.5 – 2.7 2.4 – 2.7
ment PPC cir- Directional lever: N {25.5 – 27.5} {24.5 – 27.5}
cuit basic
pressure) • Engine:
Full throttle
• Hydraulic Directional lever: N 2.5 – 2.7 2.4 – 2.7
Servo piston Brake: released {25.5 – 27.5} {24.5 – 27.5}
oil temp.: MPa
HST
control pres-
45 – 55°C Directional lever: N Max. 0.6 Max. 0.6
sure {kg/cm2}
Brake: pressed {Max. 6} {Max. 6}
Directional lever: For-
ward and reverse
Gear speed selector
Servo piston switch: 1st 2.5 – 2.7 2.3 – 2.7
actuation pres- Travel speed control
sure dial: Min. side {25.5 – 27.5} {23.5 – 27.5}
Measure while driv-
ing at full throttle
(Approx. 5 km/h).
Transfer clutch Hydraulic oil Directional lever: F 2.5 – 2.7 2.4 – 2.7
control pres- temp.: Speed selector
{25.5 – 27.5} {24.5 – 27.5}
sure 45 – 55°C switch: 3rd or 4th
30-103 58 WA150-6
Pm clinic inspection chart SEN05126-02
WA150-6 Serial No. 80001 and up

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

sec.
operating time
Steering
Engine high idle 3.4 – 4.0 2.7 – 4.7

Lock frame with frame lock bar
Steering relief Engine high idle MPa 17.7 – 19.3 16.6 – 20.6
pressure {kg/cm2} {181 – 197} {170 – 210}
Front right 0.9 – 1.1 Max. 0.6
Brake
Lining thick- Front left 0.9 – 1.1 Max. 0.6

Service brake mm
ness Rear right 0.9 – 1.1 Max. 0.6
Rear left 0.9 – 1.1 Max. 0.6
MPa 20.2 – 21.0 18.6 – 22.6
Relief pressure Bucket relief {kg/cm2} {206 – 214} {190 – 230}
Raising time 5.1 – 6.1 Max. 8.2
Work equipment
Lift arm speed Engine high

Lowering time 3.1 – 4.1 Max. 4.7
idle
Dumping time sec. 0.8 – 1.4 Max. 1.7
Bucket speed Tilting-back time 1.1 – 1.7 Max. 2.0
(At full stroke)
Engine Bucket cylinder mm/15 Max. 17 Max. 20

Hydraulic drift
stopped Lift cylinder min. Max. 20 Max. 30
• Engine coolant temperature: Min.
Hydraulic drive fan
Max. fan speed 90°C rpm 1,570 ± 50 1,570 ± 100

• Engine coolant temperature: Min.
Fan drive pres- MPa 16.2 ± 1.6 16.2 ± 2.5
90°C
sure {kg/cm2} {165 ± 16} {165 ± 25}
Front axle
Axle
Must be no excessive metal

Check differential oil visually —
Rear axle particles
MEMO
WA150-6 30-103 59
SEN05126-02

©2011 KOMATSU
All Rights Reserved
30-103 60
SEN05127-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
40 Troubleshooting 40
100 Failure code table and fuse locations

Failure codes table.......................................................................................................................................... 2
Fuse locations................................................................................................................................................. 8
WA150-6 40-100 1
SEN05127-00 Failure codes table
Failure codes table 1
Failure Action Category of Reference

Troubled part Trouble Controller
code code record document No.
Mechanical
2G40ZG Brake Oil pressure reduction MON E03
system
Mechanical
6091NX HST filter Clogging MON E01
system
Mechanical
989FN1 Travel speed Overrun alarm MON E02
system
Electrical
AB00L6 Alternator R system Hot short MON E01
system
Ground fault/Disconnec- Electrical Troubleshoot-
AB00MA Alternator R system MON E03 ing by failure
tion/Low charge level system
code (Display
Mechanical of code), Part 1
B@BAZG Engine Oil pressure reduction ENG E03
system SEN05129-00
Mechanical
B@BCNS Engine Overheat ENG E02
system
Mechanical
B@BCZK Engine Low coolant level MON E01
system
Mechanical
B@C6NS Front brake High oil temperature MON E02
system
Mechanical
B@CRNS HST High oil temperature MON E02
system
Electrical
CA111 Engine controller Internal abnormality ENG E03
system
Engine NE, Bkup speed Electrical
CA115 Abnormality ENG E03
sensor system
Electrical
CA122 Charge pressure sensor Abnormally high level ENG E03
system
Electrical
CA123 Charge pressure sensor Abnormally low level ENG E03
system
Electrical
CA131 Throttle sensor Abnormally high level ENG E03
system
Electrical
CA132 Throttle sensor Abnormally low level ENG E03
system
Electrical
CA144 Coolant temperature sensor Abnormally high level ENG E01
system Troubleshoot-
ing by failure
Electrical
CA145 Coolant temperature sensor Abnormally low level ENG E01 code (Display
system
of code), Part 2
Electrical SEN05130-00
CA153 Charge temperature sensor Abnormally high level ENG E01
system
Electrical
CA154 Charge temperature sensor Abnormally low level ENG E01
system
Electrical
system
Electrical
CA221 Ambient pressure sensor Abnormally high level ENG E01
system
Electrical
CA222 Ambient pressure sensor Abnormally low level ENG E01
system
Electrical
system
Mechanical
CA234 Engine Overspeed ENG E02
system
40-100 2 WA150-6
Failure codes table SEN05127-00

Ne speed sensor power Electrical
CA238 Abnormality ENG E03
supply system
Electrical
CA271 IMV (IMA) Short circuit ENG E03
system
Electrical
CA272 IMV (IMA) Disconnection ENG E03
system
Disconnection/Short cir- Electrical
CA322 Injector #1 system ENG E03
cuit system
Disconnection/Short cir- Electrical Troubleshoot-
CA324 Injector #3 system ENG E03 ing by failure
cuit system
code (Display
Disconnection/Short cir- Electrical of code), Part 2
cuit system SEN05130-00
Disconnection/Short cir- Electrical
cuit system
Electrical
CA351 Injector drive circuit Abnormality ENG E03
system
Electrical
system
Electrical
system
Electrical
CA431 Idle validation switch Abnormality ENG E01
system
Electrical
CA432 Idle validation switch Abnormal remedy ENG E03
system
Electrical
CA435 Engine oil pressure switch Abnormality ENG E01
system
Electrical
CA441 Power supply voltage Abnormally low level ENG E03
system
Electrical
CA442 Power supply voltage Abnormally high level ENG E03
system
Abnormally high pressure Electrical
CA449 Common rail pressure ENG E03
2 system
Common rail pressure sen- Electrical
CA451 Abnormally high level ENG E03
sor system Troubleshoot-
ing by failure
Common rail pressure sen- Electrical
CA452 Abnormally low level ENG E03 code (Display
sor system
of code), Part 3
Abnormally high pressure Electrical SEN03131-00
CA553 Common rail pressure ENG E03
1 system
Electrical
system
Electrical
CA689 Engine Ne speed sensor Abnormality ENG E03
system
Electrical
CA731 Engine Bkup speed sensor Abnormal phase ENG E03
system
Electrical
CA757 Engine controller Loss of all data ENG E03
system
Electrical
CA778 Engine Bkup speed sensor Abnormality ENG E03
system
Electrical
CA1633 KOMNET Abnormality ENG E03
system
WA150-6 40-100 3

Throttle sensor power sup- Electrical
CA2185 Abnormally high level ENG E03
ply system
Throttle sensor power sup- Electrical
CA2186 Abnormally low level ENG E03
ply system
Electrical Troubleshoot-
CA2249 Supply pump Low rail pressure 2 ENG E03 ing by failure
system
code (Display
Electrical of code), Part 3
CA2311 IMV (IMA) solenoid Abnormality ENG E03
system SEN03131-00
Electrical
CA2555 Intake air heater relay Disconnection ENG E01
system
Electrical
CA2556 Intake air heater relay Short circuit ENG E01
system
Electrical
D160KY Backup lamp/buzzer relay Hot short MON E01
system
Electrical
D192KY ECSS solenoid relay Hot short MON E01
system
Electrical
D1B0KA HST safety relay Disconnection HST E03
system
Electrical
D1B0KB HST safety relay Ground fault HST E01
system
Electrical
D1B0KY HST safety relay Hot short HST E03
system
Ground fault/Disconnec- Electrical
D5ZHL6 IGN C system MON E01
tion system
Ground fault/Disconnec- Electrical
DAF3KK UNSW power supply MON E01
tion system
Monitor panel CAN-NET Electrical
DAFRKR Disconnection HST E03
signal system
Electrical
DAJ0KK HST controller power supply Low voltage HST E03
system Troubleshoot-
ing by failure
HST controller memory Electrical
DAJ0KT Abnormality HST E01 code (Display
(EEPROM) system
of code), Part 4
HST controller main power Disconnection/Ground Electrical SEN05132-00
DAJ1L4 HST E01
supply line fault system
supply line system
Controller solenoid power Electrical
DAJ2KK Low voltage HST E03
supply system
HST controller load power Electrical
supply holding line system
HST controller load power Disconnection/ Electrical
DAJ2L4 HST E01
supply holding line Ground fault system
Electrical
DAJ5KX Sensor 5V power supply Out of input range HST E03
system
Disagreement in model
(DAJ9KQ) HST controller MON E03 —
selection
Disconnection in signal Electrical
DAJRKR HST controller CAN-NET MON E03
line system
Disagreement in option
(DAJRMA) HST controller MON E03 —
selection
40-100 4 WA150-6

Disconnection in signal Electrical
DB2RKR Engine controller CAN-NET HST E03
line system
Fan auto reverse switch sig- Electrical
DD1NL4 Abnormality HST E01
nal system
Electrical
DD1NLD Fan reverse switch signal Abnormality HST E01
system
Parking brake reminder sig- Electrical
DDB6KA Disconnection/Hot short HST E01
nal system
Parking brake indicator sig- Electrical
DDB6KB Ground fault HST E01
nal system
Parking brake indicator sig- Troubleshoot-
Electrical
DDB6KZ nal or parking brake Trouble MON E03 ing by failure
system
reminder signal code (Display
Parking brake reminder sig- Electrical of code), Part 5
DDB6L0 Ground fault HST E01 SEN05133-00
nal system
Parking brake indicator sig- Electrical
DDB6L4 Disconnection/Hot short HST E03
nal system
Disconnection/Ground Electrical
DDD7KX Travel speed control dial HST E01
fault system
Electrical
DDD7KY Travel speed control dial Hot short HST E01
system
DDK6KA FNR lever HST E03
fault system
Electrical
DDK6KY FNR lever Hot short HST E03
system
Travel speed range selec- Disconnection/Ground Electrical
DF10KA HST E01
tor switch fault system
Travel speed range selec- Electrical
DF10KB Hot short HST E01
tor switch system
Electrical
DGH1KX HST oil temperature sensor Ground fault MON E01
system
Brake oil temperature sen- Electrical
DGR2KB Ground fault MON E01
sor system
Brake oil temperature sen- Electrical
DGR2KZ Disconnection/Hot short MON E01
sor system
DHH1KX HST oil pressure sensor HST E03
fault system Troubleshoot-
ing by failure
Electrical
DHH1KY HST oil pressure sensor Hot short HST E03 code (Display
system
of code), Part 6
Electrical SEN05134-00
DHTCL6 HST filter clogging sensor Functional defect MON E01
system
Electrical
DJF1KA Fuel level sensor Disconnection/Hot short MON E01
system
Electrical
DLT3KX Travel speed sensor B Abnormality HST E03
system
Electrical
DLT4KX Travel speed sensor A Abnormality HST E03
system
Electrical
DLT4LC Travel speed sensor A & B Abnormality HST E03
system
Electrical
DV00KY Alarm buzzer Hot short MON E01
system
WA150-6 40-100 5

DW26KA Motor 2 solenoid HST E01
fault system
DW26KY Motor 2 solenoid Hot short HST E01 ing by failure
system
code (Display
DW7BKY Fan reverse solenoid circuit Hot short HST E01
system SEN05134-00
DW7BKZ Fan reverse solenoid circuit HST E01
fault system
Electrical
DX16KA Fan EPC solenoid Disconnection HST E01
system
Electrical
DX16KB Fan EPC solenoid Ground fault HST E01
system
Electrical
DX16KY Fan EPC solenoid Hot short HST E01
system
Electrical
DX19KA Motor 1 solenoid Disconnection HST E03
system
Electrical
DX19KB Motor 1 solenoid Ground fault HST E03
system
Electrical
DX19KY Motor 1 solenoid Hot short HST E03
system
Electrical
DX20KA Clutch EPC solenoid Disconnection HST E03
system
DX20KB Clutch EPC solenoid Ground fault HST E03 ing by failure
system
code (Display
DX20KY Clutch EPC solenoid Hot short HST E03
system SEN05135-00
Electrical
DXH7KB Reverse solenoid Ground fault HST E03
system
Electrical
DXH7KZ Reverse solenoid Disconnection/Hot short HST E03
system
Electrical
DXH8KB Forward solenoid Ground fault HST E03
system
Electrical
DXH8KZ Forward solenoid Disconnection/Hot short HST E03
system
Mechanical
J141N1 Steering pump Overrun alarm HST E02
system
Mechanical
M100N1 HST pump Overrun alarm HST E02
system
Mechanical
M400N1 Motor 1 Overrun alarm HST E02
system
40-100 6 WA150-6
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable controller:
Applicable controller indicates in which controller system the failure has occurred.
MON : machine monitor system
ENG : Engine controller system
HST : HST controller system
a Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
a Note: Optional equipments are also included in the table.
WA150-6 40-100 7
SEN05127-00 Fuse locations
Fuse locations 1
Connection table of fuse box and slow blow fuse

a This connection table indicates the devices to which the power of the fuse box and slow blow fuse is
supplied. (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).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and
slow blow fuse to see if the power is supplied normally.
Fuse box: FS1

Type of power supply (Power source) Fuse No. Fuse capacity Destination of power (*)
1 20A Starting switch B
2 10 A Hazard lamp
3 15 A HST controller
4 30 A Engine controller
Unswitched power supply
(Slow blow fuse [50 A]) Machine monitor
5 10 A
Buzzer
Radio
6 10 A
Room lamp
7 10 A Unswitched power supply for optional devices
8 10 A Headlamp (left)
9 10 A Headlamp (right)
10 10 A Turn signal lamp
Stop lamp relay
11 10 A Stop lamp switch
Stop lamp
VIS power supply holding relay
12 15 A
HST controller
Accessory power supply Boom detent active relay
(Slow blow fuse [80 A]) ECSS switch
Boom kick-out relay
13 10 A
PPC solenoid
Bucket leveler relay
Proximity switch
Front/Rear wiper
14 20 A Wiper timer
Window washer
Radio
15 10 A
Cigarette lighter
*: Optional devices are included.

Devices which are not set may be included.
40-100 8 WA150-6
Fuse locations SEN05127-00
Fuse box: FS2

Type of power supply (Power source) Fuse No. Fuse capacity Destination of power (*)
1 20 A Air conditioner blower
2 5A Air conditioner compressor
Beacon
3 20 A Working lamp (Front: For addition)
Rotary lamp
4 20 A Glass heater
5 10 A —
Accessory power supply 6 20 A Key ON power for optional device
(Slow blow fuse [80A])
7 10 A DC converter
8 10 A Parking brake
9 10 A Horn
10 10 A Small lamp (right)
11 10 A Small lamp (left)
12 10 A Working lamp (front)
13 10 A Working lamp (rear)
Machine monitor (Starting switch ACC signal)
14 10 A Backup lamp
ACC signal (ACC switch) Backup alarm
15 5A Engine controller (Starting switch ACC signal)
*: Optional devices are included.

Devices which are not set may be included.
Location Fuse No.

q Inside of cover (1) at rear of console in cab
WA150-6 40-100 9
SEN05127-00 Fuse locations
Slow blow fuse

Type of power supply (Power source) Fuse capacity Destination of power
Fuse box FS1 No.8 – 15
80 A
Accessory power supply (Battery) Fuse box FS2 No.1 – 15
120A Engine intake air heater relay
Unswitched power supply (Battery) 50 A Fuse box FS1 No.1 – 7
Location Arrangement of slow blow fuse

Open cover (2) on the left side of the engine com-
partment outward, remove plate (3), and remove
cover (4).
Reference: Wiring harness (5) above the slow

blow fuse is moved to illustrate
easily.
40-100 10 WA150-6
Fuse locations SEN05127-00
WA150-6 40-100 11
SEN05127-00

©2009 KOMATSU
All Rights Reserved
40-100 12
SEN05128-01
WHEEL LOADER
WA150-6

WA150-6 80001 and up
200 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
Information contained in troubleshooting table ............................................................................................... 8
Connection table for connector pin numbers ................................................................................................ 10
T- branch box and T- branch adapter table ................................................................................................... 46
WA150-6 40-200 1
SEN05128-01 Points to remember when troubleshooting
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.
40-200 2 WA150-6
Sequence of events in troubleshooting SEN05128-01
Sequence of events in troubleshooting 1
WA150-6 40-200 3
SEN05128-01 Testing before troubleshooting
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
Check fuel filter and fuel pre-filter for clogging
3. Check of fuel filter for clogging — Replace

Lubricating oil and coolant
4. Check of level and type of oil in engine oil pan Between H and L Add oil
Between FULL and

5. Check of coolant level Add coolant
LOW
6. Check of air cleaner for clogging No red Clean or replace
7. Check of level and type of hydraulic oil Between H and L Add oil
8. Check of level and type of HST oil Between H and L Add oil
9. Check of engine oil filter for clogging — Replace
10. Check of hydraulic oil filter for clogging — Replace
11. Check of HST oil filter for clogging — Replace
Retighten or
12. Check of battery terminal cables for looseness and corrosion —
replace
Electrical parts
13. Check of alternator terminal cables for looseness and Retighten or

—
corrosion replace
14. Check of starting motor terminal cables for looseness and Retighten or
—
corrosion replace
15. Check of operation of instruments — Repair or replace

mechanical equipment
16. Check for abnormal noise and smell — Repair

Hydraulic and
17. Check for oil leakage — Repair
18. Bleeding air — Bleed air
19. Check of effect of brake — Repair or adjust
20. Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace
21. Check of battery electrolyte level Between U.L and L.L Add or replace
Electrical equipment
22. Check wires for discoloration, burn, and removal of cover — Replace
23. Check for removed wire clamp and drooping wire — Repair
24. Check wiring for wetting with water (Check connectors and Disconnect and dry
—
terminals for wetting with water, in particular) connectors
25. Check of slow-blow fuses and fuses for disconnection and
— Replace
corrosion
26. Check of alternator voltage (with engine at medium speed or After several-minute
Repair or replace
higher) operation: 27.5 – 29.5 V
27. Check of operating sound of battery relay (Starting switch
— Replace
OFF o ON)
40-200 4 WA150-6
Classification and procedures of troubleshooting SEN05128-01
Classification and procedures of troubleshooting 1
Classification of troubleshooting
Mode Contents
Display of
Troubleshooting by failure code (Display of code)
code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, display the failure code in the failure code display
mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
Carry out troubleshooting in [Display of failure code] according to the displayed failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
2. Procedure for troubleshooting to be taken when failure code is recorded:

If an action code is not displayed on the machine monitor, check for a failure code in the failure code dis-
play mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
If a failure code is recorded, carry out troubleshooting in [Display of code] according to that failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is
not recorded:
If a failure code is not recorded in the machine monitor (EMMS), a trouble that the machine cannot find
out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of “Phenomena looking like troubles and troubleshooting Nos.“, and then carry out trouble-
shooting related to that phenomenon in the “E-mode“, “H-mode“, or “S-mode“.
WA150-6 40-200 5
SEN05128-01 Classification and procedures of troubleshooting
Phenomena looking like troubles and troubleshooting Nos.
Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
Phenomena related to action codes and failure codes
1 Action codes are displayed on machine monitor Check failure code
2 If failure code display function is checked, failure codes are displayed q
Phenomena related to engine
3 Engine does not start easily (Starting performance is poor) S-1
4 Engine does not turn E-1 S-2 a)
5 Engine turns but no exhaust smoke comes out S-2 b)
Engine does not start
Exhaust smoke comes out but engine does not
6 S-2 c)
start (Fuel is injected)
7 Engine does not pick up smoothly S-3
8 Engine stops during operation H-4 S-4
9 Engine does not rotate smoothly S-5
10 Engine lacks output (or lacks power) S-6
11 Exhaust smoke is black (Incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Oil becomes contaminated quickly S-9
14 Fuel consumption is excessive S-10
15 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11
16 Oil pressure drops S-12
17 Oil level rises (Entry of coolant or fuel) S-13
18 Coolant temperature becomes too high (overheating) S-14
19 Abnormal noise is made S-15
20 Vibration is excessive S-16
21 Preheater does not operate normally E-2
Phenomena related to power train
22 The machine does not start H-1
23 The travel speed is low E-3 a), b) H-2
24 The travel speed is high E-3 c)
25 The traction force is weak H-3
26 Engine stalls when traveling or engine speed drops excessively H-4
27 Shift range is not shifted H-5
28 Travel direction selection system does not function E-9
Phenomena related to steering
29 The steering wheel does not turn H-6
30 The steering wheel is heavy H-7
31 Steering wheel shakes or jerks H-8
32 Machine deviates naturally to one side when traveling H-9
Phenomena related to brake
33 The brake does not work or does not work well H-10
34 The brake is not released or is dragged H-11
40-200 6 WA150-6
Classification and procedures of troubleshooting SEN05128-01
Phenomena related to work equipment

35 The lift arm does not rise or lower H-12
36 The lift arm moves slowly or the lift arm rising force is insufficient H-13
37 When rising, the lift arm comes to move slowly at specific height H-14
The lift arm cylinder cannot hold down the bucket (The bucket rises in
38 H-15
the air)
39 Hydraulic drifts of the lift arm occur often H-16
40 The lift arm wobbles during operation H-17
When the control lever is switched from "HOLD" to "RAISE," the lift
41 H-18
arm falls temporarily
42 The bucket does not tilt back H-19
43 The bucket moves slowly or the tilting-back force is insufficient H-20
44 The bucket comes to operate slowly in the midst of tilting-back H-21
45 The bucket cylinder cannot hold down the bucket H-22
46 Hydraulic drifts of the bucket occur often H-23
The bucket wobbles during travel with load (The work equipment
47 H-24
valve is set to "HOLD")
When the control lever is switched from "HOLD" to "TILT," the bucket
48 H-25
falls temporarily
The control levers of the lift arm and bucket do not move smoothly
49 H-26
and heavy
50 The ECSS(*) does not operate and machine pitches and bounces E-4 H-27
51 ECSS(*) keeps operating E-5
52 Defective boom kick-out function and cancellation E-6
53 Defective bucket positioner function and cancellation E-7
54 Defective lift arm FLOATING holding function and cancellation E-8
Others
Fan revolution is abnormal (Fan sound/vibration is abnormally large
55 H-28
or engine overheats)
56 Fan does not reverse E-10
57 Fan keeps rotating in reverse E-11
58 Wiper does not operate E-12
59 Windshield washer does not operate E-13
Headlamp, clearance lamp, tail lamp and license lamp(*) do not light
60 E-14
up or go off
61 Working lamp does not light up or go off E-15
62 Turn signal lamp and hazard lamp do not light up or go off E-16
63 Brake lamp does not light or it keeps lighting up E-17
64 Backup lamp does not light or it keeps lighting up E-18
65 Backup alarm does not sound or it keeps sounding E-19
66 Horn does not sound or it keeps sounding E-20
67 Alarm buzzer does not sound or it keeps sounding E-21
68 Air conditioner does not operate or stop (Note)
69 The KOMTRAX(*) system does not work properly E-22
(Note): See section 80 Appendix, “100 Air conditioner” for detail.
(*): If equipped
WA150-6 40-200 7
SEN05128-01 Information contained in troubleshooting table
Information contained in troubleshooting table 1
Action code Failure code

Monitor Trouble Problem that appears on machine
Monitor display
display
Contents of
State where the monitor panel or controller detects the trouble
trouble
Action of Action taken by machine monitor or controller to protect system or devices when engine con-
controller troller detects trouble
Problem that
Problem that appears on machine as a result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related
Information related to detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting
<Described contents>
• Standard value in normal state to judge assumed cause
(good or not)
1 • Remarks required to judge whether the cause is good
<Phenomenon of defective wiring harness>

• Disconnection in wiring
The connector connection is defective or the wiring harness
is disconnected.
• Grounding fault
A harness not connected to 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 Possible causes of trouble A harnesses of an independent circuit abnormally comes
and standard is assumed to be detected into contact with one of another circuit.
value in normal (The order number indicates
state a serial number, not a priority <Notes on troubleshooting>
sequence.) (1) Method of indicating connector number and handling T-
branch
For troubleshooting, insert or connect T-branch adapter
3 as shown below unless especially specified.
• When “male” or “female” is not indicated for a con-
nector number, disconnect the connector, and insert
the T-branch adapter in both the male and female.
• When “male” and “female” is indicated for a connec-
tor number, disconnect the connector, and insert the
T-branch adapter in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
leads as shown below unless especially specified.
4 • Connect the plus (+) lead to a pin or harness indi-
cated in the front.
• Connect the minus (–) lead to a pin or harness indi-
cated in the rear.
Related circuit diagram
40-200 8 WA150-6
Information contained in troubleshooting table SEN05128-01
This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model – No. of pins) (Color)
• “Connector No. and pin No.” from each branching/
merging point: Shows the ends of branch or source of
merging within the parts of the same wiring harness.
• Arrow (io): Roughly shows the location on the
machine.
WA150-6 40-200 9
SEN05128-01 Connection table for connector pin numbers
Connection table for connector pin numbers (Rev. 2009.04)
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.
40-200 10 WA150-6
Connection table for connector pin numbers SEN05128-01
WA150-6 40-200 11
40-200 12 WA150-6
WA150-6 40-200 13
40-200 14 WA150-6
WA150-6 40-200 15
40-200 16 WA150-6
WA150-6 40-200 17
40-200 18 WA150-6
WA150-6 40-200 19
40-200 20 WA150-6
WA150-6 40-200 21
40-200 22 WA150-6
WA150-6 40-200 23
40-200 24 WA150-6
WA150-6 40-200 25
40-200 26 WA150-6
WA150-6 40-200 27
40-200 28 WA150-6
WA150-6 40-200 29
40-200 30 WA150-6
WA150-6 40-200 31
40-200 32 WA150-6
WA150-6 40-200 33
40-200 34 WA150-6
WA150-6 40-200 35
40-200 36 WA150-6
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40-200 38 WA150-6
WA150-6 40-200 39
40-200 40 WA150-6
WA150-6 40-200 41
40-200 42 WA150-6
WA150-6 40-200 43
40-200 44 WA150-6
WA150-6 40-200 45
SEN05128-01 T- branch box and T- branch adapter table
T- branch box and T- branch adapter table (Rev. 2009.03)1
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
40-200 46 WA150-6
T- branch box and T- branch adapter table SEN05128-01
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
WA150-6 40-200 47
SEN05128-01 T- branch box and T- branch adapter table
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.
40-200 48 WA150-6
T- branch box and T- branch adapter table SEN05128-01
WA150-6 40-200 49
SEN05128-01

©2009 KOMATSU
All Rights Reserved
40-200 50
SEN05129-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
301 Troubleshooting by failure code

(Display of code), Part 1
Failure code [2G40ZG] Brake: Oil pressure reduction.................................................................................... 2
Failure code [6091NX] HST filter: Clogging .................................................................................................... 4
Failure code [989FN1] Travel speed: Overrun alarm...................................................................................... 5
Failure code [AB00L6] Alternator R system: Hot short ................................................................................... 6
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage ..................... 8
Failure code [B@BAZG] Engine: Oil pressure reduction .............................................................................. 10
Failure code [B@BCNS] Engine: Overheat ...................................................................................................11
Failure code [B@BCZK] Engine: Low coolant level...................................................................................... 12
Failure code [B@C6NS] Front brake: High oil temperature.......................................................................... 14
Failure code [B@CRNS] HST: High oil temperature..................................................................................... 15
WA150-6 40-301 1
301 Troubleshooting by failure code (Display of code), Part 1
SEN05129-00 Failure code [2G40ZG] Brake: Oil pressure reduction
Failure code [2G40ZG] Brake: Oil pressure reduction

Action code Failure code Brake: Oil pressure reduction
Trouble
E03 2G40ZG (Machine monitor system)
Contents of • While engine was running (for at least 30 seconds), brake oil pressure sensor detected that oil pres-
trouble sure was below 4.4 MPa {45 kg/cm2} (circuit is open).
• Turns central warning lamp and caution buzzer ON.
• Turns brake oil pressure caution lamp ON.
Action of
• Central warning lamp, alarm buzzer and caution lamp operate for a maximum of 30 seconds after the
machine monitor
engine starts, but no failure codes are displayed.
• if cause of failure disappears, system resets itself.
Problem that
appears on • If machine is used as it is, brake may not work.
machine
Related • Input state (ON/OFF) from brake oil pressure sensor can be checked with monitoring function
information (Monitoring code: MONITOR PANEL – 40902 – D-IN-16).
Causes Standard value in normal state/Remarks on troubleshooting

System is normal.
1 Brake oil pressure reduction
a Carry out troubleshooting for hydraulic and mechanical systems.
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
T12 (male) Oil pressure Resistance
Defective brake oil pressure
2 Min. 5.88 MPa
sensor (Internal defect) Max. 1 z
{60 kg/cm2}
Between (1) – (2)
Max. 3.92 MPa
Min. 1 Mz
{40 kg/cm2}
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard
Disconnection in wiring har- without turning starting switch ON.
value in normal
state ness (Disconnection in wiring Wiring harness between T12 (female) (1) – Resis-
3 Max. 1 z
or defective contact in con- L26 (female) (1) tance
nector) Wiring harness between T12 (female) (2) – Resis-
Max. 1 z
ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
L26 Oil pressure Voltage
4 Defective machine monitor Min. 5.88 MPa
Max. 1 V
{60 kg/cm2}
Between (1) – ground
Max. 3.92 MPa
20 – 30 V
{40 kg/cm2}
40-301 2 WA150-6
Failure code [2G40ZG] Brake: Oil pressure reduction SEN05129-00
WA150-6 40-301 3
SEN05129-00 Failure code [6091NX] HST filter: Clogging
Failure code [6091NX] HST filter: Clogging

Action code Failure code HST filter: Clogging
Trouble
E01 6091NX (Machine monitor system)
Contents of • When HST oil temperature was above 50°C, HST oil filter clogging sensor signal circuit was closed
trouble (in contact with GND).
Action of • Turns HST clogging caution lamp ON.
machine monitor • if cause of failure disappears, system resets itself.
Problem that
appears on • If machine is used as it is, foreign matter may enter HST circuit.
machine
Related The input state from the HST oil filter clogging sensor can be checked with monitoring function
information (Monitoring code: MONITOR PANEL – 40903 – D-IN-24)

System is normal.
1 Clogged HST oil filter
a Check HST oil filter directly.
without turning starting switch ON.
Defective HST oil filter clog- T13 Filter condition Resistance
2
ging sensor (Internal defect)
Between T13 – Not clogged (Normal) Min. 1 Mz
ground Clogged Max. 1 z
Possible causes
and standard
value in normal
state ness (Disconnection in wiring Wiring harness between T13 – L26 (female) Resis-
3 Max. 1 z
or defective contact in con- (5) tance
nector) Wiring harness between HST oil filter clog- Resis-
Max. 1 z
ging sensor body – ground tance
4 Defective machine monitor L26 Filter condition Voltage
Not clogged (Normal) 20 – 30 V
Clogged Max. 1 V
40-301 4 WA150-6
Failure code [989FN1] Travel speed: Overrun alarm SEN05129-00
Failure code [989FN1] Travel speed: Overrun alarm

Action code Failure code Travel speed: Overrun alarm
Trouble
E02 989FN1 (Machine monitor system)
Contents of • Travel speed exceeded 43 km/h.
trouble • Auto-decelerator does not work at speed higher than 38 km/h.
Action of
• Turns central warning lamp and caution buzzer ON.
machine monitor
Problem that
appears on • If machine is used as it is, brake etc. may be damaged.
machine
Related
• If [DW26KA] or [DW26KY] is displayed, carry out troubleshooting for it first.
information

System is normal (when machine is used as it overruns by acceler-
Possible causes ating on sharp downhill road etc.)
1 Overrun
and standard a Check using condition and teach operator correct using method.
value in normal a Check related components for damage.
state • If alarm is turned ON while travel speed is below limit, machine
2 Defective machine monitor monitor may be defective. (Since trouble is in system, trouble-
shooting cannot be carried out.)
WA150-6 40-301 5
SEN05129-00 Failure code [AB00L6] Alternator R system: Hot short
Failure code [AB00L6] Alternator R system: Hot short

Action code Failure code Alternator R system: Hot short
Trouble
E01 AB00L6 (Machine monitor system)
Contents of
• When engine is stopped, alternator terminal R input voltage is above 12 V.
trouble
Action of
• Turns the charge circuit error caution lamp ON.
machine monitor
Problem that
appears on • After the engine is started, just turning on the starting switch runs the service meter.
machine
• The input state (voltage) from the alternator can be checked with the monitoring function (Monitoring
Related
code: HST – 04302 – ALTERNATOR R).
information
• Method of reproducing failure code: Turn the starting switch ON.

troubleshooting.
Defective alternator Alternator Engine Voltage
1
(Internal defect) Wiring harness Running (Throttle:
27.5 – 29.5 V
between E02 Above 1/2)
(female) (1) – ground Holds in position Max. 1.5 V
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal Hot short in wiring harness
2 Wiring harnesses between E02 (female) (1)
state (Contact with 24V circuit)
– L25 (female) (18), – circuit branch end and Voltage Max. 1 V
ground
troubleshooting.
L25 Engine Voltage
3 Defective machine monitor
Running
Between (18) and 27.5 – 29.5 V
(Throttle: Above 1/2)
ground
Holds in position Max. 1.5 V
40-301 6 WA150-6
Failure code [AB00L6] Alternator R system: Hot short SEN05129-00
WA150-6 40-301 7
SEN05129-00 Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/

Low charge voltage
Action code Failure code Alternator R system: Ground fault/Disconnection/Low charge volt-
Trouble age
E03 AB00MA (Machine monitor system)
Contents of
• While the engine is running, the alternator terminal R input voltage is below 5 V.
trouble
Action of • Turns the charge circuit failure caution lamp ON.
machine monitor • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Deterioration of battery or insufficient charging
appears on
• Engine does not start.
machine
• The input state (voltage) from the alternator can be checked with the monitoring function (Monitoring
Related
code: HST – 04302 – ALTERNATOR R).
information
• Method of reproducing failure code: Start engine

1 The battery is deteriorated. The battery may be deteriorated. Check it directly.
troubleshooting.
Defective alternator Alternator Engine Voltage
2
(Internal defect) Wiring harness Running (Throttle:
27.5 – 29.5 V
between E02 Above 1/2)
(female) (1) – ground Holds in position Max. 1.5 V
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
Possible causes 3
(Disconnection or defective Wiring harnesses between E02 (female) (1) Resis-
and standard
contact in connector) Max. 1 z
value in normal – L25 (female) (18) tance
state a Prepare by turning starting switch OFF and then start engine to
Grounding fault in wiring har- carry out troubleshooting.
4 ness Wiring harness between E02 (female) (1) –
(Contact with ground circuit) L25 (female) (18) – circuit branch end and Resis-
Min. 1 Mz
tance
ground
troubleshooting.
L25 Engine Voltage
Running (Throttle:
Between (18) and 27.5 – 29.5 V
Above 1/2)
ground
Holds in position Max. 1.5 V
40-301 8 WA150-6
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage SEN05129-00
WA150-6 40-301 9
SEN05129-00 Failure code [B@BAZG] Engine: Oil pressure reduction
Failure code [B@BAZG] Engine: Oil pressure reduction

Action code Failure code Engine: Oil pressure reduction
Trouble
E03 B@BAZG (Engine controller system)
Contents of
• While engine is run, engine oil pressure became lower than operating range.
trouble
Action of • Limits output and continues operation (Limits fuel injection rate and engine speed).
Problem that
appears on • Engine output lowers.
machine
Related
information

Low engine oil pressure Engine oil has potentially gone low. Check the pressure and if it is
1
(When the system is normal) below the specified level, locate and eliminate the cause.
Defective engine oil pressure troubleshooting.
2 switch
OIL PRESSURE SWITCH Resistance
(Internal defect)
Possible causes Between terminals Min. 1 Mz
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Ground fault in wiring harness without turning starting switch ON.
3
(Contact with GND circuit) Wiring harnesses between EC1 (female) Resis-
Min. 1 Mz
(32) – OIL PRESSURE SWITCH and ground tance
troubleshooting.
4 Defective engine controller
EC1 Resistance
Between (32) and ground Min. 1 Mz
40-301 10 WA150-6
Failure code [B@BCNS] Engine: Overheat SEN05129-00
Failure code [B@BCNS] Engine: Overheat

Action code Failure code Engine: Overheat
Trouble
E02 B@BCNS (Engine controller system)
Contents of • While engine was running, engine coolant temperature sensor signal circuit detected engine coolant
trouble overheat.
Action of • Limits fuel injection until coolant temperature lowers to operating range.
machine monitor • Turns central warning lamp and caution buzzer ON.
Problem that
appears on • Engine output decreases.
machine
Related • Engine coolant temperature can be checked with monitoring function.
information (Monitoring code: ENGINE – 04104 – COOLANT TEMP (°C))

Engine coolant overheat
1 Engine coolant may be overheating. Remove cause of overheat.
(when system is normal)
Possible causes
and standard If cause 1 is not detected, engine coolant temperature sensor sys-
Defective engine coolant
value in normal 2 tem may be defective. Carry out troubleshooting for failure codes
temperature sensor system
state [CA144] and [CA145].
If causes 1 and 2 are not detected, engine controller may be defec-
3 Defective engine controller tive. Carry out troubleshooting for failure codes [CA144] and
[CA145].
WA150-6 40-301 11
SEN05129-00 Failure code [B@BCZK] Engine: Low coolant level
Failure code [B@BCZK] Engine: Low coolant level

Action code Failure code Engine: Low coolant level
Trouble
E01 B@BCZK (Machine monitor system)
Contents of
• Radiator coolant level switch signal circuit was opened (disconnected from GND) for 30 seconds.
trouble
Action of
• Turns radiator coolant level caution lamp ON.
machine monitor
Problem that
appears on • If machine is used as it is, engine may overheat.
machine
Related • Operation of radiator coolant level switch can be checked with monitoring function.

System is normal.
Low radiator sub-tank cool-
1 a Radiator sub-tank coolant level may be low. Check and add cool-
ant level
ant, if necessary.
Sub-tank coolant
Defective radiator coolant B05 (male) Resistance
2 level
level switch (Internal defect)
Above low level
Max. 1 z
Between (1) – (2) (Normal)
Possible causes Below low level Min. 1 Mz

and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal Disconnection in wiring har- without turning starting switch ON.
state ness (Disconnection in wiring Wiring harness between L27 (female) (10) – Resis-
3 Max. 1 z
or defective contact in con- B05 (female) (1) tance
nector) Wiring harness between B05 (female) (2) – Resis-
Max. 1 z
ground tance
Sub-tank coolant
L27 Voltage
4 Defective machine monitor level
Above low level
Between (10) – Max. 1 V
(Normal)
ground
Below low level 20 – 30 V
40-301 12 WA150-6
Failure code [B@BCZK] Engine: Low coolant level SEN05129-00
WA150-6 40-301 13
SEN05129-00 Failure code [B@C6NS] Front brake: High oil temperature
Failure code [B@C6NS] Front brake: High oil temperature

Action code Failure code Front brake: High oil temperature
Trouble
E02 B@C6NS (Machine monitor system)
• Front brake (axle) high oil temperature was detected (Details are as follows).
Contents of
• Oil temperature above 130°C (when travel speed was below 35 km/h) or above 125°C (when travel
trouble
speed was above 35 km/h) was detected for 5 seconds continuously.
Action of • Turns central warning lamp and caution buzzer ON.
machine monitor • Turns brake oil temperature caution lamp ON.
Problem that
appears on • If machine is used as it is, brake may be damaged.
machine
• If temperature above 120°C is detected for 5 seconds continuously, only caution lamp is turned ON
as preliminary warning.
Related
• Brake oil temperature can be checked with monitoring function.
information
(Monitoring code: MONITOR PANEL – 30201 – F BRAKE OIL (°C))
(Monitoring code: MONITOR PANEL – 30204 – F BRAKE OIL (V))

System is normal.
Front brake (Axle) high oil
1 a Front brake (Axle) oil may be overheated. Remove cause of over-
temperature
Possible causes heat.
and standard If cause 1 is not detected, brake oil temperature sensor system may
value in normal Defective brake oil tempera-
2 be defective. Carry out troubleshooting for failure codes [DGR2KB]
state ture sensor
and [DGR2KZ].
If causes 1 and 2 are not detected, machine monitor may be defec-
3 Defective machine monitor tive. Carry out troubleshooting for failure codes [DGR2KB] and
[DGR2KZ].
40-301 14 WA150-6
Failure code [B@CRNS] HST: High oil temperature SEN05129-00
Failure code [B@CRNS] HST: High oil temperature

Action code Failure code HST: High oil temperature
Trouble
E02 B@CRNS (Machine monitor system)
Contents of
• HST oil temperature higher than 105°C was detected for 10 seconds continuously.
trouble
Action of • Turns central warning lamp and caution buzzer ON.
machine monitor • Turns HST oil temperature caution lamp ON.
Problem that
appears on • If machine is used as it is, hydraulic system equipments may be damaged.
machine
• HST oil temperature can be checked with monitoring function.
Related
(Monitoring code: MONITO PANEL – 04408 – HST OIL TEMP (°C))
information
(Monitoring code: MONITO PANEL – 04409 – HST OIL TEMP (V))

System is normal.
Possible causes 1 HST high oil temperature
a HST oil may be overheated. Remove cause of overheat.
and standard
value in normal Defective HST oil tempera- If cause 1 is not detected, HST oil temperature sensor system may
2
state ture sensor be defective. Carry out troubleshooting for failure code [DGH1KX].
tive. Carry out troubleshooting for failure code [DGH1KX].
WA150-6 40-301 15
SEN05129-00

©2009 KOMATSU
All Rights Reserved
40-301 16
SEN05130-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

Failure code [CA111] Abnormality in engine controller ................................................................................... 3
Failure code [CA115] Engine Ne or Bkup speed sensor error ........................................................................ 6
Failure code [CA122] Charge pressure sensor high error .............................................................................. 8
Failure code [CA123] Charge pressure sensor low error.............................................................................. 10
Failure code [CA131] Throttle sensor high error........................................................................................... 12
Failure code [CA132] Throttle sensor low error ............................................................................................ 14
Failure code [CA144] Coolant sensor high error........................................................................................... 16
Failure code [CA145] Coolant sensor low error ............................................................................................ 18
Failure code [CA153] Charge temperature sensor high error....................................................................... 20
Failure code [CA154] Charge temperature sensor low error ........................................................................ 22
Failure code [CA187] Sensor power supply 2 low error................................................................................ 23
Failure code [CA221] Atmospheric pressure sensor high error .................................................................... 24
Failure code [CA222] Atmospheric sensor low error .................................................................................... 26
Failure code [CA227] Sensor power supply 2 high error .............................................................................. 27
Failure code [CA234] Engine overspeed ...................................................................................................... 29
Failure code [CA238] Ne speed sensor power supply error ......................................................................... 30
Failure code [CA271] IMV (IMA) Short circuit ............................................................................................... 32
Failure code [CA272] IMV (IMA) Disconnection ........................................................................................... 34
Failure code [CA322] Injector #1 open/short error........................................................................................ 36
WA150-6 40-302 1
SEN05130-00

Failure code [CA351] Injectors drive circuit error .......................................................................................... 44
Failure code [CA352] Sensor power supply 1 low error................................................................................ 46
Failure code [CA386] Sensor power supply 1 high error .............................................................................. 48
40-302 2 WA150-6
Failure code [CA111] Abnormality in engine controller SEN05130-00
Failure code [CA111] Abnormality in engine controller 1
Action code Failure code Abnormality in engine controller

Trouble
E03 CA111 (Engine controller system)
Contents of
• Abnormality occurred in memory of engine controller or power supply circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on • The engine does not start.
machine
Related
information

1 Defective fuse FS1 (4) If fuse is broken, circuit probably has ground fault. (Refer to cause 4)
Defective power supply cut- without turning starting switch ON.
2
out relay Wiring harness between EC2 (female) (55) – Resis- 185 –
(32) tance 265 z
Wiring harness between EC2 (female) (55) – Resis-
Max. 1 z
L107 (female) (1) tance
Max. 1 z
Possible causes L108 (female) (1) tance
and standard Wiring harness between EC2 (female) (32) – Resis-
value in normal Max. 1 z
state Disconnection in wiring Wiring harness between EC2 (female) (32) – Resis-
harness Max. 1 z
3 (Disconnection in wiring or
defective contact in connec- Max. 1 z
tor) E14 tance
Max. 1 z
Max. 1 z
Wiring harness between L107 (female) (3) – Resis-
Max. 1 z
battery (+) tance
Max. 1 z
battery (+) tance
WA150-6 40-302 3
SEN05130-00 Failure code [CA111] Abnormality in engine controller

Wiring harness between EC2 (female) (55) – Resis- Min.
L107 (female) (1) and chassis ground tance 1 Mz
Ground fault in wiring har-
Possible causes 4 ness (Short circuit with GND
and standard circuit)
value in normal
state
Wiring harness between L107 (female) (3) – Resis- Min.
battery (+) and chassis ground tance 1 Mz
battery (+) and chassis ground tance 1 Mz
a Prepare with starting switch OFF, turn starting switch ON and
carry out troubleshooting.
EC3 Voltage
Between (4) – (1) 20 – 30 V
40-302 4 WA150-6
Failure code [CA111] Abnormality in engine controller SEN05130-00
WA150-6 40-302 5
SEN05130-00 Failure code [CA115] Engine Ne or Bkup speed sensor error
Failure code [CA115] Engine Ne or Bkup speed sensor error 1
Action code Failure code Engine Ne or Bkup speed sensor error

Trouble
Contents of
• Abnormality occurred in signals of engine Ne speed sensor and engine Bkup speed sensor circuit.
trouble
Action of
controller
Problem that
• Engine stops.
appears on
• The engine does not start.
machine
Related
information

Defective Ne speed sensor
1 Carry out troubleshooting for failure code [CA689].
system
Defective Bkup speed sen-
2 Carry out troubleshooting for failure code [CA778].
sor system
Possible causes
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
and standard 3
sensor installation of sensor, internal of flywheel, etc.)
value in normal
state Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defective
4
speed sensor installation of sensor, internal of supply pump, etc.)
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defec-
5
connection) tive connection (wrong connection).
If causes 1 – 5 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
Reference: Bkup speed sensor = Cam speed sensor
40-302 6 WA150-6
Failure code [CA115] Engine Ne or Bkup speed sensor error SEN05130-00
WA150-6 40-302 7
SEN05130-00 Failure code [CA122] Charge pressure sensor high error
Failure code [CA122] Charge pressure sensor high error 1
Action code Failure code Charge pressure sensor high error

Trouble
Contents of
• High voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor.
trouble
Action of • Fixes charge pressure (boost pressure) and continues operation.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: ENGINE, 36500, CHG PRESS-A).
Related
• The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
information
with the monitoring function (Code: ENGINE, 36502, CHG PRESS-A).

Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out trouble-
1
ply system shooting for it first.
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
Defective charge pressure PTIM Voltage
2 sensor Between (3) – (1) Power supply 4.75 – 5.25 V
(Internal defect)
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.
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har- Wiring harness between EC1 (female) (19) – Resis-
value in normal ness Max. 1 z
PTIM (female) (4) tance
state 3 (Disconnection in wiring or
tor) PTIM (female) (3) tance
Max. 1 z
Ground fault in wiring har- Wiring harness between EC1 (female) (19) – Resis- Min.
ness PTIM (female) (4) and chassis ground tance 1 Mz
4
(Short circuit with GND cir- Wiring harness between EC1 (female) (36) – Resis- Min.
cuit) PTIM (female) (3) and chassis ground tance 1 Mz
PTIM (female) (1) and chassis ground tance 1 Mz
40-302 8 WA150-6
Failure code [CA122] Charge pressure sensor high error SEN05130-00

Wiring harness between EC1 (female) (19) –
PTIM (female) (4) and wiring harness Resis- Min.
between EC1 (female) (36) – PTIM (female) tance 1 Mz
Short circuit in wiring har- (3)
ness Wiring harness between EC1 (female) (19) –
Possible causes 5
(With another wiring har- PTIM (female) (4) and wiring harness Resis- Min.
and standard ness) between EC1 (female) (48) – PTIM (female) tance 1 Mz
value in normal (1)
state
PTIM (female) (3) and wiring harness Resis- Min.
between EC1 (female) (48) – PTIM (female) tance 1 Mz
(1)
a Prepare with starting switch OFF, turn starting switch ON or
START and carry out troubleshooting.
EC1 Voltage
Between (36) – (48) Power supply 4.75 – 5.25 V
WA150-6 40-302 9
SEN05130-00 Failure code [CA123] Charge pressure sensor low error
Failure code [CA123] Charge pressure sensor low error 1
Action code Failure code Charge pressure sensor low error

Trouble
Contents of
• Low voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor.
trouble
Action of • Fixes charge pressure (boost pressure) and continues operation.
Problem that
machine
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: ENGINE, 36500, CHG PRESS-A).
Related
• The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
information
with the monitoring function (Code: ENGINE, 36502, CHG PRESS-A).
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA122].
state
40-302 10 WA150-6
Failure code [CA123] Charge pressure sensor low error SEN05130-00
WA150-6 40-302 11
SEN05130-00 Failure code [CA131] Throttle sensor high error
Failure code [CA131] Throttle sensor high error 1
Action code Failure code Throttle sensor high error

Trouble
Contents of
• High voltage was detected in the throttle sensor signal circuit.
trouble
Action of • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
Problem that
appears on • The engine does not reach full throttle.
machine
• The input state (accelerator pedal opening ratio) from the throttle sensor can be checked with the
monitoring function (Code: ENGINE, 31701, THROTTLE POS).
Related
• The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
information
ENGINE, 31707, THROTTLE POS).

Defective throttle sensor If failure code [CA2185] is indicated simultaneously, carry out trou-
1
power supply system bleshooting for it first.
PD1 Accelerator pedal Voltage
All range
Between (1) and (3) 4.75 – 5.25 V
Defective accelerator pedal (Power supply)
2
(Internal defect) When released 0.50 – 0.80 V
Between (2) and (3)
When pressed 3.70 – 4.00 V
ingly, if voltage is abnormal, check wiring harness and controller for
another cause of trouble before judgment
Hot short (Short circuit with and carry out troubleshooting.
3 5V, 24V circuit) in wiring har-
Possible causes Wiring harness between EC2 (female) (35) –
ness Voltage Max. 1 V
and standard PD1 (female) (2) and ground
value in normal
state
Short circuit in wiring har- without turning starting switch ON.
4 ness Wiring harness between EC2 (female) (35) –
(with another wiring harness) PD1 (female) (2), EC2 (female) (27) – PD1 Resis- Min.
tance 1 Mz
(female) (1)
Connecting parts among accelerator pedal, engine unit wiring har-
ness, and engine controller are suspected. Inspect them directly.
Defective wiring harness
5 • Loose connector, broken lock, broken seal
connector
• Corrosive, bent, broken, forced-in, or extended pin
• Humidity in connector, entry of dirt or dust, poor insulation
EC2 Accelerator pedal Voltage
6 Defective engine controller Between (27) and All range
4.75 – 5.25 V
(28) (Power supply)
Between (35) and When released 0.50 – 0.80 V
(28) When pressed 3.70 – 4.00 V
40-302 12 WA150-6
Failure code [CA131] Throttle sensor high error SEN05130-00
WA150-6 40-302 13
SEN05130-00 Failure code [CA132] Throttle sensor low error
Failure code [CA132] Throttle sensor low error 1
Action code Failure code Throttle sensor low error

Trouble
Contents of
• Low voltage was detected in the throttle sensor signal circuit.
trouble
Problem that
machine
• The input state (accelerator pedal opening ratio) from the throttle sensor can be checked with the
monitoring function (Code: ENGINE, 31701, THROTTLE POS).
Related
• The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
information
ENGINE, 31707, THROTTLE POS).

Defective throttle sensor If failure code [CA2186] is indicated simultaneously, carry out trou-
1
power supply system bleshooting for it first.
PD1 Accelerator pedal Voltage
All range
Between (1) and (3) 4.75 – 5.25 V
Defective accelerator pedal (Power supply)
2
(Internal defect) When released 0.50 – 0.80 V
Between (2) and (3)
When pressed 3.70 – 4.00 V
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
3
Possible causes (Short circuit with ground cir- Wiring harness between EC2 (female) (35) – Resis- Min.
and standard cuit) PD1 (female) (2) and ground tance 1 Mz
value in normal
state
4 ness Wiring harness between EC2 (female) (35) –
(with another wiring harness) PD1 (female) (2), EC2 (female) (28) – PD1 Resis- Min.
tance 1 Mz
(female) (3)
Connecting parts among fuel control dial, engine unit wiring har-
connector
EC2 Accelerator pedal Voltage
6 Defective engine controller Between (27) and All range
4.75 – 5.25 V
(28) (Power supply)
(28) When pressed 3.70 – 4.00 V
40-302 14 WA150-6
Failure code [CA132] Throttle sensor low error SEN05130-00
WA150-6 40-302 15
SEN05130-00 Failure code [CA144] Coolant sensor high error
Failure code [CA144] Coolant sensor high error 1
Action code Failure code Coolant sensor high error

Trouble
Contents of
• High voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes engine coolant temperature and continues operation.
controller
Problem that
• Exhaust smoke becomes white
appears on
• Overheat prevention function does not function.
machine
• The input state (temperature) from the engine coolant temperature sensor can be checked with the
monitoring function (Code: ENGINE, 04104, COOLANT TEMP).
Related
• The input state (voltage) from the engine coolant temperature sensor can be checked with the moni-
information
toring function (Code: ENGINE, 04105, COOLANT TEMP).

TWTR (male) Coolant temperature Resistance
Defective coolant tempera- 0°C 30 – 37 kz

1
ture sensor (Internal defect) 25°C 9.3 – 10.7 kz
Between (B) – (A) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
ness (Disconnection in wiring Wiring harness between EC1 (female) (47) – Resis-
Possible causes 2 Max. 1 z
or defective contact in con- TWTR (female) (A) tance
and standard nector) Wiring harness between EC1 (female) (49) – Resis-
state TWTR (female) (B) tance
Ground fault in wiring har- without turning starting switch ON.
3 ness (Short circuit with GND
circuit) Wiring harness between EC1 (female) (49) – Resis- Min.
TWTR (female) (B) and chassis ground tance 1 Mz
EC1 (female) Coolant temperature Resistance
0°C 30 – 37 kz
25°C 9.3 – 10.7 kz
Between (49) – (47) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
40-302 16 WA150-6
Failure code [CA144] Coolant sensor high error SEN05130-00
WA150-6 40-302 17
SEN05130-00 Failure code [CA145] Coolant sensor low error
Failure code [CA145] Coolant sensor low error 1
Action code Failure code Coolant sensor low error

Trouble
Contents of
• Low voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes engine coolant temperature and continues operation.
controller
Problem that
• Exhaust smoke becomes white
appears on
• Overheat prevention function does not function.
machine
• The input state (temperature) from the engine coolant temperature sensor can be checked with the
monitoring function (Code: ENGINE, 04104, COOLANT TEMP).
Related
• The input state (voltage) from the engine coolant temperature sensor can be checked with the moni-
information
toring function (Code: ENGINE, 04105, COOLANT TEMP).

and standard
state
40-302 18 WA150-6
Failure code [CA145] Coolant sensor low error SEN05130-00
WA150-6 40-302 19
SEN05130-00 Failure code [CA153] Charge temperature sensor high error
Failure code [CA153] Charge temperature sensor high error 1
Action code Failure code Charge temperature sensor high error

Trouble
Contents of • High voltage is detected in temperature signal circuit of boost pressure sensor and temperature sen-
trouble sor.
Action of
• Fixes charge temperature and continues operation.
controller
Problem that
• Exhaust smoke becomes white.
appears on
• Boost temperature-based engine protection function does not function.
machine
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: ENGINE, 18500, CHG TEMP).
Related
• The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP).

Intake air
PTIM (male) Resistance
temperature
Defective charge tempera- 0°C 29 – 36 kz

1
ture sensor (Internal defect) 25°C 9 – 11 kz
Between (2) – (1)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
Between (2) –
All range Min. 1 Mz
chassis ground
Disconnection in wiring Wiring harness between EC1 (female) (11) – Resis-
harness Max. 1 z
Possible causes 2 (Disconnection in wiring or
and standard defective contact in connec- Max. 1 z
tor) PTIM (3) tance
value in normal
state Wiring harness between EC1 (female) (48) – Resis-
Max. 1 z
circuit)
Intake air
EC1 (female) Resistance
temperature
4 Defective engine controller 0°C 29 – 36 kz
25°C 9 – 11 kz
Between (11) – (48)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
40-302 20 WA150-6
Failure code [CA153] Charge temperature sensor high error SEN05130-00
WA150-6 40-302 21
SEN05130-00 Failure code [CA154] Charge temperature sensor low error
Failure code [CA154] Charge temperature sensor low error 1
Action code Failure code Charge temperature sensor low error

Trouble
Contents of • Low voltage is detected in temperature signal circuit of boost pressure sensor and temperature sen-
trouble sor.
Action of
• Fixes charge temperature and continues operation.
controller
Problem that
• Exhaust smoke becomes white.
appears on
• Boost temperature-based engine protection function does not function.
machine
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: ENGINE, 18500, CHG TEMP).
Related
• The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP).

and standard
state
40-302 22 WA150-6
Failure code [CA187] Sensor power supply 2 low error SEN05130-00
Failure code [CA187] Sensor power supply 2 low error 1
Action code Failure code Sensor power supply 2 low error

Trouble
Contents of
• Low voltage is detected in sensor power supply 2 circuit.
trouble
• Fixes boost pressure and continues operation.
Action of • Fixes charge temperature and continues operation.
controller • Limits output and continues operation.
Problem that
machine
Related
information

and standard
state
WA150-6 40-302 23
SEN05130-00 Failure code [CA221] Atmospheric pressure sensor high error
Failure code [CA221] Atmospheric pressure sensor high error 1
Action code Failure code Ambient pressure sensor high error

Trouble
Contents of
• High voltage is detected in atmospheric pressure sensor circuit.
trouble
Action of
• Fixes atmospheric pressure and continues operation.
controller
Problem that
• Engine does not start easily.
appears on
• Engine output drops.
machine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: ENGINE, 37400, AMBIENT PRESS).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 37402, AMBIENT PRESS).

1
PAMB Voltage
Defective atmospheric pres-
2 sure sensor
(Internal defect) Between (2) – (1) Signal 0.3 – 4.7 V
Possible causes
and standard
Disconnection in wiring har- Wiring harness between EC1 (female) (36) – Resis-
ness PAMB (female) (3) tance
state
tor) PAMB (female) (2) tance
Max. 1 z
PAMB (female) (1) tance
ness PAMB (female) (3) and chassis ground tance 1 Mz
4
cuit) PAMB (female) (2) and chassis ground tance 1 Mz
PAMB (female) (1) and chassis ground tance 1 Mz
40-302 24 WA150-6
Failure code [CA221] Atmospheric pressure sensor high error SEN05130-00

PAMB (female) (3) and wiring harness Resis- Min.
between EC1 (female) (20) – PAMB (female) tance 1 Mz
Short circuit in wiring har- (2)
5
(With another wiring har- PAMB (female) (3) and wiring harness Resis- Min.
Possible causes
ness) between EC1 (female) (48) – PAMB (female) tance 1 Mz
and standard
value in normal (1)
state Wiring harness between EC1 (female) (20) –
PAMB (female) (2) and wiring harness Resis- Min.
between EC1 (female) (48) – PAMB (female) tance 1 Mz
(1)
a Prepare with starting switch OFF, then turn starting switch ON or
6 Defective engine controller EC1 Voltage
Between (36) – (48) 4.75 – 5.25 V
Between (20) – (48) 0.3 – 4.7 V
WA150-6 40-302 25
SEN05130-00 Failure code [CA222] Atmospheric sensor low error
Failure code [CA222] Atmospheric sensor low error 1
Action code Failure code Atmospheric sensor low error

Trouble
Contents of
• Low voltage is detected in atmospheric pressure sensor circuit.
trouble
Action of
• Fixes atmospheric pressure and continues operation.
controller
Problem that
• Engine does not start easily.
appears on
machine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: ENGINE, 37400, AMBIENT PRESS).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 37402, AMBIENT PRESS).

and standard
state
40-302 26 WA150-6
Failure code [CA227] Sensor power supply 2 high error SEN05130-00
Failure code [CA227] Sensor power supply 2 high error 1
Action code Failure code Sensor power supply 2 high error

Trouble
Contents of
• High voltage is detected in sensor power supply 2 circuit.
trouble
• Fixes boost pressure and continues operation.
Action of • Fixes charge temperature and continues operation.
controller • Limits output and continues operation.
Problem that
machine
Related
information

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Disconnect devices at Bkup speed sensor CAM connector
Defective sensor (Internal right in order. If failure Atmospheric
2 code disappears PAMB connector
defect) pressure sensor
when a device is dis-
connected, that Charge pressure
device has a defect in PTIM connector
sensor
it.
ness
3 (Disconnection in wiring or Max. 1 z
each sensor (female) tance
defective contact in connec-
Possible causes tor) Wiring harness between EC1 (female) (48) – Resis-
and standard Max. 1 z
each sensor (female) tance
value in normal
state
ness Wiring harness between EC1 (female) (36) – Resis- Min.
4
(Short circuit with GND cir- each sensor (female) and chassis ground tance 1 Mz
cuit) Wiring harness between EC1 (female) (48) – Resis- Min.
each sensor (female) and chassis ground tance 1 Mz
5
(With another wiring har- each sensor (female) and Resis- Min.
ness) Wiring harness between EC1 (female) (48) – tance 1 Mz
each sensor (female)
EC1 Voltage
Between (36) – (48) 4.75 – 5.25V
WA150-6 40-302 27
SEN05130-00 Failure code [CA227] Sensor power supply 2 high error
40-302 28 WA150-6
Failure code [CA234] Engine overspeed SEN05130-00
Failure code [CA234] Engine overspeed 1
Action code Failure code Engine Overspeed

Trouble
Contents of
• Engine speed is above upper control limit.
trouble
Action of • Stops injection of injector until engine speed drops to normal level.
Problem that
appears on • Engine speed fluctuates.
machine
Related • Engine speed can be checked by monitoring function (Code: ENGINE, 01001, ENG SPEED).
information • Method of reproducing failure code: Start engine and running at high idle.

1 Use of improper fuel Check fuel used directly.
Possible causes
and standard Improper way of speed con- Way of speed control may be improper. Teach proper way of use to
2
value in normal trol operator.
state If causes 1 and 2 are not detected, engine controller may be defec-
3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
WA150-6 40-302 29
SEN05130-00 Failure code [CA238] Ne speed sensor power supply error
Failure code [CA238] Ne speed sensor power supply error 1
Action code Failure code Ne speed sensor supply power error

Trouble
Contents of
• Low voltage is detected in engine Ne speed sensor power supply circuit.
trouble
Action of • Controls Ne speed sensor with signals of Bkup speed sensor.
Problem that
• Starting performance is poor.
appears on
• There is hunting from engine.
machine
Related
information

Disconnect devices at
Defective Ne speed sensor right in order. If fail-
1 ure code disappears
(Internal defect)
when a device is dis- Ne speed sensor NE connector
connected, that
device has a defect in
it.
2 Max. 1 z
or defective contact in con- NE (female) (3) tance
nector) Wiring harness between EC1 (female) (44) – Resis-
Possible causes
Max. 1 z
and standard NE (female) (2) tance
state without turning starting switch ON.
NE (female) (3) and chassis ground tance 1 Mz
circuit)
NE (female) (2) and chassis ground tance 1 Mz
4 ness (with another wiring Wiring harness between EC1 (female) (26) –
harness) Resis- Min.
NE (female) (3) and between EC1 (female)
tance 1 Mz
(44) – NE (female) (2)
EC1 Voltage
Between (26) – (44) 4.75 – 5.25 V
40-302 30 WA150-6
Failure code [CA238] Ne speed sensor power supply error SEN05130-00
WA150-6 40-302 31
SEN05130-00 Failure code [CA271] IMV (IMA) Short circuit
Failure code [CA271] IMV (IMA) Short circuit 1
Action code Failure code IMV (IMA) Short circuit

Trouble
Contents of
• There is short circuit in supply pump actuator drive circuit.
trouble
Action of
controller
Problem that • Engine speed does not rise from low idle.
machine • Common rail fuel pressure is above command value.
Related
information

Defective supply pump IMV PREG (male) Resistance
1
(Internal defect) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) – chassis
Min. 1 Mz
ground
2
(Short circuit with GND cir- PREG (female) (1) tance 1 Mz
Possible causes cuit) Wiring harness between EC1 (female) (14) – Resis- Min.
and standard
PREG (female) (2) tance 1 Mz
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
Hot short (Short circuit with
3 5V, 24V circuit) in wiring har- Voltage Max. 1 V
PREG (female) (1) and chassis ground
ness
Voltage Max. 1 V
PREG (female) (2) and chassis ground
Between (10) – (14) 2.3 – 5.3 z
Min. 1 Mz
ground
40-302 32 WA150-6
Failure code [CA271] IMV (IMA) Short circuit SEN05130-00
WA150-6 40-302 33
SEN05130-00 Failure code [CA272] IMV (IMA) Disconnection
Failure code [CA272] IMV (IMA) Disconnection 1
Action code Failure code IMV (IMA) Disconnection

Trouble
Contents of
• There is disconnection in supply pump actuator drive circuit.
trouble
Action of
controller
Problem that
• Engine runs, but in unstable condition.
appears on
• Common rail fuel pressure is above command value.
machine
Related
information

1
(Internal disconnection) Between (1) – (2) 2.3 – 5.3 z
Min. 1 Mz
ground
ness
Possible causes Wiring harness between EC1 (female) (10) – Resis-
and standard PREG (female) (1) tance
value in normal tor) Wiring harness between EC1 (female) (14) – Resis-
state Max. 1 z
PREG (female) (2) tance
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
3
cuit) PREG (female) (1) and chassis ground tance 1 Mz
4 Defective engine controller EC1 (female) Resistance
Between (10) – (14) 2.3 – 5.3 z
Between (10) – chassis ground Min. 1 Mz
40-302 34 WA150-6
Failure code [CA272] IMV (IMA) Disconnection SEN05130-00
WA150-6 40-302 35
SEN05130-00 Failure code [CA322] Injector #1 open/short error
Failure code [CA322] Injector #1 open/short error 1
Action code Failure code Injector #1 open/short error

Trouble
Contents of
• There is disconnection or short circuit in drive circuit of injector No. 1.
trouble
Action of
controller
Problem that
• There is irregular combustion or hunting.
appears on
machine
Related
information

Defective injector #1 CN1 (male) Resistance
1
(Internal defect) Between (2) – (1) 0.4 – 1.1 z
Min. 1 Mz
ground
ness
CN1 (female) (2) tance
tor) Wiring harness between EC1 (female) (53) – Resis-
Possible causes Max. 1 z
and standard
state Ground fault in wiring har- without turning starting switch ON.
3
(Short circuit with GND cir- CN1 (female) (2) and chassis ground tance 1 Mz
CN1 (female) (1) and chassis ground tance 1 Mz
Defective injector or wiring If another failure code for injector abnormality is displayed, carry out
4
harness of another cylinder troubleshooting for it.
Between (57) – (53) 0.4 – 1.1 z
Min. 1 Mz
ground
40-302 36 WA150-6
Failure code [CA322] Injector #1 open/short error SEN05130-00
WA150-6 40-302 37

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective injector #3 (Inter- CN3 (male) Resistance
1
nal defect) Between (2) – (1) 0.4 – 1.1 z
Min. 1 Mz
ground
2 Max. 1 z
or defective contact in con- CN3 (female) (2) tance
and standard
circuit)
4
Between (55) – (59) 0.4 – 1.1 z
Min. 1 Mz
ground
40-302 38 WA150-6
WA150-6 40-302 39

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
and standard
circuit)
4
Between (45) – (58) 0.4 – 1.1 z
Min. 1 Mz
ground
40-302 40 WA150-6
WA150-6 40-302 41

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
and standard
circuit)
4
Between (56) – (51) 0.4 – 1.1 z
Min. 1 Mz
ground
40-302 42 WA150-6
WA150-6 40-302 43
SEN05130-00 Failure code [CA351] Injectors drive circuit error
Failure code [CA351] Injectors drive circuit error 1
Action code Failure code Injectors drive circuit error

Trouble
Contents of
• Abnormality occurred in injector drive power supply circuit.
trouble
Action of • Limits output and continues operation (limits common rail pressure).
• Exhaust smoke is black.
Problem that
• There is irregular combustion.
appears on
machine
Related
information

1 Defect in related system If another code is displayed, carry out troubleshooting for it.
Defective fuse No. 4 of fuse
2 If the fuse is broken, the circuit probably has a grounding fault, etc.
box FS1
L107 (Male) Resistance
Defective engine control cut-
Between (1) and (2) 200 – 400 z
out relay 1 (L107) (Internal
3 a Prepare with starting switch OFF, then turn starting switch ON
disconnection or short cir-
cuit) and carry out troubleshooting.
When engine control cut-out relay 1 (L107) is replaced with a relay
of the same type, if the condition becomes normal, the engine con-
trol cut-out relay 1 is defective.
Possible causes
and standard L108 (male) Resistance
Defective engine control cut-
value in normal Between (1) and (2) 200 – 400 z
out relay 2 (L108) (Internal
state 4 a Prepare with starting switch OFF, then turn starting switch ON
disconnection or short cir-
cuit) and carry out troubleshooting.
When engine control cut-out relay 2 (L108) is replaced with a relay
of the same type, if the condition becomes normal, the engine con-
trol cut-out relay 2 is defective.
Disconnection in wiring har- Wiring harness between fuse No. 4 of fuse Resis- Max.
ness box FS1 – L107, L108 (female) (3) tance 0.5 z
5
(Disconnection or defective Wiring harness between L107 (female) (5), Resis- Max.
contact in connector) L108 (female) (5) – EC3 (female) (4) tance 0.5 z
Wiring harness between EC3 (female) (1) – Resis- Max.
ground tance 10 z
6 Defective engine controller (Since trouble is in the system, troubleshooting cannot be carried
out.)
40-302 44 WA150-6
Failure code [CA351] Injectors drive circuit error SEN05130-00
WA150-6 40-302 45
SEN05130-00 Failure code [CA352] Sensor power supply 1 low error
Failure code [CA352] Sensor power supply 1 low error 1
Action code Failure code Sensor power supply 1 low error

Trouble
Contents of
• Low voltage is detected in sensor power supply 1 (5V) circuit.
trouble
Action of • Fixes atmospheric pressure and continues operation.
Problem that
appears on
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting

and standard
state
40-302 46 WA150-6
Failure code [CA352] Sensor power supply 1 low error SEN05130-00
WA150-6 40-302 47
SEN05130-00 Failure code [CA386] Sensor power supply 1 high error
Failure code [CA386] Sensor power supply 1 high error 1
Action code Failure code Sensor power supply 1 high error

Trouble
Contents of
• High voltage is detected in sensor power supply 1 (5V) circuit.
trouble
Action of • Fixes atmospheric pressure and continues operation.
Problem that
appears on
machine
Related
information

Disconnect devices at
Defective sensor (Internal right in order. If failure
2 code disappears
defect) Common rail pres-
when a device is dis- PFUEL connector
sure sensor
connected, that
device has a defect in
it.
ness
PFUEL (female) (3) tance
Possible causes tor) Wiring harness between EC1 (female) (48) – Resis-
value in normal
state
4
(Short circuit with GND cir- PFUEL (female) (3) and chassis ground tance 1 Mz
PFUEL (female) (1) and chassis ground tance 1 Mz
5
(With another wiring har- PFUEL (female) (3) and Resis- Min.
ness) wiring harness between EC1 (female) (48) – tance 1 Mz
PFUEL (female) (1)
EC1 Voltage
Between (36) – (48) 4.75 – 5.25 V
40-302 48 WA150-6
Failure code [CA386] Sensor power supply 1 high error SEN05130-00
WA150-6 40-302 49
SEN05130-00

©2009 KOMATSU
All Rights Reserved
40-302 50
SEN05131-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

Failure code [CA431] Idle validation switch error............................................................................................ 2
Failure code [CA432] Idle validation action error ............................................................................................ 6
Failure code [CA435] Engine oil pressure switch error................................................................................. 10
Failure code [CA441] Battery voltage low error .............................................................................................11
Failure code [CA442] Battery voltage high error ........................................................................................... 12
Failure code [CA449] Common rail pressure high error 2 ............................................................................ 13
Failure code [CA451] Common rail pressure sensor high error.................................................................... 14
Failure code [CA452] Common rail pressure sensor low error ..................................................................... 16
Failure code [CA553] Common rail pressure high error 1 ............................................................................ 17
Failure code [CA559] Supply pump pressure very low error ........................................................................ 18
Failure code [CA689] Engine Ne speed sensor error ................................................................................... 22
Failure code [CA731] Engine Bkup speed sensor phase error..................................................................... 24
Failure code [CA757] All continuous data lost error...................................................................................... 25
Failure code [CA778] Engine Bkup speed sensor error................................................................................ 26
Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 28
Failure code [CA2185] Throttle sensor supply voltage high error ................................................................. 30
Failure code [CA2186] Throttle sensor power supply low error .................................................................... 32
Failure code [CA2249] Supply pump pressure very low error 2 ................................................................... 34
Failure code [CA2311] Abnormality in IMV (IMA) solenoid ........................................................................... 36
Failure code [CA2555] Intake heater relay disconnection error .................................................................... 38
Failure code [CA2556] Intake heater relay short circuit error ....................................................................... 40
WA150-6 40-303 1
SEN05131-00 Failure code [CA431] Idle validation switch error
Failure code [CA431] Idle validation switch error 1
Action code Failure code Idle validation switch error

Trouble
Contents of
• Abnormality occurred in idle validation switch circuit
trouble
Action of
• Operates at position of throttle of throttle sensor.
controller
Problem that
appears on —
machine
• The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring func-
tion (Code: ENGINE, 18300, IVS 1).
Related
information

PD1 Signal name Voltage
Defective accelerator pedal Between (5) and (4) Signal 1
1 See Fig. 1
(Internal defect) Between (6) and (4) Signal 2
Max. 1 z
PD1 (female) (5) tance
Possible causes
and standard Disconnection in wiring har- Wiring harness between EC2 (female) (15) – Resis-
Max. 1 z
value in normal ness PD1 (female) (6) tance
2
state (Disconnection or defective Wiring harness between EC2 (female) (41) – Resis-
Max. 1 z
Max. 1 z
Wiring harness among all pins between EC2
Short circuit in wiring har- Resis-
(female) (24) – EC2 (female) (PD1 and 2, Min. 1 Mz
3 ness tance
too, is disconnected.)
(with another wiring harness)
Resis-
tance
40-303 2 WA150-6
Failure code [CA431] Idle validation switch error SEN05131-00

connector
Possible causes • Humidity in connector, entry of dirt or dust, poor insulation
value in normal without turning starting switch ON.
state
EC2 (female) Signal name Voltage
5 Defective engine controller Between (24) and
Signal 1
(41)
See Fig. 1
Between (15) and
Signal 2
(41)
WA150-6 40-303 3
SEN05131-00 Failure code [CA431] Idle validation switch error
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A: Voltage when pedal opened + 0.03 x
(Voltage when pedal pressed – Voltage
when pedal opened)
B: Voltage when pedal opened + 0.1 x
when pedal opened)
40-303 4 WA150-6
Failure code [CA431] Idle validation switch error SEN05131-00
WA150-6 40-303 5
SEN05131-00 Failure code [CA432] Idle validation action error
Failure code [CA432] Idle validation action error 1
Action code Failure code Idle validation action error

Trouble
Contents of
• Signals from the idle validation switch and throttle sensor do not agree (they are contradictory)
trouble
1. When the idle validation switch recognized the accelerator pedal is OFF and the throttle sensor, on
the contrary, recognized the accelerator pedal is ON: Control the opening ratio of the throttle to 0%
after the accelerator pedal is OFF and then control the opening ratio of the throttle to 50% while after
Action of the accelerator pedal is ON.
controller 2. When the idle validation switch recognized the accelerator pedal is ON and the throttle sensor, on
the contrary, recognized the accelerator pedal is OFF: Control the opening ratio of the throttle to 0%
(fix to the low idle).
Problem that
appears on • Engine speed does not rise from low idle.
machine
Related
information
• The input state from throttle position sensor can be checked with the monitoring function
(Code: ENGINE, 31701/31707, THROTTLE POS)

PD1 Signal name Voltage
When 0.50 –
released 0.80 V
Between (2) and (3) APS sig.
When 3.70 –
1 Defective accelerator pedal
pressed 4.00 V
Between (5) and (4) IVS 1
Possible causes See Fig. 1
and standard Between (6) and (4) IVS 2
value in normal Sensor voltage is measured with wiring harness connected. Accord-
state ingly, if voltage is abnormal, check wiring harness and controller for
Disconnection in wiring har- Wiring harness between EC2 (female) (27) – Resis- Max.
ness PD1 (female) (1) tance 1z
2
(Disconnection or defective Wiring harness between EC2 (female) (35) – Resis- Max.
contact in connector) PD1 (female) (2) tance 1z
Wiring harness between EC2(female) (27) – Resis- Max.
PD2 (female) (1) tance 1z
40-303 6 WA150-6
Failure code [CA432] Idle validation action error SEN05131-00

Short circuit in wiring har- Resis-
3 ness tance
(with another wiring harness)
Resis-
tance
Possible causes ness, and engine controller are suspected. Inspect them directly.
and standard Defective wiring harness
value in normal connector
state • Humidity in connector, entry of dirt or dust, poor insulation
EC2 (female) Accelelator pedal Voltage
Between (24) and
Signal 1
5 Defective engine controller (41)
See Fig. 1
Between (15) and
Signal 2
(41)
(28) When pressed 3.70 – 4.00 V
WA150-6 40-303 7
SEN05131-00 Failure code [CA432] Idle validation action error
40-303 8 WA150-6
Failure code [CA432] Idle validation action error SEN05131-00
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A: Voltage when pedal opened + 0.03 x
when pedal opened)
B: Voltage when pedal opened + 0.1 x
when pedal opened)
WA150-6 40-303 9
SEN05131-00 Failure code [CA435] Engine oil pressure switch error
Failure code [CA435] Engine oil pressure switch error 1
Action code Failure code Engine oil pressure switch error

Trouble
Contents of
• Abnormality occurred in engine oil pressure switch signal circuit.
trouble
Action of
• None in particular.
controller
Problem that
• Engine oil switch-based engine protection function does not function.
appears on
• Engine oil pressure monitor does not indicate normally.
machine
Related
• Method of reproducing failure code: Starting switch ON or start engine
information

Defective engine oil pressure without turning starting switch ON.
1
switch POIL (Male) Resistance
Between (1) – chassis ground Max. 1 z
Possible defective contact in connec- Wiring harness between EC1 (female) (32) – Resis-
Max. 1 z
tor) POIL (female) (1) tance
causes and
standard value a Troubleshoot with starting switch OFF, then carry out trouble-
in normal state shooting without turning starting switch ON.
Short circuit in wiring harness Wiring harness among all pins between EC1
3
(With another wiring harness) (female) (32) – EC1 (female) Resis- Min.
(With all connectors of wiring harness distance 1 Mz
connected)
Between (32) – chassis ground Max. 1 z
40-303 10 WA150-6
Failure code [CA441] Battery voltage low error SEN05131-00
Failure code [CA441] Battery voltage low error 1
Action code Failure code Battery voltage low error

Trouble
Contents of
• Low voltage (Max. 6 V) occurred in controller power supply voltage circuit.
trouble
Action of
controller
Problem that
• Engine stops
appears on
• Starting performance is poor
machine
Related
information

and standard
state
WA150-6 40-303 11
SEN05131-00 Failure code [CA442] Battery voltage high error
Failure code [CA442] Battery voltage high error 1
Action code Failure code Battery voltage high error

Trouble
Contents of
• High voltage (min. 36V) occurred in controller power supply voltage circuit.
trouble
Action of
controller
Problem that
appears on • Engine may stop.
machine
Related
information

and standard
state
40-303 12 WA150-6
Failure code [CA449] Common rail pressure high error 2 SEN05131-00
Failure code [CA449] Common rail pressure high error 2 1
Action code Failure code Common rail pressure high error 2

Trouble
Contents of
• Voltage (2) in common rail circuit is abnormally high.
trouble
Action of • Limits output and continues operation (limits common rail pressure).
Problem that
• Engine sound becomes larger under no load or light load.
appears on
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: ENGINE, 36400, RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 36402, RAIL PRESS).

and standard
state
WA150-6 40-303 13
SEN05131-00 Failure code [CA451] Common rail pressure sensor high error
Failure code [CA451] Common rail pressure sensor high error 1
Action code Failure code Common rail pressure sensor high error
Trouble
Contents of
• High voltage occurred in common rail pressure sensor.
trouble
Action of • Limits output and continues operation.
Problem that
appears on
• Engine speed or output drops.
machine
Related
information

1
PFUEL Voltage
Defective common rail pres-
2 sure sensor
(Internal defect) Between (2) – (1) Signal 0.25 – 4.6 V
Possible causes
and standard
ness PFUEL (female) (3) tance
state
tor) PFUEL (female) (2) tance
Max. 1 z
ness PFUEL (female) (3) and chassis ground tance 1 Mz
4
cuit) PFUEL (female) (2) and chassis ground tance 1 Mz
PFUEL (female) (1) and chassis ground tance 1 Mz
40-303 14 WA150-6
Failure code [CA451] Common rail pressure sensor high error SEN05131-00

PFUEL (female) (3) and wiring harness Resis- Min.
between EC1 (female) (29) – PFUEL tance 1 Mz
Short circuit in wiring har- (female) (2)
5
(With another wiring har- PFUEL (female) (3) and wiring harness Resis- Min.
Possible causes
ness) between EC1 (female) (48) – PFUEL tance 1 Mz
and standard
value in normal (female) (1)
state Wiring harness between EC1 (female) (29) –
PFUEL (female) (2) and wiring harness Resis- Min.
between EC1 (female) (48) – PFUEL tance 1 Mz
(female) (1)
6 Defective engine controller EC1 Voltage
Between (36) – (48) 4.75 – 5.25 V
Between (29) – (48) 0.25 – 4.6 V
WA150-6 40-303 15
SEN05131-00 Failure code [CA452] Common rail pressure sensor low error
Failure code [CA452] Common rail pressure sensor low error 1
Action code Failure code Common rail pressure sensor low error
Trouble
Contents of
• Low voltage occurred in common rail pressure sensor.
trouble
Problem that
appears on
• Engine speed or output drops.
machine
Related
information

and standard
state
40-303 16 WA150-6
Failure code [CA553] Common rail pressure high error 1 SEN05131-00
Failure code [CA553] Common rail pressure high error 1 1
Action code Failure code Common rail pressure high error 1

Trouble
Contents of
• Voltage (1) in common rail circuit is abnormally high.
trouble
Action of • None in particular.
Problem that
• Engine sound becomes larger under no load or light load.
appears on
machine
Related
information

Check fuel used directly
2 Use of improper fuel
(for high viscosity).
Defective electrical system of Common rail pressure sensor may have electric trouble. Carry out
Possible causes 3
common rail pressure sensor troubleshooting for failure code [CA451].
and standard
value in normal Defective mechanical system
state 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
sor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
WA150-6 40-303 17
SEN05131-00 Failure code [CA559] Supply pump pressure very low error
Failure code [CA559] Supply pump pressure very low error 1
Action code Failure code Supply pump pressure very low error
Trouble
Contents of
• No-pressure feed (1) occurred in common rail circuit.
trouble
Action of
controller
Problem that • Engine does not start or starting performance is poor
appears on • Exhaust smoke is black.
machine • Engine output drops.
Related
information

2 Use of improper fuel Check fuel used directly (for high viscosity).
3 Clogging of fuel filter a If a fuel filter is clogged, replace it.
a For contents of troubleshooting, see Note 1. For check of pres-
sure in fuel low-pressure circuit, see Testing and adjusting, "Test-
Defective low-pressure cir- ing fuel pressure".
4
cuit device Pressure in fuel low-pressure
circuit –49 – 0 MPa {–0.5 – 0 kg/cm2}
(At high idle or rated (stall) load)
Defective electrical system of Supply pump EMV may have electric trouble. Carry out trouble-
5
supply pump EMV shooting for following failure codes [CA271], [CA272].
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring har-
6
sure sensor ness for damage.
Possible causes a For testing of leakage from pressure limiter, see Testing and
and standard adjusting, "Testing leakage from pressure limiter and return rate
value in normal from injector".
state 7 Defective pressure limiter Leakage from pressure limiter
Max. 20 cc/min
(At stall load)
Reference: A limit value is the value mentioned above, but a stan-
dard value in normalcy is "0 cc/min. (no leak)".
a For testing of return rate (spill) from injector, see Testing and
adjusting, "Testing leakage from pressure limiter and return rate
from injector".
Speed at rated operation
Return (Spill) limit from injector
(at stall)
8 Defective injector 1,600 rpm 190 cc/min
1,700 rpm 200 cc/min
9 Defective supply pump If causes 1 – 8 are not detected, supply pump may be defective.
40-303 18 WA150-6
Failure code [CA559] Supply pump pressure very low error SEN05131-00
<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“.
Note 1. If fuel low-pressure circuit parts seem to be defective, check the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Leaking or clogging of fuel low-pressure piping
4) Clogging of fuel prefilter
5) Clogging of fuel main filter
6) Replace the fuel filters when trouble doesn’t cancel it even if clogging is checked.
WA150-6 40-303 19
SEN05131-00 Failure code [CA559] Supply pump pressure very low error
Check sheet for no-pressure feed
Model Work No.

Machine serial No. # Date of check / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of error/failure code / / / /
Check of monitoring information
Standard value
Code Displayed item Checking condition Unit Measured value Good NG
(Reference value)
Low idle rpm 980 ± 25
*1 Engine speed
High idle rpm 2,400 ± 50
Low idle % 0
*2 Throttle opening
High idle % 100
*3 Fuel injection command Equivalent to rating mm3 — — —
Common rail pressure
*4 Equivalent to rating MPa 90
4 command
Common rail fuel
*5 Equivalent to rating MPa —
pressure
Low idle CA — — —
Fuel injection timing
*6 High idle CA — — —
command
Equivalent to rating CA — — —
*7 Boost pressure Equivalent to rating kPa — — —
Engine coolant
*8 Low idle °C — — —
temperature
*9 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Standard value
Function Reduced cylinder Checking condition Unit Measured value Good NG
(Reference value)
5 No. 1 cylinder Low idle rpm — — —
No. 2 cylinder Low idle rpm — — —
*10
C. Check of fuel circuit pressure Standard value

Checking condition Unit Measured value Good NG
(Reference value)
kPa –49 – 0
6 Fuel low-pressure circuit pressure High idle or rated (stall) load
{kg/cm2} {–0.5 – 0
D. Check of strainers and filters Good NG

7 Visual check of fuel filter
E.Check of leakage and return rate Standard value

Checking condition Unit Measured value Good NG
(Reference value)
8 Leakage through pressure limiter Equivalent to rating cc/min Max. 20 (*)
Equivalent to rating 1,600 rpm cc/min 190
Equivalent to rating 1,700 rpm cc/min 200 Speed:
9 Return rate from injector Equivalent to rating 1,800 rpm cc/min 210
Equivalent to rating 1,900 rpm cc/min 220 Return rate:
Equivalent to rating 2,000 rpm cc/min 230
*1 – *10: Refer to monitoring code table of "Special function of monitor panel" in Testing and adjusting sec-
tion.
*11: A limit value is "Max. 20 cc/min.", but a standard value in normalcy is "0 cc/min. (no leak)".
40-303 20 WA150-6
Failure code [CA559] Supply pump pressure very low error SEN05131-00
WA150-6 40-303 21
SEN05131-00 Failure code [CA689] Engine Ne speed sensor error
Failure code [CA689] Engine Ne speed sensor error 1
Action code Failure code Engine Ne speed sensor error

Trouble
Contents of
• Abnormality occurred in signals from engine Ne speed sensor.
trouble
Problem that • There is hunting from engine.
appears on • Starting performance is poor
machine • Engine output drops.
Related
information

Defective sensor power sup- If failure code [CA238] is indicated, carry out troubleshooting for it
1
ply system first.
ness Max. 1 z
NE (female) (3) tance
tor) NE (female) (2) tance
Max. 1 z
NE (female) (1) tance
ness NE (female) (3) and chassis ground tance 1 Mz
3
cuit) NE (female) (2) and chassis ground tance 1 Mz
Possible causes Wiring harness between EC1 (female) (42) – Resis- Min.
and standard NE (female) (1) and chassis ground tance 1 Mz
value in normal
state a Prepare with starting switch OFF, then carry out troubleshooting
Resis- Min.
NE (female) (3) and wiring harness between
Short circuit in wiring har- tance 1 Mz
EC1 (female) (44) – NE (female) (2)
ness
4 Wiring harness between EC1 (female) (26) –
(With another wiring har- Resis- Min.
ness) NE (female) (3) and wiring harness between
tance 1 Mz
Resis- Min.
NE (female) (2) and wiring harness between
tance 1 Mz
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (crankshaft pulley) directly
part for defect.
If causes 1 – 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
6 defective. (Since trouble is in system, troubleshooting cannot be
sensor
carried out.)
40-303 22 WA150-6
Failure code [CA689] Engine Ne speed sensor error SEN05131-00
WA150-6 40-303 23
SEN05131-00 Failure code [CA731] Engine Bkup speed sensor phase error
Failure code [CA731] Engine Bkup speed sensor phase error 1
Action code Failure code Engine Bkup speed sensor phase error
Trouble
Contents of
• Abnormal phase is detected in signals of engine Ne speed sensor and engine Bkup speed sensor.
trouble
Problem that • Engine does not start or is difficult to start.
appears on • Idle speed is unstable.
machine • Exhaust smoke is black.
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out troubleshoot-
and standard 1
sensor system ing for [CA698].
value in normal
state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trouble-
2
speed sensor system shooting for [CA778].
40-303 24 WA150-6
Failure code [CA757] All continuous data lost error SEN05131-00
Failure code [CA757] All continuous data lost error 1
Action code Failure code All continuous data lost error

Trouble
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that • Engine stops and sometimes cannot be started.
appears on • The monitoring function of the machine monitor (engine controller system) sometimes fail to work
machine normally.
Related
information

and standard
state
WA150-6 40-303 25
SEN05131-00 Failure code [CA778] Engine Bkup speed sensor error
Failure code [CA778] Engine Bkup speed sensor error 1
Action code Failure code Engine Bkup speed sensor error

Trouble
Contents of
• Abnormality is detected in signals of engine Bkup speed sensor.
trouble
Action of • Controls Bkup speed sensor with signals of Ne speed sensor.
Problem that
• Starting performance is poor
appears on
• Engine output lowers.
machine
Related
information

1
ness Max. 1 z
CAM (female) (3) tance
tor) CAM (female) (2) tance
Max. 1 z
CAM (female) (1) tance
ness CAM (female) (3) and chassis ground tance 1 Mz
Possible causes 3
and standard (Short circuit with GND cir- Wiring harness between EC1 (female) (48) – Resis- Min.
value in normal cuit) CAM (female) (2) and chassis ground tance 1 Mz
state Wiring harness between EC1 (female) (37) – Resis- Min.
CAM (female) (1) and chassis ground tance 1 Mz
Resis- Min.
CAM (female) (3) and between EC1 (female)
Short circuit in wiring har- tance 1 Mz
(48) – CAM (female) (2)
ness
4 Wiring harness between EC1 (female) (36) –
(With another wiring har- Resis- Min.
ness) CAM (female) (3) and between EC1 (female)
tance 1 Mz
(37) – CAM (female) (1)
Resis- Min.
CAM (female) (2) and between EC1 (female)
tance 1 Mz
(37) – CAM (female) (1)
Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (in supply pump) directly
part for defect.
If causes 1 – 5 are not detected, engine Bkup speed sensor may be
Defective engine Bkup
6 defective. (Since trouble is in system, troubleshooting cannot be
speed sensor
carried out.)
40-303 26 WA150-6
Failure code [CA778] Engine Bkup speed sensor error SEN05131-00
WA150-6 40-303 27
SEN05131-00 Failure code [CA1633] KOMNET datalink timeout error
Failure code [CA1633] KOMNET datalink timeout error 1
Action code Failure code KOMNET datalink timeout error

Trouble
Contents of • Engine controller detected a communication error in the KOMNET communication circuit used for the
trouble communication between the HST controller and machine monitor.
• Continues the operation from the default mode.
Action of
controller
• If problem is removed, system is returned to normal operating state.
Problem that
• KOMNET communication information may not be transmitted correctly to cause incorrect operation
appears on
of machine. (Problem depends on failure occurrence location.)
machine
• If failure code [DAJRKR] is indicated simultaneously, carry out troubleshooting for it first.
Related
information
• KOMTRAX controller (connector name in sentence: L80) is optional.

CAN1 (male) Resistance
Defective CAN end point Between (A) and (B) 110 – 140 z
1
resistance a Prepare with starting switch OFF, then carry out troubleshooting
Between (A) and (B) 110 – 140 z
Wiring harness between EC2 (female) (1), Resis-
Max. 1 z
(21) – HST (female) (28), (38) tance
Disconnection in wiring har- Wiring harness between EC2 (female) (1), Resis-
Max. 1 z
ness (21) – L29 (female) (3), (8) tance
2
(Disconnection or defective Wiring harness between EC2 (female) (1), Resis-
(21) – L80 (female) (7), (8) tance
Possible causes
(21) – CAN1 (female) (A), (B) tance
value in normal
state Wiring harness between EC2 (female) (1), Resis-
Max. 1 z
Min. 1 Mz
(21) – HST (female) (28), (38) and ground tance
Ground fault in wiring har- Wiring harness between EC2 (female) (1), Resis-
Min. 1 Mz
ness (21) – L29 (female) (3), (8) and ground tance
3
(Short circuit with ground cir- Wiring harness between EC2 (female) (1), Resis-
cuit) Min. 1 Mz
(21) – L80 (female) (7), (8) and ground tance
Min. 1 Mz
(21) – CAN1 (female) (A), (B) and ground tance
Min. 1 Mz
a If above troubleshootings 1 – 3 have not identified the cause of
Defective machine monitor, the trouble, failure on the machine monitor, HST controller,
4 HST controller, engine con- engine controller or KOMTRAX terminal should be suspected.
troller or KOMTRAX terminal (Since trouble is in system, troubleshooting cannot be carried
out.)
40-303 28 WA150-6
Failure code [CA1633] KOMNET datalink timeout error SEN05131-00
WA150-6 40-303 29
SEN05131-00 Failure code [CA2185] Throttle sensor supply voltage high error
Failure code [CA2185] Throttle sensor supply voltage high error 1
Action code Failure code Throttle sensor supply voltage high error
Trouble
Contents of
• High voltage (min. 5.25V) occurred in throttle sensor power supply circuit.
trouble
Problem that
machine
Related
information

Short circuit in wiring har- Wiring harness among all pins between EC2
Resis- Min.
1 ness (female) (28) – EC2 (female) (PD1 and 2,
tance 1 Mz
(with another wiring harness) too, is disconnected.)
Possible causes
and standard Between EC2 (female) (28) – EC3 (female) Resis- Min.
value in normal (4) (PD1 and 2, too, is disconnected.) tance 1 Mz
state Connecting parts among accelerator pedal dial, engine unit wiring
harness, and engine controller are suspected. Inspect them directly.
connector
40-303 30 WA150-6
Failure code [CA2185] Throttle sensor supply voltage high error SEN05131-00
WA150-6 40-303 31
SEN05131-00 Failure code [CA2186] Throttle sensor power supply low error
Failure code [CA2186] Throttle sensor power supply low error 1
Action code Failure code Throttle sensor power supply voltage low error
Trouble
Contents of
• Low voltage occurred in throttle sensor power supply circuit.
trouble
Problem that
machine
Related
information

1 ness
(Contact with ground circuit) Wiring harness between EC2 (female) (27) – Resis-
Min. 1 Mz
PD1 (female) (1) and ground tance
Possible causes
and standard 2 ness Wiring harness among all pins between EC2
(with another wiring harness) (female) (35) – EC2 (female) (PD1 and 2, Resis-
value in normal Min. 1 Mz
tance
state too, is disconnected.)
connector
40-303 32 WA150-6
Failure code [CA2186] Throttle sensor power supply low error SEN05131-00
WA150-6 40-303 33
SEN05131-00 Failure code [CA2249] Supply pump pressure very low error 2
Failure code [CA2249] Supply pump pressure very low error 2 1
Action code Failure code Supply pump pressure very low error 2
Trouble
Contents of
• No-pressure feed (2) occurred in common rail circuit.
trouble
Problem that • Starting performance is poor
appears on • Exhaust smoke is black.
machine • Engine output lowers.
Related
information

and standard
value in normal 1 Carry out troubleshooting for failure code [CA559].
state
40-303 34 WA150-6
Failure code [CA2249] Supply pump pressure very low error 2 SEN05131-00
WA150-6 40-303 35
SEN05131-00 Failure code [CA2311] Abnormality in IMV (IMA) solenoid
Failure code [CA2311] Abnormality in IMV (IMA) solenoid 1
Action code Failure code Abnormality in IMV (IMA) solenoid

Trouble
Contents of
• Resistance in supply pump actuator circuit is abnormally high or low.
trouble
Action of
controller
Problem that
machine
Related
information

2
solenoid
Between (1) – (2) 2.3 – 5.3 z
ness
Possible Wiring harness between EC1 (female) (10) – Resis-
causes and PREG (female) (1) tance
standard value Wiring harness between EC1 (female) (14) – Resis-
tor) Max. 1 z
in normal state PREG (female) (2) tance
Ground fault in wiring harness without turning starting switch ON.
4
(Short circuit with GND circuit) Wiring harness between EC1 (female) (10) – Resis- Min.
PREG (female) (1) tance 1 Mz
5 Defective engine controller EC1 (female) Resistance
Between (10) – (14) 2.3 – 5.3 z
40-303 36 WA150-6
Failure code [CA2311] Abnormality in IMV (IMA) solenoid SEN05131-00
WA150-6 40-303 37
SEN05131-00 Failure code [CA2555] Intake heater relay disconnection error
Failure code [CA2555] Intake heater relay disconnection error 1
Action code Failure code Intake heater relay disconnection error

Trouble
Contents of
• There is disconnection in intake air heater relay.
trouble
Action of
controller
Problem that
• Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temper-
appears on
ature)
machine
• The input state (boost temperature) can be checked with the monitoring function (Code : ENGINE,
Related 18500, CHG TEMP)
information • Method of reproducing failure code: Turn the starting switch ON when boost temperature is –4°C or
less.

and standard
value in normal Carry out troubleshooting failure code [CA2556].
state
40-303 38 WA150-6
Failure code [CA2555] Intake heater relay disconnection error SEN05131-00
WA150-6 40-303 39
SEN05131-00 Failure code [CA2556] Intake heater relay short circuit error
Failure code [CA2556] Intake heater relay short circuit error 1
Action code Failure code Intake heater relay short circuit error
Trouble
Contents of
• There is short circuit in intake air heater relay.
trouble
Action of
controller
Problem that
• Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temper-
appears on
ature)
machine
• The input state (boost temperature) can be checked with the monitoring function (Code : ENGINE,
Related 18500, CHG TEMP)
information • Method of reproducing failure code: Turn the starting switch ON when boost temperature is –4°C or
less.

without turning starting switch ON. (Test relay unit).
Resistance
Between E06 and ground
Defective heater relay 300 – 600 z
1
(Internal short circuit) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Test by replacing relay unit.)
When heater relay is replaced with a relay of the same type, if the
condition becomes normal, the heater relay is defective.
2 ness
Possible causes (Contact with ground circuit) Wiring harness between EC2 (female) (54) – Resis-
Min. 1 Mz
and standard E06 tance
state Short circuit in wiring har- without turning starting switch ON.
3 ness Wiring harness among all pins between EC2
(with another wiring harness) (female) (54) – EC2 (female) (E06, too, is Resis-
Min. 1 Mz
tance
disconnected.)
Connecting parts among heater relay, engine unit wiring harness,
and engine controller are suspected. Inspect them directly.
connector
Between (54) and ground 300 – 600 z
40-303 40 WA150-6
Failure code [CA2556] Intake heater relay short circuit error SEN05131-00
WA150-6 40-303 41
SEN05131-00

©2009 KOMATSU
All Rights Reserved
40-303 42
SEN05132-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short ............................................................. 2
Failure code [D192KY] ECSS solenoid relay: Hot short ................................................................................. 4
Failure code [D1B0KA] HST safety relay: Disconnection ............................................................................... 6
Failure code [D1B0KB] HST safety relay: Ground fault .................................................................................. 8
Failure code [D1B0KY] HST safety relay: Hot short ..................................................................................... 10
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ............................................................. 12
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection.................................................. 14
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection ................................................ 16
Failure code [DAJ0KK] HST controller power supply: Low voltage .............................................................. 18
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality .................................................... 20
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault................................... 22
Failure code [DAJ1L6] HST controller main power line: Hot short................................................................ 24
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage ....................................................... 26
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness............. 28
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault............ 30
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range......................................................... 32
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals............. 34
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection..................................................... 35
Failure code [DAJRMA] HST controller: Disagreement in option selection .................................................. 40
WA150-6 40-304 1
SEN05132-00 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short

Action code Failure code Backup alarm/lamp relay 1 circuit: Hot short
Trouble
E01 D160KY (Machine monitor system)
Contents of • Since there is hot short in backup alarm/lamp relay 1 output system, backup lamp relay 1 does not
trouble operate.
• Turns output to backup alarm/lamp relay 1 OFF.
Action of
• If hot short occurs while alarm buzzer is in operation, output is turned OFF.
machine monitor
• If hot short occurs while ECSS is in operation, output is turned OFF.
• Backup lamp is kept ON.
Problem that
• Backup alarm is kept ON.
appears on
• Alarm buzzer may not sound.
machine
• ECSS may not operate.
• This contents applies only the "ECSS (If equipped)" installation specification model.
• Output state (ON/OFF) to backup alarm/lamp relay 1 can be checked with monitoring function.
(Monitoring code: MONITOR PANEL – 40952 – D-OUT-2)
• Operating condition of alarm buzzer can be checked with monitoring function.
Related
information
• Operating condition of ECSS can be checked with monitoring function.
• Method of reproducing failure code: Turn starting switch ON + Set FNR (directional) lever or switch to
R (Reverse) position.

troubleshooting.
Condition becomes Relay (L109) is
Replace backup lamp normal. defective.
Defective backup alarm/lamp relay 1 (L109) with
another relay. Condition does not Relay (L109) is
1 relay 1 (L109) (Internal
become normal. normal
defect)
Possible causes
and standard
value in normal Resis- 200 – 400
Between L109 (male) (1) – (2)
state tance z
Hot short (Contact with 5V, (Set FNR (directional) lever or switch to R (Reverse) position.)
2
24V circuit) in wiring harness
Wiring harness between L24 (female) (12) –
Voltage Max. 1 V
L109 (female) (2)
3 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
40-304 2 WA150-6
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short SEN05132-00
WA150-6 40-304 3
SEN05132-00 Failure code [D192KY] ECSS solenoid relay: Hot short
Failure code [D192KY] ECSS solenoid relay: Hot short

Action code Failure code ECSS solenoid relay: Hot short
Trouble
E01 D192KY (Machine monitor system)
Contents of • Since there is hot short in ECSS solenoid relay output system, ECSS solenoid relay does not oper-
trouble ate.
• Turns output to ECSS solenoid relay OFF.
Action of
• If hot short occurs while backup alarm/lamp is in operation, output is turned OFF.
machine monitor
• If hot short occurs while alarm buzzer is in operation, output is turned OFF.
Problem that • ECSS does not operate.
appears on • Backup alarm/lamp may not sound.
machine • Alarm buzzer may not operate.
• This code is applied to only "ECSS (If equipped)" specification model.
• Output state (ON/OFF) to ECSS solenoid relay can be checked with monitoring function.
• Operating condition of backup alarm/lamp can be checked with monitoring function.
Related
information
• Operating condition of alarm buzzer can be checked with monitoring function.
• This fault is not detected if ECSS is not installed.
• Method of reproducing failure code: Travel at speed higher than 5 km/h.

troubleshooting.
Replace ECSS sole- normal. defective.
noid relay (L110) with
Defective ECSS solenoid another relay. Condition does not Relay (L110) is
1
relay (L110) (Internal defect) become normal. normal.
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Resis- 200 – 400
state Between L110 (male) (1) – (2)
tance z
Hot short (Contact with 5V, and carry out troubleshooting.
2
24V circuit) in wiring harness Between wiring harness L24 (female) (11) –
Voltage Max. 1 V
L110 (female) (2) and ground
3 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
40-304 4 WA150-6
Failure code [D192KY] ECSS solenoid relay: Hot short SEN05132-00
WA150-6 40-304 5
SEN05132-00 Failure code [D1B0KA] HST safety relay: Disconnection
Failure code [D1B0KA] HST safety relay: Disconnection

Action code Failure code HST safety relay: Disconnection
Trouble
E03 D1B0KA (HST controller system)
Contents of
• Disconnection was detected in HST safety relay circuit when starting switch is turned ON.
trouble
• Turns clutch EPC solenoid output OFF.
• Turns motor 1 solenoid output OFF.
Action of
• Turns HST safety relay output OFF.
machine monitor
• Even if trouble disappears, system does not reset itself until starting switch is turned OFF.
• Traction force decreases.
Problem that
• Travel speed is not limited with speed range selector switch and travel speed control dial.
appears on
• If engine is stopped without applying parking brake securely on slope, machine moves down sud-
machine
denly.
• If [DAJ2L3] or [DAJ2L4] is displayed, carry out troubleshooting for it first.
• Following output command values can be checked with monitoring function.
Related
Motor 1 solenoid output: HST – 80000 – MOTOR SOL DIR (mA)
information
HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF)
Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA)

troubleshooting.
Replace HST safety normal. defective.
relay (L111) with
Defective HST safety relay another relay. Condition does not Relay (L111) is
1
(Internal defect) become normal. normal.
Resis- 200 – 400
tance z
troubleshooting.
Replace VIS power Condition becomes Relay (L102) is
supply holding relay normal. defective.
Possible causes Defective VIS power supply (L102) with another Condition does not Relay (L102) is
and standard 2 holding relay (Internal short relay. become normal. normal.
value in normal circuit)
Resis- 200 – 400
tance z
Disconnection in wiring har- Wiring harness between HST (female) (17) – Resis-
Max. 1 z
ness (Disconnection in wiring L111 (female) (2) tance
3
or defective contact in con- Wiring harness between L102 (female) (3) – Resis-
nector) Max. 1 z
Wiring harness between fuse FS1 (No. 3) – Resis-
Max. 1 z
4 Defective HST controller
HST Voltage
Between (17) – ground Max. 1 V
40-304 6 WA150-6
Failure code [D1B0KA] HST safety relay: Disconnection SEN05132-00
WA150-6 40-304 7
SEN05132-00 Failure code [D1B0KB] HST safety relay: Ground fault
Failure code [D1B0KB] HST safety relay: Ground fault

Action code Failure code HST safety relay: Ground fault
Trouble
E01 D1B0KB (HST controller system)
Contents of
• Ground fault was detected in HST safety relay circuit when starting switch is turned ON.
trouble
Action of
machine monitor
Problem that
appears on
machine
denly.
Related Motor 1 solenoid output: HST – 80000 – MOTOR SOL DIR (mA)
information HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF)
Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA).

troubleshooting.
relay (L111) with
1
Possible causes
and standard
value in normal
state Resis- 200 – 400
tance z
2 ness (Contact with GND cir-
cuit) Between wiring harness (HST (female) (17) Resis-
Min. 1 Mz
– L111 (female) (2) and ground tance
If causes 1 and 2 are not detected, HST controller may be defective.
40-304 8 WA150-6
Failure code [D1B0KB] HST safety relay: Ground fault SEN05132-00
WA150-6 40-304 9
SEN05132-00 Failure code [D1B0KY] HST safety relay: Hot short
Failure code [D1B0KY] HST safety relay: Hot short

Action code Failure code HST safety relay: Hot short
Trouble
E03 D1B0KY (HST controller system)
Contents of
• Hot short was detected in HST safety relay circuit.
trouble
Action of
machine monitor
Problem that
appears on
machine
denly.
• If [DAJ2L3] or [DAJ2L4] is displayed, carry out troubleshooting for it first.
Related
information
Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA).

troubleshooting.
relay (L111) with
1
Possible causes
and standard
value in normal
state Resis- 200 – 400
tance z
2
24V circuit) in wiring harness Between wiring harness HST (female) (17) –
Voltage Max. 1 V
If causes 1 and 2 are not detected, HST controller may be defective.
40-304 10 WA150-6
Failure code [D1B0KY] HST safety relay: Hot short SEN05132-00
WA150-6 40-304 11
SEN05132-00 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection

Action code Failure code IGN C system: Ground fault/Disconnection
Trouble
E01 D5ZHL6 (Machine monitor system)
• Machine monitor detected disconnection or ground fault in C terminal system.
(When engine speed is above 500 rpm and there is alternator R terminal voltage and starting switch
Contents of
is ON, there is not C terminal signal input.)
trouble
a If engine speed above 250 rpm is sensed in 3 seconds after starting switch is turned ON, however,
error is not detected.
Action of • None in particular.
machine monitor • When starting switch is turned OFF after trouble is repaired, system is reset.
Problem that
appears on • Engine cannot be started (It may be able to be started, depending on faulty part).
machine
• Input state (ON/OFF) from starting switch C terminal to machine monitor be checked with monitoring
Related function.
information (MONITOR PANEL – 40900 – D-IN-2)
• Method of reproducing failure code: Turn starting switch to START position.

a Prepare with starting switch OFF, then turn starting switch to ON/
OFF/START position and carry out troubleshooting.
Defective starting switch Starting switch
1 L02 Voltage
(Internal defect) position
START 20 – 30 V
OFF/ON Max. 1 V
Disconnection in wiring har- Wiring harness between L106 (female) (5) – Resis-
Max. 1 z
ness (Disconnection in wiring L25 (female) (2) tance
2
or defective contact in con- Wiring harness between L02 (female) (3) – Resis-
nector) Max. 1 z
Possible causes
value in normal
Between wiring harness L02 (female) (3) – Resis-
Ground fault in wiring har- Min. 1 Mz
L79 (female) (3) and ground tance
cuit) Between wiring harness L79 (female) (6) – Resis-
Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch to ON/
OFF/START position and carry out troubleshooting.
Starting switch
4 Defective machine monitor L25 Voltage
position
START 20 – 30 V
OFF/ON Max. 1 V
40-304 12 WA150-6
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection SEN05132-00
WA150-6 40-304 13
SEN05132-00 Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection
Failure code [DAF3KK] UNSW power supply: Ground fault/

Disconnection
Action code Failure code UNSW power supply: Ground fault/Disconnection
Trouble
E01 DAF3KK (Machine monitor system)
Contents of • When accessory power supply (power supply for operation) voltage is above 17 V, UNSW power
trouble supply (power supply for memory) has ground fault.
Action of
machine monitor
Problem that • Service meter time gains or loses.
appears on • Odometer does not advance.
machine • Fault history data is not saved.
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Possible causes 1 ness (Contact with GND cir-
cuit) Between wiring harness battery relay R01 – Resis-
and standard Min. 1 Mz
L24 (female) (4), (5) and ground tance
value in normal
Between L24 (female) (4), (5) – (9), (10),
Voltage 20 – 30 V
(17), (18), (19), (20)
40-304 14 WA150-6
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection SEN05132-00
WA150-6 40-304 15
SEN05132-00 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection

Action code Failure code Machine monitor CAN-NET Signal: Disconnection
Trouble
E03 DAFRKR (HST controller system)
Contents of
• HST controller cannot get information from machine monitor
trouble
Action of
• Uses CAN information that was sent from machine monitor before the occurrence of the error.
machine monitor
Problem that
appears on • The monitor does not display normally
machine
Related • Method of reproducing failure code: Turn the starting switch ON.
information • KOMTRAX controller (connector name in sentence: L80) is optional.

1
Wiring harness between HST (female) (28), Resis-
Max. 1 z
(38) – L80 (female) (7), (8) tance
Disconnection in wiring har- Wiring harness between HST (female) (28), Resis-
Max. 1 z
2
(Disconnection or defective Wiring harness between HST (female) (28), Resis-
Possible causes contact in connector) Max. 1 z
(38) – EC2 (female) (1), (21) tance
and standard
state
Max. 1 z
Min. 1 Mz
Grounding fault in wiring har- (38) – L29 (female) (3), (8) and ground Min. 1 Mz
tance
3 ness (Contact with ground
circuit) Wiring harness between HST (female) (28), Resis-
Min. 1 Mz
(38) – EC2 (female) (1), (21) and ground tance
Min. 1 Mz
Min. 1 Mz
a Power supply circuit or grounding circuit may be defective.
Defective power supply cir-
4 Confirm that there is no disconnection of the circuit or defective
cuit of machine monitor
mating of the connector.
40-304 16 WA150-6
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection SEN05132-00

Possible causes a If above troubleshootings 1 – 4 have not identified the cause of
and standard Defective machine monitor, the trouble, failure on the machine monitor, HST controller,
value in normal 5 HST controller, engine con- engine controller or KOMTRAX terminal should be suspected.
state troller or KOMTRAX terminal (Since trouble is in system, troubleshooting cannot be carried
out.)
WA150-6 40-304 17
SEN05132-00 Failure code [DAJ0KK] HST controller power supply: Low voltage
Failure code [DAJ0KK] HST controller power supply: Low voltage

Action code Failure code HST controller power supply: Low voltage
Trouble
E03 DAJ0KK (HST controller system)
• Low voltage was detected in HST controller power supply.
Contents of
(While engine was running and alternator voltage was above 20 V, controller voltage was below 18
trouble
V.)
• Turns all outputs OFF.
Action of
• Trouble which may be detected wrongly is not detected.
machine monitor
Problem that
• Machine cannot travel (in either direction).
appears on
• Another trouble may be detected.
machine
Related • If gear is set in neutral and engine is restarted while controller voltage is above 20 V, system is reset.
information • Method of reproducing failure code: Turn starting switch ON

1 Defective (Broken) fuse Check fuse FS1 (No. 3) directly.
Possible causes ness (Disconnection in wiring Wiring harness between HST (female) (1) – Resis-
2 Max. 1 z
and standard or defective contact in con- fuse FS1 (No. 3) tance
value in normal nector) Wiring harness between HST (female) (11) – Resis-
state Max. 1 z
fuse FS1 (No. 3) tance
HST Voltage
Between (1), (11) – ground 20 – 30 V
40-304 18 WA150-6
Failure code [DAJ0KK] HST controller power supply: Low voltage SEN05132-00
WA150-6 40-304 19
SEN05132-00 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality

Action code Failure code HST controller memory (EEPROM): Abnormality
Trouble
E01 DAJ0KT (HST controller system)
Contents of
• Information in HST controller ROM (non-volatile memory) is abnormal.
trouble
Action of • Sets internal adjustment values to defaults.
machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Performance may lower. For example, shift-down feel from 3rd or 4th gear speed may become bad.
machine
Related
information

• Carry out troubleshooting according to the following procedure.
1. Change set information of HST controller.
(Example: Change HST selection to B.)
2. Turn starting switch OFF.
Possible causes 3. Wait for at least 30 seconds, then turn starting switch ON again.
and standard 4. At this time, check that set information is reflected.
value in normal 1 Defective HST controller (Example: See if HST selection is kept at B and value is returned
state to default A.)
<Diagnosis>
Set information is not reflected
(Value is returned to default): HST controller is defective.
Set information is reflected
(Value is not returned to default): HST controller is normal.
40-304 20 WA150-6
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality SEN05132-00
WA150-6 40-304 21
SEN05132-00 Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault
Failure code [DAJ1L4] HST controller main power line: Disconnection/

Ground fault
Action code Failure code HST controller main power line: Disconnection/Ground fault
Trouble
E01 DAJ1L4 (HST controller system)
Contents of
• Low voltage was detected in HST controller main power line (battery relay drive voltage system).
trouble
Action of
• Starts starting key OFF processing earlier.
machine monitor
Problem that
appears on • Machine is not affected in particular.
machine
Related
information

ness (Disconnection in wiring without turning starting switch ON.
Possible causes 1
or defective contact in con- Wiring harness between HST (female) (13) – Resis-
and standard nector) Max. 1 z
D09 (female) (1), D10 (female) (1) tance
value in normal
HST (female) Voltage
Between (13) – ground 20 – 30 V
40-304 22 WA150-6
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault SEN05132-00
WA150-6 40-304 23
SEN05132-00 Failure code [DAJ1L6] HST controller main power line: Hot short
Failure code [DAJ1L6] HST controller main power line: Hot short
Action code Failure code HST controller main power line: Hot short
Trouble
Contents of
• Hot short was detected in HST controller main power line (battery relay drive voltage system).
trouble
• Continues key OFF processing on assumption that battery relay is turned OFF.
Action of (Turns controller self-holding circuit OFF on assumption that alternator L signal voltage system is
machine monitor turned OFF.)
• Displays error next time when starting switch is turned ON.
Problem that
appears on • Battery voltage may lower earlier.
machine
Related
• After error is detected, it is displayed next time when starting switch is turned ON.
information

Between wiring harness HST (female) (13) –
D09 (female) (1), circuit branch end and Voltage Max. 1 V
ground
Hot short (Contact with 5V,
1
Possible causes 24V circuit) in wiring harness Wiring harness between L02 (female) (2) –
and standard D10 (female) (2), circuit branch end and Voltage Max. 1 V
value in normal ground
state Wiring harness between E02 (female) (1) –
D09 (female) (2), circuit branch end and Voltage Max. 1 V
ground
a Prepare with starting switch OFF, then turn starting switch ON to
OFF and carry out troubleshooting.
40-304 24 WA150-6
Failure code [DAJ1L6] HST controller main power line: Hot short SEN05132-00
WA150-6 40-304 25
SEN05132-00 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage

Action code Failure code Controller solenoid power supply: Low voltage
Trouble
E03 DAJ2KK (HST controller system)
• Low voltage was detected in controller solenoid power supply system.
Contents of
(While VIS power supply self-holding relay is ON and battery voltage is above 20 V, solenoid power
trouble
supply voltage below 18 V was detected.)
Action of
• Turns all outputs OFF.
machine monitor
Problem that
• Machine cannot travel.
appears on
• Another failure may not be detected.
machine
Related
• If gear is set in neutral and engine is restarted while solenoid voltage is above 19 V, system is reset.
information

(L102) with another Condition does not Relay (L102) is
Defective VIS power supply relay. become normal. normal.
1
holding relay (Internal defect) a Prepare with starting switch OFF, then check unit.
When 24 V is applied Resis-
Max. 1 z
between (1) – (2) tance
Possible causes Between terminals of
and standard L102 (male) (3) – (5) When no voltage is Resis-
applied between (1) – Min. 1 Mz
value in normal tance
(2)
state
2
nector) Max. 1 z
3 Defective HST controller Max. 1 z
fuse FS1 (No. 3) tance
HST Voltage
40-304 26 WA150-6
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage SEN05132-00
WA150-6 40-304 27
SEN05132-00 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness
Failure code [DAJ2L3] HST controller load power supply holding line:
Hot short in wiring harness
Action code Failure code HST controller load power supply holding line: Hot short in wiring
Trouble harness
Contents of • Hot short was detected in HST controller load power supply holding line.
trouble (When output command was ON, output terminal voltage above 5.7 V was detected.)
Action of
• Turns output OFF (Control protection function works).
machine monitor
Problem that • If starting switch is turned OFF without applying parking brake securely on slope, machine moves
appears on down suddenly.
machine • If starting switch is turned OFF while fan is rotating in reverse, peak pressure may occur.
Related
information

Defective VIS power supply (L102) with another Condition does not Relay (L102) is
1
holding relay (Internal defect) relay. become normal. normal.
and standard
Resis- 200 – 400
value in normal Between L102 (male) (1) – (2)
tance z
state
2
Voltage Max. 1 V
HST Voltage
40-304 28 WA150-6
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness SEN05132-00
WA150-6 40-304 29
SEN05132-00 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault
Failure code [DAJ2L4] HST controller load power supply holding line:
Disconnection/Ground fault
Action code Failure code HST controller load power supply holding line: Disconnection/
Trouble Ground fault
• Disconnection or ground fault was detected in load power supply holding line during HST controller
Contents of
final check.
trouble
(During final check, when output command was OFF, voltage below 5.7 V was detected.
Action of
• Relay cannot be driven while there is disconnection.
machine monitor
• While there is disconnection, when starting switch is turned OFF, parking brake check cannot be
Problem that
controlled and machine moves down.
appears on
• If starting switch is turned OFF while disconnection is made or fan is rotating in reverse, peak pres-
machine
sure may occur.
Related
information

and OFF, wait for 30 seconds, and turn it ON again and carry out
troubleshooting.
Defective HST safety relay (L102) with another
1 Condition does not Relay (L102) is
(Internal defect) relay. become normal. normal.
Resis- 200 – 400
tance z
Possible causes
state ness (Disconnection in wiring Wiring harness between HST (female) (7) – Resis-
2 Min. 1 Mz
nector) Wiring harness between L102 (female) (1) – Resis-
Min. 1 Mz
fuse FS1 (No.3) tance
cuit) Between wiring harness HST (female) (7) – Resis-
Min. 1 Mz
HST Voltage
40-304 30 WA150-6
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault SEN05132-00
WA150-6 40-304 31
SEN05132-00 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range

Action code Failure code Sensor 5V power supply: Out of output range
Trouble
E03 DAJ5KX (HST controller system)
Contents of
• Sensor 5V power supply of HST controller is below 4.7 V or above 5.3 V.
trouble
Action of • Turns the centralized warning lamp and alarm buzzer ON.
machine monitor • Even if cause of failure disappears, system does not reset itself until engine is started again.
Problem that
• If this trouble occurs during travel, travel speed may not increase or traction force may be insufficient.
appears on
• Once machine stops, maximum travel speed is about 4 km/h.
machine
• If there is disconnection or ground fault, [DHH1KX], [DDD7KX] or [DF10KA] is displayed, too.
Related
• If there is hot short, [DHH1KY], [DDD7KY] or [DF10KB] is displayed, too.
information
• If this failure occurs during travel, [DLT4KX] or [DLT3KX] may be displayed, too.

Defective travel speed con- Travel speed control
Disconnect devices at L54
trol dial, defective speed dial
range selector switch, defec- right in order. If failure
1 code [DAJ5KX] lights Speed range selector
tive resistor, defective travel L03
up (reset is indicated) switch
speed sensor, or defective
HST pressure sensor when a device is dis- Resistor L70
connected, that device Travel speed sensor T09
has trouble in it.
HST pressure sensor T11
and standard Ground fault in wiring har-
value in normal 2 ness (Contact with GND cir- Between wiring harness HST (female) (22) –
cuit) L54 (female) (A) or L70 (female) (2), (4) or Resis-
state Min. 1 Mz
T09 (female) (1) or T11 (female) (B) and tance
ground
troubleshooting.
Hot short (Contact with 5V, Between wiring harness HST (female) (22) –
3
24V circuit) in wiring harness L54 (female) (A) or L70 (female) (2), (4) or
Voltage Max. 1 V
T09 (female) (1) or T11 (female) (B) and
ground
HST Voltage
Between (22) – (32) 4.7 – 5.3 V
40-304 32 WA150-6
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range SEN05132-00
WA150-6 40-304 33
SEN05132-00 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals
Failure code [DAJ9KQ] HST controller model selection: Disagreement

of model selection signals
Action code Failure code HST controller model selection: Disagreement of model selection
Trouble
E03 DAJ9KQ signals (Machine monitor system)
Contents of
• The HST controller model is mistaken for another one.
trouble
• Operates on the assumption that the controller model which has been used before occurrence of the
Action of failure code is still used.
• Does not display failure codes which may be false detected.
Problem that
appears on • Continuing the travel in this condition may damage the HST.
machine
• If the model selection is not done correctly after the HST controller or machine monitor is replaced,
Related
this code is displayed.
information

Possible causes Set the model using the adjustment function of the service mode of
Improper machine monitor
and standard 1 the machine monitor (See Special functions of machine monitor
model selection
value in normal (EMMS) in Testing and adjusting)
state HST controller part number Confirm the part number of the HST controller. It must be replaced if
2
error it is not the specified controller.
40-304 34 WA150-6
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection SEN05132-00
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection

Action code Failure code HST controller CAN-NET signal: Disconnection
Trouble
E03 DAJRKR (Machine monitor system)
Contents of
• Machine monitor cannot get information from HST controller
trouble
• Uses CAN information that was sent from HST controller before the occurrence of the error.
Action of
machine monitor
Problem that
• The monitor does not display normally
appears on
• If HST controller power supply circuit is defective, machine cannot travel in either direction.
machine

1
Max. 1 z
(38) – L80 (female) (7), (8) tance
Disconnection in wiring har- Wiring harness between HST (female) (28), Resis-
Max. 1 z
2
(Disconnection or defective Wiring harness between HST (female) (28), Resis-
Possible causes
and standard (38) – EC2 (female) (1), (21) tance
value in normal Wiring harness between HST (female) (28), Resis-
Max. 1 z
state (38) – CAN1 (female) (A), (B) tance
Max. 1 z
Min. 1 Mz
tance
3 ness
(Contact with ground circuit) Wiring harness between HST (female) (28), Resis-
Min. 1 Mz
(38) – EC2 (female) (1), (21) and ground tance
Min. 1 Mz
Min. 1 Mz
a Carry out troubleshooting in "When HST controller power supply
circuit is defective" described later.
WA150-6 40-304 35
SEN05132-00 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection

out.)
40-304 36 WA150-6
When HST controller power supply circuit is defective

Broken fuse box FS1 fuse
a If fuse is broken, circuit probably has ground fault etc. (See cause c.)
No. 3
b
or defective contact in con- Wiring harness between fuse box FS1 fuse Resis-
nector) Max. 1 z
No. 3 – HST (female) (1) (11). tance
Between wiring harness fuse box FS1 fuse
Resis-
No. 3 – HST (female) (1) (11), branch end Min. 1 Mz
tance
and ground
Min. 1 Mz
branch end and ground tance
Min. 1 Mz
D07 (female) (1), T07 (3) and ground tance
Min. 1 Mz
Ground fault in wiring har- D08 (female) (1), T07 (1) and ground tance
c ness (Contact with GND cir- Between wiring harness L104 (female) (5) – Resis-
cuit) Min. 1 Mz
R59 (female) (1) and ground tance
Between wiring harness L63 (female) (5), (1) Resis-
Min. 1 Mz
– HST (female) (25) and ground tance
Possible causes
Between wiring harness L15 (female) (3),
and standard Resis-
D01 (female) (5) – HST (female) (5) and Min. 1 Mz
value in normal tance
ground
state
Min. 1 Mz
HST (female) (34) and ground tance
Between wiring harness L15 (female) (4) –
Resis-
L126 (female) (1), HST (female) (15) and Min. 1 Mz
tance
ground
L101 (male) Resistance
Between (5) – (6) 200 – 400 z
a Prepare with starting switch OFF.
a Test relay unit.
Directional pressure
(1) – (2) Resistance
Defective directional pres- selector relay (L101)
d sure selector relay (L101) When 24 V is applied
(Internal short circuit) Max. 1 z
(relay is "ON")
Between (3) – (5)
Other than above
Min. 1 Mz
(relay is "OFF")
a Prepare with starting switch OFF, then turn starting switch to
Replace directional pressure selector relay (L101) with another
relay. If condition becomes normal, directional pressure selector
relay is defective.
WA150-6 40-304 37
SEN05132-00 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection

Between (1) – (2) 200 – 400 z
a Test relay unit.
Backup alarm/lamp
Defective backup alarm/lamp (1) – (2) Resistance
relay (L126)
e relay (L126) (Internal short
circuit) When 24 V is applied
Max. 1 z
(relay is "ON")
Between (3) – (5)
Other than above
Min. 1 Mz
(relay is "OFF")
Possible causes
Replace backup alarm/lamp relay (L126) with another relay. If con-
and standard
dition becomes normal, backup alarm/lamp relay is defective.
value in normal
Defective directional pres- without turning starting switch ON.
f sure selector solenoid (Inter-
Resis-
nal short circuit) Between T07 (male) (3) – T07 (male) (4) 20 – 30 z
tance
Defective motor 2 solenoid without turning starting switch ON.
g
(Internal short circuit) Resis-
Between T07 (male) (1) – T07 (male) (2) 20 – 30 z
tance
Defective fan reverse sole- without turning starting switch ON.
h
noid (Internal short circuit) Resis-
Between R59 (male) (1) – R59 (male) (2) 35 – 45 z
tance
i Defective HST controller
HST Voltage
Between (1), (11) – ground 20 – 30 V
40-304 38 WA150-6
Related circuit diagram (When HST controller power supply circuit is defective)
WA150-6 40-304 39
SEN05132-00 Failure code [DAJRMA] HST controller: Disagreement in option selection
Failure code [DAJRMA] HST controller: Disagreement in option

selection
Action code Failure code HST controller: Disagreement in option selection
Trouble
E03 DAJRMA (Machine monitor system)
Contents of • Disagreement between the option setting done by the machine monitor and the option recognition by
trouble done the HST controller.
Action of • The HST controller follows the option setting being recognized by itself.
Problem that
appears on • The option setting does not work normally.
machine
• If the option setting is not done correctly after the HST controller or machine monitor is replaced, this
Related
code is displayed.
information

Set the option setting using the option select function of the
Possible causes 1 Defective option setting machine monitor (See “Special functions of machine monitor
and standard (EMMS)” in Testing and adjusting)
value in normal The machine monitor may be defective. (Since trouble is in system,
state 2 Defective machine monitor
troubleshooting cannot be carried out.)
The HST controller may be defective. (Since trouble is in system,
troubleshooting cannot be carried out.)
40-304 40 WA150-6
Failure code [DAJRMA] HST controller: Disagreement in option selection SEN05132-00
WA150-6 40-304 41
SEN05132-00

©2009 KOMATSU
All Rights Reserved
40-304 42
SEN05133-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line......................................... 2
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality .................................................... 6
Failure code [DD1NLD] Fan reverse switch signal: Abnormality .................................................................... 8
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short........................................ 10
Failure code [DDB6KB] Parking brake indicator signal: Ground fault........................................................... 12
(intermediate switch): Trouble................................................................................................................ 14
Failure code [DDB6L0] Parking brake reminder signal: Ground fault ........................................................... 16
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short ......................................... 18
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault................................. 20
Failure code [DDD7KY] Travel speed control dial signal: Hot short.............................................................. 22
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault .................................................................. 24
Failure code [DDK6KY] FNR lever: Hot short ............................................................................................... 28
WA150-6 40-305 1
SEN05133-00 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in

signal line
Action code Failure code Engine controller CAN-NET: Disconnection in signal line
Trouble
E03 DB2RKR (HST controller system)
Contents of
• Communication via CAN signal line between the HST controller and engine controller is defective.
trouble
• Uses CAN information that was sent from engine controller before the occurrence of the error.
• Once engine stops, recognized engine speed is fixed to low idle.
Action of
• Once engine stops, recognized operating degree of accelerator is fixed to 0%.
controller
Problem that
• The monitor does not display normally
appears on
• If engine controller power supply circuit is defective, engine stops.
machine

Defective CAN end point Between (A) – (B) 110 – 140 z
1
Between (A) – (B) 110 – 140 z
Max. 1 z
(21) – HST (female) (28), (38) tance
Disconnection in wiring har- Wiring harness between EC2 (female) (1), Resis-
Max. 1 z
2
(Disconnection or defective Wiring harness between EC2 (female) (1), Resis-
Possible causes
and standard (21) – L29 (female) (3), (8) tance
value in normal Wiring harness between EC2 (female) (1), Resis-
Max. 1 z
state (21) – CAN1 (female) (A), (B) tance
Max. 1 z
Min. 1 Mz
(21) – HST (female) (28), (38) and ground tance
tance
3 ness
(Contact with ground circuit) Wiring harness between EC2 (female) (1), Resis-
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Defective power supply cir- • Carry out troubleshooting for "When engine controller power sup-
4
cuit of engine controller ply is defective" described later.
40-305 2 WA150-6
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line SEN05133-00

out.)
WA150-6 40-305 3
SEN05133-00 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line
When engine controller power supply circuit is defective

Defective fuse No. 4 in fuse If fuse box is damaged, circuit probably has ground fault etc.
a
box FS1 or No. 15 in FS2 (See cause c.)
Wiring harness between fuse box FS1, No. 4 Resis-
Max. 1 z
fuse – L107 (female) (3), L108 (female) (3) tance
Wiring harness between L107 (female) (5), Resis-
Max. 1 z
Disconnection in wiring har- L108 (female) (5) – EC3 (female) (3), (4) tance
b Max. 1 z
or defective contact in con- ground tance
Max. 1 z
L107 (female) (1), L108 (female) (1) tance
Max. 1 z
L108 (female) (2) – EC2 (female) (32) tance
Max. 1 z
EC2 (female) (45) tance
Between wiring harness fuse box FS1, No. 4
Resis-
fuse – L107 (female) (3), L108 (female) (3) Min. 1 Mz
tance
Possible causes and ground
and standard Ground fault in wiring har- Between wiring harness L107 (female) (5),
Resis-
value in normal c ness (Contact with GND cir- L108 (female) (5) – EC3 (female) (4) and Min. 1 Mz
tance
state cuit) ground
Resis-
L107 (female) (1), L108 (female) (1) and Min. 1 Mz
tance
ground
Min. 1 Mz
EC2 (female) (45) and ground tance
L107, L108 (male) Resistance
Between (1) – (2) 200 – 400 z
a Check relay unit.
Engine controller cut
Defective engine controller (1) – (2) Resistance
relay (L107, L108)
d cut relay (L107, L108) (Inter-
nal defect) When 24 V is applied
Max. 1 z
(relay is "ON")
Between (3) – (5)
Other than above
Min. 1 Mz
(relay is "OFF")
Replace engine controller cut relay (L107, L108) with another relay.
If condition becomes normal, engine controller cut relay is defective.
40-305 4 WA150-6
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line SEN05133-00

Possible causes EC2 Voltage
and standard Between (32) – ground Max. 1 V
value in normal e Defective engine controller
state Between (45) – ground 20 – 30 V
EC3 Voltage
Related circuit diagram (When engine controller power supply circuit is defective)
WA150-6 40-305 5
SEN05133-00 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality

Action code Failure code Fan automatic reverse switch signal: Abnormality
Trouble
E01 DD1NL4 (HST controller system)
Contents of • Because of hot short in fan automatic reverse switch system, fan automatic reverse switch input and
trouble fan manual reverse switch input were sensed simultaneously.
Action of
• Turns automatic reverse switch function OFF.
controller
Problem that
• After error is detected, fan does not reverse.
appears on
• Automatic reverse switch LED lamp keeps lighting.
machine
• This code is applied to only "fan automatic reverse system (If equipped)" specification model.
Related • Input state from fan automatic reverse switch can be checked with monitoring function
information (Code: HST – 93400 – FAN REVERSE SW) (Code: MONITOR PANEL – 40901 – D-IN-9).
• Method of reproducing failure code: Turn starting switch ON and fan manual reverse switch ON.

Defective fan automatic Fan automatic reverse
1 reverse switch (Internal short L69 (male) Resistance
switch
circuit)
ON Max. 1 z
Between (3), (4) – (5)
OFF Min. 1 Mz
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal Hot short in wiring harness (Carry out troubleshooting with automatic reverse switch OFF)
2
state (Contact with 5V, 24V circuit)
Voltage Max. 1 V
L69 (female) (3), (4) and ground
Fan automatic reverse
3 Defective machine monitor L25 (male) Voltage
switch
Between (14) and ON 20 – 30 V
ground OFF Max. 1 V
40-305 6 WA150-6
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality SEN05133-00
WA150-6 40-305 7
SEN05133-00 Failure code [DD1NLD] Fan reverse switch signal: Abnormality
Failure code [DD1NLD] Fan reverse switch signal: Abnormality

Action code Failure code Fan reverse switch signal: Abnormality
Trouble
E01 DD1NLD (HST controller system)
Contents of • Since the fan manual reverse switch system is shorted with the power source, the fan manual
trouble reverse switch remains at ON position. (Continuation for 30 seconds determines fault)
Action of
controller
Problem that
appears on • Fan remains in the reverse rotation.
machine
• The input state (ON/OFF) from the fan manual reverse switch can be checked with the monitoring function
(Code: HST – 93400 – FAN REVERSE SW).
Related
(Code: MONITOR PANEL – 40900 – D-IN-1).
information
• Fan automatic reverse system is optional.

Defective fan reverse switch Fan manual reverse
1 L69 (male) Resistance
(Internal short circuit) switch
Between ON Max. 1 z
(5) – (1), (16) OFF Min. 1 Mz
Possible causes
and standard
Hot short in wiring harness and carry out troubleshooting.
value in normal 2
state (Contact with 5V, 24V circuit) Wiring harness between L25 (female) (10) –
Voltage Max. 1 V
L69 (female) (1), (6) and ground
Fan manual reverse
3 Defective machine monitor L25 (male) Voltage
switch
Between (10) and ON 20 – 30 V
ground OFF Max. 1 V
40-305 8 WA150-6
Failure code [DD1NLD] Fan reverse switch signal: Abnormality SEN05133-00
WA150-6 40-305 9
SEN05133-00 Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/

Hot short
Action code Failure code Parking brake reminder signal: Disconnection/Hot short
Trouble
E01 DDB6KA (HST controller system)
• HST controller detected disagreement with parking brake signal from machine monitor.
(While parking brake reminder signal of machine monitor was input (closed), there was not parking
Contents of
brake reminder signal of HST controller (open).
trouble
• While there was not input reminder signal (open), signal was input to parking brake indicator signal
(closed).
Action of
controller
Problem that
• If starting switch is turned OFF without applying parking brake securely on slope, machine moves
appears on
down suddenly.
machine
• Operation of parking brake can be checked with monitoring function.
[Parking brake reminder signal] (Recognition by machine monitor)
(Monitoring code: MONITOR PANEL – 40903 – D-IN-28 and 40904 – D-IN-35)
Related
[Parking brake indicator signal] (Recognition by machine monitor)
information
[Parking brake signal: reminder (A)/indicator (B)] (HST controller recognition)
(Monitoring code: HST – 99100 – PARKING A/B)

Defective diode (See Testing and adjusting, “Test procedure for diode”.)
1
(Internal defect)
Between D02 (male) (6) – (2) Continuity is secured
2
nector) Max. 1 z
(Test with parking brake applied.)
3 ness (Contact with GND cir- Between wiring harness HST (female) (16) – Resis- Min.
Possible causes cuit) D02 (female) (5) and ground tance 1 Mz
and standard Between wiring harness L27 (female) (2), Resis- Min.
value in normal (14) – D02 (female) (8) and ground tance 1 Mz
state
Hot short (Contact with 5V, (Test with parking brake released.)
4
Voltage Max. 1 V
D02 (female) (6) and ground
troubleshooting.
HST Voltage
L27 Voltage
Between (2) (14) – ground 20 – 30 V
40-305 10 WA150-6
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short SEN05133-00
WA150-6 40-305 11
SEN05133-00 Failure code [DDB6KB] Parking brake indicator signal: Ground fault
Failure code [DDB6KB] Parking brake indicator signal: Ground fault

Action code Failure code Parking brake indicator signal: Ground fault
Trouble
E01 DDB6KB (HST controller system)
Contents of • While parking brake indicator signal of machine monitor was not input (open), there was input signal
trouble (closed).
Action of
controller
Problem that
• Since machine can travel forward and reverse while parking brake is applied, parking brake may be
appears on
damaged (Alarm buzzer sounds in this case, however).
machine
Related
information

Defective diode without turning starting switch ON.
1 (See Testing and adjusting, “Test procedure for diode”.)
(Internal defect)
2
or defective contact in con- Wiring harness between L27 (female) (1), (6) Resis-
nector) Max. 1 z
– L47 (female) (2) tance
Possible causes Ground fault in wiring har- without turning starting switch ON.
and standard 3 ness (Contact with GND cir- (Test with parking brake applied.)
value in normal cuit) Between wiring harness HST (female) (16) – Resis- Min.
state D02 (female) (5) and ground tance 1 Mz
troubleshooting.
4 Defective HST controller (Test with parking brake applied.)
HST Voltage
5 Defective machine monitor (Test with parking brake released.)
L27 Voltage
Between (1) (6) – ground Max. 1 V
40-305 12 WA150-6
Failure code [DDB6KB] Parking brake indicator signal: Ground fault SEN05133-00
WA150-6 40-305 13
SEN05133-00 (intermediate switch): Trouble
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking

brake reminder switch (intermediate switch): Trouble
Action code Failure code Parking brake switch (bottom switch) or parking brake reminder
Trouble
E03 DDB6KZ switch (intermediate switch): Trouble (Machine monitor system)
Contents of • Parking brake indicator signal was closed and opening of parking brake reminder signal was
trouble detected.
machine monitor • Turns parking brake indicator and parking brake remind caution lamp ON.
Problem that • While parking brake is in intermediate position, parking brake reminder caution lamp does not light.
appears on • While parking brake is in intermediate position, parking brake reminder buzzer does not sound.
machine • While parking brake is in intermediate position, centralized warning lamp does not light.
• Input state (ON/OFF) of parking brake indicator signal and reminder signal can be checked with
Related monitoring function.
information (Monitoring code: MONITOR PANEL – 40903 – D-IN-26, 28)
(Monitoring code: MONITOR PANEL – 40904 – D-IN-35, 36)

Defective diode (See Testing and adjusting, “Test procedure for diode”.)
1
(Internal defect)
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness (Disconnection in wiring (Test with parking brake released.)
2
value in normal or defective contact in con-
state nector) Max. 1 z
(14) – L53 (female) (2) tance
3 ness (Contact with GND cir- (Test with parking brake applied.)
cuit) Between wiring harness L27 (female) (1), (6) Resis- Min.
– D02 (female) (7) and ground tance 1 Mz
If causes 1 – 3 are not detected, machine monitor may be defective.
40-305 14 WA150-6
(intermediate switch): Trouble SEN05133-00
WA150-6 40-305 15
SEN05133-00 Failure code [DDB6L0] Parking brake reminder signal: Ground fault
Failure code [DDB6L0] Parking brake reminder signal: Ground fault

Action code Failure code Parking brake reminder signal: Ground fault
Trouble
E01 DDB6L0 (HST controller system)
Contents of • While parking brake reminder signal operation signal of machine monitor was not input (open), park-
trouble ing brake reminder signal operation signal of HST controller was input (closed).
Action of • When engine is stopped while parking brake is not applied securely, move-down prevention is not
controller controlled.
Problem that
• If starting switch is turned OFF without applying parking brake securely on slope, machine moves
appears on
down suddenly.
machine
Related
information

(Internal defect)
ness (Disconnection in wiring (Test with parking brake released.)
2
or defective contact in con-
nector) Max. 1 z
(14) – L53 (female) (2) tance
Possible causes Ground fault in wiring har- without turning starting switch ON.
and standard 3 ness (Contact with GND cir- (Test with parking brake applied.)
value in normal cuit) Between wiring harness HST (female) (6) – Resis- Min.
state
D02 (female) (6) and ground tance 1 Mz
4 Defective HST controller (Test with parking brake applied.)
HST Voltage
L27 Voltage
Between (1) (6) – ground Max. 1 V
40-305 16 WA150-6
Failure code [DDB6L0] Parking brake reminder signal: Ground fault SEN05133-00
WA150-6 40-305 17
SEN05133-00 Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/

Hot short
Action code Failure code Parking brake indicator signal: Disconnection/Hot short
Trouble
E03 DDB6L4 (HST controller system)
Contents of • HST controller detected disagreement with parking brake indicator signal from machine monitor.
trouble (While signal was input to machine monitor (closed), signal was not input to HST controller (open).
Action of • Stops neutralizer (parking brake drag prevention function).
controller • If error is detected during forward or reverse travel, gear is set in neutral.
• Once FNR selector lever or switch is set to N, normal control is started again.
• If error is detected while FNR selector lever or switch is in F or R, machine cannot start until gear is
Problem that
returned to neutral.
appears on
• Since machine can travel forward and reverse while parking brake is applied, parking brake may be
machine
damaged (Caution buzzer sounds in this case, however).
Related
information

(Internal defect)
2
nector) Max. 1 z
3 ness (Contact with GND cir- (Test with parking brake applied.)
cuit) Between wiring harness L27 (female) (1), (6) Resis- Min.
Possible causes
and standard – D02 (female) (7) and ground tance 1 Mz
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state Hot short (Contact with 5V, and carry out troubleshooting.
4
Voltage Max. 1 V
D02 (female) (5) and ground
5 Defective HST controller (Test with parking brake released.)
HST Voltage
L27 Voltage
Between (1) (6) – ground 20 – 30 V
40-305 18 WA150-6
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short SEN05133-00
WA150-6 40-305 19
SEN05133-00 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/

Ground fault
Action code Failure code Travel speed control dial signal: Disconnection/Ground fault
Trouble
E01 DDD7KX (HST controller system)
Contents of
• Travel speed control dial signal voltage lowered below 0.3 V.
trouble
Action of • Continue controls on assumption that travel speed control dial is set to minimum speed side.
controller • Even if trouble disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Travel speed cannot be adjusted with travel speed control dial.
appears on
• If speed range selector switch is set in 1st, travel speed is set to about 4 km/h.
machine
Related
• If failure code [DAJ5KX] is also displayed, carry out troubleshooting for it first.
information

4.7 – 5.3
Between L54 (female) (1) – (3) Voltage
Defective travel speed con- V
1
trol dial (Internal defect) Between L54 (female) (2) – (3) (Max. speed 0.3 – 0.9
Voltage
side of dial) V
Between L54 (female) (2) – (3) (Min. speed 4.1 – 4.7
Voltage
side of dial) V
ness (Disconnection in wiring Wiring harness between HST (female) (23) – Resis-
2 Max. 1 z
Possible causes nector) Wiring harness between HST (female) (22) – Resis-
value in normal L54 (female) (1) tance
cuit) Between wiring harness HST (female) (23) – Resis- Min.
L54 (female) (2) and ground tance 1 Mz
HST (female) Resistance
Between (32) – ground Max. 1 z
4 Defective HST controller a Prepare with starting switch OFF, then turn starting switch ON
Between (22) – ground 4.7 – 5.3 V
40-305 20 WA150-6
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault SEN05133-00
WA150-6 40-305 21
SEN05133-00 Failure code [DDD7KY] Travel speed control dial signal: Hot short
Failure code [DDD7KY] Travel speed control dial signal: Hot short
Action code Failure code Travel speed control dial signal: Hot short
Trouble
E01 DDD7KY (HST controller system)
Contents of
• Travel speed control dial signal voltage exceeded 4.7 V.
trouble
Action of
controller
Problem that
• Travel speed cannot be adjusted with travel speed control dial.
appears on
• If speed range selector switch is set in 1st, travel speed is set to about 4 km/h.
machine
Related
• If failure code [DAJ5KX] is also displayed, carry out troubleshooting for it first.
information

4.7 – 5.3
Between L54 (female) (1) – (3) Voltage
Defective travel speed con- V
1
trol dial (Internal defect) Between L54 (female) (2) – (3) (Max. speed 0.3 – 0.9
Voltage
side of dial) V
Between L54 (female) (2) – (3) (Min. speed 4.1 – 4.7
Voltage
side of dial) V
2
Possible causes nector) Max. 1 z
and standard
state Hot short (Contact with 5V, and carry out troubleshooting.
3
Voltage Max. 1 V
HST (female) Resistance
Between (32) – ground Max. 1 z
4 Defective HST controller a Prepare with starting switch OFF, then turn starting switch ON
40-305 22 WA150-6
Failure code [DDD7KY] Travel speed control dial signal: Hot short SEN05133-00
WA150-6 40-305 23
SEN05133-00 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault

Action code Failure code FNR lever: Disconnection/Ground fault
Trouble
E03 DDK6KA (HST controller system)
Contents of • No signal of FNR (directional) lever is input because of disconnection or ground fault in FNR (direc-
trouble tional) lever switch signal system.
• If directional selector switch is not installed, gear is set in neutral.
• If directional selector switch actuation switch is turned OFF, gear is set in neutral (Only machine with
directional selector switch actuation switch).
Action of • If directional selector switch actuation switch is turned ON, FNR (directional) lever switch controls on
controller assumption that gear is in neutral (Only machine with directional selector switch actuation switch).
• Even if trouble disappears, system does not reset itself until FNR (directional) lever is set in N (Neu-
tral).
• Machine cannot be driven with FNR (directional) lever.
Problem that
• Machine can be driven with directional selector switch (only machine with directional selector switch
appears on
actuation switch).
machine
• Gear shift lever position lamp goes off.
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related
function (Code: HST – 40977 – D-IN-0, D-IN-1 or D-IN-2).
information
• Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever

Defective fuse No. 3 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
1
box (FS1) (See cause 5.)
FNR (directional)
L15 Voltage
lever
Between (1) and
Constant 20 – 30 V
Defective FNR (directional) ground
2 lever switch (Internal discon- Between (3) and N (Neutral) 20 – 30 V
nection or short circuit) ground Other than above Max. 1 V
Possible causes F (Forward) 20 – 30 V
Between (2) and
and standard
ground Other than above Max. 1 V
value in normal
state Between (4) and R (Reverse) 20 – 30 V
supply holding relay normal defective
3
holding relay (Internal defect) relay become normal normal
Resis- 200 –
tance 400 z
40-305 24 WA150-6
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault SEN05133-00

Wiring harness between fuse No. 3 of fuse Resis-
Max. 1 z
box (FS1) – L102 (female) (5) and ground tance
Max. 1 z
ness L15 (female) (1) tance
4
(Disconnection or defective Wiring harness between HST (female) (15) – Resis-
Wiring harness between HST (female) (5) – Resis-
Max. 1 z
Max. 1 z
Min. 1 Mz
Possible causes Wiring harness between L102 (female) (3) –

Resis-
and standard L15 (female) (1), circuit branch end and Min. 1 Mz
tance
value in normal Grounding fault in wiring har- ground
state 5 ness Wiring harness between HST (female) (15) –
(Contact with ground circuit) L15 (female) (4), L126 (female) (13) and Resis-
Min. 1 Mz
tance
ground
Wiring harness between HST (female) (5) –
Resis-
L15 (female) (3), D01 (female) (5) and Min. 1 Mz
tance
ground
Min. 1 Mz
FNR (directional)
HST Voltage
lever
Between (5) and N (Neutral) 20 – 30 V
6 Defective HST controller ground Other than above Max. 1 V
Between (34) and F (Forward) 20 – 30 V
Between (15) and R (Reverse) 20 – 30 V
WA150-6 40-305 25
SEN05133-00 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault
40-305 26 WA150-6
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault SEN05133-00
WA150-6 40-305 27
SEN05133-00 Failure code [DDK6KY] FNR lever: Hot short
Failure code [DDK6KY] FNR lever: Hot short

Action code Failure code FNR lever: Hot short
Trouble
E03 DDK6KY (HST controller system)
Contents of • Multiple FNR (directional) lever signals are input because of hot short in FNR (directional) lever
trouble switch signal system.
• Sets gear in neutral.
Action of • If directional selector switch actuation switch is turned ON, machine is driven according to directional
controller selector switch setting (only machine with directional selector switch actuation switch).
• Even if trouble disappears, system does not reset itself until FNR (directional) lever is set in N (Neu-
tral).
• Operator cannot travel machine at position other than position having hot short with FNR (directional)
Problem that lever switch. (Example: When directional lever F system has hot short, if lever is set in F, trouble is
appears on reset and machine can travel forward.)
machine • Multiple gear shift lever position lamp lights.
• Machine can be driven with directional selector switch (only machine with directional selector switch).
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related
function (Code: HST – 40977 – D-IN-0, D-IN-1 or D-IN-2).
information
• Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever

FNR (directional)
L15 Voltage
lever
Between (1) and
Defective FNR (directional) ground
1 lever switch (Internal short Between (3) and F (Forward) 20 – 30 V
circuit) ground Other than above Max. 1 V
and standard
value in normal Wiring harness between HST (female) (15) –
Voltage Max. 1 V
state Hot short in wiring harness L15 (female) (4) and ground
2
(Contact with 5V, 24V circuit) Wiring harness between HST (female) (5) –
Voltage Max. 1 V
Wiring harness between HST (female) (34) –
Voltage Max. 1 V
FNR (directional)
HST Voltage
lever
Between (34) and F (Forward) 20 – 30 V
40-305 28 WA150-6
Failure code [DDK6KY] FNR lever: Hot short SEN05133-00
WA150-6 40-305 29
SEN05133-00

©2009 KOMATSU
All Rights Reserved
40-305 30
SEN05134-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault.............................. 2
Failure code [DF10KB] Travel speed range selector switch: Hot short........................................................... 6
Failure code [DGH1KX] HST oil temperature sensor: Ground fault................................................................ 8
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault ............................................................. 9
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short ......................................... 10
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault............................................ 12
Failure code [DHH1KY] HST oil pressure sensor: Hot short ........................................................................ 14
Failure code [DHTCL6] HST filter clogging sensor: Functional defect.......................................................... 16
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short ............................................................. 18
Failure code [DLT3KX] Travel speed sensor B: Abnormality ........................................................................ 20
Failure code [DLT4KX] Travel speed sensor A: Abnormality ........................................................................ 24
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality ................................................................. 26
Failure code [DV00KY] Alarm buzzer: Hot short........................................................................................... 28
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault ....................................................... 30
Failure code [DW26KY] Motor 2 solenoid: Hot short .................................................................................... 32
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short .................................................................. 34
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault...................................... 36
WA150-6 40-306 1
SEN05134-00 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault
Failure code [DF10KA] Travel speed range selector switch:

Disconnection/Ground fault
Action code Failure code Travel speed range selector switch: Disconnection/Ground fault
Trouble
E01 DF10KA (HST controller system)
Contents of • Travel speed range selector switch signal is not input because of disconnection or ground fault in
trouble travel speed range selector switch input signal system.
Action of • Fixes gear to speed range before error occurrence.
controller • If trouble disappears, system resets itself.
• Once starting switch is turned OFF, gear speed is assumed to be 4th for control, regardless of
Problem that selected speed range.
appears on • Gear is not set in selected speed range.
machine • Indicator displays range before error occurrence.
(Once starting switch is turned OFF, 4th gear is displayed)
Related
• Method of reproducing failure code: Turn starting switch ON + Operate speed range selector switch.
information

L03 (female) Switch position Resistance
2nd Max. 1 z
Between (1) – (2)
Other than above Min. 1 Mz
1st Min. 1 Mz
2nd Min. 1 Mz
Between (1) – (3)
3rd Max. 1 z
Defective travel speed range
1 selector switch (Internal 4th Max. 1 z
defect) 4th Max. 1 z
Between (1) – (4)
Possible causes Other than above Min. 1 Mz
and standard
Between (2) – (3) – (Anytime) Min. 1 Mz
value in normal
state Between (2) – (4) – (Anytime) Min. 1 Mz
1st Max. 1 z
2nd Min. 1 Mz
Between (3) – (4)
3rd Min. 1 Mz
4th Max. 1 z
2 selector resistor (Internal Between (1) – (5) 100 z ± 1%
defect) Between (2) – (6) 220 z ± 1%
Between (3) – (7) 330 z ± 1%
Between (4) – (8) 470 z ± 1%
40-306 2 WA150-6
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault SEN05134-00

Max. 1 z
Max. 1 z
Disconnection in wiring har- L03 (female) (3), L70 (female) (5), (3) tance
ness (Disconnection in wiring Wiring harness between L03 (female) (1) – Resis-
3 Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
L70 (female) (2) (4) tance
and standard Between wiring harness HST (female) (32) – Resis-
value in normal Min. 1 Mz
state
Resis-
Ground fault in wiring har- L03 (female) (3), L70 (female) (5), (3) and Min. 1 Mz
tance
4 ness (Contact with GND cir- ground
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
HST Switch position Voltage
5 Defective HST controller 1st 1.9 – 2.3 V
2nd 2.4 – 2.7 V
Between (39) – (32)
3rd 2.9 – 3.2 V
4th 3.3 – 3.7 V
WA150-6 40-306 3
SEN05134-00 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault
40-306 4 WA150-6
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault SEN05134-00
WA150-6 40-306 5
SEN05134-00 Failure code [DF10KB] Travel speed range selector switch: Hot short
Failure code [DF10KB] Travel speed range selector switch: Hot short
Action code Failure code Travel speed range selector switch: Hot short
Trouble
E01 DF10KB (HST controller system)
Contents of • Multiple travel speed range selector switch signal is input because of hot short in travel speed range
trouble selector switch input signal system.
Action of • Fixes gear to speed range before error occurrence.
controller • If trouble disappears, system resets itself.
• Once starting switch is turned OFF, gear speed is assumed to be 4th for control, regardless of
Problem that selected speed range.
appears on • Gear is not set in selected speed range.
machine • Indicator displays range before error occurrence.
(Once starting switch is turned OFF, 4th gear is displayed)
Related
• Method of reproducing failure code: Turn starting switch ON + Operate speed range selector switch.
information

L03 (female) Switch position Resistance
2nd Max. 1 z
Between (1) – (2)
1st Min. 1 Mz
2nd Min. 1 Mz
Between (1) – (3)
3rd Max. 1 z
1 selector switch (Internal 4th Max. 1 z
defect) 4th Max. 1 z
Between (1) – (4)
1st Max. 1 z
Possible causes 2nd Min. 1 Mz
and standard Between (3) – (4)
value in normal 3rd Min. 1 Mz
state 4th Max. 1 z
2 selector resistor (Internal Between (1) – (5) 100 z ± 1%
defect) Between (2) – (6) 220 z ± 1%
Between (3) – (7) 330 z ± 1%
Between (4) – (8) 470 z ± 1%
Voltage Max. 1 V
3
L03 (female) (3), L70 (female) (5), (3) and Voltage Max. 1 V
ground
Voltage Max. 1 V
40-306 6 WA150-6
Failure code [DF10KB] Travel speed range selector switch: Hot short SEN05134-00

Voltage Max. 1 V
3 24V circuit) in wiring harness Voltage Max. 1 V
Possible causes
and standard Wiring harness between HST (female) (22) –
Voltage Max. 1 V
value in normal L70 (female) (2) (4) and ground
state HST Switch position Voltage
1st 1.9 – 2.3 V
4 Defective HST controller 2nd 2.4 – 2.7 V
Between (39) – (32)
3rd 2.9 – 3.2 V
4th 3.3 – 3.7 V
WA150-6 40-306 7
SEN05134-00 Failure code [DGH1KX] HST oil temperature sensor: Ground fault
Failure code [DGH1KX] HST oil temperature sensor: Ground fault

Action code Failure code HST oil temperature sensor: Ground fault
Trouble
E01 DGH1KX (Machine monitor system)
Contents of • HST oil temperature higher than 150°C was detected. (Ground fault in HST oil temperature signal
trouble circuit was detected.)
Action of
• HST oil overheat is not detected.
machine monitor
Problem that
appears on • HST oil temperature gauge indicates maximum.
machine
• Input state from HST oil temperature sensor can be checked with monitoring function.
Related
(Monitoring code: MONITOR PANEL – 04408 – HST OIL TEMP (°C)
information
(Monitoring code: MONITOR PANEL – 04409 – HST OIL TEMP (V)

T10 (male) HST oil temperature Resistance
Defective HST oil tempera-
1 At 25°C 35 – 50 kz
ture sensor (Internal defect) Between (1) – (2)
At 100°C 3.1 – 4.5 kz
Between (1) (2) and
Possible causes – (Anytime) Min. 1 Mz
ground
and standard
state 2 ness (Contact with GND cir-
Min. 1 Mz
T10 (female) (1) and ground tance
3 Defective machine monitor L28 (female) HST oil temperature Voltage
At 25°C 4.4 – 4.6 V
At 100°C 2.1 – 2.3 V
40-306 8 WA150-6
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault SEN05134-00
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault

Action code Failure code Brake oil temperature sensor: Ground fault
Trouble
E01 DGR2KB (Machine monitor system)
Contents of • Front brake oil temperature above 150°C was detected.
trouble (Ground fault was detected in front brake oil temperature signal circuit.)
Action of
• Brake oil overheat is not detected.
machine monitor
Problem that
• Brake oil temperature gauge indicates upper limit.
appears on
• Brake performance lowers (while system is normal).
machine
• Input state from front brake oil temperature sensor can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL – 30201 – F BRAKE OIL (°C)
information (Monitoring code: MONITOR PANEL – 30204 – F BRAKE OIL (V)
• System resets itself after brake oil temperature reduces below 130°C.

Front brake overheat
1 Check for cause of overheat directly.
(When system is normal)
Defective front brake (axle) F14 (male) Brake oil temperature Resistance
2 oil temperature sensor (Inter- At 25°C 35 – 50 kz
nal defect) Between (1) – (2)
Possible causes At 100°C 3.1 – 4.5 kz
and standard Between (1) (2) and
value in normal – (Anytime) Min. 1 Mz
ground
state
Between wiring harness F14 (female) (1) – Resis-
3 ness (Contact with GND cir- Min. 1 Mz
cuit)
4 Defective machine monitor L25, L28 Brake oil temperature Voltage
Between L28 (7) – At 25°C 4.4 – 4.6 V
L25 (9) At 100°C 2.1 – 2.3 V
WA150-6 40-306 9
SEN05134-00 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/

Hot short
Action code Failure code Brake oil temperature sensor: Disconnection/Hot short
Trouble
E01 DGR2KZ (Machine monitor system)
• Disconnection or hot short was detected in front brake oil temperature signal circuit.
Contents of
Reference: Detection is made by sudden change of brake oil temperature or by logic of comparison
trouble
with HST oil temperature.
Action of
machine monitor
Problem that
• Brake oil temperature gauge indicates lower limit.
appears on
• Brake may be broken and brake may not work because of brake oil temperature error.
machine
• Input state from front brake oil temperature sensor can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL – 30201 – F BRAKE OIL (°C)
information (Monitoring code: MONITOR PANEL – 30204 – F BRAKE OIL (V)
• System resets itself after brake oil temperature increases above 25°C.

Defective front brake (axle)
1 oil temperature sensor (Inter- F14 (male) Brake oil temperature Resistance
nal defect) At 25°C 35 – 50 kz
Between (1) – (2)
At 100°C 3.1 – 4.5 kz
ness (Disconnection in wiring Wiring harness between F14 (female) (1) – Resis-
2 Max. 1 z
Possible causes nector) Wiring harness between F14 (female) (2) – Resis-
value in normal
Hot short (Contact with 5V, Between wiring harness F14 (female) (1) –
3 Voltage Max. 1 V
24V circuit) in wiring harness L28 (female) (7) and ground
Between wiring harness F14 (female) (2) –
Voltage Max. 1 V
4 Defective machine monitor L25, L28 Brake oil temperature Voltage
Between L28 (7) – At 25°C 4.4 – 4.6 V
L25 (9) At 100°C 2.1 – 2.3 V
40-306 10 WA150-6
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short SEN05134-00
WA150-6 40-306 11
SEN05134-00 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground

fault
Action code Failure code HST oil pressure sensor: Disconnection/Ground fault
Trouble
E03 DHH1KX (HST controller system)
Contents of • HST oil pressure sensor signal is not input because of disconnection or ground fault in HST oil pres-
trouble sure sensor system (Input voltage is below 0.3 V)
• If trouble occurs during travel, control value (output) before trouble occurrence is held.
Action of
• Once machine stops, gear is assumed to be in 1st for control.
controller
Problem that
• Once machine stops, gear is set in 1st. (Travel speed can be controlled with travel speed control
appears on
dial, however.)
machine
• If [DAJ5KX] is displayed, carry out troubleshooting for it first.
Related • Input state from HST oil pressure sensor can be checked with monitoring function.
information (Monitoring code: HST 32600 HST PRESS (MPa))
(Monitoring code: HST 32601 HST PRESS (V))

a Prepare with starting switch OFF, then turn starting twitch ON and
Defective HST oil pressure T11 Voltage
1
sensor (Internal defect)
Between (C) – (A) 0.5 – 4.5 V
Between (B) – (A) 4–6V
Max. 1 z
ness (Disconnection in wiring T11 (female) (C) tance
2
Possible causes nector) Max. 1 z
T11 (female) (A) tance
and standard
state T11 (female) (B) tance
Between wiring harness HST (female) (33) – Resis- Min.
T11 (female) (C) and ground tance 1 Mz
cuit)
Between wiring harness HST (female) (22) – Resis- Min.
T11 (female) (B) and ground tance 1 Mz
troubleshooting.
4 Defective HST controller HST Voltage
Between (33) – (32) 0.5 – 4.5 V
Between (22) – (32) 4–6V
40-306 12 WA150-6
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault SEN05134-00
WA150-6 40-306 13
SEN05134-00 Failure code [DHH1KY] HST oil pressure sensor: Hot short
Failure code [DHH1KY] HST oil pressure sensor: Hot short

Action code Failure code HST oil pressure sensor: Hot short
Trouble
E03 DHH1KY (HST controller system)
Contents of • Abnormal HST oil pressure sensor signal was input because of hot short in HST oil pressure sensor
trouble system (Input voltage was above 4.7 V).
• If trouble occurs during travel, control value (output) before trouble occurrence is held.
Action of
• Once machine stops, gear is assumed to be in 1st for control.
controller
Problem that
• Once machine stops, gear is set in 1st. (Travel speed can be controlled with travel speed control
appears on
dial, however.)
machine
• If [DAJ5KX] is displayed, carry out troubleshooting for it first.
Related • Input state from HST oil pressure sensor can be checked with monitoring function.
information (Monitoring code: HST 32600 HST PRESS (MPa))
(Monitoring code: HST 32601 HST PRESS (V))

troubleshooting.
Defective HST oil pressure T11 Voltage
1
sensor (Internal defect)
Between (C) – (A) 0.5 – 4.5 V
Between (B) – (A) 4–6V
Possible causes
and standard
value in normal 2
state 24V circuit) in wiring harness Between wiring harness HST (female) (33) –
Voltage Max. 1 V
T11 (female) (C) and ground
troubleshooting.
Between (33) – (32) 0.5 – 4.5 V
Between (22) – (32) 4–6V
40-306 14 WA150-6
Failure code [DHH1KY] HST oil pressure sensor: Hot short SEN05134-00
WA150-6 40-306 15
SEN05134-00 Failure code [DHTCL6] HST filter clogging sensor: Functional defect
Failure code [DHTCL6] HST filter clogging sensor: Functional defect

Action code Failure code HST filter clogging sensor: Functional defect
Trouble
E01 DHTCL6 (Machine monitor system)
Contents of
• When engine stopped, HST filter clogging sensor was turned ON (Ground fault was detected).
trouble
Action of
• Turns HST filter clogging caution lamp OFF.
machine monitor
Problem that
appears on • Foreign matter may enter HST hydraulic circuit.
machine
Related • Input state (ON/OFF) of HST filter clogging sensor can be checked with monitoring function.

Defective HST filter clogging without turning starting switch ON.
1
sensor (Internal defect) Resis-
Possible causes Wiring harness between T13 – T14 Min. 1 Mz
tance
and standard
state 2 ness (Contact with GND cir-
Min. 1 Mz
T13 and ground tance
If causes 1 – 2 are not detected, machine monitor may be defective.
40-306 16 WA150-6
Failure code [DHTCL6] HST filter clogging sensor: Functional defect SEN05134-00
WA150-6 40-306 17
SEN05134-00 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short

Action code Failure code Fuel level sensor: Disconnection/Hot short
Trouble
E01 DJF1KA (Machine monitor system)
Contents of
• Voltage above 4 V was detected in fuel level sensor signal circuit.
trouble
Action of
machine monitor
Problem that
appears on • Fuel level gauge does not indicated normally (but keeps indicating “empty”).
machine
• Input signal from fuel level sensor can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL – 04200 – FUEL SENSOR (V))
information (Monitoring code: MONITOR PANEL – 04202 – FUEL SENSOR (%))

R21 (male) Fuel level Resistance
Defective fuel level sensor
1 When full 7 – 11 z
(Internal defect)
When 1/2
Between (1) – (2) 32 z
(Reference value)
When empty 85 – 95 z
2 Max. 1 z
or defective contact in con- R21 (female) (1) tance
Possible causes nector) Wiring harness between L26 (female) (6) – Resis-
Max. 1 z
and standard R21 (female) (2) tance
state and carry out troubleshooting.
3 R21 (female) (1) and ground Voltage Max. 2 V
(Value is upper limit when empty.)
Voltage Max. 1 V
R21 (female) (2)
L26, L28 Fuel level Voltage
4 Defective machine monitor When full 0.2 – 0.3 V
Between L28 (1) – When 1/2
0.9 V
L26 (6) (Reference value)
When empty 1.8 – 2.0 V
40-306 18 WA150-6
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short SEN05134-00
WA150-6 40-306 19
SEN05134-00 Failure code [DLT3KX] Travel speed sensor B: Abnormality
Failure code [DLT3KX] Travel speed sensor B: Abnormality

Action code Failure code Travel speed sensor B: Abnormality
Trouble
E03 DLT3KX (HST controller system)
Contents of • While machine was traveling at speed above about 4 km/h, input signal of travel speed sensor B was
trouble lost.
Action of • Recognizes travel speed by input signal of travel speed sensor A.
Problem that
appears on • None in particular.
machine
Related • If failure code [DLT3KX] and [DLT4KX] (Travel speed sensor A: Abnormality) are turned ON simulta-
information neously, see causes 6 and after.

a Prepare with starting switch OFF, then start engine (but do not
travel) and carry out troubleshooting.
T09 Voltage
Between (1) – (2) 4.7 – 5.3 V
Defective travel speed sen- Between (2) – ground Max. 1 V
1
sor (Internal defect) a Prepare with starting switch OFF, then start engine, travel at con-
stant speed, and carry out troubleshooting.
T09 Voltage
Below 1 V – Above 4 V
Between (4) – (2)
(Changes at regular intervals)
2
nector) Max. 1 z
T09 (female) (4) tance
Possible causes
and standard
value in normal
state Between wiring harness HST (female) (36) – Resis-
Min. 1 Mz
Ground fault in wiring har- a Prepare with starting switch OFF, then start engine, travel at con-
3 ness (Contact with GND cir- stant speed, and carry out troubleshooting.
cuit) Below 1 V
– Above
Between wiring harness HST (36) – T09 (4) 4V
Voltage
and ground (Changes
at regular
intervals)
a Prepare with starting switch OFF, then start engine, travel at con-
Below 1 V
Hot short (Contact with 5V, – Above
4
24V circuit) in wiring harness Between wiring harness HST (36) – T09 (4) 4V
Voltage
and ground (Changes
at regular
intervals)
40-306 20 WA150-6
Failure code [DLT3KX] Travel speed sensor B: Abnormality SEN05134-00

troubleshooting without traveling.
HST Voltage
Possible causes Between (22) – (32) 4.7 – 5.3 V
and standard
value in normal Between (32) – ground Max. 1 V
state a Prepare with starting switch OFF, then start engine, travel at con-
HST Voltage
Between (36) – (32)
WA150-6 40-306 21
SEN05134-00 Failure code [DLT3KX] Travel speed sensor B: Abnormality
a When [DLT3KX] and [DLT4KX] (Travel speed sensor A: Abnormality) are turned ON simultaneously
Contents of • While machine was traveling at speed above about 4 km/h, input signals of travel speed sensors A
trouble and B were lost.
• Keeps outputs to HST motor 1, HST motor 2 and clutch at values before trouble.
Action of
• Keeps output values after clutch is engaged or disengaged completely, if clutch is being controlled.
controller
Problem that
• Travel speed does not increase or traction force is insufficient.
appears on
• Machine monitor indicates 0 km/h as travel speed.
machine
• If trouble occurs while machine is stopped or traveling at low speed (below about 4 km/h), error is not
Related turned ON.
information • In above case, machine monitor indicates 0 km/h as travel speed and actual travel speed is limited to
4 – 7 km/h.

T09 Voltage
Between (1) – (2) 4.7 – 5.3 V
6
Defective travel speed sen- a Prepare with starting switch OFF, then start engine, travel at con-
sor (Internal defect) stant speed, and carry out troubleshooting.
T09 Voltage
Between (3) – (2)
Between (4) – (2)
and standard Disconnection in wiring har- T09 (female) (1) tance
value in normal ness (Disconnection in wiring Wiring harness between HST (female) (32) – Resis-
7 Max. 1 z
state or defective contact in con- T09 (female) (2) tance
nector) Wiring harness between HST (female) (26) – Resis-
Max. 1 z
Max. 1 z
Between wiring harness HST (female) (22) – Resis-
Ground fault in wiring har- Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
9
24V circuit) in wiring harness Between wiring harness HST (32) – T09 (2)
Voltage Max. 1 V
and ground
40-306 22 WA150-6
Failure code [DLT3KX] Travel speed sensor B: Abnormality SEN05134-00

HST Voltage
Between (22) – (32) 4.7 – 5.3 V
Possible causes
and standard
value in normal 10 Defective HST controller a Prepare with starting switch OFF, then start engine, travel at con-
state stant speed, and carry out troubleshooting.
HST Voltage
Between (26) – (32)
Between (36) – (32)
WA150-6 40-306 23
SEN05134-00 Failure code [DLT4KX] Travel speed sensor A: Abnormality
Failure code [DLT4KX] Travel speed sensor A: Abnormality

Action code Failure code Travel speed sensor A: Abnormality
Trouble
E03 DLT4KX (HST controller system)
Contents of • While machine was traveling at speed above about 4 km/h, input signal of travel speed sensor A was
trouble lost.
Action of • Recognizes travel speed by input signal of travel speed sensor B.
Problem that
appears on • None in particular.
machine
Related • If failure code [DLT4KX] and [DLT3KX] (Travel speed sensor B: Abnormality) are turned ON simulta-
information neously, see [DLT3KX], causes 6 and after.

T09 Voltage
Between (1) – (2) 4.7 – 5.3 V
Defective travel speed sen- Between (2) – ground Max. 1 V
1
sor (Internal defect) a Prepare with starting switch OFF, then start engine, travel at con-
T09 Voltage
Between (3) – (2)
2
nector) Max. 1 z
Possible causes
and standard
value in normal
state Between wiring harness HST (female) (26) – Resis-
Min. 1 Mz
Ground fault in wiring har- a Prepare with starting switch OFF, then start engine, travel at con-
3 ness (Contact with GND cir- stant speed, and carry out troubleshooting.
cuit) Below 1 V
– Above
Between wiring harness HST (26) – T09 (3) 4V
Voltage
and ground (Changes
at regular
intervals)
Below 1 V
Hot short (Contact with 5V, – Above
4
24V circuit) in wiring harness Between wiring harness HST (26) – T09 (3) 4V
Voltage
and ground (Changes
at regular
intervals)
40-306 24 WA150-6
Failure code [DLT4KX] Travel speed sensor A: Abnormality SEN05134-00

HST Voltage
Possible causes Between (22) – (32) 4.7 – 5.3 V
and standard
value in normal Between (32) – ground Max. 1 V
state a Prepare with starting switch OFF, then start engine, travel at con-
HST Voltage
Between (26) – (32)
WA150-6 40-306 25
SEN05134-00 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality

Action code Failure code Travel speed sensor A & B: Abnormality
Trouble
E03 DLT4LC (HST controller system)
Contents of
• Difference between values sensed by travel speed sensors A and B during travel is large.
trouble
controller • None in particular other than above (Uses higher value normally).
Problem that
appears on
machine
Related
• Even trouble disappears, system does not reset itself until engine is started again.
information

travel) and carry out troubleshooting without traveling.
T09 Voltage
Between (1) – (2) 4.7 – 5.3 V
1
Defective travel speed sen- a Prepare with starting switch OFF, then start engine, travel at con-
sor (Internal defect) stant speed, and carry out troubleshooting.
T09 Voltage
Between (3) – (2)
Between (4) – (2)
2 Max. 1 z
or defective contact in con- T09 (female) (3) tance
Possible causes
nector) Wiring harness between HST (female) (36) – Resis-
value in normal T09 (female) (4) tance
3 ness (Contact with GND cir- Min. 1 Mz
cuit)
Min. 1 Mz
Below 1 V
– Above
Between wiring harness HST (female) (26) – 4V
Voltage
T09 (female) (3) and ground (Changes
Hot short (Contact with 5V, at regular
4
24V circuit) in wiring harness intervals)
Below 1 V
– Above
Between wiring harness HST (female) (36) – 4V
Voltage
T09 (female) (4) (Changes
at regular
intervals)
40-306 26 WA150-6
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality SEN05134-00

HST Voltage
Between (22) – (32) 4.7 – 5.3 V
Possible causes
and standard
value in normal 5 Defective HST controller a Prepare with starting switch OFF, then start engine, travel at con-
state stant speed, and carry out troubleshooting.
HST Voltage
Between (26) – (32)
Between (36) – (32)
WA150-6 40-306 27
SEN05134-00 Failure code [DV00KY] Alarm buzzer: Hot short
Failure code [DV00KY] Alarm buzzer: Hot short

Action code Failure code Alarm buzzer: Hot short
Trouble
E01 DV00KY (Machine monitor system)
Contents of
• The alarm buzzer output circuit is shorted with the power source.
trouble
• Stops alarm buzzer output.
Action of • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
machine monitor • If trouble occurs while backup alarm/lamp is in operation, backup alarm/lamp output is turned OFF.
• If trouble occurs while ECSS is in operation, ECSS output is turned OFF.
Problem that • Alarm buzzer does not sound.
appears on • Backup alarm/lamp may not operate.
machine • ECSS may not operate.
• The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function.
• Output state (ON/OFF) to backup alarm/lamp relay can be checked with monitoring function.
Related
(Code: MONITOR PANEL – 40952 – D-OUT-2)
information
• Output state (ON/OFF) to ECSS relay can be checked with monitoring function.
(Code: MONITOR PANEL – 40952 – D-OUT-3)

1
(Contact with 5V, 24V circuit) Wiring harness between L24 (female) (14) –
Voltage Max. 1 V
L46 (female) (2) and chassis ground
Possible causes and carry out troubleshooting.
and standard • Remove the buzzer, then connect +24 V to L46 (male) (1) and
value in normal Defective alarm buzzer GND to L46 (male) (2).
state 2
(Internal short circuit) Alarm buzzer is
Alarm buzzer sounds
normal
Defective alarm
Alarm buzzer does not sound
buzzer
• When above 1 and 2 are normal, failure on the machine monitor
3 Defective machine monitor can be suspected. (Since trouble is in system, troubleshooting
cannot be carried out.)
40-306 28 WA150-6
Failure code [DV00KY] Alarm buzzer: Hot short SEN05134-00
WA150-6 40-306 29
SEN05134-00 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault

Action code Failure code Motor 2 solenoid: Disconnection/Ground fault
Trouble
E01 DW26KA (HST controller system)
Contents of • Motor 2 cannot be controlled because of disconnection or ground fault in motor 2 solenoid relay out-
trouble put system.
• Keeps output to motor 2 solenoid relay turned OFF (If there is ground fault, output cannot be turned
Action of
OFF actually).
controller
Problem that • When there is disconnection: Travel speed is not limited and maximum speed is equivalent to 4th
appears on gear speed in 3rd speed range.
machine • When there is ground fault: Travel speed is set equivalent to 3rd gear speed in 4th speed range.
• Output state (ON/OFF) to motor 2 solenoid relay can be checked with monitoring function.
Related
(Monitoring code: HST – 40980 – D-OUT-16)
information
• Method of reproducing failure code: Travel at speed above about 12 km/h in 4th speed range.

Replace motor 2 normal defective
solenoid relay (L103)
Defective motor 2 solenoid with another relay. Condition does not Relay (L103) is
1
relay (Internal defect) become normal normal
Resis- 200 –
tance 400 z
troubleshooting.
2 holding relay (Internal short relay. become normal. normal.
circuit)
value in normal Resis- 200 –
state tance 400 z
3 Max. 1 z
Max. 1 z
Min. 1 Mz
a Prepare with starting switch OFF, then start engine, travel, and
HST Condition Voltage
5 Defective HST controller Stopped Max. 1 V
Between (27) – Speed range: 4th
ground Travel speed: Above 20 – 30 V
11 km/h
40-306 30 WA150-6
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault SEN05134-00
WA150-6 40-306 31
SEN05134-00 Failure code [DW26KY] Motor 2 solenoid: Hot short
Failure code [DW26KY] Motor 2 solenoid: Hot short

Action code Failure code Motor 2 solenoid: Hot short
Trouble
E01 DW26KY (HST controller system)
Contents of
• Motor 2 solenoid cannot be operated because of hot short in motor 2 solenoid relay output system.
trouble
Action of • Keeps output to motor 2 solenoid relay turned OFF.
Problem that
• When the gear is shifted to 3rd, travel speed is not limited and maximum travel speed is equivalent to
appears on
4th-gear speed.
machine
Related • Output state (ON/OFF) to motor 2 solenoid relay can be checked with monitoring function.
information (Monitoring code: HST – 40980 – D-OUT-16)

Replace motor 2 normal defective
Defective motor 2 solenoid with another relay. Condition does not Relay (L103) is
1
and standard Resis- 200 –
value in normal tance 400 z
2 Voltage
24V circuit) in wiring harness Wiring harness between HST (female) (27) –
(When Max. 1 V
L103 (female) (2)
stopped)
HST Voltage
40-306 32 WA150-6
Failure code [DW26KY] Motor 2 solenoid: Hot short SEN05134-00
WA150-6 40-306 33
SEN05134-00 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short

Action code Failure code Fan reverse solenoid circuit: Hot short
Trouble
E01 DW7BKY (HST controller system)
Contents of • Abnormal voltage was generated because of hot short in fan reverse solenoid relay output system
trouble when fan reverse solenoid relay output was turned ON.
Action of • Keeps output to fan reverse solenoid turned OFF and stops fan reverse control function.
Problem that
appears on • Fan does not reverse (Manual reverse function and automatic reverse function do not work).
machine
• Output state (ON/OFF) to fan reverse solenoid relay can be checked with monitoring function.
Related
• Method of reproducing failure code: Start engine, wait for at least 30 seconds, and then press man-
information
ual reverse switch.
• Fan automatic reverse function is optional.

Replace fan reverse normal defective
Defective fan reverse sole- with another relay. Condition does not Relay (L104) is
1
noid relay (Internal defect) become normal normal
Possible causes Resis- 200 –

and standard tance 400 z
value in normal a Prepare with starting switch OFF, then start engine and carry out
state troubleshooting.
Hot short (Contact with 5V, Voltage (In fan for-
2 20 – 30 V
24V circuit) in wiring harness Wiring harness between HST ward mode)
(female) (37) – L104 (female) (2) Voltage (In fan
Max. 1 V
reverse mode)
troubleshooting.
3 Defective HST controller HST Fan condition Voltage
Between (37) – In fan forward mode 20 – 30 V
ground In fan reverse mode Max. 1 V
40-306 34 WA150-6
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short SEN05134-00
WA150-6 40-306 35
SEN05134-00 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/

Ground fault
Action code Failure code Fan reverse solenoid circuit: Disconnection/Ground fault
Trouble
E01 DW7BKZ (HST controller system)
Contents of • Fan reverse solenoid relay cannot be controlled because of disconnection or ground fault in fan
trouble reverse solenoid relay output system.
Action of • Keeps output to fan reverse solenoid turned OFF and stops fan reverse control function.
Problem that • Manual reverse function and automatic reverse function do not work.
appears on • Fan always turns forward (When there is disconnection).
machine • Fan always turns in reverse (When there is ground fault).
• Output state (ON/OFF) to fan reverse solenoid relay can be checked with monitoring function.
Related (Monitoring code: HST – 40980 – D-OUT-17)
information • Method of reproducing failure code: Turn starting switch ON.
• Fan automatic reverse function is optional.

Replace fan reverse normal defective
Defective fan reverse sole- with another relay. Condition does not Relay (L104) is
1
noid relay (Internal defect) become normal normal
Resis- 200 –
tance 400 z
troubleshooting.
2 holding relay (Internal short relay. become normal. normal.
Possible causes circuit)
value in normal without turning starting switch ON.
state Resis- 200 –
tance 400 z
3 Max. 1 z
Max. 1 z
Min. 1 Mz
troubleshooting.
5 Defective HST controller HST Fan condition Voltage
Between (37) – In fan forward mode 20 – 30 V
ground In fan reverse mode Max. 1 V
40-306 36 WA150-6
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault SEN05134-00
WA150-6 40-306 37
SEN05134-00

©2009 KOMATSU
All Rights Reserved
40-306 38
SEN05135-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

Failure code [DX16KA] Fan EPC solenoid: Disconnection............................................................................. 2
Failure code [DX16KB] Fan EPC solenoid: Ground fault................................................................................ 3
Failure code [DX16KY] Fan EPC solenoid: Hot short..................................................................................... 4
Failure code [DX19KA] Motor 1 solenoid: Disconnection ............................................................................... 6
Failure code [DX19KB] Motor 1 solenoid: Ground fault .................................................................................. 8
Failure code [DX19KY] Motor 1 solenoid: Hot short ..................................................................................... 10
Failure code [DX20KA] Clutch EPC solenoid: Disconnection....................................................................... 12
Failure code [DX20KB] Clutch EPC solenoid: Ground fault.......................................................................... 14
Failure code [DX20KY] Clutch EPC solenoid: Hot short............................................................................... 16
Failure code [DXH7KB] Reverse solenoid: Ground fault .............................................................................. 18
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short ............................................................ 20
Failure code [DXH8KB] Forward solenoid: Ground fault .............................................................................. 22
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short ............................................................ 24
Failure code [J141N1] Steering pump: Overrun alarm.................................................................................. 26
Failure code [M100N1] HST pump: Overrun alarm ...................................................................................... 26
Failure code [M400N1] Motor 1: Overrun alarm ........................................................................................... 27
WA150-6 40-307 1
SEN05135-00 Failure code [DX16KA] Fan EPC solenoid: Disconnection
Failure code [DX16KA] Fan EPC solenoid: Disconnection 1
Action code Failure code Fan EPC solenoid: Disconnection

Trouble
E01 DX16KA (HST controller system)
Contents of • Since the fan EPC solenoid system is disconnected, no current flows when the fan EPC solenoid
trouble output is ON.
Action of
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
controller
Problem that
appears on • The fan speed is set to the maximum.
machine
• If [DX16KY] is displayed, carry out troubleshooting for it first.
Related • The output state (current) to the fan EPC solenoid can be checked with the monitoring function
information (Code: HST – 41400 – FAN EPC DIR).

Defective fan EPC solenoid without turning starting switch ON.
1
(Internal disconnection) R29 (male) Resistance
Between (1) – (2) 5 – 10 z
Possible causes
state ness Wiring harness between HST (female) (40) – Resis-
2 Max. 1 z
(Disconnection or defective R29 (female) (2) tance
contact in connector) Wiring harness between HST (female) (29) – Resis-
Max. 1 z
R29 (female) (1) tance
• If causes 1 – 2 are not detected, HST controller may be defective.
40-307 2 WA150-6
Failure code [DX16KB] Fan EPC solenoid: Ground fault SEN05135-00
Failure code [DX16KB] Fan EPC solenoid: Ground fault 1
Action code Failure code Fan EPC solenoid: Ground fault

Trouble
E01 DX16KB (HST controller system)
Contents of • Since the fan EPC solenoid system is shorted, abnormal current flows when the fan EPC solenoid
trouble output is ON.
Action of • Turns the output to the fan EPC solenoid OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The fan speed is set to the maximum.
machine
• The output state (current) to the fan EPC solenoid can be checked with the monitoring function
Related
(Code: HST – 41400 – FAN EPC DIR).
information

Defective fan EPC solenoid R29 (male) Resistance
1
(Internal short circuit)
Possible causes Between (1) – (2) 5 – 10 z
and standard Between (1), (2) and ground Min. 1 Mz
value in normal
state Grounding fault in wiring har- without turning starting switch ON.
2 ness
(Contact with ground circuit) Wiring harness between HST (female) (29) – Resis-
Min. 1 Mz
WA150-6 40-307 3
SEN05135-00 Failure code [DX16KY] Fan EPC solenoid: Hot short
Failure code [DX16KY] Fan EPC solenoid: Hot short 1
Action code Failure code Fan EPC solenoid: Hot short

Trouble
E01 DX16KY (HST controller system)
Contents of • Since the fan EPC solenoid system is shorted with the power source, abnormal voltage is applied
trouble when the fan EPC solenoid output is OFF.
Action of • Turns the output to the fan EPC solenoid OFF.
controller • If problem is removed, system is returned to normal operating state.
Problem that
appears on • The fan speed is minimized.
machine
• The output state (current) to the fan EPC solenoid can be checked with the monitoring function
Related
(Code: HST – 41400 – FAN EPC DIR).
information

Defective fan EPC solenoid R29 (male) Resistance
1
(Internal short circuit)
and standard Between (1), (2) and ground Min. 1 Mz
value in normal
state
2
(Contact with 5V, 24V circuit) Wiring harness between HST (female) (29) –
Voltage Max. 1 V
R29 (female) (1) and ground
40-307 4 WA150-6
Failure code [DX16KY] Fan EPC solenoid: Hot short SEN05135-00
WA150-6 40-307 5
SEN05135-00 Failure code [DX19KA] Motor 1 solenoid: Disconnection
Failure code [DX19KA] Motor 1 solenoid: Disconnection 1
Action code Failure code Motor 1 solenoid: Disconnection

Trouble
Contents of • Disconnection was detected in motor 1 solenoid circuit.
trouble (Difference between output command value and actual current is large.)
Action of
controller
• Traction force is decreased.
Problem that
appears on
machine
denly.
Related
information
• If failure code [DX19KY] or [DX20KY] is also displayed, carry out troubleshooting for it first.

Defective motor 1 solenoid T06 (male) Resistance
1
(Internal defect)
Between (1) – (2) 15 – 30 z
Between (1), (2) – ground Min. 1 Mz
Max. 1 z
ness (Disconnection in wiring T06 (female) (1) tance
2
or defective contact in con- Wiring harness between T06 (female) (2) – Resis-
nector) Max. 1 z
Possible causes
value in normal HST (female) (40) tance
Replace HST safety normal defective
relay (L111) with
another relay Condition does not Relay (L111) is
Defective HST safety relay become normal normal
3
(L111) (Internal defect)
a Prepare with starting switch OFF and check safety relay unit.
Apply 24 V between Resis-
Max. 1 z
Between L111 (male) (1) – (2). tance
(3) – (5) Apply no voltage Resis-
Min. 1 Mz
between (1) – (2). tance
40-307 6 WA150-6
Failure code [DX19KA] Motor 1 solenoid: Disconnection SEN05135-00
WA150-6 40-307 7
SEN05135-00 Failure code [DX19KB] Motor 1 solenoid: Ground fault
Failure code [DX19KB] Motor 1 solenoid: Ground fault 1
Action code Failure code Motor 1 solenoid: Ground fault

Trouble
Contents of
• Ground fault was detected in motor 1 solenoid circuit.
trouble
Action of
controller
Problem that
appears on
machine
denly.

1
(Internal defect)
and standard Between (1), (2) – ground Min. 1 Mz
value in normal
Min. 1 Mz
Defective HST safety relay • If causes 1 – 2 are not detected, HST controller may be defective.
3
(L111) (Internal defect) (Since trouble is in system, troubleshooting cannot be carried out.)
40-307 8 WA150-6
Failure code [DX19KB] Motor 1 solenoid: Ground fault SEN05135-00
WA150-6 40-307 9
SEN05135-00 Failure code [DX19KY] Motor 1 solenoid: Hot short
Failure code [DX19KY] Motor 1 solenoid: Hot short 1
Action code Failure code Motor 1 solenoid: Hot short

Trouble
Contents of
• Hot short was detected in motor 1 solenoid circuit.
trouble
Action of
controller
Problem that
appears on
machine
denly.
Related HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF)
information Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA)
• [DX19KA], [DX20KA] or [DX20KY] may be also displayed, depending on condition when error was
detected.

1
(Internal defect)
Between (1) – (2) 15 – 30 z
Possible causes
and standard Between wiring harness T06 (female) (1) –
Voltage Max. 1 V
value in normal HST (female) (19)
state Wiring harness between T06 (female) (2) –
Hot short (Contact with 5V, Voltage Max. 1 V
2 L111 (female) (3) and ground.
(Check with traction control OFF and machine stopped.)
Voltage 10 – 15 V
T06 (female) (1)
Defective HST safety relay • If causes 1 – 2 are not detected, HST controller may be defective.
3
(L111) (Internal defect) (Since trouble is in system, troubleshooting cannot be carried out.)
40-307 10 WA150-6
Failure code [DX19KY] Motor 1 solenoid: Hot short SEN05135-00
WA150-6 40-307 11
SEN05135-00 Failure code [DX20KA] Clutch EPC solenoid: Disconnection
Failure code [DX20KA] Clutch EPC solenoid: Disconnection 1
Action code Failure code Clutch EPC solenoid: Disconnection

Trouble
• Disconnection was detected in clutch EPC solenoid circuit.
Contents of
(When output command was above 250 mA, difference between command value and sensed cur-
trouble
rent exceeded 200 mA.)
Action of
controller
Problem that
appears on
machine
denly.
Related
information
• If failure code [DX19KY] or [DX20KY] is also displayed, carry out troubleshooting for it first.

Defective clutch EPC sole- T05 (male) Resistance
1
noid (Internal defect)
Between (1) – (2) 5 – 15 z
Max. 1 z
2
or defective contact in con- Wiring harness between T05 (female) (2) – Resis-
nector) Max. 1 z
Possible causes
value in normal HST (female) (40) tance
Replace HST safety normal defective
relay (L111) with
another relay Condition does not Relay (L111) is
Defective HST safety relay become normal normal
3
a Prepare with starting switch OFF and check safety relay unit.
Apply 24 V between Resis-
Max. 1 z
Between L111 (male) (1) – (2). tance
(3) – (5) Apply no voltage Resis-
Min. 1 Mz
between (1) – (2). tance
40-307 12 WA150-6
Failure code [DX20KA] Clutch EPC solenoid: Disconnection SEN05135-00
WA150-6 40-307 13
SEN05135-00 Failure code [DX20KB] Clutch EPC solenoid: Ground fault
Failure code [DX20KB] Clutch EPC solenoid: Ground fault 1
Action code Failure code Clutch EPC solenoid: Ground fault

Trouble
Contents of
• Ground fault was detected in clutch EPC solenoid circuit.
trouble
Action of • Turns motor 1 solenoid output OFF.
Problem that
appears on
machine
denly.

1
and standard Between (1), (2) – ground Min. 1 Mz
value in normal
Min. 1 Mz
40-307 14 WA150-6
Failure code [DX20KB] Clutch EPC solenoid: Ground fault SEN05135-00
WA150-6 40-307 15
SEN05135-00 Failure code [DX20KY] Clutch EPC solenoid: Hot short
Failure code [DX20KY] Clutch EPC solenoid: Hot short 1
Action code Failure code Clutch EPC solenoid: Hot short

Trouble
Contents of
• Hot short was detected in clutch EPC solenoid circuit.
trouble
Action of
controller
Problem that
appears on
machine
denly.
Related HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF)
information Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA)
• [DX19KA], [DX19KY] or [DX20KA] may be also displayed, depending on condition when error was
detected.

1
Between (1) – (2) 5 – 15 z
Possible causes Between wiring harness HST (female) (9) –
and standard Voltage Max. 1 V
T05 (female) (1) and ground
value in normal
state Between wiring harness L111 (female) (3) –
Voltage Max. 1 V
Hot short (Contact with 5V, T05 (female) (2)
2
24V circuit) in wiring harness a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
(Troubleshoot with traction switch OFF and machine is stopped (do
not travel))
Voltage 10 – 15 V
40-307 16 WA150-6
Failure code [DX20KY] Clutch EPC solenoid: Hot short SEN05135-00
WA150-6 40-307 17
SEN05135-00 Failure code [DXH7KB] Reverse solenoid: Ground fault
Failure code [DXH7KB] Reverse solenoid: Ground fault 1
Action code Failure code Reverse solenoid: Ground fault

Trouble
E03 DXH7KB (HST controller system)
Contents of
• Reverse solenoid is not turned ON.
trouble
Action of • Turns output to reverse solenoid OFF.
Problem that
appears on • Machine does not travel in reverse.
machine
• Output state to HST pump R (Reverse) solenoid of HST controller can be checked with monitoring
Related
function.
information

Defective reverse solenoid T01 (male) Resistance
1
(Internal defect)
Between (3) – (4) 15 – 30 z
(Internal defect)
Between T01B (male) (1) – (2) No continuity
troubleshooting.
Possible causes Replace FR pressure normal defective
and standard select relay (L101)
value in normal Defective FR pressure select with another relay Condition does not Relay (L101) is
3
state relay (Internal defect) become normal normal
Resis- 200 –
tance 400 z
Min. 1 Mz
a Prepare with starting switch OFF, then start engine, release park-
ing brake, set directional lever in R position, and carry out trouble-
5 Defective HST controller shooting.
HST Voltage
40-307 18 WA150-6
Failure code [DXH7KB] Reverse solenoid: Ground fault SEN05135-00
WA150-6 40-307 19
SEN05135-00 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short 1
Action code Failure code Reverse solenoid: Disconnection/Hot short

Trouble
E03 DXH7KZ (HST controller system)
• Reverse solenoid is not turned ON (HST pressure selector relay does not operate) (when there is
Contents of
disconnection).
trouble
• Reverse solenoid cannot be turned OFF (Where there is hot short).
Action of • Turns output to reverse solenoid OFF.
Problem that • Machine does not travel in reverse (when there is disconnection).
appears on • Machine may start in reverse suddenly (when there is hot short).
machine • Gear is not set in neutral (when there is hot short).
• Output state to HST pump R (Reverse) solenoid of HST controller can be checked with monitoring
Related
function.
information

Defective reverse solenoid T01 (male) Resistance
1
(Internal defect)
Between (3) – (4) 15 – 30 z
(Internal defect)
Between T01B (male) (2) – (1) No continuity
Replace FR pressure normal defective
select relay (L101)
Defective FR pressure select with another relay Condition does not Relay (L101) is
3
value in normal Resis- 200 –
state Between L101 (male) (5) – (6)
tance 400 z
4 Max. 1 z
nector) Wiring harness between T01 (female) (4) – Resis-
Max. 1 z
ground tance
5
Voltage Max. 1 V
a Prepare with starting switch OFF, then start engine and release
parking brake, and carry out troubleshooting.
Directional lever
position
Between (20) – R (Reverse) 20 – 30 V
40-307 20 WA150-6
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short SEN05135-00
WA150-6 40-307 21
SEN05135-00 Failure code [DXH8KB] Forward solenoid: Ground fault
Failure code [DXH8KB] Forward solenoid: Ground fault 1
Action code Failure code Forward solenoid: Ground fault

Trouble
E03 DXH8KB (HST controller system)
Contents of
• Forward solenoid is not turned ON.
trouble
Action of • Turns output to forward solenoid OFF.
Problem that
appears on • Machine does not travel forward.
machine
• Output state to HST pump F (Forward) solenoid of HST controller can be checked with monitoring
Related
function.
information

Defective forward solenoid T01 (male) Resistance
1
(Internal defect)
Between (1) – (2) 15 – 30 z
Possible causes 2 (See Testing and adjusting, “Test procedure for diode”.)
(Internal defect)
and standard
value in normal Between T01A (male) (1) – (2) No continuity
Min. 1 Mz
ing brake, set directional lever in F position, and carry out trouble-
4 Defective HST controller shooting.
HST Voltage
40-307 22 WA150-6
Failure code [DXH8KB] Forward solenoid: Ground fault SEN05135-00
WA150-6 40-307 23
SEN05135-00 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short 1
Action code Failure code Forward solenoid: Disconnection/Hot short

Trouble
E03 DXH8KZ (HST controller system)
• Forward solenoid is not turned ON (HST pressure selector relay does not operate) (when there is
Contents of
disconnection).
trouble
• Forward solenoid cannot be turned OFF (Where there is hot short).
Action of • Turns output to forward solenoid OFF.
Problem that • Machine does not travel forward (when there is disconnection).
appears on • Machine may start forward suddenly (when there is hot short).
machine • Gear is not set in neutral (when there is hot short).
• Output state to HST pump F (Forward) solenoid of HST controller can be checked with monitoring
Related
function.
information

Defective forward solenoid T01 (male) Resistance
1
(Internal defect)
Between (1) – (2) 15 – 30 z
(Internal defect)
Between T01A (male) (1) – (2) No continuity
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness (Disconnection in wiring Wiring harness between HST (female) (10) – Resis-
value in normal 3 Max. 1 z
state nector) Wiring harness between T01 (female) (2) – Resis-
Max. 1 z
ground tance
4
Voltage Max. 1 V
a Prepare with starting switch OFF, then start engine and release
parking brake, and carry out troubleshooting.
Directional lever
position
Between (10) – F (Forward) 20 – 30 V
40-307 24 WA150-6
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short SEN05135-00
WA150-6 40-307 25
SEN05135-00 Failure code [J141N1] Steering pump: Overrun alarm
Failure code [J141N1] Steering pump: Overrun alarm 1
Action code Failure code Steering pump: Overrun alarm

Trouble
E02 J141N1 (HST controller system)
Contents of
• Steering pump speed exceeded alarm operation set value.
trouble
Action of
controller
Problem that
appears on • Steering pump may be broken (If it is broken, machine may not steer).
machine
Related • Advance alarm is turned ON before this code is displayed.
information • If steering pump speed decreases below alarm reset value, system resets itself.

and standard
value in normal a Give operator instructions to use engine in range where alarm is
1 Steering pump overrun
state not turned ON.
Failure code [M100N1] HST pump: Overrun alarm 1
Action code Failure code HST pump: Overrun alarm

Trouble
E02 M100N1 (HST controller system)
Contents of
• HST pump speed exceeded alarm operation set value.
trouble
Action of
controller
Problem that
appears on • HST pump may be broken (If it is broken, machine cannot travel).
machine
information • If HST pump speed decreases below alarm reset value, system resets itself.

and standard
1 HST pump overrun
40-307 26 WA150-6
Failure code [M400N1] Motor 1: Overrun alarm SEN05135-00
Failure code [M400N1] Motor 1: Overrun alarm 1
Action code Failure code Motor 1: Overrun alarm

Trouble
E02 M400N1 (HST controller system)
Contents of
• HST motor 1 speed exceeded alarm operation set value.
trouble
Action of
controller
Problem that
appears on • HST motor 1 may be broken (If it is broken, machine cannot travel).
machine
information • If HST motor 1 speed decreases below alarm reset value, system resets itself.

and standard
1 HST motor 1 overrun
WA150-6 40-307 27
SEN05135-00

©2009 KOMATSU
All Rights Reserved
40-307 28
SEN05136-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
400 Troubleshooting of electrical system

(E-mode)
E-1 Engine does not start ............................................................................................................................... 3
E-2 Preheater does not operate normally ..................................................................................................... 10
E-3 Travel speed is low or high..................................................................................................................... 14
E-4 ECSS does not operate.......................................................................................................................... 20
E-5 ECSS keeps operating ........................................................................................................................... 23
E-6 Defective boom kick-out function and cancellation ................................................................................ 26
E-7 Defective bucket positioner function and cancellation............................................................................ 30
E-8 Defective lift arm FLOATING holding function and cancellation............................................................. 34
E-9 Travel direction selection system does not function ............................................................................... 38
E-10 Fan does not reverse ........................................................................................................................... 42
E-11 Fan keeps rotating in reverse ............................................................................................................... 46
E-12 Wiper does not operate ........................................................................................................................ 48
E-13 Windshield washer does not operate ................................................................................................... 52
E-14 Headlamp, clearance lamp, tail lamp and license lamp do not light up or go off.................................. 56
E-15 Working lamp does not light up or go off .............................................................................................. 64
E-16 Turn signal lamp and hazard lamp do not light up or go off ................................................................. 69
E-17 Brake lamp does not light or it keeps lighting up .................................................................................. 76
E-18 Backup lamp does not light or it keeps lighting up ............................................................................... 78
E-19 Backup alarm does not sound or it keeps sounding............................................................................. 81
E-20 Horn does not sound or it keeps sounding........................................................................................... 84
E-21 Alarm buzzer does not sound or it keeps sounding ............................................................................. 86
WA150-6 40-400 1
400 Troubleshooting of electrical system (E-mode)
SEN05136-00
E-22 The KOMTRAX system does not work properly................................................................................... 88
40-400 2 WA150-6
E-1 Engine does not start SEN05136-00
E-1 Engine does not start 1
Contents of
trouble
• Before starting troubleshooting, check the following.
a. Directional lever is in N (Neutral).
b. Directional switch is in N (Neutral).
c. Starting of engine is prohibited by function of KOMTRAX system (If equipped).
d. Battery cable is not disconnected from battery.
• The engine does not start, because the starting motor does not run due to troubles in the starting
Related
motor system and starting switch terminal C signal system.
information
• Check that fuse is normal.
(If it is broken, check the related wiring harness for grounding fault.)
• The input state (ON/OFF) to the machine monitor from the starting switch terminal C can be checked
with the monitoring function (Code: MONITOR PANEL 40900, D-IN-2).
• If failure code is indicated, carry out troubleshooting for it first.
• KOMTRAX system is optional.

Specific gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
The battery relay can be judged normal if operating sounds are audible
Defective battery relay
2 when the starting switch is operated.
(Internal defect)
• Starting switch operation in the order of OFF o ON o OFF
If the fuse is burn, the circuit probably has a grounding fault, etc. (See
3 Defective fuse
cause 18.)
a Prepare with starting switch OFF (with wiring harness connected),
then turn starting switch START and carry out troubleshooting
Starting motor Voltage
Between terminals B (E30)
Defective starting motor Power supply input 20 – 30 V
4 and ground
(Internal defect)
Between terminals C (E21)
Starting input 20 – 30 V
and ground
Possible If the starting motor does not run even if power supply input, battery
causes and input and starting input is normal, the starting motor is defective.
standard value a Prepare with starting switch OFF, then turn starting switch ON and
in normal state carry out troubleshooting.
Defective alternator
5
(Internal defect) Wiring harness between alternator terminal R
Voltage Max. 1 V
E02 (female) (1) – ground
a Prepare with starting switch OFF, then carry out troubleshooting with
starting OFF and START each.
L02 (male) Position of switch Resistance
Defective starting switch OFF Min. 1 Mz
6
(Internal defect) Between (1) and (3)
START Max. 1 z
Between (1) and (2) OFF Min. 1 Mz
Between (1) and (4) ON Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.
Defective FNR switch
7 (Internal disconnection or MF1 (male) FNR (directional) lever Resistance
short circuit) N (Neutral) Max. 1 z
Between (1) and (3)
WA150-6 40-400 3
SEN05136-00 E-1 Engine does not start

Defective directional L62 (male) Switch position Resistance
8
switch (Internal defect)
N (Neutral) Max. 1 z
Between (1) – (3)
D21 (male) Diode range Continuity
Defective diodes (D21, Measure at (2) in
Between (2) and (1) Continue
D22) (Internal defect) diode range.
9
a Only when both diodes a Prepare with starting switch OFF, then carry out troubleshooting with-
are detective out turning starting switch ON.
Measure at (2) in
diode range.
Defective diodes (D01)
10 Measure at (5) in
(Internal defect) Between (5) and (1) Continue
diode range.
Measure at (6) in
Possible diode range.
causes and a Prepare with starting switch OFF, then carry out troubleshooting with-
standard value out turning starting switch ON.
in normal state
Defective diodes (D03)
11 Measure at (7) in
(Internal defect) Between (7) and (3) Continue
diode range.
Measure at (8) in
diode range.
Defective diode (D10)
12 D10 (male) Diode range Continuity
(Internal defect)
Measure on (2) side
Between (2) – (1) Continuity is secured
in diode range
a Prepare with starting switch OFF (with wiring harness connected),
then carry out troubleshooting without turning starting switch ON.
Starting motor safety relay Voltage
Between B-terminal
Power supply input 20 – 30 V
E20 – E-terminal
Defective starting motor Between R-terminal E01
Charge input Max. 1 V
13 safety relay (male) (2) – E-terminal
(Internal defect) Between S-terminal E01
Starting input 20 – 30 V
(male) (1) – E-terminal
Between C-terminal
Output 20 – 30 V
E19 – E-terminal
If power supply input and starting input are normal but output voltage is
low, starting motor safety relay is defective.
40-400 4 WA150-6

Between (1) and (2) 200 – 400 z
a Check neutral safety relay unit.
Neutral safety relay
Defective neutral safety (L106)
14 relay (L106) When 24 V is applied
(Internal defect) Max. 1 z
(When relay is "ON")
Between (3) – (5)
Other than above
Min. 1 Mz
(When relay is "OFF")
a Prepare with starting switch OFF, then turn starting switch to START
When neutral safety relay (L106) is replaced with a relay of the same
type, if the condition becomes normal, the neutral safety relay is defec-
tive.
L107 (male), L108 (male) Resistance
Possible
Between (1) and (2) 200 – 400 z
causes and
standard value a Prepare with starting switch OFF.
in normal state a Check engine control cut-out relay unit.
Engine control cut-out
Defective engine control relay (L107), (L108)
15 cut-out relays (L107, When 24 V is applied
L108) (Internal defect) Max. 1 z
Between (3) – (5)
Other than above
Min. 1 Mz
When engine control cut-out relay (L107, L108) is replaced with a relay
of the same type, if the condition becomes normal, the engine control
cut-out relay is defective.
Between (1) and (2) 200 – 400 z
Defective KOMTRAX
16 engine cut-out relay (L79) Between (3) and (6) Min. 1 Mz
(Internal defect) a Prepare with starting switch OFF, then turn starting switch to START
When KOMTRAX engine cut-out relay (L79) is replaced with a relay of
the same type, if the condition becomes normal, the KOMTRAX engine
cut-out relay is defective.
WA150-6 40-400 5

Between (1) – (2) 200 – 400 z
a Check VIS power supply holding relay
VIS power supply
Defective VIS power sup- holding relay (L102)
17 ply holding relay (L102) When 24 V is applied
(Internal defect) Max. 1 z
Between (3) – (5)
Other than above
Min. 1 Mz
When VIS power supply holding relay (L102) is replaced with another
relay, if condition becomes normal, VIS power supply holding relay is
defective.
Wiring harness between battery relay R04 – Resis-
Max. 1 z
starting motor terminal B (E30) tance
Between starting motor B-terminal E30 – starting Resis-
Max. 1 z
Possible motor safety relay B-terminal E20 tance
causes and Between starting motor C-terminal E21 – starting Resis-
standard value Max. 1 z
motor safety relay C-terminal E19 tance
in normal state
Wiring harness between L02 (female) (3) – L79 Resis-
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (3) tance
Wiring harness between L106 (female) (5) – E01 Resis-
Max. 1 z
(female) (1) tance
Disconnection in wiring Wiring harness between L15 (female) (3) – L106 Resis-
harness Max. 1 z
(female) (1) tance
18 (Disconnection in wiring
harness or defective con- Max. 1 z
tact) MF1 (female) (3), L63 (female) (3) tance
Wiring harness between L62 (female) (3), L63 Resis-
Max. 1 z
(female) (4) – ground tance
Max. 1 z
(female) (1), L108 (female) (1) tance
Wiring harness between L02 (female) (4) – EC2 Resis-
Max. 1 z
(female) (45) tance
Max. 1 z
(female) (2) – EC2 (female) (32) tance
Wiring harness between fuse No. 4 of fuse box Resis-
Max. 1 z
(FS1) – L107 (female) (3), L108 (female) (3) tance
Max. 1 z
(female) (5) – EC3 (female) (4) tance
Max. 1 z
ground tance
40-400 6 WA150-6

Wiring harness between battery relay R04 – Resis-
Min. 1 Mz
starting motor terminal B (E30) and ground tance
Between wiring harness starting motor B-termi-
Resis-
nal E30 – starting motor safety relay B-terminal Min. 1 Mz
tance
E20 and ground
Between wiring harness starting motor C-termi-
Resis-
nal E21 – starting motor safety relay C-terminal Min. 1 Mz
tance
E19 and ground
Min. 1 Mz
(female) (3), – circuit branch end and ground tance
Min. 1 Mz
(female) (5) and ground tance
Wiring harness between L106 (female) (5) – E01 Resis-
Ground fault in wiring har- (female) (1) and ground Min. 1 Mz
tance
ness
19 Between wiring harness L02 (female) (2) – L107 Resis-
(Contact with ground cir- Min. 1 Mz
(female) (1), L108 (female) (1) and ground tance
cuit)
Between wiring harness L02 (female) (4) – EC2 Resis-
Min. 1 Mz
(female) (45) and ground tance
Between wiring harness L15 (female) (3) – L106 Resis-
Min. 1 Mz
Possible (female) (1) and ground tance
causes and Between wiring harness L102 (female) (3) – L15 Resis-
Min. 1 Mz
standard value (female) (1) and ground tance
in normal state Between wiring harness fuse box (FS1) No. 3 Resis-
Min. 1 Mz
fuse – L102 (female) (5) and ground tance
Min. 1 Mz
(female) (2) – EC2 (female) (32) and ground tance
Wiring harness between fuse No. 4 of fuse box
Resis-
(FS1) – L107 (female) (3), L108 (female) (3) and Min. 1 Mz
tance
ground
Min. 1 Mz
(female) (5) – EC3 (female) (4) and ground tance
a Prepare with starting switch OFF, then turn starting switch ON and
Hot short in wiring harness Wiring harness between L107 (female) (2), L108
20 (Contact with 5V, 24V cir- (female) (2) – EC2 (female) (32), alternator ter-
cuit) minal R E02 (female) (1) – E01 (female) (2), –
Voltage Max. 1 V
circuit branch end and ground (Note: if hot short
occurs across them, the charging lamp will be
lighted as the starting switch is ON.
Between EC2 (32) – ground Voltage Max. 1 V
Between EC2 (45) – ground Voltage 20 – 30 V
Between EC3 (4) – ground Voltage 20 – 30 V
Between EC3 (1) – ground Voltage Max. 1 V
WA150-6 40-400 7
40-400 8 WA150-6
WA150-6 40-400 9
SEN05136-00 E-2 Preheater does not operate normally
E-2 Preheater does not operate normally 1
a) Preheater does not operate

Contents of
• When temperature is low (engine boost air temperature is below –4°C), preheater does not operate.
trouble
• If failure codes are displayed, carry out troubleshooting for them first.
Related • Engine boost air temperature can be checked with monitoring function.
information (Monitoring code: ENG-18500-CHG TEMP (°C))
(Monitoring code: ENG-18501-CHG TEMP (V))

a Turn starting switch OFF and remove heater relay.
a Check heater relay unit.
Heater relay E06 – R90 Resistance
Defective heater relay When 24 V is applied
1 Max. 1 z
(Internal defect) (When relay is “ON”)
Between E05 – E07
Other than above
Min. 1 Mz
(When relay is “OFF”)
Between E06 – R90 19 – 25 z
Defective intake air heater without turning starting switch ON.
2
(Internal defect) Resis- 0.17 –
Between E08 – ground
tance 0.27 z
a Replace diode (E06A).
Condition becomes normal. Diode (E06A) is defective.
Possible
causes and Condition does not become nor-
Diode (E06A) is normal.
standard value Defective diode (E06A) mal.
3
in normal state (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting
a Measure in diode range.
Between (2) – (1)
Continuity is secured.
a Apply (+) side of tester to (2).
ness (Disconnection in wiring Resis-
4 Wiring harness between E07 – E08 Max. 1 z
or defective contact in connec- tance
tor) Resis-
Wiring harness between R11 – E05 Max. 1 z
tance
Ground fault in wiring harness Between wiring harness E07 – E08 and Resis-
5 Min. 1 Mz
(Contact with GND circuit) ground tance
Between wiring harness R11 – E05 and Resis-
Min. 1 Mz
ground tance
40-400 10 WA150-6
E-2 Preheater does not operate normally SEN05136-00
WA150-6 40-400 11
SEN05136-00 E-2 Preheater does not operate normally
b) Preheater operates constantly

Contents of
• Preheater operates constantly.
trouble
• If failure code [CA144] or [CA145] is displayed, carry out troubleshooting for it first.
Related • Engine boost air temperature can be checked with monitoring function.
information (Monitoring code: ENG-18500-CHG TEMP (°C))
(Monitoring code: ENG-18501-CHG TEMP (V))

a Turn starting switch OFF and remove heater relay.
a Check heater relay unit.
Heater relay E06 – R90 Resistance
Defective heater relay When 24 V is applied
1 Max. 1 z
(Internal defect) (When relay is "ON")
Between E05 – E07
Other than above
Min. 1 Mz
Between E06 – R90 19 – 25 z
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and Ground fault in wiring harness without turning starting switch ON.
2
standard value (Contact with GND circuit) Between wiring harness EC2 (54) – E06 and Resis-
Min. 1 Mz
in normal state ground tance
When
Hot short (Contact with 5V, preheater Voltage 20 – 30 V
3
24V circuit) in wiring harness Between wiring harness E07 – is ON
E08 and ground When
preheater Voltage Max. 1 V
is OFF
If cause 1 – 3 are not detected, engine controller may be defective.

a See the circuit diagram in “E-2 a) Preheater does not operate”.
40-400 12 WA150-6
E-2 Preheater does not operate normally SEN05136-00
WA150-6 40-400 13
SEN05136-00 E-3 Travel speed is low or high
E-3 Travel speed is low or high 1
a) Max. speed is 7 km/h or below and speedometer indicates 0 km/h

Contents of • Travel speed does not increase above 4 – 7 km/h.
trouble • Speedometer of machine monitor keeps indicating 0 km/h during travel.
Related
• If failure code [DLT3KX] or [DLT4KX] is also displayed, carry out troubleshooting for it first.
information

T09 Voltage
Between (1) – (2) 4.7 – 5.3 V
Defective travel speed sensor a Prepare with starting switch OFF, then start engine, travel at con-
1
(Internal defect) stant speed, and carry out troubleshooting.
T09 Voltage
Between (3) – (2)
Between (4) – (2)
Possible Max. 1 z
causes and Disconnection in wiring har- T09 (female) (1) tance
standard value ness (Disconnection in wiring Wiring harness between HST (female) (32) – Resis-
2 Max. 1 z
in normal state or defective contact in connec- T09 (female) (2) tance
tor) Wiring harness between HST (female) (26) – Resis-
Max. 1 z
Max. 1 z
Min. 1 Mz
Ground fault in wiring harness T09 (female) (1) and ground tance
3
(Contact with GND circuit) Between wiring harness HST (female) (26) – Resis-
Min. 1 Mz
Min. 1 Mz
4
24V circuit) in wiring harness Between wiring harness HST (32) – T09 (2)
Voltage Max. 1 V
and ground
40-400 14 WA150-6
E-3 Travel speed is low or high SEN05136-00

HST Voltage
Between (22) – (32) 4.7 – 5.3 V
Possible
causes and
standard value 5 Defective HST controller a Prepare with starting switch OFF, then start engine, travel at con-
in normal state stant speed, and carry out troubleshooting.
HST Voltage
Between (26) – (32)
Between (36) – (32)
WA150-6 40-400 15
b) When speed range is set to 3rd speed, speed is not limited and max. travel speed is at 4th speed
level
Contents of • When speed range is set to 3rd speed, speed is not limited and max. travel speed is at 4th speed
trouble level.
Related
• If failure code [DW26KA] or [DW26KY] is also displayed, carry out troubleshooting for it first.
information

troubleshooting.
Replace HST motor 2 normal. defective.
with another relay. Condition does not Relay (L103) is
become normal. normal.
Defective HST motor 2 sole- a Prepare with starting switch OFF.
1
noid relay (Internal defect) a Check relay unit.
HST motor 2 solenoid
relay (L103)
When 24 V is applied
Max. 1 z
(Relay is ON)
Between (3) – (5)
Other than above
Possible Min. 1 Mz
(Relay is OFF)
causes and
standard value a Prepare with starting switch OFF, then carry out troubleshooting
in normal state Defective HST motor 2 sole- without turning starting switch ON.
2
noid (Internal defect) Resis- 15 – 30
Between T07 (male) (1) – T07 (male) (2)
tance Mz
Max. 1 z
3
or defective contact in connec- Wiring harness between T07 (female) (2) – Resis-
tor) Max. 1 z
ground tance
Max. 1 z
4
(Contact with GND circuit) Between wiring harness L103 (female) (5) – Resis-
Min. 1 Mz
40-400 16 WA150-6
WA150-6 40-400 17
c) When speed range is set to 4th speed, max. speed does not increase above 3rd gear speed level
Contents of
• When speed range is set to 4th speed, max. speed does not increase above 3rd gear speed level.
trouble
Related
• If failure code [DW26KA] is also displayed, carry out troubleshooting for it first.
information

troubleshooting.
Replace HST motor 2 normal. defective.
with another relay Condition does not Relay (L103) is
become normal. normal.
Defective HST motor 2 sole- a Prepare with starting switch OFF.
Possible 1
noid relay (Internal defect) a Check relay unit.
causes and
standard value HST motor 2
in normal state solenoid relay (L103)
Max. 1 z
(Relay is ON)
Between (3) – (5)
Other than above
Min. 1 Mz
(Relay is OFF)
2
24V circuit) in wiring harness Between wiring harness L103 (female) (5) – Resis-
Max. 1 V
40-400 18 WA150-6
WA150-6 40-400 19
SEN05136-00 E-4 ECSS does not operate
E-4 ECSS does not operate 1
Contents of
• When ECSS switch is turned ON, ECSS does not operate.
trouble
• If failure code [D192KY] is also displayed, carry out troubleshooting for it first.
Related • Output state (ON/OFF) to ECSS solenoid relay can be checked with monitoring function.
information (Monitoring code: MONITOR PANEL – 40952 – D-OUT-3)
• Input state (ON/OFF) from ECSS switch can be checked with monitoring function.
(Monitoring code: MONITOR PANEL – 40901 – D-IN-8)

Defective fuse No. 13 in fuse If fuse is broken, circuit probably has ground fault, etc.
1
box FS-1 (See cause 6.)
troubleshooting.
L09 (male) Switch position Resistance
ON Max. 1 z
Between (5) – (6)
OFF Min. 1 Mz
Defective ECSS switch (Inter-
2 Between (5), (6) –
nal defect) – (Always) Min. 1 Mz
another terminal
Resis- 200 –
tance 400 z
troubleshooting.
Possible Defective ECSS solenoid Condition does not Relay (L110) is
3 another relay.
causes and relay (L110) (Internal defect) become normal. normal.
standard value
in normal state
Resis- 200 –
tance 400 z
Defective ECSS solenoid without turning starting switch ON.
4
(Internal defect) Resis-
Between F07 (male) (1) – (2) 30 – 50 z
tance
Wiring harness between fuse box FS-1, No. Resis-
Max. 1 z
13 – L09 (female) (6) tance
Max. 1 z
ness (Disconnection in wiring L25 (female) (5), L110 (female) (1), (3) tance
5
or defective contact in connec- Wiring harness between L24 (female) (11) – Resis-
tor) Max. 1 z
Max. 1 z
F07 (female) (1) tance
Wiring harness between F07 (female) (2) – Resis-
Max. 1 z
ground tance
40-400 20 WA150-6
E-4 ECSS does not operate SEN05136-00

Between wiring harness fuse box FS-1, No.
Resis-
13 – L09 (female) (6), branch end and Min. 1 Mz
tance
Ground fault in wiring harness ground
6
(Contact with GND circuit) Between wiring harness L09 (female) (5) –
Possible Resis-
causes and L25 (female) (5), L110 (female) (1), (3), Min. 1 Mz
tance
standard value branch end and ground
in normal state Between wiring harness L110 (female) (5) – Resis-
Min. 1 Mz
F07 (female) (1), branch end and ground tance
a Prepare with starting switch OFF, then turn ECSS switch ON,
start engine, and carry out troubleshooting.
7 Defective machine monitor L24 Travel speed Voltage
Between (11) – 0 – 4 km/h 20 – 30 V
ground Min. 5 km/h Max. 1 V
WA150-6 40-400 21
SEN05136-00 E-4 ECSS does not operate
40-400 22 WA150-6
E-5 ECSS keeps operating SEN05136-00
E-5 ECSS keeps operating 1
Contents of • When ECSS switch is turned OFF, ECSS keeps operating.

trouble • When ECSS switch is turned ON, ECSS operates even at low travel speed (4 km/h or below).
• Output state (ON/OFF) to ECSS solenoid relay can be checked with monitoring function.
Related
information
• Input state (ON/OFF) from ECSS switch can be checked with monitoring function.
(Monitoring code: MONITOR PANEL – 40901 – D-IN-8)

troubleshooting.
ON Max. 1 z
Between (5) – (6)
OFF Min. 1 Mz
Defective ECSS switch
1 Between (5), (6) –
(Internal defect)
– (Always) Min. 1 Mz
another terminal
Resis- 200 –
tance 400 z
troubleshooting.
Defective ECSS solenoid another relay. Condition does not Relay (L110) is
2
relay (L110) (Internal defect) become normal. normal.
Possible Resis- 200 –
causes and tance 400 z
standard value
in normal state a Prepare with starting switch OFF, then carry out troubleshooting
Defective ECSS solenoid without turning starting switch ON.
3
Between F07 (male) (5) – (6) 30 – 50 z
tance
Wiring harness between fuse box FS-1, No. Resis-
Max. 1 z
Max. 1 z
ness (Disconnection in wiring L25 (female) (5), L110 (female) (1), (3) tance
4
or defective contact in connec- Wiring harness between L24 (female) (11) – Resis-
tor) Max. 1 z
Max. 1 z
F07 (female) (1) tance
Max. 1 z
ground tance
Ground fault in wiring harness Between wiring harness L24 (female) (11) – Resis-
5 Min. 1 Mz
(Contact with GND circuit) L110 (female) (2) and ground tance
Reference: If above is defective, ECSS operates when ECSS switch
is turned ON even at low travel speed (4 km/h or below).
WA150-6 40-400 23
SEN05136-00 E-5 ECSS keeps operating

a Prepare with starting switch OFF, then turn starting switch ON,
turn ECSS switch OFF, and carry out troubleshooting.
6 L25 (female) (5), L110 (female) (1), (3), Voltage Max. 1 V
branch end and ground
Possible Voltage Max. 1 V
F07 (female) (1), branch end and ground
causes and
standard value a Prepare with starting switch OFF, then turn ECSS switch ON,
in normal state start engine, and carry out troubleshooting.
L24 Travel speed Voltage
Between (11) – 0 – 4 km/h 20 – 30 V
ground Min. 5 km/h Max. 1 V
turn ECSS switch OFF, and carry out troubleshooting.
Between L24 (11) – ground Voltage Max. 1 V
40-400 24 WA150-6
E-5 ECSS keeps operating SEN05136-00
WA150-6 40-400 25
SEN05136-00 E-6 Defective boom kick-out function and cancellation
E-6 Defective boom kick-out function and cancellation 1
Contents of • Boom kick-out does not function or cannot be cancelled due to defective boom kick-out proximity
trouble switch system, lift arm PPC detent system and lift arm detent relay system.
Related
• This contents applies only the "boom kick-out (If equipped)" installation specification model.
information

a Replace boom kick-out relay (L113) with normal relay.
a Operate boom kick-out with engine started.
Boom kick-out function is normal. Defective relay L113.
Boom kick-out does not function. Relay L113 is normal.
a Turn starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective boom kick-out relay
1 Resis- 200 – 400
(Internal defect) Between L113 (male) (1) and (2)
tance z
a Solid part check.
Between Applies 24V impressed voltage Resis-
Max. 1 z
L113 between L113 (male) (1) – (2) tance
(male) (3) Does not apply voltage between Resis-
and (5) Min. 1 Mz
L113 (male) (1) – (2) tance
Possible a Replace detent active relay (L115) with normal relay.
causes and a Operate boom kick-out with engine started.
standard value Boom kick-out function is normal. Defective relay L115.
in normal state
Boom kick-out does not function. Relay L115 is normal.
Defective detent active relay Resis- 200 – 400
2 Between L115 (male) (1) and (2)
(Internal defect) tance z
a Solid part check.
a Applies impressed voltage between L115 (male) (1) – (2)
Max. 1 z
and (5) Min. 1 Mz
L115 (male) (1) – (2) tance
Prepare with starting switch OFF, then carry out troubleshooting
Defective boom kick-out PPC Resis-
3 Between L36 (male) (1) and (2) 30 – 50 z
detent (Internal defect) tance
Resis-
Between L36 (male) (1), (2) and ground Min. 1 Mz
tance
40-400 26 WA150-6
E-6 Defective boom kick-out function and cancellation SEN05136-00

a Interchange lift arm positioner proximity switch (F04) with bucket
positioner proximity switch (F03).
a Operate boom kick-out with engine started.
Defective lift arm positioner
Defective boom kick-
4 proximity switch (Internal
Boom kick-out function is normal. out proximity switch
defect)
F04
Boom kick-out prox-
Boom kick-out does not function. imity switch F04 is
normal.
Wiring harness between F04 (female) (A) Resis-
Max. 1 z
and fuse (FS1) (13) tance
Wiring harness between F04 (female) (B) Resis-
Max. 1 z
and L113 (female) (2) tance
Wiring harness between F04 (female) (C) Resis-
Max. 1 z
and ground tance
Max. 1 z
Wiring harness discontinuity (3) and L115 (female) (5) tance
5 (Disconnection or defective Wiring harness between L115 (female) (3) Resis-
Max. 1 z
contact) and fuse FS1 (13) tance
Wiring harness between L113 (female) (5) Resis-
Possible Max. 1 z
causes and
standard value Wiring harness between L36 (female) (2) Resis-
Max. 1 z
in normal state and ground tance
Wiring harness between E02 (female) (1) – Resis-
Max. 1 z
Max. 1 z
ground tance
a With all the above items, the boom kick-out does not function
Min. 1 Mz
and L113 (female) (2) and ground tance
Min. 1 Mz
a In this case, the boom kick-out detent does not function (lever
returns to neutral)
Wiring harness ground fault Wiring harness between F04 (female) (A) Resis-
6 Min. 1 Mz
(Contact with GND circuit) and fuse (FS1) (13) and ground tance
Min. 1 Mz
(3) and L115 (female) (5) and ground tance
Min. 1 Mz
and fuse FS1 (13) and ground tance
Min. 1 Mz
a In this case, the fuse is blown and no detents function (lever
returns to neutral)
WA150-6 40-400 27
SEN05136-00 E-6 Defective boom kick-out function and cancellation

Voltage Max. 1 V
a In this case, the boom kick-out does not function (lever does not
return to neutral)
Possible
Wiring harness between L113 (female) (1),
causes and Hot short-circuiting between Voltage Max. 1 V
(3) – L115 (female) (5) and ground
standard value 7 harnesses (Contact with 5V,
in normal state 24V circuit) a In this case, lift arm detent operates even if engine is stopped.
raise lift arm to the highest position (kick-out operated), and carry
out troubleshooting.
Wiring harness between F04 (female) (B) –
Voltage Max. 1 V
a In this case, boom kick-out detent does not function (lever returns
to neutral).
40-400 28 WA150-6
E-6 Defective boom kick-out function and cancellation SEN05136-00
WA150-6 40-400 29
SEN05136-00 E-7 Defective bucket positioner function and cancellation
E-7 Defective bucket positioner function and cancellation 1
Contents of • Bucket positioner does not function or cannot be cancelled due to defective bucket positioner proxim-
trouble ity switch system, bucket PPC detent system and bucket detent relay system.
Related
—
information

a Replace bucket leveler relay (L114) with normal relay.
a Operate bucket positioner with engine started.
Bucket positioner function is normal. Defective relay L114.
Bucket positioner does not function. Relay L114 is normal.
Defective bucket leveler relay Resis- 200 – 400
a Solid part check.
Max. 1 z
and (5) Min. 1 Mz
L114 (male) (1) – (2) tance
Possible a Turn starting switch OFF.
causes and a Replace detent active relay (L115) with normal relay.
standard value a Operate boom kick-out with engine started.
in normal state Boom kick-out function is normal. Defective relay L115.
Relay L115 is
Boom kick-out does not function.
normal.
Defective detent active relay
2 Resis- 200 – 400
tance z
a Solid part check.
Max. 1 z
and (5) Min. 1 Mz
L115 (male) (1) – (2) tance
Defective bucket PPC detent without turning starting switch ON.
3
Between L37 (male) (1) and (2) 30 – 50 z
tance
40-400 30 WA150-6
E-7 Defective bucket positioner function and cancellation SEN05136-00

a Interchange bucket positioner proximity switch (F03) with lift arm
a Operate bucket positioner with engine started.
Defective bucket positioner
Defective bucket
4 proximity switch
Bucket positioner function is normal. positioner proximity
(Internal defect)
switch F03
Bucket positioner
Bucket positioner does not function. proximity switch F03
is normal.
Max. 1 z
and fuse FS1 (13) tance
Possible
causes and Max. 1 z
standard value and L114 (female) (2) tance
in normal state Wiring harness between F03 (female) (C) Resis-
Max. 1 z
and ground tance
Max. 1 z
Wiring harness discontinuity (3), and L115 (female) (5) tance
Max. 1 z
Max. 1 z
Max. 1 z
and ground tance
Max. 1 z
Max. 1 z
ground tance
a With all the above items, the bucket positioner does not function
WA150-6 40-400 31
SEN05136-00 E-7 Defective bucket positioner function and cancellation

Wiring harness between F03 (female) (B) – Resis-
Min. 1 Mz
a In this case, the bucket positioner detent does not function (lever
does not return to neutral)
Min. 1 Mz
a In this case, the bucket positioner does not function (lever returns
Wiring harness ground fault to neutral)
6
(Contact with GND circuit) Wiring harness between F03 (female) (A) – Resis-
Min. 1 Mz
fuse FS1 (13) and ground tance
Min. 1 Mz
(3) – L115 (female) (5) and ground tance
Min. 1 Mz
fuse FS1 (13) and ground tance
Possible Wiring harness between E02 (female) (1) – Resis-
Min. 1 Mz
causes and L115 (female) (1) and ground tance
standard value a In this case, the fuse is blown and no detents function (lever
in normal state returns to neutral)
Voltage Max. 1 V
a In this case, the bucket positioner does not function (lever does
not return to neutral)
Voltage Max. 1 V
Hot short-circuiting between (3) – L115 (female) (5) and ground
7 harnesses (Contact with 5V, Wiring harness between E02 (female) (1) –
Voltage Max. 1 V
24V circuit) L115 (female) (1) and ground
a In this case, bucket detent operates even if engine is stopped.
a Prepare with starting switch OFF, then turn starting switch ON, tilt
bucket, and carry out troubleshooting.
Voltage Max. 1 V
a In this case, bucket positioner detent does not function (lever
returns to neutral).
40-400 32 WA150-6
E-7 Defective bucket positioner function and cancellation SEN05136-00
WA150-6 40-400 33
SEN05136-00 E-8 Defective lift arm FLOATING holding function and cancellation
E-8 Defective lift arm FLOATING holding function and cancellation 1
Contents of • Lift arm FLOATING holding does not function or cannot be cancelled due to defective lift arm FLOAT-
trouble ING PPC detent system.
Related
—
information

a Replace boom kick-out relay (L113) with normal relay.
a Operate lift arm FLOATING with engine started.
Lift arm FLOATING function is normal. Defective relay L113.
Lift arm FLOATING does not function. Relay L113 is normal.
a Turn starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective boom kick-out relay
1 Resis- 200 – 400
tance z
a Solid part check.
Max. 1 z
and (5) Min. 1 Mz
L113 (male) (1) – (2) tance
Possible a Replace detent active relay (L115) with normal relay.
causes and a Operate lift arm FLOATING with engine started.
standard value Lift arm FLOATING function is normal. Defective relay L115.
in normal state
Lift arm FLOATING does not function. Relay L115 is normal.
Defective detent active relay Resis- 200 – 400
a Solid part check.
Max. 1 z
and (5) Min. 1 Mz
L115 (male) (1) – (2) tance
Prepare with starting switch OFF, then carry out troubleshooting
Defective boom kick-out PPC Resis-
3 Between L36 (male) (1) and (2) 30 – 50 z
detent (Internal defect) tance
Resis-
Between L36 (male) (1), (2) and ground Min. 1 Mz
tance
40-400 34 WA150-6
E-8 Defective lift arm FLOATING holding function and cancellation SEN05136-00

a Interchange lift arm positioner proximity switch (F04) with bucket
a Operate lift arm FLOATING with engine started.
Defective lift arm positioner
Defective boom kick-
4 proximity switch (Internal
Lift arm FLOATING function is normal. out proximity switch
defect)
F04
Boom kick-out prox-
Lift arm FLOATING does not function. imity switch F04 is
normal.
Max. 1 z
and fuse (FS1) (13) tance
Max. 1 z
Wiring harness between F04 (female) (C) Resis-
Max. 1 z
and ground tance
Max. 1 z
Wiring harness discontinuity (3) and L115 (female) (5) tance
Max. 1 z
Possible Max. 1 z
causes and
standard value Wiring harness between L35 (female) (2) Resis-
Max. 1 z
in normal state and ground tance
Max. 1 z
Max. 1 z
ground tance
a With all the above items, the boom kick-out does not function
Min. 1 Mz
Min. 1 Mz
a In this case, the boom kick-out detent does not function (lever
returns to neutral)
Wiring harness ground fault Wiring harness between F04 (female) (A) Resis-
6 Min. 1 Mz
(Contact with GND circuit) and fuse (FS1) (13) and ground tance
Min. 1 Mz
(3) and L115 (female) (5) and ground tance
Min. 1 Mz
and fuse FS1 (13) and ground tance
Wiring between harness E02 (female) (1) – Resis-
Min. 1 Mz
a In this case, the fuse is blown and no detents function (lever
returns to neutral)
WA150-6 40-400 35
SEN05136-00 E-8 Defective lift arm FLOATING holding function and cancellation

Wiring harness between L113 (female) (5)
Voltage Max. 1 V
and L35 (female) (1) and ground
a In this case, the boom kick-out does not function (lever does not
Possible return to neutral)
causes and Hot short-circuiting between Wiring between harness L113 (female) (1),
Voltage Max. 1 V
standard value 7 harnesses (Contact with 5V, (3) – L115 (female) (5) and ground
in normal state 24V circuit) a In this case, lift arm detent operates even if engine is stopped.
operate lift arm FLOATING, and carry out troubleshooting.
Voltage Max. 1 V
a In this case, lift arm FLOATING detent does not function (lever
returns to neutral).
40-400 36 WA150-6
E-8 Defective lift arm FLOATING holding function and cancellation SEN05136-00
WA150-6 40-400 37
SEN05136-00 E-9 Travel direction selection system does not function
E-9 Travel direction selection system does not function 1
Contents of • Machine does not travel forward and reverse because of trouble in parking brake system, forward
trouble solenoid valve system or directional lever system.
• Before starting troubleshooting, check following items (1) and (2).
(1) Parking brake is released.
(2) Parking brake is released and parking brake indicator lamp is OFF.
• If any failure code is displayed, carry out troubleshooting for it first.
Related
• Input state of directional lever FNR input signal can be checked with indicator lamp or monitoring
information
function of machine monitor.
(Monitoring code: HST – 40977 – D-IN-0, D-IN-1, D-IN-2)
• Output state of directional solenoid FR output can be checked with monitoring function.
(Monitoring code: HST – 40980 – D-OUT-18, D-OUT-19)
a) When parking brake is released, parking brake indicator of machine monitor keeps lighting.
Defective parking brake bot- Parking brake
1 tom switch (Malfunction or L47 (male) Resistance
lever position
wrong positioning)
Bottom Max. 1 z
Between (1) – (2)
Possible Disconnection in wiring har- without turning starting switch ON.
causes and ness (Disconnection in wiring Wiring harness between HST (female) (16), Resis-
standard value 2 Max. 1 z
or defective contact in connec- L27 (female) (1), (6) – L47 (female) (2) tance
in normal state tor) Resis-
L47 (female) (1) – ground Max. 1 z
tance
Defective diode (D02) (Inter-
3 Measure at (5) in
nal defect) Between (5) – (1) Continues
diode range.
Measure at (7) in
Between (7) – (3) Continues
diode range.
40-400 38 WA150-6
E-9 Travel direction selection system does not function SEN05136-00
WA150-6 40-400 39
SEN05136-00 E-9 Travel direction selection system does not function
b) When parking brake is released, parking brake indicator of machine monitor goes off but machine
does not travel forward

Resis-
1 Defective forward solenoid Between T01 (male) (1) – (2) 15 – 30 z
(Internal defect) tance
Resis-
Between T01 (male) (1), (2) – ground Min. 1 Mz
tance
Resis-
2 Defective reverse solenoid Between T01 (male) (3) – (4) 15 – 30 z
(Internal defect) tance
Resis-
Between T01 (male) (3), (4) – ground Min. 1 Mz
tance
FNR (Directional)
lever
F (Forward) Max. 1 z
Possible 3 Defective FNR (directional) Between (1) – (2)
lever switch (Internal defect)
causes and
standard value N (Neutral) Max. 1 z
Between (1) – (3)
in normal state Other than above Min. 1 Mz
R (Reverse) Max. 1 z
Between (1) – (4)
ing brake, and carry out troubleshooting.
FNR (Directional)
HST Voltage
lever
N (Neutral) 20 – 30 V
Other than above Max. 1 V
40-400 40 WA150-6
E-9 Travel direction selection system does not function SEN05136-00
WA150-6 40-400 41
SEN05136-00 E-10 Fan does not reverse
E-10 Fan does not reverse 1
Contents of • When fan manual reverse switch is turned ON, fan does not reverse.
trouble • When fan auto-reverse switch is turned ON, fan does not reverse
• If failure code [DD1NL4], [DW7BKY] or [DW7BKZ] is also displayed, carry out troubleshooting for it first.
• Input state (ON/OFF) from fan manual reverse switch/auto-reverse switch can be checked with mon-
itoring function.
(Monitoring code: HST – 93400 – FAN REVERSE SW)
Related
(Manual reverse switch: Monitoring code: MONITOR PANEL – 40900 – D-IN-1)
information
(Auto- reverse switch: Monitoring code: MONITOR PANEL – 40901 – D-IN-9)
• Output state (ON/OFF) to fan reverse solenoid relay can be checked in monitoring mode.
• Fan automatic reverse switch is optional.

Defective fuse No. 13 in fuse
1 If fuse is broken, circuit probably has ground fault etc.
box (FS1)
without turning starting switch.
Manual reverse ON Max. 1 z
Between (5) – (6)
Auto-reverse ON Max. 1 z
Between (5) – (4)
Defective cooling fan auto- Other than above Min. 1 Mz
2 reverse switch (Internal
Between (5) –
defect)
terminal other than Any position Min. 1 Mz
(4) and (6)
Between (4), (6) – ter-
Any position Min. 1 Mz
minal other than (5)
Between (1), (3) – (2) Any position 5 – 20 kz
Possible
causes and a Prepare with starting switch OFF.
standard value a Replace relay (L104).
in normal state Condition becomes normal. Relay (L104) is defective.
Condition does not become
Relay (L104) is normal.
normal.
Resis- 200 –
Defective fan reverse solenoid Between L104 (male) (1) – (2)
3 tance 400 z
relay (L104) (Internal defect)
a Check relay unit.
Fan reverse solenoid
relay (L104)
Max. 1 z
(When relay is ON)
Between (3) -– (5)
Other than above
Min. 1 Mz
(When relay is OFF)
Defective fan reverse solenoid without turning starting switch ON.
4
Between R59 (male) (1) – (2) 30 – 50 z
tance
40-400 42 WA150-6
E-10 Fan does not reverse SEN05136-00

Wiring harness between No. 13 in fuse box Resis-
Max. 1 z
(FS1) – L69 (female) (5) tance
Max. 1 z
Disconnection in wiring har- L25 (female) (14) tance
5 Max. 1 z
or defective contact in connec- L25 (female) (10) tance
tor) Wiring harness between L102 (female) (3) – Resis-
Max. 1 z
Max. 1 z
Possible
causes and Wiring harness between R59 (female) (2) – Resis-
Max. 1 z
standard value ground tance
Between wiring harness No. 13 in fuse box Resis-
Min. 1 Mz
Ground fault in wiring harness (FS1) – L69 (female) (5) and ground tance
6
(Contact with GND circuit) Between wiring harness L69 (female) (3), (4) Resis-
Min. 1 Mz
Between wiring harness L69 (female) (1), (6) Resis-
Min. 1 Mz
a Prepare with starting switch OFF, then start engine, operate cool-
ing fan reverse switch, and carry out troubleshooting.
Defective machine monitor or HST Indicator Voltage
7
HST controller
Between (37) – OFF 20 – 30 V
ground ON Max. 1 V
WA150-6 40-400 43
SEN05136-00 E-10 Fan does not reverse
40-400 44 WA150-6
E-10 Fan does not reverse SEN05136-00
WA150-6 40-400 45
SEN05136-00 E-11 Fan keeps rotating in reverse
E-11 Fan keeps rotating in reverse 1
Contents of • When fan manual reverse switch is turned OFF, fan keeps rotating in reverse.
trouble • When fan auto-reverse switch is turned OFF, fan starts rotating in reverse automatically.
• If failure code [DD1NLD] or [DW7BKZ] is also displayed, carry out troubleshooting for it first.
• Input state (ON/OFF) from fan manual reverse switch/auto-reverse switch can be checked with mon-
itoring function.
(Monitoring code: HST – 93400 – FAN REVERSE SW)
Related
(Manual reverse switch: Monitoring code: MONITOR PANEL – 40900 – D-IN-1)
information
(Auto-reverse switch: Monitoring code: MONITOR PANEL – 40901 – D-IN-9)
• Output state (ON/OFF) to fan reverse solenoid relay can be checked in monitoring mode.
• Fan automatic reverse switch is optional.

without turning starting switch.
Manual reverse ON Max. 1 z
Between (5) – (6)
Auto-reverse ON Max. 1 z
Defective cooling fan auto- Between (5) – (4)
1 reverse switch (Internal Other than above Min. 1 Mz
defect) Between (5) – terminal
other than (4) and (6)
Between (1), (3) – (2) Any position 5 – 20 z
a Replace relay (L104).
Condition becomes normal. Relay (L104) is defective.
Possible
causes and Condition does not become
Relay (L104) is normal.
standard value normal.
Resis- 200 –
Defective fan reverse solenoid Between L104 (male) (1) – (2)
2 tance 400 z
a Check relay unit.
Fan reverse solenoid
relay (L104)
Max. 1 z
(When relay is ON)
Between (3) – (5)
Other than above
Min. 1 Mz
(When relay is OFF)
Between wiring harness L69 (female) (3), (4) –
Voltage Max. 1 V
Hot short (Contact with 5V, L25 (female) (14) and ground
3
24V circuit) in wiring harness Between wiring harness L69 (female) (1), (6) –
Voltage Max. 1 V
Voltage Max. 1 V
40-400 46 WA150-6
E-11 Fan keeps rotating in reverse SEN05136-00
Possible a Prepare with starting switch OFF, then start engine, operate cool-
ing fan reverse switch, and carry out troubleshooting.
causes and
standard value Defective machine monitor or HST Indicator Voltage
4
in normal state HST controller
Between (37) – OFF 20 – 30 V
ground ON Max. 1 V
WA150-6 40-400 47
SEN05136-00 E-12 Wiper does not operate
E-12 Wiper does not operate 1
Contents of
(1) Front wiper does not operate.
trouble
Related
• The front wiper does not operate due to the defective front wiper switch, timer, or wiring harness.
information

1
L57 Front wiper switch Voltage
Between (6) and
ground
Defective front wiper motor
2 Between (2) and
(Internal defect) Lo 20 – 30 V
ground
Between (1) and
Hi 20 – 30 V
ground
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between L57 (5) and ground until wiper motor stops.
L48 Front wiper switch Voltage
Between (3) and
Possible Constant 20 – 30 V
ground
causes and
standard value Defective wiper timer (relay) Between (4) and
3 INT 20 – 30 V
in normal state (Internal defect) ground
Between (2) and
Washer side 20 – 30 V
ground
INT (If wiper switch is
Between (5) and Repeat 20 to 30 V o
set in INT, voltage is
ground 0V
output intermittently.)
L05 Voltage
Between (7) and ground 20 – 30 V
Defective front wiper switch
4 L05 Front wiper switch Resistance
(Internal defect)
Between (7) and (5) Lo Max. 1 z
Between (7) and (4) Hi Max. 1 z
Between (7) and (2) INT Max. 1 z
Between (3) and (5) INT Max. 1 z
40-400 48 WA150-6
E-12 Wiper does not operate SEN05136-00

Max. 1 z
Disconnection in wiring har- Max. 1 z
ness
5 Wiring harness between L05 (female) (7) –
(Disconnection or defective Resis-
contact in connector) fuse No. 14 of fuse box (FS1), – circuit Max. 1 z
tance
branch end
Max. 1 z
Possible Wiring harness between L57 (female) (3) – Resis-
causes and Max. 1 z
ground tance
standard value
in normal state
Resis-
L48 (female) (5), – circuit branch end and Min. 1 Mz
tance
ground
Grounding fault in wiring har- Resis-
6 ness tance
ground
(Contact with ground circuit)
Resis-
fuse No. 14 of fuse box (FS1), – circuit Min. 1 Mz
tance
Resis-
tance
ground
WA150-6 40-400 49
SEN05136-00 E-12 Wiper does not operate
Contents of
(2) Rear wiper does not operate.
trouble
Related
• Since the rear wiper switch or wiring harness is defective, the rear wiper does not operate.
information

L52 Rear wiper switch Voltage
Between (1) and
Defective rear wiper motor Constant 20 – 30 V
1 ground
(Internal defect)
Between (2) and
ON 20 – 30 V
ground
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between L52 (3) and ground until wiper motor stops.
L05 Voltage
Defective rear wiper switch a Prepare with starting switch OFF, then carry out troubleshooting
2 without turning starting switch ON.
(Internal defect)
L05 Rear wiper switch Resistance
Between (7) and (9) ON Max. 1 z
Possible
causes and Between (8) and (9) OFF Max. 1 z
standard value Other than above Min. 1 Mz
in normal state
Max. 1 z
Disconnection in wiring har- fuse No. 14 of fuse box (FN1) tance
ness Wiring harness between L05 (female) (8) – Resis-
3 Max. 1 z
(Disconnection or defective L52 (female) (3) tance
contact in connector) Wiring harness between L05 (female) (9) – Resis-
Max. 1 z
Max. 1 z
ground tance
Resis-
Ground fault in wiring harness branch end and ground tance
4
(Contact with ground circuit)
Min. 1 Mz
Min. 1 Mz
40-400 50 WA150-6
E-12 Wiper does not operate SEN05136-00
WA150-6 40-400 51
SEN05136-00 E-13 Windshield washer does not operate
E-13 Windshield washer does not operate 1
Contents of
Windshield washer does not operate.
trouble
• Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the
Related windshield washer does not operate.
information • Perform the following troubleshooting when the wiper operates normally. (If the wiper does not oper-
ate normally, carry out troubleshooting for “E-12 Wiper does not operate” first.)

a Prepare with starting switch OFF, then hold starting switch OFF or
turn it ON and carry out troubleshooting.
B07 Front wiper switch Voltage/Resistance
Defective front washer motor
1 Between (1) – ground Window washer 20 – 30 V
(Internal defect)
Between (2) – ground operation position Max. 1 z
If voltage and resistance are normal but front washer does not oper-
ate, front washer motor is defective.
B06 Rear wiper switch Voltage/Resistance
Between (1) – ground Window washer 20 – 30 V
Defective rear washer motor Between (2) – ground operation position Max. 1 z
2
(Internal defect) If voltage and resistance are normal but rear washer does not oper-
ate, rear washer motor is defective.
B07 Front wiper switch Voltage/Resistance
L05 Voltage
Possible Between (7) and ground 20 – 30 V
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
Defective front wiper switch
in normal state 3
(Internal defect) Washer switch for
front wiper
ON Max. 1 z
Between (7) and (6)
OFF Min. 1 Mz
Between (7), (6) and
Constant Min. 1 Mz
ground
L05 Voltage
Defective rear wiper switch without turning starting switch ON.
4
(Internal defect) Washer switch for
rear wiper
ON Max. 1 z
Between (7) and (10)
OFF Min. 1 Mz
Constant Min. 1 Mz
ground
40-400 52 WA150-6
E-13 Windshield washer does not operate SEN05136-00

Washer switch for
L48 Voltage
front wiper
Defective wiper timer (relay) Between (3) and
5 Constant 20 – 30 V
(for only front wiper) ground
Between (2) and
ON 20 – 30 V
ground
Between (5) and
0.2 – 0.8 sec after ON 20 – 30 V
ground
Max. 1 z
Possible Disconnection in wiring har- B07 (female) (1), – L48 (female) (2) tance
causes and ness Wiring harness between L05(female) (7) – Resis-
standard value 6 Max. 1 z
(Disconnection or defective fuse No. 14 of fuse box (FS1) tance
in normal state contact in connector) Wiring harness between L05 (female) (10) – Resis-
Max. 1 z
B06 (female) (1) tance
Wiring harness between B07 (female) (2), Resis-
Max. 1 z
B06 (female) (2) – ground tance
Resis-
B07 (female) (1), – L48 (female) (2), – circuit Min. 1 Mz
tance
Ground fault in wiring harness
7
(Contact with ground circuit) Wiring harness between L05 (female) (7) – Resis-
tance
Resis-
B06 (female) (1), – circuit branch end and Min. 1 Mz
tance
ground
WA150-6 40-400 53
SEN05136-00 E-13 Windshield washer does not operate
40-400 54 WA150-6
E-13 Windshield washer does not operate SEN05136-00
WA150-6 40-400 55
SEN05136-00 E-14 Headlamp, clearance lamp, tail lamp and license lamp do not light up or go off
E-14 Headlamp, clearance lamp, tail lamp and license lamp do not light
up or go off 1
Contents of
(1) Headlamp, clearance lamp, tail lamp and license lamp do not light up or go off.
trouble
• Since the lamp system GND circuit is disconnected or shorted with the ground, none of the lamps
lights up.
Reference:
• Headlamp at SMALL position: Clearance lamp, tail lamp, machine monitor night lamp light up
(when normal).
• Headlamp at HEAD position: Above lamps and headlamp light up (when normal).
Related
information • The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked
with the monitoring function (Code: MONITOR PANEL 40200, SMALL LAMP).
• The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked
• The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be
checked with the monitoring function (Code: MONITOR PANEL 40904, D-IN-34).
• License lamp is optional.

L04 (male) Lamp switch Resistance
OFF Min. 1 Mz
Defective lamp switch Between (2) and (3) 1st line Min. 1 Mz
Possible 1
(Internal defect)
causes and 2nd line Max. 1 z
standard value OFF Min. 1 Mz
in normal state
Between (1) and (3) 1st line Max. 1 z
2nd line Max. 1 z
2
(Disconnection or defective Wiring harness between L04 (female) (3) – Resis-
connector contact) Max. 1 z
ground tance
40-400 56 WA150-6
E-14 Headlamp, clearance lamp, tail lamp and license lamp do not light up or go off SEN05136-00
Contents of
(2) Either of headlamp (low and high beams) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low and high beams) is defective.
• Carry out the following troubleshooting when the clearance lamp and tail lamp light up and go off nor-
mally.
Related
information

Defective fuses No. 8 and No. If the fuse is burn, the circuit probably has a grounding fault, etc.
1
9 of fuse box (FS1) (See cause 7.)
Between (1) and (2) 200 – 400 z
Defective headlamp relay, left
When headlamp relay (L120) is replaced with a relay of the same
type, if the condition becomes normal, the headlamp relay is defec-
tive.
Between (1) and (2) 200 – 400 z
Possible Defective headlamp relay,
causes and right (L119)
standard value and carry out troubleshooting.
in normal state When headlamp relay (L119) is replaced with a relay of the same
type, if the condition becomes normal, the headlamp relay is defec-
tive.
Defective lamp switch L04 (male) Headlamp switch Resistance

4
(Internal defect) OFF Min. 1 Mz
Between (2) and (3) 1st position Min. 1 Mz
2nd position Max. 1 z
L04 (male) Dimmer switch Resistance
Defective dimmer switch Low Min. 1 Mz
5
High Max. 1 z
Low Max. 1 z
Between (4) and (3)
High Min. 1 Mz
WA150-6 40-400 57

Max. 1 z
Max. 1 z
box (FS1) – L120 (female) (1), (3) tance
ness L25 (female) (1), – left FLH (female) (B) tance
6
(Disconnection or defective a Carry out above 3 items when left side does not light.
Max. 1 z
Max. 1 z
Max. 1 z
right FLH (female) (B) tance
a Carry out above 3 items when right side does not light.
Resis-
tance
ground
a Carry out above when left side does not go off.
Possible
causes and Wiring harness between fuse No. 8 of fuse
Resis-
standard value box (FS1) – L120 (female) (1), (3) and Min. 1 Mz
tance
in normal state ground
Resis-
Ground fault in wiring harness L25 (female) (1), – left FLH (female) (B) and tance
Min. 1 Mz
7
(Contact with ground circuit) ground
a Carry out above 2 items when left side does not light.
Min. 1 Mz
a Carry out above when right side does not go off.
Wiring harness between fuse No. 9 of fuse
Resis-
box (FS1) – L119 (female) (1), (3) and Min. 1 Mz
tance
ground
Min. 1 Mz
right FLH (female) (B) and ground tance
a Carry out above 2 items when right side does not light.
• Headlamp switch is OFF
Hot short in wiring harness L25 (female) (1), – left FLH (female) (B) and Voltage Max. 1 V
8 ground
(Contact with 5V, 24V circuit)
Voltage Max. 1 V
right FLH (female) (B) and ground
a Carry out above when left side does not light.
40-400 58 WA150-6
Contents of
(3) Headlamp (low beam) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low beam) is disconnected or shorted with the
ground.
• Carry out the following troubleshooting when the high beam lights up (goes off) normally.
Related
information

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb
may have a defective contact. Check the bulb directly.
2
High Max. 1 z
Possible Low Max. 1 z
Between (4) and (3)
causes and High Min. 1 Mz
standard value
in normal state
ness
3 Wiring harness between FLH (female) (A) – Resis-
(Disconnection or defective Max. 1 z
contact in connector)
Reference: Connector "FLH" is installed to both right and left sides.
Ground fault in wiring harness
4 Wiring harness between FLH (female) (A) – Resis-
(Contact with ground circuit) Min. 1 Mz
WA150-6 40-400 59
Contents of
(4) Headlamp (high beam) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (high beam) is disconnected or shorted with the
ground.
• Carry out the following troubleshooting when the low beam lights up (goes off) normally.
Related
information

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb
2
High Max. 1 z
Low Max. 1 z
Possible Between (4) and (3)
causes and High Min. 1 Mz
in normal state Disconnection in wiring har- without turning starting switch ON.
ness
3 Wiring harness between FLH (female) (C) – Resis-
(Disconnection or defective Max. 1 z
Ground fault in wiring harness Wiring harness between FLH (female) (C) –
4 Resis-
(Contact with ground circuit) L04 (female) (5), – circuit branch end and Min. 1 Mz
tance
ground
40-400 60 WA150-6
(5) Clearance lamp does not light up or go off.

Contents of
(6) Tail lamp does not light up or go off.
trouble
(7) License lamp (If equipped) does not light up or go off.
• Defective switch, lamp, or wiring harness of the clearance lamp, tail lamp or license lamp system.
Related • When the headlamp and turn signal lamp light up.
information • The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked
with the monitoring function (Code: MONITOR PANEL 40200, SMALL LAMP).

If a specific lamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Defective fuses No. 10 and If the fuse is burn, the circuit probably has a grounding fault, etc.
2
No. 11 of fuse box (FS2) (See cause 5.)
Between (1) and (2) 200 – 400 z
Defective small lamp relay, left
3
(L117) (Internal defect) a Prepare with starting switch OFF, then turn starting switch ON
When small lamp relay (L117) is replaced with a relay of the same
type, if the condition becomes normal, the small lamp relay is defec-
tive.
Between (1) and (2) 200 – 400 z
Defective small lamp relay,
4
right (L118) (Internal defect) a Prepare with starting switch OFF, then turn starting switch ON
When small lamp relay (L118) is replaced with a relay of the same
Possible type, if the condition becomes normal, the small lamp relay is defec-
causes and tive.
standard value
in normal state
Defective lamp switch L04 (male) Lamp switch Resistance

5
(Internal defect) OFF Min. 1 Mz
Between (1) and (3) 1st position Max. 1 z
2nd position Max. 1 z
Max. 1 z
L117 (female) (2), – L118 (female) (2) tance
Max. 1 z
a Carry out above 2 items when left side does not light.
Disconnection in wiring har-
ness Wiring harness between fuse No. 11 of fuse Resis-
6 Max. 1 z
(Disconnection or defective box (FS2) – L118 (female) (1), (3) tance
a Carry out above when right side does not light.
Max. 1 z
FLC1 (female) (A), – R22 (female) (6) tance
Max. 1 z
FLC (female) (A), – R23 (female) (6) tance
Max. 1 z
WA150-6 40-400 61

Resis-
L117 (female) (2), – L118 (female) (2) and Min. 1 Mz
tance
ground
a Carry out above when lamp does not go off.
Resis-
box (FS2) – L117 (female) (1), (3) and Min. 1 Mz
tance
ground
Ground fault in wiring harness Wiring harness between fuse No. 11 of fuse
7 Resis-
(Contact with ground circuit) box (FS2) – L118 (female) (1), (3) and Min. 1 Mz
tance
ground
a Carry out above when right side does not light.
Resis-
Possible FLC1 (female) (A), – R22 (female) (6) and Min. 1 Mz
tance
causes and ground
standard value Wiring harness between L118 (female) (5) –
in normal state Resis-
FLC (female) (A), – R23 (female) (6) and Min. 1 Mz
tance
ground
Min. 1 Mz
• Headlamp switch is OFF
L117 (female) (2), – L118 (female) (2), – cir- Voltage Max. 1 V
cuit branch end and ground
Hot short in wiring harness Wiring harness between L117 (female) (5) –
8
(Contact with 5V, 24V circuit) FLC1 (female) (A), – R22 (female) (6), – cir- Voltage Max. 1 V
FLC (female) (A), – R23 (female) (6), – cir- Voltage Max. 1 V
Voltage Max. 1 V
40-400 62 WA150-6
WA150-6 40-400 63
SEN05136-00 E-15 Working lamp does not light up or go off
E-15 Working lamp does not light up or go off 1
Contents of
(1) Front working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the front working lamp system is defective
Related • When the rear working lamp is normal
information • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
or may have a defective contact. Check the bulb directly.
2
Between (1) and (2) 200 – 400 z
Defective front working lamp
When front working lamp relay (L122) is replaced with a relay of the
same type, if the condition becomes normal, the front working lamp
relay is defective.
Possible without turning starting switch ON.
causes and Front working lamp
standard value Defective front working lamp switch
in normal state 4
switch (Internal defect) ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Constant Min. 1 Mz
ground
Max. 1 z
Max. 1 z
ness ground tance
5
(Disconnection or defective Wiring harness between fuse No. 12 of fuse Resis-
box (FS2) – L07 (female) (6), L122 (female) (3) tance
Max. 1 z
C04 (female) (1), – C05 (female) (1) tance
Wiring harness between C04 (female) (2), Resis-
Max. 1 z
C05 (female) (2) – ground tance
40-400 64 WA150-6
E-15 Working lamp does not light up or go off SEN05136-00

Min. 1 Mz
6 Resis-
(Contact with ground circuit) box (FS2) – L07 (female) (6), L122 (female) Min. 1 Mz
tance
(3) and ground
Possible
causes and Wiring harness between L122 (female) (5) –
Resis-
standard value C04 (female) (1), – C05 (female) (1), – circuit Min. 1 Mz
tance
in normal state branch end and ground
• Front working lamp switch turned off
7 Voltage Max. 1 V
(Contact with 5V, 24V circuit) L122 (female) (1) and ground
C04 (female) (1), – C05 (female) (1), – circuit Voltage Max. 1 V
WA150-6 40-400 65
Contents of
(2) Rear working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the rear working lamp system is defective.
Related • When the front working lamp is normal
information • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
2
Between (1) and (2) 200 – 400 z
Defective rear working lamp
When rear working lamp relay (L123) is replaced with a relay of the
same type, if the condition becomes normal, the rear working lamp
relay is defective.
Possible without turning starting switch ON.
causes and Rear working lamp
Defective rear working lamp L08 (male) Resistance
standard value switch
in normal state 4 switch
ON Max. 1 z
OFF Min. 1 Mz
Constant Min. 1 Mz
ground
Max. 1 z
Max. 1 z
ness ground tance
5
(Disconnection or defective Wiring harness between fuse No. 13 of fuse Resis-
box (FS2) – L08 (female) (6), L123 (female) (3) tance
Max. 1 z
B01 (female) (1), – B02 (female) (1) tance
Wiring harness between B01 (female) (2), Resis-
Max. 1 z
B02 (female) (2) – ground tance
40-400 66 WA150-6
E-15 Working lamp does not light up or go off SEN05136-00

Max. 1 z
6 Resis-
(Contact with ground circuit) box (FS2) – L08 (female) (6), L123 (female) Max. 1 z
tance
(3) and ground
Possible
Resis-
standard value B01 (female) (1), – B02 (female) (1), – circuit Max. 1 z
tance
in normal state branch end and ground
• Front working lamp switch turned off
7 Voltage Max. 1 V
(Contact with 5V, 24V circuit) L123 (female) (1) and ground
B01 (female) (1), – B02 (female) (1), – circuit Voltage Max. 1 V
WA150-6 40-400 67
40-400 68 WA150-6
E-16 Turn signal lamp and hazard lamp do not light up or go off SEN05136-00
E-16 Turn signal lamp and hazard lamp do not light up or go off 1
Contents of
(1) Either of turn signal lamp and hazard lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp system is defective.
• The input state (ON/OFF) to the machine monitor from the turn signal lamp & hazard lamp switch
(right turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901,
Related
D-IN-12).
information
• The input state (ON/OFF) to the machine monitor from the turn signal lamp & hazard lamp switch (left
turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901, D-
IN-13).

Defective No.2 and No.10 If the fuse is burn, the circuit probably has a grounding fault, etc.
1
fuses of fuse box (FS1) (See cause 8.)
Defective hazard relay (L125) Between (1) and (2) 200 – 400 z
2
(Internal defect) a Prepare with starting switch OFF, then turn starting switch ON
When hazard relay (L125) is replaced with a relay of the same type,
if the condition becomes normal, the hazard relay is defective.
Possible Between (5) and (6) 200 – 400 z
causes and
Defective hazard/turn signal (1), (2), (3), (4) – (6) Min. 1 Mz
standard value 3
relay (L124)
in normal state a Prepare with starting switch OFF, then turn starting switch ON
When hazard/turn signal relay (L124) is replaced with a relay of the
same type, if the condition becomes normal, the hazard/turn signal
relay is defective.
L49 Voltage
Between (3) and (1) 20 – 30 V
Defective flasher unit 20 – 30 V and 0 V are indicated
4 Between (4) and (1)
(Internal defect) repeatedly.
Between (3), (4) and ground Min. 1 Mz
WA150-6 40-400 69
SEN05136-00 E-16 Turn signal lamp and hazard lamp do not light up or go off

Max. 1 z
5
L04 (female) (6), L124 (female) (1), (3) tance
Max. 1 z
ground tance
Min. 1 Mz
Resis-
L04 (female) (6), L124 (female) (1), (3) and Min. 1 Mz
Ground fault in wiring harness tance
6 ground
Possible (Contact with ground circuit)
Resis-
standard value R23 (female) (1) – FLC [left] (female) (C) and Min. 1 Mz
tance
in normal state ground
Resis-
R22 (female) (1) – FLC [right] (female) C and Min. 1 Mz
tance
ground
Voltage Max. 1 V
L04 (female) (6), L124 (female) (1), (3) and Voltage Max. 1 V
7 ground
R23 (female) (1) – FLC [left] (female) (C) and Voltage Max. 1 V
ground
R22 (female) (1) – FLC [right] (female) C and Voltage Max. 1 V
ground
40-400 70 WA150-6
Contents of
(2) Turn signal lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the turn signal lamp system is defective.
• When the hazard lamp lights up.
• The input state (ON/OFF) to the machine monitor from the turn signal lamp and hazard lamp switch
Related (right turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901,
information D-IN-12).
• The input state (ON/OFF) to the machine monitor from the turn signal lamp and hazard lamp switch
(left turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901,
D-IN-13).

If a specific turn signal lamp does not light up, its bulb may be bro-
1 Broken bulb
ken or may have a defective contact. Check the bulb directly.
Turn signal lamp
switch
Defective turn signal lamp Left Min. 1 Mz

2 Between (6) and (7)
switch (Internal defect) Right Max. 1 z
Left Max. 1 z
Between (6) and (8)
Right Min. 1 Mz
a Prepare with starting switch OFF, then check relay unit.
3 Defective hazard relay (L125) Resis-
Between L125 (female) (3) – (6) Max. 1 z
tance
Wiring harness between fuse box FS1 No. Resis-
Possible Max. 1 z
causes and
in normal state
Max. 1 z
Disconnection in wiring har- R23 (female) (1), – FLC (female) (C) tance
ness Wiring harness between L04 (female) (8) – Resis-
4 Max. 1 z
(Disconnection or defective R22 (female) (1), – FLC1 (female) (C) tance
contact in connector) Wiring harness between R22 (female) (4) – Resis-
Max. 1 z
ground tance
Wiring harness between R23 (female) (4) – Resis-
Max. 1 z
ground tance
Wiring harness between FLC (female) (B) – Resis-
Max. 1 z
ground tance
Wiring harness between FLC1 (female) (B) – Resis-
Max. 1 z
ground tance
5
(Contact with ground circuit) Wiring harness between fuse box FS1 No. Resis-
Min. 1 Mz
10 – L125 (female) (6) and ground tance
WA150-6 40-400 71
Contents of
(3) Hazard lamp does not light up or go off.
trouble
Related • The switch or lamp of the hazard lamp is defective.
information • Carry out the following troubleshooting when the turn signal lamp flashes normally.

1
Defective hazard relay (L125) Between (1) and (2) 200 – 400 z
2
When hazard relay (L125) is replaced with a relay of the same type,
if the condition becomes normal, the hazard relay is defective.
Between (1) and (2) 200 – 400 z
Defective hazard/turn signal
When hazard/turn signal relay (L124) is replaced with a relay of the
same type, if the condition becomes normal, the hazard/turn signal
relay is defective.
Possible
causes and
standard value
Defective hazard lamp switch L06 (male) Hazard lamp switch Resistance
in normal state 4
(Internal defect)
ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Max. 1 z
box (FS1) – L125 (female) (5) tance
Max. 1 z
Max. 1 z
Disconnection in wiring har- L06 (female) (5) tance
ness Resis-
5 Between L124 (female) (6) – ground Max. 1 z
(Disconnection or defective tance
contact in connector) Resis-
Between L125 (female) (2) – ground Max. 1 z
tance
Between L49 (female) (4) – L124 (female) Resis-
Max. 1 z
(1), (3) tance
Between L124 (female) (2) – FLC [right] (C), Resis-
Max. 1 z
R23 (1) tance
Between L124 (female) (4) – FLC [left] (C), Resis-
Max. 1 z
R22 (1) tance
40-400 72 WA150-6

Min. 1 Mz
Ground fault in wiring harness box (FS1) – L125 (female) (5) and ground tance
6
(Contact with ground circuit) Wiring harness between fuse No. 2 of fuse Resis-
Min. 1 Mz
Min. 1 Mz
L06 (female) (1), (5) and ground tance
Possible a Prepare with starting switch OFF, then turn starting switch ON
causes and and carry out troubleshooting.
standard value • When hot short resulted on the wiring harnesses of the following
in normal state two circuits
R23 (female) (1), – FLC (female) (C), – cir- Voltage Max. 1 V
Hot short in wiring harness cuit branch end and ground
7
R22 (female) (1), – FLCL (female) (C), – cir- Voltage Max. 1 V
L125 (female) (1) – L06 (female) (1), (5) and Voltage Max. 1 V
ground
WA150-6 40-400 73
40-400 74 WA150-6
WA150-6 40-400 75
SEN05136-00 E-17 Brake lamp does not light or it keeps lighting up
E-17 Brake lamp does not light or it keeps lighting up 1
Contents of
Brake lamp does not light or it keeps lighting up.
trouble
Related
• The lamp or wiring harness of the brake lamp system is abnormal.
information

If a specific brake lamp does not light up, its bulb may be broken or
1 Broken bulb
Defective fuse No.11 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
2
Between (1) and (2) 200 – 400 z
Defective brake lamp relay
When brake lamp relay (L121) is replaced with a relay of the same
type, if the condition becomes normal, the brake lamp relay is defec-
tive.
L34 (male) Brake pedal Resistance
Defective brake lamp switch
4 Press Max. 1 z
Released Min. 1 Mz
Possible Constant Min. 1 Mz
ground
causes and
in normal state without turning starting switch ON.
Resis-
box (FS1) – L121 (female) (3), – L34 Max. 1 z
tance
(female) (1)
ness Max. 1 z
5 L121 (female) (1) tance
(Disconnection or defective
ground tance
Max. 1 z
R22 (female) (5), R23 (female) (5) tance
Wiring harness between R22 (female) (4), Resis-
Max. 1 z
R23 (female) (4) – ground tance
Resis-
box (FS1) – L121 (female) (3), – L34 Min. 1 Mz
tance
Ground fault in wiring harness (female) (1), – circuit branch end and ground
6
(Contact with ground circuit) Wiring harness between L34 (female) (2) – Resis-
Min. 1 Mz
Resis-
R22 (female) (5), – R23 (female) (5) and Min. 1 Mz
tance
ground
40-400 76 WA150-6
E-17 Brake lamp does not light or it keeps lighting up SEN05136-00

Possible and carry out troubleshooting.
standard value Hot short in wiring harness Voltage Max. 1 V
7 L121 (female) (1) and ground
in normal state (Contact with 5V, 24V circuit)
R22 (female) (5), – R23 (female) (5) and Voltage Max. 1 V
ground
WA150-6 40-400 77
SEN05136-00 E-18 Backup lamp does not light or it keeps lighting up
E-18 Backup lamp does not light or it keeps lighting up 1
Contents of
Backup lamp does not light or it keeps lighting up.
trouble
• The machine monitor monitors the primary circuit of the backup lamp relay for a trouble.
Related (If hot short occurs in the primary side of the back lamp relay, failure code [D160KY] is indicated.
information Carry out troubleshooting for it first.)
• If another failure code is displayed, carry out troubleshooting for it first.

If a specific backup lamp does not light up, its bulb may be broken
1 Broken bulb
2
Between (1) and (2) 200 – 400 z
Defective backup lamp 1 relay
When backup lamp 1 relay (L109) is replaced with a relay of the
same type, if the condition becomes normal, the backup lamp 1
relay is defective.
causes and without turning starting switch ON.
standard value L126 (male) Resistance
in normal state
Defective backup lamp 2 relay Between (1) and (2) 200 – 400 z
4 (L126) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting.
relay is defective.
Between (1) and (2) 200 – 400 z
Defective FR pressure select
When FR pressure select relay (L101) is replaced with a relay of the
same type, if the condition becomes normal, the FR pressure select
relay is defective.
40-400 78 WA150-6
E-18 Backup lamp does not light or it keeps lighting up SEN05136-00

Max. 1 z
Max. 1 z
R22 (female) (2), – R23 (female) (2) tance
Max. 1 z
Reference: Following 4 items are circuits for turning lamp ON with
directional lever in R position.
Max. 1 z
Max. 1 z
R22 (female) (2), – R23 (female) (2) tance
Max. 1 z
ground tance
ness
6 Reference: Following 4 items are circuits for turning lamp ON when
(Disconnection or defective
contact in connector) HST controller outputs signal to reverse solenoid.
Max. 1 z
Max. 1 z
R22 (female) (2) or R23 (female) (2) tance
Possible
causes and Wiring harness between HST (female) (20) – Resis-
Max. 1 z
standard value L101 (female) (5) tance
in normal state Wiring harness between L101 (female) (6) – Resis-
Max. 1 z
ground tance
Max. 1 z
ground tance
Max. 1 z
ground tance
Wiring harness between fuse box FS1 No. 5 Resis-
Max. 1 z
– L24 (female) (4), (5) tance
Reference: If above wiring harness is disconnected, when directional
switch is set in R and lamp lights and then directional lever or direc-
tional switch is set in position other than R, lamp may not go off.
Resis-
box (FS2) – L109 (female) (3), (1) – circuit Min. 1 Mz
tance
Ground fault in wiring harness branch end and ground
7
(Contact with ground circuit) Wiring harness between L109 (female) (5) –
Resis-
R22 (female) (2), – R23 (female) (2), – circuit Min. 1 Mz
tance
Min. 1 Mz
R22 (female) (2), – R23 (female) (2), – circuit Voltage Max. 1 V
WA150-6 40-400 79
SEN05136-00 E-18 Backup lamp does not light or it keeps lighting up
40-400 80 WA150-6
E-19 Backup alarm does not sound or it keeps sounding SEN05136-00
E-19 Backup alarm does not sound or it keeps sounding 1
Contents of
Backup alarm does not sound or it keeps sounding.
trouble
• The machine monitor monitors the primary circuit of the backup lamp relay for a trouble.
Related (If hot short occurs in the primary side of the back lamp relay, failure code [D160KY] is indicated. In
information such case, give precedence to the troubleshooting of the failure indicated with the code.)
• If another failure code is displayed, carry out troubleshooting for it first.

Defective backup alarm B03 Gear shift lever Voltage
1
(Internal defect)
R 20 – 30 V
Between (1) and (2)
Other than R Max. 1 V
2
Between (1) and (2) 200 – 400 z
Defective backup lamp 1 relay
Possible
relay is defective.
causes and
in normal state without turning starting switch ON.
Defective backup lamp 2 relay Between (1) and (2) 200 – 400 z
4 (L126) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting.
relay is defective.
Between (1) and (2) 200 – 400 z
Defective FR pressure select
When FR pressure select relay (L101) is replaced with a relay of the
same type, if the condition becomes normal, the FR pressure select
relay is defective.
WA150-6 40-400 81
SEN05136-00 E-19 Backup alarm does not sound or it keeps sounding

Max. 1 z
Max. 1 z
Max. 1 z
Reference: Following 4 items are circuits for turning backup alarm
ON with directional lever in R position.
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
ness ground tance
6
(Disconnection or defective Reference: Following 4 items are circuits for turning backup alarm
contact in connector) ON when HST controller outputs signal to reverse solenoid.
Max. 1 z
Possible Max. 1 z
causes and
in normal state
Max. 1 z
ground tance
Wiring harness between B03 (female) (2) – Resis-
Max. 1 z
ground tance
Wiring harness between fuse box FS1 No. 5 Resis-
Max. 1 z
– L24 (female) (4), (5) tance
Reference: If above wiring harness is disconnected, when directional
switch is set in R and backup alarm turned ON and then directional
lever or directional switch is set in position other than R, backup
alarm may not go OFF.
Resis-
box (FS2) – L109 (female) (3), (1) – circuit Min. 1 Mz
tance
7
(Contact with ground circuit) Wiring harness between L109 (female) (5) –
Resis-
R22 (female) (2), – R23 (female) (2), – circuit Min. 1 Mz
tance
Min. 1 Mz
R22 (female) (2), – R23 (female) (2), – circuit Voltage Max. 1 V
40-400 82 WA150-6
E-19 Backup alarm does not sound or it keeps sounding SEN05136-00
WA150-6 40-400 83
SEN05136-00 E-20 Horn does not sound or it keeps sounding
E-20 Horn does not sound or it keeps sounding 1
Contents of
Horn does not sound or it keeps sounding.
trouble
Related
—
information

1
Defective horn relay (L116) Between (1) and (2) 200 – 400 z
2
When horn relay (L116) is replaced with a relay of the same type, if
the condition becomes normal, the horn relay is defective.
Defective L13 horn switch L13 (male) Horn switch Resistance
3
(Internal defect)
Between (1) and ON Max. 1 z
ground OFF Min. 1 Mz
Possible and carry out troubleshooting. (Disconnect connector and mea-
causes and sure on female side)
standard value F01, F02 Horn switch Voltage
in normal state
Defective horn Between F01 (1) and ON Max. 1 V
4 (2)
(Internal defect) OFF 20 – 30 V
Between F02 (1) and ON Max. 1 V
(2) OFF 20 – 30 V
a If horn does not sound normally under above condition, it is
defective.
Max. 1 z
Max. 1 z
5
F01 (female) (1), – F02 (female) (1) tance
Max. 1 z
F02 (female) (2) – ground tance
Wiring harness between steering wheel horn Resis-
Max. 1 z
switch – ground tance
40-400 84 WA150-6
E-20 Horn does not sound or it keeps sounding SEN05136-00

Resis-
box (FS2) – L116 (female) (1), (3), – circuit Min. 1 Mz
tance
6
Possible (Contact with ground circuit) Wiring harness between L116 (female) (5) –
Resis-
causes and F01 (female) (1), – F02 (female) (1), – circuit Min. 1 Mz
tance
standard value branch end and ground
in normal state Wiring harness between L116 (female) (2) – Resis-
Min. 1 Mz
and carry out troubleshooting while not pressing horn switch.
F01 (female) (1) or F02 (female) (1) and Voltage Max. 1 V
ground
WA150-6 40-400 85
SEN05136-00 E-21 Alarm buzzer does not sound or it keeps sounding
E-21 Alarm buzzer does not sound or it keeps sounding 1
Contents of
• Alarm buzzer does not sound or it keeps sounding.
trouble
• Disconnection or ground fault in alarm buzzer output circuit
Related • The output state (ON/OFF) from the alarm buzzer to the machine monitor can be checked with the
information monitoring function (Code: MONITOR PANEL 40952, D-OUT-0).
• If failure code is indicated, carry out troubleshooting for it first.

1
box FS1 (See cause 4.)
• Remove the buzzer then connect +24 V to L46 (male) (1) and
Defective alarm buzzer GND to L46 (male) (2).
2
(Internal defect) Alarm buzzer is
Alarm buzzer sounds
normal
Defective alarm
Alarm buzzer does not sound
buzzer
causes and Disconnection in wiring har- without turning starting switch ON.
standard value ness Wiring harness between fuse No. 5 of fuse Resis-
in normal state 3 Max. 1 z
(Disconnection or defective box FS1 – L46 (female) (1) tance
Max. 1 z
Ground fault in wiring harness Resis- Min.
4 box FS1 – L46 (female) (1), – circuit branch
(Contact with ground circuit) tance 1 Mz
end and ground
L24 (female) (14) and ground tance 1 Mz
• When above 1 – 4 are normal, failure on the machine monitor can
be suspected.
40-400 86 WA150-6
E-21 Alarm buzzer does not sound or it keeps sounding SEN05136-00
WA150-6 40-400 87
SEN05136-00 E-22 The KOMTRAX system does not work properly
E-22 The KOMTRAX system does not work properly 1
Trouble • The KOMTRAX system does not work properly.

• This contents applies only the "KOMTRAX (If equipped)" installation specification model.
Related • If the KOMTRAX system administrator asks you to check whether any defect occurs in the machine
information system, carry out the following troubleshooting.
• A defect in the KOMTRAX system, if any, does not appear especially as a defective phenomenon.

1 Defective power supply L80 Signal Voltage
Between (39), (40) – Constant power sup-
20 – 30 V
(37) and (38) ply
a Turn the starting switch ON, then start engine and carry out trou-
bleshooting.
LED (1) Normal state
LED-C1 ON
Defective starting switch a Prepare with starting switch OFF, then start engine and carry out
2 ACC signal and alternator R troubleshooting.
signal
L80 Signal Voltage
Between (36) and
Starting switch ACC 20 – 30 V
(37), (38)
Between (28) – (37),
Alternator R 20 – 30 V
(38)
a Turn the starting switch ON, then carry out troubleshooting.
During cranking: Blinking
LED-C3
Other than above: OFF
Possible
causes and Defective starting switch C a Prepare with starting switch OFF, then turn starting switch ON
3 and carry out troubleshooting.
standard value signal
in normal state L80 Signal Voltage
During cranking:
Between (27) and 20 – 30 V
Starting switch C
(37), (38) Other than above:
Max. 1 V
a Turn the starting switch ON, and carry out troubleshooting.
LED-C4 ON
Defective CAN connection
4
L80 (female) Signal Resistance
Between (7) and (8) CAN 40 – 80 z
5 Number of unsent mails LED (7) Normal state
7 segments 0–9
Defective GPS positioning Dot ON
6
status
One or more minute may be taken until GPS positioning is com-
pleted after the starting switch was turned ON even in an outdoor
service area.
40-400 88 WA150-6
E-22 The KOMTRAX system does not work properly SEN05136-00
LED display L80 connector
LED lamps for CPU

1. LED-C1 (State of R or ACC signal)
2. LED-C2 (Starting output state)
3. LED-C3 (State of C signal)
4. LED-C4 (CAN state)
7-segment and dot displays for CPU
7. 7 segments (Number of unsent mails)
8. Dot (GPS positioning state)
WA150-6 40-400 89
SEN05136-00

©2009 KOMATSU
All Rights Reserved
40-400 90
SEN05137-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
500 Troubleshooting of hydraulic and

mechanical system (H-mode)
Method of using troubleshooting chart............................................................................................................ 3
Failure code and cause table .......................................................................................................................... 6
H-1 The machine does not start...................................................................................................................... 8
H-2 The travel speed is slow........................................................................................................................... 9
H-3 The traction force is weak ...................................................................................................................... 10
H-4 Engine stalls when traveling or engine speed drops excessively............................................................11
H-5 Speed range is not shifted...................................................................................................................... 12
H-6 The steering wheel does not turn........................................................................................................... 13
H-7 The steering wheel is heavy................................................................................................................... 14
H-8 Steering wheel shakes or jerks .............................................................................................................. 15
H-9 Machine deviates naturally to one side when traveling.......................................................................... 15
H-10 The brake does not work or does not work well................................................................................... 16
H-11 The brake is not released or is dragged ............................................................................................... 17
H-12 The lift arm does not rise or lower ........................................................................................................ 18
H-13 The lift arm moves slowly or the lift arm rising force is insufficient....................................................... 19
H-14 When rising, the lift arm comes to move slowly at specific height ....................................................... 20
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises above the ground) .................... 20
H-16 Hydraulic drifts of the lift arm occur often ............................................................................................. 20
H-17 The lift arm wobbles during operation .................................................................................................. 20
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily .................. 21
H-19 The bucket does not tilt back ............................................................................................................... 22
WA150-6 40-500 1
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN05137-00
H-20 The bucket moves slowly or the tilting-back force is insufficient .......................................................... 23
H-21 The bucket comes to operate slowly in the midst of tilting-back .......................................................... 24
H-22 The bucket cylinder cannot hold down the bucket ............................................................................... 24
H-23 Hydraulic drifts of the bucket occur often ............................................................................................. 24
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”) ................. 24
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily ...................... 25
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy................................... 25
H-27 The ECSS does not operate and machine pitches and bounces......................................................... 26
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) ................ 27
40-500 2 WA150-6
Method of using troubleshooting chart SEN05137-00
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 2. Find the matching cause in the Cause column.
the condition of the machine before starting the In the same way as in Step 2), if a problem is
actual troubleshooting. found, the Q marks on the same line for the
troubleshooting item are the causes. (In Diag-
Example: Checks before starting troubleshoot- nosis item 2 in the same diagram below the
ing cause is (c) or (e).)
q Is oil level and type of oil in hydraulic tank cor- When there is one Q mark:
rect? Carry out troubleshooting for the other items
q Is there any oil leakage from steering valve or marked with Q in the same Cause column to
demand valve? check if the problem occurs, then make
q Is steering linkage adjusted properly? repairs.
When there are two Q marks:
Go to Step 3) to narrow down the cause.
WA150-6 40-500 3
SEN05137-00 Method of using troubleshooting chart
3. Operate the machine and carry out trouble- 6. Repeat the operation in Steps 3, 4, and 5 until
shooting of the items not checked in Step 1. the cause is narrowed down to 1 item (1 com-
Operate the machine in the same way as in mon item).
Step 1, and if any problem occurs, put a check a If cause items are 2 or more, continue until
against the item. (In Troubleshooting item 5 in number of items becomes minimum.
the diagram below, the problem was re-
enacted.) 7. Remedy
After narrowing down the common causes,
4. Find the matching cause in the Cause column. take the action given in the remedy line.
In the same way as in Step 2), if a problem is Marks and remedies in remedy line
found, the Q marks on the same line for the ×: Replace E: Repair A: Adjust C: Clean
troubleshooting item are the causes. (In Diag-
nosis item 5 in the diagram below the cause is
(b) or (e).)
5. Narrow down the causes.

Of the causes found in Step 2) and Step 4),
there are common items (Q marks on the line
for each Diagnosis item and in the same
Cause column as each other) that have
causes common with the problem items found
in the troubleshooting in Step 1) and Step 3).
a The items that are not common (items that
do not have Q marks in the same cause
common as each other) are probably not
the cause, so they can be eliminated. (The
causes for Diagnosis item 2 in the dia-
gram below are (c) or (e), and the causes
in Diagnosis item 5 are (b) or (e), so
Cause (e) is the common cause.)
40-500 4 WA150-6
Method of using troubleshooting chart SEN05137-00
WA150-6 40-500 5
SEN05137-00 Failure code and cause table
Failure code and cause table 1
Part causing problem HST pump HST HST

motor 2 motor 1
Pump body (Charge pump end)

Pump body (Piston pump end)
Angle stopper control solenoid

Mode selector solenoid valve
Angle stopper solenoid valve

High pressure cut-off valve
Directional solenoid valve

High pressure relief valve
Low pressure relief valve
Inching valve linkage

(Charge relief valve)
Inching valve
Motor body
Motor body
DA valve
Damper
(SOL a)
(SOL b)
valve
Failure Code
Does not travel forward or in reverse Q Q Q Q Q Q Q Q Q Q Q
Does not travel forward (reverse is normal) Q Q
The machine does not start at reverse (Forward is normal) Q Q
Speed is slow in both forward and reverse Q Q Q Q Q Q Q Q Q Q Q
HST related
The travel speed is slow at forward (Reverse is normal) Q Q

The travel speed is slow at reverse (Forward is normal) Q Q
The traction force is weak in both forward and reverse Q Q Q Q Q Q
The traction force is weak at forward (Reverse is normal) Q
The traction force is weak at reverse (Forward is normal) Q
Engine stalls when traveling or engine speed drops excessively Q Q Q
Speed range is not shifted Q Q
Brake Steering wheel
The steering wheel does not turn

The steering wheel is heavy
There is play in steering wheel or excessive shock
Machine deviates naturally to one side when traveling
The brake does not work or does not work well
The brake is not released or is dragged
The lift arm does not rise or lower Q Q
The lift arm moves slowly or the lift arm rising force is insufficient Q
When the lift arm is rising, the lift arm comes to move slowly at
specific height
The lift arm cylinder cannot be hold down the bucket
(The bucket rises above the ground)
Hydraulic drift of the lift arm occurs often
Work equipment system
The lift arm wobbles during operation

When the control lever is switched from “HOLD” to “RAISE”, the lift
arm falls temporarily
The bucket does not tilt back Q Q
The bucket moves slowly or the tilting-back force is insufficient Q
The bucket comes to operate slowly in the midst of tilting-back
The bucket cylinder cannot be hold down to bucket
Hydraulic drift of the bucket occurs often
The bucket wobbles during travel with load
(The work equipment valve is set to “HOLD”)
When the control lever is switched from “HOLD” to “TILT”, the bucket
falls temporarily
The control levers of the lift arm and bucket do not move smoothly
and heavy
(if equipped)
ECSS does not operate but pitches and bounces

ECSS
ECSS does not move at all
Fan revolution is abnormal (Fan sound/vibration is abnormally large

Hydraulic
or engine overheats)
fan
Fan always revolves in reverse
40-500 6 WA150-6
Clutch solenoid
Q
Q
Q
Q
Clutch
Q
Q
Q
Q
Transfer
Q
Q
WA150-6
Work equipment and steering pump
Q
Q
Q
Q
Q
Q
Q
Brake pump
Q
Orbit-roll
Q
Q
Q
Priority valve
Q
Q
Q
Q
Q
Q
Q
Relief valve
Q
Q
Failure code and cause table
Steering valve
Safety valve
Q
Steering cylinder
Q
Q
Q
Q
Tire inflation pressure
Q
Accumulator charge valve
Q
Brake valve
Q
Slack adjuster
Q
Q
Brake disc and plate
Q
Q
Axle
Brake piston
Q
Q
Wheel brake linkage
Q
Main relief valve
Q
Q
Q
Q
Q
Q
Lift arm spool
Q
Q
Q
Q
Q
Bucket spool
Q
Q
Q
Q
Q
Suction and safety valve
Q
Q
Q
Q
Q
control valve
Work equipment
Suction valve
Q
Lift arm cylinder
Q
Q
Q
Q
Q
Q
Bucket cylinder
Q
Q
Q
Q
Q
Lift arm PPC valve
Q
Q
Q
Q
Bucket PPC valve
Q
Q
Q
Q
Bypass valve
Q
ECSS solenoid valve
Q
Accumulator
Q
Q
Fan pump
Q
Fan motor
Q
Q
Charge valve
40-500
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
7
SEN05137-00
SEN05137-00 H-1 The machine does not start
H-1 The machine does not start 1
Ask the operator about the following: Cause
HST motor 2
HST motor 1
q Has the machine come not start suddenly?
HST pump
Damper
o Breakage of HST pump and motor related
Others
equipment
q Was there any problem of not traveling before?
o Internal wear of HST pump and motor related
a b c d e f g h i j k l m n o
equipment, defective seal
Low pressure relief valve (Charge relief valve)

Inspection before diagnosis
q Are the oil level in the hydraulic tank and the oil type
appropriate?
q Is inching valve linkage properly adjusted?

q Is the any external oil leak found around the hydraulic
piping, pump and motor?


Clutch solenoid
Inching valve
Motor body
Motor body
DA valve
Transfer
Damper
Clutch
E E E E E E E E E E E E E E E
Remedy
No. X X X X X X X X X X X X X X X
Diagnosis A
1 Does not travel forward or in reverse Q Q Q Q Q Q Q Q Q Q Q Q Q Q
2 Does not travel forward (reverse is normal) Q Q
3 Does not start at reverse (Forward is normal) Q Q
Does not travel forward or in reverse, motor makes sound of Q Q Q
4
rotation
40-500 8 WA150-6
H-2 The travel speed is slow SEN05137-00
H-2 The travel speed is slow 1

q Did the travel speed suddenly become HST pump HST motor 2
HST
Others
slower? motor 1
o Breakage of HST pump and motor a b c d e f g h i j k l m n o
related equipment
q Was there any problem of travel speed
Low pressure relief valve (Charge relief valve)

becoming slower before?
o Internal wear of HST pump and
Mode selector solenoid valve (SOL a)
Angle stopper solenoid valve (SOL b)

motor related equipment, defective
Angle stopper control solenoid valve

seal


q Are the oil level in the hydraulic tank and

the oil type appropriate?
q Is the inching valve linkage adjusting
Clutch solenoid
Inching valve
appropriate?
Motor body
Motor body
q Is the any external oil leak found around
DA valve
Clutch
the hydraulic piping, pump and motor?
E E E E E E E E E E E E E E E
Remedy X X X X X X X X X X X X X X X
No.
Diagnosis A
1 Travel speed is slow in both forward and reverse Q Q Q Q Q Q Q Q Q Q Q Q Q
The travel speed is slow at forward (Reverse is nor-
2 Q Q
mal)
The travel speed is slow at reverse (Forward is nor-
3 Q Q
mal)
Maximum travel speed in both forward and reverse Q
4
is approx. 5 km/h
Maximum travel speed in both forward and reverse Q
5
is approx. 23 km/h
Abnormal sound comes from motor in both forward
6 Q Q
and reverse when travel speed is 10 km/h or more
WA150-6 40-500 9
SEN05137-00 H-3 The traction force is weak
H-3 The traction force is weak 1
a When the travel speed is slow, carry out troubleshooting for Cause
H-2 first. HST HST HST
Others
pump motor 2 motor 1
a b c d e f g h i j
Inclination control solenoid valve


Clutch solenoid
Inching valve
Motor body
Motor body
Transfer
Clutch
E E E E E E E E E E
Remedy
No. X X X X X X X X X X
Diagnosis A
1 The traction force is weak in both forward and reverse Q Q Q Q Q Q Q Q Q
2 The traction force is weak at forward (Reverse is normal) Q
3 The traction force is weak at reverse (Forward is normal) Q
The traction force is weak in both forward and reverse, but maxi- Q Q Q
4
mum travel speed is reached the line.
40-500 10 WA150-6
H-4 Engine stalls when traveling or engine speed drops excessively SEN05137-00
H-4 Engine stalls when traveling or engine speed drops excessively 1

q Was there any problem before? HST HST
Others
o Dirt in HST pump, motor related equipment pump motor 2
a b c
Inclination stopper solenoid valve (SOL b)

q Is the any external oil leak found around the hydraulic piping, pump and
motor?

DA valve
E E E
Remedy
No. X X X
Diagnosis
1 Engine stalls when traveling or engine speed drops excessively Q Q Q

2 Machine moves when the directional lever is at F or R and engine is at Lo Q
WA150-6 40-500 11
SEN05137-00 H-5 Speed range is not shifted
H-5 Speed range is not shifted 1
a If the speed range switch and the monitor display do not match, check Cause
the electrical wiring. HST HST
a When the travel speed is slow, carry out troubleshooting for H-2 first. Others
motor 2 motor 1
a b c d
Inclination stopper solenoid valve (SOL b)
Clutch solenoid
Clutch
E E E E
Remedy
No. X X X X
Diagnosis
1 Speed range is not shifted Q Q Q Q
40-500 12 WA150-6
H-6 The steering wheel does not turn SEN05137-00
H-6 The steering wheel does not turn 1

q Did the problem suddenly start? Hydraulic
Others
o Breakage of steering related equipment pump
q Was there previously any symptom, such as heavy steering? a b c d
o Internal wear of steering related equipment, defective seal
Internal defective steering cylinder (Defective piston seal)

Defective hydraulic pump or PTO
Steering pump and switch pump
q Are the oil level in the hydraulic tank and the oil type appropriate?
q Has the lock bar been removed from frame?
Priority valve
Relief valve
Orbit-roll
Steering
Spool
Remedy E E
No. X X X X X
Diagnosis
1 Steering wheel does not turn in both directions (left and right) Q Q Q Q Q
2 In condition in Item 1, movement of work equipment is abnormal Q
3 In condition in Item 1, movement of work equipment is normal Q
4 Steering wheel turns only in one direction (left or right) Q Q
5 Steering wheel is heavy and does not turn Q Q Q Q
6 Oil pressure of steering circuit is low or there is no pressure Q
a There is a close connection between the steering circuit and work equipment circuit, so if any abnormal-
ity is felt in the steering, check the operation of the work equipment also.
a If the steering pump is abnormal (broken), check the priority valve at the same time.
WA150-6 40-500 13
SEN05137-00 H-7 The steering wheel is heavy
H-7 The steering wheel is heavy 1

q Did the problem suddenly start? Hydraulic
Valve Others
o Breakage of steering related equipment pump
q Was there previously any symptom, such as heavy steering? a b c d e f
o Internal wear of steering related equipment, defective
The steering pump is defective The hydraulic pump is defective

seal
Clogging of hydraulic oil return filter, defective bypass valve

Internal defective steering cylinder (Defective piston seal)
q Are the oil level in the hydraulic tank and the oil type appropri-
ate?
q Is there any abnormality in Orbit-roll, steering column linkage?
Priority valve
q Is the any external oil leak found around the hydraulic piping,
valve and cylinder?
q Is there any gouging of center hinge pin bearing and steering
cylinder pin, bushing?
q Is the tire inflation pressure correct?
Check for abnormalities
Orbit-roll internal defect

q Measure operating effort of steering wheel and time taken to
Clogging of oil cooler

turn steering, and check standard judgement value table to
see if there is any abnormality.
Relief valve
Spool
E E E E E E E
Remedy
No. X X X X X X X
Diagnosis A C C
1 Steering wheel is heavy when turned in both directions (left and right) Q Q Q Q Q
2 Steering wheel is heavy when turned in one direction (left and right) Q Q
Steering wheel is heavy particularly when engine is running at low Q Q Q Q
3
speed
4 Lift arm lifting speed is slow when engine is running at full speed Q Q
5 Steering wheel is heavy and there is jerking Q Q
6 Hydraulic oil overheats Q Q Q
7 Oil pressure of steering circuit is low or there is no pressure Q Q
8 Pressure rises in return piping of steering cylinder Q
40-500 14 WA150-6
H-8 Steering wheel shakes or jerks SEN05137-00
H-8 Steering wheel shakes or jerks 1
Checks before troubleshooting Cause

q Is the hydraulic oil level correct? Is the type of oil correct? Valves Cylinder
q Is there any play in the center hinge pin bearing or steering cylinder pin or a b
bushing?
Defect inside steering cylinder (inside surface of cylinder, piston seal, nut, bolt)
q Is there any variation in the tire inflation pressure?
q Is the steering wheel play correct?
Check for abnormalities

q Operate at a safe place and check how the steering wheel shakes and under
what conditions.
a In cases where the steering wheel is heavy but does not shake, go to “H-7 The
steering wheel is heavy”.
Defect inside Orbit-roll

E E
Remedy
No. X X
Diagnosis
1 Chassis shakes when traveling on rough road surface Q Q

2 Shakes when steering is suddenly turned during operation or travel Q Q
3 Chassis shakes when accelerating during travel operations Q Q
4 Chassis shakes when engine is started Q
5 Excessive shock when steering wheel is turned back
H-9 Machine deviates naturally to one side when traveling 1
Causes: Defective steering

q Defective operation of safety valve
q Oil leakage inside steering cylinder
q Variation in tire inflation pressure
WA150-6 40-500 15
SEN05137-00 H-10 The brake does not work or does not work well
H-10 The brake does not work or does not work well 1

q Has the brake come not to work suddenly? a b c d e f g h i j k
o Breakage of brake equipment
Defective seal of accumulator piston, insufficient gas pressure

q Has the brake come not to work gradually?
Metal contact due to complete wear of brake lining in axle

o Wear of lining and disc, defective seal
Defective operation of accumulator charge valve

q Is the oil level in the hydraulic tank appropriate?
q Is the play of brake pedal appropriate?
Wear or abnormality of brake lining in axle

Defective operation of brake piston in axle
q Oil leak from brake tube and connector, deformation of
tube.
q Tire air pressure and state of tire tread.
Defective brake pump (For charge)

Defective brake piston seal in axle
Check abnormality
Mixing of air in brake circuit

q Measure the braking force and check referring to the stan-
Defect inside brake valve

Defective slack adjuster
dard value table if the brake does not work practically.
Defective brake linkage

E E E E E E E
Remedy
No. X X X X X X X X X A
Diagnosis
1 When the brake pedal is stepped on, only a little resistance is felt Q Q Q Q Q
2 When the brake pedal is stepped on, a strong resistance is felt Q Q
When the brake works, an abnormal noise occurs from the axle Q Q
3
brake
When the four wheels are jacked up, the axle is placed on a table
4 and the brake is applied at the first forward speed, only a specific Q Q Q Q
wheel rotates
An airflow is observed in bleeding air from brake circuit, and the Q
5
brake returns to normal after the bleeding
6 Brake oil leaks abnormally from the axle during inspection Q
7 Much metal powders are mixed in the axle oil Q
The brake pedal leg-power and stroke are normal, but the brake Q Q Q Q Q Q Q Q Q
8
does not work well
9 The brake does not work often when the engine is stopped Q Q Q Q Q Q
10 The accumulator is not charged, and a buzzer sounds Q Q Q
11 The brake works after some time lag Q Q Q
40-500 16 WA150-6
H-11 The brake is not released or is dragged SEN05137-00
H-11 The brake is not released or is dragged 1

q Has the brake pedal returned completely? a b c d
q Is the parking brake released completely?
Wear or abnormality of brake lining in axle

Defective operation of brake piston in axle
Check abnormality
Defective brake piston seal in axle

q Abnormal heat of brake.
q Does the machine travel smoothly inertia on a level ground?
Defective slack adjuster

Remedy E E E E
No. X X X X
Diagnosis
1 The brake pedal is released, but the brake is still applied Q Q Q Q
When the brake pedal is released, oil is drained from the air bleeder, the circuit oil pressure Q Q
2
drops and the brake is released
When the four wheels are jacked up, the axle is placed on a table, the engine is stopped, the
3 Q Q Q
parking brake is released and the tires are rotated by hand but a specific tire hardly rotates
WA150-6 40-500 17
SEN05137-00 H-12 The lift arm does not rise or lower
H-12 The lift arm does not rise or lower 1

q Has the lift arm come not to work suddenly? Work
Tank to Priority HST PPC
o Seizure or breakage of each equipment Pump valve pump valve
equipment Cylinder
Did any abnormal noise occur at the time valve
(And where)? a b c d e f g h i
q Was there the phenomenon that the lift arm
Clogging of pump suction port or mixing of much air in oil

worked slowly?
o Wear of parts or deformation of spring
Defective work equipment and steering pump
Breakage inside valve body (Lift arm spool)

q Is the oil level in the hydraulic tank appropriate?
q Is the stroke of the lift arm control lever appro-
Defective operation of main relief valve
Damage of lift arm cylinder piston seal

priate?
Defective low-pressure relief valve

q Is the engine speed appropriate?
Defective HST charge pump
Defective operation of spool
Remedy C E E Defective operation of spool

E E E
No. E X X X X X X X X
Diagnosis
The bucket cannot operate and the lift arm cannot Q Q Q Q Q Q Q
1
rise
2 The bucket operates but the lift arm cannot rise Q Q
The lift arm can rise without load but cannot rise
3 Q Q Q
when loaded
4 The hydraulic pump causes an abnormal noise Q Q Q
5 Large hydraulic drift of lift arm cylinder Q Q
When the engine is at full throttle, the steering opera- Q Q
6
tion is heavy and slow
40-500 18 WA150-6
H-13 The lift arm moves slowly or the lift arm rising force is insufficient SEN05137-00
H-13 The lift arm moves slowly or the lift arm rising force is insufficient 1
Inspection before diagnosis Cause
q Is the stroke of the lift arm control lever appropri- Tank to Priority HST PPC Work equipment
Cylinder
ate? Pump valve pump valve valve
a b c d e f g h
Check of abnormality
Defective operation or improper adjustment of main relief valve

q Rising force and speed problem are closely
related, and this problem occurs as insufficient ris-

ing speed at first. Measure the lift arm rising speed
when the lift arm is loaded and make sure referring
Wear or breakage inside valve body (Lift arm spool)

Defective work equipment pump and steering pump
to the criterion table that the speed is abnormal.
Damage of lift arm cylinder piston seal

Defective low-pressure relief valve

Remedy C E E E E A E
No. E X X X X X X X
Diagnosis
The bucket tilting force and speed are abnormal, and Q Q Q Q Q
1
the lift arm rising speed is slow
The bucket tilting force and speed are normal, and the
2 Q Q Q
lift arm rising speed is slow
When the oil temperature rises in item 1, the lift arm Q Q
3
speed becomes very slow
4 The hydraulic pump causes an abnormal noise Q Q
5 Large hydraulic drift of lift arm cylinder Q Q
The relief oil pressure from the relief valve of the work Q
6
equipment valves is low
The relief oil pressure from the relief valve of the work
7 Q
equipment valves is too high
WA150-6 40-500 19
SEN05137-00 H-14 When rising, the lift arm comes to move slowly at specific height
H-14 When rising, the lift arm comes to move slowly at specific height 1

q Deformation of lift arm cylinder in appearance
Cause
q Expansion of lift arm cylinder tube or damage inside
a For other abnormal phenomena during lift arm rise, see “H-13. The lift arm moves slowly or the lift arm
rising force is insufficient.”
H-15 The lift arm cylinder cannot hold down the bucket (The bucket
rises above the ground) 1
See “H-13. The lift arm moves slowly or the lift arm rising force is insufficient.”

q Is the stroke of the lift arm control lever appropriate?
Cause
q Defective seat of suction valve on the lift arm cylinder rod side of work equipment valve
q Oil leak from lift arm cylinder piston seal
H-16 Hydraulic drifts of the lift arm occur often 1
Ask the operator about the following:

q Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to occur often gradually? o Wear of parts

q Is the lift arm spool at the neutral position? o The spool detent is defective
Diagnosis and Cause

q Does any leaking noise occur inside the lift arm cylinder when hydraulic drift is measured? o The cylin-
der packing is defective
H-17 The lift arm wobbles during operation 1
The bucket and the lift arm moves up and down as the topography goes in digging or leveling with the lift arm
control lever in the “HOLD” position.
Diagnosis and Cause

Check at first the hydraulic drift and if the lift arm cylinder can lift the machine
1. When the hydraulic drift is more than the standard value, see “H-16. Hydraulic drifts of the lift arm occur
often.”
2. When the lift arm cylinder cannot lift the machine, see “H-15. The lift arm cylinder cannot hold down the
bucket.”
3. When the lift arm cylinder comes to enable to lift the machine after the lift arm is operated several times
with the normal hydraulic drift and after the lift arm cylinder operates to full stroke o The cause is vac-
uum generated inside the cylinder
a Frequent hydraulic drifts o The suction valve on the lift arm cylinder rod side is defective
40-500 20 WA150-6
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily SEN05137-00
H-18 When the control lever is switched from “HOLD” to “RAISE,” the
lift arm falls temporarily 1
Check of Phenomenon
q When the control lever is switched from “HOLD” to “RAISE” gradually at low idle of the engine, the lift
arm falls temporarily due to its own weight. When the control lever is completely set to “RAISE,” the lift
arm returns to normal.
Cause
q Improper adhesion of lift arm spool check valve of the work equipment valve
WA150-6 40-500 21
SEN05137-00 H-19 The bucket does not tilt back
H-19 The bucket does not tilt back 1

q Has the bucket come not to work suddenly Tank to Priority HST PPC Work equip-
Cylinder
o Seizure or breakage of each equip- Pump valve pump valve ment valve
ment a b c d e f g h i
Did any abnormal noise occur at the
The HST charge pump (which is used as PPC pump, too) is defective
time (And where)?
q Was there the phenomenon that the bucket
worked slowly?
o Wear of parts or deformation of

spring

q Is the stroke of the bucket and lift arm con-
Defective work equipment and steering pump

trol levers appropriate?
Breakage inside valve body (Bucket spool)

The low-pressure relief valve is defective
Defective operation of main relief valve
Damage of bucket cylinder piston seal

The spool is defective
Remedy C E E E E A
Diagnosis
The lift arm cannot operate and the bucket can-
1 Q Q Q Q Q Q Q
not tilt back
The bucket can lift the machine but cannot tilt
2 back, or the lift arm operates but the bucket can- Q Q Q
not tilt back
The bucket can tilt back without load but cannot Q
3 Q Q
in digging or scooping up
4 The hydraulic pump causes an abnormal noise Q Q Q
5 Large hydraulic drift of bucket cylinder Q Q
When the engine is at full throttle, the steering
6 Q Q
operation is heavy and slow
40-500 22 WA150-6
H-20 The bucket moves slowly or the tilting-back force is insufficient SEN05137-00
H-20 The bucket moves slowly or the tilting-back force is insufficient 1
Inspection before diagnosis Cause

q Is the stroke of the bucket control lever Tank to Priority HST PPC
Work equipment valve Cylinder
appropriate? Pump valve pump valve
q Seizure of work equipment linkage a b c d e f g h i
bushing (Does any abnormal noise
Defective operation or improper adjustment of main relief valve

occur?)

The hydraulic pump and the steering pump are defective
Check of abnormality
Defective operation of safety valve (With suction valve)

q Make sure in an actual operation that
Wear or breakage inside valve body (Bucket spool)

the tilting-back force is insufficient.
Defective operation of low-pressure relief valve

q Measure the operating speed of the
bucket, and make sure referring to the
criterion value table that the speed is
Damage of bucket cylinder piston seal

abnormal
on bucket cylinder bottom side

Remedy C E E E E A E
Diagnosis
The lift arm rising force and speed are
1 abnormal, and the bucket tilting force and Q Q Q Q Q
speed are abnormal
The lift arm rising force and speed are nor-
2 mal, and the bucket tilting force and speed Q Q Q Q
are abnormal
When the oil temperature rises in item 1, the
3 Q Q
bucket speed becomes worse
The hydraulic pump is causing an abnormal Q Q
4
noise
5 Large hydraulic drift of bucket cylinder Q Q Q
The relief oil pressure from the relief valve of Q Q Q
6
the work equipment valves is low
The relief oil pressure from the relief valve of
7 Q
the work equipment valves is too high
WA150-6 40-500 23
SEN05137-00 H-21 The bucket comes to operate slowly in the midst of tilting-back
H-21 The bucket comes to operate slowly in the midst of tilting-back 1

q Deformation of bucket cylinder in appearance
Cause
q Expansion of bucket cylinder tube or damage inside
q For other abnormal phenomena during bucket operation, see “H-20. The bucket moves slowly or the tilt-
ing-back force is insufficient.”
H-22 The bucket cylinder cannot hold down the bucket 1
See “H-20. The bucket moves slowly or the tilting-back force is insufficient.”

q Is the stroke of the bucket control lever appropriate?
Cause
q Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
q Oil leak from bucket cylinder piston seal
H-23 Hydraulic drifts of the bucket occur often 1
Ask the operator about the following:

q Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to occur often gradually? o Wear of parts

q Is the bucket lever (PPC valve) at the neutral position? o Seizure of link bushing or the spool detent is
defective
Check of Abnormality
q Refer to the criterion value table and check if the hydraulic drift of the bucket occurs often practically
Cause
q Oil leak in bucket cylinder
q Improper adhesion of safety valve (With suction valve) on the bottom side
q Improper oil tight of bucket spool
H-24 The bucket wobbles during travel with load

(The work equipment valve is set to “HOLD”) 1

q Pin of work equipment linkage and “play of bushing” (Is any abnormal noise heard?)
Cause
q Defective seal of bucket cylinder piston
q Defective operation of safety valve (With suction valve) on bucket cylinder rod side. For other abnormal
phenomena, refer to diagnoses for relevant abnormal phenomena.
40-500 24 WA150-6
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily SEN05137-00
H-25 When the control lever is switched from “HOLD” to “TILT,” the
bucket falls temporarily 1
Check of Phenomenon
q When the control lever is switched from “HOLD” to “TILT” gradually at low idle of the engine, the bucket
falls temporarily due to its own weight. When the control lever is completely set to “TILT,” the bucket
returns to normal.
Cause
q Improper adhesion of bucket spool check valve of the work equipment valve
H-26 The control levers of the lift arm and bucket do not move smoothly
and heavy 1
Check of Abnormality Cause

q Refer to the criterion value table and check if the lever operating efforts are large practically. PPC
valve
a

Remedy C
No. E
Diagnosis
1 Becomes heavy in some places during operation regardless of oil pressure and oil temperature Q
2 Becomes heavy overall during operation regardless of oil pressure and oil temperature Q
WA150-6 40-500 25
SEN05137-00 H-27 The ECSS does not operate and machine pitches and bounces
H-27 The ECSS does not operate and machine pitches and bounces 1
Check the following points with the operator. Cause

q Did the machine starts pitching and bouncing sud- Solenoid Accumu- Control- Work equip-
Sensor
denly? valve lator ler ment valve
o Breakage of related device a b c d e
Did abnormal sound come out when the machine
Defective valve body inner side (ECSS damper spool part)

started pitching and bouncing? From what part did
the abnormal sound come out?
q Did the machine starts pitching and bouncing gradu-
Gas leakage from accumulator or defective seal

ally?
o Wear of related device or defective seal
Check before troubleshooting

q Check that the hydraulic tank is filled with oil of a
proper type up to a proper level.
Defective travel speed sensor

q Check that the ECSS switch is set properly.
Malfunction of solenoid valve
Remedy Malfunction of controller

No. X X X X X
Troubleshooting
Travel speed to start operation of ECSS (5 km/h) changes
1 Q Q
largely
2 ECSS does not work while machine is loaded Q Q Q
3 ECSS does not work while machine is empty Q Q Q
Lift arm lowers more than 30 cm at maximum when ECSS
4 Q Q
operated while machine is loaded
5 ECSS does not work at all Q Q Q Q Q
40-500 26 WA150-6
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) SEN05137-00
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally

large or engine overheats) 1
Check the following with the operator. Cause

q Did the fan start making the abnormal sound sud- Tank to Charge
Fan motor Others
denly? Pump valve
o Damage of the devices related to the fan and a b c d e f g h i j k
fan motor
q Did the engine overheat after the fan had started
making the abnormal sound?
o Internal wear of the devices related to the fan
pump and fan motor, lowering of sealing per-
Clogging or sucked air on pump suction side

formance or dirt
Check for abnormality
Seized forward-reverse selector valve

q Measure the fan speed to check for abnormality.
Malfunction of suction safety valve

Malfunction of EPC solenoid valve
Seized brake circuit selector spool
Lowering of engine performance

Seized ON/OFF solenoid valve
Check before troubleshooting
q Check the level and type of the oil in the hydraulic
Malfunction of relief valve
Malfunction of controller
tank.
q Check the hydraulic hoses, pump and motor for oil
Defective fan motor

Defective fan pump
leakage.
q Check the fan for damage.
(Note): If “Lowering of engine performance” is judged, go to the

troubleshooting for the engine system (S mode).
Remedy C Note
No. E E E E E E E
Troubleshooting X X X X X X X X X
1 Fan speed is low (in fan 100% mode) Q Q Q Q Q Q
2 Fan hunts Q Q Q Q Q
3 Fan does not revolve Q Q Q Q
4 Fan always revolves in reverse Q Q Q
5 Fan does not revolve in reverse Q Q Q
WA150-6 40-500 27
SEN05137-00

©2009 KOMATSU
All Rights Reserved
40-500 28
SEN05138-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
600 Troubleshooting of engine (S-mode)

Method of using troubleshooting charts .......................................................................................................... 2
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).................................................................................. 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 15
S-9 Oil becomes contaminated quickly ......................................................................................................... 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 20
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 21
S-15 Abnormal noise is made....................................................................................................................... 22
S-16 Vibration is excessive ........................................................................................................................... 23
WA150-6 40-600 1
SEN05138-00 Method of using troubleshooting charts
Method of using troubleshooting charts 1
The troubleshooting chart consists of the “ques-

tions”, “check items”, “causes”, and “troubleshoot-
ing” blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
[Check items]:
Items to be simply checked by the serviceman
to narrow down causes.
They correspond to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
40-600 2 WA150-6
Method of using troubleshooting charts SEN05138-00
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E : Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the “causes“, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
WA150-6 40-600 3
SEN05138-00 Method of using troubleshooting charts
<Example of troubleshooting> Exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. 3 symptoms have
causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
40-600 4 WA150-6
Method of using troubleshooting charts SEN05138-00
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
WA150-6 40-600 5
SEN05138-00 S-1 Starting performance is poor
S-1 Starting performance is poor 1
General causes why starting performance is poor Causes

Defective electrical system
Leaking or clogged fuel piping, entry of air

q
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)

q Insufficient intake of air
Stuck, seized supply pump plunger
Defective intake air heater system
Defective or deteriorated battery

q Improper selection of fuel
a The common rail fuel injection system (CRI) controls the
Clogged air cleaner element
Clogged fuel filter, element

Worn piston ring, cylinder
fuel injection timing electrically. Accordingly, even if the
starting operation is carried out, the engine may not start
until the crankshaft revolves 2 turns at maximum. This phe-
Defective injector
nomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of use of machine Operated for long period E E E
Became worse gradually Q w w Q
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q

Replacement of filters has not been carried out according to Operation and
Maintenance Manual w w Q Q
Oil must be added more frequently w

When engine is preheated or when temperature is low, preheating monitor does not
indicate normally w
During operation, charge level monitor indicates abnormal charge w w

Dust indicator is red w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q
Starting motor cranks engine slowly w
If air bleeding plug of fuel filter is removed, fuel does not
While engine is cranked flow out w
with starting motor,
Much fuel returns from the injector w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of

w
some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w 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, strainer directly q
Troubleshooting
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display
q
of code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not q
change
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? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
*1: Failure codes [CA559] and [CA2249] in the display of code
40-600 6 WA150-6
S-2 Engine does not start SEN05138-00
S-2 Engine does not start 1
a) Engine does not turn Causes
Defective connection of battery terminal
Defective starting motor (motor section)

General causes why engine does not turn
q Seized parts inside engine
o See “S-4 Engine stops during operations”
Defective or deteriorated battery
Defective steering circuit wiring

q Defective electrical system
q Problem in drive devices on applicable machine side
Broken flywheel ring gear
Defective starting switch

o Carry out troubleshooting for devices on applicable machine
Defective battery relay
Defective safety relay

Questions
Degree of use of machine Operated for long period E E
Condition of horn when Horn does not sound Q Q w

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 w
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 again w
Makes rattling noise and does not turn Q Q Q
Inspect flywheel ring gear directly q
Carry out troubleshooting in E-mode

There is not voltage (20 – 30 V) between battery relay terminal B and q
terminal E
Troubleshooting
When terminal B and terminal C of starting switch are connected, q

engine starts
Turn starting switch OFF, When terminal B and terminal C at safety relay outlet are connected,
connect cord, and carry out q
engine starts
troubleshooting at ON
Even if terminal B and terminal C at safety relay outlet are connected,
q
engine does not start
When terminal at safety switch and terminal B at starting motor are
q
connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
WA150-6 40-600 7
SEN05138-00 S-2 Engine does not start
b) Engine turns but no exhaust smoke comes out Causes
Defective operation of overflow valve (Does not close)

General causes why engine turns but no exhaust smoke comes
out
q Fuel is not being supplied
q Supply of fuel is extremely small

q Improper selection of fuel (particularly in winter)
Defective common rail pressure limiter

Seized, abnormally worn feed pump

Defective supply pump IMV (IMA)
Clogged fuel filter element
Broken supply pump shaft

Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Questions
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w E

Fuel other than specified one is used w
Replacement of filters has not been carried out according to Operation and w E Q
Maintenance 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 E E E
When fuel filter is removed, there is not fuel in it w w
w
Check items
Fuel is leaking from fuel piping

While engine is cranked with flow out Q Q w Q
starting motor,
If spill hose from injector is disconnected, little fuel spills Q w w w Q

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in
display of code q q
Carry out troubleshooting according to “Abnormality in supply pump IMV (IMA) (*2)” in
q
display of code
Inspect pressure relief valve directly q
Fuel flows out when pressure limiter return piping is disconnected q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Add
Remedy

40-600 8 WA150-6
S-2 Engine does not start SEN05138-00
c) Exhaust smoke comes out but engine does not start Causes
Worn dynamic valve system (Valve, rocker lever, etc.)

(fuel is being injected)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does
not start
Leaking or clogged fuel system, entry of air

q Lack of rotating force due to defective electrical system

Defective intake air heater system

Clogged injector, defective spray
Defective, deteriorated battery

Clogging of fuel filter

Use of improper fuel
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

w w
Maintenance Manual
When engine is preheated or when temperature is low, preheating monitor does not w
indicate normally
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
Fuel is leaking from fuel piping w
Starting motor cranks engine slowly w
w
Check items
When engine is cranked, abnormal sound is generated around cylinder head

While engine is cranked with flow out Q w
starting motor,
If spill hose from injector is disconnected, little fuel spills w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting

Inspect fuel filter directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display
q
of code
Coolant temperature gauge does not indicate normally 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
Replace
Correct
Clean
Clean
Remedy
*1: Failure code [CA559] and [CA2249] in the display of code
WA150-6 40-600 9
SEN05138-00 S-3 Engine does not pick up smoothly
S-3 Engine does not pick up smoothly 1
General causes why engine does not pick up smoothly Causes

Seized turbocharger, interference of turbocharger

q Defective condition of fuel injection

q Controller is controlling in derate mode

Clogged injector, defective spray
(limiting injection rate (output) because of an error in electrical system)

Improper valve clearance

Degree of use of machine Operated for long period E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w
Replacement of filters has not been carried out according to Operation and Maintenance w w
Manual
Rust and water are found when fuel tank is drained w
When exhaust manifold is touched immediately after starting engine, temperature of some Q w
cylinders is low
Blue under light load w
Color of exhaust gas is
w Q w w
Check items
Black
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q

q
Troubleshooting
Inspect valve clearance directly

When turbocharger is rotated by hand, it is found to be heavy q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of q
code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Remedy
40-600 10 WA150-6
S-4 Engine stops during operations SEN05138-00
S-4 Engine stops during operations 1
General causes why engine stops during operations Causes

Internal parts of engine seized
Broken dynamic valve system (valve, rocker arm, etc.)

q
Broken auxiliary equipment (pump, compressor, etc.)

q There is overheating
Defective engine controller power supply wiring

q Problem in hydraulic pump

Broken, seized piston, connecting rod

Broken, seized crankshaft bearing
Clogging feed pump gauze filter
Defective starting switch wiring

Clogging of fuel filter, strainer
Leaking, clogged fuel piping
Broken, seized feed pump

Broken supply pump shaft
Defective hydraulic pump

Broken, seized gear train
Abnormal noise was heard and engine
stopped suddenly w w w w Q w Q w w
w Q Q Q Q
Questions
Condition when engine Engine overheated and stopped

stopped
Engine stopped slowly w Q Q Q Q
There was hunting and engine stopped w Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation
and Maintenance Manual w w
Fuel level monitor indicates low level w

Rust and water are found when fuel tank is drained w 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 cranked by Turns in opposite direction w
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

Carry out troubleshooting in H-mode
Inspect piston, connecting rod directly q

Inspect crankshaft bearing directly q
Inspect gear train directly q
Troubleshooting

Inspect feed pump gauze filter directly q
Inspect feed pump directly q
Carry out troubleshooting according to “No-pressure feed by supply
q q
pump (*1)” in display of code
Engine rotates when pump auxiliary equipment (pump, compressor, etc.)
q
is removed
Check controller power supply wiring q
Check starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Add
Remedy
WA150-6 40-600 11
SEN05138-00 S-5 Engine does not rotate smoothly
S-5 Engine does not rotate smoothly 1
General causes why engine does not rotate smoothly Causes

q Air in fuel system
Clogged injector, defective spray (dirt in injector)

q Defective speed sensor (Error at degree that it is not indicated)
Defective Ne speed sensor, wiring harness

Defective G speed sensor, wiring harness


Degree of use of machine Operated for long period E
Q Q
Questions
Occurs at a certain speed range

Occurs at low idle Q Q Q Q Q
Hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Replacement of filters has not been carried out according to Operation and Maintenance Manual w
Check items
Rust and water are found when fuel tank is drained Q


Troubleshooting

Carry out troubleshooting according to “Abnormality in Ne speed sensor (*1)” in display of code q
Carry out troubleshooting according to “Abnormality in Bkup speed sensor (*2)” in display of code q
Replace
Replace
Replace
Replace
Replace
Clean
Add
Remedy
*1: Failure code [CA689] in the display of code

*2: Failure code [CA778] in the display of code
40-600 12 WA150-6
S-6 Engine lacks output (or lacks power) SEN05138-00
S-6 Engine lacks output (or lacks power) 1
General causes why engine lacks output Causes

Clogged injector, defective spray (dirt in injector)
Defective boost pressure sensor, wiring harness

Defective installation of boost pressure sensor
Defective drive of injector (signal, solenoid)



Air leakage from air intake piping

o See “S-14 Coolant temperature becomes too
Leaking, clogged fuel piping

high (Overheating)“

Clogged fuel spill piping


(limiting injection rate (output) because of an
error in electrical system)
(air leakage)
Suddenly Q w Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q
w w
Maintenance Manual
Oil must be added more frequently Q Q
Dust indicator is red w w
Air breather hole of fuel tank cap is clogged w w
Output becomes insufficient after short stop of operation w
Black w w
w w
some cylinders is low
w
Check items
When engine is cranked, interference sound is generated 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 Q w Q Q
Engine does not pick up smoothly and combustion is irregular w w Q Q w
There is hunting from engine (rotation is irregular) Q 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
Inspect valve clearance directly q
Troubleshooting
Inspect fuel piping q

Inspect spill port check valve directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in
q
display of code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to “Abnormality in boost pressure sensor (*2)”
q
in display of code
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy

WA150-6 40-600 13
SEN05138-00 S-7 Exhaust smoke is black (incomplete combustion)
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



o See “S-14 Coolant temperature becomes too high
(Overheating)“

Improper fuel injection pressure

(limiting injection rate (output) because of an error in

Crushed, clogged muffler
Abnormally worn injector

Improper injection timing
electrical system)
Clogged, seized injector

Suddenly became black w w Q Q Q
w Q Q
Questions
Color of exhaust gas is Gradually became black

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, 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 Q w
cylinders is low
Check items

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
Much fuel returns from the injector w

When turbocharger is rotated by hand, it is fount to be heavy q
Troubleshooting
Inspect valve clearance directly q

When muffler is removed, exhaust sound improves q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of
code q q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in
q
display of code
Confirm with monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy

40-600 14 WA150-6
S-8 Oil consumption is excessive (or exhaust smoke is blue) SEN05138-00
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1
General causes why oil consumption is excessive Causes

q Abnormal consumption of oil
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

Worn, damaged valve (stem, guide, seal)
q Long-time operation of engine at low idle or high idle
(Do not run engine at idle for more than 20 minutes
Dust sucked in from intake system

continuously)
Clogged breather, breather hose

q External leakage of oil
Oil leakage from oil drain plug

Worn, damaged rear oil seal
q Wear of parts in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at turbine end
Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

E E E E
Questions
Degree of use of machine Operated for long period

Oil consumption suddenly increased w Q
Oil must be added more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is high 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 to be dirty 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
WA150-6 40-600 15
SEN05138-00 S-9 Oil becomes contaminated quickly
S-9 Oil becomes contaminated quickly 1
General causes why oil becomes contaminated quickly 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
q Use of improper fuel
q Use of improper oil
Clogged breather, breather hose

q Operation under excessive load
Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions

Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

Troubleshooting
Check 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
40-600 16 WA150-6
S-10 Fuel consumption is excessive SEN05138-00
S-10 Fuel consumption is excessive 1
General causes why fuel consumption is excessive Causes

q Leakage of fuel

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.

Defective fuel supply pump oil seal
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective spray by injector
Improper injection timing

E E E
Questions

More than for other machines of same model Q Q Q Q
Condition of fuel Gradually increased Q Q
consumption
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
cylinders is low w
Check items
Low idle speed is high Q

HST stall speed is high Q
Black Q Q Q Q
White Q
Remove head cover and inspect directly q

Inspect fuel supply pump oil seal directly q
Troubleshooting
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of code q
Much fuel returns from the injector q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in display
of code q
Confirm with monitoring function q q

Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

WA150-6 40-600 17
SEN05138-00 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Causes
q Internal leakage in lubrication system
Broken cylinder head, head gasket

q Internal leakage in cooling system
Broken oil cooler core, O-ring

Cracks inside cylinder block
Broken hydraulic oil cooler

Holes caused by pitting
E E
Questions

Suddenly rose Q Q Q
Oil level
Gradually rose 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
Check items
Hydraulic oil or power train oil on applicable machine side is milky w

When hydraulic oil or power train oil is drained, water is found w
Pressure-tightness test of cylinder head shows there is leakage q

shooting
Trouble-
Inspect cylinder block directly q q Check directly

Pressure-tightness test of oil cooler shows there is leakage q
Replace
Replace
Replace
Replace
—
Remedy
40-600 18 WA150-6
S-12 Oil pressure drops SEN05138-00
S-12 Oil pressure drops 1
General causes why oil pressure drops Causes

q Leakage, clogging, wear of lubrication system
Leaking, crushed, clogged hydraulic piping

q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the Operation
and Maintenance Manual is not observed.
Clogged, broken pipe in oil pan

q Deterioration of oil due to overheating
Clogged strainer in oil pan
Defective regulator valve

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Questions
Oil pressure monitor indicates low oil pressure Q w

Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Maintenance
w
Manual
Indicates pressure drop at low idle w
Indicates pressure drop at low, high idle Q w w w Q
Oil pressure monitor
Indicates pressure drop on slopes w
Sometimes indicates pressure drop w
Oil level in oil pan is low w
External hydraulic piping is leaking, 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

Troubleshooting
q q
See S-13
Inspect oil pan strainer, pipe directly

Oil pump rotation is heavy, there is play in oil pump q
Valve and spring of regulator valve are fatigued, damaged q
Inspect oil filter directly q
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Add
—
Remedy
WA150-6 40-600 19
SEN05138-00 S-13 Oil level rises (Entry of coolant or fuel)
S-13 Oil level rises (Entry of coolant or fuel) 1
General causes why oil level rises Causes

q Coolant in oil (milky)
Defective seal of auxiliary equipment (pump, compressor)

q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Defects in supply pump

Broken injector, O-ring
Questions

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
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,
w Q
Check items
or coolant spurts back

Exhaust smoke is white Q
Oil level in damper chamber is low w
Oil level in hydraulic tank of machine is low w

Remove injector and inspect O-ring. q
Troubleshooting
Inspect cylinder block directly q q

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
40-600 20 WA150-6
S-14 Coolant temperature becomes too high (overheating) SEN05138-00
S-14 Coolant temperature becomes too high (overheating) 1
General causes why coolant temperature becomes too Causes

high
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

q Lack of cooling air (deformation, damage of fan)
Rise in power train oil temperature

Defective operation of thermostat
Slipping fan belt, worn fan pulley

q Drop in heat dissipation efficiency
Clogged, crushed radiator fins

q Problem in coolant circulation system
Clogged, broken oil cooler
Broken fan pulley bearing

q Rise in oil temperature in power train

o Carry out troubleshooting on applicable machine
Clogged radiator core

Lack of coolant
Questions
Sudden overheated Q w Q
Condition overheating
Always tends to overheat Q Q w w Q
Rises quickly Q Q w
Coolant temperature gauge
Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level Q w
Engine oil level has risen, oil is milky w w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
w
Check items
When light bulb is held behind radiator core, no light passes through
Radiator shroud, inside of underguard 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 enters red range faster than engine coolant w
temperature

Inspect cylinder block directly q q
Inspect oil cooler directly q
q
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large

Check directly
When operation of thermostat is carried out, it does not open at cracking

q
temperature
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy
WA150-6 40-600 21
SEN05138-00 S-15 Abnormal noise is made
S-15 Abnormal noise is made 1
General causes why abnormal noise is made Causes

q Abnormality due to defective parts
Deformed cooling fan, loose fan belt, interference of fan belt

Defective inside of muffler (dividing board out of position)
q Abnormal combustion
Leakage of air between turbocharger and cylinder head

q Air sucked in from intake system
Improper fuel injection timing (abnormality in coolant

a Judge if the noise is an internal noise or an external
Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger
temperature sensor, boost temperature sensor)

noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently. Accordingly, the
Excessive wear of piston ring, cylinder

engine sound becomes a little larger. This does not indi-
cate abnormality, however.
a When the engine is accelerated, it is operated in the
Improper gear train backlash

acceleration mode and its sound becomes a little larger
Removed, seized bushing

Clogged, seized injector

for up to about 3 seconds. This does not indicate abnor-
Dirt caught in injector

mality, however.

Degree of use of machine Operated for long period E
Questions
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Non-specified fuel is being used Q
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 generated around muffler w
Check items

some cylinders is low w Q

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 found to be heavy q

When muffler is removed, abnormal noise disappears q
q
Troubleshooting
Inspect valve clearance directly

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Abnormal noise is heard only when engine is started q
Confirm with monitoring function q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
40-600 22 WA150-6
S-16 Vibration is excessive SEN05138-00
S-16 Vibration is excessive 1
General causes why vibration is excessive Causes

q Defective parts (abnormal wear, breakage)
Misalignment between engine and devices on applicable machine side

q Misalignment between engine and chassis
Improper fuel injection timing (abnormality in coolant temperature
Broken output shaft, parts in damper on applicable machine side

q Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out trou-
bleshooting for “S-15 Abnormal noise is made“, too.
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

Worn main bearing, connecting rod bearing
sensor, boost temperature sensor)

Improper gear train backlash
Worn camshaft bushing
E E E
Questions

Suddenly increased Q Q
Condition of vibration
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
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Confirm with monitoring function q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
WA150-6 40-600 23
SEN05138-00

©2009 KOMATSU
All Rights Reserved
40-600 24
SEN05185-01
WHEEL LOADER
WA150-6

WA150-6 80001 and up
50 Disassembly and assembly 50
100 General information on disassembly

and assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tools list .............................................................................................................................................. 7
Sketches of special tools .............................................................................................................................. 10
WA150-6 50-100 1
100 General information on disassembly and assembly
SEN05185-01 How to read this manual
How to read this manual (Rev. 2009.1)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.
50-100 2 WA150-6
How to read this manual SEN05185-01
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.
WA150-6 50-100 3
SEN05185-01 Coating materials list
Coating materials list (Rev. 2009.02)1

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, poly-
propylene, tetrafluoroethylene and vinyl chlo-
20 g Polyethylene
LT-1B 790-129-9050 ride), 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.
50-100 4 WA150-6
Coating materials list SEN05185-01
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-
prevention
compound
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 (*)
WA150-6 50-100 5
SEN05185-01 Coating materials list
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)
50-100 6 WA150-6
Special tools list SEN05185-01
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/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
790-101-5201 Push tool (kit) t

790-101-5311 • Plate
1 790-101-5221 • Grip Installation of engine front oil seal
01010-51225 • Bolt
Removal and instal- 795T-221-1010 Plate t Q
lation of fuel supply A 2 795-931-1100 Seal puller q 1 Removal of engine rear oil seal
pump assembly 790-101-5401 Push tool (kit) t 1
790-101-5421 • Grip 1
3 Installation of engine rear oil seal
01010-51240 • Bolt 1
795T-221-1020 Plate t 1 Q
8 791-415-2002 Remover t 1 Removed of cooling fan
1 793T-217-1110 Push tool t 1 N Q Press fitting of output shaft bear-
2 793T-217-1120 Push tool t 1 N Q ing
790-101-5201 Push tool kit t 1
• 790-101-5331 • Plate 1 Press fitting of oil seal of parking
3 brake case
Disassembly and • 790-101-5221 • Grip 1
assembly of • 01010-51225 • Bolt 1
transfer assembly, D 793T-417-1120 Push tool t 1 Q
Press fitting of dust seal of parking
parking brake 4 790-101-5221 Grip t 1 brake case
assembly 01010-81225 Bolt t 1
5 790-190-1600 Pump assembly q 1
6 799-401-3100 Adapter q 1
Operation check of clutch
7 07376-70210 Plug q 1
8 596-35-11140 Nipple q 1
793T-222-1210 Push tool t 1 N Q
Press fitting of inner race of axle
1 793T-422-1440 Push tool q Q
shaft bearing
793T-623-1170 Push tool q Q
Disassembly and
assembly of axle H
2 793-520-2600 Seal support t 1 Supporting of axle shaft oil seal
housing assembly Press fitting of inner race of axle
3 792T-413-1120 Push tool t 1 Q
shaft bearing
Adjustment of shim of axle shaft
4 793-510-1500 Holder t 1
bearing
WA150-6 50-100 7
SEN05185-01 Special tools list
New/Remodel
Necessity
Symbol
Sketch
Q'ty
5 799-301-1500 Oil leak tester t 1 Operation check of clutch piston

Removal, installation of pinion
6 797-101-1211 Wrench t 1
shaft nut
No-load operating torque of lim-
7 796-730-2140 Wrench t 1
ited-slip differential
8 790-201-2830 Push tool t 1 Press fitting of pinion shaft bear-
9 790-201-2730 Spacer t ing
Disassembly and 793T-222-1220 Push tool t 1 N Q
Press fitting of oil seal of pinion
assembly of differ- H 10 790-101-5221 • Grip t 1
ential assembly shaft cage
01010-81225 • Bolt t 1
Installation of brake piston
11 793-520-2202 Installer q 3
Check for brake oil leakage
Press fitting of dust seal of pinion
12 790-201-2750 Spacer t 1
shaft cage
13 790-190-1500 Pump assembly t 1 Check for brake oil leakage
14 799-101-5210 Nipple t 1 Check for brake oil leakage
15 793T-422-1611 Plate t 1 N Q Check for brake oil leakage
Disassembly and Press fitting of bearing of upper
assembly of center K 1 790-201-2750 Push tool t 1
hinge pin hinge pin
790-502-1003 Repair stand t 1 Disassembly, assembly of hydrau-
1
790-101-1102 Hydraulic pump t 1 lic cylinder
Removal, installation of cylinder
2 790-102-3802 Wrench assembly t
head
Socket
3 790-302-1290 t 1 Removal, installation of piston nut
(Bucket and lift arm)
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Push tool
790-201-1781 1 Press fitting of cylinder head
4 (Lift arm) bushing
Push tool
790-201-1771 1
Disassembly and (Bucket)
assembly of Push tool
U 790-201-1721 1
hydraulic cylinder (Steering)
assembly 790-201-1500 Push tool kit t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
5 Installation of dust seal
790-201-1590 Plate (Lift arm) 1
790-201-1580 Plate (Bucket) 1
790-201-1530 Plate (Steering) 1
6 790-720-1000 Expander q 1
Ring
796-720-1660 q 1
(Lift arm and bucket)
Clamp Installation of piston ring
7 07281-01159 q 1
(Lift arm and bucket)
796-720-1630 Ring (Steering) q 1
07281-00709 Clamp (Steering) q 1
50-100 8 WA150-6
Special tools list SEN05185-01
New/Remodel
Necessity
Symbol
Sketch
Q'ty
1-1 793-498-1120 Clear plate t 2

Adjustment of clearance of win-
1-2 793-498-1130 Plate t 2
Adhesion of opera- dow glass
X 1-3 793-498-1110 Magnet t 2
tor's cab glass
Removal, installation of window
2 793-498-1210 Lifter (Suction cups) t 2 glass
WA150-6 50-100 9
SEN05185-01 Sketches of special tools
Sketches of special tools 1
Note: Komatsu will not be held responsible for special tools manufactured according to these sketches.
A1 Plate
A3 Plate
50-100 10 WA150-6
Sketches of special tools SEN05185-01
D1 Push tool
D2 Push tool
WA150-6 50-100 11
D4 Push tool
H1-1 Push tool (aH1-1, 2, and 3 are extended at use.)
50-100 12 WA150-6
WA150-6 50-100 13
H3 Push tool
H10 Push tool
50-100 14 WA150-6
H15 Plate
WA150-6 50-100 15
SEN05185-01

©2010 KOMATSU
All Rights Reserved
50-100 16
SEN05186-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 6
Removal and installation of engine hood assembly ...................................................................................... 10
Removal and installation of cylinder head assembly .................................................................................... 12
Removal and installation of radiator.............................................................................................................. 22
Removal and installation of air aftercooler .................................................................................................... 25
Removal and installation of hydraulic oil cooler assembly ............................................................................ 27
Removal and installation of engine and HST pump and 3-gear pump assembly ......................................... 29
Removal and installation of engine front oil seal........................................................................................... 34
Removal and installation of engine rear oil seal ........................................................................................... 37
Removal and installation of cooling fan and fan motor assembly ................................................................. 40
Removal and installation of fuel tank assembly ............................................................................................ 43
WA150-6 50-200 1
SEN05186-00 Removal and installation of fuel supply pump assembly
Removal and installation of fuel 3. Disconnect air conditioner hose clamp (3).
supply pump assembly 1
4. Disconnect radiator hose clamp (4), and dis-
Removal connect radiator hose (5) from water pump.
k Stop the machine on a level ground and set [*1]
the lock bar to the frame to fix the front and a Mark the hose edge and tube to show the
rear frames. original hose installation position.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake 5. Disconnect radiator hose clamp (6), and move
and put chocks under the tires. radiator hose to the outside.
k Disconnect the cable from the negative (–)
terminal of the battery. 6. Disconnect fuel tube (7) and fuel hose (8) from
k If the radiator coolant temperature is high, fuel filter (9). [*2]
you may scald yourself with the hot cool-
ant. Wait until the coolant is cooled, and
disconnect radiator hose.
1. Open and fix right engine side covers (1).

a Check that the covers are locked securely.
7. Disconnect wiring harness connector PREG

(10).
8. Disconnect wiring harness clamp (11).
9. Disconnect hydraulic sensor wiring harness

2. Loosen radiator drain valve (2) and drain cool- connector (13).
ant.
6 Radiator: Coolant (14.6 l) 10. Disconnect speed sensor wiring harness con-
nector (12).
12. Remove bolts (15) to remove bracket (16).
50-200 2 WA150-6
Removal and installation of fuel supply pump assembly SEN05186-00
13. Remove bracket (17). 16. Loosen sleeve nuts (27) and (28) and remove
1) Disconnect clamp (18) of fuel hose (8). high-pressure pipe (29). [*4]
2) Disconnect clamp (20) of fuel level gauge
(19). 17. Remove the pin (30) and disconnect spill hose
3) Disconnect clamp (22) of engine oil filler (31).
tube (21).
4) Remove 2 bracket mounting bolts (23). 18. Remove joint bolts (32), (33) and (34) and
a Wiring harness clamp is tightened remove fuel tubes (35) and (36). [*5]
together with the front side bolt (23).
5) Remove bracket (17).
19. Removal of supply pump and pump holder

assembly
14. Disconnect clamp (24) of fuel tube (7) from 1) Remove 4 mounting bolts (37) from the
bracket (25). gear case side.
2) Fully loosen mounting bolts (38) on the
15. Remove boots (26) of high-pressure pipe from pump holder side. [*6]
common rail and fuel supply pump. [*3] a Mounting bolts (38) cannot be
removed from between the supply
pump and pump holder at this time.
3) Remove supply pump and pump holder
assembly (39).
WA150-6 50-200 3
SEN05186-00 Removal and installation of fuel supply pump assembly
a a: Location of mounting bolts (37) a The following figure shows locations

b: Location of mounting bolt (38) (c) of mounting bolts (42).
20. Remove the supply pump assembly from the

pump holder according to the following proce-
dure.
1) Loosen nut (40) and pull out supply pump
gear (41) with gear puller [1]. [*7]
a Fully loosen the nut and keep it
installed to the shaft until the supply
pump gear is pulled out.
2) Remove 3 nuts (42) and remove supply

pump (43) from pump holder (44).
50-200 4 WA150-6
Removal and installation of fuel supply pump assembly SEN05186-00
Installation 3 Sleeve nut (10) on the common rail side:

q Carry out the installation in the reverse order of 25.5 – 29.4 Nm {2.6 – 3.0 kgm}
removal. 3 Sleeve nut (11) on the supply pump side:
18 – 23 Nm {1.9 – 2.3 kgm}
[*1]
a Align the radiator hose to the original portion of [*5]
3
the water pump side. Joint bolts (32) and (33):
24.5 – 34.3 Nm {2.5 – 3.51 kgm}
3
(Reference)
Joint bolts (34):
a Inserted hose length: 45 mm
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
a Clamp mounting portion from hose edge: 10 mm
2 Hose mounting clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} [*6]
a For mounting bolt (38), install M6 bolt with LT-2A.
[*2]
2
[*7]
3
Fuel tube and hose joint bolt:
Pump gear mount nut (40):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
65 – 75 Nm {6.6 – 7.6 kgm}
[*3]
a Set the boot slit facing outward and downward.
a The boot is designed with fire safety to prevent
fuel from splashing onto the hot engine if fuel
leaks.
[*4]
k Never bend a high-pressure pipe for the
convenience sake.
k The clamp used for fixing a high-pressure
pipe must be a genuine Komatsu part and it
must be tightened to the specified torque.
k Be sure to install the boot to the sleeve nut
after installing the high-pressure pipe.
a Before installing a high-pressure pipe, confirm
the following points. If any abnormality was
found, replace it with new one. Otherwise,
leakage of fuel can result.
q No visible striations (b) or patchy dents (c)
in the taper seal portion of the connection
((a) portion: area 2 mm inside the tip).
q No deformation in portion (d) (at the end of
the taper seal portion: 2 mm inside the
tip).
WA150-6 50-200 5
SEN05186-00 Removal and installation of fuel injector assembly
Removal and installation of fuel

injector assembly 1
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
stop the engine, apply the parking brake
and put chocks under the tires.
terminal of the battery.
k If the radiator coolant temperature is high,
ant. Wait until the coolant is cooled, and 8. Remove muffler assembly according to the fol-
disconnect radiator hose. lowing procedure.
1) Disconnect plates (8) and (9) from buffer
1. Remove the engine hood assembly. For plate assembly (10).
details, see "Removal and installation of
engine hood assembly".
(Removal No.2, No.3 and No.4 fuel injector assembly)

2. Disconnect 2 air conditioner hose clamp (1).
3. Disconnect air conditioner hose clamp (2).
4. Remove air tube and hose assembly (3)

according to the following procedure.
1) Loosen hose clamps (4).
2) Loosen tube clamps (5).
3) Remove 2 bracket mounting bolts (6) for
air tube.
4) Remove air tube and hose assembly (3).
2) Disconnect hydraulic cooler hose clamps
5. Disconnect blow-by hose (7). (11).
]
(Removal No.1 fuel injector assembly)


3) Remove 2 bracket mounting bolts (6) for
air tube.
50-200 6 WA150-6
Removal and installation of fuel injector assembly SEN05186-00
3) Remove left and right buffer plate mount- 9. Remove mounting bolt (16a) to disconnect fuel
ing bolts (12). tube (16) from fuel filter assembly (18). [*1]
a Move buffer plate assembly to the
back side. 10. Remove mounting bolt (17a) to disconnect fuel
a Take care not to damage fin of air hose (17) from fuel filter assembly (18). [*2]
conditioner condenser.
]
11. Disconnect clamp (19) of fuel tube (16).
12. Remove 2 mounting bolts (20), and remove

fuel filter assembly together with bracket (18a).
4) Remove 2 muffler mounting bolts (13) and

4 mounting bolts (14).
]
5) Lift off muffler assembly (15) together with

bracket (15a).
4 Muffler assembly: 20 kg
WA150-6 50-200 7
SEN05186-00 Removal and installation of fuel injector assembly
13. (No. 1 – No. 4 fuel injector common) 14. Removal of injector assembly
Removal of the high-pressure pipe 1) Remove holder mounting bolt (28) and
a The following indicates the removal of injec- remove holder (29). [*5]
tor assembly of cylinder No. 1 for example. 2) Remove injector assembly (30). [*6]
1) Remove clamp (21) from the high-pres-
sure pipe.
2) Remove boot (22) from the injector and
common rail sides. [*3]
3) Remove injector wiring connector (23).

Connector No.
Cylinder No. 1: CN1
Cylinder No. 2: CN2
Cylinder No. 3: CN3
Cylinder No. 4: CN4
4) Remove pin (24) and disconnect spill hose
(25).
5) Loosen sleeve nut (26) both on the injec-
tor side and common rail side and remove
high-pressure pipe (27). [*4]
50-200 8 WA150-6
Removal and installation of fuel injector assembly SEN05186-00
Installation [*6]
q Carry out the installation in the reverse order of When reusing injector, always replace O-ring (31)
removal. and gasket (32) with new ones.
[*1] [*2]
3 Fuel tube and hose mounting joint bolts:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*3]
a Set the boot slit facing outward and downward.
a The boot is designed with fire safety to prevent
fuel from splashing onto the hot engine if fuel
leaks.
[*4]
k Never bend a high-pressure pipe for the
convenience sake.
k The clamp used for fixing a high-pressure
pipe must be a genuine Komatsu part and it
must be tightened to the specified torque.
k Be sure to install the boot to the sleeve nut
after installing the high-pressure hose.
a Before installing a high-pressure pipe, confirm
the following points. If any abnormality was
found, replace it with new one. Otherwise,
leakage of fuel can result.
q No visible striations (b) or patchy dents (c)
in the taper seal portion of the connection
((a) portion: area 2 mm inside the tip).
q No deformation in portion (d) (at the end of
the taper seal portion: 2 mm inside the
tip).
3 Sleeve nut (26):

25.5 – 29.4 Nm {2.6 – 3.0 kgm}
[*5]
3 Holder mounting bolt (28):
27 – 30 Nm {2.8 – 3.1 kgm}
WA150-6 50-200 9
SEN05186-00 Removal and installation of engine hood assembly
Removal and installation of 6. Remove mounting bolts (12a) (2 left side and 1
engine hood assembly 1
right side).
Removal
rear frames.
1. Loosen clamp (1).
2. Remove 4 bolts (2) to remove cap and bracket

assembly (3).
7. Disconnect wiring harness connector BR1 (8).

3. Open and fix left and right engine side covers
(4). 8. Disconnect wiring harness clamp (9).
a Check that the covers are locked securely.
9. Remove left and right covers (10).
10. Sling engine hood assembly (11) temporarily.
4. 4. Disconnect dust indicator hose (5) from air

cleaner (6).
5. Disconnect air hose (7) from air cleaner (6).

[*1]
a Mark the hose edge and tube to show the
original hose installation position (M).
50-200 10 WA150-6
Removal and installation of engine hood assembly SEN05186-00
11. Remove each 2 left and right mounting bolts Installation

(12). q Carry out installation in the reverse order to
removal.
[*1]
a Align the hose to the original position (marking
position).
(Reference)
q Hydraulic pump side
a Inserted hose length (L1): 732 mm
a Clamp mounting portion (L2): 5 mm
3 Air hose clamp:

10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
12. Lift off engine hood assembly (11).

4 Engine hood assembly: 82 kg
WA150-6 50-200 11
SEN05186-00 Removal and installation of cylinder head assembly
Removal and installation of 6. Remove muffler assembly according to the fol-

cylinder head assembly 1
lowing procedure.
1) Disconnect plates (8) and (9) from buffer
Removal plate (10).
k Stop the machine on a level ground and set 2) Remove air aftercooler hose (3a). [*1]
the lock bar to the frame to fix the front and 3) Disconnect radiator hose (3b) from radia-
rear frames. tor. [*2]
drain the coolant.
1. Remove the engine hood assembly. For

2. Disconnect 2 air conditioner hose clamps (1). 4) Disconnect hydraulic oil cooler hose
clamps (11).

3) Remove bracket mounting bolts (6).
5. Disconnect blow-by hose (7).
5) Remove each 2 left and right buffer plate

mounting bolts (12).
a Move buffer plate to back side.
a When moving buffer plate, take care
not to damage fin portion of air condi-
tioner condenser.
50-200 12 WA150-6
Removal and installation of cylinder head assembly SEN05186-00
6) Remove 2 muffler mounting bolts (13) and

4 bolts (14).
a Confirm the length of each bolts.
(13): (length) 20 mm
(14): (length) 25 mm
8. Disconnect fuel filter assembly (22) according

to the following procedure.
1) Remove mounting bolts (23) to disconnect
fuel tube (24) from fuel filter assembly
(22). [*4]
7) Lift off muffler assembly (15) together with 2) Remove mounting bolts (25) to disconnect
bracket (16). fuel hose (26) from fuel filter assembly
4
(22). [*5]
Muffler and bracket assembly: 20 kg
3) Disconnect fuel tube clamp (27).
4) Remove 2 mounting bolts (28), then remove
fuel filter assembly (22) together with bracket
(29).
7. Disconnect air conditioner compressor assem-

bly (17) according to the following procedure.
[*3]
1) Disconnect wiring harness connector (18).
2) Loosen 2 air conditioner compressor
3) Loosen air compressor drive belt tension
adjusting bolt (20).
4) Remove air compressor drive belt (21).
5) Remove 2 air conditioner compressor
mounting bolts (19), and disconnect air
conditioner compressor assembly (17).
WA150-6 50-200 13
9. Remove air intake manifold assembly (30)

1) Disconnect 4 fuel injector harness con-
nectors (31).
2) Disconnect boost pressure and tempera-
ture sensor connector PTIM (32).
3) Disconnect intake air heater wiring termi-
nal E08 (33) from electrical intake air
heater assembly. [*6]
a Do not disconnect ground cable (34).
4) Disconnect 5 clamps (35), and move the
wiring harness to the frame side.
8) Sling air intake manifold assembly (30)

temporarily, and remove mounting bolts
(41),(42) and (43). [*10]
a Check the stem length of each bolts.
(41): (stem length) 105 mm, 1 piece
(42): (stem length) 65 mm, 2 pieces
(43): (stem length) 75 mm, 5 pieces
a Bracket (44) is mounted together with
the manifold at bolt (41) portion.
a Spacer (44a) is installed between
bracket (44) and manifold, so take
care not to fall down when removing
5) Remove 2 high-pressure tube clamps the bolt (41).
(37). [*7] 9) Lift off air intake manifold assembly (30).
6) Remove each 4 boots (38) from high-pres-
sure tubes of fuel injector side and com-
mon rail side. [*8]
7) Loosen high-pressure tube sleeve nut
(39), and remove 4 high-pressure tubes
(40) from fuel injector side and common
rail side. [*9]
50-200 14 WA150-6
10. Remove water pump assembly according to 3] Loosen alternator mounting bolt (54).
the following procedure. 4] Loosen adjustment bolt (55), then
1) Remove radiator upper hose (46). [*11] remove alternator drive belt (50).
2) Remove radiator lower hose (47) from
water pump. [*12]
3) Disconnect heater hoses (48) and (49).
[*13]
a Check the hoses for intake side and
outlet side.
5] Remove water pump mounting bolts

(56), and remove water pump assem-
bly (45). [*15]
4) Remove alternator drive belt (50) accord-

ing to the following procedure. [*14]
1] Remove mounting bolt (52) from
cover (51).
2] Loosen alternator mounting bolt (53)
and tilt the cover (51) outside.
a Bolt (53) mounts alternator and cover
together.
11. Remove turbocharger and exhaust manifold

assembly (57) according to the following pro-
cedure.
1) Remove air hose (58). [*16]
WA150-6 50-200 15
2) Remove covers (59) – (61). 5) Lift off the turbocharger and exhaust man-
ifold assembly (57).
3) Disconnect turbocharger lubricating oil

inlet tube (62) and outlet tube (63). [*17] 12. Loosen 3 mounting nuts (65a), and remove
cylinder head cover (65). [*19]
13. Remove fuel injector assembly according to

the following procedure. [*20]
1) Remove clip (67) and spill hose (68) from
each fuel injectors.
2) Remove holder mounting bolt (69) and
holder (70).
3) Remove fuel injector assembly (66).
4) Sling the turbocharger and exhaust mani-

fold assembly (57), and remove 2 bolts
(64a) and 8 mounting bolts (64). [*18]
50-200 16 WA150-6
14. Remove rocker arm assembly and push rod Installation

according to the following procedure. [*21] q Carry out installation in the reverse order to
1) Loosen locknut (74) and loosen adjust- removal.
ment screw (73) sufficiently.
2) Remove 5 locker arm mounting bolts (75) [*1] [*16]
and 3 mounting bolts (75a), and remove q Install the air aftercooler lower hose and it's
rocker arm assembly (71). clamp as follows.
3) Remove 8 push rods (72). a When installing air tube and hose assembly,
turn the white mark on the tube (3b) and hose
15. Remove 8 cylinder head mounting bolts (76). (3c) upward.
[*22] a Align the white marked portions of tube and
hose, and install the hose.
16. Lift off cylinder head assembly (77). [*23] a Inner and outer clamps must be set up in a
position where the threads are shifted 180°.
a Mounting portion of hose and clamp

(Unit: mm)
(L1) (L2) (L3)
Hose Mounting portion
(L4) (L5) (L6)
Air aftercooler side 70 10 21
Hose (3a)
Tube side 66 10 21
Air intake manifold side 50 5 18
Hose (3c)
Tube side 65 10 21
Air aftercooler side 63.5 10 21
Hose (58)
Turbocharger side 65.6 10 21
(* Refer to hose (3c) when disconnecting hose (3c)

from tube side.)
3 Air aftercooler lower hose clamp:

10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
WA150-6 50-200 17
[*6]
q When installing air intake connector (33a) and
electrical intake air heater assembly (33b),
observe the following precautions.
a When installing air intake connector (33a)
and electrical intake air heater (33b),
replace the 2 gaskets (upper and lower)
with new one.
a When installing air intake connector
mounting bolt (33c), tighten ground cable
(34), too.
a If ground cable (34) was removed from
electrical intake air heater (33b), install it
to electrical intake air heater (33b) by
[*2] [*11] [*12] tightening ground cable mounting bolt
q Install the radiator hose and it's clamp as fol- (34a) to the following torque.
lows. 3 Ground cable mounting bolt (34a):
a Apply gasket sealant (THREEBOND1208 or 4.9 – 5.9 Nm {0.5 – 0.6 kgm}

equivalent) to inserting portion of hose.
a Mounting portion of hose and clamp

(Unit: mm)
Hose Mounting portion (L1) (L2)
Radiator side 50 10
Hose (11)
Water pump side 32 10
Hose (47) Water pump side 45 10
3 Radiator hose clamp:

8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
q When installing the intake manifold, apply gas-

ket sealant to the intake manifold mounting
face according to the following procedure.
a Evenly apply a string of gasket sealant about 1
mm in diameter without breakage around each
air intake opening.
2 Intake manifold mounting face:
Gasket sealant (LG-7)
[*3]
a For adjustment of the air conditioner compres-
sor drive belt tension, see "Testing and adjust-
ing air conditioner compressor belt tension".
[*4] [*5]
3 Fuel tube and hose mounting joint bolts:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
a Install the mounting bolts to their respective

locations recorded when they were removed.
50-200 18 WA150-6
[*7] [*8] [*9] [*13]

k After installing the high-pressure pipe, be a Check the inlet and outlet of the heater hoses
sure to install the boot to the sleeve nut. (48) and (49).
k Direct the slits of the boot out and down.
a The boot is installed so that fuel will not spout [*14]
over the hot parts of the engine and catch fire a For adjustment of the alternator belt tension,
when it leaks for some reason. see "Testing and adjusting alternator belt ten-
sion".
q Precautions for installing high-pressure pipe
k Do not bend the high-pressure pipe to col- [*15]
lect before installing. a Replace the gasket of cylinder block side with
k Be sure to use the genuine high-pressure new one.
pipe clamps and observe the tightening a Install new O-ring (98) to inserting portion of
torque. the water pump (45).
a Before installing the high-pressure pipe, check
it for the following defects. If there is any of
these defects, it can cause fuel leakage.
Accordingly, replace the high-pressure pipe.
q Check the taper seal of the connecting
part (Part (j): part of 2 mm from the end)
for visible lengthwise slit (k) and dent (I).
q Check part (m) (End of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
q Tighten water pump mounting bolt (a) to install

alternator mounting bracket (96), too.
3 Sleeve nut:
25.5 – 29.4 Nm {2.6 – 3.0 kgm}
a When installing the clamp, check that the O-
ring is fitted.
3 Clamp mounting bolt:
5.9 – 7.8 Nm {0.6 – 0.8 kgm}
[*17]
[*10] 3 Lubrication inlet hose mounting nut:
a Before installing the air intake manifold, apply 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
gasket sealant to it.
Apply gasket sealant in a string of about 1 mm
in diameter.
2 Mounting face: Gasket sealant (LG-7)
a Check the stem length and installing portion of
the each bolts (41) – (43).
a Install bolt (41) together with bracket (44) and
spacer (44a).
WA150-6 50-200 19
[*18] [*21]
q Installation procedure for exhaust manifold a Before installing rocker arm assembly (71),
a Replace the gasket with new one. loosen locknut (74) and fully loosen adjustment
1) Install the guide bolts to the cylinder head screw (73).
and set the gasket. a When installing rocker arm assembly (71),
a Set the gasket with the side of stamp ensure that the adjustment screw ball is fitted
of "6205" on the manifold side. to the push rod socket and tighten the mount-
2) Install the exhaust manifold and tighten ing bolts alternately.
the mounting bolts. a When installing 3 rocker arm mounting bolts
3 Exhaust manifold mounting bolt: (59a), check their locations.
34.3 – 53.9 Nm {3.5 – 5.5 kgm} 3 Rocker arm mounting bolts (75), (75a):
a Set the face stamped with "6205" of 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
the gasket on the manifold side. q For adjustment of the valve clearance, see
a When turbocharger was removed Testing and adjusting, "Adjusting valve clear-
from the exhaust manifold, install and ance".
tighten 4 nuts as following torque.
2 Turbocharger mounting nut:
27 – 34 Nm {2.8 – 3.5 kgm}
[*19]
a Replace the O-ring of the cylinder head cover
with new one.
3 Cylinder head cover mounting nut:
7.84 – 9.8 Nm {0.8 – 1.0 kgm}
[*20]
a If the injector assembly was removed, be sure to
replace seal (66a) and gasket (66b) with new ones.
q Installation procedure for injector assembly
1) Install seal (66a) to injector assembly (66).
2) Install gasket (66b) to injector assembly (66).
3) Insert injector assembly (66) in the cylin-
der head.
a After installing the gasket to the injec-
tor, check that it will not fall by its
weight before inserting the injector.
4) Install holder (70) to injector assembly (66).
5) Tighten holder (70) with injector mounting
bolt (69).
a Before tightening the bolt, ensure that
holder (70) is fitted to groove (e) of
injector assembly (66).
3 Holder mounting bolt:
27 – 30 Nm {2.8 – 3.1 kgm}
50-200 20 WA150-6
[*22] [*23]
a Replace the cylinder head gasket with new
one.
q Tightening procedure for cylinder head mount-
ing bolts.
Apply molybdenum disulfide lubricant (LM-P)
to the threaded parts of the cylinder head
mounting bolts and tighten the bolts in the
order shown in the figure according to the fol-
lowing procedure.
3 Cylinder head mounting bolt:
1st time: 68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
2nd time: 107.8 ± 4.9 Nm {11.0 ± 0.5 kgm}
3rd time: Make marks on bolt head and
cylinder head and tighten 90°
(+30/0°).
a After tightening, make 1 punch mark (n) on
each bolt head to indicate the number of tight-
ening time.
a If there are 5 punch marks on a bolt, do not
reuse that bolt but replace it.
Meaning of marks in drawings

(F) denotes the front of the engine.
(R) denotes the front of the engine.
(b) denotes a bolt for plastic-region angle tight-
ening.
(p1) denotes a mark on the cylinder head.

(p2) denotes a mark on the bolt head.
WA150-6 50-200 21
SEN05186-00 Removal and installation of radiator
Removal and installation of 4. Remove 4 mounting bolts (3) of air conditioner

radiator 1
condenser bracket. Disconnect air conditioner
condenser assembly (4) together with bracket
Removal (5).
k Stop the machine on a level ground and set a Move air conditioner condenser assembly
the lock bar to the frame to fix the front and to engine side.
rear frames. a When removing the air aftercooler, take
k Lower the work equipment to the ground, care not to damage fin portion of air condi-
stop the engine, apply the parking brake tioner condenser.
drain the coolant.

2. Loosen drain valve (1), and drain the coolant.

6 Radiator: Coolant (14.6 l)
5. Disconnect overflow hose (6).
6. Disconnect radiator upper hose (7). [*2]

original hose installation position.
7. Remove 2 radiator mounting bolts (8).
3. Disconnect radiator lower hose (2). [*1]

original hose installation position.
50-200 22 WA150-6
Removal and installation of radiator SEN05186-00
8. Pull out radiator (9). [*3] Installation

q Carry out installation in the reverse order to
removal.
[*1] [*2]
position).
(Reference)
2 Hose inserting portion:

Gasket sealant (THREEBOND
1208 or equivalent)
3 Radiator upper hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Radiator lower hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
a Fit grommets (10) to the mounting hole.
a Check that projection (A) of the radiator is fitted
to grommet.
a When installing the radiator, set drain hose (11)
in mounting hole (B) securely.
WA150-6 50-200 23
SEN05186-00 Removal and installation of radiator
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.
5 Total amount of coolant: 14.6 l (For
details, see "Table of fuel, coolant
and lubricants".)
50-200 24 WA150-6
Removal and installation of air aftercooler SEN05186-00
Removal and installation of air 4. Disconnect air aftercooler upper hose (5). [*2]
aftercooler 1
5. Remove 2 air aftercooler mounting bolts (6).
Removal
rear frames.

2. Disconnect air aftercooler lower hose (1). [*1] 6. Pull off air aftercooler (7). [*3]
3. Remove 4 mounting bolts (2) of air conditioner

condenser bracket. Disconnect air conditioner
condenser assembly (3) together with bracket
(4).
a Move air conditioner condenser assembly
to engine side.
a When removing the air aftercooler, take
care not to damage fin portion of air condi-
tioner condenser.
WA150-6 50-200 25
SEN05186-00 Removal and installation of air aftercooler
Installation [*3]
q Carry out installation in the reverse order to a Fit grommets (10) to the mounting hole.
removal. a Check that projection (A) of the radiator is fitted
to grommet
[*1]
q Install the air aftercooler lower hose and it's
clamp as follows.
a Inserted hose length:
Air aftercooler side (L1) 70 mm
Engine side (L4) 65 mm
a Inner and outer clamps must be set up in a

a Clamp mounting portion (L2, L5): 10 mm

10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
q Install the air aftercooler lower hose and it's
clamp as follows.
a Inserted hose length: 70 mm
3 Air aftercooler upper hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
50-200 26 WA150-6
Removal and installation of hydraulic oil cooler assembly SEN05186-00
Removal and installation of 4. Remove 2 mounting bolts (3) to open cooling

hydraulic oil cooler assembly 1
fan and fan motor assembly (4).
Removal
rear frames.
the residual pressure in the hydraulic tank.

details, see "Removal and installation of 5. Remove pin (5) to remove stopper link (6).
6. Remove 2 mounting bolts (7) to remove
2. Disconnect hydraulic oil cooler lower hose (1). bracket (8).
a Plug the disconnected hose to prevent oil.
7. Remove 2 bolts (9) to remove plate (9a).

3. Open radiator grille (2).
WA150-6 50-200 27
SEN05186-00 Removal and installation of hydraulic oil cooler assembly
9. Remove 2 hydraulic oil cooler lower mounting Installation

bolts (11). q Carry out installation in the reverse order to
removal.
q Refilling with oil

Add oil through the oil filler to the specified
level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
10. Disconnect hydraulic oil cooler upper hose

(12).
11. Remove 2 hydraulic oil cooler upper mounting

bolts (13).
12. Lift off hydraulic oil cooler assembly (14).
50-200 28 WA150-6
Removal and installation of engine and HST pump and 3-gear pump assembly SEN05186-00
Removal and installation of 3. Loosen clamp (2).

engine and HST pump and
4. Remove 4 mounting bolts (3) to remove cover
3-gear pump assembly 1
(4).
Removal
rear frames.
k Release the residual pressure in the brake
system by pressing on the brake more than
10 times.
ant. Wait until the coolant is cooled, and 5. Open and fix left and right engine covers (5).
then drain the coolant. a Check that the covers are locked securely.
1. Collect refrigerant (R134a) beforehand.

a Ask professional traders for collecting
and filling the refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant (R134a) gets in your
eyes, you may lose your sight. Accord-
ingly, put on protective goggle, gloves
and working suits with long sleeves
while you are collecting the refrigerant
or filling the air conditioner circuit with
the refrigerant. Collecting and charging
work must be conducted by a qualified
person.
6. Disconnect hose clamp (6) from bulkhead (7).
q Collecting quantity: 900 ± 50 g
7. Disconnect air hose (8) from air cleaner. [*1]
2. Loosen drain valve (1) to drain coolant.
6 Coolant: 14.6 l original hose installing position (M).
WA150-6 50-200 29
SEN05186-00 Removal and installation of engine and HST pump and 3-gear pump assembly
11. Remove left and right covers (20).
12. Sling engine hood and bulkhead assembly (21)

temporarily.
8. Disconnect fuel pre-filter assembly (9) accord-

ing to the following procedure.
1) Disconnect fuel hose (11) from fuel filter
(12).
2) Disconnect fuel hose clamp (13).
3) Disconnect fuel hose (14) from pre-filter
assembly (9). 13. Remove each 2 left and right mounting bolts
4) Remove 2 bracket mounting bolts (15) to (22) from back side of engine hood.
disconnect pre-filter assembly together
with brackets (16).
14. Remove each 2 left and right mounting bolts

(23) from bulkhead (24).
9. Remove 4 engine controller mounting bolts
(17) to disconnect engine controller assembly
(18).
50-200 30 WA150-6
15. Lift off engine hood and bulkhead assembly 19. Disconnect alternator wiring terminal B (29)
(21). and wiring harness connector E03 (30) from
4
alternator.
Engine hood and bulkhead assembly:
130 kg
20. Disconnect wiring harness connector E02 (31)
and wiring harness clamps (32) and (33).
16. Remove the operator's cab and floor frame

assembly. For details, see "Removal and
21. Disconnect air tube clamps (34) from bracket
installation of operator's cab and floor frame
(35).
assembly.
22. Remove air hose (36). [*3]
17. Disconnect air conditioner compressor hoses
(25) and (26). [*2]
18. Disconnect 3 hose clamps (27) and hose

clamp (28) from engine.
23. Disconnect 2 hose clamps (37).
WA150-6 50-200 31
SEN05186-00 Removal and installation of engine and HST pump and 3-gear pump assembly
24. Disconnect hose clamp (38) together with 27. Lift off engine and HST pump and 3-gear pump
bracket from flywheel cover. assembly (41).
a Check that all the wirings, hoses and tubes
are disconnected.
4 Engine and HST pump and 3-gear pump
assembly: 550 kg
25. Disconnect engine oil drain hose clamp (39).
28. Sling HST pump and 3-gear pump assembly

(42) temporarily and remove 2 mounting bolts
(stem length: M16) and 4 mounting bolts (stem
length: M12). [*3]
29. Lift off HST pump and 3-gear pump assembly

(42).
a Sling the HST pump and 3-gear pump
assembly horizontally and pull off them
carefully to avoid to damage HST pump
drive boss.
26. Remove 4 engine mounting bolts (40). [*4] a Lift off the HST pump and 3-gear pump
assembly carefully, after pulling out HST
pump and 3-gear pump assembly from
engine completely.
4 HST pump and 3-gear pump assembly:
110 kg
50-200 32 WA150-6
Installation [*3]
q Carry out installation in the reverse order to q Install the air aftercooler lower hose and it's
removal. clamp as follows.
[*1] Air aftercooler side (L1) 70 mm
a Align the hose to the original position (marking Turbocharger side (L4) 65 mm
position). a Inner and outer clamps must be set up in a
(Reference) position where the threads are shifted 180°.
q Hydraulic pump side a Clamp mounting portion (L2, L5): 10 mm
a Inserted hose length (L1): 32 mm a Clamp mounting portion (L3, L6): 21 mm
3 Air hose clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*4]
[*2] 3 Engine mounting bolts:
a When installing the hoses of the air conditioner 235 – 285 Nm {23.5 – 29.5 kgm}
circuit, take care that dirt, dust, water, etc. will
not enter them. q Charging with refrigerant (R134a)
a When installing each air conditioner hoses, Charge the air conditioner circuit with refriger-
check that O-ring (70) is fitted on it. ant (R134a).
a Check O-ring (70) for a flaw and deterioration. a Do not start engine before charging with
a When connecting each refrigerant tube, apply refrigerant (R134a).
compressor oil for new refrigerant (R134a) to a Charging quantity: 900 ± 50 g
O-ring (70).
2 Threaded part of hose and O-ring: q Refilling with oil
Refrigerant (R134a) Add oil through the oil filler to the specified
3 Threaded part of hose (M16 x 1.5): level. Run the engine to circulate the oil through
12 – 15 Nm {1.2 – 1.5 kgm} the system. Then check the oil level again
3 Threaded part of hose (M24 x 1.5):
30 – 35 Nm {3.0 – 3.5 kgm} q Refilling with coolant
5 Total amount of coolant: 14.6 l (For details,
see "Table of fuel, coolant and lubri-
cants".)
q Bleeding air
Bleed air from the brake circuit. For details,
see Testing and adjusting, "Bleeding air from
brake circuit".
WA150-6 50-200 33
SEN05186-00 Removal and installation of engine front oil seal
Removal and installation of 3) Disconnect wiring harness connectors (4)

engine front oil seal 1
and (5).
4) Disconnect washer tank (6).
Special tools 5) Disconnect radiator sub-tank (7).
6) Disconnect 2 hydraulic oil cooler hose
New/remodel
Necessity
clamps (8).
Sketch
Q'ty
790-101-5201 Push tool (kit) t 1

790-101-5311 • Plate 1
A 1 790-101-5221 • Grip 1
01010-51225 • Bolt 1
795T-221-1010 Plate t 1 Q
Removal
rear frames.
k
7) Sling baffle plate assembly temporarily, and
Lower the work equipment to the ground,
each 2 left and right mounting bolts (9).
disconnect radiator upper hose.

2. Remove baffle plate assembly (1) according to

the following procedure.
1) Remove air aftercooler upper hose (2). 8) Lift off the baffle plate assembly (1).
[*1] 4 Baffle plate assembly: 30 kg
2) Disconnect radiator upper hose (3) from

radiator. [*2]
3. Remove the radiator. For details, see

"Removal and installation of radiator".
50-200 34 WA150-6
Removal and installation of engine front oil seal SEN05186-00
4. Remove crankshaft pulley (10) according to Installation

the following procedure. 1. Use tool A1 (outside diameter of 80 mm) to
1) Loosen alternator mounting bolts (11) and press front oil seal (18) in gear case (19).
(12). 1) Check the crankshaft end corner and the
2) Loosen belt tension adjusting bolt (13), oil seal lip sliding surface for flaws, burrs,
and remove alternator drive belt (14). [*3] scars, or rust, before installing the oil seal.
3) Disconnect speed sensor connector (15). 2) Fill about 2 cc of grease to between the oil
4) Remove speed sensor (16). [*4] seal lips.
5) Remove crankshaft pulley mounting bolts 2 Front oil seal: Grease (G2-LI)
(17) and remove crankshaft pulley (10). [*5]
2. Install the crankshaft pulley.

a Align key (a) of crankshaft (20) with key
groove (b) of crankshaft pulley (10) and
install the pulley.
5. Remove engine front oil seal (18).
q For the rest of the installation work, carry out

the installation in the reverse order of removal.
WA150-6 50-200 35
SEN05186-00 Removal and installation of engine front oil seal
[*1]
q Install the air aftercooler upper hose and it's
clamp as follows.
Air aftercooler side (L1) 70 mm

10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
q Install the radiator upper hose and it's clamp as
follows.
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
a For adjustment of the alternator drive belt ten-
sion, see "Testing and adjusting alternator belt
tension".
[*4]
3 Speed sensor mounting bolt:
7.0 – 11 Nm {0.7 – 1.1 kgm}
[*5]
3 Crankshaft pulley mounting bolt:
343 – 402 Nm {35 – 41 kgm}
50-200 36 WA150-6
Removal and installation of engine rear oil seal SEN05186-00
Removal and installation of 2. Loosen drain valve (1) to drain coolant.

engine rear oil seal 1 6 Coolant: 14.6 l
Special tools
New/remodel
Necessity
Sketch
Q'ty
Symbol Part No Part name
2 795-931-1100 Seal puller q 1

790-101-5401 Push tool (kit) t 1
A 790-101-5421 • Grip 1
3
01010-51240 • Bolt 1
795T-221-1020 Plate t 1 Q
Removal 3. Remove the operator's cab assembly. For

k Stop the machine on a level ground and set details, see "Removal and installation of opera-
the lock bar to the frame to fix the front and tor's cab assembly".
rear frames.
k Lower the work equipment to the ground, 4. Remove the HST Pump and 3-gear pump
stop the engine, apply the parking brake assembly. For details, see "Removal and
and put chocks under the tires. installation of HST pump and 3-gear pump
k Release the residual pressure in the brake assembly."
10 times. 5. Remove flywheel according to the following
k Disconnect the cable from the negative (–) procedure. [*1]
terminal of the battery. 1) Remove cover (2).
then drain the coolant.

the atmosphere.
while you are collecting the refrigerant 2) Remove coupling (3).
person.
WA150-6 50-200 37
SEN05186-00 Removal and installation of engine rear oil seal
3) Remove 5 flywheel mounting bolts (4). a Remove the metal powders completely.
a Loosen the top bolt (4a).
4) Set eyebolt [1].

5) Set guide bar [2], and remove remaining
bolt (4a).
6) Lift off flywheel (5).
4 Flywheel: 25 kg
6. Remove rear oil seal (8) from housing accord-

ing to the following procedure. [*2]
a Take care in the removal not to damage
rear oil seal (8) installation position on
housing and the seal contact face on
crankshaft.
a Before removing, slightly drive the front oil
seal in once to free it from fixation.
a When rear oil seal (8) is fixed too hard to
the housing, carry out the following proce-
dure.
1) Drill through a hole of approx. 3 mm
dia. on rear oil seal (8).
2) Replace the tip of the tool A2 with the
drill type one.
3) Insert the top end of tool A2 into the
drilled hole, and remove the rear oil
seal by the impact of slide hammer
(SH) [1]. (Apply the slide hammer
evenly not to tilt the rear oil seal.)
50-200 38 WA150-6
Removal and installation of engine rear oil seal SEN05186-00
Installation q Measurement of flywheel facial runout

q Carry out installation in the reverse order to 1) Similarly to measurement of the radial
removal. runout, set the dial gauge so that its probe
will be applied perpendicularly to end face
[*1] (b) of the flywheel near the periphery.
q Tighten the flywheel mounting bolts according a When measuring, bring the crank-
to the following procedure. shaft to the front or rear side so that
1) Apply engine oil to the threaded portions an error will not be caused by the end
of the bolts. play.
2 Threaded portion of mounting bolt: 2) Rotate the flywheel 1 turn and measure
Engine oil (EO30) the difference between the maximum
2) Tighten the bolts in the order of [1] – [6] as readings.
shown in the figure in 2 times. a After rotating the flywheel 1 turn,
3 Mounting bolt: check that the dial gauge reads the
1st time: 58.7 – 117.7 Nm same value as before rotation.
{6.0 – 12.0 kgm} Facial runout: Max. 0.25 mm
2nd time: 186.4 – 196.2 Nm
{19.0 – 20.0 kgm}
[*2]
q Install the rear oil seal (8) according to the fol-
q Measurement of flywheel radial runout lowing procedure.
1) Install dial gauge [2] to the flywheel hous- Using tool A3 (Outside diameter: 120 mm),
ing. install the rear oil seal (8) to the flywheel hous-
2) Set the dial gauge so that its probe will be ing (1).
applied perpendicularly to faucet joint por- a Fill the space between the rear oil seal lips with
tion (a) or periphery of the flywheel. grease of about 3 cc.
3) Rotate the flywheel 1 turn and measure 2 Rear oil seal: Grease (G2-LI)
the difference between the maximum

readings.
Radial runout: Max. 0.15 mm
WA150-6 50-200 39
SEN05186-00 Removal and installation of cooling fan and fan motor assembly
Removal and installation of 3. Disconnect wiring harness connectors CN-R59

cooling fan and fan motor (3) and CN-R29 (4).
assembly 1
4. Disconnect 3 wiring harness clamps (5).
Special tools
5. Remove bracket mounting bolts (6), (7) and
New/Remodel
Necessity
(8), and remove brackets (9) and (10).
Sketch
a Wiring harness of connector (3) is
Q'ty
mounted with bolt (7) together.
a Wiring harness of connector (4) is
A 8 791-415-2002 Remover t 1 mounted with bolt (8) together.
Removal
k Stop the machine on a level ground and
install the lock bar to the frame to fix the
front and rear frames.
stop the engine, apply the parking brake,
1. Open radiator grille (1).
6. Disconnect P port hose (11), TC port hose (12)

and T port hose (13).
a Plug the disconnected hoses and ports to
prevent oil leakage.
7. Remove 2 mounting bolts (14) to open cooling

fan and fan motor assembly (15).
2. Remove cover (2).
50-200 40 WA150-6
Removal and installation of cooling fan and fan motor assembly SEN05186-00
8. Remove cushion (16) from all the periphery of 13. Remove 4 mounting bolts (24) and remove fan
the shroud. motor assembly (26) from bracket (25). [*3]
9. Remove pin (17) to remove stopper link (18).
10. Remove mounting bolt (19), stopper plate (20)

and nut (21). [*1]
11. Using tool A8, remove cooling fan assembly

(22). [*2]
12. Remove fan guard (23).
WA150-6 50-200 41
SEN05186-00 Removal and installation of cooling fan and fan motor assembly
Installation [*3]
q Carry out installation in the reverse order to a Before installing fan motor assembly (26), add
removal. hydraulic oil (for details, see "Table of fuel,
coolant and lubricants") until it flows over plug
[*1] (28) mount hole and then install the plug.
3 Nut (23): 98.0 – 127.5 Nm {10 – 13 kgm}
a Set the installed position of stopper plate (22)
in the tightening direction of nut (23).
2 Mounting bolt (21): Adhesive (LT-2)
3 Mounting bolt (21):
59 – 74 Nm {6.0 – 7.5 kgm}
[*2]
a Check that key (27) is fitted securely to the key
way on the shaft of fan motor assembly (26).
a When installing cooling fan assembly (24), set
its key way to key (27).
q Refilling with oil (Hydraulic tank)

level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Hydraulic oil (For details, see "Table of
fuel, coolant and lubricants"):
Only necessary quantity
a Adjust clearances (a) – (d) between the side of

the shroud and end of the fan ring as follows.
Clearance (a): 7.5 mm
Clearance (b): 15.5 mm
Clearance (c): 15.5 mm
Clearance (d): 15.5 mm
50-200 42 WA150-6
Removal and installation of fuel tank assembly SEN05186-00
Removal and installation of fuel 3) Disconnect oil cooler hose clamps (5).
tank assembly 1
4) Disconnect radiator sub-tank (7) and
washer tank (6).
Removal 5) Sling the baffle plate assembly (8) tempo-
k Stop the machine on a level ground and set rarily, and remove each 2 left and right
the lock bar to the frame to fix the front and mounting bolts (9).
rear frames.
then disconnect radiator hose.
1. Drain fuel from fuel tank.

6 Fuel tank: 133 l
6) Lift off the baffle plate assembly (8).

details, see "Removal and installation of 4. Open radiator grille (10).
3. Remove baffle plate assembly according to the

1) Remove aftercooler upper hose (1) and
radiator upper hose (2). [*1]
5. Disconnect fuel breather hose (11) from fuel

filler tube (12).
6. Remove 2 bolts (13) to open cooling fan and

fan motor assembly (14).
2) Disconnect wiring harness clamp (3) and
(4).
WA150-6 50-200 43
SEN05186-00 Removal and installation of fuel tank assembly
7. Pull out pin (15) and remove stopper link (16). 13. Disconnect fuel return hose (25) and fuel sup-
ply hose (26).
8. Remove 2 bolts (17) to remove bracket (18).
14. Disconnect fuel level sensor harness connec-

9. Remove 2 bolts (19) to remove plate (19a). tor R21 (27).
15. Disconnect battery relay mounting bracket (28)

from frame.
11. Remove 2 mounting bolts (21) to disconnect
bracket (22).
12. Disconnect hose clamps (23) and (24) on fuel

tank.
50-200 44 WA150-6
16. Set transmission jack [1] under the fuel tank. 19. Lower transmission jack [1] gradually and
remove fuel tank assembly (31).
a Take care not to damage fuel filer tube.

(29) from front side of fuel tank. [*2]

(30) from rear side of fuel tank. [*3]
WA150-6 50-200 45
SEN05186-00 Removal and installation of fuel tank assembly
Installation [*2] [*3]

q Carry out installation in the reverse order to 3 Fuel tank mounting bolts:
removal. 235 – 285 Nm {23.5 – 29.5 kgm}
[*1]
(Air aftercooler hose) q Refilling with coolant
q Install the air aftercooler lower hose and it's Add coolant through the coolant filler to the
clamp as follows. specified level. Run the engine to circulate the
a Inserted hose length: coolant through the system. Then check the
Air aftercooler side (L1) 70 mm coolant level again.
5
Total amount of coolant: 14.6 l (For
and lubricants".)
q Refilling with fuel
3 Air aftercooler lower hose clamp: Refill fuel through fuel filler.
5
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
Fuel tank: 133 l (with full) (For detail,
cants".)
(Radiator hose)
2 Hose inserting portion: Gasket sealant
(THREEBOND1208 or equivalent)
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
50-200 46 WA150-6
WA150-6 50-200 47
SEN05186-00

©2009 KOMATSU
All Rights Reserved
50-200 48
SEN05187-01
WHEEL LOADER
WA150-6

WA150-6 80001 and up
300 Power train

Removal and installation of transfer and HST motor assembly ...................................................................... 2
Disassembly and assembly of transfer assembly ........................................................................................... 5
Removal and installation of parking brake assembly .................................................................................... 25
Disassembly and assembly of parking brake assembly ............................................................................... 26
Removal and installation of front axle assembly ........................................................................................... 30
Removal and installation of rear axle assembly............................................................................................ 32
Disassembly and assembly of axle housing assembly ................................................................................. 34
Disassembly and assembly of differential assembly..................................................................................... 45
WA150-6 50-300 1
300 Power train
SEN05187-01 Removal and installation of transfer and HST motor assembly
Removal and installation of 3. Remove the operator's cab assembly. For

transfer and HST motor assembly1 details, see "Removal and installation of opera-
tor's cab assembly".
Removal
k Stop the machine on a level ground and set 4. Remove the HST pump and 3-gear pump
the lock bar to the frame to fix the front and assembly. For details, see "Removal and
rear frames installation of HST pump and 3-gear pump
k Lower the work equipment to the ground, assembly".
and put chocks under the tires. 5. Disconnect hose clamp (2).
system by pressing on the brake more than 6. Disconnect hose (4) from motor 1 assembly
10 times. (3).

the atmosphere.

eyes, you may lose your sight. Accord- 7. Disconnect hose (7) from HST motor 1 (6).
ingly, put on protective goggles, gloves
the refrigerant.
Collecting and filling work must be
conducted by a qualified person.
2. Loosen drain valve (1) and drain coolant.

6 Coolant: 14.6 l
8. Disconnect front drive shaft (8) at the transfer

side. [*1]
50-300 2 WA150-6
300 Power train
Removal and installation of transfer and HST motor assembly SEN05187-01
9. Disconnect HST motor 1drain hose clamp (9) 12. Disconnect wiring harness connector CN-T09
from transfer cushion. (13).
13. Disconnect hose clamp (14).
10. Disconnect accumulator charge valve drain

hose (10) from left side of transfer.
14. Remove rear drive shaft (15). [*2]
11. Disconnect hose (11) and hose clamp (12).

15. Sling transfer and HST motor assembly (16)
temporarily.
16. Remove transfer cushions (17) from left and

right side. [*3]
17. Remove transfer mounting bolts (18) from left

and right side. [*4]
WA150-6 50-300 3
300 Power train
SEN05187-01 Removal and installation of transfer and HST motor assembly
18. Sling and remove transfer and HST motor Installation

assembly (16).
a Check that all the wiring and hoses are q Carry out installation in the reverse order to
disconnected. removal.
4 Transfer and HST motor assembly:
[*1] [*2]
270 kg
a When installing the drive shaft, check that the
key way of the spider cap is fitted to the key
way of the mating yoke, and then tighten the
mounting bolts.
a Check that the radial runout of the rear axle

from the transfer in lateral direction is not
larger than 3 mm. If it is larger than 3 mm,
reduce it by moving the transfer mount.
3 Drive shaft mounting bolts:
59 – 74 Nm {6.0 – 7.5 kgm}
[*3]
3 Transfer cushion mounting bolts:
(M10 Bolts) 59 – 74 Nm {6.0 – 7.5 kgm}
(M12 Bolts) 98 – 123 Nm {10.0 – 12.5 kgm}
[*4]
3 Transfer mounting bolts:
235 – 285 Nm {23.5 – 29.5 kgm}
q Charging with refrigerant (R134a)

a Charge the air conditioner circuit with
refrigerant (R134a).
Do not start engine before charging with
a Charging quantity: 900 ± 50 g

through the system. Then check the oil level
again

5 Total amount of coolant: 14.6 l
(For details, see "Table of fuel, cool-
ant and lubricants".)
q Bleeding air from brake system

Bleed air from the brake system. For details,
brake system".
50-300 4 WA150-6
300 Power train
Disassembly and assembly of transfer assembly SEN05187-01
Disassembly and assembly of

transfer assembly 1
Special tools
New/remodel
Necessity
Sketch
Q'ty
1 793T-217-1110 Push tool t 1 Q

2 793T-217-1120 Push tool t 1 Q
790-101-5221 • Plate 1
3
790-101-5201 • Grip 1
01010-51225 • Bolt 1
D 793T-417-1120 Push tool t 1 Q
4 790-101-5221 Grip t 1
01010-81225 Bolt t 1
5 790-190-1600 Pump assembly t 1
6 799-401-3100 Adapter t 1
7 07376-70210 Plug t 1
8 596-35-11140 Nipple t 1
Disassembly
1. Drain the transfer oil.

6 Transfer case: 4.4 l
2. Remove wiring harness (1).

a Record the installed positions of wiring
harness connectors and clamps, and lay-
out of wiring harness.
3. Remove hoses (101) – (111) and tube (4).

a Put tags to the hoses and tube and record
the installed positions etc. on them.
4. Remove the following parts.

1) Speed sensor (2) and oil temperature sen-
sor (3)
2) Brake accumulators (112) and bracket
(113) assembly
3) Oil filter and bracket assembly (114)
4) Valve assembly (115)
5) Brake control charge valve (118)
6) Oil filler tube (117)
5. Remove brackets (116), (119) and (120).
6. Remove HST motor 1 assembly (121) and

HST motor 2 assembly (122).
WA150-6 50-300 5
300 Power train
SEN05187-01 Disassembly and assembly of transfer assembly
7. HST motor and oil supply pipe 9. Parking brake assembly

1) Remove 4 mounting bolts and lift off HST 1) Set the transfer assembly on a block with
motor 1 (7). the parking brake side up.
2) Remove 4 mounting bolts and lift off HST 2) Remove coupling (11) on the parking
motor 2 (8). brake side.
3) Remove oil supply pipe (9).
3) Remove the mounting bolts. Using forcing

8. Hose screws [1], remove parking brake assem-
1) Remove hose (10) from the transfer case bly (12).
strainer. a For disassembly and assembly of the
parking brake assembly, see "Disas-
sembly and assembly of parking
brake assembly."
50-300 6 WA150-6
300 Power train
10. Strainer 2) Remove 6 belleville springs (14).

1) Remove cover (86), and then remove a Check the installation direction and
strainer (87). order for the belleville springs.
a The 1st belleville spring (top) has
white marks.
a When any belleville spring needs to
be replaced, replace all of the 6
springs as a set.
11. Belleville springs

1) Turn over the case and remove cage (13)
from the HST motor 1 mounting section.
a Loosen the mounting bolts evenly
and gradually to release the belleville
springs, and then remove the cage. 12. Piston and spacer
q Free height for belleville springs 1) Using 2 bolts [2], remove piston (15).
(6-piece set): 40.2 mm
q Installed height for belleville springs
(6-piece set): 30.6 mm
q Installed load for belleville springs
(6-piece set): 16,300 N {1,662 kg}
2) Using 2 eyebolts [3], remove spacer (16).
WA150-6 50-300 7
300 Power train
13. Clutch discs, plates, and springs 4) Using puller [13], remove bearing (80).
1) Remove 5 plates (17), 4 discs (18), and 4
wave springs (19).
15. Disassembly of HST motor 1 shaft and ring

gear assembly
2) Remove end plate (20). 1) Remove snap ring (22) and sun gear (23).
14. Removal of HST motor 1 shaft, ring gear 2) Remove snap ring (24).
and clutch housing
1) Using 2 bolts [4], remove shaft and ring gear
assembly (21) and clutch housing (76).
a Use bolts [4] except for pinion shaft
portion.
2) Remove 3 pins (77).
3) Remove snap ring (78) from clutch hous-
ing (76).
50-300 8 WA150-6
300 Power train
3) Sustain ring gear (25) and use push tool 17. Cage assembly
[5] to push out HST motor 1 shaft (26) with 1) Remove the mounting bolts, and then
the press. remove cage assembly (33) using forcing
screws [6].
4) Remove bearing (27) and spacer (28)

from ring gear (25). 2) Remove shims (34).
5) Remove snap ring (29) and bearing (30). a Check the thickness and quantity of
the shims.
16. Coupling
1) Remove mounting bolts and holder (31). 3) Remove dust seal (35) and oil seal (36)
2) Remove coupling (32). from cage assembly (33).
4) Remove outer race (38).
WA150-6 50-300 9
300 Power train
18. Front case 20. Disassembly of HST motor 2 gear and bear-
1) Remove the mounting bolts, and then ing assembly
remove front case (39) using forcing 1) Using puller [8] and tool [9], remove 2
screws [7] and a screwdriver. bearings (42) from HST motor 2 gear (41).
a Be sure to remove 4 bolts from the
rear case side.
a Take care not to damage the case
mating surface when using the screw-
driver.
21. Removal of output shaft and gear assembly

1) Remove 2 mounting bolts (44) for cover
(43).
2) Remove output shaft and gear assembly
(45) and cover (43).
19. Removal of HST motor 2 gear and bearing
assembly
1) Remove HST motor 2 gear and bearing
assembly (40).
22. Disassembly of output shaft and gear

assembly
1) Using push tool [10], remove rear bearing
(46).
2) Remove gear (47) and snap ring (48).
50-300 10 WA150-6
300 Power train
3) Using puller [11], remove front bearing

(49) and spacer (50).
25. Holder
1) Remove mounting bolt (59) and holder
23. Removal of carrier assembly (60).
1) Remove 6 bolts (51).
2) Using tool [12], remove carrier assembly
(52).
2) Remove seal rings (61) and (62) and O-

ring (63) from holder (60).
24. Disassembly of carrier assembly

1) Drive in pin (54) toward shaft (53) to
remove shaft (53) from carrier (55).
a After removing the shaft, remove the
pin from the shaft.
2) Remove 2 thrust washers (56), planetary
gear (57), and bearing (58) (at 3 places).
WA150-6 50-300 11
300 Power train
26. Removal of HST motor 1 gear and outer races 27. Disassembly of HST motor 1 gear and outer
a Do not remove HST motor 1 gear shaft races
(64) (if it is removed forcibly and reused, it 1) Using puller [17], remove 2 outer races
may cause a trouble). (67) from HST motor 1 gear (66), and then
1) Using puller [14], remove bearing (65) and remove spacer (68).
HST motor 1 gear (66). 2) Remove seal ring (69).
a If the claws on puller [14] are so thick 28. Bearing

that they cannot be inserted between 1) Remove 2 plugs (70) from shaft (64).
the gear and case, screw 3 mounting
bolts (M10) [15] into the carrier
mounting holes on HST motor 1 gear
(66) by 15 mm. Then, remove bearing
(65) and HST motor 1 gear (66) using
3-claw puller [16].
2) Remove spacer (71).

3) Insert 2 push tools [18] into the plug holes
and hit them evenly to remove bearing
(72) and plate (73) from shaft (64).
a Do not remove shaft (64).
50-300 12 WA150-6
300 Power train
29. Rear case Assembly

1) Remove outer race (75) from rear case a Clean all parts and check them for dirt or dam-
(74). age. Coat their sliding surfaces with power
train oil before installing.
a Before icing a bearing with dry ice for expan-
sion fit, drop about 6 cc of power train oil onto it
and rotate it 10 times.
1. Rear case
1) Press fit outer race (75) for the output
shaft into rear case (74).
2. Assembly of HST motor 2 gear and bearing

assembly
1) Using push tool [20], press fit 2 bearings
(42) into HST motor 2 gear (41).
a After press fitting the bearings, apply
power train oil to them and rotate
them.
WA150-6 50-300 13
300 Power train
3. Installation of HST motor 2 gear and bear- 5. Bearing and HST motor 1 gear
ing assembly 1) Using push tool [22], press fit bearing (72)
1) Install HST motor 2 gear and bearing with the press.
assembly (40).
2) Install spacer (71).

4. Assembly of HST motor 1 gear and outer
races
1) Install spacer (68) on HST motor 1 gear
(66).
2) Using push tool [21], press fit 2 outer
races (67) into HST motor 1 gear (66).
3) Install seal ring (69) on HST motor 1 gear
(66).
2 Seal ring: Grease (G2-LI)
3) Install HST motor 1 gear (66).

4) Using push tool [23], press fit bearing (65)
with the press.
50-300 14 WA150-6
300 Power train
6. Holder
1) Install seal rings (61) and (62) and the O-
ring (63) on holder (60).
2 Seal ring and O-ring: Grease (G2-LI)
8. Installation of carrier assembly

1) Align carrier assembly (52) with the dowel
pin on the HST motor 1 gear and install it.
2) Tighten them with mounting bolt (51).
2) Install holder (60) and tighten the mount- 2 Mounting bolt: Adhesive (LT-2)
ing bolts. 3 Mounting bolt:
a Set the holes of 2 mm in diameter (g) 59 – 74 Nm {6 – 7.5 kgm}
on the top of the holder horizontally
(set them at 90° to the hole of 4.5 mm
in diameter (h) on shaft (64)).
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
88.2 – 107.8 Nm {9 – 11 kgm}
9. Assembly of HST motor 1 shaft and ring

gear assembly
1) Install bearing (30) on ring gear (25), and
then install snap ring (29).
7. Assembly of carrier assembly

1) Set planetary gear (57), bearing (58), and
2 thrust washers (56) on carrier (55) (at 3
places).
a Check that no flaws on thrust washer
or no burrs on edges at installation.
2) Install carrier (55) into pinion shaft (53)
and align their pin holes, and then install
pin (54).
WA150-6 50-300 15
300 Power train
2) Set ring gear (25) on HST motor 1 shaft 5) Install snap ring (24).
(26), and then using push tool [24], press
fit bearing (30) with the press.
6) Install sun gear (23), and then install snap

ring (22).
3) Install spacer (28), and then set bearing
(27).
a Take care the installation direction of
the bearing (with flange).
q Place the flange toward the
spacer.
10. Installation of HST motor 1 shaft and ring gear

1) Install HST motor 1 shaft and ring gear
assembly (21).
4) Using push tool [25], press fit bearing (27)

with the press.
50-300 16 WA150-6
300 Power train
11. Assembly of output shaft and gear assembly 4) Using tool D2, press fit rear bearing (46)
1) Using tool D1, press fit front bearing (49) with the press.
and collar (50) toward output shaft (81) a After press fitting the bearing, apply
with the press until they stop. power train oil to the bearing and
a After press fitting them, apply power rotate it.
train oil to them and rotate them.
12. Installation of output shaft and gear assembly

2) Rotate the shaft and install snap ring (48). 1) Place cover (43) over the gear and install
3) Install output gear (47). output shaft and gear assembly (45) on
2 Spline for the gear: the rear case.
Lubricant containing molybde- 2) Tighten cover (43) with bolt (44).
num disulfide (LM-G) a Check that cover (43) does not inter-
fere with the inside surface of the
gear.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
WA150-6 50-300 17
300 Power train
13. Clutch housing

1) Install snap ring (79) on the front case.
2) Install clutch housing (76) and 3 pins (77).
2) Install guide pins [27], and then install

front case (30).
a Align the match marks on their tops,
3) Install snap ring (78). and then install the cases.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
14. Front case

a Use the front case and rear case as an
assembly. 3) Install snap ring (82) on the HST motor 2
1) Apply gasket sealant to the rear case side.
a Apply the gasket sealant to the forc-
ing screw contact surface (a) to the
same dimension of the screw hole.
a Apply the gasket sealant so that the
dimensions (b) and (c) will be identical.
a Apply the gasket sealant so that the
dimension (e) x the dimension (f) will
be 2 – 5 mm.
2 Mounting face of front case flange:
50-300 18 WA150-6
300 Power train
15. Clutch discs, plates, and springs 2)Install the O-ring, and then install piston
1) Install end plate (20). (15).
2 O-ring: Grease (G2-LI)
2) Install 5 plates (17), 4 wave springs (19),

and 4 discs (18). 17. Belleville springs
a Soak the discs in clean power train oil 1) Set the 1st one (bottom) of 6 belleville
for at least 2 minutes before installing springs (14) in the convex direction (set it
them. with the white mark side down).
2) Set the 2nd–5th belleville springs in alter-
nating directions with the 1st belleville
spring.
3) (2nd–5th ones do not have mark.)
4) Set the 6th belleville spring with the white
mark side up.
a When any belleville spring needs to
be replaced, replace all of the 6
springs as a set.
16. Spacer and piston

1) Install the O-ring, and then install spacer
(16).
2 O-ring: Grease (G2-LI)
WA150-6 50-300 19
300 Power train
18. Cage
1) Install cage (13).
a Tighten the mounting bolts evenly and
gradually.
q Installed load for belleville springs
(6-piece set): 16,300 N {1,662 kg}
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
2) Using push tool [28], press fit bearing (80),
and then install snap ring (83).
20. Cage assembly

1) Press fit outer race (38) into cage (37).
2) Using tools D3 and D4, press fit oil seal
(36) and dust seal (35) into cage (37).
2 Outside surface of the oil seal:
2 Lips and clearances for the oil seal
and dust seal:
Silicone grease (G2-S)
19. Operation test of transfer clutch

1) Using tools D5, D6, D7, and D8, apply oil
pressure on the transfer clutch disengage-
ment port.
a If the transfer clutch is disengaged
when the oil pressure is applied, it is
operating normally.
q Clutch disengaging oil pressure:
1.52 MPa {15.5 kg/cm2}
a Operation check of the clutch
Hold the spline for the motor 1 and
rotate the output shaft by hand.
Clutch disengaging
Output shaft
port
Oil pressure on Rotate
Oil pressure off Not rotate
50-300 20 WA150-6
300 Power train
21. Pre-load adjustment on output shaft taper 5) Calculate the shim thickness (t).
roller bearing q Shim thickness (t) = Average of clear-
1) Install cage assembly (33) without insert- ance (k) +0.28 mm to 0.30 mm
ing any shim. 6) Insert selected shims (34) between cage
3 Mounting bolt: assembly (33) and front case (39).
4.80 ± 0.98 Nm {0.5 ± 0.1 kgm} 7) Tighten the cage mounting bolts.
2) Rotate the output shaft 20 times and 3 Mounting bolt:
check the tightening torque for the mount- 98 – 122.5 Nm {10 – 12.5 kgm}
ing bolts tightened at step 1).
3) If the tightening torque has changed,
repeat steps 1) and 2), and then check
again.
4) If the tightening torque has not changed,
measure the clearances for cage (33) at 3
places (j) and calculate average (k) of 3
values.
a To confirm that the bearing is not
leaning, check that the dispersion of
clearances at 3 places (j) is 0.15 mm
or less. If the dispersion is larger than
0.15 mm, the bearing may not be
installed adequately or there is
another cause. In this case, eliminate 8) Install holder mounting bolt (84) on the
the cause and reduce the dispersion output shaft.
to 0.15 mm or less. 9) Set the torque wrench [29] on the holder
mounting bolt and measure the rotating
torque for the output shaft.
a Measure the rotating torque without
installing the front and rear couplings.
q Rotating torque for the output shaft:
0.20 – 0.78 Nm {0.02 – 0.08 kgm}
WA150-6 50-300 21
300 Power train
22. Coupling 24. Parking brake assembly

1) Install front coupling (32). 1) Turn over the transfer assembly, and then
2 Spline for coupling: install gasket (85).
Lubricant containing molybde- a Do not reuse the gasket. Replace it
num disulfide (LM-G) with new one.
2) Install holder (31), and then tighten mount-
ing bolt (84).
3 Mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
2) Install parking brake assembly (12).

a After all internal teeth for the disc are
meshed with the spline for the output
shaft, tighten the mounting bolts with
the clearance between the parking
23. Oil filler brake housing and transfer case is
1) Install the O-ring, and then install oil filler (9). eliminated.
3 Mounting bolt: 3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm} 98 – 123 Nm {10.0 – 12.5 kgm}
50-300 22 WA150-6
300 Power train
25. Strainer 28. HST motor

1) Install strainer (87). 1) Install the O-ring, and then lift and install
2) Install the O-ring, and then install cover (86). HST motor 2 (8).
2 Spline for HST motor 2:
Lubricant containing molybdenum
disulfide (LM-G)
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
2) Install the O-ring, and then lift and install
HST motor 1 (7).
a Do not apply LM-G to the spline for
the HST motor 1.
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
26. Coupling
1) Install coupling (11) to parking brake (12).
2 Spline for coupling:
disulfide (LM-G)
29. Brake accumulator

1) Install brake accumulator and transfer oil
filter bracket assembly (6).
2) Connect clutch port hose (5).
27. Hose
1) Connect hose (10) to the transfer case
strainer.
WA150-6 50-300 23
300 Power train
3) Connect wiring connectors T06 (3) and

T11 (4).
4) Connect wiring connectors T07 (2) and

T10 (2a).
5) Install speed sensor (1).
q Refilling with oil (Transfer case)

Add oil through the oil filler to the specified level.
50-300 24 WA150-6
300 Power train
Removal and installation of parking brake assembly SEN05187-01
Removal and installation of

parking brake assembly 1
Removal
k Stop the machine on a level place and set
the lock bar to the frame.
1. Drain the transfer oil.

2. Release (Open) the parking brake with the
Installation
parking brake lever (1). q Carry out installation in the reverse order to
removal.
[*1]
a Insert cotter pin (2) into pin (3), and then open
it to both sides by 180°.
[*2]
3 Rear drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
key groove for the spider cap is fitted in the key
groove for the mating yoke, and then tighten
the mounting bolt.
a Installing the rear drive shaft, check that the
3. Remove cotter pin (2) and pin (3) for the park- misalignment between the rear axle and the
ing brake lever. [*1] transfer in lateral direction is less than 3 mm.
If the misalignment is 3 mm or larger, reduce
4. Remove rear drive shaft (4). [*2] the misalignment by moving the transfer cush-
ion and the mount position of the transfer.
[*3]
a Do not reuse the gasket. Replace it with new
one on the case side.
a Using the guide bolt, install the parking brake.
3 Parking brake mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a Adjust the parking brake. For details, see
"Testing and adjusting, Testing and adjusting
parking brake control cable".
q Refilling with oil (Transfer case)

5. Remove the parking brake mounting bolts, and level. Run the engine to circulate the oil
then remove parking brake assembly (5) using through the system. Then, check the oil level
forcing screws [1]. [*3] again.
WA150-6 50-300 25
300 Power train
SEN05187-01 Disassembly and assembly of parking brake assembly
Disassembly and assembly of 2. Cam plate

parking brake assembly 1
Remove cam plate (6).
Special tools
New/remodel
Necessity
Sketch
Q'ty

790-101-5311 • Plate 1
3
790-101-5221 • Grip 1
D 01010-51225 • Bolt 1
793T-417-1120 Push tool t 1 Q
4 790-101-5221 Grip t 1
01010-81225 Bolt t 1 3. Balls
Remove 5 balls (9).
Disassembly
1. Plates, discs, and springs
1) Remove 2 clamping bolts (1) and 2 spacers
(2).
a Loosen the 2 clamping bolts evenly
since the spring tension is applied.
4. Lever
1) Remove mounting bolt (8), washer (7),
and lever (10).
2) Remove 6 plates (3), 5 wave springs (4),

and 5 discs (5).
50-300 26 WA150-6
300 Power train
Disassembly and assembly of parking brake assembly SEN05187-01
2) Remove lever shaft (11) and spacer (12). Assembly

a Clean all parts and check them for dirt or dam-
age. Coat their sliding surfaces with power
train oil before installing.
a Do not reuse the gasket and remove it com-
pletely.
1. Oil seal and bearings

1) Install 2 bearings (17) on parking brake
case (18).
2) Install oil seal (16).
a Fill 40 – 60% with grease between
main lip and dust lip of oil seal and
between oil seal and dust seal.
a Coat with gasket sealant on fitting
5. Pin face of oil seal (Wipe protruding gas-
Remove pin (13). ket sealant off completely.)
2 Between main lip and dust lip of oil seal:
6. Dust seal and oil seal Grease (G2-LI or G2-S)

Remove dust seal (14) and oil seal (15). 2 Between oil seal and dust seal:
Grease (G2-LI or GS-S)
2 Fitting face of oil seal:
7. Oil seal and bearings

1) Remove oil seal (16).
2) Remove 2 bearings (17) from parking
brake case (18). 2. Oil seal and dust seal
1) Using tool D3, press fit oil seal (15).
WA150-6 50-300 27
300 Power train
SEN05187-01 Disassembly and assembly of parking brake assembly
2) Using tool D4, press fit the dust seal (14). 4. Lever
a Fill 40 – 60% with grease between main 1) Install lever shaft (11), and then install
lip and dust lip of oil seal and between spacer (12).
oil seal and dust seal.
a Coat with gasket sealant on fitting
face of oil seal (Wipe protruding gas-
ket sealant off completely.)
2 Between main lip and dust lip of oil seal:
Grease (G2-LI or G2-S)
2 Between oil seal and dust seal:
Grease (G2-LI or GS-S)
2 Fitting face of oil seal:
a Installing the lever shaft, align match

mark (a) on lever shaft (11) with the
center line for groove (b) on lever
(10).
3 Mounting bolt:
27 – 34 Nm {2.8 – 3.5 kgm}
3. Pin
1) Install pin (13).
a Check that dirt is not sticking to the
ball groove and inside of the housing.
5. Balls
1) Install 5 balls (9).
a Check that dirt is not sticking to the balls.
50-300 28 WA150-6
300 Power train
Disassembly and assembly of parking brake assembly SEN05187-01
6. Cam plate 7. Plates, discs, and springs

1) Install cam plate (6). 1) Install 5 discs (5), 5 wave springs (4), and
a Check that dirt is not sticking to the 6 plates (3).
ball grooves, inside of parking brake a Soak the discs in clean oil (TO10,
housing, cam plate, discs, and plates. EO10-CD) for at least 2 minutes
before installing them.
a Check that dirt is not sticking to the
discs and plates.
a Move cam plate (6) several times so

that ball (9) will be fitted into groove
"c" on cam plate (6).
a Check that the cam plate does not 2) Press plate (3) to install 2 spacers (2) and
hitch on the housing. 2 mounting bolts (1).
a Press the plate until it is flush with the
parking brake case.
a Move the lever and check that it
returns normally.
2 Clamping bolt: Adhesive (LT-2)
3 Clamping bolt:
19.6 – 27.4 Nm {2.0 – 2.8 kgm}
WA150-6 50-300 29
300 Power train
SEN05187-01 Removal and installation of front axle assembly
Removal and installation of front 4. Disconnect wiring connector F14 (3), clip (4),
axle assembly 1
and clamp (5).
Removal 5. Disconnect brake hose (6).

k Stop the machine on a level place and set
the lock bar to the frame.
accumulator circuit. For details, see Testing
and adjusting, "Releasing residual pres-
sure in the hydraulic circuit".
1. Lift up the front side of the machine with the

work equipment and set blocks [1] at the rear
of the front wheels to sustain the front side of
the machine.
6. Lift off front wheel (7). [*1]
a Lift off the front wheel on the other side in
the same procedure.
4 Front wheel (1 side): 180 kg
2. Lift up the work equipment and dump the

bucket, and then set stands [2] under the work
equipment.
3. Remove work equipment valve upper cover

(2). 7. Disconnect front drive shaft (8). [*2]
50-300 30 WA150-6
300 Power train
Removal and installation of front axle assembly SEN05187-01
8. Sling front axle assembly (9) temporarily and Installation

support it with jack [3]. Remove 4 mounting q Carry out installation in the reverse order to
bolts on both sides and remove front axle removal.
assembly (9). [*3]
4
[*1]
3
Front axle assembly: 420 kg
Front wheel mounting bolt:
785 – 980 Nm {80 – 100 kgm}
[*2]
key groove on the spider cap is fitted to the key
groove on the mating yoke, and then tighten
the mounting bolt.
3 Front drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*3]
3 Front axle mounting bolt:
666.4 – 813.4 Nm {68 – 83 kgm}
q Bleeding air
brake circuit".
WA150-6 50-300 31
300 Power train
SEN05187-01 Removal and installation of rear axle assembly
Removal and installation of rear 5. Disconnect engine oil drain hose (2).
axle assembly 1
6. Disconnect 2 grease supply tubes (3).
Removal
k Stop the machine on a level ground and set 7. Remove 2 nipples (4) (since they may inter-
the lock bar to the frame to fix the front and face with the rear axle assembly when it is
rear frames. pulled out backward at step 13).
stop the engine, apply the parking brake, 8. Remove nipple (5).
and set chocks under the tires.
accumulator circuit. For details, see
"Releasing remaining pressure in hydraulic
circuit".
1. Raise the chassis with the work equipment and

set stands [1] under the frame in front of the
rear wheels to float the rear of the chassis.
2. Support the counterweight on jack [2].
3. Set blocks [3] between top of each side of the 9. Remove rear drive shaft (6). [*2]
rear axle and the rear frame.
10. Disconnect brake hose (7) from the top of the
axle.
AJF00647
4. Lift off rear wheel (1). [*1]

a Remove the right and left fenders.
a Lift off the rear wheel on the other side 11. Remove the bolts and coupling (8). [*3]
similarly. a Remove coupling (8) so that dust seal (12)
4
in step 14 will not be damaged.
Rear wheel (1 side): 180 kg
50-300 32 WA150-6
300 Power train
Removal and installation of rear axle assembly SEN05187-01
12. Secure support (9) and both sides of the rear Installation
axle with lever block [4]. q Carry out installation in the reverse order to
removal.
13. Sling rear axle assembly (10) temporarily, sup-
port it on jack [5], and remove the mounting [*1]
bolts of support (9). [*4] 3 Rear wheel mounting bolt:
785 – 980 Nm {80 – 100 kgm}
[*2]
a Check that the radial runout of the rear axle
from the transfer in lateral direction is not
larger than 3 mm. If it is larger than 3 mm,
reduce it by moving the transfer mount.
key way of the spider cap is fitted to the key
way of the mating yoke, and then tighten the
mounting bolts.
3 Rear drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
14. Pull out the rear axle assembly toward the rear [*3]
of the chassis and disconnect it from the rear 2 Coupling mounting bolt: Adhesive (LT-2)
frame assembly. 3 Coupling mounting bolt:
a Take care not to damage dust seals (12) 245 – 309 Nm {25.0 – 31.5 kgm}
of rear frame (11).
[*4]
3 Support mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}
q Bleeding air
brake circuit".
15. Lower the crane and jack [5] simultaneously to

remove rear axle assembly (10).
4 Rear axle assembly: 380 kg
WA150-6 50-300 33
300 Power train
SEN05187-01 Disassembly and assembly of axle housing assembly
Disassembly and assembly of 3) Remove thrust plate (4), and then remove
axle housing assembly 1
rear support (2).
4) Remove brake tube and hose assembly (30).
Special Tools
New/remodel
Necessity
Sketch
Q'ty
793T-222-1210 Push tool t 1 N Q

1 793T-422-1440 Push tool q 1 Q
793T-623-1170 Push tool q 1 Q
H
2 793-520-2600 Seal support t 1
3 792T-413-1120 Push tool t 1 Q
4 793-510-1500 Holder t 1
3. Axle housing assembly

Disassembly 1) Sling axle housing assembly (31) tempo-
a The following photos and illustrations show the rarily and remove the housing mounting
rear axle housing as an example. bolts, and then remove axle housing
assembly (31).
1. Oil drain a When removing the axle housing
6 Axle(front): 14.5 l assemblies from both sides, put the
(rear): 14 l match marks on the housings and the
differential case so that the housing
assemblies will not be mixed up.
2. Axle assembly
1) Set axle assembly (1) on blocks [1].
a Set blocks so that the axle assembly
will not lean when the housing
assembly on one side is removed.
2) Sling rear support (2) temporarily and
remove cover (3).
a Check the thickness and quantity of
the shims.
50-300 34 WA150-6
300 Power train
Disassembly and assembly of axle housing assembly SEN05187-01
4. Planetary carrier assembly

1) Set axle housing assembly (31) on ring [2]
with the planetary carrier side up.
2) Remove mounting bolt (32) for the plane-
tary carrier assembly.
6. Axle shaft bearing

a Do not heat the bearing or cut it with gas
to remove it.
1) Removing bearing (7) from axle shaft (6),
push in part (a) evenly around oil seal and
3) Remove planetary carrier assembly (33). sleeve (8) toward the flange with a screw-
4) Remove shims (34). driver.
a Check the thickness and quantity of 2) Set clearance (b) at the contact part of
the shims. bearing (7) and sleeve (8a) for hitching the
claws on the puller.
3) Install bearing puller [3] at clearance (b).
4) Tighten the bolts on bearing puller [3] to
remove bearing (7).
5) Remove oil seal (8).
5. Axle shaft
1) Sling axle housing assembly (5) approxi-
mately 20 mm.
2) Put push tool [11] on the end surface of
axle shaft (6) and hit it with copper ham-
mer [11] to drive it out.
a The bearing on the planetary carrier
side is removed.
WA150-6 50-300 35
300 Power train
7. Axle housing 8. Planetary carrier

1) Use puller [4] to pull up ring gear (9) 1) Use push tool [6] to drive in roll pin (15) for
evenly to remove it from axle housing (11). planetary carrier (14) until it is fully
a Install spacers [5] on the bolt end on inserted into shaft (16).
puller [4] to adjust the height. a Take care not to drive in the roll pin
a Take care that the claws on the puller too deep.
will not come off from the ring gear.
2) Remove 4 pins (10) from axle housing (11).
3) Remove outer races (12) and (13) from

axle housing (11).
2) Use push tool [7] to remove shaft (16) with

the press.
50-300 36 WA150-6
300 Power train
3) Pull out roll pin (15) from removed shaft 2) Remove ring (38) and bushing (39) from
(16). rear axle support (2).
4) Remove pinion gear (17) and 2 bearings

(18) from planetary carrier (14).
5) Remove 2nd and 3rd pinion gears (17),
shaft (16), roll pin (15), and bearings (18)
from the planetary carrier.
6) Remove spacer (19) from planetary carrier
(14).
9. Rear axle support (for rear axle)

1) Remove thrust washer (37) from thrust
plate (4).
WA150-6 50-300 37
300 Power train
Assembly 2. Axle shaft bearing

1. Axle housing and axle shaft 1) Stand up axle shaft (6) on the block and fix
1) Press fit bearing outer races (12) and (13) it securely.
into axle housing (11). 2) Sling axle housing (11) vertically, and then
lower it slowly.
a Insert the axle housing by utilizing its
weight.
2 Oil seal fitting part and bearing:
Axle oil
a After installing the housing, leave tool
H2 installed until step 4).
3) Use tool H3 to press fit bearing (20) into
axle shaft (6).
a Press fit the bearing by turning the
axle housing with hands.
2 Outside circumference of bearing:
Axle oil
4) Remove tool H2 in horizontal direction.
2) Use tool H1 to press fit seal (8) and bear- a Check that oil seal (8) is not leaning.
ing (7) into axle shaft (6) simultaneously. a Bring the end surface of axle housing
a Press fit bearing (7) and oil seal (11) into intimate contact (the clear-
sleeve (8a) until they are flush with ance should be less than 0.2 mm)
axle shaft end (c), and then check with the flange for oil seal (8).
that there is not clearance between
bearing (7) and oil seal sleeve (8a).
3) Install tool H2 under oil seal (8).

a Adjust tool H2 so that the top of tool
H2 will contact with oil seal (8) lightly
and the clearance will be even.
50-300 38 WA150-6
300 Power train
3. Selection of shim thickness 2) Sling axle shaft and housing assembly (5)
1) After fitting bearings (7) and (20), measure 20 – 30 mm at 2 points as installing the
the torque at hole (d) on axle housing (11). axle housing.
q Torque (not static friction but kinetic 3) Turning axle shaft (6), hit the flange with a
friction) copper hammer in the direction of the
(Common among the front and rear) arrow to drive out axle shaft (6).
(Including the seal resistance) 4) Repeat step 1) until the torque falls into
15.6 – 19.6 N {1.6 – 2.0 kg} the standard value range.
a If the torque is less than the standard 5) Install planetary carrier (14) to the spline
value, press fit the bearings again for axle shaft (6) without the gear, and
and repeat step 1). then place tool H4 on it.
a If the torque exceeds the standard a Place tool H4 on the planetary carrier.
value, adjust it in steps 2) – 4). Do not tighten with the bolt.
6) Use a depth micrometer to measure dis-
tance (e) from the end surface of tool H4
to the end surface of the axle shaft.
a Letting the value obtained by sub-
tracting thickness (t) of tool H4 from
dimension (e) as (e – t).
q Thickness of shim = (e – t) +0.05
+0.05
q Adjustment allowance of shims:
0.96 ± 0.36 mm
q Varieties of shim thickness:
0.05 mm, 0.2 mm, 0.3 mm, 0.8 mm
7) After selecting the thickness of the shim,
remove planetary carrier (14).
WA150-6 50-300 39
300 Power train
4. Planetary carrier 2) Install spacer (19) into planetary carrier (14).

1) Insert 2 bearings (18) into 1st gear (17) and a Insert the spacer from side (g) of
install the gear into planetary carrier (14). planetary carrier (14) before installing
2nd gear (17).
a Align pin holes (f), and then press fit

shaft (16) with push tool [7]. 3) Install 2nd and 3rd gears (17) into plane-
2 Shaft: Axle oil tary carrier (14) similarly.
a Align pin holes (f), and then press fit
shaft (16) with push tool [8].
a Align the holes on shaft (16) and roll
pin (15), and then drive roll pin (15)
via push tool [8] so that it will be flush
with planetary carrier (14).
4) Hit the end surface of shaft (16) and the
differential side of gear (17) lightly to push
back the bearing and check that the gear
rotates smoothly.
a Align the holes on shaft (16) and roll

pin (15), and then drive roll pin (15)
via push tool [8] so that it will be flush
with planetary carrier (14).
50-300 40 WA150-6
300 Power train
5. Ring gear 2) Sling and install planetary carrier assem-

1) Install ring gear (9) into axle housing (11) bly (33).
and insert 4 pins (10). k Take care not to catch your fingers
a Align the pin holes on the housing in the gear when installing the
and ring gear, and then install the ring planetary carrier.
gear into the housing. 3) Tighten mounting bolt (32).
a Degrease and clean the bolt hole on
the axle shaft and the mounting bolt.
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
a Clean the shaft end and the planetary
carrier spline thoroughly before
installing.
6. Planetary carrier assembly

1) Install shim (34) selected at the step 3.-6)
to the end surface of the axle shaft.
4) Install dial gauge [9] into the axle housing

(11) and measure the end play with the
end surface of the planetary carrier.
q End play of planetary carrier:
0 – 0.098 mm
a If the measured end play is out of the
standard range, change the shim
thickness at step 1) and repeat the
steps.
WA150-6 50-300 41
300 Power train
5) Rotate axle housing (11) 10 or more turns 2) Sling the axle housing assembly (31) hori-
to fit it. Then, measure the starting torque zontally and install it carefully by aligning
at the mounting bolt hole for the axle hous- the assembly to the spline grooves on the
ing assembly with push-pull gauge [10]. sun gear shaft.
q Starting torque (common among the a To prevent axle housing assembly
front and rear) (Including the seal and (31) from tipping over, set blocks
planetary carrier resistances): under the assembly.
0 – 21.6 N {0 – 2.2 kg} 3) Tighten the axle housing mounting bolts in
a If the starting torque exceeds the the diagonal order.
above range, adjust it again by refer- 3 Mounting bolt:
ring to 3. Selection of the shim thick- 157 – 196 Nm {16 – 20 kgm}
ness above.
8. Rear axle support

7. Axle housing assembly 1) Install bushing (39) and ring (38) into rear
1) Degrease and clean the mating faces of axle support (2).
axle housing and differential housing and a Install the bushing with its chamfered
apply gasket sealant all over them. part toward the axle side and install
1] Degrease and clean the surface of the slit at the side position.
axle housing and dry it naturally. 2 Ring and groove: Grease (G2-LI)
2] Coat gasket sealant by 2 or 3 mm
width like [A] continuously.
3] Coat gasket sealant outside of wear
sensor mounting positions [B].
a Differential housing does not con-
tact to the axle housing assembly
at positions [B] when assembling
them. So, be careful not to break
gasket sealant off at positions [B].
2 Mating faces of housings:
Gasket sealant (LOCTITE 515)
2) Sling and install rear axle support (2).

2 Outside circumference of pivot mount-
ing part: Grease (G2-LI)
3) Install thrust plate (4) and thrust washer (37).
a Clean the mating faces of the thrust
plate and thrust washer thoroughly.
a Insert a thickness gauge all round the
mating faces of the thrust plate and
thrust washer to check that there is
no clearance.
50-300 42 WA150-6
300 Power train
4) Insert thrust plate (4) onto the rear axle 2) Similarly, measure dimension (m) between
support with its two 5 mm holes up. rear axle support (2) and thrust plate (4) at
2 Mounting bolt: 4 places on the diagonal lines with depth
Adhesive (LOCTITE 262) micrometer [11] and calculate the average.
3 Mounting bolt: a Clean the contact face of the depth
98 – 123 Nm {10 – 12.5 kgm} micrometer thoroughly.
q Standard average value (m)
(for reference): 19.65 – 20.0 mm
9. Adjust the shim for cover (trunnion cap) (3).

1) Measure dimension (k) of cover (3) at 4
places on the diagonal lines with depth 3) Calculate shim thickness (t).
micrometer [11] and calculate the average. q Shim thickness (t) = (m) – (k)
a Clean the contact face of the depth a Select the number of the shims in
micrometer thoroughly. terms of the calculated shim thick-
q Standard average value (k): ness by referring to the following
19.85 – 20.0 mm table.
q Shim thickness (1 piece): 0.2 mm
Shim thickness (t) Number of shims
0 – 0.07 mm 1
0.08 – 0.27 mm 2
0.28 – 0.47 mm 3
4) Install selected shim (40), and then install

cover (3).
2 Cover: Grease (G2-LI)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
5) Install brake tube and hose assembly (30).
WA150-6 50-300 43
300 Power train
q Refilling with oil (axle housing)

Tighten the drain plug and add oil to the speci-
fied level through the oil filler, and then check
the oil level.
3 Drain plug: 58.8 – 78.4 Nm {6 – 8 kgm}
3 Oil filler plug:
93.1 – 122.5 Nm {9.5 – 12.5 kgm}
5 Axle oil AXO80 (front): 14.5 l
(rear): 14 l
50-300 44 WA150-6
300 Power train
Disassembly and assembly of differential assembly SEN05187-01
Disassembly and assembly of 2. Removal of long cage assembly (for front

differential assembly 1
differential)
1) Set axle assembly (1) on blocks [1].
Special tools 2) Remove holder (2) and coupling (3).
a Remove the coupling protector only
New/remodel
Necessity
when it is necessary.
Sketch
Q'ty
Symbol Part No. Part Name 3) Remove long cage assembly (4).
5 799-301-1500 Oil leak tester t 1

6 797-101-1211 Wrench t 1
7 796-730-2140 Wrench t 1
8 790-201-2830 Push tool t 1
9 790-201-2730 Spacer t 1
793T-222-1220 Push tool t 1 N Q
H 10 790-101-5221 • Grip t 1
010101-81225 • Bolt t 1
11 793-520-2202 Installer q 3
12 790-201-2750 Spacer t 1
13 790-190-1500 Pump assembly t 1
14 799-101-5210 Nipple t 1 3. Disassembly of long cage assembly (for
front differential)
15 793T-422-1610 Plate t 1 N Q
1) Remove dust seal (5) and oil seal (6).
Disassembly
1. Oil drain
6 Axle (front): 14.5 l
(rear): 14 l
a For the rear differential assembly

q Remove the rear axle support, brake tube
and hose assembly and the axle housings
from both sides by referring to step 1. –
step 3.-1) in "Disassembly and assembly
of axle housing assembly".
q Perform the step 6: Removal of rear cage
assembly (for rear differential) and later. 2) Use push tool [2] to push out shaft (7)
from long cage assembly (4) with the
a Perform the following steps 2. – 5. only for press.
the front differential.
WA150-6 50-300 45
300 Power train
SEN05187-01 Disassembly and assembly of differential assembly
3) Remove snap ring (105), ring (106), and 6) Loosen nut (31) with tool H6 before
bearing (107) from long cage assembly (4). removing the cage assembly.
4. Removal of front cage assembly (for front 7) Remove front cage assembly (15) with
differential) forcing screw [3] and guiding bolts [4].
1) Remove brake tube assembly (8) and a Check the thickness and quantity of
slack adjuster (9) from both sides. the shims.
2) Remove cover (10).
3) Remove the axle oil temperature sensor (it
is invisible because of cover (10)) with
harness (11).
4) Remove 2 bleeder screws (13).
5) Remove cover (12).
5. Axle housing
a Remove the axle housing assemblies
from both sides by referring to the step 1)
in 3. Axle housing assembly in "Disassem-
bly and assembly of axle housing assem-
bly".
50-300 46 WA150-6
300 Power train
6. Removal of rear cage assembly (for rear 2) Use push tool [6] to push out pinion gear
differential) assembly (23) with the press.
1) Place and stabilize the rear differential
assembly on blocks [5].
2) Remove 2 slack adjusters (9).
3) Remove 2 bleeder screws (13).
4) Remove upper cover (12).
5) Remove holder (16) and coupling (17).
6) Remove the mounting bolts and remove
rear cage assembly (18).
a Check the thickness and quantity of the
shims.
3) Remove collar (24).

4) Use bearing puller [7] and push tool [6] to
push out bearing (25) by pressing pinion
gear (26) with the press.
7. Disassembly of rear cage assembly (for

rear differential)
1) Remove dust seal (21) and oil seal (22).
5) Remove bearing (27) and outer races (28)

and (29) from cage (30).
WA150-6 50-300 47
300 Power train
8. Disassembly of front cage assembly (for 4) Remove sun gear shaft (36).
front differential) 5) Remove disc (37), wave spring (38), plate
1) Remove nut (31) and holder (33). (39), disc (40), and wave spring (41) in order.
2) For the further disassembly procedure for

the front cage assembly, see steps 2) – 5)
in 7. Disassembly of rear cage assembly
shown above.
9. Brake
1) Place and stabilize the differential assem-
bly on blocks.
a The photo shows the rear differential.
a Remove both brakes according to the
2) Remove 2 hexagon socket head bolts
(34).
3) Remove outer plate (35).
50-300 48 WA150-6
300 Power train
10. Bearing carrier 4) Hit bearing carrier (44) with plastic ham-
a Remove both bearing carriers according mer [9] lightly to remove it from bearing
to the following procedure. carrier and piston assembly (46).
1) Sling differential carrier assembly (43)
temporarily.
2) Remove the mounting bolts for bearing
carriers (44), and then use forcing screws
[8] to remove bearing carrier and piston
assemblies (46) on both sides from bear-
ing carrier housing (45).
the shims.
a Identify the right and left bearing carri-
ers to avoid confusion.
5) Remove seal (49) and outer race (50)

from bearing carrier (44).
3) Remove seal (47) and ring (48) from bear-

ing carrier and piston assembly (46).
a Keep them with the shims.
11. Removal of differential carrier assembly

1) Lift off differential carrier assembly (43)
from differential housing (45).
a Remove carefully because the sling is
easy to come off.
a Do not damage the differential carrier
assembly by hitting it against the dif-
ferential case.
WA150-6 50-300 49
300 Power train
12. Disassembly of standard differential carrier Remove 4 spherical washers (58) and 4 pinion
assembly gears (59) from spider shaft (60).
a Identify the parts on both sides to avoid
confusion.
a Before disconnecting the bevel gear, put
the match marks on it and the case.
1) Remove 14 mounting bolts, and then
remove bevel gear (52).
6) Remove side gear (61).

7) Remove washer (62).
2) Turn the case upside down, and then

remove case (53).
3) Before disconnecting the case and
assembly, put the match marks on them.
a Disassembled parts
4) Remove washer (55) and side gear (56).

5) Remove pinion gear assembly (57).
50-300 50 WA150-6
300 Power train
8) Use puller [10] to remove bearing (63) from 2) Remove washer (71).
case (54), and then remove bearing (64) in 3) Remove plate (73).
case (53) on the other side similarly.
4) Remove disc (74), plate (75), and disc

13. Disassembly of limited-slip differential (76).
assembly (If equipped) 5) Remove pressure ring (77).
a If the machine is equipped with the lim- a Remove the pressure ring by insert-
ited-slip differential assembly, disassem- ing a finger into the hole on the side
ble it according to the following procedure. of the case and pull it up.
a Identify the parts on both sides to avoid 6) Remove side gear (78).
confusion.
a Before disconnecting the bevel gear, put
the match marks on it and the case.
1) Remove 16 mounting bolts, and then
remove bevel gear (70).
a If bevel gear (70) is too hard to
remove, thrust the bolt into case (72)
once and hit the bolt head.
7) Remove pinion gear assembly (79).
WA150-6 50-300 51
300 Power train
8) Remove 4 pinion gears (81) from spider 12) Remove washer (88).
shaft (80).
a Disassembled parts
9) Remove side gear (82).
10) Remove pressure ring (83).
13) Use push tool [21] to remove bearing (89)

from case (72).
11) Remove disc (84), plate (85), disc (86),
and plate (87) in order.
50-300 52 WA150-6
300 Power train
14) Use push tool [21] to remove bearing (90) Assembly

from bevel gear (70) similarly. a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with axle
oil (AXO80, Operation and Maintenance Man-
ual: refer to the Komatsu genuine replacement
parts table) before installing them.
1. Assembly of limited-slip differential assem-

bly (If equipped)
1) Use push tools [22] and [23] to install
bearing (90) into bevel gear (70).
2) Use push tool [22] to install bearing (89)
into case (72) similarly.
3) Install washer (88) into case (72).
WA150-6 50-300 53
300 Power train
4) Install plate (87), disc (86), plate (85), and 8) Install pinion gear assembly (79).
disc (84) from the bottom.
2 Soak the discs and plates in axle
oil (AXO80, Operation and Mainte-
nance Manual: refer to the Komatsu
genuine replacement parts table)
before installing them.
9) Install side gear (78).

10) Install pressure ring (77).
11) Install disc (76), plate (75), disc (74), and
plate (73) from the bottom.
2 Soak the discs and plates in axle oil
(AXO80, Operation and Maintenance
5) Install pressure ring (83). Manual: refer to the Komatsu genuine
6) Install side gear (82). replacement parts table) before installing
them.
7) Install 4 pinion gears (81) to spider shaft

(80).
50-300 54 WA150-6
300 Power train
12) Selection of thickness of plate

i) Use depth gauge [24] to measure dis-
tance (d) from the end surface of
case (72) to plate (73).
ii) Select the thickness of the plate so
that distance (d) will be 0.2 – 0.6 mm.
a Replace the plates on both sides at
the same time so that their thickness
(total of 2 pieces) will be the same,
and then assemble them by repeating
the above procedure from step 4).
q Varieties of plate thickness:
3.0 mm, 3.1 mm
15) Adjust the clearances of side gears (78)

and (82) in the axial direction.
i) Use clearance gauge [25] to measure
clearances (e) between side gear
(78) and washer (71) and between
side gear (82) and washer (88)
through the shaft holes on both sides
of the limited-slip differential.
q Clearances (e):
0.13 – 0.36 mm (on both sides)
a If the clearances are out of the standard
range, replace the washer with new one.
13) Install washer (71) to bevel gear (70).

a There are grooves at both sides of
the washer.
a Installing the washer to the bevel
gear, apply grease thinly to it so that it
will stuck to the bevel gear.
14) Install bevel gear (70) to case (72).
a Install bevel gear (70) by aligning the
match marks put when it was
removed.
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
WA150-6 50-300 55
300 Power train
16) Measure the operation torque under no load. 2. Assembly of standard differential carrier
i) Install sun gear shafts (36) to both assembly
s i d e s o f l i m i t e d - s l i p d i ff e r e n t i a l 1) Use push tools [11] and [12] to press fit
assembly (91). bearing (63) into case (54) on the bevel
ii) Fix the sun gear shaft on one side gear side with the press.
and install tool H7 to the sun gear 2) Similarly, use push tools [11] and [12] to
shaft on the other side. press fit bearing (64) into case (53) on the
iii) Install torque wrench [26] to tool H7 other side with the press.
and measure the operation torque
under no load.
a When measuring the torque, let the
case rotate freely.
q Operation torque under no load:
Max. 9.8 Nm {Max. 1.0 kgm}
q If the operation torque under no load
exceeds the standard value, disas-
semble the limited-slip differential
again and repeat 12) Selection of
thickness of plate and 15) Adjust the
clearance of the side gear in the axial
direction.
a Assembling parts
3) Install washer (62) into bevel gear case (54).

a Install the washer with the dimpled
side up (facing to the side gear).
50-300 56 WA150-6
300 Power train
5) Install 4 pinion gears (59) and 4 spherical 10) Stand up guide bolts [15] on bevel gear
washers (58) to spider shaft (60). (52), and then turn the case upside down
and install the case.
a Align the match marks put when the
case was removed.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
6) Install pinion gear assembly (57).

8) Install washer (55) into case (53).
a Install the washer with the dimpled
side up (toward the side gear).
a Installing the washer to the case,
apply axle oil or grease thinly to it so 3. Installation of differential assembly
that it will stuck to the case. Sling differential carrier assembly (43) and set
it to the mounting section on differential case
(45).
a Install carefully because the sling is easy
to come off.
a Do not damage the differential carrier
assembly by hitting it against the differen-
tial case.
9) Install case (53).

a Align the match marks put when the
case was removed.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
WA150-6 50-300 57
300 Power train
4. Bearing carrier
1) Install outer race (50) and seal (49) to
bearing carrier (44).
a Rotate piston several turns to smooth

the axle oil on the bearing.
4) Use push-pull gauge [17] to measure the
2) Install bearing carrier (44), ring (48) and starting torque in the tangential direction
seal (47) to piston (66). to the bevel gear.
2 Apply axle oil thinly to the piston q Starting torque:
and piston mounting section. 8.8 – 27.5 N {0.9 – 2.8 kg}
a If the starting torque is out of the stan-
dard range, adjust it by increasing or
decreasing the shim thickness of the
left and right side.
0.05 mm, 0.2 mm, 0.3 mm, 0.8 mm
a After the adjustment, the shim thick-
ness should be between 0.5 – 1.35
mm on each side.
3) Apply axle oil to the bearing, and then use

guide bolt [16] to install shim (67) and
bearing carrier and piston assembly (46).
a Install the shims of the thickness and
quantity checked when disassem-
bled to each bearing carrier. Install
the bearing carriers on both sides.
a Turning the bevel gear, tighten the
mounting bolts.
2 Bearing: Axle oil
3 Mounting bolt for bearing carrier
and piston assembly (46):
59 – 74 Nm {6.0 – 7.5 kgm}
50-300 58 WA150-6
300 Power train
5. Assembly of front cage assembly (for front 6) Install holder (33) and nut (31).
differential) a Be sure to use new nut (31).
1) Install outer races (29) and (28) to cage (30). 7) Use tool H6 (for details, see 4. Removal of
front cage assembly) to tighten nut (31) to
the specified torque.
a Secure the assembly at the maximum
diameter of the pinion gear with a
vise.
3 Mounting nut:
392 – 539 Nm {40 – 55 kgm}
2) Use push tool H8 to press fit bearing (25)

into pinion gear (26) with the press.
3) Install collar (24).
8) Apply axle oil to the bearing and rotate the

cage several turns to smooth the axle oil,
and then measure and check the follow-
ings.
2 Bearing: Axle oil
q End play amount: 0 – 0.150 mm
q Torque at cage mounting hole (A)
(Not static friction but kinetic friction):
0 – 17.7 N {0 – 1.8 kg}
a If the cage is too heavy to rotate,
4) Stand up pinion gear assembly (23), and replace the bearing, and then check
then install cage (30). the torque again.
5) Install bearing (27) to pinion gear assem-
bly (23).
a Install the bearing by shrink fit at tem-
perature below 100°C or by press fit
with the press using tool H9.
a Collar (24) should not be dropped and
make any sound even if the pinion
gear assembly is turned upside down.
WA150-6 50-300 59
300 Power train
6. Assembly of rear cage assembly (for rear 5) Remove coupling (17), and then use tool
differential) H10 to press fit oil seal (22).
1) Assemble the rear cage assembly by a Press fit depth (distance from the top
referring to 5. Assembly of front cage of oil case to end surface of cage):
assembly, steps 1) – 5). 10 ± 0.5 mm (press fit tool H10 until
2) Apply axle oil to the bearing and rotate the the end of the tool reaches to the end
cage several turns to smooth the axle oil. surface of the cage).
2 Bearing: Axle oil 2 Oil seal: Grease (G2-LI)
3) Install coupling (17).
2 Contact surfaces of coupling and
bearing:
Lubricant containing molybde-
num disulfide (LM-G or LM-P)
3 Mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
6) Use tool H12 to press fit dust seal (21).

a Press the dust seal until its top is flush
with the end surface of the cage (press fit
tool H12 until the end of the tool reaches
to the end surface of the cage).
2 Lip surface of seal ring:
Grease (G2-LI)
4) Rotate the cage several turns to smooth
the axle oil, and then measure and check
the followings.
q End play amount: 0 – 0.150 mm
q Torque at cage mounting hole (A)
(Not static friction but kinetic friction):
0 – 17.7 Nm {0 – 1.8 kg}
a If the cage is too heavy to rotate,
replace the bearing, and then check
the torque again.
7) Install coupling (17).

3 Mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
50-300 60 WA150-6
300 Power train
7. Installation of front cage assembly (for 9. Adjustment of backlash

front differential) 1) Measure the backlash of the bevel gear
Install guide bolts [4] to the differential case with dial gauge [20].
assembly and install shim (93) and O-ring, and q Standard value for backlash:
then install front cage assembly (15). 0.18 – 0.28 mm
a Install the shims of the thickness and a Measure the backlash at 3 places on
quantity checked when disassembled. the periphery of the bevel gear and
q Adjustment allowance of shims: check that the dispersion of the mea-
0.50 – 1.35 mm sured values is 0.1 mm or less.
0.05 mm, 0.2 mm, 0.3 mm, 0.8 mm
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
2) If the measured backlash is out of the

standard range, adjust it by moving a part
of the shims on either side to the opposite
side.
8. Installation of rear cage assembly (for rear a Do not change the total thickness of
differential) the shims on both sides.
Install guide bolt [18] to the differential case a If the backlash is insufficient, move a
assembly and install shim (94) and O-ring, and part of shims (g) to shims (f) (move
then install rear cage assembly (18). the bevel gear toward (A) (the right in
a For the adjustment of the shims and tight- the illustration)).
ening torque, see 7. Installation of front a If the backlash is too large, move a
cage assembly. part of shims (f) to shims (g) (move
the bevel gear toward (B) (the left in
the illustration)).
WA150-6 50-300 61
300 Power train
11. Adjustment of tooth contact

1) If the tooth contact pattern is not proper,
perform the adjustment.
a Adjust the tooth contact by increasing
or decreasing the shims on both sides
of the bearing carrier (by moving the
bevel gear) and the shims on the
cage assembly (by moving the bevel
pinion).
a After adjusting the tooth contact,
check the backlash again.
2) When the bevel pinion is too far from the
bevel gear, the tooth contact pattern will
be as follows.
q In this case, adjust the tooth contact
q Decrease the shims on the cage
assembly (on the bevel pinion side) to
move the cage assembly toward (C).
q Adjust the shims on both sides of the
bearing carrier to move the bevel
gear toward (D) to move it far from
the bevel pinion.
a Do not change the total thickness of
the shims on both sides of the bear-
ing carrier.
10. Test of tooth contact

1) Apply red lead thinly to the surfaces of the
bevel gear teeth and turn the bevel gear to
both directions, then check the tooth con-
tact pattern on the bevel gear.
a The center of the tooth contact must
be as follows.
q Middle of tooth height
q Point on a tooth at which the dis-
tance of (x) from small end (c) is
22 ± 3 mm
a Width (y) of the tooth contact must be
26 ± 3 mm
a Check that there is no strong contact
at tip (A), bottom (B), small end (C),
or large end (D).
50-300 62 WA150-6
300 Power train
3) If the bevel pinion is too close to the bevel 5) If the bevel gear is too far from the bevel
gear, the tooth contact pattern will be as pinion, the tooth contact pattern will be as
follows. follows.
In this case, adjust the tooth contact In this case, adjust the tooth contact
according to the following procedure. according to the following procedure.
q Increase the shims on the cage q Increase the shims on the cage
assembly (on the bevel pinion side) to assembly (on the bevel pinion side) to
move the cage assembly toward (E). move the cage assembly toward (E).
q Adjust the shims on both sides of the q Adjust the shims on both sides of the
bearing carrier to move bevel gear bearing carrier to move bevel gear
toward (F) to move it close to the toward (F) to move it close to the
bevel pinion. bevel pinion.
a Do not change the total thickness of a Do not change the total thickness of
the shims on both sides of the bear- the shims on both sides of the bear-
ing carrier. ing carrier.
4) If the bevel gear is too close to the bevel 12. Brake

pinion, the tooth contact pattern will be as a The photo shows the rear differential.
follows. a Remove both brakes according to the following
In this case, adjust the tooth contact procedure.
according to the following procedure. 1) Use tool H11 to press fit the piston evenly.
q Decrease the shims on the cage a Press fit the piston until it reaches to
assembly (on the bevel pinion side) to the housing.
move the cage assembly toward (C). a Do not hit the piston with a plastic
q Adjust the shims on both sides of the hammer, etc. to press fit it (the O-ring
bearing carrier to move the bevel and piston may be damaged).
gear toward (D) to move it far from
the bevel pinion.
a Do not change the total thickness of
the shims on both sides of the bear-
ing carrier.
WA150-6 50-300 63
300 Power train
a Assembling parts a Install both brakes according to the

same procedure.
7) Install bleeder screws (13).
8) Install tool H15.
a Tool H15 can be installed when
checking for the brake oil leakage.
9) Set plates [28] (equivalent to tool H11)
and use tool H5 to supply air into the
brake oil port to fit the piston.
k Set the plates before supplying air,
because the piston may jump out.
2) Install wave spring (41) so that cut-out

portion (h) will be within A in the brake oil
port (95).
3) Install and set disc (37), plate (39), and
disc (40) to sun gear shaft (36).
4) Install wave spring (38) so that cut-out por-
tion (h) will be within A in brake oil port (95).
a On the other side or the front axle,
install the wave spring so that cut-out
portion (h) will be within A in brake oil
port (95) similarly. 13. Check for brake oil leakage
a Use tool H15 because there will be a
drop in pressure at the low-pressure
leakage test due to the adverse effect of
the piston on the slack adjuster.
1) Leave plates [28] (equivalent to tool H11)
as being set.
k Do not check for the brake oil leak-
age without setting the plates
because the piston may jump out.
2) Install tool H15, nipple H14 and pump H13
to the brake port and bleed all air through
the bleeder.
a Bleed air by operating pump H13.
5) Install outer plate (35).

6) Install 2 hexagon socket head bolts (34).
50-300 64 WA150-6
300 Power train
3) Perform the low-pressure oil leakage test. 14. Top cover

a Operate tool H13 to raise the pres- 1) Remove bleeder screws (13) temporarily
sure to 98 kPa {1 kg/cm2}. and install top cover (12).
a Leave the pressure at 98 kPa {1 kg/ 2 Mating face of cover:
cm 2 } for 5 minutes and check that Adhesive (LOCTITE 515 or equivalent)
there is no drop in pressure at all. 3 Mounting bolt:
a If the oil leakage is found (the pres- 98 – 123 Nm {10 – 12.5 kgm}
sure drop is more than the standard), 2) Install bleeder screws (13).
remove the brake piston and check 3) Install slack adjusters (9) on both sides.
the seals for damage. a Take care that the O-ring will not
a Do not move the hose during measur- come off.
ing the pressure because the pres- a Check that slack adjusters (9) are
sure may fluctuate. installed on both sides instead of
4) Perform the high-pressure oil leakage tool [27].
test. 3 Mounting bolt:
a If no low-pressure brake oil leakage is 98 – 123 Nm {10 – 12.5 kgm}
found, operate tool H13 to raise the
pressure to 4,410 kPa {45 kg/cm2}.
a Check that the shaft on the test side
does not rotate even if the coupling is
rotated.
a Leave the pressure at 4,410 kPa {45
kg/cm2} for 5 minutes and check that
the pressure does not drop more than
98 kPa {1 kg/cm2}.
a If the oil leakage is found (the pres-
sure drop is more than the standard),
remove the brake piston and check
the seals for damage.
a Do not move the hose during measur-
ing the pressure because the pres-
15. Axle housing
sure may fluctuate.
1) Remove the axle housing on both sides by
5) Remove pump H13, nipple H14, tool [27],
referring to 7. Axle housing assembly in
and plate [28] (equivalent to tool H11) and
"Disassembly and assembly of axle hous-
perform the test on the other side.
ing assembly."
2) On the rear differential, install the rear axle
support and brake tube and hose assem-
bly by referring to subsequent 8.
a Perform the following steps 16 – 18
only for the front differential.
WA150-6 50-300 65
300 Power train
16. Axle oil temperature sensor (for front differ- 17. Disassembly of long cage assembly (for
ential) front differential)
1) Install axle oil temperature sensor and 1) Use push tool [30] to press fit bearing
harness assembly (11). (107) into shaft (7) with the press.
a Install the axle oil temperature sensor a Install the bearing with the shield side
at the rear of cover (10). (G) down.
2 Threads: Gasket sealant (LG-5) 2) Use push tool [31] to press fit shaft and
3 Axle oil temperature sensor: bearing assembly (108) to long cage
29.4 – 49 Nm {3 – 5 kgm} (109).
2) Install cover (10).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
3) Install oil temperature sensor clamp (96).
3 Mounting bolt for clamp (96):
27 – 34 Nm {2.8 – 3.5 kgm}
4) Install brake tube assembly (8).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
3) Install ring (106) and snap ring (105) to

long cage assembly (4).
4) Use tools H10 and H12 to press fit oil seal

(6) and dust seal (5), respectively by refer-
ring to the steps 5) and 6) in 6. Assembly
of rear cage assembly.
50-300 66 WA150-6
300 Power train
18. Installation of long cage assembly (for front

differential)
1) Sling and install long cage assembly (4).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
2) Install coupling (3) and holder (2).
2 Contact surfaces of coupling and
bearing:
num disulfide (LM-G) or (LM-P)
3 Mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
q Refilling with oil (Axle housing)

Tighten the drain plug and add oil to the speci-
fied level through the oil filler.
3 Drain plug: 58.8 – 78.4 Nm {6 – 8 kgm}
3 Oil filler plug:
93.1 – 122.5 Nm {9.5 – 12.5 kgm}
5 Axle oil AXO80 (front): 14.5 l
(rear): 14 l
WA150-6 50-300 67
SEN05187-01

©2010 KOMATSU
All Rights Reserved
50-300 68
SEN05188-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

Removal and installation of center hinge pin .................................................................................................. 2
Removal and installation of counterweight ................................................................................................... 10
WA150-6 50-400 1
SEN05188-00 Removal and installation of center hinge pin
Removal and installation of center 5. Loosen the drain valve to drain the coolant.
hinge pin 1 6 Radiator: 14.6 l
Special tools 6. Remove operator's cab and floor frame
New/Remodel
assembly. For details, see "Removal and
Necessity
installation of operator's cab and floor frame
Sketch
Q'ty
Symbol Part No. Part Name assembly".
K 1 790-201-2750 Push tool t 1
Removal
rear frames.
1. Raise the front part of the chassis with the

work equipment and set block [1] under the
frame at the rear of the front wheels.
2. Set the work equipment horizontally and raise

the rear part of the chassis and set block [2]
under the frame at the front of the rear wheels.
3. Raise the counterweight with hydraulic jack [3],

and set stands [4].
a Disconnect the cable from the negative (–)
k If the radiator coolant temperature is
high, you may scald yourself with the
hot coolant when disconnecting the
heater hoses and draining the cool-
ant. Wait until the coolant is cooled, 7. Disconnect front drive shaft (1) from the trans-
and then drain the coolant. fer. [*2]
4. Collect the air conditioner refrigerant (R134a)

from air conditioner circuit in advance. [*1]
a Ask professional traders for collecting and
filling operation of refrigerant.
a Never release the refrigerant to the atmo-
sphere.
k If refrigerant gets in your eyes, you
may lose your sight. Accordingly, put
on protective goggles, gloves and
working suits with long sleeves while
you are collecting the refrigerant or fill-
ing the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified per-
son.
q Refrigerant quantity: 900 ± 50 g
50-400 2 WA150-6
Removal and installation of center hinge pin SEN05188-00
8. Disconnect all wiring harness clamps (2)

between the front frame and rear frame from
the rear frame.
13. Disconnect hoses (14) and (15) from steering

cylinder (both side of left and right).
9. Remove cover (5). 14. Disconnect brake hose (16).
15. Remove bolt (17) and pin (17a) from the bot-
tom side of steering cylinder and disconnect
the steering cylinder (18) (both side of left and
right). [*4]
10. Disconnect the PPC hoses (6) – (10) from the

work equipment valve. [*3]
12. Disconnect port P hose (11) and port T hose

(13).
a Since oil will leak through the discon- 17. Disconnect hose clamps (20) and (21).
nected hoses and tubes, prepare oil
receivers. 18. Remove bracket (22).
19. Disconnect hoses (23) and (24).
WA150-6 50-400 3
20. Remove lower hinge pin (26). [*5] 22. Disconnect the front frame and the rear frame.
1) Remove lock bolt (25). [*8]
2) Remove lower hinge pin (26). 1) Set hand lift truck [4] under the bucket.
21. Remove upper hinge pin (28). [*6] 2) Use a tool such as a bar to lift up front
1) Remove mounting nut (27). frame assembly (30) by 2 – 3 mm, and
2) Remove the mounting bolts (27a). then move lower spacer (31) from rear
frame assembly (32).
a The front frame assembly may be
lifted up by 2 – 3 mm with a large-
sized crane, if available.
3) Adjust the heights of the front frame and

the rear frame with the hydraulic jack so
that the pin can be pulled out easily, and
then remove upper hinge pin (28). [*7]
4) Remove shims (29). 3) Turn the tires to move front frame assem-
a Check the thickness and quantity of bly (30) forward.
the shims.
50-400 4 WA150-6
23. Disassemble the lower hinge of front frame 25. Remove 2 bushings (44) from the lower hinge
(30). [*9] of the rear frame. [*11]
1) Remove washer (33).
2) Remove snap rings (34) and (35) and
bearing roller (36).
24. Disassemble the upper hinge of front frame

(30). [*10]
1) Remove lower spacer (31).
2) Remove dust seal (37).
3) Remove retainer (38) and shim (39).
the shims.
4) Remove bushing (40) and dust seal (41)
from retainer (38).
5) Use push tool [5] to remove bearings (42)

and spacer (43).
WA150-6 50-400 5
Installation [*4]
q Carry out installation in the reverse order to a Adjust the shim so that the total of the upper
removal. and lower clearances between the frame and
cylinder will be 0 – 1.0 mm.
[*1] q Varieties of shim thickness: 0.5 mm
a When installing the hoses of the air conditioner 2 Inside of bushing on cylinder side and dust
circuit, take care that dirt, dust, water, etc. will seal: Lubricant containing molybdenum
not enter them. disulfide (LM-P)
a When installing each air conditioner hose,
check that O-ring (70) is fitted to it. [*5] [*6] [*7] [*8]
a Check O-ring (70) for a flaw and deterioration. a Install the upper hinge pin and lower hinge pin
a When connecting each refrigerant pipe, apply according to the following procedure.
compressor oil for new refrigerant (R134a).
3 Threaded part of hose (M16 × 1.5): 1. Set hand lift truck [4] under the bucket and turn
12 – 15 Nm {1.2 – 1.5 kgm} the tires to move the front frame assembly
3 Threaded part of hose (M22 × 1.5): toward the rear frame.
20 – 25 Nm {2.0 – 2.5 kgm}
3 Threaded part of hose (M24 × 1.5):
30 – 35 Nm {3.0 – 3.5 kgm}
CPW11631
2. Use a tool (such as a bar) to lift up front frame

assembly (30) by 2 – 3 mm, and then move
spacer (31) to the spacer of rear frame assem-
[*2] bly (32).
3 Front drive shaft mounting bolt: a The front frame assembly may be lifted up
59 – 74 Nm {6.0 – 7.5 kgm} by 2 – 3 mm with a large-sized crane, if
a Installing the drive shaft, check that the key available.
groove for the spider cap is fitted in the key
groove for the mating yoke, and then tighten
the mounting bolt.
[*3]
a Connect PPC hoses (7) – (10) according to
their band colors shown below.
q Work equipment lever specification: monolever
No. Connecting point Band color
(7) Bucket DUMP Blue
(8) Bucket TILT Red
(9) Lift arm LOWER Orange
(10) Lift arm RAISE Yellow
3. Align the upper and lower pin holes.
a Use a hydraulic jack to adjust the height of
the front and rear frames and align the pin
holes.
k Aligning the pin holes, use a bar. Never
insert your fingers into the pin holes.
50-400 6 WA150-6
4. Insert upper hinge pin (28) and lower hinge pin 8. Loosen mounting nut (27) and space upper
(26) to the end. hinge pin (28). Insert selected shim (29)
a Do not insert the shim for the upper hinge between upper hinge pin (28) and the rear
pin. frame and tighten 4 mounting bolts.
2 Mounting bolt:
5. Install lock bolt (25) for lower hinge pin (26). Adhesive (LOCTITE #2701)
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
9. Tighten mounting nut (27) for upper hinge pin

(28).
3 Mounting nut:
509.6 – 607.6 Nm {52 – 62 kgm}
6. Tighten mounting nut (27). Do not tighten the

mounting bolts for upper hinge pin (28).
3 Mounting nut:
509.6 – 607.6 Nm {52 – 62 kgm}
7. Measure the clearance between the under sur-

face of the flange for upper hinge pin (28) and
the upper surface of the rear frame with the [*9] [*10] [*11]
feeler gauge, and then select shims so that the a Assemble the upper hinge and lower hinge
maximum clearance will be 0.4 mm or less. according to the following procedure.
q Standard shim thickness : 0.8 mm 1. Install 2 bushings (44) to the lower hinge of the
q Varieties of shim thickness: 0.4 mm rear frame.
WA150-6 50-400 7
2. Assemble the upper hinge of the front frame. 4) Press fit dust seal (41) into retainer (38).
1) Use push tool K1 [6] to press fit bearings a Press fit the dust seal with the lip out.
(42) and spacer (43) into the front frame. 2 Lip of dust seal: Grease (G2-LI)
a Press fit bearings (42) and spacer
(43) securely so that no clearance will
be made between the bearing and the
frame.
2 Bearing: Grease (G2-LI)
5) Tighten the mounting bolts for retainer

(38) to the following torque to determine
the thickness of the shims.
3 Retainer mounting bolt:
3.92 – 5.88 Nm {0.4 – 0.6 kgm}
2) Press fit dust seal (37) into the front frame. 6) Measure clearance (a) between retainer
2 Outside of dust seal: (38) and the front frame with the feeler
LOCTITE #601 gauge, and then select shims so that the
a Press fit the dust seal with the lip out. maximum clearance will be 0.1 – 0.2 mm
2 Lip of dust seal: Grease (G2-LI) when the shims are inserted.
3) Install lower spacer (31). q Standard shim thickness: 1.3 mm
a Install the spacer with the chamfered q Varieties of shim thickness:
part to the bearing side. 0.1 mm, 0.5 mm
2 Lower spacer:
num disulfide (LM-P)
7) Insert selected shim (39) and tighten 4

mounting bolts.
3 Retainer mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
50-400 8 WA150-6
3. Install upper spacer (40). q Charging the air conditioner circuit with
a Install the spacer with the chamfered part refrigerant (R134a)
to the bearing side. Charge the air conditioner circuit with refriger-
2 Upper spacer: ant (R134a).
Lubricant containing molybdenum a Quantity of refrigerant: 900 ± 50 g
disulfide (LM-P)
Add oil to the specified level through the oil
filler and start the engine to circulate the oil
again.

Add coolant up to the specified level.
Run the engine to circulate the coolant through
the system.
Then, check the coolant level again.
4. Assemble the lower hinge of the front frame.

1) Install bearing roller (36).
2 Bearing: Grease (G2-LI)
2 Seal lip: Grease (G2-LI)
2) Install snap rings (34) and (35) and
washer (33).
WA150-6 50-400 9
SEN05188-00 Removal and installation of counterweight
Removal and installation of 6. Disconnect lamp (8) according to the following

counterweight 1
procedure. (If equipped)
1) Remove cover (9a).
Removal 2) Disconnect wiring harness clamp (9b).
k Stop the machine on a level place and set 3) Disconnect lamp (8) and place it on the
the lock bar to the frame. battery case.
1. Open and fix left engine side cover (1).

a Check that the cover is locked securely.
2. Open grille (2) and sling it temporarily.
7. Sling counterweight (10) temporarily and

remove the mounting bolts (11), and then
remove the counterweight. [*1]
3. Disconnect wiring harness connector (3), and

clamps (4), (5).
4. Disconnect gas springs (6) on both sides.
5. Remove 4 mounting bolts (7) and lift off grille.
4 Counterweight: 650 kg
Installation
removal.
[*1]
3 Mounting bolt:
785 – 980 Nm {80 – 100 kgm}
50-400 10 WA150-6
Removal and installation of counterweight SEN05188-00
WA150-6 50-400 11
SEN05188-00

©2009 KOMATSU
All Rights Reserved
50-400 12
SEN05189-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

Removal and installation of transfer and HST pump and 3-gear pump assembly .......................................... 2
Removal and installation of HST motor 1 assembly ....................................................................................... 6
Removal and installation of HST motor 2 assembly ....................................................................................... 9
Removal and installation of work equipment control valve assembly ............................................................11
Removal and installation of hydraulic tank assembly.................................................................................... 14
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 16
WA150-6 50-500 1
SEN05189-00 Removal and installation of transfer and HST pump and 3-gear pump assembly
Removal and installation of 3. Remove the operator’s cab assembly. For

transfer and HST pump and details, see "Removal and installation of opera-
tor’s cab assembly".
3-gear pump assembly 1
Removal 4. Disconnect wiring harness connector CN-T01

k Stop the machine on a level ground and set (2) and clamp (3).
rear frames.
100 times.
5. Disconnect the following hoses.
1. Collect refrigerant (R134a) beforehand. (4): Transfer suction hose
(5), (6): Hose between accumulator charge
a Ask professional traders for collecting and valve A port and fan motor
filling the refrigerant (R134a). a After disconnecting hose (5), remove
a Never release the refrigerant (R134a) to bolt (6a) to disconnect hose (6) from
the atmosphere. suction tube (13).
k If the refrigerant (R134a) gets in your (7): Hose (Transfer clutch valve return)
eyes, you may lose your sight. Accord- (8): Hose (HST motor 1 T2 port)
ingly, put on protective goggles, gloves
the refrigerant.
Collecting and filling work must be
conducted by a qualified person.
2. Loosen drain valve (1) and drain coolant.

6 Coolant: 14.6 l
50-500 2 WA150-6
Removal and installation of transfer and HST pump and 3-gear pump assembly SEN05189-00
(9): HST pump T-port hose (20): Hose between steering pump and prior-
(10): Brake inching valve P-port hose ity P-port
a Disconnect hose clamp (10a). (21): Hose between brake pump and charge
(11): Hose between HST pump G-port and valve P-port
accumulator
(12): Motor 2 T2-port hose
(13): Steering pump suction tube [*1]
1) Remove bolts (13a) to disconnect
tube (13) from pump.
2) Loosen clamps (14a) of hose (14),
then remove tube (13) and hose (14)
together.
a Mark the hose edge and tube to
show the original hose installa-
tion position.
(22): Hose between HST pump FA-port hose

(23): Hose between HST pump FE-port hose
(15): Hose between HST pump and HST

motor 1 B-port
motor 1 A-port
motor 2 B-port (24): Hose
motor 2 A-port
(19): Drain hose between HST pump and
hydraulic tank
WA150-6 50-500 3
SEN05189-00 Removal and installation of transfer and HST pump and 3-gear pump assembly
(25): Hose clamp
6. Sling HST pump and 3-gear pump assembly

(27) temporarily, and remove 2 mount bolts
(26a) (M16) and 4 mount bolts (26b) (M12).
[*2]
7. Lift off HST pump and 3-gear pump assembly

(27).
a Sling the HST pump and 3-gear pump
assembly horizontally and pull off them
carefully to avoid to damage HST pump
drive boss.
a Lift off the HST pump and 3-gear pump
assembly carefully, after pulling out HST
pump and 3-gear pump assembly from
engine completely.
4 HST pump and 3-gear pump assembly:
110 kg
50-500 4 WA150-6
Removal and installation of transfer and HST pump and 3-gear pump assembly SEN05189-00
Installation a If boss (27) is removed from HST pump

q Carry out installation in the reverse order to assembly, install it according to the following
removal. procedure.
q Install boss (28) with bolt (30) so that dis-
[*1] tance (X) from the end of surface of boss
a Align the hose to the original position (marking (28) to the end surface of pump shaft (29)
position). will be 5 – 5.5 mm.
(Reference)
a Outside clamp mounting portion (L2):
12 mm
a Inside clamp mounting portion (L3):
46 mm
q Hydraulic tank side

12 mm
a Inside clamp mounting portion (L6):
46 mm

2 Hose inserting portion: Gasket sealant
(THREEBOND PANDO 0192A or equivalent)
3 Hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
q Charging with refrigerant (R134a).

Charge the air conditioner circuit with refriger-
ant (R134a).
a Do not start engine before charging with
[*3]
a Sling the HST pump and 3-gear pump assem-
bly horizontally and install them carefully to
level.
avoid to damage HST pump drive boss.
a Align the center of the pump assembly with
system.
that of the crankshaft and install the pump
Then check the oil level again.
assembly to the engine side, taking care that
its boss portion does not interfere with the
peripheral parts.
3 HST pump mounting bolts:
(M16 bolt): 235 – 285 Nm {23.5 – 29.5 kgm}
(M12 bolt): 98 – 123 Nm {10.0 – 12.5 kgm} coolant level again.
5 Total amount of coolant: 14.6 l (For details,
cants".)
WA150-6 50-500 5
SEN05189-00 Removal and installation of HST motor 1 assembly
Removal and installation of HST 3. Remove the operator’s cab assembly. For
motor 1 assembly 1
details, see "Removal and installation of opera-
Removal
k Stop the machine on a level ground and set 4. Disconnect wiring harness connector CN-T06
the lock bar to the frame to fix the front and (2).
rear frames.
10 times.
1. Collect refrigerant (R134a) beforehand. 5. Disconnect wiring harness clamp (3), pull off
a Ask professional traders for collecting and the wiring harness with connector CN-T06 (2)
filling the refrigerant (R134a). from clamp (3).
the atmosphere. 6. Disconnect hose (4) from HST motor 1.
k If the refrigerant (R134a) gets in your 7. Disconnect hoses (5) and (6).
person.
q Collecting quantity: 900 ± 50g

6 Coolant: 14.6 l
8. Disconnect valve (7).

a To prevent from damaging when lifting off
the HST motor 1.
50-500 6 WA150-6
Removal and installation of HST motor 1 assembly SEN05189-00
9. Disconnect hoses (6) and (7). Installation

10. Remove accumulators (8). [*1] removal.
a Confirm the installing positions of upper
and lower accumulators. [*1]
q Install accumulators according to the following
procedure.
1) Set the accumulator (12) to the bracket
with the clamp (13).
a Confirm the installing portion.
2) Connect hose (7).
3) Fix accumulator (12) with clamp (13).
11. Disconnect hose (9).
4) Set the accumulator (14) to the bracket

with the clamp (15).
a Confirm the installing portion.
5) Connect hose (16).
6) Fix accumulator (14) with clamp (15).
12. Sling HST motor 1 assembly (10) temporarily,

and remove mounting bolts (11). [*2]
13. Lift off HST motor 1 assembly (10).

4 HST motor 1 assembly: 30 kg
[*2]
3 HST motor 1 mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
WA150-6 50-500 7

ant (R134a).

level.
system.
Then, check the oil level again.

coolant through the system. Then, check the
5 Total amount of coolant:
14.6 l (For details, see "Table of fuel,
coolant and lubricants".)
50-500 8 WA150-6
Removal and installation of HST motor 2 assembly SEN05189-00
Removal and installation of HST 3. Remove the operator’s cab assembly. For
motor 2 assembly 1
details, see "Removal and installation of opera-
Removal
k Stop the machine on a level ground and set 4. Disconnect wiring harness connector CN-T11
the lock bar to the frame to fix the front and (2).
rear frames.
10 times.
1. Collect refrigerant (R134a) beforehand. 5. Disconnect wiring harness connector CN-T07

a Ask professional traders for collecting (3) and CN-T10 (4).
a Never release the refrigerant (R134a) to 6. Disconnect clamp (5).
the atmosphere.
7. Disconnect hose (6) from HST motor 2.
eyes, you may lose your sight. Accord- 8. Disconnect hoses (7) and (8) from HST motor 2.
person.

6 Coolant: 14.6 l
9. Disconnect hose (9).
WA150-6 50-500 9
10. Sling HST motor 2 assembly (10) temporarily, Installation

and remove mounting bolts (11). [*2] q Carry out installation in the reverse order to
removal.
11. Lift off HST motor 2 assembly (10).
4
[*1]
3
HST motor 2 assembly: 30 kg
HST motor 2 mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}

ant (R134a).

level.
system.

5 Total amount of coolant:
14.6 l (For details, see "Table of fuel,
coolant and lubricants".)
50-500 10 WA150-6
Removal and installation of work equipment control valve assembly SEN05189-00
Removal and installation of work 4. Disconnect wiring harness F07 (2).

equipment control valve
5. Disconnect tubes (3) and (4) between B3-port
assembly 1
and bottom side of lift cylinder, hose (5)
Removal between contr ol valve and acc umulator
1. Stop the machine on a level ground and articu- according to the following procedure.
late machine to the left side fully. 1) Disconnect tube (3) from B3-port (bottom
side of lift cylinder).
2. Raise the lift arm, and dump the bucket, then 2) Disconnect left and right hoses which are
support the lift arm with stand [1]. connected to the tube (3) at (HA) portion.
3) Remove left and right tube clamps (6) to
remove tube (3).
4) Disconnect hose (5) between T-port and
accumulator.
5) Disconnect tube (4) from A3-port (head
side of lift cylinder).
6) Disconnect left and right hoses which are
connected to the tube (4) at (HB) portion.
7) Remove left and right tube clamps (7) to
remove tube (4).
k Stop the engine, apply the parking brake

k Operate the work equipment control lever 2 –
3 times to release the residual pressure in
the work equipment circuit.
a Put tags to hoses and wiring harness and
record the installed portions etc. on them.
WA150-6 50-500 11
SEN05189-00 Removal and installation of work equipment control valve assembly
6. Disconnect the following hoses, tube and wir- 7. Remove work equipment control valve accord-
ing harness connector from control valve ing to the following procedure.
assembly. 1) Set guide plate [2].
(8): B2-port hose (for bucket bottom)
(9): ACC-port hose
(10): PB1-port hose (for bucket DUMP)
(11): PB2-port PPC hose (for boom RAISE)
2) Loosen work equipment control valve

(12): P-port hose

(13): A2-port hose (for bucket head)
3) Disconnect wiring harness connector CN-

F03 (18) (for bucket positioner), CN-F04
(19) (for boom positioner) and clamps of
wiring harness (21).
(14): PA2-port PPC hose (for boom DUMP) a CN-F04: If equipped.
(15): PA3-port PPC hose (for bucket DUMP) 4) Disconnect grommet (20) and pull out the
(16): TS port wiring harness (21) to inside of frame.
50-500 12 WA150-6
Removal and installation of work equipment control valve assembly SEN05189-00
7) Pull out the work equipment control valve

assembly (22).
5) Sling work equipment control valve

assembly (22) through port (P) tempo-
rarily.
Installation
removal.

level.
system.
6) Remove the work equipment control valve

mounting bolts, and lift down work equip-
ment control valve assembly (22) to the
guide plate [2].
4 Work equipment control valve
assembly: 40 kg
WA150-6 50-500 13
SEN05189-00 Removal and installation of hydraulic tank assembly
Removal and installation of 5. Remove side covers (2) and (3).

hydraulic tank assembly 1
Removal
rear frames.
a Put tags to hoses and wiring harness and 6. Remove tube (4).
record the installed portions etc. on them.
7. Disconnect hoses (5) and (6).
1. Loosen hydraulic tank drain valve (1) and drain
oil.
6 Hydraulic tank: 47 l
8. Tie oil filter assembly with rope [1] to frame and

remove mounting bolts (7).
2. Remove fender (15).
3. Remove ladder (16).
4. Remove hydraulic tank cover (17).
50-500 14 WA150-6
Removal and installation of hydraulic tank assembly SEN05189-00
9. Disconnect hoses (8), (9) and (10). Installation

removal.
[*1]
position).
(Reference)
12 mm
a Inside clamp mounting portion (L3): 46 mm
q Hydraulic tank side

10. Disconnect hose (11) (for work equipment a Inserted hose length (L5): 78 mm
pump. [*1] a Outside clamp mounting portion (L5):
a Mark the hose edge and tube to show the 12 mm
original hose installation position. a Inside clamp mounting portion (L6): 46 mm
11. Disconnect hose (12) (for HST pump). a Inner and outer clamps must be set up in a
12. Sling hydraulic tank assembly (13) temporarily 2 Hose inserting portion: Gasket sealant
and remove 4 mounting bolts (14). [*2] (THREEBOND PANDO 0192A or equivalent)
(Upper): 2 pieces 3 Hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
(Left side):1 piece
(Lower): 1 piece
13. Lift off hydraulic tank assembly (13).

4 Hydraulic tank assembly: 85 kg
[*2]
3 Hydraulic tank mounting bolts:
98 – 123 Nm {10.0 – 12.5 kgm}

level.
system.
5 Hydraulic tank:
47 l (EO10W30-DH or TOS5W30)
(For details, see "Table of fuel, cool-
ant and lubricants".)
WA150-6 50-500 15
SEN05189-00 Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1 1. Cylinder assembly
Set cylinder assembly (1) to tool U1.
Special tools
2. Cylinder head and piston rod assembly
New/Remodel
Necessity
1) Use tool U2 to remove cylinder head (2)
Sketch
Q'ty
Symbol Part No. Part Name from cylinder.
790-502-1003 Repair stand t 1

1
790-101-1102 Hydraulic pump t 1
2 790-102-3802 Wrench assembly t 1
3 790-302-1290 Socket t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
• Push tool
4 790-201-1781 1
(Lift arm)
• Push tool
790-201-1771 1
(Bucket)
2) Pull out cylinder head and piston rod
• Push tool assembly (3) from cylinder (4).
790-201-1721 1
(Steering)
a Since oil will flow out when the piston
790-201-1500 Push tool kit t 1 rod assembly is pulled out of the cyl-
U 790-101-5021 • Grip 1 inder, prepare an oil receiver.
01010-50816 • Bolt 1
• Plate
5 790-210-1590 1
(Lift arm)
• Plate
790-201-1580 1
(Bucket)
• Plate
790-201-1530 1
(Steering)
6 790-720-1000 Expander q 1
796-720-1660 Ring q 1
Clamp
07281-01159 (Bucket and lift arm) q 1
7
796-720-1630 Ring q 1
(Steering)
Clamp
07281-00709 (Steering) q 1
50-500 16 WA150-6
Disassembly and assembly of hydraulic cylinder assembly SEN05189-00
3. Piston and cylinder head 5. Disassembly of cylinder head assembly

1) Set cylinder head and piston rod assembly 1) Remove O-ring and backup ring (12).
(3) to tool U1. 2) Remove snap ring (13) and dust seal (14).
2) Use tool U3 to remove nut (5). 3) Remove rod packing (15).
q Width across flats of nut (steering): 4) Remove bushing (16).
32 mm 5) Remove O-ring (17).
q Width across flats of nut (bucket and
lift arm): 60 mm
3) Remove piston assembly (6) and cylinder
head assembly (2).
4. Disassembly of piston assembly

Remove wear ring (9) and piston ring (10) from
piston (8).
WA150-6 50-500 17
SEN05189-00 Disassembly and assembly of hydraulic cylinder assembly
Assembly 2. Assembly of piston assembly

a Take care not to damage the packings, dust 1) Use tool U6 to expand piston ring (10).
seals, O-rings, etc. a To expand the piston ring, set the tool
a Do not insert the backup ring forcibly. Warm it to the piston ring and turn its handle 8
in hot water at 50 – 60°C and then insert it. – 10 turns.
1. Assembly of cylinder head assembly

1) Use tool U4 to press fit bushing (16).
2) Remove piston ring (10) from tool U6 and

install it to piston (8).
3) Use tool U7 to tighten piston ring (10).
2) Use tool U5 to install dust seal (14). 4) Install wear ring (9).
3) Install snap ring (13).

4) Install rod packing (15).
5) Install backup ring and O-ring (12).
6) Install O-ring (17).
50-500 18 WA150-6
Disassembly and assembly of hydraulic cylinder assembly SEN05189-00
3. Assembly of cylinder head and piston rod 3) Use tool U2 to install cylinder head
assembly assembly (2) to the cylinder.
1) Set cylinder head and piston rod assembly 2 Cylinder head (steering):
(3) to tool U1. 412 ± 41.0 Nm {42 ± 4.2 kgm}
2) Install cylinder head assembly (2) and pis- 2 Cylinder head (bucket):
ton assembly (6) to the piston rod. 863 ± 86.5 Nm {88 ± 8.8 kgm}
2 Cylinder head (lift arm):
3) Use tool U3 to install and tighten nut (5) to
the specified torque. 932 ± 93.0 Nm {95 ± 9.5 kgm}
a Degrease and clean nut (5) and the
4) Remove cylinder assembly (1) from tool
threads of the piston rod.
2 Threads of piston rod:
U1.
Adhesive (LOCTITE No. 262 or
equivalent)
q Width across flats of nut (steering):
32 mm
3 Nut (Steering):
343 ± 34 Nm {35 ± 3.5 kgm}
q Width across flats of nut (bucket and
lift arm): 60 mm
3 Nut (bucket):
1.67 ± 0.17 kNm {170 ± 17.0 kgm}
3 Nut (lift arm):
1.77 ± 0.18 kNm {180 ± 18.0 kgm}
4. Cylinder head
1) Set cylinder (4) to tool U1.
2) Sling cylinder head and piston rod assem-
bly (3) and install cylinder (4).
WA150-6 50-500 19
SEN05189-00

©2009 KOMATSU
All Rights Reserved
50-500 20
SEN05190-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
600 Work equipment

Removal and installation of work equipment assembly .................................................................................. 2
WA150-6 50-600 1
600 Work equipment
SEN05190-00 Removal and installation of work equipment assembly
Removal and installation of work 3. Move the machine backward and disconnect
equipment assembly 1
the bucket.
Removal 4. Sling bucket cylinder assembly (3) temporarily

k Stop the machine on a level place and set and pull out the rod-side pin (4) to disconnect
the lock bar to the frame. the cylinder rod and bell crank. [*3]
k Lower the work equipment to the ground, a Install block [1] between the cylinder bot-
stop the engine, apply the parking brake, tom and the frame.
4
k
Bucket cylinder assembly: 50 kg
Disconnect the cable from the negative (–)
1. Sling the bucket link temporarily and remove

bucket link pin (1). [*1]
4 Bucket link: 20 kg
a Secure the bucket link to the bell crank
with wires, etc.
shims.
2. Remove bucket hinge mounting pin (2). [*2]

k Never insert your fingers into the pin
hole.
5. Place supports [2] under the end of the lift arm
shims.
and release the residual pressure in the
hydraulic piping.
50-600 2 WA150-6
600 Work equipment
Removal and installation of work equipment assembly SEN05190-00
6. Sling the lift cylinder assembly (6) temporarily 9. Sling lift arm, bell crank, and bucket link
and remove the mounting pin (5). [*4] assembly (10) temporarily and pull out mount-
a Check the thickness and quantity of the ing pin (11). [*6]
shims. a Check the thickness and quantity of the
a Lowering the lift cylinder assembly, put a shims.
block on the axle.
4
10. Lift off lift arm, bell crank, and bucket link
Lift cylinder assembly (1 piece): 65 kg
assembly (10).
4 Lift arm, bell crank, and bucket link
assembly: 650 kg
7. Disconnect the bucket positioner proximity

switch connector F04 (7).
8. Remove lift kick-out switch (8). [*5] 11. Sling bucket link assembly (12) temporarily,
pull out mounting pin (13), and remove the
bucket link assembly from the bell crank
assembly. [*7]
4 Bucket link and bell crank: 130 kg
WA150-6 50-600 3
600 Work equipment
12. Sling bell crank assembly (14) temporarily and 16. Pull out dust seal (21) and bushing (22) from
pull out the mounting pin (15). [*8] bucket link (12). [*9]
13. Lift off bell crank.

4 Bell crank: 110 kg
14. Pull out dust seal (17) and bushing (18) from
lift arm (16). [*9]
15. Pull out dust seal (19) and bushing (20) from
bell crank (14). [*9]
50-600 4 WA150-6
600 Work equipment
Installation [*2]
q Carry out installation in the reverse order to Procedure for installing bucket hinge pin
removal. 1. Apply lubricant or grease to the inside surface
of bushing of lift arm.
k When starting the engine, check that the 2 Inside of bushing:
directional lever is in neutral and the park- Lubricant containing molybdenum

ing brake is applied. disulfide (LM-P or equivalent)
k When aligning the pin holes, use a bar.
Never insert your fingers in the pin holes. 2. Align the holes for mounting pin (2), by moving
a Supply grease until it comes out of the joint. the machine forward or backward using work
a When you finish greasing every part, idle the equipment lever.
engine at low speed, and repeat 2 to 3 times k When starting the engine, check that
the operations of tilting and dumping of bucket the directional lever is in neutral and
as well as raising and lowering of lift arm, to the parking brake is applied.
allow grease to spread all over the pin.
3. Insert shims on both sides so that clearances
[*1] (b) on both sides will be the same.
Procedure for installing bucket link pin q Clearance (b) (on each side):
1. Apply lubricant or grease to the inside surface Max. 0.5 mm
of bushing of bucket link. q Varieties of shim thickness:
2 Inside of bushing:
0.5 mm, 1.5 mm, 3.0 mm
disulfide (LM-P or equivalent) 4. Install mounting pin (2) and lock it with bolt
(26).
2. Sling the bucket link and align the holes for k Never insert your fingers in the pin
mounting pin (1). holes.

a Take care not to damage the pin.
3. Insert shims on both sides so that clearances
(a) on both sides will be the same.
q Clearance (a) (On each side):
Max. 0.5 mm
0.5 mm, 1.5 mm, 3.0 mm
4. Install mounting pin (1) and lock it with bolt

(24).
k Never insert your fingers in the pin
holes.
5. After installing the pin, supply grease.

2 Bucket hinge pin:
Hyper White grease (G2-T or equiva-
lent)

2 Bucket link pin:
lent)
WA150-6 50-600 5
600 Work equipment
[*3] [*4]
Procedure for installing bucket cylinder pin (on Procedure for installing lift cylinder pin (on rod
rod side) side)
1. Apply lubricant or grease to the inside surface 1. Apply lubricant or grease to the inside surface
of bushing of bucket cylinder. of bushing of lift cylinder.
2 Inside of bushing: 2 Inside of bushing:
Lubricant containing molybdenum Lubricant containing molybdenum
disulfide (LM-P or equivalent) disulfide (LM-P or equivalent)
2. Align the holes for bucket cylinder pin (4) by 2. Align the holes for lift cylinder pin (5) by operat-
operating work equipment lever. ing work equipment lever.
k When starting the engine, check that k When starting the engine, check that
the directional lever is in neutral and the directional lever is in neutral and
the parking brake is applied. the parking brake is applied.
3. Insert shims on both sides so that clearances 3. Insert shims on both sides so that clearances
(c) on both sides will be the same. (d) on both sides will be the same.
q Clearance (c) (on each side): q Clearance (d) (on each side):
Max. 1.5 mm Max. 1.5 mm
q Varieties of shim thickness: q Varieties of shim thickness: Only 1.5 mm
0.5 mm, 1.5 mm
4. Install mounting pin (4) and lock it with bolt (28).
(27). k Never insert your fingers in the pin
k Never insert your fingers in the pin holes.

holes. a Take care not to damage the pin.

5. After installing the pin, supply grease. 2 Lift cylinder pin (on rod side):
2 Bucket cylinder pin (on rod side): Hyper White grease (G2-T or equiva-
Hyper White grease (G2-T or equivalent)
lent)
[*5]
6. Adjust the bucket positioner. For details, see a Adjust the boom kick-out. For details, see
Testing and adjusting, "Testing and adjusting Testing and adjusting, "Testing and adjusting
bucket positioner". boom kick-out switch".
50-600 6 WA150-6
600 Work equipment
[*6] [*7]
Procedure for installing lift arm pin (on frame Installation of bucket link pin
side) 1. Align the hole for bucket link mounting pin (13)
1. Apply lubricant or grease to the inside surface and insert shims into clearance (f).
of bushing of lift arm. q Clearance (f) (on each side): Max. 0.5 mm
2 Inside of bushing: q Varieties of shim thickness: 0.5, 1.5 mm
disulfide (LM-P or equivalent) 2. Install mounting pin (13) and lock it with bolt
(31).
2. Align holes of lift arm pin (11). k Never insert your fingers into the pin
hole.
3. Insert shims on both sides so that clearances a Take care not to damage the pin and seal.
(e) on both sides will be the same. a Before installing the pin, apply a lubricant
q Clearance (e) (on each side): to the inside of the bushing and seal.
Max. 1.5 mm 2 Inside of bushing and seal:
q Varieties of shim thickness: Lubricant containing molybdenum

1.0 mm, 1.5 mm, 3.0 mm disulfide (LM-P or its equivalent) or
Hyper White (G2-T)
(29).
k Never insert your fingers in the pin
holes.

2 Lift arm pin (on frame side):
lent)
WA150-6 50-600 7
600 Work equipment
[*8] [*9]
Installation of bell crank center pin a Press fit bushings (18), (20), and (22) into lift
1. Align the hole for the bell crank mounting pin arm (16), bell crank (14), and bucket link (12)
(15) and insert shims into clearance (i). respectively with hydraulic cylinder [3], etc.,
q Clearance (i) (on each side): Max. 0.5 mm and then install dust seals (17), (19), and (21).
q Varieties of shim thickness: 0.5, 1.5 mm
(32).
k Never insert your fingers into the pin
hole.
a Take care not to damage the pin and seal.
a Before installing the pin, apply a lubricant
to the inside of the bushing and seal.
2 Inside of bushing and seal:
disulfide (LM-P or its equivalent) or
Hyper White (G2-T)
a Press fit the dust seal with the lip outside.

q Installed dimension (g): 0.25 – 0.8 mm
q Installed dimension (h): 2 – 3 mm
q Greasing
Supply grease to each pin.
a Supply grease until it comes out of the
joint.
50-600 8 WA150-6
600 Work equipment
WA150-6 50-600 9
SEN05190-00

©2009 KOMATSU
All Rights Reserved
50-600 10
SEN05191-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up

Removal and installation of operator's cab and floor frame assembly............................................................ 2
Removal and installation of operator's cab glass (Stuck glass) ...................................................................... 7
Removal and installation of air conditioner unit ............................................................................................ 15
WA150-6 50-700 1
SEN05191-00 Removal and installation of operator's cab and floor frame assembly
Removal and installation of 3. Remove the following parts from left hand.
operator's cab and floor frame (2) : Fender
(3) : Fender mounting bracket
assembly 1
(4) : Cover
Removal 1 (5) : Ladder
k Stop the machine on a level ground and set (6) : Air conditioner filter case cover
the lock bar to the frame to fix the front and (7) : Front cover
rear frames (8) : side cover
10 times.

a Ask professional traders for collecting 4. Remove the following parts from right hand.
and filling the refrigerant (R134a). (9) : Fender
a Never release the refrigerant (R134a) to (10) : Fender mounting bracket
the atmosphere. (11) : Cover
(12) : Ladder
k If the refrigerant (R134a) gets in your (13) : Hydraulic tank cover
eyes, you may lose your sight. Accord- k Loosen the hydraulic tank cap
ingly, put on protective goggle, gloves gradually to release the pressure
and working suits with long sleeves in the hydraulic tank.
while you are collecting the refrigerant (14) : Front cover
or filling the air conditioner circuit with (15) : Side cover
person.

6 Coolant: 14.6 l
50-700 2 WA150-6
Removal and installation of operator's cab and floor frame assembly SEN05191-00
5. Disconnect cab grand cable (16) from the 10. Disconnect the following hoses from Orbit-roll
lower right of the floor. valve (30).
(31) : LS port hose (right)
6. Disconnect the following wiring harness con- (32) : L port hose (right-upper)
nectors from the lower right of the floor. (33) : R port hose (right-lower)
(17) : CN-FL1 (34) : T port hose (left-upper)
(18) : CN-FL2 (35) : T port hose (left-upper)
(19) : CN-FL3 (If equipped) (36) : P port hose (left-lower)
7. Remove bracket mounting bolts (21), and

remove wiring harness (22) with bracket (23).
8. Disconnect 6 PPC hoses (23) – (28).
9. Remove hose (29).
11. Disconnect 6 hoses (37) – (42).
12. Disconnect clamp (43) of hoses (39) and (40).
WA150-6 50-700 3
13. Disconnect the following wiring harness con- 15. Disconnect 2 washer hoses (55).
nectors from lower left of the floor.
(41) : CN-LR1 16. Disconnect 2 air conditioner tubes (56) and
(42) : CN-LR10 (57). [*1]
(43) : CN-LR2
(44) : CN-LR3 17. Disconnect 2 heater hoses (58) and (59).
(45) : CN-LR12
(46) : CN-LR4
(48) : CN-BL1
(49) : CN-LT1
(50) : CN-LT2
(51) : CN-LR7
(52) : CN-LR11
(53) : CN-LR6
14. Disconnect the wiring harness clamps (54).
18. Set parking brake lever (60) in the OFF

(Release) position. (Push down the lever fully
in the direction of the arrow.)
19. Remove pin (61), and then remove pin (62).
20. Loosen locknut (63), and disconnect brake

cable (64) from bracket (65).
50-700 4 WA150-6
Removal and installation of operator's cab and floor frame assembly SEN05191-00
21. Remove operator's cab mounting nuts (66). Installation 1

[*2]
removal.
[*1]
a When installing the hoses of the air conditioner
not enter them.
a When installing each air conditioner hoses,
check that O-ring (70) is fitted on it.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant tube, apply
compressor oil for new refrigerant (R134a) to
O-ring (70).
2 Threaded part of hose and O-ring:
22. Lift off operator's cab and floor flame assembly Refrigerant (R134a)
(67). 3 Threaded part of hose (M16 x 1.5):
a Check that all the wirings and pipings are 12 – 15 Nm {1.2 – 1.5 kgm}
disconnected. 3 Threaded part of hose (M24 x 1.5):
4 Operator's cab and floor frame assem- 30 – 35 Nm {3.0 – 3.5 kgm}

bly: 900 kg
[*2]
3 Operator's cab mounting nuts:
824 – 1,030 Nm {84 – 105 kgm}

ant (R134a).

again.
WA150-6 50-700 5

5 Total amount of coolant: 14.6 l (For
and lubricants".)
50-700 6 WA150-6
Removal and installation of operator's cab glass (Stuck glass) SEN05191-00
Removal and installation of a If the glass is narrow, you may cut the
operator's cab glass adhesive by the following method. Insert
a fine wire [2] (piano wire, etc.) in the
(Stuck glass) 1
adhesive and grip its both ends with pliers
Special tools 1 [3], etc. (or hold them by winding them
onto something) and cut the adhesive with
New/Remodel
the wire.
Necessity
Sketch
Q'ty
1 793-498-1120 Clear plate t 2

1 2 793-498-1130 Plate t 2
X 3 793-498-1110 Magnet t 2
2 793-498-1210 Lifter t 2
(Suction cups)
Removal 1
a All sides of each glass of the operator's cab of
this machine are stuck.
a Remove the window glass to be replaced
according to the following procedure. a The broken window glass may be
removed with knife [4] and a screwdriver.
1. Using seal cutter [1], cut the adhesive between (If the screwdriver is applied directly to the
broken window glass (1) and operator's cab normal window glass, the glass will be
(2). broken.)
a When using knife [4], insert a screwdriver
in the cut to widen it and move the knife
forward.
2. Remove the window glass.
WA150-6 50-700 7
SEN05191-00 Removal and installation of operator's cab glass (Stuck glass)
Installation 1
1. Using scraper [5], remove the remaining adhe-
sive.
a Do not scratch the paint.
4. Stick double-sided adhesive tape (4) along the

inside edge of the glass sticking section.
q Size of double-sided adhesive tape:
7 × 4.8 mm
2. Remove oil, dust, dirt, etc. from the sticking a When sticking the double-sided adhesive
surfaces of cab (2) and window glass (3) with tape, do not touch the cleaned surface as
white gasoline. long as possible.
a If the sticking surfaces are not cleaned a Do not remove the release tape of the
well, the glass may not be stuck perfectly. double-sided adhesive tape on the glass
a Clean the all black part on the back side of sticking side before sticking the glass.
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
a Take care the corner (part (b)) of double-

sided adhesive tape will not float.
3. When the adhesive was removed with the

scraper and if any paint was flaked off, coat the
bare part with paint.
a If the glass is installed without repairing
the bare part, that part will be rusted.
a Do not apply paint to the part which will be
coated with primer.
50-700 8 WA150-6
a When sticking the double-sided adhesive 3) Using tool X2 (suction cups), place win-
tape around a side or a rear window glass, dow glass (3) on tool X1-1 (5 mm spacer)
start at center of the top and make a clear- and match it to the operator's cab.
ance of about 5 mm at end joint (c).
CWW11608
4) Check the clearance between window

5. Position the replacement glass. glass (3) and operator's cab (2) on both
1) Stick X1-2 (thin steel sheet) to tool X1-1 sides and adjust it evenly.
(spacer) with adhesive. 5) Stick tape [6] between window glass (3)
q Spacer thickness ( t) : 5 mm and operator's cab (2) and draw position-
2) Match tool X1-3 (magnet) to tools X1-1 ing line (a).
and X1-2 and set them to the 2 lower 6) Cut the tape between window glass (3)
places of the window glass sticking part of and operator's cab (2) with a knife, and
operator's cab (2). then remove the window glass.
a Do not remove the tapes left on the
window glass and operator's cab till
installing the window glass.
WA150-6 50-700 9
6. Apply primer. a Parts to be coated with primer: Apply

a The expiration date of primer (5) is 4 the primer all over dimension (d) on
months after the date of manufacture. Do the outside of the double-sided adhe-
not use primer (5) after this limit. sive tape.
a Use the primer within 2 hours after open- q Dimension to apply primer (d):
ing it. 23 mm
a Even if the primer is sealed again just after a After applying the primer, leave it for
it is opened, use it within 24 hours after it at least 5 minutes (within 8 hours) to
is opened for the first time. dry.
(Discard the primer 24 hours after it is a If the glass primer is applied by mis-
packed.) take, wipe it off with white gasoline.
1) Stir the primers for paint and glass suffi- (If wrong primer is applied, the glass
ciently before using them. will not be stuck.)
a If the primer has been stored in a
refrigerator, leave it at the room tem-
perature for at least half a day before
stirring it.
(If the primer is opened just after
taken out of the refrigerator, water will
be condensed. Accordingly, leave the
primer at the room temperature for a
sufficient time.)
2) When reusing primer brush (6), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer and glass primer.
4) Evenly apply glass primer (8) to the black

3) Evenly apply paint primer (7) to the parts part of window glass (3) to be stuck.
on the outside of double-sided adhesive 2 Glass primer: SUNSTAR GLASS
tape on operator's cab (2) which will be PRIMER 580 SUPER
coated with the adhesive. a Do not apply the primer more than 2
2 Paint primer: SUNSTAR PAINT times.
PRIMER 580 SUPER (If it is applied more than 2 times, its
a Do not apply the primer more than 2 performance will be lowered.)
times. a Parts to be coated with primer: Apply
(If it is applied more than 2 times, its the primer to the sticking surface of
performance will be lowered.) window glass (3) and all over dimen-
sion (d) on double-sided adhesive
tape (4) and operator's cab (2).
q Dimension to apply primer (d):
23 mm
50-700 10 WA150-6
a Do not apply the primer to the 1) Break aluminum seal (10) of the outlet of
boarder about 5 mm wide between adhesive cartridge (9) and install the noz-
the black part and transparent part of zle.
the glass.
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
a If the paint primer is applied by mis-
take, wipe it off completely with white
gasoline.
(If wrong primer is applied, the glass
will not be stuck.)
2) Cut the tip of adhesive nozzle (11) so that

dimensions ( f) and (g) will be as follows.
q Dimension ( f) : 10 mm
q Dimension (g): 12 mm
3) Set adhesive cartridge (9) to caulking gun

[7].
a An electric caulking gun is more effi-
cient.
7. Apply adhesive.
a Use either of the 2 types of the adhesive.
2 Adhesive (Summer):
SUNSTAR PENGUINE
SEAL 580 SUPER "S"
2 Adhesive (Winter):
SUNSTAR PENGUINE
SEAL 580 SUPER "W"
a The expiration date of the adhesive is 4
months after the date of manufacture. Do
not use the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25°C.
a Never heat the adhesive higher than
30°C.
a When reusing the adhesive, remove all
the hardened part from the nozzle tip.
WA150-6 50-700 11
4) Remove release tape (13) of the double-

sided adhesive tape on the glass side.
8. Install window glass (3).

a If the glass is positioned wrongly, the
5) Apply adhesive (12) to the outside of dou- adhesive must be removed and cleaned,
ble-sided adhesive tape (4) of the opera- and then the primer and adhesive must be
tor's cab. applied again. Accordingly, position the
a Before applying the adhesive, check glass carefully when sticking it.
that the primer is applied to the sur- 1) Similarly to step 1, match tools X1-1, X1-
face to which the adhesive will be 2, and X1-3 and set them to the 2 lower
applied. places of the window glass sticking part of
operator's cab (2).
a Apply adhesive (12) to dimensions (h)

and ( j) of double-sided adhesive tape 2) Using tool X2, raise and place window
(4) of operator's cab (2). glass (3) on tool X1-1 (5-mm spacer) and
q Dimension (h): 10 mm stick it to the operator's cab.
q Dimension ( j ) : 12 mm (Approx. a Match the lines of the match tapes
twice as high as adhesive tape) stuck in step 1.
a Apply adhesive (12) higher than dou- a Stick the glass within 10 minutes after
ble-sided adhesive tape (4). applying the adhesive.
a Apply the adhesive evenly. a Before sticking the glass, check that
the primer is applied to the surface to
which the glass will be stuck.
50-700 12 WA150-6
9. Cure the stuck window glass for a certain time.

a Curing time before removing tool X1-1 (5-
mm spacer) (at temperature of 20°C and
humidity of 60%): 10 hours
a Curing time before operating machine:
1 day
10. If the front glass and both front glasses are

replaced, seal them.
1) Stick masking tapes (14) along the parts to
be sealed shown in the figure.
a Stick the masking tapes to both inside
and outside of the operator's cab.
a Check clearance ( k) between the

front side of the front glass and each
side and adjust it evenly.
q Clearance ( k ) : 5 mm
3) After sticking window glass (3), press it

evenly.
a Press all over the window glass to the
degree that the window glass will be
stuck to the double-sided adhesive
tape.
a Do not press the window glass too
strongly.
WA150-6 50-700 13
2) Fill the joint of the glasses with caulking

material (15).
a The expiration date of the following
caulking material is 4 months after the
date of manufacture. Do not use the
caulking material after its usable
period.
2 Caulking material:
SUNSTAR PENGUINE SEAL
NO. 2505
CPW11631
3) Remove the caulking material projected

from the joint with cardboard [8], etc.
CPW11632
4) Remove the masking tapes from the win-

dow glass.
11. Remove the primer and adhesive from the

operator's cab and window glass.
a Using white gasoline, wipe off the adhe-
sive before it is dried up.
a When cleaning the glass, do not make an
impact to it.
50-700 14 WA150-6
Removal and installation of air conditioner unit SEN05191-00
Removal and installation of air 3. Pull out each switch from panel cover (1) on
conditioner unit 1
the left side of the operator's seat and discon-
nect the following connectors.
Removal q (2): CN-L10
k
1
Stop the machine on a level ground and set q (3): CN-L11
the lock bar to the frame to fix the front and q (4): CN-L09 (If equipped)
rear frames. a Different specifications use different
k Lower the work equipment to the ground, switches and connectors.
you may scald yourself with the hot coolant
when disconnecting the heater hoses and CPW11631
draining the coolant. Wait until the coolant
is cooled, and then drain the coolant.
1. Collect the air conditioner refrigerant (R134a)

from air conditioner circuit in advance.
a Ask professional traders for collecting and
filling operation of refrigerant.
a Never release the refrigerant to the atmo- 4. Pull out each switch from panel cover (1) on
sphere
the right side of the operator's seat and discon-
may lose your sight. Accordingly, put q (5): CN-L19 (If equipped)
on protective goggles, gloves and q (6): CN-L07
working suits with long sleeves while q (7): CN-L08
you are collecting the refrigerant or fill- q (8): CN-L06
ing the air conditioner circuit with the a Different specifications use different
refrigerant. Collecting and charging switches and connectors.
person.
q Refrigerant quantity: 900 ± 50 g
2. Loosen the radiator cap to drain the coolant.

6 Radiator: 14.6 l
CPW11631
WA150-6 50-700 15
SEN05191-00 Removal and installation of air conditioner unit
5. Remove 8 mounting bolts (1a) and panel cover 8. Remove monitor panel assembly (11).
(1). [*2]
CPW11631
CPW11631
9. Disconnect wiper water hose (12) from the

6. Remove 2 pieces (9) and 1 piece (10) of the front outside of the cab.
monitor panel mounting bolts. [*3]
10. Remove wiper blades (13).
CPW11631
CPW11631
7. Reverse monitor panel assembly (11) halfway

and disconnect the following connectors from 11. Disconnect wiper water hose (14) from the
the rear side. inside of the cab.
(12): —
(13): CN-L30 12. Disconnect wiper wiring harness connector
(14): CN-L28 (15).
(15): CN-L27
(16): CN-L26 13. Remove wiper motor assembly (16).
(17): CN-L25
(18): CN-L29
(19): CN-L24
a Take care not to strain the wiring since it is
short.
CPW11631
50-700 16 WA150-6
14. Remove left duct (17) and right duct (18). 20. Disconnect wiring harness connector (28) and
fuse (29).
CPW11631
CPW11631
15. Disconnect right lower duct hose (19).

21. Remove right cover (30).
16. Remove 8 mounting bolts (20) and plate (21).
CPW11631
CPW11631
22. Disconnect heater hoses (32) and (33) and air

17. Remove left cover (22). conditioner pipes (34) and (35) at the lower
right of air conditioner unit (31).
18. Disconnect the following wiring harness con- a Plug the disconnected hoses and ports to
nectors. prevent foreign matter from entering them.
q (23): CN-C50 [*4]
q (24): CN-C49
q (25): CN-AL1 23. Disconnect wiring harness connector (36).
19. Remove air conditioner internal air filter case

(26).
CPW11631
CPW11631
WA150-6 50-700 17
24. Disconnect blower motor wiring harness con- 26. Blower motor assembly
nector (37) from the lower left of the operator's 1) Remove side cover (39) and front cover
cab floor and pull out the wiring harness and (40) at the lower left of the operator's cab.
grommet (38) together above the floor. 2) Remove air conditioner external air filter
case (41).
25. Remove air conditioner assembly (31) upward.

a Check that all the wiring and piping are 3) Remove air conditioner external air duct
disconnected. (42) from the lower left of the floor.
CPW11631
50-700 18 WA150-6
4) Remove the 5 mounting bolts and blower Installation 1

motor assembly (43). q Carry out installation in the reverse order to
a Remove the 5 bolts indicated with the removal.
arrows. (The ones marked with
among them are used to fix the exter-
* [*1]
nal air filter case, too.) a When installing the hoses of the air conditioner
not enter them.
a When installing each air conditioner hose,
check that O-ring (70) is fitted to it.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply
CPW11631 compressor oil for new refrigerant (R134a).
12 – 15 Nm {1.2 – 1.5 kgm}
20 – 25 Nm {2.0 – 2.5 kgm}
30 – 35 Nm {3.0 – 3.5 kgm}
CPW11631
CPW11631
[*2]
3 Panel cover mounting bolt (1a):
3.4 – 4.4 Nm {0.35 – 0.45 kgm}
[*3]
3 Monitor panel mounting bolts (9) and (10):
CPW11631 2.75 – 2.94 Nm {0.28 – 0.30 kgm}
WA150-6 50-700 19
[*4]
a Do not remove the plugs installed when the
piping was disconnected to prevent entry of
foreign matter until just before connecting the
piping.
2 O-ring and threaded part:
Refrigerant (R134a)
3 Hose adapter mounting bolt (44):

8 – 12 Nm {0.8 – 1.2 kgm}
CPW11631
q Charging with refrigerant (R134a)

ant (R134a).

5 Total amount of coolant: 14.6 l
(For details, see "Table of fuel, coolant
and lubricants".)
50-700 20 WA150-6
WA150-6 50-700 21
SEN05191-00

©2009 KOMATSU
All Rights Reserved
50-700 22
SEN05192-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
800 Electrical system

Removal and installation of monitor panel ...................................................................................................... 2
Removal and installation of engine controller assembly ................................................................................. 4
Removal and installation of HST controller assembly..................................................................................... 6
Removal and installation of KOMTRAX terminal assembly ............................................................................ 7
WA150-6 50-800 1
SEN05192-00 Removal and installation of monitor panel
Removal and installation of 3. Remove 8 mounting bolts (1a) and panel cover
monitor panel 1
(1). [*1]
Removal
rear frames.
1. Pull out each switch from panel cover (1) on

the left side of the operator's seat and discon-
q (2): CN-L10 4. Remove 2 pieces (9) and 1 piece (10) of the
q (3): CN-L11 monitor panel mounting bolts. [*2]
q (4): CN-L09 (If equipped)
a Different specifications use different
switches and connectors.
2. Pull out each switch from panel cover (1) on

the right side of the operator's seat and discon-
q (5): CN-L19 (If equipped)
q (6): CN-L07
q (7): CN-L08
q (8): CN-L06
a Different specifications use different
switches and connectors.
50-800 2 WA150-6
Removal and installation of monitor panel SEN05192-00
5. Reverse monitor panel assembly (11) halfway Installation

and disconnect the following connectors from q Carry out installation in the reverse order to
the back side. removal.
q (12): –
q (13): CN-L30 [*1]
q (14): CN-L28 3 Panel cover mounting bolt (1a):
q (15): CN-L27 3.44 – 4.40 Nm {0.35 – 0.45 kgm}
q (16): CN-L26
q (17): CN-L25 [*2]
q (18): CN-L29 3 Monitor panel mounting bolts (9) and (10):
q (19): CN-L24 2.75 – 3.53 Nm {0.28 – 0.30 kgm}
a Take care not to strain the wiring since it is
short.
6. Remove monitor panel assembly (11).
7. Remove bracket (20) from monitor panel

assembly (11).
WA150-6 50-800 3
SEN05192-00 Removal and installation of engine controller assembly
Removal and installation of 3. Remove wiring harness clamps (3) and (4).
engine controller assembly 1
4. Disconnect connectors CN-EC2 (5), CN-EC1
Removal (6) and CN-EC3 (7). [*1]
the lock bar to the frame to fix the front and 5. Disconnected clip for wiring harness connector
rear frames. (8).
stop the engine, apply the parking brake, 6. Disconnect 4 mounting bolts (9) and engine
and put chocks under the tires. controller assembly (10). [*2]
1. Open and fix right engine side cover (1).

a Check that the cover is locked securely.
2. Remove air cleaner cover (2).
50-800 4 WA150-6
Removal and installation of engine controller assembly SEN05192-00
Installation
removal.
a Before installing, remove foreign materials

(dirt, water, etc.) from the wiring harness con-
nector of the engine controller assembly.
[*1]
3 Wiring harness connector mounting bolt:
3 ± 0.1 Nm {0.31 ± 0.01 kgm}
[*2]
3 Engine controller assembly mounting bolt:
24 ± 4 Nm {2.45 ± 0.4 kgm}
WA150-6 50-800 5
SEN05192-00 Removal and installation of HST controller assembly
Removal and installation of HST Installation

controller assembly 1
removal.
Removal
k Stop the machine on a level ground and set a Before installing, remove foreign materials
the lock bar to the frame to fix the front and (dirt, water, etc.) from the wiring harness con-
rear frames. nector of the HST controller assembly.
1. Slide the operator's seat to the forward end.
2. Remove cover (1) from the rear of the opera-

tor's seat.
3. Disconnect wiring harness connector CN-HST

(2).
4. Remove HST controller (3).
50-800 6 WA150-6
Removal and installation of KOMTRAX terminal assembly SEN05192-00
Removal and installation of 5. Disconnect wiring harness connector CN-L80

KOMTRAX terminal assembly 1
(4) of the chassis from KOMTRAX terminal
assembly (3).
(If equipped) a Disconnect the machine wiring harness
first and then disconnect the antenna
Removal
k
cables (If the antenna cables are discon-
Stop the machine on a level ground and set
nected first, an antenna cable disconnec-
tion error is saved in the KOMTRAX). [*1]
rear frames.
a Remove CN-L80 (4) by loosening the
hexagon socket head screw at its center.
[*2]
6. Disconnect antenna cable connectors (5) and
(6) from KOMTRAX terminal assembly (3).
1. Open the right door of the operator's cab.
a Lock the door securely.
2. Turn over and fix floor mat (1) under cover (2).
3. Remove right armrest outside cover (2) of the

operator's seat.
Installation
removal.
a Before installing, remove foreign materials

(dirt, water, etc.) from the wiring harness con-
4. Remove the 4 mounting bolts and then remove nector of the KOMTRAX terminal assembly.
KOMTRAX assembly (3).
[*1]
a First, connect the antenna cable connec-
tors then the wiring harness connector of
the chassis.
[*2]
3 Hexagon socket head screw at center of wir-
ing harness connector CN-L80 (4):
2.82 Nm {0.288 kgm}
WA150-6 50-800 7
SEN05192-00

©2009 KOMATSU
All Rights Reserved
50-800 8
SEN05140-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
80 Appendix 80
100 Air conditioner

Structure and function ..................................................................................................................................... 4
Air conditioner component ....................................................................................................................... 4
Configuration and function of refrigerating cycle ..................................................................................... 6
Outline of refrigerating cycle .................................................................................................................... 7
Air conditioner unit ................................................................................................................................. 10
Functions of major components in the air conditioner unit .....................................................................11
Blower and intake unit ........................................................................................................................... 12
Compressor ........................................................................................................................................... 13
Condenser ............................................................................................................................................. 14
Receiver drier ........................................................................................................................................ 15
Air conditioner control panel .................................................................................................................. 16
Testing, adjusting and troubleshooting.......................................................................................................... 18
Caution about refrigerant ....................................................................................................................... 18
Troubleshooting procedure .................................................................................................................... 19
Block diagram and circuit diagram of control system ............................................................................ 20
Detail of air conditioner unit ................................................................................................................... 23
Arrangement of connector pins.............................................................................................................. 24
Part and connector locations ................................................................................................................. 25
Testing with self-diagnosis function (indication on control panel) .......................................................... 27
Testing temperature control ................................................................................................................... 28
Testing Recirc/Fresh changeover .......................................................................................................... 29
Testing evaporator temperature sensor electrically ............................................................................... 31
Testing relays......................................................................................................................................... 32
WA150-6 80-100 1
100 Air conditioner
SEN05140-00
Troubleshooting chart 1 ......................................................................................................................... 33

Troubleshooting chart 2 ......................................................................................................................... 34
Troubleshooting for electrical system (E mode)..................................................................................... 37
E-1 Power supply system (Air conditioner does not operate)......................................................... 38
E-2 Compressor or refrigerant system (Air is not cooled)............................................................... 41
E-3 Blower motor system (No air comes out or air flow is abnormal)............................................. 44
E-4 Temperature cannot be controlled............................................................................................ 47
E-5 Recirc/Fresh cannot be changed over ..................................................................................... 50
Troubleshooting with gauge pressure .................................................................................................... 52
Connection of service tool...................................................................................................................... 54
Precautions for connecting air conditioner piping .................................................................................. 55
Handling of compressor oil .................................................................................................................... 56
1. Control of compressor oil .......................................................................................................... 56
2. Adding of compressor oil .......................................................................................................... 56
3. Compressor replacement.......................................................................................................... 57
4. Applying compressor oil for O-ring............................................................................................ 57
80-100 2 WA150-6
100 Air conditioner
SEN05140-00
WA150-6 80-100 3
100 Air conditioner
Structure and function
SEN05140-00 Air conditioner component
Structure and function 1
Air conditioner component
80-100 4 WA150-6
100 Air conditioner
Air conditioner component SEN05140-00
1. Hot water piping Specifications

2. Compressor
Refrigerant R134a
3. Condenser
4. Receiver drier Refrigerant refilling level (g) 900 ± 50
5. Hot water return piping
6. Refrigerant piping
7. Fresh air filter
8. Recirc/Fresh changeover damper
9. Blower unit
10. Air conditioner unit
11. Dual pressure switch
12. Air outlet duct
13. Recirculation air filter
WA150-6 80-100 5
100 Air conditioner
SEN05140-00 Configuration and function of refrigerating cycle
Configuration and function of refrigerating cycle

Component
Compressor Condenser Expansion valve Evaporator
Item
In operator’s cab In operator’s cab
Location Engine compartment Front of radiator
(In air conditioner unit) (In air conditioner unit)
Circulates refrigerant Condenses refrigerant Lowers temperature and Evaporates refrigerant
gas and increases its to discharge heat pressure of refrigerant to absorb heat from (or
temperature and absorbed in evaporator. liquid and gas for easy cool) air around
pressure so that it can evaporation with throttle. evaporator.
Function be liquefied easily in Controls flow rate, too.
condenser.
(Compression of (condensation of (Throttle of refrigerant) (Evaporation of

refrigerant) refrigerant) refrigerant)
Gas o Liquid Liquid and gas o Gas
State of Gas o Gas Liquid o Liquid and gas
Constant pressure Constant pressure
refrigerant Adiabatic compression Adiabatic expansion
change change
80-100 6 WA150-6
100 Air conditioner
Outline of refrigerating cycle SEN05140-00
Outline of refrigerating cycle

The refrigerating cycle performs the following four 3. Expansion (Expansion valve)
actions. The refrigerant is liquefied and gasified The pressure of the refrigerant liquid is low-
repeatedly while it is circulated in the cycle. ered by the restricting action [*1] of the expan-
sion valve to a level at which the refrigerant is
1. Compression (Compressor) evaporated easily.
The refrigerant gas is compressed by the com- The action to lower the pressure of the refriger-
pressor to the state where it can be liquefied ant to a level at which the refrigerant is evapo-
easily at the normal temperature (ambient tem- rated easily before the refrigerant is sent to the
perature). evaporator is called expansion.
The refrigerant evaporated in the evaporator is The expansion valve which performs this action
sucked into the compressor. also controls the flow rate of the refrigerant.
This action is performed to keep the refrigerant In other words, the quantity of the refrigerant
pressure in the evaporator low so that the liquid evaporated in the evaporator is decided
refrigerant liquid can continue evaporation by the quantity of heat to be removed (refriger-
actively even if the ambient temperature is ation load) at the specified evaporation tem-
close to 0°C. perature (evaporation pressure), and the
The refrigerant gas sucked into the compres- expansion valve senses it and controls the
sor is compressed in the cylinder and its pres- refrigerant flow rate properly.
sure and temperature are so changed that is [*1] Restricting action
can be liquefied easily when it is cooled with If there is a suddenly narrowed part in a pipe in
the external air at the normal temperature. which a liquid is flowing, there is resistance to
the flow. Since the sectional area is increased
2. Condensation (Condenser) suddenly through this part, the liquid expands
The refrigerant gas in the condenser is cooled suddenly and its pressure and temperature
to be liquefied with the external air. lower. No heat is exchanged between the
The refrigerant gas of high temperature and inside and outside of the pipe during this
high pressure discharged from the compressor action.
is cooled to be liquefied with the external air
and then stored in the receiver drier.
The heat discharged from the refrigerant of
high temperature and high pressure dis-
charged from the compressor is called the con-
densation heat, which is the total of the heat
that the refrigerant absorbed from the opera-
tor’s cab through the evaporator (vaporization
heat) and the work performed to compress the
refrigerant (the value converted into heat).
During condensation, the refrigerant gas and
refrigerant liquid are mixed together in the con-
denser. While the refrigerant gas changes to
the refrigerant liquid, the relationship between
the pressure (condensation pressure) and
temperature (condensation temperature) is
kept constant.
Reference: The pressure varies with the type
of refrigerant and the condensa-
tion temperature.
WA150-6 80-100 7
100 Air conditioner
SEN05140-00 Outline of refrigerating cycle
4. Evaporation (Evaporator) q Receiver drier

The refrigerant changes from liquid to gas The refrigerant liquefied in the condenser is
(superheated vapor) in the evaporator. reserved in the receiver drier temporarily so
The refrigerant mist in the evaporator evapo- that it can be supplied to the evaporator
rates actively. according to the cooling load. A strainer and a
At this time, the refrigerant evaporates quickly, drying agent are sealed in the receiver drier to
absorbing heat necessary for evaporation remove "dirt" and "water" in the refrigerating
(latent heat of vaporization) from the air around cycle.
the cooling fins (air in the operator’s cab). The If any water is in the refrigerating cycle, it is fro-
cooled air is spread in the operator’s cab by zen in the small hole of the expansion valve
the fan to lower the temperature in the opera- and retards the flow of the refrigerant.
tor’s cab. It can cause a cooling trouble.
The refrigerant mist sent through the expansion
valve and the evaporated refrigerant are mixed
together in the evaporator. While the refrigerant
liquid changes to the refrigerant gas, the rela-
tionship between the pressure (evaporation
pressure) and temperature (evaporation tem-
perature) is kept constant. If the pressure is set,
the temperature is decided automatically.
That is, the relationship between the above
pressure and temperature is equal to the rela-
tionship between saturation pressure and satu-
ration temperature.
To evaporate the refrigerant at lower tempera-
ture, the pressure in the evaporator must be
kept lower.
Accordingly, the evaporated refrigerant is
sucked into the compressor.
The refrigerant circulates in the refrigerating
cycle, repeating the above four actions, to
move the heat from the operator’s cab where
the temperature is low to the outside where the
temperature is high.
If the amount of the refrigerant is insufficient,
all of the refrigerant is evaporated while it is
passing through the evaporator and the evapo-
rator capacity decreases. It can cause a cool-
ing trouble.
To the contrary, if the amount of the refrigerant
is too much, a part of it is not evaporated in the
evaporator and is absorbed in the compressor.
As a result, the compressor compresses the
liquid and may be broken.
80-100 8 WA150-6
100 Air conditioner
Outline of refrigerating cycle SEN05140-00
WA150-6 80-100 9
100 Air conditioner
SEN05140-00 Air conditioner unit
Air conditioner unit

a This air conditioner unit is manual temperature control type.
A: From receiver Outline

B: To compressor q In the air conditioner unit evaporator (1) and
C: Hot water inlet heater core (2) are located vertically. The air
D: Hot water outlet conditioner unit generates cool and hot air
together with the blower and intake unit.
1. Evaporator q The temperature adjusting switch on the air
2. Heater core conditioner control panel controls the angle of
3. Air mix damper (upper) air mix dampers (3) and (4) to adjust the blow
4. Air mix damper (lower) out temperature.
5. Expansion valve
6. Blower amplifier (AMP) Cooler
7. Blower off relay q The cooler circulates refrigerant through evap-
8. Compressor clutch relay orator (1) to cause heat exchange (dehumidifi-
9. Air mix actuator cation and cooling).
10. Evaporator temperature sensor (EVA sensor) q Air taken in by the blower and intake unit is
11. (Dual) pressure switch cooled with evaporator (1) and then blown out
from the duct and grill.
Heater
q The heater circulates engine coolant in heater
core (2) to cause heat exchange (heating).
q Air taken in by the blower and intake unit is
heated with heater core (2) and then blown out
through the duct and grill.
80-100 10 WA150-6
100 Air conditioner
Functions of major components in the air conditioner unit SEN05140-00
Functions of major components Air mix actuator (9)

in the air conditioner unit q Air mix means the temperature adjustment by
mixing cooled air and hot air.
a See previous page for numbers. q It starts the built-in motor when signal current
is received from the air conditioner control
Evaporator (1) panel. This opens or closes the air mix damp-
q Evaporator fins are cooled by low-pressure, ers (3) and (4) through the link mechanism by
low-temperature refrigerant gas being sent eight steps.
from the expansion valve. Air from the blower q The motor rotating direction is determined by
motor is cooled and dehumidified when pass- the air conditioner control panel as it reads the
ing through the fins. position of the potentiometer in the actuator.
This reading is done when the target tempera-
Heater core (2) ture is set with the temperature adjustment
switch on the air conditioner control panel.
q Fins of the heater core are heated by the hot
q Rotation of the motor stops when the electrical
water (cooling water) being sent from the
contact which moves together with the motor is
engine. Air from the blower motor is heated as
disengaged or when signal current from the air
it passes through the fins.
conditioner panel is cut off.
Expansion valve (5) Evaporator temperature sensor (10)
q This valve converts high-pressure, high-tem- (EVA sensor)
perature liquid refrigerant coming from the q In order to prevent freezing of the evaporator
receiver to low-pressure, low-temperature (1), it senses the evaporator temperature with
misty refrigerant through the throttling function. the change of sensor resistance. The air condi-
It controls the flow rate of the refrigerant by tioner panel checks the sensor voltage and
changing the level of throttling depending on controls ON/OFF of the compressor to prevent
the thermal load (heat) in the operator's cab. overcooling of the evaporator (1).
As a result, temperature of the air blown out of Resistance:
the grill is adjusted depending on the volume of 7.2 kz (at 0°C)
refrigerant circulated in evaporator (1). 2.2 kz (at 25°C)
a Use 4 mm hexagonal wrench.
3 Bolt for expansion valve: (Dual) pressure switch (11)
6.9 Nm {0.7 kgm} a (Dual) pressure switch (11) is on the air condi-
tioner hose near the air conditioner unit.
Blower AMP (6) q If abnormally low or high pressure was gener-
q It controls the blower motor speed by receiving ated in the refrigerant circulation circuit, this
signal current from the air conditioner control switch releases the magnetic clutch of the
panel. compressor to protect a series of cooler-
related equipment.
Blower off relay (7) a Normally "ON", abnormal pressure "OFF" for
q Signal current from the air conditioner control compressor.
panel controls the relay coil. When the relay
coil is energized, the relay (7) is turned "ON"
and power is supplied to the blower motor.
Compressor clutch relay (8)

q Signal current from the air conditioner control
panel through the (dual) pressure switch (11) is
used for controlling the relay coil. When the
relay coil is energized, the relay (8) is turned
"ON" and the magnetic clutch in the compres-
sor is engaged and the compressor operates.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
WA150-6 80-100 11
100 Air conditioner
SEN05140-00 Blower and intake unit
Blower and intake unit
1. Blower motor assembly Functions of major components

2. Recirc/Fresh changeover actuator Blower motor assembly (1)
3. Recirc/Fresh changeover damper
q It suctions air by rotating the sirocco fan
installed on the blower motor. It is also used for
sending the absorbed air to the evaporator and
heater core.
Recirc/Fresh changeover actuator (2)

q When receiving signal current from the air con-
ditioner control panel, it starts the built-in motor
to open or close the Recirc/Fresh changeover
damper (3) through the link mechanism.
q The motor rotation direction is determined from
the Recirc/Fresh selector switch on the air con-
ditioner control panel.
q Rotation of the motor stops when the electrical
contact which moves together with the motor is
disengaged or when signal current from the air
conditioner panel is cut off.
80-100 12 WA150-6
100 Air conditioner
Compressor SEN05140-00
Compressor
A: Refrigerant inlet port from air conditioner unit Function

B: Refrigerant outlet port to condenser q Other than circulating the refrigerant, compres-
sor compresses the refrigerant gas from the
evaporator to a high-pressure, high-tempera-
ture misty refrigerant so that it may be easily
regenerated (liquefied) at normal temperature.
q Its built-in magnetic clutch is engaged depend-
ing on the evaporator temperature and refriger-
ant pressure.
Then the compressor operates.
Specifications
Number of cylinders –
7 – 29.3 x 27.4
Bore x Stroke (mm)
Piston capacity (cc/rev) 129.2
Allowable maximum speed
4,000
(rpm)
Refrigerant oil used Sanden: SP-10
Refrigerant oil refilling volume
135
(cc)
WA150-6 80-100 13
100 Air conditioner
SEN05140-00 Condenser
Condenser
A: Refrigerant inlet port from compressor Function

B: Refrigerant outlet port to receiver drier q Condenser cools and liquefies the high-pres-
sure, high-temperature misty refrigerant from
the compressor.
a If the fins are crushed or clogged with dirt, heat

exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavail-
able. As a result, pressure in the refrigerant cir-
culation circuit will be increased, applying extra
load to the engine or degrading the cooling
effect. Thus, care must be used in its handling
and daily inspection.
Specifications
Fin pitch (mm) 1.5
Total heat dissipation area
6.55
(m2)
Max. pressure used
3.6 {36}
(MPa {kg/cm2})
80-100 14 WA150-6
100 Air conditioner
Receiver drier SEN05140-00
Receiver drier
A: Refrigerant inlet port from condenser Function

B: Refrigerant outlet port to air conditioner unit q Receiver drier is used to store liquefied high-
pressure, high-temperature misty refrigerant
1. Sight glass from the condenser. It is capable of completely
liquefying the refrigerant even when bubbles
are contained in the refrigerant due to the con-
denser condition in heat dissipation.
q It eliminates foreign substances in the circula-
tion circuit and water content in the refrigerant
by use of the built-in filter and desiccating
agent.
q Sight glass (1) allows inspection of the refriger-
ant flow.
Even if 5 minutes elapsed after engine start up
and turning ON of A/C switch, when bubbles
are still seen through sight glass (1), the
amount of the refrigerant is insufficient.
If the amount of the refrigerant is proper, no
bubbles are seen there.
a If there is no (or excessive) refrigerant in
the refrigerating cycle, no bubbles are
seen through sight glass (1), too.
Specifications
Effective cubic capacity (cm3) 578
Weight of desiccating agent (g) 300
WA150-6 80-100 15
100 Air conditioner
SEN05140-00 Air conditioner control panel
Air conditioner control panel
Display unit
Display Display
No. Display items Display range Display method Remarks
category color
Blow out All segments of current level and below
1 See above drawing
temperature light up (8-step display)
Gauge
All segments of current level and below
2 Blow out volume See above drawing
light up (4-step display)
The display indicates which is currently
Recirculation of Liquid
Recirculation of taking place - internal air recirculation or Black
internal air and crystal
3 internal air and intake of fresh air - responding to the
intake of fresh
intake of fresh air operation of the Recirc/Fresh selector
Pilot air
switch.
When air
Turns "ON" air conditioner switch, this
4 Air conditioner conditioner switch
lamp lights up.
is "ON"
Switch block
No. Switch name Function Operation
This switch is used to select either the recirculation of internal air or Recirculation
Recirc/Fresh selector
5 intake of fresh air IO
switch
(pilot display (3) is switched depending on the switch setting) Fresh
6 Air conditioner switch It turns on or off the cooling and the dehumidifying heating function. OFF io ON
It turns on or off main power supply to the air conditioner.
7 Main power switch ON: Settings done during "OFF" are indicated on the display unit. OFF io ON
OFF: Turns off the display unit lamp and stops the fan.
It controls volume of air sent from the fan.
8 Fan switch LO io HI
(adjusted in 4 steps [LO, M1, M2 and HI])
Low temperature
Temperature adjusting It controls the blowing out temperature
9 IO
switch (8-step adjustment)
High temperature
80-100 16 WA150-6
100 Air conditioner
Air conditioner control panel SEN05140-00
Outline
q CPU (central processing unit) installed on the
panel processes input signals from respective
sensors and operation signals of the panel
switches to display and output them.
q The self-diagnosis function of CPU makes the
troubleshooting easier.
See "Block diagram and circuit diagram of control

system" about input and output signals.
WA150-6 80-100 17
100 Air conditioner
Testing, adjusting and troubleshooting
SEN05140-00 Caution about refrigerant
Testing, adjusting and troubleshooting 1
Caution about refrigerant

k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit before
disconnecting air conditioner hose to
replace air conditioner unit, air conditioner
compressor or receiver drier and so on.
a Ask a qualified shop for collecting, adding and
filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. And if it touches
your skins, you may suffer from frostbite.
Accordingly, put on protective goggles,
gloves and working suits with long sleeves
(R134a) or filling the air conditioner circuit
with the refrigerant (R134a). Collecting and
filling work must be conducted by a quali-
fied person.
q Refrigerant (R134a) filling up quantity:
900 g ± 50 g
80-100 18 WA150-6
100 Air conditioner
Troubleshooting procedure SEN05140-00
The air conditioner has a self-diagnosis function for inspecting the main component parts. With this function,
you can inspect the operation of sensor and actuators in the system.
If a troubled section is detected, every part of that section must be inspected.
Troubleshooting procedure
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Find the troubled section with the self-diagnosis function (See "Inspection with self-diagnosis").
If the air conditioner unit or control panel does not operate at all, check that the power supplied to the
control panel is normal.
If any part of the air conditioner unit or control panel operates, the power supply does not need to be
checked.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic flow of troubleshooting
Occurrence of trouble:
Examination,
confirmation of failure
1. Battery voltage (24 V)
2. Tension of compressor belt
Basic check 3. Oil stain at air conditioner hose joints (*2)
4. Abnormal sound check (*3)
Compressor, blower motor and air conditioner
hose (clamp)
E-1 Power supply system (Air

operate? conditioner does not operate)
Inspection with self-diagnosis

function (*1) and with each switch
Troubleshooting with
Troubleshooting with E mode
troubleshooting chart 1
Troubleshooting with gauge

pressure
Inspection with
troubleshooting chart 2
*1: By LCD blink on air conditioner control panel

*2: If refrigerant leaks, recirculating compressor oil in the air conditioner circuit always leaks, too.
*3: Start engine and then air conditioner switch ON.
WA150-6 80-100 19
100 Air conditioner
SEN05140-00 Block diagram and circuit diagram of control system
Block diagram and circuit diagram of control system

a This air conditioner unit is manual temperature control type.
• F/B: Feed Back • R/F: Recirc/Fresh • AM: Air Mix
80-100 20 WA150-6
100 Air conditioner
Block diagram and circuit diagram of control system SEN05140-00
Input and output signals of air conditioner control panel

CN-C47 (JAE IL-AG5-22P) CN-C48 (JAE IL-AG5-14P)
Input/
Input/ Pin
Pin Signal name Circuit name output
Signal name Circuit name output No. signals
No. signals
1 GND GND —
1 NC — —
2 Sensor ground SENSOR GND —
2 NC — —
Recirc/Fresh changeover
3 R/F LIMIT Input
3 Blower motor off relay OFF RELAY Output damper actuator limiter
4 External air temperature sensor OUTER Input
Recirc/Fresh changeover SENSOR
4 R/F OUTPUT 1 Output
damper actuator output 1
5 Evaporator temperature sensor EVA SENSOR Input
Recirc/Fresh changeover
5 damper actuator output 2 R/F OUTPUT 2 Output
6 Internal air temperature sensor — Input
MODE
6 Mode selector actuator output 2 Output
OUTPUT 2 7 Starting switch (ON) IGN POWER Input
MODE NIGHT PROOF
7 Mode selector actuator output 1 Output 8 Night lamp signal Input
OUTPUT 1 POWER
8 Air mix damper actuator output 2 AM OUTPUT 2 Output 9 NC — —
9 Air mix damper actuator output 1 AM OUTPUT 1 Output 10 NC — —

Actuator potentiometer power 11 NC — —
10 supply (5 V) POTENTIO 5 V Output
11 NC — — 12 NC — —
12 NC — — 13 Day light sensor 2 — Input
13 NC — — 14 Day light sensor 1 — Output
14 NC — —
15 Magnet clutch Mg C OUTPUT Output
16 Air mix damper actuator limiter AM LIMIT Input
17 Mode selector actuator limiter MODE LIMIT Input
18 Air mix damper actuator AM POTENTIO Input

potentiometer
Mode selector actuator MODE
19 potentiometer POTENTIO Input
20 Blower gate BLOWER GATE Output
21 Blower feedback BLOWER F/B Input
22 Actuator potentiometer ground POTENTIO GND —
WA150-6 80-100 21
100 Air conditioner
SEN05140-00 Block diagram and circuit diagram of control system
q Fuse parts number: q T-adapter number

5A: 08041-00500 DT-2: 799-601-9020
15A: 08041-01500 DT-3: 799-601-9030
20A: 08041-02000 DT-6: 799-601-9050
DT-12: 799-601-9110 (GRAY) or 9120 (BLACK)
80-100 22 WA150-6
100 Air conditioner
Detail of air conditioner unit SEN05140-00
Detail of air conditioner unit
A: To blower harness under floor

P: Top position of the sensor
1. Evaporator
2. Heater core
3. Fuse
4. Sensor holder
5. Expansion valve
6. Blower amplifier (AMP)
7. Blower off relay
8. Compressor clutch relay
9. Air mix actuator
10. Evaporator temperature sensor (EVA sensor)
11. (Dual) pressure switch
WA150-6 80-100 23
100 Air conditioner
SEN05140-00 Arrangement of connector pins
Arrangement of connector pins
a W/L and WL are same meaning.
80-100 24 WA150-6
100 Air conditioner
Part and connector locations SEN05140-00
Part and connector locations

a Fuses are installed at two places in the air con- 3. Two 5A fuses and one 15A fuse are on the left
ditioner unit (wiring harness) and in the fuse of the air conditioner unit (A/C U).
box at the right rear of the operator's seat a Identify the 5A fuse by its wiring harness
(duplicated). color. (See the circuit diagram.)
1. Open the fuse box cover at the right rear of the q Fuse part Nos.
operator's seat. (See the fuse locations in 5A: 08041-00500
Troubleshooting.) 15A: 08041-01500
q No. 1 of fuse box FS2: 20A 4. Machine wiring harness connectors C49, C50
For power supply of blower (fan) and air and AL1 are on the left of the air conditioner
conditioner unit unit.
q No. 2 of fuse box FS2: 5A q [3] – [6] are symbols in the circuit diagram.
For air conditioner compressor
q Fuse part Nos.
5A: 08041-00500
20A: 08041-02000
5. Pressure switch (PRESS SW) connector [11] is

installed on the air conditioner hose on the
right of air conditioner unit (A/C U).
2. Remove covers (1) and (2)

q A/C U: Air conditioner unit
q B/I U: Blower intake unit
WA150-6 80-100 25
100 Air conditioner
SEN05140-00 Part and connector locations
6. Connectors [19] and [20] are connected to the

blower intake unit (B/I U) under the left of the
operator's cab.
q Connectors [23] and [24] (See the circuit
diagram) are in the blower intake unit.
You cannot access them unles s the
blower intake unit is disassembled.
7. Connectors C47 and C48 are on the back side

of the air conditioner control panel (CP).
80-100 26 WA150-6
100 Air conditioner
Testing with self-diagnosis function (indication on control panel) SEN05140-00
Testing with self-diagnosis 2. Opening and closing of the Recirc/Fresh selec-

function tor damper do not reach the target value (lock-
ing of the damper is detected since the limiter
(indication on control panel) input is not received) ··· Recirc/Fresh mark (2)
blinks.
Outline a Action of control panel: Stopping output to
The self-diagnosis system checks the following the Recirc/Fresh selector damper.
three items and shows the failed part by blinking a Problem: Recirc/Fresh selector switch (5)
the symbol on the air conditioner control panel does not work.
(CP). a Even if the lever comes off and the
a Once a problem is detected, indication of the damper does not rotate, the self-diagnosis
problem is not reset even if it is repaired. The assumes that the Recirc/Fresh selector
indication can be reset (blinking of the LCD actuator is normal if it rotates normally.
can be stopped) by turning the starting switch a See "Testing Recirc/Fresh selection".
OFF.
3. There is a problem (disconnection, short cir-
1. The drive line of the temperature control air cuit, etc.) in evaporation sensor input circuit ···
mix actuator has a problem (disconnection, A/C mark (3) blinks.
short circuit, etc.) or opening and closing of the a Problem: Air conditioner does not work.
temperature control air mix actuator do not a See "Testing evaporation sensor electri-
reach the target value (locking of the damper is cally".
detected since input voltage of the potentiome- a Resetting control panel: Turn starting
ter is low or limiter input are not received) ··· switch OFF.
HOT mark (1) blinks.
a Action of control panel: Stopping output to
the air mix actuator
a Problem: Temperature control switch (4)
does not work.
a Even if the link comes off and the damper
d o e s n o t r o ta t e , t h e s e l f - d i a g n o s i s
assumes that the air mix actuator is nor-
mal if it rotates normally.
a See "Testing temperature control".
WA150-6 80-100 27
100 Air conditioner
SEN05140-00 Testing temperature control
Testing temperature control 2. Check contacts of connectors C47, C50 (See

the connector locations) and [15] (for discon-
nection).
Outline
q Temperature is controlled by mixing ratio of the 3. If the HOT mark blinks (See the self-diagno-
air from the heater and from the evaporator by sis), check if links (2) – (4) have stopped half-
changing the damper angle in the air mix sec- way. If the links have stopped, remove the
tion. The damper angle is set to different eight cause (hitch, interference, foreign matter, etc.)
levels by the air mix actuator through the link and repair.
and rod. Check the link visually.
a To reset the self-diagnosis system (stop blink- 4. Turn the power of the air conditioner OFF and
ing of the LCD), the starting switch must be then turn the starting switch OFF. (Resetting of
turned OFF (While the LCD is blinking, no sig- problem)
nals are output to the air mix actuator since the
self-diagnosis system has detected a prob- 5. Turn the starting switch ON and then turn the
lem). power of the air conditioner ON.
1. Remove cover (1). 6. Operate the temperature control switch (See

q A/C U: Air conditioner unit the self-diagnosis) and check that link (2)
moves to the eight steps normally together
with links (3) and (4) between COOL MAX and
HOT MAX.
a If the above parts do not move smoothly,
clean them and apply grease to the links.
2 Link: Grease (G2-LI)
(5): Air mix actuator
a For electric problems, see "E-4 Temperature

cannot be controlled".
80-100 28 WA150-6
100 Air conditioner
Testing Recirc/Fresh changeover SEN05140-00
Testing Recirc/Fresh changeover 3. If the self-diagnosis result is abnormal, check

Recirc/Fresh changeover damper has stopped
halfway. If the damper has stopped, remove
Outline the cause (hitch, interference, foreign matter,
Recirculated air or fresh air is selected by changing etc.) and repair.
the damper angle 90° in the intake section of the q For check after repair, see step 4 below.
blower intake unit. The damper angle is changed by q When disassembling, see step 6 below.
the Recirc/Fresh changeover actuator through the
link and rod. Check the opening and closing opera- 4. If the self-diagnosis result is normal, turn the
tions of the damper visually. power of the air conditioner ON and operate
a The self-diagnosis system checks only the the Recirc/Fresh selector switch to see if
motor for locking (It does not check for discon- Recirc/Fresh changeover damper (3) opens
nection and short circuit). and closes normally.
a To reset the self-diagnosis system (stop blink-
ing of the LCD), the starting switch must be 5. If Recirc/Fresh changeover damper (3) does
turned OFF (While the LCD is blinking, no sig- not open or close, check along wiring harness
nals are output to the Recirc/Fresh changeover (H) and check blower intake unit connectors
actuator since the self-diagnosis system has [19] and [20] (See the connector locations) (for
detected a problem). disconnection).
2. Remove duct (2).

q B/I U: Blower intake unit
WA150-6 80-100 29
100 Air conditioner
SEN05140-00 Testing Recirc/Fresh changeover
6. When connectors [19] and [20] are connected

securely,
1) Remove the blower intake unit (B/I U).
2) Referring to Structure and function or
Parts book, disassemble blower intake
unit (B/I U) (only the blower side).
3) Check lever (5) between damper (3) and
damper actuator (4) to see if it has come
off and repair it if necessary.
4) Check connector [23] (damper actuator
connector) (for disconnection).
5) Assemble the blower unit and connect
connectors [20] and [23].
6) Turn starting switch ON, turn the power of

the air conditioner ON, and perform step
4. (After checking, assemble and install
the blower intake unit (B/I U).
a For electric problems, see "E-5
Recirc/Fresh cannot be changed
over".
80-100 30 WA150-6
100 Air conditioner
Testing evaporator temperature sensor electrically SEN05140-00
Testing evaporator temperature q If the result is abnormal, remove the air

sensor electrically conditioner unit (See Disassembly and
assembly, "Removal of air conditioner
q If an error is detected by the self-diagnosis, unit") and replace the evaporator temp.
perform these tests. sensor (3) (See the disassembly drawing
q To reset the self-diagnosis system (detection of in Structure and function).
trouble), the starting switch must be turned a Precautions for disassembling evaporator
OFF. temp. sensor (3) (installed position (P) of
evaporator temp. sensor)
1. Remove cover (1). With the flange outlet (OUT) of the evapo-
q A/C U: Air conditioner unit rator (2) on the right side, install the evap-
orator temp. sensor (3) so that its end will
be 100 ± 5 mm above the fin top face and
its body will be at the center of the 8th
stage of the fins. (Insert and attach the
sensor holder (4) to the 10th and 11th
stages of the fins.)
2. Check contacts of connectors [18] and [26] (for

disconnection).
3. Turn the starting switch OFF and disconnect
connectors [18] and [26].
4. Measure the resistance between the terminals
of connector [26] (on the evaporation temp.
sensor side). a If an error is detected by the self-diagnosis
Normal resistance: and the evaporator temp. sensor (3) is
0°C: 7.2 kz normal, the control panel or wiring har-
25°C: 2.2 kz ness is abnormal.
5. Turn the starting switch OFF and disconnect
connector C48 ([2]) (See the circuit diagram
and connector locations) from the control
panel. Between terminals (5) (GY) and (2) (W)
of connector [2].
Normal resistance:
0°C 7.2 kz
25°C 2.2 kz
a If the result of step 5 above is normal, the
control panel is abnormal. If the former is
abnormal, the wiring harness is abnormal.
WA150-6 80-100 31
100 Air conditioner
SEN05140-00 Testing relays
Testing relays 4. If either relay seems to be abnormal, perform

the following procedure.
q If the air conditioner compressor is normal (air 1) Turn the main power of the air conditioner
is cooled) and air comes out, the relays are OFF and disconnect the battery ground
normal. Accordingly, skip these relay tests. wire.
q Bring your ear to each relay to check its opera- 2) Remove the relay mounting screws and
tion by sound. exchange the blower-off relay (3) and
compressor relay (2).
There are two relays. 3) Connect the battery ground wire and per-
q Blower-off relay: Used to turn the fan motor ON form steps 2 and 3 above and see if the
and OFF conditions of the relays are reversed.
q Compressor relay: Used to turn the air condi-
tioner compressor (clutch) ON and OFF

q A/C U: Air conditioner unit
q Checking relay unit

1) The resistance of the coil between
terminals (1) and (2) is 320 z.
2) Without voltage (DC20 – 30 V) applied
between terminals (1) and (2), termi-
2. Turn the starting switch ON (do not start the nals (3) and (4) are disconnected
engine) and turn the main power of the air con- from each other.
ditioner ON. If the blower-off relay (3) is nor- 3) With the voltage (DC20 – 30 V) applied
mal, it is turned ON. Check its click. between terminals (1) and (2), termi-
3. Turn the air conditioner switch ON. If the com- nals (3) and (4) are connected to
pressor relay (2) is normal, it is turned ON. each other.
Check its click.
a Control panel does not turn the compres-
sor relay (2) ON in the following cases.
1) When the evaporator temperature is
below 3°C (depending on the input
voltage from the evaporator tempera-
ture sensor).
2) When the pressure switch detects
abnormality (it is turned OFF).
a If the fan sound is so loud that you cannot
hear the sound of the compressor relay
(2), perform the following.
1) Turn the main power of the air conditioner
OFF and disconnect the battery ground
wire.
2) Disconnect connector [12].
3) Connect the battery ground wire and
check the compressor relay (2).
80-100 32 WA150-6
100 Air conditioner
Troubleshooting chart 1 SEN05140-00
Troubleshooting chart 1
a The numbers in the boxes are the item numbers in the troubleshooting table.
a E-2, E-3 means Troubleshooting for electrical system (E mode).
1. Cooling trouble
2. Heating trouble
WA150-6 80-100 33
100 Air conditioner
SEN05140-00 Troubleshooting chart 2
Troubleshooting chart 2
1. Blower fan motor does not revolve or its speed is different from set value.
a See "E-3 Blower motor system (No air comes out or air flow is abnormal)" for troubleshooting for
the electrical system.
Possible cause Check method Remedy
Defective BLOWER OFF relay See "Testing relays" Replace
Check connector of blower fan motor for
Disconnection of wire or Repair broken parts and
disconnection. See E-3 and “Part and connector
defective connection connect correctly
locations”
Check two lead wires of motor with circuit tester. If
Defective blower motor there is not continuity, motor is defective. See E-3 Replace
and “Part and connector locations”
Defective BLOWER amplifier
Move fan switches in sequence and check fan speed. Replace
(AMP)
2. Blower fan motor is normal but air flow is insufficient.

Large duct resistance Check duct for crushing and filter for clogging Repair
Air leakage Check fitting condition of air conditioner unit case Replace
Obstruction on suction side of
Check evaporator for stain and obstruction Remove obstruction and clean
evaporator
Defective evaporator
Evaporator is frozen. Check sensor clip. Check Repair or replace
temperature sensor, defective
sensor for dirt (Evaporator temperature
contact of evaporator
Check the frost on the hose near pressure switch sensor and expansion valve are
temperature sensor or defective
(When freezing advances furthermore) in air conditioner unit)
expansion valve
3. Low/high pressure
Collect refrigerant, then charge
Excessive or insufficient
with proper quantity of
refrigerant
refrigerant again
If R-134a is used as refrigerant, its quantity cannot be
Repair leaking part, then
checked through sight glass.
Insufficient refrigerant charge with proper quantity of
Accordingly, check by connecting gauge manifold.
refrigerant again
Purpose of sight glass is to check refrigerant flow.
Collect refrigerant, then charge
Overcharge with refrigerant with proper quantity of
refrigerant again
Normal pressure range
Low pressure:
Approx. 0.13 – 0.2 MPa {1.3 – 2.0 kg/cm2}
Judgment by pressure at inlet/ High pressure: See Troubleshooting with
outlet of compressor Appox. 1.5 – 1.7 MPa {15 – 17 kg/cm2} gauge pressure
These values are for following condition, however.
Temperature in cab: 30 – 35°C
Engine speed: Appox. 1500 rpm
80-100 34 WA150-6
100 Air conditioner
Troubleshooting chart 2 SEN05140-00
4. Compressor does not revolve at all or its speed is low.

a See "E-2 Compressor system (Air is not cooled)" for troubleshooting for the electrical system.
Troubled part Possible cause Check method Remedy
Compressor belt Loosened compressor belt Vibration amplitude of belt is large Adjust tension
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil or seizure See "Handling compressor
Heating of compressor
in the compressor oil"
Low battery voltage Slip of clutch Charge battery
Disconnection or short circuit in coil Inspect with circuit tester Replace
Magnet clutch
Disconnection in wiring or defective Check ground wire and
Repair
connection of ground wire connections. See E-2
Relay Defective compressor relay See “Testing relay” Replace
Refrigerant Low/high pressure Troubleshooting with gauge Troubleshooting with gauge
pressure (Operation of pressure switch) pressure pressure
Pressure switch Defective pressure switch See E-2 Replace
5. Blower fan motor is normal but air flow is insufficient.

Large duct resistance Check duct for crushing and filter for clogging Repair
Check duct joints for defective duct seal and
Air leakage through duct joints Repair
disconnection of duct
Clogging of heater core fins Check heater core fins for clogging Repair
6. Check of hot water

Warm up engine, and then check engine coolant
Low engine coolant temperature Find out cause
temperature
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of engine Check engine coolant piping for clogging (Hose,
Bleed air and repair
coolant pipe, and core)
Contrary connection of IN and OUT
Check the destination of heater hoses Repair
heater hoses
7. Fan rotation speed

Fan rotation speed is low (Defective See "Testing and adjusting hydraulic drive fan" in
Repair
fan motor EPC or hydraulic system) chapter 30 "Testing and adjusting" of shop manual.
WA150-6 80-100 35
100 Air conditioner
SEN05140-00 Troubleshooting chart 2
8. Other items
Possible cause Check method Remark
See "Testing temperature control" and
Temperature cannot be adjusted
"Troubleshooting for electrical system, E-4" Common to cooling and
Recirc/Fresh cannot be changed See "Testing Recirc/Fresh changeover" and heating
over "Troubleshooting for electrical system, E-5"
Excessive compressor oil See "Handling compressor oil"
Cooling only
Water leakage into the cab Clogging of drain hole
80-100 36 WA150-6
100 Air conditioner
Troubleshooting for electrical system (E mode) SEN05140-00
Troubleshooting for electrical system (E mode)

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before troubleshooting, understand the information fully.
Trouble Problem that appears on machine
Related
Information related to detected trouble or troubleshooting
information
Causes Procedure, measuring location, standard (value) and remarks
<Information described>
• Procedure
1 • Measuring location
a “Between A – B” means “Measure voltage or resistance and
so on between A and B”
Assumed causes for trouble • Standard value in normal condition to evaluate assumed cause if
(Perform troubleshooting it is good condition or not.
Possible causes according to these numbers.) • Remarks required to evaluate the cause is correct
and standard
value in normal <Notes on troubleshooting>
2
state (1) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads
as shown below unless otherwise specified.
• Connect the plus (+) lead to pin or harness indicated in the
front.
• Connect the minus (–) lead to a pin or harness indicated in
the rear.
3 - defective (2) Example of troubleshooting by inspection of multiple items
a Normal in 1 but abnormal in 2
At this time "- defective" shown at left is applied
a If a wiring harness is burnt, replace it.
<Phenomenon of defective harness>

q Disconnection in wiring
The connector connection is defective or wiring harness is disconnected.
q Ground fault
A harness not connected to the ground (earth) circuit comes into contact with the ground (earth) circuit
or machine accidentally.
q Hot short circuit
A harness not connected to the power (24 V) circuit comes into contact with the power (24 V) circuit
accidentally.
q Short circuit
An independent wire in the abnormally contacts another wire. (Defective insulation in connector or oth-
ers)
This is the excerpted circuit diagram related to troubleshooting

q Connector No.: Indicates (Model – No. of pins) (Color).
q See "Arrangement of connector pins" and "Arrangement of parts and connectors"
q The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown,
Gr: Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are 2 colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
q N.C.: Normally closed (Normally turned ON)
q [1], [2],··· are connector numbers.
q Arrow (↔): Roughly indicates mounting place on machine.
WA150-6 80-100 37
100 Air conditioner
SEN05140-00 Troubleshooting for electrical system (E mode)
E-1 Power supply system (Air conditioner does not operate)

Problem Air conditioner does not operate due to power supply system failure.
Indication of • When main power of control panel is turned ON and switch is pressed, no LCD on control panel
problem on lights up.
machine • No air comes out (Blower motor does not rotate).
• Referring to "Part and connector locations", check fuse No. 1 (20A) of fuse FS2 and 5A fuse in air
conditioner unit (wiring harness) for breakage.
Related
• Air conditioner ground wire is grounded together with that of machine wiring harness for machine
information
electric components.
• For each connector, see "Part and connector locations".

1) Turn starting switch OFF.
2) Disconnect battery ground cable.
Defective wiring harness 3) Disconnect connector C48 ([2]) from control panel.
1
(ground)
Between [2]-(1) (black) on wiring harness Resis-
Max. 1 z
side of connector C48 and ground tance
a If any fuse referred to in the related information is broken,
replace it.
3) Disconnect connectors C47 ([1]) and C48 ([2]) from control panel.
Between [2]-(1) (black) and (7)
Defective wiring harness or Resis-
2 (YW) on wiring harness side of Min. 1 Mz A
defective air mix actuator tance
connector C48
Approx.
Between [1]-(10) (BW) and (22) 4 kz
Resis-
(red) on wiring harness side of (Potenti- B
Possible causes tance
connector C47 ometer
and standard resistance)
value in normal
state a If check result of cause 2-A is abnormal, find out abnormal wiring
harness.
1) – 3) See cause 2.
2) Disconnect connector C49 ([3]).
a If check result of C below is abnormal: Wiring harness between
air conditioner unit and control panel is abnormal.
Resis-
(YW) on wiring harness side of Min. 1 Mz C
tance
Ground fault in wiring har- connector C48
3 ness a If check result of cause 2-A is abnormal and check result of C
(Contact with GND circuit) above is normal, find out abnormal wiring harness.
2) Connect connector C49 ([3]).
3) Disconnect connector AL1.
a If check result of D below is abnormal: Wiring harness in air con-
ditioner unit is abnormal.
Resis-
(YW) on wiring harness side of Min. 1 Mz D
tance
connector C48
80-100 38 WA150-6
100 Air conditioner

a If check result of cause 2-A is abnormal and check results of C
and D are normal, machine wiring harness is abnormal. Check
for confirmation.
2) Disconnect connector AL1 and connect T-adapter to connector
[7] on machine wiring harness side.
Between [7]-(1) (green) and (5)
Resis-
(black) on machine wiring har- Min. 1 Mz
tance
Ground fault in wiring harness side of connector AL1
3 ness a If check result of cause 2-B is abnormal, check to see if wiring
(Contact with GND circuit) harness is cause.
a If check results of cause 2-B and E below are abnormal, discon-
nect connector [5] and check again in the same way to find
abnormal wiring harness.
Between [1]-(10) (BW) and (22)
Resis-
(red) on wiring harness side of Min. 1 Mz E
tance
connector C47
Possible causes 1) Turn starting switch OFF.
and standard 2) Disconnect battery ground cable.
value in normal 3) Disconnect relay connectors [12] and [14].
state a See Testing relays.
Defective relay
4
(Short circuit in relay coil) Between blower-off relay (1) – Resis-
320 z
(2) tance
Between compressor relay (1) – Resis-
320 z
(2) tance
replace it.
3) Disconnect connectors C47 ([1]) and C48 ([2]) from control
5 Defective control unit panel.
4) Connect battery ground cable, turn starting switch ON.
a Keep control panel disconnected.
Between [2]-(7) (YW) and (1)
(black) on wiring harness side of Voltage 20 – 30 V
connector C48
Defective air mix actuator
6 (Short circuit in potentiome- When check results of causes 2-B and 3-E are normal.
ter resistor)
Disconnection in wiring har- Referring to circuit diagram, check power supply line (if voltage is
7
ness not applied when cause 5 is checked).
WA150-6 80-100 39
100 Air conditioner
80-100 40 WA150-6
100 Air conditioner
E-2 Compressor or refrigerant system (Air is not cooled)

Problem Air is not cooled due to compressor or refrigerant system failure.
Indication of • When main power of control panel is turned ON and air conditioner switch is pressed, LCD on
problem on control panel lights up but air is not cooled.
machine • Air conditioner compressor does not operate.
• Check "A/C mark" and "HOT mark" with self-diagnosis function. If they are blinking, see "Self-
diagnosis function" and repair abnormality by self-diagnosis.
• Referring to "Part and connector locations", check fuse No. 2 (5A) of fuse FS2 for breakage.
Related • Pressure switch is turned OFF when refrigerant pressure is abnormally low or high (See Structure
information and function in chapter 80 “Air conditioner”).
• Referring to "Testing temperature control", check angle of air mix damper (link section).
• Air conditioner may not be turned ON even when ambient temperature is below 5°C (Normal).
• For each connector, see "Part and connector locations".

Defective wiring harness 2) Disconnect connector E10 from air conditioner compressor.
1
(ground) Between [9]-(2) (black) on wiring harness Resis-
Max. 1 z
side of connector E10 and ground tance
2) Disconnect connector E10 from air conditioner compressor and
Defective air conditioner connect T-adapter to male side.
2
compressor
Resis- Approx.
Between connector E10 (male) (1) and (2)
tance 15 z
a If any fuse referred to in the related information is broken, check
for cause 4 first. If check result of cause 4 is normal, perform
replace it.
Defective compressor relay, 1) Turn starting switch OFF.
3 pressure switch or control 2) Disconnect connector E10 from air conditioner compressor and
panel connect T-adapter to [9] on wiring harness side.
3) Turn starting switch ON, turn main power of control panel ON,
Possible causes press air conditioner switch.
and standard Between [9]-(1) and (2) on wiring
value in normal Voltage 20 – 30 V
harness side of connector E10
state
a If no fuse referred to in related information is broken, skip all
checks for cause 4.
2) Disconnect connector E10 from air conditioner compressor and
carry out troubleshooting with starting switch kept OFF.
Between [9]-(1) and (2) on wiring Resis-
Min. 1 Mz A
harness side of connector E10 tance
a If check result of A above is abnormal, find out abnormal wiring
harness.
Ground fault in wiring
4 harness
2) Disconnect battery ground terminal.
(Contact with GND circuit)
3) Disconnect connector E10 from air conditioner compressor.
4) Disconnect connector AL1.
Between [9]-(1) and (2) on wiring Resis-
Min. 1 Mz B
harness side of connector E10 tance
a If check result of A above is abnormal and check result of B
above is normal, perform following procedure.
1) – 4) See above.
a If check result C below is abnormal: Machine wiring harness
between fuse and air conditioner unit is abnormal.
WA150-6 80-100 41
100 Air conditioner

Between [7]-(3) (white) and (5)
Resis-
(black) on wiring harness side of Min. 1 Mz C
tance
connector AL1
a If check result of A above is abnormal and check results of B and
C above are normal, perform following procedure.
Ground fault in wiring 1) – 4) See above.
4 harness 4) Disconnect compressor relay connector [14].
(Contact with GND circuit) a If check result D below is abnormal: Wiring harness in air condi-
tioner unit is abnormal.
Between [8]-(3) (red) and (5)
(black) on air conditioner unit Resis-
Min. 1 Mz D
wiring harness side of connector tance
AL1
3) Replace blower-off relay with compressor relay.
a See check of relay.
Defective compressor relay 4) Connect battery ground terminal.
5 5) Turn starting switch ON.
(Relay is not turned ON)
6) Turn main power of control panel ON and press air conditioner
switch.
If air conditioner compressor operates and air does not come out,
Possible causes original compressor relay is defective.
and standard 1) Turn starting switch OFF.
value in normal 2) Disconnect battery ground terminal.
state 3) Disconnect pressure switch connector [11].
a Pressure switch may operate normally and turn off itself. Accord-
ingly, if following is abnormal (if switch is turned OFF), install
6 Defective pressure switch pressure gauge to low pressure side of air conditioner compres-
sor and check refrigerant pressure.
Between (1) and (2) on pressure Resis-
Min. 1 Mz
switch side of connector tance
k When replacing pressure switch, collect refrigerant in advance.
3) Disconnect connectors C47 ([1]) from control panel.
4) Connect battery ground terminal and turn starting switch ON.
a Keep only connector C48 connected to control panel.
7 Defective control panel 5) Turn main power of control panel ON and press air conditioner
switch.
Between (15) on control panel
side of connector C47 and Voltage Max. 1 V
ground
Disconnection in wiring
8 Refer to circuit diagram, check wiring harness for disconnection.
harness
Lowering of fan rotation See "Testing hydraulic drive fan" in chapter 30 "Testing and adjust-
9 speed (wind speed at ing" of shop manual.
condenser) Fan rotation speed at engine low idle Min. 300 rpm*
* Reference value under the following condition

• Engine coolant temp.: more than 70°C
• Engine charge air (boost) temp.: more than 60°C
• HST oil temp.: approx. 50°C
80-100 42 WA150-6
100 Air conditioner
WA150-6 80-100 43
100 Air conditioner
E-3 Blower motor system (No air comes out or air flow is abnormal)
Problem No air comes out or air flow is abnormal due to blower motor system failure.
Indication of • When main power of control panel is turned ON, LCD on control panel lights up but air does not
problem on come out.
machine • Air flow does not match fan switch setting of control panel.
• This trouble cannot be checked with self-diagnosis function.
• Referring to "Part and connector locations", check 15A fuse in air conditioner unit for breakage.
• If air flow becomes abnormal after a while in cooling mode, evaporator may be frozen. In this case,
the probable causes are as follows.
1) Defective compressor relay, (stuck close) See "Testing relays".
Related
2) Evaporator sensor mounting clip may have come off.
information
3) Expansion valve may not be adjusted correctly. (Remove and disassemble air conditioner unit.)
• If air comes out, fuse and relay are normal and wiring harness is seldom abnormal.
• If air flow is also abnormal in heating mode, replace blower amplifier first.
• For each connector and relay, see "Part and connector locations".
• Since blower intake unit is independent (under cab), disconnect it first.

2) Disconnect connector [20] from under cab and connect T-adapter
to it.
Between wiring harness (1) (R/W) and (3)
(orange) of connector [20] (on blower motor There is continuity
side)
Defective blower (fan) motor 1) Turn starting switch OFF.
1 or defective wiring harness in 2) Disconnect connector [20] from under cab and insert T-adapter
blower intake unit (Connect connectors [19] and [20]).
3) Turn starting switch ON and turn main power of control panel ON.
4) Set fan switch to HI-MAX.
a If following voltage is not applied, go to cause 4.
Between wiring harness (1) (R/
W) and (3) (orange) of connector Voltage 20 – 30 V
Possible causes [20] (on blower motor side)
and standard a If check result of cause 1 is abnormal (continuity is broken or
value in normal motor does not rotate while voltage is normal), perform following
state procedure.
2) Remove blower intake unit.
3) Referring to Structure and function, disassemble blower intake
Defective wiring harness in unit. (Disconnect connector [24])
2
blower intake unit Orange line between connectors Resis-
Max. 1 z
[20] and [24] tance
RW line between connectors [20] Resis-
Max. 1 z
and [24] tance
Between (1) (RW) and (3) Resis-
Min. 1 Mz
(orange) of connector [20] tance
a If check result of cause 1 is abnormal (continuity is broken or
motor does not rotate while voltage is normal) and check result
3 Defective blower (fan) motor of cause 2 is normal, perform following procedure.
a If blower (fan) motor coil is burnt and broken because of short
circuit, fuse (15A) is also broken.
80-100 44 WA150-6
100 Air conditioner

a If no fuse referred to in the related information is broken, skip all
checks for cause 4.
3) Disconnect connectors AL1, [12], [19] and [13].
4) Connect T-adapter to connector [19] and [8] on air conditioner
unit side of AL1.
Between [8]-(5) on air condi-
Defective wiring harness Resis-
tioner unit side of connector AL1 Min. 1 Mz
4 (Contact with GND circuit or and (3) of connector [12] tance
another line)
Between [8]-(5) on air condi-
Resis-
tioner unit side of connector AL1 Min. 1 Mz
tance
and (4) of connector [12]
Between (2) and (3) of connector Resis-
Min. 1 Mz
[12] tance
Between (1) and (3) of connector Resis-
Min. 1 Mz
[19] tance
• Referring to check of relay, check if turn-
Click is heard.
ON sound of blower-off relay is heard.
a If "click is not heard" in above troubleshooting, perform following
procedure.
Defective blower-off relay, 3) Replace blower-off relay with compressor relay.
etc. (Relay is not turned ON) a See check of relay.
5
4) Connect battery ground cable.
5) Turn starting switch ON.
Possible causes 6) Turn main power of control panel ON.
and standard a If air comes out, original blower-off relay is defective.
value in normal
state a If check result of cause 5 is abnormal but relay is normal, go to
cause 7.
2) Insert T-adapter between connectors [13] and [25].
4) Turn main power of control panel ON.
a Check about 10 V between terminals (B) and (C) (base voltage)
of blower amplifier input connector [13].
Between (A) and (C) of connec-
Voltage Max. 10 V
tor [13]
2) Operate fan switch on control panel from LO to HI.
a Between terminals (B) and (C) (base voltage) of blower amplifier
input connector [13].
Between (A) and (C) of connec- Change is 10 V or
Voltage
6 Defective blower amplifier tor [13] less
a If blower amplifier is normal, all of following are normal. Reverse
is not always satisfied, however (Amplifier cannot be checked by
checking each unit).
3) Connect T-adapter to connector [25] (Keep connector [13]
disconnected).
Between (B) and (C) of connec- Resis-
4.7 kz ± 5 %
tor [25] tance
Between (A) (+) and (C) (–) of connector There is no continuity
[25] * Diode range
Between (A) (–) and (C) (+) of connector There is continuity
[25] * Diode range
WA150-6 80-100 45
100 Air conditioner

2) Disconnect connector C49 and insert T-adapter (since there is
not T-adapter for connector C47).
4) Turn main power of control panel ON (Turn blower-OFF relay ON
Possible causes (Output = GND) to apply voltage of about 10 V to base of blower
and standard 7 Defective control panel amplifier.)
value in normal
state Between (6) and (11) of
Voltage Max. 1 V
connector C49
Between (5) and (11) of
Voltage Approx. 10 V
connector C49
Disconnection in wiring har- Referring to circuit diagram, check wiring harness for disconnec-
8
ness tion.
80-100 46 WA150-6
100 Air conditioner
E-4 Temperature cannot be controlled

Problem Temperature cannot be controlled
Indication of
problem on • When temperature control switch on control panel is operated, temperature does not change.
machine
a Temperature control means “Air Mix” of cooled air and hot air.
• When main power of control panel is turned ON, HOT mark (LCD) on control panel blinks. (See self-
diagnosis function.)
• Self-diagnosis system checks air mix actuator for disconnection and short circuit and checks
contacts (LIMIT terminal) in air mix actuator each time main power of control panel is turned ON.
• Even if link is disconnected (See "Testing temperature control", self-diagnosis system assumes that
Related
temperature control system is normal, if air mix actuator rotates when switch is operated.
information
• Operating angle of air mix actuator (COOL-MAX – HOT-MAX) is 90°.
• Referring to "Testing temperature control", check that there is not mechanical trouble (disconnection
or interference of link, etc.)
• To replace air mix actuator, link section must be removed. (See parts book and Structure and
function.)

Since there is no T-adapter for connector [15], check with connec-
tors C49 and C50.
2) Disconnect connectors C49 and C50 and connect T-adapter to
connectors [4] and [6] (on air conditioner unit side).
3) Perform troubleshooting with connectors [3] and [5] (on control
panel side) disconnected.
Between (1) of connector [4] and Resis- Approx. 110 z
Defective air mix actuator or (12) of connector [6] tance (Motor coil)
1 defective wiring harness in
air conditioner unit Between (1) and (10) of connec- Resis-
Approx. 4 kz
tor [6] tance
Approx. 500 z
Between (7) and (10) of connec- Resis- (COOL-MAX) –
tor [6] tance Approx. 3.5 kz
Possible causes (HOT-MAX)
and standard
value in normal a Contact input cannot be checked with removed unit (See related
state information).
resistance is abnormal), perform following procedure.
Defective wiring harness in 1) Turn starting switch OFF.
2 2) Disconnect connectors C49, C50 and [15] and connect T-
air conditioner unit
adapter to connectors [4] and [6] (on air conditioner unit side).
Referring to circuit diagram, check wiring harness for defect.
3 Defective air mix actuator resistance is abnormal) and check result of cause 2 is normal,
perform following procedure.
Defective wiring harness 2) Disconnect connectors C47, C49 and C50 and connect T-
4 (extended) between control adapter to connectors [3] and [5] (on extended wiring harness
panel and air conditioner unit side).
WA150-6 80-100 47
100 Air conditioner

a If self-diagnosis system does not blink LCD, output to actuator is
not stopped, thus control unit can be checked.
2) Disconnect connectors C49 and C50 and insert T-adapter (since
there is not T-adapter for connector C47).
5) Press temperature control switch and check if voltage is applied
in about 3 seconds (while damper is moving). (Voltage stops
when damper stops.)
a Polarities (+, –) in changing from COOL to HOT are reverse to
those in changing from HOT to COOL.
Approx. 24 V (For
Between connector C49 (1) (+)
about 3 seconds after
and C50 (2) (–) Voltage
temperature control
a COOL o HOT
switch is pressed)
Possible causes Approx. 24 V (For
and standard Between connector C49 (1) (–)
about 3 seconds after
value in normal and C50 (2) (+) Voltage
5 Defective control panel temperature control
state a HOT o COOL
switch is pressed)
not T-adapter for connector C47).
Between connector C50 (1) (+)
Voltage 5V
and (10) (–)
5) Measure each time you press temperature control switch.
(Measure 8 times in total from COOL-MAX to HOT-MAX.)
a If damper rotates, potentiometer resistance changes and voltage
changes consequently.
Between (7) and (10) of connec- Change between
Voltage
tor C50 0 and 5 V
80-100 48 WA150-6
100 Air conditioner
WA150-6 80-100 49
100 Air conditioner
E-5 Recirc/Fresh cannot be changed over

Problem Recirc/Fresh cannot be changed over.
Indication of
• When Recirc/Fresh selector switch on control panel is operated, recirculated or fresh air does not
problem on
change over (Recirc/Fresh changeover damper does not rotate).
machine
• When main power of control panel is turned ON, Recirc/Fresh mode LCD blinks. (See self-diagnosis
function.)
• Self-diagnosis system checks contacts (LIMIT terminal) in Recirc/Fresh changeover actuator each
time main power of control panel is turned ON.
a Since self-diagnosis system does not check Recirc/Fresh changeover actuator line for disconnec-
tion and short circuit, it does not indicate all troubles of Recirc/Fresh changeover actuator by blink-
Related ing LCD.
information • Referring to "Testing Recirc/Fresh changeover", check that there is not mechanical trouble (removal
or interference of lever, etc.)
• Operating angle of Recirc/Fresh changeover actuator is 90°.
• To replace Recirc/Fresh changeover actuator, blower intake unit must be removed and
disassembled. (See "Testing Recirc/Fresh changeover".)
• Resistance (Potentiometer) in Recirc/Fresh changeover actuator is not used.

Since there is no T-adapter for connector [23], check with connec-
tor C49.
2) Disconnect connector C49 and connect T-adapter to connector
[4] (on air conditioner unit side).
Defective Recirc/Fresh 3) Perform troubleshooting with connector [3] (on control panel
changeover actuator or side) disconnected.
defective wiring harness in
1
air conditioner unit or defec- Between (3) and (7) of connector Resis- Approx. 110 z
tive wiring harness in blower [4] tance (Motor coil)
intake unit
There is one way
Between (3) and (8) of connector [4]
continuity.
a Measure in diode range
(Because one of
a Check continuity on both directions by
internal switch is
changing polarity of tester probes
OFF.)
resistance is abnormal), perform following procedure.
Possible causes 1) Turn starting switch OFF.
and standard Defective wiring harness in
2 2) Disconnect connectors C49 and [19] and connect T-adapter to
value in normal air conditioner unit
[4] and [19] of connector C49 (on air conditioner unit side).
state
resistance is abnormal) and check result of cause 2 is normal,
perform following procedure.
Defective wiring harness in 1) Turn starting switch OFF.
3 2) Referring to "Testing Recirc/Fresh changeover", remove and
blower intake unit
disassemble blower intake unit.
3) Perform troubleshooting with connector [23] disconnected.
Defective Recirc/Fresh
4 resistance is abnormal) and check results of causes 2 and 3 are
changeover actuator
normal, perform following procedure.
Defective wiring harness 2) Disconnect connectors C47, C48 and C49 and connect T-
5 (extended) between control adapter to connector [3] (on extended wiring harness side).
panel and air conditioner unit
80-100 50 WA150-6
100 Air conditioner

not T-adapter for connectors C47 and C48).
Possible causes
and standard
5) Press Recirc/Fresh selector switch and check if voltage is
value in normal 6 Defective control panel applied in about 3 seconds (while damper is moving). (Voltage
state
stops when damper stops.)
a Polarities (+, –) in changing from Recirc to Fresh are reverse to
those in changing from Fresh to Recirc.
Approx. 24 V (For
Between (7) and (8) of connector about 3 seconds after
Voltage
C49 Recirc/Fresh selector
switch is pressed)
WA150-6 80-100 51
100 Air conditioner
SEN05140-00 Troubleshooting with gauge pressure
Troubleshooting with gauge pressure

Referring to "Connection of service tool", carry out <Measurement condition for pressure>
troubleshooting by reading the high and low gauge Item Condition value
pressures of the cooling cycle.
Atmospheric temperature 20 – 50°C
a The gauge pressure varies largely with the Engine speed Low idle
weather condition and operating condition of Air conditioner switch ON
the machine. Take care. Fan switch Hl
q High pressure is too high: Set temperature Full cool

Above approx. 2.5 MPa {25 kg/cm2}
q High pressure is too low: q Dual pressure switch
Below approx. 1 MPa {10 kg/cm2} a Normally "ON", abnormal pressure "OFF" for
q Low pressure is too high: compressor.
Above approx. 0.3 MPa {3 kg/cm2}
q Low pressure is too low:
Below approx. 0.05 MPa {0.5 kg/cm2}
a (Dual) pressure switch on high pressure side

protects air conditioner circuit with OFF:
See right
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
Indicated gauge pressure Cause Check method Remedy

Air conditioner cycle is operating normally.
If there is any trouble (cooling trouble), there is another
Pressure is normal cause.
High pressure: Approx. 1.5 – 1.7 MPa {15 – 17 kg/cm2}
Low pressure: Approx. 0.13 – 0.2 MPa {1.3 – 2.0 kg/cm2}
Collect refrigerant, then fill
Bubble can be seen in the
Insufficient refrigerant up with proper quantity of
sight glass (*1)
refrigerant again (*2)
There is a temperature dif-
ference between inlet and Replace
Clogging of receiver drier
outlet pipes of receiver drier. (*2)
Tank is frosty
Clean or replace
Clogging of expansion valve Expansion valve is frosty
(*2)
Both high pressure and low Gas leakage at heat sens- Low pressure gauge Replace
pressure are too low ing tube of expansion valve becomes vacuum (*2)
Low pressure becomes vac- Repair or replace
Evaporator is frozen
uum Defective evaporator sensor Replace receiver drier
Air flow is down by freezing
or defective contact of sen- Collect refrigerant, then fill
(At cool max. and HI speed
sor (removal of mounting up with proper quantity of
of fan, later it becomes not to
clip) refrigerant again
cold.)
(*2)
Piping between receiver
drier and compressor is
Clogging or flattening or pip- clogged or flattened. If Clean or replace
ing clogged completely, low (*2)
gauge pressure becomes
vacuum
80-100 52 WA150-6
100 Air conditioner
Troubleshooting with gauge pressure SEN05140-00
Indicated gauge pressure Cause Check method Remedy

Collect refrigerant, then fill
Filling too much with refriger- up with proper quantity of
Connect gauge manifold
ant refrigerant again
(*2)
Stain of condenser, clogging Clean, repair fins, or repair
Defective cooling of con-
or crushing of fins, or defec- or replace condenser
denser
Both high pressure and low tive revolution of cooling fan (*2)
pressure are too high Defective adjustment of
Bubble can be seen in the Replace
expansion valve (Valve is
sight glass (*2)
opened too wide)
Evacuate and then fill up with
Bubble can be seen in the proper quantity of refrigerant
Air in cycle
sight glass again
(*2)
Clogging or flattening of pip- There is a remarkable tem- Clean inside of cycle or
High pressure is too high
ing between compressor and perature difference between replace
and low pressure is too low
condenser before and after clogged part (*2)
Both high pressure and low
Defective compressor (Com- pressure are balanced while
High pressure is too low and Replace
pression trouble of compres- compressor is in operation.
low pressure is too high (*2)
sor) Compressor has seized and
is extremely hot.
*1 If refrigerant leaks, internal oil always leaks, too. So perform the check mainly on pipe joints and parts which are
stained with oil. Increase tightening of the joints or replace parts.
*2. k When replacing a cooling cycle part, see "Caution about refrigerant" and collect refrigerant. After replacing it, fill
up the air conditioner system with refrigerant again.
a Sight glass (1) is on the receiver drier (2).
WA150-6 80-100 53
100 Air conditioner
SEN05140-00 Connection of service tool
Connection of service tool

X 799-703-1200 Service tool kit
a Use the service tool kit for R134a. Connect the gauge manifold, hoses and other ser-
vice tools according to the following procedure.
Service tool kit
1. Gauge manifold 1. Close the high-pressure valve (HI) and low-
2. High pressure charging hose (red) pressure valve (LO) of gauge manifold (1).
3. Low pressure charging hose (blue) 2. Connect red charging hose (2) to the (HI) side
4. Quick joint (Hi) (Large diameter) and blue charging hose (3) to the (LO) side.
5. Quick joint (Lo) (Small diameter) 3. Connect quick joints (4) and (5) to each hose.
a. The thread is rough. So be careful not to loosen. 4. Connect the quick joints to the service valves
of the high and low-pressure pipings.
80-100 54 WA150-6
100 Air conditioner
Precautions for connecting air conditioner piping SEN05140-00
Precautions for connecting air

conditioner piping
q When connecting the piping, apply compressor
oil (SP-10) for R134a to the O-rings. (See item
4. in "Handling of compressor oil")
Do not apply oil to the threads of a bolt, nut or
union, however.
q Once an O-ring is used, it is deformed and
deteriorated. Accordingly, do not reuse it.
When removing it, use a soft tool (such as a
toothpick) so that the piping will not be dam-
aged.
q Push in each pipe to the stopper (until it clicks)
and tighten the bolt or nut fully with your fin-
gers.
q Be sure to use two wrenches to tighten each
nut (Apply a torque wrench to the tightening
side). Place one wrench and tighten the nut
with the other wrench to the specified torque.
Refrigerant piping diagram
Table of tightening torque for refrigerant piping adapter and installation

Unit: Nm {kgm}
Screw size Tightening torque
M6 x 1.0 8 – 12 {0.8 – 1.2}
M8 x 1.25 20 – 25 {2.0 – 2.6}
M8 unit 9.8 – 12 {1.0 – 1.2}
M16 x 1.5 12 – 15 {1.2 – 1.5}
M22 x 1.5 20 – 25 {2.0 – 2.6}
M24 x 1.5 30 – 35 {3.1 – 3.6}
WA150-6 80-100 55
100 Air conditioner
SEN05140-00 Handling of compressor oil
Handling of compressor oil Check compressor oil in the following cases,

and then add new oil if necessary.
1. Control of compressor oil q When much refrigerant is discharged
(SANDEN: SP-10: For R134a) because of leakage.
Compressor oil does not need to be checked q When the compressor is troubled and
or added so frequently as engine oil. Insuffi- replaced.
ciency or excess of compressor oil can cause q When a cycle parts such as the air condi-
the following troubles. tioner unit, condenser, receiver drier,
Condition Contents evaporator unit, etc. is replaced.
Lubrication trouble and seizure
Insufficiency of oil Quantity of oil to be added when cycle part is
of compressor
replaced
Cooling trouble (Excessive oil
Excess of oil stick to parts and lower heat Quantity to be added
exchange performance) Air conditioner part
(cm3)
Air conditioner unit,
Accordingly, compressor oil must be filled to evaporator
Approx. 40
the specified level, similarly to refrigerant.
Condenser Approx. 40
2. Adding of compressor oil Receiver drier Approx. 20
k Since refrigerant is dangerous and bad Hose (Cab – M24 Joint) Approx. 15
for environment, collect the refrigerant Each hose (M24 Joint –
before disconnecting the air condi- Approx. 20
Compressor – Condenser)
tioner hose. See "Caution about refrig- Each hose (Cab – M16
erant". Approx. 10
Joint – Receiver drier)
may lose your sight. (Put on protective
goggles.)
a If oil for CFC-12 (R-12) is used, lubrication
trouble will occur and the compressor may
be broken or seized.
Be sure to use the specified oil for R134a
(SANDEN: SP-10)
a Oil for R134a absorbs moisture very eas-
ily. Accordingly, fit the cap immediately
after using oil to stop the atmosphere.
Store the oil can in a dry and ventilated
place.
a Precautions for using oil
Oil for R134a (SP-10 in particular) may
dissolve acrylic resin and polystyrene
(excluding baked polystyrene paint film).
Accordingly, do not stick oil to those plas-
tics.
80-100 56 WA150-6
100 Air conditioner
Handling of compressor oil SEN05140-00
3. Compressor replacement 4. Applying compressor oil for O-ring

q In case of compressor seizure or break- When connecting a pipe or hose, apply oil
age. (SP-10) to its O-ring to prevent refrigerant
Metal chips will circulate through the air leakage.
conditioner circuit and contaminate the k When discarding a can which still has
compressor oil extremely. some oil in it, make a hole on it to dis-
In this case, flush the air conditioner circuit charge gas and oil.
and replace the compressor and receiver
drier.
The compressor oil is removed from the
air conditioner circuit by flushing.
Accordingly, install a new compressor with
the oil of the specified quantity (135 cc)
filled in it.
q Other cases
New compressor has 135 cc compressor
oil in it. So drain excessive compressor oil
before installing new compressor in the
following.
1) Prepare an oil pan and drain oil from
old compressor.
2) Measure the quantity of the drained
oil with a graduated cylinder, and note
the quantity or mark the level.
3) Drain below-mentioned quantity of oil

from new compressor.
135 cc – "the noted quantity".
EX. If drained oil quantity from
removed compressor is 30cc,
drain oil of 135 – 30 cc = 105 cc
from new one.
WA150-6 80-100 57
SEN05140-00

©2009 KOMATSU
All Rights Reserved
80-100 58
SEN05085-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
90 Diagrams and drawings 1
100 Hydraulic diagrams and drawings

Hydraulic circuit diagram................................................................................................................................. 3
WA150-6 90-100 1
SEN05085-00
90-100 2 WA150-6
Hydraulic circuit diagram
Hydraulic circuit diagram WA150-6
1
WA150-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN05085-00
WA150-6
90-100 3
SEN05085-00
WA150-6 90-100 5
SEN05085-00

©2009 KOMATSU
All Rights Reserved
90-100 6
SEN05086-00
WHEEL LOADER
WA150-6

WA150-6 80001 and up
90 Diagrams and drawings 1
200 Electrical diagrams and drawings

Electrical circuit diagram ................................................................................................................................. 3
Connector list and stereogram...................................................................................................................... 27
WA150-6 90-200 1
SEN05086-00
90-200 2 WA150-6
Common electrical circuit diagram (1/9) Electrical circuit diagram 1 Common electrical circuit diagram (1/9)
WA150-6, WA200-6, WA200PZ-6,
WA150-6, WA200-6, WA200PZ-6, WA250-6, WA250PZ-6, WA320-6, WA320PZ-6
WA250-6, WA250PZ-6, WA320-6, WA320PZ-6
SEN05086-00
WA150-6
90-200 3
Common electrical circuit diagram (2/9) Common electrical circuit diagram (2/9)
WA150-6, WA200-6, WA200PZ-6,
WA250-6, WA250PZ-6, WA320-6, WA320PZ-6
SEN05086-00
WA150-6
90-200 5
WA150-6, WA200-6, WA200PZ-6,
WA250-6, WA250PZ-6, WA320-6, WA320PZ-6
SEN05086-00
WA150-6
90-200 7
WA150-6, WA200-6, WA200PZ-6,
WA250-6, WA250PZ-6, WA320-6, WA320PZ-6
SEN05086-00
WA150-6
90-200 9
WA200-6, WA200PZ-6, WA250-6, WA250PZ-6
WA200-6, WA200PZ-6, WA250-6, WA250PZ-6
SEN05086-00
WA150-6
90-200 11
WA150-6, WA200-6, WA200PZ-6,
WA250-6, WA250PZ-6, WA320-6, WA320PZ-6
SEN05086-00
WA150-6
90-200 13
WA200-6, WA200PZ-6, WA250-6, WA250PZ-6
WA200-6, WA200PZ-6, WA250-6, WA250PZ-6
SEN05086-00
WA150-6
90-200 15
WA150-6, WA200-6, WA200PZ-6,
WA250-6, WA250PZ-6, WA320-6, WA320PZ-6
SEN05086-00
WA150-6
90-200 17
WA150-6, WA200-6, WA200PZ-6,
WA250-6, WA250PZ-6, WA320-6, WA320PZ-6
SEN05086-00
WA150-6
90-200 19
Specific electrical circuit diagram (1/3) Specific electrical circuit diagram (1/3)
WA150-6
WA150-6
SEN05086-00
WA150-6
90-200 21
WA150-6
WA150-6
SEN05086-00
WA150-6
90-200 23
WA150-6
WA150-6
SEN05086-00
WA150-6
90-200 25
Connector list and stereogram
Connector list and stereogram WA150-6 WA150-6
Connector Number Address of Connector Number Address of Connector Number Address of

Model Component name Model Component name Model Component name
No. of pins stereogram No. of pins stereogram No. of pins stereogram
AL1 DT-T 6 Intermediate connector S-1 FLH DT-T 3 Head lamp (L.H.) G-1 L115 — 5 Detent active relay AA-9
B01 DT-T 2 Rear work lamp (R.H.) J-9 FS1 — 15 Fuse box V-9 L116 — 5 Horn relay AA-9
B02 DT-T 2 Rear work lamp (L.H.) M-8 FS2 — 15 Fuse box V-9 L117 — 5 Small lamp LH relay AA-6
B03 DT-T 2 Back-up alarm M-7 HDL DT-T 6 Intermediate connector G-1 L118 — 5 Small lamp RH relay AA-5
B05 DT-T 2 Coolant level sensor M-8 HDR DT-T 6 Intermediate connector A-4 L119 — 5 Head lamp RH relay L.H. AA-5
B06 08027 2 (R) Window sealed washer M-7 HST DRC 40 HST controller Z-6 L120 — 5 Head lamp LH relay R.H. AA-5
B07 08027 2 (F) Window sealed washer M-7 J01 M6409-0075 20 Joint connector R-6 L121 — 5 Stop lamp relay Z-5
B08 DT-T 2 Diode M-4 J02 M6409-0255 20 Joint connector R-6 L122 — 5 Front work lamp relay AA-4
B09 DT-T 2 Diode M-3 J03 M6409-0071 20 Joint connector V-1 L123 — 5 Rear work lamp relay AB-4
BL1 DT-T 6 Intermediate connector A-9, X-2 J04 M6409-0075 20 Joint connector Y-9 L124 — 6 Hazard/turn relay AB-4
BR1 DT-T 4 Intermediate connector L-8 J05 M6409-0072 20 Joint connector Y-9 L125 — 5 Hazard relay AB-4
C04 DT 2 Front work lamp (R.H.) 24V/70W E-8 J06 M6409-0071 20 Joint connector Y-9 L126 — 5 Back alarm/lamp 2 relay AB-6
C05 DT 2 Front work lamp (L.H.) 24V/70W J-9 J07 M6409-0072 20 Joint connector R-8 LR1 #8 1 Intermediate connector B-9, AB-2
C07 YAZAKI 7123-2228 2 Room lamp I-9 J08 M6409-0075 20 Joint connector Q-4 LR10 DT-T 3 Intermediate connector B-9, AB-2
C08 YAZAKI-08056 1 Door switch (L.H.) (Room lamp) H-9 J09 M6440-0128 20 Joint connector Y-9 LR11 DTP 4 Intermediate connector A-8, X-1
C09 YAZAKI-08056 1 Door switch (R.H.) (Room lamp) E-8 J10 M6409-0255 20 Joint connector Y-9 LR12 #8 1 Intermediate connector B-8, AB-1
C10 Terminal 1 GND (Radio body) F-9 J11 M6440-0135 20 Joint connector Z-8 LR2 DT-T 12 Intermediate connector B-8, AB-2
C11 YAZAKI PA 9 AM/FM radio E-8 J12 M6409-0075 20 Joint connector Z-8 LR3 DT-T 6 Intermediate connector B-8, AB-1
C12 M 2 Speaker (L.H.) I-9 J13 M6409-0128 20 Joint connector R-6 LR4 #8 1 Intermediate connector B-8, AB-1
C13 M 2 Speaker (R.H.) H-9 J14 M6409-0075 20 Joint connector Z-8 LR6 #8 1 Intermediate connector A-8, X-1
C14 198-Z11-2650 2 Lighter D-7 J15 M6440-0128 20 Joint connector O-4 LR7 DT-T 12 Intermediate connector A-8, X-1
C18 SWP 6 Warning lamp (PAT. Light) switch (if equipped) — J16 M6409-0128 20 Joint connector Z-7 LT1 DT-T 12 Intermediate connector A-9, AN-7, X-2
C18 Terminal 1 GND (Cabin) E-8 J17 M6409-0072 20 Joint connector Z-7 LT2 DT-T 6 Intermediate connector A-9, AN-7, X-2
C19 SWP 6 Rear glass heater switch G-9 L02 DT-T 4 Starting switch R-9 NE — 3 Ne sensor AF-1
C20 — 5 Relay for rear glass heater G-9 L03 DT-T 4 Speed range selector switch R-8 PAMB — 3 Ambient pressure sensor AH-5
C21 YAZAKI 7116-2270 1 Rear glass heater H-9 L04 SWP 8 Combination lamp switch T-1 PD1 DT-T 6 Throttle pedal switch O-2
C22 YAZAKI 7116-2270 1 Rear glass heater J-9 L05 S 10 Wiper switch (front, rear) S-1 PD2 DT-T 2 Throttle pedal switch O-2
C23 DT 4 Intermediate connector E-8 L06 SWP 6 Hazard switch R-6 PFUEL — 3 Common rail pressure sensor AH-6
C47 — 22 Manual air conditioner control amp F-9 L07 SWP 6 Front work lamp switch Q-5 POIL — 1 Engine pressure switch (Low) AF-1
C48 — 14 Manual air conditioner control amp F-9 L08 SWP 6 Rear work lamp switch R-6 PREG — 2 IMA PREG AG-2
C49 DT-T 12 Intermediate connector E-1 L09 SWP 6 ECSS switch T-1 PTIM — 4 Boost pressure & temperature sensor AH-2
C50 DT-T 12 Intermediate connector F-1 L10 SWP 6 Monitor 1 switch U-1 R00 Terminal 1 GND K-9
CAM — 3 Bkup sensor (CAM) AE-2 L11 SWP 6 Monitor 2 switch U-1 R01 Terminal 1 Battery relay M-3
CAN1 DT-T 3 CAN resistor AC-9 L100 Terminal 1 GND (Floor) Y-3 R02 Terminal 1 Slow blow fuse C-9
CAN2 DT-T 3 CAN resistor S-1 L13 DT-T 2 Horn switch T-1 R03 Terminal 1 Slow blow fuse D-9
CHK0 X 1 KOMTRAX inspection connector (if equipped) P-6 L15 DT-T 4 FNR switch S-2 R04 Terminal 1 Battery relay M-3
CHK1 X 1 KOMTRAX inspection connector (if equipped) P-6 L19 SWP 6 Parking brake switch S-7 R05 Terminal 1 Slow blow fuse C-9
CL1 SWP 6 Intermediate connector C-6, O-2 L24 AMP 070 20 Machine monitor R-2 R06 Terminal 1 Slow blow fuse C-9
CL2 SWP 8 Intermediate connector D-6, O-3 L25 AMP 070 18 Machine monitor R-2 R06A Terminal 1 Slow blow fuse C-9
CL31 DT-T 2 Diode — L26 AMP 070 12 Machine monitor R-2 R11 Terminal 1 Slow blow fuse C-9
CL32 DT-T 2 Diode — L27 AMP 070 18 Machine monitor Q-3 R12 Terminal 1 Slow blow fuse C-9
CN1 DT 2 Injector #1 AF-5 L28 AMP 070 12 Machine monitor Q-4 R15 Terminal 1 Battery relay N-1
CN2 DT 2 Injector #2 AF-5 L29 AMP 070 12 Machine monitor T-7 R16 Terminal 1 Battery relay M-1
CN3 DT 2 Injector #3 AG-6 L30 AMP 070 14 Machine monitor S-7 R20 Terminal 1 GND (rear frame) J-1
CN4 DT 2 Injector #4 AG-6 L34 DT-T 2 Stop lamp switch W-2 R21 DT-T 2 Fuel level sensor M-1
D01 SWP 8 Diode O-8 L35 DT 2 PPC valve with electrical detent Q-9 R22 DT-T 6 Rear combination lamp (L.H.) M-5
D02 SWP 8 Diode O-8 L36 DT 2 PPC valve with electrical detent R-6 R23 DT-T 6 Rear combination lamp (R.H.) K-9
D03 SWP 8 Diode O-8 L37 DT 2 PPC valve with electrical detent R-6 R24 Terminal 1 GND K-9
D07 DT-T 2 Diode O-7 L38 DT-T OPT 2 UN SW +24V (if equipped) Z-4 R25 DT-T 2 License lamp (if equipped) M-8
D08 DT-T 2 Diode O-7 L39 DT-T OPT 2 KEY ON +24V (if equipped) Z-4 R29 DT-T 2 Oil fan EPC solenoid L-8
D09 DT-T 2 Diode O-7 L45 DT-T 6 Auto lubrication (if equipped) AB-2 R59 DT-T 2 Fan reverse solenoid K-9
D10 DT-T 2 Diode O-7 L46 M 2 Buzzer W-9 R90 Terminal 1 Heater relay terminal E C-8
D21 DT-T 2 Diode K-2 L47 DT 2 Parking brake indicator switch Y-3 R91 Terminal 1 GND D-8
D22 DT-T 2 Diode J-1 L48 08027 6 Wiper timer X-2 SV DT-T 12 Service connector Y-8
E01 DT-T 2 Starting motor safety relay D-8 L49 08027 4 Flasher AA-3 T01 DT-T 4 HST pump solenoid AC-5
SUMITOMO
E02 6189-0442 3 Alternator M-6 L50 DT-T 12 Intermediate connector Z-6 T01A DT-T 2 Diode AD-5
E03 Terminal 1 Alternator terminal B M-6 L52 M 4 Rear wiper motor X-9 T01B DT-T 2 Diode AD-4
E05 Terminal 1 Heater relay terminal B D-9 L53 DT 2 Parking brake reminder switch Z-5 T05 DT-T 2 Clutch control EPC solenoid AN-5
E06 Terminal 1 Heater relay D-9 L54 DT-T 3 Variable shift control switch T-8 T06 DT-T 2 HST motor 1 EPC solenoid AN-4
E06A DT-T 2 Diode C-8 L55 DT 2 Air suspension seat Z-5 T07 DT-T 4 HST motor 2 SOL & F/R press select solenoid AJ-7
E07 Terminal 1 Heater relay terminal A AE-5 L57 M 6 Front wiper motor Q-3 T09 DT-T 4 Speed sensor AJ-7
E08 Terminal 1 Electrical intake air heater AH-5 L58 M 2 12V converter output for optional parts Z-4 T10 DT-T 2 HST oil temperature sensor AJ-7
E10 DT-T 2 Freon compressor magnet clutch AF-6 L60 DT-T 6 Intermediate connector Z-4 T11 DT-T 3 HST oil pressure sensor AN-3
E14 Terminal 1 GND (Engine controller) AF-6 L61 DT-T 4 Boom lever MAX. traction switch Q-6 T12 DT-T 2 Accumulator pressure switch AN-4
E15 — 2 GND (Rear frame) AC-9 L62 DT-T 4 Intermediate connector Q-6 T13 Terminal 1 HST filter chock up sensor AK-8
E15A Terminal 1 GND (Engine controller) AC-9 L63 SWP 6 FNR active switch Q-9 T14 Terminal 1 GND AL-8
E19 Terminal 1 Starting motor safety relay AE-5 L64 SWP 6 Traction switch Q-9 TEL DT-T 12 Intermediate connector P-6
E19A #4 1 Intermediate connector C-9, AE-6 L65 SWP 6 Work lamp (yellow) (if equipped) R-6 TWTR — 2 Engine coolant temperature sensor AE-2
E20 Terminal 1 Starting motor safety relay D-9 L66 X 1 Intermediate connector O-3
E21 Terminal 1 Starting motor terminal C AH-2 L67 DT-T 12 Intermediate connector W-9
E30 Terminal 1 Starting motor terminal B AH-2 L68 DT-T 2 Resistor O-7
EC1 DRC 60 Engine controller AC-9 L69 SWP 6 Auto reversible fan switch Q-9
EC2 DRC 60 Engine controller AD-9 L70 SWP 8 Speed range select resistor O-9
EC3 DTP 4 Engine controller AD-9 L71 DT-T 4 Intermediate connector W-2
ER1 DT-T 12 Intermediate connector L-2, AF-6 L79 — 5 KOMTRAX engine cut relay (if equipped) P-7
ER2 DT-T 12 Intermediate connector L-2, AF-7 L80 DRC key A 40 KOMTRAX controller (if equipped) T-8
F01 08160-70001 2 Horn (High) A-4 L101 — 6 FR press select relay AB-7
F02 08160-70001 2 Horn (Low) F-1 L102 — 5 VIS power hold relay Z-8
F03 DT-T 3 Bucket positioner proximity switch A-2 L103 — 5 Motor 2 solenoid relay Z-8
F04 DT-T 3 Boom positioner proximity switch E-1 L104 — 5 Fan reverse solenoid relay Z-8
F07 DT-T 2 ECSS solenoid valve D-1 L105 — 5 Electrical parking brake relay AA-7
F09 Terminal 1 GND (Rear frame) F-1 L106 — 5 Neutral safety relay AA-7
F10 Terminal 1 GND (Front frame) A-2 L107 — 5 Eng con cut 1 relay AA-7
F14 DT-T 2 Brake oil temperature switch C-1 L108 — 5 Eng con cut 2 relay Z-8
FL1 DT-T 12 Intermediate connector D-7, V-1 L109 — 5 Back alarm/lamp 1 relay AB-8
FL2 DT-T 6 Intermediate connector D-8, V-1 L110 — 5 ECSS relay AB-7
FL4 DT-T 6 Intermediate connector V-2 L111 — 5 HST solenoid safety relay AB-9
FLC DT-T 3 Front combination lamp (R.H.) B-6 L112 — 5 Air cleaner clog relay AB-8
FLC DT-T 3 Front combination lamp (L.H.) G-1 L113 — 5 Boom kick out relay AB-9
FLH DT-T 3 Head lamp (R.H.) C-6 L114 — 5 Bucket leveler relay AA-9
SEN05086-00
WA150-6
90-200 27
SEN05086-00
WA150-6 90-200 29
SEN05086-00

©2009 KOMATSU
All Rights Reserved
90-200 30

WA150-6 Werkstatthandbuch PDF

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WA150-6 Werkstatthandbuch PDF

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SEN04885-05

WHEEL LOADER WA150 -6

Machine model Serial number

00 Index and foreword 00

Composition of shop manual 1

Section Title..................................................................................................................................... Form Number

00 Index and foreword .................................................................................................................... SEN05064-05

01 Specification ............................................................................................................................... SEN05065-00

10 Structure, function and maintenance standard........................................................................... SEN05066-00

20 Standard value table................................................................................................................... SEN05067-00

30 Testing and adjusting ................................................................................................................. SEN05068-02

306 Troubleshooting by failure code (Display of code), Part 6..................................................SEN05134-00

50 Disassembly and assembly ........................................................................................................SEN05070-01

90 Diagrams and drawings ..............................................................................................................SEN05071-00

00 Index and foreword

10 Structure, function and maintenance standard

Accumulator (for brake) ................................................................................................................................. 13

20 Standard value table

30 Testing and adjusting

Testing compression pressure ...................................................................................................................... 15

Failure code [DLT3KX] Travel speed sensor B: Abnormality......................................................................... 20

H-8 Steering wheel shakes or jerks............................................................................................................... 15

50 Disassembly and assembly

Removal and installation of cooling fan and fan motor assembly.................................................................. 40

Testing evaporator temperature sensor electrically....................................................................................... 31

90 Diagrams and drawings

WA150-6 Wheel loader

Machine model Serial number

00 Index and foreword 00

200 Foreword and general information

Safety notice (Rev. 2008/08)1

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

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-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-